4m50 мануал fuso canter

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  ( EURO 4 ) For Colombia For Colombia                              Pub.No.00ELT0085, MARCH 2015 Shop Manual Shop Manual 4M5 diesel engine 4M5 diesel engine…
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  MARCH 2015 Applicable models (engine) 4M50T5 ©2015 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan…
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  This Shop Manual contains the information classified into the following groups. If any system or equipment has two or more variations with significantly different construction, the variations are handled as different groups. These groups are identified by different alphabets preceded by the same number. 1.
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  GROUP 00 GENERAL VEHICLE MODEL CODING SYSTEM ……….00-2 EQUIPMENT TYPE CODES LIST …………00-3 POWER TRAIN TABLE …………..00-4 HOW TO READ THIS MANUAL …………00-6 CHASSIS NUMBER, ENGINE NUMBER AND VEHICLE IDENTIFICATION NUMBER……….00-14 PRECAUTIONS FOR MAINTENANCE OPERATION …………..
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  VEHICLE MODEL CODING SYSTEM 10 11 F E 8 5 D E Basic vehicle type Cab-over engine truck 2 ton class and over, 4 × 2 Load capacity, drive system Cab type Wide cab Rigid axle Vehicle variations, Suspension Light duty vehicle (G.V.M. 7000 kg or more) Engine 4M50T 3350 mm…
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  EQUIPMENT TYPE CODES LIST Component Name plate marking Code description Engine 4M50T5 Power version number Turbocharged Order of development within same series Order of development among different series Diesel engine No. of cylinders (4) Clutch C5W33 Disc OD Facing material (W: Woven) Load capacity (in tonnes) of main model Initial letter of the clutch Transmission…
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  POWER TRAIN TABLE Reduction & Vehicle model Engine Clutch Transmission Propeller shaft Rear axle Differential FE85DE6SLGP 4M50T5 C5W33 M036S6 R035T D035H FE85DG6SLGP 4M50T5 C5W33 M036S6 R035T D035H FE85DHZSLGP 4M50T5 C5W33 M036S6 R035T D035H 00-4…
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  M E M O 00-5…
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  HOW TO READ THIS MANUAL This manual consists of the following parts: • Specifications • Structure and Operation • Troubleshooting • Circuits • Electrical Equipment Installation Positions • Inspection of Electrical Equipment • On-vehicle Inspection and Adjustment • Service procedures •…
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  Tightening torque • Values are directly specified for out-of-standard tightening torques for bolts and nuts. • Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. (Values for standard tightening torques are based on thread size and material.) •…
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  HOW TO READ THIS MANUAL Illustrated Parts Breakdown and Service Procedures Symbol Denotation Application Remarks Specified values shown in table Parts not tightened to standard torques See Table of Standard Tightening Torques for Tightening torque (standard torques specified where neces- parts for which no tightening torques are speci- sary for servicing) fied.
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  00-9…
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  HOW TO READ THIS MANUAL How to Read Circuits (Electrical) 00-10…
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  1.1 Index number: • Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its own index number. 1.2 Key number: A01 to Z99 • Key numbers indicate electrical equipment installation locations. The installation location of an electrical equip- ment can be easily found using its key number shown in a circuit diagram.
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  HOW TO READ THIS MANUAL Wire color Wire color Base color + tracer Black/ Black/ Black/ Black/ Black/ Black/red BG white yellow green blue orange Black Black/ Black/ Black/ B Br pink violet brown Brown/ Brown/ Brown/ Brown/ Brown/ Brown/ white black yellow…
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  M E M O 00-13…
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  CHASSIS NUMBER, ENGINE NUMBER AND VIHICLE IDENTIFICATION NUMBER • Serial chassis and engine numbers are assigned to the vehicles and engines in manufacturing sequence. Every vehicle and engine has its own number. These numbers are required for registration and related inspection of the vehicle.
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  (12) (1) Geographic area J: Asia (Japan) (2) Country L: Japan (3) Manufacture C: Mitsubishi Fuso Truck & Bus (4) GVW & Brake type B: 3.5 t < GVW ≦ 12 t/Hydraulic (5) Model C: FE84P D: FE85P 1: FE85D (6) Series (wheel base) E: 3.2 to 3.49 m…
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  PRECAUTIONS FOR MAINTENANCE OPERATION 1. General Precautions • Before performing service operations, inquire into the customer’s complaints and ascertain the condition by checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently. •…
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  • If lifting eyes are not provided on the item being lifted, tie a ca- ble around the item taking into account the item’s center of gravity. • Do not allow anyone to pass or stay under a lifted item which may possibly fall.
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  • Oil seals, packings, O-rings and other rubber parts, gaskets, and split pins must be replaced with new ones after removal. Use only genuine MITSUBISHI replacement parts. • When disassembling parts, visually check them for wear, cracks, damage, deformation, deterioration, rust, corrosion, defective ro- tation, fatigue, clogging and any other possible defect.
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  2. Handling of Battery 2.1 Handling of battery cable • Before working on the electrical system, disconnect the (–) bat- tery cable to prevent short circuits. CAUTION • Make sure that the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. (Semiconductor components may otherwise be damaged.) •…
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  PRECAUTIONS FOR MAINTENANCE OPERATION • When applying a voltage to a part for inspection purposes, check that the (+) and (–) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily op- erate on the battery voltage.
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  (2.2) Inspections on male terminals • Perform the inspection by applying test probes directly to the pins. CAUTION • Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-circuiting of pins can cause damage to the control unit’s internal circuit- •…
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  PRECAUTIONS FOR MAINTENANCE OPERATION • Check for defective connections caused by loose terminals, by rust on terminals, or by contamination of terminals by foreign substances. (2) Checking for loose terminals • If connector terminal retainers become damaged, male and fe- male terminals may not mate with each other when the connec- tor bodies are fitted together.
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  5. Service Precautions for Alternators • When servicing alternators, observe the following precautions: • Never reverse the polarity of battery connections. If the polarity of the battery connections were to be reversed, a large current would flow from the battery to the alternator, damaging the diodes and regulator.
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  PRECAUTIONS FOR MAINTENANCE OPERATION • Disconnect the battery cables before quick-charging the battery with a quick charger. Unless the battery cables are disconnected, quick-charging can damage the diodes and regulator. 6. Intermittent Faults • An intermittent fault typically occurs only under certain operating conditions.
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  7. Precautions for Arc Welding • When arc welding is performed, current from the welder flows to ground via the vehicle’s metal parts. Unless ap- propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be largely damaged.
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  JACKING UP THE VEHICLE <Front of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Jack up the front of the vehicle with a bottle jack or garage jack. 3 Support the front of the vehicle frame on jack stands. WARNING •…
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  <Rear of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Jack up the rear of the vehicle using a bottle jack or garage jack as illustrated above. 3 Support the vehicle frame on jack stands on both sides. WARNING •…
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  DIAGNOSIS CODES 1. Diagnosis Codes • The diagnosis code indicates the faulty location(s) of the vehicle. • Reading the diagnosis code(s) and performing the corresponding remedy (troubleshooting) repairs the faulty lo- cation(s). • Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to be diagnosed.
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  Mark Tool name and shape Part No. Application Multi-Use Tester har- ness E MH063659 A: For inspection and A: MH063661 drive recorder B: MH063663 Power supply to V.C.I. and communi- B: For drive recorder C: MH063665 cation with electronic control unit C: Drive recorder har- D: MH063666 ness…
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  DIAGNOSIS CODES <Preparation for inspection using the drive recorder function> • Move the starter switch to the LOCK position. • Connect installed PC, -D and as illustrated. • Connect the Multi-Use Tester connector on the vehicle with the connector of <To extend the cable>…
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  (1) Reading diagnosis codes • To read a diagnosis code, observe how may times the warning lamp flashes and how long each illumination lasts. • The duration of illumination differs between the first and second digits. • Second digit: 1.2 sec. •…
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  TABLE OF STANDARD TIGHTENING TORQUES 1. Tightening Torques • Tightening torques are roughly classified into the following two categories: Availability of How to determine tightening Tightening torque Definition torque specifica- torque tions in text Locate a bolt or nut correspond- Standard tightening Tightening torque determined according to thread None…
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  Strength 8.8 (Nut 4T) 8.8 (Nut 6T) Automotive screw thread 18 to 27 45 to 60 {1.8 to 2.8} {4.6 to 6.1} Nominal 34 to 50 80 to 105 diameter {3.5. to 5.1} {8.2 to 11} 60 to 80 130 to 170 {6.1 to 8.2} {13 to 17} (2) Hexagon flange bolts (Unit: N·m {kgf·m})
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  TABLE OF STANDARD TIGHTENING TORQUES (3) Hexagon nuts (Unit: N·m {kgf·m}) Strength 6T (Bolt 7T) 6T (Bolt 8T) Automotive Coarse screw Automotive Coarse screw Automotive Coarse screw screw thread thread screw thread thread screw thread thread 2 to 3 4 to 6 5 to 7 –…
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  (6) Tightening torques of nylon tubes for general air piping (DIN) (Unit: N·m {kgf·m}) Nominal diameter 6 × 1 10 × 1.25 12 × 1.5 15 × 1.5 × wall thickness +0.6 +1.0 +1.0 +0.5 Tightening torque {2.0 {3.5 {5.0 {5.5 (7) Tightening torques of nylon tubes for general air piping (SAE) (Unit: N·m {kgf·m}) Nominal diameter…
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  GROUP 11 ENGINE SPECIFICATIONS……..11-2 TIMING GEARS AND BALANCE SHAFTS……….11-72 STRUCTURE AND OPERATION ……… 11-3 1. Exploded View CRANKSHAFT AND CRANKCASE ..11-80 2. Cylinder Head, Cylinder Head Gasket, BALANCE SHAFT BUSHINGS … 11-88 ..11-4 Camshaft and Camshaft Frame ……
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  SPECIFICATIONS Item Specifications Engine model 4M50T5 Type 4-cylinder, in-line, water-cooled, 4-cycle diesel engine Combustion chamber Direct injection type Valve mechanism Double overhead camshaft (DOHC) Maximum output kW {PS} / rpm 132 {180} / 2700 Maximum torque N·m {kgf·m} / rpm 530 {54} / 1600 Bore ×…
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  STRUCTURE AND OPERATION 1. Exploded View 11-3…
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  STRUCTURE AND OPERATION 2. Cylinder Head, Cylinder Head Gasket, Camshaft and Camshaft Frame • The camshaft is supported at its jour- nals from below by the cylinder head and retained from above by the cam- shaft frame. • The upper and lower camshaft bear- ings are identical, but cannot be inter- changed when they are reinstalled.
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  3. Valve Mechanism • The short rockers and the long rockers are installed differently, as shown in the illustration. • Each valve has an inner valve spring and an outer valve spring. 11-5…
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  STRUCTURE AND OPERATION 4. Connecting Rod Weight mark: “C” to “G” (with “G” as the maximum) 5. Piston • Each piston must be mated with a cyl- inder in the upper crankcase that has the same size mark as the piston. The pistons are marked with either “A”…
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  6. Timing Gears • All gears, except the vacuum pump gear, each has timing mark(s) to ensure correct engagement during assem- bly. 7. Flywheel • One side of each flywheel ring gear tooth is chamfered to facilitate the engagement of the starter pinion. 11-7…
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  STRUCTURE AND OPERATION 8. Balance Shafts • The balance shaft RH and balance shaft LH are mounted in the upper crankcase on the right and left sides of the crankshaft. The balance shafts reduce the vibration of the engine caused by the rotation of the crankshaft. •…
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  9. Crankcase and Main Bearings 9.1 Crankcase • The crankcase is a two-piece type consisting of an upper crankcase and a lower crankcase, which hold the crankshaft in between. • Cylinder liners are inserted into the cylinder bores in the upper crankcase. •…
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  STRUCTURE AND OPERATION • The upper crankcase is marked with a size mark (“1” or “2”) to be used as a reference in selecting cylinder liners. • The first to forth size marks from the front of the engine correspond to the No.
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  10. Oil Seals 10.1Front oil seal • The front oil seal is fitted in the front case, and prevents oil from leaking by contact of its lip with the front oil seal slinger. • The front oil seal slinger is press-fitted onto the fan shaft.
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  TROUBLESHOOTING Symptoms Reference Gr Possible causes Incorrect valve clearance Defective cylinder head gasket Worn valve and valve seat; carbon deposits Cylinder head and valve mechanism Weakened valve spring Defective rocker shaft and camshaft frame Poor lubrication of rocker shaft and camshaft frame Incorrect backlash in timing gears Timing gears Poor lubrication of timing gears and idler shaft…
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  M E M O 11-13…
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  ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure Service standards Location Maintenance item Standard value Limit Remedy 3100 kPa 2400 kPa Each cylinder (at 250 rpm) Inspect {32 kgf/cm {24 kgf/cm – Compression pressure 500 kPa Cylinder-to-cylinder pres- – {5 kgf/cm Inspect sure difference or less…
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  • Disconnect the injector connector and remove all injectors. • Cover the injector mounting holes with shop towels. After crank- ing the engine by the starter, check that no foreign substances are deposited on the shop towels. • If there are deposits (such as engine oil or coolant) on the shop towels, the following may be the cause: •…
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  ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Inspection and Adjustment of Valve Clearances Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Intake valve – – Valve clearance (when cold) Adjust Exhaust valve – Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks…
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  • The feeler gauge cannot be inserted under the adjusting screw pad without carrying out the above step, as the pad will block the feeler gauge as shown in the illustration. • To insert the feeler gauge under the adjusting screw pad, push the pad at the bottom on one side with a flat-blade screwdriver or a similar tool.
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  ENGINE REMOVAL AND INSTALLATION CAUTION • Only use hoisting equipment appropriate for the engine and transmission weight (approximately 600 kg). Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (front mounting installation) 69 to 88 {7 to 9} –…
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  Special tools Mark Tool name and shape Part No. Application Engine front hanger MH063636 Removal and installation of engine MF140429 Flange bolt MF140433 Installation of engine front hanger MF140421 Engine rear hanger MH063711 Removal and installation of engine Work before removal Preparing for engine removal: Installation of engine front hanger and flange bolt •…
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  ENGINE REMOVAL AND INSTALLATION Removal procedure Removal: Engine and transmission • Hook the wire rope on and hitch the chain block to Then, pull all the slack out of the slings by a crane. CAUTION • The slings must be strong enough to hang the engine and transmission assembly (weighing approximately 600 kg).
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  M E M O 11-21…
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  ROCKER COVER 11-22…
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  Disassembly sequence 1 Oil filler cap 9 Injection pipe 17 Rocker cover 2 Grommet 10 Bolt (with hexagonal hole) 18 Rocker cover gasket A 3 Spacer 11 Injector 19 Rocker cover gasket B 4 Insulator 12 O-ring 5 Cover 13 Tip gasket : Non-reusable parts 6 –…
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  ROCKERS AND CAMSHAFTS Disassembly sequence 1 Exhaust rocker shaft (See later sections.) 2 Intake rocker shaft (See later sections.) 3 Camshaft frame 4 Gasket 5 O-ring 6 Upper camshaft bearing 7 Packing 8 Intake camshaft (See later sections.) 9 Exhaust camshaft (See later sections.) 10 Lower camshaft bearing a: Head idler gear…
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  Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (rocker shaft installation: 10 places) 27 {2.8} Bolt (camshaft frame installation: 13 places) Bolt (camshaft installation: 2 places) 23.5 {2.4} – Bolt (camshaft frame installation: 4 places) 23.2 {2.4} –…
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  ROCKERS AND CAMSHAFTS Releasing valve spring tension • Before removing the bolts in the next process, loosen the adjust- ing screws on the rockers whose valve springs are compressed (due to the cams lifting these rockers). This operation is neces- sary to release the tension in the valve springs, thus preventing other parts from undue forces when the bolts are removed.
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  Installation procedure Installation: Camshaft • Install the upper camshaft bearing on the camshaft frame and the lower camshaft bearing on the cylinder head by fitting their lugs into the notches in the camshaft frame and cylinder head. • Place the No. 1 cylinder piston at the top dead center on the compression stroke.
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  ROCKERS AND CAMSHAFTS • Install on the rocker shafts to prevent the rocker arms from moving away from each other. • Set the rocker shafts to the camshaft frame and then remove • Tighten the bolts (1 to 23) to the specified torque in the order in- dicated in the illustration.
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  M E M O 11-29…
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  ROCKERS AND CAMSHAFTS Rocker Shafts and Rockers Disassembly sequence 1 Adjusting screw 7 Long rocker 2 Rocker bushing 8 Exhaust rocker shaft 3 Short rocker 9 Intake rocker shaft 4 Rocker shaft spring 5 Adjusting screw : Hole for camshaft frame locating pin 6 Rocker bushing : Non-reusable parts •…
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  Special tools (Unit: mm) Mark Tool name and shape Part No. Application Rocker bushing puller Removal and installation of rocker MH062536 φ24.5 φ22 bushing Inspection procedure Inspection: Rocker (roller) radial clearance • Replace the rocker if the radial play measurement is not within the standard value range.
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  ROCKERS AND CAMSHAFTS [Installation] • Press-fit each rocker bushing in the rocker with its ends facing in the illustrated directions. 11-32…
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  M E M O 11-33…
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  ROCKERS AND CAMSHAFTS Camshafts Disassembly sequence 1 Intake camshaft gear 2 Key 3 Intake camshaft 4 Exhaust camshaft gear 5 Key 6 Exhaust camshaft a: Sensor plate : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION •…
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  Inspection procedure Inspection: Camshaft gear-to-camshaft interference • If the measurement is not within the standard value range, re- place the defective part(s). Inspection: Camshaft (1) Cam lift • Replace the camshaft if the difference between the cam lobe height and base circle diameter measurements is less than the specified limit.
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  CYLINDER HEAD AND VALVE MECHANISM 11-36…
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  Disassembly sequence 1 Connection plates 6 Thrust plate a: Idler gear 2 Glow plug 7 Cylinder head bolt b: Upper crankcase 3 Head idler shaft 8 Cylinder head c: Front case 4 Head idler gear bushing (See later sections.) : Locating pin 5 Head idler gear 9 Cylinder head gasket : Non-reusable parts…
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  CYLINDER HEAD AND VALVE MECHANISM Special tools (Unit: mm) Mark Tool name and shape Part No. Application Idler gear bushing puller Removal and installation of idler gear MH061779 φ32 φ35 bushing Work before removal Inspection: Head idler gear-to-idler gear backlash •…
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  Inspection procedure Inspection: Head idler shaft-to-head idler gear bushing clearance • Replace the bushing if the measurement exceeds the specified limit. Replacement of head idler gear bushing [Removal] [Installation] • Position the bushing on the head idler gear with their ends fac- ing the illustrated directions and their oil holes on the same line.
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  CYLINDER HEAD AND VALVE MECHANISM • The cylinder head gasket comes in three sizes. Choose the gas- ket appropriate for the cylinder head by the following procedure. • Measure the amount of piston projection for every cylinder. (See “PISTONS, CONNECTING RODS AND CYLINDER LINERS”…
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  M E M O 11-41…
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  CYLINDER HEAD AND VALVE MECHANISM Cylinder Head Disassembly sequence 1 Valve cotter 10 Exhaust valve seat 16 Stud (short) 2 Upper retainer 11 Intake valve seat 17 Stud (long) 12 Sealing cap 18 Cylinder head 3 Outer valve spring 4 Inner valve spring (diameter: 22 mm) 5 Valve stem seal 13 Sealing cap…
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  Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Free length 87.8 83.4 Installed load 360 ± 18 N Outer valve spring – Replace (57 in installed length) {36.7 ± 1.8 kgf} Squareness – Free length 78.8 74.9 Installed load 168 ±…
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  CYLINDER HEAD AND VALVE MECHANISM Special tools (Unit: mm) Mark Tool name and shape Part No. Application Valve lifter MH061668 Valve lifter seat MH061772 φ38 Removal and installation of valve cot- ters Valve lifter hook MH061679 Valve stem seal installer MH063607 Installation of valve stem seals φ26.5 φ14.7…
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  Removal procedure Removal: Valve cotters • Remove the valve cotters by evenly compressing the valve springs. Inspection procedure Inspection: Valves • If the valve has been replaced with a new one due to the result of the following inspections, make sure to lap the valve and valve seat.
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  CYLINDER HEAD AND VALVE MECHANISM Replacement of valve guides [Removal] [Installation] • Install the valve guide until sits snugly on the cylinder head. CAUTION • The valve guides have a specified amount of depth. Make sure to use to achieve the specified depth. •…
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  • Strike the valve several times against the valve seat while rotat- ing the valve a little at a time. • Wash away the compound with diesel fuel. • Apply engine oil to the valve contact surface of the valve seat and rub in the valve and seat well.
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  CYLINDER HEAD AND VALVE MECHANISM Replacement of valve seat [Removal] • The valve seats are installed by expansion fitting. To remove a valve seat, grind inside the metal stock to reduce the wall thick- ness, then remove the valve seat at room temperature. [Inspection] •…
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  Installation procedure Installation: Sealing caps • Drive the sealing caps into the cylinder head to the specified depth. Installation: Valve stem seal • Apply engine oil to the lip of the valve stem seal. • Install the valve stem seal until sits snugly on the cylinder head.
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  PISTONS, CONNECTING ROD AND CYLINDER LINERS Disassembly sequence 1 Lower connecting rod bearing 2 Connecting rod cap 3 Upper connecting rod bearing 4 Piston and connecting rod (See later sections.) 5 Cylinder liner a: Upper crankcase b: Crankshaft : Locating pin Assembly sequence Follow the disassembly sequence in re- verse.
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  Special tools (Unit: mm) Mark Tool name and shape Part No. Application Piston guide clamp MH063432 Installation of piston and connecting rod assembly Piston guide lever MH061658 Cylinder liner extractor MH062537 Removal of cylinder liner Cylinder liner installer MH063606 Installation of cylinder liner φ113.5 Adapter MH063433…
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  PISTONS, CONNECTING ROD AND CYLINDER LINERS Inspection: Piston projection from upper crankcase top sur- face CAUTION • The amount of piston projection affects engine perfor- mance and must therefore be inspected without fail. • Set the piston at the top dead center. •…
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  Inspection procedure Inspection: Connecting rod bearing span when free CAUTION • Do not attempt to manually expand the bearings. • If the measurement is less than the limit, replace upper and low- er bearings as a set. Inspection: Connecting rod bearing-to-crankshaft oil clear- ance •…
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  PISTONS, CONNECTING ROD AND CYLINDER LINERS Replacement of cylinder liner [Removal] [Installation] • When replacing cylinder liners, select the cylinder liners which correspond to the size marks on the crankcase and the piston. Upper crankcase Cylinder liner Piston size mark size mark size mark “1”…
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  Installation procedure Installation: Connecting rod bearings CAUTION • Do not reverse the positions of the lower bearing and the upper bearing (with oil hole) when installing, as this may cause seizure in the engine. Installation: Piston and connecting rod • Check that the piston ring end gaps are in their correct positions. A: 1st compression ring gap B: 2nd compression ring gap C: Oil ring gap…
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  PISTONS, CONNECTING ROD AND CYLINDER LINERS • After installing the piston and connecting rod assembly, align the mating marks on the connecting rod and connecting rod cap and tighten the bolts alternately in the following manner. • First tighten the bolt to a torque of 29 N m {3.0 kgf ·…
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  M E M O 11-57…
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  PISTONS, CONNECTING ROD AND CYLINDER LINERS Piston and Connecting Rod Disassembly sequence 1 1st compression ring 2 2nd compression ring 3 Oil ring 4 Snap ring 5 Piston pin 6 Connecting rod bushing 7 Connecting rod 8 Piston : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse.
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  Special tools Mark Tool name and shape Part No. Application Removal and installation of piston Piston ring tool MH060014 rings Connecting rod bushing Removal and installation of connect- MH062225 puller kit ing rod bushings Removal procedure Removal: Piston ring Removal: Piston pin •…
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  PISTONS, CONNECTING ROD AND CYLINDER LINERS Inspection: Piston ring side clearance in piston groove • Remove any carbon deposits from the ring groove in the piston before measurement. • Measure the side clearance of each ring around the piston’s en- tire periphery.
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  [Installation] • Apply engine oil to the outside surface of the connecting rod bushing and the bushing fitting surface of the connecting rod. • Fit collar B, the bushing, and collar A over the puller in the illus- trated directions and lock this arrangement together with the nut. •…
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  PISTONS, CONNECTING ROD AND CYLINDER LINERS Installation procedure Installation: Piston and connecting rod • Install pistons and connecting rods as follows when replacing them. • All connecting rods used in the same engine must be of the same weight size mark. Weight mark: “C”…
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  M E M O 11-63…
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  FLYWHEEL Disassembly sequence 1 Plate 2 Bearing 3 Ring gear 4 Flywheel a: Crankshaft : Locating pin Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Friction surface runout –…
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  Special tools (Unit: mm) Mark Tool name and shape Part No. Application Socket wrench MH062183 Installation of flywheel assembly Magnet base MH062356 Work before removal Inspection: Flywheel friction surface runout • If the runout exceeds the specified limit, check that the bolts are tightened correctly and that there are no abnormalities on the crankshaft mounting surface, then rectify or replace the flywheel.
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  FLYWHEEL Inspection: Flywheel (1) Friction surface height • If the height is below the specified limit, replace the flywheel. (2) Friction surface distortion • If the measured amount of distortion is above the specified limit, rectify or replace the flywheel assembly. Rectification of friction surface •…
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  M E M O 11-67…
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  FRONT CASE Disassembly sequence 1 Power steering oil pipe 7 O-ring 14 Front case 2 Power steering oil hose 8 Water pump (See Gr14.) 15 Eyebolt 3 Power steering oil pump 9 Gasket 16 Oil jet (See Gr37.) 10 Fan pulley 17 O-ring 4 O-ring 11 Front oil seal…
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  Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Front oil seal lip Front case installation surfaces ThreeBond 1207C or D As required Special tools (Unit: mm) Mark Tool name and shape Part No.
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  FRONT CASE Installation procedure Installation: Oil jet • When installed, the oil jet must be in contact with the front case and its nozzle must face in the illustrated direction. Installation: Front case • Clean the sealant application surfaces of each part. •…
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  M E M O 11-71…
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  TIMING GEARS AND BALANCE SHAFTS 11-72…
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  Disassembly sequence 1 Thrust plate 12 No. 1 idler gear 23 Key 2 Idler gear bushing 13 No. 1 idler shaft 24 Thrust plate 3 Idler gear 14 Oil pump (See Gr12.) 25 Balance shaft LH 4 Idler shaft 15 O-ring 5 Fan shaft case bushing 16 Balance shaft gear RH a: Crankshaft gear…
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  TIMING GEARS AND BALANCE SHAFTS Special tools (Unit: mm) Mark Tool name and shape Part No. Application Idler gear bushing puller Removal and installation of idler gear MH062540 φ46.5 φ50 bushing Idler gear bushing puller Removal and installation of fan shaft MH062601 φ37 φ40…
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  Inspection procedure Inspection: Idler gear bushing-to-idler shaft clearance • If the measurement exceeds the specified limit, replace the bushing. Replacement of idler gear bushing [Removal] [Installation] • Place the idler gear with its ends facing as illustrated. • Press-fit the idler gear bushing until sits snugly on the chamfered end of the idler gear.
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  TIMING GEARS AND BALANCE SHAFTS [Installation] • Position the fan shaft case with its ends facing in the illustrated directions. • Press in the bushing until rests snugly on the chamfered end of the fan shaft case. • After press-fitting the bushing, remeasure the clearance be- tween it and the fan shaft.
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  Inspection: Balance shaft bend • Place supports under the No. 1 and No. 3 journals of the bal- ance shaft and measure the bend of the balance shaft at the No. 2 journal. • The amount of balance shaft bend is obtained by giving the bal- ance shaft one turn and dividing the dial gauge reading by two.
• Page 116
  TIMING GEARS AND BALANCE SHAFTS • Turn the balancer shaft LH while applying light force on the screwdriver. The screwdriver will enter into the shaft locking hole and the balancer shaft will be locked. • When the screwdriver enters into the locking hole, it will sink by 5 mm.
• Page 117
  M E M O 11-79…
• Page 118
  CRANKSHAFT AND CRANKCASE Disassembly sequence 1 Rear plate 7 Lower thrust plate 13 Check valve 2 Rear oil seal 8 Upper thrust plate 14 Oil jet 3 Main bearing cap bolt 9 Crankshaft gear 15 Upper crankcase 4 No. 1 Lower main bearing 10 Rear oil seal slinger 5 Lower main bearing 11 Crankshaft…
• Page 119
  CAUTION • The main bearing cap bolts are tightened using the torque-turn tightening method. Any bolt that has three punch marks must be replaced. • Do not overtighten the check valve. If it is tightened to a torque exceeding the specification, the check valve may malfunction, resulting in seizures in the engine.
• Page 120
  CRANKSHAFT AND CRANKCASE Special tools (Unit: mm) Mark Tool name and shape Part No. Application Gear puller MH061326 Removal of crankshaft gear Rear oil seal slinger installer MH062677 Installation of rear oil seal slinger φ103 φ100 φ15 Work before removal Inspection: Crankshaft end play •…
• Page 121
  Inspection procedure Inspection: Main bearing span when free CAUTION • Do not attempt to manually expand the bearings. • If the measurement is less than the limit, replace upper and low- er bearings as a set. Inspection: Main bearing-to-crankshaft oil clearance •…
• Page 122
  CRANKSHAFT AND CRANKCASE Grinding of crankshaft CAUTION • If the crankshaft is ground to an undersize, the main bear- ings must be replaced with the undersize ones of the corre- sponding undersize. • See the table of the service standards for the dimension of each part, and collect the parts as follows.
• Page 123
  Installation procedure Installation: Rear oil seal slinger • Press in the rear oil seal slinger until sits snugly on the crankshaft end surface. Installation: Crankshaft gear • Heat the crankshaft gear to approximately 150°C with a gas burner or the like. CAUTION •…
• Page 124
  CRANKSHAFT AND CRANKCASE Installation: Lower crankcase CAUTION • Before installing the main bearing cap bolts, check the number of punch marks on the head of each bolt. (A bolt with two or less marks is reusable.) • The number of punch marks corresponds with the number of times the main cap bolt has been tightened using the torque-turn tightening method.
• Page 125
  Installation: Rear oil seal • Apply engine oil to the lip of the rear oil seal. • Clean the seal surface of the crankshaft. • Apply a bead of sealant along the line on the rear oil seal evenly without any breaks. •…
• Page 126
  BALANCE SHAFT BUSHINGS Disassembly sequence 1 No. 1 balance shaft bushing 2 No. 2 balance shaft bushing 3 No. 3 balance shaft bushing a: Balance shaft : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value…
• Page 127
  Replacement of balance shaft bushing • Replace the bushing using [Removal] • To remove the bushings, use the rod fitted with an adapter corre- sponding to the size of each bushing. Unit: mm Adapter Bushing Identification mark Left “5” 26.5 φ55.25 φ…
• Page 128
  BALANCE SHAFT BUSHINGS [Installation] • To install the bushings, use the rod fitted with an adapter corre- sponding to the size of each bushing. Each bushing has an iden- tification mark. These identification marks are used to distinguish between the No. 1, No. 2 and No. 3 bushings. If the identification mark is not clear, measure the outside diameter of the bushing and use the measurement as a means of identifica- tion.
• Page 129
  • Align the oil hole in the No. 2 bushing with the oil hole in the up- per crankcase. • Force the No. 2 bushing into the upper crankcase to the illustrat- ed position by tapping on the rod from the front of the engine. •…
• Page 130
  GROUP 12 LUBRICATION SPECIFICATIONS…………….12-2 STRUCTURE AND OPERATION …………… 12-3 1. Lubrication System ………………12-4 2. Oil Pump ………………12-5 3. Oil Cooler ………………12-6 4. Oil Filter ……….12-7 5. Lubrication of Engine Components TROUBLESHOOTING …………..12-10 ON-VEHICLE INSPECTION AND ADJUSTMENT …………..
• Page 131
  SPECIFICATIONS Item Specifications Method of lubrication Forced lubrication by oil pump Grade API classification CD, CE, CF-4, CH-4 Engine oil Oil pan Approx. 8 {8} Quantity Oil filter Approx. 1 {1} Model Shell and plate type (multiple-plate type) Oil cooler Bypass valve opening pressure 390 ±…
• Page 132
  STRUCTURE AND OPERATION 1. Lubrication System 1 Main oil gallery 15 Balance shaft bushing LH 2 Bypass valve 16 Crankshaft main bearing 3 Bypass valve 17 Connecting rod bearing 4 Engine oil pressure switch 18 Connecting rod bushing 5 Oil cooler 19 Piston 6 Full-flow filter element 20 Balance shaft bushing RH…
• Page 133
  STRUCTURE AND OPERATION 2. Oil Pump • This engine uses a gear-type oil pump driven by the rotation of the crankshaft transmitted through the engage- ment of the crankshaft gear and the oil pump gear. 12-4…
• Page 134
  3. Oil Cooler 3.1 Bypass valve • When the engine oil is cool and its vis- cosity is high, or when the oil cooler el- ement becomes clogged and restricts the flow of the engine oil, the bypass valve opens to let the engine oil by- pass the oil cooler and flow directly to the main oil gallery.
• Page 135
  STRUCTURE AND OPERATION 4. Oil Filter • The oil filter used in this engine is a spin-on, paper-filter type. • A bypass valve is installed in the lower part of the oil filter. When the filter elements are clogged, this valve opens to let the engine oil bypass the filter elements and flow directly to the oil cooler, thereby preventing seizures in the engine.
• Page 136
  5. Lubrication of Engine Components • The engine oil in the main oil gallery lubricates the engine components in the following ways. 5.1 Main bearing and connecting rod bearing • Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of each connecting rod.
• Page 137
  STRUCTURE AND OPERATION 5.3 Valve mechanism • The engine oil flows from the main oil gallery to the rocker shaft through the oil passages in the upper crankcase, cylinder head, and camshaft frame. • The engine oil in the rocker shaft lubricates the rocker arms and camshaft, then returns to the oil pan. 5.4 Check valves and oil jets •…
• Page 138
  5.5 Vacuum pump • Engine oil flows through the oil pas- sages in the front case to the vacuum pump. • The oil in the pump lubricates the vanes, and then is discharged into the front case from the air discharge port of the vacuum pump along with air, and returns to the oil pan.
• Page 139
  TROUBLESHOOTING Symptoms Reference Gr Possible causes Incorrectly mounted element Defective gasket Defective O-ring Oil cooler Clogged element Damaged element Weakened bypass valve spring Malfunctioning oil pump Oil pump Interference between oil pump gear and oil pump case and/or cover Incorrect installation Oil filter Clogged element Defective gasket…
• Page 140
  M E M O 12-11…
• Page 141
  ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Drain plug 9.8 ± 1.96 {1.0 ± 0.2} – Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Engine oil (API classification CD, Approx.
• Page 142
  [Installation] • Clean the oil filter mounting surfaces of the oil filter head. • Apply a thin coat of engine oil on the oil filter gasket. • Screw in the oil filter by hand until the gasket touches the oil filter head.
• Page 143
  ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Engine Oil Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Drain plug (oil filter) 9.8 ± 1.96 {1.0 ± 0.2} – – Drain plug (oil pan) 34.3 to 43.1 {3.5 to 4.4} –…
• Page 144
  3. Oil Pressure Measurement Service standards Location Maintenance item Standard value Limit Remedy 98 kPa 195 kPa No-load minimum speed {1.0 kgf/ {2.0 kgf/cm Oil pressure – (oil temperature at 70 to Inspect 195 kPa 90°C) 295 to 490 kPa No-load maximum speed {2.0 kgf/ {3 to 5 kgf/cm…
• Page 145
  OIL PAN, OIL STRAINER AND OIL JETS Disassembly sequence 1 Drain plug 2 Oil pan 3 Oil strainer 4 O-ring 5 Oil level sensor 6 O-ring 7 Check valve 8 Oil jet : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse.
• Page 146
  Installation procedure Installation: Oil pan • Clean the mating surfaces of each part. • Apply a bead of sealant to the mating surface of the oil pan evenly and without any breaks as shown in the illustration. • Mount the oil pan within three minutes of applying the sealant. Make sure that the sealant stays in place.
• Page 147
  OIL PUMP Disassembly sequence 1 Oil pump cover 2 Driven gear 3 Gear and case 4 O-ring a: Drive gear : Locating pin : Non-reusable parts Assembly sequence Follow the disassembly procedure in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value Limit…
• Page 148
  Inspection procedure Inspection: Driven gear, drive gear and gear and case • Carry out the following inspection. Replace the oil pump if any defects are found. (1) Sinkage of each gear from gear and case end surface (2) Gear and case-to-tooth tip clearance for each gear Inspection: Oil pump cover, driven gear, drive gear and gear and case •…
• Page 149
  OIL PUMP Installation: Oil pump • Place the No.1 cylinder piston at top dead center to bring the crankshaft gear to an appropriate position. • Inject approximately 5 cm {5 mL} of engine oil. • Align the mating mark “6” on the crankshaft gear and the mating mark “7”…
• Page 150
  M E M O 12-21…
• Page 151
  OIL FILTER Disassembly sequence 1 Drain plug 2 Oil filter 3 Oil pipe 4 O-ring 5 O-ring 6 Plug 7 Regulator valve spring 8 Regulator valve 9 Oil filter head 10 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse.
• Page 152
  Special tools Mark Tool name and shape Part No. Application Oil filter element socket MH061566 Removal of oil filter Removal procedure Removal: Oil filter Installation procedure Installation: Oil filter • Clean the oil filter mounting surface of the oil filter head. •…
• Page 153
  OIL COOLER Disassembly sequence 1 Eyebolt 7 Oil cooler element 12 Coolant temperature sensor 2 Oil pipe 8 Gasket (for engine control) 3 Plug 9 Water drain plug 13 Oil cooler body 4 O-ring 10 Engine oil pressure switch 14 Gasket 5 Bypass valve spring 11 Coolant temperature sensor 6 Bypass valve…
• Page 154
  Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Load of bypass valve spring 95.3 ± 4.9 N – Replace (installed length: 48 {9.7 ± 0.5 kgf} -0.5 Air leakage from oil cooler element (air pressure: 980 0 cm {0 mL} –…
• Page 155
  GROUP 13 FUEL AND ENGINE CONTROL SPECIFICATIONS…………….13-2 STRUCTURE AND OPERATION …………13-3 1. Fuel System (Flow of Fuel) …………….13-4 2. Engine Control ………………13-5 3. Fuel Filter TROUBLESHOOTING ……………. 13-6 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspecting and Adjusting No-load Minimum and Maximum ………………
• Page 156
  SPECIFICATIONS Item Specifications Manufacturer Bosch Supply pump type CP3.3 NH Control system Electronically-controlled pump Model Radial, 3-cylinder Supply pump Feed pump type External gear type Model MPROP MPROP (rail pres- sure control valve) Rated voltage Max. common rail pressure 180 {1840} MPa {kgf/cm Manufacturer Bosch…
• Page 157
  STRUCTURE AND OPERATION 1. Fuel System (Flow of Fuel) • The feed pump, which is driven by the camshaft inside the supply pump, draws up the fuel from inside the fuel tank and sends it through the fuel filter, where dust and other impurities in the fuel are filtered out. •…
• Page 158
  STRUCTURE AND OPERATION 2. Engine Control • The engine is electronically controlled by the engine electronic control unit. • By processing accelerator pedal posi- tion data from the accelerator position sensor, the engine electronic control unit controls the injectors for optimum fuel injection.
• Page 159
  3. Fuel Filter • The fuel filter, which also serves as a water separator, removes impurities in the fuel through the filter element and also separates water from fuel. • The water that has been separated from the fuel collects at the bottom of the fuel filter. A water separator sensor is installed in the fuel filter, which activates the warning lamp on the meter cluster when the water reaches a cer- tain level.
• Page 160
  TROUBLESHOOTING Symptoms Reference Gr Possible causes Electronic control fuel system faulty O Gr13E Feed pump check valve faulty Defective feed pump Defective sealing supply pump overflow valve Supply pump Open or short circuit failure, poor contact of supply pump magnetic valve Defective supply pump magnetic valve, defec- tive base supply pump Open or short circuit failure, poor contact of…
• Page 161
  Symptoms Reference Gr Possible causes Oil viscosity unsuitable Gr12 Valve clearance incorrect Defective cylinder head gasket Wear of and/or carbon deposits on valve and valve seat Distorted valve springs Gr11 Worn or damaged piston rings Worn or damaged piston ring groove Worn piston and/or cylinder liner Poorly functioning cooling system Gr14…
• Page 162
  ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspecting and Adjusting No-load Minimum and Maximum Speeds Service standards Location Maintenance item Standard value Limit Remedy – Minimum no-load speed (idling speed) 650 ± 25 rpm – Adjust – Maximum no-load speed 3100 ± 50 rpm –…
• Page 163
  2. Air-bleeding of Fuel System Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Plug 10 ± 2 {1 ± 0.2} – • Loosen one of the air vent plugs on the fuel filter. • Move the priming pump up and down to pump out the fuel. •…
• Page 164
  ON-VEHICLE INSPECTION AND ADJUSTMENT 3. Fuel Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Water separator sensor 5 ± 1 {0.5 ± 0.1} – – Case 30 ± 2 {3.1 ± 0.2} –…
• Page 165
  • Apply a thin coat of engine oil to the O-ring, and install it on the case and water separator sensor. CAUTION • Be sure to use only genuine MITSUBISHI filter elements. The use of non-genuine fuel filters can cause engine failure. • Prevent fine dust particles from entering the fuel filter and fuel hose, as they can cause problems such as faulty fuel injection.
• Page 166
  FUEL TANK <170L> Removal sequence 1 Drain plug 6 Fuel level sensor 2 Suction hose 7 Fuel tank band 3 Return hose 8 Fuel tank 4 Air vent tube 9 Fuel tank bracket 5 Air vent tube Installation sequence Follow the removal sequence in reverse. DANGER •…
• Page 167
  <100L> Removal sequence 1 Drain plug 2 Suction hose 3 Return hose 4 Air vent tube 5 Plug <Without spare fuel tank> 6 Fuel level sensor 7 Fuel tank band 8 Fuel tank 9 Fuel tank bracket : Non-reusable parts Installation sequence Follow the removal sequence in reverse.
• Page 168
  SPARE FUEL TANK Removal sequence 1 Fuel hose 7 Fuel tank bracket 2 Fuel cock 8 Fuel hose bracket 3 Gasket 4 Connector a: Main fuel tank 5 Fuel tank band : Non-reusable parts 6 Fuel tank Installation sequence Follow the removal sequence in reverse. DANGER •…
• Page 169
  M E M O 13-15…
• Page 170
  FUEL FILTER Disassembly sequence 1 Fuel hose 2 Water separator sensor 3 O-ring 4 Case 5 O-ring 6 Filter element 7 Plug 8 Fuel filter head : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. WARNING • Fuel is highly flammable. Keep it away from flames and sources of heat.
• Page 171
  • Apply a thin coat of engine oil to the O-ring, and install it on the case and water separator sensor. CAUTION • Be sure to use only genuine MITSUBISHI filter elements. The use of non-genuine fuel filters can cause engine failure. • Prevent fine dust particles from entering the fuel filter and fuel pipe, as they can cause problems such as faulty fuel in- jection.
• Page 172
  FUEL FILTER • Use to tighten the case to the specified torque. • Install the water separator sensor, and then air-bleed the fuel system. • Start the engine, and check that there is no fuel leakage. • Reinstall the fuel filter if there is any leakage. 13-18…
• Page 173
  M E M O 13-19…
• Page 174
  ENGINE CONTROL Removal sequence 1 Accelerator pedal (See later sec- tions.) 2 Accelerator link (See later sec- tions.) Installation sequence Follow the removal sequence in reverse. Removal procedure Removal: Accelerator pedal • Using pliers, pinch the hook of the stopper on the accelerator pedal.
• Page 175
  Accelerator Pedal Disassembly sequence 1 E-ring 2 Clevis pin 3 Accelerator pedal 4 Stopper bolt 5 Accelerator pedal bracket Assembly sequence Follow the disassembly sequence in re- verse. Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Accelerator pedal and bracket contact surfaces Chassis grease [NLGI No.
• Page 176
  ENGINE CONTROL Accelerator Linkage Disassembly sequence 1 Cover 2 Spring 3 Washer 4 Bushing 5 Return spring 6 Accelerator lever 7 Accelerator position sensor and accelerator switch assembly 8 Lever stopper 9 Rubber stopper 10 Accelerator link bracket Assembly sequence Follow the disassembly sequence in re- verse.
• Page 177
  M E M O 13-23…
• Page 178
  COMMON RAIL Disassembly sequence 1 Injection pipe 11 Eyebolt 2 Fuel pipe 12 Fuel suction pipe A 3 Eyebolt 13 Eyebolt 4 Fuel return pipe B 14 Fuel return pipe A 5 Fuel pressure sensor (See Gr13E.) 15 Eyebolt 6 Common rail 16 Fuel return pipe C 7 Fuel temperature sensor 17 Adaptor…
• Page 179
  Tightening torque (Unit: N·m {kgf·m}) Location Parts to be tightened Tightening torque Remarks Injection pipe 40.5 ± 2.5 {4.1 ± 0.25} – Fuel pipe Bolt (adaptor mounting) 44.5 {4.5} – Bolt (common rail mounting) 23.2 {2.4} – Fuel temperature sensor 17.6 to 21.5 {1.8 to 2.2} –…
• Page 180
  COMMON RAIL Installation procedure Installation: Injection pipe and fuel pipe • Ensure that the pipe and mounting surfaces of the connector are flat and free from damage. • Bring the pipe into intimate contact with mounting surfaces of the connector evenly, and temporarily tighten it without applying an excessive force.
• Page 181
  M E M O 13-27…
• Page 182
  SUPPLY PUMP 13-28…
• Page 183
  Removal sequence 1 Eyebolt 8 Thrust plate 15 Key 2 Oil pipe 9 No. 2 idler gear 16 Supply pump 3 Eyebolt 10 No. 2 idler shaft 17 O-ring 11 Nut 4 Fuel return pipe C 5 Fuel pipe 12 Supply pump gear a: Front case 6 Eyebolt (with gauze filter) 13 Flange plate…
• Page 184
  SUPPLY PUMP Installation procedure Installation: Supply pump • Remove the rocker cover. • Bring the No. 1 cylinder piston to the top dead center (TDC) on the compression stroke by the following procedure: • Hook on a groove in the fan pulley. •…
• Page 185
  M E M O 13-31…
• Page 186
  INJECTOR Disassembly sequence 1 Snap ring 5 Injector 2 Fuel return hose 6 O-ring 3 Injection pipe 7 Nozzle tip gasket 4 Bolt (with hexagonal hole) : Non-reusable parts WARNING • Fuel is highly flammable. Wipe up spilled fuel to avoid the risk of fire. •…
• Page 187
  Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Injection pipe 40.5 ± 2.5 {4.1 ± 0.25} – Bolt (injector mounting) 5.2 to 7.2 {0.53 to 0.73} – Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil…
• Page 188
  GROUP 13E ENGINE CONTROL SYSTEM SPECIFICATIONS…………..(See Gr13.) STRUCTURE AND OPERATION ………………13E-2 1. Overview …………13E-11 2. Electronic Control System ……13E-16 3. Electronic Control Unit Connection Diagram TROUBLESHOOTING ……..13E-18 1. Inspections Based on Diagnosis Codes ……….. 13E-52 2. Multi-Use Tester Service Data ……..
• Page 189
  STRUCTURE AND OPERATION 1. Overview • In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, throt- tle opening, coolant temperature, etc.) using information from sensors. In accordance with these data, the elec- tronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in order to optimize the engine’s operation.
• Page 190
  • When the engine is cranked by means of the starter switch, the feed pump (this is located inside the supply pump) simultaneously draws fuel from the fuel tank and feeds it via the fuel filter to the MPROP (rail pressure control valve).
• Page 191
  STRUCTURE AND OPERATION 1.1 Supply pump 13E-4…
• Page 192
  CAUTION • Be sure to connect the MPROP (rail pressure control valve) connector to the engine harness before start- ing the engine. If the engine were started with the MPROP connector not connected, control of the supply pump by the engine electronic control unit would not be possible and a fault would ensue. •…
• Page 193
  STRUCTURE AND OPERATION (1) MPROP (rail pressure control valve) • The MPROP receives fuel from the feed pump and feeds fuel to- ward the plungers of the supply pump in such a quantity that the fuel pressure corresponds to that required by the engine elec- tronic control unit.
• Page 194
  1.2 Common rail • The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump. • Each flow limiter prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of fuel leakage from the injection pipe or excessive injection of fuel from the injector.
• Page 195
  STRUCTURE AND OPERATION 1.3 Injector • In accordance with electrical signals from the engine electronic control unit, each injector supplies high-pressure fuel from the common rail to the relevant combustion chamber of the engine at the optimal timing and in the opti- mal quantity.
• Page 196
  (5) Operation (5.1) Injection not taking place • With the magnet not energized, the ar- mature plate is pushed up by the valve spring such that the ball seat is closed. • The high-pressure fuel acts upon the control chamber via orifice Z. The same pressure acts upon the nozzle needle.
• Page 197
  STRUCTURE AND OPERATION (5.3) End of injection • When energization of the magnet is stopped, the armature plate is pushed downward by the valve spring such that the ball seat closes. At this time, fuel flows into the control chamber via orifice Z, pushing down the valve pis- ton and nozzle needle such that injec- tion finishes.
• Page 198
  2. Electronic Control System 2.1 System block diagram 13E-11…
• Page 199
  STRUCTURE AND OPERATION Part Main function/operation Engine speed sensor Sensing of engine speed Cylinder recognition sensor Cylinder recognition Water temperature sensor Sensing of coolant temperature Boost pressure sensor Sensing of boost pressure Common rail pressure sensor Sensing of common rail pressure Fuel temperature sensor Sensing of fuel temperature Intake air temperature sensor 1…
• Page 200
  2.2 Fuel injection control (1) Pilot injection • Pilot injection entails the injection of an extremely small amount of fuel ahead of the main injection. • Pilot injection suppresses heat generation early in the injection cycle and thus suppresses NOx generation and noise at the start of combustion.
• Page 201
  STRUCTURE AND OPERATION (4) Fuel injection rate adjustment resistor correction amount • To limit inconsistency in the injection quantity, the injection quan- tity is corrected by the fuel injection rate adjustment resistor. 2.4 Fuel injection timing control (1) Main injection timing •…
• Page 202
  2.7 Auxiliary brake function Input signals Output signals Engine electronic control unit Accelerator pedal position sensor Exhaust shutter 3-way Auxiliary brake Clutch switch magnetic valve function Transmission neutral switch Exhaust brake switch • The auxiliary brake function activates or deactivates the exhaust shutter 3-way magnetic valve according to the vehicle condition to control the exhaust brake.
• Page 203
  STRUCTURE AND OPERATION 3. Electronic Control Unit Connection Diagram Engine electronic control unit STARTER SW(S) Starter switch STARTER SW(M)-1 M F S STARTER SW(M)-2 LOCK ELECTRONIC CONTROL UNIT POWER(+VB)-1 ELECTRONIC CONTROL UNIT POWER(+VB)-2 ELECTRONIC CONTROL UNIT POWER(+VB)-3 START GND(POWER GND) GND(POWER GND) GND(ANALOG GND) Fuse box…
• Page 204
  To Starter relay Engine electronic control unit Safety relay Clutch switch Transmission neutral switch Torque limit switch Exhaust brake switch (Diagnosis code display: Auxiliary Brake SW 1) Exhaust shutter 3-way magnetic valve (Diagnosis code display: Auxiliary Brake PWR Service data and actuator test display: Auxiliary Brake M/V 1) Glow drive relay To Glow plug Glow relay…
• Page 205
  TROUBLESHOOTING 1. Inspections Based on Diagnosis Codes 1.1 Diagnosis code list • Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different. • The Multi-Use Tester is capable of showing more detailed diagnosis codes. •…
• Page 206
  Multi-Use Tester indication Warning lamp indication Remarks Code Message Flashes Orange P0267 Injector #3-A (Low) – P0268 Injector #3-A (High) – P0270 Injector #4-A (Low) – P0271 Injector #4-A (High) – P0335 Engine Revolution SNSR – P0339 Engine Revolution SNSR (Plausi) P0340 Camshaft Position SNSR –…
• Page 207
  TROUBLESHOOTING Multi-Use Tester indication Warning lamp indication Remarks Code Message Flashes Orange P0698 Sensor Supply Voltage 3 (Low) – P0699 Sensor Supply Voltage 3 (High) – P1171 Q Adjustment Resistor (Low) – P1172 Q Adjustment Resistor (High) – P1C01 Inter Cooler Performance –…
• Page 208
  1.2 Diagnosis code generation conditions and inspection items P0016: Ne SNSR Offset/Backup Mode (warning lamp flashes: 14) There is too large difference between engine speed sensor signal and cylinder Generation condition recognition sensor signal. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 209
  TROUBLESHOOTING P0047: VGT Actuator (Low) (warning lamp flashes: 51) Generation condition Turbocharger actuator circuit is shorted to ground. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 210
  P0089: MPROP (Over Load) (warning lamp flashes: 63) Generation condition MPROP (rail pressure control valve) circuit is overloaded. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 211
  TROUBLESHOOTING P0093: CRS (Fuel Leak) (warning lamp flashes: 22) Generation condition Fuel system is leaking (significant leakage). System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 212
  P0112: INT Air Temp. SNSR (Low) (warning lamp flashes: 44) Intake air temperature sensor 1 voltage is at or below the specified value Generation condition (0.15 V). System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 213
  TROUBLESHOOTING P0118: Water Temp SNSR (High) (warning lamp flashes: 21) Generation condition Water temperature sensor voltage is at or above the specified value (4.8 V). System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 214
  P0191: CRS Pressure SNSR (Plausibility) (warning lamp flashes: 11) Engine electronic control unit has judged that common rail pressure sensor was Generation condition faulty. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 215
  TROUBLESHOOTING P0202: Injector M/V-Cylinder 2 (Load) (warning lamp flashes: 38) Generation condition Injector magnetic valve (No. 2 cylinder) circuit shorted or open-circuited. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 216
  P0234: Over Boost (warning lamp flashes: 54) Generation condition Boost pressure is more than a regulated value the engine running. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid sig- nals are input).
• Page 217
  TROUBLESHOOTING P0261: Injector #1-A (Low) (warning lamp flashes: 37) Generation condition Injector magnetic valve (No. 1 cylinder) circuit shorted to ground. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 218
  P0267: Injector #3-A (Low) (warning lamp flashes: 39) Generation condition Injector magnetic valve (No. 3 cylinder) circuit shorted to ground. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 219
  TROUBLESHOOTING P0335: Engine Revolution SNSR (warning lamp flashes: 15) Generation condition No engine speed sensor signals are received. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
• Page 220
  P0380: Relay for Glow Relay (warning lamp flashes: 26) Generation conditions Glow drive relay short or open circuit, or overload Recoverability System recovers if signal becomes with starter switch ON position. Control effected by electronic control unit • Suspend glow control •…
• Page 221
  TROUBLESHOOTING P0403: EGR 1 (Actuator Circuit) (warning lamp flashes: 67) Exhaust gas recirculation electronic drive unit has judged that exhaust gas recir- Generation condition culation valve motor was faulty. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  P040D: EGR Gas Temp Sensor (High) (warning lamp flashes: 9) Generation condition Intake air temperature sensor 2 voltage is at or above the specified value (4.8 V). System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  TROUBLESHOOTING P0478: Exhaust Brake PWR (High) (warning lamp flashes: 93) Generation condition Exhaust shutter 3-way magnetic valve circuit is shorted to power supply. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input).
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  P0563: Power Supply Voltage (High) (warning lamp flashes: 33) Generation condition Battery voltage is too high. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  TROUBLESHOOTING P0615: Starter Safety Relay (Over Load) (warning lamp flashes: 48) Generation conditions Safety relay overload Recoverability System recovers if signal becomes with starter switch ON position. Control effected by electronic control unit • Normal control • Short-circuited harness between engine electronic control unit and safety re- Possible causes •…
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  P062D: Injector Bank 1 (warning lamp flashes: 82) Injector magnetic valve (for No. 1 and No. 4 cylinders) has stopped functioning Generation condition temporarily. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input).
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  TROUBLESHOOTING P0643: Sensor Supply Voltage 1 (High) (warning lamp flashes: 81) Engine electronic control unit internal voltage (sensor supply voltage 1) is higher Generation condition than specification. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  P0653: Sensor Supply Voltage 2 (High) (warning lamp flashes: 81) Engine electronic control unit internal voltage (sensor supply voltage 2) is higher Generation condition than specification. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  TROUBLESHOOTING P0687: EDU Relay (High) (warning lamp flashes: 84) Generation condition Electronic drive unit relay circuit shorted to power source. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  P1172: Q Adjustment Resistor (High) (warning lamp flashes: 34) Generation condition Voltage of fuel injection rate adjustment resistor is too high (above 4.8 V). System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input).
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  TROUBLESHOOTING P1C13: Injector #3-A (Plausibility) (warning lamp flashes: 39) The engine electronic control unit has judged that injector magnetic valve (for No. Generation condition 3 cylinder) was faulty in comparison with the condition of other injector magnetic valves. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input).
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  P2101: TVA (System) (warning lamp flashes: 28) The throttle electronic drive unit has judged that the power supply to intake throt- Generation condition tle was faulty or the throttle position sensor was faulty. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  TROUBLESHOOTING P2123: Acc Sensor 1 (High) (warning lamp flashes: 24) Accelerator pedal position sensor 1 voltage is at or above the specified value Generation condition (4.7 V). System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  P2138: Acc Sensor Correlation (warning lamp flashes: 24, 58) Output voltages from accelerator pedal position sensors 1 and 2 are out of spec- Generation condition ified range or result of comparison between two voltages deviates from specifica- tion. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  TROUBLESHOOTING P2151: Injector Bank 2 (High) (warning lamp flashes: 82) Generation condition Injector magnetic valve (No. 2 and No. 3 cylinder) circuit shorted to power supply. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  P2229: Atm Press SNSR (High) (warning lamp flashes: 19) Voltage of atmospheric pressure sensor (inside engine electronic control unit) is Generation condition higher than specification (4.7 V). System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  TROUBLESHOOTING P242F: DPF MFF (Accumulation) (warning lamp flashes: 55) Generation condition The voltage of diesel particulate filter pressure sensor is excessively high. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  P2562: VGT Position Sensor (warning lamp flashes: 51) Turbocharger electronic drive unit determines the turbocharger position sensor to Generation condition be faulty. System recovers if any valid signal is input when starter switch is turned from Recoverability OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input).
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  TROUBLESHOOTING 2. Multi-Use Tester Service Data • It is possible to see service data and actuator tests simultaneously. Item Data Inspection condition Requirement Value corresponds to ta- 01 Engine Revolution Racing (engine running) .rpm chometer indication. 02 LOAD Value Starter switch in ON position 0A Reference Injection Quantity Starter switch in ON position Altitude: 0 m…
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  Item Data Inspection condition Requirement Engine cranked by means of starter switch. A0 Starter SW (S) ON/OFF Starter switch in position except START Starter switch in ON position A1 Starter SW (M) ON/OFF Starter switch in position except ON Accelerator pedal not pressed A2 Accel SW ON/OFF Accelerator pedal pressed…
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  TROUBLESHOOTING Item Data Inspection condition Requirement Starter switch ON (engine not started) E0 MIL ON/OFF No error after engine startup [Actuator test] B0: MIL Starter switch ON (engine not started) E1 Diagnosis Lamp ON/OFF No error after engine startup [Actuator test] B1: Diagnosis Lamp 13E-54…
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  3. Actuator Test Using Multi-Use Tester • It is possible to see service data and actuator tests simultaneously. Item Explanation Confirmation method Maintain exhaust gas recirculation valve opening indicated Check that the exhaust gas by Multi-Use Tester during engine operation. recirculation valve opening [Can be executed when the following conditions are satisfied] is changed.
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  TROUBLESHOOTING Item Explanation Confirmation method Starter safety relay drive signal Actuation noise should be heard. [Service data] D3: Starter Safety Relay AE Starter Safety Relay Electronic drive unit relay drive signal Operating sound of relay AF EDU Relay (Errors related to exhaust gas recirculation and to the intake [Service data] throttle can be detected when this actuator test is executed.) D4: EDU Power Relay…
• Page 244
  4. Work When Replacing the Engine Electronic Control Unit • A vehicle identification number (VIN) must be written (registered) to the engine electronic control unit after: • The current engine electronic control unit is replaced with a new one. • The current engine electronic control unit is replaced with one that has been used on another vehicle. Writing a VIN (entire flow) Connect the Multi-Use Tester (See Gr00).
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  TROUBLESHOOTING • A system test automatically starts and “INCOMPLETE” is indi- cated. This raises no problem because VIN writing is incomplete at this stage. Click the OK button. (2) Writing a VIN [ENGINE menu] window • Select “Coding”. [Coding] window •…
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  [Write error] window • An error is displayed if a VIN is entered while the engine is on or the transmission is set at a position except Neutral. If so, stop the engine or set the transmission to the Neutral position, and restart from the beginning.
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  TROUBLESHOOTING (4) Confirming and deleting the diagnosis code (memory clear) [ENGINE menu] window • Select “Self-diagnosis.” [Self-diagnostic] window • Check the “Pending DTC” field for generation of a diagnosis code. • Click the “Confirmed/Stored DTCs” button. • Check the “Confirmed/Stored DTCs” field for generation of a di- agnosis code.
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  5. Electronic Control Unit Input/Output Table • For terminal locations of each signal and ground. See the Electronic control unit connection diagram. Hardware to be connected Terminal Input/Output Voltage or waveform [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side con- nector.
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  TROUBLESHOOTING Hardware to be connected Terminal Input/Output Voltage or waveform [Conditions] • Starter switch ON • Vehicle-side harness connected (Perform inspection on back A20-B33 Accelerator pedal switch Output of connector.) A20-B45 [Requirements] • With accelerator pedal pressed: 0 V • With accelerator pedal not pressed: 5 V [Conditions] •…
• Page 250
  Hardware to be connected Terminal Input/Output Voltage or waveform [Conditions] • Starter switch ON • Vehicle-side harness connected (Perform inspection on back Electronic drive unit relay B39-B14 Output of connector.) [Requirements] • With relay operating: Corresponding to battery voltage • With relay not operating: 0 V [Conditions] •…
• Page 251
  GROUP 14 COOLING SPECIFICATIONS…………….14-2 STRUCTURE AND OPERATION ……….14-4 1. Cooling System (Flow of Coolant) ………………. 14-5 2. Thermostat ……………… 14-5 3. Water Pump TROUBLESHOOTING ……………. 14-6 ON-VEHICLE INSPECTION AND ADJUSTMENT ……..14-8 1. Inspection and Adjustment of Belt Tension ……..
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  SPECIFICATIONS Item Specifications Cooling system Forced water circulation system Water pump Belt-driven involute type Thermostat Wax pellet, bottom bypass type (with jiggle valve) Automatic cooling fan coupling Continuous control type Radiator Tube and corrugated fin type Coolant capacity 16 {16} 14-2…
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  M E M O 14-3…
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  STRUCTURE AND OPERATION 1. Cooling System (Flow of Coolant) 14-4…
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  2. Thermostat • It is a bottom bypass type that uses a wax-filled pellet as its flow-regulating element. When the wax is heated, it melts from solid to liquid, changing its total volume. This allows the valve to open or close in accordance with the coolant temperature, regulating and adjusting the flow of coolant to the ra- diator and to the cylinder head (by-…
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  TROUBLESHOOTING Symptoms Reference Gr Possible causes Loose or damaged Belt Excessive tension Oil on belt Incorrectly mounted water pump Defective gasket Defective unit bearing Water pump Defective impeller Defective unit seal Too loose fit of unit bearing on flange and impeller Incorrectly mounted case Valve opening temperature too high Thermostat…
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  Symptoms Reference Gr Possible causes Poor installation of breather cover Breather cover Poor installation of gaskets Gr17 Damaged O-rings Tension pulley Poor installation of bearing Poorly airtight pressure cap Insufficient coolant amount Clogged or scaled coolant passage Incorrectly connected hoses Poor installation of pipes Excessively low exterior temperature 14-7…
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  ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection and Adjustment of Belt Tension CAUTION • Make sure that there is no oil or grease on the belts. Belts soiled with oil or grease may easily slip, result- ing in deteriorated performance of the cooling system. Service standards (Unit: mm) Location Maintenance item…
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  • Place at a central portion between pulleys of the belt and push the handle (indicated by the arrow in the illustration) until the O-ring touches the flange. • Measure the amount of deflection of the belt. • If the measured value deviates from the standard value range, adjust the tension of the belt as follows.
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  ON-VEHICLE INSPECTION AND ADJUSTMENT • Enter the unit mass of the belt and push “ (means “exe- cute”)”. Measuring point on the belt Unit mass of the belt 0.016 kg/m • Select the type of the belt. (Select “3” for ribbed belt.) •…
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  • Set the sensor microphone of approx. 10 mm above the belt, at the middle position between pulleys. • Tap the belt lightly with a grip of a screwdriver to vibrate the belt. • Measure the tension a few times and calculate the average val- •…
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  ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Inspection of Cracks or Damage of the Belt • Visually check the belts for possible cracks and damage. • If any faults are found, replace the belts. Belt condition Remaining service life (reference) • The driving distance over the which the belt can still be used is at least as long as that over which the belt has been used since the…
• Page 263
  3. Coolant Replacement and Cleaning of Cooling System Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks – Radiator drain cock 2.0 {0.2} – – Water drain plug 25 ± 5 {2.5 ± 0.5} – • Using the radiator for extended periods of time without cleaning can increase chance of rust and scale formation, which may cause engine overheating.
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  ON-VEHICLE INSPECTION AND ADJUSTMENT • Select an appropriate cleaning method according to the condition of the cooling system as shown below. • Ordinary condition • Coolant extremely dirty • Radiator clogged Cleaning using radiator cleaner. Flushing with water. Drain out coolant. Make water solution of radiator cleaner at 5 to 10% concentration in volume.
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  4. Air Bleeding of Cooling System • With the pressure cap removed and the coolant temperature at 90°C, let the engine idle in order to bleed air com- pletely out of the cooling system. • After air bleeding is completed, refill the reservoir tank with coolant as needed. 5.
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  DISCONNECTION AND CONNECTION OF HOSES AND PIPES 14-16…
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  14-17…
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  DISCONNECTION AND CONNECTION OF HOSES AND PIPES Removal sequence 1 Upper radiator hose 14 O-ring 27 Radiator pipe 2 Lower radiator hose 15 Water hose 28 Radiator hose 3 Heater hose 16 Water hose 4 Heater pipe 17 Water pipe a: Radiator 5 Heater hose 18 Eyebolt…
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  M E M O 14-19…
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  RADIATOR Removal sequence 1 Upper shroud 7 Baffle plate upper 13 Radiator drain cock 2 Lower shroud 8 Baffle plate RH 14 O-ring 3 Baffle plate RH 9 Baffle plate LH 15 Radiator support cushion 4 Baffle plate RH 10 Support rod 16 Radiator 5 Baffle plate LH 11 Support cushion…
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  Service standards Location Maintenance item Standard value Limit Remedy Air leakage from radiator – 0 cm {0 mL} – Repair or replace (air pressure 177 kPa {1.77 kgf/cm Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (upper shroud mounting) 5 to 7 {0.5 to 0.7}…
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  COOLING FAN, BELT AND WATER PUMP Removal sequence 1 Cooling fan 4 Water pump a: Alternator 2 Automatic cooling fan coupling 5 Gasket b: Tension pulley 3 Belt 6 Fan pulley : Non-reusable parts • The automatic cooling fan coupling and the water pump cannot be disassembled. It must be replaced if defective. Installation sequence Follow the removal sequence in reverse.
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  Special tools (Unit: mm) Mark Tool name and shape Part No. Application Holding bar MH062970 Holding of fan pulley φ9 Inspection and cleaning procedure Inspection: Automatic cooling fan coupling • Make an inspection of the following points. Replace the automat- ic cooling fan coupling if defective.
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  COOLING FAN, BELT AND WATER PUMP Installation procedure Installation: Fan pulley • Put in position on the studs of the fan pulley and fix the tool by using nuts. • Tighten the fan pulley mounting nut to the specified torque while holding 14-24…
• Page 275
  TENSION PULLEY Disassembly sequence 1 Sleeve 2 Snap ring 3 Bearing 4 Tension pulley 5 Spacer 6 Shaft 7 Tension pulley bracket Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Sleeve…
• Page 276
  THERMOSTAT Disassembly sequence 1 Thermostat cover 2 Thermostat a: Oil cooler Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Valve opening temperature 82 ± 2°C Thermostat – Replace Valve lift at 95°C 10 or more Inspection procedure…
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  M E M O 14-27…
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  PRESSURE CAP AND WATER OUTLET CASE Disassembly sequence 1 Pressure cap 6 Clip a: Vacuum hose 2 Clip 7 Water hose b: Breather cover 3 Eyebolt 8 Water outlet case : Non-reusable parts 4 Water pipe 9 Gasket 5 Water pipe Assembly sequence Follow the disassembly sequence in reverse.
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  Inspection procedure Inspection: Pressure cap (1) Pressure valve opening pressure • Replace the pressure cap if the measured value deviates from the standard value range. (2) Inspection of vent valve • Before starting the inspection, check the level of coolant in the reservoir tank.
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  GROUP 15 INTAKE AND EXHAUST SPECIFICATIONS…………….15-2 STRUCTURE AND OPERATION ………………15-2 1. Air Cleaner …………….15-3 2. Turbocharger …………..15-4 3. Exhaust Shutter Valve …………..15-4 4. Diesel Particulate Filter TROUBLESHOOTING ……………. 15-5 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measurement and Adjustment of Turbocharger Boost ………………
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  Item Specifications Air cleaner element type Filter paper type Model TD04 Turbocharger Manufacturer Mitsubishi Heavy Industries, Ltd. Cooling system Water-cooled Intercooler type Tube and corrugated fin air cooled type Diesel particulate filter type Continuous regeneration type (PM-CAT) STRUCTURE AND OPERATION 1.
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  2. Turbocharger • TD04 model is equipped with turbocharger, which is a variable nozzle vane type turbocharger with adjustable, heat-resistive alloy turbine vanes provided at the turbine exhaust gas inlet port. 15-3…
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  STRUCTURE AND OPERATION 3. Exhaust Shutter Valve • When a driver turns on the exhaust brake switch, the engine electronic control unit sends a signal to the ex- haust shutter 3-way magnetic valve. This turns on the exhaust shutter 3- way magnetic valve, and the valve ap- plies the vacuum pressure from the vacuum tank to the exhaust shutter…
• Page 284
  TROUBLESHOOTING Symptoms Reference Possible causes Air cleaner Clogged air cleaner element Defective cartridge assembly Turbocharger Compressor cover fitted poorly Foreign substances deposited on intercooler Intercooler front core Butterfly valve does not open Throttle actuator Gr13E Butterfly valve malfunction Front pipe/diesel particulate filter/tail pipe deformed Front pipe/diesel particulate filter/tail pipe fitted poorly Incorrect valve clearances Head gasket defective…
• Page 285
  ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measurement and Adjustment of Turbocharger Boost Pressure CAUTION • If boost pressure exceeds the standard value, the engine may malfunction or break down. Boost pressure must be within the specified range. Service standards Location Maintenance item Standard value Limit Remedy…
• Page 286
  [Calculation of boost pressure correction value] • Obtain the boost pressure correction value using the following equation. Boost pressure correction value = Measured boost pressure – intake air temperature correction value – atmospheric tempera- ture correction value • If boost pressure correction value deviates from the standard value, adjust the turbocharger.
• Page 287
  ON-VEHICLE INSPECTION AND ADJUSTMENT 1.3 Turbocharger adjustments • Follow the flow chart below when adjustments become necessary on the turbocharger. <Inspection and adjustment sequence> Measure boost pressure Check for contact between control crank and position bolt (see (1) given later) If control crank fails to contact position If control crank contacts position bolt bolt (see (2) given later)
• Page 288
  (1) Checking contact between control crank and position bolt • Start the engine. • Stop the engine. Set the starter switch to the [ON] position within 40 seconds. • Select [A5: EGR, ETV, VGT] from [Actuator Test] on the Multi- Use Tester screen.
• Page 289
  ON-VEHICLE INSPECTION AND ADJUSTMENT <Position bolt length adjustment> • Loosen the lock nut. • Using a hexagon wrench, turn the position bolt in illustrated di- rections to bring it into a position clear of the control crank. Adjusting guide: With the engine running at 2500 rpm, one full turn of the position bolt increases boost pressure by approxi- mately 3 kPa.
• Page 290
  <Actuator shaft length adjustment> • Remove snap rings and pins on the actuator side of the shaft. • Loosen the lock nut. Turning the joint part, extend the shaft until the control crank contacts the position bolt. Adjusting guide: Shaft length changes by 1 mm with one turn of the joint.
• Page 291
  ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Cleaning and Inspection of Air Cleaner Element [Cleaning] • Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm } against the inside surfaces of the element. • Move the compressed air jet up and down along all pleats of the filter paper element.
• Page 292
  6. Loose Turbocharger • Remove the bolts, loosen the clamp securing the air hose and turbocharger and remove the air hose. • Turn the compressor wheel by turning the shaft tip with fingers. Check that the compressor wheel rotate smoothly without touch- ing the compressor.
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  AIR DUCT AND AIR CLEANER Disassembly sequence 1 Air inlet duct 8 Mesh filter a: Turbocharger 2 Connector 9 Intake air temperature sensor b: Positive crankcase ventilation 3 Air hose 10 Air box hose B 4 Insulator 11 Rubber seal : Non-reusable parts 5 Air duct 12 Air cleaner cap…
• Page 294
  Cleaning procedure Cleaning: Element • Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm } against the inside surfaces of the element. • Move the compressed air jet up and down along all pleats of the filter paper element.
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  AIR DUCT AND AIR CLEANER Installation: Air box • Align slit of air box with key of air cleaner case. Installation: Connector • The protruding portion of the connector is put between clamps. • Installation is such that the space between the connector and the air cleaner case measures the amount shown in the figure.
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  M E M O 15-17…
• Page 297
  TURBOCHARGER Removal sequence 1 Air hose 16 Gasket 2 Air inlet hose 17 Front pipe 3 Turbocharger coupler 18 Gasket 4 Gasket 19 Exhaust coupler 5 Insulator 20 Gasket 6 Eyebolt 21 Eyebolt 7 Oil pipe 22 By-pass pipe 8 Eyebolt 23 Spacer 9 Water pipe 24 Bracket…
• Page 298
  Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Clamp 3 to 3.4 {0.3 to 0.35} – Clamp 3.9 to 4.9 {0.4 to 0.5} – Bolt (turbocharger coupler mounting) Bolt (insulator mounting) 23.8 {2.4} – Bolt (exhaust coupler stay mounting) Nut (front pipe mounting) 45 to 60 {4.6 to 6.1} –…
• Page 299
  TURBOCHARGER Turbocharger Removal sequence 1 Snap ring 8 Position bolt 2 Pin 9 Snap ring 3 Lever 10 Compressor cover 4 Joint 11 Turbine assembly 5 Lock nut 6 Actuator : Non-reusable parts 7 Lock nut NOTE • Do not remove the joint and position bolt from the actuator and turbine assembly unless they are defec- tive.
• Page 300
  Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy Pin outer diameter Replace 8 8.5 Lever inner diameter Replace 8 8.5 Joint inner diameter Replace Actuator shaft stroke 18.5 to 21 18.4 Replace Play in shaft axis direction of turbine assembly 0.39 to 0.67 –…
• Page 301
  TURBOCHARGER Inspection procedure Inspection: Play in shaft axis direction of turbine assembly • With the flange of the turbine assembly attached to a flat plate, measure the play with a dial gauge. • If the measurement exceeds the specified limit, replace the tur- bine assembly.
• Page 302
  Inspection: Actuator shaft stroke • Conduct the actuator check with the turbocharger electronic drive unit mounted on the vehicle. • Mark the actuator shaft at the zero stroke point. • Select [A5: EGR, ETV, VGT] from [Actuator Test] on the Multi- Use Tester screen and execute it.
• Page 303
  INTERCOOLER Disassembly sequence 1 Air inlet hose 5 Air inlet pipe RH a: Air inlet duct 2 Air inlet pipe LH 6 Air inlet hose b: Turbocharger coupler 3 Air inlet hose 7 Intercooler 4 Air inlet hose CAUTION • Do not remove forcedly the air inlet hose using a screwdriver or other similar tool. Doing so could dam- age the fluorine treatment layer on the inside surface of the hose, deteriorating the resistance to oil of the hose.
• Page 304
  Inspection procedure Inspection: Intercooler • Plug one of the air ports of the intercooler and immerse it in a tank of water. Apply the specified air pressure to the intercooler through the other air port and retain pressure for 30 seconds. •…
• Page 305
  INTERCOOLER • Connect the air inlet hose to the LH air inlet pipe with the white paint on the hose aligned with the buildup on the pipe. • Connect the air inlet hoses to the intercooler, LH air inlet pipe and air inlet duct to the dimensions indicated in the illustrations.
• Page 306
  M E M O 15-27…
• Page 307
  INTAKE MANIFOLD Disassembly sequence 1 Intake throttle 6 Vacuum pipe 11 Gasket 2 Gasket 7 Air inlet pipe 3 Vacuum hose 8 Gasket : Non-reusable parts 4 Boost pressure sensor 9 Boost air temperature sensor 5 Vacuum hose 10 Intake manifold Assembly sequence Follow the disassembly sequence in reverse.
• Page 308
  Inspection procedure Inspection: Boost air temperature sensor • Check that the sensor portion is free of soot, oily substance, etc. • If not, clean the sensor portion as follows. • Spray a cleaner on the sensor portion from 2 or 3 cm away. Recommended cleaners: Nonchlorinated solvent •…
• Page 309
  EXHAUST MANIFOLD Disassembly sequence 1 Insulator 2 Under insulator 3 Exhaust gas recirculation pipe 4 Gasket 5 Distance piece 6 Exhaust manifold 7 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque…
• Page 310
  EXHAUST PIPE Disassembly sequence 1 Brace bracket 4 Exhaust shutter a: Exhaust manifold 2 Gasket (See later section.) : Non-reusable parts 3 Front pipe 5 Front pipe CAUTION • Loosen the marked bolt first to prevent undue forces from being applied to the exhaust pipe. Assembly sequence Follow the disassembly sequence in reverse.
• Page 311
  EXHAUST PIPE Exhaust Shutter Disassembly sequence 1 Cover 2 Clevis pin 3 Clevis 4 Power chamber 5 Gasket 6 Bearing 7 Lever 8 Adjust bolt 9 Bracket 10 Seal ring A 11 Seal ring B 12 Valve CAUTION • Do not attempt to disassemble the power chamber.
• Page 312
  Inspection procedure Inspection: Air-tightness of power chamber • Connect the components with piping as illustrated. Apply the specified inspection vacuum or higher to the power chamber and stop the vacuum pump. • Fifteen seconds later, the reading on the vacuum gauge should conform to the standard value.
• Page 313
  DIESEL PARTICULATE FILTER <FE85DE, FE85DG> 15-34…
• Page 314
  <Except FE85DE, FE85DG> Removal sequence 1 Pressure hose 13 Stay 2 Pressure pipe 14 Cushion rubber 3 Tail pipe 15 Bracket 4 Pressure hose 16 Collar 5 DPF differential pressure sensor 17 Cushion rubber 6 Diesel particulate filter band 18 Stay 7 Diesel particulate filter 19 Bracket 8 Gasket…
• Page 315
  DIESEL PARTICULATE FILTER Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Pressure pipe 40 {4.0} – Nut (tail pipe mounting) 26 to 33 {2.7 to 3.2} – Nut (diesel particulate filter mounting) Nut (diesel particulate filter band mounting) 20 {2.0} –…
• Page 316
  GROUP 15E TURBOCHARGER CONTROL SYSTEM SPECIFICATIONS…………..(See Gr15.) STRUCTURE AND OPERATION ………………15E-2 1. Overview …………15E-3 2. Electronic Control System ……..15E-5 3. Electronic Control Unit Wiring Diagram TROUBLESHOOTING ……(See Gr13E.) 1. Inspection Based on Diagnosis Codes ……… (See Gr13E.) 2.
• Page 317
  STRUCTURE AND OPERATION 1. Overview • In the turbocharger control system, various engine-related information (engine speed, coolant temperature, accel- erator position) and driving status are collected by the relevant sensors and are sent to the engine electronic con- trol unit and turbocharger electronic drive unit which then control the engine based on the information received. •…
• Page 318
  2. Electronic Control System 2.1 System block diagram Part Main function/operation Engine speed sensor Sensing of engine speed Cylinder recognition sensor Cylinder recognition Water temperature sensor Sensing of coolant temperature Boost pressure sensor Sensing of boost pressure Accelerator pedal position sensor Sensing of extent of accelerator pedal depression Engine warning lamp Indication of system abnormalities…
• Page 319
  STRUCTURE AND OPERATION 2.2 Turbocharger control function • In response to output data from various sensors, the engine electronic control unit determines the opening of tur- bine vanes as required by the engine operating status and sends necessary control signals to the turbocharger electronic drive unit.
• Page 320
  3. Electronic Control Unit Wiring Diagram Starter switch M F S LOCK Engine electronic START control unit Fuse box STARTER SW(M)-1 STARTER SW(M)-2 ECU POWER(+VB)-1 ECU POWER(+VB)-2 ECU POWER(+VB)-3 GND(POWER GND) GND(POWER GND) GND(ANALOG GND) SENSOR-1 SENSOR-1 Accelerator pedal position sensor SENSOR-2 SENSOR-2 High-current…
• Page 321
  GROUP 17 EMISSION CONTROL STRUCTURE AND OPERATION ……….17-2 1. Exhaust Gas Recirculation System ……….17-3 2. Crankcase Emission Control System EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER ..17-4 CRANKCASE EMISSION CONTROL SYSTEM……… 17-6 17-1…
• Page 322
  STRUCTURE AND OPERATION 1. Exhaust Gas Recirculation System • In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units con- trol the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various aspects of the engine (engine speed, intake air quantity, coolant temperature, throttle opening, etc.).
• Page 323
  2. Crankcase Emission Control System • The crankcase emission control system returns blowby gases to an air duct to prevent them from being released to the outside air. • The positive crankcase ventilation valve keeps constant the pressure inside the crankcase. 17-3…
• Page 324
  EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER Removal sequence 1 By-pass pipe 8 EGR gasket 15 O-ring 2 Connector 9 EGR valve 3 EGR pipe C 10 EGR gasket B a: Air inlet pipe 4 EGR gasket 11 EGR pipe B b: Exhaust manifold 5 EGR gasket A 12 EGR gasket…
• Page 325
  Inspection procedures Inspection: Air leakage from EGR cooler • Perform the following inspection. If any abnormality is found, re- place the exhaust gas recirculation cooler. (1) Exhaust gas passage side • Fit a cover over the exhaust gas outlet of the exhaust gas recir- culation cooler, and connect a hose to the exhaust gas inlet.
• Page 326
  CRANKCASE EMISSION CONTROL SYSTEM Removal sequence 1 Washer 7 Gasket 13 O-ring 2 Rubber bushing 8 Breather gasket a: Front case 3 Spacer 9 PCV hose B : Non-reusable parts 4 Breather cover A 10 PCV pipe PCV: Positive crankcase ventilation 5 Separator plate 11 PCV hose 6 Breather cover B…
• Page 327
  Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mating surface of breather cover A or B ThreeBond 1216 As required Installation procedures Installation: PCV hose • Install the PCV hose to the PCV pipe with the white paint on the hose and the black paint on the pipe aligned as shown in the il- lustration.
• Page 328
  GROUP 17E EXHAUST GAS RECIRCULATION SYSTEM AND DIESEL PARTICULATE FILTER SPECIFICATIONS…………..(See Gr17.) STRUCTURE AND OPERATION ………………17E-2 1. Overview …………17E-4 2. Electronic Control System ……17E-7 3. Electronic Control Unit Connection Diagram TROUBLESHOOTING ……(See Gr13E.) 1. Inspection Based on Diagnosis Codes ………
• Page 329
  STRUCTURE AND OPERATION 1. Overview 1.1 Exhaust gas recirculation system • In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units con- trol the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various aspects of the engine (engine speed, intake air quantity, coolant temperature, throttle opening, etc.).
• Page 330
  1.2 Diesel particulate filter • Diesel particulate filter is a large-ca- pacity system consisting of an ultra-ef- ficient oxidation catalyst and a filter. Diesel particulate filter is designed to efficiently break and capture PM emit- ted by engines running on low-sulfur fuel, and the filter is continuously re- generated.
• Page 331
  STRUCTURE AND OPERATION 2. Electronic Control System 2.1 System block diagram Part Main function/operation Engine speed sensor Sensing of engine speed Water temperature sensor Sensing of coolant temperature Accelerator pedal position sensor Sensing of extent of accelerator pedal depression Intake air temperature sensor 1 Sensing of intake air temperature Intake air temperature sensor 2 Sensing of boost air temperature…
• Page 332
  2.2 Exhaust gas recirculation (1) Exhaust gas recirculation valve control function • In accordance with data from sensors, the engine electronic control unit determines the exhaust gas recirculation valve opening that suits the operating condition and sends a control signal (this indicates the target exhaust gas recirculation valve opening) to the exhaust gas recirculation electronic drive unit.
• Page 333
  STRUCTURE AND OPERATION (2.1) Intake throttle • In accordance with signals from the throttle electronic drive unit, the motor opens and closes the butterfly valve, thereby adjusting the intake air amount such that the effectiveness of exhaust gas recirculation is maximized. (3) Fault diagnosis function •…
• Page 334
  3. Electronic Control Unit Connection Diagram Starter switch M F S LOCK Engine electronic control unit START STARTER SW(S) STARTER SW(M)-1 Fuse box STARTER SW(M)-2 ELECTRONIC CONTROL UNIT POWER(+VB)-1 ELECTRONIC CONTROL UNIT POWER(+VB)-2 ELECTRONIC CONTROL UNIT POWER(+VB)-3 GND(POWER GND) GND(POWER GND) GND(ANALOG GND) Engine speed sensor Accelerator pedal position sensor…
• Page 335
  ( EURO 4 ) For Colombia Shop Manual 4M5 diesel engine MARCH 2015…
• Page 336
  Pub.No.00ELT0085, MARCH 2015…

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