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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
Version 08/2004
ENGLISH
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
WARNING
Indicates a condition that can cause personal injury or 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
Standard
Limit
Is the named size which has no specified limits of accuracy.
Is the dimension of a part to be attained at the time of assembly, or the standard performance.
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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Service Manual Mitsubishi SL-Series diesel engines
Version 08/2004
TABLE OF CONTENTS
TABLE OF CONTENTS
GENERAL INFORMATION
1
2
3
1.1
1.2
2.1
2.2
2.3
2.4
OVERHAUL INSTRUCTIONS
4
5
6
7
5.1
5.2
6.1
6.2
6.3
BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY................................................... 29
7.1
7.2
DISASSEMBLY
8
9
8.1
8.2
.................................................................................................................. 32
9.1
9.2
10
11
12
13
14
15
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
TABLE OF CONTENTS
16
INSPECTION
17
18
19
ASSEMBLY
20
21
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Service Manual Mitsubishi SL-Series diesel engines
TABLE OF CONTENTS
22
23
24
25
26
27
ELECTRICAL SYSTEM
28
29
30
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
TABLE OF CONTENTS
31
32
33
COOLING SYSTEM
34
35
LUBRICATION SYSTEM
36
37
FUEL SYSTEM
38
39
40
41
42
43
AIR INLET SYSTEM AND EXHAUST SYSTEM
44
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Service Manual Mitsubishi SL-Series diesel engines
TABLE OF CONTENTS
45
MAINTENANCE
46
47
48
49
50
51
52
53
54
SERVICE DATA
55
56
57
58
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
TABLE OF CONTENTS
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
GENERAL INFORMATION
Service Manual Mitsubishi SL-Series diesel engines
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MODEL IDENTIFICATION AND SERIAL
NUMBER LOCATION
Figure 1 Model identification location
General
General
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:
S3L
S3L2
S4L
S4L2
Displacement
1.125 liters (68.7 cu in.)
1.318 liters (80.4 cu in.)
1.500 liters (91.5 cu in.)
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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Service Manual Mitsubishi SL-Series diesel engines
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General
Serial number
Figure 2 Serial number location
MODEL IDENTIFICATION AND SERIAL
NUMBER LOCATION
1.2
Serial Number Location
The serial number is punched on the cylinder block, near the fuel injection pump mount.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
COMPONENT LOCATION
Hanger
Fuel injection nozzle
Air inlet cover
Stop solenoid
Fuel filter
Coolant drain plug
Oil pressure switch
Dipstick
Oil drain plug
REAR
Thermoswitch
Thermostat
Hanger
Alternator
Fan
V-belt
RIGHT SIDE VIEW
GENERAL INFORMATION
GENERAL INFORMATION
2 COMPONENT
LOCATION
2.1
S3L/S3L2
Oil filler
Air vent screw
Fuel injection pump
Water pump
Oil filler
Crankshaft pulley
Oil filter
FRONT
Exhaust manifold
Flywheel housing
Starter
Flywheel
Oil pan
FRONT REAR
LEFT SIDE VIEW
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Service Manual Mitsubishi SL-Series diesel engines
GENERAL INFORMATION COMPONENT LOCATION
2.2
Engine S3L-T/S3L2-T
Hanger
Fuel injection nozzle
Air inlet cover
Stop solenoid
Fuel filter
Coolant drain plug
Dipstick
Oil drain plug
REAR
Thermoswitch
Thermostat
RIGHT SIDE VIEW
Hanger
Alternator
Fan
V-belt
Oil filler
FRONT
Air vent screw
Fuel injection pump
Water pump
Oil filler
Oil pressure switch
Crankshaft pulley
Oil filter
FRONT
Turbocharger
Exhaust manifold
Flywheel housing
Starter
Flywheel
Oil pan
REAR
LEFT SIDE VIEW
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
COMPONENT LOCATION GENERAL INFORMATION
2.3
S4L/S4L2
Hanger
Fuel injection nozzle
Air inlet cover
Stop solenoid
Fuel filter
Coolant drain plug
Oil pressure switch
Oil filter
Oil drain plug
REAR
Thermoswitch
Thermostat
RIGHT SIDE VIEW
Hanger
Alternator
Fan
V-belt
Oil filler
Air vent screw
Fuel injection pump
Water pump
Oil filler
Crankshaft pulley
Dipstick
FRONT
Exhaust manifold
Flywheel housing
Starter
Flywheel
FRONT LEFT SIDE VIEW
Oil pan
REAR
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Service Manual Mitsubishi SL-Series diesel engines
GENERAL INFORMATION COMPONENT LOCATION
2.4
Engine S4L-T/S4L2-T
Hanger
Fuel injection nozzle
Air inlet cover
Stop solenoid
Fuel filter
Oil pressure switch
Oil filter
Oil drain plug
REAR
Thermoswitch
Thermostat
Hanger
Alternator
Fan
V-belt
RIGHT SIDE VIEW
Oil filler
Air vent screw
Fuel injection pump
Water pump
Oil filler
Crankshaft pulley
Dipstick
FRONT
Turbocharger
Exhaust manifold
Flywheel housing
Starter
Flywheel
FRONT LEFT SIDE VIEW
Oil pan
REAR
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SPECIFICATIONS GENERAL INFORMATION
GENERAL INFORMATION
3 SPECIFICATIONS
1
System Item
Type
Combustion chamber
No. of cylinders
ENGINE PROPER
Bore x Stroke (mm)
Total displacement (l)
Compression ratio
Firing order
Dry weight (kg)
Lubricating method
LUBRICATING
SYSTEM
Oil pump
Oil filter
Oil capacity:
FULL level/EMPTY level (l)
(Exclusive of oil filter capacity 0.5 l)
Fuel injection pump
FUEL SYSTEM
Nozzle
Fuel injection pressure
Fuel to be used
Governor
INTAKE SYSTEM
Air cleaner
Turbocharger model
COOLING
SYSTEM
Cooling method
Water pump
Coolant capacity (l)
(Engine proper only)
Starter (V - kW)
Alternator (V - A)
ELECTRICAL
SYSTEM Glow plug
Battery
(capacity depends on application)
Table 1 Specifications
Model
S3L S3L-T S3L2 S3L2-T S4L S4L-T S4L2 S4L2-T
4-cycle, water-cooled, vertical, overhead valve, diesel engine
Swirl chamber type
3 4
78x78.5
1.125
78x92
1.318
78x78.5
1.500
78x92
1.758
135 139
1-3-2
135
22
1-3-4-2
139 155
Forced lubrication
159 155
Trochoid pump
Paper element type
159
Shallow type oil pan: 3.7/2.3
Deep type oil pan: 5.7/3.1
Shallow type oil pan: 5.5/3.7
Deep type oil pan: 7.6/4.2
Bosch M
Throttle type
140 kgf/cm
2
Diesel fuel; see chapter 7
Centrifugal weight type
Paper-element type
Without TD025 Without TD025 Without TD025 Without TD03
Forced circulation of water
Centrifugal type
1.8
2.5
12 - 1.6 or 12 - 1.7 or 12 - 2.0
AC generator (12 - 50)
Sheathed type
12V, 65 Ah or more 12V, 80 Ah or more
1. All specifications are subject to change without any prior notice.
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Service Manual Mitsubishi SL-Series diesel engines
OVERHAUL INSTRUCTIONS
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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.
These troubles, however, are not always the result of low compression pressure and give no valid reason for overhauling the engine.
The engine develops troubles of widely different varieties when the compression pressure drops in it.
Following are the typical troubles caused by the compression pressure failure:
1.
Low power or loss of power
2.
Increase in fuel consumption
3.
Increase in lube oil consumption
4.
Excessive blowby through breather due to worn cylinders, pistons, etc.
5.
Excessive blowby due to poor seating of worn inlet and exhaust valves
6.
Hard starting or failure to start
7.
Excessive engine noise
In most cases, these troubles occur concurrently.
Some of them are directly caused by low compression pressure, but others are not. Among the troubles listed above, (2) and (6) are caused by a fuel injection pump improperly adjusted with respect to injection quantity or injection timing, worn injection pump plungers, faulty injection nozzles, or poor care of the battery, starter and alternator.
The trouble to be taken into account as the most valid reason for overhauling the engine is (4): in actually determining when to overhaul the engine, it is reasonable to take this trouble into account in conjunction with the other ones.
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Service Manual Mitsubishi SL-Series diesel engines
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OVERHAUL INSTRUCTIONS t
Figure 3 Compression gauge and adaptor
Figure 4 Measuring compression pressure
CAUTION
• It is important to measure the compression pressure at regular intervals to obtain the data on the gradual change of the compression pressure.
• The compression pressure would be slightly higher than the standard in a new or overhauled engine owing to breaking-in of the piston rings, valve seats, etc. It drops as the engine components wear down.
COMPRESSION PRESSURE
MEASUREMENT
OVERHAUL INSTRUCTIONS
5 COMPRESSION
PRESSURE
MEASUREMENT
5.1
Inspection
Check to make sure:
1.
The crankcase oil level is correct, and the air cleaner, starter and battery are all in normal condition.
2.
The engine is at the normal operating temperature.
5.2
Measurement
1.
Move the control lever to a position for shutting off fuel supply.
2.
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.
3.
Turn the engine with the starter and read the gauge pressure at the instant the gauge pointer comes to stop.
4.
If the gauge reading is below the limit, overhaul the engine.
CAUTION
• Be sure to measure the compression pressure on all cylinders.
• The compression pressure varies with change of engine rpm. This makes it necessary to check engine rpm at the time of measuring the compression pressure.
Engine speed, rpm
Compression pressure, kgf/ cm2 (psi) [kPa]
Maximum permissible difference between average compression pressure of all cylinders in one engine, kgf/cm2 (psi) [kPa]
Standard
290
SL
SL2
30
(427)
[2 942]
32
(455)
[3 138]
3
(42.7)
[294]
Limit
--
23
(327)
[2 256]
25
(356)
[2 452]
--
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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.
On the following pages, there are troubleshooting charts on which engine troubles can be traced to their causes. Each chart has items to be verified ahead and suggested inspection procedure.
Diesel engines exhibit some marked characteristics during operation. Knowing these characteristics will help minimize time lost in tracing engine troubles to their source. Following are the characteristics of diesel engines you should know about for diagnosis:
• Combustion knock (diesel knock)
• Some black exhaust smoke (when the engine picks up load)
• Vibration (due to high compression pressure and high torque)
• Hunting (when the engine speed is quickly decreased)
• Some white exhaust smoke (when the engine is cold, or shortly after the engine has been started)
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Service Manual Mitsubishi SL-Series diesel engines
OVERHAUL INSTRUCTIONS
Is heating system normal?
No Z
Glow plugs are energized shortly after starter switch is turned to ON.
VYes
Are fuel lines free of restriction? (Is fuel pump operating properly when starter switch in ON position?)
V Yes
Are fuel injection timing and valve clearance correct?
V Yes
Is fuel injection nozzle discharge pattern normal? Is injection pressure correct?
V Yes
Is compression pressure correct?
V Yes
Fuel injection pump is faulty.
TROUBLESHOOTING
6.2
Engine troubleshooting
6.2.1 Problem 1: Hard starting
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
No Z
No Z
No Z
No Z
No Z
Check control timer unit.
Check fuel filter, fuel lines and fuel tank.
Make adjustment to the timing and clearance.
Make adjustment to the nozzles.
Check valves, piston rings and cylinder head gasket.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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)?
VYes
Is solenoid switch normal?
V Yes
Is injection pressure (injection nozzle valve opening pressure) correct (not too low)?
V Yes
Is compression pressure correct?
V Yes
Fuel injection pump is faulty.
No Z
No Z
No Z
No Z
Make adjustment to the timing.
Check the switch.
Make adjustment to the pressure.
Check valves, piston rings, and cylinder head gasket.
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Service Manual Mitsubishi SL-Series diesel engines
OVERHAUL INSTRUCTIONS
Are cooling system components (water pump, water hoses, radiator, thermostat and cylinder head gasket) normal?
VYes
Is injection timing correct?
V Yes
Are lubrication system components (oil filter, oil pump and oil screen) normal and oil level correct?
V Yes
Is governor adjustment correct?
V Yes
Engine is in continuous fullload operation.
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).
If the ambient temperature is higher than the normal coolant temperature by more than 60°C (108°C), investigate other items than those related to the engine cooling system.
1.
Items to be checked ahead of time
• Insufficient coolant and exterior coolant leaks
• Loose fan belt
• Radiator core openings plugged with dirt
2.
Inspection procedure
No Z
No Z
No Z
No Z
Check the components.
Make adjustment to the timing.
Check the components and oil level.
Make adjustment to the governor.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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?
VYes
Is injection nozzle discharge pattern normal? Is injection pressure correct
(not too high)?
V Yes
Is compression pressure correct?
V Yes
Fuel injection pump is faulty.
No Z
No Z
No Z
Make adjustment to the clearance and timing.
Make adjustment to the nozzles.
Check valves, piston rings and cylinder head gasket.
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Service Manual Mitsubishi SL-Series diesel engines
OVERHAUL INSTRUCTIONS
Are valve clearance and injection timing correct?
VYes
Is injection nozzle discharge pattern normal? Is injection pressure constant?
V Yes
Is compression pressure correct (no difference in compression pressure between cylinders)?
V Yes
Fuel injection pump is faulty.
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
No Z
No Z
No Z
Make adjustment to the clearance and timing.
Make adjustment to the nozzles.
Check valves, piston rings and cylinder head gasket.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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?
VYes
Are fuel lines free from restriction? (Is fuel pump operating properly when starter switch is in ON position?)
V Yes
Is governor adjustment correct?
V Yes
Is injection nozzle discharge pattern normal?
Is injection pressure correct?
V Yes
Is compression pressure correct?
V Yes
Fuel injection pump is faulty.
No Z
No Z
No Z
No Z
No Z
Make adjustment to the clearance and timing.
Check fuel tank, fuel filter and fuel lines.
Make adjustment to the governor.
Make adjustment to the nozzles.
Check valves, piston rings and cylinder head gaskets.
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Service Manual Mitsubishi SL-Series diesel engines
OVERHAUL INSTRUCTIONS TROUBLESHOOTING
6.3
Starting system troubleshooting
Overruns at low speed → Make reference to “Overrun.”
Faulty starter motor
Burned contact points in switch
Layer shorted or grounded field coil
Layer shorted or grounded armature coil
Mechanical problems Misaligned armature
Machining fault of parts
Worn bearings
Pinion gap too large.
Burned motor coil or switch coil
Burned field coil
Burned coil in armature
Burned motor coil (evidence of rubbing)
Switch will not turn off only when engine fails to fire, resulting in damage to motor.
Prolonged cranking
Excessive load
Pinion fails to shift
Pinion shifts but will not spin
Pinion butts ring gear instead of meshing
Hard starting at low temperatures
Wrong starting system
High resistance in main circuit
Poor quality fuel
Mechanical problems in engine
Very low ambient temperature
Troubles in engine
No fuel
Burned motor coil
Engine directly coupled to load
Reverse torque due to incorrect injection timing
Mechanical problems in engine
Starter abused (for moving equipment)
Battery run-down
Loose battery terminals
Defective key switch
Poor S connector contact
S connector missing
Open circuit in engine switch coil
Worn starter brushes
Defective contact points in auxiliary switch
Open circuit in auxiliary switch coil
High resistance in S circuit
Voltage applied to starter too high
Contact points defective in starter switch
Pinion and ring gear improperly chamfered
Battery rating too high
Pinion chamfered insufficiently or wrong
Ring gear chamfered insufficiently or wrong
Ring gear end face badly worn (ring gear not hardened properly)
Pinion will not shift Pinion metal jammed with dirt
Overrunning clutch jammed with foreign matter
Shift lever jammed
Solenoid switch plunger jammed
Shift lever broken
Contact points close to early Shift lever broken
Pinion gap too large
Pinion shifted excessively
Pinion is forced into mesh with ring gear again when starter is coasting
Pinion chamfered insufficiently or wrong
Pinion tooth worn round
Ring gear locally chipped
Four or five teeth chipped
Overrunning clutch shell peeled
Pinion is chipped
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
TROUBLESHOOTING OVERHAUL INSTRUCTIONS
Key switch faulty
Starter faulty
Incorrect wiring
Key not returning completely
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 Pull-in and hold-in coils unbalance in number of windings
Pull-in or hold-in coil layer shorted
•
•
•
Burned motor coil
Burned pull-in and hold-in coils
(minor defect)
Plunger fails to return when voltage is applied to circuit between M and (–) terminals and plunger is pushed in with switch off starter
Contact points defective
Plunger jammed •
•
Switch will not turn off only when engine fails to fire, resulting in burning of motor coil
Burned motor coil
Burned pull-in and hold-in coils
Machining fault of parts
Lever pivot jammed
Shift lever faulty
Overrunning clutch jammed
Machining fault
Sliding part jammed
Sliding surface dirty
Machining fault of lead
Subswitch faulty
Burned contact points
Assembly fault resulting in failure to return
External load connected to S circuit
S and B circuits shorted
Dotted lines indicate failure of contact points to close
Sticking pinion metal
Burned hold-in coil and motor coil
Make reference to “Pull-in and hold-in coil unbalance”
Make reference to “Key not returning completely”
[Other possibility is sticking pinion metal in case of overrun trouble.]
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Service Manual Mitsubishi SL-Series diesel engines
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
Disassembly
1.
Always use tools that are in good condition and be sure you understand how to use them before performing any job.
2.
Use an overhaul stand or a work bench, if necessary. Also, use bins to keep engine parts in order of removal.
3.
Parts must be restored to their respective components from which they were removed at disassembly. This means that all parts must be set aside separately in groups, each marked for its component, so that the same combination or set can be reproduced at assembly.
4.
Pay attention to marks on assemblies, components and parts for their positions or directions. Put on marks, if necessary, to aid assembly.
5.
Carefully check each part or component for any sign of faulty condition during removal or cleaning.
The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning.
6.
When lifting or carrying a part too heavy or too awkward for one person to handle, get another person’s help and, if necessary, use a jack or a hoist.
7.2
Assembly
1.
Wash all parts, except for oil seals, O-rings, rubber sheets, etc., with cleaning solvent and dry them with pressure air.
2.
Always use tools that are in good condition and be sure you understand how to use them before performing any job.
3.
Use only good-quality lubricants. Be sure to apply a coat of oil, grease or sealant to parts as specified.
4.
Be sure to use a torque wrench to tighten parts for which torques are specified.
5.
Any time the engine is assembled, new gaskets and O-rings must be installed.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
BASIC PRECAUTIONS FOR
DISASSEMBLY AND ASSEMBLY OVERHAUL INSTRUCTIONS
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
DISASSEMBLY
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
t t
PREPARATION FOR DISASSEMBLY DISASSEMBLY
DISASSEMBLY
8 PREPARATION FOR
DISASSEMBLY
8.1
Engine oil draining
1
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 (1.4) (with standard oil pan)
Engine oil drain plug
Figure 5 Draining engine oil
Coolant drain plug
WARNING
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact skin.
8.2
Loose the drain plug on the right side of the cylinder block and allow the coolant to drain.
Refill capacities, liter (U.S. gal)
S3L/S3L2: 1.8 (0.5)
S4L/S4L2: 2.5 (0.7)
Figure 6 Draining coolant
1. Please refer to the applicable engine model specification sheet for actual data
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Service Manual Mitsubishi SL-Series diesel engines
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DISASSEMBLY
Push in pinion
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) Push the pinion toward the commutator end by hand to measure its free movement (pinion clearance).
3) The pinion clearance must be 0.5 to 2.0 mm
(0.020 to 0.079 in.). If the clearance is out of this range, make an adjustment to it by adding or removing the packings on the magnetic switch. Adding the packings will decrease the clearance.
Battery
(12 volts) Starter
0,5 to 2,0 mm
(0.020 to 0.079 in.) t
Figure 7 Connections for measuring pinion clearance
Switch
Ammeter
Tachometer
Starter
Battery
(12 volts)
Figure 8 Connections for testing no-load characteristics
Service Manual Mitsubishi SL-Series diesel engines
2.
No-load characteristics
1) Connect the starter to a 12 volt battery with an ammeter capable of indicating several hundred amperes as shown in the illustration.
2) Close the switch to make sure the pinion shifts into cranking position properly and the starter runs at speeds higher than is specified. If the current draw and/or operating speed is out of the standard, disassemble the starter for inspection and repairs.
CAUTION
• The size of wires used for this test must be as large as possible. Tighten the terminals securely.
• This starter has a reduction gear. Do not confuse gear noise with some abnormal noise else.
• When measuring the starter speed at the end of the pinion, be ready for accidental shifting of the pinion.
ENGLISH
t
ELECTRICAL SYSTEM
Battery
(12 volts)
Connector disconnected t
Figure 9 Connections for testing pull-in coil
Connector disconnected
Battery
(12 volts)
Figure 10 Connections for testing hold-in coil
DISASSEMBLY
Item
Model
Nominal output, V – kW
Terminal voltage, V
Current draw, A
Speed, rpm
Standard
M8T70471
12 – 2.0
11
130 maximum
3 850 minimum
M1T68281
12 – 1.7
11.5
100 maximum
3 000 minimum
3.
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. Close the switch to see if the pinion shifts. If the piston fails to shift, the magnetic switch is faulty.
CAUTION
Due to the amount of current being passed through the solenoid series winding, this test must be made within 10 seconds.
3) Connect the magnetic switch to a 12 volt battery with a switch as shown in the illustration to test the pull-in coil. Close the switch to see if the pinion shifts. If the piston fails to shift, the magnetic switch is faulty.
CAUTION
Due to the amount of current being passed through the solenoid series winding, this test must be made within 10 seconds.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
t
DISASSEMBLY
Connector disconnected
Battery
(12 volts) t
Figure 11 Connections for pinion return test
ELECTRICAL SYSTEM
4) 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.
CAUTION
Due to the amount of current being passed through the solenoid series winding, this test must be made within 10 seconds.
9.1.2 Removal
1.
Disconnect the battery wires. Disconnect the negative (–) wire first.
2.
Disconnect wire (1) from the starter.
3.
Loosen bolts (2) (two) holding starter (3) in position and remove the starter.
t
Figure 12 Removing starter
Figure 13 Alternator on engine
Service Manual Mitsubishi SL-Series diesel engines
9.2
Alternator
9.2.1 Inspection before removal
The correct diagnosis of the charging system requires a careful inspection with the alternator on the engine to determine whether or not it is necessary to remove the alternator from the engine for further inspection. The following chart, in which two troubles are listed with four possible causes of each, will help locate the cause of the trouble:
Voltage regulator setting too high
Ground return circuit defective
Wiring incorrect
Series resistor or winding open-circuited
Alternator drive belt loose
Voltage regulator setting too low
Alternator output low
Brushes worn
ENGLISH
t t
ELECTRICAL SYSTEM t
Switch
Ammeter
Voltmeter Battery
(12 volts)
Figure 14 Connections for testing voltage setting
Ammeter
Alternator indicator light
Switch
Figure 15 Connections for testing output characteristics (alternator with built-in regulator)
DISASSEMBLY
9.2.2 Precautions for removal
Following is a list of basic precautions that should always be observed for removal:
1.
When installing the battery, care must be used to make sure the negative (–) terminal is grounded.
2.
Do not use a megger (an instrument for high resistance of electrical materials).
3.
Disconnect the battery cables before charging the battery.
4.
Do not attempt to disconnect the lead from the B terminal of the alternator when the engine is running.
5.
Battery voltage is being applied to the B terminal of the alternator. Do not ground it.
6.
Do not short or ground the L terminal of the alternator with a built-in IC regulator.
7.
Do not blow a spray from the steam cleaner nozzle at the alternator.
9.2.3 Testing voltage setting
1.
Connect the alternator to a 12 volt battery with an ammeter, a voltmeter and a switch as shown in the illustration.
2.
The voltmeter reading must be zero (0) when the starter switch is in OFF position. It must be lower than the battery voltage when the switch is in ON position (the engine will not start).
3.
With one ammeter lead short-circuited, start the engine.
4.
Read the voltmeter when the ammeter reading is below five amperes and the engine is running at
1800 min–1 and also at 2500 min–1 with all electrical loads turned off. The voltage setting varies with alternator temperature. Generally, the higher the alternator temperature, the lower the voltage setting.
Item
Voltage setting [at
20°C (68°F)]
Standard
14.7 ± 0.3 V
9.2.4 Testing output characteristics
1.
Disconnect the battery ground (negative) cable.
2.
Connect one ammeter lead to the B terminal of the alternator and the other lead to the positive terminal of the battery. Connect one voltmeter lead to the B terminal and the other lead to the ground.
3.
Connect the battery ground cable.
4.
Start the engine.
5.
Turn on all electrical loads.
6.
Increase the engine speed. Measure the maximum output current at the specified alternator speed when the voltmeter reading is 13.5 volts.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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DISASSEMBLY ELECTRICAL SYSTEM
Item Model
Standards
Terminal voltage/ current
Speed
13.5 V/33 A
2 500 rpm maximum
A7T02071C
13.5 V/47 A
5 000 rpm maximum
9.2.5 Removal
1.
Disconnect the battery cables.
2.
Disconnect the lead from the B terminal of the alternator.
3.
Disconnect the connector from the alternator.
4.
Loosen the brace and support bolts. Move the alternator toward the engine and remove the drive belt.
5.
Remove the alternator.
Figure 16 Removing alternator
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
t
Cooling System t
Figure 17 Removing cooling fan
DISASSEMBLY
DISASSEMBLY
10 Cooling System
10.1 Cooling fan removal
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.
10.2 Thermostat case removal
Remove the water pump assembly.
t
Figure 18 Removing thermostat assembly
10.3 Water pump assembly removal
Remove the water pump assembly.
Figure 19 Removing water pump assembly
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
t
DISASSEMBLY Fuel System
DISASSEMBLY
11 Fuel System
11.1 Fuel injection pipe removal
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.
t
Figure 20 Removing fuel injection pipes t
Figure 21 Removing fuel injection nozzles
11.2 Fuel injection nozzle removal
Loosen the fuel injection nozzles with a wrench.
Remove the nozzles and gaskets from the cylinder head.
NOTE
Remove the gaskets from the cylinder head with a screwdriver or a similar tool. Discard defective gaskets.
11.3 Governor assembly removal
1.
Remove the tie rod cover.
2.
Remove the spring from the tie rod with a pliers to disconnect the tie rod from the fuel injection pump.
3.
Remove the governor assembly.
Figure 22 Removing governor assembly
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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Fuel System DISASSEMBLY
11.4 Governor weight removal
1.
Remove the sliding sleeve.
2.
Remove the sliding sleeve shaft and governor weights.
t
Figure 23 Removing governor weights
11.5 Fuel injection pump removal
1.
Remove the tie rod cover.
2.
Remove the spring from the tie rod with a pliers to disconnect the tie rod from the fuel injection pump.
t
Figure 24 Removing tie rod
3.
Remove the fuel injection pump.
NOTE
Keep a record of the thickness of shims for installation.
Figure 25 Removing fuel injection pump
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
t
DISASSEMBLY Lubrication System
DISASSEMBLY
12 Lubrication System
12.1 Oil filter removal
1.
Put a container under the oil filter to catch the oil.
2.
Remove the oil filter from the cylinder block with a filter wrench.
t
Figure 26 Removing oil filter
12.2 Pressure relief valve removal
Remove the pressure relief valve from the cylinder block.
t
Figure 27 Removing pressure relief valve
12.3 Oil pressure switch removal
Remove the oil pressure switch with Oil Pressure
Switch Socket Wrench (MD998054) (special tool).
Figure 28 Removing oil pressure switch
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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AIR INLET SYSTEM AND EXHAUST
SYSTEM DISASSEMBLY
DISASSEMBLY
13 AIR INLET SYSTEM
AND EXHAUST
SYSTEM
13.1 Exhaust manifold removal
Remove the exhaust manifold from the cylinder head.
t
Figure 29 Removing exhaust manifold
13.2 Air inlet cover removal
Remove the air inlet cover from the cylinder head.
Figure 30 Removing air inlet cover
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
DISASSEMBLY
CYLINDER HEAD AND VALVE
MECHANISM
DISASSEMBLY
14 CYLINDER HEAD AND
VALVE MECHANISM
1.
2.
3.
4.
Rocker cover
Rocker shaft assembly
Valve push rod
Cylinder head bolt
5.
Cylinder head
6.
Cylinder head gasket
7.
Valve lock
8.
Valve retainer
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
9.
Valve spring
10. Valve
11. Valve stem seal
12. Valve cap
t
CYLINDER HEAD AND VALVE
MECHANISM DISASSEMBLY
14.1 Rocker shaft assembly removal
1.
Remove the bolts that hold the rocker stays in position and remove the rocker shaft assembly.
2.
Remove the valve caps.
t
Figure 31 Removing rocker shaft assemblies
14.2 Rocker shaft disassembly
Put identification on each rocker arm as to its location on the rocker shaft.
t
Figure 32 Disassembling rocker shaft assembly
Front
14.3 Cylinder head bolt removal
Loosen the cylinder head bolts in two or three steps in the sequence shown.
NOTE
If any parts on the cylinder head are faulty, check the cylinder head bolts for tightness with a torque wrench before loosening them.
Figure 33 Cylinder head bolt loosening sequence
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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DISASSEMBLY
CYLINDER HEAD AND VALVE
MECHANISM
14.4 Cylinder head assembly removal
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.
t
Figure 34 Removing cylinder head assembly
14.5 Valve and valve spring removal
1.
Compress the valve spring with a valve lifter and remove the valve lock.
2.
Remove the retainer, spring and valve.
NOTE
The valves, retainers, springs and valve locks must be set aside separately in groups, each tagged for cylinder number, for correct installation.
t
Figure 35 Removing valve springs
14.6 Valve stem seal removal
Remove the valve stem seals with a pliers.
NOTE
Do not reuse the valve stem seals, but replace them by new ones.
Figure 36 Removing valve stem seals
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Timing Gears and Flywheel DISASSEMBLY
DISASSEMBLY
15 Timing Gears and
Flywheel
1.
Flywheel
2.
Rear plate
3.
Oil seal case; oil seal
4.
Tappet
5.
Speedometer driven gear
6.
P.T.O. gear
7.
Crankshaft pulley
8.
Timing gear case
9.
Idler gear
(Remove 10 thru 12 as an assembly.)
10. Camshaft gear
11. Thrust plate
12. Camshaft
(Remove 3 thru 5 as an assembly.)
13. Fuel injection pump camshaft gear
14. Bearing
15. Fuel injection pump camshaft
16. Oil pump
17. Front plate
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
t
DISASSEMBLY t
Figure 37 Holding flywheel
Safety bar t
Figure 38 Removing flywheel
Front
Figure 39 Removing rear plate
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Timing Gears and Flywheel
15.1 Flywheel removal
1.
Have someone hold the crankshaft pulley with a wrench to prevent the flywheel from rotating.
2.
Remove one of the bolts that hold the flywheel in position.
WARNING
Always signal each other to prevent possible personal injury.
3.
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.
4.
Hold the flywheel by hands and withdraw it from the crankshaft. Joggling the flywheel back and forth will facilitate removal.
WARNING
When removing the flywheel, wear heavy gloves to avoid hand injury.
15.2 Rear plate removal
The rear plate is doweled in position. Pull the plate as straight as possible when removing it.
t
Timing Gears and Flywheel DISASSEMBLY
15.3 Oil seal case removal
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.
t
Figure 40 Removing oil seal case t
Figure 41 Removing tappets
Figure 42 Removing speedometer driven gear
15.4 Tappet removal
Remove the tappets from the cylinder block with a valve push rod.
NOTE
The valves, retainers, springs and valve locks must be set aside separately in groups, each tagged for cylinder number, for correct installation.
15.5 Speedometer driven gear removal
Remove the lock plate and speedometer driven gear in that order.
NOTE
Unless the speedometer driven gear is removed, the camshaft cannot be removed.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
t
DISASSEMBLY Timing Gears and Flywheel
15.6 Crankshaft pulley removal
1.
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.
2.
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.
t
Figure 43 Removing crankshaft pulley
15.7 Timing gear case removal
Remove the bolts that hold the timing gear case in position and remove the case.
CAUTION
The front plate is bolted inside the timing gear case.
Do not attempt to remove this plate along with the timing gear case by tapping.
t
Figure 44 Front plate attaching bolts
Figure 45 Measuring timing gear backlash
Service Manual Mitsubishi SL-Series diesel engines
15.8 Timing gear backlash measurement
Measure the backlash of each gear and keep a record of it for correct installation. Replace the gears if the backlash exceeds the limit.
Standard
Unit: mm (in.)
Limit Item
Crankshaft gear and idler gear
Idler gear and camshaft gear
Idler gear and fuel injection pump camshaft gear
Camshaft gear and
P.T.O. gear
Fuel injection pump camshaft gear and oil pump gear
0.04 to 0.12
(0.001 6 to 0.004 7)
0.08 to 0.19
(0.003 1 to 0.007 5)
0.07 to 0.20
(0.002 8 to 0.007 9)
0.30
(0.011 8)
ENGLISH
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Timing Gears and Flywheel DISASSEMBLY
15.9 Idler gear removal
To remove the idler gear, rotate the gear in a direction of the helix of the teeth to pull it out of mesh.
t
Figure 46 Removing idler gear t
Figure 47 Removing camshaft
15.10 Camshaft removal
1.
Remove the bolts that hold the thrust plate.
2.
Pull the camshaft out of the cylinder block.
CAUTION
Do not cause damage to the lobes or bearing journals when removing the camshaft.
15.11 Fuel injection pump camshaft removal
1.
Remove the stopper bolt.
Figure 48 Removing camshaft stopper bolt
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
t
DISASSEMBLY Timing Gears and Flywheel
2.
Tap the rear end of the camshaft with a copper bar to push it out of the front side of the cylinder block.
t
Figure 49 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
Remove the bolts that hold the oil pump to the cylinder block and remove the pump.
t
Figure 50 Removing oil pump
Figure 51 Removing front plate
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
15.14 Front plate removal
Remove four bolts that hold the front plate in position.
Tap the plate lightly with a plastic hammer to separate the gasket.
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.
Piston pin
No. 1 ring
No. 2 ring
Oil ring
10. Piston
11. Connecting rod bearing (upper half)
12. Main bearing cap
13. Main bearing (lower half)
14. Crankshaft
15. Main bearing (upper half)
16. Cylinder block
NOTE: When the cylinder block is to be discarded, remove the components (pressure relief valve, etc.) from the block for reuse.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
t
DISASSEMBLY t
Figure 52 Removing oil pan
Cylinder Block, Crankshaft, Pistons and Oil Pan
16.1 Oil pan removal
1.
Turn the engine upside down.
2.
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.
16.2 Oil screen removal
Loosen the nut that holds the oil screen in position and remove the screen.
t
Figure 53 Removing oil screen
Figure 54 Measuring thrust clearance for connecting rod big end
16.3 Thrust clearance measurement for connecting rod big end
Install the connecting rod to its crankpin and tighten the cap nuts to the specified torque. Measure the thrust clearance with a feeler gauge. If the clearance exceeds the limit, replace the connecting rod.
Standard
Unit: mm (in.)
Limit Item
Thrust clearance for connecting rod big end
0.10 to 0.35
(0.003 9 to 0.013 8)
0.50
(0.019 7)
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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Cylinder Block, Crankshaft, Pistons and Oil Pan DISASSEMBLY
16.4 Connecting rod cap removal
1.
Lay the cylinder block on its side.
2.
Put identification on each connecting rod and cap combination as to its location in the engine.
3.
Remove the caps.
t
Figure 55 Removing connecting rod caps
16.5 Piston removal
1.
Turn the crankshaft until the piston is at top center.
2.
Push the piston and connecting rod away from the crankshaft with the handle of a hammer or the like until the piston rings are above the cylinder.
Remove the piston and connecting rod. Do Steps
(1) and (2) for the removal of the other pistons.
t
Figure 56 Removing piston
16.6 End play measurement for crankshaft
Set a dial indicator so that it will touch the end of the crankshaft and measure the end play. If the end play exceeds the limit, replace No. 3 flanged bearing.
Item Standard
Unit: mm (in.)
Limit
End play for crankshaft end play
0.050 to 0.175
(0.001 97 to 0.006 89)
0.500 (0.019
69)
Figure 57 Measuring end play for crankshaft
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
t
DISASSEMBLY
Cylinder Block, Crankshaft, Pistons and Oil Pan
16.7 Main bearing cap removal
1.
Lay the cylinder block with its bottom (oil pan) side up.
2.
Remove the bolts that hold the main bearing caps in position. Remove the caps.
3.
Remove the front and rear bearing caps with a sliding hammer.
t
Figure 58 Removing main bearing caps t
Figure 59 Removing crankshaft
16.8 Crankshaft removal
Remove the crankshaft.
CAUTION
Do not cause damage to the bearings.
NOTE
Put identification on each main bearing as to its location in the engine.
16.9 Piston separation from connecting rod
1.
Use Piston Pin Setting Tool (31A91-00100)
(special tool) to separate the piston from the connecting rod.
Figure 60 Piston pin setting tool
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
t
Cylinder Block, Crankshaft, Pistons and Oil Pan
Piston pin
Arrow mark
Piston
Push rod (tool)
Connecting rod
Identification mark
DISASSEMBLY
2.
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.
3.
Use this Piston Pin Setting Tool to install the connecting rod to the piston.
Tool body t
Figure 61 Removing piston pin (1)
CAUTION
Do not attempt to remove the piston pin by tapping.
Replace a piston pin which needs a greater force for removal.
Figure 62 Removing piston pin (2)
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
CYLINDER HEAD AND VALVE
MECHANISM INSPECTION
INSPECTION
17 CYLINDER HEAD AND
VALVE MECHANISM
Check threads for stripping
Check oil hole for clogging
Check end for wear.
Check bore for wear
Check for wear or clogged oil holes
Test
Check for damage and test
Check valve seats for impoper contact or wear
Check for warpage
Check for galling or wear
Check valve guides for wear or damage
Check for ridges or damage
Check for wear or improper contact
Check ends for wear or damage
Check for bend
Check for cracks, oil or coolant leaks.
Remove gasket, scale and carbon deposits
Figure 63 Inspection points
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
CYLINDER HEAD AND VALVE
MECHANISM
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.)
Item
Warpage of cylinder head bottom face
Standard
0.05 (0.002 0) maximum
Limit
0.10
(0.003 9)
Figure 64 Checking cylinder head bottom face for warpage
Figure 65 Measuring rocker arm and rocker shaft
17.2 Rocker arms and rocker shaft
Measure the bore in the rocker arm for the rocker shaft and the diameter of the rocker shaft to find the clearance between the arm and shaft. If the clearance has reached the limit, replace the rocker arm. If it exceeds the limit, replace both arm and shaft.
Unit: mm (in.)
Item
Bore in rocker arm for shaft
Diameter of shaft for arm
Clearance between rocker arm and shaft
Nominal size
18.9
(0.744)
18.9
(0.744)
—
Standard
18.910 to
18.930
(0.744 49 to
0.745 27)
18.880 to
18.898
(0.743 31 to
0.744 01)
0.012 to
0.050
(0.000 47 to
0.001 97)
Limit
—
—
0.200
(0.007
87)
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
CYLINDER HEAD AND VALVE
MECHANISM
Free length
Squareness
Figure 66 Testing valve spring
INSPECTION
17.3 Valve springs
Check the squareness and free length. If the squareness and/or free length exceeds the limit, replace the spring.
Unit: mm (in.)
Item
Free length
Squareness
Length under test force:
39.1 (1.54)
Length under test force:
30.5 (1.20)
Standard
47 (1.85)
1.5° maximum
13.9 ± 0.7
(30.6 ± 1.5)
[136 ± 7]
29 ± 2
(64 ± 4.4)
[284 ± 20]
Limit
46 (1.81)
–15%
17.4 Valve push rods
Using V-blocks and a dial indicator, check for bend. If the bend exceeds the limit, replace the push rod.
Unit: mm (in.)
Item
Bend (dial indicator reading) of valve push rod
Limit
0.3 (0.012) maximum
Figure 67 Checking bend of valve push rod
Figure 68 Measuring valve stem
Measuring diagram
17.5 Valves, valve guides and valve seats
1.
Diameter of valve stem
Measure the diameter of the valve stem as shown in the illustration. If the stem is worn beyond the limit, or if it is abnormally worn, replace the valve.
Unit: mm (in.)
Item
Diameter of valve stem
Inlet valve
Exhaust valve
Nominal size
6.6
(0.260)
6.6
(0.260)
Standard Limit
6.565 to
6.580
(0.258 46 to
0.259 05)
6.500
(0.255 91)
6.530 to
6.550
(0.257 09 to
0.257 87
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
Inside micrometer caliper
Figure 69 Measuring valve guide
Valve guide
Cylinder head
(0.39 ± 0.020
Figure 70 Height to top of valve guide
CYLINDER HEAD AND VALVE
MECHANISM
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.)
Item
Clearance between valve stem and valve guide
Inlet valve
Exhaust valve
Height to top of valve guide
Nominal size
—
—
10
(0.39)
Standard
0.02 to
0.05
(0.000 8 to
0.002 0)
0.05 to
0.085
(0.002 0 to
0.003 35)
9.5 to 10.5
(0.374 to
0.413)
Limit
0.10
(0.003 9)
0.15
(0.005 9)
—
NOTE
Before measuring the valve guides, clear the guides of lacquer and carbon.
3.
Valve guide replacement
1) Remove the guide from the cylinder head by pushing it with a tool and an arbor press from the bottom side of the head.
2) Install a new guide into the cylinder head by pushing it with an arbor press from the upper side of the head until the specified height to the top of the guide is obtained.
3) Insert a new valve into the guide and make sure the valve slides in the guide freely.
4) After the valve guide has been replaced, check the valve contact with its seat.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
CYLINDER HEAD AND VALVE
MECHANISM
Valve lapping tool
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.
Prussian blue
Figure 71 Checking valve contact with seat
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.
Good Bad
Contact must be uniform around the complete circumference.
Figure 72 Valve and valve seat contact
Valve sinkage Valve margin
Figure 73 Valve margin and sinkage
3) If the valve margin (valve lip thickness) exceeds the limit, replace the valve.
Unit: mm (in.)
Item
Valve margin (lip thickness)
Standard
1.0 (0.039)
Limit
0.5 (0.020)
4) If the valve sinkage (the dimension from the top of a closed valve to the face of cylinder head) exceeds the limit, recondition the valve seat or replace the cylinder head assembly.
Unit: mm (in.)
Item
Valve sinkage
(dimension from top of closed valve to face of head)
Standard
0.5 ± 0.25
(0.020 ± 0.009 8)
Limit
1.5
(0.059)
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
CYLINDER HEAD AND VALVE
MECHANISM
5.
Valve refacing
1) Set the valve refacer at an angle of 45° and grind the valve.
2) The valve margin must be not less than the limit. If the margin seems to be less than the limit when the valve is refaced, replace the valve.
Figure 74 Refacing valve face
6.
Valve seat refacing
1) Before refacing the valve seat, check the clearance between the valve and guide, and replace the guide if necessary.
2) 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.
Figure 75 Refacing valve seat
Width of valve seat 1.3 to 1.8 mm
(0.051 tot 0.071 in.) Item
Angle of seat face
Width of valve seat
Standard
45°
1.3 to 1.8
(0.051 to 0.071)
Unit: mm (in.)
Limit
—
2.5
(0.098)
3) After refacing the valve seat, put lapping compound on the valve face and lap the valve in the valve seat.
Figure 76 Valve seat width and valve face angle
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
CYLINDER HEAD AND VALVE
MECHANISM
Compound
Figure 77 Lapping valve in seat
Round bar
INSPECTION
7.
Valve lapping
Be sure to lap the valves in the seats after refacing or replacing the valves or valve seats.
1) Put a small amount of lapping compound on the valve face.
NOTE
• 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.
• Mixing the compound with a small amount of engine oil will help put the compound on the valve face uniformly.
2) Using a lapping tool, hold the valve against the seat and rotate it only a part of a turn, then raise the valve off its seat, rotating it to a new position. Press the valve against the seat for another part of a turn. Repeat this operation until the compound wears and loses its cutting property.
3) Wash the valve and valve seat with dry cleaning solvent.
4) Apply engine oil to the valve and lap it in the seat.
5) Check the valve face for contact.
17.6 Combustion jet replacement
Replace the combustion jets only when they are cracked or defective.
1.
To remove the jet, insert a 6 mm (0.24 in.) diameter round bar through the bore in the cylinder head for the glow plug and tap around the jet.
Combustion jet
Figure 78 Removing combustion jet
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
Combustion jet
Figure 79 Installing combustion jet
CYLINDER HEAD AND VALVE
MECHANISM
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.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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.
Figure 80 Inspection points
Check for wear, damage or aging.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
Figure 81 Measuring camshaft journal
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.)
Standard Item
Clearance between camshaft journal and bushing
0.15 (0.005 9)
Figure 82 Measuring bore in camshaft bushing
Front of cylinder block
Camshaft bushing
2.
Bushing replacement
Use Camshaft Bushing Installer (ST332340) (special tool) for camshaft bushing replacement.
1) Removal
Remove the oil pan. Using a “remover” end of the Installer, push out the bushing into the cylinder block. Crush and take out the bushing from the block.
Camshaft Bushing
Installer
Figure 83 Removing camshaft bushing
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
TIMING GEARS AND FLYWHEEL
1 mm (0.04 in.)
Notch in bushing
1 mm (0.04 in.)
Oil holes
Ends of bushing
INSPECTION
2) Installation
Install a new bushing in position with its oil holes in alignment with those of the oil gallery.
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.)
Item
Lobe height of camshaft
Standard
35.72
(1.404 3)
Limit
34.72
(1.366 9)
Figure 85 Measuring lobe height of camshaft
Figure 86 Measuring lobe height of fuel injection pump camshaft
18.2 Fuel injection pump camshaft
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.)
Standard Limit Item
Lobe height of fuel injection pump camshaft
44
(1.73)
43
(1.69)
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION TIMING GEARS AND FLYWHEEL
18.3 Tappets
1.
Cam contact face
Check the cam contact face of each tappet for abnormal wear. Replace the tappet if the face is defective.
Good Bad
Figure 87 Cam contact face of tappet
Bad
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.)
Standard Item
Clearance between tappet and cylinder block
0.15 (0.005 9)
Figure 88 Measuring tappet and bore in cylinder block
18.4 Idler gear
1.
Clearance between idler gear and shaft
Measure the bore in the idler gear for the shaft and the diameter of the shaft to find the clearance. If the clearance exceeds the limit, replace the gear or shaft whichever is badly worn.
.Unit: mm (in.)
Item
Clearance between idler gear and shaft
Standard
0.03 to 0.07
(0.001 2 to 0.002 8)
Limit
0.20
(0.007 9)
Figure 89 Measuring idler gear and shaft
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
TIMING GEARS AND FLYWHEEL
26,5 ± 0.5 mm
(1.043 ± 0.020 in.)
INSPECTION
2.
Idler shaft replacement
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.).
Figure 90 Idler shaft dimension
Figure 91 Measering flywheel flatness
18.5 Flywheel and ring gear
1.
Flatness (difference between lower and higher measurements) of flywheel
Put the flywheel on the surface plate. Set a dial indicator at one side of the friction (clutch contact) face and move it over to the opposite side of the face as shown in the illustration to find the flatness.
If the flatness exceeds the limit, grind the face.
Unit: mm (in.)
Item
Flatness of flywheel
Standard
0.15 (0.005 9) maximum
Limit
0.50
(0.019 7)
2.
Ring gear replacement
Check the ring gear and replace it if its teeth are abnormally worn or chipped.
1) Removal
Heat the ring gear evenly with an acetylene torch. Tap the ring gear all the way around with a bar and a hammer as shown in the illustration to remove it from the flywheel.
2) Installation
Heat a new ring gear up to a temperature of
150°C (302°F) with a piston heater and install it to the flywheel with its unchamfered side foremost.
Figure 92 Removing ring gear
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
Check top face for warpage.
Check for cracks, scores or ridges at top of ring travel.
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN
INSPECTION
19 CYLINDER BLOCK,
CRANKSHAFT,
PISTONS AND OIL PAN
Check for wear or damage.
Check clearance between ends.
Check for wear, scores, cracks, overheating or excessive widened ring grooves.
Check for damage to plugs or dowels.
Check for plugged oil holes.
Check for damage to gear teeth.
Check for bend or twist.
Check big end thrust clearance.
Check journals and crankpins for abnormal wear, cracks, bend or plugged oil holes.
CAUTION
Do not reuse crankshaft if it shows evidence of overheating.
Loss of overlay
Scratches
Defect due to poor installation
Figure 93 Points à inspecter
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN INSPECTION
Direction transverse to piston pin
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.
Figure 94 Measuring diameter of piston
Item
Standard
0.25
(0.009 8) oversize
Norminal size
78.00
(3.070 9)
78.25
(3.080 7)
Diameter of piston
0.50
(0.019 7) oversize
78.50
(3.090 5)
Maximum permissible difference between average weight of all pistons in one engine, g (oz)
Standard
77.93 to 77.95
(3.068 1 to 3.068)
77.80
(3.063 0)
Unit: mm (in.)
Limit
78.18 to 78.20 (3.077
9 to 3.078 7)
78.05
(3.072 8)
78.43 to
87.45
(3.087 8 to
3.088 6)
5 (0.18)
78.30
(3.082 7)
__
No. 1 compression ring clearance
No. 2 compression ring clearance
Figure 95 Measuring clearance between piston ring and groove
2.
Clearance between piston ring and groove
1) Measure the clearance between the groove and piston with a straight edge and a feeler gauge as shown in the illustration. If the clearance exceeds the limit, replace the ring.
.Unit: mm (in.)
Item
No. 1 compression ring
No. 2 compression ring
Oil ring
Standard
0.06 to 0.10
(0.002 4 to 0.003 9)
0.06 to 0.10
(0.002 0 to 0.003 5)
0.06 to 0.10
(0.001 2 to 0.002 8)
Limit
0.30
(0.011 8)
0.20
(0.007 9)
0.20
(0.007 9)
2) If the clearance still exceeds the limit after new piston rings have been installed, replace the piston.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
Figure 96 Measuring clearance between ends of piston ring
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN
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: 78
0
+0.03
mm (3.07
0
+0.0012
in.)
0.25 mm (0.0098 in.) oversize:
78.25
0
+0.03
mm (3.08
0
+0.0012
in.)
0.50 mm (0.0197 in.) oversize:
78.50
0
+0.03
mm (3.09
0
+0.0012
in.)
NOTE
Put the piston ring in the gauge or cylinder squarely with the piston.
Item Standard
Clearance between ends of piston ring
No. 1 compression ring
No. 2 compression ring
Oil ring
0.15 to 0.30
(0.005 9 to
0.011 8)
0.15 to 0.35
(0.005 9 to
0.013 8)
0.20 to 0.40
(0.007 9 to
0.015 7)
.Unit: mm (in.)
Limit
1.50
(0.059 1)
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN INSPECTION
Figure 97 Measuring piston pin and bore in piston for pin
Unit: mm (in.)
Piston pin
Bend Twist
Figure 98 Checking connecting rod for bend or twist
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.)
Item
Norminal size
Standard Limit
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
(0.00024 to
0.00071)
0.050
(0.001
97)
19.2 Connecting rods
Check the connecting rod for bend or twist as follows:
1) Measure “C” and “ .” If “C” exceeds 0.05 mm
(0.0020 in.) per 100 mm (3.94 in.) of “ ,” straighten the connecting rod with a press.
.Unit: mm (in.)
Item Limit
Bend or twist of connecting rod
Standard
0.05/100
(0.002 3/4.94) maximum
0.15/100
(0.005 9/3.94)
2) Generally, a connecting rod aligner is used to check the connecting rod for bend or twist.
NOTE
To check the rod for bend, install the cap to the connecting rod and tighten the cap nuts to the specified torque.
Figure 99 Check connecting rod on a connecting rod aligner
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN
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
3.55 ± 0.25 kgf m
(25.7 ± 1.8 lbf ft)
[34.8 ± 2.5 N m]
19.3 Crankshaft
1.
Clearance between crankpin and connecting rod bearing
1) Install the bearing (upper and lower halves) and cap to the big end of the connecting rod and tighten the cap nuts to the specified torque. Measure the bore in the bearing for crankpin as shown in the illustration.
Tightening torque
3.55 ± 0.25 kgf.m
(25.7 ± 1.8 lbf.ft)
[34.8 ± 2.5 N.m]
Figure 101 Measuring bore in connecting rod bearing
Measuring diagram
Figure 102 Measuring diameter of crankpin
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
2) Measure the diameter of the crankpin as shown in the illustration to find the clearance between the crankpin and connecting rod bearing.
.Unit: mm (in.)
Item
Norminal size
Standard Limit
Diameter of crankpin
(standard)
48
(1.89)
47.950 to
47.965
(1.887 79 to
1.888 38)
—
Clearance between crankpin and connecting rod bearing
—
0.025 to 0.072
(0.000 98 to
0.002 83)
0.150
(0.005
91)
3) If the clearance exceeds the limit, install a new bearing and check the clearance again.
4) If the clearance still exceeds the limit, grind the crankpin to 0.25 mm (0.0098 in.), 0.50 mm
(0.0197 in.) or 0.75 mm (0.0295 in.) undersize and use undersize connecting rod bearing.
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN
2.5 mm
(0.098 in.)
INSPECTION
Item
Crankpin
Table 2
Unit: mm (in.)
Undersize Finish
0.25
(0.009 8)
0.50
(0.019 7)
0.75
(0.029 5)
47.75
-0.035
-0.050
(1.8799
-0.00138
)
-0.00197
47.50
-0.035
-0.050
(1.8701
-0.00138
)
-0.00197
47.25
-0.035
-0.050
(1.8602
-0.00138
)
-0.00197
Crankpin undersizes
CAUTION
• 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.).
Figure 103 Crankpin fillet radius
2.
Clearance between journal and main bearing
1) Install the main bearing (upper and lower halves) and cap to the cylinder block and tighten the cap bolts to the specified torque.
Measure the bore in the bearing for the journal as shown in the illustration.
Tightening torque 5.25 ± 0.25 kgf·m
(38 ± 1.8 lbf·ft)
[51.5 ± 2.5 N·m]
Figure 104 Measuring bore in main bearing
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
Measuring diagram
Figure 105 Measuring diameter of journal
2 mm (0.08 in.)
Figure 106 Journal fillet radius
2 mm (0.08 in.)
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN
2) Measure the diameter of the journal as shown in the illustration to find the clearance between the journal and main bearing.
.Unit: mm (in.)
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
(0.003
94)
3) If the clearance exceeds the limit, install a new bearing and check the clearance again.
4) If the clearance still exceeds the limit, grind the journal to 0.25 mm (0.009 8 in.), 0.50 mm
(0.019 7 in.) or 0.75 mm (0.029 5 in.) undersize and use undersize main bearing.
Journal undersizes
Unit: mm (in.)
Item
Journal
Undersize
0.25
(0.009 8)
0.50
(0.019 7)
0.75
(0.029 5)
Finish
51.75
0
-0.015
(2.0374
0
-0.00059
)
51.50
0
-0.015
(2.0276
0
-0.00059
)
51.25
0
-0.015
(2.0177
0
-0.00059
)
CAUTION
• Grind all the journals of one crankshaft to the same undersize.
• Finish the journal fillets to a radius of 2 mm
(0.08 in.).
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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
Crankshaft runout
Standard Limit
0.025 (0.000 98) 0.05 (0.002 0)
Figure 107 Checking crankshaft runout
4.
Crankshaft gear removal
Use a gear puller to remove the gear from the crankshaft
NOTE
Do not remove the gear unless the gear or crankshaft is defective.
Figure 108 Removing crankshaft gear
To be aligned
5.
Crankshaft gear installation
1) Install the key in position on the crankshaft.
2) Install the gear in position with its keyway in alignment with the key as shown in the illustration.
Figure 109 Installing crankshaft gear
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
INSPECTION
Figure 110 Measuring bore in cylinder block
Figure 111 Checking cylinder block top face for warpage
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN
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.
Pioston and piston ring
Unit: mm (in.)
Bore
Size
Standard
0.25 (0.009 8) oversize
0.50 (0.019 7) oversize
Size code Standard
STD
25
50
Taper and out-of-round
78
+0.03
0
(3.07
+0.0012
0
78.25
+0.03
0
)
(3.0807
+0.0012
0
)
78.50
+0.03
0
(3.0905
+0.0012
0
)
0.01 (0.000 4) maximum
Limit
Standard:
+0.2
(+0.008)
—
2.
Warpage of top face
Using a heavy accurate straight edge and a feeler gauge, check the top face for warpage in two positions lengthwise, two crosswise and two widthwise as shown in the illustration. If warpage exceeds the limit, reface the top face with a surface grinder.
CAUTION
The maximum permissible amount of stock to be removed from the cylinder head and block by grinding is 0.2 mm (0.008 in.) in total.
Item
Warpage of cylinder block top face
Standard
0.05 (0.002 0) maximum
.Unit: mm (in.)
Limit
0.10
(0.003 9)
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
CYLINDER BLOCK, CRANKSHAFT,
PISTONS AND OIL PAN INSPECTION
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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
Tightening torque:
3.55 ± 0.25 kgf m (25.7 ± 1.8 lbf ft)
[34.8 ± 2.5 N m]
Coat the entire surface with
Three Bond 1207C
Tightening torque
Cast oil pan:
2.8 ± 0.3 kgf m (20.3 ± 2.2 lbf ft)
[27.5 ± 3 N m]
Plate oil pan:
1.15 ± 0.15 kgf m (8.3 ± 1.1 lbf ft)
[11.3 ± 1.5 N m]
Coat with Three Bond 1212
Tightening torque:
5.25 ± 0.25 kgf m (38 ± 1.8 lbf ft)
[51.5 ± 2.5 N m]
Figure 112 Inspection points
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
Cylinder Block, Crankshaft, Pistons and
Oil pan
20.1 Main bearing installation
1.
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.
2.
Install the flanged bearing in the No. 3 journal.
3.
Lightly lubricate the inside surfaces of the bearings with engine oil.
Figure 113 Installing main bearings
20.2 Crankshaft installation
1.
Clean the crankshaft with cleaning solvent and blow dry with compressed air.
2.
Fasten a hoist to the crankshaft and hold it in horizontal position. Carefully put the crankshaft in position in the cylinder block.
3.
Lightly lubricate the crankshaft journals with engine oil.
Figure 114 Installing crankshaft
Figure 115 Main bearing caps installed
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
20.3 Main bearing cap installation
1.
Coat the mating surfaces of the rear bearing cap and cylinder block with Three Bond 1212.
2.
Install the main bearing caps in position. Make sure the number (arrow head) on the main bearing cap is toward the front of the engine.
3.
Tighten the main bearing cap bolts finger tight only.
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.
Make sure the crankshaft rotates freely without binding or catching.
6.
Measure the end play for the crankshaft. Make reference to “End play measurement for crankshaft” (page 42). If the end play is incorrect, loosen the bolts holding the main bearing caps once and tighten them again.
Figure 118 Checking crankshaft for rotation
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
Rounded side
Side seals
Rounded side
Cylinder Block, Crankshaft, Pistons and
Oil pan
20.4 Side seal installation
1.
Coat the side seals with Three Bond 1212.
2.
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.
Figure 119 Side seals
3.
Using a flat plate, push the seals into position, taking care not to bend them.
Figure 120 Installing side seals
Figure 121 Connecting rod on Piston Setting Tool
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
20.5 Piston assembling to connecting rod
1.
Set Piston Setting Tool (31A91-00100) (special tool) in a hydraulic press.
2.
Put the connecting rod on the Tool and lubricate the bore in the rod for the piston pin with engine oil.
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.
Figure 122 Installing piston pin
Figure 123 Pressing piston pin
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.
CAUTION
Observe the indicator of the press when pressing the piston pin. If the force of the press is ready to exceed
50 kgf (110 lbf) [490 N], stop pressing the pin and check the bores in the piston and connecting rod for alignment.
5.
After assembling the piston and connecting rod, make sure the connecting rod moves freely.
Figure 124 Checking piston and connecting rod
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
Mark to be up
No. 1 compression ring
No. 2 compression ring
Oil ring
Cylinder Block, Crankshaft, Pistons and
Oil pan
20.6 Piston ring installation
Using a piston ring pliers, install the piston rings to the piston.
NOTE
1.
The piston rings must be installed with the side that has the mark “T” toward the top of the piston.
2.
The oil ring must be installed with the ring end gap 180° apart from the coil spring joint.
Figure 125 Piston rings
Coil spring joint
Ring end gap
Figure 126 Oil ring
Oil ring
Front of engine
No. 1 compression ring
No. 2 compression ring and oil ring coil spring joint
Figure 127 Relative location of piston ring end gaps
20.7 Piston and connecting rod installation
1.
Lubricate the piston and piston rings with engine oil.
2.
Move the piston rings on the piston so that the end gaps are apart from a direction parallel to, or transverse to, the piston pin.
3.
Install the connecting rod bearing (upper half) to the rod, making sure the tab in the back of the bearing is in the notch of the connecting rod.
4.
Turn the crankshaft until the crankpin for the piston and connecting rod to be installed is at the top center.
5.
Hold the piston and connecting rod with “FRONT” mark (arrow head) on the top of the piston toward the front (timing gear case side) of the engine.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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.
Push the piston into position until the big end of the connecting rod is put into position over the crankpin. Then turn the crankshaft 180° while pushing on the top of the piston.
2.
Install the lower half of the connecting rod bearing in the connecting rod cap, making sure the tab in the back of the bearing is in the notch of the cap.
3.
Install the bearing cap to the connecting rod.
Notches
Cilinder number
Figure 129 Installing connecting rod cap
Figure 130 Tightening connecting rod cap nuts
NOTE
• Make sure the number on the cap is the same as the number on the connecting rod.
• In case of a new connecting rod having no cylinder number, install the cap to the rod with the notches on the same side.
4.
Tighten the connecting rod cap nuts in steps to the specified torque.
Tightening torque
3.55 ± 0.25 kgf·m
(25.7 ± 2 lbf·ft)
[34.8 ± 2.5 N·m]
5.
Check the thrust clearance for the connecting rod big end.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
Figure 131 Installing oil screen
Cylinder Block, Crankshaft, Pistons and
Oil pan
20.9 Oil screen installation
1.
Lay the cylinder block with the bottom (oil pan side) up.
2.
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.
20.10 Oil pan installation
1.
Clean the mating surfaces of the oil pan and cylinder block and coat them with Three Bond
1207C.
Figure 132 Coating mating surfaces with adhesive
NOTE
Squeeze out a 4 mm (0.2 in.) thick bar of sealing compound (Three Bond) from the tube and put it on the flange of the oil pan as shown.
Figure 133 Oil pan for S4L and S4L2 engines
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Cylinder Block, Crankshaft, Pistons and
Oil pan ASSEMBLY
Figure 134 Oil pan for S3L and S3L2 engines
Cut nozzle here
To squeeze out a 4 mm (0.2 in.) thick bar, cut the nozzle of the tube as shown.
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 ± 1.5 N·m]
Figure 136 Tightening oil pan bolts
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
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]
Timing Gears and Flywheel
ASSEMBLY
21 Timing Gears and
Flywheel
Lubricate with engine oil
Use a new gasket
Use a new gasket
Lubricate lip with engine oil
Lubricate journals and lobes 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 ± 0.5 kgf m (98 ± 4 lbf ft)
[132 ± 5 N m]
Use a new gasket
Use a new gasket
Service Manual Mitsubishi SL-Series diesel engines
Figure 137 Inspection points
ENGLISH
Timing Gears and Flywheel ASSEMBLY
21.1 Front plate installation
1.
Scrape the gasket from the cylinder block and front plate.
2.
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.
3.
Put the front plate in position. Install four bolts and tighten them.
Figure 138 Installing front plate
21.2 Oil pump installation
1.
Make sure the packing has been put in position on the oil pump.
2.
Put the oil pump in position on the cylinder block.
Install three bolts and tighten them evenly.
3.
Make sure the oil pump gear rotates freely.
Figure 139 Installing oil pump
21.3 Engine turning
1.
Install two bolts (M12 x 1.25) in the flywheel bolt holes in the crankshaft.
2.
Put a bar between the bolts and turn the crankshaft to bring No. 1 piston to the top center as shown in the illustration.
Figure 140 Turning engine
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY Timing Gears and Flywheel
21.4 Engine turning
1.
Put the camshaft (with bearing and gear) in position in the cylinder block.
2.
Hit the gear with a plastic hammer to fit the bearing in position.
3.
Make sure the camshaft rotates freely.
4.
Tighten the stopper bolt.
Figure 141 Installing fuel injection pump camshaft
21.5 Camshaft installation
1.
Lubricate the lobes and journals with engine oil.
2.
Put the camshaft (with gear) in position in the cylinder block.
CAUTION
Do not cause damage to the lobes and journals when the camshaft is installed.
Lubricate with engine oil
Figure 142 Installing camshaft
3.
Tighten the bolts that hold the thrust plate to the specified torque.
Tightening torque
1.1 ± 0.1 kgf·m
(38 ± 2 lbf·ft)
[51.5 ± 2.5 N·m]
4.
Make sure the camshaft rotates freely. Check the end play for the camshaft.
Figure 143 Installing thrust plate
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Timing Gears and Flywheel ASSEMBLY
21.6 Idler gear installation
1.
Lubricate the idler gear with engine oil.
2.
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.
3.
Check the backlash of the gears. Make reference to “Timing gear backlash measurement” (page 37).
Figure 144 Marks on timing gears
21.7 Timing gear case installation
1.
Coat the gasket with adhesive and put it in position on the front plate.
2.
Lubricate the oil seal lip with engine oil.
3.
Tighten the bolts that hold the timing gear case.
Figure 145 Installing timing gear case
Figure 146 Tightening crankshaft pulley nut
21.8 Crankshaft pulley nut tightening
1.
Install two bolts (M12 x 1.25) in the flywheel bolt holes in the crankshaft and hold the crankshaft.
2.
Tighten the crankshaft pulley nut to the specified torque.
Tightening torque
17.5 ± 2.5 kgf·m
(127 ± 18 lbf·ft)
[172 ± 25 N·m]
WARNING
Check the strength of the bolts and bar used for holding the crankshaft.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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.
Install the O-ring in the groove in the driven gear sleeve.
2.
Install the speedometer driven gear in position in the cylinder block while rotating it or the camshaft.
Figure 148 Installing speedometer driven gear
21.11 Tappet installation
Lubricate the tappets with engine oil and put them in position in the cylinder block.
Figure 149 Installing tappets
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Timing Gears and Flywheel ASSEMBLY
21.12 Oil seal case installation
1.
Put a new gasket in position on the oil seal case.
2.
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
Figure 151 Installing rear plate
Safety bar
21.13 Rear plate installation
1.
Put a new gasket in position on the rear plate.
2.
Put the rear plate in position on the cylinder block with its dowel holes in alignment with the dowels.
Tighten the bolts that hold the rear plate to the specified torque.
Tightening torque
6.5 ± 1 kgf·m
(47 ± 7 lbf·ft)
[64 ± 10 N·m]
NOTE
Install the starter to the rear plate before installing the plate to the cylinder block for convenience of rear plate installation.
21.14 Flywheel installation
1.
Install a safety bar (M12 x 1.25) in the rear end of the crankshaft.
2.
Put the flywheel in position in alignment with the safety bar.
3.
Install three of four bolts in the flywheel and tighten them finger tight only.
4.
Remove the safety bar. Install the last bolt in the flywheel and tighten it finger tight only.
Figure 152 Safety bar
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
Figure 153 Tightening flywheel bolts
Timing Gears and Flywheel
5.
Have someone hold the crankshaft pulley with a wrench to prevent the flywheel from rotating.
6.
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.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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 ± 0.5 kgf m (65 ± 4 lbf ft)
[88 ± 5 N m]
Use a new part
Lubricate stem with engine oil
Use a new gasket
Figure 154 Inspection points
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
CYLINDER HEAD AND VALVE
MECHANISM
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
Socket 12
22.2 Valve stem seal installation
Using Socket 12, install the valve stem seal in position in the valve guide. After installation, make sure the seal is in its correct position.
NOTE
Improper stem seal installation can cause a failure to seal against downward flow of oil along the stem.
Figure 156 Installing valve stem seal
White enameled end
22.3 Valve spring installation
Install the valve spring with the white enameled end up.
Figure 157 Installing valve spring
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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
Figure 159 Putting cylinder head gasket
Guide bolts
22.5 Cylinder head gasket installation
1.
Thoroughly clean the top faces of the cylinder block and pistons.
2.
Install two guide bolts (M10 x 1.25) in the bolt holes in the cylinder block.
3.
Put a new cylinder head gasket in position on the cylinder block, making sure the guide bolts are all in alignment with their respective holes in the gasket.
CAUTION
Do not use any gasket adhesive or other substances on the top face of the cylinder block.
22.6 Cylinder head installation
Put the cylinder head in position on the cylinder block, making sure the guide bolts are all in alignment with their respective bolt holes in the head.
Figure 160 Installing cylinder head
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ASSEMBLY
Front
Figure 161 Tightening sequence
CYLINDER HEAD AND VALVE
MECHANISM
22.7 Cylinder head bolt tightening
1.
Remove the guide bolts and install the bolts that hold the cylinder head to the cylinder block.
2.
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]
22.8 Valve push rod installation
1.
Put the valve push rod into position through the bore in the cylinder head.
2.
Make sure the ball end of the push rod has been put into position over the top of the tappet.
Figure 162 Installing valve push rods
Bolt
22.9 Rocker shaft assembling
1.
Install the rocker arms, brackets and springs on the rocker shaft. Secure the brackets to the shaft by tightening the bolts.
2.
Make sure the rocker arms move freely.
Figure 163 Assembling rocker arms
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
CYLINDER HEAD AND VALVE
MECHANISM ASSEMBLY
22.10 Rocker shaft assembly installation
3.
1.
Install the valve caps in position on the top of the valves.
2.
Put the rocker shaft assembly in position on the cylinder head. Tighten the bolts that hold the rocker shaft assembly to the specified torque.
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).
Figure 165 Adjusting valve clearance
22.12 Rocker cover installation
3.
1.
Make sure the gasket is put on the rocker cover.
2.
Tighten the bolts that hold the rocker cover to the specified torque.
Tightening torque
1.15 ± 0.15 kgf·m
(8.3 ± 1.1 lbf·ft)
[11.3 ± 1.5 N·m]
Figure 166 Installing rocker cover
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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]
23.2 Exhaust manifold installation
Tighten the bolts that hold the exhaust manifold to the specified torque.
Tightening torque
1.85 ± 0.35 kgf·m
(13.4 ± 2.5 lbf·ft)
[18 ± 3.4 N·m]
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Fuel System
Gasket
Figure 167 Installing fuel injection nozzle
ASSEMBLY
ASSEMBLY
24 Fuel System
24.1 Fuel injection nozzle installation
1.
Put the gasket on the nozzle.
2.
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]
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.
Figure 168 Installing fuel injection pump
24.3 Flyweight assembly installation
Put the flyweight assembly in position on the rear end of the fuel injection pump camshaft and tighten the sliding sleeve shaft to the specified torque.
Tightening torque
3.6 ± 0.6 kgf·m
(26 ± 4.3 lbf·ft)
[35 ± 6 N·m]
Figure 169 Installing flyweight assembly
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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.
Install the governor assembly in position while putting the tie rod and spring into position in the injection pump.
2.
Install the tie rod to the pin of the control rack and secure it with the tie rod spring.
3.
Install the tie rod cover in position.
Figure 171 Installing governor assembly
24.6 Fuel injection line installation
1.
Put the fuel leak-off line in position and connect it to the fuel injection nozzles.
2.
Put the fuel injection lines in position and connect them to the fuel injection pump. Install the clamps.
Figure 172 Installing fuel injection lines
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Lubrication system
Figure 173 Installing pressure relief valve
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]
25.2 Oil filter installation
1.
Lightly lubricate the gasket with engine oil.
2.
Install the new filter element by hand. When the gasket contacts the base, tighten one turn more.
Figure 174 Installing oil filter
MD998054
To be coated with thread sealant
Figure 175 Installing oil pressure switch
25.3 Oil pressure switch installation
Coat the threads of the switch with thread sealant
(Three Bond 1102). Use Oil Pressure Switch Socket
Wrench (MD998054) (special tool) to install the oil pressure switch.
CAUTION
1.
Put the sealant on the threads only.
2.
Do not over-tighten the oil pressure switch when it is installed.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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.
Put the thermostat in the thermostat case.
2.
Put a new gasket in position on the thermostat case. Install the thermostat assembly in position on the cylinder head.
Figure 177 Installing thermostat
Figure 178 Installing cooling fan
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
26.3 Cooling fan installation
1.
Install the spacers in position in the fan as shown.
2.
Install the pulley in position on the water pump.
Install the fan and spacer combination in position on the pulley.
Cooling system
Figure 179 Installing thermoswitch and thermounit combination
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.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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
Figure 181 Installing alternator
Adjusting plate bolt
27.2 Alternator installation
1.
Put the alternator in position. Install the adjusting plate bolt in position to hold the alternator in position.
2.
Put the belt in position on the pulley. Move the alternator away from the engine to make an adjustment to the belt.
3.
Tighten the bolts.
4.
Make sure the deflection (tension) of the belt is correct.
Deflection under 10 kgf
(22 lbf) [98 N] force
Unit: mm (in.)
10 to 12
(0.4 to 0.5)
Apply 10 kgf (22 lbf) [98
N] force midway between crankshaft pulley and alternator pulley.
Figure 182 Adjusting alternator and fan belt
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Electrical System ASSEMBLY
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
GENERAL
Engine model
Starter
Alternator
Glow plug
Glow plug relay
Control timer unit
ETS type stop solenoid
Glow timer
Model
Type
Nominal output, V–kW
Model
Regulator, type
Nominal output, V–A
Model
Type
Rated voltage, V
Current draw, A
Model
Rated voltage, V
Continuous rating
Resistance in coil,
Ω
Model
Input voltage range, V
Load
Model
Type
Resistance in coil,
Ω
Stroke, mm (in.)
Operating voltage, V
Model
Rated voltage, V
Operating voltage, V
Operating temperature range °C (°F)
Storage temperature range °C (°F)
Pre-glow time, second
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
28 GENERAL
28.1 Specifications (standard)
1
S3L/S3L2 S4L/S4L2
M1T68281 M8T70471
DC solenoid shifted (with reduction gear)
12 - 1.7
12 - 2.0
A7T02071C
IC
12 – 50
008816-4C
Sheathed
10.5
9.7 ± 1.0 (30 seconds at rated voltage)
G71SP
DC 12
1 minute
13
YM-1C
DC 9 to 15
Solenoid (resistance in coil: 1.7
Ω
minimum)
YMS-1
Solenoid
1.8 ± 10% at 20°C (68°F)
13 ± 0.5 (0.53 ± 0.02)
DC 10 to 15
QGS
DC 12
7 to 15
-30 to +70 (-22 to 158)
-40 to +80 (-40 to 176)
6.2 ± 0.7
1. All specifications are subject to change without any prior notice.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM
< ETS type stop solenoid >
28.2 Wiring diagrams
GENERAL
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
GENERAL
< ETR type stop solenoid >
ELECTRICAL SYSTEM
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM STARTER
ELECTRICAL SYSTEM
29 STARTER
29.1 Disassembly
Roughness, burns, or stepped wear on commutator surface; worn or damaged gear
Abnormal rotation
Broken or damaged pinion
Figure 183 Starter component parts
Service Manual Mitsubishi SL-Series diesel engines
Brush powder deposits, uneven wear, poor brush movement in holder
Incorrect installation of pole pieces and field coils
O-rings and snap rings are not reusable.
Disassembly sequence
1.
Pinion set
2.
Solenoid switch
3.
Rear bracket
4.
Brush holder
5.
Yoke
6.
Armature
7.
Ball bearing
8.
Ball
9.
Seal set
10. Reduction gears
11. Lever set
12. Washer set
13. Gear shaft
14. Internal gear
15. Overrunning clutch
16. Front bracket
CAUTION
The pinion must be removed before removal or replacement of the following parts:
1.
Front bracket
2.
Reduction gears
3.
Overrunning clutch
ENGLISH
STARTER
S
Starter
S2
S1
Battery
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.
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. Apply a pipe-shaped implement to the pinion stopper and lightly tap it with a hammer to remove the pinion.
If the pinion returns to the retracted position before disengagement of the stopper while the tool is being tapped, repeat the procedure from the beginning.
29.1.2 Ball
The ball at the end of the armature acts as a bearing for movement of the armature in the thrust direction. When the armature is removed, the ball may stick to the grease on it. Be careful not to lose the ball.
29.2 Inspection
29.2.1 Armature
1.
Coil Short Circuit Test
Place the armature on a growler tester. Hold an iron rod parallel with the armature and slowly rotate the armature by hand. If the iron rod vibrates or is pulled toward the armature, the armature has a short-circuited coil and must be replaced.
2.
Coil Ground Test
Check whether continuity exists between the commutator and shaft (or core). If continuity exists, the coil is grounded and the armature must be replaced.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM
Good
Molding undercut depth
Segment
Bad
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 0.1 (0.004)
2) Measure the commutator’s outside diameter. If the measurement is out of specification, replace the armature.
Unit: mm (in.)
Standard value
Limit
Commutator outside diameter
32.0 (1.26) 31.4 (1.24)
3) Measure the molding undercut depth between segments. If the depth is smaller than the limit, cut the molding to a depth of 0.4-0.6 mm
(0.016-0.024 in).
Unit: mm (in.)
Limit
Commutator runout 0.1 (0.004)
29.2.2 Field Coil
1.
Coil Open Circuit Test
Check whether continuity exists between the terminal lead and each brush. If continuity does not exists, the field coil has an open circuit and the yoke assembly must be replaced
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
STARTER
Brush
ELECTRICAL SYSTEM
2.
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. If the brush is worn unevenly or has a rough contact surface, rectify the problem with fine emery paper (#300–500).
Brush length
Standard value
18 (0.71)
Unit: mm (in.)
Limit
11 (0.43)
2.
Brush Spring Force
With a new brush installed, pull the brush spring with a spring balance and read the load at the point where the spring leaves the brush. Replace the spring if its force is lower than the limit.
Brush spring force
Standard value
26.7 – 36.1
{2.7 – 3.7}
(6.0 – 8.3)
N {kgf} (lbf)
Limit
14.7
{1.5}
(3.3)
3.
Brush Holder Insulation Test
Check whether continuity exists between the (+) brush holder and the (–) brush holder plate. If continuity exists, replace the brush holder assembly.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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.
29.3 Assembly
Apply grease
Apply grease
Service Manual Mitsubishi SL-Series diesel engines
Apply grease
Assembly sequence
16 → 12 → 13 → 14 → 15 → 1 → 10 → 11 → 9 → 8 →
5 → 6 → 7 → 4 → 3 → 2
ENGLISH
STARTER
Battery (12V)
S-terminal
M-terminal
ELECTRICAL SYSTEM
29.4 Inspection and Testing after
Assembly
After assembling the starter, perform the following inspections and tests:
Pinion gap
Ammeter
Battery
(12V)
Switch
Voltmeter
Switch
Starter
Motor
29.4.1 Inspection and Adjustment of
Pinion Gap
1.
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.
2.
Lightly push the pinion shaft toward the armature and measure the amount of axial movement, which corresponds to the pinion gap.
3.
If the pinion gap is not within the 0.5 – 2.0 mm
(0.02 – 0.08 in.) range, adjust it by increasing or decreasing the number of seals in the solenoid switch. (Increasing the number of seals reduce the pinion gap). It may be necessary to replace the lever to obtain the correct pinion gap.
Unit: mm (in.)
Standard value
Pinion gap 0.5 – 2.0 (0.02 – 0.08)
NOTE
To prevent the solenoid switch coil from overheating, do not energize the solenoid switch for longer than 10 seconds.
29.4.2 No-Load Test
When the pinion gap has been correctly adjusted, connect an ammeter and a voltmeter between the starter motor and battery as shown in the drawing, then check the starter’s no-load characteristics.
CAUTION
Use the thickest wires possible, and tighten each terminal firmly.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM
M-terminal
S-terminal
B-terminal
STARTER
No-Load characteristics
Voltage
(V)
11
Current
(A)
130 maximum
Speed
(min
-1
)
3,600 minimum
29.4.3 Solenoid Switch
Perform the following continuity tests. If the solenoid switch fails either tests, replace it.
1) Test for Coil Open Circuit
Continuity should exists between the S- and
M-terminals and between the S-terminal and ground (case).
2) Test for Fused Contacts
Continuity should not exist between the B- and M-terminals.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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. Rear bracket
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM
Figure 184 Disassembling alternator
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.
30.1.2 Pulley removal
1.
Hold the rotor assembly in a vise by using thick cloth as shown in the illustration. Remove the nut that holds the pulley in position, and remove the pulley and spacer.
2.
Remove the rotor assembly from the front bracket.
Figure 185 Removing pulley
Rectifier
Unsolder
Unsolder
Figure 186 Removing stator core
30.1.3 Stator core and rectifier removal
1.
Unsolder the leads from the rectifier and remove the stator core from the rectifier.
CAUTION
Unsolder the leads as quickly as possible to prevent damage to the diodes in the rectifier.
2.
Remove the screws that hold the rectifier in position and remove the rectifier.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
ALTERNATOR
Check for cracks or other defects.
Test for open or short circuit usingthe procedure that follows.
ELECTRICAL SYSTEM
30.2 Inspection
Test for open or short circuit using theprocedure that follows.
Check for wear.
Check for cracks or other defects.
Test for open or short circuit using the procedure that follows.
Figure 187 Inspection points
Trio-diodes
Heat sink (-)
30.2.1 Diodes
1.
Test the resistance between the diode and heat sink. First touch the positive (+) prod of an ohmmeter to the diode, then the negative (–) prod.
If the resistance is infinite in both cases, the diode is open. If it is nearly zero in both cases, the diode is shorted. Do the same step for the remainder of the diodes. If any diode is open or shorted, replace the rectifier.
Heat sink (+)
Figure 188 Testing diode
Diode lead wires
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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.
Figure 189 Testing field coil for open circuit
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 190 Testing field coil for grounded circuit
30.2.3 Stator core
1.
Test for continuity between the leads as shown in the illustration. No continuity shows there is an open circuit in the stator core. Replace the stator core.
Figure 191 Testing stator core for open circuit
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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.
Wear limit line
Figure 193 Checking brush for wear
Unsolder
Brush holder
2.
To remove the brushes from the brush holder for replacement, unsolder the leads from the brushes.
This will permit removal of the brushes and springs.
Figure 194 Removing brushes for replacement
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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
Brushes
Wire-shaped tooling
Rear bracket
Wire-shaped tooling
30.3 Assembly
Follow the reverse of disassembly and use the procedure that follows.
1.
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.
2.
When installing the new rear bearing, put it in position with the side that has a groove toward the slip rings of the rotor.
3.
To install the rear bearing in the rear bracket, heat the rear bracket.
4.
Before installing the rotor in the rear bracket, insert a wire-shaped tooling into the hole in the rear bracket to lift the brushes off the slip rings.
Remove the tooling after the rotor has been installed in position.
Figure 196 Assembling alternator
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
KEY SHUTOFF SYSTEM (ETS solenoid type)
Control timer
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.
Solenoid
Figure 197 Key shutoff system
Figure 198 Control timer connection
31.2 Cord color (standard)
6
7
4
5
No.
1
2
3
Cord color
Blue
Blue
Red
Green
Red/white
Yellow
Black
Connected to
Solenoid
Solenoid
Battery (starter switch B terminal)
Starter switch ON terminal
Starter (starter switch and starter)
Oil pressure switch
Ground
31.3 Shutoff solenoid installation
1.
Remove the tie rod cover.
2.
Coat the threads of the stop solenoid with thread sealant (Three Bond 1212).
NOTE
Coat the length of the threads to be turned in the governor case.
3.
Temporarily install the shutoff solenoid and nut in the governor case.
4.
Move the injection pump control rack all the way to the non-injection (shutoff) position.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM
Plunger
Tightening torque: 4.5 ± 0.5 kgf m
(32.5 ± lbf ft) [44 ± 5 N m]
Threads: to be coated with thread sealant
Shaft
KEY SHUTOFF SYSTEM (ETS solenoid type)
5.
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.)
6.
Back off the shutoff solenoid 30 ° to 45 ° turn (the clearance between the control rack and plunger will be 0.15 to 0.20 mm (0.0059 to 0.0079 in.)) and tighten the nut to the specified torque.
7.
Start the engine and make sure the engine stops when the plunger is pushed all the way.
NOTE
• Do not allow thread sealant to contact (A)
• Do not allow cleaning solvent to enter the solenoid through (B)
Figure 199 Installing shutoff solenoid
Rubber cap
UP
Water drain hole
8.
Install the rubber cap in position with teh arrow head toward up (with the side that has a water drain hole down) as shown in the illustration.
CAUTION
Do not allow cleaning solvent to contact any solenoid parts.
Figure 200 Installing rubber cap
31.4 Inspection after assembly
1.
For the schematic of the key shutoff system, see
2.
Start the engine and make sure the engine stops when the starter switch key is turned to OFF position.
3.
Start the engine and make sure the engine stops when the oil pressure switch terminal is shorted to the switch body.
NOTE
It will take about 10 seconds to restart an engine which was shut down by the key shutoff device.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
KEY SHUTOFF SYSTEM (ETR solenoid type)
3
2
1
Red
White
Blue
Stroke 13 ± 0.5 mm
(0.51 ± 0.02 in.)
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.
During operation with the starter switch at the “ON” position, the hold-in coil of the solenoid remains energized, keeping the push rod in the retracted position.
Like the conventional energize-to-stop (ETS) solenoid engine shutdown system, this system is a safety device designed to bring the injection pump into the noinjection state whenever the wiring is open or the starter switch is turned to the “OFF” position.
32.2 Cord color (standard)
The wires of the solenoid are identified by color as follows:
No.
1
2
3
Color
Red
White
Blue
Remarks/Connection
PULL (pull-in coil)/starter
HOLD (hold-in coil)/starter switch
COM (earth)/ground
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM
Tie rod
Rack at no-injection end position
Push rod in free-tomove state
Apply sealant
Tightening torque:
49 N·m {5 kgf·m}
(36 lbf·ft)
NOTE:
Areas A must be free of sealant.
KEY SHUTOFF SYSTEM (ETR solenoid type)
32.3 Shutoff solenoid installation
1.
Remove the tie rod cover on the injection pump to enable movement of the rack to be observed.
2.
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.
NOTE
Sealant should be applied over those threads which are concealed when the solenoid is installed on the cylinder block.
Sealant Threebond 1212 or 1211
3.
Screw the solenoid 1 into the cylinder block.
4.
While moving the rack in both directions, screw in the solenoid 1 until the rack is against the solenoid’s push rod and cannot move any more.
5.
Unscrew the solenoid 1 approximately 90 – 180° from the position achieved in (d), and temporarily lock the solenoid with the nut 2.
6.
Move the rack in both directions. There should be a play of approximately 0.3 – 0.7 mm (0.01 – 0.03 in.).
7.
Tighten the nut 2 to the specified torque.
Nut tightening torque Threebond 1212 or 1211
8.
Reinstall the tie rod cover on the injection pump.
9.
Start the engine. Turn the starter switch to the OFF position. The push rod then should extend, pushing back the rack and stopping the engine.
NOTE
It will take about 10 seconds to restart an engine which was shut down by the key shutoff device.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
AUTOMATIC GLOW SYSTEM
Fuel pump
Starter switch
Fuse
Glow plug timer
Glow plug indicator
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.
Heating time 6.2 ± 0.7 seconds
Battery switch Glow plug
Ammeter
Switch
Battery
Figure 201 Automatic glow plug system
33.2 Glow timer specification
(standard)
1
Part number
Type
Rated voltage
Operating voltage range
Operating temperature range
Storage temperature range
Glow plug activating time
MM431-762
Quick heating
DC 12 V
7 to 15 V
–30°C to +70°C
(–22°F to +158°F)
–40°C to +80°C
(–40°F to +176°F)
6.2 ± 0.7 seconds
1. All specifications are subject to change without any prior notice.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
ELECTRICAL SYSTEM AUTOMATIC GLOW SYSTEM
33.3 Glow plug relay specifications
(standard)
2
Part number
Rated voltage
Continuous rating
Coil resistance
Operating temperature range
MM431-28201
DC 12 V
1 minute
13 Ω
–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
Resistance
Standard
0.55 Ω
Figure 203 Testing glow plug
Service Manual Mitsubishi SL-Series diesel engines
2. All specifications are subject to change without any prior notice.
ENGLISH
AUTOMATIC GLOW SYSTEM ELECTRICAL SYSTEM
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
COOLING SYSTEM
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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
Fan belt (for farm or industrial engine)
Cooling fan
Water pump
Thermostat
Thermo switch
Suction type
Temperature at which valve starts opening
Temperature at which valve lift is 8 mm (0.3 in.)
Type
Temperature at which switch is turned ON
Temperature difference for
ON-OFF control
Resistance in thermounit
S3L/S3L2 S4L/S4L2
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.)
No. of blades = 5, diameter = 360 mm (14.2 in.)
Centrifugal type
82 ± 1.5°C (180 ± 2.7°F)
95°C (203°F)
Bimetal
111 ± 3.5°C (232 ± 6.3°F)
8 ± 3.5°C (46.4 ± 6.3°F)
50°C (122°F): 80 ± 10 Ω
80°C (176°F): 29.5 ± 2.5 Ω
120°C (248°F): 10 ± 0.3 Ω
1. All specifications are subject to change without any prior notice.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
COOLING SYSTEM
Test thermoswitch and thermounit using the procedures that follow.
COOLING SYSTEM
35 INSPECTION
INSPECTION
Test thermostat using the procedure that follows.
Check for aging or damage
Check for cracks or distortion.
Figure 205 Inspection points
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
Use new gaskets.
Check for cracks or leaks.
Check for elongation, aging or wear.
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
Figure 207 Testing thermostat
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. Heat the water uniformly in the pan and measure a temperature at which the valve starts opening and a temperature at which the valve lift
(distance) is 8 mm (0.3 in.). Replace the thermostat if defective.
Temperature at which valve starts opening
Temperature at which valve lift is 8 mm (0.3 in.)
85 ± 1.5°C
(180 ± 2.7°F)
95°C (203°F)
WARNING
Water in the pan is hot. Any contact can cause severe burns.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
COOLING SYSTEM
Figure 208 Testing thermoswitch
Figure 209 Testing thermounit
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.
30 m Ω Resistance at 120°C
(248°F)
Temperature at which switch is turned ON
111 ± 3.5°C
(232 ± 6.3°F)
WARNING
Oil in the pan is hot. Any contact can cause severe burns.
35.4 Thermounit (standard)
Hang the thermounit in the pan of antifreeze with its temperature sensing end below the surface of antifreeze and measure the resistance while heating the antifreeze as shown in the illustration. If the resistance is incorrect, replace the thermounit.
Standard 50°C (122°F): 80 ± 10 Ω
80°C (176°F): 29.5 ± 2.5 Ω
120°C (248°F): 10 ± 0.3 Ω
WARNING
Antifreeze in the pan is hot. Any contact can cause severe burns.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
INSPECTION COOLING SYSTEM
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
LUBRICATION SYSTEM
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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 Specifications 1
Engine model
Type
Oil
Capacity (high level excl. 0.5 liter (0.13 U.S. gal) of oil in oil filter), liter (U.S. gal)
Oil pump Type
Driven by
Relief valve opening pressure
Pressure difference at which oil pressure switch is closed (indicator light comes on)
Oil filter
S3L/S3L2 S4L/S4L2
Force feed
API Service Classification CC or better
5.7 (1.5) (with deep oil pan)
3.7 (1.0 (with standard oil pan)
7.7 (2.0) (with deep oil pan)
5.4 (1.4) (with standard oil pan)
Trochoid
Camshaft gear
3.5 ± 0.5 kgf/cm
2
(50 ± 7 psi) [343 ± 49 kPa]
0.5 ± 0.1 kgf/cm
2
(7 ± 1.4 psi) [49 ± 10 kPa]
Paper-element cartridge (full flow) type
1. All specifications are subject to change without any prior notice
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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.
Figure 211 Testing oil pressure switch (1)
Small diameter bar
Figure 212 Testing oil pressure switch (2)
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
2.
Insert a small diameter bar into the oil hole in the switch and lightly push it in to test for no continuity as shown in the illustration. Any continuity is the cause for replacing the switch.
3.
Apply a pressure air of 0.5 kgf/cm 2 (7 psi) [49 kPa] to the switch through the oil hole to test for no continuity. Any continuity is the cause for replacing the switch. Also, check for air leaks. Any air leak is an indication of a ruptured diaphragm. In such a case, replace the switch.
INSPECTION
Cap nut
Shims
Figure 213 Checking pressure relief valve
LUBRICATION SYSTEM
37.3 Pressure relief valve
1.
Check the valve seat for contact. Check the spring for damage.
2.
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.
Relief valve opening pressure
3.5 ± 0.5 kgf/cm
2
(50 ± 7 psi)
[343 ± 49 kPa]
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
GENERAL
FUEL SYSTEM
38 GENERAL
38.1 Schematic
FUEL SYSTEM
Fuel injection nozzle
To fuel tank
Fuel filter overflow pipe
Fuel pump
Fuel leak-off pipe Fuel injection pipe
Fuel injection pump
Fuel filter
From fuel tank
Figure 214 Schematic overview
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM GENERAL
38.2 Specifications (standard) 1
Description
FUEL
INJECTION
PUMP
FUEL
INJECTION
NOZZLE
Type
Model
Plunger diameter
MS retard (crank angle), deg
Delivery valve, type
Air vent screw
Type
Model
Injection pressure (valve opening pressure)
FUEL
FILTER
(remote)
FUEL
FEED
PUMP
(remote)
Table 3
Type
Type
Capacity (at terminal voltage of DC 12 V and
20°C (68°F))
Specifications
Specification
S3L/S3L2 S4L/S4L2
Bosch M
ND-PFR3M ND-PFR4M
5.5 mm (0.217 in.)
8°
Silto or Bosch
Yes
Throttle
DN15PD6
140
0
+5
kgf/cm2 (1991
0
+71
psi) [13 729
0
+490 kPa]
Paper element
Electric (diaphragm)
300 cc (18.3 cu in.)/min minimum or 400 cc (24.4 cu in.)/min minimum
Service Manual Mitsubishi SL-Series diesel engines
1. All specifications are subject to change without any prior notice.
ENGLISH
FUEL INJECTION NOZZLE
Figure 215 Fuel injection nozzle ready for test
Figure 216 Removing tip from injection nozzle
FUEL SYSTEM
FUEL SYSTEM
39 FUEL INJECTION
NOZZLE
39.1 Inspection
39.1.1 Injection pressure (valve opening pressure) test
1.
Install the injection nozzle on the tester. Slowly operate the tester handle to bleed (remove) air from the tester.
2.
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.
Read the maximum gauge pressure at the instant fluid flows from the tip.
3.
If the injection pressure is incorrect, disassemble the nozzle and change the thickness of the washer.
Injection pressure (valve opening pressure) Standard
140
0
+5
(1991
[13729
kgf/cm
0
+71
0
+490
2
psi)
kPa]
NOTE
An increase or decrease of washer thickness by 0.1 mm (0.004 in.) will vary the injection pressure by 10 kgf/cm 2 (142 psi) [981 kPa]. 10 kinds of washer are available in thicknesses from 1.25 mm (0.049 2 in.) to
1.70 mm (0.066 9 in.) in increments of 0.05 mm
(0.002 0 in.).
WARNING
When the injection nozzles are tested, be sure to wear eye protection. Fuel comes from the orifices in the nozzle tip with high pressure. The fuel can pierce
(go through) the skin and cause serious injury to the operator. Keep the tip of the nozzle pointed away from the operator and into the fuel collector.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM
Good nozzle Discharge pattern for orifice with a restriction (recondition or replace)
Figure 217 Orifice restriction test
FUEL INJECTION NOZZLE
39.1.2 Orifice restriction test
1.
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.
2.
Operate the tester handle at a speed of one stroke per second to make sure the discharge is straight.
Needle valve
Figure 218 Washing nozzle tip
Body
39.1.3 Nozzle tip washing and replacement
1.
Loosen the retaining nut and remove the tip from the injection nozzle. Wash the needle valve and body in clean diesel fuel. After washing, put the needle valve in the body in clean diesel fuel.
CAUTION
Do not hit the tip when removing it from the injection nozzle.
NOTE
Keep the need valves with their respective bodies.
Do not use needle valves or bodies with other bodies or needle valves.
2.
After cleaning the tip, install it in the nozzle and tighten the retaining nut to the specified torque.
Tightening torque
3.75 ± 0.25 kgf·m
(27 ± 1.8 lbf·ft)
[36.8 ± 2.5 N·m]
3.
If the injection nozzle is still bad after the tip has been washed, replace the tip.
NOTE a.
Do not touch the sliding surface of the needle valve.
b.
When installing the new nozzle tip, remove synthetic resin film from the tip and slide the needle valve in the body in clean diesel fuel to wash off inhibitor completely.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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
Check for too much carbon on tip of nozzle or in nozzle orifice
3.75 ± 0.25 kgf·m
(27 ± 1.8 lbf·ft)
[36.8 ± 2.5 N·m]
Figure 219 Disassembly sequence and inspection points
Disassembly sequence
1.
Retaining nut
2.
Nozzle tip assembly
3.
Piece
4.
Pin
5.
Spring
6.
Washer
7.
Body
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
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
Low idle speed Use a tachometer.
Test method
Exhaust smoke
Orifice discharge patter
Table 4
1.
Check by quickly increasing engine speed under no-load condition.
2.
Check by starting load.
Remove injection nozzle and reinstall it with orifice toward outside of engine. Look at discharge pattern by cranking the engine with starter.
Injection pump chart
40.2 Disassembly
1.
Tappet guide pin
2.
Lock plate
3.
Tappet
4.
Tappet adjusting shim
5.
Lower spring seat
6.
Plunger
7.
Plunger spring
8.
Upper spring seat
9.
Control sleeve
10. Control rack
11. Delivery valve holder
12. O-ring
13. Delivery valve spring
14. Delivery valve gasket
15. Delivery valve
16. Plunger barrel
17. Pump housing
Criteria
Standard engine:
980
0
+30
min
-1
No too much black or gray smoke
Good discharge pattern
Figure 220 Disassembly sequence
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
FUEL INJECTION PUMP FUEL SYSTEM
Disassembly procedure
40.2.1 Tappet removal
1.
Hold the injection pump in a vise with the side that has tappets up.
2.
Straighten the lock plate away from the tappet guide pin with a screwdriver.
3.
Rotate the tappet guide pin 180° to unlock it from the housing.
Figure 221 Removing tappet guide pins
Figure 222 Removing tappets
4.
Remove the tappet guide pin with a needle-nose pliers while pushing down on the tappet. Remove the tappet.
5.
Do Steps (2) through (4) again for remainder of the tappets.
CAUTION
The tappet can be thrown from the housing when the tappet guide pin is removed. Hold the tappet to prevent it from falling.
40.2.2 Plunger removal
1.
Remove the tappet adjusting shim.
2.
Remove the lower spring seat and plunger with a tweezers.
3.
Remove the plunger spring.
4.
Remove the upper spring seat and control sleeve.
5.
Do Steps (1) through (4) again for remainder of the plungers.
6.
Remove the control rack.
Figure 223 Removing plungers
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM FUEL INJECTION PUMP
40.2.3 Delivery valve removal
1.
Turn the injection pump upside down and hold it in a vise.
2.
Remove the delivery valve holder.
3.
Remove the delivery valve spring.
4.
Remove the delivery valve gasket.
Figure 224 Removing delivery valve holders
5.
Remove the delivery valve with a tweezers.
6.
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.
Figure 225 Removing delivery valves
Figure 226 Removing barrels
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
40.2.4 Barrel removal
1.
Remove the barrels from the housing.
CAUTION a.
The plungers and barrels are finely finished parts. Keep them as clean as possible.
b.
Keep the plungers with their respective barrels for installation. Do not use plungers or barrels with other barrels or plungers.
FUEL INJECTION PUMP
Adjusting plates
FUEL SYSTEM
NOTE a.
When replacing the plungers and barrels or delivery valves, do not loosen the adjusting plates between the pumping elements.
b.
After these parts have been replaced, the injection quantity must be measured. Pump
Tester Cam Box is needed for measurement of injection quantity.
c.
Keep the disassembled injection pump parts in clean diesel fuel.
Figure 227 Adjusting plates
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM FUEL INJECTION PUMP
40.3 Inspection
Check delivery valve for wear or damage
Figure 228 Inspection points
Check tappet for wear.
Check plunger for wear, rusting or scoring.
Check control rack for movement.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
FUEL INJECTION PUMP
Tightening torque:
4.5±0.5 kgf·m
(32.5±4 lbf·ft) [44±5 N·m]
Use new O-ring.
40.4 Assembly
FUEL SYSTEM
Use new lock plate.
Figure 229 Assembly sequence
Locating dowel
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.
NOTE
If the slot in the barrel is not aligned with the dowel of the housing, the O-ring will not seat correctly (still visible) after the delivery valve holder has been installed.
Figure 230 Installing barrels
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM
Valve
Valve seat
Delivery valve
Figure 231 Installing delivery valves
Center tooth (visible when seen from the lower side)
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 a.
Any time the injection pump is disassembled, a new O-ring must be installed.
b.
Make sure the threads of the delivery valve holder do not cause damage to the O-rings.
40.4.3 Control sleeve installation
1.
Install each control sleeve with the center tooth in alignment with the line mark of the control rack.
Line
Figure 232 Installing control sleeves
2.
Put the plungers in position in the barrels.
CAUTION
Make sure the notch in the plunger is toward the adjusting plate.
Figure 233 Installing plungers
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
FUEL INJECTION PUMP
Figure 234 Installing tappets
4.5±0.5 kgf·m
(32.5±4 lbf·ft)
[44±5 N·m]
Figure 235 Tightening delivery valve holders
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.
40.4.5 Delivery valve holder installation
Put the delivery valve holders in position and tighten them to the specified torque.
CAUTION
Do not over tighten the delivery valve holders. This can put end force on the barrels, resulting in a failure of the plungers to move freely. If the holders are not tightened to the specified torque, engine oil would leak in the injection pump.
40.4.6 Inspection after assembly
1.
After the injection pump has been assembled, check to see if the control rack moves freely without any binding or catching.
2.
If the control rack fails to move freely, the possible causes are: a Pumping element(s) sticking b Foreign particles lodged between control rack and sleeves c Over-tightening of delivery valve holder(s)
Disassemble and check the injection pump to locate the cause of the trouble.
3.
After the injection pump has been finally assembled, check the injection timing.
Figure 236 Checking control rack movement
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM GOVERNOR
FUEL SYSTEM
41 GOVERNOR
41.1 Disassembly and inspection
Make sure levers move freely
Check sliding sleeve for wear or damage. Make sure it moves freely
Check weights for wear
Check spring for damage
Check sliding sleeve contact face for wear
Check shaft for defects
Figure 237 Disassembly sequence and inspection points
Disassembly sequence
1.
Tie rod spring
2.
Tie rod
3.
Speed control lever
4.
Spring pin
5.
Grooved pin
6.
Governor shaft (remove 7 thru 11 as an assembly)
7.
Governor lever
8.
Start spring
9.
Tension lever
10. Governor spring
11. Governor spring lever
12. Governor case
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
GOVERNOR
41.2 Assembly
1.
Install the levers in position.
FUEL SYSTEM
Figure 238 Installing governor levers
Grooved pin
Tie rod spring
2.
Put O-ring on the governor shaft.
3.
Put the governor shaft in position in the governor case and put the levers on the governor shaft.
4.
Install the grooved pin and spring pin in position with a hammer.
5.
Install the tie rod and tie rod spring in position.
Figure 239 Assembling governor
Tie rod
Spring pin
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM
Speed control lever
Governor spring
Torque spring set
Line mark on pump body
Line mark on control rack
Figure 240 Installing torque spring set
Sealing cap Special nut
Governor lever
GOVERNOR
41.3 Torque spring set installation
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.
Remove the tie rod cover.
2.
Move the speed control lever to the high idle position and hold it there.
3.
Pull the tie rod in the direction of arrow head to the point where a slight resistance is encountered.
NOTE
In this position, the tie rod does not pull on the governor spring.
4.
Turn in the torque spring set while lightly pulling the tie rod until the line mark on the control rack is aligned with the line mark on the pump body.
5.
With these line marks aligned, lock the torque spring set in position by tightening the special nut.
6.
Install the sealing cap over the torque spring set and stake the cap in position.
Figure 241 Sealing cap for torque spring set
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
FUEL PUMP
FUEL SYSTEM
42 FUEL PUMP
FUEL SYSTEM
42.1 Inspection
Look outside the pump for defects and test its performance. Do not attempt to disassemble the pump.
Figure 242 Fuel pump (plunger type)
Figure 243 Fuel pump (diaphragm type)
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
FUEL SYSTEM
Do not remove
Figure 244 Fuel filter
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
Do not remove
Air vent screw
FUEL FILTER
FUEL SYSTEM
43 FUEL FILTER
1.
Normally, the fuel filter is not to be disassembled.
Only element removal for cleaning or replacement is recommended.
2.
When installing the valve lever after washing, coat the O-ring for the lever with silicone oil and the washer with grease.
Parts fuel filter:
1.
Ring nut
2.
Cup
3.
O-ring
4.
Element
5.
Lever plate
6.
Washer
7.
Valve lever
8.
O-ring
9.
Packing
10. Valve seat
11. Filter body
Parts fuel filter:
1.
Ring nut
2.
Cup
3.
O-ring
4.
Element
5.
O-ring
6.
Valve lever
7.
O-ring
8.
Spring
9.
Valve
10. Filter body
Figure 245 Fuel filter
Wash in diesel fuel every
100 sevice hours. Replace every 400 service hours
Check for water and sediment accumulation
Priming sequence
From fuel tank
Air vent screws
To pump
Replace every 400 service hours
Check for water and sediment accumulation
Figure 246 Fuel filter (cartridge type)
Do not attempt to disassemble the cartridge type fuel filter. Check the filter for contamination or damage and replace it as an assembly if necessary
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
FUEL FILTER FUEL SYSTEM
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
AIR INLET SYSTEM AND EXHAUST
SYSTEM
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
GENERAL
Air breather pipe (for recirculation of blowby gases
Air (from air cleaner)
AIR INLET SYSTEM AND EXHAUST SYSTEM
AIR INLET SYSTEM AND EXHAUST SYSTEM
44 GENERAL
44.1 Schematic
Blowby gases
To exhaust muffler
Air inlet cover
Exhaust manifold
Figure 247 Schematic overview
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
AIR INLET SYSTEM AND EXHAUST SYSTEM
AIR INLET SYSTEM AND EXHAUST SYSTEM
45 INSPECTION
INSPECTION
Use a new packing
Check for cracks
Check for cracks
Use a new gasket
Use a new gasket
Figure 248 Inspection points
Figure 249 Checking manifold for warpage
Check for cracks
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 Standard
Warpage of manifold
Table 5
0.15 (0.005 9)
Inspection, unit mm (in.)
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
INSPECTION AIR INLET SYSTEM AND EXHAUST SYSTEM
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
MAINTENANCE
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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. For example, at Every 500 Service
Hours, also service those items listed under Every 100
(250) Service Hours, Every 50 Service Hours and
Every 10 Service Hours.
Interval Item
Every 10 Service Hours
[Pre-Start Inspection]
Every 50 Service Hours
First 50 Service Hours of New or
Reconditioned Engine
Every 100 Service
Hours
Every 250 Service
Hours or once a year
(whatever comes first)
Walk-around inspection
Check engine oil level
Check fuel level
Check coolant level
Drain water and sediment from the fuel tank and water separator
Check the battery electrolyte level and specific gravity
Change engine oil
Change oil filter
Retighten nuts and bolts
Clean fuel filter element
Clean radiator fins
Change engine oil
Change oil filter
Check and adjust valve clearance
Every 500 Service
Hours
Change fuel filter element
Check and adjust injection pressure
Check and adjust fan belt
Check glow plugs
Retighten nuts and bolts
Check starter
Every 1000 Service
Hours
Check alternator
Check turbocharger
Table 6 Lubrication and maintenance charts
Remarks (specifications)
See operation manual
See operation manual
See operation manual
See operation manual
See operation manual
After cleaning, prime
See operation manual
0.25 mm (0.0098 in.) for both inlet and exhaust valves
After changing, prime
140 kgf/cm
2
(1 991 psi) [13 729 kPa]
Deflection: 13 mm (0.5 in.)
See turbocharger manual
Page
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
MAINTENANCE LUBRICATION AND MAINTENANCE CHART
Interval Item
Every 2 Years Change coolant
Prime fuel system
Clean air cleaner element When Required
Change air cleaner element
Table 6 Lubrication and maintenance charts
Remarks (specifications)
See operation manual
See operation manual
Page
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
ENGINE OIL AND OIL FILTER MAINTENANCE
MAINTENANCE
47 ENGINE OIL AND OIL
FILTER
47.1 Engine oil specifications
1
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)
Oil viscosities S A E 15 W - 4 0
S A E 1 0 W - 3 0
S A E 5 W - 2 0
S A E 3 0
S A E 40
Table 7 Recommended oil viscosities
Dipstick
“H” mark
“L” mark
Figure 250 Checking oil level
Oil fillers
Drain plug
47.2 Oil level check
1.
Check the crankcase oil level with a dipstick with the engine put horizontal.
2.
If the oil level is at or below “L” (low level) mark on the dipstick, add oil to “H” (high level) mark on the dipstick.
NOTE a.
After adding oil, leave the engine standing for one minute and check the oil level.
b.
Avoid mixing different brands of oils. In some cases, they are not compatible with each other and deteriorate when mixed. Use the same brand at successive intervals.
c.
If the engine has been left standing for a long period of time, check the oil for level and contamination before starting the engine. Start and run the engine for a few minutes. Then stop the engine and check the oil level again.
1.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
MAINTENANCE ENGINE OIL AND OIL FILTER
47.3 Oil and oil filter change
1.
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).
2.
Warm up the engine. Remove the drain plug and allow the oil to drain in a container.
3.
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.
Figure 251 Removing used oil filter
Figure 252 Removing used oil filter
Apply oil
Service Manual Mitsubishi SL-Series diesel engines
4.
Check the new oil filter and make sure that the Oring is fitted in the groove. Apply a thin coat of lube oil to the O-ring of the new oil filter.
5.
Install the new filter by hand untill the O-ring touched the base. Tighten 3/4 to 1 turn more.
CAUTION
Do not cause damage to the O-ring when installing the filter.
6.
Install the drain plug and tighten it to the specified torque.
Tightening torque
4 ± 0.5 kgf·m
(29 ± 4 lbf·ft)
[39 ± 5 N·m]
7.
Re-fill the engine to the "H" mark on the dipstick with the new oil. Approximately an additional 0.5 liter (0.5 qt) of oil is required for the oil filter and oil lines.
8.
Start the engine, leave it idling for a few minutes and check for leaks. Re-tighten the filter in case of leakage.
9.
Stop the engine. Check the oil level and add oil if necessary.
47.4 Oil filter change
1.
Change the oil filter every 250 service hours.
2.
Remove the used filter with a filter wrench.
Discard the filter.
3.
Remove all of the old filter gasket from the filter base and apply a thin coat of engine oil to the gasket on the new filter. Install the filter by hand until its gasket contacts the base. Tighten 3/4 turn more.
ENGLISH
ENGINE OIL AND OIL FILTER MAINTENANCE
CAUTION
Do not cause damage to the O-ring when installing the filter.
4.
Add 0.5 liter (0.5 qt) of oil.
5.
Start the engine and check for leaks around the filter.
6.
Stop the engine. Check the oil level and add oil if necessary.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
MAINTENANCE
< Front of engine
Figure 253 Cylinder head bolt tightening sequence
TDC (top dead center) mark for No.
1 and No. 4 pistons
Mark on timimg gear case
IT (injection timimg) mark
TDC mark for No. 2 and No. 3 pistons
Figure 254 Timing mark
VALVE CLEARANCE
MAINTENANCE
48 VALVE CLEARANCE
NOTE
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.
Tightening torque
9 ± 0.5 kgf
2 m
(65 ± 4 lbf
2 ft)
[88 ± 5 N
2 m]
2.
Find top dead center compression position for No.
1 piston by using the procedure that follows: a Turn the crankshaft until TDC mark on the crankshaft pulley is aligned with the mark on the timing gear case.
b With No. 1 piston at top dead center on the compression stroke, the rocker arms will not be moved when the crankshaft is turned approximately 20° in both directions.
c If the rocker arms move, No. 1 piston is at top dead center on the intake or exhaust stroke.
In such a case, turn the crankshaft 360° in the direction of engine rotation again. No. 1 piston is now at top dead center on the compression stroke.
3.
Loosen the lock nut for the adjusting screw. With a feeler gauge inserted between the rocker arm and valve cap, adjust the valve clearance by turning the adjusting screw.
Item Standard
Valve clearance (both inlet and exhaust valves)
Table 8
0.25 (0.0098)
Valve clearance, unit mm (in.)
4.
Hold the adjusting screw and tighten the lock nut.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
VALVE CLEARANCE
Figure 255 Adjusting valve clearance
MAINTENANCE
5.
After the valve clearance on the valves for No. 1 cylinder has been adjusted, turn the crankshaft
180° in the direction of engine rotation and adjust the valve clearance on the valves for the remainder of the cylinders in firing order (injection sequence)
Firing order (injection sequence)
S3L(2) 1 – 3 – 2
S4L(2) 1 – 3 – 4 – 2
Table 9 Firing order
Crankshaft rotation angle
240°
180°
CAUTION
After the valve clearance on the valves for all cylinders has been adjusted, turn the crankshaft two or three times and make sure the valve clearance is correct.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
MAINTENANCE
Figure 256 Removing delivery valve and spring
FUEL INJECTION TIMING
MAINTENANCE
49 FUEL INJECTION
TIMING
49.1 Preparation
1.
Close the fuel filter valve.
2.
Disconnect the No. 1 fuel injection pipe from the cylinder head and injection pump.
3.
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.
4.
Connect the fuel injection pipe to the injection pump.
5.
Hold the speed control lever in the low speed position.
49.2 Inspection
49.2.1 Fuel flow method
1.
Open the fuel filter valve. Turn the starter switch key to ON position.
NOTE
Fuel will come from the injection pipe with high pressure when the starter switch key is turned to ON position if the engine is equipped with an electric fuel pump. Direct fuel flow into the container.
Figure 257 Fuel coming from injection pipe
2.
Slowly turn the crankshaft clockwise, looking at the free end of the injection pipe. The instant fuel stops coming out is the fuel injection timing.
NOTE
Turn the crankshaft in reverse direction just a little and do Step (2) again to verify the injection timing.
Figure 258 Fuel stops coming from injection pipe
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
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
Figure 260 Disconnecting No. 1 fuel injection pipe
49.2.2 Alternate method
In the fuel flow method, the delivery valve has to be removed. As a result, there is a good chance for dirt particles to get inside the fuel injection pump. In this alternate method, however, it is not necessary to remove the delivery valve.
1.
Disconnect No. 1 fuel injection pipe at the fuel injection nozzle (cylinder head).
2.
Prime the fuel system.
3.
Slowly turn the crankshaft clockwise until fuel just swells at the free end of the injection pipe and, at that instant, check the position of the IT mark with respect to the mark on the gear case. This timing is approximately 1° retarded. Take this 1° retardation into account when making a shim adjustment.
Figure 261 Timing mark
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
MAINTENANCE
Shims
Figure 262 Adjusting fuel injection timing
TDC mark
Angle by which fuel injection timing is advanced
Mark on timing gear case
Angle by which fuel injection timing is retarded
Increase shim thickness.
Decrease shim thickness.
FUEL INJECTION TIMING
49.3 Adjustment
1.
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°.
2.
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)
Four kinds of shims are available in thicknesses
0.2 mm (0.007 9 in.), 0.3 mm (0.011 8 in.), 0.4 mm
(0.015 7 in.) and 0.8 mm (0.031 5 in.). These shims have no identification; measure the thickness of each shim with a calipers before using it.
CAUTION
Apply sealant to both faces of each shim to prevent oil leaks.
3.
After the timing has been adjusted, make sure it is correct.
4.
Close the fuel filter valve and restore the delivery valve and injection pipe to the original state.
Retarded Advanced
Figure 263 Adjusting fuel injection timing
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
FUEL FILTER
Figure 264 Fuel filter with [AIR] valve
Valve lever
Element
Ring nut
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.
50.2 Cartridge (air vent screw) type fuel filter
Replace the filter as an assembly if water and sediment have been accumulated in it.
Figure 265 Cartridge type fuel filter
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
MAINTENANCE FUEL SYSTEM PRIMING
Overflow pipe
[AIR]
Valve lever
[ON]
OPEN position
[OFF]
Figure 266 Priming fuel filter with [AIR] valve
Figure 267 Priming cartridge (air vent screw) type fuel filter
MAINTENANCE
51 FUEL SYSTEM PRIMING
51.1 Engine with fuel filter with
[AIR] valve
5.
1.
Move the fuel filter valve lever to AIR position.
2.
Move the lever to ON position when the fuel flows free of bubbles from the overflow pipe.
3.
To prime the fuel pipe and fuel injection pump, loosen the air vent screw of the injection pump.
4.
The injection pipes and nozzles can be primed by cranking the engine.
NOTE
The fuel system of the engine with an electric fuel pump can be primed by turning the starter switch key to ON position.
51.2 Engine with cartridge (air vent screw) type fuel filter
1.
Loosen air vent screw (1). Tighten screw (1) when the fuel flows free of bubbles from this vent.
2.
Loosen air vent screw (2). Tighten screw (2) when the fuel flows free of bubbles from this vent.
3.
The injection pipes and nozzles can be primed by cranking engine engine.
NOTE
Turn the valve lever to OPEN position (if equipped) before loosening any air vent screw.
The fuel system of the engine with an electric fuel pump can be primed by turning the starter switch key to ON position.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
IDLE RPM SETTING
High idle position
Low idle position
Idling set bolt
Lock nuts High-idle set bolt
Figure 268 Idle speed setting
MAINTENANCE
MAINTENANCE
52 IDLE RPM SETTING
NOTE
Make sure that the valve clearance and injection timing are correct and that the fuel injection nozzles have no defect.
1.
Start and run the engine at low idle until the coolant temperature is above 60°C (140°F).
2.
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. Tighten the lock nut.
3.
To set the high idle speed , loosen the lock nut for the high-idle set bolt and turn the set bolt to make the engine run at the specified rpm. Tighten the lock nut.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
MAINTENANCE
Figure 269 Installing fuel injection nozzles
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
53.3 Nozzle tip washing and replacement
Make reference to FUEL INJECTION NOZZLE
53.4 Installation
1.
Put the gasket on the injection nozzle.
2.
Put the nozzle 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
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
FAN BELT
Adjusting bolt
Deflection: 10 to 12 mm
(0.4 to 0.5 in.) under 10 kgf (22 lbf) [98 N] force
Figure 270 Installing fuel injection nozzles
MAINTENANCE
MAINTENANCE
54 FAN BELT
1.
Measure the deflection of the belt. Apply 10 kgf (22 lbf) [98 N] force midway between the alternator pulley and the crankshaft pulley.
2.
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 Standard
Deflection 10 to 12
(0.4 to 0.5)
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
SERVICE DATA
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
SPECIFICATIONS
Item
Compression pressure
Maximum permissible difference between
average compression pressure of all cylinders in one engine
Standard
30 kgf/cm 2 (427 psi)
[2 942 kPa]
3 kgf/cm
2
(42.7 psi)
[294 kPa]
Limit
27 kgf/cm 2 (384 psi)
[2 648 kPa]
—
SERVICE DATA
SERVICE DATA
55 SPECIFICATIONS
1
55.1 Basic engine components
Unit: mm (in.)
Correction-Remarks
Repair or replace.
Repair or replace.
guide
Fuel injection timing (BTDC)
Clearance between valve stem and valve
(oil clearance)
Valve clearance
Inlet valve a
Clearance between rocker arm and shaft
Exhaust valve
Valve margin (valve lip thickness)
Valve seat
Valve spring
Valve sinkage
Angle
Width
Free length
Length under test force
Test force, kgf (lbf) [N]
Warpage of cylinder head bottom face
Bend (dial indicator reading) of valve push rod
17°
0.012 to 0.050
(0.000 47 to 0.001 97)
0.25 (0.009 8)
0.02 to 0.05
(0.000 8 to 0.002 0)
0.05 to 0.085
(0.002 0 to 0.003 35)
1.0 (0.039)
0.5 ± 0.25
(0.020 ± 0.009 8)
45°
1.3 to 1.8 (0.051 to 0.071)
39.1
(1.54)
47 (1.85)
30.5
(1.20)
13.9 ± 0.7
(30.6 ± 1.5)
[136 ± 7]
29 ± 2
(64 ± 4.4)
[284 ± 20]
0.05 (0.0020) maximum
—
0.200
(0.007 87)
-15%
0.10 (0.003 9)
0.3 (0.012)
0.10
(0.003 9)
0.15
(0.005 9)
0.5 (0.020)
1.5
(0.059)
—
2.5 (0.098)
46 (1.81)
—
Replace rocker arm.
Adjust.
Replace valve and valve guide.
Replace valve.
Recondition valve seat or replace cylinder head.
Recondition.
Replace.
Repair.
Replace.
1. All specifications are subject to change without any prior notice.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
SERVICE DATA SPECIFICATIONS
Timing gear backlash
Item
Crankshaft gear and idler gear
Idler gear and camshaft gear
Idler gear and fuel injection pump camshaft gear
Camshaft gear and P.T.O. gear
Fuel injection pump cam-shaft gear and oil pump gear
Lobe height of camshaft
Lobe height of fuel injection pump camshaft
Flatness of flywheel
Clearance between tappet and cylinder block
Clearance between camshaft journal and bushing
Clearance between idler gear and shaft
Warpage of cylinder block top face
Taper and out-of-round of cylinder
Diameter of piston
Standard
0.25 (0.0098) oversize
0.50 (0.0197) oversize
Clearance between piston pin and piston
Clearance between piston ring and groove
Clearance between ends of piston ring
Bore in cylinder block
No. 1 compression ring
No. 2 compression ring
Oil ring
No. 1 compression ring
No. 2 compression ring
Oil ring
Clearance between piston and cylinder
Standard
0.04 to 0.12
(0.001 6 to 0.004 7)
0.08 to 0.19
(0.003 1 to 0.007 5)
0.07 to 0.20
(0.0028 to 0.0079)
35.72 (1.406 3)
44 (1.73)
0.15 (0.005 9) maximum
—
—
0.03 to 0.07
(0.001 2 to 0.002 8)
0.05 (0.002 0) maximum
78.0
(3.07
0
+0.03
0
+0.0012
)
0.01 (0.000 4) maximum
77.93 to 77.95
(3.068 1 to 3.068 9)
78.18 to 78.20
(3.077 9 to 3.078 7)
78.43 to 78.45
(3.087 8 to 3.088 6)
0.006 to 0.018
(0.000 24 to 0.000 71)
0.06 to 0.10
(0.002 4 to 0.003 9)
0.05 to 0.09
(0.002 0 to 0.003 5)
0.03 to 0.07
(0.001 2 to 0.002 8)
0.15 to 0.30
(0.005 9 to 0.011 8)
0.15 to 0.35
(0.005 9 to 0.013 8)
0.20 to 0.40
(0.007 9 to 0.015 7)
0.035 to 0.086
(0.001 38 to 0.003 39)
Limit
0.30 (0.011 8)
34.72 (1.366 9)
43 (1.69)
0.50 (0.019 7)
0.15 (0.005 9)
0.15 (0.005 9)
0.20 (0.007 9)
0.10 (0.003 9)
78.2 (3.079)
—
77.80 (3.063 0)
78.05 (3.072 8)
78.30 (3.082 7)
0.050 (0.001 97)
0.30 (0.011 8)
0.20 (0.007 9)
0.20 (0.007 9)
1.50 (0.059)
0.300 (0.011 81)
Correction-Remarks
Replace.
Replace.
Replace.
Replace.
Replace tappet.
Replace bushing.
Replace idler gear or shaft.
Repair.
Hone out bore for oversize piston or replace cylinder block.
Replace piston ring.
Replace piston ring
Hone out bore for oversize piston or replace cylinder block.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
SPECIFICATIONS SERVICE DATA
Item
Clearance between crankpin and connecting rod bearing
Thrust clearance for connecting rod big end
Crankshaft
Diameter of journal
Diameter of crankpin
Runout
Clearance between journal and main bearing
Clearance between crankpin and connecting rod bearing
End play
Standard
0.025 to 0.072
(0.000 98 to 0.002 83)
0.10 to 0.35
(0.003 9 to 0.013 8)
51.985 to 52.000
(2.046 65 to 2.047 24)
47.950 to 47.965
(1.887 79 to 1.888 38)
0.025 (0.000 98)
0.030 to 0.077
(0.001 18 to 0.003 03)
0.025 to 0.072
(0.000 98 to 0.002 83)
0.050 to 0.175
(0.001 97 to 0.006 89)
Limit
0.150 (0.005 91)
0.50 (0.019 7)
0.05 (0.002 0)
0.100 (0.003 94)
0.150 (0.005 91)
0.500 (0.019 69) a. Please refer to the applicable engine model specification sheet for actual data
—
—
Item
Pressure relief valve setting
Pressure difference at which oil pressure switch is closed (indicator light comes on)
Correction-Remarks
Replace connecting rod bearing.
Replace connecting rod.
Repair or replace.
Replace main bearing.
Replace connecting rod bearing.
Replace No. 3 flanged bearing
55.2 Lubrication system
Limit
Unit: mm (in.)
Correction-Remarks Standard
3.5 ± 0.5 kgf/cm
2
(50 ± 7 psi)
[343 ± 49 kPa]
0.5 ± 0.1 kgf/cm
2
(7 ± 1.4 psi)
[49 ± 10 kPa]
—
—
Replace.
Replace.
Item
Injection pressure (valve opening pressure)
Item
Paper-element type air cleaner element
Warpage of mounting faces of manifolds
55.3 Fuel system
Unit: mm (in.)
Correction-Remarks Standard
140
0
+5 kgf/cm
2
(1 991
0
+71 psi)
[13 729
0
+490 kPa]
Limit
— Adjust with washer.
55.4 Air inlet system and exhaust system
Unit: mm (in.)
Correction-Remarks Standard
Clean every
100 service hours
—
Limit
Change every
500 service hours.
0.15 (0.005 9) Repair or replace.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
SERVICE DATA SPECIFICATIONS
Item
Temperature at which valve starts opening
Thermostat
Temperature at which valve lift is more than 8 mm (0.3 in.)
Temperature at which switch is turned ON
Thermoswitch
Resistance at oil temperature of 120°C (284°F)
Resistance in thermounit
At 50°C (122°F)
At 80°C (176°F)
At 120°C (248°F)
Deflection of fan belt under 10 kgf (22 lbf)
[98 N] force applied midway between alternator pulley and crankshaft pulley
No-load characteristics
Item
Pinion clearance
Terminal voltage
Current draw rpm
Brush length
Brush spring tension
Runout of commutator
Diameter of commutator
Undercut of mica
55.5 Cooling system (standard)
Unit: mm (in.)
Correction-Remarks Standard
82 ± 1.5°C
(180 ± 2.7°F)
95°C (203°F)
111 ± 3.5°C
(232 ± 6.3°F)
30 m Ω maximum
80 ± 10 Ω
29.5 ± 2.5 Ω
10 ± 0.3 Ω
10 to 12
(0.4 to 0.5)
Limit
—
—
—
—
—
—
—
—
Replace.
Replace.
Replace.
Replace.
55.6 Electrical system
Standard
0.5 to 2.0
(0.020 to 0.079)
S3L/S3L2
11.5 V
S4L/S4L2
11 V
100 A maximum
3 000 minimum
—
3.0 kgf
(6.6 lbf)
[29.4 N]
130 A maximum
3 600 minimum
0.03 (0.001 2)
32 (1.26)
0.5 (0.020)
Limit
—
—
—
—
Wear limit line
1.8 kgf
(4.0 lbf)
[17.7 N]
0.10 (0.003 9)
31 (1.22)
0.2 (0.008)
Unit: mm (in.)
Correction-Remarks
Adjust with packing.
Test.
Replace.
Replace.
Repair or replace.
Replace.
Repair.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
SPECIFICATIONS
Item
Regulated voltage at 20°C (68°F)
Output characteristics
(at operating temperature)
At 2500 rpm
At 500 rpm
Terminal voltage
Current
Terminal voltage
Current
Brush length
Resistance in glow plug
Standard
14.7 ± 0.3 V
13.5 V
33 A min.
13.5 V
47 A min.
—
0.55 Ω
Limit
—
—
—
—
—
Wear limit line
—
SERVICE DATA
Correction-Remarks
Test.
Replace.
Replace.
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
SERVICE DATA TIGHTENING TORQUES
Bolt or nut
Cylinder head bolt
Rocker cover bolt
Rocker shaft bracket bolt
Thermoswitch
Crankshaft pulley nut
Main bearing cap bolt
Connecting rod cap nut
Rear plate bolt (for tractor engine)
Rear plate bolt (standard)
Rear plate bolt (stamping)
Flywheel bolt
Oil pan bolt (for tractor engine)
Oil pan drain plug
Pressure relief valve
Oil filter
Oil pressure switch
Fuel injection pipe nut
Fuel leak-off pipe nut
Delivery valve holder
Fuel injection nozzle holder
Retaining nut for delivery valve holder body
Sliding sleeve shaft
Special nut for torque spring set
Glow plug
Glow plug connection plate
Stop solenoid nut
Starter B terminal
M16
M10
M12
M10
M4
M30
M8
M12
M8
M14
M22
M9
M12
M12
M8
Diameter
M10
M8
M8
M16
M18
M10
M20
PT1/8
M12
M12
—
M20
SERVICE DATA
56 TIGHTENING TORQUES
56.1 Major bolts and nuts
Unit: mm (in.)
Thread, mm
Pitch
1.5
1.5
1.5
—
1.25
1.25
1.25
1.25
1.5
1.5
—
1.5
1.5
1.25
1.0
1.25
1.25
1.25
1.25
1.5
0.75
1.25
1.0
1.25
0.7
1.5
1.25
Width
22
22
—
26
17
12
19
12
—
18
19
21
27
17
14
17
14
12
12
17
19
14
17
12
8
36
12
—
29.5
—
60
—
—
—
29
25
10
33
—
28
28
16
Clamp length
87
40
58
31.5
—
81
—
11
—
—
—
—
Torque, kgf·m (lbf·ft) [N·m]
9 ± 0.5 (65 ± 4) [88 ± 5]
1.15 ± 0.15 (8.3 ± 1.1) [11.3 ± 1.5]
1.5 ± 0.5 (11 ± 4) [14.7 ± 5]
2.3 ± 0.4 (16.6 ± 3) [22.6 ± 4]
17.5 ± 2.5 (127 ± 18) [172 ± 25]
5.25 ± 0.25 (38 ± 2) [51.5 ± 2.5]
3.55 ± 0.25 (25.7 ± 2) [34.8 ± 2.5]
9.5 ± 1 (69 ± 7) [93 ± 10]
6.5 ± 1 (47 ± 7) [64 ± 10]
1.15 ± 0.15 (8.3 ± 1.1) [11.3 ± 1.5]
13.5 ± 0.5 (98 ± 4) [132 ± 5]
2.8 ± 0.3 (20.3 ± 2.2) [27.5 ± 3]
4 ± 0.5 (29 ± 4) [39 ± 5]
5 ± 0.5 (36 ± 4) [49 ± 5]
1.2 ± 0.1 (8.7 ± 0.7) [12 ± 1]
1 ± 0.2 (7.2 ± 1.4) [10 ± 2]
3 ± 0.5 (22 ± 4) [29 ± 5]
2.75 ± 0.25 (20 ± 2) [27 ± 2.5]
4.5 ± 0.5 (32.5 ± 4) [44 ± 5]
5.5 ± 0.5 (40 ± 4) [54 ± 5]
3.75 ± 0.25 (27 ± 2) [37 ± 2.5]
3.6 ± 0.6 (26 ± 4) [35 ± 6]
2 ± 0.5 (14 ± 4) [20 ± 5]
1.75 ± 0.25 (12.7 ± 2) [17.2 ± 2.5]
0.125 ± 0.025 (0.9 ± 0.2) [1.2 ± 0.2]
4.5 ± 0.5 (32.5 ± 4) [44 ± 5]
1.1 ± 0.1 (8 ± 0.7) [10.8 ± 1]
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
TIGHTENING TORQUES
Thread diameter
M6
M8
M10
M12
M14
Size
NPTF 1/16
PT 1/8
PT 1/4, NPTF 1/4
PT 3/8
SERVICE DATA
4
0.4 ± 0.1
(3 ± 0.7)
[3.9 ± 1]
1.1 ± 0.1
(8 ± 0.7)
[10.8 ± 1]
2.15 ± 0.35
(15.6 ± 2.5)
[21 ± 3]
3.6 ± 0.6
(26 ± 4.3)
[35.3 ± 6]
6 ± 1
(43 ± 7)
[59 ± 10]
56.2 Torques for bolts and nuts with standard threads
Unit: kgf·m (lbf·ft) [N·m]
Identification on head
7
0.9 ± 0.1
(6.5 ± 0.7)
[8.8 ± 1]
1.85 ± 0.35
(13.4 ± 2.5)
[18 ± 3]
3.6 ± 0.6
(26 ± 4.3)
[35.3 ± 6]
6.5 ± 1
(47 ± 7)
[63.7 ± 10]
9.5 ± 1.5
(69 ± 11)
[93.2 ± 15]
—
56.3 Torques for plugs with taperlock threads
For aluminium materials
0.65 ± 0.15
(4.7 ± 1)
[6.4 ± 1]
1 ± 0.2
(7.2 ± 1)
[10 ± 2]
2.5 ± 0.5
(18 ± 4)
[25 ± 5]
Unit: kgf·m (lbf·ft) [N·m]
For ferrous materials
1 ± 0.2
(7.2 ± 1)
[10 ± 2]
1.85 ± 0.35
(13.4 ± 2.5)
[18 ± 3]
4 ± 0.5
(29 ± 4)
[39 ± 5]
6.5 ± 1
(47 ± 7)
[64 ± 10]
ENGLISH
Service Manual Mitsubishi SL-Series diesel engines
SERVICE DATA SEALANTS
SERVICE DATA
57 SEALANTS
Component
Stop solenoid
Water drain joint
Oil pressure switch
Torque spring set
Sealing cap
Expansion plug
Dipstick guide
Side seal
Main bearing caps
(front and rear)
Oil pan
Sealant
Three Bond 1212
Three Bond 1102
Three Bond 1212
Three Bond 1102
Mating part
Governor case
Remarks
Cylinder block Apply to effective thread part.
Governor case
Cylinder block
Cylinder head
Cylinder head and cylinder block
Cylinder block
Apply to holes in cylinder head and cylinder block.
Three Bond 1212
Cylinder block and main bearing caps
Cylinder block
Three Bond 1207C
Apply to external surface.
Apply to surfaces that come into contact with cylinder block.
Apply to sealing surface.
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
SPECIAL TOOLS
Tool No.
Toon Name
SERVICE DATA
SERVICE DATA
58 SPECIAL TOOLS
Style Usage
31A91-00100 Piston Pin Setting Tool Piston pin removal and installation
ST332340 Camshaft Bushin Installer Camshat front bushing removal and installation
ST332270
Compression Gauge
Adaptor
Compression pressure measurement
MD998054
Oil Pressure Switch Socket
Wrench
Oil pressure switch removal and installation
ENGLISH
NOTE
In addition to these special tools, commercially available tools such as bearing puller, valve seat cutting tool, valve guide installing tool, valve spring compressing tool, oil filter wrench, etc. are necessary.
Service Manual Mitsubishi SL-Series diesel engines
BLANK PAGE
Service Manual Mitsubishi SL-Series diesel engines
ENGLISH
195
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Key Features
- Compact design, light weight and fuel efficient
- High power and torque output
- Wet cylinder liners for increased durability
- Overhead valves for improved performance
- Direct injection for increased fuel efficiency
- Full-pressure lubrication for extended engine life
- Easy to maintain and service