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S3Q2
Mitsubishi S3Q2 User Manual
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INLET AND EXHAUST SYSTEMS
11-2
1.
Removing inlet and exhaust sysytem
Removing inlet and exhaust sysytem
Removing sequence
5
1
3
2
6
4
The illustration is an example of S3Q2-T
Replace
Replace
Replace
Replace
Replace
1
Air hose
4
Air in
let elbow
2
Air hose
5
Inlet manifold
3
Air pipe
6
Exhaust manifold
127
129
Table of Contents
General
15
How to Use this Manual
5
Fire and Explosion
7
Table of Contents
15
General
17
External View
18
Model S3Q2
18
Model S3Q2-T
19
System Flow Diagrams
20
Fuel System - Flow Diagram
20
Lubrication System - Flow Diagram
20
Cooling System - Flow Diagram
21
Inlet and Exhaust System - Flow Diagram
21
Engine Serial Number Location
22
Main Specifications
23
Tips on Disassembling and Reassembling
26
Disassembling
26
Reassembling
26
Service Data
27
1 Maintenance Service Data
28
Basic Engine
28
General
28
Service Data
30
Service Data
33
Fuel System
33
Lubrication System
33
Cooling System
33
Electrical System
34
2 Tightening Torque Table
35
Basic Engine
35
Fuel System
35
Major Bolt Tightening Torque
35
Cooling System
36
Electrical System
36
Inlet and Exhaust Systems
36
Lubrication System
36
Standard Bolt and Nut Tightening Torque
37
Service Tools
39
General Tools
39
Special Tool
41
Determination of Overhaul
45
Determining Overhaul Timing
46
Disassembly of Basic Engine
49
1 Disassembling and Inspecting Cylinder Head and Valve Mechanism
50
Disassembling Rocker Shaft Assembly
51
Removing Cylinder Head Assembly
51
Removing Rocker Shaft Assembly
51
Cleaning Cylinder Head Bottom Surface
52
Removing Valve and Valve Spring
52
Removing Valve Stem Seal
52
Measuring Piston Protrusion
53
2 Disassembling and Inspecting Flywheel
54
Removing Flywheel
55
Removing Oil Seal Case
55
Removing Rear Plate
55
3 Disassembling and Inspecting Timing Gear, Camshaft and Oil Pan
56
Removing Crankshaft Pulley
57
Removing Timing Gear Case
57
Measuring Timing Gear Backlash
57
Measuring Idler Gear End Play
58
Removing Idler Gear
58
Measuring Camshaft End Play
58
Inverting Crankcase
58
Removing Oil Pan and Oil Pan Gasket
59
Removing Oil Pump
59
Removing Camshaft
59
Removing Front Plate
59
4 Disassembling and Inspecting Piston, Connecting Rod, Crankshaft and Crankcase
60
Laying Crankcase on Its Side
61
Measuring Connecting Rod End Play
61
Removing Connecting Rod Cap
61
Removing Carbon Deposits from the Upper Part of Cylinder
62
Pulling out Piston
62
Removing Piston Ring
62
Removing Piston Pin
62
Uprearing Crankcase
63
Measuring Crankshaft End Play
63
Removing Main Bearing Cap
63
Removing Crankshaft
64
Inspection and Repair of Basic Engine
65
1 Inspecting and Repairing Cylinder Head and Valve Mechanism
66
Measuring Distortion of the Bottom Surface of the Cylinder Head
66
Measuring Clearance between Rocker Arm and Rocker Shaft
66
Measuring Perpendicularity and Free Length of Valve Spring
66
Measuring Push Rod Runout
67
Measuring Valve Stem Outside Diameter and Valve Guide Inside Diameter
67
Replacing Valve Guide
68
Inspecting Valve Face
69
Replacing Valve Seat
70
Refacing Valve Face
70
Refacing Valve Seat
71
Lapping Valve and Valve Seat
71
Removing Combustion Jet
72
2 Inspecting and Repairing Flywheel
73
Inspecting Ring Gear
73
Replacing Ring Gear
73
Removing Ring Gear
73
Installing Ring Gear
73
3 Inspecting and Repairing Timing Gear, Camshaft and Oil Pan
74
Inspecting V-Pulley
74
Inspecting Oil Seal Contact Surface
74
Measuring Clearance between Idler Bushing and Idler Shaft
74
Replacing Idler Bushing
74
Replacing Idler Shaft
75
Measuring Cam Lift
75
Measuring Camshaft Journal Diameter and Journal Bore Diameter
75
Measuring Camshaft Runout
76
Removing Camshaft Gear
76
Installing Camshaft Gear and Thrust Plate
76
4 Inspecting and Repairing Piston, Connecting Rod, Crankshaft and Crankcase
77
Measuring Piston Outside Diameter
77
Measuring Piston Ring Groove
77
Measuring Piston Ring End Gap
78
Measuring Piston Pin Bore Diameter and Piston Pin Outside Diameter
78
Measuring Clearance between Connecting Rod Bushing and Piston Pin
78
Replacing Connecting Rod Bushing
79
Inspecting Connecting Rod Bend and Twist6-15
79
Inspecting Oil Clearance of Connecting Rod Bearing
80
Inspecting Oil Clearance of Main Bearing
81
Inspecting Oil Seal Contact Surface
82
Installing Oil Seal Sleeve
82
Removing Oil Seal Sleeve
82
Measuring Crankshaft Runout
83
Removing Crankshaft Gear
83
Installing Crankshaft Gear
83
Measuring Cylinder Inside Diameter
84
Reboring Cylinder
84
Measuring Crankcase Top Surface Distortion
85
Inspecting Tappet
85
Measuring Clearance between Tappet and Tappet Guide Hole
85
Inspecting Piston Cooling Nozzle
86
Reassembly of Basic Engine
87
1 Reassembling Piston, Connecting Rod, Crankshaft and Crankcase
88
Installing Tappet
88
Installing Main Bearing
88
Installing Crankshaft
88
Installing Main Bearing Cap
89
Installing Main Bearing Cap Bolt
89
Measuring Crankshaft End Play
90
Reassembling Piston and Connecting Rod
90
Installing Piston Ring
91
Preparation for Installing Pistons
91
Installing Connecting Rod Bolt and Connecting Rod Bearing
92
Installing Pistons
92
Installing Connecting Rod Cap
93
Uprearing Crankcase
93
Inspecting Crankshaft for Rotation
93
2 Reassembling Timing Gear, Camshaft and Oil Pan
94
Installing Front Plate
94
Installing Camshaft
94
Installing Oil Pump
94
Installing Oil Pan
95
Inverting Crankcase
95
Installing Front Idler Gear
96
Inspecting and Adjusting Timing Gear after Installation
96
Installing Oil Seal
96
Installing Timing Gear Case
97
Installing Crankshaft Pulley
97
3 Reassembling Flywheel
98
Installing Rear Plate
98
Installing Oil Seal Case
98
Installing Flywheel
98
4 Reassembling Cylinder Head and Valve Mechanism
99
Installing Valve Stem Seal
99
Installing Valve and Valve Spring
99
Installing Cylinder Head Gasket
99
Installing Cylinder Head Assembly
100
Tightening Cylinder Head Bolts
100
Reassembling Rocker Shaft Assembly
100
Inserting Push Rod
100
Installing Rocker Shaft Assembly
101
Adjusting Valve Clearance
101
Fuel System
103
1 Removing Fuel System
104
Removing Fuel Injection Pump
105
2 Disassembling, Inspecting and Reassembling Fuel System
106
Disassembling and Inspecting Fuel Injection Nozzle
106
Inspecting and Adjusting Fuel Injection Valve Opening Pressure
107
Inspecting Fuel Spray Pattern of Fuel Injection Nozzle
108
Cleaning and Replacing Faulty Nozzle
108
Reassembling Fuel Injection Nozzle
109
3 Installing Fuel System
110
Lubrication System
111
1 Removing Lubrication System
112
Removing and Inspecting Oil Cooler and Relief Valve
112
Removing and Inspecting Oil Pan, Oil Pump, Oil Pressure Switch
113
Removing and Inspecting Oil Pipe and Oil Separator
114
2 Disassembling, Inspecting and Reassembling Lubrication System
115
Disassembling and Inspecting Oil Pump
115
Measuring Clearance between Outer Rotor and Inner Rotor
115
Measuring End Play of Rotor and Pump Case
116
Measuring Clearance between Outor Rotor and Pump Case
116
Reassembling Oil Pump
116
Inspecting Relief Valve
116
3 Installing Lubrication System
117
Installing Oil Pan, Oil Pump and Oil Pressure Switch
117
Installing Oil Cooler and Relief Valve
118
Installing Oil Pipe and Oil Separator
119
Cooling System
121
1 Removing Cooling System
122
2 Disassembling, Inspecting and Reassembling Cooling System
123
Disassembling, Inspecting and Reassembling Water Pump
123
Inspecting Water Pump for Smooth Rotation10-3
123
Disassembling, Inspecting and Reassembling Thermostat
124
Inspecting Thermostat
124
3 Installing Cooling System
125
Removing Inlet and Exhaust Sysytem
128
Inspecting Inlet and Exhaust System
129
Installing Inlet and Exhaust System
130
Electrical System
131
1 Removing Electrical System
132
Inspecting Alternator Operation
132
Handling Precaution
132
Inspecting Regulated Voltage
133
Inspecting Output
133
Removing Alternator
134
Removing Glow Plug
135
2 Disassembling, Inspecting and Reassembling Electrical System
136
Inspecting Magnetic Switch
136
No Load Test
137
Disassembling and Inspecting Starter
138
Inspecting and Repairing Starter
139
Inspecting Brushes for Wear
139
Measuring Brush Spring Load
139
Inspecting Armature Coil
139
Measuring Commutator Radial Runout
140
Measuring Commutator Outside Diameter12-10
140
Measuring Undercut Depth
140
Inspecting Overrunning Clutch
141
Inspecting Continuity of Magnetic Switch (between M Terminal and Case)
141
Inspecting Insulation of Magnetic Switch (between M Terminal and B Terminal)
141
Inspecting Continuity of Yoke Assembly
141
Inspecting Insulation between Yoke Body and Brush
141
Reassembling Starter
142
Applying Grease
142
Inspecting and Adjusting after Reassembling
143
Inspecting Pinion Clearance
143
No Load Test
143
Disassembling, Inspecting and Reassembling Alternator
144
Separating Front Bracket from Stator
145
Removing Pulley
145
Removing Stator
145
Inspecting Rectifier
146
Inspecting Rotor
146
Inspecting Stator
147
Inspecting Brushes for Wear
147
Replacing Brushes
148
Installing Electrical System
150
Adjustment and Operation
151
1 Adjusting Engine
152
Inspecting and Adjusting Valve Clearance13-2
152
Inspecting Valve Clearance
152
Adjusting Valve Clearances
152
Adjusting Fuel Injection Timing
153
Inspecting and Adjusting Fuel Injection Timing
153
Inspecting Fuel Injection Timing
153
Bleeding Fuel Injection Pump
154
Inspecting V-Belt
154
Inspecting and Adjusting Low Idle Speed and High Idle Speed
155
Starting Engine
155
Setting Low Idle Speed (Setting Minimum No-Load Speed)
156
Setting Rack (Setting Maximum Output)
156
Setting Governor (Setting Maximum Speed)13-7
157
Adjusting Speed Variation Rate (Changing Governor Notch Setting)
158
Sealing
158
2 Break-In Operation
159
Starting up
159
Inspecting Engine Condition after Starting up
159
Break-In Operation Time
159
Inspection and Adjustment after Break-In Operation
159
3 Performance Test (JIS Standard)
160
Engine Equipment Condition
160
Test Items and Purposes
160
Operation Load Test
160
Continuous Load Test
160
Low Idle Test
160
Other Inspections
160
Engine Output Adjustment
160
Standard Atmospheric Conditions
160
Calculation of Corrected Power
161
4
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Mitsubishi S3Q2 Specifications
General
Brand
Mitsubishi
Model
S3Q2
Category
Engine
Language
English
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