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Disassembly and inspection of the cooling system of Mitsubishi R16 diesel engine


Detailed Description:

Disassembly and inspection of the cooling system of Mitsubishi R16 diesel engine

1.1 Dismantling and Overhauling of External Mitsubishi R16 Diesel Engine Cooling System

Dismantling and maintenance of external Mitsubishi R16 diesel engine cooling system

Disassembly sequence

1 Mitsubishi S16 diesel engine cooling water pipe

2 cock

3 hose

4 Mitsubishi S16 Diesel Engine Cooling Water Pipe

5 Drain pipe

6 Drain pipe

7 Mitsubishi S16 Diesel Engine Cooling Water Pipe

Dismantling and maintenance of external Mitsubishi R16 diesel engine cooling system

Disassembly sequence

1 Mitsubishi S16 diesel engine cooling water pipe

2 rubber hose

3 Mitsubishi S16 diesel bypass pipe

4 Mitsubishi S16 diesel thermostat (approx. 22 kg)

5 pipe joints

6 Mitsubishi S16 Diesel Engine Cooling Water Pipe

7 Water pipe connection

8 Mitsubishi S16 Diesel Engine Cooling Water Pipe

9 Drain pipe

10 Drain pipe

11 Mitsubishi S16 Diesel Engine Cooling Water Pipe

Dismantling and maintenance of external Mitsubishi R16 diesel engine cooling system

Disassembly sequence

1 pipe joint

2 Mitsubishi S16 diesel engine cooling water pipe

3 Mitsubishi S16 diesel engine cooling water pipe

4 Mitsubishi S16 Diesel Engine Cooling Water Pipe

1.2 Mitsubishi S16 Diesel Engine Air Cooler Water Pipe Disassembly, Maintenance

Mitsubishi S16 diesel engine air cooler water pipe disassembly, maintenance

Disassembly sequence

1 belt

2 Mitsubishi S16 diesel air cooler pump (PTAW size about 24 kg) (MPTK size about 34 kg)

3 Mitsubishi S16 diesel engine tensioner assembly

1.3 Mitsubishi S16 diesel engine heat exchanger disassembly, maintenance

Disassembly and overhaul of Mitsubishi S16 diesel heat exchanger

Disassembly sequence

1 pipe joint

2 Mitsubishi S16 diesel engine cooling water pipe

3 Mitsubishi S16 diesel engine cooling water pipe

4 pipe connection

5 Mitsubishi S16 Diesel Engine Cooling Water Pipe

6 Mitsubishi S16 Diesel Engine Cooling Water Pipe

7 Mitsubishi S16 diesel engine heat exchanger (approx. 30 kg)

8 seats (approx. 26 kg)

9 partition

Disassembly and overhaul of Mitsubishi S16 diesel heat exchanger

Disassembly sequence

1 pipe joint

2 Mitsubishi S16 diesel engine cooling water pipe

3 Mitsubishi S16 diesel engine cooling water pipe

4 pipe connection

5 Mitsubishi S16 Diesel Engine Cooling Water Pipe

6 Mitsubishi S16 Diesel Engine Cooling Water Pipe

7 pipe joint

8 Mitsubishi S16 Diesel Engine Cooling Water Pipe

9 Mitsubishi S16 Diesel Engine Cooling Water Pipe

10 pipe connection

11 Mitsubishi S16 Diesel Engine Cooling Water Pipe

12 Mitsubishi S16 Diesel Engine Cooling Water Pipe

13 Mitsubishi S16 diesel engine heat exchanger (approx. 73 kg)

14 seats (about 79 kg)

15 partition

1.4 Mitsubishi S16 Diesel Engine Cooling Water Pipe Disassembly, Maintenance

Disassembly of Mitsubishi S16 diesel engine cooling water pipe, maintenance and disassembly sequence

1 Mitsubishi S16 Diesel Engine Cooling Water Pipe 2 Water Pipe Connector

Mitsubishi S16 diesel engine cooling water pipe disassembly, maintenance

Disassembly sequence

1 rubber hose

2 Mitsubishi S16 diesel engine cooling water pipe

3 rubber hose

4 Mitsubishi S16 Diesel Engine Cooling Water Pipe

5 rubber hose

6 Mitsubishi S16 Diesel Engine Cooling Water Pipe

7 rubber hose

8 Mitsubishi S16 Diesel Engine Cooling Water Pipe

Mitsubishi S16 diesel engine cooling water pipe disassembly, maintenance

Disassembly sequence

1 rubber hose

2 Mitsubishi S16 diesel engine cooling water pipe

3 rubber hose

4 Mitsubishi S16 Diesel Engine Cooling Water Pipe

5 rubber hose

6 Mitsubishi S16 Diesel Engine Cooling Water Pipe

7 rubber hose

8 Mitsubishi S16 Diesel Engine Cooling Water Pipe

1.5 Mitsubishi S16 diesel engine thermostat housing, cooling water pipe disassembly

Disassembly and maintenance of Mitsubishi S16 diesel thermostat housing and cooling water pipe

Disassembly sequence

1 pipe joint

2 Mitsubishi S16 diesel engine bypass hose

3 Mitsubishi S16 diesel engine bypass hose

4 Mitsubishi S16 diesel thermostat housing on the left

5 Right Mitsubishi S16 diesel thermostat housing

6 seats

7 seats

8 Nut

9 Mitsubishi S16 Diesel Pulley (for Mitsubishi S16 Diesel Charger Drive)

10 keys

11 Mitsubishi S16 diesel water pump (about 40 kg)

Disassembly and maintenance of Mitsubishi S16 diesel thermostat housing and cooling water pipe

Disassembly sequence

1 pipe joint

2 Mitsubishi S16 diesel engine bypass hose

3 Mitsubishi S16 diesel engine bypass hose

4 Mitsubishi S16 diesel thermostat housing on the left

5 Right Mitsubishi S16 diesel thermostat housing

6 Mitsubishi S16 Diesel Engine Cooling Water Pipe

7 Mitsubishi S16 Diesel Engine Cooling Water Pipe

8 seats

9 seats

10 Nut

11 Mitsubishi S16 Diesel Pulley (For Mitsubishi S16 Diesel Charger Drive)

12 keys

13 Mitsubishi S16 diesel water pump (about 40 kg)

14 Fittings

15 tubes

16 bracket

Disassembly and maintenance of Mitsubishi S16 diesel thermostat housing and cooling water pipe

Disassembly sequence

1 pipe joint

2 Mitsubishi S16 diesel engine bypass hose

3 Mitsubishi S16 diesel engine bypass hose

4 Mitsubishi S16 diesel thermostat housing on the left

5 Right Mitsubishi S16 diesel thermostat housing

6 pipe connection

7 Mitsubishi S16 Diesel Engine Cooling Water Pipe

8 Mitsubishi S16 Diesel Engine Cooling Water Pipe

9 seats

10 seats

11 Nut

12 Mitsubishi S16 diesel engine pulley (for driving Mitsubishi S16 diesel charger)

13 keys

14 Mitsubishi S16 diesel water pump (about 40 kg)

1.6 Dismantling the Mitsubishi S16 diesel water pump

Use a sleeve to remove the nut.

2. Mitsubishi R16 diesel engine cooling system dismantling, maintenance and assembly

2.1 Mitsubishi S16 Diesel Tensioner Disassembly and Maintenance

Disassembly and overhaul of Mitsubishi S16 diesel tensioner

Disintegration order

1 Mitsubishi S16 diesel engine tensioner seat

2 snap ring

3 Mitsubishi S16 Diesel Tensioner

4 snap ring

5 Bearing

6 partition

7 Bearing

2.1.1 Maintenance of Mitsubishi S16 Diesel Tensioner

Check the bearing installation parts of the Mitsubishi S16 diesel tensioner and shaft, and replace the bearing, Mitsubishi S16 diesel tensioner or Mitsubishi S16 diesel tensioner seat when it is heavily worn.

2.2 Dismantling and testing of Mitsubishi S16 diesel thermostat

Dismantling of Mitsubishi S16 diesel thermostat, testing

Disintegration order

1 Mitsubishi S16 diesel thermostat end cap

2 snap ring

3 Mitsubishi S16 Diesel Thermostat

4 Mitsubishi S16 diesel thermostat seal

5 Mitsubishi S16 diesel thermostat housing

Specifications of Mitsubishi S16 Diesel Thermostat for Mitsubishi S16 Diesel Engine Air Cooler

Dismantling of Mitsubishi S16 diesel thermostat, testing

Disintegration order

1 Mitsubishi S16 diesel thermostat end cap

2 snap ring

3 Mitsubishi S16 Diesel Thermostat

4 Mitsubishi S16 diesel thermostat seal

5 Mitsubishi S16 Diesel Thermostat End Cap

6 exhaust valve

7 Mitsubishi S16 diesel thermostat housing

2.3 Inspection of Mitsubishi R16 Diesel Engine Cylinder Liner Cooling Water and Air Cooling Water for Mitsubishi S16 Diesel Thermostat

2.3.1 Checking the Seal of the Mitsubishi S16 Diesel Thermostat

(1) Check the seals for the Mitsubishi S16 diesel thermostat. Replace the seals if they are aged or cracked.

(2) The assembly direction of the seal is shown in the figure.

2.3.2 Mitsubishi R16 diesel engine cylinder liner cooling water, air cooling water Mitsubishi S16 diesel thermostat action detection

(1) Put the Mitsubishi S16 diesel thermostat into a container filled with water.

(2) Measure the water temperature with a thermometer while heating the water, and measure the temperature when the valve starts to open and the valve rises to the standard value. When the temperature differs greatly from the standard value, replace it with a new one.

Note: (a) Stir with a stick to keep the water temperature in the container uniform. (b) When installing the Mitsubishi S16 diesel thermostat, you must first confirm the valve opening temperature marking on the valve side of the Mitsubishi S16 diesel thermostat.

2.4 Mitsubishi S16 diesel water pump dismantling and maintenance

Dismantling and overhaul of Mitsubishi S16 diesel water pump

Disintegration order

1 snap ring

2 Pump cover

3 O-ring

4 Impeller

5 Nut

6 Mitsubishi diesel oil seal bushing

7 O-ring

8 Mitsubishi S16 diesel water pump gear

9 bearing

10 snap ring

11 Mitsubishi S16 diesel water pump shaft

12 rings

13 Combined seal

14 Mitsubishi diesel oil seal

15 snap ring

16 bearing

17 Pump body (approx. 21 kg)

18 o-ring

2.4.1 Inspection of Mitsubishi S16 diesel water pump in the installed state

Visually inspect the drain in the lower center of the pump body. If water leaks, the combined seal is bad. If there is leakage of lubricant, the oil seal of Mitsubishi diesel engine is bad.

2.4.2 Removing the impeller

(1) Use a Mitsubishi S16 diesel water pump remover to remove the retaining ring holding the pump cover and remove the pump cover.

(2) Use the impeller remover to remove the impeller.

2.4.3 Dismantling Mitsubishi S16 diesel water pump shaft

(1) Remove the Mitsubishi diesel oil seal bushing.

(2) Use the gear remover to remove the gear and ball bearing together.

(3) Remove the retaining ring of the ball bearing on the impeller side of the Mitsubishi S16 diesel water pump.

(4) Insert the two half rings of the ring removal tool between the combined seal and the pump body as shown in the figure.

(5) Use the outer ring to prevent the half ring from falling off.

(6) Press the impeller side end face of the Mitsubishi S16 diesel water pump shaft with a manual pressure device, etc., and remove the combined seal and shaft.

2.5 Testing Mitsubishi S16 diesel water pump

Measure the bearing assembly parts of the pump body and shaft of the Mitsubishi S16 diesel water pump, and the outer and inner diameters of the bearings. When it exceeds the standard value, replace it with a new one.

2.6 Assembly of Mitsubishi S16 Diesel Water Pump

Assembly of Mitsubishi S16 diesel water pump

2.6.1 Installing Mitsubishi Diesel Engine Oil Seal

(1) Press the Mitsubishi diesel engine oil seal into the pump body with the installer so that the end face of the Mitsubishi diesel engine oil seal and the press-in end of the pump body are flush.

(2) Apply lubricant to the lips of the Mitsubishi diesel oil seal.

2.6.2 Installing the combined seal (fixed side)

(1) Apply sealant (ThreeBond 1102) to the outer periphery of the combined seal (fixed side).

(2) Use the combined seal installer to press the combined seal into the Mitsubishi S16 diesel water pump body.

2.6.3 Installing Mitsubishi S16 diesel water pump shaft

When pressing the Mitsubishi S16 diesel water pump shaft, take care not to damage the Mitsubishi diesel oil seal and the combined seal (fixed side) installed in the pump body.

(1) Press the impeller-side ball bearing into the Mitsubishi S16 diesel water pump shaft.

(2) Slowly press the shaft of the Mitsubishi S16 diesel water pump into the pump body until the end face of the ball bearing contacts the pump body.

(3) Secure the snap ring into the groove.

2.6.4 Install combined seal ring and combined seal (turning side)

(1) Mount the combined seal (turning side) on the combined seal ring.

(2) Apply LLC to the combination seal (turning side).

(3) Use the installer to smoothly press the combined seal ring to the specified position.

2.6.5 Installing Mitsubishi S16 Diesel Pulley Side Ball Bearings

(1) Gears are assembled by keys and shafts.

(2) Press in the Mitsubishi S16 Diesel Pulley Nut Ball Bearing with a press.

2.6.6 Press into Mitsubishi S16 Diesel Pump Impeller

Press the Mitsubishi S16 diesel water pump impeller with a press. At this time, the hub end face of the Mitsubishi S16 diesel water pump impeller must be flush with the end face of the Mitsubishi S16 diesel water pump shaft.

2.6.7 Installing Mitsubishi Diesel Engine Oil Seal Bushings

(1) O-ring is installed in the oil seal bushing of Mitsubishi diesel engine.

(2) The chamfered end face of the outer end of the sleeve is facing outward (Mitsubishi S16 diesel engine pulley side) and inserted into the pump shaft.

2.7 Mitsubishi S16 diesel engine air cooler water pump dismantling and maintenance

Mitsubishi S16 diesel engine air cooler water pump dismantling and maintenance

Disintegration order

1 Mitsubishi S16 diesel water pump pulley

2 snap ring

3 snap ring

4 Pump cover

5 Impeller

6 Mitsubishi S16 diesel water pump shaft

7 Ball bearings

8 ball bearing

9 combined seal

10 Mitsubishi S16 diesel water pump housing

2.7.1 Inspection of Mitsubishi S16 diesel water pump in the installed state

Use your finger to touch the drain in the lower center of the pump body. If water or oil leaks, the combined seal is bad.

2.7.2 Removing Mitsubishi S16 Diesel Water Pump Pulley

Remove the Mitsubishi S16 diesel water pump pulley remover hole and remove the Mitsubishi S16 diesel water pump pulley.

2.7.3 Removing the impeller

(1) Use a Mitsubishi S16 diesel water pump remover to remove the retaining ring holding the pump cover and remove the pump cover.

(2) Use the impeller remover to remove the impeller.

2.7.4 Remove Mitsubishi S16 diesel water pump shaft

Press the impeller side end face of the Mitsubishi S16 diesel water pump shaft with a manual pressure gauge, etc., and remove the Mitsubishi S16 diesel water pump shaft and the ball bearing together.

Dismantling and Repair of Seawater Pump for Mitsubishi S16 Diesel Engine Air Cooler

Disintegration order

1 Pump cover

2 Mitsubishi S16 diesel water pump impeller

3 Pump body

4 plates

5 Retaining ring, combined seal, bushing

6 Retaining ring

7 Nut

8 Mitsubishi S16 diesel water pump pulley

9 snap ring

10 Mitsubishi S16 diesel water pump shaft

11 Bearing

12 Mitsubishi diesel oil seal

13 seats

14 flange piece

Maintenance of Mitsubishi S16 diesel air cooler water pump and seawater pump (PTAW specification)

Measure the bearing assembly parts of the pump body and shaft of the Mitsubishi S16 diesel water pump, and the outer and inner diameters of the bearings. When it exceeds the standard value, replace it with a new one.

(MPTK specification)

Measure the bearing assembly parts of the pump body and shaft of the Mitsubishi S16 diesel water pump, and the outer and inner diameters of the bearings. When it exceeds the standard value, replace it with a new one.

2.9 Mitsubishi S16 Diesel Engine Air Cooler Water Pump Assembly

Assembly of Mitsubishi S16 diesel air cooler water pump

2.9.1 Installing the combined seal (fixed side)

(1) Apply sealant (ThreeBond 1102) to the outer periphery of the combined seal (fixed side).

(2) Use the combined seal installer to press the combined seal into the Mitsubishi S16 diesel water pump body.

Note: The combined seal must be replaced with a new one after it is removed from the pump body.

2.9.2 Installing Mitsubishi S16 diesel water pump shaft

When pressing the Mitsubishi S16 diesel water pump shaft, be careful not to damage the combined seal (fixed side) and Mitsubishi S16 diesel water pump shaft installed in the pump body.

(1) The shroud side of the impeller-side ball bearing faces the impeller side and presses into the Mitsubishi S16 diesel water pump shaft.

(2) Slowly press the shaft of the Mitsubishi S16 diesel water pump into the pump body until the end face of the ball bearing contacts the pump body.

(3) The rotating part of the ball bearing is filled with WPH grease (manufactured by Grease Co., Ltd.).

2.9.3 Installing Ball Bearings

(1) The ball bearing slewing part on the pulley side of Mitsubishi S16 diesel engine and the pump body of Mitsubishi S16 diesel water pump are filled with WPH grease (produced by Synergy Grease).

(2) The cover side of the ball bearing faces the impeller side, and the Mitsubishi S16 diesel water pump shaft is pressed into it.

(3) Secure the snap ring into the groove.

2.9.4 Pressing into Mitsubishi S16 Diesel Pump Impeller

(1) Press the combined seal (turning side) into the impeller of Mitsubishi S16 diesel water pump.

(2) Press the Mitsubishi S16 diesel water pump impeller with a press. At this time, the hub end face of the Mitsubishi S16 diesel water pump impeller must be flush with the end face of the Mitsubishi S16 diesel water pump shaft.

2.9.5 Installing Mitsubishi S16 Diesel Water Pump Pulley

Press the Mitsubishi S16 diesel water pump pulley into the Mitsubishi S16 diesel water pump shaft.

Assembly of Seawater Pump for Mitsubishi S16 Diesel Engine Air Cooler

2.9.6 Installing Mitsubishi Diesel Engine Oil Seal

(1) Press the Mitsubishi diesel engine oil seal into the pump body with the installer so that the end face of the Mitsubishi diesel engine oil seal and the press-in end of the pump body are flush.

(2) Apply grease to the hollow part and lip of Mitsubishi diesel oil seal.

2.9.7 Install flange

(1) Apply sealant (Three Bond 1102) to the joint surface of the flange and the pump body.

(2) Install the flange piece into the pump body and tighten the bolts according to the specified torque.

2.9.8 Installing the combined seal (fixed side)

(1) Apply sealant (ThreeBond 1102) to the outer periphery of the combined seal (fixed side).

(2) Use the combination seal installer to slowly insert the combination seal into the bushing by hand.

Note: (a) Do not use a hammer, etc. when inserting. (b) Do not damage the sliding contact surface of the combined seal.

2.9.9 Installing Mitsubishi S16 Diesel Engine Water Pump Shaft

(1) Press the ball bearing into the Mitsubishi S16 diesel water pump shaft using the installer.

(2) Press the ball bearing into the Mitsubishi S16 diesel water pump seat using the installer.

(3) Insert the snap ring into the seat.

2.9.10 Install retaining ring and bush

(1) Install the retaining ring on the shaft.

(2) Install the bushing on the seat.

(3) After cleaning the sealing contact surface of the combined seal (fixed side) with alcohol, apply turbine oil. Also, check that there are no damage or dust on the contact surface.

2.9.11 Install the combined seal (turning side)

(1) After cleaning the contact surface and inner surface of the combined seal (rotary side) with alcohol, apply turbine oil.

(2) Insert the combined seal (turning side) into the Mitsubishi S16 diesel water pump shaft.

Note: Make sure that the combination seal (turning side) is inserted vertically. When inserted at an oblique side, it will affect the snap ring installation or water leakage.

(3) Install the snap ring on the shaft of the Mitsubishi S16 diesel water pump.

2.9.12 Install the pump body

(1) Apply sealant (Three Bond 1101) to the mounting surface of the seat and pump body.

(2) Install the pump body on the seat and tighten the bolts according to the specified torque.

2.9.13 Installing the impeller

Drive the impeller into the shaft.

Note: The bending direction of the impeller blade end is opposite to the turning direction of the Mitsubishi S16 diesel water pump.

2.9.14 Install end cap

Install the end cap on the pump body and tighten the bolts according to the specified torque.

2.9.15 Installing Mitsubishi S16 Diesel Water Pump Pulley

Install the Mitsubishi S16 diesel water pump pulley on the shaft of the Mitsubishi S16 diesel water pump, and tighten the nut in accordance with the specified torque.

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