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Mitsubishi S3L User Manual

Mitsubishi S3L
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88 / 195
Service Manual Mitsubishi SL-Series diesel engines
Version 08/2004
ENGLISH
Cylinder Block, Crankshaft, Pistons and
Oil pan
ASSEMBLY
88 / 195
6. Using a piston guide (commercially available), put
the piston and connecting rod into the cylinder
from the top of the cylinder block.
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.
4. Tighten the connecting rod cap nuts in steps to the
specified torque.
5. Check the thrust clearance for the connecting rod
big end.
Figure 128 Installing piston and connecting rod
Piston guide
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..
Figure 129 Installing connecting rod cap
Notches
Cilinder
number
Figure 130 Tightening connecting rod cap nuts
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.
Tightening torque
3.55 ± 0.25 kgf·m
(25.7 ± 2 lbf·ft)
[34.8 ± 2.5 N·m]

Table of Contents

Questions and Answers:

Mitsubishi S3L Specifications

General IconGeneral
Engine ModelS3L
Number of Cylinders3
AspirationNaturally aspirated
Fuel TypeDiesel
Starting SystemElectric starter
Cooling SystemWater-cooled
Lubrication SystemForced lubrication by trochoid pump

Summary

INTRODUCTION

GENERAL INFORMATION

MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION

Locates engine model and serial number information.

COMPONENT LOCATION

Illustrates the location of engine components.

SPECIFICATIONS

Provides key technical specifications for engine models.

OVERHAUL INSTRUCTIONS

DETERMINING WHEN TO OVERHAUL THE ENGINE

Guides on identifying the need for engine overhaul based on symptoms.

COMPRESSION PRESSURE MEASUREMENT

Details the procedure for measuring engine compression pressure.

TROUBLESHOOTING

Offers systematic approaches to diagnose and resolve engine problems.

BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Outlines essential safety and procedural precautions for engine work.

DISASSEMBLY

PREPARATION FOR DISASSEMBLY

Steps to prepare the engine before commencing disassembly.

ELECTRICAL SYSTEM DISASSEMBLY

Procedures for disassembling electrical system components.

Cooling System Disassembly

Steps to disassemble cooling system components.

Fuel System Disassembly

Procedures for disassembling fuel system components.

Lubrication System Disassembly

Steps to disassemble lubrication system components.

AIR INLET SYSTEM AND EXHAUST SYSTEM DISASSEMBLY

Procedures for disassembling air inlet and exhaust systems.

CYLINDER HEAD AND VALVE MECHANISM DISASSEMBLY

Steps for disassembling cylinder head and valve train.

Timing Gears and Flywheel Disassembly

Procedures for disassembling timing gears and flywheel.

Cylinder Block, Crankshaft, Pistons and Oil Pan Disassembly

Steps for disassembling major engine block components.

INSPECTION

CYLINDER HEAD AND VALVE MECHANISM INSPECTION

Detailed inspection procedures for cylinder head and valve components.

TIMING GEARS AND FLYWHEEL INSPECTION

Inspection procedures for timing gears and flywheel components.

CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN INSPECTION

Inspection procedures for cylinder block, crankshaft, pistons, and oil pan.

ASSEMBLY

Cylinder Block, Crankshaft, Pistons and Oil pan ASSEMBLY

Procedures for assembling engine block components.

Timing Gears and Flywheel ASSEMBLY

Procedures for assembling timing gears and flywheel.

CYLINDER HEAD AND VALVE MECHANISM ASSEMBLY

Procedures for assembling cylinder head and valve train.

Air Inlet System and Exhaust System ASSEMBLY

Procedures for assembling air inlet and exhaust systems.

Fuel System ASSEMBLY

Procedures for assembling fuel system components.

Lubrication system ASSEMBLY

Procedures for assembling lubrication system components.

Cooling system ASSEMBLY

Procedures for assembling cooling system components.

Electrical System ASSEMBLY

Procedures for assembling electrical system components.

ELECTRICAL SYSTEM

GENERAL ELECTRICAL SPECIFICATIONS

General specifications for electrical system components.

STARTER SYSTEM

Detailed information on starter disassembly, inspection, and assembly.

ALTERNATOR SYSTEM

Detailed information on alternator disassembly, inspection, and assembly.

KEY SHUTOFF SYSTEM

ETS SOLENOID TYPE OPERATION AND INSTALLATION

Operation and installation of the ETS shutoff system.

ETR SOLENOID TYPE OPERATION AND INSTALLATION

Operation and installation of the ETR shutoff system.

AUTOMATIC GLOW SYSTEM

GLOW PLUG AND RELAY SPECIFICATIONS AND INSPECTION

Specifications and inspection for glow plugs and relays.

COOLING SYSTEM

COOLING SYSTEM INSPECTION

Procedures for inspecting cooling system components.

LUBRICATION SYSTEM

LUBRICATION SYSTEM INSPECTION

Procedures for inspecting lubrication system components.

FUEL SYSTEM

FUEL INJECTION NOZZLE PROCEDURES

Inspection, testing, and service of fuel injection nozzles.

FUEL INJECTION PUMP PROCEDURES

Testing, disassembly, and assembly of the fuel injection pump.

GOVERNOR PROCEDURES

Disassembly, inspection, assembly, and adjustment of the governor.

FUEL PUMP INSPECTION

Inspection of the fuel pump.

FUEL FILTER SERVICE

Procedures for servicing the fuel filter.

AIR INLET SYSTEM AND EXHAUST SYSTEM

AIR INLET AND EXHAUST SYSTEM INSPECTION

Inspection procedures for air inlet and exhaust manifolds.

MAINTENANCE

LUBRICATION AND MAINTENANCE CHART

Schedule for routine lubrication and maintenance tasks.

ENGINE OIL AND OIL FILTER SERVICE

Procedures for engine oil and filter changes and level checks.

VALVE CLEARANCE ADJUSTMENT

Steps for checking and adjusting valve clearance.

FUEL INJECTION TIMING ADJUSTMENT

Procedures for checking and adjusting fuel injection timing.

FUEL FILTER AND FUEL SYSTEM PRIMING

Servicing the fuel filter and priming the fuel system.

IDLE RPM SETTING

Procedures for setting engine idle speeds.

FUEL INJECTION NOZZLES INSTALLATION

Steps for installing fuel injection nozzles.

FAN BELT ADJUSTMENT

Procedure for checking and adjusting the fan belt.

SERVICE DATA

SPECIFICATIONS

Comprehensive technical specifications for engine components.

TIGHTENING TORQUES

Torque specifications for various bolts and nuts.

SEALANTS APPLICATION GUIDE

Guide on sealant types and their mating parts.

SPECIAL TOOLS LIST

List of essential special tools for service procedures.

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