6wg1 Engine Manual

69697_ESS-172A_SEC0A 11.8.
8 10:18 AM ページ 1
GENERAL INFORMATION 0A–1
GENERAL INFORMATION
CONTENTS
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B
GENERAL INFORMATION
CONTENTS
General Repair Instruction . . . . . . . . . . . . . . . . . . . . 0A-1 Engine External Drawing . . . . . . . . . . . . . . . . . . . . 0A-12
Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-13
Abbreviations Charts . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 0A-19
Nut and Bolt Angular Tightening Method. . . . . . . . . 0A-4 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-27
Standard Bolts Torque Specification . . . . . . . . . . . . 0A-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-29
Recommended Thread Locking Agents . . . . . . . . . 0A-8 Lubricants Application . . . . . . . . . . . . . . . . . . . . . . 0A-39
Main Data and Specification. . . . . . . . . . . . . . . . . . . 0A-9 Sealant Application . . . . . . . . . . . . . . . . . . . . . . . . . 0A-39
Performance Curve. . . . . . . . . . . . . . . . . . . . . . . . . 0A-11
General Repair Instruction 12. When a service operation is completed, make a final
check to be sure the service has been done properly
1. Before performing service operations, disconnect and the problem has been corrected.
ground cable from the battery to reduce the chance of 13. Allow the engine to cool before beginning any service
cable damage and burning due to short circuiting. procedure.
2. Use a cover on body, seats and floor to protect them This will eliminate the danger of fire and possible
against damage and contamination. injury.
3. Brake fluid and anti-freeze solution must be handled 14. Hot steam under pressure may escape from the
with reasonable care, as they can cause paint damage. radiator if the coolant is drained while the engine is
4. The use of proper tools and recommended essential hot. This can result in serious burns. Allow the engine
and available tools, where specified, is important for to cool before draining the coolant.
efficient and reliable performance of service repairs. 15. Hot engine oil can cause severe skin burns. Allow the
5. Use genuine Isuzu parts. engine to cool before draining the engine oil.
6. Used cotter pins, plastic clips, gaskets, O-rings oil 16. While working around a running engine, avoid contact
seals, lock washers and self-locking nuts should be with moving parts and hot surfaces to prevent
discarded and new ones should be installed, as possible bodily injury.
normal function of the parts cannot be maintained if 17. Wear safety glasses when using compressed air, as
these parts are reused. flying dirt particles may cause eye injury.
7. To facilitate proper and smooth reassembly 18. Always wear safety goggles when working with fuel in
operation, keep disassembled parts neatly in groups. order to protect the eye from fuel splash.
Keeping fixing bolts and nuts separate is very
19. Test fluid from the injection nozzle tester will spray out
important, as they vary in hardness and design
of the injection nozzle under great pressure.
depending on position of installation.
It can easily puncture a person’s skin.
8. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make Keep your hands away from the injection nozzle at all
certain they are free from restrictions. time.
9. Lubricate rotating and sliding faces of the parts with 20. Do not use your fingers to feel for fuel leaks at fittings.
oil or grease before installation. Fuel pressure is high enough to penetrate the skin.
10. When necessary, use a sealer on gaskets to prevent 21. Be careful when changing fuel system components:
leakage. Diesel fuel is flammable. Be sure that the ignition key
of OFF. Do not smoke or allow sources of open flame
11. Carefully observe all specifications for bolt and nut
in the area while changing fuel system components.
torques.
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0A–2 GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposed to aid your understanding of technical illustration.
Arrow Type Application Arrow Type Application
• Ambient/Clean air flow

Front of Engine
• Cool air flow
• Gas other than

Up Side ambient air
• Hot air flow
• Ambient air mixed with

another gas
Task Related
• Can indicate
temperature change
View Detail Motion of direction
Lubrication point oil or

View Angle
A fluid
Dimension (1:2) Lubrication point grease
Sectioning (1:3) Lubrication point jelly

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Abbreviations Charts lb in – Inch Pounds

LF – Left Front
List of industrial abbreviations which may be used in
LH – Left Hand
this manual
LR – Left Rear
A – Ampere(s) LS – Left Side
AC – Alternating Current L-4 – In-Line Four Cylinder Engine
ACL – Air Cleaner Max – Maximum
Adj – Adjust Min – Minimum
AMP – Ampere(s) mm – Millimeter
ASM –Assembly N – Newtons
ATDC – After Top Dead Center NA – Naturally Aspirated
Auto – Automatic NC – Normally Closed
Bat – Battery N·m – Newton Meters
B+ – Battery Positive Voltage NO – Normally Open
BHP – Brake Horsepower NOX – Nitrogen, Oxides of
BTDC – Before Top Dead Center OD – Outside Diameter
°C – Degrees Celsius OHC – Overhead Camshaft
cc – Cubic Centimeter PCV – Positive Crankcase Ventilation
CID – Cubic Inch Displacement PRESS – Pressure
CO – Carbon Monoxide PROM – Programmable Read Only Memory
Conn – Connector PSI – Pounds per Square Inch
Crank – Crankshaft PSP – Power Steering Pressure
Cu. In. – Cubic Inch Pt. – Pint
Cyl – Cylinder(s) PWM – Pulse Width Modulate
DOHC – Double Overhead Camshaft Qt. – Quart
DTC – Diagnostic Trouble Code REF – Reference
DTM – Diagnostic Test Mode RF – Right Front
DTT – Diagnostic Test Terminal RH – Right Hand
ECM – Engine Control Module RPM – Revolutions Per Minute
ECT – Engine Coolant Temperature RPM Sensor – Engine Speed Sensor
EGR – Exhaust Gas Recirculation RR – Right Rear
Exh – Exhaust RS – Right Side
°F – Degrees Fahrenheit RTV –Room Temperature Vulcanizing
FL – Fusible Link SAE – Society of Automotive Engineers
FLW – Fusible Link Wire Sec – Secondary
FP – Fuel Pump SI – System International
FRT – Front SOHC – Single Overhead Camshaft
ft – Foot Sol – Solenoid
Gal – Gallon SPEC – Specification
GND – Ground Speedo – Speedometer
Gov – Governor ST – Start / Scan Tool
g – Gram Sw – Switch
Harn – Harness SYN – Synchronize
HC – Hydrocarbons Tach – Tachometer
HD – Heavy Duty TDC – Top Dead Center
Hg – Hydrargyrum (Mercury) Term – Terminal
IC – Integrated Circuit / Ignition Control TEMP – Temperature
ID – Identification / Inside Diameter TURBO – Turbocharger
IGN – Ignition V – Volt(s)
INJ – Injection VAC – Vacuum
Int – Intake V-ref – ECM Reference Voltage
kg – Kilograms VSS – Vehicle Speed Sensor
km – Kilometers VSV – Vacuum Switch Valve
km/h – Kilometer per Hour V-6 – Six Cylinder “Vee” Engine
kPa – Kilopascals V-8 – Eight Cylinder “Vee” Engine
kV – Kilovolts (thousands of volts) W – Watt(s)
kW – Kilowatts w/ – With
L – Liter w/o – Without
lb ft – Foot Pounds WOT – Wide Open Throttle
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Nut and Bolt Angular Tightening

Method
The angular tightening method uses the plastic region of
high tensile steel nuts and bolts to precision tighten Line
important engine fasteners.
Because of the method's nature, there is a limit to the
number of times a particular fastener may be reused. This
limit is specified in this Manual where applicable. C D
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.
4. Draw a line A–B across the center of each nut or bolt
after tighten the snug torque.
F00EY00002
Center line 6. Draw another line F – G on the face of each of the

parts to be clamped. This line will be in the direction
of the specified angle Q across the center E of the
nut or bolt.
A B
Specified angle Q
F00EY00001
5. Draw another line C – D on the face of each of the

parts to be clamped. This line should be an extension
G
of the line A – B.
Coincide line
F00EY00003
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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.
Tighten
C D
B
F
F00EY00005
Example: Specified Angle and Tightening Rotation

A 30° 1 / 12 of a turn
B 60° 1 / 6 of a turn
C 90° 1 / 4 of a turn
D 180° 1 / 2 of a turn
E 360° One full turn
A B C D
E
F00EY00004
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Standard Bolts Torque Specification

The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
STANDARD BOLT N·m (kgf·m/lb.ft)

Bolt
Identification
Bolt
Diameter ×
pitch (mm)
M6 × 1.0 4 – 8 (0.4 – 0.8/3 – 6) 5 – 10 (0.5 – 1.0/4 – 7)
M8 × 1.25 8 – 18 (0.8 – 1.8/6– 13) 12 – 23 (1.2 – 2.3/9 – 17) 17 – 30 (1.7 – 3.1/12 – 22)
M10 × 1.25 21 – 34 (2.1 – 3.5/5 – 25) 28 – 46 (2.8 – 4.7/20 – 33) 37 – 62 (3.8 – 6.4/28 – 46)
* M10 × 1.5 20 – 33 (2.0 – 3.4/15 – 25) 28 – 45 (2.8 – 4.6/20 – 33) 36 – 60 (3.7 – 6.1/27– 44)
M12 × 1.25 49 – 74 (5.0 – 7.5/36 – 54) 61 – 91 (6.2 – 9.3/45 – 67) 76 – 114 (7.7 – 11.6/56 – 84)
* M12 × 1.75 45 – 69 (4.6 – 7.0/33 – 51) 57 – 84 (5.8 – 8.6/42 – 62) 72 – 107 (7.3 – 10.9/53 – 79)
M14 × 1.5 77 – 115 (7.8 – 11.7/56 – 85) 93 – 139 (9.5 – 14.2/69 – 103) 114 – 171 (11.6 – 17.4/84 – 126)
* M14 × 2.0 72 – 107 (7.3 – 10.9/53 – 79) 88 – 131 (9.0 – 13.4/65 – 97) 107 – 160 (10.9 – 16.3/79 – 118)
M16 × 1.5 104 – 157 (10.6 – 16.0/77 – 116) 135 – 204 (13.8 – 20.8/100 – 150) 160 – 240 (16.3 – 24.5/118 – 177)
* M16 × 2.0 100 – 149 (10.2 – 15.2/74 – 110) 129 – 194 (13.2 – 19.8/96 – 143) 153 – 230 (15.6 – 23.4/113 – 169)
M18 × 1.5 151 – 226 (15.4 – 23.0/110 – 166) 195 – 293 (19.9 – 29.9/144 – 216) 230 – 345 (23.4 – 35.2/169 – 255)
* M18 × 2.5 151 – 226 (15.4 – 23.0/110 – 166) 196 – 294 (20.0 – 30.0/145 – 217) 231 – 346 (23.6 – 35.5/171 – 255)
M20× 1.5 206 – 310 (21.0 – 31.6/152 – 229) 270 – 405 (27.5 – 41.3/199 – 299) 317 – 476 (32.3 – 48.5/234 – 351)
* M20× 2.5 190 – 286 (19.4 – 29.2/140 – 211) 249 – 375 (25.4 – 38.2/184 – 276) 293 – 440 (29.9 – 44.9/216 – 325)
M22× 1.5 251 – 414 (25.6 – 42.2/185 – 305) 363 – 544 (37.0 – 55.5/268 – 401) 425 – 637 (43.3 – 64.9/313 – 469)
* M22× 2.5 218 – 328 (22.2 – 23.4/161 – 242) 338 – 507 (34.5 – 51.7/250 – 374) 394 – 592 (40.2 – 60.4/291 – 437)
M24× 2.0 359 – 540 (36.6 – 55.0/265 – 398) 431 – 711 (43.9 – 72.5/318 – 524) 554 – 831 (56.5 – 84.7/409 – 613)
* M24× 3.0 338 – 507 (34.5 – 51.7/250 – 374) 406 – 608 (41.4 – 62.0/299 – 448) 521 – 782 (53.1 – 79.7/384 – 576)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such
as casting.
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The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
FLANGED HEAD BOLT N·m (kgf·m/lb.ft)

Bolt
Identification
Bolt
Diameter ×
pitch (mm)
M6 × 1.0 5 – 9 (0.5 – 0.9/4 – 7) 6 – 12 (0.6 – 1.2/4 – 9)
M8 × 1.25 11 – 20 (1.1 – 2.0/8 – 15) 15 – 28 (1.6 – 2.9/12 – 21) 18 – 34 (2.1 – 3.4/15 – 25)
M10 × 1.25 23 – 39 (2.4 – 3.9/17 – 28) 35 – 59 (3.6 – 6.1/26 – 44) 42 – 71 (4.3 – 7.2/31 – 52)
* M10 × 1.5 22 – 37 (2.3 – 3.8/17 – 28) 35 – 58 (3.5 – 5.8/25 – 42) 40 – 67 (4.1 – 6.8/30 – 49)
M12 × 1.25 55 – 82 (5.6 – 8.4/40 – 61) 77 – 117 (7.9 – 11.9/57 – 86) 85 – 128 (8.7 – 13.0/63 – 94)
* M12 × 1.75 51 – 77 (5.2 – 7.8/38 – 56) 71 – 107 (7.3 – 10.9/53 – 79) 80 – 119 (8.1 – 12.2/59 – 88)
M14 × 1.5 83 – 125 (8.5 – 12.7/62 – 92) 115 – 172 (11.7 –17.6/85 – 127) 123 – 185 (12.6 – 18.9/91 – 137)
* M14 × 2.0 77 – 116 (7.9 – 11.8/57 – 85) 108 – 162 (11.1 – 16.6/80 – 120) 116 – 173 (11.8 – 17.7/85 – 128)
M16 × 1.5 116 – 173 (11.8 – 17.7/85 – 128) 171 – 257 (17.4 – 26.2/126 – 190) 177 – 265 (18.0 – 17.1/130 – 196)
* M16 × 2.0 109 – 164 (11.2 – 16.7/81 – 121) 163 – 244 (16.6 – 24.9/120 – 180) 169 – 253 (17.2 – 25.8/124 – 187)
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
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Recommended Thread Locking

Agents
LOCTITE Type LOCTITE Color
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red
Application Steps
1. Completely remove all lubricant and moisture from the

bolts and the female-threaded surfaces of the parts to
be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
Apply LOCTITE to at least 1/3 of the

bolt's threaded area
F00RW014
3. Tighten the bolts to the specified torque.

After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until LOCTITE
hardens.
NOTE: When the application procedures are specified in
this manual, follow them.
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Main Data and Specifications

ITEMS 6WG1TQA
Engine type Four cycle, water cooled, in-line, overhead camshaft
direct injection
Combustion chamber Open type in piston crown
Cylinder liner Dry type
Timing drive system Gear drive
No. of cylinders – bore × stroke mm (in) 6 – 147 × 154 (5.79 × 6.06)
Rated output kW/min–1 235.4/1800
Max. torque kW/min–1 1274.9/1500
No. of piston rings Four rings (Compression rings: 3, Oil ring: 1)
Total piston displacement L (cid) 15.681 (956.9)
Compression ratio (to 1) 16.4
Compression pressure at 200 min–1
MPa (kg/cm2/psi) 2.75 (28/400) or more
Engine dimensions mm (in) 1,642 × 1007 × 1,287 (64.6 × 39.6 × 50.7)
Engine weight (Dry) kg (lb) 1,252 (2,764)
Fuel injection order 1–5–3–6–2–4
Fuel injection timing (TDC) deg 11
Specified fuel type SAE No.2 diesel fuel
Idling speed min–1 900
Valve clearances Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Intake valves Open at (BTDC) deg 21
Close at (ABDC) deg 27
Exhaust valves Open at (BBDC) deg 52
Close at (ATDC) deg 17
Injection pump Bosch, in-line P-Type
Governor type Mechanical
Injection nozzle Multi-hole type
Injection nozzle opening pressure
MPa (kg/cm2/psi) 20.1 (205/2,920)
Main fuel filter type Paper element
Lubrication system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CD
Oil pressure (at oil gallery)
kPa (kg/cm2/psi)/min–1 300 (3.1/44.1)/1,200
390 (4.0/56.9)/2,000
Condition: SAE 30 API CD grade engine oil at an
oil temperature of 80°C (176°F)
Oil pump type Gear (Timing gear drive)
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ITEMS 6WG1TQA
Relief valve opening pressure
kPa (kg/cm2/psi)
1st stage 440 (4.5/64.0)
2nd stage 690 (7.0/99.5)
Oil pressure switch operating pressure
kPa (kg/cm2/psi) 10 (0.1/0.7)
Main oil filter type Paper element
Bypass valve opening pressure
kPa (kg/cm2/psi) 200 (2.0/28.4)
Oil volume L (qts) 52 (55) with combined main and partial oil filter
Oil cooler Plate type – Water cooled in water jacket
Oil thermostat opening temperature
°C (°F) 98.0 (208)
Cooling system Pressured compulsory circulation water
Coolant volume L (qts) 36 (38)
Water pump type Centrifugal impeller, Gear drive
Delivery volume
Lit/min. (Imp. gal/US gal) 420 (92.4/111.0) Pump speed at 2,840 rpm
Thermostat type Wax pellet
Valve initial opening temperature °C (°F) 82 (180)
Valve lift mm (in) 11.0 (0.433)
Air cleaner
Alternator capacity V–A 24 – 50 Mitsubishi
Regulator type IC (Built-in)
Brush length mm (in) Brush less
Starter motor output V – kW 24 – 7 Mitsubishi
Number of poles 4
Turbocharger model RHC 92
Manufacturer Ishikawajima Harima Heavy Industry (IHI)
Note: Some values are different due to the difference of the models and the specifications.
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Performance Curve
1. MODEL AA-6WG1TQA
Condition
Break in period Fully Air cleaner Non
Cooling fan φ 850 Exhaust silencer Non
Alternator No load Ambient condition Standard
240 1400
Torque (Nm)
220 1200
200 1000
180
Power Output (kW)
160
140
120
240 SFC (g/kW/h)

100 230
220
210
200
1000 1200 1400 1600 1800 2000
Engine Speed (min-1)

F06EY00020
Note: Some values are different due to the difference of the models and the specifications.
0A–12
ENGINE EXTERNAL DRAWING

MODEL AA-6WG1 TQA
Oil filler cap
PCV
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GENERAL INFORMATION
Exhaust manifold Turbocharger Inlet duct Fan guide Fuel pump Oil dipstick
Water outlet pipe
Injection pump Fuel filter
Cooling fan
Fan pulley
Alternator
Crank pulley
Water pump
Coupling cover Starter motor
Water drain plug Water inlet pipe
Thermostat housing
Oil drain plug Breather hose
Oil port cover
Note: Some components and shapes are different due to the difference of the models and the specifications.
015EY00001
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Service Standard
ITEMS SERVICE STANDARD SERVICE LIMIT
ENGINE
Compression Pressure 27.5 (28 / 400 ) / 200 21.6 ( 22 / 312 )
MPa(kg/cm2/psi)/min–1 or more, after warm up the
engine.
CYLINDER HEAD and VALVE
Camshaft End Play mm(in) 0.085 – 0.170 (0.0033-0.0067) 0.25 ( 0.0098 )
Clearance between Camshaft and
0.065 – 0.125 (0.0026-0.0049) 0.15 ( 0.0059 )
Bracket mm(in)
Idle Gear “C” End Play mm(in) 0.05 – 0.14 (0.0020-0.0055) 0.25 ( 0.0098 )
Clearance between Shaft and Idle “C” Gear
0.04 – 0.105 (0.0016-0.0041) 0.2 ( 0.0079 )
mm(in)
Valve Spring Free Height mm(in) Outer
Inlet 79.3 (3.1220) 75.3 ( 2.965 )
Exhaust 102.7 (4.0433) 97.6 ( 3.843 )
Inner
Inlet – –
Exhaust 96.5 (3.7992) 91.7 ( 3.6102 )
Valve Spring Squareness mm(in) Inlet 3.5 (0.1378) 4.8 ( 0.1890 )
Exhaust
Outer 4.5 (0.1772) 6.2 ( 0.2441 )
Inner 4.2 (0.1654) 5.9 ( 0.2323 )
Valve Spring tension N(kg/lb)/mm Outer
Inlet 392
372 ( 37.9/83.6)/64
(40.0/88.2)/64
Exhaust 610
579 ( 59.0/130)/69
(62.2/137)/69
Inner
Inlet – –
Exhaust 224
213 ( 21.7/47.8 )/66
(22.8/50.3)/66
Valve Stem and Guide Clearance Inlet 0.040 – 0.077
0.15 ( 0.0059 )
mm(in) (0.0016 – 0.0030)
Exhaust 0.065 – 0.102
0.25 ( 0.0098 )
(0.0026 – 0.0040)
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Valve Stem Outside Diameter mm(in) Inlet 10.0 (0.3937) 9.92 ( 0.3906 )
Exhaust 10.0 (0.3937) 9.90 ( 0.3898 )
Bridge Guide and Bridge Clearance
0.020 – 0.057 (0.0080-0.0022) 0.10 ( 0.0039 )
mm(in)
Valve Thickness mm(in) Inlet 2.14 (0.0843) 1.64 ( 0.0646 )
Exhaust 2.3 (0.0906) 1.8 ( 0.0709 )
Valve Depression mm(in) Inlet 1.9 (0.0748) 2.9 ( 0.1142 )
Exhaust 1.8 (0.0709) 2.8 ( 0.1102 )
Valve Contact Width mm(in) Inlet 3.3 (0.1299) 3.7 ( 0.1457 )
Exhaust 2.6 (0.1024) 3.0 ( 0.1181 )
Valve Contact Surface Angle deg Inlet 30 –
Exhaust 45 –
Valve Seat Angle deg Inlet 30 –
Exhaust 45 –
Valve Bridge Guide Upper End Height
49.0 (1.9291) –
mm(in)
Valve Guide Upper End Height mm(in) Inlet 27.0 (1.0630) –
Exhaust 29.0 (1.1417) –
ROCKER ARM AND CAMSHAFT
Rocker Arm Shaft Run Out mm(in) – 0.3 ( 0.012 )
Rocker Arm Shaft Outside Diameter 27.979 – 28.000
27.85 (1.0965)
mm(in) (1.1015-1.1024)
Rocker Arm Bushing Inside Diameter 28.020 – 28.053
–
mm(in) (1.1031 – 1.1044)
Rocker Arm and Rocker Arm Shaft 0.020 – 0.074
0.2 (0.0079)
Clearance mm(in) (0.0008 – 0.0029)
Rocker Arm Roller and Pin Clearance 0.036 – 0.069
0.15 (0.0059)
mm(in) (0.0014 – 0.0027)
Camshaft Journal Diameter mm(in) 39.915 – 39.940
39.89 (1.57047)
(1.5715 – 1.5724)
Cam Height (Nose Height) mm(in) Inlet 9.4 (0.3700) 8.85 ( 0.3484 )
Exhaust 10.4 (0.4094) 9.75 ( 0.3839 )
Camshaft Run Out mm(in) 0.080 (0.0031) 0.100 ( 0.0039 )
Camshaft Bearing Inside Diameter 40.015 – 40.040
–
mm(in) (1.5754 – 1.5764)
Clearance Camshaft and Cam Bearing 0.065 – 0.125 0.15
mm(in) (0.0026 – 0.0049) ( 0.0059 )
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 15

TIMING GEAR TRAIN
Idle Gear Backlash mm(in) 0.095 – 0.135 0.25
( 0.0037 – 0.0053 ) ( 0.0098 )
Idle Gear End Play mm(in) “A” 0.155 – 0.220 0.35
(0.0061 – 0.0089) ( 0.0138 )
“B” 0.050 – 0.140 0.25
(0.0020 – 0.0055) ( 0.0098 )
“C” 0.050 – 0.140 0.25
(0.0020 – 0.0055) ( 0.0098 )
Idle Gear Spindle Outside Diameter “A” 56.93 – 56.96 56.85
mm(in) (2.2413 – 2.2425) ( 2.2382 )
“B” 141.93 – 141.96 141.85
(5.5878 – 5.5890) ( 5.5846 )
“C” 48.93 – 48.96 48.85
(1.9264 – 1.9286) ( 1.9232 )
Clearance Between Idle Gear and “A”
Spindle mm(in) 0.040 – 0.105 0.20
“B”
(0.0015 – 0.0041) ( 0.0079 )
“C”
CRANKSHAFT
Crankshaft End Play mm(in) 0.10 – 0.28 (0.0039-0.0110) 0.35 ( 0.0138 )
Crankshaft Journal Diameter mm(in) No.4 104.850 – 104.875
–
(4.1279 – 4.1289)
Others 104.880 – 104.905
–
(4.1291 – 4.1309)
Crankpin Diameter mm(in) 91.895 – 91.925
–
(3.6179 – 3.6191)
Crankshaft Run Out mm(in) 0.120 (0.0005) 0.15 ( 0.0059 )
Crankshaft End Play mm(in) 0.10 – 0.28
0.30 (0.0121)
(0.0039 – 0.0110)
Crank Bearing Spread mm(in) – 111.5 ( 4.3898 )
Clearance Crankshaft journal and No.4 0.075 – 0.150
Bearing mm(in) Journal (0.0030 – 0.0059)
0.16 (0.0063)
Others 0.045 – 0.120
(0.0018 – 0.0047)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 16

PISTON AND CONNECTING ROD
Piston Ring Gap mm(in) 1st, 3rd 0.35 – 0.50
1.0 (0.0394)
(0.0138 – 0.0197)
2nd 0.80 – 0.95
1.5 (0.059)
(0.0315 – 0.0374)
Oil 0.30 – 0.50
1.0 (0.0394)
(0.0118 – 0.0197)
Clearance Piston Ring and Groove 1st 0.115 – 0.160 0.24
mm(in) (0.0045 – 0.0063) (0.0094)
2nd 0.10 – 0.135 0.20
3rd (0.0039 – 0.0053) (0.0079)
Oil 0.025 – 0.065 0.15
(0.0010 – 0.0026) (0.0059)
Piston Pin Diameter mm(in) 55.995 – 56.000 55.970
(2.2015 – 2.2047) (2.2035)
Clearance Piston Pin and Hole mm(in) 0.008 – 0.021 0.05
(0.0003 – 0.0008) (0.0020)
Clearance Connecting Rod Small End 0.020 – 0.037 0.10
Bushing and Piston Pin mm(in) (0.0008 – 0.0015) (0.0039)
Connecting Rod Alignment mm(in) 0.05 (0.002 or less) 0.10 (0.0039)
Clearance Crankpin and Connecting 0.033 – 0.103 0.16
Rod Bearing mm(in) (0.0013 – 0.0041) (0.0063)
Clearance Connecting Rod and 0.175 – 0.290 0.35
Crankshaft mm(in) (0.0069 – 0.0114) (0.0138)
Clearance Piston and Cylinder Liner 0.166 – 0.200
–
mm(in) (0.0065 – 0.0079)
PISTON AND CYLINDER LINER GRADE
Cylinder Measuring point mm(in) 130 (5.1181)
Cylinder Liner Inside Diameter mm(in) 147.011 – 147.030
–
(5.7878 – 5.7886)
Piston Measuring Point from
113 (4.4488) –
Piston Top mm(in)
Piston Outside Diameter mm(in) 146.830 – 146.845
–
(5.7807 – 5.7813)
Clearance Cylinder Liner and Cylinder 0.001 – 0.030
Block mm(in) (0.00004 – 0.00118)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 17

CYLINDER BLOCK AND CYLINDER LINER
GRADE
Cylinder Block Bore Diameter mm(in) Grade
“1” 151.600 – 151.610
–
(5.9685 – 5.9689)
“2” 151.611 – 151.630
–
“3” (5.9689 – 5.9697)
Cylinder Liner Outside Diameter mm(in) Grade
“1X” 151.590 – 151.599
–
(5.9681 – 5.9685)
“3X” 151.600 – 151.610
–
(5.9685 – 5.9689)
CYLINDER BODY
Cylinder Liner Bore mm(in) Nominal Measurement
147.3 (5.7992)
147.0 (5.7874)
Cylinder Block Upper Face Warpage
0.0075 (0.0030) or less 0.2 (0.008)
mm(in)
Cylinder Liner Projection mm(in) 0.05 – 0.09
–
(0.0020 – 0.0035)
Projection Height Between Adjacent
0.02 (0.0008) or less –
Cylinder mm(in)
LUBRICATING SYSTEM
Clearance Oil Pump Body and Driven 0.050 – 0.098
0.15 (0.0059)
Gear mm(in) (0.0020 – 0.0039)
Side Clearance Oil Pump Cover and 0.040 – 0.094
–
Gear mm(in) (0.0016 – 0.0037)
Oil Pump Gear Shaft Diameter mm(in) 20.0 (0.7874) 19.9(0.7835)
Clearance Oil Pump Gear Shaft and 0.040 – 0.074
–
Body mm(in) (0.0015 – 0.0029)
An Interference Oil Pump Drive Gear 0.019 – 0.047
–
and Driven Gear mm(in) (0.0007 – 0.0019)
Oil Thermostat Opening Temperature
98.0 (208.4) –
°C (°F)
ENGINE COOLING SYSTEM
Clearance Water Pump Impeller and 1.7 – 2.7
3.2 (0.1260)
Pump Body mm(in) (0.0669 – 0.1063)
Thermostat Opening Temperature Initial Opening 82 (180.0) –
°C (°F) Full Opening 95 (203.0) –
Thermostat Full Valve Lift mm(in) 11 (0.433) –
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 18

ENGINE ELECTRICAL
Alternator
Rotor Coil Resistance ohm 11.7 –
Starter Motor
Commutator Undercut mm(in) 0.5 (0.197) 0.2 (0.0079)
Commutator Outside Diameter mm(in) 32 (1.26) 31.4 (1.24)
Brush Length mm(in) 18 (0.709) 11 (0.43)
TURBOCHARGER
Turbine Shaft End Play mm(in) 0.075 – 0.110
0.12 (0.0047)
(0.0030 – 0.0043)
Clearance Turbine Shaft and Bearing 0.130 – 0.235
0.275 (0.0108)
mm(in) (0.0051 – 0.0093)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 19
Torque Specifications
Auxiliary Parts N·m (kgf·m/lb ft)
118(12/87) 118(12/87)
52(5.3/38) 103(10.5/76)
52(5.3/38)
F06EY00021
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 20
Engine External Parts

N·m (kgf·m/lb ft)
43(4.4/32)
52(5.3/38)
39(4.0/29)
88(9.0/65)
108(11/80)
43(4.4/32) 20(2.0/14)
50(5.1/37)
39(4.0/29)
43(4.4/32)
F06EY00022
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 21
Cylinder Head
N·m (kgf·m/lb ft)
20(2.05/14.8)
15(1.5/11)
90(9.2/67)
Apply engine oil 49(5.0/36)
137(14/101)
M18: 177 (18/130)

245 (25/181)
60° 90°
M12: 76 (7.7/57)
M10: 38 (3.9/28)
M18: Apply molybdenum
disulfide grease
M12,M10: Apply engine oil
Apply engine oil
39(4.0/29)
Apply Loctite FMD-127
F06EY00166
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 22
Oil Pan
N·m (kgf·m/lb ft)
69(7.0/51)
55(5.6/41)
38(3.9/28)
38(3.9/28)
25(2.5/18)
19(1.9/14)
PAW0Z0LF001301
PAW0Z0LF001301
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 23
Timing Gears
N·m (kgf·m/lb ft)
135(13.8/100)
49(5.0/36)
39(4.0/29)
Apply Loctite FMD-127
39(4.0/29)
108(11.0/80)
52(5.3/38)
46(4.7/34)
22(2.2/16)
96(9.8/71)
267(27.2/197)
Apply engine oil
014EY00127
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 24
N·m (kgf·m/lb ft)
(Without Cooling Fan)
135 {13.8 / 100}
49 {5.0 / 36}
39 {4.0 / 29}
39 {4.0 / 29}
108 {11.0 / 80}
39 {4.0 / 29}
M8 23 {2.3 / 17}
M10 43 {4.4 / 32}

96 {9.8 / 71}
267 {27.2 / 197}
PAW0Z0LF001401
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 25
Flywheel
N·m (kgf·m/lb ft)
136(13.8/100)
136(13.8/100)
Apply Loctite
FMD-127
136(13.8/100)
M14: 123 (12.5/90)

M 8 : 22 (2.2/16)
78(8.0/58) 60° 30°

136(13.8/100)
Apply molybdenum disulfide grease
015EY00080
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 26
Piston, Connecting Rod, Crankshaft

N·m (kgf·m/lb ft)
98(10/72) 30° 30°

M12: 96(9.8/71)
Apply engine oil
M18: 49(5/36) 88(9/65) 105°

51743A
00/06/27 0
一般輸出
015EY00081
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 27
Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME
1-8522-1187-0
1-8523-0013-0
Installer; Valve stem seal
Remover; Nozzle holder
for intake
1-8531-7019-0 1-85221-184-0
Adapter; Compression Installer; Valve stem seal
gauge for exhaust
5-8840-0266-0 1-8522-1025-0
Angle gauge Setting tool; Piston ring
901LX030
1-8523-5013-0 1-8522-0052-0
Compressor; Valve spring Remover; Slinger
9-8523-1202-0
1-8522-0059-0
Remover; Valve
Setting tool; Piston
guide/Installer
9-8522-1324-0
1-8522-0043-0
Installer; Valve bridge
Installer; Oil seal
guide
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 28
TOOL NO.
ILLUSTRATION
TOOL NAME
1-8521-0064-0
Remover; Crankshaft gear
1-8522-0045-0
Installer; Crankshaft gear
1-8521-0062-0
Remover; Impeller
11.3 ± 0.1
1-8522-0047-0
Installer; Seal Unit
1-8521-0067-0
Puller; Seal ring
1-8522-1034-0
Installer; Seal ring
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 29
Troubleshooting
1. Hard starting
Condition Possible Cause Correction
Starter motor does not turn over Loose battery cable terminals
Poor battery connections due to rusting Clean and/or retighten the battery cable
terminals
Battery discharged or weak Recharge or replace the battery
Fusible link shorted Replace the fusible link
Defective starter switch or starter relay Replace the starter switch or starter relay
Defective magnetic switch of starter Repair or replace the magnetic switch
motor or starter relay or starter relay
Defective starter motor Repair or replace the starter motor
Starter motor operates but Loose battery cable terminals
engine does not turn over Poor battery connections due to rusting Clean and/or retighten the battery cable
terminals
Battery discharged or weak Recharge or replace the battery
Loose fan belts Adjust the fan belt tension
Defective starter motor pinion gear Replace pinion gear
Defective magnetic switch of the starter Repair or replace the magnetic switch
motor
Worn starter motor Replace the brush and /or brush spring
Weak brush spring
Piston,crank bearing seizure,or other Repair or replace the related parts
damage
Engine turns over but does not Air in the fuel system Bleed air from the fuel system
start Defective engine stop mechanism Replace the engine stop mechanism
Control wire improperly adjusted” Adjust the control wire
Fuel tank is empty Fill the fuel tank
Clogged or damaged fuel lines Repair or replace the fuel lines
Loose fuel line connections Retighten the fuel line connections
Clogged fuel filter element Replace the fuel filter element or cartridge
Fuel feed pump strainer is clogged Clean the fuel pump strainer
Defective feed pump Repair or replace the feed pump
Poor return of the engine stop button Completely return the engine stop button
Use of the wrong fuel Use the recommended fuel
Water particles in the fuel Change fuel
Air in the injection pump Bleed air from the fuel system
Injection nozzle sticking Replace the injection nozzle
Injection nozzle starting pressure too low Adjust or replace the injection nozzle
Improper spray condition
Improper injection pump control rack Repair or replace the injection pump
operation control rack
Injection pump plunger worn or stuck Replace the injection pump plunger
assembly
Injection pump camshaft seizure or Replace the injection pump camshaft
other damage
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 30
2. Unstable Idling
Trouble in the engine stop Poor return of the engine stop button Completely return the engine stop
mechanism button
Trouble in the fuel system Fuel system leakage or blockage Repair or replace the fuel system
Air in the fuel system Bleed the air from the fuel system
Water particles in the fuel Replace fuel
Clogged fuel filter element Replace the fuel filter element or
cartridge
Injection nozzle starting pressure too Adjust or replace the injection nozzle
low
Defective delivery valve resulting in fuel Replace the delivery valve
drippage after fuel injection
Injection timing improperly adjusted Adjust the injection timing
Insufficient injection volume Adjust the injection volume
Broken plunger spring of the injection Replace the plunger spring
pump
Worn plunger of the injection pump Replace the plunger assembly
Worn camshaft of the injection pump Replace the camshaft
Worn roller tappet of the injection pump Replace the roller tappet
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the valve clearance
Worn camshaft Replace the camshaft
Low compression pressure Blown out cylinder head gasket Replace the related parts
Worn cylinder liner
Piston ring sticking or broken
Improper seating between the valve and
valve seat
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 31
3. Insufficient Power
Trouble in the air intake system Clogged air cleaner element Clean or replace the air cleaner element
Trouble in the fuel system Water particles in fuel system Replace fuel
Clogged fuel filter element Replace the fuel filter element or
cartridge
Clogged strainer or defective fuel feed Repair or replace the feed pump
pump
low
Improper spray condition Adjust or replace the injection nozzle
Fuel injection pipes damaged or Replace the injection pipes
obstructed
Defective delivery valve Replace the delivery valve
Repair or replace the timing advancer
Worn plunger of the injection pump Replace the plunger assembly
Worn camshaft of the injection pump Replace the camshaft
Trouble in the turbocharged Exhaust gas leakage from the exhaust Repair or replace the related parts
system system
Air leakage from the intake system Repair or replace the related parts
Defective turbocharger assembly Replace the turbocharger assembly
Worn cylinder liner
valve seat
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the valve clearance
Worn camshaft lobe Replace the camshaft
Valve spring weak or broken Replace the valve spring
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 32
4. Excessive Fuel Consumption

Trouble in the fuel system Fuel leakage Repair or replace the fuel system
related parts
low
Improper spray condition Adjust or replace the injection nozzle
Trouble in the air intake system Clogged air cleaner element Clean or replace air cleaner element
Improper idle speed Poorly adjusted idling speed Adjust idling speed
Trouble in the cooling system Defective thermostat Replace
Trouble in the lubricating system Improper engine oil viscosity Replace engine oil
Trouble in turbocharged system Air leakage from the turbocharger intake Repair the turbocharger intake side
side
Defective turbocharger assembly Replace the turbocharger assembly
Worn cylinder liner
valve seat.
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the camshaft
Worn camshaft lobe Replace the camshaft
Valve spring weak or broken Replace the valve spring
5. Excessive Oil Consumption

Trouble in the lubricating system Engine oil unsuitable Replace engine oil
Too much engine oil volume Correct engine oil volume
Leakage Oil leakage from the oil seal and/or Replace the oil seal and/or gasket
gasket
Oil leaking into the combustion Worn valve stems and valve guides Replace the intake and exhaust valves
chamber due to poor seal in the and valve guides
valve system Worn valve stem oil seal Replace the oil seal
Improper sealing Worn or broken seal ring in the Replace the seal ring
turbocharger
Worn cylinder liner
valve seat.
Trouble in the ventilation Clogged air breather Clean the air breather
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 33
6. Engine Cooling Trouble

Overheating Insufficient cooling water Replenish coolant
Defective pressure cap or clogged Replace the radiator pressure cap or
radiator core clean radiator core
Defective water pump Repair or replace the water pump
Defective sealing cap resulting in the Replace the sealing cap
cooling water leakage
Defective thermostat Replace the thermostat
Cooling system clogged by foreign Take out the foreign material from the
material cooling system
Fuel injection timing improperly Adjust the fuel injection timing
adjusted
7. White Exhaust Smoke

Trouble in the fuel system Water particles in fuel Replace the fuel
Retarded fuel injection timing Adjust the fuel injection timing
Worn cylinder liner
valve seat.
Trouble in the cooling system Defective thermostat Replace the thermostat
Trouble in the turbocharger Defective turbocharger Repair or replace
system
8. Black Exhaust Smoke

Trouble in the fuel system Clogged air cleaner element Clean or replace the air cleaner element
Trouble in the fuel system Injection nozzle starting pressure tool Adjust or replace the injection nozzle
low
Advanced fuel injection timing Adjust the fuel injection timing
Excessive injection volume Adjust the injection volume
Trouble in the valve train Worn camshaft lobe Replace the camshaft
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 34
9. Lubrication Problems
Oil pressure does not rise Improper engine oil viscosity Replace the engine oil
Insufficient engine oil Correct the engine oil volume
Defective oil pressure gauge or unit Repair or replace the oil pressure gauge
or unit
Clogged oil filter element Replace the oil filter element or
cartridge
Relief valve sticking and/or weak by- Replace the relief valve and/or by-pass
pass valve spring valve spring
Clogged oil pump strainer Clean the oil pump strainer
Worn oil pump related parts Replace the oil pump related parts
Worn rocker arm bushing Replace the rocker arm bushing
Worn camshaft and camshaft bearing Replace the camshaft and camshaft
bearing
Worn crankshaft and bearings Replace the crankshaft and/or bearing
Oiling jet valve does not close Replace the oiling jet
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 35
10. Abnormal Engine Noise

Start the engine and allow it to warm up before beginning the troubleshooting procedure.

Engine knocking Use of wrong fuel Use correct fuel
Fuel injection timing improperly Adjust the injection timing
adjusted
Improper injection nozzle starting Adjust or replace the injection nozzle
pressure
Broken piston ring resulting in low Replace the piston ring
compression pressure
Defective fuel injection nozzle resulting Replace the fuel injection nozzle
in fuel drippage after fuel injection
Gaseous leakage noise Loosely connected exhaust pipes Tighten the exhaust pipe connection
Broken exhaust pipes Replace the exhaust pipes
Loose injection nozzles and/or glow Tighten the injection nozzles and/or
plug glow plug
Replace the washer
Loosely connected exhaust manifold Tighten the exhaust manifold
connections
Damaged cylinder head gasket Replace the cylinder head gasket
Continuous noise Loose fan belt Readjust the belt tension
Loose cooling fan Retighten cooling fan
Worn or damaged water pump bearing Replace the water pump bearing
Worn or damaged alternator bearing Replace the alternator bearing
Valve clearance improperly adjusted Adjust the valve clearance
Slapping noise Valve clearance improperly adjusted Adjust the valve clearance
Damaged rocker arm Replace the rocker arm
Worn or damaged crankshaft and/or Replace the crankshaft and/or thrust
thrust bearings bearing
Worn or damaged crankshaft and/or Replace the crankshaft and/or
connecting rod bearings connecting rod bearings
Worn or damaged connecting rod Replace the connecting rod bushing
bushing and piston pin and/or piston pin
Worn or damaged piston and cylinder Replace the piston and cylinder liner
liner
Foreign material in the cylinder
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 36
11. Alternator
Battery dead Loose alternator drive belt Adjust
Low battery fluid Replenish
Defective battery terminals Replace
Blown fuse Replace
Poor contact between the fuse holder Repair
and fuse
Low battery fluid specific gravity Adjust
Broken or poorly connected starter Repair
switch and regulator terminal wire
Broken or poorly connected regulator Repair
terminal and alternator terminal wire
Defective alternator ground circuit Repair
Defective voltage regulator Replace
Defective diode Replace
Grounded or broken alternator stator Repair or replace
coil
Broken rotor coil Replace
Excessive electrical load Check the alternator output at normal
operating speed
Battery overcharged Poor connections or open circuit Correct
Poor ground connection of voltage Correct
regulator
Voltage set of regulator too high Replace
Defective voltage regulator Replace
Flashing charge light or Loose belt Adjust
fluctuating ammeter indication Defective starter switch contacts Replace
Broken or poorly connected wiring Replace or reconnect
Charge light on but gim while Loose starter switch terminal wiring Retighten
operating Excessive resistance of alternator and Replace the wire with a large one
fuse holder terminal wire
Defective starter switch contacts Replace
Alternator noise Defective alternator bearing Replace or regrease
Exposed stator coil wires Replace
Short circuit of the stator coil Replace
Charge circuit fuse blown Grounded terminal wiring Repair
Defective alternator end flame diode Replace the end flame assembly
Out of voltage regulator adjustment Replace
Reversed battery connections Correct
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 37
12. Starter Motor

Starter and magnetic switch Low battery fluid level Replenish
does not operate Low battery specific gravity Recharge or replace
Poor battery switch contacts Replace
Defective starter switch Replace
Defective magnetic switch pull-in coil Replace
and plunger
Broken armature coil Replace
Broken field coil Replace
Broken magnetic switch Replace
Broken holding coil Replace
Magnetic switch operates but Low battery fluid level Replenish
the starter does not turn Low battery specific gravity Recharge or replace
Poor starting circuit contacts Repair
Poor contacts of magnetic switch Replace
terminal
Worn brushes Replace
Shorted armature Repair or replace
Starter runs slowly Bad contact of magnetic terminal circuit Repair
switches
Excessive brush wear Replace
Shorted starter motor armature Repair or replace
Starter operates but the engine No engaging of pinion and ring gear Repair or replace the running clutch and
does not start driving lever
Slippage of overrunning clutch Replace
Abnormal operating noise Excessive bushing wear Replace
Excessive pinion gear wear Replace overrunning clutch and pinion
gear
Rough sliding action pinion gear Lubricate or replace the overrunning
clutch
Excessive ring gear wear Replace overrunning clutch and ring
gear
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 38
13. Turbocharger
Engine has less than normal Restricted air cleaner Clean or replace
power Restricted intake pipe and hose Clean or replace
Loose connection of the turbocharger inlet and Repair
outlet
Restricted exhaust and silencers Repair
Restricted air breather Clean or replace
Impact damage of the compressor wheel Replace
Impact damage of the turbine wheel Replace
Carbon build-up on the turbine wheel Replace
Dragging or seized rotating assembly Replace
Blue or black smoke Restricted air cleaner Clean or replace
Leakage from turbocharger oil seal Replace
Restricted turbocharger oil drain pipe Repair or replace
Restricted air breather Clean
Impact damage of compressor wheel Replace
Impact damage of turbine wheel Replace
Restricted center housing oil drain passage Clean or replace
Excessive oil consumption Restricted air breather Clean
Leakage from turbocharger oil seal Replace
Impact damage of compressor wheel Replace
Impact damage of turbine wheel Replace
Excessive oil pressure Repair
Excessive turbocharger noise Restricted intake and exhaust system joints Repair
Damaged intake and exhaust system gasket Repair
Rough rotation of turbocharger rotating parts Replace
Rubbing compressor wheel against housing Replace
Damaged compressor wheel Replace
Rubbing turbine wheel against housing Replace
Damaged turbine wheel Replace
Carbon built-up on the turbine wheel Clean or replace
Too low engine oil level Correct
Contaminated oil level Replace oil
Restricted turbocharger oil feed pipe Repair or replace
Carbon built-up on the turbine housing Clean
Dirty compressor housing Clean
Worn turbine shaft bearings Replace
Excessive rotating part wear Contaminated engine oil Change
Wrong grade or type of engine oil Change
Restricted turbocharger oil feed pipe Clean or replace
Defective turbocharger oil seal Replace
Oil sludgy and coking turbine shaft Replace
In adequate oil supply Correct
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 39
Lubricants Application
Name of Sealant or
Location for Application
Lubricant
Engine Oil Turbocharger bearing
Inside of camshaft bracket
Idle gear shaft & fixing bolt
Bridge
Rocker arm
Camshaft cam nose
Crank pulley fixing bolt threads and seating face
Inside and outside of cylinder liner
Connrod bearing sliding face
Crankshaft bearing sliding face
Thrust bearing
Piston and piston rings
Piston pin
Molybdenum disulfied grease Crankcase fixing bolt threads and seating face
Cylinder head fixing bolt thread and seating face
Connrod bearing fixing bolt thread and seating face
Sealant Application
Location
Name of sealant
Name of part Name of mating part
1 Crankcase Cylinder block Loctite FMD-127
2 Gearcase Cylinder block Loctite FMD-127
3 Flywheel housing Cylinder block Loctite FMD-127
4 Gearcase Cylinder head Loctite FMD-127
5 Gearcase Upper cylinder block Loctite FMD-127
6 Upper and lower gearcase Cylinder head Loctite FMD-127
7 Crankcase Gearcase Cemedyn LG-020L
8 Crankcase Flywheel housing Cemedyn LG-020L
9 Oil cooler Cylinder block Three Bond 1207C
10 Nozzle sleeve Cylinder head Loctite TL290
11 Thermometer unit threads Cylinder head Loctite No.271 or Three Bond No. 1241
12 Oil pressure switch threads Cylinder block Loctite No.271 or Three Bond No. 1241
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 40
MEMO
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 1
SERVICE INFORMATION 0B–1
GENERAL INFORMATION
SERVICE INFORMATION
CONTENTS
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . 0B-7
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-2 Compression Pressure Measurement . . . . . . . . . . . 0B-9
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-2 Recommended Lubricants . . . . . . . . . . . . . . . . . . . 0B-10
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-6 Engine Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . 0B-10
Identification
Engine Serial Number
The engine serial number is stamped on the front, upper area of the cylinder block.
Engine model Serial number
6WG1 000000
015EY00002
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 2
0B–2 SERVICE INFORMATION
Lubrication System 2. Before installing a new fuel filter, apply fuel to the
gasket of the cartridge.
Oil filter replacement 3. Turn the fuel filter until the filter gasket comes in
The oil filter is remotely mounted on the equipment side. contact with its sealed face.
1. Set a filter wrench at the cartridge and remove the oil 4. Use the filter wrench to turn in the fuel filter by
filter. additional 2/3 of a turn.
Discard the used cartridge.
2. Before installing the new oil filter, apply engine oil to
the gasket of the cartridge.
3. Turn the oil filter until the filter gasket comes in contact
with its sealed face.
4. Use the filter wrench to turn in the oil filter by additional
one full turn.
NOTE: Be careful not to spill out the fuel retaining in the

fuel filter when the filter is removed. After changing the
fuel filter element, conduct fuel air bleeding and check for
fuel leaks.
Injection Timing Adjustment

050EY00002
Injection Timing Inspection

Fuel System 1. Disconnect the negative battery cable.
Fuel filter replacement procedure 2. Rotate the crankshaft in the normal direction of engine
rotation to align the injection timing mark on the
1. Use a filter wrench to remove the cartridge.
flywheel with the timing pointer.
Discard the used cartridge.
• Injection Timing (Static-TDC): 11 degree
T
C
5
10
15
015EY00003
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 3
3. Check that the timing advancer notched line is aligned

with the injection pump notched line.
If the notched lines are out of alignment, the injection
timing must be adjusted.
4. Move the timing advancer to the correct timing.

5. Tighten the two coupling bolts.
6. Rotate the crankshaft two turns in normal direction of
crankshaft rotation.
7. Verify the new setting is correct injection timing.
Injection Timing Adjustment
8. Connect the negative battery cable.
1. Rotate the crankshaft in normal direction of rotation
until the timing mark on the timing advancer can be
seen.
2. Align the injection timing mark on the flywheel with the
pointer.
T
C
5
10
15
015EY00003
3. Loosen the two coupling bolts.

69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 4
Injection Nozzle
Opening Pressure and Spray Condition
Check
1. Use an injection nozzle tester to check the nozzle
opening pressure. 1 2 3
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or
adjusted.
Refer to “Adjustment of Injection Nozzle Opening
Pressure”.
Injection Nozzle Opening Pressure:
20.1 MPa (205 kg/cm2 / 2,915 psi)
040EY00030
Injection Nozzle Adjustment

1. Attach the injection nozzle holder to the injection
nozzle tester.
2. Apply pressure to the nozzle tester.
Note the pressure at which the injection nozzle opens.
Injection Nozzle Opening Pressure:
20.1 MPa (205 kg/cm2 / 2,915 psi)
An adjusting shim of 0.007 mm (0.0003 in) allows the

press to change by about 98 kPa (1.0 kg/cm2 / 14.2 psi).
The adjusting shim thickness calculation method as
040EY00023
follows.
The adjusting shim thickness calculation method.
WARNING:
P × π/4 × (A2 – B2)
Test fluid from the injection nozzle tester will spray = Shim thickness (mm)
out of the injection nozzle under great pressure. It can C
easily puncture a person’s skin.
Keep your hands away from the injection nozzle at all P (kPa) = (Target injection nozzle opening pressure
times. – Indicated value (pressure) of nozzle
tester)
2. Check the spray condition. A (cm) = Needle diameter 0.6 cm
If the spray condition is bad, the injection nozzle must B (cm) = Sheet diameter 0.3 cm
be replaced or reconditioned. C (N/mm) = Spring constant 264.0 N/mm
(1) Correct
(2) Incorrect (Restrictions in orifice)
(3) Incorrect (Dripping)
If lapping is required, refer to “Nozzle Lapping
Procedure of FUEL SYSTEM”.
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 5
After calculating shim thickness, select shims from below 2. With a wrench, loosen the air plug (1) of the fuel filter
list. and pump the fuel until all the air bubbles in it
Adjusting Shim Availability mm disappear by being pumped out through the air plug.
Thickness Part number 3. There are no bubbles and the fuel comes out in a solid
stream.
0.50 5-15339-007-0
Now securely tighten the air plug and priming pump
0.52 5-15339-018-0 cap.
0.54 5-15339-019-0
0.56 5-15339-020-0
Feed pump strainer
0.58 5-15339-021-0
Remove the joint bolt on the intake side of the feed pump,
0.60 5-15339-008-0 then screw out the strainer counterclockwise and clean it.
0.70 5-15339-009-0 Then, operate the priming pump on the injection pump to
0.80 5-15339-010-0 bleed the fuel system.
0.90 5-15339-011-0
1.00 5-15339-012-0
0.10 8-94128-982-0
0.20 8-94128-983-0
0.30 8-94128-984-0
0.40 8-94128-985-0
Air Bleeding
When servicing the fuel filters or if the fuel tank is emptied,
air might be allowed to go into the fuel system. With air in
the fuel system, smooth flow of fuel into the engine is Strainer
interrupted and to prevent this, bleeding of the fuel system
should be performed.
1. Loosen the priming pump cap and pump the fuel into
the injection pump by manually operating the priming
040EY00008
pump (2).
Fuel tank
Remove the drain plug and drain the water and sediment
completely.
1
040EY00006
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 6
Cooling System Drive Belt Inspection (Scrum belt)

1. Tighten the idle pulley lock nut and generator section
Drive Belt Inspection (Single belt) lock nut.
Check the drive belt tension. 2. Adjust the belt tension so it becomes equal to the
Depress the drive belt mid-portion with a 100 N (10kg/22 standard value by adjusting the idle pulley adjusting
lb) force. bolt and generator section adjusting bolt.
Drive Belt Deflection: 8 – 12 mm (0.31 – 0.47 in)
3. The deflection when 98 N {10 kg/22 lb} is applied to
the center between the idle pulley and generator
pulley
Drive Belt Deflection: 6 – 8 mm (0.24 – 0.31 in)
1 2
4
3
033EY00001 5
Check the drive belts for cracking and other damage.
PAW5Z0MH000801
Name
1. Lock Nut (Generator)
2. Adjusting Bolt (Generator)
3. Lock Nut
4. Adjusting Bolt (Idle Pulley)
5. Belt Tension Measurement Position
6. Mounting Bolt
033EY00009
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 7
Check the drive belt for cracking and other damage. Valve Clearance Adjustment
The following instructions assume that valve clearance is
adjusted beginning with the No. 1 piston at top dead
center (TDC) on the compression stroke.
Check alignment timing mark between timing advancer
and mark line on injection pump body. In this position
indicate T.D.C. of No. 1 piston.
Valve clearance must be adjusted when the engine is
cold.
When remove the head cover, wipe off spilled oil with a
rag.
1. Bring the piston in the No. 1 or No. 6 cylinder to the
top dead center on the compression stroke by turning
the crankshaft until the T.D.C. line on the flywheel is
aligned with the timing pointer.
Check the rocker arm shaft bracket nuts for looseness
and retighten as necessary before adjusting the valve
PAW5Z0SH006001 clearance.
015EY00070
2. Check that the No. 1 intake and exhaust rocker arms

have play. If they have play, it indicates that the No. 1
piston is at TDC (Top Dead Center) on the
compression stroke. If the No. 1 exhaust valves are
depressed, the No. 6 piston is at TDC on the
compression stroke.
3. Adjust valve clearances for the No. 1 or No. 6 cylinder
which its piston is at TDC on compression stroke.
1. Loosen each adjusting screw (1) on the bridge (2)
and rocker arm (3).
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 8
4. In this condition, the opposite end of the bridge is

raised. Readjust by loosening the adjusting screw
1 on the bridge until there is a slight drag on the
feeler gauge and tighten the lock nut securely.
3
No.1 cylinder T. D. C.
(comp. stroke)
1 2 3 4 5 6
E I E I E I E I E I E I
Front
014EY00129
Valve Clearance: 0.4 mm (0.0016 in)

2. Insert a feeler gauge between the rocker arm (1)
and the cam (2) and adjust by turning the adjusting
screw on the rocker arm until there is a sight drag 014EY00125
on the feeler gauge. Tighten the lock nut securely. 4. Rotate the crankshaft 360° and realign the T.C. mark
on the flywheel with the pointer and adjust clearance
for remaining valves.
1
The “●” mark in the illustration indicates the cylinders
and valves to be adjusted.
No.6 cylinder T. D. C.
(comp. stroke)
1 2 3 4 5 6
E I E I E I E I E I E I
2
014EY00130
Front
3. With a feeler gauge inserted, screw in the

adjusting screw on the bridge gradually until it
touches to the end of the valve stem, and make
sure that the movement of the feeler gauge 014EY00126
becomes hard.
NOTE: Be sure to move the No. 1 cylinder to TDC on the
compression stroke after completing the valve clearance
adjustment procedure.
Torque: 79 N·m (8.0 kg·m/58 lb·ft)
Rocker Arm Adjusting Screw Nut
Torque: 54 N·m (5.5 kg·m/40 lb·ft)
Bridge Adjusting Screw Nut
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 9
Intake and Exhaust Valve Arrangement

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

To measure the compression pressure, the engine must
be cold. Engine coolant temperature should be at 20°C.
Battery and starter motor condition must be normal.
1. Remove the injection nozzle assembly and the
injection fuel pipe from the each cylinder, using nozzle
holder remover: 1-8523-0013-0.
011EY00025
4. Crank the engine with starter motor (about 200 min–1)

and take the compression gauge reading.
5. Repeat the procedure (Step 2 to 4) for the remaining
cylinder.
Compression Pressure
Standard : 2.75 MPa (28.0 kg/cm2 / 400 psi)
011EY00026
Limit : 2.26 MPa (23.0 kg/cm2 / 327 psi)
2. Install the compression gauge adapter 5-8531-7019- Compression pressure should be approximately the
0 to the No. 1 cylinder injection nozzle installation same for each cylinder.
hole. A variation exceeding 200 kPa (2.0 kg/cm2 / 28 psi) is
3. Install the compression gauge to the compression unacceptable.
gauge adapter.
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 10
Recommended Lubricants
ENGINE TYPE TYPES OF LUBRICANTS (API)
Diesel engine oil

Without turbocharger & With turbocharger
CD grade
Engine Oil Viscosity Chart
ENGINE OIL VISCOSITY GRADE-AMBIENT TEMPERATURE
[Single grade]
SAE 20,20W SAE 40,50
SAE 10W SAE 30
Ambient -30ºC -15ºC -0ºC 15ºC 25ºC 30ºC

temperature (-22ºF) (0ºF) (32ºF) (60ºF) (80ºF) (90ºF)
[Multi grade] SAE 10W-30
SAE 15W-40,20W-40,20W-50
F00EY00006
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 1
ENGINE MECHANICAL 6A–1
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . 6A Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . 6D3
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C Engine Induction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
ENGINE MECHANICAL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50
General Description. . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52
Engine Cleanliness and Care . . . . . . . . . . . . . . . 6A-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52
General Information on Engine Service . . . . . . . 6A-2 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-53
Fan Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Timing Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-61
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-67
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-69
Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-73
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-77
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-92
Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-93
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-97
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Crank Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99
Coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-100
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-103
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-38 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104
Rocker Arm and Shaft Assembly. . . . . . . . . . . . . 6A-47 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-105
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-47 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-109
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-48
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 2
6A–2 ENGINE MECHANICAL
Service precaution clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
CAUTION: Always use the correct fastener in the damage to the oil pick-up unit.
proper location. When you replace a fastener, use • The 12-volt electrical system is capable of damaging
ONLY the exact part number for that application. circuits. When performing any work where electrical
ISUZU will call out those fasteners that require a terminals could possibly be grounded, the ground
replacement after removal. ISUZU will also call out cable of the battery should be disconnected at the
the fasteners that require thread lockers or thread battery.
sealant. UNLESS OTHERWISE SPECIFIED, do not
• Any time the intake air duct or air cleaner is removed,
use supplemental coatings (Paints, greases, or
the intake opening should be covered. This will
other corrosion inhibitors) on threaded fasteners or
protect against accidental entrance of foreign material
fastener joint interfaces. Generally, such coatings
into the cylinder which could cause extensive damage
adversely affect the fastener torque and the joint
when the engine is started.
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these General
instructions can help you avoid damage to parts and The 6WG1 engine is a four-cycle, six-cylinder, in-line,
systems. direct fuel injection type diesel engine with the piston
displacement of 15.681 L (957 cid). It features a gear-
General Description driven OHC (overhead camshaft) timing train and
unique mechanisms and systems designed for
Engine Cleanliness and Care outstanding quietness, economy and durability.
An industrial engine is a combination of many machines,
honed, polished and lapped surfaces with tolerances
Cylinder Head
that are measured in the thousandths of a millimeter (ten The cylinder head is made of cast iron and has a cross-
thousandths of an inch). Accordingly, when any internal flow layout with the intake system in the left side and the
engine parts are serviced, care and cleanliness are exhaust system in the right side, designed to reduce
important. Throughout this section, it should be resistance in the intake and exhaust system.
understood that proper cleaning and protection of The cylinder head gasket is of the laminated of least
machined surfaces and friction areas is part of the repair fatigue in combination with the angular cylinder head
procedure. This is considered standard shop practice bolt tightening method, equally designed to increase
even if not specifically stated. reliability against gaseous and water leakage.
• A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate Cylinder Block
the surfaces on initial operation. The cylinder block is made of cast iron having dry
• Whenever valve train components, pistons, piston cylinder liner and seven bearings. The bearing cap has
rings, connecting rods, rod bearings, and crankshaft a ladder frame construction integrating the crankcase to
journal bearings are removed for service, they should increase rigidity.
be retained in oder. The cylinder liner is made of thin special iron alloys and
• At the time of installation, they should be installed in is combined with the chrome-plate piston ring to ensure
the same locations and with the same mating good resistance against wear.
surfaces as when removed.
• Battery cables should be disconnected before any
Piston
major work is performed on the engine. Failure to The piston is made of aluminum alloy. A ring trigger is
disconnect cables may result in damage to wire cast into the first and second ring groove and chrome
harness or other electrical parts. plating is applied to four sides of the first and third ring to
• The in-line cylinders of this engine are identified by ensure sufficient strength and wear resistance of the
numbers; Cylinders 1, 2, 3. …, as counted from ring and the ring groove.
crankshaft pulley side to flywheel side.
Crankshaft
General Information on Engine Service The crankshaft is made of forge steel with seven
bearings and twelve counter weights to reduce
The following information on engine service should be
revolution load to the bearing. The crankshaft is treated
noted carefully, as it is important in preventing damage
by soft nitriding to enhance the crankshaft strength.
and contributing to reliable engine performance:
• When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 3
Gear Train
The gear train is located at the front of cylinder block to
minimize influence of the torsional vibration of the
crankshaft and the radiant sound.
Noise is further reduced, to the same level as a timing
belt driven system, by integrating the crankshaft gear
with the crankshaft by shrink fit careful tuning of the gear
precision, contact gear ratio, backlash, bearing rigidity
neutral frequency, etc.
Combustion System
The combustion chamber has a clean and simple design
for maximum operating economy also easy starting. A
direct fuel injection system is adopted.
The injection nozzles are placed at the center of each
cylinder. Intake ports generate optimum swirl effect
while exhaust ports minimize exhaust resistance.
Isuzu’s unique combustion chamber design provides
maximum power output and fuel economy.
Value Arrangement
Each cylinder has two intake valves and two exhaust
valves.
To ensure high efficiency and complete combustion, the
intake system has a Isuzu’s unique designed inlet ports.
The two exhaust valves are connected to a single port.
Lubrication
All engine parts are lubricated by a gear pump pressure
circulation system.
Oil flows from the oil pump though oil cooler to main oil
filter for oil cooling and oil cleaning.
From the main oil filter it moves to the cylinder block oil
gallery and the oil circulates to lubricates the engine
parts.
Oil jets are installed to the cylinder block main oil gallery.
The jet spray oil to the inside portions of the pistons for
lubrication and cooling.
Oil Pump and Oil Filter

The oil pump is a gear type with a relief valve. The pump
is driven by the timing gear. A full flow main oil filter with
a highly efficient paper element used.
Should the element become clogged with sludge or
other foreign material, a by-pass valve open to route the
oil directly to the oil gallery.
Oil Cooler
The temperature of the engine oil circulating through the
lubricating system tends to rise with an accompanying
decrease in lubricating efficiency.
The oil cooler maintains the oil temperature at the
optimum level for effective engine lubrication.
The oil cooler consists of the body and the cooling
element.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 4
Fan Center
Removal
1. Remove the fan guide.
4 1
033EY00002
4. Remove the fan center (1) from the timing gearcase

(2).
2. Remove the cooling fan (2) from the fan center (1).
033EY00011
033EY00010
3. Remove the fan belt

• Loosen the alternator mounting bolt (2).
• Loosen the sliding piece nut (4).
• Adjust the adjusting bolt (3) to remove the fan belt.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 5
Installation 4. Install the cooling fan to the fan center and tighten
the fixing nuts to the specified torque.
1. Install the fan center (1) to the timing gearcase (2) Torque: 52 N·m (5.3 kgm)
and tighten the fixing nuts to the specified torque.
NOTE: Install the fan to the installation direction
Torque: 52 N·m (5.3 kgm) properly.
1 1
033EY00011
033EY00010
2. Install the fan belt. 5. Install the fan guide to the water outlet pipe and
3. Adjust the fan belt tension by adjusting the adjusting bracket on the gearcase with the mounting rubbers.
bolt. • Tighten the fixing bolt to the specified torque.
• Depress the fan belt at the midway between the Torque: 52 N·m (5.3 kgm)
alternator pulley and fan center pulley with 100 N
(10 kg).
Belt deflection : 8 – 12 mm
• Tighten the alternator fixing nut to the specified
torque.
Torque: 147 N·m (15.0 kgm)
033EY00001
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 6
• Adjust the clearance between the fan and fan

guide.
Clearance: 7 – 13 mm
033EY00013
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 7
Turbocharger
Removal
1. Remove the inlet pipe from the air cleaner to the
turbocharger.
2. Remove the inlet duct from the inlet pipe to the
turbocharger.
3. Remove the oil feed pipe.
• Discard the gaskets.
4. Remove the oil drain pipe.
• Discard the gaskets.
5. Remove the turbocharger.
NOTE: Plug the turbocharger body oil ports and
openings to prevent the entry of foreign material or dust.
033EY00003
2. Install the oil drain pipe for the turbocharger and

tighten the bolt to the specified torque.
3. Install the oil feed pipe for the turbocharger and
tighten the bolt to the specified torque.
Torque:
Turbocharger side: 50 N·m (5.1 kgm)
Oil port cover side: 34 N·m (3.5 kgm)
Installation
1. Install the turbocharger assembly with the gasket to
the exhaust manifold and tighten the nuts to the
specified torque.
NOTE: Lubricate the turbine shaft dripping the engine oil
from the oil feed hole and turning the turbine wheel by
hand.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 8
4. Install the inlet duct from the inlet pipe to the

turbocharger and tighten the fixing bolts to the
specified torque.
• Connect the rubber hose between the inlet duct
and turbocharger.
• Install the heat protector to the rubber hose.
5. Install the inlet pipe from the air cleaner to the
turbocharger.
Tighten the inlet pipe fixing bolts to the specified
torque.
Inlet pipe at turbocharger side
Torque: 5.4 N·m (0.55 kgm)
Inlet pipe at bracket side
Inlet pipe bracket
Torque: 118 N·m (12 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 9
Exhaust Manifold
Removal
1. Remove the inlet pipe from air cleaner to
turbocharger.
2. Remove inlet duct from the inlet pipe to the 2
1 3
turbocharger.
3. Remove the turbocharger oil feed pipe.
4. Remove the turbocharger oil drain pipe.
5. Remove the turbocharger. 5
Refer to “Turbocharger” in this section. 3
1 4 2 6
6. Remove the exhaust manifold.
Clean the sealing surfaces of the exhaust manifold. Indicator
027EY00016
2. Install the turbocharger assembly with the gasket to

the exhaust manifold.
Refer to “Turbocharger” in this section.
027EY00011
Installation
1. Install the exhaust manifold assembly with the new
gasket to the cylinder head.
Tighten the nuts to the specified torque in the order
shown.
036EY00003
3. Install the oil drain pipe for the turbocharger.

4. Install the oil feed pipe for the turbocharger.
5. Install the inlet duct from the inlet pipe to the
turbocharger.
6. Install the inlet pipe from the air cleaner to the
turbocharger.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 10
Inlet Manifold
Removal
1. Remove the breather hose.
2. Remove the oil dipstick and guide tube.
3. Remove the fuel pipes.
4. Remove the air pipe for the boost.
5. Remove the injection pipes.
6. Remove the fuel filter and bracket.
7. Remove the inlet pipe.
NOTE: Plug the outlet of the turbocharger compressor.
8. Remove the inlet cover.
9. Remove the inlet manifold.
10. Clean the sealing surfaces of the inlet manifold.
Installation
1. Install the inlet manifold with new gaskets.
• Install the rubber boot and spring.
3. Install the inlet pipe with new gasket.
• Tighten the nut to the specified torque.
Tighten the fixing bolt to the specified torque.
Rubber boot
Indicator
10
6 7
2 3 11
12 9 5 1 4 8
025EY00006
2. Install the inlet cover with new gasket.

4. Install the fuel filter and bracket to the inlet manifold.
Torque:
Fuel Filter: 52 N·m (5.3 kgm)
Bracket : 50 N·m (5.1 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 11
5. Install the injection pipes, tightening to the specified. 7. Install the guide tube to the cylinder block in the
Torque: order shown.
Cylinder head side: 29 N·m (3.0 kgm) Torque:
Injection pump side: 39 N·m (4.0 kgm) Bolt (1) 88 N·m (9.0 kgm)
Bolt (2) 49 N·m (5.0 kgm)
6. Install the fuel pipe to tighten to the specified torque

as follows.
M8 eye bolt
M10 eye bolt
M12 eye bolt
M14 eye bolt
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 12
8. Connect the breather hose to the breather and clamp

the hose.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 13
Water Pump
Removal 2. Install the thermostat housing.
• Install the thermostat to the oil cooler.
1. Remove the water inlet pipe.
Refer to “Thermostat installation” in this manual.
2. Remove the thermostat housing.
• Tighten the bolts to the specified torque.
3. Remove the water pump (1).
030EY00006
031EY00007
Installation
1. Install the water pump (1) with new gasket, tighten to
the specified torque.
• First tighten the bolts (2) to the oil cooler side then
tighten
031EY00008
3. Install the water inlet pipe (1) to the oil cooler.

Tighten the bolts to the specified torque.
030EY00006
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 14

69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 15
Alternator
Removal
1. Remove the sliding piece nut (4).
2. Remove the adjust plate fixing bolt (1).
3. Remove the alternator fixing bolt (2).
4. Remove the fan belt. 4 1
5. Remove the alternator.
2
4 1
033EY00002
033EY00002
Installation
Single belt
1. Install the alternator.
2. Install the adjusting plate.
3. Install the fan belt.
4. Adjust the belt tension by adjusting the bolt (3).
• Depress the fan belt at the midway between the
alternator. 033EY00001
Belt Deflection: 8 – 12 mm (0.3150 – 0.4724 in)

5. Tighten the alternator fixing bolt to the specified
torque.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 16
Scrum belt 1
1. Install the generator to the bracket and adjusting 2
plate.
2 3 3
5
4
PAW5Z0SH006201
Name
PAW5Z0SH006101 1. Push Gauge
2. Iron Plate
3. Deflection
Name
1. Belt
2. Adjusting Nut • Loosen the generator mounting bolt and lock nut,
3. Adjusting Bolt (Generator) then loosen the idle pulley lock nut.
4. Bolt (Generator)
• In order to set the deflection to within the stan-dard
value range when approximately 98 N {10 kg/22 lb}
of force is applied to the central sec-tion of the belt,
correctly adjust the balance using the generator
2. Install the belt (for the generator) and adjust the
adjusting bolt and idle pul-ley adjusting bolt.
tension of the belt.
• After adjusting the tension of the belt, tighten the
• Secure the reliable standard position by setting a
lock nuts (1) and (3), and the mounting bolt (6).
standard string (1) or a weighted at both ends
string (2) on the back of the belt. Torque:
Idle pulley: 147 N·m {15.0 kg m}
PAW5Z0SH006301
• Arrange the push gauge so that the edge of the

push gauge presses uniformly on the overall width
of the belt, or set an iron plate with a thickness of
about 2 mm {0.08 in} on the belt.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 17
1 2
4
3
PAW5Z0MH000801
Name
1. Lock Nut (Generator)
2. Adjusting Bolt (Generator)
3. Lock Nut (Idle Pulley)
5. Belt Tension Measurement Position
6. Bolt
Belt Deflection: 6 – 8 mm (0.2362 – 0.3150 in)

69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 18
Oil Cooler
Removal
1. Remove the turbocharger oil feed pipe.
2. Remove the turbocharger oil drain pipe.
3. Remove the oil port cover.
4. Remove the water inlet pipe.
5. Remove the water pump.
Refer to “Water Pump” in this section.
6. Remove the oil cooler assembly.
• Remove the water drain pipe (1).
• Install the two removed fixing bolts to the holes (2)
for replacement and screw the bolts, then remove
the oil cooler.
050EY00010
• Install the water drain pipe (1) and tighten the

connector (2).
• Tighten the bracket (3) to the specified torque.
1 2
050EY00009
2
Installation
1. Install the oil cooler with gaskets.
• Install the gasket shown in the illustration.
3 4
• Install the oil cooler assembly to the cylinder block
1
and tighten the bolts to the specified torque in the
order shown.
050EY00011
2. Install the thermostat housing.

• Install the thermostat to the oil cooler.
Refer to “Thermostat Installation” in this manual.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 19
031EY00007
5. Install the turbocharger oil feed pipe.

6. Install the turbocharger oil drain pipe.
Refer to “Turbocharger” in this section.
031EY00008
3. Install the water inlet pipe to the oil cooler.

4. Install the oil port cover with new gasket.
Tighten the fixing bolts to the specified torque.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 20
Injection Pump
Removal the foreign material or dust.
1. Remove the oil level gauge and guide tube.

2. Remove the coupling cover.
3. Remove the fuel pipes and fuel leak off pipe.
9. Remove the injection pump bracket.
Installation
1. Install the injection pump bracket to the cylinder
4. Remove the injection pipe with clips. block.
• Install the bracket into place over the bracket
locating dowel pin on the cylinder block.
• Install the gaskets on the bracket.
• Tighten the bracket fixing bolts to the specified
torque.
Torque: 108 N·m (11 kgm)
5. Remove the air pipe for the boost.

6. Remove oil feed pipe and oil return pipe for the
injection pump.
7. Loosen the two coupling fixing bolts and the four
injection pump fixing bolts.
8. Remove the injection pump.
NOTE: Plug the injection pump delivery holder ports with
the shipping caps or equivalent to prevent the entry of
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 21
2. Install the injection pump

• Align the flywheel injection timing mark with the
flywheel housing pointer by rotating crankshaft
counterclockwise.
Injection timing (BTDC): 11 deg.
4 2
1 3
T
C
5
10
15
• Make sure the injection pump alignment on the

injection pump, and tighten the coupling bolts to
Torque:
015EY00003 Timing advancer side: 62 N·m (6.3 kgm)
• Align the injection timing mark on the timing Coupling ASM side: 88 N·m (9.0 kgm)
advancer with the injection pump body pointer.
3. Install the injection pump coupling cover.

• Install the injection pump assembly to the injection Tighten the fixing bolts to the specified torque.
pump bracket. Torque:
• Tighten the bolts to the specified torque in the Bolt (1) : 50 N·m (5.1 kgm)
order shown.
Bolt (2) : 52 N·m (5.3 kgm)
Bolt (3) : 50 N·m (5.1 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 22
1
3
4. Install the oil pipe to the injection pump. 6. Install the fuel pipe to tighten to the specified torque
Torque: as follows.
M10 27 N·m (2.8 kgm) M8 eye bolt
M14 41 N·m (4.2 kgm) Torque: 15 N·m (1.5 kgm)
M18 58 N·m (5.9 kgm) M10 eye bolt
M12 eye bolt
M14 eye bolt
5. Install the injection pipes.

Tighten the injection pipe sleeve nuts to the specified
torque.
Torque:
Cylinder head side: 29 N·m (3.0 kgm)
Injection pump side: 39 N·m (4.0 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 23
7. Install the air pipe for the boost.

8. Install the guide tube to the cylinder block in the
order shown.
Torque:
Bolt (1) 88 N·m (9.0 kgm)
Bolt (2) 49 N·m (5.0 kgm)
1
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 24
Coupling Assembly
Removal Installation
1. Remove the coupling cover. 1. Install the coupling assembly to the gearcase.
2. Remove the oil feed pipe from the cylinder block to • Install the gear to the coupling assembly.
coupling assembly. • Apply molybdenum disulfide grease to the thread
3. Loosen the coupling fixing bolt (1) and remove the portion and flange surface of bolts and the washer,
coupling disc fixing bolt (2), (3). tightening the bolts to the specified torque in the
order shown.
Torque: 39 N·m (4.0 kgm) → 105 deg.
2
040EY00024
4. Remove the coupling.

5. Remove the coupling assembly fixing bolts and nut.
6. Remove the coupling assembly. • Align the flywheel “T/C” mark with the flywheel
housing pointer by rotating the crankshaft
counterclockwise.
038EY00001
015EY00070
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 25
• Install the new gasket to the coupling assembly. 2. Install the coupling oil pipe from the cylinder block to
• Install the injection pump coupling to the coupling the coupling assembly.
assembly shaft. Torque: M10 27 N·m (2.8 kgm)
• Align the mark “A” on the coupling with the
coupling assembly body pointer.
S
A
Mark A
039EY00003
039EY00001
3. Install the coupling.
• Tighten the coupling fixing bolt (1) to the specified
• Install the coupling assembly to the gearcase. torque.
• Check alignment mark “S” with the coupling Torque: 88 N·m (9.0 kgm)
assembly body pointer after installing the coupling • Tighten the fixing bolt (3) to the specified torque.
assembly to the timing gearcase.
• Tighten the coupling assembly fixing bolts and nut
to the specified torque.
2
S
A
Mark S
040EY00024
• Align the injection timing mark on the flywheel with

039EY00001
the flywheel housing pointer by rotating crankshaft
counterclockwise.
Injection timing (BTDC): 11 deg.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 26
T
C
5
10
15
015EY00003
• Align the injection timing mark on the timing

advancer with the injection pump body pointer.
• Tighten the coupling bolt to the specified torque.

• Rotate the crankshaft two turns in normal direction
of crankshaft rotation.
Verify that the injection timing is correct.
4. Install the coupling cover.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 27
Cylinder Head
Removal
6 7
4 10
11
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 28
Legend (7) Nozzle clamp

(1) Cylinder head cover (8) Nozzle holder assembly
(2) Gasket (9) Idle gear C and shaft
(3) Rocker arm assembly (10) Cylinder head assembly
(4) Bridge (11) Cylinder head gasket
(5) Camshaft assembly
(6) Leak off pipe
1. Remove the cylinder head cover (and Insulator). 4. Remove the bridge.
2. Remove the gasket of the cylinder head cover. NOTE: Sort or organize the bridge for assembly to
original location.
3. Remove the rocker arm assembly.

• Loosen the rocker arm shaft bracket bolts from 5. Remove the camshaft.
both outside bolt. • Use a feeler gauge to measure the camshaft end
play before removing.
Standard: 0.008 – 0.170 mm (0.0033 – 0.0067 in.)
Limit: 0.25 mm (0.0098 in)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 29
• Loosen the camshaft bracket fixing nuts from both

outside nut.
6. Remove the leak off pipe.
7. Remove the nozzle clamp.
8. Remove the nozzle holder assembly.
• Use the nozzle holder remover 1-8523-0013-0 to
remove the nozzle holder.
NOTE: Take care not to damage the injection nozzle tips
during injection nozzle holder removal.
10. Remove the cylinder head assembly.

• First loosen the bolts B – D.
• Loosen the cylinder head bolts a little at a time in
the numerical order shown in the illustration.
NOTE: Failure to loosen the cylinder bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.
11. Remove the cylinder head gasket.
011EY00026 Discard the cylinder head gasket.
9. Remove the idle gear “C” and shaft.
• Use a feeler gauge to measure the idle gear “C”
end play.
Standard: 0.05 – 0.14 mm (0.0020 – 0.0055 in.)
Limit: 0.25 mm (0.098 in.)
F 8
B
1 9 G N
M E 7
2 ; H O
L D 6
P
3 A I
C K C 5
4 B J
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 30
Installation • Apply molybdeum disulfide grease to the cylinder

head bolts (M18) threads and setting faces.
1. Install the new cylinder head gasket. • Apply engine oil to the cylinder head bolts (M10
• Clean the cylinder block surface. and M12) threads and setting faces.
• Apply Loctite FMD127 or equivalent to the cylinder • Tighten the M18 cylinder head bolts in three steps
block and the timing gearcase fitting faces. using the angular tightening method.
The sealant must be 1.0 – 2.0 mm (0.04 – 0.08 in) Follow the tightening order shown in the
thick and 5.0 mm (0.20 in.) wide. illustration.
The sealant must not obstruct the cylinder oil port. • Tighten the M10 and M12 cylinder head bolts to
NOTE: Cylinder head bolts may be installed as many as
four (4) times, and then must be replaced.
Replace if any doubt exists.
M18 bolt
Torque:
1st step 177 N·m (18 kgm)
2nd step 245 N·m (25 kgm)
3rd step 60 – 90 deg.
M12 bolt
M10 bolt
NOTE: Cover the timing gear hole by cloth for
preventing into foreign materials.
012EY00016
• Install the new cylinder head gasket to the cylinder

block.
2. Install the cylinder head assembly.
• Align the cylinder block dowel pins and the cylinder
head dowel holes.
Carefully place the cylinder head on the cylinder
head gasket.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 31
M12
M10
3. Install the idle gear “C” and shaft.

• Apply engine oil to the idle gear “C” shaft bolts.
• Tighten the idle gear “C” shaft bolt to the specified
torque.
011EY00026
6. Install the leak off pipe.

Tighten to specified torque.
4. Install the nozzle holder assembly.

5. Install the nozzle clamp.
Tighten the nozzle clamp bolt to the specified torque.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 32
014EY00068
7. Install the camshaft assembly. • Apply engine oil to the camshaft bearing sliding
• Align the flywheel TDC mark with the pointer by surfaces.
rotating the crankshaft normal direction. Same • Install the camshaft bearing caps to use same
time check alignment timing mark on injection stamped mark (1).
pump for No. 1 piston TDC. • Apply engine oil to the threads and tighten to the
specified torque.
1
015EY00070
• Apply engine oil to the camshaft bearing sliding

surfaces before installing the camshaft assembly. 014EY00069
• Install the camshaft assembly to the cylinder head. 8. Install the bridge.
• Carefully align the camshaft gear hole mark and • Loosen adjusting screw.
pointer (1) on the cylinder head shown in the • Apply engine oil on the bridge guide.
illustration.
• Install the bridge, the adjusting screw (1) facing to
the intake manifold side.
NOTE: Bridges must be reinstalled into their original
location and position.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 33
6 4 2 1 3 5 7
014EY00070
9. Install the rocker arm assembly. 10. Install the gasket of the head cover.
• Tighten the bolts in numerical order to the specified 11. Install the cylinder head cover.
torque shown in the illustration. • Apply Loctite FMD127 or equivalent to the upper
Torque: 90 N·m (9.2 kgm) surface of cylinder head and timing gear case
fitting area shown as illustration.
The sealant must be 1.0 – 2.0 mm (0.04 – 0.08 in.)
thick and 5.0 mm (0.20 in.) wide.
LOCTITE FMD127
011EY00027
• Tighten cylinder head cover bolt, follow the

numerical order shown in the illustration.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 34
10 13
11 12 1 14 15 16
9
8
17
7
6 5 4 3 2 20 19 18
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 35
Disassembly
10
9 11
12
9 15
16 19
20
13
1 21
17
8
3
2
18 6
5 14
6
4
14
Legend (11) Spring upper seat

(1) Thermometer unit (12) Valve spring
(2) Gearcase (13) Spring lower seat
(3) Gasket (14) Valve
(4) Idle gear shaft (“C”) (15) Valve stem seal
(5) Idle gear “C” (16) Valve guide
(6) Gasket (17) Bridge guide
(7) Inlet manifold (18) Valve seat insert
(8) Exhaust manifold (19) Injection nozzle sleeve
(9) Seal rings (20) Gasket
(10) Split collar (21) Cylinder head
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 36
1. Remove the thermometer unit. 5. Remove the gasket of the inlet manifold.
2. Remove the gearcase. 6. Remove the inlet manifold assembly.
3. Remove the shaft of the idle gear “C”. 7. Remove the exhaust manifold assembly.
Measure end play between the cylinder head and 8. Remove the seal rings.
idle gear “C”. 9. Remove the split collar.
Standard: 0.05 – 0.014 mm (0.0020 – 0.0055 in.) • Place the cylinder head on a flat wooden surface.
Limit: 0.25 mm (0.0098 in.) • Use the valve spring compressor 1-8523-5013-0 to
remove the split collar.
NOTE: Do not allow the valve to fall from the cylinder
head.
4. Remove the idle gear “C”.

• Disassemble the shaft of idle gear “C”. 014EY00061
• Disassemble the idle gear “C”.

10. Remove the spring upper seat.
11. Remove the valve spring.
12. Remove the spring lower seat.
13. Remove the valve.
If the intake and exhaust valves are to be reinstalled,
mark their installation position by tagging each valve
with the cylinder number from which it was removed.
If the intake and exhaust valves are to be replaced,
the valve guides must also be replaced.
14. Remove the valve stem seal.
Discard the valve stem seal.
15. Remove the valve guide.
Use valve guide remover 9-8523-1202-0 to remove
the valve guide.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 37
16. Remove the bridge guide. 18. Remove the injection nozzle sleeve.
• Electric welding (1) the bolt to bridge guide, use • Use suitable size brass bar to hit nozzle sleeve
sliding hammer to remove the bridge guide. from lower side cylinder head.
011EY00028
17. Remove the valve seat insert.

• Heat up (about 600 – 700°C) two point on the valve
seat insert by gas torch, allow the valve seat insert
to cool for few minutes.
• This will invite contraction and make removal of the
valve seat insert easier.
• Use screwdriver to pry the valve seat insert free.
Take care not to damage the cylinder head.
• Carefully remove carbon and other foreign
materials from the cylinder head insert bore.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 38
Inspection and Repair Shaft Idle Gear “C” and Idle Gear “C”
Make the necessary adjustments, repair and part 1. Measure the outside diameter of shaft idle gear “C”.
replacements if excessive wear or damage is Standard: 48.93 – 48.96 mm (1.9264 – 1.9286 in.)
discovered during inspection. Limit: 48.85 mm (1.9232 in.)
2. Measure the clearance between the shaft and idle
Bridge gear “C”.
Inspect any cracking, damage on bridge and inspect any Standard: 0.04 – 0.105 mm (0.0016 – 0.0041 in.)
separation wear out and damage on the surface of
Limit: 0.2 mm (0.0079 in.)
bridge.
Clearance between Camshaft and Bracket Valve Spring

Measure the clearance between the camshaft and 1. Use a vernier caliper to measure the valve spring
camshaft bracket. free height.
Standard: 0.065 – 0.125 mm (0.0026 – 0.0049 in.) If the measured value is less than the specified limit,
Limit: 0.15 mm (0.0059 in.) the valve spring must be replaced.
Valve spring free height
Inlet spring:
Standard: 79.3 mm (3.122 in.)
Limit: 75.3 mm (2.965 in.)
Exhaust spring: outer
Standard: 102.7 mm (4.0433 in.)
Limit: 97.6 mm (3.0843 in.)
Exhaust spring: inner
Limit: 91.7 mm (3.0610 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 39
3. 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.
Valve spring tension
Inlet spring:
Standard: 392 N (40.0 kg)/64 mm
Limit: 294 N (38.0 kg)/64 mm
Standard: 610N (62.2 kg)/69 mm
Limit: 579 N (59.0 kg)/69 mm
Standard: 224 N (22.8 kg)/66 mm
Limit: 213 N (21.7 kg)/66 mm
2, 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
Inlet spring:
Limit: 4.8 mm (0.189 in.)
Limit: 6.2 mm (0.244 in.)
Limit: 5.9 mm (0.232 in.)
Valve Stem
1. Set the dial indicator to the valve stem measuring
point.
2. Move the valve stem end from side to side.
Read the dial indicator.
Note the total indicator reading.
If the measured value exceed the specified limit, the
valve and the valve guide must be replaced as a set.
Valve stem and Valve guide clearance
Inlet:
Standard: 0.040 – 0.077 mm (0.0016 – 0.0030 in.)
Limit: 0.15 mm (0.0059 in.)
Exhaust:
Standard: 0.065 – 0.102 mm (0.0026 – 0.0040 in.)
Limit: 0.25 mm (0.0098 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 40
Bridge Guide and Bridge Clearance

1. Use a caliper calibrator or a telescoping gauge to
measure the valve bridge (2) inside diameter.
2. Calculate the difference between the valve bridge
inside diameter and the valve bridge guide (1)
outside diameter.
If the clearance exceeds the specified limit, the valve
10mm(0.4in) bridge must be replaced.
Bridge guide and bridge clearance
Standard: 0.020 – 0.057 mm (0.0080 – 0.0022 in.)
Limit: 0.10 mm (0.0039 in.)
014EY00062 1
3. Measure the valve stem diameter at three points.

the valve and the valve guide must be replaced as a 2
set.
Valve stem outside diameter
Inlet:
Limit: 9.92 mm (0.3906 in.)
Exhaust:
014EY00063
Limit: 9.90 mm (0.3898 in.)
Valve Thickness and Depression

1. Measure the valve thickness.
the valve and the valve seat insert must be replaced
as a set.
Valve thickness
Inlet:
Limit: 1.64 mm (0.0646 in.)
Exhaust:
Limit: 1.8 mm (0.0709 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 41
Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness.
Make smooth the valve contact surfaces.
2. Measure the valve contact width.
valve seat insert must be corrected or replaced.
Valve contact width
Inlet:
Limit: 3.4 mm (0.1339 in.)
Exhaust:
Standard 2.5 mm (0.0984 in.)
Limit: 2.9 mm (0.1141 in.)
2. Install the new valve (1) to the cylinder head (2).

3. Use a depth gauge or a straight edge with steel rule
to measure the valve depression from the cylinder
head lower surface.
valve seat insert and/or the valve must be replaced.
Valve depression
Inlet:
Limit: 2.9 mm (0.1142 in.)
Exhaust:
Limit: 2.8 mm (0.1102 in.)
014EY00065
Contact Surface Angle on Valve

1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
2
valve, valve guide and valve seat as a set.
Valve contact surface angle
Standard:
Inlet: 30 degree
Exhaust: 45 degree
1
014EY00064
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 42
3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. check to see if the valve contact width is correct.
7. Check to see if the valve seat insert surface is in
contact with the entire circumference of the valve.
014EY00071
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter (15°, 45°, and 75° blades) to
minimize scratches and other rough areas. This will
bring the contact width back to the standard value.
Reassembly
150° 1. Install the injection nozzle sleeve with new gasket to
90° the cylinder head.
30° • Clean the nozzle sleeve circumference and the
nozzle sleeve fitting faces of cylinder head.
• Apply the recommended sealant (LOCTITE TL290
or equivalent) to the nozzle sleeve outer
circumference (1).
• Apply engine oil to the nozzle sleeve gaskets.
• Install the new gaskets to the nozzle sleeve gasket
groove.
• Use a bench press to install the nozzle sleeve.
Apply pressure to the nozzle sleeve gradually.
CAUTION: Do not apply an excessive amount of
pressure with the bench press. Damage to the
011EY00032
injection nozzle sleeve and cylinder head will result.
Remove only the scratches and rough areas. Do not
cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.
Valve seat angle
Inlet: 30 degree
Exhaust: 45 degree
NOTE: Use an adjustable valve cutter pilot. Do not allow
the valve cutter pilot to wobble inside the valve guide.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 43
3. Install the bridge guide.

• Apply engine oil to the valve bridge guide outer
circumference.
• Attach the valve bridge guide installer 9-8522-
1324-0 to the bridge guide.
• Use a brass hammer to tap the guide into position
from the cylinder head upper face.
• Measure the height of the valve bridge guide upper
1 end from the cylinder head upper face (cylinder
head cover fitting surface).
Valve bridge guide upper end height
011EY00029
2. Install the valve seat insert into the cylinder head. 49.0mm
• Carefully place the attachment (1) (having a
smaller outside diameter than the valve seat insert)
on the valve seat insert (2).
NOTE: The smooth side of the attachment must contact
the valve seat insert.
• Use a bench press (3) to gradually apply pressure
to the attachment and press the valve seat insert
into place.
CAUTION: Do not apply excessive amount of
pressure with the bench press. Damage to the valve
seat insert will result.
4. Install the valve guide into the cylinder head.

• Apply engine oil to the valve guide outer
circumference.
• Attach the valve guide replacer 9-8523-1202-0 to
the valve guide.
• Use a hammer to drive the valve guide into position
from the cylinder head upper face.
• Measure the height of the valve guide upper end
from the upper face of the cylinder head.
Valve guide upper end height
Intake side: 27.0 mm (1.0630 in.)
Exhaust side: 29.0 mm (1.1417 in.)
NOTE: If the valve guide has been removed, both the
valve and the valve guide must be replaced as a set.
• The valve should be lapped before final assembly

to ensure a good valve seal.
Refer to “Valve Seat Insert Correction” in this
section.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 44
014EY00066
5. Install the spring lower seat to the cylinder head. • Install the intake valve springs with their fine
6. Install the valve stem seal on the valve guide. pitched end facing down. (Painted yellow)
• Apply engine oil to the oil seal inner face. • There are not assembly direction on both inner and
• Use the oil seal installer 1-8522-1187-0 for inlet outer exhaust valve spring.
and 1-8522-1184-0 for exhaust to install the oil
seal to the valve guide.
014EY00067
8. Install the spring upper seat and split collar.

• Use the spring compressor 1-8523-5013-0 to
7. Install the valve spring and valve. compress the valve spring.
• Apply engine oil to each valve stem before • Install the split collars (1) to the valve stem.
installation. Do not allow the valve to fall from the cylinder
• Install the inlet and exhaust valves. head.
• Turn the cylinder head up to install the valve • Set the split collars by tapping around the head of
springs. each collar with a rubber hammer.
Take care not to allow the installed valves to fall
free.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 45
1
2
014EY00061 027EY00014
9. Install the exhaust manifold assembly to the cylinder • The bracket tightening manner as follows.
head. Tighten the bracket (1) and (3) with out washer.
• Check that the seal ring (1) gaps are positioned Put the bracket (2) on the washer, and tighten
120 degrees apart form each other. together with exhaust manifold.
There is installation direction on seal ring as
illustration.
• Install the exhaust manifold gasket. The direction
indicator must be faced lower side.
1 2 3
1 5
3
1 4 2 6
Indicator
Rear
Front 027EY00016
10. Install the intake manifold assembly.

• Tighten the nut to numerical order shown in the
027EY00013
illustration.
• Install the rubber boot and spring with tightening
• Install distance tube (1), washer (3) and disk spring specified torque.
(2). Torque: 20 N·m (2.0 kgm)
The convex side of disk spring must be faced to
exhaust manifold nut.
• Tighten the exhaust manifold nut to specified
torque. Follow the tightening order shown in the
illustration.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 46
Rubber boot
Indicator
2
10
6 7
2 3 11
12 9 5 1 4 8 1
025EY00006 011EY00031
11. Install the idle gear “C” and the shaft of the idle gear 13. Install the thermometer unit.
“C”. • Apply Loctite FMD127 or equivalent to thread on
• Apply engine oil to the shaft of the idle gear “C”. thermometer unit.
• Install the shaft with idle gear “C” to cylinder head. • Tighten the thermometer unit to the specified
• Tighten the bolts to the specified torque. torque.
Torque: 39 N·m (4.0 kgm) Torque: 20 N·m (2.0 kgm)
Cylinder
head side
011EY00030
12. Install the gearcase with new gasket (1).

• Apply Loctite FMD127 or equivalent to the gear-
case fitting area (2) or the cylinder head shown in
the illustration.
The sealant must be 0.3 mm (0.012 in.) thick and
5 mm (0.20 in.) wide.
The sealant (2) must not obstruct the bolt holes the
of cylinder head.
69697_ESS-172A_SEC6A-2 11.8.5 10:45 AM ページ 47
Rocker Arm and Shaft Assembly

Disassembly
3
2
Front Mark
014EY00072
Legend (4) Bracket

(1) Bracket (5) Rocker Arm Shaft
(2) Rocker Arm
(3) Spring
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 48
1. Remove the rocker arm and shaft assembly.

• Loosen the bolt of the rocker arm shaft bracket
from out side bolt a little at time and remove rocker
arm and shaft assembly.
• Disassembly the bracket, rocker arm, spring,
bracket and rocker arm shaft.
014EY00073
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting
portion outside diameter.
If the measured value is less than the specified limit, the
rocker arm shaft must be replaced.
Rocker arm shaft outside diameter
Inspection and Repair Standard: 27.979 – 28.000 mm (1.1015 – 1.1024 in.)
Make the necessary adjustments, repairs, and part Limit: 27.85 mm (1.0965 in.)
replacements if excessive wear or damage is
discovered during inspection.
Rocker Arm Shaft Run-Out

1. Place the rocker arm shaft on V-blocks.
2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm
shaft run-out with a bench press. The rocker arm
must be at cold condition.
If the measured rocker arm shaft run-out exceeds
the specified limit, the rocker arm shaft must be
replaced.
Rocker arm shaft run-out
Limit: 0.3 mm (0.012 in.)
014EY00074
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 49
Rocker Arm Bushing Inside Diameter Rocker Arm Roller and Rocker Arm Pin
Use either a vernier caliper or a dial indicator to measure 1. Pass a string through the rocker arm-roller (1)
the rocker arm bushing inside diameter. clearance and measure the roller protrusion while
Rocker arm bushing inside diameter pulling both ends of the string in the arrow indicated
Standard: 28.020 – 28.053 mm (1.1031 – 1.1044 in.) directions to push out the roller.
Rocker arm and rocker arm shaft clearance 2. Mark the measuring point and draw out the string.
Measure the roller protrusion again while the roller is
Standard: 0.020 – 0.074 mm (0.0008 – 0.0029 in.)
pushed in.
Limit: 0.2 mm (0.0079 in.)
3. Note the difference in the above measurements is
the standard roller rocker arm and pin clearance.
If the clearance exceeds the limit, the rocker arm
must be replaced.
Rocker arm roller and pin clearance
Standard: 0.036 – 0.069 mm (0.0014 – 0.0027 in.)
Limit: 0.15 mm (0.0059 in.)
014EY00075
Check to see if the rocker arm and rocker arm shaft oil
port is free of obstructions.
If necessary, use compressed air to clean the rocker
arm and rocker arm shaft oil port.
014EY00076
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 50
Reassembly
3
2
Front Mark
014EY00072
Legend (4) Bracket

(1) Bracket (5) Rocker Arm Shaft
(2) Rocker Arm
(3) Spring
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 51
1. Install the bracket, spring, rocker arm and bracket to

the rocker arm shaft.
2. Apply engine oil to the roller portion of the rocker arm
and threads of the adjusting screw.
3. Put the rocker arm and shaft assembly on the
cylinder head.
4. Temporally tighten the bolts of the rocker arm and
shaft assembly to the cylinder head, sufficiently
loosen the adjusting screw.
5. Tighten the bolts of the rocker arm and shaft
assembly to the specified torque by numerical order
shown in the illustration.
6 4 2 1 3 5 7
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 52
Camshaft
Disassembly
Legend (4) Camshaft bearing lower

(1) Camshaft gear (5) Camshaft
(2) Key
(3) Camshaft bearing cap
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 53
1. Remove the camshaft gear.

• Check visually gear for excessive wear or damage.
• Use an universal puller to pull out the camshaft
gear with wooden plate (1) for prevent make
damage gear.
2. Loosen nuts to remove the camshaft bearing cap.
3. Remove the camshaft. 2
014EY00078
2. Measure the cam height A and B with a micrometer.

1
the camshaft must be replaced.
Cam height (A – B)
Inlet
014EY00077
Limit: 8.85 mm (0.3484 in.)
Inspection and Repair Exhaust
Make the necessary adjustments, repairs, and part
Limit: 9.75 mm (0.3839 in.)
1. Use a micrometer to measure each camshaft journal
diameter in two directions ((1) and (2)). If the
measured value is less than the specified limit, the
camshaft must be replaced. B
Camshaft journal diameter
Standard: 39.915 – 39.940 mm (1.5715 – 1.5724 in.)
A
Limit: 39.890 mm (1.5705 in.)
014EY00079
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 54
3. Mount the camshaft on V-blocks.

Measure the run-out with a dial indicator on the No. 4
camshaft journal.
camshaft must be replaced.
Camshaft run-out
Standard: 0.080 mm (0.0031 in.)
Limit: 0.100 mm (0.0039 in.)
4. Use an inside dial indicator to measure the camshaft

bearing inside diameter.
Camshaft bearing inside diameter
Standard: 40.015 – 40.040 mm (1.5754 – 1.5764 in.)
If the clearance between the camshaft bearing inside
diameter and the journal exceeds the specified limit,
the camshaft bearing must be replaced.
Camshaft bearing clearance
Standard: 0.065 – 0.125 mm (0.0026 – 0.0049 in.)
Limit: 0.15 mm (0.0059 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 55
Reassembly
Legend (4) Camshaft

(1) Camshaft gear (5) Camshaft bearing lower
(2) Key
(3) Camshaft bearing cap
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 56
1. Install the camshaft bearing lower.

• Install the camshaft bearing lower to the cylinder
head.
• Apply engine oil to the bearing portion.
2. Install the camshaft.
• Put camshaft onto the lower camshaft bearing.
• Apply engine oil to the journal of camshaft.
3. Install the camshaft bearing cap.
• Install the camshaft bearing cap on the stud bolts
to use same stamped mark of lower bearing.
• Apply engine oil to the threads of the stud bolt and
nut seat.
• Tighten the camshaft bearing cap nut to the
specified torque.
014EY00080
4. Insert the key to the camshaft.

5. Install the camshaft gear and tighten the bolt to the
specified torque.
• Apply engine oil to the threads of the bolt.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 57
Timing Gear
Timing Gear and Associated Parts
11
7
6
10
8
9
1
4
2
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 58
Legend (7) Gasket

(1) Fan center assembly (8) Distance bolt
(2) Crank pulley (9) Idle gear “A”
(3) Gearcase cover (10) Idle gear “B”
(4) Gasket (11) Timing gearcase
(5) Oil seat (front)
(6) Oil pump
(Without Cooling Fan)
11
7
6
10
8
5
9
4
1
PAW0Z0LF001001
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 59
Legend (7) Gasket

(1) Fan center assembly (8) Distance bolt
(2) Crank pulley (9) Idle gear “A”
(3) Gearcase cover (10) Idle gear “B”
(4) Gasket (11) Timing gearcase
(5) Oil seat (front)
(6) Oil pump
Removal
1. Remove the fan center.
2. Remove the crank pulley.
3. Remove the front oil seal to use the oil seal remover
1-8522-0052-0.
CAUTION: Take care not to damage or deform the
sealing flange surface of the gearcase.
5. Remove the oil pump with the gasket.

Discard the gasket.
6. Remove the idle gear “A”.
• Before loosening the idle gear fixing bolts,
measure the backlash of the idle gear “A” and “B”.
Idle gear backlash
Standard: 0.095 – 0.135 mm (0.0037 – 0.0053 in.)
020E100035
Limit: 0.23 mm (0.0091 in.)
4. Remove the gearcase cover.
Remove the gearcase cover gasket and discard it.
020E100030
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 60
• Measure the end play of the idle gear “A” (1) and Inspection and Repair
“B” (2).
Idle gear “A” end play 1. Visually inspect the idle gear and idle gear spindle
for damage or wear.
Standard: 0.155 – 0.220 mm (0.0061 – 0.0089 in.)
2. Use a micrometer to measure the idle gear spindle
Limit: 0.35 mm (0.0138 in.) out side diameter.
Idle gear “B” end play Spindle outside diameter for idle gear “A”
Standard: 0.050 – 0.140 mm (0.0020 – 0.0055 in.) Standard: 56.93 – 56.96 mm (2.2413 – 2.2425 in.)
Limit: 0.25 mm (0.0098 in.) Limit: 56.85 mm (2.2382 in.)
Spindle outside diameter for idle gear “B”
2 Standard: 141. 93 – 141.96 mm (5.5878 – 5.5890 in.)
Limit: 141.85 mm (5.5846 in.)
Spindle outside diameter for idle gear “C”
Standard: 48.93 – 48.96 mm (1.9264 – 1.9286 in.)
Limit: 48.85 mm (1.9232 in.)
1
3. Use a cylinder bore dial indicator to measure the idle
gear inside diameter.
4. Calculate the clearance between the idle gear and
idle gear spindle.
Clearance for idle gear “A”, “B”, and “C”
Standard: 0.040 – 0.105 mm (0.0016 – 0.0041 in.)
Limit: 0.02 mm (0.0079 in.)
If the measured value exceeds from the specified limit,
the idle gear spindle or idle gear must be replaced.
020E100031
7. Remove the idle gear “B”.

• Scribe a front mark on the thrust plate to aid in
assembly.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 61
Installation
5
Y
Y
Y
Y
020E100033
Legend (4) Idle gear “A”

(1) Camshaft gear (5) Crankshaft gear
(2) Idle gear “C” (6) Idle gear “B”
(3) Injection pump gear
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 62
1. Install the timing gearcase.

• Clean the sealing surface block and remove
sealant residue.
1
• Apply a 4 mm bead of Loctite FMD127 or
equivalent to the cylinder block.
The sealant must not obstruct the cylinder block
bolt holes.
• Install the timing gearcase to the cylinder block.
M14 Bolt
M10 Bolt
014EY00084
3. Install the idle gear “A” to the timing gearcase.

• Align the flywheel TDC mark with the pointer by
rotating the crankshaft normal direction. Same
time check alignment of the timing mark on the
injection pump for No. 1 piston TDC.
2. Install the idle gear “B”.

• Apply engine oil to the bushing area of the idle gear
and both thrust plate (1) surface.
• Face front the scribed mark on the thrust plate.
015EY00070
• Apply engine oil to the bushing of the idle gear “A”.

• Install the idle gear “A” with the idle gear shaft to
the timing gearcase.
The timing marks (“O”, “I”, “Y”) must be aligned as
• Tighten the idle gear “A” shaft bolts to the specified
torque.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 63
Y
Y
Y
Y
020E100024 051HT002
4. Install the distance bolt to the gearcase. 6. Install the timing gearcase cover.
Tighten the distance bolts to the specified torque. • Apply Loctite FMD127 or equivalent to the timing
Torque: 39 N·m (4.0 kgm) gearcase fitting face.
• Install the timing gearcase cover with new gasket.
With cooling fan
M10 bolts
M8 bolts
020HV001
5. Install the oil pump assembly.

• Install the new gasket to the oil pump assembly.
• Install the oil pump assembly to the cylinder pump.
• Tighten the oil pump bolts to the specified torque.
CAUTION: Do not tighten arrow mark bolt shown in
the illustration.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 64
HCW31BSH019301
Without cooling fan 7. Install the oil seal with the slinger.
M10 bolts
M8 bolts
020EY00028
A
1
HCW31BSH019201
4
After press
Before press
3 2
015EX00001
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 65
Legend 8. Install the crankshaft pulley assembly.

(1) Crankshaft • Install the crankshaft pulley.
(2) Slinger • Apply engine oil to the bolt threads.
(3) Oil seal • Tighten the crankshaft pulley bolts to the specified
(4) Adapter torque.
(5) Sleeve Torque: 267 N·m (27.2 kgm)
• Apply engine oil to the entire circumference of the

oil seal.
• Use the oil seal installer 1-8522-0043-0 to install
the oil seal.
• Tighten the center bolt until the sleeve comes into
contact with the adapter stopper.
• After pressing the oil seal, make sure that the
distance between the crankshaft end surface and
the oil seal is A as specified.
Distance (A): 6.7 – 7.3 mm (0.264 – 0.287 in)
• There is identification color on the oil seal.
For front oil seal: Dark violet color
For rear oil seal: Gray color
• If there is small scratch on the crankshaft, apply
Threebond 127C or equivalent to the oil slinger
015EY00096
9. Install the fan center (1) to the gearcase cover (2).

Tighten the fixing nuts to the specified torque.
;À@;
@

À À@;;À@;À@
;À@;À@
1mm
1
3mm
2
020MT001
033EY00011
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 66
Flywheel Housing
Removal
3 4
Legend (5) Flywheel housing

(1) N-TDC sensor (6) Oil seal
(2) Washer (7) Slinger
(3) Flywheel
(4) Stiffener
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 67
1. Loosen the flywheel fixing bolts. Installation

Remove the flywheel.
1. Install the flywheel housing to the cylinder block.
2. Use the oil seal remover 1-8522-0052-0 to remove
• Apply a 4 mm bead of Loctite FMD127 or
the oil seal from the crankshaft.
equivalent to the cylinder block as shown in the
• Take care not to damage on the inserting surface illustration.
of the housing.
The sealant must not obstruct the cylinder bolt
holes.
• Install the flywheel housing.
M14 bolt
M8 bolt
020E100036
3. Remove the stiffeners.

4. Remove the flywheel housing.
2. Install the stiffeners (1) to the flywheel housing.

020E100037
013EY00015
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 68
3. Install the oil seal with the slinger. 4. Install the flywheel to the crankshaft.
• Apply engine oil to the entire circumference of the • Apply molybdenum disulfied grease to the bolt and
oil seal. setting face.
• Use the oil seal installer 1-8522-0043-0 to install • Tighten the flywheel bolts in three steps using the
the oil seal. angular tightening method.
• Tighten the center bolt until the sleeve comes into Torque:
contact with the adapter stopper. 1st step: 79 N·m (8.0 kgm)
• After pressing the oil seal, make sure that the 2nd step: 60 deg.
distance between the crankshaft end surface and
3rd step: 30 deg.
the oil seal is A as specified.
Distance (A): 6.7 – 7.3 mm (0.264 – 0.287 in) • Follow the numerical order as shown in the
illustration.
• There is identification color on the oil seal.
For front oil seal: Dark violet color
For rear oil seal: Gray color
• Do not make separation between the oil seal and
slinger.
A
1
After press
Before press
2 3
015EY00203
Legend
(1) Crankshaft
(2) Slinger
(3) Oil seal
(4) Adapter
(5) Sleeve
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 69
Oil Pan
Removal
8
7
6
5 4
2 3
2
1
PAW0Z0LF000701
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 70
Legend (5) Oil strainer

(1) Oil pan (6) Oil strainer bracket
(2) Oil pan gasket (or bracket) (7) Gasket
(3) Oil pan spacer (8) Oil jet assembly
(4) Oil pan spacer gasket
1. Remove the oil pan.

Remove the oil pan gasket.
Discard the oil pan gasket.
2. Remove the oil pan spacer.
Remove the oil pan spacer gasket.
Discard the oil pan spacer gasket. 4
3. Remove the oil strainer.
6
4. Remove the oil strainer bracket.
5
5. Remove the oil jet assembly.
CAUTION: Take care not to bend the oil jet tubing. 2
3
Do not attempt to repair a damaged oil jet. If 1
damaged, replace the oil jet with a new one.
Installation
1. Install the oil jet assembly to the cylinder block.
Tighten the joint bolt to the specified torque.
3. Install the oil pan spacer with new gasket.
• Apply Cemedain LG-020L or equivalent to the
cylinder block, flywheel housing and gearcase
fitting face.
The sealant must be 3 – 4 mm of bead.
Sealant
2. Install the oil strainer with new gasket and the oil
strainer bracket.
Tighten the bolts in numerical order as shown in the
illustration.
012EY00017

Tighten the bolts in numerical order as shown in
the illustration.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 71
then re-apply the gasket and pro-ceed to re-

assemble the parts.
• When installing the oil pan, erect about four guide
studs for positioning in the oil pan spacer bolt
holes.
20 1
• After tightening the oil pan, do not remove any of
the protruding gasket from the inner or outer
circumference of the oil pan.
Front 21
• Do not fill the engine with oil or start the engine
36 until at least 30 minutes has passed since the parts
were installed.
3
2
013EY00016
1
4. Install the oil pan to the oil pan spacer.
Without liquid gasket
• Install the oil pan with new gasket.
Tighten the bolts to the specified torque in numerical
order as shown in the illustration.
V 1
Front
3
2
3 2 PAW5Z0MH000501
Name
1. Line connected to the bolt hole perimeter line (inner
side)
2. Oil pan R finish line
3. Apply to the constant clearance along the oil pan
013EY00017
angle R
With liquid gasket
• Degrease the installation surface of the oil pan
flange side, flange R, and oil pan spacer.
• Apply liquid gasket along the line on the dia-gram
below.
Liquid gasket: TB1207B
• Aim for a liquid gasket diameter of ø 4 mm {0.16 in}
(ø 3.5 — 4.5 mm {0.14 — 0.18 in}).
• Apply liquid gasket, then assemble the oil pan
within 7 minutes. If more than 7 minutes passes,
use a gasket remover to remove the liquid gasket,
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 72
2
PAW5Z0SH002801
Name
1. Aim to apply so that the edge of the gasket is on the
R finish line
2. Aim to apply so that the edge of the liquid gasket
includes the bolt hole outer circumference
PAW5ZHSH000401
• Tighten to the specified torque.

69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 73
Piston
Removal
2
4
015EY00097
Legend (3) Crankshaft

(1) Piston with connecting rod (4) Connecting rod bearing cap
(2) Connecting rod bearing
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 74
1. Remove the cylinder head assembly. 4. Remove the connecting rod bearing.
Refer to “Cylinder Head” in this section. • Mark, sort or organize the connecting rod bearing
2. Remove the oil pan. for assembly to the original location.
Refer to “Oil Pan” in this section.
3. Remove the piston with connecting rod. Installation
• Remove the carbon deposits from the upper potion
of the cylinder wall by the scraper. 1. Install the piston with the connecting rod.
• Loosen the connecting rod cap nuts. • Clean the piston in solvent. Remove all sludge.
• Move the piston to the top of the cylinder and tap it • Carefully wipe any foreign materials inside cylinder
with a hammer grip or similar object from the bore and piston with connecting rod. Clean the
connecting rod lower side to drive it out. bearing cap and bearing
CAUTION: Take care not to damage the oil jets. • Install the connecting rod upper bearing to the
connecting rod.
012EY00018
• Install the connecting rod lower bearing to the

connecting rod.
• Apply engine oil to the cylinder wall, upper/lower
bearing surface and crank pin of crankshaft.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 75
012EY00028 015EY00134
• Position the piston ring gaps as shown in the • Use the piston setting tool 1-8522-0059-1 to install
illustration. the piston with the connecting rod to the cylinder
Gap position block. At this time rotate the crankshaft until the
(1) 1st compression ring crankpin is at bottom dead center.
(2) 2nd compression ring
(3) 3rd compression ring
(4) Oil ring
(5) Coil expander
Front mark
1 2,5
4 3
CAUTION: Do not bend or damage the oil jet.
• Apply molybdenum disulfied grease to the threads

and setting faces of each connecting rod bolts.
012HW002
• Position the piston head front mark (1) so that it is

facing front of the engine.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 76
• Tighten the connecting rod cap nuts in three steps

using the angular tightening method.
Torque:
1st step: 98 N·m (10.0 kgm)
2nd step: 30 deg.
3rd step: 30 deg.
• Check the crankshaft rotation smoothly.
2. Install the oil pan to the cylinder block.
Refer to “Oil Pan” to this section.
3. Install the cylinder head to the cylinder block.
Refer to “Cylinder Head” in this section.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 77
Disassembly
3 4
2
Legend (5) Connecting rod

(1) Piston rings (6) Connecting rod cap
(2) Snap ring (7) Bearing
(3) Piston pin
(4) Piston
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 78
NOTE: When removing the piston and connection rod

assembly, pull the connecting rod in parallel with the
cylinder bore.
1. Remove the connecting rod cap.
2. Remove the bearings.
• Take out the connecting rod bearing cap nuts and
disassemble the bearing cap with the lower
bearing.
• Mark, sort or organize the connecting rod bearing
for assembly to the original location.
3. Remove the piston rings.
• Clamp the connecting rod in a vise. 1
Take care not to damage the connecting rod.
• Use piston ring replacer to reassemble the piston
rings.
Do not attempt to use some other tool to 015EY00098
disassemble the piston rings. Piston ring stretching

5. Remove the piston pin.
will result in reduced piston ring tension.
6. Remove the piston.
7. Remove the connecting rod.
Tap the piston pin out with a hammer and a brass
bar.
Mark, sort or organize the piston and piston rings for
assembly to the original location.
Inspection and Repair

Make the necessary adjustments, repairs and part
Piston Ring Gap

1. Insert the piston ring horizontally (in the position it
would assume if it were installed to the position) into
the cylinder liner bore.
2. Push the piston ring into the cylinder liner bore until it
reaches the point where the cylinder liner bore is the
smallest.
Do not allow the piston ring to slant to one side or the
4. Remove the snap ring.
other. It must be perfectly horizontal.
Use a pair of snap ring pliers to remove the snap
rings.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 79
Piston Ring and Piston Ring Groove

Clearance
1. Visually inspect the piston ring grooves.
If a piston ring groove is damaged or distorted, the
piston must be replaced.
2. Use a feeler gauge to measure the clearance
between the piston ring and the piston ring groove at
several points around the piston.
3. When measuring the clearance for 1st piston ring,
press the 1st piston ring by straight gauge show in
the illustration.
015EY00099
3. Use a feeler gage to measure the piston ring gap.

piston ring must be replaced.
2
Piston ring gap
1st, 3rd ring:
Standard: 0.35 – 0.50 mm (0.0138 – 0.0197 in.)
Limit: 1.0 mm (0.0394 in.)
2nd ring:
Standard: 0.80 – 0.95 mm (0.0315 – 0.0374 in.)
Limit: 1.5 mm (0.059 in.) 015EY00101
Oil ring:
Piston ring and piston ring groove clearance
Standard: 0.30 – 0.50 mm (0.0118 – 0.0197 in.)
1st ring:
Limit: 1.0 mm (0.0394 in.)
Standard: 0.115 – 0.160 mm (0.0045 – 0.0063 in.)
NOTE: The standards shall be met when the ring is Limit: 0.24 mm (0.0094 in.)
inserted in the liner ring (inner dia. φ147.000 ). 2nd, 3rd ring:
Standard: 0.10 – 0.135 mm (0.0039 – 0.0053 in.)
Limit: 0.20 mm (0.787 in.)
Oil ring:
1 Standard: 0.025 – 0.065 mm (0.0010 – 0.0026 in.)
Limit: 0.15 mm (0.0059 in.)
015EY00100
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 80
Piston Pin Diameter

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

Use an expansion force gauge to measure the piston
ring expansion force.
Piston ring expansion force
1st ring:
Standard: 38.5 – 49.2 N
(3.92 – 8.64 kg/8.64 – 11.07 lb)
Limit: 29 N (3.0 kg/6.6 lb)
2nd ring: Piston Pin Hole and Piston Pin Clearance
Standard: 29.9 – 38.7 N Use a inside dial indicator to measure the piston pin hole
(3.05 – 3.95 kg/6.73 – 8.71 lb) (in the piston).
Limit: 20 N (2.0 kg/4.4 lb) Piston pin hole and piston pin clearance
3rd ring: Standard: 0.008 – 0.021 mm (0.0003 – 0.0008 in.)
Standard: 28.1 – 36.6 N Limit: 0.05 mm (0.0020 in.)
(2.87 – 3.73 kg/6.33 – 8.22 lb)
Limit: 20 N (2.0 kg/4.4 lb)
Oil ring: Piston Pin and Connecting Rod Small End
Standard: 85.3 – 104.9 N Bushing Clearance
(8.7 – 10.7 kg/19.2 – 23.6 lb) Use a caliper calibrator and dial indicator to measure the
Limit: 64 N (6.5 kg/14.3 lb) clearance between the piston pin and connecting rod
small end bushing
If the clearance between the piston pin and the
connecting rod small end bushing exceeds the specified
limit, replace the piston pin and/or the connecting rod
assembly.
Small end bushing clearance
Standard: 0.020 – 0.037 mm (0.0079 – 0.0016 in.)
Limit: 0.10 mm (0.0039 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 81
Crankshaft and Connecting Rod Bearing

Clearance
1. Clean the crankshaft, connecting rod, bearing cap,
and bearings.
2. Install the bearing to the connecting rod and bearing
cap.
3. Apply a coat of molybdenum disulfide grease to the
bearing cap bolt threads and setting faces.
4. Prevent the connecting rod from moving.
5. Tighten the bearing cap to the specified torque.
Connecting rod bearing cap nut torque
1st step: 98.1 N·m (10.0 kgm/72.3 lb·ft)
2nd step: 30 deg.
3rd step: 30 deg.
6. Use a dial indicator to measure the connecting rod
bearing inside diameter.
015EY00102
Crankpin and connecting rod bearing clearance

Standard: 0.033 – 0.103 mm (0.0013 – 0.0041 in.)
Connecting Rod Alignment
Limit: 0.16 mm (0.0063 in.)
Use a connecting rod aligner to measure the distortion
and the parallelism between the connecting rod big end
hole and the connecting rod small end hole.
If either the measured distortion or parallelism exceeds
the specified limit, the connecting rod must be replaced.
Connecting rod alignment
Per length of 100 mm (3.94 in.)
Standard: 0.05 mm (0.002 in.) or less
Limit: 0.20 mm (0.008 in.) 1 2 B
A
A
1 2 B
7. If the clearance between the measured bearing

inside diameter and the crankpin exceeds the
specified limit, the bearing and/or crankshaft must be
replace.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 82
Piston and Liner Bore Clearance

Measure the cylinder liner bore after installing the
cylinder liner. Then select the appropriate piston for the
installed cylinder liner.
1. Measure the cylinder liner bore.
1 2 A Refer to the “Cylinder Liner Bore Measurement”.
Measuring Point 130 mm (5.118 in.)
B B
Cylinder liner bore
A
Standard: 147.011 – 147.030 mm
(5.7878 – 5.7886 in.)
Connecting Rod and Crankshaft Clearance 130mm

1. Fix the connecting rod assembly to the crankshaft by
The fixing manner is follow as mentioned above.
2. Use a feeler gauge to measure the clearance
between the connecting rod and crankshaft.
connecting rod must be replaced.
Connecting rod and crankshaft clearance 012EY00022
Standard: 0.175 – 0.290 mm (0.0069 – 0.0114 in.)

2. Measure the piston outside diameter (Reference).
Limit: 0.35 mm (0.0138 in.)
Piston Measuring Point 113 mm (4.449 in.)
113mm
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 83
The grade mark is stamped on the top of the piston

installed at the factory, but the piston for service part
does not have any grade.
Piston outside
Standard: 146.830 – 146.845 mm
(5.7805 – 5.7813 in.)
Piston and Liner bore clearance
Standard: 0.166 – 0.200 mm (0.0065 – 0.0079 in.)
If the piston and liner clearance exceeds the standard
value, the piston and/or liner must be replaced.
CAUTION: Cylinder liner kit clearances are preset.
However, the cylinder liner installation procedure
may result in slight decreases in cylinder liner
clearances. Always measure the cylinder liner
clearance after installation to be sure that its is
correct.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 84
Reassembly
3 4
2
Legend (5) Connecting rod

(1) Piston rings (6) Connecting rod cap
(2) Snap ring (7) Bearing
(3) Piston pin
(4) Piston
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 85
1. Install the snap ring.

Use a pair of sanp ring pliers to reassemble the snap
ring to the piston.
2. Install the connecting rod and piston pin.
1 2 3
• Clamp the connecting rod in the vise.
Take care not to damage the connecting rod.
• Install the piston so that the piston head front mark
and the connecting rod front mark are set in the
same direction.
1N 2N 3N
Red Blue Green
015EY00103
1
1
3
015EY00098
• Apply engine oil to the piston pin.

• Insert the piston pin to the connecting rod through
4
piston pin hole on the piston.
• Install the snap ring.
3. Install the piston ring.
• Apply engine oil to the piston rings.
• Confirm the discrimination mark on the piston ring.
015EY00104
Discrimination mark
1st ring: Red color • Use the piston ring setting tool 1-8522-1025-0 to
2nd ring: Blue color reassemble the four piston rings according to top
mark on the piston ring.
3rd ring: Green color
The oil ring does not have top mark.
Oil ring: Not available
NOTE: Insert the expander coil into the oil ring groove so
that there is no gap on either side of the expander coil
before installing the oil ring.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 86
Gap position
(1) 1st compression ring
(2) 2nd compression ring
(3) 3rd compression ring
(4) Oil ring
(5) Coil expander
Front mark
1 2,5
4 3
012HW002
• Apply molybdenum disulfide grease to the two

piston skirts.
This will facilitate smooth break-in when the engine
is first started after reassembly.
• Apply engine oil to the upper connecting rod
1
bearing.
• Apply engine oil to the cylinder wall.
• Position the front mark on the piston head so that it
is facing the front of the engine.
015EY00098
• Check to see if the piston rings rotate smoothly in

the piston ring grooves.
4. Install the connecting rod bearing.
Carefully wipe any oil or other foreign material from Front mark
the connecting rod bearing back face and the
bearing fitting surface.
5. Install the connecting rod cap. Engine front
• Fit the lower connecting rod bearing to the
connecting rod cap.
• Apply engine oil to the circumference of the each Front mark
piston ring, piston and crankpin.
• Position the piston ring gaps as shown in the
illustration.
015HV014
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 87
• Use the piston ring setting tool 1-8522-0059-0 to

compress the piston rings.
• Use a hummer grip to push the piston in until the

connecting rod marks contact with the crankpin.
As the same time, rotate the crankshaft until the
crankpin is at bottom dead center.
• Align the connection rod cap cylinder number

marks and the connecting rod cylinder number
marks.
• Install the connection rod caps.
• Apply molybdenum disulfide grease to the threads
and setting faces of each connecting rod bolts and
nuts.
• Tighten the connecting rod nut to the specified
torque.
Torque:
2nd step: 30°
3rd step: 30°
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 88
Crankshaft
Removal
2
6
5
6
6
5
6
3
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 89
Legend (4) Crankshaft

(1) Piston with connecting rod (5) Crankshaft bearing
(2) Connecting rod bearing (6) Crankshaft thrust bearing
(3) Lower crankcase
1. Remove the cylinder head assembly.

2. Remove the oil pan.
1
3. Remove the timing gear.
Refer to “Timing Gear” in this section.
4. Remove the flywheel.
Refer to “Flywheel” in this section. 1 5 9 C B 8 4
5. Remove the piston with connecting rod.
2 6 0 D A 7 3
Refer to “Piston” in this section.
6. Remove the lower crankcase.
• Measure the crankshaft end play at the No. 1
crankshaft journal before removing the crankshaft
thrust bearing. 1
If the measured value exceeds the specified limit,
the crankshaft thrust bearing must be replaced.
Crankshaft end play 012EY00024
Standard: 0.04 – 0.18 mm (0.0016 – 0.0070 in.) 7. Remove the crankshaft from the cylinder block.
Limit: 0.35 mm (0.0138 in.) 8. Remove the crankshaft bearing.
• Mark, sort or organize the connecting bearing for
assembly to the original location.
9. Remove the crankshaft thrust bearing.
Installation
1. Install the crankshaft bearing to the cylinder block.
• Carefully wipe any foreign materials from the fitting
area of the cylinder block and upper crankshaft
bearing.
All upper bearing have oil grooves.
• Install the upper bearings to the original location, if
to be reused.
CAUTION: Do not apply engine oil to the bearing
back faces and cylinder block bearing fitting
surfaces.
012EY00023
• Loosen the crankcase lower bolt. A little at a time in

the numerical order shown in the illustration.
• Use M10 bolts into the holes (1) for replacement to
remove the crankcase lower.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 90
Dowel pin hole

Cylinder body side
Crankcase side
Oil groove
012EY00025 015EY00108
2. Install the crankshaft to the cylinder block. 4. Install the lower crankcase to the cylinder block.
• Clean the crankshaft in solvent. Remove all sludge • Carefully wipe any foreign materials from the fitting
or restrictions from the oil passages. area of the crankcase.
• Apply engine oil to the crankshaft journal and • Apply Loctite FMD127 or equivalent to cylinder
crankshaft bearing surfaces before installing the block lower surfaces.
crankshaft. The sealant must be 0.3 mm thick and 4 mm wide.
• Install the crankshaft bearings and thrust bearing.
CAUTION: Do not apply engine oil to the bearing
back.
NOTE: The thrust bearing oil grooves must be facing the

sliding face.
Apply FMD-127
FMD-127 {
} FMD-127
Ft Rr
FMD-127 {
} FMD-127
FMD-127
015EY00107
Cylinder body lower surface
3. Install the crankshaft thrust bearing.

• Apply engine oil to the thrust bearing oil grooves
side.
• Install the upper thrust bearing to both side of the
No. 1 journal by hand. 012EY00026
NOTE: The thrust bearing oil groove must be faced the

sliding side.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 91
5. Install the piston with the connecting rod.

Refer to “Piston” in this section.
6. Install the flywheel to the crankshaft.
Refer to “Flywheel Housing” in this section.
7. Install the timing gears to the cylinder block.
Refer to “Timing Gear” in this section.
8. Install the oil pan to the cylinder block.
9. Install the cylinder head to the cylinder block.
Oil groove
015EY00109
• Install the lower crankcase to the cylinder block.

• Apply molybdenum disulfide grease to the
crankcase bolts (M18) threads and setting faces.
• Apply engine oil to the crankcase bolts (M12)
threads and setting faces.
Order 1 to 14 in the three steps using the angular
tightening method.
M18 bolt
Torque:
2nd step: 88 N·m (9.0 kgm)
3rd step: 90 – 120 deg.
M12 bolt
0 6 2 3 7
D A
C B
9 5 1 4 8
012Ey00027
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 92
Disassembly
Legend
(1) Crankshaft
(2) Bearings
(3) Crankshaft gear
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 93
1. Remove the crankshaft assembly (1) from the

cylinder block.
2. Remove the crankshaft bearing and thrust bearing
(2).
3. Use the crankshaft gear remover 1-8521-0064-0 to
A 12
remove the crankshaft gear (3).
If the slinger on the crankshaft remain, remove
B B
slinger by the slinger remover 1-8521-0027-0.
CAUTION: The crankshaft must not be ground as it A
has been treated by soft nitriding to enhance the
crankshaft strength.
Crankshaft Run-Out
• Set a dial indicator to the center of the crankshaft
No. 4 journal.
• Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
the crankshaft must be replaced.
Crankshaft run-out
Standard: 0.120 mm (0.0005 in.)
Limit: 0.15 mm (0.0059 in.)
Crankshaft Journal and Crankpin Diameter

• Use a micrometer to measure the crankshaft
journal diameter across points shown in the
illustration.
• Use a micrometer to measure the crankshaft
journal diameter at the two points as shown in the
illustration (1) and (2).
• Repeat steps 1) and 2) to measure the crankpin
diameter.
If the measured values are less than the standard
value, the crankshaft must be replaced.
Crankshaft journal and Crankpin diameter
Standard
No. 4 journal: 104.850 – 104.875 mm
(4.1279 – 4.1289 in.)
Others: 104.880 – 104.905 mm (4.1291 – 4.1309 in.)
Crankpin: 91.895 – 91.925 mm (3.6179 – 3.6191 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 94
Bearing Spread
Use a vernier caliper to measure the bearing spread.
the bearing must be replaced.
Bearing spread: 0 6 2 3 7
Limit: 111.5 mm (4.3898 in.)

D A
C B
9 5 1 4 8
012EY00027
• Measure the crankshaft bearing inside diameter by

a dial indicator.
• If the clearance between the crankshaft journal
and bearing exceeds the specified limit, the
crankshaft must be replaced.
No. 4 journal
015EY00110
Standard: 0.081 – 0.144 mm (0.0032 – 0.0057 in.)
Limit: 0.16 mm (0.0063 in.)
Crankshaft Journal and Bearing Others
Clearance Standard: 0.051 – 0.114 mm (0.0020 – 0.0045 in.)
• Clean the cylinder block and lower crankcase, the Limit: 0.16 mm (0.0063 in.)
journal bearing fitting surface, and the journal
bearings.
• Install the bearings to the cylinder block and lower
crankcase.
• Reassembly the lower crankcase to cylinder block.
• Apply molybdenum disulfide grease to the M18
bolts and apply engine oil to the M12 bolts thread
and it seat.
• Tighten the lower crankcase to the specified torque
in the numerical order shown in the illustration.
Crankcase bolt torque
M18 bolt
3rd step: 90 – 120°
M12 bolt
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 95
• Tighten the lower crankcase to the specified torque

in the numerical order shown in the illustration.
Crankcase bolt torque
M18 bolt
A 12 1st step: 49 N·m (5.0 kgm)
B B 3rd step: 90 – 120°
M12 bolt
A
0 6 2 3 7
D A
Crankshaft Journal and Bearing Clearance
C B
(with plastigage)
• Clean the cylinder block and lower crankcase, the 9 5 1 4 8
journal bearing fitting surface, and the journal
bearings.
• Install the bearings to the cylinder block and lower
crankcase.
• Reassembly the lower crankcase to the cylinder
block.
012EY00027
• Cut the plastigage same wide of crankshaft journal
and put it on the crankshaft journal. • Carefully disassembly the lower crankcase from
• Apply molybdenum disulfide grease to the M18 the cylinder block.
bolts and apply engine oil to the M12 bolts thread • Measure the width of plastigage by the scale which
and it seat. printed on the plastigage envelop.
• If the clearance between the crankshaft journal
and bearing exceeds the specified limit, the
crankshaft must be replaced.
Crankshaft journal and bearing clearance
No. 4 journal
Standard: 0.081 – 0.144 mm (0.0032 – 0.0057 in.)
Limit: 0.16 mm (0.0063 in.)
Others
Standard: 0.051 – 0.114 mm (0.0020 – 0.0045 in.)
Limit: 0.16 mm (0.0063 in.)
015EY00111
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 96
Crankshaft Tufftriding Judgment

• Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty
seconds, the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color of copper), the crankshaft
must be replaced.
• Steam clean the crankshaft surface immediately
after completing the test.
NOTE: the ammonium cuprous chloride solution is
highly corrosive. Be cause of this, it is imperative that the
surfaces being tested by cleaned immediately after
completing the test.
015EY00112
Crankshaft Tufftriding Inspection

• Use an organic cleaner to thoroughly clean the
crankshaft.
There must be not traces of oil on the surface to be
inspected.
• Prepare a 5 – 10% solution of ammonium cuprous
chloride (dissolved in distilled water).
• Use a syringe to apply the solution to the surface to
be inspected.
Hold the surface to be inspected perfectly
horizontal to prevent the solution from running.
NOTE: Do not allow the solution to come in contact with
the oil ports and their surrounding area.
The portion to be tested

must be held horizontally Test liquid should
so as not to let the test not be applied to
solution flow. the area around the
oil port.
The sliding surface
of the pin
or journal.
Approximatery
10mm (0.4in)
015EY00113
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 97
Reassembly
Legend
(1) Crankshaft
(2) Bearings
(3) Crankshaft gear
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 98
1. Install the crankshaft gear to the crankshaft.

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

Install the crankshaft bearings and thrust bearings.
Refer to “Crankshaft” in this section.
3. Install the crankshaft to the cylinder block.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 99
Crank Pulley
Disassembly
015EY00114
Legend
(1) Crank pulley
(2) Crankshaft damper
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 100
1. Loose the crankshaft pulley fixing bolts to Inspection

disassemble the crank pulley.
Visually inspect the crankshaft damper for cracking or
separation.
015EY00096
2. Loose the fixing bolts to disassemble the crankshaft

damper.
Reassembly
1. Install the crankshaft damper.
• Install the crankshaft damper to the crankshaft,
and two grooves face to the front side.
• Tighten the bolts in numerical order to the specified
torque shown in the illustration.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 101
2. Install the crank pulley.

• Apply engine oil to the threads of fixing bolts.
• Set the crank pulley to the crankshaft damper.
• Tighten the bolts in numerical order to the specified
torque shown in the illustration.
015EY00096
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 102
Flywheel
Disassembly
015EY00115
Legend
(1) Ring gear
(2) Flywheel
(3) Washer
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 103
1. Loose the fixing bolts to remove flywheel from the Reassembly

crankshaft.
2. Put the flywheel with ring gear on the wood piece, 1. Heat the ring gear evenly with a burner to invite
and strike around the edges of the ring gear with a thermal expansion.
hammer and brass bar to remove it. Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
2. Install the ring gear to the flywheel when it is
sufficiently heated.
The ring gear must be installed with the chamfer
facing the flywheel.
WARNING: Take care not to burn yourself on the
heated ring gear.

1. Visually inspect the flywheel for cracking, scratching
or worn out.
2. Visually inspect the ring gear for damage.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 104
Cylinder Block
Disassembly
3
2
012EY00029
Legend (4) Oil pressure switch

(1) Oil relief valve (5) Oil jet
(2) Cylinder liner (6) Lower crankcase
(3) Cylinder block
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 105
1. Remove the lower crankcase. Inspection and Repair

• Loosen the fixing bolts to disassemble the lower
crankcase. Make the necessary adjustment, repairs, and part
replacement if excessive wear or damage is discovered
• Put it on the wood plate or piece.
during inspection.
2. Remove the oil jet.
Loosen the bolt to disassemble the oil jet. Cylinder Block Flatness
NOTE: Take care do not bend or damage the oil jet. • Remove the cylinder liners.
3. Remove the cylinder liner. • Visually inspect the cylinder block any cracking or
• Use a scraper to remove carbon deposit. damage and the oil and/or water holes for choking.
• Use a cylinder bore dial indicator to measure the If possible it is required to specially inspect by dye
cylinder bore at measuring point in the thrust and penetrant flaw detector.
axial direction of the crankshaft.
Measuring point: 20 – 25 mm (0.79 – 1.0 in.)
the cylinder liner must be replaced.
Cylinder liner bore
Limit: 147.3 mm (5.7992 in.)
NOTE: If the inside of the cylinder liner is scored or
scratched, the cylinder liner must be replaced.
20∼
25mm
• Use a straight edge (1) and a feeler gauge (2) to

measure upper face warpage of the cylinder block
on the four sides and two diagonals of upper face
Upper face warpage
Standard: 0.075 N·m (0.0030 in.) or less
Limit: 0.2 mm (0.008 in.)
4. Visually inspect the cylinder block for damage. the cylinder block must be replaced.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 106
20∼
25mm
012EY00030
• Inspect water leakage to apply water pressure in Cylinder Liner Grade Selection and
the cylinder body water jacket.
Standard Fitting Interference
Water Pressure: 490 kPa (5 kg/cm2)
Accurately measured fitting interference and proper
If water leakage is fund, the cylinder block must be cylinder liner grade selection are extremely important.
replaced. If the cylinder liner fitting interference is too small,
engine cooling efficiency will be adversely affected.
Cylinder Liner Bore If the cylinder liner fitting interference is too large, it will
• Use a scraper to remove carbon deposit. be difficult to insert the cylinder liner into the cylinder
• Use a cylinder bore dial indicator to measure the block.
cylinder bore at measuring point in the thrust and A mark was stamped on the right side of the cylinder
axial direction of the crankshaft. block during production to indicate the correct liner.
Measuring point: 20 – 25 mm (0.79 – 1.0 in.) The liner grade (1, 2, 3) is indicated in metal stamp.
Cylinder liner grade
Cylinder liner bore
Limit: 147.3 mm (5.7992 in.) Line Cylinder Bore Service Liner Outside
Grade Diameter mm (in.) Grade Diameter mm (in.)
the cylinder liner must be replaced. 151.600 – 151.610 151.590 – 151.599
1 1X
NOTE: If the inside of the cylinder liner is scored or (5.9685 – 5.9689) (5.9681 – 5.9685)
scratched, the cylinder liner must be replaced. 151.611 – 151.630 151.600 – 151.610
2·3 3X
(5.9689 – 5.9697) (5.9685 – 5.9689)
The cylinder liner grade is stamped on the outside of the

cylinder liner.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 107
Lower Crankcase
Visually inspect the lower crankcase for cracking or
damage.
If possible it is required to specially inspect by dye
penetrant flaw detector.
Liner outside
Grade No.
012EY00020
Oil Jet
Check the oil port on the oil jet for choking.
Grade No.
012EY00021
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 108
Relief Valve
Inspect the relief valve for choking.
012EY00031
Cylinder Liner Projection

• Use a dial indicator or a straight edge and feeler
gauge to measure the cylinder liner projection.
Cylinder liner projection
Standard: 0.05 – 0.09 mm (0.0020 – 0.0035 in.)
The difference in the cylinder liner projection height
between any adjacent cylinders must not exceed
limit.
Projection height between adjacent cylinder:
0.02 mm (0.0008 in.) or less
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 109
Reassembly
3
2
012EY00029
Legend (4) Oil pressure switch

(1) Oil relief valve (5) Oil jet
(2) Cylinder liner (6) Lower crankcase
(3) Cylinder block
.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 110
1. Install the cylinder liner into the cylinder block.

• Use new kerosene or diesel fuel to thoroughly
clean the cylinder liner and bore.
• Use compressed air to brow-dry cylinder liner and
bore surface.
WARNING: Pressure air can cause personal injury
when using pressure air for cleaning. Wear safety
glasses and protection clothing.
NOTE: All foreign materials must be carefully removed

from the cylinder liner and the cylinder bore before
installation.
• Apply engine oil to outside surface cylinder liner.
• Install the cylinder liner into the cylinder block from
the top of the cylinder block by your hand.
• Check cylinder liner projection.
NOTE:
1) Do not apply unreasonableness stress or hit the
cylinder liner during installing.
2) Take care to not remove the cylinder liner when 2. Install the oil jet to the cylinder block.
cylinder block turns over. Tighten to the specified torque.
Be sure direction of the oil jet tip to cooling hole of
piston.
Do not bend or damage the oil jet.
3. Install the crankshaft to the cylinder block.

4. Install the lower crankcase.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 111
5. Install the oil relief valve.

• Apply engine oil to the relief valve assembly with
new gasket.
• Install the relief valve to the cylinder block to the
specified torque.
012EY00032
6. Install the oil pressure unit.

• Install the adapter with new gasket to the cylinder
block to the specified torque.
012EY00033
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 112
MEMO
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 1
ENGINE COOLING 6B–1
ENGINE COOLING
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6B-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6B-5
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Service precaution
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 2
6B–2 ENGINE COOLING
General Description
Coolant Flow Chart
Cylinder
Head
Air
Radiator
Thermostat Water Pump Oil Cooler Cylinder Compressor

Body (If equiped)
030EY00017
Cooling Flow Thermostat

The cooling system main parts consist of the radiator, A wax pellet type thermostat is used.
the water pump, the water outlet pipe and the
thermostat.
This top-bypass type cooling system controls the cooling
water temperature though the thermostat installed at the
water pump inlet.
The system maintains optimum cooling water volume
and minimizes cooling water temperature fluctuation
and hunting.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 3
Water Pump
Water Pump Exploded View
12
11
10
9
3
030EY00008
Legend (7) Gasket

(1) Rear cover (8) Shaft
(2) Bearing (9) Seal unit
(3) Gear (10) Impeller
(4) Bearing (11) Joint pipe
(5) Oil seal (12) Front cover
(6) Pump body
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 4
Disassembly • Use the bench press the rear cover side to

disassemble the bearings (1) and gear (2).
1. Loosen the rear cover fixing bolts to remove the front
cover.
2. Use the impeller remover (1) 1-8521-0062-0 to
remove the impeller from the shaft.
2
1
030EY00010
8. Remove the oil seal (1).

9. Remove the seal unit (2).
030EY00009 NOTE: Do not make scratch or damage seating surface
of the oil seal and the seal unit on the pump body when
3. Remove the rear cover. disassemble them from the pump body.
4. Remove the small bearing.
5. Remove the gear.
6. Remove the large bearing.
7. Remove the shaft.
• Use bench press from the impeller side to 2
disassembly the shaft with the bearings and the
gear.
030EY00011
10. Remove the pump body.

69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 5
Inspection and Repair 3. Inspect the shaft for damage or worn out.
Make the necessary adjustments, repair and part

replacement if excessive or damage wear is discovered
during inspection.
1. Inspect the impeller for corrosion and the seal unit for
worn out touching surface or some damage.
030EY00012
Reassembly
1. Install the oil seal to the pump body.
• Apply engine oil to inside and outside of the oil
seal.
2. Inspect the bearings. • Seal lip face to upper and carefully press fit the oil
seal to the pump body.
• Wash bearing in the clean kerosene.
• Visually check scratches or damages on the ball
and bearing race.
• Rotate the bearing on your hand for hearing
abnormal noise.
• Check abnormal clearance between the ball and
bearing race.
2. Install the large bearing to the shaft.

• Apply engine oil to the shaft.
• Use a bench press to press the large bearing onto
the shaft.
• Use a bench press to press the shaft with large
bearing into the pump body.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 6
030EY00013
4. Use the bench press to gradually press the bearing

small (1) into the rear cover.
1
3. Install the gear on the shaft.
• Place the gear long boss side facing to bearing 030EY00014
large on the shaft. 5. Install the rear cover.

• Use a bench press to press the gear onto the shaft • Use a bench press to install the rear cover
as shown in the illustration. assembly into the shaft shown in the illustration.
• Same time align bolt holes between rear cover
and pump body.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 7
030EY00016
6. Use seal unit installer (1) 1-8522-0047-0 to install the 8. Set the gasket to the pump body.
seal unit (2). 9. Install the front cover.
• Align bolt hole together with rear cover assembly.
• Tighten the bolt from rear cover side to the
specified torque.
1
2
030EY00015
7. Use the bench press to gradually press the impeller

(1) until make specified clearance between the
impeller and pump body (2).
Clearance between impeller and pump body
Standard: 1.7 – 2.7 mm (0.0669 – 0.1063 in.)
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 8
Thermostat
Disassembly
4
5
031EY00012
Legend (4) Thermostat housing

(1) Seal ring (5) Gasket
(2) Thermostat (6) Temperature switch
(3) Gasket
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 9
1. Loosen the fixing bolts to remove the thermostat

housing.
Discard the gaskets.
2. Remove the thermostat housing.
• Carefully remove the thermostat from the oil
cooler case.
3. Remove the seal ring.
• Loosen the seal ring puller 1-8521-0067-0 to take
out the seal rings.
2
replacements if excessive or damage wear is
1. Visually inspect leakage of wax pellet, some damage
of the spring or caulking position on the thermostat.
2. Perform the operating test.
Completely submerge the thermostat in water. 031EY00013
Heat the water.

Stir the water constantly to avoid direct heat being
applied to the thermostat.
Measure the thermostat initial opening temperature.
Thermostat initial opening temperature 79°C (174°F)
Measure the thermostat full opening temperature.
Thermostat full opening temperature 95°C (203°F)
Measure the valve lift at the thermostat full open
position.
Valve lift at full open position: 11 mm (0.433 in.)
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 10
Reassembly
1. Use the seal ring installer 1-8522-1034-0 to install
the seal ring to the oil cooler case, as the direction of
seal ring shown in the illustration.
4. Install the temperature switch on the portion “A” of

the thermostat housing.
031EY00016
2. Carefully install the thermostat to oil cooler case

031EY00015
3. Install the thermostat housing with new gaskets.

• Set the gasket to the thermostat housing to install
the thermostat housing with the new gasket.
• Pushing the thermostat housing to oil cooler case,
initially tighten the water pump side bolts then
tighten the oil cooler side bolts to the specified
torque.
Bolt Torque: 39 N·m (4.0 kgm)
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 1
ENGINE FUEL 6C–1
ENGINE FUEL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Calibration Data. . . . . . . . . . . . . . . . . . . . . . . . . 6C-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Injection Nozzle Holder – Two-Stage
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6C-6 Injection Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-17
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-6 Nozzle and Holder Specification . . . . . . . . . . . . 6C-17
Injection Nozzle Holder . . . . . . . . . . . . . . . . . . . . . 6C-7 Reassembly and Opening Pressure
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-7 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6C-8
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-10
Service precaution
systems.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 2
6C–2 ENGINE FUEL
General Description
Fuel System Operation When working on the fuel system, there are several
things to keep in mind:
The engine crankshaft drives the fuel injection pump
• Any time the fuel system is being worked on,
which in turn, drives the fuel feed pump.
disconnect the negative battery cable except for
The fuel feed pump draws fuel from the fuel tank,
those tests where the battery voltage is required.
through the fuel/water separator and transfers it, by way
of the secondary fuel filter, into the injection pump. The • Always keep a dry chemical (Class B) fire
governor regulates the flow of fuel to the delivery valves. extinguisher near the work area.
At the correct timing intervals a plunger in the injection • Always relieve the line pressure before servicing any
pump sends fuel, at high pressure, through a delivery fuel system components.
valve to one of the fuel injection nozzles. • Do not attempt repair on the fuel system until you
Fuel pressure causes a needle valve in the fuel injection have read the instructions and checked the pictures
nozzle to open. Fuel is then injected through injection relating to the repair.
nozzle holes into the cylinder in a fine spray.
Excess fuel is directed back to the fuel tank by means of
the fuel return lines.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 3
ENGINE FUEL 6C–3
Fuel Flow Diagram
040EY00031
The fuel system consists of the fuel tank, the water Fuel Filter
sedimentor, the fuel filter, the injection pump, and the
The purpose of the fuel filter is to clean the fuel in any
injection nozzle.
dirt particles that can cause wear on the fuel injection
The fuel from the fuel tank passes through the water
nozzle’s sliding surface. The water separator is located
sedimentor and the fuel filter where water particles and
between the fuel tank and the fuel feed pump.
other foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to Fuel Feed Pump
the injection nozzle in the metered volume at the
optimum timing for efficient engine operation. The fuel feed pump draws fuel from the fuel tank to the
fuel filter. It delivers the fuel, under pressure, to the
Water Sedimentor injection pump through fuel filter.
An independent priming pump permits manual fuel feed
When the condensed water in the water sedimentor
while the engine is not running.
comes to the warning level indicated on its plastic body,
drain the water immediately from the drain plug located
bottom of water sedimentor.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 4
6C–4 ENGINE FUEL
Injection Pump
Major components of the injection pump are the pump
body and plunger unit, the governor, the timing advancer
and the feed pump.
An aneroid compensator is available as an option.
The injection pump is the nucleus of the diesel engine
fuel system. It pressurizes and delivers a metered
volume of fuel to the engine cylinders at the optimum
time for the current engine load and speed.
The injection pump plungers are pushed up by cam
lobes. They are returned to their original position by the
plunger springs. This action creates a reciprocal motion.
The plunger barrel receives fuel from the feed pump and
filter through its inlet port when the injection pump
plunger is on the down stroke.
Surplus fuel is delivered to the injection pump fuel
chamber through the plunger outlet port when the
plunger is on its up stroke.
The injection pump has an identification plate attached
to the pump body.
Governor
The injection pump is equipped with a RSV type,
variable speed governor.
Diesel engine operating speed and load will very widely
during the course of normal driving.
If the engine speed falls too low, the engine may run
sluggishly or stall. If the engine speed becomes too high,
the engine overrun will result.
The governor acts to maintain engine speed within
acceptable limits, thus protection against engine stall
and/or overrun.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 5
ENGINE FUEL 6C–5
Fuel Filter
Disassembly
Legend
(1) Fuel filter
(2) Overflow valve
(3) Fuel filter body
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 6
6C–6 ENGINE FUEL
1. Remove the fuel filter with using the filter wrench. Reassembly
CAUTION: Be careful not to spill out the fuel
remaining in the fuel filter when the filter is removed. 1. Install the overflow valve to the fuel filter body.
2. Install the fuel filter.
• Before installating a new fuel filter, apply fuel to
the gasket.
• Turn the new fuel filter until the filter gasket comes
in contact with its sealed face.
• Use a filter wrench to turn in the fuel filter by
additional 1/2 – 3/4 of a turn.
040EY00007
2. Remove the overflow valve.

3. Remove the fuel filter body.

Inspection the overflow valve for restriction or leak.
Overflow valve opening pressure 280 – 310 kPa
(40 – 46 psi).
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 7
ENGINE FUEL 6C–7
Injection Nozzle Holder

Disassembly
4
6
3
2
7
8
9
10
1
040EY00032
Legend (6) Nozzle holder body

(1) Retainer nut (7) Adjusting shim
(2) Nozzle (8) Spring
(3) Nozzle holder pin (9) Pin
(4) Spring seat (10) Spacer
(5) Gasket
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 8
6C–8 ENGINE FUEL
1. Remove the retaining nut. CAUTION:

• Clamp the injection nozzle holder in a vice. 1. Wash all the part removed and arrange them on a
• Use a wrench to remove the injection nozzle cylinder basis, care should be taken not to miss
retainer nut. any parts.
2. Soak the nozzle assembly in a parts receptacle
filled clean diesel fuel.
3. Care should be taken not to miss shim, if used.

Retaining Nut
Inspect the retaining nut for any wear or corrosion.
2. Remove the nozzle from the nozzle holder.

• Keep the nozzle along with the needle valve
separately to maintain the original nozzle to
needle valve combination.
• Clean the nozzle in the clean diesel fuel.
Injection Nozzle Needle Valve

1. Remove the needle valve from the nozzle body.
2. Carefully wash the nozzle needle and the nozzle
body in the clean diesel fuel.
3. Check that the nozzle needle moves smoothly inside
the nozzle body.
If the nozzle does not move smoothly, it must be
repaired (See “Nozzle Lapping Procedure”) or
replaced nozzle assembly.
3. Remove the nozzle holder pin, spacer,spring seat,

spring and adjusting shim from the nozzle holder.
Keep the adjusting shims in the original groups to
hold the initial shim to the nozzle spring combination.
4. Remove the nozzle holder body.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 9
ENGINE FUEL 6C–9
Spring Nozzle Lapping Procedure

Inspect the spring for any wear, fell and corrosion. 1. Lap the nozzle needle (1), and the nozzle body (2) by
applying a compound of oxidized chrome with animal
oil.
NOTE: Do not apply an excessive amount of the
oxidized chrome with animal oil compound to the
injection needle valve seat area.
2. Carefully wash the needle valve and the nozzle body
in clean diesel fuel after lapping.
040EY00033
Nozzle Body and Needle Valve 2 1
Check the nozzle body and the needle valve for damage
and deformation.
The nozzle and body assembly must be replaced if
either of these two conditions are discovered during
040EY00034
inspection.
NOTE: New nozzles must be cleaned in a solvent to
remove protective coating. The nozzle body and needle
must always be replaced as an assembly.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 10
6C–10 ENGINE FUEL
Reassembly
4
6
3
2
7
8
9
10
1
040EY00032
Legend (6) Nozzle holder body

(1) Retainer nut (7) Adjusting shim
(2) Nozzle (8) Spring
(3) Nozzle holder pin (9) Pin
(4) Spring seat (10) Spacer
(5) Gasket
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 11
ENGINE FUEL 6C–11
1. Install the locating pin to the nozzle holder body. Adjustment of Injection Nozzle Opening
2. Install the adjusting shim, spring and spring seat into Pressure
the nozzle holder body.
After reassembling the injection nozzle, recheck the
3. Install the spacer to the nozzle holder body over the opening pressure and spray condition.
locating pin. With the nozzle holder set to the nozzle tester, adjust the
4. Install the locating pin to the nozzle. pressure with an adjusting shim so that the pressure
5. Install the nozzle to the nozzle holder. becomes equal to the specified injection nozzle opening
pressure.
Injection nozzle opening pressure: 20.1 MPa
(2920 psi)
An adjusting shim of 0.007 mm (0.0003 in.) allows the
press to change by about 100 kPa (14.2 psi).
The adjusting shim thickness calculation method as
follows.
WARNING: The test fluid from the injection nozzle
tester will spraying out of the injection nozzle under
great pressure. It can easily puncture a person’s
skin. Keep your hands away from the injection
nozzle at all times.
The adjusting shim thickness calculation method.

P × π/4 × (A2 – B2)
= Additional shim thickness (mm)
C × 100
P (kPa) = (Target injection nozzle opening pressure

– Indicated value (pressure) of nozzle
6. Install the retaining nut tester)
• Clamp the injection nozzle holder in a vice. A (cm) = Needle diameter. 0.6 cm
• Tighten the retaining nut to the specified torque. B (cm) = Sheet diameter. 0.3 cm
C (N/mm) = Spring constant. 264.0 N/mm
7. Install the new gasket to the nozzle holder.

69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 12
6C–12 ENGINE FUEL
Adjusting Shims
After calculates shim thickness to select shims from
below list.
mm
Thickness Part number
0.50 5-15339-007-0
0.52 5-15339-018-0
0.54 5-15339-019-0
0.56 5-15339-020-0
0.58 5-15339-021-0
0.60 5-15339-008-0
0.70 5-15339-009-0
0.80 5-15339-010-0
0.90 5-15339-011-0
1.00 5-15339-012-0
0.10 8-94128-982-0
0.20 8-94128-983-0
0.30 8-94128-984-0
0.40 8-94128-985-0
Spray Pattern
Check the spray condition to shown in the illustration.
If the spray conditions is not suitable pattern, the
injection nozzle must be replaced or readjusted.
1 2 3
040EY00030
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 13
ENGINE FUEL 6C–13
Injection Pump
Identification
1. It is important that you refer to the injection pump
assembly number on the identification plate to
determine the applicable calibration data in this
section for the injection pump being serviced.
2. In the event this section does not contain calibration
data applicable to the injection pump being serviced,
contact the nearest manufacturer’s authorized
service facility (Bosch Automotive System Corp. or
Robert Bosch GMBH).
3. Refer to the Isuzu Injection Pump Assembly Number
stamped on the injection pump assembly
Identification Plate to order a replacement injection
pump.
MADE IN
JAPAN
ISUZU part number

ZEXEL pump assembly number
F06HV015
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 14
6C–14 ENGINE FUEL
Injection Pump Calibration Data

Test Conditions
Injection nozzle ZEXEL No. 105780-0000

Injection nozzle holder ZEXEL NO. 105780-2080
Injection starting pressure 17.2 MPa
Injection line dimensions Inside diameter = 3 mm
Outside diameter = 8 mm
Length = 600 mm
Transfer pump pressure 255 kPa
Test diesel fuel ISO4113 or SAE standard test oil (SAEJ967d)
Fuel temperature 39 – 41°C (109.2 – 114.8°F)
Pump rotation Clockwise viewed from the drive side
Overflow valve opening pressure 255 kPa (2.6 kg/cm2 / 37.0 psi)
CAUTION:
Strictly observe the above test conditions during injection pump fuel injection volume adjustment.
Failure to observe the test conditions will result in misadjustment of the injection pump fuel injection volume.
Misadjustment of the fuel injection volume will result in serious engine damage.
Injection Timing
Pre-stroke 5.6 ± 0.05 mm (0.220 ± 0.01 in.)

Injection order and interval 1–5–3–6–2–4
Plungers are numbered from the drive side.
Tappet clearance Manually rotate the camshaft several times to make
sure that it rotates smoothly.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 15
ENGINE FUEL 6C–15
Injection Volume and Governor Performance Diagram

6WG1TQA
Injection Pump Assembly Number
ISUZU No. ZEXEL No. Remarks ISUZU No. ZEXEL No. Remarks
1-15603-341-0 106671-6440
Injection Volume
Control rack Pump speed Injection volume Variance Boost pressure
Remarks
position (mm) (min–1) (mm3/1,000 strokes) (%) (kPa)
11.9 900 221 ± 2 ±3 more than 128 Basic
6.6 450 9 ± 3.2 ± 13

69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 16
6C–16 ENGINE FUEL
Governor Performance
NOTCH ; 5
RACK LIMIT
14.0
IDLING SUB SPRING SET
RACK POSITION (mm)

E BOOST COMPENSATION
12.7±0.1 STROKE : 0.8±0.1mm
11.9 B A
10.2 D
350
7.2 GOVERNOR SPRING SET
6.7
6.6 C
0 +25
250 450 900 +15 1000±15
(420)
PUMP SPEED (min-1)
040EY00039
Speed Control Lever and Stop Lever
※ SPEED LEVER STOP LEVER
IDLE~STOP
18
°±
5° °
°± 5 ±5
°
19 STOP
53°
5°
13° °±
± 3° 22
5°
70°±
STOP FULL SPEED NORMAL
IDLING
040EY00036
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 17
ENGINE FUEL 6C–17
Injection Nozzle Holder – Two-Stage Injection Type

Nozzle and Holder Specification
ITEMS 6WG1
Injection nozzle & holder assembly type KBL2.4/S, two-spring
Injection nozzle type Hole
Number of injection nozzle orifices Eight holes
Orifices diameter mm (in) 0.24 (0.0094)
Opening pressure MPa (kg/cm2 / psi) 1st stage 17.7 (180/2,560)
2nd stage 22.1 (225/3,200)
Nozzle needle valve full-lift mm (in) 0.32 (0.0126)
Nozzle needle valve pre-lift mm (in) 0.06 (0.0024)
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 18
6C–18 ENGINE FUEL
Reassembly and Opening Pressure Adjustment
15
7
14
8
1 9
10
11
12
4
13
040H100004
Legend (8) Shim (Second opening pressure adjustment)

(1) Nozzle holder body (9) Spring seat
(2) shim (First opening pressure adjustment) (10) Lift piece
(3) First spring (11) Spacer & pin
(4) Spring seat (12) Nozzle & pin
(5) Collar (13) Retaining nut
(6) Second spring (14) Gasket
(7) Push rod (15) Eye bolt
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 19
ENGINE FUEL 6C–19
Adjustment Procedure
As adjustment of the two-stage injection type nozzle holder is made in hundredths of a millimeter, clean the parts
thoroughly in light oil to completely remove any dirt or foreign matter.
1 First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim.
2 Full needle valve lift confirmation Confirm the full needle valve lift in accordance with the closed
method.
3 Pre-lift confirmation Confirm pre-lift in accordance with the closed method.

CAUTION:
If not as specified, replace the nozzle assembly, lift piece,
pins and spacer using the nozzle service kit.
4 Second nozzle opening pressure Confirm the second nozzle opening pressure in accordance with
confirmation the closed method.
5 Second nozzle opening pressure

Adjust the second nozzle opening pressure using the shim.
adjustment
6 Final inspection Confirm the condition of the fuel spray with the nozzle and nozzle
holder assembled.
Adjustment Service Data
Nozzle needle valve full-lift 0.32 mm (0.0126 in)

Nozzle needle valve pre-lift 0.06 mm (0.0024 in) at 18.7 MPa (190 kg/cm2, 2,700 psi)
Nozzle pressure 1st stage 17.7 MPa (180 kg/cm2, 2,560 psi)
2nd stage 23.0 – 24.0 MPa (235 – 245 kg/cm2, 3,340 – 3,480 psi)
at lift 0.11 mm (0.0043 in) = (pre lift + 0.05 mm (0.0020 in))
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 20
6C–20 ENGINE FUEL
First Nozzle Opening Pressure Adjustment 3. Install the collar, second spring, shim, spring seat
and pushrod in the nozzle holder.
1. Clamp the nozzle holder in a vise.
Second nozzle opening pressure

Nozzle holder body adjusting shim Push rod
Second spring
Collar
Spring seat
040MV017
040MV015
4. Install the pins, lift piece and spacer in the nozzle

2. Install the shim, first spring and spring seat in the
holder.
nozzle holder.
Spring seat Spacer

Lift piece
First spring
Pin
First nozzle opening pressure
adjusting shim
040MV018
040MV016
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 21
ENGINE FUEL 6C–21
5. Install the pins in the spacer. 8. Tighten the adjustment retaining nut to the specified
6. Install the nozzle on the spacer. torque.
Torque: 34 N·m (3.5 kg·m / 25 lb·ft)
Nozzle
Torque wrench
Pin
Retaining nut
(special tool)
040MV019
040MV014-1
7. Hand-tighten the adjustment retaining nut together
with the gasket to the nozzle holder. 9. Set the nozzle holder to the nozzle tester.
Retaining nut: 157892-4000 (★Bosch AS) 10. Operate the nozzle tester and measure the first
5-86777-145-0 (ISUZU) nozzle opening pressure.
Gasket: 157892-1500 (★Bosch AS) 11. If the first nozzle opening pressure is not as
specified, disassemble the nozzle holder and
5-86777-146-0 (ISUZU)
replace the shim until the pressure is as specified.
(★Bosch Automotive Systems Corporation)
Nozzle tester
Nozzle holder
Retaining nut
(Special tool) Nozzle
Gasket
040MV030
040MV010
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 22
6C–22 ENGINE FUEL
CAUTION: Full needle valve lift confirmation

• Use a micrometer to measure shim thickness.
1. Install the gasket and plug on the adjustment
• Use some combination of 3 adjusting shims to retaining nut.
adjust the pressure.
Gasket: 026508-1140 (Bosch AS)
• First nozzle opening pressure adjusting shims
894227-6020 (ISUZU)
mm (in)
Plug: 157892-1600 (Bosch AS)
Part No. Thickness
5-86777-141-0 (ISUZU)
115349-1120 0.40 (0.0157)
115349-1130 0.50 (0.0197)
115349-1140 0.52 (0.0205)
115349-1150 0.54 (0.0213)
115349-1160 0.56 (0.0220)
Plug
115349-1170 0.58 (0.0228)
115349-1180 0.60 (0.0236)
115349-1190 0.70 (0.0276)
Gasket
Thickness
040MV013
2. Position the nozzle holder with the nozzle facing

φ3.8mm down and install the dial gauge holder on the nozzle
holder.
φ8.9mm
Dial gauge holder: 157892-5000 (Bosch AS)
586777-1420 (ISUZU)
040MY00023
Holder (special tool)
040MV012
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 23
ENGINE FUEL 6C–23
3. Install the nut on the dial gauge holder. 5. Secure the dial gauge to the nozzle holder using the
Nut: 157892-1000 (Bosch AS) nut so that the pin contacts the tip of the first spring
seat.
586777-143-0 (ISUZU)
CAUTION:
• Secure the dial gauge so that a stroke of 2 mm
(0.0787 in) can be measured.
• Do not over-tighten the nut as the dial gauge
shaft may jam. (Confirm from the dial gauge
Nut (special tool) that the shaft moves smoothly.)
Holder (special tool)
Dial gauge
Nut
Holder
Pin
040MV011
4. Install the pin to the dial gauge.

Note: The lengths of the pins do not include the threaded
Nozzle holder
portions.
Pin (l = 86 mm): 157892-6400 (Bosch AS)
Dial gauge: 157892-3800 (Bosch AS) First spring seat
(General type)
Dial gauge Pin
040MV009
040MV029
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 24
6C–24 ENGINE FUEL
6. Set the nozzle holder to the nozzle tester and put Pre-lift confirmation
needle to zero on the dial gauge.
1. With the needle valve at full lift, release the nozzle
7. Operate the nozzle tester to bleed any air from inside tester handle.
the retaining nut and to confirm that no fuel leaks.
Note: The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
Nozzle tester
Nozzle holder
300
200
100 400
0 500
kgf／cm2
Pressure gauge
040MV030
8. Operate the nozzle tester and increase the in-line

pressure to 34.3 – 44.1 MPa ( 350 – 450 kg/cm2 / 040MV007
4977 – 6399 psi) so that the nozzle’s needle valve

moves through its full lift.
Record full lift ‘L’. (Rear dial gauge)
Nozzle Holder Assy: 115300-3722 (ISUZU)
Nozzle full lift: 0.32 ± 0.02 mm (0.0126 ± 0.0008 (mm)
L
in)
Note: The above operation is used to determine whether
Needle Valve lift
the nozzle seat is worn and whether the nozzle

assembly is in good condition.
(MPa)
17.7 22.1
L In line pressure
Needle Valve lift
040H100006
0 First nozzle 34.3∼44.1MPa

opening pressure {350∼450kgf/cm 2 }
In line pressure
040MV008
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 25
ENGINE FUEL 6C–25
2. Read the needle valve lift ‘l’ from the dial gauge 4. If pre-lift is not as specified, replace the pins, lift
indication (once the needle valve has descended piece, spacer and nozzle assembly as a set with the
when the second spring has stopped operating). service kit.
Refer to the pre-lift measuring point for ‘l’. Service kit; Bosch AS: 105019-2310
Pre-lift measuring point: Service kit; ISUZU: 115319-007-1
Read the dial gauge at first nozzle opening pressure
+approx 1 MPa (10 kg/cm2).
Pre-lift: 0.06 m (0.0024 in.) at pressure 18.6 MPa
(190 kg/cm2/2700 psi)
Note: This point can be found while the pressure is
decreasing.
Pin
Lift piece
Spacer
Capsule
L
Measuring point
of prelift Nozzle
Needle valve lift
assembly
0 040HV031
First nozzle
opening pressure
confirmation
1. After pre-lift confirmation, operate the nozzle tester
040H100007
to increase in-line pressure to 34.3 – 44.1 MPa (350
– 450 kg/cm2 / 4977 – 6399 psi) so that the nozzle’s
needle valve moves through its full lift.
Pushrod Second spring

Nozzle tester
Spring seat Adjusting shim Nozzle holder
Spacer
Lift piece
Needle valve
040MV005
040MV030
3. Confirm that pre-lift ‘l’ is as specified.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 26
6C–26 ENGINE FUEL
2. Release the nozzle tester handle so that in-line Second nozzle opening pressure
pressure decreases. adjustment
Note: The in-line pressure will decrease and needle
If the second nozzle opening pressure is not as
valve lift (as indicated on the dial gauge) will also
specified, disassemble the nozzle from the nozzle
decrease a little.
holder and replace the shim until the pressure is as
specified.
CAUTION:
• Because the second opening pressure changes
when the first opening pressure changes, the
L second opening pressure must be adjusted
Needle valve lift(mm)
when the first opening pressure changes.

• Use some combination of 3 adjusting shims to
adjust the pressure.
+0.05 • Use a micrometer to measure shim thickness.
0
Second nozzle 34.3-44.1MPa
opening pressure (350-450kg/cm2)

adjusting shim Push rod
Second spring
040H100008
Collar
3. Then, read the pressure gauge indication (second Spring seat
nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift
(usually pre-lift l + 0.05 mm (0.002 in)).
Second nozzle opening pressure: 23.0 - 24.0 MPa
(235 - 240 kg/cm2/3340 - 3480 psi) at lift 0.11 mm
(0.0043 in)
040MV017
• Second nozzle opening pressure adjusting shims

mm (in)
When needle valve lift is
+ 0.05mm Part No. Thickness
90
10
115349-1200 0.40 (0.0157)
80
20 115349-1210 0.50 (0.0197)
70 115349-1220 0.52 (0.0205)
30
115349-1230 0.54 (0.0213)
60
40
50 115349-1240 0.56 (0.0220)
Full needle valve lift
115349-1250 0.58 (0.0228)
Dial gauge
115349-1260 0.60 (0.0236)
115349-1270 0.70 (0.0276)
040H100005
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 27
ENGINE FUEL 6C–27
2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins
are inserted fully into the nozzle, and then hand-
tighten the retaining nut. Then, tighten the original
retaining nut to the specified torque.
Torque: 69 N·m (7.0 kg·m / 51 lb·ft)
Thickness
φ4.8mm
Torque wrench
φ9.9mm
Retaining nut
040MY00024 (special tool)
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV014-1
4. Set the nozzle holder to the nozzle tester and check

first nozzle opening pressure, spray condition, seat
Dial gauge
oil tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle
service kit.
Nut
CAUTION:
Dial gauge
holder Pre-lift will not be as specified if only the nozzle is
replaced.
Nozzle tester
040MV028
Nozzle holder
040MV030
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 28
MEMO
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 1
STARTING AND CHARGING 6D3–1
STARTING AND CHARGING

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . 6D3-1 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-11
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-2 General Description. . . . . . . . . . . . . . . . . . . . . 6D3-11
General Description. . . . . . . . . . . . . . . . . . . . . . 6D3-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-5 Inspection and Repair . . . . . . . . . . . . . . . . . . . 6D3-16
Inspection and Repair . . . . . . . . . . . . . . . . . . . . 6D3-7 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-18
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-8
Service precaution
systems.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 2
6D3–2 STARTING AND CHARGING
Alternator
General Description
5 6
4
7
8
1
9
10
060EY00002
Legend (6) Rotor

(1) Rear bracket (7) Bearing
(2) IC regulator (8) Pulley
(3) Bearing (9) Front bracket
(4) Rectifier (10) Field coil assembly
(5) Stator
This alternator is a brushless unit. This alternator has three terminals; a terminal-B (DC
The main components are the rotor, stator, rectifier power output terminal), terminal-L and terminal-R.
assembly, front bracket, rear bracket, IC regulator, Since terminal-L is connected to the field coil, it is an
bearings and pulley. input terminal of initial exciting current together with
The movable parts in the assembly are the rotor and terminal-R until the alternator begins to generate.
pulley. Also, it has another function of a voltage output terminal
The field coil is fixed to the rear bracket. (current output capacity is only one ampere).
To rectify 3-phase alternator in the stator coil to direct When terminal-L voltage reaches to battery voltage it
current, 6 main diodes and 2 additional diodes are used: turns the indicator lamp off.
3 main diodes are called “positive diode”, while the The bearings are sealed so that no periodic lubrication is
others are called “negative” diode. required.
Also, 3 small diodes called “diode trio” are used and the The IC regulator is a solid state unit so that it can be
field current is supplied from these diodes. serviced as an assembly.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 3
Identification MITSUBISHI IDENTIFICATION PLATE

The alternator identification plate is attached to the
alternator rear bracket. The ISUZU part number, the
manufacturer’s code number, and other important A
information are stamped on the plate.
Refer to the identification plate together with the “Main
B
Data and Specifications” Tables and accompanying C D
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 E
engine, please contact ISUZU MOTORS LIMITED
through your machine supplier.
A: Isuzu part number

B: Manufacturer’s short type name
C: System voltage output
D: Manufacturer’s lot no.
E: Bar code
Charging Circuit
ADDITIONAL B
DIODES
DIODE TRIO INDICATOR LAMP
STATOR
L
COIL
L KEY
SWITCH
R R
BATTERY
(24V)
E
FIELD
COIL
IC REGULATOR
E
ALTERNATOR
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 4
Main Data and Specifications
Isuzu Part No. 1-81200-5901

Manufacturer’s code No. (MITSUBISHI) A004T05485
Rated voltage (V) 24
Rated output (A) 50
Rated speed (min–1) 5000
Rated output at r.p.m (Amp./Volt/min–1) 50/27/5000
No-load output at 0 Amp. (Volt/min–1) 24/900
Direction of rotation as viewed Clockwise
from pulley side
Polarity grounded (–)
Pulley diameter mm (in.) 80 (3.15)
Coil resistance at 20°C
Field coil (Ω) 4.5 – 5.2
Regulator’s applicable
Isuzu part No. 1-81260-0170
Manufacturer’s code No. A866X38282
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 5
Disassembly
7
5
6
9
8
060EY00004
Legend (6) Nut

(1) IC regulator (7) Side entry terminal
(2) Terminal stud (8) Terminal stud
(3) Side entry terminal (Terminal B) (9) Tube
(4) Rectifier assembly
(5) Cap
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 6
NOTE: Before disassembling alternator, be sure to put

match marks at two locations (front bracket and rear
1
bracket) so that any possible mistake can be avoided.
1. Remove four through bolts. Pry between stator and
front bracket with the blade of a screwdriver.
Carefully separate the front bracket, pulley and rotor
assembly away from the stator and rear bracket 2
assembly.
NOTE: Do not insert screwdriver too deep, or the stator
coil will be damaged.
2. Cramp the rotor in a vice, being careful not to distort
the rotor poles (1), and remove the pulley securing
nut, pulley, fan, spacer and front bracket.
NOTE: When a vice or tool is used to secure the rotor,
be sure to hold the location “A”. Do not hold the location
“B” as it does not have enough structural strength. 3
060EY00003
7. Remove the cap and nut from the terminal stud on

Ｂ the rectifier.
Pry between the rear bracket and side entry terminal,
and remove the side entry terminal.
The tube will remain in the bracket.
NOTE: Do not loss the tube.
8. Remove the rectifier retaining screw and two IC
regulator retaining screws.
Separate the stator and rectifier assemblies, as a
ＡＡ unit, from the rear bracket.
Then remove IC regulator.
1
9. Unsolder four stator coil leads and remove the stator
from the rectifier.
NOTE: High temperature solder (Melting point of 230°C)
060EY00030
is used to secure stator coil leads to rectifier terminals.
3. If necessary to remove the front bracket bearing, Disconnect quickly, use a 180 – 280 watts soldering iron
remove four retainer screws and press the bearing more than about 5 seconds because the diode may be
out of bracket with a suitable socket. damaged if it is overheated.
NOTE: Do not remove bearing for normal service. If the
bearing is removed, the bearing must be replaced.
4. If necessary to remove the rotor bearing, remove the
bearing with a normal bearing puller.
NOTE: Do not remove bearing for normal service. If
bearing is removed, the bearing must be replaced.
5. To move the coil assembly from the rear bracket;
first, remove two screws (2) that hold the terminal
plate of coil to the IC regulator.
If the screws (2) are removed before removing
screws (3) that hold the coil assembly to the rear
bracket, the terminal plate may be broken.
While being careful not to damage the terminal plate,
hold the coil assembly by hand.
Then, remove the coil assembly by removing the
screw (3).
6. Disconnect the connector (1).
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 7
Inspections and Repair Rotor

1. Check the bearing for any scraping noise,
Stator roughness, or grease leakage (If the amount of
Visually inspect the stator for damage, a loose grease leakage is very small, wipe it away.), and
connection, or discolored windings. replace it as necessary.
1. Check for continuity between each pair of the stator It is more effective to check with the bearing fitted
coil leads (1) using a circuit tester. into the rotor shaft than to check the bearing itself
Replace the stator if there is no continuity. (with no parts mounted).
Coil Assembly
1. Measure the coil resistance between both terminals
(1) on the terminal plate (2) using an ohmmeter.
If it is not within the specification, replace the coil
assembly.
1
060EY00007
2. Check for continuity between the stator coil leads

and core using a circuit tester.
Replace the stator if there is no continuity.
060EY00005
Rectifier Assembly
1 1. Check positive diodes and positive side additional
diode for continuity between the positive heat sink
(2) and each of four diodes terminals (1) with a circuit
tester.
If there is continuity in both directions, the diode is
shorted.
Replace the rectifier assembly.
2 If there is no continuity in both directions, the diode is
open-circuit.
2. Check negative diodes and negative side additional
diode for continuity between the negative heat sink
060EY00008 (3) and each of four diodes terminals (1) with a circuit
tester. If there is continuity in both directions, the
diode is shorted. Replace the rectifier assembly.
If there is no continuity in both directions, the diode is
open-circuit.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 8
3. Using a circuit tester, check the diode trio for 3. Tightening torque.
continuity in both directions. • Pulley securing nut. : 147 N·m
If there is either continuity or open circuit in both • Through bolts. : 5.1 N·m
directions, the diode trio is defective. • Bearing retainer screws. : 3.6 N·m
Replace the rectifier assembly. • Coil assembly retaining screws. : 3.6 N·m
• Rectifier retaining screw. : 3.6 N·m
• Regulator retaining screws. : 3.4 N·m
• Nut for stud bolt. : 8.8 N·m
1
4. To assemble the rear bracket / stator assembly and
front bracket / rotor assembly.
• Since the rotor bearing and rear bracket fitting is
tight, before installing the rotor into the rear
bracket assembly, heat the area around the
bearing box of the rear bracket to 50 to 60°C.
• After the alternator has been completely
assembled, rotate the pulley slowly by hand to be
sure that the rotor turns smoothly.
Bench Test
3
2
To check the alternator on a test bench, proceed as
follows:
060EY00006 Regulated Voltage Test

1. Make connections as shown in the illustration.
Front bracket bearing Use a 0 – 100 ampere scale ammeter and a 0 – 30
Check the bearing for any scraping noise, roughness, or volt scale voltmeter.
grease leakage (If the amount of leakage is very small, Use a variable load resistor of capacity 0 – 50
wipe it away.) and replace it as necessary. ampere minimum.
It is more effective to check with the bearing fitted into 2. Close switch 1. Open switch 2.
the front bracket than to check the bearing itself (with no Lamp should light. If the lamp does not light, check
parts mounted). voltage at terminal-L.
When the voltage is nearly to battery voltage, check
Regulator the alternator.
The regulator cannot be checked with a circuit tester. When the voltage is low, the lamp or relational wiring
After the alternator has been completely assembly, the is open circuit.
unit should be tested to make certain it will control the
3. Slowly increase the alternator speed.
alternator voltage properly.
Be sure the lamp goes out until the alternator speed
reaches to approx. 1300 min–1.
Reassembly Observe the voltage.
To reassemble the alternator, follow the reverse of If the voltage is uncontrolled with speed and
disassembling procedure, and observe the following increases above 30V, a defective IC regulator is
precautions: suspected.
1. Lubrication is not required. Both bearing are If the voltage does not increase higher than battery
prelubricated. voltage, this means alternator does not generate.
NOTE: For the rotor bearing with resin bands, grease Recheck the alternator.
should not be applied. Remove oils completely to 4. Increase the alternator speed to approx. 500 min–1
prevent creep of the bearing if found on the bearing box. and take the ammeter reading.
2. High temperature solder (Melting point of 230°C) If the ammeter reading is 5A or less, take the
should be used. voltmeter reading without changing the alternator
Solder quickly, use a 180 – 270 watts soldering iron speed (approx. 500 min–1).
no more than about 5 seconds because the rectifier The reading is the regulated voltage.
may be damaged if it is overheated.
If the ammeter reading is more than 5A, continue to
charge battery until the reading falls to less than 5A
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 9
or replace the battery with a fully charged one.

If the regulated voltage does not meet the specified
limits, it will have to be replaced.
AMMETER SWITCH 1
A
LAMP (24V) SWITCH 2

B (3W MAX.)
L
R
V ALTERNATOR BATTERY
(24V)
LOAD
VOLTMETER RESISTOR
Current Output Test

The current output test determines whether or not
alternator is capable of supplying its rated current
output.
1. After the regulated voltage test is completed, reduce
the alternator revolution.
2. Close the switch 1. Be sure the lamp lights.
3. Set the load resistor in maximum resistance value
position (Minimum current draw) and close the
switch 2.
4. Increase and hold the alternator speed to 5000 min–1
and adjust the load resistor to obtain maximum
current output.
Run the alternator for 15 minutes at this speed and
output to rise in the alternator temperature.
After 15 minutes rotate the alternator to specified
speed (2500 and 5000 min–1) and adjust the load
resistor to obtain maximum current output.
The output should be within the specified limits.
If the output is less than the specified limits, recheck
the alternator.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 10
Troubleshooting

No output Disconnected terminal connection Repair terminal connection
Open or short system circuit Repair the system circuit
Open field coil Replace the filed coil
Defective diode Replace the diode
Defective IC regulator Replace the regulator
Low output Loosened terminal connection Retighten the terminal connection
Loosened cooling fan belt Adjust the belt tension
Short field coil Replace the field coil
Short stator coil Replace the stator coil
Defective regulator Replace the regulator
Defective battery Replace the battery
Poor terminal contact Repair the terminal contact
Overcharging Defective regulator Replace the regulator
Defective battery Replace the battery
Unstable current Poor terminal contact Repair the terminal contact
Loosened cooling fan belt Adjust the belt tension
Short field coil Replace the field coil
Intermittent contact in wiring Repair the wiring
Poor terminal contact Repair the terminal contact
Defective regulator Replace the regulator
Abnormal noise Improper alternator installation Correct the installation
Defective bearing Replace the bearing
Contact between the rotor core and Replace the rotor core or stator core
stator core
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 11
Starter Motor
General Description
060EY00009
The starter motor adapts the planetary gears in

reduction gear mechanism.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 12
Main Data and Specifiction
Isuzu Part No. 1-81100-3411

Mitsubishi code No. M009T80971
Rated voltage V 24
Rated output kW 7.0
Rating Sec 30
Direction of rotation Clockwise
(Viewed from the pinion side)
Terminal voltage (No. Load) V 23
Minimum current (No. Load) A 85
Starter motor minimum operating speed min–1 3300
(No. Load)
Pinion gear
Modules 3.5
Number of teeth 11
Outside diameter mm (in.) 48.9 (1.93)
Yoke outside diameter mm (in.) 105 (4.13)
Brush length
Standard mm (in.) 18 (0.71)
Limit mm (in.) 11 (0.43)
Brush spring standard fitting load N 29 – 39
Commutator
Outside diameter
Standard mm (in.) 32 (1.26)
Limit mm (in.) 31.4 (1.23)
Depth of undercut mica
Standard mm (in.) 0.5 (0.02)
Limit mm (in.) 0.2 (0.008)
Pinion projection
Standard mm (in.) 0.5 – 2.0 (0.0197 – 0.079)
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 13
Identification
MITSUBISHI starter motor is identified by the name
plate attached to the yoke. (Illustration)
(1) Manufacturer’s type
(2) Isuzu part number
(3) Bar code
NOTE: Always check the identification number before
beginning a service operation.
Applicable service data will vary according to the
identification number. Use of the wrong service data will
result in starter damage.
MITSUBISHI
ELECTRIC CORP, JAPAN 24V
TYPE 1
NO.
2
060EY00012
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 14
Disassembly
20
7
19
4
3
2
1
27
9
18
13
17
16
15
14
12 26
11
25
21
10 24
22
23
060EY00029
Legend (14) Gear shaft

(1) Snap ring (15) Planetary gear
(2) Stop ring (16) Ball
(3) Pinion (17) Gasekt
(4) Pinion spring (18) Plate
(5) Screw (19) Armature
(6) Pinion case (20) Bearing
(7) Bearing (21) Gasket
(8) Magnetic switch (22) Yoke
(9) Lever (23) Brush
(10) Clutch (24) Gasket
(11) Internal gear (25) Brush holder
(12) Washer (26) Rear cover
(13) E-type stop ring (27) Through bolt
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 15
NOTE:
• When disassembling the starter motor, to make 5
reassembling easier, mark to match the magnetic
switch and yoke. 4
• First remove the pinion, or the pinion can not be
3
disassembled when proceeding disassembly without 6
disassembling the pinion. 2
1
1. Remove the pinion.
• Remove the pinion at the location travelling to
cranking position.
SW 1
SW 2 060EY00015
Legend
(1) Pinion
24 V
(2) Clutch shaft
(3) Snap ring
(4) Stop ring
(5) Pipe
(6) Pinion spring
2. Remove the magnetic switch.

3. Loosen the brush holder fixing screw and the
060EY00014
through bolt.
• Connect the starter motor to the battery. When Remove the rear bracket and gasket.
closing the switch SW1 and SW2, the pinion Discard the gasket.
travels to cranking position and the armature 4. Hold the socket (major diameter 32 mm) on the
rotates. Then opening the switch SW2, the armature commutator and remove the yoke
armature stops to rotate. assembly, sliding the brush onto the socket.
NOTE: Remove the pinion in 10 seconds as the • Removing this way makes reassembling easier.
armature generates heat with being energized. 5. Pull up the brush spring and remove the brush.
• Hold the suitable pipe on the stop ring. Hit the pipe 6. Remove the brush holder after removing the brush.
with a hammer, and remove and expose the stop
7. Pull out the armature from the planetary gear and
ring, then remove the snap ring, stop ring, pinion,
remove the bearing with a puller.
and pinion spring.
Be careful not to lose the ball.
Discard the snap ring.
8. Remove the plate and gasket.
9. Remove the planetary gears.
10. Put the internal gear, gear shaft overrunning clutch,
and lever together, then remove them from the front
bracket.
11. Remove the lever.
• Remember the lever installation direction.
12. Remove the E-type stop ring.
Then remove the overrunning clutch from the gear
shaft assembly.
Discard the E-type stop ring.
13. Remove the internal gear and washer for adjusting
the gear shaft end play together.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 16

Armature
1. Use a circuit tester to measure the armature for
continuity.
Step 1. Hold the circuit tester probes against two
commutator segments.
Step 2. Repeat step 1 at different segment of the
commutator.
There should be continuity between all segment of
the commutator.
3. Measure the commutator outside diameter.

If the measurement is less than limit, replace the
commutator assembly.
Standard: 32 mm
Limit: 31.4 mm
2. Use a circuit tester to measure the armature for

grounding.
Step 1. Hold one probe of the circuit tester against
the commutator segment.
Step 2. Hold the other probe of the circuit tester
against the armature shaft.
If the circuit tester indicates continuity, the armature
is grounded, replace the armature assembly.
4. Inspect the commutator mica segment for excessive

wear.
If the mica segment depth is less than the limit,
replace the commutator.
Measure the mica segment depth.
Standard: 0.5 mm
Limit: 0.2 mm
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 17
060EY00016 060EY00017
5. Inspect the gear for damage or wear.

Replace the armature if any damage is discovered. Brush and Brush Holder
6. Inspect the bearing for abnormal noise, rattling or 1. Measure the brush length.
grease leakage. If the measured value exceeds the limit, replace the
Replace the bearing if any malfunction is discovered. brush and/or yoke.
Standard: 18 mm
Limit: 11 mm
Field Coil 2. Visually check the brush spring for weakness and
1. Use a circuit tester to check for any broken winding. rusting.
A broken wire is indicated if no continuity is found Replace the brush spring if it is weak or rusted.
between the field coil and lead wire. Use a spring balancer to measure the spring tension.
Replace the field coil. If the measured value exceeds the limit, replace the
brush spring.
Standard: 29 – 39 N
Limit: 13.7 N
3. Use a circuit tester to check the brush holder
insulation.
• Touch one probe the field winding lead wire.
• Touch the other probe to the brush.
There should be no continuity.
If continuity is found, repair or replace the brush
holder.
060EY00018
2. Check for continuity between the field coil and the

yoke.
Repair or replace the yoke assembly if continuity is
found.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 18
Front Bracket
Check the bearing and oil seal for damage.
Replace the front bracket assembly if the malfunction is
found.
Internal Gear and Planetary Gear

Check for the gear for abnormal wear or damage.
Replace the gear if the malfunction is found.
Magnetic Switch
Check for continuity across the magnetic switch
terminal-M (1) and body. If no continuity is found,
replace the magnetic switch.
Check for continuity across the magnetic switch
terminal-M and terminal-B (3). If continuity is found,
replace the magnetic switch.
060EY00019
Overrunning Clutch and Pinion 2
Check the pinion teeth for excessive wear and damage.

Rotate the pinion in the drive direction of starter motor.
The pinion should rotate smoothly. Rotate the pinion in
the opposite direction. The pinion should lock.
Replace the overrunning clutch, if any malfunction is
discovered.
NOTE: The inside of the overrunning clutch is filled with
grease.
Do not soak in any liquid cleaner or solvent because 1 3
grease leakages may result.
Wipe the dirt of the overrunning clutch with a clean rag.
060EY00021
Reassembly
To reassemble the starter motor, follow the reverse of
disassembling procedure, and observe the following
precautions:
1. Lubricate the following portion:
• Surrounding armature bearing (1) : a little
• Plunger (2) : a little
• Gear shaft spline and sliding part (3)
• Clutch shaft (4)
• Oil seal (5)
• Pinion of overrunning clutch (6)
• Sliding part of lever with overrunning clutch (7)
060EY00020
• Sleeve bearing and ball (8)
• Armature shaft gear, internal gear and planetary
gears (9)
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 19
Recommended lubricant type:

Portion (1) to (6) : MUL TEMP OA–171 or equivalent
Portion (7) to (9) : Molycoat R AG650 or equivalent
(Dow Corning)
5
6
1
9 8 7
060EY00010
2. Tightening torque
Nut (1) : 20 – 26 N·m
Bolt (2) : 4.9 – 8.8 N·m
Bolt (3) : 7.8 – 13 N·m
Bolt (4) : 2.4 – 4.4 N·m
1 2
060EY00031
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 20
3. Armature shaft axial play

Any adjustment is not required.
Install the ball to the top of the armature shaft.
4
4. Gear shaft axial play
Any adjustment is not required. 3 5
Install the washer between the internal gear and 2
gear shaft. 1
060EY00023
4 6. Inspect the projection position of the pinion.

• After reassembling the starter motor, inspect the
2 projection position of the pinion.
1 Projection position: 0.5 to 2 mm
060EY00022
Legend
(1) Overrunning clutch
SW 1 B
(2) Internal gear
S SW 2
(3) Washer
M
(4) E-type stop ring
(5) Gear shaft 24 V
Install the washer, internal gear and overrunning clutch

to the gear shaft.
Then install the E-type stop ring.
5. Install the pinion to the clutch shaft.
• Install the pinion spring (5), pinion (1), and stop
ring (4) in sequence to the clutch shaft (2).
• Install the snap ring (3) finally.
• Then put the stop ring on the snap ring in place.
060EY00024
• Connect the starter motor to the battery.

When the switch (1) and (2) are turned on, the
pinion will travel forward to the cranking position.
At this time, the armature will rotate.
Next, stop to rotate the armature with the switch
(2) turned off.
• Lightly push the head of overrunning clutch shaft
by hand and measure the movement (return) of
the clutch shaft.
If the value is within 0.5 – 2.0 mm, it is the normal
position. If it is outside the limit, adjust the packing
(0.5 mm ) between the front bracket and magnetic
switch, or replace the lever.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 21
060EY00025
7. Conduct the performance test.

• Connect the starter motor as shown in the
illustration.
A SW B
S
1
M
3
V
060EY00026
Legend
(1) Battery
(2) Amperemeter
(3) Voltmeter
• Measure the speed, current and voltage with the

switch turned on.
If the value is outside the limit, disassemble and
inspect.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 22
MEMO
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 1
ENGINE LUBRICATION 6G–1
ENGINE LUBRICATION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6G-1 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-12
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6G-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-12
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-4 Inspection and Repair . . . . . . . . . . . . . . . . . . . . 6G-13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-14
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6G-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-9
Service precaution
systems.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 2
6G–2 ENGINE LUBRICATION
General Description
Lubricating Oil Flow
Lubrication system is of pressure feed circulation
system with a gear type oil pump driven by crankshaft.
Oil flows from the oil pump though oil cooler to main oil
filter for oil cooling and oil cleaning.
From the main oil filter it moves to the cylinder block oil
gallery and the oil circulates to lubricates the engine
parts.
Oil jets are installed to the cylinder block main oil gallery
in the inside portion of the cylinder block.
The jet sprays oil to the inside portions of the pistons for
lubrication and cooling.
Oil Pump and Oil Filter

The oil pump is of a gear type with a relief valve. The
pump is driven by the timing gear.
A full flow main oil filter with a highly efficient paper
element used.
Should the element become clogged with sludge or
other foreign material, a by-pass valve open to route the
oil directly to the oil gallery.
A warning lamp will light at this time to warn the operator
of the equipment the oil directly to the oil gallery.
The oil is cleaned and delivered to the oil pan.
Oil Cooler
The temperature of the engine oil circulating through the
lubricating system tends to rise with an accompanying
decrease in lubricating efficiency.
The oil cooler maintains the oil temperature at the
optimum level for effective engine lubrication.
The oil cooler consists of the body and the cooling
element.
LUBRICANT FLOW CHART
CYLINDER BODY
CYLINDER BODY LEFT HAND OIL GALLERY
RIGHT HAND OIL GALLERY
REMOTE OIL PRESS.

TYPE UNIT & TIMING
CYLINDER HEAD INJECTION
OIL FILTER SWITCH GEAR PUMP
OILING JET
2
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 3
TURBO
OIL FILTER CHARGER
RELIEF OIL PORT
VALVE COVER
CAMSHAFT IDLE IDLE COUPLING
JOURNAL IDLE GEAR OILING JET GEAR GEAR or
(No2 & 5) "A" "B" "C" AIR COMPRESSOR
ROCKER
RELIEF
OIL ARM CRANKSHAFT
VALVE
COOLER SHAFT JOURNAL
4
OIL CAMSHAFT ROCKER

THERMOVALVE JOURNAL ARM & CRANKPIN
(No1,3,4,6) VALVE
CONNECTING
1 ROD
OIL BUSHING
PUMP RELIEF
VALVE
STRAINER OIL PAN

Relief valve opening pressure kPa (kg/cm2/psi) 4 Oil thermostat opening temperature °C (°F) 98 (208)
ENGINE LUBRICATION
1 690 (7.0/99.5)
2 200 (2.0/28.4)
3 440 (4.5/64.0)
F06EY00033
6G–3
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 4
Oil Pump
Oil Pump Construction
8 9
2
11 10
051EY00026
Legend (7) Oil pump cover

(1) Oil pump body (8) Relief valve
(2) Oil pump driven gear (9) Split pin
(3) Ball (10) Spring seat
(4) Driven gear (11) Spring
(5) Drive gear
(6) Driven gear
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 5
Disassembly
2
8
5 9
3
4
11
7 10
Legend (7) Oil pump drive gear

(1) Cover (8) Oil pump cover
(2) Ball (9) Oil pump driven gear
(3) Split pin (10) Drive gear shaft
(4) Spring seat (11) Oil pump body
(5) Spring
(6) Oil relief valve
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 6
1. Loosen bolts to remove the cover 5. Loosen the fixing bolts to remove the oil pump cover.
2. Take out the ball from the oil pump assembly.
3. Remove the split pin, spring seat, spring and oil relief
valve.
6. Take out the oil pump driven gears and drive gear
shaft from oil pump body.
4. Use a gear puller to pull out the oil pump drive gear.

Ball
Carefully inspect the ball scratches or damage.
Oil Relief Valve

Inspect the oil relief valve seat portion damage and
spring damage.
NOTE: If there is some scratch or damage, the ball and
relief valve must be replaced.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 7
Clearance Between Oil Pump Body and Oil Pump Gear Shaft Outside Diameter and
Driven Gear Clearance between Oil Pump Gear Shaft
Use a feeler gauge to measure the clearance between and Oil Pump Body
the oil pump body and driven gear. Use an inside and outside micrometer to measure the oil
Standard: 0.050 – 0.098 mm (0.0020 – 0.0039 in.) pump gear shaft outside diameter and oil pump body
Limit: 0.15 mm (0.0059 in.) holes.
Oil pump gear shaft diameter
Nominal measurement: 20.0 mm (0.7874 in.)
Limit: 19.9 mm (0.7835 in.)
Clearance between oil pump gear shaft and oil
pump body
Standard: 0.040 – 0.074 mm (0.0016 – 0.0029 in.)
NOTE: If measuring value exceeds, the parts must be
replaced.
Side Clearance Between Oil Pump Cover

and Gears
Use a feeler gauge to measure the side clearance
between the oil pump cover and gears.
Standard: 0.040 – 0.094 mm (0.0016 – 0.0037 in.)
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 8
Interference between Oil Pump Drive Gear

and Drive Gear Shaft
Measure the inside diameter of oil pump drive gear and
outside diameter of drive gear shaft.
An interference
Standard: 0.019 – 0.047 mm (0.0007 – 0.0019 in.)
NOTE: The measuring value exceeds from limit or
standard, the parts must be replaced.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 9
Reassembly
2
8
5 9
3
4
11
7 10
Legend (7) Oil pump drive gear

(1) Cover (8) Oil pump cover
(2) Ball (9) Oil pump driven gear
(3) Split pin (10) Drive gear shaft
(4) Spring seat (11) Oil pump body
(5) Spring
(6) Oil relief valve
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 10
1. Apply engine oil to the drive gear (1) and install the 4. Install the oil pump cover.
drive gear to the oil pump body. Tighten the bolts to the specified torque.
2. Install the oil pump drive gear (2). Torque:
• Put the oil pump drive gear (2) on the bed of bench M8: 17 N·m (1.8 kgm)
press, place the oil pump body with the drive gear
M10: 39 N·m (4.0 kgm)
shaft.
• Use bench press to press the drive gear shaft into
the oil pump drive gear as shown in the illustration.
5. Install the oil relief valve, spring and spring seat to

051EY00027 the oil pump body.
6. Install the split pin into the oil pump body and lock it.
3. Install the oil pump driven gear.
7. Install the ball
• Apply engine oil and install the oil pump driven
gear to the oil pump body. 8. Install the cover
051EY00028
NOTE: Make sure the oil pump assembly to move

smoothly.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 11

69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 12
Oil Cooler
Disassembly
2
11
10
9
8
4
3 7
Legend (7) Oil thermostat

(1) Water guide (8) Spacer
(2) Oil cooler element (9) Supporter
(3) Gasket (10) Seal ring
(4) Gasket (11) Oil cooler body
(5) Oil pipe
(6) Gasket
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 13
1. Loosen the bolts to remove the water guide. Inspection and Repair
2. Loose the nuts to remove the oil cooler element with
the gaskets. Make the necessary adjustments, repairs and part
3. Loosen the bolts to remove the oil pipe with the
gasket.
Oil Cooler Element
Inspect the oil cooler element for cracking or damage.
4. Carefully remove the oil thermostat.
Oil Thermostat
1. Inspect for wear or damage on the piston and valve
seat.
2. Check for damage or decrease of the spring force.
3. Inspect opening temperature with oil heater.
Opening temperature: 98.0°C (208.4°F)
5. Remove the spacer, supporter and seal ring from the

oil cooler body.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 14
Reassembly
2
11
10
9
8
4
3 7
Legend (7) Oil thermostat

(1) Water guide (8) Spacer
(2) Oil cooler element (9) Supporter
(3) Gasket (10) Seal ring
(4) Gasket (11) Oil cooler body
(5) Oil pipe
(6) Gasket
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 15
1. Be sure seal ring direction shown in the illustration.
050EY00020
Legend 5. Install the oil cooler element with new gaskets.

(1) Seal ring • Apply Three Bond 1208 to grooves to install the
(2) Rotation stopper gaskets.
(3) Supporter • Install the gaskets to the oil cooler element.
• Reassemble the oil cooler element to the oil cooler
2. Install the supporter into the oil cooler body. body.
• Align the rotation stopper (2) on the supporter to • Tighten the fixing nuts for oil cooler element to the
the oil cooler body as shown in the illustration. specified torque.
050EY00021
050EY00022
3. Install the spacer and oil thermostat into the oil

cooler body. 6. Install the water guide.
4. Install the oil pipe to the oil cooler body.
• Install the oil pipe with new gasket to the oil cooler
body.
• Tighten the oil pipe to the specified torque.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 16
MEMO
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 1
ENGINE INDUCTION 6J–1
ENGINE INDUCTION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6J-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-4
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-2 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6J-5
General Description . . . . . . . . . . . . . . . . . . . . . . . 6J-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-7
Service precaution
systems.
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 2
6J–2 ENGINE INDUCTION
Turbocharger
General Description
037EY00003
Major turbocharger components consist of the Center The turbocharger increases air intake efficiency, the
Housing and Rotating Assembly (CHRA), the results in increased engine power, reduced fuel
compressor housing, and the turbine housing. consumption and minimal engine noise.
Rotating parts include the turbine shaft, the compressor Turbocharger rotating parts operate at very high speeds
wheel, the shaft bearings, the thrust bearings and the oil and temperatures. The parts materials have been
seal ring. There parts are supported by the center carefully selected and machined to extremely high
housing. precision.
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 3
Identification Turbocharger Servicing

The turbocharger name plate gives the date of 1. Refer to TROUBLESHOOTING in this Manual to
manufacturer and other important information required determine whether or not turbocharger repair or
to identify the unit when service inquiries are made. overhaul is required.
The turbocharger name plate has the following 2. The following procedures should also be performed
information stamped on it. Refer to the illustration. (either with the turbocharger on the equipment or
(1) Turbocharger specification, production year and removed form the equipment but not disassembled)
production month. to determine whether or not turbocharger repair or
Example: VIBU overhaul is required.
(2) Production date, serial number and production line * Visual checks
name. * Clearance measurements
Example: RHC92 * End play measurements
(3) Part number assigned is ISUZU MOTORS LIMITED. Refer to INSPECTION AND REPAIR.
Example: 1144003281 3. The turbocharger compressor and turbine housing
Part numbers (3) indicate specific designs or may be removed from the center housing and
configurations. rotating assembly (CHRA) for further visual
inspection.
Refer to DISASSEMBLY and REASSEMBLY.
Precaution
Turbocharger servicing requires great care and
Name plate example expertise.
Faulty turbocharger servicing procedures can result in
Turbo Spec. 1 serious damage to pistons, valves, cylinder liners, and
other important engine parts.
Serial No.RHC9 2 ISUZU does not recommended the performance of any
servicing procedure not specified described in this
Parts No. 3
Manual.
Contact your nearest IHI service facility to have the
turbocharger assembly repaired or overhauled.
The identification plate and assembly number will be
required by the service facility.
A list of IHI Turbocharger Service Network locations is
given at the end of this Section.
037EY00010
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 4
Disassembly
3
4
036HT001
Legend (4) Compressor housing

(1) Lock plate and bolt (5) Center housing and rotating assembly
(2) Turbine housing
(3) Lock plate and bolt
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 5
1. Remove the lock plate and bolt. Take care not to allow foreign material to enter the
Apply a setting mark across the center housing and center housing.
rotating assembly (1), the turbine housing (2), and NOTE: Disassembly and servicing of the center housing
the compressor housing (3). and rotating assembly is not recommended.

Make the necessary adjustment, repairs, and part
3
Minor servicing operations are described in this Section.
Contact the nearest IHI SERVICE FACILITY for major
1 repairs and maintenance.
Refer to IHI SERVICE NETWORK at the end of this
Section for the location of your area’s IHI SERVICE
FACILITY.
2 Turbine shaft End Play

1. Set a dial indictor to the turbine shaft end.
2. Apply a force of 11.7 N (1.2 kg/2.6 lb) alternately to
the compressor wheel end and the the turbine wheel
end.
037EY00005
3. Read the dial indicator.
Turbine shaft end play
Standard: 0.075 – 0.110 mm (0.0030 – 0.0043 in.)
Limit: 0.12 mm (0.0047 in.)
037EY00006
2. Remove the turbine housing.

3. Remove the lock plate and bolt.
4. Remove the compressor housing.
5. Remove the center housing and rotating assembly.
• Loosen the lock plate bolts. Turbine Shaft Bearing Clearance
• Disassembly the parts. Due to the unique location of the center housing casting
Handle the parts with extreme care. internal opening, access to the shaft wheel is difficult. To
check the turbine shaft and bearing clearance, a special
Be particularly careful not to damage the turbine
gauge arm assembly must be fabricated for use with a
wheel blades and the compressor wheel blades.
dial gauge.
The assembly can be constructed from any conveniently
available material. However, it must conform to the
dimensions shown in the illustration.
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 6
1. Pass the gauge arm assembly through the oil outlet

port and the casting internal opening.
The curved end of the gauge arm assembly must
make contact with the wheel shaft.
037EY00007
2. Set the dial gauge to “0”.

3. Grasp both ends of the shaft at the wheel hubs.
Move the shaft gently back and forth in a motion that
is parallel to the plane of the oil drain flange face.
Note the dial gauge reading.
If the dial gauge reading is above or below the
standard range, the center housing and rotating
assembly must be replaced.
Standard: 0.130 – 0.235 mm (0.0051 – 0.0093 in.)
Limit: 0.275 mm (0.0108 in.)
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 7
Reassembly
3
4
036HT001
Legend (4) Compressor housing

(1) Lock plate and bolt (5) Center housing and rotating assembly
(2) Turbine housing
(3) Lock plate and bolt
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 8
1. Install the center housing and rotating assembly to

the compressor housing.
• Apply Threebond 1215 or equivalent to the flange
surface of compressor houisng shown in the
illustration.
037EY00006
2. Install the turbine housing.

• Align the setting marks (applied at disassembly)
on the center housing and rotating assembly and
the turbine housing.
037EY00008 Handle the parts with extreme care to avoid
• Align the setting marks (applied at disassembly) damaging the turbine shaft wheel blades.
on the center housing and rotating assembly and • Apply an anti-seizing agent (LOCTITE
the compressor housing. ANTISEIZE LUBRICANT or equivalent) to the
Handle the parts with extreme care to avoid bolt.
damaging the compressor wheel blades. • Tighten the bolt to the specified torque.
• Apply an anti-seizing agent (LOCTITE Torque: 28 N·m (2.85 kgm)
ANTISEIZE LUBRICANT or equivalent) to the • Check that the rotating assembly turns smoothly.
new bolt threads or the V-band threads.
• Install the new lock plate and bolts to the
compressor housing.
3
037EY00005
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 9
IHI SERVICE NETWORK

For inquiries relating to turbochargers, please contact you ISUZU distributor or the nearest IHI Turbocharger Service
Facility.
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD. (IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s Republic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN
TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(3)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-2390, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALYASIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI, M.H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 10
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MEMO
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69697_ESS-172A_SEC0A 11.8.

GENERAL INFORMATION 0A–1

0A–2 GENERAL INFORMATION

Arrow Type Application Arrow Type Application

• Ambient/Clean air flow

• Gas other than

• Ambient air mixed with

View Detail Motion of direction

Lubrication point oil or

Dimension (1:2) Lubrication point grease

Sectioning (1:3) Lubrication point jelly

GENERAL INFORMATION 0A–3

Abbreviations Charts lb in – Inch Pounds

0A–4 GENERAL INFORMATION

Nut and Bolt Angular Tightening

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

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

GENERAL INFORMATION 0A–5

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

Example: Specified Angle and Tightening Rotation

0A–6 GENERAL INFORMATION

Standard Bolts Torque Specification

STANDARD BOLT N·m (kgf·m/lb.ft)

M6 × 1.0 4 – 8 (0.4 – 0.8/3 – 6) 5 – 10 (0.5 – 1.0/4 – 7)

GENERAL INFORMATION 0A–7

FLANGED HEAD BOLT N·m (kgf·m/lb.ft)

M6 × 1.0 5 – 9 (0.5 – 0.9/4 – 7) 6 – 12 (0.6 – 1.2/4 – 9)

0A–8 GENERAL INFORMATION

Recommended Thread Locking

1. Completely remove all lubricant and moisture from the

Apply LOCTITE to at least 1/3 of the

3. Tighten the bolts to the specified torque.

GENERAL INFORMATION 0A–9

Main Data and Specifications

0A–10 GENERAL INFORMATION

GENERAL INFORMATION 0A–11

240 SFC (g/kW/h)

1000 1200 1400 1600 1800 2000

Engine Speed (min-1)

ENGINE EXTERNAL DRAWING

GENERAL INFORMATION 0A–13

0A–14 GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

GENERAL INFORMATION 0A–15

ITEMS SERVICE STANDARD SERVICE LIMIT

0A–16 GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

GENERAL INFORMATION 0A–17

ITEMS SERVICE STANDARD SERVICE LIMIT

0A–18 GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

GENERAL INFORMATION 0A–19

0A–20 GENERAL INFORMATION

Engine External Parts

GENERAL INFORMATION 0A–21

M18: 177 (18/130)

Apply engine oil

Apply Loctite FMD-127

0A–22 GENERAL INFORMATION

GENERAL INFORMATION 0A–23

Apply Loctite FMD-127

0A–24 GENERAL INFORMATION

N·m (kgf·m/lb ft)

(Without Cooling Fan)