Mitsubishi K21, Service Manual

Page 1: ...K21 K25 Service Manual K21 K25 Gasoline Engine For use with FG15N FG35N Chassis Service Manual 99789 57100 ...

Page 2: ...n correct servicing the servicing consistent with what you will learn from this service manual Read the respective sections of this manual carefully and become familiar with all the truck components before attempting any work All descriptions illustrations specifications and serial numbers in this manual are effective as of the printed date of this manual Mitsubishi reserves the right to change sp...

Page 3: ...TIGHTENING TORQUE TROUBLE DIAGNOSIS SPECIAL SERVICE TOOLS REMOVAL AND INSTALLATION OF ENGINE ENGINE SERVICE EC ENGINE CONTROL PRECAUTIONS PREPARATION DESCRIPTION TROUBLE DIAGNOSIS BASIC INSPECTION COMPONENT PARTS INSPECTION PCV GAS RECIRCULATION DEVICE ECM COM PONENTS LC ENGINE LUBRICATION COOLING SYSTEM LUBRICATION SYSTEM ENGINE COOLANT SYSTEM EF ENGINE FUEL EMISSION CONTROL SYSTEM ENGINE OUTSIDE...

Page 4: ...embling GI 5 Precautions for Inspection Correction and Replacement GI 5 Precautions for Assembly and Installation GI 5 Parts Requiring Angle Tightening GI 6 Caution with Use of Power Tools GI 6 Precautions for Liquid Gasket Application GI 6 TIGHTENING TORQUE GI 7 Standard Bolt Tightening Torque GI 7 Engine Part Tightening Torque GI 8 SPECIAL SERVICE TOOLS GI 10 ENGINE OUTSIDE DRAWINGS GI 11 MAIN S...

Page 5: ...78 N m 6 0 8 0 kgf m SI Metric system Main unit changes The conventional unit can be used for SI Description Caution At the beginning of each section the precautions exclusive to the section are described Preparation At the beginning of each section and during the trouble diagnosis items the Special Tools STs gauges and other tools to be prepared before operation are described Some commercial serv...

Page 6: ...ardous emissions Do not work underneath a vehicle supported only by a jack Always use rectangular wood blocks at the prescribed points to support the vehicle Support it at the prescribed points and lock it in position with safety devices before lifting the vehicle When removing a heavy component such as the engine and vehicle side be careful the vehicle body does not become off balance and fall Do...

Page 7: ...eing mixed up Clean or flush disassembled parts prior to inspection or assembly Use Genuine MITSUBISHI parts for replacement Use authorized grease and sealer Release the pressure before disconnecting pressurized piping or hoses Be sure to check for leakage after repairing fuel oil coolant exhaust or vacuum systems Precautions for Radio Equipment Installation Check the following when installing a c...

Page 8: ...outer one If a particular untightening sequence is provided separately follow the sequence Precautions for Inspection Correction and Replacement Following the inspection procedure inspect the parts adequately and repair or replace as necessary Perform the same inspections even for new parts and replace them if necessary Precautions for Assembly and Installation Always use a torque wrench when tigh...

Page 9: ...PLICATION INSTRUCTION 1 Remove any old liquid gasket remaining on the gasket application surface and its mating surface using a scraper Remove any old liquid gasket remaining in the gasket application groove and on the threads of bolts and bolt holes 2 Wipe the gasket application surface and its mating surface using Isozole or any equivalent thinner to remove any moisture oil and foreign material ...

Page 10: ... 37 3 kgf m 1 3 1 6 2 1 2 7 3 0 3 8 M10 1 25 N m 19 6 22 6 32 4 38 2 47 1 53 9 kgf m 2 0 2 3 3 3 3 9 4 8 5 5 N m 25 5 33 3 43 1 54 9 61 8 78 5 kgf m 2 6 3 4 4 4 5 6 6 3 8 0 1 5 N m 18 6 21 6 30 4 36 3 44 1 52 kgf m 1 9 2 2 3 1 3 7 4 5 5 3 N m 24 5 31 4 41 2 52 58 8 74 5 kgf m 2 5 3 2 4 2 5 3 6 0 7 6 Flanged bolt M6 1 N m 4 9 5 69 8 14 9 51 11 8 13 7 kgf m 0 5 0 58 0 83 0 97 1 2 1 4 N m 5 98 7 65 9...

Page 11: ...olt lubricated N m 132 142 kg m 13 47 14 49 ft lb 94 4 104 8 Connecting rod nut lubricated N m 31 4 37 3 kg m 3 2 3 81 ft lb 23 27 6 Rear plate bolt N m 44 1 58 8 kg m 4 5 6 0 ft lb 33 43 Camshaft sprocket bolt N m 39 2 49 kg m 4 0 5 0 ft lb 29 36 Oil filter stud N m 29 4 39 2 kg m 3 0 4 0 ft lb 22 29 Oil filter element N m 14 7 20 6 kg m 1 5 2 1 ft lb 11 15 Spark plug N m 19 6 29 4 kg m 2 0 3 0 f...

Page 12: ...l or engine oil to the bolt threads and head bottom Do not use any power tools such as a pneumatic air tool for assembly Tightening point Unit Standard Max value Mass air flow sensor mounting screw N m 1 27 1 67 kgf m 0 13 0 17 Fuel tube flare nut N m 16 0 23 0 kgf m 1 63 2 35 Crankshaft position sensor plug bolt N m 6 37 7 45 kgf m 0 65 0 76 Thermo housing relief plug N m 6 37 7 45 kgf m 0 65 0 7...

Page 13: ...2 91H20 09111 3 91H20 09112 Crankshaft main bearing cap puller Crankshaft main bearing puller Adapter Adapter 91H20 09120 Valve lifter 91H20 09150 91H20 09160 91H20 09170 Front oil seal drift Rear oil seal drift Drift rod 91H20 09020 Heated oxygen sensor wrench Removing and installing heated oxygen sensor GIM0066 GIM0067 GIM0068 GIM0069 GIM0071 GIM0072 GI 10 SPECIAL SERVICE TOOLS ...

Page 14: ...ENGINEOUTSIDEDRAWINGS ELECTRIC CONTROLLED SPECIFICATION GI 11 ENGINE OUTSIDE DRAWINGS ...

Page 15: ...a bar kg cm2 psi rpm 1 450 14 5 14 79 210 3 250 Engine speed control system Engine Control System electric controlled throttle Fuel in use Note Unleaded regular gasoline At 20P At 20P Valve opening closing timing degree Intake open ATDC 4 Intake close ABDC 40 Exhaust open BBDC 36 Exhaust close ATDC 0 Valve clearance mm in Intake when engine is hot 0 38 0 0150 Exhaust when engine is hot 0 38 0 0150...

Page 16: ...kg cm2 psi rpm 1 510 15 1 15 4 219 Engine speed control system Engine Control System electric controlled throttle Fuel in use Note Unleaded regular gasoline At 20P At 20P Valve opening closing timing degree Intake open ATDC 4 Intake close ABDC 40 Exhaust open BBDC 36 Exhaust close ATDC 0 Valve clearance mm in Intake when engine is hot 0 38 0 0150 Exhaust when engine is hot 0 38 0 0150 Firing order...

Page 17: ... Fuel device standard type Electric controlled fuel injection device Engine Control System Electric controlled fuel injection device Engine Control System Fuel device Gasoline injector LPG injector Gasoline LPG Gasoline injector LPG injector Gasoline LPG Air fuel ratio control device Air fuel ratio feedback control Air fuel ratio feedback control Starting auxiliary device Electric throttle control...

Page 18: ...utor Full transistor type air gap mm Standard 0 35 0 45 Valve clearance Hot mm Standard Intake 0 38 0 03 Exhaust 0 38 0 03 Thermostat valve opening temperature STD C Standard 76 5 Idle speed and ignition timing BTDC rpm Standard 0 700 50 CYLINDER HEAD Cylinder head mm Material Aluminum alloy Distortion limit 0 1 CYLINDER BLOCK Block upper surface mm Distortion limit 0 1 Bore diameter dimension mm ...

Page 19: ...rance between piston ring and ring groove mm Standard Top 0 045 0 080 Second 0 030 0 070 Oil Repair limit Top 0 10 Second 0 10 Oil CONNECTING ROD Distance between both end hole centers mm Standard 143 970 144 030 K25 152 470 152 530 K21 Large end hole diameter mm Standard 48 0 48 013 Small end hole diameter mm Standard 19 965 19 978 Bend per 100 mm mm Repair limit 0 05 Torsion per 100 mm mm Repair...

Page 20: ...ir limit 0 10 Ring gear surface swing mm Repair limit 0 50 Flatness mm Repair limit 0 30 CAMSHAFT Bend mm Repair limit 0 05 Camshaft height mm Standard 36 750 36 800 For both intake and exhaust Size reduction limit 36 5 Journal dimension mm Standard Front 45 434 45 447 Center 43 897 43 910 Rear 41 218 41 231 End play mm Standard 0 025 0 255 Repair limit 0 40 Journal oil clearance mm Standard Front...

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