Mitsubishi S4S User manual

SERVICE

MANUAL

MITSUBISHI

DIESEL

ENGINES

S4S

ses

March

2002

J..

!!!!I'D'!S~~!~!.

Foreword

This service manual is written to familiarize you with the maintenance of your S4S and S6S Diesel Engine. If

the engine is carefully maintained it will deliver a long productive life and efficient performance marked by

power and economy.

Before you attempt to inspect, disassemble, or repair the engine, read this manual carefully to leam more about

the engine and how to care for it properly. AHdescriptions, illustrations, specifications and serial numbers in

this manual are effective as of the date printing of this manual.

The information contained in this manual applies to the engine model produced at the time of publication.

It should be noted that specifications and design may change due to improvements made thereafter.

For

items other than those in this publication, refer to the operation

manual

for a unit on which the

engine is mounted,

How to UseThis Manual

1. Parts in illustrations are numbered to correspond with references to these numbers in text.

2. Items or conditions to be inspected during disassembly are enclosed in a box in the disassembIed views:

IClogged oil hole I

3. Maintenance standards for inspeetion and repair are described in text wherethey are relevant. For a quick

summary of maintenance standards refer to group 2 of this manual.

4. The sequence in which parts are to be reassembled is summarized below eaeh assembIed view.

Sueh as:

.....

5. Tighteningtorque under wet conditions is indieated as "(wet)" in text, drawings, and tables. When so indieated

as (wet), apply engine oil to the threaded portion of the fastener. Unless indieated as such, the tightening

torque is to be assumed in the dry condition.

6. Pay attention to the special notes, cautions and wamings.

Pub. No. 99616-10170

Notes, Cautions, Warnings, Dangers

Notes, cautions, wamings, dangers are used in this manual to emphasize important or critical instructions or

advice.

(&OANGER)

&WARNING

(&CAUTION)

(NOTE)

'Ierms Used in This

Manual

Indicates the most serious specific potential hazard

resulting in serious bodily injury or death.

Indicates aspecific potential hazard resulting in

bodily injury.

Indicates operating procedure, practice, etc.,resulting

in personal injury or damage to or destruction

engine.

An operatingprocedure, condition, etc. that will help

you work more efficiently.

Beforeyou read this manual, note that the following special terms are used in dimensional and other specifications.

Assembly Standard Indicates the dimension of a part, the dimension to be attained at the

time of reassembly or the standard performance. The value is rounded

to the nearest whole number needed for inspeetion and is different from

the design value.

Nominal Value Indicates the standard dimension of a part.

Repair Limit.. A part which has reached this limit must be repaired.

Service Limit A part which has reached this limit must be replaced.

Standard Clearance Indicates the clearance to be obtained between mating parts atreassembly.

Summary

Manual

Contents

Group

General

Maintenance

Standards

Special

Tools

Overhaul

Instructions

5. Adjustments,

Bench

Test,

Performance

Tests

Engine

Auxiliaries

Removal

and

Installation

Engine

Main Parts

8. Inlet

and

Exhaust

System

9. Lubrication

System

lO.Cooling

System

11.Fuel

System

12.Electrical

System

13.Workshop Tips

Contents

External

view,

engine

serial

number

location,

engine

model

and

application codes, specifications, tips on disassembly and reassembly.

Maintenance standards, tightening torques, sealants and lubricants.

Alist

special tools required.

Determining when to overhaul the engine, testing compression pressure

Adjustment of valve clearance, fuel system bleeding, fuel injection

timing, no-load

minimum

and maximum speed setting, V-belt, bench

testing, performance tests.

Removal and installation of turbocharger, fuel injection pump, alternator,

water

pump,

starter, etc.

Disassembly, inspeetion and reassembly of the main parts, to include

cylinderhead and valve mechanism, flywheel, damper, timing gears and

camshaft, pistons, connecting rods, crankshaft, crankcase and tappets.

Disassembly, inspeetion and reassembly of inlet and exhaust system

(exhaust manifold).

Disassembly, inspeetion and reassembly oflubrication system, to inlcude

oil

pump,

oil filter, oil cooler, oil pressure relief valve and safety valve.

Disassembly, inspeetion and reassembly of cooling system, to include

water

pump

and thermostat.

Disassembly, inspeetion and reassembly

offuel

systern, to include fuel

filter

and

injection nozzles.

Disassembly, inspeetion and reassembly of electrical system, to include

starter, alternator, glow plugs and stop solenoid (option).

Basic

recommended

assembly procedures: oil seals, O-rings, bearings,

split pins and spring pins.

GENERAL

1. Outline 1- 2

1.1 External View 1- 2

1.2 Engine Serial Number Location 1- 6

1.3 Engine Model and Application Codes 1- 6

2. Specifications 1- 7

3. Tips on Disassembly and Reassemb1y 1-13

3.1 Disassembly 1-13

3.2 Reassembly 1-13

GENERAL

1. Outline

1.1 External View

[848 -

Standard]

Fuel filter Fuel injection pump

Fan

IFront I

Fuel feed pump

C'-I)

Inlet manifold Fuel injection nozzle

ETR

stop solenoid

Governor

Coolant drain plug

Dipstick IRear I

<>-tt-++--Flywheel

Oil drain plug

ILeft view

Oil filler

onfilter

Exhaust manifold

IRear I

Starter n

I-I:)

Thermostat

Alternator

IFront I

V-belt

üil

pan

Right

viewl

Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.

1-2

GENERAL

[S4S-DT - Standard]

IRear I

::n

(I~I\

Fuel injection pumpn

Fuel filter \

I/In,

let manifold

h--.rT,----1JI

Fuel injection nozzle

Fan

rr-.

tJUI fT"i"T"i:

r~~

~?n'\~

vETRstopsolenoid

Water

pump~

F-\.lIJ

(( --r

~Governor

;:,

Ip,~

:;::

/Coolant drain plug

[l.l.AF::J"1"-

:::"

f'\f

~!::L-

~.\

Q.r-

",-

Tb.

VDipstick

--1.

___

0:/

/1, 0

ol--

,,~

,-'-

h>'

•F

;:;

'--'-ol

Fuel feed pump -:

rUi;!=~~o?J;»-~~'-.-i~0Ë=Q:~~:

jl~~,

\~~r-~-dn

1111

~f--Ij'---H--FI

ywheel

IFront I

ondrain

PIL

Left

view I

filter

IFront I

Altemator

Thermostat

V-belt

Oil pan

Turbocharger

(1-1\

onfiller

Starter

Exhaust manifold

------.11ll-

~~~~~~

Rear

IRignt viewl

Remark: Direction of rotation

this engine is counterclockwise as seen from flywheel side.

1-3

GENERAL

[868 -Standard]

uel filter Fuel injection pump lnlet manifold

Rear

Flywheel

Oil filter

Dipstick

Governor

t:~~~ah~~::~~r

Coolant drain plug

Oil drain plug

%~-1----le:::::~I-~e:::::~~--:v:

Fuel injection nozzle

1NI"bb!l;a

ETR stop solenoid

Fan

Water pump

Front

Left

view

Oil filler

Exhaust manifold

IRear I

Starter

Oilpan

Thermostat

Alternator

Front

V-belt

Right

viewl

Remark: Direction

rotation of this engine is counterclockwise as seen from flywheel side.

1-4

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