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This workshop service repair manual PDF download for the S6S-Y3T61HF & S6S-Y3T62HF Mitsubishi Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
S6S-Y3T61HF
S6S-Y3T62HF
TABLE OF CONTENTS :
INTRODUCTION
GENERAL CONTENTS
GENERAL
SERVICE DATA
SERVICE TOOLS
DETERMINATION OF OVERHAUL
DISASSEMBLY OF BASIC ENGINE
INSPECTION AND REPAIR OF BASIC ENGINE
REASSEMBLY OF BASIC ENGINE
FUEL SYSTEM
LUBRICATION SYSTEM
COOLING SYSTEM
INLET AND EXHAUST SYSTEMS
ELECTRICAL SYSTEM
ADJUSTMENT AND OPERATION
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99616-25000
Total Pages : 204
This OEM service manual/ repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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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
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Mitsubishi S6S-Y3T61HF & S6S-Y3T62HF Diesel Engine Workshop Repair Service Manual.pdf
Source : Sitelux.com