Mitsubishi 6M70, Workshop Manual

Page 1: ... 17 GENERAL ENGINE LUBRICATION FUEL AND ENGINE CONTROL COOLING INTAKE AND EXHAUST EMISSION CONTROL Applicable models Mitsubishi 6M70 Workshop Manual diesel engine Mitsubishi 6M70 APPLICABLE SERVFICE BULLETINS FOR THIS MANUAL INDEX ...

Page 2: ...ode The fault warning lamp is lit at the same time 1 2 Past diagnosis code Past fault developed in the vehicle is indicated by corresponding diagnosis code stored in the memory of the elec tronic control unit With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or re pair against present diagnosis codes the present diagnosis code is stored ...

Page 3: ...ARE DISC Pub No SG0705A V C I MH062927 Data transmission between electronic control unit and PC Multi Use Tester test Harness E A Harness for inspec tion and drive recorder B Harness for drive re corder C Drive recorder har ness D Cigarette lighter plug harness MH063659 A MH063661 B MH063663 C MH063665 D MH063666 Power supply to V C I and communi cation with electronic control unit Multi Use Teste...

Page 4: ...corder function Move the starter switch to the LOCK position Connect PC installed A C D and as shown Connect C connector to the Multi Use Tester connector on the vehicle Connect the cigarette lighter plug of D to the cigarette light er socket on the vehicle 1 3 To extend the Multi Use Tester test harness Connect to A to extend the test harness to use the Multi Use Tester outside the vehicle DIAGNO...

Page 5: ...i Use Tester to delete all the diagnosis codes stored in the memory of the electronic control unit 2 2 Using flashing of a warning lamp on meter cluster 1 Engine control vehicle speed limiting SLD auto cruise Using the diagnosis and memory clear switches display diagnosis codes CAUTION Opening the memory clear switch followed by its reconnection will erase the stored diagnosis codes from the memor...

Page 6: ...diagnosis switch Present diagnosis codes will be displayed by flashing of the warning lamp When the diagnosis switch is connected electronic control unit will stop terminate displaying diagnosis codes 1 3 Present and past diagnosis codes Turn the starter switch to the ON position Open the diagnosis switch Present diagnosis codes will be displayed by flashing of the warning lamp Open the memory cle...

Page 7: ... is effected to mini mize trouble arising from the fault 2 2 Reading and erasing diagnosis codes To read a diagnosis code observe how may times the LED for inspection flashes and how long each illumination lasts The duration of illumination differs between the first and second digits Second digit 1 5 sec First digit 0 5 sec A diagnosis code consists of the flashing of second digit and the flashing...

Page 8: ...00 to 140 11 to 14 130 to 170 13 to 17 120 to 160 12 to 16 M16 90 to 120 9 to 12 90 to 110 9 to 11 170 to 220 17 to 23 160 to 210 16 to 21 200 to 260 20 to 27 190 to 240 19 to 25 M18 130 to 170 14 to 18 120 to 150 12 to 16 250 to 330 25 to 33 220 to 290 23 to 30 290 to 380 30 to 39 250 to 340 26 to 35 M20 180 to 240 19 to 25 170 to 220 17 to 22 340 to 460 35 to 47 310 to 410 32 to 42 400 to 530 41...

Page 9: ... 6 0 to 8 0 55 to 75 5 5 to 7 5 110 to 150 11 to 15 100 to 140 11 to 14 M16 90 to 120 9 to 12 90 to 110 9 to 11 170 to 220 17 to 23 160 to 210 16 to 21 M18 130 to 170 14 to 18 120 to 150 12 to 16 250 to 330 25 to 33 220 to 290 23 to 30 M20 180 to 240 19 to 25 170 to 220 17 to 22 340 to 460 35 to 47 310 to 410 32 to 42 M22 250 to 330 25 to 33 230 to 300 23 to 30 460 to 620 47 to 63 420 to 560 43 to...

Page 10: ...pe diameter φ4 76 mm φ6 35 mm φ8 mm φ10 mm φ12 mm φ15 mm Tightening torque 17 1 7 25 2 6 39 4 0 59 6 0 88 9 0 98 10 Nominal diameter wall thickness 6 1 mm 10 1 25 mm 12 1 5 mm 15 1 5 mm Tightening torque 20 2 0 34 3 5 49 5 0 54 5 5 Nominal diameter 1 4 in 3 8 in 1 2 in 5 8 in Tightening torque 13 1 3 29 3 0 49 5 0 64 6 5 6 0 0 6 0 10 0 1 0 0 10 0 1 0 0 5 0 0 5 0 4 0 0 4 0 5 0 0 5 0 5 0 0 5 0 5 0 0...

Page 11: ...N VEHICLE INSPECTION AND ADJUSTMENT 1 Measuring Compression Pressure 11 14 2 Inspection and Adjustment of Valve Clearances 11 16 3 Inspection and Adjustment of Powertard Clearances 11 20 ENGINE REMOVAL AND INSTALLATION 11 22 ROCKER COVER ROCKER AND SHAFT 11 26 CAMSHAFT AND ROCKER CASE 11 30 CYLINDER HEAD AND VALVE MECHANISM 11 38 PISTON CONNECTING ROD AND CYLINDER LINER 11 54 FLYWHEEL PTO WITH FLY...

Page 12: ...hanism Overhead camshaft OHC system Maximum output kW PS rpm 257 350 2000 309 420 2000 Maximum torque N m kgf m rpm 1620 165 1100 1810 185 1100 Cylinder bore stroke mm φ135 150 Total displacement cm3 L 12882 12 882 Compression ratio 17 5 SPECIFICATIONS Mitsubishi 6M70 Engine Parts contact email EngineParts HeavyEquipmentRestorationParts com Phone 269 673 1638 ...

Page 13: ...11 11 3 1 Mitsubishi 6M70 Engine Proper The 6M70 engine employs an overhead camshaft OHC system with the valve mechanism and the timing gears arranged as shown above STRUCTURE AND OPERATION ...

Page 14: ...ed to be replaced for a new set when one of them becomes defective 3 Valve Mechanism Each valve has a valve stem seal which regulates the flow of lubricating oil to the contact surface between the valve and the valve guide The valve springs have a variable pitch to prevent abnormal vibration at high engine speed The exhaust valves use a double spring with the inner and outer springs coiled in diff...

Page 15: ...11 11 5 4 Mitsubishi 6M60 Connecting Rod Weight mark A to H J to M A indicates the greatest connecting rod mass 5 Mitsubishi 6M70 Piston ...

Page 16: ...ars 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 A Idler gear A B A B Idler gear C B C Supply pump gear C 7 Flywheel STRUCTURE AND OPERATION ...

Page 17: ...11 11 7 8 Flywheel PTO The flywheel PTO is located in the upper part of the flywheel housing and is driven by the PTO drive gear ...

Page 18: ...m or higher than 2500 rpm although all the other conditions clutch pedal accelerator pedal and transmission conditions are met operation of the Powertard system will be canceled When the vehicle speed exceeds the auto cruise set vehicle speed during driving with the auto cruise engaged the Powertard is activated by the control of the engine electronic control unit even if the Powertard switch comb...

Page 19: ...trol of the Powertard in addition to ordinary valve control The pin is free to move in the adjusting screw Its movement is controlled by the control valve The adjusting screw is used to adjust the timing Powertard clearance for the control valve to press the pin 1 Operating principle In the ordinary engine brake the piston is forced up during its compression stroke when compressed air A develops a...

Page 20: ...peration of the system which causes the valve to be opened and closed in agreement with the successive piston strokes is called synchronized operation As shown above when the Powertard system is activated the engine brake provides more power than the ordinary engine brake 2 Hydraulic pressure control When the solenoid valve is activated engine oil oil pressure produced by ordinary engine oil pump ...

Page 21: ...ath A for engine oil from the rocker case and opens the out going path B to the cylinder head Engine oil in the oil passage is let out through B relieving the control valve of oil pressure The control valve opens the path C that has been closed by oil pres sure to let out engine oil in the chamber of the slave piston and oil passage As the oil pressure is removed the master piston is lowered to le...

Page 22: ...and damaged O O Piston ring s worn and damaged O O Piston pin and connecting rod small end worn O Crankshaft Crankshaft end play excessive O Fan pulley improperly mounted O Crankshaft pins and connecting rod bearings worn or damaged O Crankshaft journals and main bearings worn or damaged O Fuel system Defective supply pump O O Gr13 Defective injector O O Air trapped in fuel system O Cooling system...

Page 23: ...witch O O Defective meter cluster O O Defective engine speed sensor O O Defective powertard solenoid valve O O Defective engine control unit O O Defective ABS exhaust brake cut relay ABS ASR O O Gr35 Defective Powertard O O Valve mechanism Broken or weak exhaust valve springs O Exhaust valve sticky or not smooth in operation O Improperly adjusted powertard clearance O Oil leakage in Powertard syst...

Page 24: ...ies Place the transmission in N range Turn the steering wheel in neutral position Remove the fuse M25 from the fuse box in the cab to prevent fuel from being injected while the engine is cranked using the starter CAUTION When cranking the engine never shut off the power sup plied to the engine electronic control unit by disconnecting the engine electronic control unit connector or other similar me...

Page 25: ...a compression gauge to Crank the engine and measure the compression pressure Measure the compression pressure for all the cylinders one after another Determine the compression pressure difference be tween the cylinders If the compression pressure is below the limit or the pressure dif ference between each cylinder is not within the limit pour a small amount of engine oil into the corresponding mou...

Page 26: ...e No 1 and No 6 cylinder pistons With the No 1 or No 6 cylinder piston at TDC measure the clearance of the valves clearance between valve bridge and pad marked with a circle in the table below Any attempt to insert a feeler gauge without first securing suffi cient space as described above between the pad and the valve bridge will fail as the pad will tilt as shown in the illustration thus blocking...

Page 27: ...e inserted smoothly If the measurement deviates from the standard value adjust as follows Adjustment Loosen the lock nuts and adjusting screws on the valve bridge and rocker arm While holding the valve bridge by hand screw in the adjusting screw until it lightly contacts the valve stem end Then further screw in the adjusting screw by 45 While holding the adjusting screw in this position tighten th...

Page 28: ...e specified torque Recheck the valve clearance using the correct feeler gauge CAUTION If the valve clearance has been adjusted be sure to check and adjust the Powertard clearance See later section After the adjustment is complete install the rocker cover and the gasket See ROCKER COVER ROCKER AND SHAFT ON VEHICLE INSPECTION AND ADJUSTMENT Mitsubishi 6M70 Engine Parts contact email EngineParts Heav...

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Page 30: ...ntil the pointer is aligned with the 1 6 mark on the flywheel This will place either the No 1 or No 6 cylinder piston at TDC on the compression stroke The cylinder in which the rocker arms for both the intake and exhaust valves can be pushed down by hand by the valve clearance amounts has its piston at TDC Rotate the engine by one full turn to switch the TDCs of the No 1 and No 6 cylinder pistons ...

Page 31: ... clearance If any measurement is out of specification make adjustment as follows Adjustment To adjust Powertard clearance loosen the lock nut then tighten the adjusting screw until the moves somewhat stiffly in the gap Holding the adjusting screw in that position with a screwdriver tighten the lock nut to lock the adjusting screw Recheck the Powertard clearance using the Cylinder No Powertard clea...

Page 32: ...t N m kgf m Mark Parts to be tightened Tightening torque Remarks Nut front mounting installation 300 to 400 30 to 40 Nut rear mounting installation 120 to 160 12 to 16 Bolt rear mounting installation 70 to 95 7 0 to 9 5 1 Engine 2 Rear mounting 3 Front mounting Locating pin ENGINE REMOVAL AND INSTALLATION ...

Page 33: ...piping and other relevant parts have been disconnected Remove the bolts and nuts from the engine mounts Slowly lift the engine taking care not to hit the engine against the frame or cab Once the bottom of the engine is out of the frame turn the en gine by 90 and remove it out of the vehicle Inspection procedure Inspection Mounting Check the entire circumference of the rubber cushion of the mountin...

Page 34: ... engine Make sure that the stud of the rear mounting is placed at the il lustrated position lowermost part of the slot on the support side The slot on the cross member side needs not necessarily be on the lowermost part If the stud is not placed at the illustrated position adjust the posi tion with the cross member and support Tighten cross member and support mounting bolts and nuts to the torque ...

Page 35: ...M E M O 11 25 11 ...

Page 36: ...11 26 MITSUBISHI 6M70 ROCKER COVER ROCKER AND SHAFT ...

Page 37: ... rocker cover on it immediately after applying sealant CAUTION Never run the engine for one hour after installation If the rocker cover is removed after installation never fail to replace the packing and apply the sealant again Mark Parts to be tightened Tightening torque Remarks Bolt rocker cover mounting 8 8 0 9 6 5 Ft Lbs Oil pipe 44 4 5 M10 bolt slave piston housing mounting 55 5 5 Bolt rocker...

Page 38: ...ance item Standard value Limit Remedy 2 6 8 Clearance between rocker shaft and bushing 0 027 to 0 088 0 2 Replace 3 7 Radial clearance of rocker roller 0 068 to 0 112 Replace Mark Parts to be tightened Tightening torque Remarks Lock nut adjusting screw tightening 60 6 Mark Points of application Specified lubricant and or sealant Quantity Inside surface of rocker bushing Engine oil As required Mark...

Page 39: ...tion Clearance between rocker shaft and bushing If the measurement exceeds the limit replace the bushing Replace of rocker bushing Removal Installation Assemble the bushing onto the rocker such that the oil holes are aligned as shown in the illustration After assembly measure the clearance again If the measurement is less than the standard value ream the bushing ...

Page 40: ...11 30 MITSUBISHI 6M70 CAMSHAFT AND ROCKER CASE ...

Page 41: ... to 0 165 0 35 Replace 5 Powertard solenoid valve resistance at temperature 25 C 32 6 to 39 8 Ω Replace Mark Parts to be tightened Tightening torque Remarks Bolt camshaft cap mounting 80 8 Nut connector mounting 49 5 0 Bolt rocker case mounting 19 1 9 Bolt master piston housing mounting 54 5 5 Mark Points of application Specified lubricant and or sealant Quantity Camshaft journals and cams Engine ...

Page 42: ... Inspection Resistance in Powertard solenoid valve If the measurement deviates from the standard value replace the Powertard solenoid valve Removal procedure Removal Rocker case gasket CAUTION Be careful not to scratch the cylinder head and timing gear case when removing the rocker case gasket Cleaning procedure Cleaning Powertard solenoid valve Brush the oil screen clean and dry it with compresse...

Page 43: ...on Within three minutes following the application install the rocker case together with the rocker case gasket on the cylinder head CAUTION Do not start the engine for at least an hour after installation Whenever the rocker case mounting bolts are subsequently loosened or removed the rocker case gasket must be re placed and sealant reapplied upon reassembly Installation Camshaft Make sure that eac...

Page 44: ...l Location Maintenance item Standard value Limit Remedy 1 3 Interference between camshaft gear and camshaft 0 017 to 0 058 Replace 3 Camshaft Differ ence of cam lobe diameter and base circle di ameter Intake side Lobe diame ter 61 233 8 233 7 74 Replace Base circle diameter 53 000 Exhaust side Lobe diame ter 61 367 Base circle diameter 53 133 8 234 7 72 Powertard Lobe diame ter 60 147 Base circle ...

Page 45: ...mshaft 2 Bend Measure the camshaft at the center journal for bend while sup porting the shaft at the end journals A half of the dial gauge reading obtained as the camshaft is ro tated by a full turn represents the bend of the camshaft If the measurement exceeds the limit replace the camshaft 3 Oil clearance at journal If the measurement exceeds the limit replace the defective part s CAUTION The ca...

Page 46: ... gear as shown in the illustration press it onto the camshaft until it seats snugly on the camshaft WARNING You may burn yourself if you touch the heated camshaft gear CAUTION When installing the camshaft gear be sure to apply the load with the press at the center of the gear Apply the load on the gear may damage the gear CAMSHAFT AND ROCKER CASE ...

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Page 48: ...11 38 MITSUBISHI 6M70 CYLINDER HEAD AND VALVE MECHANISM ...

Page 49: ...nder head bolt 180 NM 18 kgfm 133 Ft Lbs Plus 90 Wet Can be reusable up to 3 times Bolt idler shaft mounting 55 5 5 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Threaded of bolt Outer periphery of idler shaft Inside surface of idler gear bushing Top mating surfaces of flywheel housing and crankcase ThreeBond 1211 As required Mating surfaces o...

Page 50: ...efective part s 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 Mark Tool name and shape Part No Application Socket wrench MH063388 Installation of cylinder head ME350196 Removal and installation of idler gear bushing Idler gear bushing pulle...

Page 51: ...ng when removing the cylinder head gasket Inspection procedure Inspection Clearance between idler shaft and idler gear bushing If the measurement exceeds the limit replace the bushing Replacement of idler gear bushing Removal Installation Press in the bushing until contacts the end face of idler gear D After installation measure the clearance again If the measurement is less than the specified val...

Page 52: ...o punch marks can be reused The number of punch marks indicates the number of times the bolt has been tightened in the past within the plastic re gion If there are three punch marks tightened three times in the past replace the bolt Remove oil or any other contamination from the surfaces where sealant is to be applied Apply sealant onto the areas shown in the illustration on the top surfaces of th...

Page 53: ...change in pro trusion See PISTON CONNECTING ROD AND CYLINDER LINER Tighten the cylinder head bolts to a torque of 180 N m 18 kgf m in the order shown in the illustration Install the bolts Further tighten the bolts in the order shown and as follows Turn the holder of counterclockwise to pretension the inter nal spring Set the tool such that the rod extension is pressed against the rocker shaft brac...

Page 54: ...r retainer 6 Valve spring Intake Outer valve spring Exhaust 7 Inner valve spring Exhaust 8 Valve stem seal 9 Exhaust valve 10 Intake valve 11 Valve bridge guide 12 Exhaust valve guide 13 Intake valve guide 14 Exhaust valve seat 15 Intake valve seat 16 Nozzle tube 17 O ring 18 Cylinder head Non reusable parts MITSUBISHI 6M70 CYLINDER HEAD AND VALVE MECHANISM Mitsubishi 6M70 Engine Parts contact ema...

Page 55: ...alve guide clearance 0 07 to 0 10 0 2 Replace 10 6M70 Intake valve Stem outer diameter 9 96 to 9 975 9 85 Replace Sinkage from cylinder head bottom surface 0 5 0 25 1 0 Replace Valve margin 2 83 2 33 Replace Seat angle 60 15 Rectify 10 13 6M70 Intake valve stem to valve guide clearance 0 035 to 0 065 0 2 Replace 11 6M70 Outer diameter of valve bridge guide 10 989 to 11 10 988 Replace 14 6M70 Exhau...

Page 56: ...seats ME350051 Installation of valve bridge guides Valve guide remover MH062177 Removal of valve guides ME350052 Installation of Mitsubishi 6M70 valve guides Caulking tool body MH062174 Installation of Mitsubishi 6M70 intake valve seats exhaust valve seats Installer ring MH062175 A φ 42 Valve stem seal installer A B φ 22 φ 11 Valve bridge guide installer A B φ 11 56 Valve guide installer A B C φ 2...

Page 57: ...spring does not lean to one side Removal Nozzle tube Mark Tool name and shape Part No Application MH061232 Removal of nozzle tube MH061231 Installation of Mitsubishi 6M70 nozzle tube ME350195 MH061229 Nozzle tube remover A B φ 8 7 φ 12 5 Nozzle tube installer bolt A B φ 8 5 M18 1 5 Nozzle tube installer body A M18 1 5 Nozzle tube stamp A φ 8 ...

Page 58: ...ge guide must be installed to the specified depth of the cylinder head Correct installation can only be possible by using Inspection Mitsubishi 6M70 Intake and exhaust valve 1 Valve stem outer diameter If the measurement is less than the limit or the valve is worn ex tremely unevenly replace the valve When the valve has been replaced with a new one make sure to lap the valve and valve seat 2 Valve...

Page 59: ... for the exhaust valves are longer than the valve guides for the inlet valves Inspection Contact between valve and valve seat Before starting inspection check that the valve and valve guide are intact Apply an even coat of red lead to the valve contact surface of the valve seat Strike the valve once against the valve seat Do not rotate the valve during this operation If the red lead deposited on t...

Page 60: ... Inspection Mitsubishi 6M70 Valve seats If the valve seat is refaced or replaced after performing the fol lowing inspection make sure to lap the valve and valve seat 1 Valve seat width If the measurement exceeds the limit reface or replace the valve seat 2 Valve sinkage from cylinder head bottom surface Perform measurement keeping the valve in close contact with the valve seat If the measurement e...

Page 61: ...om the standard value replace the cylinder head Chill the valve seat thoroughly by immersing in it in liquid nitro gen Drive in the valve seat using with the chamfered side of facing the cylinder head After driving in reverse the direction of and crimp the valve seat After reassembly make sure to lap the valve and valve seat Inspection Cylinder head bottom surface distortion If the distortion exce...

Page 62: ... airtightness Installation Mitsubishi 6M70 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 After assembly check that its spring is not deformed or dam aged Installation Mitsubishi 6M70 Valve spring Install the outer and inner valve springs onto the cylinder head while facing them as shown in the illustration Inst...

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Page 64: ... 1 3 Connecting rod bearing Oil clearance 0 06 to 0 122 0 25 Replace Span when free 90 5 4 5 Piston and cylinder liner clearance 0 247 to 0 277 Replace 5 Cylinder liner Flange protrusion 0 01 to 0 07 Replace Inner diameter φ135 to 135 03 φ135 25 Cylindricity 0 03 or less Difference in protrusion of adjacent flange 0 04 or less Mark Parts to be tightened Tightening torque Remarks Nut connecting rod...

Page 65: ...iners by holding their flanges with bolts and washers Mark Tool name and shape Part No Application Piston guide clamp MH061667 Installation of piston and connecting rod Piston guide lever MH061658 Socket wrench MH061560 MH062194 Removal of cylinder liner Adapter ME350054 Measurement of cylinder liner flange protrusion and step height between adjacent cylinder liners Bolt MF130651 Washer MF450009 C...

Page 66: ...s Inspection Cylinder liner flange protrusion and step height between adjacent cylinder liners Install so that it does not run onto the cylinder liner flange and tighten and to the torque of 49 N m 5 kgf m Measure the cylinder liner flange protrusion If the measurement deviates from the standard value inspect the installation and replace the defective part s If the difference in the adjacent flang...

Page 67: ...ds the limit replace the defective part s If a bearing has to be replaced with an undersized one machine the crankshaft pin to the specified undersize diameter See CRANKSHAFT AND CRANKCASE Inspection Mitsubishi 6M70 Piston and cylinder liner clearance If the value calculated from the measurement deviates from the standard value replace the defective part s A Measuring point on the crankcase in dir...

Page 68: ...AUTION Using a piston with the size mark different from the size mark of cylinder liner can lead to engine seizure Apply a thin coat of engine oil onto the outer periphery hatched area of the cylinder liner While pushing the cylinder liner evenly with hands gently insert the cylinder liner into the crankcase CAUTION Cylinder liners are thinly structured Therefore they must be handled with extreme ...

Page 69: ...at the size mark A B on the piston is the same as that on the cylinder liner Face the front mark of the piston toward the front of the en gine With and installed around the piston skirt tighten the adjusting bolt of until the inside diameter of matches the outside diameter of the piston skirt After adjustment remove and from the piston Apply engine oil to the following areas Then install and over ...

Page 70: ...he 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 Align any line on the holder scale with any line on the socket scale This will be used as the reference point 0 From the reference point turn the socket by 120 in the direction shown Each division on the socket scale represents 5 Aft...

Page 71: ...M E M O 11 61 11 ...

Page 72: ...ing 0 5 to 0 65 Oil ring 0 4 to 0 6 1 to 3 9 Clearance between piston ring and piston ring groove 1st compression ring 0 015 to 0 06 0 15 Replace 2nd compression ring 0 085 to 0 125 0 25 Oil ring 0 025 to 0 065 0 15 5 6 Clearance between piston pin and connecting rod bushing 0 02 to 0 055 0 1 Replace 5 9 Clearance between piston pin and piston 0 004 to 0 022 0 1 Replace 8 Connecting rod Bend 0 05 ...

Page 73: ...rown of a piston push the piston ring horizontally into a cylinder in the crankcase until it reaches the lower part of the cylinder liner where there is relatively small wear Taking care not to move the piston ring measure the end gap If the measurement exceeds the limit replace all the piston rings as a set Mark Tool name and shape Part No Application Piston ring tool 31191 02900 Removal and inst...

Page 74: ...l the pis ton rings as a set The clearance of the 1st compression ring must be measured using a thickness gauge while holding the ring against the piston ring groove with a straight edge Inspection Clearance between piston pin and piston If the measurement exceeds the limit replace the defective part s Inspection Mitsubishi 6M70 Clearance between piston pin and connecting rod bushing If the measur...

Page 75: ... 5 000 kgf to the puller until the bushing is forced into place After assembly measure the clearance again If the measurement is less than the standard value ream the bushing 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 c...

Page 76: ... pin is difficult to insert first heat the piston in hot wa ter or with a piston heater Then install the piston Installation Mitsubishi 6M70 Piston rings With the manufacturer s marks found near the piston ring end gaps facing up install the piston rings so that the end gap of each ring is positioned as shown in the illustration A 1st compression ring end gap B 2nd compression ring end gap C Oil r...

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Page 78: ...lash of gears 0 19 to 0 62 0 8 Replace Mark Parts to be tightened Tightening torque Remarks Eyebolt 21 2 1 Nut PTO gear installation 220 22 Nut flange installation 178 17 8 1 Eyebolt 2 Oil pipe 3 PTO bracket 4 Washer 5 PTO gear 6 Washer 7 Flange 8 Oil seal 9 Cover 10 Gasket 11 Roller bearing 12 PTO shaft 13 Ball bearing 14 PTO head 15 O ring a Flywheel housing Non reusable parts FLYWHEEL PTO WITH ...

Page 79: ...t of specification check each gear for wear and replace if necessary Check the PTO idler gear A PTO idler gear B and drive gear for wear See TIMING GEARS WITH FLYWHEEL PTO Removal procedure Removal Roller bearing and PTO shaft Remove the roller bearing and PTO shaft in the direction shown in the illustration Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil A...

Page 80: ...stallation Oil seal Fit the oil seal oriented as shown in the illustration Installation Split pin After fitting bend the split pin in the illustrated direction Installation PTO head Make sure that the PTO shaft turns lightly by hand before install ing the PTO head onto the flywheel housing FLYWHEEL PTO WITH FLYWHEEL PTO ...

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Page 82: ...e past replace the bolt 1 Snap ring 2 Pilot bearing 3 Ring gear 4 Flywheel 5 Rear oil seal 6 Power steering oil hose 7 O ring 8 Suction hose 9 Power steering oil pump See Gr37 10 O ring 11 O ring 12 Collar 13 Engine speed sensor 14 Stiffener 15 Air suction hose 16 Eyebolt 17 Air suction pipe 18 Eyebolt 19 Air outlet pipe 20 Eyebolt 21 Water outlet pipe 22 Eyebolt 23 Water inlet pipe 24 Eyebolt 25 ...

Page 83: ...used up to 3 times With PTO 100 10 150 Power steering oil hose 68 7 0 Bolt power steering oil pump mounting 74 7 5 Nut collar mounting 100 10 Engine speed sensor 25 2 5 Bolt rear oil seal mounting 12 1 2 Bolt flywheel housing mounting 80 8 0 Eyebolt oil pipe mounting 21 2 1 Eyebolt air outlet pipe mounting 100 10 Eyebolt water inlet pipe mounting 50 5 1 Eyebolt water outlet pipe mounting Eyebolt a...

Page 84: ...e bolts inserted into the dedicated holes in the flywheel Removal Ring gear Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200 C then remove it from the flywheel WARNING You may burn yourself if you touch the heated ring gear Removal Collar Install bolts M4 x 0 7 mm into the dedicated holes in the collar and pull the bolts to remove the collar Inspection pro...

Page 85: ...lant onto the flywheel housing surface where the crankcase is to be mounted Within three minutes following the application install the fly wheel housing onto the crankcase When installing the flywheel housing take care not to spread the sealant beyond the applica tion area CAUTION Do not start the engine at least for an hour after the flywheel housing has been installed If the flywheel housing mou...

Page 86: ...l not to dislodge the sealant CAUTION Do not start the engine at least for an hour after the rear oil seal has been installed If the rear oil seal mounting bolts are subsequently loos ened be sure to apply sealant again upon reassembly Installation Ring gear Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200 C WARNING You may burn yourself if you touch the h...

Page 87: ...cket scale This will be used as the reference point 0 From the reference point turn the socket by 90 Without fly wheel PTO 150 With flywheel PTO clockwise Each divi sion on the socket scale represents 5 After tightening the bolt within the plastic region make a punch mark on the bolt head for subsequent identification CAUTION The bolts should be tightened within the plastic region Never tighten th...

Page 88: ...een idler shaft C and idler gear bushing 0 036 to 0 08 0 2 Replace 3 9 Idler gear end play 0 1 to 0 2 0 4 Replace 8 10 Clearance between idler shaft A B and idler gear bush ing 0 025 to 0 066 0 2 Replace Mark Parts to be tightened Tightening torque Remarks Bolt idler gear C mounting 80 8 0 Idler shaft bolt idler gear A B mounting 155 16 1 Idler shaft C 2 Idler gear bushing 3 Idler gear C 4 Thrust ...

Page 89: ...urement exceeds the limit replace the defective part s Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Inside surface of bushing of gears Mark Tool name and shape Part No Application ME350197 Removal of idler gear bushing ME350198 Installation of idler gear bushing MH062046 Removal and installation of idler gear bushing Idler gear bushing puller...

Page 90: ...stall until it contacts the idler gear with idler gear C facing in the illustrated direction After installation measure the clearance again If the measurement is less than the standard value ream the bushing Inspection Clearance between idler shaft A B and idler gear bushing Inspection If the measurement exceeds the limit replace the bushing Replacement of idler gear bushing Removal TIMING GEARS W...

Page 91: ...m the bushing Installation procedure Installation idler gear Install idler gear A B such that the alignment mark A on the gear is aligned with the alignment mark A on the crankshaft gear When installing idler gear C ensure that the alignment mark B on the gear is aligned with the alignment mark B on idler gear A B and that the alignment mark C on idler gear C is aligned with the alignment mark C o...

Page 92: ...ar bushing 9 PTO idler gear B 10 Idler shaft C 11 Idler gear bushing 12 Idler gear C 13 Thrust plate C 14 Idler gear bushing 15 Idler gear A B 16 Idler shaft A 17 PTO drive gear a Supply pump gear b Rear plate c Crankcase d Crankshaft gear Locating pin Non reusable parts MITSUBISHI 6M70 TIMING GEARS WITH FLYWHEEL PTO Mitsubishi 6M70 Engine Parts contact email EngineParts HeavyEquipmentRestorationP...

Page 93: ... 10 PTO idler gear bushing to idler shaft C clearance 0 036 to 0 08 0 2 Replace 10 11 Idler gear bushing to idler shaft C clearance 0 04 to 0 08 0 2 Replace 14 16 Idler gear bushing to idler shaft A clearance 0 03 to 0 06 0 2 Replace Mark Parts to be tightened Tightening torque Remarks Idler shaft bolt for installing PTO idler gear A idler gear A B 155 16 Bolt for installing PTO idler gear B idler...

Page 94: ...the measurement exceeds the limit replace the defective part s Inspection procedure Inspection Clearance between PTO idler gear bushing and idler shaft B Inspection If the measurement exceeds the limit replace the bushing Replacement of PTO idler gear bushing Removal MH061256 Removal and installation idler gear bushings Mark Tool name and shape Part No Application Idler gear bushing puller A B C φ...

Page 95: ... and idler shaft C Inspection If the clearance exceeds the limit replace the bushing Replacement of PTO idler gear bushing Removal Installation Install until it contacts the PTO idler gear B with PTO idler gear B facing in the illustrated direction After installation measure the clearance again If the measurement is less than the standard value ream the bushing Inspection Clearance between idler s...

Page 96: ...lue ream the bushing Inspection Clearance between idler gear bushing and idler shaft A Inspection If the clearance exceeds the limit replace the bushing Replacement of idler gear bushing Removal Installation Install until it contacts the idler gear with idler gear A B fac ing in the illustrated direction After installation measure the clearance again If the measurement is less than the standard va...

Page 97: ...A on the gear is aligned with the alignment mark A on the crankshaft gear When installing idler gear C ensure that the alignment mark B on the gear is aligned with the alignment mark B on idler gear A B and that the alignment mark C on idler gear C is aligned with the alignment mark C on the supply pump gear ...

Page 98: ...11 88 MITSUBISHI 6M70 CRANKSHAFT AND CRANKCASE ...

Page 99: ...ree 106 5 Replace 12 Crankshaft End play 0 09 to 0 23 0 4 Replace thrust plate Bend 0 04 or less 0 1 Replace Pins and journals Roundness 0 01 or less 0 03 Rectify or replace Cylindricity 0 006 or less Rectify or replace Center to center distance between the journal and pin 75 0 07 Replace Journal width 42 0 3 Replace Pin width 54 Replace Fillet R5 Replace 19 Crankcase Distortion of top surface 0 0...

Page 100: ...icant and or sealant Quantity Front oil seal lip Engine oil As required Thread of bolts Inside surface of main bearing Mark Tool name and shape Part No Application Socket wrench MH063365 Installation of main bearing cap MH061817 Installation of front oil seal slinger MH061652 Installation of ring Gear puller MH061061 Removal of crankshaft gear Front oil seal slinger installer A φ 108 Rear oil seal...

Page 101: ...er using a chisel or a similar tool Removal Ring Taking care not to damage the crankshaft split the slinger using a chisel or a similar tool Removal Crankshaft gear CAUTION Do not tap off the crankshaft gear as this can damage it Inspection procedure Inspection Main bearing 1 Main bearing span when free If the measurement less than the limit replace the upper and lower bearings as a set CAUTION Do...

Page 102: ...ft journal to one of the specified undersize dimensions Inspection Crankshaft 1 Bend Measure the crankshaft at the center journal for bend while sup porting the shaft at the end journals A half of the dial gauge reading obtained as the crankshaft is ro tated by a full turn represents the bend of the crankshaft If the measurement exceeds the limit replace the crankshaft 2 Roundness and cylindricity...

Page 103: ...mality replace the crankshaft Mitsubishi 6M70 Crankshaft undersize dimensions Unit mm When grinding turn both the crankshaft and the grinder counter clockwise as viewed from the crankshaft front end When finishing the crankshaft with whestone or sandpaper ro tate the crankshaft clockwise Inspection Distortion of crankcase top surface If the measurement exceeds the limit correct the crankcase top s...

Page 104: ...l housing Installation Crankshaft gear Heat the crankshaft gear to approximately 100 C with a burner or the like WARNING You may burn yourself if you touch the heated crankshaft gear Align the locating pin fitted in the crankshaft with the notch in the crankshaft gear Drive the gear into position by lightly striking its end face with a plastic hammer Installation Rear oil seal slinger Install the ...

Page 105: ...ng cap and the rear end of the crankcase ensuring that the oil grooves face outside If oversized thrust plates are to be used those with and marks must be the same in size Oversizes available 0 15 mm 0 30 mm and 0 45 mm CAUTION If thrust plates are installed with the oil grooves facing in side the engine may seize Installation Main bearing cap CAUTION Before installing bolts check the number of pu...

Page 106: ...nce point turn the socket by 130 in the direction shown Each division on the socket scale represents 5 After tightening the bolt within the plastic region make a punch mark on the bolt head to record the number of times that they have been tightened CAUTION The bolts should be tightened within the plastic region Never tighten them further than the specified angle After tightening the bolt rotate t...

Page 107: ...l Filter 12 7 6 Engine Oil Pressure Switch 12 7 7 Regulator Valve 12 7 8 Lubrication of Engine Components 12 8 TROUBLESHOOTING 12 11 ON VEHICLE INSPECTION AND ADJUSTMENT 1 Oil Filter Replacement 12 12 2 Engine Oil Replacement 12 14 3 Oil Pressure Measurement 12 15 OIL PAN OIL JETS 12 16 OIL PUMP OIL STRAINER 12 18 OIL FILTER 12 22 OIL COOLER 12 24 REGULATOR VALVE 12 26 ...

Page 108: ...ter Filter paper element center bolt type Oil cooler Shell and plate type multiple plate type Engine oil Grade API classification CD CD SF CE CE SF CF 4 or JASO classification DH 1 DH 2 Quantity dm3 L Oil pan Approx 31 5 31 5 Oil filter 4 to 4 5 4 to 4 5 SPECIFICATIONS ...

Page 109: ... No 6 14 Powertard solenoid valve 15 Main oil gallery 16 Regulator valve 17 Check valve for oil jet 18 Piston 19 Air compressor 20 Turbocharger 21 Main bearing 22 Connecting rod bearing 23 Connecting rod bushing 24 Idler gear A B 25 Oil spray plug 26 Oil spray plug 27 Bypass oil filter 28 Oil cooler bypass valve 29 Oil cooler 30 Full flow oil filter 31 Engine oil bypass alarm switch 32 Relief valv...

Page 110: ...itted through the engagement of the crankshaft gear and the oil pump gear The oil pump has a relief valve which prevents excessive pressure from building up inside the lubricating sys tem by allowing part of the engine oil to escape to the oil pan when the oil pressure exceeds a specified level STRUCTURE AND OPERATION ...

Page 111: ...ss 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 main oil gallery ...

Page 112: ...ngine to seize To prevent this the engine oil bypass alarm switch is installed If the full flow oil filter clogs up the en gine oil bypass alarm switch trips in such a way as to direct the engine oil straight on to the oil cooler bypassing the filter elements When the engine oil bypass alarm switch trips the rele vant warning lamp illuminates to alert the operator to the clogged full flow oil filt...

Page 113: ...l gallery drops below the specified value the engine oil pres sure switch trips and illuminates the relevant warning lamp to alert the op erator to the abnormal oil pressure 7 Mitsubishi 6M70 Regulator Valve If the oil pressure in the main oil gal lery exceeds the specified value the regulator valve opens and returns a portion of the engine oil to the oil pan to adjust the oil pressure ...

Page 114: ... connecting rod s small end connecting rod bushing Beside engine oil is sprayed out of the oil jet in the head of the connecting rod into the piston to cool the piston 8 2 Mitsubishi 6M70 Timing gears Engine oil in the main oil gallery is directed through the oil passages in the crankcase and cylinder head and is used to lubricate the various gear shafts After lubricating the gear shafts the oil i...

Page 115: ...icates the valve bridges After lubricating the various parts the oil returns to the oil pan 8 4 Mitsubishi 6M70 Check valves and oil jets An oil jet is fitted in the lower part of the main oil gallery for each cylinder Engine oil is sprayed out of the oil jet into the piston to cool the piston Each oil jet is fitted with a check valve that opens and closes at predeter mined oil pressure levels At ...

Page 116: ...mp The engine oil supplied to the supply pump lubricates the inside of the pump and supply pump gear After lubricating the inside of the pump the oil is directed through the timing gear train from the rear of the pump and returns to the oil pan 8 7 Mitsubishi 6M70 Air compressor The engine oil in the main oil gallery lubricates the inside of the air com pressor is directed through the timing gear ...

Page 117: ...l pipe O O Clogged oil strainer O O Weakened relief valve spring O Oil filter Incorrect installation O Clogged element O O Defective O ring O Front cover Defective front oil seal O Gr11 Incorrectly mounted front cover O Flywheel housing Defective rear oil seal O Incorrectly mounted flywheel housing O Weakened regulator valve spring O Defective piston cooling oil jet s O O Oil working its way up in...

Page 118: ...resulting in deteriorated performance of the cooling system Do not reuse the oil filter elements by washing Install the gasket taking care not to twist it Removal Remove the drain plug and drain the oil out of the oil filter Mark Parts to be tightened Tightening torque Remarks Drain plug oil filter 24 5 4 9 2 5 0 5 Center bolt 63 7 4 9 6 5 0 5 Mark Points of application Specified lubricant and or ...

Page 119: ... respec tively Install the oil filter case so that the drain plug is positioned as shown in the illustration With the oil filter installed start the engine and ensure that there is no oil leakage through the gasket If oil is leaking remove and reinstall the oil filter Stop the engine and check the engine oil level Add engine oil if the engine oil level is low ...

Page 120: ...ngine oil into the engine Wait at least for 6 minutes after installing the filler cap and check the engine oil level Start the engine and ensure that there is no oil leakage Stop the engine wait at least for 30 minutes and check the en gine oil level Add engine oil if the engine oil level is low CAUTION Do not add engine oil too much An excessive oil level can only lead to increased oil consumptio...

Page 121: ...peed and then at maximum speed both under no load If the measurements are below the specified limits overhaul the lubrication system CAUTION Reinstall the oil pressure switch only when the engine is cold Location Maintenance item Standard value Limit Remedy Oil pressure oil tempera ture at 70 to 90 C No load minimum speed 135 to 295 kPa 1 4 to 3 kgf cm2 49 kPa 0 5 kgf cm2 Inspect No load maximum s...

Page 122: ...mbly sequence Follow the disassembly sequence in reverse CAUTION If overtightened the check valve will not operate properly leading to engine seizure Be sure to tighten the check valve to the specified torque Tightening torque Unit N m kgf m Lubricant and or sealant Mark Parts to be tightened Tightening torque Remarks Drain plug 68 7 Check valve 34 3 5 Mark Points of application Specified lubrican...

Page 123: ...d without any breaks Change the amount of application to A and B at four locations shown in the illustration Mount the oil pan within three minutes of applying the sealant Make sure that the sealant stays in place CAUTION Do not start the engine less than an hour after installation If the oil pan mounting bolts were loosened or removed be sure to reapply sealant ...

Page 124: ...between case and tooth tips of each gear 0 2 to 0 29 0 35 Replace Difference between case depth and height of each gear 0 05 to 0 12 0 15 8 Relief valve spring installed load installed length 47 7 190 11 N 19 4 1 1 kgf 179 N 18 3 kgf Replace 9 Relief valve opening pressure 0 9 MPa 9 kgf cm2 0 9 MPa 9 kgf cm2 Replace 10 11 Clearance between idler shaft and idler gear 0 03 to 0 06 0 15 Replace 11 a ...

Page 125: ...red 1 Difference between case depth and height of each gear 2 Clearance between case and tooth tips of each gear Mark Parts to be tightened Tightening torque Remarks Bolt oil pump cover mounting 44 4 9 4 5 0 5 Nut idler shaft mounting 69 10 7 1 Thread locking compound Mark Points of application Specified lubricant and or sealant Quantity Nut thread Loctite 262 As required Sliding parts of oil pump...

Page 126: ... cover 4 Clearance between driven gear shaft and case and that between the shaft and cover Installation procedure Installation Idler shaft Install the idler shaft so that is positioned within the area shown in the illustration OIL PUMP OIL STRAINER ...

Page 127: ...M E M O 12 21 12 ...

Page 128: ...res To avoid any risk of burns take care not to touch the engine oil when the engine is hot CAUTION When adding engine oil be careful not to allow engine oil to smear the belt A belt smeared with oil will slip resulting in reduced cooling efficiency Do not reuse the oil filter elements by washing Install the gasket taking care not to twist it Tightening torque Unit N m kgf m Mark Parts to be tight...

Page 129: ...M E M O 12 23 12 ...

Page 130: ...aintenance item Standard value Limit Remedy 1 Bypass valve opening pressure 294 50 kPa 3 0 0 5 kgf cm2 244 kPa 2 5 kgf cm2 Replace 5 Air leakage from oil cooler element air pressure 1 47 MPa 15 kgf cm2 15 seconds 0 cm3 0 mL Replace Mark Parts to be tightened Tightening torque Remarks Bypass valve 15 to 20 1 5 to 2 0 Bolt oil cooler cover mounting 54 5 5 Regulator valve 98 to 118 10 to 12 Nut oil c...

Page 131: ...the outlet of the oil cooler element and connect a hose to the engine oil inlet port Then immerse the oil cooler element in a tank of water Apply a specified air pressure for 15 seconds through the hose and check for any air leaks Replace the element if it leaks air ...

Page 132: ...he disassembly sequence in re verse Service standards Unit mm Location Maintenance item Standard value Limit Remedy Regulator valve opening pressure 0 49 0 03 MPa 5 0 0 3 kgf cm2 Replace 3 Spring installed load installed length 48 3 78 2 N 8 0 0 2 kgf Replace MITSUBISHI 6M70 REGULATOR VALVE ...

Page 133: ...med at Electronic Control Unit Connectors 13 54 ON VEHICLE INSPECTION AND ADJUSTMENT 1 Inspecting No load Minimum and Maximum Speeds 13 58 2 Inspection of Fuel Leakage 13 59 3 Inspection of Injection Pipe and Fuel Pipe Mounting Clamp 13 59 4 Draining of Deposit in Fuel Tank 13 59 5 Air bleeding of Fuel System 13 60 6 Fuel Filter Replacement 13 61 7 Cleaning of Gauze Filter 13 62 8 Water Separator ...

Page 134: ...e cm3 mL 20 20 Pressure limiting valve opening pressure MPa kgf cm2 185 to 195 1886 to 1988 Common rail pressure sensor supply voltage V 5 Injectors Manufacturer Bosch Control method Electronic Max operating pressure MPa kgf cm2 160 1631 Min operating pressure MPa kgf cm2 25 255 Common rail electronic control unit Manufacturer Bosch Rated voltage V 24 MITSUBISHI 6M70 FUEL SYSTEM SPECIFICATIONS Mit...

Page 135: ...M E M O 13 3 13 ...

Page 136: ... fuel injection quantity fuel injection timing and fuel injection pressure in order to optimize the engine s operation The electronic control unit has a diagnosis function that enables it to recognize abnormalities in the common rail system s major components and alert the driver to them The common rail system consists mainly of an electronically controlled supply pump injectors a common rail and ...

Page 137: ...nals from the engine electronic control unit a magnetic valve in each injector causes the injector to inject fuel into the relevant combustion chamber at the optimal timing and in the optimal quantity If fuel leakage occurs through any of the fuel line connections between the common rail and injectors the relevant flow limiter s will close shutting off fuel supply and thus preventing any further f...

Page 138: ...13 6 1 1 Mitsubishi 6M70 Supply pump STRUCTURE AND OPERATION ...

Page 139: ...ed first to the MPROP rail pressure control valve which controls the amount of fuel reaching the plungers If the fuel pressure exceeds a certain level the overflow valve returns fuel to fuel tank This operation keeps the pressure of the fuel constant Rotation of the camshaft causes via the tappets up down movement of the plungers Fuel in the plunger cham bers is thus highly pressurized ...

Page 140: ...el to ward the plungers of the supply pump in such a quantity that the fuel pressure target common rail pressure corresponds to that required by the engine electronic control unit When the MPROP is not operating i e when current is not flow ing fuel flows at its maximum rate When current flows the pis ton in the MPROP is pressed down such that fuel is not fed toward the plungers The engine electro...

Page 141: ...fuel pressure from becoming higher than the set pressure When the pressure limiting valve is activated the common rail system is faulty and needs an inspection of fuel supply system 1 Flow limiter During normal operation the piston moves thus pushing and compressing the spring to the extent necessary for one injection quantity to pass through The piston does not make contact with the seat at this ...

Page 142: ...ivided into the control section and the injector section The control section consists of the control chamber magnet valve spring armature plate valve ball valve body valve piston orifice A and orifice Z The valve piston is located between the control section and the injec tion section The injection section consists of the nozzle body nozzle needle nozzle spring and nozzle nut STRUCTURE AND OPERATI...

Page 143: ...zzle needle stays in its downward pushed position and injection does not take place 1 2 Start of injection When the magnet is energized the re sulting electromagnetic force draws the armature plate upward causing the ball seat to open Fuel in the control chamber passes through the orifice A and ball seat and flows to the fuel tank With the pressure in the control cham ber reduced the fuel acting o...

Page 144: ...alve spring such that the ball seat closes At this time fuel flows into the control chamber via orifice Z pushing down the valve pis ton and nozzle needle such that injec tion finishes STRUCTURE AND OPERATION Mitsubishi 6M70 Engine Parts contact email EngineParts HeavyEquipmentRestorationParts com Phone 269 673 1638 ...

Page 145: ...load sensor Pulse converter Turbine speed sensor Fuel injection control Warm up acceleration function Exhaust gas recirculation valve control function See Gr17 Starter continuous energization prevention function See Gr54 Fault diagnosis function Injector magnetic valve MPROP1 2 rail pressure control valve Fuel injection pressure control Fuel injection quantity control Tachometer Safety relay Elect...

Page 146: ...ke off load sensor Sensing of extent of accelerator pedal depression Pulse converter Turbine speed sensor Sensing of turbine wheel speed Injector magnetic valve Control of fuel injection rate fuel injection quantity and fuel injection timing MPROP1 2 rail pressure control valve Control of fuel injection pressure Engine warning lamp Indication of system abnormalities Tachometer Indication of engine...

Page 147: ...y control 3 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 3 2 Basic fuel injection quantity The basic fuel injection quantity is determined in accordance with the engine speed and throttle opening 3 3 Maximum injection quantity The maximum injection quantity is calculated f...

Page 148: ...injection quantity and engine speed 6 Warm up acceleration function The warm up acceleration function increases engine warm up by varying the engine s idling speed in accordance with the engine s coolant temperature It can operate either automatically or manually Selection is made using the idling speed adjustment potentiometer Water temperature sensor Accelerator pedal position sensor Idling spee...

Page 149: ...he relevant fault information on the meter cluster At the same time the system also stores a relevant diagnosis code in the memory and starts operation in the fault mode While the control during fault is taking place the system s functionality is limited to ensure vehicle and driver safe ty It is possible to read the memorized diagnosis code using a Multi Use Tester or from flashing of the warning...

Page 150: ...13 18 10 Electronic control unit connection diagram STRUCTURE AND OPERATION ...

Page 151: ...13 13 19 ...

Page 152: ...dal is pressed 2 2 Accelerator pedal position sensor The accelerator pedal position sensor monitors for change in the position of the accelerator pedal and sends rele vant electric signals to the common rail electronic control unit The lever is constantly pulled towards the idling po sition by a return spring STRUCTURE AND OPERATION ...

Page 153: ...water sep arator which separates any water from fuel Water separated from fuel accumulates at the bottom of the fuel filter assembly The water which has collected can be drained through the drain hole by loosening the drain plug To bleed air from the fuel system a manually operated pump and plug are provided on the fuel filter head ...

Page 154: ...e impurities from fuel and also separates water from fu el Water separated from fuel is collected at the bottom of the water separator and is drained when the float reaches the level line To drain water collected loosen the drain cock This allows the water to be discharged through the drain hole STRUCTURE AND OPERATION ...

Page 155: ...M E M O 13 23 13 ...

Page 156: ...ng valve malfunction O O O Incorrect injector fuel injection Defective injector magnetic valve O O O O O Defective injector O O O O Gauze filter clogged O O O O O O Fuel filter clogged O O O O Water separator clogged O O O O No fuel in fuel tank O Fuel pipe clogged and fuel leak from joint O Air or water in fuel system O O O O Poor quality fuel is used O O O O Fuel leak from high pressure joint O ...

Page 157: ...top Fuel supply insufficient Engine control warning lamp illuminates Reference Gr Possible causes Oil viscosity unsuitable O O Gr12 Valve clearance incorrect O O Gr11 Defective cylinder head gasket O O Valve and valve seat worn and carbon deposits O O Valve spring fatigued O O Piston ring worn and damaged O O Piston ring groove worn and damaged O Piston and cylinder liner worn O O Cooling system m...

Page 158: ...Gr00 Warning lamp lit Was able to identify the fault Response to transient fault See Gr00 Perform inspection based on diagnosis codes See later section Rectify or replace with new parts Clear stored diagnosis code See Gr00 Read diagnosis code s by Multi Use Tester See Gr00 Code issued End of inspection Test drive NO YES No code issued TROUBLESHOOTING DIAGNOSIS USING Multi Use Tester ...

Page 159: ... measurement with the tester handle the test bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short circuit failure between terminals in connector or between connector and car body Resistance is affected by temperature Determine the necessity of resistance measurement following given tem perature specification as a g...

Page 160: ... 1 82 O P0201 Injector M V Cylinder 1 Load 37 O P0202 Injector M V Cylinder 2 Load 38 O P0203 Injector M V Cylinder 3 Load 39 O P0204 Injector M V Cylinder 4 Load 8 O P0205 Injector M V Cylinder 5 Load 46 O P0206 Injector M V Cylinder 6 Load 47 O P0219 Engine Overrunning 7 O P0222 Accel Pedal Sensor 2 16 O P0223 Accel Pedal Sensor 2 16 O P0227 PTO Accel Sensor 61 O P0228 PTO Accel Sensor 61 O P023...

Page 161: ...256 Common Rail Pressure M V 1 63 O P1258 Common Rail Pressure M V 2 63 O P1259 Common Rail Pressure M V 2 63 O P125A Rail Pressure M V 1 Over Load 63 O P125B Rail Pressure M V 1 Long Short 63 O P125C Rail Pressure M V 2 Over Load 63 O P125D Rail Pressure M V 2 Long Short 63 O P1267 EGR 1 67 O Gr17 P1268 EGR 1 67 O Gr17 P1272 EGR 2 68 O Gr17 P1273 EGR 2 68 O Gr17 P1277 EGR 3 69 O Gr17 P1278 EGR 3 ...

Page 162: ...Control is effected using backup value of 101 3 kPa 1 03 kgf cm2 Exhaust emissions worsen Exhaust gas recirculation control is stopped Inspection Service data 30 Atmospheric Pressure Other Replace engine electronic control unit Generation condition Intake air temperature sensor 1 voltage remains less than 0 15 V for 3 seconds Recoverability System recovers when intake air temperature sensor 1 volt...

Page 163: ...sors 1 and 2 remains 70 or more for 6 seconds when the sensors are normal Recoverability System recovers if difference in output voltage between accelerator pedal posi tion sensors 1 and 2 remains less than 70 for 3 seconds when the sensors are normal Control effected by electronic control unit Low output Inspection Service data 22 Accel Pedal Position unfiltered 23 Accel Pedal Position filtered 2...

Page 164: ...ains 0 15 V or more for 1 second Control effected by electronic control unit Control is effected using backup value 40 C Inspection Service data 2F Fuel Temperature Inlet Electronic control unit connector Fuel temperature sensor Electrical equipment 323 Fuel temperature sensor Electric circuit diagram Fuel temperature sensor system Generation condition Fuel temperature sensor voltage remains highe...

Page 165: ...ylinder control is stopped Output is reduced due to three cylinder operation and exhaust emissions worsen Exhaust gas recirculation control is stopped Auto cruise control is stopped Turbocharger control is stopped Actuator tests B9 Fuel Leak Check BB to C0 Injector Test BA VGT Test are stopped Inspection Actuator test BB Injector Test 1 BC Injector Test 2 BD Injector Test 3 Electronic control unit...

Page 166: ...FF 2 minutes or more ON When open circuited System recovers if signal becomes normal with starter switch in ON posi tion Control effected by electronic control unit Exhaust gas recirculation control is stopped Injector magnetic valves No 1 2 and 3 cylinder are stopped Output is reduced and exhaust emissions worsen Auto cruise control is stopped Actuator test BA VGT Test is stopped Inspection Actua...

Page 167: ...circuited or over loaded Recoverability When short circuited or overloaded System recovers power is re supplied to electronic control unit if signal becomes normal when starter switch is turned OFF 2 minutes or more ON When open circuited System recovers if signal becomes normal with starter switch in ON posi tion Control effected by electronic control unit Exhaust gas recirculation control is sto...

Page 168: ...ns 4 5 V or less for 1 second Control effected by electronic control unit If accelerator pedal position sensor 2 alone is faulty Control is effected using accelerator pedal position sensor 1 If both accelerator pedal position sensors 1 and 2 are faulty Exhaust gas recirculation control is stopped Auto cruise control is stopped Turbocharger control is stopped Control is effected using backup value ...

Page 169: ...eneration condition Boost pressure sensor voltage remains less than 0 3 V for 3 seconds Recoverability System recovers when boost pressure sensor voltage remains 0 3 V or more for 1 second Control effected by electronic control unit Control is effected using backup value of 101 3 kPa 1 03 kgf cm2 Output is reduced and fuel economy worsens Actuator test BA VGT Test is stopped Inspection Service dat...

Page 170: ... limiting valve Have work performed by Bosch Injectors Have work performed by Bosch Generation condition Diagnosis code is generated under either of the following conditions 1 Common rail pressure sensor voltage remains less than 0 74 V for 30 sec onds 2 The difference between target common rail pressure and actual common rail pressure is 30 or more and MPROP rail pressure control valve discharge ...

Page 171: ... and 4 Engine warning lamp orange display Injection quantity is limited Output is reduced and exhaust emissions worsen Exhaust gas recirculation control is stopped Auto cruise control is stopped Inspection Service data C0 Difference Common Rail Pressure Other Supply pump Have work performed by Bosch Generation condition Diagnosis code is generated under either of the following conditions 1 Signals...

Page 172: ...ata 01 Engine Revolution Electronic control unit connector Cylinder recognition sensor Electrical equipment 320 Cylinder recognition sensor Electric circuit diagram Cylinder recognition sensor system Generation condition Vehicle speed remains 2 km h or less for 20 seconds when engine speed is 1000 rpm or more clutch pedal is released and transmission neutral signal indicates that transmission is i...

Page 173: ...ion Magnetic valve power supply remains low for 0 5 second Recoverability System recovers power is re supplied to electronic control unit if signal becomes normal when starter switch is turned OFF 2 minutes or more ON Control effected by electronic control unit Turbocharger magnetic valve control is stopped Safety relay control is stopped Powertard magnetic valve control is stopped Electronic driv...

Page 174: ...ol is effected using backup value No 1 Output is slightly reduced Inspection Service data 33 Q Adjustment Resistor No Electronic control unit connector Fuel injection rate adjustment resistor Electrical equipment 828 Fuel injection rate adjustment resistor Electric circuit diagram Fuel injection rate adjustment resistor system Generation condition Fuel injection rate adjustment resistor voltage re...

Page 175: ...ctor Test 4 BF Injector Test 5 C0 Injector Test 6 Electronic control unit connector Injector magnetic valve Electrical equipment 582 Injector magnetic valve Electric circuit diagram Injector magnetic valve No 4 5 or 6 cylinder system Generation condition Current flowing to MPROP1 rail pressure control valve remains above the spec ified value for 0 3 second Recoverability System recovers power is r...

Page 176: ...MPROP rail pressure control valve Electric circuit diagram MPROP rail pressure control valve system Other Air bleeding of fuel system See ON VEHICLE INSPECTION AND ADJUST MENT Inspection of fuel piping See COMMON RAIL Fuel filter See FUEL FILTER Gauze filter See ON VEHICLE INSPECTION AND ADJUSTMENT Supply pump Have work performed by Bosch Pressure limiting valve Have work performed by Bosch Inject...

Page 177: ...ROP1 rail pressure control valve Electrical equipment 574 MPROP1 rail pressure control valve Electric circuit diagram MPROP1 rail pressure control valve system Generation condition Diagnosis code is generated under either of the following conditions 1 MPROP2 rail pressure control valve circuit shorted to battery high level when turned ON as detected for 0 3 second 2 MPROP2 rail pressure control va...

Page 178: ... Actuator test B9 Fuel Leak Check Electronic control unit connector MPROP1 rail pressure control valve Electrical equipment 574 MPROP1 rail pressure control valve Electric circuit diagram MPROP1 rail pressure control valve system Generation condition MPROP1 rail pressure control valve circuit remains shorted to ground as detect ed for 10 seconds Recoverability System recovers power is re supplied ...

Page 179: ... unit connector Engine speed sensor Cylinder recognition sensor Electrical equipment 263 Engine speed sensor 320 Cylinder recognition sensor Electric circuit diagram Engine speed sensor and cylinder recognition sensor systems Generation condition Current flowing to Powertard solenoid valve remains above the specified value for 1 second Recoverability System recovers when the current flowing to Pow...

Page 180: ...ter 324 Accelerator pedal position sensor 1 Electric circuit diagram Accelerator pedal position sensor 1 and idling speed adjustment potentiometer systems Generation condition Circuit voltage sensor supply voltage 1 in electronic control unit remains abnor mally high for 0 5 second Recoverability System recovers when circuit voltage sensor supply voltage 1 in electronic con trol unit becomes norma...

Page 181: ... off load sensor 319 Common rail pressure sensor Electric circuit diagram Power take off load sensor and common rail pressure sensor systems Generation condition Circuit voltage sensor supply voltage 3 in electronic control unit remains abnor mally high for 0 5 second Recoverability System recovers when circuit voltage sensor supply voltage 3 in electronic con trol unit becomes normal Control effe...

Page 182: ... Starter switch ON engine is stopped 1 V altitude 0 m 0 92 V altitude 600 m Accelerator pedal pressed after engine has started Value gradually increases 28 Idle Volume Voltage SLOW to FAST 3 to 1 V 29 Vehicle Speed Vehicle in motion Value matches speedome ter indication 2A Turbine Revolution See Gr15 2B Intake Air Temperature Engine cold Value matches ambient temperature indication 2E Water Temper...

Page 183: ...OFF with connector connected ON Diagnosis switch ON with connector disconnected OFF 7E Memory Clear SW ON OFF Memory clear switch OFF with connector connected ON Memory clear switch ON with connector disconnected OFF 7F Auxiliary Brake SW 1 ON OFF Operated under following conditions Accelerator and clutch pedals are pressed Transmission in neutral position ON Other than above conditions OFF 80 Pow...

Page 184: ...condition of warn ing lamp red Service data 8B Diagnosis Lamp B8 Idle Up Cancel SW Repeatedly turn idle up cancel switch ON and OFF 5 times for 1 5 sec each Can be executed when the following conditions are satisfied Vehicle stationary vehicle speed 0 km h Transmission Neutral Check that the engine idling speed remains at low idling Service data 78 Idle Up Cancel SW B9 Fuel Leak Check Increase rai...

Page 185: ...M E M O 13 53 13 ...

Page 186: ... instructions Some inspections are performed with the connectors removed Others are performed with the connectors fitted Observe the following caution CAUTION Do not touch any terminal except those specified for the inspection Be particularly careful not to cause short circuits between terminals using the tester probes Check item Measurement method Resistance of intake air temperature sensor 1 Con...

Page 187: ...ments Terminals A72 A23 injector magnetic valve No 1 cylinder A70 A22 injector magnetic valve No 2 cylinder A71 A46 injector magnetic valve No 3 cylinder A94 A47 injector magnetic valve No 4 cylinder A96 A24 injector magnetic valve No 5 cylinder A95 A48 injector magnetic valve No 6 cylinder 0 21 to 0 295 Ω Output voltage of Power take off load sensor Conditions Starter switch ON Vehicle side harne...

Page 188: ...istor 390 19 5 Ω No 10 resistor 4300 215 Ω No 11 resistor 9100 455 Ω Resistance of Power take off resistor Conditions Starter switch OFF Disconnect connector Perform inspection on vehicle side connector Requirements Terminals A43 A19 No 1 resistor 270 13 5 Ω No 2 resistor 510 25 5 Ω No 3 resistor 820 41 Ω No 4 resistor 1300 65 Ω No 5 resistor 2000 100 Ω No 6 resistor 3300 165 Ω No 7 resistor 5600 ...

Page 189: ...M E M O 13 57 13 ...

Page 190: ...ard value check for an installed condition of the accelerator control cable and accel erator link See ENGINE CONTROL If the cable and link are found to be normal check for the accel erator pedal switch a accelerator pedal position sensor a sup ply pump b and engine electronic control unit b a See ENGINE CONTROL b Contact Bosch Service Sta tion for repair Adjustment If the measurement deviates from...

Page 191: ...the clamp mounting bolt or nuts If there is looseness tighten the bolts and nuts to the specified torque 4 Draining of Deposit in Fuel Tank DANGER Do not allow any flames or sources of heat near the fuel tank as it may explode WARNING Fuel is highly flammable Keep it away from flames and sources of heat Thoroughly wipe up any spilled fuel otherwise it may catch fire Tightening torque Unit N m kgf ...

Page 192: ...ghten the plug to the specified torque Continue operating the pump until there is strong pumping resis tance While pushing the knob of the manually operated pump screw it in to the right to fix Wipe up all spilled fuel then start the engine Check that no fuel leakage occurs WARNING Fuel is highly flammable Keep it away from flames and sources of heat Be sure to wipe up all spilled fuel Unless it i...

Page 193: ...ny spilled fuel Otherwise it may catch fire CAUTION Be careful not to damage the case Installation Clean the surface of the fuel filter head and case where the O ring is to be mounted Mark Parts to be tightened Tightening torque Remarks Drain plug 2 0 5 0 2 0 05 Case 18 to 20 1 8 to 2 0 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Mark Tool n...

Page 194: ... system Start the engine and ensure that there is no fuel leakage If there is fuel leakage remove and install the fuel filter correctly 7 Cleaning of Gauze Filter Tightening torque Unit N m kgf m Remove the eyebolt in the middle of fuel piping Pull out the gauze filter from the removed eyebolt Wash the gauze filter with light oil After washing install the gauze filter in the reverse order Bleed ai...

Page 195: ...from flames and sources of heat Thoroughly wipe up any spilled fuel Otherwise it may catch fire CAUTION Use care not to damage the cover 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 Plug A 12 3 2 5 1 25 0 3 Plug B 17 2 2 5 1 75 0 3 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Mark T...

Page 196: ...engine problems Be sure to use only genuine parts To help prevent fuel injection problems keep the water sep arator and fuel hoses free from contamination Install torque wrench to and tighten the case to the speci fied torque Tighten the drain plug and plugs A B to the specified torque With the plug correctly installed bleed air from the fuel system Start the engine and ensure that there is no fue...

Page 197: ...t Bosch Service Station for any service needs of the common rail Installation sequence Follow the removal sequence in reverse Tightening torque Unit N m kgf m Installation procedure Installation Mitsubishi 6M70 Fuel pipe and injection pipe Ensure that the pipe and mounting surfaces of the connector are flat and free from damage Bring the pipe into intimate contact with mounting surfaces of the con...

Page 198: ...rom contaminants Contact Bosch Service Station for any service needs of the supply pump Installation sequence Follow the removal sequence in reverse CAUTION Make sure that the harness marked with of MPROP rail pressure control valve is connected to the supply pump before starting the engine Starting the engine without connection causes a malfunction 1 Fuel pipe 2 Eyebolt 3 Fuel suction pipe 4 Eyeb...

Page 199: ...3 0 7 kgf cm2 Replace Mark Parts to be tightened Tightening torque Remarks Bolt supply pump mounting 54 5 5 Eyebolt fuel suction pipe mounting 25 to 29 2 6 to 3 0 Eyebolt fuel feed pipe mounting Eyebolt oil pipe mounting 21 2 1 Overflow valve mounting 30 to 40 3 1 to 4 1 Fuel pipe 29 to 35 3 0 to 3 6 Bolt supply pump mounting 125 12 7 Mark Points of application Specified lubricant and or sealant Q...

Page 200: ...ssion stroke See Gr11 Install the supply pump while ensuring that the stamped line on the supply pump gear is aligned with the stamped line on rear plate Insert into the timing checking hole of the flywheel housing If the seat surface of is securely fitted the timing is aligned If the seat surface lifts the gears are not properly engaged Re install the supply pump CAUTION Remember to remove after ...

Page 201: ...ge Bring the pipe into intimate contact with mounting surfaces of the connector evenly and temporarily tighten it without applying an excessive force Tighten it to the specified torque after temporary tightening Mitsubishi 6M70 Engine Parts contact email EngineParts HeavyEquipmentRestorationParts com Phone 269 673 1638 ...

Page 202: ...d to the injector To eliminate fuel injection and other problems protect the injectors and pipes that have been removed from the ingress of contaminants Contact Bosch Service Station for any service needs of the injector Installation sequence Follow the removal sequence in reverse CAUTION Do not attempt to clean the nozzle hole with a wire brush or other similar tools or the hole can be dam aged B...

Page 203: ...ipe otherwise the open end section may be broken Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Mark Tool name and shape Part No Application ME165088 Removing injector use with MH061071 MH061071 Removing injector ME355665 Removal and installation of injection pipe Injector extractor adapter Nozzle extractor A M8 1 25 Open end spanner A B 15 24 ...

Page 204: ... connector of the injector as a stopper CAUTION Do not use except for a stopper of the injection pipe otherwise the open end section may be broken Ensure that the pipe and mounting surfaces of the connector are flat and free from damage Bring the pipe into intimate contact with mounting surfaces of the connector evenly and temporarily tighten it without applying an excessive force Tighten it to th...

Page 205: ...M E M O 13 73 13 ...

Page 206: ... is highly flammable Keep it away from flames and sources of heat Thoroughly wipe up any spilled fuel otherwise it may catch fire 1 Drain plug 2 Strainer 3 Connecting plug 4 Suction hose 5 Return hose 6 Fuel level sensor 7 Fuel tank strap 8 Fuel tank strap Except FV51 9 Fuel tank strap 10 Fuel tank 11 Fuel tank bracket 12 Fuel tank bracket Except FV51 13 Fuel tank bracket FUEL TANK ...

Page 207: ... 2 to 1 3 Bolt fuel tank bracket mounting 54 to 72 5 5 to 7 3 Wet Bolt fuel tank bracket mounting FV51 54 to 72 5 5 to 7 3 Wet Except FV51 150 to 204 15 to 21 Location Points of application Specified lubricant and or sealant Quantity Seat surface of drain plug Seal end No 22 As required Contact area between fuel tank strap and fuel tank Soapy water As required Thread area of bolt Engine oil As req...

Page 208: ...wipe up any spilled fu el Otherwise it may catch fire CAUTION Be careful not to damage the case Service standards Tightening torque Unit N m kgf m Lubricant and or sealant Location Maintenance item Standard value Limit Remedy 3 Overflow valve 1 14 0 03 MPa 12 0 3 kgf cm2 Replace Mark Parts to be tightened Tightening torque Remarks Eyebolt 30 3 0 Drain plug 2 0 5 0 2 0 05 Case 18 to 20 1 8 to 2 0 P...

Page 209: ...e by loosening the drain plug Using remove the case Installation procedure Installation Case Clean the surface of the fuel filter head and case where the O ring is to be mounted Mark Tool name and shape Part No Application Filter wrench MH063201 Removal and installation of case ...

Page 210: ...ly genuine parts To help prevent fuel injection problems keep the fuel filter and hoses free from contamination Install a torque wrench to and tighten the case to the spec ified torque Tighten the drain plug to the specified torque With the plug cor rectly installed bleed air from the fuel system Start the engine and check that there is no fuel leakage If there is fuel leakage remove and install t...

Page 211: ...M E M O 13 79 13 ...

Page 212: ...d fu el Otherwise it may catch fire CAUTION Be careful not to damage the case Tightening torque Unit N m kgf m Lubricant and or sealant Special tools Mark Parts to be tightened Tightening torque Remarks Fuel cut valve 35 3 6 Plug A 12 3 2 5 1 3 0 3 Plug B 17 2 2 5 1 8 0 3 Drain plug 1 47 0 3 0 15 0 03 Cover 19 6 2 5 2 0 0 25 Connector 40 4 0 Mark Points of application Specified lubricant and or se...

Page 213: ...UTION Use care not to damage the cover Installation procedure Installation Cover Clean the surface of the water separator body against which O ring abuts and the O ring groove in the cover Replace the filter element and O ring with new parts Apply a thin coat of engine oil to the O ring Install the O ring onto the case CAUTION The use of non genuine filter elements will lead to engine problems Be ...

Page 214: ...ue Tighten the drain plug and plugs A B to the specified torque With the plug correctly installed bleed air from the fuel system Start the engine and ensure that there is no fuel leakage If there is fuel leakage remove and install the water separator correctly WATER SEPARATOR ...

Page 215: ...M E M O 13 83 13 ...

Page 216: ...AND ADJUSTMENT Make sure that the accelerator pedal moves smoothly Installation procedure Installation Accelerator pedal control cable Connect the accelerator pedal control cable to the accelerator link 1 Cover 2 Accelerator pedal control cable 3 Accelerator pedal pin 4 Accelerator pedal 5 Stopper bolt 6 Accelerator pedal bracket 7 Accelerator link See later section 8 Accelerator pedal position se...

Page 217: ...trol cable with the ac celerator link stopper bolt so that accelerator link B contacts the stopper Press the accelerator pedal until the control lever of the acceler ator pedal position sensor contacts the full load stopper bolt Adjust the stopper bolt so that clearance between the accelera tor pedal and stopper bolt is to the dimension shown in the illus tration ...

Page 218: ...e Installation Accelerator pedal switch Place accelerator link B against the stopper Place the push rod of the accelerator pedal switch against accel erator link B and install the accelerator pedal switch so that the stroke of the push rod is to the dimension shown in the illustra tion Mark Points of application Specified lubricant and or sealant Quantity Sliding surfaces of bushing and accelerato...

Page 219: ...M E M O 13 87 13 ...

Page 220: ... idling speed adjust ment potentiometer Turn the knob fully counterclockwise Then measure the output voltage across terminals 2 and 3 see the diagrams on the left while slowly turning the knob clockwise If any measurement is out of specification replace the idling speed adjustment potentiometer Switch position Terminals with continuity Powertard switch OFF 1st step 6 11 2nd step 6 11 3 9 Switch po...

Page 221: ...erminals 1 and 2 If the measurement is out of specification replace the sensor CAUTION The signal may not output if the sensor tightening torque is insufficient Check if the sensor is tightened with the cor rect tightening torque See Gr11 265 Inspection of vehicle speed sensor With the 24 volts DC applied to terminals 1 and 2 slowly turn the shaft of the vehicle speed sensor Measure the maximum vo...

Page 222: ...ition A deviates from standard val ue replace the sensor 318 Inspection of Mitsubishi 6M70 boost pressure sensor Apply 5 volts DC to terminals 3 and 1 Apply air pressure Gradually increase it and while doing so measure the output voltage occurring at terminals 2 and 1 If any measurement is out of specification replace the sensor 319 Inspection of Mitsubishi 6M70 common rail pressure sensor The sen...

Page 223: ...easure the output voltage at terminals 5 and 6 sensor 1 and the output voltage at terminals 2 and 3 sensor 2 with the lever in each specified position A Position in which accelerator pedal switch is fully pushed in by lever B Position in which lever is touching stopper bolt If any output voltage is out of specification make an adjustment If any output voltage is still out of specification when you...

Page 224: ...he resistor number marked on the fuel injection rate adjustment resistor If the measurement is out of specification replace the fuel injec tion rate adjustment resistor with one that has the same resistor number and same specified resistance CAUTION The fuel injection rate adjustment resistor is matched to the engine If you replace it be sure to replace it with one that has the same resistor numbe...

Page 225: ...M E M O 13 93 13 ...

Page 226: ...13 94 INSTALLED LOCATIONS OF PARTS ...

Page 227: ...13 13 95 ...

Page 228: ...13 96 INSTALLED LOCATIONS OF PARTS ...

Page 229: ...13 13 97 ...

Page 230: ...13 98 INSTALLED LOCATIONS OF PARTS ...

Page 231: ...13 13 99 ...

Page 232: ...13 100 MITSUBISHI 6M70 INSTALLED LOCATIONS OF PARTS ...

Page 233: ...13 13 101 ...

Page 234: ...13 102 ELECTRIC CIRCUIT DIAGRAM ...

Page 235: ...13 13 103 ...

Page 236: ...13 104 ELECTRIC CIRCUIT DIAGRAM ...

Page 237: ...13 13 105 ...

Page 238: ...13 106 ELECTRIC CIRCUIT DIAGRAM ...

Page 239: ...TMENT 1 Inspection and Adjustment of Belt Tension 14 6 2 Inspection of Belts 14 8 3 Coolant Replacement and Cleaning of Cooling System 14 9 4 Air Bleeding of Cooling System 14 11 5 Gas Leakage Test 14 11 6 Coolant Leakage Test 14 11 DISCONNECTION AND CONNECTION OF HOSES AND PIPES 14 12 RADIATOR AND FAN SHROUD 14 16 SURGE TANK 14 24 COOLING FAN AND BELT 14 26 WATER PUMP 14 28 THERMOSTAT 14 34 ...

Page 240: ...water circulation system Water pump Belt driven type Thermostat Wax pellet bottom bypass type with jiggle valve Automatic cooling fan coupling Continuous control type Radiator Tube and corrugated fin type Coolant capacity dm3 L 41 41 SPECIFICATIONS ...

Page 241: ...14 14 3 1 Mitsubishi 6M70 Cooling System Flow of Coolant STRUCTURE AND OPERATION ...

Page 242: ... 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 of coolant to the radiator and to the water pump bypassing the radiator 3 Mitsubishi 6M70 Water Pump The water pump has a drain hole to prevent coolant from entering the unit bearing in case of a defect in the unit seal STRUCTURE AND OPERATION ...

Page 243: ...oolant temperature sensor O O Radiator Clogged core O Cracked core and or separation in welds O O Automatic cooling fan coupling Defective bearing O O Damaged bimetal O Contaminated bimetal O O Silicon oil leakage O O Oil cooler Incorrectly mounted oil cooler O O Gr12 Defective gasket O O Cylinder head Incorrectly mounted cylinder head O O Gr11 Defective gasket O O Poorly airtight pressure cap O I...

Page 244: ...of the belt A Alternator pulley B Compressor pulley for air conditioner C Water pump pulley D Crankshaft pulley Place the small O ring on at the scale mark corresponding to 98 N 10 kgf press force Place the large O ring on at the scale mark corresponding to the maximum permissible deflection value specified for the belt Location Maintenance item Standard value Limit Remedy Belt tension For air con...

Page 245: ...Loosen the alternator mounting nuts 2 locations and adjust the tension of the belt with the adjusting bolt When the adjustment is completed tighten the bolts and nuts securely CAUTION Excessive tension in belts may damage the belts and relat ed bearings 2 Belts for air conditioner Loosen the cooler compressor mounting bolts 4 places and ad just the tension of the belt with the adjusting bolt When ...

Page 246: ...ced whichever is more recent The driving distance over the which the belt can still be used is about half of that over which the belt has been used since the vehi cle was new or since the belt was replaced whichever is more re cent The driving distance over the which the belt can still be used is about a quarter of that over which the belt has been used since the vehicle was new or since the belt ...

Page 247: ...the pressure out before opening it fully 3 2 Cleaning procedure CAUTION Water used for flushing the cooling system must be soft water that has a property meeting the require ments indicated below Using hard water will cause scale and rust to form in the system Required properties of soft water Total hardness 300 ppm or less Sulfate SO 100 ppm or less Chloride CI 100 ppm or less Total dissolved sol...

Page 248: ...the engine idling period to one hour Operating an engine containing the cleaning solution for long er time may lead to damage of the cooling system Drain out coolant Pour tap water preferably hot into the surge tank Let the engine idle for 10 minutes with the water at approximately 90 C Cleaning is complete if drained water is clear Repeat procedure if drained water is not clear After cleaning the...

Page 249: ...engine is hot boiling coolant may spurt out from the filler port when the pressure cap is loosened To avoid burning yourself make sure to remove the pressure cap only when the coolant is cold Run the engine until the coolant temperature rises to approxi mately 90 C If air bubbles appear continuously through the filler port there is air or exhaust gas penetrating into the cooling system Presence of...

Page 250: ...ose clamp to the angle indicated in the illustration so that sufficient clearance is assured between the hose clamp and its surrounding parts 1 Supply hose 2 Inlet hose 3 Overflow hose 4 Heater hose 5 Heater hose 6 Water hose 7 Hose 8 Water hose 9 Water pipe 10 Outlet hose DISCONNECTION AND CONNECTION OF HOSES AND PIPES ...

Page 251: ...the stopper of the water pipe Installation Hose Install the hose marked with a white line so that this white line is placed in the center of the clamp Mark Parts to be tightened Tightening torque Remarks Hose clamp 4 0 0 5 0 4 0 05 Hose clamp 5 0 0 5 0 5 0 05 Hose clamp 3 5 to 4 5 0 35 to 0 45 Hose clamp 4 4 0 45 Hose clamp 6 5 0 5 0 7 0 05 ...

Page 252: ...14 14 Periphery of Engine DISCONNECTION AND CONNECTION OF HOSES AND PIPES ...

Page 253: ...Unit N m kgf m Mark Parts to be tightened Tightening torque Remarks Clamp 3 9 0 4 Eyebolt water pipe mounting 39 4 0 1 Air pipe 2 Water pipe 3 Water hose 4 Water hose 5 Eyebolt 6 Eyebolt 7 Water pipe 8 Water hose 9 Water pipe 10 Eyebolt 11 Eyebolt 12 Water pipe 13 Eyebolt 14 Eyebolt 15 Water pipe 16 Water hose 17 Water hose 18 Water hose 19 Water pipe 20 Water pipe 21 Water hose a Exhaust gas reci...

Page 254: ...S for the correct insertion depth of radiator hoses into the pump as well as the correct tightening torque of clamps 1 Cushion rubber 2 Front thrust rod bracket 3 Cushion rubber 4 Cushion rubber 5 Thrust rod 6 Cushion rubber 7 Radiator See later section 8 Radiator bracket 9 Cushion rubber 10 Radiator support 11 Shroud seal 12 Fan shroud RADIATOR AND FAN SHROUD ...

Page 255: ...oud Using adjust the clearance between the fan shroud and cooling fan blades to the dimension shown in the illustration over the entire circumference Installation Shroud seal and fan shroud Install the shroud seal and fan shroud while aligning the section A as shown in the illustration Mark Tool name and shape Part No Application ME294842 Adjusting clearance between fan shroud and cooling fan blad...

Page 256: ...assemble radiator unless there is an abnormality Assembly sequence Follow the disassembly sequence in reverse Service standards Tightening torque Unit N m kgf m Location Maintenance item Standard value Limit Remedy Air leakage from radiator air pressure 177 kPa 1 8 kgf cm2 0 cm3 0 mL Rectify or replace Mark Parts to be tightened Tightening torque Remarks Drain cock 2 0 2 Bolt side member mounting ...

Page 257: ...paint marks on the joint between the core and upper tank or on the joint between the core and lower tank which indicates that the tank retaining tabs have been crimped twice before replace the core with a new part Paint a mark for each core replacement The upper and lower core replacement should be counted and marked separately Removal procedure Removal Upper tank and lower tank Use for removal an...

Page 258: ...ll tabs in the perimeter hold the pipes con nected to the inlet outlet and remove tank If it is difficult to remove tank lightly hit with rubber hammer or plastic hammer to remove CAUTION Gently handle tanks since they are made of a resin that can break on impact Inspection procedure Inspection Tank surface where core is to be mounted Check and clean the tank surface where the core is to be mount ...

Page 259: ...e entire periphery even a hair can cause leakage Repairing core CAUTION The core is repaired by means of tungsten inert gas arc welding TIG welding which should only be performed by a skilled welder It is extremely dangerous to weld on a wet core Before welding ensure that the core is completely dry Using a stainless wire brush brush both ends A of the leaky tube and the areas B around the tube en...

Page 260: ...any clearance between the tank and core plate by tapping with a rubber or plastic hammer CAUTION To prevent adhesion of foreign substances use bare hands to install the packing and tank Adjust the stopper bolt until the gap dimension shown in the il lustration is obtained on the attachment of Follow the sequence shown in the diagram bend tabs for crimp ing tank 1 to 4 Bend two tabs at the center 5...

Page 261: ...3 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 on the core where it can be easily noticed to indicate that the core has been crimped ...

Page 262: ...tandards Unit mm Tightening torque Unit N m kgf m Inspection procedure Inspection Pressure cap 1 Pressure valve opening pressure If the measurement deviates from the standard value replace the pressure cap Location Maintenance item Standard value Limit Remedy 6 Pressure valve opening pressure 49 9 8 kPa 0 5 0 1 kgf cm2 Replace Mark Parts to be tightened Tightening torque Remarks Clamp 3 to 5 0 3 t...

Page 263: ...erature check that the water level in the reservoir tank returns to the wa ter level before the engine start If the water level does not lower the vent valve is defective Re place the pressure cap CAUTION Do not remove the pressure cap before the engine coolant temperature drops to the atmospheric temperature Other wise vacuum in the radiator is lost and the engine coolant cannot return to the res...

Page 264: ...place them as a set to prevent differences in tension between the two belts After installation perform the inspection and adjustment of belt tension See ON VEHICLE INSPECTION AND ADJUSTMENT 1 Belt for air conditioner 2 Belt for alternator 3 Automatic cooling fan coupling 4 Cooling fan 5 Fan coupling 6 Torsional damper a Alternator b Cooler compressor for air conditioner c Water pump d Crankshaft p...

Page 265: ... cooling fan coupling by hand and check for irregular movement or abnormal noise caused by a defect in the bearing Check for excessive axial play in the automatic cooling fan coupling when the engine is cool Cleaning Automatic cooling fan coupling If any foreign particles have adhered to the bimetal remove them carefully without applying excessive force Mark Parts to be tightened Tightening torque...

Page 266: ...mps Service standards Unit mm Tightening torque Unit N m kgf m Lubricant and or sealant Location Maintenance item Standard value Limit Remedy 5 8 Interference between flange and bearing unit 0 05 to 0 08 Reassembly allowed only twice 6 8 Interference between impeller and bearing unit 0 03 to 0 06 Reassembly allowed only twice Mark Parts to be tightened Tightening torque Remarks Connector 39 4 0 Ma...

Page 267: ...l name and shape Part No Application MH001102 Removal and installation of snap ring MF434103 MH062411 Removal of flange MH000715 MH062192 Removal of impeller MH062195 Installation of unit seal Bolt A B M6 1 60 Nut A M6 1 Water pump pully puller A B 60 13 Bolt A B C 26 35 M10 1 5 Impeller puller A B φ 10 48 Unit seal installer A B C φ 28 9 6 0 03 φ 12 5 0 1 ...

Page 268: ...ction procedure Inspection Interference between flange and bearing unit If the measurement deviates from the standard value replace the defective part s CAUTION Even if the measurement complies with the standard value reassembly must not be carried out more than twice Inspection Interference between impeller and bearing unit If the measurement deviates from the standard value replace the defective...

Page 269: ...mp case Installation Unit seal Using install the unit seal until it securely contacts the wa ter pump case Installation Impeller CAUTION Before installing an impeller make sure that there is no or only one punch mark in the shown location on the impeller Make an additional punch mark on the flange to indicate that it undergoes the disassembly and reassembly process you are doing now Punch mark s i...

Page 270: ... in the past If there are two marks the flange must be replaced Stand the shaft of the bearing unit on a block as illustrated Place a fixture on the flange and apply the load of a press to it Press the fixture down until the shaft of the bearing unit contacts the fixture CAUTION If the flange is installed without the fixture the water pump case will be damaged Inspection after assembly Inspection ...

Page 271: ...M E M O 14 33 14 ...

Page 272: ...l as the correct tightening torque of clamps 1 Water hose 2 Bypass pipe 3 O ring 4 Eyebolt 5 Air bleeding pipe 6 Thermostat cover 7 Rubber ring 8 Thermostat Valve opening temperature 82 C 9 Thermostat Valve opening temperature 88 C 10 Water temperature sensor for engine control 11 Water temperature sensor for thermometer 12 Overheat switch 13 Water joint 14 Thermostat case 15 Gasket Non reusable p...

Page 273: ...ve closes completely when the water tem perature drops below 65 C 2 Valve lift Maintain the coolant temperature at the specified temperature for five minutes to keep the valve fully open Measure the valve lift Location Maintenance item Standard value Limit Remedy 8 Thermostat Valve opening temperature 82 2 C Replace Valve lift temperature 10 or more 95 C 9 Thermostat Valve opening temperature 88 2...

Page 274: ...uts 15 12 4 Check for Cracks and Gas Leakage in Exhaust Manifold 15 12 5 Check for Cracks and Gas Leakage in Turbocharger 15 12 TURBOCHARGER CONTROL SYSTEM 1 Diagnosis Procedure 15 14 2 Diagnostic Precautions 15 14 3 Inspections Based on Diagnosis Codes 15 15 4 Multi Use Tester Service Data 15 20 5 Actuator Tests by Multi Use Tester 15 20 6 Inspection of Electrical Equipment 15 21 7 Installed Loca...

Page 275: ... indicator type Mechanical Turbocharger Model TF08 VG Variable Geometry Variable nozzle vane type Turbocharger Manufacturer Mitsubishi Heavy Industries Intercooler type Tube and corrugated fin air cooled DPF Diesel Particulate Filter Continuous regeneration type SPECIFICATIONS ...

Page 276: ...er is provided with an un loader valve and a vacuator valve When the engine speed drops below a specified level the vacuator and un loader valves are shaken by a conse quent change in internal vacuum to automatically force out accumulated water and dust STRUCTURE AND OPERATION ...

Page 277: ...hich is a variable nozzle vane type turbocharger with adjustable heat resistive alloy turbine vanes provided at the turbine exhaust gas inlet port STRUCTURE AND OPERATION Mitsubishi 6M70 Engine Parts contact email EngineParts HeavyEquipmentRestorationParts com Phone 269 673 1638 ...

Page 278: ... valves according to sensor output data by means of the engine electronic control unit The turbocharger magnetic valves control the air cylinder movement to optimize the opening of the turbine vanes according to operating conditions When powertard brake 2nd step is activated the turbine vanes are closed the turbocharger speed is increased and more air is supplied to the combustion chamber ...

Page 279: ...tch switch Engine speed sensor Boost pressure sensor Powertard switch 2nd stage Turbine speed sensor Input signals Turbocharger control function Diagnosis function Turbocharger magnetic valve Engine warning lamp Engine electronic control unit Output signals Vehicle speed sensor Diagnosis switch Memory clear switch STRUCTURE AND OPERATION ...

Page 280: ...osis code and the system starts to effect necessary at fault control s During at fault control s the system is limited in the workings to ensure the safety of the vehicle and driver The memorized diagnosis code can be accessed on the Multi Use Tester screen or through blinking of warning lamp Diagnosis codes are different in the way of indication between the Multi Use Tester and blinking of the wa...

Page 281: ...tion the ultra efficient oxidation catalyst breaks and treats most of PM emitted from the en gine minimizing PM loading deposit onto the subsequent filter As a result the filter is unlikely to clog up even un der the driving conditions that require long hours of drive with relatively low exhaust gas temperature Also active regeneration which increases fuel consumption is not required The size of t...

Page 282: ... and or thrust bearing O O O Damaged compressor wheel O O O Oil leakage due to worn piston ring and or insert O O O Piston ring fitted poorly O Defective sliding action between parts due to clogged lubrication oil pipe and eyebolt O O O Oil seals damaged due to clogged oil return pipe O O Compressor cover fitted poorly O O O O Turbine housing fitted poorly O O Intercooler Foreign substances deposi...

Page 283: ... 5 to 15 minutes until boost pressure is stabilized Measure the following items from among Service Data 26 Boost pressure actual boost pressure 2B Intake air temperature actual intake air temperature 30 Atmospheric pressure actual atmospheric pressure Obtain corrected boost pressure by calculating above Service Data Correction with intake air temperature Corrected boost pressure kPa Measured boost...

Page 284: ...ressure must be within the specified range After adjustment secure the shaft with nut and refit the levers to the joint Measure boost pressure again If the boost pressure deviates from the standard value readjust it Make sure that the air cylinder is in the state of zero stroke when the engine is stopped Tighten the position bolt A for the illustrated clearance between the bolt and lever After adj...

Page 285: ...damp with oily smoke or soot regardless of the replacement schedule 3 Check for Looseness in Intake Manifold Mounting Bolts and Nuts Check for looseness in the intake manifold and air inlet pipe mounting bolts and nuts If there is looseness tighten the bolts and nuts to the specified torque See INTAKE MANIFOLD 4 Check for Cracks and Gas Leakage in Exhaust Manifold Inspect the exhaust manifold visu...

Page 286: ...M E M O 15 13 15 ...

Page 287: ...st bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short circuit failure between terminals in connector or between connector and car body Resistance is affected by temperature Determine the necessity of resistance measurement following given tem perature specification as a guide Otherwise use normal temperature 10 t...

Page 288: ...h 57 O P1238 Turbine Overrunning 59 O Generation condition Boost pressure remaining above the specified value for 10 seconds is repeated five times when engine speed is at 600 rpm up to 2300 rpm Recoverability In the case of above problem System recovers if boost pressure is below the specified value when en gine speed is at 600 rpm up to 2300 rpm In the case where above problem is repeated five m...

Page 289: ...comes normal high level when turned OFF for 1 second Control effected by electronic control unit Turbocharger control is stopped Exhaust gas recirculation control is stopped Auto cruise control is stopped Injection quantity is limited Output is reduced and exhaust emissions wors en Actuator test BA VGT Test is stopped Inspection Service data 21 VGT position 82 VGT M V1 Actuator test A9 VGT1 Electr...

Page 290: ...gnetic valve becomes normal high level when turned OFF for 1 second Control effected by electronic control unit Turbocharger control is stopped Exhaust gas recirculation control is stopped Auto cruise control is stopped Injection quantity is limited Output is reduced and exhaust emissions wors en Actuator test BA VGT Test is stopped Inspection Service data 21 VGT position 83 VGT M V2 Actuator test...

Page 291: ...comes normal high level when turned OFF for 1 second Control effected by electronic control unit Turbocharger control is stopped Exhaust gas recirculation control is stopped Auto cruise control is stopped Injection quantity is limited Output is reduced and exhaust emissions wors en Actuator test BA VGT Test is stopped Inspection Service data 21 VGT position 84 VGT M V3 Actuator test AB VGT3 Electr...

Page 292: ...ability System recovers when turbine speed remains less than 125000 rpm for 1 sec ond Control effected by electronic control unit Turbocharger control is stopped Inspection Service data 2A Turbine Revolution Electrical equipment 835 Turbine speed sensor and pulse converter Electric circuit diagram Turbine speed sensor and pulse converter system Generation condition Turbine speed remains 105000 rpm...

Page 293: ...netic valve OFF OFF Actuator test A9 VGT1 83 VGT M V2 ON OFF No 2 magnetic valve ON ON No 2 magnetic valve OFF OFF Actuator test AA VGT2 84 VGT M V3 ON OFF No 3 magnetic valve ON ON No 3 magnetic valve OFF OFF Actuator test AB VGT3 VGT opening 0 to 12 5 to 25 to 37 5 to 50 to 62 5 to 75 to 87 5 to 100 M V1 ON OFF ON OFF ON OFF ON OFF M V2 ON ON OFF OFF ON ON OFF OFF M V3 ON ON ON ON OFF OFF OFF OF...

Page 294: ...er unit as con nected to the turbocharger Disconnect the turbine speed sensor and pulse converter unit from the electronic control unit harness at connectors Then prepare and fit the test harness in place The sensor does not respond to manual rotation of the turbo charger compressor wheel To make the sensor responsive start the engine to be idling Measure the maximum level high pulse voltage and m...

Page 295: ...15 22 7 Installed Locations of Parts TURBOCHARGER CONTROL SYSTEM ...

Page 296: ...15 15 23 ...

Page 297: ...15 24 TURBOCHARGER CONTROL SYSTEM ...

Page 298: ...15 15 25 ...

Page 299: ...15 26 TURBOCHARGER CONTROL SYSTEM ...

Page 300: ...15 15 27 ...

Page 301: ...15 28 TURBOCHARGER CONTROL SYSTEM ...

Page 302: ...M E M O 15 29 15 ...

Page 303: ...15 30 8 Electric Circuit Diagram TURBOCHARGER CONTROL SYSTEM ...

Page 304: ...15 15 31 ...

Page 305: ...15 32 TURBOCHARGER CONTROL SYSTEM ...

Page 306: ...M E M O 15 33 15 ...

Page 307: ...ning torque Unit N m kgf m Location Maintenance item Standard value Limit Remedy 1 Dust indicator activating negative pressure 9 12 0 69 kPa 930 70 mmH2O Replace Mark Parts to be tightened Tightening torque Remarks Clamp 3 0 to 3 5 0 3 to 0 35 1 Dust indicator 2 Air tube 3 Vacuator valve 4 Lower air duct 5 Duct joint hose 6 Air intake hose 7 Cover 8 Outer element 9 Safety element 10 Body AIR CLEAN...

Page 308: ...t Do not blow compressed air against outside surfaces of the element Inspection procedure Inspection Element Shine some electric light inside the element Replace the element if thin spots or broken parts are evident in the filter paper or if the packing at the top of the element is dam aged Also replace the element if the dust on the element is damp with oily smoke or soot regardless of the replac...

Page 309: ... return pipe 11 Gasket 12 Turbine speed sensor 13 O ring 14 Eyebolt 15 Eyebolt 16 Air pipe 17 Air hose 18 Connector 19 Turbocharger magnetic valve 20 Turbocharger magnetic valve bracket 21 Bracket 22 Turbocharger See later sec tion 23 Gasket a Exhaust manifold Non reusable parts MITSUBISHI 6M70 TURBOCHARGER ATTACHING PARTS Mitsubishi 6M70 Engine Parts contact email EngineParts HeavyEquipmentRestor...

Page 310: ...there is no clearance at the joints between the bracket and air pipe and bracket and exhaust manifold After installing the bracket ensure that there is no gas leakage from the joint of turbocharger with exhaust manifold Mark Parts to be tightened Tightening torque Remarks Clamp 7 0 to 8 0 0 7 to 0 8 Eyebolt oil pipe mounting 21 2 1 Eyebolt air pipe mounting Eyebolt air pipe mounting 25 2 5 Nut tur...

Page 311: ... kPa 4 to 8 kgf cm2 No air leakage of 25 cm2 25 mL for 1 minute 7 Play between nozzle lever plate and link 0 05 to 0 40 1 0 Replace 10 14 Clearance between compressor cover and compressor wheel 0 08 to 0 28 Check parts 14 Cartridge as sembly Play in axial direction of shaft and tur bine wheel 0 075 to 0 155 Check parts Shaft and turbine wheel to turbine back plate clearance 0 48 to 0 92 Check part...

Page 312: ... the nozzle from the flange Mark Parts to be tightened Tightening torque Remarks Bolt bracket mounting 34 to 38 3 5 to 3 9 Wet Clamp bolt 6 4 to 7 4 0 65 to 0 75 Wet Bolt clamp plate mounting 25 5 to 27 4 2 6 to 2 8 Wet Mark Points of application Specified lubricant and or sealant Quantity Threads of clamp bolt Seizure preventive compound FEL PRO CA 5 As required Threads of mounting bolt O ring En...

Page 313: ...rtridge assembly are easily bent Make sure that they do not strike the turbine housing Work after disassembly Cleaning Before cleaning visually check the disassembled parts for scorches abrasion and other marks that may be difficult to see after cleaning Replace any part that appears defective Immerse the disassembled parts in a non flammable solvent a 5 to 10 aqueous solution of Oil Clean from Ne...

Page 314: ...ssembly of the nozzle all the way by hand from full opening to full closing and measure its travel with a dial gauge A Position the ring assembly roughly in the middle of measured length of its travel To center and hold the ring assembly and mount in place use appropriate shims equally spaced at 3 places between them Type of shim Width length 5 mm 10 mm Thickness 0 1 mm to 0 4 mm Measure the play ...

Page 315: ...nd turbine wheel unit Be sure to measure the clearance at the periphery of the blades using two feeler gauges If the measurement deviates from the standard value disassem ble the cartridge assembly inspect and check the parts Installation procedure Installation Turbine housing Install the cartridge assembly into the turbine then perform the following test 1 Rotating condition of cartridge assembly...

Page 316: ...ied pressure in the air cylinder from the port A B C and bring the air cylinder into the state of full stroke then connect the lever to the joint Make sure that the lever is in slight contact with the position bolt B If there is an open space between the lever and position bolt B or the lever is pushing the position bolt B loosen the lock nut and make necessary adjustment by turning the shaft Then...

Page 317: ...e diameter 20 382 Replace Inside diameter 12 042 Replace Length 11 94 Replace 17 Inside diameter of bearing insertion bore in bearing housing 20 506 Replace 1 Lock nut 2 Compressor wheel 3 Snap ring 4 Insert 5 Piston ring 6 Thrust sleeve 7 Oil deflector 8 Thrust ring 9 Thrust bearing 10 Thrust ring 11 Shaft and turbine wheel 12 Piston ring 13 Turbine back plate 14 Bearing 15 Snap ring 16 O ring 17...

Page 318: ...ock nut Inspection Turbine housing to shaft and turbine wheel clearance If the measurement deviates from the standard value replace the defective part Removal Snap ring Remove the snap ring CAUTION Remove the snap ring while holding it with your hand to prevent it from springing off Mark Parts to be tightened Tightening torque Remarks Lock nut 20 2 0 Thread locking compound Mark Points of applicat...

Page 319: ...lowly measure the extent of bending If the measurement exceeds the specified limit replace the shaft and turbine wheel unit Reconditioning Attach the shaft and turbine wheel unit to a lathe supporting it at both centers With the shaft and turbine wheel unit turning at 300 to 600 rpm smooth the journal using sandpaper 400 and engine oil Measure the outside diameter of the bearing contact portion If...

Page 320: ...e thrust ring using dry tissue paper or the like Installation Insert Fit the piston ring onto the thrust sleeve then fit it into the insert its end gap first taking care that it is not damaged CAUTION When fitting the piston ring use care not to open it exces sively or twist its end gap portion Fit necessary parts in the insert first then fit the insert into the bearing housing CAUTION Before inst...

Page 321: ...ly compromising the oil resistance of the hose Service standards Tightening torque Unit N m kgf m Inspection procedure Inspection Intercooler Plug one of the air ports of the intercooler and immerse it in a tank of water Apply the specified air pressure to the intercooler through the other air port If leakage is apparent replace the intercooler Location Maintenance item Standard value Limit Remedy...

Page 322: ...tallation Air inlet hose Fit the air inlet hose to the intercooler and air inlet pipe to the il lustrated dimension Installation Air outlet hose Fit the air outlet hose to the intercooler and air inlet pipe to the il lustrated dimension ...

Page 323: ... mounting Nut air inlet pipe mounting Eyebolt 21 2 1 Bolt boost pressure sensor mounting 4 to 6 0 4 to 0 6 Intake air temperature sensor 1 20 2 0 Intake air temperature sensor 2 25 5 2 5 0 5 1 Eyebolt 2 Boost pressure sensor 3 Intake air temperature sensor 4 Intake air temperature sensor dummy 5 Bracket 6 Air inlet pipe 7 Gasket 8 Spacer 9 Gasket 10 Intake manifold 11 Gasket a Cylinder head See Gr...

Page 324: ...er from Wako Chemical Trusco Nakayama brake and parts cleaner ALP BP Chemsearch Lexite LO In 20 to 30 seconds after spraying wipe the sensor portion clear of the sprayed cleaner using a soft waste cloth or the like CAUTION Be sure to wait for 20 or 30 seconds before wiping It takes the cleaner that long to dissolve foreign matter If the sensor portion is fouled excessively the positive crankcase v...

Page 325: ...art No Application MH063080 Installation of exhaust manifold 1 Insulator 2 Front exhaust manifold 3 Seal ring 4 Exhaust Manifold Expansion rings 5 Rear exhaust manifold 6 Seal ring 7 Expansion ring 8 Center exhaust manifold 9 Exhaust Manifold Gaskets a Cylinder head See Gr11 Non reusable parts Torque wrench A Double flat surfaced 14 MITSUBISHI 6M70 EXHAUST MANIFOLD Mitsubishi 6M70 Engine Parts con...

Page 326: ... the seal rings with their end gaps positioned 120 degrees apart from each other Fit the expansion rings so that their crests do not meet the end gaps of the seal rings Fit the seal rings with their chamfered sides facing the center ex haust manifold Installation Mitsubishi 6M70 Exhaust manifold ...

Page 327: ... pipe mounting 85 to 110 8 7 to 11 0 Nut center front pipe mounting Nut lower front pipe mounting Bolt clamp mounting 20 3 2 1 0 3 1 Lower front pipe 2 Gasket 3 Gasket 4 Rubber cushion 5 Exhaust pipe hanger 6 Stay 7 Clamp 8 Exhaust pipe cover 9 Clamp 10 Center front pipe 11 Gasket 12 Rubber cushion 13 Clamp 14 Upper front pipe a Diesel Particulate Filter Non reusable parts EXHAUST PIPE FS ...

Page 328: ...allation procedure Installation Rubber cushions Tighten the rubber cushions until they are compressed to the thickness A Location of rubber cushion Compressed thickness Upper front pipe 10 mm Lower front pipe 23 mm ...

Page 329: ...ed to the il lustrated dimension Mark Parts to be tightened Tightening torque Remarks Bolt lower front pipe mounting 44 10 4 5 1 0 Nut upper front pipe mounting 85 to 110 8 7 to 11 0 1 Spring 2 Washer 3 Clamp 4 Lower front pipe 5 Washer 6 Seal ring 7 Gasket 8 Upper front pipe 9 Gasket 10 Rubber cushion 11 Exhaust pipe clamp bracket a Diesel Particulate Filter b Turbocharger coupler Non reusable pa...

Page 330: ...M E M O 15 57 15 ...

Page 331: ...d Tightening torque Remarks Nut clamp tightening 54 10 5 5 1 0 Nut front pipe mounting 85 to 110 8 6 to 11 0 Bolt clamp tightening 20 3 2 1 0 3 1 Clamp 2 Tail pipe 3 Stay 4 Rubber cushion 5 Collar 6 Gasket 7 DPF band 8 Stay 9 Rubber cushion 10 Collar 11 DPF a Front pipe Non reusable parts DPF Diesel Particulate Filter DIESEL PARTICULATE FILTER FS ...

Page 332: ...on procedure Installation DPF Insert the DPF pipe into the tail pipe until the DPF pipe bottoms out against the expanded portion of the tail pipe Installation Rubber cushions Compress the rubber cushions until the dimensions shown in the illustration are achieved Installation Clamps Tighten the nuts just enough to loosely retain the clamps so that they can easily be moved Tighten the nut at A unti...

Page 333: ...t front pipe mounting 34 to 54 3 5 to 5 5 Nut DPF mounting 70 to 95 7 1 to 9 7 Nut bracket mounting 306 to 360 31 to 37 Nut bracket mounting 20 3 2 1 0 3 1 Spring 2 Washer 3 Seal ring 4 Clamp 5 Tail pipe 6 Muffler plate 7 Muffler plate 8 DPF cover 9 DPF insulator 10 DPF 11 Bracket a Front pipe Non reusable parts DPF Diesel Particulate Filter DIESEL PARTICULATE FILTER EXCEPT FS ...

Page 334: ...is may be due to problems with the engine Check the engine and adjust as required Also check the engine oil and fuel Installation Clamps and rubber cushions Tighten the nuts just enough to loosely retain the clamps so that they can easily be moved Tighten the nut at A until the ends of the clamps at A contact with each other Completely tighten the nut at B CAUTION Do not overtighten the nut at B o...

Page 335: ...ness in Piping of Exhaust Gas Recirculation System 17 8 EXHAUST GAS RECIRCULATION SYSTEM 1 Diagnosis Procedure 17 10 2 Diagnostic Precautions 17 10 3 Inspections Based on Diagnosis Codes 17 11 4 Multi Use Tester Service Data 17 14 5 Actuator Tests Performed Using Multi Use Tester 17 14 6 Inspections Performed at Electronic Control Unit Connectors 17 14 7 Inspection of Electrical Equipment 17 16 8 ...

Page 336: ...h then control the EGR magnetic valves based on the information received EGR achieves lower combustion temperatures by reintroducing combusted exhaust gas which contains inert gases into the intake manifold This has the effect of reducing the amount of harmful NOx nitrogen oxides formed in the engine The EGR cooler enhances the NOx nitrogen oxides reducing performance of the EGR system by cooling ...

Page 337: ... OFF by drive signals from the engine electronic control unit to re alize a 7 stage supply of air to the EGR valve 2 Mitsubishi 6M70 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 magnetic valves ...

Page 338: ... Water temperature sensor Accelerator pedal position sensor Fault diagnosis function Engine warning lamp Electronic drive unit relay EGR Exhaust gas recirculation EDU Electronic drive unit Memory clear switch Multi Use Tester connector Diagnosis switch Intake air temperature sensor Electrical signal Controller area network signal EGR EDU EGR magnetic valve STRUCTURE AND OPERATION ...

Page 339: ...ments for faults In the event that the engine electronic control unit finds a component faulty it causes an indication to be made in the meter cluster to alert the driver At the same time it memorizes the fault location in the form of a diagnosis code While the engine is running the exhaust gas recirculation electronic drive unit continuously monitors the status of communication with the exhaust g...

Page 340: ...17 6 1 3 Electronic control unit connection diagram STRUCTURE AND OPERATION ...

Page 341: ...ositive crankcase ventilation valve keeps constant the pressure inside the crankcase The oil in the blowby gas is separated by the wire mesh and the element in the oil separator and the positive crankcase ventilation valve and is returned to the oil pan When the element is clogged the regulator valve opens and the blowby gas flows to the positive crankcase venti lation hose without passing through...

Page 342: ...hi Fuso element Using an inappropriate element could result in engine trouble When replacing the element be sure to replace the O ring also 2 Check for Cracks and Damages in Piping of Blowby Gas Return System Inspect the piping of blowby gas return system visually If there is any cracks or damages replace the piping See BLOWBY GAS RETURN SYSTEM 3 Check for Cracks Damages and Looseness in Piping of...

Page 343: ...M E M O 17 9 17 ...

Page 344: ...bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short circuit failure between terminals in connector or between connector and car body Resistance is affected by temperature Determine the necessity of resistance measurement following given tem perature specification as a guide Otherwise use normal temperature 10 to 3...

Page 345: ...ent 305 Intake air temperature sensor Electric circuit diagram Intake air temperature sensor 1 system Generation condition Intake air temperature sensor 1 voltage remains higher than 4 85 V for 3 sec onds Recoverability System recovers if intake air temperature sensor 1 voltage remains lower than 4 85 V for 1 second Control effected by electronic control unit Carries out control using a backup val...

Page 346: ...R2 Electrical equipment 530 Exhaust gas recirculation magnetic valve Electric circuit diagram Exhaust gas recirculation magnetic valve system Generation condition Controller area network signal from exhaust gas recirculation electronic drive unit indicating magnetic valve M V 2 circuit shorted to power source remains being received for 2 seconds Recoverability System recovers if controller area ne...

Page 347: ...rmal driving terminal low level when turned ON for 1 second Control effected by electronic control unit Exhaust gas recirculation control is stopped Inspection Service data 89 EDU Power Relay Actuator test B2 EDU Relay Electronic control unit connector Electronic drive unit relay Electrical equipment 201 Inspection of relay Electric circuit diagram Electronic drive unit relay system Generation con...

Page 348: ...ator test A1 EGR 1 2B Intake Air Temperature C On a cold engine Equal to ambient tempera ture 89 EDU Power Relay ON OFF Starter switch ON ON Starter switch OFF OFF Actuator test B2 EDU relay No Item Explanation Confirmation method A0 EGR 1 Maintain exhaust gas recirculation valve 1 opening indicated by Multi Use Tester Can be executed when the following conditions are satisfied Vehicle stationary ...

Page 349: ...rminals using the tester probes Check item Measurement method Resistance of intake air temperature sensor 1 Conditions Starter switch OFF Disconnect connector Perform inspection on vehicle side connector Requirements Terminals A63 A32 0 C 15 kΩ 20 C 6 514 kΩ 80 C 0 874 kΩ Voltage of electronic drive unit relay Conditions Starter switch ON Vehicle side harness connected Perform inspection on back o...

Page 350: ...ecirculation magnetic valve Perform the following checks If there is any abnormality replace the exhaust gas recirculation magnetic valve 1 Check of operation Gradually increase from zero the voltage applied to terminals 3 and 6 magnetic valve 1 2 and 5 magnetic valve 2 and 1 and 4 magnetic valve 3 Observe the voltage when the exhaust gas recirculation magnet ic valve operates Determine the magnet...

Page 351: ...M E M O 17 17 17 ...

Page 352: ...17 18 8 Installed Locations of Parts EXHAUST GAS RECIRCULATION SYSTEM ...

Page 353: ...17 17 19 ...

Page 354: ...17 20 EXHAUST GAS RECIRCULATION SYSTEM ...

Page 355: ...17 17 21 ...

Page 356: ...17 22 EXHAUST GAS RECIRCULATION SYSTEM ...

Page 357: ...17 17 23 ...

Page 358: ...17 24 9 Electric Circuit Diagram EXHAUST GAS RECIRCULATION SYSTEM ...

Page 359: ...17 17 25 ...

Page 360: ...17 26 MITSUBISHI 6M70 EGR VALVE EGR MAGNETIC VALVE EGR PIPE AND EGR COOLER ...

Page 361: ...ghtening torque Remarks Bolt EGR pipe clamp mounting 54 5 5 Bolt EGR pipe mounting Bolt Bracket mounting Bolt EGR cooler mounting Nut EGR pipe mounting 42 4 2 Clamp water hose mounting 3 9 0 4 Eyebolt EGR water pipe mounting 40 4 1 Connector air pipe mounting Bolt EGR magnetic valve mounting 24 2 4 Eyebolt EGR air pipe mounting 25 2 6 Bolt EGR pipe mounting 59 6 0 1 Upper EGR pipe clamp 2 Lower EG...

Page 362: ... a container of water Make sure the coolant pas sage is full of water Apply specified air pressure through the hose Check that air does not leak from any part If there is any leakage replace the EGR cooler 2 Coolant passage side Fit covers over the EGR cooler s exhaust gas inlet exhaust gas outlet and coolant outlet and connect a hose to the coolant in let Then submerge the EGR cooler in a contain...

Page 363: ...ce Perform installation by following the removal sequence in reverse Tightening torque Unit N m kgf m Mark Parts to be tightened Tightening torque Remarks Clamp 4 0 0 4 Bolt PCV pipe mounting 54 5 5 Bolt oil separator mounting Bolt PCV valve mounting 24 2 4 1 PCV hose 2 PCV pipe 3 PCV hose 4 PCV hose 5 PCV pipe 6 O ring 7 PCV hose 8 Oil hose 9 Oil separator 10 Oil hose 11 Cap 12 O ring 13 Element ...

Page 364: ... Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required BLOWBY GAS RETURN SYSTEM Mitsubishi 6M70 Engine Parts contact email EngineParts HeavyEquipmentRestorationParts com Phone 269 673 1638 ...