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Service Manual Mitsubishi SL-Series diesel engines

Version 08/2004

ENGLISH

INTRODUCTION

This service manual has instructions and procedures for the Mitsubishi SL-series diesel engines.

The information, specifications and illustrations in this manual are on the basis of the information that was current at

the time this issue was written.

Correct servicing, test and repair procedures will give the engine a long service life. Before starting a test, repair or

rebuild job, the serviceman must read the respective sections of this manual to know all the component he will work

on.

Continuing improvement of product design may have caused changes to your engine which are not included in this

manual.

Whenever a question arises regarding your engine, or this manual, consult your Mitsubishi dealer for the latest

available information.

Service Manual

Mitsubishi SL-Series diesel engines

Version 08/2004

Summary of content (195 pages)

PAGE 1
INTRODUCTION This service manual has instructions and procedures for the Mitsubishi SL-series diesel engines. The information, specifications and illustrations in this manual are on the basis of the information that was current at the time this issue was written. Correct servicing, test and repair procedures will give the engine a long service life. Before starting a test, repair or rebuild job, the serviceman must read the respective sections of this manual to know all the component he will work on.
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HOW TO USE THIS MANUAL Exploded views In the exploded views, the component parts are separated but so arranged to show their relationship to the whole. Index numbering is used to identify the parts and to indicate a sequence in which the parts are to be removed for disassembly, or they are to be installed for assembly. Symbols The following symbols are used in this manual to emphasize important and critical instructions: Indicates a condition that is essential to highlight.
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TABLE OF CONTENTS TABLE OF CONTENTS GENERAL INFORMATION 1 2 3 MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION.................................................... 10 1.1 Model identification location................................................................................................... 10 1.2 Serial Number Location ......................................................................................................... 11 COMPONENT LOCATION......................................................
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TABLE OF CONTENTS 16 15.1 Flywheel removal ................................................................................................................... 47 15.2 Rear plate removal................................................................................................................. 47 15.3 Oil seal case removal............................................................................................................. 48 15.4 Tappet removal .................................................
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TABLE OF CONTENTS 22 23 24 25 26 27 21.2 Oil pump installation............................................................................................................... 92 21.3 Engine turning........................................................................................................................ 92 21.4 Engine turning........................................................................................................................ 93 21.5 Camshaft installation.................
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TABLE OF CONTENTS 31 32 33 30.1 Disassembly......................................................................................................................... 122 30.2 Inspection............................................................................................................................. 124 30.3 Assembly ............................................................................................................................. 127 KEY SHUTOFF SYSTEM (ETS solenoid type)............
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TABLE OF CONTENTS 45 44.1 Schematic ............................................................................................................................ 166 INSPECTION ................................................................................................................................ 167 45.1 Inspection procedure ...........................................................................................................
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TABLE OF CONTENTS 8 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines Version 08/2004
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GENERAL INFORMATION Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 9 / 195
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MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION General General t 1 MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION 1.1 Model identification location • The model identification is embossed on the right side of the cylinder block, near the fuel injection pump mount. The model identifications and displacements of the engines in current production are as listed below: • Displacement Figure 1 Model identification location S3L 1.125 liters (68.7 cu in.) S3L2 1.318 liters (80.4 cu in.) S4L 1.
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MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION General 1.2 t Serial Number Location The serial number is punched on the cylinder block, near the fuel injection pump mount.
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COMPONENT LOCATION GENERAL INFORMATION GENERAL INFORMATION 2 COMPONENT LOCATION 2.
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GENERAL INFORMATION COMPONENT LOCATION 2.
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COMPONENT LOCATION GENERAL INFORMATION 2.
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GENERAL INFORMATION COMPONENT LOCATION 2.
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SPECIFICATIONS GENERAL INFORMATION GENERAL INFORMATION SPECIFICATIONS1 3 System Model Item S3L Type S3L-T S3L2 3 Bore x Stroke (mm) Total displacement (l) 78x92 78x78.5 78x92 1.125 1.318 1.500 1.758 22 1-3-2 135 139 1-3-4-2 135 Lubricating method 139 Oil filter Shallow type oil pan: 3.7/2.3 Deep type oil pan: 5.7/3.
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OVERHAUL INSTRUCTIONS Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 17 / 195
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DETERMINING WHEN TO OVERHAUL THE ENGINE OVERHAUL INSTRUCTIONS OVERHAUL INSTRUCTIONS 4 DETERMINING WHEN TO OVERHAUL THE ENGINE Generally, when to overhaul the engine is to be determined by taking into account a drop in compression pressure as well as an increase in lube oil consumption and excessive blowby gases. Lower power or loss of power, an increase in fuel consumption, a drop in lube oil pressure, hard starting and excessive abnormal noise are also troubles.
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COMPRESSION PRESSURE MEASUREMENT OVERHAUL INSTRUCTIONS OVERHAUL INSTRUCTIONS t 5 COMPRESSION PRESSURE MEASUREMENT 5.1 Inspection Check to make sure: 1. Figure 3 Compression gauge and adaptor 2. 5.2 t 1. 2. 3. 4. Figure 4 • CAUTION • Move the control lever to a position for shutting off fuel supply. Remove all glow plugs from the engine. Install the compression gauge and adaptor (ST332270) combination to a cylinder on which the compression pressure is to be measured.
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TROUBLESHOOTING OVERHAUL INSTRUCTIONS OVERHAUL INSTRUCTIONS 6 TROUBLESHOOTING 6.1 General The diagnosis of troubles, especially those caused by a faulty fuel injection pump or injection nozzles, or low compression pressure, can be difficult. It requires a careful inspection to determine not which item is the cause, but how may causes are contributing to the trouble, someone of which is the primary cause. Several causes may be contributing to a single trouble.
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OVERHAUL INSTRUCTIONS TROUBLESHOOTING 6.2 Engine troubleshooting 6.2.1 Problem 1: Hard starting Is heating system normal? No Z 1. • • • • Items to be checked ahead of time Clogged air cleaner Wrong oil grade for weather conditions Poor quality fuel Low cranking speed 2. Inspection procedure Glow plugs are energized shortly after starter switch is turned to ON. No Z Check control timer unit. No Z Check fuel filter, fuel lines and fuel tank. No Z Make adjustment to the timing and clearance.
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TROUBLESHOOTING OVERHAUL INSTRUCTIONS 6.2.2 Problem 2: Fuel knock More or less fuel knock occurs in diesel engines. This may be caused either by an excessively large delay period or by a too fast rate of fuel injection. 1. • • Items to be checked ahead of time Clogged air cleaner Poor quality fuel 2. Inspection procedure Is injection timing correct (not too advanced)? No Z Make adjustment to the timing. No Z Check the switch. No Z Make adjustment to the pressure.
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OVERHAUL INSTRUCTIONS TROUBLESHOOTING 6.2.3 Problem 3: Overheating Overheating might also be caused by abnormal operating conditions. If the engine is overheating but its cooling system is not contributing to this trouble, it is necessary to check the difference between the ambient temperature and coolant temperature when the engine is in normal operation (with the thermostat fully open).
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TROUBLESHOOTING OVERHAUL INSTRUCTIONS 6.2.4 Problem 4: Black exhaust smoke 1. • • Items to be checked ahead of time Clogged air cleaner Poor quality fuel 2. Inspection procedure Are valve clearance and injection timing correct? No Z Make adjustment to the clearance and timing. No Z Make adjustment to the nozzles. No Z Check valves, piston rings and cylinder head gasket.
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OVERHAUL INSTRUCTIONS TROUBLESHOOTING 6.2.5 Problem 5: Erratic idle speeds 1. • • • Items to be checked ahead of time Maladjusted engine control Wrong oil grade for weather conditions Poor quality fuel 2. Inspection procedure Are valve clearance and injection timing correct? No Z Make adjustment to the clearance and timing. No Z Make adjustment to the nozzles. No Z Check valves, piston rings and cylinder head gasket.
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TROUBLESHOOTING OVERHAUL INSTRUCTIONS 6.2.6 Problem 6: Low power or loss of power 1. • • • • • • Items to be checked ahead of time Stuck running parts Wrong oil grade for weather conditions Poor quality fuel Clogged air cleaner Restricted exhaust line Faulty power take-off 2. Inspection procedure Are valve clearance and injection timing correct? No Z Make adjustment to the clearance and timing. No Z Check fuel tank, fuel filter and fuel lines. No Z Make adjustment to the governor.
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OVERHAUL INSTRUCTIONS TROUBLESHOOTING 6.3 Starting system troubleshooting Overruns at low speed → Make reference to “Overrun.
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TROUBLESHOOTING Key not returning completely Key switch faulty OVERHAUL INSTRUCTIONS Broken return spring Sticking Machining fault of parts Key not finished to close tolerances External obstacle Rust due to moisture Starter is energized for hours, resulting in: • Burned hold-in coil • Burned armature and field coils • Burned subswitch (if so equipped) Defective contact points Problems in switch Overrun Starter faulty Pull-in and hold-in coils unbalance in number of windings Pull-in or hold-in coil l
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OVERHAUL INSTRUCTIONS BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY OVERHAUL INSTRUCTIONS 7 BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY This section outlines basic precautions recommended by Mitsubishi that should always be observed. 7.1 1. 2. 3. 4. 5. 6. 7.2 1. 2. 3. 4. 5. Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH Disassembly Always use tools that are in good condition and be sure you understand how to use them before performing any job.
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BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 30 / 195 OVERHAUL INSTRUCTIONS ENGLISH Service Manual Mitsubishi SL-Series diesel engines Version 08/2004
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DISASSEMBLY Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 31 / 195
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PREPARATION FOR DISASSEMBLY DISASSEMBLY DISASSEMBLY t 8 PREPARATION FOR DISASSEMBLY 8.1 Engine oil draining1 Remove the drain plug from the bottom of the oil pan and allow the oil to drain. Refill capacities (high level excl. 0.5 liter (0.13 U.S. gal) of oil in oil filter, liter (U.S. gal) S3L/S3L2: 5.7 (1.5) (with deep oil pan) 3.7 (1.0) (with standard oil pan) S4L/S4L2: 7.7 (2.0) (with deep oil pan) 5.4 (1.
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DISASSEMBLY ELECTRICAL SYSTEM DISASSEMBLY 9 ELECTRICAL SYSTEM 9.1 Starter 9.1.1 Testing before disassembly 1. Clearance between pinion and housing (pinion clearance) 1) Connect the starter to a 12 volt battery as shown in the illustration to cause the pinion to shift into cranking position and remain there. CAUTION Due to the amount of current being passed through the solenoid series winding, this test must be made within 10 seconds. 2) t 3) Push in pinion 0,5 to 2,0 mm (0.020 to 0.079 in.
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ELECTRICAL SYSTEM DISASSEMBLY Item Model Standard M8T70471 M1T68281 12 – 2.0 12 – 1.7 11 11.5 Current draw, A 130 maximum 100 maximum Speed, rpm 3 850 minimum 3 000 minimum Nominal output, V – kW No-load characteristics Terminal voltage, V 3. t Battery (12 volts) Magnetic switch 1) Disconnect the connector from the M terminal of the magnetic switch. 2) Connect the magnetic switch to a 12 volt battery with a switch as shown in the illustration to test the pull-in coil.
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DISASSEMBLY ELECTRICAL SYSTEM 4) t Connector disconnected CAUTION Battery (12 volts) Figure 11 Connections for pinion return test Connect the magnetic switch to a 12 volt battery with a switch as shown in the illustration to make a pinion return test. Close the switch and pull the pinion away from the commutator end by hand. Release the pinion to see if it returns immediately when released. If the pinion fails to so return, the magnetic switch is faulty.
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ELECTRICAL SYSTEM DISASSEMBLY 9.2.2 Precautions for removal t Following is a list of basic precautions that should always be observed for removal: 1. 2. 3. 4. 5. 6. 7. When installing the battery, care must be used to make sure the negative (–) terminal is grounded. Do not use a megger (an instrument for high resistance of electrical materials). Disconnect the battery cables before charging the battery.
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DISASSEMBLY ELECTRICAL SYSTEM Standards Output characteristics (at normal temperature) Item Model Terminal voltage/ current Speed 13.5 V/33 A 2 500 rpm maximum 13.5 V/47 A 5 000 rpm maximum A7T02071C 9.2.5 Removal t 1. 2. 3. 4. 5. Figure 16 Disconnect the battery cables. Disconnect the lead from the B terminal of the alternator. Disconnect the connector from the alternator. Loosen the brace and support bolts. Move the alternator toward the engine and remove the drive belt.
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Cooling System DISASSEMBLY DISASSEMBLY 10 Cooling System 10.1 Cooling fan removal t Hold the fan by one hand and remove the four bolts that hold the fan in position. Remove the fan and spacers. NOTE Keep the spacers with the fan for installation. Figure 17 Removing cooling fan 10.2 Thermostat case removal t Remove the water pump assembly. Figure 18 Removing thermostat assembly 10.3 Water pump assembly removal t Remove the water pump assembly.
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DISASSEMBLY Fuel System DISASSEMBLY 11 Fuel System 11.1 Fuel injection pipe removal t Disconnect the fuel injection pipes and fuel leak-off pipe from the fuel injection pump and nozzles. NOTE Put plugs or caps on the openings of the injection pump and nozzle connectors. Figure 20 Removing fuel injection pipes 11.2 Fuel injection nozzle removal t Loosen the fuel injection nozzles with a wrench. Remove the nozzles and gaskets from the cylinder head.
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Fuel System DISASSEMBLY 11.4 Governor weight removal t 1. 2. Figure 23 Removing governor weights 11.5 Fuel injection pump removal t Figure 24 Remove the sliding sleeve. Remove the sliding sleeve shaft and governor weights. 1. 2. Remove the tie rod cover. Remove the spring from the tie rod with a pliers to disconnect the tie rod from the fuel injection pump. 3. Remove the fuel injection pump. Removing tie rod t NOTE Keep a record of the thickness of shims for installation.
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DISASSEMBLY Lubrication System DISASSEMBLY 12 Lubrication System 12.1 Oil filter removal t 1. 2. Figure 26 Put a container under the oil filter to catch the oil. Remove the oil filter from the cylinder block with a filter wrench. Removing oil filter 12.2 Pressure relief valve removal t Remove the pressure relief valve from the cylinder block. Figure 27 Removing pressure relief valve 12.
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AIR INLET SYSTEM AND EXHAUST SYSTEM DISASSEMBLY DISASSEMBLY 13 AIR INLET SYSTEM AND EXHAUST SYSTEM 13.1 Exhaust manifold removal t Remove the exhaust manifold from the cylinder head. Figure 29 Removing exhaust manifold 13.2 Air inlet cover removal t Remove the air inlet cover from the cylinder head.
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CYLINDER HEAD AND VALVE MECHANISM DISASSEMBLY DISASSEMBLY 14 CYLINDER HEAD AND VALVE MECHANISM 1. 2. 3. 4. Rocker cover Rocker shaft assembly Valve push rod Cylinder head bolt 5. 6. 7. 8. Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 Cylinder head Cylinder head gasket Valve lock Valve retainer ENGLISH 9. 10. 11. 12.
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CYLINDER HEAD AND VALVE MECHANISM DISASSEMBLY 14.1 Rocker shaft assembly removal t 1. 2. Figure 31 Remove the bolts that hold the rocker stays in position and remove the rocker shaft assembly. Remove the valve caps. Removing rocker shaft assemblies 14.2 Rocker shaft disassembly t Put identification on each rocker arm as to its location on the rocker shaft. Figure 32 Disassembling rocker shaft assembly 14.
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CYLINDER HEAD AND VALVE MECHANISM DISASSEMBLY 14.4 Cylinder head assembly removal t Lift the cylinder head straight up with a hoist. NOTE If the gasket is seized and the cylinder head cannot be separated from the cylinder block, tap around the thick side portion of the cylinder head with a plastic hammer. Figure 34 Removing cylinder head assembly 14.5 Valve and valve spring removal t 1. 2. Compress the valve spring with a valve lifter and remove the valve lock.
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Timing Gears and Flywheel DISASSEMBLY DISASSEMBLY 15 Timing Gears and Flywheel 1. 2. 3. 4. 5. 6. Flywheel Rear plate Oil seal case; oil seal Tappet Speedometer driven gear P.T.O. gear 46 / 195 7. 8. 9. Crankshaft pulley Timing gear case Idler gear (Remove 10 thru 12 as an assembly.) 10. Camshaft gear 11. Thrust plate 12. Camshaft ENGLISH (Remove 3 thru 5 as an assembly.) 13. Fuel injection pump camshaft gear 14. Bearing 15. Fuel injection pump camshaft 16. Oil pump 17.
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DISASSEMBLY Timing Gears and Flywheel 15.1 Flywheel removal t 1. 2. Have someone hold the crankshaft pulley with a wrench to prevent the flywheel from rotating. Remove one of the bolts that hold the flywheel in position. WARNING Always signal each other to prevent possible personal injury. Figure 37 Holding flywheel 3. t Safety bar 4. Install a safety bar (M12 x 1.25) into the threaded hole in the flywheel from which the bolt was removed in Step (2). Remove the remaining bolts.
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Timing Gears and Flywheel DISASSEMBLY 15.3 Oil seal case removal t Remove the bolts that hold the oil seal case in position. Remove the case from the cylinder block with a screwdriver or the like. CAUTION Do not cause damage to the oil seal. Figure 40 Removing oil seal case 15.4 Tappet removal t Remove the tappets from the cylinder block with a valve push rod.
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DISASSEMBLY Timing Gears and Flywheel 15.6 Crankshaft pulley removal t 1. 2. Install two safety bars (M12 x 1.25) into the threaded holes in the rear end of the crankshaft. Put a bar between the safety bars to hold the crankshaft to prevent it from rotating. Remove the crankshaft pulley. WARNING When removing the crankshaft pulley, be prepared to stop the job in case the bar slips off the crankshaft to prevent injury. Figure 43 Removing crankshaft pulley 15.
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Timing Gears and Flywheel DISASSEMBLY 15.9 Idler gear removal t To remove the idler gear, rotate the gear in a direction of the helix of the teeth to pull it out of mesh. Figure 46 Removing idler gear 15.10 Camshaft removal t 1. 2. Remove the bolts that hold the thrust plate. Pull the camshaft out of the cylinder block. CAUTION Do not cause damage to the lobes or bearing journals when removing the camshaft. Figure 47 Removing camshaft 15.11 Fuel injection pump camshaft removal t 1.
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DISASSEMBLY 2. t Figure 49 Timing Gears and Flywheel Tap the rear end of the camshaft with a copper bar to push it out of the front side of the cylinder block. Removing fuel injection pump camshaft 15.12 Gear removal (when required) To remove the gears from the camshaft and fuel injection pump camshaft, use an arbor press. 15.13 Oil pump removal t Remove the bolts that hold the oil pump to the cylinder block and remove the pump. Figure 50 Removing oil pump 15.
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Cylinder Block, Crankshaft, Pistons and Oil Pan DISASSEMBLY DISASSEMBLY 16 Cylinder Block, Crankshaft, Pistons and Oil Pan 1. Oil pan 2. Oil screen 3. Connecting rod cap 4. Connecting rod bearing (lower half) (Remove 5 thru 10 as an assembly.) 5. Connecting rod 6. 7. 8. 9. 10. Piston pin No. 1 ring No. 2 ring Oil ring Piston 11. 12. 13. 14. 15. 16.
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Cylinder Block, Crankshaft, Pistons and Oil Pan DISASSEMBLY 16.1 Oil pan removal t 1. 2. Turn the engine upside down. Tap the bottom corners of the oil pan with a plastic hammer to remove the oil pan. CAUTION Do not attempt to pry off the oil pan by inserting a screwdriver or a chisel between the oil pan and cylinder block. Damage to the oil pan can be the result. Figure 52 Removing oil pan 16.2 Oil screen removal t Loosen the nut that holds the oil screen in position and remove the screen.
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Cylinder Block, Crankshaft, Pistons and Oil Pan DISASSEMBLY 16.4 Connecting rod cap removal t 1. 2. 3. Figure 55 Removing connecting rod caps 16.5 Piston removal t 1. 2. Figure 56 Lay the cylinder block on its side. Put identification on each connecting rod and cap combination as to its location in the engine. Remove the caps. Turn the crankshaft until the piston is at top center.
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DISASSEMBLY Cylinder Block, Crankshaft, Pistons and Oil Pan 16.7 Main bearing cap removal t 1. 2. 3. Figure 58 Lay the cylinder block with its bottom (oil pan) side up. Remove the bolts that hold the main bearing caps in position. Remove the caps. Remove the front and rear bearing caps with a sliding hammer. Removing main bearing caps 16.8 Crankshaft removal t Remove the crankshaft. CAUTION Do not cause damage to the bearings.
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Cylinder Block, Crankshaft, Pistons and Oil Pan DISASSEMBLY 2. t Piston pin 3. Push rod (tool) Connecting rod Insert the push rod of the tool into the bore in the piston for the piston pin and, using an arbor press, remove the piston pin. Use this Piston Pin Setting Tool to install the connecting rod to the piston. Identification mark Arrow mark Piston Tool body Figure 61 Removing piston pin (1) t CAUTION Do not attempt to remove the piston pin by tapping.
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INSPECTION Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 57 / 195
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CYLINDER HEAD AND VALVE MECHANISM INSPECTION INSPECTION 17 CYLINDER HEAD AND VALVE MECHANISM Check threads for stripping Check end for wear.
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CYLINDER HEAD AND VALVE MECHANISM INSPECTION 17.1 Cylinder head Using a heavy accurate straight edge and a feeler gauge, check the bottom face for warpage in three positions lengthwise, two crosswise and two widthwise as shown in the illustration. If warpage exceeds the limit, reface the bottom face with a surface grinder. Unit: mm (in.) Figure 64 Item Standard Limit Warpage of cylinder head bottom face 0.05 (0.002 0) maximum 0.10 (0.003 9) Checking cylinder head bottom face for warpage 17.
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CYLINDER HEAD AND VALVE MECHANISM INSPECTION 17.3 Valve springs Check the squareness and free length. If the squareness and/or free length exceeds the limit, replace the spring. Squareness Unit: mm (in.) Item Free length Testing valve spring Limit Free length 47 (1.85) 46 (1.81) Squareness 1.5° maximum Test force, kgf (lbf) [N] Figure 66 Standard Length under test force: 39.1 (1.54) 13.9 ± 0.7 (30.6 ± 1.5) [136 ± 7] Length under test force: 30.5 (1.20) 29 ± 2 (64 ± 4.
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CYLINDER HEAD AND VALVE MECHANISM INSPECTION 2. Clearance between valve stem and valve guide The valve guide wears more rapidly at its both ends than at any other parts. Measure the bore in the guide for the stem at its ends with an inside micrometer caliper to find the clearance between the stem and guide. If the clearance exceeds the limit, replace the guide or valve whichever is badly worn. Unit: mm (in.
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CYLINDER HEAD AND VALVE MECHANISM INSPECTION 4. Valves 1) Put a small amount of Prussian blue or red lead on the valve face. Hold the valve with a valve lapping tool (commercially available) and press it against the seat to check its contact. 2) The width of contact must be uniform all the way around both seat and valve. If the contact is bad, reface the valve and seat. 3) If the valve margin (valve lip thickness) exceeds the limit, replace the valve. Unit: mm (in.
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CYLINDER HEAD AND VALVE MECHANISM INSPECTION 5. Valve refacing 1) 2) Figure 74 Refacing valve face 6. Valve seat refacing 1) 2) Figure 75 Before refacing the valve seat, check the clearance between the valve and guide, and replace the guide if necessary. Cut the valve seat with a valve seat cutter (commercially available), or grind it with a valve seat grinder, and finish the width of valve seat and the angle of seat face to the correct values. Refacing valve seat Unit: mm (in.
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CYLINDER HEAD AND VALVE MECHANISM INSPECTION 7. Valve lapping Be sure to lap the valves in the seats after refacing or replacing the valves or valve seats. 1) Compound NOTE • • Figure 77 • Lapping valve in seat Put a small amount of lapping compound on the valve face. Do not put lapping compound on the valve stem. Use a lapping compound of 120 to 150 mesh for initial lapping and a compound of finer than 200 mesh for finish lapping.
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CYLINDER HEAD AND VALVE MECHANISM INSPECTION Combustion jet Figure 79 2. To install a new jet, put the jet in position in the head with its tangential orifice in alignment with the center of the main chamber and tap it with a plastic hammer. The new jet must be flush with the cylinder head surface.
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TIMING GEARS AND FLYWHEEL INSPECTION INSPECTION 18 TIMING GEARS AND FLYWHEEL Check for wear. Check for damage to lobes and bearing journals. Check for wear or abnormal noise (when spun). Check teeth for wear, nicks, burrs or chips. Check speedometer driven gear for damage. Check for bend or damage to lobes. Check for cracks or distortion. Check belt groove for wear. Check clutch contact face for scores or ridges. Check ring gears for damage or wear. Check for wear, damage or aging.
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INSPECTION TIMING GEARS AND FLYWHEEL 18.1 Camshaft 1. Clearance between journal and bushing Measure the diameter of the journal and the bore in the bushing for the shaft to find the clearance as shown in the illustration. If the clearance exceeds the limit, replace the bushing. Unit: mm (in.) Figure 81 Measuring camshaft journal Figure 82 Measuring bore in camshaft bushing 2. Front of cylinder block Camshaft bushing Item Standard Clearance between camshaft journal and bushing 0.15 (0.
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TIMING GEARS AND FLYWHEEL INSPECTION 2) 1 mm (0.04 in.) Notch in bushing 1 mm (0.04 in.) Installation Install a new bushing in position with its oil holes in alignment with those of the oil gallery. Ends of bushing Oil holes Figure 84 Installing camshaft bushing 3. Lobe lift Measure the lobe height and base circle as shown in the illustration. Subtract the base circle from the lobe height to find the lobe life. If the lobe lift exceeds the limit, replace the camshaft .Unit: mm (in.
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INSPECTION TIMING GEARS AND FLYWHEEL 18.3 Tappets Good Figure 87 Figure 88 Bad 1. Cam contact face Check the cam contact face of each tappet for abnormal wear. Replace the tappet if the face is defective. 2. Clearance between tappet and cylinder block Measure the diameter of the tappet and the bore in the cylinder block for the tappet to find the clearance. If the clearance exceeds the limit, replace the tappet. Unit: mm (in.
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TIMING GEARS AND FLYWHEEL INSPECTION 2. Install a new idler shaft to the cylinder block so that its dimension from the face of the block is 26.5±0.5 mm (1.043±0.020 in.). 26,5 ± 0.5 mm (1.043 ± 0.020 in.) Figure 90 Idler shaft replacement Idler shaft dimension 18.5 Flywheel and ring gear 1. Flatness (difference between lower and higher measurements) of flywheel Put the flywheel on the surface plate.
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION INSPECTION 19 CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN Check for cracks, scores or ridges at top of ring travel. Check for wear or damage. Check clearance between ends. Check top face for warpage. Check for wear, scores, cracks, overheating or excessive widened ring grooves. Check for damage to plugs or dowels. Check for bend or twist. Check big end thrust clearance. Check for plugged oil holes. Check for damage to gear teeth.
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN Direction transverse to piston pin INSPECTION 19.1 Pistons, Piston Rings and Piston Pins 1. Diameter of piston Measure the diameter of the piston at its skirt in a direction transverse to the piston pin with a micrometer as shown in the illustration. If the diameter exceeds the limit, replace the piston. Select a new piston so that the difference between average weight of all pistons in one engine does not exceed the standard.
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION 3. Clearance between ends of piston ring Put the piston ring in a gauge or in the bore in a new cylinder block and measure the clearance between the ends of the ring with a feeler gauge as shown in the illustration. If the clearance exceeds the limit, replace all the rings. Inside diameter of gauge Standard: 780+0.03 mm (3.070+0.0012 in.) 0.25 mm (0.0098 in.) oversize: Figure 96 Measuring clearance between ends of piston ring 78.250+0.03 mm (3.
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION 4. Clearance between piston pin and piston Measure the diameter of the piston pin and the bore in the piston for the pin as shown in the illustration to find the clearance. If the clearance exceeds the limit, replace the piston or pin whichever is badly worn. .Unit: mm (in.) Norminal size Standard Diameter of piston pin 23 (0.91) 22.994 to 23.000 (0.905 027 to 0.905 51) Clearance between piston pin and piston — 0.006 to 0.018 (0.
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION 3) To check the connecting rod fitted to the piston for bend, put the connecting rod and piston on the surface plate as shown in the illustration, insert a round bar having a diameter equal to that of the crankpin into the bore in the big end of the rod and measure “A” and “B” with a dial indicator. Subtract “A” from “B” to find the bend (“C”). Figure 100 Checking connecting rod for bend with a dial indicator Measuring diagram 19.
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION Unit: mm (in.) Item Undersize Crankpin Table 2 Finish 0.25 (0.009 8) 47.75 0.50 (0.019 7) 47.50 0.75 (0.029 5) 47.25 -0.035 -0.050 -0.035 -0.050 -0.035 -0.050 (1.8799 -0.00138 (1.8701 -0.00138 (1.8602 -0.00138 -0.00197 -0.00197 -0.00197 ) ) ) Crankpin undersizes CAUTION • 2.5 mm (0.098 in.) • Grind all the crankpins of one crankshaft to the same undersize. Finish the crankpin fillets to a radius of 2.5 mm (0.098 in.).
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION 2) Measuring diagram Measure the diameter of the journal as shown in the illustration to find the clearance between the journal and main bearing. .Unit: mm (in.) Figure 105 Measuring diameter of journal Item Norminal size Standard Limit Diameter of journal (standard) 52 (2.05) 51.985 to 52.000 (2.046 65 to 2.047 24) — Clearance between journal and main bearing — 0.030 to 0.077 (0.001 18 to 0.003 03) 0.100 (0.
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION 3. Runout Support the crankshaft on its front and rear journals in V-blocks or in a lathe and check runout at the center journal with a dial indicator as shown in the illustration. Depending on the amount of runout, repair the crankshaft by grinding or by straightening with a press. If runout exceeds the limit, replace the crankshaft. Unit: mm (in.) Item Standard Limit Crankshaft runout 0.025 (0.000 98) 0.05 (0.
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CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION 19.4 Cylinder block 1. Bore Measure the bore at the top, middle and bottom points on axes A and B with a cylinder bore gauge as shown in the illustration. If any one of the cylinders exceeds the limit, hone out all the bores for oversize pistons. Unit: mm (in.) Pioston and piston ring Size Size code Standard STD Bore Standard 78 0 (3.07 Figure 110 Measuring bore in cylinder block 0.25 (0.009 8) oversize 25 +0.0012 78.25 0 +0.
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ASSEMBLY Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 81 / 195
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Cylinder Block, Crankshaft, Pistons and Oil pan ASSEMBLY ASSEMBLY 20 Cylinder Block, Crankshaft, Pistons and Oil pan Lubricate the engine surface with engine oil Force fit Lubricate the bearing (inside) surface with engine oil Coat the front and rear bearing cap contact surfaces with Three Bond 1212 Lubricate the bearing (inside) with engine oil Coat with Three Bond 1212 Tightening torque: 3.55 ± 0.25 kgf m (25.7 ± 1.8 lbf ft) [34.8 ± 2.5 N m] Tightening torque: 5.25 ± 0.25 kgf m (38 ± 1.
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ASSEMBLY Cylinder Block, Crankshaft, Pistons and Oil pan 20.1 Main bearing installation 1. 2. 3. Install the upper halves of the main bearings in the cylinder block and the lower halves in the main bearing caps so their tabs fit into the notches in the cylinder block and the main bearing caps. Install the flanged bearing in the No. 3 journal. Lightly lubricate the inside surfaces of the bearings with engine oil. Figure 113 Installing main bearings 20.2 Crankshaft installation 1. 2. 3.
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Cylinder Block, Crankshaft, Pistons and Oil pan ASSEMBLY CAUTION Install the front and rear bearing caps in position so their end faces are even with the end faces of the cylinder block. Figure 116 Installing front and rear bearing caps 4. Tighten the bolts holding the main bearing caps in steps to the specified torque. Tightening torque 5.25 ± 0.25 kgf·m (38 ± 2 lbf·ft) [51.5 ± 2.5 N·m] Figure 117 Tightening bolts holding main bearing caps 5. 6.
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Cylinder Block, Crankshaft, Pistons and Oil pan ASSEMBLY 20.4 Side seal installation Side seals Rounded side 1. 2. Coat the side seals with Three Bond 1212. Insert the side seals between the cylinder block and the front and rear caps and push in them by hand as far as possible, with their rounded side toward the outside of the cylinder block. 3. Using a flat plate, push the seals into position, taking care not to bend them. Rounded side Figure 119 Side seals Figure 120 Installing side seals 20.
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Cylinder Block, Crankshaft, Pistons and Oil pan ASSEMBLY 3. Put the piston in position on the connecting rod, making sure the model identification on the rod is on the same side as the arrow head on the top of the piston. Put the piston pin in position. 4. Insert the push rod of the Tool into the bore in the piston for the piston pin and press the pin with the press. Figure 122 Installing piston pin CAUTION Observe the indicator of the press when pressing the piston pin.
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Cylinder Block, Crankshaft, Pistons and Oil pan ASSEMBLY 20.6 Piston ring installation Mark to be up No. 1 compression ring No. 2 compression ring Oil ring Using a piston ring pliers, install the piston rings to the piston. NOTE 1. 2. The piston rings must be installed with the side that has the mark “T” toward the top of the piston. The oil ring must be installed with the ring end gap 180° apart from the coil spring joint.
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Cylinder Block, Crankshaft, Pistons and Oil pan ASSEMBLY 6. Using a piston guide (commercially available), put the piston and connecting rod into the cylinder from the top of the cylinder block. CAUTION Do not hit the piston with a hammer to install the piston and connecting rod. This will put force on the piston and connecting rod and cause damage to the piston rings and crankpin.. Piston guide Figure 128 Installing piston and connecting rod 20.8 Connecting rod cap installation 1. 2. 3.
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ASSEMBLY Cylinder Block, Crankshaft, Pistons and Oil pan 20.9 Oil screen installation 1. 2. Lay the cylinder block with the bottom (oil pan side) up. Install the oil screen in position. NOTE The oil screen must be installed in position so that it is below the oil level line and away from the oil pan. Figure 131 Installing oil screen 20.10 Oil pan installation 1. Clean the mating surfaces of the oil pan and cylinder block and coat them with Three Bond 1207C.
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Cylinder Block, Crankshaft, Pistons and Oil pan ASSEMBLY Figure 134 Oil pan for S3L and S3L2 engines To squeeze out a 4 mm (0.2 in.) thick bar, cut the nozzle of the tube as shown. Cut nozzle here Figure 135 Cutting sealing compound tube nozzle 2. Tighten the bolts that hold the oil pan to the cylinder block in a crisscross pattern to the specified torque. Cast oil pan: 2.8 ± 0.3 kgf·m (20.3 ± 2.2 lbf·ft) [27.5 ± 3 N·m] Tightening torque Plate oil pan: 1.15 ± 0.15 kgf·m (8.3 ± 1.1 lbf·ft) [11.3 ± 1.
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ASSEMBLY Timing Gears and Flywheel ASSEMBLY 21 Timing Gears and Flywheel Lubricate with engine oil Use a new gasket Tightening torque: 1.1 ± 0.1 kgf m (8 ± 0.7 lbf ft) [10.8 ± 1 N m] Tightening torque: 17.5 ± 2.5 kgf m (127 ± 18 lbf ft) [172 ± 25 N m] Lubricate journals and lobes with engine oil Use a new gasket Lubricate lip with engine oil Tightening torque: 6.5 ± 1 kgf m (47 ± 7 lbf ft) [64 ± 10 N m] Lubricate lip with engine oil Tightening torque: 13.5 ± 0.
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Timing Gears and Flywheel ASSEMBLY 21.1 Front plate installation 1. 2. 3. Scrape the gasket from the cylinder block and front plate. Coat the gasket contact surface of cylinder block with adhesive and put a new gasket in position, making sure the holes in the gasket are all in alignment with the holes in the cylinder block. Put the front plate in position. Install four bolts and tighten them. Figure 138 Installing front plate 21.2 Oil pump installation 1. 2. 3.
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ASSEMBLY Timing Gears and Flywheel 21.4 Engine turning 1. 2. 3. 4. Put the camshaft (with bearing and gear) in position in the cylinder block. Hit the gear with a plastic hammer to fit the bearing in position. Make sure the camshaft rotates freely. Tighten the stopper bolt. Figure 141 Installing fuel injection pump camshaft 21.5 Camshaft installation 1. 2. Lubricate the lobes and journals with engine oil. Put the camshaft (with gear) in position in the cylinder block.
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Timing Gears and Flywheel ASSEMBLY 21.6 Idler gear installation 1. 2. 3. Lubricate the idler gear with engine oil. Install the idler gear in position with its “3,” “2” and “11” marks in alignment with the “33” mark on the fuel injection pump camshaft gear, the “22” mark on the camshaft gear and the “1” mark on the crankshaft gear respectively. Check the backlash of the gears. Make reference to “Timing gear backlash measurement” (page 37). Figure 144 Marks on timing gears 21.
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ASSEMBLY Timing Gears and Flywheel 21.9 P.T.O. gear installation Install the P.T.O. gear in position in the timing gear case with the side that has no oil hole toward the rear of the engine. Figure 147 Installing P.T.O. gear 21.10 Speedometer driven gear installation 1. 2. Install the O-ring in the groove in the driven gear sleeve. Install the speedometer driven gear in position in the cylinder block while rotating it or the camshaft. Figure 148 Installing speedometer driven gear 21.
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Timing Gears and Flywheel ASSEMBLY 21.12 Oil seal case installation 1. 2. Put a new gasket in position on the oil seal case. Lubricate the oil seal lip with engine oil and install the oil seal in position in the cylinder block. Figure 150 Installing oil seal case 21.13 Rear plate installation 1. 2. Put a new gasket in position on the rear plate. Put the rear plate in position on the cylinder block with its dowel holes in alignment with the dowels.
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ASSEMBLY Timing Gears and Flywheel 5. 6. Have someone hold the crankshaft pulley with a wrench to prevent the flywheel from rotating. Tighten the four bolts that hold the flywheel to the specified torque. Tightening torque 13.5 ± 0.5 kgf·m (98 ± 4 lbf·ft) [132 ± 5 N·m] WARNING Always signal each other to prevent possible personal injury.
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CYLINDER HEAD AND VALVE MECHANISM ASSEMBLY ASSEMBLY 22 CYLINDER HEAD AND VALVE MECHANISM Tightening torque: 1.15 ± 0.15 kgf m (8.3 ± 1.1 lbf ft) [11.3 ± 1.5 N m] Tightening torque: 1.5 ± 0.5 kgf m (11 ± 4 lbf ft) [14.7 ± 5 N m] Tightening torque: 9 ± 0.
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CYLINDER HEAD AND VALVE MECHANISM ASSEMBLY 22.1 Cylinder head bottom face cleaning Scrape the gasket from the bottom face of the cylinder head. NOTE After scraping the gasket, rub off gasket remnants from the face with an oilstone smeared with engine oil and thoroughly clean the face. Figure 155 Removing cylinder head gasket 22.2 Valve stem seal installation Socket 12 Using Socket 12, install the valve stem seal in position in the valve guide.
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CYLINDER HEAD AND VALVE MECHANISM ASSEMBLY 22.4 Installing valve block Put compression on the valve spring with a valve lifter and install the block in position on the valve top. CAUTION Do not put excessive compression on the valve spring. This can cause the retainer to hit and damage the stem seal. Figure 158 Installing valve block Guide bolts 22.5 Cylinder head gasket installation 1. 2. 3. Thoroughly clean the top faces of the cylinder block and pistons. Install two guide bolts (M10 x 1.
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CYLINDER HEAD AND VALVE MECHANISM ASSEMBLY 22.7 Cylinder head bolt tightening 1. 2. Front Remove the guide bolts and install the bolts that hold the cylinder head to the cylinder block. Tighten the bolts in number sequence in two or three steps to the specified torque. Tightening torque 9 ± 0.5 kgf·m (65 ± 4 lbf·ft) [88 ± 5 N·m] Figure 161 Tightening sequence 22.8 Valve push rod installation 1. 2. Put the valve push rod into position through the bore in the cylinder head.
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CYLINDER HEAD AND VALVE MECHANISM ASSEMBLY 22.10 Rocker shaft assembly installation 1. 2. Install the valve caps in position on the top of the valves. Put the rocker shaft assembly in position on the cylinder head. Tighten the bolts that hold the rocker shaft assembly to the specified torque. 3. Tightening torque 1.5 ± 0.5 kgf·m (11 ± 4 lbf·ft) [14.7 ± 5 N·m] Figure 164 Installing rocker shaft assembly 22.11 Valve clearance adjustment Make reference to “VALVE CLEARANCE” (page 159).
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ASSEMBLY Air Inlet System and Exhaust System ASSEMBLY 23 Air Inlet System and Exhaust System Use a new gasket Use a new gasket Tightening torque: 1.85 ± 0.35 kgf m (13.4 ± 2.5 lbf ft’ ¨18 ± 3.4 N m* Tightening torque: 1.85 ± 0.35 kgf m (13.4 ± 2.5 lbf ft’ ¨18 ± 3.4 N m* 23.1 Air inlet cover installation Tighten the bolts that hold the air inlet cover to the specified torque. Tightening torque 1.85 ± 0.35 kgf·m (13.4 ± 2.5 lbf·ft) [18 ± 3.4 N·m] 23.
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Fuel System ASSEMBLY ASSEMBLY 24 Fuel System Gasket 24.1 Fuel injection nozzle installation 1. 2. Put the gasket on the nozzle. Put the nozzle assembly in position in the cylinder head and tighten it to the specified torque. Tightening torque 5.5 ± 0.5 kgf·m (40 ± 4 lbf·ft) [54 ± 5 N·m] Figure 167 Installing fuel injection nozzle 24.2 Fuel injection pump installation Put the pump in position on the cylinder block and tighten the bolts that hold the pump to the specified torque.
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ASSEMBLY Fuel System 24.4 Sliding sleeve installation Install the sliding sleeve on the sliding sleeve shaft and make sure the sleeve moves freely. Figure 170 Installing sliding sleeve 24.5 Governor assembly installation 1. 2. 3. Install the governor assembly in position while putting the tie rod and spring into position in the injection pump. Install the tie rod to the pin of the control rack and secure it with the tie rod spring. Install the tie rod cover in position.
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Lubrication system ASSEMBLY ASSEMBLY 25 Lubrication system 25.1 Pressure relief valve installation Put the relief valve in position on the cylinder block and tighten it to the specified torque. Tightening torque 5 ± 0.5 kgf²m (36 ± 4 lbf²ft) [49 ± 5 N²m] Figure 173 Installing pressure relief valve 25.2 Oil filter installation 1. 2. Lightly lubricate the gasket with engine oil. Install the new filter element by hand. When the gasket contacts the base, tighten one turn more.
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ASSEMBLY Cooling system ASSEMBLY 26 Cooling system 26.1 Water pump installation Put a new gasket in position on the water pump flange. Install the water pump in position on the cylinder block. Figure 176 Installing water pump 26.2 Thermostat installation 1. 2. Put the thermostat in the thermostat case. Put a new gasket in position on the thermostat case. Install the thermostat assembly in position on the cylinder head. Figure 177 Installing thermostat 26.3 Cooling fan installation 1. 2.
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Cooling system ASSEMBLY 26.4 Thermoswitch and thermounit combination installation Coat the threads of the combination with Three Bond 1104. Put the combination in position and tighten it to the specified torque.
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ASSEMBLY Electrical System ASSEMBLY 27 Electrical System 27.1 Glow plug installation Install the glow plug in position in the precombustion chamber and tighten it to the specified torque Tightening torque 1,75 ± 0,25 kgf·m (12.7 ± 1.8 lbf·ft) [17,2 ± 2,5 N·m] Figure 180 Installing glow plugs 27.2 Alternator installation 1. 2. 3. 4. Put the alternator in position. Install the adjusting plate bolt in position to hold the alternator in position. Put the belt in position on the pulley.
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Electrical System 110 / 195 ASSEMBLY ENGLISH Service Manual Mitsubishi SL-Series diesel engines Version 08/2004
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ELECTRICAL SYSTEM Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 111 / 195
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GENERAL ELECTRICAL SYSTEM ELECTRICAL SYSTEM 28 GENERAL 28.1 Specifications (standard)1 Engine model Model Starter Glow plug relay 12 - 1.7 Regulator, type IC 12 – 50 Model 008816-4C Type Sheathed Rated voltage, V 10.5 Current draw, A 9.7 ± 1.0 (30 seconds at rated voltage) Model G71SP Rated voltage, V DC 12 Continuous rating 1 minute 13 YM-1C Input voltage range, V DC 9 to 15 Load Solenoid (resistance in coil: 1.7 Model YMS-1 Type Solenoid Resistance in coil, Ω Ω minimum) 1.
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Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 1. 2.
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/ 195 ENGLISH 1. 2. Starter relay 32A66-19100 Starter Glow timer MM431-762 Battery switch 05125-00102 Pressure switch MM130-066 Charge pilot MM201-122 Diode MM434-062 Diode MM434-062 Themo switch MC880-900 Pilot lamp MM201-123 Pilot lamp MM201-124 Battery Control timer I6A12-02001 N.C.
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ELECTRICAL SYSTEM STARTER ELECTRICAL SYSTEM 29 STARTER 29.1 Disassembly Roughness, burns, or stepped wear on commutator surface; worn or damaged gear Broken or damaged pinion Incorrect installation of pole pieces and field coils Abnormal rotation Brush powder deposits, uneven wear, poor brush movement in holder O-rings and snap rings are not reusable. Figure 183 Starter component parts Disassembly sequence 1. Pinion set 2. Solenoid switch 3. Rear bracket 4. Brush holder 5. Yoke 6. Armature 7.
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STARTER ELECTRICAL SYSTEM 29.1.1 Removing Pinion The pinion can be removed when it is held in the pushed-out position during energization of the solenoid switch. S1 S Starter S2 Battery Disconnect the M-terminal connector and make a circuit that connects the starter motor and the battery as shown in the drawing. Close switches S1 and S2 to make the pinion come out and rotate. Then, open switch S2. The pinion will stop rotating but will stay in the pushed-out position.
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ELECTRICAL SYSTEM STARTER 3. Commutator Inspection 1) Measure the commutator’s runout using a dial gauge. If the measurement exceeds the specified limit, rectify the problem, making sure that the outside diameter stays within specification. If the surface is rough or has stepped wear, rectify the problem with emery paper (#300 – 500). Unit: mm (in.) Limit Commutator runout 2) Measure the commutator’s outside diameter. If the measurement is out of specification, replace the armature. Unit: mm (in.
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STARTER ELECTRICAL SYSTEM 2. Brush Coil Gound Test Check whether continuity exists between the yoke and each brush. If continuity exists, the coil is grounded and must be checked for defective insulation. If repair is impossible, replace the yoke assembly. 29.2.3 Brushes and Brush Holders 1. Brush Wear Measure the length of the brush. If the measurement is smaller than the limit, replace the brush.
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ELECTRICAL SYSTEM STARTER 29.2.4 Overrunning Clutch Make sure the pinion shaft rotates smoothly when turned clockwise (in the drive direction) and locks when turned counterclockwise. If the pinion shaft’s operation is defective, replace the overrunning clutch. 29.2.5 Gear Shaft Thrust Gap Adjustment of the gear shaft’s thrust gap is not necessary. 29.2.6 Armature Thrust Gap Adjustment of armature’s thrust gap is not necessary. 29.
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STARTER ELECTRICAL SYSTEM 29.4 Inspection and Testing after Assembly After assembling the starter, perform the following inspections and tests: S-terminal M-terminal Battery (12V) 29.4.1 Inspection and Adjustment of Pinion Gap 1. 2. 3. Pinion gap Connect the assembled starter to the battery as shown in the drawing. The pinion will come out and rotate slowly. Then, remove the M-terminal connector to stop the motor.
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ELECTRICAL SYSTEM STARTER No-Load characteristics Voltage (V) Current (A) Speed (min-1) 11 130 maximum 3,600 minimum 29.4.3 Solenoid Switch S-terminal M-terminal Perform the following continuity tests. If the solenoid switch fails either tests, replace it. B-terminal Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 1) Test for Coil Open Circuit Continuity should exists between the S- and M-terminals and between the S-terminal and ground (case).
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ALTERNATOR ELECTRICAL SYSTEM ELECTRICAL SYSTEM 30 ALTERNATOR 30.1 Disassembly Disassembly sequence 1. Through bolt 2. Pulley 3. Rotor 4. Rear bearing 5. Bearing retainer 6. Front bearing 7. Front bracket 8. Stator core 9. Brush holder 10. Rectifier 11.
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ELECTRICAL SYSTEM ALTERNATOR 30.1.1 Stator core separation from front bracket 1. Pry the stator core off the front bracket with a screwdriver as shown in the illustration. CAUTION Be careful not to insert the screwdriver too deep. Damage to the stator core can be the result. Figure 184 Disassembling alternator 30.1.2 Pulley removal 1. 2. Hold the rotor assembly in a vise by using thick cloth as shown in the illustration.
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ALTERNATOR ELECTRICAL SYSTEM 30.2 Inspection Test for open or short circuit usingthe procedure that follows. Check for cracks or other defects. Test for open or short circuit using theprocedure that follows. Check for cracks or other defects. Check for wear. Test for open or short circuit using the procedure that follows. Figure 187 Inspection points 30.2.1 Diodes Trio-diodes Heat sink (-) Heat sink (+) 1. Test the resistance between the diode and heat sink.
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ELECTRICAL SYSTEM ALTERNATOR 30.2.2 Field coil 1. Test for continuity between the slip rings as shown in the illustration. No continuity shows there is an open circuit in the field coil. Replace the field coil. 2. Test for no continuity between the slip ring and shaft (or core) as shown in the illustration. Any continuity shows there is a grounded circuit in the field coil. Replace the field coil. Figure 189 Testing field coil for open circuit Figure 190 Testing field coil for grounded circuit 30.2.
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ALTERNATOR ELECTRICAL SYSTEM 2. Test for no continuity between each lead and stator core as shown in the illustration. Any continuity shows there is a grounded circuit in the stator core. Replace the stator core. Figure 192 Testing stator core for grounded circuit 30.2.4 Brushes 1. Make replacement of brushes that have been worn down to, or beyond, the wear limit line. 2. To remove the brushes from the brush holder for replacement, unsolder the leads from the brushes.
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ELECTRICAL SYSTEM ALTERNATOR 3. To install the new brushes, put them in position in the brush holder and solder the leads to the brushes. Figure 195 Installing new brushes 30.3 Assembly Follow the reverse of disassembly and use the procedure that follows. 1. Wire-shaped tooling 2. 3. Brushes Rear bracket 4. Wire-shaped tooling The rear bearing has a groove for the snap ring. Install the snap ring in this groove, making sure its tab is in the deep portion of the groove.
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KEY SHUTOFF SYSTEM (ETS solenoid type) ELECTRICAL SYSTEM ELECTRICAL SYSTEM 31 KEY SHUTOFF SYSTEM (ETS solenoid type) 31.1 General This system, consisting of a switch, a control timer and a solenoid, permits the operator to shut off the engine by turning the starter switch key to OFF position. Another function of this system is to shut off the engine automatically when the oil pressure is too low, or when coolant temperature is too high. Control timer Solenoid Figure 197 Key shutoff system 31.
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ELECTRICAL SYSTEM KEY SHUTOFF SYSTEM (ETS solenoid type) 5. Tightening torque: 4.5 ± 0.5 kgf m (32.5 ± lbf ft) [44 ± 5 N m] Threads: to be coated with thread sealant 6. Shaft Plunger 7. Turn the shutoff solenoid in the governor case while pushing the plunger toward the control rack until the shaft is in touch with the tie rod. At this time, clearance C must be 0 mm. (Under this condition, the plunger will be rotated by the shutoff solenoid being turned in.
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KEY SHUTOFF SYSTEM (ETR solenoid type) ELECTRICAL SYSTEM ELECTRICAL SYSTEM 32 KEY SHUTOFF SYSTEM (ETR solenoid type) 32.1 General The energize-to-run (ETR) solenoid-controlled engine shutdown system operates as follows: When the starter switch is turned to the “ON” position, the pull-in coil of the solenoid is energized for three seconds, pulling the push rod inward.
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ELECTRICAL SYSTEM Tie rod KEY SHUTOFF SYSTEM (ETR solenoid type) 32.3 Shutoff solenoid installation 1. Rack at no-injection end position 2. Push rod in free-tomove state Remove the tie rod cover on the injection pump to enable movement of the rack to be observed. Put the nut 2 on the solenoid 1 and turn the nut down to the inner end of the threads on the solenoid. Apply sealant to the threads on the solenoid.
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AUTOMATIC GLOW SYSTEM ELECTRICAL SYSTEM ELECTRICAL SYSTEM 33 AUTOMATIC GLOW SYSTEM 33.1 General Turning the starter switch to ON position activates the glow plugs to heat the engine and causes the glow plug indicator to come on. Starter switch Fuse Heating time Fuel pump Glow plug timer Glow plug indicator Glow plug Battery switch Switch 6.2 ± 0.7 seconds Ammeter Battery Figure 201 Automatic glow plug system 33.
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ELECTRICAL SYSTEM AUTOMATIC GLOW SYSTEM 33.3 Glow plug relay specifications (standard)2 Part number MM431-28201 Rated voltage DC 12 V Continuous rating 1 minute Coil resistance 13 Ω Operating temperature range –40°C to +100°C (–40°F to +212°F) Figure 202 Glow plug relay 33.4 Glow plug inspection Test for continuity between the terminal and body as shown in the illustration. If no continuity, replace with new one. Item Standard Resistance 0.55 Ω Figure 203 Testing glow plug 2.
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COOLING SYSTEM Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 135 / 195
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GENERAL COOLING SYSTEM COOLING SYSTEM 34 GENERAL 34.1 Schematic Water bypass hose Thermostat Water pump Radiator Cooling fan Figure 204 Schematic 34.2 Specifications (standard)1 Engine model S3L/S3L2 Fan belt (for farm or industrial engine) Cooling fan Suction type LL or HM type (width = 10.7 mm (0.42 in.), V angle = 38°, outer circumference = 980 mm (38.6 in.) No. of blades = 5, diameter = 320 mm (12.6 in.) Water pump Thermostat No. of blades = 5, diameter = 360 mm (14.2 in.
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COOLING SYSTEM INSPECTION COOLING SYSTEM 35 INSPECTION Test thermostat using the procedure that follows. Test thermoswitch and thermounit using the procedures that follow. Check for aging or damage Check for cracks or distortion. Use new gaskets. Check for cracks or leaks. Check for elongation, aging or wear.
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INSPECTION COOLING SYSTEM 35.1 Water pump Check the impeller and shaft for rotation. If they do not rotate freely or have noise, replace the water pump assembly. Figure 206 Checking water pump 35.2 Thermostat (standard) Hang the thermostat in the pan of water as shown in the illustration. The thermostat must be below the surface of the water and its must be away from the sides of the pan.
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COOLING SYSTEM INSPECTION 35.3 Thermoswitch (standard) Hang the thermoswitch in the pan of oil with its temperature sensing end below the surface of oil and measure the resistance while heating the oil as shown in the illustration. If the resistance is incorrect, replace the thermoswitch. Resistance at 120°C (248°F) 30 mΩ Temperature at which switch is turned ON 111 ± 3.5°C (232 ± 6.3°F) Figure 208 Testing thermoswitch WARNING Oil in the pan is hot. Any contact can cause severe burns. 35.
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INSPECTION 140 / 195 COOLING SYSTEM ENGLISH Service Manual Mitsubishi SL-Series diesel engines Version 08/2004
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LUBRICATION SYSTEM Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 141 / 195
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GENERAL LUBRICATION SYSTEM LUBRICATION SYSTEM 36 GENERAL 36.1 Schematic Oil pressure switch Main oil gallery Oil filter Pressure relief valve Oil pump Oil screen Oil drain plug 36.2 Specifications1 Engine model S3L/S3L2 S4L/S4L2 Type Force feed Oil API Service Classification CC or better Capacity (high level excl. 0.5 liter (0.13 U.S. gal) of oil in oil filter), liter (U.S. gal) Oil pump 5.7 (1.5) (with deep oil pan) 3.7 (1.0 (with standard oil pan) Type 7.7 (2.0) (with deep oil pan) 5.
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LUBRICATION SYSTEM INSPECTION LUBRICATION SYSTEM 37 INSPECTION 37.1 Oil pump Visually check the pump for rough rotation or other defects. Replace the pump assembly if defective. Figure 210 Checking oil pump 37.2 Oil pressure switch 1. Test for continuity between the terminal and body with an ohmmeter as shown in the illustration. No continuity is the cause for replacing the switch. 2.
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INSPECTION LUBRICATION SYSTEM 37.3 Pressure relief valve Cap nut 1. 2. Shims Figure 213 Checking pressure relief valve 144 / 195 Check the valve seat for contact. Check the spring for damage. Measure the oil pressure at which the relief valve opens (the oil pressure with the engine running at the rated rpm). If the pressure is not correct, remove the cap nut and increase or decrease the amount of shims. The engine oil pressure tap is located on the right side of the engine.
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FUEL SYSTEM Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 145 / 195
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GENERAL FUEL SYSTEM FUEL SYSTEM 38 GENERAL 38.
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FUEL SYSTEM GENERAL 38.2 Specifications (standard)1 Specification Description S3L/S3L2 Type Bosch M Model FUEL INJECTION PUMP ND-PFR3M Plunger diameter MS retard (crank angle), deg 8° Silto or Bosch Air vent screw FUEL FILTER (remote) FUEL FEED PUMP (remote) Table 3 ND-PFR4M 5.5 mm (0.217 in.
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FUEL INJECTION NOZZLE FUEL SYSTEM FUEL SYSTEM 39 FUEL INJECTION NOZZLE 39.1 Inspection 39.1.1 Injection pressure (valve opening pressure) test 1. 2. Figure 215 Fuel injection nozzle ready for test 3. Install the injection nozzle on the tester. Slowly operate the tester handle to bleed (remove) air from the tester. Operate the tester handle at a speed of one stroke per second to make a slow increase in pressure until the valve in the injection nozzle starts to open.
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FUEL SYSTEM FUEL INJECTION NOZZLE 39.1.2 Orifice restriction test 1. Good nozzle Discharge pattern for orifice with a restriction (recondition or replace) 2. Look at the orifice discharge pattern (shape of discharge) when fluid begins to flow through the injection nozzle. The discharge must be straight. Any change is an indication of a bad nozzle. Operate the tester handle at a speed of one stroke per second to make sure the discharge is straight. Figure 217 Orifice restriction test 39.1.
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FUEL INJECTION NOZZLE FUEL SYSTEM 39.2 Disassembly and assembly 5.5 ± 0.5 kgf·m (40 ± 4 lbf·ft) [54 ± 5 N·m] Check for wear Check test force and squareness Check for wear and damage 3.75 ± 0.25 kgf·m (27 ± 1.8 lbf·ft) [36.8 ± 2.5 N·m] Check for too much carbon on tip of nozzle or in nozzle orifice Figure 219 Disassembly sequence and inspection points 150 / 195 Disassembly sequence 1. Retaining nut 2. Nozzle tip assembly 3. Piece 4. Pin 5. Spring 6. Washer 7.
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FUEL SYSTEM FUEL INJECTION PUMP FUEL SYSTEM 40 FUEL INJECTION PUMP 40.1 Test on engine Check the injection pump for items listed in the chart below and replace it if defective. Do not attempt to make repairs by disassembling. Test item Test method Criteria Low idle speed Use a tachometer. Standard engine: 9800+30 min-1 Exhaust smoke 1. No too much black or gray smoke 2. Orifice discharge patter Table 4 Check by quickly increasing engine speed under no-load condition. Check by starting load.
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FUEL INJECTION PUMP FUEL SYSTEM Disassembly procedure 40.2.1 Tappet removal 1. 2. 3. Hold the injection pump in a vise with the side that has tappets up. Straighten the lock plate away from the tappet guide pin with a screwdriver. Rotate the tappet guide pin 180° to unlock it from the housing. Figure 221 Removing tappet guide pins 4. 5. Remove the tappet guide pin with a needle-nose pliers while pushing down on the tappet. Remove the tappet. Do Steps (2) through (4) again for remainder of the tappets.
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FUEL SYSTEM FUEL INJECTION PUMP 40.2.3 Delivery valve removal 1. 2. 3. 4. Turn the injection pump upside down and hold it in a vise. Remove the delivery valve holder. Remove the delivery valve spring. Remove the delivery valve gasket. Figure 224 Removing delivery valve holders 5. 6. Remove the delivery valve with a tweezers. Do Steps (2) through (5) again for remainder of delivery valves. CAUTION The delivery valves are finely finished parts. Keep them as clean as possible.
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FUEL INJECTION PUMP Adjusting plates FUEL SYSTEM NOTE a. b. c. When replacing the plungers and barrels or delivery valves, do not loosen the adjusting plates between the pumping elements. After these parts have been replaced, the injection quantity must be measured. Pump Tester Cam Box is needed for measurement of injection quantity. Keep the disassembled injection pump parts in clean diesel fuel.
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FUEL SYSTEM FUEL INJECTION PUMP 40.3 Inspection Check delivery valve for wear or damage Check plunger for wear, rusting or scoring. Check control rack for movement. Check tappet for wear.
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FUEL INJECTION PUMP FUEL SYSTEM 40.4 Assembly Tightening torque: 4.5±0.5 kgf·m (32.5±4 lbf·ft) [44±5 N·m] Use new O-ring. Use new lock plate. Figure 229 Assembly sequence Follow the reverse of disassembly and use the procedure that follows. Assembly procedure 40.4.1 Barrel installation Put each barrel in position in the housing with its slot in alignment with the dowel of the housing and put it straight down into the bore.
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FUEL SYSTEM FUEL INJECTION PUMP 40.4.2 Delivery valve installation Install the delivery valve, gasket, spring and O-ring on the barrel and tighten the delivery valve holder finger tight. Do this step for remainder of the delivery valves. CAUTION Valve Valve seat Delivery valve a. b. Any time the injection pump is disassembled, a new O-ring must be installed. Make sure the threads of the delivery valve holder do not cause damage to the O-rings. Figure 231 Installing delivery valves 40.4.
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FUEL INJECTION PUMP FUEL SYSTEM 40.4.4 Tappet installation Move the control rack back and forth while pushing down on each tappet to align the slot in the tappet with the hole in the housing for the tappet guide pin. Install the lock plates and tappet guide pins in position. CAUTION Any time the injection pump is disassembled, new lock plates must be used. Figure 234 Installing tappets 40.4.
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FUEL SYSTEM GOVERNOR FUEL SYSTEM 41 GOVERNOR 41.1 Disassembly and inspection Make sure levers move freely Check weights for wear Check sliding sleeve for wear or damage. Make sure it moves freely Check spring for damage Check sliding sleeve contact face for wear Check shaft for defects Figure 237 Disassembly sequence and inspection points Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 Disassembly sequence 1. Tie rod spring 2. Tie rod 3. Speed control lever 4. Spring pin 5.
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GOVERNOR FUEL SYSTEM 41.2 Assembly 1. Install the levers in position. 2. 3. Put O-ring on the governor shaft. Put the governor shaft in position in the governor case and put the levers on the governor shaft. Install the grooved pin and spring pin in position with a hammer. Install the tie rod and tie rod spring in position. Figure 238 Installing governor levers Grooved pin Tie rod spring 4. 5.
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FUEL SYSTEM GOVERNOR 41.3 Torque spring set installation Speed control lever Governor spring Torque spring set Line mark on pump body The torque spring set is to be installed and adjusted after an adjustment is made to the low idle speed and high idle speed, with the engine at a standstill. 1. 2. 3. Line mark on control rack Figure 240 Installing torque spring set Sealing cap Remove the tie rod cover. Move the speed control lever to the high idle position and hold it there.
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FUEL PUMP FUEL SYSTEM FUEL SYSTEM 42 FUEL PUMP 42.1 Inspection Look outside the pump for defects and test its performance. Do not attempt to disassemble the pump.
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FUEL SYSTEM FUEL FILTER FUEL SYSTEM 43 FUEL FILTER 1. 2. Do not remove Coat with silicone oil Coat with grease Wash in diesel fuel every 100 sevice hours. Replace every 500 service hours Check for water and sediment Figure 244 Fuel filter Do not remove Air vent screw Wash in diesel fuel every 100 sevice hours. Replace every 400 service hours Normally, the fuel filter is not to be disassembled. Only element removal for cleaning or replacement is recommended.
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FUEL FILTER 164 / 195 FUEL SYSTEM ENGLISH Service Manual Mitsubishi SL-Series diesel engines Version 08/2004
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AIR INLET SYSTEM AND EXHAUST SYSTEM Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 165 / 195
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GENERAL AIR INLET SYSTEM AND EXHAUST SYSTEM AIR INLET SYSTEM AND EXHAUST SYSTEM 44 GENERAL 44.
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AIR INLET SYSTEM AND EXHAUST SYSTEM INSPECTION AIR INLET SYSTEM AND EXHAUST SYSTEM 45 INSPECTION Check for cracks Use a new packing Check for cracks Use a new gasket Use a new gasket Check for cracks Figure 248 Inspection points 45.1 Inspection procedure Using a straight edge and a feeler gauge, check the flange faces of the manifold for warpage. If warpage exceeds the limit, recondition or replace the manifold. Item Warpage of manifold Table 5 Standard 0.15 (0.005 9) Inspection, unit mm (in.
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INSPECTION 168 / 195 AIR INLET SYSTEM AND EXHAUST SYSTEM ENGLISH Service Manual Mitsubishi SL-Series diesel engines Version 08/2004
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MAINTENANCE Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 169 / 195
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LUBRICATION AND MAINTENANCE CHART MAINTENANCE MAINTENANCE 46 LUBRICATION AND MAINTENANCE CHART Recommended service should be performed at the specified intervals. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in this chart may be necessary. Perform service on items at multiples of the original requirement.
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MAINTENANCE LUBRICATION AND MAINTENANCE CHART Interval Every 2 Years When Required Item Remarks (specifications) Change coolant See operation manual Prime fuel system 181 Clean air cleaner element 180 Change air cleaner element Table 6 Page See operation manual Lubrication and maintenance charts Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 171 / 195
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ENGINE OIL AND OIL FILTER MAINTENANCE MAINTENANCE 47 ENGINE OIL AND OIL FILTER 47.1 Engine oil specifications1 Use oils that meet the Engine Service Classification CF or CF-4. Starting temperature, °C (°F) -30 (-22) -25 (-13) -20 (-4) -15 (5) -10 (14) -5 (23) 0 (32) 10 (50) 20 (68) 30 (86) 40 (104) SAE30 S A E 40 S A E 15 W - 4 0 Oil viscosities SAE10W-30 SAE5W-20 Table 7 Recommended oil viscosities 47.2 Oil level check Dipstick Oil fillers 1. 2.
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MAINTENANCE ENGINE OIL AND OIL FILTER 47.3 Oil and oil filter change 1. 2. 3. Change the oil and the oil filter after the initial 50 service hours of a new or reconditioned engine and, thereafter, every 250 service hours or once a year (whatever comes first). Warm up the engine. Remove the drain plug and allow the oil to drain in a container. Remove the used filter with a filter wrench. Make sure that the formely used O-ring is removed from the filter base and clean the base with a cloth.
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ENGINE OIL AND OIL FILTER MAINTENANCE CAUTION Do not cause damage to the O-ring when installing the filter. 4. 5. 6. 174 / 195 ENGLISH Add 0.5 liter (0.5 qt) of oil. Start the engine and check for leaks around the filter. Stop the engine. Check the oil level and add oil if necessary.
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MAINTENANCE VALVE CLEARANCE MAINTENANCE 48 VALVE CLEARANCE NOTE < Front of engine Make an adjustment to the valve clearance when the engine is cold. 1. Slightly loosen the cylinder head bolts and retighten them to the specified torque in number sequence. Figure 253 Cylinder head bolt tightening sequence Tightening torque TDC (top dead center) mark for No. 1 and No. 4 pistons 2. Mark on timimg gear case IT (injection timimg) mark TDC mark for No. 2 and No. 3 pistons Figure 254 Timing mark 3.
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VALVE CLEARANCE MAINTENANCE 5. After the valve clearance on the valves for No.
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MAINTENANCE FUEL INJECTION TIMING MAINTENANCE 49 FUEL INJECTION TIMING 49.1 Preparation 1. 2. 3. 4. 5. Close the fuel filter valve. Disconnect the No. 1 fuel injection pipe from the cylinder head and injection pump. Remove No. 1 delivery valve holder from the injection pump. Remove the delivery valve and spring from the holder. Restore the delivery valve holder only to the injection pump. Connect the fuel injection pipe to the injection pump. Hold the speed control lever in the low speed position.
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FUEL INJECTION TIMING MAINTENANCE 3. The fuel injection timing is correct if IT mark on the crankshaft pulley is aligned with the mark on the timing gear case when fuel stops from the injection pipe. Fuel injection timing (BTDC) 17° (standard)a a. Please refer to the applicable engine model specification sheet for actual data Figure 259 Timing mark 49.2.2 Alternate method In the fuel flow method, the delivery valve has to be removed.
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MAINTENANCE FUEL INJECTION TIMING 49.3 Adjustment 1. 2. If the fuel injection timing is incorrect, change the thickness of shims under the fuel injection pump. An increase or decrease of the shims by 0.1 mm (0.004 in.) will vary the timing by 1°. Increase the thickness of the shims to retard the timing or decrease it to advance the timing. Valve clearance (both inlet and exhaust valves) 0.25 (0.0098) Shims Four kinds of shims are available in thicknesses 0.2 mm (0.007 9 in.), 0.3 mm (0.011 8 in.), 0.
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FUEL FILTER MAINTENANCE MAINTENANCE 50 FUEL FILTER 50.1 Fuel filter with [AIR] valve Close the fuel filter valve. Loosen the ring nut and take out the element for cleaning or replacement. Valve lever Element Ring nut Figure 264 Fuel filter with [AIR] valve 50.2 Cartridge (air vent screw) type fuel filter Replace the filter as an assembly if water and sediment have been accumulated in it.
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MAINTENANCE FUEL SYSTEM PRIMING MAINTENANCE 51 FUEL SYSTEM PRIMING 51.1 Engine with fuel filter with [AIR] valve Overflow pipe [OFF] 1. 2. 3. [AIR] 4. [ON] Move the fuel filter valve lever to AIR position. Move the lever to ON position when the fuel flows free of bubbles from the overflow pipe. To prime the fuel pipe and fuel injection pump, loosen the air vent screw of the injection pump. The injection pipes and nozzles can be primed by cranking the engine. 5.
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IDLE RPM SETTING MAINTENANCE MAINTENANCE 52 IDLE RPM SETTING High idle position Low idle position NOTE Make sure that the valve clearance and injection timing are correct and that the fuel injection nozzles have no defect. 1. 2. 3. Idling set bolt Lock nuts Start and run the engine at low idle until the coolant temperature is above 60°C (140°F). To set the low idle speed, loosen the lock nut for the idling set bolt and turn the set bolt to make the engine run at the specified rpm.
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MAINTENANCE FUEL INJECTION NOZZLES MAINTENANCE 53 FUEL INJECTION NOZZLES 53.1 Injection pressure (valve opening pressure) test See FUEL INJECTION NOZZLE (page 148). 53.2 Orifice restriction test Make reference to FUEL INJECTION NOZZLE (page 149). 53.3 Nozzle tip washing and replacement Make reference to FUEL INJECTION NOZZLE (page 149). 53.4 Installation 1. 2. Put the gasket on the injection nozzle. Put the nozzle in position in the cylinder head and tighten it to the specified torque.
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FAN BELT MAINTENANCE MAINTENANCE 54 FAN BELT 1. Adjusting bolt 2. Measure the deflection of the belt. Apply 10 kgf (22 lbf) [98 N] force midway between the alternator pulley and the crankshaft pulley. Adjust the belt if the deflection is not correct. Loosen the adjusting bolt and move the alternator to obtain the required belt deflection. Unit: mm(in.) Item Deflection Deflection: 10 to 12 mm (0.4 to 0.5 in.) under 10 kgf (22 lbf) [98 N] force Standard 10 to 12 (0.4 to 0.
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SERVICE DATA Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 185 / 195
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SPECIFICATIONS SERVICE DATA SERVICE DATA 55 SPECIFICATIONS1 55.1 Basic engine components Unit: mm (in.) Item Standard Limit Correction-Remarks Compression pressure 30 kgf/cm2 (427 psi) [2 942 kPa] 27 kgf/cm2 (384 psi) [2 648 kPa] Repair or replace. Maximum permissible difference between average compression pressure of all cylinders in one engine 3 kgf/cm2 (42.7 psi) [294 kPa] — Repair or replace. Fuel injection timing (BTDC)a 17° Clearance between rocker arm and shaft (oil clearance) 0.
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SERVICE DATA SPECIFICATIONS Item Standard Limit Correction-Remarks 0.30 (0.011 8) Replace. Crankshaft gear and idler gear Idler gear and camshaft gear Timing gear backlash Idler gear and fuel injection pump camshaft gear 0.04 to 0.12 (0.001 6 to 0.004 7) Camshaft gear and P.T.O. gear 0.08 to 0.19 (0.003 1 to 0.007 5) Fuel injection pump cam-shaft gear and oil pump gear 0.07 to 0.20 (0.0028 to 0.0079) Lobe height of camshaft 35.72 (1.406 3) 34.72 (1.366 9) Replace.
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SPECIFICATIONS SERVICE DATA Item Standard Limit Correction-Remarks Clearance between crankpin and connecting rod bearing 0.025 to 0.072 (0.000 98 to 0.002 83) 0.150 (0.005 91) Replace connecting rod bearing. Thrust clearance for connecting rod big end 0.10 to 0.35 (0.003 9 to 0.013 8) 0.50 (0.019 7) Replace connecting rod. Diameter of journal 51.985 to 52.000 (2.046 65 to 2.047 24) — Diameter of crankpin 47.950 to 47.965 (1.887 79 to 1.888 38) — Runout 0.025 (0.000 98) 0.05 (0.
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SERVICE DATA SPECIFICATIONS 55.5 Cooling system (standard) Unit: mm (in.) Item Thermostat Thermoswitch Standard Limit Temperature at which valve starts opening 82 ± 1.5°C (180 ± 2.7°F) — Temperature at which valve lift is more than 8 mm (0.3 in.) 95°C (203°F) — Temperature at which switch is turned ON 111 ± 3.5°C (232 ± 6.3°F) — Resistance at oil temperature of 120°C (284°F) 30 mΩ maximum — At 50°C (122°F) 80 ± 10 Ω — At 80°C (176°F) 29.5 ± 2.5 Ω — At 120°C (248°F) 10 ± 0.
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SPECIFICATIONS SERVICE DATA Item Standard Limit 14.7 ± 0.3 V — Terminal voltage 13.5 V — Current 33 A min. — Terminal voltage 13.5 V — Current 47 A min. — — Wear limit line Replace. 0.55 Ω — Replace. Alternator Regulated voltage at 20°C (68°F) Output characteristics (at operating temperature) At 2500 rpm At 500 rpm Brush length Resistance in glow plug 190 / 195 ENGLISH Correction-Remarks Test.
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SERVICE DATA TIGHTENING TORQUES SERVICE DATA 56 TIGHTENING TORQUES 56.1 Major bolts and nuts Unit: mm (in.) Thread, mm Bolt or nut Torque, kgf·m (lbf·ft) [N·m] Diameter Pitch Width Clamp length Cylinder head bolt M10 1.25 14 87 9 ± 0.5 (65 ± 4) [88 ± 5] Rocker cover bolt M8 1.25 12 40 1.15 ± 0.15 (8.3 ± 1.1) [11.3 ± 1.5] Rocker shaft bracket bolt M8 1.25 12 58 1.5 ± 0.5 (11 ± 4) [14.7 ± 5] Thermoswitch M16 1.5 17 31.5 2.3 ± 0.4 (16.6 ± 3) [22.
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TIGHTENING TORQUES SERVICE DATA 56.2 Torques for bolts and nuts with standard threads Unit: kgf·m (lbf·ft) [N·m] Identification on head Thread diameter 4 7 M6 0.4 ± 0.1 (3 ± 0.7) [3.9 ± 1] 0.9 ± 0.1 (6.5 ± 0.7) [8.8 ± 1] M8 1.1 ± 0.1 (8 ± 0.7) [10.8 ± 1] 1.85 ± 0.35 (13.4 ± 2.5) [18 ± 3] M10 2.15 ± 0.35 (15.6 ± 2.5) [21 ± 3] 3.6 ± 0.6 (26 ± 4.3) [35.3 ± 6] M12 3.6 ± 0.6 (26 ± 4.3) [35.3 ± 6] 6.5 ± 1 (47 ± 7) [63.7 ± 10] M14 6±1 (43 ± 7) [59 ± 10] 9.5 ± 1.5 (69 ± 11) [93.2 ± 15] 56.
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SERVICE DATA SEALANTS SERVICE DATA Thread parts 57 SEALANTS Component Sealant Mating part Stop solenoid Three Bond 1212 Governor case Three Bond 1102 Cylinder block Three Bond 1212 Governor case Water drain joint Oil pressure switch Torque spring set Remarks Apply to effective thread part. Force-fit parts Cylinder block Cylinder head Sealing cap Three Bond 1102 Cylinder head and cylinder block Expansion plug Apply to holes in cylinder head and cylinder block.
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SPECIAL TOOLS SERVICE DATA SERVICE DATA 58 SPECIAL TOOLS Tool No.
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BLANK PAGE Service Manual Mitsubishi SL-Series diesel engines Version 08/2004 ENGLISH 195 195 / 195