Download
Share
Print this page
Mitsubishi 6D24 Manual
  1. Manuals
  2. Brands
  3. Mitsubishi Manuals
  4. Engine
  5. 6D24
  6. Manual
Mitsubishi 6D24 Manual

Mitsubishi 6D24 Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
6024
6D24T
6D24TC
6D24TL
diesel engine
Shop Manual
FOREWORD
This
shop manual contains the specification,
construction, operation, adjustment and service pro­
cedures of the Model 6024 diesel engine for
service mechanics engaged in servicing of the
Mitsubishi die­sel engines.
Please make the most of this shop manual to perform
correct servicing and wasteless operations.
Note that some of the contents of this shop manual are
subject to change owing to improvements, etc. that
may be introduced after publication of this shop
manual.
Mitsubishi 6D24 6D24T Engine Maintenance Service Kits
Includes: thermostat set, thermostat gaskets, valve cover gaskets,
oil filters, air filters, fuel filters, V-belts.
Replace thermostats and thermostat gaskets,
Adjust intake valve clearance and exhaust valve clearance, replace valve cover gaskets,
Replace filters,
Replace V-belts.
Mitsubishi 6D24 6D24T Engine Parts
Contact email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
GROUP INDEX
GENERAL .................................... •
...................................... .
ENGINE
LUBRICATION
FUEL AND ENGINE CONTROL
ELECTRONICALLY
CONTROLLED FUEL SYSTEM
................................... .
COOLING
INTAKE AND EXHAUST
ENGINE ELECTRICAL
..................................... .
CLUTCH
SPECIAL EQUIPMENT
www.6D24.com
.............................. .
........... ·
.............
................... .
....................... -
..................... .
Im
11!1

Advertisement

loading
Need help?

Need help?

Do you have a question about the 6D24 and is the answer not in the manual?

Questions and answers

Related Manuals for Mitsubishi 6D24

Summary of Contents for Mitsubishi 6D24

  • Page 1 ........CLUTCH ..... . SPECIAL EQUIPMENT Mitsubishi 6D24 6D24T Engine Maintenance Service Kits Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts. Replace thermostats and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, replace valve cover gaskets, Replace filters, Replace V-belts.
  • Page 2 Mitsubishi 6D24 6D24T Engine Parts Contact: Heavy Equipment Restoration Parts LLC 4730 118th Ave Fennville Michigan 49408 USA Phone: 269 673 1638 Fax: 269 673 7226 email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com Text message: 269 760 8652 Located in USA, Engine Parts delivery available in USA, Canada and worldwide.
  • Page 3 COMPILATION OF THIS MANUAL CONTENTS 1. TERMS AND UNITS ......4 2. UNITS ........... 5 3. READING THE ILLUSTRATION ....6...
  • Page 4 COMPILATION OF THIS MANUAL - TERMS AND UNITS 1. TERMS AND UNITS (4) lightening torque Over-or undertightening of bolts and nuts has criti­ The following terms and units are used throughout the cal effects on performance and functions. Tighten­ entire texts of this manual. ing torque is therefore specified for some tighten­...
  • Page 5 COMPILATION OF THIS MANUAL - UNITS 2. UNITS lightening torques and other parameters are given in SI* units with metric units added in brackets { }. *SI: Le Systeme International d'Unites Example: 390 N · m {40 kgf · m} Metric unit LSI unit Unit...
  • Page 6 COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION 3. READING THE ILLUSTRATION (Ex. 1: Disassembly and Inspection) *Protrusion from crankcase to surface NV 0.10 to 0.50 Indicates the service i.----3 Carbon deposits, scratches standards. on outer surfaces, cracks, discoloration c,aok,, �...
  • Page 7 COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION (Ex. 2: Reassembly) Gives instruction for jobs to ho doao at raassembly. ·• "'-. Apply engine oil. Piston projection NV 0.48 to 0.74 98N-m Face the oil groove {10 kgf-m} toward the crankshaft (Wet) End play NV 0.10 to 0.25...
  • Page 9 GENERAL CONTENTS 1. EXTERNAL VIEW ......2 4. KEY POINTS FOR 2. MAJOR SPECIFICATIONS ....3 MAINTENANCE WORK .
  • Page 10 GENERAL - EXTERNAL VIEW 1. EXTERNAL VIEW Natural-aspirated engine Turbocharged engine A0243A A0244A 00-2...
  • Page 11 1473 Overall width Overall height 1058 1169 1209 1246 kg * Empty weight * Empty weight as measured according to Mitsubishi Motors Corporation standard. 2.2 Engine Outputs Classified by Application 6D24-T 6D24-TC 6D24 Turbocharged Turbocharged with Aftercooler gine ed rpm �...
  • Page 12 The engine number is stamped near the front of the ing items. crankcase on the left-hand side. It takes the following form: Example: 6D24- 012345 j�---- Engine number VAL V E C L EAR AN C E (C O L D) Engine model 0.4mm(0.0 1 6in) l 1...
  • Page 13 GENERAL - KEY POINTS FOR MAINTENANCE WORK • 4. KEY POINTS FOR MAINTENANCE WORK When removing or installing the engine, attach the lifting wire rope hooks to the engine's lifting eyes In order to determine the condition of the vehicle ade­ and hoist the engine slowly such that it does not quately, attend the vehicle beforehand to find and keep touch other components.
  • Page 14 This will help avoid mismating of the parts later. Use only genuine MITSUBISHI replacement parts. Put the alignment marks, punch marks, etc. where per­ formance and appearance will not be affected.
  • Page 15 GENERAL - KEY POINTS FOR MAINTENANCE WORK 00019 00022 • Wear goggles when using a grinder or welder. Pay full Pull the connector, and not the harness lead, to attention to safety by wearing gloves when necessary. separate connectors. To separate a lock-type con­ nector, first push toward arrow mark.
  • Page 16 GENERAL - KEY POINTS FOR MAINTENANCE WORK Measurement Procedures Using Connectors Connect the test harness and connector A between these parts 06702 02587 • To apply voltage for testing, check that the positive Test with connectors engaged (continuity through cir­ and negative cables are connected properly, then cuit obtained) increase voltage gradually from O volt.
  • Page 17 GENERAL - KEY POINTS FOR MAINTENANCE WORK Connector Inspection Procedures 02589 Test with connectors disengaged Visual inspection Using female pins Check for loose connection and poor engagement. Insert a test probe into a terminal. However, do not force the probe into the terminal, or it will cause a poor contact.
  • Page 18 GENERAL - KEY POINTS FOR MAINTENANCE WORK Check for poor contact caused by connector pins hav­ Remove fuse B and measure resistance between the ing fallen out, rusted terminals or foreign particles. loaded side of the fuse and ground. Turn on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0, a short has occurred between the switch and the loaded point.
  • Page 19 GENERAL - KEY POINTS FOR MAINTENANCE WORK • Do not splash water over the alternator. If water is directly splashed over the alternator, in­ dividual components will be short-circuited and might be destroyed. 04747 • While the engine is running, do not remove the bat­ tery terminals.
  • Page 20 - GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE 5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE • Use specified bolts and nuts and tighten them with the applicable torques according to the following table, unless otherwise specified. • Threads and contact seats shall be dry.
  • Page 21 GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE - Hex-head Nut Unit: N-m {kgf-m } Strength classification © Repre- sentation ([eJ] Diameter symbol Standard screw Coarse screw Standard screw Coarse screw 4 to 6 {0.4 to 0.6} 2 to 3 {0.2 to 0.3} 4 to 6 {0.4 to 0.6} 7 to 11 {0.7 to 1.1} 9 to 14 {0.9 to 1.4}...
  • Page 22 GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABL E lightening torque for flare nut for general purpose Unit: N- m {kgf- m } Pipe diameter 4>6.3 «j>Smm «j>10 mm «j>12mm qi1 5 mm 4>4.7 6 mm lightening torque {2.6} 39 {4.0} 9 {6.0} 88 {9.0}...
  • Page 23 Reassembly ......25 Mitsubishi 6D24 6D24T Engine Parts Contact: Heavy Equipment Restoration Parts LLC...
  • Page 24 ENGINE - GENERAL 1. GENERAL (1) Combustion chamber Injection nozzle Cylinder head ----- 0-ring Nozzle tube Cylinder head gasket Water director B0376A Water directors pressed into the bottom of the cylinder head optimize cooling of the combustion chambers by directing the flow of coolant. B0375C The combustion chambers are formed by the cylinder head and pistons.
  • Page 25 ENGINE - GENERAL (2) Valve mechanism Rocker Rocker cover Valve cap Valve cotter :...---- _____ Upper retainer _ .. - .. -- Valve spring outer .., --· - -- Valve spring inner Valve stem seal Oil passage Rocker Push rod 85040A Tappet Camshaft...
  • Page 26 ENGINE - GENERAL (3) Crankcase and cylinder liner (4) Piston and piston rings (a) Pistons Weight mark Size mark Part ,C ) Front indicated by "F" and arrow Cooling cavity 43428 (a) Seven camshaft bushings are fitted in the camshaft bearing section of the crankcase.
  • Page 27 ENGINE GENERAL (5) Connecting rod and connecting rod bearing (6) Crankshaft and crankshaft main bearings Connecting rod bushing Balance weight 84206A Connecting rod Connecting rod (a) The crankshaft is highly rigid and is cast in one bearing (upper) "><¾?� piece with its balance. Connecting rod Cylinder number, Between each journal and pin is an oil hole.
  • Page 28 ENGINE - GENERAL (d) Main bearings Torsional damper <Rubber type> • Single mass � Crankshaft pulley ,.,. • Double mass Torsional damper Crankshaft pulley <Viscous type> Crankshaft pulley Upper main lower main Thrust plate Crankshaft 84489A bearing bearing 80382A (c) The front end of the crankshaft is flanged, and the Each main bearing is a split-type plain bearing made of crankshaft pulley is bolted to the flange.
  • Page 29 ENGINE - GENERAL (7) liming gears Each idler gear is mounted onto the crankcase with an idler shaft bolt and is supported at the other end by the flywheel housing. The idler gears turn on the idler shafts by means of pressed-in bushings.
  • Page 30 ENGINE - SPECIFICATIONS 2. SPECIFICATIONS Item Specification 6D24 6D24-T 6D24-TC 6D24-TL Engine model 6-cylinder, in-line, water-cooled, Type 4-cycle diesel Combustion chamber type Direct injection Valve mechanism Overhead valve 130 X 150 Cylinder bore x stroke (mm) Total displacement (cm 11945 Compression ratio 19.5...
  • Page 31 ENGINE - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item Nominal value Limit Remedy and remarks (Basic diameter in [ ] ) Compression pressure (at 200 rpm) 2750 kPa 1960 kPa {20 kgf/cm2} Difference between cylin- {28 kgf/cm ders: 390 KPa {4 kgf/cm or less...
  • Page 32 0.02 or less (130) 0.178 to 0.204 Correct or replace cylinder Piston-to-cylinder liner clear- 6D24 ance liner, or replace piston 6D24-T, TC, TL (130) 0.193 to 0.219 Piston 1st compression 6D24 0.09 to 0.13 0.25 Replace piston ring or piston...
  • Page 33 Crankshaft pulley mounting bolt M14x1.5 175 {18} 33{3.4} Front cover mounting bolt M12 X 1.75 Mitsubishi 6D24 6D24T Engine Parts Contact: Heavy Equipment Restoration Parts LLC 4730 118th Ave Fennville Michigan 49408 USA Phone: 269 673 1638 Fax: 269 673 7226 email: EngineParts@HeavyEquipmentRestorationParts.com...
  • Page 34 ENGINE - SPECIAL TOOLS 4. SPECIAL TOOLS Unit: mm Unit: mm Shape Tool name Shape Tool name Caulking Tool Body Compression Gauge Adapter MH061461 MH061360 Installing and caulking valve Measuring compression pres­ seat inserts sure Caulking Tool Caulking Ring (Inlet) Body MH061650 Caulking Ring...
  • Page 35 ENGINE - SPECIAL TOOLS Unit: mm Unit: mm Idler Gear Bushing Puller Camshaft Bushing Extractor MH061228 MH062118 Replacing idler gear bushing (for idler gear A) Removing camshaft bushings Nos. 1 to 6 4>39.5 03532 Idler Gear Bushing Puller MH062046 B4867A Replacing idler gear bushing (for idler gear C) Camshaft Bushing Extractor...
  • Page 36 ENGINE - SPECIAL TOOLS Unit: mm Unit: mm Camshaft Bushing Installer Camshaft Bushing Installer MH06213 1 MH062143 MH06212 5 Installing camshaft bushings Installing camshaft bushings Nos. 1 and 7 Nos. 2to 6 M2 4x 1.5 B487 1A cl>B Applicable Part No. cl>A bushing Camshaft Bushing Installer...
  • Page 37 ENGINE - SPECIAL TOOLS Unit: mm Unit: mm Cylinder Liner Extractor Oil Seal Sleeve Installer MH061490 31191-07100 Removing cylinder liners Installing rear oil seal sleeve PE7264 Oil Seal Slinger Installer MH061817 B5131A Installing front oil seal slinger Cylinder Liner Installer MH061759 Installing cylinder liners 85141A...
  • Page 38 ENGINE - SERVICE PROCEDURES 5. SERVICE PROCEDURES 5.1 Measuring Compression Pressure Compression pressure (at 200 rpm) NV 2750 kPa {28 kgf/cm Compression pressure should be measured prior to 1960 kPa {20 kgf/cm disassembly of the engine. Take measurements regu­ Difference between cylinders larly and keep track of changes.
  • Page 39 ENGINE - SERVICE PROCEDURES 5.2 Cylinder Head and Valve Mechanism 5.2.1 Disassembly Oil hole �g vlear Wear, damaged threads 17 Water leaks, Wear, damage 7 gas leaks Wear, cracks Corrosion Disassembly sequence 16 Exhaust valve 1 Rocker cover Valve cap 2 Rocker shaft bracket...
  • Page 40 ENGINE - SERVICE PROCEDURES Disassembly Procedure The cylinder head is located on the top surface of the crankcase by dowel pins. To remove the cylinder head, lift it straight upward. NOTE: Rocker cover 1. Remove the injection nozzles before taking off the cylinder head.
  • Page 41 ENGINE - SERVICE PROCEDURES 5.2.2 Inspection Item Free length Outer valve spring 89.38 Inner valve spring 65.04 Rocker bushing­ to-rocker shaft Installed load/ installed length Outer valve spring 450 N {46.1 kgf}/58.35 380 N {39 kgf}/58.35 clearance BO 28 Inner valve spring 115 N {12 kgf}/50.35 100 N {10.2 kgf}/ 5 0.35 NV 0.03 to 0.08...
  • Page 42 ENGINE - SERVICE PROCEDURES Measure the free length and installed load of each Inspection Procedure (1) Rocker bushing-to-rocker shaft clearance valve spring. Replace any spring that is not up to speci­ fication. With inner springs, check also for squareness. Measuring (4) Tappet-to-crankcase tappet hole clearance position <Tappet measurement>...
  • Page 43 ENGINE SERVICE PROCEDURES (6) Cylinder head bottom surface distortion (8) Valve stem-to-valve guide clearance Valve 21653 C3125A If distortion exceeds the specified limit, correct it using Insert the valve in the valve guide and measure the play at the specified distance from the valve guide's top (as a surface grinder.
  • Page 44 ENGINE - SERVICE PROCEDURES (10)Contact between valve and valve seat insert (11)Rectifying valve face Valve seat angle Valve margin Valve 820248 C2708A C2710B (a) Apply an even coat of minium to the valve seat With a valve refacer, grind the valve face to achieve the insert surface that comes into contact with the specified valve seat angle.
  • Page 45 ENGINE - SERVICE PROCEDURES (al Using a valve seat cutter, cut the insert to achieve the specified valve seat angle and seat width. Use a ° or 75 ° ° cutter first, followed by a 45 cutter. NOTE: Keep cutting to a minimum. If the valve sinkage exceeds the specified limit after cutting, replace the valve seat insert.
  • Page 46 ENGINE - SERVICE PROCEDURES (14)Lapping valve and valve seat insert (b) Using the Valve Lapper (special tool), lightly strike the valve against the valve seat insert while turning Contact between the valve and valve seat insert must it little by little. be even over the entire contact area.
  • Page 47 ENGINE - SERVICE PROCEDURES 5.2.3 Reassembly lightly wound end toward cylinder head Tightly wound end toward cylinder head Leak test: No leaks are allowed with 195 kPa {2 kgf/cm hydraulic pressure Apply sealant to nozzle tube. (THREEBOND 1211 or equivalent) Apply sealant (HERMESEAL S-2 or equivalent) 4.9N-m...
  • Page 48 ENGINE - SERVICE PROCEDURES Reassembly Procedure (3) Valve stem seal installation (1) Water director and sealing cap installation Water director Sealing cap Align notch with this line. F,;i.;.;z===;zf, Valve Stem Seal Installer ME067431 Apply sealant (HERMESEAL S-2 or equivalent) 10363 Valve Stem Seal Align each water director with the notch provided, as shown in the illustration.
  • Page 49 ENGINE - SERVICE PROCEDURES (4) Valve cotter installation Install the rocker shaft bracket by positioning it on the spring pin in the cylinder head. Mount the cylinder head by positioning it on the dowel pins in the crank­ case. Valve Lifter (6) lightening cylinder head bolts Hook MH061679...
  • Page 50 ENGINE - SERVICE PROCEDURES Socket Wrench MH061540 09182 ( b) Fit the socket over the cylinder head bolt and set it such that the built-in spring forces the rod against the rocker shaft bracket, an injection pipe, or another nearby part. Scale inscribed on socket Lines inscribed...
  • Page 51 ENGINE - SERVICE PROCEDURES 5.3 Flywheel, liming Gears, and Camshaft 5.3.1 Disassembly <With axial-lip-type <With electric <With mechanical tachometer drive> speed sensor> oil seal> �c � 7 Oil leaks Wear/deterioration Streaks/cracks/stepped wear on friction surface <With radial-lip-type ®43651 <With mechanical tachometer oil seal>...
  • Page 52 ENGINE - SERVICE PROCEDURES liming gear backlash Item Between crankshaft gear and idler gear B 0.08 to 0.20 Between idler gear A and camshaft gear 0.07 to 0.18 Between idler gear A and idler gear C 0.07 to 0.18 Between injection pump gear and idler gear C 0.08 to 0.20 Injection pump gear (Refer to Group 61, Special Equipment)
  • Page 53 ENGINE - SERVICE PROCEDURES Disassembly Procedure (3) Removing ring gear (1) Removing flywheel Threaded hole for removal Ring gear B2356C C19288 To remove the ring gear, heat it evenly with an acety­ lene torch, then tap around its entire periphery with a To remove the flywheel, screw its mounting bolts into hammer and rod.
  • Page 54 ENGINE - SERVICE PROCEDURES (5) Measuring idler gear and camshaft gear end play (7) Removing camshaft gear ♦ Idler gear Camshaft gear 11824 10992 If the end play exceeds the specified limit, replace the The camshaft gear is press-fitted onto the camshaft. To thrust plate.
  • Page 55 ENGINE - SERVICE PROCEDURES 5.3.2 Inspection Item Friction surface distortion 0.1 or less Distance from clutch cover 47.8 to 48.2 49.5 mounting surface to fric­ tion surface ®43653 Clearance BD 40 NV 0.03 to 0.06 Clearance BD 46 NV 0.03 to 0.06 BD ..
  • Page 56 ENGINE - SERVICE PROCEDURES Inspection Procedure (3) Idler gear-to-idler shaft clearance (1) Friction surface distortion Measuring position Measuring position Dial indicator Surface plate C3807B C3506A If the clearance exceeds the specified limit, replace the bushing in the idler gear. Place the flywheel on a surface plate. To measure dis­ tortion, pass a dial indicator over the flywheel from its (4) Replacing idler gear bushing periphery toward its center.
  • Page 57 ENGINE - SERVICE PROCEDURES (5) Cam profile (difference between base circle diame­ (7) Replacing camshaft bushings ter and lobe height) (a) Removal Remove the camshaft bushings in the following order: No.6 ➔ No.5 ➔ No.4 ➔ No.3 ➔ No.2 ➔ No.1 ➔...
  • Page 58 ENGINE - SERVICE PROCEDURES c) After removing the No. 6 bushing, remove bush­ a) Mount the Camshaft Bushing Installer Adapters ings Nos. 5 to 1 in that order using the appropriate (special tool) and bushings Nos. 2 to 4 on the Cam­ Camshaft Bushing Extractor Adapter for each one.
  • Page 59 -· ENGINE - SERVICE PROCEDURES d) After installing the bushings, remove the Camshaft 3) Installation of bushings Nos. 1 and 7 Bushing Installer Nut and gently withdraw the Camshaft Bushing Installer Bar. �""'""""'-�;�:,;l NOTE: When removing the Camshaft Bushing Installer Bar, take care not to damage the inside surfaces of the bushings.
  • Page 60 ENGINE - SERVICE PROCEDURES (8) Camshaft bend (9) Camshaft-to-camshaft gear interference 10995 11834 Measure the extent of bending in the crankshaft. If it If the interference is below the specified nominal value, exceeds the specified limit, replace the crankshaft. replace the camshaft or camshaft gear. NOTE: NOTE: Apply a dial indicator to the camshaft and turn the...
  • Page 61 ENGINE - SERVICE PROCEDURES 5.3.3 Reassembly BD . . Basic Diameter Flywheel housing NV .. Nominal Value eccentricity L ..Limit Idler gear end play NV 0.05 to 0.15 Bend lock washer Camshaft gear-to-camshaft interference , :J_ BD 40 NV 0.02 to 0.05 L.lr...,.,_ Reassemble max.
  • Page 62 ENGINE - SERVICE PROCEDURES Reassembly Procedure (3) Fitting camshaft gear (1) Mounting rear plate Camshaft gear Thrust plate Camshaft 21921 C6230C (a) With the alignment marks "4" facing away from the thrust plate, fit the camshaft gear using a press Mount the rear plate and gasket, ensuring that they are load A of 15.69 to 58.8 kN {1,600 to 6,000 kgf}.
  • Page 63 ENGINE - SERVICE PROCEDURES (4) Installing camshaft the oil seal slinger until it is seated tightly on the crank­ shaft gear. (8) Fitting oil seal sleeve <With radial-lip-type oil seal> Correct sleeve position Dowel pin Strike Camshaft gear Oil Seal Sleeve Installer C6231C 31191-07100 Crankshaft...
  • Page 64 ENGINE - SERVICE PROCEDURES (11 )Checking flywheel housing eccentricity (10)Fitting flywheel housing Apply$2 mm sealant bead (THREE BOND 1207C) B48570 C6233B lighten the flywheel housing mounting bolts to the (a) Apply a bead of sealant to the flywheel housing as shown in the illustration.
  • Page 65 ENGINE - SERVICE PROCEDURES 3. After fitting the rear oil seal, wait at least an hour (13)Checking flywheel runout before starting the engine. Apply a new bead of sealant A whenever the mounting bolts of the rear oil seal have been loos­ ened.
  • Page 66 ENGINE - SERVICE PROCEDURES Confirmation marks 10408 (c) Crank the engine in its normal direction of rotation (clockwise when viewed from the front). When cyl­ inder No.1 's exhaust valve begins to lift, confirm that the pointer on the flywheel housing is between the valve timing confirmation marks on the fly­...
  • Page 67 ENGINE - SERVICE PROCEDURES 5.4 Crankcase and Main Moving Parts 5.4.1 Disassembly NV .. Nominal Value L ..Limit Damage/ aboo,malwea, � 6 Damage/discoloration Scratches on outer periphery/ cracks on top/ '\._ <;.J..._. 8 discoloration/melting Projection of piston from top surface of crankcase NV 0.87 to 1.33 JJ-10 Cracks...
  • Page 68 ENGINE - SERVICE PROCEDURES NV .. Nominal Value Clogged oil hole L ..Limit Scratches/co�r!sion/ ✓ peeling 0 !' inner and " outer penphenes L '\ ,--...:: �-,, � � � � � � peehngon � inner and outer peripheries Scratches, cracks, dents, seisure, clogged oil hole, corrosion End play...
  • Page 69 ENGINE - SERVICE PROCEDURES Disassembly Procedure (3) Removing pistons (1) Piston projection The piston projection measurements must conform with specifications, partly since they affect engine per­ formance, and partly since the pistons must not inter­ fere with the valves. Fr.o + •...
  • Page 70 ENGINE - SERVICE PROCEDURES (7) Removing main bearing caps (5) Removing piston rings M10 x 1.5 801838 (6) Crankshaft end play The rearmost main bearing cap is located on dowel pins and must therefore be removed with a slide ham­ mer.
  • Page 71 ENGINE - SERVICE PROCEDURES 5.4.2 Inspection End gap Item 1st compression ring 0.4 to 0.55 0.5 to 0.65 2nd compression ring Oil ring 0.4 to 0.6 Clearance BO 50 NV 0.01 to 0.02 Piston ring groove-to-piston ring clearance Item 1st com- 6024 0.09 to 0.13 0.25...
  • Page 72 ENGINE - SERVICE PROCEDURES BO .. Basic Diameter NV .. Nominal Value L ..Limit Bend NV 0.04 or less Roundness NV 0.01 or less 0.08 Cylindricity NV 0.006 or less Main bearing-to-crankshaft journal clearance BO 100 NV 0.08 to 0.15 0.25 Main bearing span when free...
  • Page 73 ENGINE SERVICE PROCEDURES (2) Distortion of crankcase top surface ( 4) Cylinder liner flange projection Measurement points If distortion of the crankcase top surface exceeds the If any cylinder liner projection does not conform with specified limit, correct it with a surface grinder. its specified nominal value, replace the cylinder liner or crankcase.
  • Page 74 ENGINE - SERVICE PROCEDURES (b) Installation Strike in. Cylinder Liner Instal l e r MH061759 Cylinder l i ner Pisto n Cylinder liner C44278 C4813C Using the Cylinder Liner Installer (special tool), Make sure the new cylinder liner bears the same gently tap the cylinder liner down until its flange is size mark as that of the piston.
  • Page 75 ( A , B, C ) A:Axial direction of crank­ or more shaft 8: Direction at right angles to crankshaft C4424A Oversize piston O.D. <6D24> <6D24-T, TC , TL> Cylinder liner Piston C4428A 43429 1) Determine the amount of metal to bore out. To do...
  • Page 76 ENGINE SERVICE PROCEDURES (7) Piston-to-cylinder liner clearance (9) Piston ring gap If the clearance is out of specification, replace the pis­ ton or cylinder liner. [Refer to item (6) for details.] (8) Piston-to-piston ring clearance Piston Piston ring Cylinder liner C4807B Measure the piston ring gaps with the piston rings hor­...
  • Page 77 ENGINE - SERVICE PROCEDURES (11) Piston pin-to-connecting rod small end bushing (a) Removing bushing clearance Guide Plate Connecting Assembly rod bushing MH063368 Piston pin C5203A 1) Remove the bearing from the connecting rod's big If the clearance exceeds the specified limit, replace the end, then mount the connecting rod on the Base connecting rod bushing.
  • Page 78 ENGINE - SERVICE PROCEDURES NOTE: When press-fitting the bushing, align the oil hole in the bushing with the oil hole in the connecting rod. When the piston pin is inserted, ensure that it turns easily and without play. (13)Connecting rod bend and twist Bend e = 100 C5209A...
  • Page 79 ENGINE - SERVICE PROCEDURES ( 16) Main bearing-to-crankshaft journal clearance (18)Crankshaft bend Main bearing inside diameter C5526A C5524A Crankshaft journal outside diameter Measuring direction Measuring position Measure the extend of bending in the crankshaft at the middle journal. If the measurement exceeds the speci­ fied limit, grind to undersize or replace the crankshaft.
  • Page 80 ENGINE - SERVICE PROCEDURES (e) When grinding, turn the crankshaft counter-clock­ (d) Use magnetic flaw detection to check for ground cracks. Also, check that the Shore hardness of the wise as viewed from its front end. The grinder surface has not dropped below Hs 75. should also rotate counter-clockwise as viewed from the crankshaft's front end.
  • Page 81 ENGINE - SERVICE PROCEDURES 5.4.3 Reassembly NV .. Nominal Value L..Limit Assembly sequence Cylinder liner 2 6 ➔22➔®l➔@➔@➔ ®J➔@➔@➔@➔@ flange projection �@ ➔CD NV 0.01 to 0.08 @➔@➔7➔@➔@➔@➔@ -----� ➔@➔14➔@➔12➔11 For parts with circled numbers, refer to the following section, "Reassembly Procedure."...
  • Page 82 ENGINE - SERVICE PROCEDURES (3) Installing upper main bearing and thrust plate Reassembly Procedure (1) Installing oil spray plug Thrust _plate_ C23358 Install the upper main bearing such that the bearing lug is aligned with the lug groove on the crankcase. Install the oil spray plug such that the arrow stamped Install the rearmost thrust plate with its grooveless on it points toward the top of the engine.
  • Page 83 ENGINE - SERVICE PROCEDURES (7) Installing lower main bearings and main bearing (b) Locate the gear such that the dowel pin on the caps crankshaft will fit into the notch in the gear. Fit the gear by lightly striking it with a soft hammer. Install the lower main bearings and main bearing caps (c) Fit the rear oil seal slinger (refer to item (7) of sec­...
  • Page 84 ENGINE - SERVICE PROCEDURES counter-clockwise to tension the built-in socket (c) Only to the rearmost main bearing cap, install a spring. thrust plate on each side, with the thrust plates' grooveless sides facing the main bearing cap. NOTE: Thrust p ate for front side of the bearing cap Thrust plate for rear...
  • Page 85 SERVICE PROCEDURES ENGINE NOTE: (8) Installing connecting rod bolts All the connecting rods in an engine must have the same weight mark. Weight marks are as follows: Flattened side toward connecting rod Heavy --------------- Light (10)Fitting piston rings :::3 / f ::: Ends Check for damage/burrs Manufacturer...
  • Page 86 ENGINE - SERVICE PROCEDURES NOTE: (11 )Installing upper and lower connecting rod bear­ Check that the size mark on the piston matches ings the size mark on the cylinder liner. Ensure that the piston ring ends stay in their cor­ Align these.
  • Page 87 ENGINE - SERVICE PROCEDURES (13)Fitting connecting rod caps 5.5 Inspecting and Adjusting Valve Clearances Valve clearances should be checked and ad j usted when the engine is cold. Connecting rod cap Front of engine C5844B Ensure that the alignment marks and lug groove marks 10404 on the connecting rod caps and connecting rods are aligned with each other.
  • Page 88 857148 After tightening the lock nut, confirm that the clear­ ance is still correct. Mitsubishi 6D24 6D24T Engine Maintenance Service Kits Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts. Replace thermostats and thermostat gaskets,...
  • Page 89 ENGINE - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Probable cause Remedy Reference Engine will not Incorrect oil viscosity Replace Group 12 start Incorrect/defective fuel Group 13A Low compression pressure • Incorrect valve clearance(s) Adjust • Defective cylinder head gasket Replace • Worn valve and valve seat/carbon deposits •...
  • Page 90 ENGINE - TROUBLESHOOTING Symptom Probable cause Remedy Reference Low power Incorrect oil viscosity Replace Group 12 output Incorrect/defective fuel Group 13A, E Cooling system malfunctioning Repair or replace Group 14 Intake/exhaust system malfunctioning Repair or replace Group 15 • Clogged air cleaner •...
  • Page 91 ENGINE - TROUBLESHOOTING Symptom Probable cause Remedy Reference Abnormal Noise emanating from vicinity of flywheel housing engine noise • Incorrect timing gear backlash Replace Inspect • Incorrect lubrication of timing gears and idler shaft Noise emanating from cylinder head/crankcase • Low compression pressure lsee "Engine will not start") •...
  • Page 93 LUBRICATION CONTENTS Disassembly and inspection ..1 3 1 1. GENERAL ........4.1.2 2.
  • Page 94 LUBRICATION - GENERAL 1. GENERAL Oil pressure gauge 0---··---, Warning lamp Oil pres sure Oil pres sure ,__ ________ s _ w i t_c _ h _� U - L ..gauge unit Main oil gallery Regulator valve Water pump Models with turbocharger B1539H Engine lubrication is accomplished by forced lubrica­...
  • Page 95 LUBRICATION - GENERAL The oil pump, of a gear pump type, is mounted in the rear bottom portion of the crankcase, driven by the crankshaft gear. The oil strainer at the suction port prevents entry of for­ eign matter in the oil pan and air. The engine oil is routed to the crankcase by the oil pipe connected to the delivery port.
  • Page 96 LUBRICATION - GENERAL (2) Oil filter (3) Oil bypass alarm Element Center bolt {Bypass filter) Center bolt­ {Full-flow filter) 81543A The oil filter assembly consists of a full-flow filter and a bypass filter. Paper elements are used. Engine oil fed under pressure from the oil pump passes through the oil hole in the crankcase and enters the full­...
  • Page 97 LUBRICATION - GENERAL (4) Oil cooler Bypass valve B1545C The oil cooler is of the shell-and-plate (multi-plate) the same time, coolant from the water pump flows around the outside of the element. The engine oil in the type. It is mounted in the coolant path on the left of the crankcase.
  • Page 98 In the 6D24-T, TC and TL, there is also an oil hole in the shafts and lubricates the rocker bushings. It then spurts top of the connecting rod. Oil spurts out of this hole out of a hole in the top of each rocker to lubricate the onto the inside of the piston.
  • Page 99 It is then returned through the oil outlet at the bottom of the 6D24-T, TC, TL bearing housing back to the crankcase and to the oil only Piston pan.
  • Page 100 LUBRICATION - GENERAL (7) Injection pump and air compressor The injection pump and air compressor are lubricated as follows: Main oil gallery From oil cooler "-. Injection pum p Oil cooler From crankcase oil main gallery Crankcase Air compressor To oil pan' , Gear train �j�( -----�...
  • Page 101 LUBRICATION - SPECIFICATIONS 2. SPECIFICATIONS Item Specification API classification class CC or better (without turbocharger) Engine oil Quality API classification class CD or better (with turbocharger) Capacity Approx. 27 L Oil pan (for general use} Approx. 25 L (for construction machinery) Oil filter Approx.
  • Page 102 LUBRICATION - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Remedy and Nominal value Limit Maintenance item remarks (Basic diameter in I )) 145 kPa {1.5 kgf/cm } or more 49 kPa Inspection Oil pres- At idle {0.5 kgf/cm sure (Oil tempera-...
  • Page 103 LUBRICATION - SERVICE PROCEDURE 4. SERVICE PROCEDURE Oil Pressure Measurement At idle NV 145 kPa {1.5 kgf/cm } or more 49 kPa {0.5 kgf/cm At maximum speed NV 295 to 490 kPa {3 to 5 kgf/cm 195 kPa {2 kgf/cm2} NV .
  • Page 104 LUBRICATION - SERVICE PROCEDURE 4.1 Oil Pump 4.1.1 Removal and installation Apply sealant to inner bead. Apply sealant (Threebond 1207C) NV .. Nominal Value and fit it within 3 minutes. L ..Limit *Backlash from crankshaft gear NV 0.08 to 0.2 Section A-A Section B Pour engine...
  • Page 105 LUBRICATION - SERVICE PROCEDURE 4.1.2 Disassembly and inspection 3 Clogged oil hole *Backlash NV 0.08 to 0.2 Relief valve opening pressure NV 1080 to 1270 kPa {11 to 13 kgf/cm Spring installed load Clearance (installed length: 47.7) BO 22 NV 180 to 200 N NV 0.03 to 0.05 {18.3 to 20.5 kgf} 0.15...
  • Page 106 SERVICE PROCEDURE LUBRICATION Disassembly and Inspection Procedures (3) Gear tooth end to oil pump case clearance (1) Removal of oil pump cover C9521A 10375 If the measurement exceeds the limit, replace the gear. Note, however, that the drive gear must be replaced T he oil pump cover is positioned with the dowel pin of with a case and gear assembly.
  • Page 107 LUBRICATION - SERVICE PROCEDURE 4.1.3 Reassembly Apply thread-lock cement 39to 49 N-m (LOCTITE 262) to threads {4 to 5 kgf-m} after degreasing � u, - '-----------'4 59 to 78 N•m Backlash Section {6 to 8 kgf-m} NV 0.08 to 0.2 Arrow and HUP"...
  • Page 108 LUBRICATION - SERVICE PROCEDURE 4.2.2 Oil filter NOTE: replaced. For specific replacement intervals, refer to The elements in the bypass and full-flow oil filters the Owner's Handbook. should be replaced every other time the engine oil is (1) Disassembly and reassembly Drain plug 2 Center bolt Clogging, deformation...
  • Page 109 LUBRICATION - SERVICE PROCEDURE 4.2.3 Oil cooler (1) Disassembly and reassembly 1 Scale, damage, cracks, oil leaks 3 Scale, cracks Valve opening pressure NV 420 to 460 kPa {4.3 to 4.7 kgf/cm 1 Oil cooler element 2 Bypass valve 3 Oil cooler cover C9804E (2) Cleaning NOTE:...
  • Page 110 LUBRICATION - SERVICE PROCEDURE 4.3 Regulator Valve 98to 115 N-m {1 O to 12 kgf-m} Set load (set length: 48. 3 ) NV 76to 80 N {7.8 to 8.2 kgf} Lost tension �er Valve opening pressure NV 360 to 420 kPa {3.7 to 4.3 kgf/cm 1 Snap ring...
  • Page 111 LUBRICATION - TROUBLESHOOTING 5. TROUBLESHOOTING Ref. group Remedy Symptom Probable cause Overheating Abnormal oil level Correct and fill to specified • Oil leaks into coolant level • Oil leaks Incorrect oil viscosity • Oil out of life Replace Change oil after repair of •...
  • Page 113 FUEL AND ENGINE CONTROL CONTENTS 1. GENERAL ........2 Pump Drive Case .
  • Page 115 FUEL AND ENGINE CONTROL - GENERAL 1) The pump housing is a totally enclosed type. (1) Injection pump proper 2) The plunger barrel has an oblique hole made to (a) Injection pump return the fuel that has leaked to the oil sump to minimize the leakage of the fuel into the cam cham­...
  • Page 116 FUEL AND ENGINE CONTROL - GENERAL Effective stroke Control rod :,-: B2205A As the plunger rises and its oblique groove (the reed) meets the inlet/outlet hole, fuel flows into the plunger's vertical groove and is expelled from the inlet/outlet hole. No pressure feed takes place thereafter, regard­ Driving face less of how much the plunger rises.
  • Page 117 FUEL AND ENGINE CONTROL - GENERAL (c) Delivery valve (d) Overflow valve Suction stroke Spring Spring seat To overflow pipe Steel ball Beginning of Injection End of End of injection injection injection (beginning of suction) 01827 82208A The fuel highly pressurized by the plunger pushes the When the fuel pressure in the injection pump exceeds a delivery valve up and gushes out.
  • Page 118 FUEL AND ENGINE CONTROL - GENERAL (2) Governor The construction and operation of the governor are the same regardless of the applicable model of the injec­ tion pump. (a) RSV type governor Supporting lever shaft Governor housing Guide lever Tension lever Start spring Control lever Governor spring...
  • Page 119 FUEL AND ENGINE CONTROL - GENERAL whereas the top of the lever is coupled through the shackle to the control rack. Slider Ball bearing The start spring, attached to the top end of the control lever, always pulls the control rack in the direction that fuel is increased.
  • Page 120 FUEL AND ENGINE CONTROL - GENERAL 2) Idling control idling, the spring always keeps in contact with the ten­ sion lever to maintain a constant idling speed. The stop lever, mounted through the supporting lever to the bottom end of the control lever, returns the con­ Start spring trol rack to the stop position with a slight pressure irre­...
  • Page 121 FUEL AND ENGINE CONTROL - GENERAL position, thereby preventing over-speed operation of Maximum speed control the engine. The RSV type governor controls the entire speed range from idling to maximum speed. If load increases or decreases at a certain speed determined by the posi­ No-lo ad Adjus ting lever tion of the adjusting lever, the governor automatically (Idling)
  • Page 122 FUEL AND ENGINE CONTROL - GENERAL As the engine speed increases, the centrifugal force of flyweight increases. If it becomes larger than the pres­ sure of the Ungleich spring, the Ungleich spring is slowly compressed before the start of high speed con­ trol, and the control rack moves in the direction that fuel is reduced.
  • Page 123 FUEL AND ENGINE CONTROL - GENERAL Operation of torque spring Governor operating range � � -"' 'iii ..-"' -- 1---, i.,t- p2 Engine speed (rpm) Pump speed (rpm) - 82667A Construction machinery engines are often subjected to If a torque spring is provided, the control rack moves a large load during operation, and reduced speeds along 8-C, and the rotational displacement at the time often lead to stalls.
  • Page 124 FUEL AND ENGINE CONTROL - GENERAL (b) RFD type governor Stop lever Governor cover Governor housing Flyweight Sliding lever Floating lever 826828 The RFD type governor is a minimum-maximum gov­ the tension lever shaft holds the shifter, preventing it ernor which controls only the minimum and maximum from turning.
  • Page 125 FUEL AND ENGINE CONTROL - GENERAL normal speed ranges, therefore, the lower end of the The engine stop lever is fitted to the top of the gover­ tension lever is always in contact with the stroke nor, that moves the control rack to the non-injection adjusting bolt.
  • Page 126 FUEL AND ENGINE CONTROL - GENERAL 3 ) Control of maximum speed Normal speed operation Speed control lever Maximum speed position Floating lever 11111111 Sliding lever 82671A If the load control lever is moved in the full direction (for greater fuel delivery), the eccentric shaft coupled to the load control lever causes the sliding lever to pivot about pin D fitted in the bottom of the tension 82672A...
  • Page 127 FUEL AND ENGINE CONTROL - GENERAL As the force becomes greater than the force of the gov­ ernor spring which pulls the tension lever, the fly­ With smoke set assembly weights start moving out. This motion of the fly­ Without smoke set weights causes the shifter and tension lever to be ambi' moved to the right.
  • Page 128 FUEL AND ENGINE CONTROL - GENERAL Engine stop lever (3) Feed pump Normal position Stop - . - O ,::: ''�' Priming pump \ ®' � Stop lever assembly Inlet check valve To fuel filter 83006A 82675A To stop the engine, the stop lever on top of the gover­ Supply of fuel to the injection pump proper is accom­...
  • Page 129 FUEL AND ENGINE CONTROL - GENERAL (a) Suction stroke (c) Stop 01835 01837 When the camshaft of the injection pump forces the When the pressure in the pressure chamber exceeds push rod up, the fuel in the suction chamber is com­ specification, the piston cannot be brought back by the pressed and opens the outlet check valve.
  • Page 130 FUEL AND ENGINE CONTROL - GENERAL (a) SP type automatic timer <6D24, TC> Injection Oil seal pump side 0-ring Cover Flange Spring seat Flyweight Timer housing B3201A Two flyweights are fitted on the pins of the timer hous­ springs are held between the spring seats fitted on the ing and are held in the timer housing.
  • Page 131 FUEL AND ENGINE CONTROL - GENERAL (b) SPG type automatic timer <6D24-T> Cover Pilot pin Timer holder Timer housing 80023A � � ��,� F l yw o;g ht F l yw o;g ht p;, = - � � Eccentric cam (larger) Timer holder �...
  • Page 132 FUEL AND ENGINE CONTROL - GENERAL (5) Boost compensator <engine with turbocharger> Point A Boost pressure Flyweight Timer spring Inlet manifold Timer housing pin Flyweight pin (point Cl Small eccentric Flyweight in fully lifted position Retard angle --tt--t--+-+� �-1-+--+- ..1.L_.1. 86012A 43932 The boost compensators increase the engine's power...
  • Page 133 FUEL AND ENGINE CONTROL - GENERAL (b) Drive-side boost compensator (a) Governor-side boost compensator Boost compensator set spring Connection pipe Boost Boost compensator Inlet manifold Floating lever Control rod. B2693C 82691A As the boost pressure overcomes the compensator Load control lever idling position spring, the diaphragm and push rod are pushed to the left.
  • Page 134 FUEL AND ENGINE CONTROL - GENERAL (7) Injection nozzle Two models of hole type injection pumps are used. Their constructions are as follows. (a) KBL2.1 injection nozzle Cap nut Adjusting screw Lock nut--- �..._.,,.,., Set screw---��=!� No. 2 spring �::;..._- Spacer Control rod 82692A No.
  • Page 135 FUEL AND ENGINE CONTROL - GENERAL (b} KBL2.4 injection nozzle No. 1 spring From injection pump No. 1 valve No. 1 spring seat Push rod opening pressure, - -++�� adjusting shim No. 1 spring No. 2 spring No. 1 spring seat No.
  • Page 136 FUEL AND ENGINE CONTROL - GENERAL (9) Water separator (8) Fuel filter <6D24, T, TC> -- Element 835018 83551A The sedimenter type water separator separates gas oil and water centrifugally by taking advantage of their difference in specific gravity. 83501C The fuel that has flowed in from the inlet connector is <6D24-TL>...
  • Page 137 FUEL AND ENGINE CONTROL - SPECIFICATIONS 2. SPECIFICATIONS (1) Injection pump Item Specification Manufacturer BOSCH AUTOMOTIVE SYSTEMS Injection <6024> <6D24-T> <6D24-TC> <6O24-TL> Pump (Standard) (Optional) (Standard) (Optional) Type Bosch in-line Bosch in-line Bosch in-line Bosch in-line Bosch in-line Bosch in-line...
  • Page 138 FUEL AND ENGINE CONTROL - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table (1) Injection pump Unit: mm Limit Remedy and remarks Maintenance item Nominal value (Basic diameter in I ]) Dependent on Adjust Fuel injection start timing (BTDC) specification Adjust shims Eccentricity with respect to air compressor crankshaft...
  • Page 139 Fuel inlet side eyebolt 20 to 25 {2 to 2.5} pump Fuel outlet side eyebolt 20 to 25 {2 to 2.5} 6D24, T, TC A bolt 74 to 83 {7.5 to 8.5} 6D24-TL 83 to 93 {8.5 to 9.5} B bolt 6D24, T, TC 59 to 64 {6 to 6.5}...
  • Page 140 FUEL AND ENGINE CONTROL - SPECIAL TOOLS 4. SPECIAL TOOLS Unit: mm Tool name Shape Filter Wrench MH061572 <All except 6D24-TL> Removal of fuel filter element 85222A Filter Wrench MH061572 <6D24> Removal of fuel filter element � � ®01503 Injection Pump Centering...
  • Page 141 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5. SERVICE PROCEDURE (2) Installation procedure NOTE: 5.1 Removal and Installation of Injection Pump The following procedures assume that the injection Assembly pump is equipped with an air compressor. The same (1) Removal procedure procedures apply to one with a pump drive case.
  • Page 142 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE <When the measured value at point 8 is positive (+)> Insert shims evenly to four places. <When the measured value at point A is positive (+)> Insert shims to the lower side of point C. <When the measured value at point C is positive (+)>...
  • Page 143 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE • Fit the injection pump onto the injection pump bracket. • Temporarily fit the timing adjustment bolt onto the driving coupling. Slide the driving coupling until there is clearance of 0.5 mm or less between it and the coupling plate.
  • Page 144 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Bleeding of Fuel System 5.3 Inspection and Adjustment after Installing the Injection Pump Perform fuel system air bleeding as follows. 5.3.1 Inspection and adjustment of fuel injection start timing .. ; j!! 85909A (1) Loosen air plug of fuel filter.
  • Page 145 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Adjusting bolt <6O24,T,TC> 59 to 64 N-m {6 to 6.5 kgf-m} <6O24-TL> 83 to 93 N-m {8.5 to 9.5 kgf-m} 86117C 21839 (3) If they are out of alignment, loosen the timing If the timer is electronic, check at this time whether the inscribed lines are aligned.
  • Page 146 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.3.2 Inspection and adjustment of minimum and (2) RFD type governor maximum no-load speeds Start and idle the engine until it reaches normal operat­ ing temperature. Then, make the following checks. Stopper bolt (1) RSV type governor Idling Full-speed...
  • Page 147 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.4 Pump Drive Case 5.4.1 Removal and installation Pump drive case 84194A (1) For removal and installation of the pump drive case, refer to Section 5.1 in Group 61 Special Equipment. 5.4.2 Disassembly and inspection Deterioration, damage Cracks, wear...
  • Page 148 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.4.3 Reassembly Assembly sequence 10➔8➔6➔3➔®➔<D➔9 4➔7➔5 For parts with an encircled number, refer to Reassembly Procedure that follows. B4197A (1) Installation of injection pump gear Install the injection pump gear, sensor plate (or guide plate) and nut as shown.
  • Page 149 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.5 Injection Nozzle 5.5.2 Disassembly <KBL2.1 injection nozzle> 5.5.1 Removal and installation ,-{j Gasket 3� 2--18111 Cracks, 4- --=1 deterioration Nozzle identification mark stamped Wear position Wear6 � Carbon � deposits Shim (for prelift) � o-,o --rf Shim...
  • Page 150 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE <KBL2.4 injection nozzle> Disassembly Procedure T he following special tools should be used in disas­ sembly: Identification mark position Part No. (Zexel product No.) Tool name 11-ij 157944-9520 Plate Special Wrench 157914-2800 � 10 Removing retaining nut :--- 9 �...
  • Page 151 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (2) Inspection O7003A 070058 (a) Remove the needle valve from the nozzle and clean Clean and immerse the nozzle in gas oil, slide the the needle valve with the needle valve cleaning needle valve and check that it moves smoothly. wood piece.
  • Page 152 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Reassembly and adjustment <KBL2.1 injec- 5.5.4 tion nozzle> 1 39 to 49 N-m Adjust while assembling the parts by the following {4 to 5 kgf-m} procedures. 3 20to 25 N-m As the prelift is adjusted in 1/100 mm increments, use {2 to 2.5 kgf-m} 5 49to 59 N-m clean detergent to thoroughly remove dust and dirt...
  • Page 153 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (1) Adjustment of 1st valve opening pressure Set screw 49 to 59 N-m {5 to 6 kgf-m} Nozzle holder Spacer Shim (for 2nd valve opening pressure adjustment) 1st spring 1st push rod Gasket A 157892-1500 D7018A D7017A...
  • Page 154 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE NOTE: When using a shim, be sure to check its thickness by a micrometer. Use same shim for prelift adjustment. Use of a 0.02 mm thick shim changes the valve opening pressure by about 235 kPa {2.4 kgf/cm2}. (2) Selection of prelift adjusting shim Dial Gauge holder (a) "O"...
  • Page 155 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (4) Checking full lift of needle valve (3) Adjustment of 2nd valve opening pressure ("open" pressure) 20 to 25 N-m DialGauge {2 to 2.5 kgf-m} - ---1 157954-3800 Lock nut 39 to 49 N-m {4 to 5 kgf-m} Adjusting screw----c;:;i Connector 157892-1320...
  • Page 156 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (a) Remove the set screw, lock nut and adjusting (7) Checking 2nd valve opening pressure ("cover" screw as an assembly from the nozzle holder. pressure) NOTE: Never loosen the lock nut as loosening it changes the 2nd valve opening pressure (lift 0.05) 2nd valve opening pressure.
  • Page 157 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (b) Spray condition Good Good Poor Poor Poor Poor � � � � Good Poor Evenly sprayed from Asymmetrical five injection orifices Branched Even and symmetrical Thin Irregular O7009A When adjusting the pressure with a nozzle tester, check also for clogged injection orifices, spray condition, and fuel leaks from the orifices.
  • Page 158 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.5.5 Reassembly and adjustment <KBL2.4 injection nozzle> cleaned with the clear cleaning fluid to remove dust The adjustment should be performed during reas­ sembly as described below. The prelift should be and foreign materials completely. For the adjustment, following special tools are required.
  • Page 159 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Reassembly and Adjustment Procedure (1) Reassembly 29to 39 N-m {3 to 4 kgf-m} Nozzle holder_ Plate / 157944-9520 01895 1,..-. - - -1 2 H--- r- -- 10 (a) Secure the Plate (special tool) in a vise, then mount the nozzle holder on the Plate.
  • Page 160 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (2) Adjusting No. 1 valve opening pressure Plate 157944-9520 Injection nozzle assembly Injection pressure <All except 6D24-TL> NV 17.7 MPa {180 kgf/cm <6D24-TL> NV 15.7 {160 kgf/cm 15263 .. Nominal Value 15262 (b) Mount the injection nozzle assembly upside-down (a) Fit the injection nozzle assembly onto the tester on the Plate (special tool).
  • Page 161 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE NOTE: (4) Checking prelift Secure the Dial Gauge such that a stroke of approximately 1.2 mm can be measured. Do not overtighten the Nut. If the Nut is too tight, the Dial Gauge shaft will stick in one position. "' >...
  • Page 162 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE T he prelift measurement point (labeled "G" in the graph) corresponds to C + approx. 980 kPa {10 kgf/ }, where "C" is the No. 1 valve opening pres­ F+0.05 sure. In the graph, >...
  • Page 163 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE opening pressure adjustment shim. (This shim has an (8) Inspection outside diameter of 9.9 mm.) Shims are available in the following thicknesses: 0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, and 0.70 mm. A 0.02 mm change in shim thickness causes a change in valve opening pressure of 196 kPa {2 kgf/cm NOTE:...
  • Page 164 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.6 Fuel Filter <6D24, T, TC> 25 N-m {2.5 kgf,m} 2 Cracks, 7.8 to 12 N-m threaded {0.8 to 1.2 kgf-m} � portion ® 1§1(@) Filter Wrench MH061572 Apply thin coat 43766 of engine oil when mounting.
  • Page 165 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE <6D24-TL> 25 to 35 N-m {2.5 to 3.5 kgf,m} � 2 Cracks, 9.Sto 2 N-m © threaded {1.0 to 0.2 kgf-m} portion � "" Apply thin coat of engine oil when mounting. ®43333...
  • Page 166 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Water Separator � 25N-m {2.5 kgf-m} 7.8 to 12 N-m {0.8 to 1.2 kgf-m} �=w>�� 8�- � · 25 N-m {2.5 kgf-m} --&----ii :� � 2-<S 1� 1--- 43745 43744 ®43369 Drain plug 7 Isolation plate 2 0-ring 8 Screen assembly...
  • Page 167 FUEL AND ENGINE CONTROL - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Probable cause Remedy Ref. group Engine will not Defective feed pump start • Loaded gauze filter Clean • Check valve inoperative Replace • Seized or worn piston Replace • Seized push rod Replace •...
  • Page 168 FUEL AND ENGINE CONTROL - TROUBLESHOOTING Remedy Ref. group Probable cause Symptom Smoky engine Defective injection pump exhaust and Adjust • Incorrect injection timing knocking Replace • Worn plunger Replace • Defective valve seat Replace Low quality fuel in use Defective injection nozzle Adjust •...
  • Page 169 FUEL AND ENGINE CONTROL - TROUBLESHOOTING Remedy Ref. group Symptom Probable cause Engine max. Defective injection pump operation speed too high • Defective pump Replace • Defective governor Correct Unstable engine Defective injection pump operation idling • Defective pump Replace •...
  • Page 171 ELECTRONICALL V CONTROLLED FUEL SYSTEM CONTENTS 1. GENERA L ........2 Causes of Diagnostic Trouble Code Issue, Principle of operation .
  • Page 172 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1. GENERAL The electronic governor ECU optimally controls the With the electronically controlled injection pump sys­ governor and timer in accordance with data signals tem, electronic control is applied to the governor and from sensors mounted on the engine and other parts of timer (the components of the injection pump assem­...
  • Page 173 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.2 Electronic Governor Cover 2 RED-4 internal circuit 3 Control rack position sensor 4 Housing 5 Sensing gear 6 Emergency engine stop lever 7 Link 8 Coil assembly 9 Linear DC motor ®38928 (2) Control rack position sensor . The control rack position sensor 3 senses whether the control rack A is moved to the correct position by the linear DC motor 9.
  • Page 174 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.3 Electronic 1imer 1 Cover Engine speed sensor 2 liming sensor Disc Disc �1 Flange Large eccentric cam Small eccentric cam Plate L,.- Spring seat Timer spring Pilot pin Cylinder Piston 24960 The electronic timer uses an eccentric cam arrange­ ment to adjust the injection timing.
  • Page 175 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.4 limer Control Valve 1 Seat 2 Valve 3 Plunger 4 Spring 5 Coil 6 Pump-side solenoid valve 7 Release-side solenoid valve A: Port A P: Port P R: Port R 24961 (1) Advancement of fuel injection timing The timer control valve controls the hydraulic pressure (engine oil) that activates the electronic timer assem­...
  • Page 176 ELECTRONICALL V CONTROLLED FUEL SYSTEM - GENERAL (3) Retardation of fuel injection timing (2) Maintenance of advanced (or retarded) fuel injec­ tion timing 24965 24964 The pump-side solenoid valve 6 is not activated. The pump-side solenoid valve 6 is not activated. The release-side solenoid valve 7 is activated.
  • Page 177 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL Signal Part Main function/operation Sensing of control rack position Control rack position signal Control rack position sensor .• Sensing of engine speed Engine speed signal Engine speed sensors 1, 2 Use of two sensors allows for backup if one sensor fails.
  • Page 178 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL (2) Control of fuel injection quantity Control rack position sensor RED-4 inter- Engine ECU nal circuit - • Engine speed sensor 1 • Target rack position Engine speed sensor 2 • � Linear DC Coolant temperature sensor •...
  • Page 179 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL (a) The engine ECU controls the fuel injection timing (4) Preheat control by controlling the activation of the timer control Preheat control improves startability when the valve, which applies hydraulic pressure to the elec­ engine's coolant temperature is low.
  • Page 180 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.6 ECU Terminal Configuration A:CW32A <> B:CW25A C: CW31A D: CW16A ®43639 A: CW32A Terminal No. ltem(s) to which terminal is connected Terminal No. ltem(s) to which terminal is connected Boost pressure sensor (SIG) Engine speed sensor 2 (GND), RED-4 ECU (SIGNAL RED-4 ECU (PULL DOWN) GND-2)
  • Page 181 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 8: CW25A Terminal No. ltem(s) to which terminal is connected Terminal No. ltem(s) to which terminal is connected Warning lamp (orange) RED-4 ECU (+5 VCC-2) Accelerator pedal switch RED-4 ECU (PWM SOL-2) RED-4 ECU (V-IST) Injection quantity adjusting resistor (SIG) Frame ground (MN POWER GND) RED-4 ECU (+5 VCC-1)
  • Page 182 ELECTRONICALLY CONTROLLED FUEL S YSTEM - GENERAL Starter switch 1-t, cc M 81 82 Sl �· START STARTER SWISI CJ STARTER SWIM)-1 Engine ECU main power relay STARTER SWIMl-2 ::-, MAIN RELAY-1 MAIN RELAY-2 ECU P OWERl+VBl-1 ECU POWER(+VBl-2 --- I "' ' I t_ : "...
  • Page 183 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL En ine ECU Preheat lamp "Tn..;- -- -_. �+ Heater relay A111---- ----'-' ' � Heater relay Air heater r------ Accelerator pedal position sensor 1 89 SIG Accelerator pedal position sensor 2 B21----------' -o Accelerator pedal Depressed: OPEN, switch...
  • Page 184 ELECTRONICALLY CONTROLLED FUEL SYSTEM - SPECIFICATIONS 2. SPECIFICATIONS Item Specification Injection pump assembly Manufacturer BOSCH AUTOMOTIVE SYSTEMS Electronically controlled in-line pump Model Injection pump model NP-PE6P120 Governor model RED-4 (RED-4 with internal circuit) Timer model SPGH Feed pump model BOSCH AUTOMOTIVE SYSTEMS Timer control valve Manufacturer Rated voltage...
  • Page 185 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING • Do not forget to clear the diagnostic trouble code by 3. TROUBLESHOOTING the Multi-Use Tester II or memory clear switch after 3.1 Inspection Procedures a fault has been rectified. • As a rule, inspection operations should be per­ 3.1.1 Diagnostic function formed with the starting switch at the LOCK posi­...
  • Page 186 - ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.1.2 Inspection flowchart (1) Inspections based on diagnostic trouble codes T he system inspection can be performed effectively by stored in the engine control unit use of the Multi-Use Tester II. The types of system (2) Inspections of transient troubles inspections may be broadly divided as shown below in accordance with the trouble symptoms and diagnostic...
  • Page 187 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.2 Connection of Multi-Use Tester II 3.2.1 Special tools Unit: mm Unit: mm Tool name Shape Tool name Shape Multi-Use Tester II Multi-Use Tester II harness MB991496 MB991499 Inspection of system To use Multi-Use Tester II as a circuit tester 19492 20536...
  • Page 188 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING T he Multi-Use Tester II typically draws power from the (2) Power supplied to Multi-Use Tester II from battery cigarette lighter. In a vehicle without a cigarette lighter, the power connection of the Multi-Use Tester II is differ­ ent depending on the type of the starter switch as fol­...
  • Page 189 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.3 Reading and Erasing Diagnostic Trouble (b) Reading diagnostic trouble code Codes Two types of methods are available for reading or eras­ 10s digit Units digit ----- I I ing a diagnostic trouble code; one using the Multi-Use �...
  • Page 190 - ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING (c) Past diagnostic trouble codes Disconnect the memory clear switch 1 and the diag­ nostic switch 2 then reconnect them. Then all the diag­ 1) After reading the current diagnostic trouble codes nostic trouble codes stored in the engine control unit (with the diagnostic switch 2 disconnected), dis­...
  • Page 191 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.4 Causes of Diagnostic Trouble Code Issue, and Inspection Items 3.4.1 Diagnostic trouble codes Multi-Use Tester II display Page of Multi-Use Tester II display Page of reference reference Diagnostic Message Diagnostic Message trouble code trouble code Ll:i P13E-21...
  • Page 192 - ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 14 SUB NE SNSR (injection pump side) Diagnostic trouble code 14 indicates that the number of pulses from engine speed sensor 2 (on the injec­ Code issue condition tion pump) is smaller than the number of pulses from engine speed sensor 1 (on the flywheel housing). [Reset condition] [The code is reset when engine speed sensor 1 is normal and the number of pulses from engine speed sensor 2 returns to normal).
  • Page 193 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 16 ACCEL. SNSR-2 Diagnostic trouble code 16 indicates short or open circuit in accelerator position sensor 2 harness and Code issue condition faulty sensor proper. (If diagnostic trouble code 16 is issued, inspections for diagnostic trouble code 24 (Reset condition] must also be performed.) The code is issued when accelerator position sensor 2 voltage is out of specified limits.
  • Page 194 IBll ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 21 WTR TEMP SNSR Code issue condition Diagnostic trouble code 21 indicates open circuit in water temperature sensor harness and faulty sensor proper. [Reset condition) The code is issued when water temperature sensor voltage is out of specified limits. [When water temperature sensor voltage falls back within specified limits, a reset is made.) °...
  • Page 195 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 24 ACCEL. SNSR-1 Code issue condition Diagnostic trouble code 24 indicates short or open circuit in accelerator position sensor 1 harness and faulty sensor proper. (If diagnostic trouble code 24 is issued, inspections for diagnostic trouble code 16 [Reset condition] must also be performed.) The code is issued when accelerator position sensor 1 voltage is out of specified limits.
  • Page 196 ELECTRONICALLY CONTROLLED FUEL S YSTEM - TROUBLESHOOTING 45 ENG. REVERSE Code issue condition Diagnostic trouble code 45 indicates that an extremely low engine speed (a speed lower than that result­ ing from cranking with the starter) has been detected with the starter switch in the OFF position. [Reset condition) [The code is reset when the engine speed is no longer detected with the starter switch in the OFF position or when the starter switch is turned to the ON position.)
  • Page 197 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.5 Multi-Use Tester II Service Data Multi-Use Tester II display Condition at time of Normal condition inspection Item Data ■■.■■v BATT VOLTAGE Idling 20 to 30 V ■■■■ ENGINE SPEE D .rpm Racing Same as tachometer indication (with engine running) ■■■.■...
  • Page 198 - ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING Normal condition Multi-Use Tester II display Condition at time of inspection I tem Data Accelerator pedal depressed ACC ELSW ON/OFF Accelerator pedal released E ngine cranked with starter switch in STAR T SW ON/OFF STAR T position Starter switch in any position except...
  • Page 199 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.7 Inspection Using ECU Connector These checks allow correct transmission of ECU signals via vehicle harnesses and connectors to be verified. They are intended to assist in troubleshooting. The numbers ( C!D, etc.) in the tables correspond to reference num­ bers in section 3.4, "Causes of Diagnostic Trouble Code Issue, and Inspection Items".
  • Page 200 11]1 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING Check item Method [Check conditions] (!JI Resistance of engine • Starter switch OFF speed sensor 2 • Connector removed. Check performed on vehicle-side harness. [Normal condition) Between terminals A 7 and A 19: 2.1 to 2.5 n Resistance of engine [Check conditions] speed sensor 1...
  • Page 201 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING - • 3.8 Checks on Transient Troubles Lightly move the connector up and down and to the right and left. • Lightly move the harness up and down and to the right and left. •...
  • Page 202 - ELECTRONICAUY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT 4. INSPECTION OF ELECTRICAL EQUIP­ Standard value 2.3 ± 0.2 kn MENT (at 20 ° lmfl Checking Water Temperature Sensor (2) If the reading is out of the standard value range, re- place the engine speed sensor.
  • Page 203 ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT - (1) Screw in engine speed sensor 2 A until it touches Unit:mm the protrusion on the timer flange 8. Tool name Shape (2) Back off engine speed sensor 2 A by 0.8 to 1.0 turn Inspection Harness MC854336 to create a clearance C (1.2 to 1.5 mm) between the...
  • Page 204 - ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT (1) Remove the connector from the timer control valve Output Characteristics then connect a 24V DC power supply A and selector switch B. Slightly loosen the eyebolt D on port °...
  • Page 205 ELECTRONICAUY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT (1) Measure the resistance of the fuel injection quan­ tity adjusting resistor. The standard value corre­ sponds to the resistor number marked on the case. Standard value Resistor No. 2700 (at 20 °...
  • Page 207 COOLING CONTENTS 1. GENERAL ........Fan Drive ....... . . 2.
  • Page 208 COOLING - GENERAL 1. GENERAL (2) Thermostat The cooling system is of the water-cooling forced cir­ When coolant temperature is high culation type consisting of a radiator, water pump, (bottom bypass valve is closed) \. thermostat, and related parts. Radiator When coolant temperature is low (bottom bypass valve is open) 81747A...
  • Page 209 COOLING - GENERAL ( 3) Radiator ( 4) Pressure cap <With pressure release lever> Radiator Pressure release lever Pressure spring Reserve tank Pressure valve// Vent valve spring B1716B <Without pressure release lever> 81740A Pressure spring The radiator, with a tube-and-corrugated-fin type core (and with a reserve tank on some models), not only cools the engine coolant but also separates vapor from liquid water and regulates pressure in the cooling sys­...
  • Page 210 COOLING - GENERAL is controlled by a bimetallic strip that moves in If equipped with a reserve tank, the coolant that has overflowed is channeled into it. response to temperature changes. When the coolant temperature drops and negative <When the temperature of the air passing through the pressure builds up in the system, the vent valve opens radiator is low>...
  • Page 211 COOLING - GENERAL <When the temperature of the air passing through the radiator is high> Direct-couple fan Autocool fan coupling (at high temperature) Autocool fan coupling "0 (at medium temperature) <I) "' Autocool fan coupling (at low temperature) Crankshaft speed (rpm) 80245A B1728B The valve fully opens the control hole of the divider...
  • Page 212 COOLING - SPECIFICATIONS 2. SPECIFICATIONS Item Specification Cooling system Water-cooling forced circulation type Coolant quantity (Engine-proper only) 6D24, T Approx. 22 L 6D24-TC, TL Approx. 24 L Water pump Type Centrifugal type Drive method V-belt Radiator Type Tube-and-corrugated-fin type or Tube-and-plate-fin type...
  • Page 213 COOLING - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item Nominal value Limit Remedy and remarks (Basic diameter in I ) ) Up to second Interference between pump shaft and flange (22) 0.05 to 0.08 reassembly Interference between pump shaft and impeller (11.8) 0.03 to 0.06...
  • Page 214 COOLING - SPECIAL TOOLS 4. SPECIAL TOOLS Unit: mm Unit: mm Tool name Shape Tool name Shape Impeller Puller Water Pump Pulley Puller MH062192 MH062411 Removal of water pump Removing water pump impeller flange B5252C Unit Seal Installer 85258A MH062195 Belt Tension Gauge Water pump unit seal instal­...
  • Page 215 COOLING - SERVICE PROCEDURE 5. SERVICE PROCEDURE 5.2 Water Pump 5.2.1 Removal and installation 5.1 Removal and Installation of Cooling Fan 89019B O0914A 1 Plate 2 Fan 3 Spacer Fan pulley 14-9...
  • Page 216 COOLING - SERVICE PROCEDURE 5.2.2 Disassembly and inspection <6D24,T, TL> 7Corrosion, damage 13 Damage, wear BD .. Basic Diameter Repair kit: NV .. Nominal Value Cracks, wear in surface Water pump repair kit over which bearing fits, water leak, rust...
  • Page 217 COOLING - SERVICE PROCEDURE BD .. Basic Diameter <6D24-TC> NV .. Nominal Value Bend, rust, wear in surface over which bearing fits Rotation Interference BD 11.8 NV 0.03 to 0.06 Reassembly no more than 2 times Interference BD 25 NV 0.05 to 0.08...
  • Page 218 COOLING SERVICE PROCEDURE (3) Flange to water pump shaft tightening margin Disassembly and Inspection Procedures (1) Removal of flange Water Pump ---1,�� Flange D0031B 13480 If the tightening margin exceeds specification, replace Remove the water pump flange using the Water Pump the flange or water pump shaft.
  • Page 219 COOLING - SERVICE PROCEDURE 5.2.3 Reassembly Apply engine oil to lips. Apply engine oil to external cylinder. Installation load Installation load 39.2 kN {4000 kgf} 39.2 kN {4000 kgf} 44±8.8 N-m {4.5 ± 0.9 kgf-m} Assembly sequence ,,:: 127 , Apply engine ..
  • Page 220 COOLING - SERVICE PROCEDURE 5.3.2 Inspection 5.3 Thermostat 5.3.1 Removal and installation Thermostat marking For 76.5 ° Valve opening 74.Sto 78.5 ° temperature ( Valve lift/ 10 or more/90 temperature (mml°C) Valve lift Stirring rod Thermostat �� --1J Heat source D0301B B9021B Agitate water in the container with the stirrer to obtain...
  • Page 221 COOLING - SERVICE PROCEDURE 5.4 Fan Drive 5.4.1 Disassembly and inspection Rotation Disassembly sequence Bearing 1 Fan pulley Spacer 2 Flange Bearing 3 Snap ring 4 Fan drive shaft Bearing case B9023O 14-15...
  • Page 222 COOLING - SERVICE PROCEDURE 5.4.2 Reassembly 5.5 Tension Pulley 5.5.1 Disassembly and inspection Sealing side to be faced outward. To be packed with grease (multipurpose grease) Rotation B9023E · Disassembly sequence 1 Adjusting bolt 2 Tension pulley bracket Snap ring Tension pulley shaft To be packed with approx.
  • Page 223 COOLING - SERVICE PROCEDURE 5.5.2 Reassembly 5.6 Inspection of Auto Cool Fan Coupling Sealing side to be faced outward. To be packed with grease (multipurpose grease) 98N-m {10 kgf-m} To be packed with approx. 6 g of grease (multipurpose grease) Fan axial runout or play, continuous high noise or unusually...
  • Page 224 COOLING - SERVICE PROCEDURE 5. 7 Inspection of Radiator (1) Play in axial direction (1) Cleaning O1213A O0402A When engine is cold, pinch the fan fitting portion and move it in axial direction. If the fan blade tip has exces­ Remove mud, bugs, etc., if present on the radiator core sive runout or play is observed, replace the auto cool front surface, with a copper wire.
  • Page 225 COOLING - SERVICE PROCEDURE 5.8 V-belt Tension (3) Inspection of radiator cap 5.8.1 Inspection Adjust the belt tension to obtain the specified belt deflection when the center of each belt is pressed with a force of approximately 98 N (10 kgf). <Without fan drive>...
  • Page 226 COOLING - SERVICE PROCEDURE • 5.8.2 Adjustment Using Belt Tension Gauge (special tool) ( 1) Alternator 0-ring A Depression load scale Belt Tension Gauge MH062345 0-ring B Deflection gauge 03613 E0165 ( 1) Set 0-ri ng A at the 98 N {10 kg} mark on the depres­ sion load scale.
  • Page 227 COOLING - SERVICE PROCEDURE If much rust is found, water may leak from the ra­ diator after cleaning. Check carefully each section of the radiator after cleaning. If the coolant temperature is still very high, never attempt to remove the pressure cap. Coolant in use Cleaning interval FUSO Diesel...
  • Page 228 COOLING - SERVICE PROCEDURE (d) After discharging the solution, fill the system with tap water (preferably hot water) and with the water ° temperature kept at around 90 C, run the engine at idle for about 10 minutes. Then, drain water. Continue flushing until drained water runs clear.
  • Page 229 COOLING SERVICE PROCEDURE (b) When anti-rust and anti-freeze are used: 5.10 Gas Leak Test Air or exhaust gas leaked into the coolant promotes corrosion and rust formation. Perform the following check and, if defects are found, take remedial action. (1) Inspection 01310A 1) After cleaning, add Fuso Radiator Anti-rust (Radi­...
  • Page 230 COOLING - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Probable cause Remedy Ref. group Overheat Defective V-belt Adjust • Incorrect tension Replace • Broken belt Clean Clogged cooling system Replace Defective thermostat Defective water pump Replace • loose shaft to impeller engagement • Loose shaft to flange engagement Replace •...
  • Page 231 INTAKE AND EXHAUST CONTENTS 1. GENERAL ........5.3.1 Disassembly and reassembly .
  • Page 232 INTAKE AND EXHAUST - GENERAL 1. GENERAL The cyclone type air cleaner uses a filter paper type ele­ ment. (1) Air cleaner Because of plastic coating and heat treatment, the ele­ ment is highly resistant to water and oil. Even if it is <Single element type>...
  • Page 233 INTAKE AND EXHAUST - GENERAL (3) Vacuator valve body, indicating that it is time to clean or replace the element. After the element has been cleaned or replaced, depress the reset button on the top, and the signal will return to its original position. Warning lamp Starter switch Electrical...
  • Page 234 INTAKE AND EXHAUST - GENERAL (5) Turbocharger Bearing housing Compressor wheel Compressor Shaft-and­ cover "' turbine-wheel Exhaust Air inlet outlet Turbine housing Compressor wheel B1213A Inlet manifold Exhaust The turbocharger can be divided into three basic sec­ manifold tions: the turbine wheel that is driven by the exhaust gases, the compressor wheel which forces intake air into cylinders and the bearing housing which supports the shaft of these wheels.
  • Page 235 INTAKE AND EXHAUST - GENERAL (6) Aftercooler <6D24-TL> <6D24-TC> Turbocharger Turbocharger Plate-and-corrugated-fin type water-cooling heat lntercooler exchanger ®43534 80627A The intercooler (attached to the front of the radiator) is The intake air cooling system, incorporating a plate­ a tube-and-corrugated-fin, air-to-air heat exchanger. It and-corrugated-fin type heat exchanger, transfers heat cools the intake air, which is hot, after being com­...
  • Page 236 INTAKE AND EXHAUST - SPECIFICATIONS 2. SPECIFICATIONS 6D24 6D24-T 6O24-TC 6D24-TL � Air cleaner Type Cyclone type paper element (Nippon Donaldoson Ltd. products) element Turbocharger Supercharger Type Model Mitsubishi TD08H Aftercooler Type Plate and corrugated fin Tube-and-corrugated-fin type, water-cooling (built...
  • Page 237 Replace Shaft-and-turbine-wheel to turbine back plate clearance 0.48 to 0.92 Replace ----- -- Aftercooler Core assembly air-tightness 6D24-TC No leak is allowed with a 195 Replace kPa {2 kgf/cm } air pressure lntercooler air-tightness 6D24-TL No leak is allowed with a 150 kPa {1.5 kgf/cm...
  • Page 238 INTAKE AND EXHAUST - SPECIAL TOOL 4. SPECIAL TOOL Unit: mm Tool name Shape Socket MH061242 For exhaust manifold attach­ ing nut Width across flats 14 85341A 15-8...
  • Page 239 INTAKE AND EXHAUST - SERVICE PROCEDURE 5. SERVICE PROCEDURE 5.1 Removal and Installation of Intake System <6D24> � � • Install with the arrow mark facing toward the inlet manifold. 35N-m {3.6 kgf-m} Ground plate 2 Inlet pipe 3 Air heater...
  • Page 240 INTAKE AND EXHAUST - SERVICE PROCEDURE <6D24-T> �� 35N-m �gdown. {3.6 kgf-m} 1 Ground plate 2 Inlet pipe 3 Rubber hose 4 Air heater 5 Inlet manifold NOTE: Remove harnesses before disassembl y . Ensure that the arrow points in the correct direction when installin g the air heater.
  • Page 241 INTAKE AND EXHAUST - SERVICE PROCEDURE <6D24-TC: Standard> Install with the arrow mark facing toward the cylinder head. 1 Inlet pipe 6 Ground plate 7 Heater harness 2 Air escape pipe 3 Water inlet pipe 8 Air heater 9 Rubber hose...
  • Page 242 INTAKE AND EXHAUST - SERVICE PROCEDURE <6D24-TL> � �wfacing down. 35 N-m {3.6 kgf-m} 1 Ground plate 4 Inlet manifold 2 Air inlet pipe B 5 Air inlet pipe A 3 Air heater 6 Rubber hose NOTE: Remove harnesses before disassembly.
  • Page 243 INTAKE AND EXHAUST - SERVICE PROCEDURE 5.2 Removal and Installation of Exhaust System <6D24> 41 N-m {4.2 kgf-m} Exhaust Seal rings manifold "TOP" mark Expansion rings Install with stamped "TOP" mark facing manifold Seal ring Install the seal rings such that their gaps are staggered by 180'.
  • Page 245 INTAKE AND EXHAUST - SERVICE PROCEDURE 5.3 Air Cleaner 5.3.1 Disassembly and reassembly Dust cup <Single element type> Air cleaner body Dust indicator e-,-- Air cleaner body 84563A Dust cup <Double element type> . ,·. Installation , _ _ direction mark Clamp Gasket Outer element...
  • Page 246 INTAKE AND EXHAUST SERVICE PROCEDURE 5.3.2 Inspection and cleaning (4) Clean the inside of the air cleaner body and dust cup, and discharge the deposited dust. (1) When there is dry dust on the element (5) Dust indicator Operating resistance NV 6.2 ±...
  • Page 247 INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4 Turbocharger 5.4.1 Disassembly Wear in surface Wear receiving thrust B�de bend and damag� corrosion, marks of interference on back surface Interference with compressor wheel, cracks, damege Interference with turbine wheel, cracks due to overheat, pitching, deformation Blade bend and damage, corrosion, marks of interference on back sur­...
  • Page 248 INTAKE AND EXHAUST - SERVICE PROCEDURE Disassembly Procedure (3) Removal of compressor cover Alignment mark Compressor cover Turbine housing Bearing housing C8982C B2819D (1) Before disassembling the turbocharger, make Remove the compressor cover by tapping it with . plastic hammer or similar tool which will not damag, alignment marks on the compressor cover, bearing housing, and turbine housing so that they can be the cover, with the snap ring loosened.
  • Page 249 INTAKE AND EXHAUST - SERVICE PROCEDURE (5) Removal of insert Snap ring Shaft-and-turbine-wheel boss C8983C C89788 (b) While holding the shaft-and-turbine-wheel boss, (a) Snap off the snap ring that secures the insert onto remove the lock nut that secures the compressor the bearing housing.
  • Page 250 INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4.2 Cleaning and inspection Piston ring end gap NV 0.05 to 0.25 Clean Bearing 0.0. 20.382 1.0. 12.042 Length 11.94 BearingjournalO.O. 11.996 Shaft runout (total indi­ cator reading) 0.0,5 Clean Bearing inserting portion 1.0. 20.506 NV ..
  • Page 251 INTAKE AND EXHAUST - SERVICE PROCEDURE (2) Inspection of bearing housing C8990A C8993A (b) Blow clean compressed air against the entire inter­ Measure I.D. of the area receiving the bearing. Replace nal and external surfaces. the bearing housing if the measurement exceeds the limit.
  • Page 252 INTAKE AND EXHAUST - SERVICE PROCEDURE (5) Inspection of insert (4) Inspection of shaft (a) Journal 0.0. Insert B0467A 80465A Fit a new piston ring in the insert bore and measure the end gap of the piston ring using a feeler gauge. Measure the shaft-and-turbine-wheel journal diame­...
  • Page 253 INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4.3 Reassembly 5.9 N-m {0.6 kgf-m} • Molykote grease or equivalent Apply engine ott] to be applied to screw and seating surface in lock nut. • Hammer entire periphery. 14 j Apply engine oil 20 N-m {2 kgf-m} Molykote grease or equiva­...
  • Page 254 INTAKE AND EXHAUST - SERVICE PROCEDURE (2) Installation of snap ring (3) Measurement of clearance between shaft-and-tur­ bine-wheel and turbine housing Shaft-and­ turbine-wheel C8978C C9001B Set a dial indicator to the end of the shaft and move the shaft in the axial direction to measure the clearance. If the measurement is out of specification, disassemble and isolate the cause.
  • Page 255 INTAKE AND EXHAUST - SERVICE PROCEDURE (b l Coat threads in the shaft-and-turbine-wheel with (6) Measurement of clearance between the turbine molybdenum disulfide base grease Li soap and back plate and shaft-and-turbine-wheel back sur­ mount the compressor wheel onto the shaft. face (c) Holding the boss on the turbine wheel side, tighten the compressor wheel lock nut to the specified...
  • Page 256 INTAKE AND EXHAUST SERVICE PROCEDURE (7) Compressor wheel to compressor cover clearance (8) Installation of turbine housing and compressor cover Alignment mark Compressor cover Coupling assembly Snap ring 84468A 5.9 N•m (0.6 kgf·m) B2819E Check by the following procedures. Make sure that the alignment marks are aligned and (a) Move up and down the compressor wheel to mea- secure the parts with the coupling assembly and snap sure runout (R).
  • Page 257 INTAKE AND EXHAUST - SERVICE PROCEDURE 5.5 Aftercooler 5.5.1 Disassembly and reassembly ( 1) Water-cooled type <6D24-TC :Standard> <6D24-TC :Low profile type> Damage, water leaks, dirt on fins, water scale and rust inside core C9305C 1 Connector 4 Core assembly...
  • Page 258 5.5.2 Air pressure test 5.6 Bleeding of Aftercooler Coolant Circuit <6024-TC :Standard> (1) Inspection of core assembly <6D24-TC> Conduct the air pressure test to check for water leaks due to damaged element. To check, apply an air pres­ � Air vent plug sure of 390 kPa {4 kgf/cm } to the core assembly.
  • Page 259 Clean, check eating oil pipe • Damaged compressor wheel Replace • Damaged turbine wheel Replace • Foreign matter on front surface of intercooler core <6D24-TL> Clean ·- Low exhaust efficiency • Deformed front pipe, muffler and/or tail pipe (large exhaust Replace resistance) •...
  • Page 260 Notes: Mitsubishi 6D24 Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com...

This manual is also suitable for:

6d24t6d24tc6d24tl