Professional Documents
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MG6HK We 0011
MG6HK We 0011
F-SERIES & LT
ENGINE
6HK1-TC MODEL
SECTION 6
SECTION CONTENTS
00 Service Information
6A Engine Mechanism
6B Engine Cooling
6C Fuel System
6D Engine Electrical
6E —
6F Exhaust
6G Turbocharger
SERVICE INFORMATION 00 – 1
SECTION 00
SERVICE INFORMATION
CONTENTS
PAGE
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 3
Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–44
Service Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–47
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–51
Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–70
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–78
00 – 2 SERVICE INFORMATION
MEMO
SERVICE INFORMATION 00 – 3
TROUBLESHOOTING
CONTENTS
PAGE
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 4
Hard Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 4
Unstable Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 8
Insufficient Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–10
Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–12
Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–14
Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–15
White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–17
Black Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–18
Oil Pressure Does Not Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–19
Abnormal Engine Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–21
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–25
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–25
Starter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–30
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–35
00 – 4 SERVICE INFORMATION
ENGINE MECHANICAL
HARD STARTING
1) STARTER MOTOR DOES NOT OPERATE
NG
Battery discharged or weak Recharge or replace the battery
OK
NG
Slow blow fuse Slow blow fuse open Replace the slow blow fuse
OK
OK
NG
Battery discharged or weak Recharge or replace the battery
OK
NG
Starter motor Defective pinion gear Replace the pinion gear
OK
NG
Fuel Fuel tank is empty Fill the fuel tank
OK
OK
OK
OK
NG
Defective feed pump Repair or replace the feed pump
SERVICE INFORMATION 00 – 7
NG
Fuel Use of the wrong fuel Use the correct fuel
NG
Water particles in the fuel Change the fuel
OK
OK
NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle
OK
NG
Injection pump Defective control system Replace the injection pump ASM
00 – 8 SERVICE INFORMATION
UNSTABLE IDLING
OK
OK
OK
Blown out cylinder head gasket
NG Worn cylnder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat
OK
NG
Engine mounting rubber Broken Replace
OK
NG
Camshaft Worn camshaft lobe Replace the camshaft
OK
OK
OK
NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle
OK
NG
Injection pump Defective control system Replace the injection pump ASM
00 – 10 SERVICE INFORMATION
INSUFFICIENT POWER
OK
NG
Fuel Water particles in the fuel Replace the fuel
OK
OK
OK
NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle
OK
OK
NG
Injection pump Defective control system Replace the injection pump ASM
OK
Blown out cylinder head gasket
NG Worn cylnder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat
OK
OK
NG
Valve spring Valve spring weak or broken Replace the valve spring
OK
NG
Exhaust system Exhaust pipe clogged Clean the exhaust pipe
OK
NG
Camshaft Worn camshaft lobe Replace the camshaft
00 – 12 SERVICE INFORMATION
OK
OK
OK
NG
Thermostat Defective Replace
OK
NG
Engine oil Improper engine oil viscosity Correct
OK
OK
NG
Injection pump Defective control system Replace the injection pump ASM
OK
OK
Blown out cylinder head gasket
NG Worn cylinder liner
Compression pressure Piston ring sticking or 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 – 14 SERVICE INFORMATION
OK
NG Oil leakage from the oil seal Replace the oil seal and/or the
Oil seal and gasket
and/or the gasket gasket
OK
NG
Air breather Clogged air breather Clean the air breather
OK
OK
NG
Valve stem oil seal Worn Replace
OK
Blown out cylinder head gasket
NG Worn cylinder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat
SERVICE INFORMATION 00 – 15
OVERHEATING
NG
Engine cooling water Insufficient cooling water Replenish the cooling water
OK
OK
OK
OK
OK
OK
NG
Thermostat Defective thermostat Replace the thermostat
OK
OK
NG
Fuel Water particles in the fuel Replace the fuel
OK
NG
Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing
OK
Blown out cylinder head gasket
NG Worn cylinder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat
OK
OK
NG
Cooling system Defective thermostat Replace
OK
OK
OK
NG
Fuel injection timing Advanced fuel injection timing Adjust the fuel injection timing
OK
OK
NG
Injection pump Defective control system Replace the injection pump ASM
OK
Camshaft NG
Worn camshaft lobe Replace the camshaft
SERVICE INFORMATION 00 – 19
OK
OK
OK
NG Relief valve sticking and/or weak Replace the relief valve and/or
Relief valve and by-pass valve
by-pass valve spring the by-pass spring
OK
NG
Oil pump Clogged oil pump strainer Clean the oil pump strainer
OK
NG
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing
OK
OK
NG
Oiling jet joint bolts Loose Tighten
SERVICE INFORMATION 00 – 21
1) ENGINE KNOCKING
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.
NG
Fuel Use of the wrong fuel Use the correct fuel
OK
OK
OK
OK
NG
Injection pump Defective control system Replace the injection pump ASM
00 – 22 SERVICE INFORMATION
OK
OK
OK
OK
NG
EGR system Defective EGR system Replace the EGR system
SERVICE INFORMATION 00 – 23
3) CONTINUOUS NOISE
NG
Fan belt Loose fan belt Readjust the fan belt tension
OK
NG
Cooling fan Loose cooling fan Tighten the cooling fan
OK
OK
NG
Generator Defective generator Repair or replace the generator
OK
4) SLAPPING NOISE
OK
NG
Rocker arm Damaged rocker arm Replace the rocker arm
OK
NG
Flywheel Loose flywheel bolts Tighten the flywheel bolts
OK
OK
Crankshaft and connecting rod NG Worn or damaged crankshaft Replace the crankshaft and/or
bearings and/or connecting rod bearings 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 and/or the piston pin
OK
ENGINE ELECTRICAL
GENERATOR
1) BATTERY DEAD
NG
Generator drive belt Loose Adjust
OK
NG
Battery fluid Low Replenish
OK
NG
Battery terminal Defective (Internal short circuit) Replace
OK
NG
Fuse Blown Replace
OK
NG
Fuse holder and fuse Poor contact Repair
OK
NG
Battery fluid specific gravity Wrong Adjust
OK
OK
OK
Generator NG
Defective Repair
ground circuit
OK
NG
Voltage regulator Defective Replace
OK
NG
Diode Defective Replace
OK
NG
Generator stator coil Grounded or broken Repair or replace
OK
NG
Rotor coil Broken Replace
OK
2) BATTERY OVERCHARGED
OK
NG
Voltage regulator Poor ground connection Correct
NG
Voltage set too high Replace
NG
Defective Replace
NG
Fan belt Loose Adjust
OK
NG
Starter switch contacts Defective Replace
OK
NG
Wiring Broken or poorly connected Replace or reconnect
00 – 28 SERVICE INFORMATION
NG
Starter switch terminal wiring Loose Retighten
OK
OK
NG
Starter switch contacts Defective Replace
5) GENERATOR NOISE
NG
Generator bearing Defective Replace and regrease
OK
NG
Generator stator coil Exposed wires Replace
NG
Short circuit Replace
SERVICE INFORMATION 00 – 29
NG
Terminal wiring Grounded Repair
OK
OK
NG
Battery connections Reversed Correct
00 – 30 SERVICE INFORMATION
STARTER MOTOR
1) STARTER AND MAGNETIC SWITCH DO NOT OPERATE
NG
Battery fluid level Low Replenish
OK
OK
NG
Battery switches Poor contact Replace
OK
NG
Starter switch Defective Replace
OK
OK
NG
Armature coil Broken Replace
OK
NG
Field coil Broken Replace
OK
NG
Magnetic switch coil Broken Replace
OK
NG
Holding coil Broken Replace
00 – 32 SERVICE INFORMATION
NG
Battery fluid level Low Replenish
OK
OK
NG
Starting circuit Poor contacts Repair
OK
NG
Magnetic switch terminals Poor contact Replace
OK
NG
Brushes Worn Replace
OK
NG
Armature Shorted Repair or replace
SERVICE INFORMATION 00 – 33
OK
NG
Brushes Excessive wear Replace
OK
NG
Starter motor armature Shorted Repair or replace
4) STARTER MOTOR OPERATES BUT THE ENGINE DOES NOT TURN OVER
OK
NG
Overrunning clutch Slippage Replace
OK
NG
Brushes Excessive wear Replace
00 – 34 SERVICE INFORMATION
NG
Bushings Excessive wear Replace
OK
OK
OK
NG
Brushes Excessive wear Replace
SERVICE INFORMATION 00 – 35
TURBOCHARGER
1) ENGINE HAS LESS THAN NORMAL POWER
NG
Air cleaner Restricted Clean or replace
OK
NG
Intake pipe and hose Restricted Clean or replace
OK
NG
Compressor/Intake manifold Loose (Leaking) Repair
OK
NG
Exhaust manifold/turbine inlet Loose (Leaking) Repair
OK
NG
Exhaust piping and silencers Restricted Clean or replace
OK
NG
Air breather Restricted Clean or replace
OK
Boost compensator NG
Defective Repair or replace
(Injection pump)
OK
NG
Compressor wheel Impact damage Replace
OK
NG
Turbine wheel Impact damage Replace
NG
Carbon build-up Replace
OK
NG
Rotating assembly Dragging or seized Replace
SERVICE INFORMATION 00 – 37
NG
Air cleaner or intercooler Restricted Clean, repair, or replace
OK
NG
Turbocharger oil seal Leakage Replace
OK
NG
Turbocharger oil drain pipe Restricted Repair or replace
OK
NG
Air breather Restricted Clean
OK
Boost compensator NG
Defective Repair or replace
(Injection pump)
OK
NG
Compressor wheel Impact damage Replace
OK
NG
Turbine wheel Impact damage Replace
OK
NG
Air breather Restricted Clean
OK
Boost compensator NG
Defective Repair or replace
(Injection pump)
OK
NG
Turbocharger oil seal Leakage Replace
OK
NG
Turbocharger oil drain pipe Restricted Clean or replace
OK
NG
Turbine wheel Impact damage Replace
OK
NG
Compressor wheel Impact damage Replace
OK
NG
Oil pressure Excessive Repair
OK
OK
OK
NG
Turbocharger rotating parts Rough rotation Replace
OK
NG
Compressor wheel Rubbing against housing Repair or replace
NG
Damaged Replace
OK
NG
Turbine wheel Rubbing against housing Repair or replace
NG
Damaged Replace
NG
Carbon deposits Clean or replace
OK
NG
Oil level Too low Correct
OK
NG
Engine oil Contaminated Replace oil
OK
NG
Turbocharger oil feed pipe Restricted Repair or replace
OK
NG
Turbine housing Carbon deposits Clean
OK
NG
Compressor housing Dirty Clean
OK
NG
Turbine shaft bearings Worn Replace
SERVICE INFORMATION 00 – 43
NG
Engine oil Contaminated Change
NG
Wrong grade or type Change
OK
NG
Turbocharger oil feed pipe Restricted Clean or replace
OK
NG
Turbocharger oil seal Defective Replace
OK
OK
NG
Turbine shaft Oil sludge and coking Replace
OK
ENGINE COOLING
ENGINE MODEL 6HK1TC
ITEM
Radiator type Corrugated fin with reserve tank
Cooling capacity lit (US gal / imp gal) 24 (6.3/ 5.3)
Water pump type Centrifugal impeller
Thermostat type Wax pellet
Valve initial opening temperature ˚C (˚F) 82.0 (179.6)
Valve full opening temperature ˚C (˚F) 95.0 (203.0)
Valve lift at fully open position mm (in) 8 (0.31)
FUEL SYSTEM
ITEM 6HK1TC
Injection pump type MD – TICS Type (EURO-III)
Plunger outside diameter mm (in) 11 (0.433)
Governor type ELECTRICAL CONTROL GOVERNOR RED-IV TYPE
Timer —
Fuel feed pump Double acting
Injection nozzle type Hole
Number of injection nozzle orifices Five holes
Opening pressure kPa (kg/cm2 / psi) 22,100 (225 / 3,195)
Pre fuel filter and water separator
Main fuel filter Paper element with transparency water tank CARTRIDGE TYPE
00 – 46 SERVICE INFORMATION
ENGINE ELECTRICAL
GENERATOR
Type Brushless
Output power W 1200 (F-series)/2880 (LT)
Rated voltage V 24
Output current A 50 (F-series)/120 (LT)
Rotation (Viewed from the pulley) Clockwise
Ground polarity Negative
Pulley diameter mm (in) 80 (F-series)/90 (LT)
Rotor coil resistance at 20°C Ω 9
Regulator IC type (Built-in)
STARTER MOTOR
Voltage V 24
Output kW 4.5
Number of poles 4
Type Magnetic switch controlled
Drive gears Reduction
No. of pinion gear teeth 11
No-load characteristics
Voltage V 23
Current A 90 or less
Operating speed (Rotor) rpm 3,500 or more
Rotation Clockwise viewed from the drive pinion gear
TURBOCHARGER
Turbocharger model HONEY WELL
Turbine type Radial inflow (34.3)
Compressor type Radial outflow
Weight kg (lb) 12 (26.5) (TCS) / 11(2.43)(TCC)
SERVICE INFORMATION 00 – 47
SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT
Cylinder Head
Lower Face Warpage mm (in) 0.05 (0.002) or less 0.20 (0.008)
Do not attempt to regrind
the lower face.
Valve Guide
Valve Stem and Valve Guide Clearance
Intake: mm (in) 0.04 – 0.07 0.20
(0.0016 – 0.0028) (0.008)
Exhaust: mm (in) 0.06 – 0.10 0.25
(0.0024 – 0.0039) (0.010)
Valve Stem Outside Diameter
Intake: mm (in) 7.95 – 7.96 7.88
(0.3130 – 0.3134) (0.3102)
Exhaust: mm (in) 7.92 – 7.94 7.88
(0.3118 – 0.3126) (0.3102)
Valve Guide Upper End Height mm (in) 14.1 (0.56) —
Valve and Valve Seat Insert
Valve Thickness
Intake: mm (in) 1.7 (0.067) 1.3 (0.051)
Exhaust: mm (in) 1.8 (0.071) 1.3 (0.051)
Valve Depression A
Intake: mm (in) 1.0 (0.039) 2.5 (0.098)
Exhaust: mm (in) 1.3 (0.051) 2.8 (0.110)
Valve Contact Width
Intake: mm (in) 2.5 (0.098) 3.2 (0.126)
Exhaust: mm (in) 2.0 (0.079) 2.8 (0.110)
Valve Face Angle
Intake: deg 30 —
Exhaust: deg 45 —
Valve Spring
Spring Height
Intake mm (in) 65.9 (2.59) 64.6 (2.54)
Exhaust mm (in) 68.1 (2.68) 66.7 (2.63)
Intake Valve Spring Tension N (kg / lb)
Compression Height at
46mm (1.81 in) 348 (35.5 / 78.3) 309 (31.5 / 69.5)
Exhaust Valve Spring Tension
N (kg / lb)
Compression Height at
46mm (1.81 in) 383 (39.0 / 86.0) 329 (33.5 / 73.9)
00 – 48 SERVICE INFORMATION
Crankshaft
Crankshaft End Play mm (in) 0.040 – 0.205 0.54
(0.0026 – 0.008) (0.021)
Crankshaft Run-Out mm (in) 0.06 or less 0.45
(0.0024 or less) (0.018)
Crankshaft Journal Diameter mm (in) 81.875 – 81.895 (No 4) —
(3.2234 – 3.2242)
81.905 – 81.925 (OTHERS) —
(3.2246 – 3.2254)
Crankshaft Journal and
Bearing Clearance mm (in)
No. 4 Bearing 0.093 – 0.124 0.14
(0.00366 – 0.00488) (0.0055)
Other Bearings 0.063 – 0.094 0.14
(0.00248 – 0.00370) (0.0055)
Crankshaft Journal and
Crankpin Uneven Wear mm (in) — 0.50 (0.0020)
SERVICE INFORMATION 00 – 49
Connecting Rod
Connecting Rod mm (in) 0.05 (0.002) or less 0.20 (0.008)
Piston Pin and Connecting Rod
Small End Bushing Clearance mm (in) 0.012 – 0.027 0.05
(0.00047 – 0.00106) (0.002)
Crankpin and Bearing Clearance
mm (in) 0.037 – 0.076 0.10
(0.0015 – 0.0030) (0.004)
Flywheel
Flywheel Friction Surface Depth
mm (in) 43.0 (1.69) 44.0 (1.73)
Flywheel Friction Surface Thickness
mm (in) 41.0 (1.61) 40.0 (1.57)
49.5 (1.95) 48.0 (1.89)
Flywheel Friction Surface Roughness
mm (in) Less than —
0.006 (0.00024)
00 – 50 SERVICE INFORMATION
Idler Gear
Idler Gear Shaft "A"
Outside Diameter mm (in) 49.950 – 49.975 49.9
(1.9665 – 1.9675) (1.965)
Idler Gear Shaft "B", "C" and
"D" Outside Diameter mm (in) 29.959 – 29.980 29.9
(1.1795 – 1.1803) (1.177)
Idler Gear Backlash mm (in) 0.10 – 0.17 0.30
(0.0039 – 0.0067) (0.012)
Idler Gear End Play
Gear "A", "B" and "D" mm (in) 0.080 – 0.155 0.20
(0.00315 – 0.00610) (0.008)
Gear "C" mm (in) 0.090 – 0.144 0.20
(0.00354 – 0.00566) (0.008)
Oil Pump
Gear Teeth and Cover
Inner Wall Clearance mm (in) 0.125 – 0.221 0.30
(0.0049 – 0.0087) (0.012)
Gear and Body Clearance mm (in) 0.064 – 0.109 0.20
(0.0025 – 0.0043) (0.008)
Gear Shaft Outside Diameter mm (in) 15.989 – 16.000 15.9
(0.6295 – 0.6299) (0.626)
Gear Shaft and
Bushing Clearance mm (in) 0.04 – 0.07 —
(0.0016 – 0.0028)
Drive Gear and Drive Gear
Shaft Interfere mm (in) 0.015 – 0.044 —
(0.0006 – 0.0017)
Cylinder Body
Cylinder Body Upper Face Warpage
mm (in) — 0.20 (0.008)
Cylinder Liner Projection mm (in) 0.06 – 0.10 —
(0.0024 – 0.0039)
Cylinder Body Bore and
Cylinder Liner Outside
Diameter Clearance mm (in) 0.011 – 0.029 —
(0.0004 – 0.0011)
Cylinder Liner Grade
(See “Cylinder Body” in section 6A)
Turbocharger Bearing
Radial Clearance mm (in) — 0.076 – 0.152
(0.00299 – 0.00598)
Turbine Shaft end Pluy mm (in) — 0.025 – 0.076
(0.00098 – 0.10299)
Waste Gate Valve Opening
Pressure kPa (kg/cm2/psi) 170 – 177 —
(17 – 1.8 / 24 – 26)
SERVICE INFORMATION 00 – 51
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
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.
Snug torque
A B
00 – 52 SERVICE INFORMATION
A B C D
Coincide line G
B
F
Air Cleaner
Element Cleaning and Replacement
Element cleaning procedures will vary according to
the condition of the element.
150M100009
3
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
1
turing as you tighten the center bolt.
2
050M100001
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 oil filter.
SERVICE INFORMATION 00 – 57
WARNING:
HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
THE ENGINE OIL.
Follow the main oil filter replacement procedure for
the partial flow filter.
Fuel System
Fuel Filter
Cartridge Type
1. Use a fuel filter wrench to remove the fuel filter.
1
SERVICE INFORMATION 00 – 59
1 Pre-Fuel Filter
(FVR)
Filter Element Replacement
1. Loosen the air intake plug (1).
2. Loosen the fuel filter drain cock (2) to drain the
fuel.
NOTE:
Do not forget to reinstall the drain plug after draining
3 2
040M100016
the fuel.
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
turing as you tighten the center bolt.
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 "Injection Nozzle Adjustment."
Injection Nozzle Opening Pressure kPa (kg/cm2 / psi)
22,100 (225 / 3,199)
040M100020
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.
Air Bleeding
1. Loosen the priming pump cap 1 on the injection
pump.
Cooling System
WARNING:
HOT STEAM UNDER PRESSURE MAY ESCAPE FROM
THE RADIATOR IF THE RADIATOR SURGE TANK CAP
IS OPENED WHILE THE ENGINE IS HOT. THIS CAN
RESULT IN SERIOUS BURNS.
ALLOW THE ENGINE TO COOL BEFORE OPENING
THE RADIATOR SURGE TANK CAP.
Coolant Level
Check the coolant level and replenish the radiator
surge tank if necessary.
If 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.
WARNING:
WHEN THE COOLANT IS HEATED TO A HIGH
TEMPERATURE, BE SURE NOT TO LOOSEN OR
REMOVE THE RADIATOR CAP. OTHERWISE YOU
MIGHT GET SCALDED BY HOT VAPOR OR BOILING
WATER. TO OPEN THE RADIATOR CAP, PUT A PIECE
OF THICK CLOTH ON THE CAP AND LOOSEN THE
CAP SLOWLY TO REDUCE THE PRESSURE WHEN
THE COOLANT HAS BECOME COOLER.
NOTE:
Do not overfill the radiator surge tank.
Remove the radiator surge tank cap only when
absolutely necessary.
Always refer to the chart at the left to determine the
correct cooling water to antifreeze solution mixing
0 ratio.
Freezing point(°C)
-10
-20
-30
-40
-50
-60
0 5 10 15 20 25 30 35 40 45 50 55 60
Mixing ratio(%)
B06MX00003
F06MV021
Generator
Generator belt tension is adjusted by moving the
generator.
Depress the drive belt mid-portion with a 98N (10kg /
3
2 22lb) force.
1 Crankshaft damper pulley
2 Generator pulley
3 Water pump pulley
1
F06M100020
00 – 66 SERVICE INFORMATION
014MX032
SERVICE INFORMATION 00 – 67
011MY00037
011MY00038
Tightening Torque N·m (kg·m/lb·ft)
Position Torque
Rocker Arm Adjusting Screw Nut 22 (2.2 / 16)
FIXING TORQUE
Cylinder Head, Rocker Arm Shaft and Camshaft N·m (kg·m / lb·ft)
13(1.3/113 lb·in)
27(2.8/20)
98 147 45
M14 Bolt
(10/72) (15/108) deg
27(2.8/20) Apply molybdenum disulfide grease
M10 Bolt 38(3.9/28)
Apply engine oil
30(3.1/22)
20(2.0/14)
M8 Bolt 19(1.9/14)
M16 Bolt 118(12.0/87)
M8 Bolt 19(1.9/14)
M16 Bolt 38(3.9/28)
020M100004
SERVICE INFORMATION 00 – 71
27(2.8/20)
94(9.6/69)
41(4.2/30)
A
20(2.0/14)
20(2.0/14)
41(4.2/30)
FRONT
24(2.4/17)
15(1.5/11)
34(3.5/25)
A
20(2.0/14)
011M100008
00 – 72 SERVICE INFORMATION
19(1.9/14)
19(1.9/14)
39(4/29)→60°→30°
196(20.0/145)
19(1.9/14)
98 132
M14 Bolt 45°
(10/72) (13.5/98)
015M100004
SERVICE INFORMATION 00 – 73
Flywheel, Timing Gear, Oil Pump, and Oil Pan N·m (kg·m / lb·ft)
29 (3.0/22)→75°
24 (2.4/17)
31 (3.2/23)
95 (9.7/70)
M8 Bolt 24 (2.4/17)
M16 Bolt 48 (4.9/35)
24 (2.4/17)
020M100005
00 – 74 SERVICE INFORMATION
Oil Filter, Oil Cooler and Oiling Jet N·m (kg·m / lb·ft)
Oil Filter
64 (6.5/47)
44(4.5/33)
060M100067
19 (1.9/14)
21 (2.1/15)
19 (1.9/14)
SERVICE INFORMATION 00 – 75
Generator
108 (11/80)
8 (0.8/69)
3.6 (0.37/2.7)
Starter Motor
12.7 (1.3/9.4)
12.7 (1.3/9.4)
00 – 76 SERVICE INFORMATION
76 (7.7/56)
294 (30/127)
83 (8.5/61)
76 (7.7/56)
RH
39 (4/29)
022MV001*
SERVICE INFORMATION 00 – 77
34(3.5/25)
FRONT
39(4.0/29)
20(2.0/14)
39(4.0/29)
39(4.0/29)
44(4.5/33)
052M100003
00 – 78 SERVICE INFORMATION
SPECIAL TOOLS
ILLUSTRATION PART NO. PARTS NAME
901MW002
040RW022
SECTION 6A
ENGINE MECHANICAL
CONTENTS
PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–13
F-SERIES Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–10
LT TYPE Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–14
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–14
Engine External Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–21
Cylinder Head and Valve Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–34
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–41
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–48
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–58
Crankshaft, Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–73
Disassembly (Crankshaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–81
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–82
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–86
Disassembly (Piston and Connecting Rod) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–88
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–90
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–96
6A–2 ENGINE MECHANICAL
PAGE
Flywheel, Timing Gear, Oil Pump and Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–99
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–99
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–101
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–105
Disassembly (Oil Pump). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–112
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–114
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–116
Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–118
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–118
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–120
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–122
ENGINE MECHANICAL 6A–3
GENERAL DESCRIPTION
F06M100012
The 6HK1 engine is a four-cycle, six-cylinder, The cylinder liner is made of thin iron plus special
in-line, direct fuel injection type diesel engine with alloys and is combined with the chrome-plate piston
the piston displacement of 7,790 cm3 (475.3 in3). It ring to ensure good resistance against wear.
features a gear-driven OHC (overhead camshaft) The piston is made of aluminum alloy. A ring trigger
timing train and unique mechanisms and systems is cast into the top ring groove and chrome plating
designed for outstanding quietness, economy and is applied to four sides of the top ring to ensure
durability. sufficient strength and wear resistance of the ring
The cylinder head is made of cast iron and has a and the ring groove.
cross-flow layout with the intake system in the left The crankshaft is made of forge steel with seven
side and the exhaust system in the right side, bearings and twelve counterweights to reduce
designed to reduce resistance in the intake and revolution load to the bearing.
exhaust system.
The gear train is located at the end of cylinder body
The cylinder head gasket is of the laminated of to minimize influence of the torsional vibration of
least fatigue in combination with the angular the crankshaft and the radiant sound.
cylinder head bolt tightening method, equally
Noise is further reduced, to the same level as a
designed to increase reliability against gas and
timing belt driven system, by integrating the
water leakage.
crankshaft gear with the crankshaft by shrink fit
The cylinder body is made of cast iron having dry careful tuning of the gear precision, contact gear
cylinder liner and seven bearings. The bearing cap ratio, backlash, bearing rigidity neutral frequency,
has a ladder frame construction integrating the etc.
crankcase to increase rigidity.
6A–4 ENGINE MECHANICAL
5
CRANK- CAM TIMING INJ. TURBO-
CHARGER CHECK
SHAFT SHAFT IDLE PUMP
VALVE
BRGS. BRGS. GEAR
OIL 1
RELIEF
VALVE
OIL
PUMP 4 CYL
PARTIAL OIL CONN
HEAD PISTON
FILTER RELIEF ROD
VALVE
VALVE BRGS
SYSTEM
OIL
STRAINER
OIL PAN
1 Relief Valve Opening Pressure : 785(8.0/144) 3 Oil Pressure switch Opening Pressure :
29-49(0.3-0.5/4.3-7)
2 Bypass Valve Opening Pressure :
118-157(1.2-1.6/17-23) 4 Relief Valve Opening Pressure : 441(4.5/64)
5 Check Valve : 196(2.0/28)
051MV001
ENGINE MECHANICAL 6A–5
F-SERIES 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.
Removal Steps
• 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.
WARNING:
ALLOW THE ENGINE TO COOL BEFORE REMOVE ANY
PARTS. THIS WILL ELIMINATE THE DANGER OF FIRE
AND POSSIBLE INJURY.
2 Battery
1. Disconnect the grounding cable 1 and the battery
cable 2 from the battery terminals.
1
Be careful not to short the battery with your
wrench or another tool at this time.
6A–6 ENGINE MECHANICAL
Air Cleaner
Remove the air intake hose from the intake cover.
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.
If 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 overflow rubber hose from
the radiator and the reserve tank.
2. Remove the radiator overflow pipe from the
engine.
3. Pull the radiator upper hose and the radiator lower
hose from the engine.
ENGINE MECHANICAL 6A–7
Propeller Shaft
1. Disconnect the 1st propeller shaft flange yoke from
the parking brake drum.
2. Lower the propeller shaft carefully to the ground.
401HX00033
Transmission
Refer to Section 7, "TRANSMISSION", "Removal and
Installation."
220M100001
ENGINE MECHANICAL 6A–9
Exhaust Pipe
1. Loosen the front exhaust pipe, silencer and
exhaust pipe clamp bolts and nuts.
2. Disconnect the front exhaust pipe and exhaust
brake assembly from the exhaust manifold.
150M100006
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.
INSTALLATION
Installation Steps
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.
3. Carefully lower the engine until it is just above the
chassis frame.
Transmission
Refer to Section 7, "TRANSMISSION," "Removal and
Installation".
220M100001
Propeller Shaft
1. Install the 1st propeller shaft flange yoke to the
parking brake drum.
2. Tighten the propeller shaft flange nuts to the
specified torque.
Propeller Shaft Flange Nut
Torque N·m (kg·m / lb·ft)
M12 103 (10.5 / 76)
M14 157 (16.0 / 116)
401HX00033
M16 With spring washer 215 (22.0 / 159)
M16 With plain washer 255 (26.0 / 188)
M16 Flange nut 255 (26.0 / 188)
Radiator
1. Install the fan coupling and the cooling fan to the
water pump.
2. Install the radiator with the fan shroud to the
mounting cushion rubbers.
Be careful not to damage the radiator core.
3. Connect the radiator front stay to the radiator.
4. Tighten the radiator cushion rubber nuts.
5. Connect the radiator upper and lower hoses.
6. Connect the radiator fan shroud stays (three
positions) to the engine.
6A–12 ENGINE MECHANICAL
NOTE:
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.
3. Connect the grounding cable to the chassis frame.
F06M100016
Removal Steps
1. Bumper
2. Engine hood (upper side, out side)
3. Battery cable and other electrical cable
4. Rear cross member with fan guard frame
5. Air cleaner mounting frame
6. Radiator hose (upper and lower)
F06M100017
7. Fan belt
8. Power steering oil pipe
9. Intake duct
10. Exhaust pipe
11. Exhaust brake valve control link
12. Engine control harness
13. Engine stop cable
14. Air hose
15. Fuel hose
16. Oil hose
17. Clutch minipack hose
18. Speedometer harness (Transmission)
19. Transmission control link
20. Propeller shaft
21. Engine mounting bolt (rear)
22. Engine mounting bolt (front)
23. Engine under frame
24. Engine with transmission assembly
Support the engine and transmission on a engine jack.
After removing the engine from vehicle, remove the
transmission assembly and clutch from the engine.
Installation Steps
Guide bar
1. Engine with transmission assembly
Carefully Before installing the engine to the vehicle, install the
Horizontal line clutch and transmission to the engine.
Engine slope
Molybdenum disulfide grease Bolt Torque N·m (kg·m/lb·ft)
69 – 78 (7.0 – 8.0/51 – 58)
220M100002
6A–16 ENGINE MECHANICAL
F06M100018
220M100001
5. Propeller shaft
6. Transmission control link
7. Speedometer harness (Transmission)
8. Clutch minipack hose
9. Oil hose
10. Fuel hose
11. Air hose
12. Engine stop cable
13. Engine control harness
14. Exhaust brake valve control link
15. Exhaust pipe
16. Intake duct
17. Power steering oil pipe
18. Fan belt
Make an adjustment of drive belt deflection after
installation of the fan drive belt control rod.
1 Idler pulley drive belt ....................... 20 mm (0.8 in)
2 Fan drive belt .................................... 10 mm (0.4 in)
3 Generator drive belt ......................... 10 mm (0.4 in)
19. Radiator hose (upper and lower)
20. Air cleaner mounting frame
21. Rear cross member with fan guard frame
Bolt Torque N·m (kg·m/lb·ft)
91 (9.3/67)
22. Battery cable and other electrical cable
23. Engine hood (upper side, outside)
24. Bumper
ENGINE MECHANICAL 6A–17
4
17 1 23 21
2 9
5 7 28 12 10
20
25
29
15 26
18 14 19 8 6 3 31 13 11 16 30 27 24
22
F06M100013
Removal Steps
1. Intake pipe 17. Fuel leak off pipe
2. Air duct 18. Air Compleser
3. Intake pipe 19. Guide tube
4. EGR Assembly 20. Air compressor pipe
5. Oil feed pipe (Intake duct to air compressor)
6. Oil return pipe 21. Fuel injection pipe with clip
7. Water feed pipe 22. Fuel pipe
8. Water return pipe 23. Fuel filter
9. Turbocharger Assembly 24. Oil filter
10. Cooling fan guide 25. Air pipe
11. Cooling fan 26. Water duct (Suction)
12. Cooling fan drive belt 27. Injection pump assembly
13. Generator and adjusting plate 28. Water outlet (To Radiator)
14. Starter motor 29. BRG Case Asm
15. Power steering oil pipe 30. Injection pump bracket
16. Power steering oil pump 31. Engine foot
6A–18 ENGINE MECHANICAL
Removal Steps
1. Intake Pipe
2. Air Duct
3. Intake Pipe
4. EGR Assembly
1) Remove the EGR valve with EGR pipe (EGR valve -
EGR cooler).
EGR Valve
027M100001
Exhaust
EGR Cooler Manifold
027M100002
EGR Cooler
220M100002
INSTALLATION
30 23 27 25 22 19 21 11 31 8 10 28
13
7 1
6 17 16 24 26 29 3 18 20 15 14 4 2 5 12 9
F06M100014
Installation Steps
1. BRG Case Asm 17. Starter motor
2. Injection pump bracket 18. Generator and adjusting plate
3. Engine foot 19. Cooling fan drive belt
4. Water duct (Suction) 20. Cooling fan
5. Injection pump assembly 21. Cooling fan guide
6. Air Compressor 22. Water outlet (To Radiator)
7. Air pipe 23. Turbocharger Assembly
8. Fuel filter 24. Water return pipe
9. Oil filter 25. Water feed pipe
10. Fuel injection pipe with clip 26. Oil return pipe
11. Fuel leak off pipe 27. Oil feed pipe
12. Fuel pipe 28. EGR Assembly
13. Air compressor pipe 29. Intake pipe
(Intake duct to air compressor) 30. Air duct
14. Power steering oil pump 31. Intake pipe
15. Power steering oil pipe
16. Guide tube
6A–22 ENGINE MECHANICAL
Installation Steps
1. Bearing Case
1) Bearing Case
Install O-ring in the bearing case. (O-ring cannot be
reused.) Install the bearing case.
• Make sure that No. 1 cylinder is at TDC on the
compression stroke. Align the mark drawn when
removing the bearing case, and install. Then check
and see the pointer is aligned with the mark S on
the coupling end surface.
CAUTION:
If the "S" and pointer are not aligned as illustration
Approx. after bearing case installation, the timing gear is out
12 mm of position by one (1) tooth, reinstallation is needed.
4) Tighten the bearing case nuts and bolts to the
specified torque.
Air Compressor Nut and Bolt Torque N·m (kg·m / lb·ft)
M10 Nut 40 (4.1 / 30)
M12 Nut and Bolt 73 (7.4 / 54)
3. Engine Foot
1) Tighten the engine foot bolts to the specified
torque.
Engine Foot Bolt Torque N·m (kg·m / lb·ft)
Front 76 (7.7 / 56)
Rear 76 (7.7 / 56)
6. Air Compressor
7. Air Pipe
1) Install the air pipe to the air compressor.
2) Clamp the air pipe each other shown in the
illustration.
8. Fuel Filter
1) Install the fuel filter to the bracket.
2) Tighten the fuel filter bolts to the specified torque.
Fuel Filter Bolt Torque N·m (kg·m / lb·ft)
41 (4.1 / 30)
ENGINE MECHANICAL 6A–25
9. Oil Filter
10. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nuts.
2) Set the clip in the prescribed position.
NOTE:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
040M100010
040M100011
NOTE:
Gasket should not be reused.
NOTE:
After tightening the pipe, install the clips.
NOTE:
Gasket should not be reused.
052M100002 NOTE:
After tightening the pipe, install the clips.
ENGINE MECHANICAL 6A–29
3) EGR valve
EGR Valve • Install the EGR valve with EGR pipe temporarily.
• Tighten the bolts (A) to specified torque.
EGR valve (A) bolts N·m (kg·m/Ib·ft)
B
27 (2.8/20)
Cylinder
body
025M100006
ENGINE MECHANICAL 6A–31
14
2
4
16
6
15
5
9 7
17
12
11
3
13
10 18
Removal Steps
1. Cylinder head cover 10. Plate
2. Gasket 11. Water duct
3. Rubber plug 12. O-ring
4. Nozzle leak off pipe 13. O-ring
5. Nozzle clamp 14. Rocker arm assembly
6. Injection nozzle holder 15. Bridge cap
16. Camshaft assembly
7. Gasket
17. Cylinder head assembly
8. Glow plug connector
18. Head gasket
9. Glow plug
6A–32 ENGINE MECHANICAL
Removal Steps
1. Cylinder Head Cover
2. Gasket
Remove the cylinder head cover and gasket.
NOTE:
Be careful not to miss the collars inserted in the
cylinder head cover assembly.
010MX004
3. Rubber Plug
4. Nozzle Leak off Pipe
5. Nozzle Clamp
6. Injection Nozzle Holder
7. Gasket
8. Glow Plug Connector
9. Glow Plug
Remove the injection nozzles and glow plugs before
removing the cylinder head.
040MX042
10. Plate
11. Water Duct
12. O-Ring
13. O-Ring
14. Rocker Arm Assembly
A Loosen the rocker arm shaft bracket and rocker arm
and shaft assembly bolts evenly from the outside to
inside.
NOTE:
Leave the A indicated bolts (both side) unremoved
on the occasion, since it is the rocker arm fixing bolts.
011MV009-1
ENGINE MECHANICAL 6A–33
CAUTION:
The idler gear "C" projects from the cylinder head
lower side and easily damaged. Great care must be
taken to avoid damaging the idler gear "C" if the
cylinder head is removed from the engine.
INSTALLATION
18
5
17
15
13
4
14
10 12
2
11
7
8
16
6
9 1
Installation Steps
1. Head gasket 10. Glow plug
2. Cylinder head assembly 11. Glow plug connector
3. Camshaft assembly 12. Gasket
4. Bridge cap 13. Injection nozzle holder
5. Rocker arm assembly 14. Nozzle clamp
6. O-ring 15. Nozzle leak off pipe
7. O-ring 16. Rubber plug
8. Water duct 17. Gasket
9. Plate 18. Cylinder head cover
ENGINE MECHANICAL 6A–35
Installation Steps
1. Cylinder Head Gasket
2 1) Clean the cylinder body surface.
011MV009-1
4. Bridge Cap
1) Apply engine oil to the bridge cap.
2) Install the bridge cap to the bridge.
011MX042
014MX016
6A–38 ENGINE MECHANICAL
6. O-Ring
7. O-Ring
8. Water Duct and O-ring
9. Plate
1) Apply soapsuds to the O-ring.
2) Install the O-ring to the water duct O-ring groove.
3) Install the water duct to the water pump body.
4) Tighten the water duct bolts to the specified
torque.
Water Duct Bolt Torque N·m (kg·m / lb·ft)
M8 Bolt 19 (1.9 / 14)
M16 Bolt 118 (12.0 / 87)
011MX041
ENGINE MECHANICAL 6A–39
12. Gasket
6HH1
13. Injection Nozzle Holder
14. Nozzle Clamp
Clamp Bolt Torque N·m (kg·m / lb·ft)
30 (3.1 / 22)
17. Gasket
18. Cylinder Head Cover
1) Clean the head cover gasket groove and the head
cover gasket.
2) Install the head cover gasket and collar to the head
cover.
3) Install the cylinder head cover to the cylinder head.
010MX004
6A–40 ENGINE MECHANICAL
7 3 2 6 10
010MX003
ENGINE MECHANICAL 6A–41
DISASSEMBLY
Cylinder Head
VIEW A FRONT
8
7
1
25
2
9
17
18
A 26
7 19 15
21
22 23 16
6
28
10
27
10
5
12
24
14
13 20 4
11 3
011M100006
Disassembly Steps
1. Bridge cap 15. Sealing cup
2. Bridge 16. Idler gear “C”
3. Intake pipe 17. Split collar
4. Intake cover 18. Valve spring upper seat
5. Gasket 19. Valve spring
6. Heat protector 20. Valve
7. Exhaust manifold 21. Valve stem seal
8. Gasket 22. Spring seat
9. Heat protector 23. Valve guide
10. Engine hanger 24. Valve seat insert
11. Thermometer unit 25. Injection nozzle sleeve
12. Water outlet pipe 26. Bridge guide
13. Thermostat 27. Oil seal
14. Gasket 28. Cylinder head
6A–42 ENGINE MECHANICAL
Disassembly Steps
1. Bridge Cap
2. Bridge
3. Intake Pipe
4. Intake Cover
5. Gasket
6. Heat Protector
7. Exhaust Manifold
8. Gasket
9. Heat Protector
10. Engine Hanger
11. Thermometer Unit
12. Water Outlet Pipe
13. Thermostat
14. Gasket
15. Sealing Cup
Tap the outside of the sealing cup with a screw driver
to deform one end of it and draw it out with pliers.
Note:
Do not make scrach on seal surface of cylinder head.
011MX017
011MX027
ENGINE MECHANICAL 6A–43
011MX015
040MX038
011MX043
011MX026
28. Cylinder Head
6A–44 ENGINE MECHANICAL
014MX018
Disassembly Steps
1. Camshaft bracket 4. Rocker arm shaft bracket
2. Rocker arm 5. Rocker arm shaft
3. Spring washer
ENGINE MECHANICAL 6A–45
Disassembly Steps
1. Camshaft Bracket
2. Rocker Arm
If the rocker arms and rocker arm shaft brackets are to
be reinstalled, mark their installation positions by
tagging each rocker arm and rocker arm shaft bracket
with the cylinder number from which it was removed.
014MX027
3. Spring Washer
4. Rocker Arm Shaft Bracket
5. Rocker Arm Shaft
6A–46 ENGINE MECHANICAL
Camshaft
1
2
Disassembly Steps
1. Camshaft gear 3. Camshaft
2. Gear alignment pin
ENGINE MECHANICAL 6A–47
Disassembly Steps
1. Camshaft Gear
Replace the camshaft gear if it is excessively worn or
2 damage or if the camshaft end play is excessive.
1 1) Remove the camshaft gear bolt.
2) Use a gear remover 1 to remove the camshaft
gear 2.
Cylinder Head
Cylinder Head Lower Face Warpage
Removal Carbon
Use a straight edge and a feeler gauge to measure the
four sides and the two diagonals of the cylinder head
lower face.
If the measured values exceed the specified limit, the
cylinder head must be replaced.
Cylinder Head Lower Face Warpage mm (in)
Limit
0.20 (0.008)
NOTE:
Do not attempt to regrind the cylinder head lower
face.
A
E F
C D
B
Valve Guide
Valve Stem and Valve Guide Clearance
Measuring Method-I
1. Insert the valve to the cylinder head.
2. Set the dial indicator to the valve stem at
measuring point 1 as shown in the illustration.
Measuring Point 1: 10mm (0.4in)
3. Set the dial indicator needle to “0”.
4. Move the valve head from side to side.
1
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit,
the valve and the valve guide must be replaced as
a set.
Valve Stem and Valve Guide Clearance mm (in)
Standard Limit
0.04 – 0.07 0.20
Intake Valve
(0.0016 – 0.0028) (0.008)
0.06 – 0.10 0.25
Exhaust Valve
(0.0024 – 0.0039) (0.010)
ENGINE MECHANICAL 6A–49
Measuring Method-II
1. Measure the valve stem outside diameter.
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
3. Calculate the clearance between the valve guide
inside diameter and the valve stem outside
diameter.
If the clearance exceeds the specified limit, the
valve and the valve guide must be replaced as a
set.
011MX015
Valve Depression
A 2 1. Install the new valve 1 to the cylinder head 2.
2. Use a depth gauge or a straight edge with steel
rule to measure the valve depression from the
cylinder head lower surface.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
1
Valve Depression A mm (in)
Standard Limit
Intake Valve 1.0 (0.039) 2.3 (0.090)
Exhaust Valve 1.3 (0.051) 2.8 (0.110)
011MX018
6A–52 ENGINE MECHANICAL
011MX018
Valve Spring
Valve Spring Free Height
Use a vernier caliper to measure the valve spring free
height.
If the measured value is less than the specified limit,
the valve spring must be replaced.
Spring Free Height mm (in)
Standard Limit
Intake 65.9 (2.59) 64.6 (2.54)
Exhaust 68.1 (2.68) 66.7 (2.63)
A06MV004
Rocker Arm
Visually inspect the rocker arm camshaft contact
surfaces of the roller for excessive wear and damage.
A
ENGINE MECHANICAL 6A–55
Valve Cap
Inspect the valve cap surface contacting the rocker arm
for excessive wear and damage.
If the wear exceeds the limit, replace the valve cap with
new one.
Valve Cap Worn mm (in)
Limit 1.0 (0.039)
Camshaft
Visually inspect the journal, the cams, and the
camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be
replaced if these conditions are discovered during
inspection.
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
If the measured value exceeds the specified limit,
the camshaft must be replaced.
Camshaft Run-Out mm (in)
Standard Limit
0.025 (0.001) 0.05 (0.002)
Camshaft Gear
Visually inspect the camshaft for excessive wear and
damage.
If the camshaft gear for excessive wear or damaged it
must be replaced.
Camshaft Bracket
Check that the camshaft bracket oil port is free of
obstructions.
If necessary, use compressed air to clean the camshaft
bracket oil port.
6A–58 ENGINE MECHANICAL
REASSEMBLY
Cylinder Head
VIEW A FRONT
21
22
28
5
27
20
13
12
A 4
22 11 15
9
8 7 14
23
1
3
2
3
24
18
6
16
17 10 25
19 26
011M100007
Reassembly Steps
1. Cylinder head 15. Sealing cup
2. Oil seal 16. Gasekt
3. Engine hanger 17. Thermostat
4. Bridge guide 18. Water outlet pipe
5. Injection nozzle sleeve 19. Thermometer unit
6. Valve seat insert 20. Heat protector
7. Valve guide 21. Gasket
8. Spring seat 22. Exhaust manifold
9. Valve stem seal 23. Heat protector
10. Valve 24. Gasket
11. Valve spring 25. Intake cover
12. Valve spring upper seat 26 Intake pipe
13. Split collar 27. Bridge
14. Idler gear “C” 28. Bridge cap
ENGINE MECHANICAL 6A–59
Reassembly Steps
1. Cylinder Head
2. Oil Seal
Use the oil seal installer to install the cylinder head.
Oil Seal Installer: 5-8840-2627-0
011MX026
011MX036
3. Engine Hanger
Install the engine hanger bolts to the specifie torque.
Engine Hanger Bolts Torque N·m (kg·m / lb·ft)
94 (9.6 / 69)
011MX044
4. Bridge Guide
122.5±0.5
circumference.
2) Attach the valve bridge guide installer to the bridge
guide.
Valve Bridge Guide Installer: 5-8840-2626-0
3) Use a brass hammer to tap the guide into position
from the cylinder head upper face.
011MX012
6A–60 ENGINE MECHANICAL
040MV040-1
7. Valve Guide
1) 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: 5-8840-2628-0
4) Measure the height of the valve guide upper end
from the upper face of the cylinder head.
011MX024 Valve Guide Upper End Height
(Reference) mm (in)
19 (0.748)
8. Spring Seat
9. 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: 5-8840-2625-0
011MX020
10. Valve
Apply engine oil to intake valves and exhaust valves.
11. Valve Spring
1) Place the cylinder head on a flat wooden surface.
2) Install the valve springs with their fine pitched end
(painted) facing down.
Colored
Intake Valve Light blue
Exhaust Valve Yellow
0.5–1.5
1 16. Gasket
• Install the thermostat gaskets 1 to the flange of
thermostats.
17. Thermostat
• Install the thermostat (without jiggle valve) 2 and
2 thermostat (with jiggle valve) 3 to the cylinder
3 head.
Front
3
NOTE:
The jiggle valves of thermostat must be facing the
rear of the engine.
18. Water Outlet Pipe
1) Install the water outlet pipe to the cylinder head.
2) Tighten the water outlet pipe bolts to the specified
torque.
Water Outlet Pipe Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
032MX023
ENGINE MECHANICAL 6A–63
011MX022
011MX021
NOTE:
Gasket Check and see that the gasket is correctly installed to
the cylinder head. The gasket, if installed in a wrong
way, could get over the casting skin of the cylinder
head.
Cylinder head
96 2 4 8A
0 5 13 7 B
13 9 5 1 4 8 12
025MX016
025M100007
27. Bridge
Apply engine oil to the bridge.
28. Bridge Cap
Apply engine oil to the bridge cap.
014MX014
ENGINE MECHANICAL 6A–65
2
3
4
014MY00011
Reassembly Steps
1. Rocker arm shaft 4. Spring washer
2. Rocker arm shaft bracket 5. Rocker arm
3. Rocker arm 6. Camshaft bracket
6A–66 ENGINE MECHANICAL
Reassembly Steps
1. Rocker Arm Shaft
A 1) Apply engine oil to the rocker arm shaft.
2) Install the camshaft bracket to the rocker arm shaft.
3) Temporarily tighten the camshaft bracket bolt A.
Front
014MX028
3. Rocker Arm
Apply engine oil to the rocker arm roller and pin.
4. Spring Washer
5. Rocker Arm
6. Camshaft Bracket
ENGINE MECHANICAL 6A–67
Camshaft
3
2
Reassembly Steps
1. Camshaft 3. Camshaft gear
2. Gear alignment pin
6A–68 ENGINE MECHANICAL
Reassembly Steps
1. Camshaft
2. Gear Alignment Pin
3. Camshaft Gear
1) Fit the gear alignment pin into the camshaft pin
hole.
2) Install the camshaft gear to the camshaft.
The gear hub large side must be facing the
camshaft.
3) Apply engine oil to the camshaft gear bolt threads
and the setting faces.
4) Tighten the camshaft gear bolt to the specified
torque.
Camshaft Gear Bolt Torque N·m (kg·m / lb·ft)
142 (14.5 / 105)
ENGINE MECHANICAL 6A–69
18
9
8 11
3
4
1
15
10
17 2
7
6
16 14
13
12
Removal Steps
1. Crankshaft damper pulley 11. Piston and connecting rod with upper
2. Water duct and O-ring bearing
3. Timing gear case cover 12. Lower crankcase
4. Crankshaft front oil seal 13. Crankshaft lower bearing
5. Crankshaft front slinger 14. Crankshaft thrust bearing (Lower side)
6. Power steering oil pump idler 15. Crankshaft thrust bearing (Upper side)
gear shaft 16. Crankshaft
7. Power steering oil pump idler 17. Crankshaft upper bearing
gear 18. Cylinder body
8. Timing gear case
9. Oil thermostat and O-ring
10. Connecting rod bearing cap
with lower bearing
6A–70 ENGINE MECHANICAL
Removal Steps
1. Crankshaft Damper Pulley
1) Block the crankshaft with a piece of hard wood to
prevent the damper pulley from turning.
2) Diagonally loosen the damper pulley bolts.
No1
F06MV012
6A–72 ENGINE MECHANICAL
INSTALLATION
10
11 8
14
16
18
4
9
2 17
12
13
15
3 5
Installation Steps
1. Cylinder body 10. Oil thermostat and O-ring
2. Crankshaft upper bearing 11. Timing gear case
3. Crankshaft 12. Power steering oil pump idler gear
4. Crankshaft thrust bearing 13. Power steering oil pump idler gear shaft
(Upper side) 14. Timing gear case cover
5. Crankshaft thrust bearing 15. Crankshaft front slinger
(Lower side) 16. Crankshaft front oil seal
6. Crankshaft lower bearing 17. Water duct and O-ring
7. Lower crankcase 18. Crankshaft damper pulley
8. Piston and connecting rod with
upper bearing
9. Connecting rod bearing cap
with lower bearing
6A–74 ENGINE MECHANICAL
Installation Steps
1. Cylinder Body
Use compressed air to thoroughly clean the inside
and outside surfaces of the cylinder body, the oil
holes, and the water jackets.
3. Crankshaft
Apply engine oil to the crankshaft journal and the
crankshaft bearing sliding surfaces before installing
the crankshaft.
ENGINE MECHANICAL 6A–75
015M100005
ENGINE MECHANICAL 6A–77
F06MV030
F06MV031
F06MV008
76 543 2
NOTE:
Be sure to replace the slinger and oil seal as a set.
6A–80 ENGINE MECHANICAL
DISASSEMBLY
Crankshaft
Disassembly Steps
1. Crankshaft Gear (Front) 3. Crankshaft
2. Crankshaft Gear (Rear)
Disassembly Steps
1. Crankshaft Gear (Front)
2. Crankshaft Gear (Rear)
Use a gear pulley to remove the crankshaft gear.
3. Crankshaft
6A–82 ENGINE MECHANICAL
Bearing Spread
Check the bearing spread.
Finger pressure should be required to fit the bearing
into position.
If the bearing fits loosely, it must be replaced.
Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft
journal.
2. Gently turn the crankshaft in the normal direction
of rotation.
Read the dial indicator as you turn the crankshaft.
If the measured value exceeds the specified limit,
the crankshaft must be replaced.
Crankshaft Run-Out mm (in)
Standard Limit
0.06 (0.0024) or less 0.45 (0.018)
ENGINE MECHANICAL 6A–83
N J F B8 4 260 D H L
6A–84 ENGINE MECHANICAL
REASSEMBLY
Reassembly Steps
3. Crankshaft gear (Front)
1. Camshaft
2. Crankshaft gear (Rear)
ENGINE MECHANICAL 6A–87
Reassembly Steps
1. Crankshaft
2. Crankshaft Gear (Rear)
1) Install the crankshaft timing gear alignment pin.
2) Heat the crankshaft gear evenly with a gas burner
to invite thermal expansion.
Do not allow the temperature of the gas burner to
exceed 180°C (356°F).
3) Use the crankshaft gear installer to install the
crankshaft gear.
Crankshaft Gear Installer: 8-9439-6819-0
DISASSEMBLY
Piston and Connecting Rod
015MY00050
Disassembly Steps
1. Connecting rod bearing 5. Piston pin
2. Piston ring 6. Connecting rod
3. Piston pin snap ring 7. Piston
4. Piston pin snap ring
ENGINE MECHANICAL 6A–89
Disassembly Steps
No1
F06MV012
2. Piston Ring
1) Clamp the connecting rod in vise.
Take care not to damage the connecting rod.
2) Use a piston ring replacer to remove the piston
rings.
Do not attempt to use some other tool to remove
the piston rings. Piston ring stretching will result
in reduced piston ring tension.
F06MV015
5. Piston Pin
6. Connecting Rod
7. Piston
Use your hand to push the piston pin out.
If the pistons are to be installed, mark their installation
positions by tagging each piston with the cylinder
number from which it was removed.
6A–90 ENGINE MECHANICAL
Piston
Visual Inspection
Inspect the piston after removing carbon, sludge, etc,
and rinsing. Be sure to inspect with special care the
piston parts which may escape your notice.
Piston Pin
Piston Pin Diameter
Use a micrometer to measure the piston pin 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
39.995 – 40.000 (1.5746 – 1.5748) 39.95 (1.5728)
Piston Ring
Connecting Rod
NOTE:
Connecting rod bearing cap bolts can be reused six(6)
times.
F06MV011
6A–94 ENGINE MECHANICAL
Bearing Spread
Check the bearing spread.
Finger pressure should be required to fit the bearing
into position.
If the bearing fits loosely, it must be replaced.
6A–96 ENGINE MECHANICAL
REASSEMBLY
F06MV007
Reassembly Steps
1. Piston 5. Piston pin snap ring
2. Piston pin snap ring 6. Piston ring
3. Connecting rod 7. Connecting rod bearing
4. Piston pin
ENGINE MECHANICAL 6A–97
Reassembly Steps
1. Piston
2. Piston Pin Snap Ring
Use pliers to install the piston pin snap ring to the
piston.
3. Connecting Rod
1 1) Clamp the connecting rod in a vise.
2) Install the piston to the connecting rod.
The piston head front mark 1 and the connecting
rod forging mark (projecting) 2 must be facing the
2 opposite direction.
NOTE:
If the old connecting rods are to be replaced with new
ones, the connecting rod weight must be identical for
F06MV014 all cylinders.
4. Piston Pin
5. Piston Pin Snap Ring
1) Apply engine oil to the piston pin.
2) Use hand pressure to force the piston pin into the
piston until it makes contact with the snap ring.
3) Use pliers to install the other snap ring.
NOTE:
Take care not to damage the piston and the piston pin.
4) Check that the connecting rod moves smoothly on
F06MV015
the piston pin.
Full keystone
6. Piston Ring
1) Use a piston ring replacer to install the four piston
Inner cut
rings.
Install the piston rings from under of piston ring
groove.
Oil ring
3rd compression ring
Under cut
2nd compression ring
1st compression ring
(The stamped on the 1st compression ring must
face upward of piston.)
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.
Install the compression rings with the stamped side
facing up.
6A–98 ENGINE MECHANICAL
13
5 11
7
12 9
13 2
nt
3 Fro
6
1
020M100006
Removal Steps
1. Oil pan 8. Crankshaft rear oil seal
2. Oil strainer and O-ring 9. Crankshaft rear slinger
3. Pilot bearing and snap ring 10. Idler gear "A" and idler gear shaft
4. Flywheel and washer 11. Oil pump
5. Cover 12. Idler gear "B"
6. Idler gear "D" 13. Idler gear "B" shaft
7. Flywheel housing
6A–100 ENGINE MECHANICAL
Removal Steps
1. Oil Pan
2. Oil Strainer and O-ring
3. Pilot Bearing and Snap Ring
1) Use a snap ring pliers to remove the snap ring.
2) Remove the pilot bearing.
4. Flywheel and Washer
1) Block the crankshaft with a piece of hard wood to
prevent the flywheel from the turning.
2) Loosen the flywheel bolts a little at a time in the
1 numerical order shown in the illustration.
6 4
3 7 5. Cover
8
5
2 6. Idler Gear "D"
7. Flywheel Housing
8. Crankshaft Rear Oil Seal
Use a screwdriver to pry the oil seal from the rear of
the flywheel housing.
CAUTION:
Take care not to damage the oil seal fitting surface.
Flywheel
1. Inspect the flywheel friction surface for excessive
wear and heat cracks.
1 2. Measure the flywheel friction surface depth 1.
If the measured value exceeds the specified limit,
the flywheel must be replaced.
Flywheel Friction Surface Depth 1 mm (in)
Clutch Size Standard Limit
380 (15) 48.0 (1.89) 49.0 (1.93)
356 (14) 43.0 (1.69) 44.0 (1.73)
Ring Gear
Inspect the ring gear
If the ring gear teeth are broken or excessively worn,
the ring gear must be replaced.
INSTALLATION
4
7 3
5
2 8
10
12
nt
11 Fro
6
13
020M100007
Installation
1. Idler gear "B" shaft 7. Cover
2. Idler gear "B" 8. Crankshaft rear slinger
3. Oil pump 9. Crankshaft rear oil seal
4. Idler gear "A" and idler gear 10. Flywheel and washer
shaft 11. Pilot bearing and snap ring
5. Flywheel housing 12. Oil strainer and O-ring
6. Idler gear "D" 13. Oil pan
6A–106 ENGINE MECHANICAL
Installation Steps
3. Oil Pump
1) Carefully wipe any foreign material from the
cylinder body rear surface.
2) Apply engine oil to the cylinder body bushing
inside.
5. Flywheel Housing
1) Apply liquid gasket to the flywheel housing as
illustrated.
Three-bond No. BB401
NOTE:
Apply liquid gasket also to the parts indicated by
arrow head.
This portion do not
apply liquid gasket. 2) Install the flywheel housing.
Tightening torque N·m (kg·m/Ib·ft)
★ : 73 (7.4 / 54)
※ : 96 (9.8 / 71)
■ : 73 (7.4 / 54)
▲ : 86 (8.8 / 64)
●, ▲ : 119 (12.1 / 88)
■ : 26 (2.7 / 20)
▼ : 53 (5.4 / 39)
• Tighten the knock pin positions beforehand.
020MX007
Retightening needs no special order.
NOTE:
▼, ▲, ★) part should be tightened
The asterisked (▼
from the cyl. body side. Tightening should not be
forgotten.
6. Idler Gear D
Install the idler gear D.
Idler Gear D Tightening torque N·m (kg·m / lb·ft)
105 – 132 (10.7 –13.5 / 77 – 98)
7. Cover
Install the cover.
Tightening torque N·m (kg·m / lb·ft)
13 – 23 (1.3 – 2.3 / 113 Ib·in – 23)
ENGINE MECHANICAL 6A–109
NOTE:
Be sure to replace the slinger and oil seal as a set.
Start
F06MV006
6A–112 ENGINE MECHANICAL
DISASSEMBLY
Oil Pump
6
2
Disassembly Steps
1. Driven gear and shaft 4. Oil pump drive gear
2. Cotter pin 5. Drive gear
3. Oil relief valve 6. Oil pump body
ENGINE MECHANICAL 6A–113
Disassembly Steps
2. Cotter Pin
3. Oil Relief Valve
4. Oil Pump Drive Gear
Use a gear puller to remove the oil pump drive gear.
5. Drive Gear
6. Oil Pump Body
6A–114 ENGINE MECHANICAL
Oil Pump
REASSEMBLY
1
5
Reassembly Steps
4. Oil relief valve
1. Oil pump body
5. Cotter pin
2. Drive gear
6. Driven gear and shaft
3. Oil pump drive gear
ENGINE MECHANICAL 6A–117
Reassembly Steps
CYLINDER BODY
DISASSEMBLY
5
4
13
3
10 11
9
7
9
7
10 12
6
2
012M100003
Disassembly Steps
1. Cylinder liner 8. Oil cooler element
2. Oiling jet and check valve 9. Element gasket
3. Oil pressure unit 10. O-ring
4. Water drain cock 11. Oil thermostat and cover
5. Oil relief valve 12. Oil cooler case
6. Oil cooler assembly 13. Cylinder body
7. O-ring
ENGINE MECHANICAL 6A–119
Disassembly Steps
1. Cylinder Liner
If the cylinder liner cannot be pulled free by hand, tap
around the lower side of the liner with a hammer grip
or similar object to loosen it.
1
NOTE:
Take care not to damage the cylinder body.
When reusing the cylinder liner, mark the cylinder
body over the liner so that the mounting direction
2 may become the same as before removal. Don’t use a
punch to mark.
Measure the cylinder liner bore and projection before
disassembling the cylinder liner.
1
Refer to the "Cylinder Liner Bore Measurement" and
"Cylinder Liner Projection Measurement" on the
"INSPECTION AND REPAIR".
Cylinder Body
REFERENCE mm (in)
Outside Diameter Cylinder Body Bore Liner
Liner Diameter Grade
117.981 - 117.990 118.001 – 118.010
1
(4.64491 - 4.64527) (4.64570 – 4.64605)
117.991 – 118.000 118.011 – 118.020
2
(4.64531 – 4.64566) (4.64609 – 4.64645)
118.001 – 118.010 118.021 – 118.030
3
(4.64570 – 4.64605) (4.64649 – 4.64684)
REASSEMBLY
6
5
11
4
12 8
10
9
10
9
12 7
13
3
012M100002
Reassembly Steps
1. Cylinder body 8. Oil thermostat and cover
2. Cylinder liner 9. O-ring
3. Oiling jet and check valve 10. Element gasket
4. Oil pressure unit 11. Oil cooler element
5. Water drain cock 12. O-ring
6. Oil relief valve 13. Oil cooler assembly
7. Oil cooler case
ENGINE MECHANICAL 6A–123
REASSEMBLY STEPS
1. Cylinder Body
2. Cylinder Liner
1) Use new kerosene or diesel fuel to thoroughly
clean the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder liner
and bore surfaces.
NOTE:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.
CAUTION:
Take care not to bending the oiling jet.
4. Oil Pressure Unit
1) Set the adapter 1 to the Cyl Block 2.
Adapter Torque N·m (kg·m / lb·ft)
117 (11.9 / 86)
A06MV003
NOTE:
(1) Apply ThreeBond No. 1207C/1216C or equivalent
on groove of oil cooler assembly.
(2) Assemble within 15 minutes after apply liquid
gasket.
COOLING SYSTEM 6B–1
SECTION 6B
ENGINE COOLING
CONTENTS
PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–12
Engine Coolant Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–15
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–18
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–15
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–17
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–19
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–19
6B–2 COOLING SYSTEM
GENERAL DESCRIPTION
Coolant Flow
Reservoir tank
Cooling fan
Radiator
Water
pump Water jacket
Drain cock (CYL.Body)
Oil cooler
Drain plug
F06MY00005
The engine cooling system consists of the radiator, will begin to open and a gradually increasing
the surge tank, the water pump, the cooling fan, and amount of coolant will circulate through the
the thermostat. radiator.
To quickly increase cold engine coolant temperature The thermostat will be fully open when the coolant
for smooth engine operation, the coolant is temperature reaches 95°C (203°F).
circulated by the water pump and the thermostat All of the coolant is now circulating through the
through the radiator bypass and directly back to the radiator for effective engine cooling.
cylinder body. The coolant does not circulate
through the radiator at this time. When the coolant
temperature reaches 82°C (179.6°F), the thermostat
COOLING SYSTEM 6B–3
Thermostat
Without jiggle valve
F06MV028
F06MV027
Water Pump
WATER PUMP
1 2
4 5
030MW001
Installation Steps
4. Water pump assembly
1) Apply liquid gasket to water pump assembly Three
bond 1207C or equivalent.
• Apply liquid gasket to make bead width 2~3 mm
on the fitting surface as shown in the illustration
Do not apply liquid gasket if there is some groove.
NOTE:
The water pump must be installed within 15 minutes
after apply liquid gasket.
Torque N·m (kg·m/lb·ft)
19.0 (1.9 / 14.0)
1. Plate
• Tighten the bolt temporary of the plate fixing bolt.
DISASSEMBLY
Water Pump
1
2
9
6 8
5
4
Disassembly Steps
1. Impeller 6. Water pump shaft and ball bearing
2. Seal unit 7. Oil seal
3. Pulley 8. O-ring
4. Dust cover 9. Water pump body
5. Snap ring
COOLING SYSTEM 6B–9
Disassembly Steps
1. Impeller
1) Clamp the pump body in a vise.
2) Use the remover to remove the impeller.
NOTE:
Insert a 5mm (0.20in) rod into the 6mm (0.24in) hole
of the impeller and push the remover center bolt to
remove the impeller.
2. Seal Unit
3. Pulley
Use a remover to remove the water pump pulley.
4. Dust Cover
5. Snap Ring
6. Water Pump Shaft and Ball Bearing
Use a plastic hammer to lightly tap the water pump
shaft free.
Tap on the shaft from the impeller side.
7. Oil Seal
8. O-ring
9. Water Pump Body
6B–10 COOLING SYSTEM
Water Pump
Water Pump Impeller
1. Check the impeller for corrosion.
2. Check the seal unit fitting faces for excessive wear
and other damage.
REASSEMBLY
9
8
1
4 2
5
6
Reassembly Steps
1. Water pump body 5. Snap ring
2. O-ring 6. Dust cover
3. Oil seal 7. Pulley
4. Water pump shaft and ball 8. Seal unit
bearing 9. Impeller
COOLING SYSTEM 6B–13
Reassembly Steps
1. Water Pump Body
2. O-ring
3. Oil Seal
1) Clean the water pump body.
Be absolutely sure that the oil ports are free of
restrictions.
2) Install the O-ring to the water pump body.
3) Apply engine oil to the oil seal outside
circumference.
4) Install the oil seal to the water pump body.
The oil seal lip must be facing the ball bearing.
5) Apply grease oil to the oil seal inside
circumference.
6) Press the oil seal into place.
5. Snap Ring
6. Dust Cover
1) Use pliers to install the snap ring into the water
pump body groove.
2) Install the dust cover with the flange facing out.
6B–14 COOLING SYSTEM
7. Pulley
Use a bench press to gradually press the water pump
pulley into the water pump shaft.
NOTE:
To protect the bearings, be sure to press in the pulley
with the impeller side pump shaft end surface held
against the bench press.
8. Seal Unit
1) As seal unit surfaces (which are to contact the shaft
and pump body) are coated with liquid gasket,
press the seal unit as it is position.
2) Press in the unit to the specified position using a
bench press and installer.
A Seal Unit Installation Position A mm (in)
11.0 – 11.6 (0.433 – 0.457)
9. Impeller
Using a bench press, press in the impeller until its
stopper surface comes into contact.
NOTE:
To protect the bearings, press in the impeller with the
pulley side shaft end surface held against the bench
press.
COOLING SYSTEM 6B–15
THERMOSTAT
REMOVAL
4
4
Removal Steps
3. Thermostat (with jiggle valve)
1. Water outlet pipe
4. Gasket
2. Thermostat (without jiggle
valve)
Removal Steps
1. Water outlet pipe
2. Thermostat (without jiggle valve)
3. Thermostat (with jiggle valve)
4. Gasket
6B–16 COOLING SYSTEM
Thermostat
Operating Test
1 1. Completely submerge the thermostat in water.
2
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Measure the thermostat initial opening
temperature.
3
Thermostat Initial Opening Temperature °C (°F)
Standard
82.0 (180)
1 Thermometer
2 Agitating rod
3 Wooden piece
5. Measure the valve lift at the valve’s fully open
position.
Valve Lift At Fully Open Position mm (in)
Approximately 8 (0.31)
COOLING SYSTEM 6B–17
INSTALLATION
3
3
Installation Steps
1. Thermostat (without jiggle valve) 3. Gasket
2. Thermostat (with jiggle valve) 4. Water outlet pipe
6B–18 COOLING SYSTEM
Installation Steps
1. Thermostat (without jiggle valve)
2. Thermostat (with jiggle valve)
Install the thermostats to the cylinder head.
The thermostat with jiggle valve must be facing the
engine intake side and the jiggle valves must be facing
the engine rearward.
Jiggle valve
3. Gasket
4. Water Outlet Pipe
1) Install the water outlet pipe to the cylinder head.
2) Tighten the water outlet pipe bolts to the specified
torque.
Water Outlet Pipe Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
COOLING SYSTEM 6B–19
RADIATOR
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.
Radiator
Cooling System Leakage Check
1. Remove the radiator filler cap from the radiator.
2. Install the radiator filler cap tester to the radiator.
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/cm2 / psi)
98 (1 / 14)
SECTION 6C
FUEL SYSTEM
CONTENTS
PAGE
Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 3
Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 7
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–10
Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–12
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–13
Identification Plate and Assembly Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–14
Fuel Injection Volume Ratio and Symbol Mark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–14
Symbol Mark Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–14
6C–2 FUEL SYSTEM
GENERAL DESCRIPTION
Injection
nozzle
Injection pump
Water separator
Fuel tank
A , B : Overflow Valve
040MV002
The fuel system consists of the fuel tank, the water removed from the fuel.
separator, the prefuel filter, the fuel filter, the Fuel, fed by the injection pump plunger, is delivered
injection pump, and the injection nozzle. The fuel to the injection nozzle in the measured volume at
from the fuel tank passes through the water the optimum timing for efficient engine operation.
separator, the pre-fuel filter and the fuel filter.
Water particles and other foreign material are
6C–4 FUEL SYSTEM
Delivery valve
Plunger barrel
Timing sleeve
Timing rod
Guide pin
Control rod
Plunger spring
Plunger
Plug
Tappet
Camshaft
Major components of the injection pump are the lobes. They are returned to their original position by
pump body and plunger unit, the governor, the the plunger springs. This action creates a reciprocal
timer, and the feed pump. motion.
The injection pump is the nucleus of the diesel The plunger barrel receives fuel from the feed pump
engine fuel system. and fuel filter through its inlet port when the
It pressurizes and delivers a metered volume of fuel injection pump plunger is on the down stroke.
to the engine cylinders at the optimum time for the Surplus fuel is delivered to the injection pump fuel
current engine load and speed. chamber through the plunger outlet port when the
The injection pump plungers are pushed up by cam plunger is on its up stroke.
FUEL SYSTEM 6C–5
Rack sensor
Control rack
Governor actuator
RED-IV TYPE
060M100066
The 6HK1TC engine is equipped with an RED - IV the target rack position, so that the injection volume
type electrical control governor. will be controlled.
The basic injection volume (rack position) is sought
from acceleration opening angle and engine
revolution, and the target injection volume is
determined after adjusyment reflecting the
information from each sensor input.
A rack sensor detects actual injection volume (actual
rack position), and moves the governor actuator to
6C–6 FUEL SYSTEM
Priming pump
Piston
Filter
The fuel feed pump tappet is driven by an eccentric through the fuel filter. It delivers the fuel, under
cam in the injection pump camshaft. Tappet pressure, to the injection pump.
movement is relayed the piston through the push An independent priming pump permits manual fuel
rod. feed when the engine is not running.
The fuel feed pump draws fuel from the fuel tank
FUEL SYSTEM 6C–7
INJECTION NOZZLE
DISASSEMBLY
7 3
2
040M100017
Disassembly Steps
1. Retaining nut 5. Nozzle spring
2. Injection nozzle 6. Adjusting shim
3. Spacer 7. Nozzle holder
4. Spring seat
6C–8 FUEL SYSTEM
Disassembly Steps
1. Retaining Nut
2. Injection nozzle
1) Clamp the injection nozzle holder in a vice.
2) Use a wrench to remove the injection nozzle
retaining nut.
3) Remove the injection nozzle holder from the vice.
4) Remove the injection nozzle, the spacer, the spring
seat, the nozzle spring and the adjusting shim.
NOTE:
Tag the nozzle assemblies and nozzle holders so that
they can be reinstalled to their original positions.
Nozzle assembly and nozzle holder combinations
must be not changed.
3. Spacer
4. Spring Seat
5. Nozzle spring
6. Adjusting Shim
7. Nozzle Holder
FUEL SYSTEM 6C–9
Injection Nozzle
1. Check the injection nozzle needle valve, the valve
seat, and the injection nozzle hole for carbon
deposits.
If carbon deposits are present, the injection nozzle
and the needle valve must be cleaned or replaced.
2. Hold the nozzle body vartically.
3. Lift the needle valve about 1 / 3 of the way out of
the nozzle body.
4. Release the needle valve.
The needle valve should fall back into the nozzle
body as far as the valve seat.
If the needle valve does not fall back into the nozzle
body as far as the valve seat, the injection nozzle
and the needle valve must be replaced.
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.
REASSEMBLY
1 5
040M100013
Reassembly Steps
1. Nozzle holder 5. Spacer
2. Adjusting shim 6. Injection nozzle
3. Nozzle spring 7. Retaining nut
4. Spring seat
FUEL SYSTEM 6C–11
Reassembly Steps
1. Nozzle Holder
2. Adjusting Shim
3. Nozzle Spring
4. Spring Seat
5. Spacer
6. Injection Nozzle
7. Retaining Nut
1) Install the adjusting shim, the nozzle spring, the
spring seat, the spacer, the injection nozzle and the
retaining nut.
2) Clamp the injection nozzle holder in a vice.
3) Tighten the injection nozzle retaining nut to the
specified torque.
Injection Nozzle Holder Retaining
Nut Torque N·m (kg·m / lb·ft)
39 (4.0 / 29)
INJECTION PUMP
MD-TICS and RED-IV TYPE
(Conform in EURO-III)
INTRODUCTION
The increasing demand for medium-sized diesel This has made possible high injection rates in the
engines has resulted in extremely severe conditions low- and medium-speed ranges through a short
concerning low fuel consumption, high output and injection duration, thus contributing to higher
low exhaust emissions. torque and cleaner exhaust emissions and
TICS controls the injection timing and injection rate improving the performance of direct-injection diesel
by varying the pre-stroke position (beginning of vehicles.
static injection).
• External appearance
The illustration shows the RED-IV Type EC actuator and a rack sensor are installed on the
governor (electrical control governor) installed injection pump’s drive side. Also, a flywheel has
on the TICS Type variable injection timing and been installed, instead of a timing device, to
injection rate injection pump. A pre-stroke transmit engine rotation smoothly.
Pre-stroke actuator
RED-IV type
EC Governor
Feed pump
040M100019
FUEL SYSTEM 6C–13
SYSTEM OVERVIEW
The illustration shows a diagram of the TICS There are slight differences depending on customer
system combined and the RED-IV Type EC specifications.
governor (electrical control governor).
Clutch
switch
Accelerator
position signal
Vehicle
Starter Parking speed
Boost pressure signal switch switch signal
Fuel temperature signal
Atmospheric
Engine coolant temperature signal temperature
signal
Pre-stroke actuator
Control unit
Injection pump
EC governor
040M100014
6C–14 FUEL SYSTEM
SECTION 6D
ENGINE ELECTRICAL
CONTENTS
PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 2
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 4
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 9
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–11
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–14
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–18
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–21
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–21
6D–2 ENGINE ELECTRICAL
GENERAL DESCRIPTION
Generator
ENGINE ELECTRICAL 6D–3
Starter Motor
065HV001
6D–4 ENGINE ELECTRICAL
GENERATOR
DISASSEMBLY
11
12
13
14
15
16
4
3 17
2
1
8 10
19
7
9
20
22 18
21
Disassembly Steps
1. Pulley nut 12. Rotor assembly
2. Pulley 13. Bearing retainer
3. Fan 14. Ball bearing
4. Collar 15. Bearing cover
5. Bushing 16. Ring
6. Cover 17. Front frame
7. Rectifier holder assembly 18. Rear end frame assembly
8. Regulator 19. Ball bearing
9. Rectifier holder 20. Rotor coil
10. Through bolt 21. Stator assembly
11. Front frame and rotor assembly 22. Rectifier assembly
ENGINE ELECTRICAL 6D–5
Disassembly steps
1. Pulley Nut
2. Pulley
3. Fan
4. Collar
5. Bushing
6. Cover
7. Rectifier Holder Assembly
8. Regulator
9. Rectifier Holder
10. Through Bolt
11. Front Frame and Rotor Assembly
12. Rotor Assembly
13. Bearing Retainer
14. Ball Bearing
15. Bearing Cover
16. Ring
17. Front Frame
18. Rear End Frame Assembly
19. Ball Bearing
20. Rotor Coil
21. Stator Assembly
22. Rectifier Assembly
6D–6 ENGINE ELECTRICAL
Rotor Coil
Rotor Coil Resistance
Use a circuit tester to measure the rotor coil resistance
between the terminals.
Rotor Coil Resistance ohm
Standard
9
If the measured resistance is above or below the
specified standard, the rotor coil assembly must be
replaced.
Stator
Stator Continuity
Check for continuity across the stator coils.
If there is no continuity, the stator assembly must be
replaced.
Stator Insulation
Use a circuit tester to check that there is no continuity
between the stator coils and the core.
If there is continuity between the stator coils and the
core, the stator assembly is defective and must be
replaced.
ENGINE ELECTRICAL 6D–7
Pulley
Check the pulley for excessive wear and cracking.
Fan
Check the fan for cracking and distortion.
Ball Bearing
Check the ball bearings for binding, drag, roughness,
and noise.
ENGINE ELECTRICAL 6D–9
REASSEMBLY
12
11
10
9
8
7
19
20 6
21
22
17
18
13
15
5
16
14
1 4
2
Reassembly Steps
1. Rectifier assembly 12. Front frame and rotor assembly
2. Stator assembly 13. Through bolt
3. Rotor coil 14. Rectifier holder
4. Rear end frame assembly 15. Regulator
5. Ball bearing 16. Rectifier holder assembly
6. Front frame 17. Cover
7. Ring 18. Bushing
8. Bearing cover 19. Collar
9. Ball bearing 20. Fan
10. Bearing retainer 21. Pulley
11. Rotor assembly 22. Pulley nut
6D–10 ENGINE ELECTRICAL
Reassembly Steps
1. Rectifier Assembly
2. Stator Assembly
3. Rotor Coil
4. Rear End Frame Assembly
5. Ball Bearing
6. Front Frame
7. Ring
8. Bearing Cover
9. Ball bearing
10. Bearing Retainer
11. Rotor Assembly
12. Front Frame and Rotor Assembly
13. Through Bolt
14. Rectifier Holder
15. Regulator
16. Rectifier Holder Assembly
17. Cover
18. Bushing
19. Collar
20. Fan
21. Pulley
22. Pulley Nut
ENGINE ELECTRICAL 6D–11
STARTER MOTOR
DISASSEMBLY
4
6
3
2
1 5
14
16
15
11
13
8
12
10
Disassembly Steps
1. Lead wire 9. Magnetic switch assembly
2. Through bolt 10. Overrunning clutch
3. Yoke 11. Front end frame
4. Screw 12. Steel ball
5. Rear end frame 13. Spring
6. Brush holder 14. Idle gear
7. Armature and bearing 15. Retainer
8. Screw 16. Roller
6D–12 ENGINE ELECTRICAL
Disassembly steps
1. Lead Wire
Disconnect the lead wire from the magnetic switch.
2. Through Bolt
Remove the through bolts from the rear end frame.
3. Yoke
Remove the yoke from the magnetic switch.
4. Screw
Remove the screw from the rear end frame.
6. Brush Holder
Using a long nose pliers, take off the brushes and pull
out the brush holder.
8. Screw
9. Magnetic Switch Assembly
1) Remove the screws from the front end frame.
2) Remove the front end frame from the magnetic
switch assembly.
Armature
Commutator Face
Check the commutator face for roughness.
If necessary, dress the commutator face with fine
sandpaper (#500 or #600).
Be absolutely sure that there are no 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.
If the run-out exceeds the specified limit, the
armature assembly must be replaced.
Commutator Run-Out mm (in)
Standard Limit
0.06 (0.002) or less 0.1 (0.004)
Armature Coil
1. Place the armature in a growler tester.
2. Hold a hacksaw blade against the armature core.
Slowly rotate the armature.
If the armature is shorted, the hacksaw blade will
vibrate.
Replace the armature assembly if it is shorted.
Armature Continuity
Use a circuit tester to check for continuity between the
commutator segments.
If there is no continuity between any two points on the
commutator, the armature assembly must be
replaced.
Armature Insulation
Use a circuit tester to check that there is no continuity
between the commutator segments and the coil core.
If there is continuity between the commutator
segments and the coil core, the armature assembly is
defective and must be replaced.
Yoke
Field Coil Continuity
Use a circuit tester to check for continuity between the
connecting leads and the brushes.
Replace the yoke assembly if there is no continuity at
any point.
6D–16 ENGINE ELECTRICAL
Yoke Insulation
Use a circuit tester to check that there is no continuity
between the field coil and the yoke body.
If there is continuity between the field coil and the
yoke body, the yoke assembly is defective and must
be replaced.
Overrunning Clutch
1. Clean the overrunning clutch with a clean rag.
2. Check the overrunning clutch and pinion gear for
excessive wear and damage.
3. Turn the pinion gear clockwise.
The gear should turn smoothly with no resistance.
If the gear does not turn smoothly, the overrunning
clutch assembly must be replaced.
4. Turn the pinion gear counterclockwise.
The gear should lock firmly.
If the gear does not lock firmly, the overrunning
clutch assembly must be replaced.
ENGINE ELECTRICAL 6D–17
Bearing
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
Magnetic Switch
CAUTION:
Do not apply an operating test to the magnetic
switch as a single unit.
Coil Inspection
Inspect the continuity between M terminal and case of
the magnetic switch using a circuit tester.
6D–18 ENGINE ELECTRICAL
REASSEMBLY
12
11
14
13
15
16 10
2
3
4
5
9
6
Reassembly Steps
1. Magnetic switch assembly 9. Screw
2. Idle gear 10. Rear end frame
3. Roller 11. Brush holder
4. Retainer 12. Screw
5. Spring 13. Armature and bearing
6. Steel ball 14. Yoke
7. Overrunning clutch 15. Through bolt
8. Front end frame 16. Lead wire
ENGINE ELECTRICAL 6D–19
Reassembly Steps
12. Screw
Tighten the screw to the specified torque.
Tightening Torque N·m (kg·m / lb·ft)
3.6 (0.37 / 2.7)
13. Armature and Bearing
14. Yoke
Note:
TAB
When install the yoke to the magnetic switch, engage
the tab on the yoke with the notch in the magnetic
switch.
15. Through Bolt
Tighten the through bolt to the specified torque.
Tightening Torque N·m (kg·m / lb·ft)
12.7 (1.3 / 9.4)
19. Lead Wire
ENGINE ELECTRICAL 6D–21
GROW PLUG
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.
It is most important that electrical components be kept clean and dry at all times.
Always visibly check the fusible links, the fuses, and the indicator lights for damage as the first step in
the inspection and repair procedure.
Preheating System
Glow Plug
Check each of the glow plugs for continuity.
Replace the glow plugs as a set if one or more of the
glow plugs does not have continuity.
MEMO
EXHAUST SYSTEM 6F–1
SECTION 6F
EXHAUST SYSTEM
CONTENTS
PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 2
Removal (F-SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 3
Removal (LT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 5
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 7
Installation (F-SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 8
Installation (LT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–10
6F–2 EXHAUST SYSTEM
GENERAL DESCRIPTION
The exhaust system consists of the the exhaust The exhaust pipes are connected to each other by
pipes and the silencer. series of flange bolts. They are attached to the
The exhaust pipes run from the exhaust manifold, vehicle frame by clamps and brackets. Rubber
beneath the vehicle frame, to the rear of the vehicle. bushings are used at support points.
EXHAUST SYSTEM 6F–3
REMOVAL
F-SERIES
4 3
150M100005
Removal Steps
1. Exhaust pipe clamp (A) 4. Exhaust silencer
2. Exhaust pipe clamp (B) 5. Front exhaust pipe
3. Rear exhaust pipe
6F–4 EXHAUST SYSTEM
Removal steps
1. Exhaust Pipe Clamp (A)
2. Exhaust Pipe Clamp (B)
3. Rear Exhaust Pipe
4. Exhaust Silencer
5. Front Exhaust Pipe
EXHAUST SYSTEM 6F–5
LT
150M100004
Removal Steps
1. Exhaust pipe clamp (A) 4. Exhaust pipe clamp (C)
2. Rear exhaust pipe 5. Exhaust silencer
3. Exhaust pipe clamp (B) 6. Front exhaust pipe
6F–6 EXHAUST SYSTEM
Removal Steps
1. Exhaust Pipe Clamp (A)
2. Rear Exhaust Pipe
3. Exhaust Pipe Clamp (B)
4. Exhaust Pipe Clamp (C)
5. Exhaust Silencer
6. Front Exhaust Pipe
EXHAUST SYSTEM 6F–7
INSTALLATION
F-SERIES
2 3
150M100007
Installation Steps
1. Front exhaust pipe 4. Exhaust pipe clamp (B)
2. Exhaust silencer 5. Exhaust pipe clamp (A)
3. Rear exhaust pipe
EXHAUST SYSTEM 6F–9
Installation Steps
150M100006
2. Exhaust Silencer
3. Rear Exhaust Pipe
4. Exhaust Pipe Clamp (B)
5. Exhaust Pipe Clamp (A)
Be absolutely sure that the exhaust pipe clamps
and / or the flange bolts are securely fastened to the
exhaust pipes and the silencer.
If the vehicle is equipped with an exhaust brake, be
absolutely sure that the exhaust brake valve is
correctly installed to the exhaust pipes.
LT
150M100008
Installation Steps
1. Front Exhaust Pipe 4. Exhaust pipe clamp (B)
5. Rear exhaust pipe
2. Exhaust silencer
3. Exhaust pipe clamp (C) 6. Exhaust pipe clamp (A)
EXHAUST SYSTEM 6F–11
Installation Steps
1. Front Exhaust Pipe
1) Connect the front exhaust pipe to the exhaust
manifold.
2) Tighten the front exhaust pipe flange nuts.
150M100006
2. Exhaust Silencer
3. Exhaust Pipe Clamp (A)
4. Exhaust Pipe Clamp (B)
5. Rear Exhaust Pipe
6. Exhaust Pipe Clamp (A)
SECTION 6G
TURBOCHARGER
CONTENTS
PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 2
Identification Plate and Assembly Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 3
Turbocharger Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 3
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 4
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 6
Turbine Shaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 6
Turbine Shaft and Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 8
6G – 2 TURBOCHARGER
GENERAL DESCRIPTION
Turbocharger
F06MV026
Major turbocharger components are constituted the The turbocharger increase air intake efficiency, the
Center Housing and Rotating Assembly (CHRA), the results in increased engine power, reduced fuel
compressor housing, and the turbine housing. consumption and minimal engine noise.
Rotating parts include the turbine shaft, the Turbocharger rotating parts operate at very high
compressor wheel, the shaft bearings, the thrust speeds and temperatures. The parts materials have
bearings and the oil seal rings. These parts are been carefully selected and machined to extremely
supported by the center housing. high precision.
TURBOCHARGER 6G – 3
TURBOCHARGER SERVICING
1. Refer to TROUBLESHOOTING in this Manual to determine whether or not turbocharger repair or
overhaul is required.
2. The following procedures should also be performed (either with the turbocharger on the vehicle or
removed from the vehicle but not disassembled) to determine whether or not turbocharger repair or
overhaul is required.
* Visual checks
* Clearance measurements
* End play measurements
Refer to INSPECTION AND REPAIR
3. The turbocharger compressor and turbine housing may be removed from the center housing and
rotating assembly (CHRA) for further visual inspection.
Refer to DISASSEMBLY and REASSEMBLY.
PRECAUTIONS
Turbocharger servicing requires great care and expertise.
Faulty turbocharger servicing procedures can result in serious damage to pistons, valves, cylinder liners,
and other important engine parts.
ISUZU does not recommended the performance of any servicing procedure not specified described in this
Manual.
Contact your nearest HONEY WELL to have the turbocharger assembly repaired or overhauled.
The identification plate and assembly number will be required by the service facility.
6G – 4 TURBOCHARGER
DISASSEMBLY
037M100001
Disassembly Steps
1. Actuator
2. Actuator hose and clip
3. Lock plate and bolt
4. Compressor housing
5. Gasket
6. Center housing
7. Turbine housing
TURBOCHARGER 6G – 5
Disassembly Steps
1. Actuator
2. Actuator Hose and Clip
1 3. Lock Plate and Bolt
3
Apply a setting mark across the center housing and
rotating assembly (1), the turbine housing (2), and the
compressor housing (3).
2
4. Compressor Housing
5. Gasket
1
1
6. Center Housing
1) Loosen the lock plate bolts.
2) Disassembly the parts.
3
Handle the parts with extreme care.
Be particularly careful not to damage the turbine
wheel blades and the compressor wheel blades.
Take care not to allow foreign material to enter the
center housing.
Note:
Disassembly and servicing of the center housing and
rotating assembly is not recommended.
7. Turbine Housing
6G – 6 TURBOCHARGER
REASSEMBLY
037M100002
Reassembly Steps
1. Turbine housing
2. Center housing
3. Gasket
4. Compressor housing
5. Lock plate and bolt
6. Actuator hose and clip
7. Actuator
TURBOCHARGER 6G – 9
Reassembly Steps
Threebond 1215
1. Turbine Housing
2. Center Housing
1) Apply Threebond 1215 or equivalent to flange
surface of compressor housing shown in the
illustration.
2) Align the setting marks (applied at disassembly) on
the center housing and rotating assembly and the
compressor housing.
Handle the parts with extreme care to avoid
damaging the compressor wheel blades.
3) Apply an anti-seizing agent (LOCTITE ANTISEIZE
LUBRICANT or the equivalent) to the new bolt
threads or the V-band threads.
4) Install the new lock plate and the bolts to the
compressor housing.
5) Tighten the bolts to the specified torque.
Compressor Housing Bolt N·m (kg·m/lb·ft)
23 (2.3/17)
3. Gasket
4. Compressor Housing
• Align the setting marks (applied at disassembly) on
the center housing and rotating assembly and the
turbine housing.
Handle the parts with extreme care to avoid
damaging the turbine shaft wheel blades.
5. Look Plate and Bolt
1) Apply an anti-seizing agent (LOCTITE ANTISEIZE
LUBRICANT or the equivalent) to the bolt.
2) Tighten the bolt to the specified torque.
Turbine Housing Bolt Torque N·m (kg·m/lb·ft)
28.0 (2.85/20.6)
3) Check that the rotating assembly turns smoothly.
Issued by
Tokyo, Japan