Ring gaps, gear backlash and nozzle settings that no parts catalogue prints are settled in this 147-page Mitsubishi S4E service manual PDF, which covers the diesel engine across five designations including the 4DQ5 and S4E2. Separate chapters take the cylinder head, sleeves and pistons, timing gears, crankcase, lubrication, cooling and fuel injection system through disassembly, inspection and repair, and the electrical section carries wiring diagrams for your starter, alternator and glow plug circuits. Service data fills the back of the book with tightening torques, sealant application points and a troubleshooting chart that walks symptoms back to causes. Set piston ring gap at 0.30 to 0.50 mm, and on the 4DQ5 hold timing gear backlash between 0.12 and 0.24 mm. One tight ring gap can wreck a fresh overhaul. Bookmarked chapters and a searchable text layer let you check every clearance on the bench, so the rings and bearings you order fit the first time.
What's Inside This Mitsubishi 4DQ5, S4E, S4E2 Manual
| System | Pages | Key Topics |
|---|
| General Information | 3-25 | Exterior Views, Nomenclature and Sectional Views, Major Data and Specifications, Performance Curves, Engine Serial Number Location, Tips on Disassembly and Reassembly |
| Cylinder Head and Valve Mechanism | 26-38 | Inspection and Repair, Installation |
| Cylinder Sleeves, Pistons and Connecting Rods | 39-49 | Inspection and Repair, Reassembly |
| Flywheel and Timing Gears | 50-57 | Removal, Inspection and Repair |
| Crankcase and Major Running Parts | 58-71 | Disassembly, Inspection and Repair |
| Lubrication System | 72-77 | Oil Pump, Oil Filter, Relief Valve, Oil Strainer, Removal, Inspection and Repair |
| Cooling System | 78-83 | Removal, Inspection and Repair |
| Fuel System | 84-102 | Fuel Filter, Fuel Injection Pump, Fuel Injection Nozzles |
| Electrical System | 103-114 | Starter, Alternator, Glow Plugs |
| Overhaul Instructions | 115-119 | When to Overhaul the Engine, Bench Test |
| Special Service Tools | 120-125 | Valve Guide Installer, Valve Guide Remover, Intake Valve Insert Caulking Tool, Exhaust Valve Insert Caulking Tool, Adaptor, Piston Guide, Idler Shaft Puller, Cranking Handle |
| Service Data | 126-147 | Tightening Torque, Sealant Application Data, Troubleshooting Chart |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Backlash | 0.12~0.24 mm (0.0047~0.0094 in) | p. 55 |
| Fuel filter element replacement interval | every 6 months or 1200 operating hours | p. 88 |
| Injection nozzle spray hole diameter | 1 mm (0.04 in.) | p. 17 |
| Fuel injection nozzle tightening torque | 5 ± 0.5 kg-m (36.2 ± 3.6 lb-ft) | p. 98 |
| Water pump impeller, vane-to-casing clearance | 0.5 ~ 1 mm (0.020 ~ 0.039 in) | p. 43 |
| Thermostat valve start opening temperature | 76.5 ± 2°C (169.7 ± 3.6°F) | p. 79 |
| Thermostat valve full open temperature | 90°C (194°F) | p. 79 |
| No. of oil rings | 1 (w/spring expander) | p. 12 |
| Piston ring gap | 0.30 ~ 0.50 mm (0.0118 ~ 0.0197 in.) | p. 44 |
| Cylinder head bolts | 12.0 ± 0.5 kg-m (86.8 ± 3.6 lb-ft) | p. 137 |
| Cylinder Head Bolt Tightening Torque | 12.0 ± 0.5 kg-m (86.8 ± 3.6 lb-ft) | p. 137 |
| Main Bearing Cap Bolts Tightening Torque (4DQ5) | 8.5 ± 0.5 kg-m (61.5 ± 3.6 lb-ft) | p. 137 |
