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SERVICE
MANUAL
MITSUBISHI
DIESEL
ENGINES
S4S
ses
March
2002
J..
!!!!I’D’!S~~!~!.
Mitsubishi S4S: Available Instructions
Note for Owners:
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Summary of Contents:
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[Page 1] Mitsubishi S4S SERVICE MANUAL MITSUBISHI DIESEL ENGINES S4S ses March 2002 J.. !!!!I’D’!S~~!~!. |
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[Page 2] Mitsubishi S4S … |
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[Page 3] Mitsubishi S4S Foreword This service manual is written to familiarize you with the maintenance of your S4S and S6S Diesel Engine. If the engine is carefully maintained it will deliver a long productive life and efficient performance marked by power and economy. Bef… |
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[Page 4] Mitsubishi S4S Notes, Cautions, Warnings, Dangers Notes, cautions, wamings, dangers are used in this manual to emphasize important or critical instructions or advice. (&OANGER) &WARNING (&CAUTION) (NOTE) ‘Ierms Used in This Manual Indicates the mos… |
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[Page 5] Mitsubishi S4S Summary of Manual Contents Group 1. General 2. Maintenance Standards 3. Special Tools 4. Overhaul Instructions 5. Adjustments, Bench Test, Performance Tests 6. Engine Auxiliaries Removal and Installation 7. Engine Main Parts 8. Inlet and Exhaust Syst… |
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[Page 6] Mitsubishi S4S … |
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[Page 7] Mitsubishi S4S GENERAL 1. Outline 1- 2 1.1 External View 1- 2 1.2 Engine Serial Number Location 1- 6 1.3 Engine Model and Application Codes 1- 6 2. Specifications 1- 7 3. Tips on Disassembly and Reassemb1y 1-13 3.1 Disassembly 1-13 3.2 Reassembly 1-13 Di |
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[Page 8] Mitsubishi S4S GENERAL 1. Outline 1.1 External View [848 — Standard] Fuel filter Fuel injection pump Fan IFront I Fuel feed pump C’-I) n Inlet manifold Fuel injection nozzle ETR stop solenoid Governor Coolant drain plug Dipstick I Rear I <>-tt-++—Flywhe… |
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[Page 9] Mitsubishi S4S GENERAL [S4S-DT — Standard] IRear I ::n » .’ (I~I Fuel injection pump n Fuel filter <, I/In, let manifold h—.rT,—-1JI Fuel injection nozzle Fan ~ rr-. ~ tJUI fT»i»T»i: ~ r~~ ~?n’~ I hl vETRstopsolenoid Water pu… |
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[Page 10] Mitsubishi S4S GENERAL [868 — Standard] uel filter Fuel injection pump lnlet manifold I Rear I Flywheel Oil filter Dipstick Governor t:~~~ah~~::~~r Coolant drain plug Oil drain plug %~-1—-le:::::~I-~e:::::~~—:v: Fuel injection nozzle 1NI»bb!l;a ETR stop sol… |
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[Page 11] Mitsubishi S4S GENERAL [S6S-DT — Standard] Fan Water pump IFront I Gil filler Exhaust manifold I Rea.. I Starter Fuel injection nozzle ETR stop solenoid ).F~~~~~~ Governor I Rear I Flywheel Gil drain plug Dipstick ILef! view I Turbocharger Thermostat Alternator IFr… |
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[Page 12] Mitsubishi S4S GENERAL 1.2 Engine Serlal Number Location The engine serial number is located on the side of the crankcase. 1.3 Engine Model and Application Codes s D s — [Q][ïJ ~ 1-6 T : Equipped with turbocharger D : Direct injection type Series code Number of cy… |
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[Page 13] Mitsubishi S4S 2. Specifieations GENERAL Model designation S4S S4S-DT Type Water-cooled, 4-stroke cycle No. of cylinders — arrangement 4- in line Combustion chamber type Swirl chamber Direct injection Valve mechanism Overhead Cylinder bore x stroke mm[in.] 94 x 120… |
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[Page 14] Mitsubishi S4S GENERAL Model designation S4S S4S-DT Refill capacity (engine water jacket) 5.5 [1.5] 5 [1.3] liter [U.S. gal.] Type Centrifugal Water pump Speedrationto crankshaft 1.3 Ei Capacity 160 [42.3] at 0.075 MPa [0.75 kgf/cm’] discharge pressure 2 liter… |
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[Page 15] Mitsubishi S4S GENERAL Model designation S4S I S4S-DT Type 3-phase, with rectifier Output V-A 12-50 Working speed min:’ 1000 to 18000 Altemator Rated output generating 5000 Ei speed min:’ s <IJ Maximum perrnissib1e>-. 22000 co C;; speed min:’ o… |
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[Page 16] Mitsubishi S4S GENERAL Model designation S6S S6S-DT Type Water-cooled, 4-stroke cycle No. of cylinders — arrangement 6-in line Combustion chamber type Swirl chamber Direct injection Valve mechanism Overhead Cylinder bore x stroke mm [in.] 94 x 120 [3.70 x 4.72] Pis… |
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[Page 17] Mitsubishi S4S GENERAL Model designation S6S S6S-DT Refill capacity (engine water jacket) 9 [2.4] 8 [2.1] liter [U.S. gal.] Type Centrifugal Water pump Speedrationto crankshaft 1.3 Ei Capacity 160 [42.3] at 0.075 MPa [0.75 kgf/cm»] discharge pressure B liter [… |
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[Page 18] Mitsubishi S4S GENERAL Model designation S6S I S6S-DT Type 3-phase, with rectifier Output V-A 12 -50 Working speed min-I 1000 to 18000 a Altemator Rated output generating 5000 B speed min-I ‘» >. Maximum permissible ‘» 22000 ‘<‘J… |
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[Page 19] Mitsubishi S4S 3. Tips on Disassembly and Reassembly This service manual covers recommended procedures to be followed when servicing diesel engines. It also contains information on special tools required and basic safety precautions. It is the responsibility of ser… |
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[Page 20] Mitsubishi S4S … |
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[Page 21] Mitsubishi S4S MAINTENANCE STANDARDS 1. Maintenance Standards Table 2- 2 2. Tightening Torques , 2- 9 2.1 Important Bolts and Nuts 2- 9 2.2 Standard Bolts 2-10 2.3 Standard Studs 2-10 2.4 Standard Plugs .. 2-10 3. Sealants and Lubricants Table 2-11 |
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[Page 22] Mitsubishi S4S MAINTENANCE STANDARDS 1. Maintenance Standards Table Unit: mm [in.] Nominal Assembly Standard Repair Service Group Inspeetion Point Limit Limit Remark Value (Standard Clearance) (Clearance) (Clearance) Maximum min-I, (no-load) According to engine Adj… |
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[Page 23] Mitsubishi S4S MAINTENANCE STANDARDS Unit: mm [in.] Nominal Assembly Standard Repair Service Group Inspeetion Point Limit Limit Remark Value (Standard Clearance) (Clearance) (Clearance) ~ 14.000 to 14.018 14.100 … Inside diameter 0 ..0 [0.5512 to 0.5519] [0.5551]… |
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[Page 24] Mitsubishi S4S MAINTENANCE 8TANDARD8 Unit: mm [in.] Nominal Assembly Standard Repair Service Group Inspeetion Point Limit Limit Remark Value (Standard Clearance) (Clearance) (Clearance) Inside diameter of 19.010 to 19.030 S rocker bushing 19 [0.7484 to 0.7492] &quo… |
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[Page 25] Mitsubishi S4S MAINTENANCE STANDARDS Unit: mm [in.] Graup Inspeetion Point Repair Service Nominal Assembly Standard Limit Limit Value (StandardClearance) (Clearance) (Clearance) Remark 1.50 [0.0591] (0.200) ([0.0079]) (0.150) ([0.0059]) (0.150) ([0.0059]) 0.30 to 0… |
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[Page 26] Mitsubishi S4S MAINTENANCE STANDARDS Unit:mm [in.] Nominal Assembly Standard Repair Service Group Inspeetion Point Limit Limit Remark Value (Standard Clearance) (Clearance) (Clearance) Clearance between (0.009 to 0.050) (0.100) Replace bushing. shaft and bushing ([… |
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[Page 27] Mitsubishi S4S MAINTENANCE STANDARDS Unit: mrn [in.] Nominal Assembly Standard Repair Service Group Inspeetion Point Limit Limit Remark Value (Standard Clearance) (Clearance) (Clearance) 17.65 18.14 to 19.12 Make shirn adjustrnent. DI (180) (l85 to 195) Pressure va… |
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[Page 28] Mitsubishi S4S MAINTENANCE 8TANDARD8 Unit: mm [in.] Nominal Assembly Standard Repair Service Group Inspeetion Point Limit Limit Remark Value (Standard Clearance) (Clearance) (Clearance) Diameter of 38.7 38.1 commutator [1.S2] [I.SO] Runout of 0.03 0.1 commutator [0… |
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[Page 29] Mitsubishi S4S 2. Tightening Torques 2.1 Important Bolts and Nuts MAINTENANCE 8TANDARD8 Thread Width Tightening Torque Description Dia. x Pitch across flats, Remark (M-thread) mm N·m kgf-rn IbHt Cylinder head M12 x 1.75 19 113 to 123 11.5 ta 12.5 83 ta 90 Rocker c… |
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[Page 30] Mitsubishi S4S MAINTENANCE STANDAROS Thread Width Tightening Torque Description Dia. x Pitch across flats, Remark (M-thread) mm N·m kgf-m lbf-ft Overheat warning unit M16 x 1.5 19 20.6 to 24.5 2.1 to 2.5 15.2 to 18.1 (thermostat) Starter terminal B M8 x 1.25 12 9…. |
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[Page 31] Mitsubishi S4S 3. Sealants and Lubricants Table MAINTENANCE STANDARDS Apply to Mating part Sealant or Lubricant How to Use üil pan Crankcase Three Bond 12Ü?C Apply to seal. Rear bearing cap Rear bearing cap Three Bond 1212 Apply to corners befare seat on crankcas… |
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[Page 32] Mitsubishi S4S … |
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[Page 33] Mitsubishi S4S SPECIAL rOOlS Special TooI List 3-2 |
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[Page 34] Mitsubishi S4S SPECIAL TOOLS Special Tooi List Taal name Valve spring pusher Valve guide remave Valve guide installer Stem seal installer Valve seat insert caulking taal Piston ring pliers Part No. 30691—04500 32A91—o0300 3 2A91—o0 100 32A91-10200 Inlet valve: 3… |
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[Page 35] Mitsubishi S4S SPECIAL TOOLS Tooi name Part No. Shape Use Oil seal sleeve installer 30691-13010 set Crankshaft rear oil seal sleeve installation Engine tuming Compression pressure measurement Compression pressure measurement Compression pressure measurement 58309-7… |
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[Page 36] Mitsubishi S4S … |
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[Page 37] Mitsubishi S4S OVERHAUL INSTRUCTIONS 1. Determination of Overhaul Timing 4-2 2. Testing the Compression Pressure 4-3 |
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[Page 38] Mitsubishi S4S OVERHAUL INSTRUCTIONS 1. Determlnation of Overhaul Timing In most cases the engine should be overhauled when the engine’s compression pressure is low. Other factors that indicate the necessity of engine overhaul are as follows: (a) Decreased pow… |
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[Page 39] Mitsubishi S4S 2. Testlag the Compression Pressure (1) Remove the injection nozzle from the cylinder head where the compression pressure is to be measured. (2) On the direction injection type engine, attached gage adaptor (32A9l-01100) to the cylinder,and conneet t… |
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[Page 40] Mitsubishi S4S OVERHAUL INSTRUCTIONS ……——-i[&CAUTION JI——-. (a) Measure the compression pressure at regular intervals to obtain correct data. (b) The compression pressure will be slightly higher ina new or overhauled engine due to new piston rings, … |
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[Page 41] Mitsubishi S4S ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 1. Adjustments 5- 2 1.1 Valve Clearance 5- 2 1.2 Fuel System Bleeding 5- 3 1.3 Fuel Injection Timing 5- 4 1.4 No-load Minimum (Idling) Speed and Maximum Speed Setting 5- 5 1.5 V-belt Inspeetion and Adjustmen… |
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[Page 42] Mitsubishi S4S ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 1. Adjustments 1.1 ValveClearance Valve clearance should be inspected and adjusted when the engine is cold. Unit: mm [in.] Item Assembly Standard Valve clearance InIet 0.25 [0.0098] (cold setting) Exhaust (l… |
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[Page 43] Mitsubishi S4S (2) Adjusting (a) Loosen the loek nut of the adjusting screw. Adjust the clearance by tuming the screw in either direction to the extent that the gage is slightly gripped between the rocker arm and valve cap. (b) After adjusting the clearance, tighte… |
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[Page 44] Mitsubishi S4S ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 1.3 Fuel Injection Timing The injection timing varies according to the output, speed and specifications of the engine. Be sure to verify the timing by referring to the specifications. (1) Bringing the No.l c… |
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[Page 45] Mitsubishi S4S (3) Adjusting injecting timing (a) If the injection timing is retarded, move the injection pump toward the crankcase. If the timing is advanced, move the pump away from the crankcase. (b) One graduation of the scale on the injection pump coupling cha… |
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[Page 46] Mitsubishi S4S ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS (1) Starting engine (a) Pull speedcontrollevertothe high speed side. Operate the starter switch to crank the engine. (b) The engine will fire up at 150 min-lof cranking speed. When the engine fires, hold the… |
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[Page 47] Mitsubishi S4S (3) Setting rack (maximum output) (a) Hold the speed controllever at the position for the indicated output and speed. (b) Under this condition, check to be sure that the engine is running in a steady state. (c) With the engine running in a steady sta… |
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[Page 48] Mitsubishi S4S ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS (5) Deterrnining speed regulation (speed droop) [I] Speed regulation upon removing load (a) Run the engine with the speed control lever set at the position for the rated load and speed. (b) Vnder this condit… |
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[Page 49] Mitsubishi S4S (6) Setting no-load maximum speed (make governor notch adjustment) (a) This adjustment is to be made by turning the adjustingscrew for the swivelleverto increase ordecrease the preload of the govemor spring. (b) To gain access to the adjusting screw,… |
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[Page 50] Mitsubishi S4S ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 1.5 V-belt Inspeetion and Adjustment Push the belt inward with thumb pressure exerted midway between the pulleys, as shown, to check the belt tension (deflection). If the tension is incorrect, loosen the adj… |
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[Page 51] Mitsubishi S4S 2. Bench Testing An overhauled engine should be tested for performance on a dynamometer. This test is also for breaking in the major running parts of the engine. To test the engine, follow the procedures described below: 2.1 Starting Up (l) Inspeet t… |
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[Page 52] Mitsubishi S4S ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 3. Performance Tests There are various performance test procedures, and here the procedures for «Earth moving machinery Engines, Part 1 : Test code of net power (JIS D 0006-1)» and «Earth movi… |
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[Page 53] Mitsubishi S4S ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS (2) Calculation of corrected power Multiply the measured brake power or torque by the calculated diesel engine correction factor (see below) to obtained a corrected value. Corrected output =Correction factor… |
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[Page 54] Mitsubishi S4S … |
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[Page 55] Mitsubishi S4S ENGINE AUXlllARIES REMOVAl AND INSTAllATION 1. Preparation 6- 2 2. Engine Auxiliaries Removal 6- 2 3. Engine Auxiliaries Installation 6- 7 |
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[Page 56] Mitsubishi S4S ENGINE AUXILIARIE8 REMOVAL AND IN8TALLATION This section explains the procedures and tips for removal and installation of the auxiliaries — the pre1iminary process to go through for overhauling the engine. 1. Preparation (a) Shut off the fue1 supply,… |
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[Page 57] Mitsubishi S4S Return pipe (2) Exhaust manifold Remove the bolts that hold exhaust manifold to the cylinder head. Remove the manifold and gasket from the head. (3) Fuel filter (a) Disconneet fuel pipes and from the fuel filter. (b) Remove fuel filter complete with … |
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[Page 58] Mitsubishi S4S ENGINE AUXILIARIE8 REMOVALAND IN8TALLATION (6) Fuel injection nozzles (direct injection type) Remove gland, then remove nozzle and gasket from the cylinder head. (7) Fuel injection nozzles (swirl chamber type) Remove nozzle and gasket. (8) Glow plugs… |
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[Page 59] Mitsubishi S4S (10) Fuel injection pump (a) Remove oil pipe. (b) Remove bolts that hold the gear case cover. (c) Remove bolts that hold the flange plate. Remove pump with gear and flange from the front plate. (Some engines are not equipped with pump bracket.) (11) … |
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[Page 60] Mitsubishi S4S ENGINEAUXILIARIE8 REMOVALAND IN8TALLATION (14) Water pump (a) Remove the bolts that holdfan and pulley and remove them. (b) Remove the bolts that hold water pump and remove the pump and gaskets. (15) Starter Disconneet harness from starter. Remove nu… |
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[Page 61] Mitsubishi S4S 3. Engine Auxiliaries Installation To install the engine auxiliaries, follow the removal procedures in reverse. After installation, service them as follows: (a) Refill the engine with the recommended oil up to the specified level. (b) Refill the cool… |
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[Page 62] Mitsubishi S4S … |
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[Page 63] Mitsubishi S4S ENGINE MAIN PARTS 1. Cylinder Heads and ValveMechanism 00.0000.00000000.0000000000.000000.00.0000.0000000000.0000.0000.00′.000000.00″000000. 7- 2 1.1 Disassembly .00 00 •••••••••••••••••••••••�… |
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[Page 64] Mitsubishi S4S ENGINE MAIN PARTS 1. Cylinder Head and Valve Mechanism 1.1 Disassembly Check valve cap contact face for wear. Check oil hole for clogging. Check for cracks. or’carbon or scale deposits, Check face for pitring or ridging (exhaust valve), Check st… |
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[Page 65] Mitsubishi S4S (1) Removing rocker shaft assembly (a) Loosen the adjusting screw one rotation. (b) Loosen the bolts, short and long, that hold the rocker shaft bracket to the cylinder head. Be sure to loosen the short bolt first. Remove the rocker shaft assembly fr… |
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[Page 66] Mitsubishi S4S ENGINE MAIN PARTS (4) Remove valve and valve spring (a) Use valve spring pusher (30691-04500) to compress the valve spring, then remove the valve cotters. (b) Remove the valves and valve springs. ,…..——-I[ NOTE ÎI- -, If the original valves ar… |
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[Page 67] Mitsubishi S4S Valves, valve guldes and valve seats (1) Measuring valve stem Measure the diameter of the valve stem as shown in the illustration. If the stem is wom beyond the service limit or unevenly wom excessively, replace the valve. Unit: mm [in.] Item Nominal… |
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[Page 68] Mitsubishi S4S ENGINE MAIN PARTS (b) To install areplacement guide, use valve guide installer (32A91-o0100). Press Valve guide instalIer …..———iLLCAUTION 1——-, The installation depth for the valve guide is specified; be sure to use the valve guide instal… |
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[Page 69] Mitsubishi S4S (5) Refacing valve face If the valve face is badly wom, reface it with a valve refacer. NOTE 1———, a) Set a valve refacer to an angle of 30° b) The valve has a stellate facing. This facing will be gone if the valve margin exceeds the service l… |
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[Page 70] Mitsubishi S4S ENGINE MAIN PARTS (b) Before installing replacement valve seats in the cylinder head, measure the bores in the cylinder head for the valve seats. (c) Chill the valve seat in liquid nitrogen of — l70 DC [-274 DF] for more than 4 minutes with the cylin… |
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[Page 71] Mitsubishi S4S (b) Using lapping tool, hold the valve against the seat and rotate it only a part of a turn, then raise the valve off the seat, rotating it to a new position. Then press the valve against the seat for another part of aturn. Repeat this operation unti… |
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[Page 72] Mitsubishi S4S ENGINE MAIN PARTS (10) Measuring cylinder head warpage Using a heavy accurate straight edge and feeler gages, check the gasket contact surface for warpage in two positions lengthwise, two crosswise and two widthwise as shown in the illustration. If t… |
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[Page 73] Mitsubishi S4S (2) Installing valve and valve spring (a) Put the valve spring and retainer on the valve guide. Using valve spring pusher (30691- 04500), compress the valve spring and install the valve cotters. (b) Tap the valve stem top with a soft-faeed hammer sev… |
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[Page 74] Mitsubishi S4S ENGINE MAIN PARTS No. of bolts: 25 Cylinder head bolt tightening sequence (565) (4) Reassembling rocker shafts Af ter reassembling the rocker shafts, make sure the rocker arms move smoothly. Reassembling rocker shafts (a) Install the valve caps in po… |
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[Page 75] Mitsubishi S4S 2. Flywheel 2.1 Disassembly Replace gasket. Checks for cracks or defective dowel hole. I Disassembly sequence I CD Flywheel Check for wom or defective lip. Check for cracks or defective dowel hole. Check ring gear for wom or detective teeth. Remove �… |
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[Page 76] Mitsubishi S4S ENGINEMAIN PARTS (1) Removing flywheel (a) Remove one ofthe bolts that hold theflywheel to the crankshaft. (b) Run safety bar (M12 x 1.25) in the holefrom which the bolt was removed in Step (a). Remove the remaining flywheel bolts. (c) Remove the fly… |
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[Page 77] Mitsubishi S4S (2) Face runout and circular runout (radial eccentricity) of flywheel Set a dia! indicator at the friction(vertical) surface and turn the flywheel one full revolution to check the face run out. Set a dial indicator at the horizontal surface of the pi… |
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[Page 78] Mitsubishi S4S ENGINE MAIN PARTS 2.3 Reassembly (1) Installing oil seal (According to engine specification) Apply a thin coat of grease to the oil seal and install the oil seal to the flywheel housing with an installer. ..——-1 NOTE 1———, If the oil seal c… |
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[Page 79] Mitsubishi S4S 3. Damper, Timing Gears and Camshaft 3.1 Disassembly ENGINE MAIN PARTS Replace gasket Check for wear or damage. Check teeth for wear, nicks, burrs or chips. Check keyway apçl bushing for damage or wear. Check for we:n» Check for stripped thread… |
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[Page 80] Mitsubishi S4S ENGINE MAIN PARTS (I) Removing damper (S6SIDT) (a) Install two safety bars (MI2 x 1.25) in the rear end of the crankshaft to hold the crankshaft. (b) Remove the damper. llliWARNING Be to install the safety bars securely. (2) Removing crankshaft pulle… |
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[Page 81] Mitsubishi S4S (6) Removing oil pump gear Loosen the nut and remove the gear. (7) Removing idler gear Remove the thrust plate and remove the gear as shown. (8) Removing camshaft (a) Turn the crankcase upside down. (b) Position the camshaft gear so that its lighteni… |
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[Page 82] Mitsubishi S4S ENGINEMAIN PARTS (9) Removing camshaft gear Remove the gear from the camshaft with a puller. Now the thrust plate can be removed. r——-1( NOTE 11- —, Do not remove the camshaft gear and thrust plate unless they are damagedto the extent of requir… |
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[Page 83] Mitsubishi S4S 3.2 Inspeetion Camshaft and camshaft bushlngs (1) Measuring camshaft end play Measure the camshaft end play as shown in the illustration. If the end play exceeds the service limit, replace the thrust plate. Unit: mm [in.] Item Assembly Service Standa… |
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[Page 84] Mitsubishi S4S ENGINE MAIN PARTS (3) Measuring camshaft deflection Support the camshaft on its front and rear journals in V-blocks. With the dia! indicator set at 0.00 mm [0.0000 in.] at the center joumal, turn the camshaft full one revolution and read the indicato… |
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[Page 85] Mitsubishi S4S (5) Replacing camshaft bushings (a) Ifthe clearancebetween the camshaftjoumal and bore in the crankcase exceeds the service limit, refinish the bore to 57H6 («‘8019) 3.125 Ra. and install bushings. (c) To replace or install bushings, use ca… |
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[Page 86] Mitsubishi S4S ENGINEMAIN PARTS (2) Measuring clearance between idler gear bushing and shaft Measure the inside diameter of the bushing and the diameter of the shaft to determine the clearance between the two. If the clearance exceeds the service limit, replace the… |
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[Page 87] Mitsubishi S4S ENGINE MAIN PARTS (1) Installing front plate 3.3 Reassembly (b) Tighten the bolts that hold the front plate to the crankcase to the specified torque. Installing front plate 10.0 to 13.0 N·m (1.0 to 1.3 kgf-m) [7.23 to 9.40 lbf-ft] Tightening torque … |
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[Page 88] Mitsubishi S4S ENGINE MAIN PARTS (4) Installing idler gear (b) Tighten the thrust plate mounting bolts to the specified torque. (a) Install the idler gear by aligning its matching mark with those on the crankshaft gear, injection pump gear and camshaft gear and ins… |
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[Page 89] Mitsubishi S4S (7) Inspecting valve timing It is not necessary to inspeet the valve timing, provided that all match marks on the timing gears are aligned. Inspeetthe timing for verification as explained below: (a) Using a 3 mm [0.12 in.] thick smooth steel plate, a… |
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[Page 90] Mitsubishi S4S ENGINE MAIN PARTS (8) Installing oil seal (if necessary) Apply a small amount of grease to the oil seal and install it to the timing gear case with an installer. Installingoil seal (b) Apply oil to the lip of the oil seal. (9) Installing timing gear … |
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[Page 91] Mitsubishi S4S .———1 NOrf ‘1— —, To squeeze out a4 mm [0.2 in.] thickness ofThree Bond, cut the first node of the nozzie. ENGINE MAIN PARTS Nozzle for Three Bond 12Ü7Ctube (11) Installing crankshaft pulley Install two safety bars (MI2 x 1.25) to the … |
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[Page 92] Mitsubishi S4S ENGINE MAIN PARTS . 4. Pistons, Connecting Rods, Crankshaft, Crankcase and Tappets 4.1 Disassembly Check for scratching, pitting, flaking. chipping or loss of overlay. NOTE: When replacing the crankcase, carefully rernove the components (such as an o… |
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[Page 93] Mitsubishi S4S (l) Removing connecting rod cap (a) Remove the nuts that hold the cap to the connecting rod. Tap the bolts squarely and evenly with a hammer and, after the cap comes off the reamer bolts, remove the cap. (b) Mark the bearings for cylinder number and … |
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[Page 94] Mitsubishi S4S ENGINE MAIN PARTS (5) Removing piston pin Using snap ring pliers, remove the snap rings from the piston. Remove the piston pin to separatethe piston from the connecting rad. If it is difficult to pull out the pin, heat the piston with a piston heater… |
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[Page 95] Mitsubishi S4S 4.2 Inspeetion Crankcase (1) Gasket contact surface Measure flatness of the gasket contact (top) surface with a heavy accurate straight edge and feeler gages, in three positions lengthwise, two crosswise and two widthwise, as shown in the illustratio… |
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[Page 96] Mitsubishi S4S ENGINE MAIN PARTS (d) If any cylinder is unevenly worn, determine the oversizeon the basis of the maximum wear noted to ensure perfect roundness in the oversized bore. ..———-J[ NOrE JI———-.., (a) Refinish all cylinders to the same oversiz… |
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[Page 97] Mitsubishi S4S ENGINE MAIN PARTS WEIGHTmark FRONTmark (2) Measuring cut clearance between ends of piston ring Put the piston ring in the gage or a new cylinder sleeve and measure the cut clearance with feeler gages as shown in the illustration. Ifthe clearance exce… |
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[Page 98] Mitsubishi S4S ENGINE MAIN PARTS (3) Measuring clearance between groove and piston ring Put a new piston ring in the groove. Measure the clearance between the groove and piston ring with a straight edge and feeler gages as shown in the illustration. If the clearanc… |
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[Page 99] Mitsubishi S4S (5) Measuring piston protrusion If the piston protrusion is not correct, check the various parts for clearance. Measure the piston protrusion as outlined below. (a) Measure the top dead center of the pistons with a dial gage. (b) Install the dial ind… |
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[Page 100] Mitsubishi S4S Measuring connecting rad bearing ENGINE MAIN PARTS Connecting rods, conneetion rod hearings and piston pin bushings (1) Clearance between connecting rod bearing and crankpin Measure the diameter of the crankpin and the inside diameter of the connecti… |