Mitsubishi diesel engines User 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
1.
(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.
Note: ････This stresses important points or provides useful tips on engine operations and
service.
(6) Wherever hardware tightening requires the application of engine oil, “WET” is mentioned. If not
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/cm2
・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 cmH2O (cmAq)
・Rotational speed: 1 min-1 = 1 rpm

Group No. Group Name Page
0 SAFETY CAUTIONS 0 - 1
GENERAL 1 - 1
SERVICE STANDARDS 1 -11
TOOLS LIST 1 -21
OVERHAUL TIMING 1 -25
1
REMOVAL PREPARATIONS 1 -29
ENGINE MAIN PARTS - DISASSEMBLY 2 - 1
ENGINE MAIN PARTS - INSPECTION AND
CORRECTION 2 -17
2 Engine Main Parts
ENGINE MAIN PARTS - REASSEMBLY 2 -33
FUEL SYSTEM - REMOVAL 3 - 1
FUEL SYSTEM - DISASSEMBLY,
INSPECTION AND REASSEMBLY 3 - 9
3 Fuel System
FUEL SYSTEM - INSTALLATION 3 -25
OIL SYSTEM - REMOVAL 4 - 1
OIL SYSTEM - DISASSEMBLY,
INSPECTION AND REASSEMBLY 4 - 5
4 Lubrication System
OIL SYSTEM - INSTALLATION 4 - 9
COOLING SYSTEM - REMOVAL 5 - 1
COOLING SYSTEM - DISASSEMBLY,
INSPECTION AND REASSEMBLY 5 - 5
5 Cooling System
COOLING SYSTEM - INSTALLATION 5 - 9
INLETAND EXHAUST SYSTEMS -
REMOVAL 6 - 1
INLETAND EXHAUST SYSTEMS -
DISASSEMBLY, INSPECTION AND
REASSEMBLY 6 - 5
6 Inlet and Exhaust
Systems
INLETAND EXHAUST SYSTEMS -
INSTALLATION 6 - 7
ELECTRICAL SYSTEM - REMOVAL 7 - 1
ELECTRICAL SYSTEM - DISASSEMBLY,
INSPECTION AND REASSEMBLY 7 - 7
7 Air starter System
ELECTRICAL SYSTEM - INSTALLATION 7 -25
ENGINE - INSPECTION / ADJUSTMENT 8 - 1
RUNNING-IN TRIAL 8 -12
8
Engine -
Inspection/Adjustment,
Running-in Trial and
Performance Test PERFORMANCE TEST 8 -13
9 Others DISASSEMBLY AND REASSEMBLY OF
GENERAL PARTS 9 - 1
Supplement
Engine Inspection Sheets
GENERAL CONTENTS

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········································0-2
●Pay attention to fuel and oil leakage ·········0-2
●Use explosion-proof light························0-2
●Prevent short circuit······························0-2
●Keep fire extinguisher and first-aid kit
at hand ··············································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························0-3
●Keep away from rotating parts while the
engine is running··································0-3
●Lockout/tagout·····································0-3
●Always stop the engine before any
inspection/service·································0-3
●Remove the turning gear after use ···········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·····0-4
●Be careful when opening/closing the
radiator cap·········································0-4
●Replenish coolant only when
the coolant in the system is cold··············0-4
●Do not remove heat insulating material ·····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·····················0-5
●Secure your foothold when carrying out
service···············································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····························0-5
●Lawful disposal of waste oil and
coolant···············································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 ·····························0-6
●Never restart the engine after a sudden
stop unless the cause is eliminated ··········0-6
●Stop the engine immediately upon oil
pressure drop······································0-6
●Stop the engine immediately upon broken
fan belt···············································0-6
Caution How to handle
emergencies·······················0-6
●Engine overheat - Idle to cool down,
then stop the engine ·····························0-6
●Never restart the engine after a sudden
stop unless the cause is eliminated ··········0-6
●Stop the engine immediately upon oil
pressure drop······································0-6
●Stop the engine immediately upon broken
fan belt···············································0-6
Caution Other considerations···········0-7
●Never alter or modify the engine ··············0-7
●Do not tamper with sealing ·····················0-7
●Daily and periodical inspection ················0-7
●Running-in period·································0-7
●Warming up the engine··························0-7
●Do not overload the engine·····················0-7
●Cooling down the engine························0-7
●Do not spill water onto the engine ···········0-7
●Air cleaner maintenance precautions ········0-8
●Observe safety rules at work sites············0-8
●Wear appropriate clothes and protective
gear···················································0-8
●Use appropriate tools when carrying out service
0-8
●Do not operate the starter continuously ·····0-8
●The battery switch must be kept ON while
the engine is running·····························0-8
●Precautions for road transport ·················0-8
SAFETY CAUTIONS

SAFETY CAUTIONS
0 - 2
Warning 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.

SAFETY CAUTIONS
0 - 3
Warning Risk of entanglement into the machine
●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.

SAFETY CAUTIONS
0 - 4
Warning 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.
Warning 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 building
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
Wear ear protector whenever entering
the engine room. Otherwise, the
combustion and mechanical noises
may cause you to develop hearing
difficulty.

SAFETY CAUTIONS
0 - 5
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.

SAFETY CAUTIONS
0 - 6
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.

SAFETY CAUTIONS
0 - 7
Caution Other considerations
●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.

SAFETY CAUTIONS
0 - 8
●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.

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

GENERAL
1 - 2
1. Overview
1.1 Outline Drawing
S3L, S3L2
Oil filler
Exhaust manifold
Starter
Front end Rear end
Left-hand side
Thermostat Hanger
Alternator
Fan
V belt
Oil pan
Flywheel
Engine LH side view
Right-hand side
Fuel injection nozzle
Fuel injection pump Water pump
Stop solenoid
Coolant drain plug
Flywheel housing
Oil level gauge
Oil filter
Oil drain plug
Inlet cover
Crankshaft pulley
Front end
Rear end
Engine RH side view

GENERAL
1 - 3
S4L, S4L2
Oil filler
Exhaust
manifold
Starter
Front end Rear end
Left-hand side
Thermostat Hanger
Alternator
Fan
V belt
Oil pan
Flywheel
Engine LH side view
Right-hand side
Fuel injection nozzle
Fuel injection pump Water pump
Stop solenoid
Coolant drain plug
Flywheel housing
Oil level gauge
Oil filter
Oil drain plug
Inlet cover
Crankshaft pulley
Front end
Rear end
Engine RH side view

GENERAL
1 - 4
1.2 Fuel System Schematic
To fuel tank
From fuel tank
Fuel pump
Fuel filter
Fuel leak-off pipe Fuel injection pipe
Fuel injection nozzle
Fuel injection pump
O
P
E
N
Fuel system schematic
1.3 Oil System Schematic
Oil pressure switch
Oil main gallery
Oil filter
Relief valve
Oil pump
Oil drain plug
Oil strainer
Oil system schematic

GENERAL
1 - 5
1.4 Cooling System Schematic
Radiator
Water pump Water bypass valve
Thermostat
Cooling fan
Cooling system schematic
1.5 Inlet / Exhaust System Schematic
Exhaust gas
Intake air
Exhaust gas
(to muffler)
Air breather pipe
(positive crankcase
ventilation)
Blow-by gas
Intake air
(from air cleaner)
Inlet cover
Exhaust manifold
Inlet / exhaust system schematic

GENERAL
1 - 6
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 model code
Engine serial number location
Engine serial number

GENERAL
1 - 7
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.) 78×78.5
(3.07×3.09)
78×92
(3.07×3.62)
78×78.5
(3.07×3.09)
78×92
(3.07×3.62)
Total displacement l(U.S. gal) 1.125
(0.297)
1.318
(0.348)
1.500
(0.396)
1.758
(0.464)
Compression ratio 22.0 : 1
Fuel Diesel fuel (JIS K2204 Special 1 - 3)
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)
Overall width mm (in.) 433 (17.04) 433 (17.04)
Dimensions
Overall height mm (in.) 572 (22.52) 572 (22.52)
General
Dry mass kg (lb) 135 (297.6) 155 (341.7)
Piston ring No. of rings Compression ring :2
Oil ring (w/expander) : 1
Open BTDC 15°
Inlet valve Close ABDC 41°
Open BBDC 54°
Val v e
timing
(hot engine) Exhaust valve Close ATDC 10°
Engine mounting 4 mounts
Engine main parts
Starting method Starter
Type Bosch M
Manufacturer DENSO
Plunger
diameter mm (in.) φ5.5 (0.21)
MS retard
(crank angle) 8°
Injection
pump
Cam lift mm(in.) 15 (0.59)
Governor Governing method Centrifugal fly-weight type
Type Throttle nozzle
Manufacturer Bosch Automotive Systems Corporation
Spray angle mm (in.) 15°
Injection
nozzle Opening
pressure
MPa
(kgf/cm2)
[psi]
14.22 to 15.00 (145 to 153)
[2062 to 2176]
Fuel system
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 Displacement l(U.S. gal)
/min 18 (4.8)
Type Piston valve
Relief valve Opening
pressure
MPa
(kgf/cm2)
[psi]
0.35±0.05 (3.6±0.5)
[51±7]
Oil system
Oil filter Type Paper element (spin-on type)