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WORKSHOP MANUAL

F-SERIES

ENGINE
6HK1-TC MODEL

SECTION 6

International Service & Parts


Tokyo, Japan
NOTICE

Before using this Workshop Manual to assist you in performing


vehicle service and maintenance operations, it is
recommended that you carefully read and thoroughly
understand the information contained in Section 00 under the
headings "GENERAL REPAIR INSTRUCTIONS" and "HOW TO
USE THIS MANUAL."

All material contained in this Manual is based on the latest product


information available at the time of publication.
All rights are reserved to make changes at any time without
prior notice.

Applicable Model : FRR, FSS, FSR, FTR, FTS, FVR, FVD

This Manual is applicable to 2003 year model and later vehicles.


THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION CONTENTS
00 Service Information
6A Engine Mechanism
6B Engine Cooling
6C Fuel System
6D Engine Electrical
6E —
6F Exhaust
6G Turbocharger
SERVICE INFORMATION 00 – 1

SECTION 00
SERVICE INFORMATION

CONTENTS

PAGE
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 3
Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–46
Service Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–50
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–54
Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–73
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–81
00 – 2 SERVICE INFORMATION

MEMO
SERVICE INFORMATION 00 – 3

TROUBLESHOOTING

CONTENTS

PAGE
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 4
Hard Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 4
Unstable Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 8
Insufficient Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–10
Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–12
Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–14
Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–15
White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–17
Black Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–18
Oil Pressure Does Not Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–19
Abnormal Engine Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–21
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–25
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–25
Starter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–30
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–35
00 – 4 SERVICE INFORMATION

ENGINE MECHANICAL
HARD STARTING
1) STARTER MOTOR DOES NOT OPERATE

Checkpoint Trouble Cause Countermeasure

NG Loose battery cable terminals Clean and / or retighten the


Battery
Poor connections due to rusting battery cable terminals

NG
Battery discharged or weak Recharge or replace the battery

OK

NG
Slow blow fuse Slow blow fuse open Replace the slow blow fuse

OK

NG Defective starter switch or Replace the starter switch or the


Starter switch
starter relay starter relay

OK

NG Defective magnetic switch or Repair or replace the magnetic


Starter motor
starter relay switch

NG Repair or replace the starter


Defective starter motor
motor
SERVICE INFORMATION 00 – 5

2) STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER

Checkpoint Trouble Cause Countermeasure

NG Loose battery cable terminals Clean and/or retighten the


Battery
Poor connections due to rusting battery cable terminals

NG
Battery discharged or weak Recharge or replace the battery

OK

NG
Starter motor Defective pinion gear Replace the pinion gear

NG Repair or replace the magnetic


Defective magnetic switch
switch

NG Brush wear Replace the brush and/or the


Weak brush spring brush spring

OK

NG Piston,crankshaft bearing Repair or replace the related


Engine
seizure, or other damage parts
00 – 6 SERVICE INFORMATION

3-1) Fuel is Not Being Delivered to The Injection Pump

Checkpoint Trouble Cause Countermeasure

NG
Fuel Fuel tank is empty Fill the fuel tank

OK

Repair or replace the fuel lines


NG Clogged or damaged fuel lines
Fuel piping Retighten the fuel line
Loose fuel line connections
connections

OK

NG Replace the fuel filter element or


Fuel filter Clogged fuel filter element
the fuel filter cartridge

OK

NG Bleed the air from the fuel


Fuel system Air in the fuel system
system

OK

Fuel feed pump NG Fuel feed pump strainer is Clean the fuel feed pump
(6HK1-TCS only) clogged strainer

NG
Defective feed pump Repair or replace the feed pump
SERVICE INFORMATION 00 – 7

3-2) Fuel is Being Delivered to The Injection Pump

Checkpoint Trouble Cause Countermeasure

Engine stop knob NG


Poor return of engine stop knob
(6HK1-TCS only)
(1) Completely return the engine
stop knob.
(2) Return starter switch to the
“ACC” position and restart.
(3) Clear erroneous memory.
NG Starter switch not returned to the
“OFF” position

OK

NG See emission and electrical


Electronic control system Occurred error
diagnosis

OK

NG
Fuel Use of the wrong fuel Use the correct fuel

NG
Water particles in the fuel Change the fuel

OK

NG Bleed the air from the fuel


Fuel system Air in the injection pump
system

OK

NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle

NG Injection nozzle starting pressure


Adjust or replace the injection
too low
nozzle (6HK1-TCS only)
Improper spray condition

Continued on the next page


00 – 8 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page


OK

Injection pump NG Defective injection pump control Repair or replace the injection
(6HK1-TCS only) rack operation pump control rack
SERVICE INFORMATION 00 – 9

UNSTABLE IDLING

Checkpoint Trouble Cause Countermeasure

NG Defective idling speed control Repair or replace the idling


Idling speed control switch
switch speed control switch

OK

NG See emission and electrical


Electronic control system Occurred error
diagnosis

OK

NG Accelerator control system Adjust the accelerator control


Accelerator control system
improperly adjusted system

OK

NG Valve clearance improperly


Valve clearance Adjust the valve clearance
adjusted

OK
Blown out cylinder head gasket
NG Worn cylnder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

OK

NG
Engine mounting rubber Broken Replace

OK

NG
Camshaft Worn camshaft lobe Replace the camshaft

Continued on the next page


00 – 10 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page


OK

EGR system NG Repair or replace the EGR


Defective EGR system
(6HK1-TCS only) system

OK

NG Repair or replace the fuel


Fuel system Fuel system leakage or blockage
system

NG Bleed the air from the fuel


Air in the fuel system
system

NG Water particles in the fuel


Change the fuel
system

OK

NG Replace the fuel filter element or


Fuel filter Clogged fuel filter element
the fuel filter cartridge

OK

NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle

Injection nozzle starting


NG Adjust or replace the injection
pressure too low
nozzle (6HK1-TCS only)
Improper spray condition

OK

Injection pump NG
Defective control system Replace the injection pump ASM
(6HK1-TCS only)
SERVICE INFORMATION 00 – 11

INSUFFICIENT POWER

Checkpoint Trouble Cause Countermeasure

NG Clean or replace the air cleaner


Air cleaner Clogged air cleaner element
element

OK

NG See emission and electrical


Electronic control system Occurred error
diagnosis

OK

NG
Fuel Water particles in the fuel Replace the fuel

OK

NG Replace the fuel filter element or


Fuel filter Clogged fuel filter element
the fuel filter cartridge

OK

Fuel feed pump NG Clogged strainer or Repair or replace the fuel feed
(6HK1-TCS only) defective fuel feed pump pump

OK

NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle

Injection nozzle starting


NG Adjust or replace the injection
pressure too low
nozzle (6HK1-TCS only)
Improper spray condition

Continued on the next page


00 – 12 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page


OK

NG Fuel injection pipes damaged or


Fuel injection pipes Replace the fuel injection pipes
obstructed

OK

NG Repair or replace the EGR


EGR system Defective EGR system
system

OK

NG
Injection pump Defective control system Replace the injection pump ASM

OK
Blown out cylinder head gasket
NG Worn cylnder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

OK

NG Valve clearance improperly


Valve clearance Adjust the valve clearance
adjusted

OK

NG
Valve spring Valve spring weak or broken Replace the valve spring

OK

NG
Exhaust system Exhaust pipe clogged Clean the exhaust pipe

Continued on the next page


SERVICE INFORMATION 00 – 13

Checkpoint Trouble Cause Countermeasure

Continued from the previous page


OK

NG
Camshaft Worn camshaft lobe Replace the camshaft

OK

NG Booster compensator pipe broken Replace the booster compensator


Turbocharger
or cracked pipe

Exhaust gas leakage from the


NG exhaust system
Repair or replace the related parts
Air leakage from the intake
system

NG Replace the turbocharger


Defective turbocharger assembly
assembly
00 – 14 SERVICE INFORMATION

EXCESSIVE FUEL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

NG Repair or replace the fuel


Fuel system Fuel leakage
system related parts

OK

NG Clean or replace the air cleaner


Air cleaner Clogged air cleaner element
element

OK

NG Replace the engine control


Engine control system Defective engine control system
system

OK

NG
Thermostat Defective Replace

OK

NG
Engine oil Improper engine oil viscosity Correct

OK

Injection nozzle starting


NG Adjust or replace the injection
Injection nozzle pressure too low
nozzle (6HK1-TCS only)
Improper spray condition

OK

NG Fuel injection timing improperly


Fuel injection timing Adjust the fuel injection timing
adjusted

Continued on the next page


SERVICE INFORMATION 00 – 15

Checkpoint Trouble Cause Countermeasure

Continued from the previous page


OK

NG
Injection pump Defective control system Replace the injection pump ASM

OK

NG Valve clearance improperly


Valve clearance Adjust the valve clearance
adjusted

OK
Blown out cylinder head gasket
NG Worn cylinder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

OK

Valve spring NG Valve spring weak or broken Replace the valve spring

OK

NG Poor opening of exhaust brake


Exhaust brake system Repair or replace
valve

OK

NG Inspect, repair, or replace


Brake Dragging trouble
(Refer to other service manuals.)

OK

NG Air leakage from the turbocharger Repair the turbocharger intake


Turbocharger
intake side side

NG Replace the turbocharger


Defective turbocharger assembly
assembly
00 – 16 SERVICE INFORMATION

EXCESSIVE OIL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

NG Engine oil unsuitable Replace the engine oil


Engine oil
Too much engine oil Correct the engine oil volume

OK

NG Oil leakage from the oil seal Replace the oil seal and/or the
Oil seal and gasket
and/or the gasket gasket

OK

NG
Air breather Clogged air breather Clean the air breather

OK

NG Worn valve stems Replace the intake and exhaust


Intake and exhaust valves
valves and the valve guides

OK

NG
Valve stem oil seal Worn Replace

OK
Blown out cylinder head gasket
NG Worn cylinder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

OK

NG
Turbocharger Seal ring worn or broken Replace the turbocharger

OK

NG Repair or replace the air


Air Compressor Piston ring worn or broken
compressor
SERVICE INFORMATION 00 – 17

OVERHEATING

Checkpoint Trouble Cause Countermeasure

NG
Engine cooling water Insufficient cooling water Replenish the cooling water

OK

NG Oil leakage from the fan


Fan coupling Replace the fan coupling
coupling

OK

NG Fan belt loose or cracked


Fan belt Replace the fan belt
causing slippage

OK

NG Defective radiator cap or Replace the radiator cap or


Radiator
clogged radiator core clean the radiator core

OK

NG Repair or replace the water


Water pump Defective water pump
pump

OK

Cylinder head and cylinder body NG Defective sealing cap resulting


Replace the sealing cap
sealing cap in water leakage

OK

NG
Thermostat Defective thermostat Replace the thermostat

Continued on the next page


00 – 18 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page


OK

NG Cooling system clogged by Clean the foreign material from


Cooling system
foreign material the cooling system

OK

NG Fuel injection timing improperly


Fuel injection timing Adjust the fuel injection timing
adjusted

OK

NG Replace the engine control


Engine control system Defective engine control module
module
SERVICE INFORMATION 00 – 19

WHITE EXHAUST SMOKE

Checkpoint Trouble Cause Countermeasure

NG
Fuel Water particles in the fuel Replace the fuel

OK

NG
Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing

OK
Blown out cylinder head gasket
NG Worn cylinder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

OK

Defective valve seals


NG Replace the valve seals, the
Intake and exhaust valve seals Worn valve stems and valve
valves, and the valve guides
guides

OK

NG
Cooling system Defective thermostat Replace

OK

NG Replace the engine control


Engine control system Defective engine control module
module

OK

NG
Turbocharger Defective turbocharger Replace the turbocharger
00 – 20 SERVICE INFORMATION

BLACK EXHAUST SMOKE

Checkpoint Trouble Cause Countermeasure

NG Clean or replace the air cleaner


Air cleaner Clogged air cleaner element
element

OK

NG See emission and electrical


Electronic control system Occurred error
diagnosis

OK

Injection nozzle starting


NG Adjust or replace the injection
Injection nozzle pressure too low
nozzle (6HK1-TCS only)
Improper spray condition

OK

NG
Fuel injection timing Advanced fuel injection timing Adjust the fuel injection timing

OK

NG Repair or replace the EGR


EGR system Defective EGR system
system

OK

NG
Injection pump Defective control system Replace the injection pump ASM

OK

Camshaft NG
Worn camshaft lobe Replace the camshaft

OK

Exhaust brake system NG


Exhaust brake valve clogged Repair or replace
SERVICE INFORMATION 00 – 21

OIL PRESSURE DOES NOT RISE

Checkpoint Trouble Cause Countermeasure

NG Improper viscosity engine oil Replace the engine oil


Engine oil
Insufficient engine oil Correct the engine oil volume

OK

Defective oil pressure gauge or Repair or replace the oil


Oil pressure gauge or unit NG
unit pressure gauge or unit
Oil pressure indicator light
Defective indicator light Replace the indicator light

OK

NG Replace the oil filter element or


Oil filter Clogged oil filter element
the oil filter cartridge

OK

NG Relief valve sticking and/or weak Replace the relief valve and/or
Relief valve and by-pass valve
by-pass valve spring the by-pass spring

OK

NG
Oil pump Clogged oil pump strainer Clean the oil pump strainer

NG Replace the oil pump related


Worn oil pump related parts
parts

OK

NG
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing

Continued on the next page


00 – 22 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page


OK

NG Worn camshaft and camshaft Replace the camshaft and the


Camshaft
brackets camshaft brackets

OK

NG Replace the crankshaft


Crankshaft and bearings Worn crankshaft and bearings
and/or the bearings

OK

NG
Oiling jet joint bolts Loose Tighten
SERVICE INFORMATION 00 – 23

ABNORMAL ENGINE NOISE

1) ENGINE KNOCKING

Checkpoint Trouble Cause Countermeasure

Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

NG
Fuel Use of the wrong fuel Use the correct fuel

OK

NG Fuel injection timing improperly


Fuel injection timing Adjust the fuel injection timing
adjusted

OK

Improper injection nozzle


NG Adjust or replace the injection
Injection nozzle starting pressure and spray
nozzle (6HK1-TCS only)
condition

OK

NG Blown out head gasket Replace the head gasket or the


Compression pressure
Broken piston ring piston ring

OK

NG
Injection pump Defective control system Replace the injection pump ASM
00 – 24 SERVICE INFORMATION

2) GAS LEAKAGE NOISE

Checkpoint Trouble Cause Countermeasure

Loosely connected exhaust Tighten the exhaust pipe


NG
Exhaust pipes pipes connections
Broken exhaust pipes Replace the exhaust pipes

OK

Replace the washers


Injection nozzles and/or glow NG Loose injection nozzle and/or
Tighten the injection nozzles
plugs glow plugs
and/or the glow plugs

OK

NG Loosely connected exhaust Tighten the exhaust manifold


Exhaust manifold
manifold connections

OK

NG Replace the cylinder head


Cylinder head gasket Damaged cylinder head gasket
gasket

OK

EGR system NG
Defective EGR system Replace the EGR system
(6HK1-TCS only)
SERVICE INFORMATION 00 – 25

3) CONTINUOUS NOISE

Checkpoint Trouble Cause Countermeasure

NG
Fan belt Loose fan belt Readjust the fan belt tension

OK

NG
Cooling fan Loose cooling fan Tighten the cooling fan

OK

NG Worn or damaged water pump Replace the water pump bearing


Water pump bearing
bearing

OK

NG
Generator Defective generator Repair or replace the generator

OK

NG Valve clearance improperly


Valve clearance Adjust the valve clearance
adjusted
00 – 26 SERVICE INFORMATION

4) SLAPPING NOISE

Checkpoint Trouble Cause Countermeasure

NG Valve clearance improperly


Valve clearance Adjust the valve clearance
adjusted

OK

NG
Rocker arm Damaged rocker arm Replace the rocker arm

OK

NG
Flywheel Loose flywheel bolts Tighten the flywheel bolts

OK

NG Worn or damaged crankshaft Replace the crankshaft and/or


Crankshaft and thrust bearings
and/or thrust bearings the thrust bearings

OK

Crankshaft and connecting rod NG Worn or damaged crankshaft Replace the crankshaft and/or
bearings and/or connecting rod bearings the connecting rod bearings

OK

Connecting rod bushing and NG Worn or damaged connecting Replace the connecting rod
piston pin rod bushing and piston pin bushing and/or the piston pin

OK

Worn or damaged piston and


NG Replace the piston and the
Piston and cylinder liner cylinder liner
cylinder liner
Foreign material in the cylinder
SERVICE INFORMATION 00 – 27

ENGINE ELECTRICAL
GENERATOR
1) BATTERY DEAD

Checkpoint Trouble Cause Countermeasure

NG
Generator drive belt Loose Adjust

OK

NG
Battery fluid Low Replenish

OK

NG
Battery terminal Defective (Internal short circuit) Replace

OK

NG
Fuse Blown Replace

OK

NG
Fuse holder and fuse Poor contact Repair

OK

NG
Battery fluid specific gravity Wrong Adjust

OK

Starter switch and regulator NG


Broken or poorly connected Repair
terminal wire

Continued on the next page


00 – 28 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

Regulator terminal and NG


Broken or poorly connected Repair
generator terminal wire

OK

Generator NG
Defective Repair
ground circuit

OK

NG
Voltage regulator Defective Replace

OK

NG
Diode Defective Replace

OK

NG
Generator stator coil Grounded or broken Repair or replace

OK

NG
Rotor coil Broken Replace

OK

NG Check generator output at


Electrical load Excessive
normal driving speed
SERVICE INFORMATION 00 – 29

2) BATTERY OVERCHARGED

Checkpoint Trouble Cause Countermeasure

Wiring and terminals NG Poor connections or open


(Generator to voltage Correct
circuit
regulator)

OK

NG
Voltage regulator Poor ground connection Correct

NG
Voltage set too high Replace

NG
Defective Replace

3) FLASHING CHARGE LIGHT OR FLUCTUATING AMMETER INDICATION

Checkpoint Trouble Cause Countermeasure

NG
Fan belt Loose Adjust

OK

NG
Starter switch contacts Defective Replace

OK

NG
Wiring Broken or poorly connected Replace or reconnect
00 – 30 SERVICE INFORMATION

4) CHARGE LIGHT ON BUT DIM WHILE DRIVING

Checkpoint Trouble Cause Countermeasure

NG
Starter switch terminal wiring Loose Retighten

OK

Generator and fuse holder NG Replace the wire with a


Excessive resistance
terminal wire larger one

OK

NG
Starter switch contacts Defective Replace

5) GENERATOR NOISE

Checkpoint Trouble Cause Countermeasure

NG
Generator bearing Defective Replace and regrease

OK

NG
Generator stator coil Exposed wires Replace

NG
Short circuit Replace
SERVICE INFORMATION 00 – 31

6) CHARGER CIRCUIT FUSE BLOWN

Checkpoint Trouble Cause Countermeasure

NG
Terminal wiring Grounded Repair

OK

NG Replace the end frame


Generator end frame diodes Defective
assembly

OK

NG
Battery connections Reversed Correct
00 – 32 SERVICE INFORMATION

STARTER MOTOR
1) STARTER AND MAGNETIC SWITCH DO NOT OPERATE

Checkpoint Trouble Cause Countermeasure

NG
Battery fluid level Low Replenish

OK

NG Recharge or replace the


Battery specific gravity Low
battery

OK

NG
Battery switches Poor contact Replace

OK

NG
Starter switch Defective Replace

OK

Magnetic switch pull-in coil NG


Defective Replace
and plunger

OK

NG
Armature coil Broken Replace

OK

NG
Field coil Broken Replace

Continued on the next page


SERVICE INFORMATION 00 – 33

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG
Magnetic switch coil Broken Replace

OK

NG
Holding coil Broken Replace
00 – 34 SERVICE INFORMATION

2) MAGNETIC SWITCH CLOSES BUT STARTER DOES NOT OPERATE

Checkpoint Trouble Cause Countermeasure

NG
Battery fluid level Low Replenish

OK

NG Recharge or replace the


Battery specific gravity Low battery

OK

NG
Starting circuit Poor contacts Repair

OK

NG
Magnetic switch terminals Poor contact Replace

OK

NG
Brushes Worn Replace

OK

NG
Armature Shorted Repair or replace
SERVICE INFORMATION 00 – 35

3) STARTER MOTOR RUNS SLOWLY

Checkpoint Trouble Cause Countermeasure

Magnetic terminal circuit NG


Bad contact Repair
switches

OK

NG
Brushes Excessive wear Replace

OK

NG
Starter motor armature Shorted Repair or replace

4) STARTER MOTOR OPERATES BUT THE ENGINE DOES NOT TURN OVER

Checkpoint Trouble Cause Countermeasure

NG Repair or replace the


Pinion and ring gear No meshing over running clutch and the
drive lever

OK

NG
Overrunning clutch Slippage Replace

OK

NG
Brushes Excessive wear Replace
00 – 36 SERVICE INFORMATION

5) ABNORMAL OPERATING NOISE

Checkpoint Trouble Cause Countermeasure

NG
Bushings Excessive wear Replace

OK

NG Replace the overrunning


Pinion gear Excessive wear
clutch and the pinion gear

NG Lubricate or replace the


Rough sliding action
overrunning clutch

OK

NG Replace the overrunning


Ring gear Excessive wear
clutch and the ring gear

OK

NG
Brushes Excessive wear Replace
SERVICE INFORMATION 00 – 37

TURBOCHARGER
1) ENGINE HAS LESS THAN NORMAL POWER

Checkpoint Trouble Cause Countermeasure

NG
Air cleaner Restricted Clean or replace

OK

NG
Intake pipe and hose Restricted Clean or replace

OK

NG
Compressor/Intake manifold Loose (Leaking) Repair

OK

NG
Exhaust manifold/turbine inlet Loose (Leaking) Repair

OK

NG
Exhaust piping and silencers Restricted Clean or replace

OK

NG
Air breather Restricted Clean or replace

OK

NG
Boost compensator Defective Repair or replace

Continued on the next page


00 – 38 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG
Compressor wheel Impact damage Replace

OK

NG
Turbine wheel Impact damage Replace

NG
Carbon build-up Replace

OK

NG
Rotating assembly Dragging or seized Replace
SERVICE INFORMATION 00 – 39

2) BLUE OR BLACK SMOKE

Checkpoint Trouble Cause Countermeasure

NG
Air cleaner or intercooler Restricted Clean, repair, or replace

OK

NG
Turbocharger oil seal Leakage Replace

OK

NG
Turbocharger oil drain pipe Restricted Repair or replace

OK

NG
Boost compensator Defective Repair or replace

OK

NG
Compressor wheel Impact damage Replace

OK

NG
Turbine wheel Impact damage Replace

Continued on the next page


00 – 40 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

Center housing oil drain NG


Restricted Clean or replace
passage
SERVICE INFORMATION 00 – 41

3) EXCESSIVE OIL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

NG
P.C.V system Defective Repair or replace

OK

NG
Boost compensator Defective Repair or replace

OK

NG
Turbocharger oil seal Leakage Replace

OK

NG
Turbocharger oil drain pipe Restricted Clean or replace

OK

NG
Turbine wheel Impact damage Replace

OK

NG
Compressor wheel Impact damage Replace

OK

NG
Oil pressure Excessive Repair

Continued on the next page


00 – 42 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

Center housing oil drain NG


Restricted Clean or replace
passage
SERVICE INFORMATION 00 – 43

4) EXCESSIVE TURBOCHARGER NOISE

Checkpoint Trouble Cause Countermeasure

Intake and exhaust system NG


Restricted Repair
joints

OK

Intake and exhaust system NG


Damaged Repair
gaskets

OK

NG
Turbocharger rotating parts Rough rotation Replace

OK

NG
Compressor wheel Rubbing against housing Repair or replace

NG
Damaged Replace

OK

NG
Turbine wheel Rubbing against housing Repair or replace

NG
Damaged Replace

NG
Carbon deposits Clean or replace

Continued on the next page


00 – 44 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG
Oil level Too low Correct

OK

NG
Engine oil Contaminated Replace oil

OK

NG
Turbocharger oil feed pipe Restricted Repair or replace

OK

NG
Turbine housing Carbon deposits Clean

OK

NG
Compressor housing Dirty Clean

OK

NG
Turbine shaft bearings Worn Replace
SERVICE INFORMATION 00 – 45

5) EXCESSIVE ROTATING PART WEAR

Checkpoint Trouble Cause Countermeasure

NG
Engine oil Contaminated Change

NG
Wrong grade or type Change

OK

NG
Turbocharger oil feed pipe Restricted Clean or replace

OK

NG
Turbocharger oil seal Defective Replace

OK

Center housing oil drain NG


Restricted Clean or replace
passage

OK

NG
Turbine shaft Oil sludge and coking Replace

OK

Engine lubrication system Inadequate oil supply Correct


00 – 46 SERVICE INFORMATION

MAIN DATA AND SPECIFICATIONS


ENGINE MODEL
ITEM 6HK1-TCS

Engine type Four-cycle, overhead camshaft, water cooled, direct injection


Combustion chamber type Open type, in piston crown
Cylinder liner type Dry liner
Timing drive system Gear drive
No. of cylinders - Bore × stroke mm (in) 6 - 115 × 125 (4.53 × 4.92)
No. of piston rings Compression rings: 3 Oil ring: 1
Total piston displacement cm3 (in3) 7,790 (475.3)
Compression ratio (To 1) 16.9
Compression pressure at 200 rpm
kPa (kg/cm2 / psi) 3,236 (33 / 469)
Engine weight kg (lb) 620 (1,367) (Reference)
Fuel injection order 1-5-3-6-2-4
Fuel injection timing (BTDC) deg 2
Specified fuel type SAE No. 2 diesel fuel
Idling speed rpm 630
Valve clearances Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Intake valves Open at (BTDC) deg 15
Close at (ABDC) deg 44
Exhaust valves Open at (BBDC) deg 58
Close at (ATDC) deg 11
Fuel system
Injection pump type Bosch in line - MD-TICS type
Governor type Electronic control - RED-IV
Injection nozzle type Hole type
Number of injection nozzle orifices Five holes
Injection nozzle opening pressure
MPa (kg/cm2 / psi) 21.6 (220 / 3,128)
Main fuel filter Cartridge type
Exhaust gas recirculation system (EGR) Equipped
Lubricating system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CD
Oil pressure (at oil gallery)
kPa (kg/cm2 /psi) rpm Approx. 98 (1.0 / 14) / 525
Oil pump type Gear (Crankshaft drive)
Oil filter type Cartridge type
Oil capacity lit (US gal / imp gal) 11 - 14 (2.9 - 3.7 / 2.4 - 3.1) with combined oil filter
Oil cooler Plate type-Water cooled in water jacket
Air cleaner Cyclone type with paper element
Battery type / Volt x No. of units 65D23R 12 × 2
SERVICE INFORMATION 00 – 47

MAIN DATA AND SPECIFICATIONS


ENGINE MODEL
ITEM 6HK1-TCC 6HK1-TCN

Engine type Four-cycle, overhead camshaft, water cooled, direct injection


Combustion chamber type Open type, in piston crown
Cylinder liner type Dry liner
Timing drive system Gear drive
No. of cylinders - Bore × stroke mm (in) 6 - 115 × 125 (4.53 × 4.92)
No. of piston rings Compression rings: 3 Oil ring: 1
Total piston displacement cm3 (in3) 7,790 (475.3)
Compression ratio (To 1) 16.9
Compression pressure at 200 rpm
kPa (kg/cm2 / psi) 3,236 (33 / 469)
Engine weight kg (lb) 620 (1,367) (Reference)
Fuel injection order 1-5-3-6-2-4
Fuel injection timing (BTDC) deg 0
Specified fuel type SAE No. 2 diesel fuel
Idling speed rpm 630
Valve clearances Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Intake valves Open at (BTDC) deg 15
Close at (ABDC) deg 44
Exhaust valves Open at (BBDC) deg 58
Close at (ATDC) deg 11
Fuel system
Injection pump system Electronic cotrolled fuel injection system (common rail system)
Main fuel filter type Cartridge type
Exhaust gas recirculation system (EGR) Not equipped
Lubricating system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CD or CE
Oil pressure (at oil gallery)
kPa (kg/cm2 /psi) rpm Approx. 98 (1.0 / 14) / 525
Oil pump type Gear (Crankshaft drive)
Oil filter type Replaceable Cartridge
Oil capacity lit (US gal / imp gal) 11 - 14 (2.9 - 3.7 / 2.4 - 3.1) with combined oil filter
Oil cooler Plate type-Water cooled in water jacket
Air cleaner Cyclone type with paper element
Battery type / Volt x No. of units 75D23R-MF or 80D26R-MF 12X2
00 – 48 SERVICE INFORMATION

ENGINE COOLING
ENGINE MODEL 6HK1TCS, 6HK1TCC, 6HK1TCN
ITEM
Radiator type Corrugated fin with reserve tank
Cooling capacity lit (US gal / imp gal) 24 (6.3/ 5.3)
Water pump type Centrifugal impeller
Thermostat type Wax pellet
Valve initial opening temperature ˚C (˚F) 82.0 (179.6)
Valve full opening temperature ˚C (˚F) 95.0 (203.0)
Valve lift at fully open position mm (in) 8 (0.31)
SERVICE INFORMATION 00 – 49

ENGINE ELECTRICAL
GENERATOR

Type Brushless
Output power W 1500
Rated voltage V 24
Output current A 60
Rotation (Viewed from the pulley) Clockwise
Ground polarity Negative
Pulley diameter mm (in) 80
Regulator IC type (Built-in)

STARTER MOTOR

Voltage V 24
Output kW 4.5 5.0
Type Magnetic switch controlled
Drive gears Reduction
No. of pinion gear teeth 11
No-load characteristics
Voltage V 23
Current A 90 or less 85 or less
Operating speed (Rotor) rpm 3,500 or more 3,300 or more
Rotation Clockwise viewed from the drive pinion gear

TURBOCHARGER
Turbocharger model HONEY WELL
Turbine type Radial inflow
Compressor type Radial outflow
Waste gate without (6HK1-TCN)
Weight kg (lb) 12 (26.5)
00 – 50 SERVICE INFORMATION

SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT

Cylinder Head
Lower Face Warpage mm (in) 0.05 (0.002) or less 0.20 (0.008)
Do not attempt to regrind
the lower face.
Valve Guide
Valve Stem and Valve Guide Clearance
Intake: mm (in) 0.04 – 0.07 0.20
(0.0016 – 0.0028) (0.008)
Exhaust: mm (in) 0.06 – 0.10 0.25
(0.0024 – 0.0039) (0.010)
Valve Stem Outside Diameter
Intake: mm (in) 7.95 – 7.96 7.88
(0.3130 – 0.3134) (0.3102)
Exhaust: mm (in) 7.92 – 7.94 7.88
(0.3118 – 0.3126) (0.3102)
Valve Guide Upper End Height mm (in) 14.1 (0.56) —
Valve and Valve Seat Insert
Valve Thickness
Intake: mm (in) 1.7 (0.067) 1.3 (0.051)
Exhaust: mm (in) 1.8 (0.071) 1.3 (0.051)
Valve Depression A
Intake: mm (in) 1.0 (0.039) 2.5 (0.098)
Exhaust: mm (in) 1.3 (0.051) 2.8 (0.110)
Valve Contact Width
Intake: mm (in) 2.5 (0.098) 3.2 (0.126)
Exhaust: mm (in) 2.0 (0.079) 2.8 (0.110)
Valve Face Angle
Intake: deg 30 —
Exhaust: deg 45 —
Valve Spring
Spring Height
Intake mm (in) 65.9 (2.59) 64.6 (2.54)
Exhaust mm (in) 68.1 (2.68) 66.7 (2.63)
Intake Valve Spring Tension N (kg / lb)
Compression Height at
46mm (1.81 in) 348 (35.5 / 78.3) 309 (31.5 / 69.5)
Exhaust Valve Spring Tension
N (kg / lb)
Compression Height at
46mm (1.81 in) 383 (39.0 / 86.0) 329 (33.5 / 73.9)
SERVICE INFORMATION 00 – 51

ITEMS SERVICE STANDARD SERVICE LIMIT

Rocker Arm Shaft and Rocker Arm


Rocker Arm Shaft Run-Out mm (in) — 0.30 (0.012)
Rocker Arm Shaft Outside Diameter
mm (in) 21.979 – 22.000 21.85
(0.865 – 0.866) (0.860)
Rocker Arm Shaft and
Rocker Arm Clearance mm (in) 0.010 – 0.056 0.20
(0.0004 – 0.0022) (0.008)
Rocker Arm Pin and Roller Clearance
mm (in) 0.068 – 0.099 0.50
(0.0026 – 0.0039) (0.02)
Valve Cap Worn mm (in) — 1 (0.039)
Camshaft
Camshaft Journal Diameter mm (in) 39.950 – 39.975 39.85
(1.5728 – 1.5738) (1.569)
Camshaft Run-Out mm (in) 0.25 0.05
(0.001) (0.002)
Camshaft Bearing Clearance mm (in) 0.025 – 0.087 0.15
(0.001 – 0.035) (0.006)
Camshaft Thrust Surface and
Camshaft Gear Clearance mm (in) 28.015 – 28.055 —
(1.103 – 1.105)
Cam lift mm (in)
Intake 7.831 (0.3083) 7.331 (0.2886)
Exhaust 8.594 (0.3383) 8.094 (0.3186)

Crankshaft
Crankshaft End Play mm (in) 0.040 – 0.205 0.54
(0.0026 – 0.008) (0.021)
Crankshaft Run-Out mm (in) 0.06 or less 0.45
(0.0024 or less) (0.018)
Crankshaft Journal Diameter mm (in) 81.875 – 81.895 (No 4) —
(3.2234 – 3.2242)
81.905 – 81.925 (OTHERS) —
(3.2246 – 3.2254)
Crankshaft Journal and
Bearing Clearance mm (in)
No. 4 Bearing 0.093 – 0.124 0.14
(0.00366 – 0.00488) (0.0055)
Other Bearings 0.063 – 0.094 0.14
(0.00248 – 0.00370) (0.0055)
Crankshaft Journal and
Crankpin Uneven Wear mm (in) — 0.50 (0.0020)
00 – 52 SERVICE INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

Piston and Piston Ring


Piston Outside Diameter mm (in) 114.974 – 144.989 —
(4.5265 – 4.5721)
Cylinder Liner and Piston Clearance
mm (in) 0.042 – 0.066 —
(0.00165 – 0.00260)
Piston Ring and Piston Ring
Gloove Clearance mm (in)
1st Compression Ring 0.075 – 0.080 0.2
(0.0030 – 0.0031) (0.0079)
2nd Compression Ring 0.085 – 0.12 0.2
(0.0033 – 0.0047) (0.0079)
3rd Compression Ring 0.085 – 0.12 0.2
(0.0033 – 0.0047) (0.0079)
Oil Ring 0.02 – 0.06 0.15
(0.0008 – 0.0024) (0.0059)
Piston Ring Gap mm (in)
1st Compression Ring 0.18 – 0.28 1.20
(0.0071 – 0.0110) (0.047)
2nd Compression Ring 0.35 – 0.50 1.20
(0.0138 – 0.0197) (0.047)
3rd Compression Ring 0.35 – 0.50 1.20
(0.0138 – 0.0197) (0.047)
Oil Ring 0.15 – 0.35 1.20
(0.0059 – 0.0137) (0.047)
Piston Pin
Piston Pin Diameter mm (in) 39.995 – 40.000 39.95
(1.5746 – 1.5748) (1.5728)
Piston Pin and Piston Pin
Hole Clearance mm (in) 0.004 – 0.017 0.05
(0.00016 – 0.00067) (0.002)

Connecting Rod
Connecting Rod mm (in) 0.05 (0.002) or less 0.20 (0.008)
Piston Pin and Connecting Rod
Small End Bushing Clearance mm (in) 0.012 – 0.027 0.05
(0.00047 – 0.00106) (0.002)
Crankpin and Bearing Clearance
mm (in) 0.037 – 0.076 0.10
(0.0015 – 0.0030) (0.004)
Flywheel
Flywheel Friction Surface Depth
mm (in) 43.0 (1.69) 44.0 (1.73)
Flywheel Friction Surface Thickness
mm (in) 41.0 (1.61) 40.0 (1.57)
49.5 (1.95) 48.0 (1.89)
Flywheel Friction Surface Roughness
mm (in) Less than —
0.006 (0.00024)
SERVICE INFORMATION 00 – 53

ITEMS SERVICE STANDARD SERVICE LIMIT

Idler Gear
Idler Gear Shaft "A"
Outside Diameter mm (in) 49.950 – 49.975 49.9
(1.9665 – 1.9675) (1.965)
Idler Gear Shaft "B", "C" and
"D" Outside Diameter mm (in) 29.959 – 29.980 29.9
(1.1795 – 1.1803) (1.177)
Idler Gear Backlash mm (in) 0.10 – 0.17 0.30
(0.0039 – 0.0067) (0.012)
Idler Gear End Play
Gear "A", "B" and "D" mm (in) 0.080 – 0.155 0.20
(0.00315 – 0.00610) (0.008)
Gear "C" mm (in) 0.090 – 0.144 0.20
(0.00354 – 0.00566) (0.008)
Oil Pump
Gear Teeth and Cover
Inner Wall Clearance mm (in) 0.125 – 0.221 0.30
(0.0049 – 0.0087) (0.012)
Gear and Body Clearance mm (in) 0.064 – 0.109 0.20
(0.0025 – 0.0043) (0.008)
Gear Shaft Outside Diameter mm (in) 15.989 – 16.000 15.9
(0.6295 – 0.6299) (0.626)
Gear Shaft and
Bushing Clearance mm (in) 0.04 – 0.07 —
(0.0016 – 0.0028)
Drive Gear and Drive Gear
Shaft Interfere mm (in) 0.015 – 0.044 —
(0.0006 – 0.0017)

Cylinder Body
Cylinder Body Upper Face Warpage
mm (in) — 0.20 (0.008)
Cylinder Liner Projection mm (in) 0.06 – 0.10 —
(0.0024 – 0.0039)
Cylinder Body Bore and
Cylinder Liner Outside
Diameter Clearance mm (in) 0.011 – 0.029 —
(0.0004 – 0.0011)
Cylinder Liner Grade
(See “Cylinder Body” in section 6A)
Turbocharger Bearing
Radial Clearance mm (in) — 0.076 – 0.152
(0.00299 – 0.00598)
Turbine Shaft end Pluy mm (in) — 0.025 – 0.076
(0.00098 – 0.10299)
Waste Gate Valve Opening
Pressure kPa (kg/cm2/psi) 170 – 177 —
(17 – 1.8 / 24 – 26)
00 – 54 SERVICE INFORMATION

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.

WARNING:
ALLOW THE ENGINE TO COOL BEFORE
BEGINNING ANY SERVICING PROCEDURE. THIS
WILL ELIMINATE THE DANGER OF FIRE AND
POSSIBLE INJURY.
Nut and Bolt Angular Tightening Method
The angular tightening method uses the plastic region
of high tensile steel nuts and bolts to precision tighten
important engine fasteners.
Because of the method's nature, there is a limit to the
number of times a particular fastener may be reused.
This limit is specified in this Manual where applicable.

1. Carefully wash the nuts and bolts to remove all oil


and grease.
um
en e 2. Apply a coat of molybdenum disulfide grease to
d d
yb lfi the threads and setting faces of the nuts and bolts.
ol isu ase
M d re
g

3. Tighten the nuts and bolts to the specified torque


(snug torque) with a torque wrench.
BOLT
OR
NUT

Snug torque

4. Draw a line A–B across the center of each bolt.


Center line

A B
SERVICE INFORMATION 00 – 55

5. Draw another line C–D on the face of each of the


Line parts to be clamped. This line should be an
extension of the line A–B.

A B C D

6. Draw another line F–G on the face of each of the


parts to be clamped. This line will be in the
direction of the specified angle Q across the center
E E of the nut or bolt.
Specified angle Q

Coincide line G

7. Use a socket wrench to tighten each nut or bolt to


Tighten the point where the line A–B is aligned with the
line F–G.
A
C D

B
F

Example: Specified Angle and Tightening Rotation


A 30° 1 / 12 of a turn
B 60° 1 / 6 of a turn
A B C D E C 90° 1 / 4 of a turn
D 180° 1 / 2 of a turn
E 360° One full turn
00 – 56 SERVICE INFORMATION

Nut and Bolt Angular Tightening


um Method (Using The Special Tool)
d en e
yb lfi
d 1. Carefully wash the nuts and bolts to remove all oil
ol isu ase and grease.
M d re
g
2. Apply molybdenum disulfide grease to the threads
and setting faces of the nuts and bolts.
3. Use a torque wrench to tighten the nuts and bolts
to the specified torque (snug torque).

4. Attach the angle gauge to the socket wrench.


Angle Gauge: 5-8840-0266-0
5. Attach a magnet to some part to hold the angle
gauge stationary.
6. Tighten the nuts and bolts to the specified angle,
noting the angle gauge indication.

Air Cleaner
Element Cleaning and Replacement
Element cleaning procedures will vary according to
the condition of the element.

150M100009

Washable Paper Element (Dry Type)


1. Dust Fouled Element
Rotate the element with your hand while applying
compressed air to the inside of the element.
This will blow the dust free.
NOTE:
Compressed air pressure must not exceed 688kPa
(7kg/cm2 / 99.5psi).
If the element damaged, the element must be replaced.
SERVICE INFORMATION 00 – 57

Avoid giving a shock to the element when removing


dust, or distortion or damage will result.

2. Carbon and Dust Fouled Element


1) Prepare cleaning solution of 300grams (0.66lb
/ 10.59ounes) of Donaldson ND1500 or N1400
element cleaner diluted in 20 liters (5.3US / 4.4imp
gallons) of lukewarm.
2) Immerse the element in the solution for thirty
minutes.
Periodically shake the element within the solution
to thoroughly clean it.

3) Remove the element from the solution and rinse it


well with running water.
NOTE:
Water pressure must not exceed 274.7kPa
(2.8 kg/cm2 / 39.8psi).

4) Dry the element in a well ventilated area.


An electric fan will hasten drying.
NOTE:
Do not use compressed air or an open flame to dry
the element quickly. Damage to the element will
result.
It will usually take a couple of day for the element to
dry completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.

5) Use an inspection light to check the inside of the


element and the gasket for damage.
If the element damaged, the element must be
replaced.
00 – 58 SERVICE INFORMATION

Air Cleaner Body


Wipe the air cleaner body inside surfaces and the
gasket fitting surfaces free of foreign material.
Do not allow foreign material to enter the air intake
pipes or the manifold.

Lubricating System
WARNING:
HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
THE ENGINE OIL.

Combined Type Main Oil Filter and Partial Oil Filter


(Cartridge (Spin-on))
1. Use a oil filter wrench to remove the oil filter.
Filter Wrench: 1-8522-1097-0
2. Clean the oil filter fitting face.
This will allow the new oil filter to seat properly.

3. Apply a light coat of engine oil to the O-ring.


4. Use your hand to turn in the cartridge until the O-
ring is pressed firmly against the sealing face.
5. Use a fuel filter wrench to turn in the cartridge an
additional one of a turn (or to the specified torque).
Oil filter cartridge torque N•m (kg•m/lb•ft)
64 (6.5/47)
Oil Filter Wrench: 1-8522-1097-0

6. Check the engine oil level and replenish to the


specified level if required.
Oil Capacity lit (US / imp gal)
With combined partial oil filter 13.5 (3.6 / 3.0)
SERVICE INFORMATION 00 – 59

WARNING:
HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
THE ENGINE OIL.

Fuel System
Fuel Filter
Cartridge Type
1. Use a fuel filter wrench to remove the fuel filter.

2. Clean the fuel filter fitting face.


This will allow the new fuel filter to seat properly.
3. Apply a light coat of diesel·fuel oil to the O-ring.
4. Use your hand to turn in the cartridge until the O-
ring is pressed firmly against the sealing face.
5. Use a fuel filter wrench to turn in the cartridge an
additional 2/3 of a turn (or to the specified torque).
Fuel filter cartridge torque N·m (kg·m/lb·ft)
18 (1.8/13)

6. Bleed the air from the fuel system and check for
fuel leakage. Refer to “Air Bleeding.”
00 – 60 SERVICE INFORMATION

Water Separator (Water Sedimenter)


1 with Pre-Fuel Filter
Drain water from the water separator in the following
manner when the red float reaches drain level.
1. Place a container (Approximately 0.2 liters (0.76US/
0.04imp gallons capacity) at the end of the vinyl
hose beneath the drain plug on the separator.
2. Loosen the air intake plug 1 and drain plug 2 by
turning it counterclockwise, until the water is
drained.
3. After draining, securely tighten the drain plug and
air intake plug.
Operate the priming pump on the injection pump
to bleed the fuel system.
Refer to "Air bleeding".
2 4. After starting the engine, check to see that no fuel
Red float
leak from the drain plug.

The pre fuel filter should be serviced in the following


manner.
It is strongly advisable to use ISUZU genuine fuel filter
element kit for replacement.
1. Loosen the transparent cover and remove the
element together with the cover.
2. Discard the used element and install new ones.
Securely tighten the cover.
1 Cover
2 Element
After servicing, bleed the fuel system and check for
2 fuel leaks.

1
SERVICE INFORMATION 00 – 61

Injection Nozzle (6HK1-TCS)


Opening Pressure and Spray Condition Check
1. Use an injection nozzle tester to check the nozzle
opening pressure.
If the opening pressure is above or below the
specified value, the injection nozzle must be
replaced or adjusted.
Refer to "Injection Nozzle Adjustment."
Injection Nozzle Opening Pressure MPa (kg/cm2 / psi)
21.6 (220 / 3,128)
040M100020

WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT OF THE INJECTION NOZZLE
UNDER GREAT PRESSURE. IT CAN EASILY
PUNCTURE A PERSON'S SKIN.
KEEP YOUR HANDS AWAY FROM THE INJECTION
NOZZLE AT ALL TIMES.
2. Check the spray condition.
If the spray condition is bad, the injection nozzle
1 2 3 must be replaced or reconditioned.
1 Correct
2 Incorrect (Restrictions in orifice)
3 Incorrect (Dripping)
Refer to "FUEL SYSTEM," "Injection Nozzle" in
Section 6C of this Manual.

Injector Assembly (6HK1-TCC, 6HK1-TCN)


The injector cannot be adjusted or repaired. If the injector
is damaged, the entire assembly must be replaced.
00 – 62 SERVICE INFORMATION

Injection Nozzle Adjustment (6HK1-TCS)


1. Attach the injection nozzle holder to the injection
nozzle tester.
2. Apply pressure to the nozzle tester.
Note the pressure at which the injection nozzle
opens.
3. If required, install or remove the appropriate
number of adjusting shims to adjust it.
Reference:
040M100020
Installing or removing 0.10mm (0.004in) will
increase or decrease the nozzle opening pressure
approximately 1,638kPa (16.7kg/cm2 / 237psi).
Adjusting Shim Availability mm (in)
0.10 (0.004), 0.20 (0.008)
Increment
0.30 (0.012), 0.40 (0.016)
(0.10mm (0.004in))
0.50 (0.0196)
Increment 0.52 (0.0205) 0.54 (0.0213)
(0.02mm (0.008in)) 0.56 (0.0220) 0.58 (0.0228)
Total Number of Shims 9

Refer to "Opening Pressure and Spray Check"


immediately before this entry.
Nozzle tester : 105785-1010 (BOSCH Part Number)

4. Clamp the injection nozzle in a vise.


5. Tighten the retaining nut to the specified torque.
Injection Nozzle Retaining
Nut Torque N·m (kg·m / lb·ft)
39 (4.0 / 29)

Air Bleeding
Air bleeding the fuel system (6HK1-TCS)
2
1. Loosen the priming pump cap 1 on the injection
pump.
2. Loosen the joint bolt 2 on the fuel filter.
3. Operate the priming pump until there are no more
bubbles visible in the fuel being discharged from
the joint bolt.
1 4. Tighten the joint bolt.
5. Tighten the priming pump cap.
SERVICE INFORMATION 00 – 63

Air bleeding the fuel system


(6HK1-TCC, 6HK1-TCN)
1. Unscrew the priming pump cap (the cap will spring
free)(1).
2. Loosen the air-bleed plug on the fuel filter.
3. Press and release the priming pump cap (up and
down motion) to force fuel through the fuel filter.
Bubbles will escape from around the air bleed
plug.
040MX004 4. Continue to operate the priming pump until there
are no more bubbles escaping from around the air
bleed plug.
1
5. Tighten the air bleed plug (fuel filter).
2 6. Loosen the air bleed plug on the supply pump (2).
7. Press and release the priming pump cap (up and
down motion) to force fuel through the fuel filter.
Bubbles will escape from around the air bleed
plug.
8. Continue to operate the priming pump until there
are no more bubbles escaping from around the air
040MX001 bleed plug.
9. Tighten the air bleed plug (supply pump).

UP

DOWN
10.Turn the starter switch to the ON position.
11.Press the lower side of the idling control switch
(rocker-type switch). Fuel injector operation begins.
UP
12.Listen for the sound of injector operation. When
the sound is heard, press and release the priming
DOWN
pump cap (up and down motion) until considerable
825M200006
resistance to cap motion is felt (the cap no longer
moves freely).
13.Return the priming pump cap to its original
position and securely tighten it.
14.Wipe away any spilled fuel from the area around
the fuel filter and the supply pump.
15.Start the engine.
16.Check for fuel leakage from the fuel filter and the
supply pump.

NOTE:
If you are unable to start the engine, repeat the entire
air bleeding procedure.
00 – 64 SERVICE INFORMATION

Feed Pump Strainer Cleaning (6HK1-TCS)


1. Remove the joint bolt at the inlet side of the feed
pump.
The feed pump strainer is installed to the joint bolt.
2. Rotate the strainer counterclockwise to remove it
from the joint bolt.
3. Clean the strainer in clean diesel fuel.
4. Reinstall the strainer and the joint bolt.
Strainer

Fuel Tank Strainer Cleaning (If Required)


1. Remove the fuel tank drain plug 1.
2. Completely drain the water and sediment from the
fuel tank.
3. Remove the strainer 2.
4. Wash the strainer in clean diesel fuel.
5. Reinstall the strainer and the drain plug to the fuel
2 tank.
1

Cooling System
WARNING:
HOT STEAM UNDER PRESSURE MAY ESCAPE FROM
THE RADIATOR IF THE RADIATOR SURGE TANK CAP
IS OPENED WHILE THE ENGINE IS HOT. THIS CAN
RESULT IN SERIOUS BURNS.
ALLOW THE ENGINE TO COOL BEFORE OPENING
THE RADIATOR SURGE TANK CAP.

Coolant Level
Check the coolant level and replenish the radiator
surge tank if necessary.
If the coolant level falls below the "MIN" line, carefully
check the cooling system for leakage. Then, add
additional coolant to raise the level over the "MIN"
line.
SERVICE INFORMATION 00 – 65

Engine Coolant Filling Up Procedure


1. Make sure that the engine is cool.

WARNING:
WHEN THE COOLANT IS HEATED TO A HIGH
TEMPERATURE, BE SURE NOT TO LOOSEN OR
REMOVE THE RADIATOR CAP. OTHERWISE YOU
MIGHT GET SCALDED BY HOT VAPOR OR BOILING
WATER. TO OPEN THE RADIATOR CAP, PUT A PIECE
OF THICK CLOTH ON THE CAP AND LOOSEN THE
CAP SLOWLY TO REDUCE THE PRESSURE WHEN
THE COOLANT HAS BECOME COOLER.

2. Open radiator cap pour coolant up to filler neck.


3. Pour coolant into reservoir tank up to “MAX” line.
4. Tighten radiator cap and start the engine. After
idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.
5. After replenish the coolant tighten radiator cap,
warm up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position,
and let the coolant circulate also into heater water
system.
6. Check to see the thermometer, continuously idling
5 minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX”
line.

NOTE:
Do not overfill the radiator surge tank.
Remove the radiator surge tank cap only when
absolutely necessary.
Always refer to the chart at the left to determine the
correct cooling water to antifreeze solution mixing
0 ratio.
Freezing point(°C)

-10
-20
-30
-40
-50
-60
0 5 10 15 20 25 30 35 40 45 50 55 60
Mixing ratio(%)

B06MX00003
00 – 66 SERVICE INFORMATION

Radiator Surge Tank Cap Inspection


WARNING:
HOT STEAM UNDER PRESSURE MAY ESCAPE FROM
THE RADIATOR IF THE RADIATOR SURGE TANK CAP
IS OPENED WHILE THE ENGINE IS HOT. THIS CAN
RESULT IN SERIOUS BURNS.
ALLOW THE ENGINE TO COOL BEFORE OPENING
THE RADIATOR SURGE TANK CAP.

Cooling System Leakage Check


1. Remove the radiator filler cap from the radiator.
2. Install the radiator filler cap tester to the radiator.
3. Apply the specified test pressure to the cooling
system to check for leakage.
Do not exceed the specified test pressure.
Cooling System Test Pressure kPa (kg/cm2 / psi)
88 (0.9 / 13)

Repair or replace the radiator if required.


Radiator Cap Leakage Check
The radiator filler cap maintains cooling system
pressure.
It must tightly seal the cooling system.
1. Remove the radiator filler cap from the radiator.
2. Install the radiator cap to the radiator filler cap
tester.
3. Apply the specified test pressure to the cap to
check for leakage.
Do not exceed the specified test pressure.
Radiator Filler Cap Test Pressure kPa (kg/cm2 / psi)
49 – 59 (0.5 – 0.6 / 7.11 – 8.53)

Negative Valve Pressure kPa (kg/cm2 / psi)


2 – 5 (0.02 – 0.05 / 0.28 – 0.71)

Replace the radiator filler cap if it fails to hold the


specified test pressure.
SERVICE INFORMATION 00 – 67

DRIVE BELT INSPECTION


Check the drive belt tension.
3
Depress the drive belt mid-portion with a 98N (10kg /
2
22lb) force.
Drive Belt Deflection mm (in)
1
5 10 – 15 (0.39 – 0.59)

Check the drive belts for cracking and other damage.


4
1 Crankshaft damper pulley
2 Generator
3 Cooling fan pulley
4 Tension pulley
5 Compressor pulley

Cooling Fan Pulley Drive Belt Adjustment


Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10kg /
22lb) force.
3
2 1 Crankshaft damper pulley
2 Generator pulley
3 Cooling fan pulley
1

Compressor Pulley Drive Belt Adjustment


(Air Conditioner Equipped Vehicle)
Move the tension pulley as required to adjust the
1 compressor drive belt tension.
1 Crankshaft damper pulley
3
2 Tension pulley
PUSH 3 Compressor pulley
2

F06MV021
00 – 68 SERVICE INFORMATION

Valve Clearance Adjustment


The following instructions assume that valve
clearance is adjusted beginning with the No. 1 piston
at top dead center (TDC) on the compression stroke.
Check alignment timing mark between automatic
timer and mark line on injection pump body. In this
position indicate T.D.C. of No.1 piston.
Valve clearance must be adjusted when the engine is
cold.
When remove the head cover, wipe off spilled oil with
a rag.

1. Bring the piston in the No. 1 or No. 6 cylinder to the


top dead center on the compression stroke by
turning the crankshaft until the T.D.C line on the
flywheel is aligned with the timing pointer.
Check the rocker arm shaft bracket nuts for
looseness and retighten as necessary before
adjusting the valve clearance.
2. Check that the No. 1 intake and exhaust push rods
have play. If they have play, it indicates that the No.
1 piston is at TDC (Top Dead Center) on the
compression stroke. If the No. 1 exhaust valves are
depressed, the No. 6 piston is at TDC on the
compression stroke.
3. Adjust valve clearances for the No. 1 or No. 6
cylinder which its piston is at TDC on compression
stroke.
1) Loosen each adjusting screw on the bridge and
rocker arm.
Valve Clearance mm (in)
0.4 (0.0016)

2) Insert a feeler gauge between the rocker arm


and the cam and adjust by turning the adjusting
014MV001
screw on the rocker arm until there is a slight
drag on the feeler gauge. Tighten the lock nut
Gauge securely.
3) With a feeler gauge inserted, screw in the
adjusting screw on the bridge gradually until it
touches to the end of the valve stem, and make
sure that the movement of the feeler gauge
becomes hard.

014MX032
SERVICE INFORMATION 00 – 69

4) In this condition, the opposite end of the bridge


is raised. Readjust by loosening the adjusting
No.1 Cylinder TDC
screw on the bridge until there is a slight drag
Front
on the feeler gauge and tighten the lock nut
securely.

011MY00037

4. Rotate the crankshaft 360° and realign the T.C. mark


on the flywheel with the pointer and adjust
No.6 Cylinder TDC clearance for remaining valves.
Front The arrow mark in the illustration indicates the
cylinders and valves to be adjusted.
NOTE:
Be sure to move the No. 1 cylinder to TDC on the
compression stroke after completing the valve
clearance adjustment procedure.

011MY00038
Tightening Torque N·m (kg·m/lb·ft)
Position Torque
Rocker Arm Adjusting Screw Nut 22 (2.2 / 16)

Intake and Exhaust Valve Arrangement


Cylinder No. 1 2 3 4 5 6
Valve Names I E I E I E I E I E I E
No. 1 cyl. at TDC on compression ● ● ● ● ● ●
No. 6 cyl. at TDC on compression ● ● ● ● ● ●
I: Intake valve E: Exhaust valve

Injection Timing Adjustment


Injection Timing Inspection (6HK1-TCS)
1. Disconnect the negative battery cable.
2. Rotate the crankshaft in the normal direction of
engine rotation to align the crankshaft damper
pulley notched line with the timing notched line.
Injection Timing (Static–BTDC) deg

3. Check that flywheel notched line is aligned with the


injection pump notched line.
If the notched lines are out of alignment, the
injection timing must be adjusted.
Timing mark
00 – 70 SERVICE INFORMATION

Injection Timing Adjustment (6HK1-TCS)


1. Rotate the crankshaft in normal direction of
rotation until the timing mark on the crankshaft
damper pulley can be seen.
When the notched line has passed the fuel
injection time, return it widely to reset to the
injection time.
Align the injection timing notched line on the
crankshaft damper pulley with the timing notched
line of cylinder block.
2. Confirm injection timing mark between injection
pump body and flywheel of injection pump.
3. Loosen the two coupling bolts.
Timing mark
4. Move the flywheel to the correct timing.
5. Tighten the two coupling bolts.
Coupling Bolt Torque N·m (kg·m / lb·ft)
88 (9.0 / 65)

6. Rotate the crankshaft two turns in normal direction


of rotation.
7. Check the new setting.
8. Connect the negative battery cable.

Injection Timing Inspection (6HK1-TCC, 6HK1-TCN)


1. Rotate the crankshaft in the normal direction of
rotation to bring the piston in the No. 1 cylinder to
top-dead-center (TDC) on the compression stroke.
Align the T/C timing mark on the crankshaft
damper pulley with the timing pointer
2. Check that the etched line on the supply pump is
TDC aligned with the etched line on the coupling flange.
If necessary, align the two areas.
Fuel Injection Timing deg.
MFW31BSH000401

0 (TDC)

040MX048
SERVICE INFORMATION 00 – 71

Injection Timing Adjustment (6HK1-TCC, 6HK1-TCN)


1. Loosen the first adjusting bolt.
2. Rotate the crankshaft in the normal direction of
rotation to bring the piston in the No. 1 cylinder to
Air compressor top-dead-center (TDC) on the compression stroke.
side
Align the T/C timing mark on the crankshaft
damper pulley with the timing pointer.
3. Loosen the second adjusting bolt.
4. Adjust the gear backlash to zero.
MFW31BSH000801

5. Align the supply pump timing mark (notched line).


6. Tighten the two adjusting bolts to the specified
torque.
Adjusting Bolt Torque N·m (kgf·m/lb.ft)
61 (6.2 / 45)

Compression Pressure Measurement


0
0
0

0
0

0
0 0

0
0

0
0

0
0
0
(6HK1-TCS)
To measure the compression pressure, the engine
must be cold. Engine coolant temperature should be
at 20°C (68°F). Battery and starter motor condition
must be normal.
1. Remove the glow plugs and the injection pipes
‫ޓ‬
from each cylinder.

2. Install the compression gauge adapter to the No. 1


cylinder glow plugs installation hole.
Compression Gauge Adapter: 5-8531-7001-0
3. Install the compression gauge to the compression
gauge adapter.
4. Crank the engine with the starter motor (about
200rpm) and take the compression gauge reading.
00 – 72 SERVICE INFORMATION

5. Repeat the procedure (Step 2–4) for the remaining


cylinder.
Compression Pressure kPa (kg/cm2 / psi)
3,236 (33 / 469)

Compression pressure should be approximately


the same for each cylinder. A variation exceeding
196kPa (2.0kg/cm2 / 28psi) is unacceptable.

Compression Pressure Measurement


(6HK1-TCC, 6HK1-TCN)
1. Remove the glow plugs and the injector connectors
from cylinder head cover side.
2. From this point onward, the procedure is identical
to that for the 6HK1-TCS engine.
NOTE:
If the injector harness connector is removed, an ECU
error code will be displayed. Be sure to clear the ECU
memory after completing the measuring procedures.
SERVICE INFORMATION 00 – 73

FIXING TORQUE
Cylinder Head, Rocker Arm Shaft and Camshaft N·m (kg·m / lb·ft)

6HK1-TCC
13(1.3/9) 6HK1-TCN

13(1.3/9)

22(2.2/16)
19(1.9/24)

27(2.8/20)

2(0.2/1.4)

56(5.7/41)

1st Step 2nd Step 3rd Step

98 147 45
27(2.8/20) M14 Bolt
(10/72) (15/108) deg

Apply molybdenum disulfide grease

M10 Bolt 38(3.9/28)

30(3.1/22) Apply engine oil

20(2.0/14)

M8 Bolt 19(1.9/14)

M16 Bolt 118(12.0/87)

M8 Bolt 19(1.9/14)

M16 Bolt 38(3.9/28)

MFW31BXF000101
00 – 74 SERVICE INFORMATION

Intake, Exhaust Manifold and EGR N·m (kg·m / lb·ft)

27(2.8/20)
94(9.6/69)

41(4.2/30)
A
20(2.0/14)

20(2.0/14)

41(4.2/30)

FRONT

24(2.4/17)
15(1.5/11)

34(3.5/25)
A

20(2.0/14)

011M100008
SERVICE INFORMATION 00 – 75

Crankshaft Pulley, Timing Gear Case, Lower Crankcase


and Connecting Rod N·m (kg·m / lb·ft)

19(1.9/14)

19(1.9/14)

39(4/29)ψ60°ψ30°

196(20.0/145)

19(1.9/14)

1st Step 2nd Step 3rd Step

98 132
M14 Bolt 45°
(10/72) (13.5/98)

M10 Bolt 㧙‫ޓ‬ 38(3.9/28) 㧙‫ޓ‬

Apply molybdenum grease for M14 bolts only

015M100004
00 – 76 SERVICE INFORMATION

Flywheel, Timing Gear, Oil Pump, and Oil Pan N·m (kg·m / lb·ft)

29 (3.0/22)ψ75°

24 (2.4/17)

31 (3.2/23)
95 (9.7/70)

1st step 78 (8.0/58)


2nd step 60°
3rd step 75°

M8 Bolt 24 (2.4/17)
M16 Bolt 48 (4.9/35)

24 (2.4/17)

020M100005
SERVICE INFORMATION 00 – 77

Oil Filter, Oil Cooler and Oiling Jet N·m (kg·m / lb·ft)

Oil Filter

64 (6.5/47)

64(6.5/47)

MFW31BMF000101

Oil Cooler and Oiling Jet

19 (1.9/14)

21 (2.1/15)
19 (1.9/14)
00 – 78 SERVICE INFORMATION

Engine Electrical N·m (kg·m / lb·ft)

Generator

108 (11/80)

8 (0.8/69)
3.6 (0.37/2.7)

Starter Motor

12.7 (1.3/9.4)

12.7 (1.3/9.4)
SERVICE INFORMATION 00 – 79

Engine Foot N·m (kg·m / lb·ft)

76 (7.7/56)

294 (30/127)

83 (8.5/61)

76 (7.7/56)

RH
39 (4/29)

022MV001*
00 – 80 SERVICE INFORMATION

Turbocharger Piping N·m (kg·m / lb·ft)

34(3.5/25)

FRONT

39(4.0/29)
20(2.0/14)

39(4.0/29)

39(4.0/29)

44(4.5/33)

052M100003
SERVICE INFORMATION 00 – 81

SPECIAL TOOLS
ILLUSTRATION PART NO. PARTS NAME

5-8531-7001-0 Compression gauge adapter

Crankshaft front and rear slinger


8-9439-6858-0
remover

Crankshaft front and rear oil seal


8-9439-6856-0
installer

8-9439-6819-0 Crankshaft gear installer

5-8840-2628-0 Valve guide replacer

5-8840-2625-0 Valve stem oil seal installer

5-8840-2621-0 (Lever)
8-9439-6862-0 (Pivot) Valve spring compressor

901MW002

1-8522-1097-0 Oil filter wrench

5-8840-2623-0 Nozzle sleeve remover

040RW022

5-8840-2624-0 Nozzle sleeve installer


00 – 82 SERVICE INFORMATION

ILLUSTRATION PART NO. PARTS NAME

5-8540-0266-0 Angle gauge

5-8840-2627-0 Oil seal installer

5-8840-2626-0 Valve bridge guide installer


ENGINE MECHANICAL 6A–1

SECTION 6A
ENGINE MECHANICAL

CONTENTS

PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–13
Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–10
Engine External Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–18
Cylinder Head and Valve Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–34
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–42
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–49
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–59
Crankshaft, Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–74
Disassembly (Crankshaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–82
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–83
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–86
Disassembly (Piston and Connecting Rod) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–88
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–90
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–96
6A–2 ENGINE MECHANICAL

PAGE
Flywheel, Timing Gear, Oil Pump and Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–99
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–99
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–101
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–105
Disassembly (Oil Pump). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–112
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–114
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–116
Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–118
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–118
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–120
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–122
ENGINE MECHANICAL 6A–3

GENERAL DESCRIPTION

F06M100012

The 6HK1 engine is a four-cycle, six-cylinder, The piston is made of aluminum alloy. A ring trigger
in-line, direct fuel injection type diesel engine with is cast into the top ring groove and chrome plating
the piston displacement of 7,790 cm3 (475.3 in3). It is applied to four sides of the top ring to ensure
features a gear-driven OHC (overhead camshaft) sufficient strength and wear resistance of the ring
timing train and unique mechanisms and systems and the ring groove.
designed for outstanding quietness, economy and The crankshaft is made of forge steel with seven
durability. bearings and twelve counterweights to reduce
The cylinder head is made of cast iron and has a revolution load to the bearing.
cross-flow layout with the intake system in the left The gear train is located at the end of cylinder body
side and the exhaust system in the right side, to minimize influence of the torsional vibration of
designed to reduce resistance in the intake and the crankshaft and the radiant sound.
exhaust system.
Noise is further reduced, to the same level as a
The cylinder head gasket is of the laminated of timing belt driven system, by integrating the
least fatigue in combination with the angular crankshaft gear with the crankshaft by shrink fit
cylinder head bolt tightening method, equally careful tuning of the gear precision, contact gear
designed to increase reliability against gas and ratio, backlash, bearing rigidity neutral frequency,
water leakage. etc.
The cylinder body is made of cast iron having dry
cylinder liner and seven bearings. The bearing cap
This Manual describes procedures for the 6HK1-TCS
has a ladder frame construction integrating the
enigne. Unless otherwise indicated, this information
crankcase to increase rigidity.
is applicable to the 6HK1-TCC engine and the 6HK1-
The cylinder liner is made of thin iron plus special TCN engine.
alloys and is combined with the chrome-plate piston
ring to ensure good resistance against wear.
6A–4 ENGINE MECHANICAL

Lubricating Oil Flow

FULL FLOW FILTER OIL PRESSURE STARTER


2 WARNING LIGHT SWITCH BATTERY
BY-PASS
VALVE
THERMOSTAT
TYPE OIL PRESSURE SWITCH 3
BY-PASS
VALVE
CYLINDER BODY OIL GALLERY
PAPER OIL
FILTER COOLER

5
CRANK- CAM TIMING INJ. TURBO-
CHARGER CHECK
SHAFT SHAFT IDLE PUMP
VALVE
BRGS. BRGS. GEAR

OIL 1
RELIEF
VALVE

OIL
PUMP 4 CYL
PARTIAL OIL CONN
RELIEF ROD HEAD PISTON
FILTER
VALVE BRGS VALVE
SYSTEM
OIL
STRAINER

OIL PAN

Unit : kPa (kg/cm2/psi)

1 Relief Valve Opening Pressure : 785(8.0/144) 3 Oil Pressure switch Opening Pressure :
29-49(0.3-0.5/4.3-7)
2 Bypass Valve Opening Pressure :
118-157(1.2-1.6/17-23) 4 Relief Valve Opening Pressure : 441(4.5/64)
5 Check Valve : 196(2.0/28)

051MV001
ENGINE MECHANICAL 6A–5

ENGINE ASSEMBLY
REMOVAL
Read this section carefully before performing any removal and installation procedure. This Section gives
you important points as well as the order of operation. Be sure that you understand everything in this
Section before you begin.

Removal Steps
• Carefully remove the piping, hoses, wiring harness
connectors, engine control cables, and control rods
from the engine.
• Remove the clutch slave cylinder or clutch booster
(Minipack), the control cables, the back up light
switch, and the speedometer cable from the
transmission.

WARNING:
ALLOW THE ENGINE TO COOL BEFORE REMOVE ANY
PARTS. THIS WILL ELIMINATE THE DANGER OF FIRE
AND POSSIBLE INJURY.

2 Battery
1. Disconnect the grounding cable 1 and the battery
cable 2 from the battery terminals.
1
Be careful not to short the battery with your
wrench or another tool at this time.
6A–6 ENGINE MECHANICAL

2. Disconnect the battery cable at the starter motor


and the grounding cable at the chassis frame.

Air Cleaner
Remove the air intake hose from the intake cover.

Coolant
Remove the radiator drain plug and allow the coolant
to drain completely.
WARNING:
HOT STEAM UNDER PRESSURE MAY ESCAPE FROM
THE RADIATOR IF THE COOLANT IS DRAINED WHILE
THE ENGINE IS HOT. THIS CAN RESULT IN SERIOUS
BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
HCW31BSH002801
THE COOLANT.
If long life coolant is used, drain the coolant into a clean
container so that it can be reused.
Refer to the Maintenance Schedule in Section 00,
"GENERAL INFORMATION".

Radiator
1. Disconnect the radiator overflow rubber hose from
the radiator and the reserve tank.
2. Remove the radiator overflow pipe from the
engine.
3. Pull the radiator upper hose and the radiator lower
hose from the engine.

MFW31BSH002701
ENGINE MECHANICAL 6A–7

4. Disconnect the radiator front stay at the radiator.


5. Disconnect the radiator fan shroud stays (three
positions) at the engine.
6. Remove the radiator cushion rubber nuts.
7. Remove the radiator with the fan shroud from the
chassis frame.
Be careful not to damage the radiator core.
8. Remove the cooling fan and the fan coupling from
the water pump.

Engine Control Harness and Stop Cable


Disconnect the engine control harness and stop cable
from the injection pump.

Engine Oil Draining


Oil Pan Drain Plug
1. Remove the oil pan drain plug 1 to drain the
engine oil.
WARNING:
HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
THE ENGINE OIL.
2. Reinstall the drain plug and tighten to the specified
1 torque.
Oil Pan Drain Plug Torque N·m (kg·m / lb·ft)
49 (5 / 36)
6A–8 ENGINE MECHANICAL

Propeller Shaft
1. Disconnect the 1st propeller shaft flange yoke from
the parking brake drum.
2. Lower the propeller shaft carefully to the ground.

401HX00033

Radiator Reserve Tank


Cab Mounting Rear Member
1. Remove the radiator reserve tank from the cab
mounting rear member.
2. Remove the cab mounting rear member from the
chassis frame.

Exhaust Brake Assembly


Disconnect the exhaust brake control air hose.

Transmission
Refer to Section 7, "TRANSMISSION", "Removal and
Installation."

220M100001
ENGINE MECHANICAL 6A–9

Clutch Pressure Plate and Driven Plate


Refer to Section 7, "CLUTCH", "Removal and
Installation".

Exhaust Pipe
1. Loosen the front exhaust pipe, silencer and
exhaust pipe clamp bolts and nuts.
2. Disconnect the front exhaust pipe and exhaust
brake assembly from the exhaust manifold.

150M100006

Front Engine Mounting


Rear Engine Mounting
1 2
1. Attach lifting wires to the engine lifting hangers.
2. Raise the hoist until there is no slack in the lifting
wires.
3. Remove the front engine mounting nuts 1 and the
rear mounting bolts 2.

Engine
1. Operate the hoist to slowly raise the engine until it
is clear of the chassis frame.
Make sure that the connecting pipes, hoses, and
cables have all been removed from the engine.
The front of the engine should be held slightly
higher than the rear at this time.

2. Rotate the engine 90 degrees.


3. Continue to lift the engine from the chassis.
4. Carefully move the hoist and engine.
5. Place the engine on an engine stand.
6A–10 ENGINE MECHANICAL

INSTALLATION
Installation Steps
Follow the removal procedure in the reverse order to
perform the installation procedure.
Pay careful attention to the important points during
the installation procedure.

Engine
1. Attach a lifting wire to the engine lifting hangers.
2. Operate the hoist to position the engine above the
chassis frame.
3. Carefully lower the engine until it is just above the
chassis frame.

4. Rotate the engine 90 degrees to position it for final


installation.
5. Carefully lower the engine into the chassis.
The front of the engine should be held higher than
the rear at this time.
Be careful not to damage the exposed parts and
the cab.

6. Lower the engine until it contacts the engine


mounting rubbers.
7. Set the engine mounting bracket to the mounting
rubbers.

Front Engine Mounting


Rear Engine Mounting
Tighten the mounting nuts and bolts to the specified
torque.
Front Mounting Nut Torque N·m (kg·m / lb·ft)
83 (8.5 / 61)

Rear Mounting Bolt Torque N·m (kg·m / lb·ft)


294 (30 / 217)
ENGINE MECHANICAL 6A–11

Clutch Pressure Plate and Driven Plate


Refer to Section 7, "CLUTCH", "Removal and
Installation".

Transmission
Refer to Section 7, "TRANSMISSION," "Removal and
Installation".

220M100001

Propeller Shaft
1. Install the 1st propeller shaft flange yoke to the
parking brake drum.
2. Tighten the propeller shaft flange nuts to the
specified torque.
Propeller Shaft Flange Nut
Torque N·m (kg·m / lb·ft)
M12 103 (10.5 / 76)
M14 157 (16.0 / 116)
401HX00033
M16 With spring washer 215 (22.0 / 159)
M16 With plain washer 255 (26.0 / 188)
M16 Flange nut 255 (26.0 / 188)

Radiator
1. Install the fan coupling and the cooling fan to the
water pump.
2. Install the radiator with the fan shroud to the
mounting cushion rubbers.
Be careful not to damage the radiator core.
3. Connect the radiator front stay to the radiator.
4. Tighten the radiator cushion rubber nuts.
5. Connect the radiator upper and lower hoses.
6. Connect the radiator fan shroud stays (three
positions) to the engine.
6A–12 ENGINE MECHANICAL

7. Install the radiator overflow pipe to the engine.


8. Connect the radiator overflow rubber hose to the
radiator and the reserve tank.
Exhaust Pipe
1. Connect the front exhaust pipe and exhaust brake
assembly to the exhaust manifold.
2. Temporarily tighten the front exhaust pipe silencer
and exhaust pipe clamp bolts and nuts.
3. Tighten front exhaust pipe flange nuts evenly to
the specified torque.
Exhaust Pipe Nut Torque N·m (kg·m / lb·ft)
30 (4 / 29)
150M100006

4. Full tighten the each exhaust pipe clamp bolts and


nuts.

Cab Mounting Rear Member


Radiator Reserve Tank
1. Install the cab mounting member to the chassis
frame.
2. Tighten the rear member nuts to the specified
torque.
Rear Member Nut Torque N·m (kg·m / lb·ft)
69 (7 / 51)

3. Install the radiator reserve tank with the bracket to


the cab rear mounting member.
Engine Control Harness and Stop Cable
Connect the engine control harness and stop cable to
the injection pump.
Air Cleaner
Install the air intake hose to the intake cover.
Coolant Replenishment
Replenish the coolant to the specified capacity.
Coolant Capacity lit (US / imp gal)
24 (6.3 / 5.3)

NOTE:
Make sure that the connecting pipes, hoses, and
cables have all been installed to the engine.
ENGINE MECHANICAL 6A–13

Battery
1. Check the battery fluid level and the specific
gravity.
2. Connect the battery cable to the starter motor.
3. Connect the grounding cable to the chassis frame.

2 4. Connect the battery cable 2 and the grounding


cable 1 to the battery terminals.
1 5. Apply grease to the battery terminals.

Engine Oil Replenishment


1. Replenish the engine oil from the filler port with
Oil filler cap new engine oil of the specified grade.

2. Start the engine and let it idle for a few minutes.


3. Stop the engine and wait five minutes.
4. Recheck the oil level and replenish if necessary.
6A–14 ENGINE MECHANICAL

ENGINE EXTERNAL PARTS


REMOVAL

4
17 1 23 21
2 9
5 7 28 12 10
20

25
29

15 26
18 14 19 8 6 3 31 13 11 16 30 27 24
22

F06M100013

Removal Steps
1. Intake pipe 19. Guide tube
2. Air duct 20. Air compressor pipe
3. Intake pipe (Intake duct to air compressor)
4. EGR assembly 21. Fuel injection pipe with clip (6HK1-TCS)
(Exhaust gas recirculation) 21-A. Fuel injection pipe (6HK1-TCC, 6HK1-
5. Oil feed pipe TCN)
6. Oil return pipe 22. Fuel pipe
7. Water feed pipe 23. Fuel filter
8. Water return pipe 24. Oil filter
9. Turbocharger assembly 25. Air pipe
10. Cooling fan guide 26. Water duct (Suction)
11. Cooling fan 27. Injection pump assembly (6HK1-TCS)
12. Cooling fan drive belt 27-A. Common rail (6HK1-TCC, 6HK1-TCN)
13. Generator and adjusting plate 27-B. Fuel supply pump assembly (6HK1-TCC,
14. Starter motor 6HK1-TCN)
15. Power steering oil pipe 28. Water outlet (To Radiator)
16. Power steering oil pump 29. BRG Case assembly
17. Fuel leak off pipe 30. Injection pump bracket
18. Air Compleser 31. Engine foot
ENGINE MECHANICAL 6A–15

Removal Steps
1. Intake Pipe
2. Air Duct
3. Intake Pipe
4. EGR Assembly (6HK1-TCS only)
1) Remove the EGR valve with EGR pipe (EGR valve -
EGR cooler).
EGR Valve

027M100001

2) Remove the EGR pipe (EGR cooler - Exhaust


Manifold).

Exhaust
EGR Cooler Manifold

027M100002

3) Remove the EGR cooler.

EGR Cooler
220M100002

5. Oil Feed Pipe (From Oil Filter)


6. Oil Return Pipe (To Cylinder Body)
7. Water Feed Pipe For Water Cooling Type (From
Cylinder Body)
8. Water Return Pipe For Water Cooling Type (To
Thermo Unit)
9. Turbocharger Assembly
10. Cooling Fan Guide
11. Cooling Fan
12. Cooling Fan Drive Belt
13. Generator and Adjusting Plate
14. Starter Motor
15. Power Steering Oil Pipe
6A–16 ENGINE MECHANICAL

16. Power Steering Oil Pump


Remove the power steering oil pump.
NOTE:
Plug the power steering oil pump to prevent the entry
of foreign material.

17. Fuel Leak Off Pipe


18. Air Compressor
Plug the air compressor ports to prevent the entry of
foreign material.

19. Guide Tube


20. Air Compressor Pipe
(Intake duct to air compressor)
21. Fuel Injection Pipe with Clip (6HK1-TCS)
1) Loosen the injection pipe sleeve nuts at the
#1 #2 #3 #4 #5 #6
delivery valve side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.

21-A. Fuel Injection Pipe (6HK1-TCC, 6HK1-TCN)


Injection Pipe Remove the injection pipes.
NOTE:
Plug the delivery holder ports with the shipping caps
or equivalent to prevent the entry of foreign material.

22. Fuel Pipe


Common Rail Fuel Pipe
23. Fuel Filter
24. Oil Filter
25. Air Pipe
26. Water Duct (Suction)
ENGINE MECHANICAL 6A–17

27. Injection Pump Assembly


A
B 1) Remove the two injection pump coupling joint
bolts from the injection pump side A.
2) Use a universal wrench to remove the four
injection pump mounting bolts B.
3) Remove the injection pump.

27-A. Common Rail (6HK1-TCC, 6HK1-TCN)


Remove the common rail from the intake manifold.
NOTE:
Do not allow other parts bang against the sensors
during the service procedure (sensor damage will
result).

27-B. Fuel Supply Pump Assembly (6HK1-TCC, 6HK1-TCN)


1) Disconnect the coupling fixing bolts.
2) Remove the fuel supply pump fixing bolts.
3) Remove the fuel supply pump assembly.
NOTE:
Plug the fuel supply pump to prevent the entry of
foreign material.

28. Water Outlet (To Radiator)


29. Bearing Case
Remove the bearing case.
• Make sure that No. 1 cylinder is at TDC on the
compression stroke. Draw alignment mark on the
bearing case pointer over coupling, and then
remove the bearing case.
• There is air compressor on the right side.

30. Injection Pump Bracket


31. Engine Foot
6A–18 ENGINE MECHANICAL

INSTALLATION

30 23 27 25 22 19 21 11 31 8 10 28

13

7 1

6 17 16 24 26 29 3 18 20 15 14 4 2 5 12 9

F06M100014

Installation Steps
1. BRG case assembly 14. Power steering oil pump
2. Injection pump bracket 15. Power steering oil pipe
3. Engine foot 16. Guide tube
4. Water duct (Suction) 17. Starter motor
5. Injection pump assembly (6HK1-TCS) 18. Generator and adjusting plate
5-A. Fuel supply pump assembly (6HK1-TCC, 19. Cooling fan drive belt
6HK1-TCN) 20. Cooling fan
5-B. Common rail (6HK1-TCC, 6HK1-TCN) 21. Cooling fan guide
6. Air compressor 22. Water outlet (To Radiator)
7. Air pipe 23. Turbocharger assembly
8. Fuel filter 24. Water return pipe
9. Oil filter 25. Water feed pipe
10. Fuel injection pipe with clip (6HK1-TCS) 26. Oil return pipe
10-A. Fuel injection pipe (6HK1-TCC, 6HK1- 27. Oil feed pipe
TCN) 28. EGR assembly
11. Fuel leak off pipe 29. Intake pipe
12. Fuel pipe 30. Air duct
13. Air compressor pipe 31. Intake pipe
(Intake duct to air compressor)
ENGINE MECHANICAL 6A–19

Installation Steps

1. Bearing Case
1) Bearing Case
Install O-ring in the bearing case. (O-ring cannot be
reused.) Install the bearing case.
• Make sure that No. 1 cylinder is at TDC on the
compression stroke. Align the mark drawn when
removing the bearing case, and install. Then check
and see the pointer is aligned with the mark S on
the coupling end surface.

2) Check that the No. 1 cylinder is at TDC on the


compression stroke.
3) To install the bearing case, follow the installation
procedure below.

• Prior to installation, align the "S" 1 marked on the


coupling with the pointer 2 on the bearing case
body side as illustration.
1
2

Before air compressor


installation

• On completion of installation, make sure the mark


"S" 1 and pointer 2 are aligned with each other as
illustration (After bearing case installation).

After air compressor


installation
6A–20 ENGINE MECHANICAL

CAUTION:
If the "S" and pointer are not aligned as illustration
Approx. after bearing case installation, the timing gear is out
12 mm of position by one (1) tooth, reinstallation is needed.
4) Tighten the bearing case nuts and bolts to the
specified torque.
Air Compressor Nut and Bolt Torque N·m (kg·m / lb·ft)
M10 Nut 40 (4.1 / 30)
M12 Nut and Bolt 73 (7.4 / 54)

2. Injection Pump Bracket


1) Align the injection pump bracket with the cylinder
1 2
body dowel pin.
4 3
2) )Install the injection pump bracket to the cylinder
body.
3) Tighten the injection pump bracket bolts to the
specified torque a little at a time in the numerical
order as shown in the illustration.
Injection Pump Bracket Bolt Torque N·m (kg·m / lb·ft)
38 (3.9 / 28)

3. Engine Foot
1) Tighten the engine foot bolts to the specified
torque.
Engine Foot Bolt Torque N·m (kg·m / lb·ft)
Front 76 (7.7 / 56)
Rear 76 (7.7 / 56)

4. Water Duct (Suction)


5. Injection Pump Assembly (6HK1-TCS)
1) Check that No.1 cylinder is on the compression
stroke. (Make sure of No. 1 cylinder inlet/exhaust.)
2) Rotate the crankshaft in the normal direction of
engine rotation to align the damper pulley notched
line and the timing notched line.
When the notched line has passed the fuel
injection time, return it widely once to the fuel
injection time.
Injection Timing (Static - BTDC) deg
2
ENGINE MECHANICAL 6A–21

3) Align the injection pump body notched line and the


timing notched line on the flywheel.
4 4) Install the injection pump to the pump bracket.
NOTE:
2 When installing the pump, don’t touch the actuator at
the rear end. Hold the injection pump flywheel, using
a pump hanger.
1
5) Use a wrench to tighten the injection pump bolts to
the specified torque a little at a time in the
3
numerical order shown in the illustration.
Injection Pump Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)

6) Connect the injection pump drive coupling plate to


Injection pump flywheel Air compressor the injection pump flywheel.
NOTE:
Check that the coupling lamination is not bent or
warped.
7) Tighten the two coupling plate bolts 1 to the
specified torque.
Coupling Plate Bolt Torque N·m (kg·m / lb·ft)
1 2 62 (6.3 / 45.6)
NOTE:
Be sure to tighten the coupling bolts to the specified
torque (the bolts will slip if they are not properly
torqued). Note the position of the alignment mark
(notched line). If the mark is out of position, loosen
the coupling plate bolts and slide the mark into the
proper position. Retighten the coupling plate bolts.

8) Rotate the crankshaft two turns in the normal


direction of engine rotation.
9) Recheck the injection timing.

5-A. Fuel Supply Pump Assembly (6HK1-TCC, 6HK1-TCN)


1) Turn crankshaft until the TDC mark is aligned with
the pointer. Make sure the No. 1 cylinder is at TDC
on the compression stroke.
Injection Timing (Static-BTDC) deg
0

TDC
6A–22 ENGINE MECHANICAL

2 4 2) Align alignment mark between supply pump


coupler and supply pump housing.
3) Install supply pump assembly onto the pump
bracket.
4) Tighten supply pump fixing bolts to the specified
torque. The number indicate to tighten order.
Supply Pump Bolt Torque N·m (kg·m / lb·ft)
3 25 (2.5 / 18)
1

5) Tighten coupling bolts to the specified torque.


3 2
Coupling Bolt Torque N·m (kg·m / lb·ft)
Bolt 1 91 (9.3 / 67)
Bolt 2 61 (6.2 / 45)
Air compressor
side Bolt 3 61 (6.2 / 45)
NOTE:
1 1) Check the coupling lamination is not bent or
warped.
2
2) Be sure to tighten the coupling bolts to the
specified torque (the bolts will slip if they are not
properly torqued).

5-B. Common rail (6HK1-TCC, 6HK1-TCN)


Tighten the bolts to the specified torque (installed
together with the intake manifold).
Common Rail Bolt Torque N·m (kg·m / lb·ft)
22 (2.2 / 16)
The sensor and connector are fragile. Be careful not to
damage them.

Air compressor 6. Air Compressor


7. Air Pipe
Air pipe
1) Install the air pipe to the air compressor.
2) Clamp the air pipe each other shown in the
illustration.

MFW31BSH002901
ENGINE MECHANICAL 6A–23

8. Fuel Filter
1) Install the fuel filter to the bracket.
2) Tighten the fuel filter bolts to the specified torque.
Fuel Filter Bolt Torque N·m (kg·m / lb·ft)
41 (4.1 / 30)

9. Oil Filter
10. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nuts.
2) Set the clip in the prescribed position.
NOTE:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.

040M100010

3) Tighten the injection pipe clip bolts to the specified


torque.
Injection Pipe Clip Bolt Torque N·m (kg·m / lb·in)
6 (0.6 / 52)
4) Tighten the injection pipe sleeve nuts to the
specified torque.

Injection Pipe Sleeve Nut Torque N·m (kg·m / lb·ft)


29 (3 / 22)

10-A. Fuel Injection Pipe (6HK1-TCC, 6HK1-TCN)


Injection Pipe Injection Pipe
Tighten the injection pipe sleeve nuts to the specified
torque.
Injection Pipe Sleeve Nut Torque N·m (kg·m / lb·ft)
44 (4.5 / 33)
Fuel Pipe
Common Rail Fuel Pipe Tighten the fuel pipe sleeve nuts to the specified
torque.
Fuel Pipe Sleeve Nuts Torque N·m (kg·m / lb·ft)
Supply pump side 44 (4.5 / 33)
Common rail side 54 (5.5 / 40)
6A–24 ENGINE MECHANICAL

11. Fuel Leak Off Pipe


A 12. Fuel Pipe
1) Set the fuel pipes to the injection pump and the
fuel filter.
2) Temporarily tighten the joint bolts.

040M100011

3) Tighten the fuel pipe joint bolts to the specified


torque.
Fuel Pipe Joint Bolt Torque N·m (kg·m / lb·ft)
8 mm 15 (1.5 / 10.8)
10 mm 27 (2.8 / 20.3)
12 mm 34 (3.5 / 25.3)
14 mm 41 (4.2 / 30.4)
16 mm 50 (5.1 / 36.9)
4) Set the pipe clip to the prescribed position.
13. Air compressor pipe
(Intake duct to air compressor)

14. Power Steering Oil Pump


1) Install the O-ring to the pump body.
2) Do not reuse the “O” ring.

3) Tighten the power steering oil pump bolts to the


specified torque.
Power Steering Oil Pump Bolt Torque N·m (kg·m / lb·ft)
38 (3.9 / 28)

15. Power Steering Oil Pipe


16. Guide Tube
17. Starter Motor
1) Install the starter motor to the flywheel housing.
2) Tighten the starter motor nuts to the specified
torque.
Starter Motor Nut Torque N·m (kg·m / lb·ft)
82 (8.4 / 61)
ENGINE MECHANICAL 6A–25

18. Generator and Adjusting Plate


2 1) Install the generator and adjusting plate to the
engine.
2) Temporarily tighten the generator bolt 1.
The bolt will be finally tightened after installing and
adjusting the cooling fan belt.
3) Tighten the cooling fan drive belt adjusting plate
bolt 2 to the specified torque.
1 Adjusting Plate Bolt Torque N·m (kg·m / lb·ft)
48 (4.9 / 35)

19. Cooling Fan Drive Belt


1) Install the cooling fan belt.
2) Turn the adjusting bolt 1 to move the generator
b c and adjust the cooling fan drive belt tension.
Apply a force of 98N (10kg / 22lb) to the drive belt
mid-portion to check the belt deflection.
Cooling Fan Drive Belt Deflection mm (in)
a 10 – 15 (0.4 – 0.6)
a Crankshaft pulley
b Generator pulley
c Cooling fan pulley

3 3) Tighten the generator bolt 2 and the adjusting


plate nut 3 to the specified torque.
1 Generator Bolt Torque N·m (kg·m / lb·ft)
127 (13 / 94)

Adjusting Plate Nut Torque N·m (kg·m / lb·ft)


76 (7.7 / 56)

20. Cooling Fan


21. Cooling Fan Guide
22. Water Outlet (To Radiator)
6A–26 ENGINE MECHANICAL

23. Turbocharger Assembly


Supply oil to turbocharger turbine.
Vesco Super Engine Oil

• Supply oil through the oil filling port of the


turbocharger and give the turbine shaft a few turns
for lubrication of the bearing parts.

Install the turbocharger assembly.


Tightening torque N·m (kg·m / lb·ft)
52 (5.3 / 38)

Install adapter to the turbocharger.


Tightening torque N·m (kg·m / lb·ft)
Adapter; 25 (2.6 / 19)

• Install the adapter to the turbocharger through


gasket, and tighten nuts. Used gasket should not
be reused.
ENGINE MECHANICAL 6A–27

24. Water Return Pipe For Water Cooling Type


ٕ‫ޓ‬ (To Thermo Unit)
25. Water Feed Pipe For Water Cooling Type
(From Cylinder Body)
ٕ‫ޓ‬ 1. Install the water return pipe and feed pipe.
Tightening torque
Water Return Pipe (To Turbocharger) N·m (kg·m / lb·ft)
̪‫ޓ‬ ‫ޓغ‬ Turbocharger side Air compressor side
39 (4 / 29) 44 (4.5 / 33)

ٕ‫ޓ‬ Water Feed Pipe (To Turbocharger) N·m (kg·m / lb·ft)


FRONT
Turbocharger side Cylinder body side
036L100001 39 (4 / 29) 39 (4 / 29)

NOTE:
Gasket should not be reused.

2. Install the piping clip.


Tightening torque N·m (kg·m / lb·ft)
▼ : 20 (2 / 14)
■ : 73 (7.4 / 54)
̪ : 10 (1 / 7)

NOTE:
After tightening the pipe, install the clips.

26. Oil Return Pipe (To Cylinder Body)


27. Oil Feed Pipe (From Oil Filter)
1. Install the oil return pipe and feed pipe.
Tightening torque
Oil Return Pipe (To Cylinder Body) N·m (kg·m / lb·ft)
Turbocharger side Cylinder Body side
20 (2 / 14) 39 (4 / 29)

Oil Feed Pipe (To Turbocharger) N·m (kg·m / lb·ft)


Turbocharger side Oil Filter side
34 (3.5 / 25) 34 (3.5 / 25)

NOTE:
Gasket should not be reused.

2. Install the piping clip.


Tightening torque N·m (kg·m / lb·ft)
20 (2 / 14)

052M100002 NOTE:
After tightening the pipe, install the clips.
6A–28 ENGINE MECHANICAL

28. EGR Assembly (6HK1-TCS only)


1) EGR cooler
• Install the EGR cooler temporarily.
• Tighten the bolts (A) to specified torque.
EGR Cooler (A) Bolts Torque N·m (kg·m/Ib·ft)
41 (4.2/30)

• Tighten the bolts (B) to specified torque.


A B
EGR Cooler
027M100004
EGR Cooler (B) Bolts Torque N·m (kg·m/Ib·ft)
41 (4.2/30)

2) EGR valve and EGR pipe (left side)


• Assemble the EGR valve and the EGR pipe before
EGR valve installing them to the engine.
EGR pipe
Gasket • Tighten the bolts (A) to specified torque.
EGR Valve (A) Bolts Torque N·m (kg·m/Ib·ft)
41 (4.2/30)

MFW31BSH002801

3) EGR valve with EGR pipe


EGR Valve • Install the EGR valve with EGR pipe temporarily.
• Tighten the bolts (A) to specified torque.
EGR Valve (A) Bolts Torque N·m (kg·m/Ib·ft)

B
27 (2.8/20)

• Tighten the bolts (B) to specified torque.


A
EGR Valve (B) Bolts Torque N·m (kg·m/Ib·ft)
027M100005
20 (2.0/14)

4) EGR pipe (EGR cooler - Exhaust Manifold)


A
• Install the EGR pipe temporarily.
• Tighten the bolts (A) to specified torque.
EGR Pipe (A) Bolts Torque N·m (kg·m/Ib·ft)
20 (2.0/14)

Exhaust • Tighten the bolts (B) to specified torque.


EGR Cooler Manifold
B EGR Pipe (B) Bolts Torque N·m (kg·m/Ib·ft)
027M100006
20 (2.0/14)

NOTE:
Follow the steps to install the EGR valve and pipe to
the engine. Do not apply excessive force to the pipe.
ENGINE MECHANICAL 6A–29

29. Intake Pipe


Install the intake pipe.
• Install with the rubber hose heat protector directed
as illustrated.

Cylinder
body

30. Air Duct


Install the air duct.
Tightening Torque N·m (kg·m/Ib·ft)
13 – 23 (1.3 – 2.3 / 9 – 17)

31. Intake Pipe


Install the intake pipe.
‫ޓغ‬
Tightening Torque N·m (kg·m/Ib·ft)
ً : 13 (1.3 / 9)
ً‫ޓ‬ ■ : 20 (2.0 / 14)

‫ޓغ‬

025M100006
6A–30 ENGINE MECHANICAL

CYLINDER HEAD AND VALVE MECHANISM


REMOVAL

6HK1-TCC
1 6HK1-TCN

6A

2 14

16

6
15
5
9
7

8 17

3
12
11
13

10
18

MFW31BLF000101

Removal Steps
1. Cylinder head cover 9. Glow plug
2. Gasket 10. Plate
3. Rubber plug 11. Water duct
4. Nozzle leak off pipe 12. O-ring
5. Nozzle clamp 13. O-ring
6. Injection nozzle holder (6HK1-TCS) 14. Rocker arm assembly
6-A. Injector assembly (6HK1-TCC, 6HK1- 15. Bridge cap
TCN) 16. Camshaft assembly
17. Cylinder head assembly
7. Gasket
18. Head gasket
8. Glow plug connector
ENGINE MECHANICAL 6A–31

Removal Steps
1. Cylinder Head Cover
2. Gasket
Remove the cylinder head cover and gasket.
NOTE:
Be careful not to miss the collars inserted in the
cylinder head cover assembly.

010MX004

3. Rubber Plug
4. Nozzle Leak off Pipe
5. Nozzle Clamp
6. Injection Nozzle Holder (6HK1-TCS)

040MX042

6-A. Injector Assembly (6HK1-TCC, 6HK1-TCN)


1) Disconnect TWV harness connector from inside of
lower case joint connector.

040MX058

2) Loosen terminal nuts for TWV harness on the top


of injector and remove TWV harness.

NOTE:
The terminal nuts have a 1-piece construction (they
cannot be completely removed). Slightly turn one nut
and then the other, repeating this action 2 or 3 times
until both nuts are loose.

011MX031
6A–32 ENGINE MECHANICAL

3) Remove TWV harness assembly from top of rocker


arm assembly.
4) Loosen injector clamp bolt then remove injector
assembly.

040MX059

7. Gasket
8. Glow Plug Connector
9. Glow Plug
Remove the injection nozzles and glow plugs before
removing the cylinder head.
10. Plate
11. Water Duct
12. O-Ring
13. O-Ring
14. Rocker Arm Assembly
Loosen the rocker arm shaft bracket and rocker arm
A and shaft assembly bolts evenly from the outside to
inside.
NOTE:
Leave the A indicated bolts (both side) unremoved
on the occasion, since it is the rocker arm fixing bolts.

15. Bridge Cap


16. Camshaft Assembly
Loosen the camshaft bearing cap bolts and nuts evenly
from both side.
NOTE:
If the camshaft bearings (upper and lower) are to be
reinstalled, mark their fitting positions by tagging
each bearing with the camshaft bearing cap number
from which it was removed.

011MV009-1
ENGINE MECHANICAL 6A–33

17. Cylinder Head Assembly


3 7 A E I M QP LH D 0 6 2 Loosen the cylinder head bolts a little at a time in the
numerical order shown in the illustration.
CAUTION:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the
cylinder head lower surfaces.
48 BF JN RO KG C 9 5 1

CAUTION:
The idler gear "C" projects from the cylinder head
lower side and easily damaged. Great care must be
taken to avoid damaging the idler gear "C" if the
cylinder head is removed from the engine.

18. Cylinder Head Gasket


6A–34 ENGINE MECHANICAL

INSTALLATION

6HK1-TCC
18 6HK1-TCN

13A

17 5

15

13
4
10 14
12

11 2

16
7
8
6

9
1

MFW31BLF000201

Installation Steps
1. Head gasket 11. Glow plug connector
2. Cylinder head assembly 12. Gasket
3. Camshaft assembly 13. Injection nozzle holder (6HK1-TCS)
4. Bridge cap 13A. Injector assembly (6HK1-TCC, 6HK1-
5. Rocker arm assembly TCN)
6. O-ring 14. Nozzle clamp
7. O-ring 15. Nozzle leak off pipe
8. Water duct 16. Rubber plug
9. Plate 17. Gasket
10. Glow plug 18. Cylinder head cover
ENGINE MECHANICAL 6A–35

Installation Steps
1. Cylinder Head Gasket
2 1) Clean the cylinder body surface.

2) Apply ThreeBond 1207C or equivalent to the


3 cylinder body and the flywheel housing fitting
faces 12.
The liquid gasket must be 2.0 – 3.0mm
(0.08 – 0.118 in) thick and 2.0 – 4.0mm
1 (0.08 – 0.157 in) wide.
The liquid gasket must not obstruct the cylinder oil
port 3.

3) Install the cylinder head gasket to the cylinder


body.
The part number (indicated by arrow in the
illustration) must be facing up.

2. Cylinder Head Assembly


1) Align the cylinder body dowel pins and the cylinder
head dowel holes.
Carefully place the cylinder head on the cylinder
head gasket.

2) Apply molybdenum disulfide grease to the cylinder


P L H D 0 6 23 7A E I M Q head bolts (M14) threads and setting faces.
3) Apply engine oil to the cylinder head bolts (M10)
threads and setting faces.
4) Tighten the M14 cylinder head bolts (Number 1 to
P) in three steps using the angular tightening
method.
Follow the numerical order shown in the
OK GC 95 14 8B F J N R illustration.
Cylinder Head Bolt Torque N·m (kg·m / lb·ft)
1st Step 2nd Step 3rd Step
98 (10 / 72) 147 (15 / 108) 45 deg
6A–36 ENGINE MECHANICAL

5) Tighten the M10 cylinder head bolts (Number Q to


Q R) to the specified torque.
Cylinder Head Bolt Torque N·m (kg·m / lb·ft)
38 (3.9 / 28)
NOTE:
1. The cylinder head bolts can be reused six (6) times.
2. Cover the timing gear hole by cloth for prevent
R into foreign materials.

3. Camshaft with Gear


1) Align the crankshaft damper pulley TDC mark with
the pointer by rotating the crankshaft normal
direction. Same time check alignment timing mark
on injection pump for No.1 piston TDC.
2) Install the camshaft bearing to the cylinder head
bearing groove and the bearing caps.
3) Apply engine oil to the camshaft bearing sliding
surfaces before installing the camshaft.

4) Install the camshaft with gear assembly to the


cylinder head.
5) Carefully align the camshaft gear "B" mark and the
cylinder head upper face shown in the illustration.
6) If the "B" mark and cylinder head upper face are
not aligned, No. 1 piston is not on the compression
stroke.
Remove the camshaft.
Rotate the crankshaft one full turn and realign the
crankshaft damper pulley TDC mark with the
pointer by rotating the crankshaft normal direction.
7) Reinstall the camshaft assembly same as step 3.-5)
above.
ENGINE MECHANICAL 6A–37

Camshaft Bearing Cap


1) Apply engine oil to the camshaft bearing sliding
surfaces.
2) Install the camshaft bearing caps with the bearings
in the numerical order with the cap stamped mark
facing forward.

011MV009-1

3) Apply engine oil to the bearing cap bolts threads


and setting faces.
4) Tighten the bolt prior to the nut in each bearing
cap to the specified torque evenly from center to
outside of cylinder head.
Camshaft Bearing Cap Bolt Torque N·m (kg·m / lb·ft)
27 (2.8 / 20)

4. Bridge Cap
1) Apply engine oil to the bridge cap.
2) Install the bridge cap to the bridge.

011MX042

5. Rocker Arm Assembly


1) Apply engine oil to the front and rear camshaft
bracket sliding surfaces.
2) Apply engine oil to the camshaft bracket studs
thread and nuts setting faces.
3) Install the rocker arm and shaft assembly to the
cylinder head.

014MX016
6A–38 ENGINE MECHANICAL

4) Tighten the rocker arm bracket bolts and nuts to


the specified torque.
‫ڎ‬2 7 8 First of all tighten star mark 1 nut and star mark 3
5 9 6 ‫ڎ‬4 nut then tighten star mark 2 nut and star mark 4
‫ڎ‬1 ‫ڎ‬3
nut.
11 13 Torque N·m (kg·m / lb·ft)

10 12 Star mark Nuts 27 (2.8 / 20)

Then tighten number 5 bolt to number 9 bolt.


011MY00039
Torque N·m (kg·m / lb·ft)
Bolts 5 through 9 56 (5.7 / 41)

Tighten valve rocker arm shaft bracket bolts.


Torque N·m (kg·m / lb·ft)
Bolts 10 through 13 27 (2.8 / 20)

6. O-Ring
7. O-Ring
8. Water Duct and O-ring
9. Plate
1) Apply soapsuds to the O-ring.
2) Install the O-ring to the water duct O-ring groove.
3) Install the water duct to the water pump body.
4) Tighten the water duct bolts to the specified
torque.
Water Duct Bolt Torque N·m (kg·m / lb·ft)
M8 Bolt 19 (1.9 / 14)
M16 Bolt 118 (12.0 / 87)

10. Glow Plug


11. Glow Plug Connector
1) Install the glow plug to the cylinder head.
2) Tighten the glow plug to the specified torque.
Glow Plug Torque N·m (kg·m / lb·ft)
20 (2.0 / 14)

011MX041
ENGINE MECHANICAL 6A–39

12. Gasket
6HH1
13. Injection Nozzle Holder (6HK1-TCS)
14. Nozzle Clamp
Clamp Bolt Torque N·m (kg·m / lb·ft)
30 (3.1 / 22)

15. Nozzle Leak off Pipe


1) Install the injection nozzle holders with the new
gaskets and the O-rings to the cylinder head.
040MX041
CAUTION:
Take care not to damage the injection nozzle tops
and O-ring during nozzle holder installation.
2) Install the nozzle holder flange to the nozzle holder
bolts.
3) Temporarily tighten the nozzle holder bolts.
The bolts will be finally tightened after injection
pipe and leak off pipe installation.
Refer to external parts installation.

13-A. Injector Assembly (6HK1-TCC, 6HK1-TCN)


1) When injector assembly comes installation portion,
the injector clamp putting on the injector then
install the injector assembly together with clamp
into injector sleeve hole.
2) Temporary tighten injection pipe to injector.
3) Apply mlybdenum disulfide grease to clamp bolt,
tighten injector clamp bolt to specified torque.
Clamp Bolt Torque N·m (kg·m / lb·ft)
040MX056 30 (3.1 / 22)
4) Tighten injection pipe to the specified torque.
Injection Pipe Torque N·m (kg·m / lb·ft)
44 (4.5 / 33)
5) Install fuel return pipe, tighten eye bolt to the
specified torque.
Eye Bolt Torque N·m (kg·m / lb·ft)
12 (1.2 / 9)
NOTE:
1. Be confirm that tightening torque of injection pipe
and fuel return pipe eye bolt after tighten them for
prevent to delute of engine oil.
2. Make sure that the gasket for return pipe not ride
on the injector body when tighten eye bolt.
6A–40 ENGINE MECHANICAL

6) Install TWV harness assembly, tighten fixing bolt to


specified torque.
Bracket Bolt Torque N·m (kg·m / lb·ft)
22 (2.2 / 16)

7) There are 2integral terminal nuts. Hand-tighten


each nut 2 or 3 turns before alternately tightebing
them a little at a time the specified torque.
8) Tighten fixing nut to the specified torque.
Terminal Nut Torque N·m (kg·m / lb·ft)
2 (0.2 / 1.4)
NOTE:
Do not overtighten the terminal nuts (the TWV thread
area will be damaged.)
9) Reconnect TWV harness to lower case joint
connector.

16. Rubber Plug


1) Apply ThreeBond 1207B or equivalent to the
rubber plug as shown in the illustration.
2) Install the rubber plugs to the cylinder head.
NOTE:
If the cylinder head is to be reinstalled, be sure to
remove, clean, and reseal the rubber plug.

3) Apply ThreeBond 1207B or equivalent to the


rubber plug surfaces.
Threebond 1207B
NOTE:
Immediately (within ten (10) minutes of applying the
liquid gasket) install the cylinder head cover to the
cylinder head.
ENGINE MECHANICAL 6A–41

17. Gasket
18. Cylinder Head Cover
1) Clean the head cover gasket groove and the head
cover gasket.
2) Install the head cover gasket and collar to the head
cover.
3) Install the cylinder head cover to the cylinder head.

010MX004

4) Tighten the cylinder head cover bolts to the


specified torque a little at a time in the numerical
9 order shown in the illustration.
8 4 1 5
Cylinder Head Cover Bolt
Torque N·m (kg·m / lb·in)
11 13 (1.3 / 113)

7 3 2 6 10

010MX003
6A–42 ENGINE MECHANICAL

DISASSEMBLY
Cylinder Head

VIEW A FRONT

8
7

1
25
2
9

17
18
A 26
7 19 15
21
22 23 16
6

28
10
27
10

5
12
24
14

13 20 4
11 3

011M100006

Disassembly Steps
1. Bridge cap 15. Sealing cup
2. Bridge 16. Idler gear “C”
3. Intake pipe 17. Split collar
4. Intake cover 18. Valve spring upper seat
5. Gasket 19. Valve spring
6. Heat protector 20. Valve
7. Exhaust manifold 21. Valve stem seal
8. Gasket 22. Spring seat
9. Heat protector 23. Valve guide
10. Engine hanger 24. Valve seat insert
11. Thermometer unit 25. Injection nozzle sleeve
12. Water outlet pipe 26. Bridge guide
13. Thermostat 27. Oil seal
14. Gasket 28. Cylinder head
ENGINE MECHANICAL 6A–43

Disassembly Steps
1. Bridge Cap
2. Bridge
3. Intake Pipe
4. Intake Cover
5. Gasket
6. Heat Protector
7. Exhaust Manifold
8. Gasket
9. Heat Protector
10. Engine Hanger
11. Thermometer Unit
12. Water Outlet Pipe
13. Thermostat
14. Gasket
15. Sealing Cup
Tap the outside of the sealing cup with a screw driver
to deform one end of it and draw it out with pliers.
Note:
Do not make scrach on seal surface of cylinder head.

16. Idler Gear “C”


17. Split Collar
1) Place the cylinder head on a flat wooden surface.
2) Use the valve spring compressor to remove the
split collar.
Do not allow the valve to fall from the cylinder head.
Valve Spring Compressor: 5-8840-2621-0
Valve Spring Compressor: 8-9439-6862-0

011MX017

18. Valve Spring Upper Seat


19. Valve Spring
20. Valve
21. Valve Stem Seal
22. Spring Seat

011MX027
6A–44 ENGINE MECHANICAL

23. Valve Guide


Use valve guide remover to remove the valve guide.
Valve Guide Remover: 5-8840-2628-0

011MX015

24. Valve Seat Insert


1) Heat up (about 600 – 700°C) two point on the valve
seat insert by gas torch, allow the valve seat insert
to cool for few minutes.
2) This will invite contraction and make removal of
the valve seat insert easier.
3) Use screwdriver to pry the valve seat insert free.
Take care not to damage the cylinder head.
4) Carefully remove carbon and other foreign
materials from the cylinder head inert bore.
011MX016

25. Injection Nozzle Sleeve


Use nozzle sleeve remover to hit nozzle sleeve from
lower side cylinder head.
Nozzle Sleeve Remover: 5-8840-2623-0

040MX038

26. Bridge Guide


Electric welding the bolt to bridge guide, use sliding
hammer to remove the bridge guide.
Elec. Welding

011MX043

27. Oil Seal

011MX026
28. Cylinder Head
ENGINE MECHANICAL 6A–45

Rocker Arm and Shaft Assembly


4

014MX018

Disassembly Steps
1. Camshaft bracket 4. Rocker arm shaft bracket
2. Rocker arm 5. Rocker arm shaft
3. Spring washer
6A–46 ENGINE MECHANICAL

Disassembly Steps
1. Camshaft Bracket
2. Rocker Arm
If the rocker arms and rocker arm shaft brackets are to
be reinstalled, mark their installation positions by
tagging each rocker arm and rocker arm shaft bracket
with the cylinder number from which it was removed.

014MX027

3. Spring Washer
4. Rocker Arm Shaft Bracket
5. Rocker Arm Shaft
ENGINE MECHANICAL 6A–47

Camshaft

1
2

Disassembly Steps
1. Camshaft gear 3. Camshaft
2. Gear alignment pin
6A–48 ENGINE MECHANICAL

Disassembly Steps
1. Camshaft Gear
Replace the camshaft gear if it is excessively worn or
2 damage or if the camshaft end play is excessive.
1 1) Remove the camshaft gear bolt.
2) Use a gear remover 1 to remove the camshaft
gear 2.

2. Gear Alignment Pin


3. Camshaft
ENGINE MECHANICAL 6A–49

INSPECTION AND REPAIR


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

Cylinder Head
Cylinder Head Lower Face Warpage
Removal Carbon
Use a straight edge and a feeler gauge to measure the
four sides and the two diagonals of the cylinder head
lower face.
If the measured values exceed the specified limit, the
cylinder head must be replaced.
Cylinder Head Lower Face Warpage mm (in)
Limit
0.20 (0.008)

NOTE:
Do not attempt to regrind the cylinder head lower
face.
A
E F
C D
B

Valve Guide
Valve Stem and Valve Guide Clearance
Measuring Method-I
1. Insert the valve to the cylinder head.
2. Set the dial indicator to the valve stem at
measuring point 1 as shown in the illustration.
Measuring Point 1: 10mm (0.4in)
3. Set the dial indicator needle to “0”.
4. Move the valve head from side to side.
1
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit,
the valve and the valve guide must be replaced as
a set.
Valve Stem and Valve Guide Clearance mm (in)
Standard Limit
0.04 – 0.07 0.20
Intake Valve
(0.0016 – 0.0028) (0.008)
0.06 – 0.10 0.25
Exhaust Valve
(0.0024 – 0.0039) (0.010)
6A–50 ENGINE MECHANICAL

Measuring Method-II
1. Measure the valve stem outside diameter.
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
3. Calculate the clearance between the valve guide
inside diameter and the valve stem outside
diameter.
If the clearance exceeds the specified limit, the
valve and the valve guide must be replaced as a
set.

Valve Stem Outside Diameter


Measure the valve stem diameter at three points.
If the measured value is less than the specified limit,
the valve and the valve guide must be replaced as a set.
Valve Stem Outside Diameter mm (in)
Standard Limit
7.95 – 7.96 7.88
Intake Valve
(0.3130 – 0.3134) (0.3102)
7.92 - 7.94 7.88
Exhaust Valve
(0.3118 – 0.3126) (0.3102)

Valve Guide Replacement


Valve Guide Removal

Use a hammer and the valve guide replacer to drive out


the valve guide from the cylinder head lower face.
Valve Guide Replacer: 5-8840-2628-0

011MX015

Valve Guide Installation

1. Apply engine oil to the valve guide outer


circumference.
2. Set the ring to the valve guide replacer.
3. Attach the valve guide replacer with ring to the
valve guide.
4. Use a hammer to drive the valve guide into
position from the cylinder head upper face.
011MX024 Valve Guide Replacer: 5-8840-2628-0
ENGINE MECHANICAL 6A–51

5. Measure the height of the valve guide upper end


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

Valve and Valve Seat Insert


Valve Thickness
Measure the valve thickness
If the measured value is less than the specified limit,
the valve and the valve guide must be replaced as a set.
Intake and Exhaust Valve Thickness mm (in)
Standard Limit
Intake Valve 1.70 (0.067) 1.30 (0.051)
Exhaust Valve 1.80 (0.071) 1.30 (0.051)

Valve Depression
A 2 1. Install the new valve 1 to the cylinder head 2.
2. Use a depth gauge or a straight edge with steel
rule to measure the valve depression from the
cylinder head lower surface.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
1
Valve Depression A mm (in)
Standard Limit
Intake Valve 1.0 (0.039) 2.3 (0.090)
Exhaust Valve 1.3 (0.051) 2.8 (0.110)

Valve Contact Width


1. Check the valve contact faces for roughness and
unevenness.
Make smooth the valve contact surfaces.
2. Measure the valve contact width.
Apply red lead paint to the valve seat.
Insert the valve seat, turn several times the valve
while pressing against the valve seat, and take out
the valve.
Then check and see the width of contact from the
stain of red lead paint.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Valve Contact Width mm (in)
Standard Limit
Intake Valve 2.5 (0.098) 3.2 (0.126)
Exhaust Valve 2.0 (0.079) 2.8 (0.110)
6A–52 ENGINE MECHANICAL

Valve Seat Insert Replacement


2
Valve Seat Insert Removal
3 1. Arc weld the entire inside circumference 1 of the
valve seat insert 2.
2. Allow the valve seat insert to cool for a few
4 minutes.
This will invite contraction and make removal of
the valve seat insert easier.
1
3. Use a screwdriver 3 to pry the valve seat insert
011M100009
free.
Take care not to damage the cylinder head 4.
4. Carefully remove carbon and other foreign material
from the cylinder head insert bore.

Valve Seat Insert Installation


3 1. Carefully place the attachment 1 (having a smaller
outside diameter than the valve seat insert) on the
1 valve seat insert 2.
CAUTION:
2 The smooth side of the attachment must contact the
valve seat insert.
2. Use a bench press 3 to gradually apply pressure
to the attachment and press the valve seat insert
into the place.
CAUTION:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.

Valve Seat Insert Correction


150˚
90˚ 1. Remove the carbon from the valve seat insert
30˚ surface.

2. Use a valve cutter (15, 45, 60 and 75 degree blades)


to minimize scratches and other rough areas. This
will bring the contact width back to the standard
value.
Remove only the scratches and rough areas. Do
not cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.

011MX018
ENGINE MECHANICAL 6A–53

Valve Face Angle deg


Exhaust 45
Intake 30
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside
the valve guide.

3. Apply abrasive compound to the valve seat insert


surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.

011MX018

Valve Spring
Valve Spring Free Height
Use a vernier caliper to measure the valve spring free
height.
If the measured value is less than the specified limit,
the valve spring must be replaced.
Spring Free Height mm (in)
Standard Limit
Intake 65.9 (2.59) 64.6 (2.54)
Exhaust 68.1 (2.68) 66.7 (2.63)

Valve Spring Squareness


Use a surface plate and a square to measure the valve
spring squareness.
If the measured value exceeds the specified limit, the
valve spring must be replaced.
Inner and Outer Spring Squareness mm (in)
Standard Limit
Intake 2.9 (0.11) 3.4 (0.13)
Exhaust 3.0 (0.12) 3.4 (0.13)
6A–54 ENGINE MECHANICAL

Valve Spring Tension


Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit,
the valve spring must be replaced.
Intake Valve Spring Tension N (kg / lb)
Compression
Standard Limit
Height
46mm 348 309
(1.81in) (35.5 / 78.3) (31.5 / 69.5)

Exhaust Valve Spring Tension N (kg / lb)


Compression
Standard Limit
Height
46mm 383 329
(1.81in) (39.0 / 86.0) (33.5 / 74.0)

Rocker Arm Shaft and Rocker Arm


Rocker Arm Shaft Run-Out
1. Place the rocker arm shaft on a V-block.
2. Use a dial indicator to measure the rocker arm
shaft central portion run-out.
If the run-out is very slight, correct the rocker arm
shaft run-out with a bench press. The rocker arm
must be at cold condition.
If the measured rocker arm shaft run-out exceeds
the specified limit, the rocker arm shaft must be
replaced.
Rocker Arm Shaft Run-Out mm (in)
Limit
0.3 (0.012)

Rocker Arm Shaft Outside Diameter


Use a micrometer to measure the rocker arm fitting
portion outside diameter.
If the measured value is less than the specified limit,
the rocker arm shaft must be replaced.
Rocker Arm Shaft Outside Diameter mm (in)
Standard Limit
21.979 – 22.000 (0.865 – 0.866) 21.85 (0.860)
ENGINE MECHANICAL 6A–55

Rocker Arm Shaft and Rocker Arm Clearance


1. Use either a vernier caliper or a dial indicator to
measure the rocker arm inside diameter.
2. Measure the rocker arm shaft outside diameter.
If the measured value exceeds the specified limit,
replace either the rocker arm or the rocker arm
shaft.
Rocker Arm Shaft and Rocker Arm Clearance mm (in)
Standard Limit
0.010 – 0.056 0.20
(0.0004 – 0.0022) (0.008)

3. Check that the rocker arm oil port is free of


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

A06MV004

Rocker Arm
Visually inspect the rocker arm camshaft contact
surfaces of the roller for excessive wear and damage.

Rocker Arm Roller and Pin Clearance


1. Pass the string through the rocker arm-roller
clearance and measure the roller protrusion while
pulling both ends of the string in the arrow-
indicated directions to push out the roller.
Mark the measuring point and draw out the string.

A
6A–56 ENGINE MECHANICAL

2. Measure the roller protrusion again while the roller


is pushed in.
B
3. Note the difference in the above measurements is
the standard roller-rocker arm pin clearance.
Should the clearance exceed the limit, replace the
rocker arm.
Rocker Arm Pin and Roller Clearance mm (in)
Vernier caliper Standard Limit
0.068 – 0.099 0.5
(0.0026 – 0.0039) (0.02)

Valve Cap
Inspect the valve cap surface contacting the rocker arm
for excessive wear and damage.
If the wear exceeds the limit, replace the valve cap with
new one.
Valve Cap Worn mm (in)
Limit 0.1 (0.0039)

Camshaft
Visually inspect the journal, the cams, and the
camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be
replaced if these conditions are discovered during
inspection.

Camshaft Journal Diameter


1
Use a micrometer to measure each camshaft journal
2 2 diameter in two directions 1 and 2. If the measured
value is less than the specified limit, the camshaft must
1 be replaced.
Camshaft Journal Diameter mm (in)
Standard Limit
39.950 – 39.975 39.85
(1.5728 – 1.5738) (1.569)
F06MV017
ENGINE MECHANICAL 6A–57

Cam Lobe Height


Measure the cam lobe height A with a micrometer.
If the measured value is less than the the specified
limit, the camshaft must be replaced.
A
Cam Lift (A – B) mm (in)
Standard Limit
B Intake 7.831 (0.3083) 7.331 (0.2886)
Exhaust 8.594 (0.3383) 8.094 (0.3186)
F06MV016

Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
If the measured value exceeds the specified limit,
the camshaft must be replaced.
Camshaft Run-Out mm (in)
Standard Limit
0.025 (0.001) 0.05 (0.002)

Camshaft and Camshaft Bearing Clearance


Use an inside dial indicator to measure the camshaft
bracket inside diameter.
If the clearance between the camshaft bracket inside
diameter and the journal exceeds the specified limit,
the camshaft bracket bearing, and/or camshaft must be
replaced.
Camshaft Bearing Clearance mm (in)
Standard Limit
0.025 – 0.087 (0.001 – 0.035) 0.15 (0.006)

Camshaft and Camshaft Gear Clearance


Measure the clearance between the camshaft and
camshaft gear.
Camshaft and Camshaft Gear Clearance mm (in)
Standard
28.015 – 28.055 (1.103 – 1.105)
6A–58 ENGINE MECHANICAL

Camshaft Gear
Visually inspect the camshaft for excessive wear and
damage.
If the camshaft gear for excessive wear or damaged it
must be replaced.

Camshaft Bracket
Check that the camshaft bracket oil port is free of
obstructions.
If necessary, use compressed air to clean the camshaft
bracket oil port.
ENGINE MECHANICAL 6A–59

REASSEMBLY
Cylinder Head

VIEW A FRONT

21
22

28
5
27
20

13
12
A 4
22 11 15
9
8 7 14
23

1
3
2
3

24
18
6
16

17 10 25
19 26

011M100007

Reassembly Steps
1. Cylinder head 15. Sealing cup
2. Oil seal 16. Gasekt
3. Engine hanger 17. Thermostat
4. Bridge guide 18. Water outlet pipe
5. Injection nozzle sleeve 19. Thermometer unit
6. Valve seat insert 20. Heat protector
7. Valve guide 21. Gasket
8. Spring seat 22. Exhaust manifold
9. Valve stem seal 23. Heat protector
10. Valve 24. Gasket
11. Valve spring 25. Intake cover
12. Valve spring upper seat 26 Intake pipe
13. Split collar 27. Bridge
14. Idler gear “C” 28. Bridge cap
6A–60 ENGINE MECHANICAL

Reassembly Steps
1. Cylinder Head
2. Oil Seal
Use the oil seal installer to install the cylinder head.
Oil Seal Installer: 5-8840-2627-0

011MX026

011MX036

3. Engine Hanger
Install the engine hanger bolts to the specifie torque.
Engine Hanger Bolts Torque N·m (kg·m / lb·ft)
94 (9.6 / 69)

011MX044

4. Bridge Guide
122.5±0.5

1) Apply engine oil to the valve bridge guide outer


37.5

circumference.
2) Attach the valve bridge guide installer to the bridge
guide.
Valve Bridge Guide Installer: 5-8840-2626-0
3) Use a brass hammer to tap the guide into position
from the cylinder head upper face.

011MX012
ENGINE MECHANICAL 6A–61

5. Injection Nozzle Sleeve


1) Install O-ring to nozzle sleeve and apply engine oil
to cylinder head 2.
1
2) Apply liquid gasket the tapered part 1 of nozzle
sleeve.
LOCTITE No. TL290

040MV040-1

3) Install nozzle sleeve to cylinder head and insert


guide sleeve.
4) Push in nozzle sleeve with guide sleeve so that the
bottom surface of cylinder head can be reached.
5) Insert nozzle sleeve and fix with clamp and bolt.
6) Push a ball (bearing steel ball 9.525 mm) into guide
sleeve, and let the ball go through by hammering
through punch bar.
NOTE:
040MX039
• Remove chips from the threaded part of cylinder
head.
• Keep the cylinder head afloat so that the ball can
go out of the bottom surface.
Nozzle Sleeve Setting Tool: 5-8840-2624-0

6. Valve Seat Insert


3 1) Carefully place the attachment 1 (having a smaller
outside diameter than the valve seat insert) on the
1 valve seat insert 2.
NOTE:
2 The smooth side of the attachment must contact the
valve seat insert.
2) Use a bench press 3 to gradually apply pressure
to the attachment and press the valve seat insert
into place.
CAUTION:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.

3) The valve should be lapped before final assembly


to ensure a good valve seal.
Refer to “Valve Seat Insert Correction” in this
section.
6A–62 ENGINE MECHANICAL

7. Valve Guide
1) Apply engine oil to the valve guide outer
circumference.
2) Attach the valve guide replacer to the valve guide.
3) Use a hammer to drive the valve guide into
position from the cylinder head upper face.
Valve Guide Remover: 5-8840-2628-0
4) Measure the height of the valve guide upper end
from the upper face of the cylinder head.
011MX024 Valve Guide Upper End Height
(Reference) mm (in)
19 (0.748)

8. Spring Seat
9. Valve Stem Seal
1) Apply engine oil to the oil seal inner face.
2) Use the oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2625-0

011MX020

10. Valve
Apply engine oil to intake valves and exhaust valves.
11. Valve Spring
1) Place the cylinder head on a flat wooden surface.
2) Install the valve springs with their fine pitched end
(painted) facing down.

Colored
Intake Valve Light blue
Exhaust Valve Yellow

12. Valve Spring Upper Seat


13. Split Collar
1) Use the spring compressor to compress the valve
spring.
Spring Compressor: 5-8840-2621-0
Spring Compressor: 8-9439-6862-0
2) Install the split collars to the valve stem.
Do not allow the valve to fall from the cylinder
head.
3) Set the split collars by tapping around the head of
011MX017 each collar with a rubber hammer.
ENGINE MECHANICAL 6A–63

14. Idler Gear “C”


1) Apply engine oil to the idler gear shaft and idler
gear “C” bushing before installation.
2) Install the idler gear “C” with the boss side facing
to the front of engine as shown in the illustration.
Idle Gear “C” Bolt Torque N·m (kg·m / lb·ft)
95 (9.7 / 70.2)

15. Sealing Cup


1) Apply LOCTITE No. 962T or equivalent to sealing
cup hole circumference.
2) Drive the sealing cup into position from the
cylinder head side as shown in the illustration.

0.5–1.5

1 16. Gasket
• Install the thermostat gaskets 1 to the flange of
thermostats.
17. Thermostat
• Install the thermostat (without jiggle valve) 2 and
2 thermostat (with jiggle valve) 3 to the cylinder
3 head.
Front
3
NOTE:
The jiggle valves of thermostat must be facing the
rear of the engine.
18. Water Outlet Pipe
1) Install the water outlet pipe to the cylinder head.
2) Tighten the water outlet pipe bolts to the specified
torque.
Water Outlet Pipe Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)

19. Thermometer Unit


1) Apply LOCTITE No. 271 or equivalent to the
thermometer unit threads portion.
1
2) Install the thermometer unit 1 to the cylinder head
and tighten to the specified torque.
Thermostat Unit Torque N·m (kg·m / lb·ft)
20 (2.0 / 14)

032MX023
6A–64 ENGINE MECHANICAL

20. Head Cover Heat Protector


1) Install the heat protector to the cylinder head.
2) Tighten the heat protector bolts to the specified
torque.
Heat Protector Bolt Torque N·m (kg·m / lb·ft)
24 (2.4 / 17)

011MX022

21. Gasket : Exhaust Manifold


Install with the protruding part of gasket facing down.

011MX021

NOTE:
Gasket Check and see that the gasket is correctly installed to
the cylinder head. The gasket, if installed in a wrong
way, could get over the casting skin of the cylinder
head.
Cylinder head

22. Exhaust Manifold


1) Install the three gas seal ring to the rear exhaust
manifold.
Position the ring gaps 120 degrees apart from each
other.
Note:
Make sure, the gaskets are installed completely on
the cylinder head, if the gaskets are mis-install the
gasket onto the surface of did not make machined.
027M100007
2) Install the front exhaust manifold to the rear
exhaust other.
3) Install the exhaust manifold to the cylinder head.
1 3 4) Install the distance tube 1, washer 3 to the stud
bolts.
5) Tighten the exhaust manifold nuts to the specified
torque.
Exhaust Manifold Nut Torque N·m (kg·m / lb·ft)
34 (3.5 / 25)
ENGINE MECHANICAL 6A–65

96 2 4 8A

0 5 13 7 B

23. Heat Protector


24. Gasket
25. Intake Cover
1) Install the intake cover bolts with distance piece.
2) Tighten the intake cover bolts to the specified
torque a little at a time in the numerical order
Intake cover shown in the illustration.
10 6 2 7 11 14 Intake Cover Bolt Torque N·m (kg·m / lb·ft)
3
15 (1.5 / 11)

13 9 5 1 4 8 12

025MX016

26. Intake Pipe


Tighten the intake pipe bolts to the specified torque.
Intake Pipe Bolt Torque N·m (kg·m / lb·ft)
15 (1.5 / 11)

025M100007

27. Bridge
Apply engine oil to the bridge.
28. Bridge Cap
Apply engine oil to the bridge cap.

014MX014
6A–66 ENGINE MECHANICAL

Rocker Arm and Shaft Assembly

2
3
4

014MY00011

Reassembly Steps
1. Rocker arm shaft 4. Spring washer
2. Rocker arm shaft bracket 5. Rocker arm
3. Rocker arm 6. Camshaft bracket
ENGINE MECHANICAL 6A–67

Reassembly Steps
1. Rocker Arm Shaft
A 1) Apply engine oil to the rocker arm shaft.
2) Install the camshaft bracket to the rocker arm shaft.
3) Temporarily tighten the camshaft bracket bolt A.

2. Rocker Arm Shaft Bracket


Install the parts as shown in the installation.

Front

014MX028

3. Rocker Arm
Apply engine oil to the rocker arm roller and pin.

4. Spring Washer
5. Rocker Arm
6. Camshaft Bracket
6A–68 ENGINE MECHANICAL

Camshaft

3
2

Reassembly Steps
1. Camshaft 3. Camshaft gear
2. Gear alignment pin
ENGINE MECHANICAL 6A–69

Reassembly Steps
1. Camshaft
2. Gear Alignment Pin
3. Camshaft Gear
1) Fit the gear alignment pin into the camshaft pin
hole.
2) Install the camshaft gear to the camshaft.
The gear hub large side must be facing the
camshaft.
3) Apply engine oil to the camshaft gear bolt threads
and the setting faces.
4) Tighten the camshaft gear bolt to the specified
torque.
Camshaft Gear Bolt Torque N·m (kg·m / lb·ft)
142 (14.5 / 105)
6A–70 ENGINE MECHANICAL

CRANKSHAFT, PISTON AND CONNECTING ROD


REMOVAL

18

9
8 11

3
4
1
15
10
17 2
7
6

16 14

13

12

Removal Steps
1. Crankshaft damper pulley 11. Piston and connecting rod with upper
2. Water duct and O-ring bearing
3. Timing gear case cover 12. Lower crankcase
4. Crankshaft front oil seal 13. Crankshaft lower bearing
5. Crankshaft front slinger 14. Crankshaft thrust bearing (Lower side)
6. Power steering oil pump idler 15. Crankshaft thrust bearing (Upper side)
gear shaft 16. Crankshaft
7. Power steering oil pump idler 17. Crankshaft upper bearing
gear 18. Cylinder body
8. Timing gear case
9. Oil thermostat and O-ring
10. Connecting rod bearing cap
with lower bearing
ENGINE MECHANICAL 6A–71

Removal Steps
1. Crankshaft Damper Pulley
1) Block the crankshaft with a piece of hard wood to
prevent the damper pulley from turning.
2) Diagonally loosen the damper pulley bolts.

2. Water Duct and O-ring


3. Timing Gear Case Cover
4. Crankshaft Front Oil Seal
Use a screwdriver to pry the oil seal from the timing
gear case cover.
Take care not to damage the oil seal fitting surface.

5. Crankshaft Front Slinger


Use the slinger remover to remove the slinger.
Slinger Remover: 8-9439-6858-0
Take care not to damage the crankshaft.
NOTE:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.

6. Power Steering Oil Pump Idler Gear Shaft


7. Power Steering Oil Pump Idler Gear
1) Use a TORXR wrench to loosen the idler gear shaft
bolts.
2) Remove the idler gear shaft together with idler
gear.

8. Timing Gear Case


9. Oil Thermostat and O-ring
6A–72 ENGINE MECHANICAL

10. Connecting Rod Bearing Cap with Lower Bearing


1) If the connecting rod bearing assembly original
nt marks can not be clearly seen, remark the
Fro
assemblies with a punch or a numbering stamps.
This will ensure reassembly to their original
positions.
2) Loosen the connecting rod bearing cap bolts a little
at a time.

If the connecting rod lower bearings are to be


reinstalled, mark their fitting positions by tagging
each bearing with the cylinder number from which it
was removed.

11. Piston and Connecting Rod with Upper Bearing


1) Remove carbon deposits from the upper portion of
the cylinder wall with a scraper before removing
the piston and connecting rod.
2) Move the piston to the top of the cylinder and tap it
with a hammer grip or similar object from the
connecting rod lower side to drive it out.
NOTE:
Take care not to damage the oiling jet.

If the connecting rod upper bearings are to be


reinstalled, mark their fitting positions by tagging
each bearing with the cylinder number from which it
was removed.

No1

F06MV012
ENGINE MECHANICAL 6A–73

12. Lower Crankcase


13. Crankshaft Lower Bearing
1) Measure the crankshaft end play at the No. 7
crankshaft journal.
Do this before removing the cylinder body lower
crankcase.
If the measured value exceeds the specified limit,
the crankshaft thrust bearing must be replaced.
Crankshaft End Play mm (in)
Standard Limit
0.04 – 0.205 (0.0016 – 0.008) 0.54 (0.021)

* * 2) Loosen the cylinder body lower crankcase bolts


(M14 14 pieces) a little at a time in the numerical
order shown in the illustration.
3) Loosen the cylinder body lower outside crankcase
1 5 9 C B 8 4 bolts (M10 25 pieces) evenly from outside to inside.
4) Screw M10 bolts (Lower crankcase bolts) into the
2 6 0 D A 7 3 five threaded holes (asterisked) and tighten these
evenly, and separate the lower crankcase from the
cylinder body.
* * * NOTE:
After removing the oil pump, remove the crankcase.

If the crankshaft lower bearings are to be reinstalled,


mark their fitting positions by tagging each bearing
with the journal number from which it was removed.

14. Crankshaft Thrust Bearing (Lower Side)


15. Crankshaft Thrust Bearing (Upper Side)
16. Crankshaft
17. Crankshaft Upper Bearing
If the crankshaft upper bearings are to be reinstalled,
mark their fitting positions by tagging each bearing
with the journal number from which it was removed.

18. Cylinder Body


6A–74 ENGINE MECHANICAL

INSTALLATION

10
11 8

14
16
18
4
9
2 17
12
13

15

3 5

Installation Steps
1. Cylinder body 10. Oil thermostat and O-ring
2. Crankshaft upper bearing 11. Timing gear case
3. Crankshaft 12. Power steering oil pump idler gear
4. Crankshaft thrust bearing 13. Power steering oil pump idler gear shaft
(Upper side) 14. Timing gear case cover
5. Crankshaft thrust bearing 15. Crankshaft front slinger
(Lower side) 16. Crankshaft front oil seal
6. Crankshaft lower bearing 17. Water duct and O-ring
7. Lower crankcase 18. Crankshaft damper pulley
8. Piston and connecting rod with
upper bearing
9. Connecting rod bearing cap
with lower bearing
ENGINE MECHANICAL 6A–75

Installation Steps

1. Cylinder Body
Use compressed air to thoroughly clean the inside
and outside surfaces of the cylinder body, the oil
holes, and the water jackets.

2. Crankshaft Upper Bearing


The crankshaft upper bearings have an oil hole and oil
Upper groove. The lower bearings have only a partial oil
groove.
1) Carefully wipe any foreign material from the
crankshaft upper bearing and the crankshaft upper
bearing fitting surfaces.
Lower

2) Install the bearings to the cylinder body.


Note the tags attached at disassembly if the
removed crankshaft upper bearings are to be
reused.
3) Installing thrust bearing
Apply oil to the side surface of the bearing. Install
the bearing in the cylinder body No. 7 journal
inside groove with the oil groove facing the slide
surface of crankshaft.

3. Crankshaft
Apply engine oil to the crankshaft journal and the
crankshaft bearing sliding surfaces before installing
the crankshaft.
6A–76 ENGINE MECHANICAL

4. Crankshaft Thrust Bearing (Upper Side)


1) Apply engine oil to the thrust bearing oil grooves
side before installation.
2) Install the thrust bearing to the crankshaft No. 7
journal.
The thrust bearing oil grooves must be facing the
sliding face.

5. Crankshaft Thrust Bearing (Lower Side)


1) Apply engine oil to the thrust bearing oil grooves
side before installation.
2) Install the thrust bearing to the crankcase.
The thrust bearing oil grooves must be facing the
sliding face.

6. Crankshaft Lower Bearing


7. Lower Crankcase
1) Carefully wipe any foreign material from the
crankcase lower bearing back and the sliding
surfaces.
2) Install the lower bearings to the lower crankcase.
Note the tags attached at disassembly if the
removed crankshaft lower bearings are to be
reused.
3) Apply engine oil to the lower bearing sliding
surfaces.
4) Apply unbroken strips of the ThreeBond 1207C or
equivalent to the lower face as shown in the
illustration.
The liquid gasket must be 3.0 – 4.0mm
(0.12 – 0.16in) wide.
NOTE:
Immediately (within ten (10) minutes of applying the
liquid gasket) set the lower crankcase to the cylinder
body.
NOTE:
Do not allow the crankshaft lower bearings and
thrust bearings to fall free.
ENGINE MECHANICAL 6A–77

6) Apply molybdenum disulfide grease to the lower


crankcase bolt threads and setting faces. (14M Bolt
only)

7) Tighten the lower crankcase M14 bolts in three


steps using the angular tightening method.
Lower Crankcase M14 Bolt Torque N·m (kg·m / lb·ft)
D 0 6 2 3 7 A 1st Step 2nd Step 3rd Step
98 (10 / 72) 132 (13.5 / 98) 45 deg
C 9 5 1 4 8 B

8) Check that the crankshaft rotates smoothly.


NOTE:
Cylinder body lower crankcase M14 bolts can be
reused six(6) times.
9) Tighten the lower crankcase M10 bolts a little at a
M I E A 7 3 1 5 9 C GK O time in the numerical order shown in the
illustration.
Lower Crankcase M10 Bolt Torque N·m (kg·m / lb·ft)
38 (3.8 / 28)
CAUTION:
The lower crankcase and the cylinder body are
N J F B8 4 260 D H L machined as a single unit. They cannot be replaced
as separate unit.
Always replace the lower crankcase and the cylinder
body as a set.
8. Piston and Connecting Rod with Upper Bearing
1) Apply engine oil to the circumference of each
piston ring and piston.
2) Position the piston ring gaps as shown in the
illustration.

015M100005
6A–78 ENGINE MECHANICAL

3) Apply molybdenum disulfide grease to the piston


skirts.
This will facilitate smooth break-in when the
engine is first started after reassembly.
4) Apply engine oil to the upper bearing surfaces.
5) Apply engine oil to the cylinder wall.

F06MV030

6) Position the piston head front mark so that it is


facing the front of the engine.

F06MV031

7) Use the piston ring compressor to compress the


piston rings.
NOTE:
Bring a setting tool into contact with the cylinder
body and push it in. If the setting tool is pushed in
without making close contact with the cylinder body,
piston ring may be damaged.
8) Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC (Bottom Dead Center).
NOTE:
Take care not to strike the oiling jet with the
connecting rod big end during the installation
procedure. Damage to the oiling jet will result.

9. Connecting Rod Bearing Cap with Lower Bearing


1) Align the bearing cap cylinder number marks and
the connecting rod cylinder number marks.
The cylinder number marks must be turned toward
the intake cover side.
2) Install the connecting rod bearing caps.
ENGINE MECHANICAL 6A–79

3) Apply molybdenum disulfide grease to the threads


and setting faces of each connecting rod cap bolt.
4) Tighten the connecting rod bearing cap bolts in
three steps using angular tightening method.
Connecting Rod Bearing Cap Bolt
Torque N·m (kg·m / lb·ft)
1st Step 2nd Step 3rd Step
39 (4 / 29) 60 deg 30 deg
NOTE:
Connecting rod bearing cap bolts can be reused six(6)
times.
5) Check that the crankshaft rotates smoothly.

10. Oil Thermostat and O-ring


1) Install the rubber cap to the small end of oil
thermostat.
2) Install the oil thermostat to the cylinder body.

11. Timing Gear Case


1) Apply ThreeBond 1207C or equivalent to the timing
gear case grooves. (Including arrow mark portion.)
The liquid gasket must be 2.0 – 3.0mm
O-ring (0.08 – 0.12in) wide.
2) Install the O-ring.
3) Immediately (within ten (10) minutes of applying
the liquid gasket) set the timing gear case to the
cylinder body.
4) Tighten the timing gear case bolts to the specified
torque.
Timing Gear Case Body Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)

12. Power Steering Oil Pump Idler Gear


13. Power Steering Oil Pump Idler Gear Shaft
1) Apply engine oil to the idler gear and the idler gear
shaft.
2) Set the idler gear to the idler gear shaft.
3) Install the idler gear and idler gear shaft to the
timing gear case.
4) Tighten the idler gear shaft bolts to the specified
torque.
Idler Gear Shaft Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
6A–80 ENGINE MECHANICAL

14. Timing Gear Case Cover


1) Apply ThreeBond 1207C or equivalent to the timing
gear case cover grooves.
The liquid gasket must be 2.0 – 3.0mm
(0.08 – 0.12in) wide.
2) Immediately (within ten (10) minutes of applying
the liquid gasket) set the timing gear case cover to
the timing gear case.

F06MV008

0 AB C 3) Tighten the timing gear case cover bolts to the


D specified torque a little at a time in the numerical
order shown in the illustration.
E
9 F
Timing Gear Case Cover Bolt Torque N·m (kg·m / lb·ft)
G 19 (1.9 / 14)
1

76 543 2

15. Crankshaft Front Slinger


Use the Oil seal installer kit to install the slinger.
Oil Seal Installer Kit: 8-9439-6856-0
NOTE:
For visual identification, front slinger is black colored
and rear slinger gray colored.

1) Insert the slinger 1 into the end of adapter 2, and


4
install the adapter to the crankshaft 3.
2) Install the slinger sleeve 4 to the adapter, and
3 A tighten center bolt 5 until the sleeve comes into
5 contact with the adapter stopper (arrow marked).
2 3) After pressing in the slinger, make sure that the
distance between the crankshaft end surface and
the slinger is A.
1 A: 40.5 ± 0.3 mm (1.594 ± 0.012 in)
F06MV009

NOTE:
Be sure to replace the slinger and oil seal as a set.
ENGINE MECHANICAL 6A–81

16. Crankshaft Front Oil Seal


Use the oil seal installer kit to install the oil seal.
1
Oil Seal Installer Kit: 8-9439-6856-0
2 1) Apply engine oil to the oil seal lip.
B
2) Insert the oil seal 1 into the adapter 2.
3) Install the oil seal sleeve 3 to the adapter.
3
4) Install the oil seal sleeve to the adapter, and tighten
the center bolt until the sleeve comes into contact
with adapter stopper (arrow marked).
5) After pressing in oil seal, make sure that the
distance between the crankshaft end surface and
oil seal B.
This check should be conducted at eight different
points dividing the circumference into as many
equal parts.

B: 8.5 ± 0.2mm (0.335 ± 0.008)

Front Oil Seal Installer Kit Applicable


Part Name Stamp Slinger Oil Seal
Front use adapter FTR ● ●
Front use slinger sleeve FT ● —
Front use oil seal sleeve FT — ●
Center bolt — ● ●
Adapter bolt — ● ●

17. Water Duct and O-ring


1) Install the water duct 1 and O-ring 2 to the
2 1 cylinder body.
2) Tighten the water duct bolts to the specified
torque.
Water Duct Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)

18. Crankshaft Damper Pulley


1) Block the crankshaft with a piece of hard wood to
1 prevent the damper pulley from turning.
2) Align the Crankshaft dowel and the crankshaft
3 4 damper pulley dowel hole.
3) Tighten the crankshaft damper pulley bolts to the
specified torque a little at a time in the numerical
2 order shown in the illustration.
Pulley Bolt Torque N·m (kg·m / lb·ft)
196 (20.0 / 145)
6A–82 ENGINE MECHANICAL

DISASSEMBLY
Crankshaft

Disassembly Steps
1. Crankshaft Gear (Front) 3. Crankshaft
2. Crankshaft Gear (Rear)

Disassembly Steps
1. Crankshaft Gear (Front)
2. Crankshaft Gear (Rear)
Use a gear pulley to remove the crankshaft gear.

3. Crankshaft
ENGINE MECHANICAL 6A–83

INSPECTION AND REPAIR


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

Crankshaft and bearing


Crankshaft
Inspect the surface of the crankshaft journals and
crankpins for excessive wear and damage.
Inspect the oil ports for obstructions.
NOTE:
To increase crankshaft strength, Tufftride Method
(Soft nitriding) has been applied. Because of this, it is
not possible to regrind the crankshaft surfaces.

Bearing Spread
Check the bearing spread.
Finger pressure should be required to fit the bearing
into position.
If the bearing fits loosely, it must be replaced.

Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft
journal.
2. Gently turn the crankshaft in the normal direction
of rotation.
Read the dial indicator as you turn the crankshaft.
If the measured value exceeds the specified limit,
the crankshaft must be replaced.
Crankshaft Run-Out mm (in)
Standard Limit
0.06 (0.0024) or less 0.45 (0.018)
6A–84 ENGINE MECHANICAL

Crankshaft Journal and Crankpin Diameter


1 34
1. Use a micrometer to measure the crankshaft
journal diameter across points 1 - 1 and
2 2
2 - 2.
2. Use the micrometer to measure the crankshaft
1
journal diameter at the two points ( 3 and 4 ).
3. Repeat Steps 1 and 2 to measure the crankpin
diameter.
Crankshaft Journal Diameter mm (in)
Journal No. Standard
81.875 – 81.895
4
(3.2234 – 3.2242)
81.905 – 81.925
Others
(3.2246 – 3.2254)

Crankpin Diameter mm (in)


Standard
72.902 – 72.922
(2.8701 – 2.8709)

Crankshaft Journal and


Crankpin Uneven Wear mm (in)
Limit
0.05 (0.0020)

Crankshaft Bearing Inside Diameter


1. Clean the cylinder body and lower crankcase
bearing fitting surfaces, and the bearing inside and
outside surfaces.
D 0 6 2 3 7 A
2. Install the lower crankcase with the bearings to the
cylinder body.
C 9 5 1 4 8 B
3. Apply molybdenum disulfide grease to the lower
crankcase bolt threads and setting faces. (14M Bolt
only)
4. Tighten the lower crankcase M14 bolts in three
step using the angular tightening method.
Lower Crankcase M14 Bolt Torque N·m (kg·m / lb·ft)
1st Step 2nd Step 3rd Step
98 (10 / 72) 132 (13.5 / 98) 45 deg
NOTE:
Lower crankcase M14 bolts can be reused six(6)
times.
5. Tighten the lower crankcase M10 bolts to the
M I E A 7 3 1 5 9 C GK O specified torque.
Lower Crankcase M10 Bolt Torque N·m (kg·m / lb·ft)
36 (3.8 / 27)
6. Use an inside dial indicator to measure the
crankshaft bearing inside diameter.

N J F B8 4 260 D H L
ENGINE MECHANICAL 6A–85

Crankshaft Journal and Bearing Clearance


If the clearance between the measured bearing inside
diameter and the crankshaft journal diameter exceeds
the specified limit, the crankshaft must be or replaced.
Crankshaft Journal and Bearing Clearance mm (in)
Bearing No. Standard Limit
0.093 – 0.124
4
(0.00366 – 0.00488)
0.14 (0.0055)
0.063 – 0.094
Others
(0.00248 – 0.00370)
6A–86 ENGINE MECHANICAL

REASSEMBLY

Reassembly Steps
3. Crankshaft gear (Front)
1. Camshaft
2. Crankshaft gear (Rear)
ENGINE MECHANICAL 6A–87

Reassembly Steps

1. Crankshaft
2. Crankshaft Gear (Rear)
1) Install the crankshaft timing gear alignment pin.
2) Heat the crankshaft gear evenly with a gas burner
to invite thermal expansion.
Do not allow the temperature of the gas burner to
exceed 180°C (356°F).
3) Use the crankshaft gear installer to install the
crankshaft gear.
Crankshaft Gear Installer: 8-9439-6819-0

The crankshaft gear timing mark "L" must be facing


L mark out.
Take care not to damage the crankshaft and crankshaft
gear.
WARNING:
TAKE CARE NOT TO BURN YOURSELF ON THE
HEATED CRANKSHAFT GEAR.

3. Crankshaft Gear (Front)


Install by following the same procedure as for
crankshaft gear (rear). There is no direction of gear
installation.
6A–88 ENGINE MECHANICAL

DISASSEMBLY
Piston and Connecting Rod

015MY00050

Disassembly Steps
1. Connecting rod bearing 5. Piston pin
2. Piston ring 6. Connecting rod
3. Piston pin snap ring 7. Piston
4. Piston pin snap ring
ENGINE MECHANICAL 6A–89

Disassembly Steps

1. Connecting Rod Bearing


If the connecting rod bearings are to be reinstalled,
mark their fitting positions by tagging each bearing
with the cylinder number from which it was removed.

No1

F06MV012

2. Piston Ring
1) Clamp the connecting rod in vise.
Take care not to damage the connecting rod.
2) Use a piston ring replacer to remove the piston
rings.
Do not attempt to use some other tool to remove
the piston rings. Piston ring stretching will result
in reduced piston ring tension.

3. Piston Pin Snap Ring


4. Piston Pin Snap Ring
Use pliers to remove the piston pin snap rings.

F06MV015

5. Piston Pin
6. Connecting Rod
7. Piston
Use your hand to push the piston pin out.
If the pistons are to be installed, mark their installation
positions by tagging each piston with the cylinder
number from which it was removed.
6A–90 ENGINE MECHANICAL

INSPECTION AND REPAIR


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

Piston

Visual Inspection
Inspect the piston after removing carbon, sludge, etc,
and rinsing. Be sure to inspect with special care the
piston parts which may escape your notice.

Cylinder Liner and Piston Clearance


1. Measure the cylinder liner bore.
1) Measure the cylinder liner bore at measuring
1 points 1, 2 and 3 in direction a right angle to the
crankshaft.
2) Calculate the average value of the three (3)
2 measurements to determine the cylinder liner bore.
3
Measuring Point 1 : 20mm (0.79in)
2 : 110mm (4.33in)
3 : 190mm (7.48in)

Cylinder Liner Bore Diameter (Limit) mm (in)


115.20 (4.3554)

2. Measure the piston outside diameter.


Measuring Point : 77mm (3.03in)

Piston Outside Diameter (Non Grade) mm (in)


114.974 - 114.989 (4.5265 - 4.5271)

Cylinder Liner and Piston Clearance mm (in)


0.042 - 0.066 (0.00165 - 0.00260)
77mm
CAUTION:
It is most important that the correct piston clearance
be used.
ENGINE MECHANICAL 6A–91

Piston Ring and Piston Ring Groove Clearance


1. Use a feeler gauge to measure the clearance
between the piston ring and piston ring groove at
several points around the piston.
If the clearance between the piston ring and the
piston ring groove exceeds the specified limit,
replace either the piston and/or piston ring.
Piston Ring and Piston Ring Groove Clearance mm (in)
Standard Limit
F06MV013 1st Compression 0.075 – 0.080
Ring (0.0030 – 0.0031)
2nd Compression 0.085 – 0.12
0.2 (0.0079)
Ring (0.0033 – 0.0047)
3rd Compression 0.085 – 0.12
Ring (0.0033 – 0.0047)
0.02 – 0.06
Oil Ring 0.15 (0.0059)
(0.0008 – 0.0024)
2. Visually inspect the piston ring grooves.
If a piston ring groove is damaged or distorted, the
piston must be replaced.
The 1st ring is a keystone, and therefore, measure
at the mouth of the ring groove.

Piston Pin
Piston Pin Diameter
Use a micrometer to measure the piston pin diameter
at several points.
If the measured value is less than the specified limit,
the piston pin must be replaced.
Piston Pin Diameter mm (in)
Standard Limit
39.995 – 40.000 (1.5746 – 1.5748) 39.95 (1.5728)

Piston Pin and Piston Pin Hole Clearance


Use an inside dial indicator to measure the piston pin
hole diameter (in the piston).
If the clearance between the piston pin and the piston
pin holes exceeds the specified limit, replace the
piston pin and/or the piston.
Piston Pin Hole Diameter mm (in)
Standard
40.004 – 40.012 (1.5750 – 1.5753)

Piston Pin and Piston Pin Hole Clearance mm (in)


Standard Limit
0.004 – 0.017 0.05
(0.00016 – 0.00067) (0.002)
6A–92 ENGINE MECHANICAL

Piston Ring

Piston Ring Gap


1. Insert the piston ring horizontally (in the position it
would assume if it was installed to the piston) into
the cylinder liner.
2. Push the piston ring into the cylinder liner bore
until it reaches the measuring point (where the
cylinder liner bore is the smallest).
Do not allow the piston ring to slant to one side or
the other. It must be perfectly horizontal.

3. Use a feeler gauge to measure the piston ring gap.


If the measured value exceeds the specified limit,
the piston ring must be replaced.
Piston Ring Gap mm (in)
Standard Limit
1st Compression 0.18 - 0.28
Ring (0.0071 - 0.0110)
2nd Compression 0.35-0.50
Ring (0.0138-0.0197) 1.20
3rd Compression 0.35-0.50 (0.047)
Ring (0.0138-0.0197)
0.15-0.35
Oil Ring
(0.0059-0.0137)

Connecting Rod

Connecting Rod Alignment


Use a connecting rod aligner to measure the distortion
and the parallelism between the connecting rod big
end hole and the connecting rod small end hole.
If either the measured distortion or parallelism
exceeds the specified limit, the connecting rod must
be replaced.
Connecting Rod Alignment
Per length of 100 mm (3.94 in) mm (in)
Standard Limit
Distortion and
0.05 (0.002) or less 0.20 (0.008)
Parallelism
ENGINE MECHANICAL 6A–93

Piston Pin and Connecting Rod Small End Bushing


Clearance
Use a caliper calibrator and a dial indicator to
measure the piston pin and connecting rod small end
bushing clearance.
If the clearance between the piston pin and the
connecting rod small end bushing exceeds the
specified limit, replace the piston pin and/or the
connecting rod bushing.
Piston Pin and Connecting Rod Small End
Bushing Clearance mm (in)
Standard Limit
0.012 – 0.027 (0.00047 – 0.00106) 0.05 (0.002)

Crankpin and Bearing Clearance


1. Clean the crankshaft, the connecting rod, the
bearing cap and the bearings.
2. Install the bearings to the connecting rod and
bearing cap.
3. Apply molybdenum disulfide grease to the bearing
cap bolt threads and setting faces.
4. Tighten the bearing cap bolts in three steps using
the angular tightening method.
Connecting Rod Bearing Cap Bolt
Torque N·m (kg·m / lb.ft)
1st Step 2nd Step 3rd Step
39 (4 / 29) 60 deg 30 deg

NOTE:
Connecting rod bearing cap bolts can be reused six(6)
times.

5. Use an inside dial indicator to measure the


connecting rod bearing inside diameter.

• Measure crosswise at 4 points as illustrated.

F06MV011
6A–94 ENGINE MECHANICAL

6. Use a micrometer to measure the crankpin


1 34 diameter across points 1-1 and 2-2.
7. Use the micrometer to measure the crankpin
2 2 diameter at the two points (3 and 4).
If the clearance between the measured bearing
1 inside diameter and the crankpin exceeds the
specified limit, the crankshaft must be reground or
replaced.
If the crankshaft reground, under size bearings
must be installed.
Crankpin and Bearing Clearance mm (in)
Standard Limit
0.037 – 0.076 0.10
(0.0015 – 0.0030) (0.004)
ENGINE MECHANICAL 6A–95

Connecting Rod Side Face Clearance


1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance
between the connecting rod big end side face and
the crankpin side face.
If the measured value exceeds the specified limit,
the connecting rod must be replaced.
Connecting Rod Big End and Crankpin Side
Face Clearance mm (in)
Standard Limit
0.17 – 0.30 (0.0067 – 0.0118) 0.35 (0.014)

Bearing Spread
Check the bearing spread.
Finger pressure should be required to fit the bearing
into position.
If the bearing fits loosely, it must be replaced.
6A–96 ENGINE MECHANICAL

REASSEMBLY

F06MV007

Reassembly Steps
1. Piston 5. Piston pin snap ring
2. Piston pin snap ring 6. Piston ring
3. Connecting rod 7. Connecting rod bearing
4. Piston pin
ENGINE MECHANICAL 6A–97

Reassembly Steps

1. Piston
2. Piston Pin Snap Ring
Use pliers to install the piston pin snap ring to the
piston.

3. Connecting Rod
1 1) Clamp the connecting rod in a vise.
2) Install the piston to the connecting rod.
The piston head front mark 1 and the connecting
rod forging mark (projecting) 2 must be facing the
2 opposite direction.
NOTE:
If the old connecting rods are to be replaced with new
ones, the connecting rod weight must be identical for
F06MV014 all cylinders.

4. Piston Pin
5. Piston Pin Snap Ring
1) Apply engine oil to the piston pin.
2) Use hand pressure to force the piston pin into the
piston until it makes contact with the snap ring.
3) Use pliers to install the other snap ring.
NOTE:
Take care not to damage the piston and the piston pin.
4) Check that the connecting rod moves smoothly on
F06MV015
the piston pin.
Full keystone
6. Piston Ring
1) Use a piston ring replacer to install the four piston
Inner cut
rings.
Install the piston rings from under of piston ring
groove.
Oil ring
3rd compression ring
Under cut
2nd compression ring
1st compression ring
(The stamped on the 1st compression ring must
face upward of piston.)
NOTE:
Insert the expander coil into the oil ring groove so
that there is no gap on either side of the expander
coil before installing the oil ring.
Install the compression rings with the stamped side
facing up.
6A–98 ENGINE MECHANICAL

2) Apply engine oil to the piston ring surfaces.


3) Check to see if the piston rings rotate smoothly in
the piston ring grooves.

7. Connecting Rod Bearing


Carefully wipe any oil or other foreign material from
the connecting rod bearing back face and the
connecting rod bearing fitting surface.
ENGINE MECHANICAL 6A–99

FLYWHEEL, TIMING GEAR,


OIL PUMP AND OIL PAN
REMOVAL
10

13

5 11
7

12 9

13 2
nt
3 Fro
6
1

020M100006

Removal Steps
1. Oil pan 8. Crankshaft rear oil seal
2. Oil strainer and O-ring 9. Crankshaft rear slinger
3. Pilot bearing and snap ring 10. Idler gear "A" and idler gear shaft
4. Flywheel and washer 11. Oil pump
5. Cover 12. Idler gear "B"
6. Idler gear "D" 13. Idler gear "B" shaft
7. Flywheel housing
6A–100 ENGINE MECHANICAL

Removal Steps

1. Oil Pan
2. Oil Strainer and O-ring
3. Pilot Bearing and Snap Ring
1) Use a snap ring pliers to remove the snap ring.
2) Remove the pilot bearing.
4. Flywheel and Washer
1) Block the crankshaft with a piece of hard wood to
prevent the flywheel from the turning.
2) Loosen the flywheel bolts a little at a time in the
1 numerical order shown in the illustration.
6 4
3 7 5. Cover
8
5
2 6. Idler Gear "D"

7. Flywheel Housing
8. Crankshaft Rear Oil Seal
Use a screwdriver to pry the oil seal from the rear of
the flywheel housing.
CAUTION:
Take care not to damage the oil seal fitting surface.

9. Crankshaft Rear Slinger


Use the slinger remover to remove the slinger.
Slinger Remover: 8-9439-6858-0
Take care not to damage the crankshaft.
NOTE:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
10. Idler Gear "A" and Idler Gear Shaft
11. Oil Pump
12. Idler Gear "B"
13. Idler Gear "B" Shaft
1) Measure the idler gear backlash and the crankshaft
gear backlash before removing the idler gear.
2) Measure the idler gear end play before removing
the idler gear.
NOTE:
Refer to the following items for details on the
backlash and end play measurement procedure.
ENGINE MECHANICAL 6A–101

INSPECTION AND REPAIR


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

Idler Gear Shaft and Idler Gear

Idler Gear Backlash Measurement


1. Set a dial indicator to the idler gear to be measured.
Hold both the gear to be checked and the adjoining
gear stationary.
2. Move the gear to be checked as far as possible both
to the right and to the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit,
the idler gear must be replaced.
Idler Gear Backlash mm (in)
Standard Limit
0.10 – 0.17 0.30
(0.0039 – 0.0067) (0.012)

Idler Gear End Play Measurement


Insert a feeler gauge between the idler gear and the
thrust collar to measure the gap and determine the
idler gear end play.
If the measured value exceeds the specified limit, the
idler gear must be replaced.
Idler Gear End Play mm (in)
Standard Limit
Idler Gear "A"
0.08 – 0.155 0.20
Idler Gear "B"
(0.00315 – 0.00610) (0.008)
Idler Gear "D"
0.09 – 0.144 0.20
Idler Gear "C"
(0.00354 – 0.00566) (0.008)

Idler Gear Shaft Outside Diameter


Use a micrometer to measure the idler gear shaft
outside diameter.
If the measured value is less than the specified limit,
the idler gear shaft and/or shaft must be replaced.
Idler Gear Shaft Outside Diameter mm (in)
Standard Limit
49.950 – 49.975 49.9
Shaft "A"
(1.9665 – 1.9675) (1.965)
Shaft "B" 29.959 – 29.980 29.9
Shaft "C","D" (1.1795 – 1.1803) (1.177)
6A–102 ENGINE MECHANICAL

Idler Gear Inside Diameter


Use an inside dial indicator or an inside micrometer to
measure the idler gear inside diameter.
If the clearance between the idler gear shaft outside
diameter and the idler gear inside diameter exceeds
the limit, the idler gear and/or shaft must be replaced.
Idler Gear Shaft and Idler Gear Clearance mm (in)
Standard Limit
0.025 – 0.075 0.20
Shaft "A"
(0.0010 – 0.0030) (0.008)
Shaft "B" 0.020 – 0.062 0.20
Shaft "C","D" (0.0008 – 0.0024) (0.008)

Flywheel and Ring Gear

Flywheel
1. Inspect the flywheel friction surface for excessive
wear and heat cracks.
1 2. Measure the flywheel friction surface depth 1.
If the measured value exceeds the specified limit,
the flywheel must be replaced.
Flywheel Friction Surface Depth 1 mm (in)
Clutch Size Standard Limit
380 (15) 48.0 (1.89) 49.0 (1.93)
356 (14) 43.0 (1.69) 44.0 (1.73)

Ring Gear
Inspect the ring gear
If the ring gear teeth are broken or excessively worn,
the ring gear must be replaced.

Ring Gear Replacement


Ring Gear Removal
Strike around the edges of the ring gear with a
hammer and brass bar to remove it.
ENGINE MECHANICAL 6A–103

Ring Gear Installation


1. Heat the ring gear evenly with a gas burner to
invite thermal expansion.
Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
WARNING:
TAKE CARE NOT TO BURN YOURSELF ON THE
HEATED RING GEAR.
2. Install the ring gear when it is sufficiently heated.
The ring gear must be installed with the chamfer
facing the clutch.
6A–104 ENGINE MECHANICAL

Crankshaft Pilot Bearing


Check the pilot bearing for excessive wear and
damage and replace it if necessary.
Do not reuse the pilot bearing.
ENGINE MECHANICAL 6A–105

INSTALLATION
4

7 3
5

2 8

10

12
nt
11 Fro
6
13

020M100007

Installation
1. Idler gear "B" shaft 7. Cover
2. Idler gear "B" 8. Crankshaft rear slinger
3. Oil pump 9. Crankshaft rear oil seal
4. Idler gear "A" and idler gear 10. Flywheel and washer
shaft 11. Pilot bearing and snap ring
5. Flywheel housing 12. Oil strainer and O-ring
6. Idler gear "D" 13. Oil pan
6A–106 ENGINE MECHANICAL

Installation Steps

1. Idler Gear "B" Shaft


1) Install the idler gear "B" shaft to the cylinder body.
The idler gear shaft oil port must be facing the
cylinder head.
2) Tighten the idler gear shaft bolts to the specified
torque.
Idler Gear "B" Shaft Bolt
Torque N·m (kg·m / lb.ft)
31 (3.2 / 23)

2. Idler Gear "B"


1) Apply engine oil to the idler gear "B" inside and
thrust areas.
2) Install the idler gear to the idler gear shaft.
3) Tighten the idler gear bolts to the specified torque.
Idler Gear "B" Bolt Torque N·m (kg·m / lb.ft)
95 (9.7 / 70)

3. Oil Pump
1) Carefully wipe any foreign material from the
cylinder body rear surface.
2) Apply engine oil to the cylinder body bushing
inside.

3) Apply ThreeBond No. 1141E or equivalent to the


shaded areas shown in the illustration.
CAUTION:
The liquid gasket must not obstruct the gear and oil
ports (arrow marked).
ENGINE MECHANICAL 6A–107

4) Install the oil pump to the cylinder body.


5) Tighten the oil pump bolts to the specified torque.
Oil Pump Bolt Torque N·m (kg·m / lb.ft)
24 (2.4 / 17)

4. Idler Gear "A" and Idler Gear Shaft


1) Install the idler gear shaft 1 to the cylinder body.
The idler gear shaft oil port must be facing the
cylinder head.
2) Apply engine oil to the idler gear "A" inside and
thrust areas.

3) Install the idler gear "A" 2 to the idler gear shaft.


3
4) Align the crankshaft gear 3 "L" mark and the idler
gear 2 "0" marks.
• Set No. 1 piston to top dead center.
• Apply molybdenum disulfide to threaded part
and bearing surface of bolt and washer.
• After tightening to 29 N·m (3.0 kg·m / 22 lb·ft),
retighten to 75°.
2 • After installing the housing to the body, tighten
the shaft and housing to a tightening torque of
22 – 31 N·m (2.2 – 3.2 kg·m / 16 – 23 lb·ft).
6A–108 ENGINE MECHANICAL

5. Flywheel Housing
1) Apply liquid gasket to the flywheel housing as
illustrated.
Three-bond No. BB401

NOTE:
Apply liquid gasket also to the parts indicated by
arrow head.
This portion do not
apply liquid gasket. 2) Install the flywheel housing.
Tightening torque N·m (kg·m/Ib·ft)
̪‫ޓ‬ ̪‫ޓ‬ ★ : 73 (7.4 / 54)
ً‫ޓ‬
̪‫ޓ‬ ̪‫ޓ‬ ̪ : 96 (9.8 / 71)
̪‫ޓ‬

‫ޓغ‬
■ : 73 (7.4 / 54)
̪‫ޓ‬
▲ : 86 (8.8 / 64)
‫ޓٌ ޓع‬
‫ޓڎ‬
●, ▲ : 119 (12.1 / 88)
ٖ‫ޓ‬ ̪‫ޓ‬ ٨‫ޓ‬
̪‫ޓ‬ ■ : 26 (2.7 / 20)
̪‫ޓ‬
̪‫ޓ‬ ▼ : 53 (5.4 / 39)

̪‫ޓ‬
Tighten the knock pin positions beforehand.
020MX007
Retightening needs no special order.
NOTE:
The asterisked (▼, ▲, ★) part should be tightened
from the cyl. body side. Tightening should not be
forgotten.

6. Idler Gear D
Install the idler gear D.
Idler Gear D Tightening torque N·m (kg·m / lb·ft)
105 – 132 (10.7 –13.5 / 77 – 98)

Apply oil to the inside diameter and thrust of the idle


gear and install the idler gear in such a direction as
illustrated.
Idler Gear Shaft D

7. Cover
Install the cover.
Tightening torque N·m (kg·m / lb·ft)
13 – 23 (1.3 – 2.3 / 113 Ib·in – 23)
ENGINE MECHANICAL 6A–109

8. Crankshaft Rear Slinger


1 Use the oil seal installer to install the slinger.
4 Oil Seal Installer Kit: 8-9439-6856-0
1) Insert the slinger 1 into the end of adapter 2 , and
5 install the adapter to the crankshaft 3 .
3
2 NOTE:
For visual identification, the rear slinger is gray
colored, while the front slinger is black colored.

2) Install the slinger sleeve 4 to the adapter, and


tighten the center bolt 5 until the sleeve comes
into contact the adapter stopper.

3) After pressing in the slinger, make sure that the


distance between crankshaft end surface and the
slinger is A as specified.
A
A: 17 ± 0.3mm (0.669 ± 0.012 in)

NOTE:
Be sure to replace the slinger and oil seal as a set.

9. Crankshaft Rear Oil Seal


1 Use the oil seal installer to install the oil seal.
Oil Seal Installer Kit: 8-9439-6856-0
2 1) Apply engine oil to the oil seal lip.
2) Insert the oil seal 1 into the adapter 2.
3) Install the oil seal sleeve 3 to the adapter.
3
4) Install oil seal sleeve to the adapter, and tighten the
B center bolt until the sleeve comes into contact with
the adapter stopper.
5) After pressing the oil seal, make sure that the
distance between crankshaft end surface and the
oil seal is B as circumferential points which divide
the circumference into eight equal parts.

B : 7.5 ± 0.15 mm (0.295 ± 0.006 in)


6A–110 ENGINE MECHANICAL

Rear Oil Seal Installer Kit Applicable


Part Name Stamp Slinger Oil Seal
Rear use adapter RR ● ●
Rear use slinger sleeve RR ● —
Rear use oil seal sleeve RR — ●
Center bolt — ● ●
Adapter bolt — ● ●

10. Flywheel and Washer


1) Block the crankshaft with a piece of hard wood to
prevent the flywheel from turning.
2) Apply molybdenum disulfide grease to the
flywheel bolt threaders.
3) Align the flywheel with the crankshaft dowel pin.

4) Install the flywheel and washer to the crankshaft.


5) Tighten the flywheel bolts to the specified torque in
three steps using the angular tightening method.
Follow the numerical order shown in the
1 illustration.
6 4
3 7 Flywheel Bolt Torque N·m (kg·m / lb·ft)
8 2 1st step 2nd step 3rd step
5
78 (8.0 / 58) 60 deg 75 deg
NOTE:
The flywheel bolts can be reused six(6) times.

11. Pilot Bearing and Snap Ring


12. Oil Strainer and O-ring
1) Apply engine oil to the O-ring.
2) Install the oil strainer and O-ring to the cylinder
body.
Oil Strainer Bolt Torque N·m (kg·m / lb·ft)
M8 Bolt 24 (2.4 / 17)
M10 Bolt 48 (4.9 / 35)
ENGINE MECHANICAL 6A–111

13. Oil Pan


2 1) Apply ThreeBond 1207C or equivalent to the
cylinder body and flywheel housing fitting faces 1
and the gear case fitting faces 2.
The liquid gasket must be 2.0mm (0.08in) thick and
3.0mm (0.12in) wide.

2) Apply ThreeBond 1207C or equivalent to the oil


pan.
The liquid gasket must be 1.0 – 2.0 mm (0.04 – 0.08
in) thick and 4.0 – 5.0 mm (0.16 – 0.20 in) wide.
3) Install the oil pan to the cylinder body.
NOTE:
Immediately (within ten (10) minutes of applying the
liquid gasket) set the oil pan to the cylinder body.

4) Tighten the oil pan bolts to the specified torque a


little at a time in the numerical order shown in the
illustration.
Oil Pan Bolt Torque N·m (kg·m / lb·ft)
24 (2.4 / 17)

Start

F06MV006
6A–112 ENGINE MECHANICAL

DISASSEMBLY
Oil Pump

6
2

Disassembly Steps
1. Driven gear and shaft 4. Oil pump drive gear
2. Cotter pin 5. Drive gear
3. Oil relief valve 6. Oil pump body
ENGINE MECHANICAL 6A–113

Disassembly Steps

1. Driven Gear and Shaft

2. Cotter Pin
3. Oil Relief Valve
4. Oil Pump Drive Gear
Use a gear puller to remove the oil pump drive gear.

5. Drive Gear
6. Oil Pump Body
6A–114 ENGINE MECHANICAL

INSPECTION AND REPAIR


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

Oil Pump

Gear Teeth and Body Inner Wall Clearance


Use a feeler gauge to measure the clearance between
the gear teeth and the body inner wall.
If the clearance between the gear teeth and the body
inner wall exceeds the specified limit, the gears and/or
the body must be replaced.
Gear Teeth and Cover Inner Wall Clearance mm (in)
Standard
0.125 – 0.221
(0.0049 – 0.0087)

Gear and Body Clearance


Use a feeler gauge to measure the clearance between
the body and the gear side surfaces.
If the clearance between the gears and the body
exceeds the specified limit, the gears and/or the body
must be replaced.
Gear and Body Clearance mm (in)
Standard
0.064 – 0.109
(0.0025 – 0.0043)

Driven Gear Shaft and Oil Pump Body Clearance


1. Use a micrometer to measure the gear shafts
outside diameter.
Gear Shaft Outside Diameter mm (in)
Standard Limit
15.989 – 16.000 15.9
(0.6295 – 0.6299) (0.626)

2. Use an inside dial indicator or inside micrometer to


measure the pump body inside diameter and the
cylinder body bushing inside diameter.
If clearance between the gear shaft and the pump
body or bushing exceeds the specified limit, the oil
pump assembly and/or bushing must be replaced.
Gear Shaft and Pump Body or Bushing
Clearance mm (in)
Standard
0.04 – 0.07
(0.0016 – 0.0028)
ENGINE MECHANICAL 6A–115

Oil Relief valve


Check the ball and the valve spring for excessive wear
and damage.

Oil Pump Drive Gear and Drive Gear Shaft


Interference
Use an inside and outside micrometer to measure the
interference between the oil pump drive gear inside
diameter and drive gear shaft outside diameter.
Drive Gear and Drive Gear Shaft
Interference (Reference) mm (in)
Standard
0.015 – 0.044 (0.0006 – 0.0017)
6A–116 ENGINE MECHANICAL

REASSEMBLY

1
5

Reassembly Steps
4. Oil relief valve
1. Oil pump body
5. Cotter pin
2. Drive gear
6. Driven gear and shaft
3. Oil pump drive gear
ENGINE MECHANICAL 6A–117

Reassembly Steps

1. Oil Pump Body


2. Drive Gear
3. Oil Pump Drive Gear
1) Apply engine oil to the drive gear shaft.
2) Install the oil pump drive gear to the drive gear
shaft.
The gear hub large side must be facing the outside.
3) Use the bench press to press the drive gear to
drive gear shaft.

4. Oil Relief Valve


5. Cotter Pin
6. Driven Gear and Shaft
1) Apply engine oil to the driven gear and shaft.
2) Install the driven gear and shaft to the oil pump
body.
6A–118 ENGINE MECHANICAL

CYLINDER BODY
DISASSEMBLY

12

3
9 10

8
6
8
6

9 11

5
2

MFW31BLF000801

Disassembly Steps
1. Cylinder liner 7. Oil cooler element
2. Oiling jet and check valve 8. Element gasket
3. Oil pressure unit 9. O-ring
4. Oil relief valve 10. Oil thermostat and cover
5. Oil cooler assembly 11. Oil cooler case
6. O-ring 12. Cylinder body
ENGINE MECHANICAL 6A–119

Disassembly Steps

1. Cylinder Liner
If the cylinder liner cannot be pulled free by hand, tap
around the lower side of the liner with a hammer grip
or similar object to loosen it.
1
NOTE:
Take care not to damage the cylinder body.
When reusing the cylinder liner, mark the cylinder
body over the liner so that the mounting direction
2 may become the same as before removal. Don’t use a
punch to mark.
Measure the cylinder liner bore and projection before
disassembling the cylinder liner.
1
Refer to the "Cylinder Liner Bore Measurement" and
"Cylinder Liner Projection Measurement" on the
"INSPECTION AND REPAIR".

2. Oiling Jet and Check Valve


3. Oil Pressure Unit
4. Oil Relief Valve
5. Oil Cooler Assembly
Screw M8 bolts into the four threaded holes and
tighten these evenly, and separate the oil cooler
assembly from the cylinder body.
6. O-ring
7. Oil Cooler Element
8. Element Gasket
9. O-ring
10. Oil Thermostat and Cover
11. Oil Cooler Case
050MX003
12. Cylinder Body
6A–120 ENGINE MECHANICAL

INSPECTION AND REPAIR


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

Cylinder Body

Cylinder Body Upper Face Warpage


1
Use a straight edge 1 and a feeler gauge 2 to
measure the four sides and the two diagonals of the
cylinder body upper face.
If the measured values exceed the specified limit, the
cylinder body must be replaced.
Cylinder Body Upper Face Warpage mm (in)
Limit
2
0.20 (0.008)
NOTE:
Do not attempt to regrind the cylinder body upper
surfaces.

Cylinder Liner Projection Inspection


1 A 1. Hold a straight edge 1 along the top edge of the
cylinder liner to be measured.
2. Use a feeler gauge 2 to measure each cylinder
liner projection A.
Cylinder Liner Projection A mm (in)
Standard
0.06 – 0.10 (0.0024 – 0.0039)
2
The difference in the cylinder liner projection
height between any two adjacent cylinders must
not exceed 0.03 mm (0.0012 in).

Cylinder Liner Grade Selection and Clearance


1. The cylinder body upper left side has been marked
nt during production to indicate the correct liner.
Fro
The liner grade (1, 2, or 3) is indicated in stamped.
2. Replacement cylinder liners have their grade (1, 2
or 3) marked outside.
3. Select same grade of cylinder liners as are marked
on the upper left side of the cylinder body.
Grade mark
Cylinder Body Bore and Cylinder Liner
Outside Diameter Clearance mm (in)
Standard
0.011 – 0.029 (0.0004 – 0.0011)
NOTE:
Clearance refers to the gap between the larger
cylinder body bore and the smaller cylinder liner
outside diameter.
ENGINE MECHANICAL 6A–121

REFERENCE mm (in)
Outside Diameter Cylinder Body Bore Liner
Liner Diameter Grade
117.981 - 117.990 118.001 – 118.010
1
(4.64491 - 4.64527) (4.64570 – 4.64605)
117.991 – 118.000 118.011 – 118.020
2
(4.64531 – 4.64566) (4.64609 – 4.64645)
118.001 – 118.010 118.021 – 118.030
3
(4.64570 – 4.64605) (4.64649 – 4.64684)

Oiling Jet and Check Valve


Check to see if the oiling jet and check valve oil ports
free of obstructions.

Oil Cooler Assembly

Oil Cooler Element Cleaning Procedure


1. Use a funnel to pour cleaning solution into the oil
cooler element.
Add cleaning solution until it overflows.
2. Allow the oil cooler element to stand for ten hours
(with the cleaning solution inside).
3. Pour off approximately 1/3 of the cleaning solution
from the element.
4. Apply compressed air at 196 kPa (2.0 kg·m2 / 28
psi) to the element through the oil port.
Continue to apply compressed air until all of the
cleaning solution has been forced from the
element.
NOTE:
As long as the oil cooler element is not damaged or
excessively dirty, it may be cleaned repeatedly at
periodic intervals.

Oil Cooler Cover


Use the dye penetrant flaw detector procedure to
inspect the oil cooler cover for cracking.
6A–122 ENGINE MECHANICAL

REASSEMBLY

10

4
11 7

9
8
9
8

11
6

12
3

MFW31BLF000701

Reassembly Steps
1. Cylinder body 7. Oil thermostat and cover
2. Cylinder liner 8. O-ring
3. Oiling jet and check valve 9. Element gasket
4. Oil pressure unit 10. Oil cooler element
5. Oil relief valve 11. O-ring
6. Oil cooler case 12. Oil cooler assembly
ENGINE MECHANICAL 6A–123

REASSEMBLY STEPS

1. Cylinder Body
2. Cylinder Liner
1) Use new kerosene or diesel fuel to thoroughly
clean the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder liner
and bore surfaces.
NOTE:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.

3) Install the cylinder liner 1 into the cylinder body 2


from the top of the cylinder body.
Cylinder Body Bore and Cylinder Liner
Outside Diameter Clearance mm (in)
1
Standard
0.011 – 0.029 (0.0004 – 0.0011)
NOTE:
Clearance refers to the gap between the larger
2
cylinder body bore and the smaller cylinder liner
outside diameter.

4) Install the cylinder liner retaining bolts and


washers as shown in the illustration.
The bolts and washers will prevent the liners from
falling free.
Cylinder Liner Retaining Bolt mm (in)
OK NG
Size and Pitch Length
M14 – 2.0 30 (1.181)

Cylinder Liner Retaining Washer mm (in)


Thickness Outside Diameter
3 – 5 (0.118 – 0.197) 40 (1.575)
NOTE:
Piston and cylinder liner retaining washer
interference can result in piston and piston ring
damage.
Either remove the washers or slide out of the way
when replacing the piston and connecting rod
assemblies.
6A–124 ENGINE MECHANICAL

3. Oiling Jet and Check Valve


1) Install the oiling jet and check valve to the cylinder
body.
2) Tighten the check valve to the specified torque.
Oiling Jet and Check Valve Torque N·m (kg·m / lb·ft)
21 (2.1 / 15)

CAUTION:
Take care not to bending the oiling jet.
4. Oil Pressure Unit
1) Set the adapter 1 to the Cyl Block 2.
Adapter Torque N·m (kg·m / lb·ft)
117 (11.9 / 86)

2) Tighten the oil pressure to the specified torque.


Oil Pressure Unit Torque N·m (kg·m / lb·in)
1
2
12 (1.2 / 104)

A06MV003

5. Oil Relief Valve


10 11 6. Oil Cooler Case
7. Oil Thermostat and Cover
8. O-ring
9 9. Element Gasket
8
10. Oil Cooler Element
11. O-ring
1) Install the O-ring, element, element gasket and oil
7 cooler element to the oil cooler case.
11 2) Tighten the oil cooler element nuts to the specified
torque.
Oil Cooler Element Nut Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)

12. Oil Cooler Assembly


1) Install the oil cooler assembly to the cylinder body.
2) Tighten the oil cooler assembly bolts evenly from
the inside to outside.
Oil Cooler Assembly Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)

NOTE:
(1) Apply ThreeBond No. 1207C/1216C or equivalent
on groove of oil cooler assembly.
(2) Assemble within 15 minutes after apply liquid
gasket.
COOLING SYSTEM 6B–1

SECTION 6B
ENGINE COOLING

CONTENTS

PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–12
Engine Coolant Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–15
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–18
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–15
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–17
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–19
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–19
6B–2 COOLING SYSTEM

GENERAL DESCRIPTION
Coolant Flow

Reservoir tank

Water outlet pipe


Radiator filler cap EGR cooler
Thermostat
EGR Valve
Thermounit

Turbocharger
Cooling
fan

Radiator

Water
pump

Drain cock Oil cooler

Air compressor

MFW31BLF000901

The engine cooling system consists of the radiator, will begin to open and a gradually increasing
the surge tank, the water pump, the cooling fan, and amount of coolant will circulate through the
the thermostat. radiator.
To quickly increase cold engine coolant temperature The thermostat will be fully open when the coolant
for smooth engine operation, the coolant is temperature reaches 95°C (203°F).
circulated by the water pump and the thermostat All of the coolant is now circulating through the
through the radiator bypass and directly back to the radiator for effective engine cooling.
cylinder body. The coolant does not circulate
through the radiator at this time. When the coolant
temperature reaches 82°C (180°F), the thermostat
COOLING SYSTEM 6B–3

Thermostat
Without jiggle valve

F06MV028

With jiggle valve

F06MV027

A wax pellet type thermostat is used.


6B–4 COOLING SYSTEM

Water Pump

A centrifugal type water pump forcefully circulates


the coolant through the cooling system.
COOLING SYSTEM 6B–5

Engine coolant change procedure


1. To change engine coolant, make sure that the 5. After filling the system to the full, pull out the
engine is cool. filling hose and check to see if air trapped in the
WARNING system is disclogged and the coolant level
goes down. Should the coolant level go down,
When the coolant is heated to a high temperature,
repeat topping-up until there is no more drop
be sure not to loosen or remove the radiator cap.
in the coolant level.
Otherwise you might get scalded by hot vapor or
boiling water. To open the radiator cap, put a 6. After directly filling the radiator, fill the
piece of thick cloth on the cap and loosen the cap reservoir to the maximum level.
slowly to reduce the pressure when the coolant 7. Install and tighten radiator cap and start the
has become cooler. engine. After idling for 2 to 3 minutes, stop the
engine and reopen radiator cap. If the water
level is lower, replenish.
2. Open radiator cap and drain the cooling
system by loosening the drain valve on the
radiator and on the cylinder body. WARNING
NOTE When the coolant is heated to a high temperature,
For best result it is suggested that the engine be sure not to loosen or remove the radiator cap.
cooling system be flushed at least once a year. It is Otherwise you might get scalded by hot vapor or
advisable to flush the interior of the cooling boiling water. To open the radiator cap, put a
system including the radiator before using anti- piece of thick cloth on the cap and loosen the cap
freeze (ethylene-glycol based). slowly to reduce the pressure when the coolant
has become cooler.
Replace damaged rubber hoses as the engine anti-
freeze coolant is liable to leak out even minor
cracks. 8. After tightening radiator cap, warm up the
Isuzu recommends to use Isuzu genuine anti- engine at about 2,000 rpm.
freeze (ethylen-glycol based) or equivalent, for the Set heater adjustment to the highest
cooling system and not add any inhibitors or temperature position, and let the coolant
additives. circulate also into heater water system.
9. Check to see the thermostat has opened
CAUTION through the needle position of water
thermometer, conduct a 5-minute idling again
A failure to correctly fill the engine cooling system
and stop the engine.
in changing or topping up coolant may sometimes
cause the coolant to overflow from the filler neck 10. When the engine has been cooled, check filler
even before the engine and radiator are neck for water level and replenish if required.
completely full. Should extreme shortage of coolant is found,
check the coolant system and reservoir tank
If the engine runs under this condition, shortage of
hose for leakage.
coolant may possibly result in engine overheating.
To avoid such trouble, the following precausions 11. Fill the coolant into the reservoir tank up to
should be taken in filling the system. “MAX” line.

3. To refill engine coolant, pour coolant up to


filler neck using a filling hose which is smaller
in outside diameter of the filler neck. Otherwise
air between the filler neck and the filling hose
will block entry, preventing the system from
completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling
over this maximum rate may force air inside
the engine and radiator.
And also, the coolant overflow will increase,
making it difficult to determine whether or not
the system is completly full.
6B–6 COOLING SYSTEM

WATER PUMP

1 2

4 5

030MW001

Removal Steps Installation Steps


1. Plate 4. Water pump assembly
2. Water duct 1. Plate
3. O-ring: Water duct 5. O-ring: Water pump assembly
4. Water pump assembly 3. O-ring: Water duct
5. O-ring: Water pump assembly 2. Water duct
COOLING SYSTEM 6B–7

Installation Steps
4. Water pump assembly
1) Apply liquid gasket to water pump assembly Three
bond 1207C or equivalent.
• Apply liquid gasket to make bead width 2~3 mm
on the fitting surface as shown in the illustration
Do not apply liquid gasket if there is some groove.
NOTE:
The water pump must be installed within 15 minutes
after apply liquid gasket.
Torque N·m (kg·m/lb·ft)
19.0 (1.9 / 14.0)

1. Plate
• Tighten the bolt temporary of the plate fixing bolt.

5. O-ring to inlet port of water pump assembly


Apply soap water
• After install O-ring to apply soap water for easy
install the water duct.
3. O-ring to the water duct

2. Water duct to the cylinder head


Plate 1) Tighten the bolt to the specified torque.
Torque N·m (kg·m/lb·ft)
M8 M10
19.0
For water duct bolts —
(1.9/14.0)
19.0 38.0
For plate bolts
(1.9/14.0) (3.9/28.0)
NOTE:
Do not make damage the O-ring on the inlet port of
water pump when install the water duct.
6B–8 COOLING SYSTEM

DISASSEMBLY
Water Pump

1
2
9

6 8

5
4

Disassembly Steps
1. Impeller 6. Water pump shaft and ball bearing
2. Seal unit 7. Oil seal
3. Pulley 8. O-ring
4. Dust cover 9. Water pump body
5. Snap ring
COOLING SYSTEM 6B–9

Disassembly Steps
1. Impeller
1) Clamp the pump body in a vise.
2) Use the remover to remove the impeller.
NOTE:
Insert a 5mm (0.20in) rod into the 6mm (0.24in) hole
of the impeller and push the remover center bolt to
remove the impeller.

2. Seal Unit
3. Pulley
Use a remover to remove the water pump pulley.

4. Dust Cover
5. Snap Ring
6. Water Pump Shaft and Ball Bearing
Use a plastic hammer to lightly tap the water pump
shaft free.
Tap on the shaft from the impeller side.

7. Oil Seal
8. O-ring
9. Water Pump Body
6B–10 COOLING SYSTEM

INSPECTION AND REPAIR


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

Water Pump
Water Pump Impeller
1. Check the impeller for corrosion.
2. Check the seal unit fitting faces for excessive wear
and other damage.

Water Pump Shaft and Ball Bearing


1. Check the oil seal fitting face for excessive wear
and damage.
2. Measure the water pump shaft and pulley and
impeller interference.
If the measured interference is less than the
specified limit, the pump shaft and / or the pulley
and impeller must be replaced.
Pump Shaft and Pulley Interference mm (in)
Limit
0.048 – 0.078 (0.0019 – 0.0031)

Pump Shaft and Impeller Interference mm (in)


Limit
0.027 – 0.120 (0.0011 – 0.0047)

3. Carefully wash away any bearing grease.


4. Listen for excessive bearing operating noise.
Excessive bearing operating noise indicates severe
bearing wear.
COOLING SYSTEM 6B–11

Ball Bearing Replacement


Ball Bearing Removal
1. Place the water pump shaft 1 with the bearings
3 attached between the base plates 2 of a bench
1 press.
2 2. Use the bench press and a rod 3 to gradually apply
pressure to the water pump shaft to remove the
ball bearings from the water pump shaft.
Take care not to damage the water pump shaft.

Ball Bearing Installation


1. Apply engine oil to the water pump shaft and
1 bearings inner race shaft contact surfaces.
2 3 2. Place the water pump shaft 1 and the bearings 2
between the base plates 3.
Place soft brass or copper sheets between the base
plates and the water pump shaft to protect the
water pump shaft.

3. Install the washer 4, the ball bearing 5, the spacer


8
6 and the bearing 7 to the water pump shaft 8.
5

4. Use the bench press to gradually press the water


pump shaft down until the ball bearings are seated
correctly.
Be absolutely sure that the bearing inner race is
supported by the base plates.
6B–12 COOLING SYSTEM

REASSEMBLY

9
8
1

4 2

5
6

Reassembly Steps
1. Water pump body 5. Snap ring
2. O-ring 6. Dust cover
3. Oil seal 7. Pulley
4. Water pump shaft and ball 8. Seal unit
bearing 9. Impeller
COOLING SYSTEM 6B–13

Reassembly Steps
1. Water Pump Body
2. O-ring
3. Oil Seal
1) Clean the water pump body.
Be absolutely sure that the oil ports are free of
restrictions.
2) Install the O-ring to the water pump body.
3) Apply engine oil to the oil seal outside
circumference.
4) Install the oil seal to the water pump body.
The oil seal lip must be facing the ball bearing.
5) Apply grease oil to the oil seal inside
circumference.
6) Press the oil seal into place.

4. Water Pump Shaft and Ball Bearing


1) Repack the bearings with multipurpose grease.

2) Place the water pump body on the bench press


base plate.
3) Position the pump shaft and the bearings to the
pump body.
4) Use a bench press to gradually press the water
pump shaft into the water pump body.
NOTE:
Take care not to damage the oil seal when pressing
the water pump shaft into the water pump body.
Do not attempt to drive the bearing into position
with a hammer or similar object. Damage to the
bearing will result.

5. Snap Ring
6. Dust Cover
1) Use pliers to install the snap ring into the water
pump body groove.
2) Install the dust cover with the flange facing out.
6B–14 COOLING SYSTEM

7. Pulley
Use a bench press to gradually press the water pump
pulley into the water pump shaft.
NOTE:
To protect the bearings, be sure to press in the pulley
with the impeller side pump shaft end surface held
against the bench press.

8. Seal Unit
1) As seal unit surfaces (which are to contact the shaft
and pump body) are coated with liquid gasket,
press the seal unit as it is position.
2) Press in the unit to the specified position using a
bench press and installer.
A Seal Unit Installation Position A mm (in)
11.0 – 11.6 (0.433 – 0.457)

9. Impeller
Using a bench press, press in the impeller until its
stopper surface comes into contact.
NOTE:
To protect the bearings, press in the impeller with the
pulley side shaft end surface held against the bench
press.
COOLING SYSTEM 6B–15

THERMOSTAT
REMOVAL

4
4

Removal Steps
3. Thermostat (with jiggle valve)
1. Water outlet pipe
4. Gasket
2. Thermostat (without jiggle
valve)

Removal Steps
1. Water outlet pipe
2. Thermostat (without jiggle valve)
3. Thermostat (with jiggle valve)
4. Gasket
6B–16 COOLING SYSTEM

INSPECTION AND REPAIR


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

Thermostat

Operating Test
1 1. Completely submerge the thermostat in water.
2
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Measure the thermostat initial opening
temperature.

3
Thermostat Initial Opening Temperature °C (°F)
Standard
82.0 (180)

4. Measure the thermostat full opening temperature.


Thermostat Full Opening Temperature °C (°F)
Standard
95 (203)

1 Thermometer
2 Agitating rod
3 Wooden piece
5. Measure the valve lift at the valve’s fully open
position.
Valve Lift At Fully Open Position mm (in)
Approximately 8 (0.31)
COOLING SYSTEM 6B–17

INSTALLATION

3
3

Installation Steps
1. Thermostat (without jiggle valve) 3. Gasket
2. Thermostat (with jiggle valve) 4. Water outlet pipe
6B–18 COOLING SYSTEM

Installation Steps
1. Thermostat (without jiggle valve)
2. Thermostat (with jiggle valve)
Install the thermostats to the cylinder head.
The thermostat with jiggle valve must be facing the
engine intake side and the jiggle valves must be facing
the engine rearward.

Jiggle valve

3. Gasket
4. Water Outlet Pipe
1) Install the water outlet pipe to the cylinder head.
2) Tighten the water outlet pipe bolts to the specified
torque.
Water Outlet Pipe Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
COOLING SYSTEM 6B–19

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

Radiator
Cooling System Leakage Check
1. Remove the radiator filler cap from the radiator.
2. Install the radiator filler cap tester to the radiator.
3. Apply the specified test pressure to the cooling
system to check for leakage.
Do not exceed the specified test pressure.
Cooling System Test Pressure kPa (kg/cm2 / psi)
88 (0.9 / 13)

Repair or replace the radiator if required.

Radiator Cap Leakage Check


The radiator filler cap maintains cooling system
pressure.
It must tightly seal the cooling system.
1. Remove the radiator filler cap from the radiator.
2. Install the radiator cap to the radiator filler cap
tester.
3. Apply the specified test pressure to the cap to
check for leakage.
Do not exceed the specified test pressure.
Radiator Filler Cap Test Pressure kPa (kg/cm2 / psi)
49 – 59 (0.5 – 0.6 / 7.11 – 8.53)

Negative Valve Pressure kPa (kg/cm2 / psi)


2 – 5 (0.02 – 0.05 / 0.28 – 0.71)

Replace the radiator filler cap if it fails to hold the


specified test pressure.
MEMO
FUEL SYSTEM 6C–1

SECTION 6C
FUEL SYSTEM

CONTENTS

PAGE
TICS & RED-IV type Fuel Injection System (6HK1-TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 2
Injection Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 7
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C– 9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–10
Main Data and Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–12
Common Rail type Fuel Injection System (6HK1-TCC, TCN) . . . . . . . . . . . . . . . . . . . . . . 6C–13
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–13
System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–13
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–14
Service Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–15
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–15
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–16
Fuel Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–16
Fuel Pressure Limiter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–17
Fuel Flow Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–18
Injector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–19
Main Data and Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–20
Fuel Filter (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–21
6C–2 FUEL SYSTEM

TICS & RED-IV TYPE FUEL INJECTION SYSTEM


(6HK1-TCS)
GENERAL DESCRIPTION

Injection
nozzle

Injection pump
Water separator

Fuel tank

A , B : Overflow Valve
MFW31BLF000601

The fuel system consists of the fuel tank, the water removed from the fuel.
separator, the prefuel filter, the fuel filter, the Fuel, fed by the injection pump plunger, is delivered
injection pump, and the injection nozzle. The fuel to the injection nozzle in the measured volume at
from the fuel tank passes through the water the optimum timing for efficient engine operation.
separator, the pre-fuel filter and the fuel filter.
Water particles and other foreign material are
FUEL SYSTEM 6C–3

Delivery valve

Plunger barrel
Timing sleeve
Timing rod
Guide pin

Control rod

Plunger spring
Plunger

Plug

Tappet

Camshaft

Timing and Injection rate Control System (TICS)

Major components of the injection pump are the lobes. They are returned to their original position by
pump body and plunger unit, the governor, the the plunger springs. This action creates a reciprocal
timer, and the feed pump. motion.
The injection pump is the nucleus of the diesel The plunger barrel receives fuel from the feed pump
engine fuel system. and fuel filter through its inlet port when the
It pressurizes and delivers a metered volume of fuel injection pump plunger is on the down stroke.
to the engine cylinders at the optimum time for the Surplus fuel is delivered to the injection pump fuel
current engine load and speed. chamber through the plunger outlet port when the
The injection pump plungers are pushed up by cam plunger is on its up stroke.
6C–4 FUEL SYSTEM

Rack sensor

Control rack

Governor actuator

RED-IV TYPE

060M100066

The 6HK1TCS engine is equipped with an RED - IV the target rack position, so that the injection volume
type electrical control governor. will be controlled.
The basic injection volume (rack position) is sought
from acceleration opening angle and engine
revolution, and the target injection volume is
determined after adjusyment reflecting the
information from each sensor input.
A rack sensor detects actual injection volume (actual
rack position), and moves the governor actuator to
FUEL SYSTEM 6C–5

Priming pump

Piston

Check valve Check valve


(Suction side) (Delivery side)

Filter

The fuel feed pump tappet is driven by an eccentric through the fuel filter. It delivers the fuel, under
cam in the injection pump camshaft. Tappet pressure, to the injection pump.
movement is relayed the piston through the push An independent priming pump permits manual fuel
rod. feed when the engine is not running.
The fuel feed pump draws fuel from the fuel tank
6C–6 FUEL SYSTEM

Clutch
switch
Accelerator
position signal
Vehicle
Starter Parking speed
Boost pressure signal switch switch signal
Fuel temperature signal
Atmospheric
Engine coolant temperature signal temperature
signal

Engine speed signal

Pre-stroke actuator
Control unit
Injection pump

EC governor

Pre-stroke control signal


Pre-stroke position signal
Engine speed(backup) signal
Actual rack position signal
Target rack position signal

040M100014

The illustration shows a diagram of the TICS There are slight differences depending on customer
system combined and the RED-IV Type EC specifications.
governor (electrical control governor).
FUEL SYSTEM 6C–7

INJECTION NOZZLE
DISASSEMBLY

7 3
2

040M100017

Disassembly Steps
1. Retaining nut 5. Nozzle spring
2. Injection nozzle 6. Adjusting shim
3. Spacer 7. Nozzle holder
4. Spring seat
6C–8 FUEL SYSTEM

Disassembly Steps
1. Retaining Nut
2. Injection nozzle
1) Clamp the injection nozzle holder in a vice.
2) Use a wrench to remove the injection nozzle
retaining nut.
3) Remove the injection nozzle holder from the vice.
4) Remove the injection nozzle, the spacer, the spring
seat, the nozzle spring and the adjusting shim.
NOTE:
Tag the nozzle assemblies and nozzle holders so that
they can be reinstalled to their original positions.
Nozzle assembly and nozzle holder combinations
must be not changed.

5) Immerse the injection nozzle in a tool tray filled


with clean diesel oil.
This will protect the nozzles from dust.

3. Spacer
4. Spring Seat
5. Nozzle spring
6. Adjusting Shim
7. Nozzle Holder
FUEL SYSTEM 6C–9

INSPECTION AND REPAIR


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

Injection Nozzle
1. Check the injection nozzle needle valve, the valve
seat, and the injection nozzle hole for carbon
deposits.
If carbon deposits are present, the injection nozzle
and the needle valve must be cleaned or replaced.
2. Hold the nozzle body vartically.
3. Lift the needle valve about 1 / 3 of the way out of
the nozzle body.
4. Release the needle valve.
The needle valve should fall back into the nozzle
body as far as the valve seat.
If the needle valve does not fall back into the nozzle
body as far as the valve seat, the injection nozzle
and the needle valve must be replaced.

Injection Nozzle Operating Test


Opening Pressure and Spray Condition Check
1. Use a nozzle tester to check the injection nozzle
opening pressure.
If the opening pressure is above or below the
specified value, the injection nozzle must be
replaced or adjusted.
Refer to "Injection Nozzle Adjustment".
Injection Nozzle Opening Pressure MPa (kg/cm2 / psi)
040M100020
21.6 (220 / 3,128)

WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT OF THE INJECTION NOZZLE
UNDER GREAT PRESSURE. IT CAN EASILY
PUNCTURE A PERSON'S SKIN. KEEP YOUR HANDS
AWAY FROM THE INJECTION NOZZLE AT ALL TIMES.

2. Check the spray condition.


If the spray condition is bad, the injection nozzle
1 2 3 must be replaced or reconditioned.
1 Correct
2 Incorrect (Restrictions in orifice)
3 Incorrect (Dripping)
6C–10 FUEL SYSTEM

REASSEMBLY

1 5

040M100013

Reassembly Steps
1. Nozzle holder 5. Spacer
2. Adjusting shim 6. Injection nozzle
3. Nozzle spring 7. Retaining nut
4. Spring seat
FUEL SYSTEM 6C–11

Reassembly Steps
1. Nozzle Holder
2. Adjusting Shim
3. Nozzle Spring
4. Spring Seat
5. Spacer
6. Injection Nozzle
7. Retaining Nut
1) Install the adjusting shim, the nozzle spring, the
spring seat, the spacer, the injection nozzle and the
retaining nut.
2) Clamp the injection nozzle holder in a vice.
3) Tighten the injection nozzle retaining nut to the
specified torque.
Injection Nozzle Holder Retaining
Nut Torque N·m (kg·m / lb·ft)
39 (4.0 / 29)

4) Remove the injection nozzle holder from the vice.


5) Attach the injection nozzle holder to the injection
nozzle tester.
6) Apply pressure to nozzle tester.
Note the pressure at which the injection nozzle
opens.
7) If required, install or remove the appropriate
number of adjusting shims to adjust it.
Reference:
040M100020 Installing or removing 0.10mm (0.004in) will
increase or decrease the nozzle opening pressure
approximately 1638kPa (16.7 kg/cm2 / 237 psi).
Adjusting Shim Availability mm (in)
0.10 (0.004), 0.20 (0.008)
Increment
0.30 (0.012), 0.40 (0.016)
(0.10mm (0.004in)
0.50 (0.0196)
Increment 0.52 (0.0205) 0.54 (0.0213)
(0.02mm (0.008in) 0.56 (0.0220) 0.58 (0.0228)
Total Number of Shims 9
6C–12 FUEL SYSTEM

MAIN DATA AND SPECIFICATIONS


Item 6HK1-TCS
Injection pump type MD-TICS type
Plunger outside diameter mm (in) 11 (0.433)
Governor type Electronic control (RED - IV)
Timer –

Injection nozzle type Hole type


Number of injection nozzle orifices 5
Orifices diameter mm (in) 0.22 (0.009)
Opening pressure MPa (kg/cm2 / psi) 21.6 (220 / 3,128)
FUEL SYSTEM 6C–13

COMMON RAIL TYPE FUEL INJECTION SYSTEM


(6HK1-TCC, TCN)
GENERAL DESCRIPTION

1
040MV045

This section covers the electronically controlled fuel injection system for 6HK1-TCC and 6HK1-TCN diesel
engine.
The 6HK1-TCC and 6HK1-TCN diesel engine fuel system consists of the following.
• Fuel tank
• Fuel hoses and lines
• Water separator
• Fuel filter
• Fuel feed pump
• Fuel supply pump
• Fuel common rail
• Steel lines
• Six fuel injectors with solenoid valve
The fuel supply pump, fuel common rail and the fuel injectors are made by DENSO.
If an internal problem occurs in the fuel supply pump, the fuel supply pump must be removed from the engine
and serviced by an authorized DENSO dealer. Do not open the fuel supply pump and injector assembly, or
the warranty is void.
The fuel supply pump has an identification tag (1) attached to the fuel supply pump body.

SYSTEM OUTLINE
The COMMON RAIL SYSTEM detects engine conditions (engine speed, accelerator pedal angle, coolant
temperature, etc.) by means of its sensors and generally control fuel injection amount, timing, and pressure
by means of its microcomputer, thereby making the engine run in the best condition.
Further, the system performs the self-diagnosis/lighting function to diagnose main components and, if
abnormality found, worn the driver, the failsafe function to stop the engine depending on the parts to which
trouble has occurred, and the backup function to switch over the control method to enable the vehicle to run
continuously.
6C–14 FUEL SYSTEM

SYSTEM OPERATION
Fuel is drawn through the fuel pre-filter (2) by the fuel feed pump (3), refer to figure. The fuel feed pumps the
fuel into the fuel filter (4) and then into the fuel supply pump (5). The fuel supply pump then pressurizes and
supplies the fuel to fuel common rail.
The pressured fuel distributes through the fuel injectors line to the fuel injectors (8). The high pressure fuel
enters the fuel injector and forces the needle off its seat, same time the fuel enters the control room of fuel
injectors. The fuel injection timing is controlled by ECM. The ECM command to open the fuel return line of
solenoid valve on top of the injector, then the fuel is forced out of the fuel injector into the cylinder.

6 8

11 7

10 12

5 1
2
040MV044

1. Fuel tank 7. Fuel flow dumper


2. Fuel pre-filter 8. Injector assembly
3. Fuel feed pump 9. Fuel temperature sensor
4. Fuel filter 10. Fuel pressure limiter
5. Supply pump 11. Fuel pressure sensor
6. Fuel common rail 12. Overflow valve
FUEL SYSTEM 6C–15

SERVICE PROCEDURE
CLEANING PROCEDURE
CAUTION:
Be careful not to enter the foreign materials. Before servicing, clean the related parts or the connection part.
1. By using steam cleaner, clean around the common rail. Be careful not to damage the electrical parts.
2. Remove water by air blow.
3. Clean the common rail related parts by using parts cleaner solvent.
4. Dry the common rail by air blow, then start inspection or parts replacement.
CAUTION:
• If the parts replacement is required, do not service when the engine is warm or hot. High temperature
fuel can be blown out under pressure if the engine is still warm or hot.
• When remove the parts, cover the connection part with clean waste cloth to prevent fuel blowing out.
• Wipe leaked fuel with clean waste cloth.
• Clean and dry the threaded portion of the removed parts.
• If the foreign materials enter into the common rail, can cause trouble of the engine. Be careful not to
enter the foreign materials even if it is very small.
6C–16 FUEL SYSTEM

COMMON RAIL
FUEL PRESSURE SENSOR REPLACEMENT
CAUTION:
Be careful not to enter the foreign materials. Before
servicing, clean the related parts or the connection part.

040MA00011

Removal Steps
1. Fuel pressure sensor

Removal Steps
1. Fuel Pressure Sensor
Using 30 mm (1.181 in) deep socket wrench, remove
the fuel pressure sensor.
Note:
The fuel pressure sensor cannot be reused.

Installation Steps
1. Fuel Pressure Sensor
Apply grease to new pressure sensor. Tighten the
pressure sensor to the specified torque.
Apply Fuel Pressure Sensor Torque N·m (kg·m/lb·ft)
grease.
98 (10.0/72)

CAUTION:
• The fuel pressure sensor cannot be reused when it
was removed.
• Be careful not to enter the foreign materials.
040MA00005 • Do not touch the connector pin of the sensor.
FUEL SYSTEM 6C–17

FUEL PRESSURE LIMITER REPLACEMENT


CAUTION:
Be careful not to enter the foreign materials. Before
servicing, clean the related parts or the connection part.

24mm Hex.
040MA00008

Removal Steps
1. Fuel pressure limiter
2. Gasket

Removal Steps
1. Fuel Pressure Limiter
Using 24 mm (0.945 in) deep socket wrench, remove
the pressure limiter.
CAUTION:
Do not use 22 mm (0.866 in) hex. part.
2. Gasket
Remove the gasket using tweezers.
CAUTION:
1. Do not reuse the gasket.
2. Be careful not to damage sealing surface when
remove the gasket.

Installation Steps
1. Gasket
Install new gasket.
2. Fuel Pressure Limiter
By using 24 mm (0.945 in) deep socket wrench, tighten
the pressure limiter to the specified torque.
CAUTION:
Do not use 22 mm (0.866 in) hex. part.

Fuel Pressure Limiter Torque N·m (kg·m/lb·ft)


172 (17.5/127)
6C–18 FUEL SYSTEM

FUEL FLOW DAMPER REPLACEMENT


CAUTION:
Be careful not to enter the foreign materials. Before
servicing, clean the related parts or the connection part.

040M200004

Removal Steps
1. Fuel flow damper
2. Gasket

Removal Steps
1. Fuel Flow Damper
Remove the fuel flow damper.
2. Gasket
Remove the gasket using tweezers.
CAUTION:
1. Do not reuse the gasket.
2. Be careful not to damage sealing surface.

Installation Steps
1. Gasket
Install new gasket.
2. Fuel Flow Damper
Tighten the flow damper to the specified torque.

Fuel Flow Damper Torque N·m (kg·m/lb·ft)


172 (17.5/127)
FUEL SYSTEM 6C–19

INJECTOR ASSEMBLY
The injector cannot be adjusted or repaired. If the injector
is damaged, the entire assembly must be replaced.
6C–20 FUEL SYSTEM

MAIN DATA AND SPECIFICATIONS


Item 6HK1-TCC, 6HK1-TCN
Injection pump type Supply Pump Unit (SP120 - 6MD)
Feed pump Trochoid type
Over flow valve pressure 255 (2.6 / 37)
kPa (kg/cm2 / psi)

Injector Electronic control


Number of injector nozzle orifices 7
Orifices diameter mm (in) 0.16 (0.006)
FUEL SYSTEM 6C–21

FUEL FILTER (ALL MODELS)


DISASSEMBLY

Disassembly Steps
1. Cartridge
2. Filter cover

REASSEMBLY
Fuel filter
1. Use a fuel filter wrench to remove the fuel filter
cartridge.
2. Discard the old fuel filter cartridge.
3. Clean the fuel filter fitting face (this allows the new
fuel filter cartridge to seat properly).
4. Install the O-ring and the new fuel filter cartridge.
5. Apply a light coat of diesel fuel to the cartridge O-ring.
6. Use your hand to turn in the cartridge until the O-ring
is pressed firmly against the sealing face.
7. Use a fuel filter wrench to turn in the cartridge an
additional 2/3 of a turn (or to the specified torque).
Fuel filter cartridge torque N·m (kg·m / lb·ft)
18 (1.8 / 13)
8. Bleed the air from the fuel system and check for fuel
leakage. Refer to “Air Bleeding.”
6C–22 FUEL SYSTEM

MEMO
ENGINE ELECTRICAL 6D–1

SECTION 6D
ENGINE ELECTRICAL

CONTENTS

PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 2
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 4
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D– 9
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–11
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–14
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–18
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–21
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–21
6D–2 ENGINE ELECTRICAL

GENERAL DESCRIPTION
Generator
ENGINE ELECTRICAL 6D–3

Starter Motor

065HV001
6D–4 ENGINE ELECTRICAL

GENERATOR
DISASSEMBLY

11
12

13
14
15
16
4
3 17
2
1

8 10
19

7
9

20

22 18
21

Disassembly Steps
1. Pulley nut 12. Rotor assembly
2. Pulley 13. Bearing retainer
3. Fan 14. Ball bearing
4. Collar 15. Bearing cover
5. Bushing 16. Ring
6. Cover 17. Front frame
7. Rectifier holder assembly 18. Rear end frame assembly
8. Regulator 19. Ball bearing
9. Rectifier holder 20. Rotor coil
10. Through bolt 21. Stator assembly
11. Front frame and rotor assembly 22. Rectifier assembly
ENGINE ELECTRICAL 6D–5

Disassembly steps

1. Pulley Nut
2. Pulley
3. Fan
4. Collar
5. Bushing
6. Cover
7. Rectifier Holder Assembly
8. Regulator
9. Rectifier Holder
10. Through Bolt
11. Front Frame and Rotor Assembly
12. Rotor Assembly
13. Bearing Retainer
14. Ball Bearing
15. Bearing Cover
16. Ring
17. Front Frame
18. Rear End Frame Assembly
19. Ball Bearing
20. Rotor Coil
21. Stator Assembly
22. Rectifier Assembly
6D–6 ENGINE ELECTRICAL

INSPECTION AND REPAIR


Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.
It is most important that electrical components be kept clean and dry at all times.
Always visibly check the fusible links, the fuses, and the indicator lights for damage as the first step in
the inspection and repair procedure.

Rotor Coil
Rotor Coil Resistance
Use a circuit tester to measure the rotor coil resistance
between the terminals.
Rotor Coil Resistance ohm
Standard
9
If the measured resistance is above or below the
specified standard, the rotor coil assembly must be
replaced.

Stator
Stator Continuity
Check for continuity across the stator coils.
If there is no continuity, the stator assembly must be
replaced.

Stator Insulation
Use a circuit tester to check that there is no continuity
between the stator coils and the core.
If there is continuity between the stator coils and the
core, the stator assembly is defective and must be
replaced.
ENGINE ELECTRICAL 6D–7

Rectifier Holder Assembly


+ - Rectifier Check
Use a circuit tester to check the battery side rectifiers
(+) and the ground side rectifiers (−).
1. Touch one circuit tester lead to the battery side
terminal (+).
2. Touch the other circuit tester lead to one of the
battery side rectifiers.
Note the circuit tester gauge reading (continuity or
infinite resistance).

+ - 3. Reverse the position of the circuit tester leads.


The circuit tester gauge reading should be the
opposite of Steps 2.
4. Continue the procedure for the remaining battery
side rectifiers.
If the circuit tester gauge reading at any point is
abnormal, the rectifier holder assembly must be
replaced.

5. Touch one circuit tester lead to the ground side


+ -
terminal (−).
6. Touch the other circuit tester lead to one of the
ground side rectifiers.
Note the circuit tester gauge reading (continuity or
infinite resistance).

+ - 7. Continue as in Steps 3-4 above for the remaining


ground side rectifiers.
6D–8 ENGINE ELECTRICAL

Pulley
Check the pulley for excessive wear and cracking.

Fan
Check the fan for cracking and distortion.

Ball Bearing
Check the ball bearings for binding, drag, roughness,
and noise.
ENGINE ELECTRICAL 6D–9

REASSEMBLY

12
11

10
9
8
7
19
20 6
21
22

17

18

13
15
5

16
14

1 4
2

Reassembly Steps
1. Rectifier assembly 12. Front frame and rotor assembly
2. Stator assembly 13. Through bolt
3. Rotor coil 14. Rectifier holder
4. Rear end frame assembly 15. Regulator
5. Ball bearing 16. Rectifier holder assembly
6. Front frame 17. Cover
7. Ring 18. Bushing
8. Bearing cover 19. Collar
9. Ball bearing 20. Fan
10. Bearing retainer 21. Pulley
11. Rotor assembly 22. Pulley nut
6D–10 ENGINE ELECTRICAL

Reassembly Steps
1. Rectifier Assembly
2. Stator Assembly
3. Rotor Coil
4. Rear End Frame Assembly
5. Ball Bearing
6. Front Frame
7. Ring
8. Bearing Cover
9. Ball bearing
10. Bearing Retainer
11. Rotor Assembly
12. Front Frame and Rotor Assembly
13. Through Bolt
14. Rectifier Holder
15. Regulator
16. Rectifier Holder Assembly
17. Cover
18. Bushing
19. Collar
20. Fan
21. Pulley
22. Pulley Nut
ENGINE ELECTRICAL 6D–11

STARTER MOTOR
DISASSEMBLY

4
6
3

2
1 5

14
16
15

11

13
8
12

10

Disassembly Steps
1. Lead wire 9. Magnetic switch assembly
2. Through bolt 10. Overrunning clutch
3. Yoke 11. Front end frame
4. Screw 12. Steel ball
5. Rear end frame 13. Spring
6. Brush holder 14. Idle gear
7. Armature and bearing 15. Retainer
8. Screw 16. Roller
6D–12 ENGINE ELECTRICAL

Disassembly steps
1. Lead Wire
Disconnect the lead wire from the magnetic switch.

2. Through Bolt
Remove the through bolts from the rear end frame.

3. Yoke
Remove the yoke from the magnetic switch.

4. Screw
Remove the screw from the rear end frame.

5. Rear End Frame


Remove the rear end frame from the yoke.
ENGINE ELECTRICAL 6D–13

6. Brush Holder
Using a long nose pliers, take off the brushes and pull
out the brush holder.

7. Armature and Bearing


Remove the armature with bearings from yoke.

8. Screw
9. Magnetic Switch Assembly
1) Remove the screws from the front end frame.
2) Remove the front end frame from the magnetic
switch assembly.

10. Overrunning Clutch


Remove the overrunning clutch from the front end
frame.

11. Front End Frame


12. Steel Ball
13. Spring
14. Idle Gear
15. Retainer
16. Roller
6D–14 ENGINE ELECTRICAL

INSPECTION AND REPAIR


Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.
It is most important that electrical components be kept clean and dry at all times.
Always visibly check the fusible links, the fuses, and the indicator lights for damage as the first step in
the inspection and repair procedure.

Armature
Commutator Face
Check the commutator face for roughness.
If necessary, dress the commutator face with fine
sandpaper (#500 or #600).
Be absolutely sure that there are no metal filings in
the segment gaps.

Commutator Run-Out
1. Mount the armature assembly on V-blocks.
2. Use a dial indicator to measure the commutator
run-out.
If the run-out is greater than the specified standard
but less than the specified limit, the commutator
may be turned on a lathe to correct it.
If the run-out exceeds the specified limit, the
armature assembly must be replaced.
Commutator Run-Out mm (in)
Standard Limit
0.06 (0.002) or less 0.1 (0.004)

Commutator Segment Groove Depth


Use the V-blocks and the dial indicator to measure the
depth D of each of the commutator segment grooves.
D Replace the armature assembly if the commutator
segment groove depth is less than the specified limit.
Commutator Segment Groove Depth D mm (in)
Standard Limit
0.5 – 0.8 (0.020 – 0.031) 0.2 (0.008)

Commutator Outside Diameter


Use a vernier caliper to measure the commutator
outside diameter.
If the commutator outside diameter is less than the
specified standard but greater than the specified limit,
the commutator may be turned on a lathe to correct it.
Replace the armature assembly if the commutator
outside diameter is less than the specified limit.
Commutator Outside Diameter mm (in)
Standard Limit
36 (1.42) 35 (1.38)
ENGINE ELECTRICAL 6D–15

Armature Coil
1. Place the armature in a growler tester.
2. Hold a hacksaw blade against the armature core.
Slowly rotate the armature.
If the armature is shorted, the hacksaw blade will
vibrate.
Replace the armature assembly if it is shorted.

Armature Continuity
Use a circuit tester to check for continuity between the
commutator segments.
If there is no continuity between any two points on the
commutator, the armature assembly must be
replaced.

Armature Insulation
Use a circuit tester to check that there is no continuity
between the commutator segments and the coil core.
If there is continuity between the commutator
segments and the coil core, the armature assembly is
defective and must be replaced.

Yoke
Field Coil Continuity
Use a circuit tester to check for continuity between the
connecting leads and the brushes.
Replace the yoke assembly if there is no continuity at
any point.
6D–16 ENGINE ELECTRICAL

Yoke Insulation
Use a circuit tester to check that there is no continuity
between the field coil and the yoke body.
If there is continuity between the field coil and the
yoke body, the yoke assembly is defective and must
be replaced.

Brush and Brush Holder


Brushes
Use a vernier caliper to measure the brush lengths
(four brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length mm (in)
Limit
12 (0.47)

Brush Holder Insulation


Use a circuit tester to check that there is no continuity
between the battery side brush cages and the holder
plate.
If there is continuity between the battery side brush
cages and the holder plate, the brush holder assembly
is defective and must be replaced.

Overrunning Clutch
1. Clean the overrunning clutch with a clean rag.
2. Check the overrunning clutch and pinion gear for
excessive wear and damage.
3. Turn the pinion gear clockwise.
The gear should turn smoothly with no resistance.
If the gear does not turn smoothly, the overrunning
clutch assembly must be replaced.
4. Turn the pinion gear counterclockwise.
The gear should lock firmly.
If the gear does not lock firmly, the overrunning
clutch assembly must be replaced.
ENGINE ELECTRICAL 6D–17

Bearing
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.

Magnetic Switch
CAUTION:
Do not apply an operating test to the magnetic
switch as a single unit.
Coil Inspection
Inspect the continuity between M terminal and case of
the magnetic switch using a circuit tester.
6D–18 ENGINE ELECTRICAL

REASSEMBLY

12
11
14

13

15
16 10

2
3
4

5
9
6

Reassembly Steps
1. Magnetic switch assembly 9. Screw
2. Idle gear 10. Rear end frame
3. Roller 11. Brush holder
4. Retainer 12. Screw
5. Spring 13. Armature and bearing
6. Steel ball 14. Yoke
7. Overrunning clutch 15. Through bolt
8. Front end frame 16. Lead wire
ENGINE ELECTRICAL 6D–19

Reassembly Steps

1. Magnetic Switch Assembly


2. Idle Gear
3. Roller
4. Retainer
5. Spring
6. Steel Ball
7. Overrunning Clutch
8. Front End Frame
9. Screw
Tighten the screw to specified torque.
Tightening Torque N·m (kg·m / lb·ft)
12.7 (1.3 / 9.4)

10. Rear End Frame


Note:
When install the rear end frame to the yoke, engage
the tab on the rear end frame with the lead wire
grommet.

TAB LEAD WIRE GROMMET

11. Brush Holder


POSITIVE BRUSH
Note:
INSULATOR
BRUSH SPRING
1) Install the negative brush (brush holder side) to the
NEGATIVE BRUSH
brush holder negative hole (not insulated), and the
positive brush (yoke side) to the brush holder
positive hole (separated from plate with insulator).
Then make sure that the positive brush lead wire
are not grounded.
POSITIVE BRUSH HOLDER HOLE
2) When assembling the brush holder to the yoke,
NEGATIVE BRUSH HODLER HOLE
take care not to damage and get oil on it.
6D–20 ENGINE ELECTRICAL

12. Screw
Tighten the screw to the specified torque.
Tightening Torque N·m (kg·m / lb·ft)
3.6 (0.37 / 2.7)
13. Armature and Bearing
14. Yoke
Note:
TAB
When install the yoke to the magnetic switch, engage
the tab on the yoke with the notch in the magnetic
switch.
15. Through Bolt
Tighten the through bolt to the specified torque.
Tightening Torque N·m (kg·m / lb·ft)
12.7 (1.3 / 9.4)
19. Lead Wire
ENGINE ELECTRICAL 6D–21

GROW PLUG
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.
It is most important that electrical components be kept clean and dry at all times.
Always visibly check the fusible links, the fuses, and the indicator lights for damage as the first step in
the inspection and repair procedure.

Preheating System
Glow Plug
Check each of the glow plugs for continuity.
Replace the glow plugs as a set if one or more of the
glow plugs does not have continuity.

Note:
Note that glow plug specifications for the 6HK1TC-S
and 6HK1TC-C&N engines are different.
MEMO
EXHAUST SYSTEM 6F–1

SECTION 6F
EXHAUST SYSTEM

CONTENTS

PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 3
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F– 6
6F–2 EXHAUST SYSTEM

GENERAL DESCRIPTION
The exhaust system consists of the the exhaust The exhaust pipes are connected to each other by
pipes and the silencer. series of flange bolts. They are attached to the
The exhaust pipes run from the exhaust manifold, vehicle frame by clamps and brackets. Rubber
beneath the vehicle frame, to the rear of the vehicle. bushings are used at support points.
EXHAUST SYSTEM 6F–3

REMOVAL

4 3

150M100005

Removal Steps
1. Exhaust pipe clamp (A) 4. Exhaust silencer
2. Exhaust pipe clamp (B) 5. Front exhaust pipe
3. Rear exhaust pipe
6F–4 EXHAUST SYSTEM

Removal steps
1. Exhaust Pipe Clamp (A)
2. Exhaust Pipe Clamp (B)
3. Rear Exhaust Pipe
4. Exhaust Silencer
5. Front Exhaust Pipe
EXHAUST SYSTEM 6F–5

INSPECTION AND REPAIR


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

Exhaust Pipes and Exhaust Silencer


1. Check the exhaust pipes and the exhaust
silencer for corrosion and damage.
Repair or replace as required.
2. Check the pipe and silencer connections for
looseness and misalignment.
Align and tighten as required.
3. Check the pipe support rubber rings for
deterioration.
Replace as required.
6F–6 EXHAUST SYSTEM

INSTALLATION

2 3

150M100007

Installation Steps
1. Front exhaust pipe 4. Exhaust pipe clamp (B)
2. Exhaust silencer 5. Exhaust pipe clamp (A)
3. Rear exhaust pipe
EXHAUST SYSTEM 6F–7

Installation Steps

1. Front Exhaust Pipe


1) Connect the front exhaust pipe with to the exhaust
manifold.
2) Tighten the front exhaust pipe flange nuts to
specified torque.

Exhaust Pipe Flange Nut Torque N·m (kg·m / lb·ft)


39 (4 / 29)

150M100006

2. Exhaust Silencer
3. Rear Exhaust Pipe
4. Exhaust Pipe Clamp (B)
5. Exhaust Pipe Clamp (A)
Be absolutely sure that the exhaust pipe clamps
and / or the flange bolts are securely fastened to the
exhaust pipes and the silencer.
If the vehicle is equipped with an exhaust brake, be
absolutely sure that the exhaust brake valve is
correctly installed to the exhaust pipes.

Exhaust System Check


1. Start the engine and allow it to idle.
2. Check for gas leakage from the exhaust pipe joints.
3. Check for noise and vibration.
MEMO
TURBOCHARGER 6G – 1

SECTION 6G
TURBOCHARGER

CONTENTS

PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 2
Identification Plate and Assembly Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 3
Turbocharger Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 3
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 4
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 6
Turbine Shaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 6
Turbine Shaft and Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 8
6G – 2 TURBOCHARGER

GENERAL DESCRIPTION
Turbocharger

F06MV026

Major turbocharger components are constituted the The turbocharger increase air intake efficiency, the
Center Housing and Rotating Assembly (CHRA), the results in increased engine power, reduced fuel
compressor housing, and the turbine housing. consumption and minimal engine noise.
Rotating parts include the turbine shaft, the Turbocharger rotating parts operate at very high
compressor wheel, the shaft bearings, the thrust speeds and temperatures. The parts materials have
bearings and the oil seal rings. These parts are been carefully selected and machined to extremely
supported by the center housing. high precision.
TURBOCHARGER 6G – 3

IDENTIFICATION PLATE AND ASSEMBLY


NUMBER
The turbocharger nameplate gives the date of
manufacture and other important information
required to identify the unit when service inquiries are
made.

MFW31BSH003001

The turbocharger nameplate has the following


Name plate example information stamped on it. Refer to the illustration.
1 Turbocharger specification, production year and
Turbo Spec. 1
production month.
Serial No. 2 2 Production date, serial number and production line
name.
Parts No. 3 3 Part number assigned by ISUZU MOTORS
LIMITED.
Example: 8943906500
Part numbers 3 indicate specific designs or
configurations.

TURBOCHARGER SERVICING
1. Refer to TROUBLESHOOTING in this Manual to determine whether or not turbocharger repair or
overhaul is required.
2. The following procedures should also be performed (either with the turbocharger on the vehicle or
removed from the vehicle but not disassembled) to determine whether or not turbocharger repair or
overhaul is required.
* Visual checks
* Clearance measurements
* End play measurements
Refer to INSPECTION AND REPAIR
3. The turbocharger compressor and turbine housing may be removed from the center housing and
rotating assembly (CHRA) for further visual inspection.
Refer to DISASSEMBLY and REASSEMBLY.

PRECAUTIONS
Turbocharger servicing requires great care and expertise.
Faulty turbocharger servicing procedures can result in serious damage to pistons, valves, cylinder liners,
and other important engine parts.
ISUZU does not recommended the performance of any servicing procedure not specified described in this
Manual.
Contact your nearest HONEY WELL to have the turbocharger assembly repaired or overhauled.
The identification plate and assembly number will be required by the service facility.
6G – 4 TURBOCHARGER

DISASSEMBLY

037M100001

Disassembly Steps
1. Actuator
2. Actuator hose and clip
3. Lock plate and bolt
4. Compressor housing
5. Gasket
6. Center housing
7. Turbine housing
TURBOCHARGER 6G – 5

Disassembly Steps
1. Actuator
2. Actuator Hose and Clip
1 3. Lock Plate and Bolt
3
Apply a setting mark across the center housing and
rotating assembly (1), the turbine housing (2), and the
compressor housing (3).
2

4. Compressor Housing
5. Gasket
1
1
6. Center Housing
1) Loosen the lock plate bolts.
2) Disassembly the parts.
3
Handle the parts with extreme care.
Be particularly careful not to damage the turbine
wheel blades and the compressor wheel blades.
Take care not to allow foreign material to enter the
center housing.
Note:
Disassembly and servicing of the center housing and
rotating assembly is not recommended.

7. Turbine Housing
6G – 6 TURBOCHARGER

INSPECTION AND REPAIR


Make the necessary adjustment, repairs, and part replacements if excessive wear or damage is discovered
during inspection.

Minor servicing operations are described in this Section.


Contact the nearest HONEY WELL for major repairs and
maintenance.

Turbine Shaft End Play


1. Set a dial indicator to the turbine shaft end.
2. Apply a force of alternately to the compressor
wheel end and the turbine wheel end.
3. Read the dial indicator
Turbine Shaft End Play mm (in)
Standard
0.025 – 0.076 (0.0009 – 0.0029)

Turbine Shaft and Bearing Clearance


Due to the unique location of the center housing
casting internal opening, access to the shaft wheel is
difficult. To check the turbine shaft and bearing
clearance, a special gauge arm assembly must be
fabricated for use with a dial gauge.
The assembly can be constructed from any
conveniently available material. However, it must
conform to the dimensions shown in the illustration.

1. Pass the gauge arm assembly through the oil


outlet port and the casting internal opening.
The curved end of the gauge arm assembly must
make contact with the wheel shaft.
TURBOCHARGER 6G – 7

2. Set the dial gauge to “0”.


3. Grasp both ends of the shaft at the wheel hubs.
Move the shaft gently back and forth in a motion
that is parallel to the plane of the oil drain flange
face.
Note the dial gauge reading.
If the dial gauge reading is above or below the
standard range, the center housing and rotating
assembly must be replaced.
Turbine Shaft and Bearing Clearance mm (in)
Standard
0.076 – 0.152 (0.0029 – 0.0059)
6G – 8 TURBOCHARGER

REASSEMBLY

037M100002

Reassembly Steps
1. Turbine housing
2. Center housing
3. Gasket
4. Compressor housing
5. Lock plate and bolt
6. Actuator hose and clip
7. Actuator
TURBOCHARGER 6G – 9

Reassembly Steps
Threebond 1215
1. Turbine Housing
2. Center Housing
1) Apply Threebond 1215 or equivalent to flange
surface of compressor housing shown in the
illustration.
2) Align the setting marks (applied at disassembly) on
the center housing and rotating assembly and the
compressor housing.
Handle the parts with extreme care to avoid
damaging the compressor wheel blades.
3) Apply an anti-seizing agent (LOCTITE ANTISEIZE
LUBRICANT or the equivalent) to the new bolt
threads or the V-band threads.
4) Install the new lock plate and the bolts to the
compressor housing.
5) Tighten the bolts to the specified torque.
Compressor Housing Bolt N·m (kg·m/lb·ft)
23 (2.3/17)

3. Gasket
4. Compressor Housing
• Align the setting marks (applied at disassembly) on
the center housing and rotating assembly and the
turbine housing.
Handle the parts with extreme care to avoid
damaging the turbine shaft wheel blades.
5. Look Plate and Bolt
1) Apply an anti-seizing agent (LOCTITE ANTISEIZE
LUBRICANT or the equivalent) to the bolt.
2) Tighten the bolt to the specified torque.
Turbine Housing Bolt Torque N·m (kg·m/lb·ft)
28.0 (2.85/20.6)
3) Check that the rotating assembly turns smoothly.

6. Actuator Hose and Clip


7. Actuator
MEMO
MG6HK-WE-0221

You are requested to order this manual using the


manual number that is shown above.

This manual is applicable for vehicles in all countries


except USA and Canada.

All rights reserved. This manual may not be


reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.

Issued by

ISUZU MOTORS LIMITED

INTERNATIONAL SERVICE DEPARTMENT

Tokyo, Japan

First edition Dec., 2002 3211-01K


No. MG6HK-WE-0221 PRINTED IN JAPAN