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Mitsubishi S4Q, User Manual

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Service Manual Mitsubishi SQ-Series diesel engines
Version 08/2004

DISASSEMBLY, INSPECTION AND

REASSEMBLY

ENGLISH

INLET AND EXHAUST SYSTEM

INLET AND EXHAUST SYSTEM

12 DISASSEMBLY, 

INSPECTION AND 
REASSEMBLY

1.

Air inlet elbow

2.

Gasket

3.

Inlet manifold

4.

Gasket

5.

Exhaust manifold

6.

Gasket

Check for cracks

Replace

Check for cracks

Put gasket with

rounded side toward

exhaust manifold

when installing it

3

4

2

1

6

5

Summary of Contents for S4Q

Page 1: ...emble or repair the engine read this manual carefully to learn more about the engine and how to care for it properly All descriptions illustrations specifications and serial numbers in this manual are...

Page 2: ...5 The following symbols are used in this manual to emphasize important and critical instructions 6 The following terms are used in the dimensional and other specifications Nominal Value Indicates the...

Page 3: ...ENGINE MAIN PARTS 7 CYLINDER HEADS AND VALVE MECHANISM 20 7 1 Disassembly 20 7 2 Inspection 24 7 3 Reassembly 32 7 4 Valve Clearance Adjustment 36 8 FLYWHEEL 38 8 1 Disassembly 38 8 2 Inspection 40 8...

Page 4: ...fter reassembly 122 28 ALTERNATOR 124 28 1 On vehicle inspection 124 28 2 Removal 126 28 3 Disassembly 127 28 4 Inspection 129 28 5 Assembly 132 28 6 Installation 132 29 ETR type stop solenoid 134 29...

Page 5: ...MAINTENANCE STANDARDS 35 MAINTENANCE STANDARDS TABLE 160 36 TIGHTENING TORQUES 166 36 1 Important Bolts and Nuts 166 36 2 Standard Bolts 167 36 3 Standard Studs 167 36 4 Standard Plugs 167 37 THREAD...

Page 6: ...6 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH...

Page 7: ...7 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH GENERAL...

Page 8: ...filter Exhaust manifold Engine serial number Oil pressure switch Flywheel housing REAR FRONT Dipstick Fan Hanger Thermoswitch LEFT SIDE VIEW REAR FRONT Inlet cover Air vent screw Oil pan Speed contro...

Page 9: ...2 Engine Serial Number Location The engine serial number is located on the side of the crankcase 1 3 Engine Model and Application Codes e g S 4 Q S Initial of Sagamihara Machinery Works 4 Number of c...

Page 10: ...stroke mm in 88 x 95 3 46 x 3 74 88 x 103 3 46 x 4 06 Displacement liter cu in 2 311 141 2 505 153 Maximum permissible working angles for oil pickup level in oil pan longitudinal and lateral 10 Fuel...

Page 11: ...11 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH GENERAL INSTRUCTIONS...

Page 12: ...6 Starting problems 7 Increased noise from engine parts Any one or a combination of these symptoms may indicate that engine overhaul is required Of the items listed above some are not directly related...

Page 13: ...n is to be measured with compression gage adaptor 30691 21100 3 Crank the engine with the starter then read the compression gage indication while the engine is running at the specified speed 4 If the...

Page 14: ...PRESSION PRESSURE GENERAL INSTRUCTIONS CAUTION a Measure the compression pressure at regular intervals to obtain correct data b The compression pressure will be slightly higher in a new or overhauled...

Page 15: ...ssembly bins to keep the engine parts in order of removal 3 Lay down the disassembled or cleaned parts in the order in which they were removed This will save you time at reassembly 4 Pay attention to...

Page 16: ...the housing bore 3 Using an oil seal driver shown to guide the seal lip and drive the outer diameter squarely To avoid damage to the oil seal and leaking never hammer on it directly 6 1 2 Driving oil...

Page 17: ...le use a press to minimize shock to the bearing and to assure proper installation 6 4 Lock Plates Bend lock plates against the flats of the nuts or bolt heads as shown 6 5 Split Pins and Spring Pins G...

Page 18: ...18 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY GENERAL INSTRUCTIONS...

Page 19: ...19 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH ENGINE MAIN PARTS...

Page 20: ...cker cover 2 Adjusting screw 3 Bolt short 4 Bolt long 5 Valve cap 6 Snap ring 7 Rocker arm 8 Rocker shaft bracket 9 Rocker shaft spring 10 Rocker shaft 11 Valve pushrod 12 Cylinder head bolt 13 Cylind...

Page 21: ...same rockershaft clearance as before 7 1 3 Removing cylinder head Remove the cylinder head bolts Lift the head off the crankcase 7 1 4 Removing valves and valve springs Use valve spring pusher 30691...

Page 22: ...the illustration 7 1 6 Cleaning cylinder head Clean the machined surface of the cylinder head that makes contact with the gasket Figure 12 Removing valves and valve springs high speed option Valve spr...

Page 23: ...of the piston as shown in the illustration and average the three measurements to determine the protrusion Subtract the projection from the compressed thickness of the gasket to determine the clearanc...

Page 24: ...r pitted or fractured coils Test force and length Check ends faces for wear Check for bend Check for wear Check for pitted or fractured coils Test force and length High speed option Check face for pit...

Page 25: ...diameter of the rocker shaft as shown in the illustration to check the clearance between the rocker arm and shaft If the clearance is not correct within the repair limit replace the rocker arm If it...

Page 26: ...r runout as shown in the illustration If runout exceeds the assembly standard replace the pushrod Unit mm in Figure 19 Measuring valve spring perpendicularity and free length Free length Perpendicular...

Page 27: ...ce limit replace the guide or valve whichever is badly worn Unit mm in Figure 21 Measuring valve stem Measuring directions Measuring points Item Nominal Value Assembly Standard Service Limit Valve ste...

Page 28: ...e guides check the valve contact with the seats 4 Inspecting valve face Coat the valve face lightly with red lead Use the Valve lapper to inspect the valve contacts with its seat If the contact is not...

Page 29: ...es b Do not rotate the valve when holding it against the seat for checking the contact c After refacing or replacing the valve or valve seat lap the valve in the seat See 8 Lapping valves Figure 27 Va...

Page 30: ...Use the caulking tool to install the valve seat Tools needed 6 Refacing valve face If the valve face is badly worn reface it with a valve refacer Figure 29 Valve seat bore dimensions Unit mm in Inlet...

Page 31: ...lap raise the valve off the seat then rotate the valve only a partial turn and strike it against the seat 3 Wash off the compound with diesel fuel 4 Coat the valve face with engine oil and again lap t...

Page 32: ...on the jet so that the orifice is toward the center of the cylinder and drive it into position with a plastic hammer 7 3 Reassembly 1 Installing valve stem seal 1 Apply engine oil to the valve stem an...

Page 33: ...ng and install the valve cotters to the valve 2 Tap the top of the valve with a soft faced hammer several times to make sure the valve spring and valve cotters are properly installed Figure 37 Install...

Page 34: ...g dowels enter their holes in the gasket 4 Installing cylinder head Put the cylinder head on the crankcase Make sure the locating dowels enter their holes in the cylinder head 5 Tightening cylinder he...

Page 35: ...t the pushrod into position through the pushrod hole in the cylinder head 2 Make sure the ball end of each pushrod rests securely on the curved surface R section of the tappet 8 Installation of rocker...

Page 36: ...The No 1 piston is at the top dead center on the compression stroke when the rocker arms are not being pushed up by the pushrods If the rocker arms are being pushed up turn the crankshaft one turn 2...

Page 37: ...LISH ENGINE MAIN PARTS 5 Adjust the valve clearance on the remaining cylinders by turning the crankshaft 180 at a time in the firing order Sequence cylinder No Turning angle 1 3 4 2 180 CAUTION After...

Page 38: ...Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH FLYWHEEL ENGINE MAIN PARTS ENGINE MAIN PARTS 8 FLYWHEEL 8 1 Disassembly 1 Flywheel 2 Flywheel housing 3 Gasket 4 Oil seal Figure 48 Disasse...

Page 39: ...el 3 Screw safety bar M12 x 1 25 mm 0 47 x 0 049 in in the bolt hole and remove the remaining bolts 4 Remove the flywheel from the crankshaft by pulling it straight 2 Removing flywheel housing The fly...

Page 40: ...er to the opposite side of the surface as shown in the illustration If the friction surface is not flat over the repair limit regrind it Unit mm in Figure 51 Inspection points Check for cracks or defe...

Page 41: ...al and drive the oil seal to flywheel housing by using installer Be sure oil seal faces to the correct direction 2 Installing flywheel housing 1 Apply THREEBOND 1104 on the mounting surfaces of both c...

Page 42: ...the bolts to the specified torque 4 Measurement of flywheel runout Measure the amount of runout of the installed flywheel If the measured value exceeds the standard value check the bolts for tightenin...

Page 43: ...MSHAFT AND OIL PAN ENGLISH ENGINE MAIN PARTS ENGINE MAIN PARTS 9 TIMING GEARS CAMSHAFT AND OIL PAN 9 1 Disassembly 1 Crankshaft pulley 2 Cover 3 Timing gear case 4 Baffle plate 5 Idler gear 6 Oil pan...

Page 44: ...the backlash betw een the gears and make a record of the measurements to be referred to at the time of assembly If the backlash exceeds the service limit replace the gears Unit mm in Figure 59 Removin...

Page 45: ...remove the idler gear 6 Measuring camshaft end play Use a dial gage to measure the end play of the camshaft to which the camshaft gear is installed If the end play exceeds the service limit replace t...

Page 46: ...he bolts that hold the oil pan to the crankcase Remove the oil pan 3 Remove the gasket 8 Removing oil pump Unscrew the set bolt and remove the oil pump from the crankcase Figure 65 Turning crankcase u...

Page 47: ...and bottom sides Unscrew the bolts that hold the thrust plate with socket 34491 00300 2 Pull the camshaft from the crankcase 10 Removing front plate Unscrew the bolts that hold the front plate to the...

Page 48: ...9 2 Inspection Figure 70 Inspection points Check oil hole for clogging Replace Check for wear Replace Replace Check V belt groove and oil seal running surface for wear Check for cranks or defective d...

Page 49: ...tween idler gear and shaft Measure the inside diameter of the idler gear and the diameter of the shaft as shown in the illustra tion to check the clearance If the clearance exceeds the service limit r...

Page 50: ...B from lobe height A The difference is lobe lift C If the lobe lift is less than the service limit replace the camshaft Unit mm in Figure 74 Replacing idler gear shaft Idler gear shaft puller NOTE Wh...

Page 51: ...g camshaft journal Measuring points Measuring directions Figure 77 Measuring bore in crankcase bushing for camshaft Item Nominal Value Assembly Standard Service Limit Diameter of camshaft journal No 1...

Page 52: ...to the camshaft 2 Heat the gear up to a temperature of 250 C 482 F 3 Drive the gear onto the camshaft Figure 78 Measuring camshaft deflection CAUTION Set up a dial gage on the camshaft then turn the...

Page 53: ...he journals and lobes of the camshaft 2 Install the camshaft with gear in the crankcase 3 Tighten the thrust plate bolts to the specified torque with a torque wrench and socket 34491 00300 4 Make sure...

Page 54: ...e forced out of the seats when the oil pan gasket is installed 2 Install the oil pan gasket to the bottom of the crankcase by fitting it into the grooves in the main bearing caps and into the seats to...

Page 55: ...ear back and forth in the axial direction to make sure it has correct end play 7 Checking timing gear backlash After installing the timing gears check them for backlash as shown in the illustration Un...

Page 56: ...ir holes in the case and gasket 4 Install the eight long bolts M8 x 1 25 mm 0 315 x 0 049 in 1 50 mm 1 9685 in and one short bolt M8 x 1 25 mm 0 315 x 0 049 in 1 40 mm 1 5748 in and tighten to the spe...

Page 57: ...sel engines Version 08 2004 TIMING GEARS CAMSHAFT AND OIL PAN ENGLISH ENGINE MAIN PARTS Figure 93 Crankshaft rotation stopper CAUTION To ensure safety make sure the bar and bolt used to prevent the cr...

Page 58: ...nes Version 08 2004 ENGLISH PISTONS CONNECTING RODS CRANKSHAFT AND CRANKCASE ENGINE MAIN PARTS ENGINE MAIN PARTS 10 PISTONS CONNECTING RODS CRANKSHAFT AND CRANKCASE 10 1 Disassembly Figure 94 Disassem...

Page 59: ...lower half 3 Main bearing cap 4 Main bearing lower half 5 Crankshaft 6 Main bearing upper half 7 Connecting rod 8 Connecting rod bearing upper half 9 Snap ring 10 Piston pin 11 Piston 12 No 1 ring 13...

Page 60: ...en average weight of all connecting rod assemblies in one engine When replacing the connecting rods select new connecting rods having the same weight rank marks so that the difference between average...

Page 61: ...bon deposits from the upper areas of the cylinder liner If any carbon deposits are present this will make it difficult to pull a piston upward 6 Removing piston and connecting rod 1 Turn the crankshaf...

Page 62: ...ter or in hot water to expand the pin bore 9 Turning crankcase upside down Turn the crankcase upside down with the oil pan side up 10 Measuring end play of crankshaft 1 With a dial indicator at the en...

Page 63: ...If bearings scatter during disassembly they cannot be reinstalled in their original positions Be sure to arrange the removed bearings in a proper order so that they can be reinstalled in their origina...

Page 64: ...for wear Check for wear score marks cracks or carbon deposits Check for stripped threads Check for wear or damage Check for cracks clogged oil hole or other defects Check for nicks chipping or abnorma...

Page 65: ...f the clearance exceeds the service limit replace the piston ring Unit mm in Figure 108 Measuring piston diameter Direction transverse to piston pin 14 mm 0 6 in Figure 109 Identification on top of pi...

Page 66: ...n oversize gage 88 25 mm 3 4744 in 0 50 mm 0 0197 in oversize gage 88 50 mm 3 4843 in Unit mm in 4 Checking clearance between piston pin and bore Measure the inside diameter of the pin bore of the pis...

Page 67: ...oil holes in the bushing and connecting rod Position the ends of the bushing at the location shown in the illustration 3 After installing the bushing insert the piston pin into position and make sure...

Page 68: ...the connecting rod place the piston upside down on a surface plate insert a round bar having the same diameter as the crank pin and measure the height of the round bar using a dial gage Figure 115 In...

Page 69: ...pair limit replace the bearing and recheck the oil clearance 4 If the oil clearance still exceeds the repair limit use 0 25 mm 0 0098 in 0 50 mm 0 0197 in or 0 75 mm 0 0295 in undersize bearings When...

Page 70: ...learance of the main bearing Unit mm in 3 If the oil clearance exceeds the repair limit replace the bearing and recheck the oil clearance 4 If the oil clearance still exceeds the repair limit use 0 25...

Page 71: ...If the sleeve is badly worn by the oil seal replace the oil seal sleeve Finishing dimension Undersize of journal 0 25 0 0098 64 75 2 5492 0 50 0 0197 64 50 2 5394 0 75 0 0295 64 25 2 5295 0 015 0 035...

Page 72: ...y oil to the inside of an oil seal sleeve and using crankshaft sleeve installer set 30691 13010 install the sleeve in position as shown in the illustration When the oil seal sleeve is worn after the e...

Page 73: ...exceeds the repair limit repair the crankshaft by cold working Replace the crankshaft if runout exceeds the repair limit excessively Unit mm in 5 Removing crankshaft gear Remove the crankshaft gear w...

Page 74: ...e to be used based on the largest bore diameter of the cylinders b Measure the outside diameter of the piston to be used c Based on the measurement of the piston outside diameter calculate the finishi...

Page 75: ...shown in the illustration If warpage exceeds the repair limit grind the crankcase Unit mm in 10 2 5 Tappets 1 Checking for wear Check the cam contact face of each tappet for wear Replace badly worn ta...

Page 76: ...in bearings in the main bearing caps Install the upper halves of the main bearings in the crankcase Figure 135 Checking clearance between tappet and bore Item Nominal Value Assembly Standard Repair Li...

Page 77: ...al position by using a hoist and carefully put it in the crankcase 3 Lightly coat the journals with engine oil 4 Installing main bearing caps Install the main bearing caps in position so the front mar...

Page 78: ...the main bearing cap bolts 3 If it exceeds the service limit replace the flanged bearings 8 Reassembling piston and connecting rod 1 Put the connecting rod in position in the piston with the matching...

Page 79: ...on ring pliers 31391 12900 install the compression No 1 and No 2 rings and oil ring on the piston with the mark R toward the top of the piston Figure 144 Reassembling piston 2 Pliers NOTE The snap rin...

Page 80: ...alling connecting rod bearing 1 Install the connecting rod cap bolts in the big end of the connecting rod so the flats of their heads fit on the connecting rod properly 2 Install the tipper half of th...

Page 81: ...in the crankcase through the installer Make sure the front mark on the top of the piston is toward the front of the engine 6 Lightly tap the top of the piston with the handle of a hammer to put the b...

Page 82: ...the rod 3 Tighten the connecting rod cap nuts finger tight 4 Tighten the connecting rod cap nuts evenly to the specified torque with a torque wrench 5 Check the thrust clearance of the connecting rod...

Page 83: ...i SQ Series diesel engines Version 08 2004 PISTONS CONNECTING RODS CRANKSHAFT AND CRANKCASE ENGLISH ENGINE MAIN PARTS 16 Checking crankshaft rotation Make sure the crankshaft rotates smoothly Figure 1...

Page 84: ...84 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH PISTONS CONNECTING RODS CRANKSHAFT AND CRANKCASE ENGINE MAIN PARTS...

Page 85: ...85 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH INLET AND EXHAUST SYSTEM...

Page 86: ...86 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH DESCRIPTION INLET AND EXHAUST SYSTEM INLET AND EXHAUST SYSTEM 11 DESCRIPTION Exhaust manifold Inlet manifold...

Page 87: ...LY ENGLISH INLET AND EXHAUST SYSTEM INLET AND EXHAUST SYSTEM 12 DISASSEMBLY INSPECTION AND REASSEMBLY 1 Air inlet elbow 2 Gasket 3 Inlet manifold 4 Gasket 5 Exhaust manifold 6 Gasket Check for cracks...

Page 88: ...88 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH DISASSEMBLY INSPECTION AND REASSEMBLY INLET AND EXHAUST SYSTEM...

Page 89: ...89 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH COOLING SYSTEM...

Page 90: ...90 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH DESCRIPTION COOLING SYSTEM COOLING SYSTEM 13 DESCRIPTION Radiator Thermostat Bypass pipe Fan Water pump...

Page 91: ...tion Visually check the water pump and replace it as an assembly if any defect is found 1 Fan 2 Spacer 3 Pulley 4 V belt 5 Water Pump assembly 6 Gasket 7 Plate 8 Gasket Figure 157 Disassembly sequence...

Page 92: ...he valve starts opening and that at which the valve lift is more than 8 mm 0 3 in If these measurement are out of the assembly standard replace the thermostat Unit mm in Figure 158 Testing thermostat...

Page 93: ...93 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH FUEL SYSTEM...

Page 94: ...Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH DESCRIPTION FUEL SYSTEM FUEL SYSTEM 16 DESCRIPTION Fuel filter Air vent plug Fuel injection nozzle Fuel feed pump Fuel injection pump Air v...

Page 95: ...r vent plug when the fuel flows free of bubbles 2 Fuel injection pump 1 Loosen air vent plug on the injection pump by turning it 1 5 turns 2 Unlock bleeding pump plunger by turning it to the left and...

Page 96: ...es Using a box wrench remove the fuel injection nozzles with gaskets from the engine 3 Removing fuel injection pump 1 Check the alignment of the mark on the fuel injection pump with the mark on the fl...

Page 97: ...ler gear 4 Unscrew the bolts that hold the fuel injection pump flange to the front end plate and remove the pump and flange from the end plate Figure 162 Removing fuel injection pump 2 Idler gear Fuel...

Page 98: ...nlet and exhaust valves have some clearance 2 Checking injection timing 1 Remove delivery valve holder from the No 1 plunger of the injection pump Remove delivery valve and spring from the holder rest...

Page 99: ...iming is retarded move the injection pump toward the crankcase If the timing is advanced move the pump away from the crankcase 2 One graduation of the scale on the injection pump coupling changes the...

Page 100: ...CARTRIDGE TYPE FUEL SYSTEM FUEL SYSTEM 20 FUEL FILTER PAPER ELEMENT CARTRIDGE TYPE 20 1 Disassembly and Inspection 1 Element assembly 2 Bracket Figure 168 Disassembly sequence Air vent plug Cracks dam...

Page 101: ...LES ENGLISH FUEL SYSTEM FUEL SYSTEM 21 FUEL INJECTION NOZZLES 21 1 Disassembly 1 Retaining nut 2 Nozzle tip assembly 3 Piece 4 Pin 5 Spring 6 Washer 7 Nozzle body Figure 169 Disassembly sequence Check...

Page 102: ...pressure gage reading will slowly increase and when the nozzle starts discharging fuel it will go down fast Take the gage reading right then as the injection pressure Unit MPa kgf cm2 psi 4 If the in...

Page 103: ...dy in clean diesel fuel 3 After cleaning the nozzle tip install it to the nozzle body and tighten the retaining nut to the specified torque 4 If the discharge pattern nozzle is still bad after the noz...

Page 104: ...004 ENGLISH FUEL INJECTION NOZZLES FUEL SYSTEM 21 3 Reassembly 7 6 5 4 3 2 1 Figure 174 Ressembly sequence Retaining nut Tightening torque 37 2 5 N m 3 77 0 25 kgf m 27 1 8 lbf ft Tightening torque fo...

Page 105: ...105 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH LUBRICATION SYSTEM...

Page 106: ...8 2004 ENGLISH DESCRIPTION LUBRICATION SYSTEM LUBRICATION SYSTEM 22 DESCRIPTION Valve push rod Tappet Main gallery Pressure relief valve Valve mechanism Valve Piston Camshaft Timing gear Crankshaft Oi...

Page 107: ...between outer rotor and inner rotor Check the clearance with a feeler gage as shown in the illustration If the clearance exceeds the service limit replace the pump assembly Unit mm in Figure 175 Disas...

Page 108: ...ration If the clearance exceeds the service limit replace the pump assembly Unit mm in 23 3 Reassembly Put the outer rotor in the case Make sure the mark on the case is in alignment with the mark on t...

Page 109: ...tsubishi SQ Series diesel engines Version 08 2004 OIL FILTER ENGLISH LUBRICATION SYSTEM LUBRICATION SYSTEM 24 OIL FILTER 24 1 Inspection 1 Oil filter Apply engine oil to O ring at installation Replace...

Page 110: ...for damage 2 Check the valve opening pressure the oil pressure when the engine is running at the rated rpm If the pressure is not correct make an adjustment by adding or removing shim The pressure tap...

Page 111: ...111 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH ELECTRICAL SYSTEM...

Page 112: ...7 5 2 0 85 3 2 6 1 0 85 0 85 Glow plug Pilot lamp MM201 124 Themo switch MC880 900 Safety relay MM130 767 Model Battery Starter Alternator Glow relay MM431 28201 Pilot lamp MM201 123 Glow timer MM431...

Page 113: ...1 124 Themo switch MC880 900 Safety relay MM130 767 Model Battery Starter Alternator Glow relay MM431 28201 Pilot lamp MM201 123 Glow timer 30L66 00700 Diode MM434 062 Press switch MM130 066 Charge pi...

Page 114: ...adjustment An increase of packings results in a decrease of the pinion gap 2 No load test 1 As shown in the diagram connect an ammeter voltmeter revolution indicator and battery 2 Turning on the swit...

Page 115: ...arter model MT008T80772 Nominal output V kW 24 3 2 No load characteristics Terminal voltage V 23 Current A 80 or lower Rotation speed rpm 3000 or higher CAUTION a Use thick wires and tighten the conne...

Page 116: ...with fingers The pinion should return immediately to the original position when it is released 27 2 Removal 1 Disconnect the cables from the battery terminals Be sure to disconnect the negative cable...

Page 117: ...rmature 7 Ball bearing 8 Ball 9 Packing set 10 Gear 11 Lever 12 Washer set 13 Gear shaft 14 Internal gear 15 Overrunning clutch 16 Front bracket 17 Bearing 18 Oil Seal 2 11 17 18 16 1 15 14 12 13 5 10...

Page 118: ...lodge from the position and the pinion retracts into the original position When this happens repeat the procedure 27 3 2 Ball The ball serving as the bearing in the armature thrust direction may be st...

Page 119: ...Measure the diameter of commutator If it is smaller than the service limit replace the armature Unit mm in 3 Measure the depth of each mold between segments with a depth gauge If the depth is less tha...

Page 120: ...worn or rough recondition them with a sandpaper of 300 to 500 Unit mm in 2 Brush spring force Test the spring force using a new brush In the test read the road at the instant the spring moves off the...

Page 121: ...wise and it is locked when turned in the opposite direction If not replace the overrunning clutch 27 5 Reassembly To reassemble follow the disassembly sequence in reverse Be sure to observe the follow...

Page 122: ...kings fitted to the magnetic switch Increasing the number of packings decreases the pinion clearance Unit mm in 27 6 2 No Load Test After adjusting the pinion clearance hook up the starter as shown an...

Page 123: ...there is no continuity between S and M terminals and between S terminal and body ground replace the switch 2 Checking contactors for fusion If there is continuity between B and M terminals replace the...

Page 124: ...ttery cables in reverse Note that the negative cable is a grounding wire 2 Do not use a high voltage tester such as a megger 3 When charging the battery disconnect the cables from the battery terminal...

Page 125: ...ting at 1800 to 2500 rpm and the lamp switches turned off Unit V 28 1 3 Inspection of output unit with integrated IC regulator 1 Disconnect the grounding cable from the battery 2 Disconnect the wire f...

Page 126: ...e alternator connector 4 Unscrew the alternator brace bolt and support bolt and push the alternator toward the engine then remove the fan belt 5 Dismount the alternator Item Model Standard Value Termi...

Page 127: ...2004 ALTERNATOR ENGLISH ELECTRICAL SYSTEM 28 3 Disassembly Disassembly sequence 1 Nut and washer 2 Pulley and spacer 3 Front bracket assembly 4 Rotor assembly 5 Stator 6 Rear bracket 7 Regulator asse...

Page 128: ...2 Remove the rotor from the front bracket 3 Removal of stator core and rectifier 1 Disconnect the lead wires from the stator core to the rectifier at the soldered sections Then remove the stator core...

Page 129: ...g the negative wire to the diode If the resistance shows infinite in both measurements there is an open circuit If the resistance is close to 0 in both measurements there is a short circuit If there i...

Page 130: ...ce the field coil 2 Check the continuity between the slip ring and shaft or core If there is electric conduction the field coil is grounded replace the field coil 3 Inspecting stator core 1 Check the...

Page 131: ...ng brushes 1 If the brushes are worn close to the wear limit line service limit replace the brushes Unit mm in 2 Disconnect the brush lead wires at the soldered sections to remove the brushes and spri...

Page 132: ...must be raised before the rotor is installed to the rear bracket To do so put a wire through the small hole located on the rear bracket then remove the wire after completing the reassembly 28 6 Instal...

Page 133: ...at the above step 2 Unit mm in 4 When the belt tension is properly adjusted tighten all the bolts that secure the alternator in place Figure 204 Inspection of belt tension 98 N 10 kgf 22 lbf Water pum...

Page 134: ...t 1 second maximum 3 seconds by a special controller The hold coil of the solenoid remains energized in both the ON and START position of the starter switch keeping the stop lever in the RUN position...

Page 135: ...starter switch should be turned in the OFF position for at least 10 seconds before making another start attempt in order to reset the control timer automatically Figure 206 10 Min Spherical movement...

Page 136: ...ber boot 5 Check the spring clip to secure well 29 4 Connecting rod adjustment 1 Check the connecting rod length and adjust to 152 1 mm if necessary see Figure 206 on page 135 2 Install the connecting...

Page 137: ...e is high replace the glow plug Unit 30 3 Installation 1 Install the glow plug in the cylinder head by tightening to the specified torque 2 Install the connection plate to the glow plug and tighten th...

Page 138: ...138 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH GLOW PLUGS ELECTRICAL SYSTEM...

Page 139: ...139 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH TESTING AND ADJUSTING...

Page 140: ...on of increasing the injection and turn the starter switch to START to start the engine Do not move the control lever to the full fuel injection positon 4 After the engine starts let it to idle under...

Page 141: ...onditions Here is a summary table of bench testing conditions 31 4 Inspection and Adjustment after Bench Testing 1 Adjusting valve clearance 2 Adjusting injection timing 3 Re tightening external bolts...

Page 142: ...ontrol lever to the low idling position CAUTION a The idling speed no load and maximum speed are set for each engine at factory bench testing then the set bolts are sealed These settings are to be ins...

Page 143: ...tion using the low idling set bolt 3 Governor setting maximum rotation speed setting 1 Keep the speed control lever at the position of the specified maximum rotation speed 2 With the speed control lev...

Page 144: ...uct this test to evaluate engine output torque fuel consumption and governor perfor mance under various load conditions 2 Continuous load test Operate the engine continuously for 10 hours at 90 load c...

Page 145: ...ulation of atmospheric factor fa a Natural aspiration engine and engine with mechanically driven air charger fa 0 7 b Turbocharged engine without air cooler after cooler or with air to air cooler fa 0...

Page 146: ...plicable range of engine factor fm 37 2 qc 65 mg cycle qc 37 2 mg cycle fm 0 2 Constant 65 mg cycle qc fm 1 2 Constant 3 Range of correction equation use The range of correction factor c use is as fol...

Page 147: ...147 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH TROUBLESHOOTING...

Page 148: ...148 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH...

Page 149: ...149 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 CAUSES OF ENGINE PROBLEMS AND REMEDIES ENGLISH TROUBLESHOOTING TROUBLESHOOTING 34 CAUSES OF ENGINE PROBLEMS AND REMEDIES...

Page 150: ..._ __ __ __ __ __ __ __ Excessive fuel injection volume __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Injection nozzle defective __ __ __ __ __ __ __ __ __ __ Excessive fuel return from injecti...

Page 151: ..._ __ __ __ __ __ __ __ If disassembled replace parts __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __...

Page 152: ...old __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Excessive cooling by radiator __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Insufficient coolant __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Exce...

Page 153: ...starting After starting warm up engine thoroughly __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __...

Page 154: ...amount of exhaust smoke Large amount of exhaust smoke Engine can be cranked manually Engine can not be cranked manually White Black Mechanical problems Seizing of moving parts __ __ __ __ __ __ __ __...

Page 155: ...hts when engine operates at high speed Overheating Low Indicator does not light when engine is not operating Indicator lights when engine operates at high speed __ __ __ __ __ __ __ __ __ __ __ __ __...

Page 156: ...d repair Seizing of plunger s Disassemble and replace parts Worn plunger s Disassemble and replace parts Worn bearing s Disassemble and replace parts Loose plunger pinion s Reinstall by matching marks...

Page 157: ...large amount of oil is discharged from exhaust pipe Insufficient intake air Clogged air cleaner Clean or replace filter element Clogged intake manifold Inspect and clean Insufficient compression press...

Page 158: ...re is low Radiator is not covered Cover radiator Thermostat defective stuck open Replace parts Seizing of moving parts Seizing of cylinder s piston s or piston ring s Disassemble and repair Replace pa...

Page 159: ...159 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH MAINTENANCE STANDARDS...

Page 160: ...BTDC 30 ATDC 50 BTDC 74 ATDC 30 3 crank angle Valve clearance cold 0 25 0 0098 Bolt inlet and exhaust valves Fuel injection timing BTDC 20 Standard injection timing is indicated here The timing for ea...

Page 161: ...to 54 050 2 1272 to 2 1280 No 3 53 2 09 53 030 to 53 050 2 0878 to 2 0886 Out of round 0 02 0 0008 or less Concentricity 0 05 0 0020 or less Clearance between camshaft and journal 0 07 to 0 11 0 0028...

Page 162: ...7492 Diameter of rocker shaft 18 980 to 19 000 0 7472 to 0 7480 Clearance between rocker arm and shaft 0 010 to 0 050 0 0004 to 0 0020 0 070 0 0028 Valve pushrod Runout 0 3 0 012 or less Dial indicat...

Page 163: ...0 045 to 0 080 0 0018 to 0 0032 0 150 0 0059 Oil ring 0 025 to 0 065 0 0010 to 0 0026 Clearance between end of piston ring No 1 No 2 ring 0 25 to 0 40 0 0098 to 0 0157 1 50 0 0591 O ring 0 30 to 0 50...

Page 164: ...ase bore 0 039 to 0 076 0 0015 to 0 0030 Backlash Crankshaft gear and idler gear 0 05 to 0 15 0 0020 to 0 0059 0 25 0 0098 Replace gears Idler gear and camshaft gear Injection pump drive gear and idle...

Page 165: ...r 32 1 26 31 4 1 24 Runout 0 05 0 0020 0 10 0 0039 Commutator mica depth 0 4 to 0 6 0 016 to 0 024 0 2 0 008 Brush Length 18 0 71 11 0 43 Spring tension N kgf lbf 29 to 39 3 0 to 4 0 6 5 to 8 8 19 6 2...

Page 166: ...6 6 1 0 6 44 4 Oil pan M8 x 1 25 12 0 47 7 8 1 0 8 0 1 5 8 1 Oil pan drain plug M14 x 1 5 22 0 87 39 4 4 0 0 4 29 3 Oil filter shaft M20 x 1 5 __ 49 5 5 0 0 5 36 4 Oil filter M20 x 1 5 __ 12 1 1 2 0 1...

Page 167: ...6 0 6 26 4 M12 x 1 25 35 6 3 6 0 6 26 4 64 10 6 5 1 47 7 Thread Dia x Pitch mm M thread Torque tap end For driving in aluminium materials For driving in ferrous materials N m kgf m lbf ft N m kgf m lb...

Page 168: ...kcase coolant hole plug Crankcase Three Bond 1386D Apply to hole and install plug Crankcase oil gallery plug Crankcase Three Bond 1386D Apply to hole and install plug Crankcase oil return pipe Crankca...

Page 169: ...ltiples of the original requirement For example at Every 250 service hours also service those items listed under Every 50 service hours and Every 10 service hours Check clean wash or adjust Change S R...

Page 170: ...ean Fan belt Check tension Air inlet system Air cleaner paper element type Check indicator S Clean element Change element Electrical system Battery Check electrolyte level and specific gravity Check s...

Page 171: ...171 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH SPECIAL TOOLS...

Page 172: ...oval installation Valve guide remover 32A91 00300 Valve guide removal Valve guide installer 32A91 00100 Valve guide installation Valve seat insert caulking tool Intake 30691 02700 Exhaust 30691 02800...

Page 173: ...al sleeve installation Piston guide installer 30691 58100 Piston installation Adaptor 30691 21100 Compression pressure testing Compression gage 33391 02100 Compression pressure testing Turning handle...

Page 174: ...174 174 Service Manual Mitsubishi SQ Series diesel engines Version 08 2004 ENGLISH BLANK PAGE...

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