Intermittent engine shutdown and loss of power in a Mitsubishi forklift with a 6M60-TL engine could be caused by several factors, including:

1. Fuel System Issues
- Clogged fuel filter or fuel lines restricting fuel flow.
- Malfunctioning electronically controlled fuel system components.
- Air in the fuel system causing inconsistent fuel delivery.

2. Electrical Problems
- Faulty wiring or loose connections in the electrical system.
- Malfunctioning sensors or control modules affecting engine operation.

3. Lubrication and Cooling Issues
- Low oil pressure leading to engine protection shutdown.
- Overheating due to a malfunctioning cooling system.

4. Valve and Camshaft Problems
- Worn or damaged valve components affecting engine performance.
- Issues with the rocker and bracket assembly, camshaft, or rocker case.

Proper diagnostics should be performed, including checking fuel pressure, inspecting electrical connections, and ensuring proper lubrication and cooling system operation.

This answer is automatically generated

Summary of Contents for Mitsubishi 6M60-TL

Page 1 Service Manual 6M60-TL Diesel Engine For use with the FD80N-FD160N Service Manuals. 99709-51100...
Page 3 This Shop Manual is published for the information and INTAKE AND EXHAUST ....guidance of personnel responsible for maintenance of the Mitsubishi 6M60-TL series diesel engine, and includes EMISSION CONTROL ..... procedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is ELECTRICAL........
Page 4: Table Of Contents
GROUP 00 GENERAL HOW TO READ THIS MANUAL ............00-2 ENGINE NUMBER ................00-7 PRECAUTIONS FOR MAINTENANCE OPERATION ....... 00-8 DIAGNOSTIC CODES .............. 00-17 1. Using Multi-Use Tester 00-19 2. Use of Blinking Warning Lamp for Diagnostic Code ....00-21 3.
Page 5: General
HOW TO READ THIS MANUAL This manual consists of the following parts: • Specifications • Structure and Operation • Troubleshooting • General Inspection and Adjustment • Service procedures General Inspection and Adjustment • Procedures for inspection and adjustment of individual parts and assemblies as mounted on the machine are de- scribed including specific items to check and adjust.
Page 6 Tightening torque • Values are directly specified for out-of-standard tightening torques for bolts and nuts. • Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. • When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry. Units •...
Page 7 HOW TO READ THIS MANUAL Symbol Denotation Application Remarks Specified values shown in table Parts not tightened to standard torques See Table of Standard Tightening Torques for Tightening torque (standard torques specified where neces- parts for which no tightening torques are speci- sary for servicing) fied.
Page 8 00-5...
Page 9 HOW TO READ THIS MANUAL How to Use Diagnostic Codes <Electronically Controlled Fuel System (Gr13E)> TROUBLESHOOTING 1. Diagnostic Procedure 2. Diagnostic Precautions This section suggests areas to 3. Inspections Based On Diagnostic Codes inspect each diagnostic code. 4. Multi-use Tester Service Data 5.
Page 10: Engine
ENGINE NUMBER • Serial engine numbers are assigned to the engines in manufac- turing sequence. Every engine has its own number. These num- bers are required for registration and related inspection of the vehicle. • An engine nameplate indicates the following item. •...
Page 11: Precautions For Maintenance Operation
PRECAUTIONS FOR MAINTENANCE OPERATION • Before performing service operations, inquire into the customer’s complaints and ascertain the conditions by checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors about the vehicle. And note the necessary information. This information will help you to service the truck efficiently. •...
Page 12 • Oil seals, packings, O-rings and other rubber parts, gaskets, and split pins must be replaced with new ones after removal. Use only genuine MITSUBISHI replacement parts. • When disassembling parts, visually check them for wear, cracks, damage, deformation, deterioration, rust, corrosion, defective ro- tation, fatigue, clogging and any other possible defect.
Page 13: Electrical
PRECAUTIONS FOR MAINTENANCE OPERATION • Wear safety goggles when using a grinder or welder. Wear gloves when necessary, and watch out for sharp edges and oth- er items that might wound your hands. • Before working on the electrical system, disconnect the (–) bat- tery cable to prevent short circuits.
Page 14 • When applying a voltage to a part for inspection purposes, check that the (+) and (–) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily op- erate on the battery voltage.
Page 15 PRECAUTIONS FOR MAINTENANCE OPERATION (2.2) Inspections on male terminals • Perform the inspection by applying test probes directly to the pins. CAUTION • Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-circuiting of pins can cause damage to the control unit’s internal circuit- •...
Page 16 • Check for defective connections caused by loose terminals, by rust on terminals, or by contamination of terminals by foreign substances. (2) Checking for loose terminals • If connector terminal retainers become damaged, male and fe- male terminals may not mate with each other when the connec- tor bodies are fitted together.
Page 17 PRECAUTIONS FOR MAINTENANCE OPERATION • Never disconnect the battery cables with the engine running. Disconnection of the battery cables during engine operation would cause a surge voltage, leading to deterioration of the di- odes and regulator. • Never perform inspections using a high-voltage multimeter. The use of a high-voltage multimeter could damage the diodes and regulator.
Page 18 3. Intermittent Faults • An intermittent fault typically occurs only under certain operating conditions. Once these conditions have been identified, the cause of the intermittent fault can be ascertained easily. First, ask the customer about the vehicle operating conditions and weather conditions under which the fault occurs.
Page 19 PRECAUTIONS FOR MAINTENANCE OPERATION 4. Precautions for Arc Welding • When arc welding is performed, current from the welder flows to ground via the machine metal parts. Unless ap- propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be largely damaged.
Page 20: Using Multi-Use Tester
DIAGNOSTIC CODES NOTE: The Multi-Use tester tool will not be used to service the 6M60-TL diesel engine at this time. Please disregard the Multi-Use Tester information. The Up-Time 2.41 or later software must be used to service the 6M60-TL diesel engine.
Page 21 DIAGNOSTIC CODES • Use to extend the cable if is not long enough such as when using Multi-Use Tester outside the vehicle. 1.2 Access and Clearing of Stored Diagnostic Code (1) Difference of diagnostic code • There are two types of diagnostic codes – present code and past code. (1.1) (1.2) Present diagnostic code •...
Page 22: Use Of Blinking Warning Lamp For Diagnostic Code
2. Use of Blinking Warning Lamp for Diagnostic Code • Using the diagnostic and memory clear switches, display diagnostic codes. CAUTION • Opening the memory clear switch followed by its reconnection will erase the stored diagnostic codes from the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure de- scribed below before handling diagnostic codes.
Page 23 DIAGNOSTIC CODES 2.4 Erasing diagnostic codes • Turn the starter switch to the ON position (do not start the en- gine). • Open the memory clear switch and reconnect it; all diagnostic codes stored in electronic control unit memory will be erased. To erase diagnostic code after opening the memory clear switch, turn the starter switch to the OFF position and then reconnect the memory clear switch.
Page 24: Up-Time Service Tool Functions
TABLE OF STANDARD TIGHTENING TORQUES 3. Up-Time Service Tool Functions 3.1 Menu Monitor menu Tool menu • Input Monitor • Set-up Option Indicates the input values of the controllers. Indicates or sets the Setup Option data. • Output Monitor • Oscilloscope Indicates the output values of the controllers.
Page 25 TABLE OF STANDARD TIGHTENING TORQUES 3.2 Input Monitor and Output Monitor These screens indicate the input and output values of each controller. → 3.2.1 VCM-3 input monitor and output monitor (VCM-3 VCM-3) (InputUnit) 212339 00-22...
Page 26 OutputUnit V OutputUnit OutputUnit 212340 00-23...
Page 27 → 3.2.2 VCM-3OP input monitor and output monitor (VCM-3 VCM-3OP) 212341 00-24...
Page 28 → 3.2.3 MP input monitor (VCM-3 212342 00-25...
Page 29 → 3.2.4 ECU input monitor and output monitor (VCM-3 ECU) Accel pedal position (unfiltered) Accel pedal position (filtered) Reference injection quantity 212343 00-26...
Page 30 3.3 Fault Status This screen indicates all error codes occurring. OutputUnit Communication error InputUnit Communication error 212344 00-27...
Page 31 3.4 Fault History This screen indicates the fault data, such as the error codes and hour meter data, stored in the controller. OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error...
Page 32: Troubleshooting
4. Troubleshooting 4.1 General Information 4.1.1 Before replacing controllers Do not replace controllers casually even if replacement is required as a result of troubleshooting. Be sure to check the following items before replacing controllers. • Loose battery connectors • Abnormal wire harness connections •...
Page 33 4.1.4 How to clean harness connectors and sys- tem components (1) Open-circuits are often caused by dirty harness connectors and components. Dust, together with greasy matter, forms grime which, in time, pene- trates electrical connections, resulting in loose metal-to-metal contact or, for worse, electrical sep- aration of surfaces in contact.
Page 34: Table Of Contents
• Use specified bolts and nuts. Tighten them to the torques shown below as appropriate, unless otherwise speci- fied. • Threads and bearing surfaces shall be dry. • If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the bolt.
Page 35: Table Of Contents
Hexagon Nuts (Unit: N·m {kgf·m}) Strength Identification symbol 02155 Nominal Standard screw Coarse screw Standard screw thread Coarse screw thread diameter thread thread 2 to 3 4 to 6 – – {0.2 to 0.3} {0.4 to 0.6} 4 to 6 7 to 10 –...
Page 36 Tightening Torque for General-Purpose Flare Nut (Unit: N·m {kgf·m}) φ φ φ φ φ φ Pipe diameter 4.76 mm 6.35 mm 8 mm 10 mm 12 mm 15 mm Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10} Tightening Torque for General-Purpose Air Piping Nylon Tube (DIN Type) (Unit: N·m {kgf·m})
Page 37 GROUP 11 ENGINE SPECIFICATIONS ................11-2 STRUCTURE AND OPERATION 11-3 1. Engine Proper ..................2. Rocker and Bracket Assembly, Camshaft, Rocker Case and 11-4 Cylinder Head Gasket ................ 11-4 3. Valve Mechanism ................11-5 4. Connecting Rod ................. 11-5 5. Piston ....................11-6 6.
Page 38 SPECIFICATIONS Item Specifications Engine mode 6M60-TL Type 6-cylinder, in-line, water-cooled, 4-cycle diesel engine Combustion chamber Direct injection type Valve mechanism Overhead camshaft (OHC) system 110 {150} / 129 {175} / 145 {195} / 200 {270} / Maximum output kW {PS} /rpm...
Page 39 STRUCTURE AND OPERATION 1. Engine Proper • The 6M60-TL engine employs an overhead camshaft (OHC) system, with the valve mechanism and the timing gears arranged as shown above. 11-3...
Page 40: Valve Mechanism
STRUCTURE AND OPERATION 2. Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gas- • The camshaft is directly supported at its journals by the rocker case, and is held in place from above by the rocker and bracket assembly. •...
Page 41: Connecting Rod
4. Connecting Rod 5. Piston • The piston, the cylinder liner and the crankcase bore all must have the same size marks to ensure a good fit between them. • The pistons are made of special alumi- num alloy, and are provided with a re- cess on each end of the piston pin boss to reduce weight.
Page 42 STRUCTURE AND OPERATION 6. Timing Gears • The timing gears are provided with timing marks to help ensure correct assembly. • Timing marks are provided on the fol- lowing gears. • Camshaft gear: stamped line • Crankshaft gear: “1” • Air compressor gear: “2” •...
Page 43 (1) Non-backlash mechanism • Engine hunting during idling causes fluctuation in the speed of camshaft and No. 2 idler gears. • Without the non-backlash mechanism, the backlash changes between zero and the maximum, generating gear rattle noise. • With the non-backlash mechanism equipped on the engine, the sub-gears A and B maintain the backlash to zero even when the engine hunts, eliminat-...
Page 44 TROUBLESHOOTING Symptoms Reference Gr Possible causes Incorrect valve clearance Defective cylinder head gasket Worn valve and valve seat; carbon deposits Cylinder head and valve mechanism Weakened valve spring Defective rocker shaft and bracket Poor lubrication of rocker shaft bracket Incorrect backlash in timing gears Timing gears Poor lubrication of timing gears and idler shaft Excessive end play in camshaft...
Page 45 M E M O 11-9...
Page 46 GENERAL INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure Service standards Location Maintenance item Standard value Limit Remedy 2,940 kPa 1,960 kPa Each cylinder (at 200 rpm) Inspect {30 kgf/cm {20 kgf/cm – Compression pressure 390 kPa Cylinder-to-cylinder pres- – {4 kgf/cm Inspect sure difference or less...
Page 47 • Remove all the injectors. (See Gr13A.) • Cover the injector mounting holes with shop towels or other sim- ilar cloth. Crank the engine using the starter. Ensure that no for- eign matter is attached on the shop towels. CAUTION •...
Page 48 GENERAL INSPECTION AND ADJUSTMENT 2. Inspection and Adjustment of Valve Clearances Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy – Valve clearance (when cold) – Adjust Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks –...
Page 49 • Any attempt to insert a feeler gauge without first securing suffi- cient space, as described below, between the pad and the valve bridge will fail, as the pad will tilt as shown in the illustration, thus blocking the entry of a feeler gauge. •...
Page 50 GENERAL INSPECTION AND ADJUSTMENT • While holding the adjusting screw in this position with a socket wrench and extension, tighten the lock nut to the specified torque using CAUTION • After adjusting the adjusting screw, be sure to tighten the lock nut to the speciﬁed torque.
Page 51 M E M O 11-15...
Page 52 ROCKER COVER, ROCKER BRACKET AND CAMSHAFT 11-16...
Page 53 Disassembly sequence 1 Oil filler cap 8 Rocker case upper gasket 13 Rocker case gasket 2 Rubber 9 Packing 3 Rocker cover 10 Rocker and bracket assembly a: Cylinder head 4 Rocker cover gasket (See later pages.) b: No. 3 idler gear 5 Baffle plate 11 Camshaft 6 Cylinder recognition sensor...
Page 54 ROCKER COVER, ROCKER BRACKET AND CAMSHAFT Inspection: Camshaft end play • If the measurement exceeds the limit, replace the defective part(s). Releasing valve spring force • Before loosening the rocker and bracket assembly mounting bolts, check whether the valve springs are compressed by the rockers.
Page 55 Installation: Packing • Apply sealant onto the peripheral surface of the packing. • Immediately after the sealant application, install the packing to the rocker case. • After installing it on the rocker case, apply sealant to the top sur- face of the packing. •...
Page 56 ROCKER COVER, ROCKER BRACKET AND CAMSHAFT Rocker and Bracket Assembly Disassembly sequence 1 Front bracket 2 Adjusting screw 3 Rocker bushing 4 Intake rocker 5 Rocker shaft spring 6 Adjusting screw 7 Rocker bushing 8 Exhaust rocker 9 No. 1 center bracket 10 No.
Page 57 Inspection procedure Inspection: Radial clearance of rocker (roller) • If the measurement deviates from the standard value, replace the defective part(s). Inspection: Clearance between rocker shaft and bushing • If the measurement exceeds the limit, replace the bushing. Replace of rocker bushing [Removal] [Installation] •...
Page 58 ROCKER COVER, ROCKER BRACKET AND CAMSHAFT Camshaft Disassembly sequence 1 Camshaft gear 2 Key 3 Camshaft : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy 1, 3 Interference between camshaft gear and camshaft 0.017 to 0.062 –...
Page 59 Inspection procedure Inspection: Interference between camshaft gear and cam- shaft • If the measurement deviates from the standard value, replace the defective part(s). Inspection: Camshaft (1) Cam lift • If the measurement (difference between lobe diameter and base circle diameter) is less than the limit, replace the camshaft. (2) Bend •...
Page 60 CYLINDER HEAD AND VALVE MECHANISM 11-24...
Page 61 Disassembly sequence 1 Connecting plate 11 No. 3 idler bolt 20 Cylinder head 2 Glow plug 12 Thrust plate (See later section.) 3 Nozzle bridge 13 No. 3 idler shaft 21 Cylinder head gasket 4 Injector (See Gr13A.) 14 Snap ring 5 O-ring 15 Sub-gear a: No.
Page 62 CYLINDER HEAD AND VALVE MECHANISM Special tools (Unit: mm) Mark Tool name and shape Part No. Application Socket wrench MH063388 Installation of cylinder head Pin wrench arm MH063473 Assembly of No. 3 idler gear Idler gear push-puller Removal and installation of No. 3 idler MH061779 gear bushing φ...
Page 63 Removal procedure Removal: Cylinder head • Remove the bolts (× 4). • Progressively loosen the cylinder head bolts in the order shown in the illustration, going over them several times, before eventu- ally removing them. Removal: Cylinder head gasket CAUTION •...
Page 64 CYLINDER HEAD AND VALVE MECHANISM Installation procedure Installation: Sub-gears • Install the No. 3 idler gear on a vice. Use shop towel to protect the gear from direct contact with the vice. • Install a sub-gear, a spring and pins on one side of the No. 3 idler gear.
Page 65 • The cylinder head gasket is a part that needs to be selected for use. Choose the appropriate gasket in the following manner. • Measure the piston protrusion from each cylinder. (See Piston.) • Then, from the table below, choose the cylinder head gasket having a thickness appropriate to the average protrusion of the pistons.
Page 66 CYLINDER HEAD AND VALVE MECHANISM • Turn the holder of counterclockwise to pretension the inter- nal spring. • Set such that the rod (extension) is pressed against the the tool rocker shaft bracket by the force of the spring. • Align any line on the holder scale with any line on the socket scale.
Page 67 M E M O 11-31...
Page 68 CYLINDER HEAD AND VALVE MECHANISM Cylinder Head Disassembly sequence 1 Adjusting screw 7 Valve stem seal 14 Intake valve seat 2 Valve bridge 8 Exhaust valve 15 Stud bolt 3 Valve cotter 9 Intake valve 16 Cylinder head 4 Upper retainer 10 Valve bridge guide 5 Outer valve spring 11 Exhaust valve guide...
Page 69 Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy 2, 10 Valve bridge-to-valve bridge guide clearance 0.01 to 0.04 Replace Free length 71.7 68.1 Replace Installed load 407 ± 20.6 N 367 N Intake side (46.5 in installed Replace {42 ±...
Page 70 CYLINDER HEAD AND VALVE MECHANISM Special tools (Unit: mm) Mark Tool name and shape Part No. Application Valve lifter MH061668 Valve lifter hook MH061679 Removal and installation of valve cot- Valve lifter seat ters MH061772 φ 38 Valve stem seal installer MH062689 Installation of valve stem seals φ...
Page 71 Removal procedure Removal: Valve cotters • Using , remove the valve cotter while com- pressing the valve spring(s) evenly. Inspection procedure Inspection: Valve bridge and valve bridge guide (1) Valve bridge-to-guide clearance • If the measurement exceeds the limit, replace the defective part(s).
Page 72 CYLINDER HEAD AND VALVE MECHANISM Refacing • Limit grinding to a necessary minimum. • If the valve margin is below the limit after grinding, replace the valve. • After grinding, make sure to lap the valve and valve seat. Inspection: Valve-to-valve guide clearance •...
Page 73 • If the red lead deposited on the valve indicates a poor contact pattern, take either of the following corrective actions. Contact pattern Corrective action Minor defect Lapping Serious defect Reface or replace valve and valve seat Lapping • Lap the valve in the following sequence. •...
Page 74 CYLINDER HEAD AND VALVE MECHANISM Refacing the valve seat • Grind the valve seat using a valve seat cutter or valve seat grind- • Place a piece of sandpaper of approximately #400 between the cutter and valve seat and grind the valve seat lightly. •...
Page 75 Installation procedure Installation: Valve stem seal • Apply engine oil to the lip of the valve stem seal. • Install the valve stem seal until sits snugly on the cylinder head. CAUTION • After installing the valve stem seal, check that its spring is not deformed or damaged.
Page 76 PISTON AND CONNECTING ROD, CYLINDER LINER Disassembly sequence 1 Lower connecting rod bearing 2 Connecting rod cap 3 Upper connecting rod bearing 4 Piston and connecting rod (See later sections.) 5 Cylinder liner : Locating pin Assembly sequence Follow the disassembly sequence in re- verse.
Page 77 Special tools (Unit: mm) Mark Tool name and shape Part No. Application Piston guide clamp MH061760 Piston guide lever MH061658 Installation of piston and connecting Socket wrench MH061560 Cylinder liner extractor MH061761 Removal of cylinder liner φ117.5 Cylinder liner installer MH061771 Installation of cylinder liner φ117.5...
Page 78 PISTON AND CONNECTING ROD, CYLINDER LINER Inspection: Piston projection from crankcase top surface CAUTION • The amount of piston projection affects engine perfor- mance and must therefore be inspected without fail. • Set the piston at the top dead center. •...
Page 79 Inspection: Connecting rod bearing oil clearance • Fit the lower bearing to the connecting rod cap and the upper bearing to the connecting rod, then tighten the nut to a torque of 29 N m {3 kgf · · • Measure the inside diameter of the bearing and the outside di- ameter of the crankshaft pin.
Page 80 PISTON AND CONNECTING ROD, CYLINDER LINER [Installation] • The cylinder liner being installed must have the same size mark as that on the crankcase as well as that on the piston. Size mark Size mark Size mark on crankcase on cylinder liner on piston “1”...
Page 81 Installation: Piston and connecting rod • Check that the piston ring end gaps are in their correct positions. A: 1st compression ring gap B: 2nd compression ring gap C: Oil ring gap D: Oil ring expander spring gap “ ”: Front mark on piston •...
Page 82 PISTON AND CONNECTING ROD, CYLINDER LINER • After the piston and connecting rod have been installed, install the connecting rod cap onto the connecting rod, ensuring that the alignment marks are aligned. Tighten the bolts alternately as follows. • Tighten the bolts to a torque of 29 N m {3 kgf ·...
Page 83 M E M O 11-47...
Page 84 PISTON AND CONNECTING ROD, CYLINDER LINER Piston and Connecting Rod Disassembly sequence 1 1st compression ring 2 2nd compression ring 3 Oil ring 4 Snap ring 5 Piston pin 6 Connecting rod bushing 7 Connecting rod 8 Piston : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse.
Page 85 Special tools Mark Tool name and shape Part No. Application Removal and installation of piston Piston ring tool 30091-07100 rings Connecting rod bushing Removal and installation of connect- MH062556 puller kit ing rod bushings Removal procedure Removal: Piston ring Removal: Piston pin •...
Page 86 PISTON AND CONNECTING ROD, CYLINDER LINER Inspection: Piston ring side clearance in piston groove • Remove any carbon deposits from the ring groove in the piston. • Measure the side clearance of each ring around the piston’s en- tire periphery. •...
Page 87 Replacement of connecting rod bushing • Replace the connecting rod bushing using [Removal] • Remove the upper bearing (if fitted) from the large end of the connecting rod. • Mount the connecting rod on the base and lock it in position with the bracket and plate.
Page 88 PISTON AND CONNECTING ROD, CYLINDER LINER Inspection: Connecting rod bend and twist • Mount the connecting rod on the connecting rod aligner. Also mount the connecting rod bearings, piston pin, and connecting rod cap to create the same conditions as are expected when the connecting rod is mounted on a crankshaft.
Page 89 M E M O 11-53...
Page 90 FLYWHEEL Disassembly sequence 1 Washer plate 9 Air outlet pipe 18 O-ring 2 Pilot bearing 10 Air suction pipe 19 Rear oil seal <Type A, Type B> 11 Eyebolt 20 Stiffener 3 Ring gear 12 Water inlet pipe 21 Flywheel housing 4 Flywheel 13 Eyebolt 5 Engine speed sensor...
Page 91 Assembly sequence Follow the disassembly sequence in reverse. Service standards Location Maintenance item Standard value Limit Remedy Correct or Friction surface distortion 0.05 or less replace Type A Flywheel Friction surface height Replace <Type A, Type B> Type B 44.5 43.5 Friction surface runout Correct or...
Page 92 FLYWHEEL Special tools Mark Tool name and shape Part No. Application Socket wrench MH062354 Installation of flywheel Magnet base MH062356 Inspection before removal Inspection: Flywheel friction surface runout when ﬁtted • If the measurement exceeds the limit, check if the bolts are cor- rectly tightened as well as the crankshaft mounting surface.
Page 93 Inspection procedure Inspection: Flywheel (1) Friction surface height • If the height is less than the limit, replace the flywheel. (2) Friction surface distortion • If the measurement exceeds the limit, rectify or replace the fly- wheel. • If the ring gear is evidently defective, replace the ring gear be- fore inspecting the friction surface for distortion.
Page 94 FLYWHEEL Installation procedure Installation: Flywheel housing [Installation] • Clean the flywheel housing surface where sealant is to be ap- plied. • Apply an even and continuous bead of sealant onto the flywheel housing surface where the crankcase is to be mounted. •...
Page 95 Installation: Air compressor • Bring the No. 1 cylinder of the engine to top dead center of the compression stroke. • After aligning inscribed lines with each other, install the air com- pressor to the flywheel housing. • Remove the inspection plug and check if the inscribed line is aligned with the pointer.
Page 96 FLYWHEEL • Tighten the flywheel mounting bolts to a torque of 98 N·m {10 kgf·m}. • Further tighten the bolts in the following procedure. • Turn the holder of counterclockwise to preload the built- in spring. • Set such that the rod (extension) is pressed against by the force of the spring.
Page 97 M E M O 11-61...
Page 98 TIMING GEARS Disassembly sequence 1 No. 1 idler shaft 7 No. 2 idler bolt a: Air compressor gear 2 No. 1 idler gear bushing 8 Thrust plate b: Crankshaft gear 3 No.1 idler gear 9 No. 2 idler gear bushing 4 O-ring 10 No.
Page 99 Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy No. 1 idler gear and air 0.08 to 0.15 0.35 Replace compressor gear No. 1 idler gear and No. 2 – Backlash between gears 0.08 to 0.15 0.35 Replace idler gear No.
Page 100 TIMING GEARS Inspection before removal Inspection: Backlash between gears • For each pair of gears, measure the backlash at more than three teeth. • If any of the measurements exceeds the specified limit, replace the defective part(s). Inspection: Idler gear end play •...
Page 101 Replacement of No. 1 idler gear bushing [Removal] [Installation] • Place the No. 1 idler gear as shown in the illustration. Using , insert the bushing until contacts the chamfered tooth edge of the gear. • After installation, measure the clearance again. •...
Page 102 TIMING GEARS Installation: No. 2 idler shaft • Install the No. 2 idler shaft onto the crankcase ensuring that the boss of the shaft faces down. Installation: No. 1 idler gear • Install the No. 1 idler gear such that the alignment mark “2” on the gear is aligned with the alignment mark “2 2”...
Page 103 M E M O 11-67...
Page 104 CRANKSHAFT AND CRANKCASE 11-68...
Page 105 Disassembly sequence 1 Torsional damper 8 Front oil seal slinger 15 Oil jet 2 Crankshaft pulley 9 Rear oil seal slinger 16 Crankcase 3 Front oil seal 10 Crankshaft gear 4 Front cover 11 Crankshaft : Locating pin 5 Main bearing cap 12 Rear plate : Non-reusable parts 6 Lower main bearing...
Page 106 CRANKSHAFT AND CRANKCASE Special tools (Unit: mm) Mark Tool name and shape Part No. Application Main bearing cap ex- MH061189 Removal of main bearing cap tractor M8 × 1.25 Socket wrench MH061560 Installation of main bearing cap Front oil seal slinger installer MH062710 Installation of front oil seal slinger...
Page 107 Inspection before removal Inspection: Crankshaft end play • If the measurement exceeds the specified limit, replace the thrust plates with oversized ones. Removal procedure Removal: Main bearing caps Removal: Front oil seal slinger • Taking care not to damage the crankshaft, split the rear oil seal slinger using a chisel or a similar tool.
Page 108 CRANKSHAFT AND CRANKCASE (2) Main bearing-to-crankshaft clearance (oil clearance) • Fit the upper main bearing into the crankcase and the lower main bearing into the main bearing cap. • Tighten the main bearing cap bolts to a torque of 78 N·m {8 kgf·m}.
Page 109 Grinding of crankshaft CAUTION • If the crankshaft pins and journals are ground to undersizes, be sure to use bearings of corresponding undersizes. • Do not change the center-to-center distance A between the jour- nal and pin. +0.0252 A: 57.5 –0.075 •...
Page 110 CRANKSHAFT AND CRANKCASE Installation procedure Installation: Rear plate • Clean the rear plate surface where sealant is to be applied. • Apply an even and continuous bead of sealant onto the rear plate surface where the crankcase is to be mounted. •...
Page 111 Installation: Main bearing • Install the main bearings with their lugs aligned as shown in the illustration. When the crankshaft journals have been ground to an undersize, use undersized main bearings. Available main bearing undersizes: 0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm CAUTION •...
Page 112 CRANKSHAFT AND CRANKCASE • Tighten all the bolts to 78 N·m {8 kgf·m}, then additionally tighten them according to the following procedure. • Turn the holder of counterclockwise to pretension the inter- nal spring. • Set the tool such that the rod (extension) is pressed against the crankshaft by the force of the spring.
Page 113 GROUP 12 LUBRICATION SPECIFICATIONS ................12-2 STRUCTURE AND OPERATION 12-3 1. Lubrication System ................12-3 2. Oil Pump ..................... 12-4 3. Oil Cooler ....................................12-5 4. Oil Filter 12-6 5. Lubrication of Engine Components ..........TROUBLESHOOTING ............... 12-9 GENERAL INSPECTION AND ADJUSTMENT 12-10 1.
Page 114 SPECIFICATIONS Item Specifications Method of lubrication Oil pump type Oil filter Spin-on paper-filter type Oil cooler Shell and plate type (multiple-plate type) Grade API classification CD, CD/SF, CE, CE/SF, CF-4 Engine oil Oil pan Approx. 11 {11}, 12 {12}, 16 {16}, 28 {28}, Quantity Oil filter Approx.
Page 115: Lubrication System
STRUCTURE AND OPERATION 1. Lubrication System 1 Engine oil pressure switch 9 Oil pump 19 Camshaft bushing 2 Main oil gallery 10 Oil strainer 20 Rocker bushing 3 Bypass valve 11 Regulator valve 21 Roller 4 Oil cooler 12 Crankshaft main bearing 22 Valve bridge 5 Engine oil bypass alarm 13 Connecting rod bearing...
Page 116 STRUCTURE AND OPERATION 3. Oil Cooler 3.1 Bypass valve • When the engine oil is cool and its vis- cosity is high, or when the oil cooler el- ement becomes clogged and restricts the flow of the engine oil, the bypass valve opens to let the engine oil by- pass the oil cooler and flow directly to the oil filter.
Page 117 4. Oil ﬁlter • This oil filter is a spin-on paper-filter type that incorporates both a full-flow filter and a bypass filter. 4.1 Engine oil bypass alarm switch • If the oil filter elements clog up, this will restrict the flow of engine oil, caus- ing the engine to seize.
Page 118 STRUCTURE AND OPERATION 5. Lubrication of Engine Components • The engine oil in the main oil gallery lubricates the engine components in the following ways. 5.1 Main bearing and connecting rod bearing • Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of each connecting rod.
Page 119 5.3 Valve mechanism • Engine oil in the main oil gallery is directed through the oil passages in the cylinder head, rocker case and front rocker bracket. The oil is then supplied through the camshaft and rocker shaft. The oil flowing through the cam- shaft also lubricates the camshaft journals.
Page 120 STRUCTURE AND OPERATION 5.5 Turbocharger • Engine oil in the main oil gallery is di- rected through a pipe to the bearing housing to lubricate the inner compo- nents. • A piston ring is provided on each end of the turbine wheel shaft. The rings function as oil sealing.
Page 121 TROUBLESHOOTING Symptoms Reference Gr Possible causes Incorrectly mounted element Defective gasket Defective O-ring Oil cooler Clogged element Damaged element Weakened bypass valve spring Malfunctioning oil pump Interference between oil pump gear and oil pump case and/or cover Oil pump Incorrectly connected oil pipe Clogged oil strainer Weakened relief valve spring Incorrect installation...
Page 122: Oil Filter Replacement
GENERAL INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Drain plug (oil filter) 7.8 ± 2.0 {0.8 ± 0.2} – Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Engine oil...
Page 123 [Installation] • Clean the surface of the oil filter head where the oil filter is to be mounted. • Apply a thin coat of engine oil onto the oil filter gasket. • Screw in the oil filter by hand until the gasket contacts the oil fil- ter head.
Page 124 GENERAL INSPECTION AND ADJUSTMENT 2. Engine Oil Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Drain plug (oil filter) 7.8 ± 2.0 {0.8 ± 0.2} – – Drain plug (oil pan) 69 {7} –...
Page 125: Oil Pressure Measurement
3. Oil Pressure Measurement Service standards Location Maintenance item Standard value Limit Remedy 49 kPa 145 to 295 kPa No-load minimum speed {0.5 kgf/ {1.5 to 3 kgf/cm Oil pressure (oil tempera- – Inspect ture at 70 to 90°C) 295 to 490 kPa 195 kPa No-load maximum speed {3 to 5 kgf/cm...
Page 126 OIL PAN, OIL JETS AND OIL LEVEL SENSOR Disassembly sequence 1 Drain plug 2 Oil pan 3 Check valve 4 Oil jet : Locating pin : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION • If overtightened, the check valve will not operate properly, leading to engine seizure.
Page 127 Installation procedure Installation: Oil pan • Clean the mating surfaces of each part. • Apply a bead of sealant to the mating surface of the oil pan evenly and without any breaks. • Change the amount of application to A and B at four locations shown in the illustration.
Page 128 OIL PUMP, OIL STRAINER Disassembly sequence 1 Oil strainer 8 Relief valve 15 Oil deflector 2 Gasket 9 Relief valve spring 3 Oil pipe 10 Washer a: Crankshaft gear 4 Gasket 11 Gear and case b: Oil pump gear 5 Cover 12 Shim 6 Driven gear 13 Shim...
Page 129 Inspection before removal Inspection: Backlash between oil pump gear and crankshaft gear • If the measurement exceeds the limit, adjust by shimming. Shim feeler Change in backlash 0.1 mm 0.073 mm 0.2 mm 0.146 mm CAUTION • Perform shimming such that the shim packs on both sides will have the same feeler.
Page 130: Oil Filter
OIL FILTER Removal sequence 1 Drain plug 2 Oil filter 3 Engine oil bypass alarm switch 4 O-ring 5 Oil filter head 6 Gasket : Non-reusable parts Installation sequence Follow the removal sequence in reverse. WARNING • Wipe up any spilled engine oil, as it can cause ﬁres. •...
Page 131 [Removal] • Remove the drain plug and drain the oil out of the oil filter. • Remove the oil filter using [Installation] • Clean the surface of the oil filter head where the oil filter is to be mounted. • Apply a thin coat of engine oil onto the oil filter gasket. •...
Page 132 OIL COOLER Removal sequence 1 Bypass valve 2 O-ring 3 Plug 4 O-ring 5 Plug 6 O-ring 7 Engine oil pressure switch 8 Regulator valve (See later pages.) 9 O-ring 10 Plug 11 O-ring 12 Plug 13 O-ring 14 Oil cooler element 15 Gasket 16 Oil cooler cover 17 Gasket...
Page 133 REGULATOR VALVE Disassembly sequence 1 Snap ring 2 Valve 3 Spring 4 Body Assembly sequence Follow the removal sequence in reverse. Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy 392 ± 29 kPa – Regulator valve opening pressure –...
Page 134 GROUP 13A FUEL AND ENGINE CONTROL SPECIFICATIONS ................13A-2 STRUCTURE AND OPERATION ............13A-3 1. Fuel System (Flow of Fuel) .................. 13A-4 2. Fuel Filter ................13A-5 3. Water separator TROUBLESHOOTING ..............13A-6 GENERAL INSPECTION AND ADJUSTMENT ............13A-8 1. Air-bleeding of Fuel System 13A-10 2.
Page 135 SPECIFICATIONS Item Specifications Manufacturer DENSO Control system Electronically-controlled pump Supply pump Type HP-4 Feed pump type Trochoid pump Manufacturer DENSO Common rail capacity {mL} 26 {26} Pressure limiter valve Common rail system 221 ± 9 {2253 ± 91.8} opening pressure MPa {kgf/cm Common rail pressure sensor supply voltage...
Page 136 STRUCTURE AND OPERATION 1. Fuel System (Flow of Fuel) • Fuel in the fuel tank is sucked up by the feed pump, which is driven by the pump camshaft within the supply pump, and is fed through the fuel filter where foreign matter is filtered out. •...
Page 137 STRUCTURE AND OPERATION 2. Fuel Filter • The fuel filter removes foreign matter from fuel via the filter element. The fuel filter also incorporates a water sep- arator which separates any water from fuel. • Water separated from fuel accumulates at the bottom of the fuel filter assembly. When water has accumulated to a certain level, this is detected by the water separator sensor, provided on the fuel filter assembly, which then illu- minates a warning lamp on the meter cluster.
Page 138 3. Water separator • The water separator separates water in fuel. • The float provides visual indication of the level of the water separated from fuel. This enables the water to be drained at an appropriate timing through the drain hole by loosening the drain plug.
Page 139 TROUBLESHOOTING Symptoms Reference Possible causes Common rail system abnormal O Gr13E Defective feed pump O O O Incorrect pump output Defective pressurized-fuel delivery system Supply pump Defective SCV; Defective base supply pump SCV open-circuited, short, or intermittent connec- O Gr13E or tion Defective sealing Pressure limiter valve opening pressure too low...
Page 140 Symptoms Reference Possible causes Oil viscosity unsuitable Gr12 Valve clearance incorrect Defective cylinder head gasket Valve and valve seat worn and carbon deposits Valve spring fatigued Gr11 Piston ring worn and damaged Piston ring groove worn and damaged Piston and cylinder liner worn Crankshaft incorrectly sized O O O Cooling system malfunction...
Page 141 GENERAL INSPECTION AND ADJUSTMENT 1. Air-bleeding of Fuel System Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks ± ± – Plug 2 {1 0.2} – • Loosen one of the bleeder plugs on the fuel filter. •...
Page 142 M E M O 13A-9...
Page 143: Fuel Filter Replacement
GENERAL INSPECTION AND ADJUSTMENT 2. Fuel Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks ± ± – Water separator sensor 1 {0.5 0.1} – ± ± – Case 2 {3.1 0.2} – Lubricant and/or sealant Location Points of application Specified lubricant and/or sealant...
Page 144 [Installation] • Clean the surface of the fuel filter head where the O-ring is to be mounted. • Replace the filter element and O-rings with new parts. • Apply a thin coat of engine oil to the O-rings. Install the O-rings onto the case and water separator sensor.
Page 145 GENERAL INSPECTION AND ADJUSTMENT 3. Water Separator Element Replacement Tightening Torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks ± ± – Drain plug 1.47 0.3 {0.15 0.03} – ± ± – Cover 19.6 2.5 {2.0 0.3} –...
Page 146 [Installation] • Clean the O-ring contact surface of the water separator body and the O-ring fitting groove in the cover. • Replace the element and O-ring with new ones. • Apply a thin coat of engine oil to the O-ring and fit the O-ring onto the cover.
Page 147 FUEL FILTER Disassembly sequence 1 Fuel hose 2 Water separator sensor 3 O-ring 4 Case 5 O-ring 6 Element 7 Plug 8 Fuel filter head : Non-reusable parts WARNING • Fuel is highly ﬂammable. Keep it away from ﬂames and sources of heat.
Page 148 Installation procedure Installation: Case • Clean the surface of the fuel filter head where the O-ring is to be mounted. • Replace the filter element and O-rings with new parts. • Apply a thin coat of engine oil to the O-rings. Install the O-rings onto the case and water separator sensor.
Page 149 WATER SEPARATOR Disassembly sequence 1 Fuel hose 2 Plug A 3 O-ring 4 Plug B 5 O-ring 6 Drain plug 7 O-ring 8 Cover 9 O-ring 10 Float 11 Element 12 Body : Non-reusable parts WARNING • Fuel is highly ﬂammable. Keep it away from ﬂames and sources of heat.
Page 150 Removal procedure Removal: Fuel ﬁlter • Drain fuel from the cover by loosening the drain plug after loos- ening the plug A and B. • Remove the cover using CAUTION • Be careful not to damage the case. Installation procedure Installation: Cover •...
Page 151 WATER SEPARATOR • Using the with a torque wrench attached to it, tighten the cover to the specified torque. • Tighten the drain plug, plug A and plug B to the specified torque. Then, bleed the fuel system of trapped air. •...
Page 152 M E M O 13A-19...
Page 153 COMMON RAIL Disassembly sequence 1 Fuel temperature sensor 7 Fuel overflow pipe 13 Common rail 2 O-ring 8 Fuel pipe 3 Eyebolt 9 Injection pipe a: Crankcase 4 Fuel return pipe 10 Flow damper : Non-reusable parts 5 Connector 11 Pressure limiter 6 Eyebolt 12 Common rail pressure sensor WARNING...
Page 154 Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Fuel temperature sensor 17.6 to 21.5 {1.8 to 2.2} – Eyebolt (for fuel return pipe mounting) 25 {2.6} – Eyebolt (for fuel overflow pipe mounting) 17.7 to 22.6 {1.8 to 2.3} –...
Page 155 SUPPLY PUMP Disassembly sequence 1 Eyebolt 6 Supply pump bracket a: Air compressor 2 Fuel return pipe 7 Supply pump b: Fuel temperature sensor 3 Eyebolt 8 Driving disc c: Suction control valve 4 Fuel suction pipe 9 O-ring 5 Fuel pipe 10 Key : Non-reusable parts WARNING...
Page 156 CAUTION • If the supply pump has been replaced, perform the “initialization of supply pump unit difference learning value” using Multi-Use Tester in order to clear the correction data (learned pump unit difference) from the engine electronic control unit. (See Gr13E.) Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened...
Page 157 INJECTOR Disassembly sequence 1 Injection pipe 2 Injection pipe seal 3 O-ring 4 Nozzle bridge 5 Injector 6 O-ring 7 O-ring 8 Nozzle tip gasket 9 Eye bolt 10 Fuel return pipe a: Two-Way electromagnetic Valve : Non-reusable parts WARNING •...
Page 158 Special tools (Unit: mm) Mark Tool name and shape Part No. Application Injector extractor Removing injector MH062560 adapter (use with MH061071) Nozzle extractor MH061071 Removing injector M8 ∞ 1.25 Removal procedure Removal: Injector • Using and with the wire of engaged in the groove on the injector, remove the injector.
Page 159 GROUP 13E ELECTRONICALLY CONTROLLED FUEL SYSTEM SPECIFICATIONS ................13E-2 STRUCTURE AND OPERATION .................. 13E-4 1. Overview ............13E-12 2. Electronic Control System ......13E-18 3. Electronic Control Unit Connection Diagram TROUBLESHOOTING 13E-20 1. Diagnostic Procedure ..............13E-21 2. Diagnostic Precautions ..............13E-22 3.
Page 160 SPECIFICATIONS Item Specification Manufacturer DENSO Model HP-4 Control method Electronic type Supply pump Feed pump type Trochoid type SCV (suction control valve) Rated voltage V Max. common rail pressure MPa {kgf/cm } [psi] 155 {1580} [22473] Manufacturer DENSO Common rail volume {mL} 26 {26} Common rail...
Page 161 M E M O 13E-3...
Page 162 STRUCTURE AND OPERATION 1. Overview • In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, throt- tle opening, coolant temperature, etc.) using information from sensors. In accordance with these data, the elec- tronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in order to optimize the engine’s operation.
Page 163 • When the engine is cranked by means of the starter switch, the feed pump (this is located inside the supply pump) simultaneously draws fuel from the fuel tank and feeds it via the water separator and fuel filter to the SCV (suction control valve).
Page 164 STRUCTURE AND OPERATION 1.1 Supply pump 13E-6...
Page 165 CAUTION • Be sure to connect the SCV (suction control valve) connector to the engine harness before starting the engine. If the engine is started with the SCV (suction control valve) connector not connected, control of the supply pump by the engine electronic control unit would not be possible and a fault would ensue. •...
Page 166 STRUCTURE AND OPERATION 1.2 Common rail • The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump. • Each flow damper prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of fuel leakage from the injection pipe or excessive injection of fuel from the injector.
Page 167 1.3 Injector • In accordance with electrical signals from the engine electronic control unit, each injector supplies high-pressure fuel from the common rail to the relevant combustion chamber of the engine at the optimal timing and in the opti- mal quantity. •...
Page 168 STRUCTURE AND OPERATION (1) Operation (1.1) Injection not taking place • With the magnet not energized, the valve body, is pushed up by the spring in the magnet such that the ball seat is closed. • The high-pressure fuel acts upon the control chamber via orifice plate.
Page 169 (1.3) End of injection • When energization of the magnet is stopped, the valve body is pushed downward by the spring in the magnet such that the ball seat closes. At this time, fuel flows into the control cham- ber via orifice plate, pushing down the command piston and nozzle needle such that injection finishes.
Page 170: Electronic Control System
STRUCTURE AND OPERATION 2. Electronic Control System 2.1 System block diagram Engine electronic control unit Input signals Output signals Engine speed sensor Injector magnetic valve Cylinder recognition sensor supply pump Fuel injection control (SCV: suction control valve) Water temperature sensor Boost pressure sensor Warm-up acceleration function Fuel injection quantity control...
Page 171 Part Main function/operation Engine speed sensor Sensing of engine speed Cylinder recognition sensor Cylinder recognition Senses that the engine is in starting condition with the starter switch in Starter switch START position. Water temperature sensor Sensing of coolant temperature Accelerator pedal position sensor Sensing of extent of accelerator pedal depression Sensing of released/depressed condition of accelerator pedal (OFF with ped- Accelerator pedal switch...
Page 172 STRUCTURE AND OPERATION 2.3 Fuel injection quantity control (1) Fuel injection quantity during engine startup • During engine startup, the fuel injection quantity is determined in accordance with the engine speed and coolant temperature. (2) Basic fuel injection quantity • The basic fuel injection quantity is determined in accordance with the engine speed and throttle opening.
Page 173 2.4 Fuel injection timing control (1) Main injection timing • The main injection timing is calculated from the fuel injection quantity and engine speed. (2) Pre injection timing • The pre injection timing is calculated from the fuel injection quantity and engine speed. 2.5 Fuel injection timing control •...
Page 174 STRUCTURE AND OPERATION 2.6 Warm-up acceleration function Input signals Engine electronic control unit Output signals Comparison operations Water temperature sensor Accelerator pedal position sensor Idling speed control Idling speed adjustment potentiometer Target injection quantity • The warm-up acceleration function increases engine warm-up by varying the engine’s idling speed in accordance with the engine’s coolant temperature.
Page 175 (2) Operation mode • When the engine coolant temperature is 60°C or more. • When the engine coolant temperature is 0°C to 60°C. • When the engine coolant temperature is 0°C or less. 2.9 Fault diagnostic function • When the starter switch is in the ON position, the system continuously monitors the sensors and other system components.
Page 176 STRUCTURE AND OPERATION 3. Electronic Control Unit Connection Diagram 13E-18...
Page 177 13E-19...
Page 178 TROUBLESHOOTING 1. Diagnostic Procedure • The system can be efficiently inspected for faults using Up-Time 2.41 or later software or a Multi-Use Tester-III. System inspection can be accomplished basically in two ways according to trouble symptom and diagnostic code as shown below. •...
Page 179 2. Diagnostic Precautions • Before measuring voltage, check the battery for charged condition and specific gravity. If system inspection is per- formed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved. • To avoid having electrical parts damaged, set the starter switch to LOCK or OFF before disconnecting and recon- necting battery cables.
Page 180 TROUBLESHOOTING 3. Inspections Based on Diagnostic Codes 3.1 Diagnostic code list • Diagnostic codes displayed on the meter panel, indicated by flashing of the warning lamp and shown by the Multi- Use Tester or Up-Time 2.41 or later software are different. •...
Page 181 3.2 Diagnostic code generation conditions and inspection items E-01: Accel Pedal Sensor 1 (warning lamp ﬂashes: 24) P0122 Generation condition Accelerator pedal position sensor 1 voltage is below standard value. Recoverability System recovers if signal becomes normal with starter switch in ON position. •...
Page 182 TROUBLESHOOTING E-03: Accel SW (warning lamp ﬂashes: 65) P0510 Accelerator pedal switch signal is abnormal when compared with accelerator Generation condition pedal position sensor outputs 1 and 2. Recoverability System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit Normal control is effected using accelerator pedal position sensor signals.
Page 183 E-05: Common Rail Pressure M/V 1 (warning lamp ﬂashes: 23) P0256 Common rail pressure exceeds standard value for longer than standard period Generation condition during mid-range-speed or high-speed use of supply pump. Recoverability System recovers if signal becomes normal with starter switch in ON position. •...
Page 184 TROUBLESHOOTING E-07: CRS Pressure SNSR (Plausibility) (warning lamp ﬂashes: 11) P0191 All three conditions listed below are satisfied simultaneously while engine is be- ing cranked or while vehicle is being driven. • Engine speed, injection amount, common rail pressure and fuel type are with- in specification.
Page 185 E-10: Injector M/V - Cylinder2 (Load) (warning lamp ﬂashes: 38) P0202 Generation condition Injector magnetic valve (No. 2 cylinder) is short-circuited or open-circuited. Recoverability System recovers if signal becomes normal with starter switch in ON position. • Fuel injection stopped for faulty cylinder Control effected by electronic control unit •...
Page 186 TROUBLESHOOTING E-15: Flow Limiter - Cylinder1 (warning lamp ﬂashes: 71) P1240 Inter-cylinder injection amount correction value (FCCB) is higher than standard Generation condition value and fluctuation in engine speed is greater than standard value. Recoverability System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit FCCB learning is disabled.
Page 187 E-24: Engine Revolution SNSR (warning lamp ﬂashes: 15) P0335 Generation condition Engine speed sensor emits no pulses. Recoverability System recovers if signal becomes normal with starter switch in ON position. • Control is effected using cylinder recognition sensor. (If cylinder recognition Control effected by electronic control unit sensor also becomes faulty, engine is stopped.) Service data...
Page 188 TROUBLESHOOTING E-29: Atmospheric Pressure Sensor (warning lamp ﬂashes: 19) P0108 Atmospheric pressure sensor (incorporated into engine electronic control unit) Generation condition voltage is above standard value (4.7 V). Recoverability System recovers if signal becomes normal with starter switch in ON position. •...
Page 189 E-33: ECU System (EEPROM) (warning lamp ﬂashes: 33) P1605 Generation condition CPU in engine electronic control unit is faulty. System recovers (power is re-supplied to electronic control unit) if signal be- Recoverability comes normal when starter switch is turned OFF → ON. Common rail system control is disabled (engine is stopped immediately) if mutu- Control effected by electronic control unit al diagnoses of main CPU and sub CPU become impossible.
Page 190 TROUBLESHOOTING E-34: Injector Circuit 3 (warning lamp ﬂashes: 82) P1210 Injector drive circuit voltage in engine electronic control unit is too low or too Generation condition high. System recovers (power is re-supplied to electronic control unit) if signal be- Recoverability comes normal when starter switch is turned OFF →...
Page 191 E-37: INT Air Temp. SNSR (Low) (warning lamp ﬂashes: 44) P0112 Generation condition Intake air temperature sensor voltage is below standard value (0.1 V). Recoverability System recovers if signal becomes normal with starter switch in ON position. Boost air temperature is assumed as constant –20°C during engine startup and Control effected by electronic control unit as constant 25°C while vehicle is being driven.
Page 192 TROUBLESHOOTING E-42: CRS Press M/V 1 (Low) (warning lamp ﬂashes: 63) P1255 SCV ( suction control valve ) is short-circuited to ground, or open circuited, Generation condition or coil is broken. System recovers (power is re-supplied to electronic control unit) if signal be- Recoverability comes normal when starter switch is turned OFF →...
Page 193 E-44: EGR 2 (warning lamp ﬂashes: 68) P1272 Exhaust gas recirculation solenoid valve (M/V-2) is shorted-circuited to ground, Generation condition or open circuited. Recoverability System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit Exhaust gas recirculation control is stopped.
Page 194 TROUBLESHOOTING E-49: Starter Safety Relay (Low) (warning lamp ﬂashes: 48) P0616 Generation condition Safety relay is shorted to power supply circuit. Recoverability System recovers if signal becomes with starter switch ON position. Control effected by electronic control unit • Continuous energization prevention function suspended. Service data 8F: Starter safety relay Actuator test...
Page 195 4. Multi-Use Tester Service Data • It is possible to see service data and actuator tests simultaneously. Item Data Inspection condition Requirement Value corresponds to tachometer .rpm Engine Revolution Racing (engine running) indication. Reference Injection Quantity Starter switch ON Reference Common Rail Starter switch ON 20 to 30% Pressure...
Page 196 TROUBLESHOOTING Item Data Inspection condition Requirement Number matches number marked 1/2/3/4/5/6/7/8/ Q Adjustment Resistor No. – on fuel injection rate adjustment re- 9/10/11/NON sistor. Power Supply Voltage Starter switch ON Value matches battery voltage. Flow Limiter (#1) Starter switch ON Flow Limiter (#2) Starter switch ON Flow Limiter (#3)
Page 197 5. Reading and Erasing Diagnostic Trouble Codes Up-Time or Multi-Use Tester III is used to read or erase the diagnostic trouble code. And also, a method using the di- agnostic switch and memory clear switch without these tools is available. 5.1 Method using Up-Time or Multi-Use Tester III Refer to each service tool manual.
Page 198 TROUBLESHOOTING (4) Erasing diagnostic trouble codes Disconnect the memory clear switch connector and then recon- nect. Then all the diagnostic trouble codes stored in the engine control unit will be cleared. NOTE • Pay attention that the stored codes can be erased only by the operation of memory clear switch.
Page 199 6. Actuator Tests Performed Using Multi-Use Tester • It is possible to see service data and actuator tests simultaneously. Item Explanation Confirmation method EGR 1 Switch ON/OFF exhaust gas recirculation solenoid Operating sound of exhaust gas valve (automatic reset after six seconds) recirculation solenoid valve when EGR 2 [Can be executed under the following conditions]...
Page 200 TROUBLESHOOTING Item Explanation Confirmation method Increase rail pressure for a specified six seconds [Can be executed under the following conditions] Check that no fuel leaks from fuel Fuel Leak Check • Vehicle: stopped (vehicle speed 0 km/h) system (pipe, hose) •...
Page 201 7. Initialization of Supply Pump Unit Difference Learning Value in Engine Electron- ic Control Unit • Following replacement of the engine electronic control unit or the supply pump, this item is used to program the current supply pump data into the engine electronic control unit. 7.1 After replacement of engine electronic unit with new one Replacement of engine electronic control unit with new one Start engine.
Page 202 TROUBLESHOOTING 8. Inspections Performed at Electronic Control Unit Connectors • These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being correctly transmitted via the vehicle harness and connectors. The white-on-black numbers ( , and so on) correspond to the similarly printed reference numbers in sec- tion “3.
Page 203 Check item Measurement method [Conditions] • Starter switch ON • Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] Output voltage of accelerator pedal posi- Terminals (+)-(–) tion sensor A24-D30 (accelerator pedal position sensor 1) A23-D28 (accelerator pedal position sensor 2) •...
Page 204 TROUBLESHOOTING Check item Measurement method [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: B35-B27 • No. 1 resistor: 270 ± 13.5 Ω • No. 2 resistor: 510 ± 25.5 Ω • No. 3 resistor: 820 ± 41 Ω Resistance of fuel injection rate adjustment •...
Page 205 INSPECTION OF ELECTRICAL EQUIPMENT #029 Inspection of accelerator pedal switch Switch position Terminals with continuity – 1 – 2 • If there is any abnormality, replace the switch. #201 Inspection of relay (normally open type with 5 pins) • Test for continuity and proper operation. If there is any abnormal- ity, replace the relay.
Page 206 INSPECTION OF ELECTRICAL EQUIPMENT #305 Inspection of intake air temperature sensor • Clean the sensor as dirty sensor terminals may provide false output signals. (See Gr15.) • Place the boost air temperature sensor in a container filled with engine oil. •...
Page 207 <Fuel temperature sensor (outlet)> • Measure the resistance between terminals 1 and 2. +0.14 20°C 2.45 kΩ –0.13 Standard value 80°C 0.318 ± 0.01 kΩ 110°C 0.1417 ± 0.01 kΩ • If any measurement is out of specification, replace the sensor. #324 Inspection of accelerator pedal position sensor [Inspection] •...
Page 208 INSPECTION OF ELECTRICAL EQUIPMENT #530 Inspection of exhaust gas recirculation solenoid valve • Perform the following checks. If there is any abnormality, replace the exhaust gas recirculation solenoid valve. (1) Check of operation • Gradually increase from zero the voltage applied to terminals 1 and 4 (M/V-1), 2 and 5 (M/V-2), or 3 and 6 (M/V-3).
Page 209 #828 Inspection of fuel injection rate adjustment resistor • Measure the resistance of the resistor number marked on the fuel injection rate adjustment resistor. 270 ± 13.5 Ω 510 ± 25.5 Ω 820 ± 41 Ω 1300 ± 65 Ω 2000 ±...
Page 210 GROUP 14 COOLING SPECIFICATIONS ................14-2 STRUCTURE AND OPERATION ..........14-3 1. Cooling System (Flow of Coolant) ................. 14-4 2. Thermostat ................14-4 3. Water Pump TROUBLESHOOTING ..............14-5 GENERAL INSPECTION AND ADJUSTMENT ....14-6 1. Coolant Replacement and Cleaning of Cooling System ..........
Page 211 SPECIFICATIONS Item Specifications Cooling system Forced water circulation system Water pump Belt-driven type Thermostat Wax pellet, bottom bypass type (with jiggle valve) 14-2...
Page 212 STRUCTURE AND OPERATION 1. Cooling System (Flow of Coolant) 14-3...
Page 213 STRUCTURE AND OPERATION 2. Thermostat • The thermostat is a bottom bypass type that uses a wax-filled pellet as its flow-regulating element. When the wax is heated, it melts from solid to liq- uid, changing its total volume. This al- lows the valve to open or close in accordance with the coolant tempera- ture, regulating and adjusting the flow...
Page 214 TROUBLESHOOTING Symptoms Reference Gr Possible causes Loose or damaged V-belt Excessive tension Oil on belt Incorrectly mounted water pump Defective gasket Defective unit bearing Water pump Defective impeller Defective unit seal Fit of unit bearing on flange and impeller too loose Incorrectly mounted case Defective gasket Thermostat...
Page 215 GENERAL INSPECTION AND ADJUSTMENT 1. Coolant Replacement and Cleaning of Cooling System • Using the radiator for extended periods of time without cleaning can increase chance of rust and scale formation, which may cause engine overheating. The cooling system must be cleaned periodically. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened...
Page 216 • Select an appropriate cleaning method according to the condition of the cooling system as shown below. • Ordinary condition • Coolant extremely dirty • Radiator clogged Cleaning using FUSO RADIATOR CLEANER (RADIPET-7) Flushing with water Drain out coolant Make water solution of FUSO RADIATOR CLEANER (RADIPET-7) at 5 to 10% concentration in volume.
Page 217 GENERAL INSPECTION AND ADJUSTMENT 2. Air Bleeding of Cooling System • With the pressure cap removed and the coolant temperature at 90°C, let the engine idle in order to bleed air com- pletely out of the cooling system. • After air bleeding is completed, refill the reservoir tank with coolant as needed. 3.
Page 218 4. Inspection of V-belts • Visually check the V-belts for possible cracks and damage. V-belt replacement time varies depending on the severity of cracks and damage that may be found through the check. Study the table given below for the applicable replacement time. Belt condition Remaining service life (reference) •...
Page 219 DISCONNECTION AND CONNECTION OF HOSES AND PIPES Removal sequence 1 Water hose 5 Water hose 9 EGR cooler water pipe 2 Eyebolt 6 EGR cooler water pipe 10 Water hose 3 Joint pipe 7 Water hose 4 Water hose 8 Water hose EGR: Exhaust gas recirculation Installation sequence Follow the removal sequence in reverse.
Page 220 M E M O 14-11...
Page 221 RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD Type A Removal sequence 1 Intercooler 5 Pressure cap 9 Shroud seal 2 Hose 6 Filler 10 Fan shroud 3 Drain cock 7 Filler hose 4 Oil cooler 8 Radiator (See later pages.) Installation sequence Follow the removal sequence in reverse.
Page 222 Special tools (Unit: mm) Mark Tool name and shape Part No. Application Tip clearance <For φ600 fan> spacer MC019470 Adjusting clearance between fan shroud and cooling fan blades <For φ620 fan> φ600 ME294842 φ620 Inspection procedure Inspection: Air leaking of intercooler •...
Page 223 RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD (2) Inspection of vent valve • Note the coolant level in the reservoir tank. • Start the engine and run it at high speed until the coolant level in the reservoir tank has risen to a certain degree. Stop the engine. •...
Page 224 Type B Removal sequence 1 Plug 9 Packing 17 Radiator 2 Gasket 10 Pressure cap 18 Cushion 3 Intercooler 11 Pressure cap 19 Radiator 4 Protector 12 Water hose 20 Cushion 5 Packing 13 Water hose 21 Plate 6 Packing 14 Hose 22 Frame 7 Oil cooler...
Page 225 RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD Inspection procedure Inspection: Air leaking of intercooler • Plug an end of the intercooler and apply a specified air pressure from the other end with the intercooler immersed in water. • If any leakage is found, replace the intercooler. Inspection: Air leaking of oil cooler •...
Page 226 (2) Inspection of vent valve • Note the coolant level in the reservoir tank. • Start the engine and run it at high speed until the coolant level in the reservoir tank has risen to a certain degree. Stop the engine. •...
Page 227 RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD Radiator Assembly • Only the type A radiator can be disassembled. Disassembly sequence 1 Radiator shroud 5 Packing 2 Drain cock 6 Lower tank : Non-reusable parts 3 Side member 7 Packing 4 Upper tank 8 Core CAUTION •...
Page 228 Special tools Mark Tool name and shape Part No. Application J94-Z013 Lock-and-break tool Removal of upper and lower tanks -10000 The indicated part number is T. RAD’s part number. Inspection before removal Inspection: Air leaking of radiator • Install hose and radiator cap tester and plug to upper tank. •...
Page 229 RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD • Adjust the stopper bolt until the gap dimension shown in the il- lustration is obtained on the attachment of CAUTION • Before using , be sure to set the gap to the speciﬁed di- mension by adjusting the stopper bolt.
Page 230 Inspection: Core groove where tank is to be mounted • Check the groove on the core where the tank is to be mounted for adhesion of foreign substances or cracks. • If foreign substances are found, rub the area with #1000 sand- paper or a like gently so as to avoid scratching the surface, or use compressed air to remove them.
Page 231 RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD • Close both end of the tube by tungsten inert-gas arc welding (TIG welding). Welding conditions • Welding rod: A4043 (approx. φ2 mm) • Welding current: AC80A • After welding, check for the following problems. If any of them exist, repair again or replace the core.
Page 232 • Paint a mark on the core where it can be easily noticed to indi- cate that the core has been crimped. CAUTION • Paint a mark for each repair performed on either the upper or lower tank. 14-23...
Page 233 COOLING FAN AND V-BELT Disassembly sequence 1 V-belt 5 Water pump pulley 11 Connector <Type C> 2 Cooling fan 6 Inlet pipe 12 Grease nipple bracket <Type B and Type C> 7 Inlet hose <Type C> 3 Fan spacer <Type B> 8 Tube <Type C>...
Page 234 Service standards (Units: mm) Location Maintenance item Service standard Limit Remedy V-belt tension 10 to 15 – Adjust Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Grease nipple 12.5 ± 2.5 {1.3 ± 0.3} – Straight joint Tube 2.25 ±...
Page 235 COOLING FAN AND V-BELT • Place at a central portion between pulleys of the V-belt and push the handle (indicated by the arrow in the illustration) until the O-ring touches the flange. • Measure the amount of deflection of the V-belt. •...
Page 236 M E M O 14-27...
Page 237 WATER PUMP Disassembly sequence 1 Impeller 7 Washer 13 Cover 2 Flange 8 Water pump shaft 14 Gasket 3 Snap ring 9 Unit seal 4 Bearing 10 Grease nipple <If equipped> : Non-reusable parts 5 Spacer 11 Water pump case 6 Bearing 12 Gasket Assembly sequence...
Page 238 Special tools (Unit: mm) Mark Tool name and shape Part No. Application Impeller puller MH062192 Removal of impeller puller φ ± Removal procedure Removal: Impeller Removal: Flange Inspection procedure Inspection: Impeller-to-water pump shaft interference • If the measurement does not comply with the standard value, re- place the defective part(s).
Page 239 WATER PUMP Installation procedure Installation: Flange CAUTION • Before installing ﬂange, make sure that there is no or only one punch mark in the shown location on the ﬂange. Make an additional punch mark on the ﬂange to indicate that it undergoes the disassembly and reassembly process you are doing now.
Page 240 Inspection after assembly Inspection: Flange rotation • Rotate the flange by hand. The flange should rotate smoothly without any binding. • If the flange does not rotate freely, disassemble and check. 14-31...
Page 241 THERMOSTAT Disassembly sequence 1 Thermostat cover 2 Gasket 3 Thermostat 4 Water temperature sensor 5 Plug 6 Cock 7 Thermostat case 8 Gasket 9 O-ring 10 Joint 11 O-ring : Non-reusable parts CAUTION • Do not remove the thermostat case unless it has a water leak or any other defect.
Page 242 Inspection procedure Inspection: Thermostat • Stir the water using a stirring rod to maintain an even water tem- perature in the container, then conduct the tests indicated below. • If the measured values deviate from the standard value ranges, replace the thermostat. (1) Valve opening temperature •...
Page 243 GROUP 15 INTAKE AND EXHAUST SPECIFICATIONS ................15-2 STRUCTURE AND OPERATION .................. 15-3 1. Air Cleaner ................15-4 2. Turbocharger TROUBLESHOOTING ..............15-5 AIR CLEANER .................. 15-6 TURBOCHARGER ................15-8 INTAKE MANIFOLD ................ 15-14 EXHAUST MANIFOLD ..............15-16 15-1...
Page 244 SPECIFICATIONS Item Specifications Air cleaner element Cyclone filter paper type Dust indicator type Mechanical/electrical Model TD06 Turbocharger Manufacturer Mitsubishi Heavy Industries 15-2...
Page 245 STRUCTURE AND OPERATION 1. Air Cleaner • The air cleaner utilizes single element. • The lower air duct incorporate a vacu- ator valve. • The vacuator valve automatically works in such a way that when the en- gine speed drops below a specified level, the valve’s rubber boot which is usually subdued by internal vacuum is allowed to spring back and accumulat-...
Page 246 STRUCTURE AND OPERATION 2. Turbocharger 2.1 Waste gate mechanism • The waste gate mechanism, which is operated by an actuator, is designed to let excess exhaust gas bypass the turbocharger, thereby preventing the turbocharger from overrunning and the intake manifold pressure from rising excessively.
Page 247 TROUBLESHOOTING Symptoms Reference Gr Possible causes Air cleaner Clogged air cleaner element Carbon deposits on shaft Interference between turbine wheel and tur- bine housing Bent shaft Damaged turbine wheel unit Turbocharger Interference between compressor wheel and compressor cover Damaged compressor wheel Compressor cover fitted poorly Turbine housing fitted poorly Incorrect valve clearances...
Page 248 AIR CLEANER Removal sequence 1 Dust indicator 2 Adaptor 3 Vacuator valve 4 Cover 5 Element 6 O-ring 7 Case : Non-reusable parts Installation sequence Follow the removal sequence in reverse. Service standards Location Maintenance item Standard value Limit Remedy Operation of dust indicator under specified negative 6.2 ±...
Page 249 Cleaning procedure Cleaning: Element • Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm } against the inside surfaces of the element. • Move the compressed air jet up and down along all pleats of the filter paper element.
Page 250 TURBOCHARGER Removal sequence 1 Air inlet pipe 7 Turbocharger cover a: Exhaust manifold 2 Rubber hose 8 Exhaust pipe : Non-reusable parts 3 Eyebolt 9 Gasket 4 Oil feed pipe 10 Turbocharger 5 Oil return pipe (See later section.) 6 Gasket 11 Gasket Installation sequence Follow the removal sequence in reverse.
Page 251 Installation procedure Installation: Turbocharger • Before installing the turbocharger, pour engine oil into the oil hole to ensure smooth operation of the internal parts. 15-9...
Page 252 TURBOCHARGER Turbocharger Disassembly sequence 1 Hose 2 Actuator 3 Coupling 4 Turbine housing 5 Snap ring 6 Compressor cover 7 O-ring 8 Cartridge assembly : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION • The cartridge assembly cannot be taken to pieces.
Page 253 Removal procedure Removal: Turbine housing • Lightly tap around the entire periphery of the turbine housing with a rubber-faced hammer, taking care not to cause damage. CAUTION • The blades on the cartridge assembly are easily bent. Make sure that they do not strike the turbine housing. Removal: Compressor cover •...
Page 254 TURBOCHARGER (2) Play perpendicular to axis of shaft Installation procedure Installation: Snap ring • With the tapered surface facing up, install the snap ring into the compressor cover. CAUTION • Fit the snap ring into place using hands not to let it spring away.
Page 255 M E M O 15-13...
Page 256: Intake Manifold
INTAKE MANIFOLD Removal sequence 1 Boost pressure sensor 2 Intake air temperature sensor 3 Exhaust gas recirculation valve adapter 4 Gasket 5 Plate 6 Reed valve 7 Intake manifold fitting 8 Gasket 9 Intake manifold a: Cylinder head (See Gr11.) : Non-reusable parts Installation sequence Follow the removal sequence in reverse.
Page 257 Installation procedure Installation: Intake manifold • Clean the sealing surfaces of the intake manifold and cylinder head where they are to be mated with each other. • Apply an even and continuous bead of sealant onto the intake manifold surface where the cylinder head is to be mounted. •...
Page 258: Exhaust Manifold
EXHAUST MANIFOLD Removal sequence 1 Exhaust manifold insulator A 2 Exhaust manifold insulator B 3 Front exhaust manifold insulator 4 Exhaust manifold bracket 5 Distance piece 6 Exhaust manifold 7 Gasket a: Cylinder head (See Gr11.) : Non-reusable parts Installation sequence Follow the removal sequence in reverse.
Page 259 GROUP 17 EMISSION CONTROL STRUCTURE AND OPERATION ..........17-2 1. Exhaust Gas Recirculation System ............17-4 2. Blowby Gas Return System GENERAL INSPECTION AND ADJUSTMENT ..........17-5 1. Replacement of PCV Valve Element EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND EGR COOLER..................
Page 260: Exhaust Gas Recirculation System
STRUCTURE AND OPERATION 1. Exhaust Gas Recirculation System 1.1 Overview • EGR mixes inert gases contained in burned exhaust gases with the air on the inlet side (inlet manifold), thereby reducing the combustion temperature and thus reducing the amount of harmful NOx (nitrogen oxides) contained in the exhaust gases.
Page 261 (1) EGR solenoid valves • The EGR solenoid valves are each turned ON/OFF by drive signals from the engine electronic control unit to real- ize a 7-stage supply of air to the EGR valve. (2) EGR valve • The EGR valve realizes 7 stages of valve lift in accordance with the supply of air to its input ports from the EGR solenoid valves.
Page 262 STRUCTURE AND OPERATION 2. Blowby Gas Return System PCV: Positive Crankcase Ventilation • The blowby gas return system returns blowby gases to an air duct to prevent them from being released to the out- side air. • The PCV valve keeps constant the pressure inside the crankcase. •...
Page 263 • Securely tighten the cap until it stops slightly above the PCV body. CAUTION • Be sure to use a genuine Mitsubishi Fuso element. Using an inappropriate element could result in engine trouble. • When replacing the element, be sure to replace the O-ring also.
Page 264 EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND EGR COOLER Removal sequence 1 Water hose 10 Upper EGR pipe clamp 19 Gasket 2 Water hose 11 EGR pipe 3 Water hose 12 Gasket a: EGR valve adapter 4 EGR adapter 13 Eyebolt 5 Gasket 14 EGR air pipe...
Page 265 Service standards Location Maintenance item Standard value Limit Remedy – 1.3 ± 0.3 – 2.6 ± 0.3 – 4.6 ± 0.3 – EGR valve lift Operating stage Replace 5.7 ± 0.3 – 7.7 ± 0.4 – 9.0 ± 0.3 – 11.0 ±...
Page 266 EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND EGR COOLER Inspection procedures Inspection: EGR cooler (1) Exhaust gas passage side • Fit a cover over the exhaust gas outlet of the EGR cooler, and connect a hose to the exhaust gas inlet. Then, submerge the EGR cooler in a container of water.
Page 267 BLOWBY GAS RETURN SYSTEM <Type A> Removal sequence 1 Breather pipe 6 Oil hose stay a: Rocker cover 2 Breather hose 7 Cap b: Breather hose 3 Breather hose 8 O-ring 4 Oil hose 9 Element : Non-reusable parts 5 PCV valve bracket 10 PCV body PCV: Positive crankcase ventilation Installation sequence...
Page 268 BLOWBY GAS RETURN SYSTEM <Type B> Removal sequence 1 Breather hose 6 Cap a: Rocker cover 2 Breather hose 7 O-ring b: Air suction pipe 3 Oil hose 8 Element 4 PCV valve bracket 9 PCV body : Non-reusable parts 5 Oil hose stay PCV: Positive crankcase ventilation Installation sequence...
Page 269 <Type C> Removal sequence 1 Breather hose 7 O-ring a: Rocker cover 2 Breather pipe 8 Element b: Air suction pipe 3 Breather hose 9 PCV body 4 Breather hose 10 Oil hose stay : Non-reusable parts 5 Oil hose 11 PCV valve bracket PCV: Positive crankcase ventilation 6 Cap...
Page 270 GROUP 54 ELECTRICAL SPECIFICATIONS ................54-2 STRUCTURE AND OPERATION 54-3 1. Starter ....................................... 54-4 2. Alternator ................54-7 3. Circuit diagram TROUBLESHOOTING ............... 54-8 INSPECTION OF ELECTRICAL EQUIPMENT ..............54-10 #001 to #179 SWITCH ................ 54-11 #180 to #249 RELAY ..............
Page 271 SPECIFICATIONS Alternator Item Specifications Manufacturer MITSUBISHI ELECTRIC Alternator with built-in regulator Type (without brush external fan) Model A4T40379 A4T40399 A4TU7686 Output V–A 24–50 Starter, Preheat Item Specifications Starter Manufacturer MITSUBISHI ELECTRIC Model M008T62271 Output V–kW 24–5.0 Magnetic switch operating 16 or less...
Page 272 STRUCTURE AND OPERATION 1. Starter • This starter uses planetary gears as its reduction gearing mech- anism. 54-3...
Page 273 STRUCTURE AND OPERATION 2. Alternator <24V–50A> 54-4...
Page 274 2.1 Alternator with neutral diodes (1) Features • The alternator with neutral diodes pro- vides higher DC output during opera- tion at high speeds than the alternator without neutral diodes. (2) Variations of voltage at neutral point and operation of neutral di- odes •...
Page 275 STRUCTURE AND OPERATION • When the voltage at neutral point ex- ceeds 28 V, the positive diode oper- ates and adds extra output to the DC output for supply to each electric equipment. • When the voltage at neutral point drops below 0 V, the negative diode supplies the output from neutral point through other three diodes.
Page 276 3. Circuit diagram 54-7...
Page 277 TROUBLESHOOTING 1. Power and Charging Symptoms Reference Gr Possible causes Connector connection faulty, harness broken, grounding faulty Fuse blown V-belts loose Gr14 V-belts damaged Battery faulty Stator coil broken Stator coil short-circuited with core Field coil broken Alternator Rectifier faulty Regulator faulty Wiring faulty 54-8...
Page 278 2. Engine Starting, Preheating and Stopping Symptoms Starter operates but engine does not start. Reference Gr Possible causes Connector connection faulty, harness broken, grounding faulty Fuse blown Battery insufficiently charged Magnetic switch contacts stuck or fused together Open circuit in magnetic switch coil Starter Overrunning clutch malfunc-...
Page 279 #001 to #179 SWITCH #024 Inspection of thermo switch • Dip the switch in a container filled with engine oil. • Raise the oil temperature to the specified one while stirring oil. • Measure the operating temperature between terminals 1 and 2 respectively.
Page 280 #180 to #249 RELAY #187 Inspection of starter relay • Perform continuity check and operation check, and if any fault is found, replace the relay. #188 Inspection of main power relay • Perform continuity check and operation check, and if any fault is found, replace the relay.
Page 281 #250 to #349 SENSOR #259 Inspection of water level sensor • Remove the water level sensor from the radiator. • Turn the starter switch ON. • Dip the water level sensor in a container filled with engine cool- ant, and check that the pilot lamp goes on and out under the fol- lowing conditions.
Page 282 #250 to #349 SENSOR, #350 to #409 CONTROL UNIT #263 Inspection of engine speed sensor • Measure the resistance values between terminals 1 and 2. 125.5 ± 17 Ω Standard value (at 20°C) • If the measured value deviates from the standard value, replace the sensor.
Page 283 #750 to #859 OTHER #757 Inspection of dust indicator • Perform the following checks, and if any fault is found, replace the dust indicator. • Make sure that there is no continuity between terminals 1 and 2 when air pressure is not applied to the dust indicator. •...
Page 284 #930 STARTER Removal sequence 1 Starter relay 2 Starter WARNING • Before removing the starter, dis- connect the (–) battery cable and in- sulate the cable and the (–) battery terminal with tape. • It is dangerous to leave the (–) bat- tery cable connected since the bat- tery cable voltage is always present at terminal B.
Page 285 #930 STARTER Disassembly sequence 1 Stopper ring 12 Brush (+) 23 Plate 2 Pinion stopper 13 Yoke 24 E-ring 3 Pinion 14 Packing 25 Gear shaft 4 Spring 15 Rear bearing 26 Washer 5 Magnetic switch 16 Washer 27 Internal gear 6 Shim 17 Armature 28 Overrunning clutch...
Page 286 CAUTION • When the armature is removed, the ball may come out with it. Take care not to lose the ball. • Do not remove the bearings and unless defects are evident. • The rubber packing is serviceable if any defect is not found in it during disassembly. •...
Page 287 #930 STARTER Work before disassembly Mating mark: Rear bracket and yoke Disassembly procedure Disassembly: Pinion • For removal of the pinion, current must be supplied to the starter such that the pinion springs out. WARNING • When the starter is energized, the pinion will spring out and rotate.
Page 288 • Connect the starter as illustrated. • The following operations are performed with current supplied to the starter. Thus, the entire procedure for removal of the pinion must be completed within 30 seconds. • Turn ON switches 1 and 2 to supply current to the starter. The pinion will spring out and rotate.
Page 289 #930 STARTER Disassembly: Yoke and brush holder • Use the following method to remove the yoke and brush holder in order to prevent the commutator of the armature from being damaged by the brushes. • Lift the brushes away from the commutator and hold them lift- ed by applying the brush springs against the sides of the brush springs.
Page 290 Inspection procedure Inspection: Magnetic switch • Perform the following inspections. If any abnormality is found, re- place the switch. (1) Test for coil open circuit • Check that continuity exists between terminals S and M. • Check that continuity exists between terminal M and the body. (2) Test for fused-together contacts •...
Page 291 #930 STARTER Inspection: Brush spring pressure • Using new brushes, measure the load required to separate each brush spring from its brush. • If either measurement is lower than the specified limit, replace the brush springs. Inspection: Brush (–) (1) Brush length •...
Page 292 Inspection: Brush (+) (1) Brush length • If either brush (+) is shorter than the limit, it must be replaced. (2) Contact surface of armature’s commutator and brush • If the commutator contact surface of either brush is rough or un- evenly worn, rectify it with emery paper (#300 to 500).
Page 293 #930 STARTER (6) Mold depth between segments • If the measurement is lower than the specified limit, rectify or re- place the armature. • To rectify the armature, grind the illustrated portions. • If the mold is worn as illustrated, rectify or replace the armature. : Acceptable X : Unacceptable Inspection: Overrunning clutch...
Page 294 Assembly: Yoke and brush holder • To install the yoke and brush holder, follow the removal se- quence in reverse. (See “ Disassembly: Yoke and brush holder”) Assembly: Magnetic switch • Fit the magnetic switch onto the lever with terminal S aligned as illustrated.
Page 295 #930 STARTER Inspection after assembly Inspection: Performance and pinion gap • After assembling the starter, perform inspections with current supplied to it. WARNING • When the starter is energized, the pinion will spring out and rotate. Be careful not to touch it with your hands. •...
Page 296 (2) Pinion gap • Connect the starter as illustrated. • The following operations are performed with current supplied to the starter. Thus, the entire procedure for measurement of the pinion gap must be completed within 30 seconds. • Turn ON switches 1 and 2 to supply current to the starter. The pinion will spring out and rotate.
Page 297 #940 ALTERNATOR Removal sequence 1 Adjusting bolt 4 Alternator 2 Adjusting shaft 5 Adjusting plate <With adjusting shaft> 3 V-belt a: Alternator bracket WARNING • Before removing the alternator, disconnect the (–) battery cable and insulate the cable and the (–) battery terminal with tape.
Page 298 Inspection procedure Inspection: Alternator (1) Alternator output current (bench test) • Connect the alternator as illustrated. CAUTION • Wires with sufﬁcient thickness should be used for wiring and each connection should be securely fastened. B: Terminal B E: Terminal E L: Terminal L R: Terminal R •...
Page 299 #940 ALTERNATOR Disassembly sequence 1 Pulley & fan 7 Front bracket 2 Spacer 8 Field coil 3 Rear bearing 9 Stator 4 Rotor 10 Regulator 5 Cover 11 Rectifier 6 Front bearing 12 Rear bracket • Do not remove the rear and front bearing, stator, or unless faulty. Assembly sequence Follow the disassembly sequence in reverse.
Page 300 Disassembly procedure Disassembly: Rotor and front bracket • Insert a screwdriver between front bracket and stator. • Use the screwdriver to pry rotor and front bracket away from sta- tor and rear bracket. CAUTION • Be careful not to insert the screwdriver too deep or it will damage coil of stator and may cause a short-circuit.
Page 301 #940 ALTERNATOR Disassembly: Field coil • Remove screw A (2 places). CAUTION • If screws B are removed ﬁrst, the weight of ﬁeld coil may be placed on the joining portion with regulator which is ﬁxed with screw A, causing break of the joining portion. To avoid this, remove screw A ﬁrst.
Page 302 Inspection: Stator • Perform the following inspections. If any abnormality is found, re- place the stator. (1) Continuity between each lead wire • Check that there is continuity between each stator lead. • If there is no continuity, the lead has broken. (2) Continuity between each lead wires and the core •...
Page 303 #950 INSPECTION OF ALTERNATOR Performance test • Connect the meters to the alternator as shown. WARNING • To prevent possible injury, be sure to disconnect the nega- tive terminal of the battery and insulate it with tape before working on the wiring. With the negative terminal (–) of the battery connected, battery voltage is always applied to ter- minal B.
Page 304 #951 INSPECTION OF REGULATOR Service standards Location Maintenance item Standard value Limit Remedy – Adjusting voltage 28.5 ± 0.5 V – Replace • Connect the meters to the alternator as shown. WARNING • To prevent possible injury, be sure to disconnect the nega- tive terminal of the battery and insulate it with tape before working on the wiring.
Page 305 #955 INSPECTION OF PREHEATING SYSTEM Service standards Location Maintenance item Standard value Limit Remedy 60°C or higher No pre-glow operation – Pre-glow 0 or 60°C About 12 seconds – time Coolant – 0°C or below About 20 seconds – Inspect temperature 0°C or higher No after-glow operation...
Page 306 GROUP 61 SPECIAL EQUIPMENT SPECIFICATION ................. 61-2 STRUCTURE AND OPERATION ................61-4 1. Air Compressor ..................61-6 2. Air Dryer TROUBLESHOOTING ................ 61-9 GENERAL INSPECTION AND ADJUSTMENT ........61-10 1. Maintenance and Inspection of Air Dryer 2. Inspection and Adjustment of Air Dryer’s ..............
Page 307 SPECIFICATIONS Air compressor Item Specifications Type Water-cooled 1 cylinder Cylinder bore × stroke φ70 × 40 φ95 × 45 Cylinder displacement {mL} 154 {154} 319 {319} Manufacturer Sanwa Seiki Air dryer Item Specifications Model DU-4 Heater capacity 24-70 4 ± 4 Thermostat operating °C temperature...
Page 308 M E M O 61-3...
Page 309 STRUCTURE AND OPERATION 1. Air Compressor 61-4...
Page 310 1.1 During suction • When the piston goes down during the suction stroke cycle, the vacuum causes the suction valve to open, allowing air to be drawn into the cylinder. 1.2 During compression and delivery • When the piston goes up during the compression and delivery stroke cycle, the suction valve is closed by air pressure.
Page 311 STRUCTURE AND OPERATION 2. Air Dryer • The air dryer protects brake compo- nents by removing moisture and oil from air that has been compressed by the air compressor. • The air dryer incorporates an air pres- sure governor, which keeps the pres- sure in the air tank constant by releasing air compressed by the air compressor to the atmosphere when...
Page 312 2.2 Regeneration of desiccant • When the air pressure in the air tank reaches the upper threshold level, sig- nal pressure from the air pressure governor causes the valve in the air dryer’s control port to open. As a re- sult, the pressure in the case cleans the oil filter and pushes the water and oil out into the atmosphere.
Page 313 STRUCTURE AND OPERATION 2.4 Operation when tank pressure reaches lower threshold level • When the air pressure A from the air tank drops below the lower threshold level, the piston is pushed downward by the spring such that the inlet valve closes and the exhaust valve opens.
Page 314 TROUBLESHOOTING Air dryer Symptoms Reference Possible causes Deterioration of desiccating agent Inoperative heater causing air dryer to freeze Malfunctioning of valve due to adherence of foreign particles Heater circuit open and therefore no heat retention Heater malfunction due to thermostat malfunction Extreme lowering of temperature of air dryer main body due to ad- herence of snow/ice Heater malfunction due to disconnection with thermostat...
Page 315 GENERAL INSPECTION AND ADJUSTMENT 1. Maintenance and Inspection of Air Dryer Perform maintenance and inspections at each of the indicated in- tervals or service time. (1) Every three months or 500 hours • Check whether the air dryer is functioning properly by opening the drain cock on the air tank and checking whether water flows out.
Page 316 2. Inspection and Adjustment of Air Dryer’s Air Pressure Governor Service standards Location Maintenance item Standard value Limit Remedy Upper threshold –20 – Adjust pressure +0.3 {9.1 kgf/cm –0.2 – Threshold pressure Lower threshold 760 ± 15 kPa – Replace pressure {7.8 ±...
Page 317 GENERAL INSPECTION AND ADJUSTMENT (2) Operating pressure of air pressure governor • Remove the cap nut, plate, and seat. • Start the engine and gradually increase the air pressure in the air tank. • Turn the adjusting screw until the pressure indicated by air pres- sure gauge A when air is expelled from the exhaust cover is the standard value (the upper threshold pressure).
Page 318 M E M O 61-13...
Page 319 AIR COMPRESSOR <154 cm {154 mL}> 61-14...
Page 320 Disassembly sequence 1 Lock washer 9 1st compression ring 17 Bearing cover 2 Compressor gear 10 2nd compression ring 18 Bearing 3 Cylinder head 11 3rd compression ring 19 Connecting rod 4 Gasket 12 Oil ring 20 Crankshaft 5 Valve seat 13 Snap ring 21 Crankcase 6 O-ring...
Page 321 AIR COMPRESSOR <154 cm {154 mL}> Removal procedure Removal: Compression rings Installation procedure Installation: Compression rings • Install the compression rings, ensuring that their end gaps are located as shown in the illustration. • Install the compression rings by following the removal sequence in reverse.
Page 322 M E M O 61-17...
Page 323 AIR COMPRESSOR <319 cm {319 mL}> 61-18...
Page 324 Disassembly sequence 1 Lock washer 10 2nd compression ring 19 Coupling 2 Compressor gear 11 3rd compression ring 20 Bearing cover 3 Cylinder head 12 Oil ring 21 Bearing 4 Gasket 13 Snap ring 22 Crankshaft 5 Valve seat 14 Piston pin 23 Crankcase 6 O-ring 15 Piston...
Page 325 AIR COMPRESSOR <319 cm {319 mL}> Removal procedure Removal: Compression rings Installation procedure Installation: Connecting rod cap and connecting rod • Assemble the connecting rod and cap while noting their align- ment marks. • Install bolts in such a way that the notches in the bolt heads are directed toward the inside of the connecting rod cap.
Page 326 M E M O 61-21...
Page 327 AIR DRYER 61-22...
Page 328 Disassembly sequence 1 Purge chamber 20 Retaining ring 39 Retaining ring 2 O-ring 21 Upper spring seat 40 Exhaust cover 3 Check valve 22 Spring 41 Retaining ring 4 Case cover 23 Lower spring seat 42 Silencer plate 5 O-ring 24 Adjusting screw 43 Silencer 6 Set spring...
Page 329 AIR DRYER Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity O-ring Adjusting screw (entire surface except thread) Multipurpose grease As required [NLGI No. 2 (Li soap)] Outer periphery of piston and O-ring groove Body (inside surface) Plug thread ThreeBond 1110B As required...
Page 330 • Place the soft layer side of the filter on the desiccant, and place the filter plate on the case, then tap the desiccant down following the manners. • Before tapping the case against the work surface, lay two or three layers of shop towel on the work surface to protect the bottom of the case from scratches.

Mitsubishi 6M60-TL Service Manual

1 Using Multi-Use Tester

2 Use of Blinking Warning Lamp for Diagnostic Code

3 Up-Time Service Tool Functions

5 Piston

Quick Links

Troubleshooting

Need help?

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Summary of Contents for Mitsubishi 6M60-TL

Page 4: Table Of Contents

Page 5: General

Page 10: Engine

Page 11: Precautions For Maintenance Operation

Page 13: Electrical

Page 20: Using Multi-Use Tester

Page 22: Use Of Blinking Warning Lamp For Diagnostic Code

Page 24: Up-Time Service Tool Functions

Page 32: Troubleshooting

Page 34: Table Of Contents

Page 35: Table Of Contents

Page 40: Valve Mechanism

Page 41: Connecting Rod

Page 115: Lubrication System

Page 122: Oil Filter Replacement

Page 125: Oil Pressure Measurement

Page 130: Oil Filter

Page 143: Fuel Filter Replacement

Page 170: Electronic Control System

Page 256: Intake Manifold

Page 258: Exhaust Manifold

Page 260: Exhaust Gas Recirculation System

Mitsubishi 6M60-TL Service Manual

1 Using Multi-Use Tester

2 Use of Blinking Warning Lamp for Diagnostic Code

3 Up-Time Service Tool Functions

5 Piston

Quick Links

Troubleshooting

Need help?

Questions and answers

Related Manuals for Mitsubishi 6M60-TL

Summary of Contents for Mitsubishi 6M60-TL

Table of Contents