This Mitsubishi S3L2 Service Manual (OEM #99619-12140) runs 219 pages with one purpose: stripping your S3L, S3L2, S4L, or S4L2 diesel down to bare metal and rebuilding it to factory spec. Step-by-step procedures walk every system, from fuel injection pumps and governor teardown to cooling, lubrication, and a full electrical section for the starter, alternator, stop solenoid, and glow plugs. Exploded views back a service standards table that lists tightening torques for major bolts, union nuts, and taper bolts, plus clearance specs and test values for each wear point. Set both inlet and exhaust valve clearance to 0.25 mm, then torque the cylinder head bolts to 83.4 to 93.2 N·m. Chasing a worn bearing or a low-compression cylinder? The factory answer is right there, first try. Every page is bookmarked and keyword-searchable, so you can open it on any device and jump straight to the spec you need.
What's Inside This Mitsubishi S3L, S3L2, S4L, S4L2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Cautions | 6-13 | Risk of Fire and Explosion, Risk of Entanglement Into the Machine, Risk of Burn, Exhaust Gas Is Poisonous, Hearing Difficulty, Beware of Falling Engine |
| General | 14-23 | Overview (Outline Drawing, Fuel System Schematic, Oil System Schematic, Cooling System Schematic, Inlet / Exhaust System Schematic, Engine Serial Number, Engine Model and Application Codes) |
| Service Standards | 24-33 | Service Standards Table, Tightening Torques Table (Major Bolts and Nuts, Standard Bolts and Nuts, Standard Eyebolts, Standard Union Nuts, Taper Bolts), Sealants List |
| Tools List | 34-37 | General Tools, Special Tools |
| Overhaul Timing | 38-41 | Identifying the Timing for Overhaul, Measuring the Compression Pressure, Compression Pressure Standard Value and Limit, Importance of Regular Compression Checks |
| Removal Preparations | 42-43 | Preparations, Removing the Electric Wiring, Draining the Coolant, Draining the Engine Oil, Coolant Drain Cock, Drain Plug on the Oil Pan |
| Engine Main Parts - Disassembly | 44-61 | Cylinder Head |
| Engine Main Parts - Inspection and Correction | 62-77 | Cylinder Head |
| Engine Main Parts - Reassembly | 78-91 | Cylinder Block, Crankshaft, Pistons |
| Fuel System - Removal | 92-99 | Fuel Injection Pipes, Fuel Leak-Off Pipe, Fuel Injection Nozzles, Governor (Removing Governor: Assembly, Weights), Fuel Injection Pumps (Removing the Fuel Injection Pumps) |
| Fuel System - Disassembly, Inspection and Reassembly | 100-115 | Fuel Injection Nozzles (Disassembling the Fuel Injection Nozzles, Inspecting the Fuel Injection Nozzle, Reassembling the Fuel Injection Nozzle) |
| Fuel System - Installation | 116-123 | Fuel Injection Pumps (Installing the Fuel Injection Pumps), Governor (Installing: Governor Weights, Sliding Sleeve, Governor Assembly), Fuel Injection Pipes, Fuel Leak-Off Pipe |
| Lubrication System - Removal | 124-127 | Oil Filter, Relief Valve and Oil Pressure Switch, Oil Pan, Oil Strainer |
| Lubrication System - Disassembly, Inspection and Reassembly | 128-131 | Oil Pump (Inspecting the Oil Pump), Relief Valve (Inspecting the Relief Valve), Oil Pressure Switch (Inspecting the Oil Pressure Switch) |
| Lubrication System - Installation | 132-135 | Oil Filter, Relief Valve and Oil Pressure Switch, Oil Pan and Oil Strainer |
| Cooling System - Removal | 136-139 | Cooling Fan, Fan Pulley and V-Belt (Removing the Cooling Fan), Thermostat and Thermoswitch (Removing the Thermostat Case), Water Pump (Removing the Water Pump) |
| Cooling System - Disassembly, Inspection and Reassembly | 140-143 | Thermostat (Disassembling the Thermostat, Inspecting the Thermostat), Thermoswitch (Inspecting the Thermoswitch), Water Pump (Inspecting the Water Pump) |
| Cooling System - Installation | 144-147 | Water Pump (Installing the Water Pump), Thermostat and Thermoswitch (Installing: Thermostat Case), Cooling Fan, Fan Pulley and V-Belt (Installing the Cooling Fan) |
| Inlet and Exhaust Systems - Removal | 148-153 | Inlet Cover, Removing the Inlet Cover, Exhaust Manifold, Removing the Exhaust Manifold, Removal of the Inlet Cover and Air Pipe, Removal of the Exhaust Manifold and Gasket |
| Inlet and Exhaust Systems - Disassembly, Inspection and Reassembly | 154-155 | Inlet Cover and Exhaust Manifold, Inspecting the Inlet Cover and Exhaust Manifold, Measuring the Exhaust Manifold Mounting Face Distortion |
| Inlet and Exhaust Systems - Installation | 156-159 | Exhaust Manifold, Installing the Exhaust Manifold, Inlet Cover, Installing the Inlet Cover, Installation of the Exhaust Manifold and Gasket |
| Electrical System - Removal | 160-165 | Starter, Alternator, Stop Solenoid, Glow Plug |
| Electrical System - Disassembly, Inspection and Reassembly | 166-183 | Starter (Removing the Starter, Inspecting and Correcting the Starter, Reassembling the Starter) |
| Electrical System - Installation | 184-189 | Glow Plug, Stop Solenoid, Alternator, Starter |
| Engine - Inspection / Adjustment, Running-In Trial and Performance Test | 190-203 | Adjustment of Engine (Preparations for Valve Clearance Inspection and Adjustment, Inspecting the Valve Clearance, Valve Clearance, Inspecting and Adjusting the Fuel Injection Timing, Alternative Adjustment Method, Replacing the Fuel Filter, Bleeding the Fuel Filter of Air, Low and High Idle Speeds, Inspecting the Fuel Injection Nozzle, Inspecting the V-Belt Tension) |
| Miscellaneous | 204-207 | Disassembly and Reassembly of General Parts, Oil Seals, O-Rings, Bearings, Lock Plates, Split Pins, Spring Pins, Oil Seal Installer |
| Engine Inspection Sheet | 208-219 | Cylinder Bore, Valve Stem-To-Guide Clearance and Valve Stem Diameter, Valve Seat Angle and Width, Cylinder Head Bottom Face Distortion, Connecting Rod Bearings Oil Clearance |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head bolt torque | 83.4 to 93.2 N·m (8.5 to 9.5 kgf·m) [61.5 to 68.7 lbf·ft] | p. 29 |
| Nozzle retaining nut torque | 34.3 to 39.2 N·m (3.5 to 4.0 kgf·m) [25.3 to 28.9 lbf·ft] | p. 29 |
| Inlet valve clearance | 0.25 (0.01) mm (in.) | p. 192 |
| Exhaust valve clearance | 0.25 (0.01) mm (in.) | p. 192 |
| Cylinder head gasket replacement | Replace with new parts | p. 23 |
| Cylinder head bottom face distortion (Standard value) | 0.05 (0.002) or less mm (in.) | p. 25 |
| Cylinder head bottom face distortion (Limit) | 0.10 (0.004) mm (in.) | p. 25 |
| Thermostat opening temperature | 82±1.5℃ (179.6±2.7°F) | p. 25 |
| Thermostat 8 mm (0.32 in.) valve lift temperature | 95℃ (203°F) | p. 25 |
| Injection nozzle spray angle | 15° | p. 25 |
| Injection nozzle opening pressure | 14.22 to 15.00 MPa (145 to 153 kgf/cm²) [2062 to 2176 psi] | p. 25 |
| Injection pump plunger diameter | φ5.5 (0.21) mm (in.) | p. 25 |
Mitsubishi S3L, S3L2, S4L, S4L2 Common Problems This Manual Covers
Mitsubishi S3L/S4L engine temperature climbs rapidly, coolant disappears, white smoke from exhaust p. 140
Check coolant level, then pull and test the thermostat per page 140; it should start opening at 82±1.5°C (179.6±2.7°F). If stuck closed, replace it. Inspect the water pump at the same time; replace the entire assembly if faulty (page 142). Torque the thermostat cover bolts to 16 to 20 N·m (11.8 to 14.8 lbf·ft).
Manual Section: Cooling System - Disassembly, Inspection and ReassemblyEngine cranks but won't fire after fuel filter replacement or sitting idle for weeks p. 196
Bleed the fuel system before cranking: crack the air bleeder plug per page 196, crank until fuel flows bubble-free, then torque the plug back to 9.81 to 13.7 N·m (7.2 to 10.1 lbf·ft). If still no-start, bench-test the injection nozzles on page 100; opening pressure should hold 14.22 to 15.00 MPa (2062 to 2176 psi).
Manual Section: Engine - Inspection / Adjustment, Running-in Trial and Performance TestLow power, high oil consumption, excessive blowby smoke at the crankcase breather p. 38
Measure compression pressure at 290 min⁻¹ cranking speed; standard value is 2.9 MPa (421 psi), with a limit of 2.6 MPa (377 psi) as listed on page 25. Readings below that on any cylinder point to worn rings, valve seating faults, or a damaged head gasket. Pull the head and inspect bores, rings, and valves per the procedures starting on page 62.
Manual Section: Overhaul TimingBlue smoke on acceleration and at idle, oil level drops between service intervals p. 62
Confirm valve clearance; both inlet and exhaust should read 0.25 mm (0.01 in.) cold per the adjustment procedure on page 192. If clearance is correct, the oil is likely passing worn piston rings or valve seals. Inspect cylinder bores, pistons, and rings per the overhaul procedures on page 62; record findings in the Engine Inspection Sheet on page 208.
Manual Section: Engine Main Parts - Inspection and CorrectionBlack smoke under load, rough combustion, engine runs lumpy at rated speed p. 100
Verify fuel injection timing is set to 17° BTDC using the adjustment procedure on page 190. Next, remove and bench-test each injection nozzle on page 100; opening pressure must be 14.22 to 15.00 MPa (2062 to 2176 psi) and the spray pattern must be uniform with no drip. Replace any nozzle that fails.
Manual Section: Fuel System - Disassembly, Inspection and ReassemblyFrequently Asked Questions
What are the torque specs for Mitsubishi S3L/S3L2/S4L/S4L2 head bolts, main bearings, and injectors?
For Mitsubishi S3L/S3L2/S4L/S4L2 engines, the cylinder head bolts should be tightened to 83.4 to 93.2 N·m (8.5 to 9.5 kgf·m) [61.5 to 68.7 lbf·ft]. Main bearing cap bolts require a torque of 49.0 to 53.9 N·m (5.0 to 5.5 kgf·m) [36.2 to 39.8 lbf·ft]. Fuel injection nozzles (retaining nut IDI) should be tightened to 34.3 to 39.2 N·m (3.5 to 4.0 kgf·m) [25.3 to 28.9 lbf·ft].
How do I bleed fuel on a Mitsubishi S3L/S3L2/S4L/S4L2 after filter or injector service?
To bleed fuel after filter service on a push-button type, open the cock lever and press the push button several times until fuel comes out with no air bubbles. For a cartridge type, turn the key ON (if equipped with a fuel pump), then loosen air bleeder screw (1) until fuel runs bubble-free, tighten it, and repeat for screw (2). Air trapped in the fuel injection pipe and nozzle bleeds automatically once you crank the engine.
How do I adjust valve clearance on a Mitsubishi S3L/S3L2/S4L/S4L2?
Loosen the rocker arm nut first, then use a thickness gauge to set valve clearance to the standard 0.25 mm (0.01 in.) for both inlet and exhaust, screwing the adjusting screw in or out. Hold the adjusting screw steady so it cannot turn while you tighten the nut. Do this with the engine cold.
What are the replacement specifications for cylinder head gasket?
Replace the cylinder head gasket with a new part during reassembly. Before fitting it, make sure the cylinder block top face and piston top faces are clean, then insert two guide studs (M10×1.25) into the bolt holes. Do not use liquid packing or any similar sealant.
How quickly can I access this manual after buying?
A 219-page Service Manual in searchable PDF format, available the moment you complete checkout. View it on a computer, tablet, or phone. There is no shipping wait.
Are there any print restrictions on this manual?
The PDF is DRM-free, so print whatever sections you need to take out to the shop. Standard letter or A4 paper works fine.
Document Quality
This document is a scanned PDF with an accurate OCR layer, so you can search and copy all text. The text is crisp and consistently easy to read throughout the manual. Diagrams and illustrations are raster images, but they are clear with all labels readable. Pages are generally clean, free from significant scan artifacts, stains, or skewed content. There are a few blank pages present in the document.
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