Mitsubishi S6S-Y3T62HF Engine
MITSUBISHI S6S-Y3T62HF ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL
MITSUBISHI S6S-Y3T62HF ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL - English Workshop Manual / Repair Manual, for Mitsubishi S6S-Y3T62HF Engine. INDEX: - BINDING - INTRODUCTION - How to use this manual - Methods of presentation - Terms used in this manual - Abbreviations - Units of measurement - Safety Cautions - Fire and explosion - Keep flames away - Keep surrounding area tidy and clean - Avoid accessing crankcase until engine cools - Care about fuel, oil and exhaust gas leakage - Use explosion-proof lighting apparatus - Prevent electrical wires from short-circuiting - Keep fire extinguishers and first-aid kit handy - Stay clear of all rotating and moving parts - Install protective covers on rotating parts - Ensure safety of neighboring people before starting engine - Stay clear of moving parts during engine running - Lockout and tagout - Keep engine stopped during servicing - Always restore engine turning tools after use - Be careful of burns - Do not touch the engine during or immediately after operation - Slowly and carefully open radiator cap - Add coolant only after the coolant temperature dropped - Never remove heat shields - Be careful of exhaust fume poisoning - Operate engine in well-ventilated area - Protect ears from noises - Wear ear plugs - Be careful of falling down - Lift engine correctly - Do not climb onto the engine - Establish firm scaffold during work - Be careful of handling fuel, engine oil and LLC - Use only specified fuel, engine oil and long- life coolant (LLC) - Handle LLC (long life coolant) carefully - Proper disposal of waste oil and coolant (LLC) - Service battery - Handle the battery correctly - When abnormality occurs - Stop overheated engine after cooling run - Avoid immediate restart after abnormal stop - Avoid continuous engine operation with too low oil pressure - Stop the engine immediately if the fan belt breaks - Other cautions - Modification of engine prohibited - Never break the seals - Pre-operational check and periodic inspection/maintenance - Break-in operation - Warming-up operation - Avoid engine operations in a overload condition - Cooling operation before stopping engine - Protection of engine against water entry - Maintenance of air cleaner or pre-cleaner - Observe safety rules at work site - Work clothing and protective gear - Use of tools optimum for each work - Avoidance of prolonged time of starter operation - Do not turn off battery switch during operation - Cautionary instructions for transporting engine - Avoid continuous engine operation in a low load condition - Ventilation of engine room - Avoid contact with high-pressured fuel - About warning labels - Maintenance of warning labels - GENERAL CONTENTS - GENERAL - 1. External view - 2. System flow diagrams - 2.1 Fuel system - flow diagram - 2.2 Lubrication system - flow diagram - 2.3 Cooling system - flow diagram - 2.4 Inlet and exhaust system - flow diagram - 3. Engine serial number location - 4. Main specifications - 5. Tips on disassembling and reassembling - 5.1 Disassembling - 5.2 Reassembling - SERVICE DATA - 1. Maintenance service data - 1.1 General - 1.2 Basic engine - 1.3 Fuel system - 1.4 Lubrication system - 1.5 Cooling system - 1.6 Inlet and exhaust system - 1.7 Electrical system - 2. Tightening torque table - 2.1 Major bolt tightening torque - 2.1.1 Basic engine - 2.1.2 Fuel system - 2.1.3 Lubrication system - 2.1.4 Cooling system - 2.1.5 Inlet and exhaust systems - 2.1.6 Electrical system - 2.2 Standard bolt and nut tightening torque - 2.2.1 Metric automobile screw thread - 2.2.2 Metric course screw thread - 2.3 Standard stud tightening torque - 3. Regarding submission of parts for EPA exhaust gas regulation - SERVICE TOOLS - 1. Special tool - DETERMINATION OF OVERHAUL - 1. Determining overhaul timing - 2. Testing compression pressure - DISASSEMBLY OF BASIC ENGINE - 1. Disassembling and inspecting cylinder head and valve mechanism - 1.1 Removing rocker shaft assembly - 1.2 Disassembling rocker shaft assembly - 1.3 Removing cylinder head bolt - 1.4 Removing cylinder head assembly - 1.5 Removing valve and valve spring - 1.6 Removing valve stem seal - 2. Disassembling and inspecting flywheel - 2.1 Removing flywheel - 2.2 Removing rear plate - 3. Disassembling and inspecting damper, gear case, timing gear and camshaft - 3.1 Removing crankshaft pulley and damper - 3.2 Removing cover - 3.3 Removing timing gear case - 3.4 Measuring timing gear backlash - 3.5 Measuring idler gear and camshaft gear end play - 3.6 Removing fuel injection pump - 3.7 Removing oil pan - 3.8 Removing oil strainer - 3.9 Removing oil pump gear - 3.10 Removing idler gear - 3.11 Removing PTO drive gear - 3.12 Removing camshaft - 3.13 Separating camshaft gear - 3.14 Installing camshaft gear and thrust plate - 3.15 Removing front plate - 3.16 Removing oil pump - 4. Disassembling and inspecting piston, connecting rod, crankshaft and crankcase - 4.1 Removing connecting rod cap - 4.2 Removing carbon deposits from the upper part of cylinder liner - 4.3 Pulling out piston - 4.4 Removing piston ring - 4.5 Removing piston pin and piston - 4.6 Removing main bearing cap - 4.7 Removing crankshaft - 4.8 Removing tappet - INSPECTION AND REPAIR OF BASIC ENGINE - 1. Inspecting and repairing cylinder head and valve mechanism - 1.1 Measuring clearance between rocker bushing and rocker shaft - 1.2 Measuring valve stem outside diameter and valve guide inside diameter - 1.3 Replacing valve guide - 1.4 Inspecting valve face - 1.5 Refacing valve face - 1.6 Refacing valve seat - 1.7 Replacing valve seat - 1.8 Lapping valve and valve seat - 1.9 Measuring perpendicularity and free length of valve spring - 1.10 Measuring distortion of the bottom surface of the cylinder head - 1.11 Measuring push rod runout - 1.12 Removing combustion jet - 2. Inspecting and repairing flywheel - 2.1 Measuring flatness of flywheel - 2.2 Measuring flywheel face and radial runouts - 2.3 Inspecting ring gear - 2.4 Replacing ring gear - 2.4.1 Removing ring gear - 2.4.2 Installing ring gear - 3. Inspecting and repairing timing gear and camshaft - 3.1 Measuring timing gear backlash - 3.2 Measuring idler gear and camshaft gear end play - 3.3 Measuring cam lift - 3.4 Measuring camshaft runout - 3.5 Measuring camshaft journal outside diameter - 3.6 Measuring camshaft bushing inside diameter - 3.7 Replacing camshaft bushing - 3.7.1 Removing camshaft bushing - 3.7.2 Installing camshaft bushing - 3.8 Measuring idler bushing inside diameter and idler shaft outside diameter - 3.9 Replacing idler shaft - 3.10 Measuring clearance between tappet and tappet guide hole - 3.11 Inspecting tappet - 3.11.1 Contact surface of camshaft - 3.11.2 Contact surface of push rod - 3.12 Inspecting V-belt groove wear - 3.13 Inspecting damper - 4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase - 4.1 Measuring crankcase top surface distortion - 4.2 Measuring cylinder inside diameter - 4.3 Measuring piston outside diameter - 4.4 Measuring piston ring end gap - 4.5 Measuring clearance between piston ring groove and piston ring - 4.6 Measuring piston pin bore diameter and piston pin outside diameter - 4.7 Measuring piston protrusion - 4.8 Measuring clearance between connecting rod bearing and crankpin - 4.9 Measuring clearance between connecting rod bushing and piston pin - 4.10 Replacing connecting rod bushing - 4.11 Inspecting connecting rod bend and twist - 4.12 Inspecting connecting rod bearing - 4.13 Measuring connecting rod end play - 4.14 Weight difference of connecting rod assembly in one engine - 4.15 Measuring crankshaft journal outside diameter - 4.16 Measuring crankshaft crankpin outside diameter - 4.17 Grinding crankshaft - 4.18 Measuring crankshaft end play - 4.19 Measuring crankshaft runout - 4.20 Replacing crankshaft gear - 4.20.1 Removing crankshaft gear - 4.20.2 Installing crankshaft gear - 4.21 Inspecting oil seal contact surface - 4.22 Installing oil seal sleeve - 4.23 Removing oil seal sleeve - 4.24 Inspecting main bearing surface - 4.25 Measuring clearance between main bearing and crankshaft journal - REASSEMBLY OF BASIC ENGINE - 1. Reassembling piston, connecting rod, crankshaft and crankcase - 1.1 Installing main bearing - 1.2 Installing thrust plate - 1.3 Installing tappet - 1.4 Installing crankshaft - 1.5 Installing main bearing caps - 1.6 Inserting side seal - 1.7 Installing main bearing cap bolt - 1.8 Measuring crankshaft end play - 1.9 Reassembling piston and connecting rod - 1.10 Installing piston ring - 1.11 Preparation for installing pistons - 1.12 Installing connecting rod bolt and connecting rod bearing - 1.13 Installing pistons - 1.14 Installing connecting rod cap - 2. Reassembling timing gear and camshaft - 2.1 Installing oil pump - 2.2 Installing front plate - 2.3 Installing camshaft gear and thrust plate - 2.4 Installing camshaft - 2.5 Installing PTO drive gear - 2.6 Installing idler gear - 2.7 Installing oil pump gear - 2.8 Installing fuel injection pump - 2.9 Inspecting and adjusting timing gear after installation - 2.9.1 Inspecting backlash and end play - 2.10 Installing front oil seal - 2.11 Installing timing gear case - 2.12 Installing oil strainer - 2.13 Installing oil pan - 2.14 Installing cover - 2.15 Installing crankshaft pulley and damper - 3. Reassembling flywheel - 3.1 Installing oil seal - 3.2 Installing rear plate - 3.3 Installing flywheel - 4. Reassembling cylinder head and valve mechanism - 4.1 Cleaning cylinder head bottom surface - 4.2 Installing valve stem seal - 4.3 Installing valve and valve spring - 4.4 Installing cylinder head gasket - 4.5 Installing cylinder head assembly - 4.6 Tightening cylinder head bolts - 4.7 Inserting push rod - 4.8 Reassembling rocker shaft assembly - 4.9 Installing rocker shaft assembly - 4.10 Determining top dead center of No. 1 cylinder compression stroke - 4.10.1 When reusing the damper - 4.10.2 When replacing the damper with a new one - 4.11 Adjusting valve clearance - 4.12 Installing rocker cover - FUEL SYSTEM - 1. Removing fuel system - 1.1 Removing fuel filter - 1.2 Removing fuel injection pipe - 1.3 Removing fuel injection pump - 2. Disassembling, inspecting and reassembling fuel system - 2.1 Disassembling and inspecting fuel filter - 2.2 Changing fuel filter - 2.3 Disassembling and inspecting fuel injection nozzle - 2.4 Inspecting and adjusting fuel injection valve opening pressure - 2.5 Inspecting fuel spray pattern of fuel injection nozzle - 2.6 Cleaning and inspecting nozzle tip - 2.7 Reassembling fuel injection nozzle - 2.8 Inspecting and cleaning gauze filter of distribute type fuel injection pump - 3. Installing fuel system - 3.1 Installing fuel injection pump - 3.2 Installing fuel injection pipe - 3.3 Installing fuel filter - LUBRICATION SYSTEM - 1. Removing lubrication system - 1.1 Removing oil filter and relief valve - 1.2 Removing oil cooler - 1.3 Removing oil pump, oil pan and oil strainer - 2. Disassembling, inspecting and reassembling lubrication system - 2.1 Disassembling and inspecting oil pump - 2.2 Inspecting oil pump - 2.2.1 Measuring clearance between outer rotor and inner rotor - 2.2.2 Measuring end play of rotor and pump case - 2.2.3 Measuring clearance between outer rotor and pump case - 2.2.4 Measuring clearance between main shaft and pump case - 2.2.5 Measuring clearance between main shaft and bushing - 2.2.6 Installing oil pump bushing - 2.3 Reassembling oil pump - 2.4 Disassembling and inspecting oil cooler - 2.5 Inspecting oil filter - 2.6 Inspecting relief valve - 2.7 Inspecting safety valve - 3. Installing lubrication system - 3.1 Installing oil pump, oil pan and oil strainer - 3.2 Installing oil cooler - 3.3 Installing oil filter and relief valve - COOLING SYSTEM - 1. Removing cooling system - 1.1 Removing thermostat - 1.2 Removing water pump, water pump pulley and V-belt - 2. Disassembling, inspecting and reassembling cooling system - 2.1 Disassembling and inspecting thermostat - 2.2 Inspecting thermostat - 2.3 Disassembling water pump - 2.4 Inspecting water pump - 3. Installing cooling system - 3.1 Installing water pump, water pump pulley and V-belt - 3.2 Installing thermostat - INLET AND EXHAUST SYSTEMS - 1. Removing turbocharger, inlet and exhaust systems - 1.1 Removing turbocharger - 1.2 Removing inlet manifold - 1.3 Removing exhaust manifold - 2. Disassembling, inspecting and reassembling inlet and exhaust systems - 2.1 Measuring exhaust manifold distortion - 2.2 Disassembling and inspecting turbocharger - 2.2.1 Removing turbine housing - 2.2.2 Removing compressor cover - 2.2.3 Installing O-ring - 2.2.4 Installing compressor cover - 2.2.5 Installing snap ring - 2.3 Cleaning - 2.3.1 Measuring axial clearance of cartridge assembly - 2.3.2 Reassembling turbocharger - 2.3.3 Installing turbine housing - 2.3.4 Installing coupling assembly - 3. Installing turbocharger, inlet and exhaust systems - 3.1 Installing exhaust manifold - 3.2 Installing inlet manifold - 3.3 Installing turbocharger - ELECTRICAL SYSTEM - 1. Removing electrical system - 1.1 Removing starter - 1.2 Inspection before removing alternator - 1.2.1 Inspecting alternator operation - 1.2.2 Handling precaution - 1.3 Removing alternator - 1.4 Removing glow plug - 2. Disassembling, inspecting and reassembling electrical system - 2.1 Inspection before disassembling starter - 2.1.1 Inspecting magnetic switch - 2.1.2 No load test - 2.2 Disassembling and inspecting starter - 2.2.1 Removing pinion set - 2.2.2 Removing magnetic switch - 2.2.3 Removing rear bracket - 2.2.4 Removing brush holder and brush assembly - 2.2.5 Removing armature and yoke - 2.2.6 Removing overrunning clutch - 2.3 Inspecting and repairing starter - 2.3.1 Inspecting brushes for wear - 2.3.2 Measuring brush spring load - 2.3.3 Inspecting brush holder for insulation - 2.3.4 Measuring commutator radial runout - 2.3.5 Measuring commutator outside diameter - 2.3.6 Measuring undercut depth - 2.3.7 Checking armature coil - 2.3.8 Inspecting field coil - 2.3.9 Inspecting rear bracket - 2.3.10 Inspecting overrunning clutch operation - 2.3.11 Inspecting front bracket - 2.3.12 Inspecting gears of starter - 2.3.13 Inspecting magnetic switch - 2.3.14 Inspecting starter relay - 2.4 Reassembling starter - 2.4.1 Installing gear shaft - 2.5 Disassembling and inspecting alternator - 2.5.1 Separating front bracket from stator - 2.5.2 Removing field coil - 2.5.3 Removing pulley - 2.5.4 Removing rear bearing - 2.5.5 Removing front bearing - 2.5.6 Removing stator - 2.5.7 Removing regulator assembly - 2.5.8 Removing rectifier assembly - 2.6 Inspecting and repairing alternator - 2.6.1 Inspecting stator - 2.6.2 Inspecting rectifier - 2.6.3 Measuring field coil - 2.7 Reassembling alternator - 2.7.1 Installing rectifier assembly and regulator assembly - 2.7.2 Installing stator - 2.7.3 Installing front bearing - 2.7.4 Installing rear bearing - 2.7.5 Installing pulley - 2.7.6 Assembling stator and front bracket - 2.8 Inspecting glow plug - 2.8.1 Continuity test of glow plug - 2.8.2 Heating test of glow plug - 2.9 Inspecting magnetic valve (stop solenoid) - 2.9.1 Continuity test of magnetic valve (stop solenoid) - 2.9.2 Inspecting magnetic valve (stop solenoid) operation - 2.10 Installing magnetic valve (stop solenoid) - 3. Installing electrical system - 3.1 Installing glow plug - 3.2 Installing alternator - 3.3 Installing starter - ADJUSTMENT AND OPERATION - 1. Adjusting engine - 1.1 Inspecting and adjusting valve clearance - 1.1.1 Inspecting valve clearance - 1.1.2 Adjusting valve clearance - 1.2 Draining fuel system - 1.2.1 Draining fuel filter - 1.3 Bleeding fuel system - 1.3.1 Bleeding fuel filter - 1.4 Inspecting and adjusting fuel injection timing - 1.4.1 Adjusting fuel injection timing - 1.5 Inspecting V-belt and adjusting V-belt tension - 1.6 Inspecting V-belt - 1.7 Adjusting V-belt tension - 2. Break-in operation - 2.1 Starting up - 2.2 Inspecting engine condition after starting up - 2.3 Break-in operation time - 2.4 Inspection and adjustment after break-in operation - 3. Performance test (JIS standard) - 3.1 Engine equipment condition - 3.2 Test items and purposes - 3.2.1 Operation load test - 3.2.2 Continuous load test - 3.2.3 Low idle test - 3.3 Other inspections - 3.4 Engine output adjustment - 3.4.1 Standard atmospheric conditions: - 3.4.2 Calculation of corrected power
Mitsubishi S6S-Y3T62HF Engine - Workshop Manual / Repair Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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