ENGINE BASE SERVICE MANUAL MITSUBISHI S4S, S6S REFERENCE ONLY - EXCAVATOR(16-18TON, -7SERIES) - FORK LIFT(HDF35-70, -7SERIES)INTRODUCTION This service manual describes the specifications of the Mitsubishi Diesel Engine and the maintenance and adjustment procedures. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts. Read this manual carefully and understand the work procedures fully before reassembling, inspecting, repairing or reassembling the engine. The contents of the manual are based on the engine models that are being produced at the time of publication. Due to improvements made thereafter, the actual engine that you work on may _IL bJ6 Vebelt . | () Ds D il pan [Right view] Right view of engineGENERAL (©) S4S-DT distributor-type fuel injection pump specification Fan Foelinlet, Fel leak Water pump (coolant inlet), Magnetic valve (top solenoid) Frost Rear Pal ‘ ‘Coolant drain plug Crankshaft pulley i \ Noni Fuel injection pump [Leftview] oj drain plug titer Left view of engine “Turbocharger (exhaust outlet) inlet Oil file. Lad Coolant outlet Hanger | A “Thermostat case Flywheel housing. hj Rear LJ Froat =e] > iterator Ese J U 6 ee (| fl ‘V-belt De Starter Ria view] ‘Oil pan Right view of engineGENERAL (7) 86S distributor-type fuel injection pump specification Fuel filter Fan, ‘ Water pump (Coolant inlet) Front Fuel injection pump’ Oil filler Exhaust outlet Hanger Fuel inlet Flywheel housing, Rear] |= | Starter’ “Magnetic valve Air inlet vise a oe i : oO. | | | a a ‘Oil level gage a — uta ‘Hanger cwimte _ Frm lw, ean U oa ; U = =GENERAL (8) S6S-DT distributortype fuel injection pump specification Fal filter Fuel inet Magnet valve a {top solenoid) \y pape ‘Water pump eo a = = a eee ott ee ‘oil drain plug Left view of engine ‘Turbocharger (exhaust outlet) Aivinlet Hanger Coolant outlet Thermostat case Flywhee! housing, Alternator Rear Front ‘Damper Starter’ ola ‘V-belt [Right view] Right view of engineGENERAL 1.2 Outline of Fuel System (J) S45 in-line fuel injection pump (swirl chamber) specification Fuel filter, Fuel leak-off pipe Fuel injection pump’ Fuel inlet Outline of fuel system @)_S4S-DT in-line fuel injection pump (direct injection) specification Fuel leak-off pipe Fuel injection nozzle Fuel return pipe Fuel injection pump” Fuel Teak "Fuel inlet Outline of fuel system 1-10GENERAL ()_ SAS distributor-type fuel injection pump (swirl chamber) specification ter al Fuel leak-of pi Fuel filter ga pipe te Fuel injestion nozzle Fuel return pipe oct leak Fuel injection pump ‘Outline of fuel system (4) S4S-DT distibutor-type fuel injection pump (direct injection) specification paee. Fuel leakoff pipe Fuel injection nozzle peer Foelretum pipe "Fuel leake Fuel injection pump Outline of fuel systemGENERAL (5) _S6S in-line fuel injection pump (swirl chamber) specification Fuel filter Fuel leak-off pipe Fuel injection nozzle Ory Fuel inlet Outline of fuel system © s6s-DT Fuel filter Fuel leak-off pipe -Fuel injection nozzle Fuel return pipe Fuel injection pump’ "Fuel leak Fuel inlet Cutline of fuel systemGENERAL (1) $68 distibutor-type fue! injection pump (swirl chamber) specification Pal filter Fuel inlet Fuel leake-off pipe Mt Fuel injection nozzle Fuel return pipe ul leak Outline of fuel system (8) $6S-DT distributor-type fuel injection pump (direct injection) specification Foe! filter, uel retum pipe "Fuel leak: Fuel injection pump’ Outline of fuel system 1-13GENERAL 1.3 Outline of Lubrication System (Q)_ S43 in-line fuel injection pump specification Pushrod Piston Valve mechanism (Crankshatt ‘Tappet__| caiman Relief valve Oil main gallery: il filter Teter gear ——t6 Fuel injection pump ill pump’ Ol strainer ‘Oil pan Outline of lubrication system (2) S4S-DT in-line fuel injection pump specification Idler gear Fuel injection pump: ‘Relief valve il pump’ Oil strainer Safery valve are Outline of lubrication system 1-14GENERAL a EEEEEENEEEEma () $48 distributor-type fuel injection pump specification Pison —_Yalve mechanism Pashrod Crankshaft fi Tappet Gusar Relief valve 7 =a Oil main gallery- By Idler gear” >) : Oil pump” ‘Oil filter, Ot ssiner ‘oi pan Outline of lubrication system (4) S4S-DT distributor-type fuel injection pump specification il main gallery. Idler gear: | Retiot valve Crankahat Oil pump’ Pon ater Oi sine’ \afey valve” Oil pan Outline of lubrication systemGENERAL (S) $68 in-line fuel injection pump specification Pushroy “Tappet. Camshaft —} i main gallery —| ‘oil strainer bil pan (Outline of lubrication system (©) S6S-DT in-line fuel injection pump specification Oil strainer ‘Safety valve ‘Oil pan ‘Outline of lubrication system 1-16GENERAL (7) $68 distributor-type fuel injection pump specification Piston Crankshaft Relief valve Oil filter Oil strainer ‘oil pan Outline of lubrication system (8) S6S-DT distributor-type fuel injection pump specification Safety Oil strainer Outline of lubrication system 1-17GENERAL 1.4 Outline of Cooling System a) s4s Coolant outlet, Cylinder head ‘Thermostat Bypass pipe Winer jacket Water pump, Coolant inlet Outline of cooling system @) s4s-vT Coolant outlet, ‘Thermostat Bypass pipe. Water jcc ‘Water pump- Coolant inlet Oil cooler’ Outline of cooling systemGENERAL @) s6s Cylinder head Coolant outlet ‘Thermostat, Bypass pipe. Water jacket Water pump. Coolant infet Outline of cooling system (@) s6s-DT ‘Coolant outlet, (Cylinder head Water jacket Coolant inlet Oil cooler Outline of cooling systemGENERAL 1.5 Outline of inlet and Exhaust Systems (Q)_ Non-turbocharged engine ‘Air breather hose oe mmc P UP lita air Banaust ges PL] « [ = — O Outline of inlet and exhaust systems oo Prt Exhaust gas Sint sir WS Blow-by gas t Air breather hose & (Open {9 atmosphere Exhaust manifold ° inlet manifold Cutline of inlet and exhaust systemsGENERAL —————— 1.6 Engine Serial Number ‘The engine serial number is stamped on the side of the crankcase. Engine serial number HT lol tJ lol A 'S4S engine serial number location te EDs av fl LCL 6 ‘86S engine serial number location 1.7 Engine Model and Application Code ‘Non-turbocharged engine ‘Turbocharged engine {a Swirl chamber Combustion retot { Baas vweweses Direct injection Series code ‘Number of cylinders General Machinery & Special Vehicle Headquarters(Sagamihara)GENERAL 2. Specifications 2.4_S4S indine fuel injection pump specification (may differ in detail) Engine type sS SDT Type Titsubihi diel engine [Cooling method ‘Watercooling No. of strokes -estroke cycle No. of cylinders eylinder arrangement 4 in-line [Combustion method Suir chamber [Dive ingestion Valve mechanism ‘Overhead # [Cylinder bore x stroke ‘aim ia] 3452120 3.701 47H] © [Total displacement 4 {cu in] 3.331 (203) & [Compression ratio Bz 1 7 @ [Fuel ‘Diesel fuel GIS No, D equivalent) & [Firing order 1342 & | Rotational direction “Counterclockwise as viewed from flywheel side f reel aaa 781 (30.7) ‘mm {in] Dimension (Overall width ein oo. $67 22.3} eee 717 (282) 815 (32.11 Dry weight kg fb.) 245 [540] 250 (551) {Cylinder sieeve pe Dry Gatepral with eylinder Block) A ‘Compression ring: 2 § [Piston ring No of ings Oi rig (with expander T = (Open BIDCIO" BIDCIE Blues Inletvalv® [Close ‘ABDC 50° ‘ABDC 54" ane Exhaust — [Open BBDC 74° BBDC 66" 2 vale [Close ‘ATDC30° ‘AIDC 22" 4 | Sartng system lest saver Stating aid Glow plug Type. In-line (Bosch Type A) fen eee Peneetemt 6710.28) 69035] Feed pump ips Piston pump (Boseh) Speed control |Governor stem Contig £ Type. Bosch Type RSV. & [ype Tirole nozzle (Bosch) Hole nozzle (Bosch) i [No. of spray holes. 1 4 aE a ee $1.0 [0.039] 60.28 [0.011] Injection nozle mm fin] Sevan = 155° Valve opening sue 11.77 (120) (1707) 1765 (180) 2561] Pa (kaffem psi] Fue filter Type Paper-clement caridgeGENERAL, Engine pe SS SSDE Tbricating method Forced circulation oil pump pressure feed) (Grade (API service mi ae Seca (Class CF (SAF30 equivalent) gine ol Capacity Entire engine: 10 [2.64], £{US.gal] il pan: Maximum of 9 (2.38, oil filter: 1 [0.26] Tipe ‘Trochoid g Speed ratio to i 2 |oil pump crankshaft a 2 Discharge capacity | 286 7.6] at O3MPa G keen) (43 psi] discharge pressure of & ¢{USgal]/ min ppamp running at 2230min" 3 Type Piston valve 5 | peti Valve opening Bi | Relief valve pressure 0.3820.05 (3.620.5) [5147] ‘MPa (kgficm") [psi] ‘Valve opening Safety valve pressure - 1.10 156} ‘MPa (kgf/cm [psi] [Oil cooler Type = ‘Waier-cooled, multi-plate (Oil filter Type ‘Paper-clement cartridge Cooling method ‘Water-cooled, forced circulation (Coolant capacity (engine water jacket) aa races 55 [145] 1132] Type ‘Ceniifugal volute pamp Speedratio to i Water pump crankshaft 4 Decaecapacly | 160 G3] a 075 Mia C73 eae) [107 pal dicharge 3 £{U.S.gal] / min| ‘pressure of pump running at 3600min"* 2 Type Pusher (PP fan) 5 | cool No. of blades 6 Cooling fan of a & out meer $440 1173) Vibe Type Raw-edge cog V-belt Type B* 1 [ype ‘Wax Thermostat Waive opening 76.5215 [169.722.7] E ‘Approx.90 [194] when fully opened) CLF] i Air cleaner Type Paper element | Turbocharger type - ‘Dom iGENERAL ngine type SS SDT [Voltage ~ polarity TEV =negative ©) ground | 24 V negative C) ground Fiype MBTISITL M2TSSO71 Pinion mesh type Pinion shit Starter [Output V-W. 1222 I 2432 PinionFing gear as 122 Type Sophase alternating: current generator, builtin reciier Output ____V-A BE 24-25 eerie 1000 to 18000 Rated output ahectate generating speed 3000 Maximum permissible speed 22000 min Speed ratio i crankshaft : [Type Sheathed { loons aaa ae a) & s y-a{ _@0-second application) (G0-second application) i Operating 3 voltage 810 14 (for 12.V) 16 t027 (for 24 V) a v ie &]Openting 3 S| temperature 30 t0 90 [-22 to 194] Eater Rated time 10 or less see liana Dar les 17 ores Stop solenoid Rated voltage (option) Vv Ee a Rated 20 [68] ee °C iy Shama i Be absorbing. ss Py A Rated hold current 1 06 AGENERAL 2.2.68 in-ine fuel injection pump specification (may differ in detail) Tngine (ype 3 SDT ie TMiisab ih diesel engine (Cooling method ‘Water coo [No.of strokes “stroke cycle No. of cylinders ~eylinder arrangement in-line [Combustion method Swidchamber——_|___Direet injection Valve mechanism Overhead 4 [Colinder bore x stoke ‘mmfin] 34120 [3.701 AT] [Total displacement ‘fein 4.996 [303] & [Compression ratio. Bl 1 TH ‘G [Fuel Diesel fuel GIS No. 2 equivalent) & [Firing order 15-56-24 & [Rotational direction CountecTockowise as viewed fom Ajwheel side = (Overall engih ae ‘om fin] Dimension Senet] 579 [22.8] ee, 748 [29.4] 839 (33.0) Dryweight ig [ib 335 (7611 335 TH [Cylinder slave riype ‘Diy (integral with cylinder Block) , 5 ‘Compression ring: 2 § [Psonsing Nocorigs ‘Giring (with expander)T £ Tet vane FOREE BIDC0" BIDCIE Bae Ne TClose ‘ABDC 50° “ABDC 54° 2 ing Exhaust [Open BBDC 74° BRDC 66" 2 vatve [Close TATDC 30" ‘ATDC22° © [Saning atom Blecirc sarier Starting aid Glow plug [iipe Treline Bosch Type AD fee eee eet 6710.28) 6910.38) Feed pump Fiype Piston pump (Bosch) Speed contol aan Governor |system al i Type Bosch Type RSV. g [ype “Tiros nozzle (Bosch) Hole nozzle Gosch) q No. of spray holes 1 4 £ Spray hole diameter ; 1.0 [0.039 0.28 0.011 Injection nozzle mm fin) oe Loess) Sprayangle F 15 Valve opening presse 11.77 420) (1707) 17465 (180) (2561) MPa (kgf/cm?) psi} uel Aker Type Paper-lementcarridge 1-25GENERAL Engine pe 36S SET Eubricating method Forced circulation (oil pump pressure feed) Gea GPT seve Class CF (SAESO equivalent Engine oi! Capacity Enlre engine: 12.5 (5.30), £fUS.gal)| __Oil pan: Maximum of 11.5 [3.04], ol filter: 1 [0.26] Tipe Trochoid i ‘Speed ratio to aaa 2 Joi pump crankshaft s Discharge capactiy | 38.7 {10.2} at 03M¢Pa G kaon) [43 pl] discharge pressure of § ¢{US.gal] / min ‘pump running at 2230min 3 ype Piston valve | ketlet vabe Valve opening 3 | Patiet vat pressure 03540.085 (.620.5) [S127] MPa (kgt/em’ [psi Valve opening Safety valve pressure i 1.1 156) MPa (kgflem?) [ps] [Oil cooler Type = ‘Water cooled, muli-plaie [Oil fier Fiype Paper-element cartridge [Cooling method ‘Water-cooled, forced circulation Coolant capacity (engine wate jacket) ahaa opal 8p] ype Centrifugal volute pump ‘Speed ratio to i | Water pump crankshaft a Discharge capacity | 160 [42.3] a 0.75 MPa (7.5 katfem’) (107 psi] discharge B 4£{U.S.gal} / min’ pressure of pump running at 3600min'* # Type Pusher (PP fan) 5 | cool No. oF blades 7 iB eae [Outside diameter $500 [1927 ‘mm fin} Ce VobelE ype ‘Raveedge cog V-belt Type B = 1 [ype Wax Valve opening Thermostat, 76.521.5 (169.722.7] eee (Approx.90 [194] when fully opened) LF Lecce fae Peper nen | Trbocharger Type 7 ‘TEO6H 1-26GENERAL Engine pe 3 SDT [Voltage - polarity ‘12 V- negative (-) ground ‘24 V - negative (-) ground Type ‘3167671. ‘M8T60373 Pinion mesh type Pinion shift Starter | Output | V-KW] 123 L 24-5 Piniowing gear bing ioniz2 [ype 3 phase altemating-curent generator, builtin vecifier Output —__V-A 12:50 l 2425 Working: eee 1000 to 18000. Rated output oe venga 000 Maximam permissible speed 22000 min” Speed ratio a crankshaft = ‘Type Sheathed Eloi sug Rated age 10397 2330 & v-a[ _ G0-second application) (@0-second application) g (Operating i voltage 80 14 (for 2V) 16 t027 (for 24 V) v ig EE] Operating S|temperature 30 to 90 [-22 to 194] & $C PF] {Rated time 0orless see! eeeeena| 22.6 or less 11.7 or less Stop solenoid Rated voltage een a 2 24 Rated 20 [68] sc] BS Rated jobserving Bel 35 29 A Raed hold current 1 06 A 1-27GENERAL 2.3. S4S distributor-type fuel injection pump specification (may differ in detail) i Engine type 3S SEDI ripe ‘iisubihiaisel engine (Cooling method ‘Watercooling [No.of strokes “stroke cycle No. of cylinders~ cylinder arrangement 4 inline (Combustion method ‘Switlchamber | __Direet injection "Valve mechanism Overhead 2 [Cylinder bore x stoke mm fin] 345120 [3.701 x47] [otal displacement “feu in] 3331 [05] & [Compression ratio Dl I 1s = [Ruel Diesel fuel GIS No. 2 equivalent) & [Firing onder 1342 & [Rotational direction ‘Counterclockwise a5 viewed from flywheel side = oreatiagh mai bon Dimension ene 567 [223] Crea [tirana asta Dry weight kg ib] 245 [540] 230/55) [Cylinder sleeve Tipe ‘Dry Gategral with cylinder block) ston ri 5 ‘Compression rng: 2 § [Pstonring No. ofrings ‘ing wth expander 5 Tavane [OPS BIDCI0" BDC BY save an (Close "ABDC 50" ABDC 54 iS eecannee Exhaust [Open ‘BBDC 74" BBDC 66° 2 [valve [close ‘AIDC 30" ‘AIDC22° Staring sytem Blestc ater Starting aid Glow plug Tipe Distributor (Bosch Type VE anaes beeen 101039] 11 [043] Feed pump Type. ‘Vane pump (Bosehy ‘Speed control . [Governor |sysem Centrifugal § ‘Type “All 3 [ype ‘Tiarottle nozzle (Bosch) Hoole nozzle (Bosch) 3 (No. oF spray holes 1 5 a Spray hole diameter 1.0 [0.039] $0.20 [0.008] Injection nozzle 2m fin pray anale © TSO (wares with specification) ‘Valve opening pressure 11.77 (120) (17071 1765 (180) [2561] ‘MPa (kgm! [sil Fuel iter "Type Paper-clementcarridge 1-28GENERAL — Engine ype SS SDT Tabricating method Foreedsirculation oil pump pressure feed) os eee (Class CF (SAE30O equivalent) ae Capacity Entire engine: 10 (264), 2{US.gal) (Oi pan: Maximum of 9 [2.38] ofl filter: 1 [026] Type “roche Speed ratio fo aaa Oil pump crankshaft Discharge capacity | 286 [7.6] at 03MPa G katom') [43 psi] discharge pressure of 2{US.gal] / in ‘pump running at 2230min" Type Piston valve : Valve opening pene pressure 0.35#0.05 (.640.5) [5127] ‘MPa (kgfiem?) [psi] Valve opening Safety valve pressure - 1.1 (11) 156) MPa (ket/em?) [ps (Oil cooler Type = ‘Waier-cooled, multi-plate Oil filter Type Paper-clement cartridge [Cooling method ‘Water-cooled, forced circulation [Coolant capacity (engine water jacket) Cae 55 [143] $1.32] Centrifugal volute Speed ratio to a Water pump crankshaft & [Discharge capacity 160 [42.3] at 0.75 MPa (7.5 kgffem*) [107 psi] discharge 3 ‘{{US.gal] / min ‘ressure of pup running at 3600min 2 —Type Pusher (PP fan) 5 | coslt No, of blades 6 Oana: Outside diameter euntGal ‘mm {in & Webalt Type Raw-edge cog V-belt Type B= 1 ‘Type ‘Wax Thermostat, valve opening 76,521.5 (169.742.7] ‘Approx.90 [194] when fully opened) $c i & | air cleaner Type Paper element i 2 | Rebocharger Type i ‘Too =GENERAL Engine ype MS SDT Voliage~ polarity T2V = negative @) ground | 24 V- negative C) ground [ype MBT7SI71 M2TSSO7L ion mesh type Pinion shift Starter ‘Output VW. 12-22 I 2432 Eee a 1on22 [ype ~3;phae altemating-ourent generator, bul-in rectifier Output VA 1250 1 24-25 eee ier 1000 to 18000 Rated output ase generating speed. 5000 ‘mi Maximum permissible speed 22000 § min 5 Speed ratio to 20 z crankshaft : : Type Sheathed i | Glow plug eee 105-97 23.30 -v-a| _ (0-second application) (G0-second application) eee 2 24 Power consumption 20 “4 al Ww. Start voltage Stop solenoid Fe 7 63 or less 1Borless BQ |Reoovey voltage 2.5 or more 5 ormore v coi resistance 8 37 a)GENERAL —_— 2.4 S85 distributor-type fuel injection pump specification (may differ in detail) Engine ype. So SEDT 7] Tipe ‘Mitsubishi diesel engin [Cooling method. ‘Water cooling No.of strokes a-sroke eycle [No.of cylinders eylinder arangement 6 in-line Combustion method Sor chamber [___ Diet injestion Valve mechanism Overhead Cylinder bore x sake ‘mm fia] 94 120 [3.701 «A724] "Total displacement feu in 4.996 [305] [Compression ratio Tal T cea Fuel ‘Diesel fel GIS No. 7 equivalent) Firing order, 153-624 Rotational recon Countetelociise as viewed fom fijwheel side Overall length 1033 (40.7) mm fin] Overall width Dimension ane 379 (22.8) omnicef aweea Eq Dry weight kg {ib} 345 [761] ‘355 [783] Cylinder sleeve ripe Dy ae wa Best Piston ri No. of in ‘Compress & [Pitonsing es Oisay toma s Tmecvave BIDCIO™ BIDCI Leer [Close ‘ABDCS0> ABDC 54 2 Exhaust [Open BBDC 74° BEDC 66° 3 valve [Close ‘AIDC30® ‘ATC 22° | Starting system Elecite starter Starting ad Glow plug Type Distributor Bosch Type VE) eee erate $10 [039] 11 [0.43] Feed pump os ‘Vane pump (Bosch) Speed control Governor | system Contrifuga! & Type ‘All $ [ype Throne norle Bosch) Hote nozzle ose) 3g No. of spray holes 1 3 g Spray hole diameter 2 ee a 61.0 (0.039) e020 (0.008) pray angle 5 TSOF(waries with specification) ‘Valve opening pressure 11.77 020) (17071 1765 (180) [2561] ‘MPa (ketem?) [oi] Fuel ter Type Paper clement cartridgeGENERAL Engine type 3S S6SDT Lubricating method Forced circulation (oil pump pressure feed) (Grade (APT service a i feoancaia Class CF (SAE30 equivalent) Erect [Capacity Entire engine: 12.5 330), £{US.zal] il pan: Maximum of 11.5 {3.04}, ol filter: 1 (0.26) ype Trochoid g Speed ratio to 3 |oit pump Jrankshaft ae s Discharge capacity | 38.7 [102] at 03MPa ( Kgffem [43 pal] discharge pressure of g #{US gal] min ‘pump running at 2230min" Type Piston valve 3 Valve opening 5 | Relief valve pressure 0.3540.05 (3.60.5) [5147] ‘MPa (kaflem’ [psi] Valve opening Safety valve pressure - 1.111) (156) MPa (kgflem [psi] Oil cooler Type = Water-cooled, multi-plate Oil iter [Type Paper-clement cartridge Cooling method ‘Waier-cooled, forced circulation ‘Coolant capacity (engine water jacket) oA) spa US; Type ‘Centrifugal volute pamp ‘Speed ratio to a ‘Water pump crankshaft g Discharge capacity 160 [42.3] at 0.75 MPa (7.5 kaffem [107 psi] discharge ‘{{USgal]/ min pressure of pump runing a 3600mia" gz Type ‘Pusher (PP fan) 8 | cot No. of blades 7 Cooling fan hes g eee eel $500 [19.71 Webel Type Raw-edge cog V-belt Type BT [Type Wax Valve opening Thermostat T6.521.5 (169.42. Pee (Approx.90 [194] when fully opened) °C [°F] g & | Aircleaner Type Paper element g 2 | Torbocharger Type - ‘TEO6HGENERAL Engine pe 3S sear [Voltage = polarity ‘12 V = negative (-) ground 24 V - negative (-) ground "ype MITSISTL METOS7S Pinion mesh pe Pinion sil Staer Output VW Ba i 25 Pinko ag ar ae ratio ripe pase aliorating-curent generate, buleineciir [ouput WA 12-50 i 24:95 eras 1000 to 18000 Rated opt Fee eeeaine re 5000 Mecimam ; permissible speed 22000 5 ‘nin 3 cnmtshat baud 5 ‘Type Sheathed Bi | Glow plug aed vounee 1059.7 233.0 sent | -Glbsecond application) | G0-econd aplication) a oe 12 4 Power consumption 20 14 a w sop sled E Sfsarvoraee G3 orles pele ‘tion (cption) ES | Recovery © votage 2.5 ormore Sormore vI ‘Coil resistance 8 37 AGENERAL 3. Tips on Disassembly and Reassembly This service manual describes service _provedures, recommended by Mitsubishi Heavy Industries Ltd, and also contains information of special tools and basic safety precautions. It should be noted that the manual cannot cover all potential dangers in maintaining, inspecting and servicing an engine. ‘When working on the engine, follow the directions in this ‘manual and pay close attention to the following cautions. 3.1 Disassembly )_ Use correct tools and instruments. (2) Arrange a work bench and boxes for placing removed parts, if necessary, and follow the specified disassembly sequence, (3) Lay down disassembled parts neatly in order to prevent losing them. (4) During disassembly, pay attention to alignment marks to ensure proper reassembly and if necessary, put additional marks on parts to aid reassembly. (S)_ Carefully check each part for abnormalities before disassembly and also during removal and cleaning in order to discover any signs of abnormalities or defects that may not be found after cleaning. (© Exercise utmost caution to ensure safety, particularly for balancing removed parts and transporting heavy parts. (Use jacks and chain blocks when necessary.) 3.2 Reassembly (1) Wash all engine parts, except for oil seals, O-rings, rubber sheets, etc, in cleaning oil and dry them with compressed air. 2). Use correct tools and instruments. G) Use only high-quality lubricating oils and greases. (@) Be sure to apply a coat of oil, grease or sealant to parts as specified. (5) Use a torque wrench to tighten parts to specified tightening torque when tightening torque is indicated. (©) Replace all gaskets, packings and O-rings with new ones unless specified otherwise.MAINTENANCE STANDARDS 1. Maintenance Standards Table-- 1-36 2. Tightening Torque Table 2.1 Important Bolts and Nuts------ 2.2 Standard Bolts and Nuts: 2.3 Standard Eye Bolts - 2.4 Standard Union Nuts. ~ 2.5 Standard Plugs -- - 1-42 1-42 3. Sealants and Lubricants Table---MAINTENANCE STANDARDS 4. Maintenance Standards Table Unit mm fin i Inpetion pois Nominal vai | Standard init | Rema é ‘Maximum speed (no-load) 5 aay jon Adjust governor ‘Minimum speed (no-load) deccemaing 2 eneine Secon setting. 325 MP 2.84 MPa Set cheer sn. 29 hafe0) | ana water ‘Compression (at 300 min") (412 psi] temperature at em Gogten’) ae leery Diet jection @rigtin) [eee (384 psi) (a1 300 in) Taso 049 aaa at 1500 min* (1skatem . . al [Oiltemperure ‘Lubricating, at 70 to 90°C oll preasure, 0.05 MPa_- |[158 to 194°F) Idling (0.5 kgflem’) theater 2p (rare |BTDC 30° [BTDC 18° i niet valve open JABDCSIP Swink |ABDCS4? (Direct Vavetinng tv, sled BDC 14° Gamer) [BDC 60° jection) Exhaust valve sed ee eee |+3° (crank angle) +3° (crank angle) Bob iaeand sive clearance (Col) 025 (0.005 eel ‘The timing for ech mode of gine rks coding is ‘nlecti simnis specification. Ful injeton sar timing peidonion. tc tming by referring to the specifications of cach mode Detection ven ow resed wth beeen [0.39 to 0.47) thumb 98 N (10 my : TOIT THAD g [Reser sing #19 (0.7480) | 16-7484 to 07499] : ; 9800 19.000 | 190-7480) | aSsan2 07 80) 2 | lemance between bakingand @g1O 0050 a shaft [0.0003 to 0.0020) | 0-070 {0.00281 34016 7955 4 ave sem Inlet 681031801 | fo 5126190.3132)| 7900 (03110) | [tim fanaa | esos | 52220079, | 2s 03000 z 0.065 to 0.095 #1 Sls. [om jonas w coosn| 0150100055 ide clerance oad wo. /Exhasut 0.0031 wo 0.0045) °200 10.079] ; ; B90 Tal Heigwiowpotvaveance | 105i [9 d2Ststen 1-36MAINTENANCE STANDARDS Unit: mm fin} 3 Inspection point ‘Nominal value ‘Standard Limit Remark 6 Valve seat angle a [fam | catooisn | PSA Tossa 5 | ave sinkage 04 100.6 (0.0157 wi, z xnaust | asgooion [EEE] 10100304 4 |searwian raroossty [ptzi tsa] tatomin | Ee tete g Reams | gp oe | Valve margin 2.13 [0.0839] | permissible up to 183 (0.0720) ree engi aS LSA 47.60 (1.87) = A=13_ |A=1510.0591) 2 |Perpendicularity a. 10.051] | over entire . , Lf=4885] length 2 i 119) 5 BUTE spar Installation lengttviosd ough ae | 1509 44.1 1b] Bonon aee 0.05 [0.002] or | 9.20 0.0079] | Slightly reface tinder head} stortion Hess Cylinder head Compressed Topo | 1st 135 thickness of gasket _|_ 12104 {0.0453 to 0.0492) Ranout al E pening £ when pushrod is | Push rod Bend 0.3 [0.0118]or less supported along 2 centerline of 7 spherical surface a at either end. Flatness 0-15 10.0059)" | 9.50 (0.1971 Flywheel — TISTLOOT |p 200197 0.050 t0 0.150 y [Psst oad to 0.0039] °25010.096) [Replace sean, 100: Replace trast linwewatom copie) | tO, | onsen [EE E iat 2 canatt gered ey sioar | gotta ea | oxvooonn fS 6.384 106.788 eee linet 6.684 (0.2631) | gosh oo zehny| 6184102895] @,-D) 6.420 to 6.820 Exhaust 6.720 [0.2646] aire sampo2ues| 02 [0.0008] oF Repair or © Rocker cover © Rocker arm ® Valve cotter @ Adjusting screw © Rocker shaft spring ® Valve retainer © Bok (short) @® Rocker shaft @ Valve spring ® Bott (long) @ Valve cap ® Valve (N) © Rocker shaft bracket ® Pushrod ® Valve EX) © Snap ring ® Cylinder head bott @ Valve stem seal © Rocker am ® Cylinder head © Cylinder head gasket (Remove parts ® to @ asa unit)DISASSEMBLY OF MAIN ENGINE PARTS 4.4. Removing Rocker Shaft Assembly (1) Loosen the adjusting screw of the rocker by about one ‘urn, @) Loosen the shorter bolt of the rocker shaft bracket first. Loosen the longer bolt, then. Remove the rocker shaft assembly from the cylinder head. AC ION If these bolts are loosened in reverse order, the rocker shaft bracket may be damaged. 4.2. Disassembling Rocker Shaft Assembly In the course of disassembly, place removed rocker ‘components neatly in the order of disassembly so that they can be reassembled back onto their original locations, Doing so, original clearances between the rocker arms and the rocker shaft are restored upon reassembly. 4.3. Removing Cylinder Head Assembly Remove the cylinder head bolts. Lift the eylinder head and remove it from the crankcase. Note: Be careful not to damage the mount surfaces of the cylinder and crankcase when removing the gasket from the cylinder head, Before removing the cylinder head bolts, check the cylinder head components for any defects or faults. If faulty or defective, check the bolts for tightness ‘with a torque wrench. 1.4 Removing Valves and Valve Springs Push the valve spring evenly using the valve spring pusher (special tool), and remove the valve cotter. ‘Special tool name, Part No. Valve spring pusher 30691-04500 Note: Put match marks for easy identification of the ‘mounting position if the valve may be reused. When reassembling, do not change the combination of the valve seat and valve guide. ‘Removing valve and valve springDISASSEMBLY OF MAIN ENGINE PARTS Disassembly of flywhee! © Flywheel Oil seal @ Flywheel housing @ Gasket (Remove parts @ and @ as a unit) 2-4DISASSEMBLY OF MAIN ENGINE PARTS: 2.1. Removing Flywheel (1). Remove one flywheel mounting bolt. 2). Serew the safety rod (MI2 x 1.25) into the threaded hole, from which the mounting bolt was removed above. Remove the remaining bolts and remove the Tock washers. (3) Hold the flywheel firmly with both hands. Shake it back and forth to pul it out straight. PX Be very careful not fo cut your hand with the ring gear when pulling out the flywheel 2.2 Removing Flywheel Housing Remove the flywheel housing mounting bolts. Remove the flywheel housing, ZX CAUTION Be very careful not to damage the oil seal Removing flywheel housingDISASSEMBLY OF MAIN ENGINE PARTS: 3. Damper, Timing Gears and Camshaft Replace gasket Weuzdamess] 01 . 2 oe s ANC Ley een [Clogeing of ithe, wear] oo Replace O-ring [Wear e x “Wear of lip surface, damage, deterioration og Y ®) ‘Cracks, knock hole defects “Wear of belt groove (Cracks, knock hole defects Firat tamage Disassembly of timing gears © Damper (S68) © Timing gear case @ Camshaft gear @ Crankshaft pulley @® Oil pump gear @® Thnst plate © Cover © Thnust plate Remove parts ® to ® asa unit.) @ Fuel injection pump @ Idler gear ® Front plate © Oil pan ® Camshaft3 32 @ Q Removing Damper (S&S) Remove the mounting bolts, and remove the damper. Removing Crankshaft Pulley ‘Screw two bolts (M12 x 1.25) into the threaded holes at the rear end of the crankshaft. Prevent the crankshaft from rotating using a bar. ‘Remove the nut, and remove the crankshaft pulley. Removing Cover Remove the cover mounting bolts, and remove the Removing Fuel Injection Pump Disconnect the ol pipe. Remove the pump bracket. ction pump mounting bots, and DISASSEMBLY OF MAIN ENGINE PARTS Oil pipe” Pump bracket Removing fuel injection pumpDISASSEMBLY OF MAIN ENGINE PARTS: 3.5 Removing Oil Pan Remove the oil pan mounting bolts, and remove the oil pan, 3.6 Removing Timing Gear Case Remove the timing gear mounting bolts, and remove ‘the timing gears. 3.7 Removing Oil Pump Gear Remove the gear mounting nut, and remove the oil pump gear. 3.8 Removing Idler Gear Remove the thrust plate mounting bolt, and remove ‘the thrust plate and idler gear. ‘Removing idler gearDISASSEMBLY OF MAIN ENGINE PARTS 39 Removing Camshaft (1). Reverse the crankcase. (2). Face the lightening hole in the camshaft gear up and down, Remove the thrust plate tightening bolts, and remove the camshaft from the erankease. PAOLO) NI ‘Be careful not to damage the cam of the camshaft and ‘the camshaft bearing of the crankcase. 3.10 Separating Camshaft Gear Punch out the camshaft gear from the camshaft using a hydraulic press. Note: The camshaft gear and thrust plate will not separate unless they are defective. 3.11 Removing Front Plate ‘Remove the front plate mounting bolts, and remove the front plate from the crankcase. Removing eamshaft Punch out with press ‘Removing front plateDISASSEMBLY OF MAIN ENGINE PARTS. 4. Pistons, Connecting Rods, Crankshaft and Crankcase ‘Wear, damage Fatigue] Vv. @ Cracks, clogging ofoil hole ‘Wear, clogging of ol hole Oo Thread damage || ~ Cracks, wear of seration Flaws of inner and outer peripheries, ‘fusing, separation, wear Clogging of oil hole Scale adhesion, corrosion, sganiin | of oil hole, wear Flaws, cracks, denis, clogging Separation, uneven contact Note: [fnew crankcase isto be installed, carefully remove relief valve and other parts from old crankease and reuse them. racks ‘Thread damage Disassembly of pistons, connecting rods, crankshaft and crankcase < Nat @ Piston pin ® Tost plate ® Connecting rod cap © Piston © Lower main bearing © Connecting od bearing @ Connecting rod © Crankshaft @ No. ring ‘Remove parts ® to @ asavnit) (® Upper main bearing © No. 2ring ® Bearing cap bolt ® Tapper © Oilsing ® Main bearing cap © Crankcase © Snap ring ® Side sealDISASSEMBLY OF MAIN ENGINE PARTS 4.1, Removing Connecting Rod Caps (1) Remove each connecting rod cap tightening nut, hit the tip of the tightening bolt evenly almost squarely with an iron hammer, and remove the cap when the cap-side reamer comes off @) Clazfy the cylinder number and the upper and lower parts of the removed connecting rod bearings. 42. Preparation for Pulling Out Pistons (1) Tumthe crankease on its side. @)_Ifcarbon adheres to the upper part of the cylinder, the piston may be difficult to draw up. Remove carbon ‘with waste cloth or oil paper. 43. Pulling Out Pistons Move the connecting rod to the top, apply the hammer grip to the larger end of the connecting rod, and pall out the piston to above the crankcase. 4.4, Removing Piston Rings Remove the piston ring with the piston ring pliers (special tool). ‘Special tool name PartNo. Piston ring pliers 31391-12900 Preparation for pulling out pistons Pulling out piston 2-11