Mitsubishi S4S User manual

SERVICE MANUAL
MITSUBISHI
DIESEL ENGINES
S4S
ses
March 2002
J.. !!!!I'D'!S~~!~!.

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.
Before you attempt to inspect, disassemble, or repair the engine, read this manual carefully to leam more about
the engine and how to care for it properly. AHdescriptions, illustrations, specifications and serial numbers in
this manual are effective as of the date printing of this manual.
The information contained in this manual applies to the engine model produced at the time of publication.
It should be noted that specifications and design may change due to improvements made thereafter.
For items other than those in this publication, refer to the operation manual for a unit on which the
engine is mounted,
How to UseThis Manual
1. Parts in illustrations are numbered to correspond with references to these numbers in text.
2. Items or conditions to be inspected during disassembly are enclosed in a box in the disassembIed views:
IClogged oil hole I
3. Maintenance standards for inspeetion and repair are described in text wherethey are relevant. For a quick
summary of maintenance standards refer to group 2 of this manual.
4. The sequence in which parts are to be reassembled is summarized below eaeh assembIed view.
Sueh as:
@ ..... ~ ..... @ ..... @ ..... CD
5. Tighteningtorque under wet conditions is indieated as "(wet)" in text, drawings, and tables. When so indieated
as (wet), apply engine oil to the threaded portion of the fastener. Unless indieated as such, the tightening
torque is to be assumed in the dry condition.
6. Pay attention to the special notes, cautions and wamings.
Pub. No. 99616-10170

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 most serious specific potential hazard
resulting in serious bodily injury or death.
Indicates aspecific potential hazard resulting in
bodily injury.
Indicates operating procedure, practice, etc.,resulting
in personal injury or damage to or destruction of
engine.
An operatingprocedure, condition, etc. that will help
you work more efficiently.
Beforeyou read this manual, note that the following special terms are used in dimensional and other specifications.
Assembly Standard Indicates the dimension of a part, the dimension to be attained at the
time of reassembly or the standard performance. The value is rounded
to the nearest whole number needed for inspeetion and is different from
the design value.
Nominal Value Indicates the standard dimension of a part.
Repair Limit.. A part which has reached this limit must be repaired.
Service Limit A part which has reached this limit must be replaced.
Standard Clearance Indicates the clearance to be obtained between mating parts atreassembly.

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 System
9. Lubrication System
lO.Cooling System
11.Fuel System
12.Electrical System
13.Workshop Tips
Contents
External view, engine serial number location, engine model and
application codes, specifications, tips on disassembly and reassembly.
Maintenance standards, tightening torques, sealants and lubricants.
Alist
of special tools required.
Determining when to overhaul the engine, testing compression pressure
Adjustment of valve clearance, fuel system bleeding, fuel injection
timing, no-load
minimum and maximum speed setting, V-belt, bench
testing, performance tests.
Removal and installation of turbocharger, fuel injection pump, alternator,
water
pump, starter, etc.
Disassembly, inspeetion and reassembly of the main parts, to include
cylinderhead and valve mechanism, flywheel, damper, timing gears and
camshaft, pistons, connecting rods, crankshaft, crankcase and tappets.
Disassembly, inspeetion and reassembly of inlet and exhaust system
(exhaust manifold).
Disassembly, inspeetion and reassembly oflubrication system, to inlcude
oil
pump, oil filter, oil cooler, oil pressure relief valve and safety valve.
Disassembly, inspeetion and reassembly of cooling system, to include
water
pump and thermostat.
Disassembly, inspeetion and reassembly
offuel systern, to include fuel
filter
and injection nozzles.
Disassembly, inspeetion and reassembly of electrical system, to include
starter, alternator, glow plugs and stop solenoid (option).
Basic
recommended assembly procedures: oil seals, O-rings, bearings,
split pins and spring pins.

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

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 IRear I
<>-tt-++--Flywheel
Oil drain plug
ILeft view
Oil filler
onfilter
Exhaust manifold
IRear I
Starter n
I-I:)
Thermostat
Alternator
IFront I
V-belt
üil pan
I Right viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-2

GENERAL
[S4S-DT - Standard]
IRear I
::n
"
.'
(I~I\
Fuel injection pumpn
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 pump~ F-\.lIJ 11 (( --r
~Governor
I ~ ;:, Ip,~ -~ ! :;:: p "/ /Coolant drain plug
): [l.l.AF::J"1"- ~ ~
:::" f'\f r~ 'Q , ~ _
~!::L- ~.\ K" Q.r- ~
~ I ",- '" Tb. y ~ VDipstick
13 --1. ~ ~ ___
0:/ ra 11 : ~ "\
V ~ (0 ,0
/1, 0 ol-- ~ 0 ,,~ ,-'-
h>' •F ;:; : I1 \ '--'-ol
Fuel feed pump -: rUi;!=~~o?J;»-~~'-.-i~0Ë=Q:~~: jl~~, \~~r-~-dn
1111 ~f--Ij'---H--FI ywheel
IFront I
ondrain PIL
I Left view I
on filter
IFront I
Altemator
Thermostat
V-belt
Oil pan
Turbocharger
(1-1\
n
onfiller
Starter
Exhaust manifold
------.11ll-
~~~~~~
I Rear I
IRignt viewl
Remark: Direction of rotation
of this engine is counterclockwise as seen from flywheel side.
1-3

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 solenoid
Fan
Water pump
I Front I
I Left view
Oil filler
Exhaust manifold
IRear I
Starter
Oilpan
Thermostat
Alternator
I Front I
V-belt
I Right viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-4