WORKSHOP MANUAL C&E-SERIES and LV150 ENGINE 6WA1TC SECTION 6 ISUZU _ _ 4 PartsNOTICE Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section 00 under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL”. All material contained in this Manual is based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without prior notice. Applicable Model C&E Series and LV150 CVR80 CXZ50 EXR50 EXZ50 CVR81 CXZ51 EXR51 — EXZ51 CXHS0 © CXZ52_«« EXR52— EXZ52 CXHS1 © CXZ80«« EXRB1 —-EXZ81 CHXS2 CXZ81« EXDS1_— EXZ52 CHX81 «= CXY51 EXDS2_—LV 150 This manual is applicable to 1996 year model and later vehicles.‘SECTION 00 6A 6B 6c 6D 6E 6F 6G 6P CONTENTS Service Information Engine Mechanical Cooling System Fuel System Engine Electrical Exhaust System Turbocharger Power Take OffSERVICE INFORMATION 00-1 SECTION 00 SERVICE INFORMATION CONTENTS Troubleshooting... Main Data and Spe: Service Standard Servicing, Fixing Torque . Special ToolsSERVICE INFORMATION 00-3 TROUBLESHOOTING CONTENTS Moubleshooling ieiecuecsaewscautds susttsccauenciiniresi: seiaeugiis 1. Hard Starting 1) Starter Motor Does Not Operate . 2) Starter Motor Operates But Engine Does Not Turn Over . 3) Engine Turns Over But Does Not Start . Unstable Idling. Insutticient Power Excessive Fuel Consumption . Excessive Oil Consumption Overheating White Exhaust Smoke. .. Black Exhaust Smoke . . . Oll Prosetitel Does Not Rise st invsur er tie tauren uae iuaaeircin }0. Abnormal Engine Noise . 1) Engine Knocking . 2) Gas Leakage Noi: 3) Continuous Noise 4) Slapping Noise. 11. Alternator. 1) Battery Dead - 2) Battery Overcharged . 3) Flashing Charge light or Fluctuating Ammeter Indication 4) Charge light On But Dim While Driving. 5) Alternator Noise 6) Charger Circuit Fuse Blown 12. Starter Motor 1) Starter and Magnetic Switch Does Not Operate eee 00-35 2) Magnetic Switch Operates But Does Not Turn 3) Starter Runs Slowly 4) Starter Operates But The Engine Does Not Start ..............000e000 00-38 5) Abnormal Operating Noise.........02.0ec0eeceeeeeceeeeeeeeeeeeeees 00 -39 ZLPN MAE YN00-4 SERVICE INFORMATION 13. Turbocharger . 1) Engine Has Less Than Normal Power 2) Blue or Black Smoke 3) Excessive Engine Oil Consumption . 4) Excessive Turbocharger Noise . . 5) Excessive Rotating Part Wear.SERVICE INFORMATION 00-5 TROUBLESHOOTING Refer to the following troubleshooting charts to quickly pinpoint and repair engine problems. 1. This Section is divided into Sub-Sections. Refer to the Table of Contents. 2. Each troubleshooting chart has three headings arranged from lef to right. Example: 3. INSUFFICIENT POWER Checkpoint Trouble Cause Countermeasure 1c | Fun ter cage copes 3. Easily checkad areas are presented at the beginning of the troubleshooting chart. Procedure become more complex as the chart progresses. 4. Itis suggested that you work from the beginning of the troubleshooting chart. Do not start from the middle. 5. Itis possible that at seemingly apparent engine problem is not related to the engine. For example, the engine may appear to have insufficient power. This could be caused by dragging brakes or a slipping clutch instead of an engine malfunction. Refer to the other troubleshooting charts if required. 6. Optional equipment and variations are included in the troubleshooting charts. If the vehicle you are servicing is not equipped with a particular option or variation noted in the Checkpoint” frame, disregard the frame and move on to the next one.00-6 SERVICE INFORMATION 1. HARD STARTING 1) STARTER MOTOR DOES NOT OPERATE Checkpoint Trouble Cause Countermeasure a NG_| Loose battery cable terminals Clean andior retighten the attery Poor connections due to rusting battery cable terminals NG_| Battery discharged or weak Recharge or replace the battery ok Fusible link es Fusible link shorted Replace the fusible link OK ee NG_| Detective starter switch or Foplaco the startor switch or tho starter relay starter relay ok ‘starter motor NG_| Detective magnetic awiten or Repair or replace the magnetic starter relay switch Ne Defective starter motor Ropair or replace the starter motorSERVICE INFORMATION 00-7 2) STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Checkpoint Trouble Cause Countermeasure ae e_} Leosebatery cabo tominale clean andlor eetighten to y Poor connections due to rusting battery cable terminals bid Battery discharged or weak Recharge or replace the battery ox Starter motor a Detective pinion gear Replace the pinion goar NG} pefstve magnetic sth lite al alia se e_| oruch weer Repiae the brush andor the Weak bush spring brush spring ox cngine No} Piston, ranknesing size, oF Repao opace he rlated other damage parts00-8 SERVICE INFORMATION 3) ENGINE TURNS OVER BUT DOES NOT START Checkpoint Trouble Cause Countermeasure faa eyton NS | rin th et sytem Sesto io Oat ox |e: eiemeee eee || oe ee Control wire improperly adjusted ‘Adjust the control wire us Defective engine stop actuator Replace the engine stop actuator (1) FUELIS NOT BEING DELIVERED TO THE INJECTION PUMP Fuol xe Fuol tank is empty Fill the fuol tank ok ratoone || emma | Rat ox. Fuel fter NS) Clogged tue! filter element Lediuipn intend ok Fuel systom NG Air in the fuel system eee eee ox Fuel feed pump NG Fuel food pump strainers Gites na Continued on theCheckpoint Continued from the previous page Trouble Cause SERVICE INFORMATION 00-9 Countermeasure ok Fuel feed pump Ne Detective feed pump Repair or replace the feed pump (2) FUELIS BEING DELIVERED TO THE INJECTION PUMP Fuel Ne Use of the wrong fuel Use the correct fuel Ne Water particles in the uel Change the fuel ok Fuel system Ne Air in the injection pump alee een system ok Injection nozzle Ne Injection nozde sticking Replace the injection nozzle ig. | Inlection nozae starting pressure Adjust or replace the injection to0 low a Improper spray condition ok Sareea NG_| Defective injection pump contro! Repair or replace the injection eee rack operation pump control rack Continued on the next page00-10 SERVICE INFORMATION Checkpoint Continued from the previous page Trouble Cause Countermeasure ok oe N@_| Injection pump plunger worn or Replace the Injection pump Injection pump stuck plunger assembly NG_| Injection pump camshalt seizure Replace the injection pump or other damage camshattSERVICE INFORMATION 00-11 2. UNSTABLE IDLING Checkpoint Trouble Cause Countermeasure Idling system a Idling improperly adjusted ‘Adjust the Idling ox ting secon covce | MG] Sf send conta Pent rae eg ox restasercnl oon [8G] Meer cnt ost As err ont ox Fuel system NG} Fut ‘system leakage or blockage Repair or replace the fuel system: No | yin ve teteyten Bled tear he ta ua | war pares in tofu ae outer ox Fu itor NS | clogged ts itr sloment Replace ue ar dent or Continued on the page00 - 12 SERVICE INFORMATION Checkpoint Continued from the previous page Trouble Cause Countermeasure ok Injoction nozzle Ne Injection nozzle sticking Replace the injection nozzle nig. | Inleetion nozzle injection starting pete ene ica pressure too low ae Improper spray condition ok Detective delivery valve Injection pump NG_ resulting in fuel drippage after Replace the delivery valve {uel injection NG_| injection timing improperly Sc eneeite Bias Adjust the injection timing NG_| Insufficient injection volume ‘Adjust the injection volume Ne Defective idle spring Replace the idle spring NG_| Defective governor lever Repair or replace the governor operation lever Continued on the next pageSERVICE INFORMATION 00-13 Checkpoint Continued from the previous page Trouble Cause Countermeasure ox us eatin pump broken plunger sring sepacote plunge ping NS. Worn plunger Replace the plunger assembly a Worn camshaft Replace the camshaft Lid Worn roller tappet Replace the roller tappet ox Vaive cerance Us| valve clearcs improper Aust no vate crane ox Blown out nda Fan geke ug | Wermenindartne Picton ing compression pressure Steng or brokon place thereaod parts improper song btwoen to Yahoand ine vavesot ox us Engine mounting rubber Broken Replace Continued on the next page00-14 SERVICE INFORMATION Checkpoint Trouble Cause Countermeasure Continued from the previous page ok Camshaft a Worn camehalt lobe Replace the camshaft ok NG. Tappet Worn ReplaceSERVICE INFORMATION 00-15 3. INSUFFICIENT POWER Checkpoint Trouble Cause Countermeasure At cleaner NS | clogged ar cleaner element Ceol dale ox Fuel bid Water particles in the fuel Replace the fuel ox No Repiaoe the ue ter element or Fuel or Ctogged ue ster ota ena ox a } cogged strainer or deosive Repair o epace the ful eed Eee fuel feed pump pump ox Injection nozzle a Injection nozde sticking Replace the injection nozzle No |} injection noztoinjstion starting Adjust or pace the ection pressure too tow nome Improper spray conlton ox NNe_| ul inj pos damaged or Fuel injection pipes obstructed Replace the [uel injection pipes Continued on the next page00-16 SERVICE INFORMATION Checkpoint Continued from the previous page Trouble Cause Countermeasure ox Injection pump NG Detective delivery valve Replace the delivery valve NS. Defective timer Repair or replace the timer | mprper cont! over operation Adjust or replace tn contr Aust he ijston tng Lid Detective injection timing Repair or replace the injection pump timer a Weak governor spring Replace the governor spring NS. Worn plunger Replace the plunger assembly ae Worn camshaft Replace the camshalt us Continued on the next page Worn roller tappet Replace the roller tappetSERVICE INFORMATION 00-17 Checkpoint Trouble Cause Countermeasure Continued from the previous page oK NG_| Booster compensator pipe Replace the booster Turbocharger broken or cracked compensator pipe Exhaust gas leakage from the n@_| oxhaust system opair or replace the related Air leakage from the intake parts system NG_| Detective turbocharger Replace the turbocharger assembly assembly ok Blown out eylinder head gasket ug | Wom eylindortinor Piston ring compression prossure sticking or broken Improper Replace the related parts seating between the valve and the valve seat oK NG_| Valve clearance improperly Valve clearance woes Adjust the valve clearance oK Valve spring NG_| Valve spring weak or broken Replace the valve spring ok Exhaust system Ne Exhaust pipe clogged the exhaust pipe oK Camshaft NG Worn camshaft lobe Replace the camshalt00-18 SERVICE INFORMATION 4. EXCESSIVE FUEL CONSUMPTION Checkpoint Trouble Cause Countermeasure ee Ne oe Rapa o apace he ful eystem Fuel syst Fuel leakag related parts ox A cleaner NS] clogged ar cosner element Sooo ox No ling spood Poorly austod idling epood Acjus te ng speed ox Thermostat Lid Defective Replace ox Engine oil a Improper engine oil viscosity Correct ox wg_| Inston nostoinjstion starting ee hisction note pressure oo ow oe Improper spay conlton ox uel injection timin [-NS_| Full injection timing improperly lust the {uel injection timin Ful injection timing Fu ie Adjust the ul injection ting Continued on the next pageSERVICE INFORMATION 00-19 Checkpoint Trouble Cause Countermeasure Continued from the previous page ok Detective delivery valve Injection pump NG_| resulting is fuel drippage after Replace the delivery valve {ual injection ok NG_| Air teakage trom the Repair the turbocharger intake Turbocharger turbocharger intake side side NG _| Defective turbocharger Replace the turbocharger assembly assembly ok NG_| Vaive clearance improperly Valve clearance wovase ‘Adjust the valve clearance ok Blown out cylinder head gasket ng | Wemeylinder liner Compression pressure Piston ring sticking of broken Replace the related parts Improper seating between the valve and the valve seat ok Valve spring NG_) Valve spring weak or broken Replace the valve spring00-20 SERVICE INFORMATI TON 5. EXCESSIVE OIL CONSUMPTION Checkpoint Trouble Cause Countermeasure a NG_| Engine oil unsuitable place the engine oll Prana Too much engine cil Correct the engine oll volume ok NG_| il leakage trom the oll seal place the ol seal andior the Saheaeniah arta andior the gasket gasket ok Air breather ne Clogged air breather Clean the alr breather ok Intake and exhaust valves and |_NG_| Worn valve stems and valve Replace the intake and exhaust valve guides guides valves and the valve guides ok Valve stem oll seal Ne Worn Replace ok Blown out eylindor head gasket ng | Wereylinder tinor Compression pressure Fiston ring sticking or broken Replace tho related parts Improper seating between the valve and the vaive soatSERVICE INFORMATION 00-21 6. OVERHEATING Checkpoint Trouble Cause Countermeasure Ne Cooling water Inautticient cooling water Replenish the cooling water oK NG. Fan clutch (it s0 equipped) il leakage from the fan clutch Roplace the fan clutch ok Fan belt N@_| Fan belt loose or cracked ey causing elippage ok a NG_| Defective radiator cap or Replace the radiator cap or clean clogged radiator core the radiator core ok Ne Repair or replace the water Water pumi Defective water pum) pump pump pap ok Cylinder head and cylinder body |_NG_| Defective sealing cap resulting sealing cap in cooling water leakage Replace the sealing cap ok Thermostat Ne Defective termostat Replace the thermostat Continued of! the next page00-22 SERVICE INFORMATION Checkpoint Continued from the previous page Trouble Cause Countermeasure ok cling system NG_| Cooling eystem clogged by Take out the foreign material cooling ssi foreign material from the cooling system ok NG_| Fuel injection timing improperly Fudl injection timing adjusted ‘Adjust the fuel injection timingSERVICE INFORMATION 00-23 7. WHITE EXHAUST SMOKE Checkpoint Trouble Cause Countermeasure Fuel a Water particles in the fuel Replace the fuel ox Fuel injection timing “= Delated fuel injction timing Adjust the fuel injection timing ox Blown out ayndor head gash wg | Wom epndee ner compression pressure Feton ing tengo broken opie the elatod parts Improper soding Btween the valve andthe valve set ox Detocive valve seas take anc oxnaust vaive seals |S] orm valve stems ac valve liso ppueroun i guides ‘sina ox Ne Cooling system Defective thermostat Replace00-24 SERVICE INFORMATION 8. BLACK EXHAUST SMOKE Checkpoint Trouble Cause Countermeasure At cleaner NS | clogged ar cleaner element Ceol dale ox NG eevee merece: Adjust or replace the injection Injection noe pressure too low ue Improper spay conlton ox Fuel injection timing NG | pgyanced tue! injection timing ‘Adjust the fuel injection timing ox Detosve delivery vaio No Injection pump resuting in Wl drpage ster recting i opace the dlvery valve a Excessive injection volume Adjust the injection volume ox ‘Camshaft NS. ‘Worn camshaft lobe Replace the camshaft ox Tappet oe Worn ReplaceSERVICE INFORMATION 00-25 9. OIL PRESSURE DOES NOT RISE Checkpoint Trouble Cause Countermeasure i NG_| Improper viscosity engine oil place the engine oll Prana ineutficient engine oil Correct the engine oll volume ok Gg ug | Defective oll pressure gauge or Ropair or replace the cil Gil prossure indicator light a pee cade Detective indicator light Roplace the indicator light ok NG Replace the ol fiter element or Oil tiker Clogged ol titer element tetas corte ok NG_| oli vaivo sticking andlor weak place the relief valve andlor Folio! valve and by-pass valve WP by-pass valve spring the by-pass valve spring ok Oil pump NG) Glogged oil pump strainer Clean the oll pump strainer NG_{ Worn oil pump related parts Replace the oll pump related parts ok NG Rocker arm shalt Worn rocker arm bushing Replace the rocker arm bushing Continued on the next page00-26 SERVICE INFORMATION Checkpoint Continued from the previous page Trouble Cause Countermeasure ok camenatt N@_| Worn camshatt and camshaft oplace the camshaft and the bearing camshatt bearings oK Crankshaft and bearings NG_) Worn crankshaft and bearings Replace the crankshaft andlor tho bearings ok Ne Cling Jet check valve Clling jet valve dove not close Replace the oiling jetSERVICE INFORMATION 00-27 10. ABNORMAL ENGINE NOISE 4) Engine Knocking Checkpoint Trouble Cause Countermeasure Start the engine and allow it to warm up before beginning the troubleshooting procedure. rus LS} ever ino wrong tue Use tn oct a ox itontiming LNSL| Fu nection timing improper st th inet iin Ful inion ting ft ie Aus nel ton ting ox Improper injection nozde ee rection nezio [NS] rung prossre and oproy Aust orepace th ioc ox : we | shown out heed gate Replace te head gasket or the ener ceeae rere Broken piston ring piston ring ox wa | Pstav ut injection ozo eatin pump fouling inal ippage ater Feplceheinjection nozle Wel ijaton 2) Gas Leakage Noise ug | tee connected exhaust Thton he xa ppe haus pies pipee conmostons Bron exhaust ppes Replace te exhaust pipes ox Injection nozzles and/or glow NG | Loose injection nozdes and/or Tighten the injection nozzles and/or the glow plugs plugs slow plugs Replace the washer Continued on the next page00-28 SERVICE INFORMATION Checkpoint Continued from the previous page Trouble Cause Countermeasure ok senaust mantra ne | Leos omnes esau Thon te rhs mani ok Cylinder head gasket ue] Damaged cylinder head gasket Replace the cylinder head gasket 3) Continuous Noise Fan belt NG Loose fan belt Readjust the fan belt tension oK Cooling fan us Loose cooling fan Retighten the cooling fan oK Wat pump bearing |-NS_} Yorn damaged water pump Pepiae the water pump bearing ok avenaororvacum pnp [S| Stace tna or iam bipaterepas natn o« Valve clearance NGI) |. valve cloatance Iinircperty Adjust the valve clearance adjustedSERVICE INFORMATION 00-29 Checkpoint 4) Slapping Noise Trouble Cause Countermeasure NG_| valve clearance improperly Valve clearance SGusee ‘Adjust the valve clearance OK Rocker arm ue Damaged rockor arm Roplace the rockor arm ok Fywheo! NG Loose flywheel bolts Tighten the flywheel bolts OK sankshalt and thrust boaringe |-NS_| Worn or damaged crankshatt place the crankshaft andior Acdoieiaatatanaautts andior thrust bearings tho thrust bearings ok Crankshaft and connecting red |_NG_| Worn or damaged crankshatt Replace the crankshaft andior nbearings andior connecting rod beatings the connecting rod bearings OK Connecting rod bushing and NG_| Worn or damaged connecting Replace the connecting rod piston pin rod bushing and piston pin bushing andlor the piston pin OK ng_| Worn or damaged piston and Replace the piston and the Piston and cylinder liner cylinder liner Foreign material in the eylinder eylinder liner00-30 SERVICE INFORMATION 11. ALTERNATOR 1) BATTERY DEAD ‘Checkpoint Trouble Cause Countermeasure Alternator drive bet == | NG Loose Adjust ok Battery fluid NG. Low Replenish ox Battery terminals NG | Detective (Internal short circuit) Replace ok Fuse [Ns Blown Replace: ox Fuse holder and fuse NG Poor contact Repair ok Battery fluid specific gravity NS Wrong, Adjust ox oe ee Pair Continued on the next pageSERVICE INFORMATION 00-31 Checkpoint Trouble Cause Countermeasure Continued from the previous page ok Pegulator terminal ang NG eee Broken or pootly connected Repair ok Alternator ground circuit xe Detective Repair ok. Voltage regulator ut Detective Replace od Diode “ Detective Roplace OK. Alternator stator coil ne Grounded or broken Repair or replace OK Rotor coil xs Broken Replace ok Ne Cheek alternator output at Electrical load Excessive cara uae00-32 SERVICE INFORMATION 2) BATTERY OVERCHARGED Checkpoint Trouble Cause Countermeasure Wing andterminas | N@_} Prot comastons or open carat oK Voltage regulator NS. Poor ground connection Correct NG Voltage set too high Replace Ns Detective ReplaceSERVICE INFORMATION 00-33 3) FLASHING CHARGE LIGHT OR FLUCTUATING AMMETER INDICATION Checkpoint Trouble Cause Countermeasure Fan belt ut Loose Adjust 0K Startor switch contacts xe Detective Replace 0K Wiring NG _| Broken or poorly connected Replace or reconnect 4) CHARGE LIGHT ON BUT DIM WHILE DRIVING Checkpoint Trouble Cause Countermeasure NG. Starter switch torminal wiring Loose Rotighton oK Alternate and tusehoder NG oat Blac ne wre with larger ok NG Starter switch contacts Detective Roplaco00-34 SERVICE INFORMATION 5) ALTERNATOR NOISE Checkpoint Trouble Cause Countermeasure Alternator bearing a Detective Replace and regroase oK Alternator stator coi ue Exposod wires Roplaco ne Short ieuit Replace 6) CHARGER CIRCUIT FUSE BLOWN Checkpoint Trouble Cause Countermeasure Torminal wiring 18 Grounded Repair oK Alternator end frame diodes NS. Defective Replace the end frame assembly ok Voltage regulator Ne Out of adjustmont Roplace oK Battory connections Ne Rovorsod Correct12. STARTER MOTOR SERVICE INFORMATION 00-35 1) STARTER AND MAGNETIC SWITCH DOES NOT OPERATE Checkpoint Trouble Cause Countermeasure Battery fluid level as Low Roplenish ok Battery spositic gravity Ne Low Recharge or replace ox Battery switenes a Poor contact Replace ok Starter switeh Ys Detective Replace ok Magnetic switch pullin coil and |_NG. Detective ae plunger ok ‘Armature coil Ng Broken Replace ok Field coil tvs] Broken Replace Continued on the next page00-36 SERVICE INFORMATION Checkpoint Trouble Cause Countermeasure Continued from the previous page ok Magnetic switch coil a Broken Replace ok Holding coil ue Broken ReplaceSERVICE INFORMATION 00-37 2) MAGNETIC SWITCH OPERATES BUT STARTER DOES NOT TURN ‘Checkpoint Trouble Cause Countermeasure Battory fluid level ue Low Replenish ok Battery fluid specific gravity | NE Low Recharge or replace OK Starting circuit ue Poor contacts Repair ok Magnetic switch terminais | NS Poor contact Replace OK Brushes, 4S Worn Roplaco OK Armature NG Shorted Repair or replace00-38 SERVICE INFORMATION 3) STARTER RUNS SLOWLY ‘Checkpoint Trouble Cause Countermeasure Magnotic torminal circuit Ne monde Bad contact Popair OK Brushes ue Excossive woar Replace ok Ne Starter motor armature Shorted Repair or replace 4) STARTER OPERATES BUT THE ENGINE DOES NOT START Checkpoint Trouble Cause Countermeasure snion end ting gear NG lo mesnin Repair or replace the running anes ree clutch and the drive lever OK (Overrunning clutch Ne Stippage Replace OK Brushes NG Excessive wear ReplaceSERVICE INFORMATION 00-39 5) ABNORMAL OPERATING NOISE Checkpoint Trouble Cause Countermeasure Bushing ut Excessive wear Foplace 0K NG. oplace the overrunning clutch Pinion gear Excossive wear seelie sinion cose Ne Lubricate or replace the raven ea een overrunning eluteh OK NG. Foplace the overrunning clutch ing goar Excossive wear sealing gow 0K Brushee ut Excoselve wear Replace00-40 SERVICE INFORMATION 13. TURBOCHARGER 1) ENGINE HAS LESS THAN NORMAL POWER Checkpoint Trouble Cause Countermeasure Air cleaner as Restricted Gioan or replace ok Intake pipe and hose NS Restricted ean or replace oK Compreszoriintake manifold} NE Loose (Leaking) Repair ok Exhaust manifoldturbine inlet |-YS| Loose (Lesking) Repair ok Exhaust piping and silencers | NG Restricted Giean or replace ok Air breather NS Restricted ean or replace ok Boost compensator {injection |_NG es Detective Repair or replace pump) : : Continued on the next pageSERVICE INFORMATION 00-41 Checkpoint Trouble Cause Countermeasure Continued from the previous page ok Compressor wheel NG Impact damage Replace ok Turbine wheel ue Impact damage Roplaco ne Carbon build-up Replace ok Rotating assombly 1 Dragging or seized Replace00 - 42 SERVICE INFORMATION 2) BLUE OR BLACK SMOKE Checkpoint Trouble Cause Countermeasure Air cloaner or intercooler NG Restricted lean, repair, or replace ox Turbocharger oil seal NS. Loakage Replace ox Turbocharger oil drain pipe NS. Restricted Repair or replace ox Air breather NS. Restricted ean ox Dood compersatr tenon | Ne batetve pal orepiace ox Compressor wheel Lid Impact damage Replace ox Turbine wheel Le) Impact damage Replace Continued on the next pageSERVICE INFORMATION 00-43 Checkpoint Trouble Cause Countermeasure Continued from the previous page ok Center housing oil drain passage | NS. Restricted lean or replace00-44 SERVICE INFORMATION 3) EXCESSIVE OIL CONSUMPTION Checkpoint Trouble Cause Countermeasure Air breather NG Restricted Gean ox Boost compensator hjecion | NG boteatve repair orrepice ox Turbocharger oil seal NG Leakage Replace ox Turbocharger oil drain pipe NS. Restricted lean or replace: ox Turbine wheel a Impact damage Replace ox Compressor wheel Lid Impact damage Replace ox Oil pressure uc Excessive Repair Continued on the next pageSERVICE INFORMATION 00-45 Checkpoint Trouble Cause Countermeasure Continued from the previous page ok Center housing oll drain NG Restricted Clean or replace passage00-46 SERVICE INFORMATION 4) EXCESSIVE TURBOCHARGER NOISE Checkpoint Trouble Cause Countermeasure ake and oma este NG aoe, hopair oK Intake and oxhaust system NG mene Damaged Repair oK Turbocharger rotating parte | NS Rough rotation Replace oK Compressor wheel Ne Rubbing against housing Repair or replace ne Damaged Replace oK Turbine wheel ue ubbing against housing Repair or replace NG Damaged Replace Ne Carbon deposits Gan or replace Continued on the next pageSERVICE INFORMATION 00-47 Checkpoint Trouble Cause Countermeasure Continued from the previous page ok il level NG Too low correct NG Contaminated Roplace oil oK Turbocharger oll feed pipe | NS. Restricted Repair or replace ok Turbine housing 1 Carbon deposits Goan ok Compressor housing ud Dirty ean ok ‘Turbine shatt bearings Ne Worn Replace00-48 SERVICE INFORMATION 5) EXCESSIVE ROTATING PART WEAR Checkpoint Trouble Cause Countermeasure Engine ol a Contaminated change NG Wrong grade or type change oK Turbocharger oll feed pipe | NE Restricted Ciean or replace oK Turbocharger oil soal Ne Detective Roplaco 0K Center housing ell drain NG peatretod San passage oK Turbine shat ue il sludge and coking Replace oK Engine lubrication system — | NO Inadequate oll supply CorrectSERVICE INFORMATION 00-49 MAIN DATA AND SPECIFICATIONS ITEMS, ewWaITC Engine type Combustion chamber Cylinder liner Timing drive system No. of cylinders ~ Bore x stroke mm (in) No. of piston rings Total piston displacement Compression ratio (to 1) Compression pressure at 150 rpm kPa (Kg/cm?/Psi) ems (in?) Engine dimensions mm (in) Engine weight (Dry) Nikg /Ib) Fuel injection order Fuel injection timing (BTDC) deg Specified fuel type Idling speed rpm Valve clearances Intake = mm (in) Exhaust mm (in) Intake valves Open at (BTC) deg Close at (ABDC) deg Open at (BEDC) deg Close at (ATOC) deg Exhaust valves Injection pump Governor type Injection nozzle Injection nozzle opening pressure kPa (Kg/cm2/Psi) Main fuel filter type Lubrication system Lubrication method Specified engine oil (API grade) Oil pressure (at oil gallery) kPa (Kg/cm2/Psiy/pm il pump type Four cycle, overhead camshaft, water cooled, direct injection Open type in piston crown Dry type Gear drive 6 - 182.9 x 145.0 (5.23 x5.71) Four rings (Compression rings: 8, Oil ring: 1) 12,068 (736.4) 165 2,942 (30/427) or more 1,685 x 980 x 1,145 (66.3 x 38.6 x 45.1) 10,640 (1,087 / 2,397) 1-5-3-6-2-4 See end page of Main Data and Specifications SAE No.2 diesel fuel 600 0.40 (0.016) 0.40 (0.016) 24 a 525 175 Bosoh in-line P-type For high altitude area: HD-TICS Variable speed mechanical governor with torque cam For highaltutude area: Electric control Hole type (Eight holes) 19,618 (200/2,844) For high altitude area 22,100 (225/3,200) Paper element Full flow pressure circulation cor co 147.4 (1.5121.3)/600 304.0 (3.1/44.1)/1,200 392.8 (4.0/56.99/2,000 Condition: SAE 80 API CD grade engine oil at an oil temperature of 80°C (176°F) Gear (Timing gear drive)00-50 SERVICE INFORMATION ITEMS, ewWAITC Relief valve opening pressure kPa (Kg/cm2/Psi) ist stage 2nd stage Oil pressure switch operating pressure kPa (Kg/cm2/Psi) Main oil filter type Bypass valve opening pressure kPa (Kg/cm"iPsi) Partial oil filter type Oil capacity Lit (imp. gal/US gal) Oil cooler Oil thermostat opening temperature om Cooling system Radiator type Radiator cap pressure kPa (Kg/cm*/Psi) Pressure side Vacuum side Coolant capacity Lit (imp. gal/US gal) Water pump type Delivery volume Litimin. (Imp. gaVUS gal) Thermostat type Valve initial opening temperature °C (°F) Valve lift mm (in) Coolant capacity Lit (Imp. ga/US gal) Air cleaner Battery type / Voltage x No. of units ‘Alternator capacity v-AW) Regulator type Rotation (Viewed from the pulley) Ground polarity Pulley diameter mm (in) Rotor coll resistance at 20% ohm Brush length mm (in) Starter motor output v-KW Number of poles Type Drive gears Number of pinion gear teeth 687 (7.0/9.5) 442 (4.5164.0) 9.8 (0.1/0.7) Paper element 196.1 (2.0/28.4) Paper element 31 (6.8/8.2) with combined main and partial oil filter Plate type - Water cooled in water jacket 98.0 (208.4) Pressured compulsory circulation water Corrugated fin with sub tank 61.8 -71.6 (0.63 -0.73/8.96 - 10.38) 2.04.9 (0.02 -0.05/0.28 -0.71) 6 (1.32/1.59) Centrifugal impeller, Gear drive 420 (92.4/111.0) Pump speed at 2,840 rpm Wax pellet 79 (174.2) 11.0 (0.433) 46.6 (10.3123) Cyclone type with paper element AA5F51/12x2 24 — 40 (1,000) Nikko For high altitude area: 24 ~ 110 x 2 (6000) Mitsubishi 1G (Built-in) Clockwise Negative 82.0 (8.228) WT Brush less 24 —6 Nikko For high altitude area: 24-7 Mitsubishi 4 Magnetic switch and shift lever controlled Reduction "SERVICE INFORMATION 00-51 ITEMS ewaAITC No load characteristics Voltage v 24 Current A 150 or less (For high altitude area 125 oF less) Operation speed (Rotor) Rotation (Viewed from the pinion gear) Turbocharger model Manufacturer Turbine type Compressor type Maximum permissible operating speed rpm. Exhaust gas temperature CF) Turbocharger Weight N (kg / Ib) 1,000 or more Clockwise RHC 91 Ishikawajima Harima Heavy Industry (IMI) Radial, inward flow Radial, outward flow 96,000 750 (1,882) Maximum allowable exhaust gas temperature measured at the turbocharger exhaust gas inlet 187 (16 /35.3) Fuel Injection Timing Countries Fuel injection timing (static timing) Taiwan, Hongkong, China BTC 9° Malaysia, Thailand, Singapore BTDC 10" New Zealand BTDC 14° Central and South America, Kenya BTDC 16" For high altitude area Columbia, Chile, Peru, Ecuador, BTocs° China, KenyaSERVICE INFORMATION 00-53 SERVICE STANDARD CONTENTS PAGE Engine 00 - 54 Cylinder Head and Valve 00 ~54 Rocker Arm and Camshatt ........ 0022. 00ecc0eeeeeeeeeeeeeeeeeseeeeeeeees 00 - 56 Timing Gear Train . 00 ~57 Crankshaft 00 -57 Piston and Connecting Rod 00 ~58 Piston and cylinder Liner Grade feessggcc tees ctati cece eer teueenriaeccaat 00 ~59 Cylinder Body and Cylinder Liner Grade 00-59 Cylinder Body .. 00 ~ 59 PIVW MOO) rrcccaisnc cua ictirisueuisnea: ans cetiresauiisnuaeaen: seminar 00 -60 Lubricating System . 00-60 Engine Cooling System 00-60 Engine Electrical ...... 02.02. 02-0220eeeee eee eeeeeeteeeeeeeeeeeeteeee ees 00-60 Alternator 00-60 Starter . 00-60 Turbocharger 00-6000-54 SERVICE INFORMATION SERVICE STANDARD ITEMS SERVICE STANDARD SERVICE LIMIT ENGINE ‘Compression Pressure 2042 (30/4266) / 150 2157 (22/312) kPa(kg/om2ipsiirpm | or more, after warm up the engine CYLINDER HEAD and VALVE Camshaft End Play ‘mmi(in) | 0.085 — 0.170 (0.0033-0.0067) 0.25 ( 0.0098 ) Gearnosbotwoen Gamshattand | oops 0-25 00026-00048) | 0.15(0.0059) Idle Gear “C" End Play mmi(in) | 0.05 — 0.14 (0.0020-0.0055) 0.25 ( 0.0098 ) Shaft idle Gear "C” Outside Pane) 48.93 — 48.96 (1.9264-1.9286) 48.85 ( 1.9282} Gunvancebetwean Satara wie" | oo, pros qoowwauom Se aeel mm(in) Valve Spring Free Height enm(ny | Outer Inlet 79.3 (3.1220) 75.3 ( 2.965 ) xnaust | 1027 120838) 37.6 (38%) imer Inlet = - Exhaust 96.4 (3.7953) 91.7 (3.6102 ) Valve Spring Squareness mm(in) | Inlet 3.5 (0.1378) 4.8 ( 0.1890 ) exaust Outer 4.5 (0.1772) 6.2 (0.2441 ) Inner 4.2 (0.1654) 5.9 ( 0.2323 ) Valve Spring torsion Nikgibyinm | Outer it was Bia (ORGAN (40.0/88.2)/64 Exhaust 610.0 578.6 ( 59.0/130.1 69 (622787 2969 Taner inlet = : Exnaust [eeee@easove6) 21208 (1.747 8) Valve Stem and Guide Clearance Inlet 0.040 -0.077 0.15 (0.0059 ) mmiin) (0.0016 —0.0030) Exhaust | 0065=0.108 325 (00088) (0.0026 - 0.0040)SERVICE INFORMATION 00-55 ITEMS ‘SERVICE STANDARD ‘SERVICE LIMIT Valve Stem Outside Diameter mm(in) | Inlet 10.0 (0.3987) 9:92 (0.3906 ) Exhaust [10.0 (0.3997) 9.90 (0.3898 } Bridge Guide and Bridge Clearance (0.020 - 0.087 (0.0080-0.0022) (0.10 (0.0039) mmiin) Valve Thickness. mmiin) | inlet 2.14 (0.0843) 1.64 ( 0.0646 } Exhaust [ 23 (0.0906) 1.8 (0.0709) Valve Depression miniin) | inlet 1.9 (0.0748) 2.9 (0.1142) Exhaust 1.8 (0.0709) 2.8 (0.1102) Valve Contact Width mm(in) | Intet 3.0 (01181) 3.4 (0.1889) Exhaust [ 25 (0.0964) 2.9 (0.1141) Valve Contact Surface Angle deg | Inlet 30 = Exhaust eB = Valve Seat Angle deg | Inlet 30 = Exhaust 5 = Valve Bridge Guide Upper End Height 49.0 (1.9291) - mmiin) Valve Guide Upper End Height mmi(in) | inlet 27.0 (1.0630) = Exhaust [ 29.0 (1.1417) =00-56 SERVICE INFORMATION ITEMS ‘SERVICE STANDARD ‘SERVICE LIMIT ROCKER ARM AND CAMSHAFT Rocker Arm Shaft Run Out mimiin) = 03 (0.012) Rocker Arm Shaft Outside Diameter 27.979 - 28.000 27.85 mmiin) (1.1015-1.1024) (1.0965) Rocker Arm Bushing Inside Diameter 28.020 — 28.053, = mmiin) (1.4031 - 1.1044) Rocker Arm and Rocker Arm Shaft 0.020 -0.074 02 Clearance mmiin) (0.0008 - 0.0029) (0.0079) Rocker Arm Roller and Fin Clearance 0.036 — 0.069 05 mmiin) (0.0014 0.0027) (0.02) Camshaft Journal Diameter mmiin) 39.915 - 39.940 39.80 (1.5715 - 1.5724) (1.5705) Cam Height miniin) | inlet 19.4 (0.3700) 8.85 (0.3484) Exhaust | 10.4 (0.4094) 9.75 ( 0.3839 ) Cam height = A -B. Camshaft Run Out mim(in) (0.080 (0.0031) 0.100 (0.0039 ) ‘Camshaft Bearing inside Diameter 40.015 — 40.040 = mmiin) (1.5754 ~ 1.5764) Clearance Camshaft and Cam Bearing 0.065 — 0.125 0.15 mmiin) (0.0026 ~ 0.0049) (0.0059 )SERVICE INFORMATION 00-57 ITEMS ‘SERVICE STANDARD ‘SERVICE LIMIT TIMING GEAR TRAIN idle Gear Backlash mm(in) 0.095 - 0.135 0.28 (0.0087 ~ 0.0083 ) (0.0091 ) Idle Gear End Play mm@n)| “AY 0.165 —0.230 0.35 (0.0020 - 0.0055) (0.0138 ) 0.050 = 0.140 0.25 (0.0020 - 0.0055) (0.0098 ) c 0.050 = 0.140 0.25 (0.0020 - 0.0055) (0.0098 ) idle Gear Spindle Outside Diameter 56.99 56.96 56.85 mmiin) (2.2413 -2.2425) (2.2382) 141,93 147.96 141.85 (6.5878 - 5.5890) (5.5846) 48.98 — 48.96 48.85 (1.9264 - 1.9286) (1.9282) Clearance Between Idle Gear and nv 0.040 -0.105 0.20 Spindle mmiiny| "8" | (0.0015 -0.0041) (0.0079 ) ee CRANKSHAFT CrankShaft End Play mm(in) | _0.04—0.18 (0.0016-0.0070) 0.80 (0.012) CrankShaft Journal Diameter mmi(in) | No.4 104.850 - 104.875 = (4.1279 -4.1289) Others | 104.880 104.905 = (4.1291 ~4.1809) Crankpin Diameter miniin) 91.895 - 91.925 = (3.6179 -3.6191) Crankshaft Run Out mmiin) (0.120 (0.0005) 0.15 (0.0059) Crankshaft End Play mimiin) 0.04-0.18 0.30 (0.0121) (0.0016 ~ 0.0070)00-58 SERVICE INFORMATION ITEMS ‘SERVICE STANDARD ‘SERVICE LIMIT Crank Bearing Spread mim(in) = 1145 (4.3898) Clearance Crankshaft journal and No.4 0.081 — 0.144 Bearing mmi(in) | Journal_| (0.0032 -0.0057) 0.16 (0.0063) Others 0.051 — 0.114 (0.0020 - 0.0045) PISTON AND CONNECTING ROD Fiston Ring Gap mmi(in)] 1st 0.35 0.50 2nd | (0.0138 -0.0197) 3rd 1.00 (0.0394) Oi 0.30 -0.45 (0.0118-0.0177) Clearance Piston Ring and Groove ist 0.40-0.142 0.28 mimiin) (0.0039 - 0.0056) (0.0091) end 0.10 -0.185 0.20 ard _ | (0.0039 --0.0053) (0.0073) Oi 0.025 = 0.065 0.15 (0.0010 - 0.0026) (0.0059) Piston Pin Diameter mim(in) 155.995 — 56.000 55.970 (2.2015 2.2047) (2.2035) Clearance Piston Pin and Hole _mmi(in) (0.008 = 0.02% (0.05 (0.0003 - 0.0008) (0.0020) Clearance Connecting Rod Small End (0.020 0.037 0.10 Bushing and Piston Pin mmiin) (0.0008 - 0.0015) (0.0039) Connecting Rod Alignment __mmi(in) 0.05 (0.002 or less) 0.20 (0.008) Clearance Crankpin and Connecting 0.083 = 0.108 0.16 Rod Bearing mmiin) (0.0013 - 0.0041) (0.0063) Clearance Connecting Rod and 0.175 -0.290 0.35 Crankshaft mmiin) (0.0069 0.0114) (0.0138) Clearance Piston and Cylinder Liner mm(in) (0.146 - 0.165 (0.0057 ~ 0.0065)SERVICE INFORMATION 00-59 ITEMS ‘SERVICE STANDARD SERVICE LIMIT PISTON AND CYLINDER LINER GRADE Oylinder Liner Inside Diameter _mm(in)| Grade “AY 132,900 - 132.910 = (6.2828 ~ 5.2327) “Be [192.911 - 192.920 = (6.2827 ~ 5.2331) “@ | 192.921 - 182.980 = (6.2881 ~ 5.2335) Piston Outside Diameter mm(in) | Grade a 182.745 — 192.754) = (6.2262 - 5.2265) 182.755 — 192.765 7 (6.2266 ~ 5.2270) 182.766 — 182.775 7 (6.2270 ~ 5.2274) Clearance Cylinder Liner and Cylinder (0.006 - 0.025 = Body mm(in) (0.0002 ~ 0.0010) ‘CYLINDER BODY AND CYLINDER LINER GRADE Cylinder Body Bore Diameter mm(in) | Grade “¥" [137.000 -137.010] 7 (6.3937 ~ 5.3941) 187.011 — 197.020) = (5.3941 - 5.3945) 197.021 = 197.080 : (5.3945 — 5.3949) Ovlinder Liner Outside Diameter Grade mm(in) | — =] 796985 — 136.894 - (6.3931 ~ 5.3935) 136.995 — 187.005) = (6.3995 - 5.3939) 137.006 — 197.015 - (63939 ~5.3943) Clearance Piston and Cylinder Liner 0.146 0.165 = Bore mméin) (0.0087 - 0.0065) CYLINDER BODY Oylinder Liner Bore mm(in) | _ Nominal Measurement 192.9 183.2 Gylinder Body Upper Face Warpage (0.0075 (0.0080) or less 0.2 (0.008) mméin) Cylinder Liner Projection mméin) 0.05 -0.09 = (0.0020 - 0.0086) Projection Height Between Adjacent 0.025 (0.0010) or less = Cylinder mmi(in)00-60 SERVICE INFORMATION ITEMS ‘SERVICE STANDARD ‘SERVICE LIMIT FLYWHEEL Depth from Friction Face to Pressure [Clutch Size] Plate Fixing Face mim(in) [47° 48.0 (1.890) 50.5 (1.988) 155° 20.0 (0.787) 21.5 (0.846) LUBRICATING SYSTEM Clearance Oil Pump Body and Driven 0.050 -0.098 = Gear mmi(in) (0.0020 - 0.0039) Side Clearance Oil Pump Cover and 0.040 -0.094 = Gear mimi(in) (0.0016 - 0.0087) Oil Pump Gear Shaft Diameter _ mm(in) 20.0 (0.7874) 79.9(0.7835) Clearance Oil Pump Gear Shaft and 0.040 -0.074 = Body mmi(in) (0.0016 - 0.0029) ‘An Interference Oil Pump Drive Gear 0.019 -0.047 = and Driven Gear mmi(in) (0.0007 - 0.0019) Oil Thermostat Opening Temperature 96.5 - 99.5 (205.7 - 217.4) = O(F) ENGINE COOLING SYSTEM = Clearance water pump impeller and 47-27 (0.0669 - 0.1063) = pump body mmiin) Thermostat Opening Temperature initial Opening | 79 (174.2) = ‘C(A) Trutl Opening | 95 (203.0) = Thermostat Full Valve Lift mim(in) 11 (0.433) = Radiator Testing Pressure 98.4 (1.07 44.2) = kPa(kg/om?ipsi) Radiator Sub Tank Filler Cap Pressure 618-716 = kPa(kgiomipsi) | __(0.63-0.73 / 8.96-10.38) ENGINE ELECTRICAL Alternator Rotor Coil Resistance ohm 147 = Startor Commutator Run Out mmi(in) | __ 0.015 (0.0006) or less 0.10 (0.004) Commutator Outside Diameter _mmi(in) | _42.9-43.1 (1.690-1.697) 47.5 (1.634) Brush Length mim(in) | _21 22 (0.827 - 0.866) 13 (0.512) Drive Gear Shaft Bending mim(in) 0.2 (0.0079) or less = ‘Armature Assembly End Pray 0.2=0.7 (0.0079 -0.0276) = (Reference) mmiin) Drive Gear Shaft End Play mmi(in) | _0.2—0.8 (0.0079 - 0.0815) = ‘TURBOCHARGER Turbine Shaft End Play mimiin) 0.075 -0.110 0.42 (0.0047) (0.0030 - 0.0043) Clearance Turbine Shaft and Bearing 0.430 - 0.285 0.275 (0.0108) mm(in) (0.0051 - 0.0098)SERVICE INFORMATION 00-61 SERVICING CONTENTS Nut and Bolt Angular Tightening Method .. Nut and Bolt Angular Tightening Method (Using the Special Tool) ...........++ 00 ~ 64 Air Cleaner Lubricating System Fuel System : : Water Separator (Water Sedimentor) with Pre Fuel Filter ........-.2.000e00008 00-68 Injection Nozzle Opening Pressure and Spray Condition Check ........--.--22-02202ee0eeee 00-69 Injection Nozzle Adjustment Air Bleeding . Cooling System Coolant Level Radiator Sub Tank Cap Inspection ...........-.2-2.0sceceeee cece ceeeeeee 00-72 Cooling System Leakage Check iii cess tctsee eer r er aunemmaueeeeenn 00-73 Raidator Cap Leakage Check Drive Belt Inspection Engine Control ... Idling Speed Inspection ............00ec0eceecsecseeteeeeeceeceeeeeeeee Idling Control Cable Adjustment ........0.c0ecseeseeeeeeeeceesseeeeeee® Accelerator Pedal Stopper Adjustment . Accelerator Switch Adjustment Engine Control Adjustment . .. : Final Engine Control Adjustment Check .........0-00c0eececeeeeeee eres 00-75 Valve Clomance Adjustment: 202 c csc ee eects ceurmesciee mec 00-76 Injection Timing Adjustment ........... 22 000-0ee0eeceee eee ee eee eeee eens 00-78 Compression Pressure Measurement .......... 6-000 cse sete cece tee eee e eee 00-7900 - 62 SERVICE INFORMATION SERVICING Servicing refers to general maintenance procedures to be performed by qualified service personnel. Y WARNING: ALLOW THE ENGINE TO COOL BEFORE BEGINNING ANY SERVICING PROCEDURE. THIS WILL ELIMINATE THE DANGER OF FIRE AND POSSIBLE INJURY. Nut and Bolt Angular Tightening Method The angular tightening method uses the plastic region of high tensile steel nuts and bolts to precision tighten, important engine fasteners, Because of the method's nature, there is a limit to the number of times a particular fastener may be reused This limit is specified in this Manual where applicable. El) Sxztully wash the nuts and bolts to remove al ci and grease. 2. Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts, =~ 2 i wa 4 Bl 3. Tighten the nuts and bolts to the specified torque (snug torque) with a torque wrench BOLT OR NUT Snug torque carnal 4, Draw a line ®4@) across the center of each nut or bolt after tighten the snug torque. aSERVICE INFORMATION 00-63 5. Draw another line ©-D) on the face of each of the parts to be clamped. This line should be an extension of the line 8) 6. Draw another line @~G) on the face of each of the parts to be clamped. This line will be in the direction of the specified angle © across the center © of the nut or bolt. X] 7: Use a socket wrench to tighten each nut or bolt to the point where the line &~@ is aligned with the line 6) Example: Specified Angle and Tightening Rotation A 1/12 of aturn B 1/6 of aturn c 1/4ofatum D 1/2ofatumn E One full turn00-64 SERVICE INFORMATION ce one al al Nut and Bolt Angular Tightening Method (Using The Special Tool) 1. Carefully wash the nuts and bolts to remove all oil and grease. 2. Apply molybdenum disulfide grease to the threads and setting faces of the nuts and bolts. 3. Use a torque wrench to tighten the nuts and bolts to the specified torque (snug torque). 4, Attach the angle gauge to the socket wrench Angle Gauge: 5-88400-266-0 5. Attach amagnet to some part to hold the angle gauge stationary. 6. Tighten the nuts and bolts to the specified angle, Noting the angle gauge indication Air Cleaner Element Cleaning and Replacement Element cleaning procedures will vary according to the condition of the vehicle usage. ‘The warning light comes on when the air cleaner element becomes fouling condition Washable Paper Element (Dry Type) Fy + Dust Fouted Element Rotate the element with your hand while applying compressed air to the inside of the element This will blow the dust free. NOTE: ‘Compressed air pressure must not exceed 686kPa (7kg / em? / 99.5psi). If the element damaged, the element must be replaced.SERVICE INFORMATION 00-65 i= Avoid giving a shock to the element when removing dust, or distortion or damage will result. 2. Carbon and Dust Fouled Element 1) Prepare cleaning solution of 300grams (0.66Ib) of Donaldson ND1500 or N1400 element cleaner diluted in 20 liters (4.4imp / 5.3US gallons) of lukewarm 2) Dip the element in the solution for thirty minutes. Periodically shake the element within the solution to thoroughly clean it. 3) Remove the element from the solution and rinse it well with running clean water NOTE: Water pressure must not exceed 274.7kPa (2.8 kg/ cm?/ 39.8psi). 4) Dry the element in a well ventilated area. An electric fan will hasten drying NOTE: Do not use compressed air or an open flame to dry the element quickly. Damage to the element will result. It will usually take one week for the element to dry completely. Therefore, it is a good idea to have a spare on hand to use in the interim. 5) Use an inspection light to check the inside of the element and the gasket for damage. If the element damaged, the element must be replaced,00-66 SERVICE INFORMATION Air Cleaner Body Wipe the air cleaner body inside surfaces and the gasket fitting surfaces free of foreign material Do not allow foreign material to enter the air intake pipes or the manifold. Lubricating System Separate Type Main Oil Filter and Partial Oil Filter Replacement Procedure. WARNING: HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS. ALLOW THE ENGINE TO COOL BEFORE DRAINING THE ENGINE OIL. 1. Remove the drain plugs ©) to drain the engine oil from the main oil filter and partial oil filter FX] 2: Wait a few minutes and then retighten the drain plugs to specified torque. Drain Pug Torque N-m (kg:m /b-ft) 44.0 (4.51325) 3. Loosen the center bolts @ to remove the filter body @ together with the element @ Discard the used element, the gasket, and the O-rings. El] 4 Gean the titer body together withthe other parts by immersing them in clean diesel fuel. 5, Wipe the fitting faces of the filter bracket with a clean rag. 6. Apply light coat of engine oil to the center bolt and the new O-rings. 7. Install the filter body together with the new element and gasket to the filter cover. x] 8 Tighten the center bolt to the specified torque. Center Bolt Torque Nem (kg-m / tt) 44.0 (4.5 /82.5) Drain plig Center bolt = NOTE: Take care not to distort or twist the O-ring when tightening the center bolt. Hold the filter body with your hand to prevent it from turning as you tighten the center bolt.SERVICE INFORMATION 00-67 Air plug 9. Check the engine oil level and replenish to the specified level if required 10.Start the engine and check for oil leakage from main oil filter and partial oll filter Oil Pan Capacity lit (imp / US gal} MAX 26.5 (6.8/7.0) Fuel System Fuel Filter 1. Loosen the fuel filter drain plug @ to drain the fuel NOTE: Do not forget to retighten the drain plug after draining the fuel. Drain Plug Torque Nem (kg-m /Ib-ft) 24.5 (2.5/18.1) 2. Loosen the center bolt (#) to remove the fuel filter case @ together with the element @, the strainer D, and O-ring & from the filter case, Discard the used element and the O-ring 3. Clean the filter case together with other parts immersing them in clean diesel fuel 4, Wipe the filter case fitting surfaces with a clean rag 5. Install the filter case with the new element, the O- fing, and the strainer @ to the filter body The O-ring must be replaced with new one. 6. Tighten the center bolt to the specified torque. Filter Center Bolt Torque Nem (kgm Fb) 27.4 (28/200) NOTE: Take care not to distort or twist the O-rings when tightening the center bolt. Hold the filter case with your hand to prevent it from turning as you tighten the center bolt.00-68 SERVICE INFORMATION Red float imc) Water Separator (Water Sedimentor) with Pre-Fuel Filter Drain water from the water separator in the following manner when the red float reaches drain level 1. Place a container (Approximately 0.2 liters (0.76US/ 0.04imp gallons capacity) at the end of the vinyl hose beneath the drain plug on the separator. 2. Loosen the air intake plug and drain plug @ by turning it counterclockwise, until the water is drained. 3. After draining, securely tighten the drain plug and air intake plug. Operate the priming pump on the injection pump to bleed the fuel system Refer to “Air bleeding” 4. Alter starting the engine, check to see that no fuel leak from the drain plug The pre fuel filter should be serviced in the following manner. Itis strongly advisable to use ISUZU genuine fuel filter element kit for replacement. 1. Loosen the transparent cover and remove the element together with the cover. 2. Discard the used element and install new ones, Securely tighten the cover. ® Cover @ Bement Alter servicing, bleed the fuel system and check for fuel leaks.SERVICE INFORMATION 00-69 Injection Nozzle Opening Pressure and Spray Condition Check 1. Use an injection nozzle tester to check the nozzle opening pressure If the opening pressure is above or below the specified value, the injection nozzle must be replaced or adjusted Refer to "Adjustment of Injection Nozale Opening Pressure.” Injection Nozzle Opening Pressure _kPa (kg / om?/psi) 19/613 (2007 2,844) For high altutude area: 22,100 (225/3,200) WARNING: ‘TEST FLUID FROM THE INJECTION NOZZLE TESTER WILL SPRAY OUT OF THE INJECTION NOZZLE UNDER GREAT PRESSURE. IT CAN EASILY PUNCTURE A PERSON'S SKIN. KEEP YOUR HANDS AWAY FROM THE INJECTION NOZZLE AT ALL TIMES. 2. Check the spray condition If the spray condition is bad, the injection nozzle must be replaced or reconditioned ) Correct @ Incorrect (Restrictions in orifice) @ Incorrect (Dripping) If lapping is required, refer to ‘Nozzle Lapping Procedure of FUEL SYSTEM.”00-70 SERVICE INFORMATION Injection Nozzle Adjustment 1. Attach the injection nozzle holder to the injection nozzle tester 2. Apply pressure to the nozzle tester. Note the pressure at which the injection nozzle opens. Injection Nozzle Opening Pressure _KPa (kg /cm2/psi) 19,613 (2007 2,844) For highaltutude area: 22,100 (225/3,200) Nozzle Tester: 1-8531-1001-0 {An adjusting shim of 0.007 mm (0.0008 in) allows the press to change by about 98.1 kPa (1.0 kg/cm? / 14.2 Psi). The adjusting shim thickness calculation method as follows. The adjusting shim thickness calculation method. Px mid x (A2~B?) 7 = Shim thickness(mm) P (kPa) = (Target injection nozzle opening pressure ~ Indicated value(pressure) of nozzle tester) A(om) =Needle diameter. 0.6 om B (om) =Sheet diameter. 0.26 cm C(Nimm) = Spring constant. 263.8 Nimm After calculates shim thickness to select shims from below list, Adjusting Shim Availability mm Thickness Part number 0.50 5-15839-007-0 0.52 5-15339-018-0 0.54 5-15889-019-0 0.56 5-15339-020-0 0.58 5-15389-021-0 0.60 5-15339-008-0 0.70 5-15339-009-0 0.80 5-15339-010-0, 0.90 5-15339-011-0 1.00 5-15339-012-0, 0.10 8-94128-982-0 0.20 8-94128-983-0 0.30 8-94128-984-0 0.40 8-94128-985-0SERVICE INFORMATION 00-71 Drain plug Strainer Air Bleeding When servicing the fuel filters or if the fuel tanks emptied, air might be allowed to go into the fuel system. With air in the fuel system, smooth flow of fuel into the engine is interrupted and to prevent this, bleeding of the fuel system should be performed. 4. Loosen the priming pump cap and pump the fuel into the injection pump by manually operating the Priming pump. 2. With a wrench, loosen the air plug of the fuel filter and pump the fuel until all the air bubbles in it disappear by being pumped out through the air plug. 3. There are no bubbles and the fuel comes out in a solid stream. Now securely tighten the air plug and priming pump cap. Feed pump strainer Remove the joint bolt on the intake side of the feed pump, then screw out the strainer counterclockwise and clean it. Then, operate the priming pump on the injection Pump to bleed the fuel system Fuel tank Remove the drain plug and drain the water and sediment completely.00-72 SERVICE INFORMATION Vv Freezing point °C) MOSS e isa eww E tO Mixing ratio () Vv Cooling System WARNING: HOT STEAM UNDER PRESSURE MAY ESCAPE FROM ‘THE RADIATOR IF THE RADIATOR SUB TANK CAP IS OPENED WHILE THE ENGINE IS HOT. THIS CAN RESULT IN SERIOUS BURNS. ALLOW THE ENGINE TO COOL BEFORE OPENING ‘THE RADIATOR SUB TANK CAP. Coolant Level Check the coolant level and replenish the radiator sub tank if necessary It the coolant level falls below the "MIN’ line, carefully check the cooling system for leakage. Then, add additional coolant to raise the level over the "MIN" line. NOTE: Do not overfill the radiator sub tank. Remove the radiator sub tank cap only when absolutely necessary. Always refer to the chart at the left to determine the correct cooling water to antifreeze solution mixing ratio. Radiator Sub Tank Cap Inspection WARNING: HOT STEAM UNDER PRESSURE MAY ESCAPE FROM ‘THE RADIATOR IF THE RADIATOR SUB TANK CAP IS OPENED WHILE THE ENGINE IS HOT. THIS CAN RESULT IN SERIOUS BURNS. ALLOW THE ENGINE TO COOL BEFORE OPENING ‘THE RADIATOR SUB TANK CAP.SERVICE INFORMATION 00-73 Alternator is] Cooling System Leakage Check 1. Remove the radiator filler cap from the radiator sub tank, 2. Install the radiator filler cap tester to the radiator sub tank. 3. Apply the specified test pressure to the cooling system to check for leakage. Do not exceed the specified test pressure. Cooling System Test Pressure __kPa (kg /om2/psi) 98.1 (1.0/14.2) Repair or replace the leakage unit if required Radiator Cap Leakage Check ‘The radiator sub tank filler cap maintains cooling system pressure. It must tightly seal the cooling system 1. Remove the radiator filler cap from the radiator sub tank 2. Install the radiator cap to the radiator filler cap tester. 3. Apply the specified test pressure to the cap to check for leakage. Do not exceed the specified test pressure Radiator Filler Cap Test Pressure _ kPa (kg /om?/psi) 61.8 — 71.6 (0.63 —0.73/ 8.96 — 10.38) Negative Valve Pressure kPa (kg /om?/ psi) 2—5 (0.02 -0.05/ 0.28 -0.71) Replace the radiator sub tank filler cap if it fails to hold the specified test pressure Drive Belt Inspection Check the drive belt tension Depress the drive belt mid-portion with a 98N (10kg 1 22Ib) force. 14-17 (0.55 — 0.67) Check the drive belts for cracking and other damage.00-74 SERVICE INFORMATION Engine Control Idling Speed inspection 1. Set the vehicle parking brake and chock the drive wheels. 2, Plage the transmission in neutral 3. Start the engine and allow it to warm up. 4. Disconnect the idling control cable from the idling control lever 5, Set a tachometer to the engine. 6. Check the engine idling speed. If the engine idling speed is outside the specified range, it must be adjusted. Engine Idling Speed rpm. 500 Idling Control Cable Adjustment 1. Disconnect the engine control cable trom the injection pump control lever. 2. Rotate the idling control knob ® counterclockwise as far as possible, 8. Loosen the idling control outer cable @ at the clip ©. 4, Hold the engine control link ) against the link stopper (2 as shown in the @ area of the illustration. 5. Hold the idling control lever against the engine control link as shown in the @) area of the illustration: 6. Set the idling control outer cable @ to the clip @-There must be no slack in the inner cable. 7. Reconnest the engine control cable to the injection pump:SERVICE INFORMATION 00-75 Accelerator Pedal Stopper Adjustment = © 10-20 aprox iam ap i= 1. Set the stopper bolt cap height ® to 79 mm (3.1 in) 2, Temporarily tighten the stopper bolt lock nut. The lock nut will be finally tightened after completion of the engine control adjustment procedure below. Accelerator Switch Adjustment 1. Check that the engine control link and the link stopper are in contact with each other. 2. Adjust the height @ of the accelerator switch: Accelerator Switch Height mm (in} 16 = 17 (0.630 - 0.669) Engine Control Adjustment 1. Connect the engine control cable to the injection pump control lever 2. Adjust the cable length between the control lever and the cable clip @) to the specified value. mm (in) Control cable length (L) 213 (8.39) 3. Adjust the accelerator stopper bolt. 1) Depress the accelerator pedal ® and hold it. 2) Bring the pedal stopper bolt cap @ into contact with the full stopper. 3) Turn in the pedal stopper bolt 1~1-1/2 turns to adjust the clearance between the accelerator pedal and the stopper bolt cap to 12mm 4) Tighten the stopper bolt lock nut Final Engine Control Adjustment Check 1. Start the engine and allow it to warm up 2, Turn the idling control knob fully to the left 3. Check that the idling speed is within the specified range. Engine Idling Speed rpm 50000-76 SERVICE INFORMATION If the idling speed is outside the specified range, loosen the engine control cable end turnbuckle (arrow) to adjust it 4. Depress the accelerator pedal until it reaches the accelerator pedal stopper Check that the injection pump control lever is making contact with the full load stopper. IF the injection pump control lever is not making contact with the full load stopper, readjust the accelerator pedal stopper and the engine control cable. J] Valve Clearance Adjustment The following instructions assume that valve clearance is adjusted beginning with the No. 1 piston at top dead center (TDC) on the compression stroke. Check alignment timing mark between automatic timer and mark line on injection pump body. In this position indicate T.0.C. of No.1 piston Valve clearance must be adjusted when the engine is cold. When remove the head cover, wipe off spilled oil with arag 1. Bring the piston in the No. 1 or No. 6 cylinder to the top dead center on the compression stroke by turning the crankshaft until the T.D.C line on the flywheel is aligned with the timing pointer. Check the rocker arm shaft bracket nuts for looseness and retighten as necessary before adjusting the valve clearance. 2. Cheok that the No. 1 intake and exhaust push rods have play. if they have play, it indicates that the No. 1 piston is at TDC (Top Dead Center) on the compression stroke, If the No. 1 exhaust valves are depressed, the No. 6 piston is at TOC on the compression stroke.SERVICE INFORMATION 00-77 GT EI! 8. Adjust valve clearances for the No. 1 or No. 6 cylinder which its piston is at TOC on compression stroke 1) Loosen each adjusting screw on the bridge and rooker arm| Valve Clearance mm (in) 0.4 (0.0016) 2) Insert a feeler gauge between the rocker arm and the cam and adjust by turning the adjusting screw on the rocker arm until there is a slight drag on the feeler gauge. Tighten the lack nut securely. 3) With a feeler gauge inserted, screw in the adjusting screw on the bridge gradually until it touches to the end of the valve stem, and make sure that the movement of the feeler gauge becomes hard. 4) In this condition, the opposite end of the bridge is raised. Readjust by loosening the adjusting screw on the bridge until there is.a slight drag on the feeler gauge and tighten the lock nut securely 4, Rotate the crankshaft 360° and realign the T.C. mark ‘on the flywheel with the pointer and adjust clearance for remaining valves The "@" mark in the illustration indicates the cylinders and valves to be adjusted. NOTE: Be sure to move the No. 1 cylinder to TDC on the compression stroke after completing the valve clearance adjustment procedure. Tightening Torque N-m (kg:mn/loft) Position Torque Rocker Arm Adjusting Screw Nut_| 78.5 (8.0579) Bridge Adjusting Screw Nut 54.0 (6.5/99.8)00-78 SERVICE INFORMATION Intake and Exhaust Valve Arrangement Valve Names ylinder No. No. 1 cyl. at TDC on compression No. 6 cyl. at TDC on compression i:intake valve. E: Exhaust valve Injection Timing Adjustment Injection Timing Inspection 1. Disconnect the negative battery cable. 2. Rotate the crankshaft in the normal direction of engine rotation to align the injection timing mark on the flywheel with the timing pointer. Injection Timing (Static) ‘See Main Data and Specifications 3. Check that automatic timer notched line is aligned with the injection pump notched line. If the notched lines are out of alignment, the injection timing must be adjusted. lreereerereteerercemniemmneeperieeteetra] Injection Timing Adjustment 1. Rotate the crankshaft in normal direction of rotation until the timing mark on the automatic timer housing can be seen 2. Align the injection timing mark on the flywheel with the pointer. 3. Loosen the two coupling bolts. 4, Move the automatic timer to the correct timing 5. Tighten the two coupling bolts, 6. Rotate the crankshaft two turns in normal direction of crankshaft rotation. 7. Check the new setting the injection timing. 8. Connect the negative battery cableSERVICE INFORMATION 00-79 '@] Compression Pressure Measurement To measure the compression pressure, the engine must be cold. Engine coolant temperature should be at 20°C. Battery and starter motor condition must be normal 7 @]__*- Remove the injection nozzle assembly and the ! injection fuel pipe from the each cylinder. ie Nozzle Holder Remover: 1-8523-0013-0 = |] 2 Install the compression gauge adapter to the No. 1 cylinder injection nozzle installation hole. Compression Gauge Adapter: 5-8531-7019-0 8. Install the compression gauge to the compression gauge adapter. 4. Crank the engine with starter motor (about 200 rpm) and take the compression gauge reading 5. Repeat the procedure (Step 2 to 4) for the remaining cylinder. Compression Pressure kPa (kg /cm?/ psi} Standard Limit 2,943 (30.0 / 426.6) 2,256.8 (23.0 / 327.1) Compression pressure should be approximately the same for each oylinder. ‘A variation exceeding 196.1kPa (2.0kg/om® / 28.4psi) is unacceptable.SERVICE INFORMATION 00-81 FIXING TORQUE CONTENTS PAGE Engine External Parts 00-82 Cylinder Head, Rocker Arm Shaft and Camshaft . 00-83 Crankshaft Pulley, Timing Gear and Timing Gear Case Cover ..........2.-.--+- 00-84 Lower Crankcase and Connecting Rod 00-85 Flywheel and Engine Foot . 00-86 Oil Pan and Oiling Jet . . 00-87 (OU PUR ete eee ener 00 ~88 Oil Cooler ... 00-89 Water Pump 00-90 Bag eraregegrereree rrr ery Peace errr gerard reereererirersy arrears 00-91 Turbocharger 00-92 Flywheel PT.O. 00-93 SPECIAL TOOLS CONTENTS PAGE Special Tools 00-9400 - 82 SERVICE INFORMATION FIXING TORQUE Engine External Parts Nm (kg-m / Ib-ft) Air Compressor Bolt 133.4 (13.6/98.4) Steering Pump 38.3 (3.9/28.2) Fuel Filter Center Bolt 39.2 (4.0/28.9) Starter Motor 103.0 (10.5/75.9) Oil Cooler Bolt 7 * 43.2 (4.4/31.8) @ oy on 44.2 (4.5/32.5) iter Center Bolt 49.1 (5.0/36.2) APPT |) Injection Pump For Oil Pipe a Jie 39.3 (4.0/28.9) | Eye Bolt | 57.9 (5.9/42.7) == Coupling Bolt Injection Pump Bracket ‘Turbocharger Nut Thermostat Housing Bolt 1 40.2 (4.1/29.7) 28.9) ( gy = Exhaust Manifold Nut [37.3 (3.8/27.5) Water Pump Bolt 39.3 (4.0/28.9)SERVICE INFORMATION 00-83 Cylinder Head, Rocker Arm Shaft and Camshaft N-m (kg-m / Ib-ft) 20 (2.0/14) 29 (3.0/2) 90 (9.2/67) Apply engine oil Sa [49 (6.0736) 137 (14.0/101) Apply engine oil mot A disulfide \ grease. | nt 39 (4.0/29) Cylinder Head Bolt Torque 1st Step | 2nd Step| 3rd Step 1766 | 2453 . M18 | (18/130) | (25/181) | 8-9 M2 75.5 (7.7/55.7) M10 38.3 (3.9/28.2)00-84 SERVICE INFORMATION Crankshaft Pulley, Timing Gear and Timing Gear Case Cover N.m (kg-m / lb-ft) 49 (5.0/36) [39 14.0729) | . o® ®) 39 (4.0/29) 7 re i i 539 (55.0/398) Apply molybdenum disulfide grease fa [20s 2.07195 | ‘peor Apply engine oil 108 (11.0/80) | [me Bon | 25 @ar701 |SERVICE INFORMATION 00-85 Lower Crankcase and Connecting Rod N-m (kg-m / Ib-ft) 41 (4.27/30) & Aststep_| 2ndstep | ardstep _| 98 (10.0/72)| 30deg | 30deg OY & ‘Apply molybdenum disulfide grease v [iz Bott 96 (9.8/71) ‘Apply engine oil L Ist step | 2nd step| 3rd step mis | 49 38 90-120 Bolt _| (5.0/36) | (9.0/65)| deg [Apply molybdenum disulfide grease00-86 SERVICE INFORMATION Flywheel and Engine Foot N-m (kg-m / Ib-ft) 147 275 Ist step | 2nd step (15.0/108) | (28.0/203) M14 Bolt | 123 (12.5/90) Ms Bolt| 22 (2.2/16) ‘ist step_| 2nd step 78 (8.0/58) | 60 deg Apply molybdenum disulfide grease00-88 SERVICE INFORMATION Oil Pump Nm (kg-m / Ib-ft) [17.2 (1.8/13.0) 9s 39.3 (4.0/57.9)SERVICE INFORMATION 00-89 Oil Cooler Nm (kg-m / Ib-ft) 42 (0.4/2.9) 24.5 (2.5/18.1)00-90 SERVICE INFORMATION Water Pump N-m (kg-m / Ib-ft) 27.5 (2.8/20.3) ay 39.3 (4.0/57.9)SERVICE INFORMATION 00-91 Thermostat Housing N-m (kg-m / Ib-ft) 39.3 (4.0/57.9) 19.6 (2.0/14.5)00-92 SERVICE INFORMATION Turbocharger N-m (kg-m / Ib-ft) 23.0 (2.3/1.6) |SERVICE INFORMATION 00-93 FLYWHEEL PT.O. N-m (kg-m / Ib-ft) 112.0 (11.4/82) 82.0 (8.4/61) ‘Iststep_| 2ndstep | 3rdstep 30 (3.0/21.7)|49 (5.0/36.2)| 60 deg | co ® “ 147.0 (15.0/108.0) | [reron7anzs.0|00-94 SERVICE INFORMATION SPEC OOLS [Se 1-8523-0013-0 Nozzle Holder Remover 1-8531-7019-0 Compression Gauge Adapter 5-8840-0266-0 Angle Gauge 9-8523-1202-0 Valve Guide Remover and Installer 9-8522-1324-0 Valve Bridge Guide Installer 4.8820-1196-0 valve Stem Seeler InstallerSERVICE INFORMATION 00-95 ILLUSTRATION PART NUMBER PART NAME 1-8522-1029-0 Piston Ring Setting Too! 41-8521-0027-0 Slinger Remover 9-8521-0157-0 Pilot Bearing Puller 1-8522-1057-0 Pilot Bearing Setting Too! 1-8522-0046-0 Piston Setting Tool 1-8521-0063-0 Taper Bushing Remover 1-8522-0049-0 il Seal Installer 1-8522-0043-0 Oil Seal Installer00-96 SERVICE INFORMATION ILLUSTRATION PART NUMBER PART NAME 1-8521-0064-0 Crankshaft Gear Remover 1-8522-0045-0 Crankshatt Gear Installer 1-8521-0062-0 Impeller Remover 1-8522-0047-0 Seal Unit Installer 41-8521-0067-0 Seal Ring Puller 1-8522-1034-0 Seal Ring InstallerENGINE MECHANICAL 6A-1 SECTION 6A ENGINE MECHANICAL CONTENTS General Description ... Engine Lubrication System... Lubricating Oil Flow Lubricant Flow Chart .. Oil Pump and Oil Filter. Oil Cooler Engine External Parts. 7 Removal. . 7 Installation .. 22 Cylinder Head and Valve Mechanism. Removal... Installation... Disassembly Inspection and Repair... Reassembly ....... Rocker Arm and Shaft Assembly. Disassembly .... Inspection and Repair... Reassembly . Camshaft ... Disassembly .... Inspection and Repair. Reassembly . BSsynusgge26A-2 ENGINE MECHANICAL PAGE Installation Flywheel . Removal. Installation Crankshaft, Piston and Connecting Rod. . Removal. Installation Crankshatt ... Disassembly Inspection and Repair. Reassembly ... Piston and Connecting Rod Disassembly .... Inspection and Repair. Piston and Cylinder Liner Grade Selection Reassembly Flywheel and Crank Pulley -- 6A-103 Disassembly .... - 6A-103 Inspection and Repair. - 6A-105 Reassembly . 6A - 106 Cylinder Body. 6A - 108 Disassembly .... -- 6A-108 Inspection and Repair. - 6A-110 Reassembly - 6A-112 Oil Pump..........+. 6A-115 Oil Pump Construction. 6A-115 Disassembly .... 6A-116 Inspection and Repair. - 6A-118 Reassembly - 6A-120ENGINE MECHANICAL 6A -3 PAGE Oil Cooler 6A -123 Disassembly 6A -123 Inspection and Repair... - 6A-125 - 6A-126 - 6A-128 Disassembly 6A -128 Inspection and Repair. 6A ~130 Reassembly 6A-131 Partial Oil Filter - 6A-133 Disassembly .... - 6A-133 Inspection and Repair... - 6A-135 Reassembly - 6A-1366A~4 ENGINE MECHANICAL GENERAL DESCRIPTION The 6WAt engine is a four-cycle, six-cylinder, in-line, direct fuel injection type diesel engine with the piston displacement of 12,068 cm? (736 in®). It features a gear-driven OHC (overhead camshaft) timing train and unique mechanisms and systems designed for outstanding quietness, economy and durability The cylinder head is made of cast iron and has a cross-flow layout with the intake system in the left, side and the exhaust system in the right side, designed to reduce resistance in the intake and exhaust system The cylinder head gasket is of the laminated of least fatigue in combination with the angular cylinder head bolt tightening method, equally designed to increase reliability against gas and water leakage. The cylinder body is made of cast iron having dry cylinder liner and seven bearings. The bearing cap has a ladder frame construction integrating the crankcase to increase rigidity The cylinder liner is made of thin iron plus special alloys and is combined with the chrome-plate piston ring to ensure good resistance against wear. The piston is made of aluminum alloy. A ring trigger is cast into the first and second ring groove and chrome plating is applied to four sides of the first and third ring to ensure sufficient strength and wear resistance of the ring and the ring groove. The crankshaft is made of forge steel with seven bearings and twelve counterweights to reduce revolution load to the bearing. The gear train is located at the front of cylinder body to minimize influence of the torsional vibration of the crankshaft and the radiant sound. Noise is further reduced, to the same level as a timing belt driven system, by integrating the crankshaft gear with the crankshaft by shrink fit careful tuning of the gear precision, contact gear ratio, backlash, bearing rigidity neutral frequency, etc,ENGINE MECHANICAL 6A-5 ENGINE REMOVAL Read this section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin. Some illustrations are not same shape of actual parts, the illustration are used to make only imagination for removal or installation. [«»| Removal Steps (Those steps are based on C & E series.) ‘+ Carefully remove the piping, hoses, wiring harness connectors, engine control cables, and control rods from the engine. ‘+ Remove the clutch slave cylinder or clutch booster (Minipack), the control cables, the back up light switch, and the speedometer cable from the transmission YV WARNING: ALLOW THE ENGINE TO COOL BEFORE REMOVE ANY PARTS. THIS WILL ELIMINATE THE DANGER OF FIRE AND POSSIBLE INJURY. Battery 1, Disconnect the grounding cable © and the battery cable @ from the battery terminals. Be careful not to short the battery with your wrench or another tool at this time6A~6 ENGINE MECHANICAL 2. Disconnect the battery cable at the starter motor and the grounding cable at the chassis frame. Air Cleaner Remove the air intake hose from the intake duct. Coolant Remove the water drain plug (at the right side of the engine) and the radiator drain plug and allow the coolant to drain completely WARNING: HOT STEAM UNDER PRESSURE MAY ESCAPE FROM ‘THE RADIATOR IF THE COOLANT IS DRAINED WHILE ‘THE ENGINE IS HOT. THIS CAN RESULT IN SERIOUS BURNS. ALLOW THE ENGINE TO COOL BEFORE DRAINING ‘THE COOLANT. I long life coolant is used, drain the coolant into a clean container so that it can be reused. Refer to the Maintenance Schedule in Section 00, *GENERAL INFORMATION’. Radiator 1, Disconnect the radiator upper rubber hose to the radiator 2, Remove the radiator lower rubber hose from the radiator, 3. Disconnect the radiator overflow rubber hose from the radiator 4, Disconnect the air delivery pipe from inter cooler. 5. Disconnect the air supply pipe from turbocharger.v ENGINE MECHANICAL 6A -7 6. Remove the radiator cushion rubber nuts. 7. Remove the radiator with inter cooler. Be careful remove the radiator not to damage the radiator and inter cooler core. Engine Control Cable Disconnect the engine control cable from the interim connection bracket. Engine Oil Dr Oil Pan Drain Plug 1, Remove the oil pan drain plug @ to drain the engine oil WARNING: HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS. ALLOW THE ENGINE TO COOL BEFORE DRAINING ‘THE ENGINE OIL. 2, Reinstall the drain plug and tighten to the specified torque, Oil Pan Drain Plug Torque Nem (kg-m /Ib-ft) 78 (8.0/58) Oil Filter 4, Loosen the main and partial oil filter drain plugs @ to drain the engine oil Removing the center bolts @ will facilitate oil drainage from the oil filter. 2. Reinstall the drain plugs and tighten them to the specified torque, Oil Filter Drain Pug Torque Nem (kg-m /b-ft 44.2 (45/925) Center Bolt Torque Nem (kg-m /b-t) Main oil filter 44.2 (451825) Partial oll filter 49.1 (6.0/ 36.2)6A~8 ENGINE MECHANICAL Propeller Shaft 1, Disconnect the 1st propeller shaft flange yoke from the output shaft of transmission. 2. Lower the propeller shaft carefully to the ground. Cab Mounting Rear Member Remove the cab mounting rear member from the chassis frame. Exhaust Brake Assembly Disconnect the exhaust brake control air hose, Transmission Refer to Section 7, "TRANSMISSION," Removal and Installation”ENGINE MECHANICAL 6A -9 Clutch Pressure Plate and Driven Plate Refer to Section 7, "CLUTCH", "Removal and Installation” Exhaust Pipe 1. Loosen the front exhaust pipe, silencer and ‘exhaust pipe clamp bolts and nuts. 2, Disconnect the front exhaust pipe from the exhaust manifold/turbocharger. Front Engine Mounting Rear Engine Mounting 1. Attach lifting wires to the engine lifting hangers. 2, Raise the hoist until there is no slack in the lifting wires. 93. Remove the front engine mounting nuts and the rear mounting bolts. Engine 1. Operate the hoist to slowly raise the engine until it is clear of the chassis frame. Make sure that the connecting pipes, hoses, and cables have all been removed from the engine. The front of the engine should be held slightly higher than the rear at this time. Rotate the engine 90 degrees. Continue to lift the engine from the chassis. Carefully move the hoist and engine. Place the engine on an engine stand6A-10 ENGINE MECHANICAL INSTALLATION Pe] Installation Steps (Those steps are based on C & E series.) Follow the removal procedure in the reverse order to perform the installation procedure. Pay careful attention to the important points during the installation procedure. Engine 1, Attach a lifting wire to the engine lifting hangers. 2. Operate the hoist to position the engine above the chassis frame 8. Carefully lower the engine until itis just above the chassis frame 4, Rotate the engine 90 degrees to position it for final installation. 5, Carefully lower the engine into the chassis. The front of the engine should be held higher than the rear at this time. Be careful not to damage the exposed parts and the cab, 6. Lower the engine until it contacts the engine mounting rubbers. 7. Set the engine mounting bracket to the mounting rubbers. Front Engine Mounting Rear Engine Mounting Tighten the mounting nuts and bolts to the specitied torque. Front Mounting Nut Torque 228 (28 / 166) Rear Mounting Bolt Torque Nem (kg:m / tft) 490 (50 / 362) Nem (kg:m / Ibtt)ENGINE MECHANICAL 68-11 a Clutch Pressure Plate and Driven Plate Refer to Section 7, "CLUTCH", "Removal and Installation” Transmission Refer to Section 7, "TRANSMISSION, Installation.” Removal and Propeller Shaft 1. Install the 1st propeller shaft flange yoke to the. transmission 2. Tighten the propeller shaft flange nuts to the specified torque. Propeller Shaft Flange Nut Torque Nem (kg-m /ib-t) 255 /26.0/ 188 Radiator 1. Install the radiator with the mounting cushion rubbers. Be careful not to damage the radiator core. Tighten the radiator cushion rubber nuts. Connect the radiator upper and lower hoses. Connect the radiator overflow rubber hose. Connect the both air delivery and supply pipe to the inter cooler.6A-12 ENGINE MECHANICAL Exhaust Pipe 1. Connect the front exhaust pipe and exhaust brake assembly to the exhaust manifold 2. Temporarily tighten the front exhaust pipe silencer and exhaust pipe clamp bolts and nuts. FX]: Tighten front exhaust pipe flange nuts evenly to the specified torque. Exhaust Pipe Nut Torque Nem ¢kg-m / tft) 30 (4729) NoTI When tightening the flange nuts, the clearance between collar (*) of D.J.M. device and flange (2) must be even. 4, Full tighten the each exhaust pipe clamp bolts and nuts. Cab Mounting Rear Member Radiator Reserve Tank 1. Install the cab mounting member to the chassis frame. FR] «2 Tighten the rear member nuts to the specified torque, Rear Member Nut Torque Nem (kg-m / Ib-ft) 155 (15.8 /114.3) 8. Install the radiator reserve tank with the bracket to the cab rear mounting member. Engine Control Cable Connect the engine control cable to the interim connection bracket Air Cleaner Install the air intake hose to the intake duct. Coolant Replenishment Replenish the coolant to the specified capacity. Coolant Capacity lit imp /US gal) 48.1 (10.6/ 12.7) NoTi Make sure that the connecting pipes, hoses, and cables have all been installed to the engine.ENGINE MECHANICAL 6A - 13 Battery 1. Check the battery fluid level and the specific gravity. 2. Connect the battery cable to the starter motor. 8. Connect the grounding cable to the chassis frame. 4, Connect the battery terminal @ and the grounding terminal ©. 5. Apply grease to the battery terminals, Engine Oil Replenishment 1. Replenish the engine oil from the filler port with new engine oil of the specified grade. 2. Start the engine and let it idle for a few minutes. 8. Stop the engine and wait five minutes. 4, Recheck the oil level and replenish if necessary.6A-14 ENGINE MECHANICAL ENGINE ‘The combustion chamber has a clean and simple design for maximum operating economy also easy starting. A direct fuel injection system is used. The injection nozzles are placed at the center of each cylinder. Intake ports generate optimum ‘swirl effect while exhaust ports minimize exhaust resistanoe. Isuzu's unique combustion chamber design provides maximum power output and fuel economy. Each cylinder has two intake valves and two exhaust valves. To ensure high efficiency and complete combustion, the intake system has a Isuzu's unique designed inlet ports. The two exhaust valves are connected to a single port. Slipper skirt pistons, constructed of special aluminum alloy, reduce weight and friction loss. The piston top land helps to from Isuzu's unique combustion chamber. The piston top land in combustion with the cylinder head forms Isuzu's unique combustion chamber when the piston is at top dead center. The piston top and second ring groove is made of special iron casting to make it highly wear resistant also provides cooling oll holes for highly efficient cooling LUBRICATING SYSTEM LUBRICATING OIL FLOW All engine parts are lubricated by a gear pump pressure circulation system Oil flows from the oll pump though oil cooler to main oil filter for oil cooling and oil cleaning, From the main oil filter it moves to the cylinder body oil gallery and the oil circulates to lubricates the engine parts About 2 percent of the oil from the oil pump is routed through the partial oil filter and cleaned cil to return directly to the oil pan without passing to the oil gallery. This additional filtering and cleaning result in extended oil life. Ciling jets are installed to the cylinder body main oil gallery The jet spray oil to the inside portions of the pistons for lubrication and cooling(ovasrew © ENGINE MECHANICAL 6A - 15 2021961 © (eso 2009 © (#802) 86 (46). aunyosadusey Bumuedo yersownoin 10 @, (¢sd/,wo/6y) 8a 2ansseid Buwado anfer jou 4 A A 4 4 4 4 A t a Goin ESL (enn ONIKSNA| oO sey Loanses BATA |] (9'r'e"Lon)] won ate || Sno amwonean btbu || uence 4g NZ ® WNENOT] AaVHS: [LavHsHNveo} ty Wey oe T © f oll {HOSSaud NCO] {s 3 zon) icoll || io] |arowno| | | ureter tenn a |e [sens 7 7 HSISHVHO| pate nod) |[ waneo LV Frame avanvonna] faves wanna XSSTIVO TIO ONVH LAT AdOa BBGNITAD A008 BEGNMIXD AMVHO MOTH LNVORM6A-16 ENGINE MECHANICAL OIL PUMP AND OIL FILTERS The oil pump is a gear type with a relief valve. The pump is driven by the timing gear. Aull flow main oil filter with a highly efficient paper element used. Should the element become clogged with sludge or other foreign material, a by-pass valve open to route the oil directly to the oil gallery. OIL COOLER The temperature of the engine oil circulating through the lubricating system tends to rise with an accompanying decrease in lubricating efficiency, The oil cooler maintains the oil temperature at the optimum level for effective engine lubrication. The oil cooler consists of the body and the cooling element, warning lamp will light at this time to warn the driver of the vehicle the oil directly to the oil gallery. ‘The partial oil filter is used replaceable element A portion of the oil is diverted to the partial oil filter before reaching the main oll filter. The oil is cleaned and delivered to the oll pan.ENGINE MECHANICAL 6A -17 ENGINE EXTERNAL PARTS REMOVAL isto 2 6 4 a 12 918 10 8 4 4 | = 16 Beer Removal Steps 1. Cooling fan guide 19. Oil pipe for air compressor 2. Cooling fan 20. Air compressor 3. Alternator drive belt 21. Intake duct 4. Alternator and adjusting plate 22. Intake duct rubber hose 5. Power steering oil pipe 23. Intake pipe assembly 6. Power steering oil pump 24. Heater hose and pipe (i so 7. Starter motor equipped) 8. Airbreather 25. Exhaust brake assembly 9. Water charge pipe 26. Oil pipe for turbocharger 10. Engine stop cable 27. Oil drain pipe for turbocharger 11. Fuel pipes 28. Turbocharger assembly 12, Fuel filter 29. Exhaust manifold 13. Injection pipes 30. Main oil filter assembly 14. Inlet manifold 31. Partial oil filter assembly 15. Oil level gauge and guide tube 32. Water inlet pipe 16. Injection pump assembly 33. Thermostat housing 17. Injection pump bracket 34. Tachometer drive elbow 18. Water hose and pipe for air 35. Water pump assembly. compressor 36. Oil cooler assembly6A-18 ENGINE MECHANICAL [=] Removal Steps 1. Cooling Fan Guide Cooling fan Alternator Drive Belt Alternator and Adjusting Plate Power Steering Oil Pipe Power Steering Oil Pump. Starter motor Air Breather Water Charge Pipe ). Engine Stop CableENGINE MECHANICAL 6A -19 "1 12. 13, 14, 15, 16. 17, 18, 19, 20. 24 22. 23, Fuel Pipes Fuel Filter Injection Pipes with Clips Inlet Manifold il Level Gauge and Guide Tube Injection Pump Assembly Note: Plug the injection pump delivery holder ports with the shipping caps or equivalent to prevent the entry of foreign material. Injection Pump Bracket Water Hose and Pipe for Air Compressor Oil Pipe for Air Compressor Air Compressor Note: Plug the air compressor ports to prevent the entry of foreign material. Store the air compressor in an upright position on a flat surface. Intake Duct Intake Duct Rubber Hose Intake Pipe Assembly6A-20 ENGINE MECHANICAL 24, 25. 27. 28. 29. 30. 31. Heater Hose and Pipe (If so equipped) Exhaust Brake Assembly Oil Pipe for Turbocharger Oil Drain Pipe for Turbocharger Turbocharger Assembly Note: Plug the turbocharger body oil ports to prevent the entry of foreign material. Exhaust Manifold Main Oil Filter Assembly Partial Oil Filter AssemblyENGINE MECHANICAL 6A ~21 Et 33, 34, 3 EI Water Inlet Pipe ‘Thermostat Housing Tachometer Drive Elbow Water Pump Assembly Oil Cooler Assembly6A -22 ENGINE MECHANICAL INSTALLATION aaa a 4 25 219 oF = r 29 7 3 eaten of ss f “| % E A ia bE La i = Ise tel a | a 21 _ 30 2 Clonee sos Installation Steps 4. Oil cooler assembly 19. Water hose and pipe for air 2. Water pump assembly compressor 3. Tachometer drive elbow 20. Injection pump bracket 4. Thermostat housing 21. Injection pump assembly 5. Water inlet pipe 22. Oil level gauge and guide tube 6. Partial oil filter assembly 23. Intake manifold 7. Main oil filter assembly 24. Injection pipes 8. Exhaust manifold 25. Fuel filter 9. Turbocharger assembly 26. Fuel pipes 10. Oil drain pipe for turbocharger 27. Engine stop cable 11. Oil pipe for turbocharger 28. Water charge pipe 12. Exhaust brake assembly 29. Air breather 18. Heater hose and pipe (If so 30. Starter motor equipped) 31. Power steering oil pump 14. Intake pipe assembly 32. Power steering oil pipe 16. Intake duct rubber hose 33. Alternator and adjusting plate 16. Intake duct, 34. Alternator drive belt 17. Air compressor 35. Cooling fan 18. Oil pipe for air compressor 36. Cooling fan guideENGINE MECHANICAL 6A - 23 Fe] ka Oil cooler side bott Installation Steps 1. Oil Cooler Assembly 1) Apply Three bond 1207C or equivalent to groove of oil cooler assembly. The liquid gasket must be 0.5 ~ 1.2 mm (0.0197 ~ 0.0472 in) thick and 4-6 mm (0.1575 — 0.2362 in) wide. 2) Install the oil cooler assembly to cylinder body with tighten bolts specified torque. Tightening order shown in the illustration Cooler Bolt Torque N-m(kg-miib-ft) 43.2 (44/318) 3) Install the water drain pipe and tighten connecter a Water Drain Connector Torque Nem(kg-miib-ft) 38.5 (8.07579) 4) Tighten nipple *C" to specified torque. Nipple Torque Nem(kg-m/lbtt) 68.7 (7.0506) 2. Water Pump Assembly 1) Install O-ring 2) First tighten bolt in the oil cooler side then tighten bolt in the gear case side. Water Pump Bolt Torque Nem(kg-miib-ft) 38.8 (4.07287) 3. Tachometer Drive Elbow6A-24 ENGINE MECHANICAL see ° 7 —~_*§) 4. Thermostat Housing 4) Install thermostat to the oil cooler assembly. 2) Tighten bolts to specified torque. Bolt Torque Nem(kg-mib ft) 39.3( 40/289) 5. Water Inlet Pipe 6. Par Oi iter Assembly coat hie eee Le = isis Of eer Asean) Center Bolt Torque N-m(Kg-milb-ft) ~ ST 8. Exhaust Manifold Install the exhaust manifold assembly and tighten nut to specified torque. Exhaust manifold nut torque Nem(Kg-mibft) 373( 88/875) 9. Turbocharger Assembly Install the turbocharger, tighten nut to specified torque. ‘Turbocharger Nut Torque Nom (Kg-milo tt) 40.2 (41/297)ENGINE MECHANICAL 6A - 25 10. Oil Drain Pipe for Turbocharger Tightening Torque (Kg-mib-ft) Turbocharger side 39.2 (4.07289) Cylinder body side | 945 (9.5/253) 11. Oil Pipe for Turbocharger Tightening Torque Nem(kg-m/lbt) Turbocharger side 39.2 (40/289) Cylinder body side 39.2 (40/289) 12. Exhaust Brake Assembly 13. Heater Hose and Pipe (If so equipped) 14, Intake Pipe Assembly Intake Pipe Bolt Torque Nem(kg-milb-tt) 50.0(5.1/36.9) 15, Intake Duct Rubber Hose 16. Intake Duct 1) Install the intake duct to turbocharger with intake duct rubber hose. 2) Tighten bolts to specified torque. Bolt Torque Nem(kg-m/ib-tt) 39.2 (4.0/28.9) 17. Air Compressor 41) Align the flywheel "T/C" mark with the flywheel housing pointer by rotating the crankshaft counterciockwise. 2) Install O-ring to air compressor assembly.6A-26 ENGINE MECHANICAL 9) Align the “A" mark on the coupling with the air compressor body pointer. 4) Install the air compressor to timing gear case. 5) Check alignment mark *S" with the air compressor body pointer after install the air compressor to timing gear case. 6) Tighten air compressor bolts to specitied torque. Air Compressor Bolt Torque Nem(Kg-mfft) 133.4(13.6/98.4) 18. Oil Pipe for Air Compressor 19. Water Hose and Pipe for Air Compressor Tighten water pipe to specified torque. Water Pipe Torque 41.2 (42/304) N-m(Kg-milo-tt) 20. Injection Pump Bracket Tighten fitting bolt to specified torque. Fitting Bolt Torque N 107.9 (11/796) (Kkg-mib-tt)ENGINE MECHANICAL 6A -27 Th 21. Injection Pump Assembly 41) Align the flywheel injection timing mark with the flywheel housing pointer by rotating crankshaft counterclockwise. Injection Timing ‘See Main Data and Specifications 2) Align the injection timing mark on automatic timer with injection pump body pointer 3) Install the injection pump assembly to the injection, pump bracket. 4) Tighten the bolts to specified torque. Injection Pump Bolt Torque Nem(Kg-m/lb ft) 39.3 (4.0/28.9) 5) Make sure alignment injection timing mark on the injection pump, tighten coupling bolts to specitied torque. Coupling Bolt Torque Nem(kg-mib-ft) 157.0 (16.0/ 115.7) 22. Oil Level Gauge and Guide Tube 23, Intake Manifold 4) Install the rubber boot and spring. 2) Tighten the nuts to specified torque with tightening order shown in the illustration Intake Manifold Nut Torque Nem¢kg-miib-ft) 19.7 (2.01145) 24. Injection Pipes z Tighten to specitied torque Injection Pipe Torque Nem¢kg-mib-ft) Cylinder head side 29.5(3.0/21.7) Injection pump side 39.3 (40/289)6A-28 ENGINE MECHANICAL 25. Fuel Filter Install the fuel filter with bracket to intake manifold, 26. Fuel Pipes Install the fue! pipe to tighten with specified torque as, follows. Fuel Pipe Eye Bolt Torque Nem(Kg-mioft) Eye bolt size M8 14.8 (1.5 / 10.8) M10 [__275(28/203) Mie 34.4(3.5/253) ia 41.2 (42/804) 27. Engine Stop Cable Tightening Torque N-m(Kg-milb-t) 39.2 (4.0/28.9) 28. Water Charge Pipe 29. Air Breather 8 Air Breather 30. Starter Motor Tighten to specified torque 103.0 ( 10.5/ 75.9)ENGINE MECHANICAL 6A -29 al 31. Power Steering Oil Pump 41) Install the o-ring with grease. 2) Tighten to specified torque. Tightening Torque 38.3 (3.9/28.2) (Kg-m/lb-tt) Power Steering Oil Pipe Tighten to specified torque as follows, Tightening Torque Nem¢kg-m/lb-tt) Eye bolt 57.9 (59/427) Union nut 88.3 (9.0/65.1) Alternator and Adjusting Plate Alternator Drive Belt 1) Adjust the alternator drive belt tension Drive Belt Tension (When push the belt with 98 N (10 kgf)) mm (in) 14-17 (055-067) For two alternator fixed model. Alternator Upper Belt Tension (When push the belt with 98 N (10 kgf)) mm (in) 10= 11 (0.39-0.43) Alternator Lower Belt Tension (When push the belt with 98 N (10 kaf)) 7-80. 31) mm (in) 35. Cooling Fan 36. Cooling Fan Guide6A-30 ENGINE MECHANICAL CYLINDER HEAD AND VALVE MECHANISM REMOVAL Removal Steps 1 2. 3 4, 5. 6 Cylinder head cover 7. Nozzle clamp Gasket 8. Nozze holder assembly Rooker arm assembly 9. Idle gear C and shatt Bridge 0. Cylinder head assembly 1 Camshait assembly Cylinder head gasket Leak off pipe[-] ENGINE MECHANICAL 6A ~31 Removal Steps 1. Cylinder Head Cover 2. Gasket 3. Rocker Arm Assembly Loosen the rocker arm shaft bracket bolts from both outside bolt, 4, Bridge 5. Camshaft Use feeler gauge to measure the camshaft end play Camshaft End Play mm(in) ‘Standard Limit (0.085 — 0.170 ( 0.0033 - 0.0067) | 0.25 (0.0098) 6. Leak Off Pipe 7. Nozzle Clamp 8. Nozzle Holder Assembly Use the nozzle holder remover to remove the nozzle holder Nozzle Holder Remover: 1-8523-0013-0 Note: ‘Take care not to damage the injection nozzle tips during injection nozzle holder removal.6A -32 ENGINE MECHANICAL oo 9. Idle Gear “C" and Shaft Use feeler gauge to measure the idle gear" end play. Idle" C" End Play mmiin) Standard Limit (0.05 ~0.14 (0.0020 - 0.0085) 0.25(0.0098) 10. Cylinder Head Assembly First loosen the bolts A -D. Loosen the cylinder head bolts a little at a time in the numerical order shown in the illustration. Note: Failure to loosen the cylinder bolts in numerical order alittle at a time will adversely affect the cylinder head lower surface. 11. Cylinder Head GasketENGINE MECHANICAL 6A -33 INSTALLATION Installation Steps Nozzle clamp Leak off pipe Cylinder head cover 1. Oylinder head gasket 7. Camshaft assembly 2. Gylinder head assembly 8 Bridge 3. idle gear Cand shaft 9. Rocker arm assembly 4. Nozzle holder assembly 0. Gasket 5 1 66A-34 ENGINE MECHANICAL A is 2) Installation Steps 1. Cylinder Head Gasket 1) Clean the cylinder body surface. 2) Apply Loctite FMD127 or equivalent to the cylinder body and the timing gear case fitting faces. The liquid gasket must be 1.0-2.0mm (0.04 -0.08 in) thick and 5.0mm (0.20 in) wide. The liquid gasket must not obstruct the oylinder oil port. 3) Install the cylinder head gasket to the cylinder body. The part number (indicated by arrow in the illustration) must be facing up. 2. Cylinder Head Assembly 1) Align the cylinder body dowel pins and the cylinder head dowel holes. Caretully place the cylinder head on the cylinder head gasket. 2) Apply molybdenum disulfide grease to the oylinder head bolts (M18) threads and setting faces. 3) Apply engine oil to the cylinder head bolts (M10 and M12) threads and setting faces. 4) Tighten the M18 cylinder head bolts in three steps using the angular tightening method. Follow the tightening order shown in the illustration. 5) Tighten the M10 and M12 cylinder head bolts to the specified torque. Oylinder Head Bolt Torque Nem (kg-m /Ib-t) Bolt size tst ‘2nd Step | 3rd Step 176.6 245.3 ye fre | eeClB90) 14a (25/1 81)ia |aateaie mi2 755 (7.71557) M10 38.3 (3.9/28.2) NOTE: 1. The cylinder head bolts can be used four(4) times. 2. Cover the timing gear hole by cloth for prevent into foreign materials.ENGINE MECHANICAL 6A -35 3. Idle Gear “C” and Shaft 1) Apply engine oil to idle gear “C” shaft bolts. 2) Tighten idle gear “C’ shaft bolt to the specified torque. Idle Gear“ C” Shaft Bolt Torque Nem(kg-m/lbt) 39.3 (4.0/ 28.9) 4, Nozzle Holder Assembly 5. Nozzle Clamp Tighten nozde clamp bolt to the specified torque. Nozzle Clamp Bolt Torque Nem(Kg-miib-ft) 49.0 6.0/ 36.2) 6. Leak Off Pipe Tighten to specified torque Leak Off Pipe Bolt Torque Nem(kg-miib-tt) 14.8 (1.5/ 163)6A-36 ENGINE MECHANICAL BO 7. Camshaft Assembly 1) Align the flywheel TDC mark with the pointer by rotating the crankshaft normal direction. Same time check alignment timing mark on injection pump for No.t piston TOC. 2) Apply engine oil to the camshaft bearing sliding surfaces before installing the camshaft assembly 3) Install the camshaft assembly to the cylinder head, 4) Carefully align the camshaft gear hole mark and pointer on the cylinder head shown in the illustration. 5) Apply engine oil to the camshaft bearing sliding surfaces, 6) Install the camshaft bearing caps to use same stamped mark. 7) Apply engine oil to thread and tighten to specified torque. Camshaft Bearing Cap Nut Torque __N-m(Kg-m/tb-ft) 75.5 (7.71557) Bridge 1) Loosen adjusting sorew. 2) Apply engine oil on the bridge guide. 8) Install the bridge, the adjusting sorew facing to the intake manifold side.ENGINE MECHANICAL 6A -37 Loctite FMp127 9. Rocker Arm Assembly Tighten the bolts in numerical order to specified torque shown as illustration. Rocker Arm Assembly bolt (Kg-miib st) 90.3 (92/665) Adjust the valve clearance ‘The valve clearance adjustment procedure refer to the valve clearance adjustment in the section 00 Service Information 10. Gasket 11. Cylinder Head Cover 1) Apply Loctite FMD127 or equivalent to the upper surface of cylinder head and timing gear case fitting area shown as illustration. The liquid gasket must be 1.0 -2.0 mm (0.04 -0.08 in ) thick and 5.0 mm (0.20 in) wide. 2) Tighten cylinder head cover bolt, follow the numerical order shown in the illustration. Qylinder head cover bolt torque Nom (Kg-milb-tt) 20(2.1/ 15.2)6A -38 ENGINE MECHANICAL DISASSEMBLY a SUS \ Disassembly Steps 4. Thermometer Unit 13. Spring Upper Seat 2. Gear Case 14. Valve Spring 3. O-ring 15. Spring Lower Seat 4. Shaft Idle Gear “C’ 16. Valve 5. Idle Gear “C’ 17. Valve Stem Seal 6. O-ring 18. Valve Guide 7. Intake Manifold Assembly 19. Bridge Guide 8. Heat Protector 20. Valve Seat insert 9. Bracket 21. Injection Nozzie Sleeve 10. Exhaust Manifold Assembly 22. O-ring 41. Seal Rings 23. Cylinder Head 12. Split CollarENGINE MECHANICAL 6A -39 Splitcollar ey te Disassembly Steps Thermometer Unit Gear Case O-ring Shaft Idle Gear “C’ Measure end play between cylinder head and idle gear"C’. Idle Gear “C" End Play mm(in) Standard Limit 0.05 — 0.14 (0.0020 — 0.0055) 0.25 (0.0098) 5. Idle Gear “ 1) Disassemble shaft idle gear “C’ 2) Disassemble idle gear 6. O-ring 7. Intake Manifold Assembly 8. Heat Protector 9. 0, 1 Bracket Exhaust Manifold Assembly Seal Rings 12. Split Collar 1) Place the cylinder head on a flat wooden surtace, 2) Use the valve spring compressor to remove the split collar Do not allow the valve to fall from the cylinder head, Valve Spring Compressor: 1-8523-5010-0 13. Spring Upper Seat 14. Valve Spring 15. Spring Lower Seat 16. Valve If the intake and exhaust valves are to be reinstalled, mark their installation position by tagging each valve with the cylinder number from which it was removed. If the intake and exhaust valves are to be replaced, the valve guides must also be replaced. 17. Valve Stem Seal6A—40 ENGINE MECHANICAL . Valve Guide Use valve guide remover to remove the valve guide. Valve Guide Remover: 9-8523-1202-0 ). Bridge Guide Electric welding the bolt to bridge guide, use sliding hammer to remove the bridge guide. 1. Valve Seat Insert 1) Heat up (about 600 - 700°C) two point an the valve seat insert by gas torch, allow the valve seat insert to cool for few minutes, 2) This will invite contraction and make removal of the valve seat insert easier 8) Use screwdriver to pry the valve seat insert free. Take care not to damage the cylinder head. 4) Carefully remove carbon and other foreign materials from the cylinder head insert bore, |. Injection Nozzle Sleeve Use suitable size brass bar to hit nozzle sleeve from lower side cylinder head. . O-ring . Cylinder HeadENGINE MECHANICAL 6A ~ 41 INSPECTION AND REPAIR Make the necessary adjustments, repair and part replacements if excessive wear or damage is discovered during inspection. Bridge Inspect any cracking, damage on bridge and inspect any separation wear out and damage on the surface of bridge. Clearance between camshaft and bracket Measure clearance between camshaft and it bracket, Clearance mm (in) Standard Limit 0.065 — 0.125 (0.0026 0.0049) | _ 0.18 (0.0059) Shaft Idle Gear “C” and Idle Gear “C” Measure the outside diameter of shaft idle gear" Outside Diameter Shaft Idle Gear * C’ mm (in) Standard Limit 48,93 — 48.96 (1.9264 1.9286) | 48.85 (1.9232) Measure the clearance between shaft and idle gear 7 Clearance mm (in) Standard Limit 0.040.105 (0.0016-0.0041) [0.2 (0.0079) Valve Spring Free Height Use a vernier caliper to measure the valve spring free height If the measured valve is less than the specified limit, the valve spring must be replaced. Valve Spring Free Height mm (in) Standard Limit inlet_[ 79.3(8.1220) | 75.3 (2.965) Outer Exh. | 102.7 (4.0483) | 97.6 (8.0843) inlet = = Exh | 96.4 (6.07959) | 91:7 (8.06102) Inner6A —42 ENGINE MECHANICAL @] Valve Spring Squareness Use a surface plate and a square to measure the valve spring squareness If the measured value exceeds the specified limit, the valve spring must be replaced Valve Spring Squareness mm (in) ‘Standard Limit Inlet 3.5 (0.1378) 4.8 (0.1890) wn. | Outer | 450.1772) 62 (0.2441) Inner | 4.2 (0.1654) 5.9 (0.2823) @] Valve Spring Tension Use spring tester to measure the valve spring tension. If the measured valve is less than the specified limit, the valve spring must be replaced. Valve Spring Tension IN tkgilbymm Standard Limit Inlet | 392.3 (40.0/88.2/64 | 204 2 (38.0/83.8)/64 Exh. [610.0 (62.2/187 2)169]578.6 (59.0/130.1)/69 Outer =A i 4 Forimio.sin) lr Inlet = = Exh. [203.6 (22.8/50.3)/66 | 212.8 (21.7/47.8)166 Inner Valve Stem and Valve Guide Clearance G@] 1. Set the dial indicator to the valve stem measuring point. 2, Move the valve stem end from side to side. Read the dial indicator. Note the total indicator reading If the measured values exceed the specified limit, the valve and the valve guide must be replaced as aset Valve Stem and Valve Guide Clearance mm (in) Standard Limit 0.040 -0.07 Inlet (ooore 0.0080) 0.15 (0.0089) 0.065 -0.102 Outiet | ionae —0.0080) 0.25 (0.0098) [@] Valve Stem Outside Diameter Measure the valve stem diameter at three points. If the measured valve is less than the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Outside Diameter mm (in) Standard Limit Inlet 10.0 (0.3937) 9.92 (0.3906) Outlet 10.0 (0.8937) 9.90 (0.3898)ENGINE MECHANICAL 6A - 43, r™@] Bridge Guide and Bridge Clearance 1, Use a caliper calibrator or a telescoping gauge to measure the valve bridge © inside diameter. 2. Calculate the difference between the valve bridge inside diameter and the valve bridge guide @ outside diameter If the clearance exceeds the specified limit, the valve bridge must be replaced. Bridge Guide and Bridge Clearance mm (in) Standard Limit (0.020 — 0.087 ( 0.0080 -0.0022) [ 0.10 (0.0039) @] Valve Thickness and Depression 1, Measure the valve thickness. If the measured value is less than the specified limit, the valve and the valve seat insert must be replaced as a set. Valve Thickness mm(in) Standard Limit inlet 2.14 (0.0843) | 1.64 (0.0646) Exh 2.3 (0.0906) 1.8 (0.0709) 2. Install the new valve (to the cylinder head ©. 8. Use a depth gauge or a straight edge with stee! rule to measure the valve depression from the oylinder head lower surface. It the measured value exceeds the specified limit, the valve seat insert and/or the valve must be replaced Valve Depression mm (in) Standard Limit Inlet 1.9 (0.0748) 2.9 (0.1142) Exh 18(0.0709 | 2.8 (0.1102) fq] Valve Contact Width 1. Check the valve contact faces for roughness and unevenness. Make smooth the valve contact surfaces. 2, Measure the valve contact width If the measured value exceeds the specified limit, the valve seat insert must be corrected or replaced Valve Contact Width mm (in) Standard uimit inlet 3.0(0.1181) | 3.4 (0.1999) Exh 25 (0.0984) | 29 (0.1141)6A—44 ENGINE MECHANICAL Contact Surface Angle on Valve 1, Measure contact surface angle on valve seat 2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve Contact Surface Angle deg Standard inlet 30 Eh 45 Valve Seat Insert Correction 1, Remove the carbon from the valve seat insert surface. 2, Use a valve cutter (15°, 45°, and 75° blades) to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface, Valve Seat Angle deg inlet 30 Exh ro NOTE: Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve guide. 3. Apply abrasive compound to the valve seat insert surface, 4, Insert the valve into the valve guide. 5. Turn the valve while tapping it to fit the valve seat insert 6. Check to see if the valve contact width is correct. 7. Check to see if the valve seat insert surface is in contact with the entire circumference of the valve.ENGINE MECHANICAL 6A-45 REASSEMBLY Reassembly Steps Oylinder Head Oring Injection Nozzle Sleeve Valve Seat insert Bridge Guide Valve Guide Spring Lower Seat Valve Valve Stem Seal Valve Spring 11. Spring Upper Seat 12. Split Collar Semnonmpone 13 14, 15. 16 17, 18. 19, 20. 21. 22. 23. Seal Rings Exhaust Manifold Assembly Bracket Heat Protector Intake Manifold Assembly O-ring Idle Gear" Shaft Idle Gear °C’ O-ring Gear Case Thermometer Unit6A-46 ENGINE MECHANICAL REASSEMBLY STEPS 1. Cylinder Head 2. O-ring 4) Clean the nozzle sleeve circumference and the cylinder head nozzle sleeve fitting faces. 2) Apply the recommended liquid gasket (LOCTITE L290) or its equivalent to the nozzle sleeve outer circumference @) 8) Apply engine oil to the O-ring. 4) Install the O-ring @) to the nozzle sleeve O-ring groove. 5) Use a bench press to install the nozzle sleeve. Apply pressure to the nozzle sleeve gradually. CAUTIOI Do not apply an excessive amount of pressure with the bench press. Damage to the injection nozzle sleeve and cylinder head will result. Fi] ® Iniestion Nozzle Sleeve \S 4, Valve Seat Insert 1. Carefully place the attachment @ (having a smaller outside diameter than the valve seat insert) on the valve seat insert @ NOTE: The smooth side of the attachment must contact the valve seat insert. 2, Use a bench press @ to gradually apply pressure to the attachment and press the valve seat insert into place. CAUTION: Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will result 3. The valve should be lapped before final assembly to ensure a good valve seal. Refer to * Valve Seat Insert Correction” in this section 5. Bridge Guide 4. Apply engine oil to the valve bridge guide outer circumference. 2. Attach the valve bridge guide installer © to the bridge guide @ Valve Bridge Guide Installer: 9-8522-1324-0 3. Use a brass hammer to tap the guide into position from the cylinder head upper face.ENGINE MECHANICAL 6A-47 10. 4, Measure the height @ of the valve bridge guide upper end from the cylinder head upper face (cylinder head cover fitting surface) Valve Bridge Guide Upper End Height @ mm (in) 49.0 (7.9291) Valve Guide 4. Apply engine oil to the valve guide outer circumference. 2, Attach the valve guide replacer to the valve guide. 3. Use a hammer to drive the valve guide into Position from the cylinder head upper face. Valve Guide Remover: 9-8523-1202-0 4, Measure the height of the valve guide upper end from the upper face of the oylinder head Valve Guide Upper End Height (Reference) mm (in) Intake Side 27.0 (1.0630) Exhaust Side 29.0 (1.1417) Note: If the valve guide has been removed, both the valve and the valve guide must be replaced asa set. Spring Lower Seat Valve Valve Stem Seal 1) Apply engine oil to the oil seal inner face, 2) Use the oil seal installer to install the oil seal to the valve guide. Oil Seal installer: For Inlet 1-8522-1136-0 For Exhaust 1-8522-1140-2 Valve Spring 1) Apply engine oil to each valve stem before installation. 2) Install the intake and exhaust valves. 8) Turn the cylinder head up to install the valve springs. Take care not to allow the installed valves to fall free.6A-48 ENGINE MECHANICAL 1". 12, 13, 14, 4) Install the intake valve springs with their fine pitched end facing down. (Painted yellow) 5) There are not assembly direction on both inner and outer exhaust valve spring Spring Upper Seat Split Coltar 1) Use the spring compressor to compress the valve spring Spring Compressor: 1-8528-5010-0 2) Install the split collars to the valve stem Do not allow the valve to fall from the cylinder head. 3) Sot the split collars by tapping around the head of each collar with a rubber hammer Seal Rings Exhaust Manifold Assembly 1) Check that the seal ring gaps are positioned 120 degrees apart from each other. There is installation direction on seal ring as, illustration 2) Install the exhaust manifold gasket. The direction indicator must be faced lower side. 3) Install distance tube, washer and disk spring. The convex side of disk spring must be faced to exhaust manifold nut. 4) Tighten the exhaust manifold nut to specified torque. Follow the tightening order shown in the illustration Exh. Manifold Nut Torque N-m(Kg-m/lb-ft) = Q| cal ‘ss a a 1 —— 37.3 (3.8/275)ENGINE MECHANICAL 6A-49 A nee & ‘00 ®® ® ® ® “indicator = Rubber boot ee > a] aa Sano ® ® 6 = Cylinder Bl 15. Bracket The bracket tightening manner as follows. A) and ©) Tighten with out washer. 8) Put the bracket on the washer tighten together with exhaust manifold 16. Heat Protector Installation direction for cutting portion of heat protector shown in the illustration. 17. Intake Manifold Assembly 1) Tighten the nut to numerical order shown in the illustration! 2) Install the rubber boot and spring with tightening specified torque. Intake manifold nut torque Nem(Kg-mib ft) 19.7(2.0/145) 18. O-ring 19. Idle Gear “C” 20. Shaft Idle Gear “C’ 1) Apply engine oil to the shaft idle gear * C” 2) Install with idle gear "C” to cylinder head 8) Tighten bolts to specified torque. Idle Gear “C" Bolt Torque N-m(Kg-milb-ft) 39.3 (4.0/28.9) 21. O-ring Install O-ring to gear case,6A-50 ENGINE MECHANICAL 22. Gear Case 1) Apply Loctite FMD 127 or equivalent to gear case fitting area on cylinder head shown in the illustration The liquid gasket must be 0.8 mm (0.012 in) thick and 5 mm (0.20 in) wide The liquid gasket must not obstruct the bolt holes of cylinder head. 2) Tighten bolts to specitied torque. Gear Case Bolt Torque 38.3 (3.97282) 23. Thermometer Unit 1) Apply Loctite FMD 127 or equivalent to thread on thermometer unit. 2) Tighten the thermometer unit to specified torque. Thermometer Torque Nem (Kg-mnb-ft) 19.6 (20/145)ENGINE MECHANICAL 6A -51 ROCKER ARM AND SHAFT ASSEMBLY DISASSEMBLY Disassembly Steps 1. Bracket 4. Bracket 2. Rocker Arm 5. Rocker Arm Shaft 3. Spring6A-52 ENGINE MECHANICAL [=] Disassembly Steps 1. Rocker Arm and Shaft Assembly 1) Loosen the bolt of the rocker arm shaft bracket, from out side bolt a little at time and remove rocker arm and shaft assembly. 2) Disassembly the bracket, rocker arm, spring bracket and rocker arm shaftENGINE MECHANICAL 6A-53 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. @] Rocker Arm Shaft Run-Out 1. Place the rocker arm shaft on V-blocks. 2. Use a dial indicator to measure the rocker arm shaft central portion run-out. It the run-out is very slight, correct the rocker arm shaft run-out with a bench press. The rocker arm must be at cold condition. If the measured racker arm shaft run-out exceeds the specified limit, the rocker arm shaft must be replaced, Rocker Arm Shaft Run-Out Limit mm (in) 03 (0.012) [ga] Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm fitting portion outside diameter It the measured value is less than the specified limit, the rocker arm shaft must be replaced Rocker Arm Shaft Outside Diameter mm (in) Standard Limit 27.979 - 28.000 27.85 (1.1015 ~ 1.1024) (1.0965) [aj] Rocker Arm Bushing Inside Diameter Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter Rocker Arm Bushing Inside Diameter mm (in) ‘Standard 28.020 - 28.058 (1.1081 = 1.1044) Rocker Arm and Rocker Arm Shaft Clearance _mm (in) Standard Limit 0.020 0.074 02 (0.0008 - 0.0029) (0.0079)6A-54 ENGINE MECHANICAL Depth Gause Check to see if the rocker arm and rocker arm shaft oll Port is free of obstructions. It necessary, use compressed air to clean the rocker arm and rocker arm shaft oil port. Rocker Arm Roller and Rocker Arm Pin 1. Pass a string through the rocker arm-roller clearance and measure the roller protrusion while pulling both ends of the string in the arrow indicated directions to push out the roller. 2, Mark the measuring point and draw out the string Measure the roller protrusion again while the roller is pushed in 3. Note the difference in the above measurements is the standard roller rocker arm and pin clearance. Should the clearance exceed the limit, replace the rocker arm. Rocker Arm Roller and Pin Clearance mm (in), Standard Limit’ (0.036 — 0.069 05 (0.0014 — 0.0027) (0.02)ENGINE MECHANICAL 6A-55 REASSEMBLY Reassembly Steps 1. Rocker Arm Shaft 4. Spring 2. Bracket 5. Bracket 8. Rocker Arm6A-56 ENGINE MECHANICAL Reassembly Steps 1. Rocker Arm and Shaft Assembly 1) Reassembly the bracket, spring, rocker arm and bracket to the rocker arm shaft. 2) Apply engine oil to roller portion of the rocker arm and thread of the adjusting screw 3) Put the rocker arm and shaft assembly on the cylinder head. 4) Temporary tighten the bolts of rocker arm and shaft assembly to the cylinder head, sufficient loosen the adjusting screw. 5) Tighten bolts of the rocker arm and shaft assembly by numerical order to speciied torque shown in the illustration Rocker arm bolt torque Nem (Kg:mnilo-ft) 90.3 (9.2/ 66.5}ENGINE MECHANICAL 6A-57 CAMSHAFT DISASSEMBLY Disassembly Steps 1. Camshaft Gear 4. Camshaft 2. Key 5. Camshaft Bearing Lower 3. Camshaft Bearing Cap6A-58 ENGINE MECHANICAL FF] Wood ° Is Wood: ° Disassembly Steps 1. Camshaft Gear 1) Check visually gear it has not damaged, itis not necessary to disassembly gear from camshatt. 2) Use the universal puller to pull out the camshaft gear with waoden plate for prevent make damage gear. 2. Key 3. Camshaft Bearing Cap Loosen nuts to remove the camshaft bearing cap. 4. Camshaft 5. Camshaft Bearing LowerENGINE MECHANICAL 6A-59 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is, discovered during inspection. ‘@] Camshaft Journal Diameter Use a micrometer to measure each camshaft journal diameter in two directions (<> and @). If the ® measured value is less than the specified limit, the ® camshaft must be replaced Camshaft Journal Diameter mm (in) Standard Limit 39.915 - 39,940 (1.5715 - 1.5724) 89.890 (1.5708) ™@] Cam Height Measure the cam height A and B with a micrometer If the measured value is less than the specified limit, the camshaft must be replaced. Cam Height mim (in Standard (A-B) Limit Intake 9.4 (0.8700) 8.85 (0.3484) Exhaust | 10.4 (0.4094) 9.75 (0.3839) [@] Camshaft Run-Out 1. Mount the camshaft on V-blocks. 2. Measure the run-out with a dial indicator on the No. 4 camshaft journal if the measured value exceeds the specitied limit, the camshaft must be replaced Camshaft Run-Out mim (in) Standard Limit 0.080 (0.0081) 0.100 (0.0039) [™j] Camshaft and Camshaft Bearing Clearance Camshaft Bearing Inside Diameter mm (in) Standard | 40.015 — 40.040 (1.5754 — 1.5764) Camshaft Bearing Clearance mm (in) santana Sa SHS 0.065 - 0.125 015 (0.0026 - 0.0049) (0.0059)6A-60 ENGINE MECHANICAL REASSEMBLY Reassembly Steps 1. Camshaft Bearing Lower 4. Key 2. Camshaft 5. Camshaft Gear 3. Camshaft Bearing CapENGINE MECHANICAL 6A -61 Reassembly Steps 1. Camshaft Bearing Lower 1) Install camshaft bearing lower to cylinder head. 2) Apply engine oil to bearing portion. 2. Camshaft 1) Put camshaft onto camshaft bearing lower. 2) Apply engine oil to journal of camshaft. 3. Camshaft Bearing Cap 1) Reassembly camshaft bearing cap on stud bolts to use same stamped mark of bearing lower. 2) Apply engine oil to thread of stud bolt and nut seat 3) Tighten camshaft bearing cap nut to specified torque. Camshatt Bearing Cap Nut Torque 755 (771557) 4. Key 5. Camshaft Gear Install the camshaft gear with tighten bolt to specified torque. Camshaft Gear Bolt Torque Nem(kg 187.4 (140/101) vito-ft)6A -62 ENGINE MECHANICAL OIL PAN, OIL PUMP AND TIMING GEAR REMOVAL Removal Steps 1. Oil pipe bracket 11. Spacer 2. Breather hose clip 12. Timing gear case cover 3. Oilpan 18. Gasket 4, Gasket 14. Fan center 5. Oil strainer with O-ring 15. Oil seal 6. Oil strainer bracket 16. Oil pump assembly with O-ring 7. Ciling jet assembly 17. Distance bolt 8. Fan pulley with taper bushing 18. Idle gear “A” 9. Crankshaft pulley assembly 19. Idle gear"B 10. Oil seal 20. Timing gear caseENGINE MECHANICAL 6A -63 [e] Removal Steps Oil Pipe Bracket Breather Hose Clip Oil Pan Gasket Oil Strainer with O-ring Oil Strainer Bracket Olling Jet Assembly Remove the joint bolt. CAUTION: Take care not to bend the oiling jet tubing. Do not attempt to repair a damaged oiling jet. Itit has damaged to recommend to replace it with a new one. 8. Fan Pulley with Taper Bushing 1) Block the crankshaft with a piece of hard wood to prevent the fan pulley from turning, 2) Remove the fan pulley nut 3) Use the taper bushing remover to remove the taper bushing Taper bushing remover: 1-8521-0063-0 9. Crankshaft Pulley 10. Oil Seal (Fan center) Use sorew driver into cutting on oil seal. 11. Spacer 12. Timing Gear Case Cover 13. Gasket 14, Fan Center6A-64 ENGINE MECHANICAL 15. Oil Seal (Crankshaft) Take care not to make scratch on fitting surface of, timing gear case cover. Remove slinger with slinger remover. Slinger remover: 1-8521-0027-0 16. Oil Pump Assembly with O-ring. 17. Distance Bolt 18. Idle Gear “A” 1) Before loosen the idle gear fitting bolts, measure the backlash of idle gear "A" and “B” Idle Gear Backlash mmi(in) Standard Limit (0.095 — 0.185 (0.0087 - 0.0053) | _ 0.23 (0.0091) 2) Measure the end play of idle gear" A” and “B’ Idle Gear End Pray mm(in) Idle goar A Gear Standard Limit A’ [0.165 ~0.230 (0.0068 - 0.0094) | 0.35 (0.0138) “B" _| 0.050 —0.140(0.0020 — 0.0055) | 0.25 (0.0098) 19. Idle Gear “B” Make front marking on thrust plate 20. Timing Gear CaseENGINE MECHANICAL 6A-65 [=] Inspection and Repair 4. Visually inspect the idle gear and idle gear spindle. If a idle gear or spindle is damaged or worn.the part must be replaced. a 2. Use micrometer to measure the idle gear spindle outside diameter. Spindle Outside Diameter mm(in) Idle gear Standard Limit i 56.93 - 56.96 56.85 (2.2413 ~ 2.2425) (2.2382) B 441.98 - 141.96 141.85 (6.5878 - 5.5890) (6.5846) @ 48.93 48.96 48.85 (1.9264 - 1.9286) (1.9282) 8. Use oylinder bore dial indicator to measure the idle gear inside diameter. 4, Calculate clearance between idle gear and idle gear spindle. Clearance mm(in) idle gear Standard Limit a 3 0.040 -0.105 0.20 . (0.0016-0.0041) | (0.0079) It measuring value exceeds from specified limit, the idle gear spindle or idle gear must be replaced:6A-66 ENGINE MECHANICAL GEARTRAIN Idle Gear “A” Alignment timing marks on each gear shown in the illustration above.ENGINE MECHANICAL 6A -67 INSTALLATION Installation Steps 1. Timing gear case 11. Oil seal (Crankshaft) 2. Idle gear" B" 12. Crankshaft pulley assembly 3. Idle gear" A” 18. Fan pulley with taper bushing 4. Distance bolt 14. Ciling jet assembly 5. Oil pump assembly with O-ring 15. Oil strainer bracket 6. Fan center 46. Gil strainer with O-ring 7. Gasket 17. Gasket 8. Timing gear case cover 18. Oilpan 9. Spacer 19. Breather hose clip 10. Oil seal (Fan center) 20. Oil pipe bracket6A-68 ENGINE MECHANICAL f>«] Installation Steps EQ] *: Timing Gear case. 1) Clean the cylinder body surface |S 2) Apply Loctite FMD 127 or equivalent to the cylinder a body and the timing gear case fitting faces. The liquid gasket must be 0.3 mm (0.004 in) thick and 4 mm (0.16 in) wide: The liquid gasket must not obstruct the cylinder body bolt holes. 8) Install the timing gear case to the cylinder body. 4) Tighten the bolts by specified torque. Timing Gear Case Bolt Torque Nem(kg-milb-ft) M14 135.4 (13.8/ 99.8) MA0 43.2 (4.47318) f=] 2: Idle Gear "8" Thrust plate 1) Apply engine oil to bushing area of idle gear and Bl both thrust surface pa 2) Fit thrust plate with confirm front mark. —_ 3) Tighten the bolts by specified torque. Idle Gear “B" Bolt Torque Nem(kg-mio-ft) 39.3 (4.0289) 3. Idle Gear “A” 1) Align the flywheel TDC mark with the pointer by rotating the crankshaft normal direction. Same time check alignment timing mark on injection al pump for No.1 piston TDC. 2) Apply engine oil to the bushing of idle gear “A” 3) Install idle gear " A” with the idle gear shaft to the timing gear case. The timing marks (°0" as shown in the illustration. 4) Tighten idle gear "A" shaft bolts by specified torque. Idle Gear Shaft Bolt Torque N-m(Kg-milb-ft) 107.9 (11.0/79.6) g ) must be alignedENGINE MECHANICAL 6A -69 4. Distance Bolt Tighten distance bolt by specified torque. Distance Bolt Torque Nem (Kg-milb-ft) 39.3 (4.0289) 5. Oil Pump Assembly 1) Install O-ring to oil pump assembly. 2) Install the oil pump assembly to cylinder body. 8) Tighten the oil pump assembly bolts to the specified torque. Oil Pump Bolt Torque Nem(Kg-milb ft) 49.0 (5.01362) CAUTION Do not tighten arrow mark bolt shown in the illustration. 6. Fan Center 1) Apply engine oil to bushing and thrust face of timing gear case cover. 2) Install the fan center to timing gear case cover. 7. Gasket 8. Timing Gear Case Cover 1) Apply Loctite FMD 127 or equivalent to timing gear case cover fitting face. 2) Install timing gear case cover with gasket 8) Tighten bolts to specified torque. Timing Gear Case Bolt Torque Nem (Kg-mb-ft) Mi0 39.3 (4.0/28.9) MB. 25.5 (26/188)6A-70 ENGINE MECHANICAL 2 | 9. Spacer 10. Oil Seal (Fan center) Use oil seal installer to install the oil seal assembly, Note: If there is same small scratch on the crankshaft, apply Threebond 1207C or equivalent to oil seal stinger shown in the illustration. Oil Seal installer: 1-8522-0049-0 11. Oil Seal (Crankshaft) Use oil seal installer to install the oil seal to timing gear case cover. Note: 1) If there is same small scratch on the crankshaft, apply Threebond 1207C or equivalent to oil seal slinger shown in the illustration, 2) There are identification color on the oil seal. For front oil seal -—---—----Dark violet color For rear oil seal Gray color Oil Seal installer: 1-8522-0043-0ENGINE MECHANICAL 6A -71 2) 12. Crankshaft Pulley Assembly 1) Install the crankshaft pulley. 2) Apply engine oil to the bolt 8) Tighten the crankshaft pulley bolts to specified torque. Crankshaft Pulley Bolt torque Nem(Kg-mib ft) 266.8 (27.2/ 1965) 13. Fan Pulley with Taper Bushing 1) Apply molybdenum disulfide grease to the thread of fan center and surface of fan pulley nut. 2) Tighten fan pulley nut to specified torque. Fan Pulley Nut Torque Nem (Kg:mflo-ft) 539.6 ( 55.0/397.8) 14, Oiling Jet Assembly 1) Install the oiling jet assembly to cylinder body. 2) Tighten the joint bolt to spesitied torque. Joint Bolt Torque Nem(kg- 68.7 (7.0506) 15. Oil Strainer Bracket 16, Oil Strainer with O-ring Fix O-ring to oil strainer, tighten bolts shown in the illustration Oil Strainer Bolt Torque Nem(kg-m/lb-ft) 54.9 (56/405) 17. Gasket Apply Cemedain LG-020L or equivalent to the cylinder body, flywheel housing and timing gear case fitting face. The liquid gasket must be 3-4 mm (0.12-0.16 in) thick and wide.6A-72 ENGINE MECHANICAL 18. Oil Pan Tighten the bolts to the specified torque in the clockwise form 1 or 2 shown as the illustration. Oil Pan Bolt Torque Nem(Kg-mib ft) 38.3 (3.91282) 19. Breather Hose Clip 20. Oil Pipe BracketENGINE MECHANICAL 6A-73 FLYWHEEL REMOVAL Removal Steps 1. Snap ring 6. Parking brake cable bracket, 2. Pilot bearing 7. Flywheel housing 3. Washer 8. Oil seal 4 Flywheel 9. Slinger 5. Engine foot6A-74 ENGINE MECHANICAL [e] Removal Steps 1. Snap Ring 2, Pilot Bearing Use pilot bearing remover to remove the pilot bearing Pilot Bearing Remover: 9-8521-0157-0 Washer Flywheel Engine Foot Parking Brake Cable Bracket Flywheel Housing 8. Oil Seal Take care to do not make damage on surface of flywheel housing, 9. Slinger Use slinger remover to remove oil seal slinger from. crankshaft. Slinger Remover: 1-8521-0027-0ENGINE MECHANICAL 6A-75 INSTALLATION Installation Steps 1. Flywheel housing 5. Flywheel 2. Engine foot 6. Washer 3. Parking brake cable bracket, 7. Pilot bearing 4. Oil seal with slinger 8. Snap ring6A-76 ENGINE MECHANICAL be] Installation Steps 1. Flywheel Housing 4) Apply Loctite FMD 127 or equivalent to the cylinder body and flywheel fitting face shown in the illustration 2) The liquid gasket must be 0.3 mm (0.004 in) thick and 4 mm (0.16 in) wide. The liquid gasket must not obstruct the cylinder body bolt holes. 3) Install the flywheel housing to tighten with specified torque. Flywheel Housing Bolt Torque Nem(Kg-mfb ft) Maa 122.6 (125/ 90.4) Ma 21.6 (22/15) 2. Engine Foot 1) Apply molybdenum disulfied grease to the engine foot bolt and setting faces. 2) Tighten engine foot bolt to the specified torque. Engine Foot Bolt Torque Nem (Kg:mfl-ft) ist step 147.2 (15.0 108.5) 2nd step. 274.7 (28.0 / 202.5) 3. Parking Brake Cable BracketENGINE MECHANICAL 6A-77 Q il seal with slinger i 3 4, Oil Seal with Slinger Use oil seal setting too! to install the ol! seal Oil Seal Setting Tool: 1-8522-0043-0 Note: 41) There is identification color on the oil seal. 2) Do not make separation between oil seal and slinger. 5. Flywheel and 6. Washer 1) Apply molybdenum disulfied grease to bolt and setting face. 2) Tighten flywheel bolt in three steps using the angular tightening method. Flywheel Bolt Torque Nem(Kg-mib ft) ist step 2nd step 3rd step 78.5 (8.01579) 60 deg 30.deg 8) Follow the numerical order shown in the illustration. 7. Pilot Bearing Use pilot bearing setting tool to install the pilot bearing Pilot Bearing Setting Tool: 1-8522-1057-0 8. Snap Ring6A-78 ENGINE MECHANICAL CRANKSHAFT, PISTON AND CONNECTING ROD REMOVAL Removal Steps 1. Piston with connecting rod 4. Crankshaft 2. Connecting rod bearing 5. Crankshaft bearing 3. Crankcase lower 6. Crankshaft thrust bearingENGINE MECHANICAL 6A-79 [-»] Removal Steps 1, Piston with Connecting Rod 1) Remove carbon deposits from the upper portion of the cylinder wall a scraper before removing the piston with connecting rod 2) Loosen connecting rod cap nuts 3) Move the piston to the top of the cylinder and tap it with a hammer grip or similar object from the connecting rad lower side to drive it out Y CAUTION: Take care not to damage the oiling jets. 2. Connecting Rod Bearing If the connecting rod bearings are to be reinstalled, mark their fitting positions by tagging each bearings (upper and lower) with the cylinder number from. which it was removed. 3. Crankcase Lower 1) Measure the crankshaft end play at the No.7 crankshaft journal. Do this before remove the crankshaft thrust bearing. It the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced. Crankshaft End Play mmi(in) Standard Limit (0,04 — 0.18 (0.0016 - 0.0070) 0.30 (0.0121) 2) Loosen the crankcase lower bolts a little at a time in the numerical order shown in the illustration 3) Use M10 bolts into replace holes to remove the crankcase lower. Replace hole 4. Crankshaft Remove the crankshaft from the cylinder body.6A-80 ENGINE MECHANICAL 5. Crankshaft Bearing It the crankshaft bearings are to be reinstalled, make their fitting position by tagging each bearings with the journal number from which it was removed 6. Crankshaft Thrust Bearing ‘Same manner as crankshaft bearing removal.ENGINE MECHANICAL 6A -81 INSTALLATION Installation Steps 1. Grankshatt bearing 4. Crankcase lower 2. Crankshaft 5. Connecting rod bearing 3. Crankshaft thrust bearing 6. Piston with connecting rod6A -82 ENGINE MECHANICAL ( Cylinder body side Crankease side be] A Installation Steps 1. Crankshaft Bearing 1) Carefully wipe any foreign materials from the fitting area of the cylinder body and crankshaft bearing upper. All upper bearings have oil grooves. 2) Locate the position mark applied at removed, if the removed upper bearings are to be reused. CAUTION: Do not apply engine oil to the bearing back faces and the cylinder body bearing fitting surfaces. 2. Crankshaft Apply engine oil to the crankshaft journals and crankshaft bearing surfaces before installing the crankshaft 3. Crankshaft Thrust Bearing 1) Apply engine oil to the thrust bearing oll grooves side. 2) Install the thrust bearing upper to both side of the No.1 journal by hand Note: The thrust bearing oil grooves must be faced the sliding face.ENGINE MECHANICAL 6A-83 Apply FMD-127 B¢ 2. FMO-127 Cylinder body lower surface Crankcase Lower 1) Carefully wipe any foreign materials from the fitting area of the crankcase. 2) Apply Loctite FMD 127 or equivalent to cylinder body lower surface. The liquid gasket must be 0.8 mm (0.01 in) thick and 4 mm (0.16 in) wide 3) Install the crankshaft bearings and thrust bearing CAUTION: Do not apply engine oil to the bearing back faces and the crankcase bearing fitting surfaces. Note: The thrust bearing oll grooves must be facing the sliding face. 4) Install the crankcase lower to the cylinder body. 5) Apply molybdenum disulfide grease to the crankcase bolts (M18) threads and setting face. 6) Apply engine oil to the crankcase bolts (M12) threads and setting faces. 7) Tighten the M18 crankcase bolts (numerical order 4 to 14) in the three steps using the angular tightening method Follow the numerical order shown in the illustration Crankcase Lower Bolt Torque Nem(Kg-milo ft) Bolt size | istStep | 2nd Step | 3rd Step Mia _[49.1(6.0/36.2)]88.2(9.0/65.1)| 90 - 120deg Mie 96.1(9.8/70.9) . Piston with Connecting Rod 1) Carefully wipe any foreign materials inside cylinder bore and piston with connecting rod. 2) Install the connecting rod bearing upper to the connecting rod 3) Install the connecting rod bearing lower to the connecting rod cap. 4) Apply engine oil to the cylinder wall, upper / lower bearing surface and crankpin of crankshaft.6A-84 ENGINE MECHANICAL 5) Position the piston ring gaps as shown in the illustration 6) Position the piston head front mark so that itis. facing front of the engine. 7) Use piston setting too! to install the piston with connesting rod to the cylinder body. At the same time, rotate the crankshaft until the crankpin is at bottom dead center CAUTION: Do not bend or damage the oiling jet. Piston Setting Tool: 1-8522-0046-0 8) Apply molybdenum disulfied grease to the threads oI and setting faces of each connecting rod bolts. @J 9) Tighten the connecting rod cap nuts in three steps, using the angular tightening method. I Connecting Rod Cap Nut Torque Nem(Kg-milb-tt) ist Step 2nd Step 31a Step 98.1(10.072.3) 30 deg 30 deg i= Angular gauge: 5-8840-0266-0 40)Check crankshaft rotation smoothlyCRANKSHAFT DISASSEMBLY Disassembly Steps 4. Crankshaft Bearings 3. Crankshaft Gear6A-86 ENGINE MECHANICAL [4] Disassembly Steps 1. Crankshaft Remove crankshaft assembly from oylinder body. 2. Bearings Remove crankshaft bearing and thrust bearing @] 3 Crankshatt Gear Use the crankshaft gear remover to remove the crankshaft gear. Crankshaft Gear Remover: 1-8521-0064-0 if remain the slinger on the crankshaft remove slinger, by the slinger remover. Slinger Remover: 1-8521-0027-0ENGINE MECHANICAL 6A -87 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. 4. Crankshaft Journal and Crankpin Diameter 1) Use a micrometer to measure the crankshaft journal diameter across points shown in the illustration 2) Use a micrometer to measure the crankshaft journal diameter at the two points as shown in the illustration 1 and 2 3) Repeat steps 1) and 2) to measure the crankpin diameter If the measured values are less than the standard value, the crankshaft must be replaced. Crankshaft Journal and Grankpin Diameter mmtiny Standard No. 4Journal | 104.850 — 104.875(4.1279-4 1289) Others 104.880 — 104 905(4.1291-4.1309) Grankpin 91,895 — 91.925(8.6179-3.6191) 2. Crankshaft Run Out 1) Set a dial indicator to the center of the crankshaft No.4 journal. 2) Gently turn the crankshaft in the normal direction of rotation Read the dial indicator as you turn the crankshatt. If the measured value exceeds the specitied limit, the crankshaft must be replaced Crankshaft Run Out mmi(in) Standard Limit 0.120 (0.0005) 0.18 ( 0.0059) 3. Bearing Spread Use a vernier caliper to measure the bearing spread. If the measured value is less than the specified limit, the bearing must be replaced. Bearing Spread mm(in) Limit 111.5 (4.3898)6A-88 ENGINE MECHANICAL FE] * Crankshatt Journal and Bearing Clearance 2] es 1) Clean the cylinder body and crankcase lower, the journal bearing fitting surface, and the journal bearings. 2) Install the bearings to the cylinder body and crankcase lower. 3) Reassembly the crankcase lower to cylinder body. 4) Apply molybdenum disulfide grease to the M18 bolts and apply engine oil to the M12 bolts thread and it seat 5) Tighten the crankcase lower to the specified torque in the numerical order shown in the illustration Crankcase Bolt torque Nem(kg-mfb ft) tstStep | 2ndStep | ard Step M18 _[49.1(6.0196.17)]86.3(9.0/65.10)| 90-120" Miz 96.19.8170.) 6) Measure the crankshaft bearing inside diameter by dial indicator. 7) If the clearance between the crankshaft journal and bearing exceeds the specified limit, the crankshaft must be replaced, Crankshaft Journal and Bearing Clearance mmi(in) Standard Limit No.4 Journal 0.081 = 0.144 (0.0032 - 0.0057) 0.16 Others 0.051 = 0.114 (0.0063) (0.0020 - 0.0048 ) |. Crankshaft Journal and Bearing Clearance (With Plastigage) 1) Clean the cylinder body and crankcase lower, the journal bearing fitting surface, and the journal bearings. 2) Install the bearings to the cylinder body and crankcase lower. 3) Reassembly the crankcase lower to cylinder body. 4) Cut the plastigage same wide of crankshaft journal and put it on the crankshaft journal. 5) Apply molybdenum disulfide grease to the M18 bolts and apply engine oil to the M12 bolts thread and it seatENGINE MECHANICAL 6A-89 6) Tighten the crankcase lower to the specified torque in the numerical order shown in the illustration Crankcase Bolt torque Nem(Kg-mib ft) ist Step | 2nd Step | 3rd Step M18 |49.1(6.0/36.17)/88.3(9.0/65.10)| 90 - 120° M12 96.1(9.8/70.9) “The portion to be tested ust be held horizontally “Text liquid should fos morro Tet the tort” Test iquid should scnnion tox Tees ound the “The slicing surtace of the pin ‘Approximately Om (0-4in) 7) Carefully disassembly the crankcase lower from cylinder body. 8) Measure the width of plastigage by scale which printed on the plastigage envelop, 9) If the clearance between the crankshaft journal and bearing exceeds the specified limit, the crankshaft must be replaced, Crankshaft Journal and Bearing Clearance mm(in) Standard Limit No.4 Journal 0.081 — 0.144 (0.0032 - 0.0057) 0.16 Others 0.051 —0.114 (0.0063) (0.0020 - 0.0045 ) ;. Crankshaft Tutftriding Inspection 1) Use an organic cleaner to thoroughly clean the orankshatt There must be not traces of oil on the surface to be inspected. 2) Prepare a 5-10 % solution of ammonium cuprous chloride (dissolved in distilled water). 3) Use a syringe to apply the solution to the surface to be inspected. Hold the surtace to be inspected perfectly horizontal to prevent the solution from running Note: Do not allow the solution to come in contact with the oil ports and their surrounding area. . Crankshaft TufftridingJudgment 1) Wait for thirty to forty seconds. If there is no discoloration after thirty or forty seconds, the crankshaft is usable If discoloration appears (the surface being tested will become the color of copper), the crankshaft must be replaced 2) Steam clean the crankshaft surface immediately after completing the test. Note: The ammonium cuprous chloride solution is highly corrosive. Because of thi erative that the surfaces being tested be cleaned immediately after completing the test.REASSEMBLY Reassembly Steps 1. Grankshatt Gear Bearings 9 CrankshaftENGINE MECHANICAL 6A -91 Reassembly Steps 1. Crankshaft Gear 41) Use the oil heater to heat the crankshaft gear to 170°-180°C (838°350) 2) With the timing alignment mark "O” on the side of crankshaft gear turned outward, align the key groove on the crankshaft gear with the crankshaft dowel pin position 8) Hammer it in with a crankshaft gear installer until it hits the bottom. Crankshaft Gear Installer: 1-8522-0045-0 CAUTION: When hammered in with the gear slanted, the crankshaft gear may be caught in the middle and cannot be hammered in fully. Hammer it in quickly enough not to allow a shaft line along the gear and the crankshaft to slant. 2. Bearings Reassemble the crankshaft bearings and thrust bearings to refer the section of the crankshatt, piston and connecting rod installation steps. 3. Crankshaft Reassemble the crankshaft to the cylinder body.6A-92 ENGINE MECHANICAL PISTON AND CONNECTING ROD DISASSEMBLY Disassembly Steps 4. Connecting Rod Cap 5. Piston Pin 2. Bearings 6. Piston 3. Piston Rings 7. Connecting Rod 4. Snap RingENGINE MECHANICAL 6A-93 Disassembly Steps CAUTION: Do not bend or damage the oiling jet. Note: When removing the piston and connection rod assembly, pull the connecting rod in parallel with the cylinder bore. 1. Connecting Rod Cap 2. Bearings 1) Take out the connecting rod bearing cap nuts and disassemble the bearing cap with the lower bearing 2) If the connecting rod lower bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. 3. Piston Rings 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Use piston ring replacer to reassemble the piston rings. Do not attempt to use some other tool to disassemble the piston rings. Piston ring stretching will result in reduced piston ring tension. 4. Snap Ring Use a pair of snap ring pliers to remove the snap rings. 5. Piston Pin 6. Piston 7. Connecting Rod Tap the piston pin out with a hammer and a brass bar. It the piston to be reinstalled, mark their installation positions by tagging each piston with the cylinder number from which it was disassembled.6A-94 ENGINE MECHANICAL during inspection. INSPECTION AND REPAIR Make the necessary adjustments, repairs and part replacements if excessive wear or damage is discovered @ al oO ya Za 1st piston ring e a ~Straight gauge 1, Piston Ring Gap 1) Insert the piston ring horizontally (in the position it ‘would assume if it were installed to the position) into the cylinder liner bore. 2) Push the piston ring into the oylinder liner bore until it reaches the point where the cylinder liner bore is the smallest. Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal 8) Use the feeler gage to measure the piston ring gap. if the measured value exceeds the specitied limit, the piston ring must be replaced Piston Ring Gap mm(in) Standard Limit geet UND 035-050 —2ndring | (9.0138 -0.0197) 1.00 3rd ring (0.0394) 0.80 -0.45 ue (0.0118 -0.0177) 2. Piston Ring and Piston Ring Groove Clearance 1) Visually inspect the piston ring grooves. It a piston ring groove is damaged or distorted, the piston must be replaced 2) Use feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston 3) When measure the clearance for 1st piston ring, it pressed the 1st piston ring by straight gauge show in the illustration Piston Ring and Piston Ring Groove Clearance mm(in) Standard Limit 0.400.142, 023 {string (0.0039 - 0.0056) (0.0091), emu 0.100.185 0.20 3rd ring (0.0039 - 0.0053) (0.787) 0.025 — 0.065 0.15 Ollring (0.0010 -0.0026) (0.0059)ENGINE MECHANICAL 6A-95 |. Piston Ring Expansion Force 1) Use expansion force gauge to measure the piston ring g expansion force. 2) For measure the expansion force to oil ring it required coil expander ring with oil ring Piston Ring Expansion Force N¢kgitb) Standard Limit aaa 49.3 -625 25.3 9 (§.03-6.37/11.09-14.05)} _ (3.6/7.94) 22.0280 147 enn (2.24-2.96/4.94-6.53) | _(1.5/3.31) 22.6 -26 147 Std ring (2.28-3.02/5.03-6.66) (1.5/3.31) 62.8-785 4441 one (6.4-8.0/14.11-17.64) | (4.5/9.92) |. Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points. If the measured value is less than the specified limit, the piston pin must be replaced. Piston Pin Diameter mm(in) Standard Limit 55.995 — 56.000 55.970 (22015 ~2.2047) (2.2035) .. Piston Pin Hole and Piston Pin Clearance Use the inside dial indicator to measure the piston pin hole(in the piston). Piston Pin Hole and Piston Pin Clearance mmi(in) Standard Limit 0.008 - 0.021 0.05 (0.0003 - 0.0008) (0.0020) . Piston Pin and Connecting Rod Smalll End Bushing Clearance Use a caliper calibrator and dial indicator to measure the clearance between the piston pin and connecting rod small end bushing, It the clearance between the piston pin and the connecting rod small end bushing exceeds the specified limit, replace the piston pin and/or the connecting rod assembly ‘Small End Bushing Clearance mmi(in) Standard Limit 0.020 -0.037 0.10 (0.0079 - 0.0016) (0.0039)6A-96 ENGINE MECHANICAL 7. Connecting Rod Alignment Use a connecting rod aligner to measure the distortion and the parallelism between the connecting rod big end hole and the connecting rod small end hole. If either the measured distortion or parallelism exceeds the specified limit, the connecting rod must, be replaced Connecting Rod Alignment mm (in) Per Length of 100 (3.94) Standard Limit Distortion 0.05 (0.002) 0.20 Parallelism or less (0.008) 8. Crankpin and Connecting Rod Bearing Clearance 1. Clean the crankshaft, the connecting rod, the bearing cap, and the bearings 2. Install the bearing to the connecting rod and the bearing cap 3. Apply a coat of molybdenum disulfide grease to the bearing cap bolt threads and setting faces. 4. Prevent the connecting rod from moving 5. Tighten the bearing cap to the specified torque. Connecting Rod Bearing Cap Nut Torque Nem (kg-m/lb-ft) ist step 2nd step 3rd step 98.1 (10.0/72.3) 30° 30° 6. Use the dial indicator to measure the connecting rod bearing inside diameter. Crankpin and Connecting Rod Bearing Clearance mm (in) Standard Limit (0.033 - 0.103 (0.0013 -0.0041) | _ 0.16 (0.0063) 7. Ifthe clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or the crankshaft must be replace,ENGINE MECHANICAL 6A-97 Liner inside Grade No. + Piston outside Grade No. Grade No, Grade No, Grade No, 9. Connecting Rod and Crankshaft Clearance 1) Fix the connecting rod assembly to crankshaft by specified torque. The fixing manner is follow as mentioned above. 2) Use feeler gauge to measure the clearance between connecting rod and crankshaft. If the measured value exceeds the specified limit, the connecting rod must be replaced Connecting Rod and Crankshatt Clearance mm(in) Standard Limit 0.175 — 0.290(0.0069-0.0174) 0:35(0.0188) Piston and Cylinder liner Grade Selection 1) In case of use new piston to select same piston grade with marked cylinder liner grade on the Upper surtace of cylinder body shown in the illustration 2) In case of replace together with piston and cylinder liner, install the new liner set. In this case select the oylinder liner outside diameter grade with marked grade on the right side cylinder body and the piston grade selection must be aligned to new oylinder liner grade as shown in the illustration (Do not use to marked liner grade on cylinder body upper surface). 3) In case of reuse the removed piston, must measure the clearance between piston and cylinder liner The measuring manner refer to Piston Reassembly Section The following measurement of piston and cylinder liner for your reference. Clearance Between Piston and Gylinder Liner mm(in) Standard 0.146 - 0.165 ( 0.0057 - 0.0065 )6A-98 ENGINE MECHANICAL Piston and Cylinder Liner Grade Gylinder liner inside diameter (Minimum measurement position after insert cylinder liner to cylinder body) mm(in) Grade No. A 8 Cc 132.900 to 192.911 to 192.921 to 192.910 132.920 132.930 (6.2828-5.2327) | (5.2327-5.2831) | (5.2331-5.2895) Piston out side diameter (Grade measuring position) mmi(in) Grade No. A 8 Cc 182.745 to 192.755 to 132.766 to 192.754 182.765 182.775 (6.2262-5.2265) | (5.2266-5.2270) | (6.2270-5.2274) Clearance between Cylinder Body and Oylinder Liner mm(iny ‘Standard 0.006 = 0.025 (0.0002 - 0.0010) Cylinder Body and Cylinder Liner Grade Cylinder body bore diameter mmi(in) Grade No.1 2 3 137.000 to 197.011 to 197.021 to 197.010 137.020 137.080 (6.3987-5.3941) | (5.3941-5.9945) | (5.9945-5.9949) Cylinder liner out side diameter mm(in) Grade No.1 2 3 136.985 to 136.995 to 137.006 to 136.994 137.005 137.015 (6.3931-5.3935) | (5.3935-5.3939) | (6.9939-5.3943)ENGINE MECHANICAL 6A-99 REASSEMBLY For with glow system Reassembly Steps 1. Piston 5. Snap Ring 2. Snap Ring 6. Piston Rings 3. Connecting Rod 7. Bearing 4. Piston Fin 8. Connecting Rod Cap6A-100 ENGINE MECHANICAL Reassembly Steps 1. Piston 1) Before reuse the piston to measure the clearance between piston and cylinder liner bore, 2) Measure the cylinder bore inside diameter on the maximum wearing point. Cylinder Measuring point mmi(in) From liner top 180 — 275 (6.12-10.83) 3) Measure the piston outside diameter on the piston grade measuring point Piston measuring point mm(in) From piston top 123.0 (4.84) Piston and Liner Bore Clearance mm(in) Standard 0.146 ~ 0.165 (0.0057 — 0.0065) 2. Snap Ring Use a pair of snap ring pliers to reassemble the snap ring to the piston. 3. Connecting Rod 1) Clamp the connecting rod in the vise. Take care not to damage the connecting rod. 2) Install the piston so that the piston head front mark and the connecting rod front mark are set in the same direction. 4. Piston Pin 1) Apply engine oil to the piston pin. 2) Insert the piston pin to the connesting rod through piston pin hole on the piston 5. Snap Ring Use a pair of snap ring pliers to reassemble the snap ring to the piston.ENGINE MECHANICAL 6A - 101 2} Full keystone =a ‘Under cut 6. Piston Ring 1) Apply engine oil to the piston rings. 2) Confirm discrimination mark on the piston ring Discrimination mark ‘string tN —2ndring [aN 3rd ring 3N Oilring Not available 8) Use the piston ring setting tool to reassemble the four piston rings according to discrimination mark on the piston ring (The discrimination mark should be face upper side} The oil ring has not discrimination mark. Piston ring setting tool: 1-8522-1029-0 Note: Insert the expander coil into the oil ring groove so that there is no gap on either side of the expander coil before installing the oil ring. 4) Check to see if the piston rings rotate smoothly in the piston ring grooves. By 7 bearing Carefully wipe any oil or other foreign material from the connecting rod bearing back face and the bearing fitting surface.6A-102 ENGINE MECHANICAL Front mark [=] 8: Connecting Rod cap 1 25 1) Fit the connecting rod bearing lower to the = connecting rod cap 2) Apply engine oil to the circumference of the each Q piston ring, piston and crankpin. ( Ta] °) Position the piston ring gaps as shown in the illustration ay Gap position 4 3 =] 1 ‘ist compression ring ™ 2 2nd compression ring 3 3rd compression ring 4 Oilring 5 Coil expander 4) Apply molybdenum disulfide grease to the two piston skirts, This will facilitate smooth break-in when the engine is first started after reassembly. 5) Apply engine oil to the connecting rod upper bearing 6) Apply engine oil to the cylinder wall 7) Position the piston head front mark so that itis, facing the front of the engine. 8) Use the piston ring setting tool to compress the piston rings. Piston setting tool: 1-8522-0046-0 9) Use a hummer grip to push the piston in until the connecting rod marks contact with the crankpin As the same time, rotate the crankshaft until the crankpin is at bottom dead center. CAUTION: Do not bend or damage the oiling jet. 10)Align the connecting rod cap cylinder number marks and the connesting rad cylinder number marks. 11)Reassembly the connecting rod caps. 12)Apply molybdenum disulfide grease to the threads and setting faces of each connecting rod bolts and nuts, 19)Tighten the connecting rod nut to specified torque Cap Nut Torque Nem(kg-mfb ft) tststep 2nd step 3rd step 98.1(10.072.3) 30° 30°ENGINE MECHANICAL 6A -103 FLYWHEEL AND CRANK PULLEY DISASSEMBLY Disassembly Steps 4. Snap Ring 4, Ring Gear 2. Pilot Bearing 5. Crank Pulley 3. Flywheel 6. Crankshaft Dumper6A-104 ENGINE MECHANICAL © e o(eOe)o o @ Disassembly Steps 1. Snap Ring Use a pair of snap ring pliers to disassemble the snap ring. 2, Pilot Bearing Use pilot bearing puller to remove the pilot bearing Pilot bearing puller: 9-8521-0157-0 3. Flywheel Loose fixing bolts to disassemble the flywheel from, crankshaft. 4. Ring Gear Put the flywheel with ring gear on the wood piece, strike around the edges of the ring gear with a hammer and brass bar to disassemble it. 5. Crank Pulley Loose crank pulley fixing bolts to disassemble the crank pulley. 6. Crankshaft Dumper Loose the fixing bolts to disassemble the crankshaft dumper.ENGINE MECHANICAL 6A -105 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. 1. Pilot Bearing Visually inspection worn out or abnormal noise on the pilot bearing Note: Do not washing the pilot bearing because it is sealing grease type bearing. 2. Flywheel a 1) Visually inspect cracking, scratching or worn out on the flywheel. 2) Measure the wear value of flywheel. Depth form Friction Face to Pressure Plate Fixing Face mm(in) Clutch Size Standard Limit 17" 48.0 (1.890) _|_50.5 (1.988) 15.5" 20.0 (0.787) | 21.5 (0.846) 3. Ring Gear Visually inspection damage on the ring gear. 4. Crankshaft Dumper Visually inspection cracking or separation on the crankshaft dumper6A-106 ENGINE MECHANICAL REASSEMBLY Reassembly Steps 1. Crankshaft Dumper 4. Flywheel 2. Crank Pulley 5. Pilot Bearing 3. Ring Gear 6. Snap RingENGINE MECHANICAL 6A -107 2) t Reassembly Steps 1. Crankshaft Dumper 1) Reassemble the crankshaft dumper to crankshaft, align two grooves face to the front side. 2) Tighten bolts numerical order to specified torque shown in the illustration. Bolt Torque Nem (Kg-miflo-ft) 96.1 (9.8/70.9) Note: Do not attempt to apply any oil on the crankshatt dumper. 2. Crank Pulley 1) Apply engine oil to thread of fixing bolts. 2) Set the crank pulley to crankshaft dumper. 8) Tighten bolts numerical order to specified torque shown in the illustration. Bolt Torque Nem (Kg-mflo-ft) 266.8 (27.2 /196.7) 3. Ring Gear 4, Flywheel 1) Heat the ring gear evenly with a gas burner to invite thermal expansion Do not allow the temperature of the gas burner to exceed 200°C (390°F) 2) Install the ring gear when itis sufficiently heated The ring gear must be installed with the chamfer facing the flywheel Note: Take care not to burn yourself on the heated ring gear. 5. Pilot Bearing Reassemble the pilot bearing to flywheel. 6. Snap Ring Use a pair of snap ring pliers to reassemble the snap ring.6A-108 ENGINE MECHANICAL CYLINDER BODY DISASSEMBLY Disassembly Steps 4. Oil pressure unit 4. iling jet 2. Oilrelief valve 5. Cylinder liner 3. Crankcase lower 6. Cylinder bodyENGINE MECHANICAL 6A - 109 Disassembly Steps 1. Oil Pressure Unit 2. Oil Relief Valve 3. Crankcase Lower 4) Loosen the fixing bolts to disassemble the crankcase lower. 2) Putt on the wood plate or piece. 4. Oiling Jet Loosen the bolt to disassemble the oiling jet. Note: Take care do not bend or damage the oi a ie. 8. Cylinder Liner 1) Use the screper to remove carbon deposit. 2) Use cylinder bore dial indicator to measure the cylinder bore at measuring point in the thrust and axial direction of the crankshaft. Measuring Point mm(in) 15 ~ 20 ( 0.1969 - 0.7874) It the measured value exceeds the specified limit, the cylinder liner must be replaced Cylinder Liner Bore mmi(in) Nominal measurement Limit 182.9 (6.2822) 138.2 (5.2441) Note: If the inside of the cylinder liner is scored or scratched, the cylinder liner must be replaced. 6. Cylinder Body Visually inspection any damage.6A-110 ENGINE MECHANICAL INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. g 1. Cylinder Body 1) Disassemble the cylinder liners. 2) Visually inspection any cracking or damage and choking oil and/or water holes. It possible it is required to special inspect by dye penetrant flaw detector. 3) Use a straight edge and a feeler gauge to measure the cylinder body upper face warpage on the four sides and two diagonals of the cylinder body upper face shown in the illustration Cylinder Body Upper Face Warpage Standard mm(in) Limit 0.075 ( 0.0030) or less 0.2 (0.008) If the measured value exceeds the specified limit, the cylinder body must be replaced 4) Inspect water leakage to apply water pressure in the oylinder body water jacket Water Pressure kPa(Kg/om2/PSi) 490.5 (5.0/ 71.1) It water leakage is fund, the cylinder body must be replaced, 2. Cylinder Liner 1) Use the scraper to remove carbon deposit. 2) Use cylinder bore dial indicator to measure the cylinder bore at measuring point in the thrust and axial direction of the crankshaft. Measuring Point 15-20 ( 0.1969-0.7874 } mmi(in) Gylinder Liner Bore Nominal measurement 182.9 (5.2822) mm(in) Limit 183.2 ( 6.2441) If the measured value exceeds the specitied limit, the cylinder liner must be replaced Note: If the inside of the cylinder liner is scored or scratched, the cylinder liner must be replaced.ENGINE MECHANICAL 6A ~111 3. Crankcase Lower Visually inspection any cracking or damage on the crankcase lower. It possible it is required to special inspect by dye penetrant flaw detector. 4. Oiling Jet Check oil port choking on the oiling jet. 5. Relief Valve Inspect choking, any damage to piston, valve seat and spring 6. Cylinder Liner Projection 1) Use a dial indicator or a straight edge and feeler gauge to measure the cylinder liner projection. Gylinder Liner Projection mmi(in) Standard 0.05 - 0.09 ( 0.0020 - 0.0035) The difference in the cylinder liner projection height between any adjacent cylinders must not exceed limit. Projection Height between Adjacent Cylinder mmi(in) 0.025 (0.0010) or less6A-112 ENGINE MECHANICAL REASSEMBLY Reassembly Steps 1. Gylinder boay 4. Grankcase lower 2. Gylinder liner 5. Gil relief valve 3. Olling jet 6. Oil pressure unitENGINE MECHANICAL 6A-113 Reassembly Steps EQ) +: Svlinder Boay 2. Cylinder Liner 1) Use new kerosene or diesel fuel to thoroughly clean the cylinder liner and bore. 2) Use compressed air to brow-dry cylinder liner and bore surface. Note: All foreign materials must be carefully removed from the cylinder liner and the cylinder bore before installation. 3) Apply engine oil to outside surtace cylinder liner. 4) Install the cylinder liner into cylinder body from the top of the cylinder body by your hand. 5) Check cylinder liner projection refer to the Cylinder Body Inspection and Repair section. Note: 1) Do not apply unreasonableness stress or hit to cylinder liner during install it 2) Take care to remove the cyl cylinder body turn over. 3. Oiling Jet Tighten to specified torque Ciling Jet torque Nem (kg-mflb-ft) 68.7 (5.0/ 50.6) Be sure direction of the oiling jet tip to cooling hole of piston. Do not bend or damage oiling jet. 4. Crankcase Lower Reassemble manner refer to Crankshaft, Piston and Connecting Rod Installation section.6A-114 ENGINE MECHANICAL ¢ 2) 5. Oil Relief Valve 1) Apply engine oil to O-ring and relief valve assembly. 2) Reassemble relief valve to oylinder body to specified torque. Relief valve torque Nem (Kg-mflo-ft) 19.7 (2.0/ 14.5) 6. Oil Pressure Unit 1) Reassemble the adapter withe gasket to cylinder body by specified torque. 2) Reassemble the oil pressure unit with gasket to the adapter by specified torque Adapter Torque Nem (Kg-miflo-ft) 41.3 (42/304) Oil pressure Unit torque Nem (Kg-milo-ft) 17.6 (1.8/ 13.0)ENGINE MECHANICAL 6A-115 OIL PUMP Oil Pump Construction Relief Valve Split Pin Ball Drive Gear Driven Gear ‘Oil Pump Cover it Punip Body6A-116 ENGINE MECHANICAL DISASSEMBLY Disassembly Steps 1. Cover 7. Oil Pump Drive Gear 2 Ball 8. Oil Pump Cover 3. Split Fin 9. Oil Pump Driven Gear 4. Spring Seat 10. Drive Gear Shaft 5. Spring 11. Oil Pump Body 6. Oil Relief ValveENGINE MECHANICAL 6A-117 [4] Disassembly Steps 1. Cover Loosen Bolts to remove the cover. 2. Ball Take out the ball from the oll pump assembly. 3. Split Pin 4. Spring Seat 5. Spring 6. Oil Relief Valve Remove the split pin, spring seat, spring and oil relief, valve, 7. Oil Pump Drive Gear Use the gear puller to pull out the oil pump drive gear. 8. Oil Pump Cover Loosen the fixing bolts to disassembly the oil pump cover. 9. Oil Pump Driven Gear 10. Drive Gear Shaft Take out the oil pump driven gears and drive gear shaft from oil pump body 11. Oil Pump Body6A-118 ENGINE MECHANICAL INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. 1. Ball Carefully inspect the ball scratches or damage. 2. Oil Reliet Valve Inspect the oil relief valve seat portion damage and spring damage. Note: If there is some scratch or damage the ball and relief valve must be replaced. [@]] 3. Clearance Between Oil Pump Body and Driven Gear Use feeler gauge to measure the clearance between oil pump body and driven gear. Clearance Between Oil Pump Body and Driven Gear mmi(in) ‘Standard (0.050 — 0.098 ( 0.0020 - 0.0039) GZ] 4 Side Clearance Between Oil Pump Cover and Gears Use feeler gauge to measure the side clearance between oil pump cover and gears, Side Clearance mmi(in) Standard 0.040 — 0.094 ( 0.0016 - 0.0087)ENGINE MECHANICAL 6A-119 5. Oil Pump Gear Shaft Outside Diameter and Clearance between Oil Pump Gear Shaft and Oil Pump Body. Use inside and out side micrometer to measure the oil pump gear shaft out side diameter and oil pump body holes. Cll Pump Gear Shatt Diameter mm(in) Nominal Measurement Limit eee 00 C0808) ee OTe Clearance between Oil Pump Gear Shaft and Oil Pump Body mmcin) Standard (0.040 — 0.074 ( 0.0016 - 0.0029) Note: If measuring value exceeds, the parts must be replaced. 6. An Interference between Oil Pump Drive Gear and Drive Gear Shaft Measure the inside diameter of oil pump drive gear and outside diameter of drive gear shaft. An Interference mm(in) Standard 0.019 - 0.047 ( 0.0007 - 0.0019) Note: The measuring value exceeds from limit or standard, the parts must be replaced.6A-120 ENGINE MECHANICAL REASSEMBLY Reassembly Steps 1. Oil Pump Body 7. Spring 2. Drive Gear Shaft 8 Spring Seat 3. Oil Pump Drive Gear 9. Split Pin 4, Oil Pump Driven Gear 10. Ball 5. Oil Pump Cover 11. Cover 6. Oil Relief ValveENGINE MECHANICAL 6A - 121 il pump drive gear Drive gear shaft Reassembly Steps 10. 1". |. Oil Pump Body Drive Gear Shaft Apply engine oil to drive gear and reassemble the drive gear to oil pump body. Oil Pump Drive Gear 1) Put the oil pump drive gear on the bed of bench press, place the oil pump body with the drive gear shaft 2) Use bench press to press the drive gear shaft into the oil pump drive gear as shown in the illustration Oil Pump Driven Gear Apply engine oil and reassemble the oil pump driven gear to the oll pump body. Oil Pump Cover Tighten the bolts to specified torque. Fixing Bolt Torque Nem (Kg:mnflo-ft) Bolt Size MB 17.2 (1.8/13.0) M10 39.3 (4.0/28.9) Oil Relief Valve Spring Spring Seat Split Pin 1) Install the oil relief valve, spring and spring seat to the oll pump body. 2) Reassemble the split pin into the oil pum body and lock it Ball Cover6A -122 ENGINE MECHANICAL 12, Make sure the oll pump assembly to move smoothly.ENGINE MECHANICAL 6A - 123 OIL COOLER DISASSEMBLY Disassembly Steps 1. Water Guide 7. Oil Thermostat 2. Oil Cooler Element 8 Spacer 3. O-Ring 9. Supporter 4. Gasket 10. Seal Ring 5. Oil Pipe 14. Oil Cooler Body 6. O-Ring 12. Gasket6A-124 ENGINE MECHANICAL 10. 1". 12, [4] Disassembly Steps 1. Water Guide Loosen the bolts to remove the water guide. Oil Cooler Element O-Ring Gasket Loose the nuts to remove the oil cooler element with the O-rings and gaskets. Oil Pipe O-Ring Loosen the bolts to remove the oil pipe with O-ring Oil Thermostat Carefully remove the oil thermostat Spacer ‘Supporter Seal Ring Oil Cooler Body GasketENGINE MECHANICAL 6A - 125 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. 1. Oil Cooler Element Inspect any cracking or damage. 2. Oil Thermostat 1) Inspect worn out or damage on piston and valve seat. 3) Inspect opening temperature with oil heater. Opening temperature © 96.5 99.5 (208.7 211.1) i) 2) Same time check damage or decrease spring force.6A-126 ENGINE MECHANICAL REASSEMBLY Reassembly Steps 1. Oil Cooler Body 7. Oil Pipe 2. Seal Ring 8 Gasket 3. Supporter 9. O-Ring 4, Spacer 10. Oil Cooler Element 5. Oil Thermostat 11. Water Guide 6. O-Ring 12. GasketENGINE MECHANICAL 6A - 127 Seal ring raion topee1 Ss suppor Rotation stopper Reassembly Steps 1. Oil Cooler Body 2. Seal Ring Be sure seal ring direction shown in the illustration, 3. Supporter Align the rotation stopper on supporter to oil cooler body as shown in the illustration. Spacer Oil Thermostat O-Ring Oil Pipe 1) Reassemble the oll pipe with O-ring to the oll cooler body. 2) Tighten the oil pipe to specified torque. Oil Pipe Torque Nem (Kg-mnflo-ft) 39.2 (4.0/28.9} 8. Gasket O-Ring 10. Oil Cooler Element 1) Apply ThreeBond 1208 to O-ring grooves to install the O-rings 2) Install the gaskets to the oll cooler element. 3) Reassemble the oll cooler element to the oil cooler body. 4) Tighten the fixing nuts for oil cooler element to specified torque Element Nut Torque N.m(kg.mio ft) 245 (25/181) 11. Water Guide 12. Gasket6A-128 ENGINE MECHANICAL MAIN OIL FILTER DISASSEMBLY Disassembly Steps 1. Plug 8 O-Ring 2. O-Ring 9. Warning Switch Assembly 38. Center Bolt 10. Gasket 4. O-Ring 11. Spring 5. Case 12. Relief Valve Assembly 6. Spring 13. Bracket 7. ElementENGINE MECHANICAL 6A - 129 10. 1. 12, 13. [4] Disassembly Steps . Plug O-Ring Loosen plug with O-ring for drain engine oil form main oil filter Center Bolt O-Ring Loosen center bolt with O-ring Case Spring Element Disassemble the case, spring and element. O-Ring Warning Switch Assembly Carefully remove the warning switch assembly with the gasket for disassemble the relief valve assembly. O-Ring Spring Relief Valve Assembly Bracket Loosen Fixing bolts to disassemble the bracket with O-rings.6A-130 ENGINE MECHANICAL INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. 1. Relief Valve Assembly Check any scratches or damage on the relief valve assembly. By) ® Bracket Clean oil holes on the bracket.ENGINE MECHANICAL 6A - 131 REASSEMBLY Reassembly Steps Negaene Bracket Relief Valve Assembly Spring Gasket Warning Switch Assembly Element Spring O-Ring Case O-Ring Center Bolt O-Ring Plug6A -132 ENGINE MECHANICAL Loz ¢. soe Zao AJ 7 Oring Reassembly Steps 1. Bracket 1) Set O-rings to bracket 2) Tighten the bolts to specified torque. Tighten Torque N-m(kg-mi 43.2(4.4/31.8) 2. Relief Valve Assembly 3. Spring 4, Gasket 5, Warning Switch Assembly 1) Reinstall the relief valve assembly, the spring and the warning switch assembly to bracket 2) Tighten the warning switch assembly to specified torque. Warning switch torque Nem(kg-mf-ft) 77.5 (791571) 6. Element 7. Spring 8. O-Ring 9. Case 10. O-Ring 11. Center Bolt 1) Apply engine oil to the O-ring and set the O-ring to groove of the case. 2) Reassemble the element, the spring, the case and the center bolt with the O-ring to tighten by specified torque. Center Bolt Torque Nem (Kg:mnflo-ft) 44.2 (45/925) Note: When reassemble the case a oil drain plug must direction to engine rear side. 12, O-Ring 13. PlugENGINE MECHANICAL 6A - 133 PARTIAL OIL FILTER DISASSEMBLY Disassembly Steps 1. Plug 6. Spring 2. O-Ring 7. Element 38. Center Bolt 8 Gasket 9. Bracket 4. O-Ring 5. Case6A-134 ENGINE MECHANICAL Disassembly Steps 1. Plug 2. O-Ring Loosen Plug with O-ring for drain engine oil 3. Center Bolt 4. O-Ring 5. Case Loosen center bolt to remove the case. 6. Spring 7. Element 8. Gasket 9. BracketENGINE MECHANICAL 6A - 135 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Ey] * Center Bott Clean the oil holes on the center bolt 2 By) 2 Broset Clean the oil holes on the bracket.6A-136 ENGINE MECHANICAL REASSEMBLY Reassembly Steps 1. Bracket 6. O-Ring 2. Element 7. Genter Bolt 3. Spring 8. O-Ring 4. Gasket 9. Plug 5. Caseal Ze ROO, FUEL SYSTEM 6C-43 BOOST COMPENSATOR ADJUSTMENT € ‘Adujsiment Pump Speed 430 rpm S ryroes] R265 73m BO, (553) (180) Boost Pressure KPa [mm Hg]6C-44 FUEL SYSTEM INJECTION PUMP CALIBRATION DATA For High altitude Area: Colombia, Chile, Peru, Ecuador, China, Kenya TEST CONDITIONS Injection nozzle Injection nozzle holder Injection starting pressure Injection line dimensions Transfer pump pressure (Max.) Test diesel fuel Fuel temperature Pump rotation Overflow valve opening pressure ZEXEL No. 105025-1280 ZEXEL No. 105041-3081 22.1 MPa (225 kgiom? / 3,200 psi) Inside diameter = 2.2 mm Outside diameter = 6 mm Length = 600 mm 451 kPa (4.6 kglom? / 65.4 psi) 1804113 or SAE standard test oil (SAE J967d) 39 -419(109.2-114.8F) Clockwise viewed trom the drive side 255 kPa (2.6 kg/cm? / 37.0 psi) CAUTION: STRICTLY OBSERVE THE ABOVE TEST CONDITIONS DURING INJECTION PUMP FUEL INJECTION VOLUME ADJUSTMENT. FAILURE TO OBSERVE THE TEST CONDITIONS WILL RESULT IN MISADJUSTMENT OF THE INJECTION PUMP FUEL INJECTION VOLUME. MISADJUSTMENT OF THE FUEL INJECTION VOLUME WILL RESULT IN SERIOUS ENGINE DAMAGE. INJECTION TIMING Pre-stroke Injection order ang interval Tappet clearance 6440.03 mm (0.252 + 0.001 in) 1-5-3-6-2-4 Plungers are numbered from the drive side. Manually rotate the camshaft several times to make sure that it rotates smoothly. TOP NORMAL %ENGINE ELECTRICAL 6D-1 SECTION 6D ENGINE ELECTRICAL CONTENTS General Description . Starting System . Charging System . Wire Coding Symbols and Abbreviations. Fuses... p fan Manufacturer's Identification Marks. Alternator .. . Disassembly Inspection and Repair. Rotor Coil Stator Rectifier Holder Assembly Ball Bearing. Reassembly . Starter Motor . Disassembly Inspection and Repai Armature Field Coil and Body. Brush and Brush Holder. Drive Gear Shaft Pinion Clutch. . Preheating, Starting and Electrical Control Systems Wiring Circuit Diagram. Inspection and Repai6D -2 ENGINE ELECTRICAL GENERAL DESCRIPTION STARTING SYSTEM STARTER MOTOR The cranking system consists of a battery, starter ‘components are connected according to wiring switch, starter relay etc. and these main circuit diagramENGINE ELECTRICAL 6D-3 CHARGING SYSTEM ALTERNATOR The charging system is the IC integral regulator The generator dose not retire particular charging system and its main components are maintenance such as voltage adjustment, connected as shown in the wiring circuit diagram ‘The rectifier connected to the stator, coil has nine The regulator is a solid state type and itis mounted diodes to transform A.C. voltage into D.C. voltage. along with the brush holder assembly inside the This D.C. voltage is connected to the output generator installed on the rear end cover. terminal of generator.6D-4 ENGINE ELECTRICAL WIRE CODING 7 DESCRIPTION Hie eens Codes used in the circuit diagram represent wire size Alpeerase| ate and color El) [oo gt Example: 05.8 ee ee U____ Wire color (Red) Wire size (0.6 mm?) WIRE SIZE Wire size is specified in the metric system The metric system gives the wire size in cross- sectional area measured in the square millimeters. WIRE SIZE SPECIFICATIONS Wire size Number of wires! Resistance at normal room Maximum allowable Wire diameter temperature of 20°C (68°F) current mm? | AWG mm (in) im (aut) A os | 20 710.32 (0.013) 0.08250 (0.00991) 1.3 08s | 18 11/0.32 (0.013) 0.02050 (0.00626) 148 1.25 | 16 16/0.32 (0.013) 0.01410 (0.00430) 188 2 14 26/0.32 (0.013) 0.00867 (0.00264) 25.4 3 12 41/0.32 (0.013) 0.00550 (0.00168) 34.2 5 10 6510.32 (0.013) 0.00347 (0.00106) 45.9 8 8 50/0.45 (0.018) 0.00228 (0.00070) 59.8 15 8 8410.45 (0.018) 0.00136 (0.00042) 82.8 20 4 41/0.80 (0.031) 0.00087 (0.00027) 110.9 30 2 70/0.80 (0.31) 0.00081 (0.00016) 147.0ENGINE ELECTRICAL 6D-5 WIRE COLOR-CODING Wire Color All wires have color-coded insulation. Wires belonging to a system's main harness have a single color ©. Wires belonging to a system’s sub-curcuits have a colored strip: 2 (tracer) @ Striped wires use the following code to show wire size and colors, Example g R ‘TL_— rea (stripe (tracer) color) Green (Base color) Wire size (0.5 mm’) Abbreviations are used to indicate wire color within a circuit diagram Refer to the following table. Color-coding Meaning Gireuits B Black Starter circuit and grounding circuit w White Charging circuit R Red Lighting circuit G Green Signal circuit Y Yellow Instrument circuit ie Blue Wiper circuit ° Orange Br Brown lg Light green Gy Gray Other circuits Pp Pink sb Sky blue v Violet6D-6 ENGINE ELECTRICAL SYMBOLS AND ABBREBIATIONS DESCRIPTION The symbols and abbreviations used in the circuit diagram make the diagram easier to read and understand, SYMBOLS The illustration at the left shows typical symbols used in circuit diagrams, These same symbols may also appear in the text. Refer to the following table. 1005-001 SYMBOL AND MEANING Symbol Meaning Symbol Meaning oN | ruse @ Single flament bulb Se Fusible link (Slow blow fuse) Double filament bulb —\ pp Fusible link wire —(y— Motor —fo—o}— | switcn tw F4— | variable resistor Switch —THH— | Coil (indicator)ENGINE ELECTRICAL 6D-7 1005-002 ABBREVIATIONS AND MEANING Symbol Meaning Symbol Meaning Relay —{— Contact wiring Note: Relay contact shown in the wiring diagram 3 indicates condition ¢ Battery before actuation. —Het— | diode {TEER | connector &) Electronic part —t— Light emitting diode —vwv— _ | Resistor Read switch Speaker —h— | condenser Ground = ABBREVIATIONS. 5 U8 aw The illustration at the lett shows typical abbreviations 2 a4 used in the circuit diagrams ae These same abbreviations may also appear in the text = zh, 7 Refer to the following table. pla 23) lai ‘Abbreviation Meaning Meaning RH Right-hand side STD Standard equipment UH Left-hand side OPT Optional equipment sw Switch wy With Mir Manual transmission wor without AT Automatic transmission op Overdrive FT Front ACO Accessories RR Rear AC Air conditioner FLW Fusible link wire ATF Automatic transmission fluid TEMP | Temperature vsv Vacuum switching valve ECM Electronic control module6D-8 ENG! INE ELECTRICAL FUSES FUSE Fuses are located in the fuse box. This type of fuse is highly resistant to both heat and shock. Itis lighter in weight than conventional glass tube fuses, All {uses are transparent so that a blown fuse is easily wa &) oad NIKKO ELECTRIC INDUSTRY CO., LTD. 1010-001 ‘ identified Nousieg Fuse Specifications 1018-001 Element ‘Current (A) Housing Color 5 Yellow-brown 75 Brown 10 Red 15 Blue 20 Yellow TT J j SLOW BLOW FUSE ‘Slow blow fuse are connected in the slow blow fuse i 2 i Slow blow fuse are designed to melt in the event of ) circuit overload. This protects the wiring harnesses from damage. | Melted slow blow fuses can be visually identified. The circuit capacity is indicated on top of slow blow fuse case and the case color is identified the circuit capacity. 408 Green 0A Yellow Precautions. 4. Always determine the cause of an overload before replacing a fuse, 2. Always replace a blown fuse with a new fuse of the same amperage rating Never replace a blown fuse with a new fuse of a different amperage rating. An electrical fire with serious circuit damage can result. MANUFACTURER’S IDENTIFICATION MARKS The starter motor and the alternator have their manufacturer's identification plate attached. Refer to the illustration. (For example}ENGINE ELECTRICAL 6D-9 ALTERNATOR DISASSEMBLY Disassembly Steps 1 2. 2Seenogne Through bolt Rotor and front bracket assembly Pulley nut and washer Pulley Fan Woodruff key Front bracket assembly Retainer Retainer Ball bearing Retainer 12. 13. 14. 16. 16. 17. 18. 19. 20, 21 22. Collar Retainer Front bracket Coltar Rotor assembly Rotor coil assembly Stator assembly Rectifier assembly Regulator assembly Bearing Rear bracket assembly6D -10 ENGINE ELECTRICAL Disassembly Steps Through bolt Rotor and front bracket assembly Pulley nut and washer Pulley Fan Woodrutt key Front bracket assembly Retainer 9. Retainer 10. Ball bearing 11, Retainer 12, Collar 13. Retainer 14, Front bracket 15. Collar 16. Rotor assembly 17, Rotor coil assembly 18. Stator assembly 19, Rectifier assembly 20. Regulator assembly 21. Bearing 22. Rear bracket assemblyENGINE ELECTRICAL 6D-11 INSPECTION AND REPAIR Make the necessary adjustments, repairs and part replacements if excessive wear or damage is discovered during inspection. Itis most important that electrical components be kept clean and dry at all times. Always visibly check the slow blow fuse, the fuses, and the indicator lights for damage as the first step in the inspection and repair procedure. 101102.020 a ro1102-021, ROTOR COIL Rotor Coil Resistance Use a circuit tester to measure the rotor coil resistance between the two sides of the slip ring (separated by the segment gap) If the measured resistance is above or below the specified standard, the rotor assembly must be replaced Rotor Coil Resistance ohm ‘Standard 147 STATOR Stator Continuity Check for continuity across the stator coils. If these is no continuity, the stator assembly must be replaced, Stator Insulation Use a cirouit tester to check that there is no continuity between the stator coils and the core. It there is continuity between the stator coils and the core, the stator assembly is defective and must be replaced,6D -12 ENGINE ELECTRICAL @ 98 101102.008 101102-008, L 01102-010 ro1102-011 101102-012 RECTIFIER HOLDER ASSEMBLY Rectifier Check Use a cirouit tester to check the battery side rectifiers (+) and the ground side rectifiers (7) 1. Touch one circuit tester lead to the battery side terminal (+). 2. Touch the other circuit tester lead to one of the battery side rectifiers. Note the circuit tester gauge reading (continuity or infinite resistance} 3. Reverse the position of the circuit tester leads. The circuit tester gauge reading should be the opposite of Step 2. 4. Continue the procedure for the remaining battery side rectifiers. It the circuit tester gauge reading at any point is abnormal, the rectifier holder assembly must be replaced, 5. Touch one circuit tester lead to the ground side terminal (-) 6. Touch the other circuit tester lead to one of the ground side rectifiers. Note the circuit tester gauge reading (continuity or infinite resistance). 7. Continue as in Steps 3 -4 above for the remaining ground side rectifiers. PULLEY Check the pulley for excessive wear and crackingENGINE ELECTRICAL 6D-13 FAN Check the fan for cracking and distortion. r01102.013, BALL BEARING Check the ball bearings for binding, drag, roughness, and noise.6D -14 ENGINE ELECTRICAL REASSEMBLY Reassembly Steps 1. Rear bracket assembly 12. Retainer 2. Bearing 13, Ball bearing 3. Rotor coil assembly 14, Retainer 4. Regulator assembly 15. Retainer 5. Rectifier assembly 16. Front bracket assembly 6. Stator assembly 17. Woodrutt key 7. Rotor assembly 18 Fan 8& Collar 19. Pulley 9. Front bracket 20. Pulley nut and washer 40. Retainer 21. Rotor and front bracket assembly 11, Collar 22, Through boltENGINE ELECTRICAL 6D-15 Reassembly Steps 1. Rear bracket assembly 2. Bearing 3. Rotor, Coil assembly 4. Regulator assembly 5. Rectifier assembly 6 7. 8. . Stator assembly . Rotor assembly . Collar 9. Front bracket 10. Retainer 11. Collar 12. Retainer 13, Ball Bearing 14, Retainer 15. Retainer 16. Front bracket assembly 17. Woodruff key 18. Fan 19. Pulley 20. Pulley nut and washer 21. Rotor and front bracket assembly 22. Through bolt6D -16 ENGINE ELECTRICAL STARTER MOTOR DISASSEMBLY 101401001 Disassembly Steps 4. Lead wire 2. Shift lever pin bolt 3. Magnetic switch and push rod assembly Push rod and boot Rear cover bolt Through bolt Rear cover Brush and brush holder Brush holder spring 10. Field coil and body assembly 11. Through bolt 42. Center bracket and armature assembly 13. Armature enone 14. 16. 16. 17. 18. 19. 20, 21 22, 23, 24, 25, 26. 27. Ball bearing Ball bearing Thrust washer Center bracket Thrust washer Shift lever Pinion case assembly Drive gear shaft and pinion clutch assembly Giip ring Pinion stopper Pinion clutch assembly Bracket Bearing Drive gear shattENGINE ELECTRICAL 6D-17 101401.002 t01401-008 101401-005 Disassembly Steps Lead Wire Shift Lever Pin Bolt Magnetic Switch and Push Rod Assembly Push Rod and Boot 4) Loosen the magnetic switch bolts. 2) Use aplastic hammer to lightly tap around the magnetic switch. This will loosen the switch. 3) Remove the magnetic switch together with the push rod and boot 4) Remove the boot from the push rod. Take care not to damage the boot, Rear Cover Bolt Through Bolt Rear Cover Brush and Brush Holder 1) Apply setting marks across the rear cover and the field coil body. 2) Loosen the through bolts. 8) Use aplastic hammer to lightly tap around the rear cover. This will loosen the cover, 4) Loosen the brush lead wire screw and disconnect the lead wire. 8. Brush Holder Spring 1) Use long nose pliers to compress the brush holder spring end. Position the brush holder spring so that it holds the brush in the brush holder cage. This will prevent brush damage 2) Remove the brush and brush holder assembly from the commutator assembly.6D -18 ENGINE ELECTRICAL 101401-007 101401.008 101401008 10. Field Coll and Body Assembly 1) Apply setting marks across the field coil body and the center bracket. 2) Use aplastic hammer to lightly tap around the body assembly. This will loosen the assembly. 3) Remove the field coil and body assembly from the center bracket. 14. Through Bolt 12. Center Bracket and Armature Assembly 4) Loosen the through bolts. 2) Use aplastic hammer to lightly tap around the center bracket. This will loosen the bracket. 3) Remove the center bracket and armature assembly from the pinion case. Take care not to lose the thrust washers. 4) Pull the armature together with the bearings from the center bracket. Take care not to damage the commutator. 13. Armature 14. Ball Bearing 15. Ball Bearing Use a bearing puller to remove the ball bearings from the armature assembly. 16. Thrust Washer 17. Center Bracket 18. Thrust Washerr0r401-017 ENGINE ELECTRICAL 6D-19 19. Shift Lever 20. Pinion Case Assembly 21. Drive Gear Shaft and Pinion Clutch AssembI 1) Loosen the bracket screws. 2) Slide the drive shaft pinion toward the armature. 3) Remove the shift lever from the pinion case assembly. 4) Remove the drive gear shaft and pinion clutch assembly from the pinion case. 22. Clip Ring 23. Pinion Stopper 1) Use a bar to move the pinion stopper toward the Pinion clutch. The clip ring gap will be visible on the gear shaft groove. 2) Remove the clip ring 3) Use a pinion stopper remover to push out the pinion stopper. 24. Pinion Clutch Assembly 25. Bracket 26. Bearing 27. Drive Gear Shatt 1) Insert the drive gear shaft into a sleeve. 2) Use ahammer and abar to strike the bearing inner race free. 3) Remove the bearing from the drive gear shaft.6D -20 ENGINE ELECTRICAL INSPECTION AND REPAIR Make the necessary adjustments, repairs and part replacements if excessive wear or damage is discovered during inspection. Itis most important that electrical components be kept clean and dry at all times. Always visibly check the fusible links, and the indicator lights for damage as the first step in the inspection and repair procedure. 101302-002 ARMATURE Commutator Face Check the commutator face for roughness. It necessary, dress the commutator face with line sandpaper (#500 or #600) Be absolutely sure that there are not metal filings in the segment gaps. Commutator Run-Out 1. Mount the armature assembly on V-blocks. 2. Use a dial indicator to measure the commutator run-out If the run-out is greater than the specified standard but less than the specified limit, the commutator may be turned on a lathe to correct it It the run-out exceeds the specified limit, the armature assembly must be replaced. Commutator Run-Out mm (in) Standard Limit 0.016 (0.0006) or less 0.10 (0.004) Commutator Segment Groove Depth Use a vernier caliper to measure the depth ©) of each of the commutator segment grooves. If the commutator segment groove depth is less than the specified limit, the armature assembly must be replaced, Commutator Segment Groove Depth © mm (in) Standard 0.50.8 (0.020 - 0.081)