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INTRODUCTION
This service manual has instructions and procedures for the Mitsubishi SL-series diesel engines.
The information, specifications and illustrations in this manual are on the basis of the information that was current at
the time this issue was written.
Correct servicing, test and repair procedures will give the engine a long service life. Before starting a test, repair or
rebuild job, the serviceman must read the respective sections of this manual to know all the component he will work
on.
Continuing improvement of product design may have caused changes to your engine which are not included in this
manual.
Whenever a question arises regarding your engine, or this manual, consult your Mitsubishi dealer for the latest
available information.
Service Manual
Mitsubishi SL-Series diesel engines
Version 08/2004
Copyright © 2004 MHI Equipment Europe B.V.
Service Manual Mitsubishi SL-Series diesel engines ENGLISH 1 / 195

Version 08/2004
HOW TO USE THIS MANUAL
Exploded views
In the exploded views, the component parts are separated but so arranged to show their relationship to the whole.
Index numbering is used to identify the parts and to indicate a sequence in which the parts are to be removed for
disassembly, or they are to be installed for assembly.
Symbols
The following symbols are used in this manual to emphasize important and critical instructions:
Indicates a condition that is essential to highlight.
NOTE
Indicates a condition that can cause engine damage
CAUTION
Indicates a condition that can cause personal injury or
WARNING death.
Definition of locational terms

The fan end is “front” and the flywheel end is “rear”. The words “left” and “right” are as these directions would appear
as seen from the flywheel side. The cylinder sequencing begins on the front side (timing gearcase side) of the
engine and works its way to the flywheel side.
Dimensional or specification terms

Nominal size Is the named size which has no specified limits of accuracy.
Standard Is the dimension of a part to be attained at the time of
assembly, or the standard performance.
Limit Is the maximum or minimum permissible limit beyond which a
part must be repaired or replaced.
Tightening torques
Tighten bolts, nuts, etc. in a wet condition (apply oil to threads) when specified as [WET]. Tighten them in a dry
condition unless so specified. Use the general tightening torques unless otherwise specified.
2 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines

Version 08/2004
TABLE OF CONTENTS
TABLE OF CONTENTS
GENERAL INFORMATION
1 MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION.................................................... 10
1.1 Model identification location................................................................................................... 10
1.2 Serial Number Location ......................................................................................................... 11
2 COMPONENT LOCATION.............................................................................................................. 12
2.1 S3L/S3L2 ............................................................................................................................... 12
2.2 Engine S3L-T/S3L2-T ............................................................................................................ 13
2.3 S4L/S4L2 ............................................................................................................................... 14
2.4 Engine S4L-T/S4L2-T ............................................................................................................ 15
3 SPECIFICATIONS .......................................................................................................................... 16
OVERHAUL INSTRUCTIONS
4 DETERMINING WHEN TO OVERHAUL THE ENGINE ................................................................. 18
5 COMPRESSION PRESSURE MEASUREMENT............................................................................ 19
5.1 Inspection............................................................................................................................... 19
5.2 Measurement ......................................................................................................................... 19
6 TROUBLESHOOTING .................................................................................................................... 20
6.1 General .................................................................................................................................. 20
6.2 Engine troubleshooting .......................................................................................................... 21
6.3 Starting system troubleshooting............................................................................................. 27
7 BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY................................................... 29
7.1 Disassembly........................................................................................................................... 29
7.2 Assembly ............................................................................................................................... 29
DISASSEMBLY
8 PREPARATION FOR DISASSEMBLY............................................................................................ 32
8.1 Engine oil draining ................................................................................................................. 32
8.2 Coolant draining 1 .................................................................................................................. 32
9 ELECTRICAL SYSTEM .................................................................................................................. 33
9.1 Starter .................................................................................................................................... 33
9.2 Alternator ............................................................................................................................... 35
10 Cooling System ............................................................................................................................... 38
10.1 Cooling fan removal ............................................................................................................... 38
10.2 Thermostat case removal ...................................................................................................... 38
10.3 Water pump assembly removal ............................................................................................. 38
11 Fuel System .................................................................................................................................... 39
11.1 Fuel injection pipe removal .................................................................................................... 39
11.2 Fuel injection nozzle removal................................................................................................. 39
11.3 Governor assembly removal .................................................................................................. 39
11.4 Governor weight removal....................................................................................................... 40
11.5 Fuel injection pump removal .................................................................................................. 40
12 Lubrication System.......................................................................................................................... 41
12.1 Oil filter removal ..................................................................................................................... 41
12.2 Pressure relief valve removal................................................................................................. 41
12.3 Oil pressure switch removal................................................................................................... 41
13 AIR INLET SYSTEM AND EXHAUST SYSTEM ............................................................................. 42
13.1 Exhaust manifold removal...................................................................................................... 42
13.2 Air inlet cover removal ........................................................................................................... 42
14 CYLINDER HEAD AND VALVE MECHANISM ............................................................................... 43
14.1 Rocker shaft assembly removal............................................................................................. 44
14.2 Rocker shaft disassembly ...................................................................................................... 44
14.3 Cylinder head bolt removal .................................................................................................... 44
14.4 Cylinder head assembly removal........................................................................................... 45
14.5 Valve and valve spring removal ............................................................................................. 45
14.6 Valve stem seal removal........................................................................................................ 45
15 Timing Gears and Flywheel............................................................................................................. 46

Version 08/2004
TABLE OF CONTENTS
15.1 Flywheel removal ................................................................................................................... 47

15.2 Rear plate removal................................................................................................................. 47
15.3 Oil seal case removal............................................................................................................. 48
15.4 Tappet removal ...................................................................................................................... 48
15.5 Speedometer driven gear removal......................................................................................... 48
15.6 Crankshaft pulley removal ..................................................................................................... 49
15.7 Timing gear case removal...................................................................................................... 49
15.8 Timing gear backlash measurement...................................................................................... 49
15.9 Idler gear removal .................................................................................................................. 50
15.10Camshaft removal.................................................................................................................. 50
15.11Fuel injection pump camshaft removal .................................................................................. 50
15.12Gear removal (when required) ............................................................................................... 51
15.13Oil pump removal................................................................................................................... 51
15.14Front plate removal ................................................................................................................ 51
16 Cylinder Block, Crankshaft, Pistons and Oil Pan ............................................................................ 52
16.1 Oil pan removal...................................................................................................................... 53
16.2 Oil screen removal ................................................................................................................. 53
16.3 Thrust clearance measurement for connecting rod big end................................................... 53
16.4 Connecting rod cap removal .................................................................................................. 54
16.5 Piston removal ....................................................................................................................... 54
16.6 End play measurement for crankshaft ................................................................................... 54
16.7 Main bearing cap removal...................................................................................................... 55
16.8 Crankshaft removal................................................................................................................ 55
16.9 Piston separation from connecting rod .................................................................................. 55
INSPECTION
17.1 Cylinder head......................................................................................................................... 59
17.2 Rocker arms and rocker shaft................................................................................................ 59
17.3 Valve springs ......................................................................................................................... 60
17.4 Valve push rods ..................................................................................................................... 60
17.5 Valves, valve guides and valve seats .................................................................................... 60
17.6 Combustion jet replacement .................................................................................................. 64
18 TIMING GEARS AND FLYWHEEL ................................................................................................. 66
18.1 Camshaft................................................................................................................................ 67
18.2 Fuel injection pump camshaft ................................................................................................ 68
18.3 Tappets .................................................................................................................................. 69
18.4 Idler gear................................................................................................................................ 69
18.5 Flywheel and ring gear........................................................................................................... 70
19 CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN ..................................................... 71
19.1 Pistons, Piston Rings and Piston Pins ................................................................................... 72
19.2 Connecting rods..................................................................................................................... 74
19.3 Crankshaft.............................................................................................................................. 75
19.4 Cylinder block ........................................................................................................................ 79
ASSEMBLY
20 Cylinder Block, Crankshaft, Pistons and Oil pan............................................................................. 82
20.1 Main bearing installation ........................................................................................................ 83
20.2 Crankshaft installation............................................................................................................ 83
20.3 Main bearing cap installation ................................................................................................. 83
20.4 Side seal installation .............................................................................................................. 85
20.5 Piston assembling to connecting rod ..................................................................................... 85
20.6 Piston ring installation ............................................................................................................ 87
20.7 Piston and connecting rod installation ................................................................................... 87
20.8 Connecting rod cap installation.............................................................................................. 88
20.9 Oil screen installation............................................................................................................. 89
20.10Oil pan installation.................................................................................................................. 89
21 Timing Gears and Flywheel............................................................................................................. 91
21.1 Front plate installation............................................................................................................ 92

Version 08/2004
TABLE OF CONTENTS
21.2 Oil pump installation............................................................................................................... 92

21.3 Engine turning........................................................................................................................ 92
21.4 Engine turning........................................................................................................................ 93
21.5 Camshaft installation.............................................................................................................. 93
21.6 Idler gear installation.............................................................................................................. 94
21.7 Timing gear case installation ................................................................................................. 94
21.8 Crankshaft pulley nut tightening............................................................................................. 94
21.9 P.T.O. gear installation .......................................................................................................... 95
21.10Speedometer driven gear installation .................................................................................... 95
21.11Tappet installation.................................................................................................................. 95
21.12Oil seal case installation ........................................................................................................ 96
21.13Rear plate installation ............................................................................................................ 96
21.14Flywheel installation............................................................................................................... 96
22.1 Cylinder head bottom face cleaning....................................................................................... 99
22.2 Valve stem seal installation.................................................................................................... 99
22.3 Valve spring installation ......................................................................................................... 99
22.4 Installing valve block ............................................................................................................ 100
22.5 Cylinder head gasket installation ......................................................................................... 100
22.6 Cylinder head installation..................................................................................................... 100
22.7 Cylinder head bolt tightening ............................................................................................... 101
22.8 Valve push rod installation ................................................................................................... 101
22.9 Rocker shaft assembling...................................................................................................... 101
22.10Rocker shaft assembly installation....................................................................................... 102
22.11Valve clearance adjustment................................................................................................. 102
22.12Rocker cover installation...................................................................................................... 102
23 Air Inlet System and Exhaust System ........................................................................................... 103
23.1 Air inlet cover installation ..................................................................................................... 103
23.2 Exhaust manifold installation ............................................................................................... 103
24 Fuel System .................................................................................................................................. 104
24.1 Fuel injection nozzle installation .......................................................................................... 104
24.2 Fuel injection pump installation............................................................................................ 104
24.3 Flyweight assembly installation............................................................................................ 104
24.4 Sliding sleeve installation..................................................................................................... 105
24.5 Governor assembly installation............................................................................................ 105
24.6 Fuel injection line installation ............................................................................................... 105
25 Lubrication system ........................................................................................................................ 106
25.1 Pressure relief valve installation .......................................................................................... 106
25.2 Oil filter installation............................................................................................................... 106
25.3 Oil pressure switch installation............................................................................................. 106
26 Cooling system.............................................................................................................................. 107
26.1 Water pump installation ....................................................................................................... 107
26.2 Thermostat installation......................................................................................................... 107
26.3 Cooling fan installation......................................................................................................... 107
26.4 Thermoswitch and thermounit combination installation ....................................................... 108
27 Electrical System........................................................................................................................... 109
27.1 Glow plug installation ........................................................................................................... 109
27.2 Alternator installation ........................................................................................................... 109
ELECTRICAL SYSTEM
28 GENERAL ..................................................................................................................................... 112
28.1 Specifications (standard) ..................................................................................................... 112
28.2 Wiring diagrams ................................................................................................................... 113
29 STARTER...................................................................................................................................... 115
29.1 Disassembly......................................................................................................................... 115
29.2 Inspection............................................................................................................................. 116
29.3 Assembly ............................................................................................................................. 119
29.4 Inspection and Testing after Assembly ................................................................................ 120
30 ALTERNATOR .............................................................................................................................. 122

Version 08/2004
TABLE OF CONTENTS
30.1 Disassembly......................................................................................................................... 122

30.2 Inspection............................................................................................................................. 124
30.3 Assembly ............................................................................................................................. 127
31 KEY SHUTOFF SYSTEM (ETS solenoid type)............................................................................. 128
31.1 General ................................................................................................................................ 128
31.2 Cord color (standard) ........................................................................................................... 128
31.3 Shutoff solenoid installation ................................................................................................. 128
31.4 Inspection after assembly .................................................................................................... 129
32 KEY SHUTOFF SYSTEM (ETR solenoid type)............................................................................. 130
32.1 General ................................................................................................................................ 130
32.2 Cord color (standard) ........................................................................................................... 130
32.3 Shutoff solenoid installation ................................................................................................. 131
33 AUTOMATIC GLOW SYSTEM .................................................................................................... 132
33.1 General ................................................................................................................................ 132
33.2 Glow timer specification (standard)...................................................................................... 132
33.3 Glow plug relay specifications (standard) ............................................................................ 133
33.4 Glow plug inspection............................................................................................................ 133
COOLING SYSTEM
34 GENERAL ..................................................................................................................................... 136
34.1 Schematic ............................................................................................................................ 136
35 INSPECTION ................................................................................................................................ 137
35.1 Water pump ......................................................................................................................... 138
35.2 Thermostat (standard) ......................................................................................................... 138
35.3 Thermoswitch (standard) ..................................................................................................... 139
35.4 Thermounit (standard) ......................................................................................................... 139
LUBRICATION SYSTEM
36 GENERAL ..................................................................................................................................... 142
36.1 Schematic ............................................................................................................................ 142
36.2 Specifications....................................................................................................................... 142
37 INSPECTION ................................................................................................................................ 143
37.1 Oil pump............................................................................................................................... 143
37.2 Oil pressure switch............................................................................................................... 143
37.3 Pressure relief valve ............................................................................................................ 144
FUEL SYSTEM
38 GENERAL ..................................................................................................................................... 146
38.1 Schematic ............................................................................................................................ 146
39 FUEL INJECTION NOZZLE .......................................................................................................... 148
39.1 Inspection............................................................................................................................. 148
39.2 Disassembly and assembly ................................................................................................. 150
40 FUEL INJECTION PUMP.............................................................................................................. 151
40.1 Test on engine ..................................................................................................................... 151
40.2 Disassembly......................................................................................................................... 151
40.3 Inspection............................................................................................................................. 155
40.4 Assembly ............................................................................................................................. 156
41 GOVERNOR ................................................................................................................................. 159
41.1 Disassembly and inspection ................................................................................................ 159
41.2 Assembly ............................................................................................................................. 160
41.3 Torque spring set installation ............................................................................................... 161
42 FUEL PUMP.................................................................................................................................. 162
42.1 Inspection............................................................................................................................. 162
43 FUEL FILTER................................................................................................................................ 163
AIR INLET SYSTEM AND EXHAUST SYSTEM

44 GENERAL ..................................................................................................................................... 166

Version 08/2004
TABLE OF CONTENTS
44.1 Schematic ............................................................................................................................ 166

45 INSPECTION ................................................................................................................................ 167
45.1 Inspection procedure ........................................................................................................... 167
MAINTENANCE
46 LUBRICATION AND MAINTENANCE CHART ............................................................................. 170
47 ENGINE OIL AND OIL FILTER ..................................................................................................... 172
47.1 Engine oil specifications....................................................................................................... 172
47.2 Oil level check...................................................................................................................... 172
47.3 Oil and oil filter change ........................................................................................................ 173
47.4 Oil filter change .................................................................................................................... 173
48 VALVE CLEARANCE.................................................................................................................... 175
49 FUEL INJECTION TIMING............................................................................................................ 177
49.1 Preparation .......................................................................................................................... 177
49.2 Adjustment ........................................................................................................................... 179
50 FUEL FILTER................................................................................................................................ 180
50.1 Fuel filter with [AIR] valve .................................................................................................... 180
50.2 Cartridge (air vent screw) type fuel filter .............................................................................. 180
51 FUEL SYSTEM PRIMING ............................................................................................................. 181
51.1 Engine with fuel filter with [AIR] valve .................................................................................. 181
51.2 Engine with cartridge (air vent screw) type fuel filter ........................................................... 181
52 IDLE RPM SETTING..................................................................................................................... 182
53 FUEL INJECTION NOZZLES........................................................................................................ 183
53.1 Injection pressure (valve opening pressure) test ................................................................. 183
53.2 Orifice restriction test ........................................................................................................... 183
53.3 Nozzle tip washing and replacement ................................................................................... 183
53.4 Installation............................................................................................................................ 183
54 FAN BELT ..................................................................................................................................... 184
SERVICE DATA
55 SPECIFICATIONS ........................................................................................................................ 186
55.1 Basic engine components.................................................................................................... 186
55.2 Lubrication system ............................................................................................................... 188
55.3 Fuel system.......................................................................................................................... 188
55.4 Air inlet system and exhaust system.................................................................................... 188
55.5 Cooling system (standard) ................................................................................................... 189
55.6 Electrical system .................................................................................................................. 189
56 TIGHTENING TORQUES ............................................................................................................. 191
56.1 Major bolts and nuts............................................................................................................. 191
56.2 Torques for bolts and nuts with standard threads................................................................ 192
56.3 Torques for plugs with taperlock threads ............................................................................. 192
57 SEALANTS.................................................................................................................................... 193
58 SPECIAL TOOLS .......................................................................................................................... 194

Version 08/2004
TABLE OF CONTENTS

Version 08/2004
GENERAL INFORMATION

Version 08/2004
MODEL IDENTIFICATION AND SERIAL
NUMBER LOCATION General
General
1 MODEL
IDENTIFICATION AND
SERIAL NUMBER
LOCATION
1.1 Model identification location
t
• The model identification is embossed on the right

side of the cylinder block, near the fuel injection
pump mount.
• The model identifications and displacements of the
engines in current production are as listed below:
Displacement
S3L 1.125 liters (68.7 cu in.)
S3L2 1.318 liters (80.4 cu in.)

Figure 1 Model identification location S4L 1.500 liters (91.5 cu in.)
S4L2 1.758 liters (107.3 cu in.)
• A scheme of coding used for identifying the

engines in current production is as follows:
S 4 L (2) – 61 A
S - Identification of “Sagamihara Machinery Works”
4 - Number-of-cylinders code [“4” stands for four

cylinders]
L - Series code [Bore: 78 mm (3.07 in.)]
(2) - Stroke code

• (No code: 78.5 mm (3.09 in.)
• 2: 92 mm (3.62 in.)
61 - Export code
A - Specification code

Version 08/2004
MODEL IDENTIFICATION AND SERIAL
General NUMBER LOCATION
1.2 Serial Number Location

t
The serial number is punched on the cylinder block,

near the fuel injection pump mount.
Serial number
Figure 2 Serial number location

Version 08/2004
COMPONENT LOCATION GENERAL INFORMATION
GENERAL INFORMATION
2 COMPONENT
LOCATION
2.1 S3L/S3L2
Hanger
Oil filler
Air vent screw
Fuel injection nozzle
Fuel injection pump

Air inlet cover
Water pump
Stop solenoid
Oil filler
Fuel filter
Coolant drain plug
Oil pressure switch
Dipstick Crankshaft pulley
Oil drain plug Oil filter
REAR FRONT
RIGHT SIDE VIEW
Thermoswitch
Thermostat Exhaust manifold
Hanger
Flywheel housing
Alternator
Starter
Fan
Flywheel
V-belt
Oil pan
FRONT REAR
LEFT SIDE VIEW

Version 08/2004
GENERAL INFORMATION COMPONENT LOCATION
2.2 Engine S3L-T/S3L2-T
Hanger Oil filler

Air vent screw
Fuel injection pump

Air inlet cover
Water pump
Stop solenoid
Oil filler
Fuel filter
Coolant drain plug

Oil pressure switch
Dipstick Crankshaft pulley
Oil drain plug Oil filter
REAR FRONT
Thermoswitch
RIGHT SIDE VIEW
Turbocharger
Hanger
Flywheel housing
Alternator
Starter
Fan
V-belt Flywheel
Oil pan
FRONT REAR
LEFT SIDE VIEW

Version 08/2004
COMPONENT LOCATION GENERAL INFORMATION
2.3 S4L/S4L2
Hanger Oil filler

Air vent screw
Fuel injection pump

Air inlet cover
Water pump
Stop solenoid
Oil filler
Fuel filter
Coolant drain plug
Oil pressure switch
Oil filter Crankshaft pulley
Oil drain plug Dipstick
REAR RIGHT SIDE VIEW FRONT
Thermoswitch
Hanger
Flywheel housing
Alternator
Starter
Fan
Flywheel
V-belt
Oil pan
FRONT LEFT SIDE VIEW REAR

Version 08/2004
GENERAL INFORMATION COMPONENT LOCATION
2.4 Engine S4L-T/S4L2-T
Hanger Oil filler

Air vent screw
Fuel injection pump

Air inlet cover
Stop solenoid Water pump
Oil filler
Fuel filter
Oil pressure switch
Oil filter Crankshaft pulley
Oil drain plug Dipstick
REAR RIGHT SIDE VIEW FRONT

Thermoswitch Turbocharger
Hanger
Flywheel housing
Alternator
Starter
Fan
Flywheel
V-belt
Oil pan
FRONT LEFT SIDE VIEW REAR

Version 08/2004
SPECIFICATIONS GENERAL INFORMATION
GENERAL INFORMATION
3 SPECIFICATIONS1
Model
System Item
S3L S3L-T S3L2 S3L2-T S4L S4L-T S4L2 S4L2-T
Type 4-cycle, water-cooled, vertical, overhead valve, diesel engine
Combustion chamber Swirl chamber type
No. of cylinders 3 4
Bore x Stroke (mm) 78x78.5 78x92 78x78.5 78x92

ENGINE PROPER
Total displacement (l) 1.125 1.318 1.500 1.758
Compression ratio 22
Firing order 1-3-2 1-3-4-2
Dry weight (kg) 135 139 135 139 155 159 155 159
Lubricating method Forced lubrication
Oil pump Trochoid pump

LUBRICATING Oil filter Paper element type
SYSTEM
Oil capacity:
Shallow type oil pan: 3.7/2.3 Shallow type oil pan: 5.5/3.7
FULL level/EMPTY level (l)
Deep type oil pan: 5.7/3.1 Deep type oil pan: 7.6/4.2
(Exclusive of oil filter capacity 0.5 l)
Fuel injection pump Bosch M
Nozzle Throttle type
FUEL SYSTEM Fuel injection pressure 140 kgf/cm2
Fuel to be used Diesel fuel; see chapter 7
Governor Centrifugal weight type
Air cleaner Paper-element type

INTAKE SYSTEM
Turbocharger model Without TD025 Without TD025 Without TD025 Without TD03
Cooling method Forced circulation of water
COOLING Water pump Centrifugal type

SYSTEM
Coolant capacity (l)
1.8 2.5
(Engine proper only)
Starter (V - kW) 12 - 1.6 or 12 - 1.7 or 12 - 2.0
Alternator (V - A) AC generator (12 - 50)

ELECTRICAL
SYSTEM Glow plug Sheathed type
Battery
12V, 65 Ah or more 12V, 80 Ah or more
(capacity depends on application)
Table 1 Specifications
1. All specifications are subject to change without any prior

notice.

Version 08/2004

Version 08/2004
DETERMINING WHEN TO
OVERHAUL THE ENGINE OVERHAUL INSTRUCTIONS
4 DETERMINING WHEN
TO OVERHAUL THE
ENGINE
Generally, when to overhaul the engine is to be
determined by taking into account a drop in
compression pressure as well as an increase in lube oil
consumption and excessive blowby gases.
Lower power or loss of power, an increase in fuel

consumption, a drop in lube oil pressure, hard starting
and excessive abnormal noise are also troubles.
These troubles, however, are not always the result of
low compression pressure and give no valid reason for
overhauling the engine.
The engine develops troubles of widely different

varieties when the compression pressure drops in it.
Following are the typical troubles caused by the
compression pressure failure:
1. Low power or loss of power

2. Increase in fuel consumption
3. Increase in lube oil consumption
4. Excessive blowby through breather due to worn
cylinders, pistons, etc.
5. Excessive blowby due to poor seating of worn inlet
and exhaust valves
6. Hard starting or failure to start
7. Excessive engine noise
In most cases, these troubles occur concurrently.

Some of them are directly caused by low compression
pressure, but others are not. Among the troubles listed
above, (2) and (6) are caused by a fuel injection pump
improperly adjusted with respect to injection quantity or
injection timing, worn injection pump plungers, faulty
injection nozzles, or poor care of the battery, starter
and alternator.
The trouble to be taken into account as the most valid

reason for overhauling the engine is (4): in actually
determining when to overhaul the engine, it is
reasonable to take this trouble into account in
conjunction with the other ones.

Version 08/2004
COMPRESSION PRESSURE
OVERHAUL INSTRUCTIONS MEASUREMENT
5 COMPRESSION
t
PRESSURE
MEASUREMENT
5.1 Inspection
Check to make sure:
1. The crankcase oil level is correct, and the air

cleaner, starter and battery are all in normal
condition.
Figure 3 Compression gauge and adaptor
2. The engine is at the normal operating temperature.
5.2 Measurement
t
1. Move the control lever to a position for shutting off

fuel supply.
2. Remove all glow plugs from the engine. Install the
compression gauge and adaptor (ST332270)
combination to a cylinder on which the
compression pressure is to be measured.
3. Turn the engine with the starter and read the
gauge pressure at the instant the gauge pointer
comes to stop.
4. If the gauge reading is below the limit, overhaul the
engine.
Figure 4 Measuring compression pressure CAUTION

• Be sure to measure the compression pressure
on all cylinders.
• The compression pressure varies with change of
engine rpm. This makes it necessary to check
engine rpm at the time of measuring the
compression pressure.
CAUTION Engine speed, rpm

Standard
290
Limit
--
• It is important to measure the compression SL 30 23
pressure at regular intervals to obtain the data on (427) (327)
the gradual change of the compression pressure. [2 942] [2 256]
Compression pressure, kgf/
• The compression pressure would be slightly
cm2 (psi) [kPa]
higher than the standard in a new or overhauled SL2 32 25
engine owing to breaking-in of the piston rings, (455) (356)
valve seats, etc. It drops as the engine [3 138] [2 452]
components wear down.
Maximum permissible difference 3 --
between average compression (42.7)
pressure of all cylinders in one
engine, kgf/cm2 (psi) [kPa] [294]

Version 08/2004
TROUBLESHOOTING OVERHAUL INSTRUCTIONS
6 TROUBLESHOOTING
6.1 General
The diagnosis of troubles, especially those caused by a
faulty fuel injection pump or injection nozzles, or low
compression pressure, can be difficult. It requires a
careful inspection to determine not which item is the
cause, but how may causes are contributing to the
trouble, someone of which is the primary cause.
Several causes may be contributing to a single trouble.
On the following pages, there are troubleshooting

charts on which engine troubles can be traced to their
causes. Each chart has items to be verified ahead and
suggested inspection procedure.
Diesel engines exhibit some marked characteristics

during operation. Knowing these characteristics will
help minimize time lost in tracing engine troubles to
their source. Following are the characteristics of diesel
engines you should know about for diagnosis:
• Combustion knock (diesel knock)

• Some black exhaust smoke (when the engine
picks up load)
• Vibration (due to high compression pressure and
high torque)
• Hunting (when the engine speed is quickly
decreased)
• Some white exhaust smoke (when the engine is
cold, or shortly after the engine has been started)

Version 08/2004
OVERHAUL INSTRUCTIONS TROUBLESHOOTING
6.2 Engine troubleshooting

6.2.1 Problem 1: Hard starting
1. Items to be checked ahead of time
• Clogged air cleaner
• Wrong oil grade for weather conditions
• Poor quality fuel
• Low cranking speed
2. Inspection procedure
Glow plugs are energized

Is heating system normal? No Z shortly after starter switch is No Z Check control timer unit.
turned to ON.
VYes
Are fuel lines free of restriction? (Is fuel pump operating properly when Check fuel filter, fuel lines
No Z
starter switch in ON position?) and fuel tank.
V Yes
Make adjustment to the

Are fuel injection timing and valve clearance correct? No Z
timing and clearance.
V Yes
Is fuel injection nozzle discharge pattern normal? Is injection pressure Make adjustment to the
No Z
correct? nozzles.
V Yes
Check valves, piston rings

Is compression pressure correct? No Z
and cylinder head gasket.
V Yes
Fuel injection pump is faulty.

Version 08/2004
6.2.2 Problem 2: Fuel knock

More or less fuel knock occurs in diesel engines. This
may be caused either by an excessively large delay
period or by a too fast rate of fuel injection.


Is injection timing correct (not too advanced)? No Z
timing.
VYes
Is solenoid switch normal? No Z Check the switch.
V Yes
Is injection pressure (injection nozzle valve opening pressure) correct (not Make adjustment to the
No Z
too low)? pressure.
V Yes
Check valves, piston rings,

V Yes

Version 08/2004
6.2.3 Problem 3: Overheating

Overheating might also be caused by abnormal
operating conditions. If the engine is overheating but its
cooling system is not contributing to this trouble, it is
necessary to check the difference between the ambient
temperature and coolant temperature when the engine
is in normal operation (with the thermostat fully open).
If the ambient temperature is higher than the normal
coolant temperature by more than 60°C (108°C),
investigate other items than those related to the engine
cooling system.

• Insufficient coolant and exterior coolant leaks
• Loose fan belt
• Radiator core openings plugged with dirt
Are cooling system components (water pump, water hoses, radiator,

No Z Check the components.
thermostat and cylinder head gasket) normal?
VYes

Is injection timing correct? No Z
timing.
V Yes
Are lubrication system components (oil filter, oil pump and oil screen) Check the components and
No Z
normal and oil level correct? oil level.
V Yes

Is governor adjustment correct? No Z
governor.
V Yes
Engine is in continuous full-

load operation.

Version 08/2004
6.2.4 Problem 4: Black exhaust smoke


Are valve clearance and injection timing correct? No Z
clearance and timing.
VYes
Is injection nozzle discharge pattern normal? Is injection pressure correct Make adjustment to the
No Z
(not too high)? nozzles.
V Yes

V Yes

Version 08/2004
6.2.5 Problem 5: Erratic idle speeds

• Maladjusted engine control

VYes
Is injection nozzle discharge pattern normal? Is injection pressure Make adjustment to the
No Z
constant? nozzles.
V Yes
Is compression pressure correct (no difference in compression pressure Check valves, piston rings
No Z
between cylinders)? and cylinder head gasket.
V Yes

Version 08/2004
6.2.6 Problem 6: Low power or loss of

power
• Stuck running parts
• Restricted exhaust line
• Faulty power take-off

VYes
Are fuel lines free from restriction? (Is fuel pump operating properly when Check fuel tank, fuel filter
No Z
starter switch is in ON position?) and fuel lines.
V Yes

Is governor adjustment correct? No Z
governor.
V Yes
Is injection nozzle discharge pattern normal? Make adjustment to the

No Z
Is injection pressure correct? nozzles.
V Yes

and cylinder head gaskets.
V Yes

Version 08/2004
6.3 Starting system

troubleshooting
Overruns at low speed → Make reference to “Overrun.”
Burned contact points in switch Burned motor coil or switch coil

Layer shorted or grounded field coil Burned field coil
Layer shorted or grounded armature coil Burned coil in armature
Faulty starter Mechanical problems Misaligned armature
motor
Machining fault of parts Burned motor coil (evidence of rubbing)
Worn bearings
Pinion gap too large. Switch will not turn off only when engine fails to
fire, resulting in damage to motor.
Burned starter
Hard starting at low Wrong starting system

temperatures
High resistance in main circuit
Poor quality fuel
Prolonged
cranking Mechanical problems in engine
Very low ambient temperature
Troubles in engine
No fuel
Burned motor coil
Engine directly coupled to load
Excessive
load Reverse torque due to incorrect injection timing
Mechanical problems in engine
Starter abused (for moving equipment)
Battery run-down
Loose battery terminals
Defective key switch
Pinion fails to Poor S connector contact
shift S connector missing
Open circuit in engine switch coil
Worn starter brushes
Defective contact points in auxiliary switch
Open circuit in auxiliary switch coil
Pinion shifts High resistance in S circuit

but will not Voltage applied to starter too high
spin Contact points defective in starter switch
No cranking
Pinion and ring gear improperly chamfered
Battery rating too high

Pinion chamfered insufficiently or wrong
Ring gear chamfered insufficiently or wrong
Ring gear end face badly worn (ring gear not hardened properly)
Pinion will not shift Pinion metal jammed with dirt
Overrunning clutch jammed with
Pinion butts foreign matter
ring gear Shift lever jammed Pinion tooth worn round
instead of
meshing Solenoid switch plunger jammed
Shift lever broken
Ring gear locally chipped
Contact points close to early Shift lever broken
Pinion gap too large Four or five teeth chipped
Pinion shifted excessively
Pinion is forced into mesh with ring gear again when starter is Overrunning clutch shell peeled
coasting
Pinion chamfered insufficiently or wrong Pinion is chipped

Version 08/2004
Broken return spring

Starter is energized for hours, resulting
Key not returning Sticking in:
completely Machining fault of parts • Burned hold-in coil
Key switch Key not finished to close • Burned armature and field coils
faulty tolerances • Burned subswitch (if so equipped)
External obstacle
Rust due to moisture
Defective contact points
Starter faulty Problems in switch Pull-in and hold-in coils • Burned motor coil
unbalance in number of • Burned pull-in and hold-in coils
windings (minor defect)
Pull-in or hold-in coil layer • Plunger fails to return when
shorted voltage is applied to circuit
Overrun
between M and (–) terminals and

plunger is pushed in with switch off
starter
Contact points defective Switch will not turn off only when engine
fails to fire, resulting in burning of motor
coil
Plunger jammed • Burned motor coil
• Burned pull-in and hold-in coils
Machining fault of parts
Lever pivot jammed Dotted lines indicate failure of contact
Shift lever faulty points to close
Machining fault
Sliding part jammed Sticking pinion metal
Overrunning clutch jammed Sliding surface dirty
Machining fault of lead
Subswitch faulty Burned contact points Burned hold-in coil and motor coil
Assembly fault resulting in
failure to return
External load connected to S circuit Make reference to “Pull-in and hold-in
Incorrect coil unbalance”
wiring S and B circuits shorted Make reference to “Key not returning
completely”
[Other possibility is sticking pinion metal in case of overrun trouble.]

Version 08/2004
BASIC PRECAUTIONS FOR DISASSEMBLY
OVERHAUL INSTRUCTIONS AND ASSEMBLY
7 BASIC PRECAUTIONS
FOR DISASSEMBLY
AND ASSEMBLY
This section outlines basic precautions recommended
by Mitsubishi that should always be observed.
7.1 Disassembly
1. Always use tools that are in good condition and be
sure you understand how to use them before
performing any job.
2. Use an overhaul stand or a work bench, if
necessary. Also, use bins to keep engine parts in
order of removal.
3. Parts must be restored to their respective
components from which they were removed at
disassembly. This means that all parts must be set
aside separately in groups, each marked for its
component, so that the same combination or set
can be reproduced at assembly.
4. Pay attention to marks on assemblies,
components and parts for their positions or
directions. Put on marks, if necessary, to aid
assembly.
5. Carefully check each part or component for any
sign of faulty condition during removal or cleaning.
The part will tell you how it acted or what was
abnormal about it more accurately during removal
or cleaning.
6. When lifting or carrying a part too heavy or too
awkward for one person to handle, get another
person’s help and, if necessary, use a jack or a
hoist.
7.2 Assembly
1. Wash all parts, except for oil seals, O-rings, rubber
sheets, etc., with cleaning solvent and dry them
with pressure air.
2. Always use tools that are in good condition and be
sure you understand how to use them before
performing any job.
3. Use only good-quality lubricants. Be sure to apply
a coat of oil, grease or sealant to parts as
specified.
4. Be sure to use a torque wrench to tighten parts for
which torques are specified.
5. Any time the engine is assembled, new gaskets
and O-rings must be installed.

Version 08/2004
BASIC PRECAUTIONS FOR
DISASSEMBLY AND ASSEMBLY OVERHAUL INSTRUCTIONS

Version 08/2004
DISASSEMBLY

Version 08/2004
PREPARATION FOR DISASSEMBLY DISASSEMBLY
DISASSEMBLY
8 PREPARATION FOR
DISASSEMBLY
8.1 Engine oil draining1
t
Remove the drain plug from the bottom of the oil pan
and allow the oil to drain.
Refill capacities S3L/S3L2:

(high level excl. 0.5 5.7 (1.5) (with deep oil pan)
liter (0.13 U.S. gal) 3.7 (1.0) (with standard oil pan)
of oil in oil filter, liter
(U.S. gal) S4L/S4L2:
7.7 (2.0) (with deep oil pan)
5.4 (1.4) (with standard oil pan)
Engine oil drain plug
Figure 5 Draining engine oil
WARNING
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact skin.
8.2 Coolant draining 1

t
Loose the drain plug on the right side of the cylinder

Coolant drain block and allow the coolant to drain.
plug
Refill capacities, S3L/S3L2: 1.8 (0.5)

liter (U.S. gal) S4L/S4L2: 2.5 (0.7)
Figure 6 Draining coolant
1. Please refer to the applicable engine model specification

sheet for actual data

Version 08/2004
DISASSEMBLY ELECTRICAL SYSTEM
DISASSEMBLY
9 ELECTRICAL SYSTEM
9.1 Starter
9.1.1 Testing before disassembly
1. Clearance between pinion and housing (pinion
clearance)
1) Connect the starter to a 12 volt battery as
shown in the illustration to cause the pinion to
shift into cranking position and remain there.
CAUTION
Due to the amount of current being passed through
the solenoid series winding, this test must be made
within 10 seconds.
2) Push the pinion toward the commutator end

t
by hand to measure its free movement (pinion

clearance).
Push in 3) The pinion clearance must be 0.5 to 2.0 mm
pinion (0.020 to 0.079 in.). If the clearance is out of
this range, make an adjustment to it by adding
or removing the packings on the magnetic
switch. Adding the packings will decrease the
clearance.
Battery
(12 volts) Starter
0,5 to 2,0 mm
(0.020 to 0.079 in.)
Figure 7 Connections for measuring pinion

clearance
2. No-load characteristics
t
1) Connect the starter to a 12 volt battery with an

Switch
ammeter capable of indicating several
hundred amperes as shown in the illustration.
Ammeter 2) Close the switch to make sure the pinion shifts
into cranking position properly and the starter
runs at speeds higher than is specified. If the
current draw and/or operating speed is out of
Starter the standard, disassemble the starter for
Tachometer inspection and repairs.
Battery
(12 volts)
CAUTION
• The size of wires used for this test must be as
large as possible. Tighten the terminals securely.
Figure 8 Connections for testing no-load • This starter has a reduction gear. Do not confuse
characteristics gear noise with some abnormal noise else.
• When measuring the starter speed at the end of
the pinion, be ready for accidental shifting of the
pinion.

Version 08/2004
ELECTRICAL SYSTEM DISASSEMBLY
Item Standard
Model M8T70471 M1T68281
Nominal output, V – kW 12 – 2.0 12 – 1.7
Terminal voltage, V 11 11.5
characteristics
130 100
Current draw, A
maximum maximum
No-load
3 850 3 000
Speed, rpm
minimum minimum
3. Magnetic switch
t
1) Disconnect the connector from the M terminal

of the magnetic switch.
2) Connect the magnetic switch to a 12 volt
battery with a switch as shown in the
illustration to test the pull-in coil. Close the
switch to see if the pinion shifts. If the piston
fails to shift, the magnetic switch is faulty.
Battery
(12 volts)
Connector disconnected
CAUTION
within 10 seconds.
Figure 9 Connections for testing pull-in coil

t

Connector disconnected illustration to test the pull-in coil. Close the
switch to see if the pinion shifts. If the piston
fails to shift, the magnetic switch is faulty.
Battery
(12 volts)
CAUTION
within 10 seconds.
Figure 10 Connections for testing hold-in coil

Version 08/2004

t

illustration to make a pinion return test. Close
Connector disconnected the switch and pull the pinion away from the
commutator end by hand. Release the pinion
to see if it returns immediately when released.
If the pinion fails to so return, the magnetic
switch is faulty.
Battery
(12 volts) CAUTION
within 10 seconds.
Figure 11 Connections for pinion return test
9.1.2 Removal
t
1. Disconnect the battery wires. Disconnect the

negative (–) wire first.
2. Disconnect wire (1) from the starter.
3. Loosen bolts (2) (two) holding starter (3) in position
and remove the starter.
Figure 12 Removing starter
9.2 Alternator
t
9.2.1 Inspection before removal

The correct diagnosis of the charging system requires
a careful inspection with the alternator on the engine to
determine whether or not it is necessary to remove the
alternator from the engine for further inspection. The
following chart, in which two troubles are listed with four
possible causes of each, will help locate the cause of
the trouble:
Voltage regulator setting too high

Alternator charge
Ground return circuit defective
Wiring incorrect
too high
Figure 13 Alternator on engine

Series resistor or winding open-circuited
Alternator drive belt loose

Alternator gives
Voltage regulator setting too low

no charge
Alternator output low
Brushes worn

Version 08/2004
ELECTRICAL SYSTEM DISASSEMBLY
9.2.2 Precautions for removal

t
Following is a list of basic precautions that should

always be observed for removal:
1. When installing the battery, care must be used to

make sure the negative (–) terminal is grounded.
2. Do not use a megger (an instrument for high
resistance of electrical materials).
3. Disconnect the battery cables before charging the
battery.
4. Do not attempt to disconnect the lead from the B
terminal of the alternator when the engine is
running.
5. Battery voltage is being applied to the B terminal of
the alternator. Do not ground it.
6. Do not short or ground the L terminal of the
alternator with a built-in IC regulator.
7. Do not blow a spray from the steam cleaner nozzle
at the alternator.
9.2.3 Testing voltage setting

t
Ammeter
1. Connect the alternator to a 12 volt battery with an
ammeter, a voltmeter and a switch as shown in the
illustration.
Switch
2. The voltmeter reading must be zero (0) when the
starter switch is in OFF position. It must be lower
than the battery voltage when the switch is in ON
position (the engine will not start).
Voltmeter Battery 3. With one ammeter lead short-circuited, start the
(12 volts)
engine.
4. Read the voltmeter when the ammeter reading is
below five amperes and the engine is running at
Figure 14 Connections for testing voltage setting 1800 min–1 and also at 2500 min–1 with all
electrical loads turned off. The voltage setting
varies with alternator temperature. Generally, the
higher the alternator temperature, the lower the
voltage setting.
Item Standard
Voltage setting [at

14.7 ± 0.3 V
20°C (68°F)]
9.2.4 Testing output characteristics

t
Ammeter
1. Disconnect the battery ground (negative) cable.
2. Connect one ammeter lead to the B terminal of the
Alternator
alternator and the other lead to the positive
Battery
indicator light
terminal of the battery. Connect one voltmeter
lead to the B terminal and the other lead to the
Switch ground.
3. Connect the battery ground cable.
4. Start the engine.
5. Turn on all electrical loads.
6. Increase the engine speed. Measure the
maximum output current at the specified alternator
Figure 15 Connections for testing output speed when the voltmeter reading is 13.5 volts.
characteristics (alternator with built-in regulator)

Version 08/2004
Standards
Item Model Terminal

voltage/ Speed
current
2 500 rpm
(at normal temperature)

13.5 V/33 A
Output characteristics
maximum
A7T02071C
5 000 rpm
13.5 V/47 A
maximum
9.2.5 Removal
t
1. Disconnect the battery cables.

2. Disconnect the lead from the B terminal of the
alternator.
3. Disconnect the connector from the alternator.
4. Loosen the brace and support bolts. Move the
alternator toward the engine and remove the drive
belt.
5. Remove the alternator.
Figure 16 Removing alternator

Version 08/2004
Cooling System DISASSEMBLY
DISASSEMBLY
10 Cooling System
10.1 Cooling fan removal
t
Hold the fan by one hand and remove the four bolts
that hold the fan in position. Remove the fan and
spacers.
NOTE
Keep the spacers with the fan for installation.
Figure 17 Removing cooling fan
10.2 Thermostat case removal

t
Remove the water pump assembly.
Figure 18 Removing thermostat assembly
10.3 Water pump assembly removal

t
Remove the water pump assembly.
Figure 19 Removing water pump assembly

Version 08/2004
DISASSEMBLY Fuel System
DISASSEMBLY
11 Fuel System
11.1 Fuel injection pipe removal
t
Disconnect the fuel injection pipes and fuel leak-off

pipe from the fuel injection pump and nozzles.
NOTE
Put plugs or caps on the openings of the injection
pump and nozzle connectors.
Figure 20 Removing fuel injection pipes
11.2 Fuel injection nozzle removal

t
Loosen the fuel injection nozzles with a wrench.

Remove the nozzles and gaskets from the cylinder
head.
NOTE
Remove the gaskets from the cylinder head with a
screwdriver or a similar tool. Discard defective
gaskets.
Figure 21 Removing fuel injection nozzles
11.3 Governor assembly removal

t
1. Remove the tie rod cover.

2. Remove the spring from the tie rod with a pliers to
disconnect the tie rod from the fuel injection pump.
3. Remove the governor assembly.
Figure 22 Removing governor assembly

Version 08/2004
Fuel System DISASSEMBLY
11.4 Governor weight removal

t
1. Remove the sliding sleeve.

2. Remove the sliding sleeve shaft and governor
weights.
Figure 23 Removing governor weights
11.5 Fuel injection pump removal

t

2. Remove the spring from the tie rod with a pliers to
disconnect the tie rod from the fuel injection pump.
Figure 24 Removing tie rod
3. Remove the fuel injection pump.

t
NOTE
Keep a record of the thickness of shims for
installation.
Figure 25 Removing fuel injection pump

Version 08/2004
DISASSEMBLY Lubrication System
DISASSEMBLY
12 Lubrication System
12.1 Oil filter removal
t
1. Put a container under the oil filter to catch the oil.

2. Remove the oil filter from the cylinder block with a
filter wrench.
Figure 26 Removing oil filter
12.2 Pressure relief valve removal

t
Remove the pressure relief valve from the cylinder

block.
Figure 27 Removing pressure relief valve
12.3 Oil pressure switch removal

t
Remove the oil pressure switch with Oil Pressure

Switch Socket Wrench (MD998054) (special tool).
Figure 28 Removing oil pressure switch

Version 08/2004
AIR INLET SYSTEM AND EXHAUST
SYSTEM DISASSEMBLY
DISASSEMBLY
13 AIR INLET SYSTEM

AND EXHAUST
SYSTEM
13.1 Exhaust manifold removal
t
Remove the exhaust manifold from the cylinder head.
Figure 29 Removing exhaust manifold
13.2 Air inlet cover removal

t
Remove the air inlet cover from the cylinder head.
Figure 30 Removing air inlet cover

Version 08/2004
CYLINDER HEAD AND VALVE
DISASSEMBLY MECHANISM
DISASSEMBLY
14 CYLINDER HEAD AND

VALVE MECHANISM
1. Rocker cover 5. Cylinder head 9. Valve spring

2. Rocker shaft assembly 6. Cylinder head gasket 10. Valve
3. Valve push rod 7. Valve lock 11. Valve stem seal
4. Cylinder head bolt 8. Valve retainer 12. Valve cap

Version 08/2004
MECHANISM DISASSEMBLY
14.1 Rocker shaft assembly

t
removal
1. Remove the bolts that hold the rocker stays in
position and remove the rocker shaft assembly.
2. Remove the valve caps.
Figure 31 Removing rocker shaft assemblies
14.2 Rocker shaft disassembly

t
Put identification on each rocker arm as to its location

on the rocker shaft.
Figure 32 Disassembling rocker shaft assembly
14.3 Cylinder head bolt removal

t
Loosen the cylinder head bolts in two or three steps in

the sequence shown.
Front NOTE
If any parts on the cylinder head are faulty, check the
cylinder head bolts for tightness with a torque wrench
before loosening them.
Figure 33 Cylinder head bolt loosening sequence

Version 08/2004
DISASSEMBLY MECHANISM
14.4 Cylinder head assembly

t
removal
Lift the cylinder head straight up with a hoist.
NOTE
If the gasket is seized and the cylinder head cannot
be separated from the cylinder block, tap around the
thick side portion of the cylinder head with a plastic
hammer.
Figure 34 Removing cylinder head assembly
14.5 Valve and valve spring removal

t
1. Compress the valve spring with a valve lifter and

remove the valve lock.
2. Remove the retainer, spring and valve.
NOTE
The valves, retainers, springs and valve locks must
be set aside separately in groups, each tagged for
cylinder number, for correct installation.
Figure 35 Removing valve springs
14.6 Valve stem seal removal

t
Remove the valve stem seals with a pliers.
NOTE
Do not reuse the valve stem seals, but replace them
by new ones.
Figure 36 Removing valve stem seals

Version 08/2004
Timing Gears and Flywheel DISASSEMBLY
DISASSEMBLY
15 Timing Gears and

Flywheel
1. Flywheel 7. Crankshaft pulley (Remove 3 thru 5 as an assembly.)

2. Rear plate 8. Timing gear case 13. Fuel injection pump camshaft
3. Oil seal case; oil seal 9. Idler gear gear
4. Tappet (Remove 10 thru 12 as an 14. Bearing
5. Speedometer driven gear assembly.) 15. Fuel injection pump camshaft
6. P.T.O. gear 10. Camshaft gear 16. Oil pump
11. Thrust plate 17. Front plate
12. Camshaft

Version 08/2004
DISASSEMBLY Timing Gears and Flywheel
15.1 Flywheel removal

t
1. Have someone hold the crankshaft pulley with a

wrench to prevent the flywheel from rotating.
2. Remove one of the bolts that hold the flywheel in
position.
WARNING
Always signal each other to prevent possible
personal injury.
Figure 37 Holding flywheel
3. Install a safety bar (M12 x 1.25) into the threaded

t
hole in the flywheel from which the bolt was

removed in Step (2). Remove the remaining bolts.
Safety bar 4. Hold the flywheel by hands and withdraw it from
the crankshaft. Joggling the flywheel back and
forth will facilitate removal.
WARNING
When removing the flywheel, wear heavy gloves to
avoid hand injury.
Figure 38 Removing flywheel
15.2 Rear plate removal

t
The rear plate is doweled in position. Pull the plate as

straight as possible when removing it.
Front
Figure 39 Removing rear plate

Version 08/2004
15.3 Oil seal case removal

t
Remove the bolts that hold the oil seal case in position.
Remove the case from the cylinder block with a
screwdriver or the like.
CAUTION
Do not cause damage to the oil seal.
Figure 40 Removing oil seal case
15.4 Tappet removal

t
Remove the tappets from the cylinder block with a

valve push rod.
NOTE
The valves, retainers, springs and valve locks must
be set aside separately in groups, each tagged for
cylinder number, for correct installation.
Figure 41 Removing tappets
15.5 Speedometer driven gear

t
removal
Remove the lock plate and speedometer driven gear in
that order.
NOTE
Unless the speedometer driven gear is removed, the
camshaft cannot be removed.
Figure 42 Removing speedometer driven gear

Version 08/2004
15.6 Crankshaft pulley removal

t
1. Install two safety bars (M12 x 1.25) into the

threaded holes in the rear end of the crankshaft.
Put a bar between the safety bars to hold the
crankshaft to prevent it from rotating.
2. Remove the crankshaft pulley.
WARNING
When removing the crankshaft pulley, be prepared to
stop the job in case the bar slips off the crankshaft to
prevent injury.
Figure 43 Removing crankshaft pulley
15.7 Timing gear case removal

t
Remove the bolts that hold the timing gear case in

position and remove the case.
CAUTION
The front plate is bolted inside the timing gear case.
Do not attempt to remove this plate along with the
timing gear case by tapping.
Figure 44 Front plate attaching bolts
15.8 Timing gear backlash

t
measurement
Measure the backlash of each gear and keep a record
of it for correct installation. Replace the gears if the
backlash exceeds the limit.
Unit: mm (in.)
Item Standard Limit
Crankshaft gear and

idler gear
Idler gear and

0.04 to 0.12
camshaft gear
Timing gear backlash
(0.001 6 to 0.004 7)
Idler gear and fuel
Figure 45 Measuring timing gear backlash injection pump 0.30
camshaft gear (0.011 8)
Camshaft gear and 0.08 to 0.19

P.T.O. gear (0.003 1 to 0.007 5)
Fuel injection pump 0.07 to 0.20

camshaft gear and oil (0.002 8 to 0.007 9)
pump gear

Version 08/2004
15.9 Idler gear removal

t
To remove the idler gear, rotate the gear in a direction

of the helix of the teeth to pull it out of mesh.
Figure 46 Removing idler gear
15.10 Camshaft removal

t
1. Remove the bolts that hold the thrust plate.

2. Pull the camshaft out of the cylinder block.
CAUTION
Do not cause damage to the lobes or bearing journals
when removing the camshaft.
Figure 47 Removing camshaft
15.11 Fuel injection pump camshaft

t
removal
1. Remove the stopper bolt.
Figure 48 Removing camshaft stopper bolt

Version 08/2004
2. Tap the rear end of the camshaft with a copper bar

t
to push it out of the front side of the cylinder block.
Figure 49 Removing fuel injection pump camshaft
15.12 Gear removal (when required)

To remove the gears from the camshaft and fuel
injection pump camshaft, use an arbor press.
15.13 Oil pump removal

t
Remove the bolts that hold the oil pump to the cylinder
block and remove the pump.
Figure 50 Removing oil pump
15.14 Front plate removal

t
Remove four bolts that hold the front plate in position.

Tap the plate lightly with a plastic hammer to separate
the gasket.
Figure 51 Removing front plate

Version 08/2004
Cylinder Block, Crankshaft, Pistons
and Oil Pan DISASSEMBLY
DISASSEMBLY
16 Cylinder Block,
Crankshaft, Pistons and
Oil Pan
1. Oil pan 6. Piston pin 11. Connecting rod bearing (upper half)
2. Oil screen 7. No. 1 ring 12. Main bearing cap
3. Connecting rod cap 8. No. 2 ring 13. Main bearing (lower half)
4. Connecting rod bearing (lower half) 9. Oil ring 14. Crankshaft
(Remove 5 thru 10 as an assembly.) 10. Piston 15. Main bearing (upper half)
5. Connecting rod 16. Cylinder block
NOTE: When the cylinder block is to be discarded, remove the components (pressure relief valve, etc.) from the block for
reuse.

Version 08/2004
DISASSEMBLY and Oil Pan
16.1 Oil pan removal

t
1. Turn the engine upside down.

2. Tap the bottom corners of the oil pan with a plastic
hammer to remove the oil pan.
CAUTION
Do not attempt to pry off the oil pan by inserting a
screwdriver or a chisel between the oil pan and
cylinder block. Damage to the oil pan can be the
result.
Figure 52 Removing oil pan
16.2 Oil screen removal

t
Loosen the nut that holds the oil screen in position and
remove the screen.
Figure 53 Removing oil screen
16.3 Thrust clearance measurement

t
for connecting rod big end

Install the connecting rod to its crankpin and tighten the
cap nuts to the specified torque. Measure the thrust
clearance with a feeler gauge. If the clearance
exceeds the limit, replace the connecting rod.
Unit: mm (in.)
Item Standard Limit
Thrust clearance for

0.10 to 0.35 0.50
connecting rod big
(0.003 9 to 0.013 8) (0.019 7)
end
Figure 54 Measuring thrust clearance for connecting

rod big end

Version 08/2004
16.4 Connecting rod cap removal

t
1. Lay the cylinder block on its side.

2. Put identification on each connecting rod and cap
combination as to its location in the engine.
3. Remove the caps.
Figure 55 Removing connecting rod caps
16.5 Piston removal

t
1. Turn the crankshaft until the piston is at top center.

2. Push the piston and connecting rod away from the
crankshaft with the handle of a hammer or the like
until the piston rings are above the cylinder.
Remove the piston and connecting rod. Do Steps
(1) and (2) for the removal of the other pistons.
Figure 56 Removing piston
16.6 End play measurement for

t
crankshaft
Set a dial indicator so that it will touch the end of the
crankshaft and measure the end play. If the end play
exceeds the limit, replace No. 3 flanged bearing.
Unit: mm (in.)
Item Standard Limit
End play for

0.050 to 0.175 0.500 (0.019
crankshaft end
(0.001 97 to 0.006 89) 69)
play
Figure 57 Measuring end play for crankshaft

Version 08/2004
DISASSEMBLY and Oil Pan
16.7 Main bearing cap removal

t
1. Lay the cylinder block with its bottom (oil pan) side
up.
2. Remove the bolts that hold the main bearing caps
in position. Remove the caps.
3. Remove the front and rear bearing caps with a
sliding hammer.
Figure 58 Removing main bearing caps
16.8 Crankshaft removal

t
Remove the crankshaft.
CAUTION
Do not cause damage to the bearings.
NOTE
Figure 59 Removing crankshaft Put identification on each main bearing as to its
location in the engine.
16.9 Piston separation from

t
connecting rod
1. Use Piston Pin Setting Tool (31A91-00100)
(special tool) to separate the piston from the
connecting rod.
Figure 60 Piston pin setting tool

Version 08/2004
2. Insert the push rod of the tool into the bore in the
t
piston for the piston pin and, using an arbor press,

remove the piston pin.
Push rod (tool) 3. Use this Piston Pin Setting Tool to install the
Piston pin Connecting rod connecting rod to the piston.
Identification mark
Arrow mark
Piston
Tool body
Figure 61 Removing piston pin (1)
CAUTION
Do not attempt to remove the piston pin by tapping.
Replace a piston pin which needs a greater force for
removal.
Figure 62 Removing piston pin (2)

Version 08/2004
INSPECTION

Version 08/2004
MECHANISM INSPECTION
INSPECTION

VALVE MECHANISM
Check oil hole

Check threads for clogging
for stripping
Check end Check bore for

for wear. wear
Check for wear or clogged oil holes
Test
Check valve seats

Check for damage for impoper contact Check valve guides
and test or wear for wear or damage
Check for warpage
Check for galling or
wear
Check for ridges or

damage
Check for wear or

improper contact
Check ends for

wear or damage
Check for cracks,

Check for bend oil or coolant leaks.
Remove gasket,
scale and carbon
deposits
Figure 63 Inspection points

Version 08/2004
INSPECTION MECHANISM
17.1 Cylinder head

Using a heavy accurate straight edge and a feeler
gauge, check the bottom face for warpage in three
positions lengthwise, two crosswise and two widthwise
as shown in the illustration. If warpage exceeds the
limit, reface the bottom face with a surface grinder.
Unit: mm (in.)
Item Standard Limit
Warpage of cylinder 0.05 (0.002 0) 0.10

head bottom face maximum (0.003 9)
Figure 64 Checking cylinder head bottom face for

warpage
17.2 Rocker arms and rocker shaft

Measure the bore in the rocker arm for the rocker shaft
and the diameter of the rocker shaft to find the
clearance between the arm and shaft. If the clearance
has reached the limit, replace the rocker arm. If it
exceeds the limit, replace both arm and shaft.
Unit: mm (in.)
Nominal
Item Standard Limit
size
Bore in rocker 18.9 18.910 to —

arm for shaft (0.744) 18.930
Figure 65 Measuring rocker arm and rocker shaft (0.744 49 to
0.745 27)
Diameter of shaft 18.9 18.880 to —

for arm (0.744) 18.898
(0.743 31 to
0.744 01)
Clearance — 0.012 to 0.200

between rocker 0.050 (0.007
arm and shaft (0.000 47 to 87)
0.001 97)

Version 08/2004
17.3 Valve springs

Check the squareness and free length. If the
squareness and/or free length exceeds the limit,
Squareness replace the spring.
Unit: mm (in.)
Item Standard Limit

Free length
Free length 47 (1.85) 46 (1.81)
Squareness 1.5° maximum
Length under 13.9 ± 0.7

test force: (30.6 ± 1.5)
Figure 66 Testing valve spring
kgf (lbf) [N]

Test force,
39.1 (1.54) [136 ± 7]
–15%
Length under 29 ± 2
test force: (64 ± 4.4)
30.5 (1.20) [284 ± 20]
17.4 Valve push rods

Using V-blocks and a dial indicator, check for bend. If
the bend exceeds the limit, replace the push rod.
Unit: mm (in.)
Item Limit
Bend (dial indicator reading) of valve 0.3 (0.012)

push rod maximum
Figure 67 Checking bend of valve push rod
17.5 Valves, valve guides and valve

Measuring seats
diagram
1. Diameter of valve stem
Measure the diameter of the valve stem as shown
in the illustration. If the stem is worn beyond the
limit, or if it is abnormally worn, replace the valve.
Unit: mm (in.)
Nominal
Item Standard Limit
size
Diameter Inlet 6.6 6.565 to

Figure 68 Measuring valve stem of valve valve (0.260) 6.580
stem (0.258 46 to
0.259 05) 6.500
Exhaust 6.6 6.530 to (0.255 91)

valve (0.260) 6.550
(0.257 09 to
0.257 87

Version 08/2004
2. Clearance between valve stem and valve guide
The valve guide wears more rapidly at its both

Inside micrometer ends than at any other parts. Measure the bore in
caliper the guide for the stem at its ends with an inside
micrometer caliper to find the clearance between
the stem and guide. If the clearance exceeds the
limit, replace the guide or valve whichever is badly
worn.
Unit: mm (in.)
Nominal
Item Standard Limit
size
Clearance Inlet — 0.02 to 0.10

between valve 0.05 (0.003 9)
Figure 69 Measuring valve guide
valve stem (0.000 8 to
and valve 0.002 0)
guide
Exhaust — 0.05 to 0.15
valve 0.085 (0.005 9)
(0.002 0 to
0.003 35)
Height to top of valve 10 9.5 to 10.5 —

guide (0.39) (0.374 to
0.413)
NOTE
Before measuring the valve guides, clear the guides
of lacquer and carbon.
3. Valve guide replacement

10 ± 0.5 mm
Valve guide 1) Remove the guide from the cylinder head by

0.020 in.)
(0.39 ±
pushing it with a tool and an arbor press from

the bottom side of the head.
2) Install a new guide into the cylinder head by
Cylinder head pushing it with an arbor press from the upper
side of the head until the specified height to
(0.59 in.)
15 mm
the top of the guide is obtained.

3) Insert a new valve into the guide and make
sure the valve slides in the guide freely.
4) After the valve guide has been replaced,
check the valve contact with its seat.
Figure 70 Height to top of valve guide

Version 08/2004
4. Valves
1) Put a small amount of Prussian blue or red

lead on the valve face. Hold the valve with a
valve lapping tool (commercially available)
Valve lapping and press it against the seat to check its
tool contact.
Prussian
blue
Figure 71 Checking valve contact with seat
2) The width of contact must be uniform all the

way around both seat and valve. If the contact
is bad, reface the valve and seat.
Good Bad
Contact must be uniform

around the complete
circumference.
Figure 72 Valve and valve seat contact
3) If the valve margin (valve lip thickness)

Valve sinkage Valve margin exceeds the limit, replace the valve.
Unit: mm (in.)
Item Standard Limit
Valve margin (lip 1.0 (0.039) 0.5 (0.020)

thickness)
4) If the valve sinkage (the dimension from the

top of a closed valve to the face of cylinder
head) exceeds the limit, recondition the valve
seat or replace the cylinder head assembly.
Unit: mm (in.)
Figure 73 Valve margin and sinkage Item Standard Limit
Valve sinkage 0.5 ± 0.25 1.5

(dimension from top (0.020 ± 0.009 8) (0.059)
of closed valve to
face of head)

Version 08/2004
5. Valve refacing
1) Set the valve refacer at an angle of 45° and

grind the valve.
2) The valve margin must be not less than the
limit. If the margin seems to be less than the
limit when the valve is refaced, replace the
valve.
Figure 74 Refacing valve face
6. Valve seat refacing
1) Before refacing the valve seat, check the

clearance between the valve and guide, and
replace the guide if necessary.
2) Cut the valve seat with a valve seat cutter
(commercially available), or grind it with a
valve seat grinder, and finish the width of
valve seat and the angle of seat face to the
correct values.
Figure 75 Refacing valve seat
Unit: mm (in.)
Width of valve seat 1.3
to 1.8 mm
(0.051 tot 0.071 in.) Item Standard Limit
Angle of seat face 45° —
Width of valve seat 1.3 to 1.8 2.5

(0.051 to 0.071) (0.098)
3) After refacing the valve seat, put lapping

compound on the valve face and lap the valve
in the valve seat.
Figure 76 Valve seat width and valve face angle

Version 08/2004
7. Valve lapping
Be sure to lap the valves in the seats after refacing

or replacing the valves or valve seats.
1) Put a small amount of lapping compound on

the valve face.
Compound
NOTE
• Do not put lapping compound on the valve stem.
• Use a lapping compound of 120 to 150 mesh for
initial lapping and a compound of finer than 200
mesh for finish lapping.
• Mixing the compound with a small amount of
Figure 77 Lapping valve in seat engine oil will help put the compound on the
valve face uniformly.
2) Using a lapping tool, hold the valve against

the seat and rotate it only a part of a turn, then
raise the valve off its seat, rotating it to a new
position. Press the valve against the seat for
another part of a turn. Repeat this operation
until the compound wears and loses its cutting
property.
3) Wash the valve and valve seat with dry
cleaning solvent.
4) Apply engine oil to the valve and lap it in the
seat.
5) Check the valve face for contact.
17.6 Combustion jet replacement

Replace the combustion jets only when they are
Round bar cracked or defective.
1. To remove the jet, insert a 6 mm (0.24 in.) diameter

round bar through the bore in the cylinder head for
the glow plug and tap around the jet.
Combustion jet
Figure 78 Removing combustion jet

Version 08/2004
2. To install a new jet, put the jet in position in the

Combustion jet head with its tangential orifice in alignment with the
center of the main chamber and tap it with a
plastic hammer. The new jet must be flush with the
cylinder head surface.
Figure 79 Installing combustion jet

Version 08/2004
TIMING GEARS AND FLYWHEEL INSPECTION
INSPECTION
18 TIMING GEARS AND

FLYWHEEL
Check for wear.
Check for damage to lobes

and bearing journals.
Check for wear or abnormal

noise (when spun).
Check teeth for wear,

nicks, burrs or chips.
Check speedometer driven gear for damage.
Check for bend or damage to lobes.
Check for cracks or distortion.
Check belt groove for wear.
Check clutch contact face for scores

or ridges. Check ring gears for
damage or wear.
Check for wear, damage or aging.

Version 08/2004
INSPECTION TIMING GEARS AND FLYWHEEL
18.1 Camshaft
1. Clearance between journal and bushing
Measure the diameter of the journal and the bore in the

bushing for the shaft to find the clearance as shown in
the illustration. If the clearance exceeds the limit,
replace the bushing.
Unit: mm (in.)
Item Standard
Clearance between
Figure 81 Measuring camshaft journal camshaft journal and 0.15 (0.005 9)
bushing
Figure 82 Measuring bore in camshaft bushing
2. Bushing replacement
Front of cylinder Camshaft Use Camshaft Bushing Installer (ST332340) (special
block
bushing
tool) for camshaft bushing replacement.
1) Removal
Remove the oil pan. Using a “remover” end of
the Installer, push out the bushing into the
cylinder block. Crush and take out the
bushing from the block.
Camshaft Bushing
Installer
Figure 83 Removing camshaft bushing

Version 08/2004
2) Installation
1 mm (0.04 in.) Install a new bushing in position with its oil
holes in alignment with those of the oil gallery.
Notch in
bushing
1 mm (0.04 in.) Ends of

bushing
Oil holes
Figure 84 Installing camshaft bushing
3. Lobe lift
Measure the lobe height and base circle as shown in

the illustration. Subtract the base circle from the lobe
height to find the lobe life. If the lobe lift exceeds the
limit, replace the camshaft
.Unit: mm (in.)
Item Standard Limit
Lobe height of 35.72 34.72

camshaft (1.404 3) (1.366 9)
Figure 85 Measuring lobe height of camshaft
18.2 Fuel injection pump camshaft

Measure the lobe height and base circle as shown in
the illustration. Subtract the base circle from the lobe
height to find the lobe life. If the lobe lift exceeds the
limit, replace the camshaft.
.Unit: mm (in.)
Item Standard Limit
Lobe height of fuel

44 43
injection pump
(1.73) (1.69)
camshaft
Figure 86 Measuring lobe height of fuel injection
pump camshaft

Version 08/2004
INSPECTION TIMING GEARS AND FLYWHEEL
18.3 Tappets
1. Cam contact face
Check the cam contact face of each tappet for
abnormal wear. Replace the tappet if the face is
defective.
Good Bad Bad
Figure 87 Cam contact face of tappet
2. Clearance between tappet and cylinder block

Measure the diameter of the tappet and the bore in
the cylinder block for the tappet to find the clear-
ance. If the clearance exceeds the limit, replace
the tappet.
Unit: mm (in.)
Item Standard
Clearance between tappet

0.15 (0.005 9)
and cylinder block
Figure 88 Measuring tappet and bore in cylinder

block
18.4 Idler gear

1. Clearance between idler gear and shaft
Measure the bore in the idler gear for the shaft and
the diameter of the shaft to find the clearance. If
the clearance exceeds the limit, replace the gear
or shaft whichever is badly worn.
.Unit: mm (in.)
Item Standard Limit
Clearance between 0.03 to 0.07 0.20

idler gear and shaft (0.001 2 to 0.002 8) (0.007 9)
Figure 89 Measuring idler gear and shaft

Version 08/2004
2. Idler shaft replacement
Install a new idler shaft to the cylinder block so that

26,5 ± 0.5 mm its dimension from the face of the block is 26.5±0.5
(1.043 ± 0.020 in.)
mm (1.043±0.020 in.).
Figure 90 Idler shaft dimension
18.5 Flywheel and ring gear

1. Flatness (difference between lower and higher
measurements) of flywheel
Put the flywheel on the surface plate. Set a dial

indicator at one side of the friction (clutch contact)
face and move it over to the opposite side of the
face as shown in the illustration to find the flatness.
If the flatness exceeds the limit, grind the face.
Unit: mm (in.)
Item Standard Limit
Figure 91 Measering flywheel flatness Flatness of 0.15 (0.005 9) 0.50

flywheel maximum (0.019 7)
2. Ring gear replacement
Check the ring gear and replace it if its teeth are

abnormally worn or chipped.
1) Removal
Heat the ring gear evenly with an acetylene
torch. Tap the ring gear all the way around
with a bar and a hammer as shown in the
illustration to remove it from the flywheel.
2) Installation
Heat a new ring gear up to a temperature of
150°C (302°F) with a piston heater and install
it to the flywheel with its unchamfered side
foremost.
Figure 92 Removing ring gear

Version 08/2004
CYLINDER BLOCK, CRANKSHAFT,
INSPECTION PISTONS AND OIL PAN
INSPECTION
19 CYLINDER BLOCK,
CRANKSHAFT,
PISTONS AND OIL PAN
Check for cracks,

scores or ridges at Check for wear or
top of ring travel. damage.
Check clearance
between ends.
Check top face for Check for wear, scores,

warpage. cracks, overheating or
excessive widened ring
grooves.
Check for damage

to plugs or dowels.
Check for bend or twist.
Check big end thrust
Check for plugged clearance.
oil holes.
Check for damage to

gear teeth.
Check journals and
crankpins for abnormal
wear, cracks, bend or
plugged oil holes.
CAUTION
Do not reuse crankshaft if it
shows evidence of overheating.
Scratches
Loss of
overlay
Defect
due to
poor
installation
Figure 93 Points à inspecter

Version 08/2004
PISTONS AND OIL PAN INSPECTION
Direction transverse
to piston pin 19.1 Pistons, Piston Rings and
Piston Pins
1. Diameter of piston
Measure the diameter of the piston at its skirt in a

direction transverse to the piston pin with a micrometer
as shown in the illustration. If the diameter exceeds the
limit, replace the piston. Select a new piston so that the
difference between average weight of all pistons in one
engine does not exceed the standard.
Figure 94 Measuring diameter of piston
Unit: mm (in.)
Item Norminal size Standard Limit
78.00 77.93 to 77.95 77.80

Standard
(3.070 9) (3.068 1 to 3.068) (3.063 0)
0.25
78.25 78.18 to 78.20 (3.077 78.05
(0.009 8)
(3.080 7) 9 to 3.078 7) (3.072 8)
Diameter of piston oversize
78.43 to
0.50
78.50 87.45 78.30
(0.019 7)
(3.090 5) (3.087 8 to (3.082 7)
oversize
3.088 6)
Maximum permissible difference between average weight of all pistons in

5 (0.18) __
one engine, g (oz)
2. Clearance between piston ring and groove

No. 1 compression ring clearance
1) Measure the clearance between the groove
No. 2 compression and piston with a straight edge and a feeler
ring clearance gauge as shown in the illustration. If the
clearance exceeds the limit, replace the ring.
.Unit: mm (in.)
Item Standard Limit
No. 1 0.06 to 0.10 0.30

compression ring (0.002 4 to 0.003 9) (0.011 8)
No. 2 0.06 to 0.10 0.20

compression ring (0.002 0 to 0.003 5) (0.007 9)
Figure 95 Measuring clearance between piston ring
and groove Oil ring 0.06 to 0.10 0.20
(0.001 2 to 0.002 8) (0.007 9)
2) If the clearance still exceeds the limit after

new piston rings have been installed, replace
the piston.

Version 08/2004
3. Clearance between ends of piston ring
Put the piston ring in a gauge or in the bore in a new

cylinder block and measure the clearance between the
ends of the ring with a feeler gauge as shown in the
illustration. If the clearance exceeds the limit, replace
all the rings.
Inside diameter of gauge
Standard: 780+0.03 mm (3.070+0.0012 in.)
0.25 mm (0.0098 in.) oversize:
Figure 96 Measuring clearance between ends of 78.250+0.03 mm (3.080+0.0012 in.)

piston ring
0.50 mm (0.0197 in.) oversize:
78.500+0.03 mm (3.090+0.0012 in.)
NOTE
Put the piston ring in the gauge or cylinder squarely
with the piston.
.Unit: mm (in.)
Item Standard Limit
No. 1 0.15 to 0.30

compression (0.005 9 to
ring 0.011 8)
Clearance
No. 2 0.15 to 0.35
between 1.50
compression (0.005 9 to
ends of (0.059 1)
ring 0.013 8)
piston ring
Oil ring 0.20 to 0.40
(0.007 9 to
0.015 7)

Version 08/2004
4. Clearance between piston pin and piston
Measure the diameter of the piston pin and the bore in

the piston for the pin as shown in the illustration to find
the clearance. If the clearance exceeds the limit,
replace the piston or pin whichever is badly worn.
.Unit: mm (in.)
Norminal
Item Standard Limit
size
22.994 to
Diameter of 23.000
23 (0.91)
piston pin (0.905 027 to
Figure 97 Measuring piston pin and bore in piston for 0.905 51)
pin
Clearance
0.006 to 0.018 0.050
between
— (0.00024 to (0.001
piston pin and
0.00071) 97)
piston
19.2 Connecting rods

Unit: mm (in.) C 0.05 (0.0020)
---- < -------------------------------- Check the connecting rod for bend or twist as follows:
100 (3.94)
1) Measure “C” and “ .” If “C” exceeds 0.05 mm
(0.0020 in.) per 100 mm (3.94 in.) of “ ,”
straighten the connecting rod with a press.
Piston pin
C
---- < 0.05
(0.0020)- .Unit: mm (in.)
-------------------------------
100 (3.94)
Bend Twist Item Standard Limit
0.05/100
Bend or twist of 0.15/100
(0.002 3/4.94)
connecting rod (0.005 9/3.94)
maximum
Figure 98 Checking connecting rod for bend or twist
2) Generally, a connecting rod aligner is used to

check the connecting rod for bend or twist.
NOTE
To check the rod for bend, install the cap to the
connecting rod and tighten the cap nuts to the
specified torque.
Figure 99 Check connecting rod on a connecting rod

aligner

Version 08/2004
3) To check the connecting rod fitted to the piston

for bend, put the connecting rod and piston
on the surface plate as shown in the
illustration, insert a round bar having a
diameter equal to that of the crankpin into the
bore in the big end of the rod and measure “A”
and “B” with a dial indicator. Subtract “A” from
“B” to find the bend (“C”).
Figure 100 Checking connecting rod for bend with a

dial indicator
Measuring diagram
3.55 ± 0.25 kgf m 19.3 Crankshaft
(25.7 ± 1.8 lbf ft)
[34.8 ± 2.5 N m]
1. Clearance between crankpin and connecting rod
bearing
1) Install the bearing (upper and lower halves)

and cap to the big end of the connecting rod
and tighten the cap nuts to the specified
torque. Measure the bore in the bearing for
crankpin as shown in the illustration.
3.55 ± 0.25 kgf.m

Tightening torque (25.7 ± 1.8 lbf.ft)
[34.8 ± 2.5 N.m]
Figure 101 Measuring bore in connecting rod bearing
2) Measure the diameter of the crankpin as

Measuring diagram shown in the illustration to find the clearance
between the crankpin and connecting rod
bearing.
.Unit: mm (in.)
Norminal
Item Standard Limit
size
47.950 to
Diameter of
48 47.965
crankpin —
(1.89) (1.887 79 to
(standard)
1.888 38)
Clearance
between 0.025 to 0.072 0.150
Figure 102 Measuring diameter of crankpin crankpin and — (0.000 98 to (0.005
connecting 0.002 83) 91)
rod bearing
3) If the clearance exceeds the limit, install a new

bearing and check the clearance again.
4) If the clearance still exceeds the limit, grind
the crankpin to 0.25 mm (0.0098 in.), 0.50 mm
(0.0197 in.) or 0.75 mm (0.0295 in.) undersize
and use undersize connecting rod bearing.

Version 08/2004
Unit: mm (in.)
Item Undersize Finish
0.25 -0.035 -0.00138

47.75 (1.8799 )
(0.009 8) -0.050 -0.00197
0.50 -0.035 -0.00138

Crankpin 47.50 (1.8701 )
(0.019 7) -0.050 -0.00197
0.75 -0.035 -0.00138

47.25 (1.8602 )
(0.029 5) -0.050 -0.00197
Table 2 Crankpin undersizes
CAUTION
• Grind all the crankpins of one crankshaft to the
same undersize.
• Finish the crankpin fillets to a radius of 2.5 mm
2.5 mm
(0.098 in.) (0.098 in.).
Figure 103 Crankpin fillet radius
2. Clearance between journal and main bearing
1) Install the main bearing (upper and lower

halves) and cap to the cylinder block and
tighten the cap bolts to the specified torque.
Measure the bore in the bearing for the journal
as shown in the illustration.
Tightening torque 5.25 ± 0.25 kgf·m

(38 ± 1.8 lbf·ft)
[51.5 ± 2.5 N·m]
Figure 104 Measuring bore in main bearing

Version 08/2004
2) Measure the diameter of the journal as shown

Measuring diagram in the illustration to find the clearance between
the journal and main bearing.
.Unit: mm (in.)
Norminal
Item Standard Limit
size
51.985 to
Diameter of
52 52.000
journal —
(2.05) (2.046 65 to
(standard)
2.047 24)
Clearance
0.030 to 0.077 0.100
between
Figure 105 Measuring diameter of journal — (0.001 18 to (0.003
journal and
0.003 03) 94)
main bearing
3) If the clearance exceeds the limit, install a new

bearing and check the clearance again.
4) If the clearance still exceeds the limit, grind
the journal to 0.25 mm (0.009 8 in.), 0.50 mm
(0.019 7 in.) or 0.75 mm (0.029 5 in.)
undersize and use undersize main bearing.
Journal undersizes
Unit: mm (in.)
2 mm (0.08 in.) 2 mm (0.08 in.) Item Undersize Finish
0.25 0 0
51.75 (2.0374 )
(0.009 8) -0.015 -0.00059
0.50 0 0
Journal 51.50 (2.0276 )
(0.019 7) -0.015 -0.00059
0.75 0 0
51.25 (2.0177 )
(0.029 5) -0.015 -0.00059
Figure 106 Journal fillet radius CAUTION

• Grind all the journals of one crankshaft to the
same undersize.
• Finish the journal fillets to a radius of 2 mm
(0.08 in.).

Version 08/2004
3. Runout
Support the crankshaft on its front and rear jour-
nals in V-blocks or in a lathe and check runout at
the center journal with a dial indicator as shown in
the illustration. Depending on the amount of
runout, repair the crankshaft by grinding or by
straightening with a press. If runout exceeds the
limit, replace the crankshaft.
Unit: mm (in.)
Item Standard Limit
Crankshaft runout 0.025 (0.000 98) 0.05 (0.002 0)
Figure 107 Checking crankshaft runout
4. Crankshaft gear removal

Use a gear puller to remove the gear from the
crankshaft
NOTE
Do not remove the gear unless the gear or crankshaft
is defective.
Figure 108 Removing crankshaft gear
5. Crankshaft gear installation

1) Install the key in position on the crankshaft.
2) Install the gear in position with its keyway in
alignment with the key as shown in the
To be aligned illustration.
Figure 109 Installing crankshaft gear

Version 08/2004
19.4 Cylinder block

1. Bore
Measure the bore at the top, middle and bottom
points on axes A and B with a cylinder bore gauge
as shown in the illustration. If any one of the cylin-
ders exceeds the limit, hone out all the bores for
oversize pistons.
Unit: mm (in.)
Pioston and piston ring Bore
Size Size code Standard Limit

+0.03
Standard STD 78
0
+0.0012
(3.07 0
)
Figure 110 Measuring bore in cylinder block +0.03
0.25 (0.009 8) 25 78.25 Standard:
0
oversize +0.2
+0.0012
(3.0807 0
) (+0.008)
+0.03
0.50 (0.019 7) 50 78.50
0
oversize
+0.0012
(3.0905 0
)
Taper and out-of-round 0.01 (0.000 4) —

maximum
2. Warpage of top face

Using a heavy accurate straight edge and a feeler
gauge, check the top face for warpage in two posi-
tions lengthwise, two crosswise and two widthwise
as shown in the illustration. If warpage exceeds
the limit, reface the top face with a surface grinder.
CAUTION
The maximum permissible amount of stock to be
removed from the cylinder head and block by grinding
is 0.2 mm (0.008 in.) in total.
Figure 111 Checking cylinder block top face for

warpage .Unit: mm (in.)
Item Standard Limit
Warpage of cylinder 0.05 (0.002 0) 0.10

block top face maximum (0.003 9)

Version 08/2004

Version 08/2004
ASSEMBLY

Version 08/2004
Cylinder Block, Crankshaft, Pistons and
Oil pan ASSEMBLY
ASSEMBLY
20 Cylinder Block,
Crankshaft, Pistons and
Oil pan
Lubricate the engine

surface with engine oil
Force fit
Lubricate the bearing

(inside) surface with
engine oil
Coat the front and rear bearing cap

contact surfaces with Three Bond 1212
Lubricate the bearing

(inside) with engine oil
Coat with Three Bond 1212

Tightening torque:
3.55 ± 0.25 kgf m (25.7 ± 1.8 lbf ft)
[34.8 ± 2.5 N m]
Tightening torque:
5.25 ± 0.25 kgf m (38 ± 1.8 lbf ft)
[51.5 ± 2.5 N m]
Coat the entire surface with
Three Bond 1207C
Tightening torque
Cast oil pan:
2.8 ± 0.3 kgf m (20.3 ± 2.2 lbf ft)
[27.5 ± 3 N m]
Plate oil pan:
1.15 ± 0.15 kgf m (8.3 ± 1.1 lbf ft)
[11.3 ± 1.5 N m]

Version 08/2004
ASSEMBLY Oil pan
20.1 Main bearing installation

1. Install the upper halves of the main bearings in the
cylinder block and the lower halves in the main
bearing caps so their tabs fit into the notches in the
cylinder block and the main bearing caps.
2. Install the flanged bearing in the No. 3 journal.
3. Lightly lubricate the inside surfaces of the bearings
with engine oil.
Figure 113 Installing main bearings
20.2 Crankshaft installation

1. Clean the crankshaft with cleaning solvent and
blow dry with compressed air.
2. Fasten a hoist to the crankshaft and hold it in
horizontal position. Carefully put the crankshaft in
position in the cylinder block.
3. Lightly lubricate the crankshaft journals with
engine oil.
Figure 114 Installing crankshaft
20.3 Main bearing cap installation

1. Coat the mating surfaces of the rear bearing cap
and cylinder block with Three Bond 1212.
2. Install the main bearing caps in position. Make
sure the number (arrow head) on the main bearing
cap is toward the front of the engine.
3. Tighten the main bearing cap bolts finger tight only.
Figure 115 Main bearing caps installed

Version 08/2004
Oil pan ASSEMBLY
CAUTION
Install the front and rear bearing caps in position so
their end faces are even with the end faces of the
cylinder block.
Figure 116 Installing front and rear bearing caps
4. Tighten the bolts holding the main bearing caps in

steps to the specified torque.
5.25 ± 0.25 kgf·m
Tightening torque (38 ± 2 lbf·ft)
[51.5 ± 2.5 N·m]
Figure 117 Tightening bolts holding main bearing

caps
5. Make sure the crankshaft rotates freely without

binding or catching.
6. Measure the end play for the crankshaft. Make
reference to “End play measurement for
crankshaft” (page 42). If the end play is incorrect,
loosen the bolts holding the main bearing caps
once and tighten them again.
Figure 118 Checking crankshaft for rotation

Version 08/2004
ASSEMBLY Oil pan
Side seals
20.4 Side seal installation
1. Coat the side seals with Three Bond 1212.
2. Insert the side seals between the cylinder block
and the front and rear caps and push in them by
hand as far as possible, with their rounded side
Rounded side Rounded side toward the outside of the cylinder block.
Figure 119 Side seals
3. Using a flat plate, push the seals into position,

taking care not to bend them.
Figure 120 Installing side seals
20.5 Piston assembling to

connecting rod
1. Set Piston Setting Tool (31A91-00100) (special
tool) in a hydraulic press.
2. Put the connecting rod on the Tool and lubricate
the bore in the rod for the piston pin with engine oil.
Figure 121 Connecting rod on Piston Setting Tool

Version 08/2004
Oil pan ASSEMBLY
3. Put the piston in position on the connecting rod,

making sure the model identification on the rod is
on the same side as the arrow head on the top of
the piston. Put the piston pin in position.
Figure 122 Installing piston pin
4. Insert the push rod of the Tool into the bore in the
piston for the piston pin and press the pin with the
press.
CAUTION
Observe the indicator of the press when pressing the
piston pin. If the force of the press is ready to exceed
50 kgf (110 lbf) [490 N], stop pressing the pin and
check the bores in the piston and connecting rod for
alignment.
Figure 123 Pressing piston pin
5. After assembling the piston and connecting rod,

make sure the connecting rod moves freely.
Figure 124 Checking piston and connecting rod

Version 08/2004
ASSEMBLY Oil pan
20.6 Piston ring installation

Using a piston ring pliers, install the piston rings to the
Mark to be up piston.
No. 1
compression
ring
No. 2
NOTE
compression
ring 1. The piston rings must be installed with the side
Oil ring
that has the mark “T” toward the top of the piston.
2. The oil ring must be installed with the ring end
gap 180° apart from the coil spring joint.
Figure 125 Piston rings
Coil spring joint
Ring end gap
Figure 126 Oil ring
20.7 Piston and connecting rod

Oil ring installation
1. Lubricate the piston and piston rings with engine
oil.
Front of 2. Move the piston rings on the piston so that the end
engine gaps are apart from a direction parallel to, or
transverse to, the piston pin.
3. Install the connecting rod bearing (upper half) to
the rod, making sure the tab in the back of the
bearing is in the notch of the connecting rod.
No. 1 compression No. 2 compression 4. Turn the crankshaft until the crankpin for the piston
ring ring and oil ring and connecting rod to be installed is at the top
coil spring joint center.
5. Hold the piston and connecting rod with “FRONT”
mark (arrow head) on the top of the piston toward
Figure 127 Relative location of piston ring end gaps the front (timing gear case side) of the engine.

Version 08/2004
Oil pan ASSEMBLY
6. Using a piston guide (commercially available), put

the piston and connecting rod into the cylinder
from the top of the cylinder block.
CAUTION
Do not hit the piston with a hammer to install the
piston and connecting rod. This will put force on the
piston and connecting rod and cause damage to the
piston rings and crankpin..
Piston guide
Figure 128 Installing piston and connecting rod
20.8 Connecting rod cap

installation
1. Push the piston into position until the big end of the
connecting rod is put into position over the
crankpin. Then turn the crankshaft 180° while
pushing on the top of the piston.
2. Install the lower half of the connecting rod bearing
in the connecting rod cap, making sure the tab in
the back of the bearing is in the notch of the cap.
3. Install the bearing cap to the connecting rod.
Notches
Cilinder
number
Figure 129 Installing connecting rod cap
NOTE
• Make sure the number on the cap is the same as
the number on the connecting rod.
• In case of a new connecting rod having no
cylinder number, install the cap to the rod with
the notches on the same side.
4. Tighten the connecting rod cap nuts in steps to the

specified torque.
3.55 ± 0.25 kgf·m
Tightening torque (25.7 ± 2 lbf·ft)
[34.8 ± 2.5 N·m]
Figure 130 Tightening connecting rod cap nuts
5. Check the thrust clearance for the connecting rod

big end.

Version 08/2004
ASSEMBLY Oil pan
20.9 Oil screen installation

1. Lay the cylinder block with the bottom (oil pan
side) up.
2. Install the oil screen in position.
NOTE
The oil screen must be installed in position so that it is
below the oil level line and away from the oil pan.
Figure 131 Installing oil screen
20.10 Oil pan installation

1. Clean the mating surfaces of the oil pan and
cylinder block and coat them with Three Bond
1207C.
Figure 132 Coating mating surfaces with adhesive
NOTE
Squeeze out a 4 mm (0.2 in.) thick bar of sealing
compound (Three Bond) from the tube and put it on
the flange of the oil pan as shown.
Figure 133 Oil pan for S4L and S4L2 engines

Version 08/2004
Oil pan ASSEMBLY
Figure 134 Oil pan for S3L and S3L2 engines
To squeeze out a 4 mm (0.2 in.) thick bar, cut the

nozzle of the tube as shown.
Cut nozzle here
Figure 135 Cutting sealing compound tube nozzle
2. Tighten the bolts that hold the oil pan to the

cylinder block in a crisscross pattern to the
specified torque.
Cast oil pan:
2.8 ± 0.3 kgf·m
(20.3 ± 2.2 lbf·ft)
[27.5 ± 3 N·m]
Tightening torque
Plate oil pan:
1.15 ± 0.15 kgf·m
(8.3 ± 1.1 lbf·ft)
[11.3 ± 1.5 N·m]
Figure 136 Tightening oil pan bolts

Version 08/2004
ASSEMBLY Timing Gears and Flywheel
ASSEMBLY
21 Timing Gears and

Flywheel
Lubricate with engine oil
Use a new gasket
Tightening torque:
1.1 ± 0.1 kgf m (8 ± 0.7 lbf ft)
[10.8 ± 1 N m]
Tightening torque:
17.5 ± 2.5 kgf m (127 ± 18 lbf ft)
[172 ± 25 N m]
Lubricate journals and lobes with

engine oil
Use a new gasket
Lubricate lip with engine oil
Tightening torque:
6.5 ± 1 kgf m (47 ± 7 lbf ft)
[64 ± 10 N m]
Lubricate lip with engine oil
Tightening torque:
13.5 ± 0.5 kgf m (98 ± 4 lbf ft)
[132 ± 5 N m]
Use a new gasket
Use a new gasket

Version 08/2004
Timing Gears and Flywheel ASSEMBLY
21.1 Front plate installation

1. Scrape the gasket from the cylinder block and front
plate.
2. Coat the gasket contact surface of cylinder block
with adhesive and put a new gasket in position,
making sure the holes in the gasket are all in
alignment with the holes in the cylinder block.
3. Put the front plate in position. Install four bolts and
tighten them.
Figure 138 Installing front plate
21.2 Oil pump installation

1. Make sure the packing has been put in position on
the oil pump.
2. Put the oil pump in position on the cylinder block.
Install three bolts and tighten them evenly.
3. Make sure the oil pump gear rotates freely.
Figure 139 Installing oil pump
21.3 Engine turning

1. Install two bolts (M12 x 1.25) in the flywheel bolt
holes in the crankshaft.
2. Put a bar between the bolts and turn the crankshaft
to bring No. 1 piston to the top center as shown in
the illustration.
Figure 140 Turning engine

Version 08/2004
21.4 Engine turning

1. Put the camshaft (with bearing and gear) in
2. Hit the gear with a plastic hammer to fit the bearing
in position.
3. Make sure the camshaft rotates freely.
4. Tighten the stopper bolt.
Figure 141 Installing fuel injection pump camshaft
21.5 Camshaft installation

1. Lubricate the lobes and journals with engine oil.
2. Put the camshaft (with gear) in position in the
cylinder block.
CAUTION
Do not cause damage to the lobes and journals when
the camshaft is installed.
Lubricate with engine oil
Figure 142 Installing camshaft
3. Tighten the bolts that hold the thrust plate to the

specified torque.
1.1 ± 0.1 kgf·m
[51.5 ± 2.5 N·m]
4. Make sure the camshaft rotates freely. Check the

end play for the camshaft.
Figure 143 Installing thrust plate

Version 08/2004
21.6 Idler gear installation

1. Lubricate the idler gear with engine oil.
2. Install the idler gear in position with its “3,” “2” and
“11” marks in alignment with the “33” mark on the
fuel injection pump camshaft gear, the “22” mark
on the camshaft gear and the “1” mark on the
crankshaft gear respectively.
3. Check the backlash of the gears. Make reference
to “Timing gear backlash measurement” (page 37).
Figure 144 Marks on timing gears
21.7 Timing gear case installation

1. Coat the gasket with adhesive and put it in position
on the front plate.
2. Lubricate the oil seal lip with engine oil.
3. Tighten the bolts that hold the timing gear case.
Figure 145 Installing timing gear case
21.8 Crankshaft pulley nut

tightening
1. Install two bolts (M12 x 1.25) in the flywheel bolt
holes in the crankshaft and hold the crankshaft.
2. Tighten the crankshaft pulley nut to the specified
torque.
17.5 ± 2.5 kgf·m
[172 ± 25 N·m]
Figure 146 Tightening crankshaft pulley nut WARNING

Check the strength of the bolts and bar used for
holding the crankshaft.

Version 08/2004
21.9 P.T.O. gear installation

Install the P.T.O. gear in position in the timing gear case
with the side that has no oil hole toward the rear of the
engine.
Figure 147 Installing P.T.O. gear
21.10 Speedometer driven gear

installation
1. Install the O-ring in the groove in the driven gear
sleeve.
2. Install the speedometer driven gear in position in
the cylinder block while rotating it or the camshaft.
Figure 148 Installing speedometer driven gear
21.11 Tappet installation

Lubricate the tappets with engine oil and put them in
Figure 149 Installing tappets

Version 08/2004
21.12 Oil seal case installation

1. Put a new gasket in position on the oil seal case.
2. Lubricate the oil seal lip with engine oil and install
the oil seal in position in the cylinder block.
Figure 150 Installing oil seal case
21.13 Rear plate installation

1. Put a new gasket in position on the rear plate.
2. Put the rear plate in position on the cylinder block
with its dowel holes in alignment with the dowels.
Tighten the bolts that hold the rear plate to the
specified torque.
6.5 ± 1 kgf·m
[64 ± 10 N·m]
Figure 151 Installing rear plate

NOTE
Install the starter to the rear plate before installing the
plate to the cylinder block for convenience of rear
plate installation.
21.14 Flywheel installation

1. Install a safety bar (M12 x 1.25) in the rear end of
Safety bar the crankshaft.
2. Put the flywheel in position in alignment with the
safety bar.
3. Install three of four bolts in the flywheel and tighten
them finger tight only.
4. Remove the safety bar. Install the last bolt in the
flywheel and tighten it finger tight only.
Figure 152 Safety bar

Version 08/2004
5. Have someone hold the crankshaft pulley with a

wrench to prevent the flywheel from rotating.
6. Tighten the four bolts that hold the flywheel to the
specified torque.
13.5 ± 0.5 kgf·m
[132 ± 5 N·m]
WARNING
Always signal each other to prevent possible
personal injury.
Figure 153 Tightening flywheel bolts

Version 08/2004
MECHANISM ASSEMBLY
ASSEMBLY

VALVE MECHANISM
Tightening torque:
1.15 ± 0.15 kgf m (8.3 ± 1.1 lbf ft)
[11.3 ± 1.5 N m]
Tightening torque:
1.5 ± 0.5 kgf m (11 ± 4 lbf ft) [14.7
± 5 N m]
Tightening torque:
9 ± 0.5 kgf m (65 ± 4 lbf ft)
[88 ± 5 N m]
Use a new part
Use a new gasket
Lubricate stem with engine oil

Version 08/2004
ASSEMBLY MECHANISM
22.1 Cylinder head bottom face

cleaning
Scrape the gasket from the bottom face of the cylinder
head.
NOTE
After scraping the gasket, rub off gasket remnants
from the face with an oilstone smeared with engine oil
and thoroughly clean the face.
Figure 155 Removing cylinder head gasket
22.2 Valve stem seal installation

Using Socket 12, install the valve stem seal in position
in the valve guide. After installation, make sure the
Socket 12
seal is in its correct position.
NOTE
Improper stem seal installation can cause a failure to
seal against downward flow of oil along the stem.
Figure 156 Installing valve stem seal
22.3 Valve spring installation

White enameled
end Install the valve spring with the white enameled end up.
Figure 157 Installing valve spring

Version 08/2004
MECHANISM ASSEMBLY
22.4 Installing valve block

Put compression on the valve spring with a valve lifter
and install the block in position on the valve top.
CAUTION
Do not put excessive compression on the valve
spring. This can cause the retainer to hit and damage
the stem seal.
Figure 158 Installing valve block
22.5 Cylinder head gasket

Guide bolts installation
1. Thoroughly clean the top faces of the cylinder
block and pistons.
2. Install two guide bolts (M10 x 1.25) in the bolt
holes in the cylinder block.
3. Put a new cylinder head gasket in position on the
cylinder block, making sure the guide bolts are all
in alignment with their respective holes in the
gasket.
CAUTION
Do not use any gasket adhesive or other substances
Figure 159 Putting cylinder head gasket
on the top face of the cylinder block.
Guide bolts 22.6 Cylinder head installation

Put the cylinder head in position on the cylinder block,
making sure the guide bolts are all in alignment with
their respective bolt holes in the head.
Figure 160 Installing cylinder head

Version 08/2004
ASSEMBLY MECHANISM
22.7 Cylinder head bolt tightening

1. Remove the guide bolts and install the bolts that
hold the cylinder head to the cylinder block.
2. Tighten the bolts in number sequence in two or
three steps to the specified torque.
9 ± 0.5 kgf·m
Front Tightening torque (65 ± 4 lbf·ft)
[88 ± 5 N·m]
Figure 161 Tightening sequence
22.8 Valve push rod installation

1. Put the valve push rod into position through the
bore in the cylinder head.
2. Make sure the ball end of the push rod has been
put into position over the top of the tappet.
Figure 162 Installing valve push rods
22.9 Rocker shaft assembling

1. Install the rocker arms, brackets and springs on
the rocker shaft. Secure the brackets to the shaft
by tightening the bolts.
Bolt
2. Make sure the rocker arms move freely.
Figure 163 Assembling rocker arms

Version 08/2004
MECHANISM ASSEMBLY
22.10 Rocker shaft assembly

installation
1. Install the valve caps in position on the top of the
valves.
2. Put the rocker shaft assembly in position on the
cylinder head. Tighten the bolts that hold the
rocker shaft assembly to the specified torque.
3.
1.5 ± 0.5 kgf·m

[14.7 ± 5 N·m]
Figure 164 Installing rocker shaft assembly
22.11 Valve clearance adjustment

Make reference to “VALVE CLEARANCE” (page 159).
Figure 165 Adjusting valve clearance
22.12 Rocker cover installation

1. Make sure the gasket is put on the rocker cover.
2. Tighten the bolts that hold the rocker cover to the
specified torque.
3.
1.15 ± 0.15 kgf·m

Tightening torque (8.3 ± 1.1 lbf·ft)
[11.3 ± 1.5 N·m]
Figure 166 Installing rocker cover

Version 08/2004
ASSEMBLY Air Inlet System and Exhaust System
ASSEMBLY
23 Air Inlet System and

Exhaust System
Use a new
gasket
Use a new
gasket
Tightening torque:
1.85 ± 0.35 kgf m
(13.4 ± 2.5 lbf ft’
¨18 ± 3.4 N m*
Tightening torque:
1.85 ± 0.35 kgf m
(13.4 ± 2.5 lbf ft’
¨18 ± 3.4 N m*
23.1 Air inlet cover installation

Tighten the bolts that hold the air inlet cover to the
specified torque.
1.85 ± 0.35 kgf·m
[18 ± 3.4 N·m]
23.2 Exhaust manifold installation

Tighten the bolts that hold the exhaust manifold to the
specified torque.
1.85 ± 0.35 kgf·m
[18 ± 3.4 N·m]

Version 08/2004
Fuel System ASSEMBLY
ASSEMBLY
24 Fuel System
24.1 Fuel injection nozzle
Gasket
installation
1. Put the gasket on the nozzle.
2. Put the nozzle assembly in position in the cylinder
head and tighten it to the specified torque.
5.5 ± 0.5 kgf·m
[54 ± 5 N·m]
Figure 167 Installing fuel injection nozzle
24.2 Fuel injection pump

installation
Put the pump in position on the cylinder block and
tighten the bolts that hold the pump to the specified
torque.
Figure 168 Installing fuel injection pump
24.3 Flyweight assembly

installation
Put the flyweight assembly in position on the rear end
of the fuel injection pump camshaft and tighten the
sliding sleeve shaft to the specified torque.
3.6 ± 0.6 kgf·m

Tightening torque (26 ± 4.3 lbf·ft)
[35 ± 6 N·m]
Figure 169 Installing flyweight assembly

Version 08/2004
ASSEMBLY Fuel System
24.4 Sliding sleeve installation

Install the sliding sleeve on the sliding sleeve shaft and
make sure the sleeve moves freely.
Figure 170 Installing sliding sleeve
24.5 Governor assembly

installation
1. Install the governor assembly in position while
putting the tie rod and spring into position in the
injection pump.
2. Install the tie rod to the pin of the control rack and
secure it with the tie rod spring.
3. Install the tie rod cover in position.
Figure 171 Installing governor assembly
24.6 Fuel injection line installation

1. Put the fuel leak-off line in position and connect it
to the fuel injection nozzles.
2. Put the fuel injection lines in position and connect
them to the fuel injection pump. Install the clamps.
Figure 172 Installing fuel injection lines

Version 08/2004
Lubrication system ASSEMBLY
ASSEMBLY
25 Lubrication system
25.1 Pressure relief valve
installation
Put the relief valve in position on the cylinder block and
tighten it to the specified torque.
5 ± 0.5 kgf²m
Tightening torque (36 ± 4 lbf²ft)
[49 ± 5 N²m]
Figure 173 Installing pressure relief valve
25.2 Oil filter installation

1. Lightly lubricate the gasket with engine oil.
2. Install the new filter element by hand. When the
gasket contacts the base, tighten one turn more.
Figure 174 Installing oil filter
25.3 Oil pressure switch installation

Coat the threads of the switch with thread sealant
MD998054 (Three Bond 1102). Use Oil Pressure Switch Socket
Wrench (MD998054) (special tool) to install the oil
pressure switch.
CAUTION
1. Put the sealant on the threads only.
To be coated with 2. Do not over-tighten the oil pressure switch when
thread sealant it is installed.
Figure 175 Installing oil pressure switch

Version 08/2004
ASSEMBLY Cooling system
ASSEMBLY
26 Cooling system
26.1 Water pump installation
Put a new gasket in position on the water pump flange.
Install the water pump in position on the cylinder block.
Figure 176 Installing water pump
26.2 Thermostat installation

1. Put the thermostat in the thermostat case.
2. Put a new gasket in position on the thermostat
case. Install the thermostat assembly in position
on the cylinder head.
Figure 177 Installing thermostat
26.3 Cooling fan installation

1. Install the spacers in position in the fan as shown.
2. Install the pulley in position on the water pump.
Install the fan and spacer combination in position
on the pulley.
Figure 178 Installing cooling fan

Version 08/2004
Cooling system ASSEMBLY
26.4 Thermoswitch and thermounit

combination installation
Coat the threads of the combination with Three Bond
1104. Put the combination in position and tighten it to
the specified torque.
Figure 179 Installing thermoswitch and thermounit

combination

Version 08/2004
ASSEMBLY Electrical System
ASSEMBLY
27 Electrical System
27.1 Glow plug installation
Install the glow plug in position in the precombustion
chamber and tighten it to the specified torque
1,75 ± 0,25 kgf·m

[17,2 ± 2,5 N·m]
Figure 180 Installing glow plugs
27.2 Alternator installation

1. Put the alternator in position. Install the adjusting
plate bolt in position to hold the alternator in
position.
2. Put the belt in position on the pulley. Move the
alternator away from the engine to make an
adjustment to the belt.
3. Tighten the bolts.
4. Make sure the deflection (tension) of the belt is
correct.
Unit: mm (in.)
Deflection under 10 kgf 10 to 12
(22 lbf) [98 N] force (0.4 to 0.5)
Figure 181 Installing alternator
Adjusting plate bolt
Apply 10 kgf (22 lbf) [98

N] force midway
between crankshaft
pulley and alternator
pulley.
Figure 182 Adjusting alternator and fan belt

Version 08/2004
Electrical System ASSEMBLY

Version 08/2004
ELECTRICAL SYSTEM

Version 08/2004
GENERAL ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
28 GENERAL
28.1 Specifications (standard)1
Engine model S3L/S3L2 S4L/S4L2
Model M1T68281 M8T70471
Starter Type DC solenoid shifted (with reduction gear)
Nominal output, V–kW 12 - 1.7 12 - 2.0
Model A7T02071C
Alternator Regulator, type IC
Nominal output, V–A 12 – 50
Model 008816-4C
Type Sheathed
Glow plug
Rated voltage, V 10.5
Current draw, A 9.7 ± 1.0 (30 seconds at rated voltage)
Model G71SP
Glow plug Rated voltage, V DC 12

relay Continuous rating 1 minute
Resistance in coil, Ω 13
Model YM-1C
Control timer
Input voltage range, V DC 9 to 15
unit
Load Solenoid (resistance in coil: 1.7 Ω minimum)
Model YMS-1
Type Solenoid
ETS type stop
Resistance in coil, Ω 1.8 ± 10% at 20°C (68°F)
solenoid
Stroke, mm (in.) 13 ± 0.5 (0.53 ± 0.02)
Operating voltage, V DC 10 to 15
Model QGS
Rated voltage, V DC 12
Operating voltage, V 7 to 15
Glow timer Operating temperature

-30 to +70 (-22 to 158)
range °C (°F)
Storage temperature
-40 to +80 (-40 to 176)
range °C (°F)
Pre-glow time, second 6.2 ± 0.7

notice.

Version 08/2004
Pilot lamp Safety relay
Glow plug MM201-124 MM130-767
Model
Themo switch Battery
MM432-104 Starter
Version 08/2004
Pilot lamp Alternator
MM201-123 Diode
MM434-062 Alternator
Diode
MM434-062
Glow timer
< ETS type stop solenoid >
MM431-762 Pressure switch Connection of

Gow relay
31A90-00100 starter switch
MM431-28201
Terminal
Charge pilot
ELECTRICAL SYSTEM
MM201-122 Position
Pilot lamp
MM201-124
Service Manual Mitsubishi SL-Series diesel engines

Control timer
Starter switch 0,85 mm2 or more
I6A11-14000
30890-05200 Solénoid (ETS) 2 mm2 or more
5 mm2 or more
20 mm2 or more
ENGLISH
Battery switch
05125-00102
Fuel pump
30A60-00200 Starter relay
32A66-19100
Starter
Battery
28.2 Wiring diagrams
1. Figure indicates a nominal size of automotive low-tension line (JIS C 3406).

2. This schematic shows the electrical system of the standard engine equipped with a key shut down solenoid and glow plugs.
GENERAL
113 / 195
Pilot lamp Safety relay
Glow plug MM201-124 MM130-767
Model S3L, S3L2 S4L, S4L2
114 / 195
Themo switch Battery 12V-65AH 12V-80AH
MC880-900 Starter 12V-1.7kW 12V-2.0kW
GENERAL
Pilot lamp Alternator 12V-50A

MM201-123 Diode
MM434-062 Alternator
Diode
MM434-062
Glow timer
< ETR type stop solenoid >
MM431-762 Pressure switch

Glow relay Connection of
MM431-28201 MM130-066
starter switch
Charge pilot
Terminal
MM201-122 B R1 ACCR2 C Br
Position
Pilot lamp R1
MM201-124 OFF
ACC
St
Starter switch N.C.(B Type) relay 0,85 mm2 or more

30890-05200
3 mm2 or more
5 mm2 or more
Control timer 60 mm2 or more
ENGLISH
I6A12-02001
Hold (White)
Solénoid (ETR)
Controller
31A66-06100
Common (Blue)
Battery switch
05125-00102
Fuel pump
30A60-00200 Starter relay
32A66-19100 Pull in (Red)
Starter
Battery
1. Figure indicates a nominal size of automotive low-tension line (JIS C 3406).

2. This schematic shows the electrical system of the standard engine equipped with a key shut down solenoid and glow plugs.
ELECTRICAL SYSTEM
Service Manual Mitsubishi SL-Series diesel engines

Version 08/2004
ELECTRICAL SYSTEM STARTER
ELECTRICAL SYSTEM
29 STARTER
29.1 Disassembly
Roughness, burns, or stepped

wear on commutator surface;
worn or damaged gear
Abnormal
rotation
Brush powder deposits,

uneven wear, poor brush
Incorrect installation of movement in holder
Broken or
damaged pinion pole pieces and field
coils
O-rings and snap rings are not reusable.
Figure 183 Starter component parts
Disassembly sequence
1. Pinion set
2. Solenoid switch
3. Rear bracket
4. Brush holder
5. Yoke
6. Armature
7. Ball bearing
8. Ball
9. Seal set
10. Reduction gears
11. Lever set
12. Washer set
13. Gear shaft
14. Internal gear
15. Overrunning clutch
16. Front bracket
CAUTION
The pinion must be removed before removal or
replacement of the following parts:
1. Front bracket
2. Reduction gears
3. Overrunning clutch

Version 08/2004
STARTER ELECTRICAL SYSTEM
29.1.1 Removing Pinion

The pinion can be removed when it is held in the
pushed-out position during energization of the solenoid
S1 switch.
S S2 Disconnect the M-terminal connector and make a

circuit that connects the starter motor and the battery
Starter Battery as shown in the drawing. Close switches S1 and S2 to
make the pinion come out and rotate. Then, open
switch S2. The pinion will stop rotating but will stay in
the pushed-out position. Apply a pipe-shaped
implement to the pinion stopper and lightly tap it with a
hammer to remove the pinion.
If the pinion returns to the retracted position before

disengagement of the stopper while the tool is being
tapped, repeat the procedure from the beginning.
29.1.2 Ball
The ball at the end of the armature acts as a bearing for
movement of the armature in the thrust direction. When
the armature is removed, the ball may stick to the
grease on it. Be careful not to lose the ball.
29.2 Inspection
29.2.1 Armature
1. Coil Short Circuit Test
Place the armature on a growler tester. Hold an
iron rod parallel with the armature and slowly
rotate the armature by hand. If the iron rod vibrates
or is pulled toward the armature, the armature has
a short-circuited coil and must be replaced.
2. Coil Ground Test

Check whether continuity exists between the
commutator and shaft (or core). If continuity exists,
the coil is grounded and the armature must be
replaced.

Version 08/2004
3. Commutator Inspection
1) Measure the commutator’s runout using a dial
gauge. If the measurement exceeds the
specified limit, rectify the problem, making
sure that the outside diameter stays within
specification. If the surface is rough or has
stepped wear, rectify the problem with emery
paper (#300 – 500).
Unit: mm (in.)
Limit
Commutator runout 0.1 (0.004)
2) Measure the commutator’s outside diameter. If

the measurement is out of specification,
replace the armature.
Unit: mm (in.)
Standard
Limit
value
Commutator 32.0 (1.26) 31.4 (1.24)

outside diameter
3) Measure the molding undercut depth between

segments. If the depth is smaller than the
limit, cut the molding to a depth of 0.4-0.6 mm
(0.016-0.024 in).
Segment Unit: mm (in.)
Limit
Good Bad Commutator runout 0.1 (0.004)
Molding undercut
depth
29.2.2 Field Coil

1. Coil Open Circuit Test
Check whether continuity exists between the
terminal lead and each brush. If continuity does not
exists, the field coil has an open circuit and the
yoke assembly must be replaced

Version 08/2004
2. Coil Gound Test

Check whether continuity exists between the yoke
and each brush. If continuity exists, the coil is
grounded and must be checked for defective
insulation. If repair is impossible, replace the yoke
assembly.
29.2.3 Brushes and Brush Holders

Brush
1. Brush Wear
Measure the length of the brush. If the
measurement is smaller than the limit, replace the
brush. If the brush is worn unevenly or has a rough
contact surface, rectify the problem with fine emery
paper (#300–500).
Unit: mm (in.)
Standard value Limit
Brush length 18 (0.71) 11 (0.43)
2. Brush Spring Force

With a new brush installed, pull the brush spring
with a spring balance and read the load at the point
where the spring leaves the brush. Replace the
spring if its force is lower than the limit.
N {kgf} (lbf)
Standard value Limit
Brush spring 26.7 – 36.1 14.7

force {2.7 – 3.7} {1.5}
(6.0 – 8.3) (3.3)
3. Brush Holder Insulation Test

Check whether continuity exists between the (+)
brush holder and the (–) brush holder plate. If
continuity exists, replace the brush holder
assembly.

Version 08/2004
29.2.4 Overrunning Clutch

Make sure the pinion shaft rotates smoothly when
turned clockwise (in the drive direction) and locks when
turned counterclockwise. If the pinion shaft’s operation
is defective, replace the overrunning clutch.
29.2.5 Gear Shaft Thrust Gap

Adjustment of the gear shaft’s thrust gap is not
necessary.
29.2.6 Armature Thrust Gap

Adjustment of armature’s thrust gap is not necessary.
29.3 Assembly
Apply grease
Apply grease
Apply grease
Assembly sequence
16 → 12 → 13 → 14 → 15 → 1 → 10 → 11 → 9 → 8 →
5→6→7→4→3→2

Version 08/2004
29.4 Inspection and Testing after

Assembly
After assembling the starter, perform the following
inspections and tests:
S-terminal
M-terminal
Battery (12V)
29.4.1 Inspection and Adjustment of

Pinion Gap
1. Connect the assembled starter to the battery as
shown in the drawing. The pinion will come out and
rotate slowly. Then, remove the M-terminal
connector to stop the motor.
2. Lightly push the pinion shaft toward the armature
and measure the amount of axial movement,
which corresponds to the pinion gap.
3. If the pinion gap is not within the 0.5 – 2.0 mm
(0.02 – 0.08 in.) range, adjust it by increasing or
decreasing the number of seals in the solenoid
Pinion gap switch. (Increasing the number of seals reduce the
pinion gap). It may be necessary to replace the
lever to obtain the correct pinion gap.
Unit: mm (in.)
Standard value
Pinion gap 0.5 – 2.0 (0.02 – 0.08)
NOTE
To prevent the solenoid switch coil from overheating,
do not energize the solenoid switch for longer than 10
seconds.
29.4.2 No-Load Test
Ammeter When the pinion gap has been correctly adjusted,

connect an ammeter and a voltmeter between the
Switch starter motor and battery as shown in the drawing, then
check the starter’s no-load characteristics.
Battery Voltmeter Switch
(12V) Starter
Motor
CAUTION
Use the thickest wires possible, and tighten each
terminal firmly.

Version 08/2004
Voltage Current Speed

(V) (A) (min-1)
No-Load 11 130 3,600

characteristics maximum minimum
29.4.3 Solenoid Switch

S-terminal
Perform the following continuity tests. If the solenoid
switch fails either tests, replace it.
M-terminal
B-terminal 1) Test for Coil Open Circuit
Continuity should exists between the S- and
M-terminals and between the S-terminal and
ground (case).
2) Test for Fused Contacts

Continuity should not exist between the B-
and M-terminals.

Version 08/2004
ALTERNATOR ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
30 ALTERNATOR
30.1 Disassembly
Disassembly sequence
1. Through bolt
2. Pulley
3. Rotor
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracket
8. Stator core
9. Brush holder
10. Rectifier
11. Rear bracket

Version 08/2004
ELECTRICAL SYSTEM ALTERNATOR
30.1.1 Stator core separation from front

bracket
1. Pry the stator core off the front bracket with a
screwdriver as shown in the illustration.
CAUTION
Be careful not to insert the screwdriver too deep.
Damage to the stator core can be the result.
Figure 184 Disassembling alternator
30.1.2 Pulley removal

1. Hold the rotor assembly in a vise by using thick
cloth as shown in the illustration. Remove the nut
that holds the pulley in position, and remove the
pulley and spacer.
2. Remove the rotor assembly from the front bracket.
Figure 185 Removing pulley
30.1.3 Stator core and rectifier removal

Unsolder
1. Unsolder the leads from the rectifier and remove
Rectifier
the stator core from the rectifier.
CAUTION
Unsolder the leads as quickly as possible to prevent
damage to the diodes in the rectifier.
Unsolder
2. Remove the screws that hold the rectifier in
position and remove the rectifier.
Figure 186 Removing stator core

Version 08/2004
30.2 Inspection
Test for open or short

circuit usingthe procedure
circuit using theprocedure
that follows.
that follows.
Check for cracks or
other defects.
Check for cracks or

other defects.
Check for wear.

circuit using the
procedure that follows.
30.2.1 Diodes
Trio-diodes
Heat sink (-) 1. Test the resistance between the diode and heat
sink. First touch the positive (+) prod of an
ohmmeter to the diode, then the negative (–) prod.
If the resistance is infinite in both cases, the diode
is open. If it is nearly zero in both cases, the diode
is shorted. Do the same step for the remainder of
the diodes. If any diode is open or shorted,
replace the rectifier.
Heat sink (+) Diode lead wires
Figure 188 Testing diode

Version 08/2004
30.2.2 Field coil

1. Test for continuity between the slip rings as shown
in the illustration. No continuity shows there is an
open circuit in the field coil. Replace the field coil.
Figure 189 Testing field coil for open circuit
2. Test for no continuity between the slip ring and

shaft (or core) as shown in the illustration. Any
continuity shows there is a grounded circuit in the
field coil. Replace the field coil.
Figure 190 Testing field coil for grounded circuit
30.2.3 Stator core

1. Test for continuity between the leads as shown in
the illustration. No continuity shows there is an
open circuit in the stator core. Replace the stator
core.
Figure 191 Testing stator core for open circuit

Version 08/2004
2. Test for no continuity between each lead and stator

core as shown in the illustration. Any continuity
shows there is a grounded circuit in the stator core.
Replace the stator core.
Figure 192 Testing stator core for grounded circuit
30.2.4 Brushes
1. Make replacement of brushes that have been worn
down to, or beyond, the wear limit line.
Wear limit line
Figure 193 Checking brush for wear
2. To remove the brushes from the brush holder for

replacement, unsolder the leads from the brushes.
This will permit removal of the brushes and
Unsolder springs.
Brush holder
Figure 194 Removing brushes for replacement

Version 08/2004
3. To install the new brushes, put them in position in

the brush holder and solder the leads to the
brushes.
Figure 195 Installing new brushes
30.3 Assembly
Follow the reverse of disassembly and use the
1. The rear bearing has a groove for the snap ring.

Install the snap ring in this groove, making sure its
Wire-shaped tab is in the deep portion of the groove.
tooling 2. When installing the new rear bearing, put it in
position with the side that has a groove toward the
slip rings of the rotor.
3. To install the rear bearing in the rear bracket, heat
the rear bracket.
4. Before installing the rotor in the rear bracket, insert
Rear bracket a wire-shaped tooling into the hole in the rear
Brushes
bracket to lift the brushes off the slip rings.
Remove the tooling after the rotor has been
Wire-shaped installed in position.
tooling
Figure 196 Assembling alternator

Version 08/2004
KEY SHUTOFF SYSTEM (ETS solenoid
type) ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
31 KEY SHUTOFF SYSTEM

(ETS solenoid type)
31.1 General
This system, consisting of a switch, a control timer and
a solenoid, permits the operator to shut off the engine
by turning the starter switch key to OFF position.
Control timer Another function of this system is to shut off the engine
automatically when the oil pressure is too low, or when
coolant temperature is too high.
Solenoid
Figure 197 Key shutoff system
31.2 Cord color (standard)
No. Cord color Connected to
1 Blue Solenoid
2 Blue Solenoid
3 Red Battery (starter switch B

terminal)
4 Green Starter switch ON terminal
5 Red/white Starter (starter switch and

starter)
Figure 198 Control timer connection
6 Yellow Oil pressure switch
7 Black Ground
31.3 Shutoff solenoid installation

2. Coat the threads of the stop solenoid with thread
sealant (Three Bond 1212).
NOTE
Coat the length of the threads to be turned in the
governor case.
3. Temporarily install the shutoff solenoid and nut in

the governor case.
4. Move the injection pump control rack all the way to
the non-injection (shutoff) position.

Version 08/2004
KEY SHUTOFF SYSTEM (ETS solenoid
ELECTRICAL SYSTEM type)
5. Turn the shutoff solenoid in the governor case

while pushing the plunger toward the control rack
Tightening torque: 4.5 ± 0.5 kgf m until the shaft is in touch with the tie rod. At this
(32.5 ± lbf ft) [44 ± 5 N m] time, clearance C must be 0 mm. (Under this
condition, the plunger will be rotated by the shutoff
Threads: to be coated with solenoid being turned in.)
thread sealant 6. Back off the shutoff solenoid 30° to 45° turn (the
Shaft clearance between the control rack and plunger
Plunger
will be 0.15 to 0.20 mm (0.0059 to 0.0079 in.)) and
tighten the nut to the specified torque.
7. Start the engine and make sure the engine stops
when the plunger is pushed all the way.
NOTE
• Do not allow thread sealant to contact (A)
• Do not allow cleaning solvent to enter the
solenoid through (B)
Figure 199 Installing shutoff solenoid
8. Install the rubber cap in position with teh arrow

Rubber cap head toward up (with the side that has a water
drain hole down) as shown in the illustration.
UP CAUTION
Do not allow cleaning solvent to contact any solenoid
parts.
Water drain hole
Figure 200 Installing rubber cap
31.4 Inspection after assembly

1. For the schematic of the key shutoff system, see
page 113 or 114.
when the starter switch key is turned to OFF
position.
when the oil pressure switch terminal is shorted to
the switch body.
NOTE
It will take about 10 seconds to restart an engine
which was shut down by the key shutoff device.

Version 08/2004
KEY SHUTOFF SYSTEM (ETR solenoid
type) ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
32 KEY SHUTOFF SYSTEM

(ETR solenoid type)
32.1 General
The energize-to-run (ETR) solenoid-controlled engine
shutdown system operates as follows:
When the starter switch is turned to the “ON” position,

the pull-in coil of the solenoid is energized for three
seconds, pulling the push rod inward.
During operation with the starter switch at the “ON”

position, the hold-in coil of the solenoid remains
energized, keeping the push rod in the retracted
position.
Like the conventional energize-to-stop (ETS) solenoid

engine shutdown system, this system is a safety device
designed to bring the injection pump into the no-
injection state whenever the wiring is open or the
starter switch is turned to the “OFF” position.
32.2 Cord color (standard)

3 Red
White
The wires of the solenoid are identified by color as
Blue
follows:
1
2
No. Color Remarks/Connection
1 Red PULL (pull-in coil)/starter

Stroke 13 ± 0.5 mm 2 White HOLD (hold-in coil)/starter switch
(0.51 ± 0.02 in.)
3 Blue COM (earth)/ground

Version 08/2004
KEY SHUTOFF SYSTEM (ETR solenoid
ELECTRICAL SYSTEM type)
32.3 Shutoff solenoid installation

Tie rod
Rack at no-injection 1. Remove the tie rod cover on the injection pump to
end position enable movement of the rack to be observed.
2. Put the nut 2 on the solenoid 1 and turn the nut
Push rod in free-to- down to the inner end of the threads on the
move state solenoid.
Apply sealant to the threads on the solenoid.
NOTE
Sealant should be applied over those threads which
are concealed when the solenoid is installed on the
cylinder block.
Apply sealant Sealant Threebond 1212 or 1211

Tightening torque:
49 N·m {5 kgf·m}
(36 lbf·ft) 3. Screw the solenoid 1 into the cylinder block.
NOTE: 4. While moving the rack in both directions, screw in
Areas A must be free of sealant. the solenoid 1 until the rack is against the
solenoid’s push rod and cannot move any more.
5. Unscrew the solenoid 1 approximately 90 – 180°
from the position achieved in (d), and temporarily
lock the solenoid with the nut 2.
6. Move the rack in both directions. There should be
a play of approximately 0.3 – 0.7 mm (0.01 – 0.03
in.).
7. Tighten the nut 2 to the specified torque.
Nut tightening torque Threebond 1212 or 1211
8. Reinstall the tie rod cover on the injection pump.

9. Start the engine. Turn the starter switch to the OFF
position. The push rod then should extend,
pushing back the rack and stopping the engine.
NOTE
It will take about 10 seconds to restart an engine
which was shut down by the key shutoff device.

Version 08/2004
AUTOMATIC GLOW SYSTEM ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
33 AUTOMATIC GLOW
SYSTEM
33.1 General
Starter switch Turning the starter switch to ON position activates the
glow plugs to heat the engine and causes the glow plug
Fuse indicator to come on.
Heating time 6.2 ± 0.7 seconds

Fuel
pump Glow plug
Glow
indicator
plug
timer
Battery switch Glow plug
Ammeter
Switch
Battery
Figure 201 Automatic glow plug system
33.2 Glow timer specification

(standard)1
Part number MM431-762
Type Quick heating
Rated voltage DC 12 V
Operating voltage range 7 to 15 V
Operating temperature –30°C to +70°C

range (–22°F to +158°F)
Storage temperature –40°C to +80°C

range (–40°F to +176°F)
Glow plug activating time 6.2 ± 0.7 seconds

notice.

Version 08/2004
ELECTRICAL SYSTEM AUTOMATIC GLOW SYSTEM
33.3 Glow plug relay specifications

(standard)2
Part number MM431-28201
Rated voltage DC 12 V
Continuous rating 1 minute
Coil resistance 13 Ω
Operating temperature –40°C to +100°C

range (–40°F to +212°F)
Figure 202 Glow plug relay
33.4 Glow plug inspection

Test for continuity between the terminal and body as
shown in the illustration. If no continuity, replace with
new one.
Item Standard
Resistance 0.55 Ω
Figure 203 Testing glow plug

notice.

Version 08/2004
AUTOMATIC GLOW SYSTEM ELECTRICAL SYSTEM

Version 08/2004
COOLING SYSTEM

Version 08/2004
GENERAL COOLING SYSTEM
COOLING SYSTEM
34 GENERAL
34.1 Schematic
Water bypass hose

Thermostat
Water pump
Radiator
Cooling fan
Figure 204 Schematic

LL or HM type (width = 10.7 mm (0.42 in.), V angle = 38°, outer
Fan belt (for farm or industrial engine)
circumference = 980 mm (38.6 in.)
No. of blades = 5, No. of blades = 5,
Cooling fan Suction type
diameter = 320 mm (12.6 in.) diameter = 360 mm (14.2 in.)
Water pump Centrifugal type
Temperature at which valve
82 ± 1.5°C (180 ± 2.7°F)
starts opening
Thermostat
Temperature at which valve lift
95°C (203°F)
is 8 mm (0.3 in.)
Type Bimetal
Temperature at which switch
Thermo 111 ± 3.5°C (232 ± 6.3°F)
is turned ON
switch
Temperature difference for
8 ± 3.5°C (46.4 ± 6.3°F)
ON-OFF control
50°C (122°F): 80 ± 10 Ω
Resistance in thermounit 80°C (176°F): 29.5 ± 2.5 Ω
120°C (248°F): 10 ± 0.3 Ω

notice.

Version 08/2004
COOLING SYSTEM INSPECTION
COOLING SYSTEM
35 INSPECTION
Test thermostat using

the procedure that
follows.
Test thermoswitch
and thermounit
using the
procedures that
follow.
Check for aging or

damage
Check for cracks or

distortion.
Use new gaskets.
Check for cracks or

leaks.
Check for elongation,

aging or wear.

Version 08/2004
INSPECTION COOLING SYSTEM
35.1 Water pump

Check the impeller and shaft for rotation. If they do not
rotate freely or have noise, replace the water pump
assembly.
Figure 206 Checking water pump
35.2 Thermostat (standard)

Hang the thermostat in the pan of water as shown in
the illustration. The thermostat must be below the
surface of the water and its must be away from the
sides of the pan. Heat the water uniformly in the pan
and measure a temperature at which the valve starts
opening and a temperature at which the valve lift
(distance) is 8 mm (0.3 in.). Replace the thermostat if
defective.
Temperature at which 85 ± 1.5°C

valve starts opening (180 ± 2.7°F)
Temperature at which 95°C (203°F)

valve lift is 8 mm (0.3 in.)
Figure 207 Testing thermostat
WARNING
Water in the pan is hot. Any contact can cause
severe burns.

Version 08/2004
COOLING SYSTEM INSPECTION
35.3 Thermoswitch (standard)

Hang the thermoswitch in the pan of oil with its
temperature sensing end below the surface of oil and
measure the resistance while heating the oil as shown
in the illustration. If the resistance is incorrect, replace
the thermoswitch.
Resistance at 120°C 30 mΩ
(248°F)
Temperature at which switch 111 ± 3.5°C

is turned ON (232 ± 6.3°F)
Figure 208 Testing thermoswitch
WARNING
Oil in the pan is hot. Any contact can cause severe
burns.
35.4 Thermounit (standard)

Hang the thermounit in the pan of antifreeze with its
temperature sensing end below the surface of
antifreeze and measure the resistance while heating
the antifreeze as shown in the illustration. If the
resistance is incorrect, replace the thermounit.
Standard 50°C (122°F): 80 ± 10 Ω

80°C (176°F): 29.5 ± 2.5 Ω
120°C (248°F): 10 ± 0.3 Ω
Figure 209 Testing thermounit

WARNING
Antifreeze in the pan is hot. Any contact can cause
severe burns.

Version 08/2004
INSPECTION COOLING SYSTEM

Version 08/2004
LUBRICATION SYSTEM

Version 08/2004
GENERAL LUBRICATION SYSTEM
LUBRICATION SYSTEM
36 GENERAL
36.1 Schematic
Oil pressure switch
Main oil gallery
Oil filter
Pressure relief valve
Oil pump
Oil screen
Oil drain plug
36.2 Specifications1
Type Force feed
Oil API Service Classification CC or better
Capacity (high level excl. 0.5 liter (0.13 U.S. gal) 5.7 (1.5) (with deep oil pan) 7.7 (2.0) (with deep oil pan)
of oil in oil filter), liter (U.S. gal) 3.7 (1.0 (with standard oil pan) 5.4 (1.4) (with standard oil pan)
Oil pump Type Trochoid
Driven by Camshaft gear
Relief valve opening pressure 3.5 ± 0.5 kgf/cm2 (50 ± 7 psi) [343 ± 49 kPa]
Pressure difference at which oil pressure switch is

0.5 ± 0.1 kgf/cm2 (7 ± 1.4 psi) [49 ± 10 kPa]
closed (indicator light comes on)
Oil filter Paper-element cartridge (full flow) type

notice

Version 08/2004
LUBRICATION SYSTEM INSPECTION
LUBRICATION SYSTEM
37 INSPECTION
37.1 Oil pump
Visually check the pump for rough rotation or other
defects. Replace the pump assembly if defective.
Figure 210 Checking oil pump
37.2 Oil pressure switch

1. Test for continuity between the terminal and body
with an ohmmeter as shown in the illustration. No
continuity is the cause for replacing the switch.
Figure 211 Testing oil pressure switch (1)
2. Insert a small diameter bar into the oil hole in the

switch and lightly push it in to test for no continuity
as shown in the illustration. Any continuity is the
cause for replacing the switch.
3. Apply a pressure air of 0.5 kgf/cm2 (7 psi) [49 kPa]
Small diameter bar to the switch through the oil hole to test for no
continuity. Any continuity is the cause for replacing
the switch. Also, check for air leaks. Any air leak
is an indication of a ruptured diaphragm. In such a
case, replace the switch.
Figure 212 Testing oil pressure switch (2)

Version 08/2004
INSPECTION LUBRICATION SYSTEM
37.3 Pressure relief valve

Cap nut 1. Check the valve seat for contact. Check the spring
for damage.
2. Measure the oil pressure at which the relief valve
opens (the oil pressure with the engine running at
the rated rpm). If the pressure is not correct,
remove the cap nut and increase or decrease the
Shims amount of shims. The engine oil pressure tap is
located on the right side of the engine.
3.5 ± 0.5 kgf/cm2

Relief valve opening
(50 ± 7 psi)
Figure 213 Checking pressure relief valve pressure
[343 ± 49 kPa]

Version 08/2004
FUEL SYSTEM

Version 08/2004
GENERAL FUEL SYSTEM
FUEL SYSTEM
38 GENERAL
38.1 Schematic
Fuel leak-off pipe Fuel injection pipe Fuel injection pump

To fuel tank
Fuel filter
overflow pipe
Fuel pump
Fuel filter
From fuel tank
Figure 214 Schematic overview

Version 08/2004
FUEL SYSTEM GENERAL
Specification
Description
S3L/S3L2 S4L/S4L2
Type Bosch M
Model ND-PFR3M ND-PFR4M

FUEL Plunger diameter 5.5 mm (0.217 in.)
INJECTION
PUMP MS retard (crank angle), deg 8°
Delivery valve, type Silto or Bosch
Air vent screw Yes
Type Throttle
FUEL
INJECTION Model DN15PD6
NOZZLE
Injection pressure (valve opening pressure) 1400+5 kgf/cm2 (19910+71 psi) [13 7290+490 kPa]
FUEL
FILTER Type Paper element
(remote)
FUEL Type Electric (diaphragm)

FEED
PUMP Capacity (at terminal voltage of DC 12 V and 300 cc (18.3 cu in.)/min minimum or 400 cc (24.4 cu in.)/min
(remote) 20°C (68°F)) minimum
Table 3 Specifications

notice.

Version 08/2004
FUEL INJECTION NOZZLE FUEL SYSTEM
FUEL SYSTEM
39 FUEL INJECTION
NOZZLE
39.1 Inspection
39.1.1 Injection pressure (valve opening
pressure) test
1. Install the injection nozzle on the tester. Slowly
operate the tester handle to bleed (remove) air
from the tester.
2. Operate the tester handle at a speed of one stroke
per second to make a slow increase in pressure
until the valve in the injection nozzle starts to open.
Read the maximum gauge pressure at the instant
fluid flows from the tip.
3. If the injection pressure is incorrect, disassemble
Figure 215 Fuel injection nozzle ready for test the nozzle and change the thickness of the
washer.
Injection pressure (valve 1400+5 kgf/cm2

opening pressure) Standard (19910+71 psi)
[137290+490 kPa]
NOTE
An increase or decrease of washer thickness by 0.1
mm (0.004 in.) will vary the injection pressure by 10
kgf/cm2 (142 psi) [981 kPa]. 10 kinds of washer are
available in thicknesses from 1.25 mm (0.049 2 in.) to
Figure 216 Removing tip from injection nozzle 1.70 mm (0.066 9 in.) in increments of 0.05 mm
(0.002 0 in.).
WARNING
When the injection nozzles are tested, be sure to
wear eye protection. Fuel comes from the orifices in
the nozzle tip with high pressure. The fuel can pierce
(go through) the skin and cause serious injury to the
operator. Keep the tip of the nozzle pointed away
from the operator and into the fuel collector.

Version 08/2004
FUEL SYSTEM FUEL INJECTION NOZZLE
39.1.2 Orifice restriction test

1. Look at the orifice discharge pattern (shape of
discharge) when fluid begins to flow through the
injection nozzle. The discharge must be straight.
Any change is an indication of a bad nozzle.
2. Operate the tester handle at a speed of one stroke
Good nozzle Discharge pattern for orifice with a per second to make sure the discharge is straight.
restriction (recondition or replace)
Figure 217 Orifice restriction test
39.1.3 Nozzle tip washing and replacement

1. Loosen the retaining nut and remove the tip from
the injection nozzle. Wash the needle valve and
body in clean diesel fuel. After washing, put the
needle valve in the body in clean diesel fuel.
CAUTION
Do not hit the tip when removing it from the injection
Needle valve nozzle.
Body
Figure 218 Washing nozzle tip

NOTE
Keep the need valves with their respective bodies.
Do not use needle valves or bodies with other bodies
or needle valves.
2. After cleaning the tip, install it in the nozzle and

tighten the retaining nut to the specified torque.
3.75 ± 0.25 kgf·m
Tightening torque (27 ± 1.8 lbf·ft)
[36.8 ± 2.5 N·m]
3. If the injection nozzle is still bad after the tip has

been washed, replace the tip.
NOTE
a. Do not touch the sliding surface of the needle
valve.
b. When installing the new nozzle tip, remove
synthetic resin film from the tip and slide the
needle valve in the body in clean diesel fuel to
wash off inhibitor completely.

Version 08/2004
FUEL INJECTION NOZZLE FUEL SYSTEM
39.2 Disassembly and assembly
5.5 ± 0.5 kgf·m

(40 ± 4 lbf·ft)
[54 ± 5 N·m]
Check for wear
Check test force

and squareness
Check for wear

and damage
3.75 ± 0.25 kgf·m
(27 ± 1.8 lbf·ft)
[36.8 ± 2.5 N·m]
Check for too much carbon on
tip of nozzle or in nozzle orifice
Figure 219 Disassembly sequence and inspection Disassembly sequence

points 1. Retaining nut
2. Nozzle tip assembly
3. Piece
4. Pin
5. Spring
6. Washer
7. Body

Version 08/2004
FUEL SYSTEM FUEL INJECTION PUMP
FUEL SYSTEM
40 FUEL INJECTION PUMP

40.1 Test on engine
Check the injection pump for items listed in the chart
below and replace it if defective. Do not attempt to
make repairs by disassembling.
Test item Test method Criteria
Low idle speed Use a tachometer. Standard engine:

9800+30 min-1
Exhaust smoke 1. Check by quickly increasing engine speed under no-load No too much black or
condition. gray smoke
2. Check by starting load.
Orifice discharge patter Remove injection nozzle and reinstall it with orifice toward outside Good discharge
of engine. Look at discharge pattern by cranking the engine with pattern
starter.
Table 4 Injection pump chart
40.2 Disassembly
1. Tappet guide pin
2. Lock plate
3. Tappet
4. Tappet adjusting shim
5. Lower spring seat
6. Plunger
7. Plunger spring
8. Upper spring seat
9. Control sleeve
10. Control rack
11. Delivery valve holder
12. O-ring
13. Delivery valve spring
14. Delivery valve gasket
15. Delivery valve
16. Plunger barrel
17. Pump housing
Figure 220 Disassembly sequence

Version 08/2004
FUEL INJECTION PUMP FUEL SYSTEM
Disassembly procedure
40.2.1 Tappet removal
1. Hold the injection pump in a vise with the side that
has tappets up.
2. Straighten the lock plate away from the tappet
guide pin with a screwdriver.
3. Rotate the tappet guide pin 180° to unlock it from
the housing.
Figure 221 Removing tappet guide pins
4. Remove the tappet guide pin with a needle-nose

pliers while pushing down on the tappet. Remove
the tappet.
5. Do Steps (2) through (4) again for remainder of the
tappets.
CAUTION
The tappet can be thrown from the housing when the
tappet guide pin is removed. Hold the tappet to
prevent it from falling.
Figure 222 Removing tappets
40.2.2 Plunger removal

1. Remove the tappet adjusting shim.
2. Remove the lower spring seat and plunger with a
tweezers.
3. Remove the plunger spring.
4. Remove the upper spring seat and control sleeve.
5. Do Steps (1) through (4) again for remainder of the
plungers.
6. Remove the control rack.
Figure 223 Removing plungers

Version 08/2004
40.2.3 Delivery valve removal

1. Turn the injection pump upside down and hold it in
a vise.
2. Remove the delivery valve holder.
3. Remove the delivery valve spring.
4. Remove the delivery valve gasket.
Figure 224 Removing delivery valve holders
5. Remove the delivery valve with a tweezers.

6. Do Steps (2) through (5) again for remainder of
delivery valves.
CAUTION
The delivery valves are finely finished parts. Keep
them as clean as possible.
Figure 225 Removing delivery valves
40.2.4 Barrel removal

1. Remove the barrels from the housing.
CAUTION
a. The plungers and barrels are finely finished
parts. Keep them as clean as possible.
b. Keep the plungers with their respective barrels
for installation. Do not use plungers or barrels
with other barrels or plungers.
Figure 226 Removing barrels

Version 08/2004
NOTE
Adjusting plates
a. When replacing the plungers and barrels or

delivery valves, do not loosen the adjusting
plates between the pumping elements.
b. After these parts have been replaced, the
injection quantity must be measured. Pump
Tester Cam Box is needed for measurement of
injection quantity.
c. Keep the disassembled injection pump parts in
clean diesel fuel.
Figure 227 Adjusting plates

Version 08/2004
40.3 Inspection
Check delivery valve

for wear or damage
Check plunger for

wear, rusting or
scoring.
Check control rack

for movement.
Check tappet for wear.

Version 08/2004
40.4 Assembly
Tightening torque:
4.5±0.5 kgf·m
(32.5±4 lbf·ft) [44±5 N·m]
Use new O-ring.
Use new lock plate.
Figure 229 Assembly sequence Follow the reverse of disassembly and use the
Assembly procedure
40.4.1 Barrel installation
Put each barrel in position in the housing with its slot in
alignment with the dowel of the housing and put it
straight down into the bore.
Locating dowel
NOTE
If the slot in the barrel is not aligned with the dowel of
the housing, the O-ring will not seat correctly (still
visible) after the delivery valve holder has been
installed.
Figure 230 Installing barrels

Version 08/2004
40.4.2 Delivery valve installation

Install the delivery valve, gasket, spring and O-ring on
the barrel and tighten the delivery valve holder finger
tight. Do this step for remainder of the delivery valves.
Valve CAUTION
Valve seat a. Any time the injection pump is disassembled, a
new O-ring must be installed.
Delivery valve b. Make sure the threads of the delivery valve
holder do not cause damage to the O-rings.
Figure 231 Installing delivery valves
40.4.3 Control sleeve installation

Center tooth (visible when seen
from the lower side) 1. Install each control sleeve with the center tooth in
alignment with the line mark of the control rack.
Line
Figure 232 Installing control sleeves
2. Put the plungers in position in the barrels.
CAUTION
Make sure the notch in the plunger is toward the
adjusting plate.
Figure 233 Installing plungers

Version 08/2004
40.4.4 Tappet installation

Move the control rack back and forth while pushing
down on each tappet to align the slot in the tappet with
the hole in the housing for the tappet guide pin. Install
the lock plates and tappet guide pins in position.
CAUTION
Any time the injection pump is disassembled, new
lock plates must be used.
Figure 234 Installing tappets
40.4.5 Delivery valve holder installation

Put the delivery valve holders in position and tighten
them to the specified torque.
4.5±0.5 kgf·m
(32.5±4 lbf·ft)
CAUTION
[44±5 N·m] Do not over tighten the delivery valve holders. This
can put end force on the barrels, resulting in a failure
of the plungers to move freely. If the holders are not
tightened to the specified torque, engine oil would
leak in the injection pump.
Figure 235 Tightening delivery valve holders
40.4.6 Inspection after assembly

1. After the injection pump has been assembled,
check to see if the control rack moves freely
without any binding or catching.
2. If the control rack fails to move freely, the possible
causes are:
a Pumping element(s) sticking
b Foreign particles lodged between control rack
and sleeves
c Over-tightening of delivery valve holder(s)
Disassemble and check the injection pump to
locate the cause of the trouble.
3. After the injection pump has been finally
assembled, check the injection timing.
Figure 236 Checking control rack movement

Version 08/2004
FUEL SYSTEM GOVERNOR
FUEL SYSTEM
41 GOVERNOR
41.1 Disassembly and inspection
Make sure levers move freely
Check weights for wear
Check sliding sleeve for wear or

damage. Make sure it moves freely
Check sliding sleeve

Check spring contact face for wear
for damage
Check shaft
for defects
Figure 237 Disassembly sequence and inspection Disassembly sequence

points 1. Tie rod spring
2. Tie rod
3. Speed control lever
4. Spring pin
5. Grooved pin
6. Governor shaft (remove 7 thru 11 as an assembly)
7. Governor lever
8. Start spring
9. Tension lever
10. Governor spring
11. Governor spring lever
12. Governor case

Version 08/2004
GOVERNOR FUEL SYSTEM
41.2 Assembly
1. Install the levers in position.
Figure 238 Installing governor levers
2. Put O-ring on the governor shaft.

Grooved pin 3. Put the governor shaft in position in the governor
Tie rod case and put the levers on the governor shaft.
spring 4. Install the grooved pin and spring pin in position
with a hammer.
5. Install the tie rod and tie rod spring in position.
Tie rod
Spring pin
Figure 239 Assembling governor

Version 08/2004
FUEL SYSTEM GOVERNOR
41.3 Torque spring set installation

Speed control lever
Line mark on pump body
Governor Torque The torque spring set is to be installed and adjusted
spring spring set after an adjustment is made to the low idle speed and
high idle speed, with the engine at a standstill.

2. Move the speed control lever to the high idle
position and hold it there.
3. Pull the tie rod in the direction of arrow head to the
point where a slight resistance is encountered.
Line mark on
control rack
Figure 240 Installing torque spring set

NOTE
In this position, the tie rod does not pull on the
governor spring.
Sealing cap Special nut

4. Turn in the torque spring set while lightly pulling
the tie rod until the line mark on the control rack is
aligned with the line mark on the pump body.
5. With these line marks aligned, lock the torque
Governor spring set in position by tightening the special nut.
lever
6. Install the sealing cap over the torque spring set
and stake the cap in position.
Figure 241 Sealing cap for torque spring set

Version 08/2004
FUEL PUMP FUEL SYSTEM
FUEL SYSTEM
42 FUEL PUMP
42.1 Inspection
Look outside the pump for defects and test its
performance. Do not attempt to disassemble the pump.
Figure 242 Fuel pump (plunger type)
Figure 243 Fuel pump (diaphragm type)

Version 08/2004
FUEL SYSTEM FUEL FILTER
FUEL SYSTEM
43 FUEL FILTER
1. Normally, the fuel filter is not to be disassembled.
Only element removal for cleaning or replacement
is recommended.
2. When installing the valve lever after washing, coat
Do not
remove Coat with silicone oil the O-ring for the lever with silicone oil and the
washer with grease.
Coat with grease Parts fuel filter:
1. Ring nut
Wash in diesel fuel every 2. Cup
100 sevice hours. Replace 3. O-ring
every 500 service hours 4. Element
5. Lever plate
Check for water 6. Washer
and sediment 7. Valve lever
8. O-ring
9. Packing
Figure 244 Fuel filter 10. Valve seat
11. Filter body
Parts fuel filter:

Do not 1. Ring nut
remove
2. Cup
Air vent screw
3. O-ring
4. Element
5. O-ring
6. Valve lever
7. O-ring
8. Spring
Wash in diesel fuel every 9. Valve
100 sevice hours. Replace 10. Filter body
every 400 service hours
Check for water and

sediment accumulation
Figure 245 Fuel filter
Do not attempt to disassemble the cartridge type fuel

filter. Check the filter for contamination or damage and
Air vent screws replace it as an assembly if necessary
Priming
sequence
To pump
Replace every 400

service hours
From
fuel tank Check for water and
sediment accumulation
Figure 246 Fuel filter (cartridge type)

Version 08/2004
FUEL FILTER FUEL SYSTEM

Version 08/2004
AIR INLET SYSTEM AND EXHAUST
SYSTEM

Version 08/2004
GENERAL AIR INLET SYSTEM AND EXHAUST SYSTEM
44 GENERAL
44.1 Schematic
Air breather pipe (for recirculation of blowby gases

Blowby gases
Air (from air cleaner) To exhaust muffler
Air inlet cover
Exhaust manifold
Figure 247 Schematic overview

Version 08/2004
AIR INLET SYSTEM AND EXHAUST SYSTEM INSPECTION
45 INSPECTION
Check for cracks

Use a new packing
Check for cracks
Use a new gasket
Use a new gasket
Check for cracks
45.1 Inspection procedure

Using a straight edge and a feeler gauge, check the
flange faces of the manifold for warpage. If warpage
exceeds the limit, recondition or replace the manifold.
Item Standard
Warpage of manifold 0.15 (0.005 9)
Table 5 Inspection, unit mm (in.)
Figure 249 Checking manifold for warpage

Version 08/2004
INSPECTION AIR INLET SYSTEM AND EXHAUST SYSTEM

Version 08/2004
MAINTENANCE

Version 08/2004
LUBRICATION AND MAINTENANCE CHART MAINTENANCE
MAINTENANCE
46 LUBRICATION AND
MAINTENANCE CHART
Recommended service should be performed at the
specified intervals. Under extremely severe, dusty or
wet operating conditions, more frequent lubrication
than is specified in this chart may be necessary.
Perform service on items at multiples of the original

requirement. For example, at Every 500 Service
Hours, also service those items listed under Every 100
(250) Service Hours, Every 50 Service Hours and
Every 10 Service Hours.
Interval Item Remarks (specifications) Page
Walk-around inspection See operation manual
Every 10 Service Hours Check engine oil level 172

[Pre-Start Inspection] Check fuel level See operation manual
Check coolant level See operation manual
Drain water and sediment from the fuel See operation manual
tank and water separator
Every 50 Service Hours
Check the battery electrolyte level and See operation manual
specific gravity
Change engine oil See SPECIFICATIONS (page 16) 173

First 50 Service Hours
of New or Change oil filter 173
Reconditioned Engine
Retighten nuts and bolts 191
Every 100 Service Clean fuel filter element After cleaning, prime 181
Hours Clean radiator fins See operation manual
Every 250 Service Change engine oil See SPECIFICATIONS (page 16) 173
Hours or once a year
(whatever comes first) Change oil filter 173
Check and adjust valve clearance 0.25 mm (0.0098 in.) for both inlet and
175
exhaust valves
Change fuel filter element After changing, prime 180

Every 500 Service
Hours Check and adjust injection pressure 140 kgf/cm2 (1 991 psi) [13 729 kPa] 183
Check and adjust fan belt Deflection: 13 mm (0.5 in.) 184
Check glow plugs 133
Retighten nuts and bolts 191
Every 1000 Service Check starter 115

Hours Check alternator 122
Check turbocharger See turbocharger manual
Table 6 Lubrication and maintenance charts

Version 08/2004
MAINTENANCE LUBRICATION AND MAINTENANCE CHART
Interval Item Remarks (specifications) Page
Every 2 Years Change coolant See operation manual
Prime fuel system 181
When Required Clean air cleaner element 180
Change air cleaner element See operation manual
Table 6 Lubrication and maintenance charts

Version 08/2004
ENGINE OIL AND OIL FILTER MAINTENANCE
MAINTENANCE
47 ENGINE OIL AND OIL

FILTER
47.1 Engine oil specifications1
Use oils that meet the Engine Service Classification CF
or CF-4.
Starting -30 -25 -20 -15 -10 -5 0 10 20 30 40

temperature, °C (°F) (-22) (-13) (-4) (5) (14) (23) (32) (50) (68) (86) (104)
SAE30
S A E 40
Oil viscosities S A E 15 W - 4 0
SAE10W-30
SAE5W-20
Table 7 Recommended oil viscosities
47.2 Oil level check

1. Check the crankcase oil level with a dipstick with
Dipstick Oil the engine put horizontal.
fillers 2. If the oil level is at or below “L” (low level) mark on
the dipstick, add oil to “H” (high level) mark on the
dipstick.
“H” mark
Drain plug
NOTE
“L” mark
a. After adding oil, leave the engine standing for
one minute and check the oil level.
Figure 250 Checking oil level b. Avoid mixing different brands of oils. In some
cases, they are not compatible with each other
and deteriorate when mixed. Use the same
brand at successive intervals.
c. If the engine has been left standing for a long
period of time, check the oil for level and
contamination before starting the engine. Start
and run the engine for a few minutes. Then stop
the engine and check the oil level again.
1.

Version 08/2004
MAINTENANCE ENGINE OIL AND OIL FILTER
47.3 Oil and oil filter change

1. Change the oil and the oil filter after the initial 50
service hours of a new or reconditioned engine
and, thereafter, every 250 service hours or once a
year (whatever comes first).
2. Warm up the engine. Remove the drain plug and
allow the oil to drain in a container.
3. Remove the used filter with a filter wrench. Make
sure that the formely used O-ring is removed from
the filter base and clean the base with a cloth.
Figure 251 Removing used oil filter
4. Check the new oil filter and make sure that the O-
ring is fitted in the groove. Apply a thin coat of lube
oil to the O-ring of the new oil filter.
5. Install the new filter by hand untill the O-ring
touched the base. Tighten 3/4 to 1 turn more.
Apply oil
CAUTION
Do not cause damage to the O-ring when installing
the filter.
6. Install the drain plug and tighten it to the specified

torque.
Figure 252 Removing used oil filter
4 ± 0.5 kgf·m
[39 ± 5 N·m]
7. Re-fill the engine to the "H" mark on the dipstick

with the new oil. Approximately an additional 0.5
liter (0.5 qt) of oil is required for the oil filter and oil
lines.
8. Start the engine, leave it idling for a few minutes
and check for leaks. Re-tighten the filter in case of
leakage.
9. Stop the engine. Check the oil level and add oil if
necessary.
47.4 Oil filter change

1. Change the oil filter every 250 service hours.
2. Remove the used filter with a filter wrench.
Discard the filter.
3. Remove all of the old filter gasket from the filter
base and apply a thin coat of engine oil to the
gasket on the new filter. Install the filter by hand
until its gasket contacts the base. Tighten 3/4 turn
more.

Version 08/2004
ENGINE OIL AND OIL FILTER MAINTENANCE
CAUTION
Do not cause damage to the O-ring when installing
the filter.
4. Add 0.5 liter (0.5 qt) of oil.

5. Start the engine and check for leaks around the
filter.
6. Stop the engine. Check the oil level and add oil if
necessary.

Version 08/2004
MAINTENANCE VALVE CLEARANCE
MAINTENANCE
48 VALVE CLEARANCE
NOTE
< Front of engine Make an adjustment to the valve clearance when the
engine is cold.
1. Slightly loosen the cylinder head bolts and

retighten them to the specified torque in number
sequence.
Figure 253 Cylinder head bolt tightening sequence

9 ± 0.5 kgf2m
Tightening torque (65 ± 4 lbf2ft)
[88 ± 5 N2m]
2. Find top dead center compression position for No.

TDC (top dead
center) mark for No. 1 piston by using the procedure that follows:
1 and No. 4 pistons a Turn the crankshaft until TDC mark on the
Mark on timimg crankshaft pulley is aligned with the mark on
gear case the timing gear case.
IT (injection b With No. 1 piston at top dead center on the
timimg) mark
compression stroke, the rocker arms will not
be moved when the crankshaft is turned
approximately 20° in both directions.
c If the rocker arms move, No. 1 piston is at top
dead center on the intake or exhaust stroke.
TDC mark for No. 2 In such a case, turn the crankshaft 360° in the
and No. 3 pistons direction of engine rotation again. No. 1
piston is now at top dead center on the
compression stroke.
Figure 254 Timing mark 3. Loosen the lock nut for the adjusting screw. With a
feeler gauge inserted between the rocker arm and
valve cap, adjust the valve clearance by turning
the adjusting screw.
Item Standard
Valve clearance (both

0.25 (0.0098)
inlet and exhaust valves)
Table 8 Valve clearance, unit mm (in.)
4. Hold the adjusting screw and tighten the lock nut.

Version 08/2004
VALVE CLEARANCE MAINTENANCE
5. After the valve clearance on the valves for No. 1

cylinder has been adjusted, turn the crankshaft
180° in the direction of engine rotation and adjust
the valve clearance on the valves for the
remainder of the cylinders in firing order (injection
sequence)
Firing order (injection Crankshaft rotation

sequence) angle
S3L(2) 1–3– 2 240°
S4L(2) 1–3–4–2 180°
Table 9 Firing order
Figure 255 Adjusting valve clearance
CAUTION
After the valve clearance on the valves for all
cylinders has been adjusted, turn the crankshaft two
or three times and make sure the valve clearance is
correct.

Version 08/2004
MAINTENANCE FUEL INJECTION TIMING
MAINTENANCE
49 FUEL INJECTION
TIMING
49.1 Preparation
1. Close the fuel filter valve.

2. Disconnect the No. 1 fuel injection pipe from the
cylinder head and injection pump.
3. Remove No. 1 delivery valve holder from the
injection pump. Remove the delivery valve and
spring from the holder. Restore the delivery valve
holder only to the injection pump.
4. Connect the fuel injection pipe to the injection
pump.
5. Hold the speed control lever in the low speed
position.
Figure 256 Removing delivery valve and spring
49.2 Inspection
49.2.1 Fuel flow method
1. Open the fuel filter valve. Turn the starter switch
key to ON position.
NOTE
Fuel will come from the injection pipe with high
pressure when the starter switch key is turned to ON
position if the engine is equipped with an electric fuel
pump. Direct fuel flow into the container.
Figure 257 Fuel coming from injection pipe
2. Slowly turn the crankshaft clockwise, looking at the

free end of the injection pipe. The instant fuel
stops coming out is the fuel injection timing.
NOTE
Turn the crankshaft in reverse direction just a little
and do Step (2) again to verify the injection timing.
Figure 258 Fuel stops coming from injection pipe

Version 08/2004
FUEL INJECTION TIMING MAINTENANCE
3. The fuel injection timing is correct if IT mark on the

crankshaft pulley is aligned with the mark on the
timing gear case when fuel stops from the injection
pipe.
Fuel injection timing (BTDC) 17° (standard)a
a. Please refer to the applicable engine model specifica-

tion sheet for actual data
Figure 259 Timing mark
49.2.2 Alternate method
In the fuel flow method, the delivery valve has to be

removed. As a result, there is a good chance for dirt
particles to get inside the fuel injection pump. In this
alternate method, however, it is not necessary to
remove the delivery valve.
1. Disconnect No. 1 fuel injection pipe at the fuel

injection nozzle (cylinder head).
2. Prime the fuel system.
3. Slowly turn the crankshaft clockwise until fuel just
swells at the free end of the injection pipe and, at
that instant, check the position of the IT mark with
respect to the mark on the gear case. This timing
is approximately 1° retarded. Take this 1°
Figure 260 Disconnecting No. 1 fuel injection pipe retardation into account when making a shim
adjustment.
Figure 261 Timing mark

Version 08/2004
MAINTENANCE FUEL INJECTION TIMING
49.3 Adjustment
1. If the fuel injection timing is incorrect, change the
thickness of shims under the fuel injection pump.
An increase or decrease of the shims by 0.1 mm
(0.004 in.) will vary the timing by 1°.
2. Increase the thickness of the shims to retard the
timing or decrease it to advance the timing.
Valve clearance (both

0.25 (0.0098)
inlet and exhaust valves)
Shims
Four kinds of shims are available in thicknesses
0.2 mm (0.007 9 in.), 0.3 mm (0.011 8 in.), 0.4 mm
Figure 262 Adjusting fuel injection timing (0.015 7 in.) and 0.8 mm (0.031 5 in.). These
shims have no identification; measure the thick-
TDC mark ness of each shim with a calipers before using it.
Angle by which
fuel injection
Angle by which
fuel injection
CAUTION
timing is timing is retarded Apply sealant to both faces of each shim to prevent
advanced Mark on oil leaks.
timing gear
case
3. After the timing has been adjusted, make sure it is
correct.
4. Close the fuel filter valve and restore the delivery
Increase Decrease valve and injection pipe to the original state.
shim shim
thickness. thickness.
Retarded Advanced
Figure 263 Adjusting fuel injection timing

Version 08/2004
FUEL FILTER MAINTENANCE
MAINTENANCE
50 FUEL FILTER
50.1 Fuel filter with [AIR] valve
Close the fuel filter valve. Loosen the ring nut and take
out the element for cleaning or replacement.
Valve lever
Element
Ring nut
Figure 264 Fuel filter with [AIR] valve
50.2 Cartridge (air vent screw) type

fuel filter
Replace the filter as an assembly if water and sediment
have been accumulated in it.
Figure 265 Cartridge type fuel filter

Version 08/2004
MAINTENANCE FUEL SYSTEM PRIMING
MAINTENANCE
51 FUEL SYSTEM PRIMING

51.1 Engine with fuel filter with
Overflow pipe
[AIR] valve
[OFF]
1. Move the fuel filter valve lever to AIR position.
2. Move the lever to ON position when the fuel flows
free of bubbles from the overflow pipe.
3. To prime the fuel pipe and fuel injection pump,
[AIR] loosen the air vent screw of the injection pump.
4. The injection pipes and nozzles can be primed by
[ON] cranking the engine.
5.
NOTE
The fuel system of the engine with an electric fuel
pump can be primed by turning the starter switch key
Figure 266 Priming fuel filter with [AIR] valve
to ON position.
51.2 Engine with cartridge (air vent

OPEN position
screw) type fuel filter
1. Loosen air vent screw (1). Tighten screw (1) when
the fuel flows free of bubbles from this vent.
2. Loosen air vent screw (2). Tighten screw (2) when
Valve lever the fuel flows free of bubbles from this vent.
3. The injection pipes and nozzles can be primed by
cranking engine engine.
NOTE
Turn the valve lever to OPEN position (if equipped)
Figure 267 Priming cartridge (air vent screw) type fuel before loosening any air vent screw.
filter
The fuel system of the engine with an electric fuel
pump can be primed by turning the starter switch key
to ON position.

Version 08/2004
IDLE RPM SETTING MAINTENANCE
MAINTENANCE
52 IDLE RPM SETTING
High idle position

Low idle position
NOTE
Make sure that the valve clearance and injection
timing are correct and that the fuel injection nozzles
have no defect.
1. Start and run the engine at low idle until the coolant
temperature is above 60°C (140°F).
2. To set the low idle speed, loosen the lock nut for
the idling set bolt and turn the set bolt to make the
engine run at the specified rpm. Tighten the lock
nut.
3. To set the high idle speed , loosen the lock nut for
the high-idle set bolt and turn the set bolt to make
the engine run at the specified rpm. Tighten the
Idling set bolt lock nut.
Lock nuts High-idle set bolt
Figure 268 Idle speed setting

Version 08/2004
MAINTENANCE FUEL INJECTION NOZZLES
MAINTENANCE
53 FUEL INJECTION
NOZZLES
53.1 Injection pressure (valve
opening pressure) test
See FUEL INJECTION NOZZLE (page 148).
53.2 Orifice restriction test

Make reference to FUEL INJECTION NOZZLE
(page 149).
53.3 Nozzle tip washing and

replacement
Make reference to FUEL INJECTION NOZZLE
(page 149).
53.4 Installation
1. Put the gasket on the injection nozzle.
2. Put the nozzle in position in the cylinder head and
tighten it to the specified torque.
5.5 ± 0.5 kgf·m
[54 ± 5 N·m
Figure 269 Installing fuel injection nozzles

Version 08/2004
FAN BELT MAINTENANCE
MAINTENANCE
54 FAN BELT
1. Measure the deflection of the belt. Apply 10 kgf (22
Adjusting bolt lbf) [98 N] force midway between the alternator
pulley and the crankshaft pulley.
2. Adjust the belt if the deflection is not correct.
Loosen the adjusting bolt and move the alternator
to obtain the required belt deflection.
Unit: mm(in.)
Item Standard
Deflection 10 to 12
Deflection: 10 to 12 mm (0.4 to 0.5)
(0.4 to 0.5 in.) under 10
kgf (22 lbf) [98 N] force
Figure 270 Installing fuel injection nozzles

Version 08/2004
SERVICE DATA

Version 08/2004
SPECIFICATIONS SERVICE DATA
SERVICE DATA
55 SPECIFICATIONS1
55.1 Basic engine components
Unit: mm (in.)
Item Standard Limit Correction-Remarks
27 kgf/cm2 (384
30 kgf/cm2 (427 psi)
Compression pressure psi) Repair or replace.
[2 942 kPa]
[2 648 kPa]
Maximum permissible difference between 3 kgf/cm2

average compression pressure (42.7 psi) — Repair or replace.
of all cylinders in one engine [294 kPa]
Fuel injection timing (BTDC)a 17°
Clearance between rocker arm and shaft 0.012 to 0.050 0.200

Replace rocker arm.
(oil clearance) (0.000 47 to 0.001 97) (0.007 87)
Valve clearance 0.25 (0.009 8) Adjust.
Clearance 0.02 to 0.05 0.10

Inlet valve
between (0.000 8 to 0.002 0) (0.003 9)
Replace valve
valve stem
0.05 to 0.085 0.15 and valve guide.
and valve Exhaust valve
guide (0.002 0 to 0.003 35) (0.005 9)
Valve margin (valve lip thickness) 1.0 (0.039) 0.5 (0.020) Replace valve.
0.5 ± 0.25 1.5 Recondition valve seat

Valve sinkage
(0.020 ± 0.009 8) (0.059) or replace cylinder head.
Angle 45° —
Valve seat Recondition.
Width 1.3 to 1.8 (0.051 to 0.071) 2.5 (0.098)
Free length 47 (1.85) 46 (1.81)
39.1 30.5
Length under test force —
(1.54) (1.20)
Valve spring Replace.
13.9 ± 0.7 29 ± 2
Test force,
(30.6 ± 1.5) (64 ± 4.4) -15%
kgf (lbf) [N]
[136 ± 7] [284 ± 20]
Warpage of cylinder head bottom face 0.05 (0.0020) maximum 0.10 (0.003 9) Repair.
Bend (dial indicator reading) of valve push rod — 0.3 (0.012) Replace.
1. All specifications are subject to change without any prior notice.

Version 08/2004
SERVICE DATA SPECIFICATIONS
Crankshaft gear and idler gear
Idler gear and camshaft gear 0.04 to 0.12

(0.001 6 to 0.004 7)
Idler gear and fuel injection
Timing gear pump camshaft gear
0.30 (0.011 8) Replace.
backlash
Camshaft gear and P.T.O. 0.08 to 0.19
gear (0.003 1 to 0.007 5)
Fuel injection pump cam-shaft 0.07 to 0.20

gear and oil pump gear (0.0028 to 0.0079)
Lobe height of camshaft 35.72 (1.406 3) 34.72 (1.366 9) Replace.
Lobe height of fuel injection pump camshaft 44 (1.73) 43 (1.69) Replace.
Flatness of flywheel 0.15 (0.005 9) maximum 0.50 (0.019 7) Replace.
Clearance between tappet and cylinder block — 0.15 (0.005 9) Replace tappet.
Clearance between camshaft journal

— 0.15 (0.005 9) Replace bushing.
and bushing
0.03 to 0.07 Replace idler

Clearance between idler gear and shaft 0.20 (0.007 9)
(0.001 2 to 0.002 8) gear or shaft.
Warpage of cylinder block top face 0.05 (0.002 0) maximum 0.10 (0.003 9) Repair.
Hone out bore for

78.0 0+0.03
Bore in cylinder block 78.2 (3.079) oversize piston or
(3.07 0+0.0012)
replace cylinder block.
Taper and out-of-round of cylinder 0.01 (0.000 4) maximum —
77.93 to 77.95
Standard 77.80 (3.063 0)
(3.068 1 to 3.068 9)
Diameter 0.25 (0.0098) 78.18 to 78.20

78.05 (3.072 8)
of piston oversize (3.077 9 to 3.078 7)
0.50 (0.0197) 78.43 to 78.45

78.30 (3.082 7)
oversize (3.087 8 to 3.088 6)
0.006 to 0.018
Clearance between piston pin and piston 0.050 (0.001 97)
(0.000 24 to 0.000 71)
0.06 to 0.10
No. 1 compression ring 0.30 (0.011 8)
(0.002 4 to 0.003 9)
Clearance
between 0.05 to 0.09
No. 2 compression ring 0.20 (0.007 9) Replace piston ring.
piston ring (0.002 0 to 0.003 5)
and groove
0.03 to 0.07
Oil ring 0.20 (0.007 9)
(0.001 2 to 0.002 8)
0.15 to 0.30
No. 1 compression ring
(0.005 9 to 0.011 8)
Clearance
between 0.15 to 0.35
No. 2 compression ring 1.50 (0.059) Replace piston ring
ends of (0.005 9 to 0.013 8)
piston ring
0.20 to 0.40
Oil ring
(0.007 9 to 0.015 7)
Hone out bore for

0.035 to 0.086
Clearance between piston and cylinder 0.300 (0.011 81) oversize piston or
(0.001 38 to 0.003 39)
replace cylinder block.

Version 08/2004
Clearance between crankpin 0.025 to 0.072 Replace connecting

0.150 (0.005 91)
and connecting rod bearing (0.000 98 to 0.002 83) rod bearing.
0.10 to 0.35
Thrust clearance for connecting rod big end 0.50 (0.019 7) Replace connecting rod.
(0.003 9 to 0.013 8)
51.985 to 52.000
Diameter of journal —
(2.046 65 to 2.047 24)
47.950 to 47.965
Diameter of crankpin —
(1.887 79 to 1.888 38)
Runout 0.025 (0.000 98) 0.05 (0.002 0) Repair or replace.

Crankshaft Clearance between journal 0.030 to 0.077
0.100 (0.003 94) Replace main bearing.
and main bearing (0.001 18 to 0.003 03)
Clearance between crankpin 0.025 to 0.072 Replace connecting rod

0.150 (0.005 91)
and connecting rod bearing (0.000 98 to 0.002 83) bearing.
0.050 to 0.175 Replace No. 3 flanged

End play 0.500 (0.019 69)
(0.001 97 to 0.006 89) bearing
a. Please refer to the applicable engine model specification sheet for actual data
55.2 Lubrication system

Unit: mm (in.)
3.5 ± 0.5 kgf/cm2

Pressure relief valve setting (50 ± 7 psi) — Replace.
[343 ± 49 kPa]
0.5 ± 0.1 kgf/cm2

Pressure difference at which oil pressure
(7 ± 1.4 psi) — Replace.
switch is closed (indicator light comes on)
[49 ± 10 kPa]
55.3 Fuel system

Unit: mm (in.)
1400+5 kgf/cm2
Injection pressure (valve opening pressure) (1 9910+71 psi) — Adjust with washer.
[13 7290+490 kPa]
55.4 Air inlet system and exhaust

system
Unit: mm (in.)
Clean every Change every

Paper-element type air cleaner element
100 service hours 500 service hours.
Warpage of mounting faces of manifolds — 0.15 (0.005 9) Repair or replace.

Version 08/2004
SERVICE DATA SPECIFICATIONS
55.5 Cooling system (standard)

Unit: mm (in.)
Temperature at which valve 82 ± 1.5°C

—
starts opening (180 ± 2.7°F)
Thermostat Replace.
Temperature at which valve lift
95°C (203°F) —
is more than 8 mm (0.3 in.)
Temperature at which switch is 111 ± 3.5°C

—
Thermo- turned ON (232 ± 6.3°F)
Replace.
switch Resistance at oil temperature
30 mΩ maximum —
of 120°C (284°F)
At 50°C (122°F) 80 ± 10 Ω —
Resistance
in At 80°C (176°F) 29.5 ± 2.5 Ω — Replace.
thermounit
At 120°C (248°F) 10 ± 0.3 Ω —
Deflection of fan belt under 10 kgf (22 lbf)

10 to 12
[98 N] force applied midway between — Replace.
(0.4 to 0.5)
alternator pulley and crankshaft pulley
55.6 Electrical system

Unit: mm (in.)
0.5 to 2.0
Pinion clearance — Adjust with packing.
(0.020 to 0.079)
S3L/S3L2 S4L/S4L2
Terminal voltage 11.5 V 11 V —

No-load
charac- 100 A 130 A Test.
Current draw —
teristics maximum maximum
3 000 3 600
rpm —
Starter
minimum minimum
Brush length — Wear limit line Replace.
3.0 kgf 1.8 kgf

Brush spring tension (6.6 lbf) (4.0 lbf) Replace.
[29.4 N] [17.7 N]
Runout of commutator 0.03 (0.001 2) 0.10 (0.003 9) Repair or replace.
Diameter of commutator 32 (1.26) 31 (1.22) Replace.
Undercut of mica 0.5 (0.020) 0.2 (0.008) Repair.

Version 08/2004
Regulated voltage at 20°C (68°F) 14.7 ± 0.3 V —
Terminal
Output At 2500 13.5 V —
voltage
charac- rpm
Alternator
teristics Current 33 A min. —

(at Test.
operating Terminal
At 500 13.5 V —
tempe- voltage
rature) rpm
Current 47 A min. —
Brush length — Wear limit line Replace.
Resistance in glow plug 0.55 Ω — Replace.

Version 08/2004
SERVICE DATA TIGHTENING TORQUES
SERVICE DATA
56 TIGHTENING TORQUES
56.1 Major bolts and nuts
Unit: mm (in.)
Thread, mm
Bolt or nut Torque, kgf·m (lbf·ft) [N·m]
Dia- Clamp
Pitch Width
meter length
Cylinder head bolt M10 1.25 14 87 9 ± 0.5 (65 ± 4) [88 ± 5]
Rocker cover bolt M8 1.25 12 40 1.15 ± 0.15 (8.3 ± 1.1) [11.3 ± 1.5]
Rocker shaft bracket bolt M8 1.25 12 58 1.5 ± 0.5 (11 ± 4) [14.7 ± 5]
Thermoswitch M16 1.5 17 31.5 2.3 ± 0.4 (16.6 ± 3) [22.6 ± 4]
Crankshaft pulley nut M18 1.5 27 — 17.5 ± 2.5 (127 ± 18) [172 ± 25]
Main bearing cap bolt M10 1.25 17 81 5.25 ± 0.25 (38 ± 2) [51.5 ± 2.5]
Connecting rod cap nut M9 1.0 14 — 3.55 ± 0.25 (25.7 ± 2) [34.8 ± 2.5]
Rear plate bolt (for tractor engine) M12 1.25 17 28 9.5 ± 1 (69 ± 7) [93 ± 10]
Rear plate bolt (standard) M12 1.25 17 28 6.5 ± 1 (47 ± 7) [64 ± 10]
Rear plate bolt (stamping) M8 1.25 12 16 1.15 ± 0.15 (8.3 ± 1.1) [11.3 ± 1.5]
Flywheel bolt M12 1.25 19 29 13.5 ± 0.5 (98 ± 4) [132 ± 5]
Oil pan bolt (for tractor engine) M8 1.25 12 25 2.8 ± 0.3 (20.3 ± 2.2) [27.5 ± 3]
Oil pan drain plug M14 1.5 22 10 4 ± 0.5 (29 ± 4) [39 ± 5]
Pressure relief valve M22 1.5 22 33 5 ± 0.5 (36 ± 4) [49 ± 5]
Oil filter M20 1.5 — — 1.2 ± 0.1 (8.7 ± 0.7) [12 ± 1]
Oil pressure switch PT1/8 — 26 11 1 ± 0.2 (7.2 ± 1.4) [10 ± 2]
Fuel injection pipe nut M12 1.5 — — 3 ± 0.5 (22 ± 4) [29 ± 5]
Fuel leak-off pipe nut M12 1.5 18 — 2.75 ± 0.25 (20 ± 2) [27 ± 2.5]
Delivery valve holder — — 19 — 4.5 ± 0.5 (32.5 ± 4) [44 ± 5]
Fuel injection nozzle holder M20 1.5 21 — 5.5 ± 0.5 (40 ± 4) [54 ± 5]
Retaining nut for delivery valve holder

M16 0.75 19 — 3.75 ± 0.25 (27 ± 2) [37 ± 2.5]
body
Sliding sleeve shaft M10 1.25 14 29.5 3.6 ± 0.6 (26 ± 4) [35 ± 6]
Special nut for torque spring set M12 1.0 17 — 2 ± 0.5 (14 ± 4) [20 ± 5]
Glow plug M10 1.25 12 60 1.75 ± 0.25 (12.7 ± 2) [17.2 ± 2.5]
Glow plug connection plate M4 0.7 8 — 0.125 ± 0.025 (0.9 ± 0.2) [1.2 ± 0.2]
Stop solenoid nut M30 1.5 36 — 4.5 ± 0.5 (32.5 ± 4) [44 ± 5]
Starter B terminal M8 1.25 12 — 1.1 ± 0.1 (8 ± 0.7) [10.8 ± 1]

Version 08/2004
TIGHTENING TORQUES SERVICE DATA
56.2 Torques for bolts and nuts with

standard threads
Unit: kgf·m (lbf·ft) [N·m]
Identification on head
Thread diameter
4 7
0.4 ± 0.1 0.9 ± 0.1

M6 (3 ± 0.7) (6.5 ± 0.7)
[3.9 ± 1] [8.8 ± 1]
1.1 ± 0.1 1.85 ± 0.35

M8 (8 ± 0.7) (13.4 ± 2.5)
[10.8 ± 1] [18 ± 3]
2.15 ± 0.35 3.6 ± 0.6

M10 (15.6 ± 2.5) (26 ± 4.3)
[21 ± 3] [35.3 ± 6]
3.6 ± 0.6 6.5 ± 1

M12 (26 ± 4.3) (47 ± 7)
[35.3 ± 6] [63.7 ± 10]
6±1 9.5 ± 1.5

M14 (43 ± 7) (69 ± 11)
[59 ± 10] [93.2 ± 15]
56.3 Torques for plugs with

taperlock threads
Unit: kgf·m (lbf·ft) [N·m]
Size For aluminium materials For ferrous materials
0.65 ± 0.15 1 ± 0.2

NPTF 1/16 (4.7 ± 1) (7.2 ± 1)
[6.4 ± 1] [10 ± 2]
1 ± 0.2 1.85 ± 0.35

PT 1/8 (7.2 ± 1) (13.4 ± 2.5)
[10 ± 2] [18 ± 3]
2.5 ± 0.5 4 ± 0.5

PT 1/4, NPTF 1/4 (18 ± 4) (29 ± 4)
[25 ± 5] [39 ± 5]
6.5 ± 1
PT 3/8 — (47 ± 7)
[64 ± 10]

Version 08/2004
SERVICE DATA SEALANTS
SERVICE DATA
57 SEALANTS
Component Sealant Mating part Remarks
Stop solenoid Three Bond 1212 Governor case

Thread parts
Water drain joint

Three Bond 1102 Cylinder block Apply to effective thread part.
Oil pressure switch
Torque spring set Three Bond 1212 Governor case
Cylinder block
Cylinder head
Force-fit parts
Sealing cap Apply to holes in cylinder head and

Cylinder head and cylinder block.
Three Bond 1102
cylinder block
Expansion plug Cylinder block
Dipstick guide
Cylinder block and

Side seal Apply to external surface.
main bearing caps
Other parts
Three Bond 1212

Main bearing caps Apply to surfaces that come into
(front and rear) Cylinder block contact with cylinder block.
Oil pan Three Bond 1207C Apply to sealing surface.

Version 08/2004
SPECIAL TOOLS SERVICE DATA
SERVICE DATA
58 SPECIAL TOOLS
Tool No. Toon Name Style Usage
31A91-00100 Piston Pin Setting Tool Piston pin removal

and installation
ST332340 Camshaft Bushin Installer Camshat front bushing

removal and installation
Compression Gauge
ST332270 Compression pressure
Adaptor
measurement
Oil Pressure Switch Socket

MD998054 Oil pressure switch removal
Wrench
and installation
NOTE
In addition to these special tools, commercially
available tools such as bearing puller, valve seat
cutting tool, valve guide installing tool, valve spring
compressing tool, oil filter wrench, etc. are necessary.

Version 08/2004
BLANK PAGE

Version 08/2004
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INTRODUCTION

Service Manual Mitsubishi SL-Series diesel engines ENGLISH 1 / 195

Indicates a condition that is essential to highlight.

Definition of locational terms

Dimensional or specification terms

2 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines

Service Manual Mitsubishi SL-Series diesel engines ENGLISH 3 / 195

15.1 Flywheel removal ................................................................................................................... 47

4 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines

21.2 Oil pump installation............................................................................................................... 92

Service Manual Mitsubishi SL-Series diesel engines ENGLISH 5 / 195

30.1 Disassembly......................................................................................................................... 122

AIR INLET SYSTEM AND EXHAUST SYSTEM

6 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines

44.1 Schematic ............................................................................................................................ 166

Service Manual Mitsubishi SL-Series diesel engines ENGLISH 7 / 195

8 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines

Service Manual Mitsubishi SL-Series diesel engines ENGLISH 9 / 195

• The model identification is embossed on the right

S3L 1.125 liters (68.7 cu in.)

S3L2 1.318 liters (80.4 cu in.)

S4L2 1.758 liters (107.3 cu in.)

• A scheme of coding used for identifying the

S - Identification of “Sagamihara Machinery Works”

4 - Number-of-cylinders code [“4” stands for four

L - Series code [Bore: 78 mm (3.07 in.)]

(2) - Stroke code

10 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines

1.2 Serial Number Location

The serial number is punched on the cylinder block,

Figure 2 Serial number location

Service Manual Mitsubishi SL-Series diesel engines ENGLISH 11 / 195

Fuel injection pump

Coolant drain plug

Oil pressure switch

Dipstick Crankshaft pulley

Oil drain plug Oil filter

Thermostat Exhaust manifold

LEFT SIDE VIEW

12 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines

2.2 Engine S3L-T/S3L2-T

Hanger Oil filler

Fuel injection pump

Coolant drain plug

Dipstick Crankshaft pulley

Oil drain plug Oil filter

Thermostat Exhaust manifold

LEFT SIDE VIEW

Service Manual Mitsubishi SL-Series diesel engines ENGLISH 13 / 195

Hanger Oil filler

Fuel injection pump

Coolant drain plug

Oil pressure switch

Oil filter Crankshaft pulley

Oil drain plug Dipstick

REAR RIGHT SIDE VIEW FRONT

Thermostat Exhaust manifold

FRONT LEFT SIDE VIEW REAR

14 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines