Mitsubishi S3L, S3L2, S4L, S4L2 Service Manual

FOREWORD

This service manual describes the specifications as well as the maintenance and adjustment procedures for Mitsubishi diesel engines. This manual also includes the detailed information on basic and special tools as the need arises.

The Mitsubishi diesel engines can offer highly efficient and reliable performance for many years to come, which, however, only can be achieved through the proper handling and the periodical inspection/maintenance work exercised in according to the procedures of disassembly, inspection/adjustment and reassembly described in this manual.

Before attempting any work on your engine, thoroughly read this manual to familiarize with the engine and the required procedures of the work.

All information contained in this manual is based on the engine produced at the time of publication and is subject to change as the engine improved without notice.

Pub. No. 99619-12140

HOW TO USE THIS MANUAL

This Service Manual describes the specifications of Mitsubishi diesel engines (land and standard applications) and relevant service standards, as well as the procedures for servicing the engines such as for disassembly, inspection, repair and reassembly. This manual is divided into Groups. Each Group covers a specific area of the engine. The fuel injection pump, the governor and the turbocharger are handled in a separate manual.

Major contents of Groups are listed on the “General Contents” page. Detailed contents of each Group are listed on the first page of that Group.

For information on the operations and recommended inspection/maintenance schedule of forklift trucks, please refer to the operator’s manual for the forklift truck. For information on components/parts and spares ordering procedures, refer to the parts catalogue. For information on structures and functions, refer to appropriate training materials.

1. Notes on descriptions

(1) Parts shown in Figures as well as in the text are numbered in the order of disassembly. (2) Inspecting points during disassembly are shown in the Disassembly figures by enclosing in the box. (3) Service standards for inspection and repair are listed on the appropriate pages of this manual where the

relevant descriptions are made. Also, a comprehensive listing of service standards is provided in Group

(4) Parts reassembly sequence is provided below the Figure of that reassembly in the form of ⑤→④→③

→②→①.

(5) In this manual, the following marks are provided to draw the reader’s attention to the safety notes

described under the marks.

････ This indicates a dangerous situation which can highly likely result in death or

serious injury unless avoided.

････ This indicates a potentially dangerous situation which may possibly lead to

death or serious injury unless avoided.

････ This indicates a potentially dangerous situation which may cause minor to

moderate injury unless avoided.

････This indicates a potential danger in which property damage may result unless

avoided.

(6) Wherever hardware tightening requires the application of engine oil, “WET” is mentioned. If not

Note: ････ This stresses important points or provides useful tips on engine operations and

service.

mentioned, tighten the hardware “dry” (engine oil should not be applied).

2. Terms

Nominal value ······This is the nominal dimension of the part being measured.

Standard value ······ This is the dimension of the individual part being measured, the clearance between the

parts in question, or the standard performance in question. Standard values have been arranged within the range appropriate for the inspection being carried out, and are not necessarily the design values.

Limit·····················Parts that have reached the limit value should be replaced or repaired whichever is

appropriate.

3. Abbreviations and standards

・BTDC = Before Top Dead Center ・ATDC = After Top Dead Center ・BBDC = Before Bottom Dead Center ・ABDC = After Bottom Dead Center ・TIR = Total Indicator Reading ・API = American Petroleum Institute ・ASTM = American Society for Testing and Materials ・JIS = Japan Industrial Standards ・LLC = Long Life Coolant ・MIL = Military Specifications ・MSDS = Material Safety Data Sheets ・SAE = Society of Automotive Engineers

4. Units

Values shown in this manual are based on SI units (International System of Units). The corresponding metric values are shown in ( ) immediately after the SI values. The SI to metric conversions are based on the following.

・Pressure: 1 MPa = 10.197 kgf/cm ・Torque: 1 N･m = 0.10197 kgf･m ・Force: 1 N = 0.10197 kgf ・Horsepower: 1 kW = 1.341 HP = 1.3596 PS ・Meter of mercury: 1 kPa = 0.7 cmHg ・Meter of water: 1 kPa = 10.197 cmH ・Rotational speed: 1 min

-1

= 1 rpm

O (cmAq)

GENERAL CONTENTS

Group No. Group Name Page

0 SAFETY CAUTIONS 0 - 1

GENERAL 1 - 1 SERVICE STANDARDS 1 -11

2 Engine Main Parts

3 Fuel System

4 Lubrication System

5 Cooling System

7 Air starter System

TOOLS LIST 1 -21 OVERHAUL TIMING 1 -25 REMOVAL PREPARATIONS 1 -29

Inlet and Exhaust Systems

ENGINE MAIN PARTS - DISASSEMBLY 2 - 1 ENGINE MAIN PARTS - INSPECTION AND

CORRECTION ENGINE MAIN PARTS - REASSEMBLY 2 -33

FUEL SYSTEM - REMOVAL 3 - 1 FUEL SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y FUEL SYSTEM - INSTALLATION 3 -25

OIL SYSTEM - REMOVAL 4 - 1 OIL SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y OIL SYSTEM - INSTALLATION 4 - 9

COOLING SYSTEM - REMOVAL 5 - 1 COOLING SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y COOLING SYSTEM - INSTALLATION 5 - 9 INLET AND EXHAUST SYSTEMS -

REMOVAL INLET AND EXHAUST SYSTEMS DISASSEMBLY, INSPECTION AND REASSEMBLY INLET AND EXHAUST SYSTEMS INSTALLATION

ELECTRICAL SYSTEM - REMOVAL 7 - 1 ELECTRICAL SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y ELECTRICAL SYSTEM - INSTALLATION 7 -25

2 -17

3 - 9

4 - 5

5 - 5

6 - 1

6 - 5

6 - 7

7 - 7

Engine -

9 Others

Supplement Engine Inspection Sheets

Inspection/Adjustment, Running-in Trial and Performance Test

ENGINE - INSPECTION / ADJUSTMENT 8 - 1 RUNNING-IN TRIAL 8 -12 PERFORMANCE TEST 8 -13

DISASSEMBL Y AND REASSEMBLY OF GENERAL PARTS

9 - 1

SAFETY CAUTIONS

Warning Risk of fire and explosion ···0-2

●Never use open fire ······························0-2

●Keep things tidy around the engine ··········0-2

●Do not open the crankcase until it has

cooled down

●Pay attention to fuel and oil leakage

●Use explosion-proof light

●Prevent short circuit

●Keep fire extinguisher and first-aid kit

at hand

········································0-2

·········0-2

························0-2

······························0-2

··············································0-2

Warning Risk of entanglement into

the machine························0-3

●Keep guards on the rotating parts ············0-3

●Ensure safety in the surrounding area

when starting the engine

●Keep away from rotating parts while the engine is running

●Lockout/tagout

●Always stop the engine before any

inspection/service

●Remove the turning gear after use

··································0-3

·····································0-3

·································0-3

························0-3

···········0-3

Warning Risk of burn ························0-4

●Do not touch the engine while it is running or for a while after it is stopped

●Be careful when opening/closing the radiator cap

●Replenish coolant only when the coolant in the system is cold

●Do not remove heat insulating material ·····0-4

·········································0-4

··············0-4

·····0-4

Warning Exhaust gas is

poisonous···························0-4

●Ensure good ventilation while the engine is running

··································0-4

Warning Hearing difficulty·················0-4

●Wear ear protector································0-4

Warning Beware of falling engine·····0-5

●Exercise caution when lifting the engine····0-5

●Do not climb on the engine

●Secure your foothold when carrying out

service

···············································0-5

·····················0-5

Caution Use correct engine oil

and LLC······························0-5

●Only use the specified fuel, engine oil and coolant (LLC)

·································0-5

●Handle LLC with care

●Lawful disposal of waste oil and

coolant

···············································0-5

····························0-5

Caution Handling of battery··············0-6

●Handle the battery with care····················0-6

Caution How to handle

emergencies·······················0-6

●Engine overheat - Idle to cool down, then stop the engine

●Never restart the engine after a su dden stop unless the cause is eliminated

●Stop the engine immedia t ely upon oil pressure drop

●Stop the engine immedia t ely upon broken fan belt

···············································0-6

······································0-6

·····························0-6

··········0-6

Caution How to handle

emergencies·······················0-6

●Engine overheat - Idle to cool down, then stop the engine

●Never restart the engine after a su dden stop unless the cause is eliminated

●Stop the engine immedia t ely upon oil pressure drop

●Stop the engine immedia t ely upon broken fan belt

···············································0-6

······································0-6

·····························0-6

··········0-6

Caution Other considerations···········0-7

●Never alter or modify the engine ··············0-7

●Do not tamper with sealing

●Daily and periodical inspection

●Running-in period

●Warming up the engine

●Do not overload the engine·····················0-7

●Cooling down the engine

●Do not spill water onto the engine ···········0-7

●Air cleaner maintenance precautions

●Observe safety rules at work sites

●Wear appropriate clothes and protective

gear

···················································0-8

●Use appropriate tools when carrying out service

·································0-7

·····················0-7

················0-7

··························0-7

························0-7

········0-8

············0-8

0-8

●Do not operate the starter continuously

●The battery switch must be kept ON while

the engine is running

●Precautions for road transport

·····························0-8

·················0-8

·····0-8

SAFETY CAUTIONS

W arning Risk of fire and explosion

●Never use open fire

When topping up or replacing fuel or engine oil, or cleaning parts in wash oil, do not light a match, smoke or use any other open fire nearby. Doing these is extremely dangerous as fuel and oils can catch fire. Completely wipe off any spilt fuel or engine oil as they are flammable and can be a fire hazard. Store fuel and engine oil in a well-ventilated place. Firmly tighten the cap of the container.

●Keep things tidy around the engine

Keep fuel, engine oil or any other flammables as well as explosives and other dangerous materials away from the engine. These materials can ignite and explode. Keep the engine and the surrounding area free of waste, dirt, foreign matter, etc. These substances can be a fire hazard and invite overheating. In particular, ensure that the top of the battery is clean after service operations. Any waste left on the battery can cause short circuit. Keep a running engine at least 1 m (3.3 ft.) away from the surrounding building or equipment to eliminate the risk of fire.

●Do not open the crankcase until it has cooled down

Do not attempt to open the crankcase side cover immediately after the engine is stopped. Wait at least 10 minutes until the engine has sufficiently cooled down. If fresh air flows into the crankcase with the engine still hot, the remaining mist of oil may ignite and cause explosion.

●Pay attention to fuel and oil leakage

If leakage of fuel or oil is found, immediately take measures to stop it. If leaking fuel or engine oil spills over the heated engine, fire may start, possibly leading to bodily injury or equipment damage.

●Use explosion-proof light

When checking fuel, engine oil, coolant, battery electrolyte, etc., use explosion-proof light. If ordinary light is used, these fluids may ignite and explode.

●Prevent short circuit

Before inspecting or servicing the electrical/electronic system, disconnect the negative (-) cable from the battery terminal. Failure to observe this can cause the circuit to short, possibly starting a fire. Loose terminals and damaged cables/wires can cause short circuit or even fire. Before carrying out service operation, check for loose or damaged components and repair or replace as required.

●Keep fire extinguisher and first-aid kit at hand

Keep a fire extinguisher at hand. Become familiar with the handling of the fire extinguisher. Store a first-aid kit at the designated place. The kit should be kept fully supplied so that it can serve the purpose at any time. Establish a set of actions to take in the event of fire or accident, including emergency contact numbers and means of communication.

0 - 2

W arning Risk of entanglement into the machine

SAFETY CAUTIONS

●Keep guards on the rotating parts

Ensure that all guards are correctly installed over the rotating parts of the engine. Damaged or loose guards should be repaired. Never attempt to remove the camshaft cover, rocker cover or any other guards form rotating parts while the engine is running. Never leave exposed the drive belts and related couplers for auxiliaries and radiator. They should also be covered with guards. Never remove these guards.

●Ensure safety in the surrounding area when starting the engine

Before starting the engine, ensure that no one is near the electric power generator and that no tools or foreign matter are left behind. Shout to people around you so that they will know you are starting the engine. Never start the engine if a “Do not start” tag or any other similar message is posted on the starter switch, etc.

●Keep away from rotating parts while the engine is running

Never stand near the rotating parts while the engine is running. Do not place objects near the rotating parts that are likely to be caught by these parts. Should any part of human body (or tool) is caught by the rotating parts, dismemberment or other bodily injury will result.

●Lockout/tagout

Perform lockout/tagout before carrying out any inspection/service. Lockout/tagout is an ideal way of disconnecting the machine/equipment from the power source. To lockout/tagout, remove the starter switch key, place the battery switch in the “OFF” position, and post a “Do not start” tag or other similar message on the starter switch. The starter switch key should then be carried by the person who is going to perform inspection/service. If an air start system is used, close the air tank source valve and post a “Do not open” tag or other similar message.

●Always stop the engine before any inspection/service

Always stop the engine before performing any inspection/service. Never attempt to adjust belt tension while the engine is running. Otherwise, the operator runs a great risk of becoming entangled into the rotating parts and seriously injured.

●Remove the turning gear after use

Be sure to remove the turning gear after use. Never start the engine with the turning gear still installed or “engaged.” Otherwise, the engine will break and possibly someone may become injured.

0 - 3

SAFETY CAUTIONS

W arning Risk of burn

●Do not touch the engine while it is running or for a while after it is stopped

Never touch any part of the engine while it is running or for a while after it is stopped. Otherwise, you may become burned. Use a coolant temperature gauge to confirm that the engine has sufficiently cooled down before performing any inspection/service.

●Be careful when opening/closing the radiator cap

Never attempt to open the radiator cap while the engine is running and for a while after it is stopped. Stop the engine and wait until the coolant temperature has sufficiently dropped before opening the cap. Slowly open the radiator cap to allow the internal pressure to escape. To prevent possible burn, wear thick rubber gloves or cover the cap with cloth to protect your hands from escaping vapor. Tighten the radiator cap firmly. Coolant is extremely hot while the engine is running or for a while after the engine is stopped. You may become burned by extremely hot vapor or coolant that will gush out if the radiator cap is opened.

● Replenish coolant only when the coolant in the system is cold

Do not replenish coolant for a while after the engine is stopped. Replenish coolant when the coolant in the system is sufficiently cold. Otherwise, you may become burned.

● Do not remove heat insulating material

The exhaust system components become extremely hot and therefore are covered with heat insulating material. Never remove the material. If the material needs to be removed at all for inspection/service, be sure to install it again after the operation.

W arning Exhaust gas is

poisonous

● Ensure good ventilation while the engine is running

If the engine is installed inside a building and the exhaust gas is directed outside through a duct, regularly check the duct for any leakage through the joints etc. Do not run the engine in a building (warehouse, tunnel, etc.), confined space, or other poorly ventilated places if the engine is used for a portable generator. If the engine needs to be run in a buildin g at all, ensure to direct the exhaust gas outside and provide sufficient ventilation. Also, take care not to direct the exhaust gas towards nearby plants or animals, if any. Engine exhaust gas contains carbon monoxide and other substances that are harmful to humans. Running the engine in a poorly ventilated place can cause exhaust gas poisoning.

Warning Hearing

difficulty

●Wear ear protector

W ear ear protector whenever entering the engine room. Otherwise, the combustion and mechanical noises may cause you to develop hearing difficulty.

0 - 4

SAFETY CAUTIONS

Warning Beware of

falling engine

● Exercise caution when lifting the engine

The wire rope used to lift the engine should have enough strength to withstand the weight of the engine. Attach the specified lifting gear onto the lifting hangers on the engine. Ensure that the engine is well balanced when it is lifted by taking into account the engine’s center of gravity. The angle of wire rope relative to the lifting hangers should be maintained at 60º or less. Above this, the hangers may be subjected to overload and break. If direct contact between the wire rope and the engine is anticipated, protect them from damage by covering them with cloth or other soft material.

● Do not climb on the engine

Do not climb onto the engine, nor place a foot on the components on the side of the engine. Otherwise, you may not only break the engine components but also fall and become injured. Use a stool or a platform to work on the top of the engine. Be careful not to slip and fall.

● Secure your foothold when carrying out service

Use a stable stool or platform when working on the top of the engine or other areas of the engine difficult to reach. Do not use a rickety stool nor substitute a box of parts. Otherwise, you may fall and become injured. Do not leave anything on the stool.

Caution Use correct

engine oil and LLC

● Only use the specified fuel, engine oil and coolant (LLC)

Only use the fuel, engine oil and coolant (LLC) that are specified in this manual. Handle them with sufficient care. Using fluids other than those specified in this manual or incorrect use of those specified in this manual will lead to many problems and may possibly cause failures. Use the specified engine oil and LLC according to the instructions of MSDS (Material Safety Data Sheets) issued by and available from the manufacturers.

● Handle LLC with care

LLC is a strong alkali. Be careful not to drink it by mistake or allow it to contact your eyes. Old coolant (containing LLC) that has been drained off is toxic. Do not dispose of it carelessly. Dispose of it in accordance with the applicable laws and regulations.

● Lawful disposal of waste oil and coolant

Do not dispose of waste oil or coolant carelessly. Doing so is harmful to the environment and is prohibited by law. Harmful substances such as waste oil and coolant should be disposed of in a manner that complies with the applicable laws and regulations.

0 - 5

SAFETY CAUTIONS

Caution Handling of

battery

● Handle the battery with care

・ Batteries emit hydrogen and

oxygen gases, both of which are flammable. Never use open fire or generate sparks near the battery. Otherwise, these gases may ignite and explode.

・ Do not use the battery if the electrolyte level has

dropped below the minimum line. Otherwise, the battery may explode.

・ Be careful not to inadvertently place a metal

object such as tool between the battery terminals.

・ Always disconnect the negative (-) terminal first,

then the positive (+) terminal, from the battery. Always connect the positive (+) terminal first, then the negative (-) terminal, to the battery.

・ Recharge the battery in a well ventilated place,

with all battery plugs removed.

・ The battery terminals should have a positive

connection. Loose terminals can generate sparks, possibly causing the battery to explode.

・ Before servicing or performing electric welding

on the electrical/electronic system, position the battery switch in the OPEN/OFF position or disconnect the negative (-) terminal of the battery to isolate the electrical/electronic circuit.

・ The battery electrolyte contains dilute sulfuric

acid. Incorrect handling may lead to loss of eyesight or burn. Never drink battery electrolyte.

・ Wear protective goggles and rubber gloves when

maintaining the battery (replenishing, recharging, etc.).

・ If your skin or clothing has come into contact with

battery electrolyte, immediately wash the affected area with plenty of water and then thoroughly clean with soap.

・ Should your eyes come into contact with battery

electrolyte, loss of eyesight may result. Immediately wash your eyes with plenty of fresh water and seek medical attention immediately.

・Should you inadvertently drink battery electrolyte,

repeatedly gargle with plenty of water and then drink plenty of water. Seek medical attention immediately.

Caution How to handle

emergencies

● Engine overheat - Idle to cool down, then stop the engine

In the event of engine overheat, do not stop the engine immediately. Doing so may cause the coolant temperature to rise quickly and the engine may seize. Instead, run the engine at low idle for a while to cool it down. Then, stop the engine. Do not attempt to replenish coolant for a while after the engine is stopped. Otherwise, the cylinder head etc., which may still be hot, is cooled down rapidly and may break. Wait until the engine is sufficiently cold and then top up slowly.

● Never restart the engine after a sudden stop unless the cause is eliminated

If the engine has suddenly stopped with some alert signals, do not restart immediately. Otherwise, the engine may seriously become damaged. Locate and eliminate the cause before restarting.

● Stop the engine immediately upon oil pressure drop

If the oil pressure has dropped, immediately stop the engine. Otherwise, bearings etc. may seize. Inspect the oil system and components.

● Stop the engine immediately upon broken fan belt

If the fan belt has broken, immediately stop the engine. Otherwise, the engine will overheat. Also, coolant vapor will gush out from the reserve tank and radiator and you may get burned.

0 - 6

Caution Other considerations

SAFETY CAUTIONS

● Never alter or modify the engine

Altering or modifying the engine in any way will nullify the warranty. A modified engine may not only break but also lead to injury.

● Do not tamper with sealing

To help ensure trouble-free operation of the engine, the fuel control link has been sealed to achieve the correct fuel injection volume and engine speed. If the sealed setting is tampered with, the following will result and the correct functioning of the engine is no longer guaranteed.

・ Sliding and rotating parts will wear faster. ・ Various parts will seize/become damaged. ・ The engine will consume more fuel and oil. ・ The governor and fuel injection volume go out of

balance, reducing the engine performance.

● Daily and periodical inspection

Perform the daily and periodical inspection in accordance with the Operation and Maintenance Manual. Failure to observe the instructions of the manual may lead to many problems, and the various engine parts may eventually fail, possibly causing a serious accident.

● Running-in period

A brand new engine requires a running-in period of 50 hours, during which never put the engine under severe load. Otherwise, the service life of the engine will be reduced.

● Warming up the engine

Before starting work, warm up the engine by running it at low idle for 5 to 10 minutes. Warming up the engine will not only smoothen the operation of various engine parts but also help extend its service life. It also helps maximize the performance and achieve economical running of the engine. Do not warm up the engine longer than necessary. Doing so facilitates carbon deposit on the cylinders, possibly leading to poor combustion.

● Do not overload the engine

Do not continue to run the engine if it emits black smoke. Overloaded running of the engine (accompanied by black smoke) not only consumes excessive fuel but also facilitates carbon deposit and thus shortens the service life of the engine.

● Cooling down the engine

Before stopping the engine, cool it down (by running it at low idle) for 5 to 6 minutes. Stopping the engine suddenly while it is heavily loaded will result in some areas of the engine remaining extremely hot for a while, which is detrimental to the long service life of an engine. While the engine is being run at low idle for cooling, check the engine for any problems.

● Do not spill water onto the engine

Ensure that no rainwater etc. enters into the engine from the exhaust or inlet manifold, or via any other routes. Do not run the engine while at the same time washing it. Otherwise, cleaning fluid (water) may be sucked into the engine. If the engine is started with water trapped in the combustion chambers, water hammering will result, causing the engine to fail and possibly leading to a serious accident.

0 - 7

SAFETY CAUTIONS

● Air cleaner maintenance precautions

Wear of engine parts is accelerated largely by the dust contained in the intake air. Worn engine parts will lead to various problems such as increased oil consumption, reduced power and poor starting. Air cleaner is effective in removing dust in the intake air. When maintaining the air cleaner, observe the following precautions. ・ Never attempt to service the air cleaner while the

engine is running.

・ When removing the air cleaner, take care not to

allow the dust trapped on the air cleaner to enter into the inlet port.

・ If the engine is equipped with the dust indicator,

clean the air filter only when the indicator shows clogging. Unnecessary maintenance (removal/ installation of the filter element) runs the risk of allowing dust into the inlet port or damaging/ deforming the filter element.

● Observe safety rules at work sites

Whenever running or servicing the engine, always observe the relevant safety rules in place. If you are not in good shape, do not operate the engine. Consult the site supervisor. Poor physical conditions are accompanied by reduced attention. Do not operate the engine if you are not feeling well. Otherwise, you may incorrectly handle the engine and cause an accident. When working jointly with other people on the same task, use signals to coordinate actions involved.

● Wear appropriate clothes and protective gear

Whenever appropriate, including when using compressed air, wear protective gear such as helmet, face mask, safety shoes, dust mask, goggles and gloves. Working without appropriate protective gear may lead to serious injury.

● Use appropriate tools when carrying out service

When carrying out any service, use appropriate tools and in correct ways. Damaged tools should be replaced with new ones.

● Do not operate the starter continuously

Do not operate the starter more than 10 seconds per starting attempt. If the engine fails to start at the first attempt, wait for at least 30 seconds before trying again. Do not run the starter continuously if the engine will not start. Otherwise, the battery will go flat or the starter will seize.

● The battery switch must be kept ON while the engine is running

Do not turn off the battery switch while the engine is running. Otherwise, the instruments will become inoperative and the diode or transistor of the alternator may deteriorate.

● Precautions for road transport

When transporting the engine on public roads, the weight, width and height of the electric power generator should be taken into account while observing the relevant laws regarding road traffic and haulage, and vehicle restrictions and requirements.

0 - 8

GENERAL

1. Overview ····························································································· 1 - 2

1.1 Outline Drawing··················································································· 1 - 2

1.2 Fuel System Schematic ········································································ 1 - 4

1.3 Oil System Schematic··········································································· 1 - 4

1.4 Cooling System Schematic···································································· 1 - 5

1.5 Inlet / Exhaust System Schematic··························································· 1 - 5

1.6 Engine Serial Number··········································································· 1 - 6

1.7 Engine Model and Application Codes ······················································ 1 - 6

2. Specifications ······················································································ 1 - 7

3. Disassembly / Reassembly Notes······················································· 1 - 9

3.1 Disassembly ······················································································· 1 - 9

3.2 Reassembly························································································ 1 - 9

GENERAL

1. Overview

1.1 Outline Drawing S3L, S3L2

Thermostat

Alternator

Fan

Hanger

Oil filler

Exhaust manifold

Starter

Front end

V belt

Oil pan

Left-hand side

Rear end

Flywheel

Engine LH side view

Fuel injection nozzle

Fuel injection pump

Stop solenoid

Coolant drain plug

Water pump

Inlet cover

1 - 2

Rear end

Flywheel housing

Oil level gauge

Oil drain plug

Right-hand side

Engine RH side view

Front end

Crankshaft pulley

Oil filter

S4L, S4L2

Thermostat

Alternator

Fan

Hanger

GENERAL

Oil filler

Exhaust manifold

Starter

Fuel injection pump

Coolant drain plug

Front end

V belt

Stop solenoid

Oil pan

Left-hand side

Engine LH side view

Rear end

Flywheel

Fuel injection nozzle

Water pump

Inlet cover

Flywheel housing

Rear end

Oil filter

Oil drain plug

Right-hand side

Engine RH side view

Front end

Crankshaft pulley

Oil level gauge

1 - 3

GENERAL

1.2 Fuel System Schematic

To fuel tank

Fuel injection nozzle

Fuel pump

Fuel leak-off pipe

Fuel injection pipe

Fuel injection pump

From fuel tank

1.3 Oil System Schematic

Oil pressure switch

Oil main gallery

Oil filter

Relief valve

Fuel filter

Fuel system schematic

1 - 4

Oil pump

Oil drain plug

Oil strainer

Oil system schematic

1.4 Cooling System Schematic

Radiator

Water pump

GENERAL

Water bypass valve

Thermostat

Cooling fan

Cooling system schematic

1.5 Inlet / Exhaust System Schematic

Exhaust gas

Intake air

Air breather pipe (positive crankcase ventilation)

Intake air

(from air cleaner)

Inlet cover

Blow-by gas

Exhaust gas

(to muffler)

Exhaust manifold

Inlet / exhaust system schematic

1 - 5

GENERAL

1.6 Engine Serial Number

The engine serial number is stamped on the top face of the fuel injection pump bracket on the right-hand side of the cylinder block.

1.7 Engine Model and Application Codes

(1) The engine model code is embossed on the side

of the fuel injection pump mount on the right-hand side of the cylinder block.

(2) The engine model code consists of the following

alphanumerical digits.

Model coding

(Example) S

4 L 2

Type (2 = Type 2)

Series [L = bore size 78 mm (3.07 in.)]

No. of cylinders (4 = 4 cylinders)

S = Sagamihara Machinery Works

Engine serial number

Engine serial number location

Engine model code

1 - 6

2. Specifications

Engine Type S3L S3L2 S4L S4L2

Type Water-cooled; 4-stroke cycle; Diesel powered No. of cylinders 3 4 Combustion Swirl chamber type Valve mechanism Overhead valve type

Cylinder bore×stroke mm (in.)

Total displacement l (U.S. gal)

Compression ratio 22.0 : 1

General

Fuel Diesel fuel (JIS K2204 Special 1 - 3)

78×78.5

(3.07×3.09)

1.125

(0.297)

Firing order 1-3-2 1-3-4-2 Direction of rotation Counterclockwise when viewed from the flywheel end

Overall length mm (in.) 536 (21.10) 620 (24.40)

Dimensions

Overall width mm (in.) 433 (17.04) 433 (17.04) Overall height mm (in.) 572 (22.52) 572 (22.52)

Dry mass kg (lb) 135 (297.6) 155 (341.7)

Piston ring No. of rings

Va l ve

Inlet valve timing (hot engine)

Engine mounting 4 mounts

Engine main parts

Starting method Starter

Exhaust valve

Open BTDC 15° Close ABDC 41° Open BBDC 54° Close ATDC 10°

Type Bosch M

Manufacturer DENSO

Injection pump

Plunger

diameter

MS retard

mm (in.)

(crank angle)

Cam lift mm(in.) 15 (0.59) Governor Governing method Centrifugal fly-weight type

Type Throttle nozzle

Fuel system

Injection nozzle

Manufacturer Bosch Automotive Systems Corporation

Spray angle mm (in.) 15°

Opening

pressure

MPa

(kgf/cm

[psi]

)

Fuel filter Type Paper-element cartridge; Separate type w/ cock Lubrication method Forced circulation (pressure feed by trochoid pump)

Grade CD Class (API Classification) Engine oil

Capacity (entire engine)

l (U.S. gal)

3.7 (1.0) 4.2 (1.1) 5.4 (1.4) 6.0 (1.6)

Type Gear pump Oil pump

Oil system

Relief valve

Displacement

Type Piston valve

Opening

pressure

l (U.S. gal)

/min

MPa

(kgf/cm

)

[psi]

Oil filter Type Paper element (spin-on type)

78×92

(3.07×3.62)

1.318

(0.348)

78×78.5

(3.07×3.09)

1.500

(0.396)

Compression ring :2

Oil ring (w/expander) : 1

φ5.5 (0.21)

8°

14.22 to 15.00 (145 to 153) [2062 to 2176]

18 (4.8)

0.35±0.05 (3.6±0.5) [51±7]

GENERAL

78×92

(3.07×3.62)

1.758

(0.464)

1 - 7

GENERAL

Engine Type S3L S3L2 S4L S4L2

Cooling method Water-cooled, forced circulation Capacity (engine proper)

l (U.S. gal)

1.8 (0.5) 2.5 (0.7)

Type Centrifugal pump

Water pu m p

Displacement

l (U.S. gal)

/min

30 (8.0) up (@ 2000 min

Type Wax

Thermostat

Cooling system

Cooling fan

Opening temperature

℃ (°Ｆ)82±1.5 (179.6±2.7)

Type Pusher suction (PP fan)

No. of blades / OD

mm (in.)

5 / 340 (13.39), 6 / 320 (12.6), 6 / 340 (13.39),

6 / 360 (14.17), 6 / 380 (14.96), 7 / 380 (14.96)

Air cleaner Type Paper element

system

Voltage - Polarity

12 V - Θ ground, 24 V - Θ ground

Type M001T68281, M008T70471A, M008T81071A Manufacturer Mitsubishi Electric Corporation

Starter

Pinion engagement Output V-kW 12 V-1.7, 12 V-2.0, 24 V-3.2

Pinion shift (reduction)

No. of units 1 Reduction ratio

(pinion / ring gear)

13 / 120

Type 3-phase alternator w/ built-in IC regulator Manufacturer Mitsubishi Electric Corporation Output V-A 12-50, 24-25

Alternator

Speed at which rated voltage is

min

-1

5000 (@ 13.5 V, 47 A), 5000 (@ 27.0 V, 22 A)

generated Regulated voltage V

Electrical system

Glow plug

Type Sheathed plug

Rated voltage current

voltage

Stop solenoid

Insulation resistance

Stroke mm (in.) Working

ambient temperature

V-A

℃ (°Ｆ)

(30-second application)

12 V-ETR 12 V-ETS 24 V-ETR 24 V-ETS Operating

8 or less 10 to 15 16 or less 20 to 30

-40 to 120

(-40 to 248)

14.7±0.3 (12-50), 26.5±0.5 (24-25)

12 V plug 24 V plug

10.5-9.7 (25-second application)

100 MΩ or more at DC500 V

(at ordinary temperature and humidity)

13.5±0.5 (0.53±0.01)

-30 to 120

(-22 to 248)

-40 to 120

(-40 to 248)

-1

engine speed)

22.5-5

-30 to 120

(-22 to 248)

1 - 8

3. Disassembly / Reassembly Notes

This Service Manual specifies various procedures recommended by Mitsubishi Heavy Industries, Ltd. for servicing Mitsubishi diesel engines. These procedures include, wherever appropriate, required special tools and related safety precautions. The instructions provided in this manual, however, cannot fully guarantee safety as potential risks beyond ordinary imagination are hidden everywhere. When conduct any work, the following points should also be observed in addition to the instructions this manual.

3.1 Disassembly

(1) Use tools and equipment that are appropriate for

the work being carried out.

(2) Whenever necessary, use workbenches to work

on or sort parts out. Disassemble in accordance with the disassembly sequence given in the manual.

(3) As parts are disassembled, place them neatly in

the order of removal to eliminate missing parts on reassembly.

(4) During disassembly, note the assembly marks.

Remember to respect these marks on reassembly. Whenever appropriate, put additional assembly marks to aid reassembly.

(5) Before and during disassembly as well as during

subsequent washing, carefully check for any abnormality or other fault which otherwise may likely remain unnoticed afterwards.

(6) Pay sufficient attention to ensure safety,

especially when lifting or carrying heavy components and parts. (Use a jack or a chain block as required.)

3.2 Reassembly

(1) Parts excluding oil seals, O-rings, rubber sheets,

etc. should be thoroughly washed in wash oil and completely dried using compressed air.

(2) Use appropriate tools and equipment. (3) Use good-quality oil and grease. Never fail to

apply oil, grease, sealant and adhesive to the relevant locations if so instructed in the manual.

GENERAL

1 - 9

GENERAL

(4) Tighten hardware to the specified torque, if

provided in the manual. Be sure to use a torque wrench.

(5) Gaskets, packing and O-rings should be replaced

with new parts unless specified otherwise.

1 - 10

SERVICE STANDARDS

1. Service Standards Table····································································· 1 -12

2. Tightening Torques Table···································································· 1 -16

2.1 Major Bolts and Nuts ··········································································· 1 -16

2.2 Standard Bolts and Nuts······································································· 1 -17

2.3 Standard Eyebolts··············································································· 1 -17

2.4 Standard Union Nuts ··········································································· 1 -18

2.5 Taper Bolts ························································································ 1 -18

3. Sealants List······················································································· 1 -19

SERVICE STANDARDS

1. Service Standards Table

Unit: mm (in.)

Item

Group

Max. speed (based on the rated speed)

Min. speed

Compression pressure (at 290 min

-1

)

Rated speed

pressure

Engine oil

Low idle speed

Inlet valve

Engine general

Valve timing [with 2 mm (0.079 in.) clearance on the valve side; cold engine]

open Inlet valve closed Exhaust valve open Exhaust valve closed

Valve clearance

Inlet valve 0.25 (0.01) Exhaust valve 0.25 (0.01)

Fuel injection timing (BTDC)

Rocker arm inner diameter

Rocker shaft diameter

Rocker

Arm-to-shaft clearance (oil clearance)

Inlet

Valve stem diameter

Exhaust

Valve guide inner diameter

Va l ve

Valve stem-to-guide

Engine main parts

clearance

Inlet

Exhaust

Inlet

Exhaust

Valve seat angle

Valve head sinkage 0

Valve seat width

Valve head margin

Valve seat and valve

Installed valve guide protrusion

Nominal

value

φ19

(0.749)

φ19

(0.749)

φ6.6

(0.260)

φ6.6

(0.260)

φ6.6

(0.260)

φ6.6

(0.260)

1.6

(0.063)

1.5

(0.0591)

(0.394)

Standard value Limit Remarks

+30

2700

1000±25 min

-10

min-1

-1

2.9 MPa (30 kgf/cm [421 psi] or above

)

2.6 MPa

(27 kgf/cm

[377 psi]

or less

Both oil and coolant

)

temperatures at 20 to

30℃ (68 to 86°Ｆ)

0.29 to 0.39 MPa (3.0 to 4.0 kgf/cm2) [42.07 to 56.57 psi]

0.098 MPa

(1.0 kgf/cm

)

Oil temperature at

60 to 95℃ (140 to 194°Ｆ)

[14.22 psi]

BTDC 15

The theoretical valve

ABDC 41

timing figures for inspection vary from

BBDC 54

the actual valve timing.

ATD C 10

Cold engine

17°

18.910 to 18.930

(0.7450 to 0.7458)

18.880 to 18.898

(0.7438 to 0.7445)

0.012 to 0.050 (0.0004

to 0.0019)

6.565 to 6.580

(0.2586 to 0.2592)

6.530 to 6.550

(0.2572 to 0.2580)

6.600 to 6.615

(0.2600 to 0.2606)

6.600 to 6.615

(0.2600 to 0.2606)

0.020 to 0.050

(0.0008 to 0.0020)

0.050 to 0.085

(0.0020 to 0.0033)

0.25 to 0.75

(0.0098 to 0.0295)

1.30 to 1.80

(0.0512 to 0.0709)

1.35 to 1.65

(0.0531 to 0.0650)

9.5 to 10.5

(0.3743 to 0.4137)

―

0.200

(0.0079)

6.500

(0.256)

6.500

(0.256)

0.100

(0.004)

0.150

(0.006)

Valve seat width

1.5

(0.0591)

2.5

(0.0985)

0.5

(0.0197)

―

Replace rocker arm.

Replace valve and valve guide.

Val v e seat

Valve head

angle

sinka

Va l ve head

mar

1 - 12

SERVICE STANDARDS

Unit: mm (in.)

Group

Item

Nominal

value

Standard value Limit Remarks

Free length 47 (1.85) 46 (1.81)

θ

Squareness

39.0 (1.536)/ 131 to 145

(13.3 to 14.7)

[29 to 33]

Valve spring

Installed length / load

mm (in.)/N (kgf) [lbf]

Push rod Bend

Cylinder head

Cylinder block top face distortion

Cylinder

Bore

Bottom face distortion

φ78

(3.07)

78.0

Out of roundness

STD

Diameter

0.25 OS

0.50 OS

Max. allowable variation in weight among pistons on the

Piston

same engine

Engine main parts

Piston pin diameter

Piston pin-to-boss clearance

Piston-to-cylinder clearance

No. 1 ring Piston ring-to-groove

No. 2 ring clearance

Oil ring

Piston ring

Piston ring gap

No. 1 ring

No. 2 ring

78.00 (3.07)

78.25 (3.08)

78.50 (3.09)

φ23

(0.9062)

±5 g (0.177 oz)

22.944 to 23.000

(0.9039 to 0.9062)

(0.0002 to 0.0007)

(0.0014 to 0.0034)

(0.0035 to 0.0043)

(0.0028 to 0.0043)

(0.0012 to 0.0028)

Oil ring

Bend and twist

rod

End play

Connecting

θ=2.0° Δ=0.2

(0.0079)

Lf=47

(1.8518)

30.1 (1.185)/ 279 to 309

(28.5 to 31.5)

[63 to 69]

―

0.05 (0.002) or less

+0.03 0

(3.07

+0.0012 0

±0.01 (0.0004)

or less

77.93 to 77.95

(3.070 to 3.071)

78.18 to 78.20

(3.080 to 3.081)

78.43 to 78.45

(3.090 to 3.090)

or less

0.006 to 0.018

0.035 to 0.086

0.09 to 0.11

0.07 to 0.11

0.03 to 0.07

0.15 to 0.30

(0.006 to 0.012)

0.15 to 0.35

(0.006 to 0.014)

0.20 to 0.40

(0.008 to 0.016)

0.05/100

(0.002/3.940)

0.10 to 0.35

(0.004 to 0.014)

△= 0.5

(0.0197) across the entire length

0.3 (0.011) Replace

0.10 (0.004) Correct

78.2 (3.08) Bore or replace

)

(0.006/3.940)

-15 %

―

77.80

(3.065)

78.05

(3.075)

78.30

(3.085)

―

0.050

(0.002)

0.300

(0.012)

0.300

(0.012)

0.200

(0.008)

0.200

(0.008)

1.50

(0.06)

0.15/100

0.50

(0.020)

Bore or replace

Replace piston ring

Replace

Replace connecting rod

1 - 13

SERVICE STANDARDS

Unit: mm (in.)

Item

Group

Crank journal diameter (STD)

Crank pin diameter

Nominal

value

φ52

(2.0488)

φ48

(1.8912)

Standard value Limit Remarks

51.985 to 52.000

(2.0482 to 2.0488)

47.950 to 47.964

(1.8892 to 1.8897)

Crankshaft bend 0.025 (0.0010)

Main bearings oil clearance

Crankshaft

Connecting rod bearings oil clearance

End play

0.030 to 0.077

(0.0012 to 0.0030)

0.025 to 0.072

(0.0010 to 0.0028)

0.050 to 0.175

(0.0020 to 0.0069) Crank gear to idler gear Idler gear to valve camshaft gear Idler gear to pump camshaft gear Valve camshaft gear to PTO gear Pump camshaft gear to oil

Timing gear backlash

Engine main parts

pump gear

Camshaft cam height (including lobe)

Fuel injection pump shaft cam height (including lobe)

Flywheel flatness

0.040 to 0.120

(0.0015 to 0.0047)

0.080 to 0.190

(0.0032 to 0.0075)

0.070 to 0.200

(0.0028 to 0.0079)

(1.4073±0.0394)

(1.7336±0.0039)

0.150 (0.0059)

Tappet-to-guide clearance

Camshaft journal-to-bushing clearance

Idler gear-to-shaft clearance

0.050 to 0.125

(0.0020 to 0.0049)

0.020 to 0.070

(0.0008 to 0.0028)

35.720±0.1

44±0.1

or less

―

0.050 (0.0020)

0.100

(0.0040)

0.150

(0.0059)

0.500

(0.0197)

0.300

(0.0120)

34.720

(1.3679)

(1.6942)

0.500

(0.0197)

0.150

(0.0059)

0.150

(0.0059)

0.200

(0.0079)

Correct or replace Replace main bearings Replace connecting rod bearings Replace flanged No. 3 main bearings

Replace

Correct

Replace tappet

Replace bushing

Replace idler gear or idler shaft

Injection valve opening pressure

MPa (kgf/cm

Fuel system

Relief valve opening pressure

MPa (kgf/cm

Oil pressure switch closing pressure

Oil system

MPa (kgf/cm

Valve opening temperature

Thermostat

8 mm (0.32 in.) valve lift temperature

Thermoswitch

Fan belt deflection {when pressed

Cooling system

with a force of approx. 98 N (10

At 111±3.5℃ (231.8±6.3°Ｆ)

kgf) [22] between crankshaft and alternator pulleys and between crankshaft and fan pulleys}

1 - 14

) [psi]

14.22 (145)

[2062]

14.22 to 15.00 (145 to 153)

[2062 to 2176]

0.35±0.05 (3.5±0.5) [50±7.2]

0.05±0.01 (0.5±0.1)

[7±1.4]

82±1.5℃

(179.6±2.7°Ｆ)

95℃

(203°Ｆ)

30 MΩ

[when dipped in oil of

105℃ (221°Ｆ)]

10 to 12

(0.4 to 0.5)

―

Adjust with washer

Replace

SERVICE STANDARDS

(

)

Unit: mm (in.)

Item

Group

Paper-element type air

aus

cleaner

stems

Inlet / exhaust manifold

an e

mounting face distortion

Pinion gap

No-load characteristics

Brush length

Starter

Brush spring load

Commutator radial runout

Commutator diameter

Electrical system

Mica undercutting depth IC regulator controlled voltage

[at 20℃ (68°Ｆ)]

2500 min or

-1

cs st

less

aracter

Alternator

5000

when hot

-1

min

utput c

or less

Nominal

value

Standard value Limit Remarks

Clean every 100 hours

―

0.5 to 2.0

(0.02 to 0.08)

Term inal voltage

Current

Rotation speed

M001T68281 M008T70471A M008T81071A

11 V 11 V 23 V

110 A

or less

2400 min

16.5

(0.65)

130 A

or less

3600

-1

min-1

80 A

or less

3000

min-1

18.0

(0.71)

17.5 to

23.7 N

(1.78 to

2.41 kgf)

[3.9 to 5.3

29.4 to 39.2 N

(3.0 to 4.0 kgf)

[6.6 to 8.8 lbf]

lbf]

0.05

(0.002)

29.4

(1.16)

0.03

(0.001)

32.0

(1.26)

0.5

(0.02)

A007T02071C A007TA8571

Term inal voltage

13.5 V 27.0 V

14.7±0.3 V 28.5±0.5 V

Current 32 A or above 18 A or above

Term inal voltage

13.5 V 27.0 V

Current 47 A or above 22 A or above

Replace every

500 hours

0.15 (0.006) or less

―

― ―

M001T68281

10.0

(0.39)

6.90 N

(0.70 kgf)

[1.6 lbf]

0.10

(0.004)

28.8

(1.13)

0.2

(0.01)

―

M008T70471A,

M008T81071A

11.0

(0.43)

13.7 N

(1.40 kgf)

[3.1 lbf]

31.4

(1.24)

Grind or replace

Adjust with packing

Inspect

Replace

Correct or replace

Replace

Correct

Brush length 18.5 (0.73) 5.0 (0.20) Replace Clearance between stop solenoid plunger and rack Glow plug resistance 0.55 Ω

0.15 to 0.20

(0.006 to 0.008)

Correct

―

Replace

1 - 15

SERVICE STANDARDS

2. Tightening Torques Table

2.1 Major Bolts and Nuts

Thread

Fittings

Engine proper

Cylinder head bolt

Rocker cover bolt

Rocker shaft bracket bolt

Thrust plate bolt

Main bearing cap bolt

Connecting rod cap nut

Flywheel bolt

Crankshaft pulley nut

Rear plate mounting bolt

Fuel system

Hollow screw (fuel injection pump) Delivery valve holder (fuel injection pump) Air bleeder plug (fuel injection pump)

Nozzle retaining nut

Nozzle holder IDI

Fuel injection pipe nut

Fuel leak-off pipe nut

Sliding sleeve shaft

Torque spring set special nut

Oil system

Oil relief valve

Oil pan drain plug

Oil filter

Oil pressure switch PT1/8 7.85 to 11.8 0.8 to 1.2 5.8 to 8.7

Oil pan mounting bolt

Oil strainer nut

Cooling system

Thermoswitch

Thermostat cover bolt

Thermo case bolt

Inlet and exhaust systems

Inlet cover bolt

Exhaust manifold bolt

Electrical system

Starter terminal B

Stop solenoid fixing nut

Stop solenoid blind plug

Glow plug

IDI

diameter

×pitch

(mm)

M10×1.75

M8×1.25 M8×1.25 M8×1.25

M10×1.25

M9×1.0

M12×1.25

M18×1.5

M12×1.25

M14×1.5

―

M8×1.25

M16×0.75

M20×1.5 M12×1.5 M12×1.5

M10×1.25

M12×1.0

M22×1.5 M14×1.5 M20×1.5

M8×1.25 M16×1.5

M16×1.5 M8×1.25 M16×1.5

M8×1.25 M8×1.25

M8×1.25 M30×1.5 M30×1.5

M10×1.25

N･m kgf･m lbf･ft

83.4 to 93.2 8.5 to 9.5 61.5 to 68.7

9.81 to 12.7 1.0 to 1.3 7.2 to 9.4

9.81 to 19.6 1.0 to 2.0 7.2 to 14.5

9.8 to 11.8 1.0 to 1.2 7.2 to 8.7

49.0 to 53.9 5.0 to 5.5 36.2 to 39.8

32.4 to 37.3 3.3 to 3.8 23.9 to 27.5

127 to 137 13.0 to 14.0 94.0 to 101.3

147 to 196 15.0 to 20.0 108.5 to 144.6

53.9 to 73.5 5.5 to 7.5 39.8 to 54.2 Equivalent to 7T

19.6 to 24.5 2.0 to 2.5 14.5 to 18.1

39.2 to 49.0 4.0 to 5.0 28.9 to 36.1

9.81 to 13.7 1.0 to 1.4 7.2 to 10.1

34.3 to 39.2 3.5 to 4.0 25.3 to 28.9

49.0 to 58.8 5.0 to 6.0 36.2 to 43.4

24.5 to 34.3 2.5 to 3.5 18.1 to 25.3

20.6 to 24.5 2.1 to 2.5 15.2 to 18.1

29.4 to 41.2 3.0 to 4.2 21.7 to 30.4

14.7 to 24.5 1.5 to 2.5 10.8 to 18.1

44.1 to 53.9 4.5 to 5.5 32.5 to 39.8

34.3 to 44.1 3.5 to 4.5 25.3 to 32.5

10.8 to 12.7 1.1 to 1.3 8.0 to 9.4

9.80 to 12.7 1.0 to 1.3 7.2 to 9.4 Equivalent to 4T

24.5 to 29.4 2.5 to 3.0 18.1 to 21.7

18.6 to 26.5 1.9 to 2.7 13.7 to 19.6

16 to 20 1.6 to 2.0 11.8 to 14.8

39.2 to 49.0 4.0 to 5.0 28.9 to 36.1

14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

9.81 to 11.8 1.0 to 1.2 7.2 to 8.7

39.2 to 49.0 4.0 to 5.0 28.9 to 36.1

14.7 to 19.6 1.5 to 2.0 10.8 to 14.5

Tightening torque

Remarks

1 - 16

2.2 Standard Bolts and Nuts

Thread

diameter

×pitch (mm)

N･m kgf･m lbf･ft N･m kgf･m lbf･ft

SERVICE STANDARDS

4T 7T

M6×1.0

M8×1.25 M10×1.25 M12×1.25

2.94 to 4.90 0.3 to 0.5 2.2 to 3.6 7.85 to 9.80 0.8 to 1.0 5.8 to 7.2

9.80 to 12.7 1.0 to 1.3 7.2 to 9.4 14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

17.7 to 24.5 1.8 to 2.5 0.7 to 1.0 29.4 to 41.2 3.0 to 4.2 21.7 to 30.4

29.4 to 41.2 3.0 to 4.2 21.7 to 30.4 53.9 to 73.5 5.5 to 7.5 39.8 to 54.2

Note: (a) The above table shows the tightening torques for standard bolts and nuts. (b) The values in the table apply when tightened together with spring washers.

(d) Unless otherwise specified, standard bolts and nuts should be tightened to the torques in the table. (e) Do not apply oil to threaded portions (Tighten under dry conditions).

2.3 Standard Eyebolts

Thread diameter

×pitch (mm)

M8×1.25 8±1 0.8±0.1 M10×1.25 15±2 1.5±0.2 M12×1.25 25±3 2.5±0.3

M14×1.5 34±4 3.5±0.4

M16×1.5 44±5 4.5±0.5

M18×1.5 74±5 7.5±0.5

M20×1.5 98±10 10.0±1.0

M24×1.5 147±15 15.0±1.5

M27×1.5 226±20 23.0±2.0

(Dry conditions)

N･m kgf･m lbf･ft

Property class

5.9±0.7

11.1±1.5

18.4±2.2

25.1±3.0

32.5±3.7

54.6±3.7

72.3±7.4

108.4±10.8

166.7±14.8

1 - 17

SERVICE STANDARDS

2.4 Standard Union Nuts

Nominal diameter

Cap nut size

M14×1.5

N･m kgf･m lbf･ft

39 4 28.8

100

120

150

180

200

220

254

(Dry conditions)

M16×1.5 M20×1.5 M22×1.5 M27×1.5 M30×1.5 M30×1.5 M33×1.5 M36×1.5

49 5 36.1

78 8 57.5

98 10 72.3

157 16 115.8

196 20 144.6

245 25 180.7

294 30 216.8

2.5 Taper Bolts

Size

NPTF1/16 4.90 to 7.85 0.5 to 0.8 3.6 to 5.8 7.85 to 11.8 0.8 to 1.2 5.8 to 8.7

PT1/8 7.85 to 11.8 0.8 to 1.2 5.8 to 8.7 14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

PT1/4, NPTF1/4 19.6 to 29.4 2.0 to 3.0 14.5 to 21.7 34.3 to 44.1 3.5 to 4.5 25.3 to 32.5

PT3/8 ― ― ― 53.9 to 73.5 5.5 to 7.5 39.8 to 54.2

Tightening into aluminum Tightening into iron

N･m kgf･m lbf･ft N･m kgf･m lbf･ft

1 - 18

3. Sealants List

Stop solenoid ThreeBond 1212 Governor case

Water drain joint

Threaded part

Oil pressure switch

Torque spring set ThreeBond 1212 Governor case

Sealing item Sealant

ThreeBond 1102 Block

Mating

component

Cylinder block

SERVICE STANDARDS

Applied location

Threaded portion

Press - fit part

Other

Sealing cap

Expansion plug

Oil level gauge guide

Side seal

Main bearing cap (front and rear)

Oil pan

ThreeBond 1102

ThreeBond 1212

ThreeBond

1207C

Cylinder head

Cylinder head,

Cylinder block

Cylinder block,

Main bearing cap

Cylinder block

Holes in the cylinder head and block

Outer periphery

Contact faces with the cylinder block

Oil pan sealing face

1 - 19

SERVICE STANDARDS

1 - 20

TOOLS LIST

1. General Tools····················································································· 1 -22

2. Special Tools······················································································· 1 -23

TOOLS LIST

1. General Tools

No. Description Part number Remarks

Tool set MM413-900

―

Spanner MK96008010

①

Spanner MK96012014

②

Spanner MK96017019

③

Screwdriver MM300110 (-)

④

Tool bag MM300783

⑤

Consists of items ① to ⑤ Width across flats [8×10 mm (0.31×0.39 in.)] Width across flats [12×14 mm (0.47×0.55 in.)] Width across flats [17×19 mm (0.67×0.75 in.)]

1 - 22

TOOLS LIST

2. Special Tools

Description Part number Shape Application

Piston Pin Setting T ool

Camshaft Bushing Installer

Compression Gauge Adapter

Oil Pressure Switch Socket Wrench (26)

31A91-00100

ST332340

ST332270

MD998054

Piston pin removal / installation

Punching / press-fitting of front camshaft bushing

Compression measuring

Oil pressure switch removal / installation

Piston Ring Pliers 31391-12900

Piston ring removal / installation

1 - 23

TOOLS LIST

1 - 24

OVERHAUL TIMING

1. Identifying the Timing for Overhaul······················································ 1-26

2. Measuring the Compression Pressure················································1-27

OVERHAUL TIMING

1. Identifying the Timing for Overhaul

Generally, when the compression pressure has dropped below the specified value, overhaul of the engine needs to be considered. Other parameters should also be considered in making the decision as to whether or not to overhaul the engine, such as engine oil consumption and blow-by gas volume.

Some of the phenomena that may suggest, but are not necessarily the criteria for, the need to overhaul the engine include reduced power, increased fuel consumption, oil pressure drop, difficulty in starting and higher noise level.

More specifically, reduction in compression pressure creates various types of phenomena in various combinations, and this is why it is difficult to make a correct decision. Typical phenomena include:

(a) Reduced power (b) Increased fuel consumption (c) Increased engine oil consumption (d) Increased blow-by gas through the breather due to worn parts such as cylinder liners and pistons (e) Increased blow-by gas due to poor seating of inlet / exhaust valves (f) Poor starting (g) Increased noise levels of various engine parts (h) Abnormal color of exhaust gas after warm-up

Some of those listed above are directly related to the deterioration of the engine and some are not.

Items (b) and (f) are heavily influenced by fuel injection pump displacement, fuel injection timing, wearing of plungers, nozzle conditions, and conditions of electrical equipment such as battery and starter.

The most reliable criterion for engine overhaul is reduced compression pressure due to the wearing of cylinder liners and pistons [item (d)]. This should be combined with other items for comprehensive review to reach a rational conclusion.

1 - 26

2. Measuring the Compression Pressure

(1) Move the control lever to STOP position. (2) Remove the glow plugs from all cylinders.

Install the special tool Compression Gauge Adapter and a compression gauge onto the cylinder being measured.

Special tool Part number

Compression Gauge Adapter ST332270

(3) While cranking the engine with the starter, read

the compression gauge. Note the reading at which the gauge needle stabilizes.

(4) If the measured value is at or below the limit,

overhaul the engine.

(a) Measure all cylinders for compression

pressure. Do not measure only one cylinder and make assumption about the other cylinders as this will lead to a wrong conclusion.

(b) Compression pressure varies depending

on the engine speed. Keep the specified engine speed when measuring the compression pressure.

OVERHAUL TIMING

Compression gauge

Compression gauge adapter

Measuring the compression pressure

Standard value Limit

Engine speed 290 min-1 Compression

pressure Tolerable

difference between cylinders

2.9 MPa

(30 kgf/cm

[421 psi]

0.29 MPa

(3.0 kgf/cm

[42 psi]

or less

)

2.6 MPa

(27 kgf/cm2)

[377 psi]

It is important to regularly check the compression pressure so that you can tell the difference. ・ New or overhauled engines have slightly

higher compression pressure.

・ The compression pressure settles to the

standard value as the piston rings and valve seats fit in.

・ As wear progresses further, the

compression pressure drops.

1 - 27

OVERHAUL TIMING

1 - 28

REMOVAL PREPARATIONS

1. Preparations························································································ 1-30

1.1 Removing the Electric Wiring ································································· 1-30

1.2 Draining the Coolant············································································· 1-30

1.3 Draining the Engine Oil ········································································· 1-30

REMOVAL PREPARATIONS

1. Preparations

1.1 Removing the Electric Wiring

Remove the wiring harnesses from the following equipment. Before removal, attach mating tags etc. onto the terminals to aid reassembly.

・Starter ・Switches

1.2 Draining the Coolant

Loosen the coolant drain plug on the right-hand side face of the cylinder block to drain coolant from the engine.

1.3 Draining the Engine Oil

Remove the engine oil drain plug from the oil pan to drain the engine oil. Install and tighten the drain plug to the specified torque. Oil pan capacity: 3.7 to 6.0 l

(1.0 to 1.6 U.S. gal)

Do not touch the engine oil which may be extremely hot as it can cause burns.

Starter

Starter wiring

Retaining bol

Removing the electric wiring

Drain plug

Coolant drain cock

Tightening torqe:

34.3 to 44.1N㨯m

Drain piug

(3.5 to 4.5kgf㨯m) [25.3 to 32.5 lbf㨯ft]

Drain plug on the oil pan

1 - 30

ENGINE MAIN PARTS - DISASSEMBLY

1. Cylinder Head, Valve Mechanism························································ 2 - 2

1.1 Removing the rocker shaft assembly······················································· 2 - 3

1.2 Disassembling the rocker shaft assembly················································· 2 - 3

1.3 Removing the cylinder head bolts ··························································· 2 - 3

1.4 Removing the cylinder head assembly····················································· 2 - 4

1.5 Removing the valves and valve springs ··················································· 2 - 4

1.6 Removing the valve stem seals ······························································ 2 - 4

2. Flywheel, Timing Gear, Camshaft························································ 2 - 5

2.1 Removing the flywheel·········································································· 2 - 7

2.2 Removing the flywheel housing ······························································ 2 - 7

2.3 Removing the rear plate········································································ 2 - 8

2.4 Removing the oil seal case···································································· 2 - 8

2.5 Removing the tappets··········································································· 2 - 8

2.6 Removing the crankshaft pulley······························································ 2 - 8

2.7 Removing the timing gear case ······························································ 2 - 9

2.8 Measuring the timing gear backlash ························································ 2 - 9

2.9 Removing the idler gear······································································· 2 -10

2.10 Removing the camshaft········································································ 2 -10

2.11 Removing the fuel injection pump camshaft············································· 2 -10

2.12 Separating the gears from the shafts (as required)···································· 2 -10

2.13 Removing the oil pump ·········································································2 -11

2.14 Removing the front plate ·······································································2 -11

3. Cylinder Block, Crankshaft, Pistons, Oil Pan······································ 2 -12

3.1 Removing the oil pan··········································································· 2 -13

3.2 Removing the oil strainer······································································ 2 -13

3.3 Removing the connecting rod caps ························································ 2 -13

3.4 Removing the pistons ·········································································· 2 -14

3.5 Measuring the crankshaft end play························································· 2 -14

3.6 Removing the main bearing caps··························································· 2 -14

3.7 Removing the crankshaft······································································ 2 -14

3.8 Separating the piston from the connecting rod·········································· 2 -15

ENGINE MAIN PARTS - DISASSEMBLY

1. Cylinder Head, Valve Mechanism

Spring fatigue

Clogged oil hole

Damaged threads

Wear

Worn rocker shaft, Clogged oil hole

Spring fatigue, damage

Valve guide wear, damage

Cracks, Damage, Coolant leakage, Oil leakage, Scale formation, Gasket, Carbon deposit

Dent, Wear

Stepped wear, Damage

Wear, Valve face contact

End face wear, damage

Bend

Bottom face distortion

Valve seat contact, damage, wear

Disassembly of cylinder head and valve mechanism

① Rocker cover ② Rocker shaft assembly ③ Push rod ④ Cylinder head bolt

2 - 2

⑤ Cylinder head ⑥ Cylinder head gasket ⑦ Valve cap ⑧ Valve lock

⑨ Retainer ⑩ Valve ⑪ Valve spring ⑫ Valve stem seal

1.1 Removing the rocker shaft assembly

(1) Loosen the rocker stay bolts. Remove the

rocker shaft assembly together with the rocker stay bolts.

(2) Remove the valve caps. (3) Keep the rocker shaft assembly with the rocker

stay bolts.

1.2 Disassembling the rocker shaft assembly

In the course of disassembly, place removed valve rockers as well as the other parts neatly in the order of disassembly so that they can be reassembled back onto their original locations. Doing so, original clearances between the valve rockers and the rocker shaft is restored upon reassembly.

1.3 Removing the cylinder head bolts

Loosen the cylinder head bolts in the order of the numbers illustrated. Do not loosen one bolt completely before moving to the next bolt. Loosen the bolts in a couple of steps.

Note: Before removing the cylinder head bolts,

check the cylinder head components for any fault. If faulty, check the bolts for tighteness with a torque wrench.

ENGINE MAIN PARTS - DISASSEMBLY

Removing the rocker shaft assembly

Disassembling the rocker shaft assembly

Front of engine

10 8

S4L,

S4L2

S3L,S3L2

Tightening order for cylinder head bolts

2 - 3

ENGINE MAIN PARTS - DISASSEMBLY

1.4 Removing the cylinder head assembly

Remove the cylinder head assembly by lifting it straight up.

Note: If the bonding of the cylinder head gasket

prevents the head assembly from being separated from the cylinder block, tap the cylinder head side face on a relatively thick portion with a plastic hammer.

1.5 Removing the valves and valve springs

(1) Remove the valve caps and locks by

compressing the springs using a valve lifter.

(2) Remove the retainers, valve springs and valves. Note: If the valves are reusable, mark them so that

they can be reassembled back onto their original locations. This will ensure that the mated pairs of valves and their seats are maintained.

1.6 Removing the valve stem seals

Remove the valve stem seals by holding each of them with a pair of pliers.

Note: Replace the old valve stem seals with new parts

upon reassembly.

Removing the cylinder head assembly

Removing the valve spring

2 - 4

Removing the valve stem seal

2. Flywheel, Timing Gear, Camshaft

Flywheel end of engine

Cracks, Damage

Frictional surface streak, stepped wear, cracks; Ring gear damage, abnormal wear

ENGINE MAIN PARTS - DISASSEMBLY

Replace: Gasket

Oil seal wear, damage, deterioration

① Flywheel ② Flywheel housing

Disassembly of flywheel

③ Rear plate ④ Oil seal case, Oil seal

2 - 5

ENGINE MAIN PARTS - DISASSEMBLY

Timing gear end of engine

Wear on tappet contact face with cam

Ball bearing wear, noise

Wear, damage of each gear

Replace: Gasket

Cam lobe wear, damage

Replace: Gasket

Speedometer driven gear damage

Cam lobe wear, Bent shaft

Cracks, Damage, Distortion

Crankshaft pulley groove wear, damage

Disassembly of timing gear and camshaft

⑤ Tappet ⑥ PTO gear ⑦ Crankshaft pulley ⑧ Timing gear case ⑨ Idler gear ⑩ Camshaft gear ⑪ Thrust plate ⑫ Camshaft

(Remove ⑩ to ⑫ as an assembly.)

⑬ Fuel injection pump camshaft gear ⑭ Ball bearing ⑮ Fuel injection pump camshaft

(Remove ⑬ to ⑮ as an assembly.) ⑯ Oil pump ⑰ Front plate

2 - 6

2.1 Removing the flywheel

(1) Have an assis tant lock the flywheel pulley using

a wrench or other similar tool to prevent the flywheel from rotating.

(2) Remove one of the flywheel retaining bolts.

The person who locks the crankshaft pulley should do so with extreme care. Each worker should pay attention to the safety of the other.

(3) Install a safety stud (M12×1.25) into the hole

from which the retaining bolt has just been removed. With the stud installed, remove the remaining flywheel retaining bolts.

(4) While holding the flywheel with both hands,

rock the flywheel towards you and away to pull it out straight towards you.

(a) When pulling off the flywheel, be careful not

to cut your hands with the ring gear.

(b) Be careful not to damage the flywheel by

dropping it or bumping it against hard objects.

flywheel. Do not attempt to remove the ring gear unless it is faulty.

ENGINE MAIN PARTS - DISASSEMBLY

Locking the flywheel with a wrench etc.

Locking the flywheel

Safety stud

Removing the flywheel

2.2 Removing the flywheel housing

Remove the flywheel housing retaining bolts. Remove the flywheel housing.

Removing the flywheel housing

2 - 7

ENGINE MAIN PARTS - DISASSEMBLY

2.3 Removing the rear plate

The rear plate has been located into position with knock pins. Therefore, the plate needs to be removed by pulling it straight towards you.

2.4 Removing the oil seal case

Remove the oil seal case retaining bolts. Then, ply away the case from the cylinder block using a screwdriver or other similar tool.

Removing the rear plate

When removing the oil seal case, be careful not to damage the oil seal.

2.5 Removing the tappets

While holding the push rods, remove the tappets from the cylinder block.

Note: The camshaft should not be removed before

removing the tappets. Otherwise, the tappets will drop into the oil pan.

2.6 Removing the crankshaft pulley

(1) Lock the crankshaft so that it will not rotate.

To rock the camshaft, install two safety studs (M12×1.25) into the threaded holes at the rear

end of the crankshaft and then place a bar between the studs.

(2) Remove the crankshaft pulley.

Removing the oil seal case

Push rod

Tappet

Removing the tappet

Lock the crankshaft.

Crankshaft pulley

While trying to remove the crankshaft pulley, the bar may dislodge from the studs. Pay sufficient attention to ensure safety.

2 - 8

Removing the crankshaft pulley

2.7 Removing the timing gear case

Remove the timing gear case retaining bolts. Then, remove the timing gear case.

The front plate is bolted in place separately from the timing gear case. Do not attempt to tap away the front plate together with the timing gear case.

ENGINE MAIN PARTS - DISASSEMBLY

2.8 Measuring the timing gear backlash

Measure the backlash between the gears and use the measurements as references upon reassembly. If any of the measured values exceeds the limit, replace all gears unless otherwise specified.

Unit: mm (in.)

Standard value Limit

Crank gear - idler gear Idler gear - valve camshaft gear Idler gear - pump camshaft gear Valve camshaft gear - PTO gear Pump camshaft

Timing gear backlash

gear - oil pump gear

0.04 to 0.12

(0.0016 to 0.0047)

0.08 to 0.19

(0.0031 to 0.0075)

0.07 to 0.20

(0.0028 to 0.0079)

0.30

(0.0118)

Removing the timing gear case

Front plate retaining bolts

Measuring the timing gear backlash

2 - 9

ENGINE MAIN PARTS - DISASSEMBLY

2.9 Removing the idler gear

Remove the idler gear by sliding it out along the helical teeth.

2.10 Removing the camshaft

(1) Remove the thrust plate retaining bolts. (2) Gently pull out the camshaft, taking care not to

damage it.

Removing the idler gear

When pulling out the camshaft, pay attention to the cams as they tend to be caught by the surrounding parts.

2.1 1 Removing the fuel injection pump camshaft

(1) Remove the stopper bolt (one place).

(2) Using a copper rod or other similar tool, tap the

rear end of the fuel injection pump camshaft. Then, pull it out to the front of the engine.

2.12 Separating the gears from the shafts (as required)

Using a hydraulic jack, remove the camshaft gear and the fuel injection pump camshaft gear from the respective shafts.

Pulling out the camshaft

Removing the pump camshaft stopper bolt

2 - 10

Removing the pump camshaft

2.13 Removing the oil pump

Remove the oil pump retaining bolts. Then, remove the oil pump from the cylinder block.

2.14 Removing the front plate

Remove the four front plate retaining bolts. Then, gently tap the plate with a plastic hammer to remove the gasket.

ENGINE MAIN PARTS - DISASSEMBLY

Removing the oil pump

Removing the front plate

2 - 11

ENGINE MAIN PARTS - DISASSEMBLY

3. Cylinder Block, Crankshaft, Pistons, Oil Pan

Piston ring wear, damage, Ring gap clearance

Piston wear, seizure, streak, Ring groove wear

Damaged crankshaft gear teeth

Damaged plugs and knock pins

Connecting rod bend, twist, Big end thrust clearance

Cylinder damage, stepped wear

Top face distortion

Dirty or clogged oil and water galleries

Crank journal/pin damage, uneven wear, cracks, bend, Clogged oil hole

Caution

The main bearings may be seized due to poor oil maintenance etc. In that case, the crankshaft must be replaced.

Pealing

Scoring

Seizing

Replace: Side seal

Disassembly of cylinder block, crankshaft, pistons and oil pan

① Oil pan ② Oil strainer ③ Connecting rod cap ④ Connecting rod bearing (lower) ⑤ Connecting rod ⑥ Piston pin ⑦ No. 1 ring ⑧ No. 2 ring ⑨ Oil ring

⑩ Piston

(Remove ⑤ to ⑩ as an assembly.) ⑪ Connecting rod bearing (upper) ⑫ Main bearing cap ⑬ Main bearing (lower) ⑭ Crankshaft ⑮ Main bearing (upper) ⑯ Cylinder block

Note: If the crankcase is to be replaced, carefully remove the relief valve and other parts from the old

crankcase for reassembly onto the new crankcase.

2 - 12

3.1 Removing the oil pan

(1) Turn the engine upside down. (2) Remove the oil pan by tapping it on the bottom

corners with a plastic hammer.

Do not insert a chisel or a screwdriver between the oil pan and the cylinder block to remove the oil pan. Otherwise, the oil pan flange face will be deformed.

3.2 Removing the oil strainer

Loosen the nut to remove the oil strainer.

3.3 Removing the connecting rod caps

(1) Place the cylinder block on the side. (2) Mark the cylinder numbers on the connecting

rods and caps to ensure that they will be reassembled in original pairs.

(3) Remove the connecting rod caps.

ENGINE MAIN PARTS - DISASSEMBLY

Removing the oil pan

Removing the oil strainer

Removing the connecting rod caps

2 - 13

ENGINE MAIN PARTS - DISASSEMBLY

3.4 Removing the pistons

(1) Rotate the crankshaft to place the piston being

removed at the top dead center.

(2) Using a wooden piece such as the stem of a

hammer, push the piston and connecting rod assembly on the mating face with the connecting rod cap to remove the assembly from the cylinder block.

3.5 Measuring the crankshaft end play

With a dial gauge installed onto the end of the crankshaft, measure the shaft end play. If the measured value exceeds the limit, replace the flanged No. 3 bearing.

Unit: mm (in.)

Standard value Limit

Crankshaft end play

0.050 to 0.175

(0.0020 to 0.0069)

0.500

(0.0197)

3.6 Removing the main bearing caps

(1) Place the engine so that the cylinder block

mating surface with the oil pan faces upwards.

(2) Loosen the main bearing cap bolts. Then,

remove the caps.

(3) On the front and rear main bearing caps, remove

these using a sliding hammer.

3.7 Removing the crankshaft

(1) Remove the crankshaft by slowly lifting it

straight up.

Removing the piston

Measuring the crankshaft end play

Removing the main bearing cap

When lifting the crankshaft, take care not to damage the main bearings.

(2) The main bearings may fall down, making it not

possible to identify their original locations. Once the crankshaft is removed, place the main bearings neatly and in the original pairs so that they can be reassembled back onto their original locations.

2 - 14

Removing the crankshaft

3.8 Separating the piston from the connecting rod

(1) Remove the piston pin using the special tool

Piston Pin Setting Tool.

Special tool Part number

Piston Pin Setting Tool 31A91-00100

(2) Insert the tool’s push rod into the piston pin hole.

Using a press against the push rod, extract the piston pin.

(3) Use the Piston Pin Setting Tool again to

reassemble the piston and the connecting rod.

ENGINE MAIN PARTS - DISASSEMBLY

Piston Pin Setting Tool

Push rod

Piston pin

Piston arrow mark

Piston

Connecting rod

Identification mark

Tool body

Removing the piston pin (1)

Do not try to remove the piston pin by tapping it. If the piston has been agglutinated and requires a great force to remove, replace it with a new part.

Removing the piston pin (2)

2 - 15

ENGINE MAIN PARTS - DISASSEMBLY

2 - 16

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

1. Cylinder Head, Valve Mechanism······················································· 2 -18

1.1 Measuring the cylinder head bottom face distortion··································· 2 -18

1.2 Measuring the rocker arm bore and the rocker shaft diameter····················· 2 -18

1.3 Measuring the valve spring for squareness and free length ························ 2 -18

1.4 Measuring the push rod for bend ··························································· 2 -19

1.5 Measuring the valve stem diameter························································ 2 -19

1.6 Measuring the clearance between the valve stem and guide······················· 2 -19

1.7 Replacing the valve guide····································································· 2 -20

1.8 Inspecting the valve face······································································ 2 -20

1.9 Correcting the valve face······································································ 2 -21

1.10 Correcting the valve seat······································································ 2 -21

1.11 Lapping the valve face against the valve seat ·········································· 2 -22

1.12 Replacing the combustion jets······························································· 2 -22

2. Flywheel, Timing Gear, Camshaft······················································· 2 -23

2.1 Measuring the flywheel flatness····························································· 2 -23

2.2 Replacing the ring gear········································································ 2 -23

2.3 Measuring the timing gear backlash ······················································· 2 -23

2.4 Measuring the clearance between the idler gear and the idler shaft·············· 2 -24

2.5 Replacing the idler shaft······································································· 2 -24

2.6 Measuring the clearance between the camshaft journal and the bushing ······ 2 -24

2.7 Extracting the camshaft bushing···························································· 2 -25

2.8 Press-fitting the camshaft bushing ························································· 2 -25

2.9 Measuring the camshaft cam height······················································· 2 -25

2.10 Measuring the fuel injection pump shaft cam height ·································· 2 -25

2.11 Inspecting the cam-to-tappet contact······················································ 2 -26

2.12 Measuring the clearance between the tappet and the tappet guide ·············· 2 -26

3. Cylinder Block, Crankshaft, Pistons, Oil Pan······································ 2 -27

3.1 Measuring the piston diameter ······························································ 2 -27

3.2 Measuring the clearance between the piston ring and the ring groove·········· 2 -27

3.3 Measuring the piston ring gap ······························································· 2 -27

3.4 Measuring the clearance between the piston pin and the pin boss··············· 2 -28

3.5 Measuring the connecting rod bend and twist··········································· 2 -28

3.6 Measuring the connecting rod end play··················································· 2 -29

3.7 Inspecting the oil clearance for connecting rod bearings ···························· 2 -29

3.8 Inspecting the main bearings oil clearance ·············································· 2 -30

3.9 Measuring the crankshaft for bend························································· 2 -31

3.10 Removing the crankshaft gear······························································· 2 -31

3.11 Installing the crankshaft gear································································· 2 -31

3.12 Measuring the cylinder bore·································································· 2 -32

3.13 Measuring the cylinder block top face for distortion ··································· 2 -32

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

1. Cylinder Head, Valve Mechanism

1.1 Measuring the cylinder head bottom face distortion

Using a straight edge across the bottom face of the cylinder head and a thickness gauge, measure for any distortion. If the measured distortion exceeds the limit, correct with a surface grinder.

Unit: mm (in.)

Standard value Limit

Cylinder head bottom face distortion

1.2 Measuring the rocker arm bore and the rocker shaft diameter

Measure the rocker arm bore and the rocker shaft diameter to obtain the arm-to-shaft clearance. If the clearance is between the standard value and the limit, replace the rocker arm. If the clearance is equal to or exceeds the limit, replace both the rocker arm and shaft.

Rocker arm inner diameter

Rocker shaft diameter

Arm-to-shaft clearance

Nominal

value

φ19

(0.749)

φ19

(0.749)

―

1.3 Measuring the valve spring for squareness and free length

Measure the valve spring for squareness, free length, etc. If any of the measured values exceeds the limit, replace the spring.

Free length 47 (1.85) 46 (1.81) Squareness

Installed length/load

mm (in.)/N

(kgf) [lbf]

Standard value Limit

θ

39.0 (1.536)/ 131 to 145

(13.3 to 14.7)

[29 to 33]

0.05 less

(0.002 less)

Unit: mm (in.)

Standard value Limit

18.910 to 18.930

(0.7450 to 0.7458)

18.880 to 18.898

(0.7438 to 0.7445)

0.012 to 0.050

(0.0005 to 0.002)

Unit: mm (in.)

θ=2.0º or less

△(gap)=0.2 (0.0079)

or less

Lf=47 (1.8504)

30.1 (1.185)/ 279 to 309

(28.5 to 31.5)

[63 to 69]

0.10

(0.004)

―

0.200

(0.0079)

△=0.5

(0.0197)

across the

entire

length

-15%

Measuring the cylinder head bottom face

Measuring the rocker arm inner diameter

Free length

Measuring the spring for squareness

Measuring locations and directions

for distortion

Measuring direction

Measuring location

Measuring direction

and the rocker shaft diameter

Spring squareness (gap)

and free length

2 - 18

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

1.4 Measuring the push rod for bend

If the measured value exceeds the limit, replace the push rod.

Unit: mm (in.)

Limit

Push rod bend 0.3 (0.012)

Note: Use a dial gauge to measure the push rod for

bend.

1.5 Measuring the valve stem diameter

Measure the valve stem diameter. If the measured value is less than the limit, replace with a new part. Replace also when the valve stem has excessively uneven wear.

Unit: mm (in.)

Inlet

Valve stem diameter

Exhaust

Nominal

value

φ6.6

(0.260)

φ6.6

(0.260)

Standard

value

6.565 to 6.580

(0.2586

to 0.2592)

6.530 to 6.550

(0.2572

to 0.2580)

Limit

6.500

(0.256)

6.500

(0.256)

Push rod

1/21/2

Measuring the push rod bend

Measuring direction

Measuring location

Measuring the valve stem diameter

1.6 Measuring the clearance between the valve stem and guide

Measure the valve guide inner diameter using an inside micrometer. The valve guide wears at the top and bottom ends. Therefore, both ends need to be measured orthogonally. If the measured value exceeds the limit, replace with a new part.

Unit: mm (in.)

Inlet

Valve stem

-to-guide clearance

Exhaust

Installed valve guide protrusion

Note: Before measuring the valve stem-to-guide

clearance, remove carbon from the valve and the valve guide.

Nominal

value

―

(0.394)

Standard

value

0.020 to 0.050

(0.0008

to 0.002)

0.050 to 0.085

(0.002

to 0.003)

9.5 to 10.5

(0.3743

to 0.4137)

Limit

0.100

(0.004)

0.150

(0.006)

―

Measuring

Inside micrometer

direction

Measuring location

Measuring the valve guide inner diameter

2 - 19

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

1.7 Replacing the valve guide

(1) Using a punching tool, remove the valve guide

from the bottom to the top of the cylinder head.

(2) Using a press, insert a new valve guide from the

Cylinder head

top of the cylinder head so that the valve guide protrusion above the cylinder head face is to the indicated dimension.

(3) With the valve guide press-fit into position, insert

a new valve to verify that it slides smoothly inside the valve guide.

(4) Check the valve face-to-seat contact.

1.8 Inspecting the valve face

(1) Apply a thin coating of red lead onto the valve

face. Then, using a valve lapper (available on the market), check the valve face-to-seat contact.

(2) The valve face contact area with the valve seat

should be uniform and in the middle of the face. If not, reface with valve facer.

(3) If the measured valve head margin (valve head

thickness) is less than the limit, replace the valve.

Unit: mm (in.)

Valve head margin

Standard

value

1.35 to 0.65

(0.0531 to 0.0650)

Limit

0.5

(0.0197)

Valve lapper

Valve head sinkage

Valve guide

Valve guide protrusion

above the cylinder head face

Red lead

Inspecting the valve face

Good

Contact area (in the middle of the valve face)

Bad

Valve seat-to-face contact

Valve head sinkage

0.20 in.)

0.5 mm

(0.39

[15 mm]

Valve head margin

(0.59 in.)

2 - 20

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

(4) If the measured valve head sinkage exceeds the

limit, correct the valve seat or replace the cylinder head assembly.

Unit: mm (in.)

Valve head sinkage

Standard

value

0.25 to 0.75

(0.0098±0.0295)

Limit

1.5

(0.0600)

1.9 Correcting the valve face

If the valve face is excessively worn, correct with a valve refacer.

Note: (a) When grinding, set the refacer at 45º relative

to the valve face.

(b) The valve head margin should be maintained

above the limit. If it appears that the minimum margin cannot be maintained after refacing, replace the valve.

1.10 Correcting the valve seat

(1) Before correcting the valve seat, check the valve

stem-to-guide clearance and, if necessary, replace the valve guide.

(2) Grind with a valve seat cutter (available on the

market) or a valve seat grinder until the valve seat width and angle meet specification.

Note: Valve seat correction should be limited as

minimum as possible.

Unit: mm (in.)

Valve seat angle 45° Valve seat width

(3) After correction, lap the valve face against the

valve seat using lapping compound.

Standard

value

1.30 to 1.80

(0.0512 to 0.0709)

Limit

―

2.5

(0.0985)

Refacer set at 45 relative to the valve face

Correcting the valve face

Correcting the valve seat

Valve contact width

1.3 to 1.8 mm (0.05 to 0.07 in.)

Valve seat angle and width

2 - 21

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

1.11 Lapping the valve face against the valve seat

If the valve seat is corrected or the valve is replaced, be sure to lap the valve face against the valve seat in the following manner.

(1) Apply a light coating of lapping compound

evenly over the valve face.

Note: (a) Take care not to allow lapping compound to

attach to the valve stem.

(b) Use medium lapping compound (120 to 150

mesh) first, then finish off with fine lapping compound (200 mesh or above).

is mixed with a small amount of engine oil.

(2) Using a valve lapper, lap the valve face against

the valve seat repeatedly while rotating it gradually.

(3) Wash away the lapping compound in light oil or

other similar liquid.

(4) Apply engine oil onto the lapped faces and lap

them again.

(5) Check the lapped faces for correct contact.

Valve lapper

Lapping the valve face against the valve seat

1.12 Replacing the combustion jets

Replace the combustion jets only when they are cracked or faulty.

(1) To extract the combustion jet, insert a round rod

with a diameter of approx. 6 mm (0.23 in.) into the glow plug mounting hole and gently tap the periphery of the combustion jet bore.

(2) To install the jet, tap it into the mounting hole

using a plastic hammer or other similar tool. Ensure that the nozzle hole faces the center of the cylinder.

Combustion jet

Lapping compound

Round rod

Combustion jet

Extracting the combustion jet

2 - 22

Tapping the combustion jet into place

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

2. Flywheel, Timing Gear, Camshaft

2.1 Measuring the flywheel flatness

Place the flywheel on a surface plate. Run a dial gauge over the frictional surface of the flywheel to measure the flatness. If the measured value exceeds the limit, grind the frictional surface.

Unit: mm (in.)

Flywheel flatness

2.2 Replacing the ring gear

Check the ring gear for fractured or excessively worn gear teeth. If faulty, replace in the following manner.

(1) Removing the ring gear

(a) Using an acetylene torch or other similar

equipment, heat the ring gear evenly.

(b) Using a hammer and a ro d, tap the ring gear

evenly on the entire periphery until the gear

comes off. (2) Installing the ring gear Using a piston heater or other similar equipment,

heat the ring gear [to approximately 150℃ (302 °Ｆ) or less]. With the gear warmed up, install it onto the flywheel with the un-chamfered side first.

2.3 Measuring the timing gear backlash

Measure the backlash between the gears and use the measurements as references upon reassembly . If any of the measured values exceeds the limit, replace all gears unless otherwise specified.

Standard value Limit

Crank gear - idler gear Idler gear - valve camshaft gear Idler gear - pump camshaft gear Valve camshaft gear - PTO gear Pump camshaft

Timing gear backlash

gear - oil pump gear

Standard

value

0.150 (0.0059) or less

0.040 to 0.120

(0.0015 to 0.0047)

0.080 to 0.190

(0.0032 to 0.0075)

0.070 to 0.200

(0.0028 to 0.0079)

Limit

0.50 (0.0197)

Unit: mm (in.)

0.300

(0.0120)

Measuring the flywheel flatness

Ring gear

Removing the ring gear

Measuring the timing gear backlash

Flywheel

2 - 23

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

2.4 Measuring the clearance between the idler gear and the idler shaft

Measure the inner diameter of the idler gear. Measure the idler shaft diameter. If the difference between the two exceeds the limit, replace the idler gear or the idler shaft.

Unit: mm (in.)

Idler gear-to-shaft clearance

Standard

value

0.020 to 0.070

(0.0008 to 0.0028)

Limit

0.200

(0.0079)

2.5 Replacing the idler shaft

When installing the idler shaft into the cylinder block, observe the dimension indicated.

2.6 Measuring the clearance between the camshaft journal and the bushing

Measure the camshaft journal diameter. Measure the inner diameter of the bushing on the cylinder block. If the difference between them exceeds the limit, replace the bushing.

Unit: mm (in.)

Camshaft journal-to-bushing clearance

Standard

value

0.050 to 0.125

(0.0020 to 0.0049)

Limit

0.150

(0.0059)

Measuring direction

Measuring location

Measuring the idler gear-to-shaft clearance

26.5 0.5 mm

0.02 in.)

(1.04

Replacing the idler shaft

Measuring location

Measuring direction

Measuring the camshaft journal diameter

2 - 24

Measuring the camshaft bushing inner

diameter

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

2.7 Extracting the camshaft bushing

(1) Remove the camshaft bushing using the special

tool Camshaft Bushing Installer in the following manner.

Special tool Part number

Camshaft Bushing Installer ST332340

(2) Remove the oil pan. (3) Using the punching side of the installer, punch

the bushing off and into the cylinder block. Take it out of the block by slightly deforming it.

2.8 Press-fitting the camshaft bushing

Press-fit the bushing while ensuring that the oil holes of the bushing align with the oil galleries in the cylinder block.

2.9 Measuring the camshaft cam height

Measure the camshaft cam height as illustrated. If the measured value is less than the limit, replace the camshaft.

Unit: mm (in.)

Camshaft cam height (including lobe)

Standard

value

35.720±0.1

(1.4073±0.0039)

Limit

34.720

(1.3679)

2.10 Measuring the fuel injection pump shaft cam height

Measure the cam height as illustrated. If the measured value is less than the limit, replace the fuel injection pump shaft.

Unit: mm (in.)

Fuel injection pump shaft cam height (including lobe)

Standard

value

44±0.1

(1.736±0.0039)

Limit

(1.6942)

Cylinder block front face

Camshaft bushing installer

Camshaft bushing

Extracting the camshaft bushing

1 mm (0.04 in.)

Notch on the bushing

1 mm (0.04 in.)

Mating mark

Oil hole

Press-fitting the camshaft bushing

Measuring location

Measuring direction

Measuring the camshaft cam height

Measuring location

Measuring direction

Measuring the fuel injection pump shaft cam

height

2 - 25

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

2.11 Inspecting the cam-to-tappet contact

Inspect the tappet contact face with the cam. If abnormally worn, replace the tappet.

2.12 Measuring the clearance between the tappet and the tappet guide

Measure the tappet diameter. Measure the tappet guide bore in the cylinder block. If the difference between them exceeds the limit, replace the tappet.

Unit: mm (in.)

Limit

Tappet-to-guide clearance 0.150 (0.0059)

Measuring the clearance between the tappet

Good

Bad

Cam-to-tappet contact

Measuring direction

and the tappet guide

Bad

Measuring direction

2 - 26

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

3. Cylinder Block, Crankshaft, Pistons, Oil Pan

3.1 Measuring the piston diameter

Using a micrometer, measure the piston diameter across the piston skirt and squarely with the piston pin, as illustrated. If the measured value is less than the limit, replace with a new part. The maximum allowable variation in weight among the pistons on the same engine is 5 grams (0.18 oz).

Unit: mm (in.)

STD

Piston diameter

Max. allowable variation in weight among pistons on the same engine:

3.2 Measuring the clearance between the piston ring and the ring groove

(1) Measure the piston ring-to-groove clearance. If

the measured value exceeds the limit, replace the piston ring.

Standard value Limit

No. 1 ring 0. 09 to 0.11 (0.003 5 to 0.0 043) 0.300 (0.012) No. 2 ring 0. 07 to 0.11 (0.002 8 to 0.0 043) 0.200 (0.008) Oil ring 0.03 to 0.07 (0.0012 to 0.0028) 0.200 (0.008)

(2) With the new piston ring installed, measure the

ring-to-groove clearance again. If the measured value still exceeds the limit, replace the piston.

3.3 Measuring the piston ring gap

Install the piston ring being measured into the gauge or a new cylinder. Then, using a thickness gauge, measure the piston ring gap. If the measured value exceeds the limit, replace all rings of the relevant piston as a set.

Gauge bore size

Note: To install a piston ring into the gauge, use a

piston to push the ring evenly.

Standard value Limit

Piston ring gap

No. 1 ring 0.15 to 0.30 (0.006 to 0.012) No. 2 ring 0.15 to 0.35 (0.006 to 0.014) Oil ring 0.20 to 0.40 (0.008 to 0.016)

0.25 OS

0.50 OS

Nominal

value

78.00 (3.07)

78.25 (3.08)

78.50 (3.09)

STD=78

+0.03

25 OS=78.25 50 OS=78.50

Standard

value

77.93 to 77.95

(3.070 to 3.071)

78.18 to 78.20

(3.080 to 3.081)

78.43 to 78.45

(3.090 to 3.090)

5 g (0.18 oz)

or less

Unit: mm (in.)

mm (3.07

+0.03

+0.0012

mm (3.08 mm (3.09

Unit: mm (in.)

Limit

77.80

(3.065)

78.05

(3.075)

78.30

(3.085)

in.)

+0.0012

1.50

(0.06)

―

No. 1 piston ring-to-groove clearance

Measuring the piston ring-to-groove clearance

Thickness gauge

in.) in.)

Measure squarely with piston pin

Measuring location

Measuring the piston diameter

No. 2 piston ring-to-groove clearance

Measuring the piston ring gap

2 - 27

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

3.4 Measuring the clearance between the piston pin and the pin boss

Measure the piston pin diameter. Measure the bore size of the piston pin boss. If the difference between them exceeds the limit, replace with new parts.

Unit: mm (in.)

Piston pin diameter

Piston pin-to-boss clearance

Nominal

value

φ23

(0.9062)

―

Standard

value

22.944 to 23.000

(0.9039 to 0.9062)

0.006 to 0.018

(0.0002 to 0.0007)

Limit

―

0.050

(0.002)

Measuring the piston pin-to-boss clearance

3.5 Measuring the connecting rod bend and twist

(1) Measure C and l as illustrated. If measured C is

more than 0.05 mm (0.0020 in.) per 100 mm (3.937 in.) of measured l, correct the connecting rod using a press.

Unit: mm (in.)

Connecting rod bend and twist

Standard value Limit

0.05/100

(0.002/3.940)

or less

0.15/100

(0.006/3.940)

(2) Normally, a connecting rod aligner is used to

measure the connecting rod for bend and twist.

Note: Before measuring the connecting rod for bend,

tighten the connecting rod cap nuts to the specified torque.

(3) When measuring connecting rod bend with the

piston installed to the connecting rod, place the piston/rod assembly on a surface plate such that the top of piston lies on the plate. Then, insert a round rod with the same diameter as the crank pin into the connecting rod large end. Using a dial gauge, measure the top of the round rod for any variation in height.

Piston pin

Connecting rod bend

Measuring the connecting rod bend and twist

Tightening torque for connecting rod cap nut

32.4 to 37.3 N (3.3 to 3.8 kgf [23.9 to 27.5 lbf

Using a connecting rod aligner to measure

Measuring location

ft]

0.05

100

Connecting rod twist

the rod bend and twist

Measuring direction

0.05 100

2 - 28

Using a dial gauge to measure

the connecting rod for bend

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

3.6 Measuring the connecting rod end play

Install the connecting rod and the rod cap onto the mating crank pin. Tighten the cap nuts to the specified torque. Using a thickness gauge, measure the gap (end play). If the measured value exceeds the limit, replace the connecting rod and the rod cap.

Unit: mm (in.)

Connecting rod end play

Standard value Limit

0.10 to 0.35

(0.004 to 0.014)

0.50

(0.012)

3.7 Inspecting the oil clearance for connecting rod bearings

(1) Install the connecting rod bearings (upper and

lower) into the connecting rod large end. Tighten the cap nuts to the specified torque. Measure the inner diameter of the bearings.

(2) Measure the diameter of the mating crank pin.

The difference between the bearing inner diameter and the crank pin diameter is the oil clearance for the bearings.

Unit: mm (in.)

Crank pin diameter

Oil clearance for connecting rod bearings

(3) If the measured oil clearance exceeds the limit,

replace the bearings. With the new bearings installed, measure the oil clearance again.

(4) If the measured oil clearance still exceeds the

limit, use the undersize bearings [0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.), 0.75 mm (0.0295 in.) U.S.]

Also, grind the crank pin accordingly to the

finished dimension shown below.

Crank pin undersize

Nominal

value

φ48

(1.8912)

―

Standard

value

47.950 to 47.964

(1.8892 to 1.8897)

0.025 to 0.072

(0.0010 to 0.0028)

Crank pin ground dimensions

Unit: mm (in.)

0.25 (0.0098)

0.50 (0.0197)

0.75 (0.0295)

Finished dimension

φ47.75 φ47.50 φ47.25

-0.035

-0.050

-0.035

-0.050

-0.035

-0.050

(1.881 (1.871 (1.861

Limit

―

0.150

(0.0059)

-0.0014

)

-0.0020

-0.0014

)

-0.0020

-0.0014

)

-0.0020

Tightening torque

32.4 to 37.3 N (3.3 to 3.8 kgf [23.9 to 27.5 lbf

ft]

Thickness gauge

Measuring the connecting rod end play

Tightening torque

32.4 to 37.3 N (3.3 to 3.8 kgf [23.9 to 27.5 lbf

Measuring direction

Measuring location

Measuring the connecting rod bearings

inner diameter

Measuring direction

Measuring location

Measuring the crank pin diameter

m m)

ft]

2 - 29

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

(a) If any of the crank pins need grinding, grind

all crank pins on the same crankshaft to the same dimension.

(b) Finish the fillets to a radius of 2 mm (0.08

in.).

3.8 Inspecting the main bearings oil clearance

(1) Place the main bearings (upper and lower) onto

the cylinder block and the main bearing cap. Assemble them together and tighten the cap bolts to the specified torque. Measure the inner diameter of the main bearings.

(2) Measure the diameter of the mating crank journal.

The difference between the main bearings inner diameter and the crank journal diameter is the oil clearance for the main bearings.

Unit: mm (in.)

Crank journal diameter(STD)

Oil clearance for main bearings

(3) If the measured oil clearance exceeds the limit,

replace the main bearings. With the new bearings installed, measure the oil clearance again.

(4) If the measured oil clearance still exceeds the

limit, use the undersize bearings [0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.), 0.75 mm (0.0295 in.) U.S.]

Also, grind the crank journal accordingly to the

finished dimension shown below.

Crank journal ground dimensions

Crank journal undersize

Nominal

value

φ52

(2.0488)

―

0.25 (0.0098)

0.50 (0.0197)

0.75 (0.0295)

Standard

value

51.985 to 52.000

(2.0482

to 2.0488)

0.030

to 0.077

(0.0012

(0.0040)

to 0.003)

Unit: mm (in.)

Finished dimension

φ51.75 φ51.50

φ51.25

-0.015 0

-0.015

(2.0374 (2.0276 (2.0177

Limit

―

0.100

-0.006 0

-0.006

) )

)

Measuring direction

Measuring location

Measuring the main bearings inner diameter

Measuring direction

Measuring the crank journal diameter

R2.5 mm (0.098 in.)

Finished radius dimension of fillet

Tightening torque

49.0 to 53.9 N (5.0 to 5.5 kgf [36.2 to 39.8 lbf

Measuring location

m m)

ft]

2 - 30

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

(a) If any of the crank journals need grinding,

grind all crank journals on the same crankshaft to the same dimension.

(b) Finish the fillets to a radius of 2.5 mm (0.098

in.).

3.9 Measuring the crankshaft for bend

Support the crankshaft at the front and rear crank journals with a V block. Using a dial gauge, measure the center journal for a swing of the gauge needle (to both directions). If the measured value moderately exceeds the standard value, correct the bend by grinding. If the measured value far exceeds the standard value, correct the bend using a press or other similar equipment. If the measured value exceeds the limit, replace the crankshaft.

Unit: mm (in.)

Standard value Limit

Crankshaft bend 0.025 (0.0010) 0.050 (0.0020)

3.10 Removing the crankshaft gear

Use a gear puller to remove the crankshaft gear.

Note: Do not remove the crankshaft gear unless the

crankshaft or the gear is faulty.

3.11 Installing the crankshaft gear

(1) Install the key to the crankshaft. (2) Align the keyway in the crankshaft gear with the

key on the crankshaft, and press-fit the gear fully until it stops.

R2 mm (0.08 in.)

Finished radius dimension of fillet

Measuring the crankshaft bend

Gear puller

Removing the crankshaft gear

Align these

Installing the crankshaft gear

2 - 31

ENGINE MAIN PARTS - INSPECTION AND CORRECTION

3.12 Measuring the cylinder bore

Using a cylinder gauge, measure the cylinder bore and cylindricality. If any of the cylinders exceeds the limit, bore all cylinders of the same engine and replace the pistons and the piston rings with oversize parts. Measure at 3 locations as shown in the fig., each in directions A and B.

Unit: mm (in.)

Pistons and piston

rings available

Size Code

STD STD

0.25 OS 25

0.50 OS 50

Cylinder bore out of

cylindricality

Cylinder bore

Standard

value

+0.03

φ78

(3.07

φ78.25

(3.08

φ78.50

(3.09

+0.012

+0.03

)

±0.01

(0.0004)

max

Standard

(0.0080)

Limit

value

+0.2

―

3.13 Measuring the cylinder block top face for distortion

Using a straight edge across the top face of the cylinder block and a thickness gauge, measure for any distortion. If the measured distortion exceeds the limit, correct by grinding the top face.

Unit: mm (in.)

Cylinder block top face distortion

Standard

value

0.05 (0.002) max

Limit

0.10 (0.004)

Measuring direction

Measuring location

Measuring the cylinder bore

Measuring location, Measuring direction

Measuring the cylinder block top face for

distortion

The combined grinding limit for the cylinder block top face and the mating cylinder head bottom face is 0.2 mm (0.008 in.).

2 - 32

ENGINE MAIN PARTS - REASSEMBLY

1. Cylinder Block, Crankshaft, Pistons, Oil Pan······································ 2 -34

1.1 Installing the main bearings ·································································· 2 -34

1.2 Installing the crankshaft········································································ 2 -34

1.3 Installing the main bearing caps····························································· 2 -34

1.4 Inserting the side seals ········································································ 2 -35

1.5 Assembling the piston onto the connecting rod········································· 2 -36

1.6 Installing the piston rings······································································ 2 -37

1.7 Installing the piston/connecting rod assemblies ········································ 2 -37

1.8 Installing the connecting rod caps·························································· 2 -38

1.9 Installing the oil strainer ······································································· 2 -38

1.10 Installing the oil pan············································································· 2 -38

2. Flywheel, Timing Gear, Camshaft······················································· 2 -40

2.1 Installing the front plate········································································ 2 -40

2.2 Installing the oil pump·········································································· 2 -40

2.3 Rotating the engine············································································· 2 -40

2.4 Tapping the fuel injection pump camshaft into place·································· 2 -40

2.5 Installing the camshaft ········································································· 2 -41

2.6 Installing the idler gear········································································· 2 -41

2.7 Installing the timing gear case······························································· 2 -41

2.8 Tightening the crankshaft pulley nut ······················································· 2 -42

2.9 Installing the PTO gear ········································································ 2 -42

2.10 Inserting the tappets············································································ 2 -42

2.11 Installing the oil seal case····································································· 2 -42

2.12 Installing the rear plate········································································· 2 -43

2.13 Installing the flywheel housing······························································· 2 -43

2.14 Installing the flywheel··········································································· 2 -43

3. Cylinder Head, Valve Mechanism······················································· 2 -44

3.1 Cleaning the bottom face of the cylinder head·········································· 2 -44

3.2 Installing the valve stem seals······························································· 2 -44

3.3 Installing the valve springs···································································· 2 -44

3.4 Installing the valve locks······································································· 2 -44

3.5 Installing the cylinder head gasket ························································· 2 -45

3.6 Installing the cylinder head ··································································· 2 -45

3.7 Tightening the cylinder head bolts·························································· 2 -45

3.8 Inserting the push rods ········································································ 2 -45

3.9 Assembling the rocker shaft assembly···················································· 2 -46

3.10 Installing the rocker shaft assembly························································ 2 -46

3.11 Adjusting the valve clearance································································ 2 -46

3.12 Installing the rocker cover····································································· 2 -46



ENGINE MAIN PARTS - REASSEMBLY

1. Cylinder Block, Crankshaft, Pistons, Oil Pan

To reassembly, follow the disassembly sequence in reverse.

1.1 Installing the main bearings

(1) Install the main bearings (upper and lower) onto

the cylinder block and the main bearing cap, ensuring that the lugs engage with the lug grooves.

(2) The flanged main bearings should be installed

onto the No. 3 crank journal.

(3) Lightly coat the inner surface of each bearing

with engine oil.

1.2 Installing the crankshaft

(1) Wash the crankshaft thoroughly in wash oil.

Dry the crankshaft using compressed air.

(2) While holding the crankshaft horizontally, lower

it slowly onto the cylinder block.

(3) Lightly coat the crank journals with engine oil.

1.3 Installing the main bearing caps

(1) Apply sealant onto the mating faces of the front

and rear main bearing caps and the cylinder block.

Installing the main bearings

Installing the crankshaft

Sealant ThreeBond 1212

(2) Install the main bearing caps so that their arrow

marks point the front of the engine and that the cap numbers are in the order from the front to the rear of the engine.

(3) Loosely tighten the cap retaining bolts.

Install the front and rear main bearing caps so that they are flush with the cylinder block.

2 - 34

Correct installation of main bearing caps

Installing the main bearing cap

(4) Tighten the main bearing cap bolts progressively

in diagonal sequence and tighten to the specified torque at the final step.

(5) Ensure that the crankshaft rotates smoothly,

without any binding.

(6) Measure the crankshaft end play (refer to Page

2-14). If the measured value exceeds the limit, loosen and retighten the main bearing cap bolts.

1.4 Inserting the side seals

(1) Apply sealant to the periphery of new side seals.

ENGINE MAIN PARTS - REASSEMBLY

Tightening torque:

49.0 to 53.9 N (5.0 to 5.5 kgf [36.2 to 39.8 lbf

m m)

ft]

Tightening the main bearing cap bolts

Ensure that the crankshaft rotates smoothly

Side seal

Sealant ThreeBond 1212

(2) With the seal radius faced outside, insert the side

seals with your hand into the front and rear of the cylinder block.

(3) Using a flat piece, push the last portion of the

side seals fully into the cylinder block, taking care not to bend the seals.

Radius Radius

Face the side seals correctly

Inserting the side seal

2 - 35

ENGINE MAIN PARTS - REASSEMBLY

1.5 Assembling the piston onto the connecting rod

(1) Install the special tool Piston Pin Setting Tool

onto a hydraulic press.

Special tool Part number

Piston Pin Setting Tool 31A91-00100

(2) Place the connecting rod on the tool. Coat the

connecting rod small end with engine oil.

(3) Install the piston onto the connecting rod so that

the arrow on the top face of the piston faces the side of the connecting rod that has the engine type embossed. Insert the piston pin slightly into the pin boss.

(4) Using the push rod of the tool, press the piston

pin into the pin boss.

Piston Pin Setting Tool

Inserting the piston pin

When the hydraulic press needle almost exceeds the 50 kgf (110.23 lbf) while the piston pin is being pressed, stop pressing the pin. Reset the push rod and start pressing again.

(5) With the piston and the connecting rod

assembled together, check that they slide smoothly about the piston pin.

Inserting the piston pin with a hydraulic press

Check that the piston and the connecting rod

slide smoothly about the piston pin

2 - 36

1.6 Installing the piston rings

Using the special tool Piston Ring Pliers, install the No. 1 ring, No. 2 ring, and oil ring onto the piston.

Special tool Part number

Piston Ring Pliers 31391-12900

ENGINE MAIN PARTS - REASSEMBLY

Top face mark

No. 1 compression ring

No. 2 compression ring

Note: (a) Install the rings so that “T” mark faces the

top of the piston.

(b) The oil ring should be installed so that the

butt joint of the coil spring is located at 180o relative to the ring gap as illustrated.

1.7 Installing the piston/connecting rod assemblies

(1) Apply engine oil onto the periphery of the piston

and the piston rings.

(2) Position the piston ring gaps as illustrated. The

gaps should not face the same direction as the piston pin or squarely with the piston pin

(3) Install the connecting rod bearing (upper) onto

the connecting rod, ensuring that the lug engages with the lug groove.

(4) Rotate the crankshaft until the crank pin onto

which the piston/connecting rod assembly is being installed comes to the top dead center.

(5) Face the piston/connecting rod assembly so that

the arrow mark on top of the piston points to the timing gear case side (front) of the engine.

(6) Using a piston guide (available on the market),

insert the piston/connecting rod assembly from the top of the cylinder block down.

Oil ring

Piston ring arrangement

Coil spring butt joint

180

Oil ring gap

Assembling the oil ring

Oil ring gap

Front of engine

No. 1 ring gap

No. 2 ring coil spring butt joint

Locating the piston ring gaps

Piston guide

Do not tap the piston too hard. Doing so may break the piston rings or damage the crank pin.

Installing the piston/connecting rod assembly

2 - 37

ENGINE MAIN PARTS - REASSEMBLY

1.8 Installing the connecting rod caps

(1) While pressing the top of piston down to keep

the connecting rod large end attached to the crank pin, rotate the crankshaft 180°.

(2) Install the connecting rod bearing (lower) onto

the connecting rod cap, ensuring that the lug engages with the lug groove.

(3) Install the bearing cap onto the connecting rod,

observing the mating marks made during disassembly.

Note: If a new connecting rod without mating marks is

being installed, ensure that the lug grooves, designed to prevent the bearings from turning, are assembled on the same side.

(4) Tighten the connecting rod cap nuts alternately

in several steps, and finally to the specified torque.

(5) Check the connecting rod end play.

1.9 Installing the oil strainer

(1) Position the cylinder block with the oil pan

mounting face up.

(2) Install the oil strainer so that the tip of the

strainer will not contact the oil pan when installed. Tighten the nut to the specified torque.

1.10 Installing the oil pan

(1) Clean the mating faces of the cylinder block and

the oil pan. Apply sealant to the entire periphery of the oil pan mounting face of the cylinder block.

Lug groove

Cylinder No.

Installing the connecting rod cap

Tightening torque:

32.4 to 37.3 N (3.3 to 3.8 kgf [23.9 to 27.5 lbf

ft]

Tightening the connecting rod cap nuts

Tightening torque:

24.5 to 29.4 N (2.5 to 3.0 kgf [18.1 to 21.7 lbf

Installing the oil strainer

ft]

2 - 38

Sealant ThreeBond 1207C

Applying sealant to the oil pan mounting face

of the cylinder block

ENGINE MAIN PARTS - REASSEMBLY

Note: (a) Apply sealant in a bead of 4 mm (0.1575 in.)

and in the illustrated pattern.

(b) Cutting the end of the sealant tube at the

illustrated location will provide a 4 mm (0.1575 in.) bead.

(2) Tighten the oil pan retaining bolts diagonally in

several steps, and finally to the specified torque.

R17 (4 front and rear locations in total)

9.5 mm (0.37 in.)

36 mm

Rear

(1.42 in.)

R40 corresponding to hole centers (same for all 4 corners)

Apply oil pan liquid gasket here (top face)

R7 from hole center (same for all 17 holes)

Sealant application pattern

Cut here

Cutting the end of sealant tube

Tightening torque:

9.80 to 12.7 N (1.0 to 1.3 kgf [7.2 to 9.4 lbf

ft]

Apply sealant as lined

Front

5 mm (0.20 in.)

Installing the oil pan

2 - 39

ENGINE MAIN PARTS - REASSEMBLY

2. Flywheel, Ti ming Gear, Camshaft

To reassembly, follows the disassembly sequence in reverse.

2.1 Installing the front plate

(1) Completely scrape off any remaining gasket

from the cylinder block and the front plate.

(2) Install the front plate onto the cylinder block.

Tighten the four retaining bolts.

(3) Apply sealant onto the side of the gasket that is

to be mated to the front plate. Attach the gasket onto the front plate. The sealant will prevent the gasket from moving.

2.2 Installing the oil pump

(1) Ensure that the oil pump is correctly fitted with

packing.

(2) Install the oil pump onto the crankcase.

Tighten the three retaining bolts evenly.

(3) Ensure that the oil pump gear rotates smoothly.

2.3 Rotating the engine

(1) Install two studs (M12×1.25) into the flywheel

mounting holes in the crankshaft.

(2) Place a bar between the studs and rotate the

crankshaft until the No. 1 cylinder comes to the top dead center.

2.4 Tapping the fuel injection pump camshaft into place

(1) Insert the fuel injection pump camshaft

(complete with the bearing and the gear) into the cylinder block.

(2) Tap the gear with a plastic hammer until the

bearing is completely inserted into the mounting hole in the cylinder block.

(3) Ensure that the fuel injection pump camshaft

rotates smoothly.

(4) Tighten the stopper bolt.

Front plate retaining bolts

Installing the oil pump

Rotating the engine

Tapping the fuel injection pump camshaft

into place

2 - 40

2.5 Installing the camshaft

(1) Apply engine oil to the journals and cams. (2) Insert the camshaft (co mplete with the camshaft

gear) into the cylinder block.

Take care not to damage the journals or cams when inserting the camshaft into the cylinder block.

ENGINE MAIN PARTS - REASSEMBLY

Apply engine oil

(3) Using an appropriate torque wrench and socket,

tighten the thrust plate mounting bolts to the specified torque.

(4) Ensure that the camshaft rotates smoothly.

Also ensure that there is some end play by sliding the camshaft to the front and rear.

2.6 Installing the idler gear

(1) Apply engine oil to the idler shaft. (2) Install the idler gear so that the timing marks are

aligned with those of the meshing gears.

(3) Check the backlash between the gears. Note: Refer to “Measuring the timing gear backlash”

on Page 2-23.

2.7 Installing the timing gear case

(1) Apply sealant onto the gasket and stick it in

place. Then, install the timing gear case onto the front plate.

(2) Apply engine oil to the oil seal lips. (3) Tighten the timing gear case retaining bolts.

Installing the camshaft

Tightening torque:

9.8 to 11.8 N (1.0 to 1.2 kgf [7.2 to 8.7 lbf

Installing the thrust plate

Aligning the timing marks

ft]

Installing the timing gear case

2 - 41

ENGINE MAIN PARTS - REASSEMBLY

2.8 Tightening the crankshaft pulley nut

(1) Use the studs and the bar described in Section

“2.3” to lock the crankshaft.

(2) While locking the crankshaft, tighten the

crankshaft pulley nut to the specified torque.

The locking studs and bar should be sufficiently strong to avoid any accident.

2.9 Installing the PTO gear

Drive the PTO gear into the timing gear case. Ensure that the side of the gear with no oil hole faces the rear of the engine.

2.10 Inserting the tappets

Apply engine oil to the periphery of the tappets, and insert them into the tappet holes in the cylinder block.

2.11 Installing the oil seal case

(1) Install a new oil seal case gasket. (2) Apply engine oil to the entire periphery of the

oil seal lips, and install the oil seal and case onto the cylinder block.

Tightening torque: 147 to 196 N (15.0 to 20.0 kgf [108.5 to 144.7 lbf

ft]

Tightening the crankshaft pulley nut

Driving the PTO gear into place

Apply engine oil

Inserting the tappet

2 - 42

Installing the oil seal case

2.12 Installing the rear plate

(1) Install a new rear plate gasket. (2) Install the rear plate, aligning it with the dowel

pins. Tighten the retaining bolts to the specified torque.

Note: Install the rear plate complete with the starter.

This will facilitate the subsequent reassembly.

2.13 Installing the flywheel housing

Install the flywheel housing, aligning it with the knock pins. Tighten the retaining bolts evenly.

Note: Replace the knock pins with new parts if the

knock pins are worn or if a new flywheel housing is being installed.

2.14 Installing the flywheel

(1) Screw in a safety stud (M12×1.25) into one of

the flywheel retaining bolt holes at the rear end of the crankshaft.

(2) Insert the flywheel through the safety stud and

onto the crankshaft.

(3) Loosely tighten the three flywheel retaining

bolts.

(4) Replace the safety stud with the 4th retaining

bolt, and loosely tighten it.

(5) Using a torque wrench or other similar tool, lock

the crankshaft pulley nut.

(6) Tighten the flywheel retaining bolts to the

specified torque.

ENGINE MAIN PARTS - REASSEMBLY

Tightening torque:

53.9 to 73.5 N (5.5 to 7.5 kgf [39.8 to 54.2 lbf

m m)

ft]

Installing the rear plate

Installing the flywheel housing

Safety stud

Installing the flywheel

Tightening torque: 127 to 137 N (13.0 to 14.0 kgf [94.0 to 101.3 lbf

ft]

The person who locks the crankshaft pulley nut should do so with extreme care. Communicate with each other closely to prevent accidents.

Tightening the flywheel bolts

2 - 43

ENGINE MAIN PARTS - REASSEMBLY

3. Cylinder Head, Valve Mechanism

To reassembly, follows the disassembly sequence in reverse.

3.1 Cleaning the bottom face of the cylinder head

Scrape off any gasket from the mating faces of the cylinder head and the cylinder block, taking care not to damage the faces.

Note: Use a scraper to roughly remove the remaining

gasket. Then, using an oil stone and engine oil, polish away fine residue.

3.2 Installing the valve stem seals

Using a box wrench No. 12, install the valve stem seal on the valve guide. Ensure that the seal has been correctly installed the valve guide.

Note: Incorrectly installed stem seals will lead to oil

leaking down through the seal-to-guide gap and into the combustion chamber.

3.3 Installing the valve springs

Install the valve spring with the white enamel-coated end facing up.

3.4 Installing the valve locks

Install the valve lock by compressing the valve spring using a valve lifter.

Removing the old gasket

Box wrench No. 12

Inserting the valve stem seal

White enamel coating

Installing the valve springs

Do not compress the valve spring too hard as the bottom of the retainer may contact and damage the stem seal.

2 - 44

Installing the valve lock

3.5 Installing the cylinder head gasket

(1) Ensure that the cylinder block top face and the

piston top faces are clean.

(2) Insert two guide studs (M10×1.25) into the bolt

holes in the cylinder block.

(3) Install the cylinder head gasket through the studs

and onto the cylinder block.

Do not use liquid packing or other similar sealant.

ENGINE MAIN PARTS - REASSEMBLY

Guide stud

Installing the cylinder head gasket

3.6 Installing the cylinder head

Install the cylinder head through the guide studs and onto the cylinder block.

3.7 Tightening the cylinder head bolts

(1) Remove the guide studs. Install the cylinder

head bolts.

(2) Tighten the cylinder head bolts in the order

illustrated in a couple of steps, and finally tighten to the specified torque.

3.8 Inserting the push rods

(1) Insert the push rods into the holes in the cylinder

head.

(2) Ensure that the ball end of the push rod rests on

the recess of the tappet.

Guide stud

Installing the cylinder head

Front of engine

Tightening torque:

83.4 to 93.2 N

(8.5 to 9.5 kgf [61.5 to 68.7 lbf

S3L,S3L2

S4L,S4L2

Tightening order for the cylinder head bolts

ft]

Inserting the push rod

2 - 45

ENGINE MAIN PARTS - REASSEMBLY

3.9 Assembling the rocker shaft assembly

(1) Assemble the rocker shaft components to ensure

the correct reassembly and tighten the retaining bolt.

(2) Ensue that the rocker arms move smoothly.

3.10 Installing the rocker shaft assembly

(1) Install the valve caps. (2) Install the rocker shaft assembly onto the

cylinder head. Tighten the mounting bolts to the specified torque.

3.11 Adjusting the valve clearance

Refer to “1.3 Adjusting the valve clearance” on Page 8-3.

3.12 Installing the rocker cover

(1) Ensure that the rocker cover is correctly fitted

with gasket.

(2) Tighten the rocker cover retaining bolts to the

specified torque.

Retaining bolt

Assembling the rocker shaft assembly

Tightening torque:

9.81 to 19.6 N (1.0 to 2.0 kgf [7.2 to 14.5 lbf

ft]

Installing the rocker shaft assembly

Adjusting the valve clearance

Tightening torque:

9.81 to 12.7 N (1.0 to 1.3 kgf [7.2 to 9.4 lbf

m m)

ft]

2 - 46

Installing the rocker cover

FUEL SYSTEM - REMOVAL

1. Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles········· 3 - 2

1.1 Removing the fuel injection pipes···························································· 3 - 3

1.2 Removing the fuel injection nozzles························································· 3 - 3

2. Governor ····························································································· 3 - 4

2.1 Removing the governor assembly··························································· 3 - 5

2.2 Removing the governor weights······························································ 3 - 5

3. Fuel Injection Pumps··········································································· 3 - 6

Removing the fuel injection pumps ································································ 3 - 7

FUEL SYSTEM - REMOVAL

1. Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles

Replace: Gasket

Removal of fuel injection pipes, fuel leak-off pipe, and fuel injection nozzles

① No. 1 fuel injection pipe ② No. 2 fuel injection pipe ③ No. 3 fuel injection pipe

To prevent dirt from entering into the fuel system, plug the injection pump openings, the nozzle inlet connectors, and the injection pipes.

④ No. 4 fuel injection pipe ⑤ Fuel leak-off pipe ⑥ Fuel injection nozzle

3 - 2

1.1 Removing the fuel injection pipes

Remove the fuel injection pipes and the fuel leak-off pipe.

Note: To prevent dirt from entering into the system,

plug the fuel injection pump openings and the fuel injection nozzle connectors.

1.2 Removing the fuel injection nozzles

Using a wrench, loosen the fuel injection nozzles. Remove the nozzles and gaskets.

Note: Use a wire or a screwdriver to remove the fuel

injection nozzle gaskets from the cylinder head. Faulty gaskets should be replaced.

FUEL SYSTEM - REMOVAL

Removing the fuel injection pipe

Removing the fuel injection nozzle

3 - 3

FUEL SYSTEM - REMOVAL

2. Governor

Replace: Gasket

<Removal sequence> ① Bolt

Removal of the governor

② Governor assembly

③ Gasket

3 - 4

2.1 Removing the governor assembly

(1) Remove the tie-rod cover. (2) Using a pair of cutting pliers, remove the tie-rod

spring. Disconnect the tie-rod from the pumps.

(3) Remove the governor assembly.

2.2 Removing the governor weights

(1) Remove the sliding sleeve. (2) Remove the sliding sleeve shaft and then the

governor weights.

FUEL SYSTEM - REMOVAL

Removing the governor assembly

Removing the governor weights

3 - 5

FUEL SYSTEM - REMOVAL

3. Fuel Injection Pumps

<Removal sequence> ① Bolt

Removal of the fuel injection pumps

② Fuel injection pump

③ Shim

3 - 6

Removing the fuel injection pumps

(1) Remove the tie-rod cover. (2) Using a pair of cutting pliers, remove the tie-rod

spring. Disconnect the tie-rod from the pumps.

(3) Removing the fuel injection pumps Note: Note the thickness of shim pack for the

adjustment of the fuel injection timing.

FUEL SYSTEM - REMOVAL

Removing the tie-rod

Adjusting shim

Removing the fuel injection pump

3 - 7

FUEL SYSTEM - REMOVAL

3 - 8

FUEL SYSTEM - DISASSEMBLY,

INSPECTION AND REASSEMBL Y

1. Fuel Injection Nozzles ········································································ 3 -10

1.1 Disassembling the fuel injection nozzles ················································· 3 -10

1.2 Inspecting the fuel injection nozzle························································· 3 -10

1.3 Reassembling the fuel injection nozzle ··················································· 3 -12

2. Fuel Injection Pumps·········································································· 3 -13

2.1 Inspecting the fuel injection pumps on vehicle·········································· 3 -13

2.2 Disassembling the fuel injection pumps··················································· 3 -13

2.3 Inspecting the fuel injection pumps························································· 3 -16

2.4 Reassembling the fuel injection pumps··················································· 3 -17

3. Governor ···························································································· 3 -20

3.1 Disassembling and inspecting the governor············································· 3 -20

3.2 Reassembling the governor ·································································· 3 -21

3.3 Installing the torque spring set······························································· 3 -21

4. Fuel Pump·························································································· 3 -22

Inspecting the fuel pump············································································· 3 -22

5. Fuel Filter ··························································································· 3 -23

5.1 Disassembling, inspecting and reassembling the fuel filter

(with a selector cock)··········································································· 3 -23

5.2 Inspecting the fuel filter (cartridge type)··················································· 3 -23

Mitsubishi S3L, S3L2, S4L, S4L2 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual