Mitsubishi S4S Diesel Engine Service Manual 99616-87100

Mitsubishi S4S Diesel Engine Service Manual 99616-87100 - Image 2

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Mitsubishi S4S Diesel Engine Service Manual 99616-87100 - Image 5

mitsubishi s4s diesel engine service manual 99616 87100 2

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Mitsubishi S4S Diesel Engine Service Manual 99616-87100

$30.00

Type Of Manual: Service Manual
Manual ID: 99616-87100
Number of Pages: 190
Size: 19.5MB
Format: PDF

Category: Mitsubishi Service Manual PDF

Model List:
- S4S Diesel Engine

1. Foreword
1.1. HOW TO USE THIS MANUAL
1.1.1. Description format
1.1.2. Terms used in this manual
1.1.3. Abbreviations and Standards
1.1.4. Unit of Measurement
1.2. Safety Cautions
1.2.1. Fire and Explosion Precautions
1.2.2. Stay Away From Rotating and Moving Parts
1.2.3. Be Careful of Exhaust Gas Poisoning
1.2.4. Be Careful of Hearing Loss
1.2.5. Be Careful of Falling
1.2.6. Be Careful When Handling Fuel, Engine Oil or Coolant
1.2.7. Be Careful of Burns
1.2.8. Battery
1.2.9. When Abnormality Occurs
1.2.10. Other Cautions
1.2.11. Warning Labels
1.2.12. Points on Disassembling and Assembling
2. GENERAL CONTENTS
3. Chapter 1 GENERAL
3.1. External View
3.2. Outline of Systems
3.2.1. Outline of Fuel System
3.2.2. Outline of Lubrication System
3.2.3. Outline of Cooling System
3.2.4. Outline of Inlet and Exhaust System
3.3. Engine Serial Number
3.4. Specifications
4. Chapter 2 SERVICE DATA
4.1. Maintenance Service Data
4.1.1. Maintenance Service Data of Engine General
4.1.2. Maintenance Service Data of Basic Engine
4.1.3. Maintenance Service Data of Fuel System
4.1.4. Maintenance Service Data of Lubrication System
4.1.5. Maintenance Service Data of Cooling System
4.1.6. Maintenance Service Data of Inlet and Exhaust System
4.1.7. Maintenance Service Data of Electrical System
4.2. Tightening Torque Table
4.2.1. Tightening Torque Spec for Basic Engine
4.2.2. Tightening Torque Spec for Fuel System
4.2.3. Tightening Torque Spec for Lubrication System
4.2.4. Tightening Torque Spec for Cooling System
4.2.5. Tightening Torque Spec for Inlet and Exhaust System
4.2.6. Tightening Torque Spec for Electrical System
4.2.7. Tightening Torque for Standard Bolts
4.2.8. Tightening Torque for Standard Stud Bolts
5. Chapter 3 SERVICE TOOLS
5.1. Special Tools
6. Chapter 4 OVERHAUL INSTRUCTIONS
6.1. Determining Overhaul Timing
6.2. Compression Pressure – Measure
7. Chapter 5 DISASSEMBLY OF BASIC ENGINE
7.1. Cylinder Heads and Valve Mechanisms – Disassemble and Inspect
7.1.1. Inspection of Valve Clearance
7.1.2. Rocker Shaft Assembly – Remove
7.1.3. Cylinder Head Bolt – Remove
7.1.4. Cylinder Head Assembly – Remove
7.1.5. Measurement of Valve Sinkage
7.1.6. Valve and Valve Spring – Remove
7.2. Rear Mechanism – Disassemble and Inspect
7.2.1. Flywheel Face and Radial Runout – Measure
7.2.2. Flywheel – Remove
7.2.3. Oil Seal Case – Remove
7.2.4. Rear Plate – Remove
7.3. Front Mechanism – Disassemble and Inspect
7.3.1. Crankshaft Pulley – Remove
7.3.2. Timing Gear Case – Remove
7.3.3. Timing Gear Backlash – Measure
7.3.4. Idler Gear and Camshaft End Play – Measure
7.3.5. Fuel Injection Pump – Remove
7.3.6. Oil Pan – Remove
7.3.7. Oil Strainer – Remove
7.3.8. Oil Pump Gear – Remove
7.3.9. Idler Gear – Remove
7.3.10. PTO Drive Gear – Remove
7.3.11. Camshaft – Remove
7.3.12. Camshaft Gear – Replace
7.3.13. Front Plate – Remove
7.3.14. Oil Pump – Remove
7.4. Piston, Connecting Rod, Crankshaft and Crankcase – Disassemble and Inspect
7.4.1. Piston Protrusion – Measure
7.4.2. Carbon Deposits from the Upper Part of Cylinder – Remove
7.4.3. Connecting Rod End Play – Measure
7.4.4. Connecting Rod Cap – Remove
7.4.5. Piston – Remove
7.4.6. Piston Ring – Remove
7.4.7. Piston Pin and Piston – Remove
7.4.8. Crankshaft End Play – Measure
7.4.9. Main Bearing Cap – Remove
7.4.10. Crankshaft – Remove
7.4.11. Tappet – Remove
8. Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE
8.1. Cylinder Head and Valve Mechanism – Inspect and Repair
8.1.1. Clearance Between Rocker Bushing and Rocker Shaft – Measure
8.1.2. Valve Stem Outside Diameter and Valve Guide Inside Diameter – Measure
8.1.3. Valve Guide – Replace
8.1.4. Valve Face – Inspect
8.1.5. Valve Face – Reface
8.1.6. Valve Seat Ring – Reface
8.1.7. Valve Seat – Replace
8.1.8. Valve and Valve Seat Ring – Lap
8.1.9. Squareness and Free Length of Valve Spring – Measure
8.1.10. Push rod Runout – Measure
8.1.11. Distortion of Cylinder Head Bottom Surface – Measure
8.1.12. Combustion Jet – Replace
8.2. Rear Mechanism – Inspect and Repair
8.2.1. Flatness of Flywheel – Measure
8.2.2. Ring Gear – Inspect
8.2.3. Ring Gear – Replace
8.3. Front Mechanism – Inspect and Repair
8.3.1. Idler Bushing Inside Diameter and Idler Shaft Outside Diameter – Measure
8.3.2. Idler Shaft – Replace
8.3.3. Cam Lift of Cam Shaft Lobe – Measure
8.3.4. Camshaft Runout – Measure
8.3.5. Camshaft Journal Outside Diameter – Measure
8.3.6. Belt Groove Wear – Inspect
8.4. Piston and Connecting Rod – Inspect and Repair
8.4.1. Piston – Inspect Visually
8.4.2. Piston Weight
8.4.3. Piston Outside Diameter – Measure
8.4.4. Piston Ring Groove – Inspect
8.4.5. Piston Pin Bore Diameter and Piston Pin Outside Diameter – Measure
8.4.6. Standard for Piston Ring Replacement
8.4.7. Clearance Between Connecting Rod Bearing and Crankpin – Measure
8.4.8. Clearance Between Connecting Rod Bushing and Piston Pin – Measure
8.4.9. Connecting Rod Bushing – Replace
8.4.10. Connecting Rod Assembly Weight Rank
8.4.11. Connecting Rod Bearing – Inspect
8.4.12. Connecting Rod Bend and Twist – Inspect
8.5. Crankcase and Crankshaft – Inspect and Repair
8.5.1. Cylinder Inside Diameter – Measure
8.5.2. Crankcase Top Surface Distortion – Measure
8.5.3. Crankpin and Journal Outside Diameters – Measure
8.5.4. Width of Crankpin and Rearmost Crank Main Journal – Measure
8.5.5. Crankshaft – Grind
8.5.6. Crankshaft Runout – Measure
8.5.7. Crankshaft Gear – Inspect
8.5.8. Crankshaft Gear – Replace
8.5.9. Oil Seal Contact Surface – Inspect
8.5.10. Oil Seal Sleeve – Replace
8.5.11. Main Bearing – Inspect
8.5.12. Clearance Between Main Bearing and Crank Journal – Measure
8.5.13. Thrust Plate – Inspect
8.5.14. Tappet – Inspect
9. Chapter 7 ASSEMBLY OF BASIC ENGINE
9.1. Piston, Connecting rod, Crankshaft and Crankcase – Assemble
9.1.1. Crankcase – Turn Over (Upend)
9.1.2. Tappet – Install
9.1.3. Upper Main Bearing – Install
9.1.4. Rear Upper Thrust Plate – Install
9.1.5. Crankshaft – Install
9.1.6. Lower Main Bearing Shell and Lower Thrust Plate – Install
9.1.7. Main Bearing Cap – Install
9.1.8. Crankshaft End Play – Measure
9.1.9. Side Seal – Insert
9.1.10. Piston and Connecting Rod – Assemble
9.1.11. Piston Ring – Install
9.1.12. Piston Installation – Prepare
9.1.13. Connecting rod bolt and Upper connecting rod bearing – Install
9.1.14. Piston – Install
9.1.15. Connecting Rod Cap – Install
9.1.16. Connecting Rod End Play – Measure
9.1.17. Piston Protrusion – Measure
9.2. Front Mechanism – Assemble
9.2.1. Oil Pump – Install
9.2.2. Front Plate – Install
9.2.3. Camshaft – Install
9.2.4. PTO Drive Gear – Install
9.2.5. Idler Gear – Install
9.2.6. Oil Pump Gear – Install
9.2.7. Fuel Injection Pump – Install
9.2.8. Timing Gear Backlash – Measure
9.2.9. Idler Gear End Play – Measure
9.2.10. Camshaft End Play – Measure
9.2.11. Front Oil Seal – Install
9.2.12. Timing Gear Case – Install
9.2.13. Oil Strainer – Install
9.2.14. Oil Pan – Install
9.2.15. Crankcase – Turn Over
9.2.16. Cover – Install
9.2.17. Crankshaft Pulley – Install
9.3. Rear Mechanism – Assemble
9.3.1. Rear Plate – Install
9.3.2. Oil Seal – Install
9.3.3. Flywheel – Install
9.3.4. Flywheel Face and Radial Runout – Measure
9.4. Cylinder Head and Valve Mechanism – Assemble
9.4.1. Cylinder Head – Assemble
9.4.2. Measurement of Valve Sinkage
9.4.3. Cylinder Head Gasket – Install
9.4.4. Cylinder Head Assembly – Install
9.4.5. Cylinder Head Bolt – Tighten
9.4.6. Push Rod – Insert
9.4.7. Rocker Shaft Assembly – Install
9.4.8. Valve Clearance – Check and Adjust
9.4.9. Rocker Cover – Install
10. Chapter 8 FUEL SYSTEM
10.1. Fuel System – Remove and Inspect
10.2. Fuel System – Disassemble, Inspect and Assemble
10.2.1. Fuel Filter (Paper Element) – Disassemble, Inspect and Assemble
10.2.2. Fuel Injection Nozzle – Disassemble and Inspect
10.2.3. Fuel Injection Nozzle – Inspect and Adjust
10.2.4. Fuel Injection Nozzle – Assemble
10.2.5. Gauze Filter of Distribute Type Fuel Injection Pump – Inspect and Clean
10.3. Fuel System – Install
10.3.1. Fuel Injection Timing – Check
11. Chapter 9 LUBRICATION SYSTEM
11.1. Lubrication System – Remove and Inspect
11.2. Lubrication System – Disassemble, Inspect and Assemble
11.2.1. Oil Pump – Disassemble and Inspect
11.2.2. Oil Pump – Inspect
11.2.3. Oil Pump – Assemble
11.2.4. Oil Filter – Inspect
11.2.5. Relief Valve – Inspect
11.3. Lubrication System – Install
12. Chapter 10 COOLING SYSTEM
12.1. Cooling System – Remove and Inspect
12.2. Cooling System – Disassemble, Inspect and Assemble
12.2.1. Thermostat – Disassemble and Inspect
12.2.2. Thermostat – Inspect
12.2.3. Water pump – Disassemble and Inspect
12.3. Cooling System – Install
13. Chapter 11 INLET AND EXHAUST SYSTEMS
13.1. Inlet and Exhaust Systems – Remove and Inspect
13.2. Inlet and Exhaust Systems – Disassemble, Inspect and Assemble
13.2.1. Exhaust Manifold Distortion – Measure
13.3. Inlet and Exhaust Systems – Install
14. Chapter 12 ELECTRICAL SYSTEM
14.1. Electrical System – Remove and Inspect
14.1.1. Starter – Remove and Inspect
14.1.2. Alternator Before Removal – Inspect
14.1.3. Alternator – Remove and Inspect
14.1.4. Magnetic Valve (Stop Solenoid Valve) – Remove and Inspect
14.1.5. Glow Plug – Remove and Inspect
14.2. Electrical System – Disassemble, Inspect and Assemble
14.2.1. Starter Before Disassembling – Inspect
14.2.2. Starter – Disassemble and Inspect
14.2.3. Starter – Inspect and Repair
14.2.4. Starter – Assemble
14.2.5. Alternator – Disassemble and Inspect
14.2.6. Alternator – Inspect and Repair
14.2.7. Alternator – Assemble
14.2.8. Glow Plug – Inspect and Repair
14.2.9. Magnetic Valve (Stop Solenoid) – Inspect and Repair
14.3. Electrical System – Install
14.3.1. Glow Plug – Install
14.3.2. Magnetic Valve (Stop Solenoid) – Install
14.3.3. Alternator – Install
14.3.4. Starter – Install
15. Chapter 13 ADJUSTMENT AND OPERATION
15.1. Engine – Adjust
15.1.1. Valve Clearance – Check
15.1.2. Fuel System – Drain
15.1.3. Fuel System – Bleed Air
15.1.4. Belt and Belt Tension – Inspect and Adjust
15.2. Break-in Operation
15.2.1. Engine Start-up
15.2.2. Break-in Operation
15.3. Performance Test
15.3.1. Engine Equipment Condition
15.3.2. Test Items and Purposes
15.3.3. Other Inspections
15.3.4. Engine Output Adjustment
16. Back cover
17. Rear cover

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