Wear limits, fits and tightening values for the Mitsubishi S4S and S6S diesel engines come from one source only: the 241-page factory service manual, OEM part 99616-10180, which spans four variants including the turbocharged S4S-DT and S6S-DT. As a Mitsubishi S4S, S6S service manual PDF, it puts the maintenance standards, tightening torque and sealant tables up front, then takes the cylinder head, timing gears, pistons, rods and crankshaft through disassembly, inspection and reassembly. Fuel injection pump and nozzle work follows, then the turbocharger, electrical tests for the starter, alternator and glow plugs, and the break-in and performance tests that confirm your rebuild. Check swirl-chamber compression against 3.23 MPa (469 psi) and set valve lash at 0.25 mm cold. Bookmarked and text-searchable, the PDF goes wherever the engine does, keeping your clearances in reach before it goes back together.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| Safety Cautions | 6-13 | Danger of Fire and Explosion, Danger of Entanglement, Danger of Burns |
| General | 14-47 | Outline, Specifications, Tips on Disassembly and Reassembly |
| Maintenance Standards | 48-59 | Maintenance Standards Table, Tightening Torque Table, Sealants and Lubricants Table |
| Special Tools | 60-63 | Special Tools List |
| Overhaul Instructions | 64-67 | Determination of Overhaul Timing, Testing Compression Pressure |
| Preparation for Disassembly | 68-69 | Preparation |
| Main Engine Parts | 70-121 | Cylinder Head and Valve Mechanism, Flywheel, Damper, Timing Gears and Camshaft, Pistons, Connecting Rods, Crankshaft and Crankcase |
| Fuel System | 122-143 | Fuel Filter and Fuel Pipes, Fuel Injection Pipes and Nozzles, Fuel Injection Pump |
| Lubrication System | 144-159 | Oil Filter and Relief Valve, Oil Cooler, Oil Pump, Oil Pan and Oil Strainer |
| Cooling System | 160-171 | Cooling Fan, Fan Pulley and V-Belt, Thermostat, Water Pump |
| Inlet and Exhaust Systems | 172-185 | Turbocharger, Inlet Manifold, Exhaust Manifold |
| Electrical System | 186-211 | Starter, Alternator, Glow Plug |
| Inspection, Adjustment, Break-In Operation and Performance Tests | 212-225 | Adjustment of Engine, Break-In Operation, Performance Tests |
| Others | 226-229 | Disassembly and Reassembly of General Parts |
| Supplement | 230-241 | Engine Inspection Record Sheets |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| All Models |
| Water pump discharge capacity | 160 [42.3] £ [U.S.gal] / min at 0.75 MPa (7.5 kgf/cm²) [107 psi] discharge pressure | p. 36 |
| Thermostat case tightening torque | 17.0 to 20.0 N·m | p. 56 |
| Valve clearance (Cold) | 0.25 mm [0.009 in.] | p. 49 |
| Compression Pressure (Swirl chamber) | 3.23 MPa (33 kgf/cm²) [469 psi] | p. 49 |
| Compression Pressure (Direct injection) | 2.94 MPa (30 kgf/cm²) [426 psi] | p. 49 |
| V-belt deflection | 10 to 12 mm [0.39 to 0.47 in.] | p. 49 |
| Cylinder head bolt tightening torque | 113 to 123 N·m (11.5 to 12.5 kgf·m) [83.2 to 90.4 lbf·ft] | p. 55 |
| S4S |
| Valve clearance (when engine is cold) | 0.25 mm [0.0098 in.] | p. 121 |
| Engine Oil Capacity (S4S) | 10 L [2.64 U.S.gal] | p. 36 |
| Coolant capacity (S4S) | 5.5 L [1.45 U.S.gal] | p. 69 |
| S6S |
| Engine Oil Capacity (S6S) | 12.5 L [3.30 U.S.gal] | p. 39 |
| Coolant capacity (S6S) | 9 L [2.4 U.S.gal] | p. 39 |
