6D140 3

I n t roduct ion
This Manual describes the structure and the troubleshooting of electronic

control fuel injection system (common rail type) in 6WG1 industrial engines.
Use this manual sufficiently to perform service work properly and quickly.
Hitachi Construction Machinery Co., Ltd

General Contents
Disassemble and Assemble Engine
General Information
Engine Mechanical
Cooling System
Fuel System
Electrical System
Lubricating System
Intake System
Preheating System
Engine Manual (1/2)

Control System
Electronic control fuel injection system (Common rail type)
General Information 0A-1
General Information
General Information
Table of Contents
General Information .............................................. 0A-2
Service Precautions ........................................... 0A-2
Reading the Model ............................................. 0A-7
General Information ........................................... 0A-8
0A-2 General Information
General Information
Service Precautions 5. Always use the correct specialized tool indicated in
the instructions. Using the incorrect tool may
In order to carry out work safely cause damage to the parts or injury to the person
1. Always use an engine stand when taking the using the tool.
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical sys-
tem, always remove the minus side cable from the
battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.
WSHK0190
6. All regular tools, gauges and special tools should

be regularly inspected, and prepared before start-
ing work. Do not use bent spanners, hammers with
damaged edges, chipped chisels, or any other
faulty or damaged tools.
4. Do not perform painting work or leave the engine

running for long periods of time in an enclosed or
badly ventilated indoor workshop.
7. Always pay close attention to safety and handling 9. Pay close attention to the risk of ignition if you are
requirements when using grinders, cranes, weld- handling parts that carry a high voltage.
ers, and other such equipment. Furthermore, any oil or grease spilt onto rubber
Moreover, always wear the correct protective gar- parts must be wiped off immediately, as it will
ments and use the necessary safety tools for the cause deterioration of the rubber.
job in hand.
WSHK0192
WSHK0191
8. Always check that there are no fuel leaks when Replacement parts and part numbers
performing maintenance work on the fuel system. 1. Always replace packing, oil seals, O-rings, caulk-
(It may cause a fire.) ing lock nuts, folding lock plates, split pins and
other such parts with brand new parts.
2. The parts numbers contained in this manual may
not represent the supply condition of the parts, and
the part numbers may be changed due to revi-
sions. Therefore, parts should always be checked
against a parts catalogue before use.
Liquid gasket 3. Please take care not to apply too much or too little
liquid gasket.
1. Each time you disassemble parts that use liquid
Also, you should always re-apply the liquid gasket
gasket, completely remove the old gasket residue
upon itself when you start and finish application.
from each of the parts and matching sections using
a scraper, then clean each of the parts to com- 4. Make sure that there are no gaps when reinstalling
pletely remove oil, water, and dirt etc. from the var- the liquid gasket parts to each other. If there are
ious surfaces by a cloth. Using the specified type gaps between the two parts, re-apply the liquid
of liquid gasket, apply new liquid gasket to each of gasket. Some parts, especially the oil pan, use the
the surfaces before reassembling the parts. same size studs as a guide to eliminate the need
for knock pin positioning etc.
2. In order to make it easier to clean liquid gasket sur-
faces, apply gasket remover liquid (Pando- 391D 5. Re-install these parts within 7 minutes of applying
made by ThreeBond Co., Ltd.) and leave the part the liquid gasket.
to stand for approximately 10 minutes, after which If more than 7 minutes passes, remove the previ-
the old liquid gasket residue will be easier to ous liquid gasket and re-apply it.
remove. 6. Please wait for at least 30 minutes since the last
However, this should not be used on resin compo- part is installed before starting the engine.
nents or painted components.
Liquid gasket
Seal section Product name Manufacturer's name

Between head cover and – Gear case – Cylinder head 1207B ThreeBond
(head upper side)
Between gear case and – Cylinder head FMD–127 Loctite
Between head gasket and – Gear case and – Cylinder head 1207B ThreeBond
(head gasket upper side)
Between head gasket and – Gear case – Cylinder block 1207B ThreeBond
(head gasket lower side)
Between gear case (block) and – Cylinder block FMD–127 Loctite
Between cylinder block and – Gear case and – Gear case FMD–127 Loctite
Between idle gear A shaft and – Gear case FMD–127 Loctite
Between cylinder block and – Flywheel housing FMD–127 Loctite
Between cylinder block and – Flywheel housing and – Crank- FMD–127 Loctite
case
Between cylinder block and – Crankcase FMD–127 Loctite
Lower surface of the matching portion between crankcase and 1207B ThreeBond
– Flywheel housing
Lower surface of the matching portion between crankcase and 1207B ThreeBond
– Gear case
Contact part of cylinder head that nozzle sleeve is pushed to TL290 Loctite
Sealing cup press-fit portion between cylinder block and – 1386 ThreeBond
Head 962T Loctite
123T Hermetic seal
Cylinder block, head plug nipple, unit, switches #271 Loctite
O-ring omission prevention agent 1208 ThreeBond
CH Dyne #290 Cement dyne
• Always use the liquid gasket products listed above, or a liquid gasket identical to the ones listed above.
• Use the correct quantity of liquid gasket. Always follow the handling instructions for each product.
Application procedure Example: Procedure for measuring the clearance
1. Wipe the contact surfaces clean of all water, oil or between the connecting rod bearing and crank pin.
grease. The contact surfaces should be dry. • Clean the connecting rod and bearing, and install
2. Apply a regular bead width of liquid gasket to one the bearing to the rod.
of the contact surfaces. Make sure that the bead • Cut the plastigauge to the same width as the crank
does not break at this point. pin, and while avoiding the oil hole of the crank pin
lay the gauge parallel to the pin.
Note: • Line up the marks on the connecting rod and cap,
If there are special regulations concerning the applica- and install the crank pin. Apply molybdenum disul-
tion procedure in the repair document, please follow fide to the thread section and seating surface of
those regulations. the tightening bolt, and rotate both cap and bolt to
the correct torque.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and Important:
threads clean of water, grease, and oil. The con- Do not move the connecting rod while using the
tact surfaces should be dry. plastigauge.
2. Apply Loctite to the top 1/3 of the screw.
• Gently remove the cap and connecting rod, and
3. Tighten the bolt to the specified torque. measure the crushed width of the plastigauge
(clearance between rod and pin) using the scale
printed on the bag.
Important:
After tightening the bolt, do not apply excessive
torque or try to rotate the bolt until at least one
hour has passed, and the Loctite has hardened.
Procedure for using the plastigauge
Type Measurable range mm {in}

PG-1 (Green) 0.025 — 0.076 {0.001 — 0.003}
PR-1 (Red) 0.051 — 0.152 {0.002 — 0.006}
PB-1 (Blue) 0.102 — 0.229 {0.004 — 0.009}
Example: Measuring the clearance between the crank
bearing and crank journal
• Clean the clamp face of the cylinder block and
crankcase bearing, and also the bearing, and
install the cylinder block to the crankcase.
• Gently rest the crankshaft on the cylinder block,
and rotate it approximately 30 degree to stabilize it.
• Cut the plastigauge to the same size as the journal
width, and while avoiding the oil hole of the journal
lay the gauge parallel to the journal.
• Gently rest the crankcase on the cylinder block,
apply molybdenum disulfide to the thread section
and seating surface of the tightening bolt, and
tighten in sequence to the correct torque.
Important:
Do not rotate the crankshaft while using the plasti-
gauge.
• Gently remove the crankcase, and measure the

crushed width of the plastigauge (clearance
between bearing and journal) using the scale
printed on the bag.
Reading the Model
Engine number stamping position
Name
1. Engine Number Stamp (6WG1-• • • • • •)
General Information Description of abbreviations
Terminology, description of abbreviations
Abbrevia- Description
Terminology definitions tion
Maintenance standard AC Alternating Current
The generic name for reference values required for
ACC Accessory
maintenance, such as nominal dimension, assembly
specification, and limit. ACG Alternating Current Generator
Nominal dimension API American Petrol Institute
Shows the standard value at the point of manufacture ASM Assembly
that does not include the common difference. (Assy)
Assembly specification ATDC After Top Dead Center
Shows the standard value after assembling, repairing,
or adjusting. BAT, BATT Battery
BRG, Brg Bearing
Service limit
When this value (dimensions) is reached, it shows that BKT, BRKT Bracket
the part has reached its full limit and must be replaced
BTDC Before Top Dead Center
or repaired.
CO Carbon Oxide
Wear
Shows the difference between the dimension of non- CONN Connector
worn part (nominal dimension unless there is such part) CPU Central Processing Unit
and that of the most worn part (the dimension of worn
part). C/U Control Unit
DC Direct Current
Uneven wear
Shows the difference between the maximum and the DI Direct Injection
minimum wear amount. ECU Engine Control Unit/Electronic Control Unit
Front/Rear, Right/Left, Top/Bottom ECM Engine Control Module
These show each orientations of parts installed to the
vehicle when looking from the vehicle's forward direc- EGR Exhaust Gas Recirculation
tion. Exh, EXH Exhaust
Unit Ft, FRT Front
Units written to SI conventions (mainly torque, pres-
FWD Forward
sure, force)
[Example] Length: mm, Torque: N⋅m {kgf⋅m} F/C Fuel Cut
Warning GND Ground

Items that carry the warning mark pose a danger to life IC Integrated Circuit
or threat of serious injury if not strictly observed.
ID Plate Identification Plate
Caution
Items that carry the caution mark may cause injury or IN Intake, Inlet
lead to accidents if not strictly observed. ISO International Organization for Standardiza-
tion
Important
Items that carry the important mark may cause the I/PUMP Injection Pump
vehicle to break down, or may prevent the guaranteed JIS Japanese Industrial Standard
normal operation of the system or related parts if not
strictly observed. L/H, LH Left Hand
Note M/V Magnetic Valve

Items that should receive special mention within a work NOx Nitrogen Oxide
procedure.
N-TDC Number - Top Dead Center
OPT Option
P Pole(S)
PCV Pump Control Valve/Positive Crankcase
Ventilation
Abbrevia- Description SI (International System of Units)

tion With regards the conversion to SI (International
PM Particulate Matter System of Units)
PS Pre-Stroke The introduction of the SI systems aims to internation-
ally unify the metric system and the various units used
PTO Power Take Off by different countries (traditional weights and mea-
QOS Quick On System sures, the foot pound method etc.), and to curb the
confusion that occurs between the different units (con-
Rr, RR Rear
version calculations etc.).
R/H, RH Right Hand The new calculating method which adopted SI units
R/L Relay was completely adopted in Japan in 1992, and is stan-
dardized by JIS-Z-8203.
STD Standard All of the units in this manual are written in line
SW Switch with the International System of Units SI units, and
conventional units are written in { } brackets.
TICS Timing & Injection rate Control System
VGS Turbo Variable Geometry turbocharger System SI
Abbreviation of French word “Le Systeme International
W/L Warning Lamp
d’Unites”
Connection between main SI units and conventional units
SI Conventional unit Item, unit conversion

Length m m Same as the conventional unit
Weight (Mass) kg kg Same as the conventional unit
Force N * kg, kgf 1 kgf = 9.80665 N
Torque N⋅m * kg⋅m, kg⋅m 1 kg⋅m = 9.80665 N⋅m
Pressure Pa * kg/cm2, mmHg 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa
Power output, W PS 1 PS = 0.74 kW
horsepower
Capacity, air vol- m3 Liter, L, cc 1 Liter = 1 dm3, 1 cc = 1 m Liter = 1 cm3
ume displacement
Fuel consumption g/(kW⋅h) g/(PS⋅h) 1 g/(PS⋅h) = 1.360 g/(kW⋅h)
*1 Published service data may conveniently use kg for force and mass (weight) instead of kgf.
*2 Some conversion results may be rounded off to 1 or 2 decimal places.
Converting expressions of quantity
When converting, prefixes such as k (kilo) or m
(milli) are used.
M Mega 106 1,000,000

k Kilo 103 1,000
h Hecto 102 100
d Deci 10-1 0.1
c Centi 10-2 0.01
m Milli 10-3 0.001
µ Micro 10-6 0.000001
• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa

• 40 mmHg = 5,332 Pa = 5.3 kPa
Conversion formula
Length
• km × 0.6214 = mile
• m × 3.281 = ft
• mm × 0.03937 = in
Pressure
• kPa × 0.0101972 = kg/cm2
• kPa × 0.145038 = psi
• MPa × 10.197162 = kg/cm2
• MPa × 145.03774 = psi
Tightening torque
• N⋅m × 0.101972 = kg⋅m
• N⋅m × 0.737562 = lb⋅ft
Speed
• km/h × 0.6214 = MPH
Temperature
• °C × 1.8 + 32 = °F
Table of Isuzu standard tightening torque
The tightening torque values in the table below apply to all situations unless a special tightening torque is specified.
Isuzu standard bolts, nuts
N⋅m {kg⋅m}
Strength classifica- 4.8 7T
tion 4T
Shape of bolt head Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
*M10 × 1.5 19.6 — 33.3 {2.0 — 3.4} 22.3 — 37.2 {2.3 — 3.8} 27.5 — 45.1 {2.8 — 4.6} 30.3 — 50.4 {3.1 — 5.1}
M12 × 1.25 49.0 — 73.5 {5.0 — 7.5} 54.9 — 82.3 {5.6 — 8.4} 60.8 — 91.2 {6.2 — 9.3} 68.1 — 102.1 {6.9 —
10.4}
*M12 × 1.75 45.1 — 68.6 {4.6 — 7.0} 51.0 — 76.5 {5.2 — 7.8} 56.9 — 84.3 {5.8 — 8.6} 62.7 — 94.0 {6.4 — 9.6}
M14 × 1.5 76.5 — 114.7 {7.8 — 83.0 — 124.5 {8.5 — 93.2 — 139.3 {9.5 — 100.8 — 151.1 {10.3 —
11.7} 12.7} 14.2} 15.4}
*M14 × 2 71.6 — 106.9 {7.3 — 77.2 — 115.8 {7.9 — 88.3 — 131.4 {9.0 — 94.9 — 142.3 {9.7 —
10.9} 11.8} 13.4} 14.5}
M16 × 1.5 104.0 — 157.0 {10.6 — 115.6 — 173.3 {11.8 — 135.3 — 204.0 {13.8 — 150.1 — 225.2 {15.3 —
16.0} 17.7} 20.8} 23.0}
*M16 × 2 100.0 — 149.1 {10.2 — 109.4 — 164.2 {11.2 — 129.4 — 194.2 {13.2 — 142.5 — 213.8 {14.5 —
15.2} 16.7} 19.8} 21.8}
M18 × 1.5 151.0 — 225.6 {15.4 — — 195.2 — 293.2 {19.9 — —
23.0} 29.9}
*M18 × 2.5 151.0 — 225.6 {15.4 — — 196.1 — 294.2 {20.0 — —
23.0} 30.0}
M20 × 1.5 206.0 — 310.0 {21.0 — — 269.7 — 405.0 {27.5 — —
31.6} 41.3}
*M20 × 2.5 190.2 — 286.4 {19.4 — — 249.1 — 374.6 {25.4 — —
29.2} 38.2}
M22 × 1.5 251.1 — 413.8 {25.6 — — 362.8 — 544.3 {37.0 — —
42.2} 55.5}
*M22 × 2.5 217.7 — 327.5 {22.2 — — 338.3 — 507.0 {34.5 — —
33.4} 51.7}
M24 × 2 358.9 — 539.4 {36.6 — — 430.5 — 711.0 {43.9 — —
55.0} 72.5}
*M24 × 3 338.3 — 507.0 {34.5 — — 406.0 — 608.0 {41.4 — —
51.7} 62.0}
The * mark indicates where soft materials have been used for internal thread sections, such as castings.
N⋅m {kg⋅m}
Strength classifica- 8.8 9.8
tion 9T
Shape of bolt head Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
M6 × 1 5.6 — 11.2 {0.6 — 1.1} 6.6 — 12.2 {0.6 — 1.2} — —
M8 × 1.25 13.4 — 25.7 {1.4 — 2.6} 15.3 — 28.4 {1.6 — 2.9} 16.7 — 30.4 {1.7 — 3.1} 18.1 — 33.6 {1.9 — 3.4}
M10 × 1.25 31.3 — 52.5 {3.2 — 5.4} 35.4 — 58.9 {3.6 — 6.1} 37.3 — 62.8 {3.8 — 6.4} 42.3 — 70.5 {4.3 — 7.2}
*M10 × 1.5 31.3 — 51.4 {3.2 — 5.2} 34.5 — 57.5 {3.5 — 5.8} 36.3 — 59.8 {3.7 — 6.1} 40.1 — 66.9 {4.1 — 6.8}
M12 × 1.25 69.3 — 104.0 {7.1 — 77.7 — 116.5 {7.9 — 75.5 — 113.8 {7.7 — 85.0 — 127.5 {8.7 —
10.6} 11.9} 11.6} 13.0}
*M12 × 1.75 64.8 — 96.1 {6.6 — 9.8} 71.4 — 107.2 {7.3 — 71.6 — 106.9 {7.3 — 79.5 — 119.2 {8.1 —
10.9} 10.9} 12.2}
M14 × 1.5 106.2 — 158.8 {10.8 — 114.9 — 172.3 {11.7 — 113.8 — 170.6 {11.6 — 123.4 — 185.1 {12.6 —
16.2} 17.6} 17.4} 18.9}
*M14 × 2 100.6 — 149.8 {10.3 — 108.2 — 162.2 {11.1 — 106.9 — 160.0 {10.9 — 115.5 — 173.3 {11.8 —
15.3} 16.6} 16.3} 17.7}
M16 × 1.5 154.3 — 232.5 {15.7 — 171.1 — 256.7 {17.4 — 160.0 — 240.3 {16.3 — 176.9 — 265.3 {18.0 —
23.7} 26.2} 24.5} 27.1}
*M16 × 2 147.6 — 221.4 {15.0 — 162.5 — 243.8 {16.6 — 153.0 — 229.5 {15.6 — 168.5 — 252.7 {17.2 —
22.6} 24.9} 23.4} 25.8}
M18 × 1.5 222.5 — 334.3 {22.7 — — 229.5 — 345.2 {23.4 — —
34.1} 35.2}
*M18 × 2.5 223.6 — 335.4 {22.8 — — 230.5 — 346.2 {23.6 — —
34.2} 35.3}
M20 × 1.5 307.4 — 461.7 {31.4 — — 316.8 — 475.6 {32.3 — —
47.1} 48.5}
*M20 × 2.5 284.0 — 472.1 {29.0 — — 293.2 — 440.3 {29.2 — —
43.5} 44.9}
M22 × 1.5 413.6 — 620.5 {42.2 — — 424.6 — 636.5 {43.3 — —
63.3} 64.9}
*M22 × 2.5 385.7 — 578.0 {39.3 — — 394.2 — 592.3 {40.0 — —
58.9} 60.4}
M24 × 2 490.8 — 810.5 {50.0 — — 554.1 — 830.6 {56.5 — —
82.7} 84.7}
*M24 × 3 462.8 — 693.1 {47.2 — — 520.7 — 781.6 {53.1 — —
70.7} 79.7}
The * mark indicates where soft materials have been used for internal thread sections, such as castings.
Designations for Isuzu standard bolt heads
Name
1. Hexagon Head Bolt (4.8, 4T) 9. Hexagon Head Bolt (Nonthermal Refined 8.8)
2. Hexagon Head Bolt (4.8, 4T) 10. Hexagon Head Bolt (Nonthermal Refined 8.8)
3. Flange Bolt (4.8, 4T) 11. Flange Bolt (8.8)
4. Flange Bolt (4.8, 4T) 12. Flange Bolt (8.8)
5. Hexagon Head Bolt (7T) 13. Hexagon Head Bolt (9.8, 9T)
6. Flange Bolt (7T) 14. Hexagon Head Bolt (9.8, 9T)
7. Hexagon Head Bolt (Thermal Refined 8.8) 15. Flange Bolt (9.8, 9T)
8. Hexagon Head Bolt (Thermal Refined 8.8) 16. Flange Bolt (9.8, 9T)
Flare nut
Pipe diameter Tightening torque Width across flats of flare nut

(for medium and large size (mm)
vehicles)
Old New
Flare nut tightening torque φ 4.76 mm 12.8 — 18.6 {1.3 — 1.9} 14 14
(service standard value) N⋅m {kg⋅m}
φ 6.35 mm 23.5 — 49 {2.4 — 5.0} 17 17
φ 8.0 mm 23.5 — 49 {2.4 — 5.0} 19 17
φ 10.0 mm 44.1 — 93.2 {4.5 — 9.5} 22 19
φ 12.0 mm 58.8 — 137.3 {6.0 — 14.0} 27 24
φ 15.0 mm 78.5 — 156.9 {8.0 — 16.0} 30 30
Taper screw from connectors (brass)
N⋅m {kg⋅m}
Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 1/12
— 2.0 — 14.7 4.9 — 15.7 9.8 — 16.7 9.8 — 17.7
{0.2 — 1.5} {0.5 — 1.6} {1.0 — 1.7} {1.0 — 1.8}
Special tool classification

A; Essential tool
Servicing operation cannot be done with any other
tools than the essential tool.
B; Recommend tool
Servicing work can be done with a general-purpose
tool commercially available. However, it is advisable to
use the recommended tool as much as possible for a
reduced work time and an improved safety in work
operations.
C; Available tool
Although it takes a more working time, servicing opera-
tions can be made with a tool commercially available as
substitute for the available tool.
6WG1 Engine Mechanical 1A-1
Engine
6WG1 Engine Mechanical
Table of Contents
ISUZU Diesel Engine ............................................ 1A-2 Piston, Connecting Rod ......................................1A-93
Service Precautions ........................................... 1A-2 Components.....................................................1A-93
Reading the Model ............................................. 1A-3 Removal ...........................................................1A-94
Explanations on Functions and Operation ......... 1A-4 Disassembly.....................................................1A-94
Function Check .................................................. 1A-7 Inspection.........................................................1A-95
Specifications ................................................... 1A-11 Reassembly .....................................................1A-99
Engine Accessories............................................. 1A-12 Installation ......................................................1A-101
Components..................................................... 1A-12 Torque Specifications.....................................1A-104
Removal ........................................................... 1A-13 Crankshaft .........................................................1A-105
Installation ........................................................ 1A-14 Components...................................................1A-105
Engine Exterior Equipment ................................. 1A-16 Removal .........................................................1A-106
Components..................................................... 1A-16 Disassembly...................................................1A-106
Removal ........................................................... 1A-20 Inspection.......................................................1A-107
Inspection......................................................... 1A-30 Reassembly ...................................................1A-110
Installation ........................................................ 1A-30 Installation ......................................................1A-110
Torque Specifications....................................... 1A-43 Cylinder Block ...................................................1A-112
Cylinder Head ..................................................... 1A-45 Components...................................................1A-112
Components..................................................... 1A-45 Disassembly...................................................1A-113
Removal ........................................................... 1A-46 Inspection.......................................................1A-113
Disassembly..................................................... 1A-50 Reassembly ...................................................1A-114
Inspection......................................................... 1A-53 Torque Specifications.....................................1A-116
Reassembly ..................................................... 1A-57 Special Tool ......................................................1A-117
Installation ........................................................ 1A-62 List of Special Tool.........................................1A-117
Torque Specifications....................................... 1A-70
Rocker Arm ......................................................... 1A-71
Components..................................................... 1A-71
Disassembly..................................................... 1A-72
Inspection......................................................... 1A-72
Reassembly ..................................................... 1A-73
Camshaft............................................................. 1A-74
Components..................................................... 1A-74
Disassembly..................................................... 1A-75
Inspection......................................................... 1A-75
Reassembly ..................................................... 1A-77
Timing Gear ........................................................ 1A-78
Components..................................................... 1A-78
Removal ........................................................... 1A-79
Disassembly..................................................... 1A-80
Inspection......................................................... 1A-81
Reassembly ..................................................... 1A-82
Installation ........................................................ 1A-82
Flywheel, Flywheel Housing................................ 1A-87
Components..................................................... 1A-87
Removal ........................................................... 1A-88
Disassembly..................................................... 1A-88
Inspection......................................................... 1A-89
Reassembly ..................................................... 1A-89
Installation ........................................................ 1A-89
1A-2 6WG1 Engine Mechanical
ISUZU Diesel Engine

Service Precautions Service precautions specific to this engine
Service precautions about maintenance Holes and clearances in the fuel system which serve as
a passage of fuel, including the inside of injector, are
Confirm the following items to prevent damage on the
finished extremely precisely. For this reason, they are
engine and maintain reliability of the engine perfor-
highly sensitive to foreign matter. If it gets inside, it can
mance.
lead to breakdown on the road. Be sure to prevent it
• Do not put a jack against the oil pan when lifting up from getting inside.
or supporting the engine.
• Before beginning the service procedure, wash the
When lowering the engine onto a base, use an
fuel line and the surrounding area.
engine pallet or wooden frame and rest the engine
on the engine foot and flywheel housing. • Perform the service procedures with clean hands.
Do not wear work gloves.
• When removing the intake system, cover the
intake port to prevent dust particles from getting • Immediately after removing the fuel hose and/or
into the cylinder. Foreign materials can be a cause fuel pipe, carefully tape vinyl bags over the
for severe damage on cylinders etc. when the exposed ends of the hose or pipe.
engine is running. • Always replace the high-pressure pipe in fuel sys-
• Be sure to disconnect the battery ground cable tem with new one if it has been removed. Reuse of
when servicing the engine body. When electricity it causes damage to the seal surface, resulting in
is required for inspection etc., be careful with short fuel leakage.
circuit. • If parts are to be replaced (fuel hose, fuel pipe,
• Apply sufficient engine oil to the sliding surface to etc.), do not open the new part packaging until
protect and lubricate the surface at the first drive. installation.
• When the parts surrounding the valves, the piston,
the piston ring, the connecting rod, the connecting
rod bearing and crankshaft journal bearing have
been removed, put them order to store.
• In the installation procedure, install the same part
to the same position of removal.
• For gaskets, oil seals and O-rings, replace with
new ones each time they are disassembled.
• When applying the liquid gasket, remove the old
liquid gasket completely and clean off any oil,
moisture or foreign materials beforehand, and
apply specified liquid gasket before reassembling
the parts.
• Re-install these parts within 7 minutes of applying
the liquid gasket.
If more than 7 minutes passes, remove the previ-
ous liquid gasket and re-apply it.
• When assembling or installing parts, fasten them
with the specified tightening torque so that they
may be installed properly.
Reading the Model
Name
1. Engine Number Stamp (6WG1-• • • • • •)
Explanations on Functions and Operation
Engine structure diagram
WSWG0017
Installation position of the turbocharger differs depending upon the engine specification.
WSWG0018
Installation position of the turbocharger differs depending upon the engine specification.
Function Check Removal of the injector harness connector
Service precautions • Remove the injector harness connector from the
lower head cover (no fuel injection).
1. Engine parts are extremely hot straight after a
drive, so cool them down sufficiently.
2. Diagnostic codes (self-diagnosis codes) are
recorded on the ECU memory. Check the contents
of the memory stored on ECU using a scan tool
before starting an inspection on a sensor.
3. Make sure to disconnect battery terminals to pre-
vent damage on electronic parts such as sensors
or a fire.
4. High voltage at injector harnesses or electromag-
netic valves can cause an electric shock. Make
sure to turn the starter switch to “OFF” and pull out
the key when carrying out a service.
Measurement of the compression pressure

Measure the compression pressure when the engine is
cool (water temperature 20°C {68°F}) and there are no
errors occurring at battery or starter motor.
Removal of the glow plugs Installation of the compression gauge

• Remove all of the glow plugs. • Insert the compression gauge adapter into the
glow plug installation hole and install the compres-
sion gauge.
Special tool
Compression gauge adapter: 1-8531-7019-0
Compression gauge: 5-8840-2675-0
Measurement of the compression pressure Judgment of time to overhaul
• Turn the starter motor (200 rpm) and measure the Overhaul is necessary for cases below.
compression pressure when the indicator of com-
pression gauge is stable. The compression pressure is lowering
The compression pressure measured by the measuring
CAUTION:
method instructed is lower than 2260 kPa {328 psi}.
• Be careful, the air may be shooting out from
the glow hole when running. Rate of increase in engine oil consumption
• Measure the compression pressure of all cylin- Overhaul is needed when the consumption rate goes
ders. over 200 % of that of new engine (100 %).
• When the harness connector is removed, ECU
judges it as a breakdown and records an error Rate of increase in fuel consumption
code. Upon completion of measurement, never Overhaul is needed when the consumption rate goes
fail to clear ECU memory. (For clearing ECU over 140 % of that of new engine (100 %).
memory, refer to “Trouble Shooting Manual”)
Noise inside of engine
Compression pres- Difference between

Strange noises are coming from inside of the engine.
Item sure cylinders Carry out the overhaul at an early stage and repair.
kPa/rpm {psi/rpm} kPa {psi}
Note:
Assembly 2,750 / 200 Wear, seizure or overheating at engine parts can be
196 {28}
specification {398 / 200} causes for strange noises.
2,260 / 200
Service limit —
{328 / 200} Adjustment of valve clearance
Adjust the valve clearance twice for setting at the No.1
cylinder compression TDC (top dead center) and at the
No.6 cylinder TDC.
Set to No.1 cylinder (or No.6 cylinder) compression

TDC.
Rotate the crankshaft in proper direction, and align the
nick line of flywheel to the pointer. Make sure there is a
clearance (compression TDC) between the locker arm
of No.1 cylinder (or No.6 cylinder) and the cam.
Adjustment of valve clearance
1. Adjust the valves shown on the valve clearance
adjustment chart.
2. Loosen each adjusting screw (1) completely on the
rocker arm and bridge (2).
4. Once the thickness gauge is inserted, tighten the

adjusting screw of the bridge until the thickness
gauge is secured tightly.
5. Slowly loosen the adjusting screw of the bridge
and re-adjust ins/outs of the thickness gauge
3. Insert the thickness gauge between the rocker arm appropriately, and then secure the lock nut of the
(1) and the cam. Adjust with adjusting screws on bridge.
the rocker arm and then secure with the lock nut.
Valve clearance (at cold Including intake and exhaust
condition) 0.40 mm {0.016 in}
Tightening torque:
Rocker arm adjusting screw lock nut: 78 N⋅m {8.0
kg⋅m/58 lb⋅ft}
Bridge adjusting screw lock nut: 54 N⋅m {5.5 kg⋅m/
40 lb⋅ft}
Note:
• Stop the engine and wait for a reasonable amount
of time before starting work.
• When removing the head cover, a small amount of
oil may spill, so be prepared to clean up the oil with
a cloth, etc.
Valve clearance adjustment chart

Cylinder No. 1 2 3 4 5 6
Exh Intak Exh Intak Exh Intak Exh Intak Exh Intak Exh Intak
Conditions Valve arrangement
aust e aust e aust e aust e aust e aust e
When setting No.1 cylinder
to the compression top ❍ ❍ ❍ ❍ ❍ ❍
Adjusting dead center
valve When setting No.6 cylinder
to the compression top ❍ ❍ ❍ ❍ ❍ ❍
dead center
Injection order (1-5-3-6-2-4)

Inspection and adjustment of the belt
Inspect for belt wear and cracking.
Tension adjustments of the generator drive

belt
1. Tighten the idle pulley lock nut and generator sec-
tion lock nut.
2. Adjust the belt tension so it becomes equal to the
standard value by adjusting the idle pulley adjust-
ing bolt and generator section adjusting bolt. Name
1. Lock Nut (Generator)
3. The deflection when 98 N {10 kg/22 lb} is applied
2. Adjusting Bolt (Generator)
to the center between the idle pulley and generator
3. Lock Nut
pulley
4. Adjusting Bolt (Idle Pulley)
Standard value mm {in} 5. Belt Tension Measurement Position
6. Mounting Bolt
Belt deflection 6 — 8 {0.24 — 0.31}
Specifications
Model 6WG1-TC
Item
Engine model Water cooled 4-cycle in-line type 6 cylinder 24 valve OHC
direct injection diesel
Cylinder layout - Number − Bore × Stroke mm {in} L6 − φ147 {5.78} × 154 {6.06}
Displacement L {cu.in} 15.681 {957}
Compression ratio 16.0
Compression pressure kPa{psi}/rpm 2,750{399}/200
Dimension (Length × Width × Height) mm {in} 1,463 {57.60} × 1,036 {40.79} × 1,432 {56.38}
Weight kg 1,185
Fuel injection order 1-5-3-6-2-4
Injection pump type Electronic control fuel injection system (Common rail type)
Governor type Electronic type
Timer type Electronic type
Nozzle type DLL-P
Intake/exhaust valve clearance (while cool) mm {in} 0.4 {0.016}
Intake valve open/close timing (Open) 21° (BTDC)
Intake valve open/close timing (Closed) 27° (ABDC)
Exhaust valve open/close timing (Open) 52° (BBDC)
Exhaust valve open/close timing (Closed) 17.5° (ATDC)
Fuel filter type Filter paper type
Oil filter type Filter paper type
Oil pump type Gear type
Oil cooler type Water cooling type
Engine oil level L {qts} Oil pan: 37 — 52 {39.1 — 55.0}
Cooling device type Water cooling compulsory re-circulation type
Coolant full capacity L {qts} 36 {38.1}
Water pump model Centrifugal gear type
Thermostat model Wax type
Air cleaner model Filter paper type
Generator capacity V-A 24 − 50
Starter V-kW 24 − 7.0
Turbocharger model TD08H (Mitsubishi)
Inter cooler type Aluminum tube & end plate type
Thermostat valve-opening temperature °C {°F} 80 — 84 {176 — 183}
Thermostat full-open temperature/ lift amount °C {°F}/mm {in} 95 {203} /10 mm {0.394 in} lift when at 95°C {203°F}
Oil thermostat full-open temperature/ lift amount °C {°F}/mm {in} 98 {208} /8 mm {0.315 in} lift when at 110°C {230°F}
Exhaust gas re-circulation device (EGR) equipped
Engine Accessories
Components
Name
1. Generator 3. Belt (Generator)
2. Starter Motor
Removal
1. Remove the V-belt (for generator).
• Loosen the generator mounting bolt and nut,
and push the adjusting bolt down on the engine
side.
• Loosen the idle pulley adjusting bolt.
• After completing the work above, remove the
belt.
Name
1. V-belt
2. Adjusting Nut
4. Bolt (Generator)
3. Remove the starter motor.
Name
1. V-belt
2. Adjusting Nut
4. Bolt (Generator)
2. Remove the generator.

• Remove the generator mounting bolt, nut and
adjusting nut, and remove the generator from
the bracket.
Name
1. Flywheel Housing
2. Nut
3. Starter Motor
Installation 3. Install the belt (for the generator) and adjust the
tension of the belt.
1. Install the starter motor.
• Secure the reliable standard position by setting
• Install the starter cable to the lower section, and
a standard string (1) or a weighted at both ends
tighten it by nut to the starter and lower section.
string (2) on the back of the belt.
Tightening torque:
103 N⋅m {10.5 kg⋅m/80 lb⋅ft}
• Arrange the push gauge so that the edge of the

push gauge presses uniformly on the overall
Name width of the belt, or set an iron plate with a
1. Flywheel Housing thickness of about 2 mm {0.08 in} on the belt.
2. Nut
3. Starter Motor
2. Install the generator to the bracket and adjusting

plate.
Name
1. Push Gauge
2. Iron Plate
3. Deflection
Name • Loosen the generator mounting bolt and lock

1. Belt nut, then loosen the idle pulley lock nut.
2. Adjusting Nut • In order to set the deflection to within the stan-
3. Adjusting Bolt (Generator) dard value range when approximately 98 N {10
4. Bolt (Generator) kg/22 lb} of force is applied to the central sec-
5. Adjusting Bolt (Idle Pulley) tion of the belt, correctly adjust the balance
using the generator adjusting bolt and idle pul-
ley adjusting bolt.
• After adjusting the tension of the belt, tighten
the lock nuts (1) and (3), and the mounting bolt
(6).
Tightening torque:
Idle pulley: 147 N⋅m {15 kg⋅m/33 lb⋅ft}
Name
1. Lock Nut (Generator)
3. Lock Nut (Idle Pulley)
5. Belt Tension Measurement Position
6. Bolt
Standard value mm {in}

Belt deflection 6 — 8 {0.24 — 0.31}
Engine Exterior Equipment

Components
Name
1. Secondary EGR Cooler 11. Oil Feed Pipe (Supply Pump)
2. Intake Pipe 12. Oil Return Pipe (Supply Pump)
3. Injection Pipe 13. Oil Port
4. Fuel Pipe (Supply Pump — Common Rail) 14. Fuel Return Pipe (Supply Pump)
5. Fuel Pipe (Feed Pump — Fuel Filter) 15. Supply Pump
6. Fuel Pipe (Fuel Filter — Supply Pump) 16. Coupling
7. Fuel Return Pipe 17. Pointer
8. Fuel Filter 18. Oil Pipe (PTO Gear)
9. Air Breather Hose 19. Level Gauge, Guide Tube
10. Nozzle Leak-off Pipe
Name
1. Turbocharger 5. Oil Return Pipe (Turbocharger)
2. Thermostat Housing 6. Oil Feed Pipe (Turbocharger)
3. Plate (EGR Duct) 7. Oil Port
4. Water Inlet Pipe 8. Oil Cooler
Name
1. Water Outlet Pipe 8. Reed Valve Duct
2. Primary EGR Cooler 9. EGR Duct
3. EGR Duct 10. EGR Duct
4. Exhaust Pipe 11. EGR Valve
5. Bracket 12. PTO Gear ASM
6. Breather Hose 13. Secondary EGR Cooler
7. Fuel Pipe (Fuel Filter — Fuel Filter)
Name
1. Water Pipe, Hose (Feed Side) (EGR Cooler) 2. Water Pipe, Hose (Return Side) (EGR Cooler)
Removal 4. Unfasten the EGR pipe fixing clip, and remove the
cooling water pipe for the EGR cooler and rubber
1. Remove the engine harness (1).
hose (feed side).
Note:
Note:
It is a lot easier to re-install the harness clip if you mark
Before performing this work, drain off water from the
the installation position of the harness clip with a paint
engine interior.
marker or something similar before removing.
Name
2. Remove the EGR duct fixing plate.
1. Rubber Hose
3. Remove the EGR duct. 2. Rubber Hose
3. Water Pipe for EGR Cooler (LH) (Feed Side)
4. Rubber Hose
5. Clip
6. Water Pipe for EGR Cooler (FT) (Feed Side)
7. Clip
Name
1. EGR Pipe
2. Distance Tube, Dish Washer
3. Bolt
4. Bolt
5. Plate
6. Bolt
5. Unfasten the EGR pipe fixing clip, and remove the 7. Remove the oil feed pipe (turbocharger).
cooling water pipe for the EGR cooler and rubber
hose (return side).
Name
1. Turbocharger
2. Oil Return Pipe (Turbocharger)
3. Oil Feed Pipe (Turbocharger)
4. Oil Port
8. Remove the bolts for the exhaust pipe mounting

bracket, and remove the exhaust pipe.
Name
1. Rubber Hose
2. Water Pipe for EGR Cooler (RR) (Return Side)
3. Rubber Hose
4. Water Pipe for EGR Cooler (LH) (Return Side)
5. Water Pipe for EGR Cooler (FT) (Return Side)
6. Rubber Hose
6. Remove the oil return pipe (turbocharger).
Name
1. Exhaust Pipe Bracket
2. Clamp
3. Turbocharger
4. Exhaust Pipe
5. Bolt and Washer
9. Remove the turbocharger. 11. Remove the thermostat housing.
• Cover the turbocharger's oil opening after
removing the turbocharger. Also cover the com-
pressor and turbine openings with gum tape or
something similar.
Name
1. Bolt
2. Water Pump
3. Gasket
Name 4. Thermostat Housing
1. Exhaust Bracket
2. Exhaust Manifold 12. Remove the water pump.
3. Turbocharger
4. Gasket
10. Remove the water inlet pipe.
Name
1. O-ring
2. Water Pump
3. O-ring
Name
1. Bolt
2. Oil Cooler
3. Gear Case
4. Bolt
5. Water Inlet Pipe
13. Remove the oil port. 15. Remove the oil cooler.
• Remove the oil cooler tightening bolt, insert and
tighten the removed bolts into the replacer
holes (two places) and remove the oil cooler.
14. Remove the water drain pipe and connector for the
drain pipe.
16. Remove the level gauge and guide tube.

17. Remove the intake pipe.
Name
1. Connector
2. Water Drain Pipe
3. Drain Cock
Name
4. Bolt
1. Inlet Manifold
2. Gasket
3. Bolt
4. Bolt
5. Intake Pipe
18. Remove the primary EGR cooler. 21. Remove the EGR duct.
Name Name
1. Primary EGR Cooler 1. EGR Valve
2. Gasket 2. Gasket
3. Bolt 3. EGR Duct
4. EGR Duct
19. Remove the secondary EGR cooler. 5. Bolt and Washer
• Remove the primary side (entrance side) fixing 6. Gasket
bolts. 7. Bolt
22. Remove the left and right reed valve ducts.
Name
1. Bolt
2. Secondary EGR Cooler Name
3. Bolt 1. Reed Valve Duct
4. Gasket 2. Reed Valve Duct
3. Gasket
20. Remove the EGR valve. 4. Inlet Manifold
23. Remove the reed valve. 24. Release the clips in each position and remove the
air breather hose.
Name
1. Bolt
2. Reed Valve
3. Bolt
4. Inlet Manifold
Name
1. Air Breather
2. Clip
3. Clip
4. Clip
5. Hose
25. Release the clips and remove the fuel return pipe 27. Remove the fuel return pipe.
(filter). • Some fuel may spill, so hold the pipe with a
cloth when removing it.
Important:
Seal the installation sections of the removed pipe Important:
to prevent it from becoming dirty. Seal the installation sections of the removed pipe
to prevent it from becoming dirty.
Name
1. Fuel Filter Name
2. Fuel Return Pipe 1. Nozzle Leak-off Pipe
2. Fuel Return Pipe (Supply Pump)
26. Remove the nozzle leak-off pipe.
28. Remove the fuel pipe (feed pump — fuel filter).
29. Remove the fuel pipe (fuel filter — supply pump).
Important:
Seal the installation sections of the removed pipe
to prevent it from becoming dirty.
Name
1. Fuel Return Pipe (Filter)
2. Head Lower Cover
Name
1. Fuel Pipe (Fuel Filter — Supply Pump)
2. Fuel Pipe (Feed Pump — Fuel Filter)
30. Remove the fuel pipe (fuel filter — fuel filter). 33. Remove the injection pipe clip, and remove the
31. Remove the fuel filter from the bracket. injection pipe.
Important: Important:
Seal the installation sections of the removed pipe • Hang a spanner on the common rail flow damper
to prevent it from becoming dirty. (width across flats: 19 mm {0.75 in}) to prevent
rotating, then loosen the injection pipe sleeve
nut.
• Seal the pipe and pump to prevent dust particles
from getting in.
• Take care not to damage the shape of the injec-
tion pipe when removing it. Furthermore, a small
amount of oil may spill from the head section,
which should be cleaned with a close, etc.
• Check that there are no cracks or damage to the
clip rubber.
• Do not reuse the high-pressure pipe in fuel sys-
tem if it has been removed.
Name
1. Fuel Pipe (IN)
2. Fuel Pipe (OUT)
3. Fuel Pipe (OVER FLOW)
4. Fuel Filter
32. Remove the fuel pipe (supply pump — common

rail).
Name
1. Injection Pipe No.1
Name
1. Fuel Pipe (Supply Pump — Common Rail)
2. Common Rail
3. Supply Pump
34. Remove the fuel pipe clip BRKT and remove the
common rail.
Important:
Seal the opening part of where the common rail
pipe is installed to prevent any foreign materials
sticking there.
Name
1. Common Rail BRKT
2. Fuel Pipe BRKT
3. Fuel Pipe BRKT
4. Common Rail
35. Remove the oil pipe for the supply pump.
37. Loosen the bolt and remove the supply pump

bracket.
Name
1. Supply Pump
2. Oil Feed Pipe
3. Oil Return Pipe
36. Rotate the crankshaft and line up the No.1 cylinder

compression top dead center, then loosen the cou-
pling locking bolt and remove the supply pump.
38. Remove the clip, and remove the oil pipe for the 39. Loosen the bolt and remove the PTO gear ASM.
PTO.
Name
1. Bolt
2. Coupling
3. PTO Gear ASM
4. Bolt
Name
1. PTO Gear ASM
2. Clip
3. Oil Pipe
4. Clip
Name
1. Gasket
2. Pointer
3. Coupling
4. Bolt
5. PTO Gear ASM
40. Disconnect the water outlet pipe. Installation
1. Install the oil cooler.
• Insert four O-rings. (2 each of 2 types)
• Fix the gasket into the mounting flange side
groove towards the cylinder block, and install
the oil cooler.
Tightening torque:
50 N⋅m {5.1 kg⋅m/37 lb⋅ft}
Name
1. Bolt
2. Water Outlet Pipe
3. Bolt
4. Bolt
5. Bolt
Inspection Name
EGR reed valve 1. Gasket
2. Oil Cooler
• Check valve appearances for any damage.
3. O-ring
• Check to see if carbon is accumulated between the
stopper and the valve.
Name
1. Gasket
2. O-ring
3. Oil Cooler
4. Water Drain Pipe
2. Install the water drain pipe and connector. 3. Install the water pump.
• Temporarily install then fully tighten the con- • Insert two O-rings into the water pump, hold the
nector (A), water drain pipe (B) and tightening water pump against the gear case side while
bolt (C) in this order. tightening two bolts in the oil cooler side, then
tighten the four bolts from the gear case side.
Tightening torque:
Portion A: 78 N⋅m {8.0 kg⋅m/58 lb⋅ft} Tightening torque:
Portion B: 68 N⋅m {6.9 kg⋅m/50 lb⋅ft} 39 N⋅m {4.0 kg⋅m/29 lb⋅ft}
Portion C: 43 N⋅m {4.4 kg⋅m/32 lb⋅ft}
Portion D: 4 N⋅m {0.4 kg⋅m/35 lb⋅in}
Name
1. O-ring
Name 2. Water Pump
1. Connector (Portion A) 3. O-ring
2. Water Drain Pipe (Portion B)
3. Water Drain Cock (Portion D) 4. Install the thermostat housing.
4. Bolt (Portion C) • Install the two thermostats to the oil cooler.
• For details on installing the seal ring and ther-
mostat, refer to 1B-7, “Installation, Thermostat”.
• Fit gasket into the thermostat housing, and
tighten the two bolts in the water pump side
while holding the thermostat housing against
the oil cooler side, then tighten the three bolts in
the oil cooler side.
Tightening torque:
39 N⋅m {4.0 kg⋅m/29 lb⋅ft}
6. Connect the water outlet pipe.
• Install the two O-rings to the head section gear
case, and install the water outlet pipe.
Tightening torque:
39 N⋅m {4.0 kg⋅m/29 lb⋅ft}
Name
1. Seal Ring
2. Water Pump
3. Thermostat
4. Gasket
5. Thermostat Housing
6. O-ring Name
7. Bolt 1. Water Outlet Pipe
2. O-ring
5. Install the water inlet pipe to the oil cooler. 3. Gear Case
Tightening torque:
Oil cooler side: 39 N⋅m {4.0 kg⋅m/29 lb⋅ft}
Gear case side: 88 N⋅m {9.0 kg⋅m/65 lb⋅ft}
Name
1. Bolt
2. Water Outlet Pipe
Name 3. Bolt
1. Bolt 4. Bolt
2. Oil Cooler 5. Bolt
3. Gear Case
4. Bolt
5. Water Inlet Pipe
7. Install the oil port to the oil cooler. • Tighten the exhaust pipe to the turbocharger
with clamps, and fix to the bracket with bolts.
Tightening torque:
43 N⋅m {4.4 kg⋅m/32 lb⋅ft} Tightening torque:
Clamp: 14.7 N⋅m {1.5 kg⋅m/11 lb⋅ft}
8. Clip the gasket and install the turbocharger to the

exhaust manifold. Name
• Pour a suitable quantity of engine oil into the 1. Exhaust Pipe Bracket
opening of the turbocharger and turn the tur- 2. Clamp
bine shaft slightly, and then lubricate the shaft 3. Turbocharger
bearing. 4. Exhaust Pipe
5. Bolt
• Tighten the turbocharger with a double nut.
Tightening torque: 10. Connect the oil feed pipe (turbocharger), and fix it
40 N⋅m {4.1 kg⋅m/30 lb⋅ft} with a clip.
Tightening torque:
Eyebolt: 34 N⋅m {3.5 kg⋅m/25 lb⋅ft}
Name
1. Exhaust Bracket
2. Exhaust Manifold Name
3. Turbocharger 1. Turbocharger
4. Gasket 2. Oil Return Pipe (Turbocharger)
9. Connect the exhaust pipe.
4. Oil Port
11. Install the oil return pipe (turbocharger).
• Apply a small amount of liquid gasket to the two
O-ring grooves on the oil pipe, and then attach
the O-ring.
Tightening torque:
50 N⋅m {5.1 kg⋅m/37 lb⋅ft}
• Rotate the crankshaft in the proper direction,

and align the flywheel nick line with the timing
pointer so that the No.1 cylinder reaches the
compression top dead center. At this time
check that the No.1 cylinder intake and exhaust
valve have clearance.
Name
1. Turbocharger
2. Oil Return Pipe (Turbocharger)
4. Oil Port
12. Install PTO gear ASM.

• Install the PTO gear ASM shaft to the gears
beforehand.
Apply molybdenum disulfide to the threads and
the seating surface of the bolt, and tighten it in
the order shown in the illustration to the speci-
fied torque.
Tightening torque:
39 N⋅m {4.0 kg⋅m/29 lb⋅ft} → 90° — 120°
• Install the pointer to the PTO gear ASM side.

• Insert the O-ring into the gear case installation
section.
• Align the PTO gear ASM axel key, install the
coupling, align the pointer and coupling side
marking “A” and fit the gears. After fitting the
gears, move so that the coupling “S” mark posi-
tion and pointer tip align.
• Rotate the PTO shaft a very small amount, and
after the gears engage, completely press the
gear case in until it adheres. At this time check
to see coupling mark “S” is aligned with the
pointer. If they are out of line, the gears have
shifted so the process needs to be re-done.
13. Connect oil pipe for the PTO, and fix it with a clip.
Name
1. Pointer Name
2. S Mark (Marking) 1. PTO Gear ASM
3. A Mark (Marking) 2. Clip
4. Coupling 3. Oil Pipe
4. Clip
14. Align the supply pump bracket with the dowel hole
and install it.
Tightening torque:
Bracket: 108 N⋅m {11.0 kg⋅m/80 lb⋅ft}
16. Install the injection pipe from (1) to (6).
Important:
Replace the high-pressure pipe in fuel system with
new one if it has been removed.
• Install the injection pipe and clip in the positions

shown in the illustration.
• When installing the injection pipes, install No.3
and No.4 first.
Tightening torque:
Sleeve nut: 39 N⋅m {4.0 kg⋅m/29 lb⋅ft}
Name
1. Supply Pump
2. Bracket
15. Install the common rails.

• Install the common rail mounting bracket to the
cylinder block.
• Install the common rail to the bracket. Tighten
the fuel pipe bracket at the same time.
Tightening torque:
22 N⋅m {2.2 kg⋅m/16 lb⋅ft}
Note: 17. Install the supply pump.

Tighten the bracket after installing the pipe clip. • Reverse turn the crankshaft once up to just
below the top dead center 90° and turn it into a
proper direction. And set the nick line of the fly-
wheel P–P mark to the timing pointer. Check to
see it is close to the compression top dead cen-
ter of No.1 cylinder.
Name
1. Bracket
2. Fuel Pipe Bracket
3. Fuel Pipe Bracket
4. Common Rail
• Align the supply pump mark. • Check the supply pump alignment mark.
• Install the supply pump to the supply pump Reverse turn the crankshaft once up to just
bracket and tighten in a diagonal order. below the top dead center 90° and turn it into a
proper direction. And set the nick line of the fly-
Tightening torque: wheel P–P mark to the timing pointer. At this
31 N⋅m {3.2 kg⋅m/23 lb⋅ft} time check to see the supply pump body nick
line and coupling side nick line coincide.
If the nick lines do not coincide, loosen the two
long hole coupling bolts.
Rotate the coupling to align the nick lines of the
supply pump body and coupling side, then
tighten the coupling.
• Slide the coupling, check that it has joined to

the supply pump, and tighten the coupling bolts
(2).
Tightening torque:
62 N⋅m {6.3 kg⋅m/46 lb⋅ft}
• Make sure there is no dent on the laminate of Name
the coupling and tighten the cotter bolt (1). 1. Coupling Bolt
2. Coupling Side Nick Line
Tightening torque:
3. Pump Side Nick Line
91 N⋅m {9.3 kg⋅m/67 lb⋅ft}
4. Cotter Bolt
18. Install the fuel pipe (supply pump — common rail).
Important:
Replace the high-pressure pipe in fuel system with
new one if it has been removed.
• Fuel pump installation order

After temporarily tightening both sides of the
pipe, fully tighten from the common rail side to
the supply pump side.
Tightening torque:
Common rail side: 54 N⋅m {5.5 kg⋅m/40 lb⋅ft}
Supply pump side: 44 N⋅m {4.5 kg⋅m/32 lb⋅ft}
20. Install each fuel pipe by using procedures 21 —
27.
• Fix each of the fuel pipe installation positions
with clips.
Tightening torque:
M8: 15 N⋅m {1.5 kg⋅m/11 lb⋅ft}
M10: 28 N⋅m {2.9 kg⋅m/21 lb⋅ft}
M12: 35 N⋅m {3.6 kg⋅m/26 lb⋅ft}
M14: 41 N⋅m {4.2 kg⋅m/30 lb⋅ft}
21. Install the fuel pipe (fuel filter — fuel filter) to the
fuel filter.
22. Install the fuel filter to the bracket.
Name
1. Fuel Pipe (Supply Pump — Common Rail)
2. Common Rail
3. Supply Pump
19. Install the oil feed pipe and oil return pipe to the
supply pump.
Tightening torque:
M10: 10 N⋅m {1.0 kg⋅m/7.4 lb⋅ft}
M14: 27 N⋅m {2.8 kg⋅m/20 lb⋅ft}
23. Install the fuel pipe (feed pump — fuel filter).

24. Install the fuel pipe (fuel filter — supply pump).
• Fix the fuel pipe with clips.
Name
1. Oil Feed Pipe
2. Oil Return Pipe
3. Supply Pump
Name
1. Fuel Pipe (Fuel Filter — Supply Pump)
2. Fuel Pipe (Feed Pump — Fuel Filter)
25. Install the nozzle leak-off pipe.
Name
Name 1. Fuel Filter
1. Fuel Return Pipe (Filter) 2. Fuel Return Pipe
2. Head Lower Cover
3. Nozzle Leak-off Pipe 28. Fix the air breather with clips.
26. Connect the fuel return pipe.
Name
2. Fuel Return Pipe (Supply Pump)
27. Connect the fuel return pipe (for the filter).
Name
1. Air Breather
2. Clip
3. Clip
4. Clip
5. Breather Hose
6. Clip
29. Install the reed valve to the inlet manifold. Note:
Gently tighten the bolts to a position so that each EGR
Tightening torque:
duct and EGR cooler hit face contact, position the seal
10 N⋅m {1.0 kg⋅m/7.4 lb⋅ft}
face has no clearance, then fully tighten the bolts.
32. Clip the gasket and install the EGR valve.
Name
1. Bolt
2. Reed Valve Name
3. Bolt 1. EGR Valve
4. Inlet Manifold 2. Gasket
3. EGR Duct
30. Clip the gasket and install the right and left reed 4. EGR Duct
valve ducts. 5. Bolt
6. Gasket
Tightening torque:
7. Bolt
39 N⋅m {4.0 kg⋅m/29 lb⋅ft}
33. Connect the intake pipe.
Name
1. Reed Valve Duct Name
2. Reed Valve Duct 1. Inlet Manifold
3. Gasket 2. Gasket
4. Inlet Manifold 3. Bolt
4. Bolt
31. Clip the gasket and install the EGR duct. 5. Intake Pipe
34. Install the secondary EGR cooler. 36. Clip the gasket and install the EGR pipe.
• Always clip the gasket.
• Tighten the primary side (entrance side) fixing
bolts.
Note:
Gently tighten the bolts to a position so that each EGR
duct and EGR cooler hit face contact, position the seal
face has no clearance, then fully tighten the bolts.
Name
1. EGR Pipe
2. Distance Tube
3. Bolt
4. Bolt
5. Plate
6. Bolt
37. Install the EGR pipe fixing plate.

Name 38. Install the cooling water pipe for the EGR cooler
1. Bolt and rubber hose (return side) and fix with clips.
2. Secondary EGR Cooler
3. Bolt Note:
4. Gasket When inserting rubber hose, apply soapsuds to the
inner surface of the hose.
35. Clip the gasket and install the primary EGR cooler.
Name
1. Primary EGR Cooler
2. Gasket
3. Bolt
39. Install the cooling water pipe for the EGR cooler
and rubber hose (feed side) and fix it with clips.
Name
1. Rubber Hose
2. Rubber Hose
3. Water Pipe for EGR Cooler (LH) (Feed Side)
4. Rubber Hose
5. Clip
6. Water Pipe for EGR Cooler (FT) (Feed Side)
7. Clip
Name
1. Rubber Hose 40. Install the oil level gauge guide tube.
2. Water Pipe for EGR Cooler (RR) (Return Side)
• Apply a thin coat of oil to O-ring and insert it
3. Rubber Hose
without damaging the O-ring.
4. Water Pipe for EGR Cooler (LH) (Return Side)
5. Water Pipe for EGR Cooler (FT) (Return Side)
6. Rubber Hose
Name
1. Oil Level Gauge
2. Guide Tube
3. Stay
4. Stay
41. Install the engine harness.
• Install the engine harness as shown in diagram
(1), then fix it with clips in the position marked
when it was disassembled.
Torque Specifications
39 {4.0 / 29} 22 {2.2 / 16}

39 {4.0 / 29}
39 {4.0 / 29}
54 {5.5 / 40}
44 {4.5 / 32}
62 {6.3 / 46}
108 {11.0 / 80}
31 {3.2 / 23}
43 {4.4 / 32}
70 {7.1 / 52}
WSWG0002
40 {4.1 / 30}
39 {4.0 / 29}
88 {9.0 / 65}
39 {4.0 / 29}
34 {3.5 / 25} 39 {4.0 / 29}

43 {4.4 / 32}
50 {5.1 / 37}
WSWG0003
Cylinder Head
Components
Name
1. Head Cover 8. Rocker Arm ASM
2. Head Cover Gasket 9. Camshaft
3. Injector Harness 10. Bridge
4. Nozzle Leak-off Pipe 11. Injector & Clamp
5. Head Lower Cover 12. Cylinder Head ASM
6. Harness Connector 13. Cylinder Head Gasket
7. Head Lower Cover Gasket 14. Idle Gear C
Removal 7. Remove the head lower cover gasket.
1. Remove the air breather hoses, and then remove Note:
the head cover. When removing the lower cover, a small amount of oil
2. Remove the head cover gasket. may spill, so be prepared to clean it with a cloth.
3. Remove the injector harness.

4. Remove the nozzle leak-off pipe. 8. Remove the rocker arm ASM.
5. Disconnect the harness connector. • Remove the bracket tightening bolt from the
rocker arm ASM by loosening them equally
from both ends.
Name
2. Harness Connector
6. Remove the head lower cover.

9. Remove the bridge (1). 10. Remove the camshaft.
• Measure the axial clearance of the camshaft
CAUTION: before removing the camshaft.
Put number plates on the bridge according to each
cylinder. Assembly standard Limit of usage
mm {in} mm {in}
Axial clearance 0.085 — 0.170 0.25 {0.0098}
of the camshaft {0.0033 — 0.0067}
• Inspect the contact surfaces for wear and deb-

onding, and the bridge for cracks or damage.
• Loosen the tightening nut of the camshaft

brackets equally from both ends to remove.
• Measure the clearance between the camshaft

journal and bracket.
Assembly specifica- Limit of usage

tion mm {in} mm {in}
Clearance 0.065 — 0.125 0.15 {0.0059}
between the jour- {0.0026 — 0.0049}
nal and bracket
11. Remove the injector & clamp.

• Loosen the clamp, and use a remover to
remove the injector.
Special tool
Injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-1 (J-23907)
CAUTION:
When pulling out the fuel injector using a special
tool, check that the fuel injector sleeve does not
Name
come off.
1. Sliding Hammer
2. Injector Remover
3. Fuel Injector ASM
• Install a number to each injector before remov-

ing.
12. Remove the cylinder head ASM.
• Loosen and remove the tightening bolts (27)
and (28), then loosen and remove the tighten-
ing bolts from the outside in a balanced way in
the numbered order shown in the illustration.
Important:
• Do not forget to remove the tightening bolts (27)
and (28) first.
• Cover the hole on the timing gear with a cloth.
13. Remove the cylinder head gasket.

Disassembly
Name
1. Distance Tube 13. O-ring
2. Seal Ring 14. Valve Seat Insert
3. Seal Ring 15. Valve
4. Exhaust Pipe Bracket 16. Glow Plug
5. Exhaust Manifold ASM 17. Glow Plug Connector
6. Split Collar 18. Thermo-sensor
7. Spring Seat (Upper) 19. Inlet Manifold
8. Valve Spring 20. Idle Gear Shaft C
9. Valve Stem Oil Seal 21. Idle Gear C
10. Spring Seat (Lower) 22. Gear Case
11. Valve Guide 23. O-ring
12. Nozzle Sleeve 24. Bridge Guide
1. Remove the glow plug connector.
2. Remove the glow plug.
3. Remove the thermo-sensor.
4. Remove the gear case.
• Measure the axial clearance of the idle gear C
before removing the gear case.
Assembly standard Limit of usage

mm {in} mm {in}
Axial clearance 0.05 — 0.14 {0.0020 0.25 {0.0098}
— 0.0055}
8. Remove the inlet manifold.
5. Remove the O-ring for gear case.

6. Remove the idle gear shaft C.
7. Remove the idle gear C.
• Pull out the idle gear shaft and remove the idle
gear C from the cylinder head.
Important: 9. Remove the exhaust pipe bracket.

Be careful not to damage bushing of the idle gear
10. Remove the engine hanger (Ft) bracket.
shaft.
11. Remove the exhaust manifold ASM.
Important:
Do not reuse lock nut.
12. Remove the seal ring for the exhaust manifold.

13. Remove the split collar.
14. Remove the spring seat (upper).
• Place the cylinder head on a wooden board,
use a compressor to remove the split collar,
then remove the spring seat, valve spring, and
valve.
CAUTION:
Put number plates on the valve according to each
cylinder.
Valve spring compressor: 1-8523-5013-0

20. Remove the bridge guide.
• Do not remove the bridge guide unless it is
worn.
• Weld the bolt electrically (1) to the bridge guide,
and take out the bolt by installing the sliding
hammer.
Name
1. Bracket
2. Split Collar
3. Bridge
15. Remove the valve spring.

16. Remove the spring seat (lower). 21. Remove the valve seat insert.
17. Remove the valve. • Heat-up the two parts of insides of the insert
18. Remove the valve stem oil seal. (up to 600 — 700°C {1,112 — 1,292°F}) with
19. Remove the valve guide. welding gas burner, and leave it to cool down
• Insert the remover into the guide from the bot- for 3 to 5 minutes then pull out with a screw-
tom side of the head and hammer it out. driver.
Valve guide remover: 9-8523-1202-0
Important:
Do not cool it forcefully.
22. Remove the nozzle sleeve.

• Removal of the nozzle sleeve
Strike from the head lower side to extract.
23. Remove the nozzle sleeve O-ring.

Valve spring
• Measure the squareness of the valve spring.
Inspection
Idle gear shaft C Assembly Limit of usage
standard mm mm {in}
• Measure the outside diameter of the idle gear {in}
shaft, and the clearance between the shaft and the
bushing. Valve spring Inlet 3.5 {0.1378} 4.8 {0.1890}
Check to see if there is also any damage on the squareness Exhaust 4.5 {0.1772} 6.2 {0.2441}
bushing.
Nominal dimension Limit of usage

mm {in} mm {in}
Outside diameter 49 {1.9291} 48.85 {1.9232}
of the shaft

mm {in} mm {in}
Clearance 0.04 — 0.105 0.20 {0.0079}
between the shaft {0.0016 — 0.0041}
and bushing
• Measure the free length of the valve spring.
Nominal Limit of usage

dimension mm {in}
mm {in}
Free length Inlet 79.3 {3.1220} 75.3 {2.9646}
of the valve
Exhaust 102.7 {4.0433} 97.6 {3.8425}
spring
Valve
• Check wear of the valve stem end. Repair light
wear with the oil stone.
• Measure the tension of the spring at installation.
Nominal dimen- Limit of usage

sion N {kg/lb}/mm
N {kg/lb}/mm {in} {in} • Measure the wear level of the valve stem.
Measure three places shown on the illustration.
Inlet 392 {40.0/88}/64 372 {38.0/84}/
Tension of {2.52} 64 {2.52} Nominal Limit of usage
the valve
Exhaust 610 {62.2/137}/ 578 {59.0/ dimension mm {in}
spring
69 {2.72} 130}/69 {2.72} mm {in}
Outside diam- Inlet φ10 {0.3937} φ9.92 {0.3906}
eter of the
Exhaust φ10 {0.3937} φ9.90 {0.3898}
valve stem
If the wear level of the valve stem exceeds the

limit, replace it together with the guide.
• Measure the clearance between the valve guide

and the valve stem.
Insert the valve into the guide and measure the
clearance at a position 10 mm {0.39 in} from the
upper end of the valve guide.
Assembly specifi- Limit of usage

cation mm {in} mm {in}
Inlet 0.040 — 0.077 0.15 {0.0059}
Clearance {0.0016 —
between the 0.0030}
guide and Exhaust 0.065 — 0.102 0.25 {0.0098}
valve stem {0.0026 —
0.0040}
Name
1. Contact Width
2. Thickness of Valve
Bridge guide
• Measure the clearance between the bridge guide
and bridge (1).

mm {in} mm {in}
• Inspection of contact surface and measurement of
the thickness of the valve seat Clearance 0.020 — 0.057 0.10 {0.0039}
Check for any damage and stepped wear, and between the {0.0008 — 0.0022}
guide and bridge
measure the thickness.

sion mm {in} mm {in}
Thickness Inlet 2.02 {0.0795} 1.52 {0.0598}

of valve Exhaust 2.48 {0.0976} 1.98 {0.0780}

Contact Inlet 3.3 {0.1299} 3.7 {0.1457}
width of the
Exhaust 2.6 {0.1024} 3.0 {0.1181}
valve seat
Important:
After a polishing repair, replace the valve if its
thickness exceeded the usage limit.
Valve seat insert
• Measurement of the valve depression level
Insert a new valve into the guide, and measure the
depression level from the cylinder head installation
surface to the valve surface.
Nominal Limit of usage

dimension mm {in}
mm {in}
Valve depres- Inlet 0.4 {0.0157} 1.4 {0.0551}

sion level Exhaust 0.3 {0.0118} 1.3 {0.0512}
• Check for cracks or damage on the cylinder head

Perform magnetic flux method or red check
inspection as required.
Name
1. Depression Level
2. Cylinder Head
3. Valve Seat Insert
Cylinder head
• Measurement of the distortion on cylinder head
Clean the carbon taking care not to damage the
machining surfaces such as the head, valve seat, • Check for cracks on the water jacket
and insert. Put a straight edge to the installation Apply water pressure of 490 kPa {71 psi} with a
side of the head and measure from 1 to 4 shown hydraulic test machine for three minutes, and
on the diagram with a thickness gauge. If the mea- check for any leakage from each head part.
surement exceeds the limit, replace it.
Limit of usage mm {in}

Distortion 0.2 {0.008} or less
Important:
It cannot be modified since the backlash of the tim-
ing gear fluctuates.
Reassembly
1. Apply engine oil to the O-ring and insert into the
sleeve.
2. Apply Loctite No.TL290 to the nozzle sleeve out-
side diameter surface and end-bearing surface,
and press-fit it into the cylinder head.
5. Install the valve guide.

• Apply engine oil to valve guides all around.
Press-fit the valve guide using a remover until
the height from the cylinder head surface is lev-
elled to the specification.
Assembly stan-
Name dard mm {in}
1. Apply Loctite.
Height of valve guide Inlet 27.0 {1.0630}
from the cylinder head
Exhaust 29.0 {1.1417}
Note: surface
Insert the O-ring so that the red part is up and black
part is down. Valve guide remover: 9-8523-1202-0
3. Clean the installation face of the valve seat insert,
and force the valve seat insert with a press.
Name
1. 29.0 mm {1.1417 in}
2. 27.0 mm {1.0630 in}
4. Install the bridge guide to the head.
• Apply engine oil to the outside diameter of the
guide. Press-fit the guide with the installer until
the height of bridge guide from the upper sur-
face of the head is 49 mm {1.93 in}.
Valve bridge guide installer: 9-8522-1324-1
6. Install the valve stem seal to the valve guide using Check on the contact surface of the valve seat
the installer. • Apply red lead to the valve insert and check the
contact width of the seat surface. Also, check to
Note: see if the contact area is at the center of the valve
After installation of the valve seal, make sure there is seat.
no spring coming off or deformed. Contact width of the insert and valve
Valve stem seal installer for intake: 1-8522-1187-0 Assembly Limit of
Valve stem seal installer for exhaust: 1-8522-1184- standard usage mm
0 mm {in} {in}
Contact width Inlet 3.3 {0.1299} 3.7 {0.1457}
of the valve of
Exhaust 2.6 {0.1024} 3.0 {0.1181}
valve seat sur-
face
7. Install the valve.

Insertion of the valve
• Apply engine oil to the valve stem and insert the
valve into the cylinder head.
Name
1. Contact Width
2. Depression Level
• If the contact width of the valve or contact surface

is insufficient, repair it with a seat knife appropriate
for the seat angle and stem diameter.
Inlet 30°
Valve seat angle
Exhaust 45°
Outside diameter of the φ 10.0 {0.3937}

valve stem mm {in}
10. Install the spring seat (upper).
• Rest the cylinder head on a wooden board, and
assemble the lower spring seat, valve spring
and upper spring seat in order. Install the inlet
valve spring with its narrow pitched side point-
ing the bottom side of the head. The exhaust
valve spring has no top/bottom.
• Measure the depression level of the valve after a

polishing repair of the valve seat, and check if it is
within the usage limit.
Assembly Limit of
standard usage mm
mm {in} {in}
Valve depres- Inlet 0.4 {0.0157} 1.4 {0.0551} 11. Install the split collar.
sion level Exhaust 0.3 {0.0118} 1.3 {0.0512} • Use the valve spring compressor to push the
valve spring in and install the split collar.
Rubbing valves After installation, tap the head of the valve stem
lightly with rubber hammer to stabilize the split
• Apply compound to the insert and contact surface
collar.
of the valve seat, and rub them together ade-
Valve spring compressor: 1-8523-5013-0
quately. Clean the cylinder head and valve after
rubbing.
Name
1. Bracket
8. Install the spring seat (lower).
2. Split Collar
9. Install the valve spring. 3. Bridge
12. Install the seal ring to the exhaust manifold.

• Install seal rings (1) every 120°, and then
assemble the manifold.
Note: 14. Install the exhaust pipe bracket.
Seal rings (1) have direction. So look carefully when • Do this at the same time as installing the
assembling. exhaust manifold.
Name
13. Install the exhaust manifold. 1. Exhaust Manifold (Rr)
• Clip the gasket, install the manifold to the cylin- 2. Bracket
der head, and tighten in the numbered order 3. Exhaust Manifold (Ft)
shown in the illustration. 4. Nut
(When tightening the flanges, start with the 5. Exhaust Manifold (C)
under side flanges and proceed to tighten in a
clockwise direction.) 15. Install the engine hanger (front) bracket.
Tightening torque: 16. Install the inlet manifold.
19.6 N⋅m {2.0 kg⋅m/14 lb⋅ft}
Important:
The lock nut cannot be reused.
Note:
• Install the distance tube so that it faces the nut side.
• Assemble so that the gasket marking is at the bot-
tom right.
17. Apply engine oil to the idle gear C and insert it into
the idle gear shaft.
18. With the idle gear C assembled with the idle gear
shaft C, assemble and tighten the cylinder head.
• Always apply engine oil to the idle gear shaft.
Note:
Make sure that the gear rotates smoothly.
Important:
Make sure not to damage tooth surface of the gear
since it sticks out from the cylinder head.
Tightening torque:
46 N⋅m {4.7 kg⋅m/34 lb⋅ft}
Name
1. Applying Liquid Gasket
2. O-ring
21. Install the thermo-sensor to the cylinder head.

• Apply Loctite No.271 or ThreeBond No.1241 to
the thermometer unit screw section, and install
the unit.
Tightening torque:
20 N⋅m {2.0 kg⋅m/15 lb⋅ft}
19. Install the O-ring to the gear case.

20. Install the gear case to the head and tighten the
bolts.
• Apply approx. 0.3 mm {0.012 in} thickness,
approx. 5 mm {0.2 in} width of FMD-127 to the
gear case installation surface of the cylinder
head.
Note:
Make sure that the FMD-127 does not touch the bolt
hole.
Tightening torque:
38 N⋅m {3.9 kg⋅m/28 lb⋅ft}
22. Install the glow plug to the cylinder head.

Tightening torque:
25 N⋅m {2.5 kg⋅m/18 lb⋅ft}
Important:
Over tightening can cause damage, so do not over
tighten anything.
23. Insert the glow plug connector between the glow
plug nut and flat washer and tighten the nut.
Tightening torque:
1.0 N⋅m {0.1 kg⋅m/0.7 lb⋅ft}
Installation
1. Install the head gasket to the cylinder block.
• Use new parts when re-assembling.
Name
2. Apply liquid gasket to the cylinder head side. 1. Liquid Gasket Length
• In line with the gear case and cylinder head 2. Liquid Gasket Width
match surfaces, apply liquid gasket using the 3. Liquid Gasket Applied Area
edge of the gear case hole as a standard, with 4. Oil Hole
a width of approx. 5 mm {0.2 in}, height of 5. Liquid Gasket Length
approx. 3 — 4 mm {0.12 — 0.16 in}, and length 6. Liquid Gasket Width
of approx. 30 mm {1.18 in}. 7. Cylinder Head
Liquid gasket : TB1207B 8. Gear Case (Head)
• Assemble the parts within 7 minutes of applying 9. Head Gasket Rubber Ring Position
the liquid gasket. 10. Edge of the gear case (head) hole as a standard
3. Apply liquid gasket to the cylinder block side.

• In line with the gear case and cylinder head
match surfaces, apply liquid gasket using the
edge of the gear case hole as a standard, with
a width of approx. 5 mm {0.2 in}, height of
approx. 3 — 4 mm {0.12 — 0.16 in}, and length
of approx. 30 mm {1.18 in}.
Liquid gasket : TB1207B
• Be careful not to plug-up the oil hole shown in
the illustration.
• Assemble the cylinder head within 7 minutes of
applying the liquid gasket.
4. Assembling the cylinder head.
Assemble the head gasket. Align the cylinder head
with the knock pin and put it on carefully.
5. Tightening of the cylinder head ASM.

Apply molybdenum disulfide to the M18 bolt screw
section and seating surface, and tighten as shown
in the illustration spiralling out from the center.
Tighten M10 and M12 bolts next.
Tightening torque:
Name M18: 177 N⋅m {18 kg⋅m/86 lb⋅ft} → 245 N⋅ m {25.0
1. Gear Case kg⋅m/181 lb⋅ft} → 60 — 90°
2. Liquid Gasket Applied Area M10: 38 N⋅m {4.0 kg⋅m/28 lb⋅ft}
3. Liquid Gasket Width M12: 97 N⋅m {9.9 kg⋅m/72 lb⋅ft}
4. Liquid Gasket Length
5. Oil Hole Important:
6. Liquid Gasket Length • Do not apply molybdenum disulfide to the M10
7. Cylinder Block or M12 bolts.
8. Edge of the gear case hole as a standard • Cover the hole on the timing gear with a cloth.
• The head bolt can be recycled up to four occa-
sions.
Name
1. Liquid Gasket Applied Area
Name
1. M12 2. M10
6. Install the injector & clamp.

• Install the injector to the cylinder head, and
temporarily tighten the injection pipe. Next,
tighten the clamp using the clamp tightening
bolt, and finally tighten the injection pipe.
Important:
Do not reuse gasket.
Note:
Securely install the gasket.
Tightening torque:
Clamp: 49 N⋅m {5.0 kg⋅m/36 lb⋅ft}
Injection pipe: 39 N⋅m {4.0 kg⋅m/29 lb⋅ft}
7. Install the camshaft. c. Installation of the camshaft
a. Set No.1 cylinder to the compression top dead Apply oil to the camshaft bracket. Set the cam-
center position. shaft so that the camshaft gear mark and
Rotate the crankshaft in proper direction, and pointer line up.
align the T/C mark on the flywheel with the At this time, make sure the nick lines on the
pointer. rear side of the camshaft are horizontal and
At this time, make sure the nick lines on the vertical respectively.
coupling and pump line up.
3
b. Apply engine oil to the cam surface of camshaft
and cam gear tooth surface.
WSWG0286
Name
1. Pointer
2. Cam Gear
3. Gear Case (Head)
d. Installation of the camshaft with the lower cover

installed
When assembling with the lower cover
installed, set the camshaft so that one of the
two camshaft gear eye marks is hidden by the
lower cover as shown in the illustration.
e. Installation of the camshaft bracket
Apply engine oil to the nut seating surface and
screw section, align the bracket marking num-
ber and install the bracket, temporarily tighten
from the camshaft gear side, then retighten to
the specified torque.
Note:
• Make sure to install the No.1 camshaft bracket to
the No.1 position.
• After installing the cylinder head bolt, tighten the
bracket.
Tightening torque:
76 N⋅m {7.7 kg⋅m/56 lb⋅ft}
Name
1. Marking Number
8. Install the bridge.

• Loosen the adjusting screw to the full limit, and
apply engine oil to the bridge guide, then install.
4
3
WSWG0287
Name
1. Eye Mark CAUTION:
2. Cam Gear Assemble the parts to exactly the same cylinder
3. Gear Case (Head) number that you recorded when you disassembled
4. Lower Cover (Head) them.
Note:
Install the adjusting screw so that they face the intake
manifold side.
9. Install the rocker arm ASM. 11. Clean the upper surface of the cylinder head, and
a. Loosen the adjusting screw to the full limit, apply liquid gasket to the upper surface of the joint
apply engine oil to the roller section and adjust- between the timing gear case and cylinder head.
ing screw tip section, and install the rocker arm • Apply approx. φ4 bead width of ThreeBond
ASM. 1207B liquid gasket along the joint surface
between the cylinder head and gear case
(head).
• Install the head lower cover immediately after
applying the liquid gasket.
• Assemble the head lower cover within 7 min-
utes of applying the liquid gasket. If the parts
are left for more than 7 minutes after applying,
remove the liquid gasket, re-apply it, then
assemble.
• If head lower cover have been removed,
remove the liquid gasket applied on head and
lower cover while taking care not to allow any to
go into the gear case, then re-apply liquid gas-
ket and assemble the parts.
b. After temporarily tightening in the number order

shown in the illustration, tighten and fix to the
specified torque in the number order shown in
the diagram.
Tightening torque:
90 N⋅m {9.2 kg⋅m/66 lb⋅ft}
Name
1. Liquid Gasket Applied Area
2. Cylinder Head
3. Gear Case (Head)
c. Adjustment of valve clearance

For adjustment procedure, refer to 1A-7, “Func-
tion Check, ISUZU Diesel Engine”.
10. Install the head lower cover gasket to the head
lower cover.
12. Fit the gasket into the groove of the cover and
tighten the insert arrow bolt.
Tightening torque:
15 N⋅m {1.5 kg⋅m/11 lb⋅ft}
Name
2. Connector
15. Install the injector harness.

13. Connect the harness connector. a. Insert the harness side connector to the con-
• Insert the O-ring and install the connector to the nector installed to the lower cover until it clicks,
lower cover. then install the injector harness to the lower
cover.
Tightening torque:
22 N⋅m {2.2 kg⋅m/16 lb⋅ft}
Name
1. O-ring Name
2. Connector 1. Nut
2. Connector
14. Install the nozzle leak-off pipe.
• Install the adapter to the lower cover rear side
and install the nozzle leak-off pipe to the injec-
tor.
Tightening torque:
Adapter: 20 N⋅m {2.0 kg⋅m/15 lb⋅ft}
Eyebolt: 15 N⋅m {1.5 kg⋅m/11 lb⋅ft}
b. Insert the harness (1) terminal into the head of
each cylinder injector (2), then tighten the nut to
Tightening torque:
2.0 N⋅m {0.2 kg⋅m/17.7 lb⋅in}
Note:
Do not over-tighten the nut. It might cause damage on
injector.
Name
1. Injector Harness
2. Injector
16. Install the head cover gasket.

17. Install the head cover.
• Insert the gasket into the head cover and install
the head cover.
• Tighten in the numerical order shown in the
illustration.
Tightening torque:
15 N⋅m {1.5 kg⋅m/11 lb⋅ft}
47 {4.8 / 35}
38 {3.9 / 28} 25 {2.5 / 18}
20 {2.0 / 15}
39 {4.0 / 29}
20 {2.0 / 15}
WSWG0004
Rocker Arm
Components
Name
1. Bracket 4. Bracket
2. Rocker Arm 5. Rocker Arm Shaft
3. Spring
Disassembly
1. Remove the bracket. mm {in} mm {in}
2. Remove the rocker arm. Clearance 0.036 — 0.069 0.15 {0.0059}
3. Remove the spring. between the roller {0.0014 — 0.0029}
4. Remove the bracket. pin and roller
5. Remove the rocker arm shaft.

• While holding the locker arm shaft bracket, pull
out the tightening bolts (1) from the bracket (2),
and remove the rocker arm, spring, and
bracket.
Note:
• If you remove the tightening bolt of bracket, the
rocker arm or other parts will fly out under the force
of the spring.
• Therefore, all of the bolts should be gradually loos-
ened at an equal balanced rate.
Inspection
Rocker arm
• Check for any wear or damage on the roller side,
and measure the clearance between the roller pin
and roller. Name
Mark the measuring position when the roller of 1. Roller
rocker arm is let out to the maximum, and measure 2. B Measurement
the difference in level between the rocker arm and 3. Caliper
roller (A measurement). Then push the roller in to 4. A Measurement
the maximum, and measure the difference in level
at the marked measuring position (B measure-
ment).
The difference between the A measurement and B
measurement above is the clearance between the
roller pin and roller.
Rocker arm shaft
• Check for oil hole of the rocker arm shaft.
Reassembly
• Check for bend of the rocker arm shaft.
1. Apply a thin coat of oil to the rocker arm shaft.
Limit of usage mm {in} 2. Install the bracket.
Shaft bend 0.3 {0.0118} 3. Apply engine oil to the bushing section and roller
section, and install the rocker arm.
4. Install the spring.
5. Install the bracket.
• Install each part in the direction shown in the
illustration.
Note:
• Check the front mark (1) of the rocker arm shaft.
• Measure the outside diameter of the rocker arm

shaft, and the clearance between the shaft and the
rocker arm bushing.
Nominal Assembly Limit of

dimension standard mm usage
mm {in} {in} mm {in}
Clearance — 0.02 — 0.074 0.20 Name
between the {0.0008 — {0.0078} 1. Front Mark
shaft and the 0.0029}
rocker arm
Outside diameter φ28 — φ27.85
of the shaft {1.1023} {1.0965}
Camshaft
Components
Name
1. Camshaft Gear 4. Lower Camshaft Bracket
2. Key 5. Camshaft
3. Upper Camshaft Bracket
Disassembly Camshaft
1. Remove the camshaft gear. • Measure the bend of the camshaft.
• Put a piece of wood (1) to the gear to prevent Hold No.1 and No.7 journal part with V block and
any damage and use a puller to remove it. place the dial gauge to No.4 journal. Rotate the
camshaft slowly once and take the measurement.
CAUTION:
Inspect the gears for damage. If there are no prob- Assembly standard Limit of usage
mm {in} mm {in}
lems with it, do not remove it.
Camshaft runout 0.08 {0.0031} 0.1 {0.0039}
level
2. Remove the key from the camshaft.
• Inspect damage on the cam surface and measure

Inspection the cam lift amount.
Camshaft gear Repair light damage or wear with an oil stone.
• Check for damage. Acquire the lift amount by A – B.

Cam lift Inlet 9.4 {0.3701} 8.85 {0.3484}
amount
Exhaust 10.4 {0.4094} 9.75 {0.3839}
(A – B)
• Measure the outside diameter of the journal.
Take a measurement of the position shown on the
diagram with a micrometer.

mm {in} mm {in}
Outside diameter φ 40.0 {1.5748} φ 39.89 {1.5705}
of journal
1
2. For measuring outside diameter of the camshaft
journal, measure each of the four positions as
shown on the illustration using a micrometer.
Assembly stan- Limit of usage

dard mm{in} mm{in}
Clearance between 0.065 — 0.125 0.15 {0.0059}
the camshaft journal {0.0026 —
WSWG0024 and camshaft bracket 0.0049}
Clearance between the camshaft journal and *Refer to 0A-2, “Service Precautions, General
camshaft bracket Information” when using the plastigauge for mea-
Measure the inside diameter of camshaft bracket and surement.
the outside diameter of camshaft, then acquire the
CAUTION:
clearance measurement.
• Make sure to install the No.1 camshaft bracket
1. Clean the camshaft bracket, check the markings
to the No.1 position.
on the side surface and assemble, apply engine oil
to the screw section and tighten to the specified • The marking on the side of the camshaft bracket
torque. Next, install the rocker arm shaft, apply oil is not the journal number.
to the screw section and tighten to the specified
torque.
Measure the four positions shown on the illustra-
tion with a cylinder gauge, and acquire the inside
diameter of camshaft bracket.
Tightening torque:
Camshaft bracket: 75.5 N⋅m {7.7 kg⋅m/56 lb⋅ft}
Rocker arm shaft: 90.0 N⋅m {9.2 kg⋅m/66 lb⋅ft}
Reassembly
1. Install the key to the camshaft.
2. Install the camshaft gear.
• Assemble the larger gear center boss facing
the camshaft side. Next, apply oil to the thread
and seating side of the bolt and tighten.
Tightening torque:
137 N⋅m {14.0 kg⋅m/101 lb⋅ft}
76 {7.8 / 56}
137 {14.0 / 101}
WSWG0005
Timing Gear
Components
Name
1. Timing Gear Case 7. Idle Pulley
2. Gasket 8. Idle Gear A
3. Gear Case Cover 9. Distance Bolt
4. Cover 10. Idle Gear B
5. Oil Seal (Crankshaft) 11. Oil Pump
6. Crank Pulley ASM 12. O-ring
Removal 6. Remove the oil pump.
1. Remove the crank pulley ASM. 7. Remove the O-ring for the oil pump.
2. Remove the idle pulley. 8. Remove the distance bolt.
3. Remove the gear case cover. 9. Remove idle gear A and idle gear B.
4. Remove the gasket. • Before removing the idle gear, measure each
idle gear backlash.
5. Remove the oil seal (crankshaft Ft).
• Taking care not to damage the press-fit surface Assembly standard Service limit
of the oil seal of front cover, remove the oil seal. mm {in} mm {in}
• The oil seal cannot be reused. Backlash 0.060 — 0.095 0.23 {0.0091}
{0.0024 — 0.0037}
• Use slinger remover to remove the slinger.

• The slinger cannot be reused.
• Measure the axial clearance of the idle gear A.
CAUTION:
• When replacing the oil seal, it must be replaced Assembly standard Service limit
together with the slinger. mm {in} mm {in}
• If slinger remover is coming off the slinger eas- Axial clearance 0.165 — 0.230 0.35 {0.0138}
ily, use a clip band to tighten around the parts {0.0065 — 0.0091}
for smoother service.
• Measure the axial clearance of the idle gear B.
Slinger remover: 1-8522-0052-0
Assembly standard Service limit
mm {in} mm {in}
Axial clearance 0.050 — 0.140 0.25 {0.0098}
{0.0020 — 0.0055}
Disassembly
1. Disassemble the crank pulley ASM.
Loosen the mounting bolts and remove the
damper from the crank pulley.
Name
1. Idle Gear A
2. Idle Gear B
• Remove idle gear A and idle gear B.

Both the idle gear and thrust plate have a front
and back direction, so remember to mark these
directions when removing these parts.
10. Remove the cover.

• Do not remove if there is no oil leakage.
11. Remove the timing gear case.
Inspection
Idle gear
• Measure the spindle outside diameter and clear-
ance between gear and spindle for each idle gear.
Idle Nominal Limit of usage

gear dimension mm {in}
mm {in}
Outer diameter φ79 {3.11} φ78.85 {3.1043}
of idle gear A
φ57 {2.24} φ56.85 {2.2382}
spindle
B φ142 {5.59} φ141.85 {5.5846}
C φ49 {1.93} φ48.85 {1.9232}

dard mm {in} mm {in}
Idle gear (A, B, C) and 0.04 — 0.105 0.20 {0.0079}
spindle clearance {0.0016 —
0.0041}

Pin outside diameter φ22.2 {0.8740} φ22.0 {0.8661}
of idle A large gear
Crank pulley
Installation
1. Inspect the crankshaft pulley slot for wear or dam-
age. 1. Install the timing gear case.
2. Inspect the crankshaft damper for cracks. a. Apply approx. 0.3 mm {0.012 in} thickness,
approx. 4 mm {0.16 in} width of Loctite
No.FMD127 liquid gasket to the installation sur-
face. Also apply liquid gasket to the cylinder
block and crankcase match surfaces.
Note:
• Make sure that no liquid gasket gets into the bolt
holes.
• Install soon after applying liquid gasket.
Reassembly
1. Install the crankshaft damper to the crank pulley.
• Tighten in diagonal order.
CAUTION:
• Install the crankshaft damper so that the side
with the caution label faces forward.
• Make sure that the crankshaft damper does not
b. Install the timing gear case.
come into contact with oil or grease.
Tightening torque:
Tightening torque:
M14: 135 N⋅m {13.8 kg⋅m/100 lb⋅ft}
118 N⋅m {12.0 kg⋅m/87 lb⋅ft}
M10: 43 N⋅m {4.4 kg⋅m/32 lb⋅ft}
Important: 4. Install the idle gear A.
• To reuse the tightening bolts in the arrow sec- a. Set to No.1 cylinder compression top dead cen-
tion, apply Loctite 271 to the screw section. ter position.
• After installing the timing gear case, if there will Rotate the crankshaft in proper direction, and
be an interval of more than 30 minutes until the align the T/C mark on the flywheel with the
idle gear A and B installation work, temporarily pointer. At this time, make sure the nick lines on
tighten M10 × 1.5 bolts to the specified torque to the coupling and pump roughly line up.
sections 1 — 3 in the illustration.
b. Apply engine oil to timing gear A bore, line up

the timing marks for each gear, then assemble
2. Install the cover. timing gear A, spindle, and thrust plate.
3. Install the idle gear B. Tightening torque:
• Apply engine oil to idle gear B bore and thrust 108 N⋅m {11.0 kg⋅m/80 lb⋅ft}
sections, check the front/back markings that
you made when disassembling the idle gear B
and thrust plate, and install them.
Note:
If you have temporarily installed the bolts, do not forget
to remove them.
Tightening torque:
46 N⋅m {4.7 kg⋅m/34 lb⋅ft}
5. Install the distance bolt. 9. Install the gear case cover.
• Install three distance bolts to the positions Apply Loctite No.FMD127 liquid gasket to the idle
shown in the illustration. gear A spindle seating surface and distance bolt
seating surface, and promptly install them both.
Tightening torque: Apply Loctite No.FMD127 to the arrow diagonal
43 N⋅m {4.4 kg⋅m/32 lb⋅ft} section.
Important:
Press the gasket securely into the groove and over
all protruding sections.
Tightening torque
M10: 43 N⋅m {4.4 kg⋅m/32 lb⋅ft}
M8: 26 N⋅m {2.6 kg⋅m/19 lb⋅ft}
6. Install the O-ring to the oil pump.

7. Line up the oil pump with the dowel position and
install it.
Note:
Do not mistakenly tighten the yellow painted bolt in the
head section to the tightening torque shown above.
This bolt is only for installing the oil pump cover.
Tightening torque:
49 N⋅m {5.0 kg⋅m/36 lb⋅ft}
10. Install the oil seal (crankshaft Ft) to the gear case
cover.
Important:
8. Install the gasket and gear case cover together.
• Be sure to replace the slinger and the oil seal as
a unit.
• Take care not to damage the oil seal lip section
and slinger 4-section screw machining surface.
• If there is damage or scratches on the axel sec-
tion after extracting the slinger, apply liquid gas-
ket (Loctite FDM125) in the limits shown in the
illustration to the inner circumference surface of
the slinger before re-installation.
a. Apply a thin coat of engine oil to the outer circle

of oil seal.
b. Use a setting tool and install the oil seal and
slinger simultaneously.
Name
c. Tighten the center bolt until the sleeve contacts 1. Special Tool (Sleeve)
the adapter. 2. Special Tool (Adapter)
Oil seal setting tool: 1-8522-0043-0 3. Basic Dimension
4. Crankshaft
Basic dimension mm {in} 7.0 ± 0.3 {0.2756 ± 0.0118}
5. Slinger
6. Oil Seal
d. Wipe clean any traces of remaining oil after 7. Location of Special Tool before press-fitting
press-fitting. 8. Location of Special Tool after press-fitting
e. After installing the oil seal, measure the size
from the tip of the crankshaft to the oil seal sur- 11. Install the idle pulley.
face. 12. Install the crank pulley ASM.
• Apply engine oil to the tightening bolt screw
section, and tighten the bolts in a diagonal line.
Tightening torque:
267 N⋅m {27.0 kg⋅m/197 lb⋅ft}
135 {13.8 / 100}
49 {5.0 / 36}
39 {4.0 / 29}
39 {4.0 / 29}
100 {11.0 / 80}
39 {4.0 / 29}
25 {2.6 / 18}
118 {12.0 / 87}

267 {27.2 / 197}
WSWG0006
Flywheel, Flywheel Housing

Components
Name
1. NE Sensor 5. Flywheel Housing Stay
2. Washer 6. Flywheel Housing
3. Flywheel 7. Slinger
4. Oil Seal
Removal
1. Remove the NE sensor.
7. Use slinger remover to remove the slinger.
Important:
Name When replacing the oil seal, it must be replaced
1. NE Sensor together with the slinger.
2. Flywheel Housing
Slinger remover: 1-8522-0052-0
2. Remove the washer.
3. Remove the flywheel.
4. Remove the flywheel housing stay.
5. Remove the flywheel housing.
6. Remove the oil seal.
• Be careful not to damage or scratch the press-
fit surface of the flywheel housing's oil seal
when removing the oil seal.
Important:
When replacing the oil seal, it must be replaced
together with the slinger.
Note:
If remover is coming off the slinger easily, use a clip
band to tighten around the parts for smoother service.
Disassembly
Flywheel
1. Take out the ring gear.
• Check the ring gear for damage.
If there are no problems with it, do not remove
it.
• Removal of the ring gear
Put the flywheel on a piece of wood and place a
wooden bar to the end-side of the ring gear.
Hammer them both equally to remove.
Inspection Installation
Flywheel 1. Install the flywheel housing.
• Inspect the flywheel for cracks or scratches, and • After applying approx. 0.3 mm {0.012 in} thick-
replace if either is found. ness and approx. 4 mm {0.16 in} width of Loc-
tite No.FMD127 liquid gasket, promptly install
Ring gear the flywheel housing.
• Check the ring gear for damage. Tightening torque:
If there are no problems with it, do not remove it. M14: 123 N⋅m {12.5 kg⋅m/12.5 lb⋅ft}
M8: 22 N⋅m {2.2 kg⋅m/16 lb⋅ft}
Reassembly Important:
1. Assemble the flywheel. • Also apply ample liquid gasket to the joint
between the cylinder block and crankcase.
• Warm the ring gear evenly using a gas burner
(below 200°C {392°F}). Install it to the flywheel • Make sure that no liquid gasket gets into the
with larger cut-edge on the gear facing towards bolt holes.
you.
Note:
Tighten the bolt next to the knock pin first.
2. Install the flywheel housing stay.
Tightening torque:
109 — 163 N⋅m {11.1 — 16.6 kg⋅m/80 — 120 lb⋅ft}
a. Apply a thin coat of engine oil to the outer circle

of oil seal.
b. Use a setting tool and install the oil seal and
slinger simultaneously.
Name
1. Cylinder Block c. Tighten the center bolt until the sleeve contacts
2. Bolt (Cylinder Block side) the adapter.
3. Bolt (Flywheel Housing side) Oil seal setting tool: 1-8522-0043-0
4. Flywheel Housing
3. Install the oil seal.
Important:
• Be sure to replace the slinger and the oil seal as
a unit.
• Take care not to damage the oil seal lip section
and slinger 4-section screw machining surface.
• If there is damage or scratches on the axel sec-
tion after extracting the slinger, apply liquid gas-
ket (Loctite FDM127) in the limits shown in the
illustration to the inner circumference surface of
the slinger before re-installation.
Note:
• Installation positions for oil seal are fixed and identi-
fied by different coloring.
Engine front side: Black purple
Engine rear side: Grey
• Check that the felt dust lip is being held inside the
convex section of the slinger.
6. Install the NE sensor to the flywheel housing.
Important:
Always install the sensor after assembling the fly-
wheel, not before.
Name
1. Crankshaft
2. Basic Dimension
3. Special Tool (Adapter)
4. Special Tool (Sleeve)
5. Location of Special Tool after press-fitting
6. Location of Special Tool before press-fitting
7. Oil Seal
8. Slinger
d. Wipe and clean any traces of remaining oil after

press-fitting.
e. After installing the oil seal, measure the size (2)
from the tip of the crankshaft to the oil seal sur-
face.
Basic dimension mm {in} 7.0 ± 0.3 {0.2756 ± 0.0118}
4. Install the flywheel.

5. Install the washer and tighten the bolts.
• Apply molybdenum disulfide to the bolt screw
section and seating surface, and tighten in the
numbered order shown in the illustration.
Tightening torque:
79 N⋅m {8.1 kg⋅m/58 lb⋅ft} → 60° → 30°
109-163
{11.1-16.6 / 80-120}
109-163
{11.1-16.6 / 80-120}
109-163
{11.1-16.6 / 80-120}
M14; 113-132 {11.5-13.5 / 83-97}

M 8; 20-24 {2.0-2.4 / 15-18}
109-163
69-88 {7.0-9.0 / 51-65} 60 60 {11.1-16.6 / 80-120}
WSWG0007
Piston, Connecting Rod

Components
Name
1. Piston Ring 5. Connecting Rod
2. Snap Ring 6. Bearing
3. Piston 7. Connecting Rod Cap
4. Piston Pin
Removal Important:
1. Remove the connecting rod cap and bearing • Do not let the connection rod and liner interfere
(lower side). with each other.
• Loosen the tightening nut and hammer lightly • Be careful with damaging the oil jet.
with a copper hammer, etc. to remove the cap. • Keep removed cap, bearing and connecting rod
Next, rotate the crankshaft and move the piston as a set not to confuse them.
to be extracted to the top dead center position.
Important:
Be careful with damaging the oil jet.
3. Remove the connecting rod bearing.
CAUTION:
Put a cylinder number to store.
2. Pull out the piston and connecting rod from inside
the cylinder.
• Remove carbon from upper part of the liner
Disassembly
using a scraper etc. 1. Use a setting tool to remove the piston ring.
Note: CAUTION:
When rotating the crankshaft and when removing the Mark each removed piston ring according to each
piston, prevent the liner from being pulled out too. cylinder for identification.
Piston ring setting tool: 1-8522-1025-1
• Push the lower edge of the connecting rod

using a handle of a hammer etc.
2. Remove the snap ring (1).
Top ring 0.35 — 0.50 1.0 {0.0393}
{0.0138 — 0.0197}
Second 0.80 — 0.95 1.5 {0.0591}
Piston ring ring {0.0315 — 0.0374}
end gap Third 0.35 — 0.50 1.0 {0.0393}
ring {0.0138 — 0.0197}
Oil ring 0.3 — 0.50 1.0 {0.0393}
{0.0118 — 0.0197}
3. Put a stick on the piston pin and gently strike with a

hammer to remove it.
CAUTION:
Mark each removed piston pin according to each
cylinder for identification.
4. Store the pistons in a safe place where they will

not get damaged.
5. Assemble the connecting rod and connecting rod
cap, and store in a safe place where the contact
surface will not get damaged or scratched. WSWG0027
6. Assemble the connecting rod cap and connecting • Measurement of the clearance between the piston
rod, and store in a safe place where the contact ring groove and piston ring
surface will not get damaged or scratched. Clean off any carbon from the piston head and ring
7. Remove the bearing from the connecting rod. groove. Next, insert the ring into the ring groove
and measure the clearance using the thickness
CAUTION: gauge.
Mark each removed connecting rod bearing While pressing down the top ring into the piston
according to each cylinder for identification. with a straightedge (2), measure the clearance
with a thickness gauge (1).
Inspection Assembly stan- Limit of usage

Piston ring
Top ring 0.115 — 0.160 0.24 {0.0094}
• Inspection of the piston ring, measurement of the
{0.0045 — 0.0063}
piston ring end gap
Clean off any carbon from the piston ring. Insert Clear- Second 0.85 — 0.12 0.20 {0.0079}
ance ring {0.0335 — 0.0047}
the piston ring into the cylinder liner and push in
between
with the head of the piston to the least worn part of Third 0.85 — 0.12 0.20 {0.0079}
the groove
the liner (the lower part of the liner). and ring ring {0.0335 — 0.0047}
Insert the thickness gauge into the end of the ring
Oil ring 0.025 — 0.065 0.15 {0.0059}
to measure the gap.
{0.0010 — 0.0026}
Piston
• Inspection of piston scratches and cracks
Wipe off any carbon sludge from the piston and
clean the piston.
Check very carefully on areas not easy to look at
such as the ring groove of piston.
Carry out an inspection by red check if required.
• Measurement of the tension of the piston ring

Measure the tension of the piston ring using a ten-
sion gauge.
Measure the oil ring while the coil expander ring is
equipped.

dard N {kg/lb} N {kg/lb}
Top ring 27.5 — 41.2 24.5 {2.5/5.5}
{2.80 — 4.20/6.2
— 9.3}
Second 22.8 — 34.1 19.6 {2.0/4.4}
ring {2.32 — 3.48/5.1
Tension of — 7.7}
the piston
ring Third 28.1 — 36.6 19.6 {2.0/4.4}
ring {2.87 — 3.73/6.3
— 8.2}
Oil ring 46.3 — 57.7 39.2 {4.0/8.8}
{4.72 — 5.88/10.4
— 13.0}
• Measurement of the outside diameter of the piston
pin
Measure the outside diameter of the piston pin,
then measure the clearance between the piston
pin and piston pin hole, and the clearance between
the piston pin and connecting rod bush.
Measure six places shown on the illustration for a
piston pin.
Nominal Assembly Limit of

dimension standard usage
mm {in} mm {in} mm {in}
Piston pin out- φ 56 — φ 55.97
side diameter {2.2047} {2.2035}
Clearance — 0.008 — 0.021 0.05
between piston {0.0003 — {0.0020}
pins and piston 0.0008}
pin holes
Clearance — 0.020 — 0.037 0.10
between piston {0.0008 — {0.0039} Use a micrometer to measure the outside diameter
pins and con- 0.0015} of the crank pin at four places shown on the illus-
necting rod bush tration.

Clearance between 0.033 — 0.103 0.16 {0.0063}
the bearing and {0.0013 — 0.0041}
crank pin
Important:
The crankshaft should not be repaired as soft-
nitrating treatment has been performed to the sur-
face.
Refer to 0A-2, “Service Precautions, General Infor-
mation” when using the plastigauge for measure-
ment.
Connecting rod
• Measurement of the clearance between the con-
necting rod bearing and crank pin
Clean the bearing and bearing installation surface,
and install the bearing. Next, apply molybdenum
disulfide to the tightening nut screw section and
seating surface and alternately tighten them. Mea-
sure four places on the connecting rod bearing as
shown on the illustration with a cylinder gauge.
Tightening torque:
98 N⋅m {10.0 kg⋅m/72 lb⋅ft} → 30° → 30°
• Measurement of the deformation of the connecting
rod
Measure the torsion and the parallelism of the
large and small pore edges using a connecting rod
aligner.
Note:
Make sure that the bearing is not becoming worn as the
measurement would be based on it.

mm {in} mm {in}
Torsion and paral- 0.05 {0.0020} 0.1 {0.0039}
lelism
(L=per100 {3.94})
Bearing
• Check for wear, damage and peeling, etc.
• Assemble the bearing and check that there is a
tension.
• Measure the connecting rod large edge section

shaft orientation clearance.
Assemble the connecting rod to the crank pin, and
measure the axial clearance using a thickness
gauge.

mm {in} mm {in}
Axial clearance 0.175 — 0.290 0.35 {0.0138}
{0.0069 — 0.0114}
Reassembly
1. Select the grades for piston.
• When using a new piston, always use the spec-
ified type of replacement piston.
• When replacing a piston, it is not necessary to
select the grade. (Because there is just one
type)
• When reusing a piston, measure the clearance

between the piston and liner.
• Method to measure
Measure the outside diameter of piston in the
grade position. Clean off any carbon from the
liner, measure 130 — 275 mm {5.12 — 10.83
in} of maximum wear section (cylinder block
horizontal direction) from the top surface of the
liner, and check that the clearance between the
piston and liner is within the standard value.
WSWG0020
• When replacing just the liner, select the new
liner by grade.
Grade selection measurement 113 {4.45}

position (from major axis piston
head) mm {in}
Assembly standard
(replacement parts)
mm {in}
Clearance between the piston 0.156 — 0.190 {0.0061 —
and liner (major axis direction) 0.0075}
Name
1. Cylinder Block Inner Diameter Bore Grade Mark-
ing Position
Liner replacement (Reference)
• Match the cylinder block bore diameter and
liner outside diameter grade.
• Using the number written on the right side sur-
face of the cylinder block, select a 1X for 1 or 2,
or a 3X for 3 liner and install it.
Block inscribed Liner grade

number
Cylinder block and 1•2 1X

liner combination 3 3X
Name
1. Front Mark
2. Grade Section
3. Front Mark
4. Fix the piston pin firmly with a snap ring.

• Lastly, check to see the piston and connecting
rod move smoothly.
5. Install the piston ring.
• Installation of the expander ring
Insert the expander ring end without any gap
and fit it in the piston groove.
2. Apply oil to the piston boss.
3. Install the piston pin and connecting rod to the pis-
ton.
• Line up the piston head arrow mark and con-
necting rod front mark as shown in the illustra-
tion (same direction) and assemble. Next, apply
engine oil to the piston pin and insert it.
Installation of the piston ring
• Put the end identification color of the top ring,
second ring, and third ring to the right, and use
a setting tool to install them.
• Each top ring, second ring and third ring is iden-
tified by the markings on the side face of the
end.
• Install the piston rings so that each end is 90°
apart.
• Take care not to remove any of the coating
from the piston skirt section.
Identification Vertical
Top ring Red paint (1) No markings
Second ring Blue paint (2) 2N
Third ring Green paint (3) 3N
Name
1. Top Ring
2. Second Ring
3. Third Ring
4. Oil Ring
6. Install the connecting rod bearing to the connect-

ing rod.
Installation
1. Install the connecting rod bearing to the connect-
ing rod.
• Clean the cap and bearing installation surface
of the connecting rod well and assemble the
bearing. Apply engine oil onto the sliding sur-
face.
• Also apply oil to the piston pin.
• The oil ring has no top or bottom but assemble Important:

it so that the end gap of the oil ring and the The connecting rod side bearing has grooves and
expander ring are angled 180°. oil holes on each section.
• Apply engine oil to the whole periphery of each The cap side bearing has oil grooves on all periph-
ring and rotate the rings. At this time, make eries but no oil hole.
sure that the rings rotate smoothly.
Piston ring setting tool: 1-8522-1025-1
2. Insert the piston and connecting rod into the cylin- c. Place the end direction of the piston ring every
der. four avoiding the side-pressure direction.
a. Apply engine oil all around the cylinder liner (1).
Note:
Set the oil ring end to the opposite side to the expander
ring end.
b. Rotate the crankshaft and set the crank pin to

the top dead center of the cylinder to which the
piston is assembled.
Note: d. Apply oil onto the piston and all around the ring.
Stopper the liner so that it does not get extracted. e. Check the cylinder number of the connecting
rod, point the piston head arrow mark in the cyl-
inder block front direction, and insert the piston
by hand. Insert the piston with 5° — 10° clock-
wise. Pull it back to the right position not inter-
fering with the oil jet.
f. Use a setting tool, and insert the piston until it
touches the crank pin using a handle of a ham-
mer. Rotate the crankshaft while pushing the
piston head in. Set it to the bottom dead center.
Important:
• Make sure that the piston and the connecting
rod front mark are in the same direction.
• Use the setting tool firmly attached to the cylin-
der block. The piston ring will become damaged
if the setting tool is not firmly attached.
• Be careful not to damage crank pin or oil jet
when installing the piston connecting rod.
Piston setting tool: 1-8522-0059-0
• Rotate the crankshaft and check to see it

rotates smoothly without getting stuck. Check it
is not interfering with oil jet.
Note:
Stopper the liner so that it does not get extracted.
3. Install the connecting rod cap and bearing.

• Install the bolts so that the arrows on the con-
necting bolt tip are in the direction shown in the
illustration.
• Match the cylinder numbers on the connecting
rod and cap. Apply molybdenum disulfide to the
thread and seating side of the bolt, and tighten
them alternately. At this time, check that the
connecting rod cylinder number and cap cylin-
der number are facing to the right of the cylin-
der block.
Tightening torque:
98 N⋅m {10.0 kg⋅m/72 lb⋅ft} → 30° → 30°
98 {10.0 / 72} 30 30
WSWG0008
Crankshaft
Components
Name
1. Cylinder Block 4. Main Bearing
2. Crankshaft 5. Thrust Bearing
3. Thrust Bearing 6. Crankcase
Removal 2. Remove the crankshaft.
1. Remove the crankcase. 3. Remove the crankshaft bearing.
• Measure the axial clearance of the crankshaft • Mark the installation position of the bearing
before removing the crankcase. using tags, etc.
Take a measurement at the position of No.1
Important:
bearing thrust surface.
Do not damage the bearing sliding surface of the
Assembly standard Limit of usage crankshaft.
mm {in} mm {in}
Axial clearance of 0.10 — 0.28 {0.0039 0.30 {0.0118}
the crankshaft — 0.0110}
Important:
If it exceeds the limit, replace the thrust bearing.
4. Remove the thrust bearing.

• Mark the installation position of the thrust bear-
ing using tags, etc.
Disassembly
• Loosen the tightening bolt for the bearing from 1. Use a gear remover to remove the crankshaft
outside. Next, extract the crankcase tightening gear.
bolt, screw a M10 × 1.5 bolt with a neck lower Crankshaft gear remover: 1-8521-0064-0
length longer than 105 mm {4.13 in} into the Slinger remover: 1-8522-0052-0
crankcase replacer hole (arrow in the diagram),
Note:
raise the crankcase, lift it horizontally and
remove it. • Inspect the gears for damage. If there are no prob-
lems with it, do not remove it.
• If a slinger is installed, remove the slinger first.
Important:
The crankshaft should not be repaired as soft-
nitrating treatment has been performed to the sur-
face.
Inspection
Crankshaft
• Check for cracks on crankshaft and damage on the
• Measurement of crankshaft runout
contact surface of bearing.
Hold the No.1 journal and No.7 journal using a
crankshaft aligner or V block. Measure the runout
of the crankshaft by setting the dial gauge to No.4
journal at crankshaft and rotating the crankshaft
once slowly.
Limit of usage mm {in]

Crankshaft runout level 0.15 {0.0059}
• Measurement of wear on crank journal and pins

Measure four places shown on the illustration.
Nominal Assembly standard

dimension mm {in}
mm {in}
No.4 φ 104.850 — 104.875
Outside {4.1279 — 4.1289}
φ 105
diameter of
{4.1339} Others φ 104.880 — 104.905
journal
{4.1291 — 4.1301}
Outside φ 92 φ 91.895 — 91.925 {3.6179 —
diameter of {3.6220} 3.6191}
pin
Bearing Measurement of the clearance between the
• Check for wear, damage and peeling, etc. crank bearing and crank journal
• Assemble the bearing and check that there is a • Measure the inside diameter of crank bearing and
tension. the outside diameter of crank journal while the
crankcase is assembled, then acquire the clear-
ance measurement.
• Clean the bearing and its installation surfaces and
assemble the bearing. Then install the crankcase.
Next, apply molybdenum disulfide to the thread
and seating side of the M18 bolt, and tighten it to
The tightening order for the crankcase is shown in
the illustration.
Also, apply molybdenum disulfide to the M12 bolt
screw section and seating surface and tighten
them, then measure the four points shown in the
diagram with a cylinder gauge.
Tightening torque:
M18: 49 N⋅m {5 kg⋅m/36 lb⋅ft} → 88 N⋅m {9.0 kg⋅m/
65 lb⋅ft} → 90° — 120°
M12: 96 N⋅m {9.8 kg⋅m/71 lb⋅ft}
M18: Molybdenum disulfide application
M12: Engine oil application
Crankshaft gear
• Check for damage of the crankshaft gear. Assembly stan- Limit of usage
Note: Clearance No.4 0.075 — 0.150 0.16 {0.0063}
Always perform inspections before removing from the between the Journal {0.0030 — 0.0059}
crankshaft, and if there are no problems, do not remove bearing and
Others 0.045 — 0.120
it. crank journal
{0.0018 — 0.0047}
Note:
Refer to 0A-2, “Service Precautions, General Informa-
tion” when using the plastigauge for measurement.
10 6 2 3 7
14 11
13 12
9 5 1 4 8
WSWG0025
Name
Presence of soft-nitrating process layer 1. Do not carry out inspection on areas inside about
• Cleaning the crankshaft 10 mm {0.39 in} around the oil holes.
Clean the crankshaft. Remove any oil, especially 2. Inspection Solution
around the inspection areas (except 10 mm {0.39 3. Crankshaft
in} around the oil holes), using organic solvent.
• Judgment
Crankshaft reusable: Nothing changes even after
30 — 40 seconds.
Crankshaft is not reusable: The inspection solution
(light blue) turns transparent after 30 — 40 sec-
onds and the spot where the solution was dropped
turns copper color.
• Process after inspection
The inspection solution (1) is highly corrosive.
Wipe it off immediately after the inspection, and
thoroughly clean with water, steam, etc.
CAUTION:
Avoid the solution to contacting eyes, hands, cloth,
etc. If it goes into eyes, wash it out with plenty of
water immediately and seek for a medical treatment.
• Inspection of soft-nitrating process layer

Drop the inspection solution onto the inspection
spots using a syringe or glass rod. Keep the
inspection surface levelled not to let the inspection
solution run.
* Inspection solution...a 5 — 10 % solution of chlo-
rinated-2-copper ammonium dissolved in distilled
water.
Reassembly Installation
1. Install the crankshaft gear. 1. Install the crankshaft bearing.
• Install the knock pin to the crankshaft. • Check the assemble position marked at the dis-
• Warm up the gear using a oil heater (170 — assembling, and assemble after cleaning the
180°C {338 — 356°F}). Next, point the timing bearing and its assembling surface.
alignment mark “0” of gear to the near side, line
up the key slot of gear to the crank knock pin, Important:
and use a installer to insert until it contacts with The cylinder block side bearings have grooves and
the crankshaft collar section. oil holes on all peripheries. Bearings on the crank-
case side do not have any grooves and oil holes.
Note:
Be careful with the gear direction when installing.
Crankshaft gear installer: 1-8522-0045-0
2. Install the crankshaft.

• Apply engine oil to the sliding surface of bear-
ing. Keep the crankshaft levelled and put it on.
3. Install the thrust bearing.

• Apply oil on to the engine oil groove side of the
thrust bearing and keep the oil groove outward.
Push it into both sides of the cylinder block
No.1 journal by hands.
• Apply molybdenum disulfide to the M18 bolt

screw section and seating surface, and tighten
in the numbered order shown in the illustration.
Also, apply oil to the M12 bolt screw section
Name and seating surface, and tighten the bolts.
1. Knock Pin Hole Alignment
2. Oil Groove Note:
3. Apply Oil. • Make sure that the thrust bearing is installed
securely.
• Apply engine oil to the thrust bearing oil groove
• Make sure that the crankshaft rotates smoothly.
(1) side. With the oil groove facing the outside,
line it up to the convex section of crankcase Tightening torque:
and install it. M18: 49 N⋅m {5 kg⋅m/36 lb⋅ft} → 88 N⋅m {9.0
kg⋅m/65 lb⋅ft} → 90° — 120°
M12: 96 N⋅m {9.8 kg⋅m/71lb⋅ft}
M18: Molybdenum disulfide application
M12: Engine oil application
10 6 2 3 7
14 11
13 12
9 5 1 4 8
4. Install the crankcase.

• Apply approx. 4 mm {0.16 in} width and more
than 0.3 mm {0.012 in} thickness of Loctite
FMD-127 liquid gasket to the points on the WSWG0025
underside of the cylinder block shown in the

illustration (1, 2, 3, 4, 5, 6) and install promptly.
Cylinder Block
Components
Name
1. Oil Relief Valve 4. Oil Pressure Sensor
2. Cylinder Liner 5. Oil Jet
3. Cylinder Block 6. Crankcase
Disassembly Inspection
1. Remove the oil pressure unit. Crankcase
2. Remove the oil relief valve. • Check the crankcase for crack or damage.
3. Remove the crankcase. Perform magnetic flux method or red check
4. Remove the oil jet. inspection as required.
5. Remove the cylinder liner.
Measurement of the cylinder liner bore

• Check the inside of the liner for scratch or damage.
• Measure the maximum wear section at the position
of approx. 20 — 25 mm {0.79 — 0.98 in} from the
top surface of the liner in the condition that the liner
is installed to the cylinder block. If the value
exceeds the service limit, replace the liner.

mm {in} mm {in}
Cylinder liner bore φ 147 {5.7874} φ 147.3 {5.7992}
• When reusing the liner, clean off any carbon from

the liner upper section using a scraper or other
such tool.
Important: Oil jet

• It is not possible to repair liner boring or hon-
• Check the oil hole of the oil jet and joint bolt.
ing.
• Prevent the liner from being extracted.
Cylinder block
WSWG0021
• Inspection for corrosion and clogging of coolant
and in the oil passage
Check for any clogging carefully on coolant pas-
sage between each cylinder.
• Check the cylinder block for cracks or damage.
• Inspection for water leakage from the water jacket
Apply water pressure of 490 kPa {71 psi} with a
hydraulic test machine for three minutes, and Block inscribed Liner grade
check for any leakage from each cylinder block number
part. Cylinder block and 1•2 1X
liner combination
3 3X
Assembly specification mm {in}

Clearance between the 0.001 — 0.030
cylinder block and liner {0.0004 — 0.00118}
• Cylinder block and liner cleaning

Clean the cylinder block and liner properly, and
after cleaning thoroughly wipe off all traces of
cleaning fluid.
Note:
• The liner is very thin and should be handled with
care.
• Arrow liner outside diameter grade marking posi-
tion.
Reassembly
1. Assemble the cylinder block.
Grade selection of cylinder liner
• Match the cylinder block bore diameter (1) and
liner outside diameter grade.
• Using the number written on the right side surface
of the cylinder block, select a 1X for 1 or 2, or a 3X
for 3 liner and install it.
Important:
If the assembly was carried out without grade
selection of liner, it can cause insufficient cooling
(large clearance), liner insertion difficulties (small
clearance) and distortion.
2. Install the cylinder liners.

• Installation of the cylinder liners
Apply engine oil to the outer surface of the cyl-
inder liner, and install straight along the cylinder
block.
Important:
• Do not tap or apply an excessive force while
inserting the liner.
• After inserting the liner, make sure that the liner
does not come out when reversing the cylinder
block.
3. Install the oil jet.
• Check that the tip of the oil jet is facing the
entrance to the piston cooling cavity and tighten
it.
Tightening torque:
69 N⋅m {7.0 kg⋅m/51 lb⋅ft}
• Measurement of the cylinder liner extrusion

Measure the extrusion of the liner using a dial
gauge.

Amount of liner extrusion 0.05 — 0.09
{0.00197 — 0.00354}
Important:
Do not deform the edge of oil jet.
Difference from the 0.025 {0.00098} or less 4. Install the crankcase.

neighboring cylinders For an outline on assembly, refer to 1A-110,
“Reassembly, Crankshaft”.
5. Install the oil relief valve.
• Apply engine oil to the O-ring and install to the
relief valve.
• Apply engine oil to the relief valve screw sec-
tion and install to the cylinder block.
Tightening torque:
20 N⋅m {2.0 kg⋅m/15 lb⋅ft}
6. Install the oil pressure unit.
• Install the adapter and oil pressure unit through
the gasket.
Tightening torque:
Adapter: 59 N⋅m {6.0 kg⋅m/44 lb⋅ft}
Oil pressure unit: 18 N⋅m {1.8 kg⋅m/13 lb⋅ft}
20 {2.0 / 15} 41 {4.2 / 30}
69 {7.0 / 51}
WSWG0009
Special Tool
List of Special Tool Illustration Tool No./Tool Name/Rank
Illustration Tool No./Tool Name/Rank
5-8840-2826-0 / EN-46720
Injector remover
Rank A
1-8523-5013-0
Valve spring compressor
Rank B
1-8522-0052-0
Slinger remover
Rank B
9-8523-1202-0
Valve guide remover
Rank B 1852200520
1-8522-0043-0
Oil seal setting tool
Rank A
9-8522-1324-1
Valve bridge guide installer
Rank B
1-8522-0059-0
Piston setting tool
1-8522-1187-0 Rank B
Valve stem seal installer for
intake
Rank B
1852211870
1-8522-1025-1
Piston ring setting tool
1-8522-1184-0 Rank B
Valve stem seal installer for
exhaust
Rank B
1-8521-0064-0
Crankshaft gear remover
Rank B
5-8840-0019-1 / J-23907
Sliding hammer
Rank B
1-8522-0045-0
Crankshaft gear installer
Rank B
6WG1 Cooling System 1B-1
Engine
6WG1 Cooling System
Table of Contents
Cooling System ..................................................... 1B-2
Service Precautions ........................................... 1B-2
Explanations on Functions and Operation ......... 1B-2
List of Trouble Symptom .................................... 1B-5
Specifications ..................................................... 1B-5
Thermostat ............................................................ 1B-6
Components....................................................... 1B-6
Removal ............................................................. 1B-7
Inspection........................................................... 1B-7
Installation .......................................................... 1B-7
Torque Specifications......................................... 1B-8
Water Pump .......................................................... 1B-9
Components....................................................... 1B-9
Disassembly..................................................... 1B-10
Inspection......................................................... 1B-11
Reassembly ..................................................... 1B-11
Torque Specifications....................................... 1B-14
Special Tool ........................................................ 1B-15
List of Special Tool........................................... 1B-15
1B-2 6WG1 Cooling System
Cooling System
Service Precautions
WARNING:
Do not loosen or remove the sub tank cap when coolant is high temperature. Steam or boiling water spouts
and it may cause a burn. When opening the sub tank cap, cover the cap with thick clothes under the condi-
tion that coolant is cold, rotate it slowly to release pressure, and then remove it.

Cooling system
The cooling system is the forced circulation type and consists of the water pump, the thermostat and the radiator
(machine side component) as its main components.
Name
1. EGR Cooler 6. Thermostat
2. EGR Cooler 7. Machine Side Installation Parts
3. Cylinder Head 8. Radiator
4. Oil Cooler 9. Cooling Fan
5. Water Pump
Water pump
The water pump, which uses the centrifugal impeller system, is driven by the front gear of the engine.
Name
1. Impeller 6. Rear Cover
2. Seal Unit 7. Bearing
3. Oil Seal 8. Water Pump Body
4. Gear 9. O-ring
5. Shaft 10. Front Cover
EGR cooler air bleeding procedure
When replacing the coolant, bleed air from the EGR
cooler with the following procedure.
CAUTION:
Be sure to replace the coolant when it is cooled.
1. Loosen the air bleed plug (1) on the EGR cooler.
WSWG0001
2. Pour coolant into the radiator via its opening.

3. Tighten the plug when the coolant spills over from
the air bleed plug.
• Replace the copper packing if it is faulty.
CAUTION:
• Take care to prevent the spilt coolant from get-
ting the exhaust system parts wet.
• Be sure to wipe off the spilt coolant.
Tightening torque:
24.5 — 30.5 N⋅m {2.5 — 3.1 kg⋅m/18 — 23 lb⋅ft}
4. Pour coolant into the radiator via its opening again
until it is filled.
5. Bleed air from the engine body coolant with idling
the engine.
List of Trouble Symptom
Condition Possible cause Correction

Engine overheats. Belt is damaged or slips. Replace or adjust the belt.
Low coolant level Add.
Water temperature gauge or Replace the water temperature
water supply apparatus is faulty. gauge.
Clogging of exhaust pipe and Repair the exhaust pipe and
silencer silencer.
Low oil level Add oil.
Fatigue or damage in the radiator Replace the radiator cap.
cap
Clogging or dirt of radiator core or Clean or repair the radiator core
grill or grill.
Clogging of radiator tube due to Clean or replace the radiator core.
rust or foreign matter
Defective thermostat Replace the thermostat.
Fan clutch fault Replace the fan clutch.
Water pump fault Repair or replace the water pump.
Clogging of water jacket Clean up the water jacket.
Engine overcools. Defective thermostat Replace.
Specifications
Item Specification
Cooling method Water cooling compulsory re-circulation type
Radiator type This machine side
Type Centrifugal gear type
Water pump Discharge amount 383 (2,840 rpm)
(L/min)
Thermostat valve open start temperature °C {°F} 82 — 84 {180 — 183}
Coolant amount L {qts} 36.1 {38.2}
Thermostat
Components
Name
1. Seal Ring 4. Thermostat Housing
2. Thermostat 5. O-ring
3. Gasket
Removal • Operation check of thermostat
Put the thermostat in water and gradually increase
1. Remove the thermostat housing.
the water temperature. Measure the temperature
2. Remove the gasket. at which the valve starts to open, fully opens and
3. Remove the O-ring. lift amount.
4. Remove the thermostat.
Open start temperature 82°C {180°F}
5. Remove the seal ring.
Temperature when fully 95°C {203°F}
• Use a thermostat seal ring puller to remove the
open
seal ring.
Thermostat seal ring puller: 1-8521-0067-0 Lift amount 95°C {203°F} / 11 mm {0.43 in}
Note:
Do not directly heat the thermostat. Either perform the
measurements by covering the bottom of the container
with a plate (2), or hanging. When performing measure-
ments, constantly stir the water (1) to avoid un-even
temperature.
Inspection
Thermostat
• Check a pellet of thermostat, spring and caulking
part for damage.
Name
1. Stirrer
2. A Piece of Wood
• As wax type thermostats have a large heat capac-

ity, the action of the valve has a certain amount of
time lag compared to the fluctuation in water tem-
perature.
Installation
1. Install the seal ring.
• Turn the lip of seal ring as shown in the illustra-
tion, and use a installer to install it.
Thermostat seal ring installer: 1-8522-1034-0
2. Install the thermostat.
• Install the thermostat as shown in the illustra-
tion, taking care not to damage the seal ring.
3. Install the O-ring. Name

4. Install the gasket. 1. Seal Ring
2. Thermostat
5. Install the thermostat housing.
3. Gasket
• Tighten the water pump side bolts while holding 4. Bolt (Portion C)
the thermostat housing against the oil cooler 5. Thermostat Housing
side, then tighten the oil cooler side bolts. 6. O-ring
Tightening torque:
39 N⋅m {4.0 kg⋅m/29 lb⋅ft}
39 {4.0 / 29}
39 {4.0 / 29}
WSWG0010
Water Pump
Components
Name
1. Rear Cover 7. O-ring
2. Bearing (small) 8. Shaft
3. Gear 9. Seal Unit
4. Bearing (large) 10. Impeller
5. Oil Seal 11. Front Cover
6. Water Pump Body
Disassembly • Use a press from the gear side and extract the
shaft.
1. Remove the front cover.
2. Remove the O-ring.
Do not reuse the O-ring.
3. Remove the impeller.
• Install an impeller remover to the impeller, and
while the remover is fixed with a spanner,
screw in the bolts and extract the impeller.
Impeller remover: 1-8521-0062-0
Name
1. Bearing
2. Gear
9. Remove the oil seal (2).

10. Remove the seal unit (1).
• Remove the oil seal (2) while taking care not to
damage the press-fit portion.
4. Remove the rear cover. • Also, remove the seal unit (1) while taking care
5. Remove the bearing (small). not to damage the press-fit portion.
6. Remove the gear.
7. Remove the bearing (large).
8. Remove the shaft.
• Use a press and extract it with bearing installed
from the impeller side.
Name
1. Seal Unit
2. Oil Seal
Inspection Shaft
Impeller • Check for damage or wear of the shaft.
• Check the impeller for corrosion and the seal unit
contact surface for wear, damage, etc.
Reassembly
Bearing 1. Set the water pump body.
2. Install the oil seal.
• Check bearing for peeling, wear or noise
• Apply engine oil to the inside and outer circle of
• Check to see from the ball clearance to the full cir-
lip of oil seal lip. Face the lip section upwards
cumference of lace for damage or debonding.
and press-fit to water pump body taking care
• Check the ball and lace sections for abnormal rat- not to bend it out of shape.
tling.
• Check if you can feel anything unusual in your
hand when rotating the bearing.
3. Install the bearing (large).

4. Install the shaft.
• Apply engine oil to the shaft, and press-fit the
bearing into the shaft using a press.
7. Install the bearing (small).

8. Install the rear cover.
• Apply pipe to the outer lace of bearing, and
5. Install the shaft ASM. press-fit it while taking care not to damage the
• Press-fit the shaft ASM into the water pump rear cover.
body using a press.
Important:
Try not to damage the oil seal.
9. Install the rear cover ASM.

• Using a press, apply pipe to the bearing (small)
inner lace and press-fit it into the shaft. At this
time, line up the bolt installation positions on
the rear cover.
6. Install the gear.
• Using a press, face the large side of the project- Tightening torque:
ing center boss section towards the seal unit 27 N⋅m {2.8 kg⋅m/20 lb⋅ft}
side, and press-fit until it contacts with the bear-
ing. Note:
To prevent damage to the bearing and rear cover,
Note: press-fit it while it contacts with the impeller insertion
To prevent damage to the bearing, press-fit it while it side shaft edge.
contacts with the impeller insertion side shaft edge.
11. Install the impeller.
• Using a press, press-fit it so that the clearance
between the end surface of water pump body
and impeller reaches the specified value.
Assembly standard mm {in}

Clearance between end 1.7 — 2.7 {0.0669 — 0.1063}
surface of the body and
the impeller
10. Install the seal unit.

• Use the installer to press the seal unit until its
collar section contacts with the water pump
body.
Important:
Try not to damage the seal unit.
Seal unit installer: 1-8522-0047-0
Note:
To prevent damage to the bearing, press-fit it while it
contacts with the impeller insertion side shaft edge.
12. Install the O-ring.

13. Install the front cover.
Name
1. Installer
2. Seal Unit
39 {4.0 / 29}
26 {2.9 / 21}
WSWG0011
Special Tool
List of Special Tool
1-8521-0067-0
Thermostat seal ring puller
Rank A
1-8522-1034-0
Thermostat seal ring
installer
Rank A
1-8521-0062-0
Impeller remover
Rank B
1-8522-0047-0
Seal unit installer
Rank A
6WG1 Fuel System 1C-1
Engine
6WG1 Fuel System
Table of Contents
Fuel System ..........................................................1C-2
Service Precautions ...........................................1C-2
Explanations on Functions and Operation .........1C-3
Function Check ..................................................1C-6
Specifications .....................................................1C-7
Fuel Filter ..............................................................1C-8
Components.......................................................1C-8
Disassembly.......................................................1C-9
Inspection...........................................................1C-9
Reassembly .....................................................1C-10
Special Tool ........................................................1C-12
List of Special Tool...........................................1C-12
1C-2 6WG1 Fuel System
Fuel System
Service Precautions
Precautionary notes on the handling of fuel
related parts
The electronic control fuel injection system (common
rail type) achieves a far higher injection pressure and
far higher level of control than conventional systems.
For this reason, holes and clearances in the fuel sys-
tem which serve as a passage of fuel, including the
inside of injector, are finished extremely precisely.
They are therefore far highly sensitive to foreign matter
than conventional systems, and may lead to break-
down on the road. Be sure to prevent foreign matter
from getting inside.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• Always replace the high-pressure pipe in fuel sys-
tem with new one if it has been removed. Reuse of
it causes damage to the seal surface, resulting in
fuel leakage.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.), do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with
new ones.
Work procedure
1. The fuel opening must be quickly sealed when
removing the injector, supply pump, and common
rail.
2. The fuel pipes and injection pipes should also be
handled as in 1. above.
3. The eyebolts and gasket used in installing fuel
pipes must be stored in a clean parts box with a lid
to prevent adhesion of foreign matter. Further-
more, the parts boxes should be cleaned regularly.
4. When handling the parts, using rubber gloves or
ones bare hands is most desirable. If it is abso-
lutely necessary, work gloves can be used, but
they should be constantly checked for dirt or dust,
and new gloves should be used if possible.
5. After finishing the work, wipe off the fuel that has
leaked out and make sure there is no fuel leakage
after starting the engine as fuel leakage could
cause fires.
Fuel system diagram
Name
1. Common Rail 5. Feed Pump
2. Fuel Filter 6. Supply Pump
3. Injector 7. Feed Line
4. Fuel Tank 8. Return Line
Common rail
Name
1. Flow Damper 3. Pressure Sensor
2. Pressure Limiter
Supply pump
Name
1. Overflow Valve 7. Fuel Inlet Port : Feed Pump
2. Fuel Outlet Port : to Common Rail 8. Air Bleeder
3. Pressure Control Valve (PCV) 9. G Sensor
4. Fuel Inlet Port : Pump Body 10. Oil Outlet Port
5. Priming Pump 11. Oil Inlet Port
6. Fuel Outlet Port : Feed Pump
Function Check
Fuel filter water drain
1. Loosen the air bleed plug (2) on the fuel filter.
2. Loosen the drain plug (4) on the fuel filter and drain
the water.
3. Loosen the drain plug (4).
4. Let the air bleed from the fuel.
Name
1. Priming Pump (Fuel Filter)
2. Air Bleed Plug
3. Fuel Filter
4. Drain Plug
5. Priming Pump (Supply Pump)
6. Supply Pump
Name
1. Priming Pump (Fuel Filter) 4. Loosen the air bleeder on the supply pump and
2. Air Bleed Plug operate the priming pump until no more air comes
3. Fuel Filter out.
4. Drain Plug
5. Priming Pump (Supply Pump)
6. Supply Pump
Bleed air from fuel system

1. Turn the key switch to ON, and activate the elec-
tromagnetic pump. (on the machine with electro-
magnetic pump)
2. Loosen the air bleed plug (2) on the fuel filter.
3. Operate the priming pump on the supply pump to
bleed air from the fuel filter and fix the priming
pump.
• Move the priming pump of fuel filter to bleed the
remaining air.
• Loosen the air bleed plug (2).
Important:
Adequate care should be taken as over-tightening Name
the air bleed plug could lead to damage. 1. Priming Pump (Supply Pump)
2. Air Bleed Plug
Note: 3. Overflow Pipe (Supply Pump)
Bleed the air from the fuel filter one by one. 4. Drain Plug
5. Priming Pump
6. Supply Pump
5. Tighten the air bleeder on the supply pump.
Important:
Be careful not to tighten air bleed plug excessively.
6. After tightening all plugs, operate the priming

pump until you feel enough resistance to move.
• The priming pump needs to be moved a total of
more than 150 times.
7. Tighten the priming pump to the original position
and start the engine. If the engine does not start,
restart from step 6 again.
Specifications
Fuel injection pump specifications
Engine type 6WG1-TC

Item
Fuel injection pump type Electronic control fuel injection system (Common rail type)
Supply pump model SP160-6HD
Pump maximum discharge amount 490 mm3/ST
Revolution direction Clockwise (viewed from drive-end)
Pressurized discharge sequence 1-2-1-2-1-2 (Pump cylinder number)
Plunger diameter mm {in} φ8.5 {0.3346}
Overflow valve opening pressure kPa {psi} 255 {37}
Feed pump Trochoid-type 10.5 cm3/rev
Injector specifications
Item Specification
Injector model DLL-P
Nozzle hole (mm {in}) × number of pieces φ0.19 {0.0075} × 8
Fuel Filter
Components
Name
1. Head ASM 6. O-ring
2. Air Bleed Valve 7. Case
3. Priming Pump 8. O-ring
4. Element 9. Drain Plug
5. Level Ring
Disassembly 7. Clean the fuel passage of head ASM.
1. Loosen the air bleed plug. • The priming pump is a non-disassembled part.
2. Loosen the drain plug.
• Loosen the drain plug, and then drain the fuel
inside of the filter beforehand.
3. Remove the case using the fuel filter wrench.
Fuel filter wrench: 8-9801-3170-0
4. Remove the O-ring for case.
5. Remove the level ring.
Inspection
Overflow valve
• This over flow valve is not supplied with the fuel fil-
ter.
• Check overflow valve for clogging and ball seat for
leakage.
Name
1. Level Ring Overflow valve opening pressure: 275 — 314 kPa
2. O-ring {40 — 46 psi}
3. Case
6. Remove the element.
WSUZ0045
Reassembly
Name
1. Head ASM 5. Drain Plug
2. Element 6. O-ring
3. O-ring 7. Level Ring
4. Case
1. Install the element to the head ASM.

• Insert the element seal rubber to the head
ASM.
7. Tighten the air bleed plug to the specified torque.
Tightening torque:
9.8 N⋅m {1.0 kg⋅m/7 lb⋅ft}
Pre-filter
2. Install the O-ring to the case.

• Use a new O-ring.
3. Put the level ring in the case.
4. Tighten the case using the fuel filter wrench.
Fuel filter wrench: 8-9801-3170-0 WSWG0081
Tightening torque: Use a fuel filter wrench to exchange the element.

29.4 N⋅m {3.0 kg⋅m/22 lb⋅ft} Fuel filter wrench: 8-9801-3170-0
Pre-filter (RACOR type)
Name
1. Level Ring
2. O-ring
3. Case Use a fuel filter wrench (RACOR type) to exchange the
cartridge.
5. Install the O-ring to the drain plug. Fuel filter wrench (RACOR type): 8-9802-1941-0
• Use a new O-ring.
6. Tighten the drain plug to the specified torque.
Tightening torque:
2 N⋅m {0.2 kg⋅m/18 lb⋅in}
Special Tool
8-9801-3170-0
Fuel filter wrench
Rank A
8-9802-1941-0
Fuel filter wrench (RACOR
type)
Rank A
6WG1 Electrical System 1D-1
Engine
6WG1 Electrical System
Table of Contents
Starting System.....................................................1D-2
Service Precautions ...........................................1D-2
Explanations on Functions and Operation .........1D-2
List of Trouble Symptom ....................................1D-3
Specifications .....................................................1D-4
Starter ...................................................................1D-5
Components.......................................................1D-5
Disassembly.......................................................1D-6
Inspection...........................................................1D-8
Reassembly .....................................................1D-11
No Load Test....................................................1D-13
Maintenance Standard .....................................1D-14
Torque Specifications.......................................1D-14
Charging System.................................................1D-15
Service Precautions .........................................1D-15
Explanations on Functions and Operation .......1D-15
Charging Circuit ...............................................1D-16
Structure...........................................................1D-16
List of Trouble Symptom ..................................1D-17
Specifications ...................................................1D-18
Generator ............................................................1D-19
Components.....................................................1D-19
Disassembly.....................................................1D-20
Inspection.........................................................1D-21
Reassembly .....................................................1D-23
Bench Test .......................................................1D-23
Maintenance Standard .....................................1D-24
Torque Specifications.......................................1D-25
1D-2 6WG1 Electrical System
Starting System
Service Precautions
Precautions on handling
• Improper gap between pinion and ring gear causes
faulty mesh. (Gap 2 — 5 mm {0.08 — 0.20 in})
Also, the front bracket is installed on the engine
side securely.
• Be sure to turn off the battery switch before
removal/installation of stater.
• Tightening/inserting wiring must be performed
properly. Improper work causes starting trouble
due to high contact resistance.
Precautions on starting
• Be careful with charging status of battery. Insuffi-
ciently-charged battery causes starting trouble.
• After checking engine starting, turn off the starter
switch immediately.
• One continuous use should be less than 10 sec-
onds. If re-starting is needed, wait until the pinion
stops completely.
• If the starter does not stop rotating when the
starter switch is turned off, turn off the battery
switch immediately. In this case, check the wiring,
switch, etc.

Connections (Mitsubishi)
WSWG0022

Starter does not operate when starter switch is Full discharge of battery Replace the battery.
turned on. Open circuit, poor contact Repair.
Poor contact in starter switch or Repair or replace it.
defective tightening of terminal
Poor contact in starter relay or Repair or replace it.
plug terminal
Short or open circuit in magnetic Replace.
switch coil
Pinion moves forward but it does not engage with Insufficient capacity of battery Charge the battery.
ring gear. Wear of pinion or ring gear tooth Replace the pinion or the ring
edge gear.
Dust on pinion shaft Repair.
Pinion engages and rotates motor but it does not Slippage of clutch Replace the clutch or the starter.
run engine. Breakage of reduction gear Replace the gear or the starter.
Pinion engages but it does not run engine. Insufficient capacity of battery Charge the battery.
Defective tightening of wiring cir- Repair.
cuit terminal
Short circuit of armature or field Replace the starter.
coil
Contamination of commutator Repair, or replace the starter.
Fatigue or wear of brush spring Replace the brush spring or the
brush.
Locking of bearing Replace the bearing or the starter.
Poor contact in magnetic switch Replace the magnetic switch.
When turning starter switch off after engine starts, Retuning failure of starter switch Replace the starter switch.
starter does not stop. contact
Retuning failure of starter relay Replace the starter relay.
contact
Short circuit in magnetic switch Replace the magnetic switch.
coil
Specifications
Model (Manufacturer) Mitsubishi

Rating
Voltage (V) 24
Power output (kW) 7.0
Time (Sec.) 30
Number of pinion teeth 11
Revolution direction (viewed from pinion side) Clockwise
Mass (approx.) (kg) 12.7
No load characteristic
Voltage/Current (V/A) 23.5/ 125 or less
Speed (rpm) 3000 or more
Load characteristic
Voltage/Current (V/A) 15.8/ 500 or less
Torque N⋅m {kg⋅m/lb⋅ft} 51.5 {5.25/38} or more
Speed (rpm) 900 or more
Locking characteristic
Voltage/Current (V/A) 5/ 1,600 or less
Torque N⋅m {kg⋅m/lb⋅ft} 117.0 {11.9/86} or more
Starter
Components
24V 7.0 kW (Mitsubishi)
Name
1. Snap Ring 15. Planetary Gear
2. Stop Ring 16. Ball
3. Pinion 17. Gasket
4. Pinion Spring 18. Plate
5. Screw 19. Armature
6. Front Bracket 20. Bearing
7. Bearing 21. O-ring
8. Magnetic Switch 22. Yoke ASM
9. Lever 23. Brush
10. Overrunning Clutch 24. O-ring
11. Internal Gear 25. Brush Holder
12. Washer 26. Rear Bracket
13. E-shaped Retaining Ring 27. Through Bolt
14. Gear Shaft
Disassembly
Note:
• Before disassembling the starter, put alignment
marks on each magnetic switch, yoke, front
bracket and rear bracket to facilitate re-assembly.
• First, remove the pinion. If you proceed with the
disassembly without removing the pinion first, the
method for removing the pinion will be lost, and
you will be unable to disassemble the starter.
However, the motor section and magnetic switch
can be removed without first removing the pinion.
1. Remove the snap ring.

2. Remove the stop ring.
3. Remove the pinion.
• In normal condition, if tapping the pinion or stop
ring toward the front bracket side, the front
bracket will be broken. Therefore, tap the stop • Apply the pipe, which just fits the stop ring, on
ring when the pinion comes out to cranking the ring and tap the pipe with a hammer to
position. remove the stop ring toward the pinion side
• Connect the starter to battery as shown in the once.
illustration. Then, remove the snap ring and remove the
When closing the switches SW1 and SW2, the stop ring, pinion and pinion spring.
pinion move forward to the cranking position
and the armature rotates. Important:
Then, open the switch SW2 to stop the arma- Do not reuse the snap ring.
ture rotating.
Important:
Remove the pinion within 10 seconds since heat is
generated during electric discharge.
5
3
6
2
1
WSHK0073
Name
1. Pinion
2. Clutch Shaft
3. Snap Ring
4. Stop Ring
Name 5. Pipe
1. Snap Ring 6. Pinion Spring
2. Stop Ring
3. Pinion Gear 4. Remove the pinion spring.
5. Remove the screw.
6. Remove the magnetic switch.
• Remove the nut on M terminal of magnetic
switch and remove the lead wire with terminal.
Next, remove the magnetic switch tightening
screw and remove the magnetic switch.
Note:
Tightening screw is tight. Use a shock driver to loosen.
Name
1. Armature
2. Through Bolt
3. Rear Bracket
4. Brush Holder
5. Yoke ASM
15. Remove the plate.

16. Remove the gasket.
7. Remove the screw.
17. Remove the planetary gear.
8. Remove the through bolt.
• Remove the four planetary gears.
• Remove the brush holder-tightening screw and
• Pull out the internal gear, gear shaft, overrun-
through bolt.
ning clutch and lever as a unit from front
Next, remove the rear bracket. Also, remove
bracket.
the O-ring at the same time.
Important:
Do not reuse the O-ring.
9. Remove the rear bracket.

10. Remove the yoke ASM.
11. Remove the O-ring.
• Apply a socket (outside diameter 38 mm {1.49
in}) on a commutator of armature.
Then, slide the brush on the socket, and remove the
yoke ASM with the brush rested on the socket.
Also, remove the O-ring at the same time.
12. Remove the brush holder.
• Pull the brush spring upwards, and remove the
brush from the brush holder.
Next, remove the brush holder.
13. Remove the armature.
14. Remove the ball. Name
• Remove the armature. 1. Overrunning Clutch
The ball also comes out at the same time, but 2. Lever
sometimes it becomes stuck in grease and 3. Internal Gear
does not come out. 4. Gear Shaft
The bearing can be removed using a general 5. Planetary Gear
puller.
18. Remove the lever. • Check the armature coil for grounding (faulty
insulating) with a circuit tester.
Note: Replace the armature if grounding is present.
Remember the direction of lever.
19. Remove the E-shaped retaining ring.

• Remove the two E-shaped retaining rings. To
remove the overrunning clutch, rotate the spline
by one tooth to remove it from gear shaft ASM.
CAUTION:
Do not reuse removed E-shaped retaining ring.
20. Remove the overrunning clutch.

21. Remove the internal gear.
22. Remove the washer.
• Remove the internal gear. In this time, take out
one washer which adjusts axial play of gear
shaft.
23. Remove the gear shaft.
24. Remove the front bracket. WSHK0075
25. Remove the bearing (component parts table 20). • Check the outside of commutator for wear.
26. Remove the brush. Replace the armature if it is worn beyond the
limit.
27. Remove the bearing (component parts table 7).
Inspection
1. Armature
• Check the armature coil for internal short circuit
with a growler tester.
Replace the armature if internal short circuit is
present.
WSHK0076
WSHK0074
• Check the depth (undercut) of insulating mold
of commutator.
Remove abrasion powder on brush, and repair
if faulty.
WSHK0079
3. Brush
• Check the brush length for wear.
If the brushes are close to the wearing limit,
replace the entire brush holder ASM to replace
• Check the gears for wear or damage. the brush holder side brushes. To replace the
Replace the armature if faulty. yoke ASM side brushes, you can replace just
• Check the bearings for noise, rattle or grease the brushes only.
leakage. • Make sure the brush moves smoothly in the
Replace the bearing if faulty. brush holder.
2. Field coil Also, check the brush spring pressure.
• Check the coil for open circuit with a circuit • Check the brush holder for grounding (faulty
tester. insulating) with a circuit tester.
Replace the yoke ASM if the circuit is open. Clean the brush holder before checking.
Replace the brush holder ASM if the continuity
is present when putting one probe of circuit
tester to brush holder plate (metal part) and
another one to insulated holder.
WSHK0078
• Check the coil for grounding (faulty insulating)
with a circuit tester.
Either repair it or replace the yoke ASM if
grounding is present.
4. Overrunning clutch and pinion
• Hold the housing of overrunning clutch by hand.
Make sure that the pinion can be rotated easily
by hand with a light resistance in one direction
and must not be in the opposite direction. If this
is not the case, replace the overrunning clutch.
Check the pinion, and replace it if wear or
scratch is present.
Note:
Grease is present in overrunning clutch. If you wash
the overrunning clutch with oil remover of detergents
that remove oil, the grease may be washed out of the
overrunning clutch. Therefore, the overrunning clutch
should only be cleaned with a cloth.
8. Magnetic switch
• Check for continuity between the M terminal (4)
and the body, and replace the magnetic switch
if no continuity is present.
Also make sure that there is no continuity
between the B terminal (2) and M terminal (4).
Replace the magnetic switch if continuity is
present.
WSHK0081
5. Front bracket
• Check the bearing and oil seal, and replace the
front bracket ASM (including bearing, oil seal) if
faulty.
6. Internal gear and planetary gear
• Inspect the tooth part of the gear, and replace
the internal gear or the planetary gear if it has
serious wear or damage.
7. Lever
• If the portion which rubs the overrunning clutch
is worn, the protruded position of pinion will be Name
faulty. 1. Magnetic Switch
Refer to 1D-11, “Reassembly, Starter” to adjust 2. B Terminal
the protruded position of pinion. 3. S Terminal
3. M Terminal
Reassembly • E-shaped retaining ring
Assembly can be performed in the reverse order of dis- • O-ring (gasket on both ends of the yoke, and
assembly. However, be careful with the following pre- each screw section)
cautions.
1. The parts that require oiling are as follows. The fol-
CAUTION: lowing brands of grease are recommended: MUL-
The following parts should be replaced with new TEMP 0A-171 (Kyodo Yushi Co., Ltd.) for 1, 2, 3,
parts. 4, 5, 6 on the diagram, and Moricote RAG650
(Dow Corning) for 7, 8, 9 on the diagram.
• Snap ring (fixing the stop ring)
Name
1. Armature Bearing Outer Periphery Surface (very 6. Under Pinion
little) 7. Sliding Portion of Lever and Overrunning Clutch
2. Plunger (very little) 8. Sleeve Bearing and Ball
3. Gear Shaft Spline Section and Sliding Portion 9. Armature Shaft Gear, Planetary Gear, Internal
4. Clutch Shaft Sliding Portion Gear
5. Oil Seal
2. Tightening torque
Refer to 1D-14, “Torque Specifications, Starter” for
the tightening torques.
3. Armature shaft direction play
• No need for adjustment. Assemble the ball into
a tip of shaft.
4. Gear shaft direction play
• Appropriate gap will be obtained automatically
when one washer is inserted between internal
gear and gear shaft.
• Pass the washer, internal gear and overrunning
clutch through the gear shaft.
Next, move the overrunning clutch by one tooth
of spline to make sure that the overrunning
clutch cannot be pulled out. Then assemble the
E-shaped retaining ring.
Name
1. Pinion
2. Clutch Shaft
3. Snap Ring
4. Stop Ring
5. Pinion Spring
6. Check of the pinion protruded position

After assembling the starter, check the protruded
position of pinion.
Measurement and inspection procedures should
be carried out as follows.
• Connect the starter to battery as shown in the
illustration.
When closing the switches SW1 and SW2, the
pinion move forward to the cranking position
and the armature rotates.
Name Then, open the switch SW2 to stop the arma-
1. Overrunning Clutch ture rotating.
2. Internal Gear
3. Washer
4. E-shaped Retaining Ring
5. Gear Shaft
5. Assembly of pinion
• Assemble the pinion before assembling the
magnetic switch to front bracket.
Assemble the pinion spring, pinion and stop
ring to clutch shaft in this order, then install the
snap ring to the groove of clutch shaft tightly at
the end.
Then, pull strongly the stop ring toward the stop
ring side with a gear remover and fix both of
them.
• Press (press and release) a tip of the clutch No Load Test
shaft lightly by hand and measure the moving
1. After adjusting the protruded position of pinion,
distance (return moving distance) of it.
connect the starter as shown in the illustration.
This value should be 0.5 — 2.0 mm {0.02 —
0.08 in}. If the measured size is outside this CAUTION:
limit, adjust the number (one or two) of gaskets Use a thick electric wire and tighten the connected
(thickness 0.5 mm {0.02 in}) between the mag- portion securely.
netic switch and front bracket, or replace the
lever.
Name
1. Battery
2. Ammeter
3. Voltmeter
2. Close the switch and read the speed, current and

voltage. Then compare the read values to the
maintenance standard.
If the values differ from the maintenance standard
values, disassemble and inspect again.
Maintenance Standard
Item Standard values and limitation values

No load characteristic Voltage V 23.5
Current A 125 or less
Speed r/min 3,000 or more
Commutator Outside diameter mm {in} 38.7 {1.52}
Limit mm {in} 38.1 {1.50}
Commutator Undercut mm {in} 0.8 {0.03}
Limit mm {in} 0.2 {0.008}
Brush Length mm {in} 23 {0.91}
Limit mm {in} 12 {0.47}
Brush spring Pressure N {kg/lb} 33 – 45 {3.4 – 4.6/7.4 – 10.1}
Limit N {kg/lb} 20 {2.0/4.5}
Protruded position of pinion mm {in} 0.5 – 2.0 {0.02 – 0.08}
6 {0.6 / 53 lb in}
23 {2.3 / 17}
3 {0.3 / 27 lb in}
10 {1.0 / 88 lb in}
WSWG0012
Charging System
Service Precautions • Do not open/close the battery relay switch while
the engine runs.
Be careful with the following when handling a genera-
tor. • Disconnect the battery terminal when charging
from external source such as quick charge.
• Connecting the polarities of battery inversely
causes generator diode to be broken. • Do not pour steam cleaner or water directly on it.
• While the engine runs, Never disconnect the wiring • After connecting to B terminal and E terminal,
of battery terminal and charging circuit. tighten them to the following torque.
B terminal: 4.9 — 6.9 N⋅m {0.5 — 0.7 kg⋅m/43 —
• Wiring connection to terminal must be performed
61 lb⋅ft}
properly according to terminal symbol.
E terminal: 2.0 — 5.3 N⋅m {0.2 — 0.5 kg⋅m/18 —
• Do not perform megger test on semiconductor 47 lb⋅ft}
device.
• Refer to 1A-14, “Installation, Engine Accessories”
• Be sure to disconnect the battery terminal (−) for tension adjustment of belt.
before inspection on equipment.

Sectional view of generator
Name
1. Rectifier 6. Front Bracket
2. Stator 7. Coil ASM
3. Rotor 8. Rear Bracket
4. Bearing 9. IC Regulator
5. Pulley 10. Bearing
Charging Circuit
Name
1. Coil 6. Battery
2. Diode 7. Connector
3. Condenser 8. Regulator
4. Indicator Lamp 9. Field Coil
5. Key Switch
Structure The charging lamp will be off if the voltage on L termi-

nal reaches battery voltage.
This generator has no brush.
Main parts are a rotor, stator, rectifier ASM, front
bracket, rear bracket, IC regulator, bearing, pulley and
so on.
Six main diodes and two additional diodes are used to
convert three-phase alternating current, generated in
stator coil, into direct current. Among six main diodes,
there are three positive diodes and three negative
diodes.
In addition, three tiny diodes, called trio diode, are used
to supply field current.
This generator has three terminals, which are B termi-
nal (for direct current output), L terminal and R terminal.
The L terminal is connected to field coil. Therefore, as
well as R terminal, it becomes input terminal for initiat-
ing excitation current until the generator starts to gener-
ate electric power.
It also provides function as output terminal. (Current
capacity is 1 A.)

Charging is impossible. Defective battery Replace.
Open or short circuit, disconnec- Repair.
tion in wiring / ammeter
Open, ground short or short circuit Replace.
in each coil of generator and
breakage of diode
Defective regulator Replace.
Poor contact in terminal of regula- Repair.
tor
Charging is not sufficient. Defective battery Replace.
Open or short circuit, disconnec- Repair.
tion in wiring
Looseness of generator drive belt Adjust the tension of the belt.
Short circuit in stator coil layer Replace.
Defective diode Replace.
Poor contact in each terminal Repair.
tor
Overcharging occurs. Defective regulator Replace.
Charging current is unstable. Intermittent contact or nearly dis- Repair.
connected connection in wiring
Looseness of generator drive belt Adjust the tension of the belt.
Short circuit or nearly open circuit Repair.
in stator coil
Poor contact in each terminal Repair.
tor
Abnormal sound occurs from generator. Looseness of belt tension Adjust the tension of the belt.
Defective bearing Replace the bearing.
Contact of rotor core and stator Repair.
core
Defective diode Replace.
Short circuit or nearly open circuit Replace.
in stator coil
Specifications
Nominal output (V – A) 24 – 50
Rated speed (rpm) 5,000
Regulator-type IC type
Regulated voltage (V) 28.5±0.5
Mass (kg) 9.7
Made by Mitsubishi Electric
Generator
Components
Name
1. Nut 15. B Terminal Cap
2. Spring Washer 16. Screw (for Clamp Installing)
3. Pulley 17. Clamp
4. Through Bolt 18. Screw (for Coil ASM Tightening)
5. Screw (for Retainer Tightening) 19. Screw (for Regulator Installing)
6. Front Bracket 20. Rear Bracket
7. Front Bearing 21. Screw (for Connector Installing)
8. Retainer 22. Connector ASM
9. Key 23. Rectifier
10. Rotor 24. Regulator
11. Rear Bearing 25. Plate (L)
12. B Terminal Bolt 26. Screw (for Regulator Tightening)
13. B Terminal Tightening Nut 27. Stator
14. Nut for B Terminal Bolt 28. Coil ASM
Disassembly 2. Rotor related
• Only important points are described. • Hold the rotor with a vise without deforming the
rotor ball.
CAUTION: Remove the pulley fixing nut, and remove the
To facilitate re-assembly, put alignment marks on pulley, fan, spacer and front bracket.
front bracket and rear bracket before disassembly.
CAUTION:
1. Front/rear bracket related To hold the rotor with a vise, grip the portion (2).
• Remove the four through bolts, then pry Portion (1) is not strong enough to be gripped.
between stator and front bracket with a tip of
flathead screwdriver and separate the front
bracket from rear bracket carefully.
CAUTION:
Take care not to damage the stator coil.
3. Bearing related
• If the front bearing needs to be removed,
remove the screw which fixes retainer, and
push out the bearing using appropriate socket.
• If the rotor bearing needs to be removed, it can
be done by a general bearing puller.
Name CAUTION:
1. Pulley Do not remove it if not necessary. Do not reuse the
2. Front Bracket removed bearing.
3. Front Bearing
4. Rotor 4. Coil ASM related
5. Coil ASM
• To remove the coil ASM from rear bracket,
6. Stator
firstly remove the screw A (which fixes coil ter-
7. Rectifier
minal portion to IC regulator).
8. Rear Bracket
Removing a screw B (which fixes the coil
assembly to rear bracket) prior to screw A may
cause damage to terminal portion.
Hold the coil ASM by hand not to damage to
terminal portion.
Then, remove the screw B and remove the coil
ASM.
Name Name
1. Connector 1. IC Regulator
2. Screw A 2. Terminal Bolt
3. Screw B 3. B Terminal
5. B terminal ASM related

• Disconnect the connector and clamp. Inspection
• Remove the cap and nut from terminal bolt of
1. Stator
rectifier.
Pry between rear bracket and B terminal ASM • Check visually for damage, loose connection
to remove the B terminal ASM. A tube remains and discoloration of coil.
on rear bracket. • Check for continuity between two lead wires (1)
of stator coil with a circuit tester.
CAUTION: Replace the stator if no continuity is present.
Do not lose the tube.
6. Rectifier ASM related

• Remove one rectifier fixing screw and two regu-
lator fixing screws.
Remove the stator and rectifier ASM from rear
bracket as a unit.
Then, remove the IC regulator. 1
• Disconnect four lead wires of stator coil and
remove the stator from rectifier.
CAUTION:
Lead wires of stator coil are soldered (melting
point: 230°C {446°F}) on rectifier terminal.
Disconnect them quickly (within five seconds) by a
180 — 270 watt soldering iron not to heat the recti-
fier causing damage to diode.
WSHK0096
• Check for continuity between lead wires (1) of 4. Rectifier ASM
stator coil and core (2) with a circuit tester. • Check for continuity between positive diode,
Replace the stator if continuity is present. additional diode positive heat sink on positive
side and four diode terminals with a circuit
tester.
The positive diode has short circuit if continuity
is present in both directions. Replace the recti-
fier ASM.
The positive diode has open circuit if no conti-
1
nuity is present in both directions. Replace the
rectifier ASM.
• Negative diode and additional diode on nega-
tive side
Check for continuity between negative heat
sink and four diode terminals with a circuit
tester.
The negative diode has short circuit if continuity
2
is present in both directions. Replace the recti-
fier ASM.
The negative diode has open circuit if no conti-
WSHK0097 nuity is present in both directions. Replace the
rectifier ASM.
2. Rotor
• Diode trio (three tiny diodes)
• Check the bearings for noise, rattle or grease
Check for continuity in both directions with a cir-
leakage (wipe off if tiny amount of grease).
cuit tester.
Replace it if faulty. It is easier to check for noise
The diode is faulty if continuity is present in
and rattle when it is press-fitted into shaft than
both directions or no continuity is in both direc-
when it is a single unit.
tions. Replace the rectifier ASM.
3. Coil ASM
• Measure the resistance between terminal por-
tions with a circuit tester.
Replace the coil ASM if the measured value is
outside the specified value.
Name
1. Positive Diode
2. Diode Terminal
3. A Part of Negative Diode
WSHK0098
4. Assembly of rear bracket to stator ASM and front
bracket to rotor ASM
• The rotor bearing and rear bracket are engaged
tightly. Heat the bearing box area of rear
bracket to 50 — 60°C {122 — 140°F} prior to
assembly.
• After re-assembling the generator, rotate the
pulley to confirm that the rotor rotates smoothly.
Bench Test
5. Front bearing
• Check the bearings for noise, rattle or grease
leakage (wipe off if tiny amount of grease).
Replace it if faulty.
It is easier to check for noise and rattle when
the bearing is press-fitted into bracket than
when it is a single unit.
6. Regulator
• The regulator cannot be checked with a circuit
tester.
After re-assembling the generator, check it to WSWG0023
make sure that regulator controls the voltage

for generator. Regulated voltage check
• Wire as shown in the illustration.
Use an ammeter with 100 A rating and a voltmeter
Reassembly with 30 V rating.
Assembly can be performed in the reverse order of dis- Use a 50 A or over rated ampere meter for testing
assembly. However, be careful with the following. parts that have adjustable load resistance.
1. Bearing is filled with grease and is sealed, so there • Close the switch 1. Leave the switch 2 open.
is no need to apply oil or grease. At this time the lamp comes on.
If it does not, check the voltage on L terminal.
CAUTION: If the voltage is almost the same as battery volt-
Keep a bearing with resin band for rotor shaft away age, check the generator.
from oil. Wipe off oil on bearing box area of rear If the voltage is low, lamp or the circuit is open.
bracket. Oil may cause creep. • Increase the generator speed gradually.
Make sure that the lamp goes off before the speed
2. Use a high temperature solder (melting point:
reaches approx. 1,300 rpm.
230°C {446°F}).
Notice the voltage. If the voltage is not controlled
Using a soldering iron (with 180 — 270 watt), sol-
and exceeds 30 V, the IC regulator may be faulty.
dering must be performed quickly (within five sec-
If the voltage does not exceed battery voltage, the
onds) not to heat the rectifier.
generator does not generate electric power.
3. Tightening torque for various sections Check the generator again.
Refer to 1D-25, “Torque Specifications, Genera- If the lamp does not go off, check the generator
tor”. again.
CAUTION: • Set the generator speed to approx. 5,000 rpm and
Be careful not to overtighten them. read an ammeter.
If the value is 5 A or less, read indication on a volt-
meter. This is regulated voltage.
If an ammeter shows 5 A or more, keep charging
for a while until it shows below 5 A or replace the
battery with full-charged one.
If regulated voltage is out of specified value,
replace the regulator.
Output current test

Output current test is performed to check if the genera-
tor generates rated output.
• After checking regulated voltage, decrease the
generator speed until it stops.
• Close the switch 1. The lamp should come on.
• Set the value of load resistance to maximum (mini-
mum current) and close the switch 2.
• Increase the generator speed to 5,000 rpm and
keep it. Adjust the load resistance so that output
current becomes maximum.
Keep this condition for 15 minutes and increase in
temperature of the generator.
15 minutes later, set the generator speed to the
specified speed (2,500 and 5,000 rpm) and then
adjust the load resistance so that output current
becomes maximum in this condition.
In this time, if indication of ammeter is within speci-
fied value, the generator is normal.
If it is the specified value or less, check the genera-
tor again according to “Inspection”.
Revolution 2,500 rpm 5,000 rpm

speed
Output characteris- Voltage 27 V 27 V
tic (hot)
Current 42 A or 50 A or
more more
Field coil resistance (at 20°C 4.4 — 5.2 Ω
{68°F})
Regulated voltage by regulator 28 — 29 V
Revolution direction (viewed from Clockwise
pulley side)
3.4 {0.4 / 30 lb in}
5 {0.5 / 44 lb in} 8.8 {0.9 / 78 lb in}
147 {15.0 / 108}
3.4 {0.4 / 30 lb in}
3.4 {0.4 / 30 lb in}
3.4 {0.4 / 30 lb in}
WSWG0013
6WG1 Lubricating System 1H-1
Engine
6WG1 Lubricating System
Table of Contents
Lubrication System................................................1H-2
Service Precautions ...........................................1H-2
Explanations on Functions and Operation .........1H-2
Specifications .....................................................1H-4
Maintenance Standard .......................................1H-4
Oil Filter.................................................................1H-5
Components.......................................................1H-5
Disassembly.......................................................1H-6
Reassembly .......................................................1H-6
Oil Pan, Oil Jet ......................................................1H-7
Components.......................................................1H-7
Removal .............................................................1H-8
Installation ..........................................................1H-8
Torque Specifications.......................................1H-11
Oil Pump .............................................................1H-12
Components.....................................................1H-12
Disassembly.....................................................1H-13
Inspection.........................................................1H-13
Reassembly .....................................................1H-14
Oil Cooler ............................................................1H-17
Components.....................................................1H-17
Disassembly.....................................................1H-18
Inspection.........................................................1H-18
Reassembly .....................................................1H-19
Special Tool ........................................................1H-21
List of Special Tool...........................................1H-21
1H-2 6WG1 Lubricating System
Lubrication System
Service Precautions Explanations on Functions and Operation
• Remove old liquid gasket completely from liquid The lubrication system uses oil pump, full flow filter,
gasket applied area on each parts using a scraper water-cooling oil cooler, oil jet for cooling piston.
during disassembly. Wipe off oil, water, dust, etc.
with a cloth and apply specified liquid gasket on
each area.
• Apply appropriate amount, not excessively or
insufficiently. Applying excessively causes clog-
ging in oil gallery or oil jet resulting in seizure, and
applying insufficiently causes leakage of oil or
water.
• Be sure to re-apply upon itself when starting and
finishing application.
Lubricating system diagram

Oil pump structured diagram
Name
1. Oil Pump Body 7. Oil Pump Cover
2. Oil Pump Drive Gear 8. Relief Valve
3. Ball 9. Split Pin
4. Driven Gear 10. Spring Seat
5. Drive Gear 11. Spring
6. Driven Gear
Specifications
Item Specification
Lubrication device Forced circulation type
Oil pump Type Gear type
Discharge amount (L/min) 154 (pump speed 3,200 rpm, discharge pressure 539
kPa {78 psi})
Relief valve opening pressure kPa {psi} 686 {99}
Oil gallery relief valve opening pressure kPa {psi} 441 {64}
Main oil filter type Full flow filter paper type
Main oil filter bypass valve opening pressure kPa {psi} 98 {14}
(intake/outlet oil pressure difference)
Oil cooler type Water cooling multi-sheet type 6 layer
Oil thermostat opening temperature °C {°F} 98 {208}
Engine oil level Oil pan L {qts} 37 — 52 {39 — 55}
Full capacity L {qts} 42 — 57 {44 — 60}
Item Nominal Assembly standard Service limit

dimension
Clearance between the oil pump body inner wall and mm {in} — 0.050 — 0.098 0.15
gear tip {0.0020 — 0.0039} {0.0059}
Clearance between oil pump body cover and gear mm {in} — 0.040 — 0.094 —
{0.0016 — 0.0037}
Outside diameter of the driven gear shaft mm {in} φ20 — φ19.9
Oil pump
{0.7874} {0.7835}
Clearance between driven gear shaft and pump body mm {in} — 0.040 — 0.074 —
{0.0016 — 0.0029}
Interference of the drive gear shaft and drive gear mm {in} — 0.019 — 0.047 —
{0.0007 — 0.0019}
Oil Filter
Components
Name
1. Body 3. Cartridge Oil Filter
2. Nipple 4. Splicing Fittings (Machine Side Components)
Disassembly
The oil filter is a sub oil filter (machine side installation)
and not installed to the engine.
1. Remove the cartridge filter using the oil filter
wrench.
Oil filter wrench: 1-8522-1097-1
2. Remove the nipple.
• If there are no problems with the screw thread
of the nipple screw, do not remove it.
3. Clean the oil passages inside the body.
Reassembly
1. Set the body.
2. Apply Loctite to the nipple and install it.
3. Install the cartridge oil filter.
• Apply engine oil to the O-ring of the cartridge oil
filter, screw it into the nipple of the body, and
tighten to the specified torque.
Oil filter wrench: 1-8522-1097-1
Tightening torque:
64 N⋅m {6.5 kg⋅m/47 lb⋅ft}
WSWG0082
4. Port opening splicing fittings (machine side compo-

nents)
• Port opening splicing fittings are not installed to
the engine.
• The tightening torques for the splicing fittings
are shown below.
Tightening torque:
70 N⋅m {7.1 kg⋅m/52 lb⋅ft}
Oil Pan, Oil Jet

Components
Name
1. Oil Jet 6. Oil Pan
2. Joint Bolt 7. Bracket (Oil Pan Spacer)
3. Oil Strainer Bracket 8. Oil Strainer
4. Gasket 9. O-ring
5. Spacer (Crank Case – Oil Pan)
Removal Installation
1. Remove the oil pan. 1. Install the oil jet.
• Align the convex part of the oil jet with the posi-
tioning hole of the cylinder block, and tighten
six places with the joint bolt to the specified
torque to fix it.
Tightening torque:
70 N⋅m {7.1 kg⋅m/52 lb⋅ft}
2. Remove the spacer and bracket (oil pan).

4. Remove the oil strainer.
5. Remove the O-ring for the oil strainer.
6. Remove the oil strainer bracket.
7. Remove the joint bolt for the oil jet.
8. Remove the oil jet. Important:
Be careful when handling the pipe of oil jet as it
deforms easily.
2. Install the oil strainer bracket.

3. Install the O-ring to the oil strainer.
4. Install the oil strainer and tighten up according to
the order shown in the illustration.
Tightening torque:
49 N⋅m {5.0 kg⋅m/36 lb⋅ft}
5. Install the spacer and gasket to the crankcase. 6. Install the oil pan to the spacer.
• Apply liquid gasket ThreeBond No.TB1207B by • Degrease the installation surface of the oil pan
approx. 3 — 4 mm {0.12 — 0.16 in} thickness and flange side, flange R, and oil pan spacer.
width to the lower surface of mating portion (1) of • Apply liquid gasket along the line on the dia-
the cylinder block, flywheel housing and gear case. gram below.
Liquid gasket: TB1207B
• Aim for a liquid gasket diameter of φ4 mm {0.16
in} (φ3.5 — 4.5 mm {0.14 — 0.18 in}).
• Apply liquid gasket, then assemble the oil pan
within 7 minutes. If more than 7 minutes
passes, use a gasket remover to remove the
liquid gasket, then re-apply the gasket and pro-
ceed to re-assemble the parts.
• When installing the oil pan, erect about four
guide studs for positioning in the oil pan spacer
bolt holes.
• After tightening the oil pan, do not remove any
of the protruding gasket from the inner or outer
circumference of the oil pan.
• Do not fill the engine with oil or start the engine
until at least 30 minutes has passed since the
parts were installed.
• Install the spacer through the gasket, and
tighten in a clockwise direction starting with the
center of the side.
• Tighten to the specified torque again at the end.
Tightening torque:
38 N⋅m {3.9 kg⋅m/28 lb⋅ft}
Name
1. Line connected to the bolt hole perimeter line
(inner side)
2. Oil pan R finish line
3. Apply to the constant clearance along the oil pan
angle R
Name
1. Aim to apply so that the edge of the gasket is on
the R finish line
2. Aim to apply so that the edge of the liquid gasket
includes the bolt hole outer circumference
Name
1. Spacer
2. Oil Pan
• Install the oil pan through the gasket, and

tighten in a clockwise direction starting with the
center of the side.
• Tighten to the specified torque again at the end.
Tightening torque:
19 N⋅m {1.9 kg⋅m/14 lb⋅ft}
69 {7.0 / 51}
49 {5.0 / 36}
38 {3.9 / 28}
19 {1.9 / 14}
WSWG0014
Oil Pump
Components
Name
1. Cover 7. Split Pin
2. Ball 8. Oil Pump Drive Gear
3. Oil Pump Cover 9. Spring Seat
4. Driven Gear 10. Spring
5. Drive Gear Shaft 11. Oil Relief Valve
6. Oil Pump Body
1. Remove the cover. Oil relief valve
2. Extract the ball. • Check the oil relief valve and spring for damage.
3. Remove the split pin.
Note:
Be careful when extracting the split pin as the spring
may also fly out and become lost.
4. Remove the spring seat.

5. Remove the spring.
6. Remove the oil relief valve.
Driven gear
• Measure the clearance between the inner wall of
the oil pump body and the gear.

Clearance between the 0.050 — 0.098
body inner wall and gear {0.0020 — 0.0039}
7. Remove the oil pump drive gear. Measure the clearance with the drive gear in the
• Use a gear remover to remove the drive gear. same way.
8. Remove the oil pump cover. • Measure the clearance between the oil pump
9. Remove the driven gear. cover and gear.
10. Remove the drive gear shaft. Assembly standard mm {in}
11. Pay special attention to cleaning the inside of the
Clearance between cover 0.040 — 0.094
oil pump body.
and gear {0.0016 — 0.0037}
• Measure the outside diameter of the driven gear

shaft and the clearance between the shaft and the
pump body.
Reassembly
1. Apply a small amount of engine oil to the oil pump
Nominal Assembly Service body inner wall.
dimension specification limit
2. Apply engine oil to the drive gear shaft and insert
into the body.
Outside diameter φ20 φ19.9 3. Install the oil pump drive gear.
—
of the shaft {0.7874} {0.7835}
• Turn the drive gear in the same direction as
Clearance 0.04 — 0.074 shown in the illustration, and press-fit it with a
between the shaft — {0.0016 — — press until the gear end face is the same flat
and pump body 0.0029}
surface as the shaft head side.
Measure the outside diameter and clearance of the

drive gear side in the same way.
Name
1. Drive Gear
2. Drive Gear Shaft
• Measure the interference of the shaft and drive
gear.

Interference 0.019 — 0.047 {0.0007 — 0.0019}
4. Apply engine oil to the driven gear, and install it to 9. Install the split pin and fix each of the parts.
the pump body.
10. Insert the ball.

5. Install the oil pump cover. 11. Install the cover.
Tightening torque: 12. Check the oil pump operation.
M10: 39 N⋅m {4.0 kg⋅m/29 lb⋅ft} • After completing the re-assembly, rotate the
M8: 18 N⋅m {1.8 kg⋅m/13 lb⋅ft} drive gear by hand and confirm that it operates
smoothly.
6. Apply oil to the oil relief valve and install it.

7. Apply oil to the spring and install it.
8. Apply oil to the spring seat and install it.
18 {1.8 / 13}
18 {1.8 / 13}
39 {4.0 / 29}
WSWG0015
Oil Cooler
Components
Name
1. Cover 7. Oil Thermo Valve
2. Gasket 8. O-ring
3. Body Case 9. Oil Pipe
4. Seal Ring 10. Oil Cooler Element
5. Oil Thermo Valve Support 11. Water Guide
6. Spacer
1. Remove the cover. Oil cooler element
2. Remove the water guide. • Check the oil cooler element for cracks.
3. Remove the oil cooler element. • Carry out an inspection by red check if required.
4. Oil cooler element cleaning

• Pour cleaning fluid into the element and soak the inside Oil thermo valve
for approx. 10 hours. After that remove approx. 1/3 of • Inspection of the oil thermo valve for clogging/
the cleaning fluid, then eject the rest from the oil port by damage
blowing through approx. 196 kPa {28 psi} of com- Check the piston and valve seat surface for wear
pressed air. This operation can be repeated a number or damage.
of times depending on how dirty the element is. Also, check the spring for damage or weakness.
• Operation check of oil thermo valve
CAUTION: Check whether valve is open at 98°C {208°F}.
Fire is strictly prohibited near the cleaning fluid. Oil thermostat opening temperature: 98°C {208°F}
Wear protective glasses and masks, and the work
must not be carried out in a closed room.
Using undiluted Using diluted with

solution diesel oil
Hi-aromu 2S (New
❍ —
Nippon Oil)
Suwazoru 310
❍ —
(Maruzen)
Hi-zoru (Showa) ❍ —
Mobile Zol A (Mobil
— ❍
Sekiyu)

6. Disconnect the oil pipe.
7. Remove the O-ring for the oil pipe.
8. Remove the oil thermo valve.
9. Remove the spacer.
10. Remove the oil thermo valve support.
11. Remove the seal ring.
12. Clean the inner wall of the body case and check for
corrosion, etc.
Reassembly 7. Install the oil pipe and tighten the bolts.
1. Set the body case. Tightening torque:
2. Be careful with the seal ring direction when install- 37 N⋅m {3.8 kg⋅m/27 lb⋅ft}
ing.
8. Install the gasket to the oil cooler element.

Name
9. Install the oil cooler element and tighten the nuts.
1. Seal Ring
2. Anti-rotation Stopper Tightening torque:
3. Oil Thermo Valve Support 25 N⋅m {2.5 kg⋅m/18 lb⋅ft}
• Line up the anti-rotation stopper section and

install the oil thermo valve.
10. Install the water guide and tighten the screw.

Tightening torque:
3. Install the oil thermostat support. 4 N⋅m {0.4 kg⋅m/35 lb⋅in}
4. Install the spacer. 11. Install the cover and tighten the bolts.
5. Install the oil thermostat. Tightening torque:
6. Install the O-ring to the oil pipe. 18 N⋅m {1.8 kg⋅m/13 lb⋅ft}
39 {4.0 / 29}
50 {5.1 / 37}
78 {8.0 / 58}
39 {4.0 / 29}
69 {7.0 / 51}
39 {4.0 / 29}
88 {9.0 / 65}
43 {4.4 / 32}
WSWG0016
Special Tool
1-8522-1097-1
Oil filter wrench
Rank A
1852210971
6WG1 Intake system 1J-1
Engine
6WG1 Intake system
Table of Contents
Turbocharger System.............................................1J-2
Service Precautions ............................................1J-2
Explanations on Functions and Operation ..........1J-2
List of Trouble Symptom .....................................1J-3
Maintenance Standard ........................................1J-3
Turbocharger..........................................................1J-4
Components........................................................1J-4
Disassembly........................................................1J-5
Inspection............................................................1J-8
Maintenance Standard ......................................1J-10
Reassembly ......................................................1J-11
1J-2 6WG1 Intake system
Turbocharger System
Service Precautions • When removing or installing the turbocharger, seal
the turbine housing, compressor housing, and oil
• The turbocharger cannot be disassembled since it
supply intake and outlet to prevent dust particles
is finished extremely precisely at high speed
getting inside.
(approx. 100,000 rpm). If a fault is found, the turbo-
charger ASM must be replaced. • When replacing the turbocharger and after install-
ing the new turbocharger, inject 3 — 5 cc of engine
oil before installing the oil pipe.

Turbocharger Structured Diagram
Name
1. Compressor Cover 4. Turbine Wheel
2. Shaft 5. Compressor Wheel
3. Turbine Housing

If faulty vibrations occur. Caused by damaged bearing and Check and repair.
contact between rotary part and
its surrounding area.
Bearing failure is caused by
neglecting oil changes, foreign
matters in the feed pipe, clogged
oil filter, driving with a failure, and
repeated sudden starts and stops.
If the lubrication system is normal, Check and repair.
and damage caused by contact
between the rotary part and its
surrounding area is found, imbal-
anced rotary part or bent shaft is
suspected. This is caused by
using a worn bearing or damaged
turbine wheel or compressor
wheel due to foreign matters get-
ting in.
Output is lowered although turbocharger seems Gas leakage from exhaust system Repair or replace.
almost normal. Deformed exhaust muffler, exces- Repair or replace.
sive exhaust resistance due to
carbon deposits
Air leakage from compressor dis- Clean or replace.
charge side, dirt in air cleaner ele-
ment
Compressor internal section dirty Clean.
Rotor shaft section dirty Disassemble and clean.
Oil infiltrates into exhaust pipe or intake pipe. Dirt in oil separator, oil bypass Clean or replace.
Exhaust gas is white. due to clogging
Clogged, crushed or deformed Repair or replace.
drain pipe
Worn piston ring, or too much Replace.
abrasion of the ring grooves
Defective bearing is the cause for Repair or replace.
piston ring section damage
Clogged, crushed or deformed Repair or replace.
breather hose
Intake duct crushed or deformed Repair or replace.
Air cleaner clogged Replace element.
Maintenance item Name value Assembly standard mm {in} Remarks

Shaft orientation play 0.075 — 0.115 {0.0030 — 0.0045}
Turbocharger
Components
Name
1. Compressor Cover 13. Shaft & Turbine Wheel
2. Nut 14. Piston Ring
3. Compressor Wheel 15. Turbine Back Plate
4. Snap Ring 16. Coupling ASM
5. Insert 17. Snap Ring
6. Piston Ring 18. Bearing
7. Thrust Sleeve 19. Snap Ring
8. O-ring 20. Bearing Housing
9. Oil Deflector 21. Snap Ring
10. Thrust Bearing 22. Bearing
11. Thrust Ring 23. O-ring
12. Turbine Housing
Disassembly 3. Unfasten the snap ring (1).
CAUTION:
Take care not to drop or knock the compressor
wheel or turbine wheel during the time from disas-
sembly to reassembly, because the blades of these
parts are bent easily.
1. Remove the coupling ASM.
CAUTION:
When re-assembling, the positional relationships
between the positions of the compressor cover,
bearing housing, and turbine housing are very
important. Always use a punch or marker pen to
mark where the parts line up with each other.
4. Remove the compressor cover (1) by gently tap-

ping around its circumference with a plastic ham-
mer or similar tool.
CAUTION:
Make sure that the compressor wheel does not hit
the compressor cover.
Name
1. Bearing Housing
2. Coupling ASM
3. Turbine Housing
2. Remove the turbine housing (1).

5. Remove the nut. 7. Use snap ring pliers to remove the snap ring.
• Hold the turbine housing in a vise, and insert
the bearing housing into the turbine housing. CAUTION:
Press the shaft & turbine wheel boss with a 17 Just in case the snap ring pliers slip off the snap
mm {0.67 in} box, and use a 14 mm {0.55 in} ring, cover with your hand to stop the snap ring
box to remove the lock nut that is fixing the from flying-off and getting lost.
compressor wheel.
8. Draw out the shaft & turbine wheel from the bear-
Name
ing housing.
1. Turbine Housing
2. Compressor Wheel CAUTION:
3. Bearing Housing Do not attempt to repair bent blades or blades that
have many scratches etc. Replace them with new
6. Remove the compressor wheel (1). parts.
• Hold the turbine wheel with one hand, and gen-
tly rotate the compressor wheel with the other
hand to remove it.
CAUTION:
Do not attempt to repair bent blades or blades that
have many scratches etc. Replace them with new
parts.
Name
1. Turbine Wheel
2. Bearing Housing
3. Piston Ring
9. Remove the insert. 18. Cleaning
• Use two screwdrivers to gently extract the • Visually check all of the parts before cleaning,
insert from the bearing housing, then remove and examine any discoloring or scratches that
the next component. may become difficult to see after cleaning.
10. Remove the piston ring. • Soak the disassembled parts in a non-flamma-
11. Remove the oil deflector. ble solvent (Daido Chemical Industry CO., Ltd.
Daicleaner T-30) to remove any oily dirt or car-
12. Remove the thrust sleeve.
bon from the parts. Do not soak the O-ring,
13. Remove the thrust ring (C). bearing, or thrust bearing.
14. Remove the thrust bearing.
15. Remove the thrust ring (T).
16. Remove the piston ring from the shaft & turbine
wheel.
17. Remove the turbine back plate.
Remove the following parts from the bearing hous-
ing.
a. Remove the bearing.
b. Remove the snap ring.
c. Remove the bearing housing.
d. Remove the O-ring.
e. Remove the O-ring.
• Blow all inside and outside surfaces with com-

pressed air.
Name
1. Bearing Housing
2. Snap Ring
3. Bearing
4. Turbine Back Plate
5. Piston Ring (T)
6. Shaft & Turbine Wheel
7. O-ring • Use a plastic scraper or stiff bristled brush to
8. O-ring clean off dirt deposits.
9. Bearing
10. Snap Ring CAUTION:
Do not scratch or damage any of the parts.
When using shot blasting, always cover both sides
of the compressor wheel, shaft & turbine wheel
screw section, shaft section and ring slot section
beforehand, and protect the rear side against
becoming rough or weakened.
• Blow all inside and outside surfaces again with

clean compressed air.
Inspection
Bearing housing
• Measure the internal diameter of the bearing insert
section.
If the measurement is the limit or more, replace the
bearing housing.

Bearing housing inside diameter φ20.506 {0.80732}
• Apply clean engine oil to all sliding parts.

If the thread sections, shaft section, or ring slot
section rust, buff the rusty sections to remove
the rust. Do not damage the surfaces with the
file.
Bearing
• Measure the outside diameter of the bearing.
If the measurement is the limit or less, replace the
bearing.

Bearing outside diameter φ20.382 {0.80244}
• Measure the inside diameter of the bearing.

If the measurement is the limit or more, replace the Shaft & turbine wheel
bearing. • Measure outside diameter of the shaft & turbine
wheel journal section.
Bearing inside diameter φ12.042 {0.47409} shaft & turbine wheel.

Shaft outside diameter φ11.996 {0.47228}
• Measure the length of the bearing.

bearing.
• Set a dial gauge to the immediate width of the shaft
thread section and measure the amount of bend.
Bearing length φ11.94 {0.47008} If the dial gauge runout width value is the limit or
more, replace the shaft & turbine wheel.

Shaft bend φ0.015 {0.00059}
CAUTION:
Replace the shaft. Do not attempt to repair the shaft
bend.
Name
Insert 1. Ring End
• Fit a new piston ring firmly into the insert, and mea- 2. Insert
sure the piston ring end gap. 3. Piston Ring
If the measured end gap falls outside of the stan-
Parts for replacement when disassembling
dard value, replace the insert.
• Piston ring (C)
Limit of usage mm {in} • Piston ring (T)
Piston ring end gap 0.05 — 0.25 {0.0020 — 0.0098} • O-ring
Name Assembly standard Service limit

Maintenance item value Standard clearance Clearance Remarks
Bearing insert section inside diameter for the φ20.5 φ20.506
bearing housing {0.8071} {0.80732}
Outside diameter φ20.382
{0.80244}
Inside diameter φ12.042
Bearing
{0.47409}
Length 11.94
{0.47008}
Journal diameter of shaft & turbine wheel φ12.0 φ11.996
{0.4724} {0.47228}
Shaft & turbine wheel concentricity 0.015
{0.00059}
Piston ring end gap 0.05 — 0.25 With the piston ring
{0.0020 — 0.0098} fixed in the insert
Shaft & turbine wheel and turbine housing clear- 0.39 — 1.0 {0.0154
ance — 0.0394}
Shaft & turbine wheel shaft orientation clearance 0.075 — 0.155
{0.0030 — 0.0061}
Shaft & turbine wheel and turbine back plate 0.48 — 0.92
clearance {0.0189 — 0.0362}
Reassembly
1. Check the bearing housing for dirt, then set it.
2. Install the snap ring.
• Insert each of the snap rings into the bearing
housing, with the rounder shaped part inserted.
Name
1. Bearing
2. Snap Ring
3. Bearing Housing
4. Snap Ring
5. Bearing
Name 6. Turbine Back Plate
1. Bearing 7. Piston Ring
2. Snap Ring 8. Shaft & Turbine Wheel
3. Bearing Housing
4. Snap Ring 7. Temporarily install the bearing housing to the tur-
5. Bearing bine housing, and temporarily tighten the coupling
ASM.
3. Install the bearing.
• Apply engine oil to the inner and outer surfaces
of the bearing and install it.
4. Install the turbine back plate.
5. Install the piston ring to the shaft & turbine wheel.
• Apply engine oil to the piston ring, and install to
the shaft & turbine wheel. Do not allow the oil to
become too spread, and do not twist the end.
6. Install the shaft & turbine wheel to the bearing
housing.
CAUTION:
• Do not over apply pressure and install to the
shaft & turbine wheel when the core is not stick-
ing out. Pressing in with too much pressure will
cause damage to the ring and cause the shaft to
bend.
• Take care not to damage the shaft & turbine
8. Install the thrust ring.
wheel blades section.
CAUTION:
Wipe the end surface of the thrust ring and both
end surfaces of the thrust sleeve with dry tissue
paper to completely remove dirt and oil.
9. Install the thrust bearing. 14. Install the insert.
• Apply engine oil to the inner surface of the
thrust bearing and install it.
CAUTION:
Wipe the layered section of the shaft, and both end
surfaces of the thrust ring with dry tissue paper to
completely remove dirt and oil.
Name
1. Insert
2. Piston Ring
3. Oil Deflector
4. Thrust Sleeve
10. Install the oil deflector.

11. Apply grease to the O-ring inside the bearing hous-
ing and install it.
12. Install the piston ring to the thrust sleeve.
CAUTION:
• When installing the piston ring to the thrust
sleeve, do not allow the grease to become too
spread, and do not twist the end.
• Apply engine oil to the piston ring installed to
the thrust sleeve. Insert the thrust sleeve
through the end first and carefully install it. Take
care not to damage or scratch the piston ring.
13. Install the thrust sleeve to the insert.
Name
1. Shaft
2. Compressor Wheel
3. Nut Section Molybdenum Application
4. O-ring Section Grease Application
15. Install the snap ring. • Set the dial gauge to the shaft & turbine wheel
• Turn the taper side of the snap ring upwards, tip. Move the shaft & turbine wheel in the shaft
and install it to the bearing housing using snap direction and measure the clearance between
ring pliers. the shaft & turbine wheel and turbine housing.
• If the measured value is outside of the specified
value, disassemble once again and investigate
the cause.
Standard clearance mm {in}

Shaft axis direction 0.39 — 1.0 {0.0154 — 0.0394}
clearance
CAUTION:
• Be careful with the orientation of the snap ring.
• Insert the snap ring into the bearing housing
slot by gently tapping both division openings
with a screwdriver.
• When tapping the snap ring with a screwdriver
and hammer, be careful not to allow the screw-
driver to hit the bearing housing. 16. Install the compressor wheel.
• Install the sub-assembled turbine housing to a
vise.
• Wipe the end surface of the thrust sleeve and
both end surfaces of the compressor wheel with
dry tissue paper to completely remove dirt and
oil.
• Install the compressor wheel.
CAUTION:
• Wipe off all oil from the compressor wheel fit
insert section of shaft.
Name
1. Bearing Housing
2. Snap Ring
17. Tighten the nuts.
• Apply molybdenum disulfide to the thread sec-
tion of the lock nut, and tighten to the specified
torque.
Tightening torque:
20 N⋅m {2.0 kg⋅m/15 lb⋅ft}
• Remove the turbine housing from the bearing

housing, install the compressor cover, and take
the following measurements. Measure the
clearance between the turbine back plate and
rear side of the turbine wheel using a thickness
gauge.
• If the measured clearance value is outside of
the specified value, disassemble once again
CAUTION:
and investigate the cause.
The compressor wheel cannot be installed after
molybdenum disulfide has been applied to the Standard clearance mm {in}
shaft screw section.
Clearance between back 0.48 — 0.92 {0.189 — 0.362}
• Set the dial gauge to the shaft & turbine wheel plate and wheel rear side
tip.
Move the compressor wheel in the shaft direc- CAUTION:
tion and measure the amount of play. Always use two thickness gauges, and measure at
• If the measured play value is outside of the the tips of the blades.
specified value, disassemble once again and
investigate the cause.
Standard clearance mm {in}

Shaft axis direction 0.075 — 0.155 {0.0030 — 0.0061}
clearance
18. Apply grease to the O-ring (bearing case outer cir- 21. Install the turbine housing (1).
cumference) and install it. • Check the assembly direction of the turbine
19. Check the assembly direction of the compressor housing and install it to the bearing housing.
cover when installing it.
22. Apply Molycote to the thread section of the cou-

20. Install the snap ring. pling ASM, and tighten it to the specified torque.
Tightening torque:
6 N⋅m {0.6 kg⋅m/53 lb⋅in}
Name
1. Coupling ASM
2. Turbine Housing
3. Bearing Housing
6WG1 Preheating System 1K-1
Engine
6WG1 Preheating System
Table of Contents
Preheating System................................................ 1K-2
Service Precautions ........................................... 1K-2
Explanations on Functions and Operation ......... 1K-2
Function Check .................................................. 1K-3
List of Trouble Symptom .................................... 1K-4
Specifications ..................................................... 1K-4
1K-2 6WG1 Preheating System
Preheating System
Service Precautions
Adequate care should be taken as over-tightening the
glow plug could lead to damage.

The preheating system employs QOS-II system. Also,
the timer is controlled by the controller.
6WG1 Preheating System 1K-3
Function Check Sensor and temperature resistance values (for
engine control)
Check and repair of QOS II
Temperature °C {°F} Resistance (kΩ)
1. Thermo-sensor check
• The sensor installation position is on the left −10 {14} 9.20
side of the cylinder head. 20 {68} 2.50
50 {122} 0.84
90 {194} 0.247
100 {212} 0.190
110 {230} 0.148
2. Glow plug check

• Use a circuit tester to measure the resistance of
the glow plug.
• If the measured value deviates from the speci-
fied value, then replace the glow plug.
Resistance of glow plug = approx. 4.3Ω (at nor-
mal temperature)
CAUTION:
Use a set of six glow plugs by same manufacturer.
Name
1. Inlet Manifold
2. Sensor
• Immerse the thermo-sensor into water, and

check if the resistance value varies as shown in
the graph while changing the water tempera-
ture.
1K-4 6WG1 Preheating System

The glow indicator lamp does not light up. Slow-blow fuse blown-out Replace the slow-blow fuse.
Blown fuse Replace the fuse.
Indicator valve is burnt out Replace the indicator valve.
Preheating is not performed. Fuse blown-out Replace the fuse.
Preheating time is too long or too short. Thermo-sensor fault or open/short Replace the thermo-sensor.
circuit Repair the circuit.
Faulty glow plug Replace or tighten the glow plug.
Specifications
Item Model
Preheating system Glow plug/QOS timer
Glow plug rated voltage/current (V–A) 23 – 3.0
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: HCM-TIC-GES@hitachi-kenki.com
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:
FAX: (Located at the bottom center in the page. If two or more revisions
are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

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I n t roduct ion

This Manual describes the structure and the troubleshooting of electronic

Hitachi Construction Machinery Co., Ltd

Engine Manual (1/2)

6. All regular tools, gauges and special tools should

4. Do not perform painting work or leave the engine

Seal section Product name Manufacturer's name

Procedure for using the plastigauge

Type Measurable range mm {in}

• Gently remove the crankcase, and measure the

Warning GND Ground

Note M/V Magnetic Valve

Abbrevia- Description SI (International System of Units)

Connection between main SI units and conventional units

SI Conventional unit Item, unit conversion

M Mega 106 1,000,000

• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa

Isuzu standard bolts, nuts

Pipe diameter Tightening torque Width across flats of flare nut

Special tool classification

ISUZU Diesel Engine

Measurement of the compression pressure

Removal of the glow plugs Installation of the compression gauge

Compression pres- Difference between

Set to No.1 cylinder (or No.6 cylinder) compression

4. Once the thickness gauge is inserted, tighten the

Valve clearance adjustment chart

Injection order (1-5-3-6-2-4)

Tension adjustments of the generator drive

3. Remove the starter motor.

2. Remove the generator.

• Arrange the push gauge so that the edge of the

2. Install the generator to the bracket and adjusting

Name • Loosen the generator mounting bolt and lock

Standard value mm {in}

Engine Exterior Equipment

8. Remove the bolts for the exhaust pipe mounting

6. Remove the oil return pipe (turbocharger).

10. Remove the water inlet pipe.

16. Remove the level gauge and guide tube.

22. Remove the left and right reed valve ducts.

32. Remove the fuel pipe (supply pump — common

35. Remove the oil pipe for the supply pump.

37. Loosen the bolt and remove the supply pump

36. Rotate the crankshaft and line up the No.1 cylinder

8. Clip the gasket and install the turbocharger to the

• Rotate the crankshaft in the proper direction,

12. Install PTO gear ASM.

• Install the pointer to the PTO gear ASM side.

• Install the injection pipe and clip in the positions

15. Install the common rails.

Note: 17. Install the supply pump.

• Slide the coupling, check that it has joined to

18. Install the fuel pipe (supply pump — common rail).

• Fuel pump installation order

23. Install the fuel pipe (feed pump — fuel filter).

26. Connect the fuel return pipe.

27. Connect the fuel return pipe (for the filter).

32. Clip the gasket and install the EGR valve.

37. Install the EGR pipe fixing plate.

39 {4.0 / 29} 22 {2.2 / 16}

108 {11.0 / 80}

34 {3.5 / 25} 39 {4.0 / 29}