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Mitsubishi diesel engines User Manual

Mitsubishi diesel engines
219 pages
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FOREWORD
This service manual describes the specifications as well as the maintenance and
adjustment procedures for Mitsubishi diesel engines. This manual also includes the
detailed information on basic and special tools as the need arises.
The Mitsubishi diesel engines can offer highly efficient and reliable performance for
many years to come, which, however, only can be achieved through the proper
handling and the periodical inspection/maintenance work exercised in according to
the procedures of disassembly, inspection/adjustment and reassembly described in this
manual.
Before attempting any work on your engine, thoroughly read this manual to
familiarize with the engine and the required procedures of the work.
All information contained in this manual is based on the engine produced at the time
of publication and is subject to change as the engine improved without notice.
Pub. No. 99619-12140

Table of Contents

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Mitsubishi diesel engines Specifications

General IconGeneral
BrandMitsubishi
Modeldiesel engines
CategoryEngine
LanguageEnglish

Summary

Foreword

How to Use This Manual

Notes on Descriptions

Details how parts are numbered, inspecting points are shown, service standards are listed, reassembly sequence is provided, and safety marks are used.

General

Overview

Provides an overview of engine components with diagrams, including engine side views.

Specifications

Details technical specifications for various engine models, including dimensions, timing, and capacities.

Disassembly and Reassembly Notes

Provides general guidelines and safety precautions for engine disassembly and reassembly procedures.

Service Standards

Service Standards Table

Lists standard values, limits, and remarks for engine component measurements.

Tightening Torques Table

Provides a table of tightening torques for major bolts and nuts across different engine systems.

Sealants List

Lists specific sealants recommended for various sealing applications in engine assembly.

Tools List

General Tools

Lists common tools required for engine maintenance, including spanners and screwdrivers.

Special Tools

Lists specialized tools for specific engine service tasks like pin setting and ring pliers.

Overhaul Timing

Identifying the Timing for Overhaul

Discusses symptoms and criteria for determining when engine overhaul is necessary.

Measuring the Compression Pressure

Details the procedure for measuring engine compression pressure to assess internal condition.

Removal Preparations

Preparations

Outlines essential steps before engine removal, including wiring and fluid draining.

Removing the Electric Wiring

Instructions for safely disconnecting electrical wiring harnesses before engine removal.

Draining the Coolant

Procedure for draining engine coolant from the cooling system.

Draining the Engine Oil

Steps for draining engine oil from the oil pan.

Engine Main Parts - Disassembly

Cylinder Head, Valve Mechanism

Details the disassembly process for the cylinder head and its valve train components.

Flywheel, Timing Gear, Camshaft

Provides instructions for disassembling the flywheel, timing gears, and camshaft assembly.

Cylinder Block, Crankshaft, Pistons, Oil Pan

Explains the procedure for disassembling the engine block, crankshaft, pistons, and oil pan.

Engine Main Parts - Inspection and Correction

Cylinder Head, Valve Mechanism

Covers inspection and correction procedures for cylinder head and valve train components.

Flywheel, Timing Gear, Camshaft

Details inspection and correction methods for flywheel, timing gears, and camshaft.

Cylinder Block, Crankshaft, Pistons, Oil Pan

Describes inspection and correction procedures for engine block, crankshaft, pistons, and oil pan.

Engine Main Parts - Reassembly

Cylinder Block, Crankshaft, Pistons, Oil Pan

Provides step-by-step instructions for reassembling the engine block, crankshaft, pistons, and oil pan.

Flywheel, Timing Gear, Camshaft

Details the reassembly process for the flywheel, timing gears, and camshaft.

Cylinder Head, Valve Mechanism

Covers the reassembly procedures for the cylinder head and valve train components.

Fuel System - Removal

Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles

Instructions for removing fuel injection lines and nozzles.

Governor

Procedure for removing the engine governor assembly.

Fuel Injection Pumps

Steps for removing the fuel injection pump from the engine.

Fuel System - Disassembly, Inspection and Reassembly

Fuel Injection Nozzles

Covers disassembly, inspection, and reassembly of fuel injection nozzles.

Fuel Injection Pumps

Details the process for disassembling, inspecting, and reassembling fuel injection pumps.

Governor

Provides steps for disassembling and inspecting the engine governor.

Fuel Pump

Instructions for inspecting the engine's fuel pump.

Fuel Filter

Guidance on disassembling, inspecting, and reassembling the fuel filter.

Fuel System - Installation

Fuel Injection Pumps

Instructions for installing the fuel injection pumps onto the engine.

Governor

Procedure for installing the engine governor assembly.

Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles

Steps for installing fuel injection lines and nozzles.

Oil System - Removal

Oil Filter, Relief Valve and Oil Pressure Switch

Instructions for removing the oil filter, relief valve, and oil pressure switch.

Oil Pan, Oil Strainer

Procedure for removing the engine's oil pan and oil strainer.

Oil System - Disassembly, Inspection and Reassembly

Oil Pump

Details on inspecting the engine's oil pump.

Relief Valve

Procedure for inspecting the engine's oil relief valve.

Oil Pressure Switch

Instructions for inspecting the engine's oil pressure switch.

Oil System - Installation

Oil Filter, Relief Valve and Oil Pressure Switch

Steps for installing the oil filter, relief valve, and oil pressure switch.

Oil Pan and Oil Strainer

Procedure for installing the engine's oil pan and oil strainer.

Cooling System - Removal

Cooling Fan, Fan Pulley and V-Belt

Instructions for removing the cooling fan, pulley, and V-belt.

Thermostat and Thermoswitch

Procedure for removing the thermostat and thermoswitch components.

Water Pump

Steps for removing the engine's water pump.

Cooling System - Disassembly, Inspection and Reassembly

Thermostat

Covers disassembly and inspection of the engine thermostat.

Thermoswitch

Procedure for inspecting the engine thermoswitch.

Water Pump

Details on inspecting the engine's water pump.

Cooling System - Installation

Water Pump

Instructions for installing the engine water pump.

Thermostat and Thermoswitch

Steps for installing the thermostat and thermoswitch.

Cooling Fan, Fan Pulley and V-Belt

Procedure for installing the cooling fan, pulley, and V-belt.

Inlet and Exhaust Systems - Removal

Inlet Cover

Instructions for removing the engine's inlet cover.

Exhaust Manifold

Procedure for removing the engine's exhaust manifold.

Inlet and Exhaust Systems - Disassembly, Inspection and Reassembly

Inlet Cover and Exhaust Manifold

Covers inspection of inlet cover and exhaust manifold, including distortion measurement.

Inlet and Exhaust Systems - Installation

Exhaust Manifold

Instructions for installing the engine's exhaust manifold.

Inlet Cover

Procedure for installing the engine's inlet cover.

Electrical System - Removal

Starter

Instructions for removing the engine starter motor.

Alternator

Procedure for removing the engine alternator.

Stop Solenoid

Steps for removing the engine's stop solenoid.

Glow Plug

Procedure for removing the engine's glow plugs.

Electrical System - Disassembly, Inspection and Reassembly

Starter

Covers disassembly, inspection, and reassembly of the starter motor.

Alternator

Details the process for disassembling, inspecting, and reassembling the alternator.

Stop Solenoid

Provides steps for reassembling the engine's stop solenoid.

Glow Plug

Instructions for inspecting the engine's glow plugs.

Electrical System - Installation

Glow Plug

Instructions for installing the engine's glow plugs.

Stop Solenoid

Procedure for installing the engine's stop solenoid.

Alternator

Steps for installing the engine alternator.

Starter

Procedure for installing the engine starter motor.

Engine - Inspection / Adjustment, Running-in Trial and Performance Test

Inspection and Adjustment of Engine

Covers engine inspection and adjustment procedures, including valve clearance and timing.

Running-in Trial

Details the process for running-in a newly assembled or overhauled engine.

Performance Test

Explains methods for conducting engine performance tests and power adjustments.

Miscellaneous

Disassembly and Reassembly of General Parts

Provides guidance on disassembling and reassembling general engine parts like oil seals and bearings.

Engine Inspection Sheet

Cylinder bore

Form for recording cylinder bore measurements and comparing them to standard values.

Valve stem-to-guide clearance and valve stem diameter

Form for recording valve stem and guide measurements.

Valve seat angle and width

Form for recording valve seat angle and width measurements.

Cylinder head bottom face distortion

Form for recording cylinder head bottom face distortion measurements.

Connecting rod bearings oil clearance

Form for recording connecting rod bearing oil clearance measurements.

Rocker arm inner diameter and rocker shaft diameter

Form for recording rocker arm and shaft diameter measurements.

Piston pin boss inner diameter and piston pin diameter

Form for recording piston pin and boss diameter measurements.

Valve clearance

Form for recording valve clearance measurements before and after adjustment.

Fuel injection nozzle opening pressure

Form for recording fuel injection nozzle opening pressure measurements.

Camshaft journal diameter and camshaft bushing inner diameter

Form for recording camshaft journal and bushing diameter measurements.

Crankshaft end play

Form for recording crankshaft end play measurements.

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