Page 1 Mitsubishi 6M70 GROUP INDEX Workshop GENERAL ..........Manual ENGINE ..........LUBRICATION ........diesel engine FUEL AND ENGINE CONTROL ... COOLING ..........INTAKE AND EXHAUST....... EMISSION CONTROL ......APPLICABLE SERVFICE BULLETINS FOR THIS MANUAL INDEX Applicable models Mitsubishi 6M70...
Page 2 DIAGNOSIS CODES 1. Diagnosis Codes • Diagnosis codes indicate the faulty sections of the vehicle. • A fault can be repaired by reading out the diagnosis code(s) stored in the control unit and performing the remedy for that code(s). • Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to be diagnosed.
Page 3 2. Reading and Erasing the Diagnosis Code 2.1 Using a Multi-Use Tester (1) Connecting a Multi-Use Tester Special tools Mark Tool name and shape Part No. Application SOFTWARE DISC FMS-E07-3* Installation of the Muti-Use-Tester-III Multi-Use Tester III (Multi-Use or version-up of the current version SOFTWARE DISC Tester-III ver- into Multi-Use Tester-III SOFTWARE...
Page 4 DIAGNOSIS CODES (1.1) To perform system inspection • Move the starter switch to the LOCK position. • Connect PC installed -A and as shown. • Connect -A connector to the Multi-Use Tester connector on the vehicle. (1.2) To use drive recorder function •...
Page 5 (2) Access of diagnosis code • Set the starter switch to ON. • Operate the Multi-Use Tester for a display of necessary diagnosis code stored in the memory of the electronic control unit and identify the location of the fault. (3) Clearing of diagnosis code •...
Page 6 DIAGNOSIS CODES (1.1) Reading diagnosis codes • To read a diagnosis code, observe how may times the warning lamp flashes and how long each illumination lasts. • The duration of illumination differs between the first and second digits. • Second digit: 1.2 sec. •...
Page 7 (2) Full automatic air conditioner (2.1) Connection of LED for inspec- tion • Move the starter switch to the LOCK position. • Connect the LED for inspection to the Multi-Use Tester connector. CAUTION • Air conditioner electronic control unit and control panel has a backup power supply to keep diagnostic check results in memory.
Page 8 TABLE OF STANDARD TIGHTENING TORQUES • Use specified bolts and nuts. Tighten them to the torques shown below as appropriate, unless otherwise speci- fied. • Threads and bearing surfaces shall be dry. • If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the bolt.
Page 9 Hexagon Nuts (Unit: N·m {kgf·m}) Strength Identification symbol Nominal Standard screw Coarse screw Standard screw thread Coarse screw thread diameter thread thread 2 to 3 4 to 6 – – {0.2 to 0.3} {0.4 to 0.6} 4 to 6 7 to 10 –...
Page 10 TABLE OF STANDARD TIGHTENING TORQUES Tightening Torque for General-Purpose Flare Nut (Unit: N·m {kgf·m}) φ φ φ φ φ φ Pipe diameter 4.76 mm 6.35 mm 8 mm 10 mm 12 mm 15 mm Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0}...
Page 11 GROUP 11 ENGINE SPECIFICATIONS ................11-2 STRUCTURE AND OPERATION 11-3 1. Engine Proper ..................2. Rocker and Shaft, Camshaft, Rocker Case and 11-4 Cylinder Head Gasket ............... 11-4 3. Valve Mechanism ................11-5 4. Connecting Rod ................. 11-5 5. Piston ....................11-6 6.
Page 12 309 {420} / 2000 Maximum torque N·m {kgf·m} /rpm 1620 {165} / 1100 1810 {185} / 1100 Cylinder bore × stroke φ135 × 150 Total displacement 12882 {12.882} Compression ratio 17.5 Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 11-2...
Page 13 STRUCTURE AND OPERATION 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. 11-3...
Page 14: Valve Mechanism
STRUCTURE AND OPERATION 2. Rocker and Shaft, Camshaft, Rocker Case and Cylinder Head Gasket • The camshaft journals are directly supported by the rocker case and the camshaft cap, without using any cam- shaft bearings. The rocker case and camshaft caps have been machined together, meaning that they all need to be replaced for a new set when one of them becomes defective.
Page 15 4. Mitsubishi 6M60 Connecting Rod • Weight mark: “A” to “H”, “J” to “M” • “A” indicates the greatest connecting rod mass. 5. Mitsubishi 6M70 Piston 11-5...
Page 16 STRUCTURE AND OPERATION 6. Mitsubishi 6M70 Timing Gears • The timing gears are provided with timing marks to help ensure correct assembly. • Timing marks are provided on the fol- lowing gears. • Camshaft gear: stamped line • Crankshaft gear: “A”...
Page 17 8. Flywheel PTO • The flywheel PTO is located in the upper part of the flywheel housing and is driven by the PTO drive gear. 11-7...
Page 18 STRUCTURE AND OPERATION 9. Powertard Brake System • The Powertard is activated when all of the following conditions are met with the combination switch placed in the first stage or second stage. • Engine speed: 800 to 2400 rpm • Clutch pedal released (clutch pedal switch: OFF) •...
Page 19 9.1 Operation of Powertard brake system • The Powertard brake system is a device to enhance the engine brake performance. It opens and closes the ex- haust valve (one side only) to control the volume of compressed air in the combustion chamber in accordance with the movement of the piston, thereby providing a boosted braking force.
Page 20 STRUCTURE AND OPERATION • When the Powertard system is activated, the piston pressing force works as a braking force during the compression stroke as when the Powertard system is not activated. During the expan- sion period, the exhaust valve is opened by the working of the system to let some of the compressed air out through the ex- haust port.
Page 21 • As the Powertard cam further rotates and the cam lobe top leaves the mas- ter piston, the oil pressure in the oil passage is reduced. • As a result, the exhaust valve is closed by its spring force, which allows the valve to open and close according to ordinary valve timing.
Page 22 TROUBLESHOOTING Symptoms Reference Gr Possible causes Valve clearance incorrect Defective cylinder head gasket Valve and valve seat worn and carbon deposits Cylinder head and valve mechanism Valve spring fatigued Defective rocker shaft and bracket Poor lubrication of rocker shaft and bracket assembly Defective backlash between gears Timing gears Poor lubrication of gearts and idler shaft...
Page 23 Powertard Brake System Symptoms Reference Gr Possible causes Lubrication oil is cold and too viscous Powertard clearance too large Blown fuse Improper connection of harnesses and connectors Defective clutch switch Defective accelerator switch Defective transmission neutral switch Gr13 Electrical system Defective powertard switch (combination switch) Defective meter cluster Defective engine speed sensor...
Page 24 Maintenance item Standard value Limit Remedy 2,940 kPa 1,960 kPa Each cylinder (at 200 rpm) Inspect {30 kgf/cm {20 kgf/cm Mitsubishi 6M70 – 390 kPa Pressure difference be- Compression pressure – {4 kgf/cm Inspect tween each cylinder or less Special tools (Unit: mm)
Page 25 • Remove all the injectors. (See Gr13.) • Cover the injector mounting holes with shop towels or other sim- ilar cloth. Crank the engine using the starter. Ensure that no for- eign matter is attached on the shop towels. CAUTION •...
Page 26 – Adjust Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Lock nut ( 6M70 valve bridge adjusting screw tightening) – 68 {7} – Lock nut ( 6M70 rocker arm adjusting screw tightening) – 60 {6} –...
Page 27 • Before inserting a feeler gauge, push the adjusting screw pad on the side opposite from where a feeler gauge is to be inserted, as shown in the illustration, using a flat-blade screwdriver or other similar tool. This will create space necessary for the gauge to be inserted.
Page 28 • 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”.) Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 11-18...
Page 29 M E M O 11-19...
Page 30 ON-VEHICLE INSPECTION AND ADJUSTMENT 3. Inspection and Adjustment of Powertard Clearances Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy – Powertard clearance (when engine is cold) 1.0 ± 0.05 – Adjust Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks...
Page 31 • When the No. 1 or No. 6 piston is at the TDC position of its com- pression stroke, measure Powertard clearance for the valve marked in the following table. Cylinder No. Powertard clearance measuring point No. 1 piston at TDC of compression stroke No.
Page 32 ENGINE REMOVAL AND INSTALLATION Removal sequence 1 Engine 2 Rear mounting : Locating pin 3 Front mounting Installation sequence Follow the removal sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Nut (front mounting installation) 300 to 400 {30 to 40} –...
Page 33 Removal procedure Removal: Engine • Hook a lifting device onto front hanger, rear hanger RH and rear hanger LH, and lift the device with a crane until it is taut. WARNING • Use a lifting device that can comfortably withstand the mass of the engine (approx.
Page 34 ENGINE REMOVAL AND INSTALLATION Installation procedure Installation: Rear mounting • Install the rear mounting on the engine in the illustrated direc- tion. Installation: Engine • Loosen cross member and support mounting bolts and nuts. • Hook a lifting device onto front hanger, rear hanger RH and rear hanger LH, and lift the device with a crane to install the engine.
Page 35 M E M O 11-25...
Page 36 MITSUBISHI 6M70 ROCKER COVER, ROCKER AND SHAFT 11-26...
Page 37 Disassembly sequence 1 Oil filler cap 7 Harness 12 O-ring 2 Rubber 8 Slave piston housing 3 Rocker cover 9 Rocker shaft cap a: Rocker case 4 Rocker cover gasket 10 Rocker and shaft : Locating pin 5 Packing (See later section.) : Non-reusable parts 6 Oil pipe 11 Bushing connector...
Page 38 ROCKER COVER, ROCKER AND SHAFT Rocker and Shaft Disassembly sequence 1 Adjusting screw 2 Rocker bushing 3 Intake rocker 4 Rocker shaft spring 5 Adjusting screw 6 Rocker bushing 7 Exhaust rocker 8 Rocker shaft Assembly sequence Follow the disassembly sequence in re- verse.
Page 39 Inspection procedure Inspection: Radial clearance of rocker (roller) • If the measurement deviates from the standard value, replace the defective part(s). Inspection: Clearance between rocker shaft and bushing • If the measurement exceeds the limit, replace the bushing. Replace of rocker bushing [Removal] [Installation] •...
Page 40 MITSUBISHI 6M70 CAMSHAFT AND ROCKER CASE 11-30...
Page 41 Disassembly sequence 1 Camshaft cap 6 O-ring a: Cylinder head 2 Camshaft 7 Connector b: Idler gear D (See later section.) 8 Rocker case c: Timing gear case 3 Master piston 9 O-ring : Locating pin 4 Master piston housing 10 Rocker case gasket : Non-reusable parts 5 Powertard solenoid valve...
Page 42 CAMSHAFT AND ROCKER CASE Work before removal Inspection: Backlash between idler gear D and camshaft gear • Measure the backlash at least at three different locations. If the measurement exceeds the limit, replace the defective part(s). Inspection: Camshaft end play •...
Page 43 Installation procedure Installation: Rocker case • 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 the cylinder head and timing gear case. Take care not to spread the sealant beyond the application areas dur- ing installation.
Page 44 CAUTION • Do not attempt to remove the camshaft gear with a hammer as damage will result. Use a press or other similar tool. Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 11-34...
Page 45 Inspection procedure Inspection: Interference between camshaft gear and cam- shaft • If the measurement deviates from the standard value, replace the defective part(s). Inspection: Camshaft (1) Difference of cam lobe diameter and base circle diameter • If the measurement is less than the limit, replace the camshaft. (2) Bend •...
Page 46 CAMSHAFT AND ROCKER CASE Installation procedure Installation: Camshaft gear • Heat the camshaft gear to approximately 150°C using a gas burner. • While facing the camshaft gear as shown in the illustration, press it onto the camshaft until it seats snugly on the camshaft. WARNING •...
Page 47 M E M O 11-37...
Page 48 MITSUBISHI 6M70 CYLINDER HEAD AND VALVE MECHANISM 11-38...
Page 49 Idler gear D end play 0.1 to 0.2 Replace Backlash between idler gear D and idler gear C 0.094 to 0.181 0.35 Replace Mitsubishi 6M70 Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (nozzle bridge mounting) 54 {5.5} –...
Page 50 CYLINDER HEAD AND VALVE MECHANISM Special tools (Unit: mm) Mark Tool name and shape Part No. Application Socket wrench MH063388 Installation of cylinder head Idler gear bushing-puller Removal and installation of idler gear ME350196 bushing φ 56 φ 62 φ 57 Work before removal Inspection: Idler gear D end play •...
Page 51 Removal: Idler shaft • Remove the idler shaft together with idler gear D as a unit with a slide hammer. Removal: Cylinder head gasket CAUTION • Be careful not to scratch the cylinder head, crankcase and flywheel housing when removing the cylinder head gasket. Inspection procedure Inspection: Clearance between idler shaft and idler gear bushing...
Page 52 Installation: Cylinder head CAUTION • Before installing the Mitsubishi 6M70 cylinder head bolt, check the number of punch marks on the bolt head. (Bolts with up to two 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.
Page 53 • Remove oil or any other contamination from the surfaces where sealant is to be applied. • Install the cylinder head gasket onto the crankcase and apply sealant to the illustrated section of the cylinder head gasket. • Within three minutes following the application, install the cylinder head onto the cylinder head gasket.
Page 54 MITSUBISHI 6M70 CYLINDER HEAD AND VALVE MECHANISM Cylinder Head Disassembly sequence 1 Adjusting screw 7 Inner valve spring 15 Intake valve seat 2 Valve bridge <Exhaust> 16 Nozzle tube 3 Pin 8 Valve stem seal 17 O-ring 4 Valve cotter...
Page 55 60° ± 15° – Rectify 6M70 Intake valve stem-to-valve guide clearance 10, 13 0.035 to 0.065 Replace 6M70 Outer diameter of valve bridge guide 10.989 to 11 10.988 Replace Rectify or 6M70 Exhaust valve seat width 3.5 ± 0.2 replace...
Page 56 ME350051 Installation of valve bridge guides installer φ 11 MH062177 Removal of valve guides Valve guide remover Valve guide installer Installation of Mitsubishi 6M70 ME350052 valve guides φ 25 φ 15 16.8 Caulking tool body MH062174 Installation of Mitsubishi 6M70...
Page 57 Removal of nozzle tube φ 8.7 φ 12.5 Nozzle tube installer bolt MH061231 × φ 8.5 Nozzle tube installer body Installation of Mitsubishi 6M70 ME350195 nozzle tube × Nozzle tube stamp MH061229 φ 8 Removal procedure Removal: Valve cotter • Using , evenly compress the valve cotter to re- move so that the valve spring does not lean to one side.
Page 58 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.
Page 59 Inspection: Valve-to-valve guide clearance • If the clearance exceeds the specified limit, replace the defective part(s). Replacement of valve guides [Removal] [Installation] • Using , install the valve guide until it securely contacts the cylinder head. CAUTION • The valve guide must protrude from the cylinder head by the specified amount.
Page 60 • Inspect the contact pattern between valve and valve seat again. • If the contact pattern is still defective, replace the valve seat. 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.
Page 61 • After refacing, make sure to lap the valve and valve seat. Replacement of valve seat [Removal] • The valve seats are installed by expansion fitting. To remove a valve seat, grind inside the metal stock to reduce the wall thick- ness, then remove the valve seat at room temperature.
Page 62 • After installing the nozzle tube, be sure to perform a leak test to check for 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.
Page 63 M E M O 11-53...
Page 64: Cylinder Liner
MITSUBISHI 6M70 PISTON, CONNECTING ROD AND CYLINDER LINER Disassembly sequence 1 Lower connecting rod bearing 2 Connecting rod cap 3 Upper connecting rod bearing 4 Piston and connecting rod (See later section.) 5 Cylinder liner Assembly sequence Follow the disassembly sequence in re- verse.
Page 65 Special tools (Unit: mm) Mark Tool name and shape Part No. Application Piston guide clamp MH061667 Piston guide lever MH061658 Installation of piston and connecting Socket wrench MH061560 Cylinder liner extractor MH062194 Removal of cylinder liner φ134.5 Adapter ME350054 Measurement of cylinder liner flange Bolt MF130651 protrusion and step height between...
Page 66 PISTON, CONNECTING ROD AND CYLINDER LINER Inspection: Piston protrusion from crankcase top surface • The amount of piston protrusion affects engine performance and must therefore be inspected without fail. • Set the piston at the top dead center. • Make the measurement at the two measurement points on the top face of the piston and calculate the average value.
Page 67 • 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).
Page 68 PISTON, CONNECTING ROD AND CYLINDER LINER Replacement of cylinder liner [Removal] CAUTION • If the cylinder liners will need to be reused for some reason or other, make alignment marks to ensure correct reassem- bly. [Installation] • When replacing the cylinder liner, use the size mark on the crankcase and the size mark on the piston to select the appro- priate size of the cylinder liner.
Page 69 Installation procedure Installation: Connecting rod bearings CAUTION • Do not reverse the positions of the lower bearing and the upper bearing (with oil hole) when installing, as this may cause seizure in the engine. Installation: Piston and connecting rod • Check that the piston ring end gaps are in their correct positions. A: 1st compression ring gap B: 2nd compression ring gap C: Oil ring gap...
Page 70 Each division on the socket scale represents 5°. • After assembly of the connecting rod cap, perform the following test. • End play of connecting rod • Piston protrusion Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 11-60...
Page 71 M E M O 11-61...
Page 72 PISTON, CONNECTING ROD AND CYLINDER LINER Mitsubishi 6M70 Piston and Connecting Rod Disassembly sequence 1 1st compression ring 2 2nd compression ring 3 Oil ring 4 Snap ring 5 Piston pin 6 Connecting rod bushing 7 Connecting rod bolt 8 Connecting rod...
Page 73 Inspection procedure Inspection: Mitsubishi 6M70 Piston ring end gap • Using the crown 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.
Page 74 PISTON, CONNECTING ROD AND CYLINDER LINER Inspection: Mitsubishi 6M70 Clearance between piston ring and piston ring groove • Remove any carbon deposits from the ring groove in the piston. • Measure the side clearance of each ring around the piston’s en- tire periphery of the ring groove.
Page 75 • If either measurement exceeds the limit, replace the connecting rod. Installation procedure Installation: Mitsubishi 6M70 Connecting rod bolt • Make sure that bolt holes of the connecting rod are free of flaws and burrs. • Apply engine oil to the knurled portion of the connecting rod bolt and press fit it in the illustrated direction with the maximum press load of 5880 N {600 kgf}.
Page 76 PISTON, CONNECTING ROD AND CYLINDER LINER Installation: Mitsubishi 6M70 Piston and connecting rod • When the piston and connecting rods are replaced, install each part as follows; • Select all the connecting rods with the same weight mark on the same engine (‘‘A to H’’, ‘‘J to M’’).
Page 77 M E M O 11-67...
Page 78 FLYWHEEL PTO <WITH FLYWHEEL PTO> Disassembly sequence 1 Eyebolt 7 Flange 13 Ball bearing 2 Oil pipe 8 Oil seal 14 PTO head 3 PTO bracket 9 Cover 15 O-ring 4 Washer 10 Gasket 5 PTO gear 11 Roller bearing a: Flywheel housing 6 Washer 12 PTO shaft...
Page 79 Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Oil seal lip Multipurpose grease Sliding contact surfaces of flange and oil seal As required [NLGI No.2 (Ca soap)] Multipurpose grease Fitting surfaces of flange and PTO shaft As required [NLGI No.2 (Ca soap)] Inspection before removal...
Page 80 FLYWHEEL PTO <WITH FLYWHEEL PTO> Removal: Ball bearing • Remove the ball bearing in the direction shown in the illustration. Installation procedure Installation: 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 •...
Page 81 M E M O 11-71...
Page 82 FLYWHEEL Disassembly sequence 1 Snap ring 11 O-ring 22 Eyebolt 2 Pilot bearing 12 Collar 23 Water inlet pipe 3 Ring gear 13 Engine speed sensor 24 Eyebolt 4 Flywheel 14 Stiffener 25 Oil pipe 5 Rear oil seal 15 Air suction hose 26 Air compressor 6 Power steering oil hose 16 Eyebolt...
Page 83 Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Rectify or Friction surface distortion 0.05 replace Friction surface height 48 ± 0.2 49.5 Replace Flywheel Friction surface runout Rectify or – (when fitted) replace Rectify or Friction surface parallelism 0.1 or less –...
Page 84 FLYWHEEL Inspection before removal Inspection: Flywheel friction surface runout when fitted • If the measurement exceeds the limit, check if the bolts are cor- rectly tightened as well as the crankshaft mounting surface. Cor- rect or replace the flywheel as required. Removal procedure Removal: Flywheel •...
Page 85 (2) Friction surface distortion • If the measurement exceeds the limit, rectify or replace the fly- wheel. • If the ring gear is evidently defective, replace the ring gear be- fore inspecting the friction surface for distortion. Rectification of friction surface •...
Page 86 FLYWHEEL Installation: Air compressor • Set the No. 1 cylinder piston at the top dead center of the com- pression stroke. • Align the stamped mark “1” on the air compressor gear with the projection on the air compressor. • While keeping this condition, align the stamped mark “1” with the scribed line on the rear plate and install the air compressor to the flywheel housing.
Page 87 CAUTION • The bolts should be tightened within the plastic region. Never tighten them further than the specified angle. Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 11-77...
Page 88 MITSUBISHI 6M70 TIMING GEARS <WITHOUT FLYWHEEL PTO> Disassembly sequence 1 Idler shaft C 6 Idler shaft bolt a: Supply pump gear 2 Idler gear bushing 7 Thrust plate A, B b: Crankshaft gear 3 Idler gear C 8 Idler gear bushing...
Page 89 Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Inside surface of bushing of gears Special tools (Unit: mm) Mark Tool name and shape Part No. Application Idler gear bushing ME350197 Removal of idler gear bushing puller φ...
Page 90 TIMING GEARS <WITHOUT FLYWHEEL PTO> Inspection procedure Inspection: Clearance between idler shaft C and idler gear bushing [Inspection] • If the measurement exceeds the limit, replace the bushing. Replacement of idler gear bushing [Removal] [Installation] • Install until it contacts the idler gear with idler gear C facing in the illustrated direction.
Page 91 [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 value, ream the bushing. Installation procedure Installation: idler gear •...
Page 92 MITSUBISHI 6M70 TIMING GEARS <WITH FLYWHEEL PTO> Disassembly sequence 1 O-ring 9 PTO idler gear B 17 PTO drive gear 2 Idler shaft bolt 10 Idler shaft C 3 Thrust plate A, B 11 Idler gear bushing a: Supply pump gear...
Page 93 Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Between idler gear C and supply 0.096 to 0.198 0.35 Replace pump gear Between idler gear C and idler gear 0.089 to 0.181 0.35 Replace A, B Between idler gear A, B and crank- –...
Page 94 TIMING GEARS <WITH FLYWHEEL PTO> Mark Tool name and shape Part No. Application Idler gear bushing Removal and installation idler gear MH061256 puller bushings φ 57.3 φ 62 φ 58 Inspection before removal Inspection: Backlash between gears • For each pair of gears, measure the backlash at more than three teeth.
Page 95 [Installation] • Install until it contacts the PTO idler gear A with PTO idler gear A facing in the illustrated direction. • After installation, measure the clearance again. • If the measurement is less than the standard value, ream the bushing.
Page 96 TIMING GEARS <WITH FLYWHEEL PTO> Replacement of idler gear bushing [Removal] [Installation] • Install 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.
Page 97 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”...
Page 98 MITSUBISHI 6M70 CRANKSHAFT AND CRANKCASE 11-88...
Page 99 Crankcase Roundness 0.005 or less – Cylinder block Replace Cylindricity 0.015 or less – Mitsubishi 6M70 Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (crankshaft pulley installation) 240 {24} – Bolt (front cover installation) 45 {4.6}...
Page 100 • If the measurement exceeds the specified limit, replace the oversized thrust plates. Oversizes available: 0.15, 0.30, 0.45 mm • Replace the crankshaft if the end play cannot be adjusted within the standard range. Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 11-90...
Page 101 Removal procedure Removal: Main bearing caps • The main bearing cap on the rearmost part is located by locating pins. Use a slide hammer to remove it. Removal: Front oil seal slinger • Taking care not to damage the crankshaft, split the slinger using a chisel or a similar tool.
Page 102 CRANKSHAFT AND CRANKCASE (2) Main bearing oil clearance • Fit the upper main bearing into the crankcase and the lower main bearing into the main bearing cap. • Tighten the bolts to a torque of 100 N·m {10 kgf·m}. • Measure the inner diameter of the main bearing and the outer di- ameter of the corresponding crankshaft journal.
Page 103 Also, check that the hardness of the sur- face has not dropped below Shore hardness number (Hs) 75. • If there is any abnormality, replace the crankshaft. Mitsubishi 6M70 Crankshaft undersize dimensions (Unit: mm) Undersizes 0.25 0.50 0.75...
Page 104 CRANKSHAFT AND CRANKCASE Installation procedure Installation: Oil spray plug • Install the oil spray plug in the illustrated direction. CAUTION • Be careful that if the direction of the oil spray plug is not ap- propriate, oil supply to the timing gear becomes insuffi- cient, causing seizure.
Page 105 • Install the front oil seal slinger onto the crankshaft until the end of face of securely contacts the guide. Installation: Mitsubishi 6M70 Main bearing • Install the main bearings with their lugs aligned as shown in the illustration. When the crankshaft journals have been ground to an undersize, use undersized main bearings.
Page 106 Installation: Mitsubishi 6M70 Front oil seal • Install the front oil seal onto the front cover while pressing the seal’s entire periphery evenly to prevent it from tilting.
Page 107 GROUP 12 LUBRICATION SPECIFICATIONS................12-2 STRUCTURE AND OPERATION 12-3 1. Lubrication System ................12-4 2. Oil Pump ..................... 12-5 3. Oil Cooler ................................... 12-6 4. Full-flow Oil Filter ................12-7 5. Bypass Oil Filter 12-7 6. Engine Oil Pressure Switch .............. 12-7 7.
Page 108 SPECIFICATIONS Item Specifications Method of lubrication Oil pump type Oil filter Filter paper element center bolt type Oil cooler Shell and plate type (multiple-plate type) API classification CD, CD/SF, CE, CE/SF, CF-4 or JASO Grade classification DH-1, DH-2 Engine oil Oil pan Approx.
Page 109 STRUCTURE AND OPERATION 1. Lurication System 1 Rocker shaft 14 Powertard solenoid valve 27 Bypass oil filter 2 Camshaft journal (No.2 to 7) 15 Main oil gallery 28 Oil cooler bypass valve 3 Camshaft journal (No.1) 16 Regulator valve 29 Oil cooler 4 Rocker case (No.1) 17 Check valve for oil jet 30 Full-flow oil filter...
Page 110 STRUCTURE AND OPERATION 2. Mitsubishi 6M70 Oil Pump • This engine uses a gear-type oil pump driven by the rotation of the crankshaft transmitted through the engagement of the crankshaft gear and the oil pump gear. The oil pump has a relief valve, which...
Page 111 3. Mitsubishi 6M70 Oil Cooler 3.1 Mitsubishi 6M70 Bypass valve • When the engine oil is cool and its vis- cosity is high, or when the oil cooler el- ement becomes clogged and restricts the flow of the engine oil, the bypass...
Page 112 STRUCTURE AND OPERATION 4. Full-flow Oil Filter • The filter elements use elements made of filter paper. 4.1 Engine oil bypass alarm switch • If the full-flow oil filter elements clog up, this will restrict the flow of engine oil, causing various parts of the engine to seize.
Page 113 5. Bypass Oil Filter • The oil filter elements use elements made of filter paper. 6. Mitsubishi 6M70 Engine Oil Pressure Switch • If the oil pressure of the engine oil fed to the main oil gallery drops below the...
Page 114 • The engine oil in the main oil gallery lubricates the engine components in the following ways. 8.1 Mitsubishi 6M70 Main bearing and connecting rod bearing • Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of each connecting rod.
Page 115 The oil flowing to the adjusting screws on the rockers lubricates 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.
Page 116 • A piston ring is provided on each end of the turbine wheel shaft. The rings function as oil sealing. 8.6 Mitsubishi 6M70 Supply pump • The engine oil supplied to the supply pump lubricates the inside of the pump and supply pump gear.
Page 117 TROUBLESHOOTING Symptoms Reference Gr Possible causes Incorrectly mounted element Defective gasket Defective O-ring Oil cooler Clogged element Damaged element Weakened bypass valve spring Malfunctioning oil pump Interference between oil pump gear and oil pump case and/or cover Oil pump Incorrectly connected oil pipe Clogged oil strainer Weakened relief valve spring Incorrect installation...
Page 118: Oil Filter Replacement
ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Drain plug (oil filter) 24.5 ± 4.9 {2.5 ± 0.5} – – Center bolt 63.7 ± 4.9 {6.5 ± 0.5} –...
Page 119 • Clean other parts than the element, O-ring and gasket to be re- placed with washing oil. [Installation] • Replace the element, O-ring and gasket with new ones, respec- tively. • Install the oil filter case so that the drain plug is positioned as shown in the illustration.
Page 120 ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Engine Oil Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Drain plug (oil filter) 24.5 ± 4.9 {2.5 ± 0.5} – – Drain plug (oil pan) 68 {7} –...
Page 121 – Engine oil pressure switch 24.5 ± 4.9 {2.5 ± 0.5} With cold engine • Remove the Mitsubishi 6M70 engine oil pressure switch. • Using an adapter, connect an oil pressure gauge to the engine oil pressure switch mounting hole.
Page 122 MITSUBISHI 6M70 OIL JETS, OIL PAN, Disassembly sequence 1 Drain plug 2 Oil pan 3 Check valve 4 Oil jet : Locating pin : Non-reusable parts CAUTION • The check valve has been tightened using thread-locking compound and so, may deform during remov- al.
Page 123 Installation procedure Installation: Oil pan • Clean the mating surfaces of each part. • Apply a bead of sealant to the mating surface of the oil pan evenly and without any breaks. Change the amount of application to A and B at four locations shown in the illustration.
Page 124 MITSUBISHI 6M70 OIL PUMP, OIL STRAINER Disassembly sequence 1 Oil strainer 8 Relief valve spring a: Crankshaft gear 2 Gasket 9 Relief valve b: Oil pump gear 3 Oil pipe 10 Idler shaft 4 Gasket 11 Idler gear : Locating pin...
Page 125 • Perform the following inspections. Replace the defective part(s) as required. (1) Difference between case depth and height of each gear (2) Clearance between case and tooth tips of each gear Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 12-19...
Page 126 OIL PUMP, OIL STRAINER (3) Clearance between drive gear shaft and 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.
Page 127 M E M O 12-21...
Page 128: Oil Filter
OIL FILTER Disassembly sequence 1 Drain plug 2 Center bolt 3 Washer 4 O-ring 5 Oil filter case 6 Gasket 7 Oil filter element 8 Spring 9 Engine oil bypass alarm switch 10 Oil filter head 11 O-ring a: Oil cooler : Non-reusable parts Assembly sequence Follow the disassembly sequence in re-...
Page 129 M E M O 12-23...
Page 130 MITSUBISHI 6M70 OIL COOLER Removal sequence 1 Bypass valve 2 O-ring 3 Water pipe 4 O-ring 5 Oil cooler element 6 O-ring 7 Oil cooler cover 8 Oil cooler plug 9 O-ring 10 O-ring 11 Gasket 12 Regulator valve (See later section.)
Page 131 Inspection procedure Inspection: Oil cooler element • Plug 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.
Page 132 MITSUBISHI 6M70 REGULATOR VALVE Disassembly sequence 1 Snap ring 2 Valve 3 Spring 4 Body Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy 0.49 ± 0.03 MPa –...
Page 133 GROUP 13 FUEL AND ENGINE CONTROL SPECIFICATIONS......... 13-2 SUPPLY PUMP........13-66 STRUCTURE AND OPERATION INJECTOR........... 13-70 13-4 1. Common Rail System ....... FUEL TANK ......... 13-74 13-20 2. Engine Control ........ 13-21 3. Fuel Filter ......... FUEL FILTER ........13-76 13-22 4.
Page 134 MITSUBISHI 6M70 FUEL SYSTEM SPECIFICATIONS Item Specifications Manufacturer Bosch Model CP2L4 Control method Electronic Type In-Line 4 barrel type Supply pump Feed pump type External gear Model MPROP Rail pressure control valve Rated voltage Max. common rail pressure 160 {1631}...
Page 135 M E M O 13-3...
Page 136 STRUCTURE AND OPERATION 1. Mitsubishi 6M70 Common Rail System • In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, accel- erator position coolant temperature, etc.) using information from sensors. In accordance with these data, the elec- tronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in order to optimize the engine’s operation.
Page 137 • When the engine is cranked by means of the starter switch, the feed pump (this is located inside the supply pump) simultaneously draws fuel from the fuel tank and feeds it via the water separator, gauze filter and fuel filter to the MPROP (rail pressure control valve).
Page 138 STRUCTURE AND OPERATION 1.1 Mitsubishi 6M70 Supply pump 13-6...
Page 139 • The supply pump pressurizes fuel and supplies it in a highly pressurized state. • Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers. It is supplied first to the MPROP (rail pressure control valve), which controls the amount of fuel reaching the plungers. •...
Page 140 MPROP is pressed down such that fuel is not fed toward the plungers. • The engine electronic control unit controls the ratio of current-off time (duty ratio). Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 13-8...
Page 141 1.2 Mitsubishi 6M70 Common rail • The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump. • Each flow limiter prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of fuel leakage from the injection pipe or excessive injection of fuel from the injector.
Page 142 • The Mitsubishi 6M70 injector is divided 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.
Page 143 (1) Operation (1.1) Injection not taking place • With the magnet not energized, the ar- mature plate is pushed down by the valve spring such that the ball seat is closed. • The high-pressure fuel acts upon the control chamber via orifice Z. The same pressure acts upon the nozzle needle.
Page 144 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. Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 13-12...
Page 145 1.4 Electronic control system (1) System block diagram Input signals Output signals Engine electronic control unit Engine speed sensor Injector magnetic valve MPROP1, 2 (rail pressure Cylinder recognition sensor Fuel injection control control valve) Water temperature sensor Fuel injection Boost pressure sensor Warm-up acceleration pressure control function...
Page 146 Exhaust gas recirculation electronic drive unit issues signals to (EGR EDU) the engine electronic control unit via the CAN bus to enable it to effect engine control appropriate for type of system control. Mitsubishi 6M70 engine parts contact: EGR: Exhaust gas recirculation email: EDU: Electronic drive unit MVCU: Multifunction vehicle control unit EngineParts@HeavyEquipmentRestorationParts.com...
Page 147 (2) Fuel injection control (2.1) Pilot injection • Pilot injection entails the injection of an extremely small amount of fuel ahead of the main injection. • This suppresses hasty heat generation early in the injection cy- cle and thus suppresses NOx generation and noise at the start of combustion.
Page 148 STRUCTURE AND OPERATION (4) Fuel injection timing control (4.1) Main injection timing • The main injection timing is calculated from the fuel injection quantity and engine speed. (4.2) Pilot injection timing (pilot interval) • The pilot injection timing is calculated from the fuel injection quantity and engine speed.
Page 149 (7) Auxiliary brake function Input signals Output signals Engine electronic control unit Accelerator pedal position sensor Clutch switch Auxiliary brake Powetard solenoid valve function Transmission neutral switch Powertard switch • The auxiliary brake function activates or deactivates the Powertard solenoid valve according to the vehicle condi- tion to control the auxiliary brake.
Page 150 STRUCTURE AND OPERATION (10)Electronic control unit connection diagram 13-18...
Page 151 13-19...
Page 152 STRUCTURE AND OPERATION 2. Engine Control 2.1 Accelerator pedal switch • The accelerator pedal switch is used to monitor whether or not the accelerator pedal 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.
Page 153 3. Fuel Filter • The fuel filter removes foreign matter from fuel via the filter element. The fuel filter also incorporates a water sep- arator which separates any water from fuel. • Water separated from fuel accumulates at the bottom of the fuel filter assembly. •...
Page 154 STRUCTURE AND OPERATION 4. Water Separator • A water separator is installed between the fuel tank and the feed pump. It is designed to remove impurities from fuel and also separates water from fu- • Water separated from fuel is collected at the bottom of the water separator and is drained when the float reaches the level line.
Page 155 M E M O 13-23...
Page 156 TROUBLESHOOTING <MITSUBISHI 6M70 FUEL SYSTEM> Symptoms Reference Possible causes Defective electronic control fuel system Defective feed pump Defective sealing of supply pump overflow valve Supply pump Defective MPROP Defective base supply pump Common rail pressure sensor open-circuited, short or intermittent connection; defective sensor...
Page 157 Symptoms Reference Possible causes Oil viscosity unsuitable Gr12 Valve clearance incorrect Defective cylinder head gasket Valve and valve seat worn and carbon deposits Valve spring fatigued Gr11 Piston ring worn and damaged Piston ring groove worn and damaged Piston and cylinder liner worn Cooling system malfunction Gr14 Defective starter switch...
Page 158 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> 1. Diagnosis Procedure • Perform the inspection in accordance with the following flowchart. Warning lamp lit Vehicle in service shop Read all (past and present) diagnosis codes by Multi-Use Tester. (See Gr00.) Perform inspection based on diagnosis codes. (See later section.) Response to transient fault Was able to identify the fault? (See Gr00.)
Page 159 2. Diagnostic Precautions • Before measuring voltage, check the battery for charged condition and specific gravity. If system inspection is per- formed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved. • Before disconnecting battery cables, harnesses and connectors, set the starter switch to LOCK or OFF, then allow at least 20 seconds.
Page 160 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> 3. Inspections Based on Diagnosis Codes 3.1 Diagnosis code list • Diagnosis codes shown by the Multi-Use Tester and those indicated by warning lamp display are different. • The Multi-Use Tester is capable of showing more detailed diagnosis codes. Warning lamp indication Code Message...
Page 161 Warning lamp indication Code Message Remarks Flashes Orange P0617 Starter Safety Relay (High) – Gr54 P1130 VGT 1 – Gr15 P1132 VGT 1 – Gr15 P1133 VGT 1 – Gr15 P1135 VGT 2 – Gr15 P1137 VGT 2 – Gr15 P1138 VGT 2 –...
Page 162 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> Warning lamp indication Code Message Remarks Flashes Orange P1630 CAN (EGR 1) – Gr17 3.2 Diagnosis code generation conditions and inspection items P0107: Atmospheric Pressure Sensor (warning lamp flashes: 19) Atmospheric pressure sensor (incorporated into engine electronic control unit) Generation condition voltage remains less than 2 V for 3 seconds.
Page 163 P0117: Water Temp SNSR (Low) (warning lamp flashes: 21) Generation condition Water temperature sensor voltage remains less than 0.2 V for 3 seconds. System recovers when water temperature sensor voltage remains 0.2 V or more Recoverability for 1 second. • Control is effected using backup value (at engine startup: –20°C; when engine Control effected by electronic control unit is running: 80°C).
Page 164 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P0123: Accel Pedal Sensor 1 (warning lamp flashes: 24) Accelerator pedal position sensor 1 voltage remains higher than 4.5 V for 1 sec- Generation condition ond. System recovers when accelerator pedal position sensor 1 voltage remains 4.5 V Recoverability or less for 1 second.
Page 165 P0193: CRS Pressure SNSR (High) (warning lamp flashes: 11) Generation condition Common rail pressure sensor voltage remains higher than 4.8 V for 0.25 second. System recovers (power is re-supplied to electronic control unit) if signal becomes Recoverability normal when starter switch is turned OFF (2 minutes or more) → ON. •...
Page 166 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P0202: Injector M/V-Cylinder 2 (Load) (warning lamp flashes: 38) Injector magnetic valve (No. 5 cylinder) is short-circuited, open-circuited or over- Generation condition loaded. • 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) →...
Page 167 P0205: Injector M/V-Cylinder 5 (Load) (warning lamp flashes: 46) Injector magnetic valve (No. 2 cylinder) is short-circuited, open-circuited or over- Generation condition loaded. • 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) →...
Page 168 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P0222: Accel Pedal Sensor 2 (warning lamp flashes: 16) Generation condition Accelerator pedal position sensor 2 voltage remains less than 0.5 V for 1 second. System recovers when accelerator pedal position sensor 2 voltage remains 0.5 V Recoverability or more for 1 second.
Page 169 P0228: PTO Accel Sensor (warning lamp flashes: 61) Voltage of power take-off load sensor remains higher than 3.5 V for 1 second Generation condition when governor control switch is ON. System recovers when voltage of power take-off load sensor remains 3.5 V or Recoverability less for 1 second when governor control switch is ON.
Page 170 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P0251: Common Rail Pressure Defect (warning lamp flashes: 36) Diagnosis code is generated under either of the following conditions. (1) MPROP (rail pressure control valve) power supply remains low for 1 second. Generation condition (2) The difference between target common rail pressure and actual common rail pressure remains 30% or more for 10 seconds.
Page 171 P0254: Common Rail Pressure Defect (warning lamp flashes: 23) Diagnosis code is generated under either of the following conditions. (1) Common rail pressure sensor voltage remains 4.4 V or more for 10 seconds when common rail pressure is controlled without feedback value. (2) When above problem (1) is not occurred, common rail pressure sensor volt- age remains 2.96 V or more for 10 seconds when common rail pressure is Generation condition...
Page 172 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P0340: Camshaft Position SNSR (warning lamp flashes: 12) Diagnosis code is generated under either of the following conditions. (1) Phase difference between cylinder recognition sensor and engine speed sen- sor deviates from the standard value when engine speed is 20 rpm or more. (2) No signal from the cylinder recognition sensor during the 132-pulse inputs of Generation condition the engine speed sensor signal after recognition of the gap of the engine...
Page 173 P0507: Idle Volume (warning lamp flashes: 31) Idling speed adjustment potentiometer voltage remains higher than 4.6 V for 3 Generation condition seconds. System recovers when idling speed adjustment potentiometer voltage remains Recoverability 4.6 V or less for 1 second. • Control is effected with auto idle permanently selected. Control effected by electronic control unit •...
Page 174 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P0605: ECU System (Hardware) (warning lamp flashes: 33) Diagnosis code is generated under either of the following conditions. (1) Power supply circuit or power supply in electronic control unit is abnormal. Generation condition (2) Devices (analog-digital converter, IC for driving injector or timer IC) in electron- ic control unit or CPU gate array communication are abnormal.
Page 175 P1177: PTO Adjustment Resistor (High) (warning lamp flashes: 62) Power take-off resistor voltage remains higher than 4.8 V for 3 seconds when Generation condition governor control switch is ON. System recovers when power take-off resistor voltage remains 4.8 V or less for 1 Recoverability second when governor control switch is ON.
Page 176 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P1254: PRV Opening (warning lamp flashes: 36) Diagnosis code is generated under either of the following conditions • Common rail pressure is abnormally large. (except forced opening of pressure limiting valve by electronic control unit Generation condition control) •...
Page 177 P1256: Common Rail Pressure M/V 1 (warning lamp flashes: 63) Diagnosis code is generated under either of the following conditions. (1) MPROP1 (rail pressure control valve) circuit shorted to battery (high level Generation condition when turned ON) as detected for 0.3 second. (2) MPROP1 (rail pressure control valve) driving voltage remains abnormal for 1 second.
Page 178 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P1259: Common Rail Pressure M/V 2 (warning lamp flashes: 63) MPROP2 (rail pressure control valve) circuit shorted to ground or open-circuited Generation condition (low level when turned OFF) as detected for 0.3 second. System recovers (power is re-supplied to electronic control unit) if signal becomes Recoverability normal when starter switch is turned OFF (2 minutes or more) →...
Page 179 P125D: Rail Pressure M/V 2 (Long Short) (warning lamp flashes: 63) MPROP2 (rail pressure control valve) circuit remains shorted to ground as detect- Generation condition ed for 10 seconds. System recovers (power is re-supplied to electronic control unit) if signal becomes Recoverability normal when starter switch is turned OFF (2 minutes or more) →...
Page 180 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> P1463: Auxiliary Brake M/V 1 (warning lamp flashes: 93) Powertard solenoid valve circuit shorted to battery (driving terminal is at high lev- Generation condition el when turned ON) as detected for 1 second. System recovers when Powertard solenoid valve circuit remains normal (driving Recoverability terminal is at low level when turned ON) for 1 second.
Page 181 P1568: Sensor Supply Voltage 2 (warning lamp flashes: 81) Circuit voltage (sensor supply voltage 2) in electronic control unit remains abnor- Generation condition mally high for 0.5 second. System recovers when circuit voltage (sensor supply voltage 2) in electronic con- Recoverability trol unit becomes normal.
Page 182 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> 4. Multi-Use Tester Service Data • It is possible to see service data and actuator tests simultaneously. Item Data Inspection condition Requirement Engine speed after engine 01 Engine Revolution Racing (engine running) .rpm warm-up: 500 ± 25 rpm 02 Reference Injection Quantity Engine idling 5 to 20%...
Page 183 Item Data Inspection condition Requirement Engine cranked by means of starter switch 71 Starter SW (S) ON/OFF Starter switch in position except START Starter switch in ON position 72 Starter SW (M) ON/OFF Starter switch in position except ON Accelerator pedal not pressed 73 Accel SW ON/OFF Accelerator pedal pressed...
Page 184 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> 5. Actuator Tests Performed Using Multi-Use Tester • It is possible to see service data and actuator tests simultaneously. Item Explanation Confirmation method EGR 1 EGR 2 See Gr17. – EGR 3 VGT M/V 1 VGT M/V 2 See Gr15.
Page 185 M E M O 13-53...
Page 186 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> 6. Inspections Performed at Electronic Control Unit Connectors • These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being correctly transmitted via the vehicle harness and connectors. The white-on-black numbers ( , and so on) correspond to the similarly printed reference numbers in section “3.
Page 187 Check item Measurement method [Conditions] • Starter switch OFF Resistance of water temperature sensor • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: A40-A41 • 20°C: 2.45 ± 0.14 kΩ • 80°C: 0.32 kΩ (reference value) • 110°C: 147.1 ± 2 kΩ [Conditions] •...
Page 188 TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester> [Conditions] • Starter switch ON Output voltage of idling speed adjustment • Vehicle-side harness connected (Perform inspection on back of connector.) potentiometer [Requirements] Terminals (+)-(–): A12-A36 • AUTO position: 4.0 ± 0.1 V • SLOW position: 3.0 ± 0.2 V •...
Page 189 M E M O 13-57...
Page 190 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspecting No-load Minimum and Maximum Speeds Service standards Location Maintenance item Standard value Limit Remedy – No-load minimum speed (idling speed) 450 to 500 rpm – Inspect – No-load maximum speed 2330 to 2370 rpm –...
Page 191 • If it does not move smoothly, check for an installed condition of the accelerator control cable and accelerator link. (See “EN- GINE CONTROL”.) 2. Inspection of Fuel Leakage • Check if there is no fuel leakage from the fuel tank, fuel filter, supply pump, common rail, injector and fuel piping. If there is a fuel leakage, replace the pipe or hose and tighten to the specified torque.
Page 192 ON-VEHICLE INSPECTION AND ADJUSTMENT 5. Air-bleeding of Fuel System Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Plug 9.8 ± 2.0 {1.0 ± 0.2} – • Loosen one of the plugs on the fuel filter. •...
Page 193: Fuel Filter Replacement
6. Fuel Filter Replacement Tightening torque (Unit: N·m {kgf·m}) 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} – Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity...
Page 194 ON-VEHICLE INSPECTION AND ADJUSTMENT • Replace the filter element and O-rings with new parts. • Apply a thin coat of engine oil to the O-rings. Install the O-rings onto the case. CAUTION • The use of non-genuine filter elements will lead to engine problems.
Page 195 8. Water Separator Element Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Drain plug 1.47 ± 0.3 {0.15 ± 0.03} – – Cover 19.6 ± 2.5 {2.0 ± 0.3} – – Plug A 12.3 ±...
Page 196 ON-VEHICLE INSPECTION AND ADJUSTMENT [Installation] • 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.
Page 197 30 to 35 {3.1 to 3.6} – 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 connector evenly, and temporarily tighten it without applying an excessive force.
Page 198 MITSUBISHI 6M70 FUEL SUPPLY PUMP Removal sequence 1 Fuel pipe 7 Fuel feed pipe 13 O-ring 2 Eyebolt 8 Over flow valve 3 Fuel suction pipe 9 Fuel return pipe a: Flywheel housing 4 Eyebolt 10 Eyebolt b: Rear plate...
Page 199 CAUTION • Do not use except for a stopper of the fuel suction pipe and fuel feed pipe, otherwise the open end section may be broken. Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 13-67...
Page 200 SUPPLY PUMP Installation procedure Installation: Mitsubishi 6M70 Fuel Supply pump • Position the No. 1 piston to the top dead center in the compres- sion stroke in the following manner. • Crank the engine to align the pointer with the “1 6” mark on the flywheel.
Page 201 • 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 13-69...
Page 202 54 nm {5.5 kgfm} 40 Ft Lbs Bolt (nozzle bridge mounting) – Mitsubishi 6M70 Injection pipe 29 to 34 {3.0 to 3.5} – Eyebolt (fuel return pipe mounting) 40 {4} – Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 13-70...
Page 203 Open end spanner Removal and installation of injection ME355665 pipe Removal procedure Removal: Mitsubishi 6M70 Injection pipe Apply (width across flats: 15 mm) to the connector of the • injector as a stopper, and then loosen the union nut to remove the injection pipe.
Page 204 • Tighten the nut so that a hook of can be hung on section A of the injector. • Attach and remove the injector. Installation procedure Installation: Mitsubishi 6M70 Injection pipe Apply (width across flats: 24 mm) to the connector of the • injector as a stopper. CAUTION •...
Page 205 M E M O 13-73...
Page 206: Fuel Tank
FUEL TANK Removal sequence 1 Drain plug 6 Fuel level sensor 10 Fuel tank 7 Fuel tank strap 11 Fuel tank bracket 2 Strainer 3 Connecting plug 8 Fuel tank strap 12 Fuel tank bracket 4 Suction hose <Except FV51> <Except FV51>...
Page 207 Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Drain plug 127 {13} – Connecting plug 20 {2.0} – Nut (fuel tank strap mounting) 11.7 to 12.7 {1.2 to 1.3} – Bolt (fuel tank bracket mounting) 54 to 72 {5.5 to 7.3} FV51 54 to 72 {5.5 to 7.3}...
Page 208 FUEL FILTER Disassembly sequence 1 Cap 2 Fuel return pipe 3 Overflow valve 4 Fuel feed pipe 5 Eyebolt 6 Fuel feed pipe 7 Plug 8 Drain plug 9 O-ring 10 Case 11 Float 12 O-ring 13 Element 14 Fuel filter head : Non-reusable parts Assembly sequence Follow the disassembly sequence in re-...
Page 209 Special tools Mark Tool name and shape Part No. Application Filter wrench MH063201 Removal and installation of case Removal procedure Removal: Case • Drain fuel from the case by loosening the drain plug. • Using , remove the case. Installation procedure Installation: Case •...
Page 210 FUEL FILTER • Replace the filter element and O-rings with new parts. • Apply a thin coat of engine oil to the O-rings. Install the O-rings onto the case. CAUTION • The use of non-genuine filter elements will lead to engine problems.
Page 211 M E M O 13-79...
Page 212 WATER SEPARATOR Disassembly sequence 1 Fuel hose 2 Fuel cut valve 3 Connector 4 Plug A 5 O-ring 6 Plug B 7 O-ring 8 Drain plug 9 O-ring 10 Cover 11 O-ring 12 Float 13 Element 14 Body : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse.
Page 213 Removal procedure Removal: Cover • Loosen plugs A and B and then loosen the drain plug. Next, dis- charge fuel from the water separator. • Using , remove the cover. WARNING • Do not bring an open flame or heat near to fuel, which can catch fire easily.
Page 214 WATER SEPARATOR • 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. •...
Page 215 M E M O 13-83...
Page 216 ENGINE CONTROL Removal sequence 1 Cover 6 Accelerator pedal bracket 2 Accelerator pedal control cable 7 Accelerator link (See later section.) 3 Accelerator pedal pin 8 Accelerator pedal position sensor 4 Accelerator pedal 5 Stopper bolt : Non-reusable parts Installation sequence Follow the removal sequence in reverse.
Page 217 • Install the other end of the accelerator pedal control cable onto the accelerator position sensor control lever. • Adjust tension of the accelerator pedal control cable with the ac- celerator link stopper bolt so that accelerator link B contacts the stopper.
Page 218 ENGINE CONTROL Accelerator Link Removal sequence 1 Accelerator pedal switch 2 Bushing 3 Accelerator link A 4 Bushing 5 Accelerator link B 6 Collar 7 Return spring 8 Bushing 9 Accelerator link bracket : Non-reusable parts Installation sequence Follow the removal sequence in reverse. Lubricant and/or sealant Mark Points of application...
Page 219 M E M O 13-87...
Page 220 INSPECTION OF MITSUBISHI 6M70 ELECTRICAL PARTS #001 Inspection of combination switch DD15B connector connection table Switch position Terminals with continuity – Powertard 1st step 6 – 11 switch 2nd step 6 – 11, 3 – 9 • For other inspections than shown above, see Gr54.
Page 221 #201 Inspection of relay (normally open 5-pin) • Check continuity and operating condition of the relay. Replace the relay if necessary. #262 Inspection of Mitsubishi 6M70 water temperature sensor • Place the water temperature sensor in a container filled with en- gine oil.
Page 222 INSPECTION OF ELECTRICAL EQUIPMENT #305 Inspection of Misubishi 6M70 intake air temperature sensor • The intake air temperature sensor 1 may output false signals if its tip is contaminated. Clean it if necessary. (See Gr15.) • Place the sensor in a container filled with engine oil.
Page 223 #320 Inspection of Mitsubishi 6M70 cylinder recognition sensor • Measure the resistance between terminals 1 and 2. Standard value 860 ± 86 Ω • If the measurement is out of specification, replace the sensor. #323 Inspection of Mitsubishi 6M70 fuel temperature sensor •...
Page 224 (at 20°C) • If the measurement is out of specification, replace the supply pump. #582 Inspection of Mitsubishi 6M70 injector magnetic valve • Measure the resistance between terminals 1 and 2. 0.21 to 0.295 Ω Standard value (at 20 to 70°C) •...
Page 225 M E M O 13-93...
Page 226 INSTALLED LOCATIONS OF PARTS 13-94...
Page 227 13-95...
Page 228 INSTALLED LOCATIONS OF PARTS 13-96...
Page 229 13-97...
Page 230 INSTALLED LOCATIONS OF PARTS 13-98...
Page 231 13-99...
Page 232 MITSUBISHI 6M70 INSTALLED LOCATIONS OF PARTS 13-100...
Page 233 13-101...
Page 234 ELECTRIC CIRCUIT DIAGRAM 13-102...
Page 235 13-103...
Page 236 ELECTRIC CIRCUIT DIAGRAM 13-104...
Page 237 13-105...
Page 238 ELECTRIC CIRCUIT DIAGRAM 13-106...
Page 239 GROUP 14 COOLING SPECIFICATIONS ................14-2 STRUCTURE AND OPERATION 14-3 1. Cooling System (Flow of Coolant) ........... 14-4 2. Thermostat ..................14-4 3. Water Pump ..................TROUBLESHOOTING ..............14-5 ON-VEHICLE INSPECTION AND ADJUSTMENT ......... 14-6 1. Inspection and Adjustment of Belt Tension ...............
Page 240 SPECIFICATIONS Item Specifications Cooling system Forced 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 41 {41} 14-2...
Page 241 STRUCTURE AND OPERATION 1. Mitsubishi 6M70 Cooling System (Flow of Coolant) 14-3...
Page 242 (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.
Page 243 TROUBLESHOOTING Symptoms Reference Gr Possible causes Loose or damaged Belt Excessive tension Oil on belt Incorrectly mounted water pump Defective gasket Defective bearing unit Water pump Defective impeller Defective unit seal Fit of bearing unit on flange and impeller too loose Incorrectly mounted case Defective gasket Valve opening temperature too high...
Page 244 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection and Adjustment of Belt Tension CAUTION • Be careful not to allow engine oil to smear the belt. A belt smeared with oil slips, resulting in reduced cooling efficiency. • When replacing the belts, replace them as a set to prevent differences in tension between the two belts. Service standards (Unit: mm) Location Maintenance item...
Page 245 • Place at a central portion between pulleys of the V-belt and push the handle (indicated by the arrow in the illustration) until indicated by arrow touches the O-ring. • Measure the amount of deflection of the V-belt. • If the measurement deviates from the standard value, adjust as follows.
Page 246 ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Inspection of Belts • Visually check the belt for a crack or damage. • If there is any abnormality, replace the belt. Belt condition Remaining service life (reference) • The driving distance over the which the belt can still be used is at least as long as that over which the belt has been used since the vehicle was new or since the belt...
Page 247 3. Coolant Replacement and Cleaning of Cooling System Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Radiator drain cock 2.0 {0.2} – – Crankcase drain cock 37 {3.8} – • Using the radiator for extended periods of time without cleaning can increase chance of rust and scale formation, which may cause engine overheating.
Page 248 ON-VEHICLE INSPECTION AND ADJUSTMENT • Ordinary condition • Coolant extremely dirty • Radiator clogged Cleaning using FUSO RADIATOR CLEANER (RADIPET-7) Flushing with water Drain out coolant Make water solution of FUSO RADIATOR CLEANER (RADIPET-7) at 5 to 10% concentration in volume. Pour solution into surge tank.
Page 249 4. Air Bleeding of Cooling System • If the engine is started with the coolant filled up to the neck of the surge tank, the coolant temperature rises and the expanded coolant overflows from the neck little by little. To avoid this, fill the surge tank with a slightly smaller quantity of the coolant.
Page 250 DISCONNECTION AND CONNECTION OF HOSES AND PIPES Periphery of Radiator Removal sequence 1 Supply hose 6 Water hose 2 Inlet hose 7 Hose 3 Overflow hose 8 Water hose 4 Heater hose 9 Water pipe 5 Heater hose 10 Outlet hose Installation sequence Follow the removal sequence in reverse.
Page 251 Tightening torque (Unit: N·m {kgf·m}) 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} –...
Page 252 DISCONNECTION AND CONNECTION OF HOSES AND PIPES Periphery of Engine 14-14...
Page 253 Removal sequence 1 Air pipe 10 Eyebolt 19 Water pipe 2 Water pipe 11 Eyebolt 20 Water pipe 3 Water hose 12 Water pipe 21 Water hose 4 Water hose 13 Eyebolt a: Exhaust gas recirculation 5 Eyebolt 14 Eyebolt cooler 6 Eyebolt 15 Water pipe...
Page 254 RADIATOR AND FAN SHROUD Removal sequence 1 Cushion rubber 6 Cushion rubber 10 Radiator support 2 Front thrust rod bracket 7 Radiator 11 Shroud seal 3 Cushion rubber (See later section.) 12 Fan shroud 4 Cushion rubber 8 Radiator bracket 5 Thrust rod 9 Cushion rubber Installation sequence...
Page 255 Special tools (Unit: mm) Mark Tool name and shape Part No. Application Tip clearance spacer Adjusting clearance between fan ME294842 shroud and cooling fan blades Installation procedure Installation: Thrust rod • Tighten nuts so that the thickness of cushion rubbers on both ends of the thrust rod is to the dimension shown in the illustra- tion.
Page 256 RADIATOR AND FAN SHROUD Radiator Disassembly sequence 1 Thrust rod bracket 5 Side member 9 Packing 2 Radiator shroud 6 Upper tank 10 Core 3 Cross stay 7 Packing 4 Drain cock 8 Lower tank : Non-reusable parts CAUTION • Gently handle upper tank and lower tank, since they are made of a resin that can break on impact. •...
Page 257 Special tools Mark Tool name and shape Part No. Application J94-Z013 Lock-and-break tool Removal of upper and lower tanks -10000 The indicated part number is T.RAD’s part number. Inspection before removal Inspection: Air leakage from radiator • Install hose and radiator cap tester and plug to upper tank. •...
Page 258 RADIATOR AND FAN SHROUD • Adjust the stopper bolt until the gap dimension shown in the il- lustration is obtained on the attachment of CAUTION • Before using , be sure to set the gap to the specified di- mension by adjusting the stopper bolt. Otherwise, damaged will result.
Page 259 Inspection: Core groove where tank is to be mounted • Check the groove on the core where the tank is to be mounted for adhesion of foreign substances or cracks. • If foreign substances are found, rub the area with #1000 sand- paper or the like gently so as to avoid scratching the surface, or use compressed air to remove them.
Page 260 RADIATOR AND FAN SHROUD • Close both end of the tube by tungsten inert-gas arc welding (TIG welding). Welding conditions • Welding rod: A4043 (approx. φ2 mm) • Welding current: AC80A • After welding, check for the following problems. If any of them exist, repair again or replace the core.
Page 261 • 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. 14-23...
Page 262 SURGE TANK Disassembly sequence 1 Supply hose 2 Air bleeder hose 3 Overflow hose 4 Supply pipe 5 Supply hose 6 Pressure cap 7 Water level sensor 8 O-ring 9 Surge tank : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse.
Page 263 (2) Inspection of vent valve • Check the water level of the reservoir tank in advance. • Run the engine at high rpm. When the engine coolant overflows to the reservoir tank to some extent, stop the engine. • Leave the engine in this condition for a while. When the engine coolant temperature becomes the atmospheric temperature, check that the water level in the reservoir tank returns to the wa- ter level before the engine start.
Page 264 MITSUBISHI 6M70 COOLING FAN AND BELT Removal sequence 1 Belt (for air conditioner) a: Alternator 2 Belt (for alternator) b: Cooler compressor 3 Automatic cooling fan coupling (for air conditioner) 4 Cooling fan c: Water pump 5 Fan coupling d: Crankshaft pulley 6 Torsional damper •...
Page 265 Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (fan coupling mounting) 115 {12} – Nut (automatic cooling fan coupling mounting) 50 {5.0} – Inspection and cleaning procedure Inspection: Automatic cooling fan coupling • Perform the following inspection. If any abnormality is found, re- place the automatic cooling fan coupling.
Page 266 39 {4.0} – Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Thread of connector Threebond Sealock 2310 As required O-ring Engine oil As required Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 14-28...
Page 267 Special tools (Unit: mm) Mark Tool name and shape Part No. Application Bolt MH001102 × Removal and installation of snap ring MF434103 × Water pump pully puller MH062411 Removal of flange Bolt MH000715 × Impeller puller MH062192 Removal of impeller φ...
Page 268 WATER PUMP Removal: Flange Removal: Impeller Removal: Bearing unit • Remove the bearing unit using a press. Heating the water pump case to approximately 80°C will facilitate the removal. CAUTION • The ram load applied to remove the bearing unit should not exceed 9800 N {1000 kgf}.
Page 269 Installation procedure Installation: Bearing unit • Install the bearing unit by ramming down its outer race with the press until the end face A of the outer race and the end face B of water pump case meet flush. CAUTION •...
Page 270 WATER PUMP Installation: Flange CAUTION • Before installing a flange, make sure that there is no or only one punch mark in the shown location on the flange. Make an additional punch mark on the flange to indicate that it undergoes the disassembly and reassembly process you are doing now.
Page 271 M E M O 14-33...
Page 272 • Refer to the previous section “DISCONNECTION AND CONNECTION OF HOSES AND PIPES” for the correct insertion depth of thermostat cover and case hoses into the pump as well as the correct tightening torque of clamps. Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638...
Page 273 Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Valve opening 82 ± 2°C – temperature Thermostat Valve lift/temperature 10 or more/95°C – Replace Valve opening 88 ± 2°C – temperature Thermostat Valve lift/temperature 10 or more/100°C – Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened...
Page 274 GROUP 15 MITSUBISHI 6M70 INTAKE AND EXHAUST SPECIFICATIONS ........ 15-2 AIR CLEANER ........15-34 STRUCTURE AND OPERATION TURBOCHARGER ....... 15-36 ........15-3 1. Air Cleaner INTERCOOLER ........15-48 ........15-4 2. Turbocharger ..15-5 3. Turbocharger Control System INTAKE MANIFOLD ......15-50 ....
Page 275 Air cleaner element Cyclone filter paper type Dust indicator type Mechanical TF08 Model (VG (Variable Geometry: Variable nozzle vane Turbocharger type) Turbocharger) Manufacturer Mitsubishi Heavy Industries Intercooler type Tube and corrugated fin (air cooled) DPF (Diesel Particulate Filter) Continuous regeneration type 15-2...
Page 276 STRUCTURE AND OPERATION 1. Air Cleaner • The air cleaner is a single element type. • The air cleaner 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...
Page 277 • TF08 model is equipped with turbocharger, which is a variable nozzle vane type turbocharger with adjustable, heat-resistive alloy turbine vanes provided at the turbine exhaust gas inlet port. Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638...
Page 278 3. Turbocharger Control System 3.1 General description • The turbocharger control system uses various sensors to detect the status of the engine and controls the turbo- charger magnetic valves according to sensor output data by means of the engine electronic control unit. •...
Page 279 STRUCTURE AND OPERATION 3.2 Electronic Control System (1) System block diagram Input signals Output signals Engine-electronic control unit Engine warning lamp Starter switch (S) Turbocharger control function Water temperature sensor Turbocharger magnetic valve Vehicle speed sensor Diagnosis function Accelerator pedal position sensor Clutch switch Engine speed sensor Boost pressure sensor...
Page 280 (2) Diagnosis function • While the starter switch is on, the diagnosis function is constantly activated to find faults in various sensors. Upon any sensor being found faulty, the driver is informed of the fault through the display in the meter cluster. At the same time, the fault is memorized in the form of a diagnosis code and the system starts to effect necessary at- fault control(s).
Page 281 STRUCTURE AND OPERATION 4. Diesel Particulate Filter • Diesel particulate filter is a large-ca- pacity system consisting of an ultra-ef- ficient oxidation catalyst and a filter. Diesel particulate filter is designed to efficiently break and capture PM emit- ted by engines running on low-sulfur fuel, and the filter is continuously re- generated.
Page 282 TROUBLESHOOTING Symptoms Reference Gr Possible causes Air cleaner Clogged air cleaner element Defective bearing Carbon deposits on shaft and turbine wheel unit Interference between shaft and turbine wheel unit and turbine back plate Interference between shaft and turbine wheel unit and turbine housing Bent shaft and turbine wheel unit Damaged shaft and turbine wheel unit Interference between compressor wheel...
Page 283 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measurement and Adjustment of Turbocharger Boost Pressure Service standards Location Maintenance item Standard value Limit Remedy Boost pressure ± – (when VGT test performed with ambient temperature at 7 kPa – Adjust 25°C and atmospheric pressure at 101.5 kPa) (1) Preparation •...
Page 284 (3) Adjustment of turbocharger WARNING • The turbocharger is hot for a while after the engine is stopped. Take care not to burn yourself during adjustment work. • To adjust the turbocharger, turn the joint. • Make sure that the air cylinder is in the state of zero stroke when the engine is stopped.
Page 285 ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Cleaning and Inspection of Air Cleaner Element [Cleaning: Element] • Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm } against the inside surfaces of the element. CAUTION •...
Page 286 M E M O 15-13...
Page 287 TURBOCHARGER CONTROL SYSTEM 1. Diagnosis Procedure • Perform the inspection in accordance with the following flowchart. Warning lamp lit Vehicle in service shop Read all (past and present) diagnosis codes by Multi-Use Tester. (See Gr00.) Perform inspection based on diagnosis codes. (See later section.) Response to transient fault Was able to identify the fault? (See Gr00.)
Page 288 3. Inspections Based on Diagnosis Codes 3.1 Diagnosis code list • Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different. • The Multi-Use Tester is capable of showing more detailed diagnosis codes. Warning lamp indication Code Message...
Page 289 TURBOCHARGER CONTROL SYSTEM P1130: VGT1 (warning lamp flashes: 51) Current flowing in the turbocharger magnetic valve (No. 1 magnetic valve) re- Generation condition mains above the specified value for 1 second. System recovers when current flowing in the turbocharger magnetic valve (No. Recoverability 1 magnetic valve) becomes normal for 1 second.
Page 290 P1135: VGT2 (warning lamp flashes: 52) Current flowing in the turbocharger magnetic valve (No. 2 magnetic valve) re- Generation condition mains above the specified value for 1 second. System recovers when current flowing in the turbocharger magnetic valve (No. Recoverability 2 magnetic valve) becomes normal for 1 second.
Page 291 TURBOCHARGER CONTROL SYSTEM P1140: VGT3 (warning lamp flashes: 53) Current flowing in the turbocharger magnetic valve (No. 3 magnetic valve) re- Generation condition mains above the specified value for 1 second. System recovers when current flowing in the turbocharger magnetic valve (No. Recoverability 3 magnetic valve) becomes normal for 1 second.
Page 292 P1236: Turbine Revolution SNSR (Low) (warning lamp flashes: 57) Turbine speed remains 3000 rpm or less for 10 seconds when engine speed is Generation condition 1000 rpm or more. System recovers if turbine speed remains higher than 3000 rpm for 1 second Recoverability when engine speed is 1000 rpm or more.
Page 293 TURBOCHARGER CONTROL SYSTEM 4. Multi-Use Tester Service Data • It is possible to see service data and actuator tests simultaneously. Item Data Inspection condition Requirement VGT opening degrees displayed according to VGT M/V operations VGT Position shown below. Value matches atmospheric Starter switch ON (engine is stopped) pressure indication.
Page 294 6. Inspection of Electrical Equipment #566 Inspection of turbocharger magnetic valve • Perform the following tests on the turbocharger magnetic valve. Replace the valve if found faulty. (1) Valve activation test • Gradually increasing from 0 V, apply voltage to the turbocharger magnetic valve between the following terminals.
Page 295 TURBOCHARGER CONTROL SYSTEM 7. Installed Locations of Parts 15-22...
Page 296 15-23...
Page 297 TURBOCHARGER CONTROL SYSTEM 15-24...
Page 298 15-25...
Page 299 TURBOCHARGER CONTROL SYSTEM 15-26...
Page 300 15-27...
Page 301 TURBOCHARGER CONTROL SYSTEM 15-28...
Page 302 M E M O 15-29...
Page 303 TURBOCHARGER CONTROL SYSTEM 8. Electric Circuit Diagram 15-30...
Page 304 15-31...
Page 305 TURBOCHARGER CONTROL SYSTEM 15-32...
Page 306 M E M O 15-33...
Page 307 AIR CLEANER Removal sequence 1 Dust indicator 5 Duct joint hose 9 Safety element 2 Air tube 6 Air intake hose 10 Body 3 Vacuator valve 7 Cover 4 Lower air duct 8 Outer element CAUTION • Do not remove the safty element except for replacement. •...
Page 308 Cleaning procedure Cleaning: Element • Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm } against the inside surfaces of the element. CAUTION • For the frequency and timing of cleaning, refer to the rele- vant instruction manual.
Page 309 MITSUBISHI 6M70 TURBOCHARGER ATTACHING PARTS Removal sequence 1 Air inlet pipe 11 Gasket 20 Turbocharger magnetic valve 2 Air hose 12 Turbine speed sensor bracket 3 Air pipe 13 O-ring 21 Bracket 4 Air hose 14 Eyebolt 22 Turbocharger (See later sec-...
Page 310 Mitsubishi 6M70 Tightening torque (Unit: N·m {kgf·m}) 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} –...
Page 311 TURBOCHARGER Mitsubishi 6M70 Turbocharger Disassembly sequence 1 Connecting lever 7 Nozzle 13 Turbine housing 2 Spacer 8 Flange 14 Cartridge assembly 3 Joint 9 Snap ring (See later section.) 4 Air cylinder 10 Compressor cover : Non-reusable parts 5 Bracket...
Page 312 Removal: Nozzle • Remove the flange and nozzle in one unit from the turbine hous- ing. • Remove the clamp bolt, then remove the nozzle from the flange. Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 15-39...
Page 313 TURBOCHARGER Removal: Snap ring • Tighten the bolt to contract the snap ring and remove the ring. Removal: Compressor cover • Lightly tap around the entire periphery of the compressor cover with a rubber-faced hammer, taking care not to cause damage. CAUTION •...
Page 314 Inspection: Joint inside diameter • If the measurement exceeds the specified limit, replace the joint. Inspection: Air cylinder (1) Stroke • Apply specified air pressure to the ports (A to C) in the air cylin- der, one at a time, and measure the corresponding strokes of the air cylinder.
Page 315 TURBOCHARGER • Measure the inside diameter C of the compressor cover. • Calculate the clearance between compressor wheel and com- pressor cover as follows. C-B-A Clearance= • If the clearance deviates from the specified standard value range, disassemble and correct. Inspection: Cartridge assembly (1) Play in axial direction of shaft and turbine wheel •...
Page 316 Installation: Snap ring • Turn the snap ring in its mounting groove to confirm proper seat- ing of the ring. After confirmation, loosen the bolt and fit the ring securely. Work after installation Adjustment: Positioning of air cylinder (1) Full closing position •...
Page 317 Replace Outside diameter – 20.382 Replace Bearing Inside diameter – 12.042 Replace Length – 11.94 Replace Inside diameter of bearing insertion bore in bearing – 20.506 Replace housing Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 15-44...
Page 318 Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Thread-locking Lock nut 20 {2.0} compound Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Thread of lock nut Molykote BR-2 Plus As required O-ring Piston ring Engine oil...
Page 319 TURBOCHARGER Removal: Insert Inspection procedure Inspection: Shaft and turbine wheel [Inspection] (1) Journal outside diameter • If the measurement exceeds the specified limit or uneven wear is excessive, replace the shaft and turbine wheel unit. • Inspect the journal visually and recondition it if roughened. (2) Shaft bend •...
Page 320 Inspection: Bearing housing • If the measurement exceeds the specified limit, replace the bearing housing. Installation procedure Installation: Thrust bearing • Install the shaft and turbine wheel unit, fitted in the bearing hous- ing, in the turbine housing. Fasten it in place temporarily with the coupling.
Page 321 INTERCOOLER Removal sequence 1 Air inlet hose 2 Air outlet hose 3 Intercooler a: Turbocharger b: Intake throttle Installation sequence Follow the removal sequence in reverse. CAUTION • When removing the air inlet hose, do not try to pry it off with strong force using a screwdriver or other similar tools.
Page 322 Installation procedure Installation: 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 MITSUBISHI 6M70 INTAKE MANIFOLD Disassembly sequence 5 Bracket 10 Intake manifold 1 Eyebolt 11 Gasket 2 Boost pressure sensor 6 Air inlet pipe 3 Intake air temperature sensor 7 Gasket 4 Intake air temperature sensor 8 Spacer a: Cylinder head (See Gr11.)
Page 324 Inspection procedure Inspection: Intake air temperature sensor • Check that the sensor portion is free of soot, oily substance, etc. • If not, clean the sensor portion as follows. • Spray a cleaner on the sensor portion from 2 or 3 cm away. Recommended cleaners: Wako Chemical brake and parts cleaner from Wako Chemical Trusco Nakayama brake and parts cleaner ALP-BP...
Page 325 Cylinder head (See Gr11.) 4 Exhaust Manifold Expansion rings 8 Center exhaust manifold : Non-reusable parts Assembly sequence Follow the disassembly sequence in reverse. Mitsubishi 6M70 Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Nut (exhaust manifold mounting) 42 {4.2}...
Page 326 Installation procedure Installation: Mitsubishi 6M70 Expansion rings and seal rings • Fit 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.
Page 327 EXHAUST PIPE <FS> Disassembly sequence 1 Lower front pipe 7 Clamp 13 Clamp 2 Gasket 8 Exhaust pipe cover 14 Upper front pipe 3 Gasket 9 Clamp 4 Rubber cushion 10 Center front pipe a: Diesel Particulate Filter 5 Exhaust pipe hanger 11 Gasket : Non-reusable parts 6 Stay...
Page 328 Installation 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 15-55...
Page 329 EXHAUST PIPE <EXCEPT FS> Disassembly sequence 1 Spring 6 Seal ring 11 Exhaust pipe clamp bracket 2 Washer 7 Gasket 3 Clamp 8 Upper front pipe a: Diesel Particulate Filter 4 Lower front pipe 9 Gasket b: Turbocharger coupler 5 Washer 10 Rubber cushion : Non-reusable parts Installation sequence...
Page 330 M E M O 15-57...
Page 331 DIESEL PARTICULATE FILTER <FS> Disassembly sequence 1 Clamp 6 Gasket 11 DPF 2 Tail pipe 7 DPF band 3 Stay 8 Stay a: Front pipe 4 Rubber cushion 9 Rubber cushion : Non-reusable parts 5 Collar 10 Collar DPF: Diesel Particulate Filter Assembly sequence Follow the disassembly sequence in reverse.
Page 332 Inspection procedure Inspection: DPF • Check the inner exhaust channel of DPF for clogging with for- eign material. • If clogged, the inner exhaust channel must be cleaned with com- pressed air or DPF must be replaced. • If DPF is clogged, this may be due to problems with the engine. Check the engine and adjust as required.
Page 333 DIESEL PARTICULATE FILTER <EXCEPT FS> Disassembly sequence 1 Spring 7 Muffler plate a: Front pipe 2 Washer 8 DPF cover : Non-reusable parts 3 Seal ring 9 DPF insulator 4 Clamp 10 DPF DPF: Diesel Particulate Filter 5 Tail pipe 11 Bracket 6 Muffler plate Assembly sequence...
Page 334 Inspection procedure Inspection: DPF • Check the inner exhaust channel of DPF for clogging with for- eign material. • If clogged, the inner exhaust channel must be cleaned with com- pressed air or DPF must be replaced. • If DPF is clogged, this may be due to problems with the engine. Check the engine and adjust as required.
Page 335 GROUP 17 MITSUISHI 6M70 EMISSION CONTROL STRUCTURE AND OPERATION ..........17-2 1. Exhaust Gas Recirculation System ............17-7 2. Blowby Gas Return System ON-VEHICLE INSPECTION AND ADJUSTMENT ..17-8 1. Replacement of Positive Crankcase Ventilation Valve Element 2. Check for Cracks and Damages in Piping of Blowby Gas ................
Page 336 STRUCTURE AND OPERATION 1. Exhaust Gas Recirculation System 1.1 Overview • In the exhaust gas recirculation system, various engine-related information (engine speed, water temperature, ac- celerator position) is collected by the relevant sensors and is sent to the engine electronic control unit and EGR EDU which then control the EGR magnetic valves based on the information received.
Page 337 • The EGR magnetic valves are each turned ON/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 STRUCTURE AND OPERATION 1.2 Electronic control system (1) System block diagram Input signals Output signals Engine electronic control unit Engine speed sensor Engine warning lamp Exhaust gas recircula- Water temperature sensor tion control function Accelerator pedal position sensor Fault diagnosis function Intake air temperature sensor...
Page 339 (2) Exhaust gas recirculation valve control function • Based on inputs from various sensors, the engine electronic control unit determines the degree of opening of the exhaust gas recirculation valve and sends corresponding control signals to the exhaust gas recirculation electron- ic drive unit to activate the exhaust gas recirculation magnetic valve.
Page 340 STRUCTURE AND OPERATION 1.3 Electronic control unit connection diagram 17-6...
Page 341 2. Blowby Gas Return System • The blowby gas return system is designed to introduce blowby gases into the intake air duct for reburning, thus preventing the gases from being released to the atmosphere. • The positive crankcase ventilation valve keeps constant the pressure inside the crankcase. •...
Page 342 • Securely tighten the cap until it stops slightly above the positive crankcase ventilation body. CAUTION • Be sure to use a genuine Mitsubishi Fuso element. Using an inappropriate element could result in engine trouble. • When replacing the element, be sure to replace the O-ring also.
Page 343 M E M O 17-9...
Page 344 EXHAUST GAS RECIRCULATION SYSTEM 1. Diagnosis Procedure • Perform the inspection in accordance with the following flowchart. Warning lamp lit Vehicle in service shop Read all (past and present) diagnosis codes by Multi-Use Tester. (See Gr00.) Perform inspection based on diagnosis codes. (See later section.) Response to transient fault Was able to identify the fault? (See Gr00.)
Page 345 3. Inspections Based on Diagnosis Codes 3.1 Diagnosis code list • Diagnosis codes shown by the Multi-Use Tester and those indicated by warning lamp display are different. • The Multi-Use Tester is capable of showing more detailed diagnosis codes. Warning lamp indication Code Message Flashes...
Page 346 EXHAUST GAS RECIRCULATION SYSTEM P1268: EGR1 (warning lamp: 67) Controller area network signal from exhaust gas recirculation electronic drive unit Generation condition indicating “magnetic valve (M/V-1) circuit shorted to power source” remains being received for 2 seconds. System recovers if controller area network signal from exhaust gas recirculation Recoverability electronic drive unit indicating “magnetic valve (M/V-1) is normal”...
Page 347 P1278: EGR3 (warning lamp: 69) Controller area network signal from exhaust gas recirculation electronic drive unit Generation condition indicating “magnetic valve (M/V-3) circuit shorted to power source” remains being received for 2 seconds. System recovers if controller area network signal from exhaust gas recirculation Recoverability electronic drive unit indicating “magnetic valve (M/V-3) is normal”...
Page 348 EXHAUST GAS RECIRCULATION SYSTEM 4. Multi-Use Tester Service Data • It is possible to see service data and actuator tests simultaneously. Item Data Inspection condition Requirement Position as commanded by Perform actuator test actuator test 20 Actual EGR Position [Actuator test] A1: EGR 1 Equal to ambient tempera- °C 2B Intake Air Temperature...
Page 349 6.1 Electronic control unit connector terminal layout 6.2 Inspection 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.
Page 350 EXHAUST GAS RECIRCULATION SYSTEM 7. Inspection of Electrical Equipment #201 Inspection of relay (normally open, 5 pins) • Perform a continuity check and an operation check. If there is any abnormality, replace the relay. #305 Inspection of intake air temperature sensor •...
Page 351 M E M O 17-17...
Page 352 EXHAUST GAS RECIRCULATION SYSTEM 8. Installed Locations of Parts 17-18...
Page 353 17-19...
Page 354 EXHAUST GAS RECIRCULATION SYSTEM 17-20...
Page 355 17-21...
Page 356 EXHAUST GAS RECIRCULATION SYSTEM 17-22...
Page 357 17-23...
Page 358 EXHAUST GAS RECIRCULATION SYSTEM 9. Electric Circuit Diagram 17-24...
Page 359 17-25...
Page 360 MITSUBISHI 6M70 EGR VALVE, EGR MAGNETIC VALVE, EGR PIPE AND EGR COOLER 17-26...
Page 361 Removal sequence 1 Upper EGR pipe clamp 11 EGR water pipe 21 Gasket 2 Lower EGR pipe clamp 12 Eyebolt 22 Air pipe 3 Spacer 13 EGR water pipe 23 Connector 4 EGR pipe 14 Eyebolt 24 EGR magnetic valve 5 Gasket 15 EGR air pipe 6 Gasket...
Page 362 EGR VALVE, EGR MAGNETIC VALVE, EGR PIPE AND EGR COOLER Inspection procedures Inspection: EGR valve lift • While applying specified air pressure to the ports in accordance with the table below, measure the valve lift in operating steps 1 to 8 on each valve. •...
Page 363 BLOWBY GAS RETURN SYSTEM Removal sequence 1 PCV hose 7 PCV hose 13 Element 2 PCV pipe 8 Oil hose 14 PCV body 3 PCV hose 9 Oil separator a: Rocker cover 4 PCV hose 10 Oil hose : Non-reusable parts 5 PCV pipe 11 Cap PCV: Positive crankcase ventilation...
Page 364 BLOWBY GAS RETURN SYSTEM Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mitsubishi 6M70 Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 LAST PAGE...

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Troubleshooting

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Summary of Contents for Mitsubishi 6M70

Page 14: Valve Mechanism

Page 64: Cylinder Liner

Page 118: Oil Filter Replacement

Page 128: Oil Filter

Page 193: Fuel Filter Replacement

Page 206: Fuel Tank

Table of Contents