Motor 6U

6UZ1 - Tier 3
ISUZU ENGINE
WORKSHOP MANUAL
Printed in USA 9/2016
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General Information 0A-1
General Information
General Information
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2
Reading the Model . . . . . . . . . . . . . . . . . . . . . . . 0A-6
General Information . . . . . . . . . . . . . . . . . . . . . . 0A-6
0A-2 General Information
General Information
Service Precautions 6. Maintain tools, measuring equipment and special
tools in good condition, and prepare them before
In order to work safely use. Do not use worn wrenches, hammers that has
the rounded striking surface of the head or chipped
1. Use an engine stand when lowering the engine
chisels, etc.
from the machine.
Do not put the engine on the ground directly. And
put it so that the oil pan is not affected.
2. When performing by two persons or more, confirm
safety each other.
3. If performing repair on the electrical system,
always disconnect the negative cable from the
battery terminal beforehand. Before removing the
battery cover, keep fire away.
7. When using devices such as a grinder, crane and

welder, follow the instructions and use a special
care.
Also, when performing other works, protect
yourself with clothes and other safety tools.
4. In badly ventilated indoor workshop, do not run the

engine for a long time or perform painting work.
5. Be sure to use special tools as instructed. Use of
other than the specified tool may cause damage of
parts or injury.
WSHK0191
WSHK0190
8. After servicing the fuel system, always check for Replacement parts and part numbers
fuel leakage. (This may cause a fire.) 1. Always replace the packing, oil seal, O-ring,
caulking lock nut, folding type lock plate, split pin,
etc. with new ones every time they are
disassembled.
2. The part number information in this manual may
not represent availability of supply, or the numbers
may have been changed due to revision. Always
check the numbers with the part catalog before
use.
Liquid gasket
1. Remove old liquid gasket completely from liquid
gasket applied area on each part using a scraper
during disassembly. Wipe off oil, water, dust, etc.
with cloth and apply specified liquid gasket on
each area before assembly.
2. If the gasket remover (ThreeBond, Pando 391D) is
used to clean easily, it is recommended that you
wait for about 10 minutes after application, and
9. When handling highly-volatile material, take then remove it.
extreme care not to let it catch fire. However, do not use it for resin or painted parts.
Be sure to wipe off spilled oil and grease on
3. Be careful to apply appropriate amount, not
rubbers, as this may cause the rubber to
excessively or insufficiently.
deteriorate.
Always, the start and end of the application should
be overlapped.
4. Take care not to misalign the applied part and
opposite one when assembling it after application.
If the parts are misaligned, apply the liquid gasket
again. Especially for the oil pan, use the same size
of studs as a guide since it has no positioning such
as a knock pin.
5. Apply liquid gasket and assemble it within 7
minutes.
If more than 7 minutes have elapsed, remove the
existing liquid gasket and apply again.
6. Start the engine more than 30 minutes after each
part is assembled.
WSHK0192
Liquid gasket
Sealed Location Product Name Manufacturer

Upper surface of the mating portion between cylinder block –
1207B ThreeBond
flywheel housing
Between front cover – cylinder block 1201 ThreeBond
Between cylinder block – flywheel housing – crank case 1201 ThreeBond
Between cylinder block – crank case FMD –127 Loctite
Lower surface of the mating portion between crankcase – flywheel
1207B ThreeBond
housing
Sealed Location Product Name Manufacturer

Lower surface of the mating portion between crankcase – front
1207B ThreeBond
cover
Contact part of cylinder head that nozzle sleeve is pushed to TL290 Loctite
Sealing cup push part between cylinder block – head 962T Loctite
123T Hermetic seal
Plug nipple of oil cooler #575 Loctite
O-ring omission prevention agent 1208 ThreeBond
CH Dyne #290 Cement dyne
• Be sure to use liquid gasket of product name How to use Plastigauge

described above or equivalent product.
• Use the appropriate amount of liquid gasket.
Follow the instructions of products. Type Measurable Range (mm)
PG-1 (Green) 0.025 — 0.076
Method of application
PR-1 (Red) 0.051 — 0.152
1. Wipe off water, oil or grease from contact surface.
The contact surface should be dry. PB-1 (Blue) 0.102 — 0.229
2. Apply liquid gasket of specified bead width on the
one side of contact surfaces. At this time, there (Example) Measurement of clearance between
should be no gap in bead. connecting rod bearing and crank pin
• Clean the connecting rod and the bearing, and
Note: assemble the bearing to the connecting rod.
If the method of application is described in service
• Cut the Plastigauge in the width of the crank pin,
manual, follow the description.
and place it parallel, away from the oil hole of the
pin.
Work procedure
• Align the stamp mark of connecting rod with that of
1. Wipe off oil, grease and water completely from the cap, and assemble them to the crank pin. Apply
contact surface of bolt, bolt hole and threads molybdenum disulfide to the threads and the
portion of nut. The contact surface should be dry. seating surface of the tightening bolts, and tighten
2. Apply Loctite on 1/3 of the tip of threads. the bolts on the cap alternately to the specified
3. Tighten the bolt to the specified torque. torque.
Important:
Never move the connecting rod while using the
Plastigauge.
• Carefully remove the cap and the connecting rod,

and measure the width (clearance) of flattened
Plastigauge using the scale printed on the bag.
Important:
After tightening, do not give excessive torque or
vibration for at least 1 hour until Loctite hardens.
• Carefully remove the crankcase, and measure the
width (clearance) of the flattened Plastigauge
using the scale printed on the bag.
(Example) Measurement of clearance between

crankshaft bearing and crankshaft journal.
• Clean the bearing installation surfaces on the
crankcase and on the cylinder block, and the
bearings. Then assemble each bearing to the
cylinder block and the crankcase.
• Put the crankshaft on the cylinder block carefully,
and rotate the crankshaft for approx. 30 degrees to
fit in.
• Cut the Plastigauge in the width of the crankshaft
journal, and place it parallel, away from the oil hole
of the journal.
• Put the crankcase on the cylinder block carefully,
and apply molybdenum disulfide to the threads
and the seating surface of the tightening bolts.
Then tighten them to the specified torque in the
specified order.
Important:
Never rotate the crankshaft while using the
Plastigauge.
Reading the Model
Stamping position of engine number
WSUZ0142
Name
1. Engine Number Stamp (6UZ)1-······)
General Information
Description of terms and abbreviations
Definition of terms
Term Description
Specifications General term for the specified values that are necessary for service work, such as
nominal dimension, assembly specifications and service limit.
Nominal dimension It indicates the value without tolerance at the time of manufacture.
Assembly It indicates the specified value after assembly, repair or adjustment.
specifications
Service limit It indicates the limit value that the part must be repaired or replaced when it reaches this
value (dimension).
Front/Rear, Right/Left, These indicate directions same as those of the vehicle when mounted on.
Top/Bottom
Units In addition to SI unit, conventional unit is also shown (toque, pressure, force, in
particular).
[Example] Length: mm, Torque: N⋅m {kgf⋅m}
Term Description
Warning It means the items that danger of personal life or serious injury may occur if you do not
follow.
Caution It means the items that injury or accident may occur if you do not follow.
Important It means the items that related parts and system may lose the normal performance, or a
fault may occur in vehicle.
Note It means the items which is noted in procedures.
Abbreviation Abbreviation Description

JIS Japanese Industrial Standards
Abbreviation Description
L/H, LH Left Hand
AC Alternating Current
M/V Magnetic Valve
ACC Accessory
NOx Nitrogen Oxide
ACG Alternating Current Generator
N-TDC Number - Top Dead Center
API American Petrol Institute
OPT Option
ASM (Assy) Assembly
P Pole(S)
ATDC After Top Dead Center
PCV Pump Control Valve/Positive
BAT, BATT Battery Crankcase Ventilation
BRG, Brg Bearing PM Particulate Matter
BKT, BRKT Bracket PS Pre-Stroke
BTDC Before Top Dead Center PTO Power Take Off
CO Carbon Oxide QOS Quick On System
CONN Connector Rr, RR Rear
CPU Central Processing Unit R/H, RH Right Hand
C/U Control Unit R/L Relay
DC Direct Current STD Standard
DI Direct Injection SW Switch
ECU Engine Control Unit/Electronic TICS Timing & Injection rate Control
Control Unit System
A type of injection system
ECM Engine Control Module
VGS Turbo Variable Geometry turbocharger
EGR Exhaust Gas Recirculation
System
Exh, EXH Exhaust Variable turbo, VGS turbo
Ft, FRT Front W/L Warning Lamp
FWD Forward
SI (International System of Unit)
F/C Fuel Cut
About changeover to SI (International System of
GND Ground Unit)
IC Integrated Circuit This was introduced with the aim to internationally unify
the metric system and the units (Shakkanho (Japanese
ID plate Identification Plate measuring system), Foot-pound system, etc.) which
IN Intake, Inlet are used conventionally in various countries, and to
control the confusion among each unit (conversion by
ISO International Organization for calculation etc.)
Standardization
I/PUMP Injection Pump
In Japan, the new calculation method that fully adopts
SI unit was issued in 1992 and standardized in JIS-Z-
8203.
In this manual, SI units which are international unit
system are described, and conventional units are
also described in { }.
SI
Abbreviation of French word “Le Systeme International
d’Unites”
Relationship between SI and conventional units
SI Conventional Unit Item, Unit Conversion

Length m m Same as conventional one
Weight (mass) kg kg Same as conventional one
Force N * kg, kgf 1 kgf = 9.80665 N
Torque N⋅m * kg⋅m, kgf⋅m 1 kgf⋅m = 9.80665 N⋅m
Pressure Pa * kg/cm2, mmHg 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa
Power output, W PS 1 PS = 0.74 kW
horsepower
Cubic volume, m3 Liter, L, cc 1 Liter = 1 dm3, 1 cc = 1 mLiter = 1 cm3
displacement
Fuel g/(kW⋅h) g/(PS⋅h) 1 g/(PS⋅h) = 1.360 g/(kW⋅h)
consumption
*1 Some service data which have been issued already Table of Isuzu standard tightening torque
use “kg” instead of “kgf” to represent force and weight The tightening torque values in the following table are
(mass) for convenience sake. applied to the places where tightening torque is not
*2 The results of the conversion may be rounded to one specified.
or two decimal places.
Conversion of numeric representation

Prefixes such as “k (kiro)” or “m (milli)” are used
for numeric conversion.
M Mega 106 1,000,000

3
k Kiro 10 1,000
h Hecto 102 100
-1
d Deci 10 0.1
c Centi 10-2 0.01
-3
m Milli 10 0.001
μ Micro 10-6 0.000001
• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa

• 40 mmHg = 5,332 Pa = 5.3 kPa
Isuzu standard bolts and nuts
N⋅m {kgf⋅m}
Strength 4.8
7T
Classification 4T
Shape of Bolt
Hexagon Head Bolt Flange Bolt Hexagon Head Bolt Flange Bolt
Head
19.6 — 33.3 {2.0 — 22.3 — 37.2 {2.3 — 27.5 — 45.1 {2.8 — 30.3 — 50.4 {3.1 —
* M10 x 1.5
3.4} 3.8} 4.6} 5.1}
49.0 — 73.5 {5.0 — 54.9 — 82.3 {5.6 — 60.8 — 91.2 {6.2 — 68.1 — 102.1 {6.9 —
M12 x 1.25
7.5} 8.4} 9.3} 10.4}
45.1 — 68.6 {4.6 — 51.0 — 76.5 {5.2 — 56.9 — 84.3 {5.8 — 62.7 — 94.0 {6.4 —
* M12 x 1.75
7.0} 7.8} 8.6} 9.6}
76.5 — 114.7 {7.8 — 83.0 — 124.5 {8.5 — 93.2 — 139.3 {9.5 — 100.8 — 151.1 {10.3
M14 x 1.5
11.7} 12.7} 14.2} — 15.4}
71.6 — 106.9 {7.3 — 77.2 — 115.8 {7.9 — 88.3 — 131.4 {9.0 — 94.9 — 142.3 {9.7 —
* M14 x 2
10.9} 11.8} 13.4} 14.5}
104.0 — 157.0 {10.6 115.6 — 173.3 {11.8 135.3 — 204.0 {13.8 150.1 — 225.2 {15.3
M16 x 1.5
— 16.0} — 17.7} — 20.8} — 23.0}
100.0 — 149.1 {10.2 109.4 — 164.2 {11.2 129.4 — 194.2 {13.2 142.5 — 213.8 {14.5
* M16 x 2
— 15.2} — 16.7} — 19.8} — 21.8}
151.0 — 225.6 {15.4 195.2 — 293.2 {19.9
M18 x 1.5 — —
— 23.0} — 29.9}
151.0 — 225.6 {15.4 196.1 — 294.2 {20.0
* M18 x 2.5 — —
— 23.0} — 30.0}
206.0 — 310.0 {21.0 269.7 — 405.0 {27.5
M20 x 1.5 — —
— 31.6} — 41.3}
190.2 — 286.4 {19.4 249.1 — 374.6 {25.4
* M20 x 2.5 — —
— 29.2} — 38.2}
251.1 — 413.8 {25.6 362.8 — 544.3 {37.0
M22 x 1.5 — —
— 42.2} — 55.5}
217.7 — 327.5 {22.2 338.3 — 507.0 {34.5
* M22 x 2.5 — —
— 33.4} — 51.7}
358.9 — 539.4 {36.6 430.5 — 711.0 {43.9
M24 x 2 — —
— 55.0} — 72.5}
338.3 — 507.0 {34.5 406.0 — 608.0 {41.4
* M24 x 3 — —
— 51.7} — 62.0}
The bolt with mark * should be used to female screw portion of soft material such as casting etc.
N⋅m {kgf⋅m}
Strength 9.8
8.8
Classification 9T
Shape of Bolt
Head
5.6 — 11.2 {0.6 — 6.6 — 12.2 {0.6 —
M6 x 1 — —
1.1} 1.2}
N⋅m {kgf⋅m}
Strength 9.8
8.8
Classification 9T
Shape of Bolt
Head
13.4 — 25.7 {1.4 — 15.3 — 28.4 {1.6 — 16.7 — 30.4 {1.7 — 18.1 — 33.6 {1.9 —
M8 x 1.25
2.6} 2.9} 3.1} 3.4}
31.3 — 52.5 {3.2 — 35.4 — 58.9 {3.6 — 37.3 — 62.8 {3.8 — 42.3 — 70.5 {4.3 —
M10 x 1.25
5.4} 6.1} 6.4} 7.2}
31.3 — 51.4 {3.2 — 34.5 — 57.5 {3.5 — 36.3 — 59.8 {3.7 — 40.1 — 66.9 {4.1 —
* M10 x 1.5
5.2} 5.8} 6.1} 6.8}
69.3 — 104.0 {7.1 — 77.7 — 116.5 {7.9 — 75.5 — 113.8 {7.7 — 85.0 — 127.5 {8.7 —
M12 x 1.25
10.6} 11.9} 11.6} 13.0}
64.8 — 96.1 {6.6 — 71.4 — 107.2 {7.3 — 71.6 — 106.9 {7.3 — 79.5 — 119.2 {8.1 —
* M12 x 1.75
9.8} 10.9} 10.9} 12.2}
106.2 — 158.8 {10.8 114.9 — 172.3 {11.7 113.8 — 170.6 {11.6 123.4 — 185.1 {12.6
M14 x 1.5
— 16.2} — 17.6} — 17.4} — 18.9}
100.6 — 149.8 {10.3 108.2 — 162.2 {11.1 106.9 — 160.0 {10.9 115.5 — 173.3 {11.8
* M14 x 2
— 15.3} — 16.6} — 16.3} — 17.7}
154.3 — 232.5 {15.7 171.1 — 256.7 {17.4 160.0 — 240.3 {16.3 176.9 — 265.3 {18.0
M16 x 1.5
— 23.7} — 26.2} — 24.5} — 27.1}
147.6 — 221.4 {15.0 162.5 — 243.8 {16.6 153.0 — 229.5 {15.6 168.5 — 252.7 {17.2
* M16 x 2
— 22.6} — 24.9} — 23.4} — 25.8}
222.5 — 334.3 {22.7 229.5 — 345.2 {23.4
M18 x 1.5 — —
— 34.1} — 35.2}
223.6 — 335.4 {22.8 230.5 — 346.2 {23.6
* M18 x 2.5 — —
— 34.2} — 35.3}
307.4 — 461.7 {31.4 316.8 — 475.6 {32.3
M20 x 1.5 — —
— 47.1} — 48.5}
284.0 — 472.1 {29.0 293.2 — 440.3 {29.2
* M20 x 2.5 — —
— 43.5} — 44.9}
413.6 — 620.5 {42.2 424.6 — 636.5 {43.3
M22 x 1.5 — —
— 63.3} — 64.9}
385.7 — 578.0 {39.3 394.2 — 592.3 {40.0
* M22 x 2.5 — —
— 58.9} — 60.4}
490.8 — 810.5 {50.0 554.1 — 830.6 {56.5
M24 x 2 — —
— 82.7} — 84.7}
462.8 — 693.1 {47.2 520.7 — 781.6 {53.1
* M24 x 3 — —
— 70.7} — 79.7}
The bolt with mark * should be used to female screw portion of soft material such as casting etc.
Indication of Isuzu standard bolt head
Name
1. Hexagon Head Bolt (4.8, 4T) 9. Hexagon Head Bolt (Nonthermal Refining, 8.8)
2. Hexagon Head Bolt (4.8, 4T) 10. Hexagon Head Bolt (Nonthermal Refining, 8.8)
3. Flange Bolt (4.8, 4T) 11. Flange Bolt (8.8)
4. Flange Bolt (4.8, 4T) 12. Flange Bolt (8.8)
5. Hexagon Head Bolt (7T) 13. Hexagon Head Bolt (9.8, 9T)
6. Flange Bolt (7T) 14. Hexagon Head Bolt (9.8, 9T)
7. Hexagon Head Bolt (Thermal Refining, 8.8) 15. Flange Bolt (9.8, 9T)
8. Hexagon Head Bolt (Thermal Refining, 8.8) 16. Flange Bolt (9.8, 9T)
Flare nut
Pipe Diameter Tightening Torque (for Width across flats of Flare

medium and large size Nut (mm)
vehicles)
Old New
Tightening torque of flare nut φ 4.76 mm 12.8 — 18.6 {1.3 — 1.9} 14 14
(service standard value) N⋅m {kgf⋅m}
φ 6.35 mm 23.5 — 49 {2.4 — 5.0} 17 17
φ 8.0 mm 23.5 — 49 (2.4 — 5.0) 19 17
φ 10.0 mm 44.1 — 93.2 {4.5 — 9.5) 22 19
58.8 — 137.3 (6.0 —
φ 12.0 mm 27 24
14.0)
78.5 — 156.9 (8.0 —
φ 15.0 mm 30 30
16.0)
Tapered screw for connector (brass)
N⋅m {kgf⋅m}
Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 1/12
2.0 — 14.7 4.9 — 15.7 9.8 — 16.7 9.8 — 17.7
—
(0.2 — 1.5) (0.5 — 1.6) (1.0 — 1.7) (1.0 — 1.8)
Special tool types

A. Basic tools
Always use the “Basic tools” when performing
service work.
B. Recommend tools
Commercially available general-purpose tools can
be used when performing service work. However,
use these “Recommended tools” as much as
possible to reduce work hours and maintain high
safety.
C. Setting tools
Commercially available general-purpose tools can
be used as a substitute for the “Setting tools” but
using them leads to increase work hours.
Engine Mechanical (6UZ1X) 1B-1
Engine
Engine Mechanical
(6UZ1X)
Contents
6UZ1X Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1B-84
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1B-2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1B-85
Reading the Model . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1B-89
Description of Function and Operation. . . . . . . . 1B-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1B-90
Function Check: . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6 Tightening Torque List . . . . . . . . . . . . . . . . . . . 1B-93
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-94
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12 Piston, Connecting Rod . . . . . . . . . . . . . . . . . . . 1B-95
Engine Accessories. . . . . . . . . . . . . . . . . . . . . . . 1B-13 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1B-95
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1B-95
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1B-96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1B-97
Tightening Torque List . . . . . . . . . . . . . . . . . . . 1B-15 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-100
Engine Exterior Equipment . . . . . . . . . . . . . . . . . 1B-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-102
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Tightening Torque List . . . . . . . . . . . . . . . . . . 1B-105
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-106
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-107
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-107
Tightening Torque List . . . . . . . . . . . . . . . . . . . 1B-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-107
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-41 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-108
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-41 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-110
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-112
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-49 Tightening Torque List . . . . . . . . . . . . . . . . . . 1B-113
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-53 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-114
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-56
Tightening Torque List . . . . . . . . . . . . . . . . . . . 1B-62
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-63
Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-64
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-64
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-64
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-66
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-67
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-67
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-67
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-68
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-69
Tightening Torque List . . . . . . . . . . . . . . . . . . . 1B-70
Flywheel, Flywheel Housing and Timing Gear . . 1B-71
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-74
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-74
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75
Tightening torque list . . . . . . . . . . . . . . . . . . . . 1B-80
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
Front Cover and Crankshaft . . . . . . . . . . . . . . . . 1B-82
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-82
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-82
1B-2 Engine Mechanical (6UZ1X)
6UZ1X Engine
Service Precautions
Confirm the following items to prevent damage on the
engine and maintain reliability of the engine
performance.
• Do not put a jack against the oil pan when lifting up
or supporting the engine.
Use an engine palette or a wooden frame etc. to
support the engine foot and the flywheel housing.
• Seal to prevent any foreign materials from entering
into cylinders when the air system was removed.
Foreign materials can be a cause for sever
damages on cylinders etc..
• Be sure to disconnect the battery earth cables
when servicing. When electricity is required for
inspection etc., be careful with short circuit.
• Apply sufficient engine oil to the sliding surface to
protect and lubricate the surface.
• When valve train parts, pistons, piston rings,
bearings, and injectors etc. are removed, put them
in order for storing.
• In the installation procedure, install the same part
to the same position of removal.
• For gaskets, oil seals and O-rings, replace with
new ones each time they are disassembled.
• When applying the liquid gasket, remove the old
liquid gasket completely and clean off any oil,
moisture or foreign materials beforehand.
• Assemble the liquid gasket within 7 minutes of its
application.
If more than 7 minutes passed, remove the
existing liquid gasket and apply again.
• For assembling and installing, tighten with the
specified torque.
Service precautions specific to this engine

Inside of the injector, and the fuel passage such as
holes and clearances are finished extremely finely. For
this reason, they are highly sensitive to foreign matter.
If it gets inside, it can lead to breakdown on the road.
Be sure to prevent it from getting inside.
Reading the Model
WSUZ0011
Name
1. Engine Number Stamp (6UZ1-⋅⋅⋅⋅⋅⋅)
Description of Function and Operation
Engine structure diagram
WSUZ0012
WSUZ0013
WSUZ0014
Function Check:
Measurement of the compression pressure 4. Remove the injector leak-off pipe.
Measure the compression pressure when the engine is 5. Remove all injector ASM.
warmed-up and there are no errors occurring at • Store them in numeric order.
batteries or starters.
Measure
Removal
1. Install the compression gauge.
1. Remove the head cover.
• Insert two sheets of the gasket (2) into the
• Remove the air-breather hoses, and then compression gauge adapter (1) 1-8531-7019-0,
remove the air cleaner element. and then insert it to the injector installation hole.
2. Warm up the injection pipe. • Use the clamp for injectors to tighten the
3. Remove the injector harness. adapter.
• Loosen the terminal tightening nut and remove Place the clamp at the center of the adapter.
the harness. • Install the compression gauge to the adapter.
• Remove the harness BRKT-ASM.
Note:
Note: Remove all gaskets apart from the measuring
When the injector harness is removed, its ID code plate cylinders.
is also removed. Do not confuse it with other injector ID 2. Measure the compression pressure.
code plates.
WSUZ0101
• Turn the starter (200rpm) and measure the Set to No.1 cylinder (or No.6 cylinder) compression
compression pressure when the indicator of TDC.
compression gauge is stable. Rotate the crankshaft in proper direction, and align the
• Measure the compression pressure of all nick line of flywheel to the pointer. Make sure there is a
cylinders. clearance (compression TDC) between the locker arm
of No1. cylinder (or No.6 cylinder) and the cam.
Items Compression pressure Difference
kPa/rpm {kg/cm2/rpm} between
cylinders
kPa/rpm {kg/
cm2/rpm}
Assembly
2746 / 200 196
specificati
{28 / 200} {2.0}
ons
Service 2260 / 200
—
limit {23 /200}
Note:
• Be careful, the air may be shooting out from the
injector hole when running.
• When the harness connector is removed, ECU
judges it as a breakdown and records an error
code. Upon completion of measurement, never fail
to clear ECU memory. (For clearing ECU memory, Adjusting the valve clearance
refer to “Trouble Shooting Manual”)
1. Adjust the valves shown on the valve clearance
adjustment chart.
2. Loosen each adjust screw completely on the
rocker arm and bridge.
• Use the adjust nut wrench (1) 5-8840-2822-0
for loosening adjust screw nuts on the bridge.
Note:
The adjust screws on the bridge may come off when
they are too loose.
Installation
1. Refer to “Cylinder Head” section for installation.
Adjusting the valve clearance

Adjust the valve clearance twice for setting at the No.1
cylinder compression TDC (top dead center) and at the
No.6 cylinder TDC.
3. Insert the thickness gauge (1) between the rocker Note:
arm (2) and the cam (5). Adjust with adjust screws Stop the engine and wait until it cools down before
on the rocker arm and then secure with the lock servicing.
nut.
4. Once the thickness gauge is inserted, tighten the
adjust screw (4) of the bridge until the thickness
gauge is secured tightly.
5. Slowly loosen the adjust screw (4) of the bridge
and re-adjust ins/outs of the thickness gauge (1)
appropriately, and then secure the lock nut of the
bridge.
Valve clearance (at cold condition):

Inlet valve: 0.2mm
Exhaust valve: 0.3mm
Tightening torque:
Rocker arm – lock nut: 34.3N⋅m
{3.5 kg⋅m/25.3 lb⋅ft}
Bridge – lock nut: 21.6N⋅m
{2.2 kg⋅m/15.9 lb⋅ft}
Valve clearance adjustment chart
Cylinder No. and Conditions
No.1 cylinder
Compression top dead center position
No.6 cylinder
Compression top dead center position
(The cylinder that is marked with a circle is adjustable.)

Fuel injection order 1-5-3-6-2-4
WSUZ0147
Judgment of time to overhaul
Overhaul is necessary for cases below.
The compression pressure is lowering.

The compression pressure measured by the measuring
method instructed is lower than 2260kPa (23kg/cm2).
Rate of increase in engine oil consumption

The consumption rate (oil consumption rate per a time
unit) is below 50% against 100% of a new vehicle.
Rate of increase in fuel consumption

The consumption rate (L/h) is below 60% against 100%
of a new vehicle.
Noise inside of engine

Strange noises are coming from inside of the engine.
Carry out the overhaul at an early stage and repair.
Note:
Wear, seizure or over-heat at engine parts can be
causes for strange noises.
Service Precautions
1. Engine parts are extremely hot straight after a
drive, so cool them down sufficiently.
2. Diagnostic codes (self-diagnosis codes) are
recorded on the ECU memory. Check the contents
of the memory stored on ECU using a scan tool
before starting an inspection on a sensor.
3. Make sure to disconnect battery terminals to
prevent damages on electronic parts such as
sensors or a fire.
4. High voltage at injector harnesses or
electromagnetic valves can cause an electric
shock. Make sure to turn the starter switch to
“OFF” and pull out the key when carrying out a
service.
Specifications
Model AH-6UZ1X
Items
Engine model Water cooling 4 cycle in-line type 6 cylinder 24 valve
OHC direct injection diesel
Cylinder layout - Number - (mm)
L6 — φ120 x 145
Diameter x Stroke
Displacement (L) 9.839
Compression ratio 17.5
2
Compression pressure kPa/rpm (kg/cm /rpm) 2746 (28)/200
Cylinder liner type Dry liner, tight-fit type
Maximum output kW/rpm (PS/rpm) 270/1950 (367/1950)
Maximum torque N⋅m/rpm (kg⋅m/rpm) 1435/1500 (146/1500)
Dimension (Length x Width x (mm)
1235x953x 1244
Height)
Weight (not including air cleaner) (kg) 840
Fuel injection timing (BTDC) 0°
Fuel injection order 1-5-3-6-2-4
Injection pump type Electronic control fuel injection system (Common rail
type)
Governor type Electronic type
Timer type Electronic type
Nozzle type DLL-P
Valve clearance (at Intake (mm)
0.2
cold condition) valve
Exhaust (mm)
0.3
valve
Intake valve open/close timing (Open) 22° (BTDC)
Intake valve open/close timing (Closed) 30° (ABDC)
Exhaust valve open/close timing (Open) 48.5° (BBDC)
Exhaust valve open/close timing (Closed) 23.5 ° (ATDC)
Fuel filter type Filter paper type
Oil filter type Pleated filter type
Oil pump type Gear type
Oil cooler type Water cooling type
Engine oil level (L) Full capacity: 30 — 41 Oil pan:25 — 36
Remaining amount inside the engine: 5
Cooling device type Water cooling compulsory re-circulation type
Coolant full capacity (L) 28.9
Coolant capacity on the engine (L) 22.5
Water pump model Spiral type
Model AH-6UZ1X
Items
Thermostat model Wax type
Air cleaner model Filter paper type (varies depending on the machine.)
Generator capacity (V-kw) 24 — 1.2, 24 — 1.5, 24 — 2.5
Starter (V-kw) 24 — 5.5
Idle speed (rpm) 900
Maximum engine speed at no
(rpm) 2000
load
Turbocharger model RHG6 (IHI)
Inter cooler type Aluminum tube & end plate type
(Varies depending on the machine.)
Thermostat valve-opening
(°C) 80 — 84
temperature
Thermostat full-open
(°C/mm) 95 /11
temperature/ lift amount
Exhaust gas re-circulation device (EGR) equipped
Special Tool
6UZ1X Engine
Tool Number
Illustration Description
Special Tool Rank
1-8531-7019-0
Compression gauge
adapter
Rank A
5-8840-2822-0
Valve clearance adjust
nut wrench
Rank A
Engine Accessories
Components
WSUZ0015
Name
1. V Belt (For the Generator) 3. Starter
2. Generator
Removal Installation
1. Remove the generator. 1. Install the starter.
• Loosen the through bolt (1) and adjust lock nut • Tighten the earth cable together.
(3).
Tightening torque: 137.3N⋅m {14kg⋅m/101.3lb⋅ft}
• Remove V belt.
• Remove the generator ASM (2). 2. Install the generator.
• Install the generator (2) temporarily, and then
install the V belt.
3
• Adjust the tension of the V belt.
- Adjust the belt deflection when its middle
part is pressed with approx. 98N⋅m{10kg/
72.3lb⋅ft} as follows.
Deflection: 12 — 14mm(0.47-0.55in)
• Tighten the adjust lock nut (3) and the through
2 bolt (1) with the specified torque.
Tightening torque:
Through bolt: 156.5N⋅m {16kg⋅m/115lb⋅ft}
Lock Nut: 92.9N⋅m{9.5kg⋅m/68.5lb⋅ft}
1
Note:
• Make sure that the V belt is fitted to the pulleys
WSUZ0016
groove.
2. Remove the starter. • Crank the engine for 5 rotations and check the
tension of the belt again.
WSUZ0016
Tightening Torque List
Engine accessories
c
WSUZ0018
Name
(a) 92.9N⋅m {9.5kg⋅m/68.5lb⋅ft} (c) 137.3N⋅m {14kg⋅m/101.3lb⋅ft}
(b) 156.5N⋅m {16kg⋅m/115.4lb⋅ft}
Engine Exterior Equipment

Components
6
7 8 9 10
WSUZ0019
Name
1. EGR Duct C 7. EGR Cooler (Intake Side)
2. Water Feed Pipe (Exhaust Side EGR Cooler) 8. Water Return Pipe (Intake Side EGR Cooler)
3. EGR Cooler (Exhaust Side EGR Cooler) 9. EGR Duct B
4. Water Return Pipe (Exhaust Side EGR Cooler) 10. EGR Duct A
5. Water Feed Pipe (Intake Side EGR Cooler)
6. Air Leak Pipe (EGR Cooler)
3 4 5
1
6
15
14
13 8
12 11 10 9
WSUZ0020
Name
1. Injection Pipe 8. Bearing Case
2. Inlet Cover 9. Supply Pump
3. Inlet Duct 10. Oil Return Pipe
4. EGR Valve 11. Fuel Feed Pipe
5. Fuel Filter 12. Fuel Temperature Sensor
6. Fuel Return Pipe 13. Oil Feed Pipe
7. Crank Position Sensor 14. Oil Level Guide Tube
5 4 3 2
WSUZ0021
Name
1. Turbocharger 4. Oil Port Cover
2. Engine Foot (Ft) 5. Oil Feed Pipe
3. Oil Return Pipe 6. Engine Foot (Rr)
Removal Sensor and device Name of installed parts

1. Remove the engine harness. Camshaft position
Supply pump
• Remove connector clips from each sensor and sensor (CMP)
device, and disconnect harnesses.
Fuel pressure sensor Common rail
Fuel temperature sensor Supply pump
Sensor and device Name of installed parts
Boost pressure sensor Inlet duct
EGR motor EGR valve
Boost temperature
Crank position sensor Flywheel housing on the Inlet duct
sensor
(CKP) upper-left
Solenoid valve Injector
Pump control valve
Supply pump
(PCV) Engine coolant Thermostat housing
temperature sensor
Sensor and device Name of installed parts • Remove the EGR valve (2).
• Remove the EGR duct A (1).
Oil pressure sensor Cylinder block left side
Note:
Leave a mark with a paint on where the harness clip is
installed, then remove it.
2. Remove EGR device.
• Remove the air leak pipe (1).
WSUZ0054
• Remove the water feed (1) and (2) for EGR

cooler, and the water return pipe (3) and (4).
4 3
WSUZ0055
• Remove EGR water pipe brackets (6) and the

exhaust side EGR cooler (7).
• Remove the intake side EGR cooler (4).
• Remove the EGR duct C (8).
• Remove the exhaust side EGR cooler brackets
(9).
• Remove the intake side EGR cooler brackets
(5).
• Remove the EGR duct B (3).
1 2 3 4 5 6
9 8
WSUZ0056
3. Disconnect the air breather hose. • Remove the fuel filter return pipe (3), the
injector return pipe (2), and the return pipe (1)
between the common rail and the supply pump.
• Remove the feed pipe between the feed pump
and the fuel filter (5), and the fuel filter and the
supply pump (6).
• Remove the fuel suction pipe (8).
• Remove the fuel pipe brackets (4) and (7).
Note:
• Seal where pipes are installed to prevent any
foreign materials sticking there.
• Seal the opening part where the pipes are installed
on the supply pump to prevent any foreign materials
sticking there.
WSUZ0057
4. Remove the oil level guide tube.

5. Remove the fuel pipe.
2 3 1
1
2
WSUZ0062
9. Remove the inlet duct (1).
Note:
Seal the opening part of the inlet cover to prevent any
foreign materials getting in.
4 1
8 7 6 5
WSUZ0061
6. Remove the fuel filter ASM.

7. Remove BRKT (1) between the fuel filter brackets
and the inlet duct.
1
WSUZ0058
10. Remove the injection pipe (1).
Important:
Do not reuse the high-pressure pipe in fuel system if it
has been removed.
• Loosen the clip and remove.
WSUZ0081 Note:
8. Remove the fuel pipe clip brackets (1), the fuel • Hold the flow-damper of the common rail with a
filter brackets (2) and BRKT (3). spanner to stop rotating, then loosen the sleeve
nut on the injection pipe.
• Make sure no dust or foreign materials sticking to
the sleeve nut.
• Seal the opening part of where the common rail
pipe is installed to prevent any foreign materials
sticking there.
1 4
1
3 2
WSUZ0063 WSUZ0103
11. Remove the common rail. 12. Remove the supply pump ASM.
• Remove the fuel pipe between the supply pump • Remove the oil feed pipe and return pipe.
and the common rail. • Loosen the cotter bolt at the coupling (3).
Important: • Loosen the coupling bolts (1) and (2). At this
Do not reuse the high-pressure pipe in fuel system if it stage, move the bolts to a position easier to
has been removed. loosen them by turning the crankshaft.
• Move the coupling ASM to the bearing case (4)
• Remove the fuel pipe brackets (1). side beforehand.
5 3 4
1 2
WSUZ0094 WSUZ0068
• Remove the common rail ASM (2). • Loosen the supply pump (1) tightening bolt in
• Remove the common rail brackets (1). the order instructed on the diagram.
• Remove the supply pump brackets (2).
Note:
Seal each fuel opening to prevent any foreign materials
getting in.
4 2 1 2
1
1 3
3
WSUZ0104 WSUZ0059
13. Remove the bearing case. • Remove the turbocharger ASM (1).
• Remove the bearing case ASM from the • Remove the exhaust adapter (2).
cylinder block.
14. Remove the inlet cover. Note:
Seal the oil opening of the turbocharger, compressor
and opening on the turbine side with gummed tape, etc.
15. Remove the turbocharger ASM. 2
• Remove the oil feed pipe (1), the oil return pipe WSUZ0060
(2) and the PTO oil feed pipe (3). 16. Remove the exhaust manifold ASM.
• Loosen the tightening nut. Remove the
distance tube (1), the manifold (2) and the
gasket (3).
2
1
1
WSUZ0105 WSUZ0065
17. Remove the oil port cover. 20. Remove the thermostat housing.
• Remove the water duct (2) and BRKT (1).
• Remove the thermostat housing (3).
1 2
2
4
1
WSUZ0064
18. Remove the oil cooler.

19. Remove the engine foot. WSUZ0089
• Remove the engine foot (1).

21. Remove the air breather ASM.
1
1
WSUZ0106
WSUZ0106 2. Install the thermostat housing.

• Put the gasket (5) in, install the housing (3)
Inspection while inserting it to the water pump.
EGR reed valve Tightening torque: 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}

• Check valve appearances for any damages.
Note:
• Check to see if carb0on is accumulated between
Applying a thin coat of ThreeBond No.TB1521 to the
the stopper and the valve.
gasket is also possible.
• Install the water duct (2) and BRKT (1).
Tightening torque: 21.6N⋅m {2.2kg⋅m/15.9lb⋅ft}
2
4
1
Installation
1. Install the air breather ASM.
WSUZ0089
Tightening torque: 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft} 3. Install the engine foot.

• Apply molybdenum disulfide to the thread and
seating side of the bolt, and tighten with a
specified torque.
Tightening torque: 103N⋅m{10.5kg⋅m/76.0lb⋅ft}
Note:
The front engine foot is the same for both left and right.
1
WSUZ0065 WSUZ0043
4. Install the oil cooler. 5. Install the oil port cover.

• Clean the installing surface of the oil cooler and • Put two O-rings (2) in on the installing surface.
cylinder block. • Install the oil port cover (1) to the oil cooler.
• Insert 7 O-rings to the installing surface (2
sorts). Tightening torque: 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}
• Put the gasket into the groove of installing Note:
flange surface and install the oil cooler. A thin coat of ThreeBond No. TB1208 or CH Dine
No.290 can be applied to prevent O-rings coming off.
1 2
• Tighten the bolt from outwards to the center. WSUZ0064
Tightening torque: 50N⋅m{5.1kg⋅m/36.9lb⋅ft} 6. Install the exhaust manifold ASM.

Install sealing rings every 120°, and then assemble
Note: the manifold.
• A thin coat of ThreeBond No. TB1208 or CH Dine Note:
No.290 can be applied to prevent O-rings coming Seal rings have direction. So look carefully when
off. assembling.
• When pushing the gasket in, push the projection
part (stopping the gasket from coming off) into the
groove completely.
• Pour engine oil (approx. 1cc) into the opening
of the turbocharger ASM (1) and turn the
turbine shaft slightly, and then lubricate the
shaft bearing.
• Set the gasket to the exhaust manifold.
• Install the turbocharger ASM (1) and tighten it
with bolts and double nuts. Tighten from the
turbine inlet flange.
Tightening torque:
Bolt: 50N⋅m{5.1kg⋅m/36.9lb⋅ft}
Nut: 40N⋅m{4.1kg⋅m/29.5lb⋅ft}
• Keep the molybdenum coating (black) side

outside when installing the gasket (3).
• Install the manifold (2) to the cylinder head.
• Tighten each flange in a following order; No.3,
4, 2, 5, 1, and 6 cylinder.
Tightening torque: 53.9N⋅m{5.5kg⋅m/39.8lb⋅ft}

• Install the cover (4).

2
Note:
WSUZ0060
• Place the small hole on the distance tube (1) • Install the oil feed pipe (1) and PTO oil feed
towards the nut side and install it. pipe (3). On the oil port cover side, tighten the
• Assemble the gasket projection pointing the oil feed pipe (1) and PTO oil feed pipe (3)
bottom right. together.
Eyebolt tightening torque:
3 Turbo side: 34.3N⋅m {3.5kg⋅m/25.3lb⋅ft}
Oil port cover side: 34.3N⋅m {3.5kg⋅m/25.3lb⋅ft}
PTO side M12: 22.5N⋅m{2.3kg⋅m/16.6lb⋅ft}
PTO side M8: 14.7N⋅m{1.5kg⋅m/10.8lb⋅ft}
• Put O-rings into both sides of the oil return pipe
(2) and install it.
Bolt tightening torque:
Turbo side: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft}
Cylinder side: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft}
4 2
1
WSUZ0107
7. Install the turbocharger ASM.

• Install the exhaust adapter (2) and tighten it
with a double nut.

1 2
3
WSUZ0059
8. Install the inlet cover. • Reverse turn the crankshaft once up to just
• Put the gasket into the groove of the inlet cover below the top dead center 90° and turn it into a
and install it. proper direction. And set the nick line of the
flywheel (P/P) to the timing pointer. Check to
Tightening torque: 45N⋅m{4.6kg⋅m/33.2lb⋅ft} see it is close to the compression top dead
center of No.1cylinder.
Note:
A thin coat of ThreeBond No. TB1208 or CH Dine
No.290 can be applied to prevent the gasket coming
off.
WSUZ0102
• Apply ThreeBond No.TB1208 to 3 parts of the

O-ring and install it to the groove of the bearing
case.
• Set “A” marked on the coupling to the pointer
9. Install the bearing case.
(1) of the bearing case and assemble to the
• Install the key to the shaft of the bearing case. cylinder block.
• Apply molybdenum disulfide to inside and the • Check to see “S” marking is aligned with the
seating side of the nut and tighten with a pointer after installation.
specified torque.
• Tighten the bolt and nut with the specified
Tightening torque: 255N⋅m {26kg⋅m/188.1lb⋅ft} torque.
1
S A
S A
WSUZ0066 WSUZ0102
10. Install the supply pump ASM. • Move the coupling ASM to the bearing case
• Install the supply pump brackets (2) and the oil side beforehand.
pipe brackets (3). At this point, place the oil • Align nick lines of the coupling and the pump.
pipe brackets (3) on the engine front side when • Install the supply pump to the BRKT and tighten
tightening. in a diagonal order.
Tightening torque: 850.5N⋅m {8.7kg⋅m/63.0lb⋅ft} Tightening torque: 31N⋅m{3.2kg⋅m/22.9lb⋅ft}
• Slide the coupling and make sure it is stuck
2 4 tightly to the supply pump. Tighten it with the
coupling bolt (1) first and then with the bolt (2).
At this stage, turn the crankshaft and move the
bolt to a position easier to tighten it.
1
3 1 Tightening torque: 83 — 93N⋅m
5 {8.5 — 9.5kg⋅m/61.2 — 68.6lb⋅ft}
• Make sure there is no dent on the laminate of
2
the coupling and tighten the cotter bolt (3).
Tightening torque: 83 — 93N⋅m
3 {8.5 — 9.5kg⋅m/61.2 — 68.6lb⋅ft}
Note:
To prevent the coupling bolts from slipping, make sure
to use the specified torque.
WSUZ0108
• Make sure the nick line (P/P) of the flywheel is

aligned with the timing pointer.
5 3 4
1 4
3 2
1 2
WSUZ0068 WSUZ0103
• Install the oil feed pipe (2) commonly used by • Install the fuel pipe brackets (1).
the bearing case.
Tightening torque:
Pump side: 10.3N⋅m{1.1kg⋅m/7.6fb⋅ft}
Cylinder side: 20.2N⋅m{2.1kg⋅m/14.8lb⋅ft}
• Install the oil return pipe (1).
Tightening torque:
Pump side: 17.2N⋅m{1.8kg⋅m/12.7lb⋅ft}
Cylinder side: 41.2N⋅m {4.2kg⋅m/30.4lb⋅ft}
WSUZ0094
• Install the high-pressure pipe between the

supply pump and common rail.
Important:
Replace the high-pressure pipe in fuel system with new
one if it has been removed.
12. Install the injection pipe.
11. Install the common rail.
Important:
• Install the common rail brackets (1).
Tightening torque: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft} one if it has been removed.
• Tighten the injector side and the common rail
• Align the common rail (2) to the dowel of BRKT side alternately few times on each side.
(1) and install it. At this stage, tighten the
engine harness brackets (3) and (4) together.
• Install the clip at the specified position.
Tightening torque:
1
Sleeve Nut: 44.1N⋅m{4.5kg⋅m/32.5lb⋅ft}
2
Clip: 8.9N⋅m{0.9kg⋅m/6.4lb⋅ft}
Note:
Do not re-use the clip when there are cracks or
damages on the rubber.
WSUZ0062
15. Install BRKT (1) between the fuel filter brackets

and the inlet duct.
13. Install the inlet duct.

• Put O-rings into the bottom side of the inlet duct
(1) and install the inlet cover.
Tightening torque: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft} 1
Note:
A thin coat of ThreeBond No. TB1208 or CH Dine
No.290 can be applied to prevent O-rings coming off.
WSUZ0081
16. Install the fuel filter ASM.

17. Install the fuel pipe.
• Install the fuel pipe brackets (4) and (7).
Tightening torque:
BRKT (4): 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft}
BRKT (7): 21.6N⋅m{2.2kg⋅m/15.9lb⋅ft}
• Install the fuel suction pipe (8).
• Install the feed pipe between the feed pump
WSUZ0058
and the fuel filter (5), and the fuel filter and the
14. Install the fuel pipe clip brackets (1), the fuel filter supply pump (6).
brackets (2) and BRKT (3).
• Remove the fuel filter return pipe (3), the
injector return pipe (2), and the return pipe (1)
between the common rail and the supply pump.
• Install the clip at the specified position. • Install the guide tube to the inlet duct.
Eyebolt tightening torque: Tightening torque: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft}
Fuel suction pipe: 17.2N⋅m
{1.8kg⋅m/12.7lb⋅ft}
Feed pipe, feed 17.2N⋅m
pump side: {1.8kg⋅m/12.7lb⋅ft}
Feed pipe, filter side: 50N⋅m
{5.1kg⋅m/36.9lb⋅ft}
Feed pipe, supply 41.2N⋅m
Return pipe, supply 17.2N⋅m
Return pipe, 17.7 — 22.6N⋅m
common rail side: {1.8 – 2.3kg⋅m/13.1 – 16.7lb⋅ft}
Return pipe, M14: 41.2N⋅m
{4.2kg⋅m/30.4lb⋅ft}
Return pipe, M8: 14.7N⋅m
{1.5kg⋅m/10.8lb⋅ft}
Tightening torque:
WSUZ0069
Clip: 8.9N⋅m{0.9kg⋅m/6.4lb⋅ft} 19. Install the air breather hose.
Note: Tightening torque:
Do not re-use the clip when there are cracks or
damages on the rubber. M10: 45N⋅m {4.6kg⋅m/33.2lb⋅ft}
M8: 21.6N⋅m{2.2kg⋅m/15.9lb⋅ft}
Note:
2 3
1
Install the hose with no breakage or slackness.
WSUZ0057
20. Install the EGR device.

• Install the reed valve (1) (2 places) to the inlet
4 duct.
8 7 6 5
WSUZ0061 Tightening torque: 10N⋅m {1.0kg⋅m/7.4lb⋅ft}
18. Install the oil level gauge guide tube.
• Apply a thin coat of engine oil to O-ring (1) and
insert it without damaging the O-ring.
1) Install the EGR valve.
• Install the gasket with the identifying part (2)
placed as shown on the diagram, and then
install the EGR valve (1). (Temporal tightening
torque 5N⋅m{0.5kg⋅m/3.7lb⋅ft})
1
WSUZ0070
2
21. Install the EGR duct A (1) to the inlet duct (2).
• Assemble the gasket and align the dowel pin,
and then install it.
Tightening torque: 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft} WSUZ0071
2) Assemble the EGR duct B.

Assemble the gasket and the EGR duct B (1).
(Temporal tightening torque 5N⋅m{0.5kg⋅m/
3.7lb⋅ft})
1
1
2
WSUZ0109
22. Assemble the EGR device following the instruction

below.
Note: WSUZ0072
For installing the EGR device, make sure to tighten in 3) Install the intake side EGR cooler brackets (1).
two steps; temporal and final.
Tightening torque: 97N⋅m {9.9kg⋅m/71.5lb⋅ft}
6) Assemble the intake side EGR cooler.
Assemble the gasket, and then the intake side
EGR cooler (1) to the EGR duct B (2). (Temporal
1 tightening torque 5N⋅m{0.5kg⋅m/3.7lb⋅ft})
WSUZ0110
4) Install the exhaust side EGR cooler brackets.

WSUZ0112
5) Assemble the EGR duct C.
7) Assemble the exhaust side EGR cooler.
Assemble the gasket. And then assemble EGR
Assemble the gasket on the front and the back.
duct C (2) to the exhaust manifold (3) and to the
Then assemble the exhaust side EGR cooler (3)
exhaust side EGR cooler brackets (1). (Temporal
to the EGR duct C and to the intake side EGR
tightening torque 5N⋅m{0.5kg⋅m/3.7lb⋅ft})
cooler brackets.
Assemble with the EGR water pipe brackets (2)
tightened together to the intake side EGR cooler
(1).
(Both temporal tightening torque 5N⋅m{0.5kg⋅m/
1 3.7lb⋅ft})
3 2
1
WSUZ0111
2
3
WSUZ0074
23. Final tightening order
Note:
The circled numbers on the diagram are showing the
tightening order.
1. Between EGR duct A – and the EGR valve ➀.
2. Between EGR valve – and the EGR duct B ➁. 7. Between the exhaust manifold – and the EGR duct
C ⑦.
3. Between the inlet duct – and the EGR duct B ➂.
7 6
WSUZ0073
2 3 8. Between the exhaust side EGR cooler – and the
WSUZ0113 intake side EGR cooler brackets ⑧.
4. Between EGR duct B – and the intake side EGR
cooler ➃.
5. Between the intake side EGR cooler – and the
exhaust side EGR cooler ➄. 8
WSUZ0115
9. Between the EGR duct C – and the exhaust side

EGR cooler brackets ⑨.

5
WSUZ0114
6. Betweenthe EGR duct C – and the exhaust side

EGR cooler ⑥.
9
WSUZ0116
1 4
9 7 6
WSUZ0117
- Install the EGR water pipe. Sensor and device Name of installed parts
Note: Camshaft position
Supply pump
• Inset the rubber hose deeply and install the clip not sensor (CMP)
to let it run on to the bulge part. Fuel pressure sensor Common rail
• Do not re-use the rubber hose and clip when there
Fuel temperature sensor Supply pump
are cracks or damages on them.
• Install the water feed for the EGR cooler (1) and Boost pressure sensor Inlet duct
(2) and the water return pipe (3) and (4). Boost temperature
Inlet duct
sensor
2
Solenoid valve Injector
1 Engine coolant
Thermostat housing
temperature sensor
Oil pressure sensor Cylinder block left side
Note:
Install the clip at the specified position.
4 3
WSUZ0055
• Install the air leak pipe (1).
WSUZ0054
24. Install the engine harness.

• Install harnesses on to each sensor and device.
Sensor and device Name of installed parts

EGR motor EGR valve
Crank position sensor Flywheel housing on the
(CKP) upper-left
Pump control valve
Supply pump
(PCV)
Engine Exterior Equipment
a b c
WSUZ0075
Name
(a) 50N⋅m {5.1kg⋅m/ 38.9lb⋅ft} (e) 85.5N⋅m {8.7kg⋅m/ 63.1lb⋅ft}
(b) 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft} (f) 31N⋅m {3.2kg⋅m/ 22.9lb⋅ft}
(c) 21.6N⋅m {2.2kg⋅m/ 15.9lb⋅ft} (g) 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft}
(d) 97.4N⋅m {9.9kg⋅m/ 71.8lb⋅ft}
b c
i h g
WSUZ0076
Name
(a) 53.9N⋅m {5.5kg⋅m/ 39.8 lb⋅ft} (f) 50N⋅m {5.1kg⋅m/ 39.6lb⋅ft}
(b) 50N⋅m {5.1kg⋅m/ 39.6lb⋅ft} (g) 50N⋅m {5.1kg⋅m/ 39.6lb⋅ft}
(c) 40 N⋅m {4.1kg⋅m/29.5 lb⋅ft} (h) 103N⋅m {10.5kg⋅m/ 76.0lb⋅ft}
(d) 97.4N⋅m {9.9kg⋅m/ 71.8lb⋅ft} (i) 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft}
(e) 97.1N⋅m {9.9kg⋅m/ 71.6lb⋅ft}
WSUZ0077
Name
(a) 50N⋅m {5.1kg⋅m/ 39.6lb⋅ft} (b) 43.8N⋅m {4.5kg⋅m/ 32.3 lb⋅ft}
Cylinder Head
Components
Name
1. Leak-off Pipe 10. Gasket
2. Injector ASM 11. Idle Gear C Cover
3. Clamp 12. Idle Gear C Shaft
4. Camshaft BRKT 13. Idle Gear C
5. Head Cover 14. Glow Plug
6. Gasket 15. Glow Plug Connector
7. Rocker Arm ASM 16. Gasket
8. Camshaft 17. Cylinder Head ASM
9. Camshaft Carrier
Removal Note:
When the injector harness is removed, its ID code plate
1. Remove the EGR cooler and EGR valve.
is also removed. Do not confuse it with other injector ID
Refer to “Engine Exterior Equipment”. code plates.
2. Remove the fuel pipe and the fuel filter ASM. Injector ID code plate is unique to each injector.
Refer to “Engine Exterior Equipment”.
3. Remove the inlet duct.
4. Remove the injection pipe.
Important:
Do not reuse the high-pressure pipe in fuel system if it
has been removed.
5. Remove the common rail.
6. Remove the inlet cover.
7. Remove the turbocharger ASM.
8. Remove the exhaust manifold.
9. Remove the thermostat housing.
11. Remove the head cover gasket.
12. Remove the glow plug.

• Disconnect the connectors and remove the
glow plug.
13. Remove the injector harness.
• Loosen the terminal tightening nut and remove
the harness.
• Remove the harness BRKT-ASM.
14. Remove the injector leak-off pipe.
15. Remove the injector.

• Loosen the clamp (1) tightening bolt (2) and
remove the injector (3).
• If it is hard to pull out the injector ASM, shake it
left-to right a few times or use the injector
remover (5-8840-2826-0).
Note:
• The ends of the injector and the glow plug are
Name
sticking out of the lower surface of the cylinder
1. Sliding Hammer
head. Therefore, remove both before lowering the
2. Injector Remover
head.
3. Injector ASM
• Check the injector sleeve has not come off while
removing the injector. If the sleeve does come off, 16. Remove the rocker arm ASM.
the cooling water will go inside the cylinder.
• Remove the brackets tightening bolt from the
• Make sure to put number plates on injectors. rocker arm ASM by loosening them equally
from both ends.
1 3
WSUZ0078
17. Remove the bridge.

• Store bridges in numeric order.
18. Remove the camshaft.
• Measure the axial clearance of the camshaft
before removing the camshaft.
Axial clearance of the camshaft
(mm)
Assembly standard Limit of usage
0.085 — 0.170 0.25
• Loosen the tightening bolts of the brackets

equally from both ends to remove.
19. Remove the camshaft carrier.
20. Remove the cylinder head ASM.

• After loosening M10 bolts 1, 2, and 3, loosen
the M15 tightening bolts equally from outside to
inside as directed by arrows on the diagram.
Note:
• Remember to remove the M10 tightening bolt.
• Cover the hole on the timing gear with a cloth.
21. Remove the cylinder head gasket.

• Make sure there is no water or gas leak when
removing.
Disassembly
Name
1. Exhaust Manifold Cover 10. Valve Guide
2. Gasket 11. Injector Sleeve
3. Exhaust Manifold 12. Cylinder Head
4. Bridge Guide 13. Gasket
5. Split Collar 14. Inlet Cover
6. Spring Seat (upper) 15. Valve
7. Valve Spring 16. Valve Seat Insert
8. Valve Stem Oil Seal 17. Thermostat Housing
9. Spring Seat (lower)
1. Measure the axial clearance of the idle gear shaft Axial clearance
C.
(mm)
• Measure the axial clearance of the idle gear C
before removing the shaft. Assembly standard Limit of usage
0.135 — 0.190 0.30
2. Remove the idle gear C. 4. Remove the split collar.

• Pull out the idle gear shaft and remove the idle • Use round nails for the valve spring re-presser.
gear C from the cylinder head. 5. Remove the spring seat (upper).
Note: • Place the cylinder head on a wooden board
Be careful not to damage bushing of the idle gear shaft. with its sides down.
• Use the valve spring replacer (5-8840-2546-0)
to remove the split collar and remove the spring
sheet.
3. Remove the oil seal from the camshaft carrier.

• Place a pad from inside the carrier and pull out.
6. Remove the valve spring.
7. Remove the valve.
Note:
Put number plates on valves to store.
8. Remove the valve stem oil seal.
9. Remove the spring seat (lower).
12. Remove the valve seat insert.

• Heat-up the 2 parts of insides of the insert (up
to 600 — 700 °C) with welding gas burner, and
leave it to cool down for 3 to 5 minutes then pull
out with a screw driver.
Note:
• Do not cool it forcefully.
10. Remove the valve guide.

• Insert the valve guide replacer into the guide
from the bottom side of the head and hammer it
out.
13. Remove the injector sleeve.

• Put a stick on the bottom side of the head and
knock it out.
11. Remove the bridge guide.

• Weld the nut electrically to the bridge guide,
and take out the nut by installing the sliding
hammer.
Measure the valve spring.
• Measure the squareness of the valve spring.
Valve spring squareness
(mm)
Assembly Limit of
standard usage
Inlet 3.85 4.5
Exhaust 4.11 4.8
Inspection
Inspect on the idle gear shaft C.
• Measure the diameter of the idle gear shaft, and
the clearance between the shaft and the bushing.
Check to see if there are any damages on the
bushing.
Diameter of the shaft
(mm)
Nominal dimension Limit of usage • Measure the free length of the valve spring
38 37.85 Valve spring free length
(mm)
Clearance between the shaft and bushing
Nominal
Limit of usage
(mm) dimension
Assembly standard Limit of usage Inlet 88.09 85.00
0.02 — 0.066 0.12 Exhaust 94.09 91.10
• Measure the tension of the spring at installation. Measure 3 places shown on the diagram.
Installation length The external diameter of the valve stem
Both IN – EX: 64.5mm (mm)
Nominal
Valve spring tension (loading at installation) Limit of usage
dimension
(N{kg}) Inlet φ8.0 φ 7.88
Load Service limit Exhaust φ8.0 φ 7.88
Inlet 392 {40.0} 373 {38.0}
If the wear level of the valve stem is exceeding the
Exhaust 588 {60.0} 559{57.0}
limit, replace it together with the valve guide.
• Measure the clearance between the valve guide

and the valve stem.
Measure the valve. Insert the valve into the valve guide and measure
• Check wear of the valve stem end. Repair light the clearance at (a) 10mm from the upper end of
wear with the oil stone. the valve guide.
The clearance between the guide and valve stem.
(mm)
Assembly
Limit of usage
specification
Inlet 0.039 — 0.071 0.15
Exhaust 0.064 — 0.096 0.20
• Measure the wear level of the valve stem.

• Check around the surface of the valve seat and

measure the thickness. Check on the contact surface of the valve seat
Check for any damages and stepped wear, and • Apply red lead to the valve insert and check the
measure the thickness (b) and width (a). contact width (b) of the seat surface. Also, check to
Thickness of valve see if the contact area is at the center of the valve
(mm) seat and if there is any part off the seat.
Nominal
Limit of usage
dimension
Inlet 2.0 1.6
Exhaust 2.2 1.8
Contact width of the valve seat surface

(mm)
Nominal
Limit of usage
dimension
Inlet 3.3 3.7
Exhaust 3.5 4.0
Note:
After a polishing repair, replace the valve if its thickness
exceeded the usage limit. • If the contact width of the valve or contacting
surface is insufficient, repair it with a seat knife
appropriate for the seat angle and stem diameter.
Valve seat angle Measure the bridge guide.
Inlet valve: 30° • Measure the clearance between the bridge guide
and bridge.
Exhaust valve: 45° The clearance between the guide and bridge
(mm)
0.020 — 0.057 0.10
Rubbing valves
• Apply compound to the insert and contact surface
of the valve seat, and rub them together
adequately. Clean the cylinder head and valve
after rubbing.
Inspect on the cylinder head.
• Measure the warp on cylinder head
Remove any rust or carbon from the head, valve
seat and insert etc. without damaging the
processing surface. Put a straight edge to the
installing side of the head and measure from 1 to 4
shown on the diagram with a thickness gauge. If
the measurement exceeds the limit, replace it.
Warp level:
Service limit 0.2mm or less
Note:
The cylinder head cannot be modified since the
backlash of the timing gear fluctuates.
• Measure the depression level of the valve after a

polishing repair of the valve seat, and check if it is
within the usage limit.
Valve depression level
(mm)
Assembly
Limit of usage
standard
Inlet 0.05 1.0
Exhaust 0.40 1.4
• Check for cracks or damages on the cylinder head. 2. Install the valve seat insert
Perform magnetic flux method or red check • Remove any rust or carbon carefully from the
inspection as required. installation surface of the insert, and press-fit
insert with a press.
• Check on cracks on the water jacket.

Apply water pressure of 490kPa{5kg/cm2}with a 3. Install the bridge guide.
hydraulic test machine for 3 minutes, and check for
• Apply a thin coat of engine oil to the outer
any leakage from each head part.
surface of the guide. Hammer guides in with the
installer (5-8840-2626-0) until the height of
Assembly bridge guide from the upper surface of the head
is 43.5±0.5mm.
1. Install the injector sleeve.
• Clean the adhesive side of the cylinder head. Note:
Height of the bridge guide cannot be set to the
• Apply Loctite No.LT290 on the outer surface
specified level using the bridge guide installer. Measure
sleeve (the bottom part) and end-bearing
the height while hammering in the bridge guides.
surface. Apply a thin coat of engine oil to the O-
ring and press-fit it to the cylinder head.
Note:
Assemble red O-rings to upper side of the sleeve
groove and black O-rings to the lower side.
5. Install the spring seat. (lower).
6. Install the valve stem oil seal.
• Install the valve stem oil seal (1) to the valve
guide (2) using the installer (5-8840-2625-0).
• Hammer in while checking the measurement
(a) of the lower seat (3) is 26.3±0.5mm from the
shoulder of oil seal.
Note:
• Apply engine oil to the oil seal.
• After installation of the valve stem oil seal, make
sure there is no spring coming off or deformed.
WSUZ0143
4. Install the valve guide.

• Apply engine oil to valve guides all around.
Press-fit valve guides using a replacer (5-8840-
2628-0) until the height from the cylinder head
surface (lower seat adhesive side) is levelled to
the specification.
Note:
The valve guide cannot be set to the specified height
using the valve guide replacer. Hammer in the valve
guide while measuring the height during the work.
Height of valve guide from the cylinder head
surface.
7. Install the valve.
(mm) • Apply engine oil to the valve stem and insert
Assembly standard into the cylinder head.
Both IN and EXH 24.0 Note:

Make sure there are IN valve in the front side and EXH
valve in the rear side.
WSUZ0144
8. Install the valve spring.
• Place the cylinder head on a wooden board
with its sides down.
• Install the inlet valve spring with its narrow
pitched side (painted part) pointing the bottom
side of the head. The exhaust valve spring has
no top/bottom.
9. Install the spring seat. (upper).
11. Install the oil seal to the camshaft carrier.

surface of oil seal.
• Use an installer (5-8840-2627-0) to hammer in
without leaning the seal.
10. Install the split collar.

• Use round nails for the valve spring re-presser.
• Use the valve spring replacer (5-8840-2546-0)
to push the valve spring in and install the split
collar.
• After installation, tap the head of the valve stem 12. Install the idle gear C.
lightly with rubber hammer to stabilize the split
13. Install the idle gear shaft C.
collar.
• Apply engine oil to the idle gear shaft. Align the
oil pins of the shaft to the oil hole position on
the head and install.
seating side of the bolt, and tighten with a
specified torque.
Note:
• Make sure that the gear rotates smoothly.
• Make sure not to damage tooth surface of the gear
since it sticks out from the cylinder head.
14. Install the idle gear C cover. • Maintain the coating height and width without the
• Insert O-ring to the cover and apply a thin coat liquid gasket covering the oil hole after assembling
of engine oil to it, then install it. of the cylinder head.
• Assembling the cylinder head.

Assemble the head gasket. Align the cylinder head
with the knock pin and put it on carefully.
• Put it on while checking on how the gear is
Installation engaged.
1. Cylinder head gasket
• Use new parts when re-assembling
• Tighten the cylinder head bolt.

Apply molybdenum disulfide to the thread and
seating surface of M15 and 10 bolts, and to the
2. Install the cylinder head ASM.
seating surface of washer. Tighten M15bolt (1 —
• Clean the upper surface of cylinder block and 26) outwards in spiral from the center as shown on
the lower side of cylinder head carefully. the diagram. Tighten M10 bolt (27, 28 and 29)
• Apply ThreeBond No.TB1207B (height – next.
approx. 2mm and width – approx. 2mm to the
Tightening torque
top surface of contact part (3) of cylinder block
(1) and flywheel housing (2). M15: 98N⋅m{10kg⋅m/72.3lb⋅ft} → 196N⋅m {20kg⋅m/
144lb⋅ft} → Angle method60° +30°
-0°
Note: M10: 38N⋅m{4.0kg⋅m/28lb⋅ft}
• Assemble swiftly once applied.
Note:
• To check the tightening condition of M15 bolt, it
should be over 230N⋅m{23.5kg⋅m/169.6lb⋅ft} in re-
tightening direction.
• Cover the hole on the timing gear with a cloth.
• The head bolt can be recycled up to 2 occasions.
3. Install the camshaft carrier. - Apply engine oil to M10 and M8 bolts.
• Push the convex part of gasket into the groove - Tighten bolts temporarily in the order shown on
on the carrier securely. the diagram 1-23.
- After that, tighten finally with a specified torque
Note: in the same order as the temporal tightening.
Check all the convex parts for any sign of collapsing. If
gasket ends were found off the center of groove and - Torque of inside bolts (1-5) tend to go down. So
collapsed, push the gasket from the sides with a finger tighten them again to confirm.
to set the end back to the center of groove. And then Tightening torque:
install.
M10 bolt: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft}
• Follow the order below to tighten bolts.
M8 bolt: 21.6N⋅m{2.2kg⋅m/15.9lb⋅ft}
21
20 14 8 2 9 15
22
19 13 7 1 3 10 16
18 12 4 11
6 5 17 23
WSUZ0035
4. Install the camshaft.
• Set No. 1 cylinder to the compression top dead
center position.
Rotate the crankshaft in proper direction, and
align the T/C mark on the flywheel with the
pointer.
WSUZ0036
• Install the camshaft BRKT.

- Apply engine oil on the BRKT.
- Check the identifying symbols of BRKT
(stamped 1, 2, 3, 4, 5, 6 and 7 from the
front) and front marks. Install the cam BRKT
to a correct position.
• Apply engine oil to the journal of cam carrier,
- Apply engine oil to the bolt.
the cam BRKT and to the No.7 journal thrust
part. - Tighten temporarily in a numerical order
from the center of cam BRKT and use the
specified torque for final tightening.
Note:
Check again to see if the (U) mark on the cam gear and
the nick line (-) are matched after tightening the cam
BRKT.
• Match the marks on the camshaft.

Set the camshaft to the mark (U) on the gear
with your eye level on the upper part of cam
carrier, and set the nick line (-) to the position
shown on the diagram.
5. Install the bridge. 7. Install the inlet cover.
• Loosen the adjust screw and apply engine oil to Refer to “Engine Exterior Equipment”.
the bridge guide, then install. 8. Install the common rail.
9. Install the injector, clamp and injection pipe.
Important:
one if it has been removed.
• Put gasket into the injector (3) and install it to

the cylinder head.
Tighten the injection pipe temporarily.
Apply molybdenum disulfide to the tightening
bolt (2) for the clamp and tighten the clamp (1)
with the specified torque.
Tighten the injection pipe at the end.
Tightening torque:
Clamp: 25.5N⋅m
{2.6kg⋅m/18.8lb⋅ft}
Injection pipe: 44.1N⋅m
{4.5kg⋅m/32.5lb⋅ft}
Note:
• Install the bridge to the same position as Note:
disassembly.
• Make sure there is no old gasket remaining inside
• Adjust screws come off when loosened too much. the sleeve.
6. Install the rocker arm ASM. • Remove carbon inside the sleeve carefully.
• Apply engine oil to the camshaft and to the • Do not re-use gasket.
upper surface of bridge.
• Do not remove the ID code plate from the injector.
• Install the rocker arm ASM. If removed, put it back to the same injector.
• Tighten temporarily in a numerical order as
shown on the diagram, and then tighten finally
with specified torque.
2
1 3
WSUZ0078
10. Install the injector leak-off pipe.

• Install the leak-off pipe (1) to the injector.
Tightening torque:
M8 eye bolt: (2) 14.7N⋅m{1.5kg⋅m/10.8lb⋅ft}
• Adjust the valve clearance. M12 eye bolt: (3) 34.3N⋅m {3.5kg⋅m/25.3lb⋅ft}
For adjustment procedure, refer to the valve
clearance adjustment section on the “Function
Check”.
Note:
Do not re-use gasket.
12. Install the glow plug.

• Tighten the glow plug with the specified torque
11. Install the injector harness ASM. and install the connector.
• Insert the harness connector until it clicks and
install it to the cam carrier. Tightening torque: 19.6N⋅m{2.0kg⋅m/14.5lb⋅ft}
Tightening torque: 21.6N⋅m {22kg⋅m/15.9lb⋅ft} Note:

Adequate care should be taken as over-tightening the
glow plug could lead to damage.
13. Install the head cover.

• Make sure that the rubber-mount is inserted to
bolt holes.
• Install the gasket on the head cover.
• Tighten twice in the numerical order or arrowed
order shown on the diagram.
Note:
Make sure there are no gasket coming off or collapsed
when assembling the head cover. If there was any
came off or collapsed, repair it and then assemble.
• Tighten the harness nut at the heads of each

cylinder injector with the specified torque.
1
Note:
Do not over-tighten the nut. It might cause damages on
injector (breakage to pins).
2
WSUZ0120
14. Install the thermostat housing.
15. Install the exhaust manifold.
16. Install the turbocharger ASM.
17. Install the inlet duct.
18. Install the fuel pipe and fuel filter ASM.
19. Install the EGR cooler and EGR valve.
Cylinder head
Name
(a) 25.5N⋅m {2.6kg⋅m/ 18.8lb⋅ft} (k) M10: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft}
(b) 2N⋅m {0.2kg⋅m/ 1.5lb⋅ft} M8: 21.6N⋅m{2.2kg⋅m/15.9lb⋅ft}
(c) 14.7N⋅m {1.5kg⋅m/ 10.8lb⋅ft} (I) 80.4N⋅m {8.2kg⋅m/ 59.3lb⋅ft}
(d) 34.3N⋅m {3.5kg⋅m/ 25.3lb⋅ft} (m) 19.6N⋅m{2.0kg⋅m/14.5lb⋅ft}
(e) 53N⋅m {5.4kg⋅m/ 39.1lb⋅ft} (n) 45N⋅m {4.6kg⋅m/ 33.2lb⋅ft}
(f) 53.9N⋅m {5.5kg⋅m/ 39.8lb⋅ft} (o) 21.6N⋅m {2.2kg⋅m/ 15.9lb⋅ft}
(g) 50N⋅m {5.1kg⋅m/ 36.9lb⋅ft} (p) 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft}
(h) 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft} (q) 43.8N⋅m {4.5kg⋅m/ 32.3lb⋅ft}
(i) 14.7N⋅m {1.5kg⋅m/ 10.8lb⋅ft} (r) 98N⋅m{10kg⋅m/72.3lb⋅ft} → 196N⋅m{20kg⋅m/
(j) 90N⋅m {9.2kg⋅m/ 66.4lb⋅ft} 44.6lb⋅ft} → 60° +30°
-0°
Special Tool
Cylinder head
Tool Number
Special Tool Rank
5-8840-2826-0
Injector remover
Rank A
5-8840-2546-0
Valve spring replacer
Rank B
5-8840-2628-0
Valve guide replacer
Rank B
5-8840-2626-0
Bridge guide installer
Rank A
5-8840-2625-0
Valve stem seal installer
Rank B
5-8840-2627-0
Cam carrier oil seal
installer
Rank A
Rocker arm
Components
Name
1. Rocker Arm (IN) 4. BRKT
2. Tube 5. Front Mark
3. Rocker Arm (EXH) 6. Rocker Arm Shaft
Disassembly Note:
Store removed parts in the numerical order.
1. Remove BRKT
2. Remove the rocker arm.
3. Remove the tube.
4. Rocker arm shaft
• Remove BRKT of the rocker arm shaft together
with the bolt. Remove the rocker arm (1), tube
(2) and rocker arm (3) from the Shaft (6).
Inspection
Check the rocker arm.
• Check for any wear or damages on the roller side,
and measure the clearance between the roller pin
(1) and roller (2).
Mark the measuring position when the roller of
rocker arm is let out to the maximum, and measure
the difference in level between the rocker arm and
roller (a). Then push the roller in to the maximum,
and measure the difference in level at the marked
measuring position (b).
The gap between the measurement (a) and (b)
above is the clearance between the roller pin and
roller.
The clearance between the roller pin and roller
(mm)
Assembly standard Limit of usage Rocker arm shaft
• Check for oil hole of the rocker arm shaft.
0.036 — 0.069 0.15
• Check for bent of the rocker arm shaft.

Shaft bent Assembly
Service limit 0.3mm 1. Rocker arm shaft
• Check the front marking of the shaft.
2. Install BRKT.
3. Insert the rocker arm.
4. Insert the tube.
5. Rocker arm
• Apply engine oil to the rocker arm bushing and
fix BRKT (4) to the shaft with bolt. Then
assemble in a following order; the exhaust
rocker arm (3) (short arm), the tube (2) and the
inlet rocker arm (1) (long arm).
Note:
• Check the front marking of the rocker arm shaft.
• Assemble the inlet rocker arm to the front side.
• Measure the diameter of the rocker arm shaft, and

the clearance between the shaft and the rocker
arm bushing.
(mm)
Nominal Assembly Limit of
dimensio standard usage
n
Clearance — 0.041 — 0.20
between the 0.090
shaft and the
rocker arm.
Diameter of φ28 — φ27.85
the shaft
Camshaft
Components
Camshaft
Name
1. Camshaft 3. Camshaft Gear
2. Key
Disassembly
1. Remove the camshaft gear.
• Put a piece of wood (1) to the gear to prevent
any damages and use a puller to install it.
Inspection
Inspection of the camshaft gear
• Check to see if there are any pitching or damages
on the tooth side.
Inspection of the camshaft

• Measurement of camshaft runout
Hold No.1 and No.7 journal part with V block and
place the dial gauge to No.4 journal. Rotate the
camshaft slowly once and take the measurement.
Measurement of camshaft runout level
(mm)
Limit of usage
0.1
2. Remove the key.

3. Camshaft
• Inspecting damages on the cam surface and

measure the cam lift level
Repair light damages or wear with an oil stone.
Acquire the lift level by (a) – (b).
Cam lift level (a – b) Measuring the clearance between the camshaft
journal and cam carrier journal.
(mm)
• Measure the inner diameter of cam carrier journal
Nominal and the outer diameter of camshaft, then acquire
Limit of usage
dimension the clearance measurement.
Inlet 7.52 7.1 • Clean the cam carrier journal, and check the nick
line on upper side of BRKT. Tighten the assemble
Exhaust 8.53 8.0
bolt with the specified torque.
Measure the 4 positions shown on the diagram
with a cylinder gauge, and acquire the inner
diameter of cam carrier journal.
Tightening torque:
Cam BRKT: 53N⋅m{5.4kg⋅m/39.1lb⋅ft}
• For measuring outer diameter of the cam shaft
journal, measure the 4 positions using a micro-
meter.
Clearance between the cam shaft journal and
BRKT.
(mm)
0.075 — 0.125 0.15
*Refer to “General Information” when using the

Plastigauge for measurement.
• Measuring the outer diameter of journal
Take a measurement of the position shown on the
diagram with a micro-meter.
Outer diameter of journal
(mm)
Nominal dimension Limit of usage
φ 40.0 φ 39.89
Assembly
1. Camshaft
2. Install the key.
3. Install the camshaft gear.
• Hammer the key into the camshaft, and press-
fit it placing one with bigger gear-center-boss
part pointing towards camshaft.
• Apply oil to the thread and seating side of the
bolt, and tighten with a specified torque.
Tightening torque: 137.5N⋅m {14kg⋅m/101.4lb⋅ft}

Camshaft
Name
(a) 137.5N⋅m {14kg⋅m/101.4lb⋅ft}
Flywheel, Flywheel Housing and Timing Gear

Components
Name
1. Flywheel 7. Crankshaft Gear
2. Oil Seal 8. Idle Gear B Shaft
3. Idle Gear D Cover 9. Idle Gear B
4. Idle Gear D 10. Idle Gear A
5. Cover 11. Idle Gear A Shaft
6. Crank Position Sensor 12. Flywheel Housing
Removal 4. Remove EGR device.

1. Remove the engine accessories.
Remove the starter. Refer to “Engine Support Refer to “Cylinder Head”.
Device”
6. Remove the rocker arm.
2. Disconnect the coupling of supply pump. Refer to “Cylinder Head”.
3. Disconnect the fuel pipe. 7. Remove the camshaft.
Refer to “Cylinder Head”.
8. Remove the cylinder head. Note:
Refer to “Cylinder Head”. • If remover is coming off the slinger easily, use a
9. Remove the oil pan. clip band to tighten around the parts for smoother
Refer to “Oil Pan” in the Lubrication System service.
section. • Be careful not to damage the flywheel housing and
10. Remove the crankshaft position sensor. crankshaft.
13. Remove the idle gear D.
Note:
Remove the sensor before removing the flywheel to • Remove the idle gear D cover.
prevent any damages on sensor. • Loosen the tightening bolt of the shaft and
remove the idle gear D.
Note:
There is a bolt for installing the flywheel housing on the
back of idle gear D. Remember to remove idle gear D
before flywheel housing.
14. Remove PTO ASM.

• Remove the PTO oil feed pipe (1).
11. Remove the flywheel.

12. Remove the oil seal.
• Set the oil seal remover (1-8521-0077-0) to the
slinger of oil seal.
• Tighten in the bolt and remove oil seal.
1
WSUZ0097
• Remove the PTO ASM (1) and 2 sheets of PTO

cover (2).
1 2
WSUZ0095
15. Remove the flywheel housing.
• Knock it lightly with a wooden hammer etc. to
remove.
Note:
Remember to remove the bolt on the D side of idle
gear.
16. Measurement of the idle gear backlash.

• Measure before removing each idle gear.
Backlash of idle gear
(mm)
0.06 — 0.10 0.30
17. Remove the idle gear A (3).

18. Remove the idle gear B (1).
19. Remove the idle gear B shaft (2).
Measuring the axial clearance of the idle gear

Axial clearance of idle gear
(mm)
A 0.140 — 0.229 0.35
B 0.040 — 0.190 0.30
C 0.135 — 0.190 0.30
D 0.052 — 0.107 0.20
Disassembly Inspect on each idle gear.
1. Remove the ring gear of flywheel. • Check for damages on idle gear.
Check for wear, tooth contact, peeling and pitching
• Put the flywheel on a piece of wood and place a
on gears.
wooden bar to the end-side of the ring gear.
Hammer them both equally to remove.
WSUZ0090
• Measuring the clearance between the outer
diameter of the idle gear shaft and inner diameter
of gear.
Inspection Outer diameter of the idle gear shaft
(mm)
Check the ring gear.
• Check for wear and damages on the tooth side of Nominal
Name Limit of usage
the ring gear. dimension
A 41.0 40.85
B 30.0 29.85
C 38.0 37.85
Clearance between the shaft and gear bushing

(mm)
Name Assembly standard Limit of usage
A 0.020 — 0.062 0.12
B 0.020 — 0.062 0.12
C 0.020 — 0.066 0.12
Check the flywheel.

• Check for cracks and scratches on the flywheel.
Installation
1. Install the idle gear B shaft.
2. Install the idle gear B.

• Apply engine oil to the idle gear shaft (2),
insides of the gear (1) and on to the thrust
surface.
• Place the larger center-boss part facing
towards you when installing.
• Tighten the bolt via thrust collar.
Assembly
1. Install ring gear to the flywheel.
• Warm the ring gear evenly using a gas burner
(below 200°C). Install it to the flywheel with
larger cut-edge on the gear facing towards you.
Note:
Be careful with the gear direction when installing.
3. Install the idle gear A.

• Check to see it is close to the compression top
dead center of No.1cylinder.
• Insert idle gear A to the shaft and align the
thrust washer with pin holes, and then sub-
assemble them. At this point, apply engine oil to
the shaft, bore of the gear and the thrust
surface.
• Align the “U” marking on the crankshaft gear (2)
and “{{” marking on the idle gear (1), and pin
holes on the shaft and cylinder block to
assemble.
seating side of the bolt, and tighten.
→60° +30°
-0°
Note:
• Make sure the shaft and pin are matched before
tightening bolts.
• After assembling, check again the marks are
matched.
• Make sure there are backlashes between each 4. Install the flywheel housing.
gear. • Clean the surface on which the liquid gasket
was applied.
• As instructed on the diagram, apply the liquid
gasket (ThreeBond No. TB-1201) to the
flywheel housing without missing any part, and
install.
Tightening torque: M12 78N⋅m{8kg⋅m/57.5lb⋅ft}
Tightening torque: M8 24.5N⋅m{2.5kg⋅m/18.1lb⋅ft}
Note:
• For idle gear D hole (1) and groove part, pay
attention not to cover the hole with the liquid
gasket.
• Apply the liquid gasket also on the 4 marked parts
on the illustration.
• Install within seven minutes after applying liquid
gasket.
Tightening torque for each bolt position

78N⋅m
M12 , , ▲, ●, ★
{8kg⋅m/57.5lb⋅ft}
24.5N⋅m
M8 ✩
{2.5kg⋅m/18.1lb⋅ft}
WSUZ0037
Name
1. Idle Gear Large A
2. Bearing Case Gear
3. Idle Gear Small A
4. Idle Gear C
5. Camshaft Gear
6. Idle Gear B
7. Idle Gear D
8. PTO Gear
9. Crankshaft Gear
1
WSUZ0098 WSUZ0097
5. Install PTO ASM 6. Install the idle gear D.

• Assemble the gasket and install PTO ASM (1). • Apply engine oil to the gear and shaft, and
insert gear (1) into shaft (2) to assemble.
• Assemble the gasket and install 2 sheets of
PTO cover (2).

seating side of the bolt, and tighten via thrust
collar.
1 2 Note:
WSUZ0095 For oil lubrication, install the shaft (1) with the cut-out
• Install PTO oil feed pipe (1). (2) side up and thrust collar (3) with painted part (4) set
within the area as illustrated.
Eyebolt tightening torque:
M12: 22.5N⋅m{2.3kg⋅m/16.6lb⋅ft}
M8: 14.7N⋅m{1.5kg⋅m/10.8lb⋅ft}
4 2
45
3 1
WSUZ0124

• Insert O-ring into cover and install it to the
housing.
7. Install the oil seal.
• Install the oil seal and slinger at the same time
using the installer (1-8522-0057-0). Note:
Once the installer is set, tighten in the center • Installing positions for oil seal are fixed and
bolt until it touches the bottom. identified by different coloring.
Slinger
Front side --- Zinc chrome plating color (plating
color)
Rear side --- Grey
• Install the oil seal and slinger together without
disassembling.
• Clean the remaining oil off after press-fitting.
• If there were any damages on the crankshaft,
apply the liquid gasket (ThreeBond No.TB1207C)
within the illustrated area.
8. Install the flywheel. 10. Install the oil pan.

• Apply molybdenum disulfide to the threads and Refer to “Oil Pan” in the Lubrication System
the seating surface of the installing bolt and section.
tighten in the numerical order shown on the 11. Install the cylinder head.
diagram. Refer to “Cylinder Head”.
Tightening torque: 78.5N⋅m{8kg⋅m/57.9lb⋅ft} 12. Install the camshaft.
→60°→30° (Angle method(60° Refer to “Cylinder Head”.
+30°) +30°
-0°
) 13. Install the rocker arm.
Note: 14. Install the head cover.
Always check the tightness of bolts in re-tightening Refer to “Cylinder Head”.
direction. 15. Install the EGR device.
It should be above 245N⋅m{25kg⋅m/180.7lb⋅ft}. Refer to “Engine Exterior Equipment”.
16. Install the fuel pipe.
17. Connect coupling of the supply pump.
18. Install the engine accessories.
Install the starter. Refer to “Engine Accessories”
9. Install the crankshaft position sensor.

Tightening torque: 8.2N⋅m {0.8kg⋅m/6lb⋅ft}
Note:
To avoid any damages on the sensor, carry out after
installing the flywheel.
Tightening torque list
Flywheel, Flywheel Housing and Timing Gear
Name
(a) 78.5N⋅m{8kg⋅m/57.9lb⋅ft} → 60° → 30° (f) 95N⋅m {9.7kg⋅m/ 70.1lb⋅ft}
(Angle method60: {60°+30°) +30°
-0°
)
(b) 78N⋅m {8kg⋅m/ 57.5lb⋅ft} (g) 32N⋅m {3.3kg⋅m/ 23.6lb⋅ft}
(c) 153.9N⋅m {15.7kg⋅m/ 13.5lb⋅ft} (h) 34.3N⋅m{3.5kg⋅m/25.3lb⋅ft} → 60° +30°
-0°
(d) 24.5N⋅m {2.5kg ⋅m/ 18.1lb⋅ft} (i) 78N⋅m {8kg ⋅m/ 57.5lb⋅ft}
(e) 8.2N⋅m {0.8kg ⋅m/ 6lb⋅ft} (j) 21.6N⋅m {2.2kg⋅m/ 15.9lb⋅ft}
Special Tool
Tool Number
Special Tool Rank
1-8521-0077-0
Oil seal remover
Rank A
1-8522-0057-0
Oil seal installer
Rank A
Front Cover and Crankshaft

Components
Name
1. Oil Seal 7. Thrust Bearing
2. Front Cover 8. Crankshaft Bearing
3. Cylinder Block 9. Crankshaft
4. Crank Pulley 10. Crankshaft Gear
5. Damper 11. Crankcase
6. Oil Pump Drive Gear
Removal Refer to “Oil Pump” in the Lubrication System

section.
1. Remove the cylinder head.
4. Remove the flywheel.
Refer to “Cylinder Head”. Refer to “Flywheel and Timing Gear”.
2. Remove the oil pan. 5. Remove the flywheel housing.
Refer to “Oil Pan” in the Lubrication System Refer to “Flywheel and Timing Gear”.
section.
6. Remove the piston.
3. Remove the oil pump. Refer to “Piston”.
7. Remove the crank pulley. Play between front and back direction
(mm)
0.10 — 0.285 0.30
• If it exceeds the limit, replace the thrust

bearing.
8. Remove the front cover oil seal.

• Set the oil seal remover (1-8521-0077-0) to the
slinger of oil seal.
• Tighten in the bolt and remove oil seal.
11. Remove the crankcase.

• Loosen the tightening bolt for the bearing from
outside.
• Screw in the removed bolt into the replacer hole
on the crankcase and keep the crankcase
suspended.
• Suspend it on a level and remove it without
interfering other parts around.
Note:
• If remover is coming off the slinger easily, use a
clip band to tighten around the parts for smoother
service.
• Be careful not to damage the front cover and
crankshaft.
9. Remove the front cover.
10. Measuring the axial clearance of the crankshaft.
• Take a measurement at the position of No.7
bearing cap.
Note:
Be careful the thrust bearing can easily fall off.
12. Remove the crankshaft. Disassembly
• Suspend it on a level and remove it without 1. Remove the crankshaft damper.
interfering other parts around.
• Remove the crankshaft damper from the
crankshaft pulley.
2. Remove the crankshaft gear.
3. Remove the oil pump drive gear.
• Use a gear puller (1-8521-0051-0) to remove
the crankshaft gear.
• Remove the oil pump drive gear the same way.
Note:
Be careful not to let the puller nails catching flanges of
crankshaft. It may damage the crankshaft.
13. Remove the crankshaft bearing.

14. Remove the thrust bearing.
• Mark the installing position of the thrust bearing
using tags etc.
Note:
• Do not damage the bearing sliding surface of the
crankshaft.
• On removing, be careful with the bearing falling off.
Removing gear with general-purpose tool.

• Use a large gear puller (1).
• Pull it out without nails on the gear puller (2)
catching the flange of crankshaft (3).
Note:
• Be careful not to let the puller nails catching
flanges of crankshaft. It may damage the
crankshaft.
• The gear is burn-weld. Always use a large gear
puller because the load to pull out the gear is large.
Crankshaft
• Check for cracks on crankshaft and damages on
the touching surface of bearing.
Perform magnetic flux method or red check
inspection as required.
Inspection
Crankshaft damper
• Check for any leakage of silicon oil.
• Measuring wear on crank journal and pins.
• Check for cracks or peelings on rubber. Measure 4 places shown on the diagram.
(mm)
Nominal
Limit of usage
dimension
Outer diameter φ89.909—
φ90.0
of journal 89.929
Outer diameter φ83.894—
φ84.0
of pin 83.914
Note:
The crankshaft cannot be repaired as tuftride treatment
has been performed to the surface.
• Measuring crankshaft run-out
Hold both ends with V block. Measure the run-out
of the crankshaft by setting the dial gauge to No.4
journal at crankshaft and rotate the crankshaft
once slowly.
Crankshaft run-out level
(mm)
Limit of usage
0.15
• Measure 4 places shown on the diagram with a

cylinder gauge.
• Measuring the clearance between the bearing and

crank journal.
Measure the inner diameter of bearing and the
outer diameter of crank journal while the
crankcase is assembled, then acquire the
clearance measurement.
• Clean the bearing and installation surfaces, and
assemble the bearing. Then install the crankcase.
Apply molybdenum disulfide to the threads and the
seating surfaces of M10 and 15 bolts. Tighten M15 • For the outer diameter of crank journal, measure 4
bolt first as illustrated. places shown on the diagram with a micro-meter.
Tightening torque: N⋅m{kg⋅m/lb⋅ft}/degree

M15: 54N⋅m{5.5/39.8} (mm)
→ rotating angle90 ° +30°
-0° Assembly Limit of usage
M10: 49N⋅m {5.0/36.1} standard
Clearance 0.045—0.080 0.09
between the
bearing and
crank journal.
Note:
Refer to “General Information” when using the
plastigauge for measurement.
Crankshaft gear
• Check for wear, tooth contact, peeling and pitching
on gears.
Bearing
• Check for wear, damages and peeling on the crank
bearing.
• When assembling the bearing, check to see there Check for the tuftride layers
is a tension. • Cleaning the crankshaft.
Clean the crankshaft. Remove any oil, especially
around the inspection areas (except 10mm around
the oil holes), using organic solvent.
• Check for the tuftride layers

Drop the inspecting solution onto inspecting spots
(1) using a syringe or glass rod. Keep the
inspecting surface levelled not to let the inspecting
solution run.
Note:
• Do not carry out inspection on areas inside 10mm
around the oil holes.
• Inspecting solution...a 5 ~ 10% solution of
chlorinated-2-copper ammonium dissolved in
distilled water.
• Process after inspection.
The inspecting solution is highly corrosive. Wipe it
off immediately after the inspection, and
thoroughly clean with water, steam, etc.
• Judgment
Note:
Crankshaft can be re-used.
Nothing changes even after 30 – 40 seconds.
Caution:
Note: Avoid the solution to contacting eyes, hands, cloth, etc.
Crankshaft cannot be re-used. If it goes into eyes, wash it out with plenty of water
The inspecting solution (light blue) turns transparent immediately and seek for a medical treatment.
after 30 – 40 seconds and the spot (1) where the
solution was dropped turns copper color. Selecting crankshaft journal bearing
• When using a new bearing, select one matches
the grade of the cylinder block.
• Inner diameter grade is stamped on the right side
and on the upper part at the back of the cylinder
block.
• Stamped from the rear side in the order of the
journal No.7 to No.1.
• The middle part of the bearing side is painted
according to each grade.
Note:
Selecting a wrong bearing leads to an excessive oil
clearance causing a low-oil pressure, or a shortage of
oil clearance causing a seizure.
Bearing selection table

Cylinder block grade Bearing grade
1 Brown
2 Black
3 Blue
Note:
• Make sure to insert the gear until it touches the
end.
• Do not ever re-use gears.
Assembly
1. Install the crankshaft gear.
• Warm up the gear using a heater (170°C — 3. Install the crankshaft damper.
180°C). Pull the “U” marking towards you
• Apply a thin coat of engine oil to the thread and
watching the gear timing and align the groove
seating surface of the bolts.
of the gear with knock pins. Insert it quickly
without leaving any space between the flange • Install the crankshaft damper to the crank
of the crankshaft. pulley.
Tighten in diagonal order.
Note:
• Make sure to insert the gear until it touches the
end.
• Do not ever re-use gears.
WSUZ0017
2. Install the oil pump drive gear.

• Warm up the gear using a heater (170°C —
180°C). Place the drive gear as shown on the
illustration and insert it quickly without leaving
any space between the flange of crankshaft.
Installation 3. Install the thrust bearing.
1. Install the crankshaft bearing. • Apply oil on to the oil groove side of the thrust
bearing (1) and keep the oil groove (2) outward.
• Check the assemble position marked at the Push it into both sides of No. 7 by hand.
disassembling, assemble after cleaning the
bearing and the assembling surface.
• Upper bearing on the cylinder block side has
groove and oil holes all around it. Lower
bearing on the crank case side has groove but
oil holes.
Note:
Keep the back of bearing dry when assembling.
4. Apply liquid gasket.

• Wipe off the oil from the gasket applied surface.
• Apply Loctite FMD-127 (Width: 4mm or more,
Thickness: 0.3mm or more) onto the lower
surface of the cylinder block that is indicated as
(1) on the illustration.
• Assemble the crank case swiftly after applying
the gasket (within 15minutes).
2. Install the crankshaft.

• Apply oil to the sliding surface of bearing. Keep
the crankshaft levelled and put it on carefully.
Note:
Clean the sliding surface and oil holes well when
assembling.
5. Install the crankcase.

• Clean the crankcase and bearing well.
• Assemble the lower bearing.
• Place the oil groove (1) of the thrust bearing
outward and align with knock pins when
installing.
• Apply engine oil to the crankshaft and to the
bearing.
• Assemble it carefully not to cause any dents on
the crankshaft.
Note:
• Make sure no to leave any gap between the
cylinder block when putting on the crank case.
Repeat the same procedure if any gap was left.
• Keep the back of bearing dry when assembling.
• Assemble swiftly once the gasket was applied.
7. Install the front cover.

Application of liquid gasket
• Apply liquid gasket (ThreeBond No.TB1201) on
to the contact surface of the front cover
installation surface and of the cylinder block (1).
• Install the front cover aligned with the dowel
position.
Tighten the crank case.
• Apply molybdenum disulfide onto the thread
and seating side of the M10 and M15 bolts, and
tighten M15 first as instructed on the illustration.
Tightening torque: N⋅m{kg⋅m/lb⋅ft} 1
M15: 54 {5.5/39.8}→90° +30°
-0°
M10: 49{5.0/36.1}
WSUZ0099
8. Install the oil seal.

• Install the oil seal and slinger at the same time
using the installer (1-8522-0057-0).
• Once the installer is set, tighten in the center
bolt until it touches the bottom.
6. Check for rotation of the crankshaft.

• Check to see if it rotates smoothly without
getting stuck (15N ⋅m or less). Check to see the
oil jet is not deformed.
9. Install the crank pulley.

• Assemble the crank pulley to the crank shaft.
• Apply a thin coat of engine oil to the bolt and
washer, and tighten in a diagonal order.
Note:
• Installing positions for oil seal are fixed and
identified by different coloring.
Slinger
Front side ⋅⋅⋅ Zinc chrome plating color (plating
color)
Rear side ⋅⋅⋅ Grey
• Install the oil seal and slinger together without
disassembling.
• Wipe the running oil off after press-fitting the oil
seal.
• If there were any damages on the crankshaft,
apply the liquid gasket (ThreeBond No.TB1207C)
within the illustrated area.
10. Install the piston.
Refer to “Piston”.
11. Install the flywheel housing.
Refer to “Flywheel and Timing Gear”.
12. Install the flywheel.
13. Install the oil pump.
Refer to “Oil Pump” in the Lubrication System
section.
14. Install the oil pan.
Refer to “Oil Pan” in the Lubrication System
section.
15. Install the cylinder head.
17. Install the rocker arm.
19. Install the engine exterior equipments.
Name
(a) 200N⋅m{20.4kg⋅m/147.5lb⋅ft} (d) 54N⋅m{5.5kg⋅m/39.8lb⋅ft}→90° +30°
-0°
(b) 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft} (e) 49N⋅m{5.0kg⋅m/36.1lb⋅ft}
(c) 96N⋅m{9.8kg⋅m/70.8lb⋅ft}
Special Tool
Tool Number
Special Tool Rank
1-8521-0051-0
Gear puller
Rank B
1-8521-0077-0
Oil seal remover
Rank A
1-8522-0057-0
Oil seal installer
Rank A
Piston, Connecting Rod

Components
Name
1. Piston Ring 5. Connecting Rod
2. Snap Ring 6. Connecting Rod Cap
3. Piston Pin 7. Bearing
4. Piston
Removal 5. Remove the cylinder head.

1. Remove the engine exterior equipments.
6. Remove the oil pan.
Refer to “Engine Exterior Equipment”. Refer to “Oil Pan” in the Lubrication System
2. Remove the head cover. section.
Refer to “Cylinder Head”. 7. Remove the oil pump.
3. Remove the rocker arm. Refer to “Oil Pump” in the Lubrication System
Refer to “Cylinder Head”. section.
4. Remove the camshaft.
8. Remove carbon from the liner. • Keep removed cap, bearing and connecting rod as
• Remove carbon from upper part of the liner a temporary set not to confuse them.
using a scraper etc.
Note:
Be careful not to damage the cylinder liner.
Disassembly
1. Remove the piston ring.
• Use a ring pliers (1-8522-1029-0) to remove the
9. Remove the connecting rod cap. piston ring (1).
• Loosen the tightening bolt and hammer lightly
with a copper hammer etc. to remove the cap. Note:
Mark each removed piston ring on the upper surface
according to each cylinder for identification.
10. Remove the piston connecting rod.

• Rotate the crankshaft and set the piston to be
removed at the to top dead center position.
2. Remove the snap ring.
• Push the lower edge of the connecting rod
3. Remove the piston pin.
using a hammer handle etc..
4. Piston, Connecting Rod.
Note: • Remove the snap ring (1) and the piston pin.
• Do not let the connection rod and liner interfere
with each other. Note:
Put number plates on the piston and piston pin
• Be careful with damaging the oil jet.
according to each cylinder.
• Measuring the clearance between the groove of

piston ring and piston ring.
Inspection Remove carbon from the groove of piston ring.
Insert the ring into the ring groove and measure
Piston ring
the clearance using the thickness gauge.
• Check for chippings, scratches and peelings Clearance between the groove and ring
carefully.
(mm)
• Measuring the clearance at the joint section of the
piston ring. Assembly
Limit of usage
Remove carbon from the piston ring. Insert the standard
piston ring into the cylinder liner and push in with
Top ring — —
the head of the piston to the least worn part of the
liner (the lower part of the liner). Second ring 0.110—0.140 0.20
Insert the thickness gauge into the joint section of
Third ring 0.100—0.135 0.20
the ring to measure the clearance.
Clearance at the joint section of the piston ring. Oil ring 0.02—0.06 0.15
(mm)
Limit of
Assembly standard
usage
Top ring 0.36—0.59
Second ring 0.45—0.73 1.0
Third ring 0.35—0.63
Oil ring 0.35—0.68 0.8
• Measuring the tension of the piston ring.

Measure it using a tension gauge.
Tension of the piston ring Piston pin
(N{kg}) • Measuring the outer diameter of the piston pin.
Assembly standard Measure the outer diameter of the piston pin, then
measure the clearance between the piston pin
Top ring 23—32 {2.35—3.26} holes and connecting rod bush.
Second ring 10—15 {1.00—1.50} Measure 6 places shown on the diagram for a
piston pin.
Third ring 18—25 {1.85—2.50}
Oil ring 36—49 {3.68—4.96}
(mm)
Note: Nominal Assembly Limit of
Measure the oil ring while the coil expander is dimension standard usage
equipped.
Piston pin φ52.0 — φ51.98
outer
diameter
Clearance — 0.007 — 0.020 0.05
between
piston pins
and piston
pin holes.
Clearance — 0.015 — 0.031 0.10
between
piston pins
and
connecting
rod bush.
Piston
• Piston scratches and cracks check.
Check very carefully on areas not easy to look at
such as the ring groove of piston. Carry out an
inspection by red check if required.
Connecting rod
• Measuring the clearance between the bearing and
crank pin.
Clean the bearing and installing surface, and then
assemble the bearing. Apply molybdenum
disulfide to the thread and seating surface of the
bolt, and tighten the connecting rod cap. Measure
4 places on the connecting rod bearing as shown
on the illustration.
Tightening torque: N⋅m{kg⋅m/lb⋅ft}/angle
58 {5.9/42.8} → 60° (right side) →
120°(left side) → 60°(right side)
• Measuring deformation of the connecting rod.

Measure the parallelism of the big and small end
holes using a connecting rod aligner.
Note:
Use a bearing free of any wear as the measurement
would be based on it.
Parallelism
(mm)
Assembly Limit of usage
standard
Parallelism 0.03 0.10
• Use a micro-meter to measure the outer diameter
(L=per100)
of the crank pin at 4 places shown on the
illustration.
Clearance between the bearing and crank pin.
(mm)
0.044—0.104 0.16
Note:
• The crankshaft should not be repaired as tufftride
treatment has been performed to the surface.
• Refer to “General Information” when using the
Plastigauge for measurement.
• Measuring wears on the big-end surface of the

connecting rod.
Assemble the connecting rod to the crank pin, and
measure the axial clearance using a thickness
gauge.
Axial clearance Assembly
(mm) 1. Selecting grades for piston.
Assembly standard Limit of usage Piston replacement
• Pistons and liners can be supplied as a set.
0.17—0.28 0.35
In that case, the grades of outer diameter of the
liner and of inner diameter of the cylinder block
need to be matched.
• When replacing new pistons only, measure the
inner diameter of the liner and select grade for
piston.
Measure the inner diameter of the cylinder
liner.
• The measurement value is the average of the
measures taken at 2 places from upper surface,
in 4 direction at every 45°, total of 8 measuring
points.
Measuring points (while the crank case is
assembled)
(mm)
A B
From upper 120 216
surface
Bearing Reference
• Check for wear, damages and peeling on the As factory default, “A”, “B”, “C” and “D” are
connecting rod bearing. stamped on the upper surface of cylinder blocks
keeping the cylinder liner grades.
• When assembling the bearing, check to see there
is a tension.
Measuring piston
• Measure the piston pin holes in the right-angle
direction at 22mm (a) from the lower surface of
the piston as shown on the illustration.
Reference
As factory default, “A”, “B”, “C” and “D” are
stamped on the head of pistons keeping the piston
grades.
(mm)
Grade Liner inner diameter Piston outer
(after the cylinder diameter
block is press-fitted)
D 120.029—120.040 119.900—119.910
C 120.019—120.032 119.890—119.899
B 120.009—120.022 119.880—119.889
A 120.000—120.012 119.870—119.879
The clearance between the piston and liner

(mm)
Assembly standard 0.119—0.142
Note: 4. Install the piston ring.

Assembling parts with wrong grades can cause a
• Installing the expander ring.
seizure. Make sure to match grades.
Set the joint section (1) of expander ring without
any gap and fit it in the piston groove.
2. Assemble the piston pin.

• The oil ring has no top or bottom but assemble
3. Install the snap ring. it so that the joint section of the oil ring and the
• Place the arrow (1) on the head of piston and expander ring are angled 180°.
the mark (2) on the connection rod towards • The third ring is stamped as “3RN” for
front side and assemble. Apply oil onto the identification. Assemble it with the stamp on the
piston pin and push it in. Fix it with a snap ring. upper surface of the joint section facing up.
Lastly, check to see the piston and connecting
rod move smoothly. • The second ring has no stamp. Assemble it
with the inner cut part facing up.
Note: • The top ring is stamped as “R” for identification.
Make sure that the snap ring is properly fitted into the Assemble it with the stamp on the upper
piston groove. surface of the joint section facing up.
• Shift the joint sections of each ring 90° when
assembling piston rings.
• Use piston ring pliers (1-8522-1029-0) to
assemble. (Do not open the joint section
unnecessarily.)
Note: Installation
• New rings have identifying paint on the right side of 1. Assemble the connecting rod bearing.
their joint sections.
• Clean the cap and bearing installation surface
• Expansion allowance of joint section for each of the connecting rod well and assemble the
piston ring assemble should be kept within 8 times bearing. Apply oil onto the sliding surface (1).
the size of joint section measurement when it is
free. Do not re-use it if it is expanded more than 8 • Apply oil onto the piston pin.
times the size. Breakage or cracks may occur.
Note:
Keep the back of bearing dry when assembling.
• Apply engine oil all around the cylinder liner.
2. Set the position of crankshaft.

• Rotate the crankshaft and set the crank pin to
the top dead center of the cylinder to which the
piston is assembled.
3. Match the joint section of piston ring. • Push the piston in until it touches crank pin with
• Apply engine oil onto the piston and all around hammer handle using the piston installer (1-
the ring. 8522-1082-0). Rotate the crankshaft while
pushing the piston head in. Set it to the bottom
• Place the joint direction of the piston ring every
dead center.
90° avoiding the side-pressure direction.
Note:
• Use the installer firmly attached to the cylinder
block. If they are not attached firmly when inserting,
it may cause a damage on piston ring.
• Be careful not to damage crank pin or oil jet when
installing the piston connecting rod.
4. Insert the piston and connecting rod.

• Check the cylinder number of the connection
rod and insert it with the arrow mark on the
head of piston pointing to the front. Insert the
piston in the opposite direction 5°—10° of oil
jet. Pull it back to the right position not
interfering with the oil jet.
5. Install the connecting rod cap.
• Apply oil to the bearing on the connecting rod
cap.
• Match the marks on the connecting rod and Refer to “Cylinder Head”.
cap. Apply molybdenum disulfide to the thread 9. Install the camshaft.
and seating side of the bolt, and tighten them. Refer to “Cylinder Head”.
Make sure the stamp is on the exhaust side at
this point.
Tightening torque: 11. Install the head cover.
N⋅m{kg⋅m/lb⋅ft}/angle Refer to “Cylinder Head”.
58 {5.9/42.8}→60°(right side)120°(left side) 12. Install the engine exterior equipments.
60°(right side) (tighten alternately) final tightening Refer to “Engine Exterior Equipment”.
angle 120° +30°
-0°
• Rotate the crankshaft and check to see it

rotates smoothly without getting stuck. Check it
is not interfering with oil jet.

section.
section.
Name
(a) 58N⋅m{5.9kg⋅m/42.8lb⋅ft}→60°(right side)
120°(left side) 60°(right side) (tighten
alternately)
Special Tool
Tool Number
Special Tool Rank
1-8522-1029-0
Piston ring pliers
Rank B
1-8522-1082-0
Piston installer
Rank B
Cylinder Block
Components
Name
1. Cylinder Liner 4. Joint Bolt
2. Cylinder Block 5. Crankcase
3. Oil Jet
Removal 5. Remove the camshaft.

1. Remove the engine accessories.
6. Remove the cylinder head.
Refer to “Engine Accessories”. Refer to “Cylinder Head”.
2. Remove the engine exterior equipments. 7. Remove the oil pan.
Refer to “Engine Exterior Equipment”. Refer to “Oil Pan” in the Lubrication System
3. Remove the head cover. section.
Refer to “Cylinder Head”. 8. Remove the oil pump.
4. Remove the rocker arm. Refer to “Oil Pump” in the Lubrication System
Refer to “Cylinder Head”. section.
9. Remove the flywheel. 3. Remove the cylinder liner.
Refer to “Flywheel and Timing Gear”. • Hook the anchor of the cylinder liner remover
10. Remove the flywheel housing. (1-8523-1021-0) onto the bottom edge of the
Refer to “Flywheel and Timing Gear”. liner properly. Put the turret from above into the
11. Remove the timing gear. center bolt without interfering the liner flange.
Refer to “Flywheel and Timing Gear”. Assemble the bearing and tighten with a nut.
Set a handle to the nut and turn it to take out
12. Remove the crank pulley.
the liner.
Refer to “Front Cover and Crankshaft”.
13. Remove the water pump. Note:
Refer to “Water pump” in Cooling System section. If the anchor touches the cylinder block, the cylinder
14. Remove the front cover. bore will get damaged. So check carefully when taking
Refer to “Front Cover and Crankshaft”. out the liner.
15. Remove the piston.
16. Remove the crankshaft.
Disassembly
1. Remove the oil jet.
2. Measure the wear on the cylinder liner.
• Measure the inner diameter of cylinder liner.
Measure the maximum wear part (in the
rotating direction) at 15 – 19mm from the upper
surface of the liner (a).
Cylinder liner inner diameter
(mm)
Nominal dimension Limit of usage
120.0 120.3 WSUZ0080
Inspection
Crankcase
• Check the crank case for cracks and damages.
Carry out an inspection by red check if required.
Oil Jet
• Check for bent on oil jet and oil holes.
• Check for cracks or damages on the cylinder

block.
Carry out an inspection by red check if required.
Cylinder block
• Measure warp on the cylinder block.
Place a straight edge on the upper surface of the
cylinder block. Measure with the thickness gauge
(1).
Warping of cylinder block top surface
(mm)
Limit of usage 0.20
• Checking corrosion and clogging of oil coolant and

in the oil passage.
Check for any clogging carefully on coolant
passage between each cylinder.
• Check on cracks on the water jacket.
Apply water pressure of 490kPa{5kg/cm2}with a
hydraulic test machine for 3 minutes, and check for
any leakage from each cylinder block part.
Tightening allowance for the cylinder liner and

cylinder block.
(mm)
Assembly standard 0.011—0.029
Assembly
Grade selection of cylinder liner and cylinder block
1. Grade selection of cylinder liner
(mm)
• Grade selection of cylinder liner
• Measure the inner diameter of cylinder block Grade Cylinder block inner Cylinder liner outer
and select a grade for liner. diameter diameter
• Measure the inner diameter of cylinder block. III 123.021—123.030 123.041—123.050
Crank case is assembled.
II 123.011—123.020 123.031—123.040
The measurement value is the average of the
measures take at 120 mm and 216 mm from I 123.001—123.010 123.021—123.030
the upper surface of the cylinder block. The
measure should be taken every 45° of 8 [Reference] The grade stamping places on the
directions. cylinder blocks in the factory default condition.
• Measure the outer diameter of the cylinder liner. • (1) part before the liner is pressed in: the
The measurement value is the average of the cylinder block inner diameter grades are
measure taken at 3 points on the upper surface stamped as (I, II and III)
of the cylinder liner. At each 3 points, measure
the maximum and minimum values (6 • (2) part after the cylinder liner is pressed in: the
measurements) and get the average. liner inner diameter grades are stamped as (A,
Measuring position B, C and D).
(mm)
A B C
From upper 18 114 210
surface
Note:
If the assembly was carried out without grade selection,
it can cause insufficient cooling (tightening allowance
shortage) or a seizure (excessive tightening allowance
for the liner).
Note:
Place a square on the outer circumference of the liner
and press-fit straight against the cylinder block bore.
2. Cleaning the cylinder bore and liner.

• Clean the cylinder bore and liner properly and
air-blow them afterwards.
Note: • Measuring the cylinder liner extrusion.

Do not reuse liners once dropped. Measure the extrusion of the liner using a dial
gauge.
(mm)
Assembly Standard
Amount of liner extrusion. 0.06—0.10
Difference from the
0.015 or less
neighboring cylinders
3. Press-fitting the cylinder liner.

• Make sure there is no dust or oil stuck on the
inside of cylinder block and outside of liner.
• Use a cylinder liner installer (1-8522-1073-0)
and apply 500kg of pressure with a press to
press-fit without deforming the liner. Lastly, fix it
completely to the cylinder block by applying
2500kg of pressure.
• Measure the inner diameter of the liner after
4. Install the oil jet.
press-fitting.
Refer to “Piston-Connecting Rod” section for • Install in accordance with knock pins.
measuring method.
Note: 16. Install the engine accessories.
Do not deform the edge of oil jet. Refer to “Engine Accessories”.
Installation
1. Install the crankshaft.
2. Install the piston.
3. Install the front cover.
4. Install the water pump.
Refer to “Water pump” in Cooling System section.
6. Install the timing gear.
7. Install the flywheel housing.
8. Install the flywheel.
section.
section.
15. Install the engine exterior equipments.
Name
(a) 54N⋅m{5.5kg⋅m/39.8lb⋅ft}→90° +30°
-0° (c) 21N⋅m{2.1kg⋅m/15.5lb⋅ft}
(b) 49N⋅m{5.0kg⋅m/36.1lb⋅ft}
Special Tool
Tool Number
Special Tool Rank
1-8523-1021-0
Cylinder liner remover
Rank B
1-8522-1073-0
Cylinder liner installer
Rank B
Cooling System (6UZ1X) 1C-1
Engine
Cooling System
(6UZ1X)
Contents
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .1C-2
Description of Function and Operation. . . . . . . .1C-2
Function Check: . . . . . . . . . . . . . . . . . . . . . . . . .1C-4
List of Trouble Symptoms . . . . . . . . . . . . . . . . .1C-6
Symptom: Engine Over-heats. . . . . . . . . . . . . . .1C-7
Symptom: Engine Over-cools. . . . . . . . . . . . . . .1C-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-14
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-15
Thermostat, Thermo-Sensor . . . . . . . . . . . . . . . .1C-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-18
Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-20
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-20
1C-2 Cooling System (6UZ1X)
Cooling System
Service Precautions Description of Function and Operation
Caution: The cooling system is a forced circulation type system,
Do not loosen or remove the sub tank cap when and is constructed of the following main parts: Water
coolant is high temperature. Steam or boiling water pump, thermostat, and radiator. It cools inside of the
spouts and it may cause a burn. When opening the sub engine, oil cooler, EGR gas, and so on.
tank cap, cover the cap with thick clothes under the
condition that coolant is cold, rotate it slowly to release
pressure, and then remove it.
Coolant circulation system diagram
WSUZ0082
Name
1. Sub Tank 5. Thermostat
2. Air Bleeding Pipe 6. Water Pump
3. EGR Cooler 7. Radiator
4. Oil Cooler
Water pump structure diagram
1 4
7 6
WSUZ0131
Name
1. Pulley Center 5. Shaft
2. Bearing 6. Oil Seal (Small)
3. Seal Unit 7. Snap Ring
4. Impeller 8. Oil Seal (Large)
Function Check:
Coolant check
1. LLC concentration Example Mixture Ratio (l)
Concentrati
• Freezing temperature changes depending on of
on of Long
the concentration of long life coolant super. Freezing Long Life Tap Life
Adjust the concentration according to minimum Temperatu Coolant Water Coolant
air temperature. re
• Do not use anything except Isuzu genuine LLC. -18°C 10.12 18.78 35%
• LLC concentration calculation method:
-25°C 12.14 16.76 42%
LLC concentration (%) = {LLC capacity
(L)÷(LLC capacity (L) + water capacity (L)) -35°C 14.45 14.45 50%
×100}
-40°C 15.32 13.58 53%
2. Measurement of LLC concentration
• Use an antifreeze hydrometer and a
thermometer to measure the specific gravity
and the coolant temperature.
Caution: ANTIFREEZE CONCENTRATION ( )

Take care with boiling coolant spouting out when
)
removing the cap at high temperature.
FREEZING TEMPERATURE (
• After measurement of the temperature and the
specific gravity, find concentration in the table
below.
• Use a container whose depth is longer than a
hydrometer.
• The coolant temperature should be between 0
and 50°C at measurement.
WSUZ0149
SPECIFIC GRAVITY
WSUZ0038
TEMPERATURE ( )
WSUZ0148
Radiator check Check location
Sub tank cap • Radiator ASM, water pump ASM, radiator hose,
heater hose, water pipe & water hose, sub tank
• Use a cap tester to check the opening valve
ASM and vacuum hose.
pressure. If the opening valve pressure exceeds
the specified value, replace the sub tank cap.
positive pressure = 61.8 — 71.6 kPa

Cap {0.63 — 0.73kg/cm2}
operation
pressure negative pressure = 4.9 kPa {0.05kg/
cm2}
WSUZ0039
Replacement procedure of coolant

1. Make sure that the engine is cool.
Caution:
Do not loosen or remove the sub tank cap when
coolant is high temperature. Steam or boiling water
spouts and it may cause a burn. When opening the
cap, cover the cap with thick clothes under the
condition that coolant is cold, rotate it slowly to release
• Check the condition of the negative pressure valve pressure, and then remove it.
in the center of the cap valve seat side. If the valve 2. Press the button on the sub tank cap, release
seat does not operate smoothly due to rust, dust, pressure from inside and then remove the cap.
etc., clean or replace the cap.
3. Open the coolant drain cock in the engine and
Radiator core radiator, and drain coolant.
• Repair the radiator fin if it is deformed. Deformed 4. Loosen the drain cock.
fin lowers the heat radiation effect, which could 5. Pour “radiator cleaner” into the sub tank and fill
cause overheat. with tap water up to the “MAX” line.
Take care not to damage the base of the fin during 6. Check and clean the sub tank cap. Replace the
repair. cap if it is faulty.
• Remove foreign matter such as dust. 7. Install the sub tank cap securely.
8. Start the engine, idle it for 20 minutes, then stop
Washing of radiator
the engine. After the coolant cools down
• Wash the inside of the radiator and the coolant sufficiently, drain it.
passage with water and neutral detergent. 9. Repeat the same procedure, but fill with tap water
Remove hot water stains and rust completely. only at this time. Idle the engine for cleaning, and
then drain it.
Coolant leak check
10. Add coolant.
• Use a cap tester to apply a pressure of 88 kPa
11. Idle the engine until the coolant reaches the proper
{0.9kg/cm2} to check leakage of the following
temperature, then idle it for another 10 minutes. At
locations. Also, check the radiator hose and the
this time, set the temperature adjustment to the
heater hose for damage or deterioration and the
maximum position to circulate coolant in water
hose clamps for looseness.
channels of the heater.
12. Stop the engine, and check the coolant after the
engine cools down sufficiently. Add coolant up to
the “MAX” in case it is insufficient.
List of Trouble Symptoms
• Engine over-heats.
• Engine over-cools.
Symptom: Engine Over-heats.
Condition Possible Cause Correction

Engine overheats. Low coolant level Add.
Defective thermostat Replace.
Defective water pump Replace.
Clogging of radiator Clean or replace.
Defective sub tank cap Replace.
Engine oil shortage or use of Add or change engine oil.
improper oil
Defective cylinder head gasket Replace.
Loose fan belt Adjust.
Clogging of exhaust system Clean or replace.
Clogging of exhaust system Clean or replace.
Too much fuel injection quantity. Diagnose the engine control
system.
Fuel injection timing is incorrect. Diagnose the engine control
system.
Symptom: Engine Over-cools.

Engine over-cools. Defective thermostat Replace.
Specifications
Item Specification
Cooling method Forced circulation cooling pre-compression type
Radiator type Corrugate type
Sub tank cap operation pressure Positive
62 — 72 {0.63 — 0.73}
kPa {kgf/cm2} pressure valve
Negative
4.9 {0.05}
pressure valve
Water pump Type V-belt drive hoist type
Discharge 370 (pump speed 2000rpm, normal temperature of
amount (L/min) coolant 80°C)
Thermostat valve open start (°C)
80 — 84
temperature
Thermostat full-open (°C)
95
temperature
Coolant amount (engine unit) (L) 22.5
Water Pump
Components
8
4 6
3
10
11
12
13
WSUZ0132
Name
1. Pulley 8. Shaft
2. Pulley Center 9. O-ring
3. Oil Seal (Large) 10. Gasket
4. Snap Ring 11. Impeller
5. Bearing 12. Seal Unit
6. Spacer 13. Water Pump Body
7. Oil Seal (Small)
Removal
1. Remove the EGR water pipe and air leak pipe.
3. Remove the ACG belt.
4. Remove the crank pulley.
Note:
Take care not to drop because it is heavy.
5. Remove the water pump pulley.
6. Remove the water pump.
WSUZ0135
4. Remove the oil seal (large).

WSUZ0133 5. Remove the snap ring.
Disassembly 6. Remove the shaft.
1. Remove the impeller. • Tap it lightly from the impeller side with hammer
and remove.
• Fix the pulley center to a vise and remove with
remover (1-8521-0047-0).
Note:
Do not tap the impeller to remove because it leads to
damage.
WSUZ0136
7. Remove the two bearings.

8. Remove the spacer.
9. Remove the bearing.
• Use a press to remove the bearing.
WSUZ0134
2. Remove the seal unit.

3. Remove the pulley center.
• Use a puller to remove the pulley center.
Check the pulley center.
• Check the oil seal contact surface of pulley center
for wear or damage.
WSUZ0137
10. Remove the oil seal (small).
WSUZ0138
Inspection
Check the shaft.
Check the impeller.
• Check the oil seal contact surface of shaft for wear
• Check the impeller for corrosion or damage. or damage.
• Measure the interference of the impeller and shaft.
Interference of impeller and shaft

(mm)
Assembly standard 0.023 — 0.051
• Measure the interference of the pulley center and

shaft.
Interference of the pulley center and shaft Assembly
(mm) 1. Install the oil seal (small).
Assembly standard 0.048 — 0.082 • Apply oil to the inner side and outer
circumference part of the oil seal lip. Face the
lip section upwards and push it into the water
pump body.
Check the bearing.

2. Install the bearing.
Check bearing for peeling, wear or noise.
3. Install the spacer.
• Check to see from the ball clearance to the lace for
damage or debonding (full circumference). 4. Install the two bearings.
• Check the ball and lace sections for abnormal • Apply engine oil to inner side (shaft surface) of
rattling, and find wear by rattling. inner lace of bearing, assemble bearing (1),
spacer (2) and two bearings (3) to shaft (4) in
• Check if you can feel anything unusual in your
this order and push it using a press.
hand when rotating the bearing, and find abnormal
noise by it.
WSUZ0139
5. Install the shaft.

• Push the bearing of shaft into the water pump
body using a press.
Note:
• While pushing the shaft into the water pump body,
do not damage the oil seal.
WSUZ0140 WSUZ0141
6. Install the snap ring. 9. Install the seal unit.

7. Install the oil seal (large). • Install the seal unit to the water pump body.
• Apply oil to the inside and outer circle of lip of • Use the press to press the seal unit until its
oil seal lip. Face the lip section upwards and collar section contacts with the water pump
push it taking care not to bend it out of shape. body.
Seal unit pressing size (a) mm

Assembly standard 11.0 — 11.6
• Seal unit has seizure by liquid gasket on the

contact surface of the water pump body and
shaft.
• When making a seal unit pressing jig (1-8522-
0047-0), refer to the illustration.
8. Install the pulley center.

• Push the pulley center with a press taking care
not to damage the oil seal.
Note:
• To prevent damage to the bearing, press it in while
it contacts with the impeller side (bottom side)
shaft edge.
• Do not put a press side jig to the shaft. Always put
it to the pulley boss section and press in.
WSUZ0146
Name 11. Check after assembly.

(b) φ 17mm • Rotate the pump and check if it is rotating
(c) 40mm smoothly.
(d) 11.3 ± 0.00in • On compression test with water pressure (0.1
(e) φ 33mm MPa), no water should leak from seal unit
(f) φ 44mm section.
Installation
10. Install the impeller.
• Use the press to press in so that the end of the 1. Install the water pump ASM.
shaft aligns with the end surface of impeller. • Install the O-ring to the water pump.
• To avoid missposition of the gasket, use the two
Note: stud bolts as a guide stick.
To prevent damage to the bearing, press it in while it
contacts with the pulley side shaft edge.
Tightening torque: 38N⋅m {3.9kg⋅m/28lb⋅ft}
Clearance between body and impeller mm Note:

Clean the installing surface of gasket and install it while
0.3
avoiding misalignment of liquid gasket.
WSUZ0133
WSUZ0145
2. Install the water pump pulley.

Refer to “Front cover, crank shaft”.
4. Install the ACG belt.
Refer to “Engine accessories”.
5. Install the thermostat housing.
Refer to “Thermostat”.
6. Install the EGR water pipe and air leak pipe.
Refer to “Engine exterior equipment”.
Special Tool
Tool Number
Special Tool Rank
1-8521-0047-0
Water pump impeller
remover
Rank B
1-8522-0047-0
Seal unit setting tool
Rank A
Thermostat, Thermo-Sensor
Removal
Name
1. Thermostat Housing 4. Thermostat
2. Gasket 5. Spacer
3. Seal Ring
Removal procedure
1. Remove the EGR cooler on exhaust side.
2. Remove the water duct.
Remove the water duct (2) and BRKT (1) (4).
2
4
1
WSUZ0089 WSUZ0092
3. Remove the thermo-sensor. Inspection

Thermostat
• Shake a pellet section of thermostat to check for
rattling or caulking part for damage.
WSUZ0127
4. Remove all the water pipes connected to

thermostat housing.
6. Remove the spacer.
• Operation check of thermostat.
7. Remove the thermostat. Put the thermostat in water and gradually increase
8. Remove the seal ring on thermostat. the water temperature. Measure the temperature
• Use a seal ring remover (1-8521-0067-0) to at which the valve starts to open, fully opens and
remove the seal ring. amount of lift.
Open start temperature 80 — 84°C

Temperature when fully open,
95°C, 11mm
amount of lift
As wax type thermostats have a large heat

capacity, the action of the valve has a certain
amount of time lag compared to the fluctuation in
water temperature.
Note: Note:
Do not directly heat the thermostat. Either perform the • It is available to apply a light coat of ThreeBond
measurements by covering the bottom of the container TB1521 to the gasket.
with a plate, or hanging. When performing
• Assemble the thermostat housing after assembly
measurements, constantly stir the water to avoid un-
of water pump and cylinder head.
even temperature.
5
4
3
1 2
WSUZ0128
5. Install the thermostat sensor.

Installation
1. Install the seal ring of thermostat. Tightening torque: 19.6N⋅m {2kg⋅m/14.5lb⋅ft}
• Turn the lip of seal ring (3) to this side, and use
an installer (1-8522-1034-0) to install. Note:
Apply Loctite 271 to the threads.
WSUZ0093
WSUZ0127
2. Insert the thermostat.
• Install the thermostat (4), taking care not to 6. Install the water duct.
damage the seal ring. • Tighten together with the water duct (2) and
3. Insert the spacer (5). BRKT (1).
4. Install the thermostat housing. • Install the BRKT (4).
• Set the gasket (2) and install the housing (1) Tightening torque:
while putting it into the water pump Water duct: 21.6N⋅m {2.2kg⋅m/15.9lb⋅ft}
BRKT (4) : 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}
2
4
1
WSUZ0089
7. Install the water pipe.

• Connect each water pipe.
8. Install the EGR cooler.
• Install the EGR cooler following the procedure.
Torque Specifications
Name
(a) 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft} (c) 19.6N⋅m {2kg⋅m/14.5lb⋅ft}

(b) 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft} (d) 21.6N⋅m {2.2kg⋅m/15.9lb⋅ft}
Special Tool Tool Number

Tool Number
Special Tool Rank
Special Tool Rank
1-8522-1034-0
Seal ring installer
1-8521-0067-0
Rank A
Seal ring remover
Rank A
Fuel System (6UZ1X) 1D-1
Engine
Fuel System
(6UZ1X)
Contents
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .1D-2
Description of Function and Operation. . . . . . . .1D-2
Function Check: . . . . . . . . . . . . . . . . . . . . . . . . .1D-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-6
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-8
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-10
1D-2 Fuel System (6UZ1X)
Fuel System
Service Precautions Work procedure
Holes and clearances in the fuel system which serve as • The fuel opening must be quickly sealed when
a passage of fuel, including the inside of injector, are removing the fuel pipe, injection pipe, fuel injector,
finished extremely precisely. For this reason, they are fuel supply pump, and common rail.
highly sensitive to foreign matter. If it gets inside, it can • The eyebolts and gasket must be stored in a clean
lead to breakdown on the road. Be sure to prevent it parts box with a lid to prevent adhesion of foreign
from getting inside. matter.
Do not use water removal agent. It helps light oil to • After finishing the work, wipe off the fuel that has
absorb moisture that may cause rust. leaked out and make sure there is no fuel leakage
after starting the engine as fuel leakage could
cause fires.
Fuel system diagram
WSUZ0096
Name
1. Injector 4. Pre-fuel Filter
2. Fuel Filter 5. Supply Pump
3. Fuel Tank 6. Common Rail
Common rail
Name
1. Pressure Limiter 3. Flow Damper
2. Pressure Sensor
Supply pump
WSUZ0083
Name
1. Pump Control Valve (PCV) 3. Air Bleed
2. Overflow Valve 4. Camshaft Position Sensor
Injector
Name
1. Injector ASM 3. O-ring
2. Gasket
Note:
Do not disassemble supply pump, common rail flow
damper, fuel pressure sensor, pressure limiter and
injector.
Function Check:
Fuel filter water drainage 4. After waiting for approximately one minute, loosen
1. Loosen the air bleeder plug (2) on the fuel filter. the air bleeder plug (2) and bleed out the air in the
fuel filter. (Repeat the steps 2 — 4 a minimum of
2. Loosen the drain plug (3) on the fuel filter and drain three times until no more air comes out.)
the water.
3. Loosen the drain plug (3). Note:
4. Let the air bleed from the fuel. Bleed the air from the fuel filter one by one.
5. Let the air bleed from the another fuel filter in the
2 same way.
6. Loosen the air bleeder plug (4) on the supply pump
and operate the priming pump (1) on the fuel filter
until no air babbles appear.
7. Loosen the air bleeder plug (4) on the supply
1 pump.
Important:
air bleeder plug could lead to damage.
3
8. After tightening all the air bleeder plugs, operate
the priming pump (1) until you feel enough
resistance to move.
9. Tighten the priming pump to the original position
and start the engine. If the engine does not start,
resume from step 8 again.
4
WSUZ0130
2
Bleed air from fuel system
1. Loosen the air bleeder plug (2) on the fuel filter that
is close to the fuel tank.
2. Operate the priming pump (1) on the fuel filter to
bleed air from the fuel filter and fix the priming 1
pump (1).
3. Tighten the air bleeder plug (2) of the fuel filter and
operate the priming pump (1) more than 10 times
until it is filled with fuel.
3
Important:
air bleeder plug could lead to damage.
4
WSUZ0130
Specifications
Fuel injection pump specifications
Engine model 6UZ1X

Items
Fuel injection pump type Electronic control fuel injection system (Common rail type)
Supply pump model SP180-6HD
Injector specifications
Items Specifications
Injector model DLL-P
Fuel Filter
Components
Name
1. Head ASM 6. O-ring
2. Air Bleeder Plug 7. Case
3. Priming Pump 8. O-ring
4. Element 9. Drain Plug
5. Level Ring
Disassembly
1. Loosen the air bleeder plug.
2. Loosen the drain plug.
• Loosen the drain plug, and then drain the fuel
inside of the filter beforehand.
3. Remove the case using the fuel main filter wrench.
Fuel main filter wrench: 8-9801-3170-0
4. Remove the O-ring for case.
5. Remove the level ring.
Inspection
Overflow valve
• This over flow valve is not supplied with the fuel
filter.
• Check overflow valve for clogging and ball seat for
leakage.
Overflow valve opening pressure: 275 — 314 kPa

{2.8 — 3.2kg/cm2}
Name
1. Level Ring
2. O-ring
3. Case
6. Remove the element.
WSUZ0045
7. Clean the fuel passage of head ASM.

• The priming pump is a non-disassembled part.
Assembly
Name
1. Head ASM 5. Drain Plug
2. Element 6. O-ring
3. O-ring 7. Level Ring
4. Case
1. Install the element to the head ASM.

• Insert the element seal rubber to the head
ASM.
2. Install the O-ring to the case. Name

• Use a new O-ring. 1. Level Ring
2. O-ring
3. Put the level ring in the case.
3. Case
4. Tighten the case using the fuel main filter wrench.
5. Install the O-ring to the drain plug.
Fuel main filter wrench: 8-9801-3170-0
• Use a new O-ring.
Tightening torque: 29.4 N⋅m {3.0kgf⋅m/21.7lb⋅ft} 6. Tighten the drain plug to the specified torque.
Tightening torque: 2N⋅m {0.2kgf⋅m/1.5lb⋅ft}
7. Tighten the air bleeder plug to the specified torque.
Tightening torque: 9.8N⋅m {1.0kgf⋅m/7.2lb⋅ft}
Special Tool
Tool Number
Special Tool Rank
8-9801-3170-0
Fuel main filter wrench
Rank A
Electrical System (6UZ1X) 1E-1
Engine
Electrical System
(6UZ1X)
Contents
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1E-2
List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1E-3
Symptom: Starter does not operate when starter
switch is turned on. . . . . . . . . . . . . . . . . . . . . . . 1E-4
Symptom: Pinion moves forward but it does not
engage with ring gear. . . . . . . . . . . . . . . . . . . . . 1E-5
Symptom: Pinion engages and rotates motor but it
does not run engine. . . . . . . . . . . . . . . . . . . . . . 1E-6
Symptom: Pinion engages but it does not run engine.1E-7
Symptom: When turning starter switch off, starter
does not stop after engine starts. . . . . . . . . . . . . 1E-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-8
Sectional View (reference) . . . . . . . . . . . . . . . . . 1E-9
Output Characteristic (reference). . . . . . . . . . . 1E-10
Disassembly and Inspection of Starter . . . . . . . . 1E-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Inspection and Maintenance . . . . . . . . . . . . . . 1E-12
Assembly of Starter . . . . . . . . . . . . . . . . . . . . . . . 1E-16
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . 1E-21
Service Precautions . . . . . . . . . . . . . . . . . . . . . 1E-21
List of Trouble Symptoms . . . . . . . . . . . . . . . . 1E-22
Symptom: Charging is impossible.. . . . . . . . . . 1E-23
Symptom: Charging is not sufficient. . . . . . . . . 1E-24
Symptom: Overcharging occurs. . . . . . . . . . . . 1E-25
Symptom: Charging current is unstable. . . . . . 1E-26
Symptom: Abnormal sound occurs from generator. . 1E-27
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . 1E-28
Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-29
Disassembly and Inspection of Generator . . . . . 1E-31
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-32
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-37
Bench Testing. . . . . . . . . . . . . . . . . . . . . . . . . . 1E-38
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . 1E-39
1E-2 Electrical System (6UZ1X)
Starting System
Service Precautions
Handling of starter
1. Precautions on handling
• Improper gap between pinion and ring gear
causes faulty mesh. (Gap 2 — 5 mm)
• Also, the front bracket is installed on the engine
side securely.
• Be sure to turn off the battery switch before
removal/installation of stater.
• Tightening/inserting wiring must be performed
properly. Looseness causes starting trouble
due to high contact resistance.
2. Precautions on starting
• Be careful with charging status of battery.
Insufficiently-charged battery causes starting
trouble.
• After checking engine starting, turn off the
starter switch immediately.
• One continuous use should be less than 10
seconds. If re-starting is needed, wait until the
pinion stops completely.
• If the starter does not stop rotating when the
starter switch is turned off, turn off the battery
switch immediately. In this case, check the
wiring, switch, etc.
• Starter does not operate when starter switch is
turned on.
• Pinion moves forward but it does not engage with
ring gear.
• Pinion engages and rotates motor but it does not
run engine.
• Pinion engages but it does not run engine.
• When turning starter switch off after engine starts,
starter does not stop.
Symptom: Starter does not operate when starter switch is turned on.

Starter does not operate when Full discharge of battery Replace the battery.
starter switch is turned on. Open circuit, poor contact Repair.
Poor contact in starter switch or Repair or replace it.
improper tightening of terminal
Poor contact in starter relay or plug Repair or replace it.
terminal
Short or open circuit in magnetic Replace.
switch coil
Symptom: Pinion moves forward but it does not engage with ring gear.

Pinion moves forward but it does Insufficient capacity of battery Charge the battery.
not engage with ring gear. Wear of pinion or ring gear tooth Replace the pinion or the ring gear.
edge
Dust on pinion shaft Repair.
Symptom: Pinion engages and rotates motor but it does not run engine.

Pinion engages and rotates motor Slippage of clutch Replace the clutch or the starter.
but it does not run engine. Breakage of reduction gear Replace the gear or the starter.
Symptom: Pinion engages but it does not run engine.

Pinion engages but it does not run Insufficient capacity of battery Charge the battery.
engine. Improper tightening of wiring circuit Repair.
terminal
Short circuit of armature or field coil Replace the starter.
Contamination of commutator Repair, or replace the starter.
Fatigue or wear of brush spring Replace the brush spring or the
brush.
Locking of bearing Replace the bearing or the starter.
Poor contact in magnetic switch Replace the magnetic switch.
Symptom: When turning starter switch off, starter does not stop after engine starts.

When turning starter switch off after Retuning failure of starter switch Replace the starter switch.
engine starts, starter does not stop. contact
Retuning failure of starter relay Replace the starter relay.
contact
Short circuit in magnetic switch coil Replace the magnetic switch.
Specifications
Manufacturer Mitsubishi Electric Co.

Isuzu Part No. 181100-4322
Manufacturer code No. M009T62371
Power output (V-kw) 24-5.5
Rating (Sec) 30
Outside diameter of yoke (mm/in) 90/3.543
Revolution direction Clockwise
Protection Dust-proof, splash-proof
Reduction mechanism Internal gear
Weight (kg) 8.5
Pinion Module 3.5
Pressure angle 14.5
The number of teeth 11
Gear ratio {ring gear/pinion gear} 12.6 {139/11}
No load Voltage (V) 23
Current (A) 120 or less
Revolution speed (rpm) 3,100 or more
Restraint Voltage (V) 8
Current (A) 1,800 or less
Torque N⋅m {kgf⋅m} 76 {8} or more
Pinion engagement voltage (V) 16.0 or less
Sectional View (reference)
4 7
8
3
1 13 12 11
10
Name
1. Through Bolt 8. Pinion
2. Bearing 9. Bearing
3. Rear Bracket 10. Front Bracket
4. Brush Holder 11. Gear
5. Magnetic Switch 12. Yoke
6. Shift Lever 13. Armature
7. Gear Shaft
Output Characteristic (reference)
Rotation Rotation Output Terminal

speed force voltage
r/min N.m kW V
6000 120 6 24
Output
5000 100 5 20 Rotation force
Rotation
speed
4000 80 4 16
3000 60 3 12
Terminal voltage
2000 40 2 8
1000 20 1 4
0 0 0 0
0 200 400 600 800 1000 1200 1400 1500
Current (A)
WSUZ0150
Disassembly and Inspection of Starter

Disassembly diagram: disassemble in the order of the numbers.
18
19
27 21
9
6
28
29
14
16
17
15 5
20
4 26 8
3
2 22 10
1 25
24 13
23 12
30
11
12
Name
1. Snap Ring 16. Plate
2. Stop Ring 17. Packing
3. Pinion 18. Packing
4. Pinion Spring 19. Plate
5. Lead Wire with Terminal 20. Planetary Gear
6. Screw 21. Lever
7. Magnetic Switch 22. E-shaped Retaining Ring
8. Screw 23. Overrunning Clutch
9. Through Bolt 24. Internal Gear
10. Rear Bracket 25. Washer
11. Yoke Assembly 26. Gear Shaft
12. O-ring 27. Front Bracket
13. Brush Holder 28. Bearing
14. Armature 29. Washer
15. Ball 30. Brush
Disassembly 1. Connect the starter to battery as shown in the

illustration.
Caution:
• Before disassembling the starter, put alignment When closing the switches SW1 and SW2, the
marks on each magnet switch, yoke front bracket pinion move forward to the cranking position and
and rear bracket to facilitate re-assembly. the armature rotates.
Then, open the switch SW2 to stop the armature
• In normal condition, if tap the pinion or stop ring rotating.
toward the front bracket side, the front bracket will Caution:
be broken. Therefore, tap the stop ring when the Remove the pinion within 10seconds since heat is
pinion comes out to cranking position. generated during electric discharge.
4. Remove the brush holder-tightening screw and
through bolt.
Then, remove the rear bracket and O-ring
together.
SW 1 Caution:
B
SW 2
Do not reuse the removed O-ring.
S
Also, do not reuse also O-ring on tightening screw.
M
Battery 5. Apply a socket (outside diameter 32 mm {1.260
24V
in}) on a commutator of armature.
Disconnect the lead wire
(attached with terminal)
Then, slide the brush on the socket to yoke
from the M terminal. assembly and O-ring.
This facilitates to re-assemble.
Caution:
Do not reuse the removed O-ring.
Wiring diagram to move pinion forward 6. Remove the brush from brush holder by pulling up
the brush spring, and then remove the brush
holder.
WSHK0072 7. Remove the armature.
2. Apply the pipe, which just fits the stop ring, on the Remove a bearing using a general puller.
ring and tap the pipe with a hammer to remove the 8. Remove the plate in planetary gear and remove
stop ring toward the pinion side once. the packing.
Then, remove the snap ring and remove the stop Then, remove the packing and plate on the lever
ring, pinion and pinion spring. support.
Caution: 9. Remove the internal gear, gearshift, overrunning
Do not reuse the snap ring. clutch and lever as a unit from front bracket.
10. Remove the lever.
Caution:
Remember the direction of lever.
5 11. Remove the two E-shaped retaining rings.
4 To remove the overrunning clutch, rotate the spline
by one tooth to remove it from gearshift assembly.
3
6
Caution:
2 Do not reuse removed E-shaped retaining ring.
1 12. Remove the internal gear.
In this time, take out one washer which adjusts
axial play of gearshift.
Inspection and Maintenance
1. Armature
• Check the armature coil for internal short circuit
with a growler tester.
• Replace the armature if internal circuit is
present.
Name
1. Pinion
2. Clutch Shaft
3. Snap Ring
4. Stop Ring
5. Pipe
6. Pinion Spring
3. Remove the nut on M terminal of magnet switch

and remove the lead wire with terminal.
Caution:
Tightening screw is tight. Use a shock driver to loosen.
• Check the armature coil for grounding (faulty • Check the depth (undercut) of insulating mold
insulating) with a circuit tester. of commutator.
Replace the armature if grounding is present. Remove abrasion powder on brush, and repair
if faulty.
2
3
• Check the outside of commutator for wear.

Replace the armature if wear exceeds limit. Name
1. Good
2. Insulating
3. Commutator Segment
4. Defective
• Check the gears for wear or damage.

Replace the armature if fault is present.
• Check the bearings for noise, rattle or grease
leakage.
2. Field coil
• Check the coil for open circuit with a circuit
tester.
Replace the yoke assembly if open circuit is
present.
• Check the coil for grounding (faulty insulating) Name

with a circuit tester. 1. Brush Length
Repair or replace the yoke assembly if 2. Insulated Holder
grounding is present.
4. Overrunning clutch and pinion
Hold the housing of overrunning clutch by hand.
Make sure that the pinion can be rotated by hand
with a light resistance in one direction and cannot
be in the opposite direction. Replace the
overrunning clutch if faulty.
Check the pinion, and replace it if wear or scratch
is present.
Caution:
Grease is present in overrunning clutch. Do not use
wash oil or cleaning agent for cleaning.
Wipe off stain on overrunning clutch with a cloth.
3. Brush
• Measure the length of the brush.
If it is worn to the limit, replace the brush holder
assembly on the brush holder as a unit and only
brush on the yoke assembly side.
• Make sure the brush moves smoothly in the
brush holder. Also, check the brush spring
pressure.
• Check the brush holder for grounding (faulty
insulating) with a circuit tester.
Clean the brush holder before checking.
Replace the brush holder assembly if the
continuity is present when putting one probe of
circuit tester to brush holder plate (metal part)
and another one to insulated holder.
5. Front bracket
Check the bearing and oil seal, and replace the
front bracket assembly (including bearing, oil seal)
if faulty.
6. Internal gear and planetary gear 2
Check the internal gear and planetary gear, and
replace them if excessive wear or damage is
present.
7. Lever
If the portion which contacts the overrunning
switch is worn, the protruded position of pinion will
be faulty.
(Refer to “4. Assembly” section to adjust the 1 3
protruded position of pinion.)
Name
1. M Terminal
2. S Terminal
3. B Terminal
Name
1. Worn Part
8. Magnetic switch
Check for continuity between the M terminal and
the body, and replace the magnet switch if no
continuity is present.
Then, make sure that no continuity is present
between B terminal and M terminal. Replace the
magnet switch if continuity is present.
Assembly of Starter
Assembly diagram: Assemble in the order of the numbers.
24
13
12
4 10
22
25
3
2
17
15
14
16 5
11
27 5 23
28
29 9 21
30 6
7 18
8 19
1
20
19
Name
1. Brush 16. Ball
2. Washer 17. Armature
3. Bearing 18. Brush Holder
4. Front Bracket 19. O-ring
5. Gear Shaft 20. Yoke Assembly
6. Washer 21. Rear Bracket
7. Internal Gear 22. Through Bolt
8. Overrunning Clutch 23. Screw
9. E-shaped Retaining Ring 24. Magnetic Switch
10. Lever 25. Screw
11. Planetary Gear 26. Lead Wire with Terminal
12. Plate 27. Pinion Spring
13. Packing 28. Pinion
14. Packing 29. Stop Ring
15. Plate 30. Snap Ring
1. Lubricant locations and tightening torque
N m(kg m/lb ft)
I 4.9~8.8
19.6~25.5
(0.5~0.9 / 3.6~6.5)
(2.0~2.6 / 14.4~18.8)
C B
H F
2.4~4.4
(0.25~0.45 / 1.8~3.2)
7.8~12.7 E A D
(0.8~1.3 / 5.8~9.4)
WSHK0085
Lubricant locations
Shown in the
Lubricant locations Lubricant agent
illustration
A Sleeve bearing and ball Molycote £ AG650
B Clutch shaft sliding surface MULTEMP 6129
C Spline portion and sliding portion of gearshift MULTEMP 6129
D Sliding portion of lever and overrunning clutch Molycote £ AG650
E Armature shift gear, planetary gear, internal gear Molycote £ AG650
F Under pinion MULTEMP 6129
G Outer surface of armature bearing (tiny amount) MULTEMP 6129
H Oil seal MULTEMP 6129
I Surface of plunger (tiny amount) MULTEMP 6129
2. Axial play of armature shift 4. Assembly of gearshift

Adjustment is unnecessary (assemble the ball into Pass the gear shaft through washer, internal gear
a tip of shaft.) and overrunning clutch. Then move the
3. Axial play of gear shaft overrunning clutch by one tooth of spline to make
Adjustment is unnecessary sure that the clutch cannot be pulled out.
Appropriate gap will be obtained automatically Assemble the E-shaped retaining ring.
when one washer (removed in step 12 of Caution:
disassembly procedure) is inserted between • Do not reuse removed E-shaped retaining ring.
internal gear and gearshift. • If assembling the E-shaped retaining ring prior to
the overrunning clutch, the clutch cannot be
assembled. Be careful with it.
3
4
2
3
2
5
1
Name Name
1. Overrunning Clutch 1. Pinion
2. Washer 2. Clutch Shaft
3. Gear Shaft 3. Snap Ring
4. E-shaped Retaining Ring 4. Stop Ring
5. Internal Gear 5. Pinion Spring
5. Assembly of pinion 6. Check of the pinion protruded position

Assemble the pinion spring, pinion and stop ring to After assembling the starter, check the protruded
clutch shaft in this order, then assemble the snap position of pinion.
ring to the groove of clutch shaft at the end. How to measure and adjust
Then, pull strongly the stop ring toward the snap • Connect the starter to battery.
ring side with a gear puller and fix both of them. When closing the switches SW1 and SW2, the
Caution: pinion move forward to the cranking position
• Assemble the pinion before assembling the and the armature rotates.
magnet switch to front bracket. Then, open the switch SW2 to stop the
• Do not reuse the removed snap ring. armature rotating.
• Push into or pull back a tip of the clutch shaft
lightly by hand and measure the moving
distance of it.
Adjust by using one or two packings (0.5 mm
{0.020 in}) between magnet switch and front
bracket so that this measurement value is
between 0.5 — 2.0 mm (0.020 — 0.079 in).
If this adjustment cannot be done, replace the
lever.
No Load Test
1. After adjusting the protruded position of pinion,
connect the starter as shown in the illustration
above.
Caution:
SW 1 B Use a thick electric wire and tighten the connected
S SW 2 portion securely.
M 2. Close the switch and read the speed, current and
1
voltage.
If the measured values are out of specified value,
disassemble and inspect again.
2 A SW B
Name
S
1. Battery 24 V
M
1 V 3
Amount of shaft moved
Push back the clutch Name

shaft lightly by hand. 1. Battery 24 V
2. Ammeter
3. Voltmeter
Check of pinion moving out position
WSHK0089
Specifications
Items Standard value or limit

No load Voltage (V) 23
characteristic
Current (A) 120 or less
Speed (rpm) 3,100 or more
Commutator Outside diameter (mm/in) 32/1.260
Limit (mm/in) 31.4/1.236
Commutator Undercut (mm/in) 0.5/0.020
Limit (mm/in) 0.2/0.008
Brush Length (mm/in) 18/0.709
Limit (mm/in) 11/0.433
Items Standard value or limit

Brush spring Pressure (N) 28 — 38
Limit (N) 13.7
Protruded position of pinion (mm/in) 0.5 — 2.0/0.020 — 0.079
Charging System
Service Precautions
Handling of generator
Be careful with the following when handling a
generator.
• Connecting the polarities of battery inversely
causes generator diode to be broken.
• While the engine runs, never disconnect the wiring
of battery terminal and charging circuit.
• Wiring connection to terminal must be performed
properly according to terminal symbol.
• Do not perform megger test on semiconductor
device.
• Be sure to disconnect the battery terminal (-)
before inspection on equipment.
• Do not open/close the battery relay switch while
the engine runs.
• Disconnect the battery terminal when charging
from external source such as quick charge.
• Do not pour steam cleaner or water directly on it.
• After connecting to B terminal and E terminal,
tighten them to the following torque.
B terminal 6 N⋅m {0.6 kg⋅m}
E terminal 4 N⋅m {0.4 kg⋅m}
• Refer to “Engine Accessories” for tension
adjustment of ACG-belt.
• Charging is impossible.
• Charging is not sufficient.
• Overcharging occurs.
• Charging current is unstable.
• Abnormal sound occurs from generator.
Symptom: Charging is impossible.

Charging is impossible. Defective battery Replace.
Open or short circuit, disconnection Repair.
in wiring / ammeter
Open, ground short or short circuit Replace.
in each coil of generator and
breakage of diode
Defective regulator Replace.
Poor contact in terminal of regulator Repair.
Symptom: Charging is not sufficient.

Charging is not sufficient. Defective battery Replace.
Open or short circuit, disconnection Repair.
in wiring
Looseness of generator driven belt Adjust the tension of the belt.
Short circuit in stator coil layer Replace.
Defective diode Replace.
Poor contact in each terminal Repair.
Symptom: Overcharging occurs.

Overcharging occurs. Defective regulator Replace.
Symptom: Charging current is unstable.

Charging current is unstable. Intermittent contact or nearly Repair.
disconnected connection in wiring
Looseness of generator driven belt Adjust the tension of the belt.
Short circuit or nearly open circuit in Repair.
stator coil
Poor contact in each terminal Repair.
Symptom: Abnormal sound occurs from generator.

Abnormal sound occurs from Looseness of belt tension Adjust the tension of the belt.
generator. Defective bearing Replace the bearing.
Contact of rotor core and stator Repair.
core
Defective diode Replace.
Short circuit or nearly open circuit in Replace.
stator coil
Specifications
Manufacturer Mitsubishi Electric Co.

Isuzu Part No. 1-81200-603-2
Model by manufacturer A004TU6285
Nominal voltage (V) 24
Output current (A) 50
Rated speed (rpm) 5000
Output current/Voltage (A/V/rpm) 50/27/5000
No load voltage (V/rpm) 24/900
Revolution direction Clockwise
Polarity (−)
Pulley diameter (P. C. D) (mm/in) 80/3.150
Charging Circuit
B
3 4 5
L
2 L
R R
E 6
1
7
E
Name
1. Field Coil 5. Key Switch
2. Stator Coil 6. Battery 24 V
3. Diode Trio 7. IC Regulator
4. Charging Lamp 8. Generator
Charging circuit and internal circuit are shown in the illustration above.
Charging system consists of IC regulator built-in generator, battery, charging lamp and wires to connect them.
Structure
5 6
4
7
8
1
9
10
Name
1. Rear Bracket 6. Rotor
2. IC Regulator 7. Bearing
3. Bearing 8. Pulley
4. Rectifier 9. Front Bracket
5. Stator 10. Coil Assembly (Field Coil)
This generator has no brush. This generator has three terminals, which are B
Main parts are a rotor, stator, rectifier assembly, front terminal (for direct current output), L terminal and R
bracket, rear bracket, IC regulator, bearing, pulley and terminal.
so on. The L terminal is connected to field coil. Therefore, as
Moving parts are a rotor and pulley. A field coil is well as R terminal, it becomes input terminal for
secured to rear bracket. initiating excitation current until the generator starts to
Six main diodes and two additional diodes are used to generate electric power.
convert three-phase alternating current, generated in It also provides function as output terminal. (Current
stator coil, into direct current. Among six main diodes, capacity is 1 A.)
there are three positive diodes and three negative The charging lamp will be off if the voltage on L
diodes. terminal reaches battery voltage.
In addition, three tiny diodes, called trio diode, are used Both bearings are sealed, therefore periodic lubricant is
to supply field current. not necessary.
IC regulator cannot be disassembled. Handle it as
assembly.
Disassembly and Inspection of Generator
10
5 7
6
4
1 3
11
12
13
14
15
Name
1. Nut Washer 9. Ball Bearing
2. Pulley, Fan 10. Screw
3. Collar 11. Cover
4. Through Bolt 12. Rectifier Assembly
5. Front Bracket 13. Regulator Assembly
6. Ball Bearing 14. Stator Assembly
7. Retainer 15. Field Coil Assembly
8. Rotor Assembly
11
10
6 8
7
5
3
2
1 4
12
13
14
15
16
17
18
Name
1. Nut Washer 10. Ball Bearing
2. Pulley, Fan 11. Field Coil Assembly
3. Key 12. Connector Set
4. Collar 13. Screw
5. Through Bolt 14. Terminal Set
6. Front Bracket 15. Cover
7. Ball Bearing 16. Rectifier Assembly
8. Retainer 17. Regulator Assembly
9. Rotor Assembly 18. Stator Assembly
Disassembly Caution:
To hold the rotor with a vise, grip the portion A. Portion
Caution:
B is not strong enough to be gripped.
To facilitate re-assembly, put alignment marks on front
bracket and rear bracket before disassembly.
1. Remove out the four through-bolts.
Pry between stator and front bracket with a tip of
flathead screwdriver and separate the front bracket
pulley rotor assembly from stator rear bracket
assembly carefully.
Caution:
Take care not to damage the stator coil.
2. Hold the rotor with a vise without deforming the
rotor ball.
Remove the nut which fixes pulley, and remove the
pulley, fan, spacer and front bracket.
Caution:
Do not lose a half-moon key when removing the pulley.
5. To remove the coil assembly from rear bracket,
firstly remove the screw A (which fixes coil terminal
portion to IC regulator).
Removing a screw B (which fixes the coil assembly
to rear bracket) prior to screw A may cause
B
damage to terminal portion.
Hold the coil assembly by hand not to damage to
terminal portion.
Then, remove the screw B and remove the coil
assembly.
A A
1
1
Name
1. Ball
3. If the front bearing needs to be removed, remove

the screw which fixes retainer, and push out the
bearing using appropriate socket.
Caution: B
Do not remove it if not necessary. Do not reuse the
removed bearing.
4. If the rotor bearing needs to be removed, it can be
done by a general bearing puller. Name
Caution: 1. Connector
Do not remove it if not necessary. Do not reuse the
removed bearing. 6. Disconnect the connector.
7. Remove the cap and nut from terminal bolt of
rectifier.
Pry between rear bracket and B terminal assembly
to remove the B terminal. A tube remains on rear
bracket.
Caution:
Do not lose the tube.
2 4
12
7
8
13
11
9
1
10
Name
1. IC Regulator 8. Cap
2. Rectifier 9. Nut
3. B Terminal 10. Terminal Bolt
4. Terminal Bolt 11. Terminal Bolt
5. B Terminal 12. Terminal Bolt
6. Cap 13. Rectifier
7. Nut
5
1
N
6
Name
1. IC Regulator 4. B Terminal
2. Terminal Bolt 5. Tube
3. Nut 6. Rectifier
8. Remove two screws which fix rectifier and two

screws which fix regulator.
Remove the stator and rectifier assembly from rear
bracket as a unit.
Then, remove the IC regulator.
9. Disconnect four lead wires of stator coil and
remove the stator from rectifier.
Caution: 1
Lead wires of stator coil are soldered (melting point:
230°C {446°F}) on rectifier terminal.
Disconnect them quickly (within five seconds) not to
heat the rectifier causing damage to diode.
Inspection
1. Stator
Check visually for damage, loose connection and
discoloration of coil.
• Check for continuity between two lead wires of
stator coil with a circuit tester. Replace the Name
stator if no continuity is present. 1. Stator Coil Lead
• Check for continuity between lead wire of stator
coil and core with a circuit tester. Replace the
stator if continuity is present.
2. Rotor 4. Rectifier assembly
• Check the bearings for noise, rattle or grease • Check for continuity between positive diode,
leakage (wipe off if tiny amount of grease). additional diode positive heat sink on positive
Replace it if faulty. It is easier to check for noise side and four diode terminals with a circuit
and rattle when it is press-fitted into shaft than tester.
when it is a single unit. The positive diode has short circuit if continuity
is present in both directions. Replace the
rectifier assembly.
The positive diode has open circuit if no
continuity is present in both directions. Replace
the rectifier assembly.
• Negative diode and additional diode on
1
negative side
Check for continuity between negative heat
sink and four diode terminals with a circuit
tester.
The negative diode has short circuit if continuity
is present in both directions. Replace the
rectifier assembly.
The negative diode has open circuit if no
2 continuity is present in both directions. Replace
the rectifier assembly.
• Diode trio (three tiny diodes)
Check for continuity in both directions with a
Name circuit tester.
1. Stator Coil Lead The diode is faulty if continuity is present in
2. Core both directions or no continuity is in both
directions. Replace the rectifier assembly.
3. Coil assembly
Measure the resistance between terminal portions
with a circuit tester.
Replace the coil assembly if the value is out of
specified value. 2
1 3
Name
1. Diode Terminal Portion
2. Positive Diode
3. A Part of Negative Diode
Name
1. Terminal
2. Terminal Portion
5. Front bearing
Check the bearings for noise, rattle or grease
leakage (wipe off if tiny amount of grease).
Replace them if faulty. It is easier to check for
noise and rattle when the bearing is press-fitted
into bracket than when it is a single unit.
6. Regulator
The regulator cannot be checked with a circuit
tester. After re-assembling the generator, check it
to make sure that regulator controls the voltage for
generator.
Assembly
Assembly can be performed in the reverse order of
disassembly. However, be careful with the following.
1. Lubrication is not necessary. Bearing is filled with
grease and is sealed.
Caution:
Keep a bearing with resin band for rotor shaft away
from oil. Wipe off oil on bearing box area of rear
bracket. Oil may cause creep.
2. Use a high temperature solder (melting point:
230°C {446°F}).
Using a soldering iron (with 180 — 270 watt),
soldering must be performed quickly (within five
seconds) not to heat the rectifier.
3. Tightening torque
• Pulley fixing nut:
132 — 162 N⋅m {13.5 — 16.5kg⋅m/97 — 119lb
ft}
• Through bolt:
12.8 — 18.6 N⋅m {1.3 — 1.9kg⋅m/9 — 14lb ft}
• Bearing retainer fixing screw:
2 — 5.3 N⋅m {20 — 54kgf⋅cm/18 — 47lb in}
• Coil assembly fixing screw:
2 — 5.3 N⋅m {20 — 54kgf⋅cm/18 — 47lb in}
• Rectifier fixing screw:
2 — 5.3 N⋅m {20 — 54kgf⋅cm/18 — 47lb in}
• Regulator fixing screw:
2 — 5.3 N⋅m {20 — 54kgf⋅cm/18 — 47lb in}
• Nut for B terminal bolt:
4.9 — 8.7 N⋅m {50 — 88kgf⋅cm/43 — 77lb in}
4. Assembly of rear bracket to stator assembly and
front bracket to rotor assembly
• The rotor bearing and rear bracket are engaged
tightly. Heat the bearing box area of rear
bracket to 50 — 60°C (122 — 140°F) prior to
assembly.
• After re-assembling the generator, rotate the
pulley to confirm that the rotor rotates smoothly.
Bench Testing
Bench testing is performed as follows.
Regulated voltage check

1. Wire as shown in the illustration. 2. Close the switch 1. Leave the switch 2 open.
Use an ammeter with 100 A rating and a voltmeter In this time, the lamp comes on.
with 30 V rating. If it does not, check the voltage on L terminal.
If the voltage is almost the same as battery
voltage, check the generator.
If the voltage is low, lamp or the circuit is open.
3. Increase the generator speed gradually.
Make sure that the lamp goes off before the speed
2 4 reaches approx. 1300 rpm.
A Notice the voltage. If the voltage is not controlled
and exceeds 30 V, the IC regulator may be faulty.
3 6 If the voltage does not exceed battery voltage, the
B
L generator does not generate electric power.
R Check the generator again.
1 V 8 5 7 If the lamp does not go off, check the generator
again.
4. Set the generator speed to approx. 5000 rpm and
read an ammeter. If the value is 5 A or less, read
indication on a voltmeter. This is regulated voltage.
If an ammeter shows 5 A or more, keep charging
for a while until it shows below 5 A or replace the
Name battery with full-charged one.
1. Voltmeter If regulated voltage is out of specified value,
2. Ammeter replace the regulator.
3. Lamp (24 V) (3 W or less)
4. Key Switch 1 Output current test
5. Battery (24 V) Output current test is performed to check if the
6. Key Switch 2 generator generates rated output.
7. Load Resistance 1. After checking regulated voltage, decrease the
generator speed until it stops.
2. Close the switch 1. The lamp should come on.
3. Set the value of no load resistance to maximum
(minimum current) and close the switch 2.
4. Increase the generator speed to 5000 rpm and
keep it. Adjust the load resistance so that output
current becomes maximum.
Keep this condition for 15 minutes and increase in
temperature of the generator.
15 minutes later, set the generator speed to the
specified speed (2500 and 5000 rpm) and then
adjust the load resistance so that output current
becomes maximum in this condition.
In this time, if indication of ammeter is within
specified value, the generator is normal.
If it is the specified value or less, check the
generator again according to “Inspection”.
Trouble Diagnosis
Symptom Trouble cause

No generation of a. Defective IC regulator
electric power b. Open circuit in field coil
Output shortage a. Defective diode
b. Defective stator coil
c. Defective rectifier
d. Internal short circuit in field coil
Too high regulated a. Defective IC regulator
voltage
Noise a. Defective bearing
b. Defective rectifier
c. Foreign material in generator
Specifications
Items Standard value and limit

Isuzu Part No. 1-81200-603-2
Manufacturer code No. A004TU6285
Rated output (V-A) 24-50
Output characteristic Voltage (V) 27
(hot)
Current (A) 42 or more
Revolution speed (r/min) 2,500
Voltage (V) 27
Current (A) 50 or more
Revolution speed (r/min) 5,000
Field coil resistance (Ω: at 20°C) 4.4-5.1
Regulated voltage by regulator (V) 28-29
Revolution direction (viewed from pulley side) Clockwise
Lubricating System (6UZ1X) 1H-1
Engine
Lubricating System
(6UZ1X)
Contents
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . .1H-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .1H-2
Description of Function and Operation. . . . . . . .1H-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-3
Oil Filter (sub oil filter) . . . . . . . . . . . . . . . . . . . . . .1H-5
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-5
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-7
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-8
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-10
Torque Specifications . . . . . . . . . . . . . . . . . . . .1H-13
Oil Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-14
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-15
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1H-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1H-16
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-17
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19
1H-2 Lubricating System (6UZ1X)
Lubrication System
Service Precautions • Apply appropriate amount, not excessively or
insufficiently. Applying excessively causes
• Perform service with taking enough care not to
clogging in oil gallery or oil jet resulting in seizure,
allow dirt or dust to get into the lubrication system
and applying insufficiently causes leakage of oil.
parts since they are manufactured extremely
Therefore, take care of them.
precisely.
• Be sure to re-apply upon itself when starting and
• Each time you disassemble parts, remove old
finishing application.
gasket completely from parts that use liquid
gasket. Clean each of the parts to completely Description of Function and Operation
remove oil, water, dust, etc. and apply new liquid The lubrication system uses gear type oil pump, oil filter
gasket on each area. integrated with full flow bypass, water-cooling oil cooler,
oil relief valve and oil jet for cooling piston.
Lubricating system diagram
WSUZ0084
Oil pump structured diagram
Name
1. Drive Gear 4. Relief Valve
2. Drive Gear Shaft 5. Driven Gear
3. Spring
Specifications
Item Specification
Lubrication device Forced circulation type
Oil pump Type Gear type
Discharge (L/min) 97.4 (pump speed 2,460 rpm, discharge pressure 0.79
amount MPa)
Relief valve kPa {kg/cm2} 1079 {11}
opening
pressure
Item Specification
Oil gallery relief valve opening kPa {kg/cm2} 540 {5.5}
pressure
Oil filter type Full flow filter paper type + shunt flow lamination layer
type
Oil cooler type Water cooling multi-sheet type 6 layer
Oil thermostat opening temperature (°C) 101.5 — 104.5
Engine oil level (L) Full capacity 30 — 41
Oil Filter (sub oil filter)

Components
Name
1. Body 3. Cartridge Oil Filter
2. Nipple 4. Splicing Fittings (Machine Side Components)
Disassembly Assembly
The oil filter is a sub oil filter (machine side Installation) 1. Set the body.
and not installed to the engine. 2. Apply Loctite to the nipple and install it.
1. Remove the cartridge filter using the filter wrench. 3. Install the cartridge oil filter.
Filter wrench: 8-9801-3170-0 • Apply engine oil to the O-ring of the cartridge oil
filter, screw it into the nipple of the body, and
2. Remove the nipple. tighten to the specified torque.
• If there are no problems with the screw thread • If using the filter wrench shown in the diagram
of the nipple screw, do not remove it. below and tightening with a torque wrench, the
3. Clean the oil passages inside the body. torque must be converted.
• Conversion formula
Actual torque = displayed torque x (effective
length + 87) / effective length
Filter wrench: 8-9801-3170-0
Name
1. Filter Wrench
2. 87mm
3. Effective Length
4. Torque Wrench
5. Displayed Torque
4. Port opening splicing fittings (machine side

components)
• Port opening splicing fittings are not installed to
the engine.
• The tightening torques for the splicing fittings
are shown below.
Special Tool
Tool Number
Special Tool Rank
8-9801-3170-0
Filter wrench
Rank A
Oil Cooler
Components
WSUZ0047
Name
1. Oil Thermostat 8. O-ring
2. Support 9. Gasket
3. Seal Ring 10. Oil Cooler Element
4. Stopper 11. Water Guide
5. O-ring 12. Oil Cooler Case
6. Oil Pipe 13. O-ring
7. O-ring 14. Oil Relief Valve
Disassembly
1. Remove the water guide.
2. Remove the oil cooler element.
• Loosen the nuts on the body case side to
remove.
Note:
Seal the oil passage system to prevent foreign matter
from getting into it.
3. Remove the oil thermostat.
4. Remove the oil relief valve.
5. Clean the oil cooler element.
• Clean if the element is excessively dirty.
• Pour cleaning fluid into the element and soak
the inside for approx. 10 hours. After that
remove approx. 1/3 of the cleaning fluid, then
eject the rest from the oil port by blowing
through approx. 200 kPa {2 kgf/cm2} of Inspection
compressed air. This operation can be
Oil cooler element
repeated a number of times depending on how
dirty the element is. • Check the oil cooler element for cracks.
• Perform red check method inspection as required.
Note:
Fire is strictly prohibited near the cleaning fluid. Wear Note:
protective glasses and masks, and provide for sufficient Check when oil is mixed in the coolant.
ventilation.
Using undiluted Using diluted with

solution light oil
Hi-aromu 2S
(New Nippon { {
Oil)
Suwazoru 310
{ {
(Maruzen)
Hi-zoru
{ {
(Showa)
Mobile Zol A
{ {
(Mobil Sekiyu)
Oil thermostat
• Check the piston and valve seat surface for wear
or damage. Also, check the spring for damage or
weakness.
• Operation check of oil thermostat Assembly

Check whether valve is open between 101.5 and
104.5 °C. 1. Install the oil relief valve (1).
• Set the O-ring and install.
Oil thermostat opening temperature: 101.5 — 104.5°C
1
WSUZ0048
Oil relief valve
2. Install the oil thermostat.
• Check the piston and valve seat surface of body
for wear or damage. Also, check the spring for • Install the thermostat (4), support (3), seal ring
damage or weakness. (2), and stopper (1) into the body case in this
order.
• Face the sealing lip section upwards and install
it to the oil thermostat support.
• Set the O-rings into the both ends of the pipe,
and then install it to the body case.
Tightening torque:
M10: 19.6N⋅m {2.0kg⋅m/14.5lb⋅ft}
M8: 17.2N⋅m {1.8kg⋅m/12.7lb⋅ft}
3. Install the oil cooler element.

• Apply liquid gasket to the two O-ring grooves
on the body case, and then attach the O-ring.
Apply the gasket to the element and install to
the body case.
4. Install the water guide.
Oil cooler
a
b
WSUZ0049
Name
(a) 19.6N⋅m {2.0kg⋅m/14.5lb⋅ft} (d) 34.3N⋅m {3.5kg⋅m/25.3lb⋅ft}

(b) 17.2N⋅m {1.8kg⋅m/12.7lb⋅ft} (e) 19.6N⋅m {2.0kg⋅m/14.5lb⋅ft}
(c) 7.8N⋅m {0.8kg⋅m/5.8lb⋅ft}
Oil Jet
Removal
Oil jet
1. Loosen the joint bolt, and remove the oil jet.
• Check the oil jet, which has removed, for bend
and oil hole for clogging.
Installation
Oil jet
1. Align the oil jet with the knock pin hole and install.
2. Tighten the oil jet by joint bolt.
Note:
Do not deform the tip of the oil jet.
Oil Pump
Components
Name
1. Stay 6. Oil Pump Drive Gear
2. Oil Strainer 7. Driven Gear
3. O-ring 8. O-ring
4. Oil Pump Cover 9. Oil Pipe
5. Oil Pump Body
Removal Backlash of the gear

1. Remove the oil pan. (mm)
2. Measure the backlash of the oil pump gear. Assembly standard Service limit
• Measure the backlash of the oil pump drive
0.15 0.20
gear and crankshaft gear.
Assembly
1. Install the driven gear.
• Apply oil to the driven gear (1), and install it to
the pump body.
3. Remove the oil pump ASM.

Disassembly
1. Remove the oil strainer.
2. Disconnect the oil pipe.
2. Install the oil pump cover.
3. Remove the oil pump cover.
• Pour the clean engine oil between the gears
4. Remove the driven gear.
sufficiently before installing the cover.
Inspection
Oil relief valve
• Oil relief valve cannot be disassembled since it is Note:
sealed. Pouring the engine oil is important to avoid oil pressure
lag when starting the engine.
• Check the ball for scratch, and press the ball to
check if it moves smoothly.
Driven gear
• Clearance between the body inner wall and gear
Assembly standard mm 0.100 — 0196
Oil outlet Oil inlet
Driven gear
WSUZ0151
3. Install the oil pipe.

• Apply liquid gasket to the two O-ring grooves
on the oil pipe, and install.
Note:
Install the oil pipe after installing the oil pump.
4. Install the oil strainer. 2. Install the oil pan.

Check the oil pump operation. Refer to “Oil pan”.
• Rotate the drive gear by hand and confirm that
it operates smoothly.
Installation
• Check for the backlash between the gear.
Tightening torque: M10: 38N⋅m {3.9kg⋅m/28lb⋅ft}
Tightening torque: M8: 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft}
Oil pump
Name
(a) 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft} (d) 38 N⋅m {3.9kg⋅m/28lb⋅ft}

(b) 18.6N⋅m {1.9kg⋅m/13.7lb⋅ft} (e) 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft}
(c) 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft} (f) 21.6N⋅m {2.2kg⋅m/15.7lb⋅ft}
Oil Pan
Components
WSUZ0084
Name
1. Gasket 3. Drain Plug
2. Oil Pan
Removal Installation
1. Drain engine oil. 1. Apply liquid gasket.
• After draining oil, tighten the drain plug to the • Apply liquid gasket (ThreeBond No.TB1207B)
specified torque. by approx. 2 mm in thickness, approx. 3 mm in
width to the mating portion of the cylinder block,
Tightening torque: 70N⋅m {7.1kg⋅m/51.6lb⋅ft} the flywheel housing and the front cover.
Note: Note:
Be sure to tighten the drain plug to the specified torque Clean the applying surface before applying the gasket.
beforehand since it may be left untightened.
2. Remove the oil pan.

• Install it so that identification code “OIL PAN
SIDE” (or silicon coating surface) faces toward
the oil pan side.
• Install the plate so that its white paint faces
outside.
• Tighten the oil pan in the order indicated by
number and arrow in the illustration.
Tightening torque: 19N⋅m {1.9kg⋅m/14lb⋅ft}
Note:
• When tightening the oil pan, tighten several points
again since loose torque will occur.
• Be careful that the gasket has different figure on
each side (right and left, front and rear are
symmetry).
WSUZ0085
Oil pan
WSUZ0052
Name
(a) 19N⋅m {1.9kg⋅m/14lb⋅ft} (b) 70N⋅m {7.1kg⋅m/51.6lb⋅ft}

Intake system (6UZ1X) 1J-1
Engine
Intake system
(6UZ1X)
Contents
Turbocharger System . . . . . . . . . . . . . . . . . . . . . . 1J-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1J-2
List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1J-3
Symptom: If faulty vibrations occur . . . . . . . . . . 1J-4
Symptom: Output is lowered although turbocharger
seems almost normal . . . . . . . . . . . . . . . . . . . . . 1J-5
Symptom: Oil infiltrates into exhaust pipe or intake
pipe, exhaust gas is white . . . . . . . . . . . . . . . . . 1J-6
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-7
Table of Specifications . . . . . . . . . . . . . . . . . . . . 1J-7
Turbocharger Structured Diagram . . . . . . . . . . . 1J-8
Disassembly and Inspection of Turbocharger . . 1J-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-10
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-12
Assembly of Turbocharger . . . . . . . . . . . . . . . . 1J-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-16
1J-2 Intake system (6UZ1X)
Turbocharger System
Service Precautions
• The turbocharger has been designed precisely and
rotates at high speed (approx. 100,000rpm),
therefore if any fault such as bend, scratch is found
on the fin, housing, etc. replace the turbocharger
ASM. The turbocharger cannot be disassembled.
• During service, take measure thoroughly to
prevent foreign matters from getting inside of
them.
• If faulty vibrations occur
• Output is lowered although turbocharger seems
almost normal.
• Oil infiltrates into exhaust pipe or intake pipe.
Exhaust gas is white.
Symptom: If faulty vibrations occur

If faulty vibrations occur Caused by damaged bearing and Replace
contact between rotary part and its
surrounding area.
Bearing failure is caused by
neglecting oil changes, foreign
matters in the feed pipe, clogged oil
filter, driving with a failure, and
repeated sudden starts and stops.
If the lubrication system is normal, Replace
and damage caused by contact
between the rotary part and its
surrounding area is found,
imbalanced rotary part or bent shaft
is suspected. This is caused by
using a worn bearing or damaged
turbine wheel or compressor wheel
due to foreign matters getting in.
Symptom: Output is lowered although turbocharger seems almost normal

Output is lowered although Gas leakage from exhaust system Repair or replace
turbocharger seems almost normal Deformed exhaust muffler, Repair or replace
excessive exhaust resistance due
to carbon deposits
Air leakage from compressor Clean or replace
discharge side, dirt in air cleaner
element
Compressor internal section dirty Clean
Rotor shaft section dirty Clean
Symptom: Oil infiltrates into exhaust pipe or intake pipe, exhaust gas is white

Oil infiltrates into exhaust pipe or Dirt in oil separator, oil bypass due Clean or replace
intake pipe to clogging
Exhaust gas is white Clogged, crushed or deformed Repair or replace
drain pipe
Worn piston ring, or too much Replace
abrasion of the ring slots
Bad bearing is the cause for piston Replace
ring section damage
Turbocharger
Table of Specifications
Assembly
Items Service Limit
Specifications
Turbine shaft Axial play mm (in) 0.06 — 0.09
0.11 (0.00433)
(0.00236 — 0.00354)
Radial play mm (in) 0.10 — 0.17
0.205 (0.00807)
(0.00394 — 0.00669)
Journal outside diameter (A) mm (in) — 11.380 (0.44803)
Sealing groove width (B) mm (in) — 1.33 (0.05236)
Runout mm (in) — 0.011 (0.00043)
Sealing Turbine side (bearing housing) (F) mm (in) — 17.03 (0.67047)
Insertion part
Compressor side (seal plate) (H) mm (in) — 14.05 (0.55315)
Oil thrower Sealing groove width (G) mm (in) — 1.52 (0.05984)
Bearing Bearing housing inner diameter (B) mm (in) — 16.11 (0.63425)
Housing
Thrust bearing inside diameter for (L) mm (in)
— 23.020 (0.96030)
press-fit portion
Thrust Bearing pad height at compressor side (J) mm (in) 0.0 — 0.060
—
bearing (0.0 — 0.00236)
Thrust collar thickness (K) mm (in) — 2.950 (0.11614)
H
F L
B A
K
E G
Turbocharger Structured Diagram
4 5
2 3
10 9
1 8
Name
1. Turbine Housing 6. Seal Plate
2. Heat Protector 7. Compressor Impeller
3. Floating Metal 8. Seal Ring
4. Oil Thrower 9. Seal Ring
5. Compressor Housing 10. Turbine Shaft
Disassembly and Inspection of Turbocharger
Disassembly diagram: disassemble in the order of the numbers.
4 2
3
6
5
13
14
17
16
16
15
8
18
7
11
12
10
9
WSUZ0086
Name
1. Compressor Housing 10. Seal Ring
2. Nut 11. Gasket
3. Compressor Impeller 12. Heat Protector
4. Seal Plate 13. Thrust Bearing
5. Oil Thrower 14. Thrust Collar
6. Seal Ring 15. Snap Ring
7. G Coupling 16. Floating Metal
8. Turbine Housing 17. Thrust Bearing
9. Turbine Shaft 18. Bearing Housing
Disassembly
Caution:
If you perform inspection with the turbocharger
removed from the engine, plug the oil port opening
before work.
Inspection Prior to Disassembly
• Measurement of axial play of turbine shaft
Axial play mm (in)

0.06 — 0.09
Assembly specifications
(0.0024 — 0.0035)
Service limit 0.11 (0.0043)
If it exceeds the service limit, check the thrust

metal, the thrust bushing, and the oil thrower.
• Measurement on the machine of radial play of

turbine shaft
Insert a thickness gauge into the gap between the
compressor impeller and housing, and measure
the clearance.
The thickness gauge to be inserted must be 0.2
mm (0.0078 in) or less.
1. Compressor housing
• Put alignment marks between the compressor
housing and the seal plate, and tap the
compressor housing to drive it out.
• Liquid gasket is applied to the mating surface of
the compressor housing and the seal plate.
Caution:
Take care not to damage the impeller during removal of
the compressor housing.
• Measurement of radial play of turbine shaft
Radial play mm (in)

0.10 — 0.17
Assembly specifications
(0.00394 — 0.00669)
If it exceeds the service limit, check the floating

metal.
1
Name
1. Alignment Mark
2. Compressor impeller 4. Oil thrower
• Attach the box spanner to the turbine-side shaft • Remove the oil thrower from the seal plate.
end of the turbine shaft, and remove the nut. 5. G coupling
(The nut is left-hand screw)
• Loosen the nut and remove the G coupling from
• Remove the impeller from the turbine shaft. the turbine housing and the center housing.
• Washing of impeller 6. Turbine housing
Soak in the cleaning solvent until the foreign
• Remove turbine housing from the center
matters soften, and clean it with a plastic
housing.
scraper or hard brush.
Caution: • Washing of turbine housing
Do not use a wire brush. Soak in the cleaning solvent to remove the
foreign matters.
Name
1. Left-hand Thread 7. Turbine shaft
• Hold the heat protector lightly by hand, and
3. Seal plate take out the turbine shaft.
• Loosen the pot small screw. • If it is hard to remove, lightly tap the
• Lightly tap the bearing housing in the seal plate compressor-side shaft end with a wooden
with a wooden hammer. hammer.
• Liquid gasket is applied to the mating surfaces • Washing of turbine shaft
of the seal plate and the bearing housing. Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic
scraper or hard brush.
Caution:
• Do not use a wire brush.
• Foreign matters remaining on the surface causes
the unbalance of weight. Therefore, wash it
thoroughly.
• Take care not to damage the floating metal contact
surface of the shaft and the seal ring groove.
Inspection
Compressor housing
• Check the compressor housing for crack or
damage, and replace if defective.
8. Heat protector
• Remove the heat protector from the bearing
housing.
9. Thrust bearing (compressor side)
• Loosen the plate small screw with a Turbine housing
screwdriver, and remove the thrust bearing and
• Check the turbine housing for crack or damage,
the thrust collar.
and replace if defective.
10. Floating metal
Impeller
• Remove the turbine-side snap ring with snap
ring pliers. • Check the impeller for scratch, dent or crack.
• Draw out the floating metal from the bearing
housing.
11. Thrust bearing (turbine side)
• Using a brass bar, push out the compressor-
side floating metal from the turbine-side bearing
housing, together with the thrust bearing.
Caution:
While pushing out with a bar, take care that they do not
run on to damage the snap ring.
12. Snap ring
• Remove the 2 snap rings from the bearing
housing with snap ring pliers.
13. Seal ring
• Remove the seal ring from the turbine shaft and
the oil thrower.
Heat protector • Measurement of turbine shaft runout
• Check the heat protector for damage, thermal
deformation or corrosion.
Turbine shaft runout mm (in)
Turbine shaft
• Measure the journal outer diameter of the turbine
shaft, and the groove width of the seal ring
insertion part. Seal plate
• Inspection of damage on the seal plate,
measurement of inner diameter of the seal ring
Journal outer diameter mm (in) insertion part
Service limit φ 11.38 (0.4480)
Inner diameter of the seal ring insertion part mm (in)

Service limit
Groove width of the seal ring insertion part mm (in)
H 14.05 (0.5531)
Name
1. Journal Outer Diameter
2. Ring Groove Width
Oil thrower
• Inspection of damage on the oil thrower sliding mm (in)
surface, measurement of the seal ring groove
Location Service limit
width
Bearing housing inner diameter 16.11
(B)
(0.6343)
Seal ring groove width G mm (in) Turbine-side seal ring insertion 17.03
(F)
Service limit part (0.6705)
G 1.52 (0.0598) Turbine-side thrust bearing 23.02
(L)
press-fit part inner diameter (0.9063)
Thrust collar
• Measure the thrust collar thickness (K), and
replace with new one if it exceeds the service limit.
Measurement of thrust collar thickness K mm (in)

Service limit
K 2.950 (0.11614)
F B L
G coupling
• Replace with new one.
Seal ring
• Replace with new one.
Others
• Check the bolts for deformation, and replace with
new ones if faulty. Also, replace the plate small
screw with new one.
Thrust bearing
• Replace the compressor-side and the turbine-side
thrust bearings with new ones.
Floating metal
• Replace the floating metal with new one.
Bearing housing
• Check the casting surface for peeling from
oxidation-deterioration, dent or crack. Replace with
new one if faulty.
Assembly of Turbocharger
Assembly diagram: Assemble in the order of the numbers.
18
15 17
16
13
14
9
8
4
3
3
11
1
12
10
6
5
7
WSUZ0087
Assembly Procedure
1. Bearing Housing 10. Gasket
2. Snap Ring 11. Turbine Housing
3. Floating Metal 12. G Coupling
4. Thrust Bearing 13. Seal Ring
5. Seal Ring 14. Oil Thrower
6. Heat Protector 15. Seal Plate
7. Turbine Shaft 16. Compressor Impeller
8. Thrust Collar 17. Nut
9. Thrust Bearing 18. Compressor Housing
Assembly
1. Bearing housing
• Check that the bearing housing is free of
damage and foreign matters.
2. Snap ring
• Install the 2 snap rings to the bearing housing
with snap ring pliers.
• After assembling the floating metal (turbine
side), install the snap ring at the position shown 1
in the figure.
Name
1. Apply Oil.
4. Thrust bearing
a. Press-fitting of turbine-side thrust bearing
1 • Press-fit the turbine-side thrust bearing into the
bearing housing.
• Position the pawl of the turbine-side thrust
bearing for more than 2 mm (0.0787in) apart
from the existing press-fitting part.
• Do not press the thrust bearing pad surface
Name during press-fitting.
1. Turbine-Side Floating Metal
• The press-fit pressure must be between 215.6
3. Floating metal N {22.0 kgf} and 1862 N {190 kgf}.
• Apply oil to the floating metal, and assemble it • After press-fitting, remove the dust powder by
to the bearing housing. vacuum.
After securing it with a snap ring, assemble the b. After press-fitting, check the depth and flatness of
compressor-side floating metal. the turbine-side thrust bearing.
Caution: (Depth 3.08±0.02 mm {0.1213±0.0008 in},
• Place the snap ring with its rounded-side facing to Flatness is below 0.01 mm{0.0004 in}: See
the floating metal. illustration)
• Assemble the inner snap ring with its end gap
facing to the oil outlet-direction of the housing, to
prevent it from blocking the oil path.
• Assemble the turbine-side snap ring to the housing
with its end gap facing to the direction as shown in
the illustration.
• Apply oil to the floating metal before assembly.
Besco super engine oil

8. Thrust collar
mm(in)
• Apply engine oil to the thrust collar, and install it
to the turbine shaft.
9. Thrust bearing
• Apply engine oil to the metal portion of the
thrust bearing, and insert it to the bearing
3.08 0.02
(0.1213 0.0008)
housing.
• Apply Loctite to the plate small screw threads,
and install it using torque screwdriver.
1
Tightening torque: 3.7 N⋅m (0.38 kgf⋅m/33 lb in)

0
12
120
WSHK0147
Name
1. Common Tolerance
1
5. Seal ring
• Insert the seal ring to the turbine shaft.
• Use new seal ring.
6. Heat protector
• Install the heat protector to the bearing housing.
7. Turbine shaft
• Apply engine oil to the journal portion of the
turbine shaft, and insert it from the turbine side
of the bearing housing.
Name
• Take care not to damage the floating metal with 1. Apply Oil.
the turbine shaft. Also, insert with the end gap
of the seal ring facing to the oil inlet side so that 10. Gasket
its core matches with the turbine shaft.
• Set the gasket to the turbine housing, and
install it to the bearing housing.
11. Turbine housing
• Assemble by aligning the phase of the turbine
housing and the bearing housing with the
turbine housing positioning pin and the bearing
housing hole.
1
Name
1. Apply Oil.
Hammering procedure
1) Using a metal hammer (Approx. 250g in weight),
lightly tap 2 to 3 times (same place), from the
outer portion toward the center.
2) Do not hammer the G coupling directly. Place
brass bar between as shown in the illustration.
150 ~ 200 mm
2 (6 ~ 8 in) 3 4
12. G coupling 1
a. Check that it does not run on the turbine housing

or the bearing housing. 7 6
b. Tighten temporarily to the specified torque using a
torque wrench.
WSHK0153
Name
Tightening torque: 83 N⋅m (8.5 kg⋅m/61 lb ft)
1. Approx. φ13 mm (0.5 in)
c. Hammering: Perform the hammering of (1) to (6) 2. Hammer
in the numerical order, using the following 3. G Coupling
procedure. 4. Bearing Housing
d. Tighten to the specified torque using a torque 5. Gasket
wrench. 6. Heat Shield Plate
7. Turbine Housing
Tightening torque: 83 N⋅m (8.5 kg⋅m/61 lb ft) 13. Seal ring

e. Perform (c) and (d) of the above step again. • Install the seal ring to the oil thrower.
• Use new one.
14. Oil thrower
• Insert the oil thrower into the seal plate.
2
• Insert with the end gap of the seal ring facing to
the oil inlet side.
1 3 15. Seal plate
A
• Apply liquid gasket to the turbine-side flange
3 surface. Application thickness 0.1 — 0.2mm
(0.004 — 0.008 in) (B)
1 2
4 6 ThreeBond No. 1207
5
• Install the seal plate to the bearing housing.
• Apply Loctite (B) to the pot small screw threads,
and install it using torque screwdriver.
Name Tightening torque: 23 N⋅m (2.3 kg⋅m/17 lb ft)

1. Approx. 60°
2. Approx. 60°
3. Torque Wrench
B
A
16. Compressor impeller Check after assembly

• Insert the compressor impeller to the turbine • Make sure that the axial play and radial play of
shaft. rotor are within the specified value.
17. Nut See (1J-10) for inspection.
• Attach the box spanner to the turbine-side shaft
end of the turbine shaft, and tighten the nut.
• The nut is left-hand thread. Make sure the
turning direction.

18. Compressor housing
• Apply liquid gasket to the compressor-side
flange surface of the seal plate. Illustration
shown in the previous page (A)
Application thickness 0.1 — 0.2mm (0.004 —
0.008 in)
ThreeBond No. 1207
• Align the alignment marks that marked during

the disassembly, and assemble the compressor
housing to the seal plate.

Preheating System (6UZ1X) 1K-1
Engine
Preheating System
(6UZ1X)
Contents
Preheating System . . . . . . . . . . . . . . . . . . . . . . . . 1K-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1K-2
Description of Function and Operation. . . . . . . . 1K-2
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . 1K-3
List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1K-5
Symptom: Glow Indicator Lamp Does Not Light Up
(Varies depending on the machine) . . . . . . . . . . 1K-6
Symptom: Preheating Is Not Performed . . . . . . 1K-7
Symptom: Preheating Time Is Too Long or Too Short . . . . 1K-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1K-8
1K-2 Preheating System (6UZ1X)
Preheating System
Service Precautions
glow plug could lead to damage.

The preheating system employs QOS-II system. Also,
the timer is controlled by the controller.
Function Check
Check and repair of QOS II • If the measured value deviates from the
1. System check specified value, replace the glow relay.
Glow plug resistance value = approx. 51.5 Ω
• Disconnect the connector of the thermo-sensor (Varies depending on the machine)
(1).
WSUZ0088
3. Thermo-sensor check
• Connect a voltmeter between the glow plug and
• Immerse the thermo-sensor into water, and
the engine ground.
check if the resistance value varies as shown in
• Turn the starter switch to ON (engine stopped), the graph while changing the water
and check the followings: temperature.
- The glow indicator should come on for 3.5
seconds.
- The voltmeter should indicate the battery
voltage for approx. 18 seconds.
• If the result of the inspection is unsatisfactory,
check the glow relay, thermo-sensor and glow
plug. If it is normal, check the engine control
system.
2. Glow relay check

• Use a circuit tester to measure the resistance
value (between 1 and 2) of the glow relay.
)
Resistance (K
Engine temperature ( )
WSUZ0152
4. Glow plug check

• Use a circuit tester to measure the resistance of
the glow plug.
• If the measured value deviates from the
specified value, then replace the glow plug.
Resistance of glow plug = approx. 4.3Ω (at normal

temperature)
Note:
Use a set of six glow plugs by same manufacturer.
• The glow indicator lamp does not light up
• Preheating is not performed
• Preheating time is too long or too short
Symptom: Glow Indicator Lamp Does Not Light Up (Varies depending on the machine)

The glow indicator lamp does not Slow-blow fuse blown-out Replace the slow-blow fuse
light up Blown fuse Replace the fuse
Indicator valve is burnt out Replace the indicator valve
Symptom: Preheating Is Not Performed

Preheating is not performed Slow-blow fuse blown-out Replace the slow-blow fuse
Poor contact or faulty glow relay Re-install or replace the glow relay
connector
Symptom: Preheating Time Is Too Long or Too Short

Preheating time is too long or too Thermo-sensor fault or open/short Replace the thermo-sensor Repair
short circuit the circuit
Faulty glow plug Replace or tighten the glow plug
Specifications
Item Model
Preheating system Glow plug/QOS timer
Glow plug rated voltage/current (V-A) 23 - 3.0
Book Number 2010
Printed in USA
6UZ1 - TIER 3
ISUZU ENGINE
WORKSHOP MANUAL
6UZ1 ISUZU ENGINE - WORKSHOP MANUAL

Motor 6U

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6UZ1 - Tier 3

7. When using devices such as a grinder, crane and

4. In badly ventilated indoor workshop, do not run the

Sealed Location Product Name Manufacturer

Sealed Location Product Name Manufacturer

• Be sure to use liquid gasket of product name How to use Plastigauge

• Carefully remove the cap and the connecting rod,

(Example) Measurement of clearance between

Stamping position of engine number

Abbreviation Abbreviation Description

Relationship between SI and conventional units

SI Conventional Unit Item, Unit Conversion

Conversion of numeric representation

M Mega 106 1,000,000

• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa

Pipe Diameter Tightening Torque (for Width across flats of Flare

Special tool types

Service precautions specific to this engine

Adjusting the valve clearance

Valve clearance (at cold condition):

Cylinder No. and Conditions

(The cylinder that is marked with a circle is adjustable.)

The compression pressure is lowering.

Rate of increase in engine oil consumption

Rate of increase in fuel consumption

Noise inside of engine

Engine Exterior Equipment

Removal Sensor and device Name of installed parts

• Remove the water feed (1) and (2) for EGR

• Remove EGR water pipe brackets (6) and the

4. Remove the oil level guide tube.

9. Remove the inlet duct (1).

6. Remove the fuel filter ASM.

10. Remove the injection pipe (1).

15. Remove the turbocharger ASM. 2

18. Remove the oil cooler.

• Remove the engine foot (1).

WSUZ0106 2. Install the thermostat housing.

EGR reed valve Tightening torque: 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft}

• Install the water duct (2) and BRKT (1).

Tightening torque: 21.6N⋅m {2.2kg⋅m/15.9lb⋅ft}

Tightening torque: 43.8N⋅m {4.5kg⋅m/32.3lb⋅ft} 3. Install the engine foot.

4. Install the oil cooler. 5. Install the oil port cover.

• Tighten the bolt from outwards to the center. WSUZ0064

Tightening torque: 50N⋅m{5.1kg⋅m/36.9lb⋅ft} 6. Install the exhaust manifold ASM.

• Keep the molybdenum coating (black) side

Tightening torque: 53.9N⋅m{5.5kg⋅m/39.8lb⋅ft}

Tightening torque: 50N⋅m{5.1kg⋅m/36.9lb⋅ft}

7. Install the turbocharger ASM.

Tightening torque: 40N⋅m{4.1kg⋅m/29.5lb⋅ft}

• Apply ThreeBond No.TB1208 to 3 parts of the

• Make sure the nick line (P/P) of the flywheel is

• Install the high-pressure pipe between the

15. Install BRKT (1) between the fuel filter brackets

Tightening torque: 43.8N⋅m{4.5kg⋅m/32.3lb⋅ft}

13. Install the inlet duct.

16. Install the fuel filter ASM.

Tightening torque: 45N⋅m{4.6kg⋅m/33.2lb⋅ft}

20. Install the EGR device.

2) Assemble the EGR duct B.

22. Assemble the EGR device following the instruction

4) Install the exhaust side EGR cooler brackets.

Tightening torque: 97N⋅m {9.9kg⋅m/71.5lb⋅ft}

23. Final tightening order