Buy and Download COMPLETE Service Repair Manual for MITSUBISHI SL-SERIES S3L, S3L2, S4L, S4L2 DIESEL ENGINES. This manual very useful in the treatment and repair. ENGINES COVERED: Engine S3L/S3L2 Engine S3L-T/S3L2-T Engine S4L/S4L2 Engine S4L-T/S4L2-T Displacement S3L 1.125 liters (68.7 cu in.) S3L2 1.318 liters (80.4 cu in.) S4L 1.500 liters (91.5 cu in.) S4L2 1.758 liters (107.3 cu in.) TABLE OF CONTENTS: ========= GENERAL INFORMATION 1 MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION 1.1 Model identification location 1.2 Serial Number Location 2 COMPONENT LOCATION 2.1 S3L/S3L2 2.2 Engine S3L-T/S3L2-T 2.3 S4L/S4L2 2.4 Engine S4L-T/S4L2-T 3 SPECIFICATIONS OVERHAUL INSTRUCTIONS 4 DETERMINING WHEN TO OVERHAUL THE ENGINE 5 COMPRESSION PRESSURE MEASUREMENT 5.1 Inspection 5.2 Measurement 6 TROUBLESHOOTING 6.1 General 6.2 Engine troubleshooting 6.3 Starting system troubleshooting 7 BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 7.1 Disassembly 7.2 Assembly DISASSEMBLY 8 PREPARATION FOR DISASSEMBLY 8.1 Engine oil draining 8.2 Coolant draining 1 9 ELECTRICAL SYSTEM 9.1 Starter 9.2 Alternator 10 Cooling System 10.1 Cooling fan removal 10.2 Thermostat case removal 10.3 Water pump assembly removal 11 Fuel System 11.1 Fuel injection pipe removal 11.2 Fuel injection nozzle removal 11.3 Governor assembly removal 11.4 Governor weight removal 11.5 Fuel injection pump removal 12 Lubrication System 12.1 Oil filter removal 12.2 Pressure relief valve removal 12.3 Oil pressure switch removal 13 AIR INLET SYSTEM AND EXHAUST SYSTEM 13.1 Exhaust manifold removal 13.2 Air inlet cover removal 14 CYLINDER HEAD AND VALVE MECHANISM 14.1 Rocker shaft assembly removal 14.2 Rocker shaft disassembly 14.3 Cylinder head bolt removal 14.4 Cylinder head assembly removal 14.5 Valve and valve spring removal 14.6 Valve stem seal removal 15 Timing Gears and Flywheel 15.1 Flywheel removal 15.2 Rear plate removal 15.3 Oil seal case removal 15.4 Tappet removal 15.5 Speedometer driven gear removal 15.6 Crankshaft pulley removal 15.7 Timing gear case removal 15.8 Timing gear backlash measurement 15.9 Idler gear removal 15.10 Camshaft removal 15.11 Fuel injection pump camshaft removal 15.12 Gear removal (when required) 15.13 Oil pump removal 15.14 Front plate removal 16 Cylinder Block, Crankshaft, Pistons and Oil Pan 16.1 Oil pan removal 16.2 Oil screen removal 16.3 Thrust clearance measurement for connecting rod big end 16.4 Connecting rod cap removal 16.5 Piston removal 16.6 End play measurement for crankshaft 16.7 Main bearing cap removal 16.8 Crankshaft removal 16.9 Piston separation from connecting rod INSPECTION 17 CYLINDER HEAD AND VALVE MECHANISM 17.1 Cylinder head 17.2 Rocker arms and rocker shaft 17.3 Valve springs 17.4 Valve push rods 17.5 Valves, valve guides and valve seats 17.6 Combustion jet replacement 18 TIMING GEARS AND FLYWHEEL 18.1 Camshaft 18.2 Fuel injection pump camshaft 18.3 Tappets 18.4 Idler gear 18.5 Flywheel and ring gear 19 CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN 19.1 Pistons, Piston Rings and Piston Pins 19.2 Connecting rods 19.3 Crankshaft 19.4 Cylinder block ASSEMBLY 20 Cylinder Block, Crankshaft, Pistons and Oil pan 20.1 Main bearing installation 20.2 Crankshaft installation 20.3 Main bearing cap installation 20.4 Side seal installation 20.5 Piston assembling to connecting rod 20.6 Piston ring installation 20.7 Piston and connecting rod installation 20.8 Connecting rod cap installation 20.9 Oil screen installation 20.10 Oil pan installation 21 Timing Gears and Flywheel 21.1 Front plate installation 21.2 Oil pump installation 21.3 Engine turning 21.4 Engine turning 21.5 Camshaft installation 21.6 Idler gear installation 21.7 Timing gear case installation 21.8 Crankshaft pulley nut tightening 21.9 P.T.O. gear installation 21.10 Speedometer driven gear installation 21.11 Tappet installation 21.12 Oil seal case installation 21.13 Rear plate installation 21.14 Flywheel installation 22 CYLINDER HEAD AND VALVE MECHANISM 22.1 Cylinder head bottom face cleaning 22.2 Valve stem seal installation 22.3 Valve spring installation 22.4 Installing valve block 22.5 Cylinder head gasket installation 22.6 Cylinder head installation 22.7 Cylinder head bolt tightening 22.8 Valve push rod installation 22.9 Rocker shaft assembling 22.10 Rocker shaft assembly installation 22.11 Valve clearance adjustment 22.12 Rocker cover installation 23 Air Inlet System and Exhaust System 23.1 Air inlet cover installation 23.2 Exhaust manifold installation 24 Fuel System 24.1 Fuel injection nozzle installation 24.2 Fuel injection pump installation 24.3 Flyweight assembly installation 24.4 Sliding sleeve installation 24.5 Governor assembly installation 24.6 Fuel injection line installation 25 Lubrication system 25.1 Pressure relief valve installation 25.2 Oil filter installation 25.3 Oil pressure switch installation 26 Cooling system 26.1 Water pump installation 26.2 Thermostat installation 26.3 Cooling fan installation 26.4 Thermoswitch and thermounit combination installation 27 Electrical System 27.1 Glow plug installation 27.2 Alternator installation ELECTRICAL SYSTEM 28 GENERAL 28.1 Specifications (standard) 28.2 Wiring diagrams STARTER 29.1 Disassembly 29.2 Inspection 29.3 Assembly 29.4 Inspection and Testing after Assembly 30 ALTERNATOR 30.1 Disassembly 30.2 Inspection 30.3 Assembly 31 KEY SHUTOFF SYSTEM (ETS solenoid type) 31.1 General 31.2 Cord color (standard) 31.3 Shutoff solenoid installation 31.4 Inspection after assembly 32 KEY SHUTOFF SYSTEM (ETR solenoid type) 32.1 General 32.2 Cord color (standard) 32.3 Shutoff solenoid installation 33 AUTOMATIC GLOW SYSTEM 33.1 General 33.2 Glow timer specification (standard) 33.3 Glow plug relay specifications (standard) 33.4 Glow plug inspection COOLING SYSTEM 34 GENERAL 34.1 Schematic 34.2 Specifications (standard) 35 INSPECTION 35.1 Water pump 35.2 Thermostat (standard) 35.3 Thermoswitch (standard) 35.4 Thermounit (standard) LUBRICATION SYSTEM 36 GENERAL 36.1 Schematic 36.2 Specifications 37 INSPECTION 37.1 Oil pump 37.2 Oil pressure switch 37.3 Pressure relief valve FUEL SYSTEM 38 GENERAL 38.1 Schematic 38.2 Specifications (standard) 39 FUEL INJECTION NOZZLE 39.1 Inspection 39.2 Disassembly and assembly 40 FUEL INJECTION PUMP 40.1 Test on engine 40.2 Disassembly 40.3 Inspection 40.4 Assembly 41 GOVERNOR 41.1 Disassembly and inspection 41.2 Assembly 41.3 Torque spring set installation 42 FUEL PUMP 42.1 Inspection 43 FUEL FILTER AIR INLET SYSTEM AND EXHAUST SYSTEM 44 GENERAL 44.1 Schematic 45 INSPECTION 45.1 Inspection procedure MAINTENANCE 46 LUBRICATION AND MAINTENANCE CHART 47 ENGINE OIL AND OIL FILTER 47.1 Engine oil specifications 47.2 Oil level check 47.3 Oil and oil filter change 47.4 Oil filter change 48 VALVE CLEARANCE 49 FUEL INJECTION TIMING 49.1 Preparation 49.2 Adjustment 50 FUEL FILTER 50.1 Fuel filter with [AIR] valve 50.2 Cartridge (air vent screw) type fuel filter 51 FUEL SYSTEM PRIMING 51.1 Engine with fuel filter with [AIR] valve 51.2 Engine with cartridge (air vent screw) type fuel filter 52 IDLE RPM SETTING 53 FUEL INJECTION NOZZLES 53.1 Injection pressure (valve opening pressure) test 53.2 Orifice restriction test 53.3 Nozzle tip washing and replacement 53.4 Installation 54 FAN BELT SERVICE DATA 55 SPECIFICATIONS 55.1 Basic engine components 55.2 Lubrication system 55.3 Fuel system 55.4 Air inlet system and exhaust system 55.5 Cooling system (standard) 55.6 Electrical system 56 TIGHTENING TORQUES 56.1 Major bolts and nuts 56.2 Torques for bolts and nuts with standard threads 56.3 Torques for plugs with taperlock threads 57 SEALANTS 58 SPECIAL TOOLS ========= Model Specification: MITSUBISHI SL-SERIES S3L, S3L2, S4L, S4L2 DIESEL ENGINES LANGUAGE: English FORMAT: PDF Requirements: Adobe PDF Reader & WinZip. ZOOM IN/OUT: YES Downloadable: YES COMPATIBLE: All Versions of Windows & Mac ========= WITH THIS MANUAL, YOU MAY MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR OWN. WITH STEP BY STEP INSTRUCTION & HIGHLY DETAILED EXPLODED PICTURES & DIAGRAMS TO SHOW YOU HOW TO COMPLETE THE REQUIRED JOB CORRECTLY & EFFICIENTLY. ALL REPAIR PROCEDURES ARE COVERED. IT'S THE SAME TYPE OF MANUAL THAT YOUR LOCAL DEALER/MECHANIC WOULD USE. ALL MANUALS ARE WINDOW'S VISTA32 AND 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC! INSTANT DOWNLOAD UPON RECEIPT OF YOUR PAYMENT.. FIND IT...PRINT IT...USE IT...then Trash it. Tons of pictures and diagrams at your fingertips!! All pages are printable, so run off what you need & take it with you into the garage or workshop. Save Money $$ By doing your own repairs! These manuals make it easy for any skill level WITH THESE VERY EASY TO FOLLOW, STEP-BY-STEP INSTRUCTIONS! 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