6D1 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 6D1 series diesel engine, and includes procedures for ad- justment and maintenance services. ‘We earnestly look forward to seeing that this manual is made {ull use of in order to perform 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 fine with improvement which will be effected from time to time in the future, Applicable models 6D14 — 6D14-T eD15-T 6D16 eDIG-E 6D16-T 6DI6-TE 6D16-TL @6D16-TLE E3500 © 2001 Mitsubishi Motors Corporation Printed in Japan GROUP INDEX HOW TO READ THIS MANUAL GENERAL ENGINE LUBRICATION ta FUEL AND ENGINE CONTROL .. Ell ELECTRONICALLY CONTROLLED FUEL SYSTEM ** Ea CONG: =... | Ea INTAKE AND EXHAUST .......... El Ea 54 | Ea CLUTCH ELECTRICAL SYSTEM . SPECIAL EQUIPMENT NOTE : The parts marked "3" are deleted as they are not applicable to the E335;N)LcHOW TO READ THIS MANUAL HOW THIS MANUAL IS COMPILED .......-sseseeeeeeeeeee ii GENERAL EXPLANATION OF THIS MANUAL. TERMS AND UNITSHOW 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; -\ lubricant, fluid and sealant; ) special tools; and service procedure. ‘+ Page enumeration is independent by every group where firs page is always 1. Group ~ Group denomination Contents No. _ 00 | General General specications, engine No. and name plate, precautions for mainte | nance operations, table of standard tightening torques 1 | Engine Engine body | 12 Lubrication Lubrication system: __ 13” | Fuel and engine contre Fuel system 14 Cooling Cooling system: Z 15 [intake and exhaust Intake and exhaust eyatom, turbocharger, intercooler at Clutch Clutch proper, bearing case _ 54 | Electrical system’ ‘Alternator, starter, preheating system, engine start system, automatic stop system G1 [Soma oasipment ‘Ar compressor pressure goveror = 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 vet Descriptions are made regarding inspection and adjustment of units mounted in vehicle, @ Service procedure Inprinciple, an explanationis given atthe spread ttle page so that the service procedure can be understood. Servicing points are explained as a supplementary explanation. le Regarding the design of this manual ames om 5 =o ae eats 1. sss... Illustration for disassembly and assembly or removal and installation: 3-D exploded view of component parts is displayed 1a. ..... Names of parts show an example of the disassembly (removal) sequence. 1b. ..... When the assembly (installation) sequence differs 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 procedure, just by the foregoing description, a supple- ‘mentary description of the service procedure is given. oraenHOW TO READ THIS MANUAL 1. Illustration for disassembly and assembly or removal and installation ‘This shows that the appropriate service proce- dure is described in the text. | cLutcH Bopy / Pressure Plate and Lever Assembly (© Assombly sequence Repair okt aoa Meaning of symbols @: shows that the tightening torque is specified. -(t shows that application of lubricant, fluid or sealant is required. @: shows that the part should not be reused. iv Upotatto attr et 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. _— Voraoect 2 Wacer 3 waster ‘This shows that the service 8 Lecplt procedure Is described in 5 prem sag another section. preroo} ({MPOO-CO ohamerg > shows reference page 18 Raat within the same group. 12 Palate ver in mMeroo 18 Spat bn : shows reference group 18 Seppo ever within the same books. 1 pare ovr 1 bosang 2 Procsuro pate & lover asonby pair Eye ring pin at 2 parse) a ove \ No service procedure is referred to in this section, but the item can be an objective of various proce- dures. 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.ooo 2. Service standards table Only the relevant service standards are shown. ' Service standards ‘Unit: mm Tocaton Waintenance tem T Standard value Timit_| Remedy 1,11 | Gearance betwaen ap bolt ard erap sto DoT O16 03 | Renae 7 [Pressure apring | instalied ond SRS 5 ah FON | Replace (iret ong 49.1) esha rT zaeriess 0 | Ronse A ‘This shows the key No. of the relevant part. 3. Tightening torque table This shows specified tightening torque. @ Tightening torque ‘Unit: Nm {kgf-m) Location Par tobe ightoned Tightening torgue Remarks | Sap bate irap bot mounting) 391059 (4108) = [Bat Cec lie uningy Fai078 (08008) wa This shows the key No. of the relevant part. 4. Lubricant, fluid and sealant table Only the relevant lubricant, fluid and sealant are This shows that the item is to be tightened wet. shown. { ‘This shows the application point. A Lubricant, fluid and sealant Location Peri oT appcaion yp Kinds Guaniy 1 _[ Fears ofbot Loarine a7 ‘erewed 70, 16 | Fron surfaces oracase over plate aa release over | Moydarum ei ease ‘sronued NLS (sooo a 1 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 Unit: mn Tocation | Tool name and shape Application | ~~ y 11 | Clutch instar Removal and installation of clutch cover own [| he 16 | Mester pate S aoe Aust eoas overnights \ ae 01278 | ‘This shows the key No. of the relevant 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 5, 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. A Servicing procedures of disassembly (removal), The key No. referred to in the text is always the Sere eae sic caine same as the key No. shown in the illustration. Rina viTerms 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 identify 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 /A\, ———— Precautionary instructions, which, if not observed, could result in serious injury or death CAUTION A, ——— Precautionary instructions, which, not observed, could resultin damage to or destruction of equipment or parts. NOTE ‘Suggestions or supplementary information for more efficient use of equipment or a better understanding, @ Front and rear The terms “front” is the fan side and “rear” 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. viiHOW TO READ THIS MANUAL @ Unit Tightening torques and other parameters are given in SI* units with metric units added in brackets {}. “SI: Le Systeme Intemational d'Unités. Example: 390 N-m {40 kgf-m} '— Metric unit ‘St unit Unit ST unit (metic unith Conversion factor “Force NikaA) ‘9.80665 N {1 kal} Moment of force Nem (kaf-m) 8.80605 N-m (f kof-mj Positive pressure kPa (kg/cm?) 198.0665 kPa {1 kgl/em?) Pressure ee KPa (mmHg) 10.4992 KPa (1 mmHg) Pa {mmHz0} 9.80665 Pa {1 mmH 0} Volume ~ ‘amo (L) Tam (1 L) Power RW IPS) O7355KW (1 PSY Heat quaniity tL co) ke Heat flow W kcal) Angle ~ . ~ - “Temperature *c = Eleotric current A = Vortage v = Resistance 7 2 ~ a Electic power w = Unit Shunt Foot pound unit Conversion rae Force IN (Newton) wf T N= 0.2246 If ‘Moment of force [N-m ‘ibs TN-m= 0.7976 tbs Pressure | kPa (kilopascal) psi 1 kPa = 0.145 psi 1 kPa =0.2959 in. Hg Volume L gal, 1 L = 0.2642 gal. (U.S.) 7 Z 1L=0.220 gal. (imp,) om? o 1 om = 0.082814 oz (US.) 4 em3 = 0.035195 oz (Imp.) om? cu.in. 061023 cu.in. Power iW (iowa) PS 3596 PS Temperature °C oF PC = (1.80°C + 32)°F Mass quantity of [kg © 2046 Ib matter Ai a Dimension m tt viiiGROUP 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GENERAL SPECIFICATIONS [ Item Specifications Engine model epia €DiG | Go16 | 66 | 6DIG | Ebi [eDiE ~ | [se | -n | ne Type incline, waler-cooled 4-eycle diesel ‘Combustion chamber type Direct injection type Valve mechanism Overtiead valve (OHV) type Bore x Stroke mm Tox ie] tax 118x118 15 “otal displacement oo oss7__| 69i9 7548 ‘Compression ratio _ 75 16 175 [19 16 175 Empty mass kt 500 | 540 500 550 500) * Empty mass as measured according to Mitsubishi Motors Corporation standard. Engine Outputs Classified By Application Engine model 6D14 eDi4aT 6D16 ~~ e1eT Middle-speed | High-speed Widdle-speed | High-speed Applicaton Mpoahoaton | epbelieaton Specticaton | specication Intermittent rated output 59(791500 | 83.(111)/1500 | 79 (108)/1500 | 71 (95)/1500 | 106 (142)/1500 | 101 (136)/1500 KW (HP) | 70 (94/1800 | 98 (132)/1800 | 95 (1271800 | 85(114)/1800 | 123 (1659/1800 | 121 (1681800 777 (1032000 | 106 (14332000 | 103 (129y2000 | 9 (125y2000 | 131 (1762000 | 131 (1752000 82 (ri0ve200 | 111 (rs0y2200 | 111 crsoy2200 | 101 (1352200 | 140 tesy2z00 [739 (T88)2200 87 (41792500 +20 (1619/2600 | 111 (149972500 147 (19772500 92 (1299/2000 (162y2e00 | 120 (1619/2800 151 (20892800 ‘Continuous rated output | ‘sa crayisoo [75 (1011600 |72 (961500 | 65 (87171500 | 96 (1299/1500 | 92 (123)/1500 KW (HP) | 64 (86)/1800 | 89 (120)/1800 | 86 (1151800 | 77 (1031800 | 111 (149)/1800 | 110 (148)/1800 70 e3y2000 | 96 (129y2000 | 94 (1262000 | 84 (1132000 | 119 (160)2000 | 118 (15872000 74 (oay2200 | 101 (136y2200 | 101 (126y2500 | 03 (1252200 | 127 (172200 | 128 (T6BYEZO0 79 (1062500 +109 (146)72500 | 101 (135)2500 +193 (1782500 83 (i11y2000 114 (1892000 | 110 (1472800 137 (1842000 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 00 ‘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 the dealers when ordering spare parts. Engine Number Name Plate Name plate 18779) a Fon, wares wo Engine number 1 is punch-marked on the left of the crankcase. Example: 6016-00000 Engine model Engine number ‘The name plate is attached to the portion shown in the illustration, and in- dicate the following items. 1. Engine model 2 Total displacement 3 Maximum output 4 Valve clearance 5 Firing order 6 Fuel injection timingPRECAUTIONS FOR MAINTENANCE OPERATION In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the accumulated mileage, 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. 1er70 00-4 Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary. Then follow the proce- dure 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 AX, 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 safety when removing or installing heavy items such as engines, transmissions. When lifting up heavy items using cables, pay special attention to the fol lowing points: ‘+ Check the mass of the tem to be lifted and use a cable capable of lifting that mass. ‘© Ifyou 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 falls.0014 0016! 00 Be particularly careful net 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 levers. Check for oil leakage before cleaning the area having the fault otherwise ‘you might miss detecting the leakage. Prepare replacement part(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, dam- age, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.PRECAUTIONS FOR MAINTENANCE OPERATION 00017" 00-6 1104] Put alignment marks on part combinations before disassembly and ar- range the disassembled parts neatly. This will help avoid mismating of the parts later, Put the alignment marks, punch marks, etc. 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 /\ © Take care to avoid mixing up numerous parts, and right, etc. «Keep new parts for replacement and original (removed) paris sep- arate. ilar parts, left Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly. Use only the specified oil, 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 might 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 burning-out. CAUTION A A$ Be sure to turn starter and lighting switches, etc. off before dis- connecting or connecting battery terminals, because the semi- conductors can be damaged.00028 [00 ] ‘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 control unit. Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type connector, first push toward arrow mark. To recon- ect a lock-type connector, press the separated parts until they click to- gether. 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 that have 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 volt. Do not apply voltage higher than the specified value, In particular, pay close attention to the electronic control unitand sensors, since they are not always fed the battery voltage.PRECAUTIONS FOR MAINTENANCE OPERATION ‘Connect the test harness land connector A between| Ithese parts 02587 ‘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 circult obtained) Prepare attest harness and connectors A, then connectitbetween the two paris of harness B that is to be tested. Check the circuit by touching test probe C to the test connector. Never insert the test probe from the harness side of the waterproof con- nection, or waterproof performance might be diminished causing corro- sion of the connector. Insert test probe C from the hamess 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 the terminal, or it will cause a poor contact. 00-800 2590 Connector Inspection Procedures Using male pins ‘Touch the pins directly using test probes. CAUTION /\. Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the Internal circult of the electronic control unit. Visual inspection ‘Check for loose connection and poor engagement. Check ithamesses 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.PRECAUTIONS FOR MAINTENANCE OPERATION 02596| 00-10 Connector pin fall out inspection Damaged connector pin stoppers can cause poor engagement of the ter- minals (male and female pins) even ifthe connector body is secured, and might cause some pins to fall out. Check if the pins have fallen out from the connector by pulling each hamess gently Inspection Procedures for Blown Fuses Remove fuse B and measure resistance between the loaded side of the fuse and ground, ‘Tum on all circuit switches (connected to the fuse). ifthe 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. + Hames sheath damaged by friction or heat. + Water in connectors or circuits. ‘+ Mistakes (accidental short circuits) A: Battery B: Fuse C: Loaded switch D: Load E: Short circuit Precautions for Handling Alternator When servicing the alternator, pay attention to the following: ‘+ Do not connect the alternator with battery polarities reversed. Ifthe altemator is connected with reversed polarities, a large current flow from the battery tothe altemator occurs, and the diode or regulator might be damaged.wzsri 05165; 00 «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. ‘© Donot use a high-voltage tester such as a megger for inspection. Ifa high-voltage tester is used, the diode or regulator might be destroyed. ‘+ Donot splash water over the alternator. Ifwater is directly splashed over the alternator, individual components will be short-circuited and might be destroyed. ‘= Donotshort-circuit terminal B and terminal L while running the alterna- tor, If the terminals 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. 00-11TABLE OF STANDARD TIGHTENING TORQUES ‘+ Use specified bolts and nuts and tighten them at specified torques according o 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: N-m {kgf-m} Siren classification OL a oy Repre- x T sentation @ O ©) © @| piameto\ |W WF, symbol su9 sug | (su 7164 Ms 203 ~ 7106 - 507 : (021003) (041006) (051007) = 4106 7 Tio ~ B10 12 ~ oato0.s) | o7t01. (o8to 1.2) 7 91014 7 171026 - 201029 ~ _| 901.4) (1.7 to 2.6) (2.0 to 3.0) m0 191028 or 36 1052 B04 451060 ai1089 __ | 91028) {1.8 02.7) (3.50 5.5) {83 to 5.0} {4.5 to 6.0) {4.30 6.9) m2 351050 311046 70 t0 95 @51085 8510 110 7510 100 wastes) | eta | goes | se | esr) | (751010 mia e010 65 351075 12010 160 | 11010140 | 19010 180 | 12070 160 (eoes) | (651075) | (121016) (111014) (iato1s)_ | fi2t01m = 9010 180 3010120 | 18010240 | 160220 | 20010270} 19010200 {9.5 to 13} {9.0 to 12} {18 to 24) {16 to 22) {20 to 27} {19 to 26} - 14010 190 | 12010160 | 2e0%0840 | 2a0t0290 | 290t0990 | 26010840 | | tater) | 2tot6) estoas) | 2toany | eotoao) | (261035) ia 18010260 | 170t0240 | s60%0470 | e20%0400 | 1010650 | 87010 400 {19 to 26) (17 to 23} {36 to 48) (32 to 43) {41 to 56} {87 to 50} a 26010340 | 29010300 | 47010640 | 49010870 | 5010740 | 49010070 {26 to 35) (2310.31) (481065) | _ (4310.58) {56 t0 75) {50 to 68) Mas 34010 450, 290 0.390 63010 840, 54010730 730 0 980, 69010 640 {84 to 46) {290 40} {6310 86) {55 to 74) (74 to 100) {64 to 86} Hex-head Flange Bolt Unit: N-m {kfm} Strength classification au oy Repre- serlation Diameter symbol . cosa Me a06 : B12 - dou : {0.4 to 0.6) {0.8 to 1.2} {0.9 to 1.4} we 301015 - 191028 ~ 221092 ~ {1.0 to 1.5} {1.9 to 2.8) {2.2 to 3.3} mo 2110.80 201028 | s0t05e 7108 501065 i068 {2.1 to 3.1} {1.91029} | (8.9to6.0) {3.6 to 5.4) {5.0 to 6.5} {4.5 to 6.5} m2 aBt0 64 astost | B00 10 701095 9010 120 a5 10 110, {3.8 to 5.5) {3.4t05.2} | {8.0to 11) {7.0 to 9.5} {9.0 to 12) {8.5 to 11} 00-1200 Hex-head Nut Unit: N-m { kgf-m)} Srengih classification ou coon Repre- sentation | © O xD g Diameter S cats symbol Standard sorew_| Coarse sorew ‘Siandard serew (Coarse sorew 2103 4106 Ms {0.200.3) = (041008) : 4106 Tot a (0.41006) a (071014) = ot 14 171026 bed 0901.4} - (171026) a = 191028 jat6 25 361052 ato 49 (1.910 2.8) (1.81027) (85 t0 5.5) {8.30 6.0) a 351050 311046 701095 51085 (941050) | (1t047) 7.01095) (651085) ag 60 to 85 35075 120 to 160 Toto 140 (601085) | (6.51075) (120 16) {11t0 14) ais 9040 130 90 f9 120 718010 240 160%0 220 {9.5to 13) {9.0 to 12} (18 to 24) {16 to 22) naa 140%0 190 | 120%0 160 26010 340, 220%0 200 {1410 19) (1210 16) (2510.35) {2210.30} a 19010 260 17010230 35010470, 32010 420, (19026 (17023) (96 to 48} (20 43}, = i 26010340 | 2800 300 47010640 49010 570, (261035) (23t031), (481065), (4310.58) na 34010450 | 29010 390 3010640 ‘54010 730, {G40 46) (2910.40), (63 10.86) {65t0 74) Hex-head Flange Nut Unit: N-m {kgf-m) Strengih classification a Repre- sentation Diameter 2185 symbol Siandard sorew | Coarse sorew 4106 we {0.410 0.6} - TOI 1s | = {1.0 to 1.5) = 21 t0.90 201028 wo (2.103.1) {1.9 to 2.9} 3810 54 351051 mi {3.8 to 5.5) {3.4 to 5.2) 00-13TABLE OF STANDARD TIGHTENING TORQUES Tightening torque for flare nut for general purpose Unit: N-m {kgf-m} Pipe diameter oaTemm 96.35 mm ¢emm $10 mm 2mm $15 mm Tightening torque 707) 25 (2.6) 3014.0) 59 (6.0) 88 (9.0), 98 (10.0), Tightening torque for air piping nylon tube for general purpose 18 | 90108 wie [20:08] ai [so {DIN type} Unit: N-m {kgf m} Standard diameter ex tmm Ox 125mm Tax t5mm 18x 15 Tm Tightening torque wf [oo 5 +1.0} 3 [559°] Tightening torque for air piping nylon tube for general purpose [es [1994] > {a0 05 avs { 30°95} {SAE type} Unit: N-m (kgf>-m} Standard dametor Tin. ain Win T Bain. Tightoning torque ef [so] PayGROUP 11 ENGINE SPECIFICATIONS 11-2 STRUCTURE AND OPERATION 1. Cylinder Head and Crankcase . 11-3 2. Valve Mechanism . 14 3. Connecting Rods . 11-4 4. Pistons ........ 1-5 5. Timing Gears 1-5 6. Flywheel ... 11-6 7. Flywheel PTO 11-6 MROUBLESHOOTING cc) ee 1-7 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure 11-8 2. Inspecting and Adjusting Valve Clearances . 11-10 CYLINDER HEAD AND VALVE MECHANISM ..............4+ 11-12 PISTONS, CONNECTING RODS, AND CYLINDER LINERS ... 11-28 FLYWHEEL PTO . * FLYWHEEL ... 11-48 TIMINGGEARS = 11-54 CAMSHAFT... 11-64 CRANKSHAFT AND CRANKCASE ... 11-72 NOTE ; The parts marked "2" are deleted as they are not applicable to the £335(N)LC HlSPECIFICATIONS em ‘Specifications Engine model ei | epiT | episT | e016 | oDise | eDieT | eDIenE eD16-TE ep16-1L Type -oylinder, inline, water-cooled, 4-cycle diesel ‘Combustion chamber type Directinjection Valve mechanism Overhead valve | Cylinder bore x stroke mm mtx 115 OHSS x5 [Total aisplacement G 6587 “| eat9. 5 ‘Compression ratio 175 760 175 160 175 M2STRUCTURE AND OPERATION [11 _] 1, Cylinder Head and Crankcase 1 Connecting plate 2 Glow plug 3 Cylinder liner 4 Oxting 5 Crankease 6 Water jacket 7 Piston 8 Injection nozzle 9 Cylinder head ‘A: Cylinder liner size mark: A, B, C «The oylinder liners 3 are a removable wet type liners. They are press-fitted into the top ofthe crankcase 5 and the bottom of the wa- ter jacket 6. ‘+ The O-rings 4 are provided to 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. or024| 1 Connecting plat 2 Glow plug 3 Cylinder liner 4 Crankcase 5 Water jacket 6 Piston 7 Injection nozzle 8 Cylinder head > : Cylinder liner size mark Outer diameter mark: Inner diameter mark: ‘« Thecylindertiners 3 are a dry type liners that are easier to remove than wet liners. Liners are press-fited into the crankcase 4. '* The cylinder liners 3, crankcase 4, and pis tons 6 have size marks. They should be combined as specified accordingto the size marks. (1) P.11-28 3 or925|STRUCTURE AND OPERATION 2. Valve Mechanism 3. Connecting Rods | <6014, 15-1 (Atype), 16, 16E> = 1 <6D14-T, 15-T (B-type), 16-1, 16-TE, 16-TL, [1E-TLE|> 1 Exhaust valve Inlet valve Camshatt Tappet Push rod Rooker shaft Rocker shaft spring Rocker Rocker shaft bracket 10 Valve cap 11 Valve cotter 12 Upper retainer 13 Outer valve spring 14 Inner valve spring 15 Valve stem seal 16 Valve guide The valve stem seals 15 are fitted onto the valves 1, 2to 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. ‘Tofacilitate removal and reinstallation of the camshaft from the rear end of the crank- case, the diameter of each bushing is small- ‘er toward the front of the engine. Connecting rod bushing Connecting rod Connecting rod bearing Connecting rod cap Connecting rod bolt onana : Alignment mark : Weight mark stamp (A,B,C, D, E, FG, HIV, WX, ¥, Z: ) (A,B,C, D, E, F: RSDIETLES) o>11 4, Pistons D 16006 5. Timing Gears R ithout flywheel PTO>| 16007 to0ee B:"T" mark <6D14-T, 16-, 16-1, 16-TE, 16-TL fETLE> ©: Size mark (A, B, C: <6D14, 14-T, 15-T>) (A,B: <6D16, 16, 16-T, 46-TE, 16-TL, E=TLE!>) |: Weight mark Front mark. bo ‘Camshaft gear No. 2 idler gear No. 1 idler gear il pump gear Crankshaft gear Air compressor drive gear or injection pump drive gear No. 1 idler gear PTO idler gear - 9 PTO idler gear oasons on Each gear is stamped with a timing gear align- ‘ment mark ("1", "2", "3", or4") to facilitate reas- ‘sembly, USSTRUCTURE AND OPERATION 6. Flywheel 7. Flywheel PTO 01934 01935] 16 Flywheel Pilot bearing Ring gear ene ‘A: Angle scale, cylinder number Flange PTO shaft PTO idler shaft Flywheel housing Crankshaft gear No. 1 idler gear PTO idler gear PTO idler gear PTO gear eervonnena The flywheel PTO isfitted onto the top ofthe fly- wheel housing 4 andis driven by the crankshaft gear 5.TROUBLESHOOTING 11 Possible causes Symptoms. Remarks ‘Abnormal engine noise Incorrect oil viscosity mera Incorrect/defeative fuel mers Incorrect valve clearance Defective cylinder head gasket ‘Worn valvelvalve seat, and carbon deposits ‘Weakened vaive spring ‘Worn/damaged Piston rina(s) Worn/damaged piston ring groove(s) Inorrect injection timing MGr13 Defective injection pump ofofofofofofofo! mars Defective coaling system Mert Defective injoction nozzie(s) ° feria Ar trapped in fuel system Mer 13, (Clogged air cleaner [oerts Clogged muftier Mars Defective turbocharger olololofolofololololo}alalolalo] tow power output Marts Incorrectly fited pipe(s)/nose(s) MGr13 Injection pump, alternator, of other auxiliary devioe(s) defective/incorrecty fitted MGr 13, 54 Loose/damaged V-belt Mar14 Incorrectly fitted crankshaft pulley Defective air cleaner or muffior Gr 15 Defective vaive spring(s) Defective 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 joumal and main bearing Excessive end play in crankshaft and camshaft ‘Worn tappat(s) and camshaft ofofofofofofofofofo[ofojofojolo U7ON-VEHICLE INSPECTION AND ADJUSTMENT TSS 1. Measuring Compression Pressure Service standards [Location Maintenance item ‘Standard value Limit Remedy — [Compression [Each cylinder | Except 6016-€ £2550 kPa (26 kalfem*l | 4960 kPa {20 kgticm?} | Inspect Pressure (at200 rem) [eDte-€ 2940 KPa {30 kgtiom?) Gylinder-to-eylinder pressure diference = 300 KPa (a katiem®) | inspect ©) Special tools Unit: mm Location ‘Tool name and shape ‘Application 99 46W x 18 thread Compression ee = gic ‘6 Measuring compression pressure Contre distance 48 gg4p Reduetions in compression pressure should be used as a guide in determining the timing of engine overhauls. Take mea- surements 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 piston 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 until the coolant temperature reaches 75 to 85°C. + Tum off all lights and auxiliary devices. + To prevent injection of fuel while cranking the engine by the starter, perform the following steps. + Sot 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, referto Gr. 13E. Starter SW cs 7 ner 2 Engine ECU 7 ius Battery); 4: relay Battery T 47596 1-8Li) «Remove the injection nozzle A. Gr isa CAUTION A AAA AAA @_€_______ ‘Cover the mounting holes and injection pipes to preventthe entry of dust and dirt. + Cover the injection nozzle mounting hole B with a cloth C. Then, tum the engine over with the starter and check that no foreign matter ad- heres to the cloth. WARNING fA, any cylinder Is cracked, coolant, engine oil, and fue! 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 mount- ing hole before turning over the engine. ‘+ FittheE}] Compression Gauge Adapter onto an injectionnozzle mount- ing 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 differ ence exceeds the specified limit, pour a litle engine cilinto the cylinder via the injection nozzle mounting hole B then take the measurement again, ‘+ Ifthe compression pressure increases, there may be wear or dam- age 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 de- fective. U9ON-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 +m {kgf-m) Location Parts to be tightened F Tightening torque Remarks 2,6 _ | Rocker arr adjusting screw lock nut 34 (35) = [] u-10 Valve clearances should be checked and adjusted when the engine is cold. [Inspection] ‘= Bring piston No. 1 orpiston No. 6to 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. 6isat the TDC position of its compres sion stroke, measure the clearance B of every valve marked “O” inthe following table. Prion No TL ps Le Lele Wake arargamont [in Je [Bx fm [ox [JB Jn [Be No igatonatTaCareem 15 15])0]x|xlolo|x|x]o| x |x No.6 piston at TOO of cone pression stroke x |x] x /O]O] x} x 1O}O]x1O]O 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 gap.ae ‘* If any measurement is out of specification, make adjustments as fol- lows: [Adjustment] * To adjust the valve clearance B, loosen the lock nut 2 and tum the ad justing 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 Co stop the adjusting screw 3 from turning. Next, insert the feeler gauge 1 once moreto confirm that the clearance B iscorrect. U-1CYLINDER HEAD AND VALVE MECHANISM ® ota © Disassembly sequence 1 Joint 8 Cylinder head bolt 42 Push rod 2 Oilfiler cap 9 Rocker and bracket assembly 13. Tappet 3 Bolt mpn-t6 4 Plate 10 Cylinderheadandvalveassem- —_*: Grankcase {1 P.11-72 5 Rubber bly MP.11-20 ©: Locating pin 6 Rocker cover gasket 11 Cylinder head gasket @: Non-rousable part 7 Rocker cover @ Assembly sequence Follow the disassembly sequence in reverse. U-1211 Service standards Unit: mm Location Maintenance item ones Limit | Remedy [42 [Push rod runout . = 04 Replace 13, * | Tappetto-crankcase _[6D14, 14-T,15-T, 16, [91] 0.06 to 0.10 02 | Replace clearance 16 tappet | 016-7, TE, OTL, i008 0007 of @ Tightening torques Unit: Nm tkgf-m} Location Parts to be tightened Tightening torque Remarks 1 __[soint 2918.0) = 3 __ [Rocker cover bot 39 (04) = & | Gyiinder head bot (instalation of rock [Mia bor 78 (6) + 180° © Wet cr and bracket assembly and cylinder © Can be reused | head and valve assemby) upto 3times Miro bolt 17 (1.75) + 34 (3.5) = ¢\ Lubricant Location Points of application ‘Specified lubricant Quantity 2 _| Rubber seal ot oi filer cap Engine oll ‘As required 8 _| Threads of cylinder head bolts Engine oll ‘As required 12 __| Both ends of push rods Engine oll ‘As required 13 | Outer surfaces of tappats Engine oll ‘As required © Special tools Location Tool name and shape ‘Application eee Tightening cylinder head bots 0 oe wer (M14 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. 13021 1-13CYLINDER HEAD AND VALVE MECHANISM 12005 u-14 ‘* Loosen and remove the cylinder head bolts 8 in the sequence shown. Each cylinder head bolt should be loosened a ttle at a time. [Installation] CAUTION fi) —_$_________________ 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 fitting the [E) Socket Wrench over a cylinder head bolt, turn the holder D counter-clockwise to tension the built-in spring. E: Socket F: Rod G: 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 par. ‘* Onthe 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, $$$ ____________ ‘Since the M14 cylinder head bolts 8 utilize the plastic region tight- ening method, they must not be tightened further after this proce- dure.sa502 11 # After fiting the M14 cylinder head bolts 8, tighten the M10 bolts to the spencitied torque (34 N-m {3.5 kgf-m}) in the sequence shown, [17] 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 crank- case *. [Fitting] ‘Fit the cylinder head gasket 11 onto the crankcase * as shown. [12] Push rod runout If 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-1SCYLINDER HEAD AND VALVE MECHANISM Rocker and Bracket Assembly © Disassembly sequence 1. Rocker assembly 2 Rocker bushing 3 Lock nut 4 Adjusting screw 5 Rocker 6 No. 6 rocker shaft bracket 7 Set screw 8 No. 5 rocker shaft bracket 8 No. 4 rocker shaft bracket 10 No. 8 rocker shaft bracket 11 No. 2 rocker shaft bracket 12 No. 1 rocker shaft bracket 13 Rocker shaft spring 14 Rocker shaft @ Assembly sequence Reverse the order of disassembly. 13022| Service standards Unit: mm, Standard value Location Maintenance item (Beale rametsr in [}) uimit | Remedy 2,14 _ | Rocker bushing-to-rocker shaft clearance [24]0.01 0.0.08 O12 Replace @ Tightening torques Unit: N-m {kgf-m} Location Parts to be tightened Tightening torque Remarks 3 _| Adjusting sorew lock nut 3418.5) = 7_ | Racker shaft set screw 3.9104) = A Lubricant Location Points of application Specified lubricant Quantity 2._ | Rocker bushing inner surface Engine ol ‘As required {c) Special tools Unit: mm Location Tool name and shape Application 2 | Rocker Bushing Puller Removing and instaling rocker bushings 0 U-1612008 2 c 5 12095 @ Service procedure 2] [14] Rocker bushing and rocker shatt [Inspection] Ifany clearance exceeds the specified limit, replace the defective part(s). Rocker bushing [Removal] {Installation} © Align the oll hole A in the rocker bushing 2 with the oll hole Bin the rock- ers. « 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 Fz [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:Oilhole B: Threaded hole (for M8 rocker cover bolt) C: Threaded hole (for M6 set screw) D: No threaded hole U7CYLINDER HEAD AND VALVE MECHANISM Rocker shaft Align the oil hole G in the No. 6 rocker shaft bracket 6 with the oil hole Ht in the rocker shaft 14. 18MEMO U-19CYLINDER HEAD AND VALVE MECHANISM Cylinder Head and Valve Mechanism | Aim, | ral 20900 or985, © Disassembly sequence 1 Valve cap 9 Injection nozzle (1) Gr 13 16 Inlet valve guide 2 Valve cotter 40 Dust seal 47 Exhaust valve seat 3 Upper retainer 11 Nozzle tip gasket 4 Ot ie Sing 12 Neath Gam stags 18 bietvahe seat 5 Inner valve spring 13 Connecting plate 8 Valve stom seal 20 Cylinder head 7 Exhaust valve 14 Glow plug 8 Inlet valve Ma@rsa @: 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. 1-20——$—_—— Service standards Unit: mm ‘Standard value Location Maintenance item (easethaneet ie LD Limit | Remedy Outer [Freelengih _[6D14, 147, 15-7, 16, 7.0 40 | ‘Replace valve 16E spring 6016-7, 16-TE, 68.3 65.3, 16-7 (ETE) _ 4 Installed load | 6D14, 14-T, 16-7, 16, 390 N (63.5 kal) 290N | Replace (at 47.8 installed (20.7 koi tenath) 380 N (40.0 Kat) 350N (35.5 kal) | ‘Squareness = 25 Replace, Taner |Freelength [6D14, 14-7, 15-7, 16, 354 52.1 | Replace valve 16 spring 6D16-T, 16-TE, 65.1 615 16-TL (ETE) Installed load | 6014, 14-7, 15-7, 16, SN BAK 7aN | Replace 5 (at 40.5 installed | 16-E (2.0kaf length) e016 1876, TEEN TTBS KOH 130N 16-7. (6-TLE] 119.4 kof) Squareness | 6D14, 14-T, 15-7, 16, = 20 Replace 16 e167, 16-78, = 25 16-71, Exhaust | Stem outside diameter 8.9310 8.94 08.85 | Roplace valve | Sinkage from cylinder head bottom sur- 131017 20 | Inspect ev- 7 face ery location Valve margin 18 72 | Reface or replece ‘Seat angle a = Correct | Inlet | Siem outside diameter 289610897 98.85 | Roplace valve |Sinkage from [Except 616-€ Tits 18 | inspect ev- cylinder head ery location . bottom suriace | ED16E 130017 20 Valve margin 1 12 Reface or replace Seat angle ae 218 = Conect [7,18 _| Exhaust valve stom-io-valve guide clearance 19]0.07 60.10 02 Replace 18, 16 _|Iniot valve stem-to-valve guide clearance 19] 0.04 100.06 015 | Replace 47_| Exhaust vaive seat wicth ew22 28 | Comector _ replace ye | inlet valve seat wiath 181022 28 | Cowect or replace Gylinder | Bottom surface distortion 10108 or less 02 | Comrect or 20 | head replace Height from top fo bottom surface 94.910 95.4 248 | Replace @ Tightening torques Unit: Nem {kgm Location Parts to be tightened Tightening torque Remarks | 14 __| Glow plug 1510.20 (1.51020) = 19 | Exhaust manifold mounting stud 2918) = 1-21CYLINDER HEAD AND VALVE MECHANISM \ Lubricant Location Points of application ‘Specified lubricant Quantity, se caster sah — oe ore a oe 7,8 Valve stem Engine oil - ‘As required | ©) Special tools Unit: mm Location Tool name and shape i Application: |g |aewme te Se Poe (io = Renown a 6 Valve Stem Seal Installer oe valve stem aes 7 ae i oe +8 foie (inlet, exhaust) valve seats ova . — eee oo - 15,16 i Valve Guide Installer la | Installing inlet and ex- oe haust valve guides : orm 1-2211 Location ‘Tool name and shape ‘Application ‘R: Caulking Too! Body B: Installor Ring = <6014, 14-7, 15-7, ° Son 16, 16-TE, 16-71, || 949 (niet) oe <6014, 14-7, 15-7, 118 [est 16-7, 16-TE, 16-TL, _| Installing valve seats 948 (Exhasut) | <6D16, 16-E> (Inlet) <6016, 16-E> (Ex: haust) Service procedures 2] Valve cotters [Removal] To remove the valve cotter 2, use the [f] Valve Lifter to evenly compress the valve springs 4, 5. {Installation} To install valve cotters, follow the removal instructions in reverse. CAUTION AX, A$ Do not compress the valve springs 4, 5 more than is necessary. Ifthe valve springs are compressed excessively, the upper retain- er 3 can touch the valve stem seal 6 and be damaged. 11641 [4] [5] instatting outer and inner valve springs Fit the outer and inner valve springs 4, 8 onto the cylinder head 20 with their painted ends downward. A: Painted end ~| [6] instalting vaive stem seals or964 + 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 unti it sits snugly on the cylinder head 20. 1-23CYLINDER HEAD AND VALVE MECHANISM 01965) 2264 o1972 U-24 7] [8] vaive [inspection] (1) Valve stem outside diameter Replace the valve 7, 8 if its stem's outside diameter is below specifica- tion or severely worn. CAUTION J, $$$$$_______________ 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 if the 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 vaive 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. P4125 7] [8] [15 [19] Valves and vaive guides [Inspection] tfany clearance exceeds the specified limit, replace the defective part(s). Valve guides [Removal]18mm 15, 16 oz220) Lit | {installation} Install the vaive guide 15, 16 using the [E] Valve Guide installer. Strike the Valve Guide installer until it sits snugly on the eylinder head 20, CAUTION /\ ‘© 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 guide in each location. 7} [8] [17] [18] Valves and valve seats org70 [Inspection] © Apply an even coat of minium to the valve seat 17, 18 surface A that makes contact with the valve 7, 8. «Using the (€] Valve Lapper, strike the vaive 7, 8 against the vaive seat 17, 18 once. Do not rotate the valve during this operation. NOTE inspections after inspecting the valves and valve ‘If the minium deposited on the valve 7, 8 indicates a poor contact pat- tom, rectify the contact pattern as follows: Contact Corrective action Minor defect Lapping Serious defect | Reface or replace valve and valve seat [Refacing] Lap the vaive in accordance with the following procedure: © Apply a thin, even coat of lapping compound to the surface A of the valve 7, 8 that makes contact with the valve seat 17, 18. CAUTION A\ Ensure that no compound adheres to the stem B of the valve 7, 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 com- pound easier to apply. 1-25CYLINDER HEAD AND VALVE MECHANISM 78 7,8, 17,18 01975 17, 18) 7285 ‘© Using the ) Valve Lappe, lightly strike the valve 7, 8 against the valve seat 17, 18 while tuming it litle by litle. ‘= Wash away the compound with gas oil or a similar fluid, ‘+ Apply engine oilto the contact surfaces of the valve seat 17, 18 and rub Itin so thatthe contact surfaces are lubricated and mate together snug yy. ‘+ Inspect the contact pattem of the valve 7, 8 and valve seat 17, 18 once more. ‘Ifthe contact patter is stil defective, replace the valve seat 17, 18. 7] [1] Valve seats [Inspection] (1) Valve seat width If the measurement exceeds the specified vaive seat 17, 18. it, rectly or replace the A: Valve seat width NOTE Whenever a valve seat 17, 18s rectified or replaced, be sure to 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} ‘* Grindthe valve seat 17, 18 using a valve seatcutter or valve seat grind- er. ‘+ 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\ 1-26 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. P.11-2517,18 ate BB 05to 1.0mm 01973. We orsra| 01978 [11 | [Removal] Valve seats 17, 18 are installed by expansion fitfing. To remove a valve seat, grind the inside surface to reduce its thickness, then remove the valve seat at room temperature, D: 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 Bree 167, | eDi6 epi6€ teTE 16-1, (ie=TLE Inlet valve soat hole (E) paorgm | gsite™ |] 953" | [Exnaust vatve soathoie (F)| ¢ 4273 | g4a7g™ gas" 3 + Coo! the valve seat 17, 18 by immersing it in liquid nitrogen. + Installthe valve seat 17, 18inthe cylinder head 20 using the (E}aCaulk- ing Too! Body and {Eb Installer Ring. ‘© After installing the valve seat 17, 18, lap the valve seat and vaive 7, 8. mpa1-25 [20] inspecting cylinder head '* Measure the extent of distortion in the cylinder head's bottom surface. ‘* Ifthe degree of distortion exceeds the specified limit, rectify the distor- tion with a surface grinder. CAUTION A, Ensure that grinding does not cause the cylinder head's top sur- face-to-bottom surface distance to fall below the specified limit. H-27PISTONS, CONNECTING RODS, AND CYLINDER LINERS ti 4 A 6 | 7 MP.11-30 1 Bolt to© @ Removal sequence ta: Oil pan (1) Gr 12 br Crankshaft (1) P.11-72 @ Installation sequence @ Pre-disassembly inspection 2 Lower connecting tod bearing 3 Connecting rod cap 4 Upper connecting rod bearing 5 Piston and connecting rod assembly (P.11-36 Cylinder liner Oxting <6D14, 14-7, 15-T> et Reverse the order of removal. a 16014 Service standards Unit: mm Location Maintenance item 2a Remedy [Piston projection 0.850 1.06 = inspect each toca tion ‘Connecting rod end play 0:15 10 0.45 08 Replace 4, *b | Connecting rod Oi clearance | Except 165] 0.04 t0 0.09, 02 Replace bearing eD16-TLE [70] 0.04 to 0.08 Span when | Except = Less than free 6DI6-TLE 695 = Less than 745 5,6 | Piston and connect |6D14, 14-7 [110] 0.197 100.159 = Replace | ace are 6D15-T 1113} 0.166 to 0.138 = Replace once 6016, 168 [116] 0.075 to 0.105 = place ‘6016-T, 16-TE, 16-TL, f&-TLE) [118] 0.136 to 0.165 = Replace 6 | Gylindor [Fiange projection 10.0810 0.10 = [7 Replace liner inside [@D¥4, 14-7 9 110 10 110.085 110.25 | Replace or grind diameter {o oversize eoIsT 971316 18.085 0113.25 Replace 6016, 166, 167, 1676, 167, | 911810 118.03 $118.25 Ropiace | ty Gylindric- | 6D14, 14-7, 15-7 jS-TLE] (0.02 oriess = Replace or grind to oversize 6016, 16-E, 16-1, 16-TE, 16-TL, (0.08 orless: = Replace or grind ‘to oversize 11-28@ Tightening torques Unit: N-m {kgf-m} [Location Paris to be tightened Tightening torque “Remarks 1. | Bolt (connecting rod instalation) 29 (3) + 90° + 5° Wet mpist \ Lubricant Location | —__ Points of application —— Specified lubricant Quantity 1 |Boltthreads Engine oi ‘As required 2,4 _ | Connecting rod bearing inside surface Engine oil ‘As required 6 | Cylinder liner outside surface 7‘ Engine oll As required ©) Special tools Unit: mm Location “Toot name and Shape plication) | cf Installing piston and 5 | Socket Wrench connecting rod as- sembly : 1904 Piston Guido A SS ——— i sion eoaiat | eno | | i cost | 9113 Instaling piston and : ‘connecting rod as- A: Piston Guide Clamp B: Piston Guide Lever sembly ‘Oylinder Liner Extractor C dimen: sion aora 147 | "91005 | est | 91125 | ~ €D16, 16, 16-7, 16-TE, | 91175 16-TL, 16-TLE Removing cylinder liners ‘Gylinder Liner installer ‘Adimen- sion ys 167, 16-TE, | 91175 16-TL, 16-TLE 1983, | Instaling cylinder lin | ers (ary type) 1-29PISTONS, CONNECTING RODS, AND CYLINDER LINERS 01988 ou 1987 | 988 11-30 @ 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-£, 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 their flanges down using bolts and washers A. Measure the projection of each piston attwo points and calculate the average of the two values. A; Front of engine «Ifthe average value is out of specification, cheok the clearances be- tween all relevant parts. (2) Connecting rod end play ‘© Measure the end play of every connecting rod. «= Ifany measurement exceeds the specified limi, replace the defec- tive part(s) (8) Cylinder liner flange projection {f 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 th: glon of the bore, possibly causing gas to leak.1 01996; 2] [4] Connecting rod bearings (nstallation] Install the connecting rod bearings 2, 4 by fiting the lugs A into their re- spective grooves. CAUTION Ay ‘The upper connecting rod bearing has an oll hole B. The lower connecting rod bearing has no oil hole. Take care not to confuse the upper and lower parts. [inspection] CAUTION A, $$$$________________ + Do not attempt to manually expand a connecting rod bearing 2, 4 if its span is insufficient. Upper and lower connecting rod bearings 2, 4 must be replaced asa set. (1) Span when free Ifthe spanis less than the specified requirement, replace the upper and. lower connecting rod bearings 2, 4 as a set (2) Connecting rod bearing-to-crankshaft pin clearance Ifthe connecting rod bearing-to-crankstiaft pin clearance exceeds the specified limit, replace the defective part(s). 5] Installing piston and connecting rod assembly CAUTION J, $$$_$________ + Ensure that the piston ring gaps A remain in their correct posi- tions. (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. U-31PISTONS, CONNECTING RODS, AND CYLINDER LINERS oa84 1-32 11651 ‘© With the piston's “A” front mark facing the front ofthe engine, instal the piston and connecting rod assembly in accordance with the following procedure. D: Front of engine <6D14, 14-7, 15-T> <6D16, 16-£, 16-1, 16-TE, 16-1. [TETIE> © Fit the ja Piston Guide Clamp over the piston skirt. Using the bolt & of the jb Piston Guide Lever, adjust the clamp’s inside diameter such that it matches the piston’s dutside diameter. «Once the (Ja Piston Guide Clamp is adjusted property, remove it from the piston and smear engine oll over the following items: * Outside of piston Inside of the Ja Piston Guide Clamp Cylinder liner x + (Ela 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 follow= ing procedure.11 or991 11652] ‘Before fiting the E} Socket Wrench over bolt, tun the holder @ count- er-clockwise to tension the built-in spring, H: Socket J: Rod K: Rod (extension) ‘* Settthe socket wrench such that the built-in spring force forces the rod K against the crankshaft. ‘+ On the holder G, select the inscribed line L that is easiest to see. * Using the selected ine as.a reference, tum the socket H 90° :5° clock- wise. (One gradation on the scale M represents 5°.) NOTE After fitting the connecting rod caps 3, inspect the following items: * Connecting rod end play ( (1) P.11-30) * Piston projections (1) P.11-30) Bp mnin oF HOTS Y 25mm, 60 mm or more 01999] 5] [6] Piston-and-connecting rod assembly and cylinder liners [Inspection] <6D14, 14-7, 15-T> « Ifthe cylinder section inside diameter of the cylinderliner exceeds the ‘specified limit, remove the cylinder liner from the crankcase and rebore it to oversize. Also replace the piston and piston rings with ones suit- 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 crank- shaft axis) C: Measuring position of piston diameter (perpendicular to piston pin hole axis) ‘+ Even ifthe cylinder section inside diameter ofthe cylinder liner 6is with inthe specified limit, the piston and piston rings must be replaced ifthe piston-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 ev- ery 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- ter C (measurement) + Piston-to-cylinder clearance (nominal range central value) ~ 0.02 mm (honing margin) 1-33PISTONS, CONNECTING RODS, AND CYLINDER LINERS 02000) \pa 1-34 2001 * After boring, hone-finish the cylinder liner to the final diameter (toler- ance + 0.005 mm). Final diameter (tolerance +: 0.005 mm) = Oversize piston diameter C (measurement) + Piston-to-cylinder 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 Hany 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. [Installation] Apply soap suds G to the cylinder liner 6. Taking care not to twist the O- rings 7, insert the cylinder liner into the crankcase, CAUTION A, —__$______——_______—_ «Size marks Hare provided on the cylinder liner 6and piston. When the cylinder liner is replaced, the new one must bear the same size mark as the piston. J: Cylinder liner size mark K: Piston size mark ‘After installation, check that the O-rings 7 are not twisted.— \ 0%, D 03375; SX 2003] 20085 ©2008] 02007 <6D15-T, 16, 16-E, 16-T, 16-TE, 16-TL, [1E-TLE]> any clearance is out of specification, replace the defective part(s) D: Outside diameter measurement position 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- ers, do not remove them except for replacement. Cylinder liners [Removal] NOTE Hany cylinder liner 6 must be reused after removal, make analign- ‘ment mark with paint and use this mark to reinstall the cylinder liner in its original position. + Apply engine oil to the outside surface of the cylinder liner 6. «+ Insert the cylinder liner nto the crankcase and press itinto position us- ing the K] Cylinder Liner Installer. Push down evenly on the entire up- per surface of the Cylinder Liner Installer. CAUTION AX, 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: Oylinder 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. H-35PISTONS, CONNECTING RODS, AND CYLINDER LINERS Piston and Connecting Rod Assembly © Disassembly sequence a 1 Snap ring Piston pin, 6 Connecting rod bushing 7 Connecting rod 2nd compression ring Oilring Piston 2 3 4 5 1st compression ring 6 7 8 @ Assembly sequence | Reverse the order of disassembly. cania| Service standards Unit: mm. Location Maintenance item (ease diameterta LD) Limit | Remedy | 2,3 [Piston pin-to-connecting rod | Except 6D16-TLE 138} 0.02 to 0.05 ot Replace small end bushing cleamace Tepre7LE one Donen 2,8 Piston pin-to-piston clearance | Except 6D16-TLE [38] 0.004 to 0.02 0.05 Replace | eDI6-TLE {42}0.004 0 0.02 @ | Connecting rod bend and torsion = 0.05 | Correct or replace Bto7 |Pstonring | istoompres: [6Di4, 127, 0310048 Ts | Replace end gap ‘sion ring 15-T (B type) | @D15-T (A type) 031005 18 016, 167, 16-TL 0:35 10 055 15 | T6TE, 0851005 15 2nd compres- 0.310 0.5 15 | Replace sionring — eptaT 167 0310048 15 6016, 16-7, 16-TL 03510055 15 | 6D16-E, 16-TE 0.35 to 0.5 15 | [edie TLE 0.451006 15 0.8510 0.55 1S 1-36Standard value i Location Maintenance item eater ee Limit | Remedy BtoB | Pisioning-to- | tet compres [6014 0:09%60.18 02 | Replace piston ing | sion ring : as desellphi 0.05160.10 015 | Repl ance = D15-T (A type) 0.10100.15 02 6016 0.11 00.15 02 SDI6E 0.43100.17 02 e016: 0.13%00.18 02 Bad compres: | 6014, 0.05 10008 0.15 | Replace sion ing | 15-T (Atype), 16, 18e e0r4T, 0.07 100.10 018 15-1 (8 type). 16-7, 16-TE, 16-TL,[16-TLE] | Oilring 0.03 to 0.06 0.15, Replace | "BDIE7T (B type): wedge-shaped conneding rod small end ¢\ Lubricant Location Points of application Specified lubricant Quantity 2__| Piston pin outor surtace Engine ol ‘As required 3__| Connecting rod bushing outer surace Engine of ‘As required 4 __ | Bushing installation surface of connecting rod Engine of As required © Special tools Location Tool name and shape I ‘Application Connecting od Bushing Puller 998 o2ots 3 Removing and instaling connecting rod bushings Connecting Fd Bushing Puller Kit, Piston Ri Biot eee ‘Removing and intaling piston rings 1-37PISTONS, CONNECTING RODS, AND CYLINDER LINERS Service procedure f 02017 U-38 2] [3] Piston and connecting rod lt the clearance exceeds the specified limit, replace the defective part(s). Connecting rod bushing <6D14, 15-T (Artype), 16, 16-E> [Removal] Apply the } Connecting Rod Bushing Puller to the connecting rod bush- ing 3. Using a press, apply pressure of approximately 49 kN (5,000 kgf) such that the bushing is pressed out of the connecting rod 4. [installation] * Align oil hole A in the connecting rod bus! connecting rod 4. ‘+ Apply the &) Connecting Rod Bushing Puller to 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 from the chamfered side C. NOTE ‘After installing the connecting rod bushing 3, insertthe piston pin and check that it turns smoothly and without play.c2019) 11807 2022 <6D14-7, 15-T (B-type), 16-T, 16-TE, 16-TL,[TE-TLE|> Replace the connecting rod bushing 3 using the [E)Connecting Rod Bush- ing Puller Kit. This consists of the following parts: Base Bracket : Puller : Collar : Plate :Collar Nut Rerormg9 [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 itn 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 kgf) until the con- necting rod bushing 3 is pressed out. [Installation] «Apply engine oil to the small end of the connecting rod 4 and to the out- er surface of the connecting rod bushing 3. Fit the collar J over the puller F, position the connecting rod bushing 3 and collar G as shown in the illustration, and lock this arrangement to- gether with the nut K. ‘© Align the oil holes L in the small end of the connecting rod bushing 3 and connecting rod 4. Then, use a press to slowly apply pressure of approximately 49 kN (5,000 kgf) until the bushing is pressed into place. ‘* After press-fiting the connecting rod bushing 3, ream itto achieve the specified nominal clearance between the bushing and piston pin 2. NOTE After installing the connecting rod bushing 3, 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. 1-39PISTONS, CONNECTING RODS, AND CYLINDER LINERS [Installation] * Apply engine oil to the piston pin 2. With the connecting rod 4 and pis- ton 8 aligned as illustrated, insert the piston pin to hold these compo- nents together. ‘A: Weight mark B: Weight mark (A, B, C, D, E, F, G,H, I, V, WX, YZ) ‘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 a weight 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] [8] Piston pin-to-piston clearance 2016 02039) 100 mm L 11-40 Ifthe clearance exceeds the specified limit, replace the defective part(s). 4] Connecting rod bend and twist ‘* Fitthe connecting rod bushing 3 and piston 2 in their respective posi- tions of the connecting rod 4. ‘* Measure the extent of bending A and twisting B in the connecting rod 4 ‘+ Ifeither measurement exceeds the specified limit, replace the connect- ing tod 4 or rectify it C: 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 connecting rod cap mount- ing nuts tightened to their specified torque. ({) P.11-28am o2a2a 5107 3] to[B] Piston rings and piston Piston rings [Removal] Installation} ‘* Fitthe oil ing7 onto the piston 8 with its side rail gaps A and the expan- der spring gap B in the posttions illustrated. ‘+ Fitthe compression rings 5, 6 ontothe piston such that the manufactur- er's marks C near the gaps face upward. ‘+ Align the compression ring gaps D, E as illustrated. D: 1st compression ring gap E: 2nd compression ring gap ‘A: 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 oylinder liner F for measurement, ‘© Taking care not to move the piston ring 5, 6 or 7, measure the end gap. Replace llthe rings of a piston ifany gap exceeds the specified limit. NOTE ‘To keep the piston ring 5, 6 or 7 horizontal, be sure to insert them into the cylinder liner F using a piston 8. ‘Push the piston ring 5, 6 or 7 downto the bottom of cylinder lin- er 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. H-41PISTONS, CONNECTING RODS, AND CYLINDER LINERS H 2025; I 02026] 1-42 (2) Piston ring-to-piston ring groove clearance * Ifany measurement exceeds the specified limit, replace the defec- 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 Sand measure the clearance around the piston’s entire periph- * Piston rings 5, 6,7 must be replaced as a set. Never replace pis- ton rings individually.Ti | MEMO 11-43FLYWHEEL [Without fiywhee! PTO>| 5 ON 1 bon 16823} @ Disassembly sequence d ©orousen Spacer Bott ‘Washer plate Flywheel assembly Pilot beating Ring gear Fiywheel Rear oil seal Rear oil seal retainer @ Assembly sequence Reverse the order of disassembly. 1-48 10 " 12 13 14 Ox (O-ring Plug Bolt Flywheel housing Thrust plate Crankshaft (1) P.11-72 Locating pin Non-reusable partService standards Unit: mm, Location Maintenance item Standard value Umit | Remedy 4 | Fywheel Friction surface distortion 0.05 or less 02 | Conect or assembly replace Height of friction surface 20 [3 Replace Fiction surface runout (when — 02 | Conector fitted) replace 13 | Eccenticty of joint = 02 | Inspect or l replace @ Tightening torques Unit: N-m {kgf-m) Location Parts to be tightened Tightening torque Remarks 2 | Fiywheel mounting bolt 96 (10) + 150° © Wat ‘© Can be reused up to 3 times MP.-50 1 [Plug 88 (9) = 12 _ [Bolt 34185) = \ Lubricant and/or sealant Location Points of application ‘Specified lubricant and/or sealant | Quantity 2 | Bottthreads Engine oi ’As required @ | Rear oll seal ip Engine of 'AS required Flywheel mounting surface of rear oll seal : [40 [org Engine oll As required 13 __| Engine mounting surface of flywheel housing Threebond 12076 As required © Special tools Location Tool name and shape ‘Application Socket Wrench 0084 4 Fitting fywheel Magnetic Base 00871 149FLYWHEEL © 36164 crear sast2 11-50 @ Service procedure 4) Flywheel assembly {Removal} To remove the flywheel assembly 4, screw 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 bolt is reusable.) The num- ber 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 (£] Socket Wrench counter-clockwise to ten- sion the builtin spring. ©: Socket D: Rod : Rod (extension) ¢ Set the socket wrench such that the built-in spring forces the rod E against the E)b Magnetic Base. ¢ On the holder B, select the inscribed line F that is easiest to see. ‘© Using the selected line as a reference, tum the socket 150° clockwise. (One gradation on the scale G represents 5°.) CAUTION /\ Since the bolts 2 utilize the plastic region tightening method, they must not be tightened further after this procedure.2 11 02055 03351 [Inspection] (1) Runout * Tighten the bolts 2 to their specified torque. * Ifrunout exceeds the specified limit, check that the bolts 2 are tight- ‘ened 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 specitied value, rectify or replace the flywheel assembly 4. H: Height of friction surface (8) Distortion of friction surface If distortion exceeds the specified limit, rectify or replace the flywhee! assembly 4. NOTE Many abnormality is evident on the ring géar 6, replace the ring gear before making inspections. [Rectification] Grind the friction surface such that its height H remains greater than the ‘specified minimum. The friction surface must remain parallel with surface J with a tolerance of 0.1 mm. 6] Ring gear [Inspection] Inspect the ring gear6 for damage and abnormal wear. If any defectis evi- dent, the ring gear must be replaced. U-51FLYWHEEL 6 caasr 1-52 [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. [Installation] ‘+ Using a piston heater or the lke, 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, ‘A: Chamfered side of ring gear @] Fitting rear oil seal ‘Apply an even, unbroken bead of sealant A to the rear oil seal 8 in the position ilustrated B. «© Fit the rear cil seal 9 onto the flywheel housing 12 within 3 minutes of applying the sealant A. CAUTION A AAA + Ensure that the sealant application position B on the oll 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 start- ing the engine. + Apply anew bead of sealant A whenever the mounting bolts ofthe rear oll seal 8 have been loosened. © Apply engine oil to the lip of the rear oil seal 8. © Fitthe rear oil seal 8 onto the flywheel housing 13 in the direction illus~ trated.11704) 02082 11 «+ Fitthe rear oil seat Binto the rear oil seal retainer 9in 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 A to the crankcase mounting surface of the flywheel housing 13. ‘= Fitthe flywheel housing 13 onto the crankcase within 3 minutes of ap- plying the sealant A. CAUTION A\. «Ensure that the sealant application position on the flywheel hous- ig 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 engin: * Apply a new bead of sealant A whenever the mountling bolts of the flywheel housing 13 have been loosened. [Inspection] * Rotate the crankshaft and check the extent of eccentricity at the joint A of the flywheel housing 13. * If eccentricity exceeds the specified limit, carry out reassembly. + Feccentricity stil exceeds the specified limit after reassembly, replace the defective part(s). 1-53