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S6S-Y3T62HF
Mitsubishi S6S-Y3T62HF Manuals
Manuals and User Guides for Mitsubishi S6S-Y3T62HF. We have
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Mitsubishi S6S-Y3T62HF manual available for free PDF download: Service Manual
Mitsubishi S6S-Y3T62HF Service Manual (204 pages)
Brand:
Mitsubishi
| Category:
Engine
| Size: 16.55 MB
Table of Contents
General
15
How to Use this Manual
5
Fire and Explosion
7
Table of Contents
15
External View
18
General
20
Fuel System - Flow Diagram
20
Lubrication System - Flow Diagram
20
Cooling System - Flow Diagram
21
Inlet and Exhaust System - Flow Diagram
21
System Flow Diagrams
20
Engine Serial Number Location
22
Main Specifications
23
Tips on Disassembling and Reassembling
26
Disassembling
26
Reassembling
26
Service Data
27
1 Maintenance Service Data
28
Service Data
28
General
28
Basic Engine
29
Service Data
30
Fuel System
32
Lubrication System
32
Cooling System
33
Inlet and Exhaust System
33
Electrical System
34
2 Tightening Torque Table
35
Major Bolt Tightening Torque
35
Basic Engine
35
Fuel System
35
Lubrication System
36
Cooling System
36
Inlet and Exhaust Systems
36
Electrical System
36
Standard Bolt and Nut Tightening Torque
37
Metric Automobile Screw Thread
37
Metric Course Screw Thread
37
Standard Stud Tightening Torque
37
3 Regarding Submission of Parts for EPA Exhaust Gas Regulation
38
Service Tools
39
Special Tool
40
Determination of Overhaul
43
Determining Overhaul Timing
43
Testing Compression Pressure
45
Disassembly of Basic Engine
47
1 Disassembling and Inspecting Cylinder Head and Valve Mechanism
48
Disassembly of Basic Engine
48
Removing Rocker Shaft Assembly
49
Disassembling Rocker Shaft Assembly
49
Removing Cylinder Head Bolt
49
Removing Cylinder Head Assembly
50
Removing Valve and Valve Spring
50
Removing Valve Stem Seal
50
2 Disassembling and Inspecting Flywheel
51
Removing Flywheel
52
Removing Rear Plate
52
3 Disassembling and Inspecting Damper, Gear Case, Timing Gear and Camshaft
53
Removing Crankshaft Pulley and Damper
55
Removing Cover
55
Removing Timing Gear Case
56
Measuring Timing Gear Backlash
56
Measuring Idler Gear and Camshaft Gear End Play
57
Removing Fuel Injection Pump
57
Removing Oil Pan
57
Removing Oil Strainer
57
Removing Oil Pump Gear
58
Removing Idler Gear
58
Removing PTO Drive Gear
58
Removing Camshaft
58
Separating Camshaft Gear
59
Installing Camshaft Gear and Thrust Plate
59
Removing Front Plate
59
Removing Oil Pump
59
4 Disassembling and Inspecting Piston, Connecting Rod, Crankshaft and Crankcase
60
Removing Connecting Rod Cap
61
Removing Carbon Deposits from the Upper Part of Cylinder Liner
61
Pulling out Piston
61
Removing Piston Ring
62
Removing Piston Pin and Piston
62
Removing Main Bearing Cap
62
Removing Crankshaft
63
Removing Tappet
63
Inspection and Repair of Basic Engine
65
1 Inspecting and Repairing Cylinder Head and Valve Mechanism
66
Inspection and Repair of Basic
66
Measuring Clearance between Rocker Bushing and Rocker Shaft
66
Measuring Valve Stem Outside Diameter and Valve Guide Inside Diameter
66
Replacing Valve Guide
67
Inspecting Valve Face
68
Refacing Valve Face
68
Refacing Valve Seat
69
Replacing Valve Seat
70
Lapping Valve and Valve Seat
71
Measuring Perpendicularity and Free Length of Valve Spring
71
Measuring Distortion of the Bottom Surface of the Cylinder Head
72
Measuring Push Rod Runout
72
Removing Combustion Jet
73
2 Inspecting and Repairing Flywheel
74
Measuring Flatness of Flywheel
74
Measuring Flywheel Face and Radial Runouts
74
Inspecting Ring Gear
74
Replacing Ring Gear
74
Removing Ring Gear
74
Installing Ring Gear
74
3 Inspecting and Repairing Timing Gear and Camshaft
75
Measuring Timing Gear Backlash
75
Measuring Idler Gear and Camshaft Gear End Play
75
Measuring Cam Lift
75
Measuring Camshaft Runout
76
Measuring Camshaft Journal Outside Diameter
76
Measuring Camshaft Bushing Inside Diameter
76
Replacing Camshaft Bushing
77
Removing Camshaft Bushing
77
Installing Camshaft Bushing
77
Measuring Idler Bushing Inside Diameter and Idler Shaft Outside Diameter
77
Replacing Idler Shaft
78
Measuring Clearance between Tappet and Tappet Guide Hole
78
Inspecting Tappet
78
Contact Surface of Camshaft
78
Contact Surface of Push Rod
78
Inspecting V-Belt Groove Wear
79
Inspecting Damper
79
4 Inspecting and Repairing Piston, Connecting Rod, Crankshaft and Crankcase
80
Measuring Crankcase Top Surface Distortion
80
Measuring Cylinder Inside Diameter
81
Measuring Piston Outside Diameter
82
Measuring Piston Ring End Gap
82
Measuring Clearance between Piston Ring Groove and Piston Ring
83
Measuring Piston Pin Bore Diameter and Piston Pin Outside Diameter
83
Measuring Piston Protrusion
84
Measuring Clearance between Connecting Rod Bearing and Crankpin
85
Measuring Clearance between Connecting Rod Bushing and Piston Pin
85
Replacing Connecting Rod Bushing
86
Inspecting Connecting Rod Bend and Twist6-22
86
Inspecting Connecting Rod Bearing
87
Measuring Connecting Rod End Play
87
Weight Difference of Connecting Rod Assembly
87
Measuring Crankshaft Journal Outside Diameter
88
Measuring Crankshaft Crankpin Outside Diameter
88
Grinding Crankshaft
89
Measuring Crankshaft End Play
90
Measuring Crankshaft Runout
90
Replacing Crankshaft Gear
91
Removing Crankshaft Gear
91
Installing Crankshaft Gear
91
Inspecting Oil Seal Contact Surface
91
Installing Oil Seal Sleeve
92
Removing Oil Seal Sleeve
92
Inspecting Main Bearing Surface
93
Measuring Clearance between Main Bearing and Crankshaft Journal
93
Reassembly of Basic Engine
95
1 Reassembling Piston, Connecting Rod, Crankshaft and Crankcase
96
Reassembly of Basic Engine
96
Installing Main Bearing
96
Installing Thrust Plate
96
Installing Tappet
96
Installing Crankshaft
96
Installing Main Bearing Caps
97
Inserting Side Seal
97
Installing Main Bearing Cap Bolt
97
Measuring Crankshaft End Play
98
Reassembling Piston and Connecting Rod
98
Installing Piston Ring
99
Preparation for Installing Pistons
99
Installing Connecting Rod Bolt and Connecting Rod Bearing
100
Installing Pistons
100
Installing Connecting Rod Cap
101
2 Reassembling Timing Gear and Camshaft
102
Installing Oil Pump
102
Installing Front Plate
102
Installing Camshaft Gear and Thrust Plate
103
Installing Camshaft
103
Installing PTO Drive Gear
103
Installing Idler Gear
104
Installing Oil Pump Gear
105
Installing Fuel Injection Pump
105
Inspecting and Adjusting Timing Gear after Installation
105
Inspecting Backlash and End Play
105
Installing Front Oil Seal
106
Installing Timing Gear Case
106
Installing Oil Strainer
106
Installing Oil Pan
107
Installing Cover
108
Installing Crankshaft Pulley and Damper
108
3 Reassembling Flywheel
109
Installing Oil Seal
109
Installing Rear Plate
109
Installing Flywheel
109
4 Reassembling Cylinder Head and Valve Mechanism
110
Cleaning Cylinder Head Bottom Surface
110
Installing Valve Stem Seal
110
Installing Valve and Valve Spring
110
Installing Cylinder Head Gasket
111
Installing Cylinder Head Assembly
111
Tightening Cylinder Head Bolts
111
Inserting Push Rod
112
Reassembling Rocker Shaft Assembly
112
Installing Rocker Shaft Assembly
112
Determining Top Dead Center of No. 1 Cylinder Compression Stroke
113
When Reusing the Damper
113
When Replacing the Damper with a New One
113
Adjusting Valve Clearance
113
Installing Rocker Cover
113
Fuel System
115
1 Removing Fuel System
116
Fuel System
116
Removing Fuel Filter
116
Removing Fuel Injection Pipe
117
Removing Fuel Injection Pump
118
2 Disassembling, Inspecting and Reassembling Fuel System
119
Disassembling and Inspecting Fuel Filter
119
Changing Fuel Filter
120
Disassembling and Inspecting Fuel Injection Nozzle
121
Inspecting and Adjusting Fuel Injection Valve Opening Pressure
122
Inspecting Fuel Spray Pattern of Fuel Injection Nozzle
122
Cleaning and Inspecting Nozzle Tip
123
Reassembling Fuel Injection Nozzle
124
Inspecting and Cleaning Gauze Filter of Distribute Type Fuel Injection Pump
125
3 Installing Fuel System
126
Installing Fuel Injection Pump
126
Installing Fuel Injection Pipe
127
Installing Fuel Filter
128
Lubrication System
129
1 Removing Lubrication System
130
Lubrication System
130
Removing Oil Filter and Relief Valve
130
Removing Oil Cooler
131
Removing Oil Pump, Oil Pan and Oil Strainer
132
2 Disassembling, Inspecting and Reassembling Lubrication System
133
Disassembling and Inspecting Oil Pump
133
Inspecting Oil Pump
134
Measuring Clearance between Outer Rotor and Inner Rotor
134
Measuring End Play of Rotor and Pump Case
134
Measuring Clearance between Outer Rotor and Pump Case
134
Measuring Clearance between Main Shaft and Pump Case
135
Measuring Clearance between Main Shaft and Bushing
135
Installing Oil Pump Bushing
135
Reassembling Oil Pump
136
Disassembling and Inspecting Oil Cooler
137
Inspecting Oil Filter
138
Inspecting Relief Valve
139
Inspecting Safety Valve
139
3 Installing Lubrication System
140
Installing Oil Pump, Oil Pan and Oil Strainer
140
Installing Oil Cooler
141
Installing Oil Filter and Relief Valve
142
Cooling System
143
1 Removing Cooling System
144
Cooling System
144
Removing Thermostat
144
Removing Water Pump, Water Pump Pulley and V-Belt
145
2 Disassembling, Inspecting and Reassembling Cooling System
146
Disassembling and Inspecting Thermostat
146
Inspecting Thermostat
147
Disassembling Water Pump
148
Inspecting Water Pump
148
3 Installing Cooling System
149
Installing Water Pump, Water Pump Pulley and V-Belt
149
Installing Thermostat
150
Inlet and Exhaust Systems
151
1 Removing Turbocharger, Inlet and Exhaust Systems
152
Inlet and Exhaust Systems
152
Removing Turbocharger
152
Removing Inlet Manifold
153
Removing Exhaust Manifold
154
2 Disassembling, Inspecting and Reassembling Inlet and Exhaust Systems
155
Measuring Exhaust Manifold Distortion
155
Disassembling and Inspecting Turbocharger
156
Removing Turbine Housing
157
Removing Compressor Cover
157
Installing O-Ring
157
Installing Compressor Cover
158
Installing Snap Ring
158
Cleaning
159
Measuring Axial Clearance of Cartridge Assembly
159
Reassembling Turbocharger
160
3 Installing Turbocharger, Inlet and Exhaust Systems
162
Installing Exhaust Manifold
162
Installing Inlet Manifold
163
Installing Turbocharger
164
Electrical System
165
1 Removing Electrical System
166
Electrical System
166
Removing Starter
166
Inspection before Removing Alternator
167
Inspecting Alternator Operation
167
Handling Precaution
167
Removing Alternator
168
Removing Glow Plug
170
2 Disassembling, Inspecting and Reassembling Electrical System
171
Inspection before Disassembling Starter
171
Inspecting Magnetic Switch
171
No Load Test
172
Disassembling and Inspecting Starter
173
Removing Pinion Set
174
Removing Magnetic Switch
175
Removing Rear Bracket
175
Removing Brush Holder and Brush Assembly
175
Removing Armature and Yoke
175
Removing Overrunning Clutch
175
Inspecting and Repairing Starter
176
Inspecting Brushes for Wear
176
Measuring Brush Spring Load
176
Inspecting Brush Holder for Insulation
176
Measuring Commutator Radial Runout
176
Measuring Commutator Outside Diameter12-13
177
Measuring Undercut Depth
177
Checking Armature Coil
177
Inspecting Field Coil
178
Inspecting Rear Bracket
178
Inspecting Overrunning Clutch Operation
178
Inspecting Front Bracket
178
Inspecting Gears of Starter
178
Inspecting Magnetic Switch
179
Inspecting Starter Relay
179
Reassembling Starter
180
Installing Gear Shaft
180
Disassembling and Inspecting Alternator12-17
181
Separating Front Bracket from Stator
181
Removing Field Coil
182
Removing Pulley
182
Removing Rear Bearing
182
Removing Front Bearing
183
Removing Stator
183
Removing Regulator Assembly
183
Removing Rectifier Assembly
183
Inspecting and Repairing Alternator
184
Inspecting Stator
184
Inspecting Rectifier
184
Measuring Field Coil
185
Reassembling Alternator
186
Installing Rectifier Assembly and Regulator Assembly
186
Installing Stator
187
Installing Front Bearing
187
Installing Rear Bearing
187
Installing Pulley
187
Assembling Stator and Front Bracket
188
Inspecting Glow Plug
188
Continuity Test of Glow Plug
188
Heating Test of Glow Plug
188
Inspecting Magnetic Valve (Stop Solenoid)
189
Continuity Test of Magnetic Valve (Stop Solenoid)
189
Inspecting Magnetic Valve (Stop Solenoid) Operation
189
Installing Magnetic Valve (Stop Solenoid)12-25
189
3 Installing Electrical System
190
Installing Glow Plug
190
Installing Alternator
191
Installing Starter
193
Adjustment and Operation
195
Adjusting Engine
196
Adjustment and Operation
196
Inspecting and Adjusting Valve Clearance13-2
196
Inspecting Valve Clearance
196
Adjusting Valve Clearance
196
Bleeding Fuel Filter
197
Bleeding Fuel System
197
Draining Fuel Filter
197
Draining Fuel System
197
Adjusting Fuel Injection Timing
198
Inspecting and Adjusting Fuel Injection Timing
198
Adjusting V-Belt Tension
201
Inspecting V-Belt
201
Inspecting V-Belt and Adjusting V-Belt Tension
201
2 Break-In Operation
202
Starting up
202
Inspecting Engine Condition after Starting up
202
Break-In Operation Time
202
Inspection and Adjustment after Break-In Operation
202
3 Performance Test (JIS Standard)
203
Engine Equipment Condition
203
Test Items and Purposes
203
Operation Load Test
203
Continuous Load Test
203
Low Idle Test
203
Standard Atmospheric Conditions
203
Calculation of Corrected Power
204
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