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Engine
S4S
Service manual
Mitsubishi S4S Service Manual
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Also See for S4S
:
Users manual and maintenance manual
(48 pages)
,
Operation & maintenance manual
(93 pages)
,
Service manual
(157 pages)
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Introduction
How to Use this Manual
Methods of Indication
Terms Used in this Manual
Abbreviations, Standards, Etc.
Units of Measurement
General Contents
Safety Cautions
Danger of Fire and Explosion
Danger of Entanglement
Danger of Burns
Beware of Exhaust Gas Poisoning
Danger of Hearing Problems
Beware of Falling Equipment
Cautions Regarding Engine Oil and LLC
Cautions Regarding Battery
Response to Abnormalities
General
Outline
External View (In-Line Fuel Injection Pump and Distributor-Type Fuel Injection Pump)
Left View of Engine
Right View of Engine
S4S-DT In-Line Fuel Injection Pump Specification
S6S In-Line Fuel Injection Pump Specification
S6S-DT In-Line Fuel Injection Pump Specification
S4S Distributor-Type Fuel Injection Pump Specification
Left/Right View of Engine
S4S-DT Distributor-Type Fuel Injection Pump Specification
S6S Distributor-Type Fuel Injection Pump Specification
S6S-DT Distributor-Type Fuel Injection Pump Specification
Outline of Fuel System
S4S In-Line Fuel Injection Pump (Swirl Chamber) Specification
S4S-DT In-Line Fuel Injection Pump (Direct Injection) Specification
S4S Distributor-Type Fuel Injection Pump (Swirl Chamber) Specification
S4S-DT Distributor-Type Fuel Injection Pump (Direct Injection) Specification
S6S In-Line Fuel Injection Pump (Swirl Chamber) Specification
S6S-DT In-Line Fuel Injection Pump (Direct Injection) Specification
S6S Distributor-Type Fuel Injection Pump (Swirl Chamber) Specification
S6S-DT Distributor-Type Fuel Injection Pump (Direct Injection) Specification
Outline of Lubrication System
Outline of Cooling System S4S
Outline of Cooling System S4S-DT
Outline of Cooling System S6S
Outline of Cooling System S6S-DT
Outline of Inlet and Exhaust Systems
Non-Turbocharged Engine
Turbocharged Engine
Engine Serial Number
Engine Model and Application Code
S4S In-Line Fuel Injection Pump Specification
S6S In-Line Fuel Injection Pump Specification (May Differ in Detail)
S4S Distributor-Type Fuel Injection Pump Specification (May Differ in Detail)
S6S Distributor-Type Fuel Injection Pump Specification (May Differ in Detail)
Tips on Disassembly and Reassembly
Maintenance Standards
Maintenance Standards Table
Tightening Torque Table
Important Bolts and Nuts
Engine Main Parts
Fuel System
Lubricating System
Cooling System
Inlet and Exhaust Systems
Electrical System
Standard Bolts and Nuts
Standard Eye Bolts
Standard Union Nuts
Standard Plugs
Sealants and Lubricants Table
Special Tools
Overhaul Instructions
Determination of Overhaul Timing
Testing Compression Pressure
Preparation for Disassembly
Cutting off Fuel Supply
Removing Electrical Wiring
Draining Coolant
Draining Engine Oil
Disassembly of Main Engine Parts
Disassembly and Inspection of Cylinder Head and Valve Mechanism
Removing Rocker Shaft Assembly
Disassembling Rocker Shaft Assembly
Removing Cylinder Head Assembly
Removing Valves and Valve Springs
Disassembly of Flywheel
Removing Flywheel Housing
Damper, Timing Gears and Camshaft
Disassembly of Timing Gears
Removing Damper (S6S)
Removing Crankshaft Pulley
Removing Cover
Removing Fuel Injection Pump
Removing Oil Pan
Removing Timing Gear Case
Removing Oil Pump Gear
Removing Idler Gear
Removing Camshaft
Separating Camshaft Gear
Removing Front Plate
Disassembly of Pistons, Connecting Rods, Crankshaft and Crankcase
Removing Connecting Rod Caps
Preparation for Pulling out Pistons
Pulling out Pistons
Removing Piston Rings
Removing Piston Pins
Removing Main Bearing Caps
Removing Crankshaft
Removing Tappets
Inspection and Repair of Main Engine Parts
Cylinder Head and Valve Mechanisms
Measuring Rocker Bushing Inside Diameter and Rocker Shaft Outside Diameter
Measuring Valve Stem Outside Diameter
Measuring Clearance between Valve Stems and Valve Guides
Replacing Valve Guides
Checking Valve Faces
Contact of Valves with Valve Seats
Repairing Valve Faces
Repairing Valve Seats
Replacing Valve Seats
Inserting Valve Seats
Facing up Valves and Valve Seats
Measuring Tilt and Free Length of Valve Springs
Measuring Distortion of Cylinder Head Bottom
Surface
Measuring Bend of Pushrods
Replacing Combustion Jets
Measuring Flatness of Flywheel
Checking Flywheel for Deflection
Checking Ring Gear
Replacing Ring Gear
Measuring Backlash and End Play
Measuring Cam Height
Measuring Bend of Camshaft
Measuring Camshaft Journal Outside Diameter and Camshaft Bore Diameter
Driving Camshaft Bushing
Measuring Idler Bushing Inside Diameter and Shaft Outside Diameter
Replacing Idler Shaft
Checking V-Belt Groove of Crankshaft Pulley for
Wear
Checking Damper (S6S)
Crankcase, Pistons, Connecting Rods, Crankshaft and Tappets
Measuring Distortion of Crankcase Top Surface
Measuring Cylinder Inside Diameter
Measuring Piston Outside Diameter
Measuring Clearance of Piston Ring Abutments
Measuring Piston Ring Grooves
Measuring Piston Pin Bore Diameter and Piston Pin Outside Diameter
Measuring Piston Projection
Measuring Clearance between Connecting Rod Bearings and Crank Pins
Measuring Clearance between Connecting Rod Bushings and Piston Pins
Replacing Connecting Rod Bushings
Checking Bend and Twist of Connecting Rods
Checking Connecting Rod Bearings
Measuring End Play of Connecting Rods
Replacing Connecting Rods
Measuring Crank Journal Outside Diameter
Measuring Crank Pin Outside Diameter
Grinding Crankshaft
Measuring End Play of Crankshaft
Measuring Bend of Crankshaft
Replacing Crankshaft Gear
Checking Oil Seal Contact Surface
Installing Sleeve
Removing Sleeve
Checking Main Bearing Surfaces
Measuring Clearance of Main Bearing
Checking Contact Surfaces of Tappet Cams
Measuring Clearance between Tappets and Tappet Guide Holes
Reassembly of Main Engine Parts
Installing Main Bearings, Thrust Plates and Tappets
Installing Main Bearing Caps
Crankcase, Tappets, Crankshaft, Pistons and Connecting Rods
Installing Crankshaft
Measuring Crankshaft End Play
Installing Main Bearing Cap Bolts
Installing Piston Rings
Preparation for Installing Pistons
Installing Connecting Rod Tightening Bolts and Bearings
Orienting Piston Ring Abutments
Installing Pistons
Installing Connecting Rod Caps
Timing Gears
Installing Front Plate
Installing Camshaft Gear and Thrust Plates
Installing Idler Gear
Installing Oil Pump Gear
Check and Adjustment after Installing Timing Gears
Checking Valve Timing
Installing Oil Seals
Installing Timing Gear Case
Installing Oil Pan
Installing Fuel Injection Pump
Installing Cover
Installing Crankshaft Pulley
Installing Damper (S6S)
Installing Flywheel Housing
Installing Stem Seals
Installing Valves and Valve Springs
Installing Cylinder Head
Inserting Pushrods
Reassembling Rocker Arms and Rocker Shaft Assembly
Installing Rocker Shaft Assembly
Checking Top Dead Center of No. 1 Piston on Compression Stroke
Adjusting Valve Clearance
Removal of Fuel System
Fuel Filter and Fuel Pipes
Swirl Chamber Specification
Direct Injection Specification
Removal of Fuel Injection Pipes, Fuel Leak-Off Pipes and Fuel Injection Nozzles (In-Line Fuel Injection Pump)
Removal of Fuel Injection Pipes, Fuel Leak Injection Nozzles (Distributor-Type Fuel Injection Pump)
Removal of Fuel Injection Pump (In-Line and Distributor-Type Fuel Injection Pumps)
Disassembly and Inspection of Fuel Filter (In-Line Fuel Injection Pump, Non-Turbocharged/Turbocharged)
Disassembly and Inspection of Fuel Filter (Distributor-Type Fuel Injection Pump)
Reassembly of Fuel Filter (In-Line Fuel Injection Pump, Non-Turbocharged)
Reassembly of Fuel Filter (In-Line Fuel Injection Pump, Turbocharged)
Reassembly of Fuel Filter (Distributor-Type Fuel Injection Pump)
Fuel Injection Nozzles
Disassembly of Fuel Injection Nozzles (Swirl Chamber Specification)
Disassembly of Fuel Injection Nozzles (Direct Injection Specification)
Inspection of Fuel Injection Nozzles
Checking Fuel Injection Nozzle for Valve Opening Pressure
Checking Fuel Spray Pattern from Fuel Injection Nozzle
Cleaning or Replacing When Spraying Badly
Reassembly of Fuel Injection Nozzles (Swirl Chamber Specification)
Reassembly of Fuel Injection Nozzles (Direct Injection Specification)
Installation of Fuel System
Installation of Fuel Injection Pump (In-Line and Distributor-Type Fuel Injection Pumps)
Alignment Marks of Timing Gears
Installation of Fuel Injection Pipes, Fuel Leak-Off Pipes and Fuel Injection Nozzles (Distributor-Type Fuel Injection Pump)
Installation of Fuel Injection Pipes, Fuel Leak-Off Pipes and Fuel Injection Nozzles (In-Line Fuel Injection Pump)
Installation of Fuel Filter and Fuel Pipes
Removal of Lubrication System
Removal of Oil Filter and Relief Valve
Removal of Oil Cooler
Removal of Oil Pump, Oil Pan and Oil Strainer
Disassembly, Inspection and Reassembly of Lubrication System
Disassembly of Oil Pump
Inspection of Oil Pump
Measuring Clearance between Outer Rotor and Inner Rotor
Measuring End Play between Rotors and Pump Case
Measuring Clearance between Outer Rotor and Pump Case
Measuring Clearance between Main Shaft and Pump Case
Measuring Clearance between Main Shaft and Oil Pump Bushing
Installing Oil Pump Bushing
Reassembly of Oil Pump
Disassembly and Inspection of Oil Cooler
Inspection of Oil Filter
Inspection of Relief Valve
Inspection of Safety Valve
Installation of Lubrication System
Installation of Oil Pump, Oil Pan and Oil Strainer
Installation of Oil Cooler
Installation of Oil Filter and Relief Valve
Removal of Cooling System
Removal of Cooling Fan, Fan Pulley and V-Belt
Removal of Thermostat
Removal of Water Pump
Disassembly, Inspection and Reassembly of Cooling System
Disassembly of Thermostat
Inspection of Thermostat
Disassembly of Water Pump
Inspection of Water Pump
Installation of Cooling System
Installation of Water Pump
Installation of Thermostat
Installation of Cooling Fan, Fan Pulley and V-Belt
Removal of Inlet and Exhaust Systems
Removal of Turbocharger (In-Line Fuel Injection Pump Specification)
Removal of Turbocharger (Distributor-Type Fuel Injection Pump Specification)
Removal of Inlet Manifold
Distributor-Type Fuel Injection Pump Specification
In-Line Fuel Injection Pump Specification
Removal of Exhaust Manifold
Disassembly, Inspection and Reassembly of Inlet and Exhaust Systems
Inspection of Inlet and Exhaust Manifolds
Measurement of Exhaust Manifold Distortion
Installation of Inlet and Exhaust System
Installation of Exhaust Manifold
Installation of Inlet Manifold
Installation of Turbocharger (In-Line Fuel Injection Pump Specification)
Installation of Turbocharger (Distributor-Type Fuel Injection Pump Specification)
Removal of Electrical System
Removal of Starter
Removal of Alternator
Removal of Glow Plug
Disassembly, Inspection and Reassembly of Electrical System
Disassembly of Starter (12 V, 24 V)
Disassembly of Starter M8T60373 (24 V-5 Kw)
Removing Magnet Switch
Removing Rear Bracket
Removing Brush Holder
Removing Center Bracket
Removing Pinion Shaft
Removing Ball Bearings
Inspection and Repair of Starter
Inspecting Brushes
Inspecting Armature
Inspecting Field Coil
Inspecting Bearings
Inspecting Overrunning Clutch
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Operation & Maintenance Manual
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