615002 ASSEMBLY 1. Cylinder finer 113-23 2. Piston cooling nozzle. 13-25 3. Crankshaft 213-25 4. Piston and connecting rod assembly 13.28 5. Oil suction pipe 113-33 6. Idler gear 13.33 7. Oil pump 213-33 8 Camshaft... 213-34 9. Cam followers 13.34 10. Cam follower covers 113-34 11. Fuel pump drive gear : 13-35 12. Fuel injection pump assembly 13-36 13, Adjusting fuel injection timing 13.37 14, Front cover 213-38 18. Crankshaft pulley, vibration damper... 13-38 16. Flywheel housing 13-38 17. Rear seal. 13-40 18. Flywheel 13-42 19. Oil pan . 113-44 20. Cylinder head assemblies 13-44 21. Rocker arm housings ... on 13-46 22. Push rods... 13-46 23. Crossheads 113-47 24, 25, 26. 27. 28. 29. 30. 31 32, 33, 34. 35, 36. 37, 38. 41 42, 43, 44, 45. Rocker arms... . Adjusting vaive clearance Nozzle holders Head covers . Spill pipe, air vent tube. 13-49 Pulley, front support... 13-49 Drive sensor, tubes, bracket ee 13-50 ‘Thermostat housing, water pump ......13-50 Alternator assembly Adjusting V-belts... Aftercooler assembh 1351 13-51 13-51 Fuel injection pump pipes 13-52 Lubrication vaive 13-52 Engine oil filter. 13-53 Corrosion resistor and piping, wiring Turbocharger, exhaust manifold assembly. Air cleaner, bracket assembly Engine mounts FAM cree Moving to engine overhaul stand. Engine oil cooler assembly. Starting motor assembly Filling with oil 13-53 13-53 13.54 13-54 13-55 13.55 13-55 13-55 nee 13-55 13-21DISASSEMBLY AND ASSEMBLY TIGHTENING BOLTS BY THE PLASTIC RANGE TURNING ANGLE METHOD Important bolts in the 125-2 Series engines are tightened by the plastic range turning angle method. In this method, special bolts are used. By being tightened to the load (plastic range) at which they begin to be Permanently deformed, accurate and high tightening force can be obtained. The most common method for tightening bolts is the torque control method. In this method, how- ever, it is difficult to accurately control the tightening force because of the coefficient of friction. © The plastic range turning angle method is based on the initial tightening torque and the turning angle. asic 0090) as ned Axial force Torque method (conventional method Elongation of bolt + Elongation exceeding the elastic range re sults in permanent deformation. ‘® Bolts to be tightened by the plastic range turning angle method in the 125-2 Series engines. 1) Cylinder head mounting bolts 2} Main cap mounting bolts 3) Connecting rod cap mounting bolts + In the plastic range turning angle method, the permanent strain remains in bolts after they are tightened. Therefore, the number of times that each bolt can be reused is lim ited. Observe the following precautions. 1) Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. 2) If a bolt has been tightened in excess of the specified turning angle, loosen the bolt and measure the free length of bolt again. 13-22 GENERAL ASSEMBLY 3) The tightening angle should be targeted at the standard value plus or minus tolerance. * Clean every part thoroughly and check the part for dents, flaws, and blowholes. When assembling the parts, make sure that none of the oil and water passages are blocked. Preparation work ‘* Install adapter to the cylindar block, then raise it and place it on engine overhaul stand. ‘© Repair the cylinder block as follows before inserting the cylinder liners. 1) Remove rust and scale from surfaces @ and @ with sandpaper until the ma- chined surface is exposed. 2) Polish portion @ with No. 240 sandpa- per to make surface @ smooth. 3) Polish portions @ and @ with No. 240 sandpaper to make them smooth. If portion @ is square or burred, polish it with sandpaper or a scraper. Finish this portion to an especially smooth surface to protect the O-ring from damage. 4) If the pitting in surface @ is so rough that it cannot be repaired, replace the cylinder block, 618002615002 DISASSEMBLY AND ASSEMBLY 5) If surface 4 and portion R are roughened 8 with pitting, finish them smooth. Inspect the counterbore section and remove any burrs. Chips and dirt on surface ‘¢ will cause poor contact of the liner, which will lead to water leakage or improper liner pro- jection, * Repair the counterbore section if there is any drooping, corrosion, or pitting. Cylinder finer ‘* Replace the liner O-ring and clevis seal with ew parts just before assembling the liner. Method of installing liner O-rings and clevis, seal 1) Confirm that the cylinder liner O-ring grooves and the circumference of the liner are free from rust and pitting. If these surfaces are roughened with pitting, replace the liner to remove the cause of water leakage. 2) Coat liner O-rings and clevis seals with SAE No. 30 engine oil * The clevis seal and black O-ring will become swollen and degraded be- cause of oil. To prevent this, do not leave these parts immersed in oil * Apply a little oil a brush just before assembling the parts. 3) After fitting the O-ring on the cylinder liner, check that it is not twisted. If it is twisted, use a smooth bar (approx. 10 mm 0.0.) to remove the twist from the O-ring, 4) To prevent the clevis seal from twisting, continue to press the whole circumfe ence until it is installed properly in the groove. 5) Install the liner O-ring and clevis seal as shown in the diagram, ‘Install the clevis seal with the cham- fered side down. GENERAL ASSEMBLY Press ito the grove ‘chamfered side | IS Crevice seal Ll __-Biack (Etnyiene propylene udber! O-sing ‘Black (Ethylene propyiene rubber) O-ring ‘Orange (Silicon rubber) 13-23 ®DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY Method of inserting cylinder liners » 2) 3) 4 5) 6) 13-24 ® Coat the counterbore with gasket sealant (LG 6. %* Diameter of line of sealant: 91.5 - 2.0 mm Coat the liner O-ring and cylinder block O- fing groove with clean engine oil (SAE3O). * Coat by hand uniformly around the whole circumference, Set the “A or B” mark on the top surface of the liner facing the front, then insert the liner into the cylinder block, taking care not to damage the O-ring. Insert the liner by pushing with both hands and using ali your weight. * Ifthe liner does not go in smoothly when you push with your weight, there is dan- ger that the O-ring may be damaged, so check for any burrs or flashes on the cylinder block. Using liner driver F, press fit cylinder liner (1) to the cylinder block. Use the following procedure to squeeze out the gasket sealant coated on the counterbore, i) Use an old head gasket and tighten the \der head temporarily. G3=] Mounting bolt: 127 - 147 Nm (13 ~ 15 kgm) ii) Remove the cylinder head, then wipe off all the gasket sealant that was squeezed out between the cylinder liner and cylin- der block. If the gasket sealant gets on the grommet in the head gasket, it will deform the grommet and this will cause water leakage, so be care- ful to wipe off all the gasket sealant. After press fitting the cylinder liner, use dial gauge @) and measure the protrusion of the cylinder liner. * When measuring the protrusion of the liner, press the liner with a plate to re- move any rise of the liner caused by the O-ring. * Cylinder liner protrusion = 0.07 ~ 0.15 mm If the measurement is not within the speci- fied value, take the action given in MAINTE- NANCE STANDARD. 615002DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 2. Piston cooling nozzle (S6D125-2, SA6D125-2) Fit each piston cooling nozzle (2), then tighten ‘mounting bolts (1) - + Before assembling the nozzles, put them side by side and check that there is no bending or other defect g 3. Crankshaft %* The cylinder block and main bearing are se- lective fitting parts, but spare parts are avail able for supply to maintain the clearance. 1) Align the protrusion of upper main bearing = (6) with the groove in the cylinder block, and assemble to the cylinder block %* Check that there is no dirt or dust stuck to the rear face of the bearing before installing. Coat the inside surface of the bearing with SAE 30 engine oil. Do not coat the rear surface with oil. 2) Drive in the roll pin so that the protrusion from the end face of the block is 1.5 - 1.9 mm, and install upper thrust bearing (5). %* Assemble the thrust bearing so that the side with the groove is on the crankshaft side.DISASSEMBLY AND ASSEMBLY 3) 4) 5) 6 n 8) Before assembling the crankshaft, check the following points. i) Check for abnormality in the front or rear side thread. (The bolt can be screwed in smoothly by hand) ii) Check for any scratches or dents in the pin or main journal portion. iii) Check for any dirt stuck inside the oil hole. Using a nylon sling, raise crankshaft (4) and set it in the mounting position. When doing this, be careful not to let it hit the cylinder block and be damaged. ‘* When replacing the crankshaft gear, heat the new gear in an electric furnace at 200°C for at least 30 minutes, and shrink fit it Install lower main bearing (7) with the pro- jected part of the bearing aligned with the groove on the main cap. % Before installing the bearing, make sure that no foreign matter is stuck on the back of the bearing. Drive the roll pin into the No. 7 cap until its protrusion reaches 1.5 to 1.9 mm from the end of the cap, and install thrust bearings (3) to both sides. * Install the thrust bearings with the ‘grooved side facing the crankshaft. Coat the crankshaft journal with SAE30 en- gine oil, confirm that stamp No. on main cap (1) coincides with the number on the cylinder block, and install the main cap. Install the main cap with the cast number facing the engine front. Before tightening main cap mounting bolt (2), make sure as follows, i)" Measure the free length a of all bolts and check that bolt length exceeds tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. ii) Tolerance limit of bolt free length Max. 159.8 mm If the bolt length a exceeds tolerance limit, do not reuse. GENERAL ASSEMBLY owc00275 615002DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY ‘* Coat the main cap mounting bolt thread por- tion and main cap seat surface washer with engine oil (SAE3O). 9) Tighten mounting bolts (2) of main cap (1) in turn to fit main cap fully. 10) Tighten main cap mounting bolts (2) as fol- tows. ‘When tightening the bolts, start from the center and work to the outside. Tighten 7 the bolts to the specified tightening 2 cs torque in the following steps. i ¢ When using tool G to tighten main cap mounting bolts S32] Main cap mounting bolt | 1st step : Tighten to 98.1 + 9.8 Nm (10.0 + 1 kgm) | 2nd step: Tighten again to 196.1 + 4.9 Nm (20.0 = 0.5 kgm) 3rd step : 90°" i) Tighten mounting bolts to second stage with torque wrench or tool G. ii) With tool G set to mounting bolt, install tube and clip to too! G, then set clip to engine block. iii) Set angle scale of too! G to 90°, then tighten until scale reads 0° © When not using tool G Tube | G-H=) Main cap mounting bolt Angle set dat | | | | 615002 [st step Tighten to 98.1298 Nm ] ef | (10.0 £ 1 kgm) | | 2nd ster ‘ighten again to 196.1+ 49Nm | | (20.0 + 0.5 kgm) 3rd step : Mark bot and cap with felttip pen, then tighten bott 90° © With the above procedure, use a torque wrench to tighten the mounting bolts. oorooo8e |DISASSEMBLY AND ASSEMBLY 11) After tightening bolts, rotate crankshaft and check that it rotates smoothly. 12) Measure end play of crankshaft with dial gauge (3). If it is outside standard value, take action according to maintenance stand- ard. End play: 0.14 - 0.315 mm Piston and connecting rod assembly %* The piston and cylinder liner are selective fitting parts, and parts which ensure the nar- row clearance are provided as spare parts. Assemble piston and connecting rod assem- bly as follows. 1) Remove expander from oil ring, fit in oil ring groove of piston, then assemble oil ring. 2) Using too! D1, assemble piston rings (8) in the order of oil ring, 2nd ring, and top ring. ‘* When doing this, check that the expander is fitted completely in the ring groove. ‘Set the protruding part of the expander coil at 180° to the end gap of the oil ring. ‘* Assemble each piston ring as shown in the diagram. ‘Install each ring to the piston with the stamped mark facing up. 3). Install snap ring (4) on one side. 4) Heat up piston (7) in a heating furnace at 100°C for more than § minute Ifo heating furnace is available, heat in hot water at 100°C for more than 5 minutes. ‘If the piston is heated up in hot water, clean it completely after setting it. 13-28 @ GENERAL ASSEMBLY econo | Top Second. oir 615002615002 DISASSEMBLY AND ASSEMBLY 5) 6) 7” 8) Oy Coat piston bore with engine oil (SAE30), match number stamped on connecting rod with cylinder number on piston head, set numbers facing in same direction, then in- sert piston pin (6), and assemble piston (7) to connecting rod (5). Install snap ring (4) on opposite side. % Turn the snap rings to check that the left and right snap rings are completely fit- ted in the ring groove. Align protruding part of connecting rod up: per bearing (8) with notch in connecting rod, and install ®* Check that there is no dirt or dust stuck behind the surface of the bearing, then install. When doing this, the rear surface ‘must not be coated with oil ‘* Check that the bearing hole and connect- ing rod oil hole are aligned. Align protruding part of connecting rod lower bearing (9) with notch in connecting rod cap, and install. ‘* Check that there is no dirt or dust stuck behind the surface of the bearing, then install. When doing this, the rear surface must not be coated with oil Set the crankshaft for the cylinder to be as- sembled to the bottom dead center, and coat the inside surface of the connecting rod bear- ing and inside surface of cylinder liner with engine oil (SAE3O). GENERAL ASSEMBLYDISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 10) Set so that cast letters on connecting rod face front of engine (stamped number is at camshaft end), set relationship between po sitions of piston ring end gaps as shown in diagram, then insert piston and connecting rod assembly (3). ‘When inserting the piston and connect- ing rod assembly, be careful not to dam- age the piston cooling nozzle. | | Cylinder No. Vv {Go be aligned withthe cam side) Cast number {face it towards the front of the engine) 11) Using tool D2, compress piston ring and push in piston head with wooden ber. + When inserting the piston, be careful not to damage the piston cooling nozzle. Check also that the nozzle is positioned at the center of the notched portion of the piston. * When assembling the piston and con- necting rod assembly, assemble at the places where the crankshaft is at the | >" <2 a= bottom dead center. eS) ) : { | j NY cn 12) Coat connecting rod lower bearing (9) with engine oil (SAE30), check cap number, align with dowel pin, and install connecting rod cap (2) ‘When coating with engine oil, spread the oil over the whole surface with a finger. 13-30 615002DISASSEMBLY AND ASSEMBLY * When assembling a new connecting rod, mark the cylinder number with an elec tric pen (do not use a stamping tool). 13) Before tightening connecting rod bolt, make sure as follows. i) Measure the free length a of all bolts and check that bolt length exceeds tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. Tolerance limit of bolt free length: Max. 84.1 mm. If the bolt length a exceeds tolerance limit, do not reuse. 615002 14) Coat washer and thread of connecting rod bolt with engine oil (SAE30) 15) Tighten connecting rod bolts (1) in turn until connecting rod cap is tightly fitted. GENERAL ASSEMBLY bweo0275DISASSEMBLY AND ASSEMBLY * If'an impact wrench or other tool is used to tighten the bolts at high speed, the thread may be damaged, so tighten with a hand tool. 16) Tighten connecting rod bolts. ighten to 98.1 = 4.9 Nm (10.0 + 0.5 kgm) 2nd step: Mark bot and cap with felt-tip pen, then tighten bolt 90° Ist step ‘When tightening the connecting rod, see 3-9) and tighten to the specified value. 17) After installing the piston and connecting rod assembly, rotate the crankshaft and check that there is no catching or abnormal: ity in the rotation, 18) Using dial gauge @, measure side clearance of connecting rod. % Standard value for side clearance: 0.2 - 0.375 mm 19) Using gauge H, measure protrusion from top surface of cylinder block to top of pis- ton. Piston protrusion: (Push top surface of piston, and check that oil clearance is 0 and that there is no rocking) Unit: mm. ee ee (S)6D125-2 ‘S(A)6D125-2, | {Aluminium piston) | _(FCD piston) __ ogos- 1.151 | 0.984 - 1.335 | CTTeA—e—eEeE OE 13.32 @ GENERAL ASSEMBLY 615002615002 DISASSEMBLY AND ASSEMBLY 5. Oil suetion pipe Fit O-ring, install oi! suction pipe (2), then fit bracket (1) and secure in position. ‘%* After determining the mutual positions of the oil suction pipe and bracket, tighten the bolts. 6. Idler gear 1) Assemble plate (8) to engine block, then in- stall gear (7) and shaft (6), and tighten ‘mounting bolt (5). * Assemble plate (8) with the chamfered end facing the front of the engine. ==] Mounting bolt: 68.6 + 4.9 Nm (7.0 = 0.5 kgm) ‘* Precautions when assembling idler gear Align the “A” on the crankshaft gear with the “A” mark on main idler gear (7), then tighten mounting bolt (5). 7. Oil pump Fit O-ring, install oil pump (2), then tighten 4 mounting bolts (1). =] Mounting bolt: 68.4+ 4.9 Nm (7.0 + 0.5 kgm) 2) Knock in pin and install shaft (4) GENERAL ASSEMBLY cesooneeDISASSEMBLY AND ASSEMBLY 3) Assemble oil pump idler gear (3), then in- stall plate (2) and tighten mounting bolt (1) >5=] Mounting bolt : 161.8 + 14.7 Nm (65 + 1.5 kgm) 8. Camshaft Coat camshaft journal surface with engine oil (SAE30). Align “B" mark of camshaft gear with “B” mark of main idler gear, install camshaft (2), then tighten mounting bolts (1) =D Mounting bolt of plate : 66.2 + 7.4Nm (6.75 + 0.75 kgm) * When installing the camshaft, rotate the cam- shaft to prevent damage to the cam bush- * If the cam gear has been replaced, heat the ‘cam gear in an electric furnace at 200 - 240°C for more than 30 minutes, then shrink fit the ge: 9. Cam followers 1) Knock dowel ring (3) into cylinder block 2) Tighten 6 cam follower assemblies (2) with bolts (1). G3==] Mounting bolt : 51.5 + 7.4 Nm (5.25 + 0.75 kgm) 10. Cam follower covers Fit O-rings and install cam follower covers (1). SE] Mounting bolt : 11.3 + 1.5 Nm (1.15 + 0.15 kgm) 13.34 @ GENERAL ASSEMBLY 615002615002 DISASSEMBLY AND ASSEMBLY 11. Drive gear of fuel injection pump 1) Install drive case (4). 2) Knock in drive shaft gear, align “C" mark of main idler gear with “C" mark of drive gear, then install fuel injection pump drive gear @). 3) Fit washer (2), then tighten nut (1). + Fit a screwdriver between the gears to stop the gear from turning when tight ening Zoe Nut : 2403 + 147 Nm (245 +15 kom) ‘* Check that the match marks of each drive gear and idler gear are aligned. * Measure backlash and end play of each gear using a dial gauge :3 1) Standard backlash for each gear Range (mm) 0.127 ~ 0.393 0.127 - 0.393 0.139 - 0.427 0.128 - 0.405 0.082 - 0.389 GENERAL ASSEMBLYDISASSEMBLY AND ASSEMBLY. 2 Standard end play for each gear Range (mm) 0.09 - 0.48 Position 2 0.10 - 0.25 3 005-017 7 @ 0.05 5 0.03 - 0.09 12. Fuel injection pump assembly » 2) 3 4 5) 6 7 13-36 Fit engine oil dipstick guide (12), then install bracket (10). ‘S=] Dipstick guide mounting nut : 515 + 7.4 Nm (5.25 + 0.75 kgm) Knock key into fuel injection pump drive shaft, align key groove of pump coupling, then align fuel injection pump (6) with bracket pin and set in position, Remove 2 coupling bolts (5) from fuel injec- tion pump, then install flange coupling (8) and front laminated coupling (3) to engine drive shaft. When doing this, do not tighten coupling connection bolt (9). Align coupling key groove with drive shaft key, push in fuel injection pump assembly Tighten 4 mounti tion pump. Mounting bolt: 31.4 + 2.9 Nem(3.2 + 0.3 kgm)(6D125-2) 66.2 + 7.4 Nm{6.75 + 0.75 kgm)(S6D125-2) 66.2 + 7.4 Nm{6.75 + 0.75 kgm)(SAGD125-2) bolts (5) of fuel injec- Tighten 2 bolts (5) connecting coupling and drive shaft. 32 Coupling connecting bolt: 61.3 + 2.5 Nm (6.25 + 0.25 kgm) Tighten bolt (11) lightly. Tighten bolt (9) connecting pump coupling and drive shaft lightly. GENERAL ASSEMBLY ear laminated coupling eg Coupling block ‘weight ‘eecooee 615002615002 DISASSEMBLY AND ASSEMBLY 13. Adjusting fuel injection timing v 2 3) 4 5) 6) Loosen bolts and nuts (11), and check that coupling (8) is free. Install dial gauge 1. on top of cylinder block, then set gauge probe on top of piston. With piston (1) at top dead center. set gauge to 0, then rotate crankshaft 45° in reverse direction, Rotate crankshaft slowly in normal direction, and stop at position where dial gauge ‘matches specified distance (piston displace- ment) shown in table below. + For details of the fuel injection timing, see TESTING AND ADJUSTING, Stand: ard values for testing, adjusting, and troubleshooting ‘* Always rotate the crankshaft in the nor- ‘mal direction to align the position. Piston displacement for each injection tim- ing GENERAL ASSEMBLY Injection timing | Piston displacement BTOCI2" 2.15 = 0.20 BTOC13° 2.52 + 0.20 BTOC14* 2.91 = 0.20 Brociss | 334+ 0.20 BTDC16" 3.80 + 0.20 Align stamped mark on injection pump housing with stamped mark ‘b on coupling (dummy timer). Tighten injection mounting bolts (11) and bolt (9) in order. a=) Bolt (11) 88.3 + 4.9.Nm (9.0 + 0.5 kgm) Sz Bolt (9) : 78.5 + 4.9 Nm (8.0 + 0.5 kgm)DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 14, Front cover 1). Using tool 1, press fit oil seal (2) to cover. * Oil seal press-fitting tolerance a: 113 mm Xs Fill oil seal lip (50 ~ 80% of space at lip) with grease (G2-LI) 2) Coat gasket sealant, then install front cover a ‘When installing the cover, be careful not to damage the cil seal. X= Mating surface: Gasket sealant (LG-7). 3) Using a dial gauge, measure the stepped difference between the cylinder block and front cover. * Stepped difference: 0 - 0.275 mm 15, Crankshaft pulley, vibration damper Install crankshaft pulley and vibration damper (2), then tighten with 6 mounting bolts (1), G-3=) Mounting bolt 277.0 + 31.9 Nm (28.25 + 3.25 kgm) Mounting bolt (* mark) : 1765 + 19.6 Nm (18 + 2 kgm) 16. Flywheel housing Raise flywheel housing (1), coat mounting sur- face with gasket sealant, then install on cylinder block and tighten bolts (2). ATX. Contact surface : Gasket sealant (LG-7) ‘DX Coat the bolt thread and seat face with engine oil (SAE30) before tightening. 13-38 D 615002616002 DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY %* Tighten the mounting bolts of the flywheel [ housing in the order shown in the diagram | and to the following torques. | ®|®@ o|@ S35 Flywheel housing mounting bolt Unit : Nev kgm) O|® @|O Order | Target Rank | ® owe ® “Wststep [1863 GST 205305-29 «=| 8 @ ® 2nd step|274.6 (28)| 245.2 - 308.9 (25-315) | @ @ uel ine) 1). After installing the flywheel housing, meas- ure the face runout and radial runout with dial gauge 3 Radial runout : Max. 0.20 mm * Face runout: Max. 0.20 mm © Measuring face runout of flywheel housing © Measure as follows. 1) Put magnet stand (1) in contact with end face of crankshaft. 2) Set indicator so that probe of dial indicator (2) is in contact at right an- gles with end face of flywheel hous- ing. 3) Rotate crankshaft one turn, and read difference between maximum value and minimum value of indicator. * When measuring, measure at least 8 places evenly spaced around the circumference of the end face of the flywheel hous- ing. * When measuring, move the crankshaft either to the front or rear to prevent any error from being caused by the end play. * Check that the indicator returns to the original position when the crankshaft is rotated one full turn. % The indicator will fluctuate either to the left or right, 80 be careful not to misread the direction of fluctuation when the indicator is at the top or bottom, or left or right of the end face being meas- ured. 13-39DISASSEMBLY AND ASSEMBLY ring radial runout of flywheel hous- Measure as follows. Set in same condition as when measur- ing face runout, with probe of dial indi ator (2) in contact at right angles with pilot portion of fiywheel housing, then meacure. %* When measuring the radial runout, there is no error caused by the end play of the crankshaft, but the other precautions are the same as the pre- cautions followed when measuring the face runout. 4) Using dial gauge @, measure stepped dif- ference between cylinder block and flywheel housing, * Stepped difference: 0 - 0.35 mm 17. Rear seal Check condition of wear of shaft, then select standard seal or seal with sleeve for Teflon seal (lay-down lip seal) and assemble seal. * The condition of wear of the shaft can be judged from the degree of luster (touch with the flat of your finger to check that the depth ‘of wear is less than 10 uml. If there are no scratches, assemble a standard seal. In all other cases, assemble a seal with sleeve. Procedure for assembling standard seal ‘* Before assembling the seal, check that there is no damage, burrs, flashes, or rust on the housing, sliding surface of the lip and the corner of the end face of the crankshaft. * When assembling the seal, do not coat the shaft or seal lip with oil or grease. If there any oil or grease on the shaft, wipe it off completely. * Do not remove the plastic tube inside the standard seal provided as a spare part until immediately before assembling the seal. GENERAL ASSEMBLY {wlastic ube) Standard seal Seal with sleeve econ. eteonoe Lip at engine ona Lip at PTO end Assembly guide ‘plastic tube} Large inside ‘Small inside diameter end diameter end 615002615002 DISASSEMBLY AND ASSEMBLY v 2) 3 4) Put large inside diameter end of plastic in- ner tube (3) in contact with end of crank- shaft (4). * Be particularly careful not to mistake the direction when assembling Hold metal ring of seal (2) with both hands, push evenly, and use sudden pushing force to push in. After pushing in seal, remove plastic inner tube (3), Be particularly careful not to damage the seal lip when removing the inner tube. Tighten bolts (C2-2, €3-1) uniformly until end face of tool C3 contacts ends face of crank- shaft (4) to press fit seal (2). ‘* When press fitting the seal, be extremely careful not to damage the lip at the PTO ‘end when setting the tool. ‘* After press fitting the seal, remove the fed sealant layer from the outside cir- cumferencé Procedure for assembling seal with sleeve * Before assembling the seal, check that there is no damage, burrs, flashes, or rust on the housing, sliding surface of the lip and the corner of the end face of the crankshaft. ‘* When assembling the seal, do not coat the shaft, and the space between the sleeve and seal lip with oil or grease. If there is any oil or grease on the shaft, wipe it off completely. Handle the seal and sleeve as an assem- bly. Never separate them. GENERAL ASSEMBLY | | | | | aor ener c3 c3 | C34 iE] | 22 ec LIF | l | ee \ shew cectons | 13-41DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 1) Set sleeve/seal (2) to tool C2. ATAs Surface of sleeve inner tube: Gasket sealant (LG-7) 2) Put sleeve of seal in contact with end face of crankshaft, tighten bolt (C2-2) of too! G2 uni- formly until end face of too! C2 contacts ends face of crankshaft (2) to press fit sleeve/seal (2). 3) Remove tool C2 and replace with tool C3. 4) Tighten bolt (C3-2) of tool C3 uniformly until end face of tool C3 contacts ends face of crankshaft (4) to press fit sleeve/seal (2). ‘* After press fitting the seal, remove the red sealant layer from the outside cir- cumference. 18. Flywheel 1) Using eyebolt @ (Thread=12 mm, Pitch=1.75, mm), raise flywheel (1), install to crankshaft, then tighten bolts. Xs Coat the bolt thread and seat face with engine oil (SAE3O) before tight- ening. 13-42 ® 2 c2 ( Coat with ‘gasket sealant i _ C2 ] | {| T : iN | I cecoo108 615002615002 DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY * Tighten the mounting bolts of the flywheel i in the order shown in the diagram and to the following torques. Gaz] Flywheel housing mounting bolt | Uni Im (kgm) ge Ist step | 147.1 (15) [247.5 - 166.7 (13 - 17) 2nd step|289.3 (29.5) 269.7 ~ 308.9 (27.5 - 31.5) © Using dial gauge “1, measure the face runout cotoone and radial runout of the flywheel, * Face runout: 0.20 mm * Radial runout : 0.15 mm 2) Measuring face runout of flywheel ¢ Measure as follows. i) Stand magnet stand (1) at flywheel housing. ii) Set indicator so that probe of dial indicator (2) is in contact at right an- gles with end face near outside cir- ‘cumference of flywheel iii) Rotate flywheel crankshaft one turn, and read difference between maxi- 2 mum value and minimum value of indicator. * When measuring, measure at least 8 places evenly spaced around the circumference of the end face of the flywheel hous- ing. * When measuring, move the crankshaft either to the front or fear to prevent any error from being caused by the end play. * Check that the indicator returns to the original position when the crankshaft is rotated one full turn. 3) Measuring radial runout of flywheel hous- ing @ Measure as follows. Set in same condition as when measur- ing face runout, with probe of dial indi- cator (2) in contact at right angles with pilot portion of fiywheel housing or face of outside circumference, then measure. * When measuring the radial runout, there is no error caused by the end play of the crankshaft, but the other precautions are the same as the pre- cautions followed when measuring the face runout. cyDISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 19. Oil pan Fit gasket and install oil pan (1), * Assemble the oil pan gaskets with the punched direction at the same face. 20. Cylinder head assemblies ‘Assemble cylinder head assembly as follows. ” 13-44 e H in itty iw Fit lower seat (8) and install seal (7). ‘%* The seal is installed only to the ex- haust side. Coat valve stem and inside surface of valve guide with engine oil (SAE30), then assemble valve (6). On the $6D125-2 and SA6D125-2, there is a valve rotator installed instead of the lower seat. The free length of the intake valve spring on the S6D125-2 and SAGD125-2 is di ferent from the spring on the 6D125-2. The exhaust valve spring is different for engines equipped with a slide valve type exhaust brake. (New parts are painted white.) Only the length of the stem is different for the exhaust valve on engines equipped with an exhaust brake (slide type, butterfly type). (There is a B mark stamped on the valve.) Raise cylinder head and assemble valve spring (3) and upper seat (6). Using spring pusher B, compress valve spring and install valve cotters (4). * Tap the valve stem with a plastic hammer to check that the cotters are fitted securely in the valve stem groove. 615002615002 DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 2) Before tightening cylinder head bolt, make sure as follows. i) Measure the free length a of all bolts and check that bolt length exceeds toleance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. ii) Tolerance limit of bolt free length: Max. 171.4 mm + Ifthe bolt length a exceeds tolerance limit, do not reuse. 3) Check that there is no dirt or dust inside cylinder or on cylinder head mounting sur- face, then set cylinder head gasket (9) in position. %* When installing the gasket, check that the grommets have been installed and have not come out of position. | 4) Install each cylinder head assembly (2), then tighten mounting bolts (1). Xx Coat bolt thread and seat of bolt head | with antiriction compound (LM-P), se | then tighten * Tighten the mounting bolts by hand for the first 2 or 3 turns, then tighten as follows. ‘© When using tool G to tighten cylinder head ———___*—__.-__ mounting bolts Hz Cylinder head mounting bolt L ne00275 Ist step : Tighten to 98.1: 98. Nm | (10.0 = 1 kgm) FF 2nd step: Tighten again to | 137.3 + 4.9. Nm (140 = 0.5 kgm) rue | [3rd step : 90° = 15 \ Angle set dat | i) Tighten mounting bolts to second stage with torque wrench or too! G. ii) With tool G set to mounting bolt, install tube and clip to tool G, then set clip to engine block. iii) Set angle of tool G to 90°, then tighten chp until scale reads 0°DISASSEMBLY AND ASSEMBLY iv) Tighten head bolts in order shown in diagram on right * Tighten bolt 7 to 66.2 + 7.4Nm (6.5 + 0.75 kgm). When not using tool & Gam Cylinder head mounting bott ‘Ist step : hten to 98.1 + 9.8 Nm (10.0 + 1 kgm) 2nd step: Tighten again to | 137.3 + 4.9 Nm (14.0 + 0.5 kgm)! 3rd step : Mark bolt and cap with felt-tip pen, then tighten bolt 90° I © With the above procedure, use a torque wrench to tighten the mounting bolts. 21, Rocker arm housings Fit gaskets, install rocker arm housings (2), then tighten 42 bolts (1). HE) Mounting bolt : 66.2 + 7.4 Nm (6.75 + 0.75 kgm) 22, Push rods Install 12 push rods (1). * Check that the push rods are inserted se- curely into the holes in the cam follower levers. 13-46 GENERAL ASSEMBLY Joost fege"aea bot 615002615002 DISASSEMBLY AND ASSEMBLY 23. Crossheads Install 12 crossheads (1). %* Set the adjustment nut end at the exhaust end when installing the crossheads. ‘* Adjust the crosshead as follows. i) Loosen locknut and turn adjustment screw back. ii) Hold down top surface of crosshead (1) lightly with a finger, and screw in ad- justment screw (2) ii) Atter adjustment screw contacts valve ‘stem, tighten a further 20°. iv) Tighten locknut (3) to hold in position. Go Locknut : 66.2 : 7.4 Nm (6.75 + 0.75 kgm) 24, Rocker arms Fit gaskets, then install 6 rocker arms (2) and tighten with 12 bolts (1). Check that the ball of the adjustment screw is properly fitted into the socket of the push rod. Clean the oil hole in the bolts befor ing. G=3= Mounting bolt : 66.2 + 7.4. Nm (6.75 + 0.75 kgm) * Set the large hole (913) at the bottom and assemble the rocker arm shaft so that the blind ball plug is at the front. instal GENERAL ASSEMBLYDISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 25. Adjusting valve clearance Adjust valve clearance as follows. ‘* Adjust the valve clearance so that the clear- ance between the crosshead and rocker arm. is the following value. ‘* Valve clearance (both when hot and when cold) Intake valve _| Exhaust valve n * Crank the engine and adjust the vaive clear- ance of each cylinder in the firing order. Firing order: 1-5-3-6-2-4 1) Rotate the crankshaft in the normal di- fection to align pointer (2) with the 1.6 ‘TOP mark on vibration damper (1). When rotating, check the movement of the valves. 2) To adjust, insert feeler gauge between rocker arm (3) and crosshead (4) and turn adjustment screw (5) until clearance is a sliding fit. 3) Tighten lock nut (6) to hold adjustment screw (5) in position. Ge Locknut : 66.2 + 7.4.Nm (6.75 + 0.75 kgm) After tightening the lock nut, check the clearance ag 26. Nozzle holders Check that there is no dirt or damage inside the nozzle holder sleeve Fit O-rings, assemble 6 nozzle holders (2) to cylinder head, then tighten 12 bolts (1). + Tighten the nozzle holder mounting bolts uni- formly to prevent them from being unevenly tightened. [HE] Mounting bolt : 21.6 + 2.9 Nm (2203 kgm) 13-48 @ 615002DISASSEMBLY AND ASSEMBLY 27. Head covers Fit O-rings, then install 6 cylinder head covers (2) and tighten with 24 mounting bolts (1) + Apply adhesive compound and fit the O-rings of the head covers without twisting. S5=) Head cover mounting bolt 9.8 © 1.Nm (1.0 + 0.1 kom) 28. Spill pipe, air vent tube 1) Fit gaskets to both faces, then install spi pipe (2). HS Joint bolt : 12:3 +25 Nm (1.25 + 0.25 kgm) 2). Fit gaskets to both sides, then install air vent tube (1), 615002 29. Pulley, front support 1) Install front drive (1) to support (2). 2) Install 2 spacers (3) and (4) together with support (2). 3). Install pulley (5) and spacer (6) GENERAL ASSEMBLY 13-49 ©DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 30. Drive sensor, tubes, bracket 1) Install tubes (1) and (2). 2) Install erive sensor (3). Tighten the rive Sensor unt it contacts therring gear, then loosen 1.0 16 turns and lock n postion Xo Sensor thread: Gasket sealant (LG-6) FS ecknut 588588 Nm ws 1 kgm) 31. Water pump, thermostat housing 1) Fit O-ring and install water pump (4), then tighten bolts. =] Mounting bolt : 66.2 + 7.4. Nm. (6.7 + 0.75 kgm) 2) Fit gasket to tube (3) between water pump and cylinder block, then install tube. Ins for installing water pump mount- ing bolts 4) Install thermostat housing (1) and tube (2) 13-50 ® Water pump mounting bott 615002615002 DISASSEMBLY AND ASSEMBLY 32. Alternator assembly 1) Instait mounting brackets (9) and (8) 2), Install alternator assembly (7) to bracket (9), then install rod (1) with bolt (6). 33. Adjusting V-belts 1) Fit 2 V-belts (4) to pulley groove, loosen nut (2) of tension adjustment rod (1), then tighten nut (3) to adjust V-belt tension. ‘* Adjust so that the deflection is 13 mm. when the belt is pressed at the mid point with a force of 59 N (6 kg). 2) After adjusting tension, tighten bolts (10), (5), (2), and (1), 34, Aftercooler assembly 1) Raise aftercooler assembly (2), assemble mounting bolts (1) to gasket, heater (3), and gasket, then align with cylinder head and install temporarily. * Check that the gaskets are assembled se- curely. * Connect the heater wiring securely. 2) Tighten 2 mounting bolts (1) of aftercooler (2), GENERAL ASSEMBLYDISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 35. Fuel injection pump piping 1), Install lubrication tubes (1) and (2) and boost compensator tube (2). S[3=] Lubrication tube joint bolt Unit: Nev (kgm) Tube Mounting Tightening No. _position torque Cylinder block 113215 ‘ (1.18 + 0.45), | 172225 (1.78 + 6.25) Cylinder block > Mounting side ¢ (+05) Injection pump 27.0225 mounting side ¢ (2.75 25) * Before installing the lubrication tube joint bolts, check that there is no damage to the 2 gaskets, then assemble securely. 2) Install 6 fuel injection pipes (4), and secure with 2 clamps (5). GE) Fuel injection pipe: 23.5 + 1Nm (242 0.1 kgm) 3). Fit fuel filter assembly (3), then install hoses (2) and (1) Se Fuel hose : 22.1 + 2.5 Nm (2.25 + 0.25 kgm) 36. Lubrication valve Fit O-ring to lubrication valve (1), then install. 13-52 615002615002 DISASSEMBLY AND ASSEMBLY 37. Engine oil fitter 1) Install engine oil filter (2) to aftercooler. 2). Fit O-rings and install pipes (1). 3). Fit O-ring and gasket to aftercooler inlet pipe Q), then install 38. Corrosion resistor 1) Fit O-ring and gasket to aftercooler outlet pipe (4), then install %* Clamp the aftercooler pipe securely to bracket (5). 2) Install corrosion resistor (3), then connect hoses (2). 3) Connect wiring of heater relay (1). 39. Turbocharger, exhaust manifold assembly 1) Raise turbocharger and exhaust manifold as- sembly (3), fit gasket, then tighten 18 mount- ing bolts (4). ‘# Assemble the gasket with the mark on the outside. 2) Tighten mounting bolts as follows. i) Tighten mounting bolts 2 ~ 3 turns by hand. ii) After tightening bolts (1) - (3), tighten other bolts. = Mounting bolt : 66.2 + 7.4m (6.75 = 0.75 kam) 3) Connect connection hose for intake connec tor to turbocharge! Gaz Intake connector clamp. 8.8 + 0.5 Nm (0.9 + 0.05 kgm) GENERAL ASSEMBLYDISASSEMBLY AND ASSEMBLY 4) Fit gaskets to turbocharger lubrication tube inlet port (1) and outlet port (2), then install 40. Air cleaner Install air cleaner (1), then connect hose (2) from turbocharger a=) Hose clamp : 88 + 0.5 Nm (0.9 + 0.05 kgm) 41. Engine mounts 1) Install rear mounts (2). 2) Install front mount (1). 13-54 GENERAL ASSEMBLY 615002615002 DISASSEMBLY AND ASSEMBLY 42. 43, M4. Fan install fan (1), Resetting engine in engine stand 1) Sling engine assembly, remove bolts con: necting tool A1 and tool A2 to disconnect engine assembly. 2) Set engine assembly on engine stand or block. 3) Remove tool A2. Engine oil cooler assembly Fit gasket, install engine oil cooler, then tighten 17 bolts (1) S>3=] Mounting bolt : 66.2 + 7.4.Nm (6.75 + 0.75 kgm) Starting motor assembly Fit gasket and install starting motor (1) Refilling with oil 1). Check that engine drain plug is tightened. 2) Add engine oil through oit filler to specified level. ‘WH Engine oil pan : Approx. 37 ¢ GENERAL ASSEMBLY14 MAINTENANCE STANDARD 5 INTAKE AND EXHAUST SYSTEM Turbocharger nn 7 142 ENGINE BODY Cylinder head “4 Valve and vaive guide. “6 Rocker arm shaft. Crosshead Cylinder block Cylinder line: Crankshaft Camshaft... Cam follower and push rod. Timing gear Piston, piston ring and piston pin Connecting rod Vibration damper Flywheel and flywheel housing 615002 a COOLING SYSTEM Water pump and thermostat cen 14-25 Oil cooler... LUBRICATION SYSTEM Oil pump... eens M27 Main relief valve... . Regulator valve and safety valve....... 14-29 ACCESSORY Air compressor 14-30 14-1MAINTENANCE STANDARD TURBOCHARGER (S6D125-2, SA6D125-2) ‘SCHWITZER S3A TURBOCHARGER 2 No! tem Criteria Remedy Standard Repair init 1 | Radial play of rotor 0.480 - 0.650 oss Repair or replace 2 | End play of rotor 0.07 -0.12 0.142 Target (Ne (kgm) Range (Nm (kgm) 3 | Tightening torque of = 2 ange (Ne team) ieee clamp nut 9801.0) 9.8(1.0) poy { Standard size Repair limit 4 bearing 5.36 5.34 [Measuring point] Standard | _Rapair limit Outside A 1187 1155 Outside diameter diameter 5 | and bend of wheel shaft 8 24.45 24.38 Replace Bend Repair limit : 0.0076 (Total Indicated Runout) « | inside ameter of ar an ‘Measuring point Standard Repair limit 7 | Inside diameter of c 19.08 19.10 center housing D 25.43 25.43 1A @ 615002615002 MAINTENANCE STANDARD TURBOCHARGER GARRET TOS E 9 o -D 4 4 | 4 varoaea varoae- var036-2 Unit: mm No. tem Criteria Remedy ‘Standard size Repair limit 1 | Play of rotor in radial 0.076 ~0.150 0.15 2 | Play of rotor in axial 0.025 ~0.078 0.078 43 |Tiohening torque of Target (Nm (kgm) Range (Nm (kgm) blower housing bolt 128 3) 7 | Tiohtening torque of 18 Retighten turbine housing bolt 20) | Tightening torque of back 9.3 plate mounting bolt (095) Standard size Repair limit 5 | Thickness of thrust bearing 4s7 435 ‘Standard size Rapair limit A wt 1725 e 10.16 70.15 Curvature Repair imit : 0.010 (total eunout of indicator) Replace Standard epi 11.66 11.68 12.70 1273 Measuring point Standard Repair lnit € 15.80 15.81 D 78.03 18.05 14-3MAINTENANCE STANDARD CYLINDER HEAD CYLINDER HEAD Tightening order of cylinder he: ‘mounting bolt sisorace e1sorsoa Unit: mm No. ‘tem Criteria Remedy 1 | Distortion of cylinder head Sieaeers fener nit Repair by mounting surface oe ae grinding | Applicalbe model Standard Protrusion 7 2 ep125-2 STD. 335-425 reise eee $6D125-2 S.T.0. 3.35 - 4.25 SA60125-2 STD. 3.35 - 4.25 a Bolt No. Order | Target Nm (kgm)| Range Nm tag) Tightening torque of cylinder = 107 head mounting bots iststep 98.110) | Tighten bolts 4 | (Coat the thread areas with 0-® ‘2nd step 13710) 14 _|in accordance ‘molybdenum disutide or - Watighter wih} with bolts No. engine oi) 3rd step _| Revotise 90° 1207 ® = 68(7) ee Tightening torque of nozzle = 4 holder mounting bolt 21.22.9Nm (2.2 2 0.3 kgm) Retighten Tightening torque of ee : 5 rocker arm housing 66 + 7.3 Nm (6.75 + 0.75 kgm) 14-4 ® 615002MAINTENANCE STANDARD VALVE AND VALVE GUIDE VALVE AND VALVE GUIDE Unit: mn, No. tem rite Remedy valve Standard | Tolerance | Repair limit 1 | Amount of vaive sinking| Intake 1.88 251 Replace valve or valve seat Exhaust 1.20 1.90 Valve Standard Repair limit 2 | Thickness of vaive lip Intake 2.10 Ww Replace Exhaust 1.50 12 Valve ‘Standard Tolerance ave le intake = Repair 3 | Valve seat angl Intake 30 20°18" ee Exhaust 20°15" Lt 615002MAINTENANCE STANDARD. VALVE AND VALVE GUIDE —_a_ CALE AND VALVE GUIDE Unit: mm T g No. hem | Criteria Remedy : cee “0.045 Outside diameter Intake ° ean of valve stem Replace Exhaust 9 3888 10016 Inside diameter beak ting a 0.003 Replace - at valve guide Aor inserting 9 19.008 Valve Standard Clearance limit Clearance between valve nea Toke tas4-0074 az | Replace Exhaust 0.039 - 0.079 aa |Bend of vatve stem Repair limit : 0.01 (Total indicated runout for 100 mm) Replace a Tolerance 5 | Protrusion of valve guide Catal) Kosai Repair 20 202 Engine | Valve | Color code [Free Tengih | Repair lit Free length of vali ring] $0125-2 Intake White ‘75.2 = ae eames ‘$6D125-2 sasoi262 | Exnoust | white | 752 = 6 iar] Taal Replace Engine | valve | come | “igaled | Tales | Raper Installed toad of valve | i252 | iatano | wnite | 560 1192258] S88 spring se012s2 : jsae28ie| 7749) | 7 sasor262| Exheust | White | 560 [etozzeial witty | ‘Squarence of vaive spring 14-7MAINTENANCE STANDARD ROCKER ARM SHAFT ROCKER ARM SHAFT 2 Uni mn No. tem Criteria Remedy Standar lerance | Outside diameter of ss ue Replace rocker arm shaft, 286 ~0089 Focker arm 0.086 shaft Inside diameter of rocker ae +0038 Replace [erm shat hoe “0077 ocker arm Standard Clearance limit 7 Clearance between rocker pee arm and rocker arm shaft 0.026 -0.099 0.130 arm shaft Replace rocker Bend of rocker arm shaft [arm shatt Tightening torque of 2 | Tegening sorgue of 53-65 Nm (6.4 - 6.6 kgm) Retighten a Valve Standard Tolerance 3 | Vale clearance Intake 0.33 2002 Adjust Exhaust on 002 14-8 ® 615002MAINTENANCE STANDARD CROSSHEAD CROSSHEAD 3 ® Unit: mm No from Criteria Remedy Standard Tolerance Repair iit Inside diameter = ‘of crosshead " 90.075 118 f 10.025 Replace [Outside diameter 20.011 of crosshead guide " o a Proirusion of erosshe 2 [Pron 455 2025 : Repair ~ Aiea 66 2 7.3 Nm (6.75 = 0.75 korn) Retighten 14-9MAINTENANCE STANDARD CYLINDER BLOCK 14-10 CYLINDER BLOCK 615002MAINTENANCE STANDARD CYLINDER BLOCK Unit : mm - No. item Criteria Remedy 1 |Distonion of evinder nes Stendard Repair limit Peoar oy mounting surface 7 ing 0- 0.080 0.120 replace Inside diameter of main eanenra) olerance Replace main bearing he 16 30.015, bearing cap A “010 $ Thickness of main bearing 3 0.005 8 0.020 Replace 5 Roundness of main bearing Bewrargices Repair limit 0.005 Standard Tolerance Repair limit inside diameter of main c Replace 3 | bearing 110 ++0.040 110.15 bearing 20.010 | [inside diameter of eam @ 10.030 Repair or ~ bushing mounting hole ° replace 5 | side diameter of eam ~ 0070 60.30 Replace Order Target Nm (kom) | Range Nm Tightening torque of main ears Hin eo ge Nm kgm) «g | bearing cap [tststep 98 (10) 8-1070-1) (Cost thread area with 2nd step 196 (20) 186 ~ 205 (19-21) engine oi) cs rd step Retightan with 90° 90° - 120° io! Tightening torque of it s19Nm i nero a 53.9 + 191Nm 5.5 22.0 kom) Tgnening traue of | MIBSbotw) | 274NmzeKem | Bs° aE seg 8 | crankshaft pulley Aaa ‘mounting bolt 14 7¢ ~ 2 Mne(t bot) | T7ENM IB kom | ET EN iHference between lower 9 | face of cylinder block and Repair limit : 0.35. fiywhest housing bon ‘Difference between lower ‘epair =~ 10|fecw of eviinder Block and Repair limit :0.28 front cover, i 14-11MAINTENANCE STANDARD CYLINDER LINER CYLINDER LINER Cytinder liner | Cylinder block P siszro10 1s0r409 Unit: men No] tem Criteria Remedy ir limit : 0.07 ~ Replace liner 1 Repair limit : 0.07 -0.15 Replace Rank| Standard Tolerance Repair limit 10.020 Inside diameter of cylinder|_* bad ° au liner " 0.040 8 125 125.20 2 eoizy Replace Roundness of cylinder finer jeylinder liner " Repair limit : 0.08 {only B rank is, supplied) Shinderier e Repair imi: 008 Outside diameter of Standard Tolerance cylinder 3 | (Counter bore) “4 153 | 20.025 Tnterference between \der liner and block Standard :0-0.113, Replace liner or (Counter bore) block Outside diameter of Standard Tolerance dor liner I "40.000 Replace liner 14 (Counter bore bottorn) 148 Sana Taterference Between = " Te Eunias neroal ase Standard Interference limit Replace liner (Counter bore bottom) 0.01-0.12 007 oF block ‘Standard Tolerance Jevlinder tiner(O-ring) 30.386 Replace liner 5 iad +0.361 [Clearance between iinder liner and block Standard = 0.014 -0.079 Replece finer (rang) or block ‘*1 shows the dimension as an individual part 14-12 615002MAINTENANCE STANDARD (CRANKSHAFT CRANKSHAFT e1s0F410 Unit: mm No. ttem Criteria Remedy aa ; Tepair by usin “loom eae Tenn arin 010-0318 050 bearing g [Standard | Tolerance [Repair timit 5 30 0 109.88 ® |Outside diameter of main | _0.25US. 109.75 109.63, journal -0.050 0500S. 109.50 aan 109.38 | 075us 109.25 109.13, 2 100 US. 109.00 108.88 Standard pir i Roundness of main journal . a - 0-0.010 0.020 Standard Clearance limi i nce of main journal — Replace main 0.062 - 0.106 | 027 iu Standard | Tolerance STO 80 (Outside diameter of ozsus. 79.75 [eed ——— 0.050 kpin journal osous. 79.50 Bon 5 075US. 79.25 1.00 US. 73.00 Se Standard i Repair limit journal 0-0.010 0.020 Standard Replace connecting (0.046 - 0.080 fod mn Repair by — 4 | Bend of crankshaft Sunder’ using under 0-0.090 020 Size ening 14-13MAINTENANCE STANDARD CAMSHAFT CAMSHAFT mA ba 1 2 3 Ol ana Unit : mm No. tem Criteria Remedy Standard Repair limit 1 |End play Replace 0.15- 0.35 00 thrust plate ——— Standard Tolerance Outside diameter of Repl camshaft journal 60 0.080 cee A 0.110 Stan learance limit Clearance of camshatt —— ee Reploce journal 0.080 - 0.180 028 [cam bushing 4 [Bend of camshaft Repair limit: 0.03 (Total indicator reading) Standard Tolerance Repairlimit | Replace 5 |cam height 30.395 82 Ee 5173 14-14 615002615002 MAINTENANCE STANDARD CAM FOLLOWER AND PUSH ROD CAM FOLLOWER AND PUSH ROD Uni mm nol tem cer Femedy cues aannur oom [Sins —_[—Taranes —[~fepaci , [tower sar v8 ae 37 folower nat ae 3 2 Ouse aanewrotan | 2a nn ; Inside diameter of cam 2 pea 12.78 rico” | aie am ci of psn ro ba ood Toteraee 4 fend 127 020 5 [Rage oF aes a | 2 6 [ton of uso Peper st 050 (Tot indiestore Eire tia nonin 51473 (5.25 078 Kom) Revarten 14-15MAINTENANCE STANDARD TIMING GEAR TIMING GEAR nae Unit ‘No| item Criteria Remedy Gears Standard | Repair Ejanahan ger and nai A |idier gear arged 0.140 - 0.425) Main a 8 [eomanat er 24 Io 125-0305 ae ae earhat ger and ue = Baclsh ofeach c_[Spaearbersnetiet lous —o.ns Pea os > [iam ger tarae a | o ao wo _[apepiaer geez on [a 30-405 Ot purer ger and (Stare ete ge oe 0350 | Standard Tolerance Standard | Clearance between main isa! clearance it 1 Jidler gear bushing and a Hone he Set ois | 0118 | oom ice ATS 30.140 40.100 0.060 020 | bushing Clearance between oil 0.025 +0.065, 0.025 - 2 Pump idler gear and shaft oe 0.040 0 0.105 ozo) de Repti 3 | End play of main idler gear etandasd) ‘opal 7 Replace 050.7 oa ct 4 | End play of oil pump idier gear 0.05 -0.21 0.4 Peering 14-16 615002MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN PISTON, PISTON RING AND PISTON PIN 6D125-2 (Aluminum alloy) Ny — nis re —E£t 5 se£00785 14-18 ® 615002615002 MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN No. hem Criteria Remedy +—— Rank| Standard Tolerance Repair limit i 0.270 1 | Outside diameterof — |AorS}_ 125 12459 Replace piston piston it eozas) (supplied only 75 as rank Aor S) Bort} 125 Bao 124.59 No. [Measuring point Standard Tolerance 2 | Top ring 242 aioe Thickness of piston ring Replace 0.010 piston ring 3. | Second ring 24 Boa i 0010 4] Oiteing 40 a 2] Topring | Judge using groove wear gauge Replace Width of pistom ring aa a | 3 | Secondving | piston | | +0.025 A 4 | Oiteing 40 ad 3 a] No. [Measuring point | Standard Clearance limit | 2) Topring Clearance between piston Judge using groove wear gauge | Replace Ihe eames Sores 3 Second ring piston ring 4) Oitring 0.020 - 0.055 15 | | T 2 | Topring | 037-047 20 Replace nin rin . piston ring iston ring gap 3 Second ring 0.50 -0.60, 15 ae liner ‘ 0.28 -0.40 10 | Tolerance Outside diameter of : Replace, ston pin piston pin pinion “ -0.006 Inside diameter of piston | 8 +0.012 Replace pin hole +0.004 piston Standard ance limit | Clearance between piston ————-____} Replace | bin and piston 0.004 -0.018 0.030 piston pin — | Weight of piston 6D125-2 : 2,0592 24g S6D125-2 : 2,1702 24g Replace piston 14-19MAINTENANCE STANDARD $6D125-2, SAGD125-2 (Ductile cast iron (FCD) } 14-20 PISTON, PISTON RING AND PISTON PIN sxconont 615002615002 MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN No] ttem Criteria Remedy Rank| Standard__| Tolerance Repair limit 1 | ouside diameter ot faors) 5 “2080 24p0 | Reslace piston piston 20.105 (supplied a “078 as rank A or 8) Bort) 125 Poole ale | No. | Measuring point Standard Tolerance | 0.005, 2 Top ring 242 0.025 ‘Thickness of piston ring por er ° 3 ‘Second rin, | 24 ns im econd ring 0.030 ; 0.010 4 i i | : Citing = | om r t 2 ‘Top ring | Judge using groove wear Gaus? paises Width of pistorn ri . eon nanemere 3. | Second ring piston it ring 20.040 2 4) oineing 40 oa 3 i No. | Measuring point | Standard ___| Clearance limit 2 Top ring | clearance between piston -——-| | judge using groove wear gauge cereoeces cates 3 | Second ring piston ring 4) oi ring 0.030 - 0.070 0.15 2| Top ring 037-047 20 t Replace Piston ring gay nd ring 0. . Biston ring iston ring gap 3. | Second ring 050-060 18 ead liner 4 | oiteing 0.28-0.40 10 1 Standard Tolerance Outside diameter of Replace piston pin « piston pin 5 | Inside diameter of piston 2 Replace pin hole piston Standard Clearance between piston Replace in and piston 0.035 - 0.051 0.063 piston 035 — . piston pin — | Weight of piston 3.000 9 Permissible range: = 60 9 Replace piston 14-21MAINTENANCE STANDARD CONNECTING ROD CONNECTING ROD Unt No nem cetera Remedy Sina Teieance | _Repattii sie hametrof bushing — at connecting rod smaill end| 7 , [Remodel ard) | Replace |SA6D125-2| 0.025 | +0.040 0.09 gear ‘Standard Tolerance Standard | Clearance 2 | Radial clearance of pump size Gear 0.0. | Gear LD. clearance Keni | gear “015 | «006 | 003- | iad on | ‘0 0.10 eas Tolerance Standard [Clearance or | eunees \clearance or| interference 3 | Interference between pump | size shat [Hote |interterence| "limit | pepigce ive gear and drive sh Seeeeeesaees rai 0.106 | +0065 | 0.023- _ 40.088 40.047, 0.059 1 | Clearance between drive Fal 10.106 | «0.173 | 0.040- Replace that and cover bushing r0.088_| sous 0.085 bushing Interference between pump 70108. | +0083 | 0025 - ~ g gear and drive shaft oe 40.088 +0.028 0.078 Replace « | Clesrance between drive a 0.006 | +0061 | 0040 - opie shaft and body bushing oo | ‘oo 0.085 bushing Clearance between driven 7 +0090 | «0.129 | ooi2- ~ 7 | shatt and body ia 20.070_| +0102 0.059 Replace ¢ | Clearance between driven 5 vo.090 | +0147 | o.032- Replace | shaft and gear bushing s0070_| so.122 0.077 bushing Interference between driven | 4g +0.080 | ~0.040 | 0030- elo shaft and cover s0.070_| +0020 0.068 14-27MAINTENANCE STANDARD MAIN RELIEF VALVE MAIN RELIEF VALVE No. hem Criteria Remedy Tolerance Standara Standard | Clearance Clearance between valve and| size ‘Shah Hote | clearance | “limit 7° | body a 001 | +0003 | 0.080- -0060 | 0 0.103 Standard size Repair limit Replace Teataliad | intaled instal 11 | Reliet vaive spring Free length | “engin toad__| Freeteron | Mioad 105 N 96N na cae (10.8 kg) (9.8 kg) 12 | Roliet vaive set pressure 0.7°2'MPa7*1 kolem’) 14-28 615002615002 MAINTENANCE STANDARD REGULATOR VALVE AND SAFETY VALVE REGULATOR VALVE AND SAFETY VALVE S(A)60125-2 tsp ea Unit: eam No, tem | Criteria Remedy — Standard ut) Standard | clearance | pepiace 1 | Clearance between regulator | size Valve | Body | Clearance | limit | Replace valve and body t body a wo1s | 0028 | 007- | soz | soz 0.16 Standard size Repair limit Regulator valve spring = ca as Fretonom] ae’ | eae? [Prectenat | aaes | air Carer teen Replace | emote span 65.0 (oes ig) mounting 2 23 tener] eg.5 ai6N type seni |e 1235 i) 3 | Regulator valve set pressure reece 4 | Satory vaive set pressure (0.2 + 0.02 MPa (2.0 «0.2 kglern?MAINTENANCE STANDARD AIR COMPRESSOR O° 5 AIR COMPRESSOR Cue 615002 Unit: mm No| tem Criteria Remedy | ‘Standard clearance Repair tirit 1 [Piston ring 1st, 2nd ring] 01-03 20 bene Oitring 02-06 15 Clearance Standard size | Standard clearance | Repair limit 2 [between 1s1, 2nd ving| 3 0.015 -0.050 0.15 piston ring and ring groove Oil ing 4 0.035 - 0.110 020 Clearance between 3 - Serer 85 0.080 - 0.150 0.28 [Clearance between piston Oars 18 0.006 - 0.026 oa (Clearance between piston 5 |pin and connecting fod 16 | 0.006 - 0.026 on [small end I Clearance between crank | § |pin metal and crankpin = Cs ca 14-30