Mitsubishi Forklift GM 4.3L G6 Gasoline Engine 003103-up Service Manual – PDF DOWNLOAD

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Mitsubishi Forklift GM 4.3L G6 Gasoline Engine 003103-up Service Manual – PDF DOWNLOAD

FILE DETAILS:

Mitsubishi Forklift GM 4.3L G6 Gasoline Engine 003103-up Service Manual – PDF DOWNLOAD

DESCRIPTION:

Mitsubishi Forklift GM 4.3L G6 Gasoline Engine 003103-up Service Manual – PDF DOWNLOAD

For use with the FGC35K-FGC70K; FG35-FG50; FG40K-FG50K Chassis Service Manuals.

Pub.No :99789-74120

FOREWORD :

• This service manual covers the GM 4.3L Gasoline Engine installed in Mitsubishi Forklift Trucks and gives detailed maintenance and repair information. For your convenience the instructions are grouped by systems as a ready reference. The long productive life of your forklift truck(s) depends on regular and proper servicing.
• Servicing consistent with what you will learn from this service manual. Read the respective sections of this manual carefully and familiarize yourself with all the components before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual are for engines with serial numbers in effect at the time of printing.
• Mitsubishi Forklift Trucks reserves the right to change specifications or design without notice and without incurring obligation. Whenever a question arises regarding this engine, or this manual, consult your Cat lift truck dealer for the latest available information.

TABLE OF CONTENTS:

Mitsubishi Forklift GM 4.3L G6 Gasoline Engine 003103-up Service Manual – PDF DOWNLOAD

Forward I
How to Read This Manual II
Precautions VI
Precautions for Disassembly and Assembly VI
General Precautions VIII
Determining When to Overhaul the Engine 1
Engine Replacement 2
Removal Procedure 2
Installation Procedure 2
Specifications 6
Engine Specifications – Gas and LP 6
General Specifications 8
Major Nuts and Bolts Tightening Torque 11
Sealers, Adhesives, and Lubricants 13
Use of RTV and Anaerobic Sealer (Gasket Eliminator) 14
Diagnostic Information and Procedures 16
Base Engine Misfire Diagnosis 16
Engine Compression Test 17
Engine Noise Diagnosis 18
Valve Train Diagnosis (General) 19
Valve Train Diagnosis (Noise Diagnosis) 19
Engine Mechanical 22
Oil Consumption Diagnosis 22
Low or No Oil Pressure Diagnosis and Testing 22
Oil Leak Diagnosis 22
Repairing the Leak 23
Engine Lubrication 25
Intake Manifold 29
Intake Manifold Removal 30
Intake Manifold Installation 31
Exhaust Manifold 33
Oil Level Indicator and Tube Removal 34
Exhaust Manifold and Heat Shields Removal 34
Exhaust Manifold Clean and Inspect 34
Exhaust Manifold and Heat Shields Installation 35
Oil Level Indicator and Tube Installation 35
Cylinder Head and Valves 37
Valve Rocker Arm Cover Removal (Left) 38
Valve Rocker Arm Cover Removal (Right) 38
Valve Rocker Arm and Push Rod Removal 39
Valve Lifter Removal 41
Valve Stem Oil Seal and Valve Spring Removal 42
Cylinder Head Removal 43
Cylinder Head Disassembly and Assembly 45
Cylinder Head Clean and Inspect 46
Valve Guide Reaming/Valve and Seat Grinding 48
Valve Stem Oil Seal and Valve Spring Installation 49
Valve Lifter Installation 50
Cylinder Head Installation 51
Valve Rocker Arm and Push Rod Installation 53
Valve Rocker Arm Cover Left Installation 54
Valve Rocker Arm Cover Right Installation 55
-XITABLE
OF CONTENTS
Oil Pan, Pump and Filter 57
Oil Pan Removal 58
Oil Pump Removal 59
Oil Filter Adapter Removal 60
Oil Pump Disassembly 60
Oil Pump Assemble 62
Oil Filter Adapter Installation 63
Oil Pump Installation 64
Oil Pan Installation 65
Front Cover, Timing Chain, and Crankshaft Balancer 67
Engine Front Cover Removal 68
Engine Front Cover Oil Seal Removal 68
Timing Chain and Sprockets Removal 68
Crankshaft Balancer Removal 70
Crankshaft Balancer Installation 71
Timing Chain and Sprockets Installation 72
Engine Front Cover Oil Seal Installation 73
Engine Front Cover Installation 73
Balancer and Camshaft 77
Balance Shaft Removal 78
Camshaft Removal 80
Camshaft Bearing Removal 80
Camshaft and Bearings Clean and Inspect 82
Camshaft Bearing Installation 83
Camshaft Installation 84
Balance Shaft and Bearing Clean and Inspect 85
Balance Shaft Installation 86
Crankshaft, Flywheel, Rear Seal, and Bearings 89
Engine Flywheel Removal 90
Crankshaft Rear Oil Seal and Housing Removal 90
Crankshaft and Bearings Removal 91
Crankshaft and Bearings Clean and Inspect 91
Service Prior to Assembly 94
Crankshaft and Bearings Installation 94
Bearing Clearance Measuring Procedures 95
Micrometer Method for Crankshaft Bearings 95
Crankshaft Rear Oil Seal and Housing Installation 103
Engine Flywheel Installation 105
Cylinder Block 107
Engine Block Plug Removal 108
Cylinder Block Clean and Inspect 110
Cylinder Boring and Honing 111
Reboring the Cylinders 112
Cylinder Block Plug Installation 113
Piston and Connecting Rod 117
Piston, Connecting Rod, and Bearing Removal 118
Piston and Connecting Rod Disassembly 119
Piston and Connecting Rod and Bearings Clean and Inspect 119
Piston Selection 122
Piston, Connecting Rod and Bearing Installation 123
Piston and Connecting Rod Assembly 124
Gasoline Carburetor 127
Carburetor Assembly (Upper) 129
Carburetor Assembly (Lower) 131
Carburetor Disassembly 132
Air Horn Disassembly 132
-XIITABLE
OF CONTENTS
Carburetor Inspection 137
Carburetor Assembly 138
Air Horn Assembly 140
Carburetor Adjustment 144
Operational Adjustments 147
Carburetor Installation 148
Electrical Throttle and Governor Control System 149
System Operation 149
ECU Input/Output Interfaces 150
ECU Schematic 151
Method of Operation 152
Speed Control 152
GM 4 3L, G6 Engine ECU Error Code Description 154
Ignition System and Distributor 157
Ignition System – Distributor 158
Distributor Removal 159
Distributor Disassembly 159
Distributor Assembly 159
Coil Removal 160
Coil Installation and Testing 160
Ignition Sensing Coil Testing 160
Distributor Installation 161
Ignition Timing 163
Spark Plug Inspection 163
Alternator and V-Belt (Units built before 01/01/2004) 165
Alternator 167
Accessory Drive Belt Replacement 168
Starter Motor 169
Starter Motor Testing 170
Troubleshooting 170
Fuel System – Gasoline (Units built before 01/01/2004) 173
Fuel Pump and Fuel Hose (Units built before 01/01/2004) 175
Fuel Pump Disassembly and Reassembly (Units built before 01/01/2004) 177
Inspection 178
Main Point of Reassembly 178
Fuel System – LP (Units built before 01/01/2004) 179
Maintenance Checks 180
Vacuum Fuel Lockoff Filter 181
Model J Regulator 182
Pressure Regulator / Converter Service Procedures 182
On-Truck Pressure Test 183
Regulator / Converter Disassembly, Inspection, Cleaning, and Assembly 183
Regulator / Converter Bench Test 183
Pressure / Converter Regulator Installation Tips 183
Regulator/Lockout – Removal 183
Impco CA 100 Air Fuel Mixer 184
LPG Carburetor Adjustment Procedure-co/exhaust Analyzer 187
Governor Speed Adjustment Procedure 187
Accelerator Cable Adjustment – LPG 188
Special Tools and Equipment 189

IMAGES PREVIEW OF THE MANUAL:

MITSUBISHI FORKLIFT GM 4.3L G6 GASOLINE ENGINE 003103-UP SERVICE MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.