ISUZU WORKSHOP MANUAL INDUSTRIAL DIESEL ENGINE 6RB1-6RB1T MODELS FOREWORD ‘This Workshop Manual is designed to help you perform necessary maintenance, service, and repair procedures on applicable Isuzu industrial engines. Information contained in this Workshop Manual s the latest available at the time of publication. Isuzu reserves the right tomake changes at any time without prior notice. ‘The Table of Contents at the right hand side of this page shows you the general arrangement of the material in this Workshop Manual. A more detailed Table of Contents precedes each individual section ‘The black spot at the righthand side of some pages indicates the first page of a given section. ‘This Workshop Manual is applicable to 1987 and earlier models. SECTION 1 2 3 4 5 6 7 8 9 11 12 13 14 COOLING SYSTEM 10 TABLE OF CONTENTS NAME GENERAL INFORMATION MAINTENANCE ENGINE ASSEMBLY | (DISASSEMBLY) ENGINE ASSEMBLY II (INSPECTION & REPAIR) ENGINE ASSEMBLY II (REASSEMBLY) LUBRICATING SYSTEM FUEL SYSTEM TURBOCHARGER AIR COMPRESSOR ENGINE ELECTRICALS ‘TROUBLESHOOTING SPECIAL TOOL LIST CONVERSION TABLENOTICE Before using this Workshop Manual to assist you in perform- ing engine service and maintenance operations, it is recommended that you carefully read and throughly understand the information contained in Section - 1 under the headings “GENERAL REPAIR INSTRUCTION” and "NOTES ON THE FORMAT OF THIS MANUAL”,GENERAL INFORMATION 1—1 SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS iTEM General repair instructions Notes on the format on this manual Main data and specifications ....... Design features and general outline . Tightening torque specifications: Angular nut and bolt tightening method Major parts fixing nuts and bolts1—2 GENERAL INFORMATIONS GENERAL REPAIR INSTRUCTIONS. Before performing any service operation with the engine mounted, disconnect the grounding cable from the battery. This will reduce the chance of cable damage and burning due to short circuiting, Always use the proper tool or tools for the job at hand. Where specified, use the specially designed tool or tools. 3. Use genuine ISUZU parts cefecring ISUZU PARTS CATALOG for the engines surely 4, Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts, Discard them as you remove them, Replace them with new ones. 6. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation It is especially important to keep fastening parts separate. These parts vary in hardness and design, depending an their installation position. 6. All parts shauld be carefully cleaned before inspection or reassembly. Oil ports and other openings should be cleaned with compressed air to make sure that they are com- pletely free of obstructions. 7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly. 8 If necossary, use a Sealer on gaskets to prevent leakage 9, Nut and bolt torque specifications should be carefully followed. 10, Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine or disconnecting pipes and hoses. To not do so is extremely dangerous, 11. Always check and recheck your work. No service operation is complete until you have done this. 12. Information contained in the “Main Data and Specifications” of the Workshop Manual and the Instruc- tion Book may differ. In this case, the information contained in the Instruction Book should be considered applicable, NOTES ON THE FORMAT OF THIS MANUAL This Workshop Manual is applicable to the ISUZU industrial diesel engine model specified in the title of this Workshop Manual. lifustrations used in this Workshop Manual are based on the 6RB1TPA industrial standard model. The 6RB1 engine is non-turbocharged and the 6RB1TPA, which is abbreviated to 6RB1T in the descrip- tions, is turbocharged 1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual. 2. Common technical data such as general maintenance items, service specifications, and tightening torques are included in the “General Information” section. 3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and reas- sembly. The section ENGINE ASSEMBLY is an exception. This part is divided into three sections to facilitates quick indexing. 4, When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page. 5. For the sake of brevity, self-explanatory removal and instatlation procedures are omitted More complex procedures are covered in detailGENERAL INFORMATIONS 1~3 6. Each service operation section in this Workshop Manual begins with an expleded view of the applic: able area, A brief explanation of the notation used follows. Parts within a frame are to be removed and installed as a single unit, and their |___@ disassembly steps of reassembly steps are shown in the illustrations respect- ively. ‘The number tells you the service opera tion sequence. Removal of unnumbered parts is unne- 1 cessary unless replacement is required. The “* Repair Kit" indicates that a repair kit is available. The parts listed under "Disassembly ‘Steps’ or “Reassembly Steps” are in the service operation sequence. The removal or installation of parts marked with a triangle (4) is an import- ant operation. Detailed information is given in the text.1-4 GENERAL INFORMATION 7. Below is a sample of the text of the Workshop Manual. This is the item shown in the illus- tration, It is marked with a triangle {4} on the Major Components page. Special tools are identified by the tool name and/or number. The illustration shows how the spe- ial {001 is to be used. Zo hee rth 2 han ert te Letters and numbers contained in 2 circle refer to the illustration. ame ‘Symbols indicate the type of service operation or step to be per. formed. A detailed explanation of these symbols follows. \ Nb serie data and specications are given in this table. 8, The follawing symbols appear throughout this Workshop Manual. They tell you the type of service operation or step to perform, Commercially Available Tool Use Directional indication Required or Recommended Inspection Fe oe Vv portant Operation Rearing rs Ee] Reasons Ba] sss rae cate Aigner Mars FQ) Sesiaeauute Reauted Resom a fe] (cal | [] (al Lubrication (Oil) Measurement Lubrication (Grease) Liquid Gasket ApplicationGENERAL INFORMATION 1—5 ‘9, Measurement criteria ate defined by the terms “standard” and “tirnit” ‘A measurement falling within the “standard” range indicates that the applicable part or parts are ser- viceable, “Limit” should be thought of as an absolute value. A measurement which is outside the “limit” indicates that the applicable part or parts must be either repaired or replaced, 10. Components and parts are listed in the singular form thraughaut the Manual 11. Directions used in this Manual are as follows: Front; The cooling fan side of the engine viewed from the flywheel, Right; The injection pump side of the engine. Left The exhaust manifold side of the engine. Rear: The flywheel side of the engine. Cylinder numbers are counted fram the front af the engine. The front most cylinder is No. 1 and rear most cylinder is the final cylinder number of the engine. The engine's direction of rotation is counterclockwise viewed from the flywheel.1—6 GENERAL INFORMATIONS MAIN DATA AND SPECIFICATIONS Engine Model Item Engine type Combustion chamber type Cylinder liner type No. of eylinders — bore X stroke mmi(in) Total piston displacement omfin?} Compression ratio (To 1) “Engine dimensions mm(in} Length x width x height “Engine weight (Ory) kgllb) Fuel injection order *Fuel injection timing (BTDC) degrees Specified fuel Injection pump: Governor *Low idle speed rpm Injection nozzle “Injection starting pressure kg/em*(psi/kPa) Fuel filter type Water sedimentor Compression pressure {at warm) ka/em*(psi/kPa) Valve clearances (At cold) Intake mm(in) Exhaust_mmfin) Lubrication method il pump Main oil filter type Partial oil filter “Lubricating oil capacity litiUS/UK gal) 6RB1 ereIT Water cooled, four oycle, vertical in-line, overhead valve Direct injection Dry 6 — 135 X 160 (5.31 x 6.30) 13,741 (838) 16.5 171 X 773 X 1,027 (679 X 30.4 x 40.4) 1,871 X 885 X 1,267 (67.9 X 34.8 X 49.9) 980 (2,163) 1,076 (2,375) 1-4—-2-6-~3-5 22 W7 Diesel fuel (ASTM D975 No. 2D) livline plunger, Bosch P type Mechanical, RSV type 650 — 750 Hole type (with multi orifices) 200 (2,844/'18,620) or 225 (3,195/22,073) Center bolt or cartridge (spin-on) Optional equipment 29 (412/2,842) at 220 rpm at sea (evel 0.60 (0.024) 0.60 (0.024) Pressurized circulation Gear type Center bolt, full flaw or cartridge (spin-on) Centrifugal type 19 (6.0/3.5) 45 (11.9/9.)GENERAL INFORMATION 1—7 Engine Model | ea ereit Hem Oi cooler Water cooled integral type Cooling method Coolant capacity Pressurized forced circulation 30 (7.93/6.60) ‘Water pump Belt driven impeller type Thermostat type Wax pellet type *Alternator 24 ~ 20 or 24 — 30 “Starter 24 —TAor 24 — 1 : GARRETT AUTOMOTIVE PRODUCTS COMPANY - | ‘TV61 or 781 “Turbocharger manufacturer “Turbocharger model Note: 1. These specifications are based on the standard engine. 2. Specifications for items marked with an asterisk (*) will vary according to the type of equipment bn which the engine is installed. Regarding the injection starting pressure and the injection timing crank angle of your engine, make sure the applicable deta referring MAINTENANCE DATA PLATE affixed on your engine. If you are unable to locate the data applicable to the specifications, please contact to ISUZU MOTORS LIMITED through your machine suuplier.—8 GENERAL INFORMATION DESIGN FEATURES AND GENERAL OUTLINES The ISUZU 6RB1 industrial diesel engine is a water-cooled, in-line six-cylinders having 13,741 liters (838 cubic inches) piston displacement. The mode! 6RB1 is the naturally aspirated engine and, model 6RB1T is the turbocharged one. The combustion system is a direct fuel injection type. The valve configulation is four valves (two inlet and two exhaust valves) driven by the roiler tappet (i.e. cam-follower), push rod, rocker arm and valve bridge. In order to level up the air intake efficiency and the combustion efficiency, a dual port type intake system is employed. One of the dual ports is a conventional swirl port, while the another one is a tangential swirl type. They act together to generate an optimum air swirls. However, the exhaust system is of a single-port with two-valve configulation and, the port sectional shape is designed to reduce the exhaust resistance. The water passages specially cross-drilled around the injection nozzle position contribute to reduce the local thermal-load at this cylinder head area. The fuel injection nozzles are located at the central position of the combustion chamber to give a better fuel combustion efficiency. The Bosch P type in-line fuel injection pump with the RSV type mechanical governor is equipped giving a high versatility for various industrial applications. A forced circulation type fubricating system with a full- flow center bolt type oil filter or a spin-on type oil filter together with a partial-flow oil filter assures an improved durability and reliability.GENERAL INFORMATION 1—9 TIGHTENING TORQUE SPECIFICATIONS STANDARD BOLTS ‘The torque values given in the following table should be applied where a particular torque is not specified kal Ne) Bolt identification = LON KT Bott diameter ar 7 oT xpiteh (Low carbon steet) (High carbon steel) UAlloy steet (mm) \| mexi0 06 202 075: 02 _ ( Ags taf 588 1.96) | ( S432 143/ 7354 1.96) Max 125 13 408 1754 05 20 + 07 ( 044 34/1274 490) | | 12BBE BOB! TAGE 490) | 17.984 536/ 19602 6861 m0 x 1.26 29 207 a75t 09 50413 (203: 82/ 2744+ 606) | ( 2720 7.2 / 96.74 B82) | ( 3688: 988/ 49,004 12.74) m2 x 1.25 6251.2 278% 18 965% 19 (4525 9.2/ 6125411.76) | ( 96034 11.08/ 75.994 14:70) | ( 69.772 1377/ 9457+ 18.62) ma x15 a75i19 11858 23 1450: 29 (possiasy e75106% | 867E 166 /116.13¢ 2250) | (oAaas 2089/1421 + 28.42) m6 x15 139 £27 172308 38 20.40% 41 (940317.0/130:34226.46) | (128074 25.07/168.5¢+ 36:30) | (1475 + 29.49/19992% 40.10) ma x15 192 438 2490: 5.0 29.308 59 (1989227.9/188.16297.24) | (18003 36,3 /24a02% 4:90) | (211 84s 4289/287.14% 57.82) 0 «18 263 +53 3440 69 400% 81 (190219827287. 74451.94) | 48.724 49.7 /337.12% 67.62) | (292.108 $8.09/995.92 79.36) me x15 330 £83 46.25: 92 84.102108 (248.1460.1323.40181.38) | (34.394 66:36/459.254 90.16) | (901.15x 78.14/590.184 105.84) Maa x 20 458 492 58.2014. 7oa0214.1 (931.2460.2/448.8¢290.16) | (420,70:102.78/570.362197.20) | (SIO.44101 44/60 88192.18) sto x 45 27 407 49212 (4865 S6f 25462 686) | ( 26752 aaa) | ( 35494 8.42/ 4802+ 11.76) sna x48 ba +12 12414 91218 (4208 90/ S6e4x11.76) | (52.02% 1005/ 7056+ 13:72) | ( 65:04 12807 9:18 17.68) sma x 20 aa sta 112 + 22 136 + 27 | 65.8412.8/ 89.18417.64) ( 80.974 15.7 /109.76+ 21.56) | ( 98.3: 9.33/133.282 26.48) sume x 20 127 425 165 + 33 195 + 39 ( 91.94179724484265 ) | (1904 263 /161.70 92.34) | (140.998 2799/1911 + 98.22) Note: The asterisk (*) indicates that the bolts are used for female-threaded parts that are made of soft materials, such as casting,10 GENERAL INFORMATION ANGULAR NUT AND BOLT TIGHTENING METHOD 1, Carefully wash the nuts and bolts to remove all oil and grease. 2. Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts. 3, Tighten the nuts and bolts to the specified torque {snug torque) with a torque wrench. NUT BolT ots / | 4, Draw a line [A-B] across the center of each bolt.GENERAL INFORMATION 1—11 5. Draw another line [C-D] on the face of each af the parts to be clamped. This line should be an exten- sion of the line [A-B 6. Draw another line [F-G] on the face of each of the parts to be clamped. This line will be in the direc: ian of the specified angle [Q) across the center (E) of the nut or bok 7. Use a socket wrench to tighten each nut or bolt to the point where the line (A-B] is aligned with the line [F-G) Example: Specified Angle and Tightening Rotation A 30° 1/12 of a turn B 60" 1/6 of a turn c | ow VW ofatun D ao | C2 ofatun E 360 | (One fullturm |1—12 GENERAL INFORMATION MAJOR PARTS FIXING NUTS AND BOLTS Cylinder Head Cover, Cylinder Head, inlet Cover, and Exhaust Manifold kg-m(Ib.ft/N-m) 4.0205 (28.9:3.6/39.2:4.9) 3405 (21.73.6/28.424.9) As 33105 (23.8:13.6/32.3:4.) 33205 (23.813.6/32.314.9) ‘Apply MoS: 1 1921 184 a ~ 307" (108.317.2/147.0:9.8) ~ (137.4%7.2/186.449.8) ZGENERAL INFORMATION 1—13 Cylinder Body, Crankshaft Bearing Cap, Tappet Cover, Oil Pan kg-m(Ib.ft/N-m) & 25102 nN (8.41.4/245:20) a 1 385 (2a2.01218/882.61204) TLubrcate with engine of)1—14 GENERAL INFORMATION Timing Gear Case and Flywheel Housing kg.m(lb.ft/N.m) (20.222.2/27.42.9) For #12 Bolt 70215 (60.610.8/68.7214.7) 60 Bolt 141.0 149.1298) 40205 (29,03.6/39.24.9) For $14 Bolt 0222.5) For #8 Bolt 2.6203 g (18.842.2/25.522.9) $GENERAL INFORMATION 1—15 Crankshaft, Connecting Rod, Flywheel! and Pulley kg.mi(lb.ft/N-m) a [Apply moss 7 [ev geet eopy — sep (57.827.2/78.519.8) J [70.08 | (60.6768.8) ~ (72,343.6/98.124.9) | Lubricate with engine oi 50:10 | | 196.247.2/49.129.8) | Lubricate with engine oil 9024.0 °° (65.137.2788:3% \ Lubricate with engine off | ~ 80.0510.0 (578.5272.0/785.098.0) Apply MoS:1—16 GENERAL INFORMATION Camshaft, Rocker Arm Shaft Bracket Camshaft Gear and Idler Gear kg-m(tb.ft/N-m) Lubricate with engine oil | 9.0210 (65.1:7.2/88.3:9.8) Luicate with memlN . ¥ Ss 5.5105 (39.733.6/53.944.9) waa wine Oy 8 oP eee 17.0320 14.4/768.819.6) 40205, (28.9:3.6/39.2149) (25.3+3.6/34.34.9) 30205 (21.713.6/29.444.9) 35105GENERAL INFORMATION 1—17 Oil Pump and Oil Filter kg.m(Ib.ft/N-m) | asi05s | “10202 | [(7221.5/9.831.9)| [132.523.6/04.124.9) | faxes | (29.03.6/39.2+4.9) lL Fitten (CENTRIFUGAL) © omsitten imainy e [005 (29.03.6/39.244.9) Va 3.8202 [13.021.4/17.6+2.0) [asi05 40:05 | ee ae [is2ssseeareas) | znosse82e49 | run 2 7 { 35i03°— cama [fetieseceen| 418842.0) S008 (1s6.2:3:6/49.124.9)|1—18 GENERAL INFORMATION Water Pump, Thermostat Housing Air Compressor and Oil Cooler kg-m(|b.ft/N.m) T8202 (13.021.4/17.62.0) < rr (195.2221.6/267.8:29.4) 8202 a 4/17.642.0) 4.2405 (30.323.6/41.224.9)GENERAL INFORMATION 1—19 Fan, Fan Belt Adjuster and Fan Center kg-m(lb.ft/N-m) fj aai05 [ “1.8102 (13.0014/17.622.01 (27.443.6/37.2+4.9) | oO1—20 GENERAL INFORMATION Injection Pump, Fuel Pipes and Fuel Filter kg-m(Ib.ft/N.m} 25202 N | (18.121.4/24.542.0) \ 48 Bolt 410 Bolt 4.2102 (3621.4/118 28102 (20.241.4/27.442.0) 02 42208 3 (t@a0114/82.482.0) | o9.a19.6/41.245.) 4.2205 ] = (anassevas “" “G a2205 (soas3.6ie12180) ~~ e 28201 (20.212.2/27.422.9) aa — 28208 (20.242.2/27.432.9) 42205 (30.423.6/41.2+5.0) 42305 (90.43.6/81.2250)) “P [eossseinnze5o] S 40208 42105 / pg i0s10 | (80.037.2/107, (30.443.6/41.2+5.0) |GENERAL INFORMATIONS 1—21 Turbocharger and Intake Duct kg-m(Ib.ft/N-m) J. 26103 | (18.8:2.2/25.52.9) f' T8302 (13.01.4/17.6+1.9), 0. L, -- as rssasisrasy,1—22 GENERAL INFORMATIONS DA} Air Compressor kg-m(Ib.ft/N-m) 25-30 (18.1/245—21.7/29.4)GENERAL INFORMATION 1—23 IDENTIFICATIONS MODEL IDENTIFICATION Engine Serial Number The engine number is stamped on the front right hand side of the oylinder body. WNJECTION PUMP IDENTIFICATION Injection Pump Number Injection volume should be adjusted after referring to the adjustment data applicable to the injection pump installed. The injection pump identification number (A) is stamped ‘on the injection pump identification plate. Note: — Always check the identification number before beginn- ing a service operation Applicable service data will vary according to the ident- ification number. Use of the wrong service data will result in reduced engine performance and engine damage. NP-PE é (Licence BOSCH? ®-tdanutieavion number MAINTENANCE DATA PLATE In the 6RB1 industrial engine, the vaive clearance, injec: tion nozle opening pressure (i.e. injection starting pressure) and the injection timing crank angle vary depending on the engine applications, therefore, the data is stamped on the Maintenance Data Piate which is affixed on the cylinder head cover top. In the illustration, the figures indicate the following data respectively. 1. Firing Order 2. Valve Clearance 3. Injection Nozzle Opening Pressure 4, injection Timing Crank AngleMEMO "QUALITY PARTS YOU CAN TRUST”MAINTENANCE 2—1 SECTION 2 MAINTENANCE TABLE OF CONTENTS ITEM PAGE i Lubricating system . . Fuel system .. Cooling system . Valve clearance adjustment Injection timing ... Compression pressure measurement ... eee ee ett tr cee 21s Turbocharger inspection Engine repair kit Recommended lubricants .. Engine oil viscosity chart ...... Note: Maintenance intervals such as fuel or oil filter changes should be referred to INSTRUCTION BOOK.2-2 MAINTENANCE el | a be] LUBRICATING SYSTEM Main Oil Filter Replacement Center Bolt Type Removal 1. Loosen the drain plug @ to drain the engine oil from the oil filter Place a receptacle beneath the drain port to contain the drained oil 2. Remove the center bolt @ and the filter body @ from the filter cover along with the filter element ©, 3. Discard the used filter element. 4. Wipe the oil filter fitting face clean with a rag. This will allow the new oil filter to seat properly. Installation 1. Install the three O-rings ®, ©, ® and new element @ and, check that they are correctly positioned. 2. Reassemble the filter body © with the center bolt ©. kgmilb.ft/N-m) Center Bolt Torque 4.5 + 0.5 (32.5 + 3.6/4.1 + 4.9) 3. Check that the gasket is properly seated. This will prevent oil leakage. 4. Start the engine and check for oil leakage from the oil filter. 5. Check the engine oil level and replenish to the spec- ified level if required. kg.mi(lb.ft/Nem) Drain Plug Torque | 1.8 + 0.2 (13.0 + 1.4/17.6 + 2.0) Cartridge (Spin-On) Type Removal Remover and Installer: Filter Wrench 1. Loosen the used oil filter by turning it counterclock- wise with the filter wrench. 2. Discard the used oil filter. Installation 1. Wipe the oil filter mounting face with a clean rag. This will allow the new oil filter to seat properly. 2. Lightly oil the O-ring, 3. Turn in the new oil filter until the sealing face is fit- ted against the O-ring. 4, Use the filter wrench to turn in the oil filter an addi- tional 3/4 of a turn or one turn, 5, Start the engine and check for oil leakage from the oil filter 6. Check the engine oil level and replenish to the spec- ified lovel if required.MAINTENANCE 2—3 FUEL SYSTEM Fuel Filter Replacement Center Bolt Type Removal 1. Loosen the drain plug © to drain the fuel from the fuel filter. 2. Loosen the center bolt @ to remove the filter body @, the spring @, the washer ®, the gasket ®, and the filter element @ and the O-ring ®. aaa El 3. Discard the used element. Installation 1. Wash the filter body and the other parts immersing them into clean diesel ot 2. Reassemble the parts in reverse order. Use the new element, 3. Check that the gaskets are properly seated. This will prevent fuel leakage. kg.mi(lb f/m) Drain Plug Torque | 4.2 4 0.8 (90.3 + 5.8/41.2 + 79) kg-mnilb.ft/N-rn) Center Bolt Torque | 2.5 + 0.5 (18.1 + 3.6/24.5 + 49) Cartridge Type ‘ 2) Removal 2 1 Looeen te ful fier by tring tcountrtsiiso with the filter wrench or your hand. Discard the used fier. BS] Fier Wreneh PA 2 Wipe the fuel filter fitting face clean with a rag. This will allow the new fuel filter to seat properly.2-4 MAINTENANCE Installation 1. Apply a light coat of engine oil to 2. Supply fuel to the new fuel filter, This will facilitate air bleeding. the O-ring 3. Turn in the new fuel filter until the filter O-ring is fit- ted against the sealing face. 4, Use the filter wrench to turn in the fuel filter an ad- ditional 1/2 to 3/4 of a turn. Overflow Valve Check the overflow valve for clogging, Check the ball side for suction leakage. Parts No. 1-13200-666-0 kglem?(psi/kPa} Overflow Valve Opening Pressure (Reference) 2.8 (35.6/196.2) Parts No. 1-13200-549-0 kg/em?(psi/kPa} ‘Overflow Valve Opening Pressure 1.5 (21.3/147.2) Injection Nozzle Regarding the injection pipe and the nozzle holder rem- oval and installation, refer to the section 3 DISASSEM- BLY page 3-5 and the section 5 REASSEMBLY 5-28, 29. Inspection Procedure 1, Clamp the injection nozzle holder ina vise. 2. Use @ wrench to remove the injection nozzle holder cap. 3. Remove the injection nozzle holde F from the vise,MAINTENANCE 2—5 Adjusting Procedure Injection Starting Pressure Check 1, Attach the injection nozzle holder to the injection nozzle tester. 2. Loosen the adjusting screw ©. 3. Check the injection nozzle starting pressure and the spray condition by operating the injection nozzle tester. 4, Adjust the injection nozzle starting pressure. Turn the adjusting screw clockwise while operating the injection nozzle tester handle, kg/em*(psi/kPo) Injection Nozzle Injection | 200 (2844/19620) or Starting Pressure 225 (3199/2073) Note: The applicable nozzle pressure is indicated on the MAIN- TENANCE DATA PLATE affixed on the cylinder head cover. WARNING: TEST FLUID FROM THE NOZZLE TESTER WILL SPRAY OUT UNDER GREAT PRESSURE. {T CAN EASILY PUNCTURE A PERSON'S SKIN. KEEP YOUR HANDS ‘AWAY FROM THE NOZZLE TESTER AT ALL TIMES. Spray Condition Check (During Injection Nozzle Tes- ter Operation) 1. Tighten the adjusting screw @. 2. Check the injection nozzle starting pressure. 3, Check the injection nozzle spray condition. Operate the injection nozzle tester hand lever 4 to 6 times a second while looking for abnormal injection noz- zle spray conditions, Refer to the illustration for different spray conditions. (1) Good (2) Bad (Restrictions in orifice) (3) Bad (Dripping)26 MAINTENANCE ‘Outlet Port Inet Port Union Nu A Union Nyt 8 Level Marke Dysin Valve Bl Water Sedimentor Non-Transperent Type The sedimented water must be drained every 260 oper- ation hours. 1, Place a receptacle beneath the drain pipe to contain the drained water. 2. Loosen the drain plug to drain the water. The sedimenter water capacity is 410 cc (0.86 pints). 3. Tighten the drain plug after the water is drained out. kg.mnfb.f/Nm) Water Sedimenter DrainPlug torque | 42#08 (032 5.7/41.2 + 0.8) kg.milb fU/N. 25 + 0.5 (18.1 + 3.6/24.5 + 49) ) Water Sedimenter Center Bolt Torque Transparent Type As a transparent shell is used in this type, the sedi mented water level is visible from the outside. 1. Drain the sedimented water when the water level came to the level mark on the transparent shell. 2. Place a receptacle beneath the drain pipe to contain the drained water. 3. Loosen the drain valve to drain the water. 4, Tighten the drain valve after the water is drained out. Feed Pump Strainer 1, Remove the joint bolt. 2, Use a screwdriver to remove the strainer. 3, Wash the strainer in clean diesel fuelMAINTENANCE 2—7 Stesiner ir Bleeding 1. Loosen the priming pump cap ® on the injection pump. 2. Loosen the fuel filter fuel return eye bolt ®. 3. Operate the priming pump until there are no more bubbles visible in the fuel being discharged from the fuel fiter fuel return eye bolt. Retighten the fuel filter fuel return eye bolt. . Operate the priming pump several times and check for fuel leakage around the injection pump and the fuel filter.2—8 MAINTENANCE 85~ 12mm Asitating rod — EE i) Cooling Fan Di COOLING SYSTEM e Belt Adjustment 1. Check the cooling fan drive belt for cracking and other damage. 2. Check the drive belt tension by exerting a force of 10 kg (22 Ib) midway between the water pump pul: ley @ and the alternator pulley ©. 3, Adjust the belt tension by loosening the alternator mounting bolt and the alternator adjusting bolt and pivoting the alternator. Be sure to retighten the bolts after adjusting the bolt tension, mmiin) Cooling Fan Drive 85 — 12 Belt Deflection (0.33 — 0.47) Thermostat Inspection Visually inspect the thermostat. Replace the thermostat if excessive wear or damage is discovered during inspection Measure the valve lift. nies mm(in} | sraee naan Lift 11.0 (0.43) scr) Valve Onening 80 — 84 (176 — 183)Wher Np, 1 Cylinder sin TOC compression take, tid tt 4 fe] fal MAINTENANCE 2—9 VALVE CLEARANCE AND ADJUSTMENT Note: The cylinder head belts were previously tightened with the “Angular Tightening Method”. Therefore, it is not necessary to retighten the cylinder head bolts before adjusting the valve clearance. 1, Remove the cylinder head covers 2. Bring the piston in either the No. 1 cylinder or the No. 6 cylinder to Top Dead Center on the compres- sion stroke by turning the crankshaft until the TDC notched line on the flywheel or the crankshaft damper is aligned with the timing pointer. Check 1 see if there is play in the No. 1 intake and exhaust valve rocker arms. Hf the No. 1 cylinder intake and exhaust valve rocker arms have play, the No. 1 piston is at TOC on the compression stroke. If the No. 1 cylinder intake and exhaust valve rocker arms are depressed, the No. 6 piston is at TDC on ‘the compression stroke. Do this adjustment on the valves indicated by arrows in the illustrations when the No. 1 cylinder or the No. 6 cylinder is in T.D.C. compression stroke respectively.2—10 MAINTENANCE Aslusting Serew ® Note: For brevity of the description, the rocker arm adjusting screw is abbreviated as the screw A and, the bridge adjusting screw is also abbreviated as the screw B in this procedure. 1. Loosen the lock nuts of the screw A and B to permit the adjusting screws are turned freely. 2. Screw in the screw 8 to allow the bridge is lifted up. This will result to make no clearence condition between the valve stem and the screw B. 3. Lock the screw B by tightening the lock nut to fix the bridge position. 4, Insert a 0.6 mm (0.0024 in,} feeler gauge into the bridge and the rocker arm clearance. 5. Keep the filler gauge in the clearance and, tighten the sorew A until the feeler gauge is bound. 6. Loosen the screw A slowly until the feeler gauge move in the clearance but feel a slight drag. This is the correct valve clearance of this engine. mmtin) Valve Clearance (Cold) 0.6 (0.024) 7. Tighten the lock nut of the screw A to the specified torque. (Apply a coat of engine oil.) \lb.ft/Nem) Bridge Screw Lo Nut TorqueTiming Marks ‘nahe Damper C| DD ii (( \ MAINTENANCE 2-11 INJECTION TIMING Note: Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made. 1. Injection timing checking procedure 1) Remove the cylinder head covers. Remove the flywheel timing mark cover if necessary. 2) Bring the piston in either the No. 1 cylinder or the No. 6 cylinder to Top Dead Center on the compression stroke by turning the crankshaft umtii the TOC notched line on the fiywheel or the crankshaft damper is aligned with the tim- ing pointer.2-12 MAINTENANCE 3) Check to see if there is play in the No. 1 intake and exhaust valve rocker arms. 4) Back the crankshaft to align the applicable tim- ing notch line on the flywheel or the damper. 5) Check the injection pump notch line and the injection pump flywheel notched line for align- ment. When the two notched lines are in alignment, the injection timing is correct. 2. Injection Timing Adjustment If the two notched lines are not in alignment or an injection timing change is necessary, do the injec- tion timing adjustment referring page 2-23 ~ 2-28 in the section 5. Note: The applicable injection timing crank angle of your engine is indicated on MAINTENANCE DATA PLATE affixed on the cyinder head cover top.fey MAINTENANCE 2—13 COMPRESSION PRESSURE MEASUREMENT 1. Operate the engine 10 warm-up until the coolant temperature reachs to 75°C (167°F). 2. Remove all of the injection, nozzles and the injection pipes. Nozzle Holder Replacer : 9-8523-2001-0 3, Attach a compression gauge to the No. 1 cylinder injection nozzle fitting hole, Note: Compression pressure may be measured starting at any cylinder and in no particular cylinder order. However, it is very important that the compression pressure be measured in each cylinder. Therefore, start at the No. 1 cylinder and work back. In this way, you will be sure to measure the compression pressure in each cylinder. Compression Gauge: Compression Gauge Adapter: 9-8543-1505-0 4. Crank the engine with the starter motor and take the compression gauge reading, kg/em*(psi/kPa) at 220 rpm at sea level [ Standard Cini 29 (412/2842) 28 (70/2551) 5. Repeat the procedure (Steps 2 and 3) for the re- maining cylinders. Compression pressure should be approximately the same for each cylinder. A variation exceeding 2.0 kg/em® (28.4 psi/19.6 kPa) is unacceptable. If the measured value exceeds the specified limit, the related parts must be checked,2-14 MAINTENANCE re TURBOCHARGER INSPECTION 1. Check the air intake duct connections for air lea~ kage. 2. Check the intake manifold connections for air loa- kage. 3. Check the exhaust duct connections for smoke lea- kage. 4, Check the turbocharger mounting nuts for loose- ness. 5. Check the oil feed pipe for oil leakage. 6. Check the oil return pipe joints for oil leakage.MAINTENANCE 2—15 ENGINE REPAIR KIT All of the numbered parts listed below are included in the Engine Repair Kit. The gaskets marked with an asterisk (*) are also included in the Top Overhau\ Kit. Valve guide seal Cylinder head gasket Head cover gasket Tappet chamber cover gasket O-ring Tachometer flange O-ring Timing gear case gasket Timing gear cover gasket Oil pan drain plug gasket Oil pan gasket Partial-flow oil filter O-ring Fuel filter joint bolt gasket Seven sens 13, 14. 16. 16. 7. 18, 19. 21. 23. Oil pipe O-ring Oil pipe O-ring ‘Water pump gasket Inlet pipe gasket Water outlet pipe gasket Gil-cooler gasket Water outlet pipe gasket Air inlet cover gasket Exhaust manifold gasket Injection nozzle gasket Injection pipe sleeve nut gasket Return pipe gasket216 MAINTENANCE RECOMMENDED LUBRICANTS ENGINE TYPE TYPES OF LUBRICANTS Diesel engine oil Without turbocharger CC or CD grade Diesel engine oil With turbocharger CD grade ENGINE OIL VISCOSITY CHART ENGINE OIL VISCOSITY GRADE — AMBIENT TEMPERATURE [single oradel SAE TOW EE | ambient —y"s0% TBC ®e 5 | MTemperature (20°F) ote) ge} BOP os SAE 15W, 40,20W—40,20W 50ENGINE ASSEMBLY | 3—1 SECTION 3 ENGINE ASSEMBLY 1 (DISASSEMBLY) TABLE OF CONTENTS ITEM General descreiption . Disassembly 1st step Disassembly 2nd step Disassembly 3rd step Cylinder head disassembly step . Piston and connecting rod disassembly step Rocker arm and shaft disassembly step .. Camshaft and gear disassembly step Crankshaft disassembly step3—2 ENGINE ASSEMBLY | ENGINE ASSEMBLY GENERAL DESCRIPTION For your reference: Note: This sectional drawing is based on 6RB1T standard engine. In this engine, an oil jet piston cooling is provided to reduce the piston thermal-load. An oil jet nozzle is located at the crankcase lower position per cylinder, they are pointing the piston back side cavity to allow the oil hit the place exactly. The laminated steel sheet cylinder head gasket is very durable. This type of gasket eliminates cylinder head bolt retightening, The tufftrided crankshaft which has a long service life is used for the turbocharged model and, it cannot be reground because of itis a tufftrided one. A nontufftrided normal type crankshatt is used for the naturally aspirated engine, The crankshaft main bearings and the connecting rod bearings are aluminum plated. These bearings are especially sensitive to foreign material such as metal scraps. it is very important that the oil ports and other related parts be kept clean and free of foreign material.ENGINE ASSEMBLY | 3—3 DISASSEMBLY 1ST STEP 295 3411 6 109786 102226 35) i i 18 f } ti t/t | Fy i = ene s i ME l i : | i | ‘ 19114 1715) 12/ | 23 a go | 20° 2 1 Disassembly Steps Senog neo 10. 12, 13, 14. 15. 16, 7. rer "18, 20. a2. 422. Cooling fan and spacer Fan drive belt Alternator and adjusting plate Engine stop device (if equipped) Air intake duct Cylinder head cover Fuel pipe ; filter to injection pump Fuel pipe ; filter to feed pump. Fuel return pipe ; injection pump Fuel leak off pipe ; outer Fuel pipe ; intake heater Fuel filter Oil pipe ; cylinder block to head Oil pipe ; filter outlet Oil pipe ; filter inlet Water drain valve Oi filter Injection pipes with clip Oil pipe ; injection pump in and out Injection pump coupling cover Injection pump Tachometer drive elbow {if equipped) 423, 2a. 25. 2. 28. 23. 30. 31. 32. 33. 34. 35. Bearing case or air compressor Turbocharger oil pipe ; inlet and outlet Turbocharger Water inlet pipe Water outlet pipe Water inlet pipe (manifold type) intake cover Exhaust manifold Dipstick and guide tube Oil pipe ; partial fiker Partial-flow oil filter Fuel leak off pipe : inner Injection nozzle Engine hanger ; front and rear Air breather Tappet cover Oil pipe ; oil cooler Cit-cooler Starter3—4 ENGINE ASSEMBLY | VY Important Operations 3. Alternator and Adjusting Plate 5 Loosen the generator fixing bolts A. Loosen the bolt B until the water pump drive belt can be easily removed. . Injection Pipes with Clip Disconneci the injection pipes by loosening the nuts in the numerical sequence shown in the illustration. (©, @ and @) Keep the knurled nut @ with the mating injection pipe neatly in group. Discard the used gasket @ and replace with new one. |. Injection Pump Use the shipping plugs (or something similar) to seal the injection pump delivery valve ports. This will prevent the entry of foreign material Remove the bolts on the injection pump side. Do Not attempt to disassemble the injection pump drive gear side coupling. Not to observe this will lead miss between the both coupling centers causing a coup- ling breakage, . Tachometer Drive Elbow Remove the tachometer drive elbow or the cover from the timing gear case,| gy 7 23, [+>] 8 “at N piving out Kev el Vv Note: In this removal, take care not to fall the air compressor drive shaft key into the timing gear inside. ENGINE ASSEMBLY | 3—5 Air Compressor 1) Remove the four air compressor mounting bolts and disconnect the air compressor water pipe. 2) Remove the injection pump gear fixing nut located at the air compressor crankshaft front end fixing the gear and the air compressor. In this condition, the air compressor is. still being mounted on the original place being sup- ported by the gear adapter in the timing gear case. 3) Use the remover to push out the air compres- sor from the adapter. Remover : 1-85210-036-0 4) Loosen the coupling lock bolt and remove the coupling from the compressor. Do not attempt to disengage the coupling by removing the coupling bolts. Bearing Case (For Non-Air Compressor Engine) Before the injection pump gear removal, the nut © must be removed from the bearing case shaft @ as shown in the illustration 1) Remove the nut @ and washers from the bear- ing case shaft @ front end, 2) Remove the bearing case bolts ® and drive out the shattwith the air compressor remover. Remover : 1-85210-036-0 . Injection Nozzle Holder Use the injection nozzle holder remover to remove the injection nozzle holder. Remover : 9-8523-2001.03—6 ENGINE ASSEMBLY | DISASSEMBLY 2ND STEP Disassembly Steps 1. Rocker arm and shaft Valve bridge Push rod Cylinder head Cylinder head gasket Crankshaft pulley with damper Flywheel Oil pan Timing gear case cover i EneENGINE ASSEMBLY | 3—7 VW Important Operations [=> 1. Rocker Arm Shaft Loosen the rocker arm shaft fixing bolts a little at @ ‘time in numerical sequence as specified. 4. Cylinder Head Loosen the cylinder head bolts a little at a time in ‘the numerical order shown in the illustration 6. Crankshaft Pulley with Damper 1) Block the flywheel with a piece of wood to pre- Use an appropriate wrench to remove the crankshaft pulley nut. 2) Use the taper bushing remover to remove the Teper ‘crankshaft end taper bushing. bushing oq I Remover : 9-8521-0123-0 re Ly a Taper bushing_| 1 7. Flywheel Loosen the flywheel bolt a little at a tir numerical order as specified. e in the3~8 ENGINE ASSEMBLY | Use the flywheel remover to remove the flywheel Flywheel remover : 1-85230-006-0ENGINE ASSEMBLY | 3—9 [4] disassemBLy spp STEP Disassembly Steps a a D> 1. PaaS Oil pump and pipe Idler gear Piston and connecting rod Flywheel housing Wear ring Crankshaft bearing cap and thrust Dearing {Lower halves} Thrust bearing (Upper halves) 410. ait A172 13, Crankshaft assembly Crankshaft bearing upper halves Camshaft assembly Roller tappet No. 7 camshaft bearing Oiling jet Timing gear case310 ENGINE ASSEMBLY | Carbon deponits V Vv important Operations 2, Idler Gear Measure the following points before disassembly. mmtin} Standard Limit Idler Gear End (0.003 — 0.10 0.20 Play (0.0001 — 0.0004) | _ (0.008) mmiin) Standard Limit Timing Gears 0.125 — 0.200 0.25 | Backlash (0.0049 — 0.0078) ___ (0.0010) | Includes the crankshaft gear, the camshaft gear, and the idler gear. Messure the crankshaft end play at the thrust bear- ing on the crankshaft front end before disassembly. mmtin) Standard Limit Crankshaft End 0.04 — 0.19 03 Play (0.0016 — 0.0075) | (0.0018) 3. Piston and Connecting Rod Note: Remove any carbon deposits from the upper part of the oylinder bore. ‘This will prevent the piston and the piston rings from damage when they are removed from the cylinder bore. 5. Wear Ring Use the wear ring remover to remove the wear ring, Remover : 1-85210-027-004055, ENGINE ASSEMBLY | 3—11 6. Crankshaft Bearing Cap and Thrust Bearing (Lower halves) Loosen the beating cap bolts a little at a time in the numerical order in the illustration. 7. Thrust Bearing (Upper halves) Use a wire or @ screw driver to remove the thrust bearing. 10. Camshaft Assembly 1) Fully loosen the roller tappet guide bolt but hald the bolt on the bolt hole. 2) Do not alllow the roller tappet to come in con tact with the camshaft. 3) Remove the camshaft bearing set screw from the cylinder body. 4) Carefully pull the camshaft out from the eylin- der bos. Note: The cam gear thrust plate is incorporated within the No. 1 camshaft bearing assembly. ‘44. Roller Tappet After the camshaft has removed out, remove the tappet guide bolt and pull the tappet out toward the oil pan.3~12 ENGINE ASSEMBLY | — ) Yy azz 12. No. 7 Camshaft Bearing Remove the No. 7 camshaft bearing from the cylin- der body after the camshaft removalENGINE ASSEMBLY | 3—13 [4] _cyLINDER HEAD DISASSEMBLY STEP Disassembly Steps 4-1. Split collar A 4, Intake and exhaust valve 2. Valve spring upper seat ‘A 5. Valve stem oii seal 3. Valve spring 6. Valve spring lower seat3—14 ENGINE ASSEMBLY | Vv al Important Operations 1. Split Collar 1) Place the cylinder head on a flat wooden sur- face. 2) Use the spring compressor to remove the split collar. Do not allow the valve to fall from the cylinder head. Spring Compressor ; 9-8523-1436-0 4, Intake and Exhaust Valve If the intake and exhaust valves are to be rein- stalled, mark their installation positions by tagging each valve with the cylinder number from which it was removed. If there is excessive valve wear or damage, the valve must be replaced, Refer to Page 4 of “Inspection and Repair” for the valve and valve seat insert procedure. Note: If there is excessive valve guide wear or damage, the valve guide must be replaced, Refer to Page 4 of “Inspection and Repair” for the vaive guide replacement procedure. ‘The valve and the valve guides must be replaced as a set, never replace only one or the other. 5. Valve Stem Oil Seal Use a pair of plier to remove the valve stem oil seal.ENGINE ASSEMBLY | 3—15 PISTON AND CONNECTING ROD DISASSEMBLY STEP Disassembly Steps A. 1. Piston ring 4. Piston 2. Snap ring 5. Connecting rod A 3. Piston pin 6. Bearing3~16 ENGINE ASSEMBLY | VY nportant operation 1. Piston Rings Use @ piston ring remover to remove the piston rings. Do not attempt to use some other tool. Piston ring stretching will result in reduced piston ring tension. Piston ring replacer : 1-85221-025-0 2. Snap Ring Use a pair of snap ring pliers to remove the snap ring. 3. Piston Pin Use your thumb to push out the piston pin. ton heating is unnecessary in this engine.ENGINE ASSEMBLY | 3—17 [42] ROCKER ARM AND SHAFT DISASSEMBLY STEP Disassembly Steps 41. Piston ring 4. Spring & 2. Snap ring 5. Shaft & 3. Piston pin [4] CAMSHAFT AND GEAR DISASSEMBLY STEP Disassembly Steps 1. Gear 3. No. 2-6 bearing 2. No, 1 bearing 4. Camshaft3~18 ENGINE ASSEMBLY | CRANKSHAFT DISASSEMBLY STEP Disassembly Steps A 1. Gear 2. Thrust collar 3. Crankshaft Y tment Operation 1. Gear Use a gear remover to remove the crankshaft gear. RemoverENGINE ASSEMBLY II 4—1 SECTION 4 ENGINE ASSEMBLY II (INSPECTION & REPAIR) TABLE OF CONTENTS ITEM PAGE Cylinder head ... Valve guide ... Valve and valve seat insert ..........000.0:00eeeeeee 7 Valve spring Tappet Push rod . Cylinder body and |i Piston and piston ring ... Piston pin .... Connecting rod . Crankshaft and bearings . Flywheel and flywheel housing . Timing gear case cover4—2 ENGINE ASSEMBLY Il INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection CYLINDER HEAD Cylinder Head Lower Face Warpage 1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face. 2. Regrind the cylinder head lower face if the mea- sured values are greater than the specified limit but less than the maximum allowable grinding stock. If the warpage amount exceeds the maximum allowable grinding stock, the cylinder head must be replaced, Cylinder Head Lower Face Warpage mmtin) ‘Maximum Allowable [___Stanaara Limit GEREISBE 0.05 (0.002) or less | 9-2 (0.008) 0.3 (0.012) Cylinder Head Height (Reference) mmiin) Standard Limit 146.9 — 147.1 (6.783 — 5.791) 146.6 (6.772) Note: If the cylinder head lower face is reground, valve depression must be checked. Water Jacket Water Pressure Test Use the hydraulic gauge to check the water jacket water Pressure. Apply water pressure to the water jacket at 5 kg/cm? (71.1 psi/49.1 kPa) for three minutes. Check the entire cylinder head for water leakage.ENGINE ASSEMBLY Il 4—3 Position of VALVE GUIDE Valve Stem and Valve Guide Clearance Measuring Method - | 1. With the valve stem inserted in the valve guide, set the dial indicator needle to “0”. 2, Move the valve head from side to side, Note the total dial indicator reading (TIR).. This value is the clearance between the valve stem and the valve guide. If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set Valve Stem Clearance mmtin} Standard Limit 0.05 — 0.10 02 Intake Side TR | (0.020 —0.004)_| _ (0.008) 0.08 — 0.10 0.25 Exhaust Side TR | 9003 — 0.004) oth Measuring Method - I! 1. Measure the valve stem outside diameter. Refer to “Vaive Stem Outside Diameter”. 2. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter. Valve Guide Replacement Valve Guide Removal Use 2 hammer and the valve guide remover to drive out the valve guide from the cylinder head lower face. Valve Guide Replacer : 9-8523-1222-0 Valve Guide Installation 1. Apply engine oil to the valve guide outer circumfer- ence. 2. Attach the valve guide replacer to the valve guide. 3, Use a hammer to drive the valve guide into position from the cylinder head upper face. Valve Guide Replacer : 9-8523-1222-04—4 ENGINE ASSEMBLY II 4, Measure the height of the valve guide upper end from the upper face of the cylinder head. Valve Guide Upper End Height (H) (Reference) mmiin) Inlet Valve 25.0 (0.984) Exhaust Valve 295 (1.161) Note: If the valve guide has been removed, both the valve and the valve guide must be replaced as a set. VALVE AND VALVE SEAT INSERT Valve Stem Outside Diameter Measure the valve stem diameter at three points. If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Outside Diameter mmtin} Standard Limit 10.92 — 10.94 Intake valve (0.4302 — 0.4310) 10.85 7090-1092 (0.4275) Exhaust valve | (0.4294 — 0.4302) Valve Thickness Measure the valve thickness If the measured value is less than the specified limit, the vaive and the valve guide must be replaced as a set. Intake and Exhaust Valve Thickness mmtin) Standard Limit Intake Valve 3.3 (0.130) 28 (0.110) Exhaust Valve 2.0 (0.079) 1.5 (0.059)ENGINE ASSEMBLY II 4—5 oxoos = Tentsct width Valve Depression or Projection 1, Install the valve to the cylinder head. 2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface. If the measured value exceeds the specified limit, the valve seat insert and/or valve must be replaced, the valve guide must be also replaced For Piston Type A mm(in} Valve | Standard [Limit ; —1.5 (0.06) Projection Intake | 0.5 (0.020) sips rragsion) Depression | Exhaust | 1.0 (0.040) | 3.0 (0.12) * The projection will be @ valve depression when the mating valve seat comes to wear off. For Piston Type B mm(in) Valve | Standard Limit Depression | Intake | 1.8 (0.071) | 3.8 (0.180) Depression | Exhaust | 1.6 (0.063) | 3.6 (0.142) Refer the description in page 4-19 on the Piston Type A and B Valve Contact Width 1. Inspect the valve contact faces for roughness and unevenness. Make smooth the valve contact surfaces. 2. Measure the valve contact width If the measured value exceeds the specified limit, the valve seat insert must be replaced mmfin) Valve | Standard Limit Valve Con- | Intake | 1.9 (0.078)_|_3.4 (0.134) tact Width Exhaust | 2.0 (0.079) 4.3 (0.168)4—6 ENGINE ASSEMBLY II Valve Seat Insert Replacement Valve Seat Insert Removal @ of the 1. Are weld the entire inside circumference valve seat insert ©. 2. Allow the valve seat insert to cool for a few minutes, This will invite contraction and make removal of the valve seat insert easier. 3. Use a screwdriver @ to pry the valve seat insert free. Take care not to damage the cylinder head ©. 4, Carefully remove carbon and other foreign material from the cylinder head insert bore. Valve Seat insert installa 1. Carefully place the attachment © (having a smaller outside diameter than the valve seat insert) on the valve seat insert ©. n Note: The smooth side of the attachment must contact the valve seat insert, 2. Use a bench press @ to gradually apply pressure to the attachment and press the valve seat insert into place. Note: Press pressure required is 2,500 kg (5,512 Ibs.) Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will resultENGINE ASSEMBLY Il 4—7 Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert sur- face. 2. Use a valve cutter (15°, 45°, and 75° blades) to mini- mize scratches and other rough areas. This will bring the contact width back to the standard value Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surtace. Valve Seat Angle 45" Note: Use an adjustable valve cutter pilot. Do not allow the vaive cutter pilot to wobble inside the valve guide Angle Location Standard | Intake Valve Seat Angle © 30" Exhaust Valve Seat Angle © 45 Note: Use an adjustable vaive cutter pilot. Do not allow the cutter pilot to wobble inside the valve guide. 3. Apply abrasive compound to the valve seat insert surface 4, Insert the valve into the valve guide. 5. Hand lap the valve and the valve seat with a lapp- ing cup. This will provide optimum vaive and vaive seat con- tact for effective gas sealing 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve.4—8 ENGINE ASSEMBLY II + | — saueranass | VALVE SPRING Valve Spring Free Length Use a vernier caliper to measure the valve spring free length. If the measured value is less than the specified limit, the valve spring must be replaced. mm(in) Mating ; = Pistan Tape | Standard Limit Valve A 66.4 (2.62) | 62.0 (2.44) Spring Free 1 | 66.4 (2.62) | 69.0 (2.72) benath E | 73.6 (290) | 69.0 (2.72) 1= Intake Valve Spring, E = Exhaust Valve Spring Refer to the description in page 4-19 on the Piston Type Aand B Valve Spring Squareness Use a surface plate and a square to measure the valve spring squareness. If the measured value exceeds the specified limit, the valve spring must be replaced Valve Spring Squareness Intake Valve Spring, E Mating Piston Type| Standard A 1.50 (0.06) T_| 150 (0.06) 8 E | 20 (0.08) mmiin) Limit 2.5 (0.10) 25 (0.10) 3.0 (0.12) xxhaust Valve Spring Refer to the description in page 4-19 on the Piston Type Aand B.Roller height x78 ENGINE ASSEMBLY I! 4—9 Valve Spring Tension Use a spring tester to measure the valve spring tension. If the measured value is less than the specified limit, the valve spring must be replaced. kgllb) Mating | Piston | H mm(in) | Standard | Limit | Type 5 A__| 83.1 (2.1) | 39.0 (86.0)| 30.9 (68.1) pring Tension | g |_| 58.1.2.) | 39.0 (86.0)/ 30.9 (68.1) E | 58.1 (2.3) | 39.0 (86.0)| 30.9 (68.1) |= Intake Vaive Spring, E — Exhaust Valve Spring “H" refers to the spring compressed height. Refer to the description in 4-19 on the Piston Type A and B Valve Bridge Clearance between the valve ‘ridge and valve bridge guide. mmtin) Standard Limit 0.02 —0.0a7 0.10 (0.0008 — 0.0019) (0.004) TAPPET (Cam Follower or Valve Litter) Inspect the tappets for excessive wear, damage and any abnormalities. Use a micrometer to measure the tappet diameter. mmi{in) Standard Limit 29.94 — 29.97 29.9 Tappet Diameter | (180 — 1.181) | (1.178) mmi{in} Standard | Limit Roller Height 25 (0.099) 1.5 (0.059)4—10 ENGINE ASSEMBLY II Use a dial indicator to measure the clearance between the tappet and cylinder body tappet travelling bore. mmtin) Standard Limit Tappet and Tappet _ Treveing Bore” | gorz — 0.0095) | 0.0059 | Clearance 2 PUSH ROD Use a filler gauge to measure the valve push rod run- out, Roll the push rod along a smooth flat surface as illus- trated. mm(in) Limit Push Rod Run-Out 05 (0.02) ROCKER ARM SHAFT AND ROCKER ARM Inspect all disassembled parts for wear, damage and any abnormalities. Rocker Arm Shaft Ou Use a micrometer to measure the rocker arm outside diameter, If the measured value is less than the specified limit, the shaft must be replaced. je Diameter mm(in) Standard Limit Rocker Arm Shaft, 29.98 — 30.00 29.85 Diameter (1.181 — 1.182) (1.176) Rocker Arm Correction inspect the rocker arm valve stem contact surfaces for ridge © and scoring @. If the surfaces have light ridge or scoring, they may be honed with an oil stone. If the ridge or scoring is severe, the rocker arm must be replaced,ENGINE ASSEMBLY | 4—11 Rocker Arm Shaft and Rocker Arm Clearance 1. Use a vernier caliper to measure the rocker arm bushing inside diameter. mm(in} ‘Standard Rocker Arm Bushing | 30.03 — 30.08 Inside Diameter (1.182 — 1.185) | (1.185) 2. Measure the rocker arm shaft outside diameter. Replace either the rocker arm or the rocker arm shaft if the clearance exceeds the specified limit. mm(in) Standard | Limit Rocker Arm Bushing 0.03 — 0.10 0.2 and Rocker Arm Shaft Clearance (0.012 — 0.004) (0.008) 3. Check that the rocker arm oil port is free of obstruc- tions. If necessary, use compressed air to clean the rocker arm oil port. IDLER GEAR AND IDLER GEAR SHAFT 1, Use a micrometer to measure the idler gear shaft diameter. If measured diameter exceeds specified limit, replace the idler gear shaft. mmfin} Standard Limit Idler Gear Shatt 75.93 — 75.96 75.85 Diameter (2992 — 2.993) | (2.998) 2. Use a dial indicator to measure the idler gear inside diameter, mm(in) Standard Limit “Wdler Gear and idier | 0.04 —0.10 02 | Gear Shaft Clearance | (0.0016 — 0.004) | (0.008)4—12 ENGINE ASSEMBLY Il CAMSHAFT Inspect all disassembled parts for wear, damage or other abnormal conditions Cam Lobe Height and Camshaft Diameter Use a micrometer to measure the cam lobe height and camshatt diameter. If the cam lobe height is less than the specified limit, the camshaft must be replaced mm(in) Standard Cam Lobe Height (C-D) | 7.53 (2.96) | 7.03 (2.77) Camshaft Diameter mmtin) Standard Limit 55.94 — 55.97 55.91 No.1 Journal | (2.204 — 2.205) (2.203) 43.95 — 43.98 43,92 No. 27 Journal | (1.732 — 1.733) (1.730) Camshaft End Play 1. Before removing the camshaft gear ©, push the thrust plate @ as far as it will go toward the cam- shaft ®. 2. Use a feeler gauge to measure the clearance between the thrust plate and the camshaft gear. If the measured value exceeds the specified limit, the thrust plate must be replaced. Camshaft End Play mmtin) Standard Limit 0.06 (0.002) 0.2 (0.008)IE] SIME ENGINE ASSEMBLY Il 4—13 Thrust Plate Replacement Thrust Plate Removal 1, Use the universal puller @ to remove the camshaft gear ®. Universal Puller : 5-8840-0086-0 2. Remove the thrust plate (No. 1 camshaft bearing) ® Thrust Plate Install Install the No. 1 camshaft bearing (combined with a camshaft gear thrust plate) to the front most cam- shaft journal 2. Apply engine oil to the bolt setting face and the bolt threads, 3. Install the camshaft gear. Camshaft Gear Torque kami FUN. 76.0 + 1.5 (108.5 + 10.8/147.2 + 14.7) CYLINDER BODY AND LINER Note: ‘The cylinder liner of the 6RB1 and 6RBIT engines have two cylinder liner types depending on the engines. The types are: A. Press Fit Type adopted on the engine serial number 501436 and the earlier ones. In these engines, the cylinder liner must be installed ina press-in method, B. Loose Fit Type adopted on the engine serial number 801437 and the later ones In these engines, the cylinder liner may be installed in a manually inserting. Cylinder Liner Bore Measurement Use a cylinder indicator to measure the cylinder liner bore at measuring point @ in the lateral X-X and axial Y-Y directions of the crankshaft. Measuring Point : ©; 25 mm(1.0 in), @; 130 mm(6.1 in), @; 230 mm(9.1 in}4—14 ENGINE ASSEMBLY Il Cylinder Liner Bore Diameter mm(in) Nominal Limit [ 135.0 (6.319) 136.5 (5.378) Note: If the cylinder liner bore is scored or scorched, the cylin: der liner must be replaced. If the measured value exceeds the specified limit, the cylinder liner must be replaced. Cylinder Liner Projection Inspection 1. Hold a straight edge © along the top edge of the cylinder liner to be measured Or, use a dial indicator to measure the cylinder liner projection, 2. Use a feeler gauge @ to measure each cylinder liner projection Cylinder Liner Projection Standard 0.05 — 0.10 (0.002 — 0.0039) The difference in the cylinder liner projection height | between any two. adjacent cylinders must not exceed 0,02 mm (0.0008 in). Cylinder Liner Replacement Cylinder Liner Removal 1. Set the cylinder liner remover to the cylinder liner. 2. Check that the remover shaft ankle is firmly gripp- ing the cylinder liner bottom edge. 3. Slowly turn the remover shaft handle counterclock- wise to pull the cylinder liner free. Cylinder Liner Remover : 9-8523-1186-0 Note: Take care not to damage the cylinder body upper face during the cylinder liner removal procedure. 'ENGINE ASSEMBLY I 4—15 Cylinder Liner Grade Selection ‘The term “grade” refers to the cylinder body inside diameter and the cylinder liner outside diameter combi- nation. Measure the cylinder body bore diameter and select the appropriate cylinder liner grade. Cylinder Body Bore Measurement 1. Take measurements at measuring point © across the positions W-W, X-X, Y-Y, and Z-Z. Measuring Point © : 130 mm (6.118 in) 2. Calculate the average value of the four measure- ments to determine the correct cylinder liner grade. Cylinder Liner Outside Diameter Measurement 1. Take measurements at measuring points ©, ®, and ©. Measuring Points mm(in): ® 20 (0.984) ® 130 (5.118) ® 220 (9.055) 2. Calculate the average value of the 6 measurements to determine the correct cylinder liner grade. Press Fit Type mmtin) Cylinder Liner Fitting Clearance ) 0.006 — 0.046 (interference) Standard (0.0002 — 0.0078) Cylinder Bore and Cylinder Liner Outside Diameter Combinations (Reference) mm(in) Cylinder Liner Grade inder Bore 141.000 — 141.020 (6.5512 — 5.5520) (6.5522 — 5.5530) 141.021 — 141.040 | 141.047 — 141.066 [16.5520 — 5.5528) (6.5530 — 5.5538)4—16 ENGINE ASSEMBLY II Loose Fit Type mmtin) Cylinder Liner 0.076 — 0.045 Clearance Standard (0.0006 — 0.0018) Cylinder Bore and Cylinder Liner Outside Diameter Combinations (Reference) mm(in) Pa Cylinder Liner Grade Cylinder Bore Oieweteneen i 741.000 — 141.015 | 140.970 — 140.984 (5.5512 — 5.5518) (5.5500 — 5.5506) a 141,016 — 141.030 | 140.985 — 141,000 (5.5518 — 5.5524) (5.5506 — 5.5512) Cylinder Liner Installation 1. Carefully wipe away any foreign material from the cylinder liner inside and outside surfaces and the cylinder bore. Use new kerosene or diesel oil to thoroughly clean, the cylinder liner and bore surfaces. 3, Use a clean rag to remove all traces of kerosene or diesel oil from the cylinder liner and bore surfaces. Installation Steps for Press Fit Type Cylinder Liner 4, Insert the cylinder liner into the cylinder body from | the top of the cylinder. No specific installation direction required. 8. Set the cylinder liner installer to the top of the cylin der liner, Cylinder Liner Installer : 9-8522-0043-0 6. Check that the cylinder liner is set perpendicular to the cylinder. Check that the cylinder liner does not wobble. 7. Use a bench press to press in the cylinder liner into the cylinder body. 8 After installing the cylinder liners, measure the oylinder liner projection. Refer to “Cylinder Liner Projection Inspection”.ENGINE ASSEMBLY Ut 4—17 Installation Steps for Loose Fit Type Cylinder Liner Insert the cylinder liner into the cylinder body. As this liner is of a loose fit type, the liner may be inserted smoothly without exerting any forcing power. There is no specific liner installation direction, ston Grade Selection for Press Fit Type Cylinder Liner The term “piston grade” refers to the piston diameter and cylinder liner bore combination. Selection of the proper piston grade will ensure efficient engine operation, free from cylinder liner and piston problems, Measure the cylinder liner bore after installing the cylin- der liner. Then select the appropriate piston grade for the installed cylinder liner. Cylinder Liner Bore Measurement 1. Locate the two measuring points, Cylinder Liner Measuring Point ©: 26 mm (0.984 in), Cylinder Liner Measuring Point @: 130 mm (5.122 in) 2. Measure the cylinder liner bore at measuring point @ and @ in four different directions (W-W, X-X, 3. Calculate the average value of the eight measure: ments, mm(in} eee vylinder Lines Bere Total 134.970 — 135,069 Indicator Reading (5.3138 — 5.3177), Note: It is most important that the correct piston grade be Used. Failure to select the correct piston grade will result in piston seizure, ‘Always measure the cylinder bore and select the appro- priate piston grade.4—18 ENGINE ASSEMBLY II Piston Outside Diameter Measure the piston outside diameter at the measuring position L shown in the illustration. Piston Grade mmiin) Grade abt eRBIT a 134,763 — 134.782 | 134,747 — 134.766 (5.3056 — 5.3064) {5.3050 — 5.3058) | 134788 — 194.02 | 134.767 — 134.786 (5.3064 — 5.3072) (5.3058 — 5.3066) m | 134.803 — 134.822 | 134.787 — 134.806 (6.3072 — 5.3080) (5.3066 — 5.3073) N 134,823 — 134.842 134.807 — 134.826 (5.3080 — 5.3088) (5.3073 — 5.3081) Measur- ing Posi- | 71.15 (2.80) 71.15 (2.80) tion L Cylinder Liner Bore and Piston Clearance mm(in) RBI REIT 0.208 — 0.227 0,224 — 0,243 (0.0082 — 0.0089) | (0.0088 — 0.0996} Cylinder Liner Bore and Piston Clearance Note: Cylinder liner piston kit clearances are preset. How: ever, the cylinder liner installation procedure may result in slight decreases in cylinder liner bore clearances. Always measure the cylinder liner bore clearance after installation to be sure that it is correct.ENGINE ASSEMBLY Il 4—19 Pron Piston Grade Selection for Loose Fit Type Cylinder Liner Cylinder Liner Bore Measurement 1. Locate the two measuring points. Cylinder Liner Measuring Point ©: 25 mm (0.984 in) Cylinder Liner Measuring Point @: 130 mm (5.122 in} 2. Measure the cylinder liner bore at measuring point ® and @ in four different directions (W-W, X-X, Y-Y, and 2-2). 3. Calculate the average value of the eight measure- ments. mmtin) Cylinder Liner Bore Total 134.990 — 135.059 Indicator Reading (6.3146 — 5.3173) Note: It is most important that the correct piston grade be used. Failure to select the correct piston grade will result in piston seizure. Always measure the cylinder bore and select the appro- priate piston grade Note: In the 6RB1 and GRB1T engines later than the serial number 501437, a two types of pistons might be used depending on the engines ‘The piston types are: A. The type having a square shape combustion cham- ‘ber at the piston crown 8. The type having a round shape combustion cham- ber at the same place. In the cylinder liner and piston grade selection, they have a different grade dimensions, therefore, take care not to confuse the respective grade dimensions. For the brebity of the description, the respective piston type is called hereinafter Piston Type A for the item A and, Piston Type B for the item B.4—20 ENGINE ASSEMBLY II Piston Outside Diameter Measure the piston outside diameter at the measuring position L shown in the illustration. Piston Grade mm(in) Piston Type A Piston Type B Rat eneiT eABIT 134,783-134,795,134.767—134,779| 134.777—134.789| (5.3064—5.3069) | (5.5098--5.3063) | (5.3062—5.3067) ]134.796— 134 08 194.780— 194 792) 134,790—134.802 {2 9088—5.307H) (5 3088-5.360) | (2 087-8.0072) 35 194,803-134.815| ¢_|134809—138.801/194.793—198 {8.3074—5.3079) | (5.3068-5.3073) | (5.3072—5.3077) Measuring Pea 71.45 (2.80) 66.15 (2.60) Cylinder Liner Bore and Piston Clearance Cylinder Liner Bore and Piston Clearance mmtin) Piston Type A Piston Type B ‘REI eReIT eReIT 0,206—0.230 | 0.220.246 | 0.212-0.236 (0.0081—0.0091) | (0.0087—0.0097) | (0.0083—-0.0093) Note: Cylinder liner piston kit clearances are preset. How- ever, the cylinder liner installation procedure may resuit in slight decreases in cylinder liner bore clearances. Always measure the cylinder liner bore clearances after installation to be sure that it is correct.ENGINE ASSEMBLY 11 4—21 PISTON AND PISTON RING Piston Ring and Piston Ring Groove Clearance Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove. Do this at several points around the piston. If the clearance between the piston ring and the piston fing groove exceeds the specified limit, the piston ring must be replaced Piston Ring and Piston Groove Clearance mmiin) Standard Limit a ] 010-013 0.20 ‘st compression ring || (9.0939 — 0.0051) (0.0079) 0.05 — 0.08 0.15 2nd compression ring 19.4999 — 0.0032) (0.0059) 002-006 | 0.18 [Otrina | (o.0008 — 0.0024) | (0.0058) Piston Ring Gap 1. Insert the piston ring horizontally {in the position it would assume if it were installed to the piston) into the cylinder liner. 2. Use an inverted piston to push the piston ring into the cylinder liner until it reaches’ either measuring point © or meesuring point ®. Cylinder liner diameter is the smallest at these two points. Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal Cylinder Liner Measuring Point @: 10 mm (0.39 in) Cylinder Liner Measuring Point @: 130 mm (6.12 in) 3. Use a feeler gauge to measure the piston ring gap. If the measured value exceeds the specified limit, the piston ring must be replaced mmfin} Standard Limit ist Compression 03-05 | 18 Ring Gap (0.012 — 0.020) | (0.059) 2nd Compression 0.45 — 0.65 18 Ring Gap (0.018 — 0.026) | (0.059) 0.35 — 0.85 18 Oil ring Gap (0.014 — 0.022) | _ (0.059)4—22 ENGINE ASSEMBLY I PISTON PIN Piston Use a micrometer to measure the piston pin outside diameter at several points, If the measured piston pin outside diameter exceeds the specified limit, the piston pin must be replaced The “Combination” refers to the piston combustion chamber type and the relative parts combination. See the page 4-19. mmi(in) wating piston Type Standard Limi Piston Fin A 6001970) | 49.7 (1.968) | Diameter | B 52.0 (2.049) | 51.97 (2.048) Refer to the description in the page 4-19 on the Piston Type A and B. Piston Pin and Pin Hole Clearance Determine the clearance between the piston pin and the piston pin hole by calculating the difference between the piston pin hole diameter and the piston pin diame- ter, mmi(in) Standard Limit Piston Pin and Piston | 0.007 — 0.020 0.05 Pin Hole Clearance (0.0003 — 0.0008) | (0.002) Piston Pin Fitness Lubricated piston pin should fit snugly into the piston or connecting rod small end at normal workshop tempera- ture when a finger pressure is exerted,ENGINE ASSEMBLY I! 4—23 CONNECTING ROD Connecting Rod Alignment Use a connecting rod aligner to measure the parallelism between the connecting rod big end hole and the con- necting rod small end hole, If either the measured parallelism exceeds the specified limit, the connecting rod must be replaced Connecting Rod Alignment (Per Length of 100 mm (3.94 in)) mm(in) Standard Limit Parallelism Less than oy 0.08 (0.002) (0.004) 0.15 — "Less than 0.05 (0.002) (0.008) Piston Pin and Connecting Rod Small End Bushing Clearance Use a caliper calibrator and a micrometer to measure the piston pin and connecting rod small end bushing clearance. If the clearance between the piston pin and the connect- ing rod small end bushing exceeds the specified limit, replace either the piston pin or the connecting rod bushing. mmi(in} [Standard Limit Piston Pin and Connet-| 9 999 _ 9,937 Om ting Rod Small End Bushing Clearance | (0.0008 0.0015) | (0.004) Connecting Rod Bushing Replacement Connecting Rod Bushing Removal 1. Clamp the connecting rod in a vise. 2. Use the remover and a bench press or hammer to remove the connecting rod bushing Remover : 9-8522-004204—24 ENGINE ASSEMBLY II Connecting Rod Bushing Installation Use the connecting rod bushing installer to install the connecting rod bushing Connecting Rod Bushing Installer : 9-8522-0042.0 Note: The Connecting rod bushing oil port must be aligned with the connecting rod oil port. Use a piston pin hole grinder © fitted with a reamer @ or an adjustable pilot reamer to ream the piston pin ia [9] [¥ hole. mmtin) Mating Piston Type nee A 50.020 — 60.032 Connecting Rod hisoaeerania) Bushing Inside || ———— sl Diameter B 52.020 — 52.032 (2.0496 — 2.0501) Refer to the description in the page 4-19 on the Piston ‘Type A and B. fe Connecting Rod Bearing Inspection 1. Inspect the connecting rod bearing for excessive wear and damage. 2. Fit the connecting rod bearing lower half into the connecting rod bearing cap. 3. Check the connecting rod bearing lower half ten- sion. If the tension is insufficient, the bearing must be replaced, 4, Tighten the connecting rod and the bearing cap to the specified torque kg.milb.ft/N-m) TstStep | 2nd Step Connecting Rod and Bearing tHe erase Cop Bolt Tightening Torque | (60.6/68.6) Go * 26 5. Use an inside dial indicator to measure the connect- ing rod inside diameter. mm{in} Connecting Rod Bearing 89.96 — 90.00 Nominal Diameter (3.5444 — 3.5460)a ENGINE ASSEMBLY Il 4—25 CRANKSHAFT AND BEARINGS The 6RB1 (naturally aspirated) engine has a normal type crankshaft but, the 6RBIT (turbocharged) engine has the Tafftride Type crankshaft. The two type of engines have different crankshaft repair method respectively. # The 6RB1 engine’s crankshaft can be repaired by regrinding and the use of undersize main bearings and the connecting rod bearings. © However, the 6RBIT engine's crankshaft (Tafftride type) cannot be repaired by the above method. The tafftride type crankshaft must be replaced with a new one when it has excessively worn than the specified wear limit. ‘Summarization of the Basic Dimi Steps Main Bearing Inside Diameter ~ A Crankshaft Journal Diameter — B Crankshaft Journal-to-Main Bearing Clearance ~ A-B=C To obtain C, A and B is measured Also measure the crankpin-to-connecting rod bearing clearance (C’) in similar way The clearances C or C’ are a base to determine a way of repair. Further the descriptions cover the way of repair as sum- marized below. sion Measurement 1) Replace the bearings with of standard sized ones when the crankshaft journal wear amount and/or crankpin wear amount is within an aliowable extent but the bearing wear amount is close to the speci fied limit. 2) Regrind the crankshaft journal surfaces and/or crankpin surfaces and, replace the bearings with of undersized ones when the crankshaft journal wear and crankpin wear are exceeding the specified limit Crankshaft and Bearings Inspection 1, Inspect the crankshaft journal surfaces and the crankpin surfaces for excessive wear and damage. 2. Inspect the oil seal fitting surfaces of the crankshaft front and rear ends for excessive waar and damage. 3. Replace or repair the crankshaft if any excessive wear or damage is discovered. 4. Inspect the crankshaft oil ports for obstructions, 5. Use high pressure air to clean the oil ports if neces- sary.4—26 ENGINE ASSEMBLY It Crankshaft Journal and Crankpin Outside Diameter Measurement 1. Use a micrometer to measure the crankshaft journal diameter actoss points © — @ and @ — ®. 2. Use the micrometer to measure the crankshaft jour- nal diameter at the two points (® and ®) 3. Repeat steps 1 and 2 to measure the crankpin out- side diameter. mm(in} Standard Crankshaft Journal 99,880 — 99.905 Diameter (3.9353 — 39363) mmtin) Standard 89.895 — 89.925 Crankpin Diameter eerie cian Crankshaft Journal Main Be Bearing Clearances If the bearing clearance exceeds the specified limit, the crankshaft must be reground (except 6RB1T engine) and/or the bearing must be replaced, ing and Connecting Rod mmiin) Position at| Standard | Limit Crankshaft Journal : 0 0.045—0.120 | 0.14 and Main Bearing | Bearings | (0.0018—0.005) (0.006) Clearance mmfin) Standard Limit eomener 0.035—0.105 0.13 Connecting Rod (@.0014—0.0041) | (0,005) Bearing ClearanceENGINE ASSEMBLY I 4—27 Crankshaft Journal Bea ment 1. Install the main bearing cap with bearings to the cylinder body with the specified torque and facing the arrow mark on the bearing cap toward front, and place them in order of punched cylinder num- 19 Inside Diameter Measure- bors kg-mi(lb.ft/N-m) pei 8 [2] cranahan tan oorna m0130 Cap Bolt Torque (282.0 + 21.6/382.6 + 29.4) 2. Use an inside dial indicator to measure the main bearing diameters. mm(in} ‘Main Bearing Nominal 100 (3.937) Diameter Connecting Rod Bearing Inside Diameter Measure- ment 1. Lubricate the connecting rod bearing cap nut seving face and the bolt threads with a coat of engine oil 2, Tighten the connecting rod bearing cap nuts to the specified torque in two steps with working up 2 little at a time in the numerical order as illustrated. kgam(lb.ft/Nem) ist Step 2nd Step 5 10.0 +05 Connecting Rod " (72.3 + 3.6/ Bearing Nut Torque | (50.6/68.6) ae 3, Use an inside dial indicator to measure the connect- ing rod bearing inside diameter. kg-m|tb.f/N-m) Connecting Rod Bearing Nominal Diameter meee4—28 ENGINE ASSEMBLY II Crankshaft Run-Out 1. Mount the crankshaft on @ set of V-blocks. 2, Set a dial indicator to the center of the crankshaft journal 3. Gently turn the crankshaft in the normal direction of engine rotation, Read the dial indicator (TIR) as you turn the crank- shaft, If the measured value exceeds the specified limit, the crankshaft must be replaced, mmiin} Standard Limit Crankshaft Run-Out 0.05 (0.020)_| 0.30 (0.012) if the crankshaft generated crack after repair, replace the crankshaft, Crankshaft for 6RB1T engine can not be bench pressed, because itis finished with tufftride method, Main Bearing and Connecting Rod Bearing Tension Check to see if the bearing has enough tension, so that good finger pressure is needed to fit the bearing into position Crankshaft Regrinding To ensure crankshaft reliability, pay close attention to the following items during and after the crankshaft grinding procedure. mmtin) Undersize Bearing Availability 0.25 (0.010) 0.50 (0.020) Note: Crankshaft for 6RB1T can not be reground because it is, finished with TUFFTRIDE method ‘Therefore, the undersize bearings are not prepared for this model engines.é No. 1 Journal ENGINE ASSEMBLY 11 4—29 Crankshaft Regrinding Procedure 1. Regrind the crankshaft journals and the crankpins. 2, Fillet the crankshaft journal and the crankpin sur- faces fillet position respectively shown in the illustration to the following measurement. mm(in) Position Specified Radius @ | ___ 8.2 + 0.2 (0.204 + 0.008) a) 58 + 0.3 (0.229 + 0.012) _ © 48 £03 (0.189 + 0.012) = The fillet curve surfaces and the journal surfaces must be blended smoothly keeping free of ridge or step condition at the blending zone. 3. Finish the crankshaft journal and crankpin oil port corners to a smoath surface having a chamfer radius of 1 mm (0.04 in). Crankshaft Journal and Crankpin Surface 0.4 wor less Roughness 4, Measure the crankshaft journal and crankpin clear- Refer to “Crankshaft Journal Clearance" and “Crank- pin and Clearance" on Page 4-26. 6. Measure the crankshaft run-out Refer to “Crankshaft Run-Out” on Page 4-28.4—30 ENGINE ASSEMBLY II BOG Crankshaft Grinding Limit mm(in Limit Crank Journal Diameter 99.38 (3.916) Crankpin Diameter 89.40 (3.522) Undersize bearings 0.28 mm (0.010 in) and 0.50 mm (0.020 in} are available to compensate for excessive clearance between the crankshaft journal bearing and the crankshaft. Regrinding of the crankshaft to fit the undersize bearings is required. mm(in) Poston at] Standard Umit and Main Bearing | Bearings | (0.002—0.005) | (0.005) Undersize bearings 0.25 mm (0.010 in) and 0.50 mm (0.020 in) are available to compensate for excessive clearance between the crankpin bearing and the cran! shaft. Regrinding of the crankshaft to fit the undersize bearings is required mmi(in) Standard Crankpin and Connecting Rod Bearing Clearance 0.035—0.105 0.13 (0.0014—0.041) (0.0051) Plastigage Clearance Measurements This is another method to measure the crank journal bearing clearance. Crankshaft Journal Bearing Clearance 1. Clean the cylinder body, the journal bearing fitting portions, the bearing cap, and the inside and out- side surfaces of the bearing. 2. Install the new journal bearing to the cylinder body. 3. Carefully place the crankshaft on the bearing, 4, Rotate the crankshaft approximately 30° to seat the bearing. 5. Place the Plastigage (arrow) over the crankshaft journal across the full width of the bearing. Apply engine oil to the Plastigage to keep it from falling. 6. Install the bearing cap with the bearing, 7. Tighten the bearing cap to the specified torque. Do not allow the crankshaft to turn during bearing cap installation and tightening.ENGINE ASSEMBLY Il 4—31 Remove the bearing cap. Compare the width of the plastigage attached to either the crankshaft or the bearing against the scale printed on the plastigage container. if the measured value exceeds the limit, perform the following additional steps. 1) Use a micrometer to measure the crankshaft outside diameter. 2) Use an inside dial indicator to measure the bearing inside diameter. 3) Replace the crankshaft and/or the bearing if the measured value(s) exceed the limit Crankshaft Pin Bearing Clearance 1 Clean the crankshaft, the connecting rod, the bear ing cap, and the bearings. Install the bearing to the connecting rod, Do not allow the crankshaft to move when installing the bearing cap, Hold the connecting rod (with the bearing installed) against the crankshaft pin. Attach the plastigage to the crankshaft pin Apply engine oil to the plastigage to keep It from falling. Install the connecting rod bearing cap and tighten it to the specified torque. Do not allow the connecting rod to move when, installing and tightening the bearing cap. Remove the bearing cap. Compare the width of the plastigage attached to either the crankshaft or the bearing against the scale printed on the plastigage container. If the measured value exceeds the limit, perform the following additional steps. 1) Use a micrometer to measure the crankshaft outside diameter. 2) Use an inside dial indicator to measure the bearing inside diameter, 3) Replace the crankshaft and/or the bearing if the measured value(s) exceed the limit.4—32 ENGINE ASSEMBLY I! ‘Ammaniun evarous Tes liquid should onion fat be applies to Brea aroun Face in contact Sriournal oo Crankshaft Tufftriding Inspection (For 6RB1T only) crankshaft. There must be no traces of oil on the surfaces to be inspected. 2. Prepare a 5 — 10% solution of ammonium cuprous chloride (dissolved in distilled water). 3. Use 2 syringe to apply the solution to the surface to be inspected Hold the surface to be inspected perfectly horizontal to prevent the solution from running. Note: Do not allow the solution to come in contact with the oil ports and their surrounding area. A 1. Use an organic cleaner to thoroughly clean the Judgement 1. Wait for thirty to forty seconds. If there is no discoloration after thirty or forty sec- onds, the crankshaft is useable. If dicsoloration appears (the surface being tested will become the color of copper), the crankshaft must be replaced 2. Steam clean the crankshaft surface immediately after completing the test. Note: The ammonium cuprous chloride solution is highly cor- rosive, Because of this, it is imperative that the surfaces being tested be cleaned immediately after completing the test. Crankshaft Timing Gear Replacement Crankshaft Timing Gear Removal 1. Use the crankshaft gear remover @ to remove the crankshaft gear ®. 2. Remove the crankshaft feather key. Crankshaft Timing Gear Remover. Crankshaft Timing Gear Installation 1. Install the crankshaft gear. 2. Use the crankshaft gear installer © to install the crankshaft gear @. ‘The crankshaft gear timing mark ("XX") must be facing outward, Crankshaft Gear Installer : 9-8522-0025-0ENGINE ASSEMBLY II 4—33 FLYWHEEL AND FLYWHEEL HOUSING (REAR OIL SEAL) Ring Gear Inspection Inspect the ring gear. If the ring gear teeth are broken or excessively worn, the ring gear must be replaced. 1g Gear Replacement 1g Gear Removal Strike around the edges of the ring gear with a hammer and chisel to remove it Ring Gear Installation 1. Heat the ring gear evenly with a gas burner to invite thermal expansion. Do not allow the temperature of the ring gear to exceed 200°C (390°). 2. Use a hammer to install the ring gear when it is suf- as ficiently heated. Flywheel Housing Oil Seal Replacement Inspect oil seal for wear, damaged or other abnormal conditions. | Fs Replacement of Oil Seal To remove the oil seal without disassembling the engine, proceed as follows Remove the flywheel and pry off the oll seal using 2 conventional screw driver. 7, 9] ! 1. Install setting tool @ to rear end of the crankshaft ® Zz. ju using flywheel fixing bolt. oa 7 2, Install the setting tool @ to the tool ©. 7 Note: The tool ® serves as a guide for locating the oil seal %, a oA 3. Insert the setting tool ® with oil seal © into the setting tool ®. The tip end of the tool @ should preferabily in light contact with the oil seal 4. Insert these parts into the setting tool . 5. Install the oil seal © into place between the wear ring ® and flywheel housing © by turning in the =a o nut ©. 7 mS rages \nstaller : 1-85220-035-04—34 ENGINE ASSEMBLY It Ditport TIMING GEAR CASE COVER Crankshaft Front Oil Seal Replacement Removal Use an adapter and a hammer to remove the crankshaft front end oil seal, Check the timing gear oil jet for clogging Clean the oil jet port with compressed air if necessary. Installation Use the crankshaft front oil seal installer to install the crankshaft front oil seal. Crankshaft Front Oil Seal Installer : 9-8522-0034-0ENGINE ASSEMBLY I! 5—1 SECTION 5 ENGINE ASSEMBLY Ill (REASSEMBLY) TABLE OF CONTENTS ITEM Piston and connecting rod reassembly step Cylinder head reassembly step Rocker arm and rocker arm shaft reassembly step Reassembly 1st step Reassembly 2nd step Reassembly 3rd step Reassembly 4th step .. Engine tuning operation ...5—2 ENGINE ASSEMBLY III Ee] PISTON AND CONNECTING ROD REASSEMBLY STEP Reassembly Steps A 1. Conneeting-rod and bolt 4 Snap ring A 2. Piston 4 5, Piston ring a6 3. Piston pin BearingENGINE ASSEMBLY Ill 5—3 PISTON AND CONNECTING ROD Important Operations 1. Connecting Rod and Bolt Use a hammer or a bench press to install the con- necting rod bolts into the bolt hole. 2, Piston Install the connecting rod to the piston with setting the marks as illustrated, 2, Piston Pin As this piston pin installation is done by @ finger push fit, the piston heating is unnecessary. Refer the description of piston pin in page 4-22. 1) Lubricate the piston pin with the engine oil 2) Use a finger or thumb to fit the piston pin into the piston pin hole. 4, Piston Pin Snap Ring 1) Use a pair of snap ring pliers to install the pis ton pin snap ring, 2) Check that the piston moves smoothly on the piston pin,5—4 ENGINE ASSEMBLY Ill ‘Manufactuer's mark] 2nd compression fon this side ving a) NR ra be] be] 5, Piston Ring 1) Use a piston ring installer to install the three piston rings. Piston Ring Installer : 1-8522-1025-0 Instal the piston rings in the following order. (1) Oil ring (2) 2nd compression ring (3) 18t compression ring ‘The marked side of the two compression rings must be facing up. As the oil ring has no any facing mark, it may face in either direction, Lubricate the piston ring surfaces with engine oi 3 Check that the piston rings rotate smoothly in the piston ring grooves. 6. Connecting Rod Bearing 1) Install the connecting rod bearings to the con- necting rod large-end and the connecting rod cap. 2) Install the bearing cap to the connecting rod with semi-tightening the cap bolts. 3} Lubricate the bearing with the engine oilENGINE ASSEMBLY Ill 5—5 CYLINDER HEAD REASSEMBLY STEP. Reassembly Steps 1. Valve spring lower seat A 4. Intake and exhaust valve spring 4 2. Valve stem oil seal 5. Valve spring upper seat 3. Valve A 6. Split collar5—6 ENGINE ASSEMBLY III Painted portion Vv | | Important Operations (if itis removed in the disassembly step) 1. Nozzle Sleeve 1) Check the nozzle sleeve hole for presence of remaining sealant. Clean the hole inside if necessary. 2) Apply a coat of LOCTITE TL290 on the nozzle sleeve position A in the illustration. 3) Lubricate the nozzle sleeve O-ring with engine cil and, install it into the groove B. 4) Press in the nozzle sleeve into the sleeve hoie. 2. Valve Stem Oil Seat Use @ hammer and the valve stem oil seal installer to install the oil seal. Valve Stem Oil Seal Installer : 9-8522-1289-0 4, Intake and Exhaust Valve Springs Install the valve springs with their painted end (the close pitched end) facing down. 6. Split Collar 1) Use a spring compressor to push the valve spr- ing into position. 2) Install the spring seat split collar. 3) Set the split collar by tapping lightly around the head of the collar with a rubber hammer. Valve Spring Compressor : 9-8523-1436-0ENGINE ASSEMBLY In 5—7 ate ROCKER ARM AND ROCKER ARM SHAFT REASSEMBLY STEP Ln | Aang 9 mark > Front Reassembly Steps A -1. Rocker arm shaft Rocker arm shaft bracket Rocker arm (8) Waving washer Snap ring Rocker arm (A) Spring Rocker arm (8) >> > PVOZawN Rocker arm shaft bracket Rocker arm (A) Spring Rocker arm (B) Rocker arm shaft bracket Rocker arm (A) Waving washer 3. Snap ring5—8 ENGINE ASSEMBLY II on YY important operation 1 te The rocker arm shaft must be installed with the oil 2. Rocker Arm Shaft Bracket Install the rocker arm shaft bracket @ to the rocker arm shaft with aligning the oil ports © as illustrated, 3. Rocker Arm (B) 6. Rocker Arm (A) Install the rocker arm (A) and (B) so that the rocker arm tip facing toward respective bracket side as illustrated.ENGINE ASSEMBLY Ii 5—9 [i+] ReASsemeLy 1ST STEP Reassembly Steps PPP rrr De SNORReNS Diling jet Timing gear case and oiling jet No. 7 camshaft bearing Roller tappet Injection pump gear and adapter Camshaft assembly Crankshaft upper bearing Crankshaft assembly ag 10. an. a12. a13, a4, arp. Thrust bearing (Upper half) Crankshaft bearing cap and thrust bearing (Lower half] Wear ring Flywheel housing Piston and connecting rod assembly Idler gear Oil pump and pipe5—10 ENGINE ASSEMBLY Ill oS “it port facing Teranianate section Important Operations 1. Oil Jet Install the oil jets taking care not to damage the oil spray nozzles and, keep them to spray the oil tow- ard the piston inside cavity. kg-milb.ft/N-m) 2402 (145 + 14/196 + 2.0) Oil Jet Torque (Lubricate with engine oil) 2 1g Gear Case and Oiling Jet Install the oiling jet on the the oil jet faces downward. 1g gear case so that kgem(tb.ft/N.m) Timing Gear Case Oi Jet Torque 3.0 £ 0.3 (21.6 + 2.2/29.4 + 29) kg-mi(lb.ft/N-m) 4,040.5 (28.0 3.6/39.2+ 4.9) 7.0215 (50.62 10.8/68. 7214.7) Timing Gear Case #10 Bolt Torque 62 3. No. 7 Camshaft Bearing The oil port of No. 7 camshaft bearing is a part of the lubricating circuit coming from the cylinder body oil gallery to the valve rockers. Install the No. 7 camshaft bearing with aligning the oll port and the cylinder body oll outlet port as illus- trated. 4, Roller Tappet 1) Fill the tappet roller with the engine oil from the oil filling port as illustrated until the oil flow out from the roller part. 2) Lubricate the entire tappet surfaces with the ‘engine oil. 3) Fit the lock spring into the tappet groove and insert the tappet into the tappet setting tool as illustrated, ‘Tappet Setting Too! : 1-88430-154-0= Front injection Pune Geer rem LT Adopter ft) G3) ENGINE ASSEMBLY Ill 5—11 4) Insert the roller tappet into the cylinder block's, tappet travelling bore gently tapping the setting tool by a plastic hammer or alike, while hold the lock spring by your hand as illustrated. 5) Align the tappet guide hole with the guide bolt and fit the guide bolt with semi-tighten one by one for all tappets. 6) Tighten the guide bolts to the specified torque. 7) Make sure that the tappets travell up and down smoothly. kgam(lb.f/N-m) Tappet Guide Bolt Torque 3.0 + 0.3 (21.7 + 2.2/29.4 + 29) mam(in} ‘Tappet Roller Free Bolt Torque 8 —9 (0.31 — 0.39) 5. Injection Pump Gear 1) Place the injection pump gear to the original location as illustrated. In this work, the gear timing mark must be fac- ing front, 2) Install the injection pump gear adapter and, at the same time, fit the injection pump gear cen- ter boss into the adapter bore.5—12 ENGINE ASSEMBLY Ill e [><] LLodricate wish Engine OW 6. Camshaft Bearing and Camshaft Gear Installation The camshaft bearing has @ stamped cylinder num- ber mark. The mark must be facing front when it is installed to the camshaft as illustration. Note: The No. 1 bearing which is unitized with the thrust plate has already been described in the section 4 INSPECTION ‘AND REPAIR. 1) Lubricate the entire bearing surfaces with the engine oil 2) Install the bearing to the camshaft as illustrated The bearing halve's setting line must be in per pendicular to the crankcase lower surface. Camshaft Installation 1) Keep the tappet roller at such position not to block up the camshaft when itis inserted When the cylinder body is placed with the crankcase facing down, full way slide up and block them at the position with inserting a pin or something alike into the guide bolt groove. 2 Lubricate entire cam surfaces with the engine oil 3) Insert the camshaft into the cylinder body cam- shaft bore carefully with aligning the cam bearing bolt hole and the cylinder body side bolt hole. Do not tap the bearing in this work. 4) Tighten the No. 1 bearing set bolt to the speci- fied torque. kgm t/Nom) Camshaft No.1 Bear- ing Set Bolt Torque | 40 05 (289 + 3.6/9.2 + 49)ENGINE ASSEMBLY Ill 5—13 5) Make sure that all of the bearings are tacing toward correct direction. The bearing set bolt holes are located as the illustration, therefore, take care not 10 mix up the oil hole and the bolt hole. 6) The bearing set bolts have different length depending on the used location as_ illus ‘vated. Install them to the original position. Do not reuse the set bolt gaskets. 7) Tighten all of the bearing set bolts to the speci- fied torque. kg.milb.f/N.m) Camshaft Bearing + Ser buierore 35 + 0.5 (25.3 + 3.6/34.3 + 4.9) 7. Crankshaft Bearing Upper Half 8 Crankshaft Upper Halves 9. Thrust Bearing (Upper Half) 10. Crankshaft Bearing Cap and Thrust Bearing Journal Wo. (Lower Half) Tho crankshaft main bearing identifications are as | follows: an | © All Bearing Upper Halves ... Have Oil Groove and Leet beced bee! oxw7 Oil Hole a © All Bearing Lower Halves .. No Oil Groove and Oil Hole © No, 4 and No. 7 Bearings ... Have different Size in Width’5—14 ENGINE ASSEMBLY lil HW DAA) 1) Install the front and rear thrust bearing, The bearing oil groove must be faced to front and rear respectively as illustrated, Install the main bearing upper halves and lubric- ate them with the engine oil, 2) 3) Place the crankshaft on the main bearing upper halves. 4) Install the main bearing lower halves on the bearing cap, Lubricate the bearing lower halves and the thrust bearing lower halves with a coat of engine oil. Set the thrust bearing lower halves on the front most bearing cap and lubricate it with a coat of engine oil. Install the bearing caps on the crankshaft main journal original position. 5) 6) 7) ‘The stamped mark must be facing front. 8) Lubricate the main bearing cap bolt with a coat of engine oil 9} Tighten the bearing cap bolts to the specified torque @ little at 2 time in the numerical order shown in the illustration. kg.m(lb.ft/N.mn) Crankshaft Bearing Cap Bolt Torque | 32.0230 (282.0%21.6/382.6429.4) (Lubricate with engine oil) 10) Check that the crankshaft turns smoothly by manually rotating it 12, Wear Ring 1) Install the setting too! © to rear end of the crankshaft ® using flywheel fixing bolt. 2) Install the wear ring @ into the setting tool ©, ‘then instail the wear ring to the crankshaft @ by applying a shock load with setting tool ®. Note: Submerging wear ring in heated oil (20 — 100°C) for about 15 minutes will facilitate wear ring installation. Installer : 1-85220-014-0@ \ Matching numbers 4 Aa Ce) [#] 71.042.3 Flywheel Housing | °°" (79.5316.6/108.0222.6) Bolt Torque 2.6403 # 8Bok rags 2.2/ 25.54 2.9) ENGINE ASSEMBLY Ill 5—15 13. Flywheel Housing 1) Apply a liquid gasket to the shaded area of the illustration. 2) Install the flywheel housing. Tighten the flywhee! housing bolts to the speci fied torque a litte at a time in the numerical order shown in the illustration. kg-m(lb.ft/N-m) 14. Piston and Connecting Rod Position the piston ring gaps a8 shown in the illus- tration, 1) Set the piston ring gaps as shown in the illus- tration. 2) Lubricate the piston, the piston rings, and the connecting rod beerings with a coat of engine oil. 3) Position the piston front mark towards the front of the engine. 4) Use the piston ring compressor to compress the piston rings. Piston Ring Compressor: 9-8522-1319-0 5) Use a hammer grip to push the piston in until it makes contact with the crankpin. At the same time, rotate the crankshaft until the crankpin reaches its highest point, In this work, take care not to damage the oiling jets in the crankcase. 6) Set the bearing cap cylinder number marks and the connecting rod cylinder number marks. The marks must be facing the exhaust manifold 7) Lubricate the connecting rod bearing cap nut setting face and the bolt threads with a coat of engine oil.5—16 ENGINE ASSEMBLY II Lubeeate wh grease [| b+] Tighten the connecting rod bearing cap nuts to the specified torque in two steps with working up a little at a time in the numerical order as, illustrated, kg-milb.ft/N-m) ‘Ist Step 2nd Step Connecting Rod Bear- 7 10.040.5 ing Nut Torque (50.6/68.6) | {72.3+3.6/98.1+4.9) (Lubricate with engine oil) 13.ldler Gear 1) Install the idler gear thrust plate with the cuta- way portion facing up and the cylinder block 2) Lubricate the idler gear side surface and the thrust plate mating surface with the specified grease. 3} install the idler gear with setting the crankshaft gear timing marks (X and XX) and the camshaft gear timing marks (Y, YY) and the injection pump gear marks (Z, 22) as illustrated. 4) Install the idler gear spindle and tighten the gear with the idler gear bolt to the specified torque. kg-mitb.ft/N-m) 17.0220 (123.0414.4/166.8+19.6) Idler Gear Bolt TorqueENGINE ASSEMBLY III 5—17 14, Oil Pump Install the oil pump beneath the crankcase front most with meshing the oil pump idler gear and the crankshaft gear. kg-milb.ft/N.m) Gil Pump Bolt Torque | 5.0 + 0.5 (36.2 + 3.6/49.1 + 4.9) kg.mi(lb.ft/'v-m) Oil Pipe Joint Torque | 2.0 + 0.2 (14.5 + 1.4/19.6 + 2.0)5—18 ENGINE ASSEMBLY III [i+] ReEASsEMBLy 2nb STEP Reassembly Steps al a2 3. a4 AS. Ab 7. a8 A 8. Note: Oil cooler Air compressor (or bearing case) Timing gear case cover Oil pan Flywheel Crankshaft pulley ‘Tappet chamber cover Cylinder head gasket Cylinder head ‘The bearing case is equipped for on-air compressor engine. 10. an ai2. a13, an, 15, a6 a7. 18. aig, Push rod Valve bridge Rocker arm and rocker arm shaft Injection pura coupling Injection pump Injection nozzle Injection pipe Injection nozzle holder flange Leak off pipe Tachometer drive elbow or coverMounting Bott ENGINE ASSEMBLY Ill 5—19 V7 important operation 1. Oil Cooler 1) Apply a coat of liquid gasket on the cylinder 2} Affix the oil cooler gasket on the cylinder block. 3) Install the oil cooler and tighten the oil cooler bolts. Start up from © and ® shown in the al illustration alternately and work out to the coe kgen(lb.ft/N.m) 0.2 (1304 14/176 + 20) il Cooler Bolt Torque 2. Air Compressor (If equipped) 41) Make sure thet the key is securely fitted on the air compressor crankshaft front end. 2) Align the key and the mating key groove in the injection pump drive gear center bore work, take care not to fall the key into the timing gear case. 3) Install the air compressor with pushing in the key and the crankshaft into the pump drive gear until the air compressor counterbore is fitted with the injection pump gear adapter com- pletely. 4) Tighten the four bolts evenly to fix the air com- pressor on the timing gear case. kg-milb.ft/N.m) Air Compressor Baar 4,0 + 0.5 (29.0 + 36/39.2 + 49) 5) Connect the air compressor water pipes. kg-m(lb ft/Nm) Water Pipe Nut Torque 4.2 +05 (90.3 + 3.6/41.2 + 4.9)5—20 ENGINE ASSEMBLY Ill 2. Bearing Case (Far Non-Air Compressor Engine) Couping side 1) Install the key into the bearing case shaft key { groove, 2) Push in the bearing case shaft end into the injection pump gear center bore. 3) Tighten the four bearing case fixing bolts evenly SD to the specified torque. kg-m(ib.ft/N-m) Bearing Case Bolt Torque 40 £ 0.5 (29.0 + 3,6/39,2 + 4.9) Reference: ‘The tachometer elbow is installed on the shaft front end via adapter. ‘The injection pump coupling is installed on the shaft rear end 4) Place the plane washer and the spring washer ‘on the injection pump gear boss surface and, tighten the nut © in the illustration to the speci- fied torque, kg.milb.ft/N-m) Injection Pump Gear 26.0 + 2.0 Fixing Nut Torque (188.0 + 14.4/255.1 + 19.6) 3. Timing Gear Case Cover After the timing gear case cover has installed, fit the oil seal. 1) Apply a coat of engine oil on the entire oil seal- ing lip faces. 2) Use the oil seal setting tool to install the oil seal to the timing gear case cover. (C Oil Seal Setting Tool : 1-85220-015-0 t Stereo NSENGINE ASSEMBLY Jl 5—21 al 4, Oil Pan 1) Wipe the crankcase oil pan mounting flange surface and oil pan flange surface to clean the surfaces before the liquid gasket coating 2) Apply a coat of liquid gasket on the crankcase side flange surface in 1.5 mm (0.06 in) thick and 5.0 to 10 mm (0.2 to 0.4 inch) width. 3} Affix the oil pan gasket and install the oil pan. 4) Tighten the oil pan bolts to the specified torque starting from © and @ alternately, as shown in the illustration and, work out toward arrow direction, kg.m(lb.ft/N.m) Oil Pan Bolt Torque | 4.0 + 0.5 (28.9 + 3.6/39.2 + 4.9) 5. Flywheel 1) Apply a molybdenum disulfide grease to the fly- wheel bolt threads and setting faces. 2) Install the flywheel with aligning the dowel. 3) Tighten the flywheel bolts by the Angular Tigh- tening Method in the numerical order as _ Lubricate with illustrated. ns kg-m(lb.ft/N.m) oxi? ist Step] 2nd Step | Final Step] 1 Apply MoSz > | Flywheel ey ats Bolt Torque 8.0 + 1.0 By | 30% y (57.87.2/78.59.8)5—22 ENGINE ASSEMBLY III 6. Crankshaft Pulley 1) Use a plastic hammer to gently tap the dust thrower in to the pulley. 2) Do not lubricate the oil sealing surface of the pulley. 3) Apply MoS: to the pulley fixing nut threads. 4 Install the pulley on the crankshaft front end and tighten the pulley nut to the specified torque. Wrench : 55 mm kg-milbft/N-m) Crankshaft Pulley 80.0 + 10.0 Nut Torque (5785 + 72.0/785.0 + 98.0) 8. Cylinder Head Gasket 9. Cylinder Head 1) Carefully place the cylinder head gasket on the cylinder body upper surface. The gasket “TOP” mark must be facing up. Align the cylinder body dowels and the cylinder head dowel holes. 3) Carefully place the cylinder head on the cylinder body. 4) Apply molybdenum disulfide grease to the cylinder head bolt threads and setting faces. 5) Use the Angular Tightening Method to tighten the cylinder head bolts in three steps. Follow the numerical sequence shown in the illustration Refer to “Torque Specifications” for the angular tightening method Lubrieate with MOS, Cylinder Head Bolt Torque Angular Tightening Method kgemilb.tt/N.) 1st Step | 2nd Step _| Final Step 1841 1941 ve reat Sok (083 7.2/ |is74 = 7.2/| 90s 147.0 + 9.8) | 186.4 + 9.8) Apply a coat of MoS2 greaseENGINE ASSEMBLY Ill 5—23 _ __ san] Be nor renowe te bots, Injection Pump Side Ey al Ee] 2) 11. Valve Bridge 1) Lubricate the valve bridge arrow positions with the engine cil. 2) Install the bridge on the bridge guide 12. Rocker Arm and Rocker Arm Shaft 1) Check that the rocker arm shaft bracket lower surface oil port is free from obstruction. 2) Install the rocker arm shaft with the bracket to the cylinder head 3) Tighten the rocker arm bracket bolts to the specified torque a little at a time in the numeri- cal order shown in the illustration. 4) \ubricate the rocker arm and the rocker arm shaft with engine oil kg-mi(lb.ft/N-m) Rocker Arm Shaft Bracket Bolt Torque (Lubricate with engine oil) 9.0 + 1.0 (65.1 + 7.2/8.3 + 9.8) 5) Adjust the valve clearance, Refer to MAINTENANCE for the valve clearance adjustment procedure. 13. Injection Pump Coupling 1) Install the coupling to the air compressor crank- shaft rear end of the bearing case shaft rear end with aligning the key and the key groove. 2) Tighten the coupling lock bolt and nut to lock the coupling and the shaft end engagement. kg-m{lb.ft/Nem) Coupling Lock . Bolt Nut Torque _| © #05 (46.9 + 36/637 + 49) To avoid the timing mark misaligment, do not loosen or remove the four coupling bolts shown in the illustration,5—24 ENGINE ASSEMBLY II 14. Injection Pump co 1) Install the injection pump brakcet to the cylinder >? block (If the bracket is removed in the disas- — sembly) with aligning the dowel kg.m(ib.f/N-m) [2X] | injection Pump Bra-|#10 420.5 (28.9136/ 39.2449) cket Bolt Torque [#14 111.0 (80.0+7.2/107.819.8) | 2) Place the injection pump on the bracket and ee semictighten the injection pump fixing bolts 3) Bring the piston in either the No. 1 cylinder or the No. 6 cylinder to Top Dead Center on the compression stroke by turning the crankshaft until the TDC notched line on the flywheel or the crankshaft damper pulley is aligned with the pointer. 4) Reverse the crankshaft to the specified injection timing mark on the flywheel or the damper pul- ley as illustrated ‘Tieng Marks ‘oa the Damper Note: The specified injection timing crank angle of your engine is indicated on the MAINTENANCE DATA PLATE affixed on the cylinder head cover top. 5) Install the injection pump coupling and align the injection pump notched line and the automatic timing advancer notched line (or the injection pump flywheel notched tine) 6) Tighten the coupling bolts to the specified torque. Injection Pump Coupling Bolt Torque kg-m(lb.ft/N.mn) ¢ 8mm Bolt | 33405 (238 + 36/323 + 49) #10 mm Bolt | 48 + 0.5 (34.7 + 3.6/47.0 + 49) 7) Tighten the four injection aump fixing bolts in the numerics order as illustrated kgamilb ft/N.mn) Injection Pump 40 +05 Fixing Bolt Torque (28.9 + 3.6/39.2 + 5.0)ENGINE ASSEMBLY Ill 5—25 Injection Ti 1) Align the timing pointer and the timing notched line on the fiywheel or on the crankshaft dam- per pulley with turning the crankshaft. Refer the procedure described in the page 2-11 of the section MAINTENANCE. 2) Check alignment of the injection pump flywheel (or the automatic timing advancer) notched line and the injection pump body notched line. When the two notched lines are in alignment, the injection timing is correct. ing Inspection Procedures Injection Timing Correction Procedures Ifa timing marks misaligment is discovered in the injec- tion timing inspection, do the following adjustment after all of the fuel system parts have installed, 1) Disconnect the injection pipe from the No. 1 plunger. This will allow you to visually check the fuel injection starting flow at No. 1 plunger. 2) Use @ screw driver to remove the injection pump delivery valve cover fixing screw, 3) Remove the delivery valve cover. 4) Use the socket wrench shown in the illustration to loosen the delivery valve holder. Delivery Valve Holder Wrench : (Special Too!)5—26 ENGINE ASSEMBLY Ill me GI] 5) Use the delivery valve holder extracter as shown in the illustration to remove the delivery valve holder. Delivery Valve Holder Extracter : (Special Tool) 6) Remove the delivery valve holder @, the valve seat ®, valve spring ® and the delivery valve from the No. 1 plunger. Reinstall the delivery holder © and tighten it to the specified torque. Do not reinstall the delivery valve spring, the valve seat and the delivery valve. ‘These parts will be reinstalled later. kg-mitb.ft/N.m) 7) Hold the fuel control lever at the full fuel posi- tion. Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made.ENGINE ASSEMBLY Ill 5—27 8) Align the timing pointer on the damper pulley or the flywheel housing, whichever easily acces- sible, to the specified injection starting timing line as illustrated. INJECTION TIMING CRANK ANGLE of the engine Refer to the MAINTENANCE DATA PLATE affixed on the cylinder head cover top. 9) Loosen the two coupling bolts on the injection pump flywheel (or the automatic timing advan- cer) fo disengage the injection pump drive line. Dom the Damper 10 ‘Slowly turn the injection pump flywheel, at the ‘same time, continue to feed the fuel to the No. 1 plunger with pumping the feed pump (i. priming pump). Fuel will flow out from the No. 1 delivery valve holder freely by the pumping. 11) The fue! flow will stop at some injection pump ftywheel position when the No. 1 plunger start to fuel injection. This position is the injection starting timing. ‘mm si80 Bolt soy, sie bol 2 10mm size bot 12} Keep the engine timing condition made by procedure 4) and, engage the injection pump drive line by tightening the coupling bolts to the specified torque. 13) Do the Injection Timing Inspection Procedures to make sure that the injection timing is cor- rected.5—28 ENGINE ASSEMBLY II Delivery Valve Reinstallation 1) Remove the delivery valve holder to reinstall the delivery valve. Reinstall the delivery valve, valve seat and the spring on the plunger. 2) Lubricate the delivery valve holder O-ring with a coat of grease. Do not reuse the O-ring, replace it with the new one, 3) Use the socket wrench to tighten the valve hol- der in the following order end the tightening torque. ist Time 2nd Time Final Wt rr 8 Loosen 42) Loosen : (79.572) (79.5%22) cas) | Repeat two times tighten and loosen and, finally tighten to the specified torque. Install the delivery valve holder cover. 4) Reconnect the No. 1 injection pipe. The reinstallation procedure is described in the item 16. Injection Pipe. Reference: To advance the timing Turn the injection pump flywheel (or timing advancer} toward out while the injection pump side coupling bolts are loosened condition. To retard the timing Turn the injection pump flywheel (or timing advancer) towred in (cylinder block side) in the injection pump coupling bolts same condition. The 1 mm misalignment between the two setting mark lines corresponds to about 2" in crank angle.ENGINE ASSEMBLY Ill 5—29 ~ oo | None Hod q Zz tscten @ ese fe] Pump Side \ El 16. 7, Injection Pipe Injection Nozzle Flange In this engine, the injection nozzle is located at the combustion chamber central position, therefore, an about 120 mm (4.7 inch) length sleeve nut is used as the pipe connection parts in order to facilitates the piping from the cylinder head outside. 41) Install the nozzle holder flenge and tighten the fixing nuts in semi-tighten Before to connect the injection pipe to the noz- zie holder, make sure that the gasket © is fitted on the sleeve nut and the gasket @ is fitted on the nozzle holder inlet port threads as shown in the illustration. 2 3) Screw the sleeve nut ® full way in to the female threads @ and allow the nut ® reach to the threads @. Screw in the nut @ to the nozzle holder threads © along with the threads ® but keep them in semi-tighten, 4 8) Tighten the injection pump side sleeve nut ® in semi-tighten. 6) Make sure that the threads ® ® © and the pipe line is in free of hard threading or mis- alignment conditions. 7 Tighten the two injection pipe sleeve nuts ® and © to the specified torque. Tighten the nozzle holder flange fixing nuts to the specified torque. 3)5—30 ENGINE ASSEMBLY lit kg-milb.ft/Nem) Elsnoe #10 Bolt 28403 S Nozzle Holder Flange| | | (20.2 + 2.2/27.4 + 2.9) ey Fixing Nut Torque a 12402 Cc 7 71 jolt | (86 + 1.4/11.8 + 2.0) | Injection Pump Side kg-milb.ft/N.m} ee i Injection Pipe Sleeve 33 402 veele Holeer Nut Torque. (24.0 + 1.4/32.4 + 2.0) Nozzle Holder Side kg-milb.ft/Nem), Ql] Injection Pipe Sleeve 28402 Nozzle Nut Torque (20.2. 1.4/27.4 + 2.0) Pump side The gasket @ acts to seal the oil in the cylinder head cavity and, the nozzle holder gasket @ acts to seal the fuel leakage. 9) Finger tighten the knurled nut © to retain the gasket ©. No yNeS \Nod Nod No? [No.1] 10) Install the injection pipe clips on the position illustrated,ENGINE ASSEMBLY Ill 5—31 REASSEMBLY 3RD STEP Reassembly Steps 1 > MogRen Cylinder head cover Inlet cover Tachometer elbow Oil filter assembly and pipe Fuel filter Water pump Water inlet pipe al a2 . Injection pump oil pipe |. Air compressor oil pipe 10. Air compressor water pipe Air compressor air pipe Fuel pipe assembly !. Water outlet pipe 14, Inlet duct5—32 ENGINE ASSEMBLY Ill ; V be] BI SIE] EE) Important Operations 1, Tachometer Elbow 1) Install the tachometer adapter @ into the air compressor crankshaft end female threads ©. In this work, take care not to damage the threads because the female threads are a left- hand threads, Note: In the non-air compressor engine, this adapter is incor- porated in the bearing case shaft. 2) Place the washer and the spring washer ® and tighten the nut © to the specified torque. kg-m(lb.ft/N-m) 26.0 +2 4.4/255.1 + 19.6) Injection Pump Drive Gear Fixing Nut Torque | (188.0 3) Apply a coat of liquid gasket on the O-ring ® faces and affix it into the tachometer elbow's Orting groove. 4) Install the tachometer elbow @ to the timing gear case. 5) Place the washer and the spring washer and, tighten the nut ® to the specified torque kg.mi(lb.ft/N.m) 28403 ‘| (20.2 + 2.2/27.4 + 29) Tachometer Elbow Nut Torque 11. Air Compressor Air Pipe Install the air pipe to the air compressor and tighten the nut to the specified torque kg-mi(lb.ft/N.m) Air Pipe Nut Torque Saeed (223.2 + 61.4/303.8 + 83.3)ENGINE ASSEMBLY Ill 5—33 6. Fuel Filter 12, Fuel Pipe 1) Install the fuel filter to the filter bracket but keep the fixing nuts in semi-tighten, 2} Connect the fuel pipes and tighten the eye bolts to the specified torque 3) Tighten the filter fixi g bolt’s nuts to the speci- fied torque. Jeger {ib.ft/N-m) Fuel Filter Fixing 28403 Nut Torque (20.2 + 2.2/27.4 + 2.9) ‘This installation procedures will secure the eye bolts from damage caused by a undue stress created by the eye bolt threads and the filter fernale threads misalig- ment, i ful The eye bolts shown in the illustration are a hollow bolt incorporating a strainer. rs kg-milb.ft/N-m) [Ql (RR tate | iu Torque (30.4 + 3.6/41.2 + 6.0)5—34 ENGINE ASSEMBLY Ill [i+] REASseMBLy 4TH STEP Reassembly Steps bbb ob Seenagaens Water outiot pipe Air breather Exhaust manifold Partial-flow oil filter and pipes Starter Dipstick guide tube Air inlet duct Turbocharger Turbocharger oil pipe ; outiet Turbocharger oil pipe ; inlet 1". 12, a3 14, 15. 16. 7. 18. Water drain pipe Alternator and adjusting plate Fan belt Cooling fan Engine stop device {if originally equipped) Fuel return pipe Intake heater fuel pipe Oil pipe for valve mechanismENGINE ASSEMBLY Ill 5—35 ‘seal Ring V7 important operations 3. Exhaust Manifold 1) Install the seal rings setting the ring gaps in > 120° evenly to the exhaust manifold connecting collar. 2) Install the exhaust manifold gasket and the exhaust manifold 3) Install the distance tube on the studs and seat the washer as illustrated and, tighten the nuts evenly to the specified torque, kg-milb.ft/N-m} Exhaust Manifold Nut 33405 Torque (23.8 + 3.6/32.3 + 49) 5, Starter Motor Install the starter motor with tightening the starter fixing nuts to the specified torque. kgem(lb.ft/Nm} Starter Motor Nut 11.9 23 Torque (86.0 + 166/116.6 + 22.5) 8, Turbocharger 9. Turbocharger Oil Pipe (Return Pipe) 10. Turbocharger Oil Pipe 1) Place the turbocharger gasket on the exhaust manifold outlet port, The gasket edged side must be facing turbo- charger side. 2) Install the turbocharger and tighten the nuts to the specified torque. Turbocharger Fixing 40 +05 Nut Torque (28.9 + 3.6/39.2 + 4.9)5—36 ENGINE ASSEMBLY II! b+] 3} Install the two oil pipes and tighten the eye bolts to the specified torque. kg-milb.ft/N-m) Oil Return Pipe Eye Bolt Torque 38 +05 (27.5 + 3.6/37.3 + 4.9) Oil Inlet Pipe Bolt Torque kg.milb.ft/N.m) 26 +03 (188 + 2.2/255 + 2) Pre-lubricate the turbocharger with CD grade oil through the oil port shown by the arrow in the illustration. 13, Fan Belt Install and adjust the fan belt tension. Refer to MAINTENANCE for the fan belt tension adjustmentENGINE ASSEMBLY Ill 5—37 ENGINE TUNING OPERATION After reassembly, the engine must be tuned. This will ensure that the engine Operates at its maximum effi- ciency. 1. Mount the engine on a test bench. 2. Fill the engine with the specified oil 3. Connect the cooling pipes and the fuel pipes. oS ==" ouevog-=. ® Glow plug Amma (2 oes! | Jos Oil pressure switch en a) ny a) F Regulator Alternator Condenser = 4. Connect the electrical wiring, Refer to the wiring diagram. 5. Connect the air intake line to the air cleaner. 6. Connect the exhaust pipe. Manually operate the fuel feed pump to feed fuel to ++ the engine, 8. Bleed the fuel lines of air. Refer to Pago 27 of Section 2 MAINTENANCE for the air bleeding procedure.5—38 ENGINE ASSEMBLY Ill =| Fs] [2] 10. " 12, Crank the engine with the starter motor (non-igni- tion operation) for about twenty seconds. This will prelubricate the engine internal compo- nents Start the engine and allow it to run at 750 to 800 rpm for five minutes. Remove the cylinder head cover while the engine is running Check that the engine oil is continuously circulating from the oil pump to the valve rockers through the cylinder head If there is no oil circulation of if the oil circulation is sluggish, stop the engine and make the appropriate repairs or adjustments. Reinstall the cylinder head cover. increase the engine speed to 1,500 rpm to do the engine warming-up operation. Check the engine for oil, fuel, coolant, and air intake leakage. Check for abnormal noise and odor. Check for abnormal electrical charging Check the engine fastening parts for looseness. When the engine coolant temperature reached to 75°C (167°F) or more, increase the engine speed to 2,000 rpm and allow it to run for twenty minutes. This will give the engine the essential run-in operat ing time. ‘Adjust the engine operation speed to the specified value. Stop the engine to complete the tuning procedure.LUBRICATING SYSTEM 6—1 SECTION 6 LUBRICATING SYSTEM TABLE OF CONTENTS. ITEM. General description . Oil pump Main oil filter Oil cooler .... Partial-flow oil filter .6—2 LUBRICATING SYSTEM GENERAL DESCRIPTION [we |b cro ii vind bay ate T J [B08 eal a Beh This engine family uses a normal forced circulation lubricating system. ‘A gear type oil pump is driven by the crankshaft gear at the crankshaft front end via an idler geer. A center bolt type or a cartridge (spin-on) type main oil filter and centrifugal type pertial-flow filter assures a superior lubricating ability giving this engine a long service life.LUBRICATING SYSTEM 6—3 OIL PUMP DISASSEMBLY Disassembly Steps 1. Cover 4. Idler gear 2. Driven gear 5. Relief valve A 3. Spindle & > V Important Operation 3. Spindle | Uns bonch rosso remove tee eu6—4 LUBRICATING SYSTEM INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Use a feeler gauge to meausre the clearance between the gear teeth and the pump body inside surface. mm(in) ‘Standard Limit Gear Teeth and Body Inside Surface | 0.07 (0.0028) | 0.15 (0.0059) Clearance Use a feeler gauge to measure the clearance between the gear side surface and the pump cover. mm(in) Standard Limit Pump Cover and Gear Side Surfaco 0.07 (0.0028) | 0.18 (0.0089) Clearance [i+] Reassemety To assemble, follow the disassembly procedure in reverse order.LUBRICATING SYSTEM 6—5 MAIN OIL FILTER DISASSEMBLY Disassembly Steps 1. Drain plug 5. Element gasket 2. Center bolt 6. Spring seat 3. O-ring 7. Coil spring 4. Oil filter element 8. Oil filter body Refer to Page 2-2 of the MAINTENANCE for information on the cartridge type (spin-on type) oil filter. [re] INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. j#f+| REASSEMBLY To reassemble, follow the disassembly procedure in reverse order.6—6 LUBRICATING SYSTEM OIL COOLER i] DISASSEMBLY + Also included in engine overhaul kit Disassembly Steps 1. Baffle plate 3. Oil cooler cover 2. Element [P| INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. t+] REASSEMBLY To reassembe, follow the disassembly procedure in reverse order.LUBRICATING SYSTEM 6—7 PARTIAL-FLOW OIL FILTER [+] DISASSEMBLY = — Disassembly Steps 1. Cap nut 4, Rotor assembly 2. Filter cover 8. Nut 3. Thrust nut INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. [ie] Reassemery To reassembe, follow the disassembly procedure in reverse order,6—8 LUBRICATING SYS’ “Theyse nut TEM Clearance 0570.3 mm) \ Knurled Nut Tightening Torque Finger Tighten Note: ‘Take care not to screw in the knurled nut with an over torque or the filter cover distortion might take place. When the clearance A is 0.3 to 0.6 mm (0.012 to 0.20 in.) the nut torque is normal. kg-mitb.f/N-m) Thrust Nut Torque | 0.6—1.0 (3.6-7.2/4.9-9.8)COOLING SYSTEM 7—1 SECTION 7 COOLING SYSTEM TABLE OF CONTENTS. ITEM General description . Water pump ... Thermostat7—2 COOLING SYSTEM GENERAL DESCRIPTION Water outlet pipe Thermostat Water outlet pipe |+— cylinder head Reserve tank | = J JS J Cylinder body ‘This family of engines uses a pressurized, forced circulation cooling system with a V-belt driven centrifugal waier pump and a wax pellet thermostat.COOLING SYSTEM 7—3 WATER PUMP [+] DISASSEMBLY Disassembly Steps 1. Cover ‘5. Snap ring & 2. Impeller 6. Spindle, bearing and spacer ‘4 3. Pulley center and pulley ‘7. Seal unit, washer and seal 4, Dust thrower7—4 COOLING SYSTEM. Y_mportant operation 2. Impeller Use the remover to remove the impeller. Remover: 1-85210-028-0 3, Pulley Center and Pulley Use a bench press and a suitable rod to remove the pulley center. 5. Snap Ring Use a pair of snap ring pliers to remove the snap ting, 6. Spindle, Bearing, and Spacer Use a bench press and a suitable remover to remove the spindle, bearing, and spacer. 7. Seal Unit, Washer and Seal Use a suitable remover to remove the seal unit, the washer, and the seal.INSPECTION AND REPAIR COOLING SYSTEM 7—5 Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. Pulley Puiay conor | (a) Na) Bearing Replacement Removal: Use a bench press to remove two bearings and the spacer. Installation Use a bench press to install two bearings and the spacer, Use a micrometer to check the fitness at the three points shown in the illustrations. mm(in) Shaft to Pulley Center Fitness Fitness Shaft to Impeller 0.025 — 0.060 SS Fitness (0.001 — 0.0024) Shaft to Pulley 0.035 — 0.065 Fitness (0.0014 — 0.0026)7—6 COOLING SYSTEM Fis] Reassemery Reassembly Steps 4 1. Spindle, bearing and spacer 4 5. Impeller & 2. Shap ring 6 Cover 3. Dust thrower 7. Pulley Center and pulley 4 4. Seal unit, washer and sealCOOLING SYSTEM 7—7 Lubricate with multipurpose type grease Important Operations 1. Spindle, Bearing, and Spacer Lubricate the bearing with multipurpose grease be Sealed side outward 2. Snap Ring Use a pair of snap ring pliers to install the snap ring. 4. Seal Unit, Washer and Seal 1) Apply a thin coat of liquid gasket to the seal =] unit outer periphery before installation. Apply liquid fniker ere 7 2) Use a bench press and a bar to install the seal unit into the pump body. 5. impetier 1) Use a bench press to install the impeller to the spindle. 2) Use a feeler gauge to measure the clearance between the impeller and the pump body. mmiin) Clearance between Impeller and Pump Body oO ) Feelor sause —7—8 COOLING SYSTEM THERMOSTAT [I] sPection ano REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis covered during inspection, Visually inspect the thermostat function referring Sec- tion 2 MAINTENANCE in page 2-8. Dg Thermometer Wood pieceFUEL SYSTEM 8—1 SECTION 8 FUEL SYSTEM TABLE OF CONTENTS ITEM PAGE General description 8-2 Fuel filter ; -8-3 Injection nozzle . Injection pump calibration data 8-108—2 FUEL SYSTEM GENERAL DESCRIPTION The fuel system consists of the fuel tank, the water sedimentor, the fuel filter, the injection pump, and the injection nozzle. ‘The fuel from the fuel tank passes through the water sedimentor and the fuel filter where water particles and other foreign material are removed from the fuel. Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the ‘optimum timing for efficient engine operation,FUEL SYSTEM 8—3 FUEL FILTER [4] oisassemery + Element kit Disassembly Steps 1. Drain plug 5. Fuel filter element 2. Center bolt 6. Spring seat 3, Fuel filter body 7. Spring 4. Body cover gasket Refer to Page 2-3 of the “Maintenance” for information on the cartridge type fuel filter. [Ie] sPection anp REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. t+] REASSEMBLY To reassemble the fuel filter, follow the disassembly procedure in the reverse order,8—4 FUEL SYSTEM FUEL FILTER MAIN OIL FILTER WATER SEDIMENTOR Refer to “FUEL SYSTEM” on Page 2-6 of the "MAINTENANCE" Section of this Workshop Manual.FUEL SYSTEM 8—5 INJECTION NOZZLE [4] Fis] oisassemety ano REASSEMBLY Disassembly Steps Reassembly Steps 4. Cap nut A 7. Nozzle assembly 2. Lock nut 4 6. Nozzle nut 3. Spring adjust screw 5. Push rod 4. Spring 4. Spring 5. Push rod 4 3. Spring adjust screw 6. Nozzle nut & 2. Lock nut ‘47. Nozzle assembly 41. Cap nut Important Operation 7. Nozzle Assembly Remove the nozzle from the nozzle body. Keep the parts separately to maintain the proper needle valve to body combination8—6 FUEL SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. -—— Push Rod Spring Check the push rod spring for wear, weakness, and cor- rosion Nozzle Holder Push Rod 1. Check the nozzle holder push rod curvature, 2. Check the nozzle holder push rod and needle valve contact surfaces for excessive wear and poor con- tact. Injection Nozzle 1. Check the injection nozzle needle valve, the valve seat, and the injection nozzle hole for carbon depos its If carbon deposits are present, the injection nozzle and the needle valve must be replaced 2. Hold the nozzle body vertically. Pull the needle valve about one-third of the way out of the nozzle body. Release the needle valve. Check that the needle valve falls back into the noz- zle body as far as the valve seat. If the needle valve does not fall back into the nozzle body as far as the valve seat, the injection nozzle and the needle valve must be replaced.Vv tl 2) FUEL SYSTEM 8-7 Important Operations 7. Nozzle Assembly ‘There must be no oil on the contact surfaces of the injection nozzle and the injection nozzle holder. Clean these contact surfaces with diesel fuel before installation. The nozzle dowel pin must be aligned with the dowel hole in the nozzle holder body. 6. Nozzle Nut kg-mi(lb.ft/N-m} ? (Cap nut Lock nut Nozzle Nut Torque 7+ 1 (50.6 + 7.2/68.6 + 9.8) 3. Spring Adjust Screw Injection Starting Pressure Adjustment The injection nozzle injection starting pressure can be adjusted after the adjusting screw is installed. Refer to “FUEL SYSTEM” on Page 2-4, 5 of the “MAINTENANCE” Section of this Workshop Manual kg/om*(psi/kPa} 6RB1 6RBIT 200 (2840/20410) 200 (2840/20410) or or 225 (3195/22073) 225 (3195/22073) Injection Starting Pressure Note: The injection starting pressure might vary depending on the engine applications, therefore, refer to MAINTEN- ANCE DATA PLATE affixed on the cylinder head cover top. 2. Lock Nut 1. Cap Nut kg.m(lb.ft/Num) [5 + 0.5 (39.7 + 3.6/53.9 + 49)] 4.5 + 0.5 (32.5 + 3.6/44.1 + 4.9) Nozzle Lock Nut Torque Nozzle Cap Nut Torque. ,8—8 FUEL SYSTEM INJECTION PUMP CALIBRATION DATA LY IDENTIFICATION PLATE AND PRODUCT SERIAL NUMBER 1. Injection pump adjustment and repair should be made by the nearest DKKC (Diesel Kiki Co., Ltd.) or oC @ 1 o ROBERT BOSCH Authorized Service Outlet. el Pape 2. When you ask such authoriged service outlet the NP-PE GAGS" : adjustment or repair, the Identification Plate and (LICENCE BoscH) A Product Serial Number will give them @ necessary @-~taentienion numbar ciue to get technical date distributed by the manu- facturers previously. Without this data, the Service Outlet will be unable to effectively service your injection pump. If you are unable to locate the data applicable to your injection pump, please contact ISUZU MOTORS LTD through your machine supplier. 3. Do not remove the Identification Plate and Product Serial Number from the injection pump. Keep the Identification Plate and Product Serial Number clean at all times. Do not allow it to rust or become illegible. Note: Examples of test conditions ana calibration data are as follows. TEST CONDITIONS REQUIRED FOR THE FUEL INJECTION AMOUNT ADJUSTMENT Injection Nozzle “DKK No.: 105780-0000 Bosch Type No.: DN12DS12T Injection Nozzle Holder DKKC No.: 105780-2080 Boshe Type No.: EF8511/9A Injection Starting Pressure kg/em*(psi) 175 (2488.5) Injection Line Dimensions mmtin.) Inside Diameter 2.0 (0.079) Outside Diameter 6.0 (0.236) Length 600.0 (23.6) Transfer Pump Pressure 1.6 (22.75) Testing Giesel Fuel 1$04113 or SAE Standard Test Oil (SAEJ967D) Operating Temperature cr) 40 — 45 (104 — 113) Pump Rotation Direction Clockwise (Viewed from the drive side)FUEL SYSTEM 8-9 INJ. PUMP CALIBRATION DATA 4,., x0 00000-0000 ate ENGINE MODEL 6BD1T comer =a = : No —-0-00900-000-0 Injection pump » PES4A Governor : EP/RSV Timing device ‘000000-0000 00000-0000 1, Test Conditions Pum rotation clockwise (vowed From dive sie) Nozsle + 009000-0000 Nozzle Ho ° + o09000-0000 (BOSCH Type No, ONI2S127 (BOSCH Type No. EF8511/9A) Nozzle opering pressure: 175. Ko/em? ressure 1.6 Ko/en? Injection pipe = ier Dia 2mm ss Length 600 mm Test Oil : ISO4113 or SAE & wii(SAE J967d) Oil Temp. : 4078 °C Overton vaive opering pressure Kasem? 2. Injection Timing : Pro-stroke | No.1 Plunger 3.4 £0. 05mm Note : Adjust with control rod position of men Injection ordee : 1 i gear? Uinterval *£30) ww Plungers ace numbered from the Drive side. Tappet clearance : Boll adjustment type; More than 0. 3mm for all cylinders, ‘Shim adjustment type Manually rtate tne camshaft 2~3 times and coatirm that rotates smoothly. 4, Injection Quantity : sat] maton | Sore | lMGasG, | aL | tee rena a | 35 | 1,100 ni~ 71 [#2 | Red | Basic Ta [APPR Tao n4~ 10.2 [#14 Rod 5. Timing Advance Specification Pump Speed (com) Advance Angle (420) See ie sevice Depatmant | Teicaanae trfoncanens8-10 FUEL SYSTEM (000000-n000 3, GOVERNOR ADJUSTMENT 3 é & Recommended speed droop adjustment screw position :7 (Notcres trom tuly tightened position) Above 14 {dle-Sub spring setting Main spring setting Ditterence in control rack position between 1000 rpm and 750 rpm coe PUMP SPEEO( rpm) SPEED LEVER ANGLE the seTTING stunger beginning of injection o ~ I \e. ‘STOP LEVER ANGLE Full-speed ait gear mark “cc” PsTURBOCHARGER 9—1 SECTION 9 TURBOCHARGER TABLE OF CONTENTS ITEM PAGE General description .. Turbocharger identification .. Rotor shaft play inspection .. Regarding the details of the turbocharger repair, refer the following workshop manual. Published by: AIR RESERCH INDUSTRIAL DIVISION (A Division of The Garett Corporation) Manual No. Title of the manual: OVERHAUL MANUAL, Diesel Engine Turbochargers Series TV61_; TP20-0101-1 TV61 INSTRUCTION MANUAL, T45 & T51 Series Turbocharger; TP25-0107 Availability of the manual: ISUZU MOTORS LIMITED will send the manual upon request through your machine supplier.9—2 TURBOCHARGER GENERAL DESCRIPTION Tver Tvs1TURBOCHARGER 9—3 TURBOCHARGER IDENTIFICATION The Turbocharger nameplate gives the date of manufac- ture and other important information required to identify the unit when service inquiries or part orders are made. The arrow in the illustration indicates the location of the Turbocharger nameplate. The turbocharger nameplate has the following informa- tion stamped on it. Refer to the illustration at the left. (1), Model number eerie (2) Pat number assigned by ISUZU MOTORS LIMITED SN Example : 1144001330 el came (3) Serial_number assigned by GARRETT TURBO ; INCORPORATED (4) Part number assigned by AIRESEARCH INDUSTRIAL DIVISION Example : J467000 ‘The model number (1) indicates the group to which the turbocharger belongs. Part numbers (2) and (4) indicate specific designs or configurations.9—4 TURBOCHARGER ROTOR SHAFT PLAY INSPECTION it vevon port Rotor Shaft Axial Play Measurement 1) Install a dial indicator on the turbine housing as illustrated, 2) Use the dial indicator to measure the rotor shaft axial play with moving the shaft push and pull. Read the total indicator reading (TIR) mm(in) Modal Limit Rotor Shaft Axial |__TV61 0.25 (0.070) levale Tvsi 0.18 (0.007) 3) If the measured value exceeds the specified limit the shaft must be replaced Rotor Shaft Radial Play Measurement 1) Turn over the turbocharger with the turbine exhaust inlet flange facing up. 2) Install a dial indicator to measure the rotor shaft radial play. 4) Use the dial indicator to measure the play. Read the TIR, mmi(in) Model Limit Rotor Shaft Radial __ TV61 0.18 (0.007) Play Tst 0.18 (0.007) 5) If the measured value exceeds the specified limit replace the shaft.AIR COMPRESSOR 10—1 SECTION 16 AIR COMPRESSOR TABLE OF CONTENTS ITEM PAGE General description (Parts No. 1-19100-107-1) 2 Disassembly steps .. 3 Inspection and repairs ....... 5 Reassembly steps ......... 7 General description (Parts No. 1-19100-113-2) ...... oo . 10-11 Disassembly steps .. 10-12 Inspection and repairs ....... : 10-14 Reassembly steps 10-1610—2 AIR COMPRESSOR GENERAL DESCRIPTION AIR COMPRESSOR SECTIONAL VIEW Parts No. 1-19100-107-1 Output port to air tank — Coolant port — ‘Suction port Coolant port Main Data for Air Compressor Parts No. 1-19100-107-1 Piston ring configuration ‘Theoretical air delivery amount Cylinder bore X stroke mm(in) Maximum operating speed rpm Crankshaft rotating ratio to engine Weight kgllb) Three compression rings and one oil ring 340 cc (20.8 in')/rev. 85 (8.35) X 60 (2.36) 1400 os 11.7 (28.7)AIR COMPRESSOR 10—3 [4] DisassemBLy steps Disassembly Steps 1 a2 3. 4 5. Cylinder head assembly Cylinder body Snap ring Piston pin Piston ring Connecting rod and bearing Bearing cover fixing bolt Crankshaft and bearing VY Important Operation 2. Cylinder body 1) Remove the cylinder mounting flange bolts. 2) Remove the cylinder with tapping out from the el crankcase.10—4 AIR COMPRESSOR 9. Crankshaft and Bearing Use @ soft hammer to tap the crankshaft rear end {key grooved side) with turning the crankshaft slowly. ee This will allow the bearing cover and the bearings to be removed along with the crankshaft from the crankcase.AIR COMPRESSOR 10—5 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. Cylinder Measure the uneven wear of the cylinder bore at the piston skirt position. mm(in) Limit Cylinder Bore Uneven Wear 0.10 (0.004) Measure the piston and the cylinder bore clearance. mm(in) ‘Standard Piston and Cylinder | 0.090 — 0.155 0.18 Bore Clearance (0.0035 — 0.0061) | (0.0071) Note: The piston outside diameter must be taken at the piston skirt positions, Measure the piston ring grooves and the piston ring clearances, mm(in) Standard Limit eieton) Bing) ang 0.005 — 0.040 0.080 Piston Ring Groove cieaanee (0.0002 — 0.0016) | (0.0032) Measure the piston ring gaps. Compression Ring Gap (0.0040 — 0.0118) | (0.040) 0.3—09 1.0 een (0.0118 — 0.0354) |_(0.040)10—6 AIR COMPRESSOR Measure the piston and the piston pin hele clearance. Standard Piston Pin and Piston | 0.012— 0.016 0.080 Pin Hole Clearance | {0.0005 — 0.0006) (0.0032) Measure the piston pin and the connecting rod small- end clearance. mm(in) Standard Limit Piston Pin and Con- ae aan necting Rod Smallend | ‘9.999§ — 0.0017) (0.0028) Clearance Measure the air compressor crank pin and connecting rod large-end clearance. mm(in} Standard Limit Crenieiand cones ene Oa pace, (0.0007 — 0.0033) | (0.0039) ClearanceAIR COMPRESSOR 10—7 [i+] ReEassemBLy steps Reassembly Steps 1. Crankshaft and bearings 4 6. Piston pin & 2. Bearing cover fixing bolts & 7. Snap ring & 3. Connecting rod ‘& 8. Cylinder body 4. Piston rings 4 9. Cylinder head assembly A 5. Piston10—8 AIR COMPRESSOR ><] Z| > eal ee OT te le u| oltseat important Operations 1. Crankshaft and Bearings » 2) 3) 4) 5) 6) Use an appropriate adapter and a bench press to instali the couple of bearings to the crank- shaft. Use an appropriate pilot bar to press in the oil seal into the bearing cover bore. In this work, take care not to damage or distort the oil seal. Install the crankshaft into the bearing cover bore. Setting an adapter at the crankshaft rear end {key grooved side), as illustrated, will secure the oil seal lips from damage or distortion when the crankshaft is pressed in. Fit the O-ting into the crankcase O-ring groove. Lubricate the bearing and the crankshaft journal with a coat of engine oil, Install the bearing cover with the crankshaft and bearings to the crankcase. Use a soft hammer to tap the crankshaft front end gently. 2. Bearing Cover Fixing Bolis Tighten the bearing cover fixing bolts to the speci- fied torque evenly. Bearing Cover Fixing 07 kg-milb.tuN-m) 4 Bolt Torque (5.0 + 0.7/6.9 +AIR COMPRESSOR 10—9 —— — 3. Connecting Rod The connecting rod large end and the bearing cap has a setting mark as illustrated. 1) Lubricate the connecting rod bearing with a coat of engine oii seting mark 2) Install the bearing cap and the connecting rod to the crankshaft journal 3) Seat the lock plate under the cap mut and tigh ten the nut to the specified torque. Te - kg-mi(lb.ft/N-rn) Connecting Rod Cap 25 +02 Nut Torque (18 + 1.5/24.5 + 2.0) 4) Bend the lock plate tang to lock the nut. SepodmekSSS*Y 4, Piston Rings The piston ring stamped mark must be facing up, as illustrated, when it is installed. The side ring and the spacer must be installed to the oil ring groove before the oil ring installation The piston ring gaps must be positioned as illus- trated siden sop 2 Feue 99 5. Piston 6. Piston Pin 7. Snap Ring 1) Lubricate the connecting rod and the bushing Install the piston to the connecting rod. 2) Insert the piston pin into the piston hole and the connecting rod bushing bore. 3) Install the snap rings into the piston snap ring grooves10—10 AIR COMPRESSOR | 8. Cylinder Body 1) Fit the O-ring to the crankcase bore edge. 2) Install the piston into the cylinder. 3) Insert the piston into the cylinder bore until the cylinder body securely come into contact the crankcase. 4) Tighten the cylinder body fixing bolts to the specified torque evenly kg-milb.ft/N-m) Cylinder Body Fixing 28 £02 Bolt Torque (19.6 + 1.4/27.4 + 2.0) 9. Cylinder Head Assembly 1) Fit The O-ring into the cylinder body top O-ring groove. 2) Place the cylinder head on the cylinder body. 3} Tighten the cylinder head bolt evenly to the specified torque. kg-milb.fUN-m) Cylinder Head Bolt 2840.2 Torque (19.6 + 1.4/27.4 + 2.0) kg-mitb.ft/N-m) @ Unloader Valve 11.0 + 1.0 ° Tightening Torque (79.2 + 7.2/107.8 + 9.8) @ Discharge Valve 11.0 + 10 Tightening Torque (79.2 + 7.2/1078 + 98)AIR COMPRESSOR 10—11 GENERAL DESCRIPTION AIR COMPRESSOR SECTIONAL VIEW Parts No. 1-19100-113-2 Discharge Unloader valve port + Main Data for Air Compressor Parts No. 1-19100-113-2 Piston ring configuration Theoretical air delivery amount Cylinder bore x stroke mmi(in) Maximum operating speed rpm Crankshaft rotating ratio to engine Weight kgllb) Three compression rings and one oil ring 340 ce (20.8 in*)/rev. 85 (3.35) 60 (2.36) 1450 05 10.8 (23.8)40—12 AIR COMPRESSOR i] DISASSEMBLY STEPS ~~ Disassembly Steps 1. Cylinder head 4.7. Piston ring 2. Cylinder head gasket 8. Connecting rod 3. Cylinder body and O-ring 4 9. Bearing cover ‘4, Piston pin snap ring 410. Crankshaft and bearing 5. Piston pin 11. Crankcase 6. Piston V Important Operations 4, Piston Pin Snap Ring Use a pair of snap ring pliers to remove the snap ring.10, AIR COMPRESSOR 10—13 Piston Ring Use a pair of giston ring pliers to remove the snap ring. Bearing Cover Slowiy turn the crankshaft while tapping out the bearing cover and the crankshaft with a hammer. Crankshaft Bearing Use a bench press to remove the crankshaft bear- ing.10—14 AIR COMPRESSOR INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis- covered during inspection. Cylinder Measure the uneven wear of the cylinder bore at the piston skirt position, mmiin) Limit Cylinder Bore Uneven Wear 0.10 (0.004) Measure the piston and the cylinder bore clearance. mm(in) Standard Limit Piston and Cylinder 0.10 — 0.16 0.20 Bore Clearance (0.004 — 0.006) (0.008) Note: The piston outside diameter must be taken at the piston skirt positions, Measure the piston ring grooves and the piston ring clearances. mmtin) Standard Limit Piston Ring and 0.025 — 0.060 0.15 Fiston Ring Groove | (91 — 0.002) | (0.006) Clearance Measure the piston ring gaps mmtin) Standard Limit Compression Ring 0.103 10 Gap (0.004 — 0.012) | _ (0.04AIR COMPRESSOR 10—15 Measure the piston and the piston pin hole clearance. _ mm(in) Standard Limit Piston Pin and Piston | 0.002 — 0.023 04 Pin Hole Clearance _| (0.0001 0.001) |_ (0.004) Measure the piston pin and the connecting rod small- end clearance. mmi(in} Standard Limit Piston Pin and Con- | 9.096 — 0.022 aa necting Rod Smallend | 1g 0999 — 0.0008) (0.004) Clearance Measure the air compressor crank pin and connecting rod large-end clearance, motin) Standard Limit Crankpin and Connect 0.02 — 0.068 0.18 ing Rod Large-end | (9.908 — 0.0024) | (0.058) Clearance10—16 AIR COMPRESSOR [i+] ReassemeLy sters Reassembly Steps 1. Crankease 7. Piston pin ‘2. Crankshaft and bearing ‘8. Piston pin snap ring 3. Bearing cover 4 9. Cylinder body and O-ring ‘4 4. Connecting rod 10. Cylinder head gesket 5. Piston 411. Cylinder head A 6. Piston ring V Important Operations 2. Crankshaft and Bearings Use a brass hammer to force the bearing onto the OY cranishareAIR COMPRESSOR 10—17 4. Connecting Rod 1) Fit the bearing into the connecting rod and the bearing cap 2) Apply engine oil, Connecting Red Nut kg-milb.f1/N-m) 25202 Torque (18 + 1.5/24.5 + 2.0) 6. Piston Ring 1) The piston ring portion must be positioned as shown in the illustration, © Front mark @® 1st Compression ring ® 2nd Compression ring @ Oil ring lower side rail © Oil ring expander © Oilring upper side rail 2) Lubricate the piston engine oil Piston Ring Installer: 8. Piston Pin Snap Ring Use a pair of snap ring ring. 8. Cylinder Body and O-ring surface with a coat of pliers to install the snap kg-miib.fU/N-m) Cylinder Body Bolt Torque 2840.2 (19.6 + 1.4/27.4 + 2.0)10—18 AIR COMPRESSOR 11. Cylinder Head kg-milb.ft/N-m) @ Cylinder Head 2.8 +02 Bolt Torque (19.6 + 1.4/27.4 + 2.0) Unloader Valve 11.04 1.0 Torque (79.2 & 7.2/107.8 + 9.8) Discharge Valve 11.0 + 1.0 Torque (79.2 4 7.2/1078 + 9.8)ENGINE ELECTRICALS 11—1 SECTION 11 ENGINE ELECTRICALS TABLE OF CONTENTS ITEM PAGE Starter motor identification . Starter main data and specifications ........... Starter motor sectional view .............00065 Starter motor exploded view ..... Alternator identification .. Main data and specifications Alternator sectional view Alternator exploded view SewmVaounnan Intake heater u-111—2 ENGINE ELECTRICALS STARTER MOTOR IDENTIFICATION ‘The starter motor identification plate is attached to the starter motor outside yoke. The ISUZU partnumber, the manvfacturer’s code number, and other important information are stamped on the plate Refer 10 the identification plate together with the "Main Data and Specifications” Tables and accompanying charts in this Manual when requesting service assistance from a qualified electrical repair shop. If you are unable to locate the data applicable to your engine, please contact ISUZU MOTORS LIMITED through your machine supplier. NIKKO IDENTIFICATION PLATE an | A STARTING MOTOR L B Lc) D at (NIKKO ELEC. IND. CO.,LTD. Isuzu part number Manufacturer's code number Hated output Manufacturer's production mark pom HITACHI IDENTIFICATION PLATE Isuzu part number Manufacturer's code aumber Rated output Manufacturer's production mark A 8. G D:ENGINE ELECTRICALS 11—3 STARTER MOTOR MAIN DATA AND SPECIFICATIONS Isuzu Part No 1-81100-217-0 1-81100-180-0 Manufacturer's code No. 0-23000-1070 (NIKKO) | _$210-08 (HITACHI) Rated voltage “ 24 24 Rated output (kW) 45 an Rating (Sec) 30 30 Direction of rotation (Viewed from the pinion side) Clockwise Clockwise. Clutch type Roller Roller Terminal voltage (No load) ) 24 24 Maximum current (No load) (A) 120 170 Starter motor minimum operating speed (No load) (rpm)___-More than 2500 2000 Pinion gear a Modules 35 35 Number of teeth " n Outside diameter mmi{in.) 48.8 (1.95) 48.8 (1.92) Travel distance mmtin.) 1.64 (0.645) 1.64 (0.064) Yoke outside diameter mmiin.) 90 (355) 113 (4.45) Number ot poles 4 4 Magnetic switch (at 20°C [68°F] } “| Series coil resistance (a) 0.14 013 Shunt coil resistance (a) 1.02 1.09 Brush length | aa Standard mmi(in.) 21.0 — 22.0 22.0 (0.82 — 0.86) (0.87) Limit mmi(in.) 12.0 (0.47) 14.0 (0.55) Brush spring standard fitting load kg/(Ibs.) 4.5 (9.92) 3.5 (7.7) Commutator Outside diameter Standard mm{in.) 43.0 (1.69) 43.0 (1.69) Limit mmi{in.) 42.0 (1.65) 40.0 (1.57) Difference between the largest and smallest diameters (Run-out) Standard mmi(in.) 0.015 (0.0006) 0.05 (0.002) Limit mm(in.) 0.1 (0.004) 0.1 (0.004) Depth of undercut mica Standard mmi(in.) 05-08 05 —08 (0.020 — 0.031) (0.020 — 0.03) Limit mmiin.) 0.2 (0.008) 0.2 (0.008)11—4 ENGINE ELECTRICALS STARTER MOTOR SECTIONAL VIEW NIKKO-0-23000-6091 HITACHI-S210-108ENGINE ELECTRICALS 11—5 STARTER MOTOR EXPLODED VIEW HITACHI-S210-10811—6 ENGINE ELECTRICALS ALTERNATOR IDENTIFICATION The alternator identification plateis attached to the alternator rear bracket. The ISUZU partnumber, the manu: facturer’s code number, and other important information are stamped on the plate. Refer to the identification plate together with the “Main Data and Specifications” Tables and accompanying charts in this Manual when requesting service assistance from a qualified electrical repair shop. If you are unable to locate the data applicable to your engine, please contact ISUZU MOTORS LIMITED through your machine supplier. NIKKO IDENTIFICATION PLATE A [_ ~ ALTERNATOR BC D os NIKKO ELEC. IND. CO,LTD. Isuzu part number Manufacturer's code number Rated output Manufacturer's production mark pomp HITACHI IDENTIFICATION PLATE C6 Le] | A “pd GO On| Isuzu part number Manufacturer's code number Rated output Manufacturer's production mark goerENGINE ELECTRICALS 11—7 MAIN DATA AND SPECIFICATIONS ALTERNATOR Isuzu Part No, |___¥-81200-205-0 1-81200-146-1 Manufacturer's code No. 0-33000-3700 NIKKO) __LT220-14C (HITACHI) Rated voltage “ 24 24 Rated output a) 25 20 Operating speed (rpm) 1000 — 5000 ‘850 — 6000 Rated speed 5000 3000 Rated output at r.p.m, (Amp./Volt/spm) | 4 or more/27/1100 2 or more/28/ 900 Less than 25/27/5000 18 or more/28/3000 No-load output at 0 Amp. (Volt/rpm) | 28.5 + 1/1000 or less 28/850 or less Direction of rotation as viewed from pulley side Clockwise Clockwise Polarity grounded o 4 Pulley diameter mmiin) 80 (3.18) 80 (3.15) Coil resistance at 20°C Rotor coil (a) 14 138 Stator coil (U-V-W] (a) 0.34 0.36 Brush length Standard mm(in.} 15 (0.59) 14.5 10.57) Limit mmiin.) 4 (0.16) 7.5 (0-30) Brush spring standard fitting load @ 350 + 10% 350 + 10% Slip ring diameter Standard mméin) 33 (1.30) 34 (1.34) Limit mmi(in.) 32 (1.26) 17: (0.67) Shaft diameter Front mmi(in) 25 (0.99) 25 (0.99) Rear mmi(in) 17 (0.67) 17 (0.67) Regulator’s applicable Isuzu part No. 1-81251-024-0 1-81251-002-0 Manufacturer's code No. 0-44000-0730 T2z1811—8 ENGINE ELECTRICALS ALTERNATOR SECTIONAL VIEW NIKKO-0-33000-3700 HITACHI-LT220-14¢ENGINE ELECTRICALS 11—9 ALTERNATOR EXPLODED VIEW NIKKO-0-33000-3700 HITACHI-LT220-14C11—10 ENGINE ELECTRICALS INTAKE HEATER GENERAL DESCRIPTION 7 Pi Intake Cover mal a | Intake Air E/ Fut Filter ==> intake Heater Type B “The minimum required height H {s approximately 100mm (4in.) In these engines, a two types of intake heaters are provided, depending on the engine, as an engine start ing aid Type A : Ball Valve Type Intake Heater with an intake heater fuel tank. Type B : Orifice Type Intake Heater with a fuel control solenoid valve. The respective function of the two types are as follows. Type A The fuel is fed from the tank to the ball valve in the intake heater by the gravity. When the starter switch is operated, the intake heater coil is energized heating the ball valve barrel thereby invite a thermal expansion to the barrel permitting the barrel to create a clearance between the ball and the barrel. This results to introduce and ignite the fuel. The fuel burns and flames heating the intake air in the engine intake cover to facilitates the engine starting. Type B In this type, a fuel control solenoid valve is equipped instead of the fuel tank in the type A. When the starter switch is operated, the solenoid valve is energized opening the fuel valve. This results to the pressurized fuel comes to the intake heater orifice. As a minute clearance is provided between the intake heater barrel and the orifice, the fuel passes the clearance with being squeezed to a necessary amount in order to develop a moderate burning.