Case 6HK1 ISUZU Engines Service Manual 9-36560GB - PDF DOWNLOAD

SERVICE MANUAL 6HK1 ISUZU ENGINES

Case

Cre 9-36560GB

Copyright  2002 Case France Printed in France January 2002

Cre 9-36560GB

Issued 01-02

TABLE OF CONTENTS

SECTION

Cre 9-36560GB

DESCRIPTION

0A

General Information

0B

Maintenance

6A

Engine Mechanical

6B

Engine Cooling

6C

Engine Fuel

6D

Starting and Charging

6G

Engine Lubrication

6J

Engine Induction

12

Troubleshooting

13

Special Tool List

Issued 01-02

Cre 9-36560GB

Issued 01-02

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION TABLE OF CONTENTS ITEM PAGE General Repair Instructions ......................................................................................................................................2 Illustration Arrows .....................................................................................................................................................3 Abbreviations.............................................................................................................................................................4 Main Data and Specifications ...................................................................................................................................5 Service Standards ....................................................................................................................................................7 Engine External View Drawing ...............................................................................................................................11 Tightening Torque Specifications ...........................................................................................................................12 Angular Nut and Bolt Tightening Method ................................................................................................................15 Major Component Mounting Nuts And Bolts ..........................................................................................................17

Cre 9-36560GB

Issued 01-02

0A-2 GENERAL INFORMATION

GENERAL REPAIR INSTRUCTIONS 1. Before performing any service operation with the engine mounted, disconnect the grounding cable from the battery.

This will reduce the chance of cable damage and burning due to short circuiting.

2. Always use the proper tool or tools for the job on hand.

Where specified use the specially designed tool or tools.

3. Use genuine CASE parts, referring to the CASE PARTS CATALOG for engine safety.

4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you remove them. Replace them with new ones.

5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation. It is especially important to keep fastening parts separate. These parts vary in hardness and design, depending on their installation position.

6. All parts should be carefully cleaned before inspection or reassembly.

Oil ports and other openings should be cleaned with compressed air to make sure that they are completely free of obstructions.

7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.

8. If necessary, use sealing compound on gaskets to prevent leakage.

9. Nut and bolt torque specifications should be carefully followed.

10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine or disconnecting pipes and hoses. To not do so is extremely dangerous.

11. Always check and recheck you work. No service operation is complete until you have done this.

Cre 9-36560GB

Issued 01-02

GENERAL INFORMATION 0A-3

ILLUSTRATION ARROWS

Ambient/clean air flow Cool air flow

Front of engine CS01N612 CS01N605

Gas other than ambient air Hot air flow

Up CS01N606

CS01N613

Ambient air mixed with another gas Temperature change

Task related CS01N607 CS01N614

View detail

Direction

CS01N608 CS01N615

View angle CS01N609

Lubrication point (oil or fluid) CS01N616

Dimension (1:2)

Lubrication point (grease)

CS01N610 CS01N617

Sectionning (1:3)

Lubrication point (jelly)

CS01N611 CS01N618

Cre 9-36560GB

Issued 01-02

0A-4 GENERAL INFORMATION

ABBREVIATIONS List of abbreviations which may be used in this manual A - Ampere(s) AC - Alternating Current ACL - Air Cleaner Adj - Adjust AMP - Ampere(s) ASM - Assembly ATDC - After Top Dead Center Auto - Automatic Bat - Battery B+ - Battery Positive Voltage BHP - Brake Horsepower BTDC - Before Top Dead Center °C - Degrees Celsius cc - Cubic Centimeters CID - Cubic Inch Displacement CO - Carbon Monoxide Conn - Connector Crank - Crankshaft Cu.In. - Cubic Inch Cyl - Cylinder(s) DOHC - Double Overhead Camshaft DTC - Diagnostic Test Mode DTT - Diagnostic Test Terminal ECM - Engine Control Module ECT - Engine Coolant Temperature EGR - Exhaust Gas Recirculation Exh - Exhaust °F - Degrees Fahrenheit FL - Fusible Link FLW - Fusible Link Wire FP - Fuel Pump FRT - Front ft - Foot Gal - Gallon GND - Ground Gov - Governor g - Gram Har - Harness HC - Hydrocarbons HD - Heavy Duty Hg - Hydrargyrum (Mercury) IC - Integrated Circuit/Ignition Control ID - Identification/Inside Diameter IGN - Ignition INJ - Injection Int - Intake kg - Kilograms km - Kilometers km/h - Kilometer per Hour kPa - Kilopascals kV - Kilovolts (thousands of volts) kW - Kilowatts L - Liter lb ft - Foot Pounds lb in - Inch Pounds LF - Left Front Cre 9-36560GB

LH - Left Hand LR - Left Rear LS - Left Side L-4 - In-Line Four Cylinder Engine Max - Maximum Min - Minimum mm - Millimeter N - Newtons NA - Naturally Aspirated NC - Normally Closed Nm - Newton Meters NO - Normally Open NOX - Nitrogen oxides OD - Outside Diameter OHC - Overhead Camshaft PCV - Positive Crankcase Ventilation PRESS - Pressure PROM - Programmable Read Only Memory psi - Pounds per Square Inch PSP - Power Steering Pressure Pt. - Pint PWM - Pulse Width Modulate Qt. - Quart REF - Reference RF - Right Front RH - Right Hand RPM - Revolutions Per Minute RPM Sensor - Engine Speed Sensor RR - Right Rear RS - Right Side RTV - Room Temperature Vulcanizing SAE - Society of Automotive Engineers Sec - Secondary SI - System International SOHC - Single Overhead Camshaft Sol - Solenoid SPEC - Specification Speedo - Speedometer ST - Start/Scan Tool Sw - Switch SYN - Synchronize Tach - Tachometer TDC - Top Dead Center Term - Terminal TEMP - Temperature TURBO - Turbocharger V - Volt(s) VAC - Vacuum V-ref - ECM Reference Voltage VSS - Vehicle Speed Sensor VSV - Vacuum Switch Valve V-6 - Six Cylinder "Vee" Engine V-8 - Eight Cylinder "Vee" Engine W - Watt(s) w/ - With w/o - Without WOT - Wide Open Throttle

Issued 01-02

GENERAL INFORMATION 0A-5

MAIN DATA AND SPECIFICATIONS NOTE: 1. These specifications are based on the standard engine.

2. Specifications for items marked with an asterisk (*) will vary according to the type of equipment on which the engine is installed.

If you are unable to locate the data applicable to these specifications, please contact Isuzu Motors LTD through your machine supplier.

ITEMS

6HK1

Engine type

Four cycle, water cooled, in-line, overheat camshaft direct injection

Combustion chamber

Open type in piston crown

Cylinder liner

Dry

Timing drive system

Gear drive

No. of cylinders - bore x stroke

mm (in)

No. of piston rings

6 - 115 x 125 (4.53 x 4.92) Four rings (Compression rings: 3, Oil ring: 1)

Total piston displacement

L (cid)

Compression ration (to 1)

7.790 (475.4) 17.3

-1

Compression pressure at 200 min

MPa (kg/cm2/psi) Engine dimensions*

mm (in)

Engine weight (Dry)*

kg (lb)

Fuel injection order deg

Specified fuel type

650 (1,433) 9 SAE No. 2 diesel fuel

min-1

Idling speed* Valve clearances Intake Exhaust

Exhaust valves

1,332 x 995 x 1,143 (52.4 x 39.2 x 45.0) 1-5-3-6-2-4

Fuel injection timing (TDC)

Intake valves

3.24 (33/469) or more

1000

mm (in)

0.40 (0.016)

mm (in)

0.40 (0.016)

Open at (BTDC)

deg

15

Close at (ABDC)

deg

44

Open at (BBDC)

deg

58

Close at (ATDC)

deg

11

Injection pump

Bosch, in-line P-Type

Governor type*

Mechanical

Injection nozzles

Multi-hole

Injection nozzle opening pressure MPa (kg/cm2/psi) Main fuel filter

Cre 9-36560GB

1st stage: 18.1 (185/2630) 2nd stage: 22.1 (225/3200) Paper element

Issued 01-02

0A-6 GENERAL INFORMATION ITEMS

6HK1

Lubrication system Lubrication method

Full flow pressure circulation

Specified engine oil (API grade)

CD

Oil pressure (at oil gallery) kPa (kg/cm2/psi)/min-1

Oil pump type

290 - 490 (3.0 - 5.0/43-71)/2000 Condition: SAE 30 API CD grade engine oil at an oil temperature of 80°C (176°F) Gear (Timing gear drive)

Relief valve opening pressure kPa (kg/cm2/psi)

780 (8.0/114)

Oil pressure switch operating pressure* kPa (kg/cm2/psi) Main oil filter

29 (0.3/4) Paper element

By-pass valve opening pressure kPa (kg/cm2/psi) Oil volume*

L (qts)

200 (2.0/28.4) 36 (38) with combined main and partial oil filter

Oil cooler

Plate type - Water cooled in water jacket

Cooling system

Pressured compulsory circulation water

Coolant volume

L (qts)

Water pump

14.5 (15.3) Centrifugal impeller

Delivery volume Lit/min. (Imp. gal/US gal) Thermostat Valve initial opening temperature* Valve lift

167 (37/44) Pump speed a 1.600 min-1 Wax pellet

°C (°F)

82 (180)

mm (in)

10 (0.39)

Air cleaner Alternator capacity*

V-A

Regulator* Brush length* Starter motor output* Number of poles* Turbocharger model* Manufacturer

Cre 9-36560GB

24-50 IC (Built-in)

mm (in) V-kW

Brushless 24-5 4 RHG 6 Ishikawajima-Harima Heavy Industries (IHI)

Issued 01-02

GENERAL INFORMATION 0A-7

SERVICE STANDARDS ITEMS

SERVICE STANDARD

SERVICE LIMIT

mm (in)

0.05 (0.002) or less

0.20 (0.008) Do not regrind the lower face.

Intake

mm (in)

0.04 - 0.06 (0.0016 - 0.0024)

0.20 (0.008)

Exhaust

mm (in)

0.06 - 0.10 (0.0024 - 0.0039)

0.25 (0.010)

Intake

mm (in)

7.95 - 7.96 (0.3130 - 0.3134)

7.89 (0.3106)

Exhaust

mm (in)

7.92 - 7.94 (0.3118 - 0.3126)

7.89 (0.3106)

mm (in)

14.1 (0.56)

–

Intake

mm (in)

1.71 (0.067)

1.30 (0.051)

Exhaust

mm (in)

1.75 (0.069)

1.30 (0.051)

Intake

mm (in)

1.0 (0.039)

2.5 (0.098)

Exhaust

mm (in)

1.3 (0.051)

2.8 (0.110)

Intake

mm (in)

2.5 (0.098)

3.2 (0.126)

Exhaust

mm (in)

2.0 (0.079)

2.8 (0.110)

Cylinder Head Lower Face Warpage Valve Guide Valve Stem Clearance

Valve Stem Outside Diameter

Valve Guide Upper End Height Valve and Valve Seat Insert Valve Thickness

Valve Depression A

Valve Contact Width

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)

Inner and Outer Spring Squareness Intake

mm (in)

2.9 (0.114)

3.0 (0.118)

Exhaust

mm (in)

3.0 (0.118)

3.0 (0.118)

Intake Valve Spring Tension Compression Height

N (kg/lb)

348 (35.5/78)/46

Exhaust Valve Spring Tension Compression Height

N (kg/lb)

383 (39.0/86)/46

Rocker Arm Shaft and Rocker Arm Rocker Arm Shaft Run-Out

mm (in)

Rocker Arm Shaft Outside Diameter mm (in) Rocker Arm Inside Diameter

Cre 9-36560GB

mm (in)

0.30 (0.012) 21.979 - 22.000 (0.865 - 0.866)

21.85 (0.860)

22.010 - 22.035 (0.867 - 0.868) Issued 01-02

0A-8 GENERAL INFORMATION ITEMS Rocker Arm Shaft and Rocker Arm Clearance

mm (in)

Rocker Arm Pin and Roller Clearance mm (in) Valve Cap Worn

SERVICE STANDARD

SERVICE LIMIT

0.010 - 0.056 (0.0004 - 0.0022)

0.20 (0.008)

0.068 - 0.099 (0.0027 - 0.0039)

0.50 (0.02)

mm (in)

0.10 (0.004)

Camshaft Camshaft Journal Diameter

mm (in)

39.950 - 39.975 (1.5728 - 1.5738)

Cam Lobe Height

Intake

mm (in)

54.54 (2.1472)

Exhaust

mm (in)

52.85 (2.0807)

mm (in)

0.025 (0.001)

Camshaft Run-Out

Camshaft Bearing Inside Diameter mm (in) Camshaft Bearing Clearance

39.85 (1.5689)

0.05 (0.002)

40.00 - 40.037 (1.575 - 1.576)

mm (in)

0.025 - 0.087 (0.001 - 0.003)

0.15 (0.006)

Crankshaft End Play

mm (in)

0.040 - 0.205 (0.0026 - 0.008)

0.54 (0.021)

Crankshaft Run-Out

mm (in)

0.06 (0.002) or less

0.45 (0.016)

Crankshaft

Crankshaft Journal Diameter

Crankshaft Journal and Bearing Clearance

See section 6A crankshaft journal diameter in this manual. mm (in)

No. 4 Bearing

0.093 - 0.124 (0.00366 - 0.00488)

0.14 (0.0055)

Other Bearings

0.063 - 0.094 (0.00248 - 0.00370)

0.14 (0.0055)

Crankshaft Journal and Crankpin Uneven Wear

mm (in)

0.05 (0.0020)

Piston and Piston Ring Piston Grade

No

Cylinder Liner and Piston Clearance mm (in)

0.122 - 0.156 (0.0048 - 0.0061)

–

1st Compression Ring

0.057 - 0.097 (0.0022 - 0.0038)

0.20 (0.008)

2nd and 3rd Compression Ring

0.085- 0.120 (0.0033 - 0.0047)

0.15 (0.006)

0.02 - 0.06 (0.0008 - 0.0024)

0.15 (0.006)

Piston Ring and Piston Ring Gloove Clearance

Oil Ring

Cre 9-36560GB

mm (in)

Issued 01-02

GENERAL INFORMATION 0A-9 ITEMS

SERVICE STANDARD

SERVICE LIMIT

1st Compression Ring

0.18 - 0.28 (0.0071 - 0.0110)

1.20 (0.047)

2nd and 3rd Compression Ring

0.35 - 0.50 (0.0138 - 0.0197)

1.20 (0.047)

Oil Ring

0.15 - 0.35 (0.0059 - 0.0138)

1.20 (0.047) 35.95 (1.4154)

Piston Ring, Gap

mm (in)

Piston Pin Piston Pin Diameter

mm (in)

35.995 - 36.000 (1.4171 - 1.4173)

Piston Pin Hole Diameter

mm (in)

36.004 - 36.012 (1.4175 - 1.4178)

Piston Pin and Piston Pin Hole Clearance

mm (in)

0.004 - 0.017 (0.00016 - 0.00067)

Connecting Rod Alignment

mm (in)

0.05 (0.002) or less

Connecting Rod Small End Bushing Diameter

mm (in)

36.012 - 36.022 (1.4178 - 1.4182)

Piston Pin and Connecting Rod Small End Bushing Clearance

mm (in)

0.012 - 0.027 (0.00047 - 0.00106)

0.05 (0.002)

Crankpin and Bearing Clearance

mm (in)

0.037 - 0.076 (0.0015 - 0.0030)

0.10 (0.004)

Connecting Rod Big End and Crankpin Side Face Clearance

mm (in)

0.17 - 0.30 (0.0067 - 0.0118)

0.35 (0.014)

mm (in)

43.0 (1.69) for 14 in clutch 48.0 (1.89) for 15 in clutch

44.0 (1.73) for 14 in clutch 49.0 (1.93) for 15 in clutch

41.0 (1.61)

40.0 (1.57)

Connecting Rod 0.20 (0.008)

Flywheel Flywheel Friction Surface Depth

Flywheel Friction Surface Thickness mm (in) Flywheel Friction Surface Roughness mm (in)

Less than 0.05 (0.0020)

Idler Gear Idler Gear Shaft A Outside Diameter

mm (in)

49.950 - 49.975 (1.9665 - 1.9675)

Idler Gear Shaft B and C Outside Diameter

mm (in)

29.959 - 29.980 (1.1795 - 1.1803)

Idler Gear Shaft A and Idle Gear Clearance

mm (in)

0.025 - 0.075 (0.00098 - 0.00295)

Idler Gear Shaft B and C and Idle Gear Clearance

mm (in)

0.020 - 0.062 (0.0008 - 0.0024)

Cre 9-36560GB

29.9 (1.1772)

0.20 (0.008) Issued 01-02

0A-10 GENERAL INFORMATION ITEMS

SERVICE STANDARD

SERVICE LIMIT

mm (in)

0.10 - 0.17 (0.0039 - 0.0067)

0.30 (0.012)

Gear A and B

mm (in)

0.08 - 0.140 (0.00315 - 0.0052)

0.20 (0.008)

Gear C

mm (in)

0.09 - 0.144 (0.00354 - 0.00567)

0.20 (0.008)

Gear Teeth and Cover Inner Wall Clearance

mm (in)

0.125 - 0.221 (0.0049 - 0.0087)

Gear and Body Clearance

mm (in)

0.064 - 0.109 (0.0025 - 0.0043)

Gear Shaft Outside Diameter

mm (in)

15.989 - 16.000 (0.6295 - 0.6299)

Gear Shaft and Pump Body or Bushing Clearance

mm (in)

0.04 - 0.07 (0.0016 - 0.0028)

Drive Gear and Drive Gear Shaft Interference

mm (in)

0.015 - 0.044 (0.0006 - 0.0017)

Idler Gear Backlash Idler Gear End Play

Oil Pump

15.9 (0.626)

Cylinder Block Cylinder Block Upper Face Warpage mm (in)

0.05 - (0.002) or less

0.20 (0.008)

Cylinder Liner Projection

mm (in)

0.06 - 0.10 (0.0024 - 0.0039)

-

Cylinder Block Bore and Cylinder Liner Outside Diameter Clearance

mm (in)

0.011 - 0.029 (0.0004 - 0.0011)

-

Cylinder Liner Grade (Reference)

Cre 9-36560GB

See Section 6A (Cylinder liner grade selection & Clearance) in this manual.

Issued 01-02

GENERAL INFORMATION 0A-11

ENGINE EXTERNAL VIEW DRAWING 1. Cooling fan 1

2. Cylinder head

2

3. Cylinder head cover 4. Oil filler cup 5. Flywheel 6. Exhaust manifold 7. Turbocharger 8. Dipstick 9. Fan guide 10. Fuel filter 11. Inlet pipe 12. Intake duct 13. Flywheel housing 3

14. Starter motor

4

5

15. Oil drain plug 16. Oil pan 17. Alternator 18. Water pump 19. Crank pulley 10

9

8 6

20. Injection pump

11

21. Oil level sensor

7

12

17

22. Oil port cover

18

19 13

14

16 15

20

21

22

CS01N619

Cre 9-36560GB

Issued 01-02

0A-12 GENERAL INFORMATION

TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.

STANDARD BOLT Nm (kgf.m/lb.ft)

Bolt Identification CS01N620

CS01N622

CS01N624

CS01N626

CS01N621

CS01N623

CS01N625

CS01N627

Bolt Diameter x Pitch (mm) M6 x 1.0

4 - 8 (0.4 - 0.8/3 - 6)

5 - 10 (0.5 - 1.0/4 - 7)

–

M8 x 1.25

8 - 18 (0.8 - 1.8/6 - 13)

12 - 23 (1.2 - 2.3/9 - 17)

17 - 30 (1.7 - 3.1/12 - 22)

M10 x 1.25

21 - 34 (2.1 - 3.5/5 - 25)

28 - 46 (2.8 - 4.7/20 - 33)

37 - 62 (3.8 - 6.4/28 - 46)

*M10 x 1.5

20 - 33 (2.0 - 3.4/15 - 25)

28 - 45 (2.8 - 4.6/20 - 33)

36 - 60 (3.7 - 6.1/27 - 44)

M12 x 1.25

49 - 74 (5.0 - 7.5/36 - 54)

61 - 91 (6.2 - 9.3/45 - 67)

76 - 114 (7.7 - 11.6/56 - 84)

*M12 x 1.75

45 - 69 (4.6 - 7.0/33 - 51)

57 - 84 (5.8 - 8.6/42 - 62)

72 - 107 (7.3 - 10.9/53 - 79)

M14 x 1.5

77 - 115 (7.8 - 11.7/56 - 85)

93 - 139 (9.5 - 14.2/69 - 103)

114 - 171 (11.6 - 17.4/84 - 126)

*M14 x 2.0

72 - 107 (7.3 - 10.9/53 - 79)

88 - 131 (9.0 - 13.4/65 - 97)

107 - 160 (10.9 - 16.3/79 - 118)

M16 x 1.5

104 - 157 (10.6 - 16.0/77 - 116)

135 - 204 (13.8 - 20.8/100 - 150)

160 - 240 (16.3 - 24.5/118 - 177)

*M16 x 2.0

100 - 149 (10.2 - 15.2/74 - 110)

129 - 194 (13.2 - 19.8/96 - 143)

153 - 230 (15.6 - 23.4/113 - 169)

M18 x 1.5

151 - 226 (15.4 - 23.0/110 - 166)

195 - 293 (19.9 - 29.9/144 - 216)

230 - 345 (23.4 - 35.2/169 - 255)

*M18 x 2.5

151 - 226 (15.4 - 23.0/110 - 166)

196 - 294 (20.0 - 30.0/145 - 217)

231 - 346 (23.6 - 35.5/171 - 255)

M20 x 1.5

206 - 310 (21.0 - 31.6/152 - 229)

270 - 405 (27.5 - 41.3/199 - 299)

317 - 476 (32.3 - 48.5/234 - 351)

*M20 x 2.5

190 - 286 (19.4 - 29.2/140 - 211)

249 - 375 (25.4 - 38.2/184 - 276)

293 - 440 (29.9 - 44.9/216 - 325)

M22 x 1.5

251 - 414 (25.6 - 42.2/185 - 305)

363 - 544 (37.0 - 55.5/268 - 401)

425 - 637 (43.3 - 64.9/313 - 469)

*M22 x 2.5

218 - 328 (22.2 - 23.4/161 - 242)

338 - 507 (34.5 - 51.7/250 - 374)

394 - 592 (40.2 - 60.4/291 - 437)

M24 x 2.0

359 - 540 (36.6 - 55.0/265 - 398)

431 - 711 (43.9 - 72.5/318 - 524)

554 - 831 (56.5 - 84.7/409 - 613)

*M24 x 3.0

338 - 507 (34.5 - 51.7/250 - 374)

406 - 608 (41.4 - 62.0/299 - 448)

521 - 782 (53.1 - 79.7/384 - 576)

An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such as casting.

Cre 9-36560GB

Issued 01-02

GENERAL INFORMATION 0A-13

FLANGED HEAD BOLT Nm (kgf.m/lb.ft)

Bolt Identification

Bolt

CS01N628

CS01N629

CS01N630

Diameter x Pitch (mm) M6 x 1.0

5 - 9 (0.5 - 0.9/4 - 7)

6 - 12 (0.6 - 1.2/4 - 9)

–

M8 x 1.25

11 - 20 (1.1 - 2.0/8 - 15)

15 - 28 (1.6 - 2.9/12 - 21)

18 - 34 (2.1 - 3.4/15 - 25)

M10 x 1.25

23 - 39 (2.4 - 3.9/17 - 28)

35 - 59 (3.6 - 6.1/26 - 44)

42 - 71 (4.3 - 7.2/31 - 52)

*M10 x 1.5

22 - 37 (2.3 - 3.8/17 - 28)

35 - 58 (3.5 - 5.8/25 - 42)

40 - 67 (4.1 - 6.8/30 - 49)

M12 x 1.25

55 - 82 (5.6 - 8.4/40 - 61)

77 - 117 (7.9 - 11.9/57 - 86)

85 - 128 (8.7 - 13.0/63 - 94)

*M12 x 1.75

51 - 77 (5.2 - 7.8/38 - 56)

71 - 107 (7.3 - 10.9/53 - 79)

80 - 119 (8.1 - 12.2/59 - 88)

M14 x 1.5

83 - 125 (8.5 - 12.7/62 - 92)

115 - 172 (11.7 - 17.6/85 - 127)

123 - 185 (12.6 - 18.9/91 - 137)

*M14 x 2.0

77 - 116 (7.9 - 11.8/57 - 85)

108 - 162 (11.1 - 16.6/80 - 120)

116 - 173 (11.8 - 17.7/85 - 128)

M16 x 1.5

116 - 173 (11.8 - 17.7/85 - 128)

171 - 257 (17.4 - 26.2/126 - 190)

177 - 265 (18.0 - 17.1/130 - 196)

*M16 x 2.0

109 - 164 (11.2 - 16.7/81 - 121)

163 - 244 (16.6 - 24.9/120 - 180)

169 - 253 (17.2 - 25.8/124 - 187)

A bolt with an asterisk (*) is used for female screws that are made of soft materials such as cast iron.

Cre 9-36560GB

Issued 01-02

0A-14 GENERAL INFORMATION

RECOMMENDED THREAD LOCKING AGENTS LOCTITE Type

LOCTITE Color

LOCTITE 242

Blue

LOCTITE 262

Red

LOCTITE 271

Red

Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

2. Apply Loctite to at least 1/3 of the bolt’s treaded area.

3. Tighten the bolts to the specified torque.

After tightening, be sure to keep the bolts free from vibration and torque for at least an hour until the LOCTITE hardens.

NOTE: When the application procedures specified in this manual, follow them.

Cre 9-36560GB

are

Issued 01-02

GENERAL INFORMATION 0A-15

ANGULAR NUT AND BOLT TIGHTENING METHOD 1. Carefully wash the nuts and bolts and to remove all oil and grease.

2. Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts.

CS01N631

3. Tighten the nuts and bolts to the specified (snug torque) with a torque wrench.

CS01N632

4. Draw a line (A-B) across the center of each bolt.

CS01N633

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Issued 01-02

0A-16 GENERAL INFORMATION 5. Draw another line (C-D) on the face of each of the parts to be clamped. This line should be an extension of the line (A-B).

CS01N634

6. Draw another line (F-G) on the face of each of the parts to be clamped. This line will be in the direction of the specified angle (Q) across the center (E) of the nut or bolt.

CS01N635

7. Use a socket wrench to tighten each nut or bolt to the point where the line (A-B) is aligned with the line (F-G).

CS01N636

Example: Specified Angle and tightening Rotation A

30°

1/12 of a turn

B

60°

1/6 of a turn

C

90°

1/4 of a turn

D

180°

1/2 of a turn

E

360°

One full turn

CS01N637

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Issued 01-02

GENERAL INFORMATION 0A-17

MAJOR COMPONENT MOUNTING NUTS AND BOLTS LUBRICANT APPLICATION Name of Lubricant Engine Oil

Lubrication area Turbocharger bearings Cylinder head bolts (M10 bolt) Rocker arm rollers Camshaft cam nose and journal Camshaft fixing bolts and stud bolts Valve ends Oil seal lips Idle gear shaft & fixing bolts Cylinder liner bores Connecting rod bearing sliding surfaces Crank bearing sliding surfaces Thrust bearings Piston rings

Molybdenum disulfide grease

Cylinder head bolts Crankcase fixing bolts Flywheel bolts Connecting rod bolts Piston skirts

SEALANT APPLICATION Location Name of sealant Name of part

Name of mating part

1

Rubber plug

Cylinder head & cover

2

Oil cooler

Cylinder block

3

Crankcase

Cylinder block

4

Cylinder block

Flywheel housing

5

Cylinder block

Front cover

6

Water pump

Front cover

7

Oil pump

Cylinder block

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ThreeBond No. 1207B

ThreeBond No. 1207C or No. 1216C

ThreeBond No. 1207C or TB1141E

Issued 01-02

0A-18 GENERAL INFORMATION

ENGINE EXTERNAL PARTS Nm (kgf.m/lb.ft)

40 (4.1/30)

97 (9.9/72)

39 (4.0/29)

19 (1.9/14)

39 (4.0/29) 88 (9.0/65)

40 (4.1/30) 39 (4.0/29)

44 (4.5/32) 52 (5.3/38)

83 (8.5/61) 40 (4.1/30)

CS01N638

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Issued 01-02

GENERAL INFORMATION 0A-19

CYLINDER HEAD AND COVER Nm (kgf.m/lb.ft)

13 (1.3/9.4)

27 (2.8/20)

142 (14.5/105) 56 (5.7/41) 27 (2.8/20)

12 (1.2/8.7) 27 (2.8/20)

30 (3.1/22)

M14: M10:

98 (10/72) → 147 (15.0/108) → 30° ~ 60° 38 (3.9/28)

20 (2.0/14)

CS01N639

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Issued 01-02

0A-20 GENERAL INFORMATION

CYLINDER HEAD Nm (kgf.m/lb.ft)

95 (9.7/70)

48 (4.9/35) 48 (4.9/35)

15 (1.5/11)

20 (2.0/14)

20 (2.0/14)

20 (2.0/14)

52 (5.3/38) 34 (3.5/25)

CS01N640

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Issued 01-02

GENERAL INFORMATION 0A-21

OIL PAN Nm (kgf.m/lb.ft)

24 (2.4/17)

48 (4.9/35)

25 (2.5/18)

25 (2.5/18) CS01N641

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Issued 01-02

0A-22 GENERAL INFORMATION

TIMING GEARS Nm (kgf.m/lb.ft)

29 (3.0/22) → 60°

24 (2.4/17) 95 (9.7/70)

3.1 (3.2/23)

78 (8.0/58) → 60° → 60° 119 (12.1/88)

CS01N642

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Issued 01-02

GENERAL INFORMATION 0A-23

WATER PUMP Nm (kgf.m/lb.ft)

39 (4.0/29)

20 (2.0/14) 235 (24/174)

20 (2.0/14)

20 (2.0/14)

20 (2.0/14)

52 (5.3/38)

CS01N643

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Issued 01-02

0A-24 GENERAL INFORMATION

PISTON, CONNECTING ROD AND CRANKSHAFT Nm (kgf.m/lb.ft)

19 (1.9/14)

21 (2.1/15)

39 (4.0/29) → 60° → 30°

48 (4.9/35)

200 (20.4/148)

M14: M10:

98 (10/72) → 132 (13.5/98)→ 30° 37 (3.8/27)

CS01N644

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Issued 01-02

MAINTENANCE 0B-1

SECTION 0B

MAINTENANCE TABLE OF CONTENTS ITEM PAGE Identification .............................................................................................................................................................1 Fuel System ..............................................................................................................................................................3 Cooling System ........................................................................................................................................................4 Valve Clearance and Adjustment .............................................................................................................................4 Injection Timing ........................................................................................................................................................6 Compression Pressure Measurement ......................................................................................................................7

IDENTIFICATION ENGINE SERIAL NUMBER The engine serial number is stamped on the front of the cylinder block.

Engine model & serial No.

Engine Model

Serial Number

6HK1

000000

CS01N645

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0B-2 MAINTENANCE

ENGINE IDENTIFICATION Engine Serial Number The engine number is stamped on the front of the cylinder body.

CS01N645

INJECTION PUMP IDENTIFICATION Injection Pump Number Use the injection pump assembly number (stamped on the plate at the side of the pump) to determine the applicable injection pump calibration data.

If the applicable calibration data is not listed in this Manual, contact the manufacturer’s nearest authorized service facility (Bosch Automotive System Corporation or Robert Bosch GMBH).

CS01N646

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The Isuzu injection pump assembly number is also included on the plate. Use this number to order a replacement pump.

Issued 01-02

MAINTENANCE 0B-3

FUEL SYSTEM INJECTION NOZZLE Opening Pressure and Spray Condition Check 1. Use an injection nozzle tester to check the nozzle opening pressure.

If the opening pressure is above or below the specified value, the injection nozzle must be replaced or adjusted. Refer to "Adjustment of Injection Nozzle Opening Pressure".

Injection Nozzle Opening Pressure: • 1st stage: 18.1 MPa (185 kg/cm2/2630 psi) CS01N647

• 2nd stage: 22.1 MPa (225 kg/cm2/3200 psi) WARNING: Test fluid from the injection nozzle tester will spray out of the injection nozzle under great pressure. It can easily puncture a person's skin.

Keep your hands away from the injection nozzle at all times.

2. Check the spray condition.

If the spray condition is bad, the injection nozzle must be replaced or reconditioned.

(1)

Correct

(2)

Incorrect (Restrictions in orifice)

(3)

Incorrect (Dripping)

Injection Nozzle Adjustment Refer to "Injection Nozzle" in this manual.

CS01N648

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Issued 01-02

0B-4 MAINTENANCE

COOLING SYSTEM Thermostat Inspection Visually inspect the thermostat.

1

Replace the thermostat if excessive wear or damage is discovered during inspection.

2

Measure the valve lift.

Amount of Valve Lift at 95°C (203°F): 10.0 mm (0.39 in).

3

Valve Opening Temperature: 82°C (180°F) CS01N649

(1)

Thermometer

(2)

Agitating rod

(3)

Wood piece

VALVE CLEARANCE AND ADJUSTMENT The following instructions assume that valve clearance is adjusted beginning with the No. 1 piston at top dead center (TDC) on the compression stroke.

Check the alignment timing mark between the timing advancer and the mark line on the injection pump body. If the timing marks are aligned, the No. 1 piston is at TDC on the compression stroke.

Valve clearance must be adjusted when the engine is cold.

When removing the head cover, wipe off spilled oil with a rag.

1

1. Bring the piston in the No. 1 or No. 6 cylinder to the top dead center on the compression stroke by turning the crankshaft until the TDC line on the damper is aligned with the timing pointer (1) on the front cover.

Check the rocker arm shaft bracket nuts for looseness and retighten as necessary before adjusting the valve clearance.

CS01N650

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2. Check that the No. 1 intake and exhaust rocker arms have play. If they have play, it indicates that the No. 1 piston is at TDC (Top Dead Center) on the compression stroke. If the No. 1 exhaust valves are depressed, the No. 6 piston is at TDC on the compression stroke.

Issued 01-02

MAINTENANCE 0B-5 3. Adjust valve clearances for the No. 1 or No. 6 cylinder which its piston is at TDC on compression stroke. a. Loosen each adjusting screw on the bridge and rocker arm.

CS01N651

b. Insert a feeler gauge (1) between the rocker arm and the bridge and adjust the valve clearance by turning the adjusting screw on the rocker arm until there is a sight drag on the feeler gauge. Tighten the lock nut securely.

1

c. With a feeler gauge inserted, screw in the adjusting screw on the bridge gradually until it touches the end of the valve stem. Make sure that the movement of the feeler gauge becomes stiff.

CS01N652

d. In this condition, the opposite end of the bridge is raised. Readjust by loosening the adjusting screw on the bridge until there is a slight drag on the feeler gauge. Tighten the lock nut securely.

Valve clearance: 0.4 mm (0.0016 in)

When No. 1 cylinder is at TDC in compression stroke 1 I

2 E

I

3 E

I

4 E

•••

I

5 E

I

6 E

••

I

E

4. Rotate the crankshaft 360 degrees and realign the T.C. mark on the flywheel with the pointer.

Adjust clearance for remaining valves.

•

The " " mark in the illustration indicates the cylinders and valves to be adjusted.

NOTE: Be sure to move the No. 1 cylinder to TDC on the compression stroke after completing the valve clearance adjustment procedure.

•

➪

Torque: 22 Nm (2.2 kg.m/16 Ib.ft) Rocker Arm Adjusting Screw Nut

When No. 6 cylinder is at TDC in compression stroke 1 I

2 E

I

3 E

I

••

4 E

I

5 E

I

••

Bridge Adjusting Screw Nut

6 E

I

Torque: 22 Nm (2.2 kg.m/16 lb.ft) I: Intake Valve

E

E: Exhaust Valve

••

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Issued 01-02

0B-6 MAINTENANCE

INJECTION TIMING INJECTION TIMING INSPECTION 1. Disconnect the negative battery cable.

1

2. Rotate the crankshaft in the normal direction of engine rotation to align the injection timing mark on the damper with the timing pointer (1) on the front cover.

• Injection Timing (Static-TDC): 9 degree.

CS01N650

3. Check that the timing advancer notched line is aligned with the injection pump notched line.

If the notched lines are out of alignment, the injection timing must be adjusted.

CS01N653

INJECTION TIMING ADJUSTMENT 1. Rotate the crankshaft in the normal direction of engine rotation until the timing mark on the timing advancer can be seen.

2. Align the injection timing mark on the damper with the pointer on the front cover.

3. Loosen the two coupling bolts.

4. Move the timing advancer to the correct timing.

5. Tighten the two coupling bolts.

Torque: 88 Nm (9.0 kg.m/65 lb.ft) CS01N654

6. Rotate the crankshaft two turns in the normal direction of engine rotation.

7. Verify the new setting is the correct injection timing.

8. Connect the negative battery cable.

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Issued 01-02

MAINTENANCE 0B-7

COMPRESSION PRESSURE MEASUREMENT To measure the compression pressure, the engine must be cold. Engine coolant temperature should be at 20°C. Battery and starter motor condition must be normal.

1. Remove the glow plug and the injection fuel pipe from each cylinder.

2. Install the compression gauge adapter to the glow plug installation hole.

3. Install the compression gauge to the compression gauge adapter.

CS01N655

4. Crank the engine with starter motor (about 200 min-1) and take the compression gauge reading.

5. Repeat the procedure (Steps 2 to 4) for the remaining cylinders.

Compression Pressure: Standard: 3.24 MPa (33 kg/cm2/470 psi) Limit: 2.26 MPa (23.0 kg/cm2/327 psi) Compression pressure should be approximately the same for each cylinder.

A variation exceeding 200 kPa (2.0 kg/cm2/ 28 psi) is unacceptable.

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0B-8 MAINTENANCE

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Issued 01-02

ENGINE MECHANICAL 6A-1

SECTION 6A

ENGINE MECHANICAL TABLE OF CONTENTS ITEM PAGE Service Precautions...................................................................................................................................................2 General Description...................................................................................................................................................2 Turbocharger ............................................................................................................................................................4 Exhaust Manifold ......................................................................................................................................................5 Intake Cover .............................................................................................................................................................6 Water Pump ..............................................................................................................................................................7 Alternator ................................................................................................................................................................10 Injection Pump ........................................................................................................................................................11 Bearing Case ..........................................................................................................................................................15 Oil Cooler ................................................................................................................................................................17 Rocker Arm and Shaft Assembly ............................................................................................................................19 Camshaft ................................................................................................................................................................26 Cylinder Head .........................................................................................................................................................32 Crank Pulley and Flywheel .....................................................................................................................................54 Timing Gears ..........................................................................................................................................................58 Flywheel Housing ...................................................................................................................................................63 Oil Pan ....................................................................................................................................................................68 Front Cover .............................................................................................................................................................70 Piston ......................................................................................................................................................................75 Crankshaft ..............................................................................................................................................................86 Cylinder Block .........................................................................................................................................................98

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6A-2 ENGINE MECHANICAL

SERVICE PRECAUTIONS • Be sure to use the correct fastener in the proper location. If a used fastener is replaced with a new one, the new fastener must be identical to the previous one.

• Some fasteners must always be replaced with new ones following removal. These fasteners are specified in this Manual.

• Some fasteners require thread locker or thread sealant. These fasteners are specified in this Manual.

• Supplemental fastener coatings (paint, grease, or corrosion inhibitor) affect fastener torque and clamping force. They may damage the fastener. Do not use them unless specifically called for.

ENGINE SERVICE (GENERAL INFORMATION) Read the following carefully to avoid engine damage and ensure reliable engine performance and a long service life.

• The 12-volt electrical system is capable of damaging delicate electrical circuits. Be absolutely certain that the ground cable is disconnected at the battery when servicing the engine.

• After removing the intake air duct or air cleaner, immediately cover the intake opening with a clean cloth. This prevents the entry of foreign material capable of causing serious engine damage.

ENGINE COMPONENTS

• Tighten all fasteners to the specified torque. If there is a tightening sequence, follow it exactly.

The 6HK1 engine is a 4-cycle, 6-cylinder in-line, diesel engine with direct fuel injection. Engine displacement is 7.79 liters (475 cubic inches).

GENERAL DESCRIPTION

The engine uses a gear-driven overhead camshaft timing train.

ENGINE CLEANLINESS AND CARE An industrial engine is a combination of many machines that have been honed and polished.

Tolerances are measured in 1.000ths of millimeters (10.000ths of inches).

When servicing engine assemblies and parts, care and cleanliness are extremely important. Proper cleaning and the protection of friction areas and delicate parts are part of the service procedure.

• Apply engine oil to all friction areas during reassembly to provide protection and lubrication when the engine is started.

• When valve train components, pistons, piston rings, connecting rods, connecting rod bearings, and crankshaft bearings are removed, they must be reinstalled to their original positions. To ensure this, mark the parts at disassembly and store them neatly.

• Disconnect battery cables before working on the engine. This prevents damage to wire harnesses and other electrical parts.

• Engine cylinders are numbered 1-2-3-4-5-6 from the front of the engine (crankshaft pulley) to the rear (flywheel).

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The engine is quiet, economical, and durable.

CYLINDER HEAD The cross-flow cylinder head is constructed of cast iron. The intake system is at the left side of the engine and the exhaust system is at the right side. This configuration reduces resistance in the two systems.

A laminated cylinder head gasket is used to minimize fatigue. The head and gasket are secured to the block using the angular tightening method. This provides a reliable seal against gas and water leakage.

CYLINDER BLOCK AND CYLINDER LINERS The cast iron cylinder block has 7 bearings. Bearing caps have a ladder frame construction to integrate them with the crankcase and increase engine rigidity.

Cylinder liners are constructed of very thin, special-use iron alloys. In combination with the chrome-plated 1st and 3rd piston rings, they provide excellent wear resistance.

PISTONS The aluminum alloy pistons have a ring trigger cast into the 1st ring groove. The outer sliding surface of the 1st and 3rd piston rings are chrome plated to provide strength and wear resistance.

Issued 01-02

ENGINE MECHANICAL 6A-3

CRANKSHAFT

LUBRICATING SYSTEM

The forged steel crankshaft is soft nitride treated for additional strength. The 7 bearings together with the 4 counterweights result in reduced bearing rotational load.

All moving engine parts are lubricated by a gear pump pressure circulation system.

GEAR TRAIN The gear train is at the rear of the engine (flywheel side). This minimizes torsion vibration from the crankshaft and reduces noise.

To further reduce noise, the crankshaft gear is shrink-fitted to the crankshaft. Precise gear arrangement, gear ratio, backlash, and bearing rigidity also contribute to a quieter engine.

COMBUSTION CHAMBERS Isuzu’s unique combustion chamber design provides easy starting, maximum power output, and operating economy.

Direct fuel injection is used. Each cylinder has an injection nozzle placed precisely at the center of the cylinder.

Intake ports generate maximum swirl effect for the air-fuel mixture. Exhaust ports provide minimum exhaust resistance.

VALVE ARRANGEMENT

Oil is pumped from the crankcase through the oil filter to the oil cooler where it is cleaned. From the oil cooler, the oil travels to the cylinder block main oil gallery from where it circulates to lubricate the engine parts.

Oil jets in the oil gallery spray oil to the inside surfaces of the pistons to provide optimum lubrication and cooling.

OIL PUMP AND OIL FILTER The gear-type oil pump with relief valve is driven by the timing gear.

A full-flow oil filter with a highly efficient paper element is used.

If the oil filter element becomes clogged, a by-pass valve opens to route the oil directly to the oil gallery.

OIL COOLER Oil temperature rises as the engine warms up with a resulting decrease in lubricating efficiency. The oil cooler operates to maintain low oil temperature and high lubricating efficiency. The oil cooler consists of a body and cooling element.

Each cylinder has 2 intake valves and 2 exhaust valves. The intake valves use Isuzu’s unique inlet ports to provide high efficiency and complete combustion.

The exhaust valves are connected to a single exhaust port.

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6A-4 ENGINE MECHANICAL

TURBOCHARGER REMOVAL 1. Remove the oil feed pipe.

• Discard the gaskets.

2. Remove the oil drain pipe.

2 1

• Discard the gaskets.

3. Remove the turbocharger.

NOTE: Plug the turbocharger body oil ports and openings to prevent the entry of foreign material.

INSTALLATION 1. Install the turbocharger assembly with the new gasket to the exhaust manifold and tighten the nuts to the specified torque.

C01N656

Torque: 52 Nm (5.3 kg.m/38 lb.ft) NOTE: Lubricate the turbine shaft. Pour oil into the oil feed hole while rotating the turbine wheel with your hand.

2. Install the oil drain pipe (2) to the turbocharger and tighten the bolts to the specified torque.

Torque: 34 Nm (3.5 kg.m/25 lb.ft) 3. Install the oil feed pipe (1) to the turbocharger and tighten the bolts to the specified torque.

Torque: 34 Nm (3.5 kg.m/25 lb.ft)

CS01N657

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Issued 01-02

ENGINE MECHANICAL 6A-5

EXHAUST MANIFOLD REMOVAL 1. Remove the turbocharger oil feed pipe.

2. Remove the turbocharger oil drain pipe.

3. Remove the turbocharger.

Refer to "Turbocharger Removal" in this manual.

4. Remove the exhaust manifold.

Clean the sealing surfaces of the exhaust manifold.

CS01N658

1

INSTALLATION

2

1. Install the exhaust manifold assembly with the new gasket to the cylinder head.

• Install the distance tube (1), plain washer (2), and spring washer (3).

3

• Install the distance tube (1) and distance nut (4) to the front stud of No. 5 cylinder (indicated by arrow A).

4

1 CS01N659

2. Tighten the nuts to the specified torque in the order shown in the illustration below.

Torque: 34 Nm (3.5 kg.m/25 lb.ft) 3. Install the turbocharger assembly with the new gasket to the exhaust manifold.

Refer to "Turbocharger Installation" in this manual.

4. Install the oil drain pipe to the turbocharger.

5. Install the oil feed pipe to the turbocharger.

CS01N660

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Issued 01-02

6A-6 ENGINE MECHANICAL

INTAKE COVER REMOVAL 1. Remove the fuel pipes.

2. Remove the booster air pipe.

3. Remove the injection pipes.

4. Remove the fuel filter and bracket.

5. Remove the intake pipe.

6. Remove the intake cover.

7. Clean the sealing surfaces of the intake cover.

CS01N661

INSTALLATION 1. Install the intake cover with new gaskets.

• Tighten the bolts to the specified torque.

Torque: 13 Nm (1.3 kg.m/9.4 lb.ft) 2. Install the intake pipe with new gasket.

Tighten the fixing nuts to the specified torque.

Torque: 20 Nm (2.0 kg.m/14 lb.ft)

CS01N662

3. Install the fuel filter and bracket to the intake cover.

Tighten the fixing bolts to the specified torque.

Torque: Fuel Filter: 39 Nm (4.0 kg.m/29 lb.ft) Bracket: 20 Nm (2.0 kg.m/14 lb.ft) 4. Install the injection pipes and tighten the steeve nuts to the specified torque.

Torque: 29 Nm (3.0 kg.m/22 lb.ft) CS01N663

1

5. Install the fuel pipe and tighten the bolts to the specified torque as follows.

Torque: Fuel return pipe:

37 Nm (3.2 kg.m/23 lb.ft)

Fuel pipe (Fuel filter to Injection pump): 39 Nm (4.0 kg.m/29 lb.ft) Fuel pipe (Feed pump to fuel filter): 39 Nm (4.0 kg.m/29 lb.ft) 6. Install the fuel leak off pipe (1) with new gasket.

Tighten the eye bolts to the specified torque.

Torque: CS01N664

Cre 9-36560GB

Cylinder head side:

29 Nm (3.0 kg.m/22 lb.ft)

Fuel filter side:

25 Nm (2.5 kg.m/18 lb.ft) Issued 01-02

ENGINE MECHANICAL 6A-7

WATER PUMP

3

2 6 1

5

4 CS01N665

Legend (1)

Adapter

(4)

By-pass hose

(2)

Fan pulley

(5)

Water duct

(3)

Water pump

(6)

Water duct

REMOVAL 1. Loosen the fan fixing nuts to remove the cooling fan.

CS01N666

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Issued 01-02

6A-8 ENGINE MECHANICAL 2. Remove the fan guard and fan guide.

3. Loosen the fan pulley fixing bolts.

CS01N667

4. Remove the fan belt.

• Loosen the mounting bolt (2) and the sliding piece nut (1).

3

1

• Pivot the alternator at the mounting bolt toward the center of the engine.

5. Remove the adapter and fan pulley.

6. Disconnect the by-pass hose.

7. Loosen the fixing nuts and bolts from the water pump.

8. Remove the water pump from the front plate.

2

9. Discard the gaskets.

CS01N668

INSTALLATION 1. Install the water pump with new gaskets to the front plate. Use the locating pin.

2. Tighten the fixing nuts and bolts to the specified torque.

Torque: Nut A: 39 Nm (4.0 kg.m/29 lb.ft) Bolt: 20 Nm (2.0 kg.m/14 lb.ft)

CS01N669

3. Install the water duct with new gasket to the cylinder head.

Tighten the bolts to the specified torque.

Torque: 1

Bolt (1): 233 Nm (24 kg.m/174 lb.ft) Bolt (2): 20 Nm (2.0 kg.m/14 lb.ft)

2

CS01N670

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Issued 01-02

ENGINE MECHANICAL 6A-9 4. Install the water duct with new gasket to the oil cooler and water pump.

Tighten the bolts to the specified torque.

Torque: 20 Nm (2.0 kg.m/l4 lb.ft) 5. Connect the by-pass hose.

6. Clamp the by-pass hose.

7. Install the fan pulley and adaptor to the water pump.

Tighten the fixing bolts to the specified torque.

Torque: 52 Nm (5.3 kg.m/38 lb.ft) CS01N671

8. Install the fan belt.

B

9. Adjust the fan belt tension.

A

• Depress the drive belt midway between the alternator and fan pulley.

Drive Belt Deflection: 8 - 11 mm (0.31 - 0.43 in) Legend A. Alternator B. Water pump C. Crankshaft

C CS01N672

10. Install the cooling fan.

Tighten the fixing nuts to the specified torque.

Torque: 39 Nm (4.0 kg.m/29 lb.ft)

CS01N666

11. Install the fan guide.

Tighten the fixing bolts to the specified torque.

Torque: 30 Nm (3.1 kg.m/22 lb.ft) 12. Install the fan guard.

Tighten the fixing bolts to the specified torque.

Torque: 40 Nm (4.1 kg.m/30 lb.ft) 13. Adjust the fan tip clearance.

Clearance: 7 - 13 mm (0.28 - 0.51 in)

CS01N667

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Issued 01-02

6A-10 ENGINE MECHANICAL

ALTERNATOR REMOVAL 1. Remove the sliding piece nut (1).

2. Remove the alternator mounting bolt (2).

3. Remove the fan belt.

3

1

4. Remove the alternator.

2 CS01N668

INSTALLATION 1. Install the alternator.

2. Install the adjusting plate.

3. Install the fan belt.

4. Adjust the belt tension by turning bolt (3).

• Depress the fan belt midway between the alternator and the water pump.

Belt Deflection: 8 - 11 mm (0.31 - 0.43 in) 5. Tighten the adjusting plate fixing bolts to the specified torque.

Torque: 49 Nm (5.0 kg.m/36 lb.ft) CS01N672

6. Tighten the alternator mounting bolt (2) to the specified torque.

Torque: 127 Nm (12.9 kg.m/93 lb.ft) 7. Tighten the slide piece nut (1) to the specified torque.

Torque: 76 Nm (7.7 kg.m/56 lb.ft)

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ENGINE MECHANICAL 6A-11

INJECTION PUMP REMOVAL 1. Remove the leak off pipe (1).

1

CS01N664

2. Remove the fuel pipes (1), (2) and (3).

2 1

Legend (1)

Fuel Pipe: Feed Pump to filter

(2)

Fuel Pipe: Filter to Injection Pump

(3)

Fuel Pipe: Return

3

CS01N664

3. Remove the injection pipe.

NOTE: Protect the joint openings of the injection pipe to prevent the entry of foreign material.

CS01N673

4. Remove the fuel filter.

CS01N663

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6A-12 ENGINE MECHANICAL 5. Remove the oil feed pipe (1) from the injection pump.

6. Remove the oil return pipe (2).

1

2 CS01N675

7. Loosen the coupling bolts (1).

8. Remove the booster air pipe (injection pump governor to intake cover).

1

2

CS01N676

9. Loosen the injection pump fixing bolts (1).

10. Remove the injection pump.

1 CS01N677

11. Remove the injection pump bracket.

CS01N678

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ENGINE MECHANICAL 6A-13

INSTALLATION 2

5

1

1. Install the injection pump bracket to the cylinder block. Use the locating pin.

• Tighten the fixing bolts in the numerical order shown in the illustration.

Torque: 50 Nm (5.1 kg.m/37 lb.ft)

4

3 CS01N678

2. Align the injection timing mark on the damper with the pointer (1) on the front cover.

Injection Timing: 9° BTDC 3. Install the injection pump.

1

• Bring No. 1 cylinder to top dead center on the compression stroke.

• Align the injection timing mark on the timing advancer with the injection pump body pointer.

• Install the injection pump to the injection pump bracket. Use the locating dowel pin.

• Tighten the injection pump fixing bolts to the specified torque.

CS01N650

3

Torque: 44 Nm (4.5 kg.m/33 lb.ft) 4. Loosen the adjusting bolt (2) and fasten the coupling bolt (3) to the timing advancer.

2

Tighten the adjusting bolt (2) and fixing bolt (1).

Torque: 88 Nm (9.0 kg.m/65 lb.ft) • Verify that the Injection timing is correct by turning the crankshaft two turns in the normal direction of engine rotation.

1

CS01N679

Cre 9-36560GB

Issued 01-02

6A-14 ENGINE MECHANICAL 5. Install the oil feed pipe (1) to the injection pump.

Torque: 27 Nm (2.8 kg.m/20 lb.ft) 6. Install the oil return pipe (2).

Torque: 34 Nm (3.5 kg.m/25 lb.ft)

1

2

CS01N675

7. Install the air boost pipe (injection pump governor to intake cover).

8. Install the fuel fitter to the bracket.

• Tighten the bolts to the specified torque.

Torque: 39 Nm (4.0 kg.m/29 lb.ft) 9. Install the injection pipes.

• Tighten the sleeve nuts to the specified torque.

Torque: 29 Nm (3.0 kg.m/22 lb.ft)

CS01N673

10. Install the fuel return pipe.

• Tighten the bolts to the specified torque.

Torque: 37 Nm (3.8 kg.m/27 lb.ft) 11. Install the fuel pipe (fuel filter to injection pump).

12. Install the fuel pipe (fuel pump to fuel filter).

• Tighten the bolts to the specified torque.

Torque: 39 Nm (4 kg.m/29 lb.ft)

CS01N664

13. Install the fuel leak off pipe (1).

1

• Tighten the bolts to the specified torque.

Torque: Cylinder head side: 29 Nm (3.0 kg.m/22 lb.ft) Filter side: 25 Nm (2.5 kg.m/18 lb.ft)

CS01N664

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-15

BEARING CASE REMOVAL 1. Remove the injection pump.

Refer to "Injection Pump Removal" in this manual.

2. Remove the coupling.

• Loosen the bolt (1).

1

CS01N679

3. Remove the oil feed pipe from the bearing case.

4. Remove the bearing case.

CS01N680

Cre 9-36560GB

Issued 01-02

6A-16 ENGINE MECHANICAL

INSTALLATION 1. Bring No. 1 piston to top dead center on the compression stroke.

2. Install the bearing case with new gasket to the cylinder block.

• Apply ThreeBond No. 1208 or equivalent to the gasket.

This will hold the gasket in place during installation.

• Install the gasket to the bearing case groove.

• Install the coupling to the bearing case shaft.

CS01N650

• Align the S mark on the coupling with the pointer (A) as shown in the illustration.

• Install the bearing case to the cylinder block.

• Confirm S mark position after installation.

• Tighten the fixing nuts and bolts to the specified torque: Torque: Bolt (1): 73 Nm (7.4 kg.m/54 lb.ft) Nut (2): 73 Nm (7.4 kg.m/54 lb.ft) Nut (3), (4): 40 Nm (4.1 kg.m/30 lb.ft)

Before installation

After installation

CS01N681

3. Install the injection pump.

Refer to "Injection Pump Installation" in this manual.

3 1

4. Install the oil feed pipe to the bearing case.

A

2 4 CS01N682

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-17

OIL COOLER REMOVAL 1. Remove the fuel leak off pipe.

2. Remove the fuel pipes.

3. Remove the injection pipe.

4. Remove the fuel filter.

5. Remove the oil feed pipe from the injection pump.

6. Remove the oil return pipe.

7. Loosen the coupling bolts.

8. Remove the boost air pipe (intake cover to injection pump governor).

CS01N683

9. Loosen the injection pump fixing bolts.

10. Remove the injection pump. Refer to "Injection Pump Removal" in this manual.

11. Remove the stay for the fan guide.

12. Loosen the oil cooler fixing bolts evenly from the outside to inside.

13. Remove the oil cooler assembly from the cylinder block.

• Install the removed bolts to the replacer hole and remove the oil cooler.

• Clean the sealing surface of the block and remove sealant residue.

1

INSTALLATION

1

1. Install the oil cooler assembly with new gaskets (1) to the cylinder block.

• Clean the sealing surface of the oil cooler.

• Apply ThreeBond No. 1207C/1216C or equivalent to the groove of the oil cooler assembly.

NOTE: Install the oil cooler within 15 minutes of applying sealant.

CS01N684

• Tighten the oil cooler fixing bolts to the specified torque in the numerical order shown in the illustration.

Torque: 19 Nm (1.9 kg.m/14 lb.ft) 2. Install the stay for the fan guide.

3. Install the injection pump.

Refer to "Injection Pump Installation" in this manual.

CS01N685

Cre 9-36560GB

Issued 01-02

6A-18 ENGINE MECHANICAL 4. Install the oil feed pipe (1) to the injection pump.

Torque: 27 Nm (2.8 kg.m/20 lb.ft) 5. Install the oil return pipe (2).

Torque: 34 Nm (3.5 kg.m/25 lb.ft) 1

2

CS01N675

6. Install the air boost pipe (injection pump governor to the intake cover).

7. Install the fuel filter to the bracket.

• Tighten the bolts to the specified torque.

Torque: 39 Nm (4.0 kg.m/29 lb.ft)

CS01N663

8. Install the injection pipes.

• Tighten the sleeve nuts to the specified torque.

Torque: 29 Nm (3.0 kg.m/22 lb.ft)

CS01N673

9. Install the fuel return pipe.

1

• Tighten the bolts to the specified torque.

Torque: 37 Nm (3.8 kg.m/27 lb.ft) 10. Install the fuel pipe (fuel filter to injection pump).

11. Install the fuel pipe (fuel pump to fuel filter).

• Tighten the bolts to the specified torque.

Torque: 39 Nm (4.0 kg.m/29 lb.ft) 12. Install the fuel leak off pipe (1).

• Tighten the bolts to the specified torque.

Torque: Cylinder head side: 29 Nm (3.0 kg.m/22 lb.ft) CS01N664

Cre 9-36560GB

Filter side: 25 Nm (2.5 kg.m/18 lb.ft) Issued 01-02

ENGINE MECHANICAL 6A-19

ROCKER ARM AND SHAFT ASSEMBLY

1

2 3

6 4

5

7 8

CS01N674

Legend (1)

Cylinder head cover

(5)

Bearing

(2)

Gasket

(6)

Camshaft

(3)

Rocker arm assembly

(7)

Rubber plug

(4)

Cam bearing cap

(8)

Cylinder head

Cre 9-36560GB

Issued 01-02

6A-20 ENGINE MECHANICAL

REMOVAL 1. Remove the head cover.

2. Remove the cylinder head cover gasket. Discard the gasket.

NOTE: Be careful not to lose the collars inserted into the cylinder head cover assembly.

CS01N686

3. Remove the rocker arm shaft assembly.

Loosen the camshaft bracket fixing nuts on both sides.

Loosen the rocker arm shaft bracket fixing bolts evenly from the outside to the inside.

CS01N687

NOTE: Do not remove the rocker arm fixing bolts (indicated by an arrow).

CS01N688

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-21

INSTALLATION 1. Apply engine oil to the bridge cap.

2. Install the rocker arm assembly. a. Apply engine oil to the front and rear camshaft bracket sliding surfaces. b. Apply engine oil to the camshaft bracket stud threads and nut setting faces. c. Install the rocker arm shaft assembly to the cylinder head.

CS01N689

d. Tighten the rocker arm bracket nuts and bolts to the specified torque in the numerical order shown in the illustration.

After tightening the camshaft cap nuts, tighten the rocker arm shaft bracket bolts.

Torque: Bolts 1 through 4: 27 Nm (2.8 kg.m/20 lb.ft) Bolts 5 through 13: 56 Nm (5.7 kg.m/41 lb.ft)

CS01N690

3. Adjust the valve clearance.

Refer to "Valve Clearance Adjustment" in this manual.

1

4. Apply ThreeBond 1207B or equivalent to the rubber plug (1) surfaces.

NOTE: Immediately (within ten (10) minutes of applying the sealant) install the cylinder head cover to the cylinder head.

CS01N691

5. Install the cylinder head cover with new gasket. a. Clean the head cover gasket groove and the head cover gasket b. Install the new head cover gasket and collar to the head cover. c. Install the cylinder head cover to the cylinder head. d. Tighten the cylinder head cover bolts to the specified torque a little at a time in the numerical order shown in the illustration.

Torque: 13 Nm (1.3 kg.m/9.4 lb.ft) CS01N692

Cre 9-36560GB

Issued 01-02

6A-22 ENGINE MECHANICAL

DISASSEMBLY 1. Disassemble the rocker arm and shaft assembly.

1

• Loosen the rocker arm shaft fixing bolts (1).

• Disassemble the bracket rocker arm, washer and rocker arm shaft.

NOTE: Keep each rocker arm and bracket in order so that they can be reinstalled to their original positions.

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

CS01N693

Rocker Arm Shaft Run-Out 1. Place the rocker arm shaft on V-blocks.

2. Use a dial indicator to measure the rocker arm shaft central portion run-out.

If the run-out is very slight, correct the rocker arm shaft run-out with a bench press. The rocker arm must be at cold condition.

If the measured rocker arm shaft run-out exceeds the specified limit, the rocker arm shaft must be replaced.

Rocker arm shaft run-out CS01N694

Limit: 0.3 mm (0.012 in)

Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm fitting portion outside diameter.

If the measured value is less than the specified limit, the rocker arm shaft must be replaced.

Rocker arm shaft outside diameter Standard: 21.979 - 22.000 mm (0.865 - 0.866 in) Limit: 21.85 mm (1.0860 in)

CS01N695

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-23

Rocker Arm Bushing Inside Diameter Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter.

Rocker arm bushing inside diameter Standard: 22.010 - 22.035 mm (0.867 - 0.868 in) Rocker arm and rocker arm shaft clearance Standard: 0.01 - 0.056 mm (0.0004 - 0.0022 in) Limit: 0.2 mm (0.0079 in) Check that the rocker arm and rocker arm shaft oil port are free of obstructions.

CS01N696

If necessary, use compressed air to clean the rocker arm and rocker arm shaft oil port.

WARNING: Compressed air can cause personal injury when used for cleaning. Wear safety glasses and protective clothing.

Rocker arm roller and rocker arm pin 1. Pass a piece of string between the rocker arm and the rocker arm roller.

1

2. Pull on either end of the string in the directions shown in the illustration.

3. Measure the rocker arm protrusion (1).

4. Mark the measuring point and remove the string.

5. Press the rocker arm roller against the rocker arm with your fingers. Measure the rocker arm protrusion again.

CS01N697

6. Calculate the difference between the 2 protrusions (roller out and roller in). This is the roller and pin clearance.

If the clearance exceeds the limit, the rocker arm must be replaced.

Rocker arm roller and pin clearance Standard: 0.036 - 0.069 mm (0.0014 - 0.0027 in) Limit: 0.15 mm (0.0059 in) 7. Check the rocker arm roller and camshaft contact surfaces for excessive wear and damage.

CS01N698

Cre 9-36560GB

Issued 01-02

6A-24 ENGINE MECHANICAL

Rocker arm bracket Check that the oil hole in the rocker arm shaft bracket is free of obstructions.

CS01N699

Bridge gap Check the valve cap and rocker arm contact surfaces for excessive wear and damage.

If the wear exceeds the limit, the valve cap must be replaced.

Valve cap wear Limit: 0.1 mm (0.004 in)

CS01N700

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-25

REASSEMBLY 1. Apply engine oil to the rocker arm shaft.

1

2. Install the camshaft bracket to the rocker arm shaft.

3. Temporarily tighten the camshaft bracket bolt (1).

CS01N701

4. Install the rocker arm shaft bracket as shown in the installation.

CS01N702

5. Install the rocker arm.

• Apply engine oil to the rocker arm roller and pin.

6. Install the spring washer and camshaft bracket.

CS01N703

Cre 9-36560GB

Issued 01-02

6A-26 ENGINE MECHANICAL

CAMSHAFT

1

2 3

6 4

5

7 8

CS01N674

Legend (1)

Cylinder head cover

(5)

Bearing

(2)

Gasket

(6)

Camshaft

(3)

Rocker arm assembly

(7)

Rubber plug

(4)

Cam bearing cap

(8)

Cylinder head

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-27

REMOVAL 1. Remove the head cover.

2. Remove the cylinder head cover gasket.

Discard the gasket.

NOTE: Be careful not to lose the collars inserted into the cylinder head cover assembly.

3. Remove the rubber plug.

4. Remove the rocker arm shaft assembly.

Refer to "Rocker Arm Assembly Removal" in this manual.

CS01N686

5. Remove the camshaft bearing caps.

• Loosen the camshaft bearing cap nuts and bolts evenly from the outside to the inside.

NOTE: If the camshaft bearings are to be reinstalled, keep them in order for installation to their original location.

6. Remove the camshaft with camshaft gear.

CS01N705

Cre 9-36560GB

Issued 01-02

6A-28 ENGINE MECHANICAL

INSTALLATION 1. Install the camshaft with camshaft gear to the cylinder head.

1

a. Align the crankshaft damper pulley TDC mark with the pointer (1) by rotating the crankshaft in the normal direction of engine rotation. Check the position of the alignment timing mark on the injection pump for No. 1 piston of TDC. b. Install the camshaft bearings to the cylinder head bearing grooves and bearing caps. c. Apply engine oil to the camshaft bearing sliding surfaces before installing the camshaft.

CS01N650

d. Install the camshaft with camshaft gear to the cylinder head. e. Carefully align the camshaft gear "B" mark and the upper cylinder head face as shown in the illustration. f. If the "B" mark and upper cylinder head face are not aligned, No.1 piston is not on the compression stroke.

Remove the camshaft.

Rotate the crankshaft one full turn and realign the crankshaft damper pulley TDC mark with the pointer by rotating the crankshaft in the normal direction of engine rotation.

CS01N706

g. Reinstall the camshaft assembly repeating steps c to e.

2. Install the camshaft bearing caps. a. Apply engine oil to the camshaft bearing sliding surfaces. b. Install the camshaft bearing caps with the bearings in numerical order with the cap stamped mark facing forward. c. Apply engine oil to the bearing cap bolt thread and setting faces. d. Tighten the bearing cap bolts to the specified torque. Work from the center of the cylinder head toward the outside.

Torque: 27 Nm (2.8 kg.m/20 lb.ft) 3. Apply engine oil to the bridge cap.

CS01N705

4. Install the rocker arm assembly.

Refer to "Rocker Arm Assembly Installation" in this manual.

5. Adjust the valve clearance.

Refer to "Valve Clearance Adjustment" in this manual.

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-29 6. Install the rubber plug to the cylinder head. a. Apply ThreeBond 1207B or equivalent to the rubber plug as shown in the illustration. b. Install the rubber plug to the cylinder head.

NOTE: Clean the cylinder head and remove sealant residue.

CS01N707

c. Apply ThreeBond 1207B or equivalent to the rubber plug (1) surfaces.

NOTE: Immediately (within ten (10) minutes of applying the sealant) install the cylinder head cover to the cylinder head.

1

CS01N691

7. Install the cylinder head cover with new gasket. a. Clean the head cover gasket groove and the head cover gasket. b. Install the new head cover gasket and collar to the head cover. c. Install the cylinder head cover to the cylinder head. d. Tighten the cylinder head cover bolts to the specified torque a little at a time in the numerical order shown in the illustration.

Torque: 13 Nm (1.3 kg.m/9.4 lb.ft) CS01N692

Cre 9-36560GB

Issued 01-02

6A-30 ENGINE MECHANICAL

DISASSEMBLY 1. Remove the camshaft gear.

• Check the gear for excessive wear or damage.

• Use an universal puller to pull out the camshaft gear.

CS01N708

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

1. Measure the dimension between the camshaft thrust surface and the camshaft gear.

Camshaft and camshaft gear dimension Standard: 25.015 - 28.055 mm (1.103 - 1.105 in)

CS01N709

2. Use a micrometer to measure each camshaft journal diameter in two directions ((1) and (2)). If the measured value is less than the specified limit, the camshaft must be replaced.

Camshaft journal diameter Standard: 39.950 - 39.975 mm (1.5728 - 1.5738 in) Limit: 39.85 mm (1.5689 in)

CS01N710

3. Measure the cam height A and B with a micrometer. If the measured value is less than the specified limit, the camshaft must be replaced.

Cam height (A - B) Inlet Standard: 7.851 mm (0.3091 in) Limit: 7.351 mm (0.2894 in) Exhaust Standard: 9.540 mm (0.3756 in) Limit: 9.040 mm (0.3559 in) CS01N711

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-31 4. Mount the camshaft on V-blocks.

Measure the run-out with a dial indicator at the No. 4 camshaft journal.

If the measured value exceeds the specified limit, the camshaft must be replaced.

Camshaft run-out Standard: 0.025 mm (0.0010 in) Limit: 0. 05 mm (0.0620 in)

CS01N712

5. Use an inside dial indicator to measure the camshaft bearing inside diameter.

Camshaft bearing inside diameter Standard: 40.0 - 40.04 mm (1.575 - 1.576 in) If the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit, the camshaft bearing must be replaced.

Camshaft bearing clearance Standard: 0.025 - 0.087 mm (0.00098 - 0.00342 in) CS01N713

Limit: 0.15 mm (0.0059 in)

REASSEMBLY 1. Install the gear alignment pin to the camshaft.

2. Install the camshaft gear to the camshaft. a. The gear hub large side must be facing the camshaft. b. Apply engine oil to the camshaft bolt threads and the setting faces. c. Tighten the camshaft gear bolt to the specified torque.

Torque: 142 Nm (14.5 kg.m/105 lb.ft) CS01N714

Cre 9-36560GB

Issued 01-02

6A-32 ENGINE MECHANICAL

CYLINDER HEAD

1

2

10 4 13

6 11

12

5 9

7 14

8

3

15

CS01N674

Legend (1)

Cylinder head cover

(8)

Glow plug connector

(2)

Gasket

(9)

Glow plug

(3)

Rubber plug

(10) Rocker arm assembly

(4)

Leak off pipe

(11) Bridge cap

(5)

Injection nozzle bracket

(12) Bridge

(6)

Injection nozzle

(13) Camshaft

(7)

Gasket

(14) Cylinder head (15) Head gasket

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-33

REMOVAL 1. Remove the head cover.

2. Remove the cylinder head cover gasket. Discard the gasket.

NOTE: Be careful not to lose the collars inserted into the cylinder head cover assembly.

3. Remove the rubber plug.

4. Remove the rocker arm shaft assembly.

Refer to "Rocker Arm Assembly Removal" in this manual.

5. Remove the camshaft with the gear.

CS01N686

Refer to "Camshaft Removal" in this manual.

6. Remove the leak off pipe.

7. Remove the injection nozzle holder.

8. Remove the glow plug connector.

• Remove the injection nozzles and glow plugs before removing the cylinder head.

9. Remove the bridge cap.

10. Remove the bridge.

NOTE: Keep the bridges in order for reassembly to their original positions.

CS01N715

11. Remove the cylinder head.

• Loosen the cylinder head bolts a little at a time in the numerical order shown in the illustration.

• Clean the cylinder head surfaces and remove the sealant residue.

CAUTION: Failure to loosen the cylinder head bolts in numerical order a little at a time will damage the cylinder head lower surfaces.

CS01N716

CAUTION: The idler gear C (1) projects from the cylinder head lower side and is easily damaged.

Great care must be taken to avoid damaging the idler gear C when the cylinder head is removed from the engine.

1

12. Remove the cylinder head gasket. Discard the gasket.

CS01N717

Cre 9-36560GB

Issued 01-02

6A-34 ENGINE MECHANICAL

INSTALLATION 1. Install the new cylinder head gasket.

• Clean the cylinder block surface and remove sealant residue.

• Apply ThreeBond No. 1207C or equivalent to the cylinder block and the timing gearcase fitting faces.

The sealant must be 2.0 mm (0.08 in) thick and 3.0 mm (0.12 in) wide.

The sealant must not obstruct the cylinder oil port.

CS01N718

• Install the new cylinder head gasket to the cylinder block.

2. Install the cylinder head assembly over the locating dowel pins.

• Carefully place the cylinder head on the cylinder head gasket.

• Apply molybdenum disulfide grease to the cylinder head bolts (M14) threads and setting faces.

• Apply engine oil to the cylinder head bolts (M10) (Number (1) to (26)) threads and setting faces.

• Tighten the M14 cylinder head bolts in three steps using the angular tightening method.

CS01N719

Follow the tightening order shown in the illustration.

• Tighten the M10 (Number (27) to (28)) cylinder head bolts to the specified torque.

NOTE: Cylinder head bolts can be reused 6 times before replacement.

Replace if any doubt exists.

M14 bolt Torque: 1st step 98 Nm (10 kg.m/72 lb.ft) 2nd step 147 Nm (15 kg.m/108 lb.ft) 3rd step 30 - 60 deg.

CS01N720

M10 bolt Torque: 38 Nm (3.9 kg.m/28 lb.ft) NOTE: Cover the timing gear hole with a clear cloth to prevent the entry of foreign material.

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-35 3. Install the camshaft with gear to the cylinder head.

Refer to "Camshaft Installation" in this manual.

CS01N706

4. Install the camshaft bearing caps.

CS01N705

5. Install the bridge caps. a. Apply engine oil to the bridge cap. b. Install the bridge cap to the bridge.

CS01N689

6. Install the rocker arm assembly.

Refer to "Rocker Arm Assembly Installation" in this manual.

CS01N687

Cre 9-36560GB

Issued 01-02

6A-36 ENGINE MECHANICAL 7. Install the glow plugs to the cylinder head.

Tighten the glow plugs to the specified torque.

Torque: 20 Nm (2.0 kg.m/14 lb.ft) 8. Install the glow plug connector.

CS01N721

9. Install the injection nozzle holders. a. Install the injection nozzle holders with the new gaskets to the cylinder head.

CAUTION: Take care not to damage the injection nozzle and gasket during nozzle holder installation. b. Install the nozzle holder flange to the nozzle holder bolts. c. Temporarily tighten the nozzle holder bolts.

The bolts will be finally tightened after injection pipe and leak off pipe installation.

CS01N722

10. Adjust the valve clearance.

Refer to "valve Clearance Adjustment" in this manual.

11. Install the rubber plugs. a. Apply Threebond 1207B or equivalent to the rubber plug as shown in the illustration. b. Install the rubber plugs to the cylinder head.

NOTE: If the cylinder head is to be reinstalled, be sure to remove, clean, and reseal the rubber plugs.

CS01N707

c. Apply ThreeBond 1207B or equivalent to the rubber plug surfaces.

NOTE: Immediately (within 10 minutes of applying the sealant) install the cylinder head cover to the cylinder head.

CS01N691

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-37 12. Install the cylinder head cover and gasket. a. Clean the head cover gasket groove and the head cover gasket. b. Install the new head cover gasket and collar to the head cover. c. Install the cylinder head cover to the cylinder head. d. Tighten the cylinder head cover bolts to the specified torque a little at a time in the numerical order shown in the illustration.

Torque: 13 Nm (1.3 kg.m/9.4 lb.ft) CS01N692

Cre 9-36560GB

Issued 01-02

6A-38 ENGINE MECHANICAL

DISASSEMBLY 25 24 12 4

14

11 13 10

3

8 19 6 7 19

2

1

17

15

23

5

22

9 16

18 20 21

CS01N704

Legend (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Cylinder head cover Oil seal Bridge guide Nozzle sleeve Valve seat insert Valve guide Lower spring seat Valve stem seal Valve Valve spring Upper spring seat Split collar Idler gear C

Cre 9-36560GB

(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)

Idler gear cover Gasket Thermostat Water outlet pipe Overheat warning switch Hanger Gasket Exhaust manifold Gasket Inlet cover Bridge Bridge cap

Issued 01-02

ENGINE MECHANICAL 6A-39 1. Remove the bridge cap and bridge.

NOTE: Keep the bridges and caps in order for reassembly to their original positions.

2. Remove the intake cover and gasket.

Discard the gasket.

3. Remove the exhaust manifold and gasket.

Discard the gasket.

1

4. Remove the overheat warning switch.

5. Remove the water outlet pipe.

6. Remove the thermostat and gasket.

Discard the gasket.

CS01N723

7. Remove the idle gear cover.

• Tap the outside of the cover with a screwdriver (1) to deform one end of it and pull it free with pliers.

NOTE: Do not scratch the sealing surfaces of the cylinder head.

8. Remove the idler gear C. 9. Remove the split collar. a. Place the cylinder head on a flat wooden surface. b. Use the valve spring compressor to remove the split collar.

Do not allow the valves to fall from the cylinder head.

CS01N724

10. Remove the spring seat, spring, valve stem seal, and lower spring seat.

CS01N725

Cre 9-36560GB

Issued 01-02

6A-40 ENGINE MECHANICAL 11. Remove the valve guide.

• Use the valve guide remover to remove the valve guide.

CS01N726

12. Remove the valve seat insert. a. Heat (about 600 - 700°C) two points on the valve seat insert with a gas torch and then allow the valve seat insert to cool for a few minutes. b. This will invite contraction and make removal of the valve seat insert easier. c. Use a screwdriver to pry the valve seat insert free. Take care not to damage the cylinder head.

CS01N727

d. Carefully remove carbon built-up and other foreign materials from the cylinder head insert bore.

13. Remove the injection nozzle sleeve.

Use the nozzle sleeve remover to drive the nozzle sleeve from the lower side cylinder head.

CS01N728

14. Remove the bridge guide.

The bolt is electrically welded to the bridge guide.

Use a sliding hammer to remove it.

CS01N729

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-41 15. Remove the injection pipe oil seal.

CS01N730

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Cylinder Head Cylinder Head Lower Face Warpage Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face.

CS01N731

If the measured values exceed the specified limit, the cylinder head must be replaced.

Cylinder Head Lower Face Warpage Standard: 0.05 mm (0.002 in) or less Limit: 0.20 mm (0.008 in) NOTE: Do not attempt to regrind the cylinder head lower face.

Check the cylinder head lower face for cracking and other damage.

A E

D

C

F

B

CS01N732

Cre 9-36560GB

Issued 01-02

6A-42 ENGINE MECHANICAL

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 as shown in the illustration.

Measuring Point: 10 mm (0.4 in) 3. Set the dial indicator needle to "0".

4. Move the valve head from side to side.

Read the dial indicator.

Note the highest dial indication.

CS01N733

If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set.

Valve Stem Clearance Intake Valve Standard: 0.04 - 0.07 mm (0.0016 - 0.0028 in) Limit: 0.20 (0.008 in) Exhaust Valve Standard: 0.06 - 0.10 mm (0.0024 - 0.0039 in) Limit: 0.25 mm (0.010 in) 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.

Valve Stem Outside Diameter

CS01N734

Measure the valve stem diameter at three points.

If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set.

Valve Stem Outside Diameter Intake Valve Standard: 8.95 - 8.96 mm (0.3524 - 0.3528 in) Limit: 8.88 mm (0.3496 in) Exhaust Valve Standard 8.92 - 8.94 mm (0.3512 - 0.3520 in) Limit: 8.88 mm (0.3496 in)

CS01N735

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-43 Valve Guide Replacement Valve Guide Removal Use a hammer and the valve guide replacer to drive the valve guide from the cylinder head lower face.

CS01N726

Valve Guide Installation 1. Apply engine oil to the valve guide outer circumference.

2. Set the ring to the valve guide replacer.

3. Attach the valve guide replacer with ring to the valve guide.

4. Use a hammer to drive the valve guide into position from the cylinder head upper face.

CS01N736

5. Measure the height of the valve guide upper end from the upper face of the cylinder head.

Valve Guide Upper End Height (Reference): 14.1 mm (0.56 in) NOTE: If the valve guide has been removed, both the valve and the valve guide must be replaced as a set.

CS01N737

Valve and Valve Seat Insert Valve Thickness Measure the valve thickness.

If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set.

Intake and Exhaust Valve Thickness Intake Valve Standard: 1.80 mm (0.071 in) Limit: 1.30 mm (0.051 in) Exhaust Valve

CS01N738

Standard: 1.80 mm (0.070 in) Limit: 1.30 mm (0.051 in)

Cre 9-36560GB

Issued 01-02

6A-44 ENGINE MECHANICAL Valve Depression 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.

Valve Depression Intake Valve Standard: 1.0 mm (0.039 in) Limit: 2.5 mm (0.098 in) CS01N739

Exhaust Valve Standard: 1.3 mm (0.051 in) Limit: 2.8 mm (0.110 in) Valve Contact Width 1. Check the valve contact faces for roughness and unevenness.

Make smooth the valve contact surfaces.

2. Measure the valve contact width.

If the measured value exceeds the specified valve contact width, the valve seat insert must be replaced.

Valve Contact Width

CS01N740

Intake Valve Standard: 2.5 mm (0.098 in) Exhaust Valve Standard: 2.0 mm (0.079 in) Valve Seat Insert Removal 1. Arc weld the entire inside circumference (1) of the valve seat insert (2).

2 3

2. Allow the valve seat insert to cool for a few minutes. This will invite contraction and make removal of the valve seat insert easier.

3. Use a screwdriver (3) to pry the valve seat insert free.

Take care not to damage the cylinder head (4).

1 4 CS01N741

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-45 Valve Seat Insert Installation

3

1. Carefully place the attachment (1) (having a smaller outside diameter than the valve seat insert) on the valve seat insert (2).

CAUTION: The smooth side of the attachment must contact the valve seat insert.

1

2

Carefully remove carbon built-up and other foreign material from the cylinder head Insert bore.

2. Use a bench press (3) to gradually apply pressure to the attachment and press the valve seat insert into place.

CS01N742

CAUTION: Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will result.

Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert surface.

2. Use a valve cutter (14, 45, 60 and 75 degree blades) to minimize scratches and other rough areas. This will bring the contact width back to the standard value of 90° (A).

Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface.

CS01N743

CS01N744

Cre 9-36560GB

Issued 01-02

6A-46 ENGINE MECHANICAL Valve Face Angle Intake and exhaust: 45 degree NOTE: Use an adjustable valve cutter pilot.

Do not allow the valve cutter pilot to wobble inside the valve guide.

Check that valve depression is within the specified limit after valve seat insert correction.

CS01N745

3. Apply abrasive compound to the valve seat insert surface.

4. Insert the valve into the valve guide.

5. Turn the valve while tapping it to fit the valve seat insert.

6. Check that the valve contact width is correct.

7. Check that the valve seat insert surface is in contact with the entire circumference of the valve.

CS01N746

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

Inner

53.2 (2.09)

52.1 (2.05)

Outer

55.6 (2.19)

54.5 (2.15)

Inner

61.3 (2.41)

60.1 (2.37)

Outer

72.0 (2.83)

70.5 (2.78)

Intake CS01N747

Exhaust

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-47 Valve Spring Squareness Use a surface plate and a square to measure the valve spring squareness.

If the measured value exceeds the specified limit, the valve spring must be replaced.

Inner and Outer Spring Squareness

mm (in)

Standard

Limit

Inner

2.30 (0.091)

3.0 (0.118)

Outer

2.40 (0.094)

3.4 (0.134)

Inner

2.70 (0.106)

3.0 (0.118)

Outer

3.10 (0.122)

3.4 (0.134)

Intake

CS01N748

Exhaust

Valve Spring Tension Use a spring tester to measure the valve spring tension.

If the measured value is less than the specified limit, the valve spring must be replaced.

Intake Valve Spring Tension

N (kg / lb)

Compression Height

Standard

Limit

Inner

44.5 mm (1.75 in)

112 (11.4/25)

93 (9.5/21)

Outer

47.0 mm (1.85 in)

239 (24.4/54)

201 (20.5/45)

CS01N749

Exhaust Valve Spring Tension

Cre 9-36560GB

N (kg / lb)

Compression Height

Standard

Limit

Inner

44.5 mm (1.75 in)

157 (16.0/35)

132 (13.5/30)

Outer

47.0 mm (1.85 in)

392 (40.0/88)

329 (33.5/74)

Issued 01-02

6A-48 ENGINE MECHANICAL

REASSEMBLY 1. Use the oil seal installer to install the oil seals to the cylinder head.

CS01N730

CS01N750

2. Tighten the engine hangers to the specified torque.

Torque: 95 Nm (9.6 kg.m/69 lb.ft)

CS01N751

3. Install the bridge guides to the cylinder head. a. Apply engine oil to the valve bridge guide outer circumference. b. Attach the valve bridge guide installer to the bridge guide. c. Use a brass hammer to tap the guide into position from the cylinder head upper face.

CS01N752

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-49 4. Install the injection nozzle sleeves to the cylinder head. a. Install the gasket (2) to the nozzle sleeve and apply engine oil. b. Apply sealer to the tapered part (1) of the nozzle sleeve.

1

LOCTITE No. TL290 c. Install the nozzle sleeve to the cylinder head and insert the guide sleeve. d. Push in the nozzle sleeve with the guide sleeve installer so that the bottom surface of the cylinder head is reached.

2

CS01N753

e. Insert the nozzle sleeve and fix it with the clamp and bolt. f. Press a 9.525 mm steel ball into the guide sleeve. Use a hammer and punch bar to drive the ball through the sleeve.

NOTE: • Remove chips from the threaded part of the cylinder head.

• Keep the cylinder head raised so that the ball can escape from the bottom surface.

CS01N754

5. Install the valve seat inserts into the cylinder head. a. Carefully place the attachment (1) (having a smaller outside diameter than the valve seat insert) on the valve seat insert (2).

3 1

NOTE: The smooth side of the attachment must contact the valve seat insert.

2

b. Use a bench press (3) to gradually apply pressure to the attachment and press the valve seat insert into place.

CS01N742

CAUTION: Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will result. c. The valve should be lapped before final assembly to ensure a good valve seal.

Refer to "Valve Seat Insert Correction" in this section.

Cre 9-36560GB

Issued 01-02

6A-50 ENGINE MECHANICAL 6. Install the valve guides into the cylinder head. a. Apply engine oil to the valve guide outer circumference. b. Attach the valve guide replacer to the valve guide. c. Use a hammer to drive the valve guide into position from the cylinder head upper face. d. Measure the height of the valve guide upper end from the upper face of the cylinder head.

Valve Guide Upper End Height (Reference): 19 mm (0.748 in) CS01N736

7. Install the spring seats.

8. Install the valve stem seals on the valve guide. a. Apply engine oil to the oil seal inner face. b. Use the oil seal installer to install the oil seal to the valve guide.

9. Install the valves.

Apply engine oil to the intake valves and exhaust valves.

CS01N755

10. Install the valve springs. a. Place the cylinder head on a flat wooden surface. b. Install the valve springs with their fine pitched end (painted) facing down.

Colored Intake Valve: Light blue Exhaust Valve: Yellow

CS01N756

11. Install the valve spring upper seats.

12. Install the split collars. a. Use the spring compressor to compress the valve spring. b. Install the split collars to the valve stem.

Do not allow the valve to fall from the cylinder head. c. Set the split collars by tapping around the head of each collar with a rubber hammer.

CS01N724

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-51 13. Install the idler gear C. a. Apply engine oil to the idler gear shaft and idler gear C bushing before installation. b. Install the idler gear C with the boss side facing the front of the engine as shown in the illustration.

Torque: 95 Nm (9.7 kg.m/70 lb.ft)

CS01N757

14. Install the sealing cup to the cylinder head. a. Apply LOCTITE No. 962T or equivalent to the sealing cup hole circumference. b. Drive the sealing cup into position from the cylinder head side as shown in the illustration.

CS01N758

15. Install the thermostats to the cylinder head. a. Install the thermostat gaskets (1) to the flange of thermostats.

1

b. Install the thermostat (without jiggle valve) (2) and thermostat (with jiggle valve) (3) to the cylinder head.

2

NOTE: The jiggle valves of the thermostat must be facing the rear of the engine.

3

CS01N759

16. Install the water outlet pipe to the cylinder head.

Tighten the water outlet pipe bolts to the specified torque.

Torque: 19 Nm (1.9 kg.m/14 lb.ft)

CS01N760

Cre 9-36560GB

Issued 01-02

6A-52 ENGINE MECHANICAL 17. Install the exhaust manifold gaskets.

Install the gasket with the protruding part of the gasket facing down.

NOTE: Check and see that the gasket is correctly installed to the cylinder head. The gasket, if installed in the wrong way, can overlap the casting skin of the cylinder head.

CS01N761

18. Install the exhaust manifold to the cylinder head. a. Install the three gas seal rings to the rear exhaust manifold.

Position the ring gaps 120 degrees apart from each other.

NOTE: Be absolutely sure that the gaskets are correctly installed to the cylinder head. An incorrectly installed gasket will result in engine damage. b. Install the front exhaust manifold to the rear exhaust manifold. c. Install the exhaust manifold to the cylinder head.

CS01N658

1

2

d. Install the distance tube (1) and washer (2) to the stud bolts. e. Install the distance tube (1), washer (2), and distance nut to the stud bolt at the front side of No. 5 cylinder (arrow "A" mark). f. Tighten the exhaust manifold nuts to the specified torque.

4 3

1

Torque: 34 Nm (3.5 kg.m/25 lb.ft)

CS01N659

CS01N660

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-53 19. Install the intake cover with new gasket to the cylinder head. a. Install the intake cover bolts with the distance pipe and the mounting rubber. b. Tighten the intake cover bolts to the specified torque a little at a time in the numerical order shown in the illustration.

Torque: 15 Nm (1.5 kg.m/11 lb.ft)

CS01N762

20. Install the intake pipe with new gasket to the intake cover.

Tighten the intake pipe bolts to the specified torque.

Torque: 15 Nm (1.5 kg.m/11 lb.ft)

CS01N662

21. Install the bridge to the bridge guide.

• Apply engine oil to the bridge.

22. Install the bridge cap to the bridge.

• Apply engine oil to the bridge cap.

CS01N763

Cre 9-36560GB

Issued 01-02

6A-54 ENGINE MECHANICAL

CRANK PULLEY AND FLYWHEEL

3

2

1

6

5

4 CS01N764

Legend (1)

Crank pulley

(4)

Ring gear

(2)

Damper

(5)

Flywheel

(3)

Crankshaft

(6)

Washer

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-55

REMOVAL 1. Remove the cooling fan.

2. Remove the fan belts.

3. Remove the crankshaft damper pulley from the crankshaft.

• Block the crankshaft with a piece of hard wood to prevent the damper pulley from turning.

• Diagonally loosen the damper pulley bolts.

4. Remove the flywheel from the crankshaft.

INSTALLATION

CS01N765

1. Install the crankshaft damper pulley from the crankshaft. a. Apply engine oil to the threads and setting faces of the crankshaft damper pulley bolts. b. Block the crankshaft with a piece of hard wood to prevent the damper pulley from turning. c. Install the crankshaft damper pulley. Use the locating dowel pin. d. Tighten the crankshaft damper pulley bolts to the specified torque a little at a time in the numerical order shown in the illustration.

Torque: 200 Nm (20.4 kg.m/148 lb.ft)

CS01N766

CS01N767

2. Install the flywheel and washer to the crankshaft. a. Block the crankshaft with a piece of hard wood to prevent the flywheel from turning. b. Apply molybdenum disulfide grease to the flywheel bolt threads. c. Install the flywheel. Use the locating pin. d. Tighten the fixing bolts to the specified torque in three steps.

Follow the numerical order shown in the illustration.

Torque: 1st step: 78 Nm (8.0 kg.m/58 lb.ft) 2nd step: 60 deg.

3rd step: 60 - 90 deg.

NOTE: The flywheel housing bolts can be reused 6 times.

3. Install the fan belts.

4. Adjust the fan belt tension.

Cre 9-36560GB

Issued 01-02

6A-56 ENGINE MECHANICAL

DISASSEMBLY Ring Gear 1. Strike around the edges of the ring gear with a hammer and brass bar to remove it.

Damper 1. Remove the damper from the crankshaft pulley.

CS01N768

INSPECTION AND REPAIR 1. Inspect the ring gear for damage or excessive wear. If the ring gear teeth are broken or excessively worn the ring gear must be replaced.

CS01N769

2. Inspect the crankshaft damper for cracking or separation. If any abnormality on the crankshaft damper is found, inspect the crankshaft and the flywheel fixing bolts.

CS01N770

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-57

REASSEMBLY Ring Gear 1. Install the ring gear to the flywheel. a. Heat the ring gear evenly with a gas burner to invite thermal expansion.

Do not allow the temperature of the gas burner to exceed 200°C (390°F).

WARNING: Take care not to burn yourself on the heated ring gear.

2. Install the ring gear when it is sufficiently heated.

The ring gear must be installed with the chamfer facing outside.

CS01N771

3. Install the damper to the crankshaft pulley.

Diagonally tighten the damper fixing bolts to the specified torque.

Torque: 48 Nm (4.9 kg.m/35 lb.ft)

CS01N772

Cre 9-36560GB

Issued 01-02

6A-58 ENGINE MECHANICAL

TIMING GEARS

11

10

9

14 13

3

6

12

8

1

7 5

4

2

CS01N773

Legend (1)

Washer

(8)

Slinger

(2)

Flywheel

(9)

Idler gear shaft A

(3)

Cover

(10) Idler gear A

(4)

Idler gear D

(11) Thrust collar

(5)

Idler gear shaft D

(12) Oil pump

(6)

Flywheel housing

(13) Idler gear B

(7)

Oil seal

(14) Idler gear shaft B

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-59

REMOVAL 1. Remove the flywheel housing.

Refer to "Flywheel Housing Removal" in this manual.

2. Measure the idler gear backlash. a. Set a dial indicator to the idler gear.

Hold both the gear to be checked and the adjoining gear stationary.

Move the gear to be checked as far as possible both to the right and to the left.

Take the dial indicator reading.

CS01N774

If the measured value exceeds the specified limit, the idler gear must be replaced.

Idler Gear Backlash Standard: 0.10 - 0.17 mm (0.0039-0.0067 in) Limit: 0.30 mm (0. 12 in) 3. Measure the gear end play.

Insert a feeler gauge between the idler gear and the thrust collar to measure the gap and determine the idler gear end play.

If the measured value exceeds the specified limit, the idler gear must be replaced.

Idler Gear End Play Standard: 0.08 - 0.14 mm (0.0032 - 0.0055 in) Limit: 0.20 mm (0.008 in) 4. Remove the idler gear A, shaft, and thrust collar.

Inspect the idler gear for damage or wear.

CS01N775

Inspect the thrust collar for wear.

5. Remove the oil pump from the cylinder block.

Inspect the gear shaft for abnormal play.

Clean the fitting surfaces of the oil pump and remove the sealant residue.

6. Remove the idler gear B, shaft, and thrust collar.

Inspect the idler gear for damage or wear.

Inspect the shaft and thrust collar for wear.

Clean the front surfaces of the cylinder block and remove the sealant residue.

Cre 9-36560GB

Issued 01-02

6A-60 ENGINE MECHANICAL

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

1. Use a micrometer to measure the idler gear shaft outside diameter.

If the measured value is less than the specified limit, the idler gear shaft and/or shaft must be replaced.

Idler gear shaft outside diameter Shaft A, B and C CS01N776

Standard: 29.959 - 29.980 mm (1.1795 - 1.1803 in) Limit: 29.9 mm (1.1772 in) 2. Use an inside dial indicator or an inside micrometer to measure the idler gear inside diameter.

If the clearance between the idler gear shaft outside diameter and the idler gear inside diameter exceeds the limit, the idler gear and/or shaft must be replaced.

Idler gear shaft and Idler gear clearance Shaft A, B and C Standard: 0.020 - 0.062 mm (0.0008 - 0.0024 in) Limit: 0.2 mm (0.008 in)

CS01N582

INSTALLATION 1. Install the idler gear B shaft. a. Install the idler gear B shaft to the cylinder body.

The idler gear shaft oil port must be facing the cylinder head. b. Tighten the idler gear shaft bolts to the specified torque.

Torque: 24 Nm (2.4 kg.m/17 lb.ft)

CS01N777

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-61 2. Install the idler gear B to the idle gear shaft. a. Apply engine oil to the idler gear B inside and thrust areas. b. Install the idler gear to the idler gear shaft. c. Tighten the idler gear bolts to the specified torque.

Torque: 95 Nm (9.7 kg.m/70 lb.ft)

CS01N778

3. Install the oil pump to the cylinder block. a. Carefully wipe any foreign material from the cylinder body rear surface. b. Apply engine oil to the cylinder body inside bushing.

CS01N779

c. Apply ThreeBond No. 1141E or equivalent to the shaded areas shown in the illustration.

CAUTION: The sealant must not obstruct the gear and oil ports (indicated by arrows). d. Install the oil pump to the cylinder body within 15 minutes of sealant application. e. Tighten the oil pump bolts to the specified torque.

Torque: 24 Nm (2.4 kg.m/17 lb.ft)

CS01N780

4. Install the idler gear A and idler gear shaft to the cylinder block. a. Install the idler gear shaft (1) to the cylinder body.

The idler gear shaft oil port must be facing the cylinder head.

1

b. Apply engine oil to the idler gear A inside and thrust areas.

CS01N781

Cre 9-36560GB

Issued 01-02

6A-62 ENGINE MECHANICAL c. Install the idler gear A (1) to the idler gear shaft. d. Align the crankshaft gear (2) L mark and the idler gear (1) 0 marks.

2

e. Tighten the idler gear bolts to the specified torque.

Torque: 133 Nm (13.6 kg.m/98 lb.ft)

1

CS01N782

5. Install the flywheel housing. a. Apply ThreeBond No. TB1201 (or T131207C) or equivalent to the flywheel housing fitting faces and the area marked with an arrow in the illustration.

X: Do not apply sealant. b. Install the flywheel housing to the cylinder block.

Refer to "Flywheel Housing Installation" in this manual.

X

CS01N783

6. Install the idler gear D to the cylinder block. a. Apply engine oil to the idler gear shaft (2).

1

b. Apply engine oil to the idler gear (1) inside and thrust areas. c. Install the gear to the gear shaft. d. Install the gear and shaft to the cylinder block. e. Tighten the bolts over the thrust collar to the specified torque.

Torque: 119 Nm (12.1 kg.m/88 lb.ft)

2

CS01N784

7. Install the cover with new gasket to the flywheel housing.

8. Install the rear oil seal.

Refer to "Flywheel Housing Installation" in this manual.

9. Install the flywheel to the crankshaft.

Refer to "Flywheel Installation" in this manual.

CS01N785

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-63

FLYWHEEL HOUSING

3

6

8

1

7 5

2

4

CS01N773

Legend (1)

Washer

(5)

Idler gear shaft D

(2)

Flywheel

(6)

Flywheel housing

(3)

Cover

(7)

Oil seal

(4)

Idler gear D

(8)

Oil slinger

Cre 9-36560GB

Issued 01-02

6A-64 ENGINE MECHANICAL

REMOVAL 1. Remove the oil pan.

Refer to "Oil Pan Removal" in this manual.

2. Loosen the flywheel fixing bolts to remove the flywheel. a. Block the crankshaft with a piece of hard wood to prevent the flywheel from turning. b. Loosen the flywheel bolts a little at a time in the numerical order shown in the illustration.

CS01N767

3. Remove the cover for the idler gear D and the gasket.

Discard the gasket 4. Loosen the idler gear shaft bolt.

5. Remove the idler gear and shaft.

Inspect the idler gear for damage or wear.

6. Remove the idler gear shaft supporting bolts.

7. Loosen the flywheel housing fixing bolts to remove the flywheel housing.

8. Remove the rear oil seal.

CS01N786

9. Use the slinger remover to remove the slinger.

Take care not to damage the crankshaft.

1

CAUTION: Be careful not to damage the crankshaft oil seal contact surface during the removal procedure.

2

NOTE: if the oil seal has been removed, both the oil seal and slinger must be replaced as a set.

CS01N787

CS01N788

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-65

INSTALLATION 1. Install the flywheel housing to the cylinder block. a. Apply ThreeBond No. TB1201 or TB1207C or equivalent to the flywheel housing fitting faces and the area marked with an arrow in the illustration. b. Tighten the flywheel housing bolts to the specified torque.

Torque: Bolt A: 73 Nm (7.4 kg.m/54 lb.ft) Bolt B: 96 Nm (9.8 kg.m/71 lb.ft) Bolt C: 73 Nm (7.4 kg.m/54 lb.ft) CS01N789

Bolt D: 87 Nm (8.9 kg.m/64 lb.ft) Bolt E: 119 Nm (12.1 kg.m/88 lb.ft) Bolt F: 26 Nm (2.7 kg.m/20 lb.ft) NOTE: • Mark B and D: Tighten the bolts together with washers.

• Mark G: Tighten from the cylinder block side.

2. Install the idler gear shaft to the cylinder block. a. Apply engine oil to the idler gear shaft D. b. Apply engine oil to the inside diameter and thrust portion of the idler gear D.

1

c. Install the idler gear with the shaft and the thrust collar. d. Tighten the idler gear shaft bolts to the specified torque.

Torque: 119 Nm (12.1 kg.m/88 lb.ft) 2 CS01N784

3. Install the cover with new gasket.

CS01N785

Cre 9-36560GB

Issued 01-02

6A-66 ENGINE MECHANICAL 4. Install the rear slinger using the oil seal installer. a. Install the slinger (1) to the end of adapter (2).

1

Install the adapter to the crankshaft (3).

3

4

NOTE: The rear slinger is gray and the front slinger is black.

5

b. Install the slinger sleeve (4) to the adapter.

Tighten the center bolt (5) until the sleeve comes in contact with the adapter stopper.

2

CS01N790

c. After pressing in the slinger, make sure that the distance between crankshaft end surface and the slinger is A as specified.

Distance (A): 16.7 - 17.3 mm (0.657 - 0.681 in) NOTE: Be sure to replace the slinger and oil seal as a set.

CS01N791

5. Use the oil seal installer to install the oil seal. a. Apply engine oil to the oil seal lip.

Do not allow engine oil to come in contact with the outside oil seal and felt ring. b. Insert the oil seal (1) into the adapter (2). c. Insert the oil seal sleeve (3) to the adapter. d. Tighten the center bolt until the sleeve comes into contact with the adapter stopper. e. After pressing the oil seal, make sure that the distance between crankshaft end surface and the oil seal is B as specified.

CS01N792

Distance (B): 7.35 - 7.65 mm (0.289 - 0.301 in)

1

2

3

B

CS01N793

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-67 6. Install the flywheel and washer to the crankshaft. a. Block the crankshaft with a piece of hard wood to prevent the flywheel from turning. b. Apply molybdenum disulfide grease to the flywheel bolt threads. c. Install the flywheel. Use the locating pin. d. Tighten the fixing bolts to the specified torque in three steps.

Follow the numerical order shown in the illustration.

Torque: 1st step: 78 Nm (8.0 kg.m/58 lb.ft) CS01N794

2nd step: 60 deg.

3rd step: 60 - 90 deg.

NOTE: The flywheel housing bolts can be reused 6 times before replacement.

7. Install the oil pan with new gasket to the cylinder block.

Refer to "Oil Pan Installation" in this manual.

CS01N767

Cre 9-36560GB

Issued 01-02

6A-68 ENGINE MECHANICAL

OIL PAN

5 4

3

2

1 CS01N795

Legend (1)

Clip

(4)

Oil strainer

(2)

Oil pan

(5)

Gasket

(3)

Gasket

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-69

REMOVAL 1. Remove the breather hose clip.

2. Loosen the fixing nuts and bolts to remove the oil pan and gasket.

• Clean the lower cylinder block surfaces and remove the sealant residue.

3. Discard the oil pan gasket.

4. Remove the oil strainer from the cylinder block.

Clean the oil strainer.

CS01N796

INSTALLATION 1. Install the oil strainer with new gasket.

• Tighten the fixing bolts to the specified torque.

Torque: M8 Bolt: 24 Nm (2.4 kg.m/17 lb.ft) M10 Bolt: 48 Nm (4.9 kg.m/35 lb.ft)

CS01N797

2. Apply a 3 mm bead of sealant (ThreeBond No. 1207C or equivalent) to the cylinder block and flywheel housing fitting faces (1) and the crankcase fitting faces (2).

2

NOTE: Do not damage the oil pan gasket as it is coated with rubber.

3. Install the oil pan with new gasket to the cylinder block.

• Tighten the oil pan nuts and bolts to the specified torque.

Torque: 24 Nm (2.4 kg.m/17 lb.ft)

1 CS01N798

Cre 9-36560GB

Issued 01-02

6A-70 ENGINE MECHANICAL

FRONT COVER

3 4 5

2 1

7

6

8

CS01N799

Legend (1)

Damper pulley

(5)

Gasket

(2)

Oil seal

(6)

Slinger

(3)

Adjusting plate

(7)

Crankshaft

(4)

Front plate

(8)

Crankcase

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-71

REMOVAL 1. Remove the water pump.

Refer to "Water Pump Removal" in this manual.

2. Remove the alternator.

Refer to "Alternator Removal" to this manual.

3. Remove the adjusting plate from the front cover.

4. Remove the crankshaft damper pulley from the crankshaft.

• Block the crankshaft with a piece of hard wood to prevent the damper pulley from turning.

• Diagonally loosen the damper pulley bolts.

CS01N765

5. Remove the front plate.

• Insert bolts into the remover holes on the front plate to remove it.

6. Remove the front oil seal from the front plate.

• Use a screwdriver to pry the oil seal from the front plate.

• Take care not to damage the oil seal fitting faces.

CS01N800

7. Use the slinger remover to remove the slinger.

• Discard the removed oil seal and slinger.

NOTE: If the oil seal has been removed, both the oil seal and slinger must be replaced as a set.

CS01N801

Cre 9-36560GB

Issued 01-02

6A-72 ENGINE MECHANICAL

INSTALLATION 1. Install the front cover to the cylinder block. a. Apply a 2 - 3 mm bead of sealant ThreeBond 1207C or equivalent to the front cover grooves. b. Install the gasket (1). c. Immediately (within 10 minutes of applying the sealant) set the front cover to the cylinder block.

1

CS01N802

d. Tighten the front cover bolts to the specified torque.

Torque: 19 Nm (1.9 kg.m/14 lb.ft)

CS01N803

2. Install the adjusting plate to the front plate.

CS01N804

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-73

4 A 3 5 2

1 CS01N805

3. Install the slinger to the crankshaft.

• Use the oil seal installer to install the slinger.

NOTE: The front slinger is black and the rear slinger is gray. a. Insert the slinger (1) to the end of adapter (2), and install the adapter to the crankshaft. b. Install the slinger sleeve (4) to the adapter and tighten the center bolt (5) until the sleeve comes into contact with the adapter stopper (marked with an arrow). c. After pressing in the slinger, make sure that the distance between the crankshaft end surface and the slinger is the specified value.

Distance (A): 17.7 - 18.3 mm (0.70 - 18.3 in) NOTE: Be sure to replace the slinger and oil seal as a set.

4. Install the front oil seal to the front plate.

Use the oil seal installer kit to install the oil seal. a. Apply engine oil to the oil seal lip. b. insert the oil seal (1) into the adapter (2). c. Install the oil seal sleeve (3) to the adapter. d. Tighten the center bolt until the sleeve comes into contact with the adapter stopper (marked with an arrow). e. After pressing in the oil seal, make sure that the distance between the crankshaft end surface and oil seal (B) is the specified value.

Distance (B): 8.35 - 8.65 mm (0.33 - 0.34 in)

1 2 B

3

CS01N806

Cre 9-36560GB

Issued 01-02

6A-74 ENGINE MECHANICAL 5. Install the crankshaft damper pulley to the crankshaft. a. Apply engine oil to the threads and setting faces of the crankshaft damper pulley bolts. b. Block the crankshaft with a piece of hard wood to prevent the damper pulley from turning. c. Install the crankshaft damper pulley. Use the locating dowel pin. d. Tighten the crankshaft damper pulley bolts to the specified torque a little at a time in the numerical order shown in the illustration.

Torque: 200 Nm (20.4 kg.m/148 lb.ft) CS01N765

6. Install the water pump to the front plate.

Refer to "Water Pump Installation" in this manual.

7. Install the alternator.

Refer to "Alternator Installation" in this manual.

8. Adjust the fan belt tension.

CS01N766

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-75

PISTON

4 3

1 2

CS01N807

Legend (1)

Bearing cap

(3)

Bearings

(2)

Bolt

(4)

Piston with connecting rod

Cre 9-36560GB

Issued 01-02

6A-76 ENGINE MECHANICAL

REMOVAL 1. Remove the cylinder head assembly.

Refer to "Cylinder Head Removal" in this manual.

2. Remove the oil pan.

Refer to "Oil Pan Removal" in this manual.

3. Remove the piston with connecting rod. a. Remove carbon deposits from the upper position of the cylinder wall with a scraper.

CS01N808

b. Loosen the connecting rod cap bolts. c. Move the piston to the top of the cylinder and tap it with a hammer grip or similar object from the connecting rod lower side to drive it out.

CAUTION: Take care not to damage the oil jets.

4. Remove the connecting rod bearings.

• Keep the connecting rod bearings in order for reinstallation to their original positions.

• Inspect the connecting rod bearings for damage and wear.

CS01N809

INSTALLATION 1. Install the piston with connecting rod. a. Clean the piston in solvent to remove all sludge. b. Wipe away any foreign material in the cylinder bores and on the pistons and connecting rods. c. Install the upper connecting rod bearings to the connecting rods. d. Install the lower connecting rod bearings to the bearing caps. e. Apply engine oil to the cylinder wall, upper/ lower bearing surfaces and crank pins of the crankshaft.

CS01N810

Apply engine oil to the entire circumference of the piston rings. f. Position the piston ring gap as shown in the illustration.

Gap position: (1)

1st compression ring

(2)

2nd compression ring

(3)

3rd compression ring

(4)

Oil ring

(5)

Coil expander

CS01N811

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-77 2. Position the piston head front mark (1) so that it is facing the front of the engine.

NOTE: The connecting rod forging mark (projecting) (2) must be facing the opposite direction.

1

2

CS01N812

3. Apply engine oil or molybdenum disulfide grease to the piston skirt.

4. Bring the piston to which the crankpin is to be installed to top dead center.

5. Use a piston setting tool to install the piston with connecting rod to the cylinder block. At this time, rotate the crankshaft until the piston is at bottom dead center.

CAUTION: Do not bend or damage the oil jet.

CS01N813

6. Apply molybdenum disulfide grease to the threads and setting faces of each connecting rod bolt.

7. Install the connecting rod bearing cap.

8. Align the bearing cap cylinder number mark and the connecting rod cylinder number mark.

9. Tighten the connecting rod cap bolts in three steps using the angular tightening method.

Torque: 1st step: 39 Nm (4.0 kg.m/29 lb.ft) 2nd step: 60 deg.

CS01N814

3rd step: 30 - 60 deg. a. Check that the crankshaft rotates smoothly. b. Install the oil pan to the cylinder block.

Refer to "Oil Pan Installation" in this manual. c. Install the cylinder head to the cylinder block.

Refer to "Cylinder Head Installation" in this manual.

Cre 9-36560GB

Issued 01-02

6A-78 ENGINE MECHANICAL

DISASSEMBLY

1 2

4 3 2

5

7

6

CS01N815

Legend (1)

Piston rings

(5)

Connecting rod

(2)

Snap ring

(6)

Connecting rod cap

(3)

Piston pin

(7)

Bearings

(4)

Piston

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-79 CAUTION: Do not bend or damage the oil jet.

NOTE: When removing the piston and connection rod assembly, pull the connecting rod parallel to the cylinder bore.

1. Remove the connecting rod cap.

2. Remove the bearings.

• Take out the connecting rod bearing cap bolts and disassemble the bearing cap with the lower bearing.

• Keep the connecting rod bearings in order for reinstallation to their original position.

3. Remove the piston rings.

CS01N816

• Clamp the connecting rod in a vise.

Take care not to damage the connecting rod.

• Use a piston ring replacer to remove the piston rings.

Do not use some other tool to remove the piston rings. Piston ring stretching will result in reduced piston ring tension.

4. Remove the snap ring (1).

Use a pair of snap ring pliers to remove the snap rings.

5. Remove the piston pin.

6. Remove the piston.

7. Remove the connecting rod.

Tap out the piston pin with a hammer and a brass bar.

Keep the piston and piston rings in order for installation to their original position.

1 CS01N817

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Piston Ring Gap 1. Insert the piston ring horizontally (in the position it would assume if it were installed to the piston) into the cylinder liner bore.

2. Push the piston ring into the cylinder liner bore until it reaches the point where the cylinder liner bore is the smallest.

CS01N818

Cre 9-36560GB

Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal.

Issued 01-02

6A-80 ENGINE MECHANICAL 3. Use a feeler gage to measure the piston ring gap.

If the measured value exceeds the specified limit, the piston ring must be replaced.

Piston ring gap 1st ring: Standard: 0.18 - 0.28 mm. (0.0071 - 0.0110 in) Limit: 1.2 mm (0.047 in) 2nd, 3rd ring: Standard: 0.35 - 0.50 mm (0.0138 - 0.0197 in) Limit: 1.2 mm (0.047 in) Oil ring: CS01N819

Standard: 0.15 - 0.35 mm (0.0059 - 0.0138 in) Limit: 1.2 mm (0.047 in)

Piston Ring and Piston Ring Groove Clearance

1

1. Visually inspect the piston ring grooves.

If a piston ring groove is damaged or distorted, the piston must be replaced.

2. Use a feeler gauge (1) to measure the clearance between the piston ring and the piston ring groove at several points around the piston.

2

3. When measuring the clearance for the 1st piston ring, press the 1st piston ring with a straight gauge (2) as shown in the illustration.

CS01N820

Piston ring and piston ring groove clearance 1st ring: Standard: 0.057 - 0.097 mm (0.0022 - 0.0038 in) Limit: 0.2 mm (0.0079 in) 2nd, 3rd ring: Standard: 0.085 - 0.120 mm (0.0033 - 0.0047 in) Limit: 0.20 mm (0.787 in) Oil ring: Standard: 0.020 - 0.060 mm (0.0008 - 0.0024 in) Limit: 0.15 mm (0.0059 in)

CS01N821

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-81

Piston Ring Expansion Force Use an expansion force gauge to measure the piston ring expansion force.

Piston, ring expansion force 1st ring: Standard: 22.7 - 30.7 N (2.31 - 3.13 kg/5.09 - 6.90 lb) Limit: 12 N (1.2 kg/2.6 lb) 2nd ring: Standard: 16.7 - 22.6 N (1.70 - 2.30 kg/3.74 - 5.07 lb) Limit: 5.9 N (0.6 kg/1.3 lb) 3rd ring: Standard: 20.8 - 28.2 N (2.12 - 2.08 kg/4.67 - 4.59 lb) Limit: 4.9 N (0.5 kg/1.1 lb) Oil ring: Standard: 43.0 - 58.1 N (4.38 - 5.92 kg/9.66 - 13.0 lb) Limit: 41 N (4.2 kg/9.3 lb)

Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points.

If the measured value is less than the specified limit, the piston pin must be replaced.

Piston pin diameter Standard: 39.995 - 36.000 mm (1.5746 - 1.4173 in) Limit: 35.95 mm (1.4154 in)

Piston Pin Hole and Piston Pin Clearance CS01N822

Use a inside dial indicator to measure the piston pin hole (in the piston).

Piston pin hole and piston pin clearance Standard: 0.004 - 0.017 mm (0.0003 - 0.0008 in)

Piston Pin and Connecting Rod Small End Bushing Clearance Use a caliper and dial indicator to measure the clearance between the piston pin and connecting rod small end bushing.

CS01N823

Cre 9-36560GB

If the clearance between the piston pin and the connecting rod small end bushing exceeds the specified limit, replace the piston pin and/or the connecting rod assembly.

Small end bushing clearance Standard: 0.012 - 0.027 mm (0.00047 - 0.0011 in) Limit: 0.05 mm (0.0020 in) Issued 01-02

6A-82 ENGINE MECHANICAL

Connecting Rod Alignment Use a connecting rod aligner to measure the distortion and the parallelism between the connecting rod big end hole and the connecting rod small end hole.

If either the measured distortion or parallelism exceeds the specified limit, the connecting rod must be replaced.

Connecting rod alignment Per length of 100 mm (3.94 in) Standard: 0,05 mm (0.002 in) or less Limit: 0.20 mm (0.008 in) CS01N824

Crankshaft and Connecting Rod Bearing Clearance 1. Clean the crankshaft, connecting rod, bearing cap, and bearings.

2. Install the bearing to the connecting rod and bearing cap.

3. Apply a coat of molybdenum disulfide grease to the bearing cap bolt threads and setting faces.

4. Prevent the connecting rod from moving.

CS01N825

5. Tighten the bearing cap to the specified torque.

Connecting rod bearing cap bolt torque.

1st step: 39 Nm (4.0 kg.m/29 lb.ft) 2nd step: 60 deg.

3rd step: 30 - 60 deg.

6. Use a dial indicator to measure the connecting rod bearing inside diameter.

Crankpin and connecting rod bearing clearance Standard: 0.037 - 0.070 mm (0.0015 - 0.0030 in) Limit: 0.1 mm (0.0034 in) 7. If the clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or crankshaft must be replaced.

Connecting Clearance

Rod

and

Crankshaft

1. Fix the connecting rod assembly to the crankshaft using the specified torque.

2. Use a feeler gauge to measure the clearance between the connecting rod and crankshaft.

If the measured value exceeds the specified limit, the connecting rod must be replaced.

Connecting rod and crankshaft clearance Standard: 0.17 - 0.30 mm (0.0067 - 0.0118 in) Limit 0.35 mm (0.0138 in) CS01N826

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-83

Piston and Liner Bore Clearance If the cylinder liner has been replaced, install the piston using service parts. The cylinder liner bore and pistons have only one grade. It is not necessary to select the piston grade.

1. Measure the cylinder liner bore. (Reference) Refer to the "Cylinder Liner Bore Measurement."

Measuring Point 130 mm (5.118 in) Cylinder liner bore Standard: 115.031 - 115.050 mm (4.5288 - 4.5295 in) CS01N827

2. Measure the piston outside diameter (Reference).

Piston Measuring Point: 80 mm (3.15 in) The grade mark is stamped on the top of the piston installed at the factory, but service part pistons do not have any grade (single grade).

Piston outside diameter Standard: 114.894 - 114.909 mm (4.5233 - 4.5240 in) Piston and Liner bore clearance Standard: 0.122 - 0.156 mm (0.0048 - 0.0061 in) CS01N828

If the piston and liner clearance exceeds the standard value, the piston and/or liner must be replaced.

CAUTION: Cylinder liner kit clearances are preset.

However, the cylinder liner installation procedure may result in slight decreases in cylinder liner clearances. Always measure the cylinder liner clearance after installation to be sure that it is correct.

REASSEMBLY 1. Install the snap ring (1).

Use a pair of snap ring pliers to reassemble the snap ring to the piston.

2. Install the connecting rod and piston pin.

• Clamp the connecting rod in a vise.

Take care not to damage the connecting rod.

• Install the piston so that the piston head front mark and the connecting rod front mark face the opposite direction.

1

• Apply engine oil to the piston pin.

CS01N817

• Insert the piston pin to the connecting rod through the piston pin hole in the piston.

• Install the snap ring.

Cre 9-36560GB

Issued 01-02

6A-84 ENGINE MECHANICAL 3. Install the piston ring.

• Apply engine oil to the piston rings.

• Install the compression rings with the stamped side facing up.

• Use the piston ring setting tool to reassemble the four piston rings according to the top mark on the piston ring.

The oil ring does not have a top mark.

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.

CS01N829

• Check that the piston rings rotate smoothly in the piston ring grooves.

4. Install the connecting rod bearing.

Carefully wipe any oil or other foreign material from the connecting rod bearing back faces and the bearing fitting surfaces.

CS01N816

5. Install the connecting rod cap.

• Fit the lower connecting rod bearing to the connecting rod cap.

• Apply engine oil to the circumference of each piston ring, piston and crankpin.

• Position the piston ring gaps as shown in the illustration.

Gap position

CS01N811

(1)

1st compression ring

(2)

2nd compression ring

(3)

3rd compression ring

(4)

Oil ring

(5)

Coil expander

• Apply molybdenum disulfide grease to the two piston skirts.

1

This will facilitate smooth break-in when the engine is first started after reassembly.

• Apply engine oil to the upper connecting rod bearing.

• Apply engine oil to the cylinder wall.

• Position the front mark (1) on the piston head so that it is facing the front of the engine.

CS01N812

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-85 • Use the piston ring setting tool to compress the piston rings.

• Use a hummer grip to push the piston in until the connecting rod marks contact the crankpin.

As the same time, rotate the crankshaft until the crankpin is at bottom dead center.

CAUTION: Do not bend or damage the oil jet.

CS01N813

• Align the connecting rod cap cylinder number marks and the connecting rod cylinder number marks.

• Install the connecting rod caps.

• Apply molybdenum disulfide grease to the threads and setting faces of each connecting rod bolt.

• Tighten the connecting rod bolts to the specified torque.

Torque: 1st step: 39 Nm (4.0 kg.m/29 lb.ft) CS01N814

2nd step: 30° 3rd step: 30 - 60°

CS01N809

Cre 9-36560GB

Issued 01-02

6A-86 ENGINE MECHANICAL

CRANKSHAFT

3 4 5

7 2 1

6

8

9

11

12

10

13

CS01N807

Legend (1)

Crank pulley

(7)

Connecting rod bearing

(2)

Oil seal

(8)

Thrust bearings

(3)

Adjusting plate

(9)

Thrust bearings

(4)

Front cover

(10) Crank bearings

(5)

Gasket

(11) Crankshaft

(6)

Piston with connecting rod

(12) Slinger (13) Crankcase

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-87

REMOVAL 1. Remove the cylinder head assembly.

Refer to "Cylinder Head Removal" in this manual.

2. Remove the oil pan.

Refer to "Oil Pan Removal" in this manual.

3. Remove the flywheel housing.

Refer to "Flywheel Housing Removal" in this manual 4. Remove the crank pulley.

Refer to "Crank Pulley Removal" in this manual.

5. Remove the front cover.

Refer to "Front Cover Removal" in this manual.

6. Remove the timing gears.

Refer to "Timing Gear Removal" in this manual.

7. Remove to the piston with the connecting rod.

Refer to "Piston Removal" in this manual.

8. Measure the crankshaft end play at No. 7 crankshaft journal before removing the crankshaft thrust bearing.

Crankshaft end play Standard: 0.04 - 0.205 mm (0.0016 - 0. 81 in) Limit: 0.54 mm (0. 021 in) If the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced.

9. Remove the crankcase. a. Loosen the crankcase bolts (M14/14 pieces) a little at a time in the numerical order shown in the illustration.

CS01N830

b. Loosen the crankcase bolts (M10/25 pieces) evenly from outside to inside. c. Screw M10 bolts (crankcase bolts) into the four thread holes (marked with asterisks) and tighten them evenly. Separate the crankcase from the cylinder block. d. Remove the thrust bearing.

Clean the crankcase surfaces and remove the sealant residue.

CS01N831

Cre 9-36560GB

Issued 01-02

6A-88 ENGINE MECHANICAL 10. Remove the crankshaft from the cylinder block.

11. Remove the upper crankshaft bearings.

• Keep the crankshaft bearings in order for installation to their original position.

• Clean the cylinder block surfaces and bores.

Remove the sealant residue and carbon deposits.

• Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder block, the oil holes, and the water jackets.

CS01N832

INSTALLATION 1. Install the upper crankshaft bearings to the cylinder block. a. Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder block, the oil holes, and the water jackets.

WARNING: Compressed air can cause personal injury when used for cleaning. Wear safety glasses and protective clothing.

CS01N833

b. Carefully wipe any foreign material from the upper crankshaft bearings and the cylinder block bearing fitting surfaces.

1

• The upper crankshaft bearings (1) have an oil hole and oil groove. The lower crankshaft bearings (2) have only a partial oil groove.

2

CS01N834

c. Install the upper bearings to their original position, if they are reused.

CAUTION: Do not apply engine oil to the bearing back faces and cylinder block bearing surfaces.

CS01N835

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-89 2. Install the crankshaft thrust bearing to the cylinder block. a. Apply engine oil to the thrust bearing oil grooves before installation. b. Install the thrust bearing to the crankshaft No. 7 journal.

Thrust bearing oil grooves must face the sliding surface.

CS01N836

3. Install the crankshaft to the cylinder block.

• Carefully wipe any foreign material from the crankshaft.

• Apply engine oil to the crankshaft journal and the crankshaft bearing sliding surfaces before installing the crankshaft.

CS01N837

4. Install the upper side crankshaft thrust bearings. a. Apply engine oil to the thrust bearing oil grooves before installation. b. Install the thrust bearing to crankshaft No. 7 journal.

CS01N838

5. Install the lower side crankshaft thrust bearings. a. Apply engine oil to the thrust bearing oil grooves before installation. b. Install the thrust bearings to the crankcase.

Thrust bearing oil grooves must face the sliding surface.

CS01N839

Cre 9-36560GB

Issued 01-02

6A-90 ENGINE MECHANICAL 6. Install the lower crankcase to the cylinder block. a. Carefully wipe any foreign material from the lower bearing back and sliding faces. b. Install the lower bearings to their original position if they are reused. c. Apply engine oil to the lower bearing sliding surfaces.

CS01N840

d. Apply unbroken strips of ThreeBond 1207C or equivalent to the lower face of the cylinder block as shown in the illustration.

The sealant must be 3 - 4 mm (0.12 - 0.16 in) wide.

NOTE: Immediately (within 10 minutes of applying the sealant) set the lower crankcase to the cylinder block.

NOTE: Do not allow the lower crankshaft bearings and thrust bearing to fall free.

CS01N841

e. Apply molybdenum disulfide grease to the lower crankcase bolt threads and setting faces.

CS01N842

f. Tighten the crankcase M14 bolts in three steps using the angular tightening method.

Torque: 1st Step: 98 Nm (10 kg.m/72 lb.ft) 2nd Step: 132 Nm (13.5 kg.m/98 lb.ft) 3rd Step: 30 - 60 deg.

CS01N843

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-91 g. Check that the crankshaft rotates smoothly.

NOTE: Lower crankcase bolts can be reused six (6) times. h. Tighten the lower crankcase M10 bolts a little at a time in the numerical order shown in the illustration.

Torque: 37 Nm (3.8 kg.m/27 lb.ft) CAUTION: The lower crankcase and the cylinder block are machined as a single unit. They can not be replaced separately. Always replace the lower crankcase and the cylinder block as a set.

7. Install the piston with the connecting rod.

CS01N844

Refer to "Piston Installation" in this manual.

8. Install the timing gears to the cylinder block.

Refer to "Timing Gear Installation" in this manual.

9. Install the flywheel housing to the cylinder block.

Refer to "Flywheel Housing Installation" in this manual.

10. Install the flywheel to the crankshaft.

Refer to "Flywheel Installation" in this manual.

11. Install the front cover to the cylinder block.

Refer to "Front Cover Installation" in this manual.

12. Install the crankshaft damper pulley.

Refer to "Crank Pulley and Flywheel Installation" in this manual.

13. Install the oil pan to the cylinder block.

Refer to "Oil Pan Installation" in this manual.

14. Install the cylinder head to the cylinder block.

Refer to "Cylinder Head Installation" in this manual.

15. Install the camshaft to the cylinder head.

Refer to "Camshaft Installation" in this manual.

16. Install the rocker arm assembly to the cylinder head.

Refer to "Rocker Arm Assembly Installation" in this manual.

17. Adjust the valve clearance.

Refer to "Valve Clearance Adjustment" in this manual.

18. Install the cylinder head cover to the cylinder head.

Refer to "Cylinder Head Installation" in this manual.

Cre 9-36560GB

Issued 01-02

6A-92 ENGINE MECHANICAL 19. Install the water pump to the front cover.

Refer to "Water Pump Installation" in this manual.

20. Install the alternator to the engine.

Refer to "Alternator Installation" in this manual.

21. Adjust the fan belt tension.

22. Install the turbocharger.

Refer to "Turbocharger Installation" in this manual.

23. Install the cooling fan and fan guide.

Refer to "Water Pump Installation" in this manual.

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-93

DISASSEMBLY

3 2

1

CS01N845

Legend (1)

Crankshaft

(2)

Pin

(3)

Crankshaft gear 1. Use the crankshaft gear remover to remove the crankshaft gear.

NOTE: Do not remove the crankshaft gear from the crankshaft unless the gear is damaged.

CS01N846

Cre 9-36560GB

Issued 01-02

6A-94 ENGINE MECHANICAL

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Crankshaft Inspect the surface of the crankshaft journals and crankpins for excessive wear and damage.

Inspect the oil ports for obstructions.

CS01N847

Bearing Spread Check the bearing spread.

Finger pressure should be sufficient to fit the bearing into position.

If the bearing fits loosely, it must be replaced.

CS01N840

Crankshaft Run-Out 1. Set a dial indicator to the center of the No. 4 crankshaft journal.

2. Gently turn the crankshaft in the normal direction of engine rotation.

Read the dial indicator as you turn the crankshaft.

If the measured value exceeds the specified limit, the crankshaft must be replaced.

Standard: 0.06 mm (0.0024 in) or less Limit: 0.45 mm (0.018 in) CS01N848

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-95

Crankshaft Diameter

Journal

and

Crankpin

1. Use a micrometer to measure the crankshaft journal diameter across points (1) - (1) and (2) - (2).

2. Use the micrometer to measure the crankshaft journal diameter at the two points ((3) and (4)).

3. Repeat steps 1 and 2 to measure the crankshaft pin diameter.

Crankshaft journal diameter Standard: CS01N849

No. 4 journal: 81.875 - 81.895 mm (3.2234 - 3.2242 in) Others: 81.905 - 81.925 mm (3.2246 - 3.2254 in) Crankshaft pin diameter Standard: 65.902 - 65.922 mm (2.5946 - 2.5953 in) Crankshaft journal and crankpin uneven wear Limit: 0.05 mm (0.0020 in)

Crankshaft Bearing Inside Diameter 1. Clean the cylinder body and lower crankcase bearing fitting surfaces. Clean the bearing inside and outside surfaces.

2. Install the lower crankcase with the bearings to the cylinder body.

3. Apply molybdenum disulfide grease to the lower crankcase bolt threads and setting faces.

4. Tighten the lower crankcase M14 bolts in three steps using the angular tightening method.

Torque: 1st step: 98 Nm (10 kg.m/72 lb.ft) 2nd step: 132 Nm (13.5 kg.m/98 lb.ft) 3rd step: 30 - 60 deg.

NOTE: Cylinder body lower crankcase M14 bolts can be reused 6 times before replacement.

CS01N843

Cre 9-36560GB

Issued 01-02

6A-96 ENGINE MECHANICAL 5. Tighten the lower crankcase M10 bolts to the specified torque.

Torque: 37 Nm (3.8 kg.m/27 lb.ft)

CS01N844

6. Use an inside dial indicator to measure the crankshaft bearing inside diameter.

Crankshaft Journal and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankshaft journal diameter exceeds the specified limit, the crankshaft must be replaced.

Crankshaft journal and Bearing clearance Standard: CS01N850

No. 4 journal: 0.093 - 0.124 mm (0.00366 - 0.00488 in) Others: 0.063 - 0.094 mm (0.00248 - 0.00370 in) Limit: 0.14 mm (0.0055 in)

Crankshaft Tufftriding Inspection • Use an organic cleaner to thoroughly clean the crankshaft.

B C

There must be no oil on the crankshaft.

• Prepare a 5 - 10% solution of ammonium cuprous chloride (dissolved in distilled water).

A D

• Use a syringe to apply the solution to the crankshaft.

Hold the surface perfectly horizontal to prevent the solution from running.

CS01N851

NOTE: Do not allow the solution to come in contact with the oil ports and their surrounding area.

A: The sliding surface of the pin or journal.

B: The portion to be tested must be held horizontally so as not to let the test solution flow.

C: Test liquid should not be applied to the area around the oil port.

D: Approximately 10 mm (0.4 in).

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-97

Crankshaft Tufftriding Judgment • Wait for 30 to 40 seconds.

If there is no discoloration after 30 or 40 seconds, the crankshaft is usable.

If discoloration appears (the surface being tested will become the color of copper), the crankshaft must be replaced.

• Steam clean the crankshaft surface immediately after completing the test.

NOTE: The ammonium cuprous chloride solution is highly corrosive. Because of this, it is imperative that the surfaces being tested by cleaned immediately after completing the test.

REASSEMBLY 1. Install the crankshaft gear to the crankshaft (if necessary). a. Install the crankshaft timing gear alignment pin. b. 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).

If the crankshaft gear is not heated, it may break during installation.

CS01N852

c. Use the crankshaft gear installer to install the crankshaft gear.

The crankshaft gear timing mark L (1) must be facing out.

1

Take care not to damage the crankshaft and crankshaft gear.

WARNING: TAKE CARE NOT TO BURN YOURSELF ON THE HEATED CRANKSHAFT GEAR.

CS01N853

Cre 9-36560GB

Issued 01-02

6A-98 ENGINE MECHANICAL

CYLINDER BLOCK

4

1

3 5

2

CS01N854

Legend (1)

Oil pressure switch

(3)

Oil jet

(2)

Crankcase

(4)

Cylinder liner

(5)

Cylinder block

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-99

REMOVAL 1. Remove the turbocharger.

Refer to "Turbocharger Removal" in this manual.

2. Remove the fan guide from the engine (if so equipped.)

3. Remove the water pump.

Refer to "Water Pump" in this manual.

4. Remove the alternator.

Refer to "Alternator Removal" in this manual.

5. Remove the injection pump.

Refer to "Injection Pump Removal" in this manual.

6. Remove the bearing case.

Refer to "Bearing Case Removal" in this manual.

7. Remove the oil cooler assembly.

Refer to "Oil Cooler Removal" in this manual.

8. Remove the cylinder head cover Refer to "Cylinder Head Removal" in this manual.

9. Remove the cylinder head.

Refer to "Cylinder Head Removal" in this manual.

10. Remove the oil pan.

Refer to "Oil Pan Removal" in this manual.

11. Remove the crank pulley.

Refer to "Crank Pulley Removal" in this manual.

12. Remove the front cover.

Refer to "Front Cover Removal" in this manual.

13. Remove the flywheel housing.

Refer to "Flywheel Housing Removal" in this manual.

14. Remove the timing gears.

Refer to "Timing Gear Removal" in this manual.

15. Remove the piston from the cylinder block.

Refer to "Piston Removal" in this manual.

16. Remove the crankshaft from the cylinder block.

Refer to "Crankshaft Removal" in this manual.

17. Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder block, the oil holes, and the water jackets.

WARNING: Compressed air can cause personal injury when used for cleaning. Wear safety glasses and protective clothing.

Cre 9-36560GB

Issued 01-02

6A-100 ENGINE MECHANICAL

INSTALLATION 1. Install the crankshaft to the cylinder block.

Refer to "Crankshaft Installation" in this manual.

2. Install the piston into the cylinder block.

Refer to "Piston Installation" in this manual.

3. Install the timing gears to the cylinder block.

Refer to "Timing Gear Installation" in this manual.

4. Install the bearing case to the cylinder block.

Refer to "Bearing Case Installation" in this manual.

5. Install the flywheel housing to the cylinder block.

Refer to "Flywheel Housing Installation" in this manual.

6. Install the flywheel to the crankshaft.

Refer to "Crank Pulley and Flywheel Installation" in this manual.

7. Install the front cover to the cylinder block.

Refer to "Front Cover Installation" in this manual.

8. Install the crank pulley to the crankshaft.

Refer to "Crank Pulley and Flywheel Installation" in this manual.

9. Install the oil pan to the cylinder block.

Refer to "Oil Pan Installation" in this manual.

10. Install the oil cooler to the cylinder block.

Refer to "Oil Cooler Installation" in this manual.

11. Install the injection pump to the cylinder block.

Refer to "Injection Pump Installation" in this manual.

12. Install the cylinder head to the cylinder block.

Refer to "Cylinder Head Installation" in this manual.

13. Install the camshaft to the cylinder head.

Refer to "Camshaft Installation" in this manual.

14. Install the rocker arm assembly to the cylinder head.

Refer to "Rocker Arm Assembly Installation" in this manual.

15. Adjust the valve clearance.

Refer to "Valve Clearance Adjustment" in this manual.

16. Install the cylinder head cover to the cylinder head.

Refer to "Cylinder Head Installation" in this manual.

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-101 17. Install the cylinder head cover to the cylinder head.

Refer to "Cylinder Head Installation" in this manual.

18. Install the water pump to the front plate.

Refer to "Water Pump Installation" in this manual.

19. Install the alternator.

Refer to "Alternator Installation" in this manual.

20. Adjust the fan belt tension.

21. Install the turbocharger.

Refer to "Turbocharger Installation" in this manual.

22. Install the cooling fan and fan guide.

Refer to "Water Pump Installation" in this manual.

Cre 9-36560GB

Issued 01-02

6A-102 ENGINE MECHANICAL

DISASSEMBLY 1. Remove the lower crankcase.

• Loosen the fixing bolts to disassemble the lower crankcase.

• Place the crankcase on a flat piece of wool.

2. Remove the oil jet.

Loosen the bolt to remove the oil jet.

NOTE: Take care not to bend or damage the oil jet.

3. Remove the cylinder liner.

• Use a scraper to remove carbon deposits.

• Use a cylinder bore dial indicator to measure the cylinder bore in the thrust and axial direction of the crankshaft before removing the cylinder liner.

Measuring point: 20 - 25 mm (0.79 - 1.0 in) If the measured value exceeds the specified limit, the cylinder liner must be replaced.

Cylinder liner bore Limit: 115.2 mm (4.5354 in) CS01N855

NOTE: If the inside of the cylinder liner is scored or scratched, the cylinder liner must be replaced.

If cylinder liner removal is difficult, use following procedure. a. Set the cylinder line remover to the cylinder liner. b. Check that the remover shaft ankle is firmly gripping the cylinder liner bottom edge. c. Slowly turn the remover shaft handle clockwise to pull the cylinder liner free.

CAUTION: Take care not to damage the cylinder body upper face during the cylinder liner removal procedure.

4. Visually inspect the cylinder block for damage.

CS01N856

INSPECTION AND REPAIR Make the necessary adjustment, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-103

Cylinder Block Flatness • Remove the cylinder liners.

• inspect the cylinder block for cracks and other damage. Check the oil and water holes for clogging.

If possible use dye pendant flow detector.

• Use a straight edge (1) and a feeler gauge (2) to measure cylinder block upper face warpage (4 sides and 2 diagonals as shown in the illustration).

Upper face warpage CS01N833

Limit: 0.2 mm (0.008 in) If the measured value exceeds the specified limit, the cylinder block must be replaced.

1

• Apply water under pressure to the cylinder body water jacket to check for leakages.

Water Pressure: 490 kPa (5 kg/cm2/70 psi) If water leakage is found, the cylinder block must be replaced.

2

CS01N858

Cylinder Liner Grade Selection and Standard Fitting Interference Accurately measured fitting interference and proper cylinder liner grade selection are extremely important.

If the cylinder liner fitting interference is too small, engine cooling efficiency will be adversely affected.

If the cylinder liner fitting interference is too large, it will be difficult to insert the cylinder liner into the cylinder block.

A

A mark was stamped on the left side of the cylinder block during production to indicate the correct liner (A).

CS01N859

The liner grade (1, 2, 3) is indicated by a metal stamp.

Cylinder liner grade

B

Liner

Cylinder Bore

Service

Liner Outside

Grade

Diameter mm (in)

Grade

Diameter mm (in)

1, 2

3

CS01N860

Cre 9-36560GB

118.001 - 118.020 (4.64571 - 4.64646) 118.021 - 118.030 (4.64650 - 4.64685

1X

3X

117.991 - 118.000 (4.64531 - 4.64567) 118.001 - 118.010 (4.64571 - 4.646)

The cylinder liner grade (B) is stamped on the outside of the cylinder liner.

Issued 01-02

6A-104 ENGINE MECHANICAL

Cylinder Bore Measurement If the marking is not clear, measure the cylinder bore inside diameter.

• Use a cylinder bore dial indicator to measure the cylinder bore in the thrust and axial direction of the crankshaft.

Measuring points: 20 mm (0.79 in) 110 mm (4.33 in) 190 mm (7.18 in)

CS01N827

Lower Crankcase Visually inspect the lower crankcase for cracking and damage.

If possible, use dye penetrant flaw detector.

CS01N861

Oil Jet Check the oil port on the oil jet for clogging.

CS01N862

Cylinder Liner Projection • Use a dial indicator or a straight edge and feeler gauge to measure the cylinder liner projection.

Cylinder liner projection Standard: 0.06 - 0.10 mm (0.0024 - 0.0039 in) The difference in the cylinder liner projection height between any adjacent cylinders must not exceed the limit.

Projection height between adjacent cylinders: 0.03 mm (0.0012 in) or less CS01N863

Cre 9-36560GB

Issued 01-02

ENGINE MECHANICAL 6A-105

REASSEMBLY 1. Install the cylinder liner to the cylinder block.

• Use new kerosene or diesel fuel to thoroughly clean the cylinder liner and bore.

• Use compressed air to blow-dry the cylinder liner and bore surface.

WARNING: Compressed air can cause personal injury when used for cleaning. Wear safety glasses and protective clothing.

NOTE: All foreign materials must be carefully removed from the cylinder liner and the cylinder bore before installation.

• Apply engine oil to the outside surface of the cylinder liner.

CS01N864

• Install the cylinder liner to the cylinder block from the top of the cylinder block with your hand.

• Check the cylinder liner projection.

NOTE: (1)

Do not apply excessive force or strike the cylinder liner during installing.

(2)

Take care to not drop the cylinder liner when the cylinder block turns over.

CS01N863

2. Install the oil jet to the cylinder block.

Tighten to the specified torque.

Torque: 21 Nm (2.1 kg.m/15 lb.ft) Be sure that the oil jet tip is aligned with the piston cooling hole.

Do not bend or damage the oil jet.

3. Install the crankshaft to the cylinder block.

Refer to "Crankshaft Installation" in this manual.

4. Install the crankcase.

Refer to "Crankshaft Installation" in this manual.

CS01N865

5. Install the oil pressure switch.

1

• Install the adapter (1) to the cylinder block and tighten to the specified torque.

• Install the oil pressure switch (2).

Torque: Adapter: 118 Nm (12.0 kg.m/87 lb.ft) Oil pressure switch: 18 Nm (1.8 kg.m/13 lb.ft)

2

CS01N857

Cre 9-36560GB

Issued 01-02

6A-106 ENGINE MECHANICAL

Cre 9-36560GB

Issued 01-02

ENGINE COOLING 6B-1

SECTION 6B

ENGINE COOLING TABLE OF CONTENTS ITEM PAGE Service precaution.....................................................................................................................................................1 General Description ..................................................................................................................................................2 Thermostat ...............................................................................................................................................................3 Water Pump ..............................................................................................................................................................5

SERVICE PRECAUTION • Be sure to use the correct fastener in the proper location. If a used fastener is replaced with a new one, the new fastener must be Identical to the previous one.

• Some fasteners must always be replaced with new ones following removal. These fasteners are specified in this Manual.

• Some fasteners require thread locker or thread sealant. These fasteners are specified in this Manual.

• Supplemental fastener coatings (paint, grease, or corrosion inhibitor) affect fastener torque and clamping force. They may damage the fastener. Do not use them unless specifically called for.

• Tighten all fasteners to the specified torque. If there is a tightening sequence, follow it exactly.

Cre 9-36560GB

Issued 01-02

6B-2 ENGINE COOLING

GENERAL DESCRIPTION COOLANT FLOW

2

3 4 5

1 9 6 8

7

CS01N866

Legend (1)

Radiator

(6)

Water pump

(2)

Reserve tank

(7)

Oil cooler

(3)

Water outlet pipe

(8)

Water drain

(4)

Thermostat

(9)

Water jacket cylinder body

(5)

Water jacket, Cylinder head

The engine cooling system consists of the radiator, the surge tank, the water pump, the cooling fan, and the thermostats.

When the engine and coolant are cold, the thermostat with jiggle valve is completely closed. The water pump circulates the coolant through the radiator by-pass directly back to the cylinder body (coolant does not pass through the radiator). This provides a rapid increase in coolant temperature and smooth engine operation.

Cre 9-36560GB

When the coolant temperature reaches 82°C (180°F), the thermostat begins to open. A gradually increasing amount of coolant passes through the radiator before returning to the cylinder block.

When the coolant temperature reaches 95°C (203°F), the thermostat is fully open. All coolant now passes through the radiator before returning to the cylinder block. Effective engine cooling is ensured.

Issued 01-02

ENGINE COOLING 6B-3

THERMOSTAT

1

3

3

2

CS01N867

Legend (1)

Water outlet-pipe

(2)

Thermostats

(3)

Gaskets

Cre 9-36560GB

Issued 01-02

6B-4 ENGINE COOLING

DISASSEMBLY 1. Remove the water outlet pipe to the cylinder head.

2. Remove the thermostat (without jiggle valve) (2) and thermostat (with jiggle valve) (3) to the cylinder head.

3. Remove the thermostat gaskets (1) to the flange of thermostats.

REASSEMBLY 1. Install the new thermostat gaskets (1) to the flange of thermostats.

CS01N760

1

2. Install the thermostat (without jiggle valve) (2) and the thermostat (with jiggle valve) (3) to the cylinder head.

NOTE: The jiggle valves of the thermostat must be facing the rear of the engine.

3. Install the water outlet pipe to the cylinder head.

4. Tighten the water outlet pipe bolts to the specified torque.

2

Torque: 19 Nm (1.9 kg/14 lb.ft) 3 3

CS01N759

Cre 9-36560GB

Issued 01-02

ENGINE COOLING 6B-5

WATER PUMP 6 15 14 13 11 12

10

16

9 8 7

6 5 4 3 2 1

CS01N868

Legend (1)

Center

(9)

(2)

Dust cover

(10) Water pump body

(3)

Snap ring

(11) Dowel pin

(4)

Bearing

(12) Seal unit

(5)

Bearing

(13) Impeller

(6)

Spacer

(14) Gasket

(7)

Bearing

(15) Cover

(8)

Washer

(16) Bolt

Cre 9-36560GB

Shaft

Issued 01-02

6B-6 ENGINE COOLING

DISASSEMBLY 1. Remove the rear cover from the water pump body.

2. Use a remover to remove the impeller from the water pump.

3. Use a puller to remove the water pump center.

4. Remove the dust cover and snap ring.

5. Remove the water pump shaft with ball bearings.

• Use a plastic hammer to lightly tap on the water pump shaft from the impeller side.

6. Use a bench press to remove the bearing from the shaft.

CS01N869

7. Remove the seal unit.

CS01N870

INSPECTION AND REPAIR Make the necessary adjustments, repairs and part replacements if excessive wear or damage is discovered during inspection.

Water pump impeller 1. Check the impeller for corrosion.

CS01N871

Water pump shaft 1. Measure the water pump shaft and center or impeller interference.

If the measured interference is less than the specified limit, the pump shaft and/or the center and impeller must be replaced.

Pump shaft and center interference: Limit: 0.048 - 0.078 mm (0.0019 - 0.0031 in) Pump shaft and Impeller interference: Limit: 0.022 - 0.062 mm (0.0009 - 0.0024 in) CS01N872

Cre 9-36560GB

Issued 01-02

ENGINE COOLING 6B-7 2. Carefully wipe away any bearing grease.

3. Listen for excessive bearing operating noise.

Excessive bearing operating noise indicates severe bearing wear.

CS01N873

REASSEMBLY 5

1. Install the ball bearing to the water pump shaft. a. Apply engine oil to the water pump shaft.

3

b. Place the water pump shaft and the bearings on the base plates.

1

c. Install the washer (4), ball bearing (3), spacer (2), and bearings (1).

4 2 CS01N874

d. Use a bench press to gradually press the water pump shaft down until the bearings are seated correctly.

CS01N870

2. Install the water pump shaft with bearings to the water pump body. a. Repack the bearings with multipurpose grease. b. Place the water pump body on bench press base plate.

NOTE: To prevent damage to the water pump shaft, place soft brass or copper sheets between the base plates and the water pump shaft.

CS01N873

Cre 9-36560GB

Issued 01-02

6B-8 ENGINE COOLING c. Position the pump shaft with bearings to the water pump body. d. Use a bench press to gradually press the water pump shaft into the water pump body.

NOTE: Do not drive the bearing into position with a hammer or similar object. Bearing damage will result.

CS01N875

3. Install the snap ring and dust cover. a. Use pliers to install the snap ring into water pump body groove. b. Install the dust cover with the flange facing out.

CS01N876

4. Install the seal unit to the water pump body.

• Press in the seal unit to the specified position using a bench press and installer.

Seal unit installation position A: 11.0 - 11.6 mm (0.433 - 0.457 in)

CS01N877

5. Install the water pump impeller to the water pump shaft.

• Use a bench press to press in the impeller.

• The impeller must be flush with the water pump shaft end.

6. Use a bench press to gradually press the water pump center onto the water pump shaft to the specified dimension.

Dimension A: 202.9 mm (7.988 in) 7. Install the rear cover with new gasket to the water pump body.

CS01N878

Cre 9-36560GB

Issued 01-02

ENGINE FUEL 6C-1

SECTION 6C

ENGINE FUEL TABLE OF CONTENTS ITEM PAGE Service Precaution ...................................................................................................................................................1 General Description ..................................................................................................................................................2 Fuel Filter ..................................................................................................................................................................5 Injection Nozzle ........................................................................................................................................................6

SERVICE PRECAUTION • Be sure to use the correct fastener in the proper location. If a used fastener is replaced with a new one, the new fastener must be identical to the previous one.

• Some fasteners must always be replaced with new ones following removal. These fasteners are specified in this Manual.

• Some fasteners require thread locker or thread sealant. These fasteners are specified in this Manual.

• Supplemental fastener coatings (paint, grease, or corrosion inhibitor) affect fastener torque and clamping force. They may damage the fastener. Do not use them unless specifically called for.

• Tighten all fasteners to the specified torque. If there is a tightening sequence, follow it exactly.

Cre 9-36560GB

Issued 01-02

6C-2 ENGINE FUEL

GENERAL DESCRIPTION FUEL SYSTEM OPERATION

When working on the fuel system:

The fuel injection pump is driven by the crankshaft.

The fuel injection pump drives the fuel feed pump.

• Disconnect the negative battery cable.

The fuel feed pump draws fuel from the fuel tank. The fuel is delivered to the injection pump through the fuel/ water separator and the secondary fuel filter.

The governor regulates the flow of fuel to the delivery valves.

• Have a dry chemical (Class B) fire extinguisher where it can be reached quickly.

• Release the fuel line pressure before servicing system components.

• Carefully read and understand the appropriate instructions.

The plunger in the injection pump delivers fuel at high pressure through the delivery valves to the individual fuel injectors at precise intervals.

The pressure generated by the fuel in the fuel injector forces open a needle valve. Fuel is injected from the injection nozzle holes into the cylinder as a very fine spray.

Excess fuel is returned to the fuel tank through the fuel return line.

Cre 9-36560GB

Issued 01-02

ENGINE FUEL 6C-3

FUEL FLOW

CS01N879

FUEL SYSTEM COMPONENTS The fuel system consists of the fuel tank, the fuel feed pump, the water sedimentor, the fuel filter, the injection pump, and the injection nozzles.

Fuel is drawn from the fuel tank by the fuel feed pump.

It passes through the water sedimentor (water particle removal) and the fuel filter (solid particle removal) before being delivered to the injection pump.

Precisely metered amounts of fuel are forced into each of the injection nozzles at exact intervals to provide efficient engine operation.

Cre 9-36560GB

• Water sedimentor The water sedimentor has a clear plastic body.

There is a warning line on the body. When the water level reaches the warning line, the sedimentor must be emptied.

Open the drain plug at the bottom of the sedimentor to drain the water.

• Fuel filter The fuel filter removes solid particles from the fuel.

These particles, if allowed to reach the injection nozzles, would cause serious abrasive damage.

Issued 01-02

6C-4 ENGINE FUEL • Fuel feed pump The fuel feed pump draws fuel from the fuel tank and delivers it to the injection pump. It maintains a high pressure in the fuel line.

An independent priming pump permits manual fuel feed when the engine is off.

• Injection pump Major injection pump components are the pump body, the plungers, the governor, and the timing advancer.

GOVERNOR The fuel system uses an RSV variable speed governor.

Engine speed and load vary widely during normal driving. If the engine speed is too low, the engine will be sluggish and may stall. If engine speed is too high, overrun occurs.

The governor operates to maintain engine speed within acceptable limits thus preventing stalling and overrun.

The injection pump is the nucleus of the diesel engine fuel system. It pressurizes and delivers precisely timed and measured fuel charges to the engine cylinders. Timing and volume are determined by engine load and speed.

Each plunger is raised to the top of its stroke by a cam lobe and forced to the bottom of its stroke by a return spring.

Together, the plungers create a reciprocal motion.

Fuel enters the plunger barrel through the inlet port when the plunger is at the bottom of its stroke.

Excess fuel leaves the plunger barrel through the outlet port when the plunger is at the top of its stroke.

The injection pump has an identification tab attached to its body.

Cre 9-36560GB

Issued 01-02

ENGINE FUEL 6C-5

FUEL FILTER DISASSEMBLY

2

1. Remove the fuel filter (1) with a filter wrench.

CAUTION: Be careful not to spill the fuel remaining in the fuel filter when removing the filter.

2. Remove the overflow valve (2).

3

3. Remove the fuel filter body (3).

1

INSPECTION AND REPAIR Check the overflow valve for restrictions and/or leakage.

Overflow valve opening pressure 230 - 260 kPa (33 - 38 psi) CS01N880

REASSEMBLY 1. Install the overflow valve to the fuel filter body.

2. Install the fuel filter.

• Before installating a new fuel filter, apply fuel to the gasket.

• Turn in the new fuel filter until the filter gasket comes in contact with its sealed face.

• Use a filter wrench to turn in the fuel filter an additional 1/2 - 3/4 of a turn.

Cre 9-36560GB

Issued 01-02

6C-6 ENGINE FUEL

INJECTION NOZZLE

11

8

10 9 7

15 6

5

4

3

2

14 12

13

1 12

CS01N881

Legend (1)

Retaining nut

(8)

Push rod

(2)

Nozzle

(9)

Adjusting shim

(3)

Pin

(10) 2nd spring

(4)

Spacer

(11) Collar

(5)

Pin

(12) Spring seat

(6)

Lift piece

(13) 1st spring

(7)

Spring seat

(14) Adjusting shim (15) Nozzle holder body

Cre 9-36560GB

Issued 01-02

ENGINE FUEL 6C-7

DISASSEMBLY The 2-spring nozzle reduces nitrogen oxide Nox and particulate exhaust gas emissions.

1. Use a wire brush to remove carbon deposits from the nozzle and nozzle holder (before disassembly).

CAUTION: Do not touch the nozzle holes with wire brush.

2. Wipe clean the outside surfaces of the nozzle holder assembly using a clean damp rag.

3. Place the nozzle holder in a vise.

4. Remove the retaining nut.

5. Remove the nozzle.

6. Remove the spacer, pin, lift piece, and spring seat.

7. Remove the push rod, adjusting shim, 1st spring, and collar (1st opening pressure control).

8. Remove the spring seat, 2nd spring, and adjusting shim (2nd opening pressure control).

9. Clean the parts thoroughly in diesel fuel to remove all dirt and other foreign materials.

NOTE: Injection nozzle adjustments are made in very small steps (100ths of a millimeter). For this reason, it is extremely important that all parts be immaculate.

REASSEMBLY

3

1. Place the nozzle holder in a vise.

2

2. Install the adjusting shim (1), first spring (2), a spring seat (3).

1

CS01N882

5

3

3. Install the collar (1), 2nd spring (2), adjusting shim (3), spring seat (4), and push rod (5).

2 1 4

CS01N883

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Issued 01-02

6C-8 ENGINE FUEL 4. Install the pins (1), lift piece (2), and spacer (3).

3 2 1

CS01N884

5. Install the pin (1).

6. Install the nozzle (2).

2 1

CS01N885

7. Hand-tighten the adjustment retaining nut together with the gasket to the nozzle holder.

A

C

A: Retaining nut: (See special tools) B: Gasket: (See special tools)

B

C: Nozzle 8. Tighten the adjustment retaining nut (A) to the specified torque.

Torque: 29 - 39 Nm (3.0 - 4.0 kg.m/25 - 28 lb.ft)

CS01N886

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ENGINE FUEL 6C-9 9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester. Measure the first nozzle opening pressure.

11. If the first nozzle opening pressure is not as specified, disassemble the nozzle holder and remove the shim. Replace the shim with a new shim that adjusts the opening pressure to the specified level.

CAUTION: Use a micrometer to measure shin thickness.

• First nozzle opening pressure adjusting shims CS01N887

A: Thickness (mm) 0.40 0.50 0.52 A

0.54 0.56 0.58 0.60 0.70

CS01N888

Full needle valve lift confirmation 2

1. Install the gasket (1) and plug (2) to the adjustment retaining nut.

Gasket (See special tools) Plug (See special tools)

1

CS01N889

2. Position the nozzle holder with the nozzle facing down. Install the dial gauge holder to the nozzle holder.

1

Dial gauge holder (See special tools)

CS01N890

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6C-10 ENGINE FUEL 3. Install the nut (1) to the dial gauge holder (2).

Nut: (See special tools)

1 2

CS01N891

4. Install the pin (1) to the dial gauge (2).

NOTE: Pin lengths of the pins do not include the threaded portions.

1

Pin (l = 60 mm): (See special tools)

2

Dial gauge: (See special tools)

CS01N892

5. Secure the dial gauge to the nozzle holder using the nut so that the pin contacts the tip of the first spring seat.

6

CAUTION: • Secure the dial gauge so that a stroke of 2 mm can be measured.

5

• Do not over-tighten the nut as the dial gauge shaft may jam. Confirm from the dial gauge that the shaft moves smoothly.

4 3

Legend

2

(1)

1st spring seat

(2)

Nozzle holder

(3)

Pin

(4)

Holder

(5)

Nut

(6)

Dial gauge

1

CS01N893

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Issued 01-02

ENGINE FUEL 6C-11 6. Set the nozzle holder to the nozzle tester and zero the dial gauge.

7. Operate the nozzle tester to bleed any air from inside the retaining nut and to confirm that there is no fuel leakage.

CS01N887

8. Operate the nozzle tester to increase the in-line pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm2/ 4980 - 6400 psi). The nozzle’s needle valve should move through its full lift.

Needle Valve Lift

L

Record full lift "L" (Read dial gauge) 0 1st nozzle opening pressure

34.3~44.1 MPa (350~450 kgf/cm2)

NOTE: The above operation is used to determine whether the nozzle seat is worn and whether the nozzle assembly is in good condition.

In-line pressure

Pre-lift confirmation 1. With the needle valve at full lift, release the nozzle tester handle.

NOTE: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will fall slightly.

2. Read the needle valve lift "l" from the dial gauge indication (once the needle valve has descended when the second spring has stopped operating) Refer to the pre-lift measuring point for "l".

CS01N894

Needle Valve Lift

L

0

In-line pressure

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6C-12 ENGINE FUEL

Pre-lift measuring point: L

Read the dial gauge at first nozzle opening pressure (approx 1 MPa (10 kg/cm2/140 psi).

Needle valve lift

Measuring point (pre-lift)

NOTE: This point can be determined while the pressure is falling.

l

3. Confirm that pre-lift "l" is as specified.

Pre-lift: 0.05 mm (0.0020 in)

0 1st nozzle opening pressure In-line pressure

Legend 1

4 5

2

l 3 6

(1)

Push rod

(2)

Spring seat

(3)

Spacer

(4)

Second spring

(5)

Adjusting shim

(6)

Lift piece

(7)

Needle valve

7 CS01N895

4. If pre-lift is not as specified, replace the pin, lift piece, spacer, and nozzle assembly as a set with the service kit.

3 1

Legend 4 5

2

(1)

Lift piece

(2)

Nozzle assembly

(3)

Pin

(4)

Spacer

(5)

Capsule

CS01N896

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ENGINE FUEL 6C-13

Second nozzle confirmation

opening

pressure

1. After pre-lift confirmation, operate the nozzle tester to increase in-line pressure to 34.3 44.1 MPa (350 - 450 kg/cm2/4980 - 6400 psi).

The nozzle’s needle valve should move through its full lift.

CS01N887

Needle valve lift (mm)

L

l+ 0.05 l 0 2nd nozzle opening pressure

34.3 - 44.1 MPa (350-450 kg/cm2)

In-line pressure

2. Release the nozzle tester handle so that in-line pressure decreases.

A

NOTE: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will fall slightly.

A: When needle valve lift is l + 0.05 mm B: Full needle valve lift

B

CS01N897

3. Read the pressure gauge indication (second nozzle opening pressure) the instant that the dial gauge indicates the specified needle valve lift (usually pre-lift l + 0.05 mm).

CS01N898

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6C-14 ENGINE FUEL

3

5

Second nozzle adjustment

4

If the second nozzle opening pressure is not as specified, disassemble the nozzle holder and remove the shim. Replace the shim with a new shim that adjusts the opening pressure to the specified level.

2 1

opening

pressure

CAUTION: • The 2nd opening pressure changes when 1st opening pressure changes. Therefore, 2nd opening pressure adjustment is always required when the 1st opening pressure is adjusted.

CS01N883

• Use a micrometer to measure shim thickness.

• Second nozzle opening pressure adjusting shims.

Legend

A

A : Thickness (mm)

(1)

Collar

(2)

2nd spring

(3)

Adjusting shim

(4)

Spring seat

(5)

Push rod

0.40 0.50 0.52 0.54 0.56

CS01N899

0.58 0.60 0.70

Final inspection 1

1. Remove the dial gauge (1), nut (2), and dial gauge holder (3).

2

3

CS01N900

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ENGINE FUEL 6C-15 2. Remove the retaining nut (1) and gasket.

3. Install but do not tighten the original retaining nut.

4. Check that the pins are fully inserted into the nozzle.

5. Hand-tighten the retaining nut.

6. Tighten the retaining nut to the specified torque.

1

Torque: 59 - 79 Nm (6 - 8 kg.m/43 - 58 lb.ft)

CS01N901

7. Set the nozzle holder to the nozzle tester.

8. Check the 1st nozzle opening pressure.

9. Check the spray condition.

10. Check for oil leakage.

CAUTION: The nozzle, lift piece, pins, and spacers must be replaced as a set (nozzle service kit). If only the nozzle is replaced, pre-lift specifications will not be applicable.

CS01N887

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Issued 01-02

6C-16 ENGINE FUEL

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Issued 01-02

STARTING AND CHARGING 6D3-1

SECTION 6D3

STARTING AND CHARGING TABLE OF CONTENTS ITEM PAGE Service precaution ....................................................................................................................................................1 Alternator ..................................................................................................................................................................2 Starter Motor ...........................................................................................................................................................11

SERVICE PRECAUTION • Be sure to use the correct fastener In the proper location. If a used fastener is replaced with a new one, the new fastener must be identical to the previous one.

• Some fasteners must always be replaced with new ones following removal. These fasteners are specified in this Manual.

• Some fasteners require thread locker or thread sealant. These fasteners are specified in this Manual.

• Supplemental fastener coatings (paint, grease, or corrosion inhibitor) affect fastener torque and clamping force. They may damage the fastener. Do not use them unless specifically called for.

• Tighten all fasteners to the specified torque. If there is a tightening sequence, follow it exactly.

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6D3-2 STARTING AND CHARGING

ALTERNATOR GENERAL DESCRIPTION

6 5 4

7 8

3

2

1

10

9

CS01N902

Legend (1)

Rear bracket

(6)

Rotor

(2)

IC regulator

(7)

Bearing

(3)

Bearing

(8)

Pulley

(4)

Rectifier

(9)

Front bracket

(5)

Stator

(10) Field coil assembly

The engine uses a brushless alternator.

Main alternator components are the rotor, the stator, the rectifier, the front and rear brackets, the IC regulator, the bearings, and the pulley.

Moving parts include the rotor and the pulley.

The field coil is installed to the rear bracket.

6 main diodes (3 positive and 3 negative) in conjunction with 2 sub-diodes provide 3-phase rectification. The diodes are installed to the stator coil.

An additional 3 diodes (diode trio) are used to provide field current.

The alternator has 3 terminals. a. Terminal B: DC power output b. Terminal L: Exciting current input c. Terminal R: Exciting current input Terminal R is active only until the alternator begins to generate electricity.

Terminal L also serves as a voltage output terminal.

When the voltage across terminal L is equal to the battery voltage, the indicator lamp (no charging) turns off.

Sealed bearings requiring no lubrication are used throughout the alternator.

The IC regulator is a solid-state device and is serviced as a unit. It cannot be disassembled.

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STARTING AND CHARGING 6D3-3

CHARGING CIRCUIT

1

3

4

5 2

9 6 7

8

CS01N903

Legend (1)

Additional diodes

(6)

Field coil

(2)

Stator coil

(7)

IC regulator

(3)

Diode trio

(8)

Alternator

(4)

Indicator lamp

(9)

Battery (24 V)

(5)

Key switch

MAIN DATA AND SPECIFICATIONS Rated voltage

(V)

24

Rated output

(A)

50

Rated speed

(min-1)

Rated output

(Amp./Volt/min-1)

No-load output at 0 Amp.

(Volt/min-1)

Direction of rotation as viewed from pulley side

Coil resistance at 20°C Field coil

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50/27/5000 24/900 Clockwise

Ground polarity Pulley diameter

5000

(-) mm (in)

80 (3.15)

( Ω)

4.5 - 5.2

Issued 01-02

6D3-4 STARTING AND CHARGING

DISASSEMBLY 2

3

1 4

7 5

6

9

8

CS01N904

Legend 1. IC regulator

6. Nut

2. Terminal stud

7. Side entry terminal

3. Side entry terminal (Terminal B)

8. Terminal stud

4. Rectifier assembly

9. Tube

5. Cap

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Issued 01-02

STARTING AND CHARGING 6D3-5 1. Scratch setting marks between the front and rear brackets and the alternator body (2 locations).

This will ensure installation to its original position.

B

2. Remove the 4 through bolts.

3. Use the blade of a screwdriver to pry the front bracket and the stator apart.

4. Carefully separate the front bracket, pulley, and rotor from the stator and rear bracket.

NOTE:

A

A

1 CS01N905

1

• Do not push the screwdriver blade too deeply into the stator. Coil damage will result.

• A vise may be used to secure the rotor. Be sure to clamp the vise at points A (see illustration). Do not clamp the vise at points B. Damage to the rotor will result.

5. Remove the 2 screws (2) attaching the coil terminal plate to the IC regulator.

2

6. Hold the coil assembly in your hand. Be careful not to damage the terminal plate.

7. Remove the 3 screws (3) and the coil assembly.

8. Disconnect the connector (1).

NOTE: It is very important that Steps 5, 6 and 7 be performed in that order. If Step 6 is performed before Step 5, terminal damage will result.

9. Remove the cap and nut from the rectifier terminal stud.

3

10. Use a screwdriver to pry the rear bracket and the side entry terminal apart.

CS01N906

11. Remove the side entry terminal.

NOTE: The tube will remain in the rear bracket. Take care not to lose it.

12. Remove the rectifier retaining screw and the 2 IC regulator retaining screws.

13. Remove the stator and rectifier assembly (as a single unit) from the rear bracket.

14. Remove the IC regulator.

15. Unsolder the 4 stator coil leads from the rectifier terminals.

16. Remove the stator from the rectifier.

NOTE: High temperature solder with a melting point of 230°C connects the stator coil leads to the rectifier.

Use a 180~280 watt soldering iron to free the leads as quickly as possible. Do not apply the soldering iron for more than 5 seconds. Diode damage will result.

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6D3-6 STARTING AND CHARGING

Bearing removal NOTE: Bearings are not normally removed. If they are removed, they must be replaced with new ones.

• Front bracket bearing Remove the 4 retainer screws. Press out the bearing with a suitable tool.

• Rotor bearing Use an ordinary bearing puller.

INSPECTIONS AND REPAIR Stator 1. Check the stator for damage, loose connections, and discolored windings.

1

2. Use a circuit tester to check for continuity between each pair of stator coil leads (1). Replace the stator if there is no continuity.

CS01N907

3. Use a circuit tester to check for continuity between each of the stator coil leads (1) and the stator core (2). Replace the stator if there is no continuity.

1

2 CS01N908

Rotor

2

1. Turn the rotor. Listen for bearing noise (a scraping sound). Feel for rough rotation. Replace the rotor if either of these conditions is present.

2. Check for grease leakage. If leakage is minimal, wipe it away. If leakage is excessive, replace the rotor.

1

NOTE: It is recommended that inspection be made with the bearing fitted to the rotor shaft. Coil Assembly.

Coil Use an ohmmeter to measure the coil resistance between both terminals (1) and the terminal plate (2).

CS01N909

Replace the coil assembly if the resistance is outside the specifications.

Coil resistance at 20°C: 4.5 - 5.2 ohms

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STARTING AND CHARGING 6D3-7

Rectifier 1

1. Use a circuit tester to test for continuity between each diode terminal (2) and the positive heat sink.

Test in both directions.

If there is continuity and/or an open circuit in both directions, the rectifier must be replaced.

2. Use a circuit tester to test for continuity between each diode terminal (2) and the negative heat sink. Test in both directions.

3

2 CS01N910

It there is continuity and/or an open circuit in both directions, the rectifier must be replaced.

3. Check the diode trio for continuity in both directions. If there is continuity and/or an open circuit in both directions, the rectifier must be replaced.

Legend (1)

Positive diode

(2)

Diode terminals

(3)

A part of negative diode

Front bracket Turn the bracket. Listen for bearing noise (a scraping sound). Feel for rough rotation. Replace the bracket if either of these conditions is present.

Check for grease leakage. If leakage is minimal, wipe it away. If leakage is excessive, replace the bracket.

Regulator The regulator cannot be checked in the absence of the other components. Check regulator operation after alternator reassembly.

REASSEMBLY Follow the disassembly steps in the reverse order.

Note the following precautions.

• No lubrication prelubricated.

is

required.

Bearings

are

• Wipe away any grease leakage from the bearing area.

• Use high-temperature solder (melting point of 230°C).

• Use a 180 - 280 watt soldering iron to solder the leads as quickly as possible. Do not apply the soldering iron for more than 5 seconds. Diode damage will result.

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6D3-8 STARTING AND CHARGING • Bracket, rotor, and stator reassembly is difficult because of the tight fit of the components. To make reassembly easier, heat the area around the rear bracket bearing box to approximately 55°C. Tightening torques Pulley fixing nut: 147 Nm (15 kg.m/108 lb.ft) Through bolts: 5.1 Nm (0.52 kg.m/3.8 lb.ft) Bearing retainer screws: 3.6 Nm (0.37 kg.m/2.7 lb.ft) Coil retaining screws: 3.6 Nm (0.37 kg.m/2.7 lb.ft) Rectifier retaining screws: 3.6 Nm (0.37 kg.m/2.7 lb.ft) Regulator retaining screws: 3.4 Nm (0.35 kg.m/2.5 lb.ft) Nuts for stud bolts: 8.8 Nm (0.9 kg.m/6.5 lb.ft)

Bench testing AMMETER

SWITCH 1

Voltage regulation

LAMP (24 V) (3 W MAX.)

ALTERNATOR

VOLTMETER

Perform bench tests on the reassembled alternator.

SWITCH 2

1. Make connections as shown in the illustration on the following page. Use an ammeter with a scale of 0 - 100 amperes and voltmeter with a scale of 0 - 30 volts.

BATTERY (24 V)

LOAD RESISTOR

CS01N911

2. Close switch 1 and open switch 2. The lamp should light.

If the lamp does not light, check the voltage at terminal-L. If the voltage is nearly equal to battery voltage (24 V), check the alternator.

If the voltage is low, check for an open lamp and related circuitry.

3. Slowly increase alternator speed.

The lamp should turn off as alternator speed approaches 1.300 min-1.

4. Check the voltage as alternator speed increases.

If the voltage fluctuates wildly during alternator speed increase and rises above 30 volts, the IC regulator is probably defective.

If the voltage does not exceed battery voltage (24 V), the alternator is defective (no generation of electricity). Check alternator components again.

5. Increase alternator speed to approximately 500 min-1.

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Issued 01-02

STARTING AND CHARGING 6D3-9 6. Note the ammeter reading.

If the reading is 5 amperes or less, note the voltmeter reading (be sure that alternator speed remains constant). This is the regulated voltage.

If the reading is more than 5 amperes, continue to operate the ammeter at 500 min-1 until the reading fails to 5 amperes or less.

If the reading does not fall, replace the battery.

If the reading still does not fall, the alternator is defective and must be repaired or replaced.

Current output 1. Operate the alternator at minimum speed.

2. Close switch 1. Check that the lamp lights.

3. Set the load resistor to its maximum resistance (minimum current).

4. Close switch 2.

5. Increase the alternator speed to a constant 5.000 min-1.

6. Adjust the load resistor for maximum current output.

7. Allow the alternator to run for 15 minutes. Output should increase as alternator temperature increases.

8. Once again, adjust the load resistor for maximum current output.

The maximum current output must equal the specified value. If it does not, the alternator must be rechecked.

Alternator output: 50 A/27 volt/5.000 min-1

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6D3-10 STARTING AND CHARGING

TROUBLESHOOTING Condition

No output

Possible Cause

Correction

Bad terminal connection

Repair

Open or shorted circuit

Repair

Open field coil

Replace

Defective diode

Replace

Defective IC regulator

Replace

Loose terminal connection

Tighten

Loose cooling fan belt

Adjust belt tension

Defective diode

Replace

Shorted field coil

Replace

Shorted stator coil

Replace

Defective regulator

Replace

Defective battery

Replace

Poor terminal contact

Repair

Defective regulator

Replace

Defective battery

Replace

Poor terminal contact

Repair

Loose cooling fan belt

Adjust belt tension

Short field coil

Replace

Shorted stator coil

Replace

Intermittent contact in wiring

Replace

Poor terminal contact

Repair

Defective regulator

Replace

Improper alternator installation

Correct

Defective bearing

Replace

Low output

Overcharging

Unstable current

Abnormal noise

Cre 9-36560GB

Contact between the rotor core and stator core Replace the rotor core and/or stator core Defective diode

Replace

Shorted stator coil

Replace

Issued 01-02

STARTING AND CHARGING 6D3-11

STARTER MOTOR GENERAL DESCRIPTION

CS01N912

The starter motor has a reduction gear assembly that uses planetary gears.

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6D3-12 STARTING AND CHARGING

MAIN DATA AND SPECIFICATIONS Rated voltage

V

24

Rated output

kW

5.0

Rating

Sec

30

Direction of rotation (Viewed from the pinion side)

Clockwise

Terminal voltage (No load)

V

23

Minimum current (No load)

A

85

Starter motor minimum operating speed (No load)

min-1

3300

Pinion gear Modules

3

Number of teeth

11

Outside diameter

mm (in)

48.9 (1.93)

Yoke outside diameter

mm (in)

85 (3.35)

Standard

mm (in)

18 (0.71)

Limit

mm (in)

11 (0.43)

Brush length

Brush spring standard fitting load

N (lb)

29 - 39 (6.6 - 8.8)

Commutator Outside diameter Standard

mm (in)

32 (1.26)

Limit

mm (in)

31.4 (1.23)

Standard

mm (in)

0.5 (0.02)

Limit

mm (in)

0.2 (0.008)

mm (in)

0.5 - 2.0 (0.0197 - 0.079)

Depth of undercut mica

Pinion projection Standard

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STARTING AND CHARGING 6D3-13

DISASSEMBLY

8 7 6 5 20 19 18 27 17 16 15 14 4

13

3

12

2

11

1

26

10

25

9

24 23 22 21 CS01N913

Legend (1)

Snap ring

(14) Planetary gear

(2)

Stop ring

(15) Ball

(3)

Pinion

(16) Gasket

(4)

Pinion spring

(17) Plate

(5)

Screw

(18) Armature

(6)

Pinion case

(19) Washer

(7)

Lever

(20) Bearing

(8)

Magnetic switch

(21) Gasket

(9)

Clutch

(22) Yoke

(10) Internal gear

(23) Brush

(11) Washer

(24) Gasket

(12) E-type stop ring

(25) Brush holder

(13) Gear shaft

(26) Rear cover (27) Through bolt

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Issued 01-02

6D3-14 STARTING AND CHARGING 1. Place matching marks on the magnetic switch and yoke to ensure reassembly to their original positions.

2. Connect the starter motor to a battery. The pinion rises and begins to rotate.

SW 1 SW 2

3. Open switch-2 to stop pinion rotation.

24 V

4. Separate the stop ring by striking it with a pipe and bar.

5. Remove the stop ring, the snap ring, the pinion, and the pinion spring.

6. Discard the stop ring.

CS01N914

NOTE: Pinion removal should require no more than 10 seconds. If more time is required, heat from the armature will cause the starter damage.

Legend

5 4

3

(1)

Pinion

6

(2)

Clutch shaft

(3)

Snap ring

(4)

Stop ring

(5)

Pipe

(6)

Pinion spring

2 1

7. Remove the magnetic switch.

8. Loosen the brush holder fixing screws and the through bolt.

9. Remove the rear bracket and gasket.

CS01N915

10. Discard the gasket.

11. Use a socket wrench with a 32 mm diameter to hold the armature commutator in place. Remove the yoke assembly.

12. Slide the brush on to the socket.

13. Lift the brush spring and remove the brush.

14. Remove the brush holder.

15. Pull the armature from the planetary gear.

16. Use a bearing puller to remove the bearing. Be careful not to lose the ball.

17. Remove the plate and gasket.

18. Remove the planetary gear.

19. Hold the internal gear, the gear shaft overrunning clutch, and the lever together. Remove them a unit from the front bracket.

20. Remove the lever from the gear shaft (mark installation position).

21. Remove the E-type stop ring from the gear shaft discard it.

22. Remove the overrunning clutch from the gear shaft.

23. Remove the internal gear and washers.

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STARTING AND CHARGING 6D3-15

INSPECTION AND REPAIR Armature 1. Use a circuit tester to check armature continuity.

Hold the circuit tester probes against 2 commutator segments. Repeat the procedure for several other segment pairs.

There must be continuity between all commutator segments. If there is not, the commutator must be replaced.

2. Use a circuit tester to check the armature ground.

CS01N916

Hold one probe against a commutator segment.

Hold the other probe against the armature shaft.

If there is continuity, the armature is grounded. It must be replaced.

CS01N917

3. Measure the commutator outside diameter.

4. If the measured diameter is less than the specified limit, the commutator must be replaced.

Commutator outside diameter Standard: 32 mm (1.28 in) Limit: 31.4 mm (1.256 in) 5. Inspect the commutator mica segments for excessive wear and damage.

6. Measure the depth of the commutator mica segments.

CS01N918

If the depth is less than the specifed limit, the commutator must be replaced.

Commutator mica segment depth Standard: 0.5 mm (0.02 in) Limit: 0.2 mm (0.008 in) 7. Inspect the gear for excessive wear and damage.

Replace if required.

8. Rotate the commutator with your hand. Listen for abnormal noise or rattling from the bearing.

Check for grease leakage. Replace if required.

CS01N1919

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6D3-16 STARTING AND CHARGING

Field Coil 1. Use a circuit tester to check for continuity between the field coil and the lead wire.

If there is no continuity, a field coil wire is broken.

The field coil must be replaced.

CS01N920

2. Check for continuity between the field coil and the yoke.

If there is continuity, the yoke must be repaired or replaced.

CS01N921

Brush and Brush Holder 1. Measure the brush length.

If the brush length is less than the specified limit, the brush and/or yoke must be replaced.

Brush length Standard: 18 mm (0.72 in) Limit: 11 mm (0.44 in) 2. Check the brush spring for weakness and corrosion. Replace the spring if required.

CS01N922

3. Use a spring balancer to measure the brush spring tension.

If the spring tension is less than the specified limit, the spring must be replaced.

Brush spring tension Standard: 29 - 39 N (3 - 4 kg/6.6 - 8.8 Ib) Limit: 13.7 N (1.4 kg/3.1 Ib) 4. Use a circuit tester to check the brush holder insulation.

Touch one probe to the field winding lead wire and the other probe to the brush.

If there is continuity between the lead wire and the brush, the insulation is bad. Repair or replace the brush holder.

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Issued 01-02

STARTING AND CHARGING 6D3-17

Overrunning Clutch and Pinion 1. Wipe away dirt and grime adhering to the overrunning clutch and pinion.

2. Check the pinion teeth for excessive wear and damage.

3. Rotate the pinion in the direction of normal rotation. It must turn smoothly.

4. Rotate the pinion in the opposite direction. It must lock.

Replace the overrunning clutch if any problems are discovered during inspection.

CS01N923

NOTE: The inside of the overrunning clutch is packed with grease. Do not soak the clutch in liquid cleaner or solvent to clean it. Grease leakage will result.

Front Bracket Check the front bracket bearing and oil seal for damage. Replace if required.

Internal Gear and Planetary Gear Check the gears for excessive wear and damage.

Replace if required.

Magnetic Switch

2

1. Use a circuit tester to check for continuity between the magnetic switch terminal-M (1) and the body (2). If there is no continuity, the switch must be replaced.

2. Check for continuity between the magnetic switch terminal-M (1) and terminal-B (3). If there is continuity, the switch must be replaced.

1

3

CS01N924

Cre 9-36560GB

Issued 01-02

6D3-18 STARTING AND CHARGING

REASSEMBLY To reassemble the starter motor, disassembly steps in the reverse order.

2 3

follow

the

Pay close attention to the following.

4

• Lubrication points and recommended lubricants 5

No.

6 1

9

8

Lubrication area

1

Armature bearing area (Light lubrication)

2

Plunger (Light lubrication)

3

Gear shaft spline and sliding parts

4

Clutch shaft

5

Oil seal

6

Pinion (Overrunning clutch)

7

Lever sliding surfaces (Overrunning clutch)

8

Sleeve bearing and ball

9

Armature shaft gear, internal gear, and planetary gears

7 CS01N912

Lubricant

MULTEMP OA-171 or equivalent

Molycoat R AG650 or equivalent

• Tighten the fixing bolts to the specified torque.

Torque Nut (1):

2

1

23 Nm (2.3 kg.m/17 lb.ft)

Bolt (2): 6.8 Nm (0.7 kg.m/5.1 lb.ft) Bolt (3): 9.8 Nm (1.0 kg.m/7.2 lb.ft) Bolt (4): 3.4 Nm (0.35 kg.m/2.5 lb.ft)

Armature shaft axial play

4

Install the ball to the top of the armature shaft. No adjustment is required.

3 CS01N912

Gear shaft axial play Install the washer between the internal gear and the gear shaft.

No adjustment is required.

Cre 9-36560GB

Issued 01-02

STARTING AND CHARGING 6D3-19 Legend 5 3

(1)

Overrunning clutch

(2)

Internal gear

(3)

Washer

(4)

E-type, stop ring

(5)

Gear shaft

4 2 1 CS01N925

Gear shaft

4 5 3 2

1. Install the washer, internal gear, and overrunning clutch to the gear shaft.

2. Install the pinion spring (5), the pinion (1), and the stop ring (4) to the clutch shaft (2).

1

3. Install the snap ring (3).

4. Attach the stop ring to the snap ring.

CS01N926

Pinion projection 1. Connect the starter motor to the battery.

SW 1

B S

2. Turn switch-1 and switch-2 on.

SW 2

The pinion moves forward to the cranking position and the armature rotates.

M 24 V

3. Turn switch-2 off. The armature stops rotating.

4. Measure the pinion projection.

Pinion projection: 0.5 - 2 mm (0.02 - 0.08 in)

CS01N914

Cre 9-36560GB

Issued 01-02

6D3-20 STARTING AND CHARGING

Overrunning clutch shaft return Press against the head of the overrunning clutch with your hand.

Measure the movement (return) of the clutch shaft.

If the return is outside the specified range, adjust the packing between the front bracket and the magnetic switch.

If adjustment is not possible. Replace the lever.

CS01N927

Performance test 1. Connect the starter motor as shown in the illustration.

2

Legend

1

(1)

3

Battery

(2)

Ammeter

(3)

Voltmeter

2. Turn the switch on.

3. Measure the starter motor speed, the current, and the voltage.

CS01N928

If the starter motor speed is less than the specified value, the starter motor requires further servicing.

Starter motor minimum speed: 3.300 min-1 (No load) If the measured starter motor minimum current and/or terminal voltage is different from the specified value, the starter motor requires further servicing.

Starter motor minimum current: 85 A (No load) Starter motor terminal voltage: 23 V (No load)

Cre 9-36560GB

Issued 01-02

ENGINE LUBRICATION 6G-1

SECTION 6G

ENGINE LUBRICATION TABLE OF CONTENTS ITEM PAGE Service precaution.....................................................................................................................................................1 General Description ..................................................................................................................................................2 Oil Pump ...................................................................................................................................................................4 Oil Cooler ..................................................................................................................................................................8 Oil Port Cover .........................................................................................................................................................11 Oil Filter ..................................................................................................................................................................13

SERVICE PRECAUTION • Be sure to use the correct fastener in the proper location. If a used fastener is replaced with a new one, the new fastener must be identical to the previous one.

• Some fasteners must always be replaced with new ones following removal. These fasteners are specified in this Manual.

• Some fasteners require thread locker or thread sealant. These fasteners are specified in this Manual.

• Supplemental fastener coatings (paint, grease, or corrosion inhibitor) affect fastener torque and clamping force. They may damage the fastener. Do not use them unless specifically called for.

• Tighten all fasteners to the specified torque. If there is a tightening sequence, follow it exactly.

Cre 9-36560GB

Issued 01-02

6G-2 ENGINE LUBRICATION

GENERAL DESCRIPTION LUBRICATING OIL FLOW The engine uses a pressure-feed lubrication system.

Oil flows from the oil pump to the oil filter for cleaning.

It then travels to the oil cooler where it is cooled.

From the oil cooler, the oil moves to the cylinder block oil gallery for distribution to the moving parts of the engine. Oil jets are arranged in a line near the center of the cylinder block oil gallery. The oil jets spray oil to the inside portions of the pistons to provide the most effective lubrication and cooling.

OIL PUMP AND OIL FILTER The gear-type oil pump is driven by the timing gear.

The pump is equipped with a relief valve.

The full-flow oil filter uses a highly-efficient paper element.

If the element becomes clogged, the by-pass valve opens to route the oil directly to the oil gallery. A warning lamp turns on to warn the equipment operator that the oil filter is being by-passed.

OIL COOLER Engine oil temperature rises with engine temperature with a corresponding decrease in lubricating efficiency. The oil cooler consists of the body and the cooling element.

The oil cooler maintains oil temperature at the level required for optimum engine lubrication.

Cre 9-36560GB

Issued 01-02

ENGINE LUBRICATION 6G-3

LUBRICATION OIL FLOW 1

16

2

17

18

9 8

19

10

3

11

4

12

20

21

24

22 23

160 kPa

13

25 5 26 6 14

15

7

CS01N929

Legend (1) Oil filter (2) By-pass valve opening pressure separate type oil filter 200 kPa (3) Main oil filter (4) Partial oil filter (combined type) (5) Relief valve opening pressure 780 kPa (6) Oil pump (7) Oil strainer (8) Oil thermostat opening temperature 90°C (9) Oil cooler (10) Sub oil gallery (11) Check valve (12) Idler gear A (13) Piston cooling oil jet Cre 9-36560GB

(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)

Injection pump Bearing case Starter switch Battery Oil pressure switch opening pressure 30 kPa Main oil gallery Crank shaft bearing Idler gear B Idler gear C Camshaft bearing and rocker arm Relief valve opening pressure 490 kPa Idler gear B Connecting rod bearing

Issued 01-02

6G-4 ENGINE LUBRICATION

OIL PUMP OIL PUMP CONSTRUCTION

3 5

2

4

1

6

CS01N930

Legend (1)

Oil pump drive gear

(4)

Cotter pin

(2)

Oil pump body

(5)

Drive gear

(3)

Oil relief valve

(6)

Driven gear and shaft

Cre 9-36560GB

Issued 01-02

ENGINE LUBRICATION 6G-5

DISASSEMBLY 1. Remove the driven gear and shaft.

CS01N931

2. Remove the cotter pin.

3. Remove the oil relief valve.

CS01N932

4. Remove the oil pump drive gear.

Use a gear puller to remove the oil pump drive gear.

CS01N933

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear of damage is discovered during inspection.

1. Use a feeler gauge to measure the clearance between the gear teeth and the body inner wall.

If the clearance between the gear teeth and the body inner wall exceeds the specified limit, the gear and/or the body must be replaced.

Gear Teeth and Cover Inner Wall Clearance Standard: 0.125 - 0.221 mm (0.0049 - 0.0087 in) CS01N934

Cre 9-36560GB

Limit: 0.221 mm (0.0087 in) Issued 01-02

6G-6 ENGINE LUBRICATION 2. Use a feeler gauge to measure the clearance between the body and the gear side surfaces.

If the clearance between the gears and the body exceeds the specified limit, the gears and/or the body must be replaced.

Gear and Body Clearance Standard: 0.064 - 0.109 mm (0.0025 - 0.0043 in) Limit: 0.109 mm (0.0043 in)

CS01N935

3. Use a micrometer to measure the gear shaft outside diameter.

Gear Shaft Outside Diameter Standard: 15.989 - 16.000 mm (0.6295 - 0.6299 in) Limit: 15.9 mm (0.626 in)

CS01N936

4. Use an inside dial indicator or inside micrometer to measure the pump body inside diameter and the cylinder block bushing inside diameter.

If the clearance between the gear shaft and the pump body or bushing exceeds the specified limit, the oil pump assembly and/or bushing must be replaced.

Gear Shaft and Pump Body or Bushing Clearance Standard: 0.04 - 0.07 mm (0.0016 - 0.0028 in) Limit: 0.07 mm (0.0028 in) CS01N947

5. Check the ball and the valve spring for excessive wear and damage.

CS01N948

Cre 9-36560GB

Issued 01-02

ENGINE LUBRICATION 6G-7 6. Use an inside and outside micrometer to measure the interference between the oil pump drive gear inside diameter and drive gear shaft outside diameter.

Drive Gear and drive Gear Shaft Interference (Reference) Standard: 0.015 - 0.044 mm (0.0006 - 0.0017 in)

CS01N949

REASSEMBLY 1. Install the drive gear and oil pump drive gear. a. Apply engine oil to the drive gear shaft. b. Install the oil pump drive gear to the drive gear shaft.

The gear hub large side must be facing the outside. c. Use the bench press to press the drive gear onto the drive gear shaft.

CS01N950

2. Install the oil relief valve.

3. Install the cotter pin.

4. Install the driven gear and shaft. a. Apply engine oil to the driven gear and shaft. b. Install the driven gear and shaft to the oil pump body.

CS01N931

Cre 9-36560GB

Issued 01-02

6G-8 ENGINE LUBRICATION

OIL COOLER DISASSEMBLY

3 1

2

5 7

6

4

CS01N951

Legend (1)

Oil cooler element

(5)

Plug

(2)

Gasket

(6)

Oil thermostat

(3)

Gasket

(7)

By-pass pipe

(4)

Body

Cre 9-36560GB

Issued 01-02

ENGINE LUBRICATION 6G-9 1. Loosen the fixing nuts to remove the element.

Discard the gaskets.

2. Remove the by-pass pipe.

3. Remove the oil thermostat.

4. Clean the inside of the oil cooler element. a. Use a funnel to pour cleaning solution into the oil cooler element.

Add cleaning solution until it overflows. b. Allow the oil cooler element to stand for ten hours (with the cleaning solution inside).

CS01N952

c. Pour off approximately 1/3 of the cleaning solution from the element. d. Apply compressed air at 200kPa (28 psi) to the element through the oil port. Continue to apply compressed air until all cleaning solution has been forced from the element.

WARNING: Compressed air can cause personal injury, when used protective for cleaning. Wear safety glasses and protective clothing.

NOTE: As long as the oil cooler element is not damaged or excessively dirty, it may be cleaned repeatedly at periodic intervals.

INSPECTION AND REPAIR 1. Use the dye penetrant detector procedure to inspect the element for cracking.

2. Use the dye penetrant detector procedure to inspect the oil cooler cover for cracking.

CS01N953

Cre 9-36560GB

Issued 01-02

6G-10 ENGINE LUBRICATION

REASSEMBLY 1. Install the by-pass pipe with new gasket to the body.

1

2. Install the oil thermostat with the rubber cap to the body.

3. Install the plug with new gasket to the body and tighten to the specified torque.

Torque: 20 Nm (2.0 kg.m/14 lb.ft)

CS01N954

4. Install the oil cooler element with new gasket to the body.

5. Tighten the element fixing nuts to the specified torque.

Torque: 20 Nm (2.0 kg.m/14 lb.ft)

CS01N951

Cre 9-36560GB

Issued 01-02

ENGINE LUBRICATION 6G-11

OIL PORT COVER

7

4 3

6

5

2

1

CS01N955

Legend (1)

Oil port cover

(5)

Plug

(2)

Gasket

(6)

Gasket

(3)

Oil relief valve

(7)

Port cover

(4)

Gasket

Cre 9-36560GB

Issued 01-02

6G-12 ENGINE LUBRICATION

REMOVAL 1. Remove the oil port cover from the cylinder block.

Discard the gaskets.

2. Remove the oil relief valve from the oil port cover.

Check the oil valve for restrictions.

INSPECTION AND REPAIR 1. Remove the plugs from the port cover.

2. Inspect the port cover for restrictions.

3. Remove all sludge and restrictions from the port cover.

INSTALLATION 1. Install the plugs with new gasket to the port cover.

Tighten the plug to the specified torque.

Torque: 25 Nm (2.6 kg.m/19 lb.ft) 2. Install the oil relief valve with new gasket to the port cover.

Tighten the valve to the specified torque.

Torque: 54 Nm (5.5 kg.m/40 lb.ft) 3. Install the oil port cover with new gasket to the cylinder block.

Tighten the fixing bolts to the specified torque.

CS01956

Cre 9-36560GB

Torque: 39 Nm (4.0 kg.m/29 lb.ft)

Issued 01-02

ENGINE LUBRICATION 6G-13

OIL FILTER

5 2

3

5 4

1

CS01N957

Legend (1)

Oil filter

(4)

Oil filter body

(2)

By-pass valve

(5)

Gaskets

(3)

Gasket

Cre 9-36560GB

Issued 01-02

6G-14 ENGINE LUBRICATION

DISASSEMBLY 1. Use the filter wrench to remove the oil filter.

2. Remove the by-pass valve.

Discard the gasket.

3. Remove the oil filter body from the cylinder body.

Discard the gaskets.

CS01N958

INSPECTION AND REPAIR 1. Inspect the by-pass valve for restrictions.

CS01N959

2. Inspect the oil filter.

• Inspect the orifice of the partial oil filter for restriction.

• Supply compression air to the orifice (indicated by an arrow).

• Confirm that air blows out from the holes of the oil filter installation joint.

CS01N960

REASSEMBLY 1. Install the oil filter body with new gaskets to the cylinder block.

• Tighten the bolts to the specified torque.

Torque: 37 Nm (3.8 kg.m/27 lb.ft)

CS01N961

Cre 9-36560GB

Issued 01-02

ENGINE LUBRICATION 6G-15 2. Install the by-pass valve with new gasket to the filter body.

• Tighten the valve to the specified torque.

Torque: 37 Nm (3.8 kg.m/27 lb.ft)

CS01N962

3. Install the oil filter to the oil filter body.

• Apply engine oil to the oil filter gasket.

• Turn the oil filter until the filter gasket comes in contact with its sealed face.

• Use a filter wrench to turn in the oil filter an additional one full turn.

CS01N958

Cre 9-36560GB

Issued 01-02

6G-16 ENGINE LUBRICATION

Cre 9-36560GB

Issued 01-02

ENGINE INDUCTION 6J-1

SECTION 6J

ENGINE INDUCTION TABLE OF CONTENTS ITEM PAGE Service precaution ....................................................................................................................................................1 Turbocharger ............................................................................................................................................................2 Troubleshooting ........................................................................................................................................................4

SERVICE PRECAUTION • Be sure to use the correct fastener in the proper location. If a used fastener is replaced with a new one, the new fastener must be identical to the previous one.

• Some fasteners must always be replaced with new ones following removal. These fasteners are specified in this Manual.

• Some fasteners require thread locker or thread sealant. These fasteners are specified in this Manual.

• Supplemental fastener coatings (paint, grease, or corrosion inhibitor) affect fastener torque and clamping force. They may damage the fastener. Do not use them unless specifically called for.

• Tighten all fasteners to the specified torque. If there is a tightening sequence, follow it exactly.

Cre 9-36560GB

Issued 01-02

6J-2 ENGINE INDUCTION

TURBOCHARGER GENERAL DESCRIPTION

CS01N963

Major turbocharger components are the center housing and rotating assembly (CHRA), the compressor housing, and the turbine housing.

Rotating parts are supported by the center housing and include the turbine shaft, the compressor wheel, the shaft bearings, the thrust bearings, and the oil seal ring.

Cre 9-36560GB

Turbocharger rotating parts operate at very high speeds and temperatures. The parts are built from carefully selected materials and machined to extremely high precision.

The turbocharger improves air intake efficiency resulting in increased engine power, reduced fuel consumption, and low engine noise.

Issued 01-02

ENGINE INDUCTION 6J-3

TURBOCHARGER SERVICING 1. Refer to TROUBLESHOOTING in this Section to determine whether or not turbocharger repair or overhaul is required.

2. The following procedures should also performed (either with the turbocharger on equipment or removed from the equipment not disassembled) to determine whether or turbocharger repair or overhaul is required.

be the but not

• 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.

PRECAUTION 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.

It is not recommended to perform servicing procedure not described in this Manual.

Cre 9-36560GB

Issued 01-02

6J-4 ENGINE INDUCTION

TROUBLESHOOTING If the engine does not run well (insufficient output or irregular acceleration) 1. Run the engine at idle.

2. Check for oil leakage from the turbocharger.

3. Listen for abnormal turbocharger noise.

4. Write down any abnormal conditions and their location.

5. Stop the engine.

6. Allow sufficient time for the turbocharger to cool.

7. Check the turbocharger air inlet hose and outlet hose. The bands attaching the hoses to the turbocharger must be tight. There must be no oil leakage.

WARNING: The turbocharger generates very high temperatures during operation. It will remain dangerously hot for some time after the engine is stopped. Allow sufficient time for the turbocharger to cool before touching it.

OIL LEAK Leak point

Cause

Countermeasure

Turbine housing gas inlet and outlet tightening area

Bearing abrasion (Trouble in the oil Turbine and bearing housing mating supply system) surfaces

Check the turbocharger air inlet

Loose bolts

Tighten bolts

O-ring damage

Replace O-ring

Oil leak from tightening area (Air compressor oil leak)

Turbocharger OK

Turbocharger oil inlet tightening area

Compressor housing case

ABNORMAL NOISE Description Whistling sound

Cause High-speed turbocharger operation

Countermeasure Normal sound of rotor rotation

Foreign particles in turbocharger Grinding sound

Bearing abrasion (Trouble in the oil supply system)

Hissing sound

Loose air or gas pipe

Check the turbocharger air inlet

Tighten bolts, screws, and/or hose bands as required

INSUFFICIENT OUTPUT OR IRREGULAR ACCELERATION Problem Poor engine performance because of air and/or gas leakage

Cre 9-36560GB

Cause Loose air and/or gas pipes running to the turbocharger

Countermeasure Tighten bolts, screws, and/or hose bands as required

Issued 01-02

ENGINE INDUCTION 6J-5 Disconnect the air inlet hose at the turbocharger to perform the following inspection.

Checkpoint Air inlet

Problem Oil on air inlet inside and outside surfaces resulting from oil leakage

Countermeasure Turbocharger OK

Loose or missing Shaft end nuts or blades

Foreign particles in turbocharger Bearing abrasion (Trouble in the oil supply system)

Replace turbocharger

Blade and housing interference Compressor housing

Bearing abrasion (Trouble in the oil supply system)

Oil feed pipe

Clogged

Cre 9-36560GB

Remove restrictions

Issued 01-02

6J-6 ENGINE INDUCTION

INSPECTION AND REPAIR Turbocharger damage or maladjustment results in a reduced volume of air to the engine. Engine performance suffers.

If there is a marked drop in engine performance, first check the engine. If the engine appears normal, check the turbocharger.

If excessive wear or damage is discovered during turbocharger inspection, the appropriate parts must be adjusted, repaired, or replaced.

Rotor Shaft Axial Play 1. Install a dial indicator to the turbine housing as shown in the illustration.

2. Move the shaft back-and-forth to measure the rotor shaft axial play. Note the total indicator reading (TIR).

Rotor shaft axial play: Standard: 0.06 - 0.09 mm (0.0024 - 0.0035 in) Limit: 0.11 mm (0.00433 in) If the measured value exceeds the specified limit, the rotor shaft must be replaced.

CS01N964

Rotor Shaft Radial Play 1. Invert the turbocharger so that the turbine exhaust inlet flange is facing up.

2. Install a dial indicator to the turbine housing as shown in the illustration.

3. Measure the rotor shaft axial play. Note the total indicator reading (TIR).

Rotor shaft radial play Standard: 0.10 - 0.17 mm (0.0039 - 0.0067 in) Limit: 0.205 mm (0.00807 in) CS01N965

Cre 9-36560GB

If the measured value exceeds the specified limit, the rotor shaft must be replaced.

Issued 01-02

TROUBLESHOOTING 12-1

SECTION 12

TROUBLESHOOTING TABLE OF CONTENTS ITEM PAGE Hard starting .............................................................................................................................................................2 Unstable Idling ..........................................................................................................................................................3 Insufficient Power .....................................................................................................................................................4 Excessive Fuel Consumption ...................................................................................................................................5 Excessive Oil Consumption ......................................................................................................................................5 Engine Cooling Trouble ............................................................................................................................................6 White Exhaust Smoke ..............................................................................................................................................6 Black Exhaust Smoke ...............................................................................................................................................6 Lubrication Problems ................................................................................................................................................7 Abnormal Engine Noise ............................................................................................................................................8 Alternator ..................................................................................................................................................................9 Starter Motor ...........................................................................................................................................................10 Turbocharger ..........................................................................................................................................................11

NOTE: Use this section to quickly diagnose and repair engine failures.

Each troubleshooting chart has three headings arranged from left to right: (1)

Check point

(2)

Trouble cause

(3)

Remedy

Cre 9-36560GB

Issued 01-02

12-2 TROUBLESHOOTING

HARD STARTING Condition

Possible Cause Loose battery cable terminals

Starter motor does not turn over

Poor battery connections due to rusting

Clean and/or retighten the battery cable terminals

Battery discharged or weak

Recharge or replace the battery

Fusible link shorted

Replace the fusible link

Defective starter switch or starter relay

Replace the starter switch or starter relay

Defective magnetic switch of starter motor or starter relay

Repair or replace the magnetic switch or starter relay

Defective starter motor

Repair or replace the starter motor

Loose battery cable terminals Poor battery connections due to rusting

Starter motor operates but engine does not turn over

Engine turns over but does not start

Correction

Clean and/or retighten the battery cable terminals

Battery discharged or weak

Recharge or replace the battery

Loose fan belt

Adjust the fan belt tension

Defective starter motor pinion gear

Replace pinion gear

Defective magnetic switch of the starter motor

Repair or replace the magnetic switch

Worn starter motor. Weak brush spring

Replace the brush and/or brush spring

Piston, crank bearing seizure, or other damage

Repair or replace the related parts

Air in the fuel system

Bleed air from the fuel system

Defective engine stop mechanism

Replace the engine stop mechanism

Control wire improperly adjusted

Adjust the control wire

Fuel tank is empty

Fill the fuel tank

Clogged or damaged fuel lines

Repair or replace the fuel lines

Loose fuel line connections

Retighten the fuel line connections

Clogged fuel filter element

Replace the fuel filter element or cartridge

Fuel feed pump strainer is clogged

Clean the fuel pump strainer

Defective feed pump

Repair or replace the feed pump

Poor return of the engine stop button

Completely return the engine stop button

Use of the wrong fuel

Use the recommended fuel

Water particles in the fuel

Change fuel

Air in the injection pump

Bleed air from the fuel system

Injection nozzle sticking

Replace the injection nozzle

Injection nozzle starting pressure too low Adjust or replace the injection nozzle Improper spray condition Improper injection pump control rack operation

Repair or replace the injection pump control rack

Injection pump plunger worn or stuck

Replace the injection pump plunger assembly

Injection pump camshaft seizure or other Replace the injection pump camshaft damage

Cre 9-36560GB

Issued 01-02

TROUBLESHOOTING 12-3

UNSTABLE IDLING Condition Trouble in the engine stop mechanism

Possible Cause

Correction

Poor return of the engine stop button

Completely return the engine stop button

Fuel system leakage or blockage

Repair or replace the fuel system

Air in the fuel system

Bleed the air from the fuel system

Water particles in the fuel

Replace fuel

Clogged fuel filter element

Replace the fuel filter element or cartridge

Injection nozzle sticking

Replace the injection nozzle

Injection nozzle starting pressure too low Adjust or replace the injection nozzle Improper spray condition Trouble in the fuel system

Trouble in the valve gear train

Low compression pressure

Cre 9-36560GB

Defective delivery valve resulting in fuel drippage after fuel injection

Replace the delivery valve

Injection timing improperly adjusted

Adjust the injection timing

Insufficient injection volume

Adjust the injection volume

Broken plunger spring of the injection pump

Replace the plunger spring

Worn plunger of the injection pump

Replace the plunger assembly

Worn camshaft of the injection pump

Replace the camshaft

Worn roller tappet of the injection pump

Replace the roller tappet

Valve clearance improperly adjusted

Adjust the valve clearance

Worn camshaft

Replace the camshaft

Blown out cylinder head gasket Worn cylinder liner Replace the related parts Piston ring sticking or broken Improper seating between the valve and valve seat

Issued 01-02

12-4 TROUBLESHOOTING

INSUFFICIENT POWER Condition Trouble in the air intake system

Possible Cause

Correction

Clogged air cleaner element

Clean or replace the air cleaner element

Water particles in fuel system

Replace fuel

Clogged fuel filter element

Replace the fuel filter element or cartridge

Clogged strainer or defective fuel feed pump

Repair or replace the feed pump

Injection nozzle sticking

Replace the injection nozzle

Injection nozzle starting pressure too low Adjust or replace the injection nozzle Trouble in the fuel system

Trouble in the turbocharger system

Low compression pressure

Trouble in the valve gear train Trouble in the intercooler

Cre 9-36560GB

Improper spray condition

Adjust or replace the injection nozzle

Fuel injection pipes damaged or obstructed

Replace the injection pipes

Defective delivery valve

Replace the delivery valve

Injection timing improperly adjusted

Adjust the injection timing Repair or replace the timing advancer

Worn plunger of the injection pump

Replace the plunger assembly

Worn camshaft of the injection pump

Replace the camshaft

Exhaust gas leakage from the exhaust system

Repair or replace the related parts

Air leakage from the intake system

Repair or replace the related parts

Defective turbocharger assembly

Replace the turbocharger assembly

Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Replace the related parts Improper seating between the valve and valve seat Valve clearance improperly adjusted

Adjust the valve clearance

Worn camshaft lobe

Replace the camshaft

Valve spring weak or broken

Replace the valve spring

Clogged intercooler

Clean the intercooler

Issued 01-02

TROUBLESHOOTING 12-5

EXCESSIVE FUEL CONSUMPTION Condition

Possible Cause Fuel leakage

Trouble in the fuel system

Correction Repair or replace the fuel system related parts

Injection nozzle starting pressure too low Adjust or replace the injection nozzle Improper spray condition

Adjust or replace the injection nozzle

Injection timing improperly adjusted

Adjust the injection timing

Trouble in the air intake system

Clogged air cleaner element

Clean or replace air cleaner element

Improper idle speed

Poorly adjusted idling speed

Adjust idling speed

Trouble in the cooling system

Defective thermostat

Replace

Trouble in the lubricating system

Improper engine oil viscosity

Replace engine oil

Trouble in turbocharger system

Low compression pressure

Trouble in the valve gear train

Air leakage from the turbocharger intake Repair the turbocharger intake side side Defective turbocharger assembly

Replace the turbocharger assembly

Blown out cylinder head gasket Worn cylinder liner Replace the related parts Piston ring sticking or broken Improper seating between the valve and valve seat Valve clearance improperly adjusted

Adjust the camshaft

Worn camshaft lobe

Replace the camshaft

Valve spring weak or broken

Replace the valve spring

EXCESSIVE OIL CONSUMPTION Condition Trouble in the lubricating system Leakage

Possible Cause

Correction

Engine oil unsuitable

Replace engine oil

Too much engine oil

Correct engine oil volume

Oil leakage from the oil seal and/or gasket

Replace the oil seal and/or gasket

Oil leaking into the Worn valve stems and valve guides combustion chamber due to poor seal in the valve Worn valve stem oil seal system

Replace the intake and exhaust valves and valve guides Replace the oil seal

Improper sealing

Worn or broken seal ring in the turbocharger

Low compression pressure

Blown out cylinder-head gasket Worn cylinder liner Piston ring sticking or broken Replace the related parts Improper seating between the valve and valve seat

Poor engine ventilation

Clogged air breather

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Replace the seal ring

Clean the air breather Issued 01-02

12-6 TROUBLESHOOTING

ENGINE COOLING TROUBLE Condition

Overheating

Possible Cause

Correction

Insufficient coolant

Replenish coolant

Defective pressure cap or clogged radiator core

Replace the radiator pressure cap or clean radiator core

Defective water pump

Repair or replace the water pump

Defective sealing cap resulting in the cooling water leakage

Replace the sealing cap

Defective thermostat

Replace the thermostat

Cooling system clogged by foreign material

Remove foreign material from the cooling system

Fuel injection timing improperly adjusted Adjust the fuel injection timing

WHITE EXHAUST SMOKE Condition

Possible Cause

Correction

Water particles in fuel

Replace the fuel

Retarded fuel injection timing

Adjust the fuel injection timing

Trouble in the fuel system Blown out cylinder head gasket Worn cylinder liner Low compression pressure

Piston ring sticking or broken

Replace the related parts

Improper seating between the valve and valve seat Trouble in the cooling system

Defective thermostat

Replace the thermostat

Trouble in the turbocharger system

Defective turbocharger

Repair or replace

BLACK EXHAUST SMOKE Condition Trouble in the fuel system

Trouble in the fuel injection system

Trouble in the valve train

Cre 9-36560GB

Possible Cause

Correction

Clogged air cleaner element

Clean or replace the air cleaner element

Injection nozzle starting pressure tool low

Adjust or replace the injection nozzle

Improper spray condition Advanced fuel injection timing

Adjust the fuel injection timing

Excessive injection volume

Adjust the injection volume

Worn camshaft lobe

Replace the camshaft

Issued 01-02

TROUBLESHOOTING 12-7

LUBRICATION PROBLEMS Condition

Oil pressure does not rise

Cre 9-36560GB

Possible Cause

Correction

Improper engine oil viscosity

Replace the engine oil

Insufficient engine oil

Add engine oil

Defective oil pressure gauge or unit

Repair or replace the oil pressure gauge or unit

Clogged oil filter element

Replace the oil filter element or cartridge

Relief valve sticking and/or weak bypass valve spring

Replace the relief valve and/or by-pass valve spring

Clogged oil pump strainer

Clean the oil pump strainer

Worn oil pump related parts

Replace the oil pump related parts

Worn rocker arm bushing

Replace the rocker arm bushing

Worn camshaft and camshaft bearing

Replace the camshaft and camshaft bearing

Worn crankshaft and bearings

Replace the crankshaft and/or bearing

Oiling jet valve does not close

Replace the oiling jet

Issued 01-02

12-8 TROUBLESHOOTING

ABNORMAL ENGINE NOISE Start the engine and allow it to warm up before beginning the troubleshooting procedure.

Condition

Possible Cause Use of wrong fuel

Correction Use correct fuel

Fuel injection timing improperly adjusted Adjust the injection timing Improper injection nozzle starting pressure Engine knocking

Gas leakage noise

Continuous noise

Slapping noise

Cre 9-36560GB

Adjust or replace the injection nozzle

Improper spray condition Broken piston ring resulting in low compression pressure

Replace the piston ring

Defective fuel injection nozzle resulting in fuel drippage after fuel injection

Replace the fuel injection nozzle

Loosely connected exhaust pipes

Tighten the exhaust pipe connections

Broken exhaust pipes

Replace the exhaust pipes

Loose injection nozzles and/or glow plugs

Tighten the injection nozzles and/or glow plugs Replace the washers

Loosely connected exhaust manifold

Tighten the exhaust manifold connections

Damaged cylinder head gasket

Replace the cylinder head gasket

Loose fan belt

Readjust the belt tension

Loose cooling fan

Retighten cooling fan

Worn or damaged water pump bearing

Replace the water pump bearing

Worn or damaged alternator bearing

Replace the alternator bearing

Valve clearance improperly adjusted

Adjust the valve clearance

Valve clearance improperly adjusted

Adjust the valve clearance

Damaged rocker arm

Replace the rocker arm

Worn or damaged crankshaft and/or thrust bearings

Replace the crankshaft and/or thrust bearings

Worn or damaged crankshaft and/or connecting rod bearings

Replace the crankshaft and/or connecting rod bearings

Worn or damaged connecting rod bushing and piston pin

Replace the connecting rod bushing and/ or piston pin

Worn or damaged piston and cylinder liner Foreign material in the cylinder

Replace the piston and cylinder liner

Issued 01-02

TROUBLESHOOTING 12-9

ALTERNATOR Condition

Battery dead

Possible Cause

Correction

Loose alternator drive belt

Adjust

Low battery fluid

Replenish

Defective battery terminals

Replace

Blown fuse

Replace

Poor contact between the fuse holder and fuse

Repair

Low battery fluid specific gravity

Adjust

Broken or poorly connected starter switch and regulator terminal wire

Repair

Broken or poorly connected regulator terminal and alternator terminal wire

Repair

Defective alternator ground circuit

Repair

Defective voltage regulator

Replace

Defective diode

Replace

Grounded or broken alternator stator coil Repair or replace

Battery overcharged

Flashing charge light or fluctuating ammeter indication Charge light on but dim during operation

Alternator noise

Charge circuit fuse blown

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Broken rotor coil

Replace

Excessive electrical load

Check the alternator output at normal operating speed

Poor connections or open circuit

Correct

Poor ground connection of voltage regulator

Correct

Voltage set of regulator too high

Replace

Defective voltage regulator

Replace

Loose belt

Adjust

Defective starter switch contacts

Replace

Broken or poorly connected wiring

Replace or reconnect

Loose starter switch terminal wiring

Retighten

Excessive resistance of alternator and fuse holder terminal wire

Replace the wire with a larger one

Defective starter switch contacts

Replace

Defective alternator bearing

Replace or regrease

Exposed stator coil wires

Replace

Short circuit of the stator coil

Replace

Grounded terminal wiring

Repair

Defective alternator end flame diode

Replace the end flame assembly

Out of voltage regulator adjustment

Replace

Reversed battery connections

Correct

Issued 01-02

12-10 TROUBLESHOOTING

STARTER MOTOR Condition

Possible Cause

Correction

Low battery fluid level

Replenish

Low battery specific gravity

Recharge or replace

Poor battery switch contacts

Replace

Defective starter switch

Replace

Starter and magnetic switch Defective magnetic switch pull-in coil and Replace does not operate plunger Broken armature coil

Replace

Broken field coil

Replace

Broken magnetic switch

Replace

Broken holding coil

Replace

Low battery fluid level

Replenish

Low battery specific gravity

Recharge or replace

Poor starting circuit contacts Magnetic switch operates Poor contacts of magnetic switch but the starter does not turn terminal

Starter runs slowly

Starter operates but the engine does not start

Abnormal operating noise

Cre 9-36560GB

Repair Replace

Worn brushes

Replace

Shorted armature

Repair or replace

Bad contact of magnetic terminal circuit switches

Repair

Excessive brush wear

Replace

Shorted starter motor armature

Repair or replace

Pinion and ring gear not engaged

Repair or replace the running clutch and driving lever

Overrunning clutch slippage

Replace

Excessive brush wear

Replace

Excessive bushing wear

Replace

Excessive pinion gear wear

Replace overrunning clutch and pinion gear

Rough sliding action pinion gear

Lubricate or replace the overrunning clutch

Excessive ring gear wear

Replace overrunning clutch and ring gear

Excessive brush wear

Replace

Issued 01-02

TROUBLESHOOTING 12-11

TURBOCHARGER Condition

Engine has less than normal power

Blue or black smoke

Excessive oil consumption

Excessive turbocharger noise

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Possible Cause

Correction

Restricted air cleaner

Clean or replace

Restricted intake pipe and hose

Clean or replace

Loose connection of the turbocharger inlet and outlet

Repair

Restricted exhaust and silencers

Repair

Restricted air breather

Clean or replace

Compressor wheel damage

Replace

Turbine wheel damage

Replace

Carbon build-up on the turbine wheel

Replace

Dragging or seized rotating assembly

Replace

Restricted air cleaner

Clean or replace

Leakage from turbocharger oil seal

Replace

Restricted turbocharger oil drain pipe

Repair or replace

Restricted air breather

Clean

Compressor wheel damage

Replace

Turbine wheel damage

Replace

Restricted center housing oil drain passage

Clean or replace

Restricted air breather

Clean

Leakage from turbocharger oil seal

Replace

Compressor wheel damage

Replace

Turbine wheel damage

Replace

Excessive oil pressure

Repair

Restricted center housing oil drain passage

Clean or replace

Restricted intake and exhaust system joints

Repair

Damaged intake and exhaust system gaskets

Repair

Rough rotation of turbocharger parts

Replace

Compressor wheel rubbing against housing

Replace

Damaged compressor wheel

Replace

Turbine wheel rubbing against housing

Replace

Damaged turbine wheel

Replace

Carbon build-up on the turbine wheel

Clean or replace

Low engine oil level

Correct

Issued 01-02

12-12 TROUBLESHOOTING Condition

Excessive turbocharger noise (Continued)

Excessive rotating part wear

Cre 9-36560GB

Possible Cause

Correction

Contaminated oil

Replace oil

Restricted turbocharger oil feed pipe

Repair or replace

Carbon build-up on the turbine housing

Clean

Dirty compressor housing

Clean

Worn turbine shaft bearings

Replace

Contaminated engine oil

Change

Wrong grade or type of engine oil

Change

Restricted turbocharger oil feed pipe

Clean or replace

Defective turbocharger oil seal

Replace

Restricted center housing oil drain passage

Clean or replace

Turbine shaft sludge and/or coking

Replace

Inadequate oil supply

Correct

Issued 01-02

SPECIAL TOOL LIST 13-1

SECTION 13

SPECIAL TOOL LIST TABLE OF CONTENTS ITEM PAGE Special Tool List .......................................................................................................................................................2

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Issued 01-02

13-2 SPECIAL TOOL LIST

SPECIAL TOOL LIST This section will be distributed at a later date.

Cre 9-36560GB

Issued 01-02