Valve lash on a Mitsubishi 6D24 is set at the rocker arm adjusting screw, and this 418-page Mitsubishi 6D24 shop manual PDF (OEM ID 97841-02020-00) covers that job and the whole engine across four variants of the series. Wiring diagrams map the electronic governor and timer circuits, and fault code tables give you a lookup for the electronically controlled fuel system. Chapters run from cylinder head, timing gears and crankcase through lubrication, injection pump and nozzles, cooling, turbocharger, starter, alternator, clutch and air compressor. Check oil pressure at maximum speed against 295 to 490 kPa, and fill the oil pan to approx. 27 L for general use. Refitting injection pipes? Union nuts take 29 N·m at the nozzle and 29 to 49 N·m at the pump. With bookmarks and a searchable text layer, your lash adjustment ends with the lock nut at 59 N·m and every union nut at Mitsubishi's own figure.
What's Inside This Mitsubishi 6D24, 6D24-T, 6D25-TC, 6D24-TL Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 10-23 | External View, Major Specifications, Engine Number and Caution Plate, Key Points for Maintenance Work |
| Engine | 24-93 | Cylinder Head and Valve Mechanism, Flywheel, Timing Gears, And Camshaft, Crankcase and Main Moving Parts |
| Lubrication | 94-113 | Oil Pump, Oil Filter and Oil Cooler |
| Fuel and Engine Control | 114-171 | Injection Pump Assembly, Injection Nozzle |
| Electronically Controlled Fuel System | 172-207 | Electronic Governor, Electronic Timer |
| Cooling | 208-231 | Water Pump, Fan Drive |
| Intake and Exhaust | 232-261 | Air Cleaner, Turbocharger |
| Engine Electrical | 262-375 | Starter, Alternator |
| Clutch | 376-393 | Clutch Proper, Bearing Case |
| Special Equipment | 394-418 | Air Compressor, Air Pressure Governor |
Every system also includes troubleshooting.
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Rocker arm-to-valve cap adjusting screw lock nut torque | 59 N·m (6 kgf·m) | p. 90 |
| Injection pipe union nut torque (On pump side) | 29 to 49 Nm {3 to 5 kgf-m} | p. 141 |
| Injection pipe union nut torque (On nozzle side) | 29 Nm {3 kgf-m} | p. 141 |
| Oil pressure at maximum speed | 295 to 490 kPa | p. 103 |
| Engine oil capacity (oil pan, general use) | Approx. 27 L | p. 102 |
| Engine oil capacity (oil pan, construction machinery) | Approx. 25 L | p. 102 |
| Fuel filter connector bolt torque (All except 6D24-TL) | 25 Nm {2.5 kgf-m} | p. 141 |
| Fuel filter connector bolt torque (6D24-TL) | 25 to 35 Nm {2.5 to 3.5 kgf-m} | p. 141 |
| Fuel feed pump fuel inlet side eyebolt torque | 20 to 25 Nm {2 to 2.5 kgf-m} | p. 141 |
| Fuel feed pump fuel outlet side eyebolt torque | 20 to 25 Nm {2 to 2.5 kgf-m} | p. 141 |
| Interference between pump shaft and flange | 0.05 to 0.08 mm | p. 214 |
| Interference between pump shaft and impeller | 0.03 to 0.06 mm | p. 214 |
Mitsubishi 6D24, 6D24-T, 6D25-TC, 6D24-TL Common Problems This Manual Covers
Mitsubishi 6D24 diesel engine will not start or idles rough with low compression pressure
Check valve clearance first and adjust it following page 90, then torque the rocker arm adjusting screw lock nut to 59 N·m (6 kgf·m). If compression stays low, inspect the cylinder head gasket, valves and seats for wear or carbon, valve springs, piston rings and grooves, pistons and liners. Never reuse old piston rings, and replace them only as a full set (pages 76 and 77).
Manual Section: Engine Troubleshooting p. 90Fuel feed pump check valve or gauze filter fault, engine starts but soon stops
Clean the loaded gauze filter in the feed pump, and replace an inoperative check valve, a seized or worn piston, a seized push rod or a worn tappet per the chart on page 168. Replace a loaded fuel filter and bleed out trapped air or water. Torque the feed pump inlet and outlet eyebolts to 20 to 25 N·m (2 to 2.5 kgf·m) per page 141.
Manual Section: Fuel System Troubleshooting p. 168Injection nozzle with low valve opening pressure or clogged orifice, engine knocks and smokes
Test each nozzle's 1st valve opening pressure against the value listed for your engine variant on page 140. Adjust it if low, clean a clogged injection orifice and replace a broken spring. Disassemble only when a fault is evident, and never change the nozzle and needle valve combination (page 151). Do not touch the spray from the nozzle (page 161). Reinstall nozzles at 15 N·m per page 150.
Manual Section: Fuel System Troubleshooting p. 169Oil pump, filter element or relief valve fault, oil pressure does not increase
Measure oil pressure at maximum speed against 295 to 490 kPa on page 103. If it reads low, confirm the oil pressure switch works, replace a loaded oil filter element and torque the center bolt to 59 to 69 N·m. Correct a loaded oil strainer, loose oil pump joint or cracked pipe, check the relief and bypass valves, and replace a worn oil pump.
Manual Section: Lubrication System Troubleshooting p. 112Cooling system with defective thermostat, incorrect V-belt tension or water pump fault, engine overheats
Never remove the pressure cap while coolant temperature is still very high (page 228). Replenish low coolant, then check V-belt deflection under about 98 N: 17 to 22 mm without fan drive, 10 to 15 mm with fan drive (page 214). Test the thermostat for opening at 74.5 to 78.5°C and 10 mm or more lift at 90°C. Clean radiator fins and inspect the water pump impeller and autocool fan coupling.
Manual Section: Cooling System Troubleshooting p. 231Turbocharger with worn insert piston ring or damaged oil seal, whitish heavy exhaust smoke
Rule out incorrect injection timing, low compression and poor quality fuel first. Then check the turbocharger for oil leaks past a worn piston ring or insert, measuring ring end gap in the insert against 0.05 to 0.25 mm on page 238 and replacing if out of limit. Verify shaft-and-turbine-wheel axial play at 0.075 to 0.155 mm, and clear a clogged oil return pipe before fitting a new oil seal.
Manual Section: Intake and Exhaust Troubleshooting p. 260Frequently Asked Questions
How do I reset the air cleaner dust indicator?
After the air cleaner element has been cleaned or replaced, depress the reset button on the top of the dust indicator. This will return the signal to its original position. p. 234
What are the torque specifications for the cylinder head bolts on a 6D24 engine?
The cylinder head bolts must be tightened to 175 N.m (18 kgf.m) in the specified order. After confirming this torque, each bolt must be given an extra turn of 90 to 110 degrees (1 pitch = 10 degrees). p. 50
What are the Mitsubishi 6D24, 6D24-T, 6D25-TC, 6D24-TL connecting rod cap nut and main bearing cap bolt torque specs?
The connecting rod cap nuts are tightened to 115 N.m (12 kgf.m) in a wet state. The main bearing cap bolts are tightened to 115 N.m (12 kgf.m) in a wet state, followed by an extra turn of 60 degrees. p. 34
What is the standard valve clearance for the Mitsubishi 6D24, 6D24-T, 6D25-TC, 6D24-TL engine?
The valve clearance for the inlet valve is 0.4 mm (0.016 in) and for the exhaust valve is 0.6 mm (0.024 in) when the engine is cold. p. 13
What is the engine oil capacity for the 6D24 engine?
The engine oil capacity for the oil pan is approximately 27 liters for general use, or approximately 25 liters for construction machinery. The oil filter capacity is approximately 4 to 4.5 liters. p. 102
How will I receive this Mitsubishi 6D24 Shop Manual?
One searchable PDF covering 418 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Is printing allowed for this Mitsubishi 6D24 Shop Manual?
Yes. It prints from any PDF reader, so run off the pages you need for your own repair work.
