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ENGINE

FE series
FE6,FE6T & FE6TA

Pub.No. SMEFES2E01

ENGINE
SERVICE MANUAL
MODEL
FE6 series

QUICK REFERENCE INDEX

GENERAL

GE

MAINTENANCE

MA

TROUBLE DIAGNOSIS

TD

ENGINE DISASSEMBLY AND REASSEMBLY DR


Applicable Engine Numbers
FE6-200001

ENGINE PROPER

EP

CYLINDER HEAD AND VALVE MECHANISM HV

FOREWORD
This manual describes the service, by system, of the
engine of FE6A, FE6B, FE6T and FE6TA models.
In order for a vehicle to perform at its best, and to
extend vehicle life, maintenance should be performed
properly. Also, overhaul and repair should be
effected in accordance with prescribed service standards.
This manual should be kept readily available in the
workshop as a helpful reference for those engaged in
servicing vehicles.
Nissan Diesel Motor Co., Ltd. reserves the right to
make changes for improvement at any time without
notice.
This manual is based on vehicles that were manufactured on or before April.1, 1998. Revisions, if any, will
be introduced in the Technical Bulletin.

1999 NISSAN DIESEL MOTOR CO., LTD.

LUBRICATION SYSTEM

LB

COOLING SYSTEM

EC

FUEL SYSTEM

EF

AIR INTAKE AND EXHAUST SYSTEM

IE

ELECTRICAL SYSTEM

EE

AUXILIARY EQUIPMENT

EA

FM edition: Mar. 2005


1st edition: Jun. 1998
9904K30-14203-100-SZ1(M)

HOW TO USE THIS MANUAL


X

A quick reference index, a black tab is provided on the first page, so you can quickly find the first
page of each chapter by mating it to the chapters black tab.

The contents are listed on the first page of each chapter.

Construction illustration:
The assembled unit is indicated. The construction illustration includes the names of the major components, items requiring adjustment after reassembling and their maintenance standards.
[EXAMPLE]

-1-

Exploded illustration:
The number given to each part in the illustration corresponds to the number attached to each part
name, and the number is determined according to the operation sequence.
No. 1, 2, 3
Disassembly sequence
Reassembly sequence is in the reverse order of disassembly.
The marks + and , affixed to the part name number indicate that the key points of operation (precautions, technique, use of special tools, and other maintenance information) are explained in the text.
+: Key points of disassembly

,: Key points of reassembly


The tightening torque necessary for maintenance and lubricating points are indicated by symbols in the
illustration.
NOTE
z

Disassembly and reassembly sequences show general examples and in some operations it
may be possible to change sequences.

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Plug
, 2. Gasket
, 3. Spring

4. Ball
5. Cover
6. Gasket

7. Driven gear assembly


,+ 8. Pump gear assembly

Marks , and + indicate that the key points of operation are explained in the text.

-2-

Removal and installation, disassembly and reassembly:


Explanation of removal and installation, disassembly and reassembly is limited to the parts indicated by
the star marks + and , affixed to the sequence number in the exploded illustration.
NOTE

If there are no + and , marks affixed to the parts, general explanation is given for those
parts.
X The following marks and abbreviations are used in this manual.
Marks:
: Tightening torque
: Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease.
: Should be lubricated with oil.
: Sealing point
: Always replace after every disassembly.
z

Abbreviations
T.D.C.:

Top dead center

I.D.:

Inside diameter

B.T.D.C.:

Before top dead center

Dia.:

Diameter

A.T.D.C.:

After top dead center

S.T.D.:

Standard

B.B.D.C.:

Before bottom dead center

O.S.:

Oversize

A.B.D.C.:

After bottom dead center

U.S.:

Undersize

O.D.:

Outside diameter

Assy:

Assembly

Engine position:

Unit:
This manual uses mainly SI units with metric and yard/pound system equivalents in braces.

Specific terms related to the maintenance standard


z Maintenance standard
Maintenance standard indicates the standard clearance when parts are assembled or the standard
performances of assembly parts.
zService limit
Service limit indicates the limit value where adjustment, correction or parts replacement must be
done.

The captions WARNING and CAUTION warn you about procedures that must be followed to prevent personal injury and/or damage to some parts of the vehicle.

-3-

Engine model:
Engine model

Max. gross output (JIS)


kW {PS}/rpm

For general markets

For TAIWAN

118 {160}/3,000

FE6A

119 {162}/3,000

FE6B

FE6

132 {180}/3,000

FE6B

135 {183}/3,000

FE6T

FE6T

151 {205}/2,800

FE6T

FE6T-Z

162 {220}/2,800

FE6T

157 {213}/2,800

FE6TA

173 {235}/2,800

FE6TA

FE6TA

Engine models specified for TAIWAN are different from those for general markets. Hereinafter, engine models will be described by specifications for general markets. For TAIWAN specifications, use the above table to
identify the engine model specification for TAIWAN when reading this service manual.
NOTE
z

Only maintenance interval information includes information for TAIWAN engine models.

-4-

- MEMO -

-5-

GE

GENERAL

CONTENTS
SPECIFICATIONS .................................. GE-1-1
ENGINE SPECIFICATIONS ............................. GE-1-1
ENGINE NUMBERS ......................................... GE-1-9
LUBRICATION ........................................ GE-2-1
PRECAUTIONS ...................................... GE-3-1

PREPARATION ................................................ GE-3-1


GENERAL REMARKS REGARDING
IN DISASSEMBLY OPERATIONS ................... GE-3-1
CLEANING AND INSPECTION ........................ GE-3-2
STANDARD TIGHTENING TORQUE ..... GE-4-1

SPECIFICATIONS

SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine models FE6A and FE6B
Engine model
Item
Max. gross output (JIS)

kW {PS}/rpm

FE6A

FE6B

118 {160}/3,000

Type

Water cooled

Number of cylinders and cylinder arrangement

6, in-line

Stroke cycle

Combustion chamber

Direct fuel injection

Valve mechanism

Overhead valve

Cylinder liner

Dry

Bore x stroke

mm (in)

108 x 126 (4.25 x 4.96)

Compression ratio

18.0
kPa {kgf/cm2, psi}/rpm

Cylinder compression

2,942 {30, 427}/200

Idling speed

600
Intake

Valve timing
Exhaust
Valve clearance mm (in)

Open (B.T.D.C.)

15

Closed (A.B.D.C.)

40

Open (B.B.D.C.)

53

Closed (A.T.D.C.)

Intake

0.3 - 0.4 (0.012 - 0.016)

Exhaust

0.3 - 0.4 (0.012 - 0.016)

Lubrication system
Lubrication
system

132 {180}/3,000

Diesel

Cooling method

Forced-circulation type

Oil pump

Gear pump

Oil filter

Cartridge type

Oil cooler

Water cooled flat tube type

Regulator valve opening pressure

kPa {kgf/cm , psi}

Cooling system
Cooling system

119 {162}/3,000

422 - 461 {4.3 - 4.7, 61 - 67}


Forced-circulation type

Radiator type
Cooling fan

Corrugated fin
Outside diameter - Number of fins
mm (in)

480 (18.90) - 6
485 (19.09) - 8

510 (20.08) - 6
485 (19.09) - 8

530 (20.87) - 6

510 (20.08) - 7
530 (20.87) - 6

Water pump

Centrifugal, belt-driven type

Thermostat

Wax pellet type

GE-1-1

SPECIFICATIONS

Engine model
Item

FE6A

FE6B

Ignition system

Compression ignition

Fuel injection timing (B.T.D.C.)

14

15

Ignition order

1-4-2-6-3-5

Fuel feed pump

Plunger type

Fuel filter

Cartridge type and primary fuel filter


Type

Bosch

Plunger diameter

mm (in)

9.5 (0.374)

9.0 (0.354)

Fuel system

Plunger lead
Fuel injection
pump

Cam lift

mm (in)

Governor

8.0 (0.315)

6.0 (0.236)

Type

Centrifugal

Type name

RAD/RLD/RFD

RLD

Type name

Conventional type
Flange type

Nozzle

Multi-jet

Identification mark

D2

kPa {kgf/cm2, psi}

Overflow valve
Injection pump outlet
opening pressure
kPa {kgf/cm2, psi} Fuel filter

19,614 {200, 2,844}


157 {1.6, 23}
108 - 147 {1.1 - 1.5, 16 - 21}

Air cleaner

Paper element (Dry: Single or dual type)


Model
External dimensions
(Length x Width x Height)

mm (in)

Maximum permissible continuous


speed

Direction of rotation

Air volume

kg (lb)/min

Compression ratio
Exhaust brake

SA (RAD, RLD)
/SAG (RFD)

SA

Number of nozzle holes

Turbocharger

RAD/RLD/RFD

Centrifugal

Nozzle holder

Air intake and exhaust system

9.0 (0.354)

Feed pump

Type

Injection pressure

9.5 (0.374)

Right lead
Injection pump

Type
Timer

Fuel injection
nozzle

12

Type

Chamber type

Cylinder type

Operating method

Vacuum type

Air type

GE-1-2

SPECIFICATIONS

Engine model
Item

Electrical system

Starting motor

FE6A

Type

Shift type

Model

0350 502 0310/0350 502 0321

Output

V-kW

24-4.5

Type
Alternator

AC, diode-rectified
0202 152 0310

Model

0202 152 0311

Output

V-A

IC-transistor type

Type

Ribbon

Voltage x Current - Number

V-A

22 x 85 - 1

Type
Air compressor

Engine rear PTO

Reciprocating type

Bore x stroke - Number of cylinders


mm (in)

85 x 40 - 1 (3.35 x 1.57 - 1)

Cooling system

Water cooled

Allowable maximum torque


Nm {kgfm, ftlbf}

343 {35, 253}

Direction of rotation

Clockwise (as viewed from the rear)

Gear ratio (PTO gear : crankshaft gear)


Vacuum pump

0201 152 0420/0201 152 0421


24-50

Regulator
Air heater

Auxiliary equipment

FE6B

1.264 (67 : 53)

Type

Vane

Model

VD-120

GE-1-3

SPECIFICATIONS

Engine model FE6T


Engine model

FE6T

Item
Max. gross output (JIS)

kW {PS}/rpm 135 {183/3,000}

Type

Water cooled

Number of cylinders and cylinder arrangement

6, in-line

Stroke cycle

Combustion chamber

Direct fuel injection

Valve mechanism

Overhead valve

Cylinder liner

Dry

Bore x stroke

mm (in)

Compression ratio

108 x 126 (4.25 x 4.96)


18.0

Cylinder compression

kPa

{kgf/cm2,

17.5
2,942 {30, 427}/200

psi}/rpm

Idling speed

600
Intake

Valve timing
Exhaust
Valve clearance mm (in)

Open (B.T.D.C.)

15

Closed (A.B.D.C.)

30

Open (B.B.D.C.)

53

Closed (A.T.D.C.)

Intake

0.3 - 0.4 (0.012 - 0.016)

Exhaust

0.3 - 0.4 (0.012 - 0.016)

Lubrication system
Lubrication
system

162 {220/2,800}

Diesel

Cooling method

Forced-circulation type

Oil pump

Gear pump

Oil filter

Cartridge type

Oil cooler

Water cooled flat tube type

Regulator valve opening pressure

kPa

{kgf/cm2,

psi}

Cooling system
Cooling system

151 {205/2,800}

422 - 461 {4.3 - 4.7, 61 - 67}


Forced-circulation type

Radiator type
Cooling fan

Corrugated fin
Outside diameter - Number of fins
mm (in)

510 (20.08) - 7
510 (20.08) - 7

580 (22.83) - 6

580 (22.83) - 7

580 (22.83) - 7

Water pump

Centrifugal, belt-driven type

Thermostat

Wax pellet type

GE-1-4

SPECIFICATIONS

Engine model

FE6T

Item
Ignition system

Compression ignition

Fuel injection timing (B.T.D.C.)

12

10

Ignition order

1-4-2-6-3-5

Fuel feed pump

Plunger type

Fuel filter

Cartridge type and primary fuel filter


Type

Bosch

Plunger diameter

mm (in)

9.0 (0.354)

Fuel system

Plunger lead
Fuel injection
pump

Cam lift

mm (in)

Governor
Timer

Right lead
Injection pump

9.0 (0.354)

6.0 (0.236)

Type

Centrifugal

Type name

RLD

Type

Centrifugal

Type name

SA

SAG
Conventional type

Nozzle holder

Flange type

Nozzle

Multi-jet

Identification mark

D3

A5

Number of nozzle holes


Injection pressure

kPa {kgf/cm2, psi}

19,614
{200, 2,844}

19,614
{200, 2,844}

108 - 147 {1.1 - 1.5, 16 - 21}


Paper element (Dry: Single or dual type)

Model
Air intake and exhaust system

21,575
{220, 3,128}
157 {1.6, 23}

Air cleaner

External dimensions
(Length x Width x Height)

mm (in)

Maximum permissible continuous


speed

Air volume

T04B

RHC62E

220 x 190 x 160


(8.66 x 7.48 x
6.30)

218 x 238 x 145


(8.58 x 9.37 x 5.71)

138,000

150,000

Counterclockwise as viewed from the exhaust turbine side

Direction of rotation
kg (lb)/min

Compression ratio
Exhaust brake

A6

Overflow valve
Injection pump outlet
opening pressure
kPa {kgf/cm2, psi} Fuel filter

Turbocharger

10.0 (0.394)

Feed pump

Type

Fuel injection
nozzle

21 (46)

18.8 (41.5)
3.2

Type

Cylinder type

Operating method

Air type

GE-1-5

SPECIFICATIONS

Engine model

FE6T

Item
Type
Starting motor

Shift type

Model

0350 502 0310/0350 502 0321

Electrical system

Output

V-kW

24-4.5

Type

AC, diode-rectified

Model

0201 152 0420/0201 152 0421

Alternator
Output

V-A

0201 152 0420


0201 152 0421

Regulator

Auxiliary equipment

Engine rear PTO

24-80
Ribbon

Voltage x Current - Number

V-A

22 x 85 - 1

Type

Air compressor

0201 222 0273

IC-transistor type

Type

Bore x stroke Number of cylinders


mm (in)

0201 152 0421

24-50

0201 222 0273

Air heater

0350 502 0321

Reciprocating type
408738-5600
408738-5601

85 x 40 - 1 (3.35 x 1.57 - 1)

408738-5611

408738-5741

85 x 40 - 1
(3.35 x 1.57 - 1)

85 x 60 - 1 (3.35 x 2.36 - 1)

Cooling system

Water cooled

Allowable maximum torque


Nm {kgfm, ftlbf}

343 {35, 253}

Direction of rotation

Clockwise (as viewed from the rear)

Gear ratio (PTO gear : crankshaft gear)

GE-1-6

1.264 (67 : 53)

SPECIFICATIONS

Engine model FE6TA


Engine model

FE6TA

Item
Max. gross output (JIS)

kW {PS}/rpm

157 {213}/2,800

Type

Diesel

Cooling method

Water cooled

Number of cylinders and cylinder arrangement

6, in-line

Stroke cycle

Combustion chamber

Direct fuel injection

Valve mechanism

Overhead valve

Cylinder liner

Dry

Bore x stroke

mm (in)

108 x 126 (4.25 x 4.96)

Compression ratio

17.5

Cylinder compression

kPa

{kgf/cm2,

2,942 {30, 427}/200

psi}/rpm

Idling speed

600
Intake

Valve timing
Exhaust
Valve clearance mm (in)

Open (B.T.D.C.)
Closed (A.B.D.C.)

Lubrication
system

15
30

40

Open (B.B.D.C.)

53

Closed (A.T.D.C.)

Intake

0.3 - 0.4 (0.012 - 0.016)

Exhaust

0.3 - 0.4 (0.012 - 0.016)

Lubrication system

Forced-circulation type

Oil pump

Gear pump

Oil filter

Cartridge type

Oil cooler

Water cooled flat tube type

Regulator valve opening pressure

kPa

{kgf/cm2,

psi}

Cooling system
Cooling system

173 {235}/2,800

Forced-circulation type

Radiator type
Cooling fan

422 - 461 {4.3 - 4.7, 61 - 67}


Corrugated fin

Outside diameter - Number of fins


mm (in)

510 (20.08) - 7

580 (22.83) - 6

580 (22.83) - 7

580 (22.83) - 7

Water pump

Centrifugal, belt-driven type

Thermostat

Wax pellet type

GE-1-7

SPECIFICATIONS

Engine model

FE6TA

Item
Ignition system

Compression ignition

Fuel injection timing (B.T.D.C.)

12

Ignition order

1-4-2-6-3-5

Fuel feed pump

Plunger type

Fuel filter

Cartridge type and primary fuel filter


Type
Plunger diameter

mm (in)

TC-MD

Bosch

11.0 (0.433)

9.0 (0.354)

Fuel system

Plunger lead
Fuel injection
pump

Cam lift

mm (in)

Governor
Timer

Right lead
Injection pump

10.0 (0.394)

Feed pump

6.0 (0.236)

Type

Centrifugal

Type name

RLD

Type

Centrifugal

Type name

SAG

Electronic (MD-TICS)

Injection timing control


Type

Conventional type

Nozzle holder
Fuel injection
nozzle

Flange type

Nozzle

Multi-jet

Identification mark

F4 or C1

Number of nozzle holes

Injection pressure

19,614 {200, 2,844}

1st: 16,672 {170, 2,417}


2nd: 21,575 {220, 3,128}

Overflow valve
Injection pump outlet
opening pressure
kPa {kgf/cm2, psi} Fuel filter

255 {2.6, 37}

157 {1.6, 23}

Air cleaner

Paper element (Dry: Single or dual type)

kPa {kgf/cm2, psi}

Air intake and exhaust system

A3

108 - 147 {1.1 - 1.5, 16 - 21}

Model
External dimensions
(Length x Width x Height)
Turbocharger

mm (in)

Maximum permissible continuous


speed

kg (lb)/min

Compression ratio
Exhaust brake

RHC6V

230 x 195 x 265


(9.06 x 7.68 x 10.43)

246 x 214 x 196


(9.69 x 8.43 x 7.72)

125,000

150,000

Counterclockwise as viewed from the exhaust turbine side

Direction of rotation
Air volume

T04E

20 (44)

19.4 (42.8)
3.2

Type

Cylinder type

Operating method

Air type

GE-1-8

SPECIFICATIONS

Engine model

FE6TA

Item
Type

Electrical system

Starting motor

Shift type

Model
Output

V-kW

24-4.5

Type
Alternator

AC, diode-rectified

Model
V-A

24-50

Regulator

IC-transistor type

Type

Ribbon

Voltage x Current - Number

V-A

22 x 85 - 1

Type

Reciprocating type

Auxiliary equipment

408738-5610
408738-5611

Air compressor

Engine rear PTO

Bore x stroke Number of cylin408738-5780


ders
mm (in)
F8040

85 x 40 - 1
(3.35 x 1.57 - 1)

85 x 40 - 1
(3.35 x 1.57 - 1)

80 x 40 - 1
(3.15 x 1.57 - 1)

Cooling system

Water cooled

Allowable maximum torque


Nm {kgfm, ftlbf}

343 {35, 253}

Direction of rotation

Clockwise (as viewed from the rear)

Gear ratio (PTO gear : crankshaft gear)


Vacuum pump

0202 152 0220/


0202 152 0221

0201 152 0421

Output

Air heater

0350 502 0310/


0350 502 0321

0350 502 0321

1.264 (67 : 53)

Type

Vane

Model

VD-30

ENGINE NUMBERS
The engine serial number is stamped on the right side of the cylinder block.
FE6-XXXXXXC*
Engine serial number
Engine model
*Engine specification
A: Natural aspirated engine
B: Natural aspirated engine
C: Turbocharged engine
D: Turbocharged engine with intercooler

GE-1-9

LUBRICATION

LUBRICATION
RECOMMENDED FUEL AND LUBRICANTS
Lubricant

Specifications

Remarks

Engine oil

API CC or CD

For further details, refer to the recommended SAE viscosity chart.

Power steering fluid

DEXRON or DEXRON II

GM ATF type

Bearing grease

NLGI No. 2

Lithium soap base

Antifreeze
Fuel

Ethylene glycol base

Above 7C (20F) 2-D Diesel fuel or equivalent blended diesel fuel Check with the service establishment to
Below 7C (20F) 1-D Diesel fuel or equivalent blended diesel fuel be sure you get the properly blended fuel.

NOTE
z

It is recommended that API CD class multi-grade oil be used as engine oil for turbocharged
engines.

RECOMMENDED SAE VISCOSITY NUMBER


Use oil having the proper viscosity beforehand which meets temperatures forecast for areas where you are planning to drive.

CAPACITIES (APPROXIMATELY)
Item
Engine oil pan (H-level)
Engine oil
Total
Power steering system

Liter (Imp measure)


FE6A, FE6B, FE6T, FE6TA

12 (2-5/8 gal)

FE6TA*

14 (3-1/8 gal)

FE6A, FE6B, FE6T, FE6TA

15 (3-1/4 gal)

FE6TA*

17 (3-3/4 gal)

MK and LK series
PK series

3 (2-5/8 qt)
5.5 (4-7/8 qt)

Cooling system

22 (4-7/8 gal)
Square type

100 (22 gal)


130 (28-5/8 gal)
200 (44 gal)
100 + 100 (22 gal + 22 gal)

Round type

109 (24 gal)


150 (33 gal)
227 (50 gal)

Fuel tank

NOTE

Capacities shown are for reference only. When filling, observe the specified level.
z * Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).
z

GE-2-1

PRECAUTIONS

PRECAUTIONS
PREPARATION
Observe the following when servicing the vehicle.
z
Park the vehicle on a flat surface; otherwise, the correct oil level cannot be checked and the vehicle
may move abruptly.
z
Engage the parking brake and chock the wheels securely.
z
If the engine is hot, wait until it cools off.
z
Set the transmission gear shift lever to NEUTRAL.
z
Turn the key switch to OFF. Disconnect the ground cable when servicing the electrical system.
z
Do not touch rotating parts of the engine if servicing requires engine operation. Always operate the
engine in a well-ventilated area.
z

When tilting the cab indoors, make sure that there is a


clearance of at least 4 m (13.1 ft) in H and a clearance of 1
m (3.3 ft) in F.

GENERAL REMARKS REGARDING IN DISASSEMBLY OPERATIONS


Checks before disassembly
Before starting to disassemble a system or unit, familiarize yourself with the cause of the problem. For
instance, if the engine is to be disassembled, the problem may be due to an unusual noise, lack of power or oil
leakage. Recognizing the problem in advance will be extremely helpful in locating which part of the engine
needs to be disassembled and which part does not. It will also save time and labor.

Work required during disassembly


Scribe alignment marks on parts where necessary so that they can be easily reinstalled in their original positions. When repairs involve the electrical system, disconnect the ground cable from the battery.

Checks during disassembly


Whenever each part is disassembled, check for mounting condition, scratches, dirt, damage, etc. Work efficiency will be degraded after all parts have been disassembled.

Keeping disassembled parts in order


Keep all disassembled parts in order so that they can be readily reinstalled. Separate parts which must be
replaced with new ones and those which should be reinstalled. Replace packings, gaskets, cotter pins, etc.
Do not touch electrical parts, rubber parts, V-belt, etc., with dirty hands. These parts should not be contaminated with water or oil. Keep them in one place and away from those having engine oil on them.

Cleaning disassembled parts


Clean all disassembled parts in cleaning solvent immediately before reassembly. If they are not cleaned,
scratches, cracks or damage may be overlooked. This may result in entry of dirt or dust, causing problems
after reassembly.

Reinstallation
Install parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.).
Apply a coat of grease, liquid packing or sealer to designated parts.

Adjustment and operational checks


Use gauges or testers to adjust the parts within specifications if so designated. Also check movable parts for
proper operation.

GE-3-1

PRECAUTIONS

CLEANING AND INSPECTION


CLEANING
The parts will be coated with dirty oil and sludge. Cleaning is mandatory. Suitable cleaning methods include
steam cleaning, light oil cleaning, acidic or alkaline solution cleaning, neutral agent cleaning, trichloroethylene
steam cleaning, and magnus solution cleaning. The cleaning process may reveal damage. So check closely
while the cleaning is in process.

METAL PARTS
Light oil
Unlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless the
surface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with two
washings.

Alkaline solution
Do not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steel
and cast iron parts quite well.
NOTE
z

If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent
(such as boric acid solution), since the alkaline solution must be immediately washed from the
skin or eyes in the event of contact.

RUBBER PARTS
Do not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.

OIL PASSAGES
Pass a wire through oil passages to make sure that they are free. Clean the oil passages with solvent that is
injected under pressure from a nozzle.

PROTECTION AGAINST CORROSION


After removing all traces of old oil and grease from the surfaces of the parts, apply a coat of clean oil to them to
prevent corrosion.

INSPECTION
Parts should be inspected using designated measuring instruments or tools. Whether the parts are suitable for
further use should be determined by consulting the specified Maintenance Standards chart. Faulty parts
should be corrected or replaced as required. If one of the mating parts is found to be worn to such an extent
that the specified clearance is exceeded, replace it and/or its mate as the occasion demands.
Parts which are still within the repair or wear limit should sometimes be replaced before they exceed the limit
from preventive maintenance viewpoint.
All parts should be checked carefully by looking at their appearance or by using the red (penetration) method,
whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities,
the affected part(s) should be repaired or replaced, as required.
All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed.
Abnormalities
z
Uneven wear
z
Graded wear
z
Scratches
z
Cracks
z
Deformity
z
Fatigue or weakness (for springs and rubbers, etc.)
z
Bends
z
Loose fit
z
Unusual noise (for bearings)
z
Discoloration or jamming
z
Rust formation
z
Deterioration (for brake linings, etc.)

GE-3-2

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE


The tightening torque of the bolts and other fasteners that secure the major components parts is specified in
the text. In case there is no mention of tightening torque, these bolts and fasteners should be tightened according to the following table of bolt standard tightening torque.
NOTE
z

All bolts and nuts are sized using the metric system. Do not use parts other than those designated.
Nominal
size

Bolt dia.
mm

Pitch
mm

M6

6.0

M8

8.0

M10

10.0

M12

12.0

M14

Standard tightening torque (Without lubricant)


4T

7T

9T

Nm

kgfm

ftlbf

Nm

kgfm

ftlbf

Nm

kgfm

ftlbf

1.0

5.1

0.52

3.8

8.4

0.86

6.2

12

1.2

1.25

13

1.3

21

2.1

15

29

3.0

22

1.0

13

1.3

22

2.2

16

31

3.2

23

1.5

25

2.5

18

41

4.2

30

59

6.0

43

1.25

25

2.6

19

43

4.4

32

62

6.3

46

1.75

42

4.3

31

71

7.2

52

98

10.0

72

1.25

46

4.7

34

77

7.9

57

108

11.0

80

14.0

1.5

74

7.5

54

127

13.0

94

177

18.0

130

M16

16.0

1.5

108

11.0

80

186

19.0

137

275

28.0

203

M18

18.0

1.5

167

17.0

123

275

28.0

203

392

40.0

289

M20

20.0

1.5

226

23.0

166

382

39.0

282

549

56.0

405

M22

22.0

1.5

304

31.0

224

510

52.0

376

736

75.0

542

NOTE

Special parts are excluded.


z This standard is applicable to bolts having the following marks embossed on the bolt head.
Mark
4T .............................. 4
7T .............................. 7
9T .............................. 9
z

Standard tightening torque of tubing connector


Standard tightening torque

Item

Nm

kgfm

4.76 (0.1874)

13 - 18

1.3 - 1.8

9 - 13

6.35 (0.2500)

16 - 24

1.6 - 2.4

12 - 17

8.0 (0.315)

29 - 39

3.0 - 4.0

22 - 29

10.0 (0.394)

39 - 49

4.0 - 5.0

29 - 36

12.0 (0.472)

59 - 78

6.0 - 8.0

43 - 58

15.0 (0.591)

69 - 93

7.0 - 9.5

51 - 69

Nipple nut [Tube O.D. 6.35 mm (0.2500 in)]

21 - 28

2.1 - 2.9

15 - 21

Eye connector [Tube O.D. 6.35 mm (0.2500 in)]

42 - 57

4.3 - 5.8

31 - 42

Flared nut

Tube O.D. mm (in)

GE-4-1

ftlbf

- MEMO -

- MEMO -

MA

MAINTENANCE

CONTENTS
SERVICE DATA ...................................... MA-1-1
SERVICE DATA ............................................... MA-1-1
TIGHTENING TORQUE ................................... MA-1-2
TOOLS .................................................... MA-2-1

PERIODIC MAINTENANCE
SCHEDULES .......................................... MA-3-1
MAINTENANCE INTERVALS........................... MA-3-2
PERIODIC PARTS REPLACEMENT ............... MA-3-4

MAINTENANCE PROCEDURE............... MA-4-1


BASIC MECHANICAL SYSTEM.......................
LUBRICATION SYSTEM ..................................
COOLING SYSTEM..........................................
FUEL SYSTEM .................................................
INTAKE AND EXHAUST SYSTEM...................
OTHERS ...........................................................

MA-4-1
MA-4-4
MA-4-9
MA-4-17
MA-4-27
MA-4-32

SERVICE DATA

SERVICE DATA
SERVICE DATA
Maintenance
standard

Service limit

Intake

0.3 - 0.4
(0.012 - 0.016)

Exhaust

0.3 - 0.4
(0.012 - 0.016)

2,942 {30, 427}

1,961 {20, 284}

Less than
392 {4, 57}

Open

15 B.T.D.C.

Closed

40 A.B.D.C.

Open

53 B.B.D.C

Closed

9 A.T.D.C.

Open

15 B.T.D.C.

Closed

30 A.B.D.C.

Open

53 B.B.D.C

Closed

9 A.T.D.C.

10 - 15 (0.39 - 0.59)

7 - 12 (0.28 - 0.47)

With a force of about


98 N {10 kgf, 22 lbf}
applied to the mid
part

39 - 59
{0.4 - 0.6, 6 - 9}

Pressure side

74.5 - 78.5
(166 - 173)

71.5 - 81.5
(161 - 179)

82 (180)

80 - 84 (176 - 183)

77 - 87 (171 - 189)

88 (190)

86 - 90 (187 - 194)

85 - 93 (185 - 199)

76.5 (170)

More than 10/90


(0.39/194)

Less than 9/90


(0.35/194)

82 (180)

More than 10/95


(0.39/203)

Less than 9/95


(0.35/203)

88 (190)

More than 10/100


(0.39/212)

Less than 9/100


(0.35/212)

Item

Valve clearance
mm (in)

Basic mechanical system

Cylinder compression pressure


kPa {kgf/cm2, psi}
Difference between cylinders

Valve
timing

FE6A
FE6B
FE6TA
173 kW
{235 PS}

Intake

FE6T
FE6TA
157 kW
{213 PS}

Intake

Exhaust

Exhaust

kPa {kgf/cm2, psi}

Fan pulley alternator pulley


V-belt deflection
mm (in) Fan pulley cooler compressor pulley
Radiator cap operating pressure
Cooling system

kPa {kgf/cm2, psi}


Valve opening
temperature
C (F)
Thermostat
Valve lift/ temperature
mm/C (in/F)

76.5 (170)

MA-1-1

Remarks

When engine is cold

At 200 rpm with


engine warm

SERVICE DATA
Maintenance
standard

Service limit

14

119 kW {162 PS}

15

132 kW {180 PS}

12

135 kW {183 PS}

12

151 kW {205 PS}

10

162 kW {220 PS}

157 kW {213 PS}

173 kW {235 PS}

12

600

650

Item
FE6A
FE6B

Fuel system

Fuel injection timing


(B.T.D.C.)

FE6T

FE6TA
FE6A, FE6B, FE6T
Idle speed

rpm

157 kW {213 PS}

FE6TA

550

Maximum speed

173 kW {235 PS}


rpm

3,200

No-load maximum engine speed

rpm

3,600

Remarks

MD-TICS system

TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Valve clearance adjusting screw lock nut


Cylinder head mounting bolt
Basic
mechanical
system

Lubrication
system
Cooling
system

34 - 44 {3.5 - 4.5, 25 - 33}


177 - 196 {18.0 - 20.0, 130 - 145}

Air intake manifold mounting bolt and nut

16 - 20 {1.6 - 2.0, 12 - 14}

Exhaust manifold mounting nut

34 - 44 {3.5 - 4.5, 25 - 33}

Compression gauge mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Crank damper mounting bolt

59 - 69 {6.0 - 7.0, 43 - 51}

Oil pan drain plug

59 - 69 {6.0 - 7.0, 43 - 51}

Alternator adjusting bolt

34 - 44 {3.5 - 4.5, 25 - 33}

Alternator anchor bolt and nut

59 - 74 {6.0 - 7.5, 43 - 54}

Cooler tension pulley lock nut

35 - 47 {3.6 - 4.8, 26 - 35}

MA-1-2

SERVICE DATA
Item

Injection pump drive coupling bolt


and nut

Injection pump drive coupling cotter bolt

Fuel
system

Delivery valve holder

FE6A, FE6B, FE6T,


FE6TA
173 kW {235 PS}

29 - 34 {3.0 - 3.5, 22 - 25}

FE6TA
157 kW {213 PS}

59 - 64 {6.0 - 6.5, 43 - 47}

FE6A, FE6B, FE6T,


FE6TA
173 kW {235 PS}

59 - 64 {6.0 - 6.5, 43 - 47}

FE6TA
157 kW {213 PS}

83 - 93 {8.5 - 9.5, 61 - 69}

FE6A, FE6B, FE6T,


FE6TA
173 kW {235 PS}

49 - 54 {5.0 - 5.5, 36 - 40}

FE6TA
157 kW {213 PS}

103 - 113 {10.5 - 11.5, 76 - 83}

Injection nozzle retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Nozzle holder mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Injection pump bleeder screw

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

Fuel filter (center bolt type) center bolt

20 - 29 {2.0 - 3.0, 14 - 22}

Primary fuel filter center bolt

Air intake
and exhaust
system

Tightening torque

Type I

20 - 29 {2.0 - 3.0, 14 - 22}

Type II

59 - 69 {6.0 - 7.0, 43 - 51}

Primary fuel filter drain plug (Type II only)

16 - 22 {1.6 - 2.2, 12 - 16}

Fuel strainer center bolt

15 - 20 {1.5 - 2.0, 11 - 14}

Fuel filter eye bolt

25 - 41 {2.5 - 4.2, 18 - 30}

T04B
Compressor housing and back
T04E
plate mounting bolt
Nm {kgfcm, inlbf} RHC62E
RHC62V
T04B
Turbine housing and center hous- T04E
ing mounting bolt
Nm {kgfcm, inlbf} RHC62E
RHC62V

MA-1-3

11.3 - 14.7 {115 - 150, 100 - 130}


7.4 - 8.3 {75 - 85, 65 - 74}
18.0 - 21.5 {184 - 219, 160 - 190}
27.0 - 28.9 {275 - 295, 239 - 256}

TOOLS

TOOLS
Tool name and number

Description

Feeler gauge
99541 Z5000

For adjusting valve clearance Thickness mm


(in): 0.25 (0.0098), 0.3 (0.012), 0.35 (0.0138),
0.4 (0.016), 0.45 (0.0177), 0.5 (0.020)

Timing plate
99646 Z5001

For measuring valve timing

Compression gauge
99640 Z5500

For measuring compression pressure

Compression gauge hose


99644 97000

Used with the compression gauge (99640


Z5500) when the gauge cannot be installed
directly due to interference with the air duct,
etc.

*Plate
157944-9520

For fixing nozzle holder

* Tool number designated by Zexel Co.

MA-2-1

Shape

TOOLS

Tool name and number

Description

Pin vice
99727 Z5005

For cleaning nozzle injection hole.

Nozzle cleaner
99726 Z5000

For cleaning injector tip.

MA-2-2

Shape

PERIODIC MAINTENANCE SCHEDULES

PERIODIC MAINTENANCE SCHEDULES


Abbreviations: A = Adjust, R = Replace, I = Inspect. Correct, adjust or replace if necessary.
C = Cleaning, RB = Rebuilding, T = Tighten to specified torque,
= Initial maintenance
NOTE

The maintenance or lubrication service shown below are to be performed at the indicated intervals (km, miles or months, whichever occurs first).
z Scheduled maintenance services beyond 60,000 km (36,000 miles) or 12 months should be continued at the same intervals as before except the initial maintenance.
z Under the following severe operating conditions, more frequent servicing will be required.
Operation in heavy dust conditions
Operation at extremely low or high ambient temperature
Extended high-speed operation with vehicle fully-loaded to its GVW (Gross Vehicle Weight)
Extended low-speed operation
Frequent stop-and-go operation
z Any replacement parts used for required maintenance service or repairs should be genuine
Nissan Diesel parts.
z

EMISSIONS CONTROL SYSTEMS MAINTENANCE


(FOR TAIWAN ONLY)
To maintain efficient emissions control systems operation, have the
maintenance services shown in this section performed at the intervals indicated.
CAUTION
z

Do not modify, alter, disconnect or remove any part of the vehicle which could affect, directly or
indirectly, vehicle emissions.

MA-3-1

PERIODIC MAINTENANCE SCHEDULES

MAINTENANCE INTERVALS
Maintenance intervals
Items

Kilometers x 1,000
Miles x 1,000

Daily

Months

10

15

20

25

30

35

40

45

50

55

60

0.6

12

15

18

21

24

27

30

33

36

10

11

12

Valve clearance

Cylinder head and manifold bolts

T
I : After 200,000 km (125,000 miles)

Crank damper

I: Every 100,000 km (62,500 miles)

Cylinder compression pressure

Oil leakage

Oil level and contamination

Engine oil and


filter

Remarks

Full-flow type

R: Every 10,000 km (6,000 miles) or 6 months

(1)

Full-flow and bypass


type

R: Every 15,000 km (9,000 miles) or 6 months

(1)

Coolant leakage

Coolant level

I
I

Coolant (incl. anticorrosive)

I
I

I
I

I
R

(3)

Coolant (incl. antifreeze)

(4)

Radiator cap

Fan clutch
V-belt

I
I

Thermostat

Injection timing

Nozzle (injection pressure and pattern)

Fuel leakage

Fuel filter element

R
I
I
I
I
I
I
I
I
I
I
I
I
Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain

Primary fuel filter


Primary fuel filter element

Fuel strainer
Fuel level

I
Drain

I
Drain

I
Drain

I
Drain

I
Drain

I/C
Drain

I/C

I/C

I/C

I/C

I/C

I/C

(2)

(2)

Air cleaner element


Air cleaner element (Dry type)
Condition of exhaust

Turbocharger

I
I

(5)

Remarks:
(1) Replace the engine oil and oil filter whenever the oil filter warning light comes on, even before the scheduled replacement.
(2) If the warning light comes on even before the scheduled replacement, clean or replace element.
(3) Service every 6 months.
(4) Service every 12 months.
(5) With turbocharger engine equipped vehicles only.

MA-3-2

PERIODIC MAINTENANCE SCHEDULES

For Taiwan only


Maintenance intervals
Maintenance
Item

Kilometers x 1,000
Miles x 1,000

Daily

Months

10

15

20

25

30

35

40

45

50

55

60

0.6

12

15

18

21

24

27

30

33

36

10

11

12

*Idle speed

Acceleration and deceleration

*Air intake system (duct, hose and


clamp)

Intake* and exhaust manifold

I/C

I/C

I/C

I/C

I/C

Cylinder compression pressure

R
I

*Valve clearance

Oil CC or CD class
*Engine oil and
oil filters
Oil CD class
*Engine oil and
bypass oil filter Oil CD class
(if equipped)
Oil level and contamination

I
I

*Air cleaner element

Every 10,000 km (6,000 miles) or 6 months : R

FE6 engine

Every 10,000 km (6,000 miles) or 6 months : R

FE6T, FE6T-Z
and FE6TA
engines

Every 15,000 km (9,000 miles) or 6 months : R

Oil pressure

Coolant and fuel level

Coolant, oil and fuel leakage

Strainer (if equipped)

*Fuel filter element

*Primary fuel filter element


(if equipped)

I
I
I
I
I
Drain Drain Drain Drain Drain

*Governor setting (checking seals)

I
I
I
I
I
Drain Drain Drain Drain Drain

Every 30,000 km (18,000 miles) or 6 months : I

*Nozzle (injector tip)

Every 80,000 km (50,000 miles) : C

*Nozzle holder (injector)

Every 240,000 km (145,000 miles) : RB

*Injection timing

Every 60,000 km (36,000 miles) or 12 months : I

Fuel tubing

Accelerator linkage

Drive belt (V-belt)

Crank damper

Every 24 months : I

Cooling system (hose and clamp)

Engine coolant

Water filter (if equipped)

Thermostat

Fan clutch

Fan and fan shroud

Exhaust tubing and muffler

Alternator

Starter

*PCV valve
*PCV system

*Turbocharger

Remarks

Every 80,000 km (50,000 miles) : R


(hose and clamp)

I
I

(piping)
Every 240,000 km (145,000 miles) : C

* refers to items related to the Emission Control System Maintenance.

MA-3-3

FE6 engine

FE6 engine

FE6 engine
FE6T, FE6T-Z
and FE6TA
engines

PERIODIC MAINTENANCE SCHEDULES

PERIODIC PARTS REPLACEMENT


Periodic replacement parts are rubber parts such as the fuel hose, etc. which deteriorate with the lapse of time
and require maintenance. It is absolutely necessary to replace those parts periodically to maintain driving
safety.
Items

PERIODIC PARTS REPLACEMENT INTERVAL


Number of years

10

Remarks

ENGINE
Fuel hose (engine side)

Fuel hose (fuel tank side)


Air compressor rubber hose

R
R

Remarks: (1) AOH brake vehicles.

MA-3-4

R
R

(1)

MAINTENANCE PROCEDURE

MAINTENANCE PROCEDURE
BASIC MECHANICAL SYSTEM
VALVE CLEARANCE
NOTE
z

Ensure the engine is cool when checking and adjusting


the valve clearance.

1.
2.

Remove the rocker cover.


Remove the pointer cover from the upper section of the flywheel housing. Secure the pointer to the flywheel housing
using bolts.
Using a lever, rotate the ring gear on the outer edge of the
flywheel in the standard direction (or counterclockwise as
viewed from the flywheel side) until the mark 16 stamped
on the outer edge of the flywheel is aligned with the pointer.
If the mark goes past the pointer, back it off past the pointer
and then rotate in the standard direction until the mark is
aligned with the pointer. At this point, if the mark stamped
on the fuel injection pump timer is nearly aligned with the
mark on the pump housing, the No. 1 cylinder is at TDC
(Top Dead Center) on the compression stroke. If the mark
on the timer is not visible, the No. 6 cylinder is at TDC on
the compression stroke.
Valve clearances (1), (2), (4), (5), (8) and (9) can be
checked and adjusted when No. 1 cylinder is at TDC on the
compression stroke; valve clearances (3), (6), (7), (10), (11)
and (12) can be checked and adjusted when the No. 6 cylinder is at TDC on the compression stroke.

3.

4.

5.

Place a feeler gauge between the valve stem and rocker


arm to ensure that the gauge fits snugly.
Unit: mm (in)
Maintenance standard

Service
limit

Intake

0.3 - 0.4 (0.012 - 0.016)

Exhaust

0.3 - 0.4 (0.012 - 0.016)

Item
Valve
clearance

Remarks
When
engine is
cold

MA-4-1

MAINTENANCE PROCEDURE

Valve clearance adjustment


1.
2.

3.
4.

If the valve clearance is not correct, loosen the lock nut for
the adjusting screw and adjust the screw until the specified
clearance is obtained.
After adjusting the valve clearance, hold the adjusting
screw and tighten the lock nut.
: 34 - 44 Nm {3.5 - 4.5 kgfm, 25 - 33 ftlbf}
Recheck the valve clearance.
Rotate the flywheel one complete turn until the mark 16 is
aligned with the pointer. Next, check and adjust the remaining valve clearances.
If the engine operates erratically or vibrates even though
the valve clearances are properly adjusted, problems may
be due to improperly adjusted valve timing which results
from incorrect assembling of the timing gear train, etc. If
erratic operation is noticed, check the valve timing as
described below.

Procedure for checking valve timing


1.
2.

Remove the V-belt, cooling fan and crank pulley assembly.


Turn the flywheel in the normal direction until the No. 1 piston is at the TDC on the compression stroke.
NOTE
z If the flywheel has been rotated excessively, rotate it
backwards beyond the desired position then gradually
rotate it back in the normal direction until it is set in the
proper position.

3.
4.

Attach the timing plate (99646 Z5001) to the end of the


crankshaft. Also attach a needle pointer utilizing the front
cover mounting bolt, and align the needle to 0.
Set a dial gauge so that the contact arm is in contact with
the upper valve spring seats of the intake valve and exhaust
valve.

MA-4-2

MAINTENANCE PROCEDURE
5.

If the needle of the dial gauge begins to move, it means that


the valve is beginning to open; the movement of the needle
will stop as the valve closes. Read the needle position on
the timing plate on each occasion.
Maintenance
standard

Item

Valve
timing

FE6A
Intake
FE6B
FE6TA
173 kW
Exhaust
{235 PS}
FE6T
Intake
FE6TA
157 kW
{213 PS} Exhaust

Service
Remarks
limit

Open

15 B.T.D.C.

(1)

Closed

40 A.B.D.C.

(2)

Open

53 B.B.D.C.

(3)

Closed

9 A.T.D.C.

(4)

Open

15 B.T.D.C.

(1)

Closed

30 A.B.D.C.

(2)

Open

53 B.B.D.C.

(3)

9 A.T.D.C.

(4)

Closed

CYLINDER HEAD AND MANIFOLD BOLTS


Check the cylinder head, air intake and exhaust manifold mounting
bolts and nuts for proper torque. Also check the manifolds for damage or traces of leakage at the cylinder head connections.
Cylinder head mounting bolt
: 177 - 196 Nm {18.0 - 20.0 kgfm, 130 - 145 ftlbf}
Air intake manifold bolt
: 16 - 20 Nm {1.6 - 2.0 kgfm, 12 - 14 ftlbf}
Exhaust manifold bolt
: 34 - 44 Nm {3.5 - 4.5 kgfm, 25 - 33 ftlbf}

CRANK DAMPER
Check the crank damper for cracks or flaking, and the mounting
bolts for looseness. Replace faulty parts if necessary.
Crank damper mounting bolt
: 59 - 69 Nm {6.0 - 7.0 kgfm, 43 - 51 ftlbf}

CYLINDER COMPRESSION PRESSURE


1.
2.

Warm up the engine.


Disconnect all nozzle tubes and remove all nozzle holders.
Refer to the DR section for details.

MA-4-3

MAINTENANCE PROCEDURE
3.

Install a compression gauge (99640 Z5500) on the nozzle


hole using a nozzle holder gasket. Press the gauge bleeder
to set the pointer to zero.
Compression gauge mounting bolt
: 25 - 29 Nm {2.5 - 3.0 kgfm, 18 - 22 ftlbf}
NOTE
z Be careful to prevent foreign matter from getting into the
other nozzle holder holes.
z Be sure to remove the old nozzle holder gasket.
4. Move the engine stop lever completely in the FUEL CUT
direction and hold it at that position.
5. Crank the engine until the gauge pointer stabilizes. Read
the cylinder compression pressure. Measure compression
pressure for the remaining cylinders as described above. If
the measured values or the differences in compression
pressure between cylinders are not within specifications,
pistons and/or piston rings may be worn or the valve mechanism may be faulty. Overhaul the engine and repair as
necessary.
Unit: kPa {kgf/cm2, psi}
Item
Compression
pressure
Difference
between cylinders

Maintenance standard

Service limit

Remarks

2,942 {30, 427}

1,961
{20, 284}

At 200 rpm
with engine
warm

Less than 392 {4, 57}

NOTE
z

The above engine rpm range refers to that when the battery is fully charged and the starting motor is in good
condition.

LUBRICATION SYSTEM
OIL LEAKAGE
Check the cylinder head, timing gear case cover, oil pan, oil filters
and other related parts for sign of leakage. If necessary, replace
gaskets. After replacing the gasket, check that point to ensure there
is no leakage.

OIL LEVEL AND CONTAMINATION


WARNING
WARNING
z

To help avoid serious personal injury from hot engine oil,


perform lubrication system checks and maintenance
only after the engine has cooled.

MA-4-4

MAINTENANCE PROCEDURE
Check the engine oil level and for contamination of engine oil
before driving the vehicle each day and when you stop for fuel.
Check the oil level with the engine off. When checking the oil level
after stopping the engine, wait at least 15 minutes to allow the oil to
return to the oil pan.

To check the engine oil level


1.
2.

Park the vehicle on a flat surface.


Remove the oil dipstick located on the left hand side of the
engine. Wipe the dipstick clean with a rag and reinsert it.
Remove the dipstick and check the oil level. Maintain the oil
level between the H and L marks on the dipstick.

3.

If oil level is low, add engine oil of the proper viscosity for
the anticipated temperature range during the service interval through the oil filler port located on the valve cover on
top of the engine. Do not add oil above the H mark on the
dipstick.
CAUTION
z Use care to keep dirt and debris from entering the crankcase through the oil filler port when adding engine oil.
Avoid spilling oil. Clean up any engine oil that spills accidentally.
4.

Change the oil if it shows signs of contamination such as


discoloration and changes in oil texture. See the instructions in this manual under the caption CHANGING ENGINE
OIL.
5. After adding oil, wait at least 6 minutes, then recheck the oil
level.
6. After checking, securely insert the oil dipstick.
CAUTION
z Do not drive the vehicle with the oil level below the L
mark on the oil dipstick. An insufficient quantity of
engine oil can cause engine seizure.

To check for engine oil contamination


Remove the oil dipstick and check the oil on it for signs of contamination such as discoloration and changes in texture. See the
instructions in this manual under the caption ENGINE OIL AND OIL
FILTER.

MA-4-5

MAINTENANCE PROCEDURE

CHANGING ENGINE OIL AND OIL FILTER


Engine oil
WARNING
WARNING
z

To help avoid serious personal injury from hot engine oil,


perform lubrication system checks and maintenance
only after the engine has cooled.

NOTE
z

Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner
as soon as possible.

The engine oil and oil filter change interval varies with the type of
engine oil used and vehicle driving conditions. If the vehicle is
driven for extended periods of time at high or low speeds, in dusty
areas, with frequent idling or carrying heavy loads, engine oil will
deteriorate faster and require more frequent changing.
As the temperature rises, the engine oils viscosity decreases,
reducing its lubricating effect. To choose an oil with the proper viscosity for the anticipated ambient temperature range, refer to the
viscosity chart in the GE section of this manual.
To change the engine oil
1. Loosen the oil filler cap.

2.
3.

Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly (if equipped).
Place a container under the drain plugs in the bottom of the
oil pan and oil filter. Remove the plugs and drain the oil into
the container.

MA-4-6

MAINTENANCE PROCEDURE
4.

5.
6.
7.

8.

When all the oil has been drained from the oil pan and oil filter, replace the drain plugs in the drain hole and tighten the
drain plug.
Oil pan drain plug
: 59 - 69 Nm {6.0 - 7.0 kgfm, 43 - 51 ftlbf}
Replace the oil filter. See the instructions under the caption
OIL FILTER.
Add engine oil through the oil filler port to the specified
level.
After refilling the engine oil, wait for at least 6 minutes, then
using the dipstick check the oil level. If the oil level is low,
add additional oil. Wait 6 minutes, then recheck the oil level.
Repeat this procedure until the engine oil reading on the
dipstick is between H and L.
Install the engine undercover (if equipped).

Oil filter
WARNING
WARNING
z

Do not handle hot oil filter without hand protection. Failure to do so may result in burn injury.

NOTE

Use genuine filter or equivalent in quality and design.


z Use of an inferior filter could hinder engine operation and
emission controls.
z Always replace the oil filter at the same time engine oil is
replaced.
z

MA-4-7

MAINTENANCE PROCEDURE
To replace the oil filter
1. Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly (if equipped).
2. Place a container under the oil filter and remove the drain
plug in the bottom of the oil filter. Drain oil from the filter.
3. Remove the filter with a filter wrench and drain all oil into
the container.

4.

Apply a thin coat of clean engine oil to the packing of a new


oil filter.
CAUTION
z Installation of the oil filter without coating the packing
with oil may damage the packing, resulting in loss of
engine oil and damage to the engine and/or lubrication
system.

5.

Install the new filter by hand. After the packing comes in


contact with the bracket sealing surface, tighten an additional 3/4 turn (Full flow only type) or 1-1/8 to 1-1/8 turn (Full
flow & bypass combination type).
CAUTION
z When installing an oil filter, tighten it by hand. Do not use
a wrench or other tools which could result in overtightening and damage to the filter.
6.
7.

Run the engine. Check the filter and seal for leaks.
After checking, install the under cover.

MA-4-8

MAINTENANCE PROCEDURE

COOLING SYSTEM
The engine cooling system was filled at the factory with a high-quality, year-round, coolant solution with a 50/50 antifreeze/water mixture. The antifreeze solution contains rust and corrosion inhibitors.
The solution provides protection against freezing to approximately 30C (-22F). The solution must remain in the system year round to
provide protection against freezing, boiling, rust and corrosion. Do
not use additional cooling system additives or inhibitors. They may
interfere with the proper operation of the cooling system.
Check the engine, radiator, hoses and pipes daily. Repair any
leaks. Replace swollen and worn hoses and tighten loosen clamps.
Check the OVERHEATING AND COOLANT LEVEL warning light
daily to be sure that it does not operate.
WARNING
WARNING

To help avoid serious personal injury from hot coolant or


steam release:
z Do not open the radiator filler cap while the engine cooling system is hot. Wait until it cools down.
z Be extremely careful when opening the radiator filler cap.
Place a thick cloth on the cap and slowly loosen it to
allow a reduction in pressure in the cooling system.

COOLANT LEAKAGE

Check the cooling system for leakage, especially at tube and hose
connections. Also check piping for fractures, cracks or damage.
Replace parts if faulty.
If water leaks through the small hole in the water pump body, the
water seal may be faulty.
Disassemble and repair the water pump.

MA-4-9

MAINTENANCE PROCEDURE

WATER HOSE AND CLAMP


Check the water rubber hose and clamp of the cooling system for
installation, cracks or damage. Replace faulty parts if necessary.

COOLANT LEVEL
WARNING
WARNING
To help avoid serious personal injury from hot coolant or
steam release:
z Do not open the radiator filler cap while the engine cooling system is hot; wait until it cools.
z Be extremely careful when opening the radiator filler cap.
Place a thick cloth on the cap and slowly loosen it to
allow a reduction in pressure in the cooling system.
z If the coolant is accidentally ingested, force the person to
vomit and secure medical help immediately. If the coolant gets in the eye, flood the eye with lots of water and
get medical attention immediately.
Open the front lid.
Check the coolant level daily only when the engine is cool.
Check the coolant level in the coolant reservoir tank located behind
the front lid.
The coolant level should be between the HIGH and LOW lines. If
the coolant level is below the LOW line, add the proper coolant
solution to the HIGH line.
Be sure to use an ethylene glycol antifreeze with water at the
proper mixture ratio. To ensure the proper mixture ratio, carefully
read the instructions on the container or obtain the instructions from
the antifreeze manufacturer. Examples are shown below.
Outside temperature
down to

Antifreeze

Soft water

-10 (14)

30%

70%

-20 (-4)

40%

60%

-30 (-22)

50%

50%

C (F)

Antifreeze concentration greater than 60 to 70% will adversely


affect freezing protection, corrosion inhibitor additives and heat
transfer rates. Follow the instructions on the container or obtain the
instructions from the antifreeze manufacturer for proper concentration.
A complete drain, flush and refill with proper antifreeze and coolant
is recommended once a year. This recommendation applies to all
vehicles including those with low total annual mileage.

MA-4-10

MAINTENANCE PROCEDURE
CAUTION

Antifreeze made with methoxy propanol or propylene


glycol is not recommended for use with Nissan Diesel
engines. These types of antifreeze can damage engine
internal seals and coolant hoses and create a potential
fire hazard due to lower flash points than ethylene glycol
type antifreeze.
z Use only municipally supplied water (tap water) in the
cooling system. River, well or other water produces scale
in the cooling system, which may cause damage to the
engine or cooling system.
z Do not add water without adding ethylene glycol antifreeze to the engine cooling system, except in an emergency. If plain water is added in an emergency, restore
the proper mixture of antifreeze and water as soon as
possible.
z If the coolant should get extremely low and the engine
very hot, let the engine cool before adding coolant; then,
with the engine running, add coolant slowly. Adding cold
coolant to a hot engine may crack the cylinder head or
crankcase. Never use water alone.
z

CHECKING AND CLEANING RADIATOR


To maintain cooling system efficiency and keep the engine from
overheating, always keep the front surface of the radiator core
clean. Remove insects, dirt and other debris by directing pressurized air at the rear surface of the radiator core.
CAUTION
z

Do not direct pressurized air to the front surface of the


radiator (that is, with the air hose pointed toward the
engine). Doing so will force insects, dirt and other debris
into the radiator core and possibly cause engine overheating.

CHANGING COOLANT
WARNING
WARNING
To help avoid serious personal injury from hot coolant or
steam release:
z Do not open the radiator filler cap while the engine cooling system is hot. Wait until it cools down.
z Be extremely careful when opening the radiator filler cap.
Place a thick cloth on the cap and slowly loosen to allow
a reduction in pressure in the cooling system.

MA-4-11

MAINTENANCE PROCEDURE
Once a year the cooling system should be drained and thoroughly
flushed.
Unless the cooling system is treated with a corrosion preventive,
rust and scale will eventually clog up passages in the radiator and
water jackets. This condition is aggravated in some localities by formation of insoluble salts from the water used.
CAUTION
z

Do not use chemical mixtures to stop radiator leaks


except in an emergency. Never use such solutions in
place of needed radiator repair.

To clean the cooling system


1.
2.
3.

Move the heater control temperature lever to the HOT position.


Open the radiator filler cap.
Place containers under the radiator drain cock and the cylinder block drain cock.

4.

Connect a drain hose to the radiator drain cock.

5.

Open the radiator drain cock and the cylinder block drain
cock.
Drain all coolant solution from the system into the containers.
Shut the drain cocks. Fill the cooling system with a proper
mixture of water and a good quality cooling system detergent. (Refer to the additional instructions on the detergent
container.)
Start the engine and run it at a high idling speed until the
indicator points to the middle region of the coolant temperature gauge. Maintaining the above coolant temperature with
the thermostat open, run the engine and allow the detergent
to circulate throughout the cooling system for at least 15
minutes.
Stop the engine. Open the drain cocks and completely drain
the detergent from the system.

6.
7.

8.

9.

MA-4-12

MAINTENANCE PROCEDURE
10. Shut the drain cocks and fill the cooling system with plain
water. Start the engine and run it at a moderate speed in
the same manner as described in step 8.
11. Stop the engine. Open the drain cocks and drain the rinsing
water.
12. Repeat rinsing procedure 2 or 3 times until the discharged
rinsing water appears clean.
13. Drain the coolant from the coolant reservoir tank as necessary.
14. Close the drain cocks and remove the drain hose from the
radiator drain cock.

To fill up the cooling system (with coolant)


Use the following refill procedure to remove air from the system and
provide proper coolant level.
1. Fill the radiator slowly with the proper coolant solution up to
the filler opening.
Add coolant solution up to the HIGH level of the coolant reservoir tank.
The cooling system holds approximately 22 liters (4-7/8 Imp
gal) of coolant solution.
Then properly close the radiator filler cap and the reservoir
tank cap.
2. Operate the engine at a slightly higher than normal idling
speed with the engine idling control button until the coolant
temperature indicator points the middle region of the gauge.
Run the engine an additional 10 minutes to allow the air to
escape from the engine cooling system.
3. Stop the engine. After the engine has completely cooled
down, remove the radiator filler cap and check the coolant
level in the radiator. If low, add coolant to the radiator filler
opening.
Reinstall the radiator filler cap.
4. Check the coolant level in the coolant reservoir tank. If the
level is between the LOW and HIGH lines, it is normal. If it is
below the LOW level, add coolant solution up to the HIGH
level.
5. If the added coolant solution is more than 500 milliliter (17.6
Imp fl oz), check and correct for any sign of leakage, then
repeat steps 1 to 4.
6. Check the drain cock for leaks.

COOLIG FAN AND FAN SHROUD


Check the cooling fan and fan shroud for proper installation, cracks
or damage. Replace faulty parts.
WARNING
WARNING

Never get your hand near the fan, when the engine is
operated.
z If fan clutch is equipped, the fan rotating speed may
seem to slow when the coolant is cool, but never try to
touch the fan and other rotating parts while the engine is
running.
z

MA-4-13

MAINTENANCE PROCEDURE

RADIATOR CAP
Attach the radiator cap to a cap tester, and measure the operating
pressure of the radiator cap valve. If the measured value exceeds
the maintenance standard, replace.
Unit: kPa {kgf/cm2, psi}
Maintenance standard

Service limit

39 - 59 {0.4 - 0.6, 6 - 9}

FAN CLUTCH
Ensure that the engine is off when checking the fan clutch.
1. Check the fan clutch for oil leakage. If leakage is present,
replace the fan clutch assembly.
2. Check the fan clutch for proper operation:
z
Rotate the cooling fan by hand (adjacent parts should be
cool) to ensure it moves smoothly without binding.
z
Then, start the engine and operate it until the pointer of the
water temperature gauge stays within the H range. Stop
the engine to ensure that the cooling fan no longer rotates
by hand.
NOTE
z

The fan clutch operates in a manner similar to a direct


drive when the temperature of parts near the bimetal
located at the front center of the clutch reaches approximately TC (TF). For this reason, it is best to measure
the temperature of those parts to assure proper maintenance during inspection.

Unit: C (F)
Item
FE6A
FE6B 119 kW {162 PS}
FE6B 132 kW {180 PS}
FE6B 132 kW {180 PS}
FE6T 135 kW {183 PS}
FE6T 151 kW {205 PS}
FE6TA 157 kW {213 PS}
FE6T 151 kW {205 PS}
FE6T 162 kW {220 PS}
FE6TA 157 kW {213 PS}
FE6TA 173 kW {235 PS}

FD1300L

ON - OFF
type

Run the
engine
continuously

Operating
temperature (T)

3,000
rpm

755
(1679)

FDL1700
Linear
type
FDL2000

3,400
rpm

6510 805
(14918 1769)
5010 805
(12218 1769)

MA-4-14

MAINTENANCE PROCEDURE

V-BELT
Be sure the engine is off and the transmission is in Neutral.
Engage the parking brake securely.
1. Visually check the V-belt daily for cracks and damage. If the
belt is cracked or damaged excessively, replace it. Also
check that the belt does not come in contact with the bottom
of the pulley groove. Replace the belt if necessary.

2.

Check the drive belt for proper deflection by depressing the


midpoint with a force of 98 N {10 kgf, 22 lbf}.
Unit: mm (in)
Item

Maintenance standard

Service limit

Fan pulley - alternator pulley

10 - 15 (0.39 - 0.59)

Fan pulley - cooler pulley

7 - 12 (0.28 - 0.47)

<To adjust V-belt deflection>


Fan belt
1. Loosen the alternator anchor bolt and the adjusting bolt.

2.

3.

Adjust the alternator position so that the belt deflects as


specified and tighten the adjusting bolt.
: 34 - 44 Nm {3.5 - 4.5 kgfm, 25 - 33 ftlbf}
Tighten the alternator anchor bolt.
: 59 - 74 Nm {6.0 - 7.5 kgfm, 43 - 54 ftlbf}

Cooler belt
1. Loosen the lock nut.
2. Adjust the belt tension to the specified value by the adjusting bolt.
3. Tighten the lock nut.
: 35 - 47 Nm {3.6 - 4.8 kgfm, 26 - 35 ftlbf}

MA-4-15

MAINTENANCE PROCEDURE

THERMOSTAT
1.
2.

3.
z

Drain coolant completely. Refer to the CHANGING COOLANT for procedures.


Remove the upper radiator hose, water outlet and thermostat.

Check the thermostat as described below, and replace if


faulty.
Ensure that the valve contacts the seat at room temperature.
Check the valve opening temperature and the lift of the
valve.
Item
76.5 (170)
Valve opening
temperature
82 (180)
C (F)

Thermostat

88 (190)
76.5 (170)
Valve lift/ temperature
82 (180)
mm/C (in/F)
88 (190)

Maintenance
standard

Service limit

74.5 - 78.5
(166 - 173)

71.5 - 81.5
(161 - 179)

80 - 84
(176 - 183)

77 - 87
(171 - 189)

86 - 90
(187 - 194)

85 - 93
(185 - 199)

More than 10/90


(0.39/194)

Less than 9/90


(0.35/194)

More than 10/95


(0.39/203)

Less than 9/95


(0.35/203)

More than 10/100


(0.39/212)

Less than 9/100


(0.35/212)

NOTE
z

4.
5.

The valve opening temperature (82, 88, etc.) is marked on


the thermostat.
Ensure that the difference between the valve opening and
closing temperatures is less than 5C (9F).
Install the thermostat, the outlet and the gasket. Connect
the upper radiator hose. Three types of thermostats, which
open at different temperatures, are used.
Add coolant to the radiator. Refer to CHANGING COOLANT for procedures.

MA-4-16

MAINTENANCE PROCEDURE

FUEL SYSTEM
WARNING
WARNING
Observe the following when removing parts of the fuel system:
z Post a placard that reads: CAUTION: FLAMMABLE.
z Prepare a fire extinguisher.
z Disconnect the ground terminal from the battery.

GOVERNOR SETTING
Make sure that the parts shown in the figure below are secured with
sealing caps and wires. If the cap or wire is broken, check and
adjust the injection pump and governor.
CAUTION
z

Any unauthorized adjustments in the injection pump and


governor settings, other than as specified, can cause
serious damage to the engine.

INJECTION TIMING
1.
2.

Remove the pointer cover. Secure the pointer to the flywheel housing using bolts.
Crank the engine in the standard direction by turning the flywheel with a lever until the pointer is aligned with the timing
mark.
Maintenance
standard

Service
limit

14

119 kW {162 PS}

15

132 kW {180 PS}

12

135 kW {183 PS}

12

151 kW {205 PS}

10

162 kW {220 PS}

157 kW {213 PS}

173 kW {235 PS}

12

Item
FE6A
FE6B
Fuel
injection
timing

FE6T

FE6T
A

Remarks

MD-TICS
system

NOTE
z

If the mark goes past the pointer, move it back past the
pointer and turn again in the standard direction until
alignment is made.

MA-4-17

MAINTENANCE PROCEDURE
3.

The flywheel is correctly positioned if the timing mark is set


as shown in the figure.

4.

If the timing mark is slightly out of alignment, crank the


engine until the correct alignment is made. There is no
problem as long as the timing mark on the flywheel is somewhere between the following value.
Engine model

FE6A
FE6B

FE6T

FE6TA

Timing mark

Remarks

13 - 15
119 kW {162 PS}

14 - 16

132 kW {180 PS}

11 - 13

135 kW {183 PS}

11 - 13

151 kW {205 PS}

9 - 11

162 kW {220 PS}

8 - 10

157 kW {213 PS}

2 - 4

173 kW {235 PS}

11 - 13

MD-TICS system

If the timing mark is not within this range, adjust as follows:

Adjustment of fuel injection timing ..... Method 1


z
Loosen the coupling bolts (two places).

MA-4-18

MAINTENANCE PROCEDURE
z

Slightly back the timer off in the direction opposite to that in


which the engine rotates, then move it in the standard direction until the timer mark is aligned.
Tighten the coupling bolts (nut) and cotter bolt.
Coupling bolt and nut
: FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS}
29 - 34 Nm {3.0 - 3.5 kgfm, 22 - 25 ftlbf}
: FE6TA 157 kW {213 PS}
59 - 64 Nm {6.0 - 6.5 kgfm, 43 - 47 ftlbf}
Cotter bolt
: FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS}
59 - 64 Nm {6.0 - 6.5 kgfm, 43 - 47 ftlbf}
: FE6TA 157 kW {213 PS}
83 - 93 Nm {8.5 - 9.5 kgfm, 61 - 69 ftlbf}

Adjustment of Fuel Injection Timing ..... Method 2


If the engine continues erratic operation even though method 1
above is conducted, the camshaft or bearings, etc. may be worn to
such an extent that fuel injection timing is not properly adjusted. To
check and adjust fuel injection timing, proceed as follows:
1.
2.

3.
4.
5.
6.

Remove the nozzle pipe.


Remove the delivery valve holder of the No. 1 cylinder, take
out the delivery valve spring, and tighten the delivery valve
holder to the specified torque.
: FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS}
49 - 54 Nm {5.0 - 5.5 kgfm, 36 - 40 ftlbf}
: FE6TA 157 kW {213 PS}
103 - 113 Nm {10.5 - 11.5 kgfm, 76 - 83 ftlbf}
Rotate the flywheel in reverse direction until the No. 1 piston is 25 B.T.D.C. on compression stroke.
Set the fuel control lever in the full-injection position.
Slowly rotate the flywheel in the normal direction while feeding fuel by the priming pump.
Fuel injection starts when fuel stops discharging from the
delivery valve holder. At this point, the timing mark on the
flywheel should be somewhere between the following value.
Engine model

FE6A
FE6B

FE6T

FE6TA

Timing mark

Remarks

13 - 15
119 kW {162 PS}

14 - 16

132 kW {180 PS}

11 - 13

135 kW {183 PS}

11 - 13

151 kW {205 PS}

9 - 11

162 kW {220 PS}

8 - 10

157 kW {213 PS}

2 - 4

173 kW {235 PS}

11 - 13

MD-TICS system

NOTE
z

Perform this measurement at least three times, and calculate the average value.
MA-4-19

MAINTENANCE PROCEDURE

IDLE SPEED
NOTE
z

1.
2.
3.

When checking engine idle speed, make sure that the


engine idle control knob inside the cab is set to the lowspeed position.
The state of the exhaust shutter (open or closed) is not
specified.
Start the engine and warm it up to the normal operating
temperature.
Allow the engine to idle and observe the engine speed on
the tachometer.
If idle speed is not within specified range, adjust as follows:
Unit: rpm

Idle
speed

Item

Maintenance
standard

Service limit

FE6A, FE6B, FE6T

600

157 kW {213 PS}

650

173 kW {235 PS}

550

FE6T
A

NOTE

If equipped with an air conditioner, the air conditioner


switch must be turned off when checking idle speed.
z Be sure to adjust the idling with the magnetic valve wiring of the exhaust shutter disconnected. If the wiring is
connected, the idling cannot be adjusted correctly as the
exhaust shutter is closed.
z

Idle speed adjustment


1.
2.
3.

Loosen the lock nut on the idle adjusting bolt.


Turn the idle adjusting bolt to obtain the correct idle speed.
Tighten the lock nut.
: 15 - 20 Nm {1.5 - 2.0 kgfm, 11 - 14 ftlbf}
NOTE
z Accelerate the engine two or three times. Allow the
engine to return to idle speed and observe the tachometer reading. If the idle speed is not within the specified
range, check the accelerator linkage for binding and
repeat idle adjustment.
4.

After adjustment, connect the magnetic valve wiring of the


exhaust shutter.

ACCELERATION AND DECELERATION


1.
2.

Start the engine and warm it up to the normal operating


temperature.
Depress the accelerator pedal to check that engine speed
smoothly increases from idle to the maximum and that it
returns to idle.

MA-4-20

MAINTENANCE PROCEDURE
NOTE
z

If the engine does not accelerate smoothly, disengage


the accelerator linkage from the injection pump and
operate the fuel control lever of the injection pump to
check engine acceleration. If the engine rotates
smoothly, the accelerator linkage may be faulty. Check
and repair the linkage. If engine operation is erratic, the
injection pump or governor may be faulty. Check and
repair these parts.

3.

Attach the pickup of the tachometer to the No. 1 injection


tube, and measure the no-load maximum engine rpm.
Unit: rpm
Item

No-load maximum
engine speed

Maintenance standard

Service limit

3,600

ACCELERATOR LINKAGE
Check accelerator linkage for bent rods, interference with nearby
parts or looseness.

NOZZLE (INJECTOR PRESSURE AND PATTERN)


Cleaning nozzle
1.
2.
3.

Remove the nozzle holder assembly from the engine. Refer


to the ENGINE DISASSEMBLY AND REASSEMBLY section for details.
Clamp the nozzle holder in a vise with a holder plate
(157944-9520).
Loosen the retaining nut, and then remove the nozzle from
the nozzle holder. Do not drop the nozzle needle.

4. Pull the nozzle needle from the nozzle body.


NOTE
z Do not use the nozzle needle in another nozzle body.
5.

Remove carbon from around the openings by using the corner of a hard piece of wood. Do not use waste or any other
material to push carbon into the openings.

MA-4-21

MAINTENANCE PROCEDURE
6.

Removing carbon in openings


Use the pin vice (99727 Z5005) and wire to clean the openings.
Unit: mm (in)

Nozzle identification mark

Number of injection nozzle hole

Injection nozzle
hole diameter

Wire diameter

Z
D3

0.29 (0.0114)

0.26 (0.0102)

D2
A5
A6
A3

0.30 (0.0118)

0.29 (0.0114)

C1

0.245 (0.0096)

0.23 (0.0091)

7.

Allowing too much wire to protrude at the tip of the holder


will permit the wire to bend inside the nozzle, and withdrawal becomes difficult. The wire should protrude less
than 2 to 2.5 mm (0.079 to 0.098 in).
Carefully push the carbon into the nozzle. Too much force
will bend the wire. Proceed slowly.
Remove carbon at the inside end of the openings with the
nozzle cleaning tool (99726 Z5000).
Exercise care to avoid damaging the surface which the nozzle needle contacts. The use of compressed air may clog
the openings with foreign particles.
Tighten the retaining nut.
: 59 - 78 Nm {6.0 - 8.0 kgfm, 43 - 58 ftlbf}

NOZZLE HOLDER (INJECTOR)


Rebuild the nozzle holder at the specified interval. Check and
adjust the nozzle opening pressure and spray pattern. Refer to the
EF section for rebuilding procedures.
WARNING
WARNING
z

Fuel from the injection nozzle is injected under extremely


high pressure. If it is directed at your hand, etc., serious
injury may result. KEEP YOUR HANDS AWAY FROM THE
NOZZLE DURING TESTS.

FUEL LEAKAGE
Check the fuel system for leakage at tube or hose connections.

MA-4-22

MAINTENANCE PROCEDURE

REPLACEMENT OF FUEL FILTER


NOTE
z

Use genuine filter or equivalent in quality and design.


Use of an inferior filter could hinder engine operation and
emission controls.

Cartridge type
1.
2.

Remove the engine side cover (left side).


Place a container under the filter. Remove the filter with a
filter wrench. Drain any remaining fuel into the container.

3.

Apply a thin coat of clean engine oil to the gasket of the new
filter.
WARNING
WARNING
z Installation of the fuel filter without coating the gasket
with oil may damage the gasket resulting in loss of fuel
and fire hazard due to spilled fuel.
4.

Install the new fuel filter by hand. After the gasket comes in
contact with the bracket sealing surface, tighten an additional 3/4 of a turn.
CAUTION
z When installing the fuel filter, tighten by hand. Do not
use a wrench or other tools which could result in overtightening and damage to the filter.
5.

After installing the filter, purge air from the fuel system and
check for fuel leaks.
For air purging details, refer to PURGING AIR FROM
FUEL SYSTEM.

Center bolt type


1.
2.

Place a container under the filter.


Remove the drain plug, and empty out fuel and sediments.

MA-4-23

MAINTENANCE PROCEDURE
3.

Loosen the center bolt and remove the filter case, set
spring, element and other parts.
4. Check the element for clogging and contamination.
5. Clean the filter parts in light oil.
6. Replace the packings.
7. Reassemble the parts correctly.
Center bolt
: 20 - 29 Nm {2.0 - 3.0 kgfm, 14 - 22 ftlbf}
WARNING
WARNING
z Make sure fuel leaks are not present after installing
parts. Leaks will not only waste fuel but also create a fire
hazard.
NOTE
z

Do not excessively tighten bolts.

Disassembly sequence (Reassembly sequence is in the


reverse order of disassembly.)

8.

1.

Drain plug

6.

Seat spring

2.

Packing

7.

Retainer

3.

Center bolt

8.

Element

4.

Packing

9.

Packing

5.

Filter case

10.

Filter cover

After installing the filter, purge air from the fuel system and
check for fuel leaks.
For air purging details, refer to PURGING AIR FROM
FUEL SYSTEM.

PRIMARY FUEL FILTER


Draining sediment from primary fuel filter
NOTE
z

It is not necessary to drain all the fuel in the primary fuel


filter case.

Place a receiver under the filter, then loosen the drain plug to drain
sediment.
Put the drained precipitates in a glass container such as a test tube.
If there is fuel on top of the water, dust and precipitates, it indicates
that the precipitates have been removed.
Bleed air from the fuel system after draining sediments.

MA-4-24

MAINTENANCE PROCEDURE

Replacing primary fuel filter element


1.
2.

Place a container under the filter.


Place a suitable oil can under the drain cock, and drain the
fuel and sediment.
Also loosen the plug to speed up draining.

3.

Loosen the center bolt, and remove the filter case, set sprig
and element.
4. Clean each part in light oil.
5. Replace the element packings.
6. Reassemble each part correctly.
Center bolt
: Type I
20 - 29 Nm {2.0 - 3.0 kgfm, 14 - 22 ftlbf}
: Type II
59 - 69 Nm {6.0 - 7.0 kgfm, 43 - 51 ftlbf}
Drain plug (Type II only)
: 16 - 22 Nm {1.6 - 2.2 kgfm, 12 - 16 ftlbf}
z
Do not excessively tighten the bolts and plugs.
Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
Type I
1.

Plug

7.

Set spring

2.

Packing

8.

Retainer

3.

Drain cock

9.

Element

4.

Center bolt

10.

Packing

5.

Packing

11.

Filter cover

6.

Filter case

Type II

7.

1.

Drain plug

7.

Seat

2.

Packing

8.

Element

3.

Center bolt

9.

Packing

4.

Packing

10.

Filter cover

5.

Filter case

11.

Filter plug

6.

Spring

12.

O-ring

After installing the filter, purge air from the fuel system and
check fuel leaks.
For air purging details, refer to PURGING AIR FROM
FUEL SYSTEM.

MA-4-25

MAINTENANCE PROCEDURE

FUEL STRAINER
Draining sediment from fuel strainer
1.
2.
3.

Place a container under the drain plug.


Loosen the drain plug, and drain sediment and water from
the fuel strainer.
After draining, securely tighten the drain plug.

Cleaning procedure
1.

Place a suitable oil can under the drain plug, and drain the
fuel and sediment.
2. Loosen the center bolt, and remove the case, set spring
baffle and other parts.
3. Clean each part in light oil.
4. Replace the packings.
5. Reassemble each part correctly.
Center bolt
: 15 - 20 Nm {1.5 - 2.0 kgfm, 11 - 14 ftlbf}
NOTE
z

Do not excessively tighten the bolts and plugs.


1.

Strainer cover

6.

Spring retainer

2.

Packing

7.

Strainer case

3.

Screen

8.

Packing

4.

Baffle

9.

Center bolt

5.

Set spring

10.

Drain plug

NOTE
z

Numbers before part names do not indicate the disassembly sequence.

6.

After installing the filter, purge air from the fuel system and
check fuel leaks.
For air purging details, refer to PURGING AIR FROM
FUEL SYSTEM.

PURGING AIR FROM FUEL SYSTEM


Air entrapped in the fuel system will cause poor injection of the fuel,
thus resulting in difficult starting, jerking, or even stoppage of the
engine. After completing any service procedure on the fuel system
(inspection, replacement of fuel filter element, or reconnection of
any fuel pipe), be sure to bleed air from the fuel system.

MA-4-26

MAINTENANCE PROCEDURE
1.

Twist the knob on the priming pump, which is connected to


the injection pump, and the knob will rise up by itself.

2.

Loosen the bleeder screw on the injection pump front upper


side. (MKB and LKC212 series only)
Keep moving the priming pump knob up and down until
moving it becomes difficult and you can no longer hear the
sound of air hissing from the bleeder screw.
Retighten the bleeder screw.
: 7 - 9 Nm {0.7 - 0.9 kgfm, 5.1 - 6.5 ftlbf}

3.

4.

Move the priming pumps knob up and down to send fuel


from fuel tank into the filter.
Continue this procedure until the overflow valve of the fuel
filter no longer gives off a hissing sound and movement of
the priming pump is difficult. The air bleeding operation is
now complete.
After bleeding air, return the pump knob to its original position. Start the engine, and make sure that no fuel is leaking
from the fuel system.
Fuel leaks can cause a fire. If a leak is discovered, immediately repair the affected part.

INTAKE AND EXHAUST SYSTEM


AIR CLEANER ELEMENT
Precautions for handling cleaner
1.
2.

Be sure to install the element and cover securely. Loose or


improper installation will allow dust to enter, preventing normal functioning of the air cleaner.
Do not touch the filter paper of the element directly with
your hand. Wear gloves. Use special care not to stain the
element with oils.

To inspect the air cleaner element


Start the engine and check if the air cleaner warning light comes
on. If the warning light comes on frequently, clean or replace the
element as follows:
NOTE
z

If the air cleaner element reaches a checking or replacing


period, clean or replace the element regardless of
whether the warning light comes on or not.

MA-4-27

MAINTENANCE PROCEDURE

<FE6A, FE6B, FE6T and FE6TA>


Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
1.

Cover assembly

4.

Inner element

2.

Packing

5.

Evacuator valve

3.

Outer element

6.

Body assembly

1.
2.

Unlock the clips and remove the cover assembly.


Pull out and remove the outer element.

3.

Check the outer element and packing, and replace if broken


or deformed.
If there is dirt or dust on the outer element, clean it by blowing compressed air at 196 to 294 kPa {2.0 to 3.0 kgf/cm2,
28 to 43 psi} from inside.

4. Pull out and remove the inner element.


NOTE
z Do not remove the inner element until the specified
replacement time. In other words, the inner element need
not be checked between replacements.
5.

When installing the elements, clean the inside of the body


assembly and evacuator valve and assembly each part in
the reverse order of disassembly.

MA-4-28

MAINTENANCE PROCEDURE

<FE6T 151 kW {205 PS}/162 kW {220 PS} and FE6TA>


Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
1.

Wing nut

7.

Outer element

2.

Packing

8.

Wing nut

3.

Cover assembly

9.

Packing

4.

Packing

10.

Inner element

5.

Wing nut

11.

Evacuator valve

6.

Packing

12.

Body assembly

1.
2.

Loosen the wing nut and remove the cover assembly.


Loosen the wing nut securing the outer element and
remove the outer element.

3.

Check the outer element and packing, and replace if broken


or deformed.
If there is dirt or dust on the outer element, clean it by blowing compressed air at 196 to 294 kPa {2.0 to 3.0 kgf/cm2,
28 to 43 psi} from inside.

4. First remove the wig nut and then the inner element.
NOTE
z Do not remove the inner element until the specified
replacement time. In other words, the inner element need
not be checked between replacements.

AIR INTAKE SYSTEM (DUCT, HOSE AND CLAMP)


Check the air intake duct connections for loose clamps or cracked
hoses. Check the connection between the air cleaner and air intake
manifold especially. Tighten loose clamps, if any.

MA-4-29

MAINTENANCE PROCEDURE

EXHAUST TUBING AND MUFFLER


Check the various connections of the exhaust tubing for looseness.
Tighten loose parts as necessary. Also check for any sign of gas
leakage from connections or muffler.

CONDITION OF EXHAUST
Warm up the engine sufficiently, then visually inspect exhaust
smoke during idling, acceleration and deceleration with the vehicle
at a stop.
Color of smoke

Judgment standard

Colorless or light blue

Normal

Black

Abnormal
Incomplete combustion

White

Abnormal
Engine oil is also burning. However,
exhaust gases are often white when either
the air or engine temperature is low.

TURBOCHARGER (FE6T AND FE6TA)


NOTE

Before attempting any servicing of the turbocharger,


clean its entire exterior surface.
z Never use a caustic solution. Caustic solutions attack
aluminum.
z

To clean the compressor side


1.
2.

Remove the turbocharger from the engine.


Remove the compressor housing and check the condition
of the impeller (compressor wheel). If it is not excessively
dirty, clean the impeller and the inner surface of the housing
with a brush and a cloth dampened with diesel fuel.
CAUTION
z Do not use a wire brush or scraper.

3.

If the impeller is excessively dirty, overhaul and clean. Refer


to the ENGINE IE section for cleaning instructions.
4. When the impeller is wet with cleaning solvent, dry with
compressed air.
CAUTION
z Hold the impeller by hand to prevent it from turning while
drying.

MA-4-30

MAINTENANCE PROCEDURE
5.

Install the compressor housing in its original position.


T04B and T04E
: 11.3 - 14.7 Nm {115 - 150 kgfcm, 100 - 130 inlbf}
RHC62E and RHC6V
: 7.4 - 8.3 Nm {75 - 85 kgfcm, 65 - 74 inlbf}

To clean the turbine side


1.

Remove the turbine housing and check the condition of the


turbine. If the turbine is not excessively dirty, clean the turbine and the inner surface of the turbine housing in a manner similar to that outlined under To clean the compressor
side.
2. If the turbine is excessively dirty, overhaul and clean.
3. When the impeller is wet with cleaning solvent, dry with
compressed air.
CAUTION
z Hold the impeller with your hand to prevent it from turning while cleaning.
4.

5.

Install the turbine housing in its original position.


T04B and T04E
: 18.0 - 21.5 Nm {184 - 219 kgfcm, 160 - 190 inlbf}
RHC62E and RHC62V
: 27.0 - 28.9 Nm {275 - 295 kgfcm, 239 - 256 inlbf}
Check that the turbine wheel rotates smoothly by your
hand. Install the turbocharger on the engine and check for
gas or air leakage.

PCV VALVE
Point of inspection
Cover the hole at the center of the bottom of the valve with
masking tape and suck on the valve outlet to check that air
is sucked into the inlet hole on the bottom of the valve.
z
Next, cover the inlet hole on the bottom of the valve and
suck on the outlet pipe to check that the diaphragm opens
and closes properly. This can be confirmed by the operating
sound which the diaphragm makes when opening and closing.
If there are any abnormalities, replace the valve.
NOTE
z When sucking on the valve, be careful not to get any oil
in mouth. First remove the oil from inside the valve.
z

MA-4-31

MAINTENANCE PROCEDURE

PCV SYSTEM
Hose and clamp
Check hose connections for signs of chafing, leaks or deterioration.
Replace faulty hoses or tighten clamps, as necessary.

Piping
Check piping and connections for improper installation, cracks or
damage. Remove the hose when the PCV valve is replaced and
clean the inside of the hose with compressed air.
Replace faulty hoses or retighten clamps, as necessary.

OTHERS
ALTERNATOR
Check the ball bearings for proper rotation and abnormal noise.

STARTING MOTOR
Inspect the moving contactor of the magnetic switch.

MA-4-32

- MEMO -

TROUBLE DIAGNOSIS
TD

CONTENTS
DIAGNOSIS ............................................ TD-1-1
DIFFICULT ENGINE STARTING .....................
BLACK EXHAUST SMOKE ..............................
WHITE EXHAUST SMOKE ..............................
IRREGULAR ENGINE OPERATION................

TD-1-2
TD-1-3
TD-1-3
TD-1-4

DECREASED ENGINE POWER ......................


EXCESSIVE OIL CONSUMPTION...................
EXCESSIVE FUEL CONSUMPTION ...............
NOISY ENGINE ................................................
ENGINE OVERHEATS .....................................

TD-1-5
TD-1-6
TD-1-7
TD-1-8
TD-1-9

DIAGNOSIS

DIAGNOSIS
DIAGNOSIS GUIDE
The diagnosis guide is a table which can be used for seeking out the cause of trouble without disassembling
the engine on the basis of the symptoms of the problem complained of by the user and the result of checks
performed in the shop with the engine mounted in the body.

HOW TO USE THE GUIDE


1.
2.
3.

Open the page of the guide corresponding to the trouble symptom complained of by the user.
Check all of the points listed in the page.
If there is any applicable item in the checking points, the cause of the trouble may be assumed in the
following manner.
z
Each item in the Symptoms and checking points section corresponds to one or more items in the
Cause of trouble section through the dot mark z. If there are more than one applicable Cause of
trouble items, the item having the largest number of dot marks should be regarded as the central
cause of the trouble.
z
The cause items having no dot mark can be regarded as not being the cause of the trouble.
NOTE
z If more than one cause is assumed, the repair should begin with the simplest operation.

TD-1-1

Faulty starter

Faulty starter switch and starter relay

Electrical system
Fuel system
Engine proper and others

Symptoms and checking points

Poor fuel consumption or oil consumption

Engine lacks power

Breaks in electrical wire

Engine cannot be cranked manually

Excessive exhaust smoke

Poor connection of connector and terminal

Moderate exhaust smoke

Little exhaust smoke

Cause of trouble

Sound of magnetic switch is heard with starter switch ON

Slow starter rotation (less than 100 rpm)

Discharged battery

DIFFICULT ENGINE STARTING

Insufficient starter rotation

Starter fails to rotate

DIAGNOSIS

z
z

Faulty air heater

Lack of fuel

Faulty feed pump

Incorrectly installed fuel pipe

Faulty injection pump

Faulty nozzle

z
z
z
z

Clogged fuel filter element

Air in fuel system

Incorrect injection timing

Broken or damaged fuel pipe

Clogged gauge filter

Damaged ring gear

Damaged or seized rotating engine parts

High engine oil viscosity

z
z

z
z

z
z
z

Incorrect valve clearance

Inadequate compression pressure

Incorrect valve timing

Clogged air cleaner element

Faulty clutch and subsequent power train


(Check by connecting and disconnecting the clutch)

TD-1-2

Exhaust smoke gradually turns black

Clogged air cleaner element

Engine knocks

Symptoms and checking points

Irregular idling

Intake
system
Fuel system

Oil leakage from compressor side of turbocharger

Excessive injection quantity

Uneven plunger wear

Turbocharger failure (jamming, etc.)

Faulty nozzle

Excessively advanced injection timing

Faulty boost compensator


Engine
proper

Malfunction of delivery valve


Poor fuel quality

Excessive oil in oil pan

z
z

Wear on piston rings, and cylinder liner

Low compression pressure

Engine lacks power

High blow-by gas pressure

Poor fuel consumption or oil consumption

Accumulation of sludge in air heater

BLACK EXHAUST SMOKE

Exhaust smoke suddenly turns black

Cause of trouble

Poor engine starting

DIAGNOSIS

z
z

Engine proper
and others

WHITE EXHAUST SMOKE


Delayed injection timing

Engine temperature too low

z
z

Engine oil leakage down through valve stem

Wear on piston ring or cylinder liner

Excessive oil in oil pan

Incorrect valve clearance

TD-1-3

Fuel system

z
z

Improper fuel spray of nozzle

Improper adjustment of idle spring


Malfunction of delivery valve

z
z

Air in fuel system


Engine proper

Uneven injection pressure of nozzle

Improper adjustment of damper spring

Others

z
z

Improper placement of valve seat

Improper valve clearance

Incorrect valve timing

Incorrect compression pressure


Engine temperature too low

z
z

z
z

z
z

Rusted control wire

TD-1-4

z
z

Deteriorated engine mount rubber


Improper adjustment of idling

z
z

z
z

Low compression pressure

Malfunction of governor

Specified maximum rpm is exceeded

Specified maximum rpm is not achieved

Uneven injection quantity

Irregular idling

Engine often stalls

Engine stabilizes at two speeds

Fuel leakage from injection pipe

Engine knock

Poor fuel consumption

Difficulty in starting engine

White exhaust smoke

Incorrect adjustment of link or rod

Cause of trouble

Black exhaust smoke

Engine lacks power

IRREGULAR ENGINE
OPERATION

Symptoms and checking points

DIAGNOSIS

z
z

Clogged fuel filter element

Fuel system
Intake and exhaust
system
Engine proper
Others

z
z

Improper fuel spray from nozzle

Improper injection timing

Malfunction of delivery valve

Malfunction of feed pump

Malfunction of injection pump

Faulty boost compensator

Clogged air cleaner element

Thin or hot intake air

Accumulation of carbon to air heater

z
z

z
z
z

z
z

Half-opened exhaust shutter

Wear on piston rings and cylinder liner

Worn, sticking, or broken piston ring

Seized piston

Worn or seized valve stem

Improper seating of valve insert

Improper selection of gear while traveling

z
z

Improper adjustment of control linkage

Poor returning of engine stop wire

TD-1-5

Low specific gravity of fuel

Clogged or crushed exhaust pipe or muffler


Turbocharger malfunction

Low compression pressure

Specified maximum rpm is not achieved

Excessive blow-by gas

Low boost pressure

Engine overheats

Water or air in fuel system


Low fuel pressure (overflow valve)

Difficulty in starting engine

Poor oil consumption

Poor fuel consumption

White exhaust smoke

Irregular idling

Improper adjustment of injection quantity

Engine knock

Improper fuel quality

Black exhaust smoke

Cause of trouble

Little exhaust smoke

DECREASED ENGINE POWER

Symptoms and checking points

DIAGNOSIS

Turbocharger

Engine proper

Aligned piston ring end gaps

Insufficient piston ring tension

Improper break-in of piston ring

Inversely fitted piston rings

Broken or seized piston rings

Worn piston ring

Scuffing of cylinder liner

z
z
z

Worn valve stem or guide

Worn valve stem seal

Worn or broken seal ring

Oil return hole obstructed by carbon

Improper installation of seal ring

Excess of engine oil

Engine oil measuring method incorrect

Engine knock

Worn piston rings and cylinder liner

Leakage of engine oil


Others

Low compression pressure

High blow-by gas pressure

Poor fuel consumption

Oil attaching to exhaust pipe and manifold

Difficulty in starting engine

Engine overheated previously

Engine lacks power

Engine emits white smoke after idling

Cause of trouble

Continuous emission of white smoke at high-speed running

EXCESSIVE OIL
CONSUMPTION

Symptoms and checking points

DIAGNOSIS

z
z

Improper quality of engine oil


Clogged air cleaner element

TD-1-6

Others

Engine
proper

Fuel system

Maladjusted nozzle injection pressure

Irregular idling

Low compression pressure

Low boost pressure

Maladjusted injection quantity

Improper seating of delivery valve seat

Improper injection timing

Faulty boost compensator

Worn or seized piston, or piston ring

Worn cylinder liner

Improper seating between valve seat and insert

Maladjusted valve clearance

Clogged air cleaner element

Clogged or crushed exhaust pipe or muffler

z
z

Seizure in drive line


Insufficient tire inflation pressure
Unnecessary acceleration and deceleration
z

TD-1-7

Clutch slip

Prolonged idling

z
z

Improper gear shifting

Half-opened exhaust shutter


z

Dragged brake
Chassis

High blow-by gas pressure

Improper fuel spray from nozzle

Engine temperature too high

Driving
habits

Poor oil consumption

Engine overheats

Engine knock

White exhaust smoke

Black exhaust smoke

Cause of trouble

Engine lacks power

EXCESSIVE FUEL CONSUMPTION

Symptoms and checking points

DIAGNOSIS

Others

Fuel system

Improper timer advance angle

Uneven injection quantity

Injection timing too early

Injection timing delayed

Uneven nozzle injection pressure

Improper fuel spray from nozzle

Malfunction of delivery valve

Poor fuel quality

Wear or seizure on rotating and sliding portions

Insufficient intake air quantity

Improper valve clearance, or seizure of valve

TD-1-8

Low compression pressure

Low boost pressure

High blow-by gas pressure


z

z
z
z

z
z

Engine too cold, or overheated

Excessive oil coming up into cylinder

Engine overheats
z

z
z

Low intake air temperature


Insufficient compression pressure and compression air
temperature

Poor fuel consumption

White exhaust smoke

Cause of trouble

Black exhaust smoke

Symptoms and checking points

NOISY ENGINE

Engine lacks power

DIAGNOSIS

Water pump

Improper fan belt tension

Worn or seized bearing

Air drawn from suction side

Improper water seal

Coolant
passage

Accumulation of water scale in cylinder block

Radiator

Clogging by water seal

Coolant leakage

Malfunction of radiator cap

Engine coolant acidified

Clogged core due to accumulation of mud and insects


State of combustion

Clogging by oxide of iron

Air bubbles is radiator

z
z

Overflow of engine coolant due to blow-out of gas

Air bubbles appear in water tank only after engine racing

z
z

Air bubbles appear in water tank only when water temperature is high

Damaged impeller
Coolant leakage from engine coolant passage

Radiator remains cold even after engine warm up

Malfunction of thermostat

Others

Water temperature difference between water inlet and outlet is great

Water temperature difference between water inlet and outlet is small

High blow-by gas pressure

Engine noisy in operation

Engine lacks power

Cause of trouble

Engine coolant reduces in quantity only after high-speed operation

Symptoms and checking points

ENGINE OVERHEATS

Excessive reduction of cooling water

DIAGNOSIS

Improper fuel spray from nozzle

Improper injection timing

Half-opened exhaust shutter

Clogged or crushed exhaust pipe or muffler

Gas leakage from cylinder head nozzle tube

Gas leakage from head gasket

Continuous operation under heavy load, or other


improper operation
Improper selection of gears while traveling
Incorrect indication of thermometer

TD-1-9

- MEMO -

- MEMO -

ENGINE DISASSEMBLY
AND REASSEMBLY
DR

CONTENTS
SERVICE DATA ...................................... DR-1-1
TIGHTENING TORQUE ................................... DR-1-1
TOOLS .................................................... DR-2-1
CONSTRUCTION.................................... DR-3-1
ENGINE ............................................................ DR-3-1
GEAR TRAIN.................................................... DR-3-5
ENGINE REAR PTO ........................................ DR-3-6

DISASSEMBLY AND
REASSEMBLY ........................................ DR-4-1
OUTSIDE OF ENGINE .....................................
CYLINDER HEAD.............................................
ENGINE PROPER ............................................
ENGINE REAR PTO.........................................

DR-4-1
DR-4-11
DR-4-17
DR-4-27

SERVICE DATA

SERVICE DATA
TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Air intake manifold mounting bolt

16 - 20 {1.6 - 2.0, 12 - 14}

Alternator adjusting bolt

34 - 44 {3.5 - 4.5, 25 - 33}

Alternator anchor bolt and nut

59 - 74 {6.0 - 7.5, 43 - 54}

Camshaft gear mounting nut

186 - 226 {19.0 - 23.0, 137 - 166}

Connecting rod bearing cap nut

132 - 142 {13.5 - 14.5, 98 - 105}

Cooling fan mounting bolt

59 - 69 {6.0 - 7.0, 43 - 51}


1st

Cylinder head bolt


Engine mounting bolt
and nut

Front side
Rear side

275 - 294 {28.0 - 30.0, 203 - 217}

2nd

Loosen the nut.

3rd

834 - 883 {85.0 - 90.0, 615 - 651}

1st

98 {10.0, 72}

2nd

177 - 196 {18.0 - 20.0, 130 - 145}

Bracket

29 {3.0, 22}

Cushion

49 {5.0, 36}

Cushion

49 {5.0, 36}

Exhaust manifold connector mounting nut

34 - 44 {3.5 - 4.5, 25 - 33}

Exhaust manifold mounting nut

34 - 44 {3.5 - 4.5, 25 - 33}

Fan pulley mounting nut

20 - 25 {2.0 - 2.5, 14 - 18}

Flywheel housing mounting bolt and


nut

M8

15 - 20 {1.5 - 2.0, 11 - 14}

M12

69 - 74 {7.0 - 7.5, 51 - 54}

Flywheel mounting bolt and nut


Front end plate mounting bolt

235 - 255 {24.0 - 26.0, 174 - 188}


16 - 21 {1.6 - 2.1, 11.6 - 15}

Hydraulic pump drive gear mounting nut

49 - 64 {5.0 - 6.5, 36 - 47}

Idler gear plate mounting bolt

34 - 39 {3.5 - 4.0, 25 - 29}

Idler gear shaft mounting bolt

34 - 39 {3.5 - 4.0, 25 - 29}

Injection bracket mounting bolt

37 - 42 {3.8 - 4.3, 27 - 31}

Injection nozzle tube

23 - 27 {2.3 - 2.8, 17 - 20}

Injection pump drive


coupling cotter bolt

Injection pump drive


coupling bolt and nut

Secure camshaft before tightening.

10 - 12 {1.0 - 1.2, 7 - 9}

Crank damper mounting bolt


Crank pulley nut

Remarks

FE6A, FE6B, FE6T,


FE6TA
173 kW {235 PS}

59 - 64 {6.0 - 6.5, 43 - 47}

FE6TA
157 kW {213 PS}

83 - 93 {8.5 - 9.5, 61 - 69}

FE6A, FE6B, FE6T,


FE6TA
173 kW {235 PS}

29 - 34 {3.0 - 3.5, 22 - 25}

FE6TA
157 kW {213 PS}

59 - 64 {6.0 - 6.5, 43 - 47}

DR-1-1

Tighten diagonally.

SERVICE DATA
Unit: Nm {kgfm, ftlbf}
Item
Injection pump drive gear mounting nut
Injection pump mounting bolt
Injection pump stay
mounting bolt

Cylinder block side


Injection pump side

Locating plate mounting bolt


Main bearing cap bolt
Nozzle holder mounting bolt

Tightening torque
147 - 167 {15.0 - 17.0, 108 - 123}
20 - 25 {2.0 - 2.5, 14 - 18}
21 - 26 {2.1 - 2.7, 15 - 20}
29 - 39 {3.0 - 4.0, 22 - 29}
21 - 26 {2.1 - 2.7, 15 - 20}
177 - 196 {18.0 - 20.0, 130 - 145}

Apply oil to the bolt seat and


thread.

25 - 29 {2.5 - 3.0, 18 - 22}

Oil cooler mounting bolt

25 {2.5, 18}

Oil filter mounting bolt

25 {2.5, 18}

Oil jet connector bolt

34 - 49 {3.5 - 5.0, 25 - 36}

Oil pan drain plug

59 - 69 {6.0 - 7.0, 43 - 51}

Oil pan mounting bolt and nut

18 - 25 {1.8 - 2.5, 13 - 18}

Oil pipe mounting bolt

20 {2.0, 14}

Oil pump mounting bolt

20 {2.0, 14}

Oil screen mounting bolt

9 - 12 {0.9 - 1.2, 6.5 - 8.7}

PTO companion flange mounting nut

Remarks

392 - 412 {40.0 - 42.0, 289 - 304}

PTO idler gear mounting bolt

98 {10.0, 72}

Rocker cover mounting bolts

10 - 15 {1.0 - 1.5, 7 - 11}

Do not overtighten.

Rocker shaft bracket mounting bolt

44 - 54 {4.5 - 5.5, 33 - 40}

Tighten center bolts first then


move toward outer bolts.

Spill tube connector

8 - 10 {0.8 - 1.0, 5.8 - 7.2}

Tighten nut before tightening


connector.

Starting motor mounting bolt

59 - 78 {6.0 - 8.0, 43 - 58}

Timing gear case mounting bolt and nut

21 - 26 {2.1 - 2.7, 15 - 20}

Water pump mounting bolt and nut

10 - 13 {1.0 - 1.3, 7 - 9}

Cooler tension pulley lock nut

35 - 47 {3.6 - 4.8, 26 - 35}

Turbocharger assembly mounting nut

34 - 44 {3.5 - 4.5, 25 - 33}

Turbocharger oil pipe


Turbocharger oil drain pipe

12 - 15 {1.2 - 1.5, 9 - 11}


18 - 22 {1.8 - 2.2, 13 - 16}

DR-1-2

TOOLS

TOOLS
Tool name and number

Description

Socket wrench
99535 Z5007

Used to remove and install crank pulley nut.


Width across flats: 55 mm (2.17 in)

Guide bolt
99687 97001

Used to remove and install flywheel.

Engine stand attachment


99554 97001

Used as an attachment for engine stand when


installing engine.

Engine stand
99550 96001

Used when disassembling and reassembling


engine.

Piston insert tool


99631 Z5502

Used as a guide when inserting piston into cylinder liner.

DR-2-1

Shape

TOOLS

Tool name and number

Description

Cylinder head bolt socket


wrench
99664 Z5000

Used to remove, install and tighten cylinder


head bolts.

Engine jack
99890 Z0001

Used to remove and install engine assembly.

DR-2-2

Shape

CONSTRUCTION

CONSTRUCTION
ENGINE
ENGINE MODEL FE6

DR-3-1

CONSTRUCTION

DR-3-2

CONSTRUCTION

ENGINE MODEL FE6T


(Refer to FE6T for FE6TA construction)

DR-3-3

CONSTRUCTION

DR-3-4

CONSTRUCTION

GEAR TRAIN

DR-3-5

CONSTRUCTION

ENGINE REAR PTO

DR-3-6

DISASSEMBLY AND REASSEMBLY

DISASSEMBLY AND REASSEMBLY


OUTSIDE OF ENGINE
FRONT SIDE OF ENGINE

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Fan and fan pulley
2. V-belt
,+ 3. Crank pulley assembly

4. Alternator
5. Hydraulic pump

, 6. Thermostat housing
7. Water pump

Marks + and , indicate that the key points of operation are explained in the text.

DR-4-1

DISASSEMBLY AND REASSEMBLY

Key point of disassembly


3 Crank pulley assembly
Remove the pointer cover and pointer from the flywheel housing.
Lock the flywheel ring gear to prevent it from turning. Loosen the
crank pulley nuts using the socket wrench (99535 Z5007).
NOTE
If the crankshaft thread is staked, perform as follows:
z Loosen the pulley nut and remove it. (The removed nut
cannot be reused.)
z Correct the staked portion of the crankshaft thread with a
triangular rod file.
z Using a new pulley nut, make sure that the nut turns
smoothly on the crankshaft thread.

Key point of reassembly


6 Thermostat housing
Install the thermostat housing using liquid gasket (THREE BOND
1216 or equivalent) and connect the hose.
NOTE
z Ensure the flange surface is clean and free from oil,
water, dust, etc. before applying liquid gasket.
z During application, be sure to overlap the start and end
points of the liquid gasket. The gasket should be continuous.
z Install parts properly and within 20 minutes after gasket
application.
z Do not apply pressure to parts for at least 40 minutes
after installation.

DR-4-2

DISASSEMBLY AND REASSEMBLY


3 Crank pulley assembly
1. Install the crank pulley assembly and temporarily tighten the
crank pulley nut.
NOTE
z Be sure to install the key.
z If the crank pulley is reused, remove the adhesive agent
coated on the tapered surface.
z Apply one or two drops of Loctite 221 or 222 to the
tapered surface of the crankshaft.
z Be sure not to apply adhesive agent to the crankshaft tip
thread.
2.

Lock the flywheel ring gear. Using the socket wrench


(99535 Z5007), install the crank pulley nut.
: 1st : 275 - 294 Nm {28.0 - 30.0 kgfm, 203 - 217 ftlbf}
2nd: Loosen the nut.
3rd : 834 - 883 Nm {85.0 - 90.0 kgfm, 615 - 651 ftlbf}
NOTE
z First, tighten the nut then loosen it. Secondly, retighten
the nut to the specified torque.
z Do not leave the pulley temporarily installed without
tightening the nut.

DR-4-3

DISASSEMBLY AND REASSEMBLY

RIGHT SIDE OF ENGINE

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Air pipe
2. Alternator
3. Turbocharger

4. Exhaust manifold cover


5. Exhaust connector
, 6. Exhaust manifold

, 7. Oil pipe
, 8. Oil filter
9. Oil cooler

Marks + and , indicate that the key points of operation are explained in the text.

Key point of reassembly


8 Oil filter
Install the oil filter using an O-ring.
NOTE
z Be careful not to damage the O-ring.
z Tighten the filter by hand. (Refer to the MA section of To
replace the oil filter.)

DR-4-4

DISASSEMBLY AND REASSEMBLY

7 Oil pipe
Connect the oil pipe using an O-ring.
NOTE
z

Be careful not to damage the O-ring.


: 20 Nm {2.0 kgfm, 14 ftlbf}

6 Exhaust manifold
Install the exhaust manifold using a gasket.
NOTE
z

Start by tightening the middle nut and then alternate


between the upper and lower ones.

These nuts are heat-resistant and should not be confused with other types.
: 34 - 44 Nm {3.5 - 4.5 kgfm, 25 - 33 ftlbf}

DR-4-5

DISASSEMBLY AND REASSEMBLY

LEFT SIDE OF ENGINE

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Air duct
2. Fuel tube
3. Fuel filter
4. Air heater
5. Breather tube

6. Intake manifold
7. Nozzle assembly
, 8. Timer coupling
, 9. Injection pump assembly and stay
10. Starting motor

11. Drain cock


,+ 12. Air compressor or injection pump
support
13. Oil pan

Marks + and , indicate that the key points of operation are explained in the text.

Key point of disassembly


12 Air compressor or injection pump support
Remove the air compressor (AOH model only) or injection pump
support. (VAC model only)
NOTE
z Measure the backlash of the front gear train before
removing the air compressor (AOH model only) or injection pump support. (VAC model only)

DR-4-6

DISASSEMBLY AND REASSEMBLY

Key point of reassembly


12 Air compressor or injection pump support
Install the air compressor (AOH model only) or injection pump support (VAC model only) using an O-ring (if removed after measuring
front gear train backlash).

1.

Rotate the flywheel in the standard direction to determine


the 1.6 point at TDC of No. 1 cylinder on the compression
stroke. (TDC is the point at which both intake and exhaust
valves for No. 1 cylinder are closed and there is a valve
clearance.)

2.

Align the scribe mark on the injection pump drive gear tooth
with the pointer at the check window on the upper side of
the timing gear case. Then, install the compressor or injection pump support.

9 Injection pump assembly and stay, 8 Timer coupling


1. Install the injection pump stay on the injection pump body
and tighten to the specified torque.
:29 - 39 Nm {3.0 - 4.0 kgfm, 22 - 29 ftlbf}

2.

Put the injection pump body on the injection pump bracket


and temporarily tighten the injection pump stay-to-cylinder
block securing bolts.

DR-4-7

DISASSEMBLY AND REASSEMBLY


3.

Temporarily tighten the injection pump body securing bolts


(1), (2), (3) and (4).
NOTE
z Be sure to equally tighten the bolts in the order enumerated above.

4.

Tighten the injection pump stay-to-cylinder block securing


bolts to the specified torque.
:21 - 26 Nm {2.1 - 2.7 kgfm, 15 - 20 ftlbf}

5.

Set a dial gauge probe to the periphery of the injection timer


perpendicularly and horizontally as shown in the figure at
right, then reset the pointer to zero (0).

6.

Equally tighten the bolts (1), (2), (3) and (4) in that order so
that the dial gauge pointer stays in the 00.05 mm
(00.0020 in) range. Then tighten these bolts to the specified torque.
NOTE
z Be sure to equally tighten the bolts in the order enumerated above.
:20 - 25 Nm {2.0 - 2.5 kgfm, 14 - 18 ftlbf}

DR-4-8

DISASSEMBLY AND REASSEMBLY


7.

Loosen the plate (coupling half side) and cross coupling


securing bolts.

8.

Make sure the plate (coupling half side) is smoothly inserted


into the cross coupling spigot joint. If it is not, loosen the
injection pump securing bolts (1), (2), (3) and (4), readjust
by repeating from step 3 above.

9.

Tighten the plate (coupling half side)-to-cross coupling


securing bolts to the specified torque.
: FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS}
29 - 34 Nm {3.0 - 3.5 kgfm, 22 - 25 ftlbf}
: FE6TA 157 kW {213 PS}
59 - 64 Nm {6.0 - 6.5 kgfm, 43 - 47 ftlbf}

10. Rotate the flywheel so that the pointer is aligned with the
specified fuel injection timing mark. If the timing marks on
the injection pump body and injection pump timer are not
close each other, rotate the flywheel an additional turn until
the No. 1 cylinder is set at TDC on the compression stroke.
Maintenance
standard

Service
limit

14

119 kW {162 PS}

15

132 kW {180 PS}

12

135 kW {183 PS}

12

151 kW {205 PS}

10

162 kW {220 PS}

157 kW {213 PS}

173 kW {235 PS}

12

Item
FE6A
FE6B
Fuel
injection
timing

FE6T

FE6T
A

Remarks

MD-TICS
system

DR-4-9

DISASSEMBLY AND REASSEMBLY


11. Align the line scribed on the injection pump timer with the
line on the injection pump body.

12. Tighten the bolts to the specified torque.


: FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS}
29 - 34 Nm {3.0 - 3.5 kgfm, 22 - 25 ftlbf}
: FE6TA 157 kW {213 PS}
59 - 64 Nm {6.0 - 6.5 kgfm, 43 - 47 ftlbf}

13. Tighten the coupling half cotter bolts to the specified torque.
: FE6A, FE6B, FE6T and FE6TA 173 kW {235 PS}
59 - 64 Nm {6.0 - 6.5 kgfm, 43 - 47 ftlbf}
: FE6TA 157 kW {213 PS}
83 - 93 Nm {8.5 - 9.5 kgfm, 61 - 69 ftlbf}

DR-4-10

DISASSEMBLY AND REASSEMBLY

CYLINDER HEAD
DISASSEMBLY AND REASSEMBLY
Step 1

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Breather hose
2-A. Breather (Type Z5506)
2-B. Breather (Type Z5507)
2-C. Air control valve

3. Gasket
4. O-ring
5. Breather adapter
6. O-ring

DR-4-11

7. Oil filler cap


8. Rocker cover
9. Baffle plate
10. Cover gasket

DISASSEMBLY AND REASSEMBLY

Step 2

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


11. Stopper bolt
, 12. Rocker shaft bracket
13. Rocker arm

,+ 14. Rocker shaft


15. Push rod

16. Exhaust valve


17. Intake valve

Marks + and , indicate that the key points of operation are explained in the text.

DR-4-12

DISASSEMBLY AND REASSEMBLY

Step 3

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


, 18. Cylinder head bolt
, 19. Cylinder head bolt
, 20. Cylinder head bolt
21. Nozzle sleeve
22. Nozzle tube

23. O-ring
24. Valve guide
25. Push rod pipe
26. Front engine slinger

27. Stay
28. Rear engine slinger
,+ 29. Cylinder head
30. Head gasket

Marks + and , indicate that the key points of operation are explained in the text.

DR-4-13

DISASSEMBLY AND REASSEMBLY

Key point of disassembly


14 Rocker shaft
Remove the rocker shaft assembly and push rods.
NOTE
z Loosen the rocker shaft assembly mounting bolts, starting with the outer bolt and moving toward the center.

29 Cylinder head
Remove the cylinder head assembly. Attach chains or cables to the
engine lifters and lift the cylinder head away from the cylinder block
using a hoist.
NOTE
z

Loosen the head bolts diagonally, starting with the outer


one and moving toward the center.

Key point of reassembly


29 Cylinder head
Install the cylinder head using gaskets.
NOTE
z Ensure that the stamped part number side faces upward
when installing the gasket.

20, 19, 18 Cylinder head bolt


Tighten the cylinder head bolts to the specified torque using the
socket wrench (99664 Z5000). Note that seven of the head bolts
are also secured to the rocker shaft bracket.
: 1st : 98 Nm {10.0 kgfm, 72 ftlbf}
2nd: 177 - 196 Nm {18.0 - 20.0 kgfm, 130 - 145 ftlbf}
: Refers to the bolts which are also secured to the rocker
shaft bracket. [L = 180 mm (7.09 in)]
O : Circled numbers refer to tightening sequence of head bolts.

DR-4-14

DISASSEMBLY AND REASSEMBLY


14 Rocker shaft
Insert the push rod and install the rocker shaft assembly.
NOTE
z

Be sure to align the end of the rocker arm with that of the
push rod.

12 Rocker shaft bracket


Tighten seven rocker shaft bracket bolts.
: 44 - 54 Nm {4.5 - 5.5 kgfm, 33 - 40 ftlbf}
NOTE
z

Tighten the middle bolt first and move toward the outer
ones.

DR-4-15

DISASSEMBLY AND REASSEMBLY

- MEMO -

DR-4-16

DISASSEMBLY AND REASSEMBLY

ENGINE PROPER
DISASSEMBLY AND REASSEMBLY

DR-4-17

DISASSEMBLY AND REASSEMBLY

DR-4-18

DISASSEMBLY AND REASSEMBLY

DR-4-19

DISASSEMBLY AND REASSEMBLY


Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)
,+ 1. Flywheel
2. Oil pan
3. Gasket
4. Oil screen
5. Gasket
6. Timing gear case
7. O-ring
8. Oil seal
9. Revolution sensor
,+ 10. Hydraulic pump
11. Gasket
12. O-ring

,+ 13-A. Air compressor (AOH model)


,+ 13-B. Injection pump support (VAC model)
14. O-ring
15. Stiffener (If so equipped)
,+ 16. Flywheel housing
17. Oil seal
18. Gasket
19. Gasket
20. Gasket
21. Connecting rod cap and bearing shell

,+ 22. Piston assembly


,+ 23. Crankshaft assembly
,+ 24. Idler gear
25. Idler gear shaft
+ 26. Camshaft assembly
27. Cam follower
28. Gasket
29. Front end plate
30. Gasket
31. Oil jet

Marks + and , indicate that the key points of operation are explained in the text.

Key point of disassembly


z

Install the engine stand attachment (99554 97001).

Lift the engine with a hoist and attach it to the engine stand
(99550 96001).

1 Flywheel
1. Measure and record the surface runout of the flywheel that
engages with the clutch disc. (Manual transmission model
only)

DR-4-20

DISASSEMBLY AND REASSEMBLY


2.

Remove the bolts. Using the two guide bolts (99687


97001), remove the flywheel.

10 Hydraulic pump, (13)-A Air compressor, (13)-B Injection


pump support
Measure and record the backlash of the front gear train.
NOTE
z Before measuring the backlash, install the air compressor (AOH model only) or injection pump support (VAC
model only), if previously removed.
z Before measuring the backlash of the hydraulic pump
gear, install the timing gear case. Apply grease to a fuse
and affix the fuse to a tooth of the pump gear. Install the
pump gear on the timing gear case. Rotate the gear and
measure the thickness of the smashed fuse to determine
the backlash.
16 Flywheel housing
Remove the flywheel housing.
NOTE
z

Before removing the flywheel housing, remove the


engine rear PTO (if so equipped).

22 Piston assembly
1. Measure the side clearance of the large end of the connecting rod.

DR-4-21

DISASSEMBLY AND REASSEMBLY


2. Remove the piston assembly and connecting rod as a unit.
NOTE
z Before removing these parts, remove carbon from the
upper inside wall of the cylinder liner.

23 Crankshaft assembly
1. Measure and record the end play of the crankshaft.

2.

Remove the crankshaft, thrust washer and upper main


bearing shell.
NOTE
z Keep the upper and lower thrust washers together as a
set.
z Keep the upper and lower main bearing halves and main
bearing cap as a set.

24 Idler gear
Measure and record the end play of the idler gear.

26 Camshaft assembly
Remove the camshaft gear and camshaft.
NOTE
z Turn the oil pan sideways so that the cam follower cannot drop into the oil pan when removing the camshaft.

DR-4-22

DISASSEMBLY AND REASSEMBLY

Key point of reassembly


CAUTION
z

Before reassembling the engine, replace all gaskets,


packings and O-ring with new ones and apply a coat of
engine oil to the frictional surfaces of all parts.

22 Crankshaft
1. Install upper main bearing shells.
NOTE
z Be sure to reinstall all shells in their original positions.
2.

Attach the upper thrust washer to both sides of No. 6 bearing.


NOTE
z Face the side with the stamped mark toward the cylinder
block.

3.

Position the lower main bearing shell in the main bearing


cap and install the bearing cap.
: 177 - 196 Nm {18.0 - 20.0 kgfm, 130 - 145 ftlbf}
NOTE
z Ensure that all main bearing shells are reinstalled in their
original positions.

Install the main bearing cap with the arrow mark facing
the front of the engine in the order of embossed numbers.

4.

Be sure to attach the lower thrust washer to both sides of


No. 6 bearing.
NOTE
z Face the side with the stamped mark of the thrust washer
toward the main bearing cap.

DR-4-23

DISASSEMBLY AND REASSEMBLY


5.

Measure the end play of the crankshaft.


Unit: mm (in)
Maintenance standard

Service limit

0.06 - 0.14 (0.0024 - 0.0055)

0.40 (0.0157)

22 Piston assembly
1. Insert the piston assembly (including the connecting rod,
upper bearing shell and bolts) into the cylinder liner using
the piston insert tool (99631 Z5502).
NOTE
z When installing the piston rings, ensure that their gaps
are 180 opposite of each other and are not positioned in
the direction of the piston pin and at a right angle to it.
z Face the arrow mark on the piston toward the front of the
engine when inserting the piston assembly.
z Ensure that the number stamped on the large end of
each connecting rod is the same as that on the cylinder
when installing the piston assembly.
Engine model
FE6T

151 kW {205 PS}

FE6TA

Piston assembly type


Type I

FE6A
FE6B
FE6T

Type II
135 kW {183 PS}
162 kW {220 PS}

Type III

DR-4-24

DISASSEMBLY AND REASSEMBLY


2.

Install the connecting rod cap on which the lower bearing


shell has already been installed.
: 132 - 142 Nm {13.5 - 14.5 kgfm, 98 - 105 ftlbf}
NOTE
z Ensure that the stamped mark on the end face of the connecting rod cap is the same as that stamped on the large
end of the connecting rod.

3.

Measure the side clearance of the large end of the connecting rod.
Unit: mm (in)
Maintenance standard

Service limit

0.10 - 0.30 (0.0039 - 0.0118)

24 Idler gear
1. Install the idler gear.
NOTE
z Align the timing mark on the camshaft gear with that on
the crank gear.
: 34 - 39 Nm {3.5 - 4.0 kgfm, 25 - 29 ftlbf}

2.

Measure the end play of the idler gear.


Unit: mm (in)
Maintenance standard

Service limit

0.03 -0.12 (0.0012 - 0.0047)

0.3 (0.012)

13-A Air compressor, 13-B Injection pump support


1. Install the air compressor (AOH model only) or injection
pump support (VAC model only).
: 147 - 167 Nm {15.0 - 17.0 kgfm, 108 - 123 ftlbf}
NOTE
z Align the timing mark on the injection pump drive gear
with that on the idler gear.
z Installing the air compressor in this step may facilitate
subsequent operations.

DR-4-25

DISASSEMBLY AND REASSEMBLY


2.

Measure the backlash of the front gear train (Refer to key


point (10) for measurement of backlash of the hydraulic
pump gear).
Unit: mm (in)
Maintenance standard

Service limit

0.06 - 0.16 (0.0024 - 0.0063)

0.30 (0.0118)

10 Hydraulic pump
Using grease, affix a fuse to a tooth of the hydraulic pump gear and
install the hydraulic pump on the timing gear case. Rotate the pump
gear and measure the thickness of the smashed fuse to determine
the backlash.
Unit: mm (in)
Maintenance standard

Service limit

0.06 - 0.16 (0.0024 - 0.0063)

0.30 (0.0118)

16 Flywheel housing
Install the flywheel housing using a gasket.
NOTE
z On models equipped with the PTO, remove the idler gear
bracket in advance.

1 Flywheel assembly
1. Install the flywheel using the two guide bolts (99687 97001),
and tighten the bolts.
: 235 - 255 Nm {24.0 - 26.0 kgfm, 174 - 188 ftlbf}

2.

Measure the surface runout of the flywheel that engages


with the clutch disc.
Unit: mm (in)
Maintenance standard

Service limit

0.15 (0.0059) (max.)

0.18 (0.0071)

DR-4-26

DISASSEMBLY AND REASSEMBLY

ENGINE REAR PTO

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Connector bolt
2. Gasket
3. Oil tube
4. Gasket
5. Pointer cover
6. Gasket
7. Pointer
8. Gasket
9. Nut
10. Companion flange
11. Slinger
12. Oil seal

13. Tray
14. PTO holder
15. O-ring
16. Ball bearing
17. Retaining ring
18. O-ring
19. Retaining ring
, 20. Sub gear
21. Retaining ring
, 22. PTO gear
23. Ball bearing

24. Drive shaft


25. PTO cover
26. Cover gasket
27. Housing cover
28. Gasket
29. Idler shaft
30. Bushing
, 31. Idler gear
32. Idler gear bracket
33. Flywheel housing
34. Housing gasket

Marks + and , indicate that the key points of operation are explained in the text.

DR-4-27

DISASSEMBLY AND REASSEMBLY

Key point of disassembly


z

Measure and record the backlash between the idler gear


and crankshaft gear.
Measure and record the backlash between the PTO gear
and idler gear.

Key point of reassembly


31 Idler gear
Make sure that the backlash between the idler gear and crankshaft
gear is within the maintenance standard.
Unit: mm (in)
Maintenance standard

Service limit

0.06 - 0.14 (0.0024 - 0.0055)

0.3 (0.012)

22 PTO gear, 20 Sub gear


1. Install the spring into the PTO gear. Hang the tip of the
spring from the 11 mm (0.43 in) diameter hole in the PTO
gear and the other tip from the 11 mm (0.43 in) diameter
hole in sub gear, and install the sub gear.

NOTE
z

When installing the sub gear, face the F mark toward the
outside and lock it with a retaining ring.

2.

Secure the PTO gear and turn the sub gear in the direction
where the spring opens. When the 8 mm (0.31 in) diameter
hole in the PTO gear aligns with that in the sub gear, insert
an 8 mm (0.31 in) diameter pin.

DR-4-28

DISASSEMBLY AND REASSEMBLY


3.

Assemble the PTO gear, aligning the oil hole of the drive
shaft with the oil hole of the PTO gear.

4.

Align the pin position with the M24 threaded hole in the
PTO holder and install the pin.
5. Install the holder assembly into the flywheel housing and
extract the pin.
NOTE
z Be sure to extract the pin.
6.

With the gasket in place, plug the M24 threaded hole.

7.

Make sure that the backlash between the PTO gear and
idler gear is within the maintenance standard.
Unit: mm (in)
Maintenance standard

Service limit

0.05 - 0.15 (0.0020 - 0.0059)

0.3 (0.012)

DR-4-29

- MEMO -

- MEMO -

ENGINE PROPER

EP

CONTENTS
SERVICE DATA ...................................... EP-1-1
TOOLS .................................................... EP-2-1
INSPECTION........................................... EP-3-1
CYLINDER BLOCK ..........................................
CRANKSHAFT .................................................
MAIN BEARING SHELL ...................................
CYLINDER LINER ............................................
PISTON AND CONNECTING ROD..................
CAMSHAFT ......................................................
GEAR TRAIN....................................................
FLYWHEEL ......................................................
FLYWHEEL HOUSING AND
TIMING GEAR CASE .......................................
CRANK PULLEY AND DAMPER .....................

EP-3-1
EP-3-2
EP-3-4
EP-3-4
EP-3-5
EP-3-10
EP-3-11
EP-3-12
EP-3-13
EP-3-13

V-BELT ............................................................. EP-3-13

REPAIR AND REPLACEMENT .............. EP-4-1


CYLINDER LINER REPLACEMENT ................
CAMSHAFT BUSHING REPLACEMENT.........
CRANKSHAFT CORRECTION ........................
CONNECTING ROD REPLACEMENT.............
REPLACING CONNECTING ROD
SMALL-END BUSHING ....................................
REPLACING IDLER GEAR BUSHING .............
OIL SEAL COLLAR REPLACEMENT...............
FLYWHEEL CORRECTION .............................
REPLACING INJECTION PUMP BRACKET....
REAR OIL SEAL REPLACEMENT ...................

EP-4-1
EP-4-2
EP-4-3
EP-4-4
EP-4-4
EP-4-5
EP-4-5
EP-4-6
EP-4-6
EP-4-7

SERVICE DATA

SERVICE DATA
Unit: mm (in)
Maintenance
standard

Service limit

Longitudinal
direction

Less than 0.10 (0.0039)

Transverse direction

Less than 0.05 (0.0020)

0.02 (0.0008)

0.05T - 0.02L
(0.0020T - 0.0008L)

Journal outside diameter

77.930 - 77.950
(3.0681 - 3.0689)

77.82 (3.0638)

Crank pin outside diameter

64.925 - 64.945
(2.5561 - 2.5569)

64.80 (2.5512)

Item

Upper surface warpage


Cylinder
block

Inner wall roundness at liner


Clearance between main bearing cap and cylinder block

Crankshaft

Journal out-of-roundness

Less than 0.01 (0.0004)

0.02 (0.0008)

Crank pin out-of-roundness

Less than 0.01 (0.0004)

0.02 (0.0008)

Taper of journal

Less than 0.01 (0.0004)

Taper of crank pin

Less than 0.01 (0.0004)

Journal

Less than 0.07 (0.0028)

Contacting surface with oil


seal

Less than 0.01 (0.0004)

Flywheel mounting surface

Less than 0.02 (0.0008)

End play

0.06 - 0.14
(0.0024 - 0.0055)

0.40 (0.0157)

Clearance to crankshaft journal

0.03 - 0.09
(0.0012 - 0.0035)

0.15 (0.0059)

Runout

Main bearing shell

Inside diameter (when installed in cylinder block)

Cylinder
liner

108.00 - 108.03
(4.2520 - 4.2531)

Less than 0.02 (0.0008)

Taper

Less than 0.025 (0.0010)

0 - 0.07
(0 - 0.0028)

0.03 (0.0012)

FE6A
FE6B
FE6T 135 kW {183 PS}

107.825 - 107.855
(4.2451 - 4.2463)

FE6T 151 kW {205 PS}


FE6T 162 kW {220 PS}
FE6TA

107.940 - 107.970
(4.2496 - 4.2508)

FE6A
FE6B
FE6T 135 kW {183 PS}

0.145 - 0.205
(0.0057 - 0.0081)

FE6T 151 kW {205 PS}


FE6T 162 kW {220 PS}
FE6TA

0.050 - 0.070
(0.0020 - 0.0028)

36.00 - 36.02
(1.4173 - 1.4181)

Difference between adjacent cylinders

Outside
diameter

Piston
Clearance
to cylinder
liner

Piston pin bore inside diameter

EP-1-1

T = Tight
L = Loose
Refinishing allowance:
1.0 (0.039)

Indicator reading

Measuring position
From top
108.23 (4.2610)
25, 50, 75, 100, 150, 200
(0.98, 1.97, 2.95, 3.94, 5.91,
7.87)

Out-of-roundness

Flange protrusion from block upper surface

Remarks

z Lateral to piston pin


z Measure at 18.5 (0.728) posi-

tion from bottom surface, perpendicular to piston pin

SERVICE DATA
Unit: mm (in)
Maintenance
standard

Service limit

2nd

0.04 - 0.08
(0.0016 - 0.0031)

0.4 (0.016)

Oil

0.02 - 0.06
(0.0008 - 0.0024)

0.2 (0.008)

1st
2nd

0.30 - 0.45
(0.0118 - 0.0177)

1.5 (0.059)

FE6A
FE6B
FE6T 135 kW
{183 PS}

0.15 - 0.35
(0.0059 - 0.0138)

1.5 (0.059)

FE6T 151 kW
{205 PS}
FE6T 162 kW
{220 PS}
FE6TA

0.25 - 0.45
(0.0098 - 0.0177)

1.5 (0.059)

35.993 - 36.000
(1.4170 - 1.4173)

0 - 0.03L
(0 - 0.0012L)

0.05 (0.0020)

Small-end bushing inside diameter

36.025 - 36.041
(1.4183 - 1.4189)

Clearance between small-end bushing and piston pin

0.03 - 0.05
(0.0012 - 0.0020)

0.10 (0.0039)

Less than 0.15 (0.0059)

Less than 0.10 (0.0039)

Crank pin side clearance

0.10 - 0.30
(0.0039 - 0.0118)

Clearance between big-end bearing and crank pin

0.035 - 0.095
(0.0014 - 0.0037)

0.15 (0.0059)

No. 1

57.33 - 57.35
(2.2571 - 2.2579)

No. 2

57.13 - 57.15
(2.2492 - 2.2500)

No. 3

56.93 - 56.95
(2.2413 - 2.2421)

No. 4

56.73 - 56.75
(2.2335 - 2.2342)

FE6A
FE6B
FE6TA 173 kW
{235 PS}

IN

48.47 - 48.51
(1.9083 - 1.9098)

47.99 (1.8894)

EXH

48.41 - 48.45
(1.9059 - 1.9075)

47.93 (1.8870)

FE6T
FE6TA 157 kW
{213 PS}

IN

48.79 - 48.83
(1.9209 - 1.9224)

48.31 (1.9020)

EXH

48.41 - 48.45
(1.9059 - 1.9075)

47.93 (1.8870)

0.02 - 0.10
(0.0008 - 0.0039)

0.15 (0.0059)

Less than 0.03 (0.0012)

0.06 (0.0024)

End play

0.08 - 0.28
(0.0031 - 0.0110)

0.3 (0.012)

Front gear train backlash

0.06 - 0.16
(0.0024 - 0.0063)

0.3 (0.012)

Idler gear end play

0.03 - 0.12
(0.0012 - 0.0047)

0.3 (0.012)

Clearance between idler gear bushing and shaft

0.02 - 0.06
(0.0008 - 0.0024)

0.2 (0.008)

Item

Clearance between piston


ring and ring groove

Piston ring
Joint gap
Oil

Outside diameter
Piston pin
Clearance to piston pin hole

Connecting Twist
rod
Bend

Journal outside diameter

Camshaft

Height of
cam profile

Journal-to-bushing clearance

Runout (indicator reading)

Gear train

EP-1-2

Remarks

L = Loose

Runout of No. 1 & No. 4 with


No. 2 & No. 3 supported Vblocks

SERVICE DATA
Unit: mm (in)
Maintenance
standard

Service limit

Remarks

Less than 0.15 (0.0059)

0.18 (0.0071)

Manual transmission model only

20.5 (0.807)

18.5 (0.728)

21.5 (0.846)

19.5 (0.768)

FE6B, FE6T,
FE6TA

23.0 (0.906)

21.0 (0.827)

FE6B, FE6T,
FE6TA

43.0 (1.693)

45.0 (1.772)

FE6T 162 kW
{220 PS}
FE6TA 157 kW
{213 PS}

48.0 (1.890)

50.0 (1.969)

Fan pulley - alternator pulley (A)

10 - 15 (0.39 - 0.59)

Fan pulley - cooler compressor pulley (B)

7 - 12 (0.28 - 0.47)

Backlash of PTO gear

0.05 - 0.15
(0.0020 - 0.0059)

0.3 (0.012)

Backlash of idler gear

0.06 - 0.14
(0.0024 - 0.0055)

0.3 (0.012)

Item
Clutch disc contact surface runout
Type I
Thickness (A)
Flywheel

Type II

Reduced
size of worn
surface
Height (H)

V-belt

Engine rear
PTO

Type II

FE6A, FE6B
FE6T 135 kW
{183 PS}

Deflection

EP-1-3

Refer to page EP-3-12 (FLYWHEEL). Manual transmission


model only

Refer to page EP-3-13


(V-BELT).
When midpoint is pressed with
98 N {10 kgf, 22 lbf}

TOOLS

TOOLS
Tool name and number

Description

Straightedge
99645 Z5001

Used to measure flatness of cylinder block

Piston ring tool


99630 Z5001

Used to remove and install piston rings

Cylinder liner tool


99600 Z5002

Used to remove and install cylinder liners

Cam bushing remover


99590 Z5002

Used to remove camshaft bushings

Tool kit cam bushing


replacer
99590 Z5003
(1) 99594 Z5002
(2) 99594 Z5003
(3) 99595 Z5004
(4) 99595 Z5005
(5) 99597 Z5001

Used to install camshaft bushings


Cam bushing replace
(1) For No. 1
(2) For No. 4
(3) For No. 2
(4) For No. 3
Cam bushing replace bar
(5) For No. 2 and No. 3

EP-2-1

Shape

TOOLS

Tool name and number

Description

Oil seal collar replacer


99718 Z5002

Used to press-fit oil seal collars

Injection pump bracket setting tool


99720 Z5500

Used to center injection pump bracket


[For 25 mm (0.98 in) air compressor crankshaft
rear edge outside diameter]

Injection pump bracket setting tool


99720 Z5501

Used to center injection pump bracket


[For 30 mm (1.18 in) air compressor crankshaft
rear edge outside diameter]

Oil seal and sleeve replacer


99691 Z5500
(1) 99718 Z5500
(2) 99687 97002

Used to press-fit rear oil seal and sleeve


(1) Oil seal replacer
(2) Guide bolt
[For 110 mm (4.33 in) crankshaft rear edge
outside diameter and 115 mm (4.53 in) oil seal
sleeve outside diameter

Oil seal and sleeve replacer


99691 Z5501
(1) 99718 Z5504
(2) 99687 97002

Used to press-fit rear oil seal


(1) Oil seal replacer
(2) Guide bolt
[For 120 mm (4.72 in) crankshaft rear edge
outside diameter and 145 mm (5.71 in) oil seal
outside diameter]

Oil seal replacer


(1) 99718 Z5501
(2) 99687 97002

Used to press-fit rear oil seal


(1) Oil seal replacer
(2) Guide bolt
[For 145 mm (5.71 in) and 148 mm (5.83 in) oil
seal outside diameters]

Puller assembly
99718 Z5502

Used to remove oil seal sleeve


[For 115 mm (4.53 in) oil seal sleeve outside
diameter]

Puller assembly
99718 Z5503

Used to remove oil seal sleeve


[For 125 mm (4.92 in) oil seal sleeve outside
diameter]

EP-2-2

Shape

INSPECTION

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

CYLINDER BLOCK
Upper surface warpage
Measure using the straightedge (99645 Z5001).
Unit: mm (in)
Item

Maintenance standard

Service limit

Longitudinal direction

Less than 0.10 (0.0039)

Transverse direction

Less than 0.05 (0.0020)

Inner wall roundness of liner


Unit: mm (in)
Maintenance standard

Service limit

0.02 (0.0008)

Camshaft bushing inside diameter


Measure the inside diameter of the camshaft bushing.

EP-3-1

INSPECTION

Clearance between main bearing cap and cylinder


block
Unit: mm (in)
Maintenance standard

Service limit

0.05T - 0.02L
(0.0020T - 0.0008L)

Remarks
T: Tight

L: Loose

CRANKSHAFT
Journal outside diameter
When the journal outside diameter exceeds the service limit, it must
be corrected by grinding and undersized main bearing shells must
be installed.
Unit: mm (in)
Maintenance standard
77.930 - 77.950
(3.0681 - 3.0689)

Service limit

Remarks

77.82 (3.0638)

Refinishing allowance:
1.0 (0.039)

Journal out-of-roundness
When the journals exceeds the service limit in out-of-roundness,
they must be corrected by grinding. Install new undersized main
bearing shells.
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.01 (0.0004)

0.02 (0.0008)

Taper of journal
When the journals exceeds the service limit in taper, they must be
corrected by grinding. Install new undersized main bearing shells.
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.01 (0.0004)

Crank pin outside diameter


When the outside diameter of the crank pin exceeds the service
limit, it must be corrected by grinding, and install new undersized
bearing shells.
Unit: mm (in)
Maintenance standard

Service limit

Remarks

64.925 - 64.945
(2.5561 - 2.5569)

64.80 (2.5512)

Refinishing allowance:
1.0 (0.039)

EP-3-2

INSPECTION

Crank pin out-of-roundness


When the crank pin out-of-roundness exceeds the service limit, the
crank pins must be ground and used with new undersized bearing
shells.
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.01 (0.0004)

0.02 (0.0008)

Taper of crank pin


When the crank pin taper exceeds the service limit, the crank pin
must be ground and used with new undersized bearing shells.
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.01 (0.0004)

Runout
Support the crankshaft at No. 2 and 6 journals, and measure the
runout of each part.
Unit: mm (in)
Maintenance
standard

Service limit

Journal A

Less than 0.07


(0.0028)

Contacting surface with oil seal B

Less than 0.01


(0.0004)

Flywheel mounting surface C

Less than 0.02


(0.0008)

Item

Remarks

Indicator reading

End play
When end play measured at the time of engine disassembly
exceeds the service limit, replace the thrust washers selectively as
a set.
Unit: mm (in)
Maintenance standard

Service limit

0.06 - 0.14 (0.0024 - 0.0055)

0.40 (0.0157)

Types of thrust washer


Size symbol
STD

Thickness mm (in)

2.965 - 2.995 (0.1167 - 0.1179)

2.930 - 2.965 (0.1154 - 0.1167)

2.900 - 2.930 (0.1142 - 0.1154)

0.20 OS

3.150 - 3.200 (0.1240 - 0.1260)

0.40 OS

3.350 - 3.400 (0.1319 - 0.1339)

Remarks
STD: Standard

OS: Oversize

EP-3-3

INSPECTION

MAIN BEARING SHELL


Clearance to crankshaft journal
Install the main bearing shell in the cylinder block, and tighten the
main bearing cap to the specified torque. Then measure the shell
inside diameter and calculate the shell clearance from the journal
outside diameter.
: 177 - 196 Nm {18.0 - 20.0 kgfm, 130 - 145 ftlbf}
Unit: mm (in)
Maintenance standard

Service limit

0.03 - 0.09 (0.0012 - 0.0035)

0.15 (0.0059)

CYLINDER LINER
Measure the cylinder liners with installed in the cylinder block. [The
measuring positions are 25, 50, 75, 100, 150 and 200 mm (0.98,
1.97, 2.95, 3.94, 5.91 and 7.87 in) from the block upper surface.]

Inside diameter
Unit: mm (in)
Maintenance standard

Service limit

108.00 - 108.03 (4.2520 - 4.2531)

108.23 (4.2610)

Out-of-roundness
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.02 (0.0008)

Taper
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.025 (0.0010)

Flange protrusion from block upper surface


Unit: mm (in)
Maintenance standard

Service limit

0 - 0.07 (0 - 0.0028)

Difference between adjacent cylinders


Unit: mm (in)
Maintenance standard

Service limit

0.03 (0.0012)

EP-3-4

INSPECTION

PISTON AND CONNECTING ROD


Before inspection, disassemble the piston and connecting rod
assemblies. Keep the disassembled parts of each cylinder together
so that they may be reinstalled in the cylinder from which they were
removed.
NOTE
z

The piston rings for all cylinders should be replaced as


an assembly during overhaul.
1.

1st ring

8.

Bolt

2.

2nd ring

9.

Connecting rod

3.

Oil ring

10.

Bearing shell (upper)

4.

Piston

11.

Bearing shell (lower)

5.

Snap ring

12.

Connecting rod cap

6.

Piston pin

13.

Nut

7.

Bushing

Disassembling piston and connecting rod


z

Remove the snap rings and piston pin.

Remove the piston rings using the piston ring tool (99630
Z5001).

EP-3-5

INSPECTION

PISTON
Outside diameter
The piston outside diameter should be checked at 18.5 mm (0.728
in) from the piston bottom and perpendicular to the piston pin.
Unit: mm (in)
Item

Maintenance standard

Service limit

FE6A, FE6B,
FE6T 135 kW {183 PS}

107.825 - 107.855
(4.2451 - 4.2463)

FE6T 151 kW {205 PS}


FE6T 162 kW {220 PS}
FE6TA

107.940 - 107.970
(4.2496 - 4.2508)

Clearance to cylinder liner


Calculate the clearance from the cylinder liner inside diameter and
piston outside diameter.
Unit: mm (in)
Item

Maintenance standard

Service limit

FE6A, FE6B,
FE6T 135 kW {183 PS}

0.145 - 0.205
(0.0057 - 0.0081)

FE6T 151 kW {205 PS}


FE6T 162 kW {220 PS}
FE6TA

0.050 - 0.070
(0.0020 - 0.0028)

Piston pin bore inside diameter


Unit: mm (in)
Maintenance standard

Service limit

36.00 - 36.02 (1.4173 - 1.4181)

EP-3-6

INSPECTION

PISTON RING
Clearance between piston ring and ring groove
NOTE
z

The 1st ring clearance cannot be measured because of


the ring groove shape.
Unit: mm (in)
Item

Maintenance standard

Service limit

2nd

0.04 - 0.08 (0.0016 - 0.0031)

0.4 (0.016)

Oil

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

Joint gap
Unit: mm (in)
Item

Maintenance standard

Service limit

0.30 - 0.45
(0.0118 - 0.0177)

1.5 (0.059)

FE6A
FE6B
FE6T 135 kW {183 PS}

0.15 - 0.35
(0.0059 - 0.0138)

1.5 (0.059)

FE6T 151 kW {205 PS}


FE6T 162 kW {220 PS}
FE6TA

0.25 - 0.45
(0.0098 - 0.0177)

1.5 (0.059)

1st
2nd

Oil

PISTON PIN
Outside diameter
Unit: mm (in)
Maintenance standard

Service limit

35.993 - 36.000 (1.4170 - 1.4173)

EP-3-7

INSPECTION

Clearance to piston pin hole


Calculate the clearance from the piston pin outside diameter and
pin hole inside diameter.
Unit: mm (in)
Maintenance standard

Service limit

0 - 0.03L (0 - 0.0012L)

0.05 (0.0020)

Remarks
L = Loose

CONNECTING ROD
Small-end bushing inside diameter
Unit: mm (in)
Maintenance standard

Service limit

36.025 - 36.041 (1.4183 - 1.4189)

Clearance between small-end bushing and piston pin


Unit: mm (in)
Maintenance standard

Service limit

0.03 - 0.05 (0.0012 - 0.0020)

0.10 (0.0039)

Clearance between big-end bearing and crank pin


Fit each bearing shell to the connecting rod having the same cylinder No., then the connecting rod and cap to the specified torque.
: 132 - 142 Nm {13.5 - 14.5 kgfm, 98 - 105 ftlbf}
Calculate the clearance between the crank pin O.D. and bearing
shell I.D. from the measured values.
Unit: mm (in)
Maintenance standard

Service limit

0.035 - 0.095 (0.0014 - 0.0037)

0.15 (0.0059)

EP-3-8

INSPECTION

Bend and twist


To check connecting-rod alignment, install the piston pin in the
small-end bushing. Mount the connecting rod with the cap on the
aligner. Then measure the clearance at aligner pin A or B to determine the bend and twist of the rod. If the distance between pins A
and B is not 200 mm (7.87 in), make the following calculation.
Amount of bend
or twist

200 (7.87)

x Measured value [mm (in)]

Distance between pins

Unit: mm (in)
Maintenance
standard

Service limit

Remarks

Bend

Less than 0.10 (0.0039)

Twist

Less than 0.15 (0.0059)

Distance between
pins: 200 (7.87)

Item

Crank pin side clearance


Check the measurements made during engine overhaul.
Unit: mm (in)
Maintenance standard

Service limit

0.10 - 0.30 (0.0039 - 0.0118)

Assembling piston and connecting rod


1.

Install the piston rings using the piston ring tool (99630
Z5001).
NOTE

Install the rings with the mark facing up.

Piston ring design


1st ring

Type I

FE6A, FE6B, FE6T [135 kW {183 PS}]

Type II

FE6T [151 kW {205 PS}], FE6T [162 kW {220 PS}],


FE6TA

2nd ring
Oil ring

Engine model

FE6A, FE6B, FE6T, FE6TA


Type I

FE6A, FE6B, FE6T [135 kW {183 PS}]

Type II

FE6T [151 kW {205 PS}], FE6TA

Type III

FE6T [162 kW {220 PS}]

EP-3-9

INSPECTION
2.

Assemble the piston, piston pin, snap rings and connecting


rod.
NOTE
z Assemble so that the triangular mark on the piston head
points to the left side with respect to the cylinder number
(facing the front) stamped on the connecting rod.

CAMSHAFT
End play
Unit: mm (in)
Maintenance standard

Service limit

0.08 - 0.28 (0.0031 - 0.0110)

0.3 (0.012)

Removing camshaft gear


1.

Nut

5.

Locating plate

2.

Lock washer

6.

Key

3.

Plain washer

7.

Camshaft

4.

Camshaft gear

Journal outside diameter


Unit: mm (in)
Item

Maintenance standard

Service limit

No. 1

57.33 - 57.35 (2.2571 - 2.2579)

No. 2

57.13 - 57.15 (2.2492 - 2.2500)

No. 3

56.93 - 56.95 (2.2413 - 2.2421)

No. 4

56.73 - 56.75 (2.2335 - 2.2342)

EEP3-025

Journal-to-bushing clearance
Calculate the clearance from the journal outside diameter and
bushing inside diameter.
Unit: mm (in)
Maintenance standard

Service limit

0.02 - 0.10 (0.0008 - 0.0039)

0.15 (0.0059)

EP-3-10

INSPECTION

Height of cam profile


Unit: mm (in)
Item
FE6A
IN
FE6B
FE6TA 173 kW
EXH
{235 PS}
FE6T
IN
FE6TA 157 kW
EXH
{213 PS}

Maintenance standard

Service limit

48.47 - 48.51 (1.9083 - 1.9098) 47.99 (1.8894)


48.41 - 48.45 (1.9059 - 1.9075) 47.93 (1.8870)
48.79 - 48.83 (1.9209 - 1.9224) 48.31 (1.9020)
48.41 - 48.45 (1.9059 - 1.9075) 47.93 (1.8870)

Runout
Support the camshaft at No. 2 and 3 journals and measure the
runout of No. 1 and 4 journals.
Unit: mm (in)
Maintenance standard

Service limit

Remarks

Less than 0.03


(0.0012)

0.06 (0.0024)

Indicator reading

Installing camshaft gear


1.
2.
3.

Install the locating plate on the camshaft.


Insert the key into the keyway and install the camshaft gear.
Install the plain washer, lock washer and nut in sequence.
: 186 - 226 Nm {19.0 - 23.0 kgfm, 137 - 166 ftlbf}

GEAR TRAIN
Front gear train backlash
Unit: mm (in)
Maintenance standard

Service limit

0.06 - 0.16 (0.0024 - 0.0063)

0.3 (0.012)

EP-3-11

INSPECTION

Clearance between idler gear bushing and shaft


Unit: mm (in)
Maintenance standard

Service limit

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

Idler gear end play


Unit: mm (in)
Maintenance standard

Service limit

0.03 - 0.12 (0.0012 - 0.0047)

0.3 (0.012)

FLYWHEEL
Clutch disc contact surface runout
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.15 (0.0059)

0.18 (0.0071)

REDUCED SIZE OF WORN SURFACE


NOTE
z

Be careful since dimension A may exceed service limits. Dimension H is within service limits on type II flywheel where the clutch contacting surface was ground to
the specification.
Unit: mm (in)
Item

FE6A, FE6B
Type I FE6TA 135 kW
{183 PS}
Thickness (A)
FE6B, FE6T
Type II
FE6TA
FE6B, FE6T
FE6TA
Height (H)

Type II FE6T 162 kW


{220 PS}
FE6TA 157 kW
{213 PS}

Maintenance
standard

Service limit

20.5 (0.807)

18.5 (0.728)

21.5 (0.846)

19.5 (0.768)

23.0 (0.906)

21.0 (0.827)

43.0 (1.693)

45.0 (1.772)

48.0 (1.890)

50.0 (1.969)

EP-3-12

INSPECTION

FLYWHEEL HOUSING AND TIMING GEAR


CASE
NOTE
z

Oil seals should be replaced each time the engine is


overhauled.

CRANK PULLEY AND DAMPER


Check the entire assembly for cracks or damage. Also, check for
separation of the damper from the disc.

V-BELT
Check the V-belt for cracks or damage. Also check if it is out of contact with the pulley grooves.
Unit: mm (in)
Maintenance
standard

Service limit

Remarks

10 - 15 (0.39 - 0.59)

7 - 12 (0.28 - 0.47)

When midpoint is
pressed with
98 N {10 kgf, 22 lbf}

Item
Deflection

EP-3-13

REPAIR AND REPLACEMENT

REPAIR AND REPLACEMENT


CYLINDER LINER REPLACEMENT
1.

Remove and install the cylinder liners using the cylinder


liner tool (99600 Z5002).
NOTE
z When installing the cylinder liners, clean the cylinder
block inner walls and cylinder liner outer surfaces. Then
coat them with a thin coat of engine oil.

2.

When replacing the cylinder liners, use liners whose marks


on the outer skirts coincide with the stamp (0 or 1) on the
upper surface of the cylinder block.

EP-4-1

REPAIR AND REPLACEMENT


3.

After press-fitting the cylinder liners, check the inside diameter, out-of-roundness, taper and flange protrusion.
NOTE
z The main bearing caps should be tightened to the specified torque.
: 177 - 196 Nm {18.0 - 20.0 kgfm, 130 - 145 ftlbf}
Unit: mm (in)
Item

Inside diameter

Maintenance
standard

Service
limit

Measuring position
From top
108.00 - 108.03 108.23
25, 50, 75, 100, 150,
(4.2520 - 4.2531) (4.2610)
200 (0.98, 1.97, 2.95,
3.94, 5.91, 7.87)

Out-of-roundness

Less than 0.02


(0.0008)

Taper

Less than 0.025


(0.0010)

0 - 0.07
(0 - 0.0028)

0.03 (0.0012)

Flange protrusion from


block upper surface
Difference between
adjacent cylinders

Remarks

CAMSHAFT BUSHING REPLACEMENT


Removing bushings
Using the cam bushing remover (99590 Z5002), remove bushings
No. 1 and No. 2 toward the rear of the engine and No. 3 and No. 4
toward the front.

EP-4-2

REPAIR AND REPLACEMENT

Installing bushings
1.
2.

Install bushings No. 2 and No. 3 using the Cam Bushing


Replacer (3), (4) and (5).
Install bushings No. 1 and No. 4 using the Cam Bushing
Replacer (1) and (2).
99590 Z5003 (Tool kit cam bushing replacer)
(1) 99594 Z5002 (for No. 1)
(2) 99594 Z5003 (for No. 4)
(3) 99595 Z5004 (for No. 2)
(4) 99595 Z5005 (for No. 3)
(5) 99597 Z5001 (for No. 2 and No. 3)

NOTE
z

Install the bushing with their notched section on the right


side of the block, facing to the front. Make sure that the
oil passages are aligned with the oil holes in the bushings.

CRANKSHAFT CORRECTION
Journals
When correcting the crankshaft journals by grinding, they must be
ground undersized so that the clearance between the new undersized bearing shell and the journal is within the maintenance standard.

Crank pins
When correcting the crank pins by grinding, they must be ground
undersized so that the clearance between the new undersized
bearing shell and the crank pin is within the maintenance standard.

NOTE

Be careful not to extend the width of the journal and


crank pin.
z Finish both shoulders by rounding, referring to the figure
to the right.
Crankshaft journals R 3.5 mm (0.138 in)
Crank pins R 4.0 mm (0.157 in)
z

EP-4-3

REPAIR AND REPLACEMENT

Size symbol

Journal grinding standard mm (in)

STD

Grinding not required

0.25US

77.680 - 77.700 (3.0583 - 3.0590)

0.50US

77.430 - 77.450 (3.0484 - 3.0492)

0.75US

77.230 - 77.250 (3.0405 - 3.0413)

1.00US

76.930 - 76.950 (3.0287 - 3.0295)

US: Undersized
Size symbol

Crank pin grinding standard mm (in)

STD

Grinding not required

0.25US

64.675 - 64.695 (2.5463 - 2.5470)

0.50US

64.425 - 64.445 (2.5364 - 2.5372)

0.75US

64.175 - 64.195 (2.5266 - 2.5274)

1.00US

63.925 - 63.945 (2.5167 - 2.5175)

US: Undersized

CONNECTING ROD REPLACEMENT


When a connecting rod is replaced, stamp the cylinder No. on it in
the same position as before.

REPLACING CONNECTING ROD SMALL-END


BUSHING
1.

Drive the bushing into the chamfered side of the connecting


rod small end.
NOTE
z Align the oil holes. The difference in height of the bushing above or below the chamfered surface should be less
than 1 mm (0.04 in).
Engine model

Connecting rod type

FE6A
FE6B
FE6T 135 kW {183 PS}
FE6T 151 kW {205 PS}
FE6TA

Type I

FE6T 162 kW {220 PS}

Type II

EP-4-4

REPAIR AND REPLACEMENT


2.

After driving in the bushing, cut both ends of it by aligning


with the tapered surface of the connecting rod. (Type II
only)

3.

Measure the inside diameter of the busing and outside


diameter of the piston pin to determine the bushing-to-piston pin clearance. If the clearance is less than maintenance
standards, grind the inside diameter of the bushing to within
the specified maintenance standard.
Unit: mm (in)
Maintenance standard

Service limit

0.03 - 0.05 (0.0012 - 0.0020)

0.10 (0.0039)

REPLACING IDLER GEAR BUSHING


1.

Press-fit the bushing so that the end face of the boss on the
front of the engine is level with the end face of the bushing.
NOTE
z The fitted face of the boss at the front should be 1.5 mm
(0.059 in) lower than the rear end face (H).
2.

After fitting the bushing, finish the inside diameter so that


the clearance with the idler gear shaft is within the maintenance standard.
Unit: mm (in)
Maintenance standard

Service limit

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

OIL SEAL COLLAR REPLACEMENT


1.
2.

Remove the oil seal collar by heating.


Using the collar replacer (99718 Z5002), press-fit the oil
seal collar until it contacts the crank gear.
NOTE
z Face the side with a groove on the end to the front.

EP-4-5

REPAIR AND REPLACEMENT

FLYWHEEL CORRECTION
The runout of the surface which contacts the clutch disc should be
corrected to the maintenance standard by grinding and/or cutting.
NOTE

The flywheel is serviceable until wear on the contacting


surface with the clutch disc is 2.0 mm (0.079 in) and
thickness (A) reaches the service limit. However, if the
flywheel is to be ground, do not grind more than 1.5 mm
(0.059 in).
z When grinding, also grind the flange so that height (H) is
within the maintenance standard.
z If the flywheel has to be ground more than 1.5 mm (0.059
in), replace the flywheel.
z

Unit: mm (in)
Item
FE6A, FE6B
Type I FE6TA 135 kW
{183 PS}
Thickness (A)
FE6B, FE6T
Type II
FE6TA
FE6B, FE6T
FE6TA
Height (H)

Type II FE6T 162 kW


{220 PS}
FE6TA 157 kW
{213 PS}

Maintenance
standard

Service limit

20.5 (0.807)

18.5 (0.728)

21.5 (0.846)

19.5 (0.768)

23.0 (0.906)

21.0 (0.827)

43.0 (1.693)

45.0 (1.772)

48.0 (1.890)

50.0 (1.969)

REPLACING INJECTION PUMP BRACKET


When replacing the cylinder block or injection pump bracket, center
the injection pump bracket.
1. Temporarily install a shim (of the same thickness as the one
removed) to the pump bracket.
Types (thickness) of shim: 0.05, 0.10, 0.20 and 0.30 mm
(0.0020, 0.0039, 0.0079 and 0.0118 in)

EP-4-6

REPAIR AND REPLACEMENT


2.

Using the injection pump bracket setting tool, install the


coupling A to the shaft of the air compressor. Then hold the
setting tool C, slide the shaft B, and insert it into the coupling A. If the shaft can be fitted in place, it is properly centered. If it interfaces, adjust with shim(s).
Tool name

Injection pump
bracket setting
tool

Tool number

Remarks

99720 Z5500

For 25 mm (0.98 in) air compressor


crankshaft rear edge outside diameter

99720 Z5501

For 30 mm (1.18 in) air compressor


crankshaft rear edge outside diameter

3.

After centering, tighten the pump bracket to the specified


torque.
: 37 - 42 Nm {3.8 - 4.3 kgfm, 27 - 31 ftlbf}

4.

After reaming, driven in the dowel pin and caulk the dowel
pin hole. The dowel pin should be driven in so that it is
slightly below 1 mm (0.04 in) or so the bracket surface.

REAR OIL SEAL REPLACEMENT


<Without oil seal sleeve>
1. Remove the oil seal.
2. Apply engine oil to the lip of the oil seal.
3. Using the oil seal replacer, press-fit the oil seal to the flywheel housing.
Unit: mm (in)
Oil seal and
Oil seal or Guide
Outside
bolt diameter of
sleeve replacer
sleeve
assembly No. replacer No. No.
oil seal
99691 Z5500

99718 Z5500

99687
99718 Z5501 97002

Outside diameter
of the rear edge of
the crankshaft

135 (5.31)

110 (4.33)

145 (5.71)
148 (5.83)

120 (4.72)

EP-4-7

REPAIR AND REPLACEMENT


<With oil seal sleeve>
1. Remove the oil seal.
2. Using the puller assembly, pull out the oil seal sleeve.
Unit: mm (in)

3.
4.

Puller assembly No.

Outside diameter of
sleeve

Outside diameter of
the rear edge of the
crankshaft

99718 Z5502

115 (4.53)

110 (4.33)

99718 Z5503

125 (4.92)

120 (4.72)

Apply sealant (LOCTITE 962T or equivalent) to the inside


surface of the oil seal sleeve.
Using the oil seal sleeve replacer, press-fit the oil seal
sleeve to the crankshaft.
Unit: mm (in)

Oil seal and


Oil seal or
sleeve
sleeve
replacer
replacer No.
assembly No.
99691 Z5500 99718 Z5500
99691 Z5501 99718 Z5504

5.
6.

Guide bolt
No.

99687 97002

Outside
diameter of
sleeve

Outside
diameter of
the rear edge
of the crankshaft

115 (4.53)

110 (4.33)

125 (4.92)

120 (4.72)

Apply engine oil to the lip of the oil seal.


Using the oil seal replacer, press-fit the oil seal to the flywheel housing.
Unit: mm (in)

Oil seal and


Oil seal or
sleeve
sleeve
replacer
replacer No.
assembly No.
99691 Z5500 99718 Z5500
99691 Z5501 99718 Z5504

Guide bolt
No.

99687 97002

Outside
diameter of
oil seal

Outside
diameter of
the rear edge
of the crankshaft

135 (5.31)

110 (4.33)

145 (5.71)

120 (4.72)

EP-4-8

- MEMO -

CYLINDER HEAD AND


VALVE MECHANISM

CONTENTS
SERVICE DATA ...................................... HV-1-1
SERVICE DATA ............................................... HV-1-1
TIGHTENING TORQUE ................................... HV-1-3
TOOLS .................................................... HV-2-1
CONSTRUCTION.................................... HV-3-1
REMOVAL............................................... HV-4-1
DISASSEMBLY....................................... HV-5-1
CYLINDER HEAD ............................................ HV-5-1
ROCKER SHAFT ............................................. HV-5-2
INSPECTION........................................... HV-6-1
CYLINDER HEAD ............................................ HV-6-1
VALVE INSERT ................................................ HV-6-1
VALVE .............................................................. HV-6-1
VALVE GUIDE.................................................. HV-6-2
VALVE SPRING ............................................... HV-6-2

VALVE ROCKER PARTS ................................. HV-6-3


PUSH ROD ....................................................... HV-6-4
CAM FOLLOWER............................................. HV-6-4
REPAIR AND REPLACEMENT .............. HV-7-1
REPAIRING CYLINDER HEAD ........................ HV-7-1
REPAIRING VALVE AND VALVE INSERT ...... HV-7-1
REPLACING VALVE INSERT .......................... HV-7-2
LAPPING VALVE AND VALVE INSERT .......... HV-7-3
REPLACING VALVE GUIDE ............................ HV-7-3
REPLACING VALVE ROCKER BUSHING....... HV-7-4
REPLACING NOZZLE TUBE ........................... HV-7-4
REASSEMBLY ........................................ HV-8-1
CYLINDER HEAD............................................. HV-8-1
ROCKER SHAFT.............................................. HV-8-2
INSTALLATION....................................... HV-9-1

HV

SERVICE DATA

SERVICE DATA
SERVICE DATA
Unit: mm (in)
Maintenance
standard

Service limit

Remarks

89.9 - 90.1
(3.539 - 3.547)

89.7 (3.531)

Max. allowable
grinding limit:
0.3 mm (0.012 in)

Longitudinal
direction

Less than 0.05


(0.0020)

0.2 (0.008)

Transverse direction

Less than 0.05


(0.0020)

0.2 (0.008)

Intake

50.0 - 50.02
(1.9685 - 1.9693)

Exhaust

41.0 - 41.02
(1.6142 - 1.6150)

1.25 - 1.35
(0.0492 - 0.0531)

Intake

30 - 3030

Exhaust

45 - 4530

Intake

2.2 - 2.4
(0.087 - 0.094)

3.5 (0.138)

Exhaust

2.0 - 2.3
(0.079 - 0.091)

3.5 (0.138)

Intake

2930 - 30

Exhaust

4430 - 45

Intake

8.96 - 8.98
(0.3528 - 0.3535)

Exhaust

8.92 - 8.94
(0.3512 - 0.3520)

Intake

2.16 (0.0850)

1.8 (0.071)

Exhaust

1.65 (0.0650)

1.3 (0.051)

Intake

1.33 - 1.83
(0.0524 - 0.0720)

2.8 (0.110)

Exhaust

1.03 - 1.53
(0.0406 - 0.0602)

2.3 (0.091)

Intake

0.3 - 0.4
(0.012 - 0.016)

Exhaust

0.3 - 0.4
(0.012 - 0.016)

Item

Cylinder head

Height of cylinder head

Flatness

Diameter of valve insert


bore

Valve insert

Thickness of head gasket


Seat face angle

Contact width of valve


and valve insert

Valve face angle

Valve

Outside diameter of
valve stem

Valve head thickness


Depth of valve below
lower surface of cylinder
head

Valve clearance

HV-1-1

When bolts are tightened


to specified torque

When engine is cold

SERVICE DATA
Unit: mm (in)
Maintenance
standard

Service limit

Intake

9.00 - 9.02
(0.3543 - 0.3551)

Exhaust

9.00 - 9.02
(0.3543 - 0.3551)

Intake

0.02 - 0.05
(0.0008 - 0.0020)

0.15 (0.0059)

Exhaust

0.05 - 0.09
(0.0020 - 0.0035)

0.20 (0.0079)

15 (0.59)

Outer

62.8 (2.472)

55.0 (2.165)

Inner

60.9 (2.398)

58.0 (2.283)

Outer

246.2 - 271.7
{25.1 - 27.7,
55.3 - 61.1}

When spring is compressed to 44.6 mm


(1.756 in)

Inner

126.5 - 140.2
{12.9 - 14.3,
28.4 - 31.5}

When spring is compressed to 41.6 mm


(1.638 in)

Less than 2.0


(0.079)

Inner and outer springs

19.98 - 20.00
(0.7866 - 0.7874)

19.90 (0.7835)

0.06 (0.0024)

0.1 (0.004)

Inside diameter of valve rocker bushing

20.02 - 20.04
(0.7882 - 0.7890)

20.10 (0.7913)

Clearance between valve rocker bushing and


rocker shaft

0.02 - 0.06
(0.0008 - 0.0024)

0.2 (0.008)

60.0 (2.362)

49.0 (1.929)

21.6 - 31.4
{2.2 - 3.2,
4.9 - 7.1}

16.7 {1.7, 3.7}

Less than 0.30


(0.0118)

Outside diameter

19.96 - 19.98
(0.7858 - 0.7866)

19.85 (0.7815)

Clearance to cylinder block cam follower bore

0.02 - 0.06
(0.0008 - 0.0024)

0.12 (0.0047)

Item

Valve guide

Inside diameter of valve


guide

Clearance to valve stem

Protrusion above drive-in surface of cylinder


head

Valve spring

Free length

Tension

N {kgf, lbf}

Squareness

Valve rocker parts

Outside diameter of rocker shaft


Rocker shaft runout

Free length
Inside spring

Tension
N {kgf, lbf}

Cam follower

Runout of push rod

HV-1-2

Remarks

Intake and exhaust


valves
Intake and exhaust
valves

When spring is compressed to 33.5 mm


(1.319 in)
When measured with
each spherical end supported

SERVICE DATA

Maintenance
standard

Item

Service limit

Remarks

Valve clearance adjustment sequence:


Cylinder No.

Other

Valve arrangement
No. 1 piston at TDC on compression stroke
No. 6 piston at TDC on compression stroke

10

11

12

IN

EX

IN

EX

IN

EX

IN

EX

IN

EX

IN

EX

TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Engine slinger mounting bolt

29 - 49 {3.0 - 5.0, 22 - 36}

Nozzle sleeve

34 - 38 {3.5 - 3.9, 25 - 28}

Cylinder head bolts

1st

98 {10.0, 72}

2nd

177 - 196 {18.0 - 20.0, 130 - 145}

Rocker shaft bracket mounting bolts

44 - 54 {4.5 - 5.5, 33 - 40}

Exhaust manifold mounting nuts

34 - 44 {3.5 - 4.5, 25 - 33}

Air intake manifold mounting bolts

16 - 20 {1.6 - 2.0, 12 - 14}

Nozzle holder mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Injection nozzle tube

23 - 27 {2.3 - 2.8, 17 - 20}

Spill tube connector

8 - 10 {0.8 - 1.0, 5.8 - 7.2}

HV-1-3

Remarks

Tighten center bolts first then move


toward outer bolts.

TOOLS

TOOLS
Tool name and number

Description

Split collar tool


99624 Z5001

Used to remove and install split collar

Valve insert remover


99660 Z5503
(1) 99669 Z5502
(2) 99669 Z5503
(3) 99668 95000
(4) 99532 95000
(5) 99531 Z6000
(6) 89-11246-1A
(7) 89-15446-1A

Used to remove intake and exhaust valve


insert
(1) Puller (for inlet)
(2) Puller (for exhaust)
(3) Bridge
(4) Puller bolt
(5) Bolt (M8 x 1.25)
(6) Nut (M16 x 1.5)
(7) Plain washer

Valve insert replacer


99665 Z5002

Used to install valve insert on cylinder head


(cold-fit)

Valve insert caulking tool


(1) 99675 Z5002
(2) 99676 Z5000
(3) 81-20616-1A

Used to caulk valve insert (for exhaust)


(1) Caulking tool
(2) Guide
(3) Bolt

Valve guide remover


99667 Z5000

Used to remove valve guide

HV-2-1

Shape

TOOLS

Tool name and number

Description

Valve guide replacer


99666 Z5001

Used to press valve guide into place

Reamer
99662 Z5500

Used to finish I.D. of valve guide

Nozzle holder sleeve


wrench
99656 Z5501

Used to remove and install nozzle holder


sleeve

Nozzle tube remover


99655 Z5500

Used to remove nozzle tube

Nozzle tube setting tool


99651 Z5500

Used to press nozzle tube into place

Stem seal replacer


99674 Z5001

Used to press valve stem seal into place

HV-2-2

Shape

CONSTRUCTION

CONSTRUCTION

HV-3-1

REMOVAL

REMOVAL
1.

Remove the following parts:


Fuel tubes
z
Fuel filter assembly and bracket as a unit
z
Injection nozzle tubes and spill tubes
z
Injection nozzles
NOTE
z Use a container to catch fuel. Wipe up any fuel spilled on
the exterior of the engine with a rag.
z

2. Remove the rocker shaft assembly and push rods.


NOTE
z Loosen the rocker shaft assembly mounting bolts, starting with the outer bolts and moving toward the center.

3.

Remove the cylinder head assembly. Attach chains or


cables to the engine lifter and lifters and lift the cylinder
head away from the cylinder block using a hoist.
NOTE
z Loosen the head bolts diagonally, starting with the outer
one and moving toward the center.

HV-4-1

DISASSEMBLY

DISASSEMBLY
CYLINDER HEAD

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Push rod
,+ 2. Split collar
3. Upper spring seat
, 4. Outer valve spring
, 5. Inner valve spring
, 6. Valve stem seal

7. Lower spring seat


,+ 8. Intake valve
,+ 9. Exhaust valve
10. Water jet
11. Water jet
12. Exhaust valve insert

, 13. Intake valve insert


14. Push rod pipe
15. Valve guide
16. Nozzle sleeve
17. Nozzle tube
18. O-ring

Marks + and , indicate that the key points of operation are explained in the text.

HV-5-1

DISASSEMBLY

Key point of disassembly


Before disassembling the cylinder head, measure the depth of the
valve head below the cylinder head.
NOTE
z

Be sure to remove carbon from these parts before measurement.

2 Split collar
Remove the split collar using the split collar tool (99624 Z5001).

8 Intake valve, 9 Exhaust valve


Remove the upper spring seat, outer and inner valve springs, valve
stem seal and lower spring seat from each cylinder.
NOTE
z

Arrange all removed parts for each valve.

ROCKER SHAFT
Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
1.

Stopper bolt

6.

Inside spring

2.

Shaft bracket

7.

Exhaust valve rocker

3.

Adjusting screw

8.

Bushing

4.

Intake valve rocker

9.

Rocker shaft

5.

Bushing

HV-5-2

INSPECTION

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

CYLINDER HEAD
Flatness
Unit: mm (in)
Item

Maintenance standard

Service limit

Longitudinal direction

Less than 0.05 (0.0020)

0.2 (0.008)

Transverse direction

Less than 0.05 (0.0020)

0.2 (0.008)

VALVE INSERT
Contact width of valve and valve insert
Unit: mm (in)
Item

Maintenance standard

Service limit

Intake

2.2 - 2.4 (0.087 - 0.094)

3.5 (0.138)

Exhaust

2.0 - 2.3 (0.079 - 0.091)

3.5 (0.138)

VALVE
Depth of valve below lower surface of cylinder head
Check that the depth is the same as that measured before disassembly.
Unit: mm (in)
Item

Maintenance standard

Service limit

Intake

1.33 - 1.83 (0.0524 - 0.0720)

2.8 (0.110)

Exhaust

1.03 - 1.53 (0.0406 - 0.0602)

2.3 (0.091)

Valve head thickness


Unit: mm (in)
Item

Maintenance standard

Service limit

Intake

2.16 (0.0850)

1.8 (0.071)

Exhaust

1.65 (0.0650)

1.3 (0.051)

HV-6-1

INSPECTION

Outside diameter of valve stem


Unit: mm (in)
Item

Maintenance standard

Service limit

Intake

8.96 - 8.98 (0.3528 - 0.3535)

Exhaust

8.92 - 8.94 (0.3512 - 0.3520)

VALVE GUIDE
Clearance to valve stem
Unit: mm (in)
Item

Maintenance standard

Service limit

Intake

0.02 - 0.05 (0.0008 - 0.0020)

0.15 (0.0059)

Exhaust

0.05 - 0.09 (0.0020 - 0.0035)

0.20 (0.0079)

VALVE SPRING
Free length
Unit: mm (in)
Item

Maintenance standard

Service limit

Remarks

Outer

62.8 (2.472)

55.0 (2.165)

Inner

60.9 (2.398)

58.0 (2.283)

Intake and
exhaust

Tension
Unit: N {kgf, lbf}
Item

Maintenance standard

Service limit

Remarks

Outer

246.2 - 271.7
{25.1 - 27.7, 55.3 - 61.1}

When compressed to
44.6 mm (1.756 in)

Inner

126.5 - 140.2
{12.9 - 14.3, 28.4 - 31.5}

When compressed to
41.6 mm (1.638 in)

Squareness
For the outer spring, measure clearance at points A and B shown in
the figure.
Unit: mm (in)
Maintenance standard

Service limit

Remarks

Less than 2.0 (0.079)

Inner and outer springs

HV-6-2

INSPECTION

VALVE ROCKER PARTS


Outside diameter of rocker shaft
Unit: mm (in)
Maintenance standard

Service limit

19.98 - 20.00 (0.7866 - 0.7874)

19.90 (0.7835)

Rocker shaft runout


Unit: mm (in)
Maintenance standard

Service limit

0.06 (0.0024)

0.1 (0.004)

Inside diameter of valve rocker bushing


Unit: mm (in)
Maintenance standard

Service limit

20.02 - 20.04 (0.7882 - 0.7890)

20.10 (0.7913)

Clearance between valve rocker bushing and rocker


shaft
Unit: mm (in)
Maintenance standard

Service limit

0.02 - 0.06 (0.0008 - 0.0024)

0.2 (0.008)

Inside spring
Unit: mm (in)
Item

Maintenance standard

Service limit

Free length

60.0 (2.362)

49.0 (1.929)

Tension
N {kgf, lbf}

21.6 - 31.4
{2.2 - 3.2, 4.9 - 7.1}

16.7
{1.7, 3.7}

Remarks
When compressed
to 33.5 mm
(1.319 in)

HV-6-3

INSPECTION

PUSH ROD
Runout
Measure push rod runout while supporting the center of the spherical surface at each end of the push rod as shown.
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.30 (0.0118)

CAM FOLLOWER
Outside diameter
Unit: mm (in)
Maintenance standard

Service limit

19.96 - 19.98 (0.7858 - 0.7866)

19.85 (0.7815)

Clearance to cylinder block cam follower bore


Unit: mm (in)
Maintenance standard

Service limit

0.02 - 0.06 (0.0008 - 0.0024)

0.12 (0.0047)

HV-6-4

REPAIR AND REPLACEMENT

REPAIR AND REPLACEMENT


REPAIRING CYLINDER HEAD
Grind the cylinder head using a surface grinder. The maximum
allowable grinding limit is 0.3 mm (0.012 in).
Unit: mm (in)
Maintenance standard (B)

Service limit (A)

89.9 - 90.1 (3.539 - 3.547)

89.7 (3.531)

REPAIRING VALVE AND VALVE INSERT


1.

Dress the valve face using a valve refacer. If thickness of


the valve head after dressing reaches the service limit,
replace the valve.
NOTE
z Ensure that the valve face is free from stepped wear, etc.
Unit: mm (in)
Item

Maintenance standard

Service limit

Valve face
angle

Intake

2930 - 30

Exhaust

4430 - 45

Valve head
thickness

Intake

2.16 (0.0850)

1.8 (0.071)

Exhaust

1.65 (0.0650)

1.3 (0.051)

2.

Dress the end of the valve stem using a valve refacer or oil
stone.
NOTE
z Ensure that the end of the valve stem is dressed at a
right angle to the axis and is free from roughness or
damage.

3.

Dress the surface (A) of the valve insert using a valve seat
grinder.
NOTE
z Ensure that the surface (A) is free from stepped wear,
etc.
Item
Seat face
angle

Maintenance standard

Service limit

Intake

30 - 3030

Exhaust

45 - 4530

HV-7-1

REPAIR AND REPLACEMENT

REPLACING VALVE INSERT


1.
2.

Remove both the intake and exhaust valve inserts using


valve insert removers (99660 Z5503).
Install the intake and exhaust valve inserts using a cold-fit
method.

Cold-fit procedure
a.

Immerse the valve inserts in dry ice for at least five minutes
before fitting. Some alcohol may be added to the dry ice for
better results.
WARNING
WARNING
z Do not touch the valve insert or dry ice with bare hands
to prevent injury.

b.

Immerse the cylinder head in hot water of at least 80C


(176F).
WARNING
WARNING
z Do not touch the cylinder head or hot water with bare
hands to prevent injury.

c.

Remove the valve inserts and the cylinder head. Using the
valve insert replacer (99665 Z5002), press the inserts into
place on the cylinder head.

3.

After positioning the valve inserts, caulk only the exhaust


valve at four points using the insert caulking tool.
NOTE
z When caulking the exhaust valve, use a press pressure
of 14,711 N {1,500 kgf, 3,308 lbf}.
Tool name
Caulking tool
Valve insert caulking tool Guide
Bolt

Tool number
99675 Z5002
99676 Z5000
81-20616-1A

HV-7-2

REPAIR AND REPLACEMENT

LAPPING VALVE AND VALVE INSERT


When the valve or valve insert is repaired or replaced, lap both
parts using a grinding compound.
1. Apply grinding compound evenly to the mating surface of
the valve.

2.

3.

4.

Apply engine oil to the valve stem and insert the valve into
the valve guide. Attach a suction cup to the top of the valve
head and turn the valve while lightly tapping the insert with
the valve.
After properly lapping these parts, thoroughly clean the
compound off the parts. Then apply oil to the mating surfaces of the parts and relap.

Clean oil from the mating surfaces. Apply Prussian blue and
repeat lapping both parts until they are lapped properly.
Unit: mm (in)
Item

Contact
width of valve
and valve
insert

Maintenance standard

Service limit

Intake

2.2 - 2.4 (0.087 - 0.094)

3.5 (0.138)

Exhaust

2.0 - 2.3 (0.079 - 0.091)

3.5 (0.138)

REPLACING VALVE GUIDE


1.

Drive the valve guide from the lower surface of the cylinder
head using the valve guide remover (99667 Z5000).

2.

Using the valve guide replacer (99666 Z5001), drive the


valve guide form the upper surface of the cylinder head until
the replacer contacts the head surface.
NOTE
z Clean the valve guide hole in the cylinder head. Apply
engine oil beforehand.

HV-7-3

REPAIR AND REPLACEMENT


3.

Press the valve guide into place. Ream it using the reamer
(99662 Z5500) so that the inside diameter is within the
maintenance standard.
Unit: mm (in)
Item

Inside
diameter

Maintenance standard

Service limit

Intake

9.00 - 9.02
(0.3543 - 0.3551)

Exhaust

9.00 - 9.02
(0.3543 - 0.3551)

REPLACING VALVE ROCKER BUSHING


1.

While supporting the valve rocker, drive out the bushing


with a 23 mm (0.91 in) dia. rod.
NOTE
z Scribe alignment marks on the mating surfaces of the
bushing and valve rocker before driving out the bushing.
z Be careful not to damage the mating surfaces.

2. Align the marks and drive the bushing into place.


NOTE
z Also check that the oil holes in the bushing and valve
rocker are aligned.

3.

Ream the bushing so that the inside diameter is within the


maintenance standard.
Unit: mm (in)
Maintenance standard

Service limit

20.02 - 20.04 (0.7882 - 0.7890)

REPLACING NOZZLE TUBE


1.

Remove the nozzle holder sleeve using the nozzle holder


sleeve wrench (99656 Z5501).

HV-7-4

REPAIR AND REPLACEMENT


2.
3.

Drive the nozzle tube form the lower surface of the cylinder
head using the nozzle tube remover (99655 Z5500).
Remove the O-ring from the nozzle tube.

4. Attach a new O-ring to the nozzle tube.


NOTE
z Apply soapy water to the O-ring before installation. To
avoid breaking or deforming the O-ring, install the O-ring
8 mm (0.31 in) below the top of the tube (see A in the
figure).
5. Apply LOCTITE #601 to the mating periphery of the tube.
NOTE
z Clean the mating surface of the cylinder head. Be careful
not to apply excess Loctite to the tube.
6.

Attach the guide of the nozzle tube setting tool (99651


Z5500) to the nozzle tube and insert the tube into the cylinder head by hand.
NOTE
z Be careful not to damage the O-ring.

7.

8.

Using the nozzle holder mounting bolts, install the bridge of


the nozzle tube setting tool (99651 Z5500) on the cylinder
head. Tighten the set bolt and press the nozzle tube into
place.
When the nozzle tube contacts the seat of the cylinder
head, resistance is felt on the bolt. From the point where
resistance is felt, further tighten the set bolt approximately
10.

9.

Apply THREE BOND #1344 to the thread of the nozzle


holder sleeve.
10. Tighten the nozzle holder sleeve using the nozzle holder
sleeve wrench (99656 Z5501).
: 34 - 39 Nm {3.5 - 4.0 kgfm, 25 - 29 ftlbf}

HV-7-5

REASSEMBLY

REASSEMBLY
CYLINDER HEAD
Key point of reassembly
Before assembling parts, apply engine oil to the sliding surfaces.
9 Exhaust valve, 8 Intake valve
Install the intake and exhaust valves.
NOTE
z

Be sure to install the valves in their original positions.

6 Valve stem seal


Install the stem seal on the valve guide using the stem seal replacer
(99674 Z5001).
NOTE
z

Insert the stem seal by hand.

5 Inner valve spring, 4 Outer valve spring


Install the inner and outer valve springs and the upper spring seat.
NOTE
z

Face the narrow pitch sides (painted blue) of the inner


and outer springs toward the lower spring seats.

2 Split collar
1. Install the split collar using the split collar tool (99624
Z5001).

2.

Check that the depth of the valve below the lower surface of
the cylinder head is correct.
Unit: mm (in)
Item

Maintenance standard

Service limit

Intake

1.33 - 1.83 (0.0524 - 0.0720)

2.8 (0.110)

Exhaust

1.03 - 1.53 (0.0406 - 0.0602)

2.3 (0.091)

HV-8-1

REASSEMBLY

ROCKER SHAFT
Key point of reassembly
Before assembling parts, apply engine oil to the sliding surfaces.
Assemble the rocker shaft assembly.
NOTE
z

Face the oil hole downward when assembling.


1.

Stopper bolt

6.

Inside spring

2.

Shaft bracket

7.

Exhaust valve rocker

3.

Adjusting screw

8.

Bushing

4.

Intake valve rocker

9.

Rocker shaft

5.

Bushing

HV-8-2

INSTALLATION

INSTALLATION
1. Install the cylinder head gasket and cylinder head.
NOTE
z Ensure that the stamped part number side faces upward
when installing the gasket.

2.

Tightening the cylinder head bolts to the specified torque


using the socket wrench (99664 Z5000). Note that seven of
the head bolts are also secured to the rocker shaft bracket.
: 1st : 98 Nm {10.0 kgfm, 72 ftlbf}
2nd: 177 - 196 Nm {18.0 - 20.0 kgfm, 130 - 145 ftlbf}

: Refers to the bolts which are also secured to the rocker


shaft bracket. [L = 180 mm (7.09 in)]
O : Circled numbers refer to tightening sequence of head bolts.
3. Position the rocker shaft assembly on the head.
NOTE
z Be careful that the rocker arm tip and push rod do not
dislocate.
4. Install the rocker shaft mounting bolts.
NOTE
z Be sure to tighten the bolts, starting from the inside and
working outside.
: 34 - 44 Nm {3.5 - 4.5 kgfm, 25 - 33 ftlbf}
5. Install the following parts:
z
Injection nozzles
z
Injection nozzle tubes and spill tubes
z
Fuel filter assembly and bracket as a unit
z
Fuel tubes
Unit: Nm {kgfm, ftlbf}
Location

Tightening torque

Injection nozzle holder

25 - 29 {2.5 - 3.0, 18 - 22}

Injection nozzle tube

23 - 27 {2.3 - 2.8, 17 - 20}

Spill tube

8 - 10 {0.8 - 1.0, 5.8 - 7.2}

6.

Start the engine. Check connections and other parts for


signs of water leakage. Recheck the cooling water level and
add cooling water if necessary.

HV-9-1

- MEMO -

- MEMO -

LUBRICATION SYSTEM

CONTENTS
SERVICE DATA ...................................... LB-1-1
SPECIFICATIONS............................................
SERVICE DATA ...............................................
TIGHTENING TORQUE ...................................
LUBRICATION SYSTEM..................................

TOOLS ....................................................
OIL PUMP ...............................................
CONSTRUCTION.............................................
REMOVAL ........................................................
DISASSEMBLY ................................................
INSPECTION....................................................
REASSEMBLY .................................................

LB-1-1
LB-1-1
LB-1-2
LB-1-3
LB-2-1
LB-3-1
LB-3-1
LB-3-1
LB-3-2
LB-3-3
LB-3-4

OIL COOLER........................................... LB-4-1


CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................

OIL FILTER..............................................
CONSTRUCTION .............................................
REPLACING OIL FILTER .................................
INSPECTION ....................................................

OIL JET....................................................
CONSTRUCTION .............................................
REMOVAL ........................................................

LB-4-1
LB-4-2
LB-4-2
LB-4-3
LB-5-1
LB-5-1
LB-5-2
LB-5-3
LB-6-1
LB-6-1
LB-6-1

LB

SERVICE DATA

SERVICE DATA
SPECIFICATIONS
Lubrication type

Forced-circulation type

Oil pump

Gear pump
Cartridge type
(Full flow only type and full flow & by pass combination type)

Oil filter
Oil cooler

Water cooled flat tube type

Engine oil capacities


(Approximately)
liter (lmp gal)

Engine oil pan


(H-level)

Total

FE6A, FE6B,
FE6T, FE6TA

12 (2-5/8)

FE6TA*

14 (3-1/8)

FE6A, FE6B,
FE6T, FE6TA

15 (3-1/4)

FE6TA*

17 (3-3/4)

NOTE
z

*Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).

SERVICE DATA
Unit: mm (in)
Maintenance
standard

Service limit

Side clearance

0.04 - 0.10
(0.0016 - 0.0039)

0.15 (0.0059)

Tip clearance

0.04 - 0.10
(0.0016 - 0.0039)

0.20 (0.0079)

Backlash between pump gears

0.16 - 0.27
(0.0063 - 0.0106)

0.50 (0.0197)

Clearance between O.D. of driven gear shaft


and gear bushing

0.03 - 0.08
(0.0012 - 0.0031)

0.20 (0.0079)

Relief pressure
kPa {kgf/cm2, psi}

1,030
{10.5, 149}

Free length of spring

40.0 (1.575)

Spring tension
N {kgf, lbf}

260.9 - 288.3
{26.6 - 29.4,
58.7 - 64.8}

kPa {kgf/cm2, psi}

981 {10, 142}

Item

Oil pump

Relief valve

Oil cooler

Water pressure test

LB-1-1

Remarks

Fully opening pressure


1,765 {18, 256}

When spring is compressed


to 46.0 mm (1.811 in)

SERVICE DATA
Unit: mm (in)
Maintenance
standard

Service limit

275 - 314
{2.8 - 3.2, 40 - 46}

Free length of spring

58.5 (2.303)

Spring tension
N {kgf, lbf}

47.515 - 52.516
{4.845 - 5.355,
10.683 - 11.808}

Relief pressure
kPa {kgf/cm2, psi}

98 - 137
{1.0 - 1.4, 14 - 20}

Free length of spring

62.0 (2.441)

Spring tension
N {kgf, lbf}

28.882 - 31.922
{2.945 - 3.255,
6.494 - 7.177}

Relief pressure
kPa {kgf/cm2, psi}

422 - 461
{4.3 - 4.7, 61 - 67}

Free length of spring

61.0 (2.402)

Spring tension
N {kgf, lbf}

102.48 - 113.27
{10.45 - 11.55,
23.04 - 25.47}

Relief pressure
kPa {kgf/cm2, psi}

275 - 314
{2.8 - 3.2, 40 - 46}

Free length of spring

58.5 (2.303)

Spring tension
N {kgf, lbf}

50.0 {5.1, 11.2}

Relief pressure
kPa {kgf/cm2, psi}

98 - 137
{1.0 - 1.4, 14 - 20}

Free length of spring

97.0 (3.819)

Spring tension
N {kgf, lbf}

60.8 {6.2, 13.7}

Relief pressure
kPa {kgf/cm2, psi}

422 - 461
{4.3 - 4.7, 61 - 67}

Free length of spring

62.0 (2.441)

Spring tension
N {kgf, lbf}

115.7 {11.8, 26.0}

Item
Relief pressure
kPa {kgf/cm2, psi}
Oil cooler
short valve

Type I

Oil filter short


valve

Regulating
valve
Oil filter

Oil
pipe

Type II

Oil
cooler
short
valve

Oil filter short


valve

Regulating
valve

Remarks

When spring is compressed


to 42.0 mm (1.654 in)

When spring is compressed


to 38.0 mm (1.496 in)

When spring is compressed


to 47.25 mm (1.8602 in)

When spring is compressed


to 42.0 mm (1.654 in)

When spring is compressed


to 40.5 mm (1.594 in)

When spring is compressed


to 47.25 mm (1.8602 in)

TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Location

Tightening torque

Oil pump relief valve mounting plug

47 - 71 {4.8 - 7.2, 35 - 52}

Oil pump mounting bolt

20 {2.0, 14}

Oil pump cover mounting bolt

14 - 20 {1.4 - 2.0, 10 - 14}

Oil filter short valve mounting cap

25 - 34 {2.5 - 3.5, 18 - 25}

Regulating valve mounting cap

25 - 34 {2.5 - 3.5, 18 - 25}

Oil jet bolt

34 - 49 {3.5 - 5.0, 25 - 36}

Cooler element mounting nut

20 - 29 {2.0 - 3.0, 14 - 22}

Oil cooler mounting bolt and nut

25 {2.5, 18}

LB-1-2

SERVICE DATA

LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM

LUBRICATION CIRCUIT

LB-1-3

TOOLS

TOOLS
Tool name and number

Description

Hydraulic pump
99570 Z5000

For testing oil pressure of oil cooler element.

Oil cooler attachment


99573 Z5500
(1) 99578 Z5500
(2) 99578 Z5501

Used when performing the oil cooler core oil


pressure test.
(1) Leak test attachment
(2) Leak test attachment

LB-2-1

Shape

OIL PUMP

OIL PUMP
CONSTRUCTION

REMOVAL
Key point of removal
Remove the drain plug from the oil pan and drain engine oil into a
container.
WARNING
WARNING
z

Do not drain oil while engine is hot to avoid scalding


yourself.

NOTE
z

Do not disassemble the oil pump except for the removal


of the valve and driven gear.

LB-3-1

OIL PUMP

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Plug
2. Gasket
3. Spring

4. Ball
5. Cover
6. Gasket

7. Driven gear assembly


,+ 8. Pump gear assembly

Marks , and + indicate that the key points of operation are explained in the text.

Key point of disassembly


The oil pump gears and the drive gear are shrink-fitted to the drive
shaft. Disassembly of the oil pump must be limited to the valve and
driven gear assembly.
8 Pump gear assembly
1. Measure the side clearances between the pump gears
(drive and driven) and cover.

2.

Measure the clearance between tips of the pump gears


(drive and driven) and pump body.

LB-3-2

OIL PUMP
3.

Measure the backlash between the drive and driven gears


using a fuse.

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

Side clearance
Unit: mm (in)
Maintenance standard

Service limit

0.04 - 0.10 (0.0016 - 0.0039)

0.15 (0.0059)

Tip clearance
Unit: mm (in)
Maintenance standard

Service limit

0.04 - 0.10 (0.0016 - 0.0039)

0.20 (0.0079)

Backlash between pump gears


Unit: mm (in)
Maintenance standard

Service limit

0.16 - 0.27 (0.0063 - 0.0106)

0.50 (0.0197)

Clearance between O.D. of driven gear shaft and gear


bushing
Unit: mm (in)
Maintenance standard

Service limit

0.03 - 0.08 (0.0012 - 0.0031)

0.20 (0.0079)

Relief valve
Item

Maintenance
standard

Service limit

Relief pressure
kPa {kgf/cm2, psi}

1,030
{10.5, 149}

Free length of
spring
mm (in)

40.0 (1.575)

Spring tension
N {kgf, lbf}

260.9 - 288.3
{26.6 - 29.4,
58.7 - 64.8}

Remarks
Fully opening
pressure 1,765
{18, 256}

When spring is
compressed to
46.0 mm (1.811 in)

LB-3-3

OIL PUMP

REASSEMBLY
Key point of reassembly
8 Pump gear assembly
Attach the driven gear to the pump gear assembly. Measure the
clearances and backlash to ensure that they do not exceed the
maintenance standard.
Unit: mm (in)
Item

Maintenance standard

Service limit

Side clearance

0.04 - 0.10 (0.0016 - 0.0039)

0.15 (0.0059)

Tip clearance

0.04 - 0.10 (0.0016 - 0.0039)

0.20 (0.0079)

Backlash between
pump gears

0.16 - 0.27 (0.0063 - 0.0106)

0.50 (0.0197)

LB-3-4

OIL COOLER

OIL COOLER
CONSTRUCTION
Type I

Type II

Type I: Former
Type II: New

LB-4-1

OIL COOLER

REMOVAL
Key point of removal
Remove the drain plug from the oil pan and drain engine oil into a
container.
WARNING
WARNING
z

Do not drain while the engine is hot to prevent scalding


yourself.

DISASSEMBLY
Type I and Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Cooler housing
2. Gasket

3. Cooler element

LB-4-2

4. Housing gasket

OIL COOLER

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

Water pressure test


Conduct hydraulic tests on the element using the oil cooler attachment (99573 Z5500) and hydraulic pump (99570 Z5000). If any
abnormality is noticed, replace the element.
NOTE
z

After completing the test, discharge the water completely


and dry the oil cooler.
Maintenance standard

Service limit

Water leakage should not occur when a pressure of 981


kPa {10kgf/cm2, 142psi}, is directed to the element

LB-4-3

OIL FILTER

OIL FILTER
CONSTRUCTION
Type I (Full flow only type)

Type II (Full flow & by pass combination type)

LB-5-1

OIL FILTER

REPLACING OIL FILTER


Refer to the MA section for LUBRICATION SYSTEM.

Type I (Full flow only type)

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Regulating valve cap
2. Packing
3. Regulating valve spring
4. Regulating valve
5. Bracket
6. Short valve cap
7. Packing

8. Short valve spring


9. Short valve
10. Clog warning switch
11. Packing
12. Short valve spring
13. Contactor case
14. Contactor

LB-5-2

15. Contactor spring


16. Short valve
17. Snap ring
18. Oil cooler short valve
19. Oil cooler short valve spring
20. Oil filter element assembly

OIL FILTER

Type II (Full flow & by pass combination type)

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Regulating valve cap
2. Packing
3. Regulating valve spring
4. Regulating valve
5. Bracket
6. Short valve cap

7. Packing
8. Short valve spring
9. Oil filter short valve
10. Clog warning switch
11. Packing
12. Short valve spring

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

Oil cooler short valve


Unit: mm (in)
Maintenance
standard

Service
limit

Type I
Type II

58.5 (2.303)

Type I

47.515 - 52.516
{4.845 - 5.355,
10.683 - 11.808}

When compressed to
42.0 mm (1.654 in)

Type II 50.0 {5.1, 11.2}

When compressed to
42.0 mm (1.654 in)

Item
Free length of
spring

Spring tension
N {kgf, lbf}

Remarks

LB-5-3

13. Contactor case


14. Contactor
15. Contactor spring
16. Short valve
17. Oil filter element assembly

OIL FILTER

Oil filter short valve


Unit: mm (in)
Maintenance
standard

Service
limit

Type I

62.0 (2.441)

Type II

97.0 (3.819)

Type I

28.882 - 31.922
{2.945 - 3.255,
6.494 - 7.177}

When compressed to
38.0 mm (1.496 in)

Type II 60.8 {6.2, 13.7}

When compressed to
40.5 mm (1.594 in)

Item
Free length of
spring

Spring tension
N {kgf, lbf}

Remarks

Regulating valve
Unit: mm (in)
Maintenance
standard

Service
limit

Type I

61.0 (2.402)

Type II

62.0 (2.441)

Type I

102.48 - 113.27
{10.45 - 11.55,
23.04 - 25.47}

When compressed to
47.25 mm (1.8602 in)

Type II

115.7
{11.8, 26.0}

When compressed to
47.25 mm (1.8602 in)

Item
Free length of
spring

Spring tension
N {kgf, lbf}

Remarks

LB-5-4

OIL JET

OIL JET
CONSTRUCTION
1.

Straight pin

2.

Oil jet

3.

Oil jet bolt

NOTE
z

Numbers before part names do not indicate the disassembly sequence.

REMOVAL
Key point of removal
Remove the oil jet bolt, being careful not to drop the gasket into the
cylinder block.

LB-6-1

- MEMO -

COOLING SYSTEM

CONTENTS
SERVICE DATA ...................................... EC-1-1
SPECIFICATIONS............................................
SERVICE DATA ...............................................
TIGHTENING TORQUE ...................................
COOLING SYSTEM .........................................

EC-1-1
EC-1-2
EC-1-3
EC-1-4
TOOLS .................................................... EC-2-1
WATER PUMP ........................................ EC-3-1
CONSTRUCTION............................................. EC-3-1
EXTERNAL APPEARANCE CHECK AND CORRECTION
EC-3-1
DISASSEMBLY ................................................ EC-3-2
INSPECTION.................................................... EC-3-4

REASSEMBLY.................................................. EC-3-4

THERMOSTAT ........................................ EC-4-1


REMOVAL ........................................................ EC-4-1
INSPECTION .................................................... EC-4-1
INSTALLATION ................................................ EC-4-1

RADIATOR AND COOLANT RESERVOIR TANK


EC-5-1
FLUSHING COOLING SYSTEM ...................... EC-5-1
INSPECTION .................................................... EC-5-1
FAN CLUTCH .......................................... EC-6-1
CONSTRUCTION ............................................. EC-6-1
INSPECTION .................................................... EC-6-2

EC

SERVICE DATA

SERVICE DATA
SPECIFICATIONS
Cooling system

Forced-circulation type

Water pump

Centrifugal, belt-driven type

Thermostat

Wax pellet type

Fan clutch

Refer to the description in this manual.

Type of water pump


Unit: mm (in)
Item

Type I

Type IV

Type II

Type V

Type III

100 (3.94)

116 (4.57)

80 (3.15)

96 (3.78)

36 (1.42)

55 (2.17)

Screw hole in impeller

Provided

Packed grease

None

Provided

None

General specification

Disassembly and reassembly


Former and new

Provided

Type VI

None

Cold resistant specification

OK

NG

OK

NG

OK

NG

Former

New

Former

New

Former

New

Packed
grease
differs from
that for
Type II.

Packed
grease
differs from
that for
Type V.

Remarks

Type of thermostat
Unit: mm (in)
Item

Type I

Type III

Type IV

Type V

51 (2.01)

46 (1.81)

27 (1.06)

33 (1.30)

10 (0.39)

15 (0.59)

Valve opening temperature


C (F)
Former and new

Type II

76.5 (170)

82 (180)
Former

EC-1-1

88 (190)

76.5 (170)

82 (180)
New

Type VI

88 (190)

SERVICE DATA

Fan clutch
Item
FE6A
FE6B 119 kW {162 PS}
FE6B 132 kW {180 PS}

FD1300L

FE6B 132 kW {180 PS}


FE6T 135 kW {183 PS}
FE6T 151 kW {205 PS}
FE6TA 157 kW {213 PS}

FDL1700

FE6T 151 kW {205 PS}


FE6T 162 kW {220 PS}
FE6TA 157 kW {213 PS}
FE6TA 173 kW {235 PS}

FDL2000

Run the engine


continuously

Operating temperature
C (F)

3,000 rpm

755 (1679)

ON-OFF type

6510 - 805
(14918 - 1769)
Linear type

3,400 rpm
5010 - 805
(12218 - 1769)

SERVICE DATA
Unit: mm (in)
Item

Maintenance standard

Service limit

Type I

0.4 - 2.0 (0.016 - 0.079)

Type II
Type III

0.3 - 2.1 (0.012 - 0.083)

13.03 - 13.05
(0.5130 - 0.5138)

0.03T - 0.06T
(0.0012T - 0.0024T)

45 (1.77)

74.5 - 78.5
(166 - 173)

71.5 - 81.5
(161 - 179)

80 - 84
(176 - 183)

77 - 87
(171 - 189)

86 - 90
(187 - 194)

85 - 93
(185 - 199)

76.5C
(170F)

More than 10/90 (0.39/194)

Less than
9/90 (0.35/194)

82C
Valve lift/temperature
(180F)
mm/C (in/F)

More than 10/95 (0.39/203)

Less than
9/95 (0.35/203)

88C
(190F)

More than 10/100 (0.39/212)

Less than
9/100 (0.35/
212)

Radiator cap operating pressure


kPa {kgf/cm2, psi}

39 - 59 {0.4 - 0.6, 6 - 9}

Test air pressure for radiator leakage


kPa {kgf/cm2, psi}

157 {1.6, 23}

Fan pulley - alternator pulley

10 - 15 (0.39 - 0.59)

Fan pulley - cooler pulley

7 - 12 (0.28 - 0.47)

Water pump
(Type I, Type
II and Type
III only)

Clearance between
housing and impeller

Outside diameter of shaft at


impeller location
Fit of impeller and shaft
Valve port diameter
76.5C
(170F)

Thermostat

V-belt deflection

Valve opening tem82C


perature
(180F)
C (F)
88C
(190F)

EC-1-2

Remarks
Side clearance

T: Tight

Pressure side

With a force of about


98 N {10 kgf, 22 lbf}
applied to the mid part

SERVICE DATA

TIGHTENING TORQUE
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Water pump grease nipple

10 - 15 {1.0 - 1.5, 7 - 11}

Water pump mounting bolt

10 - 13 {1.0 - 1.3, 7 - 9}

Fan pulley mounting nut

20 - 25 {2.0 - 2.5, 14 - 18}

Cooling fan mounting bolt

10 - 12 {1.0 - 1.2, 7 - 9}

Fan clutch mounting nut

20 - 25 {2.0 - 2.5, 14 - 18}

EC-1-3

SERVICE DATA

COOLING SYSTEM

EC-1-4

TOOLS

TOOLS
WATER PUMP
Type I
Tool name and number

Description

Pulley hub puller


99749 Z5503

Used to remove flange and impeller

Drive shaft remover


99758 Z5500

Used to remove drive shaft

Bearing replacer
99759 Z5503

Used to remove and install ball bearing

Water seal replacer


99759 Z5504

Used to remove water seal

Drive shaft guide


99789 Z5500

Used to install drive shaft

Fan pulley hub replacer


99788 Z5501

Used to drive flange into place

EC-2-1

Shape

TOOLS

Type II and Type III


Tool name and number

Description

Pulley hub puller


99749 Z5504

Used to remove flange and impeller

Drive shaft remover


99758 Z5500

Used to remove drive shaft

Bearing replacer
99759 Z5505

Used to remove ball bearing

Bearing replacer
99759 Z5506

Used to install ball bearing

Water seal replacer


99759 Z5507

Used to remove and install water seal

Drive shaft guide


99789 Z5501

Used to install drive shaft

Fan pulley hub replacer


99788 Z5503

Used to drive flange into place

EC-2-2

Shape

WATER PUMP

WATER PUMP
CONSTRUCTION

EXTERNAL APPEARANCE CHECK AND CORRECTION


The water pump should not be disassembled if no defects are
found by visual inspection.
1. If coolant leaks at the hole on the lower side of the water
pump housing or if there are signs of coolant leakage on the
pump housing, check the seal and impeller and replace
both at the same time if necessary.
2. If grease leaks at the hole on the lower side of the water
pump housing or on the pulley side, replace the ball bearing
on that side.
3. If the impeller interferes with the pump housing due to a
worn ball bearing, or if the axial play of the ball bearing is
excessive, replace both ball bearings as a unit.

EC-3-1

WATER PUMP

DISASSEMBLY
Type I, Type II and Type III

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


, 1. Grease nipple
,+ 2. Impeller
,+ 3. Flange
4. Retaining ring

+ 5. Drive shaft assembly


,+ 6. Ball bearing
7. Spacer
,+ 8. Ball bearing

9. Washer
, 10. Drive shaft
,+ 11. Water seal*

*Before installing the water seal, install the flange.


Marks , and + indicate that the key points of operation are explained in the text.

Type IV, Type V and Type VI


z

Disassembly is not possible as there are no screw holes in


the impeller. If any abnormality is found by checking the
exterior appearance, replace the assembly.

EC-3-2

WATER PUMP

Key point of disassembly


2 Impeller
Secure the flange and remove the impeller using the puller bolt.
NOTE
z To secure the flange and puller bolt, use the pulley hub
puller.
Tool name
Pulley hub puller

Tool number

Type I

99749 Z5503

Type II, Type III

99749 Z5504

3 Flange
Drive out the flange using the pulley hub puller.
Tool name
Pulley hub puller

Tool number

Type I

99749 Z5503

Type II, Type III

99749 Z5504

5 Drive shaft assembly


Remove the retaining ring and drive shaft assembly from the impeller side using the drive shaft remover (99758 Z5500).

6, 8 Ball bearing
Drive out the ball bearing together with the spacer and washer
using the bearing replacer.
Tool name
Bearing replacer

Tool number

Type I

99759 Z5503

Type II, Type III

99759 Z5505

EC-3-3

WATER PUMP
10 Water seal
Drive out the water seal using the water seal replacer.
Tool name
Water seal replacer

Tool number

Type I

99759 Z5504

Type II, Type III

99759 Z5507

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

Outside diameter of shaft at impeller location


Unit: mm (in)
Maintenance standard

Service limit

13.03 - 13.05 (0.5130 - 0.5138)

Fit of impeller and shaft


Unit: mm (in)
Maintenance standard

Service limit

0.03T - 0.06T
(0.0012T - 0.0024T)

Remarks
T = Tight

REASSEMBLY
Key point of reassembly
10 Drive shaft
Attach the drive shaft guide to the pump body, and press the drive
shaft assembly into place.
Tool name
Drive shaft guide

Tool number

Type I

99789 Z5500

Type II, Type III

99789 Z5501

8 Ball bearing
Install the washer and press the ball bearing into place on the
impeller side using the bearing replacer.
NOTE
z Apply bearing grease to the rolling surface of the bearing.
Tool name
Bearing replacer

Tool number

Type I

99759 Z5503

Type II, Type III

99759 Z5506

EC-3-4

WATER PUMP
6 Ball bearing
Install the spacer and press the ball bearing into place on the flange
side using the bearing replacer.
NOTE
z

Apply bearing grease to the rolling surface of the bearing.


Tool name

Bearing replacer

Tool number

Type I

99759 Z5503

Type II, Type III

99759 Z5506

3 Flange
Press the flange onto the drive shaft using the fan pulley hub
replacer.
Tool name
Fan pulley hub replacer

Tool number

Type I

99788 Z5501

Type II, Type III

99788 Z5503

11 Water seal
Apply a coat of THREE BOND #1702 to the outer periphery of the
water seal. Press the water seal into the pump body using the water
seal replacer.
Tool name
Water seal replacer

Tool number

Type I

99759 Z5504

Type II, Type III

99759 Z5507

2 Impeller
Press the impeller into place so that the clearance between the
pump housing and impeller is within maintenance standards.
Unit: mm (in)
Item
Clearance between
pump housing and
impeller

Maintenance standard

Service limit

0.4 - 2.0 (0.016 - 0.079)

Type II,
0.3 - 2.1 (0.012 - 0.083)
Type III

Type I

1 Grease nipple
Pour bearing grease into the grease nipple.
Unit: g (oz)
Item

Amount of grease

Type I

38 (1.34)

Type II, Type III

42 (1.48)

EC-3-5

THERMOSTAT

THERMOSTAT
REMOVAL

INSPECTION
Check thermostat operation as shown in the figure on the right.
Item
76.5C
(170F)

Valve opening
82C
temperature
(180F)
C (F)
88C
(190F)
76.5C
(170F)

Valve lift/
82C
temperature
(180F)
mm/C (in/F)
88C
(190F)

Maintenance
standard

Service limit

74.5 - 78.5
(166 - 173)

71.5 - 81.5
(161 - 179)

80 - 84 (176 - 183)

77 - 87 (171 - 189)

86 - 90 (187 - 194)

85 - 93 (185 - 199)

More than 10/90


(0.39/194)

Less than 9/90


(0.35/194)

More than 10/95


(0.39/203)

Less than 9/95


(0.35/203)

More than 10/100


(0.39/212)

Less than 9/100


(0.35/212)

INSTALLATION
Install a new gasket so that it covers the periphery of the thermostat
as shown in the figure.

EC-4-1

RADIATOR AND COOLANT RESERVOIR TANK

RADIATOR AND COOLANT RESERVOIR TANK


FLUSHING COOLING SYSTEM
1.

Drain approximately 5% of the engine coolant from the cooling system and replenish with the same amount of cleaning
solvent (genuine product. Cooling Mate). Allow the engine
to idle for approximately 30 minutes.
NOTE
z Engine coolant temperature should be maintained at
approximately 80C (176F).
2. Drain the cooling system and replenish with tap water.
WARNING
WARNING
z Do not remove the radiator cap quickly. Otherwise, you
may be sprayed and scalded with hot flashing fluid.
Cover the cap with a thick and heavy rag, and remove it
gradually.
3.
4.

Start the engine again and continue to flush the cooling system. Repeat the flushing operation until drained water is
clean.
Remove dust, leaves, and other foreign matter from the
radiator core fins, water tubes, etc.

INSPECTION
Check the radiator and coolant reservoir tank for cracks or damage.
If necessary, repair or replace.

Water leakage test


Plug the inlet and outlet of the radiator with suitable taps and
immerse the entire radiator in water. While holding the radiator in
water, apply 157 kPa {1.6 kgf/cm2, 23 psi} of compressed air to the
radiator core to check for air leakage. If leakage is present, repair or
replace as necessary.

Radiator cap operating pressure


Unit: kPa {kgf/cm2, psi}
Maintenance standard

Service limit

39 - 59 {0.4 - 0.6, 6 - 9}

Remarks
Pressure side

EC-5-1

RADIATOR AND COOLANT RESERVOIR TANK

Engine coolant
Check density of anti-freeze solution or LLC (Long Life Coolant)
using a tester. If it is low, add anti-freeze solution or LLC as
required to suit the areas where the vehicle is to be operated.

EC-5-2

FAN CLUTCH

FAN CLUTCH
CONSTRUCTION
FD1300L

FDL1700

EC-6-1

FAN CLUTCH

FDL2000

INSPECTION
After removing the fan clutch, inspect it visually, and if there are any
cracks or oil leakage (silicone oil), replace the fan clutch assembly.

OPERATING TEMPERATURE CHECK


1.
2.
3.
4.
5.

Remove the fan and fan shroud.


Reinstall the fan.
Set a thermometer between the fan and radiator.
Start the engine and keep it running at a steady N rpm.
As the thermometer reaches the range for TC (TF) ascertain that fan speed gradually increases from low speed to
high speed. If there is any abnormality, replace the fan
clutch.

EC-6-2

FAN CLUTCH
Unit: C (F)
Item
FE6A
ON-OFF
FE6B 119 kW {162 PS} FD1300L
type
FE6B 132 kW {180 PS}
FE6B 132 kW {180 PS}
FE6T 135 kW {183 PS}
FDL1700
FE6T 151 kW {205 PS}
FE6TA 157 kW {213 PS}
Linear
type
FE6T 151 kW {205 PS}
FE6T 162 kW {220 PS}
FDL2000
FE6TA 157 kW [213 PS}
FE6TA 173 kW {235 PS}

Run the
Operating
engine
temperature
continuously
(T)
3,000 rpm

755
(1679)
6510 - 805
(14918 1769)

3,400 rpm
5010 - 805
(12218 1769)

EC-6-3

- MEMO -

FUEL SYSTEM

CONTENTS
SERVICE DATA ...................................... EF-1-1
SPECIFICATIONS............................................
SERVICE DATA ...............................................
TIGHTENING TORQUE ...................................
FUEL SYSTEM.................................................

TOOLS ....................................................

EF-1-1
EF-1-2
EF-1-4
EF-1-6
EF-2-1

= FE6A, FE6B, FE6T AND FE6TA


[173 kW 235 PS] =
EF-3-1
EF-3-6
EF-3-7
EF-3-16
EF-3-24
EF-3-25
EF-3-27

= FE6TA [157 kW {213 PS}] =


INJECTION PUMP ASSEMBLY ............. EF-4-1
CONSTRUCTION.............................................
REMOVAL ........................................................
FUEL FEED PUMP AND PRIMING PUMP ......
INSTALLATION ................................................
FUEL INJECTION QUANTITY ADJUSTMENT

NOZZLE AND NOZZLE HOLDER ..........

CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................
ADJUSTMENT..................................................
INSTALLATION ................................................

EF-5-1
EF-5-1
EF-5-2
EF-5-3
EF-5-4
EF-5-4
EF-5-5

= TWO-SPRING TYPE =

INJECTION PUMP ASSEMBLY ............. EF-3-1


INJECTION PUMP PROPER ...........................
FEED PUMP.....................................................
TIMER ..............................................................
GOVERNOR.....................................................
ADJUSTMENT .................................................
INITIAL INJECTION TIMING ADJUSTMENT...
FUEL INJECTION QUANTITY ADJUSTMENT

= CONVENTIONAL TYPE =

EF-4-1
EF-4-11
EF-4-12
EF-4-15
EF-4-16
EF-5-1

CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................
ADJUSTMENT..................................................
INSTALLATION ................................................

EF-5-6
EF-5-6
EF-5-7
EF-5-8
EF-5-9
EF-5-9
EF-5-16
FUEL FILTER .......................................... EF-6-1
CONSTRUCTION ............................................. EF-6-1
REPLACING FUEL FILTER ELEMENT............ EF-6-3
ENGINE CONTROL SYSTEM................. EF-7-1

= FE6A, FE6B, FE6T AND FE6TA


[173 kW {235 PS}] =
CONSTRUCTION ............................................. EF-7-1
ADJUSTMENT.................................................. EF-7-1

= FE6TA [157 kW {213 PS}] =


CONSTRUCTION ............................................. EF-7-4
ADJUSTMENT.................................................. EF-7-4
MD-TICS SYSTEM............................... EF-8-1

EF

SERVICE DATA

SERVICE DATA
SPECIFICATIONS
Engine model

FE6A

Max. gross output

kW {PS/}rpm

Fuel injection timing (B.T.D.C.)

FE6B

FE6T

118 {160}/ 119 {162}/ 132 {180}/ 135 {183}/ 151{205}/ 162 {220}/ 173 {235}/
3,000
3,000
3,000
3,000
2,800
2,800
2,800
14

15

12

10

Ignition order

12

Plunger diameter
mm (in)

9.5
(0.374)

Injection
pump
Cam lift
mm (in) Feed
pump

8.0
(0.315)

9.0
(0.354)

9.5
(0.374)

11.0
(0.433)

9.0 (0.354)

9.0 (0.354)

10.0 (0.394)
6.0 (0.236)

Type

Centrifugal
RAD-B
RLD-E
RFD-B

RLD-E

RAD-B
RLD-E
RFD-B

RLD-E

Type
Timer

Bosch
(TC-MD type)

Bosh (PE-A type)

Governor Type
name

RLD-F

RLD-J

SAG

Centrifugal

Type
name

SA

SA/SAG

Injection timing control

SA

Electronic
(MD-TICS)

Nozzle holder

Flange type

Nozzle

Multi-jet

Identification mark

Fuel injection
nozzle

157 {213}/
2,800

1-4-2-6-3-5
Type

Fuel injection
pump

FE6TA

D2

Number of nozzle
holes

Injection opening
pressure

D3

A5

A6

A3

19,614
{200,
2,844}

1st stage:
16,672
{170,
2,417}
2nd stage:
21,575
{220,
3,128}

*1
C1/F4

*2
C1

19,614 {200, 2,844}

kPa {kgf/cm , psi}

NOTE

*1: For HONG KONG only (F4 FE6-206670)


z *2: For NORWAY only
z

EF-1-1

21,575
{220,
3,128}

19,614
{200, 2,844}

SERVICE DATA

SERVICE DATA
INJECTION PUMP ASSEMBLY
FE6A, FE6B, FE6T AND FE6TA [173 KW {235 PS}]
Unit: mm (in)

Housing and
associated parts

Camshaft

Item

Maintenance standard

Service limit

I.D. of housing tappet

24.00 - 24.03
(0.9449 - 0.9461)

24.15 (0.9508)

Pump housing to tappet clearance

0.03 - 0.07
(0.0012 - 0.0028)

0.2 (0.008)

Pump housing to bearing cover clearance

0.01 - 0.05
(0.0004 - 0.0020)

0.1 (0.004)

O.D. of contact surface of oil seal

20.0 (0.787)

19.8 (0.780)

Runout

Less than
0.05 (0.0020)

0.15 (0.0059)

End play of camshaft

0 - 0.02
(0 - 0.0008)

0.1 (0.004)

23.95 - 23.97
(0.9429 - 0.9437)

23.9 (0.941)

0.2 (0.008)

Tappet O.D.
Tappet

Play of tappet roller


Depth of tappet roller adjusting bolt

0.2 (0.008)

0.15 (0.0059)

0.3 (0.012)

0.03 - 0.08
(0.0012 - 0.0031)

0.12 (0.0047)

Less than 1.471 N


{150 g, 5.29 oz}

3.00.05
(0.11810.0020)

0.5

Clearances between pins and holes in


tension lever, speed setting lever and
guide lever

0.01 - 0.09
(0.0004 - 0.0035)

0.2
(0.008)

Clearance of flyweight pin bushing

0.02 - 0.05
(0.0008 - 0.0020)

0.08
(0.0031)

Rod control lever-to-bushing clearance

0.03 - 0.08
(0.0012 - 0.0031)

0.15
(0.0059)

Roller I.D.-to-roller pin O.D. clearance

0.04 - 0.08
(0.0016 - 0.0031)

Tappet roller pin hole-to-roller pin O.D.

0.02 - 0.07
(0.0008 - 0.0028)

Roller I.D.

14.98 - 15.00
(0.5898 - 0.5906)

14.6 (0.575)

Housing-to-piston clearance

0.03 - 0.06
(0.0012 - 0.0024)

0.15 (0.0059)

Control rack to pinion backlash


Control sleeve to plunger flange play
Plunger and
delivery valve

Sliding resistance of control rack


Static fuel injection starting (Cam lift)
Difference in injection interval among cylinders

Governor

Feed pump

Remarks

Support center holes at both


ends.

Measure at right angle to roller


pin.

When static

Total play
0.3 (0.012)

Less than 30 sec. (Time required for oil pressure to


reach 177 kPa {1.8 kgf/cm2, 26 psi} with the engine
running at 600 rpm

Discharge pressure

Overflow valve
opening pressure

Discharge flow rate

Less than 300 milliliter (10.6 Imp fl oz) (Oil discharged


for 15 seconds with engine running at 1,000 rpm)

Priming pump

25 times (Number of cycles required for priming pump


running at a stroke of 60 - 100 per minute)

Injection pump outlet


Fuel filter

kPa {kgf/cm2, psi}

157 {1.6, 23}

kPa {kgf/cm2, psi}

108 - 147
{1.1 - 1.5, 16 - 21}

EF-1-2

When suction pipe of 8.0 mm


(0.315 in) I.D. and 2.0 m (6.56
ft) length is used
When cam lift is 6.0 mm (0.236
in)

SERVICE DATA

FE6TA [157 kW {213 PS}]


Unit: mm (in)

Housing and
associated parts

Camshaft

Tappet

Item

Maintenance standard

Service limit

I.D. of housing tappet

28.000 - 28.021
(1.1024 - 1.1032)

28.15 (1.1083)

Pump housing to tappet clearance

0.020 - 0.062
(0.0008 - 0.0024)

0.2 (0.008)

Pump housing to bearing cover clearance

0 - 0.06
(0 - 0.0024)

0.1 (0.004)

O.D. of contact surface of oil seal

25.0 (0.984)

19.8 (0.780)

Runout

Less than
0.05 (0.0020)

0.15 (0.0059)

End play of camshaft

0.02 - 0.06
(0.0008 - 0.0024)

0.1 (0.004)

Tappet O.D.

27.959 - 27.980
(1.1007 - 1.1016)

27.9 (1.098)

0.2 (0.008)

Play of tappet roller


Depth of tappet roller adjusting bolt

0.2 (0.008)

0 - 0.056
(0 - 0.0022)

0.3 (0.012)

0.025 - 0.083
(0.0010 - 0.0033)

0.12 (0.0047)

Sliding resistance of control rack

1.275 N
{130 g, 4.59 oz}

1.471 N
{150 g, 5.29 oz}

Static fuel injection starting (Cam lift)

5.60.03
(0.22050.0012)

0.25

Control rack to pinion backlash


Control sleeve to plunger flange play
Plunger and
delivery valve

Difference in injection interval among cylinders

Clearances between pins and holes in


tension lever, speed setting lever and
guide lever

0.01 - 0.09
(0.0004 - 0.0035)

0.2 (0.008)

Clearance of flyweight pin bushing

0.018 - 0.039
(0.0007 - 0.0015)

0.08 (0.0031)

Rod control lever-to-bushing clearance

0.031 - 0.075
(0.0012 - 0.0030)

0.15 (0.0059)

Housing and push rod clearance

0.003 - 0.018
(0.0001 - 0.0007)

0.1 (0.004)

Housing and piston clearance

0.014 - 0.056
(0.0006 - 0.0022)

0.15 (0.0059)

Governor

Remarks

Support center holes at both


ends.

Measure at right angle to roller


pin.

At standstill

Shaft to tension lever guide


0.05 - 0.08
(0.0020 - 0.0031)
Lever shaft to bushing
0.022 - 0.051
(0.0009 - 0.0020)

Less than 30 sec. (Time required for oil pressure to


Feed pump

Overflow valve
opening pressure
kPa {kgf/cm2,
psi}

Discharge pressure

reach 177 kPa 1.8 {kgf/cm2, 26 psi} with the engine


running at 600 rpm)

Discharge flow rate

Less than 300 milliliter (10.6 Imp fl oz) (Oil discharged


for 15 seconds with engine running at 1,000 rpm)

Priming pump

25 times (Number of cycles required for priming pump


running at a stroke of 60 to 100 per minute)

Injection pump outlet


Fuel filter

255 {2.6, 37}

108 - 147
{1.1 - 1.5, 16 - 21}

EF-1-3

when suction pipe of 8.0 mm


(0.315 in) I.D. and 2.0 m (6.56
ft) length is used
when cam lift is 6.0 mm (0.236
in)

SERVICE DATA

NOZZLE AND NOZZLE HOLDER


Unit: kPa {kgf/cm2, psi}
Item
Conventional
type
Valve opening
pressure
(Regulated
pressure)

Maintenance standard

Service limit

Z, D2, A5
A6, C1, F4

20,104 - 20,595
{205 - 210, 2,915 - 2,986}

D3, F4

22,066 - 22,556
{225 - 230, 3,200 - 3,271}

17,162 - 17,947
{175 - 183, 2,489 - 2,602}

23,046 - 23,537
{235 - 240, 3,342 - 3,413}

Nozzle cover method

24,321 - 24,910
{248 - 254, 3,527 - 3,612}

Push rod contacting


method

1st
stage
Two-spring
type

A3

2nd
stage

Remarks

TIGHTENING TORQUE
INJECTION PUMP ASSEMBLY
Unit: Nm {kgfm, ftlbf}
Item
Injection pump
assembly

Delivery valve holder

Tightening torque
PE-A type

M20

39 - 44 {4.0 - 4.5, 29 - 33}

M24

49 - 54 {5.0 - 5.5, 36 - 40}

TC-MD type

103 - 113 {10.5 - 11.5, 76 - 83}

Bearing cover mounting bolt


Timer

Timer round nut

7 - 9 {0.7 - 0.9, 5.1 - 6.5}


SAG type

54 - 59 {5.5 - 6.0, 40 - 43}

SA type

83 - 98 {8.5 - 10.0, 61 - 72}

Flyweight round nut

RAD-B
RLD-E, F
RFD-B
Governor

RLD-J

Actuator housing

Governor housing
mounting bolt

59 - 69 {6.0 - 7.0, 43 - 51}


M6

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

M8

15 - 18 {1.5 - 1.8, 11 - 13}

Governor cover mounting bolt

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

Idle spring assembly lock nut

18 - 22 {1.8 - 2.2, 13 - 16}

Ungleich spring assembly lock nut

16 - 20 {1.6 - 2.0, 12 - 14}

Speed setting bolt lock nut

10 - 14 {1.0 - 1.4, 7 - 10}

Flyweight round nut

49 - 59 {5.0 - 6.0, 36 - 43}

Governor housing mounting bolt

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

Governor cover mounting bolt

7 - 9 {0.7 - 0.9, 5.1 - 6.5}

Idle spring assembly lock nut

39 - 59 {4.0 - 6.0, 29 - 43}

Speed setting bolt lock nut

10 - 14 {1.0 - 1.4, 7 - 10}

Actuator housing mounting bolt

1.0 - 1.5 {0.10 - 0.15, 0.7 - 1.1}

EF-1-4

SERVICE DATA

NOZZLE AND NOZZLE HOLDER


Unit: Nm {kgfm, ftlbf}
Item
Conventional
type

Two-spring
type

Cap nut

Tightening torque
Z, D2, D3, A5, A6

39 - 49 {4.0 - 5.0, 29 - 36}

C1, F4

29 - 39 {3.0 - 4.0, 22 - 29}

Retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Inlet connector

59 - 69 {6.0 - 7.0, 43 - 51}

Cap nut

39 - 49 {4.0 - 5.0, 29 - 36}

Retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Inlet connector

59 - 69 {6.0 - 7.0, 43 - 51}

Nut

20 - 25 {2.0 - 2.5, 14 - 18}

Set screw

49 - 59 {5.0 - 6.0, 36 - 43}

Nozzle holder assembly mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

FUEL FILTER
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Fuel filter (center bolt type) center bolt


Primary fuel filter center bolt

20 - 29 {2.0 - 3.0, 14 - 22}


Type I

20 - 29 {2.0 - 3.0, 14 - 22}

Type II

59 - 69 {6.0 - 7.0, 43 - 51}

Primary fuel filter drain plug (Type II only)

16 - 22 {1.6 - 2.2, 12 - 16}

Fuel strainer center bolt

15 - 20 {1.5 - 2.0, 11 - 14}

EF-1-5

SERVICE DATA

FUEL SYSTEM

EF-1-6

TOOLS

TOOLS
Injection pump (Part numbers designated by ZEXEL)
Tool name and number

Description

Measuring device
105782-4080

For measuring camshaft in the axial direction

Measuring device
105782-4330

For measuring plunger pre-stroke

Adjusting device
105782-6170

For measuring control lever angle


(RLD governor)

Adjusting device
105782-6220

For measuring governor control lever

Measuring device
105782-6280

For measuring control rack travel

Timing checker
157830-3320

For testing timer advance angle

Sensor
157830-3420

EF-2-1

Shape

TOOLS
Tool name and number

Description

Lamp
157830-3520

Holder
157842-5220

For testing timer advance angle


Cut the reflection plate to a size of 5.0 x 7.0
mm (0.197 x 0.276 in)

Reflection plate
157951-1100

Handle
157910-1120

Used together with socket wrench and special


wrench

Socket wrench
157914-0500

For dismounting and mounting delivery valve


holder

Wrench
157915-0100

For dismounting and mounting flyweight fixing


nut

Socket wrench
157914-0300

For dismounting and mounting round nut


(SA type timer)

EF-2-2

Shape

TOOLS

Tool name and number

Description

Wrench
157915-0300

For dismounting and mounting round nut


(SAG type timer)

Spanner
157916-4620

For fixing coupling for timer

Extractor
157926-6210

For removing timer assembly

Seal guide
157920-5400

For protecting lip of camshaft oil seal

Tappet insert
157921-0120

For inserting tappet assembly

Plunger insert
157921-5620

For inserting plunger

Extractor
157925-0520

For removing oil seal

Extractor
157925-6520

For removing bearing

EF-2-3

Shape

TOOLS
Tool name and number

Description

Extractor
157926-5120

For removing flyweight

Holder
157931-2500

For holding tappet

Holder
157931-4100

For holding plunger spring

Tappet inserter
157931-6120

For installing tappet

Universal vise assembly


105794-0090
Vise
157944-8520
Bracket
197944-8720

For disassembling and reassembling pump


vise

Lock
157976-3100

For locking control rack

Wrench
157916-2620

For adjusting idling


(RAD and RFD governors)

EF-2-4

Shape

TOOLS

Tool name and number

Description

Wrench
157913-3520

For adjusting boost compensator stroke

Wrench
157913-3620

For adjusting governor torque cam


(RLD governor)

Wrench
157913-5320

For adjusting governor shaft


(RLD governor)

Wrench
157913-5400

For adjusting idling


(RLD governor)

Rod
157923-5800 [18 mm,
(0.71 in)] dia.
157923-5900 [22 mm,
0.87 in)] dia.
157923-6000 [26 mm,
(1.02 in)] dia.

For press-fitting plate plug


(RLD governor)

Plug
029111-4050

For adjusting injection timing (M14 x 1.5)


(RLD governor)

Measuring device
105782-6030

For measuring the load control lever angle


(RAD governor)

EF-2-5

Shape

TOOLS

Tool name and number

Description

Measuring device
105782-6090

For measuring control rack

Coupling
105784-0510

For measuring timing device advance angle

Coupling
157842-4420

For driving injection pump

Box wrench
157916-2800

For removing and installing timing device


round nut

Spanner
157916-5420

For fixing timing device and pump coupling

Extractor
157926-5110

For removing governor flyweight

EF-2-6

Shape

TOOLS

Tool name and number


Tappet holder
157931-7320
Pin
157931-7300
Holder
157931-7400

Description

Shape

For holding tappet

Timer (Part numbers designated by ZEXEL)


SAG type
Tool name and number

Description

Base
157924-2520

For disassembling and reassembling the timer

Spring compressor
157921-9820

For disassembling and reassembling the flyweight assembly

Shape

SA type
Tool name and number

Description

Block
157924-0800

For inserting the oil seal on the flange side

Thrust bushing
157924-0500

For disassembling the timer

EF-2-7

Shape

TOOLS

Tool name and number

Description

Guide
157924-0900

For inserting the oil seal on timer case side

Guide bolt
157924-1100

For inserting the oil seal

Oil seal guide


157924-0700

For inserting the oil seal

Guide bushing
157924-1200

For inserting the oil seal on flange side

Guide bushing
157924-1300
or
157924-1400

For inserting the oil seal on timer case side

Supporter
157932-0100

For supporting the timer spring

Bolt
029001-2220

For reassembling the timer

Washer
029301-2260

Band spanner
157916-6120

For removing or installing the timer case

EF-2-8

Shape

TOOLS

Tool name and number

Description

Base
157924-0110

For disassembling and reassembling the timer

Guide bolt
157924-0300

For disassembling the timer

Guide
157924-0400

For disassembling the timer

Thrust bushing
157924-1500

For inserting the oil seal on flange and timer


case side

Shape

Nozzle and nozzle holder


Tool name and number

Description

Pin vise
99727 Z5005

For cleaning nozzle injection hole

Nozzle cleaner
99726 Z5000

Used to remove carbon from rear of nozzle

* Nozzle tester
105785-0960

Used to measure nozzle opening pressure and


to check spray characteristics and oil leakage
from nozzle seat
(Conventional type)

* Nozzle tester
105785-1010

Used to confirm the first and second valve


opening pressures (regulated pressures) of the
nozzle
Used to bleed air from the retaining nut and to
check fuel leakage (Two-spring type)

* Part numbers designated by ZEXEL

EF-2-9

Shape

TOOLS

Tool name and number

Description

* Plate
157944-9520

For fixing nozzle holder

Retaining nut
157892-2020
(1) 157892-2000
(2) 026508-1140
(3) 157892-1600

Used to adjust the first valve opening pressure


(regulated pressure) and the overall lift of the
needle valve (Two-spring type)
(1) Retaining ring
(2) Gasket
(3) Plug

Dial gauge
157954-3800

Used to adjust the pre-lift and the overall lift of


the needle valve (Two-spring type)

Pin
157892-1100

Used to adjust the pre-lift (Two-spring type)


L = 60.5 mm (2.382 in)

Pin
157892-1200

Used to adjust the overall lift of the needle


valve
(Two-spring type)

Base
157892-1800

Used to adjust the pre-lift (Two-spring type)

Adjusting device
105789-0560
(1) 157892-0220
(2) 157892-1320

Used to adjust the pre-lift and the overall lift of


the needle valve (Two-spring type)
(1) Adjusting device
(2) Connector

* Part numbers designated by ZEXEL

EF-2-10

Shape

- MEMO -

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

= FE6A, FE6B, FE6T AND FE6TA [173 kW {235 PS}] =


INJECTION PUMP ASSEMBLY
INJECTION PUMP PROPER
DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Gasket
+ 2. Cover
3. Eyebolt
4. Gasket
5. Adapter
6. Overflow valve
7. Gasket
8. Adapter
+ 9. Plug
10. Bearing cover
11. O-ring
12. Oil seal

,+ 13. Camshaft
+ 14. Ball bearing
15. Shim
16. Ring
17. Gasket
18. Center bearing
,+ 19. Tappet assembly
20. Shim
21. Spring seat
22. Plunger spring
23. Upper spring seat

24. Control sleeve


25. Lock plate
+ 26. Delivery valve holder
27. O-ring
28. Stopper
29. Delivery valve spring
30. Gasket
31. Delivery valve
, 32. Plunger assembly
33. Rack limiter
34. Rack guide screw
, 35. Control rack

Marks + and , indicate that the key points of operation are explained in the text.

EF-3-1

INJECTION PUMP ASSEMBLY

Key point of disassembly


Set the injection pump on the universal vise assembly (1057940090).

2 Cover
Remove the pump cover plate and, using the special wrench
(157916-4620), turn the camshaft. When the tappet reaches top
dead center, insert the tappet holder (157931-7320) into the tappet
hole, so that the tappet can be released from the cam.

9 Plug
Remove the screw plug at bottom of the housing using the handle
(157910-1120).

13 Camshaft
Rotate the camshaft until its drive side key groove is facing vertically upward. Then attach the seal guide (157920-5400) to the
camshaft.

14 Ball bearing
1. Use the extractor (159725-0520) and remove the outer race
from the bearing cover. Install the outer race extractor and
tighten the nut to force the flared portion of the tool between
the outer race and the oil seal. Hold the bearing cover and
tap the tool with a hammer.

EF-3-2

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


2.

Place the extractor (157925-6520) over the inner race of


the bearing and pull the inner race from the camshaft. At
the same time remove the shim plate and washer.

19 Tappet assembly
1. Insert the tappet insert (157921-0120) from the screw plug
hole, compress the plunger spring by pushing the tappet up
and pull the plunger spring holder out.

2.

After pulling the tappet holder, insert the tappet inserter


(157931-6120) from the bearing insertion hole of the pump
housing and pull the tappet out with the shim.

3.

After removing the tappet, insert the plunger insert (1579215620) from the screw plug hole and pull the plunger with the
lower spring seat.

26 Delivery valve holder


Using a socket wrench (157914-0500), remove the delivery valve
holder, stopper and delivery spring.

EF-3-3

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Key point of reassembly


Before assembling the fuel injection pump, clean parts thoroughly
and apply a thin coat of engine oil to rotating and sliding parts.

35 Control rack
Tilt the pump housing onto its side and set the punch mark at both
sides of the control rack to the same dimension from the ends of
the pump housing.

32 Plunger assembly
Install the plunger to the special tool plunger insert (157921-5620)
and assemble to the barrel.
At this time, the lower spring seat must be installed to the plunger.
NOTE
z Since the plunger and barrel are precision manufactured
as pair, they must not be matched with those of another
cylinder.
z Assemble the plunger with the matching mark facing the
front (cover side) of the pump housing.

19 Tappet assembly
Assemble the tappet to the pump housing using the tappet inserter
(157931-6120) and tappet insert (157921-0120) the same as when
disassembling. Push the tappet itself forcefully and install the tappet holder.

13 Camshaft
1. Install the camshaft, together with the center bearing, to the
pump housing so that the assembly mark is at the timer
side. (This work can be facilitated by coating the center
bearing with a small amount of grease and sticking it to the
camshaft.)

EF-3-4

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


2. Install the bearing cover to the pump housing.
NOTE
z Since the oil seal may be damaged by the key groove of
the camshaft when installing the bearing cover, install
the seal guide (157920-5400) to the threaded part of the
camshaft.

3.

Measure the end play of the camshaft with the measuring


device (105782-4080). Adjust the end play by changing the
thickness of the adjusting shim at the inside of the bearing.
In this case, first measure the end play of the camshaft with
the measuring device and then adjust to 0 to 0.02 mm (0 to
0.0008 in) dividing the end play equally at the front and rear
with the shim.
Unit: mm (in)

4.

Maintenance standard

Service limit

0 - 0.02 (0 - 0.0008)

0.1 (0.004)

After injection pump reassembly, use a spring balance to


check that the control rack moves smoothly over its complete stroke.
Unit: N {g, oz}
Item

Maintenance
standard

Service limit

Sliding resistance
of control rack

Less than 1.471


{150, 5.29}

Remarks
When static

5.

Ensure control rack stroke is 21.0 mm (0.827 in), from the


position where the control rack is fully pushed toward the
governor to the position where it is fully pulled toward the
drive side.
Use a vernier caliper or depth gauge to perform measurement.
NOTE
z If the control rack stroke is not within 21.0 mm (0.827 in)
reengage the control pinion with the control rack to
obtain the control rack stroke of 21.0 mm (0.827 in).

EF-3-5

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

FEED PUMP
CONSTRUCTION

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Priming pump
2. O-ring
3. Spring
4. Valve
5. Eyebolt
6. Eyebolt

7. Adapter
8. Gasket
9. Spring
10. Valve
11. Plug

12. Gasket
13. Piston spring
14. Piston
15. Straight pin
16. Housing

EF-3-6

INJECTION PUMP ASSEMBLY

TIMER
CONSTRUCTION
SAG type

SA type

EF-3-7

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

DISASSEMBLY AND REASSEMBLY


SAG type

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

,+
,+
,
,

1. Plug
2. Gasket
3. Screw
4. Cover
5. Flange
6. Eccentric cam (large)
7. Eccentric cam (small)

+ 8. Snap ring
9. Seat
10. Shim
11. Shim
12. Spring
13. Spring

14. Seat
15. Pilot pin
16. Spacer
, 17. Flyweight
18. O-ring
19. Housing

Marks + and , indicate that the key points of operation are explained in the text.

Key point of disassembly


1.

Using a socket wrench (157915-0300), handle (1579101120) and special wrench (157916-4620), remove the
round nut and then remove the timer assembly, using an
extractor (157926-6210).

EF-3-8

INJECTION PUMP ASSEMBLY


2.

Record the relationship between the housing punch mark


and the location of the holder key groove before disassembly.

3.

Clamp the base (157924-2520) in a vise and set it on the


timer assembly.

4 Cover
Remove the six screws holding the cover and then remove the
cover.
NOTE
z At this time, be careful not to damage the lip of the oil
seal.

5 Flange
Remove the holder together with the flyweight assembly from the
housing.
NOTE
z Sometimes large and small cams may be left in the housing.
Do not change the order of those cams at this time.
Install them in the holder correctly, and note the directions and locations of the key groove and cams.
8 Snap ring
Compress springs using the spring compressor (157921-9820) and
draw out the snap ring.

EF-3-9

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Key point of reassembly


Install large and small cams in the position specified. The specified
position for cams can be identified by the Bosch No. marked on the
outer periphery of the housing.

17 Flyweight
Install the flyweight as shown in the figure so that the holder key
groove faces the upper portion, and the right-hand flyweight pin
faces the upper portion. (The left-hand flyweight pin will face the
bottom portion.)

6, 7 Eccentric cam
1. Install the large and small cams in each specified position.
Large cams: t1 is wider than t2
Small cams: t3 is narrow

2.

Measure the pitch of the housing pin.

3.

Set the pitch of the small cam housing pin hole to the measured value found in step 2.

EF-3-10

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


4.

Make sure that the distance between both the small cam
hole and holder center is the same.
NOTE
z If not, repeat step 2.

5 Flange
1. With both housing punch mark and holder key groove in
position, install the housing into the holder. At this time, be
careful not to damage the oil seal.
NOTE
z If the housing pin cannot be inserted into the small cam
hole, repeat step 1 and subsequent steps.

2.

Check that cams are assembled correctly. The figure shows


the cams from the cover side.

4 Cover
Lubrication of timing device.
Lubricating oil: Mobil oil #20
Oil level: Approximately 1 mm (0.04 in) below the upper surface of
flyweights.

EF-3-11

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

SA type

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Plug
2. Gasket
,+ 3. Timer case
4. Oil seal

5. O-ring
, 6. Flange
7. Timer spring
, 8. Adjusting shim

9. Flyweight
, 10. Oil seal
11. Flyweight holder

Marks + and , indicate that the key points of operation are explained in the text.

Key point of disassembly


Using a socket wrench (157914-0300), handle (157910-1120) and
special wrench (157916-4620), remove the round nut and then
remove the timer assembly, using an extractor (157926-6210).

EF-3-12

INJECTION PUMP ASSEMBLY


3 Timer case
1. Clamp the base (157924-0110) in a vise and thread in the
guide bolt (157924-0300).

2.
3.

Remove one of the screw from the flyweight holder. Attach


the flyweight to the base (157924-0110) and secure with
the guide (157924-0400).
Unscrew the staked section of the timer case and flyweight
holder. Remove the timer case by turning it clockwise with
the band spanner (157916-6120).

Key point of reassembly


1.

Clamp the base (157924-0110) in a vise and install in the


guide bolt (157924-1100).

2.

Place the block (157924-0800) over the base pin.

3.

Fit the oil seal to the flange hole. With the guide bushing
(157924-1200) intervening, thread in the thrust bushing
(157924-1500) to force in the oil seal.

EF-3-13

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


10 Oil seal
1. Clamp the base (157924-0110) in a vise and install the
guide bolt (157924-1100).
2. Place the block (157924-0800) over the base and install the
guide (157924-0900).

3.

Insert the oil seal, fit the guide bushing (157924-1300 or


157924-1400), and thread in the thrust bushing (1579241500), completing the job.

8 Adjusting shim
1. Clamp the base (157924-0110) in a vise and install the
guide bolt (157924-0300).
2. Place the flyweight holder over the pin of the base (1579240110) and fit the rubber ring.

3.

Insert the adjusting shim at one end of the timer spring at


the seat portion of the flyweight holder pin. Insert the supporter (157932-0100) beneath the spring, and thread the
guide (157924-0400) over the guide bolt.

6 Flange
Mount the flange, apply a special wrench (157916-4620) to the
flange claw, and fit the thrust bushing (157924-0500), washer
(029301-2260), and bolt (029001-2220) to the flange.

EF-3-14

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


3 Timer case
Position the oil seal guide (157924-0700). Install the timer case and
tighten it with the band spanner (157916-6120).

EF-3-15

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

GOVERNOR
DISASSEMBLY AND REASSEMBLY
RAD type

EF-3-16

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Bracket
2. Cover
3. O-ring
4. Cap nut
5. Gasket
6. Cap nut
7. Gasket
8. Damper spring
9. Plug
10. Gasket
11. Idling stopper bolt
12. Full-load stopper bolt
13. Control lever
14. Shim
15. Oil seal
16. Bushing
17. Plug
18. Tension lever shaft
19. Plug

, 20. Governor cover assembly


21. Gasket
22. Speed adjusting bolt
23. Spring
24. Tube
25. Torque control spring assembly
26. Nut
+ 27. Idling spring assembly
28. Stroke adjusting bolt
29. Tension lever
30. Speed setting lever
31. Governor spring
32. Guide lever assembly
33. Lever shaft
34. Snap ring
35. Snap ring
36. Spring seat
37. Spring seat

38. Snap ring


39. Floating lever
40. Collar
41. Shim
42. Sleeve assembly
43. Rack limiter
44. Start spring
45. Spring eye
+ 46. Round nut
47. Lock washer
,+ 48. Flyweight assembly
49. Key
50. Snap ring
51. Governor housing
52. Gasket
53. Impeller
54. Adapter
55. Control lever

Marks + and , indicate that the key points of operation are explained in the text.

Key point of disassembly


20 Governor cover assembly
1. Removal of governor cover assembly
z
Remove the governor shaft plate plug (1) then loosen
the lock nut with the wrench (157913-5320).

Remove the idling spring plate plug (2) then loosen the
lock nut with the wrench (157913-5400).
Next, use a Phillips screwdriver to remove the idling
spring assembly.

EF-3-17

INJECTION PUMP ASSEMBLY


2.

Using a Phillips screwdriver, remove the seven bolts to separate the governor cover from the governor housing. Then
remove the governor cover.
NOTE
z Be sure to keep an oil pan under the governor to receive
lubricating oil.

27 Idling spring assembly


Loosen the lock nut with a socket wrench (157914-0500) and handle (157910-1120). Then loosen the nut and remove the idling
spring assembly.

46 Round nut, 48 Flyweight assembly


1. Using the special wrench (157916-4620), hold the timer so
that the camshaft will not turn. Then, using the wrench
(157915-0100) and handle (157910-1120), remove the
round nut securing the flyweight.

2.

Screw the extractor (157926-5110) onto the threaded part


of the flyweight holder to pull out the flyweight assembly.

Key point of reassembly


48 Flyweight assembly
Using the spanner (157916-5420), hold the timer so that the cam
shaft will not turn. Then, using the wrench (157915-0100) and handle (157910-1120), install the round nut securing the flyweight.

EF-3-18

A, B, T, TA 173 kW {235 PS}

- MEMO -

INJECTION PUMP ASSEMBLY

RLD type

EF-3-20

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Plate plug
2. Lock nut
, 3. Idling spring assembly
4. Plate plug
5. Lock nut
6. Plate plug
7. Plate plug
8. Lock nut
9. Idling-speed setting bolt
10. Maximum-speed setting bolt and
lock nut
11. Spring
12. Tube
13. Support
14. Control lever
15. Adjusting shim
16. Adjusting shim
17. Oil seal
18. Bushing
19. Plate plug
20. Tension lever shaft
21. Governor cover
22. Gasket
23. Control lever shaft
24. Cancel spring
25. Supporting lever

26. Snap ring


27. Floating lever
28. Guide lever
29. Cancel spring
30. Lock screw
31. Adjusting nut
32. Spring inner
33. Spring outer
34. Rod
35. Snap ring
36. Torque cam
37. Snap ring
38. Pin
39. Tension lever
40. Shifter
41. Adjusting shim
42. Sleeve sub-assembly
43. Governor shaft
44. Spring seat
45. Governor spring outer
46. Round nut
47. Rack connecting link
48. Start spring
49. Spring eye
50. Round nut

, 51. Flyweight assembly


52. Woodruff key
53. Full-load set lever
54. Return spring
55. Shim
56. O-ring
57. Full-load lever shaft
58. Cancel spring
59. Snap ring
60. Sensor lever
61. U-shaped lever
62. Stop lever
63. Cap
64. Return spring
65. Shim
66. O-ring
67. Bushing
68. Collar
69. Shaft
70. Guide screw
71. Lock nut
72. Full-load setting bolt
73. Governor housing
74. Gasket
75. Adapter

Marks + and , indicate that the key points of operation are explained in the text.

Key point of reassembly


51 Flyweight assembly
Using the special wrench (157916-4620), hold the timer so that the
cam shaft will not turn. Then, using the wrench (157915-0100) and
handle (157910-1120), install the lock nut securing the flyweight.

3 Idling spring assembly


Install the idling spring assembly using the Phillips screwdriver and
tighten the lock nut using the wrench (157913-5400).

EF-3-21

INJECTION PUMP ASSEMBLY

RFD type

EF-3-22

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Bracket
2. Closing cover
3. O-ring
4. Cap nut
5. Gasket
6. Damper spring
7. Plug
8. Gasket
9. Stopper bolt
10. Idling stopper bolt
11. Full load stopper bolt
12. Spring
13. Tube
14. Lock washer
15. Control lever
16. Shim
17. Oil seal
18. Bushing
19. Plug
20. Bushing

21. O-ring
22. Snap ring
23. Lever
24. Woodruff key
25. Collar
26. Shim
27. Oil seal
28. Bushing
29. O-ring
30. Snap ring
31. Plug
32. Tension lever shaft
33. Governor cover
34. Gasket
35. Governor spring
36. Swivel lever
,+ 37. Idling spring assembly
38. Stroke adjusting bolt
39. Tension lever
40. Guide lever assembly

41. Lever shaft


42. Sliding lever
43. Snap ring
44. Snap ring
45. Floating lever
46. Collar
47. Smoke limiter
48. Adjusting shim
49. Sleeve assembly
50. Start spring
51. Spring eye
52. Round nut
,+ 53. Flyweight assembly
54. Control lever
55. Stopper bolt
56. Governor housing
57. Impeller
58. Adapter
59. Gasket

Marks + and , indicate that the key points of operation are explained in the text.

Key point of disassembly


37 Idling spring assembly
Loosen the lock nut with a socket wrench (157914-0500), and
remove the idling spring assembly.

53 Flyweight assembly
1. Using a box wrench (157916-2800) and handle (1579101120), remove the round nut and then remove timer assembly using an extractor (157926-6210).
2. Attach the coupling (151842-4420) for disassembly and
reassembly to the pump camshaft.

3.

Hold the timer, using a special wrench (157916-4620), and


remove the round nut from the flyweight side, using a
wrench (157915-0100) and handle (157910-1120).

EF-3-23

INJECTION PUMP ASSEMBLY


4.

Screw the extractor (157926-5110) onto the threaded part


of the flyweight holder to pull out the flyweight assembly.

Key point of reassembly


53 Flyweight assembly
1. Hold the timer, using a spanner (157916-5420).

2.

Using the wrench (157915-0100) and torque wrench,


tighten the flyweight with the lock washer and round nut.

37 Idling spring assembly


Install the idling spring assembly with the socket wrench (1579140500) and handle (157910-1120).

ADJUSTMENT
When the injection pump has been disassembled, plungers or
plunger springs have been replaced, or other reasons exist, use a
pump tester and adjust the injection pump.

EF-3-24

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Injection pump preparations


Remove the cap of the control rack and install the measuring
device (105782-6280).

INITIAL INJECTION TIMING ADJUSTMENT


The start of injection is considered as the time at which the top of
the plunger covers the fuel intake hole of the barrel. The pump
tester must be capable of developing a pressure in the range of
2,942 to 3,923 kPa {30 to 40 kgf/cm2, 427 to 569 psi} in order to
overcome tension of the delivery valve spring (to force the delivery
valve open).

Adjusting the injection timing of the standard cylinder


1.
2.
3.

Fix the control rack to full rack position.


Removing the 1st cylinder delivery valve holder. To do this,
use the socket wrench (157914-0500).
Install the measuring device (105782-4330) to the No. 1 cylinder as viewed from the drive side.

EF-3-25

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


4.
5.
6.

7.

8.

Set the tappet to top dead center of the camshaft and set
the scale of the dial gauge to 0.
Loosen the bleeder screw of the pump and bleed the air
from the fuel system.
When the drive shaft of the tester is slowly turned in the
drive direction while feeding fuel to the fuel inlet of the
pump, the fuel will stop flowing from the pipe of the test use
nozzle holder. This is the injection start position. The injection timing is normal if the tappet has risen by the specified
value from bottom dead center.
When the flow of fuel does not stop when the tappet has
been lifted within 3.35 to 3.45 mm (0.1319 to 0.1358 in)
from bottom dead center, adjust the adjusting shim using
the plunger spring holder (157931-4100).
When the fuel flow stops before the tappet is raised 3.45
mm (0.1358 in), add adjusting shims until the fuel flow stops
at a life of 3.35 mm (0.1319 in).

Adjusting injection interval


1.

2.

After completing adjustment of initial injection timing of the


reference No. 1 cylinder (timer side), turn the camshaft to
the right (as viewed from the drive end) and set the injection
interval for the remaining cylinders by adjusting shims.
See the table below.
Adjust the cylinder injection intervals within 30

Injection order ...........................

Injection interval........................

|
|
|

60

|
|
|

60

|
|
|

60

|
|
|

60

|
|
|

60

|
|
|

60

|
|
|

Scale plate indication................

60 120 180 240 300 360

EF-3-26

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

FUEL INJECTION QUANTITY ADJUSTMENT


Testing conditions
Failure of pump to deliver fuel evenly throws the engine out of balance so that roughness and loss of power is
evident. In calibrating a pump, observe the following:
Item

Test condition

Nozzle

105780-0000 (BOSCH Type No. DN12SD12T)

Nozzle holder

105780-2080 (BOSCH Type No. EF8511/9)

Nozzle opening pressure

kPa {kgf/cm2, psi}

17,162 {175, 2,489}

Feed pump oil pressure

kPa {kgf/cm2, psi}

157 {1.6, 23}

Injection pipe (OD x ID L)

mm (in)

6 x 2 600 (0.24 x 0.08 23.62)

Test oil

IS04113 or SAE standard test oil (SAE J967d)

Test oil temperature

C (F)

40 - 45 (104 - 113)

Injection quantity standards (ZEXEL No. is Inj. Pump assy No.)


RAD governor
z

ZEXEL No. 101607-9351


Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

8.2 (0.323)

600

421 (1.480.04)

3.5

Lever

8.0 (0.315)

1,000

531 (1.90.04)

10

Lever

Approx. 7.0
(0.276)

300

91.8 (0.320.06)

10

Rack

Adjust max. var. bet. cyl. at R  7.0 mm


(0.276 in).
Adjust governor as per gov. adj. spec.

100

Above 80 (2.8)

Lever

After setting excessive fuel for starting

D
z

Remarks
Basic

ZEXEL No. 101607-9331


Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

9.8 (0.386)

600

58.91 (2.070.04)

3.5

Lever

R1 [10.0
(0.394)]

1,500

80.61 (2.840.04)

Lever

Approx. 7.9
(0.311)

300

8.31.8 (0.290.06)

10

Rack

100

Above 80 (2.8)

Lever

EF-3-27

Remarks
Basic

After setting excessive fuel for starting

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

RLD governor
z

ZEXEL No. 101607-9270


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

11.3 (0.445)

600

48.21.6 (1.700.06)

3.5

Rack

Basic

Approx. 9.8
(0.386)

300

91.8 (0.320.06)

10

Rack

Adjust max. var. bet. cyl.


at R  9.8 mm (0.386 in).
Adjust governor as per gov. adj. spec.

R1 [11.3
(0.445)]

600

48.21 (1.700.04)

Lever

R1 0.2
(0.008)

1,000

[62.0 - 65.2 (2.2 2.3)]

Lever

100

80+10 (2.8+0.4)

Lever

Adjusting
point

Rack limit

ZEXEL No. 101696-9410


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

12.6 (0.496)

1,500

77.51.6 (2.730.06)

3.5

Rack

Basic

Approx. 9.7
(0.382)

300

9.51.8 (0.330.06)

10

Rack

Adjust max. var. bet. cyl.


at R  9.7 mm (0.382 in).
Adjust governor as per gov. adj. spec.

R1 [12.6
(0.496)]

1,500

77.51 (2.730.04)

Lever

Basic

R1 1.65
(0.0650)

600

[40 - 44 (1.4 - 1.55)]

Lever

150

77.5+20 (2.73+0.7)

Lever

Adjusting
point

Remarks

Remarks

Rack limit

ZEXEL No. 101607-9260


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

11.8 (0.465)

600

66.31.6 (2.330.06)

3.5

Rack

Approx. 9.5
(0.374)

300

9.51.8 (0.330.06)

10

Rack

R1 [11.8
(0.465)]

600

66.31 (2.330.04)

Lever

R1 0.2
(0.008)

900

[71.4 - 74.6
(2.51 - 2.63)]

Lever

R1 [11.8
(0.465)]

1,500

[81.9 - 85.9
(2.88 - 3.02)]

Lever

100

84+10 (3.0+0.4)

Lever

Adjusting
point

EF-3-28

Remarks
Basic

Basic

Rack limit

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9380


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

12.5 (0.492)

1,500

83.71.6 (2.950.06)

3.5

Rack

Approx. 9.5
(0.374)

300

9.51.8 (0.330.06)

10

Rack

R1 [12.5
(0.492)]

1,500

83.71 (2.950.04)

Lever

R1 0.55
(0.0217)

900

68.72 (2.420.07)

Lever

150

85+20 (3.0+0.7)

Lever

Adjusting
point

Remarks
Basic

Basic

Rack limit

ZEXEL No. 101696-9370


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

12.5 (0.492)

1,500

83.71.6 (2.950.06)

3.5

Rack

Approx. 9.5
(0.374)

300

9.51.8 (0.330.06)

10

Rack

R1 [12.5
(0.492)]

1,500

83.71 (2.950.04)

Lever

Basic Boost press. kPa {mmHg, inHg}


Above 23.3 {175, 6.89}

R1 0.55
(0.0217)

900

68.72 (2.420.07)

Lever

Boost press. kPa {mmHg, inHg}


Above 23.3 {175, 6.89}

150

85+20 (3.0+0.7)

Lever

Boost press.
0
Rack limit

Adjusting
point

A, B, T, TA 173 kW {235 PS}

Remarks
Basic

ZEXEL No. 101696-9390


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

12.4 (0.488)

700

77.52 (2.730.07)

3.5

Rack

Approx. 9.5
(0.374)

300

9.51.8 (0.330.06)

10

Rack

R1 [12.4
(0.488)]

700

77.51 (2.730.04)

Lever

Basic Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

R1 +0.15
(+0.0059)

1,400

[89.4 - 92.6 (3.15 3.26)]

Lever

Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

R2 [R1 0.3
(0.012)]

550

[66.9 - 70.1 (2.35 2.47)]

Lever

Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

R2 0.9
(0.035)

550

[46.5 - 48.5 (1.64 1.71)]

Lever

Boost press.
0

150

85+20 (3.0+0.7)

Lever

Boost press.
0
Rack limit

Adjusting
point

EF-3-29

Remarks
Basic

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9200


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

12.4 (0.488)

700

77.52 (2.730.07)

3.5

Rack

Approx. 9.5
(0.374)

300

9.51.8 (0.330.06)

10

Rack

R1 [12.4
(0.488)]

700

77.51 (2.730.04)

Lever

Basic Boost press. kPa {mmHg, inHg}


Above 23.3 {175, 6.89}

R1 +0.15
(+0.0059)

1,400

[89.4 - 92.6 (3.15 3.26)]

Lever

Boost press. kPa {mmHg, inHg}


Above 23.3 {175, 6.89}

R2 [R1 0.3
(0.012)]

550

[66.9 - 70.1 (2.35 2.47)]

Lever

Boost press. kPa {mmHg, inHg}


Above 23.3 {175, 6.89}

R2 0.6
(0.024)

550

[53.5 - 55.5 (1.88 1.95)]

Lever

Boost press.
0

150

84+20 (3.0+0.7)

Lever

Boost press.
0
Rack limit

Adjusting
point

Remarks
Basic

ZEXEL No. 101696-9360


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

12.5 (0.492)

1,500

83.71.6 (2.950.06)

3.5

Rack

Approx. 9.5
(0.374)

300

9.51.8 (0.330.06)

10

Rack

R1 [12.5
(0.492)]

1,500

83.71 (2.950.04)

Lever

R1 0.55
(0.0217)

900

68.72 (2.420.07)

Lever

150

85+20 (3.0+0.7)

Lever

Adjusting
point

A, B, T, TA 173 kW {235 PS}

Remarks
Basic

Basic

Rack limit

ZEXEL No. 101696-9210


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.3 (0.524)

700

97.52 (3.430.07)

3.5

Rack

Basic

Approx.
10.1 (0.398)

275

101.8 (0.350.06)

10

Rack

Adjust max. var. bet. cyl.


at R  10.1 mm (0.398 in).
Adjust governor as per gov. adj. spec.

R1 [13.3
(0.524)]

700

97.51 (3.430.04)

Lever

Basic Boost press. kPa {mmHg, inHg}


Above 26.7 {200, 7.87}

R1 +0.1
(+0.004)

1,400

[102.9 - 106.1 (3.62 3.73)]

Lever

Boost press. kPa {mmHg, inHg}


Above 26.7 {200, 7.87}

R1 2.0
(0.079)

700

[56.5 - 58.5 (1.99 2.06)]

Lever

Boost press.
0

150

85+20 (3.0+0.7)

Lever

Boost press.
0
Rack limit

Adjusting
point

EF-3-30

Remarks

INJECTION PUMP ASSEMBLY


z

A, B, T, TA 173 kW {235 PS}

ZEXEL No. 101696-9400


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.3 (0.524)

700

97.52 (3.430.07)

3.5

Rack

Basic

Approx.
10.1 (0.398)

275

101.8 (0.350.06)

10

Rack

Adjust max. var. bet. cyl.


at R  10.1 mm (0.398 in).
Adjust governor as per gov. adj. spec.

R1 [13.3
(0.524)]

700

97.51 (3.430.04)

Lever

Basic Boost press. kPa {mmHg, inHg}


Above 26.7 {200, 7.87}

R1 +0.1
(+0.004)

1,400

[102.9 - 106.1 (3.62 3.73)]

Lever

Boost press. kPa {mmHg, inHg}


Above 26.7 {200, 7.87}

R1 2.0
(0.079)

700

[56.5 - 58.5 (1.99 2.06)]

Lever

Boost press.
0

150

85+20 (2.8+0.7)

Lever

Boost press.
0
Rack limit

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

Adjusting
point

Remarks

RFD governor
z

ZEXEL No. 101607-9361


Adjusting
point

Rack
position
mm (in)

8.1 (0.319)

600

42.21 (1.490.04)

3.5

Lever

7.8 (0.307)

1,000

53.31 (1.880.04)

10

Lever

Approx. 7.0
(0.276)

300

91.8 (0.320.06)

10

Rack

Adjust max. var. bet. cyl.


at R  7.0 mm (0.276 in).
Adjust governor as per gov. adj. spec.

100

Above 80 (2.8)

Lever

After setting excessive fuel for starting

D
z

Remarks
Basic

ZEXEL No. 101607-9341


Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

9.8 (0.386)

600

58.91 (2.070.04)

3.5

Lever

R1 [10.0
(0.394)]

1,500

80.61 (2.840.04)

Lever

Approx. 7.9
(0.311)

300

8.31.8 (0.290.06)

10

Rack

100

Above 80 (2.8)

Lever

EF-3-31

Remarks
Basic

After setting excessive fuel for starting

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

RLD governor
z

ZEXEL No. 101608-9030


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

11.8 (0.465)

600

66.31.6 (2.330.06)

3.5

Rack

Approx. 9.5
(0.374)

300

9.51.8 (0.330.06)

10

Rack

R1 [11.8
(0.465)]

600

66.31 (2.330.04)

Lever

R1 0.2
(0.008)

900

[731.6 (2.570.06)]

Lever

R1 [11.8
(0.465)]

1,500

[83.92 (2.950.07)]

Lever

100

84+10 (3.0+0.4)

Lever

Adjusting
point

Remarks
Basic

Basic

Rack limit

ZEXEL No. 101697-9000


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

12.4 (0.488)

700

86.42 (3.040.07)

3.5

Rack

Approx. 9.5
(0.374)

300

9.51.8 (0.330.06)

10

Rack

R1 [12.4
(0.488)]

700

86.41 (3.040.04)

Lever

Basic Boost press. kPa {mmHg, inHg}


Above 23.3 {175, 6.89}

R1 +0.15
(+0.0059)

1,400

[86.51.6
(3.040.06)]

Lever

Boost press. kPa {mmHg, inHg}


Above 23.3 {175, 6.89}

R2 [R1 0.3
(0.012)]

550

[761.6 (2.680.06)]

Lever

Boost press. kPa {mmHg, inHg}


Above 23.3 {175, 6.89}

R2 0.6
(0.024)

550

[651 (2.290.04)]

Lever

Boost press.
0

150

90+20 (3.2+0.7)

Lever

Boost press.
0
Rack limit

Adjusting
point

EF-3-32

Remarks
Basic

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9920


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.6 (0.535)

700

92.52 (3.260.07)

3.5

Rack

Approx. 9.7
(0.382)

275

171.8 (0.600.06)

10

Rack

R1 [13.6
(0.535)]

700

92.51 (3.260.04)

Lever

[R1 +0.3 +0.05


0.15
(+0.0118
+0.0020
0.0059 )]

1,400

[99.51.6
(3.500.06)]

Lever

R2 [R1 0.2
(0.008)]

420

[801.6 (2.820.06)]

Lever

Boost press. kPa {mmHg, inHg}


Above 40.0 {300, 11.81}

R2 1.8
(0.071)

420

[461 (1.620.04)]

Lever

Boost press.
0

150

105+20 (3.7+0.7)

Lever

Boost press.
0
Rack limit

Adjusting
point

A, B, T, TA 173 kW {235 PS}

Remarks
Basic

Basic Boost press. kPa {mmHg, inHg}


Above 40.0 {300, 11.81}
Boost press. kPa {mmHg, inHg}
Above 40.0 {300, 11.81}

ZEXEL No. 101696-9751


Rack
position
mm (in)

Pump
speed
rpm

Injection qty
milliliter (Imp fl oz)/
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.6 (0.535)

700

92.52 (3.260.07)

3.5

Rack

Approx. 9.7
(0.382)

275

171.8 (0.600.06)

10

Rack

R1 [13.6
(0.535)]

700

92.51 (3.260.04)

Lever

[R1 +0.3 +0.05


0.15
(+0.0118
+0.0020
0.0059 )]

1,400

[99.51.6
(3.500.06)]

Lever

R2 [R1 0.2
(0.008)]

420

[801.6 (2.820.06)]

Lever

Boost press. kPa {mmHg, inHg}


Above 28.7 {215, 8.46}

R2 1.15
(0.0453)

420

[56.51 (1.990.04)]

Lever

Boost press.
0

150

105+20 (3.7+0.7)

Lever

Boost press.
0
Rack limit

Adjusting
point

EF-3-33

Remarks
Basic

Basic Boost press. kPa {mmHg, inHg}


Above 28.7 {215, 8.46}
Boost press. kPa {mmHg, inHg}
Above 28.7 {215, 8.46}

INJECTION PUMP ASSEMBLY

Injection quantity adjustment procedure


1.

Check the control rack 0 position.

2.
3.

Remove the control rack guide screw.


Attach the lock screw instead of the control rack guide
screw (to secure the control rack) to the pump housing.

4.

Set the pump speed, control rack position and plunger


strokes as specified in the service data.
5. Measure the fuel injection quantity for each cylinder.
If the fuel injection quantity is not as specified, adjust as follows.
(1) Loosen the control pinion clamp screw.

(2) Rotate the control sleeve clockwise or counterclockwise


using an appropriate tool. The control sleeve is rotated
toward the governor side to increase fuel injection quantity.

EF-3-34

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

GOVERNOR ADJUSTMENT
This section is divided into 3 parts according to the governor type.
Each part describes the general adjustment procedure first and
then each governors performance chart.

RAD type
Preparations
1. Mount the injection pump assembly securely on a pump test
stand. Then, attach the test nozzle and nozzle holder
assembly, test lines and measuring device to measure control rack travel, to the injection pump.
2. Remove the damper spring, cover, torque control spring
using a socket wrench (157914-0500) and Idling spring.
Loosen adjusting screw.

3.

Fill governor chamber and camshaft chamber with injection


pump oil.
Cam chamber: 15 milliliter (0.5 Imp fl oz) for every cylinder
Governor chamber: 200 milliliter (7.0 Imp fl oz)

4.

Mount a measuring device (105782-6030) to measure the


load control lever angle.

5.

With injection pump off, ensure that control rack travels


smoothly by moving load control lever in both fuelincrease and fuel-decrease directions.

EF-3-35

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Setting the control rack zero point


1.

After fixing load control lever in the idling position, temporarily set speed adjusting screw so that governor begins to
move the control rack in the fuel-decrease direction at
pump speed of 500 to 600 rpm.

2.

Increase the pump speed so that the control rack travels to


the non-injection position.
Then, press the control pinion with a screw driver until control rack stops. Make this position the zero point of the
control rack, and set the measuring device pointer to correspond with zero of the scale.
NOTE
z The operation of the stopping lever will not cause the
control rack to travel to zero point.

Flyweight lift and full load position


The total lift of the flyweight is divided into two categories; one for
high-speed control and the other for idling control. Firstly, adjust the
flyweight lift for high-speed control.
1. Fix the load control lever at full position (control rack position Rb), and temporarily set speed setting screw so that
governor begins to move the control rack in the fueldecrease direction at pump speed of 700 to 800 rpm.

2.

While raising pump speed to Na, make adjustments by


means of full-load stopper bolt so that control rack position
corresponds with Ra.
NOTE
z The control rack position Ra equals control rack position Rb minus the travel L.
z If Ra is below zero, set the control rack to the Ra
plus 2.0 mm (0.079 in) position.
3.

Next, decrease pump speed to Nb and, by means of


stroke adjusting screw adjust flyweight lift for high-speed
control L (control rack position Rb).
NOTE
z If the control rack is set to the Ra plus 2.0 mm (0.079 in)
position in Step 2, set the stroke adjusting screw to the
Rb plus 2.0 mm (0.079 in) position.

EF-3-36

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

4.

Readjust the full-load stopper bolt to the full-load fuel injection quantity position according to the service data.

Idling
1.
2.

Run injection pump at Nc (Nd plus 100 rpm) rpm.


Make adjustments by means of idling adjusting screw, so
that control rack position corresponds with Rc.

3.
4.

Decrease pump speed so as to maintain Ne rpm.


Incorporate idling spring assembly into tension lever. Screw
in the assembly until control rack position corresponds with
Rd, and then lock it at this point, with a wrench (1579162620).
NOTE
z At this time, pump speed may sometimes drop.
Ascertain that Ne rpm is maintained.

EF-3-37

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


5.
6.

7.
z

A, B, T, TA 173 kW {235 PS}

Make sure control rack position remains above Re even


when pump speed is decreased to 0 rpm.
Next, increase pump speed slowly and ensure that when
control rack reaches position Rc the corresponding speed
is Nd rpm.

Measure the load control lever angle at the idling position.


When load control lever is depressed toward the full position side, replace shifter shim with a thicker one.
When load control lever is depressed toward the idling
position side, replace shifter shim with a thinner one.

Damper spring
1.
2.

Fix the load control lever at idling control position.


Increase pump speed slowly from idling speed (Ne rpm) to
the speed where control rack position corresponds with Rf
minus 0.2 mm (0.008 in), and maintain this speed.

ZEF109A

3.

Screw in damper spring until control rack position corresponds with Rf minus 0.1 mm (0.004 in) and lock the spring
at this point.

EF-3-38

INJECTION PUMP ASSEMBLY

Stopper bolt
If idling performance is included in service data, as represented by
dotted line, adjust stopper bolt setting.
1. After setting damper spring when pump speed is decreased
to 0 rpm, control rack position moves to Re.

2.

After loosening stopper bolt, move the load control lever


until control rack position is Rg and set stopper bolt at this
point.

High-speed control starting point and speed droop


check
1.
2.

Fix the load control lever at full position.


Raise pump speed slowly to Nh rpm. Make adjustments to
setting screw so that control rack starts to travel from position Rb.

3.

Ensure by raising pump speed that it remains below Ni


rpm when control rack position reaches Rh.
NOTE
z When Ni rpm exceeds the standard value, the no-load
maximum speed of the engine is also increased, which is
dangerous. Recheck both Rb, (full-load rack position)
and Rf 0.1 mm (0.004 in), (the set position of damper
spring).
4.

Further increase the pump speed to Nj rpm and ensure


the control rack is positioned at Ri mm (in).

Stopping lever
1.
2.
3.

4.

Fix the load control lever at full position.


Maintain the pump speed at approximately 800 rpm.
Move the stopping lever to the fuel-decrease position and
ensure the control rack reaches the non-injection zone
[injection quantity of less than 3 milliliter (0.11 Imp fl oz) per
1,000 strokes].
Check that the control rack moves smoothly to the fullload position when releasing the stopping lever.

EF-3-39

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Smoke limiter
1.

Attach the measuring device (105782-6090) to the plunger


spring chamber.

2.
3.
4.

Fix the load control lever at full position.


Maintain the pump speed at Nb rpm.
Fix the measuring device scale plate with the indicator at
control rack position Rb mm (in).

5.

Remove the measuring device (105782-6280) attached to


the control rack tip and attach the smoke limiter.

6.

Maintaining the pump speed at Nk rpm, adjust and set the


control rack in Rj mm position [normally Rb plus 0.2 mm
(0.008 in) with the smoke limiter spring capsule].
Reduce the pump speed to 80 to 100 rpm, then check that
the control rack position is Rk. Check the fuel injection
quantity for engine start at point E.

7.

EF-3-40

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

Governor adjustment diagram (ZEXEL No. is Inj. pump assy No.)

EF-3-41

INJECTION PUMP ASSEMBLY

RLD type
Preparation
Follow the instructions below to prepare for adjustment.
1. Secure the fuel injection pump on the pump test stand and
fill both the governor chamber and cam chamber with lubricating oil (injection pump oil 131453-0120 is recommended).

2.

Mounting the adjusting device (105782-6170)


1) Align the mark on the supporting bracket with the matching mark on the scale plate, then tighten the locknut.
NOTE
z The angle scale plate has three matching marks; use any
that is convenient.

2) Move the supporting bracket to position pin A over the


center hole of the control lever shaft and bolt the supporting bracket. Then, insert pin B into the rod connecting hole of the control lever.

Setting the control racks zero position


1.
2.

Mount the control rack travel measuring device (1057826280) on the end of the control rack.
Setting the control racks 0 position.
1) Screw in the governor shaft fully, and hold the control
lever at the idling position.

2) Raise the pump speed gradually until it reaches point


((06)), where the governor spring stops operating. Then,
push the rack fully in the fuel decrease direction. The
position where it stops moving is the control racks 0
position.
3) Set the indicator of the measuring devices dial gauge to
0.

EF-3-42

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


NOTE
z

The control rack of the RLD type governor-mounted fuel


injection pump cannot be set at zero unless the pump is
operated at point (06). If the control rack is pushed to the
non-injection position while the injection pump is running at less than point (06), the governor links may be
damaged.

Cautions on adjustment
[Governor performance chart]

EF-3-43

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


1.

2.

3.

Locking the control rack


At this time it is necessary to fix the control rack. Normally,
injection timing adjustment and fuel injection quantity
adjustment are performed before governor adjustment.
Fix the control rack according to the following procedure:
Increase the pump speed to 500 to 600 rpm with the control
lever held at the idling position, then shift the lever to the
maximum-speed position. Next, set the control rack 3 mm
(0.12 in) beyond the full-speed position using the full-load
setting bolt. Various adjustments can now be made with the
control rack locked in the specified position.
Control lever operation
Before shifting the control lever to the maximum-speed
position, increase the pump speed to 500 to 600 rpm while
the control lever is held at the idling position.
The performance of the governor depends on the engine
specifications.
The performance chart given above is typical of this governor.

Idling adjustment
1.

With the pump speed maintained at 80 to 100 rpm, temporarily set the control lever so that the control rack position is
Rs mm (in).

2.

Maintain pump speed at Nb rpm and screw in the idling


spring assembly. When the rack position is Rb mm (in),
tighten the locknut.
: 18 - 22 Nm{1.8 - 2.2 kgfm, 13 - 16 ftlbf}

EF-3-44

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


3.

Increase the pump speed until the control rack position is at


Ri mm (in) and then check that the pump speed is Ni rpm.
NOTE
z If the pump speed Ni rpm is not as specified, adjust by
altering the shim thickness.
Adjusting shims
Part No.

Thickness
mm (in)

029310-9240
029310-9250
029310-9260
029310-9270

0.10 (0.0039)
0.20 (0.0079)
0.25 (0.0098)
1.00 (0.0394)

Remarks

ZEF119A

4.

Adjustment of the governor springs


1) Maintain pump speed at Nh1 rpm and adjust the amount
the governor shaft is screwed in so that the rack position
is Rh1 mm (in)].

2) Check that the control rack position is Rh2 mm (in) when


the pump speed is Nh2 rpm. If it is not as specified,
replace the governor springs with new ones.
NOTE
z The adjustment sequence may be reversed. [Set to Rh2
mm (in) at Nh2 rpm, check that speed is Nh1 rpm at Rh1
mm (in)].

5.

3) Further increase the pump speed until the control rack


reaches position 0 mm (in), and ensure the pump
speed is Ne rpm.
Idling adjustment
1) Decrease the pump speed to Nb rpm and adjust the
idling setting bolt so that the control rack will be at position Rc mm (in). Then lock the nut.

EF-3-45

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


2) Further decrease the pump speed to 80 to 100 rpm, and
ensure the control rack is positioned at Ra mm (in).
3) Check that the control lever angle is as specified with
the adjusting device (105782-6170).

Full-load rack position adjustment


When adjusting the boost compensator-equipped governor, perform the full-load rack position adjustment using the values for a
boost-compensator equipped governor, as shown in the service
data.
1. With the pump speed maintained at Nf rpm, temporarily set
the control lever at the position where the lever contacts the
maximum-speed setting bolt.

2.

Adjust the maximum-speed setting bolt so that the control


rack begins moving toward the fuel decrease direction at a
pump speed of Ng rpm. Then, lock the maximum-speed
setting bolt with the nut.

3.

Adjust the full-load setting bolt so that the control rack position is Rf mm (in) when the pump speed is Nf rpm.
NOTE
z When the full-load setting bolt is turned clockwise, the
control rack position value decreases.

EF-3-46

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


4.

Adjusting the torque cam


1) Using wrench (157913-3620), adjust the adjusting nut
so that the control rack position is Rf4 mm (in) when the
pump speed is Ni rpm. Lock the adjusting nut with a lock
screw.
NOTE
z Torque cam adjustment can be performed at a pump
speed of either Nk rpm or Ni rpm, whichever is convenient.

2) Decrease the pump speed to Nj minus approximately


100 rpm, then increase it to Ng rpm to ensure that the
torque cam stroke is within the specified range. If the
torque cam stroke is not as specified, readjust the fullload setting bolt and torque cam. If this adjustment cannot be performed to obtain the specified control rack
position, replace the torque cam.
NOTE
z Before installing a new torque cam, ensure the stamping
mark is the same as the number given in the service
data.
3) Next, increase the pump speed from Nj minus approximately 100 rpm to Ng rpm, then ensure the pump speed
is as specified for each control rack position. If the pump
speed is not as specified, the torque cam has not been
adjusted properly. Readjust it. If the torque cam cannot
be adjusted to obtain the specified pump speed, replace
the torque cam.

5.

Measure the fuel injection quantity at each of the adjusting


points (as specified; that is, the fuel injection characteristics
for full-load). If the fuel injection quantity is not as specified,
adjust the full-load setting bolt and the torque cam adjusting
nut carefully. Lock the nut and bolt after adjustments.
NOTE
z If this adjustment is not executed properly, the specified
fuel injection quantity cannot be obtained, there will be
decreased engine output and black smoke may be produced.
EF-3-47

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Maximum-speed control adjustment


1.
2.

3.
4.

5.

Lock the control lever when it contacts the maximum-speed


setting bolt.
With the pump speed maintained at Ng rpm, adjust the
maximum-speed setting bolt so that the control rack begins
moving from Rf3 mm (in) in the fuel decrease direction.
Then, lock the bolt with the nut.

Checking the speed droop


Gradually increase the pump speed and ensure the pump
speed is Nh rpm when the control rack reaches Rg mm (in).
Increase the pump speed further to ensure the control rack
reaches 0 mm (0 in).

Check that the control lever angle is as specified with the


adjusting device (105782-6170).

Boost compensator adjustment (If so equipped)


If the governor does not have a boost compensator, proceed to
confirmation of the excess fuel limit for engine starting.
1. Install the spacer (1A); refer to the illustration on page EF-349 (EEF3-177) on the governor cover, and ensure the
pushrod can move smoothly.

EF-3-48

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


2.

A, B, T, TA 173 kW {235 PS}

Checking pushrod protrusion


1) Fix the control lever in the maximum-speed position.
2) Operate the injection pump at the specified speed,
marked BASIC in the injection quantity table of the injection pump calibration data (usually adjusting point A).
3) In this condition, use calipers to measure the protrusion
(dimension L) of push rod B from the end face of the
spacer. If dimension L is not within the specified range,
replace pushrod B so that L is as specified.

Pushrod table
Part No.

Length
mm (in)

159274-0120
159274-0220
159274-0320
159274-0420
159274-0520
159274-0620
159274-0720
159274-0820
159274-0920
159274-1120
159274-1220
159274-1320
159274-1420
159274-1520

125.0 (4.92)
127.5 (5.02)
128.0 (5.04)
127.0 (5.00)
126.0 (4.96)
129.0 (5.08)
128.5 (5.06)
125.5 (4.94)
126.5 (4.98)
119.5 (4.70)
120.0 (4.72)
120.5 (4.74)
121.0 (4.76)
121.5 (4.78)

Part No.

Length
mm (in)

159274-1620
159274-1720
159274-1820
159274-1920
159274-4220
159274-4320
159274-4420
159274-4520
159274-4620
159274-4720
159274-4820
159274-4920
159274-5020

122.0 (4.80)
122.5 (4.82)
123.0 (4.84)
123.5 (4.86)
129.5 (5.10)
130.0 (5.12)
130.5 (5.14)
131.0 (5.16)
131.5 (5.18)
132.0 (5.20)
132.5 (5.22)
133.0 (5.24)
133.5 (5.26)

3.

Install the boost compensator assembly, then attach the


compressed-air pipe.

4.

Boost compensator stroke adjustment


1) Confirm that the screw (62) position is the same as that
before disassembly.
2) Remove the plug (46) and gasket (45).
3) Maintain the pump speed at N1 rpm.
4) Fully loosen the screw (55) with the wrench (1579133520), and then confirm that the control rack position R2
mm (in) can be obtained.
If the control rack position R2 mm (in) is not as specified,
readjust the full-load setting bolt and torque cam.

EF-3-49

Remarks

INJECTION PUMP ASSEMBLY

5) Shift the control rack position from R2 mm (in) to R1 mm


(in) using the screw (55), and then lock it with the nut
(54).
NOTE
z During boost compensator stroke adjustment, it is not
necessary to supply compressed air.

5.

Setting the boost compensator spring force


1) With the pump speed maintained at N1 rpm, gradually
increase the boost pressure.
2) Adjust the screw (62) so that the control rack begins
moving from R1 mm (in) in the fuel increase direction
when the boost pressure reaches P1 kPa {mmHg, inHg}.
Lock the screw with the nut (63).

3) Increase the boost pressure, and ensure it reaches P2


kPa {mmHg, inHg} when the control rack is at R2 mm
(in). If the boost pressure is not as specified, replace the
boost compensator spring (16).
4) Recheck the boost compensator stroke, and if not as
specified, readjust the screw (55).

EF-3-50

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Confirming the excess fuel limit for engine starting


1.
2.
3.

With the pump speed maintained at Ns rpm, lock the control


lever when the control rack position is Rc mm (in) (point J).
Ensure the control rack moves beyond Ra mm (in) when
the pump speed is reduced to 0 rpm.
Maintaining a pump speed of less than N liter rpm, ensure
the control rack moves beyond Rs mm (in) when the control
lever is shifted toward the maximum-speed position.

The above confirmation ensures that the sensor lever and torque
cam are positioned as shown in the figure when the control rack
moves beyond Rs mm (in).
NOTE

The control rack must not move to Rs mm (in) if the


pump speed is decreased to N liter rpm with the control
lever locked at the maximum-speed position.
z If control rack positions Ra Aa and Rs mm (in) are not
indicated in the calibration data, confirmation of the
excess fuel limit is unnecessary.
z

Confirming the black smoke limit


1.

With the pump speed maintained above N liter (that is, Nb)
rpm, fix the control lever at the idling position.
2. Ensure the control rack does not move beyond Rf5 mm (in)
when the control lever is shifted toward the maximumspeed position.
3. Keep the control lever at the maximum-speed position and
gradually increase the pump speed.
4. Confirm that the control rack begins moving from Rf5 mm
(in) in the fuel decrease direction when the pump speed
exceeds Nj rpm.
The above confirmation ensures that the sensor lever and torque
cam are as shown in the figure when the control lever is shifted
toward the maximum-speed position during engine operation.

Control rack limiter adjustment


Screw type
1. Using the lock (157976-3100), lock the control rack at the
position given with the calibration data, maintaining the
pump speed at 0 rpm.

EF-3-51

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

2.

Measure the depth liter of the rack cap.

3.
4.

Attach both the bolt and nut to the end of the control rack.
Adjust the bolt so that the distance between the end face of
the pump housing and the bolt top is liter, that is, the rack
cap depth. Tighten the nut to lock the bolt.

5.

Install the rack cap.

Installation of plate plugs


After adjusting the governor, check that there is no damage to the
inside surfaces where the governor cover plates are press fitted. In
addition, remove as much oil as possible from inside.
1) Push in new plate plugs with a finger, and drive them
securely into place with the rods (157923-5800, -5900, 6000).
2) After press-fitting each plug, thoroughly coat the outside
surface with adhesive (THREE BOND No. 1405D).

EF-3-52

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Sealing
All adjusting stoppers (bolts, nuts) that directly affect engine performance are sealed after adjustment. Do not readjust any stopper
without using the pump test stand or the engine test bench, as this
will adversely effect the engine, which will then be unable to operate at peak performance. In addition, the engine may overrun or
overheat, causing damage.

1 On full-load stopper
z
Sealing cap part No.: 154062-1900
Unit: mm (in)
Stopper bolt protrusion

L1 = 21 - 24 (0.83 - 0.94)

2 On maximum-speed stopper
z
Sealing cap part No.: 154062-1700
Unit: mm (in)
Stopper bolt protrusion

L2 = 29 - 36 (1.14 - 1.42)

EF-3-53

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

Governor adjustment diagram (ZEXEL No. is Inj. pump assy No.)


z

ZEXEL No. 101607-9270

EF-3-54

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9410

EF-3-55

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101607-9260

EF-3-56

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9380

EF-3-57

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


ZEXEL No. 101696-9370

EF-3-58

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


ZEXEL No. 101696-9390

EF-3-59

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9200

EF-3-60

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9360

EF-3-61

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9210

EF-3-62

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9400

EF-3-63

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101608-9030

EF-3-64

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101697-9000

EF-3-65

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Aneroid compensator kit adjustment


1.

Aneroid compensator adjustment (Before governor installation).


Select a suitable push rod so that L is as follows:
10.5 - 11.5 mm (0.413 - 0.453 in)
NOTE
z As L cannot be measured after the spacer is installed,
select the push rod 2 before installing the spacer.
2.

Adjustment at governor installation.


With the control lever at the full position and Np = 1,400
rpm/min, screw in the aneroid compensator kit body so that
push rod 1 contacts push rod 2 and the performance as
shown is obtained.
NOTE
z As there is some hysteresis, measure the injection quantity when the absolute pressure is decreasing.
z Screw the aneroid compensator into the spacer and confirm that the performance is as shown (adjust the beginning of operation by adjusting the amount that the
aneroid compensator is screwed in).
Rack variation characteristics when negative pressure is applied to
the inside of the case.

EF-3-66

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9920

EF-3-67

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101696-9751

EF-3-68

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

RFD type
Preparations
1. Remove damper spring, cover, torque control springs and
idling spring, and loosen adjusting screws.
2. Mount injection pump assembly securely on a pump test
stand. Then, attach the test nozzle and nozzle holder
assembly, test lines and measuring device to measure control rod travel, to injection pump.
3.

Fill governor chamber and camshaft chamber with injection


pump oil.

4.

Mount measuring device (105782-6030) to measure the


angle of load control lever.

5.

With injection pump off, assure by moving load control lever


in the directions of both increase fuel and decrease fuel,
that control rack travels smoothly.

Setting the control rack zero point


1.

After fixing load control lever in the idling position, temporarily set speed control lever so that governor begins to
move the control rack to the fuel decrease direction at pump
speed of 500 to 600 rpm.

EF-3-69

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


2.

Increase pump speed so that control rack travels to the


non-injection position. Then, press with a screw driver the
tip of control rack or control pinion until it stops. Make this
position the zero point of control rack, and set the indicating pointer of measuring device to correspond with zero of
scale.
NOTE
z The operation of stopping lever will not cause control
rack to travel to zero point.

Torque control stroke


1.
2.

Fix load control lever in the full load position.


Temporarily hold speed control lever in position so that governor begins to move the control rack to the fuel decrease
direction at pump speed of approximately 800 rpm.

3.

Using a wrench (157913-3520) make adjustments by


means of adjustment screws, while raising and lowering
pump speed within the range of 500 to 600 rpm, so that
control rack position corresponds with the specified value
liter.

Flyweight lift and full load position


The total lift of flyweight is divided into two categories: one for high
speed control and the other for idling control. Firstly, adjust the flyweight lift for high speed control.
1. Fix load control lever at full position (control rack position
Rb), and temporarily set speed control lever so that governor begins to move the control rack to the fuel decrease
direction at pump speed to 700 to 800 rpm.

EF-3-70

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


2.

While raising pump speed to Na, make adjustments by


means of full load stopper bolt so that control rack position
corresponds with Ra.
NOTE
z The control rack position Ra is the result of control
rack position Rb minus the travel L.
z If Ra is below zero, set the control rack to Ra plus 2
mm (0.08 in) position.
3.

Next, decrease pump speed to Nb and by means of stroke


adjusting screw adjust flyweight lift for high speed control
L (control position Rb).
NOTE
z If the control rack is set to the Ra plus 2.0 mm (0.079
in) position in Step 2, set the stroke adjusting screw to
the Rb plus 2.0 mm (0.079 in) position.

EF-3-71

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Idling
1.
2.

Run injection pump at Nc (Nd + 100 rpm) rpm.


Make adjustments by means of idling adjusting screw so
that control rack position corresponds with Rc.

3.
4.

Decrease pump speed so as to maintain Ne rpm.


Incorporate idling spring assemblies into tension lever.
Screw in the assemblies until control rack position corresponds with Rd, and then lock them at this point using a
wrench (157916-2620).
NOTE
z At this time, pump speed may sometimes drop. Ascertain
that the Ne rpm is maintained.
5.
6.
7.
z

Make sure control rack position remains above Re even


when pump speed is brought down to 0 rpm.
Next, raise pump speed slowly and ensure that when control rack reaches the position Rc, the corresponding speed
is Nd rpm.
Measure the load control lever angle.
When load control lever is depressed toward the full position, replace shifter shim with a thicker one.
When load control lever is depressed toward the idling
position side, replace shifter shim with a thinner one.

Damper spring
1.
2.

Fix load control lever at idling control position.


Raise pump speed slowly from idling speed (Ne rpm) to
the speed where control rack position corresponds with Rf
minus 0.2 mm (0.008 in), and maintain this speed.

EF-3-72

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY


3.

A, B, T, TA 173 kW {235 PS}

Screw in damper spring until control rack position corresponds with Rf minus 0.1 mm (0.004 in) and lock the
spring at this point.

Stopper bolt
1.

After setting damper spring, when pump is brought to 0


rpm, control rack position moves to Re.

2.

After loosening the stopper bolt, move the load control lever
until control rack position is Rg and set stopper bolt at this
point.

EEF3-222

EF-3-73

INJECTION PUMP ASSEMBLY

High-speed control starting point and speed droop


check
1.
2.
3.

Fix load control lever at full position.


Raise pump speed slowly to Nk rpm. Make adjustments to
stopper bolt so that control rack starts to travel from the
position Rb.
Ensure by raising pump speed that it remains below N liter
rpm when control rack position reaches Ri.

NOTE
z

If N liter rpm exceed the standard value, the no-load


maximum speed of the engine is also increased, creating
dangerous conditions. Recheck both Rb, (full-load
rack position) and Rf 0.1 mm (0.004 in) (the set position
of damper spring).

4.

Further increase the pump speed to Nm rpm and ensure


the control rack reaches in the non-injection zone [injection
quantities are less than 3 milliliter (0.11 Imp fl oz) per 1,000
strokes].

Stopper bolt
When used as variable speed governor.
1. After making adjustments as described in the figure, fix load
control lever at full-load position.
2. Then, run the injection pump at speed Ny rpm which is
slightly higher than the idling speed.
3. Return stopper bolt to the low-speed position side and lock
it with nut, at control rack position Rd mm (in).

Full-load fuel delivery


Readjust the full-load stopper bolt to the full-load fuel injection
quantity position according to the service data.

EF-3-74

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Smoke limiter
1.
2.
3.

Fix load control lever at full position.


Maintain pump speed at Nn rpm.
Screw in spring capsule or screw and lock it at point E,
where the specified fuel delivery may be obtained.

EF-3-75

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

A, B, T, TA 173 kW {235 PS}

Governor adjustment diagram (ZEXEL No. is Inj. pump assy No.)


z

ZEXEL No. 101607-9361

EF-3-76

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 101607-9341

EF-3-77

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

TESTING TIMER
In general, measurement of the timer advance angle is performed
on the pump tester after completing an adjustment of the injection
timing, injection quantity and governor.

Timing Advance Specification


z

ZEXEL No. 101607-9351, 101607-9270, 101607-9361


Pump speed (rpm)

(1,140)

1,500

Advance angle ()

Start

Finish 4.00.5

ZEXEL No. 101607-9331, 101607-9260, 101607-9341,


101608-9030
Pump speed (rpm)

Below 850

800

1,500

Advance angle ()

Start

Below 0.5

Finish 4.00.5

ZEXEL No. 101696-9410


Pump speed (rpm)

Below 1,250

1,200

1,500

Advance angle ()

Start

Below 0.5

Finish 1.00.5

ZEXEL No. 101696-9380, 101696-9370, 101696-9360


Pump speed (rpm)

Below 1,050

1,000

1,500

Advance angle ()

Start

Below 0.5

Finish 2.00.5

ZEXEL No. 101696-9390, 101696-9200, 101697-9000


Pump speed (rpm)

1,400

Advance angle ()

Finish 2.00.3

ZEXEL No. 101696-9210, 101696-9400


Pump speed (rpm)

Below 1,170

1,120

1,400

Advance angle ()

Start

Below 0.5

Finish 2.00.5

ZEXEL No. 101696-9920, 101696-9751


Pump speed (rpm)

Below 1,170

1,120

1,400

Advance angle ()

Start

Below 0.5

Finish 3.00.5

EF-3-78

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Measuring equipment handling precautions


1.
2.
3.

4.

5.
6.

7.

Be sure not to apply any large shock or vibration to the timing checker.
Do not use the reflection plate excessively. Carefully store
the remaining plate to avoid discoloration.
Never use the equipment in any location where inflammable
gases or any other explosive atmosphere may exist
because very high pulse voltages are generated in the
equipment.
This equipment has a built-in DC high-tension circuit. Do
not use the equipment at any location where it may get wet;
otherwise, equipment may be damaged and electric shock
to the human body may result.
The sensor generates an intense flash of light. Do not look
straight at the light source of this equipment; otherwise,
eyesight may be harmed.
The light source unit is separate from the power supply unit
of this equipment. Before disconnecting or connecting the
lamp cable, be sure to turn OFF the power switch to avoid
electrical shock.
This equipment uses high tension current. Be sure to connect the ground terminal of the equipment to the ground by
using a proper ground cable.

Installation
1.

Attach the coupling (105784-0510) to the injection pump


camshaft.
NOTE
z At this time, note that both the camshaft and coupling
shaft unit key groove must face in the same direction.
2.
3.

Attach the timer to the coupling shaft unit and fix it firmly.
Fix the timer to the test stand flywheel firmly. At this time,
make sure that there is no eccentricity in the center of the
rotating portion.

Reflection plate attaching position


1.
2.

With attaching the reflection plate (157951-1100), avoid the


stamped portion and the caution plate on the timer causing.
Cut the reflection plate to a 5 x 7 mm (0.20 x 0.28 in) size
each time the timer advance characteristics are checked.

EF-3-79

A, B, T, TA 173 kW {235 PS}

INJECTION PUMP ASSEMBLY

Measuring equipment installation


1.
2.
3.
4.
5.
6.

Securely fix the holder (157842-5220) to the groove in the


pump tester bed.
Temporarily tighten the sensor (157830-3420) to the holder
with the sensor light source facing the timer.
Connect the sensor cable to the INPUT terminal of the timing checker (157830-3320).
Connect the lamp (157830-3520) cable to the LAMP terminal of the checker.
With the checker POWER switch set to OFF, connect the
power cable to a power outlet (AC 100V 50/60 Hz).
The distance between the reflection plate and the sensor
must be 10 to 55 mm (0.39 to 2.17 in).

Operating procedure for timing check


1.
2.

3.

4.
5.

Run the injection pump at a low speed and change the


selector switch of the timing checker (157830-3320) from
the OFF to ON position.
Direct the light from the sensor (157830-3420) to the reflection plate (157951-1100) and be sure the angle scale graduation on the pump tester flywheel can be read by use of
the lamp (157830-3520).
Set the pump at a speed approximately 100 rpm below the
beginning rpm of the timer advance. Move the dial plate and
determine the zero point at any desired position while
directing the lamp light to the pump tester flywheel.
Increase the pump speed from low to high, and read the
timer advance angle at each representative rpm position.
Upon completing measurement, stop the rotation of the
injection pump after turning the timing selector switch to the
OFF position.

ADJUSTMENT OF TIMING DEVICES


Using a timing checker, measure the advance angle characteristics
of the timer. The measurement should be taken both when pump
speed increases and when it reduces. In any case, its performance
must satisfy the specified value. The governor control lever at this
time must be at full speed status, unless any special instruction is
given.
1. The figure shows the timer performance line. Ensure that
the specified advance angle characteristics can be obtained
as the pump speed is increased gradually, according to calibration data of the injection pump (including timer).
2. If the specified characteristics cannot be satisfied, adjust
the thickness of the shim built into the spring end, or
replace the spring. (Refer to Section on Disassembly/Reassembly timer.) After reassembling, perform a verification
test once again.

EF-3-80

A, B, T, TA 173 kW {235 PS}

- MEMO -

INJECTION PUMP ASSEMBLY

TA 157 KW {213 PS}

= FE6TA [157 kW {213 PS}] =


INJECTION PUMP ASSEMBLY
z

For information on disassembly, inspection, reassembly, adjusting and testing of the injection pump,
refer to the service manual published by Zexel Co.

CONSTRUCTION
INJECTION PUMP ASSEMBLY
Type I (for HONG KONG)

EF-4-1

INJECTION PUMP ASSEMBLY

Type II (for NORWAY)

EF-4-2

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY

TA 157 KW {213 PS}

INJECTION PUMP PROPER


Type I (for HONG KONG)

1. Sleeve
2. Oil seal
3. Bolt
4. Cover
5. Pointer
6. Socket head bolt
7. Shim
8. O-ring
9. Bearing
10. Camshaft
11. Woodruff key
12. Bushing
13. Socket head bolt
14. Connector
15. Bushing
16. Bearing
17. Washer
18. Control rod
19. Plug
20. Gasket
21. Stud

22. Nut
23. Washer
24. Delivery valve holder
25. O-ring
26. Spring
27. Valve assembly
28. O-ring
29. O-ring
30. Stopper
31. Plunger assembly
32. Control sleeve
33. Spring seat
34. Plunger spring
35. Spring seat
36. Shim
37. Guide
38. Snap ring
39. Bushing
40. Plug
41. Pin

42. Roller
43. Screw
44. Gasket
45. Center bearing
46. Stud
47. Gasket
48. Nut
49. Overflow valve
50. Control rack
51. Pin
52. Bushing
53. Bushing
54. Gasket
55. Plug
56. Plug
57. Bearing
58. Ring
59. Shim
60. Eye bolt
61. Eye bolt

NOTE
z

Numbers before part names do not indicate the disassembly sequence.


EF-4-3

INJECTION PUMP ASSEMBLY

TA 157 KW {213 PS}

Type II (for NORWAY)

1. Sleeve
2. Oil seal
3. Bolt
4. Cover
5. Pointer
6. Socket head bolt
7. Shim
8. O-ring
9. Bearing
10. Camshaft
11. Woodruff key
12. Bushing
13. Socket head bolt
14. Connector
15. Bushing
16. Bearing
17. Washer
18. Control rod
19. Plug
20. Gasket
21. Stud

22. Nut
23. Washer
24. Delivery valve holder
25. O-ring
26. Spring
27. Valve assembly
28. O-ring
29. O-ring
30. Stopper
31. Plunger assembly
32. Control sleeve
33. Spring seat
34. Plunger spring
35. Spring seat
36. Shim
37. Guide
38. Snap ring
39. Bushing
40. Plug
41. Pin

42. Roller
43. Screw
44. Gasket
45. Center bearing
46. Stud
47. Gasket
48. Nut
49. Overflow valve
50. Control rack
51. Pin
52. Bushing
53. Bushing
54. Gasket
55. Plug
56. Plug
57. Bearing
58. Ring
59. Shim
60. Eye bolt
61. Eye bolt

NOTE
z

Numbers before part names do not indicate the disassembly sequence.


EF-4-4

INJECTION PUMP ASSEMBLY

GOVERNOR

EF-4-5

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY

1. Nut
2. Lever
3. Spring
4. Shim
5. O-ring
6. Nut
7. Spring washer
8. Lever
9. Washer
10. Oil seal
11. Bolt
12. Gasket
13. Governor housing
14. Nut
15. Bolt
16. Cover cap
17. Shaft
18. Oil seal
19. Washer
20. Shim
21. Snap ring
22. Lever
23. Snap ring
24. Bolt
25. Lever
26. Plug
27. Nut
28. Shaft
29. Spring
30. Woodruff key
31. Bolt
32. Flyweight assembly
33. Lever
34. Shaft
35. Spring seat
36. Governor spring
37. Governor spring
38. Spring seat
39. Plate
40. Bolt
41. Spring
42. Socket head bolt
43. Link
44. Spring washer
45. Nut

46. Sleeve
47. Shim
48. Shifter
49. Rack sensor assembly
50. Snap ring
51. Washer
52. Shaft
53. Spring
54. Washer
55. Lever
56. Lever
57. Snap ring
58. Lock screw
59. Adjusting nut
60. Guide lever
61. Spring
62. Snap ring
63. Tension lever assembly
64. Plug
65. Snap ring
66. Shaft
67. Snap ring
68. Pin
69. Rod
70. Spring
71. Spring
72. Spring
73. Nut
74. Shifter
75. Screw
76. Snap ring
77. Snap ring
78. Cam plate
79. Snap ring
80. Snap ring
81. Plug
82. Gasket
83. Gasket
84. Bolt
85. Lever
86. Nut
87. Lever
88. Oil seal
89. Snap ring
90. Shim

TA 157 KW {213 PS}

91. Nut
92. Bolt
93. Cover cap
94. Bolt
95. Nut
96. Screw
97. Plug
98. Bracket
99. Bolt
100. Nut
101. Plug
102. Plug
103. Governor cover
104. Bolt
105. Spring
106. Washer
107. Spring assembly
108. Screw
109. Plug
110. Tube
111. Spring
112. Nut
113. Spring washer
114. Disk
115. Plate
116. Bushing
117. Nut
118. Spring
119. Diaphragm
120. Gasket
121. Screw
122. Cover
123. Gasket
124. Eye bolt
125. Bolt
126. Spring washer
127. Bolt
128. Nut
129. Gasket
130. Cap nut
131. Push rod
132. Bolt
133. Guide plate
134. Bolt
135. Lever assembly

NOTE
z

Numbers before part names do not indicate the disassembly sequence.

EF-4-6

INJECTION PUMP ASSEMBLY

TA 157 KW {213 PS}

COUPLING
Type I (for HONG KONG) and Type II (for NORWAY)

1. Bolt
2. Plate
3. Bolt
4. Nut
5. Lock washer
6. Coupling
7. Nut
8. Washer

9. Coupling
10. Bolt
11. Bolt
12. Plate
13. Bolt
14. Cross coupling
15. Sensor

16. Nut
17. Washer
18. Plate
19. Bolt
20. Washer
15 - 20. Type II only

NOTE
z

Numbers before part names do not indicate the disassembly sequence.

EF-4-7

INJECTION PUMP ASSEMBLY

TA 157 KW {213 PS}

ACTUATOR HOUSING

1. Socket head bolt


2. Spring washer
3. Harness clamp
4. Washer
5. Socket head bolt
6. Spring washer
7. Washer

8. Socket head bolt


9. Spring washer
10. Cover
11. Seal ring
12. Socket head bolt
13. Spring washer
14. Washer

15. Bolt
16. Seal ring
17. Eye bolt
18. Bolt
19. Gasket
20. Seal ring
21. Housing

NOTE
z

Numbers before part names do not indicate the disassembly sequence.

EF-4-8

INJECTION PUMP ASSEMBLY

FEED PUMP

EF-4-9

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY

1. Plug
2. Gasket
3. Check valve spring
4. Check valve
5. Priming pump
6. Gasket

7. Check valve spring


8. Check valve
9. Eye bolt
10. Eye bolt
11. Housing

TA 157 KW {213 PS}

12. Push rod


13. Piston
14. Piston spring
15. Gasket
16. Plug

NOTE
z

Numbers before part names do not indicate the disassembly sequence.

EF-4-10

INJECTION PUMP ASSEMBLY

REMOVAL
1.

Apply chocks to the front and rear wheels and tilt open the
cab.
2. Turn the key switch OFF and disconnect the ground cable
from the battery.
3. Remove the left side cover.
4. Disconnect the fuel line.
z
Disconnect the fuel tube.
z
Remove the fuel filter assembly and bracket as a unit.
z
Disconnect the injection nozzle tube.
NOTE
z Use a container or a clean cloth to catch and wipe oil as
required.

5.

Disconnect the accelerator wire and auto-stop solenoid


plate.

EF-4-11

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY


6.

Disconnect the harness connector of engine speed sensor,


rack sensor and pre-stroke sensor of MD-TICS.

7.

Disconnect the inlet and outlet oil tubes from the injection
pump.

8.

Remove the bolts which secure the coupling.

9.

Remove the bolts which secure the injection pump.


Remove the injection pump assembly from the stay.

FUEL FEED PUMP AND PRIMING PUMP


DISASSEMBLY
1.
z

Removing the push rod


Pull out the push rod.

EF-4-12

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY


2.

Place the fuel feed pump in a vise, remove the plug, gasket
and pull out the piston spring and piston.

3.

Disassembling the priming pump


It is recommended that the priming pump not be disassembled unless the rubber seat in the piston part of the pump
has become defective or the piston has seized or is rusty.
Apply a wrench to the Hex section at the bottom of the cylinder and remove the priming pump assembly.
Remove the check valve spring and check valve.

INSPECTION
Wash all disassembled parts in cleaning solvent. Carefully check
for scratches, cracks or damage. Replace faulty parts as necessary.

Housing and push rod clearance


Unit: mm (in)
Maintenance standard

Service limit

0.003 - 0.018 (0.0001 - 0.0007)

0.1 (0.004)

Housing and piston clearance


Unit: mm (in)
Maintenance standard

Service limit

0.014 - 0.056 (0.0006 - 0.0022)

0.15 (0.0059)

Gauze filter
Check the gauze filter for clogging.

EF-4-13

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY

REASSEMBLY
Before assembling the feed pump, replace old gaskets and O-rings
with new ones.
1. Insert the piston, piston spring and gasket, and tighten the
plug.
2. Install the discharge side check valve, check valve spring
and gasket, and tighten adapter and priming pump.
3. Install the push rod in the housing.
NOTE

Coat the threads of the plug with the adhesive agent.

SUPPLY PUMP TEST


Suction test
1.

Attach a hose to the supply pump suction port and insert


the other end into a fuel oil container.
NOTE
z Ensure suction head of approx. 1 m (3 ft).
2.
3.

Operate the injection pump at 100 rpm.


Fuel oil must be discharged in less than 40 seconds.

Priming pump test


1.
2.
3.

Fully loosen the priming pumps screw cap.


Operate the priming pump using the screw cap, at 60 to 100
strokes per minute.
Fuel oil must be discharged in less than 25 strokes.

Capacity test
1.
2.

Place discharge hose in a measuring cylinder (1579700500).


Operate the injection pump and check the supply rate,
referring to the following table:

Pump speed

Supply rate

100 rpm

More than 60 m liter (2.1 Imp fl oz)/15 seconds

500 rpm

More than 340 m liter (12.0 Imp fl oz)/15 seconds

1,000 rpm

More than 405 m liter (14.3 Imp fl oz)/15 seconds

1,500 rpm

More than 430 m liter (15.1 Imp fl oz)/15 seconds

EF-4-14

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY

Feed pressure measurement


1.
2.
3.

Connect the hose (157984-8400) between the supply pump


discharge port and the pressure gauge.
Operate the injection pump at 600 rpm.
Ensure that the supply pump maintains a feed pressure of
333 to 412 kPa {3.4 to 4.2 kgf/cm2, 48 to 60 psi.}

Air tightness test


1.
2.
3.

Plug the supply pump discharge port using the plug


(029111-4050).
Apply 196 kPa {2 kgf/cm2, 28 psi} air pressure to the suction port.
Immerse the supply pump in a container of fuel oil, and
check for air leakage. There must be no air leakage.

INSTALLATION
1.

Install the injection pump assembly. (Refer to the DR section for procedures.)

2.

Connect the inlet and outlet oil tubes to the injection pump.

3.

Connect the accelerator wire and auto-stop solenoid plate.


For adjustment procedures, refer to the instructions under
the ENGINE CONTROL SYSTEM in this manual.

EF-4-15

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY


4.

TA 157 KW {213 PS}

Connect the fuel system parts:


Connect the injection nozzle tube.
z
Install the fuel filter assembly.
z
Connect the fuel tube.
Connect the harness connector of engine speed sensor,
rack sensor and pre-stroke sensor of MD-TICS.
Bleed air from the fuel system. (Refer to the MA section
for procedures.)
z

5.
6.

FUEL INJECTION QUANTITY ADJUSTMENT


Testing conditions
Failure of pump to deliver fuel evenly throws the engine out of balance so that roughness and loss of power is
evident. In calibrating a pump, observe the following:
Item

Test condition

Nozzle & Nozzle holder assembly

105780-8250 (BOSCH Type No. 1 688 901 101)

Pump rotation

Clockwise (Viewed from driver side)

Nozzle

105780-0120 (BOSCH Type No. 1 688 901 990)

Nozzle holder

105780-2190
kPa {kgf/cm2, psi}

Nozzle opening pressure

20,693 {211, 3,000}

157 {1.6, 23}

kPa {kgf/cm , psi}

Feed pump oil pressure


Injection pipe (OD x ID - L)

mm (in)

8 x 2 - 600 (0.31 x 0.08 - 23.62)

Test oil

IS04113 or SAE standard test oil (SAE J967d)

Test oil temperature

C (F)

40 - 45 (104 - 113)

Type of selector switch setting

11

Injection quantity standards (ZEXEL No. is Inj. pump assy No.)


RLD governor
z
ZEXEL No. 107692-0831
Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
m liter (lmp fl oz)
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.8
(0.543)

1,400

1121 (3.940.04)

Lever

12.1
(0.476)

900

1052 (3.700.07)

Lever

Boost press. kPa {mmHg, inHg}


Above 37.3 {280, 11.02}

9.85
(0.3878)

350

332 (1.160.07)

Lever

Boost press.
0

Approx.
11.45
(0.4508)

100

89 (3.1)

Lever

Boost press.
0

EF-4-16

Remarks
Basic

Boost press. kPa {mmHg, inHg}


Above 37.3 {280, 11.02}

INJECTION PUMP ASSEMBLY


z

TA 157 KW {213 PS}

ZEXEL No. 107692-0832 and 107692-0920

Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
m liter (lmp fl oz)
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

R1 [13.8
(0.543)]

1,400

1121 (3.940.04)

Lever

R1 -1.7
(0.067)

900

1052 (3.700.07)

Lever

Boost press. kPa {mmHg, inHg}


Above 26.7 {200, 7.87}

R2 -0.6
(0.024)

350

252 (0.880.07)

Lever

Boost press.
0

Approx.
R1 -2.0
(0.079)

100

90 (3.17)

Lever

Boost press.
0

Remarks
Basic

Boost press. kPa {mmHg, inHg}


Above 26.7 {200, 7.87}

ZEXEL No. 107069-1220

Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
m liter (lmp fl oz)
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.8
(0.543)

1,400

1121 (3.940.04)

Lever

12.1
(0.476)

900

1052 (3.700.07)

Lever

Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

9.85
(0.3878)

350

332 (1.160.07)

Lever

Boost press.
0

Approx.
11.45
(0.4508)

100

89 (3.1)

Lever

Boost press.
0

EF-4-17

Remarks
Basic

Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

INJECTION PUMP ASSEMBLY

Governor adjustment diagram (ZEXEL No. is Inj. pump assy No.)


z

ZEXEL No. 107692-0831

EF-4-18

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 107692-0832 and 107692-0920

EF-4-19

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY


z

ZEXEL No. 107069-1220

EF-4-20

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY

Injection timing
Pre-stroke: No. 1 Plunger 5.60.03 mm (0.22050.0012 in)
NOTE
1. Adjust using the shim (1).
2. Adjust with the rack in the full-load position.
z

3. Adjust with the connector (2) contacting the stopper pin


(3).

4. Plungers are numbered from the drive side.


z
Injection order:

14,

12,

16,

13,

15,

6015

12015

18015

24015

30015

Tappet clearance:
Manually rotate the camshaft 2 to 3 times and confirm that it
rotates smoothly.

Pre-stroke actuator adjustment


Pre-stroke Actuator type: Retard
Power supply voltage: 240.5V
Ambient temperature: 235C (739F)
z
ZEXEL No. 107692-0831
Pre-stroke
mm (in)

Pre-stroke sensor
Output Voltage
V

Remarks

2.50.05
(0.09840.0020)

2.830.01

Pre-stroke actuator adjustment

5.60.03
(0.22050.0012)

V1=1.20.2

Confirmation

Above 3.05

Confirmation (Pre-stroke actuator operating range)

EF-4-21

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY


z

TA 157 KW {213 PS}

ZEXEL No. 107692-0832, 107069-1220 and 107692-0920


Pre-stroke
mm (in)

Pre-stroke sensor
Output Voltage
V

Remarks

2.50.01
(0.09840.0004)

2.830.01

Pre-stroke actuator adjustment

5.60.01
(0.22050.0004)

V1=1.20.2

Confirmation

Above 3.05

Confirmation (Pre-stroke actuator operating range)

NOTE

1. Move the pre-stroke actuator fully counterclockwise


(viewed from the drive side), and temporarily secure it to
the actuator housing using the bolts.
: 1.0 - 1.5 Nm {0.10 - 0.15 kgfm, 0.7 - 1.1 ftlbf}
2. Move the pre-stroke actuator clockwise (viewed from the
drive side) to adjust it.
3. After pre-stroke actuator adjustment, stamp both the prestroke actuator and the housing with an aligning mark.

Injection quantity variation rate adjustment


NOTE
z

At adjustment
Item

Pre-stroke

Adjustment point

3.60.05 mm (0.14170.0020 in)


(V = 2.250.01)

Adjustment point Z

5.50.03 mm (0.21650.0012 in)


(V = [V1+0.05]0.01)

Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
m liter (lmp fl oz)
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.8
(0.543)

1,400

1122 (3.940.07)

Rack

Basic

Approx.
8.0
(0.315)

465

10.61.8
(0.370.06)

10

Rack

Adjust injection qty at N=465.


Adjust governor as per gov. adj. spec.

EF-4-22

Remarks

INJECTION PUMP ASSEMBLY

TA 157 KW {213 PS}

Injection quantity adjustment (after governor adjustment)


Adjustment the injection quantity at a pre-stroke of 3.60.05 mm (0.14170.0020 in) (pre-stroke sensor output
voltage: 2.250.01V).
z
ZEXEL No. 107692-0831
Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
m liter (lmp fl oz)
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.8
(0.543)

1,400

1121 (3.940.04)

Lever

12.1
(0.476)

900

1052 (3.700.07)

Lever

Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

9.85
(0.3878)

350

[6.92 (0.240.07)]

Lever

Boost press.
0

Approx.
11.45
(0.4508)

100

[80 (2.8)]

Lever

Boost press.
0

Remarks
Basic

Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

ZEXEL No. 107692-0832 and 107692-0920

Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
m liter (lmp fl oz)
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

R1 [13.8
(0.543)]

1,400

1121 (3.940.04)

Lever

R1 -1.7
(0.067)

900

1052 (3.700.07)

Lever

Boost press. kPa {mmHg, inHg}


Above 26.7 {200, 7.87}

R2 -0.6
(0.024)

350

252 (0.880.07)

Lever

Boost press.
0

Approx.
R1 -2.0
(0.079)

100

90 (3.17)

Lever

Boost press.
0

Remarks
Basic

Boost press. kPa {mmHg, inHg}


Above 26.7 {200, 7.87}

ZEXEL No. 107069-1220

Adjusting
point

Rack
position
mm (in)

Pump
speed
rpm

Injection qty
m liter (lmp fl oz)
1,000 strokes

Max. var.
bet. cyl.
(%)

Fixed

13.8
(0.543)

1,400

1121 (3.940.04)

Lever

12.1
(0.476)

900

1052 (3.700.07)

Lever

Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

9.85
(0.3878)

350

332 (1.160.07)

Lever

Boost press.
0

Approx.
11.45
(0.4508)

100

89 (3.1)

Lever

Boost press.
0

EF-4-23

Remarks
Basic

Boost press. kPa {mmHg, inHg}


Above 24.0 {180, 7.09}

INJECTION PUMP ASSEMBLY

RACK SENSOR
1.

Do not operate the aneroid compensator if installed. Secure


the speed control lever in the full position and set the pump
speed at 1,400 rpm.
(If equipped with a boost compensator, first apply boost
pressure.)

Adjust the rack sensor after determining VR from the control unit
part no.
VR
2V

Control unit part No.


407912-1742
105782-6320
407910-2901

3V

407910-3032
407910-6010
407910-7210

2.
3.

Adjust the bobbin (1) so that the rack sensors output voltage is VR0.01.
After adjustment, mark the area where the joint (2) and the
nut (3) contact and the area where the joint (2) and the
pump housing contact with red paint.

Injection timing setting


1.
2.

Turn the pre-stroke actuator OFF.


Position the camshaft in the No. 1 plungers beginning of
injection position.

EF-4-24

TA 157 KW {213 PS}

INJECTION PUMP ASSEMBLY


3.
4.
5.

Confirm that the injection pump pointer aligning mark and


the flywheel aligning mark are aligned.
If not aligned, remove the incorrect flywheel aligning mark,
and remark the flywheel aligning mark.
Confirm that the center of the coupling key groove is as
specified.

Speed sensor
ZEXEL No. 107069-1220 and 107692-0920
Install the speed sensor so that the gap between the sensor and
the coupling (flywheel) projection is 0.8 to 1.0 mm (0.031 to 0.039
in), and then secure it using the lock nut (i.e. the position when the
speed sensor is returned 1 revolution from the point where it contacts the coupling (flywheel) projection).
z

ZEXEL No. 107692-0831 and 107692-0832


Install the speed sensor so that the gap between the sensor and
the drive gear (air compressor) projection is 0.7 to 1.3 mm (0.028 to
0.051 in), and then secure it using the lock nut (i.e. the position
when the speed sensor is returned 1 revolution from the point
where it contacts the drive gear (air compressor) projection).
z

EF-4-25

TA 157 KW {213 PS}

NOZZLE AND NOZZLE HOLDER

CONVENTIONAL TYPE

NOZZLE AND NOZZLE HOLDER


= CONVENTIONAL TYPE =
CONSTRUCTION

REMOVAL
1.
2.
3.

Chock wheels and tilt open the cab.


Turn the key switch OFF and disconnect the ground cable
from the battery.
Disconnect the injection nozzle tube and spill tube, remove
the nozzle holder assembly from the cylinder head.

EF-5-1

NOZZLE AND NOZZLE HOLDER

CONVENTIONAL TYPE

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


+ 1. Cap nut
2. Gasket
3. Adjusting screw
4. Nozzle spring

5. Push rod
6. Inlet connector
7. Gasket
+ 8. Retaining nut

9. Nozzle
10. Pin
11. Nozzle holder

Marks + and , indicate that the key points of operation are explained in the text.

Key point of disassembly


1 Cap nut
1. Clamp the nozzle holder into a vise with holder plate
(157944-9520).
2. Set the nozzle holder in the plate and remove the cap nut.
Loosen the adjusting screw until the nozzle spring no longer
has tension on it.
3. Remove the adjusting screw and separate the nozzle spring
and push rod.
8 Retaining nut
1. Reverse the nozzle holder position by facing the nozzleside up, and remove the retaining nut with a appropriate
wrench.
2. Remove the nozzle from the nozzle holder. Do not drop the
nozzle needle.

EF-5-2

NOZZLE AND NOZZLE HOLDER

INSPECTION
Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
NOTE
z Remove carbon from around nozzle jets using a wire
brush.
z

1.

Remove carbon from around nozzle jets using the pin vice
(99727 Z5005).
Unit: mm (in)

Nozzle identification mark

Number of injection nozzle holes

Z, D3
D2, A5, A6
C1, F4

Injection nozzle
hole diameter

Wire diameter

0.29 (0.0114)

0.26 (0.0102)

0.30 (0.0118)

0.29 (0.0114)

0.245 (0.0096)

0.23 (0.0091)

NOTE

Do not extend tip of the holder more than 2 to 2.5 mm


(0.079 to 0.098 in). Otherwise, it may bend inside the nozzle body so that it cannot be removed.
z Carefully push the holder into the inside of the nozzle to
remove carbon.
z Use an oil stone to grind the wire tip of the holder until it
is shaped as shown in the figure.
z

2.

Clean remaining carbon off the back of the nozzle jet using
the nozzle cleaner (99726 Z5000).
NOTE
z Be careful not to scratch the seating surface of the nozzle jet and the nozzle needle.
Do not use compressed air to remove carbon because
this may introduce foreign matter into the jet.
3.

Install the needle on the nozzle body while immersing both


in clean diesel fuel.

4.

Visually check the needle valve seat, guide shaft and injection shaft for damage or carbon accumulation.
Position the nozzle body vertically. Pull out the needle so
that it protrudes approximately 1/3 its total length beyond
the top of the nozzle body. Then release it to ensure that it
drops to the valve seat under its own weight.

5.

EF-5-3

CONVENTIONAL TYPE

NOZZLE AND NOZZLE HOLDER

REASSEMBLY
To reassemble, reverse the order of the above removal procedures. Observe the following:
NOTE

Clean the mating surfaces of the nozzle and nozzle


holder and the retaining nut in clean diesel fuel before
installation.
z Use new gaskets.
z

ADJUSTMENT
1.
2.

Loosen the adjusting screw and install the nozzle on a nozzle tester (105785-0960). Operate the hand lever forcefully
two or three times to remove foreign matter.
Adjust fuel valve opening pressure using the adjusting
screw.
Unit: kPa {kgf/cm2, psi}
Maintenance
standard

Service limit

Z, D2, A5,
A6, C1, F4

20,104 - 20,595
{205 - 210, 2,915 - 2,986}

D3, F4

22,066 - 22,556
{225 - 230, 3,200 - 3,271}

Item
Valve opening
pressure
(Regulated
pressure)

WARNING
WARNING
z

Be extremely careful not to direct fuel spray to hand


while adjusting fuel injection. It may penetrate into blood
vein to the skin and cause toxic symptoms.

3.

After adjusting injection pressure to specifications, install


the cap nut. Recheck injection pressure.
Z, D2, D3, A5 and A6
: 39 - 49 Nm {4.0 - 5.0 kgfm, 29 - 36 ftlbf}
C1 and F4
: 29 - 39 Nm {3.0 - 4.0 kgfm, 22 - 29 ftlbf}

4.

While adjusting injection pressure, check the spray pattern.


Also check for signs of fuel leakage or obstruction. If
inspection reveals slight wear on the seating surfaces of the
nozzle body and needle, lap both using lapping compound.
If either part requires replacement, replace both parts as a
unit.
1.

Equal, symmetrical fuel


spray pattern

4.

Lean fuel spray pattern

2.

Asymmetrical fuel spray


pattern

5.

Stepped fuel spray pattern

3.

Incorrect fuel spray pattern

6.

Equal fuel spray (from 5


jets)

EF-5-4

CONVENTIONAL TYPE

NOZZLE AND NOZZLE HOLDER

INSTALLATION
1.
2.
3.
4.

Install the nozzle holder assembly on the cylinder head.


: 25 - 29 Nm {2.5 - 3.0 kgfm, 18 - 22 ftlbf}
Connect the spill tube and injection nozzle tube.
Bleed air from the fuel system. (Refer to the MA section
for procedures.)
Connect the ground cable to the battery.

EF-5-5

CONVENTIONAL TYPE

NOZZLE AND NOZZLE HOLDER

= TWO-SPRING TYPE =
CONSTRUCTION

REMOVAL
1.
2.
3.

Chock wheels and tilt open the cab.


Turn the key switch OFF and disconnect the ground cable
from the battery.
Disconnect the injection nozzle tube and spill tube, remove
the nozzle holder assembly from the cylinder head.

EF-5-6

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER

TWO-SPRING TYPE

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Cap nut
2. Gasket
3. Nut
4. Adjusting screw
5. No. 2 spring
6. No. 2 push rod
7. Shim (for pre-lift adjustment)

8. Setscrew
9. Spacer
10. Shim (for valve opening pressure
adjustment)
11. No. 1 spring
12. No. 1 push rod

Key point of disassembly


Nozzle and nozzle holder assembly
1. Secure nozzle in vice by holding nozzle holder portion with
nozzle holes facing down.
2. Loosen cap nut and remove gasket.
3. Loosen nut, and remove adjusting nut, and then take out
No. 2 spring, No. 2 push rod and pre-lift adjusting shim.
4. Remove set screw, and take out spacer, valve opening
pressure adjusting shim, No. 1 spring and No. 1 push rod.
5. Secure nozzle by holding nozzle holder in vice with nozzle
hole facing up, and loosen retaining nut, then remove nozzle assembly and pin.
6. Remove nozzle needle from nozzle body.
NOTE
z Be sure to keep nozzle needle and nozzle body as a
matched set.

EF-5-7

13. Retaining nut


14. Nozzle assembly
15. Pin
16. Connector
17. Gasket
18. Nozzle holder

NOZZLE AND NOZZLE HOLDER

INSPECTION
Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
NOTE
z Remove carbon from around injection hole using wire
brush.
z

1.

Using pin vise (99727 Z5005), remove carbon from nozzle


hole.
Unit: mm (in)

Nozzle identification mark


A3

Number of injection nozzle holes

Injection nozzle
hole diameter

Wire diameter

0.30 (0.0118)

0.29 (0.0114)

NOTE

Do not extend tip of the holder more than 2 to 2.5 mm


(0.079 to 0.098 in). Otherwise, it may bend inside the nozzle body so that it cannot be removed.
z Carefully push the holder into the inside of the nozzle to
remove carbon.
z Use an oil stone to grind the wire tip of the holder until it
is shaped as shown in the figure.
z

2.

Clean remaining carbon off the back of the nozzle jet using
the nozzle cleaner (99726 Z5000).
NOTE
z Be careful not to scratch the seating surface of the nozzle jet and the nozzle needle.
Do not use compressed air to remove carbon because
this may introduce foreign matter into the jet.
3.

Install the needle on the nozzle body while immersing both


in clean diesel fuel.

4.

Visually check the needle valve seat, guide shaft and injection shaft for damage or carbon accumulation.
Position the nozzle body vertically. Pull out the needle so
that it protrudes approximately 1/3 its total length beyond
the top of the nozzle body. Then release it to ensure that it
drops to the valve seat under its own weight.

5.

EF-5-8

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER

REASSEMBLY
To reassemble, reverse the sequence of disassembly, paying
attention to the following points.
NOTE

When assembling nozzle to nozzle holder, be sure to


clean each contacting surface and retaining nut with
clean light oil.
z Replace gasket with a new one each time nozzle is disassembled.
See section Adjustment when reassembling.
z

Unit: Nm {kgfm, ftlbf}


Item

Tightening torque

Cap nut

39 - 49{ 4.0 - 5.0, 29 - 36}

Retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Nut

20 - 25 {2.0 - 2.5, 14 - 18}

Set screw

49 - 59 {5.0 - 6.0, 36 - 43}

Inlet connector

59 - 69 {6.0 - 7.0, 43 - 51}

ADJUSTMENT
OVERHAULING TYPE
Adjusting nozzle opening pressure
1.

Using retaining nut (157892-2020), fix nozzle assembly on


nozzle holder.
: 59 - 78 Nm {6.0 - 8.0 kgfm, 43 - 58 ftlbf}
NOTE
z Tighten retaining nut after confirming that dowel pin is
entered fully into nozzle.
2.

Remove screw from end of retaining nut (157892-2020).

3.

Install No. 1 push rod, No. 1 spring, opening pressure


adjusting shim and spacer to nozzle holder, and tighten with
set screw.
: 49 - 59 Nm {5.0 - 6.0 kgfm, 36 - 43 ftlbf}

EF-5-9

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER


4.

Using nozzle tester (105785-1010) [with 49,035 kPa {500


kgf/cm2, 7,110 psi} gauge], measure valve opening pressure (regulated pressure) of nozzle.
Unit: kPa {kgf/cm2, psi}
Maintenance standard

Service limit

17,162 - 17,947
{175 - 183, 2,489 - 2,602}

5.

If the valve opening pressure is out of standard, change


thickness of valve opening pressure adjusting shim so that
specified pressure is obtained.
NOTE
z Before installing a shim, be sure to measure its thickness with a micrometer.
z If necessary, use a set of two shims.
z Select proper shims, noting that a 0.02 mm (0.0008 in)
thick shim changes the valve opening pressure by 235
kPa {2.4 kgf/cm2, 34 psi}.
0.10 (0.0039), 0.20 (0.0079), 0.30 (0.0118),
Adjusting shim 0.40 (0.0157), 0.50 (0.0197), 0.52 (0.0205),
thickness
0.54 (0.0213), 0.56 (0.0220), 0.58 (0.0228),
mm (in) 0.60 (0.0236), 0.70 (0.0276), 0.80 (0.0315),
0.90 (0.0354), 1.00 (0.0394)

Pre-lift adjustment
1.

Install a 60.5 mm (2.382 in) pin (157892-1100) to the dial


gauge (157954-3800) and connect it to the adjusting device
(157892-0220).

2.

Secure base (157892-1800) in vise, assemble No. 2 push


rod, and set adjusting device (157892-0220), then align dial
gauge needle with 0.
3. Assemble push rod into nozzle holder.
NOTE
z Do not assemble No. 2 spring and pre-lift adjusting shim.

EF-5-10

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER


4.

Fit adjusting device to nozzle holder set screw, secure with


intermediate screw, and move dial gauge holder up and
down to check for smooth dial gauge movement.
5. Push down by holding dial gauge holder, and read dial
gauge needle deflection (lift: h).
NOTE
z Read dial gauge indication in units of 1/100 mm.
6.

Select proper thickness of pre-lift adjusting shim.


t = (l + h)
t: Thickness of shim (measured value)
l: Pre-lift (standard value)
h: Lift (measured value in step 5) above)
Thickness of shim to be selected must be T = t0.015 mm.
0.10 (0.0039), 0.20 (0.0079), 0.30 (0.0118), 0.40 (0.0157),
Adjusting shim
0.50 (0.0197), 0.52 (0.0205), 0.54 (0.0213), 0.56 (0.0220),
thickness
0.58 (0.0228), 0.60 (0.0236), 0.70 (0.0276), 0.80 (0.0315),
mm (in)
0.90 (0.0354), 1.00 (0.0394)

7.

Remove adjusting device from nozzle holder.

Adjustment of No. 2 spring


1.

Assemble No. 2 spring adjusting screw and nut on nozzle


holder.
NOTE
z Do not assemble pre-lift adjusting shim at this stage.
Accordingly, No. 1 and No. 2 push rods are in contact.
2.

Using nozzle tester, adjust No. 2 spring by turning adjusting


screw, and lock with nut.
: 20 - 25 Nm {2.0 - 2.5 kgfm, 14 - 18 ftlbf}
NOTE
z Reconfirm the valve opening pressure after adjustment;
it changes by securing with the lock nut.
Unit: kPa {kgf/cm2, psi}
Item
Valve opening
pressure
(Regulated
pressure)

Maintenance standard

Service limit

Remarks

24,321 - 24,910
{248 - 254, 3,527 - 3,612}

Push rod contacting method

NOTE
z

Push rod contacting method means that the plug at the


tip of the special tools retaining nut has been removed.

EF-5-11

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER

Checking total lift of nozzle (needle valve)


1.
2.

Install screw on retaining nut (157892-2020).


Install connector (157892-1320) on nozzle holder set screw.
: 39 - 49 Nm {4.0 - 5.0 kgfm, 29 - 36 ftlbf}

3.

Install a 50.0 mm (1.969 in) pin (157892-1200) to the dial


gauge (157954-3800) and connect it to the connector.
NOTE
z Secure the dial gauge so that it can measure a stroke of
about 1.2 mm (0.047 in).
z Be careful not to tighten the nut excessively as the dial
gauge shaft may seize causing malfunction.
4. Set dial gauge to 0 point.
5. Using nozzle tester, bleed air from retaining nut, and also
check for fuel leaks.
6. Operate nozzle tester (105785-1010), pressurize up to
34,325 to 44,132 kPa {350 to 450 kgf/cm2, 4,977 to 6,399
psi}, and read total lift L of nozzle needle indicated on dial
gauge.
NOTE
z Dimension L indicated at this time is pre-lift plus prelift adjusting shim thickness.
7.

Remove connector (with dial gauge) from nozzle holder.

Assembling pre-lift adjusting shim


1.

Remove set screw assembly (consisting of set screw,


adjusting screw and nut) and No. 2 push rod from nozzle
holder.
NOTE
z Never attempt to loosen nut, otherwise, No. 2 spring
adjusting pressure will change.

EF-5-12

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER


2.

Insert pre-lift adjusting shim selected in step 6 (under Prelift adjustment) between spacer and No. 2 push rod, and
assemble spacer and rod onto nozzle holder, and fit No. 2
spring; then tighten with set screw assembly.
: 49 - 59 Nm {5.0 - 6.0 kgfm, 36 - 43 ftlbf}
NOTE
z At this stage, No. 1 and No. 2 push rods are separated by
space equivalent to pre-lift.
3.

4.

Install connector (157892-1320) on nozzle holder set screw,


install dial gauge, and set dial gauge needle to 0 point.
: 39 - 49 Nm {4.0 - 5.0 kgfm, 29 - 36 ftlbf}
Using nozzle tester, bleed air from within retaining nut.

5.

Operate nozzle tester (105785-1010), pressurize up to


34,325 to 44,132 kPa {350 to 450 kgf/cm2, 4,977 to 6,399
psi}, and read total lift S of nozzle needle on dial gauge.
NOTE
z Dimension S is total lift of needle valve minus pre-lift.

Checking pre-lift
1.

2.
3.

Confirm amount of pre-lift from dimension L measured in


step 4 (under Checking total lift of nozzle) and dimension
S measured in step 5 (under Assembling pre-lift adjusting
shim).
Uliter = L - S mm (in)
Uliter: Pre-lift (measured value)
L:
Total lift of needle valve (measured value)
S:
Needle valve lift after subtracting pre-lift (measured value)
Confirm that dimension Uliter is within pre-lift range of
0.120.02 mm (0.00470.0008 in).
If dimension Uliter is not within range of specified dimension 0.120.02 mm (0.00470.0008 in), replace pre-lift
adjusting shim, and perform operations 4 and 5 (under
Assembling pre-lift adjusting shim). Select thickness (t) of
shim, proceeding as follows:
t = t + (liter - Uliter)
t: Shim thickness
t: Thickness of shim assembled.
T = t0.015
T: Thickness of shim to be used

Checking No. 2 spring adjusting pressure


1.

After checking for pre-lift, pressurize up to 34,325 to 44,132


kPa {350 to 450 kgf/cm2, 4,977 to 6,399 psi} to fully stroke
(total lift) nozzle needle valve.
EF-5-13

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER


2.

After needle valve is lifted up fully, release nozzle tester


handle to allow pipe pressure to lower spontaneously.
When 0.05 mm (0.0020 in) drop in needle valve lift is indicated on dial gauge, read pressure on pressure gauge.
Unit: kPa {kgf/cm2, psi}
Item

Valve opening
pressure
(Regulated
pressure)

Maintenance standard

Service limit

23,046 - 23,537
{235 - 240, 3,342 - 3,413}

Remarks
Nozzle cover
method

NOTE
z

Nozzle cover method means that the special tools retaining nut and the plug at the tip are attached.

3.

If No. 2 spring adjusting pressure is not within specified


value, perform adjustment as explained in step Adjustment
of No. 2 spring Push rod contacting method, then check
No. 2 spring adjusting pressure again.
4. Remove connector (157892-1320) together with dial gauge.
Finish inspection
1. Remove retaining nut (157892-2020), and install standard
retaining nut.
: 59 - 78 Nm {6.0 - 8.0 kgfm, 43 - 58 ftlbf}
NOTE
z Before tightening retaining nut, confirm that dowel pin is
completely fitted into nozzle.
2.

Install cap nut.


: 39 - 49 Nm {4.0 - 5.0 kgfm, 29 - 36 ftlbf}

3.

Install nozzle on nozzle tester (105785-1010), and check


injection opening pressure.
Unit: kPa {kgf/cm2, psi}
Item

Injection opening
pressure
(1st stage)

Maintenance standard

Service limit

16,672 {170, 2,417}

NOTE
z

Never spray injected fuel on hand: otherwise, fuel spray


under high pressure will penetrate deeply into the skin,
causing blood poisoning.

EF-5-14

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER


4.

Check spray pattern, injection holes for clogging, and for oil
tightness. If nozzle body seat face and nozzle needle are
scratched or worn by chips or carbon in fuel, repair by lapping with compound, provided damage is very small.
If replacement is needed, be sure to replace nozzle needle
and body as a matched set.
1.

Even and symmetrical

4.

Too thin

2.

Asymmetrical

5.

Stepped

3.

Branching

6.

Uniform injection from


five nozzle holes

SIMPLIFIED INSPECTION
Checking injection beginning pressure and spray pattern
1.

Install nozzle on nozzle tester, and check injection opening


pressure.
Unit: kPa {kgf/cm2, psi}
Item

Injection opening
pressure (1st stage)

Maintenance standard

Service limit

16,672 {170, 2,417}

NOTE
z

Never spray injected fuel on hand: otherwise, fuel spray


under high pressure will penetrate deeply into the skin,
causing blood poisoning.

2.

Check spray pattern, injection holes for clogging, and oil


tightness.

3.

1.

Even and symmetrical

4.

Too thin

2.

Asymmetrical

5.

Stepped

3.

Branching

6.

Uniform injection from


five nozzle holes

If nozzle is found to be faulty, replace or overhaul nozzle,


and perform adjustment according to step 1 above.

EF-5-15

TWO-SPRING TYPE

NOZZLE AND NOZZLE HOLDER

Checking No. 2 spring adjusting pressure


1.

Remove retaining nut, and install retaining nut (1578922020) for adjustment.
: 59 - 78 Nm {6.0 - 8.0 kgfm, 43 - 58 ftlbf}
NOTE
z Be sure to tighten retaining nut after making sure that
dowel pin is fitted completely into nozzle.
2.

3.

4.

Remove cap nut, and install connector (157892-1320)


together with dial gauge. Use dial gauge pin of 50.0 mm
(1.969 in) in length.
: 39 - 49 Nm {4.0 - 5.0 kgfm, 29 - 36 ftlbf}
Install nozzle holder on nozzle tester, and purge air from
inside of retaining nut, then raise pressure in pipe to 34,325
to 44,132 kPa {350 to 450 kgf/cm2, 4,977 to 6,399 psi} to
move nozzle needle valve to maximum lift position.

After moving needle valve to maximum lift position, leave


nozzle tester handle as it is to allow pressure to lower. As
pressure drops, needle valve lift will decrease. Read pressure gauge indication when dial gauge indicates a needle
valve drop of 0.05 mm (0.0020 in).
Unit: kPa {kgf/cm2, psi}
Item

Valve opening
pressure
(Regulated
pressure)

5.

Maintenance standard

Service limit

23,046 - 23,537
{235 - 240, 3,342 - 3,413}

Remarks
Nozzle cover
method

If adjusting pressure of No. 2 spring is not within specified


range, perform adjustment according to step 1 above.

Finish inspection
Check injection beginning pressure, spray condition and oil tightness according to steps 1 and 2 (under Checking injection beginning pressure and spray pattern).

INSTALLATION
1.
2.
3.
4.

Install the nozzle holder assembly on the cylinder head.


: 25 - 29 Nm {2.5 - 3.0 kgfm, 18 - 22 ftlbf}
Connect the spill tube and injection nozzle tube.
Bleed air from the fuel system. (Refer to the MA section
for procedures.)
Connect the ground cable to the battery.
EF-5-16

TWO-SPRING TYPE

FUEL FILTER

FUEL FILTER
CONSTRUCTION
Cartridge type

Center bolt type

EF-6-1

FUEL FILTER

Primary fuel filter


<Type I>

<Type II>

EF-6-2

FUEL FILTER

Fuel strainer

REPLACING FUEL FILTER ELEMENT


Refer to the MA section for replacement of the fuel filter.

Cartridge type
Disassembly sequence (Reassembly sequence is the reverse
order of disassembly.)
1.

Cartridge assembly

2.

Cover

EF-6-3

FUEL FILTER

Center bolt type


Disassembly sequence (Reassembly sequence is the reverse
order of disassembly.)
1.

Drain plug

6.

Seat spring

2.

Packing

7.

Retainer

3.

Center bolt

8.

Element

4.

Packing

9.

Packing

5.

Filter case

10.

Filter cover

Primary fuel filter


<Type I>
Disassembly sequence (Reassembly sequence is the reverse
order of disassembly.)
1.

Plug

7.

Set spring

2.

Packing

8.

Retainer

3.

Drain cock

9.

Element

4.

Center bolt

10.

Packing

5.

Packing

11.

Filter cover

6.

Filter case

EF-6-4

FUEL FILTER
<Type II>
Disassembly sequence (Reassembly sequence is the reverse
order of disassembly.)
1.

Drain plug

7.

Seat

2.

Packing

8.

Element

3.

Center bolt

9.

Packing

4.

Packing

10.

Filter cover

5.

Filter case

11.

Filter plug

6.

Spring

12.

O-ring

Fuel strainer
Disassembly sequence (Reassembly sequence is the reverse
order of disassembly.)
1.

Drain plug

6.

Set spring

2.

Center bolt

7.

Baffle

3.

Packing

8.

Screen

4.

Strainer case

9.

Packing

5.

Spring retainer

10.

Strainer cover

EF-6-5

ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM


= FE6A, FE6B, FE6T AND FE6TA [173 kW {235 PS}] =
CONSTRUCTION

ADJUSTMENT
ENGINE CONTROL WIRE
Turn the engine control knob fully counterclockwise and connect
the engine control wire to lever.
Securely fit the clips (2 places on the wire end) in the bracket.
Dimension L: 78.0 - 80.0 mm (3.071 - 3.150 in)

EF-7-1

ENGINE CONTROL SYSTEM

ACCELERATOR WIRE
1.

Connect one end of the accelerator wire to lever. Securely


fit the clip on the wire in the panel.
NOTE
z Be careful not to break the boot.

2.

Connect the other end of the accelerator wire to the engine


side. Check that the control lever of the injection pump
touches the stopper bolt and that there is no free play at the
wire connection. Then, tighten the nut.

3.

Depress the accelerator pedal until the control lever of the


injection pump contacts the stopper bolt. While holding the
control lever in that position, adjust the clearance between
the pedal and stopper to H and secure the stopper bolt.
Clearance H: 0 - 4.0 mm (0 - 0.157 in)

ENGINE STOP LINKAGE


Manual stop type
Connect the engine stop wire on the fuel injection pump side. The
knob should be positioned at load position. Before securing the
threaded section of the wire, ensure that the adjusting section of
the wire has no slack, and that dimension L is maintained.
Item

Dimension L mm (in)

Except vacuum brake vehicle

118.0 (4.646)

Vacuum brake vehicle only

128.0 (5.039)

Auto stop type


1. Turn the ignition switch OFF and stop the motor.
NOTE
z Make sure the wire inner cable is retracted on the motor
side.
Stroke A: 35.0 mm (1.378 in)
Set length B: 90.0 mm (3.543 in)

EF-7-2

ENGINE CONTROL SYSTEM


2.

Connect the clevis of the cable tip to the stop lever of the
injection pump. Pull the stop lever to the stop position and
temporarily install the wire adjusting nut on the support.

3.

Turn the wire adjusting nut in the wire tensioning direction,


approximately one turn additionally from the condition under
which there is no slack in the wire.

EF-7-3

ENGINE CONTROL SYSTEM

= FE6TA [157 kW {213 PS}] =


CONSTRUCTION

ADJUSTMENT
ENGINE CONTROL WIRE
Turn the engine control knob fully counterclockwise and connect
the engine control wire to lever.
Securely fit the clips (2 places on the wire end) in the bracket.
L length: 78.0 - 81.0 mm (3.071 - 3.189 in)

EF-7-4

ENGINE CONTROL SYSTEM

ACCELERATOR WIRE
1.

Connect one end of the accelerator wire to lever. Securely


fit the clip on the wire in the panel.
NOTE
z Be careful not to break the boot.

2.

Connect the other end of the accelerator wire to the engine


side. Check that the control lever of the injection pump
touches the stopper bolt and that there is no free play at the
wire connection. Then, tighten the nut.

3.

Depress the accelerator pedal until the control lever of the


injection pump contacts the stopper bolt. While holding the
control lever in that position, adjust the clearance between
the pedal and stopper to H and secure the stopper bolt.
Clearance H: 0 - 4.0 mm (0 - 0.157 in)

EF-7-5

ENGINE CONTROL SYSTEM

ENGINE STOP LINKAGE


To install and adjust the engine auto-stop system, proceed as follow:
1. Temporarily install the solenoid assembly on bracket and
connect wiring.
2. Install the rod between the stop lever on the injection pump
and on the solenoid on the injection pump side. Tighten the
lock nuts.

3.

Turn the key switch ON. Current flows so that the solenoid
retracts.
NOTE
z Ensure that solenoid retracts completely.

4.
5.

Turn the swivel one more turn in the direction of the arrow,
and move the stop lever approximately 3.0 mm (0.118 in)
towards the stop side.
After stop lever adjustment, tighten the lock nut and solenoid mounting bolts.

EF-7-6

- MEMO -

MD-TICS SYSTEM

MD-TICS SYSTEM
CONTENTS
SYSTEM OVERVIEW ................................................................................................. EF-8-2
SYSTEM DIAGRAM ............................................................................................................................. EF-8-2
LOCATION OF EQUIPMENT .............................................................................................................. EF-8-4
FUNCTION OF EQUIPMENT ............................................................................................................. EF-8-5

FUNCTION AND CONSTRUCTION .......................................................................... EF-8-7


OUTLINE .............................................................................................................................................
FUEL INJECTION RATE CONTROL ..................................................................................................
PRE-STROKE CONTROL MECHANISM ...........................................................................................
FUEL INJECTION TIMING CONTROL ...............................................................................................
SELF-DIAGNOSIS AND BACK UP FUNCTION ...............................................................................
Trouble Display and Back-up .......................................................................................................
Trouble Diagnosis ..........................................................................................................................

EF-8-7
EF-8-8
EF-8-9
EF-8-13
EF-8-14
EF-8-14
EF-8-14

TROUBLE DIAGNOSIS AND TROUBLE-SHOOTING ............................................. EF-8-16


[1] TROUBLE DISPLAY ......................................................................................................................
[2] TROUBLE DIAGNOSIS .................................................................................................................
[3] TROUBLE-SHOOTING ..................................................................................................................
(1) Checking Diagnosis Light System ............................................................................................
(2) Checking Control Unit Power Supply System ..........................................................................
(3) Checking Rack Sensor System ................................................................................................
(4) Checking Engine Speed Sensor System .................................................................................
(5) Checking Engine Coolant Temperature Sensor System ..........................................................
(6) Checking Pre-stroke Sensor System .......................................................................................
(7) Checking Pre-stroke Servo System .........................................................................................
(8) Checking Pre-stroke Power Supply System ............................................................................
[4] CLEARING DIAGNOSTIC MEMORY ............................................................................................

EF-8-17
EF-8-18
EF-8-21
EF-8-29
EF-8-33
EF-8-36
EF-8-43
EF-8-49
EF-8-54
EF-8-58
EF-8-62
EF-8-64

APPENDIX ................................................................................................................. EF-8-65


Table 1 Failure Judgement Conditions For MD-TICS System ....................................................
Table 2 BACK-UP Operations For MD-TICS System ...............................................................
Terminal Connection Drawing .......................................................................................................
Wiring Diagram ..............................................................................................................................

EF-8-65
EF-8-66
EF-8-67
EF-8-70

NOTE
z

There are two types of MD-TICS SYSTEM; one is destined for HONG KONG and the other for
NORWAY. On the following pages, Type I refers to HONG KONG specifications and Type II
refers to NORWAY specifications.

EF-8-1

MD-TICS SYSTEM

SYSTEM OVERVIEW
The MD-TICS system is a system that optimizes the fuel injection rate and fuel injection timing by using electronic control.
MD - TICS
Code

Timing & Injection rate Control System

The MD-TICS system consists of the control unit, the pre-stroke actuator that is actuated by the signal from the
control unit, the sensors (engine speed sensor, rack sensor, engine coolant temperature sensor, and prestroke sensor) that read the operating condition of the engine and give signals to the control unit, the switches
and lights, and the electrical wiring.
This is an electronic control system in which the action of these units is used to compare the ideal values programmed beforehand into the microcomputer (control unit) with the actual values. In this way, the injection timing and fuel feed rate are controlled, the exhaust gas is cleaned, and the output is improved.

SYSTEM DIAGRAM
<Type I>

EF-8-2

MD-TICS SYSTEM
<Type II>

EF-8-3

MD-TICS SYSTEM

LOCATION OF EQUIPMENT

EF-8-4

MD-TICS SYSTEM

FUNCTION OF EQUIPMENT
Control Unit
Main function
z
Fuel injection rate control
z
Fuel injection timing control
Supplementary function
z
Self-diagnosis function
z
Back up function

Pre-stroke Actuator/Sensor
The pre-stroke actuator is installed at the front of the injection
pump. It consists of the pre-stroke sensor and pre-stroke servo that
is actuated by signals from the control unit.
The pre-stroke sensor is inside the pre-stroke actuator. It compares
the target position instructed from the pre-stroke control unit with
the actual position to detect if the position is correct, and feeds this
information back to the control unit.

Engine Speed Sensor


<Type I>
The engine speed sensor is installed to the gear case and detects
the engine speed with a magnetic pick-up.
The engine speed sensor detects the potential difference generated when gear teeth traverse the tip of the engine speed sensor
and sends the potential difference to the control unit (25 pulses by
one rotation of the engine).

<Type II>
The engine speed sensor is installed to the injection pump and
detects the engine speed with a magnetic pick-up.
It detects the potential difference generated when the protrusions
(12 places at equal distances) on the coupling (flywheel) of the
injection pump pass the tip of the engine speed sensor and sends
this to the control unit.

Engine Coolant Temperature Sensor


The engine coolant temperature sensor is a variable resistor (thermistor type) in which the resistor changes according to the change
in the temperature of the engine cooling water. It reads the engine
coolant temperature as the change in the resistance, and inputs an
electrical signal to the control unit.
The engine coolant temperature sensor is installed at the water
manifold.

EF-8-5

MD-TICS SYSTEM

Rack Sensor
The rack sensor is a non-contact displacement meter that acts to
send the movement of the control rack of the injection pump to the
control unit.
The rack sensor sends out an alternating wave current (sine wave)
from the OSC terminal (oscillation terminal) of the control unit. It
detects the position of the rack from the MDL (middle) signal generated by the change in the impedance (self-induction) between the
two coils, and sends this to the control unit.

Diagnostic Switch
The diagnostic switch is the switch used to carry out trouble-shooting of the electronic control system.
The diagnostic switch consists of one pair of male and female terminals. These are normally connected; they are disconnected only
when carrying out trouble-shooting.
The diagnostic switch is installed behind the electrical unit board
and labeled with a DIAGNOSIS tag.

Memory Reset Switch


This switch is used to delete the control unit trouble data from memory. To delete the data, short circuit the connector terminals for
about ten seconds.
The memory reset switch is installed behind the electrical unit
board and labeled with a MEMORY tag.

EF-8-6

MD-TICS SYSTEM

FUNCTION AND CONSTRUCTION


OUTLINE
The MD-TICS system is a system that optimizes the fuel injection rate and fuel injection timing by using electronic control.
In more concrete terms, it controls the pre-stroke of the injection pump, and changes the injection timing and
injection rate.
The concept of the pre-stroke control is shown in the diagram below.
Pre-stroke Characteristic

EF-8-7

MD-TICS SYSTEM

FUEL INJECTION RATE CONTROL


With the present type of injection pump, the pre-stroke is fixed.
However, with the variable injection rate injection pump, the operating condition of the engine and control condition of the driver are
detected by various sensors, and the information signal is processed by the control unit. Based on the control signal from the
control unit, the control sleeve installed in the fuel chamber of the
barrel portion is moved up and down by the pre-stroke actuator to
change the pre-stroke and control the fuel injection rate.
NOTE
z

Hereafter in this text, from the point of explaining the


action with the operation diagrams, the expression fuel
injection rate is not used. The term fuel feed rate is
used instead.

<Fuel Feed Rate (proportion of fuel supplied per unit of


time)>
When supplying a fixed amount of fuel, if the feed timing is long, a
smaller amount of fuel is supplied per unit time, and this gives a low
fuel feed rate. On the other hand, if the feed timing is short, a larger
amount of fuel is supplied per unit time, and this gives a high fuel
feed rate.

<Pre-stroke>
The amount of cam lift when the injection pump cam rotates and
moves from the plunger lift starting point a to the fuel feed starting
point A is called the pre-stroke.

EF-8-8

MD-TICS SYSTEM

PRE-STROKE CONTROL MECHANISM


<Fuel Feed Mechanism>
The operation of the fuel feed for the variable fuel feed rate injection pump is as follows.

1.

Before fuel feed


Until the plunger rises and the suction port is blocked by the control sleeve, the fuel in the pressure
chamber passes through the suction port and flows out to the fuel chamber. Therefore, the pressure
in the pressure chamber does not rise.

2.

Start of fuel feed


When the plunger rises further and the suction port is blocked by the bottom end of the control
sleeve, the fuel feed operation starts.

3.

During fuel feed


While the suction port is between the bottom of the control sleeve and the spill port, the fuel continues to be fed.

4.

Completion of fuel feed


When the suction port and the notched groove (lead) of the plunger are connected with the spill port
of the control sleeve, the high pressure fuel in the pressure chamber is drained through the spill port
to the fuel chamber, and this completes the fuel feed.

EF-8-9

MD-TICS SYSTEM

<Relation between Fuel Feed Rate and Position of Control Sleeve>

Change in fuel feed rate for same fuel feed amount


When the control sleeve is at the top, the pre-stroke is at its maximum, and as the plunger lift speed is fast, the
fuel feed time can be made shorter. This means that the amount of fuel fed per unit time is larger and the fuel
feed rate is higher.
On the other hand, when the control sleeve is at the bottom, the pre-stroke is at its minimum, and as the
plunger lift speed is slow, the fuel feed time is longer. This means that the amount of fuel fed per unit time is
smaller and the fuel feed rate is lower.
Under normal operating conditions, for low speed, the control sleeve is at the top to give a high fuel feed rate,
and at high speed, the control sleeve is moved to the bottom to prevent the fuel feed rate from becoming too
high.

<Pre-stroke Control Mechanism>


The pre-stroke control mechanism consists of the following.
(1) The control sleeve that is moved up and down by the control rod
inside the barrel
(2) The control rod that rotates and moves the control sleeve with a
pin
(3) The rotary solenoid that rotates the control rod

(4) The pre-stroke sensor that always feeds back the movement of
the rotary solenoid to the control unit
When the control sleeve goes up, the pre-stroke becomes larger,
and when it goes down, the pre-stroke becomes smaller.

EF-8-10

MD-TICS SYSTEM

<Pre-stroke Actuator>

The pre-stroke actuator has a shape that forms three sides of a square, and consists of an iron core with a coil
wound around it. A rotor is placed between the jaws of the actuator, and a magnetic force proportional to the
control signal (current) from the control unit is generated by the rotary solenoid. The action of this magnetic
force then causes the rotor to rotate. The control sleeve is interconnected, so it moves up or down.

EF-8-11

MD-TICS SYSTEM

<Power Circuit>
The power source for the pre-stroke actuator has a separate circuit. If there is any abnormality in the pre-stroke
servo system, this circuit functions to stop the control, and at the same time it opens the pre-stroke cut relay to
cut the power for the pre-stroke actuator.
At the same time, the boost compensator cut 3-way magnetic valve is switched OFF, and the maximum injection amount is limited to prevent any secondary damage being caused when the control of the injection pump
is stopped.

EF-8-12

MD-TICS SYSTEM

<Pre-stroke Sensor>
The pre-stroke sensor compares the target position sent from the
control unit and detects if the pre-stroke actuator is actually in the
correct position.
Like the rack sensor, it is a non-contact displacement meter, and
sends out an alternating wave current (sine wave) from the OSC
terminal (oscillation terminal) of the control unit. It detects the position of the pre-stroke actuator (control sleeve) from the MDL (middle) signal generated by the change in the impedance (selfinduction) between the two coils, and sends this to the control unit.
The pre-stroke sensor harness is equipped with a shielding wire to
prevent noise.
The shielding wire acts to prevent the influence of any outside interference, thereby protecting the signal detected by the sensor; it
also acts to set the measurement standard. If there is improper
connection of the shielding wire (particularly at the connector), or
there is improper grounding of the control unit case, this may cause
disconnections or resistance (increased or reduced) which will
cause abnormalities in the pre-stroke control. To prevent this,
please be sure to carry out the grounding connection of the control
unit and the pre-stroke sensor wiring harness properly.

FUEL INJECTION TIMING CONTROL


The timing for the start of fuel injection from the variable fuel feed rate injection pump is interconnected with the
control of the pre-stroke.
If the fuel feed rate is made high, the pre-stroke will become larger, so this well result in retarding the timing for
the start of fuel injection; if the fuel feed rate is made low, the pre-stroke will become smaller, so this will result
in advancing the timing for the start of fuel injection.
Under actual operating conditions, the fuel feed rate is set high when the engine is rotating at low speed, such
as during warming-up operations, and is set low when the engine is rotating at high speed. Therefore, the timing for the start of fuel injection is also delayed when the engine speed is low and is advanced when the engine
speed is high, which is more or less the same action as with the present timer. In addition, when the weather is
cold, to prevent white smoke, control is carried out by the control unit in accordance with the operating condition of the engine to give the optimum fuel feed rate and timing for the start of injection.

EF-8-13

MD-TICS SYSTEM

SELF-DIAGNOSIS AND BACK-UP FUNCTION


The control unit always uses the signals input from each sensor to
diagnose whether there is any abnormality inside the system. If it
judges that there is an abnormality, it lights up the Engine Control
warning light inside the cluster meter to warn the drive of the abnormality.
At the same time, it carries out a back-up function to move the system to a safe zone where there is no excessive load on the engine.
By using the diagnostic switch, the Diagnosis Display Code is displayed on the diagnosis light (Engine Control warning light and
Overheat warning light), and trouble-shooting is carries out.

Trouble display and back-up


If a failure occurs in the MD-TICS system (refer to Table 1 Failure
Judgement Conditions at the end of the chapter), the Engine Control warning light comes on and displays the occurrence of a failure.
[User mode]
At the same time, the back-up system is actuated to keep the system in the safety zone so that there is no excessive load on the
engine, while making it possible to continue to travel. Table 2 at the
end of the chapter gives details of the back-up operation.

Trouble diagnosis
Trouble diagnosis can be carried out by releasing the diagnostic
switch. The results of the diagnosis are displayed by the diagnosis
light (Engine Control warning light and Overheat warning light)
(flashing light: Diagnosis Display Code). [Dealer mode]
When the Overheat warning light flashes, the buzzer also sounds at
the same time.

EF-8-14

MD-TICS SYSTEM
Engine Control warning light: displays present trouble

Overheat warning light: displays the past trouble (*)

NOTE (*)
z To carry out analysis of past troubles, the system is
equipped with a diagnostic memory function. This function stores in the memory any failure signals for abnormality that occurred during travel. It acts to replay these
signals when carrying out analysis of the trouble.
The signals stored in the memory are retained even when
the ignition key switch is turned OFF.
z Normally, the Overheat warning light lights up when the
engine overheats or when the coolant level becomes too
low. However, when the diagnostic switch is released, it
displays the result of the diagnosis of past troubles in
the MD-TICS system.
The overheat warning function is not incorporated in the
control unit.

EF-8-15

MD-TICS SYSTEM

TROUBLE DIAGNOSIS AND TROUBLE-SHOOTING


The MD-TICS system always uses the signals input from each sensor to diagnose whether there is any
abnormality inside the system.
If it judges that there is an abnormality (for judgement standards, refer to Table 1 at the end of the chapter), it
lights up the Engine Control warning light inside the cluster meter to warn the driver of the abnormality. The
abnormality is displayed by the lighting up of the Engine Control warning light in the cluster meter. If any abnormality occurs, the back-up function is automatically carried out to move the system to a safe zone where there
is no excessive load on the engine. (For details of the back-up operation, refer to Table 2 at the end of the
chapter.)
When the Engine Control warning light lights up to display an abnormality, carry out trouble diagnosis and trouble-shooting using the procedure given below.

EF-8-16

MD-TICS SYSTEM

[1] TROUBLE DISPLAY


If it is judged that there is an abnormality in the MD-TICS system,
the Engine Control warning light comes on to display trouble.
NOTE
z

This is called the User mode. The user mode is displayed when the diagnostics switch is ON (connected).

<Trouble Display Chart>


Item
MD-TICS
Normal
Abnormal

Ignition key switch ON

Remarks

Engine stopped

Engine running

Light ON

Light OFF

Lights come ON to check for blown bulbs

Light ON

Light ON

Abnormality in MD-TICS

Light OFF

Light OFF

Light bulb blown or other abnormality

EF-8-17

MD-TICS SYSTEM

[2] TROUBLE DIAGNOSIS


If the trouble display shows that there is an abnormality in the MD-TICS system, carry out trouble diagnosis
according to the following procedure.
1) TURN THE DIAGNOSTIC SWITCH OFF.
2) IGNITION KEY SWITCH
1. OFF ON: Do not run the engine.
2. After cranking, stop the engine.
With the ignition key switch ON.
3. Run the engine.
Carry out diagnosis under the above three conditions.
NOTE
z

The reason for using these three positions of the ignition key switch is to allow diagnosis to be
carries out under all three conditions so that all troubles can be located.
Refer to Diagnosis Display Code and Trouble Location table.

3)

DISPLAY OF RESULT OF TROUBLE DIAGNOSIS


The result of the trouble diagnosis is displayed by the flashing (Diagnosis Display Code) of the diagnosis light (Engine Control warning light and Overheat warning light)
NOTE
z This is called the Dealer mode. The dealer mode is displayed when the diagnostic switch is
OFF (released).

<Diagnosis Light Display>


Diagnosis light

Engine control warning light

Overheat warning light & buzzer

Displays present trouble

Displays past trouble (*)

Normal

Displays Diagnosis Display Code <0-1>

Key ON: Light ON, Buzzer shows <0-1> code


Eng. ON: Light & Buzzer show Diagnosis Code

Abnormal

Displays Diagnosis Display Code

Displays Diagnosis Display Code

MD-TICS

NOTE (*)
z The diagnostic memory of the control unit has a memory that stores the past trouble conditions, and displays them. When the diagnostic switch is released, it does not show the engine
overheating condition; instead of this, it displays the results of diagnosis of past troubles.
z If the trouble that occurred in the past is the same as the trouble that is occurring at the
present, only the present condition (Engine Control warning light) is displayed.

EF-8-18

MD-TICS SYSTEM

<Diagnosis Display Code and Location of Trouble>


Dealer mode

OFF ON

ON
(after cranking, stop engine)

ON
(engine running)

Diagnosis light
(Engine control warning light
Overheat warning light)

01

OFF

Light bulb blown, etc.

(1)

ON

C.U. power supply system

(2)

13

Rack sensor system

(3)

15

Engine speed sensor system (disconnection)

User mode
[MD-TICS normal or
abnormal]

Diagnosis
display code

Normal

OFF

Location of trouble
(trouble-shooting item number)

Position of ignition key switch (*)

Lighting pattern

(4)
16

Engine speed sensor system (no pulse)

21

Engine coolant temperature sensor system

(5)

23

Pre-stroke sensor system

(6)

12

Pre-stroke servo system

(7)

22

Pre-stroke power supply


system

(8)

24

Pre-stroke learning function

(6)

Abnormal
ON

Note (*)
O: Displayed
X: Not displayed

EF-8-19

MD-TICS SYSTEM

<Explanation of Diagnosis Display Code>


Meaning of Diagnosis Display Code

Actual Display Method for Diagnosis Display Code


The diagnosis light displays the diagnosis continuously as follows.

Example: Compound trouble (1-2 and 1-3 occur together)


After displaying 1-2 three times, 1-3 is displayed three times. After this, 1-2 and 1-3 are displayed
three times each in turn.

EF-8-20

MD-TICS SYSTEM

[3] TROUBLE-SHOOTING
If the trouble diagnosis makes the condition of the trouble clear, go on to trouble-shooting.
The explanation below gives the procedure for trouble-shooting for each trouble location (this forms a pair with
the diagnosis display code).

[Precautions when carrying out trouble-shooting]


(1) Precautions when checking the wiring harness
There is a high probability that problems with the wiring harnesses, such as disconnections, short circuits, and improper contact, will occur at the connector. It is rare for disconnections or short circuits to
occur in the wiring inside the wiring harness, but these problems can occur if there is interference
between the wiring harness and other parts, causing it to ground with the body. When checking for
abnormalities in the wiring harness, be particularly careful to check the following.
1) Is the connector properly connected?
2) Are any pins deformed?
3) Is there any dirt or dust stuck in the terminal, or is there
any corrosion?
4) Is there any disconnection or short circuit at the joint of
the connector.
5) Has the grounding been carries out properly?
6) Is there any interference between the wiring harness
and other parts, or any improper insulation?
(2) Precautions when measuring resistance at connector and
checking continuity
1) When checking the resistance at the connector terminal
and checking the continuity, the terminal hole is small,
so strip the lead wire, insert two or three copper wires,
and make sure that the terminal and lead wire are properly in contact. (For female terminals)

2) Do not insert the test lead of the tester directly into the
connector terminal. If it is pushed in by force, the terminal inside the connector will be expanded and this will
cause improper contact.

3) After completing this operation, check the connection of


the connectors. Be particularly careful with the Z connectors for the engine because these can easily remain
incompletely connected.

EF-8-21

MD-TICS SYSTEM

[Preparation]
Parts name and parts number

Use

Memory clear connector


(24004 00Z09)

To clear diagnostic memory

Circuit tester
(Commercially available; use
tester with digital display)

Inspecting MD-TICS component and circuit

Lead wire x 2 (make yourself)

Connecting tester lead

EF-8-22

Shape

MD-TICS SYSTEM

[How to read wiring diagram]


<Connector No. and terminal No.>

<Abbreviation>
C.U.
U
CF
M
C

: Control Unit
: Unit Harness
: Cab Front Harness
: Main Harness
: Chassis Harness

EF-8-23

MD-TICS SYSTEM
<Connector symbol>

All connector symbols are shown from the terminal side.


The number inside the box shows the number of the pins.

<Connector joint indication>


For single lines, a connector is indicated in the midway of the line.
For plural lines, a connector and connector terminal position are
shown in the midway of the lines. In this vicinity, connector shapes
are shown and terminal positions are indicated by numbers.

EF-8-24

MD-TICS SYSTEM
<How to match connectors>

<Wire size and color code>


Wire size: sectional area (mm2)

Color code:
Unicolor
Alphabetical symbol

Color

White

Black

Red

Yellow

Green

Blue

Pink

BR

Brown

LG

Light green

OR

Orange

PU

Purple

GR

Gray

SB

Sky Blue

When the wire color is striped, the base color is given first, followed by the
stripe color as shown below:
Example: L/W = Blue with White Stripe

EF-8-25

MD-TICS SYSTEM

[Position of harnesses and connectors]

A. Under the passenger seat


Pull out the control unit from under the front passenger seat.

Locations for inspection


1. Control unit proper
2. Unit harness connector U-12 (18 pin, black)
3. Unit harness connector U-13 (12 pin, black)

EF-8-26

MD-TICS SYSTEM

B. Inside of glove compartment


Remove the lid and front cover of the glove compartment.
Locations for inspection
1. Fuse block

C. Under the cab


Tilt the cab and remove the cover.
Locations for inspection
<Type I>
1. Unit harness connector U-4 (6, 12 pin)
2. Unit harness connector U-5 (5, 12 pin)
3. Unit harness connector U-1 (4, 16 pin)
4. Chassis harness connector C-3 (6, 12 pin)
5. Chassis harness connector C-4 (5, 12 pin)
6. Cab front harness connector CF-18 (4, 16 pin)
<Type II>
1. Unit harness connector U-18 (6, 12 pin)
2. Unit harness connector U-17 (5, 8 pin)
3. Unit harness connector U-16 (4, 12 pin)
4. Chassis harness connector C-82 (6, 12 pin)
5. Chassis harness connector C-81 (5, 8 pin)
6. Cab front harness connector CF-23 (4, 12 pin)

D. Front of engine
Location for inspection
1. Engine coolant temperature sensor harness connector C27 (2 pin)
NOTE
z

There are two engine coolant temperature sensors of the


same type beside each other.
The one for the MD-TICS is distinguished by the wiring at
the engine harness end (blue/red, blue/black).

EF-8-27

MD-TICS SYSTEM
2.
3.
4.

Pre-stroke actuator harness connector C-85 (8 pin)


Rack sensor harness connector C-24 (4 pin)
Engine speed sensor harness connector C-22 (3 pin)

E. Inside of electric unit board


Locations for inspection
1. Rack sensor harness connector M-83 (2 pin)

[Service data]
Item

Terminals to measure

Maintenance standard

Control unit power voltage

U-12 (3) - (12) U-12

20 - 28

Rack sensor resistance

C-24 (3) - (2) C-24


C-24 (2) - (1) C-24
C-24 (3) - (1) C-24

92.5 - 101.5
92.5 - 101.5
186

Pre-stroke sensor resistance

C-85 (2) - (5) C-85


C-85 (2) - (4) C-85
C-85 (5) - (4) C-85

5-7
5-7
10 - 14

Resistance

C-85 (7) - (6) C-85

2.5 - 2.9

Power source voltage

U-12 (2) - Body ground

20 - 28

Pre-stroke actuator

Engine speed
sensor

Type I
Type II

Gap from protrusion


Resistance
Gap from protrusion
Resistance

Engine coolant temperature sensor resistance

mm (in)

0.7 - 1.3 (0.028 - 0.051)


C-22 (2) - (1) C-22

mm (in)

C-22 (3) - (2) C-22

2.1 - 2.5

C-27 (1) - (2) C-27

Refer to EF-8-51.
[Engine coolant temperature
and resistance of engine
coolant temperature sensor]

Alignment of lines (B.T.D.C.)


Rack sensor output voltage (Rack out voltage)
when idling (630 - 670 rpm)

867 - 1,073
0.8 - 1.0 (0.031 - 0.039)

3
V

EF-8-28

M-83 (2) - (1) M-83

MTM 1.77

MD-TICS SYSTEM

(1) Checking Diagnosis Light System (light do not light up)


Stays OFF

CHECK

NG

FUSE
1
OK

CHECK
LIGHT

NG

2
OK
CHECK
Check continuity between terminal (4) - light - fuse
OK
4
NG
CHECK
Check continuity between terminal (12) and body ground

NG

3
OK

Replace fuse

Replace C.U.

Repair or replace C.U. GND


line harness

Repair or replace wiring harness for light system, or replace


blown light bulb

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

CHECK (1) Check fuses


1.
2.

Check if the other lights on the cluster meter light up.


Judgement
z
If it lights up fuse is normal go to CHECK (2).
z
If it does not light up replace fuse

EF-8-29

MD-TICS SYSTEM

CHECK (2) Check lights


1.
2.
3.

Turn the ignition key switch OFF, then remove control unit
harness connector U-12.
Turn the ignition switch ON, then use the lead wire to
ground terminal (4) of connector U-12, and check if the light
lights up.
Judgement
z
If it lights up lamp is normal go to CHECK (3).
z
If it does not light up go to CHECK (4).

CHECK (3) Check continuity between control unit and


body ground
1.
2.

Check the continuity between the body and terminal (12) of


control unit harness U-12.
Judgement
z
Continuity abnormality in control unit replace control unit
z
No continuity abnormality in harness repair or
replace harness

EF-8-30

MD-TICS SYSTEM

CHECK (4) Check continuity between control unit


light fuse <Type I>

1.

Check the continuity between the fuse (monitor panel 10A) and terminal (4) of control unit harness
connector U-12.
2. Judgement
z
Continuity check again from CHECK (2).
z
No continuity light bulb blown or disconnection in harness replace light, or repair or replace
harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.

EF-8-31

MD-TICS SYSTEM

CHECK (4) Check continuity between control unit


lamp fuse <Type II>

1.

Check the continuity between the fuse (monitor panel 10A) and terminal (4) of control unit harness
connector U-12.
2. Judgement
z
Continuity check again from CHECK (2).
z
No continuity lamp bulb blown or disconnection in harness replace lamp, or repair or replace
harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.

EF-8-32

MD-TICS SYSTEM

(2) Checking Control Unit Power Supply System (lights do not go out)
Lights stay
lighted up

CHECK
FUSE

NG

1
OK

NG

Replace fuse.
Locate cause of
blown fuse

CHECK
Check power circuit (+end)
4
OK

CHECK
Does light go
out?
2

NO

YES
CHECK
Check power circuit

NG

Check continuity
of unit harness
2
NG

3
OK

Repair or replace
harness for diagnostic light system

CHECK

C.U. abnormal, replace

Repair or replace unit harness

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

EF-8-33

OK

MD-TICS SYSTEM

CHECK (1) Check fuse


1.

Check that the fuse for the control unit power is not blown.
When doing this, measure the voltage at the fuse also.
Voltage values
Unit: V

2.

Place of measurement

Standard value

Fuse for control unit power

20 - 28

Judgement
Fuse is blown replace fuse (voltage is normal)

z
z
z

Fuse is normal go to CHECK (2).


Voltage is not as specified disconnection in harness
between battery and fuse, abnormality in battery
repair harness or inspect battery

CHECK (2) Check that lights go out


1.
2.
3.

Remove connector U-12 from control unit.


Turn the ignition key switch ON.
Judgement
z
Lamp stays ON abnormality in wiring harness of
diagnostic light system repair or replace harness
z
Lamp goes out go to CHECK (3).

CHECK (3) Check power circuit


1.
2.

Turn the ignition key switch ON.


Measure voltage between terminal (3) (+end) and terminal
(12) (end) of control unit harness connector U-12.
Values for voltage of control unit power
Unit: V

3.
z
z

Measurement location

Standard value

Connector U-12, (3) (+end) - (12) (end)

20 - 28

Judgement
Voltage normal replace control unit
Voltage abnormal go to CHECK (4).

EF-8-34

MD-TICS SYSTEM

CHECK (4) Check power circuit (+end)


1.
2.

Turn the ignition key switch ON.


Measure voltage between terminal (3) (+end) of control unit
harness connector U-12 and body ground (end).
Voltage of control unit power
Unit: V

3.

Measurement location

Standard value

Connector U-12, (3) (+end) - body (end)

20 - 28

Judgement
Voltage normal go to CHECK (5)
z
Voltage abnormal harness abnormal repair or
replace
z

CHECK (5) Check continuity of unit harness


1.

Check the continuity between the body and terminal (12) of


control unit harness connector U-12.
2. Judgement
z
Continuity check again from CHECK (3).
z
No continuity harness abnormal repair of replace
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no
abnormality.

EF-8-35

MD-TICS SYSTEM

(3) Checking Rack Sensor System


DIAGNOSIS DISPLAY CODE
1-3

CHECK
Check harness of C.U. portion

NG

1
OK
NG

CHECK

CHECK
Check resistance of rack sensor
3
OK

NG

Check rack sensor output voltage

2
OK
or
NG

C.U. abnormal, replace

Replace injection pump

CHECK
Check each harness
4
OK

Repair or replace harness

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

EF-8-36

MD-TICS SYSTEM

CHECK (1) Check harness at control unit end


1.
2.

Turn the ignition key switch OFF.


Measure the resistance between terminals (22) and (21),
(21) and (27), (22) and (27) of connector U-13.
3. Check the insulation of each terminal and the rack sensor
body.
Resistance and insulation of rack sensor
Unit:
Measurement location

Connector U-13

4.

Standard value

(22) - (21)

92.5 - 101.5

(21) - (27)

92.5 - 101.5

(22) - (27)

186

(21), (22), (27)


Injection pump body

Min. M

Judgement
Resistance value normal rack sensor harness normal go to CHECK (2).
z
Resistance value abnormal check resistance of rack
sensor body go to CHECK (3).
z

CHECK (2) Check output voltage of rack sensor


1.
2.

Start the engine and run the engine at idling speed.


Measure the voltage between terminal (2) (end) and terminal (1) (+end) of rack out connector M-83 inside the control
unit cover.
Rack out voltage (when idling)
Unit: V

3.

Measurement location

Standard
reference value

Connector M-83, (2) (end) - (1) (+end)

MTM 1.77
(630 - 670 rpm)

Judgement
Output voltage normal rack sensor position normal
carry out CHECK (1) again or replace C.U.
z
Output voltage abnormal replace injection pump
assembly
z

EF-8-37

MD-TICS SYSTEM

CHECK (3) Check rack sensor body


1.

Measure the resistance between terminals (3) and (2), (2)


and (1), (3) and (1) of connector C-24.
2. Check the insulation of each terminal and the rack sensor
body.
Resistance and insulation of rack sensor
Unit:
Measurement location

Connector C-24

3.

Standard value

(3) - (2)

92.5 - 101.5

(2) - (1)

92.5 - 101.5

(3) - (1)

186

(2), (3), (1) - Injection


pump body

Min. M

Judgement
Resistance value is as specified go to CHECK (4).
z
Disconnection, short circuit, or resistance value is not
as specified rack sensor abnormal replace injection pump
z

EF-8-38

MD-TICS SYSTEM

CHECK (4) Check harness <Type I>

1.
2.

Turn the ignition key switch OFF.


Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-24 of the rack sensor and harness connector U-13 of the control unit.
Harness

Chassis harness

Connector No.

Terminal

Unit harness

C-24

C-3

U-4

U-13

Check 1

(1)

(6)

(6)

(27)

Check 2

(2)

(5)

(5)

(21)

Check 3

(3)

(4)

(4)

(22)

Check 4

Shield

(7)

(7)

(27)

EF-8-39

MD-TICS SYSTEM
3.

Judgement
If the harness is abnormal (disconnection, short circuit,
etc.) repair or replace the harness
z
If the harness is not abnormal improper output voltage of rack sensor or abnormality in control unit
contact ZEXEL sales for repair
NOTE
z If there is no abnormality in the harness or resistance
value of the rack sensor, the rack sensor output voltage
may be defective or the may be an abnormality in the
control unit. However, the set condition cannot be reenacted when the equipment is mounted on the machine,
so it is difficult to check.
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no
abnormality.
z

EF-8-40

MD-TICS SYSTEM

CHECK (4) Check harness <Type II>

1.
2.

Turn the ignition key switch OFF.


Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-24 of the rack sensor and harness connector U-13 of the control unit.
Harness

Chassis harness

Connector No.

Terminal

Unit harness

C-24

C-82

U-18

U-13

Check 1

(1)

(6)

(6)

(27)

Check 2

(2)

(5)

(5)

(21)

Check 3

(3)

(4)

(4)

(22)

Check 4

Shield

(7)

(7)

(27)

EF-8-41

MD-TICS SYSTEM
3.

Judgement
If the harness is abnormal (disconnection, short circuit,
etc.) repair or replace the harness
z
If the harness is not abnormal improper output voltage of rack sensor or abnormality in control unit
contact ZEXEL sales for repair
NOTE
z If there is no abnormality in the harness or resistance
value of the rack sensor, the rack sensor output voltage
may be defective or the may be an abnormality in the
control unit. However, the set condition cannot be reenacted when the equipment is mounted on the machine,
so it is difficult to check.
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no
abnormality.
z

EF-8-42

MD-TICS SYSTEM

(4) Checking Engine Speed Sensor System


DIAGNOSIS DISPLAY CODE
1 - 5, 1 - 6

CHECK
Check harness of C.U.
portion

NG

1
OK
NG

CHECK
Check resistance of engine
speed sensor body
2

CHECK
Check engine speed sensor
gap

OK
NG

4
OK
or

NG

CHECK
Check each harness
3
OK

Replace C.U.

Adjust gap

Replace engine speed


sensor

Repair or replace harness

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

Reference
If the Diagnosis Display Code is 1-5, it can be taken that there is a disconnection, and if it is 1-6, the problem is something other than disconnection (short circuit, improper adjustment of gap, etc.).

EF-8-43

MD-TICS SYSTEM

CHECK (1) Check harness at control unit end


1.
2.

Turn the ignition key switch OFF and remove connector U12.
Measure the resistance between terminal (9) and terminal
(18) of unit harness connector U-12.

3.

Check the insulation between terminal (9) of connector U12 and the body.
4. Check the insulation between terminal (18) of connector U12 and the body.
Resistance of engine speed sensor
Unit: k
Measurement location
(9) - (18)
Connector U-12

(9) - Body
(18) - Body

5.

Standard value
2.1 - 2.5

Judgement
Resistance value is as specified sensor normal
go to CHECK (4).
z
Disconnection, short circuit, defective insulation, or
resistance value is not as specified go to CHECK
(2).
z

CHECK (2) Check engine speed sensor body <Type I>


1.

Measure the resistance between terminal (1) and terminal


(2) of harness connector C-22 of engine speed sensor.
2. Check the insulation between the body and terminals (3),
(2), and (1) of connector C-22.
Resistance of engine speed sensor
Unit:
Measurement location
(2) - (1)
Connector C-22

Standard value
867 - 1,073

(3) - Body
(2) - Body

(1) - Body

EF-8-44

MD-TICS SYSTEM
3.

Judgement
Resistance value is as specified sensor normal
go to CHECK (3).
z
Disconnection, short circuit, defective insulation, or
resistance value is not as specified replace sensor
go to CHECK (4).
z

CHECK (2) Check engine speed sensor body <Type II>


1.

Measure the resistance between terminal (3) and terminal


(2) of harness connector C-22 of engine speed sensor.
2. Check the insulation between the body and terminals (3),
(2), and (1) of connector C-22.
Resistance of engine speed sensor
Unit: k
Measurement location
(3) - (2)
Connector C-22

Standard value
2.1 - 2.5

(3) - Body
(2) - Body

(1) - Body

3.

Judgement
Resistance value is as specified sensor normal
go to CHECK (3).
z
Disconnection, short circuit, defective insulation, or
resistance value is not as specified replace sensor
go to CHECK (4).
z

EF-8-45

MD-TICS SYSTEM

CHECK (3) Check for abnormality in harness <Type I>

1.

Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-22 of the engine speed sensor and harness connector U-12of the control unit.
Harness

Chassis harness

Connector No.
Terminal

2.

Unit harness

C-22

C-3

U-4

U-12

Check 1

(2)

(2)

(2)

(18)

Check 2

(3)

(1)

(1)

(9)

Check 3

(1)

(3)

(3)

(18)

Judgement
z
If the harness is abnormal (disconnection, short circuit, etc.) repair or replace the harness
z
If the harness is not abnormal abnormality in control unit replace control unit

EF-8-46

MD-TICS SYSTEM

CHECK (3) Check for abnormality in harness <Type II>

1.

Refer to the table below and check for continuity, short circuit, and insulation between harness connector C-22 of the engine speed sensor and harness connector U-12of the control unit.
Harness

Chassis harness

Connector No.
Terminal

Unit harness

C-22

C-82

U-18

U-12

Check 1

(2)

(2)

(2)

(18)

Check 2

(3)

(1)

(1)

(9)

Check 3

(1)

(3)

(3)

(18)

Judgement
z
If the harness is abnormal (disconnection, short circuit, etc.) repair or replace the harness
z
If the harness is not abnormal abnormality in control unit replace control unit

EF-8-47

MD-TICS SYSTEM

CHECK (4) Check engine speed sensor gap <Type I>


1.

Check the gap between the engine speed sensor and the
drive gear (Air compressor).
Standard value for engine speed sensor gap
Unit: mm (in)
0.7 - 1.3 (0.028 - 0.051)

2.

Judgement
Gap normal check again from CHECK (1), or
replace C.U.
z
Gap defective adjust as follows
1) Align the centers of the engine speed sensor and the
protrusions on the drive gear (Air compressor).
2) Set so that the end face of the sensor contacts the protrusions, then turn back one turn and lock with the locknut.
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no
abnormality.
z

CHECK (4) Check engine speed sensor gap <Type II>


1.

Check the gap between the engine speed sensor and the
protrusions on the coupling (flywheel) of the injection pump.
Standard value for engine speed sensor gap
Unit: mm (in)
0.8 - 1.0 (0.031 - 0.039)

2.

Judgement
z
Gap normal check again from CHECK (1), or
replace C.U.
z
Gap defective adjust as follows
1) Align the centers of the engine speed sensor and the
protrusions on the coupling (flywheel) of the injection
pump.
2) Set so that the end face of the sensor contacts the protrusions, then turn back one turn and lock with the locknut.
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no
abnormality.

EF-8-48

MD-TICS SYSTEM

(5) Checking Engine Coolant Temperature Sensor System


DIAGNOSIS DISPLAY CODE
2-1

CHECK
Check harness at C.U. portion

NG

1
OK
CHECK
NG

or

Check engine coolant temperature sensor


2
OK

NG

Replace C.U.

Replace engine coolant temperature sensor

CHECK
Check each harness
3
OK

Repair or replace harness

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

EF-8-49

MD-TICS SYSTEM

CHECK (1) Check harness between engine coolant


temperature sensors at control unit
1.
2.
3.

Turn the ignition key switch ON.


Remove control unit harness connectors U-12 and U-13.
Measure the resistance between terminal (14) of connector
U-12 and terminal (19) of connector U-13.

4.

Check for insulation and short circuit between the body and
terminal (14) of connector U-12 and terminal (19) of connector U-13.
Resistance of engine coolant temperature sensor
Sensor resistance (x102)

454

270

55

Engine coolant temperature


C (F)

Sensor
error

40
(40)

39
(38)

1 (30)

3.2

1.8

0.9

111
(232)

130
(266)

Sensor
error

24
20 (68)

5.

12

40 (104) 62 (144) 86 (187)

Judgement
z
Resistance corresponds to engine coolant temperature
sensor normal
z
Disconnection, short circuit, or defective insulation, or
resistance does not correspond to engine coolant temperature go to CHECK (2).

EF-8-50

MD-TICS SYSTEM

CHECK (2) Check engine coolant temperature sensor


body
1.

2.

Measure the resistance between terminals (1) and (2) of


engine coolant temperature sensor harness connector C27.
For details of the resistance value of the engine coolant
temperature sensor, see the table for CHECK (1).

Judgement
Resistance corresponds to engine coolant temperature
engine coolant temperature sensor normal go to
CHECK (3).
z
Disconnection, short circuit, or defective insulation, or
resistance does not correspond to engine coolant temperature engine coolant temperature sensor abnormal replace engine coolant temperature sensor
z

EF-8-51

MD-TICS SYSTEM

CHECK (3) Check for abnormality in harness <Type I>

1.

Check for continuity, short circuit, and insulation between control unit harness connectors U-12 and
U-13 and harness connector C-27 of the engine coolant temperature sensor.
Harness

Chassis harness

Connector No.
Terminal

Unit harness

C-27

C-4

U-5

Check 1

(1)

(5)

(5)

Check 2

(2)

(4)

(4)

2.

U-13

U-12
(14)

(19)

Judgement
If harness is abnormal (disconnection, short circuit) repair or replace harness
z
If there is no abnormality in the harness carry out CHECK (1) again if it is normal, the control unit is abnormal replace unit
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.
z

EF-8-52

MD-TICS SYSTEM

CHECK (3) Check for abnormality in harness <Type II>

1.

Check for continuity, short circuit, and insulation between control unit harness connectors U-12 and
U-13 and harness connector C-27 of the engine coolant temperature sensor.
Harness

Chassis harness

Connector No.
Terminal

Unit harness

C-27

C-81

U-17

Check 1

(1)

(5)

(5)

Check 2

(2)

(4)

(4)

2.

U-13

U-12
(14)

(19)

Judgement
If harness is abnormal (disconnection, short circuit) repair or replace harness
z
If there is no abnormality in the harness carry out
CHECK (1) again if it is normal, the control unit is abnormal replace unit
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.
z

EF-8-53

MD-TICS SYSTEM

(6) Checking Pre-stroke Sensor System


DIAGNOSIS DISPLAY CODE
2 - 3 or 2 - 4

CHECK
Check wiring harness at C.U. portion

NG

1
OK

If error is 1-2, check pre-stroke actuator

CHECK

NG

Check pre-stroke
sensor
2
OK

NG

Check each
harness
3
OK

or

CHECK

If abnormality is 1-2 or 2-4, operation


of pre-stroke actuator is probably
defective

Replace C.U.

Replace injection pump

Repair or replace
harness

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

EF-8-54

MD-TICS SYSTEM

CHECK (1) Check harness between pre-stroke sensors


at control unit
1.
2.

Turn the ignition key switch OFF.


Measure the resistance between terminals (23) and (24),
(23) and (29), and (24) and (29) of control unit harness connector U-13.
Resistance value for pre-stroke sensor
Unit:
Measurement location
Connector U-13

3.

Standard value

(23) - (24)

5-7

(23) - (29)

5-7

(24) - (29)

10 - 14

Judgement
z
Resistance is as specified pre-stroke sensor normal
check pre-stroke actuator (refer to (7) Check prestroke servo system)
z
Resistance value is not as specified disconnection,
short circuit, or pre-stroke sensor abnormal go to
CHECK (2).

CHECK (2) Check pre-stroke sensor body


1.
2.

Turn the ignition key switch OFF.


Measure the resistance between terminals (2) and (5), (2)
and (4), and (5) and (4) of pre-stroke sensor harness connector C-85.
Resistance value for pre-stroke sensor
Unit:
Measurement location
Connector C-85

3.

Standard value

(2) - (5)

5-7

(2) - (4)

5-7

(5) - (4)

10 - 14

Judgement
z
Resistance is as specified pre-stroke sensor normal
check harness go to CHECK (3).
z
Resistance value is not as specified pre-stroke sensor abnormal replace pre-stroke sensor (injection
pump assembly)

EF-8-55

MD-TICS SYSTEM

CHECK (3) Check for abnormality in harness <Type I>

1.
2.

Turn the ignition key switch OFF.


Check continuity between pre-stroke sensor harness connector C-85 and control unit harness connector U-13.
Harness

Chassis harness

Connector No.

Terminal

Unit harness

C-24

C-82

U-4

U-13

Check 1

(1)

(12)

(12)

(30)

Check 2

(2)

(11)

(11)

(23)

Check 3

(3)

(10)

(10)

(29)

Check 4

(4)

(9)

(9)

(29)

Check 5

(5)

(8)

(8)

(24)

3.

Judgement
Continuity is as specified control unit abnormal replace control unit
z
Continuity is not as specified harness abnormal repair or replace harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.
z

EF-8-56

MD-TICS SYSTEM

CHECK (3) Check for abnormality in harness <Type II>

1.
2.

Turn the ignition key switch OFF.


Check continuity between pre-stroke sensor harness connector C-85 and control unit harness connector U-13.
Harness

Chassis harness

Connector No.

Terminal

Unit harness

C-85

C-82

U-18

U-13

Check 1

(1)

(12)

(12)

(30)

Check 2

(2)

(11)

(11)

(23)

Check 3

(3)

(10)

(10)

(29)

Check 4

(4)

(9)

(9)

(29)

Check 5

(5)

(8)

(8)

(24)

3.

Judgement
Continuity is as specified control unit abnormal replace control unit
z
Continuity is not as specified harness abnormal repair or replace harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.
z

EF-8-57

MD-TICS SYSTEM

(7) Checking Pre-stroke Servo System


DIAGNOSIS DISPLAY CODE
1-2

CHECK
Check wiring harness at C.U. portion

NG

1
OK

NG

Check pre-stroke actuator also

CHECK
Check resistance
of pre-stroke
actuator
2
OK

or

CHECK
NG

Operation of pre-stroke actuator is


probably defective

Replace C.U.

Replace injection pump

Check each
harness
3
OK

Repair or replace
harness

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

EF-8-58

MD-TICS SYSTEM

CHECK (1) Check harness between pre-stroke actuator


at control unit end
1.

Turn the ignition key switch OFF, then remove control unit
harness connector U-12.
2. Measure the resistance between terminals (1) and (10) of
harness connector U-12.
Resistance value for pre-stroke sensor
Unit:
Measurement location
Connector U-12

3.

(1) - (10)

Standard value
2.5 - 2.9

Judgement
Resistance is as specified check pre-stroke sensor
z
Resistance value is not as specified pre-stroke actuator or harness abnormal go to CHECK (2).
z

CHECK (2) Check pre-stroke actuator body


1.

Turn the ignition key switch OFF, then remove the harness
connector of the pre-stroke actuator.
2. Measure the resistance between terminals (7) and (6) of
connector C-85 at the pre-stroke actuator end.
Resistance value for pre-stroke sensor
Unit:
Measurement location
Connector U-85

3.

(7) - (6)

Standard value
2.5 - 2.9

Judgement
Resistance is as specified pre-stroke actuator normal check harness go to CHECK (3).
z
Resistance value is not as specified replace injection pump
z

EF-8-59

MD-TICS SYSTEM

CHECK (3) Check for abnormality in harness <Type I>

1.
2.

Turn the ignition key switch OFF.


Check continuity between pre-stroke actuator connector C-85 and control unit connector U-12.
Harness

Chassis harness

Connector No.
Terminal

Unit harness

C-85

C-4

U-5

U-12

Check 1

(6)

(7)

(7)

(10)

Check 2

(7)

(6)

(6)

(1)

3.

Judgement
Continuity is normal check for CHECK (1) again replace control unit or replace injection
pump
z
Continuity is not normal harness abnormal repair or replace harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic light and confirm that there is no abnormality.
z

EF-8-60

MD-TICS SYSTEM

CHECK (3) Check for abnormality in harness <Type II>

1.
2.

Turn the ignition key switch OFF.


Check continuity between pre-stroke actuator connector C-85 and control unit connector U-12.
Harness

Chassis harness

Connector No.
Terminal

Unit harness

C-85

C-81

U-17

U-12

Check 1

(6)

(7)

(7)

(10)

Check 2

(7)

(6)

(6)

(1)

3.

Judgement
Continuity is normal check for CHECK (1) again replace control unit or replace injection
pump
z
Continuity is not normal harness abnormal repair or replace harness
NOTE
z After completing each operation, carry out trouble-shooting with the diagnostic lamp and confirm that there is no abnormality.
z

EF-8-61

MD-TICS SYSTEM

(8) Checking Pre-stroke Power Supply System


DIAGNOSIS DISPLAY CODE
2-2

NG

CHECK
FUSE
1

or

OK

CHECK
Check continuity between fuse
and connector

NG

2
OK
or

Replace fuse

Replace C.U.

Repair or replace harness or


pre-stroke cut relay

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

EF-8-62

MD-TICS SYSTEM

CHECK (1) Check fuse


1.

Check that the power fuse for the pre-stroke actuator is not
blown.
2. Measure the voltage at the fuse portion.
Value for power source voltage
Unit: V

3.

Measurement location

Standard value

Power source fuse for pre-stroke actuator

20 - 28

Judgement
Fuse is blown (voltage is normal) after finding
cause, replace fuse
z
Fuse is normal go to CHECK (2).
z
Voltage is not as specified disconnection in harness
between battery and fuse, battery abnormal repair
harness or check battery
z

CHECK (2) Check harness between unit and power


source for pre-stroke actuator system
1.

Remove all harness connectors from the control unit, turn


the ignition key switch ON, then measure the voltage the
body(end) and between terminal (2) (+end) of connector
U-12.
Value for power source voltage
Unit: V

2.

Measurement location

Standard value

Connector U-12, (2) (+end) - body (end)

20 - 28

Judgement
Voltage is as specified control unit abnormal
replace control unit
z
Voltage is not as specified abnormality in power harness between power harness connectors, or pre-stroke
cut relay abnormal repair or replace harness, or
replace pre-stroke cut relay
z

EF-8-63

MD-TICS SYSTEM

[4] CLEARING DIAGNOSTIC MEMORY


To clear the diagnostic memory, short circuit the memory reset
switch at the behind the electrical unit board.

<Procedure for Clearing>


1.
2.
3.

Release the diagnostic switch.


Turn the ignition key switch ON.
Check that the Overheat warning light is displaying the
Diagnosis Display Code.
4. Connect the harness or memory clear connector (24004
00Z09) to the memory reset switch terminal, and short circuit the switch.
NOTE
z When connecting the harness, the battery voltage is
applied to the Y/R cord side, so be careful not to short
circuit any other part.
5.

Check that the Overheat warning light and buzzer display


shows the normal Diagnosis Display Code (0-1). The memory will be erased in about ten seconds.
6. Remove the special connector or harness from the memory
reset switch terminal.
7. Connect the diagnostic switch.
8. Turn the ignition key switch OFF, then turn the ignition key
switch ON again and check that the Overheat warning
buzzer shows code <0-1>.
NOTE
z If the ignition key switch is turned ON with the sensor terminals still disconnected, a trouble signal will be
recorded in the memory.

EF-8-64

MD-TICS SYSTEM

APPENDIX
Table 1 Failure Judgement Conditions For MD-TICS System
Trouble system

Failure judgement conditions

Judgement
time (sec)

C.U. power voltage system

When voltage at C.U. power terminal (3)


is less than approx. 0V

Immediate

When control unit power source


voltage recovers

When the detected voltage has


become normal, or when the
engine speed is no longer under
judgement conditions.

Reset when pulse is input

Rack sensor system

Engine speed sensor


system

1) When detected voltage is 3.5V or


more at all speed ranges
2) When detected voltage is less than
0.2V at 300 - 1,600 rpm
1) When resistance for all engine speed
sensors (including harness) is more
than 50 k (disconnection)
2) When the pulse cannot be recognized
with the ignition key switch at the
START position

Immediate

Reset condition

Reset when pulse is input After


error judgement is reset, and ignition key switch is turned again to
START, then start again

Engine coolant temperature sensor system

When detected voltage (resistance) is


0.1V (30) or less, or 4.9V (73.5) or
more

When the detected voltage has


become normal

Pre-stroke sensor system

When detected voltage is 0.9V or less,


or 3.4V or more

When the detected voltage has


become normal

Pre-stroke servo system

When difference between target value


and detected value is more than 3.9 at
pre-stroke actuator angle

20

Do not reset while power remains


ON

Pre-stroke power voltage


system

When detected voltage at pre-stroke


actuator power terminal (2) is 1.5V or
less

When power voltage is reset

When electricity is not passing through


Pre-stroke learning func- pre-stroke actuator, detected voltage of
tion system
pre-stroke sensor is 1.0V or less or 1.4V
or more

EF-8-65

2.4

Do not reset while power remains


ON

MD-TICS SYSTEM
Table 2 BACK-UP Operations For MD-TICS System
Back-up operation
Trouble system

Diagnosis display code

Pre-stroke control

Max. injection
limit by boost
compensator cut
(Yes: O, No: X)

Expected result

Control stopped (pre-stroke:


injection timing fixed at most
retarded angle)

Lack of power, excessive


white smoke

Pre-stroke control characteristic


fixed at characteristic for full
load

No abnormality is felt

1-5 or 1-6

Fixed at a constant pre-stroke


value

Slight lack of power

Engine coolant temperature sensor system

2-1

Control is carried out assuming


engine coolant temperature of
80C (176F)

Excessive white smoke


when cold.

Pre-stroke sensor system

2-3

Control stopped (pre-stroke:


injection timing fixed at most
retarded angle)

Lack of power, excessive


white smoke

Pre-stroke servo system

1-2

Same as above

Same as above

Pre-stroke power voltage system

2-2

Same as above

Same as above

Pre-stroke learning
function system

2-4

Controlled with learning compensation at 0

Engine performance
changes slightly but no
abnormality is felt

C.U. power voltage


system

Stays lighted
up

Rack sensor system

1-3

Engine speed sensor


system

EF-8-66

MD-TICS SYSTEM

Terminal Connection Drawing <Type I>

EF-8-67

MD-TICS SYSTEM

Terminal Connection Drawing <Type II>

EF-8-68

MD-TICS SYSTEM

- MEMO -

EF-8-69

MD-TICS SYSTEM

Wiring Diagram <Type I>

EF-8-70

MD-TICS SYSTEM

EF-8-71

MD-TICS SYSTEM

Wiring Diagram <Type II>

EF-8-72

MD-TICS SYSTEM

EF-8-73

- MEMO -

AIR INTAKE AND EXHAUST SYSTEM

CONTENTS
SERVICE DATA ...................................... IE-1-1
SPECIFICATIONS............................................
SERVICE DATA ...............................................
TIGHTENING TORQUE ...................................
INTAKE AND EXHAUST SYSTEM ..................

IE-1-1
IE-1-3
IE-1-4
IE-1-6
TOOLS .................................................... IE-2-1
AIR CLEANER ........................................ IE-3-1
CONSTRUCTION............................................. IE-3-1
REPLACING AIR CLEANER ELEMENT .......... IE-3-3
TURBOCHARGER.................................. IE-4-1

= MODELS T04B AND T04E =


CONSTRUCTION.............................................
REMOVAL ........................................................
DISASSEMBLY ................................................
INSPECTION....................................................
REASSEMBLY .................................................
INSTALLATION ................................................

IE-4-1
IE-4-1
IE-4-2
IE-4-6
IE-4-9
IE-4-13

= MODELS RHC62E AND RHC6V =


CONSTRUCTION.............................................
REMOVAL ........................................................
DISASSEMBLY ................................................
INSPECTION....................................................
REASSEMBLY .................................................

IE-4-14
IE-4-15
IE-4-16
IE-4-20
IE-4-22

INSTALLATION ................................................ IE-4-24

EXHAUST SYSTEM ................................ IE-5-1


REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
INSTALLATION ................................................
INSPECTION AFTER INSTALLATION.............

EXHAUST BRAKE ..................................


= CHAMBER TYPE =
CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................
INSTALLATION ................................................

IE-5-1
IE-5-2
IE-5-2
IE-5-3
IE-5-4
IE-6-1
IE-6-1
IE-6-1
IE-6-2
IE-6-4
IE-6-4
IE-6-5

= CYLINDER TYPE =
CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................
INSTALLATION ................................................

IE-6-6
IE-6-8
IE-6-9
IE-6-14
IE-6-15
IE-6-16

IE

SERVICE DATA

SERVICE DATA
SPECIFICATIONS
AIR CLEANER
Engine model
Max. gross output

FE6A
kW {PS/rpm}

FE6B

118 {160}/3,000

119 {162}/3,000

132 {180}/3,000

Paper element (Dry type)


Type I (Single) or Type II (Dual)

Type

Type III (Single)


or Type IV (Dual)

135 {183}/3,000

151 {205}/2,800

Engine model
Max. gross output

FE6T
kW {PS/rpm}

162 {220}/2,800

Paper element (Dry type)


Type I (Single) or Type II (Dual)
Type

Type III (Single)


or Type IV (Dual)

Type V (Single) or Type VI (Dual)

Engine model
Max. gross output

FE6TA
kW {PS}/rpm

173 {235}/2,800

157 {213}/2,800

Paper element (Dry type)


Type I (Single) or Type II (Dual)

Type

Type III (Single) or Type IV (Dual)

Type VII (Single)

T04B

T04E

External dimensions (Length x Width x


Height)
mm (in)

220 x 190 x 160


(8.66 x 7.48 x 6.30)

230 x 195 x 265


(9.06 x 7.68 x 10.43)

Max. permissible continuous speed


rpm

138,000

125,000

TURBOCHARGER
Models T04B and T04E
Model

Direction of rotation
Air volume
Compression ratio

Counterclockwise as viewed from the exhaust turbine side


kg (lb)/min

21 (46)

20 (44)

3.2

3.0

IE-1-1

SERVICE DATA

Models RHC62E and RHC6V


Model
External dimensions (Length x Width x
Height)
mm (in)

RHC62E

RHC6V

218 x 238 x 145


(8.58 x 9.37 x 5.71)

246 x 214 x 196


(9.69 x 8.43 x 7.72)

Max. permissible continuous speed


rpm
Direction of rotation
Air volume

140,000
Counterclockwise as viewed from the exhaust turbine side

kg (lb)/min

18.8 (41.5)

19.4 (42.8)

Compression ratio

3.2

EXHAUST BRAKE
Engine model
Max. gross output

FE6A
kW {PS}/rpm

FE6B

118 {160}/3,000

119 {162}/3,000

132 {180}/3,000

Type

Chamber type

Cylinder type

Operating method

Vacuum type

Air type

286-04505

*286-04446 (286-04442)

Model

Engine model
Max. gross output

FE6T
kW {PS}/rpm

135 {183}/3,000

151 {05}/2,800

Type

Cylinder type

Operating method

Air type
*286-04446 (286-04442)
*286-04453 (286-04441)
286-06109

Model

*286-04446
(286-04442)

Engine model
Max. gross output

286-06109

FE6TA
kW {PS}/rpm

157 {213}/2,800

Type

173 {235}/2,800
Cylinder type

Operating method

Air type
*286-04446 (286-04442)
*286-04453 (286-04441)

Model

NOTE
z

162 {220}/2,800

*286-04446 (New) 286-04442 (Former)


*286-04453 (New) 286-04441 (Former)

IE-1-2

SERVICE DATA

SERVICE DATA
TURBOCHARGER
Models T04B and T04E
Unit: mm (in)
Maintenance standard

Service limit

Play in shaft axial direction

Item

0.025 - 0.080 (0.0010 - 0.0031)

Play in shaft radial direction

0.08 - 0.15 (0.0031 - 0.0059)

0.011 (0.0004)

Journal part

10.16 (0.4000)

Piston ring part

17.34 (0.6827)

Inside diameter of back plate

12.71 (0.5004)

Distance between contact surface of thrust collar and


end of plate

11.66 (0.4591)

Bearing part

15.81 (0.6224)

Piston ring part

18.06 (0.7110)

4.36 (0.1717)

Runout of shaft
Outside diameter of shaft

Inside diameter of center housing


Thrust bearing thickness

Remarks

Models RHC62E and RHC6V


Unit: mm (in)
Item
Turbine wheel
shaft

Thrust bushing,
Oil thrower,
Thrust bearing

Maintenance standard

Service limit

Outside diameter of journal

10.39 (0.4091)

Outside diameter of seal ring


groove

1.33 (0.0524)

Runout

0.011 (0.0004)

Distance between thrust bushing


grooves

4.08 (0.1606)

1.25 (0.0492)

Seal ring
groove width

Small diameter

1.46 (0.0575)

Thrust bearing width

3.98 (0.1567)

Inside diameter

10.44 (0.4110)

Outside diameter

14.98 (0.5898)

Inside diameter

15.10 (0.5945)

Seal ring insertion hole

17.03 (0.6705)

Small diameter

12.45 (0.4902)

Large diameter

14.05 (0.5531)

Play in shaft axial direction

0.05 - 0.08 (0.0020 - 0.0031)

0.10 (0.0039)

Play in shaft radial direction

0.08 - 0.12 (0.0031 - 0.0047)

0.17 (0.0067)

Floating bearing
Center housing
Seal plate

Seal ring
insertion hole

Large diameter

IE-1-3

Remarks

SERVICE DATA

EXHAUST BRAKE
Chamber type
Unit: mm (in)
Item
Clearance between
valve and body

Only one side


Both total

Maintenance standard

Service limit

Remarks

0.80 - 1.05
(0.0315 - 0.0413)

1.6 - 2.1
(0.063 - 0.083)

When 86.6 - 93.3 kPa


{650 - 700 mmHg, 25.59 - 27.56 inHg}
Vacuum pressure is applied to power
chamber

Cylinder type
<Models 286-04446 (286-04442), 286-04453 (286-04441) and 286-06109>
Unit: mm (in)
Item

Maintenance
standard

Service limit

Spindle O.D.

286-04446 (286-04442)
286-04453 (286-04441)

16.50 (0.6496)

16.43
(0.6468)

Clearance between
spindle and bushing

286-04446 (286-04442)
286-04453 (286-04441)

0.3 - 0.4
(0.012 - 0.016)

Clearance between
bushing and body

286-04446 (286-04442)
286-04453 (286-04441)

0.015 - 0.090
(0.0006 - 0.0035)

0.80 - 1.05
(0.0315 - 0.0413)

1.6 - 2.1
(0.063 - 0.083)

Free length

151.5 (5.965)

Tension
N {kgf, lbf}

134.4 - 161.2
{13.70 - 16.44,
30.2 - 36.3}

Clearance between
valve and body

286-04446
(286-04442)
286-04453
(286-04441)

Air cylinder spring

286-04446
(286-04442)
286-04453
(286-04441)
286-06109

Only one side


Both total

Remarks

When an air pressure of 637


kPa {6.5 kgf/cm2, 92 psi} is
applied to the air cylinder and
the valve is fully closed

When compressed to
107.8 mm (4.244 in)

TIGHTENING TORQUE
TURBOCHARGER
Models T04B and T04E
Unit: Nm{kgfcm, inlbf}
Item
Compressor wheel lock nut
Back plate and center housing mounting bolt

Tightening torque
2.1 - 2.3 {21 - 23, 18 - 20} Tighten (110)
8.4 - 10.2 {86 - 104, 75 - 90}

Turbine housing and center housing mounting bolt

18.0 - 21.5 {184 - 219, 160 - 190}

Compressor housing and back plate mounting bolt

11.3 - 14.7 {115 - 150, 100 - 130}

IE-1-4

Remarks

SERVICE DATA

Models RHC62E and RHC6V


Unit: Nm {kgfcm, ftlbf}
Item

Tightening torque

Turbine housing mounting bolt

Remarks

27.0 - 28.9 {275 - 295, 239 - 256}

Compressor housing mounting bolt

7.4 - 8.3 {75 - 85, 65 - 74}

Thrust bearing mounting screw

1.2 - 1.4 {12 - 14, 10 - 12}

Seal plate mounting screw

3.4 - 4.0 {35 - 41, 30 - 36}

Compressor impeller mounting nut

5.1 - 5.9 {52 - 60, 45 - 52}

With Torx driver

EXHAUST BRAKE
Chamber type
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Stopper bolt lock nut

5 - 7 {0.5 - 0.7, 3.6 - 5.1}

Cover mounting bolt (at body)

10 - 16 {1.0 - 1.6, 7 - 12}

Body-to-bracket mounting bolt

10 - 16 {1.0 - 1.6, 7 - 12}

Lever mounting nut

10 - 16 {1.0 - 1.6, 7 - 12}

Clevis adjusting nut

10 - 16 {1.0 - 1.6, 7 - 12}

Power chamber mounting nut

10 - 16 {1.0 - 1.6, 7 - 12}

Cover mounting bolt

5 - 7 {0.5 - 0.7, 3.6 - 5.1}

Cylinder type
<Models 286-04446 (286-04442), 286-04453 (286-04441) and 286-06109>
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Stopper bolt lock nut

286-04446 (286-04442)
286-04453 (286-04441)

10 - 16 {1.0 - 1.6, 7 - 12}

Cover mounting bolt (at body)

286-04446 (286-04442)
286-04453 (286-04441)

21 - 26 {2.1 - 2.7, 15 - 20}

Body-to-plate mounting bolt

286-04446 (286-04442)
286-04453 (286-04441)

21 - 26 {2.1 - 2.7, 15 - 20}

Lever mounting nut

286-04446 (286-04442)
286-04453 (286-04441)

10 - 16 {1.0 - 1.6, 7 - 12}

Cylinder shaft nut

286-04446 (286-04442)
286-04453 (286-04441)
286-06109

10 - 16 {1.0 - 1.6, 7 - 12}

Air cylinder cover mounting bolt

286-04446 (286-04442)
286-04453 (286-04441)
286-06109

10 - 16 {1.0 - 1.6, 7 - 12}

Insulator (air cylinder) to shield plate


bolt and nut

286-04446 (286-04442)
286-04453 (286-04441)
286-06109

21 - 25 {2.1 - 2.6, 15 - 19}

IE-1-5

SERVICE DATA

INTAKE AND EXHAUST SYSTEM


INTAKE SYSTEM
FE6A, FE6B and FE6T
For suction under the cab

For suction behind the cab

IE-1-6

SERVICE DATA

FE6TA

EXHAUST SYSTEM (EXAMPLE)

IE-1-7

TOOLS

TOOLS
TURBOCHARGER
Models T04B and T04E
Tool name and number

Description

Turbocharger tool kit


99760 Z5500

Used when disassembling and reassembling


the turbocharger.

Radial play measuring tool


99764 96000

Used to measure play in the radial direction of


the turbine wheel.

Radial play adapter


99765 96000

Adapter mounted to the end of the dial gauge


when measuring radial play.

End play measuring tool


99766 96000

Used when measuring axial play of the turbine


wheel.

End play adapter


99765 96001

Adapter mounted to the end of the dial gauge


when measuring end play

Pick
99767 96003

Used when fitting the piston ring of the shaft to


the center housing

IE-2-1

Shape

TOOLS

Tool name and number

Description

T-handle
99773 96000

Used to remove and install the compressor


wheel lock nut.

Torque wrench
99537 96001

Used to tighten and disassemble the center


housing and back plate.
Torque 9.3 Nm {95 kgfcm, 82 inlbf}

Piston ring guide


99763 Z5500

Used when inserting the piston ring to the turbine wheel.

Retaining ring plier


99546 Z5500

Used when removing the retaining ring at the


center housing.

Holding fixture
99768 Z5500

Used when disassembling and assembling the


rotating assembly.

Torque wrench
99537 Z5500

Used to tighten and remove the turbine housing and center housing.
Torque 16.7 Nm {170 kgfcm, 148 inlbf}

IE-2-2

Shape

TOOLS

Tool name and number

Description

Torque wrench
99537 Z5501

Used to tighten and remove the turbine housing and center housing.
Torque 16.7 Nm {170 kgfcm, 148 inlbf}

Torque wrench
99537 Z5502

Used to tighten and remove the compressor


housing and back plate.
Torque 12.7 Nm {130 kgfcm, 113 inlbf}

Hex socket head bolt


14220 Z9001

Used when mounting the radial play measuring tool.

Shape

Models RHC62E and RHC6V


Tool name

Description

Bar

Used to remove the thrust bearing and bushing

Measuring needle

Attached to the dial gauge for measurement of


free play in both axial and radial directions.

IE-2-3

Shape

TOOLS

Tool name

Description

Plier

Used to remove or install the retaining ring

Plier

Used to remove or install the seal ring.

Torx driver

Used to install the thrust bearing and seal


plate.

Torque wrench

Used to tighten bolts and nuts.


M8 ... 13 mm (0.51 in) 27.9 Nm {285 kgfcm,
247 inlbf}
M6 ... 10 mm (0.39 in) 7.8 Nm {80 kgfcm,
69 inlbf}
M6 ... 10 mm (0.39 in) 5.3 Nm {54 kgfcm,
47 inlbf}

Box spanner

Used to prevent turbine wheel from turning


during installation.
11 mm (0.43 in) x 12 angular type

Measuring needle

Used to measure free play in both axial and


radial direction.

IE-2-4

Shape

AIR CLEANER

AIR CLEANER
CONSTRUCTION
Type I

Type II

IE-3-1

AIR CLEANER

Type III and Type IV

Type V, Type VI and Type VII

IE-3-2

AIR CLEANER

REPLACING AIR CLEANER ELEMENT


For inspection and maintenance procedures, refer to the MA section.

Type I and Type II

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Clip
2. Cover
3. Packing

4. Inner element (Type II only)


5. Outer element

IE-3-3

6. Evacuator valve
7. Body assembly

AIR CLEANER

Type III and Type IV

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Clip
2. Cover
3. Packing

4. Inner element (Type IV only)


5. Outer element

6. Evacuator valve
7. Body assembly

Type V, Type VI and Type VII

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Wing nut
2. Packing
3. Cover
4. Packing

5. Wing nut
6. Packing
7. Outer element
8. Wing nut

IE-3-4

9. Packing
10. Inner element
11. Evacuator valve
12. Body assembly

TURBOCHARGER

TURBOCHARGER
= MODELS T04B AND T04E =
CONSTRUCTION

REMOVAL
Key point of removal
WARNING
WARNING
z

To avoid being burned, do not touch the exhaust pipe,


turbocharger and muffler while the engine is running or
immediately thereafter. Check that the engine has cooled
before starting work.

IE-4-1

T04B, T04E

TURBOCHARGER

T04B, T04E

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

+
+
,
+
+
,+
+

1. Retaining ring
2. Actuator
3. Lock plate
4. Clamp
5. Turbine housing
6. Lock plate
7. Clamp
8. Compressor housing
9. Rotating assembly

10. Lock nut


,+ 11. Compressor wheel
, 12. Turbine wheel
,+ 13. Piston ring
14. Shroud wheel
15. Lock plate
,+ 16. Back plate
+ 17. Thrust collar
+ 18. Thrust bearing

+ 19. Piston ring


20. Seal ring
21. Retaining ring
,+ 22. Journal bearing
23. Retaining ring
24. Retaining ring
,+ 25. Journal bearing
26. Retaining ring
27. Center housing

Marks + and , indicate that the key points of operation are explained in the text.

IE-4-2

TURBOCHARGER

OPERATIONS BEFORE DISASSEMBLY


When disassembling or reassembling the turbocharger, use special
tool kits (99760 Z5500) designed for that purpose.

INSPECTION BEFORE DISASSEMBLY


Place the turbocharger on a level surface, and turn the compressor
wheel with finger tip to determine whether it operates smoothly,
then use the following procedure to measure both axial and radial
play.

Measuring play in the axial direction


1.
2.
3.

Set the dial gauge to the end play measuring tool (99766
96000). Replace the dial gauge adapter with the end play
adapter (99765 96001).
Set the end play measuring tool so that the end of the
adapter is contacting the compressor wheel end of the
shaft.
Measure the play in the axial direction.
Unit: mm (in)
Maintenance standard

Service limit

0.025 - 0.080 (0.0010 - 0.0031)

Measuring play in the radial direction


1.
2.
3.

Set the dial gauge to the radial play measuring tool (99764
96000) and replace the dial gauge adapter with the radial
play adapter (99765 96000).
Tighten the measuring tool with hex socket head bolt
(14220 Z9001). Make sure the measuring element contacts
the center of the shaft.
Measure the play in the radial direction.
Unit: mm (in)
Maintenance standard

Service limit

0.08 - 0.15 (0.0031 - 0.0059)

IE-4-3

T04B, T04E

TURBOCHARGER

Key point of disassembly


Before disassembly, spread a piece of clean oil paper or cardboard
on the work bench and make matching marks at the connection
sections of the turbine housing, center housing, and compressor
housing so that there will be no mistakes during reassembly. Since
the turbocharger is a precision device, disassemble it with the
utmost care.

3 Lock plate, 4 Clamp


Unbend the lock plate, remove the lock plate, clamp, bolt and turbine housing.
NOTE
z If the bolt has seized, apply thread-release oil to the
bolt, then remove it, being careful not to damage the turbine wheel. If necessary, tap the turbine housing with a
wooden hammer.

6 Lock plate, 7 Clamp


Unbend the lock plate, and remove the lock plate, clamp and bolt.
NOTE
z

Make a matching mark on the compressor housing and


back plate.

8 Compressor housing
Remove the compressor housing being careful not to damage the
compressor wheel.
NOTE
z

The compressor wheel and turbine wheel are precisely


dynamically balanced and cannot be repaired. Therefore,
they must be handled with extra special care.

9 Rotating assembly
Place holding fixture (99768 Z5500) in a vise, and set the turbine
wheel on it with the compressor wheel on it with the turbine wheel
side facing downward.

IE-4-4

T04B, T04E

TURBOCHARGER
11 Compressor wheel
Remove the compressor wheel.
z
Using a T-handle (99773 96000), remove the lock nut, and
then remove the compressor wheel by hand.
NOTE
Since bending of the shaft is also related to the life of the
turbocharger, be careful not to bend it.
z Support the turbine wheel by hand while loosening the
lock nuts.
z

13 Piston ring
Remove the piston ring.
NOTE
z

Once removed, the piston ring must always be replaced


with a new ring when reassembling. However, since the
turbine wheel can be reused, be careful not to damaged
it.

16 Back plate
Unbend the lock plate and remove the back plate.
NOTE
z

When the back plate cannot be removed by hand, tap the


center housing lightly with a wooden mallet and then
remove it.

17 Thrust collar, 18 Thrust bearing,19 Piston ring


Pull out the thrust collar and thrust bearing from the center of the
back plate and remove the piston ring from the thrust collar. The
piston ring can be removed by hand.

22, 25 Journal bearing


NOTE
z Be careful not to damage the center housing when
removing the retaining ring.
1.

Using retaining ring pliers (99546 Z5500), remove the compressor wheel side retaining ring and journal bearing.

IE-4-5

T04B, T04E

TURBOCHARGER
2.
3.

T04B, T04E

Using retaining ring pliers (99546 Z5500), remove the turbine side retaining ring and journal bearing.
Remove the two retaining rings located in the rear of the
center housing.

EIE3048A

INSPECTION
INSPECTION BEFORE CLEANING
Turbocharger failure may sometimes be due to faulty engine parts.
It is, therefore advisable to closely inspect parts for accumulation of
carbon, presence of dirt or dust, obstruction of oil passages, etc.
prior to cleaning, so that the cause of problems may be located
easily.

CLEANING
After soaking all the parts in clean detergent for about 20 to 30 minutes, remove dirt and grime with a rough brush and then blow dry
with compressed air.
NOTE
z

Be extremely careful not to damage parts. Avoid filing


any rotating parts. Also be sure to clean parts completely. Failure to observe these points may cause the
parts to become imbalanced.
Contents of inspection

Inspection point

Carbon accumulation (check whether parts are jammed)

z
z
z
z
z

Lubrication (wear, burning, discoloration etc.)

z
z
z
z
z

Oil leakage

z
z
z
z
z
z

Foreign matter (Also check for obstruction while cleaning


parts.)

z
z
z

Clogging

z
z
z
z

IE-4-6

Turbine wheel journal parts.


Outside periphery of center housing.
Inside periphery of heat shroud.
Inside wall of center housing.
Surface of blades of turbine wheel.
Turbine wheel journal parts.
Journal bearing.
Center housing bore part.
Thrust collar.
Thrust bearing.
Inside and outside periphery of turbine housing.
Inside periphery of heat shroud.
Inside of compressor housing.
Surface of back plate.
Surface of blades of turbine wheel.
Rear surface of compressor wheel.
Inside of center housing.
Inside of turbine case.
Inside of compressor case.
Center housing of oil hole.
Oil inlet adapter.
Oil outlet adapter.
Thrust bearing of oil hole.

TURBOCHARGER

T04B, T04E

INSPECTION
Inspect parts visually, replacing as necessary.
Inspection position

Inspection item

Compressor housing

Scratches caused by interference with compressor


wheel.
Scratches on contact surfaces with back plate.
Cracks and dents.

Clamp

Corrosion, deterioration and damage.

Turbine housing

Scratches caused by interference with turbine wheel.


Burrs caused by rust formation.
Thermal deformity and cracks.

z
z

z
z

Compressor wheel

z
z
z
z

Turbine wheel

z
z
z
z
z
z

Back plate

z
z
z

Thrust collar

z
z

Thrust bearing

z
z

Center housing

z
z

Heat shroud

z
z

Corrosion.
Scratches caused by interference with housing.
Blade breakage and deformity.
Clogging in shaft holes.
Scratches from interference with turbine housing.
Blade breakage, deformity and cracks.
Shaft bent.
Discolored journals and blades.
Worn and scratched journals.
Worn and damaged piston rings.
Worn bore.
Wear and damage on contact surface of thrust collar.
Scratches on rear face of compressor wheel.
Wear and scratches on contact surface.
Worn and damaged piston ring groove.
Thermal discoloration.
Wear and scratches on contact surface.
Wear and scratches on journal bores and inner surfaces
of piston rings.
Obstruction in oil hole
Scratches caused by contact.
Thermal discoloration and corrosion.

Runout of shaft
NOTE
z

Since the turbine side is heavy and the front end of the
shaft will lift when the shaft is supported by V-block, use
a magnet V-block or place another V-block to keep the
journal part in place.
Unit: mm (in)
Maintenance standard

Service limit

0.011 (0.0004)

IE-4-7

TURBOCHARGER

Inside diameter of back plate (A)


Unit: mm (in)
Maintenance standard

Service limit

12.71 (0.5004)

Outside diameter of shaft


Unit: mm (in)
Item

Maintenance standard

Service limit

Journal part

10.16 (0.4000)

Piston ring part

17.34 (0.6827)

Distance between contact surface of thrust collar and


end of plate (B)
Unit: mm (in)
Maintenance standard

Service limit

11.66 (0.4591)

Inside diameter of center housing


Unit: mm (in)
Item

Maintenance standard

Service limit

Bearing part (1)

15.81 (0.6224)

Piston ring part (2)

18.06 (0.7110)

Thrust bearing thickness


Unit: mm (in)
Maintenance standard

Service limit

4.36 (0.1717)

IE-4-8

T04B, T04E

TURBOCHARGER

REASSEMBLY
PREPARATIONS BEFORE REASSEMBLY
Repair light damage by polishing. Aluminum parts must be polished
with a polishing cloth, using silicon carbide. Moreover, steel parts
must be polished with a polishing cloth, using polishing powder.

Key point of reassembly


25, 22 Journal bearing
Using retaining ring pliers (99546 Z5500), install the retaining rings
in the rear of the center housing, then install the journal bearing and
the outer retaining ring.
NOTE
z Ensure that the open end of the retaining ring faces the
oil outlet and the round portion faces the journal bearing.
z Be careful not to damage the center housing when
installing the retaining ring.
z Coat the inner and outer periphery of journal bearing
with engine oil.

16 Back plate
1. Install the back plate.
z
Install the piston ring to the thrust collar.
z
Coat the thrust bearing with engine oil and then install the
thrust bearing and thrust collar.

2.

Fit the thrust collar into the groove pin of the center housing, and fit the seal ring to the peripheral groove of the center housing.
NOTE
z When installing the thrust collar, align the portions indicated by dotted lines in the figure at right.

IE-4-9

T04B, T04E

TURBOCHARGER
3.

Use bolt and lock plate to install the back plate to the center
housing and bend the lock plate.
: 8.4 - 10.2 Nm {86 - 104 kgfcm, 75 - 90 inlbf}
NOTE
z Ensure that the bosses are ready to be detached from the
flanged portions of the inlet and outlet.

13 Piston ring
Install the piston ring to the turbine wheel using the piston ring
guide (99763 Z5500).

12 Turbine wheel
Apply a coat of engine oil to the turbine wheel journal, and carefully
insert the turbine wheel into the bore in the center housing. Use
pick (99767 96003) to compress the piston ring and install it while
rotating the wheel shaft.
NOTE
z Be careful not to scratch or break the piston ring.

11 Compressor wheel
NOTE
z Before installing the compressor wheel, clean the parts
and check carefully the tightening surface for dust or foreign matter.
z When tightening the nut, be careful not to give the bending force to the shaft.
z Keep the rated tightening torque and tightening angle.

1.
2.
3.

Coat the compressor wheel mounting and screw section of


the turbine wheel and the surface of the lock nut seat with a
thin coat of seizure preventative.
Fit the compressor wheel into the turbine wheel and tighten
the lock nut temporarily.
Attach the rotating assembly to a holding fixture (99768
Z5500) which has been placed in a vise.

IE-4-10

T04B, T04E

TURBOCHARGER
4.

Using a torque wrench, tighten the lock nut temporarily.


: 2.1 - 2.3 Nm {21 - 23 kgfcm, 18 - 20 inlbf}

5.

Tighten the lock nut completely with T-handle (99773


96000) by turning nut 110 further than the temporary position.

Measuring play in shaft axial direction and radial direction


1. Seat the dial gauge to the radial play measuring tool (99764
96000) and replace the dial gauge adapter with the radial
play adapter (99765 96000).

2.

Attach the measuring element to the center bearing, and


measure its radial play.
Unit: mm (in)

3.

Maintenance standard

Service limit

0.08 - 0.15 (0.0031 - 0.0059)

Seat the dial gauge to the end play measuring tool (99766
96000). At this time, replace the dial gauge adapter with the
end play adapter (99765 96001).

IE-4-11

T04B, T04E

TURBOCHARGER
4.

Temporarily install the compressor housing. Attach the


measuring element to the compressor housing and measure the end play of the shaft.
Unit: mm (in)
Maintenance standard

Service limit

0.025 - 0.080 (0.0010 - 0.0031)

8 Compressor housing
1. Attach the compressor housing to the back plate by properly aligning their marks, then tighten the bolts with the
clamps and lock plates in place.
: 11.3 - 14.7 Nm {115 - 150 kgfcm, 100 - 130 inlbf}

2.

Compressor housing assembly angle (View from the air


intake side)
T04B
= 292
T04E
= 170

5 Turbine housing
1. Align the marks on the turbine housing and center housing,
attach the turbine housing to the rotating assembly, then
tighten bolts with a clamp and lock plate in place.
: 18.0 - 21.5 Nm {184 - 219 kgfcm, 160 - 190 inlbf}
NOTE
z Apply a gauge-preventive compound to bolts. Do not
confuse these bolts (designed especially for high temperature use) with other conventional bolts.
2.

Turbine housing assembly angle (View from exhaust outlet


side)

IE-4-12

T04B, T04E

TURBOCHARGER

INSTALLATION
Key point of installation
1.

Install the turbocharger assembly on the exhaust manifold


using a gasket.
NOTE
z Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
2.

Install the exhaust connector using a gasket and spacer to


the turbocharger assembly.
NOTE
z Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
3.

After installing the turbocharger assembly, crank the engine


using the sub-starter switch. Crank for approximately 10 to
20 seconds while pulling the engine stop lever. Crank the
engine until the oil pressure gauge activates, since oil is not
distributed to the oil line.
NOTE
z Do not crank the engine for more than 20 seconds at a
time; otherwise, the starter motor may be damaged.
Repeat cranking several times.
4.

Start the engine. Check that no oil leaks.

IE-4-13

T04B, T04E

TURBOCHARGER

= MODELS RHC62E AND RHC6V =


CONSTRUCTION
Model RHC62E

IE-4-14

RHC62E, RHC6V

TURBOCHARGER

Model RHC6V

REMOVAL
Key point of removal
WARNING
WARNING
z

To avoid being burned, do not touch the exhaust pipe,


turbocharger and muffler while the engine is running or
immediately thereafter. Check that the engine has cooled
before starting work.

IE-4-15

RHC62E, RHC6V

TURBOCHARGER

RHC62E, RHC6V

DISASSEMBLY
Model RHC62E

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Holder plate
,+ 2. Compressor housing
3. Holder plate
+ 4. Turbine housing
,+ 5. Nut
6. Compressor impeller
,
7. Seal ring (large)
8. Turbine shaft

9. Sealed wheel
,+ 10. Snap ring
11. Floating metal
,+ 12. Center housing
,+ 13. Torx screw
14. Seal plate
, 15. Oil thrower
16. Thrust bearing

,+ 17. Torx screw


18. Thrust bearing
19. Seal ring (small)
20. Seal ring
21. Snap ring
22. Actuator
23. Clip
24. Hose

Marks + and , indicate that the key points of operation are explained in the text.

IE-4-16

TURBOCHARGER

RHC62E, RHC6V

Model RHC6V

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Holder plate
,+ 2. Compressor housing
3. Holder plate
+ 4. Turbine housing
,+ 5. Nut
6. Compressor impeller
,
7. Seal ring

8.Turbine shaft
9. Sealed wheel
,+ 10. Snap ring
11. Floating metal
,+ 12. enter housing
,+ 13. Torx screw
14. Seal plate

15. Oil thrower


16. Thrust bushing
,+ 17. Torx screw
18. Thrust bearing
19. Seal ring
20. Seal ring
,

Marks + and , indicate that the key points of operation are explained in the text.

IE-4-17

TURBOCHARGER

INSPECTION BEFORE DISASSEMBLY


On-board inspection
Turbine shaft rotation
Check for abnormal noise from the turbine shaft while rotating the
turbocharger.
1. If a sound-detecting rod is used, firmly attach the tip of the
rod to the turbocharger case, then increase engine speed.
2. If a high-pitch sound is heard every 2 to 3 seconds during
turbocharger rotation, the metal and/or turbine shaft may be
damaged. Disassemble and repair the turbocharger or
replace it as required.

Turbocharger assembly
1. Cover the oil inlet and outlet using masking tape.
2. Check if the turbine vane is in contact with the compressor
impeller or if there is evidence of leaking oil.
3. Check the actuator for improper movement or wear.
4. Check that the impeller spins smoothly by hand.
5. Measure the turbine shaft axial play.
z
Fix the dial gauge to the turbocharger by the magnetic
base.
z
Move the tip of the turbine shaft by hand in the axial direction so that the dial gauge registers the maximum deflection.
Unit: mm (in)

6.
z

Maintenance standard

Service limit

0.05 - 0.08 (0.0020 - 0.0031)

0.10 (0.0039)

Measure the turbine shaft radial play.


Fix the dial gauge to the turbocharger assembly by the
magnetic base.
Replace the dial gauge measuring probe with a measuring
needle.
While holding both ends of the turbine shaft in both hands,
move the turbine shaft in the radial direction. Read the maximum dial gauge deflection.
Unit: mm (in)
Maintenance standard

Service limit

0.08 - 0.12 (0.0031 - 0.0047)

0.17 (0.0067)

IE-4-18

RHC62E, RHC6V

TURBOCHARGER

Key point of disassembly


CAUTION

The VNT actuator is set to the specified boost pressure


before shipment. Do not attempt to remove the actuator
in the field.
z The variable exhaust nozzle mechanism is complex in
design since it slides without lubrication under high temperature conditions. Never attempt to disassemble the
nozzle mechanism in the field.
z

2, 12 (RHC62E) 2, 12 (RHC6V) Compressor housing, Center


housing
1. Before disassembling, place an alignment mark on the joining surfaces of the compressor housing, center housing and
turbine housing so that they can be installed in their original
positions during reassembly.
2. Liquid gasket is applied to the mating surfaces of the compressor housing and center housing. When removing these
parts, be careful not to damage impeller.
4 (RHC62E) 4 (RHC6V) Turbine housing
Before removing the turbine housing, place it parallel with the center housing.

5 (RHC62E) 5 (RHC6V) Nut


Using a 17-mm (0.67-in) box wrench, remove the nut from the end
(turbine side) of the turbine shaft.
NOTE
z The nut is a left-hand thread type.

10 (RHC62E) 10 (RHC6V) Snap ring


Use snap ring pliers when removing or installing snap rings.
13 (RHC62E) 13 (RHC6V) Torx screw
Use a Torx driver when removing the Torx T type screws which
secure the seal plate.
NOTE
z

The seal plate can be driven out by equally and firmly


tightening the two screws by hand.

IE-4-19

RHC62E, RHC6V

TURBOCHARGER

RHC62E, RHC6V

17 (RHC62E) 17 (RHC6V) Torx screw


Use a Torx driver when removing the Torx T type screws which
secure the thrust bearing.

INSPECTION
Check all parts for scratches (frictional), scratches (on the joining
surfaces), cracks, corrosion, bends, wear, thermal deformation, pitting, discoloration, breakage, oil clogging, etc. Replace faulty parts
with new ones.

INSPECTION BEFORE CLEANING


Before cleaning, visually check various parts for seizure, wear or
foreign particles (including carbon) to determine if they are suitable
for further use.

Cleaning procedure
Turbine shaft

Turbine housing and center housing

Compressor housing and compressor


impeller

Pour cleaning liquid (decarbonizing agent) into the cleaning basket. Immerse parts in the liquid, then heat them.
NOTE
z Protect the turbine shaft journal surface and seal ring groove from damage in advance.

Wait until foreign particles are loose.

Using a scraper or hard brush, clean the parts.


NOTE
z Do not use a wire brush.

Check all parts as specified under the topic INSPECTION.

NOTE

Clean all other parts in kerosene.


z Clean the oil passage using dry compressed air.
z After cleaning, check all parts as specified under the topic INSPECTION.
z

IE-4-20

TURBOCHARGER

TURBINE WHEEL SHAFT


Outside diameter of journal (A) and outside diameter of
seal ring groove (E)
Unit: mm (in)
Item

Maintenance standard

Service limit

Outside diameter of journal (A)

1.33 (0.0524)

Outside diameter of seal ring


groove (E)

10.39 (0.4091)

Runout
Unit: mm (in)
Maintenance standard

Service limit

0.011 (0.0004)

THRUST BUSHING, OIL THROWER AND THRUST


BEARING
Distance between thrust bushing grooves (K)
Unit: mm (in)
Maintenance standard

Service limit

4.08 (0.1606)

Oil thrower seal ring groove widths (G1 and G2)


Unit: mm (in)
Item

Maintenance standard

Service limit

Small diameter (G2)

1.25 (0.0492)

Large diameter (G1)

1.46 (0.0575)

Thrust bearing width (J)


Unit: mm (in)
Maintenance standard

Service limit

3.98 (0.1567)

IE-4-21

RHC62E, RHC6V

TURBOCHARGER

FLOATING BEARING
Inside diameter (C) and outside diameter (D)
Unit: mm (in)
Item

Maintenance standard

Service limit

Inside diameter (C)

10.44 (0.4110)

Outside diameter (D)

14.98 (0.5898)

CENTER HOUSING
Inside diameter (B) and seal ring insertion hole (F) (on
turbine side)
Unit: mm (in)
Maintenance standard

Service limit

Inside diameter (B)

Item

15.10 (0.5945)

Seal ring insertion hole (F)

17.03 (0.6705)

SEAL PLATE
Seal ring insertion hole (H1 and H2) (on impeller side)
Unit: mm (in)
Item

Maintenance standard

Service limit

Small diameter (H1)

12.45 (0.4902)

Large diameter (H2)

14.05 (0.5531)

REASSEMBLY
Key point of reassembly
NOTE
z

After reassembling the turbocharger, measure the axial


and radial play of the turbine shaft.

17 (RHC62E) 17 (RHC6V) Torx screw


Use a Torx driver when installing the Torx T type screws which
secure the thrust bearing.
15 (RHC62E) 15 (RHC6V) Oil thrower
Fit the two seal rings to their grooves on the oil thrower, as shown in
the figure.

IE-4-22

RHC62E, RHC6V

TURBOCHARGER
13 (RHC62E) 13 (RHC6V) Torx screw
Use a Torx driver when installing the Torx T type screws which
secure the seal plate.
7 (RHC62E) 7 (RHC6V) Seal ring
Fit the seal ring to the groove on the turbine shaft, as shown in the
figure.

10 (RHC62E) 10 (RHC6V) Snap ring


Note the direction of the snap ring gap during installation. Refer to
the figure.
NOTE
z Face the tapered side of the snap ring toward the bearing.

5 (RHC62E) 5 (RHC6V) Nut


Using a 17 mm (0.67 in) box wrench, tighten the nut on the end (turbine side) of the turbine shaft.
NOTE
z The nut is a left-hand thread type.
z Align the alignment marks on the turbine shaft, compressor impeller and nut (on the end of the turbine shaft) during reassembly.
2, 12 (RHC62E) 2, 12 (RHC6V) Compressor housing, Center
housing
1. Before installation, apply 0.1 to 0.2 mm (0.004 to 0.008 in)
thick liquid gasket (THREE BOND #1215 or equivalent) to
the mating surfaces of the compressor housing and center
housing.
2. Align the alignment marks on the joining surfaces of the
compressor housing, center housing and turbine housing
during reassembly.

IE-4-23

RHC62E, RHC6V

TURBOCHARGER

INSTALLATION
Key point of installation
1.

Install the turbocharger assembly on the exhaust manifold


using a gasket.
NOTE
z Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
2.

Install the exhaust connector, connector support and seal


plate.
NOTE
z Mounting nuts or bolts are heat-resistant types. Do not
confuse them with conventional nuts or bolts.
3.

After installing the turbocharger assembly, crank the engine


using the sub-starter switch. Crank for approximately 10 to
20 seconds while pulling the engine stop lever out. Crank
the engine until the oil pressure gauge activates, since oil is
not distributed to the oil line.
NOTE
z Do not crank the engine for more than 20 seconds at a
time; otherwise, the starter motor may be damaged.
Repeat cranking several times.
4.

Start the engine. Check that no oil leaks.

IE-4-24

RHC62E, RHC6V

EXHAUST SYSTEM

EXHAUST SYSTEM
REMOVAL
Key point of removal
WARNING
WARNING
z

Before removing the exhaust system, ensure that the


engine is cool. If it is hot, wait until it cools off to prevent
scalding yourself.

Tail pipe
1.
2.

Disconnect the tail pipe clamp and hanger.


Remove the tail pipe by loosening the bolts which secure
the rear pipe of the muffler to the tail pipe.

Muffler
1.
2.

Remove the bolt from the exhaust shutter, and separate the
exhaust brake from the muffler.
Separate the hanger from the bracket which secures the
rear pipe of the muffler. Remove the muffler.

Exhaust pipe
1.
2.
3.

Disconnect the pipes from the exhaust manifold.


Disconnect the exhaust pipe bracket from the hanger.
Remove the hanger and clamp from the exhaust pipe.

IE-5-1

EXHAUST SYSTEM

DISASSEMBLY
(Example)

1. Gasket
2. Exhaust tube assembly
3. Hanger
4. Rubber

5. Sleeper exhaust tube assembly


6. Gasket
7. Exhaust shutter assembly

8. Muffler
9. Hanger
10. Tail tube assembly

NOTE
z

Numbers before part name do not indicate the disassembly sequence.

INSPECTION
Carefully check all disassembled parts for scratches, cracks or
damage. Repair or replace faulty parts if necessary.

IE-5-2

EXHAUST SYSTEM

INSTALLATION
1.

Replace all gaskets with new ones.

2. Install the hanger and rubber pad on the tail pipe bracket.
NOTE
z Always install the hanger using the hole at the outer end
of the bracket.
z Make sure that the convex end of the rubber pad faces
down and that the bolt is inserted from the lower side.
z Make sure that the nut which secures the rubber pad
makes contact with the graded portion of the bolt when
tightened.
3.

Install the exhaust pipe on the exhaust manifold using a


gasket. Fasten it with the clamp. Install the assembled unit
on the hanger.

4.

Temporarily install the clamp, sleeper and rubber pad on the


bracket which secures the rear of the muffler.

5.

Insert the rear pipe of the muffler into the clamp. Connect
the front pipe to the exhaust pipe by using the exhaust
brake assembly and gasket.
NOTE
z Install the muffler so that the bent part is 30 degrees
towards the vehicle from the bottom of the muffler.
6.
7.

Insert the tail pipe between the clamp (which was installed
temporarily in step 4 above) and the rear pipe of the muffler.
Secure the tail pipe hanger to the tail pipe clamp.

IE-5-3

EXHAUST SYSTEM
8. Adjust the position of the tail pipe and tighten the clamp.
NOTE
z Make sure that the tail pipe clamp is tightened at a point
approximately 5 mm (0.20 in) from the end of the tail pipe.

INSPECTION AFTER INSTALLATION


1.

2.

Check that the exhaust pipe, muffler and tail pipe are sufficiently clear of adjacent parts for safety. Also check that
there is sufficient clearance between the exhaust pipes and
the seats and ropes.
Start the engine. Check the muffler for proper function and
connections for signs of air leakage.

IE-5-4

EXHAUST BRAKE

EXHAUST BRAKE
= CHAMBER TYPE =
CONSTRUCTION

REMOVAL
Position the vehicle on a flat surface and apply chocks to the front
and rear wheels.
WARNING
WARNING
z

Do not remove the exhaust brake parts while the engine


is hot to prevent scalding yourself.

IE-6-1

CHAMBER TYPE

EXHAUST BRAKE

CHAMBER TYPE

DISASSEMBLY
EXHAUST SHUTTER AND POWER CHAMBER ASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Cover
2. Pin
3. Clevis pin

, 4. Clevis
5. Power chamber assembly
6. Bearing

7. Gasket
8. Insulator
9. Exhaust shutter assembly

Marks + and , indicate that the key points of operation are explained in the text.

IE-6-2

EXHAUST BRAKE

CHAMBER TYPE

EXHAUST SHUTTER

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Lever
, 2. Seal ring
, 3. Seal ring

4. Cover
5. Gasket

6. Body
7. Bracket assembly

Marks + and , indicate that the key points of operation are explained in the text.

IE-6-3

EXHAUST BRAKE

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

REASSEMBLY
EXHAUST SHUTTER
Key point of reassembly
3, 2 Seal ring
Position the spindle, valve and bushing in the body. Install the seal
rings on the spindle.
NOTE
z Make sure that the different seal rings are installed alternately.
Adjustment of clearance between the valve and body
Apply a vacuum pressure of 86.6 to 93.3 kPa {650 to 700 mmHg,
25.59 to 27.56 inHg} to the power chamber with the valve fully
closed. Check to ensure that the clearance between the body and
valve is in the specified range indicated in the table below. If it is
not, adjust the stopper bolt and tighten the lock nut.
: 5 - 7 Nm {0.5 - 0.7 kgfm, 3.6 - 5.1 ftlbf}
Unit: mm (in)
Item
Clearance
between valve
and body

Only one side


Both total

Maintenance
standard

Service limit

0.80 - 1.05
(0.0315 - 0.0413)

1.6 - 2.1
(0.063 - 0.083)

EXHAUST SHUTTER AND POWER CHAMBER ASSEMBLY


Key point of reassembly
4 Clevis
Install the clevis on the push rod, and connect the lever using a pin.
Adjust the position of the clevis so that the push rod can be set in
position when pushed 2 mm (0.08 in) against the power chamber.
Check that clearances A and B between the valve and body are
equal and that the push rod makes contact with the stopper bolt on
the full-open side. If no contact is made, adjust it as outlined in
Adjustment of clearance between the valve and body.

IE-6-4

CHAMBER TYPE

EXHAUST BRAKE
: Clevis adjusting nut
10 - 16 Nm {1.0 - 1.6 kgfm, 7 - 12 ftlbf}
: Stopper bolt lock nut
5 - 7 Nm {0.5 - 0.7 kgfm, 3.6 - 5.1 ftlbf}

INSTALLATION
Key point of installation
1. Connect the vacuum hoses.
NOTE
z Be careful not to twist the hoses.
2.

Start the engine. When vacuum pressure reaches the specified value, turn the exhaust brake switch ON to ensure
that the exhaust brake operates properly. Also check to be
sure there is no air leakage.

IE-6-5

CHAMBER TYPE

EXHAUST BRAKE

= CYLINDER TYPE =
CONSTRUCTION
EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLY
Models 286-04442 and 286-04441

IE-6-6

CYLINDER TYPE

EXHAUST BRAKE
Models 286-04446 and 286-04453

IE-6-7

CYLINDER TYPE

EXHAUST BRAKE
Model 286-06109

REMOVAL
Key point of removal
Position the vehicle on a flat surface and apply chocks to the front
and rear wheels.
WARNING
WARNING
z

Do not remove the exhaust brake parts while the engine


is hot to prevent scalding yourself.

IE-6-8

CYLINDER TYPE

EXHAUST BRAKE

CYLINDER TYPE

Remove the exhaust shutter assembly.


Separate the exhaust brake air-hose connection, and
remove the hose. When removing, hold the hose stationary
and loosen the nut.
NOTE
z Be careful not to twist the hose when removing.
z

DISASSEMBLY
EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLY
Models 286-04442 and 286-04441

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Pin
2. Clevis pin
, 3. Clevis

4. Shield plate
5. Air cylinder assembly

6. Insulator
7. Exhaust shutter assembly

Marks + and , indicate that the key points of operation are explained in the text.

IE-6-9

EXHAUST BRAKE

CYLINDER TYPE

Models 286-04446, 286-04453 and 286-06109

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Pin
2. Clevis pin
, 3. Clevis

4. Shield plate
5. Air cylinder assembly

6. Insulator
7. Exhaust shutter assembly

Marks + and , indicate that the key points of operation are explained in the text.

IE-6-10

EXHAUST BRAKE

CYLINDER TYPE

EXHAUST SHUTTER
Models 286-04442, 286-04441, 286-04446 and 286-04453

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Cover
2. Gasket
3. Lever

4. Plate
, 5. Seal ring

, 6. Seal ring
7. Exhaust shutter

Marks + and , indicate that the key points of operation are explained in the text.
CAUTION
z

Do not disassemble the exhaust shutter in model 286-06109. Never loosen the stopper bolt.

IE-6-11

EXHAUST BRAKE

CYLINDER TYPE

AIR CYLINDER ASSEMBLY


Models 286-04442 and 286-04441

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Cover
2. O-ring
3. Nut
4. Washer
5. Retainer

6. Packing
7. Plate
8. Wear ring
9. Protector
+ 10. Spring

11. Shaft
12. Guide
13. Cover
14. Dust seal
15. Cylinder

Marks + and , indicate that the key points of operation are explained in the text.

IE-6-12

EXHAUST BRAKE

CYLINDER TYPE

Models 286-04446, 286-04453 and 286-06109

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Cover
2. O-ring
3. Nut
4. Washer
5. Retainer
6. Packing

7. Plate
8. Wear ring
9. Protector
+ 10. Spring
11. Shaft
12. Guide

13. Washer
14. Cover
15. Dust seal
16. Retaining ring
17. Filter
18. Cylinder

Marks + and , indicate that the key points of operation are explained in the text.

Key point of disassembly


10 Spring
Remove the cover and detach the spring and shaft assembly from
the cylinder.
NOTE
z Be careful not to allow the shaft assembly to jump out
because the cover is spring-loaded.

IE-6-13

EXHAUST BRAKE

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

Spindle O.D.
Unit: mm (in)
Maintenance standard

Service limit

16.50 (0.6496)

16.43 (0.6468)

Clearance between spindle and bushing


Unit: mm (in)
Maintenance standard

Service limit

0.3 - 0.4 (0.012 - 0.016)

Clearance between bushing and body


Unit: mm (in)
Maintenance standard

Service limit

0.015 - 0.090 (0.0006 - 0.0035)

Spring
Unit: mm (in)
Item

Maintenance
standard

Service limit

Free length

151.5 (5.965)

134.4 - 161.2
{13.70 - 16.44,
30.2 - 36.3}

Tension
N {kgf, lbf}

Remarks

When compressed to 107.8


mm (4.244 in)

IE-6-14

CYLINDER TYPE

EXHAUST BRAKE

REASSEMBLY
EXHAUST SHUTTER
Key point of reassembly
6, 5 Seal ring
Position the spindle, valve and bushing in the body and attach the
seal rings on the spindle.
NOTE
z Alternately install different types of seal rings.
Adjustment of clearance between the valve and body
Move the lever toward the full-open side. When the lever contacts
the stopper bolt, adjust the stopper bolt so that clearances A and B
are equal. Move the lever toward the full-close side. When the lever
contacts the stopper bolt, adjust the stopper bolt so that the clearance between the valve and body is within specifications. After
adjusting the clearance, tighten the stopper bolt with the lock nut.
: 10 - 16 Nm {1.0 - 1.6 kgfm, 7 - 12 ftlbf}

Unit: mm (in)
Item

Maintenance
standard

0.80 - 1.05
One side
Clearance
(0.0315 - 0.0413)
between valve
1.6 - 2.1
and body
Both total
(0.063 - 0.083)

Service limit

Remarks

(*)

(*) When an air pressure of 637 kPa {6.5 kgf/cm2, 92 psi} is applied to the
air cylinder and the valve is fully closed

EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLY


Key point of reassembly
3 Clevis
Connect the shaft of the cylinder assembly and clevis using a pin.
Move the lever toward the full-open side until it contacts the stopper
bolt. From that position, pull out the shaft less than 1 mm (0.04 in)
to ensure that the hole in the shaft is aligned with the clevis hole.
Stopper bolt lock nut (at spindle)
: 10 - 16 Nm {1.0 - 1.6 kgfm, 7 - 12 ftlbf}

IE-6-15

CYLINDER TYPE

EXHAUST BRAKE

INSTALLATION
Key point of installation
Install the connector so that its hose mounting hole faces upward.
NOTE
z

Wind two turns of sealing on the threads of the connector in the opposite direction of the threads.

IE-6-16

CYLINDER TYPE

- MEMO -

- MEMO -

ELECTRICAL SYSTEM

CONTENTS
SERVICE DATA ...................................... EE-1-1
SPECIFICATIONS............................................ EE-1-1
SERVICE DATA ............................................... EE-1-1
TIGHTENING TORQUE ................................... EE-1-2
STARTING MOTOR ................................ EE-2-1
CONSTRUCTION............................................. EE-2-1
DISASSEMBLY ................................................ EE-2-3
INSPECTION.................................................... EE-2-4
ADJUSTMENT ................................................. EE-2-7

PERFORMANCE CHECK ................................ EE-2-8

ALTERNATOR ........................................ EE-3-1


CONSTRUCTION .............................................
DISASSEMBLY................................................
INSPECTION ....................................................
PERFORMANCE CHECK ................................

EE-3-1
EE-3-5
EE-3-7
EE-3-8
AIR HEATER ........................................... EE-4-1
CONSTRUCTION ............................................. EE-4-1
INSPECTION .................................................... EE-4-1

EE

SERVICE DATA

SERVICE DATA
SPECIFICATIONS
STARTING MOTOR
Model

0350 502 0310

0350 502 0321

Type

Shift

Output

V-kW

24-4.5

ALTERNATOR
0202 152
Model

0201 152

0202 152 0310 0202 152 0311 0202 152 0220 0202 152 0221 0201 152 0420 0201 152 0421 0201 222 0273
With vacuum pump

Output

0201 222

Without vacuum pump

V-A

24-50

Type of
regulator

24-80

IC transistor (Built-in)

Vacuum pump
model

1290 011 00 (VD-120)

1290 009 00 (VD-30)

AIR HEATER
Type

Ribbon

Rated current

V-A

Rated time

Second

22-85
Less than 50

SERVICE DATA
STARTING MOTOR
Models 0350 502 0310 and 0350 502 0321
Unit: mm (in)
Item

Service limit

36.0 (1.417)

34.0 (1.339)

Runout

Less than
0.09 (0.0035)

More than
0.10 (0.0039)

0.5 - 0.8
(0.020 - 0.031)

0.2 (0.008)

18.0 (0.709)

13.0 (0.512)

29.4 {3.0, 6.6}

20.6 {2.1, 4.6}

Magnetic
Brush
switch

Undercut depth
Brush height

Gear shaft

Commutator

Maintenance standard

Outside diameter

Shaft runout

Brush spring tension


Continuity
test

N {kgf, lbf}

Pull coil resistance

0.70 - 0.86

Hold coil resistance

0.85 - 1.05

Less than
0.09 (0.0035)

More than
0.10 (0.0039)

0.1 - 0.5
(0.004 - 0.020)

Thrust gap

Armature, field coil

Insulation resistance M

More than 1.0

0.5

Brush holder

Insulation resistance M

More than 1.0

0.5

EE-1-1

Remarks

When spring is set

SERVICE DATA
Unit: mm (in)

Performance
Adjustment
check

Bracket

Item

Maintenance standard

Service limit

Front bearing (metal) inside diameter

15.0 (0.591)

15.2 (0.598)

Commutator bearing fit section inside


diameter

28.0 (1.102)

28.1 (1.106)

Gear bearing fit section inside diameter

35.0 (1.378)

35.1 (1.382)

0.5 - 3.0
(0.020 - 0.118)

Less than 100

Terminal voltage 24V

More than 4,000

Terminal voltage 24V

Less than 16

Clearance between pinion gear and


pinion stopper (Dimension L)
Current

Number of rotations

rpm

Measure minimum voltage which is


necessary for pinion to pop out
V

Remarks

ALTERNATOR

Performance check

Field coil Starter coil

Item

Resistance

Service limit

0.18 - 0.22

0201 222

0.14 - 0.18

5.6 - 6.8

5.0 - 7.0

Less than 950

Less than 900

28 - 29

Less than 50

Less than 80

0202 152
0201 152
0201 222

Resistance

No-load speed

Maintenance standard
0202 152
0201 152

0202 152
rpm 0201 152
0201 222

Regulating voltage

V
0202 152
A 0201 152
0201 222

Output current

Remarks
Between two phases at
20C (68F)

At 20C (68F)

TIGHTENING TORQUE
STARTING MOTOR
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

C terminal

1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}

B terminal

8 - 11 {0.8 - 1.1, 5.8 - 8.0}

M terminal

6 - 11 {0.6 - 1.1, 4.3 - 8.0}

Magnetic switch mounting bolt

16 - 18 {1.6 - 1.8, 12 - 13}

Through bolt

16 - 18 {1.6 - 1.8, 12 - 13}

Brush holder mounting screw

3.6 - 4.9 {0.37 - 0.50, 2.7 - 3.6}

Gear case mounting bolt

16 - 18 {1.6 - 1.8, 12 - 13}

EE-1-2

SERVICE DATA

ALTERNATOR
Unit: Nm {kgfm, ftlbf}
Item
Pulley mounting nut

Tightening torque
0202 152
0201 152

127 - 157 {13.0 - 16.0, 94 - 116}

0201 222

113 - 147 {11.5 - 15.0, 83 - 108}

EE-1-3

STARTING MOTOR

STARTING MOTOR
CONSTRUCTION

EE-2-1

0350 502

No

EE-2-2

Starting motor does not


stop when key switch is
turned off.

Check ignition system and fuel system.

O.K.

N.G.
(Turns
Does starting motor slowly)
turn normally?

Yes

Does engine turn


by cranking?

Engine does not


start.

Yes

Check inside of engine.

No

Does engine turn by


replacing starting motor
with a new one?

O.K.

Check engine oil viscosity.

O.K.

Repair or replace
starting motor.

Replace engine
oil.

*A

Check pinion roller


clutch for damage.
Replace if necessary.

Repair or replace key


switch, block relay or magnetic switch.

Yes

N.G.

Check battery for charging N.G.


condition and battery terminals for connections and
corrosion.

Check reduction gear


parts (armature, gear
shaft). Replace if necessary.

No

Does gear shaft turn?

Yes

Does starting motor turn?

No

No

N.G.

No

No

: Problem or corrective action

Replace motor (field coil or armature).

tion, weak return spring and pinion


for sliding condition.
z Correct meshing condition of pinion
and ring gear. Replace if necessary.

z Check lever assembly for deforma-

z Repair or replace magnetic switch.

netic switch.

z Check and repair wiring up to mag-

Check and repair wiring system of block


relay.
z Key switch.
z Starter relay.
z Connections.

battery terminals.

z Charge or replace battery.


z Repair connections and corrosion of

*A

If any abnormality is found, immediately disconnect battery negative terminal.

: Check item

Check magnetic switch contacts.


Replace if necessary.

Yes

Remove starting motor from engine.


Does starting motor turn under no load
by connecting battery (+) terminal to M
terminal of starting motor and battery
() terminal to starting motor body?

O.K.

Is meshing condition of pinion and ring


gear normal?

Yes

Can you hear magnetic switch operating


sound?

Yes

Can you hear starter relay operating?


(Block relay equipped model only)

O.K.

Check battery for charging condition


and battery terminals for connections
and corrosion.

N.G.

STARTING MOTOR
0350 502

TROUBLESHOOTING

STARTING MOTOR

0350 502

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Magnetic switch assembly
2. Rear bracket
+ 3. Brush holder assembly
4. O-ring
5. Yoke assembly
6. Armature assembly
7. O-ring
8. Gear case

9. Packing
10. Retaining ring
11. Hook
+ 12. Pinion stopper
13. Holder
14. Shaft
15. Lever assembly

16. Center holder


17. Shim washer
18. Pinion assembly
19. Pinion case
20. Felt
21. Cover
22. Metal

Marks + and , indicate that the key points of operation are explained in the text.

EE-2-3

STARTING MOTOR

Key point of disassembly


3 Brush holder assembly
Contact the negative side of the brush spring to the side of the
brush. Lift the brush from the armature commutator surface. Extract
the positive side of the brush from the brush holder. Then, remove
the brush holder assembly.

12 Pinion stopper
Move the pinion stopper toward the pinion. Using a screwdriver, pry
off the pinion stopper clip. Then, extract the pinion assembly and
center plate.

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

COMMUTATOR
Outside diameter
Unit: mm (in)
Maintenance standard

Service limit

36.0 (1.417)

34.0 (1.339)

NOTE
z

If the commutator surface is rough, grind with No. 500 to


600 sandpaper and then measure the outside diameter.

Runout
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.09 (0.0035)

More than 0.10 (0.0039)

EE-2-4

0350 502

STARTING MOTOR

Undercut depth
Unit: mm (in)
Maintenance standard

Service limit

0.5 - 0.8 (0.020 - 0.031)

0.2 (0.008)

BRUSH
Brush height
Unit: mm (in)
Maintenance standard

Service limit

18.0 (0.709)

13.0 (0.512)

Brush spring tension


Unit: N {kgf, lbf}
Maintenance standard

Service limit

29.4 {3.0, 6.6}

20.6 {2.1, 4.6}

Remarks
When spring is set

MAGNETIC SWITCH
Continuity test (Pull coil resistance)
Perform the continuity test between the M and C terminals.
Unit:
Maintenance standard

Service limit

0.70 - 0.86

Continuity test (Hold coil resistance)


Check the continuity between the C terminal and coil case.
Unit:
Maintenance standard

Service limit

0.85 - 1.05

EE-2-5

0350 502

STARTING MOTOR

GEAR SHAFT
Shaft runout
Unit: mm (in)
Maintenance standard

Service limit

Less than 0.09 (0.035)

More than 0.10 (0.0039)

Thrust gap
Unit: mm (in)
Maintenance standard

Service limit

0.1 - 0.5 (0.004 - 0.020)

ARMATURE COIL
Continuity test
Make sure there is no continuity between the commutator and
armature assembly.

Insulation resistance
Unit: M
Maintenance standard

Service limit

More than 1.0

0.5

FIELD COIL
Continuity test
Make sure there is continuity between the field coil terminals.

EE-2-6

0350 502

STARTING MOTOR

Insulation resistance
Unit: M
Maintenance standard

Service limit

More than 1.0

0.5

BRUSH HOLDER
Insulation resistance
Unit: M
Maintenance standard

Service limit

More than 1.0

0.5

BRACKET
Front bearing (metal) inside diameter
Unit: mm (in)
Maintenance standard

Service limit

15.0 (0.591)

15.2 (0.598)

Commutator bearing fit section inside diameter


Unit: mm (in)
Maintenance standard

Service limit

28.0 (1.102)

28.1 (1.106)

Gear bearing fit section inside diameter


Unit: mm (in)
Maintenance standard

Service limit

35.0 (1.378)

35.1 (1.382)

ADJUSTMENT
Measure dimension L moved towards the thrust direction of the pinion when the magnetic switch pushes out the pinion.
1. Connect the S terminal to the battery positive terminal
through the magnetic switch. Ground the M terminal midway and then connect it to the battery negative terminal.

EE-2-7

0350 502

STARTING MOTOR
2.

Turn on the switch and make sure the magnetic switch


pushes out the pinion. Then, push back the pinion lightly
and measure dimension L.
Unit: mm (in)
Item

Dimension L

3.

Maintenance standard

Service limit

0.5 - 3.0 (0.020 - 0.118)

If dimension L exceeds the maintenance standard, replace


the starting motor assembly with a new one.

PERFORMANCE CHECK
1.

Connect as shown in the illustration. Turn off the key switch


and turn the starting motor. Under these conditions, measure the current and the number of rotations. (Terminal voltage: 24 volts)
Item

Current

Maintenance standard

Service limit

Less than 100

More than 4,000

Number of rotations rpm

2.

Check that the pinion gear pops smoothly out and in when
the switch is turned on and off.

3.

Measure the minimum voltage which is necessary for the


pinion to pop out. Prepare a variable resistor and battery
voltmeter as testing equipment. Set the resistance higher at
first so that a lower voltage applies to the starting motor.
Then, slowly lower the resistance and measure the voltage
when the pinion pops out.
Unit: V
Maintenance standard

Service limit

Less than 16

EE-2-8

0350 502

- MEMO -

ALTERNATOR

ALTERNATOR
CONSTRUCTION
Models 0202 152 0310 and 0202 152 0311

Models 0201 152 0420 and 0201 152 0421

EE-3-1

0202 152, 0201 152, 0201 222

ALTERNATOR
Models 0202 152 0220 and 0202 152 0221

Model 0201 222 0273

EE-3-2

0202 152, 0201 152, 0201 222

EE-3-3

(Check the battery and its related


parts.)

Normal alternator

Yes

Measure the alternator charging current at B terminal. Is it over 35A?


(Engine speed: 2,000 rpm)

Yes

Is the voltage across alternator terminals B and E over 27V?


(Engine speed: 1,000 rpm)

*B

Yes

Does voltage exist across alternator


terminals IG and E?
(Key switch is ON)

*A

Yes

Is the voltage across alternator terminals B and E above 22V?


(When the key switch is ON and
engine is stopped.)

The battery runs down.

No

No

No

No

No

Normal

Yes

Increase the electrical load (Turn on


all the lights.)
Is the charging current over 35A?

Faulty alternator

Normal

Normal

Is the key switch normal?

To *A

Is the belt broken?


Is the belt slipping?

Yes

Does voltage exist?

Check the battery relay.

No

Normal

Faulty alternator

To *B

Is the fuse blown?

Abnormal

To *A

Normal

Abnormal

Abnormal

To *A
Abnormal

O Is the fuse blown?


O Is the wiring between the alternator and battery normal?

Abnormal

No

Check the wiring.

Abnormal

O Repair the alternator.


(Replace the diode, stator or
regulator.)

O Replace the fuse.

O Replace the key switch

O Change the belt.


O Adjust the belt tension.

O Replace the fuse.


O Repair the wiring.

Repair the wiring.

Replace the battery relay.

ALTERNATOR
0202 152, 0201 152, 0201 222

TROUBLESHOOTING

(Check the battery and its related


parts.)

Normal alternator

No

Is the voltage across alternator terminals B and E over 29V?


(Engine speed: 1,000 rpm)

The battery becomes overcharged.


(The battery fluid decreases.).

Yes
Faulty alternator (Regulator)

(Battery fluid decreases)

: Check item

: Problem or corrective action

O Repair the alternator


(Faulty regulator)
(Broken internal wiring)

ALTERNATOR

EE-3-4

0202 152, 0201 152, 0201 222

ALTERNATOR

0202 152, 0201 152, 0201 222

DISASSEMBLY
Models 0202 152 and 0201 152

1. Nut
2. Lock washer
3. Washer
+ 4. Pulley assembly
5. Spacer
+ 6. Front cover
7. Oil seal
8. Washer

9. Ball bearing
10. Washer
11. Oil seal
12. Cover
13. Rotor assembly
14. Stator assembly
15. Field coil assembly
16. Housing

17. Rubber cap


18. Heat sink
19. Terminal
20. Through bolt
21. Charge light circuit assembly
22. Cover
23. Regulator

Marks + and , indicate that the key points of operation are explained in the text.
NOTE
z

Numbers before part names do not indicate the disassembly sequence.

EE-3-5

ALTERNATOR

0202 152, 0201 152, 0201 222

Model 0201 222

1. Nut
2. Lock washer
3. Washer
+ 4. Pulley assembly
+ 5. Front cover
6. Bearing felt
7. Retainer

8. Ball bearing
9. Retainer
10. Cover
11. Rotor assembly
12. Stator assembly
13. Field coil assembly
14. Housing

15. Through bolt


16. Needle bearing
17. Regulator
18. Heat sink
19. Terminal
20. Cover

Marks + and , indicate that the key points of operation are explained in the text.
NOTE
z

Numbers before part names do not indicate the disassembly sequence.

EE-3-6

ALTERNATOR

Key point of disassembly


6 Models 0202 152 and 0201 152
5 Model 0201 222

} Front cover

To separate the front cove assembly, insert a screwdriver into the


clearance between the front cover and stator core.
NOTE
z

Be careful not to damage the stator coil with the screwdriver tip.

4 Models 0202 152 and 0201 152


4 Model 0201 222

} Pulley assembly

When separating the pulley assembly, secure the rotor periphery


with a vise. Then, remove the pulley nut, pulley assembly and
spacer. If the pulley assembly is difficult to remove, use a generalpurpose puller.

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

STATOR COIL
Continuity test of the stator coil
Unit:
Maintenance
standard

Service
limit

0202 152
0201 152

0.18 - 0.22

0201 222

0.14 - 0.18

Item

Resistance

Remarks
Between two
phases at
20C (68F)

If there is no continuity, the stator coil may be broken. Replace the


stator coil as an assembly.

Insulation test of the stator coil


Make sure there is no continuity. If there is continuity, the stator coil
may be shorted. Replace the stator coil as an assembly.

EE-3-7

0202 152, 0201 152, 0201 222

ALTERNATOR

FIELD COIL
Continuity test of the field coil
Unit:
Maintenance
standard

Service
limit

0202 152
0201 152

5.6 - 6.8

0201 222

5.0 - 7.0

Item

Resistance

Remarks

At 20C (68F)

If there is no continuity, the field coil may be broken. Replace the


field coil as an assembly.

Insulation test of the field coil


Make sure there is no continuity. If there is continuity, the field coil
may be shorted. Replace the field coil as an assembly.

PERFORMANCE CHECK
NOTE

Use leads with a cross-sectional area greater than 8 mm2


(0.0124 sq in) and a length less than 2.5 m (8.2 ft) to connect the line between the alternators B terminal and positive battery terminal, the E terminal and battery ground
terminal, and the L terminal and battery ground terminal.
z Use switches with as small a contact resistance as possible in the circuit.
z Conduct performance test in areas where ambient temperature is maintained at 20C (68F).
Start-up revolution
1. Install the alternator on a vehicle or connect to a variable
velocity motor and connect the leads as shown in the figure.
2. Turn switches SW1 and SW2 ON, then gradually increase
alternator speed.
3. When the voltmeter registers a voltage higher than the voltage when the alternator is stopped, turn switch SW1 OFF.
4. While observing the voltmeter, increase alternator speed.
5. Read alternator speed (rpm) when the voltmeter registers
27 volts.
z

EE-3-8

0202 152, 0201 152, 0201 222

ALTERNATOR
Unit: rpm
Maintenance
standard

Service
limit

0202 152
0201 152

Less than 950

0201 222

Less than 900

Item
No-load
speed

Remarks

At 20C (68F)

Measuring of regulating voltage


Turn switch SW1 off and turn switch SW2 on. Increase the alternator speed up to the rated rpm of 5,000. Then, measure the voltage.
Unit: V
Maintenance standard

Service limit

28.0 - 29.0

Measuring output current


1.
2.

Adjust the variable resistor to zero and turn switches SW1


and SW2 on.
Keep the alternator speed at the rated rpm and adjust the
variable resistor so that the terminal voltage is at the specified value. Then, read the current.
Terminal voltage: 28V - 5,000 rpm
Unit: A
Maintenance
standard

Service
limit

0202 152
0201 152

Less than 50

0201 222

Less than 80

Item

Remarks

At 20C (68F)

EE-3-9

0202 152, 0201 152, 0201 222

AIR HEATER

AIR HEATER
CONSTRUCTION

INSPECTION
z

1.
2.

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
Check wiring for improper connections or discontinuity. If
there is no continuity, replace the air heater assembly.
If carbon builds up on the ribbon heater, clean. Check the
heater for discontinuity. If there is discontinuity, replace the
air heater assembly.

EE-4-1

- MEMO -

AUXILIARY EQUIPMENT

CONTENTS
SERVICE DATA ...................................... EA-1-1
SPECIFICATIONS............................................ EA-1-1
SERVICE DATA ............................................... EA-1-2
TIGHTENING TORQUE ................................... EA-1-4
TOOLS .................................................... EA-2-1
AIR COMPRESSOR......................................... EA-2-1
AIR COMPRESSOR ............................... EA-3-1

= MODEL F8040 =
CONSTRUCTION.............................................
REMOVAL ........................................................
DISASSEMBLY ................................................
INSPECTION....................................................
REASSEMBLY .................................................

EA-3-1
EA-3-1
EA-3-2
EA-3-3
EA-3-5

= MODEL 408738 =
CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................

VACUUM PUMP ......................................


CONSTRUCTION .............................................
DISASSEMBLY.................................................
INSPECTION ....................................................
REASSEMBLY..................................................

PUMP SUPPORT ....................................


CONSTRUCTION .............................................
REMOVAL ........................................................
DISASSEMBLY AND REASSEMBLY...............
INSTALLATION ................................................

EA-3-7
EA-3-9
EA-3-10
EA-3-13
EA-3-14
EA-4-1
EA-4-1
EA-4-2
EA-4-2
EA-4-3
EA-5-1
EA-5-1
EA-5-1
EA-5-2
EA-5-2

EA

SERVICE DATA

SERVICE DATA
SPECIFICATIONS
AIR COMPRESSOR
<SANWA make>
Model

F8040

Bore x Stroke - No. of cylinders

mm (in)

80 x 40 - 1 (3.15 x 1.57 - 1)

cm3 (cu in)/rev

Theoretical discharge
Operating speed (max. service revolutions)
Working pressure (max. service pressure)

201 (12.27)

rpm

1,600

834 {8.5, 121}

kPa {kgf/cm , psi}

<ZEXEL make>
408738

Model

5600

Bore x Stroke - No. of cylinders


mm (in)
Theoretical discharge

cm3(cu in)/rev

5601

5610

5611

5741

5780

85 x 40 - 1
(3.35 x 1.57 - 1)

85 x 60 - 1
(3.35 x 2.36 - 1)

227 (13.85)

340 (20.75)

Operating speed (max. service revolutions)


rpm

1,600

Working pressure (max. service pressure)


kPa {kgf/cm2, psi}

834 {8.5, 121}

VACUUM PUMP
Model

1290 009 00 (VD-30)

Type

Vane

Theoretical discharge

cm3 (cu in)/rev

Max. operating speed

rpm

Vacuum
performance

1290 011 00 (VD-120)

Time required to reach 66.7 kPa {500


mmHg, 19.69 inHg}/Engine speed
Max. degree of vacuum/Engine speed

Alternator model

30 (1.83)

120 (7.32)
7,800

Less than 40 seconds/1,000 rpm


Less than 10 seconds/5,000 rpm

Less than 27 seconds/1,500 rpm

More than 90.6 kPa {680 mmHg,


26.77 inHg}/5,000 rpm

More than 80.0 kPa {600 mmHg,


23.62 inHg}/900 rpm

0202 152 0220/0202 152 0221

0202 152 0310/0202 152 0311

EA-1-1

SERVICE DATA

SERVICE DATA
AIR COMPRESSOR
Model F8040
Unit: mm (in)
Maintenance
standard

Service
limit

800 rpm

290 sec.

3,200 rpm

85 sec.

Piston top

0.25 - 0.35
(0.0098 - 0.0138)

0.38
(0.0150)

Piston skirt

0.10 - 0.20
(0.0039 - 0.0079)

0.25
(0.0098)

Compression ring

0.30 - 0.50
(0.0118 - 0.0197)

1.0
(0.039)

Oil ring

0.30 - 0.50
(0.0118 - 0.0197)

1.0
(0.039)

Compression ring

0.01 - 0.05
(0.0004 - 0.0020)

0.08
(0.0031)

Oil ring

0.01 - 0.05
(0.0004 - 0.0020)

0.08
(0.0031)

0.01L - 0.02T
(0.0004L - 0.0008T)

0.08
(0.0031)

L: Loose
T: Tight

Clearance between connecting rod


small-end piston pin hole and piston pin

0.015 - 0.045
(0.0006 - 0.0018)

0.07
(0.0028)

Replace piston pin or connecting rod.

Clearance between connecting rod bigend bushing and crank pin

0.015 - 0.085
(0.0006 - 0.0033)

0.1
(0.004)

Replace bushing if worn so that copper color shows.


Replace crankshaft in the cases.

0 - 0.22
(0 - 0.0087)

Item
Charging performance

Air compressor proper

Piston-to-cylinder
clearance

Piston ring joint


gap

Piston ring-to-ring
groove clearance

Engine
speed

Piston pin hole-to-piston pin clearance

Cylinder head

End play of crankshaft


Suction valve
Tension of valve
spring
N {kgf, lbf} Delivery valve

Valve lift

Remarks
Tank capacity: 30 liter (6-5/8 Imp gal)
Tank pressure:
0 - 785 kPa {0 - 8 kgf/cm2,
0 - 114 psi}

Replace piston or cylinder.

Replace ring.

Replace piston or cylinder.

Replace.

4.41
{0.45, 0.99}

3.53
Measured length 7.0 mm (0.276 in)
{0.36, 0.79}

4.51
{0.46, 1.01}

3.63
Measured length 9.5 mm (0.374 in)
{0.37, 0.82}

Delivery valve

3.0 (0.118)

Unloader valve

1.0 (0.039)

Suction valve

2.6 (0.102)

EA-1-2

SERVICE DATA

Model 408738
Unit: mm (in)
Maintenance
standard

Service
limit

500 rpm

448 sec.

3,200 rpm

66 sec.

500 rpm

264 sec.

3,200 rpm

46 sec.

Piston skirt

0.07 - 0.12
(0.0028 - 0.0047)

0.25
(0.0098)

Compression ring

0.15 - 0.30
(0.0059 - 0.0118)

0.6
(0.024)

Oil ring

0.15 - 0.35
(0.0059 - 0.0138)

0.7
(0.028)

Compression ring

0.02 - 0.05
(0.0008 - 0.0020)

0.08
(0.0031)

Oil ring

0.03 - 0.07
(0.0012 - 0.0028)

0.10
(0.0039)

Piston pin hole-to-piston pin clearance

0.006 - 0.026
(0.0002 - 0.0010)

0.08
(0.0031)

Clearance between connecting rod smallend piston pin hole and piston pin

0.006 - 0.026
(0.0002 - 0.0010)

0.08
(0.0031)

Replace piston pin or connecting


rod.

Clearance between connecting rod bigend crank pin hole and crank pin

0.034 - 0.075
(0.0013 - 0.0030)

0.1
(0.004)

Replace connecting rod if worn so


that copper color shows. Replace
crankshaft in other cases.

0 - 0.50
(0 - 0.0197)

1.0
(0.039)

Replace.

Suction valve
spring

1.18 {0.12, 0.26}

1.0
{0.1, 0.2}

N {kgf, lbf} Delivery valve


spring

7.65 {0.78, 1.72}

Item

Charging
performance

5600
5601
5610
5611

Engine
speed

5741
5780

Engine
speed

Air compressor proper

Piston-to-cylinder
clearance

Piston ring joint gap

Piston ring-to-ring
groove clearance

Cylinder head

End play of crankshaft

Tension

Valve lift

Tank capacity:
30 liter (6-5/8 Imp gal)
Tank pressure:
0 - 785 kPa {0 - 8 kgf/cm2,
0 - 114 psi}
Replace piston or cylinder.

Replace ring.

Replace piston or cylinder.

When compressed to
8.2 mm (0.323 in)

6.08
When compressed to
{0.62, 1.37} 12.5 mm (0.492 in)

Suction valve

2.0 (0.079)

Delivery valve

1.5 (0.059)

EA-1-3

Remarks

SERVICE DATA

VACUUM PUMP
Unit: mm (in)
Item
Vane height

Maintenance standard

Service limit

1290 009 00 (VD-30)

13.5 (0.531)

13.0 (0.512)

1290 011 00 (VD-120)

21.5 (0.846)

21.0 (0.827)

Remarks

TIGHTENING TORQUE
AIR COMPRESSOR
Model F8040
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Suction valve holder

98 - 118 {10.0 - 12.0, 72 - 87}

Unloader valve connector

29 - 34 {3.0 - 3.5, 22 - 25}

Delivery valve holder

98 - 118 {10.0 - 12.0, 72 - 87}

Nut for connecting rod cap

23 - 25 {2.3 - 2.6, 17 - 19}

Cylinder head mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Cylinder mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22}

Lock plate mounting bolt

14 - 18 {1.4 - 1.8, 10 - 13}

Model 408738
Unit: Nm {kgfm, ftlbf}
Item

Tightening torque

Unloader valve connector

44 - 54 {4.5 - 5.5, 33 - 40}

Cylinder head bolt

44 - 54 {4.5 - 5.5, 33 - 40}

Bearing holder mounting bolt

Except model 5780

Bearing holder mounting screw

Model 5780 only

13.2 - 16.2 {1.35 - 1.65, 9.8 - 11.9}


5.3 - 6.5 {0.54 - 0.66, 3.9 - 4.8}

Cylinder bolt

26 - 32 {2.7 - 3.3, 20 - 24}

EA-1-4

TOOLS

TOOLS
AIR COMPRESSOR
Model F8040
Tool name and number

Description

Piston inserting kit


99750 Z5500
(1) 99754 96002
(2) 99756 Z5500
(3) 81-11025-1A
(4) 81-10825-1A

Used to install piston in air compressor


(1) Piston inserting tool
(2) Crankshaft holder
(3) Bolt (M10 x 1.5)
(4) Bolt (M8 x 1.25)

Valve holder tool


99744 97000

Used to remove and install air compressor


suction valve holder

Shape

Model 408738
Tool name and number

Description

Piston inserting kit


99750 Z5501
(1) 99754 96001
(2) 99756 Z5500
(3) 81-11025-1A
(4) 81-10825-1A

Used to install piston in air compressor


(1) Piston inserting tool
(2) Crankshaft holder
(3) Bolt (M10 x 1.5)
(4) Bolt (M8 x 1.25)

Oil seal replacer


99753 Z5501

Used to install sleeve and oil seal in air compressor


[Air compressor crankshaft rear end
outside diameter: 25 mm (0.98 in)]

EA-2-1

Shape

AIR COMPRESSOR

AIR COMPRESSOR
= MODEL F8040 =
CONSTRUCTION

REMOVAL
1.
2.
3.

Release air from the air reservoir tank.


Drain the cooling water from the radiator through the drain
cock.
Remove the injection pump (see section ENGINE DISASSEMBLY AND REASSEMBLY).

EA-3-1

F8040

AIR COMPRESSOR

F8040

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Cylinder head
2. O-ring
, 3. Cylinder
4. O-ring
5. Piston and connecting rod assembly
6. Snap ring
7. Piston pin
, 8. Connecting rod cap
, 9. Connecting rod
, 10. Bushing
, 11. Compression ring
, 12. Oil ring
13. Piston
14. Injection pump drive gear
15. Lock plate

+ 16. Ball bearing


17. Bearing holder
18. O-ring
19. Crankshaft
,+ 20. Ball bearing
21. Oil seal collar
, 22. Oil seal
23. Crankcase
, 24. Delivery valve assembly
25. Delivery valve holder
26. O-ring
27. Spring holder
28. Valve spring
29. O-ring

30. Delivery valve


31. Valve seat
, 32. Unloader valve assembly
33. Unloader valve connector
34. O-ring
35. Unloader valve
36. Valve guide
37. Valve spring
, 38. Suction valve assembly
, 39. Suction valve holder
40. Valve spring
41. Suction valve
42. Valve seat
43. Packing

Marks + and , indicate that the key points of operation are explained in the text.

EA-3-2

AIR COMPRESSOR

Key point of disassembly


Before disassembling the air compressor, measure the end play of
the crankshaft.
Unit: mm (in)
Maintenance standard

Service limit

0 - 0.22 (0 - 0.0087)

16, 20 Ball bearing


Using a puller, remove the ball bearing from the crankshaft.
NOTE
z Remove the ball bearing on the oil seal side together with
the oil seal collar.

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

Piston-to-cylinder clearance
Unit: mm (in)
Item

Maintenance standard

Service limit

Piston top

0.25 - 0.35 (0.0098 - 0.0138)

0.38 (0.0150)

Piston skirt

0.10 - 0.20 (0.0039 - 0.0079)

0.25 (0.0098)

Piston ring joint gap


Unit: mm (in)
Item

Maintenance standard

Service limit

Compression ring

0.30 - 0.50
(0.0118 - 0.0197)

1.0 (0.039)

Oil ring

0.30 - 0.50
(0.0118 - 0.0197)

1.0 (0.039)

EA-3-3

F8040

AIR COMPRESSOR

Piston ring-to-ring groove clearance


Unit: mm (in)
Item

Maintenance standard

Service limit

Compression ring

0.01 - 0.05
(0.0004 - 0.0020)

0.08 (0.0031)

Oil ring

0.01 - 0.05
(0.0004 - 0.0020)

0.08 (0.0031)

Piston pin hole-to-piston pin clearance


Unit: mm (in)
Maintenance standard

Service limit

0.01L - 0.02T
(0.0004L - 0.0008T)

0.08 (0.0031)

Remarks
L: Loose
T: Tight

Clearance between connecting rod small-end piston


pin hole and piston pin
Unit: mm (in)
Maintenance standard

Service limit

0.015 - 0.045 (0.0006 - 0.0018)

0.07 (0.0028)

Clearance between connecting rod big-end bushing


and crank pin
Unit: mm (in)
Maintenance standard

Service limit

0.015 - 0.085 (0.0006 - 0.0033)

0.1 (0.004)

NOTE
z

Replace the bearing if its lining is worn to the extent that


copper color shows. In other cases, replace the crankshaft.

Tension of valve spring


Unit: N {kgf, lbf}
Item

Maintenance
standard

Service limit

Remarks

Suction valve

4.41 {0.45, 0.99}

3.53 {0.36, 0.79}

Measured length
7.0 mm (0.276 in)

Delivery valve

4.51 {0.46, 1.01}

3.63 {0.37, 0.82}

Measured length
9.5 mm (0.374 in)

EA-3-4

F8040

AIR COMPRESSOR

REASSEMBLY
38 Suction valve assembly, 32 Unloader valve assembly,
24 Delivery valve assembly
1. Install the suction valve assembly (using special tool 99744
97000), unloader valve assembly, and delivery valve
assembly to the cylinder head through the packing or Oring.
Unit: Nm {kgfm, ftlbf}
Item
Suction valve holder
Unloader valve connector
Delivery valve holder

Tightening torque
98 - 118 {10.0 - 12.0, 72 - 87}
29 - 34 {3.0 - 3.5, 22 - 25}
98 - 118 {10.0 - 12.0, 72 - 87}

NOTE
z

Apply 0.1 to 0.2 milliliter (0.003 to 0.007 Imp fl oz) of a


screw lock (TB1323B) to the threads on the cylinder head
side of the delivery valve holder.

2.

Using an inspection rod, measure the lift of each valve to


see if it is within the maintenance standard.
Unit: mm (in)
Item

Maintenance standard

Service limit

Delivery valve (A)

3.0 (0.118)

Unloader valve (B)

1.0 (0.039)

Suction valve (C)

2.6 (0.102)

39 Suction valve holder


Lock the suction valve holder with a punch.
NOTE
z Do not caulk in the same position as before.
22 Oil seal
Install the oil seal to the crankcase.
NOTE
z Coat the oil seal lip with engine oil.
20 Ball bearing
Install the ball bearings on the crankshaft by press-fitting.
NOTE
z

The ball bearing on the oil seal side should be installed


with its shield plate facing outward (oil seal side).

EA-3-5

F8040

AIR COMPRESSOR
12 Oil ring, 11 Compression ring
Install the piston rings in the ring grooves, and attach the connecting rod to the piston.
NOTE
z

Install the piston rings so that their joints are neither parallel nor normal to the piston pin and the manufacturers
mark faces up.

10 Bushing, 9 Connecting rod, 8 Connecting rod cap


Fit the bushings in the connecting rod and connecting rod cap, and
install the connecting rod to the crankshaft through the spring
washer.
: 23 - 25 Nm {2.3 - 2.6 kgfm, 17 - 19 ftlbf}
NOTE
z

Match the alignment marks on the connecting rod and


connecting rod cap, and ensure the marks face the drive
gear.

3 Cylinder
Using the piston inserting kit (99750 Z5500), install the cylinder with
the O-ring in place.
: 25 - 29 Nm {2.5 - 3.0 kgfm, 18 - 22 ftlbf}
Piston insert kit (99750 Z5500)
(1) Piston inserting tool (99754 96002)
(2) Crankshaft holder (99756 Z5500)
(3) Bolt (81-11025-1A)
(4) Bolt (81-10825-1A)

EA-3-6

F8040

AIR COMPRESSOR

= MODEL 408738 =
CONSTRUCTION
Model 5600, 5601, 5610 and 5611

EA-3-7

408738

AIR COMPRESSOR
Model 408738-5741

EA-3-8

408738

AIR COMPRESSOR
Model 408738-5780

REMOVAL
1.
2.
3.

Release air from the air reservoir tank.


Drain the cooling water from the radiator through the drain
cock.
Remove the injection pump (see section ENGINE DISASSEMBLY AND REASSEMBLY).

EA-3-9

408738

AIR COMPRESSOR

408738

DISASSEMBLY
Model 5600, 5601, 5610 and 5611

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


, 1. Cylinder head assembly
2. O-ring
, 3. Cylinder
4. O-ring
5. Piston and connecting rod assembly
6. Retaining ring
7.Piston pin

8. Piston
9. Connecting rod
, 10. Piston rings
, 11. Oil seal
12. Bearing holder
13. O-ring

, 14. Sleeve
+ 15. Ball bearing
+ 16. Ball bearing
17. Crankshaft
18. Crank case
19. Unloader valve

Marks + and , indicate that the key points of operation are explained in the text.

EA-3-10

AIR COMPRESSOR

408738

Model 5741

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


, 1. Cylinder head assembly
2. O-ring
, 3. Cylinder
4. O-ring
5. Piston and connecting rod assembly
6. Retaining ring
7. Piston pin

8. Piston
9. Connecting rod
, 10. Piston rings
, 11. Oil seal
12. Bearing holder
13. O-ring

, 14. Sleeve
+ 15. Ball bearing
+ 16. Ball bearing
17. Crankshaft
18. Crank case
19. Unloader valve

Marks + and , indicate that the key points of operation are explained in the text.

EA-3-11

AIR COMPRESSOR

408738

Model 5780

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


, 1. Cylinder head assembly
2. O-ring
, 3. Cylinder
4. O-ring
5. Piston and connecting rod assembly
6. Retaining ring
7. Piston pin

8. Piston
9. Connecting rod assembly
, 10. Piston rings
, 11. Oil seal
12. Bearing holder
13. O-ring

, 14. Sleeve
+ 15. Ball bearing
+ 16. Ball bearing
17. Crankshaft
18. Crank case
19. Unloader valve

Marks + and , indicate that the key points of operation are explained in the text.

EA-3-12

AIR COMPRESSOR

Key point of disassembly


Before disassembling the air compressor, measure the end play of
the crankshaft.
Unit: mm (in)
Maintenance standard

Service limit

0 - 0.50 (0 - 0.0197)

1.0 (0.039)

15, 16 Ball bearing


Using a puller, remove the ball bearing from the crankshaft.
NOTE
z Remove the ball bearing on the oil seal side together with
the oil seal collar.

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

Piston-to-cylinder clearance
Unit: mm (in)
Item
Piston skirt

Maintenance standard

Service limit

0.07 - 0.12 (0.0028 - 0.0047)

0.25 (0.0098)

Piston ring joint gap


Unit: mm (in)
Item

Maintenance standard

Service limit

Compression ring

0.15 - 0.30 (0.0059 - 0.0118)

0.6 (0.024)

Oil ring

0.15 - 0.35 (0.0059 - 0.0138)

0.7 (0.028)

Piston ring-to-ring groove clearance


Unit: mm (in)
Item

Maintenance standard

Service limit

Compression ring

0.02 - 0.05 (0.0008 - 0.0020)

0.08 (0.0031)

Oil ring

0.03 - 0.07 (0.0012 - 0.0028)

0.10 (0.0039)

EA-3-13

408738

AIR COMPRESSOR

Piston pin hole-to-piston pin clearance


Unit: mm (in)
Maintenance standard

Service limit

0.006 - 0.026 (0.0002 - 0.0010)

0.08 (0.0031)

Clearance between connecting rod small-end piston


pin hole and piston pin
Unit: mm (in)
Maintenance standard

Service limit

0.006 - 0.026 (0.0002 - 0.0010)

0.08 (0.0031)

Clearance between connecting rod big-end crank pin


hole and crank pin
Unit: mm (in)
Maintenance standard

Service limit

0.034 - 0.075 (0.0013 - 0.0030)

0.1 (0.004)

Tension of valve spring


Unit: N {kgf, lbf}
Item

Maintenance
standard

Service limit

Remarks

Suction valve
spring

1.18
{0.12, 0.26}

1.0
{0.1, 0.2}

When compressed to
8.2 mm (0.323 in)

Delivery valve
spring

7.65
{0.78, 1.72}

6.08
{0.62, 1.37}

When compressed to
12.5 mm (0.492 in)

REASSEMBLY
Key point of reassembly
14 Sleeve
Press-fit the ball bearing onto the crankshaft, and using the oil seal
replacer (99753 Z5501), install the sleeve.
11 Oil seal
Using the oil seal replacer (99753 Z5501), install the oil seal.

EA-3-14

408738

AIR COMPRESSOR
10 Piston rings
Install the piston rings in the ring grooves, and attach the connecting rod to the piston.
NOTE
z Install the piston rings so that their joints are neither parallel nor normal to the piston pin and the manufacturers
mark faces up.

3 Cylinder
Using the piston inserting kit (99750 Z5501), install the cylinder with
the O-ring in place.
: 26 - 32 Nm {2.7 - 3.3 kgfm, 20 - 24 ftlbf}
Piston insert kit (99750 Z5501)
(1) Piston inserting tool (99754 96001)
(2) Crankshaft holder (99756 Z5500)
(3) Bolt (81-11025-1A)
(4) Bolt (81-10825-1A)

1 Cylinder head assembly


Using a checking rod, etc., measure the valve lift of each valve.
Make sure it is within the maintenance standard and install the cylinder head assembly.
Unit: mm (in)
Item

Maintenance standard

Service limit

Suction valve

2.0 (0.079)

Delivery valve

1.5 (0.059)

Make sure that the end play of the crankshaft is within the
maintenance standard.
Unit: mm (in)
Maintenance standard

Service limit

0 - 0.50 (0 - 0.0197)

1.0 (0.039)

EA-3-15

408738

VACUUM PUMP

VACUUM PUMP
CONSTRUCTION
Model 1290 009 00 (VD-30)

Model 1290 011 00 (VD-120)

EA-4-1

VACUUM PUMP

DISASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Housing
2. Valve
3. Packing
4. Connector
5. Packing

6. Connector
7. Packing
8. Retaining ring
9. Oil seal

, 10. Center plate


11. O-ring
, 12. Rotor assembly
, 13. Vane

Marks + and , indicate that the key points of operation are explained in the text.

INSPECTION
z

Clean all disassembled parts in cleaning solvent. Check for


scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.

VANE
Unit: mm (in)
Item
Height

Maintenance standard

Service limit

1290 009 00

13.5 (0.531)

13.0 (0.512)

1290 011 00

21.5 (0.846)

21.0 (0.827)

CENTER PLATE
Check for damage at the sliding surface with the rotor and replace
when worn or damaged.

HOUSING
Inspect the sliding surface with the rotor for damage and replace
when worn or damaged, especially when the inside diameter is
worn or damaged.

EA-4-2

VACUUM PUMP

OTHERS
z
z

Replace the O-ring at each disassembly.


Replace and discolored copper packing. Moreover, check
the threads of each part for damaged and replace when
damaged beyond use.

REASSEMBLY
Key point of reassembly
13 Vane
Assemble the four vanes with the end having the round chamfer at
the outside.

12 Rotor assembly, 10 Center plate


1. Insert the rotor into the housing. The side which has no
crossed oil groove should face the center plate.
2. Position the center plate on the housing. Make sure a gasket is used between both parts.

3.

Position the vacuum pump assembly so that it is horizontal


when the center plate is placed downward.
Make sure that the hole in the center plate is aligned with
the hole in the rotor shaft when looking through the rotors
hole from the floor side.

EA-4-3

PUMP SUPPORT

PUMP SUPPORT
CONSTRUCTION

REMOVAL
Remove the injection pump support.
NOTE
z

Measure the backlash of the front gear train before


removing the injection pump support.

EA-5-1

PUMP SUPPORT

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)


1. Key
2. O-ring
3. Retaining ring

4. Drive shaft assembly


5. Ball bearing
6. Ball bearing

INSTALLATION
Install the injection pump support using an O-ring (if removed after
measuring front gear train backlash).

1.

Rotate the flywheel in the standard direction to determine


the 1.6 point at TDC of No. 1 cylinder on the compression
stroke. (TDC is the point at which both intake and exhaust
valves for No. 1 cylinder are closed and there is a valve
clearance.)

EA-5-2

7. Drive shaft
8. Oil seal
9. Bearing holder

PUMP SUPPORT
2.

Align the scribe mark on the injection pump drive gear tooth
with the pointer at the check window on the upper side of
the timing gear case. Then, install the injection pump support.

EA-5-3

- MEMO -