Mitsubishi Sl Series Servicemanual

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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
Copyright © 2004 MHI Equipment Europe B.V.

Service Manual Mitsubishi SL-Series diesel engines ENGLISH 1 / 195

Version 08/2004

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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.

NOTE
Indicates a condition that can cause engine damage

CAUTION
Indicates a condition that can cause personal injury or

WARNING death.

Definition of locational terms

The fan end is “front” and the flywheel end is “rear”. The words “left” and “right” are as these directions would appear
as seen from the flywheel side. The cylinder sequencing begins on the front side (timing gearcase side) of the
engine and works its way to the flywheel side.

Dimensional or specification terms

Nominal size Is the named size which has no specified limits of accuracy.
Standard Is the dimension of a part to be attained at the time of
assembly, or the standard performance.
Limit Is the maximum or minimum permissible limit beyond which a
part must be repaired or replaced.

Tightening torques
Tighten bolts, nuts, etc. in a wet condition (apply oil to threads) when specified as [WET]. Tighten them in a dry
condition unless so specified. Use the general tightening torques unless otherwise specified.

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 TABLE OF CONTENTS

TABLE OF CONTENTS
GENERAL INFORMATION
1 MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION.................................................... 10
1.1 Model identification location................................................................................................... 10
1.2 Serial Number Location ......................................................................................................... 11
2 COMPONENT LOCATION.............................................................................................................. 12
2.1 S3L/S3L2 ............................................................................................................................... 12
2.2 Engine S3L-T/S3L2-T ............................................................................................................ 13
2.3 S4L/S4L2 ............................................................................................................................... 14
2.4 Engine S4L-T/S4L2-T ............................................................................................................ 15
3 SPECIFICATIONS .......................................................................................................................... 16

OVERHAUL INSTRUCTIONS
4 DETERMINING WHEN TO OVERHAUL THE ENGINE ................................................................. 18
5 COMPRESSION PRESSURE MEASUREMENT............................................................................ 19
5.1 Inspection............................................................................................................................... 19
5.2 Measurement ......................................................................................................................... 19
6 TROUBLESHOOTING .................................................................................................................... 20
6.1 General .................................................................................................................................. 20
6.2 Engine troubleshooting .......................................................................................................... 21
6.3 Starting system troubleshooting............................................................................................. 27
7 BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY................................................... 29
7.1 Disassembly........................................................................................................................... 29
7.2 Assembly ............................................................................................................................... 29

DISASSEMBLY
8 PREPARATION FOR DISASSEMBLY............................................................................................ 32
8.1 Engine oil draining ................................................................................................................. 32
8.2 Coolant draining 1 .................................................................................................................. 32
9 ELECTRICAL SYSTEM .................................................................................................................. 33
9.1 Starter .................................................................................................................................... 33
9.2 Alternator ............................................................................................................................... 35
10 Cooling System ............................................................................................................................... 38
10.1 Cooling fan removal ............................................................................................................... 38
10.2 Thermostat case removal ...................................................................................................... 38
10.3 Water pump assembly removal ............................................................................................. 38
11 Fuel System .................................................................................................................................... 39
11.1 Fuel injection pipe removal .................................................................................................... 39
11.2 Fuel injection nozzle removal................................................................................................. 39
11.3 Governor assembly removal .................................................................................................. 39
11.4 Governor weight removal....................................................................................................... 40
11.5 Fuel injection pump removal .................................................................................................. 40
12 Lubrication System.......................................................................................................................... 41
12.1 Oil filter removal ..................................................................................................................... 41
12.2 Pressure relief valve removal................................................................................................. 41
12.3 Oil pressure switch removal................................................................................................... 41
13 AIR INLET SYSTEM AND EXHAUST SYSTEM ............................................................................. 42
13.1 Exhaust manifold removal...................................................................................................... 42
13.2 Air inlet cover removal ........................................................................................................... 42
14 CYLINDER HEAD AND VALVE MECHANISM ............................................................................... 43
14.1 Rocker shaft assembly removal............................................................................................. 44
14.2 Rocker shaft disassembly ...................................................................................................... 44
14.3 Cylinder head bolt removal .................................................................................................... 44
14.4 Cylinder head assembly removal........................................................................................... 45
14.5 Valve and valve spring removal ............................................................................................. 45
14.6 Valve stem seal removal........................................................................................................ 45
15 Timing Gears and Flywheel............................................................................................................. 46

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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

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21.2 Oil pump installation............................................................................................................... 92

21.3 Engine turning........................................................................................................................ 92
21.4 Engine turning........................................................................................................................ 93
21.5 Camshaft installation.............................................................................................................. 93
21.6 Idler gear installation.............................................................................................................. 94
21.7 Timing gear case installation ................................................................................................. 94
21.8 Crankshaft pulley nut tightening............................................................................................. 94
21.9 P.T.O. gear installation .......................................................................................................... 95
21.10Speedometer driven gear installation .................................................................................... 95
21.11Tappet installation.................................................................................................................. 95
21.12Oil seal case installation ........................................................................................................ 96
21.13Rear plate installation ............................................................................................................ 96
21.14Flywheel installation............................................................................................................... 96
22 CYLINDER HEAD AND VALVE MECHANISM ............................................................................... 98
22.1 Cylinder head bottom face cleaning....................................................................................... 99
22.2 Valve stem seal installation.................................................................................................... 99
22.3 Valve spring installation ......................................................................................................... 99
22.4 Installing valve block ............................................................................................................ 100
22.5 Cylinder head gasket installation ......................................................................................... 100
22.6 Cylinder head installation..................................................................................................... 100
22.7 Cylinder head bolt tightening ............................................................................................... 101
22.8 Valve push rod installation ................................................................................................... 101
22.9 Rocker shaft assembling...................................................................................................... 101
22.10Rocker shaft assembly installation....................................................................................... 102
22.11Valve clearance adjustment................................................................................................. 102
22.12Rocker cover installation...................................................................................................... 102
23 Air Inlet System and Exhaust System ........................................................................................... 103
23.1 Air inlet cover installation ..................................................................................................... 103
23.2 Exhaust manifold installation ............................................................................................... 103
24 Fuel System .................................................................................................................................. 104
24.1 Fuel injection nozzle installation .......................................................................................... 104
24.2 Fuel injection pump installation............................................................................................ 104
24.3 Flyweight assembly installation............................................................................................ 104
24.4 Sliding sleeve installation..................................................................................................... 105
24.5 Governor assembly installation............................................................................................ 105
24.6 Fuel injection line installation ............................................................................................... 105
25 Lubrication system ........................................................................................................................ 106
25.1 Pressure relief valve installation .......................................................................................... 106
25.2 Oil filter installation............................................................................................................... 106
25.3 Oil pressure switch installation............................................................................................. 106
26 Cooling system.............................................................................................................................. 107
26.1 Water pump installation ....................................................................................................... 107
26.2 Thermostat installation......................................................................................................... 107
26.3 Cooling fan installation......................................................................................................... 107
26.4 Thermoswitch and thermounit combination installation ....................................................... 108
27 Electrical System........................................................................................................................... 109
27.1 Glow plug installation ........................................................................................................... 109
27.2 Alternator installation ........................................................................................................... 109

ELECTRICAL SYSTEM
28 GENERAL ..................................................................................................................................... 112
28.1 Specifications (standard) ..................................................................................................... 112
28.2 Wiring diagrams ................................................................................................................... 113
29 STARTER...................................................................................................................................... 115
29.1 Disassembly......................................................................................................................... 115
29.2 Inspection............................................................................................................................. 116
29.3 Assembly ............................................................................................................................. 119
29.4 Inspection and Testing after Assembly ................................................................................ 120
30 ALTERNATOR .............................................................................................................................. 122

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30.1 Disassembly......................................................................................................................... 122

30.2 Inspection............................................................................................................................. 124
30.3 Assembly ............................................................................................................................. 127
31 KEY SHUTOFF SYSTEM (ETS solenoid type)............................................................................. 128
31.1 General ................................................................................................................................ 128
31.2 Cord color (standard) ........................................................................................................... 128
31.3 Shutoff solenoid installation ................................................................................................. 128
31.4 Inspection after assembly .................................................................................................... 129
32 KEY SHUTOFF SYSTEM (ETR solenoid type)............................................................................. 130
32.1 General ................................................................................................................................ 130
32.2 Cord color (standard) ........................................................................................................... 130
32.3 Shutoff solenoid installation ................................................................................................. 131
33 AUTOMATIC GLOW SYSTEM .................................................................................................... 132
33.1 General ................................................................................................................................ 132
33.2 Glow timer specification (standard)...................................................................................... 132
33.3 Glow plug relay specifications (standard) ............................................................................ 133
33.4 Glow plug inspection............................................................................................................ 133

COOLING SYSTEM
34 GENERAL ..................................................................................................................................... 136
34.1 Schematic ............................................................................................................................ 136
34.2 Specifications (standard) ..................................................................................................... 136
35 INSPECTION ................................................................................................................................ 137
35.1 Water pump ......................................................................................................................... 138
35.2 Thermostat (standard) ......................................................................................................... 138
35.3 Thermoswitch (standard) ..................................................................................................... 139
35.4 Thermounit (standard) ......................................................................................................... 139

LUBRICATION SYSTEM
36 GENERAL ..................................................................................................................................... 142
36.1 Schematic ............................................................................................................................ 142
36.2 Specifications....................................................................................................................... 142
37 INSPECTION ................................................................................................................................ 143
37.1 Oil pump............................................................................................................................... 143
37.2 Oil pressure switch............................................................................................................... 143
37.3 Pressure relief valve ............................................................................................................ 144

FUEL SYSTEM
38 GENERAL ..................................................................................................................................... 146
38.1 Schematic ............................................................................................................................ 146
38.2 Specifications (standard) ..................................................................................................... 147
39 FUEL INJECTION NOZZLE .......................................................................................................... 148
39.1 Inspection............................................................................................................................. 148
39.2 Disassembly and assembly ................................................................................................. 150
40 FUEL INJECTION PUMP.............................................................................................................. 151
40.1 Test on engine ..................................................................................................................... 151
40.2 Disassembly......................................................................................................................... 151
40.3 Inspection............................................................................................................................. 155
40.4 Assembly ............................................................................................................................. 156
41 GOVERNOR ................................................................................................................................. 159
41.1 Disassembly and inspection ................................................................................................ 159
41.2 Assembly ............................................................................................................................. 160
41.3 Torque spring set installation ............................................................................................... 161
42 FUEL PUMP.................................................................................................................................. 162
42.1 Inspection............................................................................................................................. 162
43 FUEL FILTER................................................................................................................................ 163

AIR INLET SYSTEM AND EXHAUST SYSTEM

44 GENERAL ..................................................................................................................................... 166

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44.1 Schematic ............................................................................................................................ 166

45 INSPECTION ................................................................................................................................ 167
45.1 Inspection procedure ........................................................................................................... 167

MAINTENANCE
46 LUBRICATION AND MAINTENANCE CHART ............................................................................. 170
47 ENGINE OIL AND OIL FILTER ..................................................................................................... 172
47.1 Engine oil specifications....................................................................................................... 172
47.2 Oil level check...................................................................................................................... 172
47.3 Oil and oil filter change ........................................................................................................ 173
47.4 Oil filter change .................................................................................................................... 173
48 VALVE CLEARANCE.................................................................................................................... 175
49 FUEL INJECTION TIMING............................................................................................................ 177
49.1 Preparation .......................................................................................................................... 177
49.2 Adjustment ........................................................................................................................... 179
50 FUEL FILTER................................................................................................................................ 180
50.1 Fuel filter with [AIR] valve .................................................................................................... 180
50.2 Cartridge (air vent screw) type fuel filter .............................................................................. 180
51 FUEL SYSTEM PRIMING ............................................................................................................. 181
51.1 Engine with fuel filter with [AIR] valve .................................................................................. 181
51.2 Engine with cartridge (air vent screw) type fuel filter ........................................................... 181
52 IDLE RPM SETTING..................................................................................................................... 182
53 FUEL INJECTION NOZZLES........................................................................................................ 183
53.1 Injection pressure (valve opening pressure) test ................................................................. 183
53.2 Orifice restriction test ........................................................................................................... 183
53.3 Nozzle tip washing and replacement ................................................................................... 183
53.4 Installation............................................................................................................................ 183
54 FAN BELT ..................................................................................................................................... 184

SERVICE DATA
55 SPECIFICATIONS ........................................................................................................................ 186
55.1 Basic engine components.................................................................................................... 186
55.2 Lubrication system ............................................................................................................... 188
55.3 Fuel system.......................................................................................................................... 188
55.4 Air inlet system and exhaust system.................................................................................... 188
55.5 Cooling system (standard) ................................................................................................... 189
55.6 Electrical system .................................................................................................................. 189
56 TIGHTENING TORQUES ............................................................................................................. 191
56.1 Major bolts and nuts............................................................................................................. 191
56.2 Torques for bolts and nuts with standard threads................................................................ 192
56.3 Torques for plugs with taperlock threads ............................................................................. 192
57 SEALANTS.................................................................................................................................... 193
58 SPECIAL TOOLS .......................................................................................................................... 194

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 GENERAL INFORMATION

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Mitsubishi Sl Series Servicemanual
MODEL
Full download: IDENTIFICATION AND SERIAL
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NUMBER LOCATION General

General

1 MODEL
IDENTIFICATION AND
SERIAL NUMBER
LOCATION
1.1 Model identification location
t

• 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

S3L 1.125 liters (68.7 cu in.)

S3L2 1.318 liters (80.4 cu in.)

Figure 1 Model identification location S4L 1.500 liters (91.5 cu in.)

S4L2 1.758 liters (107.3 cu in.)

• A scheme of coding used for identifying the

engines in current production is as follows:

S 4 L (2) – 61 A

S - Identification of “Sagamihara Machinery Works”

4 - Number-of-cylinders code [“4” stands for four

cylinders]

L - Series code [Bore: 78 mm (3.07 in.)]

(2) - Stroke code

• (No code: 78.5 mm (3.09 in.)
• 2: 92 mm (3.62 in.)

61 - Export code

A - Specification code

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