Hino Ha6eti2 Bs II Engine

ALMDV
Service Manual
Hino HA6ETI2 Engine (BS II)
14.02 HINO HA6ETI2 ENGINE
HINO HA6ETI2 ENGINE 14.03
CONTENTS
GROUP - 14
HINO HA6ETI2
Section Subject Page No.
Contents ........................................................................................................................ 14.03
14.0 General .......................................................................................................................... 14.07

14.0.0 Engine Type and Number ........................................................................................................... 14.07
14.0.1 Design and Operation .................................................................................................................. 14.07
14.0.2 General Data .................................................................................................................................... 14.08
14.0.3 Repair Data ....................................................................................................................................... 14.09
14.0.4 Tightening Torques ........................................................................................................................ 14.14
14.0.5 Crank Shaft Main Journals and Crank Journals Dimensions ........................................ 14.15
14.0.6 Main and Crank Journals Grinding Sizes .............................................................................. 14.15
14.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness) ............................................. 14.15
14.0.8 Crankcase Parent Bore and Cylinder Liner Outer Dia ................................................. 14.15
14.0.9 Fuel Oil (High Speed Diesel) ..................................................................................................... 14.16
14.0.9.0 Fuel Specifications - as per IS 1460 : 2000 (BS II) ................................................................ 14.16
14.0.10 Recommended coolant .................................................................................................................. 14.17
14.0.11 Recommended Lubricants ............................................................................................................ 14.17
14.0.12 Filling Capacity ................................................................................................................................. 14.17
14.0.13 Liquid Gasket and Application Points ................................................................................... 14.18
14.0.14 Description of Leading Engine Components ....................................................................... 14.19
14.0.15 Special Tools ..................................................................................................................................... 14.20
14.0.16 Engine Preliminary Checks .......................................................................................................... 14.21
14.0.17 To Test Engine Compression .................................................................................................... 14.25
14.1 To Remove and Refit Engine from Vehicle ......................................................... 14.26

14.1.0 To Remove Engine ......................................................................................................................... 14.26
14.1.1 To Refit Engine ................................................................................................................................ 14.26
14.2 Crankcase ...................................................................................................................... 14.27

14.2.0 To Remove and Refit Cylinder Liners ................................................................................... 14.27
14.2.1 To Remove and Refit Timing Casing Cover and Back Plate ....................................... 14.28
14.2.2 To Remove and Refit Flywheel Housing ............................................................................... 14.29
14.2.3 Install the Oil Seal in the Flywheel Housing ...................................................................... 14.29
14.2.4 To Remove and Refit Flywheel ................................................................................................. 14.29
14.2.5 To Remove Ring Gear .................................................................................................................. 14.29
14.2.6 To Install Ring Gear ..................................................................................................................... 14.29
14.2.7 Install Flywheel ................................................................................................................................. 14.30
14.3 Crankshaft ..................................................................................................................... 14.31

14.3.0 To Remove and Refit Crankshaft ............................................................................................. 14.31
14.3.1 To Renew Crankshaft Gear ........................................................................................................ 14.31
14.3.2 To Refit the Crankshaft Gear ................................................................................................... 14.32
14.3.3 To Check Crankshaft Bend ........................................................................................................ 14.32
14.3.4 Installation .......................................................................................................................................... 14.32
CONTENTS
GROUP - 14
HINO HA6ETI2
14.3.5 To Renew Crankshaft Main & Connecting Rod Bearing and

Check Main & Connecting Rod Bearing Spread ................................................................ 14.32
14.3.6 To Check and Grind Crankshaft ............................................................................................. 14.33
14.3.7 To Remove and Refit Vibration Damper .............................................................................. 14.33
14.4 Piston and Connecting Rods ................................................................................... 14.34

14.4.0 To Remove Piston Assembly ..................................................................................................... 14.34
14.4.1 To Dismantle and Assemble Piston and connecting rod .............................................. 14.34
14.4.2 Connecting Rod Bush ................................................................................................................... 14.34
14.4.2.0 To Remove Bush ................................................................................................................................................... 14.34
14.4.2.1 Installation of Connecting Rod Bush ...................................................................................................... 14.35
14.4.2.2 Inspect the Bushing Position after Installation ................................................................................ 14.36
14.4.2.3 Check for Bend of Connecting Rod ...................................................................................................... 14.36
14.4.2.4 Install the Connecting Rod Bearing ......................................................................................................... 14.36
14.4.3 Piston and Piston Rings ............................................................................................................... 14.37
14.4.3.0 Piston General .......................................................................................................................................................... 14.37
14.4.3.1 To Remove Piston rings ................................................................................................................................... 14.37
14.4.3.2 Assemble Piston and Connecting Rod ................................................................................... 14.37
14.4.3.3 Install Piston rings .......................................................................................................................... 14.38
14.4.3.4 Installation .......................................................................................................................................... 14.39
14.5 Cylinder Head Assembly ........................................................................................... 14.40

14.5.0 To Remove Cylinder Head ......................................................................................................... 14.40
14.5.1 To Grind Valves and Valve Seats ............................................................................................ 14.41
14.5.2 To Refit the Valve Seat and To Check and Reface Valve Seat ................................. 14.41
14.5.3 Valve Seat Installation ................................................................................................................... 14.41
14.5.3.0 To Check the Valve Guide ........................................................................................................................... 14.42
14.5.3.1 To Renew Valve Guide .................................................................................................................................... 14.42
14.5.3.2 To Refit Valve and Valve Stem Seals .................................................................................................. 14.42
14.5.3.3 To Check Valve Springs ................................................................................................................................... 14.43
14.5.4 To Assemble the Cylinder Head .............................................................................................. 14.43
14.6 Timing .......................................................................................................................... 14.44

14.6.0 To Remove and Refit Rocker Levers ..................................................................................... 14.44
14.6.1 To Remove, Refit and Check Push Rod and Tappets .................................................... 14.44
14.6.2 To Remove and Refit Camshaft ................................................................................................ 14.45
14.6.3 Removal and Replacement of Camshaft Bushes ................................................................. 14.45
14.6.4 Camshaft Bush Dimensions (in mm) ....................................................................................... 14.45
14.6.5 Installation .......................................................................................................................................... 14.46
14.6.6 Install the camshaft gear on the shaft ................................................................................... 14.48
CONTENTS
GROUP - 14
HINO HA6ETI2
14.6.7 To Refit the Camshaft .................................................................................................................. 14.48

14.6.8 To Remove and Refit Intermediate Timing Gear .............................................................. 14.48
14.6.9 Install the Idler Gear Shaft (Spindle) ..................................................................................... 14.49
14.6.10 Install the Idler Gear ..................................................................................................................... 14.49
14.6.11 To Re-bush Intermediate Gear ................................................................................................. 14.49
14.6.12 To Position Timing Gears for Valve Timing and FIP Timing ...................................... 14.50
14.6.13 Timing Gear Backlash Checking ............................................................................................... 14.50
14.6.14 To Fit Air Compressor ................................................................................................................. 14.50
14.6.15 To Remove and Refit Fuel Injection Pump and To Adjust the Injection Timing 14.50
14.6.16 To Adjust the Valve Clearance ................................................................................................ 14.52
14.6.17 Fuel Filters .......................................................................................................................................... 14.53
14.6.18 Water Separator .............................................................................................................................. 14.54
14.6.19 To Remove and Refit Injector Nozzle ................................................................................... 14.54
14.6.19.0 Cleaning ......................................................................................................................................................................... 14.54
14.6.19.1 Test the nozzle sinking ...................................................................................................................................... 14.55
14.6.19.2 Test the spray profile ......................................................................................................................................... 14.55
14.6.19.3 Test the fuel leakage (Dribbling) .............................................................................................................. 14.55
14.6.19.4 Install the nozzle holder assembly. .......................................................................................................... 14.55
14.7 Engine Lubrication ..................................................................................................... 14.56

14.7.0 Design and Operation .................................................................................................................. 14.56
14.7.1 To Remove and Refit Oil Pump .............................................................................................. 14.57
14.7.2 To Overhaul Oil Pump ................................................................................................................ 14.57
14.7.3 To Refit the Oil Pump ................................................................................................................. 14.57
14.7.4 To Overhaul Oil Cooler and Filter Assy ............................................................................. 14.58
14.7.4.0 To Remove ................................................................................................................................................................. 14.58
14.7.4.1 To Refit Oil Cooler ............................................................................................................................................. 14.59
14.8 Cooling System ............................................................................................................ 14.60

14.8.0 General ................................................................................................................................................ 14.60
14.8.1 To Flush Cooling System ............................................................................................................. 14.60
14.8.2 External Cleaning of Radiator ................................................................................................... 14.61
14.8.3 Engine Cooling Fan and Fan Clutch ...................................................................................... 14.61
14.8.4 Service Tips for Viscous Fan / Clutch .................................................................................. 14.61
14.8.5 To Test Thermostat ....................................................................................................................... 14.61
14.8.6 To Remove and Refit Water Pump ........................................................................................ 14.62
14.8.7 To Overhaul Water Pump .......................................................................................................... 14.63
14.8.8 To Remove and Refit V Belt. To Adjust V Belt Tension. .......................................... 14.64
14.9 Exhaust And Intake Manifold ................................................................................... 14.65

14.9.0 To Remove and Refit Exhaust Manifold ............................................................................... 14.65
14.9.1 To Remove and Refit Intake Manifold ................................................................................... 14.65
14.9.2 Maintenance and Servicing of Dry Type Air cleaner ..................................................... 14.65
CONTENTS
GROUP - 14
HINO HA6ETI2
14.10 Aluminium Radiators and charge air cooler ...................................................... 14.67

14.10.0 Service Instruction .......................................................................................................................... 14.67
14.10.0.0 Introduction ................................................................................................................................................................. 14.67
14.10.0.1 Details of Radiator ............................................................................................................................................... 14.67
14.10.0.2 Servicing Kit ................................................................................................................................................................ 14.67
14.10.0.3 Procedure for Servicing ..................................................................................................................................... 14.68
14.10.0.4 Radiator Installation .............................................................................................................................................. 14.70
14.10.0.5 Do's and Don'ts ................................................................................................................................................... 14.70
14.11 Turbocharger ................................................................................................................ 14.71

14.11.0 General ................................................................................................................................................ 14.71
14.11.0.0 Design and Operation ....................................................................................................................................... 14.71
14.11.0.1 Benefits of Turbocharging ................................................................................................................................ 14.72
14.11.0.2 For Enhancing Turbocharger Life ............................................................................................................... 14.72
14.11.0.3 Preliminary Checks ................................................................................................................................................ 14.73
14.11.0.4 Serviceable Parts of Turbocharger ........................................................................................................... 14.73
14.11.1 Precautions to be taken for Turbocharger Installation .................................................. 14.74
14.11.2 Do's and Don'ts .............................................................................................................................. 14.74
14.11.3 Turbo charger trouble shooting ............................................................................................... 14.75
14.12 Maintenance Programme .......................................................................................... 14.76

14.0 GENERAL
14.0.0 Engine Type and Number
The engine no is stamped onto the

crankcase on the left side rear top corner.
Fig - 1
Fig. 1
14.0.1 Design and Operation only from one direction. Upon entering, the
air is given a swirling m o t i o n c a u s i n g
Water cooled 4 stroke Diesel Engine with t h e f u e l to mix, w h i c h i s injected
direct fuel injection into a hemispherical through a multi hole nozzle into the
combustion chamber arranged in the piston combustion chamber. Combustion is
crown. initiated at the end of compression stroke.
The engine employs the Hino Micro Mixing The shape of the combustion chamber
Combustion System (HMMCS) which allows full use of the energy contained in
features a specially shaped combustion the fuel, because the cooling surfaces are
chamber in the piston crown. comparatively small in relation to the
volume of the combustion chamber whilst
Another characteristics is the special shape the air swirls ensures that air and fuel are
and arrangement of the intake ducts in the mixed uniformly.
cylinder head which allows the air to enter
Fig - 2 Representative Diagram

14.0.2 General Data

Description HA6ETI2
Type Diesel four stroke, 6 cylinder, Water

cooled direct injection, in-line overhead
valve.
Aspiration Turbocharged with inter cooler
Max output 84 kw @ 2400 rpm
Max torque 410 Nm @ 1700 - 1800 rpm
Bore and Stroke 104 x 118 mm
Piston displacement 6.014 l
Compression Ratio 17.9 : 1
Firing order 1-4-2-6-3-5
Direction of rotation Counter clockwise viewed from flywheel.
Compression pressure 36 - 39 kg/cm² @ 280 rpm

(Limit - 25.356 kg/cm²)
Idling revolution 600 ± 50 rpm
Fuel Injection Equipment Inline pump with manifold compensator
Injection pipe (OD x ID x Length)
Valve Timing
Intake opens 16° Before Top Dead Centre
Intake closes 40° After Bottom Dead Centre
Exhaust opens 55° Before Bottom Dead Centre
Exhaust closes 13° After Top Dead Centre
Valve clearance (when cold)

Intake 0.30 mm
Exhaust 0.45 mm
Engine Oil Pump

Type Full forced Pressure feed by gear pump
Drive By timing gears
Engine oil cooler Multi plates types (5 plates), water cooled
Injection Nozzle
Type Multi hole nozzle type
Valve opening pressure 247 - 260 bar
Coolant Pump
Type Forced circulation by volute pump
Drive By V-belt
Thermostat Wax type, Bottom bypass system
Injection timing (Flywheel Travel) 11° ± 1° BTDC No.1 cylinder on

compression stroke
Turbocharger Without wastegate
14.0.3 Repair Data

SPECIFICATION
(Measurements in mm) MEASURING DEVICE
DESCRIPTION
AND REMARKS
HA6ETI2
Crankcase
Cylinder block flatness 0.05 (limit 0.1)
Crankcase bore for cylinder liner fitment Refer section 14.0.8 W,X,Y,Z, punch marked on
crank case LH side adjacent
to each bore
Cylinder liner outside diameter Refer section 14.0.8 W,X,Y,Z, paint mark given on
cylinder liner collar for identification
Interference fit of cylinder liner in Selective
crankcase bore Transition Fit assembly
Cylinder liner bore: Size 104.008 - 104.040 Bore dial gauge (To be measured
(limit 104.15) at 80 mm from top)
Liner projection 0.01 - 0.08
Block Top Surface to Crankshaft Centre 299.950 - 300.05
Block Top Surface to sump face height 369.9 - 370.1
Main journal dia 77.085 - 78.00
Cylinder counter bore depth 8.020 - 7.980
Cylinder counter bore dia 112.00 (+0.290 to 0.150)
Crank Assembly
Piston diameter Standard size 103.875 - 103.860 Micrometer (measure at gudgeon
pin axis)
Diametral piston clearance (at skirt) 0.140 - 0.172 Feeler gauge
Piston ring Groove Width
Top —
Second 2.53 - 2.55 (limit 2.70) Micrometer
Oil Ring 3.015 - 3.035 (limit 3.08)
Piston ring width
Top —
Second 2.47 - 2.49 (limit 2.32) Micrometer
Oil Ring 2.97 - 2.99 (limit 2.95)
Piston ring side clearance in groove
Top 0.08 - 0.12 (limit 0.7)
Second 0.04 - 0.08 (limit 0.2) Feeler gauge
Oil Ring 0.025 - 0.065 (limit 0.1)
Piston Ring gap
Top 0.30 - 0.45 (limit 1.2)
2nd 0.30 - 0.42 (limit 1.2)
Oil 0.20 - 0.40 (limit 1.2)
Maximum permissible piston weight NIL No need to check weight diffe-
difference per set rence as pistons are serviced as set
Piston pin hole inside diameter 34.998 - 35.003 Bore dial gauge
(limit 35.020)
Gudgeon pin outside diameter 34.989 - 35.00 Micrometer (Push fit in piston
(limit 34.980) heated to 80oC)
SPECIFICATION
DESCRIPTION
AND REMARKS
HA6ETI2
Clearance between Piston pin -0.009 - 0.014

and Piston pin hole (limit 0.04)
Small end bush bore 35.015 - 35.025 Bore dial gauge
(limit 35.07)
Diametral clearance between gudgeon 0.015 - 0.036 Bore dial gauge and micrometer
pin and con. rod small end bush bore (limit 0.08)
Max. permissible clearance
Interference fit of small end bush in 0.035 - 0.092 Bore dial gauge and micrometer
connecting rod
Connecting rod centre to centre distance 181.480 - 181.520
Connecting rod bend / twist limit 0.1 per 200
Connecting rod big end dia 65.985 - 66
Crankshaft journals and crankpin grinding Refer section 14.0.5 Micrometer
dimensions
Surface hardness of journals and 269-311 BHN Hardness Tester. No further heat
crankpins treatment recommended
Maximum permissible run-out of centre limit 0.4 V-Blocks and dial gauge
journal
Crankshaft Main Bearing Cap roundness 0.06
Crankshaft end play 0.05 - 0.22 Feeler gauge
Maximum permissible clearance 0.4 (limit)
Diametral clearance between main 0.039 - 0.09 Bore dial gauge and micrometer
journal and bearing Maximum 0.13 (limit)
permissible clearance
Main bearing inside diameter 77.98 - 78.00 Bore dial gauge
Main bearing spread 79.00 - 79.06 Vernier Calliper
Connecting rod side clearance 0.20 - 0.52 (limit 0.6) Feeler gauge
Diametral clearance between Connecting 0.031 - 0.082 Bore dial gauge and micrometer
Rod Big End Bearing & Crank pin (limit 0.12)
Connecting rod Big end ovality/taper 0.06
Connecting rod big end bearing spread 67.05 - 67.55 Vernier caliper
Connecting rod bend/twist limit 0.1 per 200 Fixture and feeler gauge
Connecting rod twist limit 0.1 per 200 Fixture and feeler gauge
Connecting rod weight
Group A 1790 - 1830 grams All the connecting rods should
Group B 1831 - 1870 grams be from the same group in an
Group C 1871 - 1910 grams Engine.
Group D 1911 - 1950 grams
Group E 1951 - 1990 grams
Flywheel face out limit 0.15 Dial gauge
SPECIFICATION
DESCRIPTION
AND REMARKS
HA6ETI2
Cylinder Heads and Valves
Cylinder head flatness 0.05 (limit 0.1) Straight edge and feeler gauge
Cylinder head height 87.0 (limit 86.8) Vernier caliper
Nozzle protrusion from cylinder head
surface 5.5 - 6.00
Valve sink (Valve head depth below Dial gauge
cylinder head face)
Inlet 2.65 - 2.75
Exhaust 2.37 - 2.47
Valve stem diameter
Inlet 8.95 - 8.97 (limit 8.9) Micrometer
Exhaust 8.93 - 8.95 (limit 8.8)
Intake and Exhaust Valve Guide dia 9.000 - 9.015 Internal micro meter
Diametral valve stem clearance in guide Plug gauge and Micrometer
Intake 0.035 - 0.068
Exhaust 0.050 - 0.083
Valve seat angle
Intake 30° - 30° 15' Bevel Protractor (for both inlet and
Exhaust 45° - 45° 15' exhaust)
Valve seat seating depth on cylinder head
Inlet 8.9 ± 0.1
Exhaust 7.3 ± 0.1
Valve seat thickness
Inlet 7.5 - 7.7
Exhaust 6.0 - 6.2
Valve seat seating dia on cylinder head
Inlet 46.5 (+0.016, - 0.0)
Exhaust 41.0 (+0.10, - 0.0)
Outer dia of valve seat
Inlet 46.5 (+0.10 to +0.085)
Exhaust 41.0 (+0.145 to 0.130)
Valve angle
Intake 29° 45' - 30°15' Protractor (for both inlet and
Exhaust 44° 45' - 45°15' exhaust)
Valve head diameter:
Inlet 45.3 - 45.5 Micrometer.
Exhaust 39.8 - 40.0
Maximum permissible out of true 0.03 Lathe and dial gauge
head face head to stem
Interference fit of valve guide in 0.010 - 0.039 Plug gauge and micrometer
cylinder head
Height of valve guide above spring seat 14.5 - 15.00
Maximum permissible out of true of 0.030
valve seat to guide
Valve spring straightness 2.0 (limit) Tri Square
Spring load 44.9 @ 24.2 kg Valve spring scale
(limit 20.6 kg) (inlet and exhaust)
Valve stroke 12.3 - 12.4 Depth gauge (inlet and exhaust)
SPECIFICATION
DESCRIPTION
AND REMARKS
HA6ETI2
Timing
Rocker arm shaft diameter 18.966 - 18.984
Diametral clearance between rocker 0.036 - 0.079 Plug gauge and micrometer
lever on rocker shaft (limit 0.15)
Push Rod Bend 0.3 Centres and dial gauge
Tappet Diameter 26.95 - 26.97 Micro meter
Tappet guide inside diameter 27.00 - 27.02 Internal micro meter
Diametral tappet clearance in crankcase 0.025 - 0.071 Bore dial gauge and micrometer
bore Maximum permissible limit 0.1 (limit)
Camshaft Bend 0.05 (limit) Dial gauge and V blocks
Camshaft Cam lift (Intake) 6.8433 - 6.9433 Vernier height gauge & V blocks
Camshaft Cam lift (Exhaust) 6.7854 - 6.8854 Vernier height gauge & V blocks
Camshaft end play 0.10 - 0.18 (limit 0.3) Dial gauge with magnetic base
Camshaft Journal Diameter Micro meter
Journal 1 56.95 - 56.97 (limit 56.85)
Journal 2 56.75 - 56.77 (limit 56.65)
Journal 3 56.55 - 56.57 (limit 56.45)
Journal 4 56.35 - 56.37 (limit 56.25)
Camshaft Journal Bearing inside Diameter Bore dial gauge
after pressing the bushes.
Journal 1 57.0 (limit 57.070)
Diametral camshaft clearance in bushes 0.03 - 0.12 Internal measuring gauge and
Max. permissible clearance 0.15 (limit) micrometer
Idler Shaft Diameter 49.95 - 49.975 (limit 49.94) Micrometer
Idler Gear bushing inside Diameter 50.00 - 50.025 (limit 50.05) Internal micro meter
Diametral clearance between Idler Gear 0.03 to 0.08 Internal measuring gauge and
shaft and Bush (limit 0.1) micrometer
Idler Gear end play 0.04 - 0.10 (limit 0.15) Dial gauge
Tooth Backlash between Crank gear 0.068 - 0.194 Feeler gauge or dial gauge
& Idler gear
Tooth Backlash between Idler gear 0.065 - 0.182 Feeler gauge or dial gauge
& Oil Pump gear (limit 0.3)
Tooth Backlash between Injection Pump 0.065 - 0.232 Feeler gauge or dial gauge
gear & Idler gear
Tooth Backlash between Cam gear 0.065 - 0.182 Feeler gauge or dial gauge
& Oil Pump gear (limit 0.3)
SPECIFICATION
DESCRIPTION
AND REMARKS
HA6ETI2
Engine lubrication
Max. oil pressure:
Full-load 4.5/4.8 kg/cm² Pressure gauge
Idling 1.2/1.6 kg/cm² Pressure gauge
Minimum oil pressure 1.0 kg/cm² (engine idling)
Oil flow rate 21 - 24 l per minute at 4 kg/cm² at 1000 rpm
Valve opening pressure: (Oil filter)
Release valve 3.7 - 4.3 kg/cm² Hydraulic pump with pressure
By-pass valve for paper element 4 kg/cm² gauge
By-pass valve for heat exchanger 1.5 kg/cm²
Oil pump gear height 27.00 - 27.04
Oil pump gear outer dia 49.2
Oil Pump Gear Backlash (Drive & Driven) 0.09 - 0.21 (limit 0.30) Feeler gauge
Drive Gear shaft Diameter 18.088 - 18.106 (limit 18.060) Micro meter
Drive shaft Bushing inside Diameter 18.146 - 18.173 (limit 18.20) Internal micro meter
Clearance between Drive Shaft & Bushing 0.040 - 0.085 (limit 0.1) Bore dial gauge/Micro meter
Driven Gear shaft Diameter 17.979 - 17.997 (limit 17.970) Micro meter
Driven Gear Inside Diameter 18.037 - 18.054 (limit 18.070) Bore dial gauge/Internal micro
meter
Clearance between driven gear and shaft 0.040 - 0.075 (limit 0.1) Dial gauge
Oil Cooler air pressure testing 6 kg/cm²
Cooling System
Permissible maximum cooling temp. 95°C Temperature gauge
Maximum water pump output 125 l pm @ 0.5 kg/cm² Test tank
Commencement of thermostat opening 82°C + 2°C Test tank thermometer & dial
gauge
Thermostat working stroke at 95°C 10 mm or more Test tank thermometer & dial
gauge
Cooling system capacity 22.5 l
14.0.4 Tightening Torques Kgm lb.ft Nm

Liner Pressing Special Tool 5 - 6 36 - 42 49 - 59
Main Bearing Cap Bolts 14 - 16 102 - 115 137 - 157
Flywheel Housing Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
18 - 20 131 - 144 177 - 196
Flywheel Fitting Bolts 18 - 20 131 - 144 177 - 196
Connecting Rod Cap Bolts 4 + 68° Angle 29 + 68° Angle 39 + 68° Angle
Timing Gear Plate Bolts 1.9 - 2.6 14 - 18 19 - 26
Oil Pump Assembly Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Camshaft Drive Gear Fitting Bolt 11 - 13 80 - 94 108 - 128
Camshaft Thrust Plate Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Idler Gear Fitting Bolt 4 + 60-65° Angle 29 + 60-65° Angle 39 + 60-65° Angle
Timing Gear Cover Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Crankshaft Pulley Fitting Nut 48 - 57 348 - 412 471 - 559
Oil Strainer Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Oil Pan Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Oil Pan Drain Plug 5.5 - 6.5 40 - 47 54 - 64
FIP Drive Shaft Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
FIP Mounting Bolts 1.9 - 2.6 14 - 18 19 - 26
FIP Bracket Fitting Bolt & Nut 3.8 - 5.0 28 - 36 37 - 49
FIP Drive Gear Fitting Bolt 3 - 3.5 22 - 25 29 - 34
FIP - Bearing Holder 4 - 4.5 23 - 31 39 - 44
Air Compressor Fitting Bolts 4.5 - 5.0 33 - 36 44 - 49
Alternator Bracket 4.5 - 5.0 33 - 36 44 - 49
Alternator Supporting Bolt & Nut. 4.5 - 5.0 33 - 36 44 - 49
Fan Belt Adjusting Bracket 4.5 - 5.0 33 - 36 44 - 49
Water Jacket Elbow 4.5 - 5.0 33 - 36 44 - 49
Water Drain Plug on Elbow 4.5 - 5.0 33 - 36 44 - 49
Oil filter Drain Plug 5.5 - 6.2 40 - 45 54 - 61
Centre Bolt 4 - 5 29 - 32 39 - 49
Oil Cooler Element Fitting Nuts 1 - 1.5 8 - 10 10 - 15
Oil Cooler Assembly Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Water Pump Assembly Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Water Pump Pulley Nuts 1.9 - 2.6 14 - 18 19 - 26
Fan to Spacer Bolts 2.0 - 3.0 15 - 21 20 - 29
Cooling Fan Fitting Bolts 1.5 - 2.2 11 - 16 15 - 22
Cylinder Head Bolts (M12) 12 - 13 87 - 94 118 - 128
Cylinder Head Bolts (M10) 4.5 - 5.0 33 - 36 44 - 49
Rocker Shaft Locking Bolts 0.6 - 0.7 4 - 5 6 - 7
Rocker Shaft Assembly Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Rocker Arm Adjusting Screw Nuts 1.9 - 2.6 14 - 18 19 - 26
Thermostat Case & Cover 4.5 - 5.0 33 - 36 44 - 49
1.9 - 2.6 14 - 18 19 - 26
Injector Holder Fitting Nuts 1.3 - 1.9 10 - 13 13 - 19
Glow Plugs Fitting Nuts 2.25 - 2.75 17 - 19 22 - 27
Flare Nuts on Injector Pipes 1.5 - 2.5 11 - 18 15 - 25
Injector Pipe Clip fasteners 0.5 - 1.0 3.7 - 7.2 5 - 10
Exhaust Manifold 4.5 - 5.0 33 - 36 44 - 49
Inlet Manifold Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Cylinder Head Cover Bolts 1.3 - 1.8 10 - 13 13 - 18
14.0.5 Crank Shaft Main Journals and Crank Journals Dimensions
DESCRIPTION mm
1. Std diameter of main journals 72.94 - 72.96

2. Std diameter of conrod journals 61.94 - 61.96
3. Fillet Radius main journal 3.00 - 3.50
4. Con. rod journal fillet radius 3.75 - 4.25
5. Wear limits
Taper (across total width) 0.1
Ovality 0.1
Bend 0.04
Wear limit 0.2
Concentricity 0.03
Maximum permissible out of round 0.02
6. Available under sizes (only 4 under sizes) 0.25/0.50/0.75/1.00
14.0.6 Main and Crank Journals Grinding Sizes

Under size Crank pin Main Journal
mm mm mm
0.25 61.69 - 61.71 72.69 - 72.71
0.50 61.44 - 61.46 72.44 - 72.46
0.75 61.19 - 61.21 72.19 - 72.21
1.00 60.94 - 60.96 71.94 - 71.96
Width of crank pin - 38.00 - 38.25 mm
Note: Correct by regrinding if worn unevenly more than 0.10 mm

Regrind if the wear is more than 0.2 mm
Replace crankshaft if wear is more than 1.2 mm
14.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness)
Under size (mm) Thickness (mm) Tolerance

STANDARD 2.00 -0.003 To -0.013
0.25 2.125 - do -
0.50 2.250 - do -
0.75 2.375 - do -
1.00 2.500 - do -
14.0.8 Crankcase Parent Bore and Cylinder Liner Outer Dia
Crankcase Parent Bore Cylinder Liner Outer Dia

Grade Size (mm) Grade Size (mm)
W 107 + 0.0060
W 107 - 0.0125
+ 0 - 0.0190
X 107 + 0.0125
X 107 - 0.0060
+ 0.0060 - 0.0125
Y 107 + 0.0190
Y 107 + 0
+ 0.0125 - 0.0060
Z 107 + 0.0250
Z 107 + 0.0060
+ 0.0190 + 0.
Note: Interchangeability is allowed w.r.t. next oversize or undersize liners.

14.0.9 Fuel Oil (High Speed Diesel)

Users are recommended to obtain their fuel supplies from a source which can be depended upon to
maintain a consistent standard of quality and service.
Fuel should be free from water and dirt, care should be taken by the user to protect fuel from
contamination.
14.0.9.0 Fuel Specifications - as per IS 1460 : 2000 (BS II)
1. Acidity, inorganic ... Nil
2. Acidity, total mg.of KOH/g (Max.) ... 0.20
3. Ash, % by Mass (Max.) ... 0.01
4. Carbon residue (Ramsbottom) on 10 percent residue,

percent by Mass, Max ... 0.30
5. Cetane Number (Minimum) ... 48

or
Cetane index (Minimum) ... 46
6. Pour point (Max.) ... 3°C for Winter &

15ºC for Summer
7. Copper Strip Corrosion for 3 hours @ 100°C ... Not worse than No.1
8. Distillation, percent v/v, recovered:

a) at 350°C, Min ... 85
b) at 370°C, Min ... 95
9. Flash point (Min.)

a) Abel, °C, Min ... 35
10. Kinematic viscosity in centistokes @ 40°C ... 2.0 to 5.0
11. Sediment % by mass (Max.) ... 0.05
12. Density at 15ºC kg/m3 ... 820 - 860
13. Total Sulphur, % by mass (Max.) ... 0.05
14. Water content % by volume (Max.) ... 0.05
15. Cold Filter Plugging Point (CFPP) max ... 6ºC for Winter and
18ºC for Summer
16. Total Sediments mg per 100 ml. (max) 1.6

14.0.10 Recommended coolant
Recommended
Change
Name & Address Concentration
Coolant intervals
of the manufacturer For Brass- Copper For Aluminium
in km
Radiator Radiator
Gulf Oil Corporation Limited,
Lubricants Division
Gulf Euro Cool 20% 50% 75,000
IN Centre, 49/50, MIDC, 12th Road,
Andheri (E), Mumbai - 400 093. INDIA
GC 1200 Sunstar-CCI (India) Private Ltd., 30% 50% 60,000
67, Maruthi Industrial Area, Sector 18,
GCL-2000 Gurgaon - 122 015. Haryana. 20% 50% 75,000
Tejon 800 S S Industrial Corporation 20% 50% 75,000
G-10, Udyog Nagar,
Tejon 1200 Delhi - 110 041. 30% 50% 60,000
Bharat Petroleum Corporation Limited,
MAK®
ECE House, 28A Kasturba Gandhi Marg, 20% 50% 75,000
SuperKool
New Delhi - 110 001.
Note: For Sub-zero temperature application use 1 : 1 Ratio.
To Prepare the coolant, it is recommended that only potable drinking water is used.
Caution: Use of any hard water will only increase scale formation in the Engine. Also please note that coolant
does not alter the hardness level of water.
14.0.11 Recommended Lubricants

Use of correct grades of lubrication is most important to prevent the wear and tear of components.
The chart shows the oil grade recommended by AL.
ASHOK
LEYLAND
GENUINE
LUBRICANTS
Ashok Ambient Sah Valvoline
Gulf Indian Oil Hindustan Bharat Elf
Aggregate Leyland Temp. IBP Chemoleums Petroleums Cummins
Oil India Corporation Petroleum Petroleum Lubricants
Specification °C IPOL Ltd.
Bharat Gulf Elf IPOL MCG VALVOLINE
Servo HP Milcy IBP
Stage II API CG4 + -15 and Superfleet MAK®-CG4 Performance Turbo CG4 Diesel All Fleet
Premium Eurol Turbo CG4
Norm MB 228.3 above Special 15W-40 Trophy DX 15W40 Premium Premium
CG4 15W40 15W40 15W40
Engines # 15W40 15W 40 15W40 15W40
14.0.12 Filling Capacity
Aggregates Qty (ll) Change Period (km)
Engine (Including Oil Filter) 10.5 16000
Note: The drain limits indicated are only for plains operation. For Ghat operations drain interval to be halved.
14.0.13 Liquid Gasket and Application Points

Use liquid gasket (Anabond 673/Loctite 587) instead of conventional sheet gaskets. The following are
the liquid gasket application points.
Liquid gasket application points and coating width

Parts Name Application Coating width
a) Oil pan Flange face which mate with cylinder 1.5 - 2.5 mm
block, timing gear cover and flywheel housing
b) Timing gear cover Faces which mates with timing gear 1.5 - 2.5 mm
plate (flange face, boss face)
c) Flywheel housing Faces which mate with cylinder block 1.5 - 2.5 mm
(flange face, boss face)
d) Coolant pump Flange face which mates with timing gear cover 1.5 - 2.5 mm
e) Thermostat case Flange face which mates with cylinder head 1.5 - 2.5 mm
f) Camshaft end plate Flange face which mates with cylinder block 1.5 - 2.5 mm
Coating Liquid Gasket and parts Assembly Procedure

1. Completely remove old liquid gasket from each part and the respective mating part, and
remove oil, water, and dirt using cloth.
2. Be careful not to apply excessive or insufficient liquid gasket. Also, be sure to overlap the start
and end of each coating.
3. When assembling coated parts, be careful that there is no misalignment between mating parts.
If there is any misalignment, coat the parts again.
4. Assemble the various parts within 20 minutes after applying liquid gasket. If more than 20
minutes have elapsed, remove the liquid gasket and apply it again.
5. After assembling the various parts wait for at least 15 minutes before starting the engine.
Applicator Gun
Fig. 3
Loading Cartridge
Press lever 1 and simultaneously pull lever 2 back completely. Insert the cartridge. The open
cartridge can be dispensed by pressing lever 3.
Unloading Cartridge
Press lever 1 and simultaneously pull lever 2 back completely - Remove cartridge from the gun.
14.0.14 Description of Leading Engine

Components
Cylinder Block - of high grade cast iron.

Cylinders and the crankcase form an integral
casting. The crankcase is enclosed from
below by the oil sump.
Cylinder Liners (dry, pre finished, hard,

easy fit type) - made of cast iron. There
are four selectable sizes available i.e. W, X,
Y, Z based on liner outer diameter.
Cylinder Head - made of high-grade cast

iron, accommodating all cylinders, fitted with
exchangeable, pre finished valve seats and
valve guides.
Crankshaft - an alloy steel forging,

mounted in seven bearings with
exchangeable shells. The main journals and
crank-joints are induction hardened.
Vibration Damper - is mounted on the

front end of the crankshaft. Care should
be taken while handling the vibration
damper. Use proper special tool while
extracting the damper pulley.
Alfin Pistons - made of special grade

aluminium alloy with cast iron insert to form
the first compression ring seat. The
combustion chamber design is called Hino
Micro Mixing System (HMMS).
Main and Small - End Bearing Shells

- thin-walled, with aluminium and tin or lead
bronze linings for sliding surfaces.
Camshaft - made of steel, mounted in the

cylinder block in four exchangeable bearing
bushes. Drive is supplied from the engine
crankshaft through a gear train.
Valves - made of high-grade alloy steel.

Valve stem seals prevent oil leakage into
combustion chamber.
Valve Spring - made of spring steel,

constant pitched coil.
14.0.15 Special Tools
Special Tool 0102001 Special Tool 0102002 Special Tool 0102003 Special Tool 0102004
Special Tool 0102020 Special Tool Special Tool

0102021 0102007
Fig - 4 Hino Engine Special Tools

14.0.16 Engine Preliminary Checks

It is mandatory to carryout few preliminary checks on engine before dismounting the engine from the
vehicle. The following cause and effects can lead to overhauling decision.
MECHANICAL HIGH ENGINE LOW ENGINE

LOSS OF
NOISE / OIL OIL
POWER.
FAILURES. CONSUMPTION PRESSURE.
ENGINE
OVERHAULING
AFTER LONG PREVENTIVE ENGINE ENGINE

STORAGE MAINTENANCE COOLANT SEIZURES
WITHOUT AND ENGINE
PROPER OIL MIXING
STORAGE COMPLAINT
PRECAUTIONS /
REPRESERVATION
Fig - 5 Engine Overhauling
Fig - 6 Low Engine Oil Pressure

Fig - 7 High Oil Consumption
Fig - 8 Loss of Power

Fig - 9 Mechanical Noise / Failures
Fig - 10 Engine Overheating / Seizures

Fig - 11 Bearing Rotation / Bearing Seizures

14.0.17 To Test Engine Compression
Use Special Tool 0102007 - Adaptor

Engine Compression with Special Tool
0102021 - Gauge Compression
Checking. (Use Adaptor Cylinder
Compression in place of nozzle).
Fig - 12
Warm-up engine to normal operation

temperature (approx 80°C). Disconnect fuel
delivery pipes and remove all six injectors.
Note: Use Special Tool 0102015 - Adaptor Fig. 12

Injector Removal with Special Tool
0102003 - Sliding Hammer, if injector
extraction is difficult.
Set the Adaptor Cylinder Compression with

standard gauge compression on First cylinder.
Fig - 13
Check valve clearance, if necessary adjust as

per recommendation.
Crank the engine approx 8 to 10 revolutions

by actuating the starter motor. The battery
must be in properly charged condition as to
Fig. 13
achieve a cranking speed of atleast 280 rpm.
Keep engine stop cable in pulled in condition.
Repeat this procedure for all 6 cylinders.
Compression pressure kg/cm² @ 280 rpm
Minimum 25
Maximum 36 - 39
Pressure difference between each cylinders

should be below 3 kg/cm²
If compression pressure is found below

minimum recommendation engine requires
reconditioning.
In the last case it will be necessary to check

valve tightness, condition of piston clearance
of the respective cylinder.
Wet Compression Pressure Check
If the particular cylinder compression pressure is

below 300 psi as per above dry check
procedure, to locate fault with valve tightness or
piston clearance repeat the compression
pressure check after pouring few drops of
engine oil thru Injector hole. If low compression
persists, the fault is with valve seats.
14.1 TO REMOVE AND REFIT ENGINE

FROM VEHICLE
14.1.0 To Remove Engine
- Disconnect battery terminals and choke the
wheels.
- Drain engine oil
- Drain the coolant and remove cooling
system, radiator, pipes, hoses etc.
- Remove air intake system, turbo connection,
charge air cooler, exhaust system and fuel
pipe connections,
- Disconnect electrical connection from fuel
shut off solenoid.
- Disconnect the clutch / gear linkage system.
- Remove gear box and clutch.
- Unscrew engine fixing bolts of the engine
mounting pad.
- Fasten hoisting cable to the lifting eyes on
right front and left rear of engine.
- Use multipurpose jip crane SME 11001 to
lift the engine. Fig - 1
- Lift the engine slightly and move it
outwards. Fig. 1
- Place the engine on suitable platform

keeping in mind that the oil sump is not
damaged.
Note: Use Engine stand of proper dimensions to
keep the engine or use Special Maintenance
Equipment, SME No. 01006. Fig - 2
- Engine should be thoroughly washed with a
suitable cleaning liquid before it is
dismantled.
- Dismantling and assembly should be carried
out by experienced personal and atmost
cleanliness must be observed. Special tools Fig. 2
manufactured for this purpose to be used.
14.1.1 To Refit Engine

- The above mentioned procedure to be
fitted back in reverse order.
- Ensure the alignment of the engine in the
exact centre of the chassis frame.
- Before initial starting of the engine, check
whether, engine oil, gear box oil and coolant
level are verified.
14.2 CRANKCASE
14.2.0 To Remove and Refit Cylinder Liners

Use Special Tool 0102011 - Extractor
Cylinder Liner for removal of cylinder liners.
Note: Liners are of transition fit type. Special tool

to be used only when liner removal is
difficult. Fig - 1.
Incase you want to reuse the liner be sure

to put matching marks with marker pen on Fig. 1
the cylinder block and liner flange for
repositioning. Fig - 2
After removing the cylinder liners, put

numbers on their periphery or arrange them
in sequence.
Make sure that the liner grade mark has the

same mark on the cylinder block.
There are 4 different grades of liners and

cylinder block matches. Each liner has any
Fig. 2
one of the following markings W, X, Y or Z
of the OD. These indicate the size of the
O.D. of the liner. Similarly, the matching I.D.
markings of the cylinder bore is indicated by
W, X, Y or Z on crank case LH side top
for each Bore. Fig - 3
Apply a small amount of clean engine oil on

the outer periphery of liner. The special tool
should be used as liner is extremely thin and
can easily get damaged. Thin and sharp ring
on the top face of the liner is called
"FLAME ARRESTER". Any damage to this Fig. 3
flame arrester ring can cause cylinder head

gasket failures.
When reusing a liner, insert the liner in its

original position aligning the markings marked
before disassembly. Use Special Tool
0102012 - Guide Cylinder Liner. Fig - 4
Fig. 4
Measure the projection of the

cylinder liner.
Fix Special Tool 0102013 - Retainer Cylinder

Liner (Fig - 5) and measure the amount of
projection of the liner from the cylinder block
with a dial gauge and magnetic stand. Fig
- 6
Refer data for liner projection.
Fig. 5
Fig. 6
14.2.1 To Remove and Refit Timing Casing

Cover and Back Plate
Backout fixing screws of the Timing back

plate. Fig - 7
Take off the Timing back plate, taking care

of both dowel pins. Before refitting, remove
the old Liquid gasket material and clean
front face of the crankcase.
Apply fresh liquid gasket (Anabond 683) Fig. 7
with new gasket to crank case face of the

Timing Back plate.
Screw down Timing Back plate with hex

screws and spring washers.
Remove timing cover and Replace new oil

seal using Special Tool 0102001 - Drift Oil
Seal Gear Case. Fig - 8
Installation should only take place with

engine in normal upright position. Fig. 8
14.2.2 To Remove and Refit Flywheel

Housing
Backout fixing screws of the flywheel housing.

Fig - 9. Start with M8 bolts (6 nos.) and
then M14 bolts (8 nos.).
Take off the flywheel housing, taking care of

rear main oil seal.
14.2.3 Install the Oil Seal in the Flywheel

Housing
Fig. 9
Using a special tool, press in the oil seal in
the flywheel housing. Fig - 10
Special tool 0102004 : Drift for Oil Seal

Flywheel Housing.
Before refitting, remove the old Liquid gasket

material and clean rear face of the
crankcase. Apply fresh Liquid gasket to
inner side of the flywheel housing.
Fit flywheel housing and tighten it securely

with hex screw. Fig - 11. Start with M14 Fig. 10
bolts (8 nos.) and M8 bolts (6 nos).
14.2.4 To Remove and Refit Flywheel
Backout fixing screws and remove flywheel.

Fig - 11
Check ring gear, if necessary replace.
14.2.5 To Remove Ring Gear (Fig - 12a)
- Heat the ring gear with a blow torch in a

Fig. 11
uniform manner (approx. 180°C).
- Using a metal rod as pad and strike all

around the ring gear in uniform manner and
remove the ring gear.
14.2.6 To Install Ring Gear (Fig - 12b)

Fig. 12a
- Heat the ring gear uniformly using a blow

torch (approx. 180°C).
- Drive the ring gear with its chamfered gear

Fig. 12b
teeth facing the block onto the flywheel
using a metal rod.
14.2.7 Install Flywheel
Align the 'O' mark on the flywheel and

crankshaft collar knock pin. Fig - 13.
Install the flywheel and tighten the bolts

through several repetition of the tightening
order so as to reach specified torque evenly
and gradually then slacken and tighten them
by one by one to the specified torque as
per sequence. Fig - 14a & 14b.
Fig. 13
When tightening the bolt, apply engine oil to
the threads and flywheel surface of the bolts.
Install the pilot bearing and stopper.
Check the flywheel runout as per

recommendation. Fig - 15
Fig. 14a
Fig. 14b
Fig. 15
14.3 CRANKSHAFT
The crankshaft is supported by 7 main

bearings.
Thrust is taken up by the thrust washer at

the fourth journal.
14.3.0 To Remove and Refit Crankshaft
Backout collared bolts and remove bearing

caps. Fig. 1
Remove thrust bearing cap (4th) last.

Fig - 1
Arrange all the caps bearing and thrust

washer in order. Fig - 2
The bearing caps are match marked with the

crankcase by punch marking 1 to 7,
commencing from timing gear side.
Timing Gear Side
Fig. 2
Lift the crankshaft out of the crankcase.

Fig - 3
Fig. 3
14.3.1 To Renew Crankshaft Gear
By using Conventional puller remove

crankshaft gear from crankshaft. Fig - 4
Fig. 4
14.3.2 To Refit the Crankshaft Gear
Heat the gear upto 130°C and fix it.
14.3.3 To Check Crankshaft Bend
Maximum permissible bend is 0.04 mm.

Fig - 5
14.3.4 Installation
Clean crankcase, crankshaft and bearing
shells by blowing compressed air through the
lubrication holes.
Fig. 5
14.3.5 To Renew Crankshaft Main &

Connecting Rod Bearing and Check
Main & Connecting Rod Bearing
Spread
Hold the bearing shell without applying any

pressure and measure the outside diameter.
Main bearing dimension : 79.00-79.60 mm
Connecting rod
Fig. 6
bearing dimension : 67.05 - 67.55 mm
Fig - 6
Install the crankshaft, main bearing on the

crankcase and bearing caps.
Lubricate crankshaft journals, bearing shells,

cap bolt threads and under the bolt heads
with the engine oil. Carefully lower the
crankshaft into position.
Fit bearing caps and starting off with the Fig. 7

thrust bearing No.4, adhering to the match
marks. Connecting faces, of bearing caps
and crankshaft should be perfectly clean.
Fig - 7.
Bearing cap set identification no punched on

the bearing cap and LH side rear end of
the crankcase.
Tighten cap collared bolts uniformly in the

three stages in tightening order 4-5-3-6-2-7-1.
Fig - 8 Fig. 8
Do not attempt to rotate crankshaft

before all bearing caps have been bolted
down. The crankshaft must turn freely
without binding i.e. a strong push by hand
should make it turn atleast one revolution.
Fig - 9
Check endplay of crankshaft as follows:
Force crankshaft in one axial direction and
measure the gap between thrust bearing
side and crank web face.
The initial end clearance with new thrust and
main bearings should amount to 0.05 to Fig. 9
0.22 mm and end clearance should not

exceed 0.4 mm.. Fig - 10
14.3.6 To Check and Grind Crankshaft

Clean crankshaft and blow out lubrication
holes with compressed air, check journals
and crankpins for cracks.
Check wear of crankshaft if wear is more
than 1.2 mm from standard size, replace
crankshaft.
No further heat treatment is recommended.
Fig. 10
Support crankshaft at front and rear journals.
The bend must not exceed 0.04 mm.
Grind the crankshaft according to the
available replacement bearing shells. This
work may only be performed by experienced
crankshaft grinders. For repair data of
undersize big end bearings and main
bearings refer section 14.0.7.
14.3.7 To Remove and Refit Vibration

Damper
Backout the hex nut with box spanner 46
mm. Fig - 11 Fig. 11
Withdraw the vibration damper.

If found externally damaged, replace with
new one.
Fit the new O ring on the inner dia of the
hub.
To refit vibration damper reverse the
procedure for removal.
14.4 PISTON AND CONNECTING RODS
14.4.0 To Remove Piston Assembly
Fix Special Tool 0102013 - Retainer Cylinder

Liner to hold the liner.
Backout connecting rod bolts and remove

bearing cap.
Scrape off carbon deposit from the upper

end of the cylinder liner with the help of Fig. 1
emery paper or scraper. Fig. 1
Extract all the pistons and connecting rod

assemblies through top of the cylinders.
14.4.1 To Dismantle and Assemble Piston

and connecting rod
Remove gudgeon pin circlip with the circlip

plier. Fig - 2
Fig. 2
Place a copper drift on the pin and strike it

out with the hammer. Fig - 3
14.4.2 Connecting Rod Bush

Fig. 3
14.4.2.0 To Remove Bush
Using a special tool 0102017 - Drift and

extractor.
Align supporting surfaces of the guide and

press sub assembly flush on the flat plain.
Set the connecting rod assembly without

crank pin bearing on the guide and press
assembly. Fig - 4
Fig. 4
Install the spindle into the bushing. Align

the grooving of the spindle with the oil hole
of the bush. Fig - 5
Fig. 5
Using a hydraulic press, remove the bush

slowly and smoothly. Fig - 6
Fig. 6
14.4.2.1 Installation of Connecting Rod Bush
Chamfer one edge of the bush hole at the

small end of the connecting rod uniformly by
C 0.5 - 1.0 mm. Fig - 7
Set the bush and guide on the spindle then

secure them with the bolt.
Fig. 7
Be sure to slip the bushing over the spindle

in the proper direction, so that oil hole 'A'
will later align with the rifle hole in the
connecting rod. Fig - 8
Fig. 8
lubricate the bush guide and bush bore on

the connecting rod.
Align oil hole 'B' in the bushing with the rifle

hole of the connecting rod. Fig - 9
Always operate the press slowly and

smoothly.
Fig. 9
14.4.2.2 Inspect the Bushing Position after
Installation
Make sure that the oil holes of the bushing

and connecting rod are aligned. Fig - 10
Insert a pin of 3 mm dia into the hole at

the end of the connecting rod, and make
sure that the pin fully goes in.
If there is any deviation in the alignment of

the oil holes correct it with a drill of 3 mm Fig. 10
dia. If drilling is carried out, take care to
remove the machined burrs clears off the
connecting rod small end bore and oil holes.
14.4.2.3 Check for Bend of Connecting Rod
Check for bend of connecting rod by means

of bend checking tool and feeler gauge. The
permissible tolerance is 0.1 measured at the
distance of 200 mm from the longitudinal
axis of connecting rod. Fig - 11
Fig. 11
14.4.2.4 Install the Connecting Rod Bearing

Confirm the oil hole A & B are in line.
Fig - 12
Fig. 12
14.4.3 Piston and Piston Rings
14.4.3.0 Piston General
The piston combustion chamber is of re-

entrant type for faster and more efficient
combustion. The piston consists of two
compression Ring grooves, one oil scraper
ring groove and crown face with valve
pockets.
Max. difference in the weight of the piston is

an engine set of 6 pistons not to exceed 5
gms.
Weight group identification mark punched on

the piston crown.
14.4.3.1 To Remove Piston rings
Remove compression rings and oil scraper

rings with the aid of piston ring plier. Fig -
13
Fig. 13
Remove carbon deposits from piston ring
grooves.
14.4.3.2 Assemble Piston and Connecting Rod
Heat the piston to approximately 80°C

temperature.
Insert the gudgeon pin into the piston with

Fig. 14
O mark on the piston top and connecting

rod match mark should remain opposite to
each other, while assembling the piston to
Fig. 15
14.4.3.3 Install Piston rings
Before fitting new piston rings, check each

ring gap separately by inserting the ring into
the cylinder bore at right angles and
measure the ring gap with a feeler gauge.
Fig - 16
Apply oil over the piston ring. use a piston

ring expander while fitting the piston rings.
Install the piston ring in sequence viz; oil Fig. 16

ring, second ring and top ring with the
identification mark at the top of the ring
facing upwards.
Connect the ends of the coil expander and

then fit the coil inside the piston ring after
ensuring that the gap of the piston ring is
180° away from the joint of the coil. Coil
expander and piston scraper ring are
supplied together. Fig - 17
Fig. 17
Check the side clearance of the piston rings.

Fig - 18
Fig. 18
Stagger the piston ring gaps so that they

are not in line, approximately at 120 o away
from each other. Fig - 19
Fig. 19
14.4.3.4 Installation
Lubricate piston, piston rings, cylinder bore

and con rod bearing with engine oil.
Displace the piston ring gaps relative to

each other by 120°.
Make sure that 'O' mark on the piston top

is on the tappet side, when fitted.
Rotate crankshaft so that the crankpin of Fig. 20

the respective piston is in B.D.C. position.
Insert piston with connecting rod assembly

into the cylinder bore compressing the piston
rings by means of Special Tool 0102014 -
Compressor Piston Ring. Fig - 20
Push the piston into the crankcase until the

big end bearing is seated on the crankpin.
Align the punch mark on the connecting rod

and cap. Fig - 21
Fig. 21
Fit bearing cap with bearing, taking care that

the bearing halves are seated properly in the
connecting rod and cap. Tighten con rod
bolts alternatively to recommended torque.
Fig - 22
Fig. 22
14.5 CYLINDER HEAD ASSEMBLY
14.5.0 To Remove Cylinder Head
Loosen the cylinder head bolts / rocker

arm support bolts as per sequence shown.
Fig - 1. Start with M10 bolts and then
M12 bolts.
Using a special tool 0102010 - Wrench

Cylinder Head Bolt
Fig. 1
Lift the cylinder head from the dowels on
the cylinder block and place it on wooden
blocks (supporting on both the ends) to
avoid nozzle tip damage. Nozzle protrusion
from the cylinder head surface 5.5 - 6.0 mm.
Fig - 2
Ensure that all the nozzles are removed from

the cylinder head.
Remove the valve split cone lock, collar and

spring from cylinder head.
Fig. 2
Using Special Tool 0102005 - Compressor

Valve Spring. Fig - 3
Remove the inlet and exhaust valves.
Before removal of all valves, punch the serial

nos of cylinder numbers on the valve face,
to avoid mixing of valves. Fig. 3
Clean the cylinder head, valves, spring and

all other parts thoroughly with the suitable
solvent.
Check cylinder head surface unevenness.

Fig - 4.
Fig. 4
Hand lap valve and valve seat.
Lightly apply lapping compound to the valve

face. Install the valve with a Valve Lapping
Tool, tap and rotate valve against the seat.
Fig - 5.
Fig. 5
14.5.1 To Grind Valves and Valve Seats
Note : Grinding of valves and valve seats should

only be performed when handlapping does
not result in proper seating. Any
conventional valve grinding machine can be
used. Fig - 6 & 7
After grinding, always recheck the valve sink.
For repair data refer section 14.0.3.

Fig. 6
14.5.2 To Refit the Valve Seat and To

Check and Reface Valve Seat
Cut the circumference of a valve head at

three places with a grinder and install it into
seat and weld valve to seat. Then drive
out valve and seat with a hammer and a
brass block.
14.5.3 Valve Seat Installation

Fig. 7
Heat the cylinder head to about 80° -

100°C with hot water. On the other hand,
cool the valve seat with dry ice or liquid
nitrogen for about 30 minutes. Hold the
seat with pincers and place it into the
heated cylinder head. Fig - 8
Fig. 8
Valve seat section machining specifications
Fig. 9
Fig - 9
14.5.3.0 To Check the Valve Guide
The Valve guide may require replacement if

stem to valve guide clearance exceeds
Intake - 0.035 - 0.068 mm
Exhaust - 0.050 - 0.083 mm
Fig - 10
14.5.3.1 To Renew Valve Guide

Fig. 10
Remove the valve stem seal.
Using a brass rod and hammer, drive out

the valve guide.
Install the valve guide.
Special Tool 0102009 - Drift Valve Guide.
Note : Apply engine oil lightly to the valve guide

outer circumference before installation.
14.5.3.2 To Refit Valve and Valve Stem Seals
Install the valves and lower spring seat.
Use fitment sleeve for valve guide Fig. 11

seal to part no. X1102160.
Fig - 11
Then apply engine oil to the lip of the stem

seal and install the stem seals.
Remove and scrap the fitment sleeve.
Drive the special tool until it hits the lower

spring seat.
Special Tool 0102006 - Drift Valve Stem

Seal. Fig - 12
Fig. 12
14.5.3.3 To Check Valve Springs
Check valve springs on a valve spring scale

for re-usability
Valve spring
straightness = 2.0 mm
Setting load = 26.5 kg at 45.5 mm

limit 24.6 mm
14.5.4 To Assemble the Cylinder Head
Apply engine oil to contact surface of all the

parts. Make sure that the valves are
installed in the respective cylinders.
Valve springs are constant pitch in place of

progressive spring (Equal pitch coil).
Press valve spring and collar to install split

cone lock.
Using Special Tool 0102005 - Compressor

Valve Spring. Fig - 13.
Install the Cylinder Head Fig. 13
Install the cylinder head gasket, always use

new cylinder head gasket. After cleaning the
surfaces of the cylinder head, cylinder block
and head gasket free from dirt, water and
grease.
Fit 12 numbers valve lifters on to the

cylinder block after applying the oil to the
tappet bores on the cylinder block.
Ensure fitment of two dowel pins on the

cylinder block top, to locate cylinder head
gasket.
Install the cylinder head over the dowels on

the cylinder block.
Insert push rod in correct order.
Tighten the cylinder head bolts in three

stages as per tightening sequence and
recommended torque. Fig - 14. Start with
M12 bolts and then M10 bolts.
Mount the rocker arm assembly on the

cylinder head, make sure that the push rods
interlock with the adjusting screws.
Fig. 14
14.6 TIMING
14.6.0 To Remove and Refit Rocker Levers
Backout fixing bolt and remove rocker shaft

assembly.
Reassemble rocker arm assy. in the order as

follows:-
Bracket, Inlet valve lever, Spacer, Exhaust

valve lever, Bracket . . . ,
Fig. 1
The tappet adjusting screws in BS II are
longer by 1.5 mm then compared to BS I
engine. Hence care should be taken to
ensure that the right screws are fitted.
Confirm that oil hole of rocker arm

assembly No.7 support aligns with shaft oil
hole.
Fig - 1
Improper installation will result in seizure of

the entire valve assembly.
14.6.1 To Remove, Refit and Check Push

Rod and Tappets
Remove push rods and tappets.
Check out of true of push rods between

centres.
Maximum permissible out of true = 0.3

mm.
Examine push rod ends for wear. Replace

if necessary and check rocker lever and
tappet lubrication in this case.
Check diametral clearance of tappet in

crankcase bore and inspect sliding surface
and push rod seat for wear.
If necessary replace worn out parts.
To refit push rods and tappets, reverse the

14.6.2 To Remove and Refit Camshaft

Unscrew 2 Nos Hex screws of 12mm size
from camshaft holding flange through
opening provided in camshaft gear.
Do not unscrew camshaft drive gear
holding bolt and try to pull the gear using
puller.
Extract camshaft after removing push rods
and tappets.
Pull out the camshaft slowly turning it, so
that the bearings are not damaged. Fig - 2
14.6.3 Removal and Replacement of Fig. 2

Camshaft Bushes
Use Special Tool 0102018 - Drift &
Extractor Camshaft Bushes to remove and
refit camshaft bushes. Fig - 3
Extraction
The HINO cylinder block is designed with
minimum aperture, the camshaft bushes are
not approachable from the LH side or
bottom side of the engine. Hence the parent
bores of camshaft bushes in the cylinder
block have been machined in different
diameters to facilitate the removal and re-
fitment of the bushes. For this reason, the
diameters of the camshaft bearing journals
are in descending order.
14.6.4 Camshaft Bush Dimensions (in mm)

Parent bore diameter
First Bush - 60 Second Bush - 59.8
Third Bush - 59.6 Fourth Bush - 59.8
Bush inner diameter
First Bush - 57 Second Bush - 56.8
Third Bush - 56.6 Fourth Bush - 56.4
Fig. 3
Proceed in the following manner to remove

the camshaft bushes.
1. Remove the 1st and 4th bushes one after

one using collapsible puller assembly and
support bracket from front and rear
respectively. Fig - 4
2. Compress the collapsible puller and insert

the same in to the bush until the collapsible
bunk expands and holds the bush snugly.
3. Lightly tighten the nut next to the collapsible Fig. 4

bunk so that the bunk does not collapse
when the bush is being pulled out.
4. Place the support bracket and thrust bearing

in place and using the nut and handle
assembly, pull out the bush.
5. Fix the extractor bunk on the appropriate

groove on the puller shaft, insert the puller
shaft from rear side of the engine carefully
locating the bunk inside the 3rd bush.
Fig - 5
Fig. 5
6. Arrange the guiding bunk, support bracket,
thrust bearing and nut & handle assembly at
the front end of the engine on the puller
shaft and extract the 3rd bush. The 3rd
bush will fall between the 3rd and 2nd
parent bores of the camshaft bushes now.
7. Guide the extractor bunk along with the

extracted 3rd bush in to the 2nd bush and
continue to rotate the nut & handle
assembly until the 2nd bush is extracted.
Fig. 6
Fig. 6
8. Take out the puller arrangement along with
the 2nd and 3rd bushes carefully through
the 1st bush parent bore of the camshaft.
14.6.5 Installation:
The camshaft bushes are pre-finished; hence

handle them carefully.
1. Fix the drift bunk on the puller shaft in the

appropriate groove on the longer puller
shaft as shown. Place the 3rd camshaft bush
on the extractor and carefully insert the
puller shaft from rear of the engine until the

front portion of the drift bunk sufficiently
enters the 3rd camshaft bush parent bore.
Arrange the guide bunk, support bracket,
thrust bearing and nut & handle assembly
at the front end of the cylinder block as
shown and tighten the nut & handle
assembly until the 3rd camshaft bush is in
its place. Fig - 7.
2. Remove the puller from the cylinder block

and place the 2nd camshaft bush on the
drift bunk. Insert the puller from the front Fig. 7
side of the engine until the front portions of
the drift bunk sufficiently enter the 2nd
camshaft bush parent bore. Arrange the
guide bunk, support bracket, thrust bearing
and nut & handle assembly at the rear end
of the cylinder block as shown and tighten
the nut & handle assembly until the 2nd
camshaft bush is in its place. Fig - 8

and fix the drift bunk in the appropriate
groove as shown in figure. Place the 4th
camshaft bush on the bunk and insert the Fig. 8
puller shaft from rear end of cylinder block
until the front end of the bunk is sufficiently
inside the parent bore of the 4th camshaft
bush as shown. Arrange the guide bunk,
support bracket, thrust bearing and nut &
handle assembly at the frond end of the
cylinder block as shown and tighten the nut
and handle assembly until the 4th camshaft
bush is in its place. Check for the alignment
of oil holes when the bush is in its place, it
would be about 2 mm inside the parent
bore. Fig - 9
Fig. 9
and place the 1st gear bush on the drift
bunk. Insert the puller from front end until
the front portion is sufficiently inside the
parent bore of 1st camshaft bush parent
bore. . Arrange the support bracket, thrust
bearing and nut & handle assembly at the
front end of the cylinder block as shown in
the figure, centralize the puller shaft at the
rear and tighten the nut & handle assembly
until the 1st camshaft bush is in its place.
Fig - 10.
Fig. 10
To refit camshaft reverse the procedure for

removal.
If necessary, remove the camshaft

gear
Hold the camshaft assembly with a suitable

vice through wooden supports.
Remove the nut, then using a gear puller,

remove the gear. Fig - 11
Fig. 11
14.6.6 Install the camshaft gear on the shaft
Install the camshaft bearing with a thrust

bearing. When installing the gear to the
camshaft, heat the gear in hot water
(approx. 100°C), then install the gear on the
camshaft by using a press. When tightening
the bolts, apply engine oil to the threads and
bearing surface of the bolt. Fig - 12
14.6.7 To Refit the Camshaft
Fig. 12
Set the no. 1 piston to Top Dead Centre
of the compression stroke.
Lubricate all journals of the camshaft and

insert the camshaft assembly into the
cylinder block, by slowly turning, so that the
bearing will not be damaged.
Align the camshaft timing gear matching

mark with the oil pump gear mark.
14.6.8 To Remove and Refit Intermediate

Timing Gear Fig. 13
Backout fixing bolt and remove it with

thrust washer, withdraw intermediate gear.
Fig - 13
To remove the spindle use special tool

0102003 - Sliding Hammer and special
tool 0102002 - Adaptor Idler Gear Shaft.
Fig - 14
Fig. 14
14.6.9 Install the Idler Gear Shaft (Spindle)
Install idler gear shaft with thrust plate using

a plastic hammer.
Make sure that the two oil holes is facing

downward (oil pan side) so that it does
not become clogged due to accumulation of
sludge and other foreign material in the oil.
Fig - 15
14.6.10 Install the Idler Gear
Install the Idler gear, be sure that the Fig.15

matching marks of the crankshaft gear, oil
pump drive gear and idler gears are aligned
correctly. Fig - 16
Check end play within 0.040 - 0.095 mm.
Ensure backlash - 0.068 - 0.194 mm.
Tightening torque procedure for

idler gear bolt
- Apply oil on bolt thread and face
- Initial torque by 100 Nm, then loosen the Fig.16

bolt.
- Then torque the bolt to 40 Nm + 60° -

65°
- Resultant torque 135 - 195 Nm.
14.6.11 To Re-bush Intermediate Gear
Press out the worn bush with a suitable

drift. Fig - 17
Drive in the new bush.

Fig.17
Note: The replacement bush is supplied finished.
Max. oil clearance

between spindle
and bush = 0.1 mm
Intermediate gear
endplay = 0.15 mm
Fig - 18
Bush internal diameter = 50.00 mm
Spindle dia = 49.95-49.97 mm

Fig. 18
14.6.12 To Position Timing Gears for Valve

Timing and FIP Timing
1. Crankshaft Gear
2. Idler Gear
The gear train to be matched as per
3. Injection Pump
matching punch marks on gear Drive Gear
circumference. Fig - 19 4. Oil Pump
Drive Gear
5. Camshaft Gear
14.6.13 Timing Gear Backlash Checking
6. Power Steering
(Fig - 20) Oil Pump
Drive Gear
Check tooth backlash with feeler gauge. (Option)
Backlash between driving gear and

intermediate gear. Fig. 19
Max. limit = 0.3 mm.
14.6.14 To Fit Air Compressor
While assembling, keep engine first cylinder

at TDC, align 'N' punch mark on the gear
teeth with the bottom mounting hole, then
assemble the compressor and tighten the
mounting bolts. Fig - 21
14.6.15 To Remove and Refit Fuel Injection

Pump and To Adjust the Injection
Timing Fig. 20
Use special Tool 0102019 - Wrench for

Engine Cranking.
A. Removal of FIP from Engine:
1. Isolate battery.
2. Remove high pressure pipe connections,

remove over flow pipe and boost
compensator pipe. Remove the FIP support
bracket.
Fig. 21
3. Remove the front cover case bearing holder.
4. Rotate the engine clockwise direction viewing

from the front of the engine.
Fig - 22
Fig. 22
Align the ING mark on the flywheel with the

timing pointer on the flywheel housing. Also
ensure that the first cylinder at the end of
the compression stroke.
Fig - 23
5. Remove the plug from the timer hole.
Fig - 24
6. Check the injection timing mark on the timer

is aligned with the timer cover pointer.
Fig. 23
Fig - 25
7. Loosen and remove the mounting bolts of

the FIP from the timing casing, Remove the
FIP.
C. To Refit the Fuel Injection Pump and

adjusting the Fuel Injection Timing
1. Bring the no.1 cylinder at TDC on

compression stroke.
2. Align ING mark on the engine flywheel with Fig. 24

the timer pointer on the engine flywheel by
rotating the engine clockwise direction
(viewing from the front of the engine). Also
ensure that the first cylinder at the end of
the compression stroke. (Fig - 23).
NOTE: Engine should not be rotated anticlockwise

direction to align ING mark.
3. Check the FIP mounting Gasket.
4. Fit the FIP onto the engine aligning the

injection pump drive gear.
Fig. 25
5. Fix the FIP mounting bolts onto the timing

case and tighten.
6. Check the injection timing mark on the timer

is aligned with the timer cover pointer. (Fig
- 25).
7. If not adjust the injection timing mark, by

loosening the four mounting bolts of the
injection pump drive gear and align the
mark.
Fig - 26 Fig. 26
8. Tighten the injection pump drive gear

mounting bolts (If loosened).
9. Fix the timer hole plug and front bearing

casing cover and tighten.
10. Refit the injector pipe connections, overflow

pipe and boost compensator pipe, lub oil
pipe connections and FIP support brackets.
Fig - 27
Fig. 27
14.6.16 To Adjust the Valve Clearance
Method for determining if the No. 1

or No.6 piston is at the Top Dead
Center on compression stroke.
* Turning the crankshaft, align the mark

"1-6" on the flywheel pointer on the
flywheel housing.
* In this position either the No. 1 or

No. 6 piston is at the top dead
center on compression stroke.
If both No. 1 intake and exhaust rocker

arms can be moved easily by hand, the No.
1 piston is at top dead center on
compression stroke.
With the No. 1 piston positioned at top

dead center on compression stroke, adjust
the No. 1 valve clearance using a feeler
gauge.
The feeler gauge should move with a very Fig. 28
slight pull.
Valve clearance -
To adjust the other cylinder valves, by
turning the crankshaft clockwise 120°
(viewed from the front side). Adjust the
valve clearance for each cylinder as per firing
order. Fig - 28 & 29
Fig. 29
14.6.17 Fuel Filters
Effective fuel filtration is absolutely essential

for trouble free operation of the fuel
injection equipment. Fuel filters have been
designed to retain even the smallest of the
impurities and protect the extremely sensitive
precision parts of the injection pump and
nozzle from damage.
Note: Do not use star type filter inserts. Always

use coil type fuel filter. Fig - 30
Fig. 30
Maintenance
Filter inserts must be replaced at regular
intervals. Guidelines for replacement period
under normal conditions are given below.
Filter Change Period (Both Paper Coil

Type)
First stage First 16000 km and

element thereafter every 16000 km
Second stage First 24000 km and

element thereafter every 16000 km
Note: Never change both the filters at a same

time.
The filter elements (inserts) should never be

cleaned, at an interval lesser than the
recommended period. Sometimes the filter
inserts get clogged in a very short time due
to asphaltene or waxy compounds present in
fuel. In such cases the filter inserts have to
be replaced.
Renew Fuel Filter Element
- Unscrew centre bolt and withdraw the

bowl and filter, Install new sealing ring
and ensure it is correctly located.
- Clean the bowl free of sediments.

Replace a genuine filter element and
refit the bowl.
Bleed the fuel system

While bleeding the fuel system bleed the fuel
through the high pressure injector pipes upto
the injector end. It is necessary to crank
the engine intermediately.
Note: Do not disturb FIP for bleeding.

14.6.18 Water Separator
Remove and empty the bowl and wash out

with clean fuel. Prefill the bowl with clean
fuel before refitting. Always renew the
sealing ring. Fig - 31
14.6.19 To Remove and Refit Injector Nozzle
Clean the surrounding area of the nozzle

and fuel line connections. Fig - 32
Remove injector pipes, clean and cover both

the ends of the pipes to prevent entry of Fig. 31
the dirt.
Remove nozzle assembly.
Use a special tools 0102015 - Adaptor

Injector Removal and 0102003 - Sliding
Hammer. Fig - 33
14.6.19.0 Cleaning
Important: The ball profile of DSLA nozzle is not

hardened, extreme care to be
exercised in handling the injectors and
nozzles at all levels. Do not use Fig. 32
emery sheet or hard material to clean
the nozzles.
To Clean nozzles
Use ultrasonic cleaning equipment.
Ultrasonic cleaning is a safe and effective

way of cleaning the nozzles.
Ultrasonic cleaning equipment consists of

generator capable of generating electrical
energy at an ultrasonic frequency and a
'transducerized tank' which holds the cleaning
Fig. 33
solution and the parts to be cleaned. The
Ultrasonic frequency waves are transmitted
to the cleaning solution contained in the
tank, which dislodges the dirt and soot.
The main objective of using this equipment

is to clean the spray holes of the nozzles
especially the DSLA type in which the ball
profile is soft.
14.6.19.1 Test the nozzle sinking
Wash the nozzle with the diesel then

immerse it in diesel oil.
Slide the needle inside the nozzle and ensure

moves smoothly. The needle should fall
under its own weight when withdraw
vertically about 1/3rd and released. If its
motion is sluggish, replace the nozzle with
new one. Fig - 34
Fig. 34
Adjust the injection pressure.
Connect the nozzle holder with a nozzle

tester and move the lever at the rate of
about 50 - 60 strokes per minute.
Adjust the injection pressure as

recommended. Fig - 35
If the injection pressure is not within

specifications, readjust the injection pressure
with the shims.
Fig. 35
14.6.19.2 Test the spray profile
In case of the new nozzle, operate the lever

at the rate of 30 - 60 strokes per minute
and for a used nozzle, operate the lever at
the rate of 15 - 60 strokes per minute.
Fig - 36
14.6.19.3 Test the fuel leakage (Dribbling)
When checking for fuel leakage from the

nozzle, apply a pressure of about 10 - 20 Fig. 36
kg/cm², to lower than correct injection

pressure to the nozzle. If there is no
leakage, the nozzle is normal. Fig - 37
14.6.19.4 Install the nozzle holder assembly.
Fit the new nozzle washer.
Tight the nozzle holder bolts alternatively

right and left, tightening the bolts gradually
until the specified torque is reached evenly
[Torque 150 kgcm (11 lb.ft.)]. Fig. 37
14.7 ENGINE LUBRICATION cooler and filter respectively. After cleaning

the oil passes to the main gallery via oil
14.7.0 Design and Operation pressure relief valve it is forced through oil
ducts to the crankshaft and camshaft
The Fig-1 diagram illustrates the bearings. The connecting rod big end
arrangement of the equipment, and the bearings are supplied with lubricant from
flow of oil through the systems. the crankshaft main bearings, through
inclined oil ducts. The lubricating oil rises
The engine is arranged for forced feed from the camshaft bearing No.4 to the
lubrication. The oil pump supplies the rocker shaft assembly. The intermediate
lubricating oil for engine. The oil pump is gear pin is lubricated from the 1st main
located within timing gear cover and driven Journal Bearing & Aux. gallery. This oil
by Intermediate gear, the oil pump gear in also lubricates the other timing gears. The
turn drives the engine camshaft. lubricating oil for the injection pump and
Air compressor is tapped off from the
The oil pump forces the oil from the sump duct feeding 1st main journal and carried
to the oil cooler 7. The oil is then filtered to the injection pump and Air compressor
through full flow paper type oil filter, there by the pipe arranged outside the
are by pass valves (11) and (12) for crankcase.
1. Piston 10. Oil filter

2. Connecting rod 11. Oil cooler by pass valve
3. Idler gear 12. Oil filter by pass valve
4. Crank shaft 13. Relief valve
5. Cam shaft 15. Strainer
6. Rocker shaft 16. Oil sump
7. Oil cooler 17. Oil pump
8. Turbo charger 18. Fuel Injection Pump
9. Turbo feed 19. Air compressor
Fig. 1
14.7.1 To Remove and Refit Oil Pump

Remove oil pump from front face of Crank
case after removing intermediate gear and
camshaft. Fig - 2.
14.7.2 To Overhaul Oil Pump
Check Gear backlash between oil pump

gears standard 0.09 - 0.21 mm (limit -
0.30 mm). Fig - 3
Replace the gear if Backlash exceeds the

Fig. 2
limit. Drive gear shaft diameter to drive
gear Bushing Inner diameter clearance should
not exceed 0.040 mm - 0.085 mm, If found
excess by measuring the Drive gear shaft
and Bushing inner dia separately. The drive
gear shaft diameter dimension - 18.088 -
18.106 mm (limit 18.06 mm). Fig - 5
Check clearance between driven gear and

shaft 0.040 - 0.075 mm (limit - 0.1mm).
Replace gear or shaft whichever is worn
excessively.
Fig. 3
Driven gear Shaft Diameter 17.979 -
17.997mm (Limit 17.970 mm). Driven gear
inside diameter 18.037 - 18.054 mm (Limit
18.070 mm).
Ensure height of the oil pump gear is

27.00 - 27.04 mm. Fig - 4
14.7.3 To Refit the Oil Pump
The oil pump assembly is fixed by means of

7 screws, Tightening sequence of the oil
pump. Fig - 6.
Fig. 4
Fig. 6 Fig. 5
14.7.4 To Overhaul Oil Cooler and Filter Assy

14.7.4.0 To Remove
Remove the entire assy of oil cooler and oil
filter from engine after draining coolant from
cylinder block and oil from filter drain plug.
Fig - 7
Note: All Bolts are of 13 mm size, But of Varied
length. Be careful to identify the bolts to
its original place during reassembly. Remove
& refit O-rings 4 nos during reassembly
Fig - 8 Fig. 7
Clean the oil filter head and oil cooler plate.

Clean the oil cooler.
Assemble the oil cooler by-pass valve.
Assemble the oil filter by-pass valve.
Assemble oil pressure regulator valve.
Assemble oil pressure gauge adaptor.
Assemble the oil cooler on the oil cooler
plate.
Replace the `O' ring at oil filter centre bolt
and position the bolt in oil filter bowl. Fig. 8
Replace the ‘O’ ring on the top of filter

bowl.
Refit the spring and the plate washer in the
bowl.
Fit a new oil filter element, washer, sealing
ring facing upwards.
Fit filter bowl with filter element to the filter
head tighten the centre bolt.
Also tighten the drain plug.
Fig - 9, 10 & 11
Fig. 9 Filter Correct Fitment
Fig. 11 Fig. 10 Filter Wrong Fitment

14.7.4.1 To Refit Oil Cooler
Clean the gasket sealing faces thoroughly.
* Oil cooler / oil filter assembly a compressed

asbestos gasket is used.
Fig - 12 & 13
This will prevent oil cooler casing from

direct contact with coolant, in turn aluminium
surface erosion. Fig. 12
Note: Install Oil Cooler with filter.
Fig. 13
1. Radiator
2. Cooling Fan
3. Thermostat
4. Coolant Pump
5. De-aeration Tank
6. Non-return valve
Water pump : Heavy Duty sealed 55 mm dia integral shaft bearing

Fig. 1 - Cooling System
14.8 COOLING SYSTEM 14.8.1 To Flush Cooling System
Flushing of the cooling system might

14.8.0 General become necessary because of impurities in
the coolant itself.
The engine is water cooled, and forced
The cooling system may also be clogged by
circulated by a water pump.
rust deposits, grease or other impurities in
the coolant. This should be removed by
The coolant, drawn by the pump from the
flushing the system several times with hot
radiator or the thermostat control by-pass
water containing a grease dissolving agent.
enters the crankcase and oil cooler. It is
then passed to the cylinder head. The Let the engine run when flushing the system.
coolant returns to the radiator via Note : Make sure that solution does not contain
thermostat housing. any acid as even the smallest amount of it
in the cleaning fluid is likely to affect the
During vehicle operation the thermostat cooling system unfavourably.
functions to maintain the operating
Having drained off the solvents, flush the
temperature of 80° to 85°C (176 to
system several times whilst the engine is
185°F). running.
The thermostat installed in the cooling The use of hard water fosters the formation
of fur which may be removed with aid of an
system controls not only the flow of coolant
acid free solvent. The fur removing agent
to the radiator but also regulates the by-
must not be aggressive to copper brass and
pass flow alternately i.e when it allows the
zinc materials used in the cooling systems.
coolant to flow back to the radiator it
closes the by pass fully and vice versa. Also flush the cooling system several times
after application of a fur solvent.
The sensing unit of the coolant temperature Should lime has deposited too heavily in the
is provided at thermostat housing. It shows radiator tubes remove radiator and have it
the engine coolant outlet temperature. cleaned mechanically by a specialised
workshop.
14.8.2 External Cleaning of Radiator
The radiator tubes/fins may be cleaned by

washing them with using a suitable hot
cleaning solutions such as 0.5ll of HP
Radiator cleaner (supplied by M/s Hindustan
Petroleum corporation).
A 5% caustic soda solution (sodium

hydroxide) may also be used for this
purpose. In addition, the radiator fins can
be blown from the inside with air or water
with less than 2 kg/cm² pressure.
14.8.3 Engine Cooling Fan and Fan Clutch
* 470 mm dia 10 bladed fan with viscous

clutch. Fig - 2
* Fan clutch engages when the sensor senses

at 55°C (air temperature).
* Reduces fan power consumption at low

temperatures, thereby improving fuel
economy.
14.8.4 Service Tips for Viscous Fan / Clutch
* Handle the fan / fan clutch with care.
* Check the bimetallic temp sensing coil for

any mud or dust. If the coil is covered with
mud or dust, the fan performance will be
erratic. Remove any mud / dust carefully
with a brush.
* Do not paint the fan / clutch. Fig. 2
* Do not try to dismantle the clutch, the

clutch is a sealed unit.
14.8.5 To Test Thermostat
Remove hose connection and take out

thermostat. Fig - 3
Fig. 3
Inspection of thermostat function
Place the thermostat in hot water and

check the valve opening temperature and
valve lift. The thermostat valve opening
temperature is punched on the thermostat
seat, and it should be confirmed. Fig - 4
Check commencement of opening. This is

the temperature at which the stroke of the
thermostat has risen to 0.1 mm in a
gradually heated water bath.
Fig. 4
Commencement of opening = 80°C ± 1°C.
Measure the stroke with the aid of special

device and dial gauge.
Check full working stroke.
Working stroke = 10 mm at 92°C
Fig - 5
Install the thermostat Fig. 5
Remove the water and dirt adhering to the

thermostat casing.
Replace the gasket without fail, if it is

corroded, damaged or flattened.
Before install the casing cover apply the

liquid gasket or the casing joint.
14.8.6 To Remove and Refit Water Pump
Drain off coolant collecting it in a clean

container if anti-freeze has been added.
Unscrew fan and remove V belt for water

pump fan and alternator.
Remove hose connection from water pump

and backout attaching bolts.
To refit water pump reverse the procedure

for removal. Fig - 6
Fig. 6
14.8.7 To Overhaul Water Pump
Dismantling
Unscrew water pump mounting Hex screws,

remove water pump by prying loose with
screw driver at the 2 points on the flange.
Fig - 7
Fig. 7
Remove the water pump vane from shaft

by screwing in a bolt of 10 mm dia, 1.5
mm pitch. Fig - 8
Fig. 8
Using a conventional puller remove the

pulley from the shaft. Fig - 9
Fig. 9
Using a steel pipe and press, remove the

water pump shaft along with sealed
bearings from water pump body. Fig - 10
Fig. 10
To install new water pump seal apply a

little liquid sealant to the water pump seal
outer circumference and water pump body.
Install the slinger and coolant seal.
To install Vane. (Impeller)
Using a press install the Vane to the shaft.
Note: Apply a little engine oil to the seal face.
Maintain distance between water

Fig. 11
pump mounting face to impeller
outer dia end tip.
Dimension (in mm)

Model
A B C
HA6ETI2 21 75 dia 90
Fig - 11 & 12
Refit the water pump assy after applying

fresh liquid sealant over clean surface.
Using a press install the pulley drive flange. Fig. 12
For distance from water pump installation

face to flange outer face refer Fig - 12.
14.8.8 To Remove and Refit V Belt. To

Adjust V Belt Tension.
Loosen the adjusting Bolt on the Alternator

and remove the V belt. Fig. 13
To refit V Belt, swing the alternator towards

the crankcase
Fig. 13
To Tension the V belt swing the alternator
outwards.
Tighten the fixing screw on the alternator

adjusting bracket. Fan belt play (tension)
should be 10 - 15 mm, when applying
load of 10 kg by pressing with your finger.
Fig - 14.
The V belt should not touch the bottom of

the pulley groove. Fig - 14.
Fig. 14
14.9 EXHAUST AND INTAKE MANIFOLD
14.9.0 To Remove and Refit Exhaust

Manifold
Exhaust manifold
Disconnect front exhaust pipe from the
turbocharger outlet elbow.
Inlet manifold
Backout manifold attaching screws from

cylinder heads and remove the exhaust
manifold taking care of the gaskets.
To refit manifold, reverse the procedure for Fig. 1

removal.
14.9.1 To Remove and Refit Intake Manifold
Backout fixing screws and remove the

vertical intake pipe. Backout manifold
attaching screws from cylinder head and
remove intake manifold.
Clean thoroughly inlet manifold gasket

sealing face and refit new gasket.
To refit intake manifold, reverse the

Note: Use liquid gasket. Take care that the

gasket does not get into the inside surfaces.
Tighten down the attaching screws evenly.
14.9.2 Maintenance and Servicing of Dry

Type Air cleaner
* Remove dust deposit weekly by cleaning the

bowl provided at the bottom of the air cleaner.
* Never operate the engine, if the restriction

indicator is either broken or missing.
* If red band appear in restriction indicator, clean

the primary element immediately and reset the
restriction indicator by pressing the top button.
Caution: It is recommended that the primary

filter element should not be cleaned
till the red band appears. Good
cleaning practice can increase the life
of the filter element.
* Check for proper adhesion between end plate

of the element and the sealing ring. Fig - 2
Fig. 2
* Always clean the primary element with

pressurised air. Keep a distance between the
nozzle and the element. Use the pressurised air
from inside to outside of the primary element.
* Don't tap on the element and never try to clean
it with compressed air, flowing from outside to
inside of the primary element. Fig - 3
* Glow an electric bulb inside the primary element.

Check for any holes. If light comes out through
any hole, replace the element. Fig - 4 Fig. 3
* Change the air filter primary element only if
- due for cleaning after two consecutive

cleaning
- primary element get punctured (refer

electric bulb test) OR
- red band appears in restriction indicator

with engine stopped condition, even after
cleaning the primary element.
Fig. 4
* Replace the safety element after third

replacement of the primary element. Safety
element should never be cleaned but
always replaced.
Note: The wing bolt should be tightened

with hand alone, excessive tightening
would damage the air cleaner.
Caution: Frequent cleaning of the air filter

element leads to drop in the dust
holding capacity, weakening of the air
filter media and ruptures. This, in turn,
could result in serious damage to the
engine because of entry of dust in the
system.
14.10 ALUMINIUM RADIATORS AND

CHARGE AIR COOLER
14.10.0 Service Instruction
14.10.0.0 Introduction
This manual explains the procedure for
servicing (specifically, the sealing of leakages)
of aluminium radiators fitted with plastic
tanks that may damage in actual usage due
to improper handling before installation on
the vehicle.
The procedure covers the following aspects Fig. 1 Construction of Aluminium Radiators
of servicing :-
* Leakage spot detection
* Sealing Techniques and the tools

required
* Confirmation of proper sealing
14.10.0.1 Details of Radiator
A typical radiator is shown in Fig - 2 for

reference.
Fig. 2
CAUTION: Users are requested to get themselves
familiar with all the parts and the
assembly of radiator before
undertaking the servicing.
14.10.0.2 Servicing Kit
The radiator servicing kit consists of

following items:-
* Screw Driver
* Monkey Plier
* Sealant resin and hardener containers

(Araldite Standard of M/s Ciba Geigy
make or on equivalent Epo x y based
system)
* Alumaseal container
* Araldite applicator
* Brush
NOTE: Araldite rapid may be used in place of

Araldite standard for faster drying and curing
of seal.
14.10.0.3 Procedure for Servicing

Removal of radiator from vehicle -
* Allow the coolant in the radiator to
reach to the room temperature.
* Drain the coolant from radiator
completely by unscrewing the drain
cock.
* Remove all the mounting fasteners,
attachments like shroud, hoses etc.
* Take out the radiator from the vehicle
carefully without damaging the core.
CAUTION: Radiator core and plastic tanks are
susceptible to cracking due to impact
and deformation.
Detection of Leakage Spot –

* Connect the inlet of the radiator to
air supply at the gauge pressure of
1.5 bar.
* Seal all other outlet points.
* Dip the radiator completely in a clean
water tank.
* Tilt the radiator and shake it
vigorously to let the air bubbles
trapped at the clinching area to
escape.
* Observe carefully for one minute and
locate the source of air leakage on
the radiator from the direction of air
bubbles that are coming out of the
radiator.
CAUTION: Do not use the water tank that is
used for copper radiators.
Sealing the leakage spot –

Following procedures shall be adopted for
arresting leakages at different locations of
the radiator.
Replacement of Plastic tank –

Fig. 3
* Take out the member supports using
13 size spanner
* Release the clinch projections of
header plate using screw driver.
Fig - 3
* After making all the clinching
projections up, take out the tank from
its seat in header plate while grasping
the outlet.
* In case, it takes more effort, pat the
tank with rubber or plastic hammer
lightly.
Fig - 4 Fig. 4
* Take off the tank packing.

* Clean the area of the header plate
where the tank sits, thoroughly.
* Insert new tank packing in the place
without twisting.
* Insert new tank (top or bottom) as

applicable.
NOTE: If the source of leakage is at the base

of the tank, i.e. area between header
plate and tank there is no need to
replace the tank.
Fig. 5
CAUTION: Tank packing shall be replaced, every
time, the tank is taken off for
servicing.
* If gap is found between the clinching

projections of header plate and tank,
softly hammer the projections.
Fig - 5
* Clinch the header plate projections

with monkey plier.
* The sequence of clinching should be

followed as illustrated in the figure.
Fig. 6
Fig - 6
* After clinching, confirm the dimension.
Fig - 7
CAUTION: If any of the clinching projections is

broken during the clinching or releasing
process, discontinue the servicing and
replace the entire radiator by a new
one.
* Fix the member supports and tighten

the bolts properly wherever applicable.
Fig. 7
Bottom Type pipe, Drain Cock and
Pressure Cap –
Bottom Type pipe -

* Take out the Bottom Type pipe using
10 size spanner.
* Remove the ‘O’ ring.
* Clean the seat of Bottom Type pipe
and the ‘O’ ring groove.
* Insert a new ‘O’ ring.
* Fit the Bottom Type pipe back,
ensuring proper tightness of the bolts.
Drain Cock * Silver colour paint may be used for

* Unscrew the drain cock. touching up the araldite spots and
impart the aluminium type appearance.
* Remove the ‘O’ ring.
* Clean the ‘O’ ring groove. CAUTION: * Do not damage the fins during
the process.
* Insert a new ‘O’ ring.
* Confirm that fins are set properly,
* Screw the drain cock back.
if disturbed during the process.
Pressure Cap – * As the Araldite is inflammable, do
not dry it by heating.
* Replace the pressure cap with a new
one, if leakage is through if after * Proper cleaning of radiator core
cleaning the filler neck. is must for proper setting of
Araldite or else it will come off.
CAUTION: Always use recommended radiator
pressure cap. Confirmation of Proper Sealing
Radiator Core – * After the sealing work is over,

Different procedure of sealing shall be assemble the radiator properly.
followed for minor and major leaks in the * Subject the assembled radiator to
radiator core. leakage test as shown in point 4.2.
Minor Leaks : Leak spots which are very NOTE: If the problem of leakage persists, it is
minute, are to be sealed in following manner. advisable to replace the radiator with new
* Install the radiator onto the vehicle as one.
explained in section 14.10.0.4.
14.10.0.4 Radiator Installation
* Pour the contents of alumaseal in the
radiator. * Ensure that all the openings of the
radiator are closed properly except
* Fill proper quantity of coolant liquid. the inlet.
* Run the engine in idling for more than * Install the radiator on the vehicle
20 minutes to detect leakage, if any. ensuring proper alignment, damping
Major Leaks: Procedure of sealing major etc. as applicable.
leaks in the radiator is as follows : * Connect the inlet and outlet pipes
* Wash the core with clean water and and clamp them.
brush provided in the kit to remove * Fit the fan shroud.
dirt, dust etc.
Fill the radiator with proper quantity of
* To remove the greasy spot on the fresh coolant as recommended.
core, apply thinner with cotton swab
and take off the grease. 14.10.0.5 Do's and Don'ts
* Dry the core using a dryer. Do's
CAUTION: Drying by heating must be avoided. Always use the clinching tool for removing
and refitting the radiator tanks.
* Mix adequate quantity of Araldite
resin and hardener in the ratio of 1:1 Always drain the radiator fully before
and stir it thoroughly. removing it from vehicle.,
* Apply the mixture immediately at the Always refill the radiator with coolant
leakage spot with the applicator. recommended by the manufacturer.
* If required, apply the mixture to dry Always check tank packing before
and harden under the shade at room reassembly of tank to core.
temperature for 10-12 hour.
Don'ts
* Allow the mixture to dry and harden
under the shade at room temperature Never open the pressure cap when the
for 10-12 hour. radiator is hot.
Don't use acid for cleaning the tubes and
NOTE: * Araldite Rapid of M/s Ciba Geigy
tanks.
dries and hardens within one hour and
hence users may use it to minimize Don't use manual force for cleaning clogged
the down time. tubes.
14.11 TURBOCHARGER
1. Air Outlet from Compressor 6. Center Bearing Housing

2. Back Plate 7. Turbine Wheel
3. Compressor Wheel 8. Journals
4. Thrust Bearing 9. Waste Gate Valve
5. Boost Pressure Hose to Actuator 10. Actuator
Fig. 1 Turbocharger with Waste gate
14.11.0 General 4. Compressor housing

In exhaust gas turbocharging, the thermal 5. Journals
energy in the exhaust gas, which would 6. Bearing housing
normally be wasted, is used to drive a 7. Waste gate ( When provided)
turbine.
8. Actuator (moved by the boost
The turbine drives a compressor, which pressure opens or closes the waste
draws in filtered air and feeds this, at a gate valve)
higher pressure, to the engine.
Exhaust gas is used to drive the turbine
This enables more fuel to be burnt with a wheel. Turbine wheel rotates the
greater mass of charge air, increasing engine compressor wheel, which is mounted on the
power output. same shaft. Compressor wheel sucks the
clean air through the air filter. The clean air
Better air availability enhances better
is compressed and sent into the engine.
combustion, thus leading to lower fuel
consumption and less emission. Due to more air in the engine more fuel
can be burnt. Due to more fuel and more
14.11.0.0Design and Operation air, we get more power from the same
Turbocharger is operated on the exhaust engine. When waste gate valve is fitted, at
gas, which is normally wasted. higher engine speeds the waste gate limits
the exhaust gas flow through the turbine
Turbocharger consists of:
by diverting a portion of the exhaust gas
1. Turbine wheel direct to the exhaust pipe.
2. Turbine housing
3. Compressor wheel
1. Air Outlet from Compressor 5. Center Bearing Housing

2. Back Plate 6. Turbine Wheel
3. Compressor Wheel 7. Journals
4. Thrust Bearing
Fig. 2 Turbocharger without Waste gate
14.11.0.1Benefits of Turbocharging 3. Filtered oil at required pressure is essential

to lubricate and cool the journals.
Lower fuel consumption
Lower emission 4. The clearances between the rotating parts
Better torque characteristics are very close(in microns)
Lower weight and a smaller engine package 5. Turbocharger rotor assembly rotates at high
Lower engine noise speeds up to 1,00,000 rpm at the rated
engine power. Therefore turbocharger
Altitude compensating rotating parts are balanced to very high
accuracy for optimum performance.
14.11.0.2For Enhancing Turbocharger Life
Turbocharger needs CLEAN ENGINE OIL 6. Since turbocharger compressor wheel is
& CLEAN AIR (from the air filter.) for it's made of aluminum alloy rotating at very
proper functioning and durability for the high speeds, dust, sand or any foreign
following reasons. particle entering in to the turbocharger
compressor housing will damage the
1. Oil contaminated with dirt or foreign compressor wheel blades, which will lead to
material will wear the journals and journal turbocharger failure.
seating area.
7. Damaged blades will lead to imbalance in
2. Dirt in the oil also blocks the oil holes in the rotor assembly resulting in shaft or
the journals (bearings) and bearing housing bearing failure.
leading to oil starvation to the
turbocharger.
14.11.0.3 Preliminary Checks Overhaul Kit

If your Turbo engine does not run the way Description Qty
it Should, For For
Do not start your Search For Defects Non-Waste Waste
at the Turbocharger. Gated Gated
Turbo Turbo
Check for the following:
Journal 2 2
a. Is the clutch slipping?
Snap Ring 4 4
b. Does the vehicle brake drag?
Thrust Plate 1 1
c. Is the throttle opening fully? Thrust Ring 1 1
d. Is the air filter system blocked? Piston Ring T.S 2 2
e. Is the compression of the engine low? Piston Ring C.S 1 1
f. Is the fuel injection system correct? O’ Ring (Big) 1 1
g. Does the crankcase breather system O’ Ring (Small) 1 1
function? Socket Head Bolt 4 4
h. Is the exhaust pipe blocked/ damaged? Washer 4 4
Shaft Nut 1 1
After the above inspection now you can
Bolt Hex. (C.S) 8 8
look at the turbocharger for cause of
Segment (T.S) 3 3
trouble.
Bolt Hex. (T.S) 6 6
Please do not try to service or repair the Segment (C.S) 4 3
Turbocharger yourself. Sealing Ring - 2
Consult TEL Service centre along with AL Tube Clamp - 2
Service engineer. Boost Pressure Hose - 1
Locking plate - 1
If all parameters outside turbocharger are
satisfactory as per the checklist given earlier,
inspect the turbocharger. Secondary kit
Sl. No. Description Qty
Disconnect compressor inlet and turbine
outlet pipes and visually examine both the 1. Flinger Sleeve
wheels. If no fault is found remove (Single Piece Type) 1
turbocharger from the engine and send it for
detailed inspection by TEL Service Centre. Gasket Kit
(Please refer to serviceable parts while
overhauling.) Sl.No. Description Qty
1 Gasket (Oil Inlet) 1
2 Gasket (Oil Outlet) 1
14.11.0.4 Serviceable Parts* of Turbocharger
3 Gasket (Turbine inlet) 1
1. Core assembly kit
2. Overhaul kit
3. Secondary kit Boost Pressure Hose Kit
4. Gasket kit SL. No Description Qty
5. Actuator Assembly kit (For Waste 1 Boost pressure Hose 1
gated turbocharger) 2 Tube Clamp 2
6. Boost pressure Hose kit (For Waste 3 Sealing Ring 2
gated turbocharger) 4 Connecting Adaptor 1
5 Hollow screw 1
Core Assembly Kit
Description Qty Actuator Assembly kit
For For SL. No Description Qty
Non-Waste Waste
Gated Gated 1 Actuator Assembly
Turbo Turbo + Tube clamp
+ Boost pressure hose 1
Core assy 1 1 2 Tube clamp 1
Segment (CS) 4 3 3 Connecting Adaptor 1
Bolts 8 8 4 Sealing ring 2
Segment (TS) 3 3 5 Hollow screw 1
Bolts 6 6 6 Locking plate 1
* These are serviceable parts recommended for use only by TEL Authorised Service Centres for repair / overhaul of
Turbochargers.
14.11.1 Precautions to be taken for 14.11.2 Do's and Don'ts

Turbocharger Installation Do's
Check air cleaner (filter element) and it's * Regular change of engine oil / oil
connecting pipes for blockage, distortion etc, filter.
and should be cleaned / replaced. * Regular change / cleaning of air filter
Check and clean engine intake and exhaust element.
manifold pipes. The oil feed and drainpipe * Check for oil pressure at engine
to the turbocharger should be examined for idling condition. (Minimum oil
dirt, cracks, distortion, etc. pipes should be pressure to be as per
thoroughly cleaned before fitment. If found recommendation during idling.)
damaged it should be replaced. * Idle the engine for two minutes after
Remove any tape or cover used as starting the engine.
temporary cover to the pipe inlet. * Idle the engine for two minutes
before switching off the engine.
Examine the engine oil and the oil filter
condition. * Periodic cleaning of crankcase
breather is necessary to allow free
Replace the oil and the filter element if flow of oil from turbocharger outlet.
necessary. (Adhere to Ashok Leyland's
* Regularly check all air, oil and exhaust
recommendation for correct grade & change
connections for leaks and abnormal
period).
dust / oil / carbon build up.
Use recommended new gaskets for fitment
of the turbocharger to the engine. Do not Don'ts
apply gasket sealant (Shellac, Anabond, * Don't run the engine with low oil
grease etc.,) at the oil inlet and the oil pressure.
outlet flanges for pasting the gaskets.
* Don't put the engine under full load
Do not use a strainer type gasket . ( This is immediately after starting. (Always
a temporary gasket used only for the initial run the engine/vehicle at moderate
testing in the Factory) speed and load for a few minutes
Ensure correct fitment of the turbocharger to before going to full load and speed.)
the engine (rotate the turbine shaft and * Don't switch off the engine under full
check for its free rotation). load.
Fitment of inlet and outlet pipes (to * Don't run the engine with
turbocharger) under strain may result in DAMAGED
turbocharger failure. - Oil feed and drain pipes
NOTE: - After long storage before starting the - Pipes between air filter and
engine, fill-up the oil feed hole of the turbocharger
turbocharger with clean engine oil to - Exhaust pipes
ensure lubrication during start-up. * Don't run with Leaky connections
- Crank the engine till you notice oil from the air cleaner to the
pressure in the gauge before you start turbocharger and turbocharger to the
the engine. inlet manifold.
- Start the engine and idle for two CAUTION: - Don't open the Turbocharger
minutes before accelerating the engine. yourself.
- Please contact the Ashok Leyland
- Check the engine oil pressure. Authorised Dealers for any
- Do not run the engine if oil pressure turbocharger problems.
is found less than that recommended. - As the turbocharger is
- When the engine in running, check all precision built, assembled and
air, oil and exhaust connections for tested by highly skilled personnel,
leaks. we do not recommend opening
of the Turbocharger for servicing
CAUTION - Do not accelerate the engine by unauthorised persons.
immediately after start.
- However, if need be, please
- Idle the engine for at least two contact Turbo Energy Ltd Service
minutes after start and before the centres for assistance for
engine is stopped. servicing Turbochargers.
14.11.3 Turbo charger trouble shooting
High oil consumption
Oil leak from turbine

Engine Lacks power
Turbocharger noisy
compressor side
Oil leak from
Black smoke
Blue Smoke
Possible Cause
seal
Dirty air cleaner
Restricted compressor intake duct / piping
Restricted air duct from compressor to intake manifold
Air leak in pipe from air cleaner to turbocharger
Air leak in pipe from compressor to inlet manifold
Air leak from inlet manifold
Foreign object in exhaust manifold (from engine)
Restricted exhaust system
Exhaust manifold cracked, gaskets blown or missing
Gas leak at turbine inlet/exhaust manifold joint
Gas leak in exhaust piping
Restricted turbocharger oil drain line
Restricted/blocked/distorted crankcase breather
Turbocharger bearing housing sludged or coked
Fuel Injection System defective / incorrectly adjusted
Engine valve timing incorrect
Worn engine piston / piston rings / liners
Eroded valves and / or pistons
Excessive dirt build up on compressor wheel and housing
Boost pressure control swing valve / poppet valve

doesn’t close/damaged
Boost pressure pipe to actuator leaking / damaged
Piston ring sealing defective
Turbocharger journal (bearing) defective
Foreign body damage on compressor / turbine wheels
Insufficient oil supply to turbocharger

14.12 MAINTENANCE PROGRAMME
km x 1000
Lubricant
16000 km
8000 km
Weekly
Remarks
No. of
points
Every
Every
Every
Daily
PDI
A. General
1. Check and adjust valve clearance on cold engine
2. Check and tighten front and rear engine
mounting / other peripheral bolts
3. Check compression pressure 60
4. Check and tighten cylinder head nut / bolts 80
for correct torque in correct sequence
B. Lubrication system
1. Check and top up engine oil O 1
2. Change engine oil and oil filter element
3. Clean oil cooler 60
4. Check engine oil pressure (min. 1 kg/cm² at
idling and 80°C engine temperature
5. Check oil leakages, if any
C. Cooling System
1. Check and tight fan mounting bolts
2. Check coolant level and top up if necessary
3. Check radiator hoses and clamps for
leakages and tightness
4. Check fan belt tension and adjust If necessary
5. Check radiator stay rod & radiator mounting bolts
6. Drain cooling system and fill recommended Refer
coolant. section
14.0.10.
7. Replace cooling system hoses and radiator
rubber pads for radiator mounting & stay rod 72
D. Fuel System
1. Replace fuel filter element *
a. Primary element
b. Secondary element First
24000kms
& thereafter
every
16000kms
2. Check water separator and drain if necessary
3. Clean fuel feed pump strainer
4. Lubricate accelerator linkages G 2
5. Lubricate accelerator link pedal shaft O 1
6. Check FIP control lever return spring
7. Proper functioning of Solenoid switch
8. Check and tighten F.I.P. mountings 32
9. Check injection timing 32
* Both the fuel filter elements must not be changed at the same time
MAINTENANCE PROGRAMME
km x 1000
Lubricant
16000 km
8000 km
Weekly
Remarks
No. of
points
Every
Every
Every
Daily
PDI
10. Clean Fuel tank and suction strainer 48
11. Adjust Fuel Injector Nozzle opening 56 First
Pressure (247 - 260 kg/cm²) 16000km
also.
12. Recalibrate fuel pump 150
13. Replace fuel hoses 150
E. Air Intake and Exhaust
1. Check and clean air cleaner - primary element
(If restriction indicator shows red band -
refer section 14.9.2)
2. Replace air cleaner primary element (After
2 consecutive cleaning).
3. Replace air cleaner safety element (At the
time of third replacement of primary element
or once in a year - whichever earlier).
4. Check restriction indicator, if necessary clean
the element
5. Check air inlet hose for any puncture/damage
6. Check for any blockage / breakage at
rainhood assembly
7. Check Turbocharger mounting 24
8. Check charge air cooler for any blockage of
fins and clean the cooler if necessary 32
9. Check charge air cooler hoses for any damage
10. Check exhaust manifold and silencer for
leaks and tightness
11. Check intake and exhaust manifold mounting
fasteners 32

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ALMDV

Section Subject Page No.

Contents ........................................................................................................................ 14.03

14.0 General .......................................................................................................................... 14.07

14.1 To Remove and Refit Engine from Vehicle ......................................................... 14.26

14.2 Crankcase ...................................................................................................................... 14.27

14.3 Crankshaft ..................................................................................................................... 14.31

Section Subject Page No.

14.3.5 To Renew Crankshaft Main & Connecting Rod Bearing and

14.4 Piston and Connecting Rods ................................................................................... 14.34

14.5 Cylinder Head Assembly ........................................................................................... 14.40

14.6 Timing .......................................................................................................................... 14.44

Section Subject Page No.

14.6.7 To Refit the Camshaft .................................................................................................................. 14.48

14.7 Engine Lubrication ..................................................................................................... 14.56

14.8 Cooling System ............................................................................................................ 14.60

14.9 Exhaust And Intake Manifold ................................................................................... 14.65

Section Subject Page No.

14.10 Aluminium Radiators and charge air cooler ...................................................... 14.67

14.11 Turbocharger ................................................................................................................ 14.71

14.12 Maintenance Programme .......................................................................................... 14.76

14.0.0 Engine Type and Number

The engine no is stamped onto the

Fig - 2 Representative Diagram

14.0.2 General Data

Type Diesel four stroke, 6 cylinder, Water

Aspiration Turbocharged with inter cooler

Max output 84 kw @ 2400 rpm

Max torque 410 Nm @ 1700 - 1800 rpm

Bore and Stroke 104 x 118 mm

Piston displacement 6.014 l

Compression Ratio 17.9 : 1

Firing order 1-4-2-6-3-5

Direction of rotation Counter clockwise viewed from flywheel.

Compression pressure 36 - 39 kg/cm² @ 280 rpm

Idling revolution 600 ± 50 rpm

Fuel Injection Equipment Inline pump with manifold compensator

Injection pipe (OD x ID x Length)

Valve clearance (when cold)

Engine Oil Pump

Engine oil cooler Multi plates types (5 plates), water cooled

Thermostat Wax type, Bottom bypass system

Injection timing (Flywheel Travel) 11° ± 1° BTDC No.1 cylinder on

14.0.3 Repair Data

Clearance between Piston pin -0.009 - 0.014

Rocker arm shaft diameter 18.966 - 18.984

14.0.4 Tightening Torques Kgm lb.ft Nm

14.0.5 Crank Shaft Main Journals and Crank Journals Dimensions

1. Std diameter of main journals 72.94 - 72.96

14.0.6 Main and Crank Journals Grinding Sizes

Note: Correct by regrinding if worn unevenly more than 0.10 mm

14.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness)

Under size (mm) Thickness (mm) Tolerance

14.0.8 Crankcase Parent Bore and Cylinder Liner Outer Dia

Crankcase Parent Bore Cylinder Liner Outer Dia

Note: Interchangeability is allowed w.r.t. next oversize or undersize liners.

14.0.9 Fuel Oil (High Speed Diesel)

14.0.9.0 Fuel Specifications - as per IS 1460 : 2000 (BS II)

1. Acidity, inorganic ... Nil

2. Acidity, total mg.of KOH/g (Max.) ... 0.20