Mitsubishi 6d15 6d15t Shop Manual, Service Manual

ae. Shop Manual diesel engine ate 3 : eter 6D1 (for industrial use) 60 Loy b0)5 6DIST 6hib 60/8 boil Pub. No. 97821-02031, SEPTEMBER 20016D1 diesel engine Shop Manual (for industrial use) FOREWORD This Shop Manual is published for the information and guid- ance of personnel responsible for maintenance of Mitsubishi 601 series diesel engine, and includes procedures for adjustment and maintenance services. ‘We eamestly look forward to seeing that this manual is made {ulluse of n order to pertorm correct service with no wastage. For'more details, please consult your nearest authorized Mitsubishi dealer or distributor, Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. Applicable models 6D14 — 6D14-T 6D15-T 616 6DIG-E 6D16-T 6D16-TE 6D16-TL 6D16-TLE ‘© 2001 Mitsubishi Motors Corporation Printed in Japan GROUP INDEX HOW TO READ THIS MANUAL GENERAL ENGINE .......... 00... cee eee FUEL AND ENGINE CONTROL ELECTRONICALLY CONTROLLED FUEL SYSTEM COOLING INTAKE AND EXHAUST CLUTCH ... SPECIAL EQUIPMENT .HOW TO READ THIS MANUALHOW TO READ THIS MANUAL How This Manual Is Compiled This manual is compiled by classifying various systems into certain groups. Each group contains specifications; troubleshooting; maintenance service standards; @ tightening torque: -4\ lubricant, fluid and sealant; ) special tools; and service procedure. * Page enumeration is independent by every group where firs page Is always 1 Siow ‘Group denomination Contents lo 00 | General “Genaral specications, engine No. and name plate, precautions for mainte nance operations, table of standard tightaning torques 7 [Engine Engine body 12 [Lubrication Lubrication system ~ - 13__| Fuel and engine control Fuel system z a 14 | Goating Cooling system 15 [intake and exhaust Intake and exhaust system, turbocharger, intercooler 21 | Clutch Clutch proper, bearing case ‘54 | Electrical system ‘Alternator, starter, preheating system, engine start system, automatic stop om 61__| Special equipment i Compressor, pressure governor ii—_ General Explanation of This Manual © Specifications Particulars relative to maintenance service are made. @ Structure and operation (1) Regarding conventional equipment, descriptions are made in brief. (2) Regarding new equipment, descriptions of system and operating condition are made in detail, @ Troubleshooting ‘Symptoms of troubles and possible causes are described comparatively. @ Inspection and adjustment mounted in vehicle Descriptions are made regarding inspection and adjustment of units mounted in vehiclo. © Service procedure |nprinciple, an explanation s given atthe spread tle page so that the service procedure can be understood Servicing points are explained as a supplementary explanation. Regarding the design of this manual ccuuTen Boy fein] a ere pe ee 1. -s-+s-Ilustration for disassembly and assembly or removal and installation: 3-D exploded view of component parts is displayed. ta. ..... Names of parts show an example of the disassembly (removal) sequence. 1b. ----. When the assembly (installation) sequence difers from the disassembly (removal) sequence, an example of the assembly (installation) sequence is shown, Service standards are shown collectively, classified by location. + Tightening torques are shown collectively, classified by location. Points of lubricant, fluid and sealant application are shown collectively, classified by location. + Special tools to be used are shown collectively, classified by location. When it is considered hard to understand the service proceduro, just by the foregoing description, a supplo- mentary description of the service procedure is given. egnon itHOW TO READ THIS MANUAL 1. Illustration for disassembly and assembly or removal and installation ‘This shows that the appropriate service procedure is described in the text. CLUTCH BODY @ Assam sequence Meaning of symbols ©: shows that the tightening torque is specified. 16917-41210-19-9847 46-95-41 IBL Pepa leh lease aver bt This shows the key No. of the part. In the text, this No. is referred to uniformly throughout, This shows an example of the disassembly (removal) sequence. Tena tot 2 Maser This shows thatthe sorvice 2 Kotla procedure is described in Sa another section. (Mer 00: MPOO-0O esau pea cap : shows reference page 10 Release isver plate. within the same group. 12 ata vera me@roo 43 Sipporioerpm : shows reference group 5 oceans within the same book, 18 ewan 1 banca 2 Prossur plate over esuny meat 9 Catena + Boot Aen pin at 2 aces) O:Nonsousale pat \ \ No service procedure is referred to in this section, but the item can be an objective of various procedures. ‘4: shows that application of lubricant, fluid or sealant is required. ©: shows that the part should not be iv roused. This is shown when the assembly (installation) ‘sequence is not the reverse of the disassembly (removal) sequence. This shows that a repair kit Is available.oe 2. Service standards table Only the relevant service standards are shown. ' Service standards Unit nm Tocaton aintenance tom Standard value init | Romedy 7.11 _ | Gesrancebeiveen sap botand rap plato oareae 03 | Replace 7 [Pressure pring | installed oad : 395 N (05 kg Tron | Replace | (installed length 49.1) (72.3 kg) Tt ~ 2.9 orless. 5.0 Replace | This shows the key No. of the relevant part. 3. Tightening torque table This shows specified tightening torque. © Tightening torque Unit Nm tmp Tocation aris tobe tightened Tightening torque Remarks 1__[ Srapbots Sap bot mouning) 391059 (106) = 4 [Bot (Lec plato mounting) 591078 (081008) War ‘This shows the key No. of the relevant part. ‘This shows that the item Is to be tightened wet. 4, Lubricant, fluid and sealant table Only the relevant lubricant, fluid and sealant are shown, { ‘This shows the application point. -Q Lubricant, fluid and sealant Loeaton Pains Tapalcaion y= ins vantiy | Teudarenotbon ToomTe are [ Asrequted 70, 16 | Fon surfaces oeoaso avr pate andracaolavor | woijbdanam dle pease zsroqued _ INLGI No. 2 (Lisoap)) | This shows the key No. of the relevant part. This shows the specified brand,HOW TO READ THIS MANUAL 5. Special tools table Only the relevant special tools are shown. Purpose of special tools is shown. ) Special tools Unt Location Tool name and shape ParNo, aplication | v 11 | cutehinstator NHost051 | Removal and instalation of ch over wwrios2201 | Agustretease lover eights 16 | Master pate | ol | | This shows the key No. of the relevant part. Quote this number when placing an order for the part. 6. Service procedure This indicates a special __This shows the key No. of the relevant part. service tool. | [17] Removal and installation of clutch cover ‘© Depress pressure spring 7 using (E) clutch installer, then remove the following parts: Strap bolt 1, washer 2, washer 3, bolt 4, lock plate 8, support nut 6 + Loosen the clutch installer gradually, then remove clutch cover 11 when. the pressure spring is fully released + For installation, follow the removal sequence in reverse. Servicing procedures of disassembly (removal), The key No. referred to In the text Is always the assembly (installation), inspection, adjustment, same as the key No. shown in the illustration, otc. are shown collectively. viTerms and Units ‘The terms and units in this manual are defined as follows. @ This service manual contains important cautionary instructions and supplementary information under the following four headings which identity the nature of the instructions and information: DANGER A, ———— Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives. WARNING /\, ———— Precautionary instructions, which, it not obsorved, could result serious injury or death, CAUTION A, ——— Precautionary instructions, which, ifnot observed, could resultin damage tor destruction of equipment or parts. NOTE ‘Suggestions or supplementary information for more efticient use of equipment ora better understanding. @ Front and rear The terms “front” is the fan side and ar" the flywheels side of the engine. @ Left and right The terms “right” and “left shall be used to indicate the side as viewed from the flywheel side of the engine. @ Terms of service standards (1) Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. The figure in [] is the basic diameter. (2) Limit When the value of a part exceeds this, itis no longer serviceable in respect of performance and strength and must be replaced or repaired. © Tightening torque Excessive or insufficient tightening torque has particular importance in respect of performance. Accordingly, tightening torque is specified in locations that are to be tightened Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. When the item is to be tightened in a wet state, wet is indicated. Where there is no indication, read it as dry, and tighten at specified torque. viiHOW TO READ THIS MANUAL @ Unit Tightening torques and other parameters are given in SI* units with metric units added in brackets { ). *SI: Le Systéme International d'Unités Example: 390 N-m {40 kgf-m} {— Metric unit — stunit Unit Suni (metic unit) Conversion factor Force Nikath ‘9.80665 N (1 kath Moment of force Nem {kgt-mp 9.80665 N-m (1 kgl-mp Positive pressure kPa {katiom?) (98,0665 kPa (1 kat/om?) Pressure (aes | kPa (mmHg) 0.199822 kPa (1 mmiig) a (rmmtiz0) 9.80665 Pa {1 mmHz0} Volume ane tam (1) Powor kW (PS) 0.7355KW (1 PS) Heat quantity J (heal) 186,05 J (1 eal) Heat low W tkeatm) 1.16279 W (1 Keath) ‘Angle : = Temperature ca == Elects current A = “Voltage v = Resistance a = Electric power w = Unit ‘Stunit Foot pound unit Conversion rato Force N (Newton) bf TN = 0.2248 bof ‘Moment of foros [Nem fib 1 Nem = 0.7975 flbs Pressure KPa (klopascal) pel 1 kPa = 0.145 psi 1 kPa = 0.2953 in. Ho Volume v gal 11 = 0.2642 gal. US) .220 gal. {imp.) om® oz 1099814 02 (U.S.) 035195 oz (Imp.) om® unin, 4 em? = 0.061023 cu.n. Power Ie (ilowatt) PS RW = 1.3596 PS Temperature (°C * PO = (180C + 32)°F ‘Mass quantity of [kg b kg = 2.2046 mater oz 1.9 =0.095274 02 Dimension | m t 1 m= 3.2606 rm in, 4mm = 0.03997 in. viiiGROUP 00 GENERAL GENERAL SPECIFICATIONS .. 00-2 ENGINE NUMBER AND NAME PLATE . 00-3 PRECAUTIONS FOR MAINTENANCE OPERATION 00-4 TABLE OF STANDARD TIGHTENING TORQUES . 00-12 00-1GENERAL SPECIFICATIONS Item Specifications | Engine model ‘6014 | 6014 | 6015 | 6016 | aD16 | e016 | 6016 | 60t6 | 6D16 < | 1 [se | nm |-ne Type ino, walr-cocled cycle csel ‘Combustion chamber ype Direct injection type Valve mechanism (Overhead valve (OHV) type Bore x Stoke mm WOxtis | Hox 118x116 115 Total eeplacement oo ess7__| gor 7545 Compression ratio wel 6 | ws] 6 175 Empty mass ko soo | 540 500 350) 560 = Empty mass as measured according to Miteublahi Motors Corporation standard Engine Outputs Classified By Application Engine model om | 6D14-T 6D16 6D16-T Middle-speed | High-speed Middle-speed | High-speed Application Spectication | spsclieaton Spectication | specication Intormitont rated ouput [50 (76)1500 | aa tr1y/1600 | 79 (roByA600 [74 (esyI600 | Y0s cr4ay/1600 | Tor (186) 1600 KW (HP) | 70 @4y1a00 | 98 t32y1000 |95,x27/1800 | as 114y1800 | 123 (185)1800 | 121 (169)1800 77 1032000 | 106 1432000 | 103 (1992000 | 93 (1252000 | +91 (1762000 | 191 (1752000 2 r10y2200 | 111 (1S0y2000 | 111 (1S0y2200 | 101 (125)2200 | 140 (188y2200 | 139 (186)/2200 7 (11792500 +20 16192500 | 111 (1402500 147 (1972500 92 (1292800 126 (1682800 | 120 1619/2800 151 2092800 Continuous rated output | 59 (721600 | 78 01/1500 |72(aeyis00 [a5 (71500 |e (reavi600 [ee (1281800 KW (HP) | 64 asy1200 | e0(s20y1000 Ja6,115y1800 | 77 (oayre00 | 11 149yte00 | 10 (1481800 o(say2000 | 96(r28y2000 | 94 (1262000 | e4 (113V2000 | 119 (1602000 | 118 (188)/2000 74,9sy2200 | 101 (1962200 | 101 (1962500 | 09 (1252000 | 127 (170y 200 | 125 (168)/2200 79 10872500 109 (1462500 | 101 (135)2500 1239 (1782500 ___|eacisnvaso0 114 (1532800 | 110 (1472900 137 (104/200 NOTE 1 ‘The output (SAE, gross) is corrected to standard ambient conditions based on SAE J1349. 2. The continuous rated output allows 10% (one hour) overload operation.ENGINE NUMBER AND NAME PLATE The serial number for engine is assigned to the respective engine in manufacturing sequence: every engine has its own number. This number is required for incidental inspection of the engine. Please do not fall to mention this number to tho dealers when ordering spare parts, Engine Number Engine number 1 is punch-marked on the left of the crankcase. Example: 6016-OOO000 L___ Engine Engine number mode! The namo plate is attached to the portion shown in the illustration, and indicate the following items. te770 1 Engine model ees 2 Total displacement 3 Maximum output tec [2 | 4 vivocmere Absron, arene” cron off eed : rl ee 6 Fuel injection timing 6 6 18780PRECAUTIONS FOR MAINTENANCE OPERATION inorder to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the ‘accumulated mileago, operating condition, what the customer's demand is, and other information that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure. sar70' sats! Determine where the fault exists and check for the cause to see whether ‘removal or disassembly of the part is necessary. Then follow the procedure specified by this manual. Perform maintenance work at a level area. Prepare the following. « Prepare general and special tools necessary for the maintenance work. WARNING /\ Do not attempt to use tools other than special tools where use of special tools is specified in this manual. This will avoid injury or damage. Pay special attention to safely when removing or installing heavy items such as engines, transmissions, ‘When lifting up heavy items using cables, pay special attention to the following points: ‘* Check the mass of the item to be lifted and use a cable capable of liting that mass. ‘* If you do not have the specified lifting hanger, secure the item using cable taking the point-of-balance of the item into consideration © You must work in a position where you will not be injured even if the cable comes undone and the lifted item falls0014 00016 Bo particularly careful not to work in shoes that have oily soles and are slippery. When working as a team of two or more, arrange signals in ad- vance and keep confirming safety. Be careful not to accidentally bump switches or lovers. ‘Check for oil leakage before cleaning the area having the fault othenwise You might miss detecting the leakage. Prepare replacement pari(s) beforehand. Replace oll seals, packing, O-rings and other rubber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts. On disassembly, visually inspect all parts for wear and tear, cracks, damage, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.PRECAUTIONS FOR MAINTENANCE OPERATION 00017! vote sated) Put alignment marks on part combinations before disassembly and arrange the disassembled parts neatly. This will help avoid mismating of the parts later. Put the alignment marks, punch marks, ete. where performance and ap- pearance will not be affected. Cover the area left open after removal of parts to keep it free from dust. CAUTION A, ‘« Take care to avoid mixing up numerous parts, similar parts, left and right, etc. * Keep new parts for replacement and original (removed) parts separate. Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly. Use only the specified oll, grease, etc. for lubricant, remove the excess immediately after application with a piece of waste, etc. CAUTION A\. When the specified lubricant, fluid and sealant is not available, you may use an equivalent. ‘Wear goggles when using a grinder or welder. Pay full attention to safely by wearing gloves when necessary. Watch out for sharp edges, etc. that right injure your hands or fingers. Before carrying out maintenance work on the electric system, disconnect the negative terminals of the batteries to prevent them from short-circuit ing and buring-out. CAUTION A\, Be sure to turn starter and lighting switches, etc. off before disconnecting or connecting battery terminals, because the semi- conductors can be damaged.0029 14105 ‘Take care when handling sensors, relays, etc. which are vulnerable to shock and heat. Do not attempt to remove the cover from, or apply paint to, the electronic contro! unit Pull the connector, and not the hamess lead, to separate connectors. To ‘separate a lock-lype connector, frst push toward arrow mark. To recon nect a lock-type connector, press the separated parts until they click together. When washing the vehicle, cover the electric system parts and instru- ‘ments with waterproof material beforehand (Cover with vinyl sheet or the like). Keep water away from harness wire connectors and sensors. If any of them should get wet, wipe them off immediately. When using an electric welder, such electronic parts that are directly con- ‘nected to the batteries might be damaged due to the flow of current from the welder that flows through the negative circuit, Parts thathave switches might be subject to the same danger ifthe switches are left on. Therefore, do not fail to observe the following. * Connect the negative terminal of the welder as near as possible to the area that is to be welded, ‘* Disconnect the negative terminals of batteries. ‘To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from 0 voll. Do not apply voltage higher than the specified valuo. In particular, pay close attention to the electronic control unit and sensors, since they are not always fed the battery voltage.PRECAUTIONS FOR MAINTENANCE OPERATION those parts IConhoct the test harness| land connector A between, When using testers or the like for continuity tests, be careful not to allow test probes to touch the wrong terminals, Connectors Test with connectors engaged (continuity through circuit obtained) Waterproof connector> Prepareatest hamess and connectors A, then connect fbetween the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector. Never inser the test probe from the hamess side of the waterproof connection, or waterproof performance might be diminished causing coro sion of the connector. - Insert test probe C from the harness side of the connector. Where control Units, etc. have connectors that are too small to accept the test probe, do not force the test probe into them. Test with connectors disengaged Using female pins Insert a test probe into a terminal. However, do not force the probe into tho terminal, or it wil cause a poor contact02590] n Procedures Connector Inspec 02503) Using male pins ‘Touch the pins directly using test probes. CAUTION A\ Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the internal circuit of the electronic control unit. Visual inspection Check for loose connection and poor engagement. Check if harnesses are broken by pulling gently around the terminals. Check for a decrease in contact pressure between the male and female terminals. Check for poor contact caused by connector pins having fallen out, rusted terminals or foreign particles. 00-9PRECAUTIONS FOR MAINTENANCE OPERATION 02504 02596] Inspection Procedures for Blown Fuses 00-10 Connector pin fall out inspection Damaged connector pin stoppers can cause poor engagement ofthe ter ‘minals (male and female pins) even ifthe connector body is secured, and ight cause some pins to fall out. Check ifthe pins have fallen out from the connector by pulling each harness gently. Remove fuse B and measure resistance between the loaded side of the fuse and ground. Tum on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0, a short has occurred between the switch and the loaded point. A value of other than zero may indicate that the fuse was blown by a temporary short but the short is no longer present. ‘The major causes of a short circuit are as follows: ‘¢ Hamess stuck onto the vehicle body. ‘© Hamess sheath damaged by friction or heat. © Water in connectors or circuits. ‘© Mistakes (accidental short circuits) A: Battery B: Fuso D: Load E: Shor circuit Precautions for Handling Alternator ‘When servicing the alternator, pay attention to the following: + Donot connect the alternator with battery polarities reversed. Ifthe altemator is connected with reversed polarities, a large current flow from the battery to the alternator occurs, and the diode or regulator might be damaged.was7t 05165: onrag * While the engine is running, do not remove the battery terminals. Ifthe battery terminals are removed at that time, a surge voltage is gener- ated and the diode or regulator might be weakened. + Do not use a high-voltage tester such as a megger for inspection, fa high-voltage tester s used, the diode or regulator might be destroyed, ‘© Dornot splash water over the alternator. Ifwater is directly splashed over the alternator, individual components will be short-circuited and might be destroyed. * Donot short-circuit terminal B and terminal L while running the alternator. {tthe torminals are short-circuited while the alternator is running, the diode trio might be destroyed. * Disconnect the battery terminals before quick-charging the battery. Quick-charging without disconnecting the battery terminals might damage the diode or regulator. 00-11TABLE OF STANDARD TIGHTENING TORQUES + Use specified bolts and nuts and tighten them at specified torques according to the following table, unless otherwise spe- ified. «Threads and contact seats shall be dry. ‘+ Where there is a difference in strength classification between the nut and bolt (or stud bolt) the torque specified for the bolt shall apply. Hex-head Bolt and Stud Bolt Unit: Nm (kgf-m) Sirengih classification oy aa or ay (4) © @ omen (4) OC} ©) |W symbol cus) (sw stu) | a 2i03 = ai06 7 5007 - {0.21003} {0.4 100.6) - (0.51007) a 4106 ~ Toit ~ @t0 12 = (041006) — | ezrin | (08t01.2) we 9t014 ~ 171026 ~ 201029 ~ (0901.4) (1.71026) | 20030) 191028 1.036 361082 B04 451060 a089 (1.9 to 2.8) {1.8 to 2.7} (85 to 5.5) {8.3 to 5.0} (4.5 to 6.0) {4.3 to 6.9) 235 1060 3110 46 70 t095 951085 a5 10 110 7510 100 {3.4 to 5.0} {3.1 104.7) {7.00 9.5) {6.5 to 8.5} {8.5 to 11) (7.5 to 10) nad 601085 551075 12010160 | tio%0140 | 190t0180 | 12010 160 (608s) | (651075) | (12t016) (181044) (19 018) (2017) ae 9010 190 010120 | 180t240 | 16010220 | 20010270 | 19010260 | (stor) | oti | (18t024) {16t022) (201027) {191026} a 14010190 | 1200160 | 260t0840 | 220t0200 | 80%0500 | 260%0 640 (14019), (12016) | _@5t095) (22030) {20t040)_| (261095) as 19010260 | 170% 200 | 95010470 | a20to420 | a10t0560 | 7010400 (19025) (17023) (96 t0 48), (2210.43) (41 1056) (6710 50) = 26010840 | 230%0300 | 7010640 | 43010570 | Ss0t0740 | 400t0670 (2610.35) (@stost) | (481065) (43 to 58) {6561075} (6010 68) ay 34010450 | 280%0300 | 63010840 | 54010730 | 7a0toa80 | 63010840 (4 to 46) (29%0 40}, (63085) 55t074)_|_(74t0100)_|_(641086) Hex-head Flange Bolt Unit: N-m (kgf-m) Sirengih classification a a a Repre- ~ sentation Diameter symbol 02164 a 406 ~ Biot ~ D104 ~ (041000) “(oatoi2) (0901.4) a 10t0 15 ~ 191028 ~ 221082 ~ (1.01015) 1.9102.) e239 | _| mo 2110.90 201028 391058 B70 53 501065 0 21031 | fo29 | sso | sta | otoes) | (4sto6s) as 381064 351051 80 0 110 701095 9010 120 9510 110 {3.8 to 5.5) (3.4 to 5.2) {8.0 to 11) {7.010 9.5) {9.0 to 12) {8.5 to 11) 00-12Hex-head Nut Unit: Nem { kgf-m) a > = = a xB aD ote es i Senet aaaanee [tiameimer |} Sameer ana MS {0.2 10.0.3} > [0.4100.6) = MG {0.4t0 0.6) = {0.7 to 1.1) > us 0.9 to 1.4) 7 {1.7 to 2.6} - es, | th aces ard ma ee} ee ee aoe ene, (aes, ie aoe acon mane Pace ae ee ee ee ie oo Saal Rance iseed imo ma te area ee (1410 19) {12to 16) (250.35) (22 10 30} a ee rae a ence eet aad meat a se pe reer eee ae ae cet ca ee pee eee ee {34 to 46) {29 to 40) {63 to 86} {55 to 74) Hex-head Flange Nut Gtsteaon is Repre- sentation Diameter oatss symbol ‘Standard sorew | Coarse sorow oe 40. 4 - 6) - Me | dowry) - mio | einen | dooee bli eswss | gawsy Unit: N-m {kgf+-m) 00-13TABLE OF STANDARD TIGHTENING TORQUES Tightening torque for flare nut for general purpose Unit: N-m (kgf) Pipe dameter Garémm | 9635 mm dem Hom aia Emm Tightening torque [17 0-7) 25 (2.8) 394.0) 59/60) 89 (90) 98 (10.0) Tightening torque for air piping nylon tube for general purpose {DIN type} Unit: N-m (kgf) Standard ameter Oxtmm 10x 1.25 mm 12x45 mm 15x15 mm Tightening torque W6 [99108 HO [ 49410 10 [ 59 +10 "5 [55t10 wg [aoee] | meg (once) | oe [soe] [oot (oe) Tightening torque for air piping nylon tube for general purpose {SAE type} Unit: N-m (kgf+-m) Standard dameler a ain Win. sin Tiakwening © 4 40.4 5 40.5 +5 40.5 +5 40.5 wom [se fasie4] | arg (s0:05) | aos [50795] | on (e5:95]TY GROUP 11 ENGINE SPECIFICATIONS ............. 02 ccc eecececcuceeuseecuces 11-2 STRUCTURE AND OPERATION 1. Cylinder Head and Crankcase . 1-3 2. Valve Mechanism 11-4 3. Connecting Rods 11-4 4. Pistons .... 15 5. Timing Gears . 11-5 6. Flywheel . 11-6 7. Flywheel PTO . 1-6 TROUBLESHOOTING ......... 0... ccceeceeeceecuseesecuee 11-7 ON-VEHICLE INSPECTION AND ADJUSTMENT 1, Measuring Compression Pressure . . 11-8 2. Inspecting and Adjusting Valve Clearances . 11-10 CYLINDER HEAD AND VALVE MECHANISM 11-12 PISTONS, CONNECTING RODS, AND CYLINDER LINERS ... 11-28 FLYWHEEL PTO .............c000ee wees 11-44 FLYWHEEL .. 11-48 TIMING GEARS 11-54 CAMSHAFT 11-64 CRANKSHAFT AND CRANKCASE ..........0...0.ceeccee 11-72 UlSPECIFICATIONS Silla tem Specifications Engine model eo1a | epiaT | opis7 | 6D16 | eD16e | GD16T | eDIE-TLE 6D16-TE eD16-TL Type -oylinder, n-ne, water-cooled, 4-cycle diesel ‘Combustion chamber type Direct injection ‘Valve mechanism Overhead valve Cylinder bore x stroke mm] gtOx 118 13 x 15: e118 x15 Total displacement oc 6557 6919 7545 ‘Compression ratio 175 16.0 75 19 16.0 175 U2STRUCTURE AND OPERATION 1, Cylinder Head and Crankcase 19241 01925} 1 Connecting plate 2 Glow plug 3 Cylinder liner 4 O-ing 5 Crankcase 6 Water jacket 7 Piston 8 Injection nozzle 9 Cylinder head ‘A: Cylinder liner size mark: A, B,C Tho cylinder liners 3 are a removable wet ‘ype liners. They are press-fittedinto the top of the crankcase § and the bottom of the wa- tor jacket 6. The O-rings 4 are provided o prevent the in- {gress of coolant. The cylinder liners 3 and pistons 7 have size ‘marks. The liner and piston that are paired should be of the same size mark. 16-7, 16-TE, 16-TL, 16-TLE> 1 Connecting plate 2 Glow plug 3 Cylinder liner 4 Crankcase 5 Water jacket 6 Piston 7 Injection nozzle 8 Cylinder head A: Cylinder liner size mark Outer diameter mark: 1, 2, 3 Inner diameter mark: A, B The oylinder liners 3 are a dry type liners that are easier to remove than wet liners. Liners are press-fitted into the crankcase 4. ‘The cylinder liners 3, crankcase 4, and pistons 6 have size marks, They should be ‘combined as specified according to the size marks. (1) P.11-28 3STRUCTURE AND OPERATION 2. Valve Mechanism 1926] 3. Connecting Rods <6D14, 15-T (A-type), 16, 16E> 4 1 Exhaust valve Inet valve Camshaft Tappet Push rod Rocker shaft Rocker shaft spring Rocker Rocker shaft bracket 10 Valve cap 11 Valve cotter 412 Upper retainer 13 Outer valve spring 14 Inner valve spring 15 Valve stem seal 16 Valve guide wevoasen The valve stem seals 15 are fitted onto the valves 1, 20 control the amount of lubricant flowing onto the sliding surfaces of the valves 1, 2 and valve guides 16. The valve springs 13, 14 are unevenly pitched to prevent abnormal vibration at high speeds. To prevent the inner and outer springs from meshing with each other, the springs are wound in opposite directions. To facilitate removal and reinstallation ofthe camshaft from the rear end of the crankcase, the diameter of each bushings small ‘er toward the front of the engine 1 Connecting rod bushing 2 Connecting rod 3 Connecting rod bearing 4 Connecting rod cap 5 Connecting rod bolt A: Alignment mark B: Weight mark stamp (A,B,C, D, E,F,G, HI, WX ¥ ~) (A.B, C, D, E, F: <6D16-TLE>)Lat | 4. Pistons c B A 0 “a” i) 5. Timing Gears 16937 16938 B:T mark <6D14-T, 15-T, 16-T, 16-TE, 16-TL, 16-TLE> C: Size mark (A, B, C: <6D14, 14-T, 15-T>) (A,B: <6016, 16-€, 16-1, 16-TE, 16-TL, 16-TLE>) 1D: Weight mark ‘A: Front mark Camshaft gear No. 2 idler gear No. 1 idler gear Oil pump gear Crankshaft gear Air compressor drive gear or injection Pump drive goar No. 1 idler gear PTO idler gear 9 PTO idler gear easena en Each gearis stamped with a timing gear align- ‘mont mark ("", "2", "3", or) to facilitate reas- sombly. USSTRUCTURE AND OPERATION 6. Flywheel Flywheel Pilot bearing 3 Ring gear ‘A: Angle scale, cylinder number 01994 7. Flywheel PTO Flange PTO shaft PTO idlor shaft Flywheel housing Crankshaft gear No. 1 idler gear PTO idler gear PTO idler gear PTO gear eovousens 8 The flywheel PTO is fitted onto the top of the fly- Wheelhousing 4 and isdriven by the crankshaft gear 5. ih 01995} 1-6TROUBLESHOOTING 11 ee ee ‘Symptoms Possible causes ‘Abnormal engine noise Remarks Incorrect oll viscosity Merte Incorrectidefective fuel Meri Incorrect valve clearance Defective cyintior hoad gasket ‘Worn valve/vaive seat, and carbon dapasits Weakened valve spring Worn/damaged piston ring(s) \Worn/damaged piston ring groove(s) Incorrect injection timing Meri Defective injection pump ofofofofofofofo Mears Defective cooling system Mert Defective injection nozzle(s) ° Mer13 Air trapped in fuel systom mer13 Clogged air cleaner Maris Clogged mutier Marts Defective turbocharger ofofofofofofofofofo[ofofololo/o} tow power output Maris Incorrect fied pipe(s)hoso(s) Marts Injeétion pump, alternator, or other auxiliary device(s) defectiverincorrecty fitted Marts, 54 Loose/damaged V-belt Mera Incorrectly fitted crankshaft pulley Dofective air cleaner or muitler Marts Detective valve spring(s) Detective rocker shaft and bracket Incorrect lubrication of rocker shaft bracket Incorrect backlash in timing gears Incorrect lubrication of timing gear peripheries and idler shafts ‘Worn connecting rod small end bushing and piston pin ‘Worn/damaged crankshaft pin and connecting rod big end bearing ‘Worn/damaged crankshaft journal and main bearing Excessive end play in crankshaft and camshaft ‘Worn tappot(s) and camshaft ofofofofo[ofofolojofofofofofolo 7ON-VEHICLE INSPECTION AND ADJUSTMENT 4, Measuring Compression Pressure Service standards Location Maintenance item Standard value Limit Remedy | — [Compression [Each oylinder | Except 6D16-E 2550 kPa (26 katlom?? | 4960 KPa (20 katiom®) | Inspect pressure |(at200%m)[epie-e 2940 kPa (30 kolfon?) Cylinder-to-cylinder pressure difference = 390 kPa {4 kgf/cm?) Inspect © Special tools Unit; mm Location Tool name and shape Part No. Application 99 10W 19 thread Compression — | gemeression 1MH061461 | Measuring comprossion pressure Contre distance 46 giggp Reductions in compression pressure should be used as a guide in determining the timing of engine overhauls. Take measurements regularly and keep track of changes; an overview of pressure variations can be useful in fault diagnosis. During the engine's run-in period and after parts have been replaced, the compression pressure will increase slightly as ton rings, valve seats, and other parts fit snugly in position. The pressure will then normalize as parts wear. Before inspections, check that the engine oil, starter, and battery are normal Warm up the engine unti the coolant temperature reaches 75 to 85°C. Turn off all ights and auxiliary devices. To prevent injection of fuel while cranking the engine by the starter, perform the following steps. * Set the stop lever of the injection pump governor to the stop position. Remove fuse 1 shown in the diagram below. For the terminal arrangement of the engine ECU, refer to Gr. 13E. Starter SW on i a ae Engine ECU z scene, ia stare a Battory relay | Battery > " T | e47306 IL-81938 01999 L411] ‘Remove the injection nozzle A. MM Gr13a CAUTION A, Cover the mounting holes and injection pipes to prevent the entry of dust and dirt. + Cover the injection nozzle mounting hole B with a cloth ©. Then, turn the engine over with the starter and check that no foreign matter adheres to the cloth. WARNING A\, If any cylinder is cracked, coolant, engine oil, and fuel will enter the cylinder through the crack. When the engine is turned over, these substances will spray out of the nozzle mounting hole B at ahigh temperature. For safety, move away from the nozzle mounting hole before turning over the engin + Fitthe ) Compression Gauge Adapter onto an injection nozzle mounting hole B together with a nozzle gasket. Then, connect the compres sion gauge 1 + Tum the engine over and measure the compression pressure. ‘* Measure the compression pressure in every cylinder and determine the pressure differences between cylinders, «If any compression pressure or cylinder-to-cylinder pressure dlifer- tence exceeds the specified limit, poura Iitle engine cil into the cylinder via the injection nozzle mounting hole B then take the measurement again. «© the compression pressure increases, there may be wear or damage on piston rings and inner surfaces of cylinders. « If the compression pressure does not increase, valves may be seized or incorrectly seated, or the cylinder head gasket may be defective. U9ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Inspecting and Adjusting Valve Clearances Service standards Unit: mm Location’ Maintenance item ‘Standard value Limit] Remedy —_ [Valve clearance (when cold) oa = ‘Adjust @ Tightening torques Unit: N-m (kgf-m} Location: Parts to be tightened Tightening torque Remarks 2,6 Rocker arm adjusting screw lock nut 34 (3.5) = / = 11620 1-10 Valve clearances should be checked and adjusted when the engine is cold, [Inspection] # Bringpiston No. 1 orpiston No. 6o the top-dead-centre (TDC) position of its compression stroke. To do this, crank the engine until the “1.6” mark inscribed on the flywheel is aligned with the pointer A in the fly- ‘wheel housing inspection window. (If the engine has a flywheel PTO, align the pointer A with the “O" mark inscribed on the torsional damper.) NOTE Pistons whose push rods are not pushing up their rockers are at top-dead-centre (TDC) of their compression strokes. ‘* When piston No. 1 or piston No. 6is at the TDC position of its compression stroke, measure the clearance B of every valve marked "0" in the following table. Piston No, ite |r atee | ox | ease mee an Valvoarangement |i. [Ex|in. [Ex] im. [Ex in. [Ex [n. [Ex | mJ. No. 1 piston at TOG of com prossion stoke eee No, 6 plsion at TOC of eon pression stroke NOTE To measure the clearance, insert a feeler gauge 1. The gauge should be able to move in the gap, albeit not loosely. Accurate measurements cannot be taken if the gauge moves loosely in the 9aL141. © If any measurement is out of specification, make adjustments as follows: [Adjustment] * To adjust the valve clearance B, loosen the lock nut 2 and turn the adjusting screw 3 until the feeler gauge 1 moves more stifly in the gap. ‘+ After adjusting the clearance, tighten the lock nut 2. At this time, use a screwdriver C to stop the adjusting screw 3 from turning. Next, insert the feeler gauge 1 once more to confirm that the clearance B is correct. UUCYLINDER HEAD AND VALVE MECHANISM conta @ Disassembly sequence 1 2 3 4 5 6 7 Joint Oil filer cap Bolt Plate Rubber Rocker cover gasket Rocker cover © Assembly sequence Follow the disassembly sequence in reverse. U-12 8 Cylinder head bolt 9 Rocker and bracket assembly Mp6 10 Cylinder head and valve assembly (1) P.11-20 11. Cylinder head gasket 12 Push rod 13 Tappet ‘#:Crankease ([] P.11-72 @: Locating pin © : Non-reusable part[11] Service standards Unit mm ; Standard value = Location Maintenanc: ease emer nL Limit | Remedy 12__ | Push od runout = 04 | Replace 48, * | Tappetio-crankcase 6D i4, 147.15-7 16, 181]0.06100.10 02 | Replace clearance 16E tappet 6016, 167E, 1671, {91]009t00.07 on 16TLE @ Tightening torques Unit: Nem {kgf-m) Location Parts to be tightened Tightening torque Remarks 1 [seine 0) = 3 | Rocker cover bolt 3.9 (0.4) = 8 | Cylinder head bolt (installation of rock [M14 bolt 78 {8} + 180° “|e Wet er and bracket assembly and cylinder © Can be roused head and valve assembly) up to 3 times: ‘Mio bot T7175) +34 GS) =_ A) Lubricant Location Points of application ‘Specified lubricant ‘Quantity 2 | Rubber seal of ol filer cap Engine ol ‘As required @ | Threads of onder head bots Engine ol As required 12_| Both ends of push rods Engine ot ‘As required 13 | Outer surfaces of tappets Engine oll = As required | Special tools Location Tool name and shape Part No. ‘Application 10 ‘Socket Wrench (MH063388° Tightening cinder head tits (N14 bolt only) 1984 ¢ Service procedure [10] Cylinder head and valve assembly [Removal] ‘© Before loosening the cylinder head bolts 8, loosen the adjusting screw Con every rocker A that is compressing its valve spring B. U-13CYLINDER HEAD AND VALVE MECHANISM 2-6 @ 0. a @ oo ooo (Be go Bo Wo do Cpe aie oe este oreo *@o *Ho *Bo ° U4 ‘= Loosen and remove the cylinder head bolts 8 in the sequence shown, Each cylinder head bolt should be loosened a litle ata time. [Installation] CAUTION A A AAA AAA Before fitting any cylinder head bolt 8, check the punch marks A. on its head. Do not use the bolt if there are more than two punch marks, The punch marks indicate the number of times each bolt has been tightened using the plastic area tightening method. Any bolt that already has three punch marks must be replaced. Tighten the cylinder head bolts 8 to the specified torque (M14 bolts: 78 N-m (8 kgf-m); M10 bolts: 17 N-m (1.75 kgf-m}) in the sequence shown. Then, turn the bolts further in accordance with the following procedure, * Tighten together with rocker and bracket assembly © to® : M14 bolt (wet) @ to® ; M10 bolt + Before fiting the ] Socket Wrench over a cylinder head bolt, tun the holdor D counter-clockwise to tension the builtin spring E: Socket F: Rod @: Rod (extension) # Set the socket such that the built-in spring force forces the rod G against the rocker shaft bracket, an injection pipe, or another nearby part. * On the holder D, select the inscribed line H that is easiest to see. '* Using the selected line as a reference, turn the socket E 180° clock- ‘wise. (One gradation on the scale J represents 5°.) CAUTION A, AA Since the KI14 cylinder head bolts 8 utilize the plastic region tightening method, they must not be tightened further after this procedure.0194s, 802 1948 11 «After fiting the M14 cylinder head bolts 8, tighten the M10 bolts to the spencified torque (34 N-m {3.5 kgf-m)) in the sequence shown ii] Cylinder head gasket [Removal] CAUTION A\. When removing the cylinder head gasket 11, be careful not to scratch the cylinder head and valve assembly 10 and the crankcase *. {Fitting} ‘* Fit the cylinder head gasket 11 onto the crankcase * as shown. [12] Push rod runout I any measurement exceeds the specified limit, replace the defective part(s). 13] |*} Tappet-to-crankcase clearance If any measurement exceeds the specified limit, replace the defective part(s). U-1SCYLINDER HEAD AND VALVE MECHANISM Rocker and Bracket Assembly -” 13 @ Disassembly sequence 1 Rocker assembly 2 Rocker bushing 3 Lock nut 4 Adjusting serew 5 Rocker 6 No. 6 rocker shaft bracket 7 Sot screw 8 No. 5 rocker shaft bracket 9 No. 4 rocker shaft bracket 10 No. 8 rocker shaft bracket 11 No.2 rocker shaft bracket 12 No. 1 rocker shaft bracket 19. Rocker shaft spring 14 Rocker shaft @ Assembly sequence Reverse the order of disassembly. Service standards Unit: mm : Standard value Location Maintenance item (ect denotes op Limit | Remedy 2, 14 _ | Rocker bushing-to-rocker shail clearance [240.01 00.08 012 | Replace @ Tightening torques Unit: Nem fkgf-m} Location Parts to be tightened Tightening torque Remarks 3 __|Adusting serew lock nut 34(8.5) = 7 [Rocker shaft set screw 3.9 (0.4) = A Lubricant Location Points of application ‘Specified lubricant ‘Quantity 2 [Rocker bushing inner surface Engine oll ‘As required ] Special tools Unit: mm Location Tool name and shape Part No. ‘Application 2 cee a MH081777 | Removing and installing rocker bushings H-16Service procedure 12905 2] [14] Rocker bushing and rocker shaft {Inspection} Hany clearance exceeds the specified limit, replace the defective part(s). Rocker bushing [Removal] {Instatlation] * Align the ollhole Ain the rocker bushing 2 with the ol hole Bin the rockers. * Position the notch C and seam D on the rocker bushing 2 as shown. ‘Install the rocker bushing 2 into the rocker § from the chamfered side F 6] [8] to[12] [74] installing rocker shaft brackets and rocker shaft Rocker shaft brackets Be sure to fit the rocker shaft brackets 6, 8, 12 in their correct positions, A: Oil hole B: Threaded hole (for M8 rocker cover bolt) C: Threaded hole (for M6 set screw) D: No threaded hole U-I7CYLINDER HEAD AND VALVE MECHANISM i 9024 M18 Rocker shaft ‘Align the oil hole G in the No. 6 rocker shaft bracket 6 with the oil hole H in the rocker shaft 14.MEMO u-19CYLINDER HEAD AND VALVE MECHANISM Cylinder Head and Valve Mechanism ~ 20300 - 01985, © Disassembly sequence 1 Valve cap 9 Injection nozzle (1) Gr 13 16 Inlet valve guide 2 Valve cotter 10 Dust seal 17 Exhaust valve seat 3 Upper retainer 11 Nozzle tip gasket 4 Outer valve spring 12 Nut 18 oyvane seat 5 Inner valve spring 13 Connecting plate 6 Valve stem seal 20 Cylinder head 7 Exhaust valve 14 Glow plug 8 Inlet valve maers4 @: Non-reusable part 15 Exhaust valve guide CAUTION A\. The injection nozzles 9 and glow plugs 14 project from the bottom surface of cylinder head 20. Take care not to damage them. @ Assembly sequence Follow the disassembly sequence in reverse. NOTE Any valve stem seal 6 removed from an exhaust valve 7 or inlet valve 8 must be replaced. 1-20OS Service standards Unit: mm i Standard value Location Maintenance iter oan Limit | Remedy Outer [Freciengh | edi4, 14-7, 15.7, 16, 670 40 | Replace valve 16E sering 0016-7, 16-76, ea 53 16-71, 16-TLE 4 inslalod oad [6D14, 14-7, 157, 16, 330 N (98.5 kal) 200N | Replace (2147.8 installed | 16-6 (29.7 ko {ength) 6016-7, 16-TE, ‘390 N {40.0 kof} ‘350 N 46-TL, 16-TLE {35.5 ko ‘Sauareness| = 25 | Replace inner [Freelength | 6Di4, 14-7, 15°7, 16, 554 521 | Replace valve 18E spring 6016, 16-TE, 51 ots 16-TL, 16-TLE Installed load | 6Di4, 14-7, 1577, 16, SON (@.4 kal) 7aN | Replace (2t 405 instated | 16-€ (8.0K9) 0 length) D167, 16, TSN (58 kgH 120NN 16-TL, 16-TLE (13.4 ko Squareness | 6D14, 14°7, 15 = 20 | Replace 16E 6016-7, 16, = 25 16-11, 16TLE Exhaust | Stem outside diameter p893t0 894 9885 | Replace valve | Sinkage from cylinder head battom sur- 13t017 20 | inspectev- 7 face ary location Valve margin 18 72 | Relace or replace Seat angle ae = Comect Inlet | Stom outside diameter 989610897 $885 | Replace valve [Sinkage from | Except @D16-= 111015 18 | inspect ev- oylnder head ry location e bottom surface [OD16-E 1St017 20 Valve margin 15 12 Reface or | replace Seat angle wae = Correct 7, 18 _| Exhaust valve stem-to-valve guide clearance (9]0.07%0.10 02 | Replace 8, 16 _ | inlet valve stomto-valve guide clearance {9]0.04 10.006 018 | Replace Exhaust valve seat width Tew22 28 | Gowector 7 replace 49 | let valve seat wiath Tew22 28 | Comoctor | replace ‘ylinder | Bottom surface distortion 0.08 orless| 02 | Conoctor 20 | head replace Height from top o bottom surface 94910 95.41 345 | Replace @ Tightening torques Unit: Nm (kgf) Location Parts tobe tightened Tightening torque Remarks 14 | Glow plug 151020 (151020) = 19 | Exhaust manifold mounting stud 2913) = U-21CYLINDER HEAD AND VALVE MECHANISM A Lubricant | Location Points of application ‘Specified lubricant Quantity 1___| Rocker contact surlace on valve cap top Engine ol 7s roquirod 6 __ [Lip of valve stom seal Engine of ‘As required 7,8 [Valve stom Engine oi As required ©) Special tools Unit: mm | Location ‘Tool name and shape Part No. ‘Application ‘A: M06 1660 a [A vaveuner (wan ¢42 _. B: Valve Liter Hook ea valve cottars 8: MHO61670 6 | Valve Stem Seal installer 2 ‘MH061293 ee 1067 : 30001-07600 Lapping valves and Valve Lapper (inet, exhaust valve seats 913 ‘uvi061066 ; Valve Guide Remover or Removing valve guides ° : 01989 15,16 92089 ney ‘s Instaling inlet and ex: Valve Guide Installer MHo61998 haust valve guides 10 orseo 11-22Location 17,18 ‘Tool name and shape Part No. ‘Application ‘K: Caulking Tool Body he MHO61067 B: Installor Ring B: MHos1605 Cdimen- <6014, 14-7, 15-7, sion. 16-7, 16-TE, 16-TL, ‘mnostees | 9 49 ee te MH06 1696 MHo6i606 | 942 <6D14, 14-7, 15: wrioet693 | 051 4677, 16-TE, 16-TL, _ | Installing valve seats wHoetes4 | 944 16-TLE> (Exhasut) 7 MH06 1693 <6D16, 16-E> (inlet) MHO61694 <6016, 16-E> (Ex: hhaust) Service procedures teat 1964 2] Valve cotters [Removal] To remove the valve cotter 2, use the [E] Valve Lifter to evenly compress the valve springs 4, 5. [Installation] To install valve cotters, follow the removal instructions in reverse, CAUTION A\ Do not compress the valve springs 4, 5 more than is necessary. Ifthe valve springs are compressed excessively, the upper retainer 3 can touch the valve stem seal 6 and be damaged. 4] [5] Installing outer and inner valve springs Fit the outer and inner valve springs 4, 5 onto the cylinder head 20 with their painted ends downward, A: Painted end 6] Installing valve stem seals ‘© Apply engine oil to the lip A of the valve stem seal 6. * Install the valve stem seal 6 using the ) Valve Stem Seal Installer. ‘Strike the Valve Stem installer until it sits snugly on the cylinder head 20, 11-23CYLINDER HEAD AND VALVE MECHANISM 196s 78 02204 7) [8] Valve [Inspection] (1) Valve stem outside diameter Replace the valve 7, 8 if its stem's outside diameter is below specification or severely worn, CAUTION A, Whenever a valve 7, 8 Is replaced, be sure to lap the valve and valve seat 17, 18. (|) P.11-25. (2) Valve seat angle and valve margin Reface or replace the valve 7,8 ifthe valve seat angle or valve margin ‘exceeds the specified limits. A: Valve seat angle B: Valve margin [Rectification] NOTE © Keep grinding to a minimum. © Ifthe valve margin Is below specification after grinding, replace the valve 7, 8. © After grinding, be sure to lap the valve and 7,8 valve seat 17, 18. (QP1t-25 11-24 \ 7] (8) [19] [1g] Vatves and valve guides {Inspection} Ifany clearance exceeds the specified limit, replace the defective pari(s). Valve guides [Removal]20 [=] 18 mm +18, 16 e220 TI | (nett) Install the valve guide 15, 16 using the E] Valve Guide Installer. Strike the Valve Guide Installer untiit sits snugly on the cylinder head 20. CAUTION A, » The valve guides 15, 16 must be pressed in to the specified depth. Be sure to use the ([E] Valve Guide Installer for this operation. © Exhaust valve guides 15 are longer than inlet valve guides 16. Be sure to install the correct type of guicle in each location. 7) [8] [17] [19] Vatves and vaive seats [Inspection] ‘+ Apply an even coat of minium to the valve seat 17, 18 surface A that ‘makes contact with the valve 7, 8 + Using tho (€] Valve Lapper, strike the valve 7, 8 against the valve seat 17, 18 once. Do not rotate the valve during this operation. NOTE Carry out these inspections after inspecting the valves and valve guides. «Ifthe minium deposited on the valve 7, 8 indicates a poor contact pattem, rectify the contact pattem as follows: 01970 Contact, Corrective aation Minor defect Lapping ‘Serious defect Reface or replace valve and valve seat [Refacing} Lap the valve in accordance with the following procedure: + Apply a thin, even coat of lapping compound tothe surface A of the valve 7,8 that makes contact with the valve seat 17, 18. CAUTION AA, $$$ Ensure that no compound adheres to the stem B of the valve 7, 8. NOTE ‘* Start with intermediate-mesh compound (120 to 150 mesh) and finish with fine-mesh compound (200 mesh or more).. ‘+ The addition of a small amount of engine oil makes lapping compound easier to apply. U-25CYLINDER HEAD AND VALVE MECHANISM 7,8 17,18 A 1975 7,8, 17, 18| 1-26 ‘Using the &] Valve Lapper, lightly strike the valve 7, 8 against the valve seat 17, 18 while turning it tle by litle. ‘© Wash away the compound with gas oil ora similar fluid, ‘© Apply engine oilto the contact surfaces of the valve seat 17, 18 and rub itin so that the contact surfaces are lubricated and mate together snug- y ‘* Inspect the contact pattern of the valve 7, 8 and valve seat 17, 18 once more. «Ifthe contact pattern is still defective, replace the valve seat 17, 18. [17] [19] valve seats {Inspection} (1) Valve seat width Ifthe measurement exceeds the specified limit, rectify o replace the valve seat 17, 18. A: Valve seat width NOTE Whenever a valve seat 17, 18 is rectified or replaced, be sureto lap the valve seat and valve 7, 8. ({] P.11-25 (2) Valve sinkage from cylinder head bottom surface \fany measurement exceeds the specified limit, rectify or replace the defective part(s) B: Valve sinkage [Rectification] ‘© Grind the valve seat 17, 18 using a valve seat cutter or valve seat grinder. ‘After grinding, put some sandpaper of around #400 grade between the cutter and valve seat and grind the valve seat lightly ‘+ Use a 15° or 17° cutter to achieve the specified valve seat width A. C: Valve seat angle CAUTION A\ Ensure that grinding does not cause the valve sinkage B to ex- ceed the specified limit. © After rectification, lap the valve 7, 8 and valve seat 17, 18, a p.t-2517,18 0.510 1.0mm cers. 3s 1974 1978 [Removal] Valve seats 17, 18 are installed by expansion fiting. To remove a valve seat, grind the inside surface to reduce its thickness, then remove the valve seat at room temperature. 1D: Material to remove [installation] * Check that the valve seat hole diameters E, F in the cylinder head 20, ‘conform with the values shown below. Unit: mm ent16 eD18£ Inlet valve seat hole (E) 9578 | gsa°ge Exhaust valve seat hole (F)| te ee © Cool the valve seat 17, 18 by immersing it in liquid nitrogen. © Install the valve seat 17, 18 n the cylinder head 20 using the Ja Caulk- Ing Tool Body and jb Installer Ring, * After installing the valve seat 17, 18, lap the valve seat and valve 7, 8. p.1t-25 2d Inspecting cylinder head ‘* Measure the extent of distortion in the cylinder head's bottom surface. «© Ifthe degree of distortion exceeds the specified limit, rectly the distortion with a surface grinder, CAUTION A\ Ensure that grinding does not cause the cylinder head's top surface-to-bottom surface distance to fall below the specified limit. 1-27PISTONS, CONNECTING RODS, AND CYLINDER LINERS © Pre-disassembly inspection MPat-30 © Removal sequence 1 Bolt 2 Lower connecting rod bearing 3. Connecting rod cap 4 Upper connecting rod bearing 5 Piston and connecting rod assembly (OPAt-36 6 Cylinder liner 7 Orting <6D14, 14-1, 15-T> ll pan (1) Gr 12 : Crankshaft (1) P.11-72 @ Installation sequence Reverse the order of removal. Service standards Unit: mm, Laton Maintenance tem eamaayane | int | _ Remedy =] Ran moaion 085 0 106 rata on Connecting rod end play 0.15 100.45 06 Replace 24,4 |Comeaingred [Oi dearnca | Ean (sjo04ieacs | —02 | — Replace beat soene 6D16-TLE {70} 0.04 to 0.09 Span when Escopt = Taastian ime oorene sos SOrETLE = Tass itan ; m8 36 [Pon andomneot [6014 T0T TagaeTeoIs | — as Ingrodasonbtyo- . = a etertertese [SET [199] 0.166 to 0.198, Replace ae 016,16 Tiejaarst60x05 | = lao eO16T, 1GTE TTL ETE | hejoras wares | = Felco © | Cros [Range rokecion 003190:10 = Felco ney Inside 6014, 14-T 6 110 to 110.035. 6110.25 Replace or grind Senet teovedsa wer dee names | eTaas | Ropes 0016, ETT TGTE TTL | oTt@te wens —| 91825] — Replace torte Spina oor, TST Taare =| Replas ord ity, to oversize W016 TEE, 18 OTE TOT, | om arieas —T Repiaceo ed tone Downie 1-28@ Tightening torques Unit: N-m {kgf} Location ~ Parts to be tightened Tightening torque Remarks 1 | Bol (connecting ro instalation) 29 (9)+ 90° 5° Wet mena Lubricant Location Points of application specified lubricant ‘Quantity 1 [Bolthreads Engine of As required 2,4 | Connecting rod bearing inside surface Engine of As required 6 | Oyinder liner outside surface Engine of Aa required I tools Unit: mm ‘Toot name and shape Part No, ‘Application Inctaing piston and 5 | Socket Wrench ito61560 connecting rod assembly 1984 Piston Guide| ‘Adimen- <6014, 14-T> ~|__ sion 30091-08200, aor, 147 | 9110 <6015-T> MHo51327 eoist | oto {nstaling piston and 5 connecting rod assembly <8016, 16, 167, As: Piston Guide Clamp 16-TE, 16-TL, 16-1LE> B: Piston Guide Lever ‘A: MH061760 8: MHOsi6sa yin Liner Extractor Caimen- <0014, 14-T> sion A: MHOST719 e014, 147 | 1095 A. Removing cylinder eoiet | 91125 BS ee liners . <0016, 16-£, 16-1, Serie 16-TE, 16-TL, 16-TLE> 16-7, 16-7E, | 41175 lore: a 16-TL, 16-TLE c c 01982 06173} Gynder Liner Instalior Adimen- <6015-T> (err type) ons Mio6i771 a 01983 1-29PISTONS, CONNECTING RODS, AND CYLINDER LINERS 01986 1-30 1988 Service procedure © Pre-disassembly inspection (1) Piston projection from crankcase top surface NOTE The piston projections affect engine performance and must therefore be checked. WARNING /\ With 6D16, 16-E, 16-T, 16-TE, 16-TL and 16-TLE engines, thecyl- Inder liners may rise out of position when the crankcase is turned over or the crankshaft is turned. Hold thelr flanges down using bolts and washers A. * Measure the projection of each piston at two points and calculate the average of the two values. AA: Front of engine Ifthe average value is out of specification, check the clearances between all relevant parts. (2) Connecting rod end play ‘* Measure the end play of every connecting rod. « Ifany measurement exceeds the specified limit, replace the det tive part(s) (3) Cylinder tiner flange projection If any measurement is out of specification, replace the defective part(s). B: Flange projection CAUTION A\. If the cylinder liner 6 flange projection is insufficient, bearing pressure on the cylinder head gasket will be too low in the region of the bore, possibly causing gas to leak.Lit] 01995 01996) 01997} 2] [4] Connecting rod bearings [Installation] Install the connecting rod bearings 2, 4 by fiting the lugs A into their respective grooves. CAUTION A, ‘The upper connecting rod bearing has an oil hole B. The lower connecting rod bearing has no oil hole. Take care not to confuse the upper and lower parts. {Inspection} CAUTION A\ ‘+ Do not attempt to manually expand a connecting rod bearing 2, 4 if its span is insufficient, Upper and lower connecting rod bearings 2, 4 must be replaced asa set, (1) Span when free Ifthe spanis less than the specified requirement, replace the upper and lower connecting rod bearings 2, 4 as a set. (2) Connecting rod bearing-to-crankshaft pin clearance {the connecting rod bearing-to-crankshaft pin clearance exceeds the specified limit, replace the defective part(s) 11650 5] Installing piston and connecting rod assembly CAUTION A\, * Ensure that the piston ring gaps A remain in their correct positions. (1) P.11-41 * Take care not to damage the piston crown B (the area that forms. part of the combustion chamber). * Ensure that the connecting rod does not touch the oil jet C. 1-31PISTONS, CONNECTING RODS, AND CYLINDER LINERS 1651 1-32 + With the piston’s “A" front mark facing the front ofthe engine, installthe piston and connecting rod assembly in accordance with the following procedure. D: Front of engine <6D14, 14-1, 15-T> <6016, 16-E, 16-T, 16-TE, 16-TL, 16-TLE> «© Fit the (Ela Piston Guide Clamp over the piston skirt. Using the boll E of the Eb Piston Guide Lever, adjust the clamp’s inside diameter such that it matches the piston’ outside diameter. * Once the (EJa Piston Guide Clamp is adjusted properly, remove itfrom the piston and smear engine oil over the following items: * Outside of piston «Inside of the (Eja Piston Guide Clamp # Cylinder liner F: la Piston Guide Clamp tightening direction + With the piston installed, align the mating marks F on the connecting rod and connecting rod cap 3 and tighten the bolts to the specified torque. Then, tighten the bolts 1 further in accordance with the following procedure.1901 le 11852 11 | ‘* Before fitting the [E] Socket Wrench over a bolt, tun the holder G count- cer-clockwise to tension the built-in spring. H: Socket J: Rod K: Rod (extension) ‘© Set the socket wrench such that the built-in spring force forces the rod K against the crankshaft. * On the holder G, selact the inscribed line L that is easiest to seo. + Using the selected line asa reference, tun the socket H90°+5°clockwise. (One gradation on the scale M represents 5°.) NOTE ‘ter fitting the connecting rod caps3, inspect the following items: ¢ Connecting rod end play ( (J) P.11-30) * Piston projections ((1) P.11-30) 5mm 50 mm or more 1099] LoS I 03375 5] [6] Piston-and-connecting rod assembly and cylinder liners {Inspection} <6014, 14-7, 15-T> «Ifthe cylinder section inside diameter ofthe cylindertiner6 exceeds the specified limit, remove the cylinder liner from the crankcase and rebore ito oversize. Also replace the piston and piston rings with ones sult- able for the oversized cylinder liner inside diameter. CAUTION A, Even if only one cylinder requires boring, bore every cylinder to the same oversized inside diameter. ‘A; Measuring direction of cylinder liner bore (crankshaft axis direction) ‘B: Measuring direction of cylinder liner bore (perpendicular to crankshaft axis) C: Measuring position of piston diameter (perpendicular to piston pin hole axis) ‘+ Evenif the cylinder section inside diameter of the cylinder liner 6s with- inthe specified limit, the piston and piston rings must be replacedifthe iston-to-cylinder liner clearance is out of specification, [Use of oversize pistons] * Oversizes available: 0.50 mm, 0.75 mm, 1.00 mm (three sizes in total) * Todetermine the required oversize, measure the inside diameter of every cylinder and find the cylinder of the largest inside diameter. Select ‘an oversize most suitable for the diameter. ‘+ Measure the outside diameter C of the oversize piston to be used. ‘* Bore all the cylinder liners to achieve the specified nominal piston-to- cylinder clearance. Diameter after boring (tolerance + 0.005 mm) = Oversize piston diame- tor € (measurement) + Piston-to-cylinder clearance (nominal range central value) — 0.02 mm (honing margin) 1-33PISTONS, CONNECTING RODS, AND CYLINDER LINERS 2000) ° 2001 I-34 * After boring, hone-finish the cylinder liner to the final diameter (tolerance + 0.005 mm). Final diameter (tolerance + 0.005 mm) = Oversize piston diameter © (measurement) + Piston-to-oylinder clearance (nominal range central value) CAUTION A, « Honed surface roughness: 2 to 4 um © Honing cross-hatching angle: 15 to 25° (half angle) + Squareness of cylinder bore: 0.05 mm © Check the piston-to-cylinder clearance, Cylinder liners [Removal] NOTE Many cylinder liner 6 mustbe reused after removal, makeanalign- ‘ment mark with paint and use this mark to reinstall the cylinder liner in its original position. {Installation] Apply soap suds G to the cylinder liner 6, Taking care not to twist the O- tings 7, insert the cylinder liner into the crankcase. CAUTION A, © Sizemarks Hare provided on the cylinder liner 6 and piston. When the oylinder liner is replaced, the new onemust beartthe same size mark as the piston. J: Oylinder liner size mark K: Piston size mark © After installation, check that the O-rings 7 are not twisted.185 mm or more 7 '5 mm of more 20 mm or more Fy 0975 ZA ©2008} 2004} <6D16-T, 16, 16-, 16-1, 16-TE, 16-TL, 16-TLE> fany clearance is out of specification, replace the defective part(s). D: Outside diameter measurement position E: Direction of crankshaft axis F: Perpendicular to crankshaft axis NOTE The cylinder liners are of a thin design and cannot be bored to ‘oversize dimensions. To prevent deformation of the cylinder lin- ets, do not remove them except for replacement. Cylinder liners [Removal] NOTE Ifany cylinder liner 6 must be reused after removal, make an align- ‘ment mark with paint and use this mark to reinstall the cylinder liner in its original position. + Apply engine oll to the outside surface of the cylinder liner 6. «Insert the oylinder liner into the crankcase and press itinto position using the (&) Cylinder Liner installer. Push down evenly on the entire upper surface of the Cylinder Liner Installer. CAUTION A\ + Size marks L are provided on the cylinder liner 6, piston, and ‘crankcase (6 places). When the cylinder liner is replaced, select the proper one according to the size marks on the crankcase and the piston, as shown in the illustration, M: Crankcase size mark N: Cylinder liner size mark P: Piston size mark © The cylinder liners are of a thin design. Handle them with care, and do not subject them to hammer blows or other severe shocks. I-35PISTONS, CONNECTING RODS, AND CYLINDER LINERS Piston and Connecting Rod Assembly © Disassembly sequence 1 Snap ring 2 Piston pin 3 Connecting rod bushing 4 Connecting rod 5. tst compression ring 66 2nd compression ring 7 Oilring 8 Piston © Assembly sequence Reverse the order of disassembly. 2012] Service standards Unit: mm Location Maintenange item Cate oD Limit} Remedy 2,8 [ison pinto-onecing vod [Excopt 6016 TLE {38}0.02 10 0.08 oi | Replace small end bushing elearace bpp TLE eaomeaons 2,8 | Piston pinto-iston dearance | Except 6D16-TLE [38] 0.004 190.08 005 | Replace eore Tle [210.004 10 0.02 “4 | Connecting rd bend and torsion = 005 | Corrector replace Bto7 |Pistonring | 1st compres ]6D14, 14-7, 0.310 0.48 15 Replace endgep [soning |15-T type) . 6D15-T (A type) 031005 15 6016, 1677, 167 03510055 15 eDI6-, 167E, 0351008 15 10-TLE 2nd compres- | 6014 a 0.3100.5 15 Replace sion ring 6014-7, 15-T 0.3 10 0.45 15 616, 16-T, 16-TL i 0.35 to 0.55 15 eD16-, 167 036 1005 15 6D16-TLE - 0.45 to 0.6 15 Oring [eDt4, 147, 187 031005 15 | Replace 6016, 16, 167, 03510055 15 16-78, 1611, iene 1-36——$———— SO Standard value Location Maintenance item (Gaate diameter ie) Limit | Remedy 5108 | Piston ringto- | tet compres- [eDt4 0.0916 0.48 02 Replace Bilston ring |sonring enter, 0.05 00.10 018 | Replace ee a 15-T (B type) ance D15-T (A type) 0.10 10 0.18 02 e016 O11 0.15 02 eoI6E 0.41810 0.17 02 e016, 1671, 0.1910 0.18 02 t6-TLE ‘2nd compres- | 6D14, 0.05 00.08 0.15 | Replace sion ring | 18-7 (A type), 16, 16 e014, 0.07 100.10 018 15-T 6 type), 16, 16-TE, 16-71, 16-TLE Oilting 0.0810 0.06 018 | Replace “6016-7 (B type}: wedge-shaped connecting rod small end A Lubricant Location Points of application Specified lubricant Quantity 2 __[ Piston pin outer surface Engine oil ‘As roquied '3__ | Connecting rod bushing outer surface Engine oll As required 4 _ [Bushing installation surface of connecting rod Engine oll As required © Special tools Location ‘Tool name and shape Part No. Application oat <0014, comeing 15 (A type), ushing rue 16, 16-E> . ioe 1778, $98 cao 3 EL Romoving and insaling connecting rod bushings 60147, 15-7 (Btype), Connecting 185 16Te, Rod Bushing > Puller Kit Clee) -<6D16-TLE> cans | MHO6a556 St07 |rision Ring 30091-07100 | Removing and insaling piston rings 1-37PISTONS, CONNECTING RODS, AND CYLINDER LINERS Service procedure 2] [3] Piston and connecting rod It the clearance exceeds the specified limit, replace the defective part(s) 1 hi @ I 02017 Connecting rod bushing <6D14, 15-T (A-type), 16, 16-E> [Removal] 4 Apply the (E] Connecting Rod Bushing Puller to the connecting rod bushing 3. Using a press, apply pressure of approximately 49 KN (5,000 kgf) | | 3 ‘such that the bushing is pressed out of the connecting rod 4, Unstattation] ‘* Align oil hole A in the connecting rod bushing 3 with oll hole B in the connecting rod 4, + Apply the (E) Connecting Rod Bushing Puller fo the connecting rod bushing 3. Using a press, apply pressure of approximately 49 KN (6,000 kgf) such that the bushing is pressed into the connecting rod 4 C4 {rom the chamfered side ¢. a NOTE After installing the connecting rod bushing3, insert the piston pin 13617] and check that it turns smoothly and without play. o>oh 1-382019) 11 <6D14-T, 15-T (Betype), 16-T, 16-TE, 16-TL, 16-TLE> Replace the connecting rod bushing 8 using the (€} Connecting Rod Bush- ing Pullor Kit. This consists of the following parts: D:Base E: Bracket F: Puller G: Collar H: Plate J:Collar K: Nut [Removal] ‘+ Remove the bearing (if fitted) from the big end of the connecting rod 4 ‘+ Mount the connecting rod 4 on the base D and lock it in position with the bracket E and plate H. ‘* Position the puller F and collar G as shown in the illustration. Then, slowly apply pressure of approximately 49 kN (5,000 kat) unti!the connecting rod bushing 3 is pressed out. [Installation] * Apply engine oil to the small end of the connecting rod 4 andto the outer surface of the connecting rod bushing 3. * Fitthe collar J over the puller F, position the connecting rod bushing 3 and collar G as shown in the illustration, and lock this arrangement together with the nut K. ‘* Align the oll holes Lin the small end of the connecting rod bushing 3 land connecting rod 4, Then, use a press to slowly apply pressure of ‘approximately 49 KN (5,000 kgf) until the bushing is pressedinto place. ‘+ After press-fiting the connecting rod bushing 3, ream ito achieve the specified nominal clearance between the bushing and piston pin 2 NOTE After installing the connecting rod bushing, insert the piston pin 2 and check that it turns smoothly and without play. 2] [4] [8] Piston pin, connecting rod, and piston [Removal] ‘© Tap out the piston pin 2 using a rod and hammer, «Ifthe piston pin 2 is difficult to remove, heat the piston 8 in hot water or using a piston heater. 1-39PISTONS, CONNECTING RODS, AND CYLINDER LINERS a er 2 0 tW4eD 202s) i 02016 [installation] ‘© Apply engine oil to the piston pin 2. With the connecting rod 4 and piston 8 aligned as illustrated, insert the piston pin to hold these components together. ‘A: Weight mark B: Weight mark (A, B, C, D, E, F, G, H, 1, V, W, X, ¥,Z) C: Alignment mark for connecting rod cap ‘A: Front mark ‘© Ifthe piston pin 2 is difficult to insert, heat the piston 4 in hot water or using a piston heater. CAUTION A, + No piston should differ from any other piston by awelght of more than log. * The connecting rods must all have the same weight mark. « After inserting the piston pin 2, check that it turns smoothly and without play. [2] [B] Piston pin-to-piston clearance Ifthe clearance exceeds the specified limit, replace the defective parts), 100 mm. 1-40 4] Connecting rod bend and twist «Fit the connecting rod bushing 3 and piston 2 in their respective positions of the connecting rod 4. + Measure the extent of bending A and twisting B in the connecting rod 4 + Ifeither measurement exceeds the specitied limit, replace the connect ing rod 4 or rectify i. €: Connecting rod 4 aligner (measurement device) NOTE © Before mounting the connecting rod 4 on the connecting rod aligner C, install the upper and lower connecting rod bearings in their respective positions. ¢ Measurements must be made with the connectingrod cap mounting nuts tightened to their specified torque. ([) P.11-295] to[8] Piston rings and piston Piston rings [Removal] {installation] '* Fitthe oil ring 7 onto the piston 8 with its side rail gaps A and the expan- der spring gap B in the positions illustrated, + Fitthe compression rings , 6 onto the piston such thatthe manufactur- er’s marks C near the gaps face upward. + Align the compression ring gaps D, E as illustrate D: 1st compression ring gap E:2nd compression ring gap :: Front mark [Inspection] (1) Piston ring end gap ‘= Using the crown of a piston 8, push the piston ring 5, 6 or 7 horizon- tally into a cylinder liner F for measurement. + Taking care not to move the piston ring 5, 6 or 7, measure the end. gap. Replace allthe ings ofapiston ifany gap exceeds the specified limit NOTE * To keep the piston ring 5, 6 or 7 horizontal, be sure to insort them into the cylinder liner F using a piston 8. * Push the piston ring 5, 6 or 7 downto the bottom of cylinder liner F; the bottom should be less worn than the'top. * Piston rings 5, 6 or 7 must be replaced as a set. Never replace piston rings individually. U-4lPISTONS, CONNECTING RODS, AND CYLINDER LINERS 2025; 2026) 11-42 (2) Piston ring-to-piston ring groove clearance + Ifany measurement exceeds the specified limit, replace the defeo- tive parts). * Measure the 1st compression ring 5 clearance with a thickness ‘gauge H while pressing the ring against the piston 8 with a straight edge G. NOTE ‘* Remove any carbon deposits from the ring groove of the piston Band measure the clearance around the piston’s entire periphery. + Piston rings 5,6, 7 must be replaced asa set. Never replace piston rings individually.MEMO [11] 1-43FLYWHEEL PTO 16019 @ Pre-disassembly inspection Cn P.t-45 © Disassembly sequence Flywheel PTO head assembly (1) P.11-46 Shim Seal cap ‘Nut Cover Ball bearing Cotter PTO idler shaft PTO idler gear A eerousena @ Assembly sequence Reverse the order of disassembly, 1-44 10 Spacer 11 PTO idler gear B 12 Spacer 13 Snap ring 14 Ball bearing 15 Snap ting © : Locating pin +: Flywheel housing (1) P.11-48Service standards Unit: mm Location Maintenance iter Standard value Limit Remedy = [Gearbaci [Between PTO idler gear [ 6016, 0.081020 0.38 | Reference lash AandNo. idler gear | 16-€ value e016, 0120026 0.36 16-7E Between PTO gearand | 6016, 0.08 19 0.20 035 | Raterence idler gear B 16E value e016, 0.121026 0.38 16-TE Total PTO goar backlash 0.181035 =P Reatiy or l replace @ Tightening torques Unit: N-m {kgf-m) Location Parts to be tightened Tightening torque Remarks 4__ [PTO idler shaft mounting nut 125 (12.8) a 204s @ Service procedure © Pre-disassembly inspection Gear backlash * Measurementof the backlash between PTO idler gear A andNo. 1 idler ‘gear and of the total backlash should be carried out at the 4100 pitch, circle on the PTO flange A. If backlash is out of specification, adjust it using a shim 2, ‘Shims are available in the following sizes: 0.1 mm, 0.2 mm, and 0.3 mm, '* Measurement of the backlash between the PTO gear and PTO idler ‘gear B should be carried out at the 6100 pitch circle on the PTO flange. Hold the PTO idler shaft B steady while taking measurements. Ifthe backlash is out of specification, adjust it using a shim 2. ‘Shims are available in the following sizes: 0.4 mm, 0.2 mm, and 0.3 mm,FLYWHEEL PTO Flywheel PTO Head Assembly 16021 © Disassembly sequence 1 Split pin 6 Seal cap 41. Spacer 2 Nut 7 Ball beating 12. Snap ring 3 Flange 8 Cotter 49 Ball bearing 4 Oil seal 9 PTO shaft 14 Cover 5 Rear cover 10 PTO gear @ Assembly sequence Opposite of disassembly sequence. Service standards Unit: mm Location Maintenance item Standard value Limit Remedy —_ [PFO shaft end play 01008 —__ | Replace @ Tightening torques Unit: N-m {kgf-m) Location Parts to be tightened Tightening torque Remarks 2 Flange mounting nut 7 125 (12.8) |e _ | ‘A Lubricant Location Points of application Specified lubricant Quantity 3__[ Flange splines Wheel bearing grease [NUGINO.2(Lisoap)] [As required 4 __|Oisoalip ‘Whee! bearing grease [NLGI NO.2 (Lisoap)) | As required [9 _[PTOshatt splines _ ‘Wheel bearing grease [NLGI NO.2 (Li soap)} | As requiredLit] Service procedure @ Pre-disassembly inspection PTO shaft end play If the measurement exceeds the specified limit, replace the defective part(s). 19610] 9] Removing PTO shaft A: Plastic mallet 16922! 47FLYWHEEL @ Disassembly sequence 1 2 3 4 5 6 7 8 9 Spacer Bolt ‘Washer plate Flywheel assembly Pilot bearing Ring gear Flywheel Rear oil seal Rear oil seal retainer © Assembly sequence Reverse the order of disassembly. 11-48 10 O-ting 11 Plug 12 Bolt 13. Flywheel housing 14 Thrust plate +: Crankshaft ([) P.11-72 ©: Locating pin ©: Non-rousable partes Service standards Unit: mm Location Maintenance item Standard value Limit | Remedy | 4 [Fiywheet | Friction surface distorion 0.05 or less 02 | Corrector assembly replace Height of fition surface 20 19 | Replace Friction surface runout (when = 02 Correct oF fited) replace 13 | Esoontcy of int = 02 | inspector replace @ Tightening torques Unit: Nm {kgf-m) Location Parts to be tightened Tightening torque Remarks 2 | Fivwhnee! mounting bolt 98 (10) + 150" © Wet © Can be reused Lp to 3 times meso Gr) 88 (9) = 12__ | Bolt 3405) = 40 [O-ring Engine of As required 13 | Engine mounting surface of fywheet housing Thresbond 12076 ‘As required ©) Special tools Location Tool name and shape Part No. Application Socket Wrench MHos2354 1904 4 Fiting lywio Magnetic Base Ho62356 oar 1-49FLYWHEEL Service procedure vate. 11-50 4] Flywheel assembly [Removal] ‘To remove the flywheel assembly 4, scrow the mounting bolts 2 into the removal holes A. [Installation] CAUTION A\ Before installing the bolt 2, check the number of punch marks K onits head. (If there are two or less, the boltis reusable.) The number of punch marks corresponds with the number of times a bolt has been tightened by the plastic region tightening method. If there are three (which means that the bolt has been tightened 3 times), replace the bolt. © Tighten the bolts 2 to their specified torque, then tighten them further in accordance with the following procedure: «Tum the holder B of the (E] Socket Wrench counter-clockwise to tension the builtin spring. C: Socket D: Rod E: Rod (extension) ‘© Set the socket wrench such that the built-in spring forces the rod E against the (EJb Magnetic Base. * On the holder B, select the inscribed line F that is easiest to see. '* Using the selected line as a reference, turn the socket 150° clockwise. (One gradation on the scale G represents 5°.) CAUTION A, Aa ‘Since the bolts 2 utilize the plastic region tightening method, they must not be tightened further after this procedure.0351 {Inspection} (1) Runout * Tighten the bolts 2 to their specified torque. * Ifrunout exceeds the specified limit, check that the bolts 2 are tightened correctly and inspect the crankshaft mounting surface. Then, rectify or replace the flywheel assembly 4 as required. (2) Height of friction surface Ifthe measurement is below the specified value, rectify or replace the flywheel assembly 4, H: Height of friction surface (3) Distortion of friction surface {t distortion exceeds the specified limit, rectify or replace the flywheel assembly 4, NOTE Hany abnormality is evident on the ring gear 6, replace the ring gear before making inspections. {[Resttication} Grind the friction surface such that its height H remains greater than the specified minimum. The fiction surface must remain parallel with surface J with a tolerance of 0.1 mm. 6] Ring gear {Inspection} Inspect the ring gear 6 for damage and abnormal wear. f any defectis evident, the ring gear must be replaced, USIFLYWHEEL [Removal] * Heat the ring gear 6 evenly with an acetylene torch or the like. CAUTION A, Be careful not to get burned. ‘® Remove the ring gear 6 from the flywheel 7 by tapping around its entire periphery. 8 cans [Installation] + Using a piston heater or the like, heat the ring gear 6 to approximately 100°C for 3 minutes. CAUTION A\. Be careful not to get burned. * Fit the ring gear 6 with the non-chamfered side of its teeth toward the flywheel 7. on ‘A: Chamfered side of ring gear '8] Fitting rear oll seal ‘© Apply an even, unbroken bead of sealant A to the rear oll seal 8 in the position illustrated B. « Fitthe rear oil seal 9 onto the flywheel housing 12 within 3 minutes of applying the sealant A. CAUTION Ay ‘* Ensure that the sealant application position B on the oil seal 8 is clean before applying sealant. ‘« When fitting the rear oil seal 8, hold it firmly in position to prevent spreading the sealant. «After fitting the rear oil seal 8, wait at least 30 minutes before starting the engine. Apply anew bead of sealant A whenever the mounting bolts of the rear oil seal 8 have been loosened. ‘© Apply engine oil to the lip of the rear oil seal 8. * Filthe rear oil seal 8 onto the flywheel housing 13 in the direction ilus- trated, 1-5211704 2062, * Fitthe rear ol seal 8 into the rear oil seal retainer 9 in the direction ilus- trated by pushing its periphery evenly until the end A becomes flush with the end surface of the rear oil seal retainer 9 all around. [13] Flywheel housing [Installation] * Apply an even, unbroken bead of sealant Ato the crankcase mounting surface of the flywheel housing 13. '* Fitthe flywheel housing 13 onto the crankcase wit plying the sealant A. CAUTION A\ + Ensure that the sealant application position on the flywheel housing 13 is clean before applying sealant. * When fitting the flywheel! housing 13, hold it firmly in position to Prevent spreading the sealant, * After fitting the flywheel housing 13, wait at least an hour before starting the engine. * Apply a new bead of sealant A whenever the mounting bolts of the flywheel housing 13 have been loosened. in 3 minutes of ap- {Inspection} * Rotate the crankshaft and check the extent of eccentricity atthe joint A of the flywheel housing 13. + eccentricity exceeds the specified limit, carry out reassembly + Ifeccentricity still exceeds the specified limit after reassembly, replace the defective part(s). 1-53TIMING GEARS _ _ 10960] @ Pre-disassembly inspection 1 Pa1-56 © Disassembly sequence 1 Bolt 10 Thrust washer @: Non-reusable part 2 No. 1 idler shaft 11 No. 2 idler gear bushing 3. No. 1 idler gear bushing 12 No.2 idler gear CAUTION A,X 4 No. 1 idler gear 13 No.2 idler shat ‘Since the No.1 Idler gear 4is sup- 5 Nut ported by the No. 1 idler shaft 2, 6 O-ring ‘ta: Drive gear these parts must be removed as 7 Collar +b: Camshaft gear (1) P.11-64 a single unit, 8 Orting +*e: Crankshaft gear (7) P.11-72 9 Bolt @ Assembly sequence Reverse the order of disassembly. U-S4Service standards ‘Unit: mm i Standard value imi Location Maintenance item (aslo wemeteria [D) Limit | Remedy — [Gear [Betweon No. 1 idler gear and crank: 0.08 100.15 0.38 | Replace backlash | shaft gear Betwoen No. 1 idlor oar and No. 2 0.07 190.18 035 | Replace ‘der gear Between No. 1 idler gear and drive 0.07 0.18 035 | Replace gear Between No. 2 idler gear and camshaft 0.08 100.16 035 | Replace ‘gear 2,3 _ [No.1 idler shafv-to-gear bushing clearance [8710001 100.05 02 Replace 4,12 _| idler gear end play 0.05 100.15 (03 | Replace 11, 13 [No.2 idler gear bushing-o-shaft clearance 182] 0.0% to 0.05 02 | Replace @ Tightening torques Unit: N-m (kgf-m) Location Parts to be tightoned Tightening torque Remarks 1 No. 1 idler gear mounting bolt 88 (9) tn 8 _ | Collar mounting nut 82 (8.4) = 9 [No.2idler gear mounting bort 95107) = A\ Lubricant Location Points of application ‘Specified lubricant Quantity 68 [Oxing Engine ol ‘As required I-55TIMING GEARS © Special tools Unit: mm Location ‘Tool name and shape Part No, Application Flemoving No. 1 idler 2,4 | Gear Pullor Hos 1326 fecep ps 2065 Toler Gear Bushing Pullor B No. 1> No. 1 idler 3.11 | [gearbush- ‘MHO62601 Romoving and iting iho idler gear bushings ‘No. 2 flor MH061779 gearoushe [92 | 935 ing A ©2066 — MIO x15 Removing No. 2 idler 13 |{Idlor Shaft Puller Ss MHos2405 pee ~ M8 x 1.5 ee 02067 @ Service procedure © Pre-disassembly inspection (1) Gear backlash For each gear pair, measure backlash at three or more points. f any measurement exceeds the specified limit, replace the defective part(s). 7288 (2) Idler gear end play Ifthe measurement exceeds the specified value, replace the defective part(s) 1-5602576 srt ga ©. 3 B casa 2070 2074 [2] [3] No. 1 idler shaft and No. 1 idler gear bushing {inspection} Ifthe clearance exceeds the specified limit, replace the defective part(s). No. 1 Idler gear bushing [Removal] A: Press [Installation] * Using the } Idler Gear Bushing Puller, press the No. 1 idler gear bushing 3into the No. 1 idler gear 4 from the side of the gear whose intemal diameter is chamfered B. A: Press ‘+ Alterinstallation, measure the clearance again. Ifthe measurement is below the nominal value range, ream the bushing 3. 2] [4] Removing No. 1 idler shaft and No. 1 idler gear Loosen the bolt 1 by approximately 15 mm, then remove the No. shaft 2 and No. 1 idler gear 4 as a single unit 4] [12] installing No. 1 and No. 2 idler gears Fit the No. 1 and No. 2 idler gears 4, 12 such that their alignment marks (1",°2", "3°," are aligned with those on the gears with which they mate. a: Drive gear *b: Camshaft gear 0: Crankshaft gear u-57TIMING GEARS [14] [13] No. 2 idler gear bushing and No. 2 idler shaft [inspection] Ifthe clearance exceeds the specified limit, replace the defective part(s). 02579) No. 2 idler gear bushing & [Romovall A: Press ra} {installation] ‘© Using the ] Idler Gear Bushing Puller, press the No. 2 idler gear bushing 11 into the No. 2idler gear 12 from the side of the gear whose intor- nal diameter is chamfered B. aN A: Press 12 a] + Aterinstallaton, measur the clearance again If the measurements é&T-=1 below the nominal value range, ream the bushing 11. se [13] Removing No. 2 idler shaft exors H-581 MEMO 1-59TIMING GEARS ad © Disassembly sequence 1 Bolt 6 Thrust washer a: Drive gear 2 Oring 7 No. 2 idler gear bushing *b: Camshaft gear(T] P.11-64 3. No. 1 idler gear bushing 8 No. 2idler gear +e. Crankshaft gear (1) P.11-72 4 No. 1 idler gear 9 No. 2 idler shaft +d: Thrust plate (1) P.11-48 5 No. 1 idler shaft © Assembly sequence Reverse the order of disassembly. ©: Non-reusable part Service standards Unit: mm it Standard value : Location Maintenance item (oasle diameter [) Limit | Remedy — [Gear [Between No. 1 idler gear and crank (0.07 10 0.20 0.35 Replace backlash | shaft gear zl Betwoon No. 1 idler gear and No. 2 (0.1010 0.22 035 | Replace idler gear Betwoon No. 1 idler gear and drive 0.10 10 0.20 035 Replace gear Between No. 2 idler gear and camshaft 01210 026 035 Replace gear 3,5 _ [No.1 idl shaf-to-gear bushing clearance 140] 0.08 to 0.07 02 Replace 4 _ [No.1 idler gear end play 0.11006 10 Replace 7,9 _ | No. 2 idler gear bushing-to-shaft clearance (32}0.01 t0 0.05 02 Replace 8 _ | No. 2idler gear end play 0.05 to 0.20 04 Replace 11-60@ Tightening torques Unit: N-m {kgf-m) Location Parts to be tightened Tightening torque Remarks 1__ | No. 1 idler goar mounting bolt 195 to 165 {14 10 17) = + Lubricant Location Points of application Specified lubricant Quantity 2 [Oring Engine oll As requied| © Special tools Unit: mm Location Part No. ‘Application Ter Gear Bushing Puller ale 8 No. 1 idler No. 1» 3,7, || gearbush- | o40|qaa MHO6 1228 Removing and fing . a idler gear bushings ‘No. 2 lor MHO6179 gear busi | @ 32 | 935 ‘ha rN 02066 26a dd Service procedure @ Pre-disassembly inspection (1) Gear backtash For each gear pair, measure backlash at three or more points. f any measurement exceeds the specified limit, replace the defective part(s). (2) No. 2 idler gear end play Ifthe end play measurement exceeds the specified value, replace the defective part(s). U-61TIMING GEARS [3)[5] No. 1 tater gear bushing and No.1 idler shatt {ispecton] Ifthe clearance exceeds the specified limit, replace the defective part(s). QA No. 1 Idler gear bushing pe [Removal] ‘The No. 1 idler gear bushing 3 consists of two parts, Press out both paris [;* together. T A: Press GAS [Installation] aS ‘© Using the (€] Idler Gear Bushing Puller, press each part of the No. 1 idler gear bushing 3 into the No. 1 idler gear 4 from its respective side of the gear. A: Press, pe + After installation, measure the clearance again. if the measurementis below the nominal value range, ream the bushing 3. io a 02584 4] No. 1 idler gear end play ‘Measure the dimensions shown in the illustration and determine the end play D using the formula shown below. If the end play exceeds the specified limit, replace the defective part(s). D=72.15mm—(A+B+0) 4] [B] installing No. 1 and No. 2 idler gears Fitthe No. 1 and No. 2idler gears 4, 8 such that hei as wmentmarks ("", "“4") are aligned with those on the gears with which they mate. a: Drive gear ‘*b: Camshaft gear 0: Crankshaft gear 11-62om a So, a 7 7} [9] No. 2 idler gear bushing and No. 2 idler shaft Linspection] Ifthe clearance exceeds the specified limit, replace the defective part(s). No. 2 idler gear bushing [Removal] A: Press, [Press fitting] * Using the ¢} Idler Gear Bushing Puller, press the No. 2 idler gearbush- ing7 into the No. 2 idler gear 2 from the side of the gear whose internal diameter is chamfered B. A: Press, ‘* Afr installation, measure the clearance again. If the measurementis below the nominal value range, ream the No.2 idler gear bushing 7. 1-63CAMSHAFT “Ath electie speed sensors 0410 agile - Aye Alay . 9 ea 18061 @ Pre-disassembly inspection (2 P.tt-66 @ Disassembly sequence 1 Engine speed sensor speed sensor> 41 Camshaft 2 Adapter ‘models with mechanical 13 No. 3 camshaft bushing Tachometer drive case 14 No. 2 camshaft bushing with mechanical tachometer> 5 Side cover 15 No, 1 camshaft bushing 3 O-ting 6 Camshaft assembly 7 Bolt +: Crankcase [1] P.11-72 8 Camshaft gear ©: Non-reusable part 9 Thrust plate NOTE ‘* Do not remove the engine speed sensor 1 unless defects are evident. ‘* Do not remove the camshaft gear 8 unless defects are evident, © Assembly sequence Reverse the order of disassembly. 11-64Service standards Unit: mm 5 Standard value ji Location Maintenance item eatnervaie Limit | Remedy 1__ | Resistance of engine speed sonsor (at 25°C) 23402kO = Replace 6 | Camshaft assembly end play 0.05 10 0.22 oa Inspect ‘each part 11 [Camshaft [Cami inlet Excopt 6901 640 | Lobo SDI6E height: 49.011 Base circle diameter: 42.110 SOI6E 72 693 | Lobe height: 50.33 Base circle diameter: 42.91 Exhaust 7.680 748 [Lobe height: 49.307 Baso circle diamoter: 41.627 Bond 0.02 orless 0.04 | Replace 11, | Camshattjounato- [No.1 journal [57,75]0.05 16 0.10 025 | Replace p2tong camshalt bushing clear- Tio, 2 journal [58.00] 0.05 to 0.10 No. 3 journal (58.25) 0.13 to 0.18 No. 4 journal [58.50] 0.05 t0 0.10 @ Tightening torques Unit: N-m (kgf-m) Location Parts to be tightened Tightening torque Remarks 1 | Engine speed sensor 98 (10) = 7___[Camshatt gear mounting bot 175 (18) = A Lubricant and/or sealant Location Points of application ‘Specified lubricant and/or sealant | Quantity 11 | Engine speed sensor threads ‘5 __|Crankcase mounting surlace of side cover Threobond 12076 ‘As required 41 | Camshattjourals Engine oil As required 12 to 15 | inside surlaces of camshaft bushings Engine oll ‘As required H-65CAMSHAFT “J Special tools Unit: mm Location TTool name and shape Part No. Application Blanking plug for uso Plug MF665007 when removing cam- rine shalt gear | 2082 8 Goar Pullor Hosts28 Ronoving cars 02065 ‘Camshaft Bushing installer ‘and Extractor ‘A.C ak | Bdimen- mension | ~ sion c, Romoving and instal tate ts ||No1} #6200 | 987.75 MHos2025 ling camshatt bust No.2 | ¢6225 | 458.00 inge No.8 | @62.50_ | 958.25 No.4] ¢62.75 | 95850 | A 2063 Service procedure 2084 © Pre-disassembly inspection Camshatt end play It the end play measurement exceeds the specified limit, replace the defective parts). 03674 7] Inspecting engine speed sensor Measure the electrical resistance between terminals ® and @. Ifthe measurementis out of specification, replace the speed sensor 1. mort (CAUTION AX, A Check the tightening torque of the engine speed sensor 1. If the sensor is insufficiently tightened, it may not produce signals. 11-66}<6D14, 6D14-T, 6D15-T> O15 — A -<6D16, 16-E, 6D16-T, 16-TE, 6D16-TL, 16-TLE> '5] Fitting side cover ‘Apply an even, unbroken bead of sealant A to the side cover 6, « Fitthe side cover S onto the crankcase within 3 minutes of applying the sealant A. CAUTION A, Ensure that the sealant application surface of the side cover 5is clean before applying sealant. «When fitting the side cover 5, hold it firmly in position to prevent spreading the sealant. © After fitting the side cover 5, wait at least an hour before starting the engine. * Apply anew bead of sealant A whenever the mounting bolts of the side cover § have been loosened. 6] Camshaft assembly [Removal] * When removing the camshaft assembly 6, take off the side cover Sand ‘support the camshaft by hand. ‘* Remove the bolts A from the camshaft gear holes, then slowly remove the camshaft assembly 6. CAUTION A, ‘Take care not to damage the camshaft bushings 12 to 15 when removing the camshaft assembly 6, 2092! [Installation] + Before insaling the camshaft assembly 6, measure the end play between the thrust plate 9 and camshatt 11. «Ifthe measurement exceeds the spectted limit, replace the defective part(s). + With the alignment marks lined up on the camshaft gear 8 and No. 2 idler gear, fit the camshaft assembly. [1] P.11-54 8] Camshaft gear [Removal] CAUTION /\, The camshaft gear 8 must be removed with the appropriate special tools. Do not tap off the camshaft gear since this would damage it. Gla: Gear Puller (eb: Plug 11-67CAMSHAFT [installation] © Fitthe camshaft gear 8 onto the camshaft 11 in the direction illustrated, ‘* Do not forget to fit the key 10. - 111] inspecting camshaft n (1) Cam lift a fany base circle-to-lobe height difference is less than the required val- | _ue, replace the camshatt 11 Pea NOTE Vn J ‘Since the cams are tapered, they must be measured at the posi- oe ed tion A shown in the diagram. A A e290] B: Lobe height C: Base circle diameter D: Front of engine. (2) Camshaft bend ‘Support the camshaft 11 atits No. 1 journal E and No. 4 journal F, then take measurements at the No. 2 journal G and No. 3 journal H. If either measurement exceeds the specified limi, replace the camshaft. NOTE ‘Turn the camshaft 11 through one revolution. One-half of the dial indicator reading represents the camshaft’s bend. [14] to [15] Camshaft and camshaft bushings [Inspection] any clearance exceeds the specified limit, replace the defective paris). NOTE Measure the camshaft bushings 12 to 15 with the camshaft Installed in the crankcase. 1-6811 Camshaft bushings Romoval and installation of camshaft bushings should be carried out using the (€] Camshaft Bushing Installer and Extractor. Each guide of the tools stamped with an identification mark ("1",°2", "3°, "a" in the position shown, Use correct adapter and/or guide piece to remove and install a 121015 sat A bushing according to the table below. Bushing No. (rom front of engine) Identification marie Noa 1 1020 No2 2 Nos - 3 Nod 4 A: Rod B: Camshaft bushing adapter ©: Guide piece D: Nut [Removal] tater | Flamovo the No. 4 and No, 3 camshaft bushings 12, 18 from the rear of the engine. Remove the No. 2 and No. 1 camshaft bushings 14, 15 from the front of the engine. ():Camshaft Bushing Installer and Extractor [Installation] ‘+ Identify the No. 1 toNo. 4 camshaft bushings 12 to 15 from their identi cation marks ("1”, "2", 3", “in accordance with the table below. Ifany bushings identification mark is unclear, identify the bushing from its in- tomal diameter E. Bushing No. Identification mark. Internal diameter (from front of engine) (rom) No.1 1 957.75 No.2 2 958.00, Noa 3 958.25 Nod 4 958.50 11-69

Mitsubishi 6d15 6d15t Shop Manual, Service Manual

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Mitsubishi 6d15 6d15t Shop Manual, Service Manual

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