Case ISUZU 6UZ1X Engine Service Manual - PDF DOWNLOAD

ENGINE SERVICE MANUAL ENGINE

ISUZU 6UZ1X

Bur • Issued 01Nov 06 Printed in U.S.A. • Book/Form Number 87606798A EN-US Copyright © 2009. CNH America, LLC. All Rights Reserved.

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer This unit first became available 11-2006 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01Nov 06

Isuzu 6UZ1X Engine

87606798A EN-US

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED. ● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. ● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ● The first panel indicates the nature of the hazard. ● The second panel indicates the appropriate avoidance of the hazard. ● Background color is YELLOW ● Prohibition symbols such as and STOP if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ❷ Is instructed in safe and proper use of the machine. ❷ Reads and understands the Manual(s) pertaining to the machine. ❷ Reads and understands ALL Safety Decals on the machine. ❷ Clears the area of other persons. ❷ Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow instructions on machine operation and maintenance.

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine.

Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.

Always give the Machine Name, Model, and P. I.N. (Product Identification Number) or S. N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A..

General Information OA-1

General Information General Information Contents General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2 Reading the Model. . . . . . . . . . . . . . . . . . . . . . . 0A-6 General Information . . . . . . . . . . . . . . . . . . . . . . 0A-6

General Information OA-2

General Information Service Precautions In order to work safely 1. Use an engine stand when lowering the engine from the machine.

Do not put the engine on the ground directly. And put it so that the oil pan is not affected.

2. When performing by two persons or more, confirm safety each other.

3. If performing repair on the electrical system, always disconnect the negative cable from the battery terminal beforehand. Before removing the battery cover, keep fire away.

6. Maintain tools, measuring equipment and special tools in good condition, and prepare them before use. Do not use worn wrenches, hammers that has the rounded striking surface of the head or chipped chisels, etc.

7. When using devices such as a grinder, crane and welder, follow the instructions and use a special care.

Also, when performing other works, protect yourself with clothes and other safety tools.

4. In badly ventilated indoor workshop, do not run the engine for a long time or perform painting work.

5. Be sure to use special tools as instructed. Use of other than the specified tool may cause damage of parts or injury.

WSHK0191

WSHK0190

General Information OA-3 8. After servicing the fuel system, always check for fuel leakage. (This may cause a fire.)

Replacement parts and part numbers 1. Always replace the packing, oil seal, O-ring, caulking lock nut, folding type lock plate, split pin, etc. with new ones every time they are disassembled.

2. The part number information in this manual may not represent availability of supply, or the numbers may have been changed due to revision. Always check the numbers with the part catalog before use.

Liquid gasket

9. When handling highly-volatile material, take extreme care not to let it catch fire.

Be sure to wipe off spilled oil and grease on rubbers, as this may cause the rubber to deteriorate.

1. Remove old liquid gasket completely from liquid gasket applied area on each part using a scraper during disassembly. Wipe off oil, water, dust, etc. with cloth and apply specified liquid gasket on each area before assembly.

2. If the gasket remover (ThreeBond, Pando 391D) is used to clean easily, it is recommended that you wait for about 10 minutes after application, and then remove it.

However, do not use it for resin or painted parts.

3. Be careful to apply appropriate amount, not excessively or insufficiently.

Always, the start and end of the application should be overlapped.

4. Take care not to misalign the applied part and opposite one when assembling it after application.

If the parts are misaligned, apply the liquid gasket again. Especially for the oil pan, use the same size of studs as a guide since it has no positioning such as a knock pin.

5. Apply liquid gasket and assemble it within 7 minutes.

If more than 7 minutes have elapsed, remove the existing liquid gasket and apply again.

6. Start the engine more than 30 minutes after each part is assembled.

WSHK0192

Liquid gasket Sealed Location

Product Name

Manufacturer

1207B

ThreeBond

Between front cover – cylinder block

1201

ThreeBond

Between cylinder block – flywheel housing – crank case

1201

ThreeBond

FMD –127

Loctite

1207B

ThreeBond

Upper surface of the mating portion between cylinder block – flywheel housing

Between cylinder block – crank case Lower surface of the mating portion between crankcase – flywheel housing

General Information OA-4 Sealed Location

Product Name

Manufacturer

Lower surface of the mating portion between crankcase – front cover

1207B

Three Bond

Contact part of cylinder head that nozzle sleeve is pushed to

TL290

Loctite

Sealing cup push part between cylinder block – head

962T 123T

Loctite Hermetic seal

Plug nipple of oil cooler

#575

Loctite

1208 CH Dyne #290

Three Bond Cement dyne

O-ring omission prevention agent

• Be sure to use liquid gasket of product name described above or equivalent product.

• Use the appropriate amount of liquid gasket.

Follow the instructions of products.

Method of application 1. Wipe off water, oil or grease from contact surface.

The contact surface should be dry.

2. Apply liquid gasket of specified bead width on the one side of contact surfaces. At this time, there should be no gap in bead.

Note: If the method of application is described in service manual, follow the description.

Work procedure 1. Wipe off oil, grease and water completely from the contact surface of bolt, bolt hole and threads portion of nut. The contact surface should be dry.

2. Apply Loctite on 1/3 of the tip of threads.

3. Tighten the bolt to the specified torque.

How to use Plastigauge Type

Measurable Range (mm)

PG-1 (Green)

0.025 — 0.076

PR-1 (Red)

0.051 — 0.152

PB-1 (Blue)

0.102 — 0.229

(Example) Measurement of clearance between connecting rod bearing and crank pin • Clean the connecting rod and the bearing, and assemble the bearing to the connecting rod.

• Cut the Plastigauge in the width of the crank pin, and place it parallel, away from the oil hole of the pin.

• Align the stamp mark of connecting rod with that of cap, and assemble them to the crank pin. Apply molybdenum disulphide to the threads and the seating surface of the tightening bolts, and tighten the bolts on the cap alternately to the specified torque.

Important: Never move the connecting rod while using the Plastigauge.

• Carefully remove the cap and the connecting rod, and measure the width (clearance) of flattened Plastigauge using the scale printed on the bag.

Important: After tightening, do not give excessive torque or vibration for at least 1 hour until Loctite hardens.

General Information OA-5 • Carefully remove the crankcase, and measure the width (clearance) of the flattened Plastigauge using the scale printed on the bag.

(Example) Measurement of clearance between crankshaft bearing and crankshaft journal.

• Clean the bearing installation surfaces on the crankcase and on the cylinder block, and the bearings. Then assemble each bearing to the cylinder block and the crankcase.

• Put the crankshaft on the cylinder block carefully, and rotate the crankshaft for approx. 30 degrees to fit in.

• Cut the Plastigauge in the width of the crankshaft journal, and place it parallel, away from the oil hole of the journal.

• Put the crankcase on the cylinder block carefully, and apply molybdenum disulphide to the threads and the seating surface of the tightening bolts.

Then tighten them to the specified torque in the specified order.

Important: Never rotate the crankshaft while using the Plastigauge.

General Information OA-6

Reading the Model Stamping position of engine number

WSUZ0142

Name 1. Engine Number Stamp (6UZ)1-······)

General Information Description of terms and abbreviations Definition of terms Term Specifications Nominal dimension Assembly specifications Service limit Front/Rear, Right/Left, Top/Bottom Units

Warning

Description General term for the specified values that are necessary for service work, such as nominal dimension, assembly specifications and service limit.

It indicates the value without tolerance at the time of manufacture.

It indicates the specified value after assembly, repair or adjustment.

It indicates the limit value that the part must be repaired or replaced when it reaches this value (dimension).

These indicate directions same as those of the vehicle when mounted on.

In addition to SI unit, conventional unit is also shown (toque, pressure, force, in particular).

[Example] Length: mm, Torque: N⋅m {kgf⋅m} It means the items that danger of personal life or serious injury may occur if you do not follow.

General Information OA-7 Term

Description

Caution

It means the items that injury or accident may occur if you do not follow.

Important Note

It means the items that related parts and system may lose the normal performance, or a fault may occur in vehicle.

It means the items which is noted in procedures.

Abbreviation

Abbreviation

Abbreviation AC

Description Alternating Current

ACC

Accessory

ACG

Alternating Current Generator

API

American Petrol Institute

Description

M/V

Magnetic Valve

NOx

Nitrogen Oxide

N-TDC

Number - Top Dead Center

OPT

Option

P

Pole(S)

PCV

Pump Control Valve/Positive Crankcase Ventilation

After Top Dead Center

PM

Particulate Matter

BAT, BATT

Battery

PS

Pre-Stroke

BRG, Brg

Bearing

PTO

Power Take Off

BKT, BRKT

Bracket

QOS

Quick On System

ASM (Assy) ATDC

BTDC CO

Assembly

Before Top Dead Center Carbon Oxide

Rr, RR R/H, RH

Rear Right Hand

Connector

R/L

Relay

CPU

Central Processing Unit

STD

Standard

C/U

Control Unit

SW

Switch

DC

Direct Current

DI

Direct Injection

CONN

ECU

Engine Control Unit/Electronic Control Unit

ECM

Engine Control Module

EGR

Exhaust Gas Recirculation

Exh, EXH Ft, FRT

Exhaust Front

FWD

Forward

F/C

Fuel Cut

GND

Ground

IC

Integrated Circuit

ID plate

Identification Plate

IN ISO I/PUMP JIS L/H, LH

Intake, Inlet International Organization for Standardization Injection Pump Japanese Industrial Standards Left Hand

TICS

VGS Turbo

W/L

Timing & Injection rate Control System A type of injection system Variable Geometry turbocharger System Variable turbo, VGS turbo Warning Lamp

SI (International System of Unit) About changeover to SI (International System of Unit) This was introduced with the aim to internationally unify the metric system and the units (Shakkanho (Japanese measuring system), Foot-pound system, etc.) which are used conventionally in various countries, and to control the confusion among each unit (conversion by calculation etc.)

General Information OA-8 In Japan, the new calculation method that fully adopts SI unit was issued in 1992 and standardized in JIS-Z8203.

In this manual, SI units which are international unit system are described, and conventional units are also described in { }.

SI Abbreviation of French word “Le Systeme International d’Unites” Relationship between SI and conventional units SI

Conventional Unit

Length

m

m

Same as conventional one

Weight (mass)

kg

kg

Same as conventional one

Force

N

* kg, kgf

Torque

N⋅m

* kg⋅m, kgf⋅m

Pressure

Pa

* kg/cm2, mmHg

Power output, horsepower

W

PS

Cubic volume, displacement

m3

Liter, L, cc

g/(kW⋅h)

g/(PS⋅h)

Fuel consumption

*1 Some service data which have been issued already use “kg” instead of “kgf” to represent force and weight (mass) for convenience sake. *2 The results of the conversion may be rounded to one or two decimal places.

Conversion of numeric representation Prefixes such as “k (kiro)” or “m (milli)” are used for numeric conversion.

M

Mega

106 3

1,000,000

k

Kiro

10

h

Hecto

102

100

-1

1,000

d

Deci

10

0.1

c

Centi

10-2

0.01

m

Milli

µ

Micro

-3

10

10-6

0.001 0.000001

• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa • 40 mmHg = 5,332 Pa = 5.3 kPa

Item, Unit Conversion

1 kgf = 9.80665 N 1 kgf⋅m = 9.80665 N⋅m 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa 1 PS = 0.74 kW 1 Liter = 1 dm3, 1 cc = 1 mLiter = 1 cm3 1 g/(PS⋅h) = 1.360 g/(kW⋅h)

Table of Isuzu standard tightening torque The tightening torque values in the following table are applied to the places where tightening torque is not specified.

General Information OA-9 Isuzu standard bolts and nuts N⋅m {kgf⋅m} Strength Classification Shape of Bolt Head

4.8 4T Hexagon Head Bolt

7T

Flange Bolt

Hexagon Head Bolt

Flange Bolt

19.6 — 33.3 {2.0 — 3.4}

22.3 — 37.2 {2.3 — 3.8}

27.5 — 45.1 {2.8 — 4.6}

30.3 — 50.4 {3.1 — 5.1}

M12 x 1.25

49.0 — 73.5 {5.0 — 7.5}

54.9 — 82.3 {5.6 — 8.4}

60.8 — 91.2 {6.2 — 9.3}

68.1 — 102.1 {6.9 — 10.4}

* M12 x 1.75

45.1 — 68.6 {4.6 — 7.0}

51.0 — 76.5 {5.2 — 7.8}

56.9 — 84.3 {5.8 — 8.6}

62.7 — 94.0 {6.4 — 9.6}

76.5 — 114.7 {7.8 — 11.7}

83.0 — 124.5 {8.5 — 12.7}

93.2 — 139.3 {9.5 — 14.2}

100.8 — 151.1 {10.3 — 15.4}

71.6 — 106.9 {7.3 — 10.9}

77.2 — 115.8 {7.9 — 11.8}

88.3 — 131.4 {9.0 — 13.4}

94.9 — 142.3 {9.7 — 14.5}

104.0 — 157.0 {10.6 — 16.0}

115.6 — 173.3 {11.8 — 17.7}

135.3 — 204.0 {13.8 — 20.8}

150.1 — 225.2 {15.3 — 23.0}

100.0 — 149.1 {10.2 — 15.2}

109.4 — 164.2 {11.2 — 16.7}

129.4 — 194.2 {13.2 — 19.8}

142.5 — 213.8 {14.5 — 21.8}

M18 x 1.5

151.0 — 225.6 {15.4 — 23.0}

—

195.2 — 293.2 {19.9 — 29.9}

—

* M18 x 2.5

151.0 — 225.6 {15.4 — 23.0}

—

196.1 — 294.2 {20.0 — 30.0}

—

M20 x 1.5

206.0 — 310.0 {21.0 — 31.6}

—

269.7 — 405.0 {27.5 — 41.3}

—

* M20 x 2.5

190.2 — 286.4 {19.4 — 29.2}

—

249.1 — 374.6 {25.4 — 38.2}

—

M22 x 1.5

251.1 — 413.8 {25.6 — 42.2}

—

362.8 — 544.3 {37.0 — 55.5}

—

* M22 x 2.5

217.7 — 327.5 {22.2 — 33.4}

—

338.3 — 507.0 {34.5 — 51.7}

—

M24 x 2

358.9 — 539.4 {36.6 — 55.0}

—

430.5 — 711.0 {43.9 — 72.5}

—

* M24 x 3

338.3 — 507.0 {34.5 — 51.7}

—

406.0 — 608.0 {41.4 — 62.0}

—

* M10 x 1.5

M14 x 1.5 * M14 x 2 M16 x 1.5 * M16 x 2

The bolt with mark * should be used to female screw portion of soft material such as casting etc.

N⋅m {kgf⋅m} Strength Classification Shape of Bolt Head M6 x 1 M8 x 1.25

9.8 9T

8.8 Hexagon Head Bolt

Flange Bolt

Hexagon Head Bolt

Flange Bolt

5.6 — 11.2 {0.6 — 1.1}

6.6 — 12.2 {0.6 — 1.2}

—

—

13.4 — 25.7 {1.4 — 2.6}

15.3 — 28.4 {1.6 — 2.9}

16.7 — 30.4 {1.7 — 3.1}

18.1 — 33.6 {1.9 — 3.4}

General Information OA-10 N⋅m {kgf⋅m} Strength Classification Shape of Bolt Head

9.8 9T

8.8 Hexagon Head Bolt

Flange Bolt

Hexagon Head Bolt

Flange Bolt

31.3 — 52.5 {3.2 — 5.4}

35.4 — 58.9 {3.6 — 6.1}

37.3 — 62.8 {3.8 — 6.4}

42.3 — 70.5 {4.3 — 7.2}

31.3 — 51.4 {3.2 — 5.2}

34.5 — 57.5 {3.5 — 5.8}

36.3 — 59.8 {3.7 — 6.1}

40.1 — 66.9 {4.1 — 6.8}

M12 x 1.25

69.3 — 104.0 {7.1 — 10.6}

77.7 — 116.5 {7.9 — 11.9}

75.5 — 113.8 {7.7 — 11.6}

85.0 — 127.5 {8.7 — 13.0}

* M12 x 1.75

64.8 — 96.1 {6.6 — 9.8}

71.4 — 107.2 {7.3 — 10.9}

71.6 — 106.9 {7.3 — 10.9}

79.5 — 119.2 {8.1 — 12.2}

106.2 — 158.8 {10.8 — 16.2}

114.9 — 172.3 {11.7 — 17.6}

113.8 — 170.6 {11.6 — 17.4}

123.4 — 185.1 {12.6 — 18.9}

100.6 — 149.8 {10.3 — 15.3}

108.2 — 162.2 {11.1 — 16.6}

106.9 — 160.0 {10.9 — 16.3}

115.5 — 173.3 {11.8 — 17.7}

154.3 — 232.5 {15.7 — 23.7}

171.1 — 256.7 {17.4 — 26.2}

160.0 — 240.3 {16.3 — 24.5}

176.9 — 265.3 {18.0 — 27.1}

147.6 — 221.4 {15.0 — 22.6}

162.5 — 243.8 {16.6 — 24.9}

153.0 — 229.5 {15.6 — 23.4}

168.5 — 252.7 {17.2 — 25.8}

M18 x 1.5

222.5 — 334.3 {22.7 — 34.1}

—

229.5 — 345.2 {23.4 — 35.2}

—

* M18 x 2.5

223.6 — 335.4 {22.8 — 34.2}

—

230.5 — 346.2 {23.6 — 35.3}

—

M20 x 1.5

307.4 — 461.7 {31.4 — 47.1}

—

316.8 — 475.6 {32.3 — 48.5}

—

* M20 x 2.5

284.0 — 472.1 {29.0 — 43.5}

—

293.2 — 440.3 {29.2 — 44.9}

—

M22 x 1.5

413.6 — 620.5 {42.2 — 63.3}

—

424.6 — 636.5 {43.3 — 64.9}

—

* M22 x 2.5

385.7 — 578.0 {39.3 — 58.9}

—

394.2 — 592.3 {40.0 — 60.4}

—

M24 x 2

490.8 — 810.5 {50.0 — 82.7}

—

554.1 — 830.6 {56.5 — 84.7}

—

* M24 x 3

462.8 — 693.1 {47.2 — 70.7}

—

520.7 — 781.6 {53.1 — 79.7}

—

M10 x 1.25 * M10 x 1.5

M14 x 1.5 * M14 x 2 M16 x 1.5 * M16 x 2

The bolt with mark * should be used to female screw portion of soft material such as casting etc.

General Information OA-11 Indication of Isuzu standard bolt head

Name 1. Hexagon Head Bolt (4.8, 4T) 2. Hexagon Head Bolt (4.8, 4T) 3. Flange Bolt (4.8, 4T) 4. Flange Bolt (4.8, 4T) 5. Hexagon Head Bolt (7T) 6. Flange Bolt (7T) 7. Hexagon Head Bolt (Thermal Refining, 8.8) 8. Hexagon Head Bolt (Thermal Refining, 8.8)

9.

10.

11.

12.

13.

14.

15.

16.

Hexagon Head Bolt (Nonthermal Refining, 8.8) Hexagon Head Bolt (Nonthermal Refining, 8.8) Flange Bolt (8.8) Flange Bolt (8.8) Hexagon Head Bolt (9.8, 9T) Hexagon Head Bolt (9.8, 9T) Flange Bolt (9.8, 9T) Flange Bolt (9.8, 9T)

Flare nut Pipe Diameter

Tightening torque of flare nut (service standard value) N⋅m {kgf⋅m}

Tightening Torque (for medium and large size vehicles)

Width across flats of Flare Nut (mm) Old

New

φ 4.76 mm

12.8 — 18.6 {1.3 — 1.9}

14

14

φ 6.35 mm

23.5 — 49 {2.4 — 5.0}

17

17

φ 8.0 mm

23.5 — 49 (2.4 — 5.0)

19

17

φ 10.0 mm

44.1 — 93.2 {4.5 — 9.5)

22

19

φ 12.0 mm

58.8 — 137.3 (6.0 — 14.0)

27

24

φ 15.0 mm

78.5 — 156.9 (8.0 — 16.0)

30

30

General Information OA-12 Tapered screw for connector (brass) N⋅m {kgf⋅m} Screw size

PT (R) 1/8

PT (R) 1/4

PT (R) 3/8

PT (R) 1/12

—

2.0 — 14.7 (0.2 — 1.5)

4.9 — 15.7 (0.5 — 1.6)

9.8 — 16.7 (1.0 — 1.7)

9.8 — 17.7 (1.0 — 1.8)

Special tool types A. Basic tools Always use the “Basic tools” when performing service work.

B. Recommend tools Commercially available general-purpose tools can be used when performing service work. However, use these “Recommended tools” as much as possible to reduce work hours and maintain high safety.

C. Setting tools Commercially available general-purpose tools can be used as a substitute for the “Setting tools” but using them leads to increase work hours.

Engine Mechanical (6UZ1X) 1B-1

Engine Engine Mechanical (6UZ1X) Contents 6UZ1X Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . 1B-2 Reading the Model. . . . . . . . . . . . . . . . . . . . . . 1B-3 Description of Function and Operation . . . . . . 1B-4 Function Check: . . . . . . . . . . . . . . . . . . . . . . . . 1B-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12 Engine Accessories. . . . . . . . . . . . . . . . . . . . . . 1B-13 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Tightening Torque List . . . . . . . . . . . . . . . . . . 1B-15 Engine Exterior Equipment . . . . . . . . . . . . . . . . 1B-16 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Tightening Torque List . . . . . . . . . . . . . . . . . . 1B-38 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-41 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-41 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-49 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-56 Tightening Torque List . . . . . . . . . . . . . . . . . . 1B-62 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-63 Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-64 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-64 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-64 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-65 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-66 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-67 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-67 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-67 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-68 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-69 Tightening Torque List . . . . . . . . . . . . . . . . . . 1B-70 Flywheel, Flywheel Housing and Timing Gear . 1B-71 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-74 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-74 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75 Tightening torque list . . . . . . . . . . . . . . . . . . . 1B-80 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81 Front Cover and Crankshaft . . . . . . . . . . . . . . . 1B-82 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-82 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-82 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-84

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-85 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-89 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-90 Tightening Torque List . . . . . . . . . . . . . . . . . . 1B-93 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-94 Piston, Connecting Rod . . . . . . . . . . . . . . . . . . . 1B-95 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-96 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-97 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-100 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-102 Tightening Torque List . . . . . . . . . . . . . . . . . 1B-105 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . 1B-106 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1B-107 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-107 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-107 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-108 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-108 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-110 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-112 Tightening Torque List . . . . . . . . . . . . . . . . . 1B-113 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . 1B-114

Engine Mechanical (6UZ1X) 1B-2

6UZ1X Engine Service Precautions Confirm the following items to prevent damage on the engine and maintain reliability of the engine performance.

• Do not put a jack against the oil pan when lifting up or supporting the engine.

Use an engine palette or a wooden frame etc. to support the engine foot and the flywheel housing.

• Seal to prevent any foreign materials from entering into cylinders when the air system was removed.

Foreign materials can be a cause for sever damages on cylinders etc..

• Be sure to disconnect the battery earth cables when servicing. When electricity is required for inspection etc., be careful with short circuit.

• Apply sufficient engine oil to the sliding surface to protect and lubricate the surface.

• When valve train parts, pistons, piston rings, bearings, and injectors etc. are removed, put them in order for storing.

• In the installation procedure, install the same part to the same position of removal.

• For gaskets, oil seals and O-rings, replace with new ones each time they are disassembled.

• When applying the liquid gasket, remove the old liquid gasket completely and clean off any oil, moisture or foreign materials beforehand.

• Assemble the liquid gasket within 7 minutes of its application.

If more than 7 minutes passed, remove the existing liquid gasket and apply again.

• For assembling and installing, tighten with the specified torque.

Service precautions specific to this engine Inside of the injector, and the fuel passage such as holes and clearances are finished extremely finely. For this reason, they are highly sensitive to foreign matter. If it gets inside, it can lead to breakdown on the road. Be sure to prevent it from getting inside.

Engine Mechanical (6UZ1X) 1B-3

Reading the Model

1

WSUZ0011

Name 1. Engine Number Stamp (6UZ1-⋅⋅⋅⋅⋅⋅)

Engine Mechanical (6UZ1X) 1B-4

Description of Function and Operation Engine structure diagram

WSUZ0012

WSUZ0013

Engine Mechanical (6UZ1X) 1B-5

WSUZ0014

Engine Mechanical (6UZ1X) 1B-6

Function Check: Measurement of the compression pressure Measure the compression pressure when the engine is warmed-up and there are no errors occurring at batteries or starters.

4. Remove the injector leak-off pipe.

5. Remove all injector ASM. • Store them in numeric order.

Measure

Removal

1. Install the compression gauge.

1. Remove the head cover.

• Remove the air-breather hoses, and then remove the air cleaner element.

• Insert two sheets of the gasket (2) into the compression gauge adapter (1) 380002635, and then insert it to the injector installation hole.

WSUZ0053 2. Warm up the injection pipe.

3. Remove the injector harness.

• Loosen the terminal tightening nut and remove the harness.

• Remove the harness BRKT-ASM. Note: When the injector harness is removed, its ID code plate is also removed. Do not confuse it with other injector ID code plates.

• Use the clamp for injectors to tighten the adapter.

Place the clamp at the center of the adapter.

• Install the compression gauge to the adapter.

Note: Remove all gaskets apart from the measuring cylinders.

2. Measure the compression pressure.

WSUZ0101

Engine Mechanical (6UZ1X) 1B-7 • Turn the starter (200rpm) and measure the compression pressure when the indicator of compression gauge is stable.

• Measure the compression pressure of all cylinders.

Items

Compression pressure kPa/rpm {kg/cm2/rpm}

Difference between cylinders kPa/rpm {kg/ cm2/rpm}

Assembly specificati ons

2746 / 200 {28 / 200}

196 {2.0}

Service limit

2260 / 200 {23 /200}

—

Note: • Be careful, the air may be shooting out from the injector hole when running.

• When the harness connector is removed, ECU judges it as a breakdown and records an error code. Upon completion of measurement, never fail to clear ECU memory. (For clearing ECU memory, refer to “Trouble Shooting Manual”)

Set to No.1 cylinder (or No.6 cylinder) compression TDC. Rotate the crankshaft in proper direction, and align the nick line of flywheel to the pointer. Make sure there is a clearance (compression TDC) between the locker arm of No1. cylinder (or No.6 cylinder) and the cam.

Adjusting the valve clearance 1. Adjust the valves shown on the valve clearance adjustment chart.

2. Loosen each adjust screw completely on the rocker arm and bridge.

• Use the adjust nut wrench (1) 380300021 for loosening adjust screw nuts on the bridge.

Note: The adjust screws on the bridge may come off when they are too loose.

Installation 1. Refer to “Cylinder Head” section for installation.

Adjusting the valve clearance Adjust the valve clearance twice for setting at the No.1 cylinder compression TDC (top dead center) and at the No.6 cylinder TDC.

Engine Mechanical (6UZ1X) 1B-8 3. Insert the thickness gauge (1) between the rocker arm (2) and the cam (5). Adjust with adjust screws on the rocker arm and then secure with the lock nut.

4. Once the thickness gauge is inserted, tighten the adjust screw (4) of the bridge until the thickness gauge is secured tightly.

5. Slowly loosen the adjust screw (4) of the bridge and re-adjust ins/outs of the thickness gauge (1) appropriately, and then secure the lock nut of the bridge.

Note: Stop the engine and wait until it cools down before servicing.

Valve clearance (at cold condition): Inlet valve: 0.2mm Exhaust valve: 0.3mm Tightening torque: Rocker arm – lock nut: Bridge – lock nut:

34.3N.m {3.5 kg.m/25.3 lb⋅ft} 21.6N.m {2.2 kg.m/15.9 lb⋅ft}

Valve clearance adjustment chart

Cylinder N°. and Conditions N°1 Cylinder: Compression top dead center position N°6 Cylinder: Compression top dead center position Fuel injection order 1-5-3-6-2-4

(The cylinder that is marked with a circle is adjustable.)

WSUZ0147E

Engine Mechanical (6UZ1X) 1B-9 Judgment of time to overhaul Overhaul is necessary for cases below.

The compression pressure is lowering.

The compression pressure measured by the measuring method instructed is lower than 2260kPa (23kg/cm2).

Rate of increase in engine oil consumption The consumption rate (oil consumption rate per a time unit) is below 50% against 100% of a new vehicle.

Rate of increase in fuel consumption The consumption rate (L/h) is below 60% against 100% of a new vehicle.

Noise inside of engine Strange noises are coming from inside of the engine.

Carry out the overhaul at an early stage and repair.

Note: Wear, seizure or over-heat at engine parts can be causes for strange noises.

Service Precautions 1. Engine parts are extremely hot straight after a drive, so cool them down sufficiently.

2. Diagnostic codes (self-diagnosis codes) are recorded on the ECU memory. Check the contents of the memory stored on ECU using a scan tool before starting an inspection on a sensor.

3. Make sure to disconnect battery terminals to prevent damages on electronic parts such as sensors or a fire.

4. High voltage at injector harnesses or electromagnetic valves can cause an electric shock. Make sure to turn the starter switch to “OFF” and pull out the key when carrying out a service.

Engine Mechanical (6UZ1X) 1B-10

Specifications Model

AH-6UZ1X

Items Engine model

Water cooling 4 cycle in-line type 6 cylinder 24 valve OHC direct injection diesel

Cylinder layout - Number Diameter x Stroke

(mm)

Displacement

(L)

Compression ratio

L6 — φ120 x 145 9.839 17.5

2

Compression pressure

kPa/rpm (kg/cm /rpm)

Cylinder liner type

2746 (28)/200 Dry liner, tight-fit type

Maximum output

kW/rpm (PS/rpm)

270/1950 (367/1950)

Maximum torque

N⋅m/rpm (kg⋅m/rpm)

1435/1500 (146/1500)

Dimension (Length x Width x Height) Weight (not including air cleaner) Fuel injection timing

(mm) (kg) (BTDC)

1235x953x 1244 840 0°

Fuel injection order

1-5-3-6-2-4

Injection pump type

Electronic control fuel injection system (Common rail type)

Governor type

Electronic type

Timer type

Electronic type

Nozzle type

DLL-P

Valve clearance (at cold condition)

Intake valve

(mm)

Exhaust valve

(mm)

0.2 0.3

Intake valve open/close timing

(Open)

22° (BTDC)

Intake valve open/close timing

(Closed)

30° (ABDC)

Exhaust valve open/close timing

(Open)

48.5° (BBDC)

Exhaust valve open/close timing

(Closed)

23.5 ° (ATDC)

Fuel filter type

Filter paper type

Oil filter type

Pleated filter type

Oil pump type

Gear type

Oil cooler type

Water cooling type

Engine oil level

(L)

Cooling device type

Full capacity: 30 — 41 Oil pan:25 — 36 Remaining amount inside the engine: 5 Water cooling compulsory re-circulation type

Coolant full capacity

(L)

28.9

Coolant capacity on the engine

(L)

22.5

Water pump model

Spiral type

Thermostat model

Wax type

Engine Mechanical (6UZ1X) 1B-11 Model

AH-6UZ1X

Items Air cleaner model

Filter paper type (varies depending on the machine.)

Generator capacity

(V-kw)

24 — 1.2, 24 — 1.5, 24 — 2.5

Starter

(V-kw)

24 — 5.5

Idle speed

(rpm)

900

Maximum engine speed at no load

(rpm)

2000

Turbocharger model

RHG6 (IHI)

Inter cooler type Thermostat valve-opening temperature Thermostat full-open temperature/ lift amount Exhaust gas re-circulation device (EGR)

Aluminum tube & end plate type (Varies depending on the machine.) (°C) (°C/mm)

80 — 84 95 /11 equipped

Engine Mechanical (6UZ1X) 1B-12

Special Tool 6UZ1X Engine Illustration

Tool Number Description Special Tool

380002635 Compression gauge adapter

380300021 Valve clearance adjust nut wrench

Engine Mechanical (6UZ1X) 1B-13

Engine Accessories Components 2

1

3

WSUZ0015

Name 1. V Belt (For the Generator) 2. Generator

3. Starter

Engine Mechanical (6UZ1X) 1B-14

Removal

Installation

1. Remove the generator.

1. Install the starter.

• Loosen the through bolt (1) and adjust lock nut (3).

• Remove V belt.

• Remove the generator ASM (2).

3

• Tighten the earth cable together.

Tightening torque:

137.3N.m {14kg.m/101.3lb⋅ft}

2. Install the generator.

• Install the generator (2) temporarily, and then install the V belt.

• Adjust the tension of the V belt.

- Adjust the belt deflection when its middle part is pressed with approx. 98N⋅m{10kg/ 72.3lb⋅ft} as follows.

Deflection:

12 — 14mm(0.47-0.55in)

• Tighten the adjust lock nut (3) and the through bolt (1) with the specified torque.

2

Tightening torque: Through bolt: Lock Nut: 1

WSUZ0016

2. Remove the starter.

156.5N.m {16kg.m/115lb⋅ft} 92.9N.m{9.5kg.m/68.5lb⋅ft}

Note: • Make sure that the V belt is fitted to the pulleys groove.

• Crank the engine for 5 rotations and check the tension of the belt again.

3

2

1

WSUZ0016

Engine Mechanical (6UZ1X) 1B-15

Tightening Torque List Engine accessories a

b

c WSUZ0018

Name (a) (b)

92.9N.m {9.5kg.m/68.5lb⋅ft} 156.5N.m {16kg.m/115.4lb⋅ft}

(c)

137.3N.m {14kg.m/101.3lb⋅ft}

Engine Mechanical (6UZ1X) 1B-16

Engine Exterior Equipment Components

1

2

3

4

5

6 7

8

9

10

WSUZ0019

Name 1. EGR Duct C 2. Water Feed Pipe (Exhaust Side EGR Cooler) 3. EGR Cooler (Exhaust Side EGR Cooler) 4. Water Return Pipe (Exhaust Side EGR Cooler) 5. Water Feed Pipe (Intake Side EGR Cooler) 6. Air Leak Pipe (EGR Cooler)

7.

8.

9.

10.

EGR Cooler (Intake Side) Water Return Pipe (Intake Side EGR Cooler) EGR Duct B EGR Duct A

Engine Mechanical (6UZ1X) 1B-17

3

4

5

2 1

6

7

15

14

13

8

12

11

10

9

WSUZ0020

Name 1. Injection Pipe 2. Inlet Cover 3. Inlet Duct 4. EGR Valve 5. Fuel Filter 6. Fuel Return Pipe 7. Crank Position Sensor

8.

9.

10.

11.

12.

13.

14.

Bearing Case Supply Pump Oil Return Pipe Fuel Feed Pipe Fuel Temperature Sensor Oil Feed Pipe Oil Level Guide Tube

Engine Mechanical (6UZ1X) 1B-18

1

6

5

4

3

2

WSUZ0021

Name 1. Turbocharger 2. Engine Foot (Ft) 3. Oil Return Pipe

4. Oil Port Cover 5. Oil Feed Pipe 6. Engine Foot (Rr)

Removal

Sensor and device

Name of installed parts

Fuel pressure sensor

Common rail

Fuel temperature sensor

Supply pump

Boost pressure sensor

Inlet duct

Boost temperature sensor

Inlet duct

Solenoid valve

Injector

Engine coolant temperature sensor

Thermostat housing

Oil pressure sensor

Cylinder block left side

1. Remove the engine harness.

• Remove connector clips from each sensor and device, and disconnect harnesses.

Sensor and device

Name of installed parts

EGR motor

EGR valve

Crank position sensor (CKP)

Flywheel housing on the upper-left

Pump control valve (PCV)

Supply pump

Camshaft position sensor (CMP)

Supply pump

Engine Mechanical (6UZ1X) 1B-19 Note: Leave a mark with a paint on where the harness clip is installed, then remove it.

2. Remove EGR device.

• Remove the air leak pipe (1).

1

WSUZ0054

• Remove the water feed (1) and (2) for EGR cooler, and the water return pipe (3) and (4).

2 1

4

3

WSUZ0055

• Remove EGR water pipe brackets (6) and the exhaust side EGR cooler (7).

• Remove the intake side EGR cooler (4).

• Remove the EGR duct C (8).

• Remove the exhaust side EGR cooler brackets (9).

• Remove the intake side EGR cooler brackets (5).

• Remove the EGR duct B (3).

• Remove the EGR valve (2).

• Remove the EGR duct A (1).

Engine Mechanical (6UZ1X) 1B-20

1

2

3

4

5

6

7

9

8

WSUZ0056

3. Disconnect the air breather hose.

• Remove the fuel filter return pipe (3), the injector return pipe (2), and the return pipe (1) between the common rail and the supply pump.

• Remove the feed pipe between the feed pump and the fuel filter (5), and the fuel filter and the supply pump (6).

• Remove the fuel suction pipe (8).

• Remove the fuel pipe brackets (4) and (7).

Note: • Seal where pipes are installed to prevent any foreign materials sticking there.

• Seal the opening part where the pipes are installed on the supply pump to prevent any foreign materials sticking there.

WSUZ0057

4. Remove the oil level guide tube.

5. Remove the fuel pipe.

Engine Mechanical (6UZ1X) 1B-21

3

2 1

1 2

3

WSUZ0062

9. Remove the inlet duct (1).

Note: Seal the opening part of the inlet cover to prevent any foreign materials getting in.

8

7

4 6

5

1

WSUZ0061

6. Remove the fuel filter ASM. 7. Remove BRKT (1) between the fuel filter brackets and the inlet duct.

1 WSUZ0058

10. Remove the injection pipe (1).

Important: Do not reuse the high-pressure pipe in fuel system if it has been removed.

• Loosen the clip and remove.

WSUZ0081

8. Remove the fuel pipe clip brackets (1), the fuel filter brackets (2) and BRKT (3).

Note: • Hold the flow-damper of the common rail with a spanner to stop rotating, then loosen the sleeve nut on the injection pipe.

• Make sure no dust or foreign materials sticking to the sleeve nut.

• Seal the opening part of where the common rail pipe is installed to prevent any foreign materials sticking there.

Engine Mechanical (6UZ1X) 1B-22

4

1

1

3

2

WSUZ0103

WSUZ0063

11. Remove the common rail.

• Remove the fuel pipe between the supply pump and the common rail.

Important: Do not reuse the high-pressure pipe in fuel system if it has been removed.

• Remove the fuel pipe brackets (1).

12. Remove the supply pump ASM. • Remove the oil feed pipe and return pipe.

• Loosen the cotter bolt at the coupling (3).

• Loosen the coupling bolts (1) and (2). At this stage, move the bolts to a position easier to loosen them by turning the crankshaft.

• Move the coupling ASM to the bearing case (4) side beforehand.

5

3

4

1 1 WSUZ0094

• Remove the common rail ASM (2).

• Remove the common rail brackets (1).

Note: Seal each fuel opening to prevent any foreign materials getting in.

2 WSUZ0068

• Loosen the supply pump (1) tightening bolt in the order instructed on the diagram.

• Remove the supply pump brackets (2).

Engine Mechanical (6UZ1X) 1B-23 4

2

1

3

1

2

1

2

WSUZ0104

13. Remove the bearing case.

• Remove the bearing case ASM from the cylinder block.

14. Remove the inlet cover.

3 WSUZ0059

• Remove the turbocharger ASM (1).

• Remove the exhaust adapter (2).

Note: Seal the oil opening of the turbocharger, compressor and opening on the turbine side with gummed tape, etc.

1

15. Remove the turbocharger ASM. • Remove the oil feed pipe (1), the oil return pipe (2) and the PTO oil feed pipe (3).

2 WSUZ0060

16. Remove the exhaust manifold ASM. • Loosen the tightening nut. Remove the distance tube (1), the manifold (2) and the gasket (3).

Engine Mechanical (6UZ1X) 1B-24

3

2 1

1 WSUZ0105

17. Remove the oil port cover.

1

WSUZ0065

20. Remove the thermostat housing.

• Remove the water duct (2) and BRKT (1).

• Remove the thermostat housing (3).

2

5

3

4

2 1

WSUZ0064

18. Remove the oil cooler.

19. Remove the engine foot.

• Remove the engine foot (1).

WSUZ0089

Engine Mechanical (6UZ1X) 1B-25 21. Remove the air breather ASM.

1 1

WSUZ0106 WSUZ0106

Inspection EGR reed valve • Check valve appearances for any damages.

• Check to see if carbon is accumulated between the stopper and the valve.

2. Install the thermostat housing.

• Put the gasket (5) in, install the housing (3) while inserting it to the water pump.

Tightening torque:

43.8N.m {4.5kg.m/32.3lb⋅ft}

Note: Applying a thin coat of ThreeBond No.TB1521 to the gasket is also possible.

• Install the water duct (2) and BRKT (1).

Tightening torque:

21.6N.m {2.2kg.m/15.9lb⋅ft}

5

3

4

2 1

Installation 1. Install the air breather ASM. Tightening torque: 43.8N.m {4.5kg.m/32.3lb⋅ft}

WSUZ0089

3. Install the engine foot.

• Apply molybdenum disulphide to the thread and seating side of the bolt, and tighten with a specified torque.

Tightening torque: 103N.m{10.5kg.m/76.0lb⋅ft} Note: The front engine foot is the same for both left and right.

Engine Mechanical (6UZ1X) 1B-26

1 WSUZ0043

WSUZ0065

4. Install the oil cooler.

• Clean the installing surface of the oil cooler and cylinder block.

• Insert 7 O-rings to the installing surface (2 sorts).

• Put the gasket into the groove of installing flange surface and install the oil cooler.

5. Install the oil port cover.

• Put two O-rings (2) in on the installing surface.

• Install the oil port cover (1) to the oil cooler.

Tightening torque: 43.8N.m {4.5kg.m/32.3lb⋅ft} Note: A thin coat of ThreeBond No. TB1208 or CH Dine No.290 can be applied to prevent O-rings coming off.

1

• Tighten the bolt from outwards to the center.

Tightening torque:

50N.m{5.1kg.m/36.9lb⋅ft}

Note: • A thin coat of ThreeBond No. TB1208 or CH Dine No.290 can be applied to prevent O-rings coming off.

• When pushing the gasket in, push the projection part (stopping the gasket from coming off) into the groove completely.

2

WSUZ0064

6. Install the exhaust manifold ASM. Install sealing rings every 120°, and then assemble the manifold.

Note: Seal rings have direction. So look carefully when assembling.

Engine Mechanical (6UZ1X) 1B-27 • Pour engine oil (approx. 1cc) into the opening of the turbocharger ASM (1) and turn the turbine shaft slightly, and then lubricate the shaft bearing.

• Set the gasket to the exhaust manifold.

• Install the turbocharger ASM (1) and tighten it with bolts and double nuts. Tighten from the turbine inlet flange.

Tightening torque: Bolt: Nut:

50N.m{5.1kg.m/36.9lb⋅ft} 40N.m{4.1kg.m/29.5lb⋅ft}

1

• Keep the molybdenum coating (black) side outside when installing the gasket (3).

• Install the manifold (2) to the cylinder head.

• Tighten each flange in a following order; No.3, 4, 2, 5, 1, and 6 cylinder.

Tightening torque: 53.9N⋅m{5.5kg⋅m/39.8lb⋅ft} • Install the cover (4).

Tightening torque: 50N⋅m{5.1kg⋅m/36.9lb⋅ft} 2

Note: • Place the small hole on the distance tube (1) towards the nut side and install it.

• Assemble the gasket projection pointing the bottom right.

3

WSUZ0060

• Install the oil feed pipe (1) and PTO oil feed pipe (3). On the oil port cover side, tighten the oil feed pipe (1) and PTO oil feed pipe (3) together.

Eyebolt tightening torque: Turbo side: Oil port cover side: PTO side M12: PTO side M8:

34.3N.m {3.5kg.m/25.3lb⋅ft} 34.3N.m {3.5kg.m/25.3lb⋅ft} 22.5N.m{2.3kg.m/16.6lb⋅ft} 14.7N.m{1.5kg.m/10.8lb⋅ft}

• Put O-rings into both sides of the oil return pipe (2) and install it.

Bolt tightening torque: Turbo side: Cylinder side:

4

2 1 WSUZ0107

7. Install the turbocharger ASM. • Install the exhaust adapter (2) and tighten it with a double nut.

Tightening torque: 40N.m{4.1kg.m/29.5lb⋅ft}

43.8N.m{4.5kg.m/32.3lb⋅ft} 43.8N.m{4.5kg.m/32.3lb⋅ft}

Engine Mechanical (6UZ1X) 1B-28

1

2

3 WSUZ0059

8. Install the inlet cover.

• Put the gasket into the groove of the inlet cover and install it.

Tightening torque: 45N.m{4.6kg.m/33.2lb⋅ft} Note: A thin coat of ThreeBond No. TB1208 or CH Dine No.290 can be applied to prevent the gasket coming off.

• Reverse turn the crankshaft once up to just below the top dead center 90° and turn it into a proper direction. And set the nick line of the flywheel (P/P) to the timing pointer. Check to see it is close to the compression top dead center of No.1cylinder.

WSUZ0102

9. Install the bearing case.

• Install the key to the shaft of the bearing case.

• Apply molybdenum disulphide to inside and the seating side of the nut and tighten with a specified torque.

Tightening torque: 255N.m {26kg.m/188.1lb⋅ft}

• Apply ThreeBond No.TB1208 to 3 parts of the O-ring and install it to the groove of the bearing case.

• Set “A” marked on the coupling to the pointer (1) of the bearing case and assemble to the cylinder block.

• Check to see “S” marking is aligned with the pointer after installation.

• Tighten the bolt and nut with the specified torque.

Tightening torque: 85.5N⋅m {8.7kg⋅m/63.1lb⋅ft}

Engine Mechanical (6UZ1X) 1B-29

S A

S A

1

WSUZ0066

10. Install the supply pump ASM. • Install the supply pump brackets (2) and the oil pipe brackets (3). At this point, place the oil pipe brackets (3) on the engine front side when tightening.

Tightening torque: 850.5N.m {8.7kg.m/63.0lb⋅ft}

2

4

3

1 5

WSUZ0102

• Move the coupling ASM to the bearing case side beforehand.

• Align nick lines of the coupling and the pump.

• Install the supply pump to the BRKT and tighten in a diagonal order.

Tightening torque: 31N.m{3.2kg.m/22.9lb⋅ft} • Slide the coupling and make sure it is stuck tightly to the supply pump. Tighten it with the coupling bolt (1) first and then with the bolt (2).

At this stage, turn the crankshaft and move the bolt to a position easier to tighten it.

1

Tightening torque: 83 — 93N.m {8.5 — 9.5kg.m/61.2 — 68.6lb⋅ft} • Make sure there is no dent on the laminate of the coupling and tighten the cotter bolt (3).

2

Tightening torque: 83 — 93N.m {8.5 — 9.5kg.m/61.2 — 68.6lb⋅ft}

3

Note: To prevent the coupling bolts from slipping, make sure to use the specified torque.

WSUZ0108

• Make sure the nick line (P/P) of the flywheel is aligned with the timing pointer.

Engine Mechanical (6UZ1X) 1B-30

5

3

4 4

1

3 1

2

2 WSUZ0068

• Install the oil feed pipe (2) commonly used by the bearing case.

Tightening torque: Pump side: Cylinder side:

WSUZ0103

• Install the fuel pipe brackets (1).

Tightening torque: 21.6N.m{2.2kg.m/15.9lb⋅ft}

10.3N.m{1.1kg.m/7.6fb⋅ft} 20.2N.m{2.1kg.m/14.8lb⋅ft}

• Install the oil return pipe (1).

Tightening torque: Pump side: Cylinder side:

17.2N.m{1.8kg.m/12.7lb⋅ft} 41.2N.m {4.2kg.m/30.4lb⋅ft}

1

WSUZ0094

• Install the high-pressure pipe between the supply pump and common rail.

Important: Replace the high-pressure pipe in fuel system with new one if it has been removed.

Tightening torque: 44.1N.m{4.5kg.m/32.5lb⋅ft} 12. Install the injection pipe.

11. Install the common rail.

• Install the common rail brackets (1).

Tightening torque: 43.8N.m{4.5kg.m/32.3lb⋅ft} • Align the common rail (2) to the dowel of BRKT (1) and install it. At this stage, tighten the engine harness brackets (3) and (4) together.

Tightening torque: 43.8N.m{4.5kg.m/32.3lb⋅ft}

Important: Replace the high-pressure pipe in fuel system with new one if it has been removed.

• Tighten the injector side and the common rail side alternately few times on each side.

Engine Mechanical (6UZ1X) 1B-31 • Install the clip at the specified position.

Tightening torque: Sleeve Nut: Clip:

1

44.1N.m{4.5kg.m/32.5lb⋅ft} 8.9N.m{0.9kg.m/6.4lb⋅ft}

2

Note: Do not re-use the clip when there are cracks or damages on the rubber.

3

WSUZ0062

15. Install BRKT (1) between the fuel filter brackets and the inlet duct.

Tightening torque: 43.8N.m{4.5kg.m/32.3lb⋅ft}

13. Install the inlet duct.

• Put O-rings into the bottom side of the inlet duct (1) and install the inlet cover.

1

Tightening torque: 43.8N.m{4.5kg.m/32.3lb⋅ft} Note: A thin coat of ThreeBond No. TB1208 or CH Dine No.290 can be applied to prevent O-rings coming off.

1 WSUZ0081

16. Install the fuel filter ASM. Tightening torque: 45N.m{4.6kg.m/33.2lb⋅ft} 17. Install the fuel pipe.

• Install the fuel pipe brackets (4) and (7).

Tightening torque: BRKT (4): BRKT (7):

WSUZ0058

14. Install the fuel pipe clip brackets (1), the fuel filter brackets (2) and BRKT (3).

Tightening torque: 43.8N.m{4.5kg.m/32.3lb⋅ft}

43.8N.m{4.5kg.m/32.3lb⋅ft} 21.6N.m{2.2kg.m/15.9lb⋅ft}

• Install the fuel suction pipe (8).

• Install the feed pipe between the feed pump and the fuel filter (5), and the fuel filter and the supply pump (6).

• Remove the fuel filter return pipe (3), the injector return pipe (2), and the return pipe (1) between the common rail and the supply pump.

• Install the clip at the specified position.

Engine Mechanical (6UZ1X) 1B-32 Eyebolt tightening torque: Fuel suction pipe: Feed pipe, feed pump side: Feed pipe, filter side: Feed pipe, supply pump side: Return pipe, supply pump side: Return pipe, common rail side: Return pipe, M14: Return pipe, M8:

• Install the guide tube to the inlet duct.

17.2N.m {1.8kg.m/12.7lb⋅ft} 17.2N.m {1.8kg.m/12.7lb⋅ft} 50N.m {5.1kg.m/36.9lb⋅ft} 41.2N.m {4.2kg.m/30.4lb⋅ft} 17.2N.m {1.8kg.m/12.7lb⋅ft} 17.7 — 22.6N.m {1.8 – 2.3kg.m/13.1 – 16.7lb⋅ft} 41.2N⋅m {4.2kg.m/30.4lb⋅ft} 14.7N.m {1.5kg.m/10.8lb⋅ft}

Tightening torque: 43.8N.m{4.5kg.m/32.3lb⋅ft}

Tightening torque: Clip:

8.9N.m{0.9kg.m/6.4lb⋅ft} WSUZ0069

Note: Do not re-use the clip when there are cracks or damages on the rubber.

19. Install the air breather hose.

Tightening torque: M10: M8:

45N.m {4.6kg.m/33.2lb⋅ft} 21.6N.m{2.2kg.m/15.9lb⋅ft}

3

2

Note: Install the hose with no breakage or slackness.

1

WSUZ0057

8

7

4 6

5 WSUZ0061

18. Install the oil level gauge guide tube.

• Apply a thin coat of engine oil to O-ring (1) and insert it without damaging the O-ring.

20. Install the EGR device.

• Install the reed valve (1) (2 places) to the inlet duct.

Tightening torque: 10N.m {1.0kg⋅m/7.4lb⋅ft}

Engine Mechanical (6UZ1X) 1B-33 1) Install the EGR valve.

• Install the gasket with the identifying part (2) placed as shown on the diagram, and then install the EGR valve (1). (Temporal tightening torque 5N⋅m{0.5kg⋅m/3.7lb⋅ft})

1

1 WSUZ0070

21. Install the EGR duct A (1) to the inlet duct (2).

• Assemble the gasket and align the dowel pin, and then install it.

2

Tightening torque: 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}

WSUZ0071

2) Assemble the EGR duct B. Assemble the gasket and the EGR duct B (1).

(Temporal tightening torque 5N⋅m{0.5kg⋅m/ 3.7lb⋅ft})

1

1

2

WSUZ0109

22. Assemble the EGR device following the instruction below.

Note: For installing the EGR device, make sure to tighten in two steps; temporal and final.

WSUZ0072

3) Install the intake side EGR cooler brackets (1).

Tightening torque: 97N⋅m {9.9kg⋅m/71.5lb⋅ft}

Engine Mechanical (6UZ1X) 1B-34 6) Assemble the intake side EGR cooler.

Assemble the gasket, and then the intake side EGR cooler (1) to the EGR duct B (2). (Temporal tightening torque 5N⋅m{0.5kg⋅m/3.7lb⋅ft})

1

1

2

WSUZ0110

4) Install the exhaust side EGR cooler brackets.

Tightening torque: 97N⋅m {9.9kg⋅m/71.5lb⋅ft} 5) Assemble the EGR duct C. Assemble the gasket. And then assemble EGR duct C (2) to the exhaust manifold (3) and to the exhaust side EGR cooler brackets (1). (Temporal tightening torque 5N⋅m{0.5kg⋅m/3.7lb⋅ft})

1

3

WSUZ0112

7) Assemble the exhaust side EGR cooler.

Assemble the gasket on the front and the back.

Then assemble the exhaust side EGR cooler (3) to the EGR duct C and to the intake side EGR cooler brackets.

Assemble with the EGR water pipe brackets (2) tightened together to the intake side EGR cooler (1).

(Both temporal tightening torque 5N⋅m{0.5kg⋅m/ 3.7lb⋅ft})

2 1

WSUZ0111

3

2

WSUZ0074

23. Final tightening order Note: The circled numbers on the diagram are showing the tightening order.

1. Between EGR duct A – and the EGR valve (1).

Tightening torque: 21.6N⋅m {2.2kg⋅m/15.9lb⋅ft}

Engine Mechanical (6UZ1X) 1B-35 2. Between EGR valve – and the EGR duct B (2).

Tightening torque: 21.6N⋅m {2.2kg⋅m/15.9lb⋅ft} 3. Between the inlet duct – and the EGR duct B (3).

1. Between the exhaust manifold – and the EGR duct C (7).

Tightening torque: 50N⋅m {5.1kg⋅m/36.9lb⋅ft}

Tightening torque: 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}

1

7

6 WSUZ0073

2

3 WSUZ0113

4. Between EGR duct B – and the intake side EGR cooler (4).

2. Between the exhaust side EGR cooler – and the intake side EGR cooler brackets (8).

Tightening torque: 50N⋅m {5.1kg⋅m/36.9lb⋅ft}

Tightening torque: 50N⋅m {5.1kg⋅m/36.9lb⋅ft} 5. Between the intake side EGR cooler – and the exhaust side EGR cooler (5).

8

Tightening torque: 50N⋅m {5.1kg⋅m/36.9lb⋅ft}

4

WSUZ0115

3. Between the EGR duct C – and the exhaust side EGR cooler brackets (9).

Tightening torque: 50N⋅m {5.1kg⋅m/36.9lb⋅ft} 5 WSUZ0114

6. Betweenthe EGR duct C – and the exhaust side EGR cooler (6).

Tightening torque: 50N⋅m {5.1kg⋅m/36.9lb⋅ft}

Engine Mechanical (6UZ1X) 1B-36

9 WSUZ0116

1

4

2

5

3 8

9

7

6 WSUZ0117

Engine Mechanical (6UZ1X) 1B-37 - Install the EGR water pipe.

Note: • Inset the rubber hose deeply and install the clip not to let it run on to the bulge part.

• Do not re-use the rubber hose and clip when there are cracks or damages on them.

• Install the water feed for the EGR cooler (1) and (2) and the water return pipe (3) and (4).

2 1

Sensor and device

Name of installed parts

Camshaft position sensor (CMP)

Supply pump

Fuel pressure sensor

Common rail

Fuel temperature sensor

Supply pump

Boost pressure sensor

Inlet duct

Boost temperature sensor

Inlet duct

Solenoid valve

Injector

Engine coolant temperature sensor

Thermostat housing

Oil pressure sensor

Cylinder block left side

Note: Install the clip at the specified position.

4

3

WSUZ0055

• Install the air leak pipe (1).

1

WSUZ0054

24. Install the engine harness.

• Install harnesses on to each sensor and device.

Sensor and device

Name of installed parts

EGR motor

EGR valve

Crank position sensor (CKP)

Flywheel housing on the upper-left

Pump control valve (PCV)

Supply pump

Engine Mechanical (6UZ1X) 1B-38

Tightening Torque List Engine Exterior Equipment

a

b

c

d g

e

f

WSUZ0075

Name (a) (b) (c) (d)

50N⋅m {5.1kg⋅m/ 38.9lb⋅ft} 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft} 21.6N⋅m {2.2kg⋅m/ 15.9lb⋅ft} 97.4N⋅m {9.9kg⋅m/ 71.8lb⋅ft}

(e) 85.5N⋅m {8.7kg⋅m/ 63.1lb⋅ft} (f) 31N⋅m {3.2kg⋅m/ 22.9lb⋅ft} (g) 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft}

Engine Mechanical (6UZ1X) 1B-39

b

c d

a

e

f

i

h

g

WSUZ0076

Name (a) (b) (c) (d) (e)

53.9N⋅m {5.5kg⋅m/ 39.8 lb⋅ft} 50N⋅m {5.1kg⋅m/ 39.6lb⋅ft} 40 N⋅m {4.1kg⋅m/29.5 lb⋅ft} 97.4N⋅m {9.9kg⋅m/ 71.8lb⋅ft} 97.1N⋅m {9.9kg⋅m/ 71.6lb⋅ft}

(f) (g) (h) (i)

50N⋅m {5.1kg⋅m/ 39.6lb⋅ft} 50N⋅m {5.1kg⋅m/ 39.6lb⋅ft} 103N⋅m {10.5kg⋅m/ 76.0lb⋅ft} 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft}

Engine Mechanical (6UZ1X) 1B-40

b

a

WSUZ0077

Name (a)

50N⋅m {5.1kg⋅m/ 39.6lb⋅ft}

(b) 43.8N⋅m {4.5kg⋅m/ 32.3 lb⋅ft}

Engine Mechanical (6UZ1X) 1B-41

Cylinder Head Components

Name 1. Leak-off Pipe 2. Injector ASM 3. Clamp 4. Camshaft BRKT 5. Head Cover 6. Gasket 7. Rocker Arm ASM 8. Camshaft 9. Camshaft Carrier

10.

11.

12.

13.

14.

15.

16.

17.

Gasket Idle Gear C Cover Idle Gear C Shaft Idle Gear C Glow Plug Glow Plug Connector Gasket Cylinder Head ASM

Engine Mechanical (6UZ1X) 1B-42

Removal 1. Remove the EGR cooler and EGR valve.

Refer to “Engine Exterior Equipment”.

2. Remove the fuel pipe and the fuel filter ASM. Refer to “Engine Exterior Equipment”.

3. Remove the inlet duct.

Refer to “Engine Exterior Equipment”.

4. Remove the injection pipe.

Important: Do not reuse the high-pressure pipe in fuel system if it has been removed.

Refer to “Engine Exterior Equipment”.

5. Remove the common rail.

Refer to “Engine Exterior Equipment”.

6. Remove the inlet cover.

Refer to “Engine Exterior Equipment”.

7. Remove the turbocharger ASM. Refer to “Engine Exterior Equipment”.

8. Remove the exhaust manifold.

Refer to “Engine Exterior Equipment”.

9. Remove the thermostat housing.

Refer to “Engine Exterior Equipment”.

10. Remove the head cover.

11. Remove the head cover gasket.

WSUZ0053 12. Remove the glow plug.

• Disconnect the connectors and remove the glow plug.

13. Remove the injector harness.

• Loosen the terminal tightening nut and remove the harness.

• Remove the harness BRKT-ASM.

Note: When the injector harness is removed, its ID code plate is also removed. Do not confuse it with other injector ID code plates.

Injector ID code plate is unique to each injector.

Engine Mechanical (6UZ1X) 1B-43 14. Remove the injector leak-off pipe.

15. Remove the injector.

• Loosen the clamp (1) tightening bolt (2) and remove the injector (3).

• If it is hard to pull out the injector ASM, shake it left-to right a few times or use the injector remover (380002601).

Note: • The ends of the injector and the glow plug are sticking out of the lower surface of the cylinder head. Therefore, remove both before lowering the head.

• Check the injector sleeve has not come off while removing the injector. If the sleeve does come off, the cooling water will go inside the cylinder.

• Make sure to put number plates on injectors.

Name 1. Sliding Hammer 2. Injector Remover 3. Injector ASM 16. Remove the rocker arm ASM. • Remove the brackets tightening bolt from the rocker arm ASM by loosening them equally from both ends.

2

1

3

4

WSUZ0078

17. Remove the bridge.

• Store bridges in numeric order.

Engine Mechanical (6UZ1X) 1B-44 18. Remove the camshaft.

• Measure the axial clearance of the camshaft before removing the camshaft.

Axial clearance of the camshaft (mm) Assembly standard

Limit of usage

0.085 — 0.170

0.25

• Loosen the tightening bolts of the brackets equally from both ends to remove.

19. Remove the camshaft carrier.

20. Remove the cylinder head ASM. • After loosening M10 bolts 1, 2, and 3, loosen the M15 tightening bolts equally from outside to inside as directed by arrows on the diagram.

Note: • Remember to remove the M10 tightening bolt.

• Cover the hole on the timing gear with a cloth.

Engine Mechanical (6UZ1X) 1B-45

21. Remove the cylinder head gasket.

• Make sure there is no water or gas leak when removing.

Engine Mechanical (6UZ1X) 1B-46

Disassembly

Name 1. Exhaust Manifold Cover 2. Gasket 3. Exhaust Manifold 4. Bridge Guide 5. Split Collar 6. Spring Seat (upper) 7. Valve Spring 8. Valve Stem Oil Seal 9. Spring Seat (lower) 1. Measure the axial clearance of the idle gear shaft C. • Measure the axial clearance of the idle gear C before removing the shaft.

10.

11.

12.

13.

14.

15.

16.

17.

Valve Guide Injector Sleeve Cylinder Head Gasket Inlet Cover Valve Valve Seat Insert Thermostat Housing

Axial clearance (mm) Assembly standard

Limit of usage

0.135 — 0.190

0.30

Engine Mechanical (6UZ1X) 1B-47

2. Remove the idle gear C. • Pull out the idle gear shaft and remove the idle gear C from the cylinder head.

Note: Be careful not to damage bushing of the idle gear shaft.

4. Remove the split collar.

• Use round nails for the valve spring re-presser.

5. Remove the spring seat (upper).

• Place the cylinder head on a wooden board with its sides down.

• Use the valve spring replacer (380300011) to remove the split collar and remove the spring sheet.

3. Remove the oil seal from the camshaft carrier.

• Place a pad from inside the carrier and pull out.

6. Remove the valve spring.

7. Remove the valve.

Note: Put number plates on valves to store.

Engine Mechanical (6UZ1X) 1B-48 8. Remove the valve stem oil seal.

9. Remove the spring seat (lower).

12. Remove the valve seat insert.

• Heat-up the 2 parts of insides of the insert (up to 600 — 700 °C) with welding gas burner, and leave it to cool down for 3 to 5 minutes then pull out with a screw driver.

Note: • Do not cool it forcefully.

10. Remove the valve guide.

• Insert the valve guide replacer into the guide from the bottom side of the head and hammer it out.

13. Remove the injector sleeve.

• Put a stick on the bottom side of the head and knock it out.

11. Remove the bridge guide.

• Weld the nut electrically to the bridge guide, and take out the nut by installing the sliding hammer.

Engine Mechanical (6UZ1X) 1B-49 Measure the valve spring.

• Measure the squareness of the valve spring.

Valve spring squareness (mm) Assembly standard

Limit of usage

Inlet

3.85

4.5

Exhaust

4.11

4.8

Inspection Inspect on the idle gear shaft C. • Measure the diameter of the idle gear shaft, and the clearance between the shaft and the bushing.

Check to see if there are any damages on the bushing.

Diameter of the shaft (mm) Nominal dimension

Limit of usage

38

37.85

• Measure the free length of the valve spring Valve spring free length (mm)

Clearance between the shaft and bushing (mm)

Nominal dimension

Limit of usage

Assembly standard

Limit of usage

Inlet

88.09

85.00

0.02 — 0.066

0.12

Exhaust

94.09

91.10

Engine Mechanical (6UZ1X) 1B-50 • Measure the tension of the spring at installation.

Installation length Both IN – EX:

Measure 3 places shown on the diagram.

The external diameter of the valve stem

64.5mm

(mm) Nominal dimension

Limit of usage

Inlet

φ 8.0

φ 7.88

Exhaust

φ 8.0

φ 7.88

Valve spring tension (loading at installation) (N{kg}) Load

Service limit

Inlet

392 {40.0}

373 {38.0}

Exhaust

588 {60.0}

559{57.0}

Measure the valve.

• Check wear of the valve stem end. Repair light wear with the oil stone.

If the wear level of the valve stem is exceeding the limit, replace it together with the valve guide.

• Measure the clearance between the valve guide and the valve stem.

Insert the valve into the valve guide and measure the clearance at (a) 10mm from the upper end of the valve guide.

The clearance between the guide and valve stem. (mm)

• Measure the wear level of the valve stem.

Assembly specification

Limit of usage

Inlet

0.039 — 0.071

0.15

Exhaust

0.064 — 0.096

0.20

Engine Mechanical (6UZ1X) 1B-51

• Check around the surface of the valve seat and measure the thickness.

Check for any damages and stepped wear, and measure the thickness (b) and width (a).

Thickness of valve (mm) Nominal dimension

Limit of usage

Inlet

2.0

1.6

Exhaust

2.2

1.8

Check on the contact surface of the valve seat • Apply red lead to the valve insert and check the contact width (b) of the seat surface. Also, check to see if the contact area is at the center of the valve seat and if there is any part off the seat.

Contact width of the valve seat surface (mm) Nominal dimension

Limit of usage

Inlet

3.3

3.7

Exhaust

3.5

4.0

Note: After a polishing repair, replace the valve if its thickness exceeded the usage limit.

• If the contact width of the valve or contacting surface is insufficient, repair it with a seat knife appropriate for the seat angle and stem diameter.

Engine Mechanical (6UZ1X) 1B-52 Measure the bridge guide.

Valve seat angle Inlet valve:

30°

Exhaust valve:

45°

• Measure the clearance between the bridge guide and bridge.

The clearance between the guide and bridge (mm) Assembly standard

Limit of usage

0.020 — 0.057

0.10

Rubbing valves • Apply compound to the insert and contact surface of the valve seat, and rub them together adequately. Clean the cylinder head and valve after rubbing.

Inspect on the cylinder head.

• Measure the warp on cylinder head Remove any rust or carbon from the head, valve seat and insert etc. without damaging the processing surface. Put a straight edge to the installing side of the head and measure from 1 to 4 shown on the diagram with a thickness gauge. If the measurement exceeds the limit, replace it.

Warp level: Service limit

0.2mm or less

Note: The cylinder head cannot be modified since the backlash of the timing gear fluctuates.

• Measure the depression level of the valve after a polishing repair of the valve seat, and check if it is within the usage limit.

Valve depression level (mm) Assembly standard

Limit of usage

Inlet

0.05

1.0

Exhaust

0.40

1.4

Engine Mechanical (6UZ1X) 1B-53

• Check for cracks or damages on the cylinder head.

Perform magnetic flux method or red check inspection as required.

• Check on cracks on the water jacket.

Apply water pressure of 490kPa{5kg/cm2}with a hydraulic test machine for 3 minutes, and check for any leakage from each head part.

Assembly 1. Install the injector sleeve.

• Clean the adhesive side of the cylinder head.

• Apply Loctite No.LT290 on the outer surface sleeve (the bottom part) and end-bearing surface. Apply a thin coat of engine oil to the Oring and press-fit it to the cylinder head.

Note: Assemble red O-rings to upper side of the sleeve groove and black O-rings to the lower side.

2. Install the valve seat insert • Remove any rust or carbon carefully from the installation surface of the insert, and press-fit insert with a press.

3. Install the bridge guide.

• Apply a thin coat of engine oil to the outer surface of the guide. Hammer guides in with the installer (380001722) until the height of bridge guide from the upper surface of the head is 43.5±0.5mm.

Note: Height of the bridge guide cannot be set to the specified level using the bridge guide installer. Measure the height while hammering in the bridge guides.

Engine Mechanical (6UZ1X) 1B-54 5. Install the spring seat. (lower).

6. Install the valve stem oil seal.

• Install the valve stem oil seal (1) to the valve guide (2) using the installer (380300013).

• Hammer in while checking the measurement (a) of the lower seat (3) is 26.3±0.5mm from the shoulder of oil seal.

Note: • Apply engine oil to the oil seal.

• After installation of the valve stem oil seal, make sure there is no spring coming off or deformed.

WSUZ0143

4. Install the valve guide.

• Apply engine oil to valve guides all around.

Press-fit valve guides using a replacer (380300014) until the height from the cylinder head surface (lower seat adhesive side) is levelled to the specification.

Note: The valve guide cannot be set to the specified height using the valve guide replacer. Hammer in the valve guide while measuring the height during the work.

Height of valve guide from the cylinder head surface. (mm) Assembly standard Both IN and EXH

24.0

7. Install the valve.

• Apply engine oil to the valve stem and insert into the cylinder head.

Note: Make sure there are IN valve in the front side and EXH valve in the rear side.

WSUZ0144

Engine Mechanical (6UZ1X) 1B-55 8. Install the valve spring.

• Place the cylinder head on a wooden board with its sides down.

• Install the inlet valve spring with its narrow pitched side (painted part) pointing the bottom side of the head. The exhaust valve spring has no top/bottom.

9. Install the spring seat. (upper).

11. Install the oil seal to the camshaft carrier.

• Apply a thin coat of engine oil to the outer surface of oil seal.

• Use an installer (380001719) to hammer in without leaning the seal.

10. Install the split collar.

• Use round nails for the valve spring re-presser.

• Use the valve spring replacer (380300011) to push the valve spring in and install the split collar.

• After installation, tap the head of the valve stem lightly with rubber hammer to stabilize the split collar.

12. Install the idle gear C. 13. Install the idle gear shaft C. • Apply engine oil to the idle gear shaft. Align the oil pins of the shaft to the oil hole position on the head and install.

• Apply molybdenum disulphide to the thread and seating side of the bolt, and tighten with a specified torque.

Tightening torque: 80.4N⋅m {8.2kg⋅m/59.3lb⋅ft} Note: • Make sure that the gear rotates smoothly.

• Make sure not to damage tooth surface of the gear since it sticks out from the cylinder head.

Engine Mechanical (6UZ1X) 1B-56 14. Install the idle gear C cover.

• Insert O-ring to the cover and apply a thin coat of engine oil to it, then install it.

• Maintain the coating height and width without the liquid gasket covering the oil hole after assembling of the cylinder head.

Tightening torque: 21.6N⋅m {2.2kg⋅m/15.9lb⋅ft}

Installation

• Assembling the cylinder head.

Assemble the head gasket. Align the cylinder head with the knock pin and put it on carefully.

• Put it on while checking on how the gear is engaged.

1. Cylinder head gasket • Use new parts when re-assembling

2. Install the cylinder head ASM. • Clean the upper surface of cylinder block and the lower side of cylinder head carefully.

• Apply ThreeBond No.TB1207B (height – approx. 2mm and width – approx. 2mm to the top surface of contact part (3) of cylinder block (1) and flywheel housing (2).

Note: • Assemble swiftly once applied.

• Tighten the cylinder head bolt.

Apply molybdenum disulphide to the thread and seating surface of M15 and 10 bolts, and to the seating surface of washer. Tighten M15bolt (1 — 26) outwards in spiral from the center as shown on the diagram. Tighten M10 bolt (27, 28 and 29) next.

Tightening torque M15: M10:

98N⋅m{10kg⋅m/72.3lb⋅ft} → 196N⋅m {20kg⋅m/ 144lb⋅ft} → Angle method 60° +30° -0° 38N⋅m{4.0kg⋅m/28lb⋅ft}

Engine Mechanical (6UZ1X) 1B-57 Note: • To check the tightening condition of M15 bolt, it should be over 230N⋅m{23.5kg⋅m/169.6lb⋅ft} in retightening direction.

• Cover the hole on the timing gear with a cloth.

• The head bolt can be recycled up to 2 occasions.

- Apply engine oil to M10 and M8 bolts.

- Tighten bolts temporarily in the order shown on the diagram 1-23.

- After that, tighten finally with a specified torque in the same order as the temporal tightening.

- Torque of inside bolts (1-5) tend to go down. So tighten them again to confirm.

3. Install the camshaft carrier.

• Push the convex part of gasket into the groove on the carrier securely.

Note: Check all the convex parts for any sign of collapsing. If gasket ends were found off the center of groove and collapsed, push the gasket from the sides with a finger to set the end back to the center of groove. And then install.

• Follow the order below to tighten bolts.

14

20

Tightening torque: M10 bolt: M8 bolt:

8

2

43.8N⋅m{4.5kg⋅m/32.3lb⋅ft} 21.6N⋅m{2.2kg⋅m/15.9lb⋅ft}

9

21

15

22 19

13 18

7

1

12

3

10 4

6

5

16 11 17

23

WSUZ0035

Engine Mechanical (6UZ1X) 1B-58 4. Install the camshaft.

• Set No. 1 cylinder to the compression top dead center position.

Rotate the crankshaft in proper direction, and align the T/C mark on the flywheel with the pointer.

WSUZ0036

• Apply engine oil to the journal of cam carrier, the cam BRKT and to the No.7 journal thrust part.

• Install the camshaft BRKT. - Apply engine oil on the BRKT. - Check the identifying symbols of BRKT (stamped 1, 2, 3, 4, 5, 6 and 7 from the front) and front marks. Install the cam BRKT to a correct position.

- Apply engine oil to the bolt.

- Tighten temporarily in a numerical order from the center of cam BRKT and use the specified torque for final tightening.

Tightening torque: 53N⋅m {5.4kg⋅m/39.1lb⋅ft} Note: Check again to see if the (U) mark on the cam gear and the nick line (-) are matched after tightening the cam BRKT.

• Match the marks on the camshaft.

Set the camshaft to the mark (U) on the gear with your eye level on the upper part of cam carrier, and set the nick line (-) to the position shown on the diagram.

Engine Mechanical (6UZ1X) 1B-59 5. Install the bridge.

• Loosen the adjust screw and apply engine oil to the bridge guide, then install.

7. Install the inlet cover.

Refer to “Engine Exterior Equipment”.

8. Install the common rail.

Refer to “Engine Exterior Equipment”.

9. Install the injector, clamp and injection pipe.

Important: Replace the high-pressure pipe in fuel system with new one if it has been removed.

• Put gasket into the injector (3) and install it to the cylinder head.

Tighten the injection pipe temporarily.

Apply molybdenum disulphide to the tightening bolt (2) for the clamp and tighten the clamp (1) with the specified torque.

Tighten the injection pipe at the end.

Tightening torque: Clamp: Injection pipe:

Note: • Install the bridge to the same position as disassembly.

• Adjust screws come off when loosened too much.

6. Install the rocker arm ASM. • Apply engine oil to the camshaft and to the upper surface of bridge.

• Install the rocker arm ASM. • Tighten temporarily in a numerical order as shown on the diagram, and then tighten finally with specified torque.

25.5N⋅m {2.6kg⋅m/18.8lb⋅ft} 44.1N⋅m {4.5kg⋅m/32.5lb⋅ft}

Note: • Make sure there is no old gasket remaining inside the sleeve.

• Remove carbon inside the sleeve carefully.

• Do not re-use gasket.

• Do not remove the ID code plate from the injector.

If removed, put it back to the same injector.

2

Tightening torque: 90N⋅m{9.2kg⋅m/66.4lb⋅ft}

1

3

4

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10. Install the injector leak-off pipe.

• Install the leak-off pipe (1) to the injector.

Tightening torque: • Adjust the valve clearance.

For adjustment procedure, refer to the valve clearance adjustment section on the “Function Check”.

M8 eye bolt: (2) M12 eye bolt: (3)

14.7N⋅m{1.5kg⋅m/10.8lb⋅ft} 34.3N⋅m {3.5kg⋅m/25.3lb⋅ft}

Engine Mechanical (6UZ1X) 1B-60 Note: Do not re-use gasket.

11. Install the injector harness ASM. • Insert the harness connector until it clicks and install it to the cam carrier.

Tightening torque: 21.6N⋅m {22kg⋅m/15.9lb⋅ft}

12. Install the glow plug.

• Tighten the glow plug with the specified torque and install the connector.

Tightening torque: 19.6N⋅m{2.0kg⋅m/14.5lb⋅ft} Note: Adequate care should be taken as over-tightening the glow plug could lead to damage.

13. Install the head cover.

• Make sure that the rubber-mount is inserted to bolt holes.

• Install the gasket on the head cover.

• Tighten twice in the numerical order or arrowed order shown on the diagram.

Tightening torque: 14.7N⋅m{1.5kg⋅m/10.8lb⋅ft} Note: Make sure there are no gasket coming off or collapsed when assembling the head cover. If there was any came off or collapsed, repair it and then assemble.

• Tighten the harness nut at the heads of each cylinder injector with the specified torque.

Tightening torque: 2N⋅m {0.2kg⋅m/1.5lb⋅ft} Note: Do not over-tighten the nut. It might cause damages on injector (breakage to pins).

1

2

WSUZ0120

Engine Mechanical (6UZ1X) 1B-61 14. Install the thermostat housing.

Refer to “Engine Exterior Equipment”.

15. Install the exhaust manifold.

Refer to “Engine Exterior Equipment”.

16. Install the turbocharger ASM. Refer to “Engine Exterior Equipment”.

17. Install the inlet duct.

Refer to “Engine Exterior Equipment”.

18. Install the fuel pipe and fuel filter ASM. Refer to “Engine Exterior Equipment”.

19. Install the EGR cooler and EGR valve.

Refer to “Engine Exterior Equipment”.

Engine Mechanical (6UZ1X) 1B-62

Tightening Torque List Cylinder head

Name (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

25.5N⋅m {2.6kg⋅m/ 18.8lb⋅ft} 2N⋅m {0.2kg⋅m/ 1.5lb⋅ft} 14.7N⋅m {1.5kg⋅m/ 10.8lb⋅ft} 34.3N⋅m {3.5kg⋅m/ 25.3lb⋅ft} 53N⋅m {5.4kg⋅m/ 39.1lb⋅ft} 53.9N⋅m {5.5kg⋅m/ 39.8lb⋅ft} 50N⋅m {5.1kg⋅m/ 36.9lb⋅ft} 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft} 14.7N⋅m {1.5kg⋅m/ 10.8lb⋅ft} 90N⋅m {9.2kg⋅m/ 66.4lb⋅ft}

(k) (I) (m) (n) (o) (p) (q) (r)

M10: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft} M8: 21.6N⋅m{2.2kg⋅m/15.9lb⋅ft} 80.4N⋅m {8.2kg⋅m/ 59.3lb⋅ft} 19.6N⋅m{2.0kg⋅m/14.5lb⋅ft} 45N⋅m {4.6kg⋅m/ 33.2lb⋅ft} 21.6N⋅m {2.2kg⋅m/ 15.9lb⋅ft} 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft} 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft} 98N⋅m{10kg⋅m/72.3lb⋅ft} → 196N⋅m{20kg⋅m/ 44.6lb⋅ft} → 60° +30° -0°

Engine Mechanical (6UZ1X) 1B-63

Special Tool Cylinder head Illustration

Tool Number Description Special Tool

380002601 Injector remover

380300011 Valve spring replacer

380300014 Valve guide replacer

380001722 Bridge guide installer

380300013 Valve stem seal installer

380001719 Cam carrier oil seal installer

Engine Mechanical (6UZ1X) 1B-64

Rocker arm Components

Name 1. Rocker Arm (IN) 2. Tube 3. Rocker Arm (EXH)

Disassembly 1. Remove BRKT 2. Remove the rocker arm.

3. Remove the tube.

4. Rocker arm shaft • Remove BRKT of the rocker arm shaft together with the bolt. Remove the rocker arm (1), tube (2) and rocker arm (3) from the Shaft (6).

4. BRKT 5. Front Mark 6. Rocker Arm Shaft

Note: Store removed parts in the numerical order.

Engine Mechanical (6UZ1X) 1B-65

Rocker arm shaft • Check for oil hole of the rocker arm shaft.

Inspection Check the rocker arm.

• Check for any wear or damages on the roller side, and measure the clearance between the roller pin (1) and roller (2).

Mark the measuring position when the roller of rocker arm is let out to the maximum, and measure the difference in level between the rocker arm and roller (a). Then push the roller in to the maximum, and measure the difference in level at the marked measuring position (b).

The gap between the measurement (a) and (b) above is the clearance between the roller pin and roller.

The clearance between the roller pin and roller (mm) Assembly standard

Limit of usage

0.036 — 0.069

0.15

• Check for bent of the rocker arm shaft.

Engine Mechanical (6UZ1X) 1B-66

Assembly

Shaft bent Service limit

0.3mm

1. Rocker arm shaft 2.

3.

4.

5.

• Check the front marking of the shaft.

Install BRKT. Insert the rocker arm.

Insert the tube.

Rocker arm • Apply engine oil to the rocker arm bushing and fix BRKT (4) to the shaft with bolt. Then assemble in a following order; the exhaust rocker arm (3) (short arm), the tube (2) and the inlet rocker arm (1) (long arm).

Note: • Check the front marking of the rocker arm shaft.

• Assemble the inlet rocker arm to the front side.

• Measure the diameter of the rocker arm shaft, and the clearance between the shaft and the rocker arm bushing. (mm) Nominal dimension

Assembly standard

Limit of usage

Clearance between the shaft and the rocker arm.

—

0.041 — 0.090

0.20

Diameter of the shaft

φ28

—

φ27.85

Engine Mechanical (6UZ1X) 1B-67

Camshaft Components Camshaft

Name 1. Camshaft 2. Key

Disassembly 1. Remove the camshaft gear.

• Put a piece of wood (1) to the gear to prevent any damages and use a puller to install it.

3. Camshaft Gear

Engine Mechanical (6UZ1X) 1B-68

Inspection Inspection of the camshaft gear • Check to see if there are any pitching or damages on the tooth side.

Inspection of the camshaft • Measurement of camshaft runout Hold No.1 and No.7 journal part with V block and place the dial gauge to No.4 journal. Rotate the camshaft slowly once and take the measurement.

Measurement of camshaft runout level (mm) Limit of usage 0.1

2. Remove the key.

3. Camshaft

• Inspecting damages on the cam surface and measure the cam lift level Repair light damages or wear with an oil stone.

Acquire the lift level by (a) – (b).

Engine Mechanical (6UZ1X) 1B-69 Cam lift level (a – b) (mm) Nominal dimension

Limit of usage

Inlet

7.52

7.1

Exhaust

8.53

8.0

Measuring the clearance between the camshaft journal and cam carrier journal.

• Measure the inner diameter of cam carrier journal and the outer diameter of camshaft, then acquire the clearance measurement.

• Clean the cam carrier journal, and check the nick line on upper side of BRKT. Tighten the assemble bolt with the specified torque.

Measure the 4 positions shown on the diagram with a cylinder gauge, and acquire the inner diameter of cam carrier journal.

Tightening torque: Cam BRKT:

53N⋅m{5.4kg⋅m/39.1lb⋅ft}

• For measuring outer diameter of the cam shaft journal, measure the 4 positions using a micrometer.

Clearance between the cam shaft journal and BRKT. (mm) Assembly standard

Limit of usage

0.075 — 0.125

0.15

*Refer to “General Information” when using the Plastigauge for measurement.

• Measuring the outer diameter of journal Take a measurement of the position shown on the diagram with a micro-meter.

Outer diameter of journal (mm) Nominal dimension

Limit of usage

φ 40.0

φ 39.89

Assembly 1. Camshaft 2. Install the key.

3. Install the camshaft gear.

• Hammer the key into the camshaft, and press-fit it placing one with bigger gear-center-boss part pointing towards camshaft.

• Apply oil to the thread and seating side of the bolt, and tighten with a specified torque.

Tightening torque: 137.5N⋅m {14kg⋅m/101.4lb⋅ft}

Engine Mechanical (6UZ1X) 1B-70

Tightening Torque List Camshaft

Name (a)

137.5N⋅m {14kg⋅m/101.4lb⋅ft}

Engine Mechanical (6UZ1X) 1B-71

Flywheel, Flywheel Housing and Timing Gear Components

Name 1. Flywheel 2. Oil Seal 3. Idle Gear D Cover 4. Idle Gear D 5. Cover 6. Crank Position Sensor

Removal 1. Remove the engine accessories.

Remove the starter. Refer to “Engine Support Device” 2. Disconnect the coupling of supply pump.

3. Disconnect the fuel pipe.

7.

8.

9.

10.

11.

12.

Crankshaft Gear Idle Gear B Shaft Idle Gear B Idle Gear A Idle Gear A Shaft Flywheel Housing

4. Remove EGR device.

Refer to “Engine Exterior Equipment”.

5. Remove the head cover.

Refer to “Cylinder Head”.

6. Remove the rocker arm.

Refer to “Cylinder Head”.

7. Remove the camshaft.

Refer to “Cylinder Head”.

Engine Mechanical (6UZ1X) 1B-72 8. Remove the cylinder head.

Refer to “Cylinder Head”.

9. Remove the oil pan.

Refer to “Oil Pan” in the Lubrication System section.

10. Remove the crankshaft position sensor.

Note: Remove the sensor before removing the flywheel to prevent any damages on sensor.

Note: • If remover is coming off the slinger easily, use a clip band to tighten around the parts for smoother service.

• Be careful not to damage the flywheel housing and crankshaft.

13. Remove the idle gear D. • Remove the idle gear D cover.

• Loosen the tightening bolt of the shaft and remove the idle gear D. Note: There is a bolt for installing the flywheel housing on the back of idle gear D. Remember to remove idle gear D before flywheel housing.

14. Remove PTO ASM. • Remove the PTO oil feed pipe (1).

11. Remove the flywheel.

12. Remove the oil seal.

• Set the oil seal remover (380300003) to the slinger of oil seal.

• Tighten in the bolt and remove oil seal.

1 WSUZ0097

• Remove the PTO ASM (1) and 2 sheets of PTO cover (2).

1

2 WSUZ0095

Engine Mechanical (6UZ1X) 1B-73 15. Remove the flywheel housing.

• Knock it lightly with a wooden hammer etc. to remove.

Note: Remember to remove the bolt on the D side of idle gear.

16. Measurement of the idle gear backlash.

• Measure before removing each idle gear.

Backlash of idle gear (mm) Assembly standard

Limit of usage

0.06 — 0.10

0.30

17. Remove the idle gear A (3).

18. Remove the idle gear B (1).

19. Remove the idle gear B shaft (2).

Measuring the axial clearance of the idle gear Axial clearance of idle gear (mm) Assembly standard

Limit of usage

A

0.140 — 0.229

0.35

B

0.040 — 0.190

0.30

C

0.135 — 0.190

0.30

D

0.052 — 0.107

0.20

Engine Mechanical (6UZ1X) 1B-74

Disassembly

Inspect on each idle gear.

1. Remove the ring gear of flywheel.

• Put the flywheel on a piece of wood and place a wooden bar to the end-side of the ring gear.

Hammer them both equally to remove.

WSUZ0090

Inspection

• Check for damages on idle gear.

Check for wear, tooth contact, peeling and pitching on gears.

• Measuring the clearance between the outer diameter of the idle gear shaft and inner diameter of gear.

Outer diameter of the idle gear shaft (mm)

Check the ring gear.

• Check for wear and damages on the tooth side of the ring gear.

Name

Nominal dimension

Limit of usage

A

41.0

40.85

B

30.0

29.85

C

38.0

37.85

Clearance between the shaft and gear bushing (mm)

Check the flywheel.

• Check for cracks and scratches on the flywheel.

Name

Assembly standard

Limit of usage

A

0.020 — 0.062

0.12

B

0.020 — 0.062

0.12

C

0.020 — 0.066

0.12

Engine Mechanical (6UZ1X) 1B-75

Installation 1. Install the idle gear B shaft.

Tightening torque: 320.5N⋅m {3.3kg⋅m/23.6lb⋅ft} 2. Install the idle gear B. • Apply engine oil to the idle gear shaft (2), insides of the gear (1) and on to the thrust surface.

• Place the larger center-boss part facing towards you when installing.

• Tighten the bolt via thrust collar.

Tightening torque: 95N⋅m{9.7kg⋅m/70.1lb⋅ft}

Assembly 1. Install ring gear to the flywheel.

• Warm the ring gear evenly using a gas burner (below 200°C). Install it to the flywheel with larger cut-edge on the gear facing towards you.

Note: Be careful with the gear direction when installing.

3. Install the idle gear A. • Check to see it is close to the compression top dead center of No.1cylinder.

• Insert idle gear A to the shaft and align the thrust washer with pin holes, and then subassemble them. At this point, apply engine oil to the shaft, bore of the gear and the thrust surface.

• Align the “U” marking on the crankshaft gear (2) and “{{” marking on the idle gear (1), and pin holes on the shaft and cylinder block to assemble.

• Apply molybdenum disulphide to the thread and seating side of the bolt, and tighten.

Tightening torque: 34.3N⋅m {3.5kg⋅m/25.3lb⋅ft} →60° +30° -0° Note: • Make sure the shaft and pin are matched before tightening bolts.

• After assembling, check again the marks are matched.

Engine Mechanical (6UZ1X) 1B-76 • Make sure there are backlashes between each gear.

4. Install the flywheel housing.

• Clean the surface on which the liquid gasket was applied.

• As instructed on the diagram, apply the liquid gasket (ThreeBond No. TB-1201) to the flywheel housing without missing any part, and install.

Tightening torque: Tightening torque:

M12 78N⋅m{8kg⋅m/57.5lb⋅ft} M8 24.5N⋅m{2.5kg⋅m/18.1lb⋅ft}

Note: • For idle gear D hole (1) and groove part, pay attention not to cover the hole with the liquid gasket.

• Apply the liquid gasket also on the 4 marked parts on the illustration.

• Install within seven minutes after applying liquid gasket.

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Name 1. Idle Gear Large A 2. Bearing Case Gear 3. Idle Gear Small A 4. Idle Gear C 5. Camshaft Gear 6. Idle Gear B 7. Idle Gear D 8. PTO Gear 9. Crankshaft Gear

Engine Mechanical (6UZ1X) 1B-77 Tightening torque for each bolt position (1)

M12

78N⋅m {8kg⋅m/57.5lb⋅ft}

(2)

M8

24.5N⋅m {2.5kg⋅m/18.1lb⋅ft}

(1)

(1)

(1)

(1)

(1)

(1) (1) (2)

(2)

(1)

(1) (1)

(2) (1)

(1)

1

(1)

(1)

(1)

(1)

WSUZ0097

(1)

6. Install the idle gear D. • Apply engine oil to the gear and shaft, and insert gear (1) into shaft (2) to assemble.

(1)

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5. Install PTO ASM • Assemble the gasket and install PTO ASM (1).

Tightening torque: 85.5N⋅m {8.7kg⋅m/63.1lb⋅ft} • Assemble the gasket and install 2 sheets of PTO cover (2).

Tightening torque: 156.9N⋅m {16.0kg⋅m/115.7lb⋅ft}

• Apply molybdenum disulphide to the thread and seating side of the bolt, and tighten via thrust collar.

Note: For oil lubrication, install the shaft (1) with the cut-out (2) side up and thrust collar (3) with painted part (4) set within the area as illustrated.

2

1

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• Install PTO oil feed pipe (1).

Eyebolt tightening torque: M12: M8:

22.5N⋅m{2.3kg⋅m/16.6lb⋅ft} 14.7N⋅m{1.5kg⋅m/10.8lb⋅ft}

Engine Mechanical (6UZ1X) 1B-78

2

4 45̨

3

1

WSUZ0124

Tightening torque: 153N⋅m {15.7kg⋅m/113.5lb⋅ft} • Insert O-ring into cover and install it to the housing.

Tightening torque: 21.6N⋅m{2.2kg⋅m/15.9lb⋅ft} 7. Install the oil seal.

• Apply a thin coat of engine oil to the outer surface of oil seal.

• Install the oil seal and slinger at the same time using the installer (380300004).

Once the installer is set, tighten in the center bolt until it touches the bottom.

Note: • Installing positions for oil seal are fixed and identified by different coloring.

Slinger Front side --- Zinc chrome plating color (plating color) Rear side --- Grey • Install the oil seal and slinger together without disassembling.

• Clean the remaining oil off after press-fitting.

• If there were any damages on the crankshaft, apply the liquid gasket (ThreeBond No.TB1207C) within the illustrated area.

Engine Mechanical (6UZ1X) 1B-79

8. Install the flywheel.

• Apply molybdenum disulphide to the threads and the seating surface of the installing bolt and tighten in the numerical order shown on the diagram.

Tightening torque:

78.5N⋅m{8kg⋅m/57.9lb⋅ft} →60°→30° (Angle method(60° +30°) +30° ) -0°

Note: Always check the tightness of bolts in re-tightening direction.

It should be above 245N⋅m{25kg⋅m/180.7lb⋅ft}.

9. Install the crankshaft position sensor.

Tightening torque: 8.2N⋅m {0.8kg⋅m/6lb⋅ft} Note: To avoid any damages on the sensor, carry out after installing the flywheel.

10. Install the oil pan.

Refer to “Oil Pan” in the Lubrication System section.

11. Install the cylinder head.

Refer to “Cylinder Head”.

12. Install the camshaft.

Refer to “Cylinder Head”.

13. Install the rocker arm.

Refer to “Cylinder Head”.

14. Install the head cover.

Refer to “Cylinder Head”.

15. Install the EGR device.

Refer to “Engine Exterior Equipment”.

16. Install the fuel pipe.

Refer to “Engine Exterior Equipment”.

17. Connect coupling of the supply pump.

Refer to “Engine Exterior Equipment”.

18. Install the engine accessories.

Install the starter. Refer to “Engine Accessories”

Engine Mechanical (6UZ1X) 1B-80

Tightening torque list Flywheel, Flywheel Housing and Timing Gear

Name (a) (b) (c) (d) (e)

78.5N⋅m{8kg⋅m/57.9lb⋅ft} → 60° → 30° (Angle method60: {60°+30°) +30° ) -0° 78N⋅m {8kg⋅m/ 57.5lb⋅ft} 153.9N⋅m {15.7kg⋅m/ 13.5lb⋅ft} 24.5N⋅m {2.5kg ⋅m/ 18.1lb⋅ft} 8.2N⋅m {0.8kg ⋅m/ 6lb⋅ft}

(f)

95N⋅m {9.7kg⋅m/ 70.1lb⋅ft}

(g) (h) (i) (j)

32N⋅m {3.3kg⋅m/ 23.6lb⋅ft} 34.3N⋅m{3.5kg⋅m/25.3lb⋅ft} → 60° +30° -0° 78N⋅m {8kg ⋅m/ 57.5lb⋅ft} 21.6N⋅m {2.2kg⋅m/ 15.9lb⋅ft}

Engine Mechanical (6UZ1X) 1B-81

Special Tool Illustration

Tool Number Description Special Tool

380300003 Oil seal remover

380300004 Oil seal installer

Engine Mechanical (6UZ1X) 1B-82

Front Cover and Crankshaft Components

Name 1. Oil Seal 2. Front Cover 3. Cylinder Block 4. Crank Pulley 5. Damper 6. Oil Pump Drive Gear

Removal 1. Remove the cylinder head.

Refer to “Cylinder Head”.

2. Remove the oil pan.

Refer to “Oil Pan” in the Lubrication System section.

3. Remove the oil pump.

7.

8.

9.

10.

11.

Thrust Bearing Crankshaft Bearing Crankshaft Crankshaft Gear Crankcase

Refer to “Oil Pump” in the Lubrication System section.

4. Remove the flywheel.

Refer to “Flywheel and Timing Gear”.

5. Remove the flywheel housing.

Refer to “Flywheel and Timing Gear”.

6. Remove the piston.

Refer to “Piston”.

Engine Mechanical (6UZ1X) 1B-83 7. Remove the crank pulley.

Play between front and back direction (mm) Assembly standard

Limit of usage

0.10 — 0.285

0.30

• If it exceeds the limit, replace the thrust bearing.

8. Remove the front cover oil seal.

• Set the oil seal remover (380300003) to the slinger of oil seal.

• Tighten in the bolt and remove oil seal.

11. Remove the crankcase.

• Loosen the tightening bolt for the bearing from outside.

• Screw in the removed bolt into the replacer hole on the crankcase and keep the crankcase suspended.

• Suspend it on a level and remove it without interfering other parts around.

Note: • If remover is coming off the slinger easily, use a clip band to tighten around the parts for smoother service.

• Be careful not to damage the front cover and crankshaft.

9. Remove the front cover.

10. Measuring the axial clearance of the crankshaft.

• Take a measurement at the position of No.7 bearing cap.

Note: Be careful the thrust bearing can easily fall off.

Engine Mechanical (6UZ1X) 1B-84 12. Remove the crankshaft.

• Suspend it on a level and remove it without interfering other parts around.

Disassembly 1. Remove the crankshaft damper.

• Remove the crankshaft damper from the crankshaft pulley.

2. Remove the crankshaft gear.

3. Remove the oil pump drive gear.

• Use a gear puller (380300001) to remove the crankshaft gear.

• Remove the oil pump drive gear the same way.

Note: Be careful not to let the puller nails catching flanges of crankshaft. It may damage the crankshaft.

13. Remove the crankshaft bearing.

14. Remove the thrust bearing.

• Mark the installing position of the thrust bearing using tags etc.

Note: • Do not damage the bearing sliding surface of the crankshaft.

• On removing, be careful with the bearing falling off.

Removing gear with general-purpose tool.

• Use a large gear puller (1).

• Pull it out without nails on the gear puller (2) catching the flange of crankshaft (3).

Note: • Be careful not to let the puller nails catching flanges of crankshaft. It may damage the crankshaft.

• The gear is burn-weld. Always use a large gear puller because the load to pull out the gear is large.

Engine Mechanical (6UZ1X) 1B-85 Crankshaft • Check for cracks on crankshaft and damages on the touching surface of bearing.

Perform magnetic flux method or red check inspection as required.

Inspection Crankshaft damper • Check for any leakage of silicon oil.

• Check for cracks or peelings on rubber.

• Measuring wear on crank journal and pins.

Measure 4 places shown on the diagram. (mm) Nominal dimension

Limit of usage

Outer diameter of journal

φ 90.0

φ 89.909— 89.929

Outer diameter of pin

φ 84.0

φ 83.894— 83.914

Note: The crankshaft cannot be repaired as tuftride treatment has been performed to the surface.

Engine Mechanical (6UZ1X) 1B-86 • Measuring crankshaft run-out Hold both ends with V block. Measure the run-out of the crankshaft by setting the dial gauge to No.4 journal at crankshaft and rotate the crankshaft once slowly.

Crankshaft run-out level (mm) Limit of usage 0.15

• Measure 4 places shown on the diagram with a cylinder gauge.

• Measuring the clearance between the bearing and crank journal.

Measure the inner diameter of bearing and the outer diameter of crank journal while the crankcase is assembled, then acquire the clearance measurement.

• Clean the bearing and installation surfaces, and assemble the bearing. Then install the crankcase.

Apply molybdenum disulphide to the threads and the seating surfaces of M10 and 15 bolts. Tighten M15 bolt first as illustrated.

• For the outer diameter of crank journal, measure 4 places shown on the diagram with a micro-meter.

Tightening torque: N⋅m{kg⋅m/lb⋅ft}/degree M15: 54N⋅m{5.5/39.8} → rotating angle90 ° +30° -0° M10: 49N⋅m {5.0/36.1}

(mm)

Clearance between the bearing and crank journal.

Assembly standard

Limit of usage

0.045—0.080

0.09

Note: Refer to “General Information” when using the plastigauge for measurement.

Engine Mechanical (6UZ1X) 1B-87 Crankshaft gear • Check for wear, tooth contact, peeling and pitching on gears.

Bearing • Check for wear, damages and peeling on the crank bearing.

• When assembling the bearing, check to see there is a tension.

Check for the tuftride layers • Cleaning the crankshaft.

Clean the crankshaft. Remove any oil, especially around the inspection areas (except 10mm around the oil holes), using organic solvent.

• Check for the tuftride layers Drop the inspecting solution onto inspecting spots (1) using a syringe or glass rod. Keep the inspecting surface levelled not to let the inspecting solution run.

Note: • Do not carry out inspection on areas inside 10mm around the oil holes.

• Inspecting solution...a 5 ~ 10% solution of chlorinated-2-copper ammonium dissolved in distilled water.

Engine Mechanical (6UZ1X) 1B-88 • Process after inspection.

The inspecting solution is highly corrosive. Wipe it off immediately after the inspection, and thoroughly clean with water, steam, etc.

• Judgment Note: Crankshaft can be re-used.

Nothing changes even after 30 – 40 seconds.

Note: Crankshaft cannot be re-used.

The inspecting solution (light blue) turns transparent after 30 – 40 seconds and the spot (1) where the solution was dropped turns copper color.

Caution: Avoid the solution to contacting eyes, hands, cloth, etc.

If it goes into eyes, wash it out with plenty of water immediately and seek for a medical treatment.

Selecting crankshaft journal bearing • When using a new bearing, select one matches the grade of the cylinder block.

• Inner diameter grade is stamped on the right side and on the upper part at the back of the cylinder block.

• Stamped from the rear side in the order of the journal No.7 to No.1.

• The middle part of the bearing side is painted according to each grade.

Note: Selecting a wrong bearing leads to an excessive oil clearance causing a low-oil pressure, or a shortage of oil clearance causing a seizure.

Bearing selection table Cylinder block grade

Bearing grade

1

Brown

2

Black

3

Blue

Engine Mechanical (6UZ1X) 1B-89 Note: • Make sure to insert the gear until it touches the end.

• Do not ever re-use gears.

Assembly 1. Install the crankshaft gear.

• Warm up the gear using a heater (170°C — 180°C). Pull the “U” marking towards you watching the gear timing and align the groove of the gear with knock pins. Insert it quickly without leaving any space between the flange of the crankshaft.

Note: • Make sure to insert the gear until it touches the end.

• Do not ever re-use gears.

3. Install the crankshaft damper.

• Apply a thin coat of engine oil to the thread and seating surface of the bolts.

• Install the crankshaft damper to the crank pulley.

Tighten in diagonal order.

Tightening torque: 96N⋅m{9.8kg⋅m/70.8lb⋅ft}

WSUZ0017

2. Install the oil pump drive gear.

• Warm up the gear using a heater (170°C — 180°C). Place the drive gear as shown on the illustration and insert it quickly without leaving any space between the flange of crankshaft.

Engine Mechanical (6UZ1X) 1B-90

Installation 1. Install the crankshaft bearing.

• Check the assemble position marked at the disassembling, assemble after cleaning the bearing and the assembling surface.

• Upper bearing on the cylinder block side has groove and oil holes all around it. Lower bearing on the crank case side has groove but oil holes.

3. Install the thrust bearing.

• Apply oil on to the oil groove side of the thrust bearing (1) and keep the oil groove (2) outward.

Push it into both sides of No. 7 by hand.

Note: Keep the back of bearing dry when assembling.

2. Install the crankshaft.

• Apply oil to the sliding surface of bearing. Keep the crankshaft levelled and put it on carefully.

4. Apply liquid gasket.

• Wipe off the oil from the gasket applied surface.

• Apply Loctite FMD-127 (Width: 4mm or more, Thickness: 0.3mm or more) onto the lower surface of the cylinder block that is indicated as (1) on the illustration.

• Assemble the crank case swiftly after applying the gasket (within 15minutes).

Note: Clean the sliding surface and oil holes well when assembling.

5. Install the crankcase.

• Clean the crankcase and bearing well.

• Assemble the lower bearing.

• Place the oil groove (1) of the thrust bearing outward and align with knock pins when installing.

• Apply engine oil to the crankshaft and to the bearing.

Engine Mechanical (6UZ1X) 1B-91 • Assemble it carefully not to cause any dents on the crankshaft.

Note: • Make sure no to leave any gap between the cylinder block when putting on the crank case.

Repeat the same procedure if any gap was left.

• Keep the back of bearing dry when assembling.

• Assemble swiftly once the gasket was applied.

7. Install the front cover.

Application of liquid gasket • Apply liquid gasket (ThreeBond No.TB1201) on to the contact surface of the front cover installation surface and of the cylinder block (1).

• Install the front cover aligned with the dowel position.

Tightening torque: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft} Tighten the crank case.

• Apply molybdenum disulphide onto the thread and seating side of the M10 and M15 bolts, and tighten M15 first as instructed on the illustration.

Tightening torque: M15: M10:

N⋅m{kg⋅m/lb⋅ft} 54 {5.5/39.8}→90° +30° -0° 49{5.0/36.1}

1

WSUZ0099

8. Install the oil seal.

• Apply a thin coat of engine oil to the outer surface of oil seal.

• Install the oil seal and slinger at the same time using the installer (380300004).

• Once the installer is set, tighten in the center bolt until it touches the bottom.

6. Check for rotation of the crankshaft.

• Check to see if it rotates smoothly without getting stuck (15N ⋅m or less). Check to see the oil jet is not deformed.

Engine Mechanical (6UZ1X) 1B-92

9. Install the crank pulley.

• Assemble the crank pulley to the crank shaft.

• Apply a thin coat of engine oil to the bolt and washer, and tighten in a diagonal order.

Tightening torque: 200N⋅m{20.4kg⋅m/147.5lb⋅ft}

Note: • Installing positions for oil seal are fixed and identified by different coloring.

Slinger Front side ⋅⋅⋅ Zinc chrome plating color (plating color) Rear side ⋅⋅⋅ Grey • Install the oil seal and slinger together without disassembling.

• Wipe the running oil off after press-fitting the oil seal.

• If there were any damages on the crankshaft, apply the liquid gasket (ThreeBond No.TB1207C) within the illustrated area.

10. Install the piston.

Refer to “Piston”.

11. Install the flywheel housing.

Refer to “Flywheel and Timing Gear”.

12. Install the flywheel.

Refer to “Flywheel and Timing Gear”.

13. Install the oil pump.

Refer to “Oil Pump” in the Lubrication System section.

14. Install the oil pan.

Refer to “Oil Pan” in the Lubrication System section.

15. Install the cylinder head.

Refer to “Cylinder Head”.

Engine Mechanical (6UZ1X) 1B-93 16. Install the camshaft.

Refer to “Cylinder Head”.

17. Install the rocker arm.

Refer to “Cylinder Head”.

18. Install the head cover.

Refer to “Cylinder Head”.

19. Install the engine exterior equipments.

Refer to “Engine Exterior Equipment”.

Tightening Torque List

Name (a) (b) (c)

200N⋅m {20.4kg⋅m/147.5lb⋅ft} 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft} 96N⋅m {9.8kg⋅m/70.8lb⋅ft}

(d) (e)

54N⋅m {5.5kg⋅m/39.8lb⋅ft}→90° +30° -0° 49N⋅m {5.0kg⋅m/36.1lb⋅ft}

Engine Mechanical (6UZ1X) 1B-94

Special Tool Illustration

Tool Number Description Special Tool

380300001 Gear puller

380300003 Oil seal remover

380300004 Oil seal installer

Engine Mechanical (6UZ1X) 1B-95

Piston, Connecting Rod Components

Name 1. Piston Ring 2. Snap Ring 3. Piston Pin 4. Piston

Removal 1. Remove the engine exterior equipments.

2.

3.

4.

5.

Refer to “Engine Exterior Equipment”.

Remove the head cover.

Refer to “Cylinder Head”.

Remove the rocker arm.

Refer to “Cylinder Head”.

Remove the camshaft.

Refer to “Cylinder Head”.

Remove the cylinder head.

5. Connecting Rod 6. Connecting Rod Cap 7. Bearing

Refer to “Cylinder Head”.

6. Remove the oil pan.

Refer to “Oil Pan” in the Lubrication System section.

7. Remove the oil pump.

Refer to “Oil Pump” in the Lubrication System section.

Engine Mechanical (6UZ1X) 1B-96 8. Remove carbon from the liner.

• Remove carbon from upper part of the liner using a scraper etc.

• Keep removed cap, bearing and connecting rod as a temporary set not to confuse them.

Note: Be careful not to damage the cylinder liner.

Disassembly 1. Remove the piston ring.

9. Remove the connecting rod cap.

• Loosen the tightening bolt and hammer lightly with a copper hammer etc. to remove the cap.

10. Remove the piston connecting rod.

• Rotate the crankshaft and set the piston to be removed at the to top dead center position.

• Push the lower edge of the connecting rod using a hammer handle etc..

Note: • Do not let the connection rod and liner interfere with each other.

• Be careful with damaging the oil jet.

• Use a ring pliers (380300005) to remove the piston ring (1).

Note: Mark each removed piston ring on the upper surface according to each cylinder for identification.

2. Remove the snap ring.

3. Remove the piston pin.

4. Piston, Connecting Rod. • Remove the snap ring (1) and the piston pin.

Note: Put number plates on the piston and piston pin according to each cylinder.

Engine Mechanical (6UZ1X) 1B-97

Inspection Piston ring • Check for chippings, scratches and peelings carefully.

• Measuring the clearance at the joint section of the piston ring.

Remove carbon from the piston ring. Insert the piston ring into the cylinder liner and push in with the head of the piston to the least worn part of the liner (the lower part of the liner).

Insert the thickness gauge into the joint section of the ring to measure the clearance.

Clearance at the joint section of the piston ring.

• Measuring the clearance between the groove of piston ring and piston ring.

Remove carbon from the groove of piston ring.

Insert the ring into the ring groove and measure the clearance using the thickness gauge.

Clearance between the groove and ring (mm) Assembly standard

Limit of usage

Top ring

—

—

Second ring

0.110—0.140

0.20

Third ring

0.100—0.135

0.20

Oil ring

0.02—0.06

0.15

(mm) Assembly standard Top ring

0.36—0.59

Second ring

0.45—0.73

Third ring

0.35—0.63

Oil ring

0.35—0.68

Limit of usage 1.0 0.8

• Measuring the tension of the piston ring.

Measure it using a tension gauge.

Engine Mechanical (6UZ1X) 1B-98 Piston pin

Tension of the piston ring (N{kg}) Assembly standard Top ring

23—32 {2.35—3.26}

Second ring

10—15 {1.00—1.50}

Third ring

18—25 {1.85—2.50}

Oil ring

36—49 {3.68—4.96}

Note: Measure the oil ring while the coil expander is equipped.

Piston • Piston scratches and cracks check.

Check very carefully on areas not easy to look at such as the ring groove of piston. Carry out an inspection by red check if required.

• Measuring the outer diameter of the piston pin.

Measure the outer diameter of the piston pin, then measure the clearance between the piston pin holes and connecting rod bush.

Measure 6 places shown on the diagram for a piston pin. (mm) Nominal dimension

Assembly standard

Limit of usage

Piston pin outer diameter

φ 52.0

—

φ 51.98

Clearance between piston pins and piston pin holes.

—

0.007 — 0.020

0.05

Clearance between piston pins and connecting rod bush.

—

0.015 — 0.031

0.10

Engine Mechanical (6UZ1X) 1B-99 Connecting rod • Measuring the clearance between the bearing and crank pin.

Clean the bearing and installing surface, and then assemble the bearing. Apply molybdenum disulphide to the thread and seating surface of the bolt, and tighten the connecting rod cap. Measure 4 places on the connecting rod bearing as shown on the illustration.

Tightening torque:

N⋅m{kg⋅m/lb⋅ft}/angle 58 {5.9/42.8} → 60° (right side) → 120°(left side) → 60°(right side)

• Measuring deformation of the connecting rod.

Measure the parallelism of the big and small end holes using a connecting rod aligner.

Note: Use a bearing free of any wear as the measurement would be based on it.

Parallelism (mm)

• Use a micro-meter to measure the outer diameter of the crank pin at 4 places shown on the illustration.

Clearance between the bearing and crank pin.

Parallelism (L=per100)

Assembly standard

Limit of usage

0.03

0.10

(mm) Assembly standard

Limit of usage

0.044—0.104

0.16

Note: • The crankshaft should not be repaired as tufftride treatment has been performed to the surface.

• Refer to “General Information” when using the Plastigauge for measurement.

• Measuring wears on the big-end surface of the connecting rod.

Assemble the connecting rod to the crank pin, and measure the axial clearance using a thickness gauge.

Engine Mechanical (6UZ1X) 1B-100

Assembly

Axial clearance (mm) Assembly standard

Limit of usage

0.17—0.28

0.35

1. Selecting grades for piston.

Piston replacement • Pistons and liners can be supplied as a set.

In that case, the grades of outer diameter of the liner and of inner diameter of the cylinder block need to be matched.

• When replacing new pistons only, measure the inner diameter of the liner and select grade for piston.

Measure the inner diameter of the cylinder liner.

• The measurement value is the average of the measures taken at 2 places from upper surface, in 4 direction at every 45°, total of 8 measuring points.

Measuring points (while the crank case is assembled) (mm) From upper surface

Bearing • Check for wear, damages and peeling on the connecting rod bearing.

• When assembling the bearing, check to see there is a tension.

A

B

120

216

Reference As factory default, “A”, “B”, “C” and “D” are stamped on the upper surface of cylinder blocks keeping the cylinder liner grades.

Measuring piston • Measure the piston pin holes in the right-angle direction at 22mm (a) from the lower surface of the piston as shown on the illustration.

Reference As factory default, “A”, “B”, “C” and “D” are stamped on the head of pistons keeping the piston grades.

Engine Mechanical (6UZ1X) 1B-101 (mm) Grade

Liner inner diameter (after the cylinder block is press-fitted)

Piston outer diameter

D

120.029—120.040

119.900—119.910

C

120.019—120.032

119.890—119.899

B

120.009—120.022

119.880—119.889

A

120.000—120.012

119.870—119.879

The clearance between the piston and liner (mm) Assembly standard

0.119—0.142

Note: Assembling parts with wrong grades can cause a seizure. Make sure to match grades.

2. Assemble the piston pin.

3. Install the snap ring.

• Place the arrow (1) on the head of piston and the mark (2) on the connection rod towards front side and assemble. Apply oil onto the piston pin and push it in. Fix it with a snap ring. Lastly, check to see the piston and connecting rod move smoothly.

Note: Make sure that the snap ring is properly fitted into the piston groove.

4. Install the piston ring.

• Installing the expander ring.

Set the joint section (1) of expander ring without any gap and fit it in the piston groove.

• The oil ring has no top or bottom but assemble it so that the joint section of the oil ring and the expander ring are angled 180°.

• The third ring is stamped as “3RN” for identification. Assemble it with the stamp on the upper surface of the joint section facing up.

• The second ring has no stamp. Assemble it with the inner cut part facing up.

• The top ring is stamped as “R” for identification.

Assemble it with the stamp on the upper surface of the joint section facing up.

• Shift the joint sections of each ring 90° when assembling piston rings.

• Use piston ring pliers (380300005) to assemble.

(Do not open the joint section unnecessarily.)

Engine Mechanical (6UZ1X) 1B-102 Note: • New rings have identifying paint on the right side of their joint sections.

• Expansion allowance of joint section for each piston ring assemble should be kept within 8 times the size of joint section measurement when it is free. Do not re-use it if it is expanded more than 8 times the size. Breakage or cracks may occur.

Installation 1. Assemble the connecting rod bearing.

• Clean the cap and bearing installation surface of the connecting rod well and assemble the bearing. Apply oil onto the sliding surface (1).

• Apply oil onto the piston pin.

Note: Keep the back of bearing dry when assembling.

• Apply engine oil all around the cylinder liner.

2. Set the position of crankshaft.

• Rotate the crankshaft and set the crank pin to the top dead center of the cylinder to which the piston is assembled.

Engine Mechanical (6UZ1X) 1B-103

3. Match the joint section of piston ring.

• Apply engine oil onto the piston and all around the ring.

• Place the joint direction of the piston ring every 90° avoiding the side-pressure direction.

• Push the piston in until it touches crank pin with hammer handle using the piston installer (380300006). Rotate the crankshaft while pushing the piston head in. Set it to the bottom dead center.

Note: • Use the installer firmly attached to the cylinder block.

If they are not attached firmly when inserting, it may cause a damage on piston ring.

• Be careful not to damage crank pin or oil jet when installing the piston connecting rod.

4. Insert the piston and connecting rod.

• Check the cylinder number of the connection rod and insert it with the arrow mark on the head of piston pointing to the front. Insert the piston in the opposite direction 5°—10° of oil jet.

Pull it back to the right position not interfering with the oil jet.

5. Install the connecting rod cap.

• Apply oil to the bearing on the connecting rod cap.

Engine Mechanical (6UZ1X) 1B-104 • Match the marks on the connecting rod and cap. Apply molybdenum disulphide to the thread and seating side of the bolt, and tighten them. Make sure the stamp is on the exhaust side at this point.

Tightening torque: N⋅m{kg⋅m/lb⋅ft}/angle 58 {5.9/42.8}→60°(right side)120°(left side) 60°(right side) (tighten alternately) final tightening angle 120° +30° -0°

• Rotate the crankshaft and check to see it rotates smoothly without getting stuck. Check it is not interfering with oil jet.

6. Install the oil pump.

Refer to “Oil Pump” in the Lubrication System section.

7. Install the oil pan.

Refer to “Oil Pan” in the Lubrication System section.

8. Install the cylinder head.

Refer to “Cylinder Head”.

9. Install the camshaft.

Refer to “Cylinder Head”.

10. Install the rocker arm.

Refer to “Cylinder Head”.

11. Install the head cover.

Refer to “Cylinder Head”.

12. Install the engine exterior equipments.

Refer to “Engine Exterior Equipment”.

Engine Mechanical (6UZ1X) 1B-105

Tightening Torque List

Name (a)

58N⋅m{5.9kg⋅m/42.8lb⋅ft}→60°(right side) 120°(left side) 60°(right side) (tighten alternately)

Engine Mechanical (6UZ1X) 1B-106

Special Tool Illustration

Tool Number Description Special Tool

380300005 Piston ring pliers

380300006 Piston installer

Engine Mechanical (6UZ1X) 1B-107

Cylinder Block Components

Name 1. Cylinder Liner 2. Cylinder Block 3. Oil Jet

Removal 1. Remove the engine accessories.

2.

3.

4.

5.

Refer to “Engine Accessories”.

Remove the engine exterior equipments.

Refer to “Engine Exterior Equipment”.

Remove the head cover.

Refer to “Cylinder Head”.

Remove the rocker arm.

Refer to “Cylinder Head”.

Remove the camshaft.

Refer to “Cylinder Head”.

4. Joint Bolt 5. Crankcase

6. Remove the cylinder head.

Refer to “Cylinder Head”.

7. Remove the oil pan.

Refer to “Oil Pan” in the Lubrication System section.

8. Remove the oil pump.

Refer to “Oil Pump” in the Lubrication System section.

Engine Mechanical (6UZ1X) 1B-108 9. Remove the flywheel.

Refer to “Flywheel and Timing Gear”.

10. Remove the flywheel housing.

Refer to “Flywheel and Timing Gear”.

11. Remove the timing gear.

Refer to “Flywheel and Timing Gear”.

12. Remove the crank pulley.

Refer to “Front Cover and Crankshaft”.

13. Remove the water pump.

Refer to “Water pump” in Cooling System section.

14. Remove the front cover.

Refer to “Front Cover and Crankshaft”.

15. Remove the piston.

Refer to “Piston”.

16. Remove the crankshaft.

Refer to “Front Cover and Crankshaft”.

3. Remove the cylinder liner.

• Hook the anchor of the cylinder liner remover (380300007) onto the bottom edge of the liner properly. Put the turret from above into the center bolt without interfering the liner flange.

Assemble the bearing and tighten with a nut.

Set a handle to the nut and turn it to take out the liner.

Note: If the anchor touches the cylinder block, the cylinder bore will get damaged. So check carefully when taking out the liner.

Disassembly 1. Remove the oil jet.

2. Measure the wear on the cylinder liner.

• Measure the inner diameter of cylinder liner.

Measure the maximum wear part (in the rotating direction) at 15 – 19mm from the upper surface of the liner (a).

Cylinder liner inner diameter (mm) Nominal dimension

Limit of usage

120.0

120.3 WSUZ0080

Inspection Crankcase • Check the crank case for cracks and damages.

Carry out an inspection by red check if required.

Engine Mechanical (6UZ1X) 1B-109 Oil Jet • Check for bent on oil jet and oil holes.

• Check for cracks or damages on the cylinder block.

Carry out an inspection by red check if required.

Cylinder block • Measure warp on the cylinder block.

Place a straight edge on the upper surface of the cylinder block. Measure with the thickness gauge (1).

Warping of cylinder block top surface (mm) Limit of usage

0.20

• Checking corrosion and clogging of oil coolant and in the oil passage.

Check for any clogging carefully on coolant passage between each cylinder.

Engine Mechanical (6UZ1X) 1B-110 • Check on cracks on the water jacket.

Apply water pressure of 490kPa{5kg/cm2}with a hydraulic test machine for 3 minutes, and check for any leakage from each cylinder block part.

Tightening allowance for the cylinder liner and cylinder block. (mm) Assembly standard

Assembly

Grade selection of cylinder liner and cylinder block

1. Grade selection of cylinder liner • Grade selection of cylinder liner • Measure the inner diameter of cylinder block and select a grade for liner.

• Measure the inner diameter of cylinder block.

Crank case is assembled.

The measurement value is the average of the measures take at 120 mm and 216 mm from the upper surface of the cylinder block. The measure should be taken every 45° of 8 directions.

• Measure the outer diameter of the cylinder liner.

The measurement value is the average of the measure taken at 3 points on the upper surface of the cylinder liner. At each 3 points, measure the maximum and minimum values (6 measurements) and get the average.

Measuring position (mm) From upper surface

0.011—0.029

A

B

C

18

114

210

Note: If the assembly was carried out without grade selection, it can cause insufficient cooling (tightening allowance shortage) or a seizure (excessive tightening allowance for the liner).

(mm) Grade

Cylinder block inner diameter

Cylinder liner outer diameter

III

123.021—123.030

123.041—123.050

II

123.011—123.020

123.031—123.040

I

123.001—123.010

123.021—123.030

[Reference] The grade stamping places on the cylinder blocks in the factory default condition.

• (1) part before the liner is pressed in: the cylinder block inner diameter grades are stamped as (I, II and III) • (2) part after the cylinder liner is pressed in: the liner inner diameter grades are stamped as (A, B, C and D).

Engine Mechanical (6UZ1X) 1B-111 Note: Place a square on the outer circumference of the liner and press-fit straight against the cylinder block bore.

2. Cleaning the cylinder bore and liner.

• Clean the cylinder bore and liner properly and air-blow them afterwards.

Note: Do not reuse liners once dropped.

• Measuring the cylinder liner extrusion.

Measure the extrusion of the liner using a dial gauge. (mm) Assembly Standard

3. Press-fitting the cylinder liner.

• Make sure there is no dust or oil stuck on the inside of cylinder block and outside of liner.

• Use a cylinder liner installer (380300008) and apply 500kg of pressure with a press to press-fit without deforming the liner. Lastly, fix it completely to the cylinder block by applying 2500kg of pressure.

• Measure the inner diameter of the liner after press-fitting.

Refer to “Piston-Connecting Rod” section for measuring method.

Amount of liner extrusion.

0.06—0.10

Difference from the neighboring cylinders

0.015 or less

4. Install the oil jet.

• Install in accordance with knock pins.

Tightening torque: 21N⋅m{2.1kg⋅m/15.5lb⋅ft}

Engine Mechanical (6UZ1X) 1B-112 Note: Do not deform the edge of oil jet.

Installation 1. Install the crankshaft.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Refer to “Front Cover and Crankshaft”.

Install the piston.

Refer to “Piston”.

Install the front cover.

Refer to “Front Cover and Crankshaft”.

Install the water pump.

Refer to “Water pump” in Cooling System section.

Install the crank pulley.

Refer to “Front Cover and Crankshaft”.

Install the timing gear.

Refer to “Flywheel and Timing Gear”.

Install the flywheel housing.

Refer to “Flywheel and Timing Gear”.

Install the flywheel.

Refer to “Flywheel and Timing Gear”.

Install the oil pump.

Refer to “Oil Pump” in the Lubrication System section.

Install the oil pan.

Refer to “Oil Pan” in the Lubrication System section.

Install the cylinder head.

Refer to “Cylinder Head”.

Install the camshaft.

Refer to “Cylinder Head”.

Install the rocker arm.

Refer to “Cylinder Head”.

Install the head cover.

Refer to “Cylinder Head”.

Install the engine exterior equipments.

Refer to “Engine Exterior Equipment”.

16. Install the engine accessories.

Refer to “Engine Accessories”.

Engine Mechanical (6UZ1X) 1B-113

Tightening Torque List

Name (a) (b)

54N⋅m {5.5kg⋅m/39.8lb⋅ft}→90° +30° -0° 49N⋅m {5.0kg⋅m/36.1lb⋅ft}

(c)

21N⋅m {2.1kg⋅m/15.5lb⋅ft}

Engine Mechanical (6UZ1X) 1B-114

Special Tool Illustration

Tool Number Description Special Tool

380300007 Cylinder liner remover

380300008 Cylinder liner installer

Cooling System (6UZ1X) 1C-1

Engine Cooling System (6UZ1X) Contents Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . .1C-2 Description of Function and Operation . . . . . . .1C-2 Function Check: . . . . . . . . . . . . . . . . . . . . . . . . .1C-4 List of Trouble Symptoms . . . . . . . . . . . . . . . . .1C-6 Symptom: Engine Over-heats. . . . . . . . . . . . . . .1C-7 Symptom: Engine Over-cools. . . . . . . . . . . . . . .1C-8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-8 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-14 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-15 Thermostat, Thermo-Sensor . . . . . . . . . . . . . . . .1C-16 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-18 Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-20 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-20

Cooling System (6UZ1X) 1C-2

Cooling System Service Precautions

Description of Function and Operation

Caution: Do not loosen or remove the sub tank cap when coolant is high temperature. Steam or boiling water spouts and it may cause a burn. When opening the sub tank cap, cover the cap with thick clothes under the condition that coolant is cold, rotate it slowly to release pressure, and then remove it.

The cooling system is a forced circulation type system, and is constructed of the following main parts: Water pump, thermostat, and radiator. It cools inside of the engine, oil cooler, EGR gas, and so on.

Coolant circulation system diagram

WSUZ0082

Name 1. Sub Tank 2. Air Bleeding Pipe 3. EGR Cooler 4. Oil Cooler

5. Thermostat 6. Water Pump 7. Radiator

Cooling System (6UZ1X) 1C-3 Water pump structure diagram

3 2

4

1

5

8 7

6

WSUZ0131

Name 1. Pulley Center 2. Bearing 3. Seal Unit 4. Impeller

5.

6.

7.

8.

Shaft Oil Seal (Small) Snap Ring Oil Seal (Large)

Cooling System (6UZ1X) 1C-4

Function Check:

• Freezing temperature changes depending on the concentration of long life coolant super.

Adjust the concentration according to minimum air temperature.

• Do not use anything except Isuzu genuine LLC. • LLC concentration calculation method: LLC concentration (%) = {LLC capacity (L)÷(LLC capacity (L) + water capacity (L)) ×100} 2. Measurement of LLC concentration • Use an antifreeze hydrometer and a thermometer to measure the specific gravity and the coolant temperature.

Caution: Take care with boiling coolant spouting out when removing the cap at high temperature.

• After measurement of the temperature and the specific gravity, find concentration in the table below.

• Use a container whose depth is longer than a hydrometer.

• The coolant temperature should be between 0 and 50°C at measurement.

Example of Freezing Temperatu re

Mixture Ratio (l) Long Life Coolant

Tap Water

Concentrati on of Long Life Coolant

-18°C

10.12

18.78

35%

-25°C

12.14

16.76

42%

-35°C

14.45

14.45

50%

-40°C

15.32

13.58

53%

ANTIFREEZE CONCENTRATION (%) FREEZING TEMPERATURE (°C)

Coolant check 1. LLC concentration

SPECIFIC GRAVITY

WSUZ0149

WSUZ0038

TEMPERATURE (°C) WSUZ0148

Cooling System (6UZ1X) 1C-5 Radiator check Sub tank cap • Use a cap tester to check the opening valve pressure. If the opening valve pressure exceeds the specified value, replace the sub tank cap.

Cap operation pressure

Check location • Radiator ASM, water pump ASM, radiator hose, heater hose, water pipe & water hose, sub tank ASM and vacuum hose.

positive pressure = 61.8 — 71.6 kPa {0.63 — 0.73kg/cm2} negative pressure = 4.9 kPa {0.05kg/ cm2}

WSUZ0039

Replacement procedure of coolant 1. Make sure that the engine is cool.

• Check the condition of the negative pressure valve in the center of the cap valve seat side. If the valve seat does not operate smoothly due to rust, dust, etc., clean or replace the cap.

Radiator core • Repair the radiator fin if it is deformed. Deformed fin lowers the heat radiation effect, which could cause overheat.

Take care not to damage the base of the fin during repair.

• Remove foreign matter such as dust.

Washing of radiator • Wash the inside of the radiator and the coolant passage with water and neutral detergent. Remove hot water stains and rust completely.

Coolant leak check • Use a cap tester to apply a pressure of 88 kPa {0.9kg/cm2} to check leakage of the following locations. Also, check the radiator hose and the heater hose for damage or deterioration and the hose clamps for looseness.

Caution: Do not loosen or remove the sub tank cap when coolant is high temperature. Steam or boiling water spouts and it may cause a burn. When opening the cap, cover the cap with thick clothes under the condition that coolant is cold, rotate it slowly to release pressure, and then remove it.

2. Press the button on the sub tank cap, release pressure from inside and then remove the cap.

3. Open the coolant drain cock in the engine and radiator, and drain coolant.

4. Loosen the drain cock.

5. Pour “radiator cleaner” into the sub tank and fill with tap water up to the “MAX” line.

6. Check and clean the sub tank cap. Replace the cap if it is faulty.

7. Install the sub tank cap securely.

8. Start the engine, idle it for 20 minutes, then stop the engine. After the coolant cools down sufficiently, drain it.

9. Repeat the same procedure, but fill with tap water only at this time. Idle the engine for cleaning, and then drain it.

10. Add coolant.

11. Idle the engine until the coolant reaches the proper temperature, then idle it for another 10 minutes. At this time, set the temperature adjustment to the maximum position to circulate coolant in water channels of the heater.

12. Stop the engine, and check the coolant after the engine cools down sufficiently. Add coolant up to the “MAX” in case it is insufficient.

Cooling System (6UZ1X) 1C-6

List of Trouble Symptoms • Engine over-heats.

• Engine over-cools.

Cooling System (6UZ1X) 1C-7

Symptom: Engine Over-heats.

Condition Engine overheats.

Possible Cause

Correction

Low coolant level

Add.

Defective thermostat

Replace.

Defective water pump

Replace.

Clogging of radiator

Clean or replace.

Defective sub tank cap

Replace.

Engine oil shortage or use of improper oil

Add or change engine oil.

Defective cylinder head gasket

Replace.

Loose fan belt

Adjust.

Clogging of exhaust system

Clean or replace.

Clogging of exhaust system

Clean or replace.

Too much fuel injection quantity.

Diagnose the engine control system.

Fuel injection timing is incorrect.

Diagnose the engine control system.

Cooling System (6UZ1X) 1C-8

Symptom: Engine Over-cools.

Condition

Possible Cause

Engine over-cools.

Defective thermostat

Correction Replace.

Specifications Item

Specification

Cooling method

Forced circulation cooling pre-compression type

Radiator type

Corrugate type

Sub tank cap operation pressure Positive kPa {kgf/cm2} pressure valve Negative pressure valve Water pump

Type

4.9 {0.05} V-belt drive hoist type

Discharge amount (L/min) Thermostat valve open start temperature

(°C)

Thermostat full-open temperature

(°C)

Coolant amount (engine unit)

62 — 72 {0.63 — 0.73}

(L)

370 (pump speed 2000rpm, normal temperature of coolant 80°C) 80 — 84 95 22.5

Cooling System (6UZ1X) 1C-9

Water Pump Components 8 7

5 4

6

3 2

1

9

10

11 12

13

Name 1. Pulley 2. Pulley Center 3. Oil Seal (Large) 4. Snap Ring 5. Bearing 6. Spacer 7. Oil Seal (Small)

Removal 1. Remove the EGR water pipe and air leak pipe.

2. Remove the thermostat housing.

3. Remove the ACG belt.

4. Remove the crank pulley.

Note: Take care not to drop because it is heavy.

8.

9.

10.

11.

12.

13.

WSUZ0132

Shaft O-ring Gasket Impeller Seal Unit Water Pump Body

Cooling System (6UZ1X) 1C-10 5. Remove the water pump pulley.

6. Remove the water pump.

WSUZ0135

WSUZ0133

Disassembly 1. Remove the impeller.

• Fix the pulley center to a vise and remove with remover (380300000).

4. Remove the oil seal (large).

5. Remove the snap ring.

6. Remove the shaft.

• Tap it lightly from the impeller side with hammer and remove.

Note: Do not tap the impeller to remove because it leads to damage.

WSUZ0136

WSUZ0134

2. Remove the seal unit.

3. Remove the pulley center.

• Use a puller to remove the pulley center.

7. Remove the two bearings.

8. Remove the spacer.

9. Remove the bearing.

• Use a press to remove the bearing.

Cooling System (6UZ1X) 1C-11 Check the pulley center.

• Check the oil seal contact surface of pulley center for wear or damage.

WSUZ0137

10. Remove the oil seal (small).

WSUZ0138

Inspection Check the impeller.

• Check the impeller for corrosion or damage.

Check the shaft.

• Check the oil seal contact surface of shaft for wear or damage.

• Measure the interference of the impeller and shaft.

Interference of impeller and shaft (mm) Assembly standard

0.023 — 0.051

• Measure the interference of the pulley center and shaft.

Cooling System (6UZ1X) 1C-12

Assembly

Interference of the pulley center and shaft (mm) Assembly standard

0.048 — 0.082

Check the bearing.

Check bearing for peeling, wear or noise.

• Check to see from the ball clearance to the lace for damage or debonding (full circumference).

• Check the ball and lace sections for abnormal rattling, and find wear by rattling.

• Check if you can feel anything unusual in your hand when rotating the bearing, and find abnormal noise by it.

1. Install the oil seal (small).

• Apply oil to the inner side and outer circumference part of the oil seal lip. Face the lip section upwards and push it into the water pump body.

2. Install the bearing.

3. Install the spacer.

4. Install the two bearings.

• Apply engine oil to inner side (shaft surface) of inner lace of bearing, assemble bearing (1), spacer (2) and two bearings (3) to shaft (4) in this order and push it using a press.

4

3

2 1

WSUZ0139

5. Install the shaft.

• Push the bearing of shaft into the water pump body using a press.

Note: • While pushing the shaft into the water pump body, do not damage the oil seal.

Cooling System (6UZ1X) 1C-13

WSUZ0140

6. Install the snap ring.

7. Install the oil seal (large).

• Apply oil to the inside and outer circle of lip of oil seal lip. Face the lip section upwards and push it taking care not to bend it out of shape.

WSUZ0141

9. Install the seal unit.

• Install the seal unit to the water pump body.

• Use the press to press the seal unit until its collar section contacts with the water pump body.

Seal unit pressing size (a) Assembly standard

mm 11.0 — 11.6

• Seal unit has seizure by liquid gasket on the contact surface of the water pump body and shaft.

• When making a seal unit pressing jig (380002616), refer to the illustration.

8. Install the pulley center.

• Push the pulley center with a press taking care not to damage the oil seal.

Note: • To prevent damage to the bearing, press it in while it contacts with the impeller side (bottom side) shaft edge.

• Do not put a press side jig to the shaft. Always put it to the pulley boss section and press in.

Cooling System (6UZ1X) 1C-14

WSUZ0146

Name (b) (c) (d) (e) (f)

11. Check after assembly.

• Rotate the pump and check if it is rotating smoothly.

• On compression test with water pressure (0.1 MPa), no water should leak from seal unit section.

φ 17mm 40 mm 11.3 mm φ 33 mm φ 44 mm

10. Install the impeller.

• Use the press to press in so that the end of the shaft aligns with the end surface of impeller.

Note: To prevent damage to the bearing, press it in while it contacts with the pulley side shaft edge.

Clearance between body and impeller

mm

0.3

Installation 1. Install the water pump ASM. • Install the O-ring to the water pump.

• To avoid missposition of the gasket, use the two stud bolts as a guide stick.

Tightening torque:

38N⋅m {3.9kg⋅m/28lb⋅ft}

Note: Clean the installing surface of gasket and install it while avoiding misalignment of liquid gasket.

WSUZ0133 WSUZ0145

2. Install the water pump pulley.

Tightening torque:

58.1N⋅m {5.9kg⋅m/42.9lb⋅ft}

Cooling System (6UZ1X) 1C-15 3. Install the crank pulley.

Refer to “Front cover, crank shaft”.

4. Install the ACG belt.

Refer to “Engine accessories”.

5. Install the thermostat housing.

Refer to “Thermostat”.

6. Install the EGR water pipe and air leak pipe.

Refer to “Engine exterior equipment”.

Special Tool Illustration

Tool Number Description Special Tool

380300000 Water pump impeller remover

380002616 Seal unit setting tool

Cooling System (6UZ1X) 1C-16

Thermostat, Thermo-Sensor Removal

Name 1. Thermostat Housing 2. Gasket 3. Seal Ring Removal procedure 1. Remove the EGR cooler on exhaust side.

Refer to “Engine exterior equipment”.

2. Remove the water duct.

Remove the water duct (2) and BRKT (1) (4).

4. Thermostat 5. Spacer

Cooling System (6UZ1X) 1C-17

5

3

4

2 1

WSUZ0089

3. Remove the thermo-sensor.

WSUZ0092

Inspection Thermostat • Shake a pellet section of thermostat to check for rattling or caulking part for damage.

WSUZ0127

4. Remove all the water pipes connected to thermostat housing.

5. Remove the thermostat housing.

6. Remove the spacer.

7. Remove the thermostat.

8. Remove the seal ring on thermostat.

• Use a seal ring remover (380300002) to remove the seal ring.

• Operation check of thermostat.

Put the thermostat in water and gradually increase the water temperature. Measure the temperature at which the valve starts to open, fully opens and amount of lift.

Open start temperature

80 — 84°C

Temperature when fully open, amount of lift

95°C, 11mm

As wax type thermostats have a large heat capacity, the action of the valve has a certain amount of time lag compared to the fluctuation in water temperature.

Cooling System (6UZ1X) 1C-18 Note: Do not directly heat the thermostat. Either perform the measurements by covering the bottom of the container with a plate, or hanging. When performing measurements, constantly stir the water to avoid uneven temperature.

Note: • It is available to apply a light coat of ThreeBond TB1521 to the gasket.

• Assemble the thermostat housing after assembly of water pump and cylinder head.

5 4 3 1

2

WSUZ0128

5. Install the thermostat sensor.

Installation 1. Install the seal ring of thermostat.

Tightening torque:

• Turn the lip of seal ring (3) to this side, and use an installer (380002634) to install.

19.6N⋅m {2kg⋅m/14.5lb⋅ft}

Note: Apply Loctite 271 to the threads.

WSUZ0093

2. Insert the thermostat.

• Install the thermostat (4), taking care not to damage the seal ring.

3. Insert the spacer (5).

4. Install the thermostat housing.

• Set the gasket (2) and install the housing (1) while putting it into the water pump Tightening torque:

43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}

WSUZ0127

6. Install the water duct.

• Tighten together with the water duct (2) and BRKT (1).

• Install the BRKT (4).

Tightening torque: Water duct: BRKT (4) :

21.6N⋅m {2.2kg⋅m/15.9lb⋅ft} 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}

Cooling System (6UZ1X) 1C-19

5

3

4

2 1

WSUZ0089

7. Install the water pipe.

• Connect each water pipe.

Refer to “Engine exterior equipment”.

8. Install the EGR cooler.

• Install the EGR cooler following the procedure.

Refer to “Engine exterior equipment”.

Cooling System (6UZ1X) 1C-20

Torque Specifications

Name (a) (b)

43.8N⋅m {4.5kg⋅m/32.3lb⋅ft} 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}

(c) (d)

19.6N⋅m {2kg⋅m/14.5lb⋅ft} 21.6N⋅m {2.2kg⋅m/15.9lb⋅ft}

Special Tool Illustration

Tool Number Description Special Tool

380300002 Seal ring remover

Illustration

Tool Number Description Special Tool

380002634 Seal ring installer

Fuel System (6UZ1X) 1D-1

Engine Fuel System (6UZ1X) Contents Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . .1D-2 Description of Function and Operation . . . . . . .1D-2 Function Check: . . . . . . . . . . . . . . . . . . . . . . . . .1D-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-6 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-8 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-8 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-9 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-10

Fuel System (6UZ1X) 1D-2

Fuel System Service Precautions

Work procedure

Holes and clearances in the fuel system which serve as a passage of fuel, including the inside of injector, are finished extremely precisely. For this reason, they are highly sensitive to foreign matter. If it gets inside, it can lead to breakdown on the road. Be sure to prevent it from getting inside.

Do not use water removal agent. It helps light oil to absorb moisture that may cause rust.

• The fuel opening must be quickly sealed when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and common rail.

• The eyebolts and gasket must be stored in a clean parts box with a lid to prevent adhesion of foreign matter.

• After finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine as fuel leakage could cause fires.

Description of Function and Operation Fuel system diagram

1

2

6

3

5

4

WSUZ0096

Name 1. Injector 2. Fuel Filter 3. Fuel Tank

4. Pre-fuel Filter 5. Supply Pump 6. Common Rail

Fuel System (6UZ1X) 1D-3 Common rail

Name 1. Pressure Limiter 2. Pressure Sensor

3. Flow Damper

Fuel System (6UZ1X) 1D-4 Supply pump

1

2

3

4

WSUZ0083

Name 1. Pump Control Valve (PCV) 2. Overflow Valve

3. Air Bleed 4. Camshaft Position Sensor

Fuel System (6UZ1X) 1D-5 Injector

Name 1. Injector ASM 2. Gasket Note: Do not disassemble supply pump, common rail flow damper, fuel pressure sensor, pressure limiter and injector.

3. O-ring

Fuel System (6UZ1X) 1D-6

Function Check: Fuel filter water drainage 1. Loosen the air bleeder plug (2) on the fuel filter.

2. Loosen the drain plug (3) on the fuel filter and drain the water.

3. Loosen the drain plug (3).

4. Let the air bleed from the fuel.

2

1

Note: Bleed the air from the fuel filter one by one.

5. Let the air bleed from the another fuel filter in the same way.

6. Loosen the air bleeder plug (4) on the supply pump and operate the priming pump (1) on the fuel filter until no air babbles appear.

7. Loosen the air bleeder plug (4) on the supply pump.

Important: Adequate care should be taken as over-tightening the air bleeder plug could lead to damage.

8. After tightening all the air bleeder plugs, operate the priming pump (1) until you feel enough resistance to move.

9. Tighten the priming pump to the original position and start the engine. If the engine does not start, resume from step 8 again.

3

4

4. After waiting for approximately one minute, loosen the air bleeder plug (2) and bleed out the air in the fuel filter. (Repeat the steps 2 — 4 a minimum of three times until no more air comes out.)

WSUZ0130

2

Bleed air from fuel system 1. Loosen the air bleeder plug (2) on the fuel filter that is close to the fuel tank.

2. Operate the priming pump (1) on the fuel filter to bleed air from the fuel filter and fix the priming pump (1).

3. Tighten the air bleeder plug (2) of the fuel filter and operate the priming pump (1) more than 10 times until it is filled with fuel.

1

3

Important: Adequate care should be taken as over-tightening the air bleeder plug could lead to damage.

4

Specifications Fuel injection pump specifications Engine model

6UZ1X

Items Fuel injection pump type Supply pump model

Electronic control fuel injection system (Common rail type) SP180-6HD

WSUZ0130

Fuel System (6UZ1X) 1D-7 Injector specifications Items Injector model

Specifications DLL-P

Fuel System (6UZ1X) 1D-8

Fuel Filter Components

Name 1. Head ASM 2. Air Bleeder Plug 3. Priming Pump 4. Element 5. Level Ring

6.

7.

8.

9.

O-ring Case O-ring Drain Plug

Fuel System (6UZ1X) 1D-9

Disassembly 1. Loosen the air bleeder plug.

2. Loosen the drain plug.

• Loosen the drain plug, and then drain the fuel inside of the filter beforehand.

3. Remove the case using the fuel main filter wrench.

Fuel main filter wrench:

380002630

4. Remove the O-ring for case.

5. Remove the level ring.

Inspection Overflow valve • This over flow valve is not supplied with the fuel filter.

• Check overflow valve for clogging and ball seat for leakage.

Name 1. Level Ring 2. O-ring 3. Case

Overflow valve opening pressure: 275 — 314 kPa {2.8 — 3.2kg/cm2}

6. Remove the element.

WSUZ0045

7. Clean the fuel passage of head ASM. • The priming pump is a non-disassembled part.

Fuel System (6UZ1X) 1D-10

Assembly

Name 1. Head ASM 2. Element 3. O-ring 4. Case 1. Install the element to the head ASM. • Insert the element seal rubber to the head ASM.

5. Drain Plug 6. O-ring 7. Level Ring

Fuel System (6UZ1X) 1D-11

2. Install the O-ring to the case.

• Use a new O-ring.

3. Put the level ring in the case.

4. Tighten the case using the fuel main filter wrench.

Fuel main filter wrench: Tightening torque:

380002630

29.4 N⋅m {3.0kgf⋅m/21.7lb⋅ft}

Name 1. Level Ring 2. O-ring 3. Case 5. Install the O-ring to the drain plug.

• Use a new O-ring.

6. Tighten the drain plug to the specified torque.

Tightening torque:

2N⋅m {0.2kgf⋅m/1.5lb⋅ft}

7. Tighten the air bleeder plug to the specified torque.

Tightening torque:

9.8N⋅m {1.0kgf⋅m/7.2lb⋅ft}

Fuel System (6UZ1X) 1D-12 Special Tool Illustration

Tool Number Description Special Tool

380002630 Fuel main filter wrench

Electrical System (6UZ1X) 1E-1

Engine Electrical System (6UZ1X) Contents Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1E-2 List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1E-3 Symptom: Starter does not operate when starter switch is turned on. . . . . . . . . . . . . . . . . . . . . . . 1E-4 Symptom: Pinion moves forward but it does not engage with ring gear. . . . . . . . . . . . . . . . . . . . . 1E-5 Symptom: Pinion engages and rotates motor but it does not run engine. . . . . . . . . . . . . . . . . . . . . . 1E-6 Symptom: Pinion engages but it does not run engine. . . . . <$attribute1E-7 Symptom: When turning starter switch off, starter does not stop after engine starts.. . . . . . . . . . . . 1E-8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-8 Sectional View (reference) . . . . . . . . . . . . . . . . . 1E-9 Output Characteristic (reference). . . . . . . . . . . 1E-10 Disassembly and Inspection of Starter . . . . . . . . 1E-11 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11 Inspection and Maintenance . . . . . . . . . . . . . . 1E-12 Assembly of Starter . . . . . . . . . . . . . . . . . . . . . . . 1E-16 No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19 Charging System. . . . . . . . . . . . . . . . . . . . . . . . . 1E-21 Service Precautions . . . . . . . . . . . . . . . . . . . . . 1E-21 List of Trouble Symptoms . . . . . . . . . . . . . . . . 1E-22 Symptom: Charging is impossible.. . . . . . . . . . 1E-23 Symptom: Charging is not sufficient. . . . . . . . . 1E-24 Symptom: Overcharging occurs. . . . . . . . . . . . 1E-25 Symptom: Charging current is unstable. . . . . . 1E-26 Symptom: Abnormal sound occurs from generator. . . . . . . <$attribute1E-27 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-27 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . 1E-28 Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-29 Disassembly and Inspection of Generator . . . . . 1E-31 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-32 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-37 Bench Testing . . . . . . . . . . . . . . . . . . . . . . . . . 1E-38 Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . 1E-39 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-39

Electrical System (6UZ1X) 1E-2

Starting System Service Precautions Handling of starter 1. Precautions on handling • Improper gap between pinion and ring gear causes faulty mesh. (Gap 2 — 5 mm) • Also, the front bracket is installed on the engine side securely.

• Be sure to turn off the battery switch before removal/installation of stater.

• Tightening/inserting wiring must be performed properly. Looseness causes starting trouble due to high contact resistance.

2. Precautions on starting • Be careful with charging status of battery.

Insufficiently-charged battery causes starting trouble.

• After checking engine starting, turn off the starter switch immediately.

• One continuous use should be less than 10 seconds. If re-starting is needed, wait until the pinion stops completely.

• If the starter does not stop rotating when the starter switch is turned off, turn off the battery switch immediately. In this case, check the wiring, switch, etc.

Electrical System (6UZ1X) 1E-3

List of Trouble Symptoms • Starter does not operate when starter switch is turned on.

• Pinion moves forward but it does not engage with ring gear.

• Pinion engages and rotates motor but it does not run engine.

• Pinion engages but it does not run engine.

• When turning starter switch off after engine starts, starter does not stop.

Electrical System (6UZ1X) 1E-4

Symptom: Starter does not operate when starter switch is turned on.

Condition Starter does not operate when starter switch is turned on.

Possible Cause

Correction

Full discharge of battery

Replace the battery.

Open circuit, poor contact

Repair.

Poor contact in starter switch or improper tightening of terminal

Repair or replace it.

Poor contact in starter relay or plug terminal

Repair or replace it.

Short or open circuit in magnetic switch coil

Replace.

Electrical System (6UZ1X) 1E-5

Symptom: Pinion moves forward but it does not engage with ring gear.

Condition Pinion moves forward but it does not engage with ring gear.

Possible Cause

Correction

Insufficient capacity of battery

Charge the battery.

Wear of pinion or ring gear tooth edge

Replace the pinion or the ring gear.

Dust on pinion shaft

Repair.

Electrical System (6UZ1X) 1E-6

Symptom: Pinion engages and rotates motor but it does not run engine.

Condition Pinion engages and rotates motor but it does not run engine.

Possible Cause

Correction

Slippage of clutch

Replace the clutch or the starter.

Breakage of reduction gear

Replace the gear or the starter.

Electrical System (6UZ1X) 1E-7

Symptom: Pinion engages but it does not run engine.

Condition Pinion engages but it does not run engine.

Possible Cause

Correction

Insufficient capacity of battery

Charge the battery.

Improper tightening of wiring circuit terminal

Repair.

Short circuit of armature or field coil

Replace the starter.

Contamination of commutator

Repair, or replace the starter.

Fatigue or wear of brush spring

Replace the brush spring or the brush.

Locking of bearing

Replace the bearing or the starter.

Poor contact in magnetic switch

Replace the magnetic switch.

Electrical System (6UZ1X) 1E-8

Symptom: When turning starter switch off, starter does not stop after engine starts.

Condition When turning starter switch off after engine starts, starter does not stop.

Possible Cause

Correction

Retuning failure of starter switch contact

Replace the starter switch.

Retuning failure of starter relay contact

Replace the starter relay.

Short circuit in magnetic switch coil

Replace the magnetic switch.

Specifications Manufacturer

Mitsubishi Electric Co.

Isuzu Part No.

181100-4322

Manufacturer code No.

M009T62371

Power output Rating Outside diameter of yoke

(V-kw)

24-5.5

(Sec)

30

(mm/in)

Revolution direction

Clockwise

Protection

Dust-proof, splash-proof

Reduction mechanism

Internal gear

Weight Pinion

(kg)

3.5

Pressure angle

14.5 11

Gear ratio {ring gear/pinion gear}

12.6 {139/11}

Voltage

(V)

23

Current

(A)

120 or less

Revolution speed Restraint

8.5

Module The number of teeth

No load

90/3.543

(rpm)

3,100 or more

Voltage

(V)

8

Current

(A)

1,800 or less

Torque

N⋅m {kgf⋅m}

Pinion engagement voltage

(V)

76 {8} or more 16.0 or less

Electrical System (6UZ1X) 1E-9

Sectional View (reference)

5

6

4

7 8

3 2

9 1

Name 1. Through Bolt 2. Bearing 3. Rear Bracket 4. Brush Holder 5. Magnetic Switch 6. Shift Lever 7. Gear Shaft

13

12

11

10

WSHK0069 8.

9.

10.

11.

12.

13.

Pinion Bearing Front Bracket Gear Yoke Armature

Electrical System (6UZ1X) 1E-10

Output Characteristic (reference) Rotation speed

Rotation force

Output

Terminal Voltage

Output

Rotation force

Terminal Voltage

Current (A) Rotation speed WSU0150A

Electrical System (6UZ1X) 1E-11

Disassembly and Inspection of Starter Disassembly diagram: disassemble in the order of the numbers.

7

18 27

21

19 9

6

28 29 14 16 17 15 20

4 1

2

5 8

26

3

22

10

25 13

24 12

23 30 11 12

Name 1. Snap Ring 2. Stop Ring 3. Pinion 4. Pinion Spring 5. Lead Wire with Terminal 6. Screw 7. Magnetic Switch 8. Screw 9. Through Bolt 10. Rear Bracket 11. Yoke Assembly 12. O-ring 13. Brush Holder 14. Armature 15. Ball

Disassembly Caution: • Before disassembling the starter, put alignment marks on each magnet switch, yoke front bracket and rear bracket to facilitate re-assembly.

• In normal condition, if tap the pinion or stop ring toward the front bracket side, the front bracket will be broken. Therefore, tap the stop ring when the pinion comes out to cranking position.

WSHK0071 16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

Plate Packing Packing Plate Planetary Gear Lever E-shaped Retaining Ring Overrunning Clutch Internal Gear Washer Gear Shaft Front Bracket Bearing Washer Brush

1. Connect the starter to battery as shown in the illustration.

When closing the switches SW1 and SW2, the pinion move forward to the cranking position and the armature rotates.

Then, open the switch SW2 to stop the armature rotating.

Caution: Remove the pinion within 10seconds since heat is generated during electric discharge.

Electrical System (6UZ1X) 1E-12

Disconnect the lead wire (attached with terminal) from the «M» terminal.

Battery 24V

Wiring diagram to move pinion forward

WSHK0072EA

2. Apply the pipe, which just fits the stop ring, on the ring and tap the pipe with a hammer to remove the stop ring toward the pinion side once.

Then, remove the snap ring and remove the stop ring, pinion and pinion spring.

Caution: Do not reuse the snap ring.

5 4 3 2

6

1

4. Remove the brush holder-tightening screw and through bolt.

Then, remove the rear bracket and O-ring together.

Caution: Do not reuse the removed O-ring.

Also, do not reuse also O-ring on tightening screw.

5. Apply a socket (outside diameter 32 mm {1.260 in}) on a commutator of armature.

Then, slide the brush on the socket to yoke assembly and O-ring.

This facilitates to re-assemble.

Caution: Do not reuse the removed O-ring.

6. Remove the brush from brush holder by pulling up the brush spring, and then remove the brush holder.

7. Remove the armature.

Remove a bearing using a general puller.

8. Remove the plate in planetary gear and remove the packing.

Then, remove the packing and plate on the lever support.

9. Remove the internal gear, gearshift, overrunning clutch and lever as a unit from front bracket.

10. Remove the lever.

Caution: Remember the direction of lever.

11. Remove the two E-shaped retaining rings.

To remove the overrunning clutch, rotate the spline by one tooth to remove it from gearshift assembly.

Caution: Do not reuse removed E-shaped retaining ring.

12. Remove the internal gear.

In this time, take out one washer which adjusts axial play of gearshift.

Inspection and Maintenance 1. Armature

Name 1. Pinion 2. Clutch Shaft 3. Snap Ring 4. Stop Ring 5. Pipe 6. Pinion Spring

WSHK0073

3. Remove the nut on M terminal of magnet switch and remove the lead wire with terminal.

Caution: Tightening screw is tight. Use a shock driver to loosen.

• Check the armature coil for internal short circuit with a growler tester.

• Replace the armature if internal circuit is present.

Electrical System (6UZ1X) 1E-13

WSHK0074 • Check the armature coil for grounding (faulty insulating) with a circuit tester.

Replace the armature if grounding is present.

WSHK0076 • Check the depth (undercut) of insulating mold of commutator.

Remove abrasion powder on brush, and repair if faulty.

2 3

1

4

WSHK0075 • Check the outside of commutator for wear.

Replace the armature if wear exceeds limit.

Name 1. Good 2. Insulating 3. Commutator Segment 4. Defective

WSHK0077

• Check the gears for wear or damage.

Replace the armature if fault is present.

• Check the bearings for noise, rattle or grease leakage.

2. Field coil • Check the coil for open circuit with a circuit tester.

Replace the yoke assembly if open circuit is present.

Electrical System (6UZ1X) 1E-14

2

1

WSHK0078 • Check the coil for grounding (faulty insulating) with a circuit tester.

Repair or replace the yoke assembly if grounding is present.

Name 1. Brush Length 2. Insulated Holder

WSHK0080

4. Overrunning clutch and pinion Hold the housing of overrunning clutch by hand.

Make sure that the pinion can be rotated by hand with a light resistance in one direction and cannot be in the opposite direction. Replace the overrunning clutch if faulty.

Check the pinion, and replace it if wear or scratch is present.

Caution: Grease is present in overrunning clutch. Do not use wash oil or cleaning agent for cleaning.

Wipe off stain on overrunning clutch with a cloth.

WSHK0079 3. Brush • Measure the length of the brush.

If it is worn to the limit, replace the brush holder assembly on the brush holder as a unit and only brush on the yoke assembly side.

• Make sure the brush moves smoothly in the brush holder. Also, check the brush spring pressure.

• Check the brush holder for grounding (faulty insulating) with a circuit tester.

Clean the brush holder before checking.

Replace the brush holder assembly if the continuity is present when putting one probe of circuit tester to brush holder plate (metal part) and another one to insulated holder.

WSHK0081

Electrical System (6UZ1X) 1E-15 5. Front bracket Check the bearing and oil seal, and replace the front bracket assembly (including bearing, oil seal) if faulty.

6. Internal gear and planetary gear Check the internal gear and planetary gear, and replace them if excessive wear or damage is present.

7. Lever If the portion which contacts the overrunning switch is worn, the protruded position of pinion will be faulty.

(Refer to “4. Assembly” section to adjust the protruded position of pinion.)

2

1

Name 1. M Terminal 2. S Terminal 3. B Terminal

1

Name 1. Worn Part

WSHK0082

8. Magnetic switch Check for continuity between the M terminal and the body, and replace the magnet switch if no continuity is present.

Then, make sure that no continuity is present between B terminal and M terminal. Replace the magnet switch if continuity is present.

3

WSHK0083

Electrical System (6UZ1X) 1E-16

Assembly of Starter Assembly diagram: Assemble in the order of the numbers.

24

13 4

10

12 22

25

3 2 17 15 14 16 11

27 30

29

5 23

5

28

9

21

6 18

7 19

8 1 20 19

Name 1. Brush 2. Washer 3. Bearing 4. Front Bracket 5. Gear Shaft 6. Washer 7. Internal Gear 8. Overrunning Clutch 9. E-shaped Retaining Ring 10. Lever 11. Planetary Gear 12. Plate 13. Packing 14. Packing 15. Plate

WSHK0084 16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

Ball Armature Brush Holder O-ring Yoke Assembly Rear Bracket Through Bolt Screw Magnetic Switch Screw Lead Wire with Terminal Pinion Spring Pinion Stop Ring Snap Ring

Electrical System (6UZ1X) 1E-17 1. Lubricant locations and tightening torque N m(kg m/lb ft)

4.9~8.8 (0.5~0.9 / 3.6~6.5)

I

19.6~25.5 (2.0~2.6 / 14.4~18.8)

C

B

H

F

G

2.4~4.4 (0.25~0.45 / 1.8~3.2)

7.8~12.7 (0.8~1.3 / 5.8~9.4)

E

A

D

WSHK0085

Lubricant locations Shown in the illustration

Lubricant locations

Lubricant agent Molycote ® AG650

A

Sleeve bearing and ball

B

Clutch shaft sliding surface

MULTEMP 6129

C

Spline portion and sliding portion of gearshift

MULTEMP 6129

D

Sliding portion of lever and overrunning clutch

Molycote ® AG650

E

Armature shift gear, planetary gear, internal gear

Molycote ® AG650

F

Under pinion

MULTEMP 6129

G

Outer surface of armature bearing (tiny amount)

MULTEMP 6129

H

Oil seal

MULTEMP 6129

I

Surface of plunger (tiny amount)

MULTEMP 6129

2. Axial play of armature shift Adjustment is unnecessary (assemble the ball into a tip of shaft.)

3. Axial play of gear shaft Adjustment is unnecessary Appropriate gap will be obtained automatically when one washer (removed in step 12 of disassembly procedure) is inserted between internal gear and gearshift.

4. Assembly of gearshift Pass the gear shaft through washer, internal gear and overrunning clutch. Then move the overrunning clutch by one tooth of spline to make sure that the clutch cannot be pulled out. Assemble the E-shaped retaining ring.

Caution: • Do not reuse removed E-shaped retaining ring.

• If assembling the E-shaped retaining ring prior to the overrunning clutch, the clutch cannot be assembled. Be careful with it.

Electrical System (6UZ1X) 1E-18

3 4

2

3 2 5 1 4 5

1

Name 1. Overrunning Clutch 2. Washer 3. Gear Shaft 4. E-shaped Retaining Ring 5. Internal Gear

WSHK0086

5. Assembly of pinion Assemble the pinion spring, pinion and stop ring to clutch shaft in this order, then assemble the snap ring to the groove of clutch shaft at the end.

Then, pull strongly the stop ring toward the snap ring side with a gear puller and fix both of them.

Caution: • Assemble the pinion before assembling the magnet switch to front bracket.

• Do not reuse the removed snap ring.

Name 1. Pinion 2. Clutch Shaft 3. Snap Ring 4. Stop Ring 5. Pinion Spring

WSHK0087

6. Check of the pinion protruded position After assembling the starter, check the protruded position of pinion.

How to measure and adjust • Connect the starter to battery.

When closing the switches SW1 and SW2, the pinion move forward to the cranking position and the armature rotates.

Then, open the switch SW2 to stop the armature rotating.

• Push into or pull back a tip of the clutch shaft lightly by hand and measure the moving distance of it.

Adjust by using one or two packings (0.5 mm {0.020 in}) between magnet switch and front bracket so that this measurement value is between 0.5 — 2.0 mm (0.020 — 0.079 in).

If this adjustment cannot be done, replace the lever.

Electrical System (6UZ1X) 1E-19

No Load Test 1. After adjusting the protruded position of pinion, connect the starter as shown in the illustration above.

SW 1

Caution: Use a thick electric wire and tighten the connected portion securely.

2. Close the switch and read the speed, current and voltage.

If the measured values are out of specified value, disassemble and inspect again.

B SW 2

S M 1

WSHK0088

Name 1. Battery 24 V

A

SW

B S M

V

Amount of shaft moved

WSHK0090

Name 1. Battery 24 V 2. Ammeter 3. Voltmeter

Push back the clutch shaft lightly by hand

Check of pinion moving out position WSHK0089EA

Specifications Items No load characteristic

Voltage

(V)

23

Current

(A)

120 or less

Speed Commutator Commutator Brush Brush spring

Standard value or limit

(rpm)

3,100 or more

Outside diameter

(mm/in)

32/1.260

Limit

(mm/in)

31.4/1.236

Undercut

(mm/in)

0.5/0.020

Limit

(mm/in)

0.2/0.008

Length

(mm/in)

18/0.709

Limit

(mm/in)

11/0.433

Pressure

(N)

28 — 38

Limit

(N)

13.7

Electrical System (6UZ1X) 1E-20 Items Protruded position of pinion

Standard value or limit (mm/in)

0.5 — 2.0/0.020 — 0.079

Electrical System (6UZ1X) 1E-21

Charging System Service Precautions Handling of generator Be careful with the following when handling a generator.

• Connecting the polarities of battery inversely causes generator diode to be broken.

• While the engine runs, never disconnect the wiring of battery terminal and charging circuit.

• Wiring connection to terminal must be performed properly according to terminal symbol.

• Do not perform megger test on semiconductor device.

• Be sure to disconnect the battery terminal (-) before inspection on equipment.

• Do not open/close the battery relay switch while the engine runs.

• Disconnect the battery terminal when charging from external source such as quick charge.

• Do not pour steam cleaner or water directly on it.

• After connecting to B terminal and E terminal, tighten them to the following torque.

B terminal 6 N⋅m {0.6 kg⋅m} E terminal 4 N⋅m {0.4 kg⋅m} • Refer to “Engine Accessories” for tension adjustment of ACG-belt.

Electrical System (6UZ1X) 1E-22

List of Trouble Symptoms • • • • •

Charging is impossible.

Charging is not sufficient.

Overcharging occurs.

Charging current is unstable.

Abnormal sound occurs from generator.

Electrical System (6UZ1X) 1E-23

Symptom: Charging is impossible.

Condition Charging is impossible.

Possible Cause

Correction

Defective battery

Replace.

Open or short circuit, disconnection in wiring / ammeter

Repair.

Open, ground short or short circuit in each coil of generator and breakage of diode

Replace.

Defective regulator

Replace.

Poor contact in terminal of regulator

Repair.

Electrical System (6UZ1X) 1E-24

Symptom: Charging is not sufficient.

Condition Charging is not sufficient.

Possible Cause

Correction

Defective battery

Replace.

Open or short circuit, disconnection in wiring

Repair.

Looseness of generator driven belt

Adjust the tension of the belt.

Short circuit in stator coil layer

Replace.

Defective diode

Replace.

Poor contact in each terminal

Repair.

Defective regulator

Replace.

Poor contact in terminal of regulator

Repair.

Electrical System (6UZ1X) 1E-25

Symptom: Overcharging occurs.

Condition Overcharging occurs.

Possible Cause Defective regulator

Correction Replace.

Electrical System (6UZ1X) 1E-26

Symptom: Charging current is unstable.

Condition Charging current is unstable.

Possible Cause

Correction

Intermittent contact or nearly disconnected connection in wiring

Repair.

Looseness of generator driven belt

Adjust the tension of the belt.

Short circuit or nearly open circuit in stator coil

Repair.

Poor contact in each terminal

Repair.

Defective regulator

Replace.

Poor contact in terminal of regulator

Repair.

Electrical System (6UZ1X) 1E-27

Symptom: Abnormal sound occurs from generator.

Condition Abnormal sound occurs from generator.

Possible Cause

Correction

Looseness of belt tension

Adjust the tension of the belt.

Defective bearing

Replace the bearing.

Contact of rotor core and stator core

Repair.

Defective diode

Replace.

Short circuit or nearly open circuit in stator coil

Replace.

Specifications Manufacturer

Mitsubishi Electric Co.

Isuzu Part No.

1-81200-603-2

Model by manufacturer

A004TU6285

Nominal voltage

(V)

24

Output current

(A)

50

Rated speed Output current/Voltage No load voltage

(rpm) (A/V/rpm) (V/rpm)

Revolution direction

50/27/5000 24/900 Clockwise

Polarity Pulley diameter (P. C. D)

5000

(−) (mm/in)

80/3.150

Electrical System (6UZ1X) 1E-28

Charging Circuit

N B 3

4

5

L

2

L R

R

F

6

E

1

7 E 8

Name 1. Field Coil 2. Stator Coil 3. Diode Trio 4. Charging Lamp

WSHK0091 5.

6.

7.

8.

Key Switch Battery 24 V IC Regulator Generator

Charging circuit and internal circuit are shown in the illustration above.

Charging system consists of IC regulator built-in generator, battery, charging lamp and wires to connect them.

Electrical System (6UZ1X) 1E-29

Structure

5

6

4 7

8

3

2

1

9 10

Name 1. Rear Bracket 2. IC Regulator 3. Bearing 4. Rectifier 5. Stator This generator has no brush.

Main parts are a rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator, bearing, pulley and so on.

Moving parts are a rotor and pulley. A field coil is secured to rear bracket.

Six main diodes and two additional diodes are used to convert three-phase alternating current, generated in stator coil, into direct current. Among six main diodes, there are three positive diodes and three negative diodes.

In addition, three tiny diodes, called trio diode, are used to supply field current.

WSHK0092 6.

7.

8.

9.

10.

Rotor Bearing Pulley Front Bracket Coil Assembly (Field Coil)

This generator has three terminals, which are B terminal (for direct current output), L terminal and R terminal.

The L terminal is connected to field coil. Therefore, as well as R terminal, it becomes input terminal for initiating excitation current until the generator starts to generate electric power.

It also provides function as output terminal. (Current capacity is 1 A.) The charging lamp will be off if the voltage on L terminal reaches battery voltage.

Both bearings are sealed, therefore periodic lubricant is not necessary.

Electrical System (6UZ1X) 1E-30 IC regulator cannot be disassembled. Handle it as assembly.

Electrical System (6UZ1X) 1E-31

Disassembly and Inspection of Generator 9 8 10 7

5 6 4 2 1

3

11 12 13

14 15

Name 1. Nut Washer 2. Pulley, Fan 3. Collar 4. Through Bolt 5. Front Bracket 6. Ball Bearing 7. Retainer 8. Rotor Assembly

WSHK0160 9.

10.

11.

12.

13.

14.

15.

Ball Bearing Screw Cover Rectifier Assembly Regulator Assembly Stator Assembly Field Coil Assembly

Electrical System (6UZ1X) 1E-32 11 10 9 8

6 7 5 3 2 1

4

12 13

14

15 16 17

18

Name 1. Nut Washer 2. Pulley, Fan 3. Key 4. Collar 5. Through Bolt 6. Front Bracket 7. Ball Bearing 8. Retainer 9. Rotor Assembly

Disassembly Caution: To facilitate re-assembly, put alignment marks on front bracket and rear bracket before disassembly.

1. Remove out the four through-bolts.

Pry between stator and front bracket with a tip of flathead screwdriver and separate the front bracket pulley rotor assembly from stator rear bracket assembly carefully.

Caution: Take care not to damage the stator coil.

2. Hold the rotor with a vise without deforming the rotor ball.

Remove the nut which fixes pulley, and remove the pulley, fan, spacer and front bracket.

Caution: Do not lose a half-moon key when removing the pulley.

WSHK0161 10.

11.

12.

13.

14.

15.

16.

17.

18.

Ball Bearing Field Coil Assembly Connector Set Screw Terminal Set Cover Rectifier Assembly Regulator Assembly Stator Assembly

Caution: To hold the rotor with a vise, grip the portion A. Portion B is not strong enough to be gripped.

Electrical System (6UZ1X) 1E-33

B

A

5. To remove the coil assembly from rear bracket, firstly remove the screw A (which fixes coil terminal portion to IC regulator).

Removing a screw B (which fixes the coil assembly to rear bracket) prior to screw A may cause damage to terminal portion.

Hold the coil assembly by hand not to damage to terminal portion.

Then, remove the screw B and remove the coil assembly.

A 1 1

A

Name 1. Ball

WSHK0093

3. If the front bearing needs to be removed, remove the screw which fixes retainer, and push out the bearing using appropriate socket.

Caution: Do not remove it if not necessary. Do not reuse the removed bearing.

4. If the rotor bearing needs to be removed, it can be done by a general bearing puller.

Caution: Do not remove it if not necessary. Do not reuse the removed bearing.

B

Name 1. Connector

WSHK0094

6. Disconnect the connector.

7. Remove the cap and nut from terminal bolt of rectifier.

Pry between rear bracket and B terminal assembly to remove the B terminal. A tube remains on rear bracket.

Caution: Do not lose the tube.

Electrical System (6UZ1X) 1E-34

3 2

4

5 6 12 7 8

13 11

9

1

10

Name 1. IC Regulator 2. Rectifier 3. B Terminal 4. Terminal Bolt 5. B Terminal 6. Cap 7. Nut

WSHK0095 8.

9.

10.

11.

12.

13.

Cap Nut Terminal Bolt Terminal Bolt Terminal Bolt Rectifier

Electrical System (6UZ1X) 1E-35

3

2 4

5 1 N

6

Name 1. IC Regulator 2. Terminal Bolt 3. Nut 8. Remove two screws which fix rectifier and two screws which fix regulator.

Remove the stator and rectifier assembly from rear bracket as a unit.

Then, remove the IC regulator.

9. Disconnect four lead wires of stator coil and remove the stator from rectifier.

Caution: Lead wires of stator coil are soldered (melting point: 230°C {446°F}) on rectifier terminal.

Disconnect them quickly (within five seconds) not to heat the rectifier causing damage to diode.

WSHK0159 4. B Terminal 5. Tube 6. Rectifier

1

Inspection 1. Stator Check visually for damage, loose connection and discoloration of coil.

• Check for continuity between two lead wires of stator coil with a circuit tester. Replace the stator if no continuity is present.

• Check for continuity between lead wire of stator coil and core with a circuit tester. Replace the stator if continuity is present.

Name 1. Stator Coil Lead

WSHK0096

Electrical System (6UZ1X) 1E-36 2. Rotor • Check the bearings for noise, rattle or grease leakage (wipe off if tiny amount of grease).

Replace it if faulty. It is easier to check for noise and rattle when it is press-fitted into shaft than when it is a single unit.

1

2

The positive diode has short circuit if continuity is present in both directions. Replace the rectifier assembly.

The positive diode has open circuit if no continuity is present in both directions. Replace the rectifier assembly.

• Negative diode and additional diode on negative side Check for continuity between negative heat sink and four diode terminals with a circuit tester.

The negative diode has short circuit if continuity is present in both directions. Replace the rectifier assembly.

The negative diode has open circuit if no continuity is present in both directions. Replace the rectifier assembly.

• Diode trio (three tiny diodes) Check for continuity in both directions with a circuit tester.

The diode is faulty if continuity is present in both directions or no continuity is in both directions.

Replace the rectifier assembly.

WSHK0097

Name 1. Stator Coil Lead 2. Core

2

3. Coil assembly Measure the resistance between terminal portions with a circuit tester.

Replace the coil assembly if the value is out of specified value.

1

Name 1. Diode Terminal Portion 2. Positive Diode 3. A Part of Negative Diode

1

2

Name 1. Terminal 2. Terminal Portion

WSHK0098

4. Rectifier assembly • Check for continuity between positive diode, additional diode positive heat sink on positive side and four diode terminals with a circuit tester.

3

WSHK0099

Electrical System (6UZ1X) 1E-37 5. Front bearing Check the bearings for noise, rattle or grease leakage (wipe off if tiny amount of grease). Replace them if faulty. It is easier to check for noise and rattle when the bearing is press-fitted into bracket than when it is a single unit.

6. Regulator The regulator cannot be checked with a circuit tester. After re-assembling the generator, check it to make sure that regulator controls the voltage for generator.

Assembly Assembly can be performed in the reverse order of disassembly. However, be careful with the following.

1. Lubrication is not necessary. Bearing is filled with grease and is sealed.

Caution: Keep a bearing with resin band for rotor shaft away from oil. Wipe off oil on bearing box area of rear bracket. Oil may cause creep.

2. Use a high temperature solder (melting point: 230°C {446°F}).

Using a soldering iron (with 180 — 270 watt), soldering must be performed quickly (within five seconds) not to heat the rectifier.

3. Tightening torque • Pulley fixing nut: 132 — 162 N⋅m {13.5 — 16.5kg⋅m/97 — 119lb ft} • Through bolt: 12.8 — 18.6 N⋅m {1.3 — 1.9kg⋅m/9 — 14lb ft} • Bearing retainer fixing screw: 2 — 5.3 N⋅m {20 — 54kgf⋅cm/18 — 47lb in} • Coil assembly fixing screw: 2 — 5.3 N⋅m {20 — 54kgf⋅cm/18 — 47lb in} • Rectifier fixing screw: 2 — 5.3 N⋅m {20 — 54kgf⋅cm/18 — 47lb in} • Regulator fixing screw: 2 — 5.3 N⋅m {20 — 54kgf⋅cm/18 — 47lb in} • Nut for B terminal bolt: 4.9 — 8.7 N⋅m {50 — 88kgf⋅cm/43 — 77lb in} 4. Assembly of rear bracket to stator assembly and front bracket to rotor assembly • The rotor bearing and rear bracket are engaged tightly. Heat the bearing box area of rear bracket to 50 — 60°C (122 — 140°F) prior to assembly.

• After re-assembling the generator, rotate the pulley to confirm that the rotor rotates smoothly.

Electrical System (6UZ1X) 1E-38

Bench Testing Bench testing is performed as follows.

Regulated voltage check 1. Wire as shown in the illustration.

Use an ammeter with 100 A rating and a voltmeter with 30 V rating.

2

4

A B 1

V

8

3

6

L R 5

7

WSHK0100

Name 1. Voltmeter 2. Ammeter 3. Lamp (24 V) (3 W or less) 4. Key Switch 1 5. Battery (24 V) 6. Key Switch 2 7. Load Resistance

2. Close the switch 1. Leave the switch 2 open.

In this time, the lamp comes on.

If it does not, check the voltage on L terminal.

If the voltage is almost the same as battery voltage, check the generator.

If the voltage is low, lamp or the circuit is open.

3. Increase the generator speed gradually.

Make sure that the lamp goes off before the speed reaches approx. 1300 rpm.

Notice the voltage. If the voltage is not controlled and exceeds 30 V, the IC regulator may be faulty.

If the voltage does not exceed battery voltage, the generator does not generate electric power.

Check the generator again.

If the lamp does not go off, check the generator again.

4. Set the generator speed to approx. 5000 rpm and read an ammeter. If the value is 5 A or less, read indication on a voltmeter. This is regulated voltage.

If an ammeter shows 5 A or more, keep charging for a while until it shows below 5 A or replace the battery with full-charged one.

If regulated voltage is out of specified value, replace the regulator.

Output current test Output current test is performed to check if the generator generates rated output.

1. After checking regulated voltage, decrease the generator speed until it stops.

2. Close the switch 1. The lamp should come on.

3. Set the value of no load resistance to maximum (minimum current) and close the switch 2.

4. Increase the generator speed to 5000 rpm and keep it. Adjust the load resistance so that output current becomes maximum.

Keep this condition for 15 minutes and increase in temperature of the generator.

15 minutes later, set the generator speed to the specified speed (2500 and 5000 rpm) and then adjust the load resistance so that output current becomes maximum in this condition.

In this time, if indication of ammeter is within specified value, the generator is normal.

If it is the specified value or less, check the generator again according to “Inspection”.

Electrical System (6UZ1X) 1E-39

Trouble Diagnosis Symptom

Trouble cause

No generation of electric power

a. Defective IC regulator b. Open circuit in field coil

Output shortage

a. Defective diode b. Defective stator coil c. Defective rectifier d. Internal short circuit in field coil

Too high regulated voltage

a. Defective IC regulator

Noise

a. Defective bearing b. Defective rectifier c. Foreign material in generator

Specifications Items

Standard value and limit

Isuzu Part No.

1-81200-603-2

Manufacturer code No.

A004TU6285

Rated output Output characteristic (hot)

(V-A)

24-50

Voltage

(V)

27

Current

(A)

42 or more

Revolution speed

(r/min)

2,500

Voltage

(V)

27

Current

(A)

50 or more

Revolution speed Field coil resistance Regulated voltage by regulator Revolution direction (viewed from pulley side)

(r/min)

5,000

(Ω: at 20°C)

4.4-5.1

(V)

28-29 Clockwise

Lubricating System (6UZ1X) 1H-1

Engine Lubricating System (6UZ1X) Contents Lubrication System . . . . . . . . . . . . . . . . . . . . . . . .1H-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . .1H-2 Description of Function and Operation . . . . . . .1H-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-3 Oil Filter (sub oil filter) . . . . . . . . . . . . . . . . . . . . . .1H-5 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-5 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-5 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-7 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-8 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-8 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-9 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-10 Torque Specifications . . . . . . . . . . . . . . . . . . . .1H-13 Oil Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-14 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-14 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-15 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1H-15 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-15 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1H-16 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-16 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-17 Torque Specifications . . . . . . . . . . . . . . . . . . . .1H-18 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19 Torque Specifications . . . . . . . . . . . . . . . . . . . .1H-21

Lubricating System (6UZ1X) 1H--2

Lubrication System Service Precautions

• Apply appropriate amount, not excessively or insufficiently. Applying excessively causes clogging in oil gallery or oil jet resulting in seizure, and applying insufficiently causes leakage of oil.

Therefore, take care of them.

• Be sure to re-apply upon itself when starting and finishing application.

• Perform service with taking enough care not to allow dirt or dust to get into the lubrication system parts since they are manufactured extremely precisely.

• Each time you disassemble parts, remove old gasket completely from parts that use liquid gasket.

Clean each of the parts to completely remove oil, water, dust, etc. and apply new liquid gasket on each area.

Description of Function and Operation The lubrication system uses gear type oil pump, oil filter integrated with full flow bypass, water-cooling oil cooler, oil relief valve and oil jet for cooling piston.

Lubricating system diagram

ASM

Oil cooler

Main oil filter

Main oil gallery

Opening pressure Relief 540kPa valve (5.5kg/ cm2)

Oil thermo valve Main bearing

ASM

Oil pump

Sub oil gallery

Opening pressure 1080kPa (11kg/ cm2)

Relief valve

Conn-rod bearing

Turbo charger

Idle gear D

Idle gear B

Supply Pump

Camshaft Cam bearing Rocker arm

Idle gear C

Bearing case

Idle gear A

Water pump

Oiling jet

Gear case P.T.O

Piston

Bearing case

Lubricating System (6UZ1X) 1H-3 Oil pump structured diagram

Name 1. Drive Gear 2. Drive Gear Shaft 3. Spring

4. Relief Valve 5. Driven Gear

Specifications Item

Specification

Lubrication device Oil pump

Forced circulation type Type

Gear type

Discharge amount

(L/min)

Relief valve opening pressure

kPa {kg/cm2}

97.4 (pump speed 2,460 rpm, discharge pressure 0.79 MPa) 1079 {11}

Lubricating System (6UZ1X) 1H--4 Item

Specification 2

Oil gallery relief valve opening pressure

kPa {kg/cm }

Oil filter type

Full flow filter paper type + shunt flow lamination layer type

Oil cooler type

Water cooling multi-sheet type 6 layer

Oil thermostat opening temperature Engine oil level

540 {5.5}

(L)

(°C) Full capacity

101.5 — 104.5 30 — 41

Lubricating System (6UZ1X) 1H-5

Oil Filter (sub oil filter) Components

Name 1. Body 2. Nipple

3. Cartridge Oil Filter 4. Splicing Fittings (Machine Side Components)

Disassembly

Assembly

The oil filter is a sub oil filter (machine side Installation) and not installed to the engine.

1. Remove the cartridge filter using the filter wrench.

Filter wrench:

380002630

2. Remove the nipple.

• If there are no problems with the screw thread of the nipple screw, do not remove it.

3. Clean the oil passages inside the body.

1. Set the body.

2. Apply Loctite to the nipple and install it.

3. Install the cartridge oil filter.

• Apply engine oil to the O-ring of the cartridge oil filter, screw it into the nipple of the body, and tighten to the specified torque.

• If using the filter wrench shown in the diagram below and tightening with a torque wrench, the torque must be converted.

Lubricating System (6UZ1X) 1H--6 • Conversion formula Actual torque = displayed torque x (effective length + 87) / effective length Filter wrench: Tightening torque:

380002630 64N⋅m {6.5kgf⋅m/47.2lb⋅ft}

Name 1. Filter Wrench 2. 87mm 3. Effective Length 4. Torque Wrench 5. Displayed Torque 4. Port opening splicing fittings (machine side components) • Port opening splicing fittings are not installed to the engine.

• The tightening torques for the splicing fittings are shown below.

Tightening torque:

70N⋅m {7.1kgf⋅m/51.6lb⋅ft}

Lubricating System (6UZ1X) 1H-7

Special Tool Illustration

Tool Number Description Special Tool

380002630 Filter wrench

Lubricating System (6UZ1X) 1H--8

Oil Cooler Components

WSUZ0047

Name 1. Oil Thermostat 2. Support 3. Seal Ring 4. Stopper 5. O-ring 6. Oil Pipe 7. O-ring

8.

9.

10.

11.

12.

13.

14.

O-ring Gasket Oil Cooler Element Water Guide Oil Cooler Case O-ring Oil Relief Valve

Lubricating System (6UZ1X) 1H-9

Disassembly 1. Remove the water guide.

2. Remove the oil cooler element.

• Loosen the nuts on the body case side to remove.

Note: Seal the oil passage system to prevent foreign matter from getting into it.

3. Remove the oil thermostat.

4. Remove the oil relief valve.

5. Clean the oil cooler element.

• Clean if the element is excessively dirty.

• Pour cleaning fluid into the element and soak the inside for approx. 10 hours. After that remove approx. 1/3 of the cleaning fluid, then eject the rest from the oil port by blowing through approx. 200 kPa {2 kgf/cm2} of compressed air. This operation can be repeated a number of times depending on how dirty the element is.

Note: Fire is strictly prohibited near the cleaning fluid. Wear protective glasses and masks, and provide for sufficient ventilation.

Using undiluted solution

Using diluted with light oil

Hi-aromu 2S (New Nippon Oil)

{

{

Suwazoru 310 (Maruzen)

{

{

Hi-zoru (Showa)

{

{

Mobile Zol A (Mobil Sekiyu)

{

{

Inspection Oil cooler element • Check the oil cooler element for cracks.

• Perform red check method inspection as required.

Note: Check when oil is mixed in the coolant.

Oil thermostat • Check the piston and valve seat surface for wear or damage. Also, check the spring for damage or weakness.

Lubricating System (6UZ1X) 1H--10

• Operation check of oil thermostat Check whether valve is open between 101.5 and 104.5 °C. Oil thermostat opening temperature: 101.5 — 104.5°C

Assembly 1. Install the oil relief valve (1).

• Set the O-ring and install.

Tightening torque: 34.3N⋅m {3.5kg⋅m/25.3lb⋅ft}

1

Oil relief valve • Check the piston and valve seat surface of body for wear or damage. Also, check the spring for damage or weakness.

WSUZ0048

2. Install the oil thermostat.

• Install the thermostat (4), support (3), seal ring (2), and stopper (1) into the body case in this order.

• Face the sealing lip section upwards and install it to the oil thermostat support.

• Set the O-rings into the both ends of the pipe, and then install it to the body case.

Tightening torque: M10: 19.6N⋅m {2.0kg⋅m/14.5lb⋅ft} M8: 17.2N⋅m {1.8kg⋅m/12.7lb⋅ft}

Lubricating System (6UZ1X) 1H-11

3. Install the oil cooler element.

• Apply liquid gasket to the two O-ring grooves on the body case, and then attach the O-ring.

Apply the gasket to the element and install to the body case.

Tightening torque: 19.6N⋅m {2.0kg⋅m/14.5lb⋅ft}

Lubricating System (6UZ1X) 1H--12 4. Install the water guide.

Tightening torque:

7.8N⋅m {0.8kg⋅m/5.8lb⋅ft}

Lubricating System (6UZ1X) 1H-13

Torque Specifications Oil cooler

a b

c

e

d WSUZ0049

Name (a) 19.6N⋅m {2.0kg⋅m/14.5lb⋅ft} (b) 17.2N⋅m {1.8kg⋅m/12.7lb⋅ft} (c) 7.8N⋅m {0.8kg⋅m/5.8lb⋅ft}

(d) 34.3N⋅m {3.5kg⋅m/25.3lb⋅ft} (e) 19.6N⋅m {2.0kg⋅m/14.5lb⋅ft}

Lubricating System (6UZ1X) 1H--14

Oil Jet Removal Oil jet 1. Loosen the joint bolt, and remove the oil jet.

• Check the oil jet, which has removed, for bend and oil hole for clogging.

Installation Oil jet 1. Align the oil jet with the knock pin hole and install.

2. Tighten the oil jet by joint bolt.

Tightening torque:

21N⋅m {2.1kg⋅m/15.5lb⋅ft}

Note: Do not deform the tip of the oil jet.

Lubricating System (6UZ1X) 1H-15

Oil Pump Components

Name 1. Stay 2. Oil Strainer 3. O-ring 4. Oil Pump Cover 5. Oil Pump Body

Removal

6.

7.

8.

9.

Oil Pump Drive Gear Driven Gear O-ring Oil Pipe

Backlash of the gear

1. Remove the oil pan.

2. Measure the backlash of the oil pump gear.

• Measure the backlash of the oil pump drive gear and crankshaft gear.

(mm) Assembly standard

Service limit

0.15

0.20

Lubricating System (6UZ1X) 1H--16

Assembly 1. Install the driven gear.

• Apply oil to the driven gear (1), and install it to the pump body.

3. Remove the oil pump ASM.

Disassembly 1. Remove the oil strainer.

2. Disconnect the oil pipe.

3. Remove the oil pump cover.

4. Remove the driven gear.

2. Install the oil pump cover.

• Pour the clean engine oil between the gears sufficiently before installing the cover.

Inspection

Tightening torque:

Oil relief valve • Oil relief valve cannot be disassembled since it is sealed.

• Check the ball for scratch, and press the ball to check if it moves smoothly.

Driven gear • Clearance between the body inner wall and gear Assembly standard mm

0.100 — 0196

18.6N⋅m {1.9kg⋅m/13.7lb⋅ft}

Note: Pouring the engine oil is important to avoid oil pressure lag when starting the engine.

Oil outlet

Oil inlet

Driven gear

WSUZ0151A

3. Install the oil pipe.

• Apply liquid gasket to the two O-ring grooves on the oil pipe, and install.

Tightening torque:

21.6N⋅m {2.2kg⋅m/15.7lb⋅ft}

Note: Install the oil pipe after installing the oil pump.

Lubricating System (6UZ1X) 1H-17

4. Install the oil strainer.

Check the oil pump operation.

• Rotate the drive gear by hand and confirm that it operates smoothly.

Installation 1. Install the oil pump.

• Check for the backlash between the gear.

Tightening torque: M10: 38N⋅m {3.9kg⋅m/28lb⋅ft} Tightening torque: M8: 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft}

2. Install the oil pan.

Refer to “Oil pan”.

Lubricating System (6UZ1X) 1H--18

Torque Specifications Oil pump

Name (a) (b) (c)

21.6N⋅m {2.2kg⋅m/15.7lb⋅ft} 18.6N⋅m {1.9kg⋅m/13.7lb⋅ft} 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft}

(d) (e) (f)

38 N⋅m {3.9kg⋅m/28lb⋅ft} 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft} 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft}

Lubricating System (6UZ1X) 1H-19

Oil Pan Components

1

2

3

WSUZ0084

Name 1. Gasket 2. Oil Pan

3. Drain Plug

Removal

Installation

1. Drain engine oil.

1. Apply liquid gasket.

• After draining oil, tighten the drain plug to the specified torque.

Tightening torque:

70N⋅m {7.1kg⋅m/51.6lb⋅ft}

Note: Be sure to tighten the drain plug to the specified torque beforehand since it may be left untightened.

2. Remove the oil pan.

• Apply liquid gasket (ThreeBond No.TB1207B) by approx. 2 mm in thickness, approx. 3 mm in width to the mating portion of the cylinder block, the flywheel housing and the front cover.

Note: Clean the applying surface before applying the gasket.

Lubricating System (6UZ1X) 1H--20

2. Install the oil pan.

• Install it so that identification code “OIL PAN SIDE” (or silicon coating surface) faces toward the oil pan side.

• Install the plate so that its white paint faces outside.

• Tighten the oil pan in the order indicated by number and arrow in the illustration.

Tightening torque:

19N⋅m {1.9kg⋅m/14lb⋅ft}

Note: • When tightening the oil pan, tighten several points again since loose torque will occur.

• Be careful that the gasket has different figure on each side (right and left, front and rear are symmetry).

2

1

WSUZ0085

Lubricating System (6UZ1X) 1H-21

Torque Specifications Oil pan

a

b

WSUZ0052

Name (a)

19N⋅m {1.9kg⋅m/14lb⋅ft}

(b)

70N⋅m {7.1kg⋅m/51.6lb⋅ft}

Intake System (6UZ1X) 1J-1

Engine Intake system (6UZ1X) Contents Turbocharger System . . . . . . . . . . . . . . . . . . . . . . 1J-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1J-2 List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1J-3 Symptom: If faulty vibrations occur . . . . . . . . . . 1J-4 Symptom: Output is lowered although turbocharger seems almost normal. . . . . . . . . . . . . . . . . . . . . 1J-5 Symptom: Oil infiltrates into exhaust pipe or intake pipe, exhaust gas is white . . . . . . . . . . . . . . . . . 1J-6 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-7 Table of Specifications . . . . . . . . . . . . . . . . . . . . 1J-7 Turbocharger Structured Diagram . . . . . . . . . . . 1J-8 Disassembly and Inspection of Turbocharger . . 1J-9 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-10 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-12 Assembly of Turbocharger . . . . . . . . . . . . . . . . 1J-15 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-16

Intake System (6UZ1X) 1J-2

Turbocharger System Service Precautions • The turbocharger has been designed precisely and rotates at high speed (approx. 100,000rpm), therefore if any fault such as bend, scratch is found on the fin, housing, etc. replace the turbocharger ASM. The turbocharger cannot be disassembled.

• During service, take measure thoroughly to prevent foreign matters from getting inside of them.

Intake System (6UZ1X) 1J-3

List of Trouble Symptoms • If faulty vibrations occur • Output is lowered although turbocharger seems almost normal.

• Oil infiltrates into exhaust pipe or intake pipe.

Exhaust gas is white.

Intake System (6UZ1X) 1J-4

Symptom: If faulty vibrations occur Condition If faulty vibrations occur

Possible Cause

Correction

Caused by damaged bearing and contact between rotary part and its surrounding area.

Bearing failure is caused by neglecting oil changes, foreign matters in the feed pipe, clogged oil filter, driving with a failure, and repeated sudden starts and stops.

Replace

If the lubrication system is normal, and damage caused by contact between the rotary part and its surrounding area is found, imbalanced rotary part or bent shaft is suspected. This is caused by using a worn bearing or damaged turbine wheel or compressor wheel due to foreign matters getting in.

Replace

Intake System (6UZ1X) 1J-5

Symptom: Output is lowered although turbocharger seems almost normal Condition Output is lowered although turbocharger seems almost normal

Possible Cause

Correction

Gas leakage from exhaust system

Repair or replace

Deformed exhaust muffler, excessive exhaust resistance due to carbon deposits

Repair or replace

Air leakage from compressor discharge side, dirt in air cleaner element

Clean or replace

Compressor internal section dirty

Clean

Rotor shaft section dirty

Clean

Intake System (6UZ1X) 1J-6

Symptom: Oil infiltrates into exhaust pipe or intake pipe, exhaust gas is white Condition Oil infiltrates into exhaust pipe or intake pipe Exhaust gas is white

Possible Cause

Correction

Dirt in oil separator, oil bypass due to clogging

Clean or replace

Clogged, crushed or deformed drain pipe

Repair or replace

Worn piston ring, or too much abrasion of the ring slots

Replace

Bad bearing is the cause for piston ring section damage

Replace

Intake System (6UZ1X) 1J-7

Turbocharger Table of Specifications

Items Turbine shaft

Assembly Specifications

Service Limit

Axial play

mm (in)

0.06 — 0.09 (0.00236 — 0.00354)

0.11 (0.00433)

Radial play

mm (in)

0.10 — 0.17 (0.00394 — 0.00669)

0.205 (0.00807)

Journal outside diameter

(A)

mm (in)

—

11.380 (0.44803)

Sealing groove width

(B)

mm (in)

—

1.33 (0.05236)

mm (in)

—

0.011 (0.00043)

Runout Sealing Turbine side (bearing housing) Insertion part Compressor side (seal plate)

(F)

mm (in)

—

17.03 (0.67047)

(H)

mm (in)

—

14.05 (0.55315)

Oil thrower

Sealing groove width

(G)

mm (in)

—

1.52 (0.05984)

Bearing Housing

Bearing housing inner diameter

(B)

mm (in)

—

16.11 (0.63425)

Thrust bearing inside diameter for press-fit portion

(L)

mm (in)

—

23.020 (0.96030)

Bearing pad height at compressor side

(J)

mm (in)

—

0.0 — 0.060 (0.0 — 0.00236)

Thrust collar thickness

(K)

mm (in)

—

2.950 (0.11614)

Thrust bearing

J

H

F B

L

A K

E

G

WSHK0126

Intake System (6UZ1X) 1J-8

Turbocharger Structured Diagram

4 2

5

3

6

7

10 1

Name 1. Turbine Housing 2. Heat Protector 3. Floating Metal 4. Oil Thrower 5. Compressor Housing

9 8

WSHK0127 6.

7.

8.

9.

10.

Seal Plate Compressor Impeller Seal Ring Seal Ring Turbine Shaft

Intake System (6UZ1X) 1J-9

Disassembly and Inspection of Turbocharger Disassembly diagram: disassemble in the order of the numbers.

1

2

4

3

6 14 17 16

13

5

16

15

8 18 7 11 12 10 9

WSUZ0086

Name 1. Compressor Housing 2. Nut 3. Compressor Impeller 4. Seal Plate 5. Oil Thrower 6. Seal Ring 7. G Coupling 8. Turbine Housing 9. Turbine Shaft

10.

11.

12.

13.

14.

15.

16.

17.

18.

Seal Ring Gasket Heat Protector Thrust Bearing Thrust Collar Snap Ring Floating Metal Thrust Bearing Bearing Housing

Intake System (6UZ1X) 1J-10

Disassembly Caution: If you perform inspection with the turbocharger removed from the engine, plug the oil port opening before work.

Inspection Prior to Disassembly • Measurement of axial play of turbine shaft Axial play

mm (in)

Assembly specifications

0.06 — 0.09 (0.0024 — 0.0035)

Service limit

0.11 (0.0043)

If it exceeds the service limit, check the thrust metal, the thrust bushing, and the oil thrower.

WSHK0130 • Measurement on the machine of radial play of turbine shaft Insert a thickness gauge into the gap between the compressor impeller and housing, and measure the clearance.

The thickness gauge to be inserted must be 0.2 mm (0.0078 in) or less.

1. Compressor housing

WSHK0129

• Put alignment marks between the compressor housing and the seal plate, and tap the compressor housing to drive it out.

• Liquid gasket is applied to the mating surface of the compressor housing and the seal plate.

Caution: Take care not to damage the impeller during removal of the compressor housing.

• Measurement of radial play of turbine shaft Radial play

mm (in)

Assembly specifications

0.10 — 0.17 (0.00394 — 0.00669)

Service limit

0.205 (0.00807)

If it exceeds the service limit, check the floating metal.

1

Name 1. Alignment Mark

WSHK0131

Intake System (6UZ1X) 1J-11 2. Compressor impeller • Attach the box spanner to the turbine-side shaft end of the turbine shaft, and remove the nut.

(The nut is left-hand screw) • Remove the impeller from the turbine shaft.

• Washing of impeller Soak in the cleaning solvent until the foreign matters soften, and clean it with a plastic scraper or hard brush.

Caution: Do not use a wire brush.

4. Oil thrower • Remove the oil thrower from the seal plate.

5. G coupling • Loosen the nut and remove the G coupling from the turbine housing and the center housing.

6. Turbine housing • Remove turbine housing from the center housing.

• Washing of turbine housing Soak in the cleaning solvent to remove the foreign matters.

1

Name 1. Left-hand Thread

WSHK0132 WSHK0134

3. Seal plate • Loosen the pot small screw.

• Lightly tap the bearing housing in the seal plate with a wooden hammer.

• Liquid gasket is applied to the mating surfaces of the seal plate and the bearing housing.

WSHK0133

7. Turbine shaft • Hold the heat protector lightly by hand, and take out the turbine shaft.

• If it is hard to remove, lightly tap the compressor-side shaft end with a wooden hammer.

• Washing of turbine shaft Soak in the cleaning solvent until the foreign matters soften, and clean it with a plastic scraper or hard brush.

Caution: • Do not use a wire brush.

• Foreign matters remaining on the surface causes the unbalance of weight. Therefore, wash it thoroughly.

• Take care not to damage the floating metal contact surface of the shaft and the seal ring groove.

Intake System (6UZ1X) 1J-12

Inspection Compressor housing • Check the compressor housing for crack or damage, and replace if defective.

WSHK0135 8. Heat protector • Remove the heat protector from the bearing housing.

9. Thrust bearing (compressor side) • Loosen the plate small screw with a screwdriver, and remove the thrust bearing and the thrust collar.

10. Floating metal • Remove the turbine-side snap ring with snap ring pliers.

• Draw out the floating metal from the bearing housing.

11. Thrust bearing (turbine side) • Using a brass bar, push out the compressorside floating metal from the turbine-side bearing housing, together with the thrust bearing.

Caution: While pushing out with a bar, take care that they do not run on to damage the snap ring.

12. Snap ring • Remove the 2 snap rings from the bearing housing with snap ring pliers.

13. Seal ring • Remove the seal ring from the turbine shaft and the oil thrower.

WSHK0136 Turbine housing • Check the turbine housing for crack or damage, and replace if defective.

Impeller • Check the impeller for scratch, dent or crack.

WSHK0137

Intake System (6UZ1X) 1J-13 Heat protector

• Measurement of turbine shaft runout

• Check the heat protector for damage, thermal deformation or corrosion.

Turbine shaft runout

mm (in)

Service limit

0.011 (0.00043)

WSHK0138 Turbine shaft • Measure the journal outer diameter of the turbine shaft, and the groove width of the seal ring insertion part.

Journal outer diameter

mm (in)

WSHK0140 Seal plate • Inspection of damage on the seal plate, measurement of inner diameter of the seal ring insertion part

φ 11.38 (0.4480)

Service limit

Inner diameter of the seal ring insertion part Groove width of the seal ring insertion part Service limit

mm (in)

1.33 (0.0524)

mm (in)

Service limit H

14.05 (0.5531)

2

H

1

Name 1. Journal Outer Diameter 2. Ring Groove Width

WSHK0139

WSHK0141

Intake System (6UZ1X) 1J-14 Oil thrower • Inspection of damage on the oil thrower sliding surface, measurement of the seal ring groove width

mm (in) Location Bearing housing inner diameter

Seal ring groove width G G

(B)

16.11 (0.6343)

Turbine-side seal ring insertion part

(F)

17.03 (0.6705)

Turbine-side thrust bearing press-fit part inner diameter

(L)

23.02 (0.9063)

mm (in) Service limit 1.52 (0.0598)

Thrust collar

Service limit

• Measure the thrust collar thickness (K), and replace with new one if it exceeds the service limit.

Measurement of thrust collar thickness K

mm (in)

Service limit K

2.950 (0.11614) F

B

L

G

K

WSHK0143 G coupling • Replace with new one.

Seal ring • Replace with new one.

Others

WSHK0142 Thrust bearing • Replace the compressor-side and the turbine-side thrust bearings with new ones.

Floating metal • Replace the floating metal with new one.

Bearing housing • Check the casting surface for peeling from oxidation-deterioration, dent or crack. Replace with new one if faulty.

• Check the bolts for deformation, and replace with new ones if faulty. Also, replace the plate small screw with new one.

Intake System (6UZ1X) 1J-15

Assembly of Turbocharger Assembly diagram: Assemble in the order of the numbers.

18

17

15

16

13

3

4

8

9

14

3

2

11 1 12 10 6 5 7

WSUZ0087

Assembly Procedure 1. Bearing Housing 2. Snap Ring 3. Floating Metal 4. Thrust Bearing 5. Seal Ring 6. Heat Protector 7. Turbine Shaft 8. Thrust Collar 9. Thrust Bearing

10.

11.

12.

13.

14.

15.

16.

17.

18.

Gasket Turbine Housing G Coupling Seal Ring Oil Thrower Seal Plate Compressor Impeller Nut Compressor Housing

Intake System (6UZ1X) 1J-16

Assembly 1. Bearing housing • Check that the bearing housing is free of damage and foreign matters.

2. Snap ring • Install the 2 snap rings to the bearing housing with snap ring pliers.

• After assembling the floating metal (turbine side), install the snap ring at the position shown in the figure.

1

Name 1. Apply Oil.

1

Name 1. Turbine-Side Floating Metal

WSHK0145

3. Floating metal • Apply oil to the floating metal, and assemble it to the bearing housing.

After securing it with a snap ring, assemble the compressor-side floating metal.

Caution: • Place the snap ring with its rounded-side facing to the floating metal.

• Assemble the inner snap ring with its end gap facing to the oil outlet-direction of the housing, to prevent it from blocking the oil path.

• Assemble the turbine-side snap ring to the housing with its end gap facing to the direction as shown in the illustration.

• Apply oil to the floating metal before assembly.

Besco super engine oil

WSHK0146

4. Thrust bearing a. Press-fitting of turbine-side thrust bearing • Press-fit the turbine-side thrust bearing into the bearing housing.

• Position the pawl of the turbine-side thrust bearing for more than 2 mm (0.0787in) apart from the existing press-fitting part.

• Do not press the thrust bearing pad surface during press-fitting.

• The press-fit pressure must be between 215.6 N {22.0 kgf} and 1862 N {190 kgf}.

• After press-fitting, remove the dust powder by vacuum. b. After press-fitting, check the depth and flatness of the turbine-side thrust bearing.

(Depth 3.08±0.02 mm {0.1213±0.0008 in}, Flatness is below 0.01 mm{0.0004 in}: See illustration)

Intake System (6UZ1X) 1J-17

8. Thrust collar • Apply engine oil to the thrust collar, and install it to the turbine shaft.

9. Thrust bearing • Apply engine oil to the metal portion of the thrust bearing, and insert it to the bearing housing.

• Apply Loctite to the plate small screw threads, and install it using torque screwdriver.

0

1 12

3.08 0.02 (0.1213 0.0008)

mm(in)

Tightening torque:

3.7 N⋅m (0.38 kgf⋅m/33 lb in)

120

WSHK0147

Name 1. Common Tolerance 5. Seal ring • Insert the seal ring to the turbine shaft.

• Use new seal ring.

6. Heat protector • Install the heat protector to the bearing housing.

7. Turbine shaft • Apply engine oil to the journal portion of the turbine shaft, and insert it from the turbine side of the bearing housing.

• Take care not to damage the floating metal with the turbine shaft. Also, insert with the end gap of the seal ring facing to the oil inlet side so that its core matches with the turbine shaft.

1

Name 1. Apply Oil.

WSHK0149

1

Name 1. Apply Oil.

WSHK0150

10. Gasket • Set the gasket to the turbine housing, and install it to the bearing housing.

11. Turbine housing • Assemble by aligning the phase of the turbine housing and the bearing housing with the turbine housing positioning pin and the bearing housing hole.

Intake System (6UZ1X) 1J-18 Hammering procedure 1) Using a metal hammer (Approx. 250g in weight), lightly tap 2 to 3 times (same place), from the outer portion toward the center.

2) Do not hammer the G coupling directly. Place brass bar between as shown in the illustration.

150 ~ 200 mm (6 ~ 8 in)

2

3

4 5

WSHK0151 12. G coupling a. Check that it does not run on the turbine housing or the bearing housing. b. Tighten temporarily to the specified torque using a torque wrench.

1

7

6

WSHK0153

Tightening torque:

83 N⋅m (8.5 kg⋅m/61 lb ft)

c. Hammering: Perform the hammering of (1) to (6) in the numerical order, using the following procedure. d. Tighten to the specified torque using a torque wrench.

Tightening torque:

83 N⋅m (8.5 kg⋅m/61 lb ft)

e. Perform (c) and (d) of the above step again.

2

1

A

3 3

1

2

Name 1. Approx. φ13 mm (0.5 in) 2. Hammer 3. G Coupling 4. Bearing Housing 5. Gasket 6. Heat Shield Plate 7. Turbine Housing 13. Seal ring • Install the seal ring to the oil thrower.

• Use new one.

14. Oil thrower • Insert the oil thrower into the seal plate.

• Insert with the end gap of the seal ring facing to the oil inlet side.

15. Seal plate • Apply liquid gasket to the turbine-side flange surface. Application thickness 0.1 — 0.2mm (0.004 — 0.008 in) (B)

6

4

ThreeBond No. 1207 5

Name 1. Approx. 60° 2. Approx. 60° 3. Torque Wrench

WSHK0152

• Install the seal plate to the bearing housing.

• Apply Loctite (B) to the pot small screw threads, and install it using torque screwdriver.

Tightening torque: 23 N⋅m (2.3 kg⋅m/17 lb ft)

Intake System (6UZ1X) 1J-19

B

A

WSHK0154 16. Compressor impeller • Insert the compressor impeller to the turbine shaft.

17. Nut • Attach the box spanner to the turbine-side shaft end of the turbine shaft, and tighten the nut.

• The nut is left-hand thread. Make sure the turning direction.

Tightening torque: 7.8 N⋅m (0.80 kgf⋅m/69 lb in) 18. Compressor housing • Apply liquid gasket to the compressor-side flange surface of the seal plate. Illustration shown in the previous page (A) Application thickness 0.1 — 0.2mm (0.004 — 0.008 in) ThreeBond No. 1207 • Align the alignment marks that marked during the disassembly, and assemble the compressor housing to the seal plate.

Tightening torque: 7.9 N⋅m (0.81 kgf⋅m/70 lb in)

WSHK0156 Check after assembly • Make sure that the axial play and radial play of rotor are within the specified value.

See (1J-10) for inspection.

Preheating System (6UZ1X) 1K-1

Engine Preheating System (6UZ1X) Contents Preheating System . . . . . . . . . . . . . . . . . . . . . . . . 1K-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1K-2 Description of Function and Operation . . . . . . . 1K-2 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . 1K-3 List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1K-5 Symptom: Glow Indicator Lamp Does Not Light Up (Varies depending on the machine) . . . . . . . . . . 1K-6 Symptom: Preheating Is Not Performed . . . . . . 1K-7 Symptom: Preheating Time Is Too Long or Too Short . . . . . . 1K-8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1K-8

Preheating System (6UZ1X) 1K-2

Preheating System Service Precautions Adequate care should be taken as over-tightening the glow plug could lead to damage.

Description of Function and Operation The preheating system employs QOS-II system. Also, the timer is controlled by the controller.

Preheating System (6UZ1X) 1K-3

Function Check Check and repair of QOS II 1. System check • Disconnect the connector of the thermo-sensor (1).

• If the measured value deviates from the specified value, replace the glow relay.

Glow plug resistance value = approx. 51.5 Ω (Varies depending on the machine)

1

WSUZ0088

• Connect a voltmeter between the glow plug and the engine ground.

• Turn the starter switch to ON (engine stopped), and check the followings: - The glow indicator should come on for 3.5 seconds.

- The voltmeter should indicate the battery voltage for approx. 18 seconds.

• If the result of the inspection is unsatisfactory, check the glow relay, thermo-sensor and glow plug. If it is normal, check the engine control system.

2. Glow relay check • Use a circuit tester to measure the resistance value (between 1 and 2) of the glow relay.

3. Thermo-sensor check • Immerse the thermo-sensor into water, and check if the resistance value varies as shown in the graph while changing the water temperature.

Preheating System (6UZ1X) 1K-4

Resistance (KΩ)

Engine temperature (°C) WSUZ0152a

4. Glow plug check • Use a circuit tester to measure the resistance of the glow plug.

• If the measured value deviates from the specified value, then replace the glow plug.

Resistance of glow plug = approx. 4.3Ω (at normal temperature) Note: Use a set of six glow plugs by same manufacturer.

Preheating System (6UZ1X) 1K-5

List of Trouble Symptoms • The glow indicator lamp does not light up • Preheating is not performed • Preheating time is too long or too short

Preheating System (6UZ1X) 1K-6

Symptom: Glow Indicator Lamp Does Not Light Up (Varies depending on the machine) Condition The glow indicator lamp does not light up

Possible Cause

Correction

Slow-blow fuse blown-out

Replace the slow-blow fuse

Blown fuse

Replace the fuse

Indicator valve is burnt out

Replace the indicator valve

Preheating System (6UZ1X) 1K-7

Symptom: Preheating Is Not Performed Condition Preheating is not performed

Possible Cause

Correction

Slow-blow fuse blown-out

Replace the slow-blow fuse

Poor contact or faulty glow relay connector

Re-install or replace the glow relay

Preheating System (6UZ1X) 1K-8

Symptom: Preheating Time Is Too Long or Too Short Condition

Possible Cause

Preheating time is too long or too short

Correction

Thermo-sensor fault or open/short circuit

Replace the thermo-sensor Repair the circuit

Faulty glow plug

Replace or tighten the glow plug

Specifications Item

Model

Preheating system Glow plug rated voltage/current

Glow plug/QOS timer (V-A)

23 - 3.0

Preheating System (6UZ1X) 1K-9