5. CYLINDER HEAD
Loosening of the bolts - sequence -
Tightening of the bolts - sequence -
Tightening torque, cylinder head bolts: 88 ± 5 Nm
Technical Data
Valve clearance, cold 0.25 mm inlet & exhaust
Injection pressure 140 bar + 5 bar
Compression pressure new 30 bar lower limit: 27 bar
Injection timing 17° before top dead centre
Oil pressure, service temperature 3.5 bar ± 0.5 bar
Tightening torques: Bolts/nuts in general
Thread Quality class 4 Quality class 7
M 6 4 Nm 9 Nm
M 8 11 Nm 18 Nm
M 10 21 Nm 35 Nm
M 12 35 Nm 64 Nm
M14 60 Nm 93 Nm
Typ/Model/Type
Mitsubishi SL-Series
Datum/Edition/Date
01.2008
Benennung/Description/Dénomination
Diesel engine
Blatt/Page/Feuille
3.600.03
7. Injection nozzles - injection figures
good ⎜ ← bad, replace → ⎜
Injection nozzle
Typ/Model/Type
Mitsubishi SL- Series
Datum/Edition/Date
01.2008
Benennung/Description/Dénomination
Diesel engine
Blatt/Page/Feuille
3.600.04
filter
fuel pump
from fuel tank
overflow pipe
to fuel tank
fuel injection nozzle
injection pipe injection pump
threaded sleeve
injection nozzle compl.
spacer
pin
spring
washer
body
leak-off pipe
8. Oil circuit
Water circuit
3.600.04/01.2008
oil pressure switch
oil filter
pressure relief valve
oil pump
main oil gallery
drain plug
oil screen
cooler
fan
bypass
hose thermostat
water pump
9. starter
water pump
fuel injection nozzle oil filler plug
intake manifold
fuel injection pump
ventilation pump
fuel system
engine serial number
flywheel housing
oil drain plug
oil pressure switch
oil dipstick
thermostat
fan
oil pan
oil filter
alternator
v-belt pulley on crankshaft
exhaust manifold
fuel filter
coolant drain plug
Typ/Model/Type Datum/Edition/Date
Mitsubishi S 4 Q 01.2007
Blatt/Page/Feuille
Benennung/Description/Dénomination
Diesel engine 3.800.01
10. CYLINDER HEAD
Tightening order of bolts
Tightening torque of cylinder head studs: 118 ± 5 Nm
Technical Data
Tappet clearance cold 0.25 mm inlet & exhaust
Injection pressure 120 bar + 10 bar
Compression pressure new 30 bar Lower limit: 26 bar
Injection timing 22° before top dead centre
Oil pressure, service temperature 2 - 4 bar (under load) ± 0,5 bar
Tightening torques: bolts / nuts, general
Thread Quality class 4 Quality class 7
M 6 4 Nm 9 Nm
M 8 11 Nm 18 Nm
M 10 21 Nm 35 Nm
M 12 35 Nm 64 Nm
M 14 60 Nm 93 Nm
3.800.01/01.2007
11. Fuel feed
Fuel filter
• Slacken the ventilation plug (A) of the
fuel filter (B) by means of an open end
wrench.
• Put a clean cloth around the ventilation
plug (A) to collect the escaping fuel,
then operate the feed pump (C) as
shown in the illustration.
• The ventilation plug (A) is to be closed
when the fuel escapes from the
ventilation without bubbles.
If the fuel pump valve is dirty and
the fuel cannot be fed through the
fuel filter, the ventilation plug as
well as the feed line of the fuel filter
are to be dismounted and cleaned
with compressed air.
• To unlock the fuel pump cover (D), turn
it to the left.
• Operate the fuel feed pump (C) ap-
proximately 20 times, then turn the
cover (D) to the right and lock.
Mitsubishi S 4 Q
Datum/Edition/Date
Typ/Model/Type
01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Diesel engine 3.800.02
12. Remove fuel lines
• Remove pipe clamp (E) from the injection
lines (F). Unscrew lines (F) at the injection
pump and at the injection nozzles (G).
• Unscrew the drain oil lines (H) at the injection
nozzles (G) by slackening the nuts (J).
Mount protective caps to protect the
fuel system against dirt or foreign
particles at the pump and injection
nozzles !
Removal of the injection nozzles
• Screw out the injection nozzles (G) of the
engine by means of a socket wrench.
Remove the injection nozzle seals
with a wire or a screwdriver and
dispose of according to regulations.
3.800.02/01.2007
14. Removal of the injection pump
• Check the alignment of the marking on
the injection pump with the marking on
the flange.
• Remove the front cover of the injection
pump gear.
• Make markings (K) at the idler gear and
injection pump gear.
• Slacken the bolts of the intermediate
flange and remove the injection pump
including the intermediate flange and
gear.
Make sure that the engine does not
turn after the removal of the injec-
tion pump.
To remove the gear of the injection
pump, slacken the nut of the gear
prior to the removal of the pump.
Check the injection timing
• Adjust the piston no. 1 to top dead
centre.
3.800.03/01.2007
flange marking
injection pump
marking
injection pump gear
15. • Turn the crankshaft approximately 30°
counter-clockwise, facing the engine
front side (fan side). Then slowly turn
clockwise up to 20° before top dead
centre until the marking on the
crankshaft V-belt pulley is in line with
the one of the control housing.
• Remove the maintenance cover from
the fuel injection pump.
• Make sure that the flat side „A“ of the
circlip aligns with marking „E“ on the
setting plate. If this is alright, the
injection timing is adjusted correctly.
• If the flat side „A“ is not in alignment
with line „E“, the nuts holding the
injection pump are to be slackened and
the pump is to be turned in such a
manner that the markings align.
• Hold the injection pump in that position
and tighten the nuts.
Typ/Model/Type
Mitsubishi S 4 Q
Datum/Edition/Date
01.2007
Benennung/Description/Dénomination
Diesel engine
Blatt/Page/Feuille
3.800.04
flange marking
flange marking
injection pump
marking
16. Engine control
The setting data of the injection system
depends on the performance, speed (rpm)
and specification of the engine. For the
correct data, please refer to the do-
cumentation of the engine manufacturer.
1) Adjustment of the first piston to top
dead centre in compression stroke
a) Turn the crankshaft clockwise (with a
view of the engine front side) until the
„O“ at the crankshaft V-belt pulley is in
line with the marking.
b) Press the inlet and outlet rocker at the
first cylinder downward.
Tappets must be free.
2) Check of the injection timing
a) Remove the retainer ring of the valve
holder for the first cylinder at the
injection pump.
b) Dismount the valve holder (1) for the
first cylinder. Remove the piston of the
pressure valve (2) and the spring (3).
c) Re-mount the valve holder (1).
d) Mount the overflow pipe on the valve
holder (1) for the first cylinder.
e) Turn the crankshaft until the piston of
the first cylinder is 60° before top dead
centre.
f) Turn the crankshaft in engine turning
direction by operating the hand feed
pump until the fuel flow from the
overflow pipe stops.
g) Check injection timing (marking on the
crankshaft V-belt pulley of the
crankshaft).
Typ/Model/Type
Mitsubishi S 4 Q
Datum/Edition/Date
01.2007
Benennung/Description/Dénomination
Engine control
Blatt/Page/Feuille
3.800.05
17. 3) Adjustment of the injection timing
a) If the injection timing must be changed,
turn the injection pump as shown in the
illustration opposite.
b) Only the setscrew for max. engine
speed is sealed.
c) If this setting is checked and adjusted,
please ensure that there is somebody
near the engine to be able to operate
the engine cut-off mechanically in case
of engine overspeeding.
d) A marking unit at the injection pump
flange changes the injection timing by
6° to the crankshaft angle.
Off-load min. speed (idle running
speed) and max. speed setting
For inspections and settings warm the
engine up thoroughly until the coolant and
engine oil temperatures are higher than
70°C (158° F).
3.800.05/01.2007
a) The off-load min. speed (idle running
speed) as well as the max. speed of
each engine are set on the test
bench in the factory. The setscrew
for max. speed is sealed. These
settings are to be performed by an
authorised workshop only.
b) After removing the leaden seals and
adjusting the regulator, all visisble
stops are to be sealed as though
they would have been sealed by the
factory.
c) It is decisive for the settlement of
warranty claims whether the stop
screw leaden seals are alright or not.
d) When this setting is checked and
adjusted, please make sure that
there is somebody near the engine
in order to be able to stop engine
mechanically in case of engine
overspeeding.
injection timing
earlier
injection
timing later
18. 1) Engine start-up
a) Set speed adjusting lever to high idle
running speed. Actuate starter.
b) The engine fires from a crankshaft
speed of 150 min-1
. When the engine is
running, the speed is to be held
between 800 and 1,000 min-1
.
c) When the engine is running with
constant speed, the speed adjusting
lever is to be brought into idle running
position.
2) Set off-load low idle running speed
a) Hold the speed adjusting lever in off-
load min. speed position and set low
idle running speed by means of the
setscrew (2)
b) Engine speed increase:
Turn the setscrew of the low idle
running speed clockwise.
To be performed by trained and
qualified personnel only:
c) In case of speed variations (fluctuations
of the engine), turn the setscrew (3) of
the idle running speed spring clockwise
to increase the spring preload.
In case of a critical speed (speed
resulting in bad engine vibrations
due to torsional oscillations), a
higher or lower speed range is to
be chosen.
An excessive spring preload
results in engine overspeeding
with the load decreasing. Make
sure that this is prevented.
Mitsubishi S 4 Q
Datum/Edition/Date
01.2007
Engine control
Blatt/Page/Feuille
3.800.06
19. 3) Set max. output (capacity)
To be performed by trained and
qualified personnel only:
a) Bring speed adjusting lever into full load
position and load engine with its
indicated output.
b) While the engine is running with
constant speed, adjust the full load stop
screw in such a manner that the engine
achieves its indicated output.
c) If the full load stop screw is turned
counter-clockwise, the capacity is
reduced, and the engine speed is
lowered.
If the full load stop screw is turned
clockwise, the capacity is increased,
and the exhaust gas values deteriorate.
This setting can only be performed
on the test bench as it is sealed by
the factory.
3.800.06/01.2007
20. Oil circuit
valve tappet
pressure valve
oil pump
oil main
distribution
intake
manifold
drain plug
engine oil filter
crankshaft
control
gears
camshaft
rocker arm
piston
Water circuit
radiator
fan
waterpump
thermostat
Datum/Edition/Date
Typ/Model/Type
Mitsubishi S 4 Q 01.2007
Blatt/Page/Feuille
Benennung/Description/Dénomination
3.800.07
Diesel engine
21. Yanmar
4 TNV 88
Typ Motor Datum
Model Engine Edition
Type Moteur Date
Tipo Motor Fecha
01.2007
Benennung
Technische Daten
Specification data
Blatt
Description Page
Dénomination Feuille
Denominación Página
3.900.01
Kolben
(Piston)
Nockenwelle
(Cam Shaft)
Ölwanne
(Oil Pan)
Kurbelwelle
(Crank Shaft)
Stößel
(Tappet)
Generator
Thermostat
(Cooling Water Thermostat)
Auslasskrümmer
(Exhaust Manifold)
Kurbelgehäuseentlüftung
(Breether)
Einspritzdüse (Fuel Injection Valve)
Ventil (Valve)
Kipphebel (Rocker Arm)
Zylinderkopf (Cylinder Head)
Einlasskrümmer
(Intake Manifold)
Kraftstoffilter
(Fuel Filter)
Schwungrad
(Flywheel)
Ölmesstab
(Oil-Level Gauge)
Einspritzpumpe
(Injection Pump)
Ölfilter
(Oil Filter)
Yanmar 4TNV88
22. Ventilspiel einstellen:
Valve clearence adjustment:
Einstellungen bei kaltem Motor.
Adjustments to do when engine is cold.
Zündreihenfolge: 1-3-4-2
Firing order:
Ventilspiel bei OT bzw. Überschneidung des 1. Zylinders
(Schwungradseite) an folgenden Ventilen Einstellbar.
Valve clearence to be adjust at TDC respectively overlap of cylinder 1 (flywheelside)
at following valves.
Zylinder Nummer :
Cylinder No. : 1 2 3 4
Ventil
Valve
EIN
IN
AUS
OUT
EIN
IN
AUS
OUT
EIN
IN
AUS
OUT
EIN
IN
AUS
OUT
Zylinder 1 OT
No.1 TDC
X X X X
Zylinder 1
überschneidung
No. 1 overlap
X X X X
Ventilspiel : 0,15 - 0,25 mm
Valve clearence : 0,15 – 0,25 mm
Typ/Model/Type
Yanmar 4TNV88
Datum/Edition/Date
01.2007
Benennung/Description/Dénomination
Antriebsmotor
Engine
Blatt/Page/Feuille
3.900.02
30. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
GET MORE OTHER MANUALS https://www.aservicemanualpdf.com/
GET MORE OTHER MANUALS https://www.aservicemanualpdf.com/