WORKSHOP MANUAL

C&E-SERIES

ENGINE
6WG1-TC

SECTION 6
 NOTICE

Before using this Workshop Manual to assist you in performing

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

All material contained in this Manual is based on latest product

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

Applicable Model : FSR33, FTR33, FVR33

This manual is applicable to 2003 year model.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:

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

SECTION 00
SERVICE INFORMATION

CONTENTS

PAGE
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 3
Main Data and Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 45
Service Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 49
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 57
Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 73
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 87
00 – 2 SERVICE INFORMATION

MEMO
 SERVICE INFORMATION 00 – 3

TROUBLESHOOTING

CONTENTS

PAGE
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 4
Hard Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 4
Unstable Idling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 9
Insufficient Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 11
Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 13
Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 15
Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 16
White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 18
Black Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 19
Oil Pressure Does Not Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 20
Abnormal Engine Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 22
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 26
Engine Has Less Than Normal Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 26
Blue Or Black Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 28
Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 30
Excessive Turbocharger Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 32
Excessive Rotating Part Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 34
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 35
Battery Dead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 35
Battery Overcharged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 37
Flashing Charge Light Or Fluctuating Ammeter Indication . . . . . . . . . . . . . . . . . . . . . . 00 – 38
Charge Light On But Dim While Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 38
Generator Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 39
Charger circuit Fuse Blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 39
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 40
Starter And Magnetic Switch Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 40
Magnetic Switch Closes But Starter Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 42
Starter Motor Runs Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 43
Starter Motor Operates But the Engine Does Not Turn Over . . . . . . . . . . . . . . . . . . . . 00 – 43
Abnormal Operating Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 44
00 – 4 SERVICE INFORMATION

ENGINE MECHANICAL
HARD STARTING
1) STARTER MOTOR DOES NOT OPERATE

Checkpoint Trouble Cause Countermeasure

NG Loose battery cable terminals Clean and / or retighten the

Battery
Poor connections due to rusting battery cable terminals

NG
Battery discharged or weak Recharge or replace the battery

OK

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

OK

NG Defective starter switch or Replace the starter switch or the

Starter switch
starter relay starter relay

OK

NG Defective magnetic switch or Repair or replace the magnetic

Starter motor
starter relay switch

NG Repair or replace the starter

Defective starter motor
motor
 SERVICE INFORMATION 00 – 5

2) STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER

Checkpoint Trouble Cause Countermeasure

NG Loose battery cable terminals Clean and/or retighten the

Battery
Poor connections due to rusting battery cable terminals

NG
Battery discharged or weak Recharge or replace the battery

OK

NG
Starter motor Defective pinion gear Replace the pinion gear

NG Repair or replace the magnetic

Defective magnetic switch
switch

NG Brush wear Replace the brush and/or the

Weak brush spring brush spring

OK

NG Piston, crankshaft bearing Repair or replace the related

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

3) ENGINE TURNS OVER BUT DOES NOT START

Checkpoint Trouble Cause Countermeasure

NG Bleed the air from the fuel

Fuel system Air in the fuel system
system

Fuel is not being delivered to See next page

the supply pump Continued to next page

OK

Contaminate the fuel Replace the fuel

NG See emission and electrical

Electronic control system Occurred error
diagnosis
 SERVICE INFORMATION 00 – 7

4) Fuel is Not Being Delivered to The Supply Pump

Checkpoint Trouble Cause Countermeasure

NG
Fuel Fuel tank is empty Fill the fuel tank

OK

Repair or replace the fuel lines

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

OK

NG
Fuel filter Clogged fuel filter element Replace the fuel filter element

OK

NG Bleed the air from the fuel

Fuel system Air in the fuel system
system

OK

NG
Fuel feed pump Defective feed pump Replace the supply pump
00 – 8 SERVICE INFORMATION

5) Fuel is Being Delivered to The Supply Pump

Checkpoint Trouble Cause Countermeasure

NG
Fuel Use of the wrong fuel Use the correct fuel

NG
Water particles in the fuel Change the fuel

OK

NG Bleed the air from the fuel

Fuel system Air in the supply pump
system

OK

NG See emission and electrical

Electronic control system Occurred error
diagnosis
 SERVICE INFORMATION 00 – 9

UNSTABLE IDLING

Checkpoint Trouble Cause Countermeasure

NG Repair or replace the fuel

Fuel system Fuel system leakage or blockage
system

NG Bleed the air from the fuel

Air in the fuel system
system

NG Water particles in the fuel

Change the fuel
system

OK

NG
Fuel filter Clogged fuel filter element Replace the fuel filter element

OK

NG See emission and electrical

Electronic control system Occurred error
diagnosis

NG Valve clearance improperly

Valve clearance Adjust the valve clearance
adjusted

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

Continued on the next page

00 – 10 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG
Engine mounting rubber Broken Replace

OK

NG
Camshaft Worn camshaft lobe Replace the camshaft
 SERVICE INFORMATION 00 – 11

INSUFFICIENT POWER

Checkpoint Trouble Cause Countermeasure

NG Clean or replace the air cleaner

Air cleaner Clogged air cleaner element
element

OK

NG
Fuel Water particles in the fuel Replace the fuel

OK

NG
Fuel filter Clogged fuel filter element Replace the fuel filter element

OK

NG See emission and electrical

Electronic control system Occurred error
diagnosis

OK

NG Fuel injection pipes damaged or

Fuel injection pipes Replace the fuel injection pipes
obstructed

OK

NG
Engine oil Improper engine oil level Readjust oil level

OK
Exhaust gas leakage from the
NG exhaust system Repair or replace the related
Turbocharger
Air leakage from the intake parts
system

NG Defective turbocharger Replace the turbocharger

assembly assembly

Continued on the next page

00 – 12 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

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

OK

NG Valve clearance improperly

Valve clearance Adjust the valve clearance
adjusted

OK

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

OK

NG
Exhaust system Exhaust pipe clogged Clear the exhaust pipe

OK

NG
Camshaft Worn camshaft lobe Replace the camshaft
 SERVICE INFORMATION 00 – 13

EXCESSIVE FUEL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

NG Repair or replace the fuel

Fuel system Fuel leakage
system related parts

OK

NG Clean or replace the air cleaner

Air cleaner Clogged air cleaner element
element

OK

NG
Thermostat Defective Replace

OK

NG
Engine oil Improper engine oil viscosity Correct

OK

NG Air leakage from the Repair the turbocharger intake

Turbocharger
turbocharger intake side side

NG Defective turbocharger Replace the turbocharger

assembly assembly

OK

NG Valve clearance improperly

Valve clearance Adjust the valve clearance
adjusted

Continued on the next page

00 – 14 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

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

OK

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

OK

NG
Exhaust brake system Poor opening exhaust brake valve Correct or replace

OK

NG Inspect, repair, or replace

Brake Dragging trouble
(Refer to other service manuals)
 SERVICE INFORMATION 00 – 15

EXCESSIVE OIL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

NG Engine oil unsuitable Replace the engine oil

Engine oil
Too much engine oil Correct the engine oil volume

OK

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

OK

NG
Air breather Clogged air breather Clean the air breather

OK

NG Worn valve stems Replace the intake and exhaust

Intake and exhaust valves
valves and the valve guides

OK

NG
Valve stem oil seal Worn Replace

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

OK

NG
Turbocharger Seal ring worn or broken Replace the turbocharger

OK

NG Repair or replace the air

Air compressor Piston ring worn or broken
compressor
00 – 16 SERVICE INFORMATION

OVERHEATING

Checkpoint Trouble Cause Countermeasure

NG
Cooling water Insufficient cooling water Replenish the cooling water

OK

NG Oil leakage from the fan

Fan coupling Replace the fan coupling
coupling

OK

NG Fan belt loose or cracked

Fan belt Replace the fan belt
causing slippage

OK

NG Defective radiator cap or Replace the radiator cap or

Radiator
clogged radiator core clean the radiator core

OK

NG Repair or replace the water

Water pump Defective water pump
pump

OK

Cylinder head and cylinder body NG Defective sealing cap resulting

Replace the sealing cap
sealing cap in water leakage

OK

NG
Thermostat Defective thermostat Replace the thermostat

Continued on the next page

 SERVICE INFORMATION 00 – 17

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG Cooling system clogged by Clean the foreign material from

Cooling system
foreign material the cooling system

OK

NG Replace the engine control

Engine control system Defective engine control module
module
00 – 18 SERVICE INFORMATION

WHITE EXHAUST SMOKE

Checkpoint Trouble Cause Countermeasure

NG
Fuel Water particles in the fuel Replace the fuel

OK

NG
Engine oil Improper viscosity engine oil Replace the engine oil

OK

NG See emission and erectrical

Electronic control system Occurred error
diagnosis

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

OK

Defective valve seals

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

OK

NG
Cooling system Defective thermostat Replace

OK

NG
Turbocharger Defective turbocharger Replace the turbocharger
 SERVICE INFORMATION 00 – 19

BLACK EXHAUST SMOKE

Checkpoint Trouble Cause Countermeasure

NG Clean or replace the air cleaner

Air cleaner Clogged air cleaner element
element

OK

NG See emission and electrical

Electronic control system Occurred error
diagnosis

OK

NG
Fuel Use of the wrong fuel Use the correct fuel

OK

NG
Engine oil Improper viscosity engine oil Replace the engine oil

OK

NG
Camshaft Worn camshaft lobe Replace the camshaft

OK

NG Poor opening of exhaust brake

Exhaust brake system Repair or replace
valve
00 – 20 SERVICE INFORMATION

OIL PRESSURE DOES NOT RISE

Checkpoint Trouble Cause Countermeasure

NG Improper viscosity engine oil Replace the engine oil

Engine oil
Insufficient engine oil Correct the engine oil volume

OK

Defective oil pressure gauge or Repair or replace the oil

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

OK

NG Replace the oil filter element or

Oil filter Clogged oil filter element
the oil filter cartridge

OK

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

OK

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

NG Replace the oil pump related

Worn oil pump related parts
parts

OK

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

Continued on the next page

 SERVICE INFORMATION 00 – 21

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG Worn camshaft and camshaft Replace the camshaft and the

Camshaft
brackets camshaft brackets

OK

NG Replace the crankshaft

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

OK

NG
Oiling jet joint bolts Loose Tighten
00 – 22 SERVICE INFORMATION

ABNORMAL ENGINE NOISE

1) ENGINE KNOCKING

Checkpoint Trouble Cause Countermeasure

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

NG
Fuel Use of the wrong fuel Use the correct fuel

OK

NG Blown out head gasket Replace the head gasket or the

Compression pressure
Broken piston ring piston ring
 SERVICE INFORMATION 00 – 23

2) GAS LEAKAGE NOISE

Checkpoint Trouble Cause Countermeasure

Loosely connected exhaust Tighten the exhaust pipe

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

OK

NG Replace the washers

Glow plugs Loose glow plugs
Tighten the glow plugs

OK

NG Loosely connected exhaust Tighten the exhaust manifold

Exhaust manifold
manifold connections

OK

NG Replace the cylinder head

Cylinder head gasket Damaged cylinder head gasket
gasket
00 – 24 SERVICE INFORMATION

3) CONTINUOUS NOISE

Checkpoint Trouble Cause Countermeasure

NG
Fan belt Loose fan belt Readjust the fan belt tension

OK

NG
Cooling fan Loose cooling fan Tighten the cooling fan

OK

NG Worn or damaged water pump

Water pump bearing Replace the water pump bearing
bearing

OK

NG
Generator Defective generator Repair or replace the generator

OK

NG Valve clearance improperly

Valve clearance Adjust the valve clearance
adjusted
 SERVICE INFORMATION 00 – 25

4) SLAPPING NOISE

Checkpoint Trouble Cause Countermeasure

NG Valve clearance improperly

Valve clearance Adjust the valve clearance
adjusted

OK

NG
Rocker arm Damaged rocker arm Replace the rocker arm

OK

NG
Flywheel Loose flywheel bolts Tighten the flywheel bolts

OK

NG Worn or damaged crankshaft Replace the crankshaft and/or

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

OK

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

OK

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

OK

Worn or damaged piston and

NG Replace the piston and the
Piston and cylinder liner cylinder liner
cylinder liner
Foreign material in the cylinder
00 – 26 SERVICE INFORMATION

TURBOCHARGER
1) ENGINE HAS LESS THAN NORMAL POWER

Checkpoint Trouble Cause Countermeasure

NG
Air cleaner Restricted Clean or replace

OK

NG
Intake pipe and hose Restricted Clean or replace

OK

NG
Compressor / intake manifold Loose (Leaking) Repair

OK

Exhaust manifold / NG
turbine inlet Loose (Leaking) Repair

OK

Exhaust piping and NG

silencers Restricted Clean or replace

OK

NG
Air breather Restricted Clean or replace

OK

NG
Boost sensor Defective Replace the boost sensor

Continued on the next page

 SERVICE INFORMATION 00 – 27

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG
Compressor wheel Impact damage Replace

OK

NG
Turbine wheel Impact damage Replace

NG
Carbon build-up Replace

OK

NG
Rotating assembly Dragging or seized Replace
00 – 28 SERVICE INFORMATION

2) BLUE OR BLACK SMOKE

Checkpoint Trouble Cause Countermeasure

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

OK

NG
Turbocharger oil seal Leakage Replace

OK

NG
Turbocharger oil drain pipe Restricted Repair or replace

OK

NG
PCV system Defective Repair or replace

OK

NG
Crankcase Excessive pressure Repair

OK

NG
Compressor wheel Impact damage Replace

OK

NG
Turbine wheel Impact damage Replace

Continued on the next page

 SERVICE INFORMATION 00 – 29

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

Center housing oil drain NG

passage Restricted Clean or replace
00 – 30 SERVICE INFORMATION

3) EXCESSIVE OIL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

NG
P.C.V system Defective Repair or replace

OK

Crankcase NG
Excessive pressure Repair

OK

NG
Turbocharger oil seal Leakage Replace

OK

NG
Turbocharger oil drain pipe Restricted Clean or replace

OK

NG
Turbine wheel Impact damaged Replace the turbine housing

OK

NG Replace the compressor

Compressor wheel Impact damage housing and rotating
assembly

OK

NG
Oil Pressure Excessive Repair

Continued on the next page

 SERVICE INFORMATION 00 – 31

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

Center housing oil drain NG

passage Restricted Clean or replace
00 – 32 SERVICE INFORMATION

4) EXCESSIVE TURBOCHARGER NOISE

Checkpoint Trouble Cause Countermeasure

Intake and exhaust NG

system joints Loose Repair

OK

Intake and exhaust NG

system gaskets Damaged Repair

OK

NG
Turbocharger rotating parts Rough rotation Replace

OK

NG
Compressor wheel Rubbing against housing Repair or replace

NG
Damaged Replace

OK

NG
Turbine wheel Rubbing against housing Repair or replace

NG
Damaged Replace

Continued on the next page

 SERVICE INFORMATION 00 – 33

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

NG
Carbon deposits Clean or replace

OK

NG
Oil Level Too low Correct

NG
Contaminated Replace oil

OK

NG
Turbocharger oil feed pipe Restricted Repair or replace

OK

NG
Turbine housing Carbon deposits Clean

OK

NG
Compressor housing Dirty Clean

OK

NG
Turbine shaft bearings Worn Replace
00 – 34 SERVICE INFORMATION

5) EXCESSIVE ROTATING PART WEAR

Checkpoint Trouble Cause Countermeasure

NG
Engine oil Contaminated Change

NG
Wrong grade or type Change

OK

NG
Turbocharger oil feed pipe Restricted Clean or replace

OK

NG
Turbocharger oil seal Defective Replace

Center housing oil drain NG

passage Restricted Clean or replace

OK

NG
Turbine shaft Oil sludge and coking Replace

OK

NG
Engine lubrication system Inadequate oil supply Correct
 SERVICE INFORMATION 00 – 35

GENERATOR
BATTERY DEAD

Checkpoint Trouble Cause Countermeasure

NG
Generator drive belt Loose Adjust

OK

NG
Battery fluid Low Replenish

OK

NG
Battery terminal Defective (Internal short circuit) Replace

OK

NG
Fuse Blown Replace

OK

NG
Fuse holder and fuse Poor contact Repair

OK

NG
Battery fluid specific gravity Wrong Adjust

OK

Starter switch and regulator NG

Broken or poorly connected Repair
terminal wire

Continued on the next page

00 – 36 SERVICE INFORMATION

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

Regulator terminal and NG

Broken or poorly connected Repair
generator terminal wire

OK

Generator NG
Defective Repair
ground circuit

OK

NG
Voltage regulator Defective Replace

OK

NG
Diode Defective Replace

OK

NG
Generator stator coil Grounded or broken Repair or replace

OK

NG
Rotor coil Broken Replace

OK

NG Check generator output at

Electrical load Excessive
normal driving speed
 SERVICE INFORMATION 00 – 37

BATTERY OVERCHARGED

Checkpoint Trouble Cause Countermeasure

Wiring and terminals NG Poor connections or open

(Generator to voltage circuit (B—B and/or N—N Correct
regulator) terminals)

OK

NG
Voltage regulator Poor ground connection Correct

NG
Voltage set too high Replace

NG
Defective Replace
00 – 38 SERVICE INFORMATION

FLASHING CHARGE LIGHT OR FLUCTUATING AMMETER INDICATION

Checkpoint Trouble Cause Countermeasure

NG
Fan belt Loose Adjust

OK

NG
Starter switch contacts Defective Replace

OK

NG
Wiring Broken or poorly connected Replace or reconnect

CHARGE LIGHT ON BUT DIM WHILE DRIVING

Checkpoint Trouble Cause Countermeasure

NG
Starter switch terminal wiring Loose Retighten

OK

Generator and fuse holder NG Replace the wire with a

Excessive resistance
terminal wire larger one

OK

NG
Starter switch contacts Defective Replace
 SERVICE INFORMATION 00 – 39

GENERATOR NOISE

Checkpoint Trouble Cause Countermeasure

Generator bearing Defective Replace and regrease

NG
OK

NG
Generator stator coil Exposed wires Replace

NG
Short circuit Replace

CHARGER CIRCUIT FUSE BLOWN

Checkpoint Trouble Cause Countermeasure

NG
Terminal wiring Grounded Repair

OK

NG Replace the end frame

Generator end frame diodes Defective
assembly

OK

NG
Battery connections Reversed Correct
00 – 40 SERVICE INFORMATION

STARTER MOTOR
STARTER AND MAGNETIC SWITCH DO NOT OPERATE

Checkpoint Trouble Cause Countermeasure

NG
Battery fluid level Low Replenish

OK

NG
Battery specific gravity Low Recharge or replace

OK

NG
Battery switches Poor contact Replace

OK

NG
Starter switch Defective Replace

OK

Magnetic switch pull-in coil NG

Defective Replace
and plunger

OK

NG
Armature coil Broken Replace

OK

NG
Field coil Broken Replace

Continued on the next page

 SERVICE INFORMATION 00 – 41

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG
Magnetic switch coil Broken Replace

OK

NG
Holding coil Broken Replace
00 – 42 SERVICE INFORMATION

MAGNETIC SWITCH CLOSES BUT STARTER DOES NOT OPERATE

Checkpoint Trouble Cause Countermeasure

NG
Battery fluid level Low Replenish

OK

NG
Battery specific gravity Low Recharge or replace

OK

NG
Starting circuit Poor contacts Repair

OK

NG
Magnetic switch terminals Poor contact Replace

OK

NG
Brushes Worn Replace

OK

NG
Armature Shorted Repair or replace
 SERVICE INFORMATION 00 – 43

STARTER MOTOR RUNS SLOWLY

Checkpoint Trouble Cause Countermeasure

Magnetic terminal circuit NG

Bad contact Repair
switches

OK

NG
Brushes Excessive wear Replace

OK

NG
Starter motor armature Shorted Repair or replace

STARTER MOTOR OPERATES BUT THE ENGINE DOES NOT TURN OVER

Checkpoint Trouble Cause Countermeasure

NG Repair or replace the

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

OK

NG
Overrunning clutch Slippage Replace

OK

NG
Brushes Excessive wear Replace
00 – 44 SERVICE INFORMATION

ABNORMAL OPERATING NOISE

Checkpoint Trouble Cause Countermeasure

NG
Bushings Excessive wear Replace

OK

NG Replace the overrunning

Pinion gear Excessive wear
clutch and the pinion gear

NG Lubricate or replace the

Rough sliding action
overrunning clutch

OK

NG Replace the overrunning

Ring gear Excessive wear
clutch and the ring gear

OK

NG
Brushes Excessive wear Replace
 SERVICE INFORMATION 00 – 45

MAIN DATA AND SPECIFICATIONS

ITEMS 6WG1-TC
Applicable exhaust emission regulations EURO3
Engine type Four cycle, overhead camshaft, water cooled,
direct injection
Combustion chamber Open type in piston crown
Cylinder liner Dry type
Timing drive system Gear
No. of cylinders – Bore × stroke mm (in) 6 – 147 × 154 (5.79 × 6.06)
No. of piston rings Four rings (Compression rings: 3, Oil ring: 1)
Total piston displacement cm3 (in3) 15,681 (956.9)
Compression ratio (to 1) 16.0
Compression pressure at 200 rpm
kPa (kg/cm2/psi) 2,844 (29/412) or more
Engine dimensions mm (in) 1,685 × 995 × 1,172 (66.3 × 39.2 × 46.1)
Engine weight (Dry) kg (lb) Approximately
(without air conditioner compressor) 1,124 (2,478)
Fuel injection order 1–5–3–6–2–4
Fuel injection timing deg 0 (BTDC)
Specified fuel type SAE No.2 diesel fuel
Idling speed rpm 500
Valve clearances Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Intake valves Open at (BTDC) deg 21
Close at (ABDC) deg 27
Exhaust valves Open at (BBDC) deg 52.5
Close at (ATDC) deg 17.5
Injection system Electronically controlled fuel injection system
(common rail system)
Exhaust gas recirculation system (EGR) Equipped
Main fuel filter type Paper element
Lubrication system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CC or CD
Oil pressure (at oil gallery)
kPa (kg/cm2/psi)/rpm 150 (1.5/21)/600
300 (3.1/44)/1,200
390 (4.0/57)/2,000
Condition: SAE 30 API CD grade engine oil at an
oil temperature of 80°C (176°F)
00 – 46 SERVICE INFORMATION

ITEMS 6WG1-TC
Applicable exhaust emission regulations EURO3
Oil pump type Gear (Timing gear drive)
Relief valve opening pressure
kPa (kg/cm2/psi)
1st stage 690 (7.0/100)
2nd stage 440 (4.5/64)
Oil pressure switch operating pressure
kPa (kg/cm2/psi) 9.8 (0.1/0.7)
Main oil filter type Paper element
Bypass valve opening pressure
kPa (kg/cm2/psi) 200 (2.0/28)
Partial oil filter type Paper element
Oil capacity Lit (Imp. gal/US gal) 28 (6.2/7.4) with combined main and partial oil filter
Oil cooler Plate type – Water cooled in water jacket
Oil thermostat opening temperature
°C (°F) 98.0 (208)
Cooling system Pressured compulsory circulation water
Radiator type Corrugated fin with sub tank
Radiator cap pressure kPa (kg/cm2/psi)
Pressure side 62 – 72 (0.63 – 0.73/9.0 – 10.4)
Vacuum side 2.0 – 4.9 (0.02 – 0.05/0.28 – 0.71)
Coolant capacity Lit (Imp. gal/US gal) 48.4 (10.6/12.8)
Water pump type Centrifugal impeller, Gear drive
Delivery volume
Lit/min. (Imp. gal/US gal) 420 (92.4/111.0) Pump speed at 2,840 rpm
Thermostat type Wax pellet
Valve initial opening temperature °C (°F) 82 (180)
Valve lift mm (in) 10 (0.39)
Air cleaner Cyclone type with paper element
Battery type / Voltage × No. of units 115F51 / 12 × 2
Generator capacity V – kW 24 – 1.2 or 1.5
Regulator type IC (Built-in)
Rotation (Viewed from the pulley) Clockwise
Ground polarity Negative
Pulley diameter mm (in) 82.0 (3.228)
Rotor coil resistance at 20°C ohm 11.7
Brush length mm (in) Brush less
Starter motor output V – kW 24 – 6
Number of poles 4
Type Magnetic switch and shift lever controlled
Drive gears Reduction
Number of pinion gear teeth 11
 SERVICE INFORMATION 00 – 47

ITEMS 6WG1-TC
Applicable exhaust emission regulations EURO3
No load characteristics
Voltage V 24
Current A 150 or less
Operation speed (Rotor) 1,000 or more
Rotation (Viewed from the pinion gear) Clockwise
Turbocharger model TD08H
Manufacturer MITSUBISHI
Turbine type Radial, inward flow
Compressor type Radial, outward flow
Maximum permissible operating speed
rpm 105,000
Exhaust gas temperature °C (°F) 600 (1,112) Maximum allowable exhaust gas
temperature measured at the turbocharger
exhaust gas intake.
Cooling method Water
00 – 48 SERVICE INFORMATION

MEMO
 SERVICE INFORMATION 00 – 49

SERVICE STANDARD

CONTENTS

PAGE
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 50
Cylinder Head and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 50
Rocker Arm and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 52
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 53
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 53
Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 54
Piston and Cylinder Liner Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 54
Cylinder Body and Cylinder Liner Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 55
Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 55
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 55
Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 55
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 56
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 56
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 56
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 56
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 56
00 – 50 SERVICE INFORMATION

SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT
ENGINE
Compression Pressure 2,844 (29 / 412) / 200 2157 ( 22 / 312 )
kPa(kg/cm2/psi)/rpm or more
CYLINDER HEAD and VALVE
Camshaft End Play mm(in) 0.085 – 0.170 (0.0033-0.0067) 0.25 ( 0.0098 )
Clearance between Camshaft and
0.065 – 0.125 (0.0026-0.0049) 0.15 ( 0.0059 )
Bracket mm(in)
Idler Gear “C” End Play mm(in) 0.05 – 0.14 (0.0020-0.0055) 0.25 ( 0.0098 )
Shaft Idler Gear “C” Outside Diameter
48.93 – 48.96 (1.9264-1.9286) 48.85 ( 1.9232 )
mm(in)
Clearance between Shaft and Idler “C”
0.04 – 0.105 (0.0016-0.0041) 0.2 ( 0.0079 )
mm(in)
Valve Spring Free Height mm(in) Outer
Intake 79.3 (3.1220) 75.3 ( 2.965 )
Exhaust 102.7 (4.0433) 97.6 ( 3.843 )
Inner
Intake – –
Exhaust 96.5 (3.7992) 91.7 ( 3.6102 )

Valve Spring Squareness mm(in) Intake 3.5 (0.1378) 4.8 ( 0.1890 )

Exhaust
Outer 4.5 (0.1772) 6.2 ( 0.2441 )
Inner 4.2 (0.1654) 5.9 ( 0.2323 )

Valve Spring tension N(kg/lb)/mm Outer

Intake 392.3 294.2 ( 38.0/83.8)/64
(40.0/88.2)/64
Exhaust 610.0 578.6 ( 59.0/130.1 )/69
(62.2/137.2)/69
Inner
Intake – –
Exhaust 223.6(22.8/50.3)/66 212.8 ( 21.7/47.8 )/66

Valve Stem and Guide Clearance Intake 0.040 – 0.077 0.15 ( 0.0059 )
mm(in) (0.0016 – 0.0030)
Exhaust 0.065 – 0.102 0.25 ( 0.0098 )
(0.0026 – 0.0040)
 SERVICE INFORMATION 00 – 51

ITEMS SERVICE STANDARD SERVICE LIMIT

Valve Stem Outside Diameter mm(in) Intake 10.0 (0.3937) 9.92 ( 0.3906 )
Exhaust 10.0 (0.3937) 9.90 ( 0.3898 )
Bridge Guide and Bridge Clearance 0.020 – 0.057 (0.0080-0.0022) 0.10 ( 0.0039 )
mm(in)
Valve Thickness mm(in) Intake 2.14 (0.0843) 1.64 ( 0.0646 )
Exhaust 2.3 (0.0906) 1.8 ( 0.0709 )

Valve Depression mm(in) Intake 1.9 (0.0748) 2.9 ( 0.1142 )

Exhaust 1.8 (0.0709) 2.8 ( 0.1102 )

Valve Contact Width mm(in) Intake 3.3 (0.1299) 3.7 ( 0.1457 )

Exhaust 2.6 (0.1024) 3.0 ( 0.1181 )

Valve Contact Surface Angle deg Intake 30 –

Exhaust 45 –
Valve Seat Angle deg Intake 30 –
Exhaust 45 –
Valve Bridge Guide Upper End Height 49.0 (1.9291) –
mm(in)
Valve Guide Upper End Height mm(in) Intake 27.0 (1.0630) –
Exhaust 29.0 (1.1417) –
00 – 52 SERVICE INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

ROCKER ARM AND CAMSHAFT
Rocker Arm Shaft Run Out mm(in) – 0.3 ( 0.012 )
Rocker Arm Shaft Outside Diameter 27.979 – 28.000 27.85
mm(in) (1.1015-1.1024) (1.0965)
Rocker Arm Bushing Inside Diameter 28.020 – 28.053 –
mm(in) (1.1031 – 1.1044)
Rocker Arm and Rocker Arm Shaft 0.020 – 0.074 0.2
Clearance mm(in) (0.0008 – 0.0029) (0.0079)
Rocker Arm Roller and Pin Clearance 0.036 – 0.069 0.5
mm(in) (0.0014 – 0.0027) (0.02)
Camshaft Journal Diameter mm(in) 39.915 – 39.940 39.80
(1.5715 – 1.5724) (1.5705)
Cam Height mm(in) Intake 9.4 (0.3700) 8.85 ( 0.3484 )
Exhaust 10.4 (0.4094) 9.75 ( 0.3839 )

Cam height = A – B

Camshaft Run Out mm(in) 0.080 (0.0031) 0.100 ( 0.0039 )

Camshaft Bearing Inside Diameter 40.015 – 40.040 –

mm(in) (1.5754 – 1.5764)
Clearance Camshaft and Cam Bearing 0.065 – 0.125 0.15
mm(in) (0.0026 – 0.0049) ( 0.0059 )
 SERVICE INFORMATION 00 – 53

ITEMS SERVICE STANDARD SERVICE LIMIT

TIMING GEAR TRAIN
Idler Gear Backlash mm(in) 0.095 – 0.135 0.23
( 0.0037 – 0.0053 ) ( 0.0091 )
Idler Gear End Play mm(in) “A” 0.165 – 0.230 0.35
(0.0020 – 0.0055) ( 0.0138 )
“B” 0.050 – 0.140 0.25
(0.0020 – 0.0055) ( 0.0098 )
“C” 0.050 – 0.140 0.25
(0.0020 – 0.0055) ( 0.0098 )

Idler Gear Spindle Outside Diameter “A” 56.93 – 56.96 56.85

mm(in) (2.2413 – 2.2425) ( 2.2382 )
“B” 141.93 – 141.96 141.85
(5.5878 – 5.5890) ( 5.5846 )
“C” 48.93 – 48.96 48.85
(1.9264 – 1.9286) ( 1.9232 )

Clearance Between Idler Gear and “A” 0.040 – 0.105 0.20

Spindle mm(in) “B” (0.0015 – 0.0041) ( 0.0079 )
“C”
CRANKSHAFT
CrankShaft End Play mm(in) 0.10 – 0.28 (0.0039-0.0110) 0.35 ( 0.0138 )
CrankShaft Journal Diameter mm(in) No.4 104.850 – 104.875 –
(4.1279 – 4.1289)
Others 104.880 – 104.905 –
(4.1291 – 4.1309)
Crankpin Diameter mm(in) 91.895 – 91.925 –
(3.6179 – 3.6191)
Crankshaft Run Out mm(in) 0.120 (0.0005) 0.15 ( 0.0059 )
Crank Bearing Spread mm(in) – 111.5 ( 4.3898 )
Clearance Crankshaft journal and No.4 0.075 – 0.150
Bearing mm(in) Journal (0.0030 – 0.0059)
0.16 (0.0063)
Others 0.045 – 0.120
(0.0018 – 0.0047)
00 – 54 SERVICE INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

PISTON AND CONNECTING ROD
Piston Ring Gap mm(in) 1st, 0.35 – 0.50
3rd (0.0138 – 0.0197)
2nd 0.80 – 0.95 1.00 (0.0394)
(0.0315 – 0.0374)
Oil 0.30 – 0.50
(0.0118 – 0.0197)

Clearance Piston Ring and Groove 1st 0.115 – 0.160 0.24

mm(in) (0.0045 – 0.0063) (0.0094)
2nd 0.10 – 0.135 0.20
3rd (0.0039 – 0.0053) (0.0079)
Oil 0.025 – 0.065 0.15
(0.0010 – 0.0026) (0.0059)

Piston Pin Diameter mm(in) 55.995 – 56.000 55.970

(2.2015 – 2.2047) (2.2035)
Clearance Piston Pin and Hole mm(in) 0.008 – 0.021 0.05
(0.0003 – 0.0008) (0.0020)
Clearance Connecting Rod Small End 0.020 – 0.037 0.10
Bushing and Piston Pin mm(in) (0.0008 – 0.0015) (0.0039)
Connecting Rod Alignment mm(in) 0.05 (0.002 or less) 0.20 (0.008)
Clearance Crankpin and Connecting 0.033 – 0.103 0.16
Rod Bearing mm(in) (0.0013 – 0.0041) (0.0063)
Clearance Connecting Rod and 0.175 – 0.290 0.35
Crankshaft mm(in) (0.0069 – 0.0114) (0.0138)
Clearance Piston and Cylinder Liner 0.166 – 0.200 –
mm(in) (0.0065 – 0.0079)
PISTON AND CYLINDER LINER GRADE
Cylinder Measuring Point mm(in) 130 (5.1181) –
Cylinder Liner Inside Diameter mm(in) 147.011 – 147.030 –
(5.7878 – 5.7886)
Piston Measuring Point from 113 (4.4488) –
Piston Top mm(in)
Piston Outside Diameter mm(in) 146.830 – 146.845 –
(5.7807 – 5.7813)
Clearance Cylinder Liner and 0.001 – 0.030 –
Cylinder Body mm(in) (0.00004 – 0.00118)
 SERVICE INFORMATION 00 – 55

ITEMS SERVICE STANDARD SERVICE LIMIT

CYLINDER BODY AND CYLINDER LINER
GRADE
Cylinder Body Bore Diameter mm(in) Grade
“1” 151.600 – 151.610 –
(5.9685 – 5.9689)
“2” 151.611 – 151.630 –
“3” (5.9689 – 5.9697)
Cylinder Liner Outside Diameter Grade
mm(in) “1X” 151.590 – 151.599 –
(5.9681 – 5.9685)
“3X” 151.600 – 151.610 –
(5.9685 – 5.9689)
CYLINDER BODY
Cylinder Liner Bore mm(in) Nominal Measurement 147.3 (5.7992)
147.0 (5.7875)
Cylinder Body Upper Face Warpage 0.0075 (0.0030) or less 0.2 (0.008)
mm(in)
Cylinder Liner Projection mm(in) 0.05 – 0.09 –
(0.0020 – 0.0035)
Projection Height Between Adjacent 0.02 (0.0008) or less –
Cylinder mm(in)
FLYWHEEL
Depth from Friction Face to Pressure Clutch Size
Plate Fixing Face mm(in) 17′′ 48.0 (1.890) 50.5 (1.988)
15.5′′ 27.0 (1.063) 29.5 (1.161)
LUBRICATING SYSTEM
Clearance Oil Pump Body and Driven 0.050 – 0.098 –
Gear mm(in) (0.0020 – 0.0039)
Side Clearance Oil Pump Cover and 0.040 – 0.094 –
Gear mm(in) (0.0016 – 0.0037)
Oil Pump Gear Shaft Diameter mm(in) 20.0 (0.7874) 19.9(0.7835)
Clearance Oil Pump Gear Shaft and 0.040 – 0.074 –
Body mm(in) (0.0015 – 0.0029)
An Interference Oil Pump Drive Gear 0.019 – 0.047 –
and Driven Gear mm(in) (0.0007 – 0.0019)
Oil Thermostat Opening Temperature 98.0 (208) –
°C (°F)
00 – 56 SERVICE INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

ENGINE COOLING SYSTEM
Clearance water pump impeller and 1.7 – 2.7 (0.0669 – 0.1063) –
pump body mm(in)
Thermostat Opening Temperature Initial Opeing
°C (°F) 82 (180)
–
Full Opening
95 (203)
Thermostat Full Valve Lift mm(in) 10 (0.39) –
Radiator Testing Pressure 108 (1.1 / 15.6) –
kPa(kg/cm2/psi)
Radiator Sub Tank Filler Cap Pressure 62 – 72 –
kPa(kg/cm2/psi) (0.63-0.73 / 9.0-10.4)
ENGINE ELECTRICAL –
Generator
Rotor Coil Resistance ohm 4.45 – 5.2 –
Starter
Commutator Run Out mm(in) 0.015 (0.0006) or less 0.10 (0.004)
Commutator Outside Diameter mm(in) 38.7 (1.524) 38.1 (1.500)
Brush Length mm(in) 23 (0.906) 12 (0.472)
Drive Gear Shaft Bending mm(in) 0.2 (0.0079) or less –
Armature Assembly End Play 0.2 – 0.7 (0.0079 – 0.0276) –
(Reference) mm(in)
Drive Gear Shaft End Play mm(in) 0.2 – 0.8 (0.0079 – 0.0315) –
TURBOCHARGER
Turbine Shaft End Play mm(in) 0.075 – 0.155 –
(0.0030 – 0.0061)
Clearance Turbine Shaft and 0.39 – 1.00 –
Turbine Housing Gap mm(in) (0.0154 – 0.0394)
 SERVICE INFORMATION 00 – 57

SERVICING

CONTENTS

PAGE
Nut and Bolt Angular Tightening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 58
Nut and Bolt Angular Tightening Method (Using the Special Tool) . . . . . . . . . . . . . 00 – 60
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 60
Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 62
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 63
Water Separator (Water Sedimentor) with Pre Fuel Filter . . . . . . . . . . . . . . . . . . . . . 00 – 64
Air Bleeding of Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 65
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 65
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 66
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 66
Radiator Sub Tank Cap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 66
Cooling System Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 67
Radiator Cap Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 67
Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 67
Generator Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 68
Air Conditioner Compressor Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 68
Accelerator Pedal Stopper Bolt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 69
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 69
Injection Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 71
Compression Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 72
00 – 58 SERVICE INFORMATION

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

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

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

and grease.
2. Apply a coat of molybdenum disulfide grease to
the threads and setting faces of the nuts and bolts.

3. Tighten the nuts and bolts to the specified torque

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

Snug torque

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

Center line
bolt after tighten the snug torque.

A B
 SERVICE INFORMATION 00 – 59

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

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

C D

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

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

Coincide line G

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

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

Example: Specified Angle and Tightening Rotation

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

Nut and Bolt Angular Tightening

Method (Using The Special Tool)
1. Carefully wash the nuts and bolts to remove all oil
and grease.
2. Apply molybdenum disulfide grease to the threads
and setting faces of the nuts and bolts.
3. Use a torque wrench to tighten the nuts and bolts
to the specified torque (snug torque).

4. Attach the angle gauge to the socket wrench.

Angle Gauge: 5-88400-266-0
5. Attach a magnet to some part to hold the angle
gauge stationary.
6. Tighten the nuts and bolts to the specified angle,
noting the angle gauge indication.

Air Cleaner
Element Cleaning and Replacement
Element cleaning procedures will vary according to
the condition of the vehicle usage.
The warning light comes on when the air cleaner
element becomes fouling condition.

Washable Paper Element (Dry Type)

1. Dust Fouled Element
Rotate the element with your hand while applying
compressed air to the inside of the element.
This will blow the dust free.
NOTE:
Compressed air pressure must not exceed 686kPa
(7kg/cm2 / 99.5psi).
If the element damaged, the element must be replaced.
130H100001
 SERVICE INFORMATION 00 – 61

Avoid giving a shock to the element when removing

dust, or distortion or damage will result.

2. Carbon and Dust Fouled Element

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

130H100002

3) Remove the element from the solution and rinse it

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

130RY00005

4) Dry the element in a well ventilated area.

An electric fan will hasten drying.
NOTE:
Do not use compressed air or an open flame to dry
the element quickly. Damage to the element will
result.
It will usually take one week for the element to dry
completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.
130RY00006

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

element and the gasket for damage.
If the element damaged, the element must be
replaced.

130H100003
00 – 62 SERVICE INFORMATION

Air Cleaner Body

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

HCW31BSH003201

Lubricating System
Separate Type Main Oil Filter and Partial Oil Filter
Replacement Procedure.
WARNING:
HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
THE ENGINE OIL.

1. Remove the drain plugs 5 to drain the engine oil

from the main oil filter and partial oil filter.
2. Wait a few minutes and then retighten the drain
plugs to specified torque.
Drain Plug Torque N·m (kg·m / lb·ft)
25 (2.5 / 18.1)
3. Loosen the center bolts 8 to remove the filter body
3 together with the element 2.
Discard the used element, the gasket, and the
O-rings.
4. Clean the filter body together with the other parts
by immersing them in clean diesel fuel.
5. Wipe the fitting faces of the filter bracket with a
clean rag.
6. Apply light coat of engine oil to the center bolt and
the new O-rings.
7. Install the filter body together with the new
element and gasket to the filter cover.
8. Tighten the center bolt to the specified torque.
Center Bolt Torque N·m (kg·m / lb·ft)
44.0 (4.5 / 32.5)

NOTE:
Take care not to distort or twist the O-ring when
tightening the center bolt.
Hold the filter body with your hand to prevent it from
turning as you tighten the center bolt.
 SERVICE INFORMATION 00 – 63

9. Check the engine oil level and replenish to the

specified level if required.
10.Start the engine and check for oil leakage from
main oil filter and partial oil filter.
Oil Pan Capacity lit (imp / US gal)
MAX 28 (6.2 / 7.4)

Fuel System
Fuel Filter
1. Loosen the fuel filter drain plug 9 to drain the fuel.
NOTE:
Do not forget to retighten the drain plug after
draining the fuel.
Drain Plug Torque N·m (kg·m / lb·ft)
24.5 (2.5 / 18.1)

2. Loosen the center bolt 1 to remove the fuel filter

case 8 together with the element 6, the strainer
7, and O-ring 5 from the filter case.
Discard the used element and the O-ring.
3. Clean the filter case together with other parts
immersing them in clean diesel fuel.
4. Wipe the filter case fitting surfaces with a clean
rag.
5. Install the filter case with the new element, the O-
ring, and the strainer 7 to the filter body 8.
The O-ring must be replaced with new one.
6. Tighten the center bolt to the specified torque.
Filter Center Bolt Torque N·m (kg·m / lb·ft)
27.4 (2.8 / 20.0)

NOTE:
Take care not to distort or twist the O-rings when
tightening the center bolt.
Hold the filter case with your hand to prevent it from
turning as you tighten the center bolt.
00 – 64 SERVICE INFORMATION

Water Separator (Water Sedimentor)

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

The pre fuel filter should be serviced in the following

manner.
It is strongly advisable to use ISUZU genuine fuel filter
element kit for replacement.
1. Loosen the transparent cover and remove the
element together with the cover.
2. Discard the used element and install new ones.
Securely tighten the cover.
1 Cover
2 Element
After servicing, bleed the fuel system and check for
fuel leaks.
 SERVICE INFORMATION 00 – 65

Air Bleeding of fuel system

Air bleeding plug 1. Unscrew the priming pump cap (the cap will spring
free).
2. Loosen the air-bleed plug on the fuel filter.
3. Press and release the priming pump cap (up and
down motion) to force fuel through the fuel filter.
Bubbles will escape from around the air bleed plug.
4. Continue to operate the priming pump until there
are no more bubbles escaping from around the air
905M200001
bleed plug.
5. Tighten the air bleed plug (fuel filter).
Air bleeding plug
6. Loosen the air bleed plug on the supply pump.
7. Press and release the priming pump cap (up and
down motion) to force fuel through the fuel filter.
Bubbles will escape from around the air bleed plug.
8. Continue to operate the priming pump until there
are no more bubbles escaping from around the air
bleed plug.
9. Tighten the air bleed plug (supply pump).
Priming pump
905M200002

10.Turn the starter switch to the ON position.

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

If you are unable to start the engine, repeat the entire

air bleeding procedure.

Fuel tank
Remove the drain plug and drain the water and
sediment completely.
00 – 66 SERVICE INFORMATION

Cooling System
WARNING:
HOT STEAM UNDER PRESSURE MAY ESCAPE FROM
THE RADIATOR IF THE RADIATOR SUB TANK CAP IS
OPENED WHILE THE ENGINE IS HOT. THIS CAN
RESULT IN SERIOUS BURNS.
ALLOW THE ENGINE TO COOL BEFORE OPENING
THE RADIATOR SUB TANK CAP.
Coolant Level
Check the coolant level and replenish the radiator sub
tank if necessary.
If the coolant level falls below the "MIN" line, carefully
check the cooling system for leakage. Then, add
additional coolant to raise the level over the "MIN"
line.

NOTE:
Do not overfill the radiator sub tank.
Remove the radiator sub tank cap only when
absolutely necessary.
Always refer to the chart at the left to determine the
Good Quality Ethylene Glycol anti-freeze
correct cooling water to antifreeze solution mixing
0 ratio.
Freezing Point(°C)

-10
-20
-30
-40
-50
-60
0 5 10 15 20 25 30 35 40 45 50 55 60
Mixing ratio(%)
B06H100006

Radiator Sub Tank Cap Inspection

WARNING:
HOT STEAM UNDER PRESSURE MAY ESCAPE FROM
THE RADIATOR IF THE RADIATOR SUB TANK CAP IS
OPENED WHILE THE ENGINE IS HOT. THIS CAN
RESULT IN SERIOUS BURNS.
ALLOW THE ENGINE TO COOL BEFORE OPENING
THE RADIATOR SUB TANK CAP.
 SERVICE INFORMATION 00 – 67

Cooling System Leakage Check

1. Remove the radiator filler cap from the radiator sub
tank.
2. Install the radiator filler cap tester to the radiator
sub tank.
3. Apply the specified test pressure to the cooling
system to check for leakage.
Do not exceed the specified test pressure.
Cooling System Test Pressure kPa (kg/cm2 / psi)
060HT008 98.1 (1.0 / 14.2)

Repair or replace the leakage unit if required.

Radiator Cap Leakage Check

The radiator sub tank filler cap maintains cooling
system pressure.
It must tightly seal the cooling system.
1. Remove the radiator filler cap from the radiator sub
tank.
2. Install the radiator cap to the radiator filler cap
tester.
3. Apply the specified test pressure to the cap to
110HY00001
check for leakage.
Do not exceed the specified test pressure.
Radiator Filler Cap Test Pressure kPa (kg/cm2 / psi)
61.8 – 71.6 (0.63 – 0.73 / 8.96 – 10.38)

Negative Valve Pressure kPa (kg/cm2 / psi)

2 – 5 (0.02 – 0.05 / 0.28 – 0.71)

Replace the radiator sub tank filler cap if it fails to

hold the specified test pressure.

Adjust bolt Idler pulley

Generator
11~13mm
Drive Belt Inspection
Check the drive belt tension.
Depress the drive belt mid-portion with a 98N (10kg
/ 22lb) force.
Drive Belt Deflection mm (in)

Nut
11 – 13 (0.43 – 0.51)

Air conditioner
compressor
033H100017
00 – 68 SERVICE INFORMATION

Generator Drive Belt Tension Adjustment

1. Loosen the idler pulley center nut.
2. Move the idler pulley to adjust the belt tension to
the specified value.
3. Tighten the idler pulley center nut to the specified
torque.
Pulley Center Nut Torque N·m (kg·m / lb·ft)
147.1 (15.0 / 108.5)

A Air Conditioner Compressor Drive Belt Adjustment

Air conditioner 1. Loosen bolts A, B and C (refer to illustration).
compressor
2. Move the adjust bolt to adjust the belt tension to
the specified value.
3. Tighten bolts A, B and nut C to the specified
B torque.
Drive Belt Deflection mm (in)
Adjust bolt 10 – 13 (0.39 – 0.51)
C (Back side)
850H100001
Nut and Bolts Torque N·m (kg·m / lb·ft)
A, B bolts 135.2 (13.8 / 99.8)
C nut 93.2 (9.5 / 68.7)

Check the drive belts for cracking and other damage.

 SERVICE INFORMATION 00 – 69

Accelerator Pedal Stopper Bolt Adjustment

Accelerator pedal
pressed to the floor Adjust the accelerator stopper bolt.
1.0~2.0mm(Gap)
1. Depress the accelerator pedal and hold it.
2. Bring the pedal stopper bolt cap into contact with
the full stopper.
Stopper bolt
3. Turn in the pedal stopper bolt 1–1-1/2 turns to
adjust the clearance between the accelerator pedal
and the stopper bolt cap to 1–2 mm (0.0394 –
Lock nut
0.0787 in).
060H100007
4. Tighten the stopper bolt lock nut.

Valve Clearance Adjustment

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

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

Flywheel top dead center on the compression stroke by
Housing
turning the crankshaft until the T.D.C line on the
flywheel is aligned with the timing pointer.
Front T Check the rocker arm shaft bracket nuts for
C
looseness and retighten as necessary before
adjusting the valve clearance.
2. Check that the No. 1 intake and exhaust push rods
have play. If they have play, it indicates that the No.
1 piston is at TDC (Top Dead Center) on the
020H100008 compression stroke. If the No. 1 exhaust valves are
depressed, the No. 6 piston is at TDC on the
compression stroke.
00 – 70 SERVICE INFORMATION

3. Adjust valve clearances for the No. 1 or No. 6

cylinder which its piston is at TDC on compression
stroke.
1) Loosen each adjusting screw on the bridge and
rocker arm.
Valve Clearance mm (in)
0.4 (0.0016)

2) Insert a feeler gauge between the rocker arm

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

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

is raised. Readjust by loosening the adjusting
screw on the bridge until there is a slight drag
on the feeler gauge and tighten the lock nut
securely.

4. Rotate the crankshaft 360 deg and realign the T.C.

mark on the flywheel with the pointer and adjust
clearance for remaining valves.
The “●” mark in the illustration indicates the
cylinders and valves to be adjusted.
NOTE:
Be sure to move the No. 1 cylinder to TDC on the
compression stroke after completing the valve
clearance adjustment procedure.
Tightening Torque N·m (kg·m/lb·ft)
Position Torque
Rocker Arm Adjusting Screw Nut 78.5 (8.0/57.9)
Bridge Adjusting Screw Nut 54.0 (5.5/39.8)
 SERVICE INFORMATION 00 – 71

Intake and Exhaust Valve Arrangement

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

Injection Timing Adjustment

Fuel injection timing inspection
Flywheel
Housing 1. Rotate the crankshaft in the normal direction of
rotation to bring the piston in the No. 1 cylinder to
T
top-dead-center (TDC) on the compression stroke.
Front C Align the T/C timing mark on the flywheel with the
timing pointer
2. Check that the notched line on the supply pump is
aligned with the notched line on the coupling
flange. If necessary, align the two areas.
020H100006
Fuel Injection Timing deg.
0 (TDC)
Align to 0 degree
(TDC)

040M200006

3 Fuel injection timing adjustment

1. Loosen the first adjusting bolt (2).
2. Rotate the crankshaft in the normal direction of
rotation to bring the piston in the No. 1 cylinder to
Air compressor side
top-dead-center (TDC) on the compression stroke.
Align the T/C timing mark on the flywheel with the
timing pointer.
1 3. Loosen the second adjusting bolt (2).
4. Adjust the gear backlash to zero.
2
040M200007

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

Align to 0 degree
(TDC) 6. Tighten the two adjusting bolts (2) to the specified
torque.
Adjusting Bolt Torque N·m (kgf·m)
61 (6.2 / 45)

040M200006
00 – 72 SERVICE INFORMATION

Compression Pressure Measurement

To measure the compression pressure, the engine
must be cold. Engine coolant temperature should be
at 20°C. Battery and starter motor condition must be
normal.
1. Remove the injection nozzle assembly and the
injection fuel pipe from the each cylinder.

011HY000123

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

cylinder injection nozzle installation hole.
Compression Gauge Adapter: 5-8531-7019-0
3. Install the compression gauge to the compression
gauge adapter.
4. Crank the engine with starter motor (about 200
rpm) and take the compression gauge reading.

5. Repeat the procedure (Step 2 to 4) for the

remaining cylinder.
Compression Pressure kPa (kg/cm2 / psi)
Standard Limit
2,844 (29 / 412) 2,157 (22 / 312)

Compression pressure should be approximately

the same for each cylinder.
A variation exceeding 196.1kPa (2.0kg/cm2 / 28.4psi)
is unacceptable.
 SERVICE INFORMATION 00 – 73

FIXING TORQUE

CONTENTS

PAGE
Engine External Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 74
Cylinder Head, Rocker Arm Shaft and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 75
Crankshaft Pulley, Timing Gear and Timing Gear Case Cover . . . . . . . . . . . . . . . . . . 00 – 76
Lower Crankcase and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 77
Flywheel and Engine Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 78
Oil Pan and Oiling Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 79
Exhaust Gas Recirculation Valve and Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 80
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 81
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 82
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 83
Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 84
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 85
Flywheel P.T.O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 86
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 – 87
00 – 74 SERVICE INFORMATION

FIXING TORQUE
Engine External Parts N·m (kg·m / lb·ft)
Head Cover Fuel Filter Center Bolt
15(1.5/11) 39(4.0/29)
Air Compressor Bolt
133(13.6/98)

Starter Motor
103(10.5/76)

Supply Pump
Steering Pump 31(3.2/23)
38(3.9/28) Coupling Bolt Supply Pump Bracket
61(6.2/45) 108(11.0/80)
Oil Pan Drain Plug
78(8.0/58) HCW31BMF001301

Turbocharger Nut
Exhaust Manifold Nut
40(4.1/30)
37(3.8/27)

EGR Pipe
38(3.9/28)
Fan Belt Deflection
11-13mm(0.43-0.51 in)

Main Oil Filter Center Bolt

44(4.5/33)
Partial Oil Filter Center Bolt
49(5.0/36)
HCW31BMF001201
 SERVICE INFORMATION 00 – 75

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

18(1.8/13)

15(1.5/11)

15(1.5/11)

41(4.2/30)
(Dry)

90(9.2/67)

Apply engine oil

76(7.7/56)

137(14.0/101) 49(5.0/36)
(Dry)

M18
Apply molybdenum
disulfide grease

M10,M12
Apply engine oil

39(4.0/29)

Cylinder Head Bolt Torque

Bolt
1st Step 2nd Step 3rd Step
size
176.6 245.3
M18 60 – 90 deg
(18/130) (25/181)
M12 97.1 (9.9/71.6)
M10 39.2 (4.0/28.9)

HCW31BMF00401
00 – 76 SERVICE INFORMATION

Crankshaft Pulley, Timing Gear and Timing Gear Case Cover N·m (kg·m / lb·ft)
 SERVICE INFORMATION 00 – 77

Lower Crankcase and Connecting Rod N·m (kg·m / lb·ft)

00 – 78 SERVICE INFORMATION

Flywheel and Engine Foot N·m (kg·m / lb·ft)

 SERVICE INFORMATION 00 – 79

Oil Pan and Oiling Jet N·m (kg·m / lb·ft)

69(7.0/51)

55(5.6/41)

38(3.9/28)

HCW31BXF00201
00 – 80 SERVICE INFORMATION

Exhaust Gas Recirculation Valve and Cooler N·m (kg·m / lb·ft)

49.0(5.0/36.2)

39.2(4.0/29)

39.2(4.0/29)

9.8(1.0/7.2)

39.2(4.0/29) 29.4(3.0/21.7)

19.6(2.0/14.5)

F06H100020
 SERVICE INFORMATION 00 – 81

Oil Pump N·m (kg·m / lb·ft)

00 – 82 SERVICE INFORMATION

Oil Cooler N·m (kg·m / lb·ft)

 SERVICE INFORMATION 00 – 83

Water Pump N·m (kg·m / lb·ft)

00 – 84 SERVICE INFORMATION

Thermostat Housing N·m (kg·m / lb·ft)

39(4.0/29)

50(5.1/37)

78.4(8.0/58)

39(4.0/29)

69(7.0/51)

39(4.0/29)

88(9.0/65)

50(5.1/37)

HCW31BXF000301
 SERVICE INFORMATION 00 – 85

Turbocharger N·m (kg·m / lb·ft)

20 (2.0/14.5)
27 (2.8/20)
Apply molybdenum disulfide grease

Apply engine oil

Apply engine oil

Apply engine oil

Apply engine oil

Apply grease

HCW31JLF000101
00 – 86 SERVICE INFORMATION

FLYWHEEL P.T.O. N·m (kg·m / lb·ft)

112.0 (11.4/82)

(*A)

(*B)

82.0 (8.4/61)

1st step 2nd step 3rd step

30 (3.0/21.7) 49 (5.0/36.2) 60 deg.

88.3 (9.0/65.1)

343.0 (35.0/253.2)

(*A)

(*B)

147.0 (15.0/108.0)

167.0 (17.0/123.0)

090H100001
 SERVICE INFORMATION 00 – 87

SPECIAL TOOLS
ILLUSTRATION PART NUMBER PART NAME

1-8531-7019-0 Compression Gauge Adapter

5-8840-0266-0 Angle Gauge

1-8523-5013-0 Valve Spring Compressor

9-8523-1202-0 Valve Guide Remover and Installer

9-8522-1324-0 Valve Bridge Guide Installer

Valve Stem Sealer Installer

1-8522-1187-0
for Intake Valve

Valve Stem Seal Installer

1-8522-1184-0
for Exhaust Valve

1-8522-1025-0 Piston Ring Setting Tool

00 – 88 SERVICE INFORMATION

ILLUSTRATION PART NUMBER PART NAME

1-8521-0027-0 Slinger Remover

9-8521-0157-0 Pilot Bearing Puller

1-8522-1057-0 Pilot Bearing Setting Tool

1-8522-0059-0 Piston Setting Tool

1-8521-0063-0 Taper Bushing Remover

1-8522-0049-0 Oil Seal Installer

1-8522-0043-0 Oil Seal Installer

1-8521-0064-0 Crankshaft Gear Remover

 SERVICE INFORMATION 00 – 89

ILLUSTRATION PART NUMBER PART NAME

1-8522-0045-0 Crankshaft Gear Installer

1-8521-0062-0 Impeller Remover

1-8522-0047-0 Seal Unit Installer

1-8521-0067-0 Seal Ring Puller

1-8522-1034-0 Seal Ring Installer

00 – 90 SERVICE INFORMATION

MEMO
 ENGINE MECHANICAL 6A – 1

SECTION 6A
ENGINE MECHANICAL

CONTENTS

PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 5
Lubricating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 14
Lubricating Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 14
Lubricant Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 15
Oil Pump and Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 16
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 16
Engine External Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 17
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 24
Exhaust Gas Recirculation System (EGR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 36
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 38
Cylinder Head and Valve Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 41
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 45
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 52
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 55
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 59
Rocker Arm and Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 65
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 65
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 67
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 69
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 71
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 73
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 74
6A – 2 ENGINE MECHANICAL

PAGE
Oil Pan, Oil Pump and Timing Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 76
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 76
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 79
Geartrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 80
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 81
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 88
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 90
Crankshaft, Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 94
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 94
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 97
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 101
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 101
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 103
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 106
Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 108
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 108
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 110
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 114
Flywheel and Crank Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 118
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 118
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 120
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 121
Cylinder Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 123
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 123
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 125
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 127
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 130
Oil Pump Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 130
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 131
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 133
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 135
 ENGINE MECHANICAL 6A – 3

PAGE
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 138
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 138
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 140
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 141
Main Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 143
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 143
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 145
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 146
Partial Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 148
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 148
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 150
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A – 151
6A – 4 ENGINE MECHANICAL

GENERAL DESCRIPTION
The 6WG1 engine is a four-cycle, six-cylinder, in- first and third ring to ensure sufficient strength and
line, direct fuel injection type diesel engine with the wear resistance of the ring and the ring groove.
piston displacement of 15,681 cm3 (957 in 3). It The crankshaft is made of forge steel with seven
features a gear-driven OHC (overhead camshaft) bearings and twelve counterweights to reduce
timing train and unique mechanisms and systems revolution load to the bearing.
designed for outstanding quietness, economy and
The gear train is located at the front of cylinder
durability.
body to minimize influence of the torsional
The cylinder head is made of cast iron and has a vibration of the crankshaft and the radiant sound.
cross-flow layout with the intake system in the left
Noise is further reduced, to the same level as a
side and the exhaust system in the right side,
timing belt driven system, by integrating the
designed to reduce resistance in the intake and
crankshaft gear with the crankshaft by shrink fit
exhaust system.
careful tuning of the gear precision, contact gear
The cylinder head gasket is of the laminated of ratio, backlash, bearing rigidity neutral frequency,
least fatigue in combination with the angular etc.
cylinder head bolt tightening method, equally
designed to increase reliability against gas and Exhaust gas recirculation system (EGR)
water leakage. The EGR recirculates a portion of the exhaust gas to
The cylinder body is made of cast iron having dry the intake manifold. The recirculated gas mixes
cylinder liner and seven bearings. The bearing cap with insert gases (air) during the intake stroke.
has a ladder frame construction integrating the Recirculated gas temperature is reduced by a water
crankcase to increase rigidity. cooler. A lead valve prevents the recirculated gas
The cylinder liner is made of thin iron plus special from flowing backward. Combustion temperatures
alloys and is combined with the chrome-plate are lowered resulting in reduced nitrogen oxide
piston ring to ensure good resistance against wear. (Nox) emissions.
The piston is made of aluminum alloy. A ring
trigger is cast into the first and second ring groove
and chrome plating is applied to four sides of the
 ENGINE MECHANICAL 6A – 5

ENGINE
REMOVAL
Read this section carefully before performing any removal and installation procedure. This Section gives
you important points as well as the order of operation. Be sure that you understand everything in this
Section before you begin. Some illustrations are not same shape of actual parts, the illustration are used to
make only imagination for removal or installation.

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

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

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

2. Disconnect the battery cable at the starter motor

and the grounding cable at the chassis frame.

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

HCW31BSH002901

Coolant
Remove the water drain plug (at the right side of the
engine) and the radiator drain plug and allow the
coolant to drain completely.
WARNING:
HOT STEAM UNDER PRESSURE MAY ESCAPE FROM
THE RADIATOR IF THE COOLANT IS DRAINED WHILE
THE ENGINE IS HOT. THIS CAN RESULT IN SERIOUS
BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
THE COOLANT.
If good quality ethylene glycol anti-freeze coolant is
used, drain the coolant into a clean container so that it
can be reused.
Refer to the Maintenance Schedule in Section 00,
"GENERAL INFORMATION".

Radiator
1. Disconnect the radiator upper rubber hose to the
radiator.
2. Remove the radiator lower rubber hose from the
radiator.
3. Disconnect the radiator overflow rubber hose from
the radiator.
4. Disconnect the air delivery pipe from inter cooler.
5. Disconnect the air supply pipe from turbocharger.
HCW31BSH002801
 ENGINE MECHANICAL 6A – 7

6. Remove the radiator cushion rubber nuts.

7. Remove the radiator with inter cooler.
Be careful remove the radiator not to damage the
radiator and inter cooler core.

HCW31BSH003301

Engine Control Cable

Disconnect the engine control cable from the interim
connection bracket.

Engine Oil Draining

Oil Pan Drain Plug
1. Remove the oil pan drain plug to drain the engine
oil.
WARNING:
HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
THE ENGINE OIL.
2. Reinstall the drain plug and tighten to the specified
torque.
Oil Pan Drain Plug Torque N·m (kg·m / lb·ft)
78 (8.0 / 58)

Oil Filter
1. Loosen the main and partial oil filter drain plugs to
drain the engine oil.
Removing the center bolts will facilitate oil
drainage from the oil filter.
2. Reinstall the drain plugs and tighten them to the
specified torque.
Oil Filter Drain Plug Torque N·m (kg·m / lb·ft)
44.2 (4.5 / 32.5)

Center Bolt Torque N·m (kg·m / lb·ft)

Main oil filter 44.2 (4.5 / 32.5)
Partial oil filter 49.1 (5.0 / 36.2)
6A – 8 ENGINE MECHANICAL

Propeller Shaft
1. Disconnect the 1st propeller shaft flange yoke from
the output shaft of transmission.
2. Lower the propeller shaft carefully to the ground.

Cab Mounting Rear Member

Remove the cab mounting rear member from the
chassis frame.

Exhaust Brake Assembly

Disconnect the exhaust brake control air hose.

Transmission
Refer to Section 7, "TRANSMISSION", "Removal and
Installation".
 ENGINE MECHANICAL 6A – 9

Clutch Pressure Plate and Driven Plate

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

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

Front Engine Mounting

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

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

2. Rotate the engine 90 degrees.

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

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

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

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

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

6. Lower the engine until it contacts the engine

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

Front Engine Mounting

Rear Engine Mounting
Tighten the mounting nuts and bolts to the specified
torque.
Front Mounting Nut Torque N·m (kg·m / lb·ft)
228 (23 / 166)

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

490 (50 / 362)
 ENGINE MECHANICAL 6A – 11

Clutch Pressure Plate and Driven Plate

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

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

Propeller Shaft
1. Install the 1st propeller shaft flange yoke to the
transmission.
2. Tighten the propeller shaft flange nuts to the
specified torque.
Propeller Shaft Flange Nut
Torque N·m (kg·m / lb·ft)
255 (26.0 / 188)

Radiator
1. Install the radiator with the mounting cushion
rubbers.
Be careful not to damage the radiator core.
2. Tighten the radiator cushion rubber nuts.
3. Connect the radiator upper and lower hoses.
4. Connect the radiator overflow rubber hose.
5. Connect the both air delivery and supply pipe to
the inter cooler.
HCW31BSH003301
6A – 12 ENGINE MECHANICAL

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

NOTE:
When tightening the flange nuts, the clearance
between collar 1 of D.J.M. device and flange 2 must
be even.
4. Full tighten the each exhaust pipe clamp bolts and
nuts.

Cab Mounting Rear Member

Radiator Reserve Tank
1. Install the cab mounting member to the chassis
frame.
2. Tighten the rear member nuts to the specified
torque.
Rear Member Nut Torque N·m (kg·m / lb·ft)
155 (15.8 / 114.3)

3. Install the radiator reserve tank with the bracket to

the cab rear mounting member.
Engine Control Cable
Connect the engine control cable to the interim
connection bracket.
Air Cleaner
Install the air intake hose to the intake duct.
Coolant Replenishment
Replenish the coolant to the specified capacity.
Coolant Capacity lit (imp / US gal)
48.1 (10.6 / 12.7)

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

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

4. Connect the battery terminal 2 and the grounding

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

Engine Oil Replenishment

1. Replenish the engine oil from the filler port with
new engine oil of the specified grade.
2. Start the engine and let it idler for a few minutes.
3. Stop the engine and wait five minutes.
4. Recheck the oil level and replenish if necessary.
6A – 14 ENGINE MECHANICAL

ENGINE
The combustion chamber has a clean and The two exhaust valves are connected to a
simple design for maximum operating single port.
economy also easy starting. Slipper skirt pistons, constructed of special
The 6WG1-TC engine is turbocharger equipped. aluminum alloy, reduce weight and friction loss.
The fuel system consists of the electronically The piston top land helps to from Isuzu's
controlled fuel injection system. unique combustion chamber.
Intake ports generate optimum swirl effect The piston top land in combustion with the
while exhaust ports minimize exhaust cylinder head forms Isuzu's unique combustion
resistance. Isuzu's unique combustion chamber chamber when the piston is at top dead center.
design provides maximum power output and
The piston top and second ring groove is made
fuel economy.
of special iron casting to make it highly wear
Each cylinder has two intake valves and two resistant also provides cooling oil holes for
exhaust valves. highly efficient cooling .
To ensure high efficiency and complete
combustion, the intake system has a Isuzu's
unique designed intake ports.

LUBRICATING SYSTEM
LUBRICATING OIL FLOW LUBRICATING OIL FLOW
All engine parts are lubricated by a gear pump This additional filtering and cleaning result in
pressure circulation system. extended oil life.
Oil flows from the oil pump though oil cooler Oiling jets are installed to the cylinder body
to main oil filter for oil cooling and oil cleaning. main oil gallery.
From the main oil filter it moves to the cylinder The jet spray oil to the inside portions of the
body oil gallery and the oil circulates to pistons for lubrication and cooling.
lubricates the engine parts.
About 2 percent of the oil from the oil pump is
routed through the partial oil filter and cleaned
oil to return directly to the oil pan without
passing to the oil gallery.
 LUBRICANT FLOW CHART

CYLINDER BODY
CYLINDER BODY LEFT HAND OIL GALLERY
RIGHT HAND OIL GALLERY

OIL PRESS.
UNIT & TIMING
CYLINDER HEAD FAN SUPPLY
SWITCH GEAR
CENTER PUMP
2 OILING JET
OIL FILTER MAIN PARTIAL
By-Pass OIL OIL TURBO
VALVE FILTER FILTER CHARGER

CAMSHAFT IDLE IDLE

JOURNAL IDLE GEAR AIR
OILING JET GEAR GEAR
(No2 & 5) "A" COMPRESSOR
"B" "C"

OIL ROCKER
RELIEF
COOLER ARM CRANKSHAFT
VALVE
SHAFT JOURNAL
4

OIL CAMSHAFT ROCKER

THERMOVALVE JOURNAL ARM & CRANKPIN
(No1,3,4,6) VALVE

CONNECTING
ROD
1 BUSHING
OIL
PUMP RELIEF
VALVE

STRAINER OIL PAN

2
Relief valve opening pressure kPa (kg/cm /psi) 4 Oil thermostat opening temperature C ( F) 98 (208.4)
1 687 (7.0/99.5)
2 196.1 (2.0/28.4)
3 442 (4.5/64.0)

HCW31BXF000101
ENGINE MECHANICAL 6A – 15
6A – 16 ENGINE MECHANICAL

OIL PUMP AND OIL FILTERS OIL PUMP AND OIL FILTERS
The oil pump is a gear type with a relief valve. The A warning lamp will light at this time to warn the
pump is driven by the timing gear. driver of the vehicle the oil directly to the oil gallery.
A full flow main oil filter with a highly efficient The partial oil filter is used replaceable element.
paper element used. A portion of the oil is diverted to the partial oil filter
Should the element become clogged with sludge or before reaching the main oil filter.
other foreign material, a by-pass valve open to The oil is cleaned and delivered to the oil pan.
route the oil directly to the oil gallery.

OIL COOLER
The temperature of the engine oil circulating
through the lubricating system tends to rise with an
accompanying decrease in lubricating efficiency.
The oil cooler maintains the oil temperature at the
optimum level for effective engine lubrication.
The oil cooler consists of the body and the cooling
element.
 ENGINE MECHANICAL 6A – 17

ENGINE EXTERNAL PARTS

REMOVAL
17 1
14

16

15

13

4 19 18
7 6
HCW31BMF000101

9 23

11

10

20

22

21

HCW31BMF000301
12 8
6A – 18 ENGINE MECHANICAL

31 26 30 25 24

36

38

37

34
32 27 33 28 29 35

HCW31BMF000401

Removal Steps Removal Steps

1. Air breather hose 21. Oil pipe for air compressor
2. Cooling fan guide 22. Air compressor assembly
3. Cooling fan 23. Intake manifold
4. Generator drive belt 24. Intake pipe
5. Generator 25. Intake duct
6. Power steering oil pipe 26. Exhaust brake assembly
7. Power steering oil pump 27. Oil pipe for turbocharger
8. Starter motor 28. Oil return pipe for turbocharger
9. Water charge pipe 29. Water pipe for turbocharger
10. EGR system 30. Turbocharger assembly
11. Intake pipe 31. Exhaust manifold
12. Oil level guide tube 32. Main oil filter assembly
13. Fuel pipes 33. Partial oil filter assembly
14. Fuel filter 34. Heater hose and pipe
15. Fuel pipes 35. Water intake pipe
16. Injection pipes 36. Thermostat housing
17. Common rail assembly 37. Water pump assembly
18. Supply pump assembly 38. Oil cooler assembly
19. Supply pump bracket
20. Water hose and pipe for air
compressor
 ENGINE MECHANICAL 6A – 19

Removal Steps
1. Air Breather Hose
2. Cooling Fan Guide
3. Cooling Fan
4. Generator Drive Belt
5. Generator

6. Power Steering Oil Pipe

7. Power Steering Oil Pump

8. Starter Motor
9. Water Charge Pipe

10. EGR System

Refer to section “Exhaust Gas Recirculation System
(EGR)” Removal.

032H100002
6A – 20 ENGINE MECHANICAL

11. Intake Pipe

12. Oil Level Guide Tube
13. Fuel Pipes

2
1

3
6

HCW31BSF000101

1 Fuel leak off pipe: from injector

2 Fuel return pipe: from fuel filter
3 Fuel pipe: fuel feed pump to fuel filter
4 Fuel pipe: fuel filter to supply pump
5 Fuel return pipe
6 Fuel feed pipe

14. Fuel Filter

15. Fuel Pipes

Injection pipe 1 ∼ 6
16. Injection Pipes with Clips

1 2 3 4 5 6

HCW31BSH001901

17. Common Rail Assembly

Common rail

HCW31BSH001201
 ENGINE MECHANICAL 6A – 21

18. Supply Pump Assembly

Supply pump bracket Remove the oil pipes.
O-ring 19. Supply Pump Bracket
CAUTION:
• If the foreign materials enter into the common rail
system, can cause trouble of the engine. Be careful
not to enter the foreign materials even if it is very
small.
Bracket

HCW31BSH001701

Water pipe
20. Water Hose and Pipe for Air Compressor
21. Oil Pipe for Air Compressor
22. Air Compressor Assembly
Note:
Plug the air compressor ports to prevent the entry of
foreign material. Store the air compressor in an
upright position on a flat surface.

Air compressor
HCW31BSH001301

23. Intake Manifold

HCW31BSH002601

24. Intake Pipe

25. Intake Duct
26. Exhaust Brake Assembly

Exhaust brake
HCW31BSH001401
6A – 22 ENGINE MECHANICAL

27. Oil pipe for Turbocharger

1
28. Oil Return Pipe for Turbocharger
29. Water Pipe for Turbocharger

3
HCW31BSH001501

30. Turbocharger Assembly

Note:
Plug the turbocharger body oil ports to prevent the
entry of foreign material.
Gasket

HCW31BSH001501

31. Exhaust Manifold

32. Main Oil Filter Assembly

33. Partial Oil Filter Assembly

Main oil filter Partial oil filter

050H100013

34. Heater Hose and Pipe

 ENGINE MECHANICAL 6A – 23

35. Water Intake Pipe

36. Thermostat Housing
37. Water Pump Assembly

38. Oil Cooler Assembly

Install the two oil cooler fixing bolts to the oil cooler
puller bolt holes as shown in the illustration, and
tighten the bolts alternate a little at a time.

Puller bolt hole

HCW31BSH000201
6A – 24 ENGINE MECHANICAL

INSTALLATION

14 15
9
8
13

10 4
7 12 6 11
HCW31BMF001101

30
16

28

29

19

17

18

27 31
HCW31BMF001001
 ENGINE MECHANICAL 6A – 25

22 38
25

23

34 24

26

36

37

35
20 21
32 33

HCW31BMF000901

Installation Steps Removal Steps

1. Oil cooler assembly 20. Supply pump bracket
2. Water pump assembly 21. Supply pump assembly
3. Thermostat housing 22. Common rail
4. Water intake pipe 23. Injection pipes
5. Heater hose and pipe 24. Fuel pipes
6. Partial oil filter assembly 25. Fuel filter
7. Main oil filter assembly 26. Fuel pipes
8. Exhaust manifold 27. Oil level guide tube
9. Turbocharger assembly 28. Intake pipe
10. Water pipe for turbocharger 29. EGR system
11. Oil return pipe for turbocharger 30. Water charge pipe
12. Oil pipe for turbocharger 31. Starter motor
13. Exhaust brake assembly 32. Power steering oil pump
14. Intake duct 33. Power steering oil pipe
15. Intake pipe 34. Generator
16. Intake manifold 35. Generator drive belt
17. Air compressor assembly 36. Cooling fan
18. Oil pipe for air compressor 37. Cooling fan guide
19. Water hose and pipe for air 38. Air breather hose
compressor
6A – 26 ENGINE MECHANICAL

Installation Steps
1. Oil Cooler Assembly
O-ring
1) Install O-ring shown in the illustration.
2) Install the oil cooler assembly to cylinder body
with tighten bolts specified torque.
Tightening order shown in the illustration.
Cooler Bolt Torque N·m(kg·m/lb·ft)
43.2 ( 4.4 / 31.8 )

3) Install the water drain pipe and tighten connector

“A”.
050HW001

Water Drain Connector Torque N·m(kg·m/lb·ft)

78.5 ( 8.0 / 57.9 )

4) Tighten nipple “C” to specified torque.

Nipple Torque N·m(kg·m/lb·ft)
3.9 ( 0.4 / 2.9 )

Cover Oil cooler 5) Add the insulator to the illustration.

Front

HCW31BSH001001

6) Add the insulator to the illustration.

Front

Cover

HCW31BSH001901

2. Water Pump Assembly

1) Install O-ring.
2) First tighten bolt in the oil cooler side then tighten
bolt in the gear case side.
Water Pump Bolt Torque N·m(kg·m/lb·ft)
39.2 ( 4.0 / 28.9 )
O-ring

O-ring Water pump

HCW31BSH000801
 ENGINE MECHANICAL 6A – 27

3. Thermostat Housing
1) Install thermostat to the oil cooler assembly.
Thermostat 2) Tighten bolts to specified torque.
Thermostat Bolt Torque N·m(kg·m/lb·ft)
housing
39.2 ( 4.0 / 28.9 )

HCW31BSH002701

3) Add the insulator to the illustration.

Oil cooler
Insulator
HCW31BSH000301

4. Water Intake Pipe

5. Heater Hose and Pipe

6. Partial Oil Filter Assembly

Bracket
Bolt Torque N·m(kg·m/lb·ft)
A 43 ( 4.4 / 31.8 )

7. Main Oil Filter Assembly

A Bolt Torque N·m(kg·m/lb·ft)
B 43 ( 4.4 / 31.8 )
Partial oil filter
Main oil filter C 50 ( 5.1 / 36.9 )
C B
HCW31BSH000101

8. Exhaust Manifold
A B Install the exhaust manifold assembly and tighten nut
to specified torque.
Exhaust manifold nut torque N·m(kg·m/lb·ft)
5 37.3 ( 3.8 / 27.5 )
3 1 4 2 6

Indicator

027H100005
6A – 28 ENGINE MECHANICAL

9. Turbocharger Assembly
Install the turbocharger, tighten nut to specified
torque.
Turbocharger Nut Torque N·m(kg·m/lb·ft)
Gasket 40.2 ( 4.1 / 29.7 )

HCW31BSH001601

10. Water Pipe for Turbocharger

Water Pipe Bolt Torque N·m(kg·m/lb·ft)
41.2 (4.2 / 30.4)
Water return
pipe

Water feed pipe

037H100005

11. Oil Return Pipe for Turbocharger

Oil return pipe
Tightening Torque N·m(kg·m/lb·ft)
Oil feed pipe Turbocharger side 39.2 ( 4.0 / 28.9 )
Cylinder body side 34.3 ( 3.5 / 25.3 )

12. Oil Pipe for Turbocharger

Tightening Torque N·m(kg·m/lb·ft)
Turbocharger side 39.2 ( 4.0 / 28.9 )
037H100004
Cylinder body side 39.2 ( 4.0 / 28.9 )

13. Exhaust Brake Assembly

Exhaust brake

155H100004
 ENGINE MECHANICAL 6A – 29

14. Intake Duct

Intake pipe 1) Install the intake duct to turbocharger with intake
duct rubber hose.
2) Tighten bolts to specified torque.
Bolt Torque N·m(kg·m/lb·ft)
Intake duct 39.2 ( 4.0 / 28.9 )
Rubber
hose
15. Intake Pipe
Intake Pipe Bolt Torque N·m(kg·m/lb·ft)
037H100006

39.2 ( 4.0 / 28.9 )

16. Intake Manifold

Install the rubber boot and spring.
Intake Manifold Bolt Torque N·m(kg·m/lb·ft)
19.6 ( 2.0 / 14.5 )

HCW31BSH002601

17. Air Compressor Assembly

Flywheel
Housing
1) Align the flywheel “T/C” mark with the flywheel
housing pointer by rotating the crankshaft
clockwise.
Front T
C
In this position indicate T.D.C. of No. 1 piston.
2) Install O-ring to air compressor assembly.

020H100008

3) Align the “A” mark on the coupling with the air

compressor body pointer.
4) Install the air compressor to timing gear case.
5) Check alignment mark “S” with the air compressor
body pointer after install the air compressor to
timing gear case.
6) Tighten air compressor bolts to specified torque.
Air Compressor Bolt Torque N·m(kg·m/lb·ft)
133.4 ( 13.6 / 98.4 )
6A – 30 ENGINE MECHANICAL

Water pipe 18. Oil Pipe for Air Compressor

19. Water Pipe and Air Pipe for Air Compressor
Tighten water pipe to specified torque.
Water Pipe Torque N·m(kg·m/lb·ft)
41.2 ( 4.2 / 30.4 )

Air compressor
HCW31BSH001301

Bracket Air Pipe for Air Compressor

Air pipe Nut
Tighten air pipe to specified toruqe.
Air Pipe Torque N·m(kg·m/lb·ft)
M24 (0.945 in) 147 (15.0 / 108.5)
Washer M14 (0.551 in) 41.1 (4.2 / 30.4)

Note:
Air pipe
When tightening the nut, clamp the pipe with an
adjustable wrench to prevent it from turning.
038H100005

20. Supply Pump Bracket

Supply pump bracket 1) Install O-rings shown in the illustration.
O-ring 2) Install the supply pump bracket with fuel pipe
bracket to cylinder body.
Tighten fitting bolt to specified torque.
Fitting Bolt Torque N·m(kg·m/lb·ft)
107.9 (11 / 79.6 )
Bracket

HCW31BSH001701

21. Supply Pump Assembly

Flywheel
Housing
1) Rotate the crankshaft in the normal direction of
rotation to bring the piston in the No. 1 cylinder to
top-dead-center (TDC) on the compression stroke.
Front T Align the T/C timing mark on the flywheel with the
C
timing pointer.
2) Check the camshaft timing marks to be sure that
the No. 1 cylinder is at TDC on the compression
stroke.
Injection Timing (BTDC) deg
020H100008

3) Check the valve clearances.

4) Be sure that the coupling is moved toward the air
compressor.
 ENGINE MECHANICAL 6A – 31

5) Align the supply pump timing marks with the

pointer (pump body).
6) Install the supply pump on the bracket.
7) Tighten the supply pump bolts to the specified
torque using the diagonal tightening method (one
corner followed by the diagonally opposite corner).
Supply Pump Bolt Torque N·m(kg·m / lb·ft)
31 (3.2 / 23)

Do not overtighten the bolts.

Dowel pin

4 2
1 3

HCW31BMH000101

Adjusting bolt 8) Slide the coupling on to the supply pump.

9) Fit the coupling tightly to the pump.
10) Tighten the coupling bolts to the specified torque.
Coupling Bolt Torque N·m(kg·m / lb·ft)
61 (6.2 / 45)

11) Check that the laminated portion of the coupling is

not bent or cracked.
Cotter bolt Coupling bolt 12) Tighten the cotter bolt to the specified torque.
HCW31BSH002001
Cotter Bolt Torque N·m(kg·m / lb·ft)
91 (9.3 / 67)

• Bolt tightening torque is very important. Loose

bolts (insufficient tightening torque) will cause the
coupling to slip.
• Fuel injection timing must be checked following
coupling installation.

22. Common rail

Tighten the bolts to the specified torque (installed
together with the intake manifold bracket).
Common rail Common Rail and Bracket Bolt Torque N·m(kg·m / lb·ft)
22 (2.2 / 16)

The sensor and connector are fragile. Be careful not to

damage them .

HCW31BSH001201
6A – 32 ENGINE MECHANICAL

23. Injection Pipes

Injection pipe 1 ∼ 6
Tighten the injection pipe sleeve nuts to the specified
torque.
Injection Pipe Sleeve Nut Torque N·m(kg·m / lb·ft)
1 2 3 4 5 6
44 (4.5 / 33)

HCW31BSH001901

24. Fuel Pipes

1) Install the clips to their specified positions.
2) Tighten the fuel pipe sleeve nuts to the specified
c b torque.
a
d Fuel Pipe Sleeve Nut Torque N·m(kg·m / lb·ft)
Common rail side 54 (5.5 / 40)
Supply pump side 44 (4.5 / 33)

If the clip rubber is cracked, do not reuse the clips.

042HY00138
Replace them with new ones.

25. Fuel Filter

C
B Install the fuel filter with bracket to intake manifold.
Fuel Filter Bracket Bolt Torque N·m(kg·m / lb·ft)
D
39 (4.0 / 29)

A
041HY00008
 ENGINE MECHANICAL 6A – 33

26. Fuel Pipes

2
1

3
6

HCW31BSF000101

1 Fuel leak off pipe: from injector

2 Fuel return pipe: from fuel filter
3 Fuel pipe: fuel feed pump tofuel filter
4 Fuel pipe: fuel filter to supply pump
5 Fuel return pipe
6 Fuel feed pipe

Install the clips to their specified positions.

Fuel Pipe Joint Bolt Torque N·m(kg·m / lb·ft)
M8 15 ( 1.5 / 10.8 )
M10 27 ( 2.8 / 20.3)
M12 34 ( 3.5 / 25.3 )
M14 41 ( 4.2 / 30.4)

CAUTION:
If the clip rubber is cracked, do not reuse the clips.
Replace them with new ones.

27. Oil Level Guide Tube

Guide Tube Sleeve Nut and
Bolt Torque N·m(kg·m/lb·ft)
2 1 88 ( 9.0 / 65)
3
2, 3 49 ( 5.0 / 36.2)
Oil level
guide tube
1

HCW31BSH000501
6A – 34 ENGINE MECHANICAL

28. Intake Pipe

Install the intake pipe with gasket to the intake
manifold.
Intake Pipe Bolt Torque N·m(kg·m / lb·ft)
Gasket 39 (4.0 / 29)

Boost
sensor
F

Intake pipe

HCW31BMH000201

29. EGR System

Refer to section “Exhaust Gas Recirculation System
(EGR)” Install.
30. Water Charge Pipe

31. Starter Motor

Tighten to specified torque.
Tightening Torque N·m(kg·m/lb·ft)
103.0 ( 10.5 / 75.9 )

32. Power Steering Oil Pump

1) Install the o-ring with grease.
2) Tighten to specified torque.
Tightening Torque N·m(kg·m/lb·ft)
38.3 ( 3.9 / 28.2 )
 ENGINE MECHANICAL 6A – 35

33. Power Steering Oil Pipe

Tighten to specified torque as follows.
Tightening Torque N·m(kg·m/lb·ft)
Eye bolt 57.9 ( 5.9 / 42.7 )
Union nut 88.3 ( 9.0 / 65.1 )

34. Generator
35. Generator Drive Belt
1) Adjust the generator drive belt tension.
Drive Belt Tension mm (in)
11 – 13 (0.43 – 0.51)

36. Cooling Fan

37. Cooling Fan Guide

38. Air Breather Hose

6A – 36 ENGINE MECHANICAL

EXHAUST GAS RECIRCULATION SYSTEM (EGR)

REMOVAL

9
4
11
12

10
5 Front

2
8
7
3

HCW31BMF001401

Removal Steps Removal Steps

1. Water pipe (out) 7. EGR valve (rear side)
2. Water pipe (out) 8. EGR pipe (front side)
3. Water pipe (in) 9. EGR valve (front side)
4. Water pipe 10. Gas cooler (rear side)
5. Water pipe 11. Gas cooler (front side)
6. EGR pipe (rear side) 12. Gas reed valve
 ENGINE MECHANICAL 6A – 37

Removal Steps
1. Water Pipe (out)
2. Water Pipe (out)
3. Water Pipe (in)
4. Water Pipe
5. Water Pipe

032H100002

6. EGR Pipe (Rear side)

HCW31BSH003001

7. EGR Pipe (Front side)

057HY00009

8. EGR Valve (Rear side)

Gas reed valve
9. EGR Valve (Front side)
10. Gas Cooler (Rear side)
11. Gas Cooler (Front side)
12. Gas Reed Valve

Gas cooler
EGR valve

025H100008
6A – 38 ENGINE MECHANICAL

INSTALLATION

4
9
2
1

3
8 Front

11
5
6
10

12

HCW31BMF001501

Installation Steps Removal Steps

1. Gas reed valve 7. EGR pipe (rear side)
2. Gas cooler (front side) 8. Water pipe
3. Gas cooler (rear side) 9. Water pipe
4. EGR valve (front side) 10. Water pipe (in)
5. EGR pipe (front side) 11. Water pipe (out)
6. EGR valve (rear side) 12. Water pipe (out)
 ENGINE MECHANICAL 6A – 39

Installation Steps
1. Gas Reed Valve
Reed valve
1) Install the gas reed valves to the intake manifold.
Mark 2) Tighten the bolts to specified torque.
Gas Reed Valve Bolt Torque N·m(kg·m/lb·ft)
9.8 (1.0 / 7.2)

Duct
3) Install the EGR ducts to the intake manifold.
4) Tighten the bolts to specified torque.
EGR Duct Bolt Torque N·m(kg·m/lb·ft)
F06H100019 39.2 (4.0 / 29)

2. Gas Cooler (front side)

3. Gas Cooler (rear side)
Tightning order shown in the illustration.
2 Cooler Bolt Torque N·m(kg·m/lb·ft)
39.2 (4.0 / 29)
1

F06H100021

Front Mark
4. EGR Valve (front side)
Rear Side
Locate the F mark on the EGR valve (the valve was
Rear Mark previously installed to the front side). Temporarily
tighten the EGR valve with the F mark facing up.

Front Side
057H100006

5. EGR Pipe (front side)

Temporarily tighten the EGR pipe bolts (refer to the
illustration). Use the flange holes to adjust front-to-
rear, left-to-right, and top-to-bottom position. Do not
apply excessive force to the pipe.

057HY00009
 ;;;
6A – 40 ENGINE MECHANICAL

Tighten the EGR pipe bolts to the specified temporary

Gasket Distance tube
torque.
Washer

;;;
N·m(kg·m/lb·ft)
4.9 (0.5 / 3.6)

Bolt

Washer
057H100005

Tighten the EGR pipe bolts to their final specified

2 torque in the following order.
1 3 bolts connecting the EGR valve to the EGR pipe.
2 2 EGR bolts.
1 3 3 bolts connecting the EGR pipe to the exhaust
manifold.
3 EGR Pipe and EGR Pipe Bolt Torque N·m(kg·m/lb·ft)
37.5 (3.8 / 27.5)

057HX00010

6. EGR Valve (rear side)

7. EGR Pipe (rear side)
The installation procedure for the rear side EGR pipe
and EGR valve is identical to that for the front side
EGR pipe and EGR valve.

HCW31BSH003001

Note:
2
Temporary tightening of the EGR bolts followed by
sequential final tightening reduces static stress.

HCW31BSH003101

8. Water Pipe
9. Water Pipe
10. Water Pipe (in)
11. Water Pipe (out)
12. Water Pipe (out)

032H100002
 ENGINE MECHANICAL 6A – 41

CYLINDER HEAD AND VALVE MECHANISM

REMOVAL

5
2

10

9
11

12
13

14

011HY00126
6A – 42 ENGINE MECHANICAL

Removal Steps Removal Steps

1. Cylinder head cover 8. Rocker arm assembly
2. Gasket 9. Bridge
3. Injector harness 10. Camshaft assembly
4. Leak off pipe 11. Injector assembly and clamp
5. Harness connector 12. Idler gear C and shaft
6. Lower cover 13. Cylinder head assembly
7. Gasket 14. Cylinder head gasket

Removal Steps
1. Cylinder Head Cover
2. Gasket
3. Injector Harness
Ft Leak off pipe 4. Leak Off Pipe
5. Harness Connector

Connector
HCW31BSH002201

6. Lower Cover
7. Gasket

010HY00037

8. Rocker Arm Assembly

Loosen the rocker arm shaft bracket bolts from both
outside bolt.

011HX00014
 ENGINE MECHANICAL 6A – 43

9. Bridge

10. Camshaft
Use feeler gauge to measure the camshaft end play
Camshaft End Play mm(in)
Standard Limit
0.085 – 0.170 ( 0.0033 – 0.0067 ) 0.25 (0.0098)

11. Injector Assembly and Clamp

Note:
Take care not to damage the Injector tips during
injector assembly removal.

011HY00123

12. Idler Gear "C" and Shaft

Use feeler gauge to measure the idler gear “C” end
play.
Idler “C” End Play mm(in)
Standard Limit
0.05 – 0.14 ( 0.0020 – 0.0055 ) 0.25(0.0098)
6A – 44 ENGINE MECHANICAL

B 16 8
1 9 17 24
23 15 7

2 10 18 25
22 14 6

26
3 11 19
C 21 13 5
4 12 20

011H100013

13. Cylinder Head Assembly

First loosen the bolts B – C – D.
Loosen the cylinder head bolts a little at a time in the
numerical order shown in the illustration.
Note:
Failure to loosen the cylinder bolts in numerical order
a little at a time will adversely affect the cylinder head
lower surface.
14. Cylinder Head Gasket
 ENGINE MECHANICAL 6A – 45

INSTALLATION

12

14

11

10
13

6
4

3
2

011HY00127
6A – 46 ENGINE MECHANICAL

Installation Steps Removal Steps

1. Cylinder head gasket 8. Gasket
2. Cylinder head assembly 9. Lower cover
3. Idler gear C and shaft 10. Harness connector
4. Injector assembly and clamp 11. Leak off pipe
5. Camshaft assembly 12. Injector harness
6. Bridge 13. Gasket
7. Rocker arm assembly 14. Cylinder head cover

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

2) Apply Loctite FMD127 or equivalent to the cylinder

body and the timing gear case fitting faces.
The liquid gasket must be 1.0 – 2.0mm
FMD-127 (0.04 – 0.08 in) thick and 5.0mm
(0.20 in) wide.
The liquid gasket must not obstruct the cylinder oil
011HY00026
port.
3) Install the cylinder head gasket to the cylinder
body.
The part number (indicated by arrow in the
illustration) must be facing up.

2. Cylinder Head Assembly

1) Align the cylinder body dowel pins and the cylinder
head dowel holes.
Carefully place the cylinder head on the cylinder
head gasket.
 ENGINE MECHANICAL 6A – 47

M12

M10

011H100014

2) Apply molybdenum disulfide grease to the cylinder

head bolts (M18) threads and setting faces.
3) Apply engine oil to the cylinder head bolts (M10
and M12) threads and setting faces.
4) Tighten the M18 cylinder head bolts in three steps
using the angular tightening method.
Follow the tightening order shown in the
illustration.

5) Tighten the M10 and M12 cylinder head bolts to

the specified torque.
Cylinder Head Bolt Torque N·m (kg·m / lb·ft)
Bolt size 1st 2nd Step 3rd Step
176.6 245.3
M18 60 – 90 deg
(18/130) (25/181)
M12 97.1 (9.9 / 71.6)
M10 39.2 (4.0 / 28.9)

NOTE:
1. The cylinder head bolts can be used four(4) times.
2. Cover the timing gear hole by cloth for prevent
into foreign materials.

3. Idler Gear “C” and Shaft

1) Apply engine oil to idler gear “C” shaft bolts.
2) Tighten idler gear “C” shaft bolt to the specified
torque.
Idler Gear “C” Shaft Bolt Torque N·m(kg·m/lb·ft)
39.2 ( 4.0 / 28.9 )

011HY00135
6A – 48 ENGINE MECHANICAL

4. Injector Assembly and Clamp

1) Install the gasket to the injector (the larger side of
the chamfered edge must be facing up).
2) Install the injector and gasket to the engine
through the cylinder head.
3) Temporarily tighten injection pipe sleeve nut.
4) Tighten the injector clamp bolt to the specified
torque.
Injector Clamp Bolt Torque N·m(kg·m/lb·ft)
040HY00099 49.0 (5.0 / 36.2)

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

44 (4.5 / 33)

5. Camshaft Assembly
Flywheel
Housing
1) Align the flywheel TDC mark with the pointer by
rotating the crankshaft normal direction. Same
time check alignment timing mark on injection
Front T pump for No.1 piston TDC.
C

020H100008

2) Apply engine oil to the camshaft bearing sliding

surfaces before installing the camshaft assembly.
3) Install the camshaft assembly to the cylinder head.
4) Carefully align the camshaft gear hole mark (1) and
pointer on the cylinder head shown in the
illustration.

014HY00070
 ENGINE MECHANICAL 6A – 49

5) Install the camshaft with the lower cover in place.

• Align the punch marks (2) on the camshaft gear
with the upper surface of the lower cover. Refer
to the illustration.

Punched
mark

Camshaft gear

Lower cover

HCW31BMH000301

6) Apply engine oil to the camshaft bearing sliding

surfaces.
7) Install the camshaft bearing caps to use same
stamped mark.
8) Apply engine oil to thread and tighten to specified
torque.
Camshaft Bearing Cap Nut Torque N·m(kg·m/lb·ft)
75.5 ( 7.7 / 55.7 )

6. Bridge
1) Loosen adjusting screw.
2) Apply engine oil on the bridge guide.
3) Install the bridge, the adjusting screw facing to the
intake manifold side.

011HY00118
6A – 50 ENGINE MECHANICAL

7. Rocker Arm Assembly

1) Completely loosen the adjusting screw.
2) Apply engine oil to the tip of the adjusting screw
and the roller.
3) Install the rocker arm assembly.

011HX00014

4) Temporarily tighten the bolts in the order shown in

the illustration.
5) Final tighten the bolts to the specified torque in the
order shown in the illustration.
Rocker Arm Bolt Torque N·m(kg·m/lb·ft)
90 ( 9.2 / 67 )

6) Adjust the valve clearances. Follow the procedure

described in Chapter 00 of this Manual.

8. Gasket
Loctite FMD127
9. Lower Cover
1) Carefully clean the upper surface of the cylinder
head.
2) Apply liquid gasket to the contact surfaces of the
cylinder head and timing gear case.
Gasket thickness is 1 ~ 2 mm. Gasket width is
approximately 5 mm.

HCW31BSH002010

▲ 3) Press the gasket into the cylinder head cover

groove.
▲
4) Tighten the bolts to the specified torque.
▲ Lower Cover Bolt Torque N·m(kg·m/lb·ft)
▲
15 ( 1.5 / 11 )
▲
▲ Loctite No. FMD127
▲ ▲
Ft
010HY00040

10. Harness Connector

1) Place the O-ring on the harness connector.
2) Install the harness connector to the cylinder head
lower cover and tighten the bolt to the specified
torque.
O-ring Connector Bolt Torque N·m(kg·m/lb·ft)
Connector 20 ( 2.0 / 14 )

Ft
HCW31BSH002501
 ENGINE MECHANICAL 6A – 51

11. Leak Off Pipe

Ft Leak off pipe
1) Install the adapter to the rear of the lower cover.
2) Install the nozzle leak-off pipe to the fuel injector
and tighten the bolts to the specified torque.
Bolt Tightening Torque N·m(kg·m/lb·ft)
Adapter 20 ( 2.0 / 14 )
Eye bolt 15 ( 1.5 / 11 )

Connector
HCW31BSH002201

12. Injector Harness

1) Install the harness side connectors (2) to the lower
cover. A distinct clicking sound should be heard
when the connectors are pressed into place.
2) Install the injector harness bracket to the lower
cover and tighten the bolts to the specified torque.
Nut
Injector Harness Bracket Bolt Torque N·m(kg·m/lb·ft)
22 ( 2.2 / 16 )

HCW31BSH002301

Harness 3) Attach the harness terminal to the top of the

injector.
4) Tighten the fixing nuts to the specified torque.
Fixing Nut Torque N·m(kg·m/lb·ft)
2 ( 0.2 / 1.4 )

Note:
Do not overtighten the terminal nuts (the TWV thread
Injector area will be damaged.)
HCW31BSH002401

13. Gasket
14. Cylinder Head Cover
9 10 11 12 13 1 14 15 16
1) Press the head cover gasket into place.
2) Install the head cover.
8
17 3) Tighten the bolts to the specified torque in the
7 order shown in the illustration.
18
6 5 4 3 2 20 19 Cylinder Head Cover Bolt Torque N·m(kg·m/lb·ft)
15 ( 1.5 / 11 )

010HY00038
6A – 52 ENGINE MECHANICAL

DISASSEMBLY

14
15

16
10 12
18
19
9
20

23
11
13
24

21
13

5 22
4

17

7
3 2
6

HCW31BLF000201

Disassembly Steps Removal Steps

1. Glow plug connector 13. Seal rings
2. Glow plug 14. Split collar
3. Thermometer unit 15. Spring upper seat
4. Gear case 16. Valve spring
5. O-ring 17. Valve
6. Shaft idler gear “C” 18. Valve stem seal
7. Idler gear “C” 19. Spring lower seat
8. Intake manifold assembly 20. Valve guide
9. Bracket 21. Bridge guide
10. Exhaust pipe bracket 22. Valve seat insert
11. Engine hanger 23. Fuel injector sleeve
12. Exhaust manifold assembly 24. O-ring
 ENGINE MECHANICAL 6A – 53

Disassembly Steps
1. Glow Plug Connector
2. Glow Plug
3. Thermometer Unit
4. Gear Case
5. O-ring
6. Shaft Idler Gear “C”
Measure end play between cylinder head and idler
gear “C”.
Idler Gear “C” End Play mm(in)
Standard Limit
0.05 – 0.14 (0.0020 – 0.0055) 0.25 (0.0098)

7. Idler Gear “C”

1) Disassemble shaft idler gear “C”.
2) Disassemble idler gear “C”.
8. Intake Manifold Assembly
9. Bracket
10. Exhaust Pipe Bracket
11. Engine Hanger
12. Exhaust Manifold Assembly
13. Seal Rings
011HY00135

14. Split Collar

1) Place the cylinder head on a flat wooden surface.
2) Use the valve spring compressor to remove the
split collar.
Do not allow the valve to fall from the cylinder head.
Valve Spring Compressor: 1-8523-5013-0
15. Spring Upper Seat
16. Valve Spring

17. Valve
If the intake and exhaust valves are to be reinstalled,
mark their installation position by tagging each valve
with the cylinder number from which it was removed.
If the intake and exhaust valves are to be replaced, the
valve guides must also be replaced.
18. Valve Stem Seal
19. Spring Lower Seat
6A – 54 ENGINE MECHANICAL

20. Valve Guide

Use valve guide remover to remove the valve guide.
Valve Guide Remover: 9-8523-1202-0

21. Bridge Guide

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

22. Valve Seat Insert

1) Heat up (about 600 – 700 °C) two point on the valve
seat insert by gas torch, allow the valve seat insert
to cool for few minutes.
2) This will invite contraction and make removal of
the valve seat insert easier.
3) Use screwdriver to pry the valve seat insert free.
Take care not to damage the cylinder head.
4) Carefully remove carbon and other foreign
011HV035
materials from the cylinder head insert bore.

23. Fuel Injector Sleeve

Use suitable size brass bar to hit fuel injector sleeve
from lower side cylinder head.
24. O-ring
 ENGINE MECHANICAL 6A – 55

INSPECTION AND REPAIR

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

Bridge
Inspect any cracking, damage on bridge and inspect
any separation wear out and damage on the surface
of bridge.

Clearance between camshaft and bracket

Measure clearance between camshaft and it bracket.
Clearance mm (in)
Standard Limit
0.065 – 0.125 (0.0026 – 0.0049) 0.15 (0.0059)

Shaft Idler Gear “C” and Idler Gear “C”

Measure the outside diameter of shaft idler gear “C”.
Outside Diameter Shaft Idler Gear “C” mm (in)
Standard Limit
48.93 – 48.96 (1.9264 – 1.9286) 48.85 (1.9232)

Measure the clearance between shaft and idler gear

“C”.
Clearance mm (in)
Standard Limit
0.04 – 0.105 (0.0016 – 0.0041) 0.2 (0.0079)

Valve Spring Free Height

Use a vernier caliper to measure the valve spring free
height.
If the measured value is less than the specified limit,
the valve spring must be replaced.
Valve Spring Free Height mm (in)
Standard Limit
Intake 79.3 (3.1220) 75.3 (2.965)
Outer
Exh. 102.7 (4.0433) 97.6 (3.0843)
Intake – –
Inner
Exh. 96.4 (3.07953) 91.7 (3.06102)
6A – 56 ENGINE MECHANICAL

Valve Spring Squareness

Use a surface plate and a square to measure the valve
spring squareness.
If the measured value exceeds the specified limit, the
valve spring must be replaced.
Valve Spring Squareness mm (in)
Standard Limit
Intake 3.5 (0.1378) 4.8 (0.1890)
Outer 4.5 (0.1772) 6.2 (0.2441)
Exh.
Inner 4.2 (0.1654) 5.9 (0.2323)

Valve Spring Tension

Use spring tester to measure the valve spring tension.
If the measured value is less than the specified limit,
the valve spring must be replaced.
Valve Spring Tension N (kg/lb)/mm
Standard Limit
Intake 392.3 (40.0/88.2)/64 294.2 (38.0/83.8)/64
Outer
Exh. 610.0 (62.2/137.2)/69 578.6 (59.0/130.1)/69
011LX026
Intake – –
Inner
Exh. 223.6 (22.8/50.3)/66 212.8 (21.7/47.8)/66

Valve Stem and Valve Guide Clearance

1. Set the dial indicator to the valve stem measuring
point.
2. Move the valve stem end from side to side.
Read the dial indicator.
Note the total indicator reading.
If the measured values exceed the specified limit,
the valve and the valve guide must be replaced as
a set.
Valve Stem and Valve Guide Clearance mm (in)
Standard Limit
0.040 – 0.077
Intake 0.15 (0.0059)
(0.0016 – 0.0030)
0.065 – 0.102
Outlet 0.25 (0.0098)
(0.0026 – 0.0040)

Valve Stem Outside Diameter

Measure the valve stem diameter at three points.
If the measured value is less than the specified limit,
the valve and the valve guide must be replaced as a
set.
Valve Stem Outside Diameter mm (in)
Standard Limit
Intake 10.0 (0.3937) 9.92 (0.3906)
011HY00007 Outlet 10.0 (0.3937) 9.90 (0.3898)
 ENGINE MECHANICAL 6A – 57

Bridge Guide and Bridge Clearance

1. Use a caliper calibrator or a telescoping gauge to
measure the valve bridge 1 inside diameter.
2. Calculate the difference between the valve bridge
inside diameter and the valve bridge guide 2
outside diameter.
If the clearance exceeds the specified limit, the
valve bridge must be replaced.
Bridge Guide and Bridge Clearance mm (in)
Standard Limit
0.020 – 0.057 ( 0.0080 – 0.0022 ) 0.10 (0.0039)

Valve Thickness and Depression

1. Measure the valve thickness.
If the measured value is less than the specified
limit, the valve and the valve seat insert must be
replaced as a set.
Valve Thickness mm(in)
Standard Limit
Intake 2.14 (0.0843) 1.64 (0.0646)
011LX032 Exh 2.3 (0.0906) 1.8 (0.0709)

2. Install the new valve 1 to the cylinder head 2.

3. Use a depth gauge or a straight edge with steel
rule to measure the valve depression from the
cylinder head lower surface.
If the measured value exceeds the specified limit,
the valve seat insert and/or the valve must be
replaced.
Valve Depression mm (in)
Standard Limit
Intake 1.9 (0.0748) 2.9 (0.1142)
Exh 1.8 (0.0709) 2.8 (0.1102)

Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness.
Make smooth the valve contact surfaces.
2. Measure the valve contact width.
If the measured value exceeds the specified limit,
the valve seat insert must be corrected or replaced.
Valve Contact Width mm (in)
Standard Limit
Intake 3.0 (0.1181) 3.4 (0.1339)
Exh 2.5 (0.0984) 2.9 (0.1141)
6A – 58 ENGINE MECHANICAL

Contact Surface Angle on Valve

1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Valve Contact Surface Angle deg
Standard
Intake 30
Exh 45

150˚
Valve Seat Insert Correction
90˚
1. Remove the carbon from the valve seat insert
30˚
surface.
2. Use a valve cutter (15 deg, 45 deg, and 75 deg
blades) to minimize scratches and other rough
areas. This will bring the contact width back to
the standard value.
Remove only the scratches and rough areas. Do
not cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.
Valve Seat Angle deg
Intake 30
Exh 45

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

3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check to see if the valve contact width is correct.
7. Check to see if the valve seat insert surface is in
contact with the entire circumference of the valve.
 ENGINE MECHANICAL 6A – 59

REASSEMBLY

11
10

9
15 13
7
6
16
5

2
14
12
1

4
12

20 3
21

18
22 23
19

24

17

HCW31BLF000101

Reassembly Steps Removal Steps

1. O-ring 13. Exhaust manifold assembly
2. Fuel injector sleeve 14. Engine hanger
3. Valve seat insert 15. Exhaust pipe bracket
4. Bridge guide 16. Bracket
5. Valve guide 17. Intake manifold assembly
6. Spring lower seat 18. Idler gear “C”
7. Valve stem seal 19. Shaft idler gear “C”
8. Valve 20. O-ring
9. Valve spring 21. Gear case
10. Spring upper seat 22. Thermometer unit
11. Split collar 23. Glow plug
12. Seal rings 24. Glow plug connector
6A – 60 ENGINE MECHANICAL

REASSEMBLY STEPS
1. O-ring
2. Fuel Injector Sleeve
1) Clean the fuel injector sleeve circumference and
the cylinder head fuel injector sleeve fitting faces.
2) Apply the recommended liquid gasket (LOCTITE
TL290) or its equivalent to the fuel injector sleeve
outer circumference 1.
3) Apply engine oil to the O-ring.
4) Install the O-ring 2 to the fuel injector sleeve O-ring
groove.
5) Use a bench press to install the fuel injector sleeve.
Apply pressure to the fuel injector sleeve
gradually.
CAUTION:
Do not apply an excessive amount of pressure with
the bench press. Damage to the fuel injector sleeve
and cylinder head will result.

3. Valve Seat Insert

1) Carefully place the attachment 1 (having a smaller
outside diameter than the valve seat insert) on the
valve seat insert 2.
NOTE:
The smooth side of the attachment must contact the
valve seat insert.
2) Use a bench press 3 to gradually apply pressure
to the attachment and press the valve seat insert
into place.
CAUTION:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.
3) The valve should be lapped before final assembly
to ensure a good valve seal.
Refer to “Valve Seat Insert Correction” in this
section.

4. Bridge Guide
1) Apply engine oil to the valve bridge guide outer
circumference.
2) Attach the valve bridge guide installer 1 to the
bridge guide 2.
Valve Bridge Guide Installer: 9-8522-1324-0
3) Use a brass hammer to tap the guide into position
from the cylinder head upper face.
 ENGINE MECHANICAL 6A – 61

4) Measure the height H of the valve bridge guide

upper end from the cylinder head upper face
(cylinder head cover fitting surface).
Valve Bridge Guide Upper End Height H mm (in)
49.0 (1.9291)

5. Valve Guide
1) Apply engine oil to the valve guide outer
circumference.
2) Attach the valve guide replacer to the valve guide.
3) Use a hammer to drive the valve guide into
position from the cylinder head upper face.
Valve Guide Remover: 9-8523-1202-0
4) Measure the height of the valve guide upper end
from the upper face of the cylinder head.
Valve Guide Upper End Height H
(Reference) mm (in)
Intake Side 27.0 (1.0630)
Exhaust Side 29.0 (1.1417)

Note:
If the valve guide has been removed, both the valve
and the valve guide must be replaced as a set.
6. Spring Lower Seat
7. Valve Stem Seal
1) Apply engine oil to the oil seal inner face.
2) Use the oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: For Intake 1-8522-1187-0
For Exhaust 1-8522-1184-0

8. Valve
9. Valve Spring
Engine oil 1) Apply engine oil to each valve stem before
installation.
2) Install the intake and exhaust valves.
3) Turn the cylinder head up to install the valve
springs.
Take care not to allow the installed valves to fall
free.
011H100009
6A – 62 ENGINE MECHANICAL

4) Install the intake valve springs with their fine

pitched end facing down. (Painted yellow)
5) There are not assembly direction on both inner
and outer exhaust valve spring.

10. Spring Upper Seat

11. Split Collar
1) Use the spring compressor to compress the valve
spring.
Spring Compressor: 1-8523-5013-0
2) Install the split collars to the valve stem.
Do not allow the valve to fall from the cylinder
head.
3) Set the split collars by tapping around the head of
each collar with a rubber hammer.

12. Seal Rings

13. Exhaust Manifold Assembly
1) Check that the seal ring gaps are positioned 120
degrees apart from each other.
There is installation direction on seal ring as
illustration.
2) Install the exhaust manifold gasket. The direction
indicator must be faced lower side.
3) Install distance tube, washer and disk spring.
The convex side of disk spring must be faced to
exhaust manifold nut.
4) Tighten the exhaust manifold nut to specified
torque. Follow the tightening order shown in the
illustration.
Exh. Manifold Nut Torque N·m(kg·m/lb·ft)
37.3 ( 3.8 / 27.5 )
 ENGINE MECHANICAL 6A – 63

14. Engine Hanger

15. Exhaust Pipe Bracket
16. Bracket
A B
The bracket tightening manner as follows.
A) and C) Tighten with out washer.
B) Put the bracket on the washer tighten together with
5 exhaust manifold.
3 1 4 2 6

Indicator

027H100005

17. Intake Manifold Assembly

Install the rubber boot and spring with tightening
specified torque.
Intake Manifold Nut Torque N·m(kg·m/lb·ft)
19.7( 2.0 / 14.5 )

HCW31BSH002601

18. Idler Gear “C”

19. Shaft Idler Gear “C”
1) Apply engine oil to the shaft idler gear “C”.
2) Install with idler gear “C” to cylinder head.
3) Tighten bolts to specified torque.
Idler Gear “C” Bolt Torque N·m(kg·m/lb·ft)
39.2 ( 4.0 / 28.9 )

20. O-ring
Install O-ring to gear case.
6A – 64 ENGINE MECHANICAL

21. Gear Case

1) Apply Loctite FMD 127 or equivalent to gear case
fitting area on cylinder head shown in the
illustration.
The liquid gasket must be 0.3 mm (0.012 in) thick
and 5 mm (0.20 in) wide.
The liquid gasket must not obstruct the bolt holes
of cylinder head.
2) Tighten bolts to specified torque.
Gear Case Bolt Torque N·m(kg·m/lb·ft)
38.3 ( 3.9 / 28.2 )

22. Thermometer Unit

1) Apply Loctite FMD 127 or equivalent to thread on
thermometer unit.
2) Tighten the thermometer unit to specified torque.
Thermometer Torque N·m(kg·m/lb·ft)
19.6 ( 2.0 / 14.5 )

826HY00037

23. Glow Plug

1) Install the glow plugs into the cylinder head.
2) Tighten the glow plugs to specified torque.
Glow Plug Torque N·m(kg·m/lb·ft)
24.5 (2.5 / 18.1)

24. Glow Plug Connector

Glow Plug Connector Nut Torque N·m(kg·m/lb·ft)
1.0 (0.1 / 0.7)
 ENGINE MECHANICAL 6A – 65

ROCKER ARM AND SHAFT ASSEMBLY

DISASSEMBLY

Disassembly Steps Removal Steps

1. Bracket 4. Bracket
2. Rocker Arm 5. Rocker Arm Shaft
3. Spring
6A – 66 ENGINE MECHANICAL

Disassembly Steps
1. Rocker Arm and Shaft Assembly
1) Loosen the bolt of the rocker arm shaft bracket
from out side bolt a little at time and remove
rocker arm and shaft assembly.
2) Disassembly the bracket, rocker arm, spring,
bracket and rocker arm shaft.

011HX00014
 ENGINE MECHANICAL 6A – 67

INSPECTION AND REPAIR

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

Rocker Arm Shaft Run-Out

1. Place the rocker arm shaft on V-blocks.
2. Use a dial indicator to measure the rocker arm
shaft central portion run-out.
If the run-out is very slight, correct the rocker arm
shaft run-out with a bench press. The rocker arm
must be at cold condition.
If the measured rocker arm shaft run-out exceeds
the specified limit, the rocker arm shaft must be
014HV030 replaced.
Rocker Arm Shaft Run-Out mm (in)
Limit 0.3 (0.012)

Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting
portion outside diameter.
If the measured value is less than the specified limit,
the rocker arm shaft must be replaced.
Rocker Arm Shaft Outside Diameter mm (in)
Standard Limit
27.979 – 28.000 27.85
014H100005
(1.1015 – 1.1024) (1.0965)

Rocker Arm Bushing Inside Diameter

Use either a vernier caliper or a dial indicator to
measure the rocker arm bushing inside diameter.
Rocker Arm Bushing Inside Diameter mm (in)
Standard
28.020 – 28.053
(1.1031 – 1.1044)

Rocker Arm and Rocker Arm Shaft Clearance mm (in)

Standard Limit
0.020 – 0.074 0.2
(0.0008 – 0.0029) (0.0079)
6A – 68 ENGINE MECHANICAL

Check to see if the rocker arm and rocker arm shaft oil
port is free of obstructions.
If necessary, use compressed air to clean the rocker
arm and rocker arm shaft oil port.

Rocker Arm Roller and Rocker Arm Pin

1. Pass a string through the rocker arm-roller
clearance and measure the roller protrusion while
pulling both ends of the string in the arrow
indicated directions to push out the roller.
2. Mark the measuring point and draw out the string.
Measure the roller protrusion again while the roller
is pushed in.
3. Note the difference in the above measurements is
the standard roller rocker arm and pin clearance.
Should the clearance exceed the limit, replace the
rocker arm.
Rocker Arm Roller and Pin Clearance mm (in)
Standard Limit
0.036 – 0.069 0.5
(0.0014 – 0.0027) (0.02)
 ENGINE MECHANICAL 6A – 69

REASSEMBLY

Reassembly Steps Removal Steps

1. Rocker Arm Shaft 4. Spring
2. Bracket 5. Bracket
3. Rocker Arm
6A – 70 ENGINE MECHANICAL

Reassembly Steps
1. Rocker Arm and Shaft Assembly
1) Reassembly the bracket, spring, rocker arm and
bracket to the rocker arm shaft.
2) Apply engine oil to roller portion of the rocker arm
and thread of the adjusting screw.
3) Put the rocker arm and shaft assembly on the
cylinder head.
4) Temporary tighten the bolts of rocker arm and
011HX00014
shaft assembly to the cylinder head, sufficient
loosen the adjusting screw.
5) Tighten bolts of the rocker arm and shaft assembly
by numerical order to specified torque shown in
the illustration.
Rocker Arm Bolt Torque N·m(kg·m/lb·ft)
90.3 ( 9.2 / 66.5 )
 ENGINE MECHANICAL 6A – 71

CAMSHAFT
DISASSEMBLY

Disassembly Steps Removal Steps

1. Camshaft Gear 4. Camshaft
2. Key 5. Camshaft Bearing Lower
3. Camshaft Bearing Cap
6A – 72 ENGINE MECHANICAL

Disassembly Steps
1. Camshaft Gear
1) Check visually gear it has not damaged, it is not
necessary to disassembly gear from camshaft.
2) If it is required to disassembly gear, use the
universal puller to pull out the camshaft gear with
wooden plate for prevent make damage gear.
2. Key
3. Camshaft Bearing Cap
Loosen nuts to remove the camshaft bearing cap.
4. Camshaft
5. Camshaft Bearing Lower
 ENGINE MECHANICAL 6A – 73

INSPECTION AND REPAIR

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

Camshaft Journal Diameter

Use a micrometer to measure each camshaft journal
diameter in two directions (1 and 2). If the
measured value is less than the specified limit, the
camshaft must be replaced.
Camshaft Journal Diameter mm (in)
Standard Limit
39.915 – 39.940
39.890 (1.5705)
(1.5715 – 1.5724)

Cam Height
Measure the cam height A and B with a micrometer.
If the measured value is less than the specified limit,
the camshaft must be replaced.
Cam Height mm (in)
Standard (A-B) Limit
Intake 9.4 (0.3700) 8.85 (0.3484)
Exhaust 10.4 (0.4094) 9.75 (0.3839)

Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator on the
No. 4 camshaft journal.
If the measured value exceeds the specified limit,
the camshaft must be replaced.
Camshaft Run-Out mm (in)
Standard Limit
0.080 (0.0031) 0.100 (0.0039)

Camshaft and Camshaft Bearing Clearance

Use an inside dial indicator to measure the camshaft
bearing inside diameter.
Camshaft Bearing Inside Diameter mm (in)
Standard 40.015 – 40.040 (1.5754 – 1.5764)

If the clearance between the camshaft bearing inside

diameter and the journal exceeds the specified limit,
the camshaft bearing must be replaced.
Camshaft Bearing Clearance mm (in)
Standard Limit
0.065 – 0.125 0.15
(0.0026 – 0.0049) (0.0059)
6A – 74 ENGINE MECHANICAL

REASSEMBLY

Reassembly Steps Removal Steps

1. Camshaft Bearing Lower 4. Key
2. Camshaft 5. Camshaft Gear
3. Camshaft Bearing Cap
 ENGINE MECHANICAL 6A – 75

Reassembly Steps
1. Camshaft Bearing Lower
1) Install camshaft bearing lower to cylinder head.
2) Apply engine oil to bearing portion.
2. Camshaft
1) Put camshaft onto camshaft bearing lower.
2) Apply engine oil to journal of camshaft.
3. Camshaft Bearing Cap
1) Reassembly camshaft bearing cap on stud bolts to
use same stamped mark of bearing lower.
2) Apply engine oil to thread of stud bolt and nut
seat.
3) Tighten camshaft bearing cap nut to specified
torque.
Camshaft Bearing Cap Nut Torque N·m(kg·m/lb·ft)
75.5 ( 7.7 / 55.7 )

4. Key
5. Camshaft Gear
Install the camshaft gear with tighten bolt to specified
torque.
Camshaft Gear Bolt Torque N·m(kg·m/lb·ft)
137.4 ( 14.0 / 101.3 )
6A – 76 ENGINE MECHANICAL

OIL PAN, OIL PUMP AND TIMING GEAR

REMOVAL

Removal Steps Removal Steps

1. Oil pipe bracket 11. Spacer
2. Breather hose clip 12. Timing gear case cover
3. Oil pan 13. Gasket
4. Gasket 14. Fan center
5. Oil strainer with O-ring 15. Oil seal
6. Oil strainer bracket 16. Oil pump assembly with O-ring
7. Oiling jet assembly 17. Distance bolt
8. Fan pulley with taper bushing 18. Idler gear “A”
9. Crankshaft pulley assembly 19. Idler gear “B”
10. Oil seal 20. Timing gear case
 ENGINE MECHANICAL 6A – 77

Removal Steps
1. Oil Pipe Bracket
2. Breather Hose Clip
3. Oil Pan
4. Gasket
5. Oil Strainer with O-ring
6. Oil Strainer Bracket
7. Oiling Jet Assembly
Remove the joint bolt.
CAUTION:
Take care not to bend the oiling jet tubing.
Do not attempt to repair a damaged oiling jet.
If it has damaged to recommend to replace it with a
new one.

8. Fan Pulley with Taper Bushing

1) Block the crankshaft with a piece of hard wood to
prevent the fan pulley from turning.
2) Remove the fan pulley nut
3) Use the taper bushing remover to remove the
taper bushing.
Taper bushing remover: 1-8521-0063-0
9. Crankshaft Pulley

10. Oil Seal (Fan center)

Use screw driver into cutting on oil seal.
11. Spacer
12. Timing Gear Case Cover
13. Gasket
14. Fan Center
6A – 78 ENGINE MECHANICAL

15. Oil Seal (Crankshaft)

Take care not to make scratch on fitting surface of
timing gear case cover.
Remove slinger with slinger remover.
Slinger remover: 1-8521-0027-0

16. Oil Pump Assembly with O-ring

17. Distance Bolt
18. Idler Gear “A”
1) Before loosen the idler gear fitting bolts, measure
the backlash of idler gear “A“ and “B”.
Idler Gear Backlash mm(in)
Standard Limit
0.095 – 0.135 (0.0037 – 0.0053) 0.23 (0.0091)

2) Measure the end play of idler gear “A” and “B”

Idler Gear End Play mm(in)
Gear Standard Limit
“A” 0.165 – 0.230 (0.0065 – 0.0091) 0.35 (0.0138)
“B” 0.050 – 0.140(0.0020 – 0.0055) 0.25 (0.0098)

19. Idler Gear “B”

Make front marking on thrust plate.
20. Timing Gear Case
 ENGINE MECHANICAL 6A – 79

Inspection and Repair

1. Visually inspect the idler gear and idler gear
spindle.
If a idler gear or spindle is damaged or worn, the
part must be replaced.
2. Use micrometer to measure the idler gear spindle
outside diameter.
Spindle Outside Diameter mm(in)
Standard Limit
56.93 – 56.96 56.85
A
(2.2413 – 2.2425) (2.2382)
141.93 – 141.96 141.85
B
(5.5878 – 5.5890) (5.5846)
48.93 – 48.96 48.85
C
(1.9264 – 1.9286) (1.9232)

3. Use cylinder bore dial indicator to measure the

idler gear inside diameter.
4. Calculate clearance between idler gear and idler
gear spindle.
Clearance mm(in)
Standard Limit
Idler gear A
0.040 – 0.105 0.20
Idler gear B
(0.0016 – 0.0041) (0.0079)
Idler gear C

If measuring value exceeds from specified limit, the

idler gear spindle or idler gear must be replaced.
6A – 80 ENGINE MECHANICAL

GEARTRAIN

Alignment timing marks on each gear shown in the illustration above.

 ENGINE MECHANICAL 6A – 81

INSTALLATION

Installation Steps Removal Steps

1. Timing gear case 11. Oil seal (Crankshaft)
2. Idler gear “B” 12. Crankshaft pulley assembly
3. Idler gear “A” 13. Fan pulley with taper bushing
4. Distance bolt 14. Oiling jet assembly
5. Oil pump assembly with O-ring 15. Oil strainer bracket
6. Fan center 16. Oil strainer with O-ring
7. Gasket 17. Gasket
8. Timing gear case cover 18. Oil pan
9. Spacer 19. Breather hose clip
10. Oil seal (Fan center) 20. Oil pipe bracket
6A – 82 ENGINE MECHANICAL

Installation Steps
1. Timing Gear Case
1) Clean the cylinder body surface.
2) Apply Loctite FMD 127 or equivalent to the cylinder
body and the timing gear case fitting faces.
The liquid gasket must be 0.3 mm (0.004 in) thick
and 4 mm (0.16 in) wide.
The liquid gasket must not obstruct the cylinder
body bolt holes.
3) Install the timing gear case to the cylinder body.
4) Tighten the bolts by specified torque.
Timing Gear Case Bolt Torque N·m(kg·m/lb·ft)
M14 135.4 ( 13.8 / 99.8 )
M10 43.2 ( 4.4 / 31.8 )

2. Idler Gear "B"

1) Apply engine oil to bushing area of idler gear and
both thrust surface.
2) Fit thrust plate with confirm front mark.
3) Tighten the bolts by specified torque.
Idler Gear “B” Bolt Torque N·m(kg·m/lb·ft)
39.2 ( 4.0 / 28.9 )

Idler gear A Assembling Procedure for Fan Idler Gear and Idler Gear A
Fan idler gear Large gear Small gear 1. Apply engine oil to the outer periphery of spring or to
the inner periphery of fan idler gear side hole.

Spindle Spring Dowel pin

014H100011

2. Push springs into seven holes of fan idler gear to such

More than 6.5 an extent as illustrated.
3. Apply engine oil to fan idler gear bushing inside
surface and end surface, and insert spindle.
4. Apply engine oil to idler gear A (double gear) bushing
inside surface and end surface.

Fan idler gear

014H100009
 ENGINE MECHANICAL 6A – 83

5. Set small gear in sich a position where its “Y” mark is

"Y" Mark Fan idler gear hole
visible through the idler gear empty hole, and insert
spindle.
Y

"I" Mark
014H100010

NOTE:
If double gear is forced on spindle and spring, the
spring could be damaged. After pin makes contact
with spring, push on the double gear while shaking it
in its turning direction.

014HV004

3. Idler Gear “A”

Flywheel
Housing 1) Align the flywheel TDC mark with the pointer by
rotating the crankshaft normal direction. Same
time check alignment timing mark on injection
Front T pump for No.1 piston TDC.
C
2) Apply engine oil to the bushing of idler gear “A”.
3) Install idler gear “A” with the idler gear shaft to the
timing gear case.
The timing marks (“O”, “I”, “Y”) must be aligned
as shown in the illustration.
020H100008

4) Tighten idler gear "A" shaft bolts by specified

torque.
Idler Gear Shaft Bolt Torque N·m(kg·m/lb·ft)
107.9 ( 11.0 / 79.6 )
6A – 84 ENGINE MECHANICAL

4. Distance Bolt
Tighten distance bolt by specified torque.
Distance Bolt Torque N·m(kg·m/lb·ft)
39.2 ( 4.0 / 28.9 )

5. Oil Pump Assembly

1) Install O-ring to oil pump assembly.
2) Install the oil pump assembly to cylinder body.
3) Tighten the oil pump assembly bolts to the
specified torque.
Oil Pump Bolt Torque N·m(kg·m/lb·ft)
49.0 ( 5.0 / 36.2 )

CAUTION
051ht002 Do not tighten arrow mark bolt shown in the
illustration.
6. Fan Center
1) Apply engine oil to bushing and thrust face of
timing gear case cover.
2) Install the fan center to timing gear case cover.

7. Gasket
8. Timing Gear Case Cover
1) Apply Loctite FMD 127 or equivalent to timing gear
case cover fitting face.
2) Install timing gear case cover with gasket.
3) Tighten bolts to specified torque.
Timing Gear Case Bolt Torque N·m(kg·m/lb·ft)
M10 39.2 ( 4.0 / 28.9 )
M8 25.5 ( 2.6 / 18.8 )
 ENGINE MECHANICAL 6A – 85

9. Spacer
10. Oil Seal (Fan center)
Use oil seal installer to install the oil seal assembly.
Note:
If there is same small scratch on the crankshaft, apply
Threebond 1207C or equivalent to oil seal slinger
shown in the illustration.
Oil Seal Installer: 1-8522-0049-0

1mm

3mm

020MT001

11. Oil Seal (Crankshaft)

1) Use oil seal installer to install the oil seal to timing
gear case cover.
2) The oil seal position is specified as the distance
from the crankshaft end.
7 ± 0.3 mm (0.276 ± 0.012 in)
Oil Seal Installer: 1-8522-0043-0
Note:
1) There are identification color on the oil seal.
For front oil seal ----------Dark violet color
For rear oil seal -----------Gray color
2) The front slinger has left-hand threads running
from inside to outside.
3) The rear slinger has right-hand threads running
from inside to outside.
1mm

4) Be careful to install the front and rear slinger in

their proper positions (do not reverse them).
5) If there is same small scratch on the crankshaft,
3mm apply Threebond 1207C or equivalent to oil seal
020MT001
slinger shown in the illustration.
6A – 86 ENGINE MECHANICAL

12. Crankshaft Pulley Assembly

1) Install the crankshaft pulley.
2) Apply engine oil to the bolt.
3) Tighten the crankshaft pulley bolts to specified
torque.
Crankshaft Pulley Bolt torque N·m(kg·m/lb·ft)
266.8 ( 27.2 / 196.5 )

13. Fan Pulley with Taper Bushing

1) Apply molybdenum dissulfide grease to the thread
of fan center and surface of fan pulley nut.
2) Tighten fan pulley nut to specified torque.
Fan Pulley Nut Torque N·m(kg·m/lb·ft)
539.6 ( 55.0 / 397.8 )

14. Oiling Jet Assembly

1) Install the oiling jet assembly to cylinder body.
2) Tighten the joint bolt to specified torque.
Joint Bolt Torque N·m(kg·m/lb·ft)
68.7 ( 7.0 / 50.6 )

15. Oil Strainer Bracket

16. Oil Strainer with O-ring
Fix O-ring to oil strainer, tighten bolts shown in the
illustration.
Oil Strainer Bolt Torque N·m(kg·m/lb·ft)
54.9 ( 5.6 / 40.5 )

17. Gasket
Apply Cemedain LG-020L or equivalent to the cylinder
body, flywheel housing and timing gear case fitting
face.
The liquid gasket must be 3 – 4 mm (0.12 – 0.16 in)
thick and wide.
 ENGINE MECHANICAL 6A – 87

18. Oil Pan

Tighten the bolts to the specified torque in the
clockwise form 1 or 2 shown as the illustration.
Oil Pan Bolt Torque N·m(kg·m/lb·ft)
38.3 ( 3.9 / 28.2 )

19. Breather Hose Clip

20. Oil Pipe Bracket
6A – 88 ENGINE MECHANICAL

FLYWHEEL
REMOVAL

10
3
2
4

8
6
9
7

020HY00171

Removal Steps Removal Steps

1. N-TDC sensor 7. Flywheel housing stay
2. Snap ring 8. Flywheel housing
3. Pilot bearing 9. Oil seal
4. Washer 10. Slinger
5. Flywheel
6. Engine foot
 ENGINE MECHANICAL 6A – 89

Removal Steps
1. N-TDC Sensor
Note:
1) To prevent damage to the N-TDC sensor, the
sensor should be removed before the flywheel
assembly.
2) Brackets must be removed when the N-TDC
sensor is removed.

826HY00113

2. Snap Ring
3. Pilot Bearing
Use pilot bearing remover to remove the pilot
bearing.
Pilot Bearing Remover: 9-8521-0157-0
4. Washer
5. Flywheel
6. Engine Foot
7. Flywheel Housing Stay
8. Flywheel Housing

9. Oil Seal
Take care to do not make damage on surface of
flywheel housing.

10. Slinger
Use slinger remover to remove oil seal slinger from
crankshaft.
Slinger Remover: 1-8521-0027-0
6A – 90 ENGINE MECHANICAL

INSTALLATION

7
8
6

1
2
4
3

HCW31BLF000301

Installation Steps Removal Steps

1. Flywheel housing 6. Washer
2. Engine foot 7. Pilot bearing
3. Flywheel housing stay 8. Snap ring
4. Oil seal with slinger 9. N-DTC sensor
5. Flywheel
 ENGINE MECHANICAL 6A – 91

Installation Steps
1. Flywheel Housing
1) Apply Loctite FMD 127 or equivalent to the cylinder
body and flywheel fitting face shown in the
illustration.
2) The liquid gasket must be 0.3 mm (0.004 in) thick
and 4 mm (0.16 in) wide.
The liquid gasket must not obstruct the cylinder
body bolt holes.
3) Install the flywheel housing to tighten with
specified torque.
Flywheel Housing Bolt Torque N·m(kg·m/lb·ft)
M14 122.6 (12.5 / 90.4)
M8 21.6 (2.2 / 15.9)

2. Engine Foot
1) Apply molybdenum disulfied grease to the engine
foot bolt and setting faces.
2) Tighten engine foot bolt to the specified torque.
Engine Foot Bolt Torque N·m(kg·m/lb·ft)
1st step 147.2 (15.0 / 108.5)
2nd step 274.7 (28.0 / 202.5)

3. Flywheel Housing Stay

1) Install the flywheel housing stay.
2) Tighten flywheel housing stay bolt to the specified
torque.
Flywheel Housing Stay Bolt Torque N·m(kg·m/lb·ft)
112.8 (11.5 / 83.2)
6A – 92 ENGINE MECHANICAL

4. Oil Seal with Slinger

1) Use oil seal setting tool to install the oil seal.
2) The oil seal position is specified as the distance
from the crankshaft end.
7 ± 0.3 mm (0.276 ± 0.012 in)
Oil Seal Setting Tool: 1-8522-0043-0
Note:
1) There are identification color on the oil seal.
For front oil seal ----------Dark violet color
For rear oil seal -----------Gray color
2) The front slinger has left-hand threads running
from inside to outside.
3) The rear slinger has right-hand threads running
from inside to outside.
@
€
À
;
4) Be careful to install the front and rear slinger in
@;;@;@
their proper positions (do not reverse them).
5) If there is same small scratch on the crankshaft,
@;;@
Oil seal
with slinger apply Threebond 1207C or equivalent to oil seal
slinger shown in the illustration.
;@
5. Flywheel
6. Washer
1) Apply molybdenum disulfied grease to bolt and
setting face.
2) Tighten flywheel bolt in three steps using the
angular tightening method.
Flywheel Bolt Torque N·m(kg·m/lb·ft)
1st step 2nd step 3rd step
78.5 (8.0 / 57.9) 60 deg 30 deg

3) Follow the numerical order shown in the

illustration.
7. Pilot Bearing
Use pilot bearing setting tool to install the pilot
bearing.
Pilot Bearing Setting Tool: 1-8522-1057-0
8. Snap Ring
 ENGINE MECHANICAL 6A – 93

9. N-TDC Sensor

826HY00113
6A – 94 ENGINE MECHANICAL

CRANKSHAFT, PISTON AND CONNECTING ROD

REMOVAL

Removal Steps Removal Steps

1. Piston with connecting rod 4. Crankshaft
2. Connecting rod bearing 5. Crankshaft bearing
3. Crankcase lower 6. Crankshaft thrust bearing
 ENGINE MECHANICAL 6A – 95

Removal Steps
1. Piston with Connecting Rod
1) Remove carbon deposits from the upper portion of
the cylinder wall a scraper before removing the
piston with connecting rod.
2) Loosen connecting rod cap nuts
3) Move the piston to the top of the cylinder and tap
it with a hammer grip or similar object from the
connecting rod lower side to drive it out.
CAUTION:
Take care not to damage the oiling jets.

2. Connecting Rod Bearing

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

3. Crankcase Lower
1) Measure the crankshaft end play at the No.7
crankshaft journal.
Do this before remove the crankshaft thrust
bearing.
If the measured value exceeds the specified limit,
the crankshaft thrust bearing must be replaced.
Crankshaft End Play mm(in)
Standard Limit
0.04 – 0.18 (0.0016 – 0.0070) 0.30 (0.0121)

2) Loosen the crankcase lower bolts a little at a time

in the numerical order shown in the illustration.
3) Use M10 bolts into replace holes to remove the
crankcase lower.

4. Crankshaft
Remove the crankshaft from the cylinder body.
6A – 96 ENGINE MECHANICAL

5. Crankshaft Bearing
If the crankshaft bearings are to be reinstalled, make
their fitting position by tagging each bearings with the
journal number from which it was removed.
6. Crankshaft Thrust Bearing
Same manner as crankshaft bearing removal.
 ENGINE MECHANICAL 6A – 97

INSTALLATION

Installation Steps Removal Steps

1. Crankshaft bearing 4. Crankcase lower
2. Crankshaft 5. Connecting rod bearing
3. Crankshaft thrust bearing 6. Piston with connecting rod
6A – 98 ENGINE MECHANICAL

Installation Steps
1. Crankshaft Bearing
1) Carefully wipe any foreign materials from the
fitting area of the cylinder body and crankshaft
bearing upper.
All upper bearings have oil grooves.
2) Locate the position mark applied at removed, if the
removed upper bearings are to be reused.
CAUTION:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.

2. Crankshaft
Apply engine oil to the crankshaft journals and
crankshaft bearing surfaces before installing the
crankshaft.

3. Crankshaft Thrust Bearing

1) Apply engine oil to the thrust bearing oil grooves
side.
2) Install the thrust bearing upper to both side of the
No.1 journal by hand.
Note:
The thrust bearing oil grooves must be faced the
sliding face.
 ENGINE MECHANICAL 6A – 99

4. Crankcase Lower
1) Carefully wipe any foreign materials from the
fitting area of the crankcase.
2) Apply Loctite FMD 127 or equivalent to cylinder
body lower surface.
The liquid gasket must be 0.3 mm (0.01 in) thick
and 4 mm (0.16 in) wide.
3) Install the crankshaft bearings and thrust bearing
CAUTION:
Do not apply engine oil to the bearing back faces and
the crankcase bearing fitting surfaces.
Note:
The thrust bearing oil grooves must be facing the
sliding face.
4) Install the crankcase lower to the cylinder body.
5) Apply molybdenum disulfide grease to the
crankcase bolts (M18) threads and setting face.
6) Apply engine oil to the crankcase bolts (M12)
threads and setting faces.

7) Tighten the M18 crankcase bolts (numerical order

1 to 14) in the three steps using the angular
tightening method.
Follow the numerical order shown in the
illustration.
Crankcase Lower Bolt Torque N·m(kg·m/lb·ft)
Bolt size 1st Step 2nd Step 3rd Step
M18 49.1(5.0/36.2) 88.3(9.0/65.1) 90 – 120deg
M12 96.1(9.8/70.9)

6. Piston with Connecting Rod

1) Carefully wipe any foreign materials inside
cylinder bore and piston with connecting rod.
2) Install the connecting rod bearing upper to the
connecting rod.
3) Install the connecting rod bearing lower to the
connecting rod cap.

4) Apply engine oil to the cylinder wall, upper / lower

bearing surface and crankpin of crankshaft.
6A – 100 ENGINE MECHANICAL

5) Position the piston ring gaps as shown in the

illustration.
6) Position the piston head front mark so that it is
facing front of the engine.
7) Use piston setting tool to install the piston with
connecting rod to the cylinder body. At the same
time, rotate the crankshaft until the crankpin is at
bottom dead center.
CAUTION:
Do not bend or damage the oiling jet.
015HX00036

Piston Setting Tool: 1-8522-0059-0

015HW00001

8) Apply molybdenum disulfied grease to the threads

and setting faces of each connecting rod bolts.
9) Tighten the connecting rod cap nuts in three steps
using the angular tightening method.
Connecting Rod Cap Nut Torque N·m(kg·m/lb·ft)
1st Step 2nd Step 3rd Step
98.1(10.0/72.3) 30 deg 30 deg

Angular gauge: 5-8840-0266-0

10) Check crankshaft rotation smoothly.
 ENGINE MECHANICAL 6A – 101

CRANKSHAFT
DISASSEMBLY

Disassembly Steps Removal Steps

1. Crankshaft
2. Bearings
3. Crankshaft Gear
6A – 102 ENGINE MECHANICAL

Disassembly Steps
1. Crankshaft
Remove crankshaft assembly from cylinder body.
2. Bearings
Remove crankshaft bearing and thrust bearing.

3. Crankshaft Gear
Use the crankshaft gear remover to remove the
crankshaft gear.
Crankshaft Gear Remover: 1-8521-0064-0
If remain the slinger on the crankshaft remove slinger
by the slinger remover.
Slinger Remover: 1-8521-0027-0
 ENGINE MECHANICAL 6A – 103

INSPECTION AND REPAIR

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

1. Crankshaft Journal and Crankpin Diameter

1) Use a micrometer to measure the crankshaft
journal diameter across points shown in the
illustration.
2) Use a micrometer to measure the crankshaft
journal diameter at the two points as shown in the
illustration 1 and 2.
3) Repeat steps 1) and 2) to measure the crankpin
diameter.
If the measured values are less than the standard
value, the crankshaft must be replaced.
Crankshaft Journal and
Crankpin Diameter mm(in)
Standard
No. 4 Journal 104.850 – 104.875(4.1279-4.1289)
Others 104.880 – 104.905(4.1291-4.1309)
Crankpin 91.895 – 91.925(3.6179-3.6191)

2. Crankshaft Run Out

1) Set a dial indicator to the center of the crankshaft
No.4 journal.
2) Gently turn the crankshaft in the normal direction
of rotation.
Read the dial indicator as you turn the crankshaft.
If the measured value exceeds the specified limit,
the crankshaft must be replaced.
Crankshaft Run Out mm(in)
Standard Limit
0.120 ( 0.0005 ) 0.15 ( 0.0059 )

3. Bearing Spread
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit,
the bearing must be replaced.
Bearing Spread mm(in)
Limit 111.5 ( 4.3898 )
6A – 104 ENGINE MECHANICAL

4. Crankshaft Journal and Bearing Clearance

1) Clean the cylinder body and crankcase lower, the
journal bearing fitting surface, and the journal
bearings.
2) Install the bearings to the cylinder body and
crankcase lower.
3) Reassembly the crankcase lower to cylinder body.
4) Apply molybdenum disulfide grease to the M18
bolts and apply engine oil to the M12 bolts thread
and it seat.
5) Tighten the crankcase lower to the specified torque
in the numerical order shown in the illustration.
Crankcase Bolt torque N·m(kg·m/lb·ft)
1st Step 2nd Step 3rd Step
M18 49.1(5.0/36.17) 88.3(9.0/65.10) 90 – 120 deg
M12 96.1(9.8/70.9)

6) Measure the crankshaft bearing inside diameter by

dial indicator.
7) If the clearance between the crankshaft journal and
bearing exceeds the specified limit, the crankshaft
must be replaced.
Crankshaft Journal and
Bearing Clearance mm(in)
Standard Limit
No.4 Journal 0.081 – 0.144
(0.0032 – 0.0057) 0.16
Others 0.051 – 0.114 (0.0063)
(0.0020 – 0.0045 )

4. Crankshaft Journal and Bearing Clearance (With

Plastigage)
1) Clean the cylinder body and crankcase lower, the
journal bearing fitting surface, and the journal
bearings.
2) Install the bearings to the cylinder body and
crankcase lower.
3) Reassembly the crankcase lower to cylinder body.
4) Cut the plastigage same wide of crankshaft journal
and put it on the crankshaft journal.
5) Apply molybdenum disulfide grease to the M18
bolts and apply engine oil to the M12 bolts thread
and it seat.
 ENGINE MECHANICAL 6A – 105

6) Tighten the crankcase lower to the specified torque

in the numerical order shown in the illustration.
Crankcase Bolt torque N·m(kg·m/lb·ft)
1st Step 2nd Step 3rd Step
M18 49.1(5.0/36.17) 88.3(9.0/65.10) 90 – 120 deg
M12 96.1(9.8/70.9)

7) Carefully disassembly the crankcase lower from

cylinder body.

8) Measure the width of plastigage by scale which

printed on the plastigage envelop.
9) If the clearance between the crankshaft journal and
bearing exceeds the specified limit, the crankshaft
must be replaced.
Crankshaft Journal and
Bearing Clearance mm(in)
Standard Limit
No.4 Journal 0.081 – 0.144
(0.0032 – 0.0057) 0.16
Others 0.051 – 0.114 (0.0063)
(0.0020 – 0.0045 )

5. Crankshaft Tufftriding Inspection

1) Use an organic cleaner to thoroughly clean the
crankshaft.
There must be not traces of oil on the surface to be
inspected.
2) Prepare a 5 – 10 % solution of ammonium cuprous
chloride (dissolved in distilled water).
3) Use a syringe to apply the solution to the surface
to be inspected.
Hold the surface to be inspected perfectly
horizontal to prevent the solution from running.
Note:
Do not allow the solution to come in contact with the
oil ports and their surrounding area.
6. Crankshaft TufftridingJudgment
1) Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty
seconds, the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color of copper), the crankshaft
must be replaced.
2) Steam clean the crankshaft surface immediately
after completing the test.
Note:
The ammonium cuprous chloride solution is highly
corrosive.
Because of this, it is imperative that the surfaces
being tested be cleaned immediately after completing
the test.
6A – 106 ENGINE MECHANICAL

REASSEMBLY

Reassembly Steps Removal Steps

1. Crankshaft Gear
2. Bearings
3. Crankshaft
 ENGINE MECHANICAL 6A – 107

Reassembly Steps
1. Crankshaft Gear
1) Use the oil heater to heat the crankshaft gear to
170°-180°C (338°-350°F).
2) With the timing alignment mark “O” on the side of
crankshaft gear turned outward, align the key
groove on the crankshaft gear with the crankshaft
dowel pin position.
3) Hammer it in with a crankshaft gear installer until it
hits the bottom.
Crankshaft Gear Installer: 1-8522-0045-0
CAUTION:
When hammered in with the gear slanted, the
crankshaft gear may be caught in the middle and
cannot be hammered in fully. Hammer it in quickly
enough not to allow a shaft line along the gear and
the crankshaft to slant.

2. Bearings
Reassemble the crankshaft bearings and thrust
bearings to refer the section of the crankshaft, piston
and connecting rod installation steps.
3. Crankshaft
Reassemble the crankshaft to the cylinder body.
6A – 108 ENGINE MECHANICAL

PISTON AND CONNECTING ROD

DISASSEMBLY

6
5

4
7

015H100006

Disassembly Steps Removal Steps

1. Connecting Rod Cap 5. Piston Pin
2. Bearings 6. Piston
3. Piston Rings 7. Connecting Rod
4. Snap Ring
 ENGINE MECHANICAL 6A – 109

Disassembly Steps
CAUTION:
Do not bend or damage the oiling jet.
Note:
When removing the piston and connection rod
assembly, pull the connecting rod in parallel with the
cylinder bore.
1. Connecting Rod Cap

2. Bearings
1) Take out the connecting rod bearing cap nuts and
disassemble the bearing cap with the lower
bearing.
2) If the connecting rod lower bearings are to be
reinstalled, mark their fitting positions by tagging
each bearing with the cylinder number from which
it was removed.

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

4. Snap Ring
Use a pair of snap ring pliers to remove the snap
rings.
5. Piston Pin
6. Piston
7. Connecting Rod
Tap the piston pin out with a hammer and a brass bar.
If the piston to be reinstalled, mark their installation
positions by tagging each piston with the cylinder
number from which it was disassembled.
6A – 110 ENGINE MECHANICAL

INSPECTION AND REPAIR

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

1. Piston Ring Gap

1) Insert the piston ring horizontally (in the position it
would assume if it were installed to the position)
into the cylinder liner bore.
2) Push the piston ring into the cylinder liner bore
until it reaches the point where the cylinder liner
bore is the smallest.
Do not allow the piston ring to slant to one side or
the other. It must be perfectly horizontal.
3) Use the feeler gage to measure the piston ring
gap.
If the measured value exceeds the specified limit,
the piston ring must be replaced.
Piston Ring Gap mm(in)
Standard Limit
1st ring
0.35 – 0.50
2nd ring 1.00
(0.0138 – 0.0197)
3rd ring (0.0394)
0.30 – 0.45
Oil ring
(0.0118 – 0.0177)

2. Piston Ring and Piston Ring Groove Clearance

1) Visually inspect the piston ring grooves.
If a piston ring groove is damaged or distorted, the
piston must be replaced.
2) Use feeler gauge to measure the clearance
between the piston ring and the piston ring groove
at several points around the piston.
3) When measure the clearance for 1st piston ring, it
pressed the 1st piston ring by straight gauge show
in the illustration.

Piston Ring and Piston Ring

Groove Clearance mm(in)
Standard Limit
0.10 – 0.142 0.23
1st ring
(0.0039 – 0.0056) (0.0091)
2nd ring 0.10 – 0.135 0.20
(0.0039 – 0.0053) (0.787)
3rd ring
0.025 – 0.065 0.15
Oil ring
015HX00033
(0.0010 – 0.0026) (0.0059)
 ENGINE MECHANICAL 6A – 111

3. Piston Ring Expansion Force

1) Use expansion force gauge to measure the piston
ring g expansion force.
2) For measure the expansion force to oil ring it
required coil expander ring with oil ring.
Piston Ring Expansion Force N(kg/lb)
Standard Limit
49.3 – 62.5 35.3
1st ring
(5.03-6.37/11.09-14.05) (3.6/7.94)
22.0 – 29.0 14.7
2nd ring
(2.24-2.96/4.94-6.53) (1.5/3.31)
22.4 – 29.6 14.7
3rd ring
(2.28-3.02/5.03-6.66) (1.5/3.31)
62.8 – 78.5 44.1
Oil ring
(6.4-8.0/14.11-17.64) (4.5/9.92)

4. Piston Pin Diameter

Use a micrometer to measure the piston pin outside
diameter at several points.
If the measured value is less than the specified limit,
the piston pin must be replaced.
Piston Pin Diameter mm(in)
Standard Limit
55.995 – 56.000 55.970
(2.2015 – 2.2047) (2.2035)

5. Piston Pin Hole and Piston Pin Clearance

Use the inside dial indicator to measure the piston pin
hole(in the piston).
Piston Pin Hole and
Piston Pin Clearance mm(in)
Standard Limit
0.008 – 0.021 0.05
(0.0003 – 0.0008) (0.0020)

015HX00034

6. Piston Pin and Connecting Rod Small End Bushing

Clearance
Use a caliper calibrator and dial indicator to measure
the clearance between the piston pin and connecting
rod small end bushing.
If the clearance between the piston pin and the
connecting rod small end bushing exceeds the
specified limit, replace the piston pin and/or the
connecting rod assembly.
Small End Bushing Clearance mm(in)
Standard Limit
0.020 – 0.037 0.10
(0.0079 – 0.0016) (0.0039)
6A – 112 ENGINE MECHANICAL

7. Connecting Rod Alignment

Use a connecting rod aligner to measure the
distortion and the parallelism between the connecting
rod big end hole and the connecting rod small end
hole.
If either the measured distortion or parallelism
exceeds the specified limit, the connecting rod must
be replaced.
Connecting Rod Alignment mm (in)
012HV023
Per Length of 100 (3.94)
Standard Limit
Distortion 0.05 (0.002) 0.20
Parallelism or less (0.008)

8. Crankpin and Connecting Rod Bearing Clearance

1) Clean the crankshaft, the connecting rod, the
bearing cap, and the bearings.
2) Install the bearing to the connecting rod and the
bearing cap.
B 3) Apply a coat of molybdenum disulfide grease to
1 2 A
the bearing cap bolt threads and setting faces.
A 4) Prevent the connecting rod from moving.
1 2 B
5) Tighten the bearing cap to the specified torque.
Connecting Rod Bearing
015HV027 Cap Nut Torque N·m (kg·m/lb·ft)
1st step 2nd step 3rd step
98.1 (10.0/72.3) 30 deg 30 deg

6) Use the dial indicator to measure the connecting

rod bearing inside diameter.
Crankpin and Connecting Rod
Bearing Clearance mm (in)
Standard Limit
0.033 – 0.103 (0.0013 – 0.0041) 0.16 (0.0063)

7) If the clearance between the measured bearing

inside diameter and the crankpin exceeds the
specified limit, the bearing and/or the crankshaft
must be replace.
 ENGINE MECHANICAL 6A – 113

9. Connecting Rod and Crankshaft Clearance

1) Fix the connecting rod assembly to crankshaft by
specified torque.
The fixing manner is follow as mentioned above.
2) Use feeler gauge to measure the clearance
between connecting rod and crankshaft.
If the measured value exceeds the specified limit,
the connecting rod must be replaced.
Connecting Rod and
Crankshaft Clearance mm(in)
Standard Limit
0.175 – 0.290(0.0069-0.0114) 0.35(0.0138)

Cylinder Liner Grade Selection and Standard

Fitting Clearance
Accurately measured fitting clearance and proper
cylinder liner grade selection are extremely important.
Liner outside If the cylinder liner fitting clearance is too large,
Grade No. engine cooling efficiency will be adversely affected.
If the cylinder liner fitting clearance is too small, it will
be difficult to insert the cylinder liner into the cylinder
body.
012EY00020

A mark was stamped on the right side of the cylinder

block during production to indicate the correct liner.
The liner grade (1, 2, 3) is indicated in metal stamp.
Cylinder Liner grade mm(in)
Liner Cylinder Bore Service Liner Outside
Grade Diameter Grade Diameter
151.600 – 151.610 151.590 – 151.599
1 1X
(5.9685 – 5.9689) (5.9681 – 5.9685)
151.611 – 151.630 151.600 – 151.610
2–3 3X
(5.9689 – 5.9697) (5.9685 – 5.9689)

The cylinder liner grade is stamped on the outside of

the cylinder liner.
6A – 114 ENGINE MECHANICAL

REASSEMBLY

1
4

2
3

015H100007

Reassembly Steps Removal Steps

1. Piston 5. Snap Ring
2. Snap Ring 6. Piston Rings
3. Connecting Rod 7. Bearing
4. Piston Pin 8. Connecting Rod Cap
 ENGINE MECHANICAL 6A – 115

Reassembly Steps
1. Piston
Measure the cylinder liner bore after installing the
cylinder liner. Then select the appropriate piston
grade for the installed cylinder liner.
1) Measure the cylinder liner bore.
Refer to the “Cylinder Liner Bore Measurement”.
Measuring point 130 mm (5.118 in)
Cylinder Liner Bore mm(in)
130 mm Standard 147.011 – 147.030 (5.7878 – 5.7996)

2) Measure the piston outside diameter (Reference).

Piston Measuring Point 113 mm (4.449 in)
Piston Outside mm(in)
Standard 146.830 – 146.845 (5.7807 – 5.7813)

Piston and Liner Bore Clearance mm(in)

Standard 0.166 – 0.200 (0.0065 – 0.0079)

113mm If the piston and liner clearance exceeds the standard

value, the piston and/or liner must be replaced.
015HV026
CAUTION:
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in
slight decreases in cylinder liner clearances. Always
measure the cylinder liner clearance after installation
to be sure that it is correct.

2. Snap Ring
Use a pair of snap ring pliers to reassemble the snap
ring to the piston.
3. Connecting Rod
1) Clamp the connecting rod in the vise.
Take care not to damage the connecting rod.
2) Install the piston so that the piston head front mark
and the connecting rod front mark are set in the
same direction.

4. Piston Pin
1) Apply engine oil to the piston pin.
2) Insert the piston pin to the connecting rod through
piston pin hole on the piston.
5. Snap Ring
Use a pair of snap ring pliers to reassemble the snap
ring to the piston.
6A – 116 ENGINE MECHANICAL

6. Piston Ring
1 2 3 1) Apply engine oil to the piston rings.
2) Confirm discrimination mark on the piston ring.
Discrimination mark
1st ring Not available Red color
2N 3N
2nd ring 2N Blue color
3rd ring 3N Green color
Red Blue Green
Oil ring Not available –
015H100008

3) Use the piston ring setting tool to reassemble the

four piston rings according to discrimination mark
on the piston ring (The discrimination mark should
be face upper side).
The oil ring has not discrimination mark.
Piston ring setting tool: 1-8522-1025-0
Note:
Insert the expander coil into the oil ring groove so
that there is no gap on either side of the expander
coil before installing the oil ring.
4) Check to see if the piston rings rotate smoothly in
the piston ring grooves.

7. Bearing
Carefully wipe any oil or other foreign material from
the connecting rod bearing back face and the bearing
fitting surface.
 ENGINE MECHANICAL 6A – 117

Front mark 8. Connecting Rod cap

1 2,5 1) Fit the connecting rod bearing lower to the
connecting rod cap.
2) Apply engine oil to the circumference of the each
piston ring, piston and crankpin.
3) Position the piston ring gaps as shown in the
illustration.
Gap position

4 3 1. 1st compression ring

012HW002
2. 2nd compression ring
3. 3rd compression ring
4. Oil ring
5. Coil expander

4) Apply molybdenum disulfide grease to the two

Front mark piston skirts.
Engine front This will facilitate smooth break-in when the
engine is first started after reassembly.
5) Apply engine oil to the connecting rod upper
bearing.
6) Apply engine oil to the cylinder wall.
7) Position the piston head front mark so that it is
Projection
for front mark
facing the front of the engine.
015H100009
8) Use the piston ring setting tool to compress the
piston rings.
Piston setting tool: 1-8522-0059-0

9) Use a hummer grip to push the piston in until the

connecting rod marks contact with the crankpin.
As the same time, rotate the crankshaft until the
crankpin is at bottom dead center.
CAUTION:
Do not bend or damage the oiling jet.
10) Align the connecting rod cap cylinder number
marks and the connecting rod cylinder number
marks.
015HW00001
11) Reassembly the connecting rod caps.
12) Apply molybdenum disulfide grease to the threads
and setting faces of each connecting rod bolts and
nuts.
13) Tighten the connecting rod nut to specified torque.
Cap Nut Torque N·m(kg·m/lb·ft)
1st step 2nd step 3rd step
98.1(10.0/72.3) 30 deg 30 deg

015HW00003
6A – 118 ENGINE MECHANICAL

FLYWHEEL AND CRANK PULLEY

DISASSEMBLY

Disassembly Steps Removal Steps

1. Snap Ring 4. Ring Gear
2. Pilot Bearing 5. Crank Pulley
3. Flywheel 6. Crankshaft Dumper
 ENGINE MECHANICAL 6A – 119

Disassembly Steps
1. Snap Ring
Use a pair of snap ring pliers to disassemble the snap
ring.
2. Pilot Bearing
Use pilot bearing puller to remove the pilot bearing.
Pilot bearing puller: 9-8521-0157-0
3. Flywheel
Loose fixing bolts to disassemble the flywheel from
crankshaft.

4. Ring Gear
Put the flywheel with ring gear on the wood piece,
strike around the edges of the ring gear with a
hammer and brass bar to disassemble it.

5. Crank Pulley
Loose crank pulley fixing bolts to disassemble the
crank pulley.

6. Crankshaft Dumper
Loose the fixing bolts to disassemble the crankshaft
dumper.
6A – 120 ENGINE MECHANICAL

INSPECTION AND REPAIR

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

1. Pilot Bearing
Visually inspection worn out or abnormal noise on the
pilot bearing.
Note:
Do not washing the pilot bearing because it is sealing
grease type bearing.

2. Flywheel
1) Visually inspect cracking, scratching or worn out
on the flywheel.
2) Measure the wear value of flywheel.
Depth form Friction Face to
Pressure Plate Fixing Face mm(in)
Clutch Size Standard Limit
17" 48.0 (1.890) 50.5 (1.988)
15.5" 20.0 (0.787) 21.5 (0.846)

3. Ring Gear
Visually inspection damage on the ring gear.

4. Crankshaft Dumper
Visually inspection cracking or separation on the
crankshaft dumper.
 ENGINE MECHANICAL 6A – 121

REASSEMBLY

Reassembly Steps Removal Steps

1. Crankshaft Dumper 4. Flywheel
2. Crank Pulley 5. Pilot Bearing
3. Ring Gear 6. Snap Ring
6A – 122 ENGINE MECHANICAL

Reassembly Steps
1. Crankshaft Dumper
1) Reassemble the crankshaft dumper to crankshaft,
align two grooves face to the front side.
2) Tighten bolts numerical order to specified torque
shown in the illustration.
Bolt Torque N·m(kg·m/lb·ft)
96.1 ( 9.8 / 70.9 )

Note:
Do not attempt to apply any oil on the crankshaft
dumper.

2. Crank Pulley
1) Apply engine oil to thread of fixing bolts.
2) Set the crank pulley to crankshaft dumper.
3) Tighten bolts numerical order to specified torque
shown in the illustration.
Bolt Torque N·m(kg·m/lb·ft)
266.8 ( 27.2 / 196.7 )

3. Ring Gear
4. Flywheel
1) Heat the ring gear evenly with a gas burner to
invite thermal expansion.
Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
2) Install the ring gear when it is sufficiently heated.
The ring gear must be installed with the chamfer
facing the flywheel.
Note:
Take care not to burn yourself on the heated ring
gear.
5. Pilot Bearing
Reassemble the pilot bearing to flywheel.
6. Snap Ring
Use a pair of snap ring pliers to reassemble the snap
ring.
 ENGINE MECHANICAL 6A – 123

CYLINDER BODY
DISASSEMBLY

Disassembly Steps Removal Steps

1. Oil pressure unit 4. Oiling jet
2. Oil relief valve 5. Cylinder liner
3. Crankcase lower 6. Cylinder body
6A – 124 ENGINE MECHANICAL

Disassembly Steps
1. Oil Pressure Unit
2. Oil Relief Valve
3. Crankcase Lower
1) Loosen the fixing bolts to disassemble the
crankcase lower.
2) Put it on the wood plate or piece.
4. Oiling Jet
Loosen the bolt to disassemble the oiling jet.
Note:
Take care do not bend or damage the oiling jet.

5. Cylinder Liner
1) Use the screper to remove carbon deposit.
2) Use cylinder bore dial indicator to measure the
cylinder bore at measuring point in the thrust and
axial direction of the crankshaft.
Measuring Point mm(in)
15 – 20 ( 0.1969 – 0.7874 )

If the measured value exceeds the specified limit, the

cylinder liner must be replaced.
Cylinder Liner Bore mm(in)
Nominal measurement Limit
147 (5.7874) 147.3 (5.7992)

Note:
If the inside of the cylinder liner is scored or
scratched, the cylinder liner must be replaced.
6. Cylinder Body
Visually inspection any damage.
 ENGINE MECHANICAL 6A – 125

INSPECTION AND REPAIR

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

1. Cylinder Body
1) Disassemble the cylinder liners.
2) Visually inspection any cracking or damage and
choking oil and/or water holes.
If possible it is required to special inspect by dye
penetrant flaw detector.

3) Use a straight edge and a feeler gauge to measure

the cylinder body upper face warpage on the four
sides and two diagonals of the cylinder body upper
face shown in the illustration.
Cylinder Body Upper Face Warpage mm(in)
Standard Limit
0.075 ( 0.0030 ) or less 0.2 (0.008)

If the measured value exceeds the specified limit,

the cylinder body must be replaced.
4) Inspect water leakage to apply water pressure in
the cylinder body water jacket.
Water Pressure kPa(kg/cm2/psi)
490.5 ( 5.0 / 71.1 )

If water leakage is found, the cylinder body must

be replaced.

2. Cylinder Liner
1) Use the scraper to remove carbon deposit.
2) Use cylinder bore dial indicator to measure the
cylinder bore at measuring point in the thrust and
axial direction of the crankshaft.
Measuring Point mm(in)
15 – 20 ( 0.1969 – 0.7874 )

Cylinder Liner Bore mm(in)

Nominal measurement Limit
147 (5.7874) 147.3 (5.7992)

If the measured value exceeds the specified limit,

the cylinder liner must be replaced.
Note:
If the inside of the cylinder liner is scored or
scratched, the cylinder liner must be replaced.
6A – 126 ENGINE MECHANICAL

3. Crankcase Lower
Visually inspection any cracking or damage on the
crankcase lower.
If possible it is required to special inspect by dye
penetrant flaw detector.

4. Oiling Jet
Check oil port choking on the oiling jet.

5. Relief Valve
Inspect choking, any damage to piston, valve seat and
spring.

6. Cylinder Liner Projection

1) Use a dial indicator or a straight edge and feeler
gauge to measure the cylinder liner projection.
Cylinder Liner Projection mm(in)
Standard
0.05 – 0.09 ( 0.0020 – 0.0035)

The difference in the cylinder liner projection height

between any adjacent cylinders must not exceed limit.
Projection Height between
Adjacent Cylinder mm(in)
0.02 (0.0008) or less
 ENGINE MECHANICAL 6A – 127

REASSEMBLY

Reassembly Steps Removal Steps

1. Cylinder body 4. Crankcase lower
2. Cylinder liner 5. Oil relief valve
3. Oiling jet 6. Oil pressure unit
6A – 128 ENGINE MECHANICAL

Reassembly Steps
1. Cylinder Body
2. Cylinder Liner

Cylinder Liner Grade Selection and Standard Fitting

Clearance
Accurately measured fitting clearance and proper
cylinder liner grade selection are extremely important.
If the cylinder liner fitting clearance is too large,
Liner outside engine cooling efficiency will be adversely affected.
Grade No.
If the cylinder liner fitting clearance is too small, it will
be difficult to insert the cylinder liner into the cylinder
body.

012EY00020

A mark was stamped on the right side of the cylinder

block during production to indicate the correct liner.
The liner grade (1, 2, 3) is indicated in metal stamp.
Cylinder Liner grade mm(in)
Liner Cylinder Bore Service Liner Outside
Grade Diameter Grade Diameter
151.600 – 151.610 151.590 – 151.599
1 1X
(5.9685 – 5.9689) (5.9681 – 5.9685)
151.611 – 151.630 151.600 – 151.610
2–3 3X
(5.9689 – 5.9697) (5.9685 – 5.9689)

The cylinder liner grade is stamped on the outside of

the cylinder liner.

1) Use new kerosene or diesel fuel to thoroughly

clean the cylinder liner and bore.
2) Use compressed air to brow-dry cylinder liner and
bore surface.
Note:
All foreign materials must be carefully removed from
the cylinder liner and the cylinder bore before
installation.
3) Apply engine oil to outside surface cylinder liner.
4) Install the cylinder liner into cylinder body from the
top of the cylinder body by your hand.
 ENGINE MECHANICAL 6A – 129

5) Check cylinder liner projection refer to the Cylinder

Body Inspection and Repair section.
Note:
1) Do not apply unreasonableness stress or hit to
cylinder liner during install it.
2) Take care to remove the cylinder liner when
cylinder body turn over.

3. Oiling Jet
Tighten to specified torque
Oiling Jet Torque N·m(kg·m/lb·ft)
49.0 ( 5.0 / 36.2 )

Be sure direction of the oiling jet tip to cooling hole of

piston.
Do not bend or damage oiling jet.

4. Crankcase Lower
Reassemble manner refer to Crankshaft, Piston and
Connecting Rod Installation section.

5. Oil Relief Valve

1) Apply engine oil to O-ring and relief valve
assembly.
2) Reassemble relief valve to cylinder body to
specified torque.
Relief Valve Torque N·m(kg·m/lb·ft)
19.7 ( 2.0 / 14.5 )

6. Oil Pressure Unit

1) Reassemble the adapter withe gasket to cylinder
body by specified torque.
2) Reassemble the oil pressure unit with gasket to the
adapter by specified torque.
Adapter Torque N·m(kg·m/lb·ft)
41.3 ( 4.2 / 30.4 )

Oil Pressure Unit Torque N·m(kg·m/lb·ft)

17.6 ( 1.8 / 13.0 )
6A – 130 ENGINE MECHANICAL

OIL PUMP
Oil Pump Construction
 ENGINE MECHANICAL 6A – 131

DISASSEMBLY

Disassembly Steps Removal Steps

1. Cover 7. Oil Pump Drive Gear
2. Ball 8. Oil Pump Cover
3. Split Pin 9. Oil Pump Driven Gear
4. Spring Seat 10. Drive Gear Shaft
5. Spring 11. Oil Pump Body
6. Oil Relief Valve
6A – 132 ENGINE MECHANICAL

Disassembly Steps
1. Cover
Loosen Bolts to remove the cover.

2. Ball
Take out the ball from the oil pump assembly.
3. Split Pin
4. Spring Seat
5. Spring
6. Oil Relief Valve
Remove the split pin, spring seat, spring and oil relief
valve.

7. Oil Pump Drive Gear

Use the gear puller to pull out the oil pump drive gear.

8. Oil Pump Cover

Loosen the fixing bolts to disassembly the oil pump
cover.

9. Oil Pump Driven Gear

10. Drive Gear Shaft
Take out the oil pump driven gears and drive gear
shaft from oil pump body.
11. Oil Pump Body
 ENGINE MECHANICAL 6A – 133

INSPECTION AND REPAIR

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

1. Ball
Carefully inspect the ball scratches or damage.

2. Oil Relief Valve

Inspect the oil relief valve seat portion damage and
spring damage.
Note:
If there is some scratch or damage the ball and relief
valve must be replaced.

3. Clearance Between Oil Pump Body and Driven Gear

Use feeler gauge to measure the clearance between
oil pump body and driven gear.
Clearance Between
Oil Pump Body and Driven Gear mm(in)
Standard
0.050 – 0.098 ( 0.0020 – 0.0039 )

4. Side Clearance Between Oil Pump Cover and Gears

Use feeler gauge to measure the side clearance
between oil pump cover and gears.
Side Clearance mm(in)
Standard
0.040 – 0.094 ( 0.0016 – 0.0037)
6A – 134 ENGINE MECHANICAL

5. Oil Pump Gear Shaft Outside Diameter and Clearance

between Oil Pump Gear Shaft and Oil Pump Body
Use inside and out side micrometer to measure the oil
pump gear shaft out side diameter and oil pump body
holes.
Oil Pump Gear Shaft Diameter mm(in)
Nominal Measurement Limit
20.0 ( 0.7874 ) 19.9 (0.7835)

Clearance between Oil Pump Gear Shaft

and Oil Pump Body mm(in)
Standard
0.040 – 0.074 ( 0.0016 – 0.0029 )

Note:
If measuring value exceeds, the parts must be
replaced.

6. An Interference between Oil Pump Drive Gear and

Drive Gear Shaft
Measure the inside diameter of oil pump drive gear
and outside diameter of drive gear shaft.
An Interference mm(in)
Standard
0.019 – 0.047 ( 0.0007 – 0.0019 )

Note:
The measuring value exceeds from limit or standard,
the parts must be replaced.
 ENGINE MECHANICAL 6A – 135

REASSEMBLY

Reassembly Steps Removal Steps

1. Oil Pump Body 7. Spring
2. Drive Gear Shaft 8. Spring Seat
3. Oil Pump Drive Gear 9. Split Pin
4. Oil Pump Driven Gear 10. Ball
5. Oil Pump Cover 11. Cover
6. Oil Relief Valve
6A – 136 ENGINE MECHANICAL

Reassembly Steps
1. Oil Pump Body
2. Drive Gear Shaft
Apply engine oil to drive gear and reassemble the
drive gear to oil pump body.

3. Oil Pump Drive Gear

1) Put the oil pump drive gear on the bed of bench
press, place the oil pump body with the drive gear
shaft.
2) Use bench press to press the drive gear shaft into
the oil pump drive gear as shown in the
illustration.
4. Oil Pump Driven Gear
Apply engine oil and reassemble the oil pump driven
gear to the oil pump body.

5. Oil Pump Cover

Tighten the bolts to specified torque.
Fixing Bolt Torque N·m(kg·m/lb·ft)
Bolt Size
M8 17.2 ( 1.8 / 13.0 )
M10 39.2 ( 4.0 / 28.9 )

6. Oil Relief Valve

7. Spring
8. Spring Seat
9. Split Pin
1) Install the oil relief valve, spring and spring seat to
the oil pump body.
2) Reassemble the split pin into the oil pump body
and lock it.
10. Ball
11. Cover
 ENGINE MECHANICAL 6A – 137

12. Make sure the oil pump assembly to move smoothly.

6A – 138 ENGINE MECHANICAL

OIL COOLER
DISASSEMBLY

11

2 10
9
4
3 8
7

12 6

050H100009

Disassembly Steps Removal Steps

1. Water Guide 7. Oil Thermostat
2. Oil Cooler Element 8. Spacer
3. O-Ring 9. Supporter
4. Gasket 10. Seal Ring
5. Oil Pipe 11. Oil Cooler Body
6. O-Ring 12. Gasket
 ENGINE MECHANICAL 6A – 139

Disassembly Steps
1. Water Guide
Loosen the bolts to remove the water guide.
2. Oil Cooler Element
3. O-Ring
4. Gasket
Loose the nuts to remove the oil cooler element with
the O-rings and gaskets.
5. Oil Pipe
6. O-Ring
Loosen the bolts to remove the oil pipe with O-ring.

7. Oil Thermostat
Carefully remove the oil thermostat.
8. Spacer
9. Supporter
10. Seal Ring
11. Oil Cooler Body
12. Gasket
6A – 140 ENGINE MECHANICAL

INSPECTION AND REPAIR

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

1. Oil Cooler Element

Inspect any cracking or damage.

2. Oil Thermostat
1) Inspect worn out or damage on piston and valve
seat.
2) Same time check damage or decrease spring force.
3) Inspect opening temperature with oil heater.
Opening temperature °C (°F)
98.0 (208)
 ENGINE MECHANICAL 6A – 141

REASSEMBLY

11

10 2
3
8
9 4
5

12 6

050H100010

Reassembly Steps Removal Steps

1. Oil Cooler Body 7. Oil Pipe
2. Seal Ring 8. Gasket
3. Supporter 9. O-Ring
4. Spacer 10. Oil Cooler Element
5. Oil Thermostat 11. Water Guide
6. O-Ring 12. Gasket
6A – 142 ENGINE MECHANICAL

Reassembly Steps
1. Oil Cooler Body
2. Seal Ring
Be sure seal ring direction shown in the illustration.

3. Supporter
Align the rotation stopper on supporter to oil cooler
body as shown in the illustration.

4. Spacer
5. Oil Thermostat
6. O-Ring
7. Oil Pipe
1) Reassemble the oil pipe with O-ring to the oil
cooler body.
2) Tighten the oil pipe to specified torque.
Oil Pipe Torque N·m(kg·m/lb·ft)
39.2 ( 4.0 / 28.9 )

8. Gasket
9. O-Ring
10. Oil Cooler Element
1) Apply ThreeBond 1208 to O-ring grooves to install
the O-rings.
2) Install the gaskets to the oil cooler element.
3) Reassemble the oil cooler element to the oil cooler
body.
4) Tighten the fixing nuts for oil cooler element to
specified torque.
Element Nut Torque N·m(kg·m/lb·ft)
24.5 ( 2.5 / 18.1 )

11. Water Guide

12. Gasket
 ENGINE MECHANICAL 6A – 143

MAIN OIL FILTER

DISASSEMBLY

Disassembly Steps Removal Steps

1. Plug 8. O-Ring
2. O-Ring 9. Warning Switch Assembly
3. Center Bolt 10. Gasket
4. O-Ring 11. Spring
5. Case 12. Relief Valve Assembly
6. Spring 13. Bracket
7. Element
6A – 144 ENGINE MECHANICAL

Disassembly Steps
1. Plug
2. O-Ring
Loosen plug with O-ring for drain engine oil form
main oil filter.
3. Center Bolt
4. O-Ring
Loosen center bolt with O-ring.
5. Case
6. Spring
7. Element
Disassemble the case, spring and element.
8. O-Ring

9. Warning Switch Assembly

Carefully remove the warning switch assembly with
the gasket for disassemble the relief valve assembly.

10. O-Ring
11. Spring
12. Relief Valve Assembly
13. Bracket
Loosen Fixing bolts to disassemble the bracket with
O-rings.
 ENGINE MECHANICAL 6A – 145

INSPECTION AND REPAIR

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

1. Relief Valve Assembly

Check any scratches or damage on the relief valve
assembly.

2. Bracket
Clean oil holes on the bracket.
6A – 146 ENGINE MECHANICAL

REASSEMBLY

Reassembly Steps Removal Steps

1. Bracket 8. O-Ring
2. Relief Valve Assembly 9. Case
3. Spring 10. O-Ring
4. Gasket 11. Center Bolt
5. Warning Switch Assembly 12. O-Ring
6. Element 13. Plug
7. Spring
 ENGINE MECHANICAL 6A – 147

Reassembly Steps
1. Bracket
1) Set O-rings to bracket.
2) Tighten the bolts to specified torque.
Tighten Torque N·m(kg·m/lb·ft)
43.2 ( 4.4 / 31.8 )

2. Relief Valve Assembly

3. Spring
4. Gasket

5. Warning Switch Assembly

1) Reinstall the relief valve assembly, the spring and
the warning switch assembly to bracket.
2) Tighten the warning switch assembly to specified
torque.
Warning switch torque N·m(kg·m/lb·ft)
77.5 ( 7.9 / 57.1 )

6. Element
7. Spring

8. O-Ring
9. Case
10. O-Ring

11. Center Bolt

1) Apply engine oil to the O-ring and set the O-ring
to groove of the case.
2) Reassemble the element, the spring, the case and
the center bolt with the O-ring to tighten by
specified torque.
Center Bolt Torque N·m(kg·m/lb·ft)
44.2 ( 4.5 / 32.5 )

Note:
When reassemble the case a oil drain plug must
direction to engine rear side.
12. O-Ring
13. Plug
6A – 148 ENGINE MECHANICAL

PARTIAL OIL FILTER

DISASSEMBLY

Disassembly Steps Removal Steps

1. Plug 6. Spring
2. O-Ring 7. Element
3. Center Bolt 8. Gasket
4. O-Ring 9. Bracket
5. Case
 ENGINE MECHANICAL 6A – 149

Disassembly Steps
1. Plug
2. O-Ring
Loosen Plug with O-ring for drain engine oil.
3. Center Bolt
4. O-Ring
5. Case
Loosen center bolt to remove the case.
6. Spring
7. Element
8. Gasket

9. Bracket
6A – 150 ENGINE MECHANICAL

INSPECTION AND REPAIR

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

1. Center Bolt
Clean the oil holes on the center bolt.
2. Bracket
Clean the oil holes on the bracket.
 ENGINE MECHANICAL 6A – 151

REASSEMBLY

Reassembly Steps Removal Steps

1. Bracket 6. O-Ring
2. Element 7. Center Bolt
3. Spring 8. O-Ring
4. Gasket 9. Plug
5. Case
6A – 152 ENGINE MECHANICAL

Reassembly Steps
1. Bracket
1) Set the O-ring to the bracket.
2) Tighten fixing bolts to specified torque.
Bolt Torque N·m(kg·m/lb·ft)
43.2 ( 4.4 / 31.8 )

2. Element
3. Spring
4. Gasket

5. Case
1) Apply engine oil to gasket and reinstall it to the
groove of case.
2) Reassemble the element, spring and case with
gasket to bracket.
6. O-Ring

7. Center Bolt
Tighten center bolt with O-ring to specified torque.
Center Bolt Torque N·m(kg·m/lb·ft)
49.1 ( 5.0 / 36.2 )

Note:
The drain plug must face to engine rear side.
8. O-Ring
9. Plug
 ENGINE COOLING 6B – 1

SECTION 6B
ENGINE COOLING

CONTENTS

PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 2
Coolant Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 2
Coolant Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 2
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 3
Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 4
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 9
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 15
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 18
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 20
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B – 20
6B – 2 ENGINE COOLING

GENERAL DESCRIPTION
Coolant Flow Chart

EGR Valve

EGR Cooler
er
reath
Air b
Sub tank
Air compressor

Oil cooler

Water pump Turbocharger

Thermostat

Radiator

Fan clutch

Cooling fan

HCW31BLF000401

COOLANT FLOW THERMOSTAT

The cooling system main parts are constituted A wax pellet type thermostat is used.
the radiator, the sub tank, the water pump, the
water outlet pipe and the thermostat.
The sub tank is mounted at the back of the cab
on the right-hand-side. Cooling water level can
be checked and additional water added at the
sub tank. This makes daily inspection and/or
maintenance easier for vehicle operator.
This top-bypass type cooling system controls
the cooling water temperature though the
thermostat installed at the water pump inlet.
The system maintains optimum cooling water
volume and minimizes cooling water
temperature fluctuation and hunting.
 ENGINE COOLING 6B – 3

Water Pump Construction

WATER PUMP
A centrifugal type water pump circulates the
coolant through the cooling system.
The water pump is driven by timing gear train.
The water pump has an engine oil lubricating
system, no need greasing.
6B – 4 ENGINE COOLING

COOLING FAN
DISASSEMBLY

Disassembly Steps Removal Steps

1. Fan Clutch
2. Cooling Fan
 ENGINE COOLING 6B – 5

Disassembly Steps
1. Fan Clutch
Loosen the nuts to disassemble the fan clutch with
cooling fan from the engine assembly.
2. Cooling Fan
Loosen the nuts to disassemble the cooling fan from
the fan clutch.
6B – 6 ENGINE COOLING

INSPECTION AND REPAIR

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

Fan Clutch
Rotate by hand to inspect leakage or any abnormal
noise.
 ENGINE COOLING 6B – 7

REASSEMBLY

Reassembly Steps Removal Steps

1. Cooling Fan
2. Fan Clutch
6B – 8 ENGINE COOLING

Reassembly Steps
1. Cooling Fan
2. Fan Clutch
1) Reassemble the cooling fan to the fan clutch.
2) Reassemble the fan clutch with the cooling fan to
engine assembly by specified torque.
Cooling Fan Nut Torque N·m(kg·m/lb·ft)
28.4 ( 2.9 / 21.0 )

Fan Clutch Nut Torque N·m(kg·m/lb·ft)

67.7 ( 6.9 / 49.9 )
 ENGINE COOLING 6B – 9

WATER PUMP
DISASSEMBLY

Disassembly Steps Removal Steps

1. Front Cover 7. Bearing Large
2. O-Ring 8. Shaft
3. Impeller 9. Oil Seal
4. Rear Cover 10. Seal Unit
5. Bearing Small 11. Pump Body
6. Gear 12. Water Drain Hose
6B – 10 ENGINE COOLING

Disassembly Steps
1. Front Cover
Loosen the rear cover fixing bolts to disassemble the
front cover.
2. O-Ring
3. Impeller
Use impeller remover to remove the impeller from the
shaft.
Impeller remover: 1-8521-0062-0
4. Rear Cover
5. Bearing Small
6. Gear

7. Bearing Large
8. Shaft
1) Use bench press from the impeller side to
disassemble the shaft with the bearings and the
gear.
2) Use the bench press the rear cover side to
disassemble the bearings and gear.
9. Oil Seal

10. Seal Unit

Note:
Do not make scratch or damage seating surface of the
oil seal and the seal unit on the pump body when
disassemble them from the pump body.
11. Pump Body
12. Water Drain Hose
 ENGINE COOLING 6B – 11

INSPECTION AND REPAIR

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

1. Impeller
Inspect corrosion on impeller, worn out of seal unit
touching surface or some damage.

2. Bearings
1) Wash bearing in the clean kerosene.
2) Visually check scratches or damages on ball and
bearing race.
3) Rotate the bearing on your hand for hearing
abnormal noise.
4) Check abnormal clearance between ball and
bearing race.

3. Shaft
Inspect damage or worn out on the shaft.
6B – 12 ENGINE COOLING

REASSEMBLY

Reassembly Steps Removal Steps

1. Pump Body 7. Rear Cover
2. Oil Seal 8. Seal Unit
3. Bearing Large 9. Impeller
4. Shaft 10. O-Ring
5. Gear 11. Front Cover
6. Bearing Small 12. Water Drain Hose
 ENGINE COOLING 6B – 13

Reassembly Steps
1. Pump Body
2. Oil Seal
1) Apply engine oil to inside and out side of the oil
seal.
2) Seal lip face to upper and carefully press fit the oil
seal to the pump body.
3. Bearing Large

4. Shaft
1) Apply engine oil to the shaft.
2) Use bench press to pess fit the bearing large onto
the shaft.
3) Use bench press to press fit shaft with bearing
large into the pump body.

5. Gear
1) Place the gear long boss side facing to bearing
large on the shaft.
2) Use the bench press to press fit the gear onto the
shaft as shown in the illustration.
6B – 14 ENGINE COOLING

6. Bearing Small
Use the bench press to gradually press the bearing
small into the rear cover.

7. Rear Cover
1) Use the bench press to install the rear cover
assembly into the shaft shown in the illustration.
2) Same time align bolt holes between rear cover and
pump body.

8. Seal Unit
Use seal unit installer to install the seal unit.
Seal unit installer: 1-8522-0047-0

9. Impeller
Use the bench press to gradually press the impeller
until make specified clearance between impeller and
pump body.
Clearance between impeller
and pump body mm(in)
Standard
1.7 – 2.7 ( 0.0669 – 0.1063 )

10. O-Ring
Set the o-ring to the pump body.
11. Front Cover
1) Align bolt hole together with rear cover assembly.
2) Tighten the bolt from rear cover side to specified
torque.
Bolt torque N·m(kg·m/lb·ft)
27.5 ( 2.8 / 20.3 )

12. Water Drain Hose

 ENGINE COOLING 6B – 15

THERMOSTAT
DISASSEMBLY

Disassembly Steps Removal Steps

1. Thermostat Housing 4. Thermostat
2. Gasket 5. Seal Ring
3. O-Ring
6B – 16 ENGINE COOLING

Disassembly Steps
1. Thermostat Housing
Loosen the fixing bolts to disassemble the thermostat
housing.
2. Gasket
3. O-ring
4. Thermostats
Carefully remove the thermostats from the oil cooler
case.
5. Seal Ring
Use a seal ring puller to take out the seal rings.
Seal Ring Puller : 1-8521-0067-0
 ENGINE COOLING 6B – 17

INSPECTION AND REPAIR

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

1. Thermostat
1) Visually inspect leakage wax pellet, some damage
the spring or caulking position on the thermostat.
2) Operating Test
Completely submerge the thermostat in water.
Heat the water
Stir the water constantly to avoid direct heat being
applied to the thermostat.
Measurer the thermostat initial opening
temperature.
Thermostat Initial Opening
Temperature °C (°F )
82 ( 180 )

Measure the thermostat full opening temperature.

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

Measure the valve lift at the thermostat full open

position.
Valve Lift At Full Open Position mm (in)
10 ( 0.39 )
6B – 18 ENGINE COOLING

REASSEMBLY

Reassembly Steps Removal Steps

1. Seal Ring 4. O-Ring
2. Thermostat 5. Thermostat Housing
3. Gasket
 ENGINE COOLING 6B – 19

Reassembly Steps
1. Seal Ring
Use seal ring installer to install the seal ring to the oil
cooler case, the direction of seal ring shown in the
illustration.
Seal Ring Installer : 1-8522-1034-0

2. Thermostat
Carefully reassemble the thermostat to oil cooler case
shown in the illustration.

3. Gasket
4. O-Ring
5. Thermostat Housing
1) Set the O-ring to the thermostat housing to
reassemble the thermostat housing with the
gasket.
2) Pushing the thermostat housing to oil cooler case,
initially tighten the water pump side bolts then
tighten the oil cooler side bolts to specified torque.
Bolt Torque N·m(kg·m/lb·ft)
39.2 ( 4.0 / 28.9 )
6B – 20 ENGINE COOLING

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

1. Radiator
1) Set a radiator filler cap tester to the sub tank filler
neck.
2) Apply testing pressure to the cooling system to
check for leakage.
The testing pressure must not exceed the specified
pressure.
Testing Pressure kPa(kg/cm2/psi)
98 ( 1.0 / 14.2 )
060HT008

2. Sub Tank Filler Cap

The radiator sub tank filler cap is designed to maintain
coolant pressure in the cooling system at 108 kPa
(1.1 kg/cm2 / 15.6 psi).
Check the radiator sub tank filler cap with a radiator
cap tester.
The radiator sub tank filler cap must be replaced if it
fails to hold the specified pressure during the test
procedure.
110HY00001
Radiator Sub Tank Filler
Cap Pressure kPa(kg/cm2/psi)
62 – 72 ( 0.63 – 0.73 / 9.0 – 10.4 )
 FUEL SYSTEM 6C – 1

SECTION 6C
FUEL SYSTEM

CONTENTS

PAGE
Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 2
Fuel System Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 3
Common Rail System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 3
System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 3
Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 4
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 4
Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 5
Cleaning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 5
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 6
Fuel Pressure Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 6
Fuel Pressure Limiter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 7
Fuel Flow Damper Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 8
Injector Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 9
Water Separator with Pre-Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 10
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 13
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 15
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C – 18
6C – 2 FUEL SYSTEM

MAIN DATA AND SPECIFICATIONS

Injection pump specifications

Fuel injection system Common rail (Electronically controlled)

Supply pump SP120-6HD
Pump capacity (maximum) 525 mm3/ST
Direction of rotation Clockwise (Viewed from the drive shaft side)
Pressure delivery order (Pump cylinder number) 1-2-1-2-1-2
Plunger diameter 8.5 mm
Overflow valve opening pressure 255 kPa (2.6 kgf/cm2)
Feed pump type and output volume Trochoidal (10.5 cm3/revolution)

Fuel injector specifications

Fuel injector manufacturer and type DENSO-U2

Nozzle diameter 0.21 mm (Each fuel injector has 8 holes)

FUEL SYSTEM PRECAUTIONS

The electronically-controlled, common rail fuel injection system has several advantages over previous
systems. Higher fuel injection pressure and more accurate control permit smaller and more precise fuel
route apertures and spacing.
Because of the high precision, the system is extremely sensitive to foreign material. The entry of foreign
material into the injection system can easily damage delicate parts. Because of this, extreme care must be
taken to avoid contamination.
• During servicing of the system components (fuel injectors, supply pump, common rail, fuel pipe,
injection pipes, etc.), immediately seal any exposed openings.
• I-bolts and packing are used in the installation of the fuel pipe. Carefully check the bolts and packing
for dirt and other contamination before using them. Carefully clean if required.
• Always store parts such as I-bolts and packing in a covered container to protect them from
contamination.
• Fuel leakage can result in a serious fire. At the completion of a service procedure, carefully wipe up
any spilled fuel before starting the engine. After starting the engine, check for additional fuel leakage.
 FUEL SYSTEM 6C – 3

GENERAL DESCRIPTION
COMMON RAIL SYSTEM

1
040MV045

This section covers the electronically controlled fuel injection system for 6WG1TC diesel engine.
The diesel engine fuel system consists of the following.
• Fuel tank
• Fuel hoses and lines
• Water separator
• Fuel filter
• Fuel feed pump
• Fuel supply pump
• Fuel common rail
• Steel lines
• Six fuel injectors with solenoid valve
The fuel supply pump, fuel common rail and the fuel injectors are made by DENSO.
If an internal problem occurs in the fuel supply pump, the fuel supply pump must be removed from the
engine and serviced by an authorized DENSO dealer. Do not open the fuel supply pump and injector
assembly, or the warranty is void.
The fuel supply pump has an identification tag (1) attached to the fuel supply pump body.

SYSTEM OUTLINE
The COMMON RAIL SYSTEM detects engine conditions (engine speed, accelerator pedal angle, coolant
temperature, etc.) by means of its sensors and generally control fuel injection amount, timing, and pressure
by means of its microcomputer, thereby making the engine run in the best condition.
Further, the system performs the self-diagnosis/lighting function to diagnose main components and, if
abnormality found, worn the driver, the failsafe function to stop the engine depending on the parts to which
trouble has occurred, and the backup function to switch over the control method to enable the vehicle to
run continuously.
6C – 4 FUEL SYSTEM

FUEL INJECTION SYSTEM

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

4
9
6
11 7
8

10

12

C06M200002

1. Fuel tank 7. Fuel flow dumper

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

SERVICE PROCEDURE
CLEANING PROCEDURE
CAUTION:
Be careful not to enter the foreign materials. Before servicing, clean the related parts or the connection part.
1. By using steam cleaner, clean around the common rail. Be careful not to damage the electrical parts.
2. Remove water by air blow.
3. Clean the common rail related parts by using parts cleaner solvent.
4. Dry the common rail by air blow, then start inspection or parts replacement.

CAUTION:
• If the parts replacement is required, do not service when the engine is warm or hot. High temperature
fuel can be blown out under pressure if the engine is still warm or hot.
• When remove the parts, cover the connection part with clean waste cloth to prevent fuel blowing out.
• Wipe leaked fuel with clean waste cloth.
• Clean and dry the threaded portion of the removed parts.
• If the foreign materials enter into the common rail, can cause trouble of the engine. Be careful not to
enter the foreign materials even if it is very small.
6C – 6 FUEL SYSTEM

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

040MA00011

Removal Steps
1. Fuel pressure sensor

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

Installation Steps
1. Fuel Pressure Sensor
Apply grease to new pressure sensor. Tighten the
pressure sensor to the specified torque.

Apply
Fuel Pressure Sensor Torque N·m (kg·m/lb·ft)
grease. 98 (10.0/72)

CAUTION:
• The fuel pressure sensor cannot be reused when it
was removed.
040MA00005
• Be careful not to enter the foreign materials.
• Do not touch the connector pin of the sensor.
 FUEL SYSTEM 6C – 7

FUEL PRESSURE LIMITER REPLACEMENT

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

24mm Hex.
040MA00008

Removal Steps
1. Fuel pressure limiter
2. Gasket

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

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

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

172 (17.5/127)
6C – 8 FUEL SYSTEM

FUEL FLOW DAMPER REPLACEMENT

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

040M200004

Removal Steps
1. Fuel flow damper
2. Gasket

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

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

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

172 (17.5/127)
 FUEL SYSTEM 6C – 9

INJECTOR ASSEMBLY
The injector cannot be adjusted or repaired. If the injector
is damaged, the entire assembly must be replaced.
6C – 10 FUEL SYSTEM

WATER SEPARATOR
WITH PRE-FUEL FILTER
DISASSEMBLY

145MT001

Disassembly Steps Removal Steps

1. Plug 4. Float
2. Drain plug 5. Filter element
3. Cover 6. Body
 FUEL SYSTEM 6C – 11

Disassembly Steps
1. Plug
2. Drain Plug
Loosen drain plug with O-ring to drain fuel and water.
3. Cover
Carefully turn the cover to disassemble the cover with
O-ring.
4. Float
5. Filter Element
6. Body
6C – 12 FUEL SYSTEM

INSPECTION AND REPAIR

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

Cover
Check any damage or scratch on the cover.

Filter Element
Check dirt, break and distortion on the filter element.

Body
Check any clog in the through hole of body.
 FUEL SYSTEM 6C – 13

REASSEMBLY

145HT001

Reassembly Steps Removal Steps

1. Body 4. Cover
2. Filter element 5. Drain plug
3. Float 6. Plug
6C – 14 FUEL SYSTEM

Reassembly Steps
1. Body
2. Filter Element
3. Float
4. Cover
Apply a little fuel on the O-ring then tight the cover to
specified torque.
Cover torque N·m(kg·m/lb·ft)
19.6 ( 2.0 / 14.5 )

5. Drain Plug
Tighten to specified torque N·m(kg·m/lb·ft)
1.47 (0.15 / 1.1 )

6. Plug
After air breading tighten the plug to specified torque.
Plug torque N·m(kg·m/lb·ft)
12.3 ( 1.25 / 9.0 )
 FUEL SYSTEM 6C – 15

FUEL FILTER
DISASSEMBLY

Disassembly Steps Removal Steps

1. Drain Plug 7. Element
2. Over Flow Valve 8. Water Strainer
3. Breather Plug 9. Spring
4. Center Bolt 10. Center Tube
5. Upper Cover 11. Fuel Filter Body
6. O-Ring
6C – 16 FUEL SYSTEM

Disassembly Steps
1. Drain Plug
2. Over Flow Valve
3. Breather Plug
4. Center Bolt
5. Upper Cover
6. O-Ring
7. Element
8. Water Strainer
9. Spring
10. Center Tube
11. Fuel Filter Body
 FUEL SYSTEM 6C – 17

INSPECTION AND REPAIR

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

Over Flow valve

Inspect clogging or leakage on the over flow valve.
Over Flow Valve Opening Pressure kPa(kg/cm2/psi)
250 – 310 ( 2.8 – 3.2 / 40 – 46 )

Center Tube
Clean the hole for fuel flow.
6C – 18 FUEL SYSTEM

REASSEMBLY

Reassembly Steps Removal Steps

1. Fuel Filter Body 7. Upper Cover
2. Center Tube 8. Center Bolt
3. Spring 9. Breather Plug
4. Water Strainer 10. Over Flow Valve
5. Element 11. Drain Plug
6. O-Ring
 FUEL SYSTEM 6C – 19

Reassembly Steps
1. Fuel Filter Body
2. Center Tube
3. Spring
4. Water Strainer
5. Element
6. O-Ring
7. Upper Cover
8. Center Bolt
1) Set O-ring to upper cover.
2) Tighten Center Bolt to Specified Torque.
Center Bolt Torque N·m(kg·m/lb·ft)
24.5 ( 2.5 / 18.1 )

9. Breather Plug
10. Over Flow Valve
11. Drain Plug
6C – 20 FUEL SYSTEM

MEMO
 ENGINE ELECTRICAL 6D – 1

SECTION 6D
ENGINE ELECTRICAL

CONTENTS

PAGE
Wire Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 3
Symbols and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 5
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 7
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 8
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 9
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 12
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 12
Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 12
Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 13
Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 13
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 13
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 14
Bench Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 15
Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 15
Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 16
Generator Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 17
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 18
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 22
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 22
Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 23
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 24
Overrunning Clutch and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 24
Front Bracket (Bearing and Oil Seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 25
Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 25
Magneto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 25
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 26
Starter Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 29
Starter Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 29
6D – 2 ENGINE ELECTRICAL

PAGE
Preheating and Starting Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 30
Wiring Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 30
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D – 31
 ENGINE ELECTRICAL 6D – 3

WIRE CODING

DESCRIPTION
Codes used in the circuit diagram represent wire size
and color.
Example: 0.5 R
Wire color (Red)
Wire size (0.5 mm2)

WIRE SIZE
Wire size is specified in the metric system.
The metric system gives the wire size in cross-
sectional area measured in the square millimeters.

WIRE SIZE SPECIFICATIONS

Wire size Number of wires/ Resistance at normal room Maximum allowable
Wire diameter temperature of 20°C (68°F) current
mm2 AWG mm (in) Ω/m (Ω/ft) A

0.5 20 7/0.32 (0.013) 0.03250 (0.00991) 11.3

0.85 18 11/0.32 (0.013) 0.02050 (0.00625) 14.8
1.25 16 16/0.32 (0.013) 0.01410 (0.00430) 18.8
2 14 26/0.32 (0.013) 0.00867 (0.00264) 25.4
3 12 41/0.32 (0.013) 0.00550 (0.00168) 34.2
5 10 65/0.32 (0.013) 0.00347 (0.00106) 45.9
8 8 50/0.45 (0.018) 0.00228 (0.00070) 59.8
15 8 84/0.45 (0.018) 0.00136 (0.00042) 82.8
20 4 41/0.80 (0.031) 0.00087 (0.00027) 110.9
30 2 70/0.80 (0.31) 0.00051 (0.00016) 147.0
6D – 4 ENGINE ELECTRICAL

Wire Color
All wires have color-coded insulation.
Wires belonging to a system’s main harness have a
single color 1.
Wires belonging to a system’s sub-curcuits have a
colored stripe (tracer) 2.
Striped wires use the following code to show wire size
and colors.

Example 0.5 G R
Red (Stripe (tracer) color)
Green (Base color)
Wire size (0.5 mm2)

Abbreviations are used to indicate wire color within a

circuit diagram.
Refer to the following table.

WIRE COLOR-CODING
Color-coding Meaning Circuits
B Black Starter circuit and grounding circuit
W White Charging circuit
R Red Lighting circuit
G Green Signal circuit
Y Yellow Instrument circuit
L Blue Wiper circuit
O Orange
Br Brown
Lg Light green
Gy Gray Other circuits
P Pink
Sb Sky blue
V Violet
 ENGINE ELECTRICAL 6D – 5

SYMBOLS AND ABBREVIATIONS

DESCRIPTION
The symbols and abbreviations used in the circuit
diagram make the diagram easier to read and
understand.

SYMBOLS
The illustration at the left shows typical symbols used
in circuit diagrams.
These same symbols may also appear in the text.
Refer to the following table.

SYLBOL AND MEANING

Symbol Meaning Symbol Meaning

Fuse Single filament bulb

Fusible link (Slow blow fuse) Double filament bulb

Fusible link wire Motor

Switch Variable resistor

Switch Coil (Indicator)

6D – 6 ENGINE ELECTRICAL

Symbol Meaning Symbol Meaning

Relay
Contact wiring Note:
Relay contact shown in
the wiring diagram
indicates condition
Battery before actuation.

Diode Connector

Electronic part Light emitting diode

Resistor Read switch

Speaker Condenser

Ground

ABBREVIATIONS
The illustration at the left shows typical abbreviations
used in the circuit diagrams.
These same abbreviations may also appear in the text.
Refer to the following table.

SYMBOL AND MEANING

Abbreviation Meaning Abbreviation Meaning
RH Right-hand side STD Standard equipment
LH Left-hand side OPT Optional equipment
SW Switch W/ With
M/T Manual transmission WO/ Without
A/T Automatic transmission OD Overdrive
FT Front ACC Accessories
RR Rear A/C Air conditioner
FLW Fusible link wire ATF Automatic transmission fluid
TEMP Temperature VSV Vacuum switching valve
ECM Electronic control module
 ENGINE ELECTRICAL 6D – 7

FUSES
FUSE
Fuses are located in the fuse box.
This type of fuse is highly resistant to both heat and
shock. It is lighter in weight than conventional glass
tube fuses.
All fuses are transparent so that a blown fuse is easily
identified.
Fuse Specifications
Current (A) Housing Color
5 Yellow-brown
7.5 Brown
10 Red
15 Blue
20 Yellow

SLOW BLOW FUSE

Slow blow fuse are connected in the slow blow fuse
box.
Slow blow fuse are designed to melt in the event of
circuit overload. This protects the wiring harnesses
from damage.
Melted slow blow fuses can be visually identified. The
circuit capacity is indicated on top of slow blow fuse
case and the case color is identified the circuit capacity.
40A Green
60A Yellow
Precautions
1. Always determine the cause of an overload before
replacing a fuse.
2. Always replace a blown fuse with a new fuse of the
same amperage rating.
Never replace a blown fuse with a new fuse of a
different amperage rating. An electrical fire with
serious circuit damage can result.
6D – 8 ENGINE ELECTRICAL

CHARGING CIRCUIT

Additional
diode Ignition
Diode trio Charging lamp swith
Stator coil

Battery(24V)
Field
coil
IC regulator

Generator

D06H100005

Generator description
Main components of the brushless generator are the rotor, the stator, the rectifier assembly, the front
bracket, the rear bracket, the C regulator, the front bearing, the rear bearing, and the pulley.
The stator coil produces AC current that must be converted to DC current. This conversion occurs in the
rectifier assembly.
The rectifier assembly uses the following diodes.
• 6 main diodes (3 positive diodes and 3 negative diodes)
• 2 additional diodes (1 positive diode and 1 negative diode)
• 1 diode trio (3 small diodes used to supply field current)
The generator has 3 terminals
• Terminal-B (DC output)
• Terminal-L (Excitation voltage)
• Terminal-R (Excitation voltage)
Termimal-L and Terminal-R are connected to the field coil. They provide excitation voltage at the start of
generator operation.
When the voltage at Terminal-L reaches the same level as the battery voltage, the charging lamp (inside the
vehicle) turns off.
 ENGINE ELECTRICAL 6D – 9

GENERATOR
DISASSEMBLY

14
27 15
16
17

25

26
12

6 13

24 7
8
1
23
4
22
3
21
2
20
19
10
18

11
9

066HY00008

Disassembly Steps
1. Through bolt (4) 15. Terminal-B nut (Bolt)
2. Nut 16. Terminal-B fixing nut
3. Spring washer 17. Terminal-B bolt
4. Pulley 18. Stator
5. Rotor 19. Screw (Regulator)
6. Front bracket 20. Plate (L)
7. Screw (Coil assembly) 21. Regulator
8. Screw (Regulator) 22. Rectifier assembly
9. Coil assembly 23. Rear bracket
10. Screw (Connector) 24. Screw (Retainer)
11. Connector assembly 25. Retainer
12. Screw (Clamp) 26. Front bearing
13. Clamp 27. Rear bearing
14. Terminal-B cap
• To reassemble the generator, follow the
disassembly steps in the reverse order.
6D – 10 ENGINE ELECTRICAL

Disassembly Steps
Scribe setting marks on the front and rear brackets before
beginning disassembly. This makes reassembly easier.

Through bolts
1. Remove the 4 through bolts.
2. Carefully insert the tip of a screwdriver into the space
between the stator and the front bracket.
Take care not to damage the stator coil.
3. Use the screwdriver to carefully pry the front bracket
and pulley from the stator and rear bracket.

Rotor
Ｂ
1. Place the rotor in a vise. Take care not to damage the
rotor balls.
2. Remove the pulley fixing nut.
3. Remove the pulley, the fan, the spacer, and the front
bracket.

Ａ Ａ

Pawl
066H100007

Bearings
• If the front bearing must be removed, loosen the
screws holding the retainer. Use a socket to push the
bearing free.
• If the rotor bearing must be removed, use an ordinary
bearing puller.
Remove the bearings only if absolutely necessary.
Discard the old bearings and replace them with new ones.
Never reuse the old bearings.

Coil assembly
Connector 1. Remove the 2 ‘A’ screws (securing the coil terminal to
the IC regulator).
A 2. Support the coil assembly with your hand. Take care
not to damage the terminals.
3. Remove the 3 ‘B’ screws (securing the coil assembly
to the rear bracket).
4. Remove the coil assembly.
B If the ‘B’ screws are removed before the ‘A’ screws, the
066H100008
terminals may be damaged.
 ENGINE ELECTRICAL 6D – 11

Connector
Remove the connector and the clamp.

Terminal-B assembly
1. Remove the cap and nut from the rectifier terminal
Terminal bolt bolt.
IC 2. Carefully insert the tip of a screwdriver into the space
Terminal-B
regulator between the rear bracket and the Terminal-B
assembly.
3. Pry the Terminal-B assembly free. The tube should
remain attached to the rear bracket.
Take care not to lose the tube.

Cap
Nut

Terminal-B

Terminal bolt

066H100009

Stator
Rectifier assembly
IC Regulator
1. Remove the 1 screw holding the rectifier.
2. Remove the 2 screws holding the regulator.
3. Remove the stator and the rectifier assembly from the
rear bracket as a single unit.
4. Remove the IC regulator.
5. Use a soldering iron to disconnect the 4 stator coil
lead wires at the rectifier.
6. Separate the stator and the rectifier.
The stator coil lead wires are secured to the rectifier with
the high-temperature solder (melting point 230°C (446°F)).
Use a 180 – 270 watt soldering iron to disconnect the lead
wires.
Heat from the soldering iron will damage the diodes if
applied for too long a time. Work as quickly as possible.
Do not apply heat to any connection for more than 5
seconds.
6D – 12 ENGINE ELECTRICAL

INSPECTION AND REPAIR

1. Check the stator for damage. Look for coils that have
Stator
coil lead changed color.
2. Check for loose wiring connections.
3. Use a circuit tester to check for continuity between
stator leads.
If there is no continuity, the stator must be replaced.

066H100010

4. Check for continuity between the stator core leads

Stator and the stator core.
coil lead If there is continuity, the stator must be replaced.

Core

060H100011

Rotor
Check for abnormal bearing noise, looseness, and
significant grease leakage (minimal grease leakage is
normal and should be wiped away with a clean rag.)
Bearing noise and looseness is more easily checked when
pressure is applied to the shaft end.
Replace the rotor if any of the above conditions are
present.

Coil assembly
Measure the resistance between the 2 terminals.
Terminal If the measured resistance is outside the specified range,
the coil assembly must be replaced.

Terminal assembly

066H100012
 ENGINE ELECTRICAL 6D – 13

Rectifier assembly
Positive diode
1. Use a circuit tester to check for continuity between
the 3 positive diodes and their respective terminals.
Also check for continuity between the positive
additional diode and its terminal.
Touch one probe of the tester to the diode’s heat sink
and the other probe to the terminal.
There should be continuity in one direction and no
Diode terminals Negative diode continuity in the other direction.
(Partial view)
066H100013 If there is continuity in both directions, the diode is
shorted. The rectifier assembly must be replaced.
If there is no continuity in either direction, the diode
is open. The rectifier assembly must be replaced.
2. Repeat Step 1 for the 3 negative diodes and the 1
negative additional diode.
3. Repeat Step 1 for the diode trio.

066HHY00012

Front bearing
Check for abnormal bearing noise, looseness, and
significant grease leakage (minimal grease leakage is
normal and should be wiped away with a clean rag.)
Bearing noise and looseness is more easily checked when
pressure is applied to the shaft end.
Replace the bearing if any of the above conditions are
present.

Regulator
The regulator cannot be checked with the circuit tester.
The regulator is checked during bench testing following
generator reassembly. The regulator must precisely
control generator voltage.
6D – 14 ENGINE ELECTRICAL

Reassembly
To reassemble the generator, follow the disassembly
procedure in reverse order. Pay careful attention to the
items below.

Bearing grease
Bearings are packed with grease and sealed when they are
manufactured. No further grease is required.
The rotor shaft bearing has a lubrication band. Do not
apply further grease or oil.
Check the rear bracket bearing box for oil and grease. If
present, carefully wipe it away with a clean rag. Excess
lubricant in the box can cause creeping.

High-temperature solder
Use high-temperature solder (melting point 230°C
(446°F)) and a 180 – 270 watt soldering iron to reconnect
the lead wires.
Heat from the soldering iron will damage the diodes if
applied for too long a time. Work as quickly as possible.
Do not apply heat to any connection for more than 5
seconds.

Tightening torques
N·m (kg·m/lb·ft)
Fastener or component Torque
Pulley nut 147 (15/108.5)
Through bolts 5 (0.5/3.6)
Bearing retainers
Coil assembly
3.4 (0.4/2.9)
Rectifier
Regulator
Terminal-B nut 8.8 (0.9/6.5)

Do not overtighten the fasteners.

Rear bracket, stator assembly, and front bracket rotor

assembly
• The clearance between the rotor bearing and the rear
bracket is very tight. To make installation easier, heat
the rear bracket bearing box to 50 – 60°C (122 – 140°F).
• Following generator installation, turn the pulley with
your hand to make sure that the rotor rotates
smoothly.
 ENGINE ELECTRICAL 6D – 15

BENCH TESTING

Ammeter Switch1

Voltmeter
Lamp
(24Volt/Less than 3 watts) Switch2

Battery(24V)

Generator

Variable resistance

Voltage regulation
1. Connect the circuit as shown in the diagram above.
• 100-ampere capacity ammeter.
• 30-volt capacity voltmeter.
• Variable resistor with a rating of more than 50
amperes
2. Close Switch 1 and open Switch 2 to operate the
generator. The lamp should light.
If the lamp does not light, check the voltage at
Terminal-L.
If the voltage is close to battery voltage, inspect the
generator.
If the voltage is much lower than battery voltage, the
lamp or the lamp circuit is open.
3. Gradually increase generator speed. The lamp should
turn off before the generator reaches a speed of 1,300
rpm. If it does not, inspect the generator.
Pay close attention to the voltage. If the unregulated
voltage exceeds 30 volts, the IC regulator will be
damaged.
If the voltage does not rise above the battery voltage
level, the generator is no producing electricity.
Inspect the generator.
4. Increase generator speed to 5,000 rpm. Read the
ammeter.
If the ammeter reading is less than 5 amperes, read
the voltmeter. The voltmeter reading is the regulated
voltage.
If the ammeter reading is more than 5 amperes, wait
a few seconds while further charging occurs. If the
ampere reading remains above 5 amperes, replace
the battery with another battery that you know to be
fully charged.
If the regulated voltage remains outside the specified
range, the regulator must be replaced.
6D – 16 ENGINE ELECTRICAL

Output current
The output current test determines whether or not the
generator is capable of producing its rated output.
1. Stop generator operation.
2. Close Switch 1. The lamp should light.
3. Set the variable resistance to its highest value
(current at lowest level).
4. Close Switch 2.
5. Start the generator and increase its speed to 5000
rpm.
6. Adjust the variable resistor for maximum power
output.
7. Allow the generator to run for 15 minutes.
Generator temperature will increase.
8. Operate the generator at 2,500 rpm.
9. Adjust the variable resistor for maximum power
output.
10. Read the ammeter. If the ammeter reading (output
current) is within the specified range, the generator is
operating correctly.
11. Increase the generator speed to 5,000 rpm.
12. Repeat Steps 9 and 10.
If the output current is outside the specified range, inspect
the generator again. Follow the steps outlined earlier in
this Section.

Maintenance criteria

Generator speed 2,500 rpm 5,000 rpm

Output characteristics Voltage 27V 27V

(Generator hot) Current More than 42A More than 50A
Field coil resistance (20°C (68°F)) 4.45 – 5.2Ω
Regulator adjusted voltage 28 – 29V
Rotational direction (Viewed from the front of the engine) Clockwise
 ENGINE ELECTRICAL 6D – 17

GENERATOR HANDLING PRECAUTIONS

• Be absolutely sure that the battery connections are
correct. If the polarity is reversed, the generator
diodes will be damaged.
• Do not disconnect the battery terminals or the
charging circuity while the engine is running.
• Be absolutely sure that each wire is connected to the
proper terminal.
• Do not use a megatester to check diode operation
(the diode will be damaged).
• When inspecting the generator, always disconnect
the battery negative terminal.
• Do not open and close the battery relay switch when
the engine is running.
• If using a quick charge device to charge the battery
from outside the vehicle, be sure to disconnect the
wires leading to the generator from the terminals.
• Do not use steam and/or water to clean the generator
and related parts.
• Tighten Terminal-B and Terminal-E to the specified
torque.
N·m (kg·mlb·/ft)
Terminal-B 5.9 (0.6 / 4.3)
Terminal-E 3.7 (0.4 / 2.9)

• Adjust the V-belt tension after installing the

generator. Refer to the item in this Manual on tension
adjustment.
6D – 18 ENGINE ELECTRICAL

STARTER MOTOR
DISASSEMBLY

24V 7.0kW (Manufactured by Mitsubishi)

7

28

14

16
17 9
27 15
6
18 20
19 26
21 8
5

12

4 22 11 10
3 25 29
2 12
1 24
13

23

065HY00019

Disassembly Steps
1. Snap ring 18. Packing
2. Stop ring 19. Plate
3. Pinion 20. Planetary gear
4. Pinion spring 21. Lever
5. Lead wire with terminal 22. E-type retaining rings
6. Screw 23. Overrunning clutch
7. Magneto switch 24. Internal gear
8. Screw 25. Washer
9. Through bolt 26. Gear shaft
10. Rear bracket 27. Front bracket
11. Yoke assembly 28. Bearing
12. O-ring 29. Brush
13. Brush holder
14. Armature Follow the disassembly steps in reverse order
15. Ball to reassemble the starter motor.
16. Plate
17. Packing
 ENGINE ELECTRICAL 6D – 19

Disassembly Steps
• Before disassembling the starter, mark the mating
surfaces of the magnet switch, the yoke, the front
bracket, and the rear bracket. This will make
reassembly easier.
• Remove the pinion first. If the pinion is not removed
first, complete starter disassembly is impossible.
• If only the motor and/or magneto switch is to be
removed, pinion removal is not necessary.

1. Snap Ring
SW1 2. Stop Ring
SW2
3. Pinion
Battery 4. Pinion Spring
24V 5. Lead Wire withTerminal
1) Remove the snap ring (1) and discard it.
Disconnect the lead wire
2) Disconnect the lead wire with terminal at the
terminal at Terminal M Terminal M (Refer to the illustration).
3) Close Switch 1 and Switch 2 to move the pinion to
D06H100001
the cranking position (protruding). The armature
rotates.
Pipe 4) Open Switch 2 to stop armature rotation.
Stop ring 5) Place a pipe having precisely the same diameter as
the stop ring over the stop ring.
Clutch shaft 6) Tap on the pipe with a hammer to loosen the stop
Snap ring
ring (2) in the direction of the pinion
Pinion spring
7) Remove the stop ring, the pinion (3), and the
Pinion pinion spring (4).

065H100006

Note:
• If the pinion is not in the cranking position and the
stop ring is tapped toward the front bracket, the
front bracket will be broken.
• Do not take more than 10 seconds to remove the
pinion. Current flow through the starter for more
than 10 seconds will cause overheating and
damage.
• The snap ring cannot be reused.
6D – 20 ENGINE ELECTRICAL

6. Screw
7. Magneto Switch
Use a shock screwdriver to remove the 3 screws
holding the magneto switch.
8. Screw
9. Through Bolt
10. Rear Bracket
11. Yoke Assembly
12. O-rings
1) Remove the screw holding the brush holder (13).
2) Remove the through bolt.
3) Remove the rear bracket and O-ring.
Discard the O-ring.
4) Place a socket with a diameter of 38 mm (1.496 in)
over the commutator of the armature (14).
5) Slide the brush (29) over the socket and hold it
there.
6) Remove the yoke assembly and the O-ring.
Discard the O-ring.
The O-rings cannot be reused.
13. Brush Holder
1) Pull the brush spring up and hold it.
2) Remove the brush from the brush holder.
3) Remove the brush holder.
14. Armature
15. Ball
Remove the armature.
The ball should fall free. However, if the grease
surrounding the ball has thickened, it may not.

065HV003

16. Plate (Planetary gear)

17. Gasket (Planetary gear)
18. Gasket (Lever)
19. Plate (Lever)
1) Remove the plate from the planetary gear (20)
area.
2) Remove the gasket.
3) Remove the gasket supporting the lever (21).
4) Remove the plate.
 ENGINE ELECTRICAL 6D – 21

20. Planetary Gears (4)

Remove the planetary gears.
Remove the internal gear (24), the gear shaft (26), the
overrunning clutch (23), and the lever (21) as a single
unit before disassembling it into its component parts.
21. Lever
Mark the lever to ensure reassembly to its original
position.
22. E-type Retaining Rings (2)
23. Overrunning Clutch
1) Remove the retaining rings. Discard the rings.
2) Rotate the spline tooth.
3) Pull the overrunning clutch from the gear shaft
(26).
The retaining rings cannot be reused.
24. Internal Gear
25. Washer
26. Gear Shaft
27. Front Bracket
28. Bearing
Use an ordinary bearing puller to remove the bearing.
29. Brush
6D – 22 ENGINE ELECTRICAL

INSPECTION AND REPAIR

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

ARMATURE
Growler test
Use a growler tester to check the inside of the
armature coil for shorting.
If there is shorting, the armature must be replaced.

065HY00002

Grounding
Use a circuit tester to check the armature coil for
grounding (insulation breakdown).
If there is grounding, the armature must be replaced.

065HY00041

Commutator
Check the outside of the commutator for abrasion and
wear.
If the abrasion and/or wear exceeds the specified limit,
the armature must be replaced.

065HY00044

Commutator insulation mold depth (Undercut)

Insulation mold
Clean the brush to remove abrasive particles and
Commutator
segment other foreign material. Inspect the brush. Repair the
brush if any abnormal conditions are present.

Good

Bad
065H100007
 ENGINE ELECTRICAL 6D – 23

Gear
Check the gears for wear and damage.
If the wear and/or damage is significant, the armature
must be replaced.

Bearing
Check the bearing for abnormal noise, rattle, and
grease leakage.
If any of these conditions are present, the bearing
must be replaced.

FIELD COIL
Continuity
Use a field tester to check the field coil for continuity.
If there is no continuity, the yoke assembly must be
replaced.

065MY00006

Grounding
Use a circuit tester to check the field coil for
grounding (insulation breakdown).
If there is grounding, the yoke assembly must be
replaced.

065MY00007
6D – 24 ENGINE ELECTRICAL

BRUSHES
Insulated portion of
Length (Abrasion loss)
brush holder Measure the brush length (brush holder assembly and
yoke assembly) to determine abrasion loss.
If the length of the brush on the brush holder side is
Brush length close to or exceeds the limit, the entire brush holder
assembly must be replaced.
If the length of the brush on the yoke assembly side is
close to or exceeds the limit, only the brush must be
replaced.
065H100008

Smoothness
Check that the brushes rotate smoothly.

Spring force
Check that the brush spring force is adequate.

Brush holder grounding

Carefully clean the brush holder.
Use a circuit tester to check the brush holder for
grounding (insulation breakdown).
Touch one probe to the metallic surface of the brush
holder plate. Touch the other probe to several
insulated points on the brush holder.
If there is grounding, the brush holder assembly must
be replaced.

OVERRUNNING CLUTCH AND PINION

1) Use a clean rag to wipe away dirt from the
overrunning clutch and pinion.
2) Hold the overrunning clutch in your hand.
3) Inspect the pinion for abrasion and other damage.
4) Use your other hand to rotate the pinion in the
direction of normal rotation. A slight resistance
should be felt.
5) Try to rotate the pinion in the opposite direction.
This should be impossible.
065MU00009
If the pinion is excessively worn or damaged, it must
be replaced.
If you are able to rotate the pinion in the opposite
direction of normal rotation, the pinion must be
replaced.
Do not wash the overrunning clutch in water and
detergent. The inside of the overrunning clutch is
packed with grease. If washer in detergent, the grease
will run and the overrunning clutch will be unusable.
 ENGINE ELECTRICAL 6D – 25

FRONT BRACKET (BEARING AND OIL

SEAL)
Check the bearing and oil seal for abnormal
conditions. If abnormal conditions are present, the
front bracket assembly together with the bearing and
oil seal must be replaced.

INTERNAL GEAR AND PLANETARY

GEARS
Check the gear teeth for wear and damage.
Replace the gear(s) if necessary.

LEVER
If the area of the lever that contacts the overrunning
clutch is badly worn, pinion projection position is
affected. Adjustment is required. Refer to the
reassembly procedure.

Worn portion
065H100009

Terminal B MAGNETO SWITCH

Terminal S
1. Use a circuit tester to check for continuity between
Terminal M and the switch body.
If there is no continuity, the switch must be
replaced.
2. Use the circuit tester to check for continuity
between Terminal B and Terminal M.
If there is continuity, the switch must be replaced.
Terminal M
065H1000010
6D – 26 ENGINE ELECTRICAL

REASSEMBLY
Follow the disassembly steps in reverse order to
reassemble the starter motor. Pay careful attention to
the instructions below.
The following parts cannot be reused. They must be
replaced with new ones.
• Snap ring (Securing the stop ring)
• E-type retaining ring
• O-rings (Yoke assembly packing and all screws)

LUBRICATION
Apply the recommended lubricant (grease) to the
points shown in the table and illustration below.

Point Lubrication area Recommended lubricant

A Sleeve bearing and ball MOLYCOAT R-AG650
B Clutch shaft contact surfaces
Gear shaft (Splines and MULTEMP 0A-171
C
contact surfaces)
Lever and overrunning clutch
D
contact surfaces
Armature shaft gear, MOLYCOAT R-AG650
E planetary gears, and internal
gear
F Pinion (Lower side)
Armature bearing outside
G
surface (Apply very sparingly)
MULTITEMP 0A-171
H Oil seal
Plunger surfaces (Apply very
I
sparingly)

• MOLYCOAT R-AG650 is manufactured by Dow Corning.

• MULTEMP 0A-171 is manufactured by Showa Petroleum.

N·m (kg·m/lb·ft)
G (Apply sparingly)
(Apply sparingly grease)
I (Apply sparingly)
I
5.9(0.6/4.3)
23(2.3/16.6)
C B H F

(Apply sparingly grease)

G

2.9(0.3/2.2)
E A D
9.8(1.0/7.2)
 ENGINE ELECTRICAL 6D – 27

TIGHTENING TORQUE
Tightening torques are shown in the illustrations.

ARMATURE SHAFT PLAY (AXIAL)

No adjustment is required. Simply install the ball to
the shaft end.

Gear shaft GEAR SHAFT PLAY (AXIAL)

Washer
The washer inserted between the internal gear and
the gear shaft (see below) establishes the required
gap. No further adjustment is necessary.

E-type retaining INTERNAL GEAR AND OVERRUNNING CLUTCH

rings INSTALLATION
Internal gear
1) Install the washer, internal gear, and overrunning
Overrunning clutch
clutch to the gear shaft.
065H100012

2) Slide the overrunning clutch on to the spline tooth.

3) Make sure that the overrunning clutch is securely
in place.
4) Install the E-type retaining rings.

PINION INSTALLATION
The pinion must be installed before the magneto
Stop ring
Press pinion down to create gap switch is installed to the front bracket.
Insert claw of puller into gap
1) Install the pinion spring, the pinion, and the stop
Snap ring
ring to the clutch shaft in that order.
2) Firmly press the stop ring into the clutch shaft
Clutch shaft Pinion spring groove.
Pinion 3) Use a gear puller to pull the stop ring firmly into
place.
4) Make sure that both sides of the stop ring are
firmly set.

065H100013
6D – 28 ENGINE ELECTRICAL

PINION CRANKING (PROTRUDING) POSITION

SW1 Check the pinion cranking position after installing the
SW2 starter motor. Measure and adjust as required.
1. Connect the starter to the battery as shown in the
Battery
illustration. Do not connect the lead wire with
24V
terminal to Terminal M.
2. Close switch 1 and Switch 2. The pinion rises to
Lead wire with terminal not the cranking position and the armature rotates.
connected to Terminal M 3. Open Switch 2 to stop armature rotation.
D06H100002 4. Lightly press against the end of the clutch shaft
with your hand.
5. Measure the distance the clutch shaft travels.
Lightly press the clutch shaft in Clutch shaft travel mm (in)
0.5 – 2 (0.02 – 0.08)

If the clutch shaft travel exceeds the specified range,

insert 1 or 2 additional packing sheets (thickness 0.5
Shaft travel mm (0.02 in) between the magnetic switch and the
front bracket.
If further adjustment is required, replace the lever.
065H100014

NO LOAD TEST
1. After adjusting the pinion cranking position (clutch
Ammeter SW
shaft travel), connect the starter and measuring
instruments as shown in the illustration.
Voltmeter • Use wire to sufficient thickness to handle the
Battery
24V current flow.
• Make sure that all connections are secure.
2. Note the rotation speed, current flow, and voltage
level. They must meet the specifications. Refer to
D06H100003
the table below.
If the rotation speed, current flow, and voltage
level do not meet the specifications, the starter
must be disassembled and inspected once again.
Standard and limit values
Test/Part Item Value
Voltage (V) 23.5
No-load test Current (A) Less than 125
Rotation speed (rpm) More than 3,000
38.7 (1.52) (Standard)
Outside diameter mm (in)
38.1 (1.50) (Limit)
Commutator
0.8 (0.031) (Standard)
Undercoat mm (in)
0.2 (0.008) (Limit)
23 (0.91)(Standard)
Brush Length mm (in)
12 (0.47) (Limit)
33 – 45 (Standard)
Brush spring Force (N)
20 (Limit)
0.5 – 2.0
Pinion Projection mm (in)
(0.0197 – 0.0787)
 ENGINE ELECTRICAL 6D – 29

STARTER HANDLING PRECAUTIONS

• The gap between the ring gear 2 – 5 mm (0.079 – 0.197
in) is very important. If the gap is too large or too
small, the pinion and ring gear teeth will not mesh
properly.
• Be absolutely sure that the front bracket is installed to
the engine side of the vehicle.
• Always turn the battery switch off before servicing the
starter.
• Make sure that all wiring connections are tight and
secure. Loose wire raises electrical resistance and will
affect starter motor operation.

STARTER OPERATING PRECAUTIONS

• Be sure that the battery is fully charged before starting
the engine. A weak battery makes engine starting
difficult.
• Disengage the starter immediately after the engine
starts.
• Do not continuously operate the starter for more than
10 seconds.
• Be sure that the pinion has returned to its original
position before operating the starter again.
• If starter operation does not stop when the starter
switch is released, immediately open the battery
switch. Check the wiring and switches.
6D – 30 ENGINE ELECTRICAL

PREHEATING AND STARTING SYSTEMS

WIRING CIRCUIT DIAGRAM

FUSE28

FUSE10

FUSE12
FUSE 8

FUSE 9

FUSE 6
(7.5A)

(7.5A)

(7.5A)

(7.5A)

(7.5A)
(15A)

0.5BR
3WR

2L

0.5BR
WARNING
SW;STARTER CHARGE
B1 S G M1M2 B2 P2 P1
P/L R/L;GLOW
OFF
3LW

ACC
3W

ON
HEAT

5BR
START

R/L;EXH,SHAT

0.5B
CONTROL
1.25L RESISTER
(ELEC.GVNR)

R/L;NEUTRAL

5W
0.5
0.5BY
0.85BR

DIODE
(NEUTRAL)
0.85BW

0.5WR
0.85Br

0.85L
0.5BG
3LW

5BY
5W

8W

R/L;STARTER

SW;NEUTRAL
SLOW BLOW1

SLOW BLOW2

SLOW BLOW3

SLOW BLOW4

SLOW BLOW5

SLOW BLOW6

0.5BL
(40A)

(40A)

(40A)

(80A)

(40A)

(40A)

0.85BL

SW;SUB STARTER GLOW PLUG

8BW
5W

FUSE BOX
8W ACG50A/60A
8W
8W

B R
R/L;
FL BATTERY
2
2
FL

L 0.85WR
(C) SG
BATTERY N
0.85BL

+ - + -
STARTER REGULATOR E 5B

GENERATOR

060H100005
 ENGINE ELECTRICAL 6D – 31

INSPECTION AND REPAIR

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

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

Glow Relay
Check the glow relay operation.
Terminal Positions
A From the slow blow fuse
B To the control resistor
1 From the starter switch “G”
2 To ground

Control Resistor
Check the heat coil for breakage and fusing.
Replace the control resistor if the heat coil is broken or
fused.
Note:
Common control resistor problems are:
1. Broken wires caused by vibration
2. Fusing caused by overheating
This is usually the result of mismatching the glow
plug and the control resistor.
When installing the control resistor:
1. Be sure that you are installing a control resistor of the
proper rating.
2. Be sure that the glow plug is compatible with the
control resistor.
3. Be sure that the control resistor is securely
connected.
6D – 32 ENGINE ELECTRICAL

Control Resistor Continuity

Use a circuit tester to check that there is continuity
between the terminal 1 and the terminal 2.
If there is no continuity between the terminal 1 and
the terminal 2, the control resister is defective and
must be replaced.

STARTING SYSTEM
Circuit diagram terminal positions are shown in the
illustration.

Starter Relay
Check the starter relay operation.
Terminal Positions
S (To starter switch “S”)
B (To starter terminal “B”)
S E C (To slow blow fuse)
E (To ground)

060HT005
 EXHAUST SYSTEM 6F – 1

SECTION 6F
EXHAUST SYSTEM

CONTENTS

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

GENERAL DESCRIPTION

Exhaust Manifold

Silencer Outlet

Horizontal Outlet Type

Outlet

Silencer

Exhaust Manifold

Vertical Outlet Type

HAW36FLF000301

The exhaust system consists of the exhaust pipes and the silencer.
In the horizontal exhaust system, the exhaust pipes run from the exhaust manifold, beneath the vehicle
frame, to the rear of the vehicle.
In the vertical exhaust system, the exhaust pipes run from the exhaust manifold, beneath the vehicle frame,
to the top of the vehicle just behind the cab.
The exhaust pipes are connected to each other by a series of sleeve clamps and/or flange bolts. They are
attached to the vehicle frame by clamps and brackets. Rubber bushing are used at support points.
 EXHAUST SYSTEM 6F – 3

REMOVAL AND INSTALLATION

HORIZONTAL TYPE EXHAUST SYSTEM

2 3

HAW36FLF000201

Removal Steps Installation Steps

1. Clamp 8. Front exhaust pipe with vibnon
2. U-bolt 7. Clamp and silencer
3. Tail pipe 6. Silencer bolt
4. Clamp 4. Clamp
5. Exhaust pipe 3. Tail pipe
6. Silencer bolt 2. U-bolt
7. Clamp and silencer 1. Clamp
8. Front exhaust pipe with vibnon
6F – 4 EXHAUST SYSTEM

VERTICAL TYPE EXHAUST SYSTEM

FRONT

4
1

HAW36FLF000401

Removal Steps Installation Steps

1. Heat protector 5. Front exhaust pipe with vibnon
2. U-bolt 4. Exhaust silencer
3. Rear exhaust pipe 3. Rear exhaust pipe
4. Exhaust silencer 2. U-bolt
5. Front exhaust pipe with vibnon 1. Heat protector
 EXHAUST SYSTEM 6F – 5

INSPECTION AND REPAIR

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

Exhaust Pipes and Exhaust Silencer

1. Check the exhaust pipes and the exhaust silencer
for corrosion and damage.
2. Check the pipe and silencer connections for
looseness and misalignment.
Align and tighten as required.
3. Check the pipe support rubber rings for
deterioration.
Replace as required.
4. Check the vibnon springs and seal bearing for
damage or deterioration.
If there is some problem on the vibnon during
inspection, the parts must be replaced.
6F – 6 EXHAUST SYSTEM

MEMO
 TURBOCHARGER 6G – 1

SECTION 6G
TURBOCHARGER

CONTENTS

PAGE
Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 3
Identification Plate and Assembly Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 4
Turbocharger Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 4
Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 5
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 7
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 20
Measuring Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G – 21
6G – 2 TURBOCHARGER

TURBOCHARGER
MAIN DATA AND SPECIFICATIONS

Item 6WG1-TC

Manufacturer MITSUBISHI
Model TD08H
Turbine type Radial, inward flow
Compressor type Radial, outward flow
Maximum permissible speed rpm 105,000
Exhaust gas temperature* °C(°F) 600 (1,112)
Cooling method Water

* Maximum allowable exhaust gas temperature measured at the turbocharger exhaust gas inlet.
 TURBOCHARGER 6G – 3

GENERAL DESCRIPTION

HCW31JMF000101

Major turbocharger components are the Center Housing and Rotating Assembly (CHRA), the compressor
housing, and the turbine housing.
Rotating parts include the turbine shaft, the compressor wheel, the shaft bearings, the thrust washers, and
the oil seal rings.
These parts are supported by the center housing.
The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel
consumption, and minimal engine noise.
Turbocharger rotating parts operate at very high speeds and temperatures. Part materials have been
carefully selected and machined to extremely high precision.
6G – 4 TURBOCHARGER

IDENTIFICATION PLATE AND ASSEMBLY

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

HCW31JSH000101

TURBOCHARGER SERVICING
1. Refer to TROUBLESHOOTING in this Manual to determine whether or not turbocharger repair or
overhaul is required.
2. The following procedures should also be performed (either with the turbocharger on the vehicle or
removed from the vehicle but not disassembled) to determine whether or not turbocharger repair or
overhaul is required.
* Visual checks
* Clearance measurements
* End play measurements
Refer to INSPECTION AND REPAIR.
3. The turbocharger compressor and turbine housing may be removed from the center housing and
rotating assembly (CHRA) for further visual inspection.
Refer to DISASSEMBLY and REASSEMBLY.
 TURBOCHARGER 6G – 5

MAINTENANCE STANDARD
mm (in)
Reassembly
Item Standard standard Limit Remarks
(Gap)
Bearing insert inside diameter φ 20.5 φ 20.506
—— ——
(Bearing housing) (0.807) (0.807)
φ 20.382
Outside diameter —— —— ——
(0.802)
φ 12.042
Bearing Inside diameter —— —— ——
(0.474)
φ 11.94
Length —— —— ——
(0.470)
Journal outside diameter φ 12 φ 11.996
—— ——
(Shaft and turbine wheel) (0.472) (0.472)
0.015
Shaft and turbine wheel concentricity —— —— ——
(0.0006)
Piston ring
0.05~0.25
Piston ring gap —— —— installed to piston
(0.002~0.010)
ring groove
0.39~1
Shaft/turbine wheel and turbine housing gap —— —— ——
(0.015~0.039)
0.075~0.155
Shaft and turbine wheel axial play —— —— ——
(0.003~0.006)
0.48~0.92
Shaft/turbine wheel and turbine back plate gap —— —— ——
(0.019~0.036)
6G – 6 TURBOCHARGER

SCHEMATIC

4 3
16
7 13
22 2
14 19
10

15

6
21 18
17
9 20
12

11

HCW31JLF000201

HCW31JLF000201

1. Bolt 12. Thrust ring

2. Turbine housing 13. Thrust bearing
3. Snap ring 14. Thrust ring
4. Compressor cover 15. Shaft and turbine wheel
5. Nut 16. Piston ring
6. Compressor wheel 17. Turbine back plate
7. Snap ring 18. Bearing
8. Insert 19. Snap ring
9. Piston ring 20. Bearing housing
10. Oil deflector 21. O-ring
11. Thrust sleeve 22. O-ring
 TURBOCHARGER 6G – 7

DISASSEMBLY

14
13
12
11
10
9
8
7
6
5
4

2
1
15

16

17
3
18
19
20
19
18
21

22

HCW31JLF000301

Disassembly steps
1. Bolt, clamp plate 12. Thrust ring
2. Turbine housing 13. Thrust bearing
3. Snap ring 14. Thrust ring
4. Compressor cover 15. Shaft and turbine wheel
5. Nut 16. Piston ring
6. Compressor wheel 17. Turbine back plate
7. Snap ring 18. Bearing
8. Insert 19. Snap ring
9. Piston ring 20. Bearing housing
10. Oil deflector 21. O-ring
11. Thrust sleeve 22. O-ring
6G – 8 TURBOCHARGER

Important Operations
Compressor wheel and turbine wheel blades are easily
bent. Take care during servicing to avoid blade damage.
Do not drop the parts or strike the parts other objects.

Compressor housing 1. Bolt and Clamp plate

Bearing housing
Remove the clamp plate.

During reassembly, compressor cover, bearing

housing, and turbine housing position is very
Turbine
important. Use a punch or marking pencil to apply
housing
setting marks to the clamp plate. This ensures
reassembly of the components to their original
positions.
Clamp plate
037M200011

2. Turbine housing
Turbine housing
Remove the turbine housing.

037M200012

3. Snap ring
Remove the snap ring.

Snap ring

037M200013

4. Compressor cover
Tap lightly around the perimeter of the compressor
cover with a plastic hammer to loosen and remove the
cover.
Compressor housing

Do not allow the compressor wheel to touch the

compressor cover.

037M200050
 TURBOCHARGER 6G – 9

5. Nut
Compressor wheel
Place the turbine housing in a vise and fit the bearing
housing to the turbine housing.
Use a 17 mm box wrench to hold the shaft and turbine
wheel boss.
Bearig housing Use a 14 mm box wrench to remove the left hand
thread
lock nut that has attached the compressor wheel.

037M200015
The lock nut has left-hand threads.
6. Compressor wheel
Compressor Press down on the turbine wheel with one hand. Use
wheel the other hand to rotate and remove the compressor
wheel.

037M200016

7. Snap ring
Use snap ring pliers to remove the snap ring.
Snap ring
If the snap ring slips from the pliers, it will spring free
and fly through the air. To prevent this, hold the ring
in place with your hand.

037M200017

8 8. Insert
9 After using 2 screwdrivers to carefully pull the insert
10 from the bearing housing, remove the following parts.
11
12
13 9. Piston ring
14
10. Oil deflector
11. Thrust sleeve
12. Thrust ring
13. Thrust bearing
HCW31JSH000201
14. Thrust ring
Hold the shaft and the shaft of the turbine wheel with
one hand. Use the other hand to carefully pull the
parts from the turbine housing.

037HY00017
6G – 10 TURBOCHARGER

15 Remove the parts from the bearing housing.

16
18 17
19
20 15. Shaft and turbine wheel
16. Piston ring
17. Turbine back plate
18. Bearing
19 19. Snap ring
18
21 20. Bearing housing
22
21. O-ring
HCW31JSH000301
22. O-ring
• Check the blades for bending and other damage. If
there is damage, discard the blades. Install new
blades at reassembly.
• Do not attempt to repair the bend of the blades.
 TURBOCHARGER 6G – 11

INSPECTION AND REPAIR

Cleaning
1. Before beginning the cleaning procedure, check the
dirty parts for signs of scoring and other heat-caused
damage.
2. Immerse the reassembled parts in non-flammable
solvent (Daido Dye Cleaner T-30 or the equivalent).
Remove the oil residue and carbon from the parts.
Do not immerse the O-rings and bearings.

037HY00019

3. Spray the compressed air to the inside and outside

surfaces of the parts.

HCW31JSH000401

4. Use a plastic scraper or a bristle brush to clean away

any remaining residue.

• Take care not to damage the parts.

• Shot blasting may be used to clean the parts if
necessary. Be sure to completely cover the
compressor wheel, the shaft and turbine wheel
threaded areas, the axle, and the ring grooves to
protect them from damage.

037HY00021

5. Once again, spray the compressed air to the inside

and outside surfaces of the clean parts.

HCW31JSH000401
6G – 12 TURBOCHARGER

6. Apply the clean engine oil to the each sliding portion.

Check the threaded areas, the axle, and the ring
grooves for corrosion. If there is corrosion, remove
the corrosion with the buff.
Be careful not to damage delicate part surfaces with
the file.

037HY00023
 TURBOCHARGER 6G – 13

Inspection
1. Bearing housing
Measure the inside diameter of the bearing insert
area.
If the measured diameter exceeds the specified limit,
the bearing housing must be replaced.
Bearing housing inside diameter mm (in)
Limit 20.506 (0.807)

037HY00024

2. Bearing
• Measure the bearing outside diameter.
If the measured diameter is below the specified
limit, the bearing must be replaced.
Bearing outside diameter mm (in)
Limit 20.382 (0.802)

037HY00025

• Measure the bearing inside diameter.

If the measured diameter is below the specified
limit, the bearing must be replaced.
Bearing inside diameter mm (in)
Limit 12.042 (0.474)

037HY00026

• Measure the bearing length.

If the measured length is below the specified limit,
the bearing must be replaced.
Bearing length mm (in)
Limit 11.94 (0.470)

037HY00027

3. Shaft and turbine wheel

• Measure the outside diameter of the shaft and
turbine wheel journal.
If the measured diameter is below the specified
limit, the shaft and turbine wheel must be replaced.
Shaft outside diameter mm (in)
Limit 11.996 (0.472)

037HY00028
6G – 14 TURBOCHARGER

• Attach a dial gauge to the threaded area of the shaft.

Measure the shaft curvature.
If the dial gauge fluctuation exceeds the specified
limit, the shaft and turbine wheel must be replaced.
Shaft curvature (Fluctuation) mm (in)
Limit 0.015 (0.0006)

Do not attempt to correct the curvature of the shaft.

Replace the part.
037HY00029

Insert
4. Insert
Gap Piston ring
• Insert a new piston ring into the center of the insert
securely. Measure the piston ring gap.
If the measured gap is off the standard value, the
insert must be replaced.
Piston ring gap mm (in)
Limit 0.05 – 0.25 (0.002 – 0.010)

037M200018

5. The parts listed below must be replaced with new

ones.
• 9 Piston ring
• 16 Piston ring
• 21 O-ring
• 22 O-ring

Numbers in parentheses refer to the disassembly

order shown in the schematic and exploded drawings.
 TURBOCHARGER 6G – 15

REASSEMBLY

7
8
9
12
11
13
14
15
16
17
18

21
22
6

4
20
3
2
1
2
3
10

19

HCW31JLF000401

Reassembly steps
1. Bearing housing 12. Thrust sleeve
2. Snap ring 13. Piston ring
3. Bearing 14. Insert
4. Turbine back plate 15. Snap ring
5. Piston ring 16. Compressor wheel
6. Shaft and turbine wheel 17. Nut
7. Thrust ring 18. Compressor cover
8. Thrust bearing 19. O-ring
9. Thrust ring 20. Snap ring
10. O-ring 21. Turbine housing
11. Oil deflector 22. Bolt and Clamp plate
6G – 16 TURBOCHARGER

7 Reassembly
1. Bearing housing
6
5 2. Snap ring
4 Press the round edge of the snap ring into the bearing
3
1 and hold it in place. Insert the bearing and snap ring
combinations into either side of the bearing housing.
4 3
3. Bearing
Apply engine oil to the bearing inside circumference.
4. Turbine back plate
037M200044
5. Piston ring
6. Shaft & Turbine wheel
1 • Do not apply too much oil to the piston ring and do
not twist the piston ring in the gap area. Install the
3 3 Piston ring to the shaft and turbine wheel.
4 4
• Do not force the shaft and turbine wheel. Ring and
shaft damage (bending) will result.
• Take care not to damage the fins of the turbine
wheel.
• Temporarily install the bearing housing to the
037M200045
Turbine housing and temporarily tighten it with the
Clamp plate.
Bearing housing 7. Thrust ring
8. Thrust bearing
9. Thrust ring
• Apply engine oil to both sides of the thrust bearing.
Install the thrust bearing.
Turbine housing • Carefully clean the joggled part of the Shaft and the
both sides of the thrust ring with dry tissue paper
to remove all oil residue and other foreign material.
Install the thrust ring.
037M200021
10. O-ring
• Coat the O-ring with grease and install it.
Thrust bearing

037M200022

O-ring

037M200023
 TURBOCHARGER 6G – 17

• Assemble the sub-assembly of the Insert as

11 12 following procedure.
11.Oil deflector
14 13 12.Thrust sleeve
13.Piston ring
14.Insert
• Carefully install the piston ring to the Thrust sleeve.
Insert the gap area first.
Apply a light coat of oil to the piston ring.
HCW31JSH000501
Install the plunger sleeve and piston ring to the
insert.
Do not apply too much oil to the piston ring.
Take care not to damage the piston ring.
• Carefully clean the 2nd thrust ring and plunger
16
17 sleeve with dry tissue paper to remove all oil
residue and other foreign material.
• Install the insert assembly (insert, plunger sleeve,
and piston ring) to the bearing housing.

= areas to be coated with engine oil, or grease.

6 Apply grease
to the o-ring
= areas to be wiped clean of all foreign material (oil,
grease, molybdenum, etc.).

HCW31JMH000101

Snap ring

15. Snap ring

037M200017
Use the Snap ring pliers to install the snap ring to
the bearing housing. The tapered side of the snap
Bearing housing ring must be facing up.

• Pay close attention to snap ring installation

Snap ring direction.
• If necessary, use a wooden hammer and a
screwdriver to lightly tap the ends of the snap
ring into the bearing housing grooves.
• Do not allow the hammer or screwdriver to strike
the inside of the bearing housing.
037M200025
6G – 18 TURBOCHARGER

• Set a dial gauge to the tip of the shaft and turbine

wheel. Turn the shaft and turbine wheel in the
normal direction of rotation. Measure the gap
Turbine wheel between the turbine wheel and the turbine housing.
• If the measured gap is outside the specified range,
the problem must be corrected.
Turbine wheel and turbine housing gap mm (in)
Standard 0.39 – 1.0 (0.015 – 0.039)

037M200026

16. Compressor wheel

• Clamp the turbine housing in a vise. And mount the
bearing housing to the turbine housing.
• Carefully clean the both sides of the compressor
wheel and the plunger sleeve with dry tissue paper
to remove all oil residue and other foreign material.
• Install the compressor wheel.
17. Nut
Compressor wheel • Apply molybdenum to the threads of the lock nut.
Tighten the lock nut to the specified torque.
Left-hand threads Lock nut torque N·m (kg·m / lb·ft)
20 (2.0 / 14.5)

• The lock nut has left-hand threads.

• Do not apply molybdenum to the shaft and then
attempt to install the compressor wheel.
037M200027

• Set a dial gauge to the tip of the shaft and turbine

Turbine wheel wheel.
Turn the compressor wheel in the normal direction
Compressor of rotation. Measure the compressor wheel play.
wheel • If the measured play is outside the specified range,
the problem must be corrected.
Compressor wheel play mm (in)
Standard 0.075 – 0.155 (0.003 – 0.006)

037M200028

• Remove the turbine housing from the bearing

housing. Mount the Compressor cover and
measure the following.
Use 2 thickness gauges to measure the gap
Turbine back plate between the turbine back plate and the back of the
turbine wheel (measure at the tip of the fins) .
Bearing housing • If the measured play is outside the specified range,
the problem must be corrected.
Compressor housing Turbine wheel and back plate gap mm (in)
037M200029
Standard 0.48 – 0.92 (0.019 – 0.036)

Be sure to use two thickness gauge and measure at

the tip of the fins.
 TURBOCHARGER 6G – 19

18. Compressor Cover

• Install the O-ring and the compressor cover. Pay
O-ring Compressor cover
careful attention to the direction of installation.

19. O-ring
• Apply grease to the O-ring.

037M200030

20. Snap ring

• Install the snap ring.

Snap ring

037M200013

21. Turbine housing

Turbine housing
• Install the bearing housing. Pay careful attention to
the direction of installation.

037M200012

Compressor housing 22. Bolt and clamp plate

Bearing housing
• Install the clamp plate and tighten the bolts to the
specified torque.
Clamp plate bolt torque N·m (kg·m / lb·ft)
Turbine 27 (2.8 / 20)
housing

Clamp plate
037M200011
6G – 20 TURBOCHARGER

Troubleshooting
Symptom Cause and countermeasure
Bearing damage and/or contact between the rotating parts and the
stationary parts is likely.

• Possible causes include dirty oil (too much time between oil
changes), foreign material in the lubricating system, a clogged oil
filter, and continued operation under any of these conditions.
Frequent fast starts and sudden stops may also be responsible.
Vibration
• Check the lubricating system. If the lubricating system is normal,
look for out-of-balance rotating parts and shaft distortion (bending)
that may result in abrasion. Check also for foreign material that may
fly around and cause damage to the turbine wheel and the
compressor wheel.

These conditions require immediate check and repair.

(1) Check the exhaust system for leakage. Make necessary repairs.

(2) Check the muffler for damage (denting) and clogging.

Measure the muffler’s resistance to the passage of exhaust gases.

Operation appears normal except (3) Check for air leakage around the compressor outlet. Check the air
for reduced power output cleaner. If the element is dirty, clean or replace it.

(4) Remove the compressor cover and check for dirt inside the
compressor. Clean if necessary.

(5) Use your hand to gently rotate the rotor. If the rotor does not spin
freely, disassemble and clean it.

(1) Check the air cleaner for dirt and clogging (this often causes oil
leakage). Clean or replace the element if necessary.

(2) Check the oil discharge pipe for obstructions, structural collapse,
and dents. Repair or replace the pipe as required.
• Oil leakage from intake or
exhaust system
(3) Check the piston ring for and the piston ring groove for abrasion. If
abrasion is excessive, replace the piston ring.
• White exhaust gas
(4) Find out if the vehicle has been operated for a long time with
damaged bearings. Operation with damaged bearings will
eventually lead to piston ring damage and oil leakage from the
intake and exhaust.
 TURBOCHARGER 6G – 21

Measuring equipment
Illustration Name Measurement area

• Bearing outside diameter

Outside micrometer
• Bearing length

Inside micrometer Bearing inside diameter

Cylinder gauge Bearing housing inside diameter

• Shaft axial gap

Dial gauge
• Shaft distortion (Bending)

• Turbine back plate and turbine wheel gap

Thickness gauge
• Piston ring gap
6G – 22 TURBOCHARGER

MEMO
 FLYWHEEL POWER TAKE OFF 6P – 1

FLYWHEEL POWER TAKE OFF

CONTENTS

PAGE
Flywheel Power Take Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6P – 2
Flywheel P.T.O. Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6P – 2
Disassembly Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6P – 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6P – 4
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6P – 5
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6P – 6
6P – 2 FLYWHEEL POWER TAKE OFF

FLYWHEEL POWER TAKE OFF

FLYWHEEL P.T.O. CONSTRUCTION

Bearing case

P.T.O. Gear
Oil seal

Washer

P.T.O. Shaft bolt

P.T.O. Bearing

P.T.O. Bearing

O-ring

020HT002
 FLYWHEEL POWER TAKE OFF 6P – 3

FLYWHEEL P.T.O.

Disassembly Steps
1. P.T.O. assembly 12. Roller bearing
2. P.T.O. shaft bolt 13. P.T.O. gear
3. Washer 14. Spindle bolt
4. Flange 15. Bearing nut
5. Oil seal 16. Lock washer
6. Thrower 17. Inner spacer
7. Roller bearing 18. Outer spacer
8. Shim 19. Idler gear bearing
9. Spacer 20. Idler gear spindle
10. Bearing case 21. Idler gear
11. Oil seal
6P – 4 FLYWHEEL POWER TAKE OFF

DISASSEMBLY
1. P.T.O. Assembly
Loosen the fixing bolts to remove the P.T.O. assembly
if necessary.

2. P.T.O. Shaft Bolt

3. Washer
4. Flange
Remove the P.T.O. shaft bolt to disassemble the
washer and flange.
5. Oil Seal
6. Thrower
7. Roller Bearing
8. Shim
9. Spacer
10. Bearing Case
11. Oil Seal
12. Roller Bearing
13. P.T.O. Gear
14. Spindle Bolt
15. Bearing Nut
16. Lock Washer
17. Inner Spacer
18. Outer Spacer
19. Idler Gear Bearing
20. Idler Gear Spindle
21. Idler Gear
1) Use suitable brass bar to remove the idler gear
spindle.
2) Same time remove the idler gear together with
idler gear bearing, inner and outer spacer.

020HT005
 FLYWHEEL POWER TAKE OFF 6P – 5

INSPECTION AND REPAIR

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

P.T.O. Bearings
1) Visually check separation and/or any damage on
the bearing race.
2) Inspect the bearing assembly for any wear.
3) Rotate the bearing for inspect abnormal noise.

P.T.O. Gear
Inspect the P.T.O. gear for wear and/or damage.
Same time check any wear or damage on the spline of
the P.T.O. gear.

Idler Gear Bearings

1) Visually check separation and/or any damage on
the bearing race.
2) Inspect the bearing assembly for any wear.
3) Rotate the bearing for inspect abnormal noise and
abnormal rotating feeling.
6P – 6 FLYWHEEL POWER TAKE OFF

Idler Gear
Inspect any wear and/or damage on the idler gear.

REASSEMBLY
This section mentioned important items only.

Idler Gear Bearing

1
2 1) Install the idler gear bearing outer spacer 2 to
3 idler gear 1.
4
2) Press the idler gear bearing outer race 3, 4 to
Discviminative idler gear.
Mark
5 3) Initially install the bearing inner race 5 from front
side of the idler gear.

020HT003

4) The discriminative mark of idler gear turns on this

side and it inserts into the P.T.O. hole.

020HT008

5) Install the idler gear spindle 6 to the idler gear.

6) Tighten the idler gear bolt 7 to the specified
6 torque.
7 Idler Gear Bolt Torque N·m (kg·m / lb·ft)
167.0 ( 17.0 / 123.0 )

020HT006
 FLYWHEEL POWER TAKE OFF 6P – 7

7) Install the bearing inner space 8 and the bearing

inner race 9.
9 8
10 6) Tighten the idler gear nut A with lock washer 0 to
11 the specified torque.
Idler Gear Nut Torque N·m (kg·m / lb·ft)
147.0 ( 15.0 / 108.0 )

020HT007

9) Twist the hook of the lock washer.

P.T.O. Gear
1) Fit P.T.O. gear on to shaft.
2) Tighten with lock washer and nut to the specified
tightening torque.
P.T.O. Gear Nut Torque N·m (kg·m / lb·ft)
147.0 ( 15.0 / 108 )

O-Ring
Apply engine oil to O-ring and install in bearing case.
6P – 8 FLYWHEEL POWER TAKE OFF

Bearing case P.T.O. Gear P.T.O. Bearing

Oil Thrower 1) Press bearing 1 on to shaft and install in bearing
Washer case.
P.T.O. Shaft 2) Put spacer and shim on shaft.
bolt NOTE:
P.T.O. Choose spacer and sh to make axial clearance 0.01 –
Bearing 2
0.07 mm (0.0004 – 00027 in) in an assembled status.
3) Install in bearing 2, oil thrower, and flange
P.T.O.
Shim Bearing 1
Spacer 4) Tighten washer and bolt to the specified tightening
020HT011 torque.
P.T.O. Shaft Bolt Torque N·m (kg·m / lb·ft)
343.0 ( 35.0 / 253.2 )

NOTE:
After tightening, make sure the assembly’s axial
clearance is 0.01 – 0.07 mm (0.0004 – 0.0027 in).
5) Loosen bolt and take out flange.

Oil Seal
1) Apply engine oil to the oil seal lip.
2) Coat silicone rubber KE42 or equivalent to outside
Coat silicon Apply engine oil oil seal.
Rubber KE42
3) Install the oil seal until coming same surface with
the bearing case.

020HT009

O-Ring Flange
Washer 1) Attach bolt, nut, spacer and spring washer to
P.T.O. Shaft bolt flange.
2) Install flange and O-ring.
3) Tighten with washer and bolt to the specified
Spring Washer
tightening torque.
P.T.O. Shaft Bolt Torque N·m (kg·m / lb·ft)
Nut Bolt 343.0 ( 35.0 / 253.2 )
Spacer
020HT012
 FLYWHEEL POWER TAKE OFF 6P – 9

P.T.O. Assembly
1) Install the P.T.O. assembly to the flywheel housing.
2) Tighten the fixing bolts to the specified torque with
three steps angular tightening method.
Fixing Bolt Torque N·m (kg·m / lb·ft)
1st Step 2nd step 3rd step
30 ( 3.0 / 21.7 ) 49 ( 5.0 / 36.2 ) 60 deg.

NOTE :
020HT010 Do not damage to the O-ring on the bearing case.
6P – 10 FLYWHEEL POWER TAKE OFF

MEMO
 HG6WG-WE-0321

You are requested to order this manual using the

manual number that is shown above.

This manual is applicable for vehicles in all countries

except the USA and Canada.

All rights reserved. This manual may not be

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

Issued by

ISUZU MOTORS LIMITED

INTERNATIONAL SERVICE DEPARTMENT

Tokyo, Japan

First edition Dec., 2002 0321-01K

No.HG6WG-WE-0321 PRINTED IN JAPAN