MANUAL DE SERVICIO Motor UD CWB459

ENGINE
PF series
PF6,PF6T & PF6TA
& PF6TB
Pub.No. SMEPFS2E01
ENGINE QUICK REFERENCE INDEX
SERVICE
GENERAL GE
MANUAL
MAINTENANCE MA
TROUBLE DIAGNOSIS TD
MODEL
ENGINE DISASSEMBLY AND REASSEMBLY DR
PF series
PF6: PF6-101001 ∼ ENGINE PROPER EP
PF6T: PF6-101001T ∼
PF6TA: PF6-101001A ∼ CYLINDER HEAD AND VALVE HV
PF6TB: PF6-101001B ∼
LUBRICATION SYSTEM LB
COOLING SYSTEM EC
FUEL SYSTEM EF
FOREWORD
This manual describes the service, by system, of
the engines of PF6, PF6T, PF6TA and PF6TB mod- AIR INTAKE AND EXHAUST SYSTEM IE
els.
In order for a vehicle to perform at its best, and to
extend vehicle life, maintenance should be per- ELECTRICAL SYSTEM EE
formed properly. Also, overhaul and repair should be
effected in accordance with prescribed service stan-
dards. AUXILIARY EQUIPMENT EA
This manual should be kept readily available in the
workshop as a helpful reference for those engaged in
servicing vehicles. Nissan Diesel Motor Co., Ltd.
reserves the right to make changes for improvement
at any time without notice.
This manual is based on vehicles that were manu-
factured on or before May 1, 1996. Revisions, if any,
will be introduced in the Technical Bulletin.
FM 1st edition: Apr. 2005

1st edition: May. 1996
© 1998 NISSAN DIESEL MOTOR CO, LTD 9807K80-20009-200-SZ2(M)
HOW TO USE THIS MANUAL
X This Service Manual is designed as a guide for servicing vehicles.
X This manual deals with the engine.
X A QUICK REFERENCE INDEX is provided on the first page: Refer to this index along with the index
of the particular section you wish to consult.
X The first page of each section lists the contents and gives the page numbers for the respective top-
ics.
X SERVICE DATA AND SPECIFICATIONS are contained in each section.
X A list of SPECIAL SERVICE TOOLS is included in each section. The special service tools are
designed to assist you in performing repair safely, accurately and quickly.
X Construction illustration:
The assembled unit is indicated. The construction illustration includes the names of the major compo-
nents, items requiring adjustment after reassembling and their maintenance standards.
[EXAMPLE]
-1-
X Exploded illustration:
The number given to each part in the illustration corresponds to the number attached to each part
name, and the number is determined according to the operation sequence.
No. 1, 2, 3 Disassembly sequence
Reassembly sequence is in the reverse order of disassembly.
The marks “+” and “,” affixed to the part name number indicate that the key points of operation (pre-
cautions, technique, use of special tools, and other maintenance information) are explained in the text.
+Key points of disassembly
,Key points of reassembly
The tightening torque necessary for maintenance and lubricating points are indicated by symbols in the
illustration.
NOTE
z Disassembly and reassembly sequences show general examples and in some operations it
may be possible to change sequences.
Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1. Cover assembly , 5. Idler gear 9. Relief valve
2. Bolt 6. Spindle 10. Spring
,+ 3. Idler gear (Pump gear) 7. Case assembly 11. Seat
4. Nut 8. Split pin
Marks “+” and “,” indicate that the key points of operation are explained in the text.
-2-
X Removal and installation, disassembly and reassembly:
Explanation of removal and installation, disassembly and reassembly is limited to the parts indicated
by the star marks “+”and “,” affixed to the sequence number in the exploded illustration.
NOTE
z If there are no “+” and “,” marks affixed to the parts, general explanation is given for those
parts.
X The following marks and abbreviations are used in this manual.

Marks:
: Tightening torque
: Should be lubricated with grease. Unless otherwise indicated, use recommended multi-pur-
pose grease.
: Should be lubricated with oil.
: Sealing point
: Always replace after every disassembly.
Abbreviations
T.D.C. : Top dead center I.D. : Inside diameter
B.T.D.C. : Before top dead center Dia. : Diameter
A.T.D.C. : After top dead center S.T.D. : Standard
B.B.D.C. : Before bottom dead center O.S. : Oversize
A.B.D.C. : After bottom dead center U.S. : Undersize
O.D. : Outside diameter Ass'y : Assembly
X Engine position:
X Unit:
This manual uses mainly SI units with metric and yard/pound system equivalents in braces.
X Specific terms related to the maintenance standard
z Maintenance standard
“Maintenance standard” indicates the standard clearance when parts are assembled or the standard
performances of assembly parts.
z Service limit
“Service limit” indicates the limit value where adjustment, correction or parts replacement must be
done.
X The captions WARNING and CAUTION warn you about procedures that must be followed to pre-
vent personal injury and/or damage to some parts of the vehicle.
-3-
GE
GENERAL
CONTENTS
SPECIFICATIONS .............................. GE-1-1 PRECAUTIONS ON MAINTENANCE..... GE-3-1
ENGINE SPECIFICATIONS ...........GE-1-1 GENERAL PRECAUTIONS IN
ENGINE NUMBERS.......................GE-1-3 DISASSEMBLY ........................... GE-3-1
LUBRICATION ................................. GE-2-1 CLEANING AND INSPECTION ... GE-3-2
GENERAL PRECAUTIONS TIGHTENING TORQUE OF
ON SERVICING............................... GE-3-1 STANDARD BOLTS........................ GE-4-1
SPECIFICATIONS
SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine model
PF6 PF6T PF6TA PF6TB
Item
Type Diesel
Aspiration system Natural Turbocharged Turbocharged with intercooler
Cooling method Water cooled
Number of cylinders and cylinder arrangement 6, in-line
Stroke cycle 4
Combustion chamber Direct fuel injection
Valve mechanism Overhead
Cylinder liner Dry
Bore x stroke mm (in) 133.0 x 150.0 (5.236 x 5.906)
Total displacement cm3 (cu in) 12,503 (763)
Compression ratio 18.0 16.5
Cylinder compression 2 3,040 {31,441}/200 ± 20
kPa {kgf/cm , psi}/rpm
Maximum engine speed under full load conditions rpm 2,300
Limit speed governor 500 - 530
Idle speed rpm
All speed governor 550 - 600
Compression ring 2
Number of piston rings
Oil ring 1
Open B.T.D.C. 20º 16º
Intake valve
Closed A.B.D.C. 42º 20º
Valve timing
Open B.B.D.C. 52º 52º
Exhaust valve
Closed A.T.D.C. 12º 12º
Valve clearance Intake valve 0.30 - 0.40 (0.012 - 0.016)

mm (in) Exhaust valve 0.30 - 0.40 (0.012 - 0.016)
Lubricating method Forced lubrication
Type Gear pump
138 (30-3/8)/
Discharge amount liter (Imp gal)/rpm 174 (38-1/4)/2,300
Oil pump 2,300
Safety valve opening pressure
1,079 {11.0, 156}
kPa {kgf/cm2, psi}
Full-flow Filter paper
Type
By-pass Laminated 3-plate type
Lubricating system
Oil filter Replacement method Disassembly type

Short valve opening pressure
98 - 137 {1.0 - 1.4, 14 - 20}
kPa {kgf/cm2, psi}
Type Water cooled flat tube type
Oil cooler
Number of cores 6
Regulator valve opening pressure
392 - 432 {4.0 - 4.4, 57 - 63}
kPa {kgf/cm2, psi}
Without filter 21 (4-5/8)
Total capacity
Oil capacity With filter 29 (6-3/8)
liter (Imp gal) High 21 (4-5/8)
Oil pan
capacity Low 14 (3-1/8)
GE-1-1
SPECIFICATIONS
Engine model
Item
Cooling method Water cooled, forced circulation
Radiator Corrugated fin
Number of fins 6
Cooling fan Fan clutch change over temperature 60 - 70 60 - 70 (140 - 158) [On-off type]
Cooling system
ºC (ºF) (140 - 158) 60±10 - 75±5 (140±18 - 167±9) [Linear type]

Type Centrifugal
Water pump Drive Gear drive
Number of impellers 6
Type Wax pellet
Thermostat Valve opening temperature x Number
76.5 (169.7) x 1
ºC (ºF)
Cooling water capacity liter (Imp gal) 37 (8-1/8)
Ignition system Compression ignition
Fuel injection timing B.T.D.C. 16º 17º 16º, 14 *1 16º, 14 *2
Ignition order 1-4-2-6-3-5
Main Filter paper x 1
Fuel filter Type x Number
Primary Filter paper x 1
Type Bosch
Fuel injection Plunger diameter mm (in) 11.5 (0.453) 12.0 (0.472)

Fuel system
pump Governor Centrifugal (Mechanical RFD-C type)

Timer Centrifugal (Mechanical SP or SPG type)
Nozzle holder type Flange type
Nozzle type Multi-hole type
Number x Diameter 5 x 0.36 (0.0142),
Nozzle Nozzle holes 6 x 0.31 (0.0122) 5 x 0.35 (0.0138)
mm (in) 6 x 0.32 (0.0126)
Injection pressure 19,614
22,556 {230, 3,271}
kPa {kgf/cm2, psi} {200, 2,844}
Over flow valve opening pres- Injection pump outlet 157 {1.6, 23}
sure kPa {kgf/cm2, psi} Fuel filter 108 - 147 {1.1 - 1.5, 16 - 21}
Air cleaner Type Paper element (dry) or Metallic element
Air intake and exhaust system
Model T51
Max. permissible continuous speed
105,000
Turbocharger rpm
Counterclockwise as viewed from the exhaust turbine
Direction of rotation
side
Type Air to air
Intercooler
Intercooler Corrugated fin
Intake and Type Cylinder
exhaust shut-
ter Operation Air
NOTE
*1 CKB454, 455, CWB454, 455
*2 CKB453, CWB453, 455
GE-1-2
SPECIFICATIONS
Engine model
Item
Model S210-112, 0350 602 0260, 0350 602 0330
Starting motor Type Shift
Output V-kW 24-6.0
LR240-602, LR240-603, LR250-602, LR250-603
Model
0201 102 0290, 0201 102 2973, 0201 152 0020, 0201 152 0053
Electrical system
Alternator Type AC, diode-rectified

24-40 (LR240-602, LR240-603, 0201 102 0290, 0201 102 2973)
Output V-A
24-50 (LR250-602, LR250-603, 0201 152 0020, 0201 152 0053)
Type Ribbon
Air heater
Voltage (V) x Current (A) x Number 11.2 x 85 x 2
Model F9560W12
Auxiliary equipment
Theoretical discharge cm3 (cu in) 425 (26)
Air compressor Normal maximum discharge pressure

834 {8.5, 121}
kPa {kgf/cm2, psi}
Cooling method Water-cooled
ENGINE NUMBERS
The engine serial number is stamped on the right of the cylinder
block.
PF6—101001
PF6—101001 T
PF6—101001 A
PF6—101001 B
T: With turbocharger
A: With turbocharger and intercooler
B: With turbocharger and intercooler
Engine serial number
Engine model
GE-1-3
LUBRICATION
LUBRICATION
RECOMMENDED FUEL AND LUBRICANTS
Lubricant/Fluid Specifications Remarks
For further details, refer to the recom-
Engine oil API CC or CD
mended SAE viscosity number.
Grease NLGI No. 2 Lithium soap base
Antifreeze Ethylene glycol base
2-D Diesel fuel or equivalent
Above -7ºC (20ºF) Check with the service establishment
blended diesel fuel
Fuel to be sure you get the properly
1-D Diesel fuel or equivalent blended fuel.
Below -7ºC (20ºF)
blended diesel fuel
NOTE
z It is recommended that API CD class multi-grade oil be used as engine oil for turbocharged
engines.
RECOMMENDED SAE VISCOSITY NUMBER

Use oil having the proper viscosity beforehand which meets tem-
peratures forecast for areas where you are planning to drive.
CAPACITIES (APPROXIMATELY)
Unit: liter (Imp gal)
Item Refill capacities
System total capacity
Lubrication oil capacity 29 (6-3/8)
Engine oil (With oil filter)
(gauge H-level)
Oil pan (H-level) 21 (4-5/8)
Cooling system 37 (8-1/8)
130 (28-5/8)
200 (44)
Fuel tank 300 (66)
200 (44) + 200 (44)
300 (66) + 300 (66)
NOTE
z Capacities shown are for reference only. When filling, observe the specified level.
GE-2-1
GENERAL PRECAUTIONS ON SERVICING

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

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

Checks before disassembly
Before starting to disassemble a system or unit, familiarize yourself with the cause of the problem. For
instance, if the engine is to be disassembled, the problem may be due to an unusual noise, lack of power or oil
leakage. Recognizing the problem in advance will be extremely helpful in locating which part of the engine
needs to be disassembled and which part does not. It will also save time and labor.
Work required during disassembly
Scribe alignment marks on parts where necessary so that they can be easily reinstalled in their original posi-
tions. When repairs involve the electrical system, disconnect the ground cable from the battery.
Checks during disassembly
Whenever each part is disassembled, check for mounting condition, scratches, dirt, damage, etc. Work effi-
ciency will be degraded after all parts have been disassembled.
Keeping disassembled parts in order
Keep all disassembled parts in order so that they can be readily reinstalled. Separate parts which must be
replaced with new ones and those which should be reinstalled. Replace packings, gaskets, cotter pins, etc.
Do not touch electrical parts, rubber parts, V-belt, etc., with dirty hands. These parts should not be contami-
nated with water or oil. Keep them in one place and away from those having engine oil on them.
Cleaning disassembled parts
Clean all disassembled parts in cleaning solvent immediately before reassembly. If they are not cleaned,
scratches, cracks or damage may be overlooked. This may result in entry of dirt or dust, causing problems
after reassembly.
GE-3-1
Reinstallation
Install parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.).
Apply a coat of grease, liquid packing or sealer to designated parts.
Adjustment and operational checks
Use gauges or testers to adjust the parts within specifications if so designated. Also check movable parts for
proper operation.
CLEANING AND INSPECTION

Cleaning
The parts will be coated with dirty oil and sludge. Cleaning is mandatory. Suitable cleaning methods include
steam cleaning light oil cleaning, acidic or alkaline solution cleaning, neutral agent cleaning, trichloroethylene
steam cleaning, and magnus solution cleaning. The cleaning process may reveal damage. So check closely
while the cleaning is in process.
METAL PARTS
Light oil
Unlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless the
surface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with two
washings.
Alkaline solution
Do not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steel
and cast iron parts quite well.
NOTE
z If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent
(such as boric acid solution), since the alkaline solution must be immediately washed from the
skin or eyes in the event of contact.
RUBBER PARTS
Do not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.
OIL PASSAGES
Pass a wire through oil passages, to make sure that they are free. Clean the oil passages with solvent that is
injected under pressure from a nozzle.
PROTECTION AGAINST CORROSION
After removing all traces of old oil and grease from the surfaces of the parts, apply a coat of clean oil to them to
prevent corrosion.
INSPECTION
Parts should be inspected using designated measuring instruments or tools. Whether the parts are suitable for
further use should be determined by consulting the specified Maintenance Standards chart. Faulty parts should
be corrected or replaced as required. If one of the mating parts is found to be worn to such an extent that the
specified clearance is exceeded, replace it and/or its mate as the occasion demands.
Parts which are still within the service limit should sometimes be replaced before they exceed the limit from
preventive maintenance viewpoint.
All parts should be checked carefully by looking at their appearance or by using the “red” (penetration) method,
whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities,
the affected part(s) should be repaired or replaced, as required.
All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed.
GE-3-2
Abnormalities
z Uneven wear
z Graded wear
z Scratches
z Cracks
z Deformity
z Fatigue or weakness (for springs)
z Bends
z Loose fit
z Unusual noise (for bearings)
z Discoloration or jamming
z Rust formation
z Deterioration (for brake linings, etc.)
GE-3-3
TIGHTENING TORQUE OF STANDARD BOLTS
TIGHTENING TORQUE OF STANDARD BOLTS

The tightening torque of the bolts and other fasteners that secure the major components parts is specified in
the text. In case there is no mention of tightening torque, these bolts and fasteners should be tightened accord-
ing to the following table of bolt standard tightening torque.
NOTE
z All bolts and nuts are sized using the metric system. Do not use parts other than those designated.
Standard tightening torque (Without lubricant)

Nominal Bolt dia. Pitch
4T 7T 9T
size mm mm
N·m kgf·m ft·lbf N·m kgf·m ft·lbf N·m kgf·m ft·lbf
M3 3.0 0.5 0.7 0.07 0.5 1.1 0.11 0.8 1.6 0.16 1.2
M4 4.0 0.7 1.5 0.15 1.1 2.5 0.25 1.8 3.5 0.36 2.6
M5 5.0 0.8 2.9 0.3 2.2 5.0 0.51 3.7 7.2 0.73 5.3
M6 6.0 1.0 5.1 0.52 3.8 8.4 0.86 6.2 12 1.2 9
1.25 13 1.3 9 21 2.1 15 29 3.0 22
M8 8.0
1.0 13 1.3 9 22 2.2 16 31 3.2 23
1.5 25 2.5 18 41 4.2 30 59 6.0 43
M10 10.0
1.25 25 2.6 19 43 4.4 32 62 6.3 46
1.75 42 4.3 31 71 7.2 52 98 10.0 72
M12 12.0
1.25 46 4.7 34 77 7.9 57 108 11.0 80
M14 14.0 1.5 74 7.5 54 127 13.0 94 177 18.0 130
M16 16.0 1.5 108 11.0 80 186 19.0 137 275 28.0 203
M18 18.0 1.5 167 17.0 123 275 28.0 203 392 40.0 289
M20 20.0 1.5 226 23.0 166 382 39.0 282 549 56.0 405
M22 22.0 1.5 304 31.0 224 510 52.0 376 736 75.0 542
2.0 275 28 203 461 47 340 667 68 492
M24 24.0
1.5 284 29 210 481 49 354 686 70 506
NOTE
z Special parts are excluded.
z This standard is applicable to bolts having the following marks embossed on the bolt head.
Material code Mark
4T 4 or 40
4T 7 or 70
9T 9 or 90
Standard tightening torque of tubing connector

Item Standard tightening torque N·m {kgf·m, ft·lbf}
4.75 (0.1870) 13 - 18 {1.3 - 1.8, 9 - 13}
6.35 (0.2500) 16 - 24 {1.6 - 2.4, 12 - 17}
Tube outer diameter 8 (0.31) 29 - 39 {3.0 - 4.0, 22 - 29}
Flared nut
mm (in) 10 (0.39) 39 - 49 {4.0 - 5.0, 29 - 36}
12 (0.47) 59 - 78 {6.0 - 8.0, 43 - 58}
15 (0.59) 69 - 88 {7.0 - 9.0, 51 - 65}
Nipple nut 21 - 28 {2.1 - 2.9, 15 - 21}
Eye connector 42 - 57 {4.3 - 5.8, 31 - 42}
GE-4-1
- MEMO -
MA
MAINTENANCE
CONTENTS
SERVICE DATA................................. MA-1-1 MAINTENANCE PROCEDURE ....... MA-4-1
SERVICE DATA............................ MA-1-1 BASIC MECHANICAL SYSTEM .. MA-4-1
TIGHTENING TORQUE ............... MA-1-2 LUBRICATION SYSTEM.............. MA-4-5
TOOLS.............................................. MA-2-1 COOLING SYSTEM ..................... MA-4-9
PERIODIC MAINTENANCE FUEL SYSTEM .......................... MA-4-14
SCHEDULES................................... MA-3-1 INTAKE AND EXHAUST SYSTEM........ MA-4-24
MAINTENANCE INTERVALS....... MA-3-2 OTHERS .................................... MA-4-28
PERIODIC PARTS REPLACEMENT... MA-3-4
SERVICE DATA
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit v
0.30 - 0.40
Intake valve
Valve clearance (0.012 - 0.016)
(While cold) 0.30 - 0.40
Exhaust valve
(0.012 - 0.016)
Intake Open 20º B.T.D.C.
valve Closed 42º A.B.D.C.
PF6
Exhaust Open 52º B.B.D.C.
valve Closed 12º A.T.D.C.
Valve timing
Intake Open 16º B.T.D.C.
PF6T valve Closed 20º A.B.D.C.
PF6TA
PF6TB Exhaust Open 52º B.B.D.C.
valve Closed 12º A.T.D.C.
Cylinder compression pres- PF6, PF6T, PF6TA 3,040 {31, 441} 2,059 {21, 299}
sure At 180 - 220 rpm
2 PF6TB 3,040 {31, 441} 1,961 {20, 284} (With engine warm)
kPa {kgf/cm , psi}
Compression pressure difference
Less than 392 {4, 57}
kPa {kgf/cm2, psi}
Open water tank cap valve pressure 49 - 69
Pressure side
kPa {kgf/cm2, psi} {0.5 - 0.7, 7 - 10}
8 - 12
Fan pulley - Tension pulley With a force of about 98 N
Deflection of (0.31 - 0.47)
{10 kgf, 22 lbf} applied to
V-belt Idler (cooler compressor) pulley 15 - 18 the mid part
- Alternator pulley (0.59 - 0.71)
Valve opening temperature 74.5 - 78.5 73.0 - 80.0
ºC (ºF) (166 - 173) (163 - 176)
Thermostat
More than More than
Valve lift mm (in)/ºC (ºF)
10 (0.39)/90 (194) 8.5 (0.335)/90 (194)
PF6 16º
PF6T 17º
Fuel injection timing Type I 16º

PF6TA
B.T.D.C. *1 Type II 14º
Type I 16º
PF6TB
*2 Type III 14º
Limit speed governor 500 - 530
Idle speed rpm
All speed governor 550 - 600
NOTE
z CKB454, 455, CWB454, 455
z CKB453, CWB453, 455
MA-1-1
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque Remarks
Valve clearance adjusting screw lock nut 34 - 44 {3.5 - 4.5, 25 - 33}
1st 88 - 98 {9.0 - 10.0, 65 - 72} Snug torque
Cylinder head bolt L = 147 mm (5.79 in) 85º - 95º Tightening angle
2nd
L = 119 mm (4.69 in) 70º - 80º Tightening angle
1st 34 {3.5, 25}
Cylinder head sub bolt
2nd 44 - 54 {4.5 - 5.5, 33 - 40}
Intake manifold nut 49 - 54 {5.0 - 5.5, 36 - 40}
Exhaust manifold nut 29 - 44 {3.0 - 4.5, 22 - 33}
Crank damper bolt 98 - 108 {10.0 - 11.0, 72 - 80}
Oil pan drain plug 98 - 127 {10.0 - 13.0, 72 - 94}
Center bolt 49 - 59 {5.0 - 6.0, 36 - 43}
Full-flow and bypass oil filter
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
Injection pump coupling mounting Coupling bolt 59 - 64 {6.0 - 6.5, 43 - 47}

bolt Cotter bolt 83 - 93 {8.5 - 9.5, 61 - 69}
Nozzle retaining nut 59 - 78 {6.0 - 8.0, 43 - 58}
Fuel filter center bolt 20 - 29 {2.0 - 3.0, 14 - 22} Center bolt type
Center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Primary fuel filter
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
9 - 11.3
Turbocharger compressor housing clamp mounting bolt
{0.92 - 1.15, 6.7 - 8.3}
MA-1-2
TOOLS
TOOLS
Tool name and number Description Shape
Feeler gauge For adjusting valve clearance
99541 Z5000 Thickness mm (in)
0.25 (0.0098), 0.3 (0.012), 0.35 (0.0138), 0.4
(0.016), 0.45 (0.0177), 0.5 (0.020)
Feeler gauge For adjusting valve clearance

99541 Z0001 Thickness mm (in)
0.2 (0.008), 0.3 (0.012), 0.4 (0.016)
Timing plate For measuring valve timing

99646 Z5001 (Type I)
NOTE
99646 Z0000 (Type II)
z The tool number can be identified by the
crankshaft tip design.
Compression gauge For measuring compression pressure

99640 96000
Compression gauge hose Used with the compression gauge (99640 96000)
99644 97000 when the gauge cannot
be installed directly due to interference with the air
duct, etc.
Plate For fixing nozzle holder

157944-9520
NOTE
z Tool number designated by ZEXEL COR-
PORATION
MA-2-1
TOOLS

Pin vice For cleaning nozzle orifice
99727 Z5005
Nozzle cleaner For removal of carbon from rear of nozzle orifice

99726 Z5000
Filter wrench For removal of fuel filter

99755 00Z01 (Only when replacing cartridge type element)
MA-2-2
MAINTENANCE SCHEDULES
Abbreviations:
I = Inspect. Correct, adjust or replace if necessary.
A = Adjust R = Replace C = Cleaning
RB = Rebuilding T = Tighten to specified torque F = Initial maintenance
NOTE
z The maintenance or lubrication services shown below are to be performed at the indicated
intervals (km, miles or months, whichever occurs first).
z Scheduled maintenance services beyond 60,000 miles (36,000 km) or 12 months should be con-
tinued at the same intervals as before except the initial maintenance.
z Under the following severe operating conditions, more frequent servicing will be required.
— Operation in heavy dust conditions
— Operation at extremely low or high ambient temperature
— Extended high-speed operation with vehicle fully-loaded to its GVWR
— Extended low-speed operation
— Frequent stop-and-go operation
z Any replacement parts used for required maintenance service or repairs should be genuine
parts or equivalent in quality and design to genuine parts.
EMISSIONS CONTROL SYSTEMS MAINTENANCE (FOR TAIWAN ONLY)

To maintain efficient emissions control systems operation, have the maintenance services shown in this sec-
tion performed at the intervals indicated.
CAUTION
z Do not modify, alter, disconnect or remove any part of
the vehicle which could affect, directly or indirectly, vehi-
cle emissions.
MA-3-1
MAINTENANCE INTERVALS
Maintenance intervals
Kilometers x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Items Remarks
Miles x 1,000 Daily 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months – 1 2 3 4 5 6 7 8 9 10 11 12
Valve clearance I I
Manifold bolts T T
I : After 200,000 km (125,000 miles)
Crank damper
I : Every 100,000 km (60,000 miles)
Cylinder compression pressure I
Oil leakage I I I I I I I I I I I I I I
Oil level and contamination I I I I I I I I I I I I I I
Engine oil and Oil R R: Every 10,000 km (6,000 miles) or 6 months (1)
filter
Oil filter R: Every 10,000 km (6,000 miles) or 6 months (1)
Coolant leakage I I I I I I
Coolant level I I I I I I I I I I I I I
Coolant (incl. anticorrosive) R R (3)
Coolant (incl. antifreeze) R (4)
Water tank cap I
Fan clutch I
V-belt I I I I I I I I I I I I I
Thermostat I
Injection timing I
Nozzle (injection pressure and pat-
I
tern)
Fuel leakage I I I I I I I I I I I I I I
I I I I I I
Fuel filter (6)
Drain Drain Drain Drain Drain Drain
Fuel filter element R
I I I I I I I I I I I I
Primary fuel filter
Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain
Primary fuel filter element R R
Fuel level I
Air cleaner element I/C I/C I/C I/C I/C I/C (2)
Air cleaner element (Dry type) R (2)
Air cleaner element (Metallic type) R: Every 3 years (2)
Condition of exhaust I I I I I I I I I I I I I
Exhaust tubing and muffler I I I I I

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

Maintenance intervals
Kilometers x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Items Remarks
Miles x 1,000 Daily 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months – 1 2 3 4 5 6 7 8 9 10 11 12
*Idle speed I
Acceleration and deceleration I
*Air intake system (duct, hose and
I I I I I I
clamp)
Intake* and exhaust manifold I I

*Air cleaner element I/C I/C I/C I/C I/C R
Cylinder compression pressure I
*Valve clearance I A
*Engine oil and
Oil CD class R Every 10,000 km (6,000 miles) or 6 months: R
oil filters
Oil level and contamination I I I I I I I I I I I I I I

Oil pressure I
Coolant and fuel level I I I I I I I I I I I I I
Coolant, oil and fuel leakage I I I I I I
Strainer (if equipped) I

*Fuel filter element R
*Primary fuel filter element I I I I I I I I I I
R R
(if equipped) Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain
*Governor setting (checking seals) Every 30,000 km (18,000 miles) or 6 months: I
*Nozzle (injector tip) Every 80,000 km (50,000 miles): C
*Nozzle holder (injector) Every 240,000 km (145,000 miles): RB
*Injection pump timing Every 60,000 km (36,000 miles) or 12 months: I
Fuel tubing I
Accelerator linkage I
Drive belt I I I I I I I I I I I I I
Crank damper Every 100,000 km (60,000 miles): I
Cooling system (hose and clamp) I
Engine coolant R
Water filter (if equipped) R
Thermostat I
Fan clutch I
Fan and fan shroud I
Exhaust tubing and muffler I I
Alternator I
Starter I
*Turbocharger Every 240,000 km (145,000 miles): C
Condition of exhaust I I I I I I I I I I I I
Cylinder head bolt T
Water tank cap I
“*” refers to items related to the Emission Control System Maintenance.
MA-3-3
PERIODIC PARTS REPLACEMENT

Periodic replacement parts are rubber parts such as brake hose and fuel hose which require maintenance and
deteriorate over time. It is necessary to periodically replace these parts in order to maintain driving safety.
PERIODIC PARTS REPLACEMENT INTERVAL

Items Remarks
Number of years 1 2 3 4 5 6 7 8 9 10
Fuel hose (engine side) R R R R R
Fuel hose (fuel tank side) R R
Air compressor rubber hose R R R R R
MA-3-4
MAINTENANCE PROCEDURE
BASIC MECHANICAL SYSTEM
VALVE CLEARANCE
NOTE
z Ensure the engine is cool when checking and adjusting
the valve clearance.
1. Align the flywheel housing pointer with the stamp on the fly-
wheel.
NOTE
z When turning the flywheel to align the stamp, turn it
counterclockwise when viewed from behind the engine.
2. When the stamps on the injection pump housing and timer
are close to each other, it indicates T.D.C. on the compres-
sion stroke. When they are located opposite to each other, it
indicates T.D.C. on the exhaust stroke.
3. Using a feeler gauge, inspect the valves indicated by a cir-

cle in the following chart in sequence.
NOTE
z The cylinders and valves are numbered as starting from
the side of the fan.
Unit: mm (in)
Item Maintenance standard Service limit
Valve clear- Intake valve 0.30 - 0.40 (0.012 - 0.016)
ance (While
cold) Exhaust valve 0.30 - 0.40 (0.012 - 0.016)
IN: Intake valve EX: Exhaust valve

Cylinder number 1 2 3 4 5 7
1 2 3 4 5 6 7 8 9 10 11 12
Valve arrangement
IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 piston at TDC on com-
O O O O O O
pression stroke
No. 6 piston at TDC on com-
O O O O O O
pression stroke
4. In the valve clearance is not within the specified range,

loosen the lock nut located at the tip of the rocker arm and
adjust the adjusting screw with a standard screw-driver.
After properly adjusting, tighten the lock nut and re-check
the valve clearance.
Lock nut
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
MA-4-1
Valve clearance adjustment

1. If the valve clearance is not correct, loosen the lock nut for
the adjusting screw and adjust the screw until the specified
clearance is obtained.
2. After adjusting the valve clearance, hold the adjusting
screw and tighten the lock nut.
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
3. Recheck the valve clearance.

4. Rotate the flywheel one complete turn until the mark “1·6” is
aligned with the pointer. Next, check and adjust the remain-
ing valve clearances.
If the engine operates erratically or vibrates even though
the valve clearances are properly adjusted, problems may
be due to improperly adjusted valve timing which results
from incorrect assembling of the timing gear train, etc. If
erratic operation is noticed, check the valve timing as
described below.
Procedure for checking valve timing

1. Remove the V-belt, cooling fan and crank pulley assembly.
2. Turn the flywheel in the normal direction until the No. 1 pis-
ton is at the top dead center on the compression stroke.
NOTE
z If the flywheel has been rotated excessively, rotate it
backwards beyond the desired position then gradually
rotate it back in the normal direction until it is set in the
proper position.
3. Attach the timing plate (99646 Z5001 or 99646 Z0000) to

the end of the crankshaft. Also attach a needle pointer utiliz-
ing the front cover mounting bolt, and align the needle to
“0”.
4. Set a dial gauge so that the contact arm is in contact with
the upper valve spring seats of the intake valve and exhaust
valve.
MA-4-2
5. If the needle of the dial gauge begins to move, it means that

the valve is beginning to open; the movement of the needle
will stop as the valve closes. Read the needle position on
the timing plate on each occasion.
PF6T
Item PF6 PF6TA Remarks
PF6TB
Intake Open 20º B.T.D.C. 16º B.T.D.C. 1
Valve tim- valve Closed 42º A.B.D.C. 20º A.B.D.C. 2

ing Open 52º B.B.D.C. 52º B.B.D.C. 3
Exhaust
valve Closed 12º A.T.D.C. 12º A.T.D.C. 4
CYLINDER HEAD AND MANIFOLD BOLTS

Cylinder head bolts
Tightening of cylinder head bolts is specified by the tightening
angle (snug torque). It is not necessary to additionally tighten
cylinder head bolts.
Intake and exhaust manifolds

Check the intake and exhaust manifold mounting bolts and nuts for
proper torque. Also check the manifolds for damage or traces of
leakage at the cylinder head connections.
Intake manifold
: 49 - 54 N·m {5.0 - 5.5 kgf·m, 36 - 40 ft·lbf}
Exhaust manifold
: 29 - 44 N·m {3.0 - 4.5 kgf·m, 22 - 33 ft·lbf}
NOTE
z Tighten the nuts evenly to the specified torque, starting
from the inside then to the outside.
MA-4-3
CRANK DAMPER
Check the crank damper for cracks or flaking, and the mounting
bolts for looseness. Replace faulty parts if necessary.
Crank damper
: 98 - 108 N·m {10.0 - 11.0 kgf·m, 72 - 80 ft·lbf}
NOTE
z Be careful not to confuse peeling paint for cracks.
CYLINDER COMPRESSION PRESSURE

1. Warm up the engine.
2. Disconnect all nozzle tubes and remove all nozzle holders.
Refer to the “DR” section for details.
3. Install the compression gauge (99640 96000) to the cylin-
der head with a tightening torque of 25 to 29 N·m {2.5 to 3.0
kgf·m, 18 to 22 ft-lbf} with the nozzle holder in place. Press
the gauge bleeder to set the pointer to “zero”.
If the gauge interferes with surrounding parts, connect a
specially designed hose (99644 97000) between the gauge
and gauge holder to avoid interference.
NOTE
z Be careful to prevent foreign matter from getting into the
other nozzle holder holes.
z Be sure to remove the old nozzle holder gasket.
4. Move the engine stop lever completely in the “FUEL CUT”
direction and hold it at that position.
5. Crank the engine with the starting motor. Stop cranking the
engine when the gauge pointer stabilizes. Read the cylinder
compression pressure.
Measure compression pressure for the remaining cylinders
as described above. If the measured values or the differ-
ences in compression pressure between cylinders are not
within specifications, pistons and/or piston rings may be
worn or the valve mechanism may be faulty. Overhaul the
engine and repair as necessary.
Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit Remarks
PF6 At 180 - 220
Cylinder 3,040 {31, 441}
PF6T 2,059 {21, 299} rpm
compression PF6TA (With engine
pressure
PF6TB 3,040 {31, 441} 1,961 {20, 284} warm)
Compression Less than

pressure difference 392 {4, 57}
MA-4-4
NOTE
z Measure the cylinder compression pressure with the
engine warm. Measure each cylinder two or three times
and average the measured values. Use the average value
as a reference value. Measurement should be done in all
the cylinders.
LUBRICATION SYSTEM
ENGINE OIL LEAKAGE
Check the cylinder head, front cover, oil pan, oil filters and other
related parts for sign of leakage. If necessary, replace gaskets.
After replacing the gasket, check that point to ensure there is no
leakage.
ENGINE OIL LEVEL AND CONTAMINATION

WARNING
WARNING
z To help avoid serious personal injury from hot engine oil,
perform lubrication system checks and maintenance
only after the engine has cooled.
Check the engine oil level and contamination of engine oil before
driving vehicle each day and when you stop for fuel. Check the oil
level and contamination of engine oil with the engine off. When
checking the oil level after stopping the engine, wait at least 6 min-
utes to allow the oil to return to the oil pan.
To check the engine oil level

1. Park the vehicle on a flat surface.
2. Open the front lid and remove the oil dipstick. Wipe the dip-
stick clean with an oil rag and reinsert it. Remove the dip-
stick and check the oil level. Maintain the oil level between
the high and low marks on the dipstick.
MA-4-5
3. If oil level is low, add engine oil of the proper viscosity for
the anticipated temperature range during the service inter-
val through the oil filler port on the valve cover. After adding
oil, wait at least 6 minutes, then recheck the oil level. Do not
add oil above the high mark on the dipstick.
CAUTION
z Do not drive the vehicle with the oil level below the low
mark on the oil dipstick. An insufficient quantity of
engine oil can cause engine seizure.
z Use care to keep dirt and debris from entering the crank-
case through the oil filler port when adding engine oil.
Avoid spilling oil. Clean up any engine oil that spills acci-
dentally.
NOTE
z To check the oil level and to add oil while the cab is being
tilted, there is a sub oil dipstick and oil filler.
To check the engine oil for contamination

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

Engine oil
WARNING
WARNING
z To help avoid serious personal injury from hot engine oil,
perform lubrication system checks and maintenance
only after the engine has cooled.
The engine oil and oil filter change interval varies with the type of
engine oil used and vehicle driving conditions. If the vehicle is
driven for extended periods of time at high or low speeds, in dusty
areas, with frequent idling or carrying heavy loads, engine oil will
deteriorate faster and require more frequent changing.
As the temperature rises, the engine oil's viscosity decreases,
reducing its lubricating effect. To choose an oil with the proper vis-
cosity for the anticipated ambient temperature range, refer to the
viscosity chart in the “GE” section of this manual.
MA-4-6
To change the engine oil

1. Loosen the oil filler cap.
2. Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly. (if equipped)
3. Place a container under the drain plugs in the bottom of the
oil pan and oil filter. Remove the plugs and drain the oil into
the container.
4. When all the oil has been drained from the oil pan and oil fil-
ter, replace the drain plugs in the drain hole and tighten the
drain plugs.
Oil pan drain plug
: 98 - 127 N·m {10.0 - 13.0 kgf·m, 72 - 94 ft·lbf}
5. Replace the oil filter. See the instructions under the caption
OIL FILTER.
6. Add engine oil through the oil filler port to the specified
level.
Refer to the oil capacities in the “GE” section of this manual.
7. After refilling the engine oil, wait for at least 6 minutes, then
using the dipstick check the oil level. If the oil level is low,
add additional oil. Wait 6 minutes, then recheck the oil level.
Repeat this procedure until the engine oil reading on the
dipstick is between the high and low marks.
8. Install the engine undercover (if equipped).
Oil filter
WARNING
WARNING
z Do not handle hot oil filter without hand protection. Fail-
ure to do so may result in burn injury.
NOTE
z Use genuine filter or equivalent in quality and design.
z Always replace the oil filter at the same time engine oil is
replaced.
MA-4-7
To replace the filter

1. Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly (if equipped).
2. Place a container under the oil filter and remove the drain
plug in the bottom of the oil filter. Drain oil from the filter.
3. Loosen the center bolt, and remove the filter case, element
and other parts.
Full-flow oil filter

1 Drain plug 6 Set spring
2 Packing 7 Element
3 Center bolt 8 Packing
4 Packing 9 Filter body
5 Filter case
Bypass oil filter

1 Drain plug 6 Seat
2 Packing 7 Element
4 Filter case 9 Filter body
5 Set spring
MA-4-8
4. Clean all filter parts, except the element, in cleaning fluid.

5. Discard the old element, and insert the new element and
packing.
6. Reassemble each part correctly.
Center bolt
: 49 - 59 N·m {5.0 - 6.0 kgf·m, 36 - 43 ft·lbf}
Drain plug
: 16 - 22 N·m {1.6 - 2.2 kgf·m, 12 - 16 ft·lbf}
7. Pour engine oil into the filter, start the engine and check all
parts of oil filter for signs of oil leakage.
NOTE
z Do not excessively tighten the center bolt.
8. Install the engine under cover (if equipped).
COOLING SYSTEM
WARNING
WARNING
z To help avoid serious personal injury from hot coolant or
steam release:
z Do not open the water tank cap while the engine cooling
system is hot. Wait until it cools down.
z Be extremely careful when opening the water tank cap.
Place a thick cloth on the cap and slowly loosen it to
allow a reduction in pressure in the cooling system.
COOLANT LEAKAGE
Check the cooling system for leakage, especially at tube and hose
connections. Also check piping for fractures, cracks or damage.
Replace parts if faulty.
If water leaks through the small hole in the water pump body, the
water seal may be faulty.
Replace the water pump with a new one.
COOLANT LEVEL
Check the coolant level daily only when the engine is cool.
Check the coolant level in the coolant reservoir tank located in rear
of the cab.
The coolant level should be between the HIGH and LOW lines. If
the coolant level is below the LOW line, add the proper coolant
solution to the HIGH line.
MA-4-9
CAUTION
z Antifreeze made with methoxy propanol or propylene
glycol is not recommended for use with Nissan Diesel
engines. These types of antifreeze can damage engine
internal seals and coolant hoses and create a potential
fire hazard due to lower flash points than ethylene glycol
type antifreeze.
z Use only municipally supplied water (tap water) in the
cooling system. River, well or other water produces scale
in the cooling system, which may cause damage to the
engine or cooling system.
z Do not add water without adding ethylene glycol anti-
freeze to the engine cooling system, except in an emer-
gency. If plain water is added in an emergency, restore
the proper mixture of antifreeze and water as soon as
possible.
z If the coolant should get extremely low and the engine
very hot, let the engine cool before adding coolant; then,
with the engine running, add coolant slowly. Adding cold
coolant to a hot engine may crack the cylinder head or
crankcase. Never use water alone.
CHANGE COOLANT AND CLEAN INSIDE

Point of change and flushing
Flush the interior of the cooling system whenever any heavy con-
tamination in the coolant is noticed. Flushing removes water scale
and fat from the cooling system, and restores its original cooling
efficiency, which greatly reduces the possibility of the engine over-
heating.
Flushing procedure
<To clean the cooling system>
The cooling system must be flushed when the coolant temperature
is higher than 80ºC (176ºF) and the engine is run at high idle. If the
water temperature is too low, the thermostat will remain closed, and
the flushing agent will not circulate in the radiator, so no flushing
effect will occur.
MA-4-10
1. Set the heater control temperature lever to the HOT posi-

tion.
2. Open the water tank cap.
3. Drain the cooling water from the radiator drain cock com-
pletely.
4. Close the drain cock, and pour city water and flushing agent
into the radiator.
5. Run the engine at high idling speed (refer to the flushing
agent manufacturer's instruction). Cover the front end of the
radiator to prevent the temperature of the fluid in the cooling
system from dropping. Observe the fluid level carefully for
five minutes after starting the engine. If it lowers, add city
water.
6. After flushing, stop the engine, and thoroughly drain the
fluid from the radiator drain cock.
7. Close the drain cock, and add fresh city water. Start the
engine and run it at high idle until the water temperature
goes above 80ºC (176ºF). Then stop the engine, and drain
the water from the drain cock once again. Repeat this oper-
ation two or more times, until only clean water is discharged
from the drain cock. Dirty or colored water from the drain
cock means that fat or scale is still in the cooling system.
8. After completing the flushing operation, close the radiator
drain cock securely, and add fresh city water with antifreeze
(or anticorrosive) up to the specified level. Then start the
engine, and purge the air from the system until the coolant
level is stabilized at the specified position. If the coolant
level lowers during this operation, add fresh city water with
antifreeze (or anticorrosive).
WATER TANK CAP

Attach the water tank cap to a cap tester, and measure the operat-
ing pressure of the water tank cap valve. Replace the water tank
cap if faulty.
Maintenance standard Service limit Remarks
49 - 69 {0.5 - 0.7, 7 - 10} Pressure side
MA-4-11
FAN CLUTCH
Ensure that the engine is off when checking the fan clutch.
1. Check the fan clutch for oil leakage. If leakage is present,
replace the fan clutch assembly.
2. Check the fan clutch for proper operation:
z Rotate the cooling fan by hand (adjacent parts should be
cool) to ensure it moves smoothly without binding.
z Then, start the engine and operate it until the pointer of the
water temperature gauge stays within the “H” range. Stop
the engine to ensure that the cooling fan no longer rotates
by hand.
NOTE
z The fan clutch operates in a manner similar to a “direct
drive” when the temperature of parts near the bimetal
located at the front center of the clutch reaches approxi-
mately NºC (NºF). For this reason, it is best to measure
the temperature of those parts to assure proper mainte-
nance during inspection.
Unit: ºC (ºF)
Run the engine con- Operating temperatures
Item
tinuously (N)
FD1800L 2,500 rpm
FD2000 On-off type 2,300 rpm 65±5 (149±9)
FD2000-C 2,300 rpm
60±10 - 75±5
FDL2000-C Linear type 2,300 rpm
(140±18 - 167±9)
FAN AND FAN SHROUD

Check the cooling fan and fan shroud for proper installation, cracks
or damage. Replace faulty parts.
CAUTION
z Do not put your hand near the fan when the engine is
operated.
MA-4-12
V-BELT
Be sure the engine is off and the transmission is in “Neutral”.
Engage the parking brake securely.
Visually check the V-belt daily for cracks and damage. If the belt is
cracked or damaged excessively, replace it.
Also check that the belt does not come in contact with the bottom of
the pulley groove.
Check the belt tension by applying approximately 98 N {10 kgf, 22
lbf} force to the belt midway between the fan [or idler (cooler com-
pressor)] pulley and the tension (or alternator) pulley.
Unit: mm (in)
Fan pulley - Tension pulley 8 - 12 (0.31 - 0.47)
Idler (cooler compressor) pul-
15 - 18 (0.59 - 0.71)
ley - Alternator pulley
To adjust V-belt deflection

1. Loosen the lock nuts.
2. Turn the adjusting nut so that the belt deflection is the spec-
ified value when pushed midway between the fan [or idler
(cooler compressor)] pulley and tension (or alternator) pul-
ley by a force of 98 N {10 kgf, 22 lbf}.
Unit: mm (in)
Fan pulley - Tension pulley 8 - 12 (0.31 - 0.47)
Idler (cooler compressor) pul-
15 - 18 (0.59 - 0.71)
ley - Alternator pulley
NOTE
z The cooler compressor and alternator are driven by a
common belt. Malfunction of the cooler compressor
while in motion results in a defective charging system.
Be sure to check for the proper belt tension or the proper
operation of cooler compressor (there should be no
noise while in operation) and also conduct a cooler gas
check.
3. Tighten the lock nuts.
THERMOSTAT
1. Drain coolant completely. Refer to “CHANGE COOLANT
AND CLEAN INSIDE” for procedures.
2. Disconnect the radiator hose from the water outlet, then
remove the water outlet and rubber ring.
3. Remove the thermostat.
1 Water outlet 4 Thermostat housing
2 Thermostat 5 Rubber ring
3 Rubber ring
MA-4-13
4. Check the thermostat as described below, and replace if

faulty.
z Ensure that the valve contacts the seat at room tempera-
ture.
z Check the valve opening temperature and the “lift” of the
valve.
A Bar thermometer C Thermostat holder
B stirring rod D Heat source

ºC (ºF) (166 - 173) (163 - 176)
Valve lift Greater than 8.5 (0.335)/90
mm (in)/ºC (ºF) 10 (0.39)/90 (194) (194)
5. Install the thermostat, the outlet and the gasket. Connect

the upper radiator hose.
6. Add coolant to the radiator. Refer to “CHANGE COOLANT
AND CLEAN INSIDE” for procedures.
FUEL SYSTEM
WARNING
WARNING
Observe the following when removing parts of the fuel sys-
tem:
z Post a placard that reads: “CAUTION: FLAMMABLE''.
z Prepare a fire extinguisher.
z Disconnect the ground terminal from the battery.
GOVERNOR SETTING (CHECKING SEALS)

Ensure that the parts shown in the figure below are secured with
sealing caps and wires. If the cap or wire is broken, check and
adjust the injection pump and governor.
CAUTION
z Any unauthorized adjustments in the injection pump and
governor settings, other than as specified, can cause
serious damage to the engine.
MA-4-14
INJECTION TIMING
1. Remove the pointer cover. Secure the pointer to the fly-
wheel housing using bolts.
2. Crank the engine in the standard direction by turning the fly-
wheel with a lever until the pointer is aligned with the timing
mark.
NOTE
z If the mark goes past the pointer, move it back past the
pointer and turn again in the standard direction until
alignment is made.
Maintenance
Item Service limit Remarks
standard
PF6 16º 1
PF6T 17º 2
Fuel injection timing 16º 3

PF6TA
(B.T.D.C.) 14º 4 *1
16º 5
PF6TB
14º 6 *2
NOTE
z *1 CKB454, 455, CWB454, 455
z *2 CKB453, CWB453, 455
3. If the timer marks are not aligned as shown in the figure,

adjust as follows:
MA-4-15
Adjustment of fuel injection timing

1. Make sure the pointer points to the specified injection timing
graduation on the outer periphery of the flywheel and
Loosen the coupling bolts (2 places).
2. Back the timer off a little in the reverse direction of the nor-
mal timer direction. Turn the timer in the normal direction to
adjust the pointer to the mark.
3. Tighten the coupling bolts and cotter bolt.
Coupling bolt
: 59 - 64 N·m {6.0 - 6.5 kgf·m, 43 - 47 ft·lbf}
Cotter bolt
: 83 - 93 N·m {8.5 - 9.5 kgf·m, 61 - 69 ft·lbf}
IDLE SPEED
NOTE
z When checking engine idle speed ensure that the engine
idle control knob inside the cab is set to the low-speed
position.
1. Start the engine and warm it up to the normal operating
temperature.
2. Allow the engine to idle and observe the engine speed on
the tachometer.
3. If idle speed is not within specified range, adjust as follows:
NOTE
z If equipped with an air conditioner, the air conditioner
switch must be turned off when checking idle speed.
Unit: rpm
Maintenance
standard
500 - 530 Limit speed governor
Idle speed
550 - 600 All speed governor
MA-4-16
Idle speed adjustment

1. Loosen the lock nut on the idle adjusting bolt.
2. Turn the idle adjusting bolt to obtain the correct idle speed.
3. Tighten the lock nut on the idle adjusting bolt.
NOTE
z Accelerate the engine two or three times. Allow the
engine to return to idle speed and observe the tachome-
ter reading. If the idle speed is not within the specified
range, check the accelerator linkage for binding and
repeat idle adjustment.
ACCELERATION AND DECELERATION

1. Start the engine and warm it up to the normal operating
temperature.
2. Depress the accelerator pedal to ensure the engine speed
increases smoothly from idle to the maximum and that it
returns to idle.
NOTE
z If the engine does not accelerate smoothly, disengage
the accelerator linkage from the injection pump and
operate the fuel control lever of the injection pump to
check engine acceleration. If engine rotates smoothly,
the accelerator linkage may be faulty. Check and repair
the linkage. If engine operation is erratic, the injection
pump or governor may be faulty. Check and repair these
parts.
ACCELERATOR LINKAGE
Check accelerator linkage for bent rods, interference with adjacent
parts or looseness.
NOZZLE (INJECTOR PRESSURE AND PATTERN)

Cleaning nozzle
1. Remove the nozzle holder assembly from the engine. Refer
to the “ENGINE DISASSEMBLY AND REASSEMBLY” sec-
tion for details.
2. Clamp the nozzle holder in a vise with a holder plate
(157944-9520).
NOTE
z 157944-9520 is the assembly number of the nozzle holder
plate which is detailed in the “EF” section.
MA-4-17
3. Loosen the retaining nut, and then remove the nozzle from
the nozzle holder. Do not drop the nozzle needle.
4. Pull the nozzle needle from the nozzle body.

NOTE
z Do not use the nozzle needle in another nozzle body.
5. Remove carbon from around the openings by using the cor-
ner of a hard piece of wood. Do not use waste or any other
material to push carbon into the openings.
6. Removing carbon in openings

Use the pin vice (99727 Z5005) and wire to clean the open-
ings.
Unit: mm (in)
Nozzle identifica- Number of injec- Injection nozzle
Wire diameter
tion mark tion nozzle holes hole diameter
F8 6 0.310 (0.0122) 0.29 (0.0114)
H4 5 0.350 (0.0138) 0.29 (0.0114)
H2 5 0.360 (0.0142) 0.35 (0.0138)
H5 6 0.315 (0.0124) 0.29 (0.0114)
K1 6 0.320 (0.0126) 0.29 (0.0114)
z Allowing too much wire to protrude at the tip of the holder

will permit the wire to bend inside the nozzle, in which case
withdrawal proves difficult. The wire should protrude no
more than 2.0 to 2.5 mm (0.079 to 0.098 in).
z Carefully push the carbon into the nozzle. Too much force
will bend the wire. Proceed slowly.
z Remove carbon at the inside end of the openings with the
nozzle cleaner (99726 Z5000).
Exercise care to avoid damaging the surface which the noz-
zle needle contacts. The use of compressed air may clog
the openings with foreign particles.
Tighten the retaining nut.
: 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf}
MA-4-18
NOZZLE HOLDER (INJECTOR)

Rebuild the nozzle holder at the specified interval. Check and
adjust the nozzle opening pressure and spray pattern. Refer to the
“EF” section for rebuilding procedures.
WARNING
WARNING
z Fuel from the injection nozzle is injected under extremely
high pressure. If it is directed at your hand, etc., serious
injury may result KEEP YOUR HANDS AWAY FROM THE
NOZZLE DURING TESTS.
FUEL TUBING
Check the fuel rubber hose and clamp of the fuel system for instal-
lation, cracks or damage.
Replace faulty parts if necessary.
Check the fuel tubing for fractures, damage or improper installation.
Replace faulty parts if necessary. Whenever the fuel tubing is dis-
connected, be sure to bleed air from the fuel system.
FUEL LEAKAGE
Check the fuel system for leakage at tube or hose connections.
FUEL FILTER ELEMENT

NOTE
z Use genuine filter or equivalent in quality and design.
Replacing fuel filter element

<Center bolt type>
1. Place a container under the drain cock, and drain the fuel
and sediment. CX-105E
2. Loosen the center bolt, and remove the filter case, spring
and element.
3. Clean each part in light oil.
4. Replace the element and packings.
MA-4-19
5. Reassemble each part correctly, and after reassembly, be

sure to bleed air from the fuel system.
Center bolt
: 20 - 29 N·m {2.0 - 3.0 kgf·m, 14 - 22 ft·lbf}
NOTE
z Do not excessively tighten bolts and plug.
1 Drain plug 6 Spring
2 Packing 7 Seat
3 Center bolt 8 Element
4 Packing 9 Packing
5 Filter case 10 Filter cover
6. Purge air from the fuel system.
<Cartridge type>
1. Place a container under the filter. Remove the filter with a
filter wrench (99755 00Z01). Drain any remaining fuel into
the container.
2. Apply a thin coat of clean engine oil to the gasket of the new
filter.
WARNING
WARNING
z Installation of the fuel filter without coating the gasket
with oil may damage the gasket resulting in loss of fuel
and fire hazard due to spilled fuel.
3. Install the new fuel filter by hand. After the gasket comes in
contact with the bracket sealing surface, tighten an addi-
tional three-fourths of a turn.
4. After installing the filter, purge air from the fuel system and
check for fuel leaks.
Bleeding air from the fuel system

Refer to “PURGING AIR FROM FUEL SYSTEM”.
MA-4-20
PRIMARY FUEL FILTER

Draining sediment from primary fuel filter
NOTE
z It is not necessary to drain all the fuel in the primary fuel
filter case.
Place a container under the filter, then loosen the drain plug to
drain sediment.
Bleed air from the fuel system after draining sediments and tighten-
ing the drain plug.
: 16 - 22 N·m {1.6 - 2.2 kgf·m, 12 - 16 ft·lbf}
Replacing primary fuel filter element

1. Place a container under the drain plug, and drain the fuel
and sediment.
and element.
Center bolt
: 59 - 69 N·m {6.0 - 7.0 kgf·m, 43 - 51 ft·lbf}
NOTE
z Do not excessively tighten bolts and plugs.
1 Drain plug 7 Seat

2 Packing 8 Element
4 Packing 10 Filter cover
5 Filter case 11 Filter plug
6 Spring 12 O-ring
MA-4-21
PURGING AIR FROM FUEL SYSTEM

Air entrapped in the fuel system will cause poor injection of the fuel,
thus resulting in difficult starting, jerking, or even stoppage of the
engine. After completing any service procedure on fuel system
(replacement of fuel filter element, or reconnection of any fuel pipe),
be sure to bleed air from the fuel system.
Procedure 1
When the fuel pipe is disconnected or precipitates are removed,
bleed air as follows:
1. Twist the knob on the priming pump, which is connected to
the injection pump, and the knob will rise up by itself.
2. Move the priming pump's knob up and down to send fuel

from fuel tank into the filter. Continue this procedure until
the overflow valve of the fuel filter no longer gives off a
“hissing” sound and movement of the priming pump is diffi-
cult. The air bleeding operation is now complete.
3. After bleeding air, return the pump knob to its original posi-
tion, and replace the cover. Start the engine, and make sure
that no fuel is leaking from the fuel system.
Fuel leaks can cause a fire.
MA-4-22
Procedure 2
When the fuel filter element or primary fuel filter element is
replaced, bleed air as follows:
1. When the primary fuel filter element is replaced, refill with
fuel through the filler plug hole.
2. Remove the priming pump cover on the injection pump, and
turn the pump knob counterclockwise to prepare the prim-
ing pump for operation.
3. Slightly loosen the connector bolt on the inlet side of the
fuel filter and move the pump up and down to bleed air from
between the fuel tank and fuel filter. Perform the above
operation until no air comes out.
NOTE
z Place a receiver under the fuel filter. Thoroughly wipe up
any spilled fuel.
4. When bleeding air from between the fuel tank and fuel filter
is completed, retighten the connector bolt and move the
priming pump up and down.
Continue this procedure until the overflow valve of the fuel
filter no longer gives off a “hissing” sound and movement of
the priming pump is difficult.
The air bleeding operation is now complete.
tion, and replace the cover. Start the engine, and make sure
that no fuel is leaking from the fuel system as it could cause
a fire.
MA-4-23
INTAKE AND EXHAUST SYSTEM

AIR CLEANER ELEMENT
Either a dry or metallic air cleaner element is installed, depending
on the type of the vehicle.
Precautions for handling cleaner

1. Be sure to install the element and cover securely. Loose or
improper installation will allow dust to enter, preventing nor-
mal functioning of the air cleaner.
2. Do not touch the filter paper of the element directly with
your hand. Wear gloves. Use special care not to stain the
element with oils.
To inspect the air cleaner element

Start the engine and check if the air cleaner warning light comes on.
If the warning light comes on frequently, clean or replace the ele-
ment as follows:
NOTE
z If the air cleaner element reaches a checking or replacing
period, clean or replace the element regardless of
whether the warning light comes on or not.
<Dry type element>

Type I
1 Wing nut 7 Outer element

2 Cover 8 Wing nut
3 Packing 9 Inner element
4 Clip 10 Evacuator valve
5 Adapter (if so equipped) 11 Air cleaner case
6 Wing nut
MA-4-24
Type II
1 Wing nut 7 Outer element

2 Washer 8 Wing nut
3 Cover 9 Washer
4 Packing 10 Inner element
5 Wing nut 11 Evacuator valve
6 Washer 12 Air cleaner case
1. Loosen the wing nut and remove the cover assembly and
adapter (if so equipped).
2. Loosen the wing nut and remove the outer element.
3. Check the outer element and packing, and replace if broken

or deformed.
If there is dirt or dust on the outer element, clean it by blow-
ing compressed air at 196 to 294 kPa {2 to 3 kgf/cm2, 28 to
43 psi} from inside.
NOTE
z After the outer element has been thoroughly dried, shine
light through from the inside of the outer element, and
check it for damage, pin holes, and thinned areas; also
check the packing for damage and/or deformation.
Replace the elements (outer and inner) if necessary.
MA-4-25
4. First remove the wing nut and then the inner element.
NOTE
z Do not remove the inner element until the specified
replacement time. In other words, the inner element need
not be checked between replacements.
5. When installing the elements, clean the inside of the case

and the evacuator valve and assemble each part in the
reverse order of disassembly.
NOTE
z Tighten the elements and cover wing nut firmly.
<Metallic type element>
1 Wing nut 6 Wing nut

2 Cover 7 Outer element
3 Packing 8 Evacuator valve
4 Clip 9 Air cleaner case
5 Adapter (if so equipped)
MA-4-26
6. Loosen the wing nut and remove the cover assembly and
adapter (if so equipped).
7. Loosen the wing nut and remove the outer element.
8. Place the element in a container large enough to hold the
entire element, and pour light oil into the container until the
element is covered by the oil. Wash the element by shaking
it in the oil. After washing, dry the element using com-
pressed air at 196 to 294 kPa {2 to 3 kgf/cm2, 28 to 43 psi}
from inside.
NOTE
z Be sure to use light oil for this cleaning operation.
z If the packing is damaged or deformed, replace with a
new one.
9. When installing the elements, clean the inside of the case
and the evacuator valve and assemble each part in the
reverse order of disassembly.
NOTE
z Tighten the elements and cover wing nut firmly.
AIR INTAKE SYSTEM (DUCT, HOSE AND CLAMP)

Check the air intake duct connections for loose clamps or cracked
hoses. Check the connection between the air cleaner and air intake
manifold especially. Tighten loose clamps, if any.
CONDITION OF EXHAUST
Warm up the engine sufficiently, then visually inspect exhaust
smoke during idling, acceleration and deceleration with the vehicle
at a stop.
Color of smoke Judgment standard
Colorless or light blue Normal
Abnormal
Black
Incomplete combustion
Abnormal
Engine oil is also burning. However, exhaust
White
gases are often white when
either the air or engine temperature is low.
MA-4-27
EXHAUST TUBING AND MUFFLER

Check the various connections of the exhaust tubing for looseness.
Tighten loose parts as necessary. Also check for any sign of gas
leakage from connections or muffler.
TURBOCHARGER (PF6T, PF6TA AND PF6TB)

NOTE
z Before attempting any servicing of the turbocharger,
clean its entire exterior surface.
z Never use a caustic solution. Caustic solutions attack
aluminum.
To clean the compressor side
1. Remove the turbocharger from the engine.
2. Remove the compressor housing and check the condition
of the impeller (compressor wheel). If it is not excessively
dirty, clean the impeller and the inner surface of the housing
with a brush and a cloth dampened with diesel fuel.
CAUTION
z Do not use a wire brush or scraper.
3. If the impeller is excessively dirty, overhaul and clean. Refer

to the ENGINE “IE” section for cleaning instructions.
4. When the impeller is wet with cleaning solvent, dry with
compressed air.
CAUTION
z Hold the impeller by hand to prevent it from turning while
drying.
5. Install the compressor housing in its original position.

: 9 - 11.3 N·m {0.92 - 1.15 kgf·m, 6.7 - 8.3 ft·lbf}
OTHERS
STARTING MOTOR
Inspect the moving connector of the magnetic valve. Refer to the
EE section for INSPECTION procedures.
MA-4-28
ALTERNATOR
Inspect the charging system.
Refer to the EE section for INSPECTION procedures.
MA-4-29
TROUBLE DIAGNOSIS
MA
CONTENTS
DIAGNOSIS...................................... TD-1-1 DECREASED ENGINE POWER ..... TD-1-5
DIFFICULT ENGINE STARTING...... TD-1-2 EXCESSIVE OIL CONSUMPTION .. TD-1-6
BLACK EXHAUST SMOKE.............. TD-1-3 EXCESSIVE FUEL CONSUMPTION TD-1-7
WHITE EXHAUST SMOKE .............. TD-1-3 NOISY ENGINE ............................... TD-1-8
IRREGULAR ENGINE ENGINE OVERHEATS .................... TD-1-9
OPERATION..................................... TD-1-4
DIAGNOSIS
DIAGNOSIS
DIAGNOSIS GUIDE
The diagnosis guide is a table which can be used for seeking out the cause of trouble without disassembling
the engine on the basis of the symptoms of the problem complained of by the user and the result of checks
performed in the shop with the engine being mounted in the body.
HOW TO USE THE GUIDE

1. Open the page of the guide corresponding to the trouble symptom complained of by the user.
2. Check all of the points listed in the page.
3. If there is any applicable item in “Symptoms and checking points”, the cause of the trouble may be
assumed in the following manner.
z Each item in the “Symptoms and checking points” section corresponds to one or more items in the
“Cause of trouble” section through the dot mark “O”. If there are more than one applicable “Cause of
trouble” items, the item having the largest number of dot marks should be regarded as the central
cause of the trouble.
z The “cause” items having no dot mark can be regarded as not being the cause of the trouble.
NOTE
z If more than one cause is assumed, repair operation should begin with the simplest operation.
TD-1-1
DIAGNOSIS
Sound of magnetic switch is heard with starter switch ON
Poor fuel consumption or oil consumption

Slow starter rotation (less than 100 rpm)
Engine cannot be cranked manually

Symptoms and checking points
DIFFICULT ENGINE STARTING
Excessive exhaust smoke

Moderate exhaust smoke
Sufficient starter rotation
Little exhaust smoke

Starter fails to rotate
Engine lacks power

Cause of trouble
Discharged battery O O O
Electrical system
Poor connection of connector and terminal O O
Breaks in electrical wire O
Faulty starter O O
Faulty starter switch and/or starter relay O
Faulty air heater O O O
Lack of fuel O O
Faulty feed pump O O
Incorrectly installed fuel pipe O O
Faulty injection pump O O O O

Fuel system
Faulty nozzle O O O O
Clogged fuel filter element O O O O
Air in fuel system O O
Incorrect injection timing O O O
Broken or damaged fuel pipe O O
Clogged gauze filter O O O
Damaged ring gear O O
Damaged or seized rotating engine parts

Engine proper and others
O O
High engine oil viscosity O O
Incorrect valve clearance O O O O
Inadequate compression pressure O O O O
Incorrect valve timing O O
Clogged air cleaner element O O
Faulty clutch and subsequent power train (Check by connecting and dis-
O O O
connecting the clutch)
TD-1-2
DIAGNOSIS
Poor fuel consumption or oil consumption
Exhaust smoke gradually turns black
Exhaust smoke suddenly turns black

Low compression pressure

High blow-by gas pressure
BLACK EXHAUST SMOKE
Poor engine starting
Low boost pressure

Engine lacks power
Engine knocks
Irregular idling
Cause of trouble
Accumulation of sludge in air heater O O O O O

Intake system
Clogged air cleaner element O O O O O
Turbocharger failure (jamming, etc.) O O O
Oil leakage from compressor side of turbocharger O O
Excessive injection quantity O
Uneven plunger wear O O O O O

Fuel system
Malfunction of delivery valve O O O O O O
Faulty nozzle O O O O O O
Poor fuel quality O O O O O
Excessively advanced injection timing O O O O
Faulty boost compensator O O

Engine proper
Wear on piston rings and/or cylinder liner O O O O O O
Excessive oil in oil pan O O
WHITE EXHAUST SMOKE

Delayed injection timing O O O O
Engine proper and others
Engine temperature too low O O O O O O
Engine oil leakage down through valve stem O
Wear on piston rings or cylinder liner O O O O O O
Excessive oil in oil pan O
Incorrect valve clearance O O O O O O
TD-1-3
DIAGNOSIS
Specified maximum rpm is not achieved
Specified maximum rpm is exceeded

Engine stabilizes at two spaeeds

Difficulty in starting engine
Poor fuel consumption

IRREGULAR ENGINE OPERATION
White exhaust smoke

Black exhaust smoke
Engine lacks power
Engine often stalls

Engine knocks
Irregular idling
Cause of trouble
Incorrect adjustment of link or rod O O O O O
Fuel leakage from injection pipe O O O O O O
Uneven injection quantity O O O O
Malfunction of governor O O O O
Fuel system
Uneven injection pressure of nozzle O O O O O
Improper fuel spray of nozzle O O O O O
Improper adjustment of idle spring O O O O
Improper adjustment of damper spring O O
Malfunction of delivery valve O O O O O
Air in fuel system O O O O O
Improper placement of valve seat O O O O O
Improper valve clearance O O O O O

Engine proper
Incorrect valve timing O O O O O O
Incorrect compression pressure O O O O O O
Engine temperature too low O O O O O
Deteriorated engine mount rubber O O

Others
Improper adjustment of idling O O O
Rusted control wire O O O O O
TD-1-4
DIAGNOSIS
Specified maximum rpm is not achieved

Low specific gravity of fuel

Excessive blow-by gas

White exhaust smoke
Black exhaust smoke
DECREASED ENGINE POWER
Poor oil consumption

Little exhaust smoke
Low boost pressure

Engine overheats
Engine knocks
Irregular idling
Cause of trouble
Improper fuel quality O O O O O O
Improper adjustment of injection quantity O O O O O
Clogged fuel filter element O O O
Water or air in fuel system O O O
Low fuel pressure (overflow valve)

Fuel system
O O O O
Improper fuel spray from nozzle O O O O O O
Improper injection timing O O O O O O O
Malfunction of delivery valve O O O
Malfunction of feed pump O O O
Malfunction of injection pump O O O O
Faulty boost compensator O
Clogged air cleaner element O O O O O

Intake and exhaust system
Thin or hot intake air O O O O O O
Accumulation of carbon to air heater O O O O O
Clogged or crushed exhaust pipe or muffler O O O O
Half-opened exhaust shutter O O O O
Turbocharger malfunction O O O O
Wear on piston rings and/or cylinder liner O O O O O

Engine proper
Worn, sticking, or broken piston ring O O O O O O
Seized piston O O O O
Worn or seized valve stem O O O O
Improper seating of valve insert O O O O O
Improper selection of gear while travelling O O

Others
Improper adjustment of control valve O O O
Poor returning of engine stop wire O O
TD-1-5
DIAGNOSIS
Continuous emission of white smoke at high-speed running
Oil attaching to exhaust pipe and manifold
Engine oil measuring method incorrect

Engine emits white smoke after idling
EXCESSIVE OIL CONSUMPTION
Engine overheated previously


Engine lacks power
Engine knocks
Cause of trouble
Wear on piston and/or cylinder liner O O O O O O
Aligned piston ring end gaps O O O
Insufficient piston ring tension O O
Improper break-in of piston ring O O

Engine proper
Inversely fitted (up and down) piston rings O
Broken or seized piston rings O O O O O O
Worn piston ring O O O O O
Scuffing of cylinder liner O O
Worn valve stem or guide O O O
Worn valve stem seal O O
Worn or broken seal ring O O

Turbocharger
Oil return hole obstructed by carbon O O
Improper installation of seal ring O O
Leakage of engine oil O
Excess of engine oil O O

Others
Improper quality of engine oil
Clogged air cleaner element O O
TD-1-6
DIAGNOSIS

White exhaust smoke
Black exhaust smoke
Poor oil consumption
Low boost pressure

Engine lacks power
Engine overheats
EXCESSIVE FUEL CONSUMPTION
Engine knocks
Irregular idling
Cause of trouble
Maladjusted nozzle injection pressure O O
Improper fuel spray from nozzle O O O O

Fuel system
Maladjusted injection quantity O O O
Improper seating of delivery valve seat O O O
Improper injection timing O O O O
Faulty boost compensator O
Worn or seized piston, and piston ring O O O O O O O

Engine proper
Worn cylinder liner O O O O O
Improper seating between valve seat and insert O O O O
Maladjusted valve clearance O O O O
Clogged air cleaner element O O O O
Half-opened exhaust shutter O

Others
Clogged or crushed exhaust pipe or muffler O
Engine temperature too high O O O O
Dragged brake
Clutch slips
Chassis
Seizure in drive line
Insufficient tire inflation pressure
Unnecessary acceleration and deceleration

Driving habits
Improper gear shifting O
Prolonged idling
TD-1-7
DIAGNOSIS

White exhaust smoke
Black exhaust smoke
Low boost pressure

Engine lacks power
Engine overheats
NOISY ENGINE
Cause of trouble
Improper timer advance angle O O O
Uneven injection quantity O O O
Excessively advanced injection timing O O O

Fuel system
Delayed injection timing O O O
Uneven nozzle injection pressure O O O
Improper fuel spray from nozzle O O O O
Malfunction of delivery valve O O O O
Poor fuel quality O
Wear or seizure on rotating and sliding portions O O O O O
Insufficient intake air quantity O O O
Improper valve clearance, or seizure of valve O O

Others
Low intake air temperature O
Engine too cold, or overheated O
Insufficient compression pressure and compression air temperature O O O
Excessive oil coming up into cylinder O O O O
TD-1-8
DIAGNOSIS
Air bubbles appear in upper tank only when water temperature is high
Water temperature difference between water inlet and outlet is small
Water temperature difference between water inlet and outlet is great

Cooling water reduces in quantity only after high-speed operation
Air bubbles appear in upper tank only after engine racing

Radiator remains cold even after engine warm up
Excessive reduction of cooling water
ENGINE OVERHEATS

Engine noisy in operation
Air bubbles in upper tank
Engine coolant acidified

Engine lacks power
Cause of trouble
Improper fan belt tension O O
Worn or seized bearing

Water pump
O O
Air drawn from suction side O O
Improper water seal O
Damaged impeller O O
Malfunction of thermostat O O
Coolant passage
Water leakage from cooling water passage O
Overflow of cooling water due to blow-out of gas O O O
Accumulation of water scale in cylinder block O O
Clogging by oxide of iron O O O O O
Clogging by water seal O O O

Radiator
Water leakage O
Malfunction of water tank cap O
Clogged core due to accumulation of mud and insects O O
Improper fuel spray from nozzle O

State of combustion
Improper injection timing O
Half-opened exhaust shutter O O
Clogged or crushed exhaust pipe or muffler O O
Gas leakage from cylinder head nozzle tube O O O O
Gas leakage from head gasket O O O O
Continuous operation under heavy load, or other improper

operation
Others
Improper selection of gears while traveling
Incorrect indication of thermometer
TD-1-9
ENGINE DISASSEMBLY
AND REASSEMBLY
DR
CONTENTS
SERVICE DATA................................ DR-1-1 ENGINE REAR PTO ........................ DR-3-4
TIGHTENING TORQUE .................. DR-1-1 DISASSEMBLY AND REASSEMBLY......... DR-4- 1
TOOLS.............................................. DR-2-1 OUTSIDE OF ENGINE ................... DR-4- 1
CONSTRUCTION ............................. DR-3-1 CYLINDER HEAD ........................... DR-4- 8
ENGINE........................................... DR-3-1 ENGINE PROPER ......................... DR-4-10
GEAR TRAIN................................... DR-3-3 ENGINE REAR PTO ...................... DR-4-21
SERVICE DATA
SERVICE DATA
TIGHTENING TORQUE
Nozzle holder assembly mounting bolt 25 - 34 {2.5 - 3.5, 18 - 25}
Spill tube mounting bolt 10 - 18 {1.0 - 1.8, 7.2 - 13.0}
Pump side 29 - 49 {3.0 - 5.0, 22 - 36}
Injection tube
Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}
Fuel tube & fuel return tube 25 - 29 {2.5 - 3.0, 18 - 22}
1st 392 {40.0, 289}
Type I 2nd Loosen
Crank pulley nut
3rd 637 - 667 {65.0 - 68.0, 470 - 492}
Type II 177 - 196 {18.0 - 20.0, 130 - 145}
Fan pulley mounting bolt 186 - 196 {19.0 - 20.0, 137 - 145}
Cooling fan mounting nut 16 - 19 {1.6 - 1.9, 12 - 14}
Hydraulic pump drive gear mounting nut 59 - 78 {6 - 8, 43 - 58}
Alternator mounting bolt 59 - 78 {6 - 8, 43 - 58}
Exhaust manifold mounting nut 29 - 44 {3.0 - 4.5, 22 - 33}
Oil outlet pipe mounting bolt 13 - 14 {1.30 - 1.45, 9.4 - 10.5}
Oil inlet tube connector bolt 13 - 14 {1.30 - 1.45, 9.4 - 10.5}
Oil cooler housing mounting bolt 20 {2.0, 14}
Turbocharger mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
Air intake manifold mounting nut 49 - 54 {5.0 - 5.5, 36 - 40}
Air compressor mounting bolt 30 - 41 {3.1 - 4.2, 22 - 30}
Starting motor mounting bolt 69 {7.0, 51}
Injection pump bracket mounting bolt 30 - 41 {3.1 - 4.2, 22 - 30}
Injection pump mounting bolt 48 - 62 {4.9 - 6.3, 35 - 46}
Injection pump coupling mounting Coupling bolt 59 - 69 {6.0 - 7.0, 43 - 51}

bolt Cotter bolt 83 - 93 {8.5 - 9.5, 61 - 69}
Feed side 10 - 18 {1.0 - 1.8, 7.2 - 13.0}
Injection pump oil tube connector Return Pump side 15 - 34 {1.5 - 3.5, 11 - 25}
side Block side 25 - 41 {2.5 - 4.2, 18 - 30}
Engine mounting bracket mounting bolt 98 - 127 {10.0 - 13.0, 72 - 94}
Engine lifter mounting bolt 74 - 93 {7.5 - 9.5, 54 - 69}
Water pump gear nut 59 - 69 {6 - 7, 43 - 51}
1st 34 {3.5, 25}
2nd 44 - 54 {4.5 - 5.5, 33 - 40}
Snug torque (1st) 88 - 98 {9.0 - 10.0, 65 - 72}
L = 147 mm (5.79
Tightening 85º - 95º
Cylinder head bolt in)
angle
(2nd) L = 119 mm (4.69
70º - 80º Only bolts marked with *
in)
Rocker shaft bracket mounting bolt 34 - 49 {3.5 - 5.0, 25 - 36}
NOTE
z For discrimination between Type I and Type II of the crank pulley nuts, refer to page DR-3-2.
DR-1-1
SERVICE DATA

Oil jet connector bolt 29 - 39 {3.0 - 4.0, 22 - 29}
Main bearing cap bolt 265 - 284 {27.0 - 29.0, 195 - 210}
Type I 196 - 216 {20.0 - 22.0, 145 - 159}
Connecting rod cap nut
Type II 230 - 245 {23.5 - 25.0, 170 - 181}
Front gear case mounting bolt 54 - 74 {5.5 - 7.5, 40 - 54}
Injection pump drive gear mounting nut 392 - 441 {40 - 45, 289 - 325}
Camshaft gear mounting nut 245 - 265 {25.0 - 27.0, 181 - 195}
Camshaft locating plate mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}
Cam chamber cover mounting bolt 10 - 13 {1.0 - 1.3, 7.2 - 9.4}
Idler gear mounting bolt 18 - 22 {1.8 - 2.2, 13 - 16}
Idler gear shaft bolt 49 - 57 {5.0 - 5.8, 36 - 42}
Air compressor drive gear mounting nut 186 - 206 {19 - 21, 137 - 152}
Oil pump mounting bolt 30 - 41 {3.1 - 4.2, 22 - 30}
Oil screen & oil outlet pipe mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
M8 15 - 20 {1.5 - 2.0, 11 - 14}
Flywheel housing mounting bolt
M12 78 - 98 {8.0 - 10.0, 58 - 72}
Housing side 74 - 88 {7.5 - 9.0, 54 - 65}
Stiffener mounting bolt
Block side 98 - 137 {10.0 - 14.0, 72 - 101
Oil pan mounting bolt 15 {1.5, 11}
Flywheel mounting bolt 255 - 304 {26 - 31, 188 - 224}
Crank damper mounting bolt 98 - 108 {10 - 11, 72 - 80}
Electrical timer magnetic valve eye bolt 25 - 41 {2.5 - 4.2, 18 - 30}
Rear PTO idler shaft mounting bolt 127 {13.0, 94}
Engine rear PTO companion flange nut 392 - 412 {40.0 - 42.0, 289 - 304}
NOTE
z For discrimination between Type I and Type II of the connecting rod cap nuts, refer to page DR-
3-2.
DR-1-2
TOOLS
TOOLS
Socket wrench For removal and installation of crank pulley nut
99535 Z5007 Width across flats: 55 mm (2.17 in)
(Used for Type I only)
Crank pulley puller For removal of crank pulley

99690 95500 (Used for Type I only)
Guide bolt For removal and installation of flywheel

99687 97001
Engine stand For disassembling and reassembling engine

99550 96001 proper
Head assembly
99551 96001
Engine stand attachment For disassembling and reassembling engine

99554 96001 proper
To be used together with engine stand
To confirm the crank pulley nut and crank pulley type before using
the socket wrench and crank pulley puller, refer to page DR-3-2.
DR-2-1
TOOLS

Piston insert tool For inserting piston into cylinder
99631 96502
Cylinder head bolt socket wrench For removal, installation and retightening of cylin-
99664 96000 der head bolt
Injection pump bracket setting For centering of injection pump bracket

tool
99720 95500
Angle wrench Used for tightening cylinder head bolts (snug

1800 WQL torque, angle tightening)
DR-2-2
CONSTRUCTION
CONSTRUCTION
ENGINE
* This illustration is of the PF6TA model.
DR-3-1
CONSTRUCTION
* This illustration is of the PF6TA model.
DR-3-2
CONSTRUCTION
GEAR TRAIN
DR-3-3
CONSTRUCTION
ENGINE REAR PTO
DR-3-4
DISASSEMBLY AND REASSEMBLY

Procedures for assembly and disassembly noted here are based on the PF6TA engine. Please note that in the
case of other engines externally mounted components, etc. may be different.
OUTSIDE OF ENGINE
UPPER SIDE OF ENGINE
Disassembly sequence (Reassembly sequence is the reverse of disassembly.)
1 Air intake duct 2 Air intake 3 Water tube

4 Fuel filter 5 Water manifold 6 Nozzle tube
7 Intake manifold 8 Nozzle holder assembly
DR-4-1
FRONT SIDE OF ENGINE
1 Cooling fan 5 Idler pulley 8 Crank pulley

2 Alternator belt 6 Idler pulley 9 Breather
3 Fan belt 7 Fan pulley bracket 10 Hydraulic pump
4 Alternator
Marks “ ” and “ ” indicate that the key points of operation are explained in the text.
DR-4-2
Key point of disassembly

8 Crank pulley
Prior to removing the crank pulley, be sure to remove the fan pulley
bracket, or the crank damper will come into contact with the fan pul-
ley.
Key points of reassembly

3 Fan belt, 2 Alternator belt
1. Measure the deflection while pushing downward on the
middle of the V-belt with around 98.1 N {10.0 kgf, 22.1 lbf}
of force.
Unit: mm (in)
Location Maintenance standard Service limit
A 8 - 12 (0.31 - 0.47)
B 15 - 18 (0.59 - 0.71)
2. If the deflection is not within the specified range, loosen the

lock nut and adjust the deflection to the specified value,
then fasten the lock nut. When the alternator has been
adjusted, the bolts at the supporting point and the mounting
bar should be tightened.
NOTE
z On PF series engines the cooler compressor and genera-
tor are driven by a common belt. Malfunction of the
cooler compressor while in motion results in a defective
charge system.
Be sure to check for the proper belt tension or the proper
operation of cooler compressor (there should be no
noise while in operation) and also conduct a cooler gas
check.
DR-4-3
RIGHT SIDE OF ENGINE

1 Air intake duct 5 Turbocharger 9 Car heater pipe
2 Exhaust outlet 6 Exhaust manifold 10 Oil filter
3 Exhaust shutter 7 Water duct 11 Oil cooler
4 Air pipe 8 Water pump
DR-4-4
LEFT SIDE OF ENGINE
1 Air compressor 4 Injection pump 7 Starting motor

2 Air intake manifold 5 Injection pump drive support 8 Stiffener
3 Fuel tube 6 By-pass oil filter
DR-4-5

4 Injection pump
When the injection pump bracket has been removed, center it using
the following procedure:
1. Fasten the injection pump bracket.
: 30 - 41 N·m {3.1 - 4.2 kgf·m, 22 - 30 ft·lbf}
2. Centering the injection pump bracket

Set a bracket setting tool (99720 95500) in place. Then
check to make sure that the shaft of the injection pump sup-
port enters the hole on the end of the shaft smoothly.
3. If it does not enter smoothly, adjust by changing the thick-

ness of the injection pump bracket shims.
Shim thickness [mm (in)] : 0.05 (0.0020)
: 0.1 (0.0039)
: 0.2 (0.0079)
4. Install the injection pump.

: 48 - 62 N·m {4.9 - 6.3 kgf·m, 35 - 46 ft·lbf}
5. Turn the flywheel in the standard direction of rotation to
align the scribed line of the injection timer on the No. 1 cyl-
inder with the pointer. If not aligned properly, rotate the fly-
wheel in the reverse direction sufficiently, and realign.
Type Injection timing [B.T.D.C.] Remarks
PF6 16º 1
PF6T 17º 2
16º 3
PF6TA
14º 4 *1
16º 5
PF6TB
14º 6 *2
NOTE
z *1 CKB454, 455, CWB454, 455
z *2 CKB453, CWB453, 455
DR-4-6
6. Align the mark on the injection pump with the scribed line on
the timer, then connect the coupling.
Item Tightening torque
Coupling bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Cotter bolt 83 - 93 {8.5 - 9.5, 61 - 69}
DR-4-7
CYLINDER HEAD
1 Cylinder head cover assembly 3 Cylinder head bolt 5 Cylinder head gasket
2 Valve rocker assembly 4 Cylinder head assembly
DR-4-8
Key points of disassembly

2 Valve rocker assembly
Be sure to loosen the mounting bolts proceeding from the outside
in.
3 Cylinder head bolt
Be sure to loosen the bolts diagonally proceeding from the outside
in.

3 Cylinder head bolt
Insert cylinder head bolts and tighten them evenly in 2 steps and in
the sequence shown in the figure. (Use an angle wrench and
socket wrench 99664 96000.)
1st : 88 - 98 N·m {9.0 - 10.0 kgf·m, 65 - 72 ft·lbf}
2nd Tightening angle
85º - 95º (Except bolts marked with *)
70º - 80º (Bolts marked with *)
NOTE
z If no angle wrenches are available, mark the bolt and cyl-
inder head after the 1st tightening. Tighten the bolt to the
specified angle, starting from the marked position.
For sub bolt (Mark )
1st : 34 N·m {3.5 kgf·m, 25 ft·lbf}
2nd : 44 - 54 N·m {4.5 - 5.5 kgf·m, 33 - 40 ft·lbf}
2 Valve rocker assembly
Be sure to tighten the mounting bolts starting with inner ones and
proceeding to the outer ones.
: 34 - 49 N·m {3.5 - 5.0 kgf·m, 25 - 36 ft·lbf}
DR-4-9
ENGINE PROPER
z This section gives the entire procedures for disassembly
and reassembly. Numbers at the top of each step are noth-
ing to do with those attached to the part names in illustra-
tions.
z When reassembling the engine, be sure to replace all the
gasket, packings and O-rings with new ones, and apply
engine oil to the sliding surface of each component part of
the engine.
z For discrimination between Type I and Type II, refer to page
DR-3-2.
1. Remove the crank pulley and crank damper (Type I only).

Apply a brake on the ring gear of the flywheel, and remove
the crank pulley nut using a socket wrench (99535 Z5007).
Attach the crank puller (99690 95500) to the crank pulley, then
remove the crank pulley and crank damper as a set.
2. Measure and record the lateral runout of the clutch disc sur-
face of the flywheel.
DR-4-10
3. Apply a brake to the ring gear. Then loosen the flywheel

mounting bolt and remove the flywheel using two guide
bolts (99687 97001).
4. Attach the engine stand attachment (99554 96001), then

raise the engine using a crane or other devices, and mount
it on the engine stand (99550 96001).
5. Measure and record the misalignment of the crankshaft and

flywheel housing.
6. Remove the rear oil slinger and flywheel housing.

NOTE
z When an engine rear PTO is equipped, be sure to remove
the special PTO parts prior to removing the flywheel
housing.
z Remove the flywheel housing by suspending it with a
belt using a hoist.
7. Measure and record the backlash of the gear train.

NOTE
z Measure the backlash by inserting fuse wire between the
gears.
z When the air compressor and water pump has been
removed, temporarily install them and measure the gear
backlash.
DR-4-11
8. Measure and record the end play of the idler gears.
9. Measure and record the side clearance at the large end of

the connecting rod.
NOTE
z Side clearance for every cylinder should be measured.
10. Remove the connecting rod cap and bearing shell.

NOTE
z Keep the bearing shells for each connecting rod being
careful not to interchange the upper and lower shells.
11. Remove the piston together with the connecting rod.

NOTE
z Be sure to remove carbon accumulated at the top of the
cylinder before removing the piston.
12. Measure and record the end play of the crankshaft.
DR-4-12
13. Remove the crankshaft, thrust washer and upper main

bearing shell.
NOTE
z Be sure to keep the upper and lower thrust washers as a
set.
z Be sure to keep the upper and lower main bearing shells
as a set for each bearing cap.

z For discrimination between Type I and Type II, refer to page
DR-3-2.
1. Attach the engine stand attachment (99554 96001), then

raise the cylinder block using a crane or other devices, and
mount it on the engine stand (99550 96001).
2. Install the oil jet.

: 29 - 39 N·m {3.0 - 4.0 kgf·m, 22 - 29 ft·lbf}
3. Install the main bearing upper shell.

NOTE
z Be sure to install the main bearing upper shell in the orig-
inal position before disassembly.
DR-4-13
4. Attach the upper thrust washer to both side of the No. 7

main bearing and measure the end play of the crankshaft. If
the measured value exceeds the service limit, replace the
thrust washer with a new one.
Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.14 (0.0020 - 0.0055) 0.5 (0.020)
Unit: mm (in)
A 3.995 - 4.025 (0.15728 - 0.15846)
B 3.970 - 4.000 (0.15629 - 0.15748) Standard
Class of thrust
C 3.945 - 3.975 (0.15531 - 0.15649)
washer
0.15 O.S. 4.100 - 4.150 (0.16142 - 0.16339) O.S.: Over
0.30 O.S. 4.250 - 4.300 (0.16732 - 0.16929) size
NOTE
z Be sure the oil groove side of the thrust washer toward
the crankshaft.
5. Fit the main bearing lower shell into the main bearing cap,
and install the main bearing cap. Install the lower thrust
washer onto both sides of the No. 7 main bearing cap.
1 No. 7 main bearing cap 2 Lower thrust washer
: 265 - 284 N·m {27.0 - 29.0 kgf·m, 195 - 210 ft·lbf}
NOTE
z Make sure the main bearing cap is installed following the
stamped numbers with the mark “ ” indicating the
engine front side.
z The thrust washer has an oil groove which should face
the crankshaft when installed. Be careful not to inter-
change the upper and lower washers.
DR-4-14
6. Using a piston insert tool (99631 96502) insert the piston,

connecting rod and bearing upper shell into the cylinder
liner.
NOTE
z Do not install the piston rings in such a way that their
gaps face the direction of the piston pin and are in a ver-
tical direction. Moreover install them so that their gaps
are located exactly on opposite sides to each other. Also
make sure that the mark “ ” at the top of the piston
F
faces the engine front side and the stamped mark at the
large end of the connecting rod is on the injection pump
side.
NOTE
z Place each piston at its top dead center, and check to
make sure that the piston top clearance at this position is
within the maintenance standard. If any abnormality is
noted, disassemble again and inspect each part.
Unit: mm (in)
+0.32 - +0.72 (+0.0126 - +0.0284)
7. Install the connecting rod cap and bearing lower shell.
NOTE
z Make sure stamped mark at the large end of the connect-
ing rod aligns with that on the connecting rod cap.
Type I : 196 - 216 N·m
{20.0 - 22.0 kgf·m, 145 - 159 ft·lbf}
Type II : 230 - 245 N·m
{23.5 - 25.0 kgf·m, 170 - 181 ft·lbf}
DR-4-15
8. Make sure the side clearance at the connecting rod large

end is within the service limit.
NOTE
z Side clearance for every cylinder should be measured.
Unit: mm (in)
0.1 - 0.3 (0.004 - 0.012) 1.0 (0.039)
9. Install the front gear case and oil jet.

Front gear case mounting bolt
: 54 - 74 N·m {5.5 - 7.5 kgf·m, 40 - 54 ft·lbf}
10. Install the injection pump gear.

NOTE
z When installing, align the timing marks “Y” and “YY”.
: 392 - 441 N·m {40 - 45 kgf·m, 289 - 325 ft·lbf}
11. Install the camshaft assembly together with the gears.

NOTE
z When installing, align the timing marks “V” and “VV”.
Locating plate mounting bolt
: 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf}
Camshaft gear mounting nut
: 245 - 265 N·m {25.0 - 27.0, 181 - 195 ft·lbf}
12. Install the cover for the cam chamber.

: 10 - 13 N·m {1.0 - 1.3 kgf·m, 7.2 - 9.4 ft·lbf}
DR-4-16
13. Install the oil jet.

NOTE
z It should be installed with the injection orifices facing the
crank gear and idler gear contacting point (so that they
point 30 degrees below the horizontal).
14. Install the idler gear and idler gear shaft.

NOTE
z Install the idler gear aligning the timing marks “W” and
“WW”.
Mounting bolt
: 18 - 22 N·m {1.8 - 2.2 kgf·m, 13 - 16 ft·lbf}
Idler gear shaft
:49 - 57 N·m {5.0 - 5.8 kgf·m, 36 - 42 ft·lbf}
15. Install the air compressor drive gear.

:186 - 206 N·m {19 - 21 kgf·m, 137 - 152 ft·lbf}
16. Install the oil pump assembly.

: 30 - 41 N·m {3.1 - 4.2 kgf·m, 22 - 30 ft·lbf}
17. Install the oil outlet pipe.
: 16 - 21 N·m {1.6 - 2.1 kgf·m, 12 - 15 ft·lbf}
18. Install the oil screen.
: 16 - 21 N·m {1.6 - 2.1 kgf·m, 12 - 15 ft·lbf}
19. Measure the end play of the idler gear and oil pump idler
gear. Check that the end play is within the service limit.
Unit: mm (in)
Idler gear 0.05 - 0.12 (0.0020 - 0.0047) 0.3 (0.012)
Oil pump idler
0.08 - 0.15 (0.0031 - 0.0059)
gear
DR-4-17
20. Measure the backlash of the gear train.

NOTE
z Measure the backlash by inserting fuse wire between the
gears.
z When the air compressor and water pump have been
removed, temporarily install them and measure the gear
backlash.
z Check that the backlash for each gear is within the ser-
vice limit.
Unit: mm (in)
A.B.C.D.E.F 0.065 - 0.138 (0.00256 - 0.00543)
G.H 0.085 - 0.215 (0.00335 - 0.00847)
21. Install the rear oil slinger and flywheel housing.

: M8 ........ 15 - 20 N·m {1.5 - 2.0 kgf·m, 11 - 14 ft·lbf}
: M12 ...... 78 - 98 N·m {8.0 - 10.0 kgf·m, 58 - 72 ft·lbf}
NOTE
z When an engine rear PTO is equipped, be sure to install
the special PTO parts prior to installing the flywheel
housing.
z Install the flywheel housing by suspending it with a belt
using a hoist.
22. Install the right and left stiffeners.
On the housing side
: 74 - 88 N·m {7.5 - 9.0 kgf·m, 54 - 65 ft·lbf}
On the block side
: 98 - 137 N·m {10.0 - 14.0 kgf·m, 72 - 101 ft·lbf}
23. Turn the engine upside down and install the oil pan. Apply a
coat of liquid gasket to the contacting surfacers. Fasten
twice.
: 15 N·m {1.5 kgf·m, 11 ft·lbf}
DR-4-18
24. Measure the misalignment of the crankshaft and flywheel

housing. Check that the misalignment is within the mainte-
nance standard.
Unit: mm (in)
Less than 0.2 (0.008)
25. Install the flywheel using two guide bolts (99687 97001).
Apply a brake to the ring gear. Then tighten the flywheel
mounting bolt.
: 255 - 304 N·m {26 - 31 kgf·m, 188 - 224 ft·lbf}
26. Measure the lateral runout of the clutch disc surface of the
flywheel. Check that the runout is within the service limit.
Unit: mm (in)
Less than 0.12 (0.0047) 0.15 (0.0059)
27. Install the crank damper to the crank pulley.

: 98 - 108 N·m {10 - 11 kgf·m, 72 - 80 ft·lbf}
28. Apply a brake on the ring gear of the flywheel and install the
crank pulley.
[Type I]
Install the crank pulley nut using a socket wrench (99535
Z5007).
1st ..... : 392 N·m {40.0 kgf·m, 289 ft·lbf}
2nd.... : Loosen
3rd..... : 637 - 667 N·m {65.0 - 68.0 kgf·m,
470 - 492 ft·lbf}
DR-4-19
[Type II]
Tighten the crank pulley securing bolts diagonally to the
specified torque.
: 177- 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf}
DR-4-20
ENGINE REAR PTO

1 Oil tube 10 Nut 19 Bearing
2 Bolt 11 Washer 20 O-ring
3 Washer 12 Drive shaft 21 PTO gear
4 Companion flange nut 13 Holder bolt 22 Bearing
5 Companion flange 14 Nut 23 Shaft holder
6 Slinger 15 Washer 24 O-ring
7 Oil seal 16 Stud 25 Idler gear bolt
8 Tray 17 Holder 26 Washer
9 Shaft holder bolt 18 O-ring 27 Idler gear assembly
DR-4-21

12 Drive shaft
Remove the shaft holder mounting bolt. Then remove the drive
shaft with the PTO gear by lightly tapping the tip of the shaft.
23 Shaft holder
Disassemble the drive shaft assembly as shown in the following fig-
ure.

22 Bearing
Press the small ball bearing into the drive shaft.
NOTE
z Press in the ball bearing with the shield plate side facing
the PTO gear.
21 PTO gear
Fit the PTO gear onto the drive shaft aligning the oil groove of the
PTO gear with the oil hole of the drive shaft.
19 Bearing
Press the large ball bearing into the oil seal holder.
NOTE
z Press in the ball bearing with the shield plate side facing
the companion flange.
DR-4-22
17 Holder
Press the bearing holder onto the drive shaft.
6 Slinger, 7 Oil seal, 8 Tray

When installing, be sure to apply a coat of engine oil to the oil seal-
ing lip. Place the oil tray with its cut-out portion facing the oil pas-
sage of the bearing holder.
DR-4-23
ENGINE PROPER
EP
CONTENTS
SERVICE DATA................................. EP-1-1 REPAIR AND REPLACEMENT ......... EP-4-1
TOOLS............................................... EP-2-1 CYLINDER LINER REPLACEMENT EP-4-1
INSPECTION ..................................... EP-3-1 CAMSHAFT BUSHING
CYLINDER BLOCK ........................... EP-3-1 REPLACEMENT ............................... EP-4-1
CRANKSHAFT .................................. EP-3-2 CRANKSHAFT CORRECTION......... EP-4-2
MAIN BEARING SHELL .................... EP-3-5 CRANKSHAFT ACCESSORIES
CYLINDER LINER............................. EP-3-5 REPLACEMENT .............................. EP-4-4
PISTON AND CONNECTING ROD... EP-3-6 CONNECTING ROD
CAMSHAFT..................................... EP-3-10 REPLACEMENT .............................. EP-4-5
GEAR TRAIN................................... EP-3-11 CONNECTING ROD SMALL END
FLYWHEEL ..................................... EP-3-12 BUSHING REPLACEMENT.............. EP-4-5
FLYWHEEL HOUSING, REAR END IDLER GEAR (A) BUSHING
PLATE AND FRONT COVER.......... EP-3-13 REPLACEMENT ............................... EP-4-5
CRANK PULLEY AND DAMPER .... EP-3-13 FLYWHEEL CORRECTION.............. EP-4-6
V-BELT ............................................ EP-3-13
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Posi
tion
Flatness of the top sur- Longitudinal direction Less than 0.01 (0.0004) 0.10 (0.0039)
Cylinder block
face Transverse direction Less than 0.02 (0.0008) 0.10 (0.0039)

Roundness of the liner engaging inner wall Less than 0.02 (0.0008)
Clearance between main bearing cap and cylinder 0.05 T - 0.02 L
T: Tight L: Loose
block (0.0020 T - 0.0008 L)
99.87 - 99.89
Outside diameter of journal 98.87 (3.8925)
(3.9319 - 3.9327)
84.89 - 84.91
Outside diameter of crankshaft pin 83.89 (3.3027)
(3.3421 - 3.3429)
Less than 0.01
Out-of-roundness of journal and crank pin 0.06 (0.0024)
(0.0004)
Less than 0.01
Taper of journal and crank pin
(0.0004)
99.62 - 99.64
0.25 U.S.
(3.9220 - 3.9228)
99.37 - 99.39
0.50 U.S.
Journal grinding dimen- (3.9122 - 3.9130)
sions 99.12 - 99.14
0.75 U.S.
(3.9024 - 3.9031)
98.87 - 98.89
Crankshaft
1.00 U.S.
(3.8925 - 3.8933)
84.64 - 84.66
0.25 U.S.
(3.3323 - 3.3331)
84.39 - 84.41
0.50 U.S.
(3.3224 - 3.3232)
Type I U.S.: Undersize
84.14 - 84.16
0.75 U.S.
(3.3126 - 3.3134)
83.89 - 83.91
1.00 U.S.
Crank pin grinding (3.3027 - 3.3035)
dimensions 89.64 - 89.66
0.25 U.S.
(3.5291 - 3.5299)
89.39 - 89.41
0.50 U.S.
(3.5193 - 3.5201)
Type II
89.14 - 89.16
0.75 U.S.
(3.5094 - 3.5102)
88.89 - 88.91
1.00 U.S.
(3.4996 - 3.5004)
EP-1-1
SERVICE DATA
Posi-
tion
Journal Less than 0.03
0.01 (0.0004)
location (A) (0.0012)
Oil seal Less than 0.01
Type I 0.01 (0.0004)
location (B) (0.0004)
Flywheel Less than 0.02
0.01 (0.0004)
location (C) (0.0008) Support the No. 2 and
Runout
Journal Less than 0.07 No. 6 journals
0.01 (0.0004)
location (A) (0.0028)
Oil seal Less than 0.04
Type II 0.01 (0.0004)
location (B) (0.0016)
Flywheel Less than 0.01
0.01 (0.0004)
location (C) (0.0004)
Crankshaft
0.05 - 0.14
End play 0.50 (0.0197)
(0.0020 - 0.0055)
3.995 - 4.025
A
(0.1573 - 0.1585)
3.970 - 4.000
B Standard
(0.1563 - 0.1575)
3.945 - 3.975 (
Thrust washer types C
0.1553 - 0.1565)
4.100 - 4.150 (
0.15 O.S.
0.1614 - 0.1634)
O.S.: Oversize
4.250 - 4.300
0.30 O.S.
(0.1673 - 0.1693)
Clearance between main bearing shell and crankshaft 0.04 - 0.13
0.20 (0.0079)
journal (0.0016 - 0.0051)
NOTE
z For discrimination between Type I and Type II, refer to page DR-3-2.
EP-1-2
SERVICE DATA
Unit: mm (in)
Position Item Maintenance standard Service limit Remarks
Measure at 25, 50, 75, 125, 175
Inside diameter (without dismounting it 133.00 - 133.03 and 245 mm (0.98, 1.97, 2.95,
133.25 (5.2461)
from the cylinder block) (5.2362 - 5.2374) 4.92, 6.89 and 9.65 in) positions
from the top surface of the block
Cylinder liner
Out-of-roundness Less than 0.10 (0.0039)

Taper Less than 0.03 (0.0012)
Protrusion of cylinder liner flange 0.02 - 0.10
above cylinder block (0.0008 - 0.0039)
Less than 0.05 Between cylinders #1 and #2,
Gap between adjoining cylinders
(0.0020) #2 and #3, #4 and #5, #5 and #6
Measure at 20 mm (0.787 in)
132.92 - 132.95
Outside diameter position from bottom surface,
(5.2331 - 5.2342)
perpendicular to piston pin
Clearance between piston and cylinder 0.07 - 0.09
Piston
liner (0.0028 - 0.0035)

50.00 - 50.02
Inside diameter of piston pin 50.10 (1.9724)
(1.9685 - 1.9693)
0.32 - 0.72 Upper surfaces of piston and
Top clearance
(0.0126 - 0.0283) cylinder block
0.08 - 0.12
Clearance between 2nd ring 0.40 (0.0157)
(0.0031 - 0.0047)
Piston ring
the piston ring and

ring groove 0.02 - 0.06
Oil ring 0.20 (0.0079)
(0.0008 - 0.0024)
Piston and connecting rod
End gap of each pis- 1st ring 2nd 0.40 - 0.60

2.00 (0.0787)
ton ring ring Oil ring (0.0157 - 0.0236)
49.99 - 50.00
Outside diameter 49.90 (1.9646)
(1.9681 - 1.9685)
Piston pin
Clearance between piston pin and pis- 0 - 0.03

0.10 (0.0039)
ton pin bore (0 - 0.0012)
Clearance between connecting rod 0.03 - 0.05
0.10 (0.0039)
small end bushing and piston pin (0.0012 - 0.0020)
50.03 - 50.04
Inside diameter of small end bushing
(1.9697 - 1.9701)
For discrimination between Type
0.04 - 0.11
Clearance between Type I 0.20 (0.0079) I and Type II, refer to page DR-
(0.0016 - 0.0043)
Connecting rod
large end bearing 3-2.

and crank pin 0.05 - 0.11
Type II
(0.0020 - 0.0043)
When the distance between pins
Bend Less than 0.06 (0.0024)
is 100 mm (3.94 in)
Twist Less than 0.08 (0.0032)
Side clearance between connecting 0.10 - 0.30
1.00 (0.0394)
rod and crank pin (0.004 - 0.0118)
EP-1-3
SERVICE DATA
Unit: mm (in)
Posi- Maintenance Service

Item Remarks
tion standard limit
0.05 - 0.25
End play 0.50 (0.0197)
(0.0020 - 0.0098)
62.72 - 62.74
No. 1
(2.4693 - 2.4701)
62.52 - 62.54
No. 2
(2.4614 - 2.4622)
Outside diameter of jour- 62.32 - 62.34
No. 3
nal (2.4535 - 2.4543)
62.12 - 62.14
No. 4
(2.4457 - 2.4465)
Camshaft
61.92 - 61.94
No. 5
(2.4378 - 2.4386)
Clearance between journal and bush- 0.030 - 0.116
0.20 (0.0079)
ing (0.0012 - 0.0046)
53.0275 - 53.0675
PF6
(2.0877 - 2.0893)
Height of Intake PF6T
54.080 - 54.120
cam PF6TA
(2.1291 - 2.1307)
profile PF6TB
50.505 - 50.545
Exhaust
(1.9884 - 1.9900)
Support the No. 2 and No. 4 jour-
Runout Less than 0.03 (0.0012) 0.06 (0.0024)
nals
A, B, C, 0.065 - 0.135
D, E, F (0.0026 - 0.0053)
Gear train backlash
0.085 - 0.215
G, H
(0.0033 - 0.0085)
Gear train
0.05 - 0.12
Idler gear end play 0.30 (0.0118)
(0.0020 - 0.0047)
Clearance between idler gear bush- 0.025 - 0.061

0.20 (0.0079)
ing and shaft (0.0010 - 0.0024)
Less than 0.10

Lateral runout of clutch disc surface 0.15 (0.0059)
(0.0039)
Flywheel
Thickness (A) 50.5 (1.9882) 48.5 (1.9094)
Standard and depth from flange end 47.90 - 48.10

face (B) (1.8858 - 1.8937)
8 - 12
A
(0.31 - 0.47)
Deflection of V-belt [when

V-belt
applied with 98 N {10 kgf,

22 lbf} force at midpoint]
15 - 18
B
(0.59 - 0.71)
EP-1-4
TOOLS
TOOLS
Straight edge For measuring flatness of cylinder block and cylin-
99645 Z5001 der head gasketed surfaces
Piston ring tool For removal and installation of piston ring

99630 Z0001
Cylinder liner tool For removal and installation of cylinder

99600 96001 liner
Cam bush tool assembly For removal of cam bushing

99590 95500
Cam bush tool assembly For installation of cam bushing

99590 96003 Cam bush replacer
1 For No. 1
2 For No. 5
3 For No. 2
4 For No. 3
5 For No. 4
Replace bar
6 For No. 2 - 4
EP-2-1
TOOLS

Collar replacer For pressing front oil seal
99718 96000 (Used for Type I only)
Collar replacer For pressing front oil seal

99718 96006 (Used for Type II only)
1 Sleeve replacer Used together with guide bolt when press

99718 96004 fitting crankshaft rear oil seal sleeve
2 Guide bolt
99687 96001
1 Oil seal replacer Used together with guide bolt when press fitting
99718 96005 crankshaft rear oil seal
2 Guide bolt
99687 96001
NOTE
z For discrimination between Type I and Type II of the collar replacer, refer to page DR-3-2.
EP-2-2
INSPECTION
INSPECTION
z Clean all the disassembled parts thoroughly with cleaning
fluid. While cleaning, inspect the parts for cracks and other
damage carefully. If faulty, replace with a new one.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
CYLINDER BLOCK
Flatness of the top surface
Using a straight edge (99645 Z5001), measure the flatness of the
top surface.
Unit: mm (in)
Longitudinal direction Less than 0.10 (0.0039) 0.10 (0.0039)
Transverse direction Less than 0.02 (0.0008) 0.10 (0.0039)
Roundness of the liner engaging inner wall

Unit: mm (in)
Roundness Less than 0.02 (0.0008)
Inside diameter of the camshaft bushing

Measure and record the inside diameter of the camshaft bushing.
EP-3-1
INSPECTION
Clearance between main bearing cap and cylinder block

Unit: mm (in)
Maintenance standard Remarks
0.05 T - 0.02 L
T: Tight, L: Loose
(0.0020 T - 0.0008 L)
CRANKSHAFT
Outside diameter of the journal
Measure and record the outside diameter of the journal. If the mea-
sured value has reached the service limit, grind the journal to the
undersize, and install the undersize main bearing shell.
Unit: mm (in)
S.T.D. 99.87 - 99.89 (3.9319 - 3.9327) 98.87 (3.8925)
0.25 U.S. 99.62 - 99.64 (3.9220 - 3.9228)
U.S.:
0.50 U.S. 99.37 - 99.39 (3.9122 - 3.9130)
Undersize
0.75 U.S. 99.12 - 99.14 (3.9024 - 3.9031)
1.00 U.S. 98.87 - 98.89 (3.8925 - 3.8933)
Out-of-roundness of the journal

If the out-of-roundness has exceeded the maintenance standard,
grind the journal to the undersize, and install the undersize main
bearing shell.
Unit: mm (in)
Less than 0.01 (0.0004) 0.06 (0.0024)
Taper of the journal

If the taper has exceeded the maintenance standard, grind the jour-
nal to the undersize, and install the undersize main bearing shell.
Unit: mm (in)
Less than 0.01 (0.0004)
EP-3-2
INSPECTION
Outside diameter of the crankshaft pin

Measure and record the outside diameter of the crankshaft pin. If
the measured value has reached the service limit, grind the pin to
the undersize, and install the undersize bearing shell.
Unit: mm (in)
84.89 - 84.91
S.T.D. 83.89 (3.3027)
(3.3421 - 3.3429)
84.64 - 84.66
0.25 U.S.
(3.3323 - 3.3331)
84.39 - 84.41
Type I 0.50 U.S.
(3.3224 - 3.3232)
84.14 - 84.16
0.75 U.S.
(3.3126 - 3.3134)
83.89 - 83.91
1.00 U.S.
(3.3027 - 3.3035)
89.89 - 89.91
S.T.D. 88.89 (3.4996)
(3.5390 - 3.5398)
89.64 - 89.66
0.25 U.S.
(3.5291 - 3.5299)
89.39 - 89.41
Type II 0.50 U.S.
(3.5193 - 3.5201)
89.14 - 89.16
0.75 U.S.
(3.5094 - 3.5102)
88.89 - 88.91
1.00 U.S.
(3.4996 - 3.5004)
U.S.: Undersize
NOTE
z For discrimination between Type I and Type II, refer to
page DR-3-2.
Out-of-roundness of the crankshaft pin
If the out-of-roundness has exceeded the maintenance standard,
grind the pin to the undersize, and install the undersize bearing
shell.
Unit: mm (in)
Less than 0.01 (0.0004) 0.06 (0.0024)
Crankshaft pin taper

If the taper has exceeded the maintenance standard, grind the pin
to the undersize, and install the undersize bearing shell.
Unit: mm (in)
Less than 0.01 (0.0004)
EP-3-3
INSPECTION
Runout
Support the No. 2 and No. 6 journals and measure the runout of
each part.
Unit: mm (in)
Journal location (A) Less than 0.03 (0.0012) 0.01 (0.0004)
Type I Oil seal location (B) Less than 0.01 (0.0004) 0.01 (0.0004)
Flywheel location (C) Less than 0.02 (0.0008) 0.01 (0.0004)
Journal location (A) Less than 0.07 (0.0028) 0.01 (0.0004)
Type II Oil seal location (B) Less than 0.04 (0.0016) 0.01 (0.0004)
Flywheel location (C) Less than 0.01 (0.0004) 0.01 (0.0004)
NOTE
page DR-3-2.
End play
If the end play measured during disassembly has reached the
specified service limit, replace the upper and lower thrust washers
as a unit with a suitable set of thrust washers so that the end play is
within the maintenance standard.
Unit: mm (in)
0.05 - 0.14 (0.0020 - 0.0055) 0.50 (0.0197)
Unit: mm (in)
Size identification mark Thickness Remarks
3.995 - 4.025
A
(0.1573 - 0.1585)
3.970 - 4.000
B Standard
(0.1563 - 0.1575)
Thrust washer 3.945 - 3.975
C
type (0.1553 - 0.1565)
4.100 - 4.150
0.15 O.S.
(0.1614 - 0.1634)
O.S.: Oversize
4.250 - 4.300
0.30 O.S.
(0.1673 - 0.1693)
EP-3-4
INSPECTION
MAIN BEARING SHELL

Clearance between main bearing shell and crankshaft jour-
nal
With the main bearing shell assembled to the cylinder block, tighten
the main bearing cap to the specified torque and measure the
inside diameter of the main bearing shell.
Calculate the clearance between the journal O.D. and main bearing
shell I.D. from the measured values.
: 265 - 284 N·m {27.0 - 29.0 kgf·m, 195 - 210 ft·lbf}
Unit: mm (in)
0.04 - 0.13 (0.0016 - 0.0051) 0.20 (0.0079)
CYLINDER LINER
Measure the cylinder liner without dismounting it from the cylinder
block.
Inside diameter
Unit: mm (in)
133.00 - 133.03 (5.2362 - 5.2374) 133.25 (5.2461)
Out of roundness
Unit: mm (in)
Less than 0.10 (0.0039)
Taper
Unit: mm (in)
Less than 0.03 (0.0012)
Protrusion of cylinder liner flange above cylinder block and

gap between adjoining cylinder
Unit: mm (in)
Protrusion 0.02 - 0.10 (0.0008 - 0.0039)
As a set including #1-
Gap Less than 0.05 (0.0020) #2, #2-#3, #4-#5, #5-
#6
EP-3-5
INSPECTION
PISTON AND CONNECTING ROD

It is necessary to examine the piston and connecting rod. When
they are disassembled, keep the component parts grouped by cyl-
inder numbers.
NOTE
z The piston rings for all cylinders should be replaced as
an assembly during overhaul.
1 1st ring 8 Bolt
2 2nd ring 9 Connecting rod
3 Oil ring 10 Bearing shell (upper)
4 Piston 11 Bearing shell (lower)
5 Retaining ring 12 Connecting rod cap
6 Piston pin 13 Nut
7 Bushing
Disassembling the piston and connecting rod
z Remove the retaining ring and piston pin.
z Remove the piston rings using a piston ring tool (99630

Z0001).
PISTON
Outside diameter
Measurement should be made at 20.0 mm (0.787 in) “L” position
from the bottom side of the piston at a right angle to the piston pin
axis.
Unit: mm (in)
132.920 - 132.950 (5.2331 - 5.2342)
EP-3-6
INSPECTION
Clearance between piston and cylinder liner

Calculate the clearance between the cylinder liner I.D. and piston
O.D. from the measured values.
Unit: mm (in)
0.07 - 0.09 (0.0028 - 0.0035)
Inside diameter of the piston pin

Unit: mm (in)
50.00 - 50.02 (1.9685 - 1.9693) 50.10 (1.9724)
PISTON RINGS
Clearance between the piston ring and ring groove
Unit: mm (in)
2nd ring 0.08 - 0.12 (0.0031 - 0.0047) 0.40 (0.0157)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.20 (0.0079)
NOTE
z The first ring is a keystone ring and cannot be measured.
End gap of each piston ring

Unit: mm (in)
1st, 2nd, oil ring 0.40 - 0.60 (0.0157 - 0.0236) 2.00 (0.0787)
PISTON PIN
Outside diameter
Unit: mm (in)
49.99 - 50.00 (1.9681 - 1.9685) 49.90 (1.9646)
EP-3-7
INSPECTION
Clearance between piston pin and piston pin bore

Calculate the clearance between the piston pin O.D. and piston pin
bore I.D. from the measured values.
Unit: mm (in)
0 - 0.03 (0 - 0.0012) 0.10 (0.0039)
CONNECTING ROD
Inside diameter of small end bushing
Unit: mm (in)
50.03 - 50.04 (1.9697 - 1.9701)
Clearance between small end bushing and piston pin

Calculate the clearance between the piston pin O.D. and small end
bushing I.D. from the measured values.
Unit: mm (in)
0.03 - 0.05 (0.0012 - 0.0020) 0.10 (0.0039)
Clearance between large end bearing and crank pin

Fit each bearing shell to the connecting rod having the same cylin-
der No., then tighten the connecting rod and cap to the specified
torque.
Type I
: 196 - 216 N·m {20.0 - 22.0 kgf·m, 145 - 159 ft·lbf}
Type II
: 230 - 245 N·m {23.5 - 25.0 kgf·m, 170 - 181 ft·lbf}
Calculate the clearance between the crank pin O.D. and bearing
shell I.D. from the measured values.
Unit: mm (in)
Type I 0.04 - 0.11 (0.0016 - 0.0043) 0.20 (0.0079)
Type II 0.05 - 0.11 (0.0020 - 0.0043) 0.20 (0.0079)
NOTE
page DR-3-2.
EP-3-8
INSPECTION
Bend and twist

Mount the connecting rod fitted with the connecting rod cap to the
connecting rod aligner, and insert the piston pin into the small end
bushing. Measure the clearance at the aligner pin (A) and (B) to
check the bend and twist of the connecting rod. If the dimensions of
the pins A and B are other than 100 mm (3.94 in), calculate the
bend or twist when they are 100 mm (3.94 in) by using the following
equation:
100 (3.94)
Bend or twist = X Measured value
Distance between [mm (in)]
(A) and (B)
Unit: mm (in)
Less than 0.06
Bend
(0.0024) When the distance between
Less than 0.08 pins is 100 mm (3.94 in).
Twist
(0.0031)
Side clearance between connecting rod and crank pin

Check the value (A) measured when the engine was disassembled.
Unit: mm (in)
0.10 - 0.30 Measure with one side
1.00 (0.0394)
(0.004 - 0.0118) set to zero
Reassembling piston and connecting rod

1. Install the piston rings using a piston ring tool (99630
Z0001).
NOTE
z Be sure to install with the manufacturer's mark facing
upward.
2. Reassemble the piston, piston pin, snap ring and connect-
ing rod.
NOTE
z Reassemble so that the piston I.D. and the cylinder No.
stamped on the connecting rod face the same direction.
EP-3-9
INSPECTION
CAMSHAFT
End play
If the end play measured during disassembly of the engine has
reached the specified service limit, replace the locating plate with a
new one.
Unit: mm (in)
0.05 - 0.25 (0.0020 - 0.0098) 0.50 (0.0197)
Disassembly of camshaft gear

1 Nut 4 Locating plate
2 Washer 5 Key
3 Camshaft gear 6 Camshaft
Outside diameter of the journal

Measure the outside diameters of each journal.
Unit: mm (in)
Journal No. Maintenance standard Service limit
62.72 - 62.74
No. 1
(2.4693 - 2.4701)
62.52 - 62.54
No. 2
(2.4614 - 2.4622)
62.32 - 62.34
No. 3
(2.4535 - 2.4543)
62.12 - 62.14
No. 4
(2.4457 - 2.4465)
61.92 - 61.94
No. 5
(2.4378 - 2.4386)
Clearance between journal and bushing

Calculate the clearance between the journal O.D. and the camshaft
bushing I.D. previously measured under the heading “Cylinder
block”. If the clearance has reached the service limit, replace the
camshaft bushing.
Unit: mm (in)
0.030 - 0.116 (0.0012 - 0.0046) 0.20 (0.0079)
EP-3-10
INSPECTION
Height of cam profile

Unit: mm (in)
Type Maintenance standard Service limit
53.0275 - 53.0675
PF6
(2.0877 - 2.0893)
Intake PF6T
54.080 - 54.120
PF6TA
(2.1291 - 2.1307)
PF6TB
50.505 - 50.545
Exhaust All types
(1.9884 - 1.9900)
Runout
Support the No. 2 and No. 4 journals, and measure the runout of
the No. 1, No. 3 and No. 5 journals.
Unit: mm (in)
Support the No. 2 and
Less than 0.03 (0.0012) 0.06 (0.0024)
No. 4 journals.
GEAR TRAIN
Check all gears for damaged teeth or abnormal wear. Replace
faulty gears.
Gear train backlash
Check the backlash between gears measured during disassembly
of the engine proper. If it has reached the service limit, replace the
gears with new ones.
Unit: mm (in)
Type Maintenance standard Service limit
0.065 - 0.135
A, B, C, D, E, F
(0.0026 - 0.0053)
0.085 - 0.215
G, H
(0.0033 - 0.0085)
EP-3-11
INSPECTION
Idler gear end play

Check the end play of the idler gear measured during disassembly
of the engine proper. If it has reached the service limit, replace the
idler shaft and plate or idler gear with new ones.
Unit: mm (in)
0.05 - 0.12 (0.0020 - 0.0047) 0.30 (0.0118)
Clearance between idler gear bushing and shaft

Calculate the clearance between the idler gear bushing I.D. and
idler shaft O.D. from the measured values.
Unit: mm (in)
0.025 - 0.061 (0.0010 - 0.0024) 0.20 (0.0079)
FLYWHEEL
Check the flywheel for scratches. Also check for abnormal wear on
the contact surface of the clutch disc, damage or wear on the ring
gear teeth, and noise, damage or seizure of the ball bearing. Repair
or replace parts if faulty.
Lateral runout of clutch disc surface
Check the lateral runout of the clutch disc surface measured during
disassembly of the engine proper.
Unit: mm (in)
Less than 0.10 (0.0039) 0.15 (0.0059)
EP-3-12
INSPECTION
Wear of the clutch disc surface

Replace the flywheel if it has been dressed once and exceeds the
specified dimension (Thickness “A”), even though it may not
exceed the specified height (Standard depth from flange end face
“B”).
Unit: mm (in)
50.5
Thickness (A) 48.5 (1.9094)
(1.9882)
Standard depth from 47.90 - 48.10
flange end face (B) (1.8858 - 1.8937)
FLYWHEEL HOUSING, REAR END PLATE, FRONT

COVER
In principle, the oil seal and gaskets should be replaced with new
ones at time of overhauling. Do not use the old parts.
CRANK PULLEY AND DAMPER

Check the crank pulley for cracks and damage. Also check the
damper for damage, cracks, and separation from the disc.
V-BELT
Check the V-belt (drive belt) for cracks or damage. Replace if faulty.
If the belt contacts the bottom of the pulley groove, replace the belt.
Deflection
Check belt deflection by depressing the midpoint of the drive belt
between the alternator (or fan) and cooler (or tension) pulley with a
force of approximately 98 N {10 kgf, 22 lbf}. If belt deflection is not
within maintenance standards, adjust the belt. If beyond adjust-
ment, replace.
Unit: mm (in)
A 8 - 12 (0.31 - 0.47)
B 15 - 18 (0.59 - 0.71)
EP-3-13
REPAIR AND REPLACEMENT

CYLINDER LINER REPLACEMENT
1. Using a cylinder liner tool (99600 96001), remove the faulty
cylinder liner and install a new one.
NOTE
z Prior to insertion, be sure to clean the inside wall of the
cylinder block and the outer surface of the cylinder thor-
oughly and lightly apply a coat of engine oil to them.
2. After installing the cylinder liner, make sure that the inside
diameter, out-of-roundness, taper and flange projection are
all within the maintenance standards.
NOTE
z Before measuring these, be sure to tighten the main
bearing cap to the specified torque.
: 265 - 284 N·m {27.0 - 29.0 kgf·m, 195 - 210 ft·lbf}
Unit: mm (in)
133.00 - 133.05
Inside diameter
(5.2362 - 5.2382)
Out of roundness Less than 0.10 (0.0039)
Taper Less than 0.03 (0.0012)
0.02 - 0.10
Flange protrusion
(0.0008 - 0.0039)
Gap between adjoining
Less than 0.05 (0.0020)
cylinder
CAMSHAFT BUSHING REPLACEMENT

Driving out camshaft bushing
Using a cam bushing remover (99590 95500), drive out the cam-
shaft bushings.
1. Drive out the No. 1, No. 2, No. 3 and No. 4 camshaft bush-
ings in that order.
2. Drive out the No. 5 camshaft bushing.
EP-4-1
Driving in camshaft bushing

Drive in the camshaft bushings using a cam bushing replacing tool
(99590 96003).
NOTE
z When driving in the bushings, be sure to align the oil
hole of each bushing to the oil way of the block, with the
cut-out portion on the chamfered side facing the right
side of the cylinder block.
No. Tool name Tool number

1-6 Cam bushing replacer assembly 99590 96003
1 99594 96000 (No. 1)
2 99594 96001 (No. 5)
Cam bushing replacer
3 99595 96005 (No. 2)
4 99595 96006 (No. 3)
5 99595 96007 (No. 4)
6 Cam bushing replacer bar 99597 96000
1. Drive in the No. 4, No. 3 and No. 2 camshaft bushings in

that order.
2. Drive in the No. 1 and No. 5 camshaft bushings.
CRANKSHAFT CORRECTION
Journal
Grind the crankshaft journal so that the clearance between the
undersize main bearing shell I.D. and the journal O.D. are within
the maintenance standard.
Pin
Grind the crankshaft pin so that the clearance between the
undersize bearing shell I.D. and the crankshaft pin O.D. are within
the maintenance standard.
Grinding dimension
The grinding dimensions for the journal and pin are as follows.
NOTE
z Be careful to prevent the width of the journal and crank
pin sections from increasing.
z Finish both the rounding corners as shown in the figure.

R=5 mm (0.20 in)
z Be sure to keep the out-of-roundness and taper within
maintenance standards.
Unit: mm (in)
Out of roundness Less than 0.01 (0.0004) Journal and crank pin sec-
Taper Less than 0.01 (0.0004) tions
EP-4-2
Unit: mm (in)
Clearance between outside diame-
0.04 - 0.13
ter of journal and inside diameter of
(0.0016 - 0.0051)
main bearing shell
Clearance between outside diame-
0.04 - 0.11
ter of pin and inside diameter of
(0.0016 - 0.0043)
bearing shell
Journal
Unit: mm (in)
Size identification
Grinding dimension of journal Remarks
mark
S.T.D.
Grinding not necessary
0.07 U.S.
0.25 U.S. 99.62 - 99.64 (3.9220 - 3.9228) S.T.D.: Standard
0.50 U.S. 99.37 - 99.39 (3.9122 - 3.9130) U.S.: Undersize
0.75 U.S. 99.12 - 99.14 (3.9024 - 3.9031)

1.00 U.S. 98.87 - 98.89 (3.8925 - 3.8933)
Pin
Unit: mm (in)
Size identification
Grinding dimension of journal Remarks
mark
S.T.D.
Grinding not necessary
0.07 U.S.
0.25 U.S. 84.64 - 84.66 (3.3323 - 3.3331) S.T.D.: Standard
0.50 U.S. 84.39 - 84.41 (3.3224 - 3.3232) U.S.: Undersize
0.75 U.S. 84.14 - 84.16 (3.3126 - 3.3134)

1.00 U.S. 83.89 - 83.91 (3.3027 - 3.3035)
EP-4-3
CRANKSHAFT ACCESSORIES REPLACEMENT
NOTE
page DR-3-2.
CRANK GEAR
1. Warm the crank gear, then remove it.
2. Warm the crank gear in a bath of oil maintained at approx.
200ºC (390ºF), and install it onto the crankshaft by aligning
its keyway with the straight pin.
WARNING
WARNING
z Be careful not to touch the crank gear with bare hands
because it is hot; otherwise, you may be burned.
NOTE
z Be sure to install the crank gear with “X” stamped on the
end face facing toward the front side.
OIL SEAL COLLAR
1. Using a puller, remove the oil seal collar.
2. Using a collar replacer, press the oil seal collar onto the
crankshaft until it comes in contact with the crank gear.
Collar replacer:
Type I.... 99718 96000
Type II... 99718 96006
REAR OIL SEAL AND OIL SEAL SLEEVE (Type II only)

1. Using a puller, remove the oil seal collar and sleeve.
2. Using a sleeve replacer (99718 96004), press fit the sleeve
until it comes into contact with the replacer.
3. Using an oil seal replacer (99718 96005), press fit the oil
seal until it comes into contact with the flywheel housing.
EP-4-4
CONNECTING ROD REPLACEMENT

After the connecting rod has been replaced with a new one, stamp
the cylinder number in the same position as before.
CONNECTING ROD SMALL END BUSHING REPLACE-

MENT
1. Press in the bushing fully up to the bottom surface with the
chamfered side of the connecting rod small end upward.
NOTE
z Press in aligning the oil holes. Note that a height differ-
ence of 1 mm (0.04 in) is generated between the top sur-
face and the bushing when the bushing is pressed in
fully up to the bottom surface.
2. Ream the inside diameter of the bushing within the mainte-
nance standard after installing the bushing.
Unit: mm (in)
50.03 - 50.04
Inside diameter of bushing
(1.9697 - 1.9701)
IDLER GEAR (A) BUSHING REPLACEMENT

1. Press in the bushing with the end face of the boss section
on the engine front side aligned with the bushing end face.
NOTE
z When aligned with the engine front side, the height differ-
ence (i.e. “H” in the following figure) is 2.5 mm (0.098 in).
2. Ream the inside diameter of the bushing within the mainte-
nance standard after installing the bushing.
Unit: mm (in)
Bushing A 40.00 - 40.02 (1.5748 - 1.5756)
EP-4-5
FLYWHEEL CORRECTION
Grind or machine the clutch disc so that the runout of the contacting
surface will be within the maintenance standards. However, replace
the flywheel with a new one when the runout of the clutch disc con-
tacting surface has exceeded the service limit.
Unit: mm (in)
Lateral runout of clutch disc
Less than 0.10 (0.0039) 0.15 (0.0059)
surface
Service limit of clutch disc
50.50 (1.9882) 48.50 (1.9094)
surface (A)
Standard depth from flange 47.90 - 48.10
end (B) (1.8858 - 1.8937)
EP-4-6
CYLINDER HEAD AND
VALVE MECHANISM
HV
CONTENTS
SERVICE DATA................................ HV-1-1 REPAIRING VALVE.......................... HV-6-1
SERVICE DATA................................ HV-1-1 REPAIRING VALVE INSERT ........... HV-6-2
TIGHTENING TORQUE ................... HV-1-3 REPLACING VALVE INSERT .......... HV-6-2
TOOLS.............................................. HV-2-1 LAPPING THE VALVE AND
CONSTRUCTION ............................. HV-3-1 VALVE INSERT ................................ HV-6-3
DISASSEMBLY ................................ HV-4-1 REPLACING VALVE GUIDE ............ HV-6-4
REMOVAL ........................................ HV-4-1 REPLACING VALVE ROCKER
DISASSEMBLY ................................ HV-4-3 BUSHING......................................... HV-6-4
INSPECTION .................................... HV-5-1 REASSEMBLY .................................. HV-7-1
REPAIR AND REPLACEMENT ....... HV-6-1 INSTALLATION................................. HV-8-1
REPAIRING CYLINDER HEAD ........ HV-6-1
SERVICE DATA
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Posi-
tion
Grinding tolerance:
Cylinder head
Cylinder head height 110 (4.33) 109.5 (4.311)

0.5 mm (0.020 in)
Flatness
Intake 30º - 30º15’

Valve insert
Seat angle
Exhaust 45º - 45º30’
Intake 2.66 (0.1047) 3.0 (0.118)
Contacting width
Exhaust 2.83 (0.1114) 3.0 (0.118)
Valve face angle
11.960 - 11.975
Intake
(0.4709 - 0.4715)
Outside diameter of valve stem
11.925 - 11.935
Exhaust
(0.4695 - 0.4699)
Intake 3.0 (0.118)
Valve head thickness
Valve
Exhaust 1.9 (0.075)

-0.214 - +0.314
Distance between valve and Intake 0.7 (0.0276)
(-0.0084 - +0.0124)
bottom surface of the cylinder
head 0.75 - 1.25
Exhaust
(0.0295 - 0.0492)
0.3 - 0.4
Intake
(0.012 - 0.016)
Valve clearance While cold
0.3 - 0.4
Exhaust
(0.012 - 0.016)
Dimensions after
12.00 - 12.02
Intake 12.17 (0.4791) installed into the cyl-
(0.4724 - 0.4732)
Inside diameter inder head
Valve guide
12.00 - 12.02
Exhaust 12.16 (0.4787)
(0.4724 - 0.4732)
Valve guide and valve stem 0.025 - 0.070
Intake 0.15 (0.0059)
clearance (0.0010 - 0.0028)
Projection from top of cylinder Intake

21.0 (0.827)
head Exhaust
Outer 85.10 (3.3504)
Free length Intake and exhaust
Inner 80.50 (3.1693)
When compressed
351.1 - 388.4 to 50.7 mm (1.996
Outer
Valve spring
{35.8 - 39.6, 78.9 - 87.3} in)

Tension Intake and exhaust
N {kgf, lbf} When compressed
199.1 - 220.7 to 49.0 mm (1.929
Inner
{20.3 - 22.5, 44.8 - 49.6} in)
Intake and exhaust
Intake and exhaust
Squareness 2.5 (0.098)
Inner and outer
HV-1-1
SERVICE DATA
Unit: mm (in)
Posi-
tion
19.99 - 20.00
(0.7870 - 0.7874)
Runout Less than 0.03 (0.0012) 0.05 (0.0020)
Rocker shaft
Inside diameter of valve rocker 20.02 - 20.04

20.10 (0.7913)
bushing (0.7882 - 0.7890)
Clearance between rocker 0.02 - 0.06
0.20 (0.0079)
shaft and valve rocker bushing (0.0008 - 0.0024)
Free length of inside spring 80 (3.15)
Tension of inside spring 19.6 - 29.4 When compressed
16.7 1.7, 3.7
N {kgf, lbf} {2.0 - 3.0, 4.4 - 6.6} to 57 mm (2.24 in)
Length 236.73 (9.3201)

Push rod
Deviation Less than 0.3 (0.012) 0.5 (0.020)
26.945 - 26.965
Cam follower

(1.0608 - 1.0616)
Clearance between cam fol- 0.03 - 0.08

0.20 (0.0079)
lower and hole (0.0012 - 0.0031)
Others
Valve clearance adjusting sequence
Cylinder No. 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12
Valve arrangement
IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 piston at TDC on compression
O O O O O O
stroke
No. 6 piston at TDC on compression
O O O O O O
stroke
HV-1-2
SERVICE DATA
TIGHTENING TORQUE
Tightening point Tightening torque
Preset (snug) torque: 1st time 88 - 98 {9.0 - 10.0, 65 - 72}
Cylinder head bolt 85º - 95º (long size except for bolts marked with *)
Tightening angle: 2nd time
70º - 80º (bolts marked with * are of short size)
1st time 34 {3.5, 25}
2nd time 44 - 54 {4.5 - 5.5, 33 - 40}
Rocker shaft mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
Exhaust manifold mounting nut 29 - 44 {3.0 - 4.5, 22 - 33}
Air intake manifold mounting nut 49 - 54 {5.0 - 5.5, 36 - 40}
Injection nozzle holder mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}
Pump side 29 - 39 {3.0 - 4.0, 22 - 29}
Injection tube
Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}
Spill tube mounting bolt 10 - 18 {1.0 - 1.8, 7 - 13}
Turbocharger mounting nut 34 - 44 {3.5 - 4.5, 25 - 33}
Rocker arm adjusting screw lock nut 34 - 44 {3.5 - 4.5, 25 - 33}
Rocker shaft stopper bolt 8 - 13 {0.8 - 1.3, 5.8 - 9.4}
NOTE
z For bolts marked with *, refer to the illustration in the text under the heading “INSTALLATION”.
HV-1-3
TOOLS
TOOLS
Split collar tool Used to remove and install the split collar.
99624 Z5001
Valve insert puller assembly For removal of valve insert

99660 96003 1 Puller (for exhaust)
1 99669 96009 2 Puller (for inlet)
2 99669 96008 3 Bridge
3 99668 95000 4 Puller bolt
4 99532 95000 5 Bolt (M8 x 1.25)
5 81-20830-1A 6 Nut (M16 x 1.5)
6 89-11246-1A 7 Plain washer
7 89-15446-1A
Valve insert replacer For installation of valve insert (cold fitting)

99665 96002 (Intake)
Valve insert replacer For installation of valve insert (cold fitting)

99665 96003 (Exhaust)
Caulking tool assembly Used to caulk after the exhaust valve insert has
99670 96002 been fitted to the cylinder head.
1 99675 96002
2 99676 96001 1 Caulking tool
3 81-20616-1A 2 Guide
3 Bolt
Valve guide remover For removal of valve guide

99667 96000 (Both intake and exhaust)
HV-2-1
TOOLS

Reamer For finishing of valve guide inside diameter
Stem seal replacer Used to install the valve stem seal into the
99674 97005 valve guide.
Valve guide replacer For installation of valve guide

Cylinder head bolt socket wrench For removal, installation and retightening of cylin-
99664 96000 der head bolts
Angle wrench Used for tightening cylinder head bolts (preset

1800 WQL torque, tightening angle)
HV-2-2
CONSTRUCTION
CONSTRUCTION
HV-3-1
DISASSEMBLY
DISASSEMBLY
REMOVAL
Dismount the cylinder head keeping the engine mounted in a vehicle.
1. Chock the wheels, then tilt the cab.
2. Turn the key switch off and disconnect the cable from the negative terminal of the battery.
3. Drain the engine cooling water.
4. Remove the right and left side cover for the engine room.
5. Disconnect the water hose, tube and wire harness.
6. Remove the intake hose.
7. Remove the air intake manifold with the air heater and air intake duct attached to the air intake mani-
fold.
8. Remove the fuel system.
z Remove the fuel lines.
z Remove the injection nozzle tube and spill tube.
z Remove the injection nozzle.
NOTE
z When removing fuel lines, use a pan to catch dripping fuel so that fuel does not get on engine
parts. If any fuel is spilled on engine parts, use a rag to completely remove all spilled fuel.
9. Remove the shield plate, oil pipe and other parts attached to the turbocharger, then remove the tur-
bocharger together with the actuator assembly.
10. Remove the exhaust manifold.
11. Remove the rocker cover.
12. Remove the rocker shaft assembly and push rod.
NOTE
z Loosen the rocker shaft assembly mounting bolts proceeding from the outside in.
13. Remove the cylinder head and gasket.
NOTE
z Use a crane or other devices to dismount the cylinder head.
z Loosen the cylinder head bolts proceeding from the outside in.
PF6
HV-4-1
DISASSEMBLY
PF6T
PF6TA, B
HV-4-2
DISASSEMBLY
DISASSEMBLY
CYLINDER HEAD

+, 1 Split collar 7 Head gasket 13 Taper plug
2 Upper spring seat 8 Valve 14 Side cover
, 3 Inner valve spring 9 Valve guide 15 Rubber ring
, 4 Outer valve spring 10 Valve insert 16 Engine lifter (front)
, 5 Valve stem seal 11 Water jet 17 Cylinder head
6 Lower spring seat 12 Water nozzle
HV-4-3
DISASSEMBLY
ROCKER SHAFT ASSEMBLY

1 Bracket A 6 Exhaust rocker arm 11 Adjusting screw
2 Stopper bolt 7 Bushing 12 Bushing
3 Rocker shaft 8 Bracket A 13 Push rod
4 Bracket B 9 Intake rocker arm 14 Cam follower
5 Inside spring 10 Lock nut
HV-4-4
DISASSEMBLY

z Measure the distance between the valve and the bottom
surface of the cylinder head prior to disassembling the cylin-
der head assembly.
NOTE
z Be sure to remove the carbon from the valve and the bot-
tom surface of the cylinder head.
1 Split collar
Remove the split collar using a split collar tool (99624 Z5001).
NOTE
z All the parts removed should be grouped together for
each valve.
HV-4-5
INSPECTION
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
CYLINDER HEAD
Flatness
Unit: mm (in)
VALVE INSERT
Contacting width and contact pattern
Unit: mm (in)
Intake 2.66 (0.1047) 3.0 (0.118)
Exhaust 2.83 (0.1114) 3.0 (0.118)
VALVE
Distance between the valve and the bottom surface of the
cylinder head
Check the value measured before disassembling the cylinder head.
Unit: mm (in)
-0.214 - +0.314
Intake 0.7 (0.028)
(-0.0084 - +0.0124)
0.75 - 1.25
Exhaust
(0.0295 - 0.0492)
HV-5-1
INSPECTION
Valve head thickness

Unit: mm (in)
Intake 3.0 (0.118)
Exhaust 1.9 (0.075)
Outside diameter of valve stem

Unit: mm (in)
11.960 - 11.975
Intake
(0.4709 - 0.4715)
11.925 - 11.935
Exhaust
(0.4695 - 0.4699)
VALVE GUIDE
Valve guide and valve stem clearance
Unit: mm (in)
0.025 - 0.070
Intake 0.15 (0.0059)
(0.0010 - 0.0028)
0.065 - 0.105
Exhaust 0.15 (0.0059)
(0.0026 - 0.0041)
VALVE SPRING
Free length
Unit: mm (in)
Outer 85.10 (3.3504) Intake and
Inner 80.50 (3.1693) exhaust
Tension
Unit: N {kgf, lbf}
When compressed to
351.1 - 388.4
Outer 50.7 mm (1.996 in) Intake
{35.8 - 39.6, 78.9 - 87.3}
and exhaust
When compressed to
199.1 - 220.7
Inner 49.0 mm (1.929 in) Intake
{20.3 - 22.5, 44.8 - 49.6}
and exhaust
HV-5-2
INSPECTION
Squareness
Measure the squareness of the outer spring by calculating the
clearance difference between A and B in the figure.
Unit: mm (in)
Outer 2.5 (0.098) Intake and
Inner 2.5 (0.098) exhaust
ROCKER SHAFT
Outside diameter
Unit: mm (in)
19.99 - 20.00 (0.7870 - 0.7874) 19.90 (0.7835)
Runout
Unit: mm (in)
Less than 0.03 (0.0012) 0.05 (0.0020)
Inside diameter of valve rocker bushing

Unit: mm (in)
20.02 - 20.04 (0.7882 - 0.7890)
Clearance between rocker shaft and valve rocker bushing

Unit: mm (in)
0.02 - 0.06 (0.0008 - 0.0024) 0.2 (0.008)
HV-5-3
INSPECTION
Free length of inside spring

Unit: mm (in)
80.0 (3.15)
Tension of inside spring

Unit: N {kgf, lbf}
19.6 - 29.4 When compressed to
16.7 {1.7, 3.7}
{2.0 - 3.0, 4.4 - 6.6} 57 mm (2.24 in)
PUSH ROD
Deviation
Measure the deviation while supporting the center of the spherical
surfaces at both ends of the push rod.
Unit: mm (in)
Less than 0.3 (0.012) 0.5 (0.020)
Length
Unit: mm (in)
236.73 (9.3201)
CAM FOLLOWER
Outside diameter
Unit: mm (in)
26.945 - 26.965 (1.0608 - 1.0616) 26.85 (1.0571)
HV-5-4
INSPECTION
Clearance between cam follower and hole

Unit: mm (in)
0.03 - 0.08 (0.0012 - 0.0031) 0.20 (0.0079)
HV-5-5

REPAIRING CYLINDER HEAD
Using a surface grinder, grind the cylinder head. The amount of
grinding should not exceed 0.5 mm (0.02 in).
Unit: mm (in)
Cylinder head height 110 (4.33) 109.5 (4.311)
REPAIRING VALVE
1. Using a valve refacer, repair the valve face portion. If the
thickness of the valve face exceeds the service limit after
repaired, replace it with a new one.
NOTE
z There should be no stepped wear on the valve face.
Unit: mm (in)
Valve face angle
Valve head thick- Intake 3.0 (0.118)
ness Exhaust 1.9 (0.075)
2. Using a valve refacer or oil stone, repair the valve stem end.
NOTE
z Finish the valve stem end surface so that it is perpendic-
ular to the axis. Also, the finished surface should have
no scrape marks or scratches.
HV-6-1
REPAIRING VALVE INSERT

Using a valve seat grinder, repair the seat surface of the valve
insert.
NOTE
z There should be no stepped wear on the seat surface of
the valve insert.
Valve seat angle
REPLACING VALVE INSERT

1. Using a valve insert puller (99660 96003), remove the
intake and exhaust valve inserts.
2. Fit in the intake and exhaust valve inserts. Be sure to cold-

fit them.
<Cold-fitting procedure>
z Keep the valve insert in dry ice for more than five minutes.
Use of alcohol will improve the cooling effect.
NOTE
z Do not touch the cold valve insert or dry ice directly, or it
will cause chilblains.
z Immerse the cylinder head in hot water until its temperature

exceeds 80ºC (176ºF).
NOTE
z Do not touch the cylinder head or hot water directly, or it
will cause a scald.
HV-6-2
z Take out the cylinder head and valve inserts, then fit the
valve inserts quickly into the cylinder head using a special
valve insert replacer (Intake: 99665 96002 and Exhaust:
99665 96003).
z After fitting the valve inserts, caulk four locations around the
insert (on the exhaust side only) using a special valve insert
caulking tool (99670 96002).
NOTE
z When caulking with a hammer, drop a 4-pound copper
hammer from a height of about 300 mm (11.81 in) once.
When a press is used, make the pressure 122,588 to
171,623 kPa {1,250 to 1,750 kg/cm2, 17,775 to 24,885 psi}.
LAPPING THE VALVE AND VALVE INSERT

After repairing or replacing the valve or valve insert, be sure to per-
form valve lapping.
1. Apply grinding compound uniformly to the seat of the valve.
2. Apply a coat of engine oil to the valve stem, then insert the
valve into the valve guide. With the lapping rod coming into
contact with the valve head, lap the valve by rotating it while
lightly tapping the valve insert.
3. After oil lapping, coat the contacting surface of the valve
with red lead and repeat lapping operation in the same
manner as previously done with the grinding compound,
then check the condition of the valve surface. Repeat lap-
ping until the valve surface is properly corrected.
Unit: mm (in)
Intake 2.66 (0.1047) 3.0 (0.118)
Contacting width
Exhaust 2.83 (0.1114) 3.0 (0.118)
HV-6-3
REPLACING VALVE GUIDE

1. Using a valve guide remover (99667 96000), drive out the
valve guide from the bottom side of the cylinder head.
2. Using a valve guide replacer (99666 96002), drive the valve

guide perpendicularly into place until the lower end of the
tool just touches the surface of the cylinder head.
NOTE
z Thoroughly clean the valve guide hole of the cylinder
head prior to driving in.
3. After driving in the valve guide, finish the inside diameter to

the maintenance standard with a reamer (99662 96000).
Unit: mm (in)
12.00 - 12.02
Intake 12.17 (0.4791)
(0.4724 - 0.4732)
Inside diameter
12.00 - 12.02
Exhaust 12.16 (0.4787)
(0.4724 - 0.4732)
REPLACING VALVE ROCKER BUSHING

1. Fix the valve rocker and drive the bushing out with a press
tool.
NOTE
z Mark the bushing clinching position on the valve rocker
prior to removing the bushing.
z Take care so that the fitting surface of the bushing is not
damaged when the bushing is driven out.
HV-6-4
2. Correctly line up the bushing clinching mark on the valve

rocker with the bushing, and drive in the bushing using a
press tool.
NOTE
z After driving in the bushing, check to make sure that the
valve rocker and bushing oil holes are aligned.
3. After driving in the bushing, finish the inside diameter of the

bushing with a reamer.
Unit: mm (in)
Inside diameter of valve 20.02 - 20.04
20.10 (0.7913)
rocker bushing (0.7882 - 0.7890)
HV-6-5
REASSEMBLY
REASSEMBLY
CYLINDER HEAD
z Before reassembling, be sure to apply engine oil to each
sliding surface.
5 Valve stem seal

1. Install the lower spring seat.
2. Using a special valve stem seal replacer (99674 97005),
install the stem seal to the valve guide.
NOTE
z Be sure to push in the stem seal by hand.
4 Outer valve spring, 3 Inner valve spring

Install the inner and outer valve springs and upper spring seat.
NOTE
z When installing the inner and outer springs, be sure to
install them so that the side which has a smaller spring
winding pitch (i.e. the side painted in green) faces the
lower spring seat side.
1 Split collar
1. Using a split collar tool (99624 Z5001), install the split collar.
HV-7-1
REASSEMBLY
2. Measure the distance between the valve and the bottom

surface of the cylinder head and check to make sure that it
does not exceed the maintenance standard.
Unit: mm (in)
Maintenance
Item Service limit
standard
-0.214 - +0.314
Distance between the Intake 0.7 (0.028)
(-0.0084 - +0.0124)
valve and bottom surface
of the cylinder head 0.75 - 1.25
Exhaust
(0.0295 - 0.0492)
HV-7-2
INSTALLATION
INSTALLATION
Cylinder head bolt
Insert the cylinder head bolts, then tighten them in two stages
uniformly following the sequence shown in the figure. (Use an angle
wrench and socket wrench: 99664-96000.)
: 1st time 88 - 98 N·m {9.0 - 10.0 kgf·m, 65 - 72 ft·lbf}
: 2nd time
Tightening angle
85º - 95º (long size except for bolts marked with *)
70º - 80º (bolts marked with * are of short size)
Cylinder head sub bolts (Mark )
: 1st time 34 N·m {3.5 kgf·m, 25 ft·lbf}
: 2nd time 44 - 54 N·m {4.5 - 5.5 kgf·m, 33 - 40 ft·lbf}
NOTE
z Tightening of cylinder head bolts in the PF series engine
is specified by the tightening angle. Do not tighten them
additionally.
<Using an angle wrench>
1. Set the torque graduations of the torque wrench to the pre-
set (snug) torque.
2. Connect the torque wrench to the needle flexible tube.
Secure the clip. (For reading the turning angle)
3. When reading the angle: Adjust the needle to a proper posi-
tion to read the angle in the graduations and then tighten
the bolt. When tightening reaches the preset (snug) torque,
the angle graduation plate begins to turn. Tighten the bolt
while reading the angle.
4. When presetting the angle: Adjust the needle to the prede-
termined angle and tighten the bolt. When tightening
reaches the preset (snug) torque, the angle graduation
plate begins to turn. Tighten the bolt until the needle points
to “0”.
NOTE
z If no angle wrenches are available, mark the bolts and
cylinder head after the 1st tightening. Tighten the bolt to
the specified angle, starting from the marked position.
HV-8-1
- MEMO -
LUBRICATION SYSTEM
CONTENTS
SERVICE DATA................................ LB-1-1 DISASSEMBLY ................................. LB-4-2
SPECIFICATIONS ............................ LB-1-1 INSPECTION .................................... LB-4-3 LB
SERVICE DATA................................ LB-1-2 INSTALLATION ................................. LB-4-3
TIGHTENING TORQUE ................... LB-1-3 OIL FILTER ....................................... LB-5-1
LUBRICATING SYSTEM .................. LB-1-4 CONSTRUCTION ............................. LB-5-1
TOOLS.............................................. LB-2-1 DISASSEMBLY ................................. LB-5-2
OIL PUMP......................................... LB-3-1 INSPECTION .................................... LB-5-3
CONSTRUCTION............................. LB-3-1 REASSEMBLY .................................. LB-5-3
REMOVAL ........................................ LB-3-2 OIL JET ............................................. LB-6-1
DISASSEMBLY ................................ LB-3-3 CONSTRUCTION ............................. LB-6-1
INSPECTION.................................... LB-3-4 REMOVAL......................................... LB-6-1
REASSEMBLY ................................. LB-3-5 INSPECTION .................................... LB-6-1
INSTALLATION ................................. LB-3-6 INSTALLATION ................................. LB-6-1
OIL COOLER.................................... LB-4-1
REMOVAL ........................................ LB-4-1
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
Item
Lubricating method Forced lubrication
Type Gear pump
Discharge amount 138 (30-3/8)
174 (38-1/4)/2,300
Oil pump liter (Imp gal)/rpm /2,300
Relief valve opening pressure
1,079 {11.0, 156}
kPa {kgf/cm2, psi}
Full-flow Filter paper
Type
By-pass Laminated 3-plate type
Oil filter Replacement method Disassembling type
98 - 137 {1.0 - 1.4, 14 - 20}
kPa {kgf/cm2, psi}
Type Water cooled flat tube type
Oil cooler
Number of cores 6
Regulator valve opening pressure
392 - 432 {4.0 - 4.4, 57 - 63}
kPa {kgf/cm2, psi}
Lubricating oil refill capacity With oil filter 29 {6-3/8}
(gauge H-level)
liter {lmp gal} Without oil filter 21 {4-5/8}
LB-1-1
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Posi- Maintenance
tion standard
0.05 - 0.11
Side clearance 0.15 (0.0059)
(0.0020 - 0.0043)
Pump gear
0.07 - 0.19
(Drive and Idler Tip clearance 0.20 (0.0079)
(0.0028 - 0.0075)
gear)
0.09 - 0.22
Backlash 0.50 (0.0197)
(0.0035 - 0.0087)
Clearance between idler shaft and idler gear 0.01 - 0.04
Oil pump
0.20 (0.0079)
bushing (0.0004 - 0.0016)
Valve opening pressure
1,079 {11.0, 156}
kPa {kgf/cm2, psi}
Relief valve Spring free length 50.2 (1.976)
Spring tension 352.1 - 410.9 When compressed to 44
N {kgf, lbf}} {35.9 - 41.9, 79.2 - 92.4} mm (1.73 in)
0.08 - 0.15
Side clearance between idler gear and spindle
(0.0031 - 0.0059)
324 {3.3, 47]
Oil cooler
kPa {kgf/cm2, psi}

Water pressure test on the element
981 {10, 142 }
kPa {kgf/cm2, psi}
Valve opening pressure 98 - 137
kPa {kgf/cm2, psi} {1.0 - 1.4, 14 - 20}
Oil filter
Short valve Spring free length 62.7 (2.468)

Spring tension When compressed
39.2 {4.0, 8.8}
N {kgf, lbf}} to 40.0 mm (1.575 in)
Valve opening pressure 392 - 432
Regulator valve
kPa {kgf/cm2, psi} {4.0 - 4.4, 56.9 - 62.6}

Spring free length 54.5 (2.146)
Spring tension When compressed
97.1 {9.9, 21.8}
N {kgf, lbf}} to 40.0 mm (1.575 in)
Oil jet
177 - 216
kPa {kgf/cm2, psi} {1.8 - 2.2, 26 - 31}
LB-1-2
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}}
Oil pump cover assembly mounting bolt 25 - 39 {2.6 - 4.0, 19 - 29 }
Oil pump assembly mounting bolt 30 - 41 {3.1 - 4.2, 22 - 30 }
Oil pump idler gear mounting bolt 59 - 78 {6.0 - 8.0, 43 - 58}
Oil cooler element mounting nut 20 - 30 {2.0 - 3.0, 14 - 22}
54 - 93 {5.5 - 9.5, 40 - 69}
Oil cooler housing mounting bolt
30 - 54 {3.0 - 5.5, 22 - 40}
Oil cooler housing mounting nut 54 - 93 {5.5 - 9.5, 40 - 69}
Full-flow oil filter center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
By-pass oil filter center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Oil filter drain plug (Full-flow, by-pass) 16 - 22 {1.6 - 2.2, 12 - 16}
Oil jet connector bolt 29 - 39 {3.0 - 4.0, 22 - 29}
Oil pipe, oil screen mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Oil pan mounting bolt 15 {1.5, 11}
LB-1-3
SERVICE DATA
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LB-1-4
SERVICE DATA
LUBRICATION CIRCUIT
LB-1-5
TOOLS
TOOLS
Hydraulic pump For testing water pressure of oil cooler element
99570 Z5000
Oil cooler attachment For water pressure test of oil cooler element
99573 95500
1 99578 95500
2 99578 95501
LB-2-1
OIL PUMP
OIL PUMP
CONSTRUCTION
LB-3-1
OIL PUMP
REMOVAL
1. Remove the drain plug from the oil pan and drain the engine
oil into an oil tray.
WARNING
WARNING
z Before draining engine oil, ensure the engine is cool;
otherwise, you may be burned.
2. Remove the oil level gauge and guide.

3. Remove the oil pan and gasket.
CAUTION
z Be sure to support the oil pan when removing the mount-
ing bolts.
4. Remove the oil screen and oil pipe.

5. Remove the oil pump assembly.
NOTE
z Be sure to support the oil pump when removing it.
z Use a copper hammer to drive out the dowel pin.
LB-3-2
OIL PUMP
DISASSEMBLY

1 Cover assembly , 5 Idler gear 9 Relief valve
2 Bolt 6 Spindle 10 Spring
+, 3 Idler gear (Pump gear) 7 Case assembly 11 Seat
4 Nut 8 Split pin

The oil pump drive gear is shrinkage-fitted into the drive shaft, and
the idler shaft is pressed into the case. Stop disassembling the oil
pump, therefore, after separating the relief valve and idler gear
assembly.
LB-3-3
OIL PUMP
3 Idler gear (Pump gear)

1. Measure the side clearance between the pump gears (both
the drive and idler gears) and the cover and record it.
2. Measure the tip clearance between the tips of the pump

gears (the drive and idler gears) and the body, and record it.
3. Stick a fuse on a tooth surface of the idler gear and rotate

the gear. Then calculate the backlash of the pump gear
from the squeezed amount of the fuse, and record it.
INSPECTION
Clearances and backlash of pump gears
Unit: mm (in)
0.05 - 0.11
(0.0020 - 0.0043)
0.07 - 0.19
Tip clearance 0.20 (0.0079)
(0.0028 - 0.0075)
0.09 - 0.22
Backlash 0.50 (0.0197)
(0.0035 - 0.0087)
Clearance between idler shaft and idler gear bushing

Unit: mm (in)
0.01 - 0.04 (0.0004 - 0.0016) 0.20 (0.0079)
LB-3-4
OIL PUMP
Tension and free length of relief valve spring

Maintenance
standard
When spring is com-
Tension 352.1 - 410.9
pressed to 44 mm
N {kgf, lbf} {35.9 - 41.9, 79.2 - 92.4 }
(1.73 in)
Free length
50.2 (1.976)
mm (in)
Side clearance between idler gear and spindle

Unit: mm (in)
0.08 - 0.15 (0.0031 - 0.0059)
REASSEMBLY
When assembling each part, apply a coat of engine oil to the rotat-
ing and sliding surfaces.
5 Idler gear
Install the idler gear.
: 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf}
NOTE
z Apply a coat of adhesive to the threading portion.
3 Idler gear (Pump gear)

Install the idler gear into the case, then check to make sure that
each clearance and backlash are within the service limit.
Unit: mm (in)
0.05 - 0.11
(0.0020 - 0.0043)
0.07 - 0.19
Tip clearance 0.20 (0.0079)
(0.0028 - 0.0075)
0.09 - 0.22
Pump gear backlash 0.50 (0.0197)
(0.0035 - 0.0087)
LB-3-5
OIL PUMP
INSTALLATION
1. Install the oil pump assembly.
: 30 - 41 N·m {3.1 - 4.2 kgf·m, 22 - 30 ft·lbf}}
2. Install the oil pipe and oil screen.
: 16 - 21 N·m {1.6 - 2.1 kgf·m, 12 - 15 ft·lbf}
3. Install the oil pan with the gasket in place.
: 15 N·m {1.5 kgf·m, 11 ft·lbf}
4. Install the drain plug with the gasket in place.
: 98 - 127 N·m {10.0 - 13.0 kgf·m, 72 - 94 ft·lbf}
5. Install the oil level gauge and guide.
6. Add the specified amount of engine oil.
NOTE
z The engine oil level is correct if it is close to the H mark
on the level gauge. It takes approximately 6 minutes for
the engine oil level to stabilize.
LB-3-6
OIL COOLER
OIL COOLER
REMOVAL
1. Remove the drain plug from the oil pan and drain the engine
oil into an oil tray.
NOTE
z Do not perform removal operations while the engine is
hot, e.g. just after the engine is stopped, as you may be
scalded.
2. Drain the cooling water by loosening the water drain cock.
3. Remove the oil pipe for the turbocharger.

NOTE
z When removing the oil pipe, use an oil tray to catch drip-
ping oil.
4. Remove the full-flow oil element.
5. Remove the air intake pipe for the intercooler.
6. Remove both the hot water outlet and return inlet for the
heater.
7. Remove the portion at which the turbocharger bracket and
the oil cooler element have been fastened together.
8. Loosen the oil cooler housing mounting bolt, then remove
the housing and oil cooler element utilizing the three lugs on
the housing.
LB-4-1
OIL COOLER
DISASSEMBLY

1 Eye bolt 8 Bolt 15 Gasket
2 Eye bolt 9 Bolt 16 Cooler element
3 Gasket 10 Nut 17 Cover assembly
4 Water tube 11 Wave washer 18 Plug
5 Bolt 12 Gasket 19 O-ring
6 Water pipe 13 Nut
7 O-ring 14 Spring washer
LB-4-2
OIL COOLER
INSPECTION
Leakage in oil cooler element

Using the oil cooler attachment (99573 95500) and hydraulic pump
(99570 Z5000), perform the water pressure test on the oil cooler
element. If any abnormality is noted, replace the element.

Water leakage should not occur when a pressure of 981 kPa
{10 kgf/cm2, 142 psi} is directed to the element.
NOTE
z Do not apply a pressure higher than 1,471 kPa {15 kgf/
cm2, 213 psi} for the water pressure test.
z Apply pressure for 2 to 3 minutes.
INSTALLATION
1. Install the element into the oil cooler housing with the pack-
ing in place.
: 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf}
2. Install the oil cooler housing to the engine block with the
gasket in place.
: 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf}
3. Install the other pipes removed.
4. Add the specified amount of engine oil from the cap of the
oil filler.
5. Close the water drain cock and refill the specified amount of
cooling water.
6. Start up the engine and check to make sure that there is no
leakage of air or engine oil.
LB-4-3
OIL FILTER
OIL FILTER
CONSTRUCTION
LB-5-1
OIL FILTER
DISASSEMBLY

1 Center bolt 9 Packing 17 Connector case
2 Gasket 10 Snap ring 18 Connector
3 Case 11 Orifice 19 Spring
4 Spring 12 Spring 20 Short valve
4-1 Spring retainer (By-pass
13 Regulator valve 21 Short valve assembly
only)
5 Element 14 Connector 22 Spring
6 O-ring 15 Packing 23 Drain plug
7 Bracket 16 Spring 24 Gasket
8 Plug
LB-5-2
OIL FILTER
INSPECTION
Free length and tension of short valve spring

Unit: mm (in)
Maintenance
standard
Free
62.7 (2.468)
length
Tension When compressed to 40.0 mm
39.2 {4.0, 8.8}
N {kgf, lbf} (1.575 in)
Free length and tension of regulator valve spring

Unit: mm (in)
Maintenance
standard
Free length 54.5 (2.146)
Tension 97.1 When compressed to 40.0 mm
N {kgf, lbf} {9.9, 21.8} (1.575 in)
REASSEMBLY
Reassemble the oil filter using the construction drawing. For the
tightening torque, refer to the following table.
Unit: N·m {kgf·m, ft·lbf }
Full-flow oil filter center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
By-pass oil filter center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
LB-5-3
OIL JET
OIL JET
CONSTRUCTION
1 Oil jet 2 Oil jet connector bolt
NOTE
z Numbers before part names do not indicate the disas-
sembly sequence.
REMOVAL
Loosen the oil jet connector bolt and remove it together with the oil
jet.
INSPECTION
Valve opening pressure of oil jet
Unit: kPa {kg/cm2, psi}
177 - 216 {1.8 - 2.2, 26 - 31}
INSTALLATION
Align the straight pin of the oil jet to the pin hole, then fix the oil jet
with the oil jet connector bolt.
: 29 - 39 N·m {3.0 - 4.0 kgf·m, 22 - 29 ft·lbf}
LB-6-1
COOLING SYSTEM
CONTENTS
SERVICE DATA................................ EC-1-1 INSPECTION ................................... EC-3-1
SPECIFICATIONS ............................ EC-1-1 INSTALLATION ................................ EC-3-1
SERVICE DATA................................ EC-1-1 RADIATOR AND COOLANT
TIGHTENING TORQUE ................... EC-1-2 RESERVOIR TANK.......................... EC-4-1
EC
COOLING SYSTEM ......................... EC-1-2 FLUSHING COOLING SYSTEM...... EC-4-1
WATER PUMP.................................. EC-2-1 INSPECTION ................................... EC-4-1
REMOVAL ........................................ EC-2-1 FAN CLUTCH................................... EC-5-1
EXTERNAL APPEARANCE CHECK AND CONSTRUCTION ............................ EC-5-1
CORRECTION ................................ EC-2-1 REMOVAL........................................ EC-5-3
INSTALLATION................................. EC-2-1 INSPECTION ................................... EC-5-3
THERMOSTAT EC-3-1 INSTALLATION ................................ EC-5-3
REMOVAL ........................................ EC-3-1
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
Item
Cooling method Water cooled - forced circulation
Radiator Corrugated fin
FD1800L O
Type I O O O O
On-Off type FD2000
Type II O O O O
Fan clutch FD2000-C O O
Linear type FDL2000-C O O O
Changeover temperature of fan clutch 60 - 70 60 - 70 (140 - 158) Standard type

ºC (ºF) (140 - 158) 60±10 - 75±5 (140±18 - 167±9) Linear type
Type Centrifugal
Water pump
Drive Gear drive
Type Wax pellet
Thermostat Valve opening temperature ºC (ºF)
76.5 (169.7) x 1
x Number
Cooling water capacity
37 (8-1/8)
liter (Imp gal)
SERVICE DATA
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
ºC (ºF) (166 - 173) (163 - 176)
Thermostat
Valve lift Greater than Greater than
mm/ºC (in/ºF) 10/90 (0.39/194) 8.5/90 (0.33/194)
Valve opening pressure of coolant reservoir tank cap 49 - 69
Pressure side
kPa {kgf/cm2, psi} {0.5 - 0.7, 7 - 10}
Radiator leak test pressure kPa {kgf/cm2, psi} 98 {1.0, 14} By compressed air
0.072 - 0.142
Clearance between bearing box and pulley bracket bushing
(0.0028 - 0.0056)
600 mm (23.6 in)
Fan clutch 60 - 70
650 mm (25.6 in) Standard type (On-off type)
changeover temper- (140 - 158)
Fan dia. 700 mm (27.6 in)
ature
ºC (ºF) 60±10 - 75±5 Linear type (Disconnecting
700 mm (27.6 in)
(140±18 - 167±9) temperature)
Entire periphery (when
Clearance between cooling fan and fan shroud 5.0 (0.197) directly mounted to
engine)
8 - 12
Cooling fan to tension pulley When applied with 98 N
(0.32 - 0.47)
V-belt tension {10.0 kgf, 22 lbf} force at
15 - 18 midpoint.
Idler pulley to alternator
(0.59 - 0.71)
EC-1-1
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}}
Cooling fan 16 - 19 {1.6 - 1.9, 12 - 14}
Fan clutch assembly (with cooling fan) 30 - 36 {3.1 - 3.7, 22 - 27}
COOLING SYSTEM
EC-1-2
WATER PUMP
WATER PUMP
z Do not disassemble the water pump. If any abnormality is noted as a result of the external appear-
ance check, replace the whole water pump assembly.
REMOVAL
1. Drain the engine cooling water.
2. Disconnect the hoses, ducts, and tubes connected to the
water pump.
3. Remove the three bolts with the rubber ring in place.
EXTERNAL APPEARANCE CHECK AND CORRECTION

1. Is there any corrosion due to cavitation on the vane body or
any other parts?
2. Is there any wear, abnormal noise or seizure noted on the
bearing?
3. Is there any excessive wear or water leakage noted on the
water seal?
NOTE
z The guideline for water leakage is 10 cc (0.4 Imp fl oz) or
more per 50 hours.
4. Is there any grease leakage from the gear side of the water
pump?
INSTALLATION
Installation is the reverse of the removal procedure.
EC-2-1
THERMOSTAT
THERMOSTAT
REMOVAL
1. Drain the engine coolant.
2. Disconnect the radiator hose from the water outlet, then
remove the water outlet and rubber ring.
3. Remove the thermostat.

1 Water outlet 4 Thermostat housing
2 Thermostat 5 Rubber ring
3 Rubber ring
INSPECTION

Valve opening tempera-
74.5 - 78.5 73.0 - 80.0
ture
(166 - 173) (163 - 176)
ºC (ºF)
Valve lift Greater than Greater than
mm/ºC (in/ºF) 10/90 (0.39/194) 8.5/90 (0.33/194)
INSTALLATION
Installation is the reverse of the removal procedure.
EC-3-1
RADIATOR AND COOLANT RESERVOIR TANK

FLUSHING COOLING SYSTEM
Including radiator (with the radiator in its mounted condi-
tion).
1. Drain approx. 5% of coolant while adding the same amount
of cleaning solvent, and allow the engine to idle for approxi-
mately 30 minutes.
NOTE
z During this flushing operation, be careful to maintain the
temperature of the flushing fluid of a constant 80ºC
(176ºF).
2. Thoroughly drain the flushing fluid, and fill the radiator and
engine with clean tap water, and run the engine again for
additional flushing.
WARNING
WARNING
z Do not remove the radiator cap quickly. Otherwise, you
may be sprayed and scalded with hot flushing fluid.
NOTE
z Cover the cap with a thick and heavy rag, and remove it
gradually.
3. Flush repeatedly with tap water until the water drained from
the cooling system is completely clean.
4. Remove any dirt and dust accumulated between the radia-
tor core fins and tubes.
INSPECTION
Radiator leak test pressure
Plug all openings with wooden taps or the like, dip the entire radia-
tor into a container of water, and direct compressed air of 98 kPa
{1.0 kgf/cm2, 14 psi} into the radiator to determine if air leakage is
noticed. If air leakage is noticed, repair or replace the radiator.
Valve opening pressure of coolant reservoir tank cap
49 - 69 {0.5 - 0.7, 7 - 10} Pressure side
EC-4-1
Engine coolant
Check density of anti-freeze solution or LLC (Long Life Coolant)
using a tester. If it is low, add anti-freeze solution or LLC as
required to suit the areas where the vehicle is to be operated.
EC-4-2
FAN CLUTCH
FAN CLUTCH
CONSTRUCTION
ON-OFF TYPE
Model: FD1800L
Model: FD2000
EC-5-1
FAN CLUTCH
Model: FD2000-C
LINEAR TYPE
Model: FDL2000-C
EC-5-2
FAN CLUTCH
REMOVAL
1. Remove the fan and the fan clutch assembly as a unit.
2. Remove the fan from the fan clutch assembly.
INSPECTION
NOTE
z Care should be taken lest the bimetal is damaged or
deformed during removal and inspection.
Operation temperature check
1. Install the fan onto the fan clutch. Then run the fan drive
shaft continuously at a constant speed in the range from
2000 to 3000 rpm.
2. Install a thermometer and a drier, then blow hot air at the
bimetal.
3. Check to make sure that the speed of the fan changes from
low to high when the thermometer is indicating the following
temperature.
Unit: ºC (ºF)
Maintenance
Item Service limit
standard
FD1800L,
Fan clutch On-off 60 - 70
FD2000 and
changeove type (140 - 158)
FD2000-C
r tempera-
Linear 60±10 - 75±5
ture FDL2000-C
type (140±18 - 167±9)
INSTALLATION
1. Install the fan onto the fan clutch assembly.
: 16 - 19 N·m {1.6 - 1.9 kgf·m, 12 - 14 ft·lbf}
2. Install the fan and the fan clutch assembly as a unit.
: 30 - 36 N·m {3.1 - 3.7 kgf·m, 22 - 27 ft·lbf}
EC-5-3
FUEL SYSTEM
CONTENTS
SERVICE DATA................................. EF-1-1 NOZZLE AND NOZZLE HOLDER .... EF-4-1
SPECIFICATIONS ............................ EF-1-1 CONSTRUCTION ............................ EF-4-1
SERVICE DATA................................ EF-1-2 REMOVAL........................................ EF-4-1
TIGHTENING TORQUE ................... EF-1-2 DISASSEMBLY ................................ EF-4-2
FUEL SYSTEM................................. EF-1-3 REASSEMBLY ................................. EF-4-4
TOOLS............................................... EF-2-1 ADJUSTMENT ................................. EF-4-4
INJECTION PUMP ASSEMBLY........ EF-3-1 INSTALLATION ................................ EF-4-5 EF
INJECTION PUMP PROPER ........... EF-3-1 FUEL FILTER .................................... EF-5-1
FEED PUMP..................................... EF-3-4 REPLACEMENT .............................. EF-5-1
TIMER .............................................. EF-3-5 ENGINE CONTROL SYSTEM .......... EF-6-1
GOVERNOR..................................... EF-3-8 CONSTRUCTION ............................ EF-6-1
ADJUSTMENT ............................... EF-3-14 ADJUSTMENT ................................. EF-6-1
INJECTION PUMP CALIBRATION
DATA ............................................... EF-3-26
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
Item
Ignition system Compression ignition
Fuel injection timing B.T.D.C. 16º 17º 16º 14º *1 16º 14º *2
Ignition order 1-4-2-6-3-5
Main Filter paper x 1
Fuel filter Type x Number
Primary Filter paper x 1
Type Bosch
Fuel injection Plunger diameter mm (in) 11.5 (0.453) 12.0 (0.472)

pump Governor Centrifugal [Mechanical RFD-C type]
Timer Centrifugal [Mechanical SP or SPG type]
Nozzle holder Flange type
Nozzle Multi-hole type
Nozzle Number of nozzle holes 6 5 5 or 6
19,614 22,556
Injection pressure kPa {kgf/cm2, psi} {200, 2,844} {230, 3,271}
Over flow valve opening Injection pump outlet 157 {1.6, 23}
pressure 108 - 147
Fuel filter
kPa {kgf/cm2, psi } {1.1 - 1.5, 16 - 21}
NOTE
z *1: CKB454, 455. CWB454, 455
z *2: CKB453, CWB453, 455
EF-1-1
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
PF6 19,614 {200, 2,844}
PF6T, PF6TA
kPa {kgf/cm2, psi} 22,556 {230, 3,271}
PF6TB
Nozzle 20,104 - 20,889
PF6
Fuel injection pressure {205 - 213, 2,915 - 3,029}
kPa {kgf/cm2, psi} PF6T, PF6TA 23,046 - 23,831
PF6TB {235 - 243, 3,342 - 3,455}
TIGHTENING TORQUE
INJECTION PUMP
Delivery valve holder 108 - 118 {11.0 - 12.0, 80 - 87}
Delivery valve holder lock nut 39 - 44 {4.0 - 4.5, 29 - 33}
Screw bushing 39 - 59 {4.0 - 6.0, 29 - 43}
Timer special nut 83 - 93 {8.5 - 9.5, 61 - 69}
Bearing cover setting screw 7 - 9 0.{7 - 0.9, 5.1 - 6.5}
Governor housing setting screw 5 - 6 {0.5 - 0.6, 3.6 - 4.3}
Flyweight round nut 59 - 69 {6.0 - 7.0, 43 - 51}
Governor cover setting screw 5 - 7 {0.5 - 0.7, 3.6 - 5.1}
NOZZLE AND NOZZLE HOLDER

Nozzle holder assembly mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}
Type I 39 - 49 {4 - 5, 29 - 36}
Nozzle cap nut
Type II 29 - 39 {3 - 4, 22 - 29}
Nozzle retaining nut 59 - 78 {6 - 8, 43 - 58}
FUEL FILTER
Connector bolt 25 - 41 {2.5 - 4.2, 18 - 30}
Center bolt 20 - 29 {2 - 3, 14 - 22}
PRIMARY FUEL FILTER

Center bolt 59 - 69 {6 - 7, 43 - 51}
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
EF-1-2
SERVICE DATA
FUEL SYSTEM
PF6T, PF6TA & PF6TB
EF-1-3
TOOLS
TOOLS
Pin vice For cleaning nozzle orifice
99727 Z5005
Nozzle cleaner For removal of carbon from rear of nozzle orifice

99726 Z5000
Filter wrench For removal of fuel filter

99756 00Z01 (Only when replacing cartridge type ele-
ment)
* Tool numbers are designated by Zexel Co.

Special wrench For removal and installation of screw bushing
157915-6500
Special wrench For adjusting idling

157916-2620
Special wrench For supporting SP flange

157916-8320
Plunger inserter For inserting plunger

157921-5620
Mounting device For removal and installation of tappet

157921-8020
EF-2-1
TOOLS

Spring compressor For disassembling and reassembling the flyweight
157921-9820 assembly
Base For disassembling and reassembling the timer

157924-2520
Tappet holder For support of tappet

157931-4800
Plate For fixing nozzle holder

157944-9520
1 157944-9500
2 157944-9620
3 157944-9800
4 157944-9900
Socket wrench For dismounting and mounting delivery valve

157914-0500 holder
Measuring device For plunger pre-stroke

105782-4270
EF-2-2
INJECTION PUMP ASSEMBLY

INJECTION PUMP PROPER
DISASSEMBLY & REASSEMBLY
EF-3-1
Disassembly sequence (Reassembly sequence is in the reverse of disassembly.)

1 Cover 17 Plunger 33 Gasket
2 Gasket 18 Plunger spring 34 O-ring
3 Plug ,+ 19 Spring seat 35 Retaining ring
4 Key ,+ 20 Control sleeve 36 Deflector
5 Cover ,+ 21 Screw bushing 37 Washer
6 Shim 22 Pin 38 O-ring
7 O-ring 23 Control rack 39 Ring
,+ 8 Center bearing 24 Bushing 40 Plunger barrel
,+ 9 Camshaft 25 Bushing 41 Flange sleeve
10 Oil seal 26 Washer 42 Eye bolt
11 Bearing 27 Shim 43 Overflow valve
12 Bearing 28 Delivery valve holder 44 Eye bolt
13 Ring 29 O-ring 45 Plug
14 Shim 30 Stopper 46 Gasket
,+ 15 Tappet assembly 31 Spring 47 Gasket
16 Lower spring seat 32 Delivery valve
EF-3-2
Key points of disassembly & reassembly

8 Center bearing
9 Camshaft
Operate the spanner to position the tappets in the top lead center
position. Then, insert the tappet holders into each cylinder's plug
hole to separate the tappets from the camshaft.
Tool Name Tool Number Remarks
Cam lift:
10 mm (0.39 in);
Tappet holder 157931-4800
11 mm (0.43 in);
12 mm (0.47 in)
15 Tappet assembly
1. Attach the tappet inserter to both end-faces of the pump
housing.
Tool Name Tool Number Remarks
Tappet insert Shaft 157921-8020 For 6 cylinders
2. Operate the tappet inserter lever to raise the tappet, and

then remove the tappet holder.
NOTE
z Return the lever slowly after removing the tappet holder,
as the plunger spring force may cause the tappet assem-
bly to spring out.
19 Spring seat
20 Control sleeve
Using the plunger inserter (157921-5620), remove the control
sleeve and the upper spring seat together.
NOTE
z If the ball attached to the sleeve and the pump housing's
tappet guide groove are not aligned during control sleeve
removal, the control sleeve and upper spring seat cannot
be removed.
EF-3-3
21 Screw bushing
Using the special wrench (157915-6500), remove the governor side
screw bushing.
FEED PUMP
DISASSEMBLY

1 Eye bolt 7 Plug 13 Spring
2 Eye bolt 8 Gasket 14 Piston
3 Priming pump 9 Spring 15 Rod
4 Gasket 10 Valve 16 Snap ring
5 Spring 11 Plug 17 Tappet
6 Valve 12 Gasket 18 Housing
EF-3-4
TIMER
SP timer

1 Cap 7 Cover 13 Spring
2 Nut 8 O-ring 14 Spring seat
3 O-ring 9 Washer 15 Flange
4 Spring washer +, 10 Roller 16 Flyweight
5 Bolt +, 11 Bushing 17 Oil seal
6 Gasket 12 Retainer
EF-3-5
SPG timer

1 Cap 5 O-ring 9 Flange
2 Nut +, 6 Flyweight assembly 10 Oil seal
3 Spring washer 7 Eccentric cam
4 Cover 8 Eccentric cam
EF-3-6
Key points of disassembly & reassembly

z Clamp the base (157924-2520) in a vise, then install the
timer on the base.
<SP timer>
10 Roller
11 Bushing
Turn the wrench (157916-8320) to compress the timing device
spring and remove the washer, roller and bushing from the fly-
weight pin.
<SPG timer>
6 Flyweight assembly
EF-3-7
GOVERNOR
Whole view
EF-3-8
Governor cover
EF-3-9

1 Eye bolt 13 Control rod 25 Collar
2 Bracket 14 Start spring 26 Shim
3 Cover 15 Plug 27 Retaining ring
4 O-ring 16 Shaft 28 Bushing
5 Spring capsule 17 Guide lever assembly 29 Oil seal
6 Spring capsule 18 Collar 30 Governor spring
7 Nut 19 Stroke adjusting bolt 31 Speed setting lever
8 Cap nut 20 Pin 32 Control lever
9 Spring capsule 21 Tension lever 33 Control lever
10 Bolt 22 Speed control lever 34 Shaft
11 Governor cover 23 Key 35 Supporting lever
12 Gasket 24 Washer 36 Lever
EF-3-10
Governor housing

1 Round nut 5 Return spring 9 Plate
2 Flyweight assembly 6 Collar 10 Governor housing
3 Key 7 Shaft 11 Gasket
4 Stop lever 8 Lever
EF-3-11
Boost compensator

1 Cap nut 5 Lever 9 Spring
2 Spring capsule 6 Cap nut 10 Collar
3 Boost compensator assembly 7 Cover 11 Boost compensator housing
4 Pin 8 Diaphragm 12 Governor housing
EF-3-12
Aneroid compensator
1 Cap 5 Link 8 Lock nut

2 Joint 6 Nut 9 Retaining ring
3 Cap nut 7 Rubber boot 10 Housing
4 Nut
NOTE
z Numbers before part names do not indicate the disassembly sequence.
EF-3-13
ADJUSTMENT
When the injection pump has been disassembled, plungers or
plunger springs have been replaced, or other reasons exist, use a
pump tester and adjust the injection pump.
INJECTION PUMP PREPARATIONS

Remove the cap of the control rack and install the measuring
device (105782-6280).
INITIAL INJECTION TIMING ADJUSTMENT

The start of injection is considered as the time at which the top of
the plunger covers the fuel intake hole of the barrel. The pump
tester must be capable of developing a pressure in the range of
3,138 to 4,707 kPa {32 to 48 kgf/cm2, 455 to 683 psi} in order to
overcome tension of the delivery valve spring (to force the delivery
valve open).
Installing injection pump
1. Attach the injection pump to the tester and connect the fuel
system lines. Arrange so that the camshaft angle can be
read on the tester angle scale plate.
2. Secure the control lever at the full injection position.
Adjusting the injection timing of the standard cylinder

1. Removing the 1st cylinder delivery valve holder. To do this,
use the Socket wrench (157914-0500). The delivery valve
spring, delivery valve and gasket can then be taken out.
2. Install the special tool “Plunger stroke measuring tool

(105782-4270)” to the flange sleeve by turning it as for as it
will go.
3. Rotate the camshaft to bring the tappet for No. 1 cylinder in
the bottom dead center position, zero the dial indicator.
4. Proper position is indicated by the stop of fuel flowing out of
the end of the nozzle pipe when turning the camshaft to
raise the plunger, if the tappet lift reads 3.65±0.05 mm
(0.1437±0.0020 in) (PF6 and PF6T) or 3.90±0.05 mm
(0.1535±0.020 in) (PF6TA, B), the pump is set for the start
of injection of No. 1 cylinder.
The engine is then set to the proper position for injection on
that cylinder.
EF-3-14
5. When fuel injection does not stop even when the tappet has
risen more than 3.65±0.05 mm (0.1437±0.0020 in) (PF6
and PF6T) or 3.90±0.05 mm (0.1535±0.0020 in) (PF6TA,
B), pull out the plunger block assembly, and remove adjust-
ing shims until the fuel flow stops at a lift of 3.65±0.05 mm
(0.1437±0.0020 in) (PF6 and PF6T) or 3.90±0.05 mm
(0.1535±0.0020 in) (PF6TA, B).
6. When the fuel flow stops before the tappet is raised
3.65±0.05 mm (0.1437±0.0020 in) (PF6 and PF6T) or
3.90±0.05 mm (0.1535±0.0020 in) (PF6TA, B), pull out the
plunger block assembly and add adjusting shims until the
fuel flow stops at a lift of 3.65±0.05 mm (0.1437±0.0020 in)
(PF6 and PF6T) or 3.20±0.05 mm (0.1535±0.0020 in)
(PF6TA, B).
Checking timer mark

Under conditions described in “Installing injection pump'' and
“Adjusting the injection timing of the standard cylinder'' above, the
position of initial injection of the reference plunger must appear
when the mark of the flyweight holder and that of the bearing cover
(pump body) coincide. If these marks do not coincide at this time,
the timer flyweight holder mark must be shifted. When the timer has
been replaced, alignment must also be made to the bearing cover
mark after adjusting initial injection timing for the reference cylinder.
Adjusting injection interval
1. After completing adjustment of initial injection timing of the
reference No. 1 cylinder (timer side), turn the camshaft to
the right (as viewed from the drive end) and set the injection
interval for the remaining cylinders by adjusting shims.
See the table below.
2. Adjust the cylinder injection intervals within ±30’.
Injection
--------- 1 — 4 — 2 — 6 — 3 — 5 — 1
order
Injection
--------- 60º 60º 60º 60º 60º 60º
interval
Scale plate
--------- 0º — 60º — 120º — 180º — 240º — 300º — 360º
indication
EF-3-15
Setting the control rod's zero position

1. Remove the rack limiter (or rack cap) mounted on the
pump's drive side and then mount the measuring device
used for setting the control rod position.
NOTE
z If a boost compensator is installed on the pump's drive
side, remove it and then mount the measuring device.
2. Fix the load control lever in the idling position.

3. Drive the pump at 500 rpm to 600 rpm and temporarily fix
the speed control lever so that governor control starts within
this speed range.
4. Increase pump speed so that the control rod travels to the

non-injection position.
Push the end of the measuring device mounted on the end
of the control rod fully to the governor side and set the mea-
suring device at “0”.
NOTE
z Do not set the control rack's “0'' position by operating
the control lever when the pump is not being driven. This
can damage the link connection.
Flyweight lift and full load position

Total flyweight lift includes the lift necessary for high-speed control
and the lift necessary for idling.
1. Temporarily fix the load control lever in the full load position
(control rod position “Rb”).
2. Temporarily set the speed control lever so that governor
control starts at a pump speed of approximately 700 rpm to
800 rpm.
EF-3-16
3. Increase the pump speed to “Na rpm” and adjust using the
full load stopper bolt so that the control rod position is “Ra”.
4. Next, lower the pump speed to “Nb rpm” and adjust the
high-speed lift to “L” using the stroke adjusting screw.
Maximum-speed control and speed droop

1. Set the load control lever to the full position. Temporarily fix
the speed control lever in the maximum speed position.
2. Slowly increase the pump speed, adjust the minimum
speed stopper bolt so that the control rod starts moving in
the fuel-decrease direction at “Nk rpm” and then fix the lock
nut.
3. Further increase the pump speed and check that the pump
speed is “N liter rpm” or less when the control rod is at the
“Ri” position.
Also increase the pump speed and confirm the flyweight lift
(L) for high speed control.
NOTE
z When the high-speed droop confirmation point is at the
point where the damper spring is operating, adjust the
idling and damper springs and then make the above
adjustments and confirmations.
z Replace the governor spring if the specified values can-
not be obtained.
4. Further increase the pump speed and confirm that the con-
trol rod is in the non-injection zone [or 3 mili-liter (0.11 Imp fl
oz)/1,000 st or less) at “Nm rpm”.
EF-3-17
Idling
1. Drive the pump at “Nc rpm” (Nd + 100 rpm).
2. Adjust the control rod position to “Rc” using the idle adjust-
ing screw.
3. Decrease the pump speed to “Ne rpm” and adjust the idling
spring capsule using the wrench (157916-2620) so that the
control rod position is “Rd”.
4. Confirm that the control rod position is “Re” or more when

the pump speed is 0 rpm and that the control rod position is
“Rc” when the pump speed is increased to “Nd rpm”.
Load control lever angle measurement

Confirm that the lever angles are as specified when the load control
lever is at the idling position and the full load position. If not as
specified, replace the shim located between the shifter and sleeve.
NOTE
z When the shim is replaced, the maximum speed control
and idling adjustments must be repeated.
EF-3-18
Damper spring
1. Hold the load control lever at the idling position.
2. Slowly increase the pump speed from idling speed “Ne
rpm”, and maintain the pump speed of “Nc rpm” where the
control rod position is “Rf - 0.2mm”.
3. Screw in the damper spring so that the rod position is “Rf -

0.1mm” and fix it with the lock nut.
Stopper bolt
If idling performance is included in calibration data, as represented
by the dotted line in the illustration at right, adjust the setting of the
idle adjusting screw.
1. After adjusting the damper spring, the control rod position
should be “Re” when the pump is stopped.
2. Under the above conditions, loosen the idle adjusting screw

and adjust it so that the control rod position is “Rg”.
EF-3-19
Positive torque control (When installed)

1. Drive the pump at “Nc rpm” and hold the load control lever
in the full load position.
2. Next, adjust the torque control spring capsule using the
wrench (157916-2620) so that the torque control stroke is
the specified value. After adjustment, fix it securely with a
lock nut.
3. Slowly increase the pump speed from “Nc rpm” and adjust
the screw so that the torque control spring starts to take
effect at “Nf rpm”.
NOTE
z When shims are used, adjust by varying the shim thick-
ness.
4. Increase the pump speed and confirm that the torque con-
trol spring stops taking effect at “Nh rpm”.
5. Increase and decrease the pump speed between “Nc rpm”
and “Nb rpm” and confirm that the torque control stroke is
NOTE the specified value.
z If the torque control stroke is not the specified value,
readjust using the spring capsule screw.
z If the torque control spring does not stop taking effect at
the specified speed, replace the spring capsule.
Minimum-speed stopper bolt

z Minimum-maximum speed governor
1. Move the speed control lever until it contacts the maximum
speed stopper bolt, and then screw the minimum speed
stopper bolt in until it contacts the speed control lever.
EF-3-20
z Variable-speed governor
1. Fix the load control lever in the full load position.
2. Return the speed control lever in the fuel-decrease direction
and drive the pump at “Ny rpm”, slightly faster than idling
speed.
3. Next, adjust the minimum-speed stopper bolt so that the

control lever is at the “Rb/Ny” position and then fix it with the
lock nut.
Speed control lever angle confirmation

1. Confirm that the angle of the speed control lever is the
specified value at the maximum-speed position.
2. Confirm that the angle of the speed control lever is the
specified value at the minimum-speed position.
3. If the angle is not as specified, replace the governor spring.
Torque spring (when installed)

1. Hold the load control lever in the full load position. Also hold
the speed control lever in the maximum speed position.
2. Confirm that governor control starts at a speed of “Nk rpm”.
3. Slowly decrease the pump speed from “Nv rpm” and adjust
the torque spring capsule so that the control rod is at posi-
tion “Rc” at a speed of “Nq rpm”.
4. Confirm that the control rod is at position “Rd” at a pump
speed of “Nr rpm”, and at position “Rp” at a pump speed of
“Np rpm”.
5. Also confirm the injection quantity at point B.
EF-3-21
NOTE
z The plug on the side of the governor cover is used to
hold the torque lever. Thus, this plug has no relationship
to torque spring adjustment and should not be touched.
The plug is coated with paint to draw attention to it at
repair shops. If this paint seal should be broken, disas-
semble the governor, check the torque lever position and
then repaint it.
Full load injection quantity confirmation

1. Hold the load control lever in the full load position.
2. Next, confirm that the fuel injection quantity (point A) under
a full load is as specified.
3. If not as specified, adjust using the full load stopper bolt.
Smoke limiter
1. Hold the load control lever in the full load position.
2. Maintain the pump speed at “Nn rpm”.
3. Screw in the spring capsule or screw and lock it at point E,
where the specified fuel injection quantity may be obtained.
NOTE
z There is no rack limiter when a boost compensator is
mounted on the drive side.
EF-3-22
Stop lever position

1. Drive the pump at 800 rpm.
2. Move the stopper lever to the stop side and confirm that the
control rod enters the non-injection zone.
3. If the control rod does not enter the non-injection zone,
check the linkage inside the governor.
Boost compensator (if equipped)

1. Mount the boost compensator assembly on the top of the
governor. Set the screw to the position measured at the
time of disassembly.
2. Attach a tube to the eye of the boost pressure intake port
and install the air tube.
3. Hold the load control lever in the full load position and drive
the pump at a speed of “Nu rpm” (500 rpm unless otherwise
specified).
4. With no boost pressure applied, adjust the boost compen-

sator stroke to the specified value using the screw for rack
position adjustment.
EF-3-23
5. Adjust using the adjusting screw (250/62) so that, when the

pressure is P1, the control rod begins to move in the fuel-
increase direction.
Then lock it with the nut.
6. Increase the boost pressure and confirm that the control rod
is in position R1 at P1. Also confirm that the control rod is at
the R2 position at P2.
7. If not as specified, replace the boost compensator spring.
Aneroid compensator (if equipped)

1. Aneroid compensator kit adjustment (Before governor
installation)
EF-3-24
2. Adjustment at governor installation

With the load control lever in the Full position (pump speed
= 1,050 rpm), screw in the aneroid compensator assembly
so that the following performance can be obtained.
NOTE
z After adjusting the A.C.S housing and the retaining ring
is 0.1 to 0.5 mm (0.004 to 0.020 in).
EF-3-25
INJECTION PUMP CALIBRATION DATA

Testing conditions
Failure of pump to deliver fuel evenly throws the engine out of balance so that roughness and loss of power is
evident. In calibrating a pump, observe the following:
Item Test condition
Nozzle and Nozzle holder assembly 105780-8140 (BOSCH Type No. EF8511/9A)
Nozzle 105780-0000 (BOSCH Type No. DN12SD12T)
Nozzle holder 105780-2080 (BOSCH Type No. EF8511/9)
2, 17,162 {175, 2,489}
Nozzle opening pressure kPa {kgf/cm psi}
2 157 {1.6, 23}
Feed pump oil pressure kPa {kgf/cm , psi}
Injection pipe (OD x ID - L) mm (in) 8 x 3 - 600 (0.31 x 0.12 - 23.62)
Test oil IS04113 or SAE standard test oil (SAE J967d)
Test oil temperature ºC (ºF) 40 - 45 {104 - 113}
2, 157 {1.6, 23}
Overflow valve opening pressure kPa {kgf/cm psi}
Injection quantity standards (“ZEXEL No.” is Inj. Pump assembly No.)
z ZEXEL No. 106691-0550

Pump Injection q'ty Max. var.
Adjusting Rack Position
Speed mili-liter (Imp fl oz)/1,000 bet. cyl. Fixed Remarks
Point mm (in)
rpm strokes (%)
A 8.0 (0.315) 650 114.5±2 (4.03±0.07) ±4 Lever Basic Excessive fuel setting for starting
Approx. 5.1
C 260 12.5±1.3 (0.44±0.05) ±10 Rack
(0.201)
z ZEXEL No. 106671-5064

Pump Injection q'ty Max. var
Speed mili-liter (Imp fl oz)/1,000 bet. cyl Fixed Remarks
Point mm (in)
rpm strokes (%)
A 11.9 (0.457) 600 166.4±2 (4.10±0.07) ±14 Rack
Approx. 7.2 Basic
H 250 16.7±1 (0.59±0.04) ±10 Rack
(0.283)
Basic
A 11.9 (0.457) 600 166.4±2 (4.10±0.07) Lever Boost press. kPa {mmHg, inHg}
Above 30.7 {230, 9.06}
Boost press. kPa {mmHg, inHg}
B 11.9 (0.457) 1,050 Lever
Above 30.7 {230, 9.06}
C 9.8 (0.386) 300 101.6±3 (3.58±0.11) Lever Boost press. 0
D 11.9 (0.457) 40 Lever
Above 30.7 {230, 9.06}
Approx. 7.2
E 290 Lever Boost press. 0
(0.283)
NOTE
z The injection quantity and the governor must be adjusted at an ambient temperature of at least
15ºC (59ºF) (as the boost compensator start spring is a shape-memory alloy).
EF-3-26
z ZEXEL No. 106671-5161

Speed mili-liter (Imp fl oz)/1,000 bet. cyl Fixed Remarks
Point mm (in)
rpm strokes (%)
Basic
A 11.9 (0.469) 600 166.4±2 (5.86±0.07) ±4 Lever
Above 30.7 {230, 9.06} Rack limit using
stop lever
Approx. 7.2
C 250 16.7±1 (0.59±0.04) ±10 Rack Boost press. 0
(0.283)
D 9.8 (0.386) 300 101.6±3 (3.58±0.1) Lever Boost press. 0
NOTE
z ZEXEL No. 106671-5101
Pump Injection q'ty mili- Max. var
Speed liter (Imp fl oz)/ bet. cyl Fixed Remarks
Point mm (in)
rpm 1,000 strokes (%)
159.5±2
A 10.8 (0.425) 600 ±4 Rack
(5.61±0.07)
Basic
Approx. 6.2 14±1.3
H 260 ±10 Rack
(0.244) (0.49±0.05)
Basic
159.5±2
A 10.8 (0.425) 600 Lever Boost press. kPa {mmHg, inHg}
(5.61±0.07)
Above 34.7 {260, 10.3}
B 10.8 (0.425) 1,050 Lever
Above 34.7 {260, 10.3}
125±3
C 9.5 (0.374) 400 Lever Boost press. 0
(4.40±0.11)
D 10.8 (0.425) 40 Lever
Above 34.7 {260, 10.3}
E 10.3 (0.406) 500 Lever 16.0±1.3
{120±10, 4.72±0.39}
Approx. 6.2
F 290 Lever Boost press. 0
(0.244)
EF-3-27
z ZEXEL No. 106671-5151

Pump Injection q'ty mili- Max. var
Speed liter (Imp fl oz)/1,000 bet. cyl Fixed Remarks
Point mm (in)
rpm strokes (%)
Basic
A 10.8 (0.425) 600 159.5±2 (5.61±0.07) ±4 Lever Boost press. kPa {mmHg, inHg}
Above 34.7 {260, 10.3}
Approx. 6.2
C 260 14±1.3 (0.49±0.05) ±10 Rack Boost press. 0
(0.244)
D 9.5 (0.374) 400 125±3 (4.40±0.11) Lever Boost press. 0
The injection quantity and the governor must be adjusted at an ambient temperature of at least 15ºC
(59ºF) (as the boost compensator start spring is a shape-memory alloy).
z ZEXEL No. 106671-5111

Speed mili-liter (Imp fl oz)/ bet. cyl Fixed Remarks
Point mm (in)
A 11.4 (0.449) 600 174±2 (6.1±0.07) ±4 Rack
Approx. 6.2 Basic
H 260 14±1.3 (0.49±0.05) ±10 Rack
(0.244)
Basic
A 11.4 (0.449) 600 174±2 (6.1±0.07) Lever Boost press. kPa {mmHg, inHg} Above 41.3
{310, 12.2}
B 11.4 (0.449) 1,050 Lever
Above 41.3 {310, 12.2}
C 9.5 (0.374) 400 125±3 (4.40±0.11) Lever Boost press. 0
D 11.4 (0.449) 40 Lever
Above 41.3 {310, 12.2}
E 10.3 (0.406) 500 Lever
16.0±1.3 {120±10, 4.72±0.39}
Approx. 6.2
F 290 Lever Boost press. 0
(0.244)
The injection quantity and the governor must be adjusted at an ambient temperature of at least 15ºC
(59ºF) (as the boost compensator start spring is a shape-memory alloy).
EF-3-28
z ZEXEL No. 106671-5251

Point mm (in)
Basic
A 12.4 (0.488) 1,050 202±2 (7.11±0.07) ±4 Lever Boost press. kPa {mmHg, inHg}
Above 80.0 {600, 23.62}
Approx. 6.4
(0.252)
(91.5)±3
D 8.8 (0.346) 400 Lever Boost press. 0
[(3.22)±0.11]
NOTE
z ZEXEL No. 106671-5371

Point mm (in)
Basic
A 12.4 (0.488) 1,050 202±2 (7.11±0.07) ±4 Lever Boost press. kPa {mmHg, inHg}
Above 77.3 {580, 22.83}
Approx. 6.4
(0.252)
D 8.6 (0.339) 400 95±3 (3.34±0.11) Lever Boost press. 0
NOTE
EF-3-29
Governor adjustment diagram (“ZEXEL No.” is Inj. pump assembly No.)

ZEXEL No. 106691-0550
EF-3-30
ZEXEL No. 106671-5064
EF-3-31
ZEXEL No. 106671-5161
EF-3-32
ZEXEL No. 106671-5101
EF-3-33
ZEXEL No. 106671-5151
EF-3-34
ZEXEL No. 106671-5111
EF-3-35
ZEXEL No. 106671-5251
EF-3-36
ZEXEL No. 106671-5371
EF-3-37
TESTING TIMER
In general, measurement of the timer advance angle is performed
on the pump tester after completing an adjustment of the injection
timing, injection quantity and governor.
Timing Advance Specification

z ZEXEL No. 106691-0550 Only
Pump speed (rpm) Below 900 850 1,050
Finish
Advance angle (º) Start Below 0.5
1.0±0.5
Except for ZEXEL No. 106691-0550

Pump speed (rpm) Below 750 700 1,050
Finish
Advance angle (º) Start Below 0.5
1.0±0.5
EF-3-38

CONSTRUCTION
NOTE
z Type I: Nozzle holder assembly abbreviation No. 31-4370
z Type II: Nozzle holder assembly abbreviation No. 30-4540
REMOVAL
1. Chock the wheels and tilt the cab.
2. Turn the key switch off and disconnect the cable from the
negative terminal of the battery.
3. Disconnect the injection nozzle tube and spill tube, remove
the nozzle holder assembly from the cylinder head.
EF-4-1
DISASSEMBLY
1 Cap nut 5 Nozzle spring 9 Nozzle holder

2 Gasket 6 Push rod 10 Connector
,+ 3 Adjusting screw ,+ 7 Retaining nut 11 Gasket
4 Spring seat (Type I only) ,+ 8 Nozzle assembly 12 Pin

3 Adjusting screw
1. Clamp the nozzle holder into a vise with plate (157944-
9520).
2. Set the nozzle holder in the plate and remove the cap nut.
3. Loosen the adjusting screw unit.
Remove the adjusting screw and separate the nozzle spring
and push rod.
EF-4-2
7 Retaining nut
Reverse the nozzle holder position by facing the nozzle-side up,
and remove the retaining nut with a appropriate wrench.
8 Nozzle assembly
Remove the nozzle needle from the nozzle body.
NOTE
z Do not use the nozzle needle in another nozzle body.
INSPECTION
NOTE
z Remove carbon from around nozzle jets using a wire
brush.
Clearance between nozzle body and nozzle
1. Remove carbon from around nozzle jets using the pin vise
(99727 Z5005).
Unit: mm (in)
Nozzle identifica- Number of injection Injection nozzle
Wire diameter
tion mark nozzle holes hole diameter
F8 6 0.310 (0.0122) 0.29 (0.0114)
H4 5 0.350 (0.0138) 0.29 (0.0114)
H2 5 0.360 (0.0142) 0.35 (0.0138)
H5 6 0.315 (0.0124) 0.29 (0.0114)
K1 6 0.320 (0.0126) 0.29 (0.0114)
NOTE
z Do not extend tip of the holder more than 2 to 2.5 mm
(0.079 to 0.098 in). Otherwise, it may bend inside the noz-
zle body and it cannot be removed.
z Carefully push the holder into the inside of the nozzle to
remove carbon.
z Use an oil stone to grind the wire tip of the holder until it
is shaped as shown in the figure.
EF-4-3
2. Clean remaining carbon off the back of the nozzle jet using
the nozzle cleaner (99726 Z5000).
NOTE
z Be careful not to scratch the seating surface of the noz-
zle jet and the nozzle needle.
Do not use compressed air to remove carbon because
this may introduce foreign matter into the jet.
3. Install the needle on the nozzle body while immersing both
in clean diesel fuel.
4. Visually check the needle valve seat, guide shaft and injec-
tion shaft for damage or carbon accumulation.
5. Position the nozzle body vertically. Pull out the needle so
that it protrudes approximately 1/3 its total length beyond
the top of the nozzle body. Then release it to ensure that it
drops to the valve seat under its own weight.
REASSEMBLY
1. To reassemble, reverse the order of the above removal pro-
cedures. Observe the following:
NOTE
z Clean the mating surfaces of the nozzle and nozzle
holder and the retaining nut in clean diesel fuel before
installation.
z Use new gaskets.
ADJUSTMENT
1. Loosen the adjusting screw and install the nozzle on a noz-
zle tester. Operate the hand lever forcefully two or three
times to remove foreign matter.
2. Adjust fuel injection pressure using the adjusting screw.
20,104 - 20,889
Fuel injec- PF6
{205 - 213, 2,915 - 3,029}
tion pres-
sure 23,046 - 23,831
PF6T PF6TA PF6TB
{235 - 243, 3,342 - 3,455}
EF-4-4
WARNING
WARNING
z Be extremely careful not to direct fuel spray to hands,
etc. while adjusting fuel injection. It may penetrate into
blood vein through the skin and cause toxic symptoms.
3. After adjusting injection pressure to specifications, install

the cap nut. Recheck injection pressure.
Type I
: 39 - 49 N·m {4 - 5 kgf·m, 29 - 36 ft·lbf}
Type II
: 29 - 39 N·m {3 - 4 kgf·m, 22 - 29 ft·lbf}
Checking spray and fuel leakage

While adjusting injection pressure, check the spray pattern. Also
check for signs of fuel leakage or obstruction. If inspection reveals
slight wear on the seating surfaces of the nozzle body and needle,
lap both using lapping compound. If either part requires replace-
ment, replace both parts as a unit.
1. Equal, symmetrical fuel spray pattern

2. Asymmetrical fuel spray pattern
3. Incorrect fuel spray pattern
4. Lean fuel spray pattern
5. Stepped fuel spray pattern
6. Equal fuel spray (from 5 jets)
INSTALLATION
1. Install the nozzle holder assembly on the cylinder head.
: 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf}
2. Connect the spill tube and injection nozzle tube.
3. Bleed air from the fuel system. (Refer to the “MA” section
for procedures.)
EF-4-5
FUEL FILTER
FUEL FILTER
REPLACEMENT
REPLACE FUEL FILTER ELEMENT
Method of replacement
Cartridge type
1. Place a container under the filter. Remove the filter with a
filter wrench. Drain any remaining fuel into the container.
2. Apply a thin coat of clean engine oil to the gasket of the new
filter.
CAUTION
z Installation of the fuel filter without coating the gasket
with oil may damage the gasket resulting in leakage of
fuel and fire hazard due to spilled fuel.
3. Install the new fuel filter. After the gasket comes in contact
with the bracket sealing surface, tighten an additional three-
fourths of a turn.
NOTE
z When installing the fuel filter, securely tighten it three-
fourths of a turn using the exclusive filter wrench pro-
vided in the vehicle.
EF-5-1
FUEL FILTER
Center bolt type

1. Place a suitable oil can under the drain cock, and drain the
fuel and sediment.
and element.3.
Fuel filter center bolt
: 20 - 29 N·m {2 - 3 kgf·m, 14 - 22 ft·lbf}
NOTE
Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
1 Drain plug 6 Spring
2 Packing 7 Seat
3 Center bolt 8 Element
4 Packing 9 Packing
5 Filter case 10 Filter cover

DRAIN SEDIMENT FROM PRIMARY FUEL FILTER

Draining procedure
NOTE
z It is not necessary to drain all the fuel in the primary fuel
filter case.
Place a receiver under the filter, then loosen the drain plug to drain
sediment. Put the drained precipitates in a glass container such as
a test tube. If there is fuel on top of the water, dust and precipitates,
it indicates that the precipitates have been removed.Bleed air from
the fuel system after draining sediments.
EF-5-2
FUEL FILTER
REPLACE PRIMARY FUEL FILTER ELEMENT

Method of replacement
1. Place a suitable oil can under the drain cock, and drain the
fuel and sediment.
and element.
Fuel filter center bolt
: 20 - 29 N·m {2.0 - 3.0 kgf·m, 14 - 22 ft·lbf}
NOTE
Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
1 Drain plug 7 Seat
2 Packing 8 Element
4 Packing 10 Filter cover
5 Filter case 11 O-ring
6 Spring 12 Plug assembly

PURGING AIR FROM FUEL SYSTEM

Air entrapped in the fuel system will cause poor injection of the fuel,
thus resulting in difficult starting, jerking, or even stall of the engine.
After completing any service procedure on the fuel system (inspec-
tion, replacement of fuel filter element, or reconnection of any fuel
pipe), be sure to bleed air from the fuel system.
1. Twist the knob on the priming pump, which is connected to

the injection pump, and the knob will rise up by itself.
2. Move the priming pump's knob up and down to send fuel
from fuel tank into the filter. Continue this procedure until
the overflow valve of the fuel filter no longer gives off a
"hissing” sound and movement of the priming pump is diffi-
cult. The air bleeding operation is now complete.
tion. Start the engine, and make sure that no fuel is leaking
from the fuel system. Fuel leaks can cause a fire. If a leak is
found, immediately repair the affected part.
EF-5-3
ENGINE CONTROL SYSTEM

CONSTRUCTION
Schematic diagram
ADJUSTMENT
ENGINE CONTROL WIRE
1. Turn the engine control knob counterclockwise all the way.
Under this condition, install the engine control wire to lever
B.
2. Install the engine control wire clamp to the accelerator link-
age assembly.
3. With the accelerator pedal contacting lever B, make sure
the accelator pedal angle is 50º to the floor.
EF-6-1
ACCELERATOR WIRE
1. Connect one end of the accelerator wire to lever. Securely
fit the clip on the wire in the panel.
NOTE
z Be careful not to break the boot.
2. Connect the accelerator wire to the engine side. When the

load control lever of the injection pump touches the full load
position of the set bolt, ensure that there is clearance "H"
between the pedal and stopper bolt. Then, secure the stop-
per bolt.
Unit: mm (in)
Clearance (H) 1 - 2 (0.04 - 0.08)
ENGINE STOP LINKAGE

1. Temporarily install the engine stop wire to the bracket and
connect the clevis to the engine stop lever.
2. Turn the wire lock nut until the stop lever comes into contact
with the set bolt on the stop side. Then, tighten the lock nut.
EF-6-2
- MEMO -
AIR INTAKE AND EXHAUST
SYSTEM
CONTENTS
SERVICE DATA.................................. IE-1-1 INSTALLATION ................................ IE-3-15
SPECIFICATIONS ............................. IE-1-1 INTERCOOLER.................................. IE-4-1
SERVICE DATA................................. IE-1-2 CONSTRUCTION .............................. IE-4-1
TIGHTENING TORQUE .................... IE-1-3 AIR CLEANER ................................... IE-5-1
INTAKE AND EXHAUST SYSTEM.... IE-1-4 DISASSEMBLY .................................. IE-5-1
TOOLS................................................ IE-2-1 ELEMENT REPLACEMENT .............. IE-5-1
TURBOCHARGER ............................. IE-3-1 EXHAUST BRAKE ............................. IE-6-1
CONSTRUCTION .............................. IE-3-1 CONSTRUCTION .............................. IE-6-1 IE
REMOVAL ......................................... IE-3-1 DISASSEMBLY .................................. IE-6-4
DISASSEMBLY ................................. IE-3-2 INSPECTION ..................................... IE-6-7
INSPECTION..................................... IE-3-7 REASSEMBLY ................................... IE-6-7
REASSEMBLY ................................ IE-3-11
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
AIR CLEANER
Engine model PF6 PF6T PF6TA PF6TB
Type Cyclone
Element Paper element (Dry) or Metallic element Paper element (Dry)
TURBOCHARGER
Model and (Type) T51 (Type I) T51 (Type I), T51 (Type II)
External dimensions
(Length x Width x Height) 220 x 209.5 x 178 (8.66 x 8.25 x 7.01)
mm (in)
Max. permissible continu-
ous speed 105,000
rpm
Direction of rotation Counterclockwise as viewed from the exhaust turbine side
Air volume
21 (46) 22.8 (50.3)
kg/min (lb/min)
Compression ratio 3.2
NOTE
z Type I: No O-ring on back plate
z Type II: O-ring provided on back plate
Refer to the illustration on page IE-3-2.
INTERCOOLER
Type Air to air
Intercooler Corrugated fin
EXHAUST BRAKE
Type Cylinder type
Operating method Air type
Exhaust shutter type Type II Type I
IE-1-1
SERVICE DATA
SERVICE DATA
TURBOCHAGER
Unit: mm (in)
0.025 - 0.080
Play in shaft axial direction
(0.0010 - 0.0031)
Inside diameter of cen- Bearing part 20.19 (0.7949)

ter housing Piston ring part 20.93 (0.8240)
Outside diameter of tur- Journal part 12.99 (0.5114)

bine wheel shaft Piston ring part 17.48 (0.6882)
Outside diameter of turbine wheel shaft hub 19.89 (0.7831)
Piston ring groove width of shaft 1.74 (0.0685)
Runout of shaft 0.01 (0.0004)
Inside diameter of back plate 17.49 (0.6886)
Thrust collar groove width 4.44 (0.1748)
Inside diameter of thrust collar 7.95 (0.3130)
Outside diameter of thrust spacer 17.06 (0.6717)
Inside diameter of thrust spacer 7.95 (0.3130)
Piston ring groove width of thrust spacer 1.77 (0.0697)
Thrust bearing thickness 4.36 (0.1717)
Outside diameter of journal bearing 20.07 (0.7902)
Inside diameter of journal bearing 13.04 (0.5134)
Compressor wheel inside diameter 7.94 (0.3126)
INTERCOOLER
Intercooler check pressure (air) 196 {2.0, 28}
EXHAUST BRAKE
Unit: mm (in)
When compressed to 105
Air intake shutter side 94.1 {9.6, 21.2}
Spring tension mm (4.13 in)
Air cylinder
N {kgf, lbf} When compressed to 113.2
Exhaust shutter side 77.5 {7.9, 17.4}
mm (4.46 in)
More than
Valve movement in the Type I
0.7 (0.028)
axial direction when clos-
ing the valve More than
Type II
0.5 (0.020)
Exhaust shutter
0.1 - 0.4
One side
Clearance between valve (0.004 - 0.016)
and body 0.2 - 0.5
Both sides
(0.008 - 0.020)
More than
Clearance between air cylinder shaft and clevis
1.0 (0.04)
IE-1-2
SERVICE DATA
TIGHTENING TORQUE
TURBOCHARGER
Oil inlet adapter mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Oil drain pipe mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Thrust bearing mounting screw 3.4 - 3.9 {0.35 - 0.40, 2.5 - 2.9}
Back plate and center housing mounting bolt 10.2 - 11.9 {1.04 - 1.21, 7.5 - 8.8}
Compressor wheel mounting nut 3.6 - 4.7 {0.37 - 0.48, 2.7 - 3.5} -> Tighten (120º)
Clamp mounting bolt 9.0 - 11.3 {0.92 - 1.15, 6.7 - 8.3}
Turbine housing and center housing mounting V-band lock nut 17.0 {1.73, 12.5} -> Loosen -> 13.7 {1.40, 10.1}
Turbocharger assembly mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
EXHAUST BRAKE
Air cylinder mounting nut Exhaust shutter side 21 - 25 {2.1 - 2.6, 15 - 19}
Air cylinder mounting bolt Air intake shutter side 36 - 50 {3.7 - 5.1, 27 - 37}
Air cylinder cover mounting bolt 10 - 16 {1.0 - 1.6, 7 - 12}
Air cylinder shaft nut 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter shaft nut 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter shaft cover mounting nut 21 - 25 {2.1 - 2.6, 15 - 19}
Lever mounting nut (Exhaust shutter only) 10 - 16 {1.0 - 1.6, 7 - 12}
Stopper bolt lock nut (Exhaust shutter only) 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter mounting bolt 21 - 25 {2.1 - 2.6, 15 - 19}
IE-1-3
SERVICE DATA
INTAKE AND EXHAUST SYSTEM

INTAKE SYSTEM
Without turbocharger
With turbocharger
IE-1-4
SERVICE DATA
IE-1-5
SERVICE DATA
EXHAUST SYSTEM
NOTE
z The above illustration is an example. It differs according to model and specifications.
IE-1-6
TOOLS
TOOLS
TURBOCHARGER
Turbocharger tool kit Used when disassembling and reassembling the
99760 96004 turbocharger.
Deep socket Used to tighten and remove the nut of the V-band.
99535 96000
Retaining ring plier Used when removing the retaining ring at

99546 96000 the center housing.
T-handle Used to remove and install the impeller

99773 96000 lock nut.
Holding fixture Used when disassembling and reassem-

99768 96009 bling the rotating assembly.
Piston ring guide Used when inserting the piston ring to the
99763 96000 turbine wheel.
Pick Used when fitting the piston ring of the

99767 96003 shaft to the center housing.
IE-2-1
TURBOCHARGER
TURBOCHARGER
CONSTRUCTION
REMOVAL
WARNING
WARNING
z To avoid being burned, do not touch the exhaust pipe,
turbocharger and muffler while the engine is running or
immediately thereafter. Check that the engine has cooled
before starting work.
1. Remove the air intake duct and shield plate.

2. Remove the exhaust brake assembly and exhaust connec-
tor.
3. Remove the oil inlet tube and oil inlet adapter.
4. Remove the oil outlet pipe.
5. Remove the air intake hose and intake housing.
6. Remove the turbocharger assembly.
IE-3-1
TURBOCHARGER
DISASSEMBLY
TYPE I & TYPE II

1 Lock nut ,+ 8 Compressor wheel ,+ 15 Piston ring
2 V-band , 9 Turbine wheel 16 Seal ring
,+ 3 Turbine housing ,+ 10 Piston ring ,+ 17 Thrust bearing
4 Clamp 11 Shroud wheel ,+ 18 Thrust collar
,+ 5 Compressor housing + 12 Back plate ,+ 19 Journal bearing
+ 6 Rotating assembly 13 O-ring (Type II only) , 20 Retaining ring
7 Lock nut ,+ 14 Thrust spacer 21 Center housing
IE-3-2
TURBOCHARGER
INSPECTION BEFORE DISASSEMBLY

Place the turbocharger on a level surface, and turn the compressor
wheel with finger tip to determine whether it operates smoothly.
Then use the following procedure to measure both axial play.
Measuring play in the axial direction

The purpose of this procedure is to determine whether it is neces-
sary to replace or repair the thrust bearing and/or rotating assembly
of the center housing rotating assembly.
1. Set the dial gauge to the magnet base at the turbine wheel
end of the turbocharger.
2. Move the turbine wheel axially back and forth by hand.
(being careful not to rock turbine wheel)
3. Measure the play in the axial direction and record the
results.
NOTE
z When measuring the axial play, do not turn the turbine
wheel as this will cause the measurement error to
become large.
Unit: mm (in)
IE-3-3
TURBOCHARGER
5 Compressor housing
Remove the compressor housing.
Loosen the compressor bolt and remove the clamp.
NOTE
z Be careful not to damage the compressor wheel.
NOTE
z The compressor wheel and turbine wheel are precisely
dynamically balanced and cannot be repaired. Therefore,
they must be handled with extra special care.
6 Rotating assembly
Place Holding Fixture (99768 96009) in a vise, and set the turbine
wheel on it with the compressor wheel on it with the turbine wheel
side facing downward.
8 Compressor wheel
1. Remove the compressor wheel.
z Using a T-handle (99773 96000), remove the lock nut, and
then remove the compressor wheel by hand.
NOTE
z Since bending of the turbine wheel is also related to the
life of the turbocharger, be careful not to bend it.
z Support the turbine wheel by hand while loosening the
lock nut.
IE-3-4
TURBOCHARGER
2. Remove the compressor wheel by hand.
10 Piston ring
Remove the piston ring.
NOTE
z Once removed, the piston ring must always be replaced
with a new piston ring when reassembling.
However, since the turbine wheel can be reused, be care-
ful not to damage it.
12 Back plate
Remove the backplate. Loosen the backplate bolt, remove the
washer and remove the backplate.
NOTE
z When the backplate cannot be removed by hand, tap the
center housing lightly with a wooden mallet and then
remove.
14 Thrust spacer, 15 Piston ring

Pull out the thrust spacer from center of the backplate and remove
the piston ring from the thrust spacer.
The piston ring can be removed by hand.
17 Thrust bearing, 18 Thrust collar

Loosen the thrust bearing bolt, then remove the thrust collar and
thrust bearing.
IE-3-5
TURBOCHARGER
19 Journal bearing
1. Remove the journal bearing.
NOTE
z Be careful not to damage the center housing when
removing the retainer ring.
2. Using retaining ring pliers (99546 96000), remove the com-

pressor wheel side retaining ring and journal bearing.
3. Using retaining ring pliers (99546 96000), remove the tur-
bine wheel side retaining ring and journal bearing.
4. Remove the two retaining rings located in the rear of the
center housing.
IE-3-6
TURBOCHARGER
INSPECTION
INSPECTION BEFORE CLEANING
Turbocharger failure may sometimes be due to faulty engine parts.
It is, therefore advisable to closely inspect parts for accumulation of
carbon, presence of dirt or dust, obstruction of oil passages, etc.
prior to cleaning, so that the cause of problems may be located
easily.
CLEANING
After soaking all the parts in clean detergent for about 20 to 30 min-
utes, remove dirt and grime with a rough brush and then blow dry
with compressed air.
NOTE
z Be extremely careful not to damage parts. Avoid filing
any rotating parts. Also be sure to clean parts com-
pletely. Failure to observe these points may cause the
parts to become imbalanced.
Contents of inspection Inspection point

z Turbine wheel journal parts.
z Outside periphery of center housing.
Carbon accumulation (check whether parts are jammed) z Inside periphery of heat shroud.
z Inside wall of center housing.
z Surface of blades of turbine wheel.
z Turbine wheel journal parts.
z Journal bearing.
Lubrication (wear, burning, discoloration etc.) z Center housing bore part.
z Thrust collar.
z Thrust bearing.
z Inside and outside periphery of turbine housing.
z Inside periphery of heat shroud.
z Inside of compressor housing.
Oil leakage
z Surface of back plate.
z Surface of blades of turbine wheel.
z Rear surface of compressor wheel.
z Inside of center housing.
Foreign matter (Also check for obstruction while cleaning
z Inside of turbine case.
parts.)
z Inside of compressor case.
z Center housing of oil hole.
z Oil inlet adapter.
Clogging
z Oil outlet adapter.
z Thrust bearing of oil hole.
IE-3-7
TURBOCHARGER
INSPECTION
Inspect parts visually, replacing as necessary.
Contents of inspection Inspection point

V-band coupling z Deformity, elongation and damage.
z Scratches caused by interference with impeller.
Compressor housing z Scratches on contact surfaces with V-band coupling and back plate.
z Cracks or dents.
Clamp z Corrosion, deterioration and damage.
z Scratches caused by interference with shaft wheel.
Turbine housing z Burrs caused by rust formation.
z Thermal deformity and cracks.
z Corrosion.
z Scratches caused by interference with housing.
Compressor wheel
z Blade breakage and deformity.
z Gauging in shaft holes.
z Scratches from interference with turbine housing.
z Blade breakage, deformity and cracks.
z Shaft bent.
Turbine wheel
z Discolored journals and blades.
z Worn and scratched journals.
z Worn and damaged piston rings.
z Worn bore. Wear and damage on contact surface of thrust collar.
Back plate
z Scratches on rear face of impeller.
z Damage and wear on outer surface.
Thrust spacer
z Thermal discoloration. Worn and damaged piston rings.
z Thermal discoloration.
Thrust collar
z Wear and scratches on contact surface.
z Thermal discoloration.
Thrust bearing
z Scratches and wear on contact surface of thrust collar.
z Wear and scratches on journal bores and inner surfaces of piston rings.
Center housing
z Obstruction in oil hole.
z Scratches caused by contact.
Heat shroud
z Thermal discoloration and corrosion.
IE-3-8
TURBOCHARGER
NOTE
z If the measured value exceeds the maintenance stan-
dard, replace the part.
Inside diameter of center housing
Unit: mm (in)
Bearing part (A) 20.19 (0.7949)
Piston ring part (B) 20.93 (0.8240)
Outside diameter of turbine wheel shaft

Unit: mm (in)I
tem Maintenance standard Service limit
Journal part 12.99 (0.5114)
Piston ring part 17.48 (0.6882)
Outside diameter of turbine wheel shaft hub

Unit: mm (in)
19.89 (0.7831)
Piston ring groove width

Unit: mm (in)
1.74 (0.0685)
Runout of shaft
Unit: mm (in)
0.01 (0.0004)
IE-3-9
TURBOCHARGER
Inside diameter of back plate

Unit: mm (in)
Back plate seal bore
diameter (measure- 17.49 (0.6886)
ment A)
Thrust collar
Unit: mm (in)
Groove width (A) 4.44 (0.1748)
Inside diameter of thrust collar

Unit: mm (in)
7.95 (0.3130)
Outside diameter of thrust spacer

Unit: mm (in)
17.06 (0.6717)
Inside diameter of thrust spacer

Unit: mm (in)
7.95 (0.3130)
Piston ring groove width of thrust spacer

Unit: mm (in)
1.77 (0.0697)
IE-3-10
TURBOCHARGER
Thrust bearing thickness

Unit: mm (in)
4.36 (0.1717)
Journal bearing
Unit: mm (in)
Inside diameter 13.04 (0.5134)
Compressor wheel inside diameter

Unit: mm (in)
7.94 (0.3126)
REASSEMBLY
PREPARATIONS BEFORE REASSEMBLY
Repair light damage by polishing. Aluminum parts must be polished
with a polishing cloth using silicon carbide.
Moreover, steel parts must be polished with a polishing cloth using
polishing powder. Always replace the following parts.
Part name Quantity

Turbine V-band lock nut 1
Bolt (Compressor housing) 6
Lock nut (Compressor wheel) 1
Piston ring (Turbine wheel) 1
Bolt (Back plate) 4
Seal ring 1
Piston ring (Thrust spacer) 2
Screw (Thrust bearing) 3
Thrust bearing 1
Journal bearing 2
Retaining ring 3
IE-3-11
TURBOCHARGER
Key point of reassembly

20 Retaining ring, 19 Journal bearing
Using retaining ring pliers (99546 96000), install the retaining rings
in the rear of the center housing, then install the journal bearing and
the outer retaining ring.
1 Journal bearing 4 Retaining ring
2 Retaining ring 5 Center housing
3 Journal bearing
NOTE
z Ensure that the open end of the retaining ring faces the
oil outlet and the round portion faces the journal bearing.
z Be careful not to damage the center housing when
installing the retaining ring.
z Coat the inner and outer periphery of journal bearing
with engine oil.
z Replace the journal bearing with a new one.
18 Thrust collar, 17 Thrust bearing

Coat the thrust bearing pads with engine oil and then install the
thrust bearing and thrust collar into the center housing with three
screws.
1 Screw 3 Thrust bearing
2 Thrust collar 4 Center housing
: 3.4 - 3.9 N·m {0.35 - 0.40 kgf·m, 2.5 - 2.9 ft·lbf}
NOTE
z All tapped holes in the TA5103 turbochargers are metric
with a selflocking thread form.
15 Piston ring, 14 Thrust spacer

1. Install the piston rings on the thrust spacer.
2. Install the thrust spacer assembly to the back plate.
NOTE
z Ensure that the open end of the turbine side piston ring
faces the oil outlet and the open end of the compressor
side piston ring faces the oil inlet.
IE-3-12
TURBOCHARGER
10 Piston ring
Using a piston ring guide (99763 96000), insert the piston ring into
the turbine wheel.
9 Turbine wheel
1. Place the center housing assembly on the compressor
housing.
2. Apply a coat of engine oil to the turbine wheel journal, and
carefully insert the turbine wheel into the bore in the center
housing.
Use a pick (99767 96003) to compress the piston ring and
install it while rotating the wheel shaft.
NOTE
z Be careful not to scratch or break the piston ring.
z Ensure that the open end of the piston ring faces the oil
inlet.
8 Compressor wheel
z Before installing the compressor wheel, clean the parts and
check carefully the tightening surface for dust or foreign
matter.
z Coat the compressor wheel mounting and screw section of

the turbine wheel and the surface of the lock nut seat with a
thin coat of seizure preventative.
z Fit the compressor wheel into the turbine wheel and tighten
the lock nut temporarily.
z Attach the rotating assembly to a holding fixture (99768
96009) which has been placed in a vise.
IE-3-13
TURBOCHARGER
1. Using a torque wrench, tighten the lock nut temporarily.

: 3.6 - 4.7 N·m {0.37 - 0.48 kgf·m, 2.7 - 3.5 ft·lbf}
NOTE
z When tightening the nut, be careful not to give the bend-
ing force to the shaft.
2. Tighten the lock nut completely with T-handle (99773

96000) by turning nut 120º further than the temporary posi-
tion.
NOTE
z Keep the rated tightening torque and tightening angle.
5 Compressor housing
Attach the compressor housing to the back plate by properly align-
ing their marks, then tighten the bolts with the clamps.
: 9.0 - 11.3 N·m {0.92 - 1.15 kgf·m, 6.7 - 8.3 ft·lbf}
3 Turbine housing
1. Install the turbine housing to the center housing by aligning
the alignment marks. Using a deep socket (99535 96000),
tighten the V-band.
1st ... 17.0 N·m {1.73 kgf·m, 12.5 ft·lbf}
2nd ... Loosen
3rd ... 13.7 N·m {1.4 kgf·m, 10.1 ft·lbf}
2. Compressor housing assembly angle (View from the air

intake side)
Engine model Value α
PF6T 292º
PF6TA, PF6TB 180º
IE-3-14
TURBOCHARGER
INSTALLATION
1. Install the turbocharger assembly on the exhaust manifold
using a gasket.
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
NOTE
z Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
2. Install the exhaust connector using a gasket and spacer to
the turbocharger assembly.
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
NOTE
z Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
3. Install the oil pipe.
: 21 - 26 N·m {2.1 - 2.7 kgf·m, 15 - 20 ft·lbf}
4. Connect the oil drain pipe to the turbocharger.
: 21 - 26 N·m {2.1 - 2.7 kgf·m, 15 - 20 ft·lbf}
5. Install the turbocharger shield plate, shield bracket and
exhaust connector shield plate.
6. Connect the air intake duct and exhaust pipe using a gas-
ket.
7. After installing the turbocharger assembly, crank the engine
using the sub-starter switch. Crank for approximately 10 to
20 seconds while pulling the engine stop lever. Crank the
engine until the oil pressure gauge activates, since oil is not
distributed to the oil line.
IE-3-15
INTERCOOLER
INTERCOOLER
CONSTRUCTION
INSPECTION
Remove the intercooler. If mud, insects, etc. are attached to the front surface of the intercooler core, remove
them using a copper wire or the like exercising care not to damage the tube.
Water pressure test
Seal one of the air intakes on the intercooler with a lid and connect a hose to the other intake. Then submerge
the intercooler under water in a tank and blow compressed air through the hose to the specified pressure to
check for air leakage.
Intercooler check pressure (air): 196 kPa {2.0 kgf/cm2, 28 psi}
IE-4-1
AIR CLEANER
AIR CLEANER
DISASSEMBLY
1 Cover 4 Adapter (Type II only) 7 Body

2 Packing 5 Element assembly (Outer) 8 Evacuator valve
3 Clip (Type II, Type III only) 6 Element assembly (Inner)
NOTE
z Type I ... With 13” Resonator
z Type II ... With 13” Adapter
z Type III ... Without 15” Adapter
ELEMENT REPLACEMENT
For inspection and maintenance procedures, refer to the “MA” section.
IE-5-1
EXHAUST BRAKE
EXHAUST BRAKE
CONSTRUCTION
EXHAUST SHUTTER
Type I
IE-6-1
EXHAUST BRAKE
Type II
IE-6-2
EXHAUST BRAKE
AIR INTAKE SHUTTER

PF6 engine model only
IE-6-3
EXHAUST BRAKE
DISASSEMBLY
WARNING
WARNING
z Before disassembling the exhaust system, ensure that
the engine is cool. If it is hot, wait until it cools off to pre-
vent scalding yourself.
EXHAUST SHUTTER
Type I and Type II

1 Snap 7 Lever , 13 Seal ring
2 Pin , 8 Stopper bolt 14 Cover
3 Clevis 9 Plate 15 Gasket
4 Collar (Type II only) , 10 Seal ring 16 Exhaust shutter assembly
5 Air cylinder assembly , 11 Seal ring
6 Shield plate , 12 Seal ring
Mark “+” and “,” indicates that the key points of operation are explained in the text.
IE-6-4
EXHAUST BRAKE
AIR INTAKE SHUTTER

PF6 engine model only
1 Snap 6 Dust indicator 11 O-ring

2 Pin 7 Connector 12 Plug
3 Connector 8 Straight pin 13 Straight pin
4 Air cylinder assembly 9 Valve 14 Bracket
5 Connector 10 Shaft 15 Shutter housing
IE-6-5
EXHAUST BRAKE
AIR CYLINDER

1 Snap 7 O-ring 13 Guide
14 Washer (Exhaust shutter side
2 Pin 8 Retainer
only)
3 Clevis 9 Packing 15 Protector
4 Dust seal 10 Wear ring 16 Shaft
5 Cover 11 Plate 17 Cylinder body
+ 6 Cover 12 Spring
EXHAUST BRAKE AIR CYLINDER

6 Cover
Remove the cover and O-ring.
NOTE
z Be careful when removing the cover - the shaft assembly
may jump out due to spring tension.
IE-6-6
EXHAUST BRAKE
INSPECTION
AIR CYLINDER
Spring tension
Unit: N {kgf, lbf}
Maintenance Service
Item Remarks
standard limit
Air intake shutter When compressed to 105 mm
94.1 {9.6, 21.2}
side (4.13 in)
Exhaust shutter When compressed to 113.2 mm
77.5 {7.9, 17.4}
side (4.46 in)
EXHAUST SHUTTER
Valve movement in the axial direction when closing the
valve
Unit: mm (in)
PF6T, PF6TA, B Type I More than 0.7 (0.028)
PF6 Type II More than 0.5 (0.020)
Clearance between valve and body

Unit: mm (in)
One side 0.1 - 0.4 (0.004 - 0.016)
Both sides 0.2 - 0.5 (0.008 - 0.020)
REASSEMBLY
EXHAUST SHUTTER
10 11 12 13 Seal ring
Install the seal rings so that rings with different shapes are placed
next to each other.
IE-6-7
EXHAUST BRAKE
8 Stopper bolt
Turn the lever open all the way until it hits the stopper bolt.
Adjust the stopper bolt with the lever in this position, so that the
valve and the body flange surface make a 90 degree angle. Then,
turn the lever shut all the way until it hits the stopper bolt again.
Adjust the stopper bolt with the lever in this position, so that the
valve-to-body clearance is 0.1 to 0.4 mm (0.004 to 0.016 in) for one
side, and 0.2 to 0.5 mm (0.008 to 0.020 in) when both sides are
added.
After adjustment, fasten the stopper bolt with the lock nut.
Unit: mm (in)
0.1 - 0.4
Clearance One side
(0.004 - 0.016)
between valve
and body 0.2 - 0.5
Both sides
(0.008 - 0.020)
INSTALLING EXHAUST SHUTTER AND AIR CYLINDER

1. Install the air cylinder onto the plate.
2. Connect the shaft of the air cylinder with the clevis using a
pin. When connecting, turn the lever open all the way until it
hits the stopper bolt and pull out the shaft by the specified
length (L) with the lever in this position. In this state, fasten
the air cylinder.
Unit: mm (in)
Clearance between air Type I
More than 1.0 (0.04)
cylinder shaft and clevis Type II
: 21 - 25 N·m {2.1 - 2.6 kgf·m, 15 - 19 ft·lbf}
INSTALLING AIR INTAKE SHUTTER AND AIR CYLIN-

DER
1. Install the air cylinder and connect the lever and clevis. At
this time, make sure the air cylinder shaft is being pulled by
3 to 5 mm (0.12 to 0.20 in).
2. Apply an air pressure of 490 to 834 kPa {5.0 to 8.5 kgf/cm2,
71 to 121 psi} to the air cylinder to operate it to the fully
closed position. Under this condition, make sure the lever
comes into contact with the stopper.
IE-6-8
- MEMO -
ELECTRICAL SYSTEM
CONTENTS
SERVICE DATA................................ EE-1-1 ALTERNATOR EE-4-1
SPECIFICATIONS ............................ EE-1-1
SERVICE DATA................................ EE-1-1 = UNIT NAME LR240-602, LR240-603,
TIGHTENING TORQUE ................... EE-1-3 LR250-602 AND LR250-603 =
STARTING MOTOR ......................... EE-2-1 CONSTRUCTION ............................ EE-4-1
TROUBLESHOOTING ..................... EE-4-2
= UNIT NAME S210-112 = DISASSEMBLY ................................ EE-4-3
CONSTRUCTION............................. EE-2-1 INSPECTION ................................... EE-4-5
TROUBLESHOOTING ..................... EE-2-2 PERFORMANCE TEST ................... EE-4-8
DISASSEMBLY ................................ EE-2-3
INSPECTION.................................... EE-2-4 = UNIT NAME 0201 102 2920,
ADJUSTMENT ................................. EE-2-7 0201 102 2973, 0201 152 0020
EE
PERFORMANCE CHECK ................ EE-2-8 AND 0201 152 0053 =
CONSTRUCTION ............................ EE-5-1
= UNIT NAME 0350 602 0260 TROUBLESHOOTING ..................... EE-5-2
AND 0350 602 0330 = DISASSEMBLY ................................ EE-5-4
CONSTRUCTION............................. EE-3-1 INSPECTION ................................... EE-5-6
TROUBLESHOOTING ..................... EE-3-2 PERFORMANCE TEST ................... EE-5-7
DISASSEMBLY ................................ EE-3-3 AIR HEATER ..................................... EE-6-1
INSPECTION.................................... EE-3-4 CONSTRUCTION ............................ EE-6-1
ADJUSTMENT ................................. EE-3-8 INSPECTION ................................... EE-6-1
PERFORMANCE CHECK ................ EE-3-8
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
STARTING MOTOR
Model 0350 602 0260
S210-112
Item 0350 602 0330
Type Shift
Output V-kW 24-6.0
Rated time Second 30
Manufacturer Hitachi Sawafuji
ALTERNATOR
Model LR240-602 LR250-602 0201 102 2920 0201 152 0020
Item LR240-603 LR250-603 0201 102 2973 0201 152 0053
Output V-A 24-40 24-50 24-40 24-50
Type of regulator IC type
Manufacturer Hitachi Sawafuji
AIR HEATER
Type Ribbon
Rated current V-A 11.2-85
Rated time Second Less than 60
SERVICE DATA
STARTING MOTOR
Model S210-112
Unit: mm (in)
Part Item Maintenance standard Service limit Remarks
Runout 0.05 (0.0020) 0.4 (0.016)
Commutator 0.5 - 0.8
Undercut depth 0.2 (0.008)
(0.020 - 0.031)
Brush height 14.0 (0.551)
Brush Brush spring tension
34.3 {3.5, 7.7} 24.5 {2.5, 5.5} When spring is set
N {kgf, lbf}
Shaft diameter 14.9 (0.587)
Armature shaft Clearance between rear cover side

bushing and calculate armature shaft 0.2 (0.008)
diameter
Clearance between pinion sliding shaft
0.2 (0.008)
and pinion
Clearance between pinion side bushing
0.2 (0.008)
Gear shaft and shaft
Shaft outside diameter 17.9 (0.705)
Less than 0.5
Shaft runout 0.1 (0.004)
(0.020)
Current Terminal voltage
Less than 170
A 24V
Performance test (no
Motor speed rpm More than 2,000
load)
Pinion pop out voltage
Less than 18
V
EE-1-1
SERVICE DATA
Model 0350 602 0260 and 0350 602 0330

Unit: mm (in)
Front 17.0 (0.669) 17.2 (0.677)
Metal inside diameter
Holder 28.0 (1.102) 28.2 (1.110)
Bracket section
Inside diameter at bear- Commutator side 32.0 (1.260) 32.1 (1.264)
ing Gear side 52.0 (2.047) 52.1 (2.051)
Outside diameter 40.0 (1.575) 38.0 (1.496)
Less than
Runout 0.1 (0.004)
Commutator 0.05 (0.0020)
0.5 - 0.8
Undercut depth 0.2 (0.008)
(0.020 - 0.031)
Brush height 20.0 (0.787) 14.0 (0.551)
Brush
Brush spring tension N {kgf, lbf} 29.4 {3.0, 6.6} 20.6 {2.1, 4.6} When spring is set
Series coil resistance Ω 0.13 - 0.15
Magnetic switch Shunt coil resistance Ω 0.6 - 0.8
Contactor point deflection 1.0 - 2.0 (0.039 - 0.079)
Shaft runout Less than 0.05 (0.0020) 0.1 (0.004)
Gear shaft
Thrust gap 0.1 - 0.5 (0.004 - 0.020)
Insulation resis- Armature, field MΩ More than 1.0 Less than 0.5
tance Brush holder MΩ More than 1.0 Less than 0.5
Clearance between pinion gear and pinion
Pinion gear 0.5 - 3.0 (0.020 - 0.118)
stopper
Terminal voltage
Current A Less than 100
24V
Performance test
(no load) Motor speed rpm More than 4,000
Pinion pop out voltage V Less than 16
ALTERNATOR
Model LR240-602, LR240-603, LR250-602 and LR250-603
LR240-602
0.14
LR240-603 Single phase [At
Resistance Starter coil
LR250-602 20ºC (68ºF)]
Ω 0.09
LR250-603
Coil Field coil 11
LR240-602
More than 40
Output current LR240-603 27V
A LR250-602 At 20ºC (68ºF)
More than 50
LR250-603
Regulating voltage
28.0 - 29.0 At 20ºC (68ºF)
V
Speed required to increase voltage to 27 volts
Less than 950 At 20ºC (68ºF)
rpm
EE-1-2
SERVICE DATA
Model 0201 102 2920, 0201 102 2973, 0201 152 0020
and 0201 152 0053
Unit: mm (in)
Maintenance
Part Item Service limit Remarks
standard
0201 102 2920
0.36 - 0.44
0201 102 2973 Between two phases
Starter coil
0201 152 0020 [At 20ºC (68ºF)]
0.19 - 0.24
Resistance 0201 152 0053
Coil
W 0201 102 2920
7.0 - 9.0
0201 102 2973
Field coil At 20ºC (68ºF)
0201 152 0020
5.0 - 7.0
0201 152 0053
Less than
Shaft outside diameter of the front part 25.0 (0.9843)
24.98 (0.9835)
Rotor
Less than
Shaft outside diameter of the rear part 17.0 (0.6693)
16.98 (0.6685)
More than
Inside diameter of front bearing fitting hole 62.0 (2.441)
62.1 (2.445)
Bracket
More than
Inside diameter of rear bearing fitting hole 23.8 (0.937)
23.80 (0.9370)
0201 102 2920
More than 40
Output current 0201 102 2973 28V, 5,000 rpm
A 0201 152 0020 [At 20ºC (68ºF)]
More than 50
0201 152 0053
Regulating voltage
28.0 - 29.0 At 20ºC (68ºF)
V
Speed required to increase voltage to 27 volts
rpm
TIGHTENING TORQUE
STARTING MOTOR
Model S210-112
Part Tightening torque Remarks
C terminal 2.5 - 2.9 {0.25 - 0.30, 1.8 - 2.2}
B terminal 20 - 22 {2.0 - 2.2, 15 - 16}
Model 0350 602 0260 and 0350 602 0330

C terminal 1.9 - 2.5 0.19 - 0.25, 1.4 - 1.8
B and M terminals 16.2 - 22.1 1.65 - 2.25, 11.9 - 16.3
0350 602 0260: 5.9 - 8.8 0.6 - 0.9, 4.3 - 6.5,
Magnetic switch mounting bolt
0350 602 0330: 14 - 16 1.4 - 1.6, 10 - 12
0350 602 0260: 14 - 16 1.4 - 1.6, 10 - 12,
Through bolt
0350 602 0330: 16 - 18 1.6 - 1.8, 12 - 13
Brush holder mounting bolt 3.9 - 4.9 0.40 - 0.50, 2.9 - 3.6
EE-1-3
SERVICE DATA
ALTERNATOR
Model LR240-602, LR240-603, LR250-602 and LR250-603
Alternator mounting nut 13.7 - 25.5 {1.40 - 2.60, 10.1 - 18.8}
B and E terminals 3.9 - 4.9 {0.4 - 0.5, 2.9 - 3.6}
Model 0201 102 2920, 0201 102 2973, 0201 152 0020 and 0201 152 0053
Size M4 1.0 - 1.4 {0.10 - 0.14, 0.7 - 1.0}
Screw
Size M5 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
Pulley mounting nut 96 - 127 {9.8 - 13.0, 71 - 94}
B and E terminals 3.2 - 4.4 {0.33 - 0.45, 2.4 - 3.3}
Through bolt 6 - 9 {0.6 - 0.9, 4.3 - 6.5}
EE-1-4
STARTING MOTOR S210-112
STARTING MOTOR
= UNIT NAME S210-112 =
CONSTRUCTION
EE-2-1
Engine does not
start.
*A
Does engine turn No Does starting motor turn? No Check battery for charging condition N.G. z Charge or replace battery.
by cranking? and battery terminals for connections z Repair connections and corrosion of
and corrosion. battery terminals.
Yes Yes
O.K.
Yes No
TROUBLESHOOTING
Does gear shaft turn? Check pinion roller Can you hear starter relay operating? Check and repair wiring system of block
clutch for damage. (Block relay equipped model only) relay.
Replace if neces- z Key switch.
No sary. Yes z Starter relay.
z Connections.
Check reduction gear Can you hear magnetic switch operating No z Check and repair wiring up to mag-
parts (armature, gear sound? netic switch.
shaft). Replace if neces- z Repair or replace magnetic switch.
sary. Yes
N.G.
(Turns
Does starting motor slowly) Check battery for charging N.G. Is meshing condition of pinion and ring N.G. z Check lever assembly for deforma-
turn normally? condition and battery ter- *A gear normal? tion, weak return spring and pinion
minals for connections and for sliding condition.
O.K. corrosion. O.K. z Correct meshing condition of pinion
EE-2-2
and ring gear. Replace if necessary.
O.K.
N.G. No
STARTING MOTOR
Check ignition sys- Replace engine Remove starting motor from engine. Replace motor (field coil or armature).
Check engine oil viscosity. oil.
tem and fuel sys- Does starting motor turn under no load
tem. by connecting battery (+) terminal to M
O.K. terminal of starting motor and battery
(–) terminal to starting motor body?
Yes
Does engine turn by Yes Repair or replace Check magnetic switch contacts.
replacing starting motor starting motor. Replace if necessary.
with a new one?
No
Check inside of engine.
Starting motor does not Repair or replace key

: Check item : Problem or corrective action
stop when key switch is switch, block relay or mag-
turned off. netic switch.
If any abnormality is found, immediately disconnect battery negative terminal.
S210-112
DISASSEMBLY

1. Magnetic switch assembly 9. Packing 16. Center holder
2. Rear bracket 10. Retaining ring 17. Shim washer
3. Brush holder assembly 11. Hook 18. Pinion assembly
4. O-ring 12. Pinion stopper 19. Pinion case
5. Yoke assembly 13. Holder 20. Felt
6. Armature assembly 14. Shaft 21. Cover
7. O-ring 15. Lever assembly 22. Metal
8. Gear case
EE-2-3
INSPECTION
COMMUTATOR
Runout
Unit: mm (in)
0.05 (0.0020) 0.4 (0.016)
NOTE
z If the commutator surface is rough, grind with No. 500 to
600 sandpaper and then measure the runout.
Undercut depth
Unit: mm (in)
0.5 - 0.8 (0.020 - 0.031) 0.2 (0.008)
BRUSH
Brush height
Unit: mm (in)
14.0 (0.551)
Brush spring tension

Unit: N {kgf, lbf}
34.3 3.5, 7.7 24.5 2.5, 5.5 When spring is set
EE-2-4
ARMATURE SHAFT
Shaft diameter
Measure the armature shaft diameter at the “A” point.
Unit: mm (in)
14.9 (0.587)
Clearance between rear cover side bushing and calcu-

late armature shaft diameter
Unit: mm (in)
0.2 (0.008)
NOTE
z Check the tooth profile of the armature shaft for wear or
damage. If worn or damaged, replace the armature shaft.
GEAR SHAFT
Clearance between pinion sliding shaft and pinion
Unit: mm (in)
0.2 (0.008)
Clearance between pinion side bushing and shaft

Unit: mm (in)
0.2 (0.008)
Shaft outside diameter

Measure the gear shaft diameter at the two points.
Unit: mm (in)
17.9 (0.705)
EE-2-5
Shaft runout
Turn the gear shaft and measure the run-out of the shaft by reading
the movement of the dial gauge pointer. The bend is 1/2 of this
reading.
Unit: mm (in)
Less than 0.5 (0.020) 0.1 (0.004)
ARMATURE COIL
Continuity test
Make sure there is no continuity between the commutator and
armature assembly.
Insulation test
Check the insulation between commutator and shaft. If there is con-
tinuity, the armature coil and shaft insulation is faulty, and should
therefore be replaced.
FIELD COIL
Continuity test
Make sure there is continuity between the field coil terminals.
Insulation test
Check for continuity between the yoke and any one of the field
coil's terminals. If no continuity exists, the field coil is broken and
should be replaced.
EE-2-6
BRUSH HOLDER
Insulation test
Check for continuity between the positive (insulated) and the nega-
tive (base) sides of the brush holder, using an insulation tester. If
continuity exists, it indicates faulty insulation, and the brush holder
should be replaced.
MAGNETIC SWITCH
Continuity test (Series coil resistance)
Check the continuity between the magnetic switch terminal C and
terminal M and replace when there is no continuity.
Continuity test (Shunt coil resistance)

Check the continuity between magnetic switch terminal C and the
coil case (metal part) and replace when there is no continuity.
PINION
1. Check the pinion teeth for wear or damage. If necessary,
replace the pinion assembly.
2. Ensure that the pinion slides smoothly. Replace when the
pinion bushing is scratched, burned or otherwise damaged.
BALL BEARING
Check the ball bearing for noise, play, thermal discoloration or dam-
age. If there is any abnormality, replace the ball bearing together
with the armature as an assembly.
ADJUSTMENT
The pinion position dimension pushed out by the magnetic switch is
called dimension L.
1. Pass current between the magnetic switch terminal C and
ground.
EE-2-7
2. Advance the pinion and stop at the pinion stopper position.

3. Measure dimension L with the pinion pushed in the direc-
tion of the arrow so that there is no play as shown in the fig-
ure.
Unit: mm (in)
Dimension L 0.3 - 1.5 (0.012 - 0.059)
When dimension L is outside the prescribed value, adjust by insert-

ing the adjusting plate. There are two adjusting plates, one is 0.4
mm (0.016 in) thick and the other is 0.8 mm (0.031 in) thick.
PERFORMANCE CHECK
1. Connect as shown in the illustration. Turn off the key switch
and turn the starting motor. Under these conditions, mea-
sure the current and the number of rotations. (Terminal volt-
age: 24 volts)
Current
Less than 170
A
Number of rotations
More than 2,000
rpm
2. Check that the pinion gear pops smoothly out and in when
the switch is turned on and off.
3. Measure the minimum voltage which is necessary for the
pinion to pop out. Prepare a variable resistor and battery
voltmeter as testing equipment. Set the resistance higher at
first so that a lower voltage applies to the starting motor.
Then, slowly lower the resistance and measure the voltage
when the pinion pops out.
Unit: V
Less than 18
EE-2-8
STARTING MOTOR 0350 602
STARTING MOTOR
= UNIT NAME S350 602 0260 AND 0350 602 0330 =
CONSTRUCTION
EE-3-1
Engine does not
start.
*A
Does engine turn No Does starting motor turn? No Check battery for charging condition N.G. z Charge or replace battery.
by cranking? and battery terminals for connections z Repair connections and corrosion of
and corrosion. battery terminals.
Yes Yes
O.K.
Yes No
TROUBLESHOOTING
Does gear shaft turn? Check pinion roller Can you hear starter relay operating? Check and repair wiring system of block
clutch for damage. (Block relay equipped model only) relay.
Replace if neces- z Key switch.
No sary. Yes z Starter relay.
z Connections.
Check reduction gear Can you hear magnetic switch operating No z Check and repair wiring up to mag-
parts (armature, gear sound? netic switch.
shaft). Replace if neces- z Repair or replace magnetic switch.
sary. Yes
N.G.
(Turns
Does starting motor slowly) Check battery for charging N.G. Is meshing condition of pinion and ring N.G. z Check lever assembly for deforma-
turn normally? condition and battery ter- *A gear normal? tion, weak return spring and pinion
minals for connections and for sliding condition.
O.K. corrosion. O.K. z Correct meshing condition of pinion
EE-3-2
and ring gear. Replace if necessary.
O.K.
N.G. No
STARTING MOTOR
Check ignition sys- Replace engine Remove starting motor from engine. Replace motor (field coil or armature).
Check engine oil viscosity. oil.
tem and fuel sys- Does starting motor turn under no load
tem. by connecting battery (+) terminal to M
O.K. terminal of starting motor and battery
(–) terminal to starting motor body?
Yes
Does engine turn by Yes Repair or replace Check magnetic switch contacts.
replacing starting motor starting motor. Replace if necessary.
with a new one?
No
Check inside of engine.
Starting motor does not Repair or replace key

: Check item : Problem or corrective action
stop when key switch is switch, block relay or mag-
turned off. netic switch.
If any abnormality is found, immediately disconnect battery negative terminal.
0350 602
DISASSEMBLY

1. Magnetic switch assembly 9. Packing 16. Center holder
2. Rear bracket 10. Retaining ring 17. Shim washer
+ 3. Brush holder assembly 11. Hook 18. Pinion assembly
4. O-ring + 12. Pinion stopper 19. Pinion case
5. Yoke assembly 13. Holder 20. Cover
6. Armature assembly 14. Shaft 21. Metal
7. O-ring 15. Lever assembly
8. Gear case
Marks “+” and “,” indicate that key points of operation are explained in the text.
EE-3-3

3 Brush holder assembly
Contact the negative side of the brush spring to the side of the
brush. Lift the brush from the armature commutator surface. Extract
the positive side of the brush from the brush holder. Then, remove
the brush holder assembly.
12 Pinion stopper
Move the pinion stopper toward the pinion. Using a screwdriver, pry
off the pinion stopper clip. Then, extract the pinion assembly and
center plate.
INSPECTION
BRUSH
Brush height
Unit: mm (in)
20.0 (0.787) 14.0 (0.551)
Brush spring tension

Unit: N {kgf, lbf}
29.4 3.0, 6.6 20.6 2.1, 4.6 When spring is set
EE-3-4
COMMUTATOR
Outside diameter
Unit: mm (in)
40.0 (1.575) 38.0 (1.496)
NOTE
z If the commutator surface is rough, grind with No. 500 to
600 sandpaper and then measure the outside diameter.
Runout
Unit: mm (in)
Less than 0.05 (0.0020) 0.1 (0.004)
Undercut depth
Unit: mm (in)
0.5 - 0.8 (0.020 - 0.031) 0.2 (0.008)
GEAR SHAFT
Shaft runout
Unit: mm (in)
Less than 0.05 (0.0020) 0.1 (0.004)
Thrust gap
Unit: mm (in)
0.1 - 0.5 (0.004 - 0.020)
EE-3-5
BRACKET
Metal inside diameter (Front)
Unit: mm (in)
17.0 (0.669) 17.2 (0.677)
Metal inside diameter (Holder)

Unit: mm (in)
28.0 (1.102) 28.2 (1.110)
Inside diameter at bearing (Commutator side)

Unit: mm (in)
32.0 (1.260) 32.1 (1.264)
Inside diameter at bearing (Gear side)

Unit: mm (in)
52.0 (2.047) 52.1 (2.051)
ARMATURE COIL
Continuity test
Make sure there is no continuity between the commutator and
armature assembly.
Insulation test
Unit: MΩ
More than 1.0 0.5
EE-3-6
FIELD COIL
Continuity test
Make sure there is continuity between the field coil terminals.
Insulation test
Unit: MΩ
More than 1.0 0.5
BRUSH HOLDER
Insulation test
Unit: MΩ
More than 1.0 0.5
MAGNETIC SWITCH
Continuity test (Series coil resistance)
Perform the continuity test between the M and C terminals.
Unit: Ω
0.13 - 0.15
Continuity test (Shunt coil resistance)

Check the continuity between the C terminal and coil case.
Unit: Ω
0.6 - 0.8
EE-3-7
Contactor point deflection

Check deflection when the contactor makes contact.
Unit: mm (in)
1.0 - 2.0 (0.039 - 0.079)
PINION GEAR
Clearance between pinion gear and pinion stopper
Unit: mm (in)
0.5 - 3.0 (0.020 - 0.118)
ADJUSTMENT
Measure dimension L moved towards the thrust direction of the pin-
ion when the magnetic switch pushes out the pinion.
1. Connect the S terminal to the battery positive terminal
through the magnetic switch. Ground the M terminal mid-
way and then connect it to the battery negative terminal.
2. Turn on the switch and make sure the magnetic switch

pushes out the pinion. Then, push back the pinion lightly
and measure dimension L.
Unit: mm (in)
Dimension L 0.3 - 1.5 (0.012 - 0.059)
3. If dimension L exceeds the maintenance standard, replace

the starting motor assembly with a new one.
PERFORMANCE CHECK
1. Connect as shown in the illustration. Turn off the key switch
and turn the starting motor. Under these conditions, mea-
sure the current and the number of rotations. (Terminal volt-
age: 24 volts)
Current A More than 100
Motor speed rpm More than 4,000
EE-3-8
2. Check that the pinion gear pops smoothly out and in when
the switch is turned on and off.
3. Measure the minimum voltage which is necessary for the

pinion to pop out. Prepare a variable resistor and battery
voltmeter as testing equipment. Set the resistance higher at
first so that a lower voltage applies to the starting motor.
Then, slowly lower the resistance and measure the voltage
when the pinion pops out.
Unit: V
Less than 16
EE-3-9
ALTERNATOR LR240, LR250
ALTERNATOR
= UNIT NAME LR240-602, LR240-603, LR250-602 AND LR250-603 =
CONSTRUCTION
EE-4-1
OFF
Turn the key switch ON. OFF Replace the charge lamp.
Does the charge lamp come on with the chassis coupler removed and
Does the charge lamp Inspect or replace the
the wiring harness terminal "L~ grounded to the chassis?
come on? charge lamp relay.
ON ON
NOTE:
Charge lamps are available from the
Turn the key switch to chassis maker.
START position. Put the coupler into ALT.
TROUBLESHOOTING
(Engine starts.)
ON Replace RG.
Does the charge lamp come on with the ALT terminal “F” grounded to the
chassis?
OFF Check the field coil and diode.
Does the charge lamp ON Check the fan belt and ALT.
go out?
EE-4-2
OFF
Lamp flashes. Check the diode (positive side).
ALTERNATOR
Engine speed: 1,500 rpm VB 28.5 Replace the RG.

Determine VB.
VB = 28 - 29 All in order
* Remarks ABBREVIATION:
1) Full charged battery must be used. ALT: Alternator
2) DC voltmeter: 0 to 75V, class 0.5 RG: Regulator
3) Checking method also applies to the bench test. VB: Voltage at the battery terminal
LR240, LR250
DISASSEMBLY
REMOVAL
Key point of removal
z Before removing the alternator from the engine, be sure to
turn the key switch off, then disconnect the battery cable
from the negative terminal of the battery.
EE-4-3
DISASSEMBLY

1 Lead wire 7 Cover 13 Terminal plate
2 Pulley assembly 8 Condenser 14 Stator assembly
3 Rotor assembly + 9 Regulator assembly 15 Field coil
4 Ball bearing 10 Packing 16 Terminal bolt
5 Retainer 11 Condenser 17 Diode
+ 6 Front cover 12 Terminal block 18 Rear cover
Marks “+” and “,” indicate that key points of disassembly are explained in the text.
EE-4-4

6 Front cover
Separate into the front and rear parts;
Insert a slotted screwdriver into gaps (two places) between the front
cover and the stator core, then separate into the front (consisting of
front cover and rotor) and the rear (consisting of rear cover and sta-
tor) parts.
NOTE
z Be careful not to damage the stator coil with the screw-
driver tip.
z Be sure to replace oil seals with new ones when separa-
tion into two parts is made.
9 Regulator assembly
Remove regulator assembly by removing its mounting screws and
bolts.
NOTE
z No shocks nor loads should be applied onto the regula-
tor cooling fins at the time of disassembly and reassem-
bly.
INSPECTION
STATOR COIL
Continuity test of the stator coil
Unit: Ω
Maintenance
standard
LR240-602
0.14
LR240-603
Single phases [At 20ºC (68ºF)]
LR250-602
0.09
LR250-603
EE-4-5
If there is no continuity, the stator coil may be broken. Replace the

stator coil as an assembly.
Insulation test of the stator coil

Make sure there is no continuity. If there is continuity, the stator coil
may be shorted. Replace the stator coil as an assembly.
FIELD COIL
Continuity test of the field coil
Unit: Ω
11
If there is no continuity, the field coil may be broken. Replace the

field coil as an assembly.
Insulation test of the field coil

Make sure there is no continuity. If there is continuity, the field coil
may be shorted. Replace the field coil as an assembly.
ROTOR
Check the ball bearings for proper rotation and abnormal noise.
Replace the ball bearings if necessary.
EE-4-6
OIL SEAL
Be sure to replace the oil seals with new ones whenever the alter-
nator is disassembled.
NOTE
z Oil seals must be pressed into position after oil seal to
rotor shaft contact surface is wiped clean. Use a cloth
dampened with alcohol for this purpose.
z Care must be taken not to damage surface “D” when
replacing the oil seals.
z Oil seals should never be reused.
DIODE
Use a tester to check to see if continuity is present between the ter-
minals.
The diode is acceptable for use if continuity exists and they are
defective or damaged if continuity does not exist.
Next, connect a tester reversely. This time, the diode is acceptable
for use if continuity does not exist, and it is defective or damaged if
continuity exists. Replace diode assembly if one diode is found
defective as a result of the test mentioned above.
Negative diode
E side
(+) (-)
U, V and W sides
Positive (+) Continuity exists
Negative (\-) No continuity
Positive (+) diode

BAT side
(+) (-)
U, V and W sides
Positive (+) No continuity
Negative (-) Continuity exists
NOTE
z High tension insulation resistance tester such as Megger
etc. should never be used for this test, because the diode
could be damaged.
EE-4-7
IC REGULATOR UNIT
Using instruments listed below, connect them as shown in Figure.
Instruments to be prepared:
1. Variable resistor (RV): 0 to 300Ω, 50W............... 1 ea
2. Resistor (R1): 100Ω, 10W .................................. 1 ea
3. Batteries (BAT1, BAT2, BAT3): 12V ................... 3 ea
4. DC voltmeter: 0 to 50V, class 0.5 ....................... 1 ea
(Used for measurement at three places.)
Measuring procedures
1. Check for V3 (Voltage resulted from BAT1 + BAT2 + BAT3).
The batteries are normal if 30 to 29V is registered on the
gauge.
2. Using a variable resistor, check for V2 (Voltage between ter-
minal “F” and “E”) by gradually changing resistance from
zero. Check to see if V2 voltage changes from less than
2.0V 20 thru 26V. Replace the regulator with a new one if no
voltage change is registered.
3. Check for V1 (Voltage between variable resistor intermedi-
ate tap and terminal “E”). Check for variable RV fixed (not
changing the position) to see if voltage is in the specified
range. The regulator is normal if it is within the range.
Replace regulator with new one if it is out of range as it is
defective.
PERFORMANCE TEST
z Use leads with a cross-sectional area greater than 8 mm2
(0.0124 sq in) and a length less than 2.5 m (8.2 ft) to con-
nect the line between the alternator's B terminal and posi-
tive battery terminal, the E terminal and battery ground
terminal, and the L terminal and battery ground terminal.
z Use switches with as small a contact resistance as possible
in the circuit.
z Conduct performance test in areas where ambient tempera-
ture is maintained at 20ºC (68ºF).
Start-up revolution
1. Install the alternator on a vehicle or connect to a variable
velocity motor and connect the leads as shown in the figure.
2. Turn switches SW1 and SW2 “ON”, then gradually increase
alternator speed.
3. When the voltmeter registers a voltage higher than the volt-
age when the alternator is stopped, turn switch SW1 “OFF”.
4. While observing the voltmeter, increase alternator speed.
5. Read alternator speed (rpm) when the voltmeter registers
27 volts.
EE-4-8
Unit: rpm
Less than 950
Measuring of regulating voltage

Turn switch SW1 off and turn switch SW2 on. Increase the alterna-
tor speed up to the rated rpm of 5,000. Then, measure the voltage.
Unit: V
28.0 - 29.0
Measuring output current

1. Adjust the variable resistor to zero and turn switches SW1
and SW2 on.
2. Keep the alternator speed at the rated rpm and adjust the
variable resistor so that the terminal voltage is at the speci-
fied value. Then, read the current.
Terminal voltage: 27V
Unit: A
LR240-602
More than 40
LR240-603
LR250-602
More than 50
LR250-603
EE-4-9
ALTERNATOR 0201 102, 0201 152
ALTERNATOR
= UNIT NAME 0201 102 2920, 0201 102 2973, 0201 152 0020 AND 0201 152 0053 =
CONSTRUCTION
EE-5-1
The battery runs down.
No Abnormal
Check the battery relay. Replace the battery relay.
Normal Abnormal
Check the wiring. Repair the wiring.
To *A
No No Abnormal
Is the voltage across alternator termi- Does voltage exist? O Is the fuse blown? O Replace the fuse.
TROUBLESHOOTING
nals B and E above 22V? O Is the wiring between the alterna- O Repair the wiring.
(When the key switch is ON and Yes tor and battery normal?
engine is stopped.)
Normal
Yes
To *A
*A Abnormal
Is the belt broken? O Change the belt.
Is the belt slipping? O Adjust the belt tension.
Normal
To *A
No Abnormal
Does voltage exist across alternator Is the key switch normal? O Replace the key switch
terminals IG and E?
(Key switch is ON) Normal Abnormal
Is the fuse blown? O Replace the fuse.
EE-5-2
Yes
*B Normal
ALTERNATOR
To *B
No
Is the voltage across alternator termi- Faulty alternator O Repair the alternator.
nals B and E over 27V? (Replace the diode, stator or
(Engine speed: 1,000 rpm) regulator.)
Yes
No No
Measure the alternator charging cur- Increase the electrical load (Turn on Faulty alternator
rent at B terminal. Is it over 35A? all the lights.)
(Engine speed: 2,000 rpm) Is the charging current over 35A?
Yes Yes
Normal alternator
(Check the battery and its related

parts.)
0201 102, 0201 152
The battery becomes overcharged. (Battery fluid decreases)
(The battery fluid decreases.).
Yes
Is the voltage across alternator termi- Faulty alternator (Regulator) O Repair the alternator
nals B and E over 29V? (Faulty regulator)
(Engine speed: 1,000 rpm) (Broken internal wiring)
No
Normal alternator
(Check the battery and its related

parts.) : Check item : Problem or corrective action
EE-5-3
ALTERNATOR
0201 102, 0201 152
ALTERNATOR 0201 102, 0201 152
DISASSEMBLY
REMOVAL
z Before removing the alternator from the engine, be sure to
turn the key switch off, then disconnect the battery cable
from the negative terminal of the battery.
EE-5-4
ALTERNATOR 0201 102, 0201 152
DISASSEMBLY

1 Cover 8 Oil seal 14 Field coil assembly
2 Housing 9 Washer 15 Charge light circuit assembly
3 Rotor assembly 10 Ball bearing 16 Terminal
+ 4 Front cover assembly 11 Washer 17 Regulator
+ 5 Pulley assembly 12 Oil seal 18 Rubber cap
6 Spacer 13 Stator assembly 19 Heat sink
7 Cover
Marks “+” and “,” indicate that key points of disassembly are explained in the text.
EE-5-5
ALTERNATOR 0201 102, 0201 152

6 Front cover assembly
To separate the front cover assembly, insert a screwdriver into the
clearance between the front cover and stator core.
NOTE
z Be careful not to damage the stator coil with the screw-
driver tip.
5 Pulley assembly
When separating the pulley assembly, secure the rotor periphery
with a vise. Then, remove the pulley nut, pulley assembly and
spacer. If the pulley assembly is difficult to remove, use a general-
purpose puller.
INSPECTION
STATOR COIL
Continuity test of the stator coil
Unit: Ω
Maintenance stan-
Part number Service limit Remarks
dard
0201 102 2902
0.36 - 0.44 At 20ºC (68ºF)
0201 102 2973
Between two
0201 152 0020 phases
0.19 - 0.24
0201 152 0053
If there is no continuity, the stator coil may be broken. Replace the

stator coil as an assembly.
Insulation test of the stator coil

Make sure there is no continuity. If there is continuity, the stator coil
may be shorted. Replace the stator coil as an assembly.
EE-5-6
ALTERNATOR 0201 102, 0201 152
FIELD COIL
Continuity test of the field coil
Unit: Ω
Maintenance stan-
dard
0201 102 2902
7.0 - 9.0
0201 102 2973
At 20ºC (68ºF)
0201 152 0020
5.0 - 7.0
0201 152 0053
If there is no continuity, the field coil may be broken. Replace the

field coil as an assembly.
Insulation test of the field coil

Make sure there is no continuity. If there is continuity, the field coil
may be shorted. Replace the field coil as an assembly.
PERFORMANCE TEST
NOTE
z Use leads with a cross-sectional area greater than 8 mm2
(0.0124 sq in) and a length less than 2.5 m (8.2 ft) to con-
nect the line between the alternator's B terminal and pos-
itive battery terminal, the E terminal and battery ground
terminal, and the L terminal and battery ground terminal.
z Use switches with as small a contact resistance as possi-
ble in the circuit.
z Conduct performance test in areas where ambient tem-
perature is maintained at 20ºC (68ºF).
Start-up revolution
1. Install the alternator on a vehicle or connect to a variable
velocity motor and connect the leads as shown in the figure.
2. Turn switches SW1 and SW2 “ONÛ, then gradually
increase alternator speed.
3. When the voltmeter registers a voltage higher than the volt-
age when the alternator is stopped, turn switch SW1 “OFF”.
4. While observing the voltmeter, increase alternator speed.
5. Read alternator speed (rpm) when the voltmeter registers
27 volts.
EE-5-7
ALTERNATOR 0201 102, 0201 152
Unit: rpm
Measuring of regulating voltage

Turn switch SW1 off and turn switch SW2 on. Increase the alterna-
tor speed up to the rated rpm of 5,000. Then, measure the voltage.
Unit: V
28.0 - 29.0 At 20ºC (68ºF)
Measuring output current

1. Adjust the variable resistor to zero and turn switches SW1
and SW2 on.
2. Keep the alternator speed at the rated rpm and adjust the
variable resistor so that the terminal voltage is at the speci-
fied value. Then, read the current.
Terminal voltage: 28V - 5,000 rpm
Unit: A
Maintenance stan-
dard
0201 102 2902
More than 40
0201 102 2973 28V, 5,000 rpm [At
0201 152 0020 20ºC (68ºF)]
More than 50
0201 152 0053
EE-5-8
AIR HEATER
AIR HEATER
CONSTRUCTION
INSPECTION
z Check the condition of the wiring for breaks. If broken,
replace the air heater assembly with a new one.
z Check the ribbon element for accumulation of carbon. If
necessary, clean it. Also check it for breaks. If broken,
replace the air heater assembly with a new one.
EE-6-1
AUXILIARY EQUIPMENT
CONTENTS
SERVICE DATA................................ EA-1-1 AIR COMPRESSOR (F9560W12).... EA-3-1
SPECIFICATIONS ............................ EA-1-1 CONSTRUCTION ............................ EA-3-1
SERVICE DATA................................ EA-1-1 DISASSEMBLY ................................ EA-3-1
TIGHTENING TORQUE .................... EA-1-2 INSPECTION ................................... EA-3-4
TOOLS.............................................. EA-2-1 REASSEMBLY ................................. EA-3-6
EA
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Model F9560W12
Type Reciprocating type
Bore x stroke — No. of cylinders mm (in) 95 x 60 — 1 (3.74 x 2.36 - 1)
3 425 (25.93)
Theoretical discharge cm (cu in)/rev
Normal maximum speed rpm 2,400
Normal maximum pressure kPa {kg/cm2, psi} 834 {8.5, 121}

Cooling method Water cooled
SERVICE DATA
Unit: mm (in)
400 Tank capacity:
Less than 124 sec.
Air charging perfor- Engine rpm 30 liter (6-5/8 Imp gal)
mance speed 2,000 0 → 785 kPa {0 → 8 kg/cm2, 0 →
Less than 32 sec.
rpm 114 psi}
0.18 - 0.25
Piston top 0.28 (0.0110)
Clearance between (0.0071 - 0.0098)
piston and cylinder 0.08 - 0.15
Piston skirt 0.18 (0.0071)
(0.0031 - 0.0059)
0.15 - 0.30
Compression ring 1.00 (0.0394)
(0.0059 - 0.0118)
Piston ring end gap
0.20 - 0.70
Oil ring 1.00 (0.0394)
(0.0079 - 0.0276)
Clearance between piston ring and ring 0.010 - 0.045
0.08 (0.0031) Compression ring only
groove (0.0004 - 0.0018)
Clearance between piston pin hole and pis- 0.01 T - 0.02 L T: Tight
0.08 L (0.003 L)
ton pin (0.0004 T - 0.0008 L) L: Loose
Clearance between connecting rod small 0.02 - 0.04
0.07 (0.0028)
end and piston pin (0.0008 - 0.0016)
Clearance between connecting rod large end 0.02 - 0.09
0.10 (0.0039)
bushing and crank pin (0.0008 - 0.0035)
0.1 - 0.7
Crankshaft end play 1.0 (0.0039)
(0.004 - 0.028)
Free length of valve Suction valve spring 11.5 (0.453)

spring Delivery valve spring 13.4 (0.528)
12.26 8.53 When compressed to 7.5 mm
Tension of valve Suction valve
{1.25, 2.76} {0.87, 1.92} (0.295 in)
spring
N {kgf, lbf} 10.79 7.85 When compressed to 10.0 mm
Delivery valve spring
{1.10, 2.43} {0.80, 1.76} (0.394 in)
EA-1-1
SERVICE DATA
TIGHTENING TORQUE
Suction valve holder 137 - 157 {14.0 - 16.0, 101 - 116}
Delivery valve holder 137 - 157 {14.0 - 16.0, 101 - 116}
Unloader valve connector 98 - 118 {10.0 - 12.0, 72 - 87}
Cylinder head mounting bolts and nut 25 - 29 {2.5 - 3.0, 18 - 22}
Bearing holder securing screws 2.5 - 4 {0.25 - 0.40, 1.8 - 2.9}
Cylinder liner mounting bolts 25 - 29 {2.5 - 3.0, 18 - 22}
Connecting rod cap mounting nuts 23 - 25 {2.3 - 2.6, 17 - 19}
Air compressor drive gear mounting nut (Left-hand screw) 186 - 206 {19.0 - 21.0, 137 - 152}
Air compressor mounting bolts 30 - 41 {3.1 - 4.2, 22 - 30}
EA-1-2
TOOLS
TOOLS
AIR COMPRESSOR
Valve holder tool For removal and installation of suction valve holder
99744 97003
Piston insert tool kit For installation of air compressor piston

99750 97001 1: Piston insert tool
1: 99754 97002
2: Crankshaft holder
2: 99756 97001
EA-2-1
AIR COMPRESSOR F9560
AIR COMPRESSOR
CONSTRUCTION
DISASSEMBLY
REMOVAL
Remove the three bolts and one nut, then pull out the air compres-
sor to the back side along the stud being careful not to drop the O-
ring.
EA-3-1
DISASSEMBLY

1 O-ring 14 Bearing case 27 Delivery valve
2 Nut 15 O-ring 28 Delivery valve seat
3 Plain washer , 16 Crankshaft 29 Connector
+ 4 Drive gear , 17 Connecting rod cap 30 Packing
5 Cylinder head 18 Connecting rod metal 31 O-ring
, 6 Cylinder liner 19 Connecting rod , 32 Unloader valve
7 O-ring +, 20 Ball bearing 33 Unloader valve spring
8 O-ring +, 21 Ball bearing +, 34 Suction valve holder
9 Clip , 22 Delivery valve holder 35 Suction valve spring
10 Piston pin 23 O-ring 36 Suction valve
11 Piston 24 O-ring 37 Suction valve seat
, 12 Compression ring 25 Spring holder 38 Suction valve packing
, 13 Oil ring 26 Delivery valve spring 39 Crankcase
EA-3-2

4 Drive gear
Using a puller, remove the drive gear from the air compressor.
z Before disassembling the air compressor, measure the end

play of the crankshaft.
20, 21 Ball bearing

Using a puller, remove the ball bearing from the crankshaft.
34 Suction valve holder

Remove the suction valve holder, using the valve holder tool
(99744 97003). Then remove the suction valve spring, suction
valve, suction valve seat and suction valve packing from the cylin-
der head.
EA-3-3
INSPECTION
Clearance between piston and cylinder

Unit: mm (in)
0.18 - 0.25
Piston top 0.28 (0.0110)
(0.0071 - 0.0098)
0.08 - 0.15
Piston skirt 0.18 (0.0071)
(0.0031 - 0.0059)
Piston ring end gap

Unit: mm (in)
0.15 - 0.30
Compression ring 1.00 (0.0394)
(0.0059 - 0.0118)
0.20 - 0.70
Oil ring 1.00 (0.0394)
(0.0079 - 0.0276)
Clearance between piston ring and ring groove

Unit: mm (in)
0.010 - 0.045
0.08 (0.0031) Compression ring only
(0.0004 - 0.0018)
EA-3-4
Clearance between piston pin hole and piston pin

Unit: mm (in)
0.01 T - 0.02 L T: Tight
0.08 L (0.003 L)
(0.0004 T - 0.0008 L) L: Loose
Clearance between connecting rod small end and pis-

ton pin
Unit: mm (in)
0.02 - 0.04 (0.0008 - 0.0016) 0.07 (0.0028)
Clearance between connecting rod large end bushing

and crank pin
NOTE
z Before measuring the clearance between the connecting
rod large end bushing and crank pin, tighten the nut to
the specified torque.
: 23 - 25 N·m {2.3 - 2.6 kgf·m, 17 - 19 ft·lbf}
Unit: mm (in)
0.02 - 0.09 (0.0008 - 0.0035) 0.10 (0.0039)
Crankshaft end play

NOTE
z Check the end play of the crankshaft measured while dis-
assembling.
Unit: mm (in)
0.1 - 0.7 (0.004 - 0.028) 1.0 (0.039)
EA-3-5
Free length of valve spring

Unit: mm (in)
Suction valve spring 11.5 (0.453)
Delivery valve spring 13.4 (0.528)
Tension of valve spring

Unit: N {kgf, lbf}
Maintenance
standard
Suction valve 12.26 8.53 When compressed to
spring {1.25, 2.76} {0.87, 1.92} 7.5 mm (0.295 in)
Delivery valve 10.79 7.85 When compressed to
spring {1.10, 2.43} {0.80, 1.76} 10.0 mm (0.394 in)
REASSEMBLY
34 Suction valve holder
1. Install the suction valve packing, suction valve seat, suction
valve and suction valve spring, then, using a valve holder
tool (99744 97003), tighten the suction valve holder into the
cylinder head.
: 137 - 157 N·m {14.0 - 16.0 kgf·m, 101 - 116 ft·lbf}
2. After tightening the valve holder, push the suction valve with
your fingers or a rod from the unloader valve side. When
doing so, make sure the suction valve and suction valve
spring operate smoothly.
EA-3-6
3. Using a punch, stake the periphery of the suction valve

holder in three locations so that the suction valve does not
rotate.
NOTE
z Do not stake the same portion that has previously
staked.
32 Unloader valve
1. Install the O-ring and unloader valve spring to the unloader
valve. After inserting them into the cylinder head, tighten the
connector with the packing in place.
: 98 - 118 N·m {10.0 - 12.0 kgf·m, 72 - 87 ft·lbf}
NOTE
z Before installing, be sure to coat the O-ring and O-ring
groove in the valve with grease.
2. After tightening the connector, push the unloader valve with

your fingers or a rod. When doing so, make sure the
unloader valve and unloader valve spring operate smoothly.
22 Delivery valve holder

1. Install the O-ring to the delivery valve holder.
2. Insert the delivery valve seat, delivery valve, delivery valve
spring and spring holder into the cylinder head.
3. Tighten the delivery valve holder with the O-ring in place.
: 137 - 157 N·m {14.0 - 16.0 kgf·m, 101 - 116 ft·lbf}
NOTE
z Apply a coat of 0.2 to 0.3 mili-liter (0.007 to 0.11 Imp fl oz)
LOCTITE No. 271 to three threads of the delivery valve
holder.
EA-3-7
4. After tightening the delivery valve holder, push the spring

holder with your fingers or a rod. When doing so, make sure
the spring holder and delivery valve spring operate
smoothly.
20, 21 Ball bearing

Install the ball bearings on the crankshaft by press-fitting.
17 Connecting rod cap

Fit the metals in the connecting rod and bearing cap, and install the
connecting rod to the crankshaft through the lock washer.
: 23 - 25 N·m {2.3 - 2.6 kgf·m, 17 - 19 ft·lbf}
NOTE
z Assemble with the matching marks of the connecting rod
and bearing cap on the same side.
16 Crankshaft
Press-fit the crankshaft assembly to the crankcase.
EA-3-8
13 Oil ring
12 Compression ring
Install the piston rings in the ring grooves, and attach the connect-
ing rod to the piston.
NOTE
z Install the piston rings so that their joints are neither par-
allel nor normal to the piston pin and the manufacturer's
mark faces up.
6 Cylinder liner
Install the O-ring onto the cylinder liner, then, using a piston
insert tool kit (99750 97001), install them into the crankcase with
the O-ring in place.
: 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf}
99750 97001 (Piston insert tool kit)
1: 99754 97002 (Piston insert tool)
2: 99756 97001 (Crankshaft holder)
z Make sure that the end play of the crankshaft is within the
service limit.
Unit: mm (in)
0.1 - 0.7 (0.004 - 0.028) 1.00 (0.0394)
EA-3-9

MANUAL DE SERVICIO Motor UD CWB459

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MANUAL DE SERVICIO Motor UD CWB459

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ENGINE

FM 1st edition: Apr. 2005

X This Service Manual is designed as a guide for servicing vehicles.

X This manual deals with the engine.

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

X The following marks and abbreviations are used in this manual.

Valve clearance Intake valve 0.30 - 0.40 (0.012 - 0.016)

Oil filter Replacement method Disassembly type

ºC (ºF) (140 - 158) 60±10 - 75±5 (140±18 - 167±9) [Linear type]

Fuel injection Plunger diameter mm (in) 11.5 (0.453) 12.0 (0.472)

pump Governor Centrifugal (Mechanical RFD-C type)

Alternator Type AC, diode-rectified

Theoretical discharge cm3 (cu in) 425 (26)

Air compressor Normal maximum discharge pressure

Cooling method Water-cooled

RECOMMENDED SAE VISCOSITY NUMBER

GENERAL PRECAUTIONS ON SERVICING

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

GENERAL PRECAUTIONS IN DISASSEMBLY

CLEANING AND INSPECTION

TIGHTENING TORQUE OF STANDARD BOLTS

Standard tightening torque (Without lubricant)

Standard tightening torque of tubing connector

Fuel injection timing Type I 16º

Injection pump coupling mounting Coupling bolt 59 - 64 {6.0 - 6.5, 43 - 47}

Feeler gauge For adjusting valve clearance

Timing plate For measuring valve timing

Compression gauge For measuring compression pressure

Plate For fixing nozzle holder

Tool name and number Description Shape

Nozzle cleaner For removal of carbon from rear of nozzle orifice

Filter wrench For removal of fuel filter

EMISSIONS CONTROL SYSTEMS MAINTENANCE (FOR TAIWAN ONLY)

Oil level and contamination I I I I I I I I I I I I I I

Exhaust tubing and muffler I I I I I

For Taiwan only

Intake* and exhaust manifold I I

Oil level and contamination I I I I I I I I I I I I I I

Strainer (if equipped) I

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

PERIODIC PARTS REPLACEMENT

PERIODIC PARTS REPLACEMENT INTERVAL

3. Using a feeler gauge, inspect the valves indicated by a cir-

IN: Intake valve EX: Exhaust valve

4. In the valve clearance is not within the specified range,

Valve clearance adjustment

3. Recheck the valve clearance.

Procedure for checking valve timing

3. Attach the timing plate (99646 Z5001 or 99646 Z0000) to

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

Intake Open 20º B.T.D.C. 16º B.T.D.C. 1

Valve tim- valve Closed 42º A.B.D.C. 20º A.B.D.C. 2

CYLINDER HEAD AND MANIFOLD BOLTS

Intake and exhaust manifolds

CYLINDER COMPRESSION PRESSURE

Compression Less than

ENGINE OIL LEVEL AND CONTAMINATION

To check the engine oil level

To check the engine oil for contamination

ENGINE OIL AND OIL FILTER

To change the engine oil

To replace the filter

Full-flow oil filter

Bypass oil filter