2008 Mitsubishi S6S-Y3T61HF & S6S-Y3T62HF Diesel Engine Service Manual (P/N 99616-25000)

This Mitsubishi service manual covers the 2008 S6S-Y3T61HF and S6S-Y3T62HF diesel engines. Publication No. 99616-25000 is the August 2008 edition for Hyundai Heavy Industries Co., Ltd.

• Engine overhaul: Disassembly, inspection, repair, and reassembly of the cylinder head, valve mechanism, flywheel, camshaft, pistons, connecting rods, and crankshaft.

• Fuel system: Bosch VE distributor-type injection pump removal and installation, nozzle testing, fuel-filter service, fuel-system bleeding, and injection-timing adjustment.

• Lubrication system: Oil-pump clearance inspection, oil-cooler disassembly, and relief- and safety-valve checks, with component-specific service limits.

• Cooling system: Thermostat testing, water-pump removal and inspection, pulley installation, and V-belt inspection and tension adjustment.

• Inlet and exhaust systems: Turbocharger and manifold removal, housing disassembly, cartridge axial-clearance measurement, and exhaust-manifold distortion checks.

• Electrical system: Starter and alternator repair, magnetic-switch test circuits, glow-plug checks, and magnetic-valve/stop-solenoid inspection.

Suited to technicians experienced in diesel engine repair who have precision measuring equipment and access to the specified service tools.

Variant Details and Internal Engine Repair

The S6S-Y3T61HF has a side PTO drive; the S6S-Y3T62HF layout does not. Separate timing-gear and alternator-mounting illustrations help match the engine configuration before choosing the relevant removal or assembly procedure.

Compression-pressure testing and overhaul criteria help assess low output, oil consumption, blow-by, and hard starting before teardown. The compression-test procedure specifies gauge 33391-02100 and adapter 30691-21100.

Internal repair coverage extends to valve-guide replacement, valve-seat refacing and angle data, push-rod runout, piston-ring gaps, crankshaft grinding, and main-bearing clearances. Tightening-torque tables distinguish dry fasteners from those requiring engine oil; exploded views identify inspection points and replacement seals.

The cylinder-head section warns that excessive resurfacing can cause piston-to-valve contact.

Routine operation and periodic maintenance are covered by a separate Operation and Maintenance Manual; parts ordering is handled by a separate parts catalog.

Injection Pump Service and Nozzle Testing

Pump work covers gauze-filter cleaning, assembly replacement, and timing alignment. Denso nozzle procedures include opening-pressure adjustment, spray-pattern checks, and needle-and-body inspection.

Injection pump repair limit: The emissions-control pump is not intended for internal disassembly or rebuilding; a failed pump is replaced as a complete OEM assembly. The manual assigns fuel and exhaust system repairs to an authorized Mitsubishi forklift truck dealer.

Oil Circulation, Cooling, and Turbocharger Checks

Fuel, lubrication, cooling, and inlet/exhaust system flow diagrams show the connections between the relevant components. Lubrication data includes oil-pump delivery specifications alongside rotor, shaft, and housing inspection limits.

Water-pump inspection checks shaft and impeller rotation and specifies assembly replacement if faulty. Turbocharger procedures cover the compressor cover, turbine housing, and cartridge clearance; axial clearance outside the specified range calls for cartridge replacement.

Starter, Alternator, and Final Engine Tests

The M008T60373 pinion-shift starter section includes pull-in, holding, return, and no-load test circuits, plus commutator, brush, armature, and overrunning-clutch checks.

Alternator work covers the stator, field coil, rectifier, and regulator. Its soldering cautions address diode damage from prolonged heating.

Post-overhaul coverage includes dynamometer break-in and JIS performance tests for operation under load, continuous load, and low-idle stability.

Review the manual's precautions for rotating equipment, engine lifting, and high-pressure fuel before service.

Selected Cylinder-Head and Crankshaft Specifications

These are a few examples from the manual's engine assembly and inspection specifications.

Final cylinder-head bolt torque is 118 ± 5 N·m with dry fasteners. Main-bearing cap torque is 103 ± 5 N·m with engine oil on the bolt threads and bearing surfaces.

Cold intake and exhaust valve clearance is 0.25 mm. For a standard-size crankshaft, the specified crankpin outside diameter is 57.955–57.970 mm.

Searchable PDF with Section Bookmarks

Text search and circuit detail: The manual has searchable body text and embedded bookmarks for sections and individual procedures. Small starter-circuit terminal labels are best read with magnification.

The download contains one printable, English-language, 204-page PDF. The total includes the original cover spread, counted as one PDF page, and eight blank pages.