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1. Lift CAT Trucks 6D16 Diesel Engine DP80 T32B 00011 up DP90 T32B 50001 up DP100 3DP 00001 up DP115 4DP 00001 up DP135 5DP 00001 up DP150 6DP 00011 up For use with Chassis Service Manual 99709 68130 6D16 diesel engine Shop Manual for industrial use FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of 6D16 diesel engine and includes procedures for adjustment and maintenance services We earnestly look forward to seeing that this manual is made full use of in order to perform correct service with no wastage For more details please consult your nearest authorized Cat dealer or distributor Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future Applicable models 6D16 6D16 TLE GROUP INDEX HOW TO READ THIS MANUAL GENERAL ENGINE LUBRICATION FUEL AND ENGINE CONTROL COOLING INTAKE AND EXHAUST ELECTRICAL SYSTEM SPECIAL EQUIPMENT Pub No 99709 68130 HOW TO READ THIS MANUAL How This Manual Is Compiled e This manual is compiled by classifying various systems into certain groups e Each group contains specifications troubleshooting maintenance service standards tightening torque A lubricant fluid and sealant special tools and service procedure e Page enumeration is i2. This shows the application point A Lubricants and sealant Points of application Kinds Quantity Thread area of bolt LOCTITE 272 10 16 Friction surfaces of release lever plate and release Molybdenum disulfide grease As required lever NLGI No 2 Li soap This shows the key No of the relevant part This shows the specified brand HOW TO READ THIS MANUAL 5 Special tools table Only the relevant special tools are shown Purpose of special tools is shown C Speen tools Unit mm Tool name and shape PartNo Application Removal and installation of clutch cover Clutch installer Pd De MH061051 Adjust release lever MH062291 heights This shows the key No of the relevant part Quote this number when placing an order for the part 6 Service procedure This indicates a special This shows the key No of the relevant part service tool Removal and installation of clutch cover e Depress pressure spring 7 using clutch installer then remove the following parts Strap bolt 1 washer 2 washer 3 bolt 4 lock plate 5 support nut 6 e Loosen the clutch installer gradually then remove clutch cover 11 when the pressure spring is fully released e For installation follow the removal sequence in reverse The key No referred to in the text is always the Servicing procedures of disassembly removal same as the key No shown in the illustration assembly installation inspection adjustment etc a
3. Tightening torque for air piping nylon tube for general purpose DIN type Unit N m kgf m Ibf ft Standard diameter 6 x 1 mm 10 x 1 25 mm 12 x 1 5 mm 15 x 1 5 mm 0 236 x 0 0394 in 0 394 x 0 0492 in 0 472 x 0 0591 in 0 591 x 0 0591 in Tightening torque Tightening torque for air piping nylon tube for general purpose SAE type 00 16 SPECIFICATIONS Cylinder bore x stroke mm in 0118 x 115 04 65 x 4 53 Total displacement CC Cu IN 7545 460 4 11 2 STRUCTURE AND OPERATION 11 1 Cylinder Head and Crankcase Connecting plate Glow plug Cylinder liner Crankcase Water jacket Piston Injection nozzle Cylinder head OO N OOF WN gt Cylinder liner size mark Outer diameter mark 1 2 3 Inner diameter mark A B e The cylinder liners 3 are a dry type liners that are easier to remove than wet liners Liners are press fitted into the crankcase 4 e The cylinder liners 3 crankcase 4 and pistons 6 have size marks They should be combined as specified according to the size marks N P 11 36 11 3 STRUCTURE AND OPERATION 2 Valve Mechanism Exhaust valve Inlet valve Camshaft Tappet Push rod Rocker shaft Rocker shaft spring Rocker 9 Rocker shaft bracket 10 Valve cap 11 Valve cotter 12 Upper retainer 13 Outer valve spring 14 Inner valve spring 15 Valve stem seal 16 Valve guide OO N OO BOON e The valve stem seals 15 are fitted onto the valves 1 2 to cont
4. 103 90 to 130 90 to 120 180 to 240 160 to 220 M16 9 5 to 13 9 0 to 12 18 to 24 16 to 22 66 4 to 95 9 66 4 to 88 5 133 to 177 118 to 162 140 to 190 120 to 160 260 to 340 220 to 290 M18 14 to 19 12 to 16 25 to 35 22 to 30 103 to 140 88 5 to 118 192 to 251 162 to 214 190 to 260 170 to 230 350 to 470 320 to 420 M20 19 to 26 17 to 23 36 to 48 32 to 43 140 to 192 125 to 170 251 to 347 236 to 310 260 to 340 230 to 300 470 to 640 430 to 570 M22 26 to 35 23 to 31 48 to 65 43 to 58 192 to 251 170 to 221 347 to 472 317 to 420 340 to 450 290 to 390 630 to 840 540 to 730 M24 34 to 46 29 to 40 63 to 86 55 to 74 251 to 332 214 to 288 465 to 620 398 to 538 00 14 Hex head Flange Nut Unit N m kgf m lbf ft Strength Repre sentation Standard screw Coarse screw 4 to 6 0 4 to 0 6 3 69 to 5 16 Diameter 10 to 15 1 0 to 1 5 2 95 to 4 43 21 to 30 20 to 28 M10 2 1to 3 1 1 9 to 2 9 7 38 to 11 1 28 0 to 39 8 38 to 54 35 to 51 3 8 to 5 5 3 4 to 5 2 15 5 to 22 1 14 8 to 20 6 00 15 TABLE OF STANDARD TIGHTENING TORQUES Tightening torque for flare nut for general purpose Unit N m kgf m Ibf ft Pipe diameter pee 66 35 mm 08 mm 010 mm 612 mm 615 mm p 0 187 in 60 250 in 00 315 in 00 394 in 60 472 in 60 591 in Tightening torque 7 o aa i an ree 12 5 18 4 28 8 43 5 64 9 72 3
5. 16 Cylinder head and valve assembly P 11 20 Cylinder head gasket 12 Push rod 13 Tappet Crankcase P 11 66 A Locating pin Non reusable part _11 Service standards Unit mm in Tappet to crankcase clearance 6D16 0 06 to 0 10 0 2 Replace Basic diameter 0 00237 to 0 00394 0 00787 tappet EE 6D16 TLE 0 03 to 0 07 0 1 0 00118 to 0 00276 0 00394 Tightening torques Unit N m kgf m lbf ft Parts to be tightened Tightening torque Remarks 29 8 0 214 s9 0 4 2 88 Cylinder head bolt M14 bolt 78 8 57 5 180 e Wet installation of rocker and e Can be reused bracket assembly and cylinder up to 3 times head and valve assembly M10 bolt 17 1 75 12 5 34 3 5 25 1 Sy Lubricant Rubber seal of oil filler cap Threads of cylinder head bolts Tightening cylinder head bolts Socket Wrench MH063388 M14 bolt only Service procedure Cylinder head and valve assembly Removal e Before loosening the cylinder head bolts 8 loosen the adjusting screw C on every rocker A that is compressing its valve spring B 11 13 CYLINDER HEAD AND VALVE MECHANISM e Loosen and remove the cylinder head bolts 8 in the sequence shown Each cylinder head bolt should be loosened a little at a time Qa ago o O 25 Q 23 Installation CAUTION N Before fitting any cylinder head bolt 8 check the punch marks A on its head Do not use the bolt if there are mo
6. 3 10 to 15 19 to 28 22 to 32 1 0 to 1 5 1 9 to 2 8 2 2 to 3 3 7 38 to 11 1 14 0 to 20 6 16 2 to 23 6 21 to 30 20 to 28 39 to 58 37 to 53 50 to 65 45 to 65 2 1 to 3 1 1 9 to 2 9 3 9 to 6 0 3 6 to 5 4 5 0 to 6 5 4 5 to 6 5 15 5 to 22 1 14 8 to 20 6 28 8 to 42 8 27 3 to 39 1 66 8 to 47 9 33 2 to 47 9 38 to 54 35 to 51 80 to 110 70 to 95 90 to 120 85 to 110 3 8 to 5 5 3 4 to 5 2 8 0 to 11 7 0 to 9 5 9 0 to 12 8 5 to 11 28 0 to 39 8 25 8 to 37 6 59 0 to 81 1 51 6 to 70 1 66 4 to 88 5 62 7 to 81 1 00 13 TABLE OF STANDARD TIGHTENING TORQUES Hex head Nut Unit N m kgf m lbf ft Strength Repre sentation Diameter symbol Standard screw Coarse screw Standard screw Coarse screw 2to3 M5 0 2 to 0 3 0 4 to 0 6 1 48 to 2 21 2 95 to 4 43 4to6 7 to 11 0 4 to 0 6 0 7 to 1 1 2 95 to 4 43 5 16 to 8 11 9 to 14 17 to 26 0 9 to 1 4 1 7 to 2 6 6 64 to 10 3 12 5 to 19 2 19 to 28 18 to 26 36 to 52 33 to 49 M10 1 9 to 2 8 1 8 to 2 7 3 5 to 5 5 3 5 to 5 0 14 0 to 20 6 13 3 to 19 2 26 6 to 38 4 24 3 to 36 1 35 to 50 31 to 46 70 to 95 65 to 85 M12 3 4 to 5 0 3 1 to 4 7 7 0 to 9 5 6 5 to 8 5 25 8 to 36 9 22 9 to 33 9 51 6 to 70 1 47 9 to 62 7 60 to 85 55 to 75 120 to 160 110 to 140 M14 6 0 to 8 5 5 5 to 7 5 12 to 16 11 to 14 44 3 to 62 7 40 6 to 55 3 88 5 to 118 81 1 to
7. Adapter onto an injection nozzle mounting hole B together with a nozzle gasket Then connect the compression gauge 1 e Turn the engine over and measure the compression pressure e Measure the compression pressure in every cylinder and determine the pressure differences between cylinders e If any compression pressure or cylinder to cylinder pressure difference exceeds the specified limit pour a little engine oil into the cylinder via the injection nozzle mounting hole B then take the measurement again e If the compression pressure increases there may be wear or damage on piston rings and inner surfaces of cylinders e If the compression pressure does not increase valves may be seized or incorrectly seated or the cylinder head gasket may be defective 11 9 ON VEHICLE INSPECTION AND ADJUSTMENT 2 Inspecting and Adjusting Valve Clearances Service standards Unit mm in pe Valve clearance when cold 0 4 0 0158 pe Adjust Tightening torques Unit N m kgf m lbf ft Parts to be tightened Tightening torque Remarks Rocker arm adjusting screw lock nut 34 3 5 25 1 Valve clearances should be checked and adjusted when the engine is cold Inspection e Bring piston No 1 or piston No 6 to the top dead centre TDC position of its compression stroke To do this crank the engine until the 1 6 mark inscribed on the flywheel is aligned with the pointer A in the flywheel housing inspection window NOTE
8. Pistons whose push rods are not pushing up their rockers are at top dead centre TDC of their compression strokes e When piston No 1 or piston No 6 is at the TDC position of its compression stroke measure the clearance B of every valve marked in the following table Rem eks else ril EE di al KP 7 EF P No 1 piston at TDC of compression lt X xix lt x stroke No 6 piston at TDC of compression EES ae x stroke NOTE To measure the clearance insert a feeler gauge 1 The gauge should be able to move in the gap albeit not loosely Accurate measurements cannot be taken if the gauge moves loosely in the gap 11 10 _11 e If any measurement is out of specification make adjustments as follows Adjustment e To adjust the valve clearance B loosen the lock nut 2 and turn the adjusting screw 3 until the feeler gauge 1 moves more stiffly in the gap e After adjusting the clearance tighten the lock nut 2 At this time use a screwdriver C to stop the adjusting screw 3 from turning Next insert the feeler gauge 1 once more to confirm that the clearance B is correct 11621 11 11 CYLINDER HEAD AND VALVE MECHANISM Disassembly sequence 1 Joint Oil filler cap Bolt Plate Rubber Rocker cover gasket Rocker cover N oo BW DY Assembly sequence 10 11 Follow the disassembly sequence in reverse 11 12 Cylinder head bolt Rocker and bracket assembly N P 11
9. and installing rocker Bushing Puller SO ANY bushings Rocker MH061777 11 16 _11 Service procedure Rocker bushing and rocker shaft Inspection If any clearance exceeds the specified limit replace the defective part s Rocker bushing Removal Installation e Align the oil hole A in the rocker bushing 2 with the oil hole B in the rocker 5 e Position the notch C and seam D on the rocker bushing 2 as shown e Install the rocker bushing 2 into the rocker 5 from the chamfered side F 6 8 to Installing rocker shaft brackets and rocker shaft Rocker shaft brackets Be sure to fit the rocker shaft brackets 6 8 12 in their correct positions A Oil hole B Threaded hole for M8 rocker cover bolt C Threaded hole for M6 set screw D No threaded hole 11 17 CYLINDER HEAD AND VALVE MECHANISM Rocker shaft Align the oil hole G in the No 6 rocker shaft bracket 6 with the oil hole H in the rocker shaft 14 11 18
10. unit Foot pound unit Conversion rate Force N Newton lof 1 N 0 2248 IDf Moment of force 1 N m 0 7375 ft lbs Pressure kPa kilopascal psi 1 kPa 0 145 psi 1 kPa 0 2953 in Hg Volume L 1 L 0 2642 gal U S 1 L 0 220 gal Imp cm 1 cm 0 033814 oz U S 1 cm 0 035195 oz Imp cm IN 1 cm 0 061023 cu in Power kW kilowatt 1 kW 1 3596 PS Mass quantity of matter kg lb 1 kg 2 2046 Ib g OZ 1 g 0 035274 oz Dimension m ft 1 m 3 2808 ft i 1 mm 0 03937 in 3 3 5 viii GENERAL SPECIFICATIONS Engine model 6D16 6D16 TLE 6 cylinder in line water cooled 4 cycle diesel Combustion chamber type Direct injection type Overhead valve OHV type Total displacement cc Cu in Empty mass as measured according to Mitsubishi Motors Corporation standard Engine Outputs Classified By Application 6D16 TLE Middle speed High speed specification Engine model Application specification Intermittent rated output Coutinuous rated output NOTE 1 The output SAE gross is corrected to standard ambient conditions based on SAE J1349 71 95 1500 85 114 1800 93 125 2000 101 135 2200 111 149 2500 120 161 2800 65 87 1500 77 103 1800 84 113 2000 93 125 2200 101 135 2500 110 147 2800 106 142 1500 123 165 1800 131 176 2000 140 188 2200 96 129 1500 111 149 1800 119 160 2000 127 170 2200 2 The continuous rated output allows
11. viscosity fei Incorrect defective fuel O Incorrect valve clearance O Defective cylinder head gasket O Worn valve valve seat and carbon deposits Ol Weakened valve spring Ol Worn damaged piston ring s ei Worn damaged piston ring groove s O Incorrect injection timing fer Defective injection pump fe Defective cooling system ker Defective injection nozzle s Ol Air trapped in fuel system O Clogged air cleaner O Clogged muffler fer N Gr 13 z Gr 13 N Gr 14 N Gr 13 N Gr 13 N Gr 15 N Gr 15 N Gr 15 N Gr 13 N Gr 13 54 N Gr 14 11 6 N Gr 15 ME ee ON VEHICLE INSPECTION AND ADJUSTMENT 1 Measuring Compression Pressure Service standards Compression Each cylinder at 200 rom 2550 kPa 1960 kPa Inspect pressure 26 kgf cm 20 kgf cm 370 psi 284 psi Cylinder to cylinder 390 kPa Inspect pressure difference 4 kgf cm 56 6 psi Special tools Unit mm in Tool name and shape Application 16 W x18 thread Compression MHOG1461 Measuring compression Gauge Adapter pressure Centre distance 46 1 81 Reductions in compression pressure should be used as a guide in determining the timing of engine overhauls Take measurements regularly and keep track of changes an overview of pressure variations can be useful in fault diagnosis During the engine s run in period and after parts have been replaced the compression pressure will increase slightly as piston rings valve seats and other parts fit snug
12. 10 one hour overload operation 00 2 101 136 1500 121 163 1800 131 175 2000 139 186 2200 147 197 2500 151 203 2800 92 123 1500 110 148 1800 118 158 2000 125 168 2200 133 178 2500 137 184 2800 ENGINE NUMBER AND NAME PLATE The serial number for engine is assigned to the respective engine in manufacturing sequence every engine has its own number This number is required for incidental inspection of the engine Please do not fail to mention this number to the dealers when ordering spare parts Engine Number Engine number 1 is punch marked on the left of the crankcase Example 6D16 LICIOOUT Engine Engine number model Name Plate The name plate is attached to the portion shown in the illustration and mae Rial indicate the following items Engine model Total displacement Maximum output Valve clearance Firing order Fuel injection timing TOTAL CYL VOL 6557cce 400cu in OUT PUT ME se rpm MITSUBISHI MOTORS CORPORATION TOKYO JAPAN OO POND Ad VALVE CLEARANCE COLD INLET amp EXHAUST 0 4mm 0 016 in FIRING ORDER 00 3 PRECAUTIONS FOR MAINTENANCE OPERATION In order to determine the condition of the vehicle adequately attend the vehicle beforehand to find and keep record of the accumulated mileage operating condition what the customer s demand is and other information that may be necessary Prepare the steps to be taken and perform efficient and waste
13. 177 260 to 340 25 to 35 192 to 251 350 to 470 36 to 48 251 to 347 470 to 640 48 to 65 347 to 472 630 to 840 63 to 86 465 to 620 33 to 49 3 5 to 5 0 24 3 to 36 1 65 to 85 6 5 to 8 5 47 9 to 62 7 110 to 140 11 to 14 81 1 to 103 160 to 220 16 to 22 118 to 162 220 to 290 22 to 30 162 to 214 320 to 420 32 to 43 236 to 310 430 to 570 43 to 58 317 to 420 540 to 730 55 to 74 398 to 538 0 5 to 0 7 3 69 to 5 16 8 to 12 0 8 to 1 2 5 90 to 8 85 20 to 29 2 0 to 3 0 14 8 to 21 4 45 to 60 4 5 to 6 0 33 2 to 44 3 85 to 110 8 5 to 11 62 7 to 81 1 130 to 180 13 to 18 95 9 to 133 200 to 270 20 to 27 148 to 199 290 to 390 30 to 40 214 to 288 410 to 550 41 to 56 302 to 406 550 to 740 56 to 75 406 to 546 730 to 980 74 to 100 538 to 723 41 to 59 4 3 to 6 9 30 2 to 43 5 75 to 100 7 5 to 10 55 3 to 73 8 120 to 160 12 to 17 88 5 to 118 190 to 260 19 to 26 140 to 192 260 to 340 26 to 35 192 to 251 370 to 490 37 to 50 273 to 361 490 to 670 50 to 68 361 to 494 630 to 840 64 to 86 465 to 620 Hex head Flange Bolt Unit N m kgf m lbf ft Strength classification Repre sentation Diameter symbol 4to6 0 4 to 0 6 0 8 to 1 2 0 9 to 1 4 95 to 4 90 to 8 64 to 10 2 95 to 4 43 5 90 to 8 85 6 64 to 10
14. cified bolts and nuts and tighten them at specified torques according to the following table unless otherwise specified e Threads and contact seats shall be dry e Where there is a difference in strength classification between the nut and bolt or stud bolt the torque specified for the bolt shall apply Hex head Bolt and Stud Bolt Unit N m kgf m Ibf ft Strength Repre 00 12 4 O Diameter Stud 2 to 3 0 2 to 0 3 1 48 to 2 21 4 to 6 0 4 to 0 6 2 95 to 4 43 9 to 14 0 9 to 1 4 6 64 to 10 3 19 to 28 1 9 to 2 8 14 0 to 20 6 35 to 50 3 4 to 5 0 25 8 to 36 9 60 to 85 6 0 to 8 5 44 3 to 62 7 90 to 130 9 5 to 13 66 4 to 95 9 140 to 190 14 to 19 103 to 140 190 to 260 19 to 26 140 to 192 260 to 340 26 to 35 192 to 251 340 to 450 34 to 46 251 to 332 18 to 26 1 8 to 2 7 13 3 to 19 2 31 to 46 3 1 to 4 7 22 9 to 33 9 55 to 75 5 5 to 7 5 40 6 to 55 3 90 to 120 9 0 to 12 66 4 to 88 5 120 to 160 12 to 16 88 5 to 118 170 to 230 17 to 23 125 to 170 230 to 300 23 to 31 170 to 221 290 to 390 29 to 40 214 to 288 0 4 to 0 6 2 95 to 4 43 to 11 0 7 to 1 1 5 16 to 8 11 17 to 26 1 7 to 2 6 12 5 to 19 2 36 to 52 3 5 to 5 5 26 6 to 38 4 70 to 95 7 0 to 9 5 51 6 to 70 1 120 to 160 12 to 16 88 5 to 118 180 to 240 18 to 24 133 to
15. d must be replaced or repaired Tightening torque Excessive or insufficient tightening torque has particular importance in respect of performance Accordingly tightening torque is specified in locations that are to be tightened Where there is no specified figure for tightening torque follow the table covering standard tightening torques When the item is to be tightened in a wet state wet is indicated Where there is no indication read it as dry and tighten at specified torque Unit Length weight surface area and capacity are in SI units with foot pound units are given in brackets Tightening torques and other parameters are given in SI units with metric and foot pound units added in brackets and Example 390 N m 40 T 289 2 Metric unit Foot pound unit SI unit Temperatures are given in degrees Celsius with degrees Fahrenheit given brackets For the conversion into the foot pound system refer to the following conversion table ao HOW TO READ THIS MANUAL Unit SI unit metric unit Conversion factor Force N kgf 9 80665 N 1 kgf Moment of force N m kgf m 9 80665 N m 1 kgf m Positive pressure kPa kgf cm 98 0665 kPa 1 kgf cm 0 133322 kPa 1 mmHg Pa mmH O 9 80665 Pa 1 mmH O volun art Power 0 7355 kW 1 PS Heat quantity 4186 05 J 1 kcal Heat flow 1 16279 W 1 kcal h Angle Pressure Vacuum pressure Temperature rr Electric current Voltage Electric power Unit SI
16. d not be reused This shows an example of the disassembly removal sequence This shows that the service procedure is described in another section M P OO OO shows reference page within the same group N GrOO shows reference group within the same book No service procedure is referred to in this section but the item can be an objective of various procedures This is shown when the assembly installation sequence is not the reverse of the disassembly removal sequence This shows that a repair kit is available 2 Service standards table Only the relevant service standards are shown Service standards Unit mm in 1 11 Clearance between strap bolt and strap 0 01 to 0 16 0 3 0 0118 Replace plate 0 0039 to 0 0629 7 Pressure spring Installed load 835 N 710 N Replace Installed length 49 1 85 kgf 72 3 kgf 187 7 lbf 159 6 Ibf 29 1 4417 orless 5 0 0 197 This shows the key No of the relevant part 3 Tightening torque table This shows specified tightening torque Tightening torques Unit N m kgf m lbf ft Parts to be tightened Tightening torque Strap bolts Strap bolt mounting 39 to 59 4 to 6 28 8 to 43 5 4 Bolt Lock plate mounting 5 9 to 7 8 0 6 to 0 8 4 3 to 10 5 This shows the key No of the relevant part This shows that the item is to be tightened wet 4 Lubricants and sealant table Only the relevant lubricants and sealant are shown
17. e carrying out maintenance work on the electric system disconnect the negative terminals of the batteries to prevent them from short circuiting and burning out CAUTION N Be sure to turn starter and lighting switches etc off before disconnecting or connecting battery terminals because the semiconductors can be damaged Take care when handling sensors relays etc which are vulnerable to shock and heat Do not attempt to remove the cover from or apply paint to the electronic control unit Pull the connector and not the harness lead to separate connectors To separate a lock type connector first push toward arrow mark To reconnect a lock type connector press the separated parts until they click together When washing the vehicle cover the electric system parts and instruments with waterproof material beforehand Cover with vinyl sheet or the like Keep water away from harness wire connectors and sensors If any of them should get wet wipe them off immediately When using an electric welder such electronic parts that are directly connected to the batteries might be damaged due to the flow of current from the welder that flows through the negative circuit Parts that have switches might be subject to the same danger if the switches are left on Therefore do not fail to observe the following e Connect the negative terminal of the welder as near as possible to the area that is to be welded e Disconnect the negat
18. ged by friction or heat e Water in connectors or circuits e Mistakes accidental short circuits Battery Fuse Loaded switch Load Short circuit moov gt p Precautions for Handling Alternator When servicing the alternator pay attention to the following e Do not connect the alternator with battery polarities reversed If the alternator is connected with reversed polarities a large current flow from the battery to the alternator occurs and the diode or regulator might be damaged 00 10 e While the engine is running do not remove the battery terminals If the battery terminals are removed at that time a surge voltage is generated and the diode or regulator might be weakened e Do not use a high voltage tester such as a megger for inspection If a high voltage tester is used the diode or regulator might be destroyed ed e Do not splash water over the alternator If water is directly splashed over the alternator individual components will be short circuited and might be destroyed e Do not short circuit terminal B and terminal L while running the alternator If the terminals are short circuited while the alternator is running the diode trio might be destroyed e Disconnect the battery terminals before quick charging the battery Quick charging without disconnecting the battery terminals might damage the diode or regulator 00 11 BUY NOW TABLE OF STANDARD TIGHTENING TORQUES e Use spe
19. ing torques are shown collectively classified by location N Points of lubricant fluid and sealant application are shown collectively classified by location EN Special tools to be used are shown collectively classified by location or Ed When it is considered hard to understand the service procedure just by the foregoing description a Supplementary description of the service procedure is given ili HOW TO READ THIS MANUAL 1 Illustration for disassembly and assembly or removal and installation This shows that the appropriate service procedure is described in the text This shows the key No of the part In the text this No is referred to uniformly throughout oureneoor Pressure Plate and Lever Assembly Assembly sequence Disassembly sequence 1 Strap bolt 2 Washer 3 Washer 4 Bolt 5 Lock plate 6 Support nut 7 Pressure spring N Groo 8 Pressure spring cap 9 Return spring 10 Release lever plate 11 Clutch cover 12 Release lever pin 18 Support lever pin 14 Bushing 15 Support lever 16 Release lever 17 Bushing 2 Pressure plate amp lever assembly MP 21 12 3 Clutch disc Flywheel A Positioning pin at 2 places Non retsable part 16917 12510 39 87 65 9 4335 145 15 13 Repair kit clutch release lever kit Meaning of symbols O shows that the tightening torque is specified shows that application of lubricant fluid or sealant is required shows that the part shoul
20. it mm o Roum spring Tool nae and shape 10 Release lever plate 11 Clutch cover 12 Release lever pin 13 Support lever pin MHO61051 R el and inataliggion ol chach cover 14 Bushing 15 Support lever 16 Release lever 17 Bushing 2 Pressure plate amp lever assembly g E P 21 12 TAFU 3 Clutch disc MH062291 Release lever plate height adjustment Flywheel Y Pa A Positioning pin at 2 places g Non reusable part Assembly sequence Service procedure 1631751 7 46 95343533251 1 A Clearance between strap bolt and strap piate 14 15 5 a H the measurement exceeds the limit replace the defective part Repair kit clutch release A Strap plate Service standards Unit mm Standard value SS Toe to 0 16 Replace ik a 76 7 kgf 2 9 or less Replace E installation of pressure spring If pressure plate 19 has been reground insert adjusting washer A corre sponding to the arnount of regrind in the space between the pressure meer ge mee ss Ee EP ee Ee ies ER Illustration for disassembly and assembly or removal and installation 3 D exploded view of component parts is displayed Won asbes Names of parts show an example of the disassembly removal sequence TD mos When the assembly installation sequence differs from the disassembly removal sequence an example of the assembly installation sequence is shown e EE MEET Service standards are shown collectively classified by location EENDERS EE Tighten
21. ive terminals of batteries To apply voltage for testing check that the positive and negative cables are connected properly then increase voltage gradually from 0 volt Do not apply voltage higher than the specified value In particular pay close attention to the electronic control unit and sensors since they are not always fed the battery voltage 00 7 PRECAUTIONS FOR MAINTENANCE OPERATION 00 6 Connect the test harness and connector A between these parts 02587 When using testers or the like for continuity tests be careful not to allow test probes to touch the wrong terminals Test with connectors engaged continuity through circuit obtained lt Waterproof connector gt Prepare a test harness and connectors A then connect if between the two parts of harness B that is to be tested Check the circuit by touching test probe C to the test connector Never insert the test probe from the harness side of the waterproof connection or waterproof performance might be diminished causing corrosion of the connector lt Non waterproof connector gt Insert test probe C from the harness side of the connector Where control units etc have connectors that are too small to accept the test probe do not force the test probe into them Test with connectors disengaged Using female pins Insert a test probe into a terminal However do not force the probe into the terminal or it will cause a poor contact Connector Inspecti
22. l CAUTION N When removing the cylinder head gasket 11 be careful not to scratch the cylinder head and valve assembly 10 and the crankcase x Fitting e Fit the cylinder head gasket 11 onto the crankcase as shown Push rod runout If any measurement exceeds the specified limit replace the defective part s Tappet to crankcase clearance lf any measurement exceeds the specified limit replace the defective part s 11 15 CYLINDER HEAD AND VALVE MECHANISM Rocker and Bracket Assembly Disassembly sequence 1 Rocker assembly 2 Rocker bushing 3 Lock nut 4 Adjusting screw 5 Rocker 6 No 6 rocker shaft bracket 7 Set screw 8 No 5 rocker shaft bracket 9 No 4 rocker shaft bracket 10 No 3 rocker shaft bracket 11 No 2 rocker shaft bracket 12 No 1 rocker shaft bracket 13 Rocker shaft spring 14 Rocker shaft Assembly sequence Reverse the order of disassembly Service standards Unit mm ET Location Standard value Limit Remedy E 14 Rocker bushing to rocker shaft a Ad 01 to 0 08 E 12 Replace Basic diameter 24 mm 0 945 in 0 000394 to 0 00315 0 00472 T TOE torques Unit N m kgf m lbf ft Parts to be tightened Tightening torque Adjusting screw lock nut 34 3 5 25 1 e Rocker shaft set screw 3 9 0 4 2 88 Lubricant Points of application Specified lubricant Quantity KC tools Unit mm in Tool name and shape Application A Removing
23. less maintenance procedure 00 4 Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary Then follow the procedure specified by this manual Perform maintenance work at a level area Prepare the following e Prepare general and special tools necessary for the maintenance work WARNING N Do not attempt to use tools other than special tools where use of special tools is specified in this manual This will avoid injury or damage Pay special attention to safety when removing or installing heavy items such as engines transmissions When lifting up heavy items using cables pay special attention to the following points e Check the mass of the item to be lifted and use a cable capable of lifting that mass e If you do not have the specified lifting hanger secure the item using cable taking the point of balance of the item into consideration e You must work in a position where you will not be injured even if the cable comes undone and the lifted item falls Be particularly careful not to work in shoes that have oily soles and are slippery When working as a team of two or more arrange signals in advance and keep confirming safety Be careful not to accidentally bump switches or levers Check for oil leakage before cleaning the area having the fault otherwise you might miss detecting the leakage Prepare replacement part s beforehand Replace oil
24. ly in position The pressure will then normalize as parts wear e Before inspections check that the engine oil starter and battery are normal e Warm up the engine until the coolant temperature reaches 75 to 85 C 167 to 185 F e Turn off all lights and auxiliary devices e To prevent injection of fuel while cranking the engine by the starter perform the following steps e Set the stop lever of the injection pump governor to the stop position lt Mechanical governor gt e Remove fuse 1 shown in the diagram below For the terminal arrangement of the engine ECU refer to Gr 13E lt Electronic governor gt Starter SW Engine ECU STARTER SW S 03 een ewan SW M 1 c STARTER SW M 2 c B MAIN RELAY 2 D13 ECU POWER VB 1 ECU POWER VB 2 8 7 D8 D1 D2 47396 11 8 _11 e Remove the injection nozzle A N Gr 13 CAUTION N Cover the mounting holes and injection pipes to prevent the entry of dust and dirt e Cover the injection nozzle mounting hole B with a cloth C Then turn the engine over with the starter and check that no foreign matter adheres to the cloth WARNING N If any cylinder is cracked coolant engine oil and fuel will enter the cylinder through the crack When the engine is turned over these substances will spray out of the nozzle mounting hole B at a high temperature For safety move away from the nozzle mounting hole before turning over the engine e Fit the Compression Gauge
25. ndependent by every group where first page is always 1 We General specifications engine No and name plate precautions for maintenance operations table of standard tightening torques Fuel and engine control Fuel system Intake and exhaust Intake and exhaust system intercooler Electrical system Alternator starter preheating system engine start system automatic stop system General Explanation of This Manual Specifications Particulars relative to maintenance service are made Structure and operation 1 Regarding conventional equipment descriptions are made in brief 2 Regarding new equipment descriptions of system and operating condition are made in detail Troubleshooting Symptoms of troubles and possible causes are described comparatively Inspection and adjustment mounted in vehicle Descriptions are made regarding inspection and adjustment of units mounted in vehicle Service procedure In principle an explanation is given at the spread title page so that the service procedure can be understood Servicing points are explained as a supplementary explanation Regarding the design of this manual CLUTCH BODY Pressure Plate and Lever Assembly Disassembly sequence Pairis of application ORE es 1 Bot Oa eno 2 Washer 10 16 Sliding surfaces of relear 3 Washer 4 Bot 12 17 Sliding surfaces of supp 5 Lo ae Sliding suxfaces of suppo s 1A 7 Pres Gr a Pele ei ap EF Special tools Un
26. on Procedures Using male pins Touch the pins directly using test probes CAUTION N Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the internal circuit of the electronic control unit Visual inspection Check for loose connection and poor engagement Check if harnesses are broken by pulling gently around the terminals Check for a decrease in contact pressure between the male and female terminals Check for poor contact caused by connector pins having fallen out rusted terminals or foreign particles 00 9 PRECAUTIONS FOR MAINTENANCE OPERATION Connector pin fall out inspection Damaged connector pin stoppers can cause poor engagement of the terminals male and female pins even if the connector body is secured and might cause some pins to fall out Check if the pins have fallen out from the connector by pulling each harness gently Inspection Procedures for Blown Fuses Remove fuse B and measure resistance between the 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 A value of other than zero may indicate that the fuse was blown by a temporary short but the short is no longer present The major causes of a short circuit are as follows e Harness stuck onto the vehicle body e Harness sheath dama
27. re shown collectively vi Terms and Units The terms and units in this manual are defined as follows This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information DANGER A Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives WARNING N Precautionary instructions which if not observed could result in serious injury or death CAUTION Precautionary instructions which if not observed could result in damage to or destruction of equipment or parts NOTE Suggestions or supplementary information for more efficient use of equipment or a better understanding Front and rear The terms front is the fan side and rear the flywheels side of the engine Left and right The terms right and left shall be used to indicate the side as viewed from the flywheel side of the engine Terms of service standards 1 Standard value Standard value dimensions in designs indicating the design dimensions of individual parts the standard clearance between two parts when assembled and the standard value for an assembly part as the case may be The figure in is the basic diameter 2 Limit When the value of a part exceeds this it is no longer serviceable in respect of performance and strength an
28. re than two punch marks The punch marks indicate the number of times each bolt has been tightened using the plastic area tightening method Any bolt that already has three punch marks must be 21229 replaced e Tighten the cylinder head bolts 8 to the specified torque M14 bolts 78 Nm 8 kgf m 57 5 IDf ft M10 bolts 17 Nm 1 75 kgf m 12 5 lof ft in the sequence shown Then turn the bolts further in accordance with the following procedure Tighten together with rocker and bracket assembly to M14 bolt wet to M10 bolt lt M14 Bolts gt e Before fitting the Socket Wrench over a cylinder head bolt turn the holder D counter clockwise to tension the built in spring E Socket F Rod G Rod extension e Set the socket such that the built in spring force forces the rod G against the rocker shaft bracket an injection pipe or another nearby part e On the holder D select the inscribed line H that is easiest to see e Using the selected line as a reference turn the socket E 180 clockwise One gradation on the scale J represents 5 CAUTION N Since the M14 cylinder head bolts 8 utilize the plastic region tightening method they must not be tightened further after this procedure 11 14 lt M10 Bolts gt e After fitting the M14 cylinder head bolts 8 tighten the M10 bolts to the specified torque 34 N m 3 5 kgf m 25 1 Ibf ft in the sequence shown Cylinder head gasket Remova
29. rol the amount of lubricant flowing onto the sliding surfaces of the valves 1 2 and valve guides 16 e The valve springs 13 14 are unevenly pitched to prevent abnormal vibration at high speeds To prevent the inner and outer springs from meshing with each other the Springs are wound in opposite directions e To facilitate removal and reinstallation of the camshaft from the rear end of the crankcase the diameter of each bushing is smaller toward the front of the engine 3 Connecting Rods Connecting rod bushing Connecting rod Connecting rod bearing Connecting rod cap Connecting rod bolt lt 6D16 gt lt 6D16 TLE gt 0O PhOoON m Alignment mark Weight mark stamp A B C D E F G H I V W X Y Z lt 6D16 gt A B C D E F lt 6D16 TLE gt U gt 4 Pistons 6 Flywheel OO POND Ad _11 Part number T mark lt 6D16 TLE gt Size mark A B lt 6D16 6D16 TLE gt Weight mark Front mark Camshaft gear No 2 idler gear No 1 idler gear Oil pump gear Crankshaft gear Air compressor drive gear or injection pump drive gear No 1 idler gear Each gear is stamped with a timing gear alignment mark 1 2 8 or 4 to facilitate reassembly Flywheel Pilot bearing Ring gear Angle scale cylinder number 11 5 TROUBLESHOOTING Remarks Possible causes Gr 11 Gr 13 2 gt O D O O O Incorrect oil
30. seals packing O rings and other rubber parts gaskets and split pins with new parts whenever any of them has been removed Use only genuine MITSUBISHI replacement parts On disassembly visually inspect all parts for wear and tear cracks damage deformation degradation rust corrosion smoothness in rotation fatigue clogging and any other possible defect 00 5 PRECAUTIONS FOR MAINTENANCE OPERATION 14184 00 6 Put alignment marks on part combinations before disassembly and arrange the disassembled parts neatly This will help avoid mismating of the parts later Put the alignment marks punch marks etc where performance and appearance will not be affected Cover the area left open after removal of parts to keep it free from dust CAUTION N e Take care to avoid mixing up numerous parts similar parts left and right etc e Keep new parts for replacement and original removed parts separate Apply the specified oil or grease to U packings oil seals dust seals and bearings during assembly Use only the specified oil grease etc for lubricant remove the excess immediately after application with a piece of waste etc CAUTION N When the specified lubricant fluid and sealant is not available you may use an equivalent Wear goggles when using a grinder or welder Pay full attention to safety by wearing gloves when necessary Watch out for sharp edges etc that might injure your hands or fingers Befor
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