Professional Documents
Culture Documents
PF series
PF6,PF6T & PF6TA
& PF6TB
Pub.No. SMEPFS2E01
ENGINE QUICK REFERENCE INDEX
SERVICE
GENERAL GE
MANUAL
MAINTENANCE MA
TROUBLE DIAGNOSIS TD
MODEL
ENGINE DISASSEMBLY AND REASSEMBLY DR
PF series
PF6: PF6-101001 ∼ ENGINE PROPER EP
PF6T: PF6-101001T ∼
PF6TA: PF6-101001A ∼ CYLINDER HEAD AND VALVE HV
PF6TB: PF6-101001B ∼
LUBRICATION SYSTEM LB
COOLING SYSTEM EC
FUEL SYSTEM EF
FOREWORD
This manual describes the service, by system, of
the engines of PF6, PF6T, PF6TA and PF6TB mod- AIR INTAKE AND EXHAUST SYSTEM IE
els.
In order for a vehicle to perform at its best, and to
extend vehicle life, maintenance should be per- ELECTRICAL SYSTEM EE
formed properly. Also, overhaul and repair should be
effected in accordance with prescribed service stan-
dards. AUXILIARY EQUIPMENT EA
This manual should be kept readily available in the
workshop as a helpful reference for those engaged in
servicing vehicles. Nissan Diesel Motor Co., Ltd.
reserves the right to make changes for improvement
at any time without notice.
This manual is based on vehicles that were manu-
factured on or before May 1, 1996. Revisions, if any,
will be introduced in the Technical Bulletin.
X A QUICK REFERENCE INDEX is provided on the first page: Refer to this index along with the index
of the particular section you wish to consult.
X The first page of each section lists the contents and gives the page numbers for the respective top-
ics.
X SERVICE DATA AND SPECIFICATIONS are contained in each section.
X A list of SPECIAL SERVICE TOOLS is included in each section. The special service tools are
designed to assist you in performing repair safely, accurately and quickly.
X Construction illustration:
The assembled unit is indicated. The construction illustration includes the names of the major compo-
nents, items requiring adjustment after reassembling and their maintenance standards.
[EXAMPLE]
-1-
X Exploded illustration:
The number given to each part in the illustration corresponds to the number attached to each part
name, and the number is determined according to the operation sequence.
No. 1, 2, 3 Disassembly sequence
Reassembly sequence is in the reverse order of disassembly.
The marks “+” and “,” affixed to the part name number indicate that the key points of operation (pre-
cautions, technique, use of special tools, and other maintenance information) are explained in the text.
+Key points of disassembly
,Key points of reassembly
The tightening torque necessary for maintenance and lubricating points are indicated by symbols in the
illustration.
NOTE
z Disassembly and reassembly sequences show general examples and in some operations it
may be possible to change sequences.
-2-
X Removal and installation, disassembly and reassembly:
Explanation of removal and installation, disassembly and reassembly is limited to the parts indicated
by the star marks “+”and “,” affixed to the sequence number in the exploded illustration.
NOTE
z If there are no “+” and “,” marks affixed to the parts, general explanation is given for those
parts.
Abbreviations
T.D.C. : Top dead center I.D. : Inside diameter
B.T.D.C. : Before top dead center Dia. : Diameter
A.T.D.C. : After top dead center S.T.D. : Standard
B.B.D.C. : Before bottom dead center O.S. : Oversize
A.B.D.C. : After bottom dead center U.S. : Undersize
O.D. : Outside diameter Ass'y : Assembly
X Engine position:
X Unit:
This manual uses mainly SI units with metric and yard/pound system equivalents in braces.
X Specific terms related to the maintenance standard
z Maintenance standard
“Maintenance standard” indicates the standard clearance when parts are assembled or the standard
performances of assembly parts.
z Service limit
“Service limit” indicates the limit value where adjustment, correction or parts replacement must be
done.
X The captions WARNING and CAUTION warn you about procedures that must be followed to pre-
vent personal injury and/or damage to some parts of the vehicle.
-3-
GE
GENERAL
CONTENTS
SPECIFICATIONS .............................. GE-1-1 PRECAUTIONS ON MAINTENANCE..... GE-3-1
ENGINE SPECIFICATIONS ...........GE-1-1 GENERAL PRECAUTIONS IN
ENGINE NUMBERS.......................GE-1-3 DISASSEMBLY ........................... GE-3-1
LUBRICATION ................................. GE-2-1 CLEANING AND INSPECTION ... GE-3-2
GENERAL PRECAUTIONS TIGHTENING TORQUE OF
ON SERVICING............................... GE-3-1 STANDARD BOLTS........................ GE-4-1
SPECIFICATIONS
SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine model
PF6 PF6T PF6TA PF6TB
Item
Type Diesel
Aspiration system Natural Turbocharged Turbocharged with intercooler
Cooling method Water cooled
Number of cylinders and cylinder arrangement 6, in-line
Stroke cycle 4
Combustion chamber Direct fuel injection
Valve mechanism Overhead
Cylinder liner Dry
Bore x stroke mm (in) 133.0 x 150.0 (5.236 x 5.906)
Total displacement cm3 (cu in) 12,503 (763)
Compression ratio 18.0 16.5
Cylinder compression 2 3,040 {31,441}/200 ± 20
kPa {kgf/cm , psi}/rpm
Maximum engine speed under full load conditions rpm 2,300
Limit speed governor 500 - 530
Idle speed rpm
All speed governor 550 - 600
Compression ring 2
Number of piston rings
Oil ring 1
Open B.T.D.C. 20º 16º
Intake valve
Closed A.B.D.C. 42º 20º
Valve timing
Open B.B.D.C. 52º 52º
Exhaust valve
Closed A.T.D.C. 12º 12º
GE-1-1
SPECIFICATIONS
Engine model
PF6 PF6T PF6TA PF6TB
Item
Cooling method Water cooled, forced circulation
Radiator Corrugated fin
Number of fins 6
Cooling fan Fan clutch change over temperature 60 - 70 60 - 70 (140 - 158) [On-off type]
Cooling system
Model T51
Max. permissible continuous speed
105,000
Turbocharger rpm
Counterclockwise as viewed from the exhaust turbine
Direction of rotation
side
Type Air to air
Intercooler
Intercooler Corrugated fin
Intake and Type Cylinder
exhaust shut-
ter Operation Air
NOTE
*1 CKB454, 455, CWB454, 455
*2 CKB453, CWB453, 455
GE-1-2
SPECIFICATIONS
Engine model
PF6 PF6T PF6TA PF6TB
Item
Model S210-112, 0350 602 0260, 0350 602 0330
Starting motor Type Shift
Output V-kW 24-6.0
LR240-602, LR240-603, LR250-602, LR250-603
Model
0201 102 0290, 0201 102 2973, 0201 152 0020, 0201 152 0053
Electrical system
ENGINE NUMBERS
The engine serial number is stamped on the right of the cylinder
block.
PF6—101001
PF6—101001 T
PF6—101001 A
PF6—101001 B
T: With turbocharger
A: With turbocharger and intercooler
B: With turbocharger and intercooler
Engine serial number
Engine model
GE-1-3
LUBRICATION
LUBRICATION
RECOMMENDED FUEL AND LUBRICANTS
Lubricant/Fluid Specifications Remarks
For further details, refer to the recom-
Engine oil API CC or CD
mended SAE viscosity number.
Grease NLGI No. 2 Lithium soap base
Antifreeze Ethylene glycol base
2-D Diesel fuel or equivalent
Above -7ºC (20ºF) Check with the service establishment
blended diesel fuel
Fuel to be sure you get the properly
1-D Diesel fuel or equivalent blended fuel.
Below -7ºC (20ºF)
blended diesel fuel
NOTE
z It is recommended that API CD class multi-grade oil be used as engine oil for turbocharged
engines.
CAPACITIES (APPROXIMATELY)
Unit: liter (Imp gal)
Item Refill capacities
System total capacity
Lubrication oil capacity 29 (6-3/8)
Engine oil (With oil filter)
(gauge H-level)
Oil pan (H-level) 21 (4-5/8)
Cooling system 37 (8-1/8)
130 (28-5/8)
200 (44)
Fuel tank 300 (66)
200 (44) + 200 (44)
300 (66) + 300 (66)
NOTE
z Capacities shown are for reference only. When filling, observe the specified level.
GE-2-1
GENERAL PRECAUTIONS ON SERVICING
GE-3-1
GENERAL PRECAUTIONS ON SERVICING
Reinstallation
Install parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.).
Apply a coat of grease, liquid packing or sealer to designated parts.
Adjustment and operational checks
Use gauges or testers to adjust the parts within specifications if so designated. Also check movable parts for
proper operation.
METAL PARTS
Light oil
Unlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless the
surface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with two
washings.
Alkaline solution
Do not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steel
and cast iron parts quite well.
NOTE
z If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent
(such as boric acid solution), since the alkaline solution must be immediately washed from the
skin or eyes in the event of contact.
RUBBER PARTS
Do not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.
OIL PASSAGES
Pass a wire through oil passages, to make sure that they are free. Clean the oil passages with solvent that is
injected under pressure from a nozzle.
PROTECTION AGAINST CORROSION
After removing all traces of old oil and grease from the surfaces of the parts, apply a coat of clean oil to them to
prevent corrosion.
INSPECTION
Parts should be inspected using designated measuring instruments or tools. Whether the parts are suitable for
further use should be determined by consulting the specified Maintenance Standards chart. Faulty parts should
be corrected or replaced as required. If one of the mating parts is found to be worn to such an extent that the
specified clearance is exceeded, replace it and/or its mate as the occasion demands.
Parts which are still within the service limit should sometimes be replaced before they exceed the limit from
preventive maintenance viewpoint.
All parts should be checked carefully by looking at their appearance or by using the “red” (penetration) method,
whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities,
the affected part(s) should be repaired or replaced, as required.
All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed.
GE-3-2
GENERAL PRECAUTIONS ON SERVICING
Abnormalities
z Uneven wear
z Graded wear
z Scratches
z Cracks
z Deformity
z Fatigue or weakness (for springs)
z Bends
z Loose fit
z Unusual noise (for bearings)
z Discoloration or jamming
z Rust formation
z Deterioration (for brake linings, etc.)
GE-3-3
TIGHTENING TORQUE OF STANDARD BOLTS
NOTE
z Special parts are excluded.
z This standard is applicable to bolts having the following marks embossed on the bolt head.
Material code Mark
4T 4 or 40
4T 7 or 70
9T 9 or 90
GE-4-1
- MEMO -
MA
MAINTENANCE
CONTENTS
SERVICE DATA................................. MA-1-1 MAINTENANCE PROCEDURE ....... MA-4-1
SERVICE DATA............................ MA-1-1 BASIC MECHANICAL SYSTEM .. MA-4-1
TIGHTENING TORQUE ............... MA-1-2 LUBRICATION SYSTEM.............. MA-4-5
TOOLS.............................................. MA-2-1 COOLING SYSTEM ..................... MA-4-9
PERIODIC MAINTENANCE FUEL SYSTEM .......................... MA-4-14
SCHEDULES................................... MA-3-1 INTAKE AND EXHAUST SYSTEM........ MA-4-24
MAINTENANCE INTERVALS....... MA-3-2 OTHERS .................................... MA-4-28
PERIODIC PARTS REPLACEMENT... MA-3-4
SERVICE DATA
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit v
0.30 - 0.40
Intake valve
Valve clearance (0.012 - 0.016)
(While cold) 0.30 - 0.40
Exhaust valve
(0.012 - 0.016)
Intake Open 20º B.T.D.C.
valve Closed 42º A.B.D.C.
PF6
Exhaust Open 52º B.B.D.C.
valve Closed 12º A.T.D.C.
Valve timing
Intake Open 16º B.T.D.C.
PF6T valve Closed 20º A.B.D.C.
PF6TA
PF6TB Exhaust Open 52º B.B.D.C.
valve Closed 12º A.T.D.C.
Cylinder compression pres- PF6, PF6T, PF6TA 3,040 {31, 441} 2,059 {21, 299}
sure At 180 - 220 rpm
2 PF6TB 3,040 {31, 441} 1,961 {20, 284} (With engine warm)
kPa {kgf/cm , psi}
Compression pressure difference
Less than 392 {4, 57}
kPa {kgf/cm2, psi}
Open water tank cap valve pressure 49 - 69
Pressure side
kPa {kgf/cm2, psi} {0.5 - 0.7, 7 - 10}
8 - 12
Fan pulley - Tension pulley With a force of about 98 N
Deflection of (0.31 - 0.47)
{10 kgf, 22 lbf} applied to
V-belt Idler (cooler compressor) pulley 15 - 18 the mid part
- Alternator pulley (0.59 - 0.71)
Valve opening temperature 74.5 - 78.5 73.0 - 80.0
ºC (ºF) (166 - 173) (163 - 176)
Thermostat
More than More than
Valve lift mm (in)/ºC (ºF)
10 (0.39)/90 (194) 8.5 (0.335)/90 (194)
PF6 16º
PF6T 17º
NOTE
z CKB454, 455, CWB454, 455
z CKB453, CWB453, 455
MA-1-1
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque Remarks
Valve clearance adjusting screw lock nut 34 - 44 {3.5 - 4.5, 25 - 33}
1st 88 - 98 {9.0 - 10.0, 65 - 72} Snug torque
Cylinder head bolt L = 147 mm (5.79 in) 85º - 95º Tightening angle
2nd
L = 119 mm (4.69 in) 70º - 80º Tightening angle
1st 34 {3.5, 25}
Cylinder head sub bolt
2nd 44 - 54 {4.5 - 5.5, 33 - 40}
Intake manifold nut 49 - 54 {5.0 - 5.5, 36 - 40}
Exhaust manifold nut 29 - 44 {3.0 - 4.5, 22 - 33}
Crank damper bolt 98 - 108 {10.0 - 11.0, 72 - 80}
Oil pan drain plug 98 - 127 {10.0 - 13.0, 72 - 94}
Center bolt 49 - 59 {5.0 - 6.0, 36 - 43}
Full-flow and bypass oil filter
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
MA-1-2
TOOLS
TOOLS
Tool name and number Description Shape
Feeler gauge For adjusting valve clearance
99541 Z5000 Thickness mm (in)
0.25 (0.0098), 0.3 (0.012), 0.35 (0.0138), 0.4
(0.016), 0.45 (0.0177), 0.5 (0.020)
Compression gauge hose Used with the compression gauge (99640 96000)
99644 97000 when the gauge cannot
be installed directly due to interference with the air
duct, etc.
MA-2-1
TOOLS
MA-2-2
MAINTENANCE SCHEDULES
MAINTENANCE SCHEDULES
Abbreviations:
I = Inspect. Correct, adjust or replace if necessary.
A = Adjust R = Replace C = Cleaning
RB = Rebuilding T = Tighten to specified torque F = Initial maintenance
NOTE
z The maintenance or lubrication services shown below are to be performed at the indicated
intervals (km, miles or months, whichever occurs first).
z Scheduled maintenance services beyond 60,000 miles (36,000 km) or 12 months should be con-
tinued at the same intervals as before except the initial maintenance.
z Under the following severe operating conditions, more frequent servicing will be required.
— Operation in heavy dust conditions
— Operation at extremely low or high ambient temperature
— Extended high-speed operation with vehicle fully-loaded to its GVWR
— Extended low-speed operation
— Frequent stop-and-go operation
z Any replacement parts used for required maintenance service or repairs should be genuine
parts or equivalent in quality and design to genuine parts.
MA-3-1
MAINTENANCE SCHEDULES
MAINTENANCE INTERVALS
Maintenance intervals
Kilometers x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Items Remarks
Miles x 1,000 Daily 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months – 1 2 3 4 5 6 7 8 9 10 11 12
Valve clearance I I
Manifold bolts T T
I : After 200,000 km (125,000 miles)
Crank damper
I : Every 100,000 km (60,000 miles)
Cylinder compression pressure I
Oil leakage I I I I I I I I I I I I I I
Engine oil and Oil R R: Every 10,000 km (6,000 miles) or 6 months (1)
filter
Oil filter R: Every 10,000 km (6,000 miles) or 6 months (1)
Coolant leakage I I I I I I
Coolant level I I I I I I I I I I I I I
Coolant (incl. anticorrosive) R R (3)
Coolant (incl. antifreeze) R (4)
Water tank cap I
Fan clutch I
V-belt I I I I I I I I I I I I I
Thermostat I
Injection timing I
Nozzle (injection pressure and pat-
I
tern)
Fuel leakage I I I I I I I I I I I I I I
I I I I I I
Fuel filter (6)
Drain Drain Drain Drain Drain Drain
Fuel filter element R
I I I I I I I I I I I I
Primary fuel filter
Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain
Primary fuel filter element R R
Fuel level I
Air cleaner element I/C I/C I/C I/C I/C I/C (2)
Air cleaner element (Dry type) R (2)
Air cleaner element (Metallic type) R: Every 3 years (2)
Condition of exhaust I I I I I I I I I I I I I
Remarks:
1. Replace the engine oil and oil filter whenever the oil filter warning light comes on, even before the
scheduled replacement.
2. If the warning light comes on even before the scheduled replacement, clean or replace element.
3. Service every 6 months.
4. Service every 12 months.
5. With turbocharger engine equipped vehicles only.
6. Center bolt type
MA-3-2
MAINTENANCE SCHEDULES
MA-3-3
MAINTENANCE SCHEDULES
MA-3-4
MAINTENANCE PROCEDURE
MAINTENANCE PROCEDURE
BASIC MECHANICAL SYSTEM
VALVE CLEARANCE
NOTE
z Ensure the engine is cool when checking and adjusting
the valve clearance.
1. Align the flywheel housing pointer with the stamp on the fly-
wheel.
NOTE
z When turning the flywheel to align the stamp, turn it
counterclockwise when viewed from behind the engine.
2. When the stamps on the injection pump housing and timer
are close to each other, it indicates T.D.C. on the compres-
sion stroke. When they are located opposite to each other, it
indicates T.D.C. on the exhaust stroke.
Lock nut
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
MA-4-1
MAINTENANCE PROCEDURE
MA-4-2
MAINTENANCE PROCEDURE
Intake manifold
: 49 - 54 N·m {5.0 - 5.5 kgf·m, 36 - 40 ft·lbf}
Exhaust manifold
: 29 - 44 N·m {3.0 - 4.5 kgf·m, 22 - 33 ft·lbf}
NOTE
z Tighten the nuts evenly to the specified torque, starting
from the inside then to the outside.
MA-4-3
MAINTENANCE PROCEDURE
CRANK DAMPER
Check the crank damper for cracks or flaking, and the mounting
bolts for looseness. Replace faulty parts if necessary.
Crank damper
: 98 - 108 N·m {10.0 - 11.0 kgf·m, 72 - 80 ft·lbf}
NOTE
z Be careful not to confuse peeling paint for cracks.
MA-4-4
MAINTENANCE PROCEDURE
NOTE
z Measure the cylinder compression pressure with the
engine warm. Measure each cylinder two or three times
and average the measured values. Use the average value
as a reference value. Measurement should be done in all
the cylinders.
LUBRICATION SYSTEM
ENGINE OIL LEAKAGE
Check the cylinder head, front cover, oil pan, oil filters and other
related parts for sign of leakage. If necessary, replace gaskets.
After replacing the gasket, check that point to ensure there is no
leakage.
Check the engine oil level and contamination of engine oil before
driving vehicle each day and when you stop for fuel. Check the oil
level and contamination of engine oil with the engine off. When
checking the oil level after stopping the engine, wait at least 6 min-
utes to allow the oil to return to the oil pan.
MA-4-5
MAINTENANCE PROCEDURE
3. If oil level is low, add engine oil of the proper viscosity for
the anticipated temperature range during the service inter-
val through the oil filler port on the valve cover. After adding
oil, wait at least 6 minutes, then recheck the oil level. Do not
add oil above the high mark on the dipstick.
CAUTION
z Do not drive the vehicle with the oil level below the low
mark on the oil dipstick. An insufficient quantity of
engine oil can cause engine seizure.
z Use care to keep dirt and debris from entering the crank-
case through the oil filler port when adding engine oil.
Avoid spilling oil. Clean up any engine oil that spills acci-
dentally.
NOTE
z To check the oil level and to add oil while the cab is being
tilted, there is a sub oil dipstick and oil filler.
The engine oil and oil filter change interval varies with the type of
engine oil used and vehicle driving conditions. If the vehicle is
driven for extended periods of time at high or low speeds, in dusty
areas, with frequent idling or carrying heavy loads, engine oil will
deteriorate faster and require more frequent changing.
As the temperature rises, the engine oil's viscosity decreases,
reducing its lubricating effect. To choose an oil with the proper vis-
cosity for the anticipated ambient temperature range, refer to the
viscosity chart in the “GE” section of this manual.
MA-4-6
MAINTENANCE PROCEDURE
2. Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly. (if equipped)
3. Place a container under the drain plugs in the bottom of the
oil pan and oil filter. Remove the plugs and drain the oil into
the container.
4. When all the oil has been drained from the oil pan and oil fil-
ter, replace the drain plugs in the drain hole and tighten the
drain plugs.
Oil pan drain plug
: 98 - 127 N·m {10.0 - 13.0 kgf·m, 72 - 94 ft·lbf}
5. Replace the oil filter. See the instructions under the caption
OIL FILTER.
6. Add engine oil through the oil filler port to the specified
level.
Refer to the oil capacities in the “GE” section of this manual.
7. After refilling the engine oil, wait for at least 6 minutes, then
using the dipstick check the oil level. If the oil level is low,
add additional oil. Wait 6 minutes, then recheck the oil level.
Repeat this procedure until the engine oil reading on the
dipstick is between the high and low marks.
8. Install the engine undercover (if equipped).
Oil filter
WARNING
WARNING
z Do not handle hot oil filter without hand protection. Fail-
ure to do so may result in burn injury.
NOTE
z Use genuine filter or equivalent in quality and design.
z Always replace the oil filter at the same time engine oil is
replaced.
MA-4-7
MAINTENANCE PROCEDURE
MA-4-8
MAINTENANCE PROCEDURE
COOLING SYSTEM
WARNING
WARNING
z To help avoid serious personal injury from hot coolant or
steam release:
z Do not open the water tank cap while the engine cooling
system is hot. Wait until it cools down.
z Be extremely careful when opening the water tank cap.
Place a thick cloth on the cap and slowly loosen it to
allow a reduction in pressure in the cooling system.
COOLANT LEAKAGE
Check the cooling system for leakage, especially at tube and hose
connections. Also check piping for fractures, cracks or damage.
Replace parts if faulty.
If water leaks through the small hole in the water pump body, the
water seal may be faulty.
Replace the water pump with a new one.
COOLANT LEVEL
Check the coolant level daily only when the engine is cool.
Check the coolant level in the coolant reservoir tank located in rear
of the cab.
The coolant level should be between the HIGH and LOW lines. If
the coolant level is below the LOW line, add the proper coolant
solution to the HIGH line.
MA-4-9
MAINTENANCE PROCEDURE
CAUTION
z Antifreeze made with methoxy propanol or propylene
glycol is not recommended for use with Nissan Diesel
engines. These types of antifreeze can damage engine
internal seals and coolant hoses and create a potential
fire hazard due to lower flash points than ethylene glycol
type antifreeze.
z Use only municipally supplied water (tap water) in the
cooling system. River, well or other water produces scale
in the cooling system, which may cause damage to the
engine or cooling system.
z Do not add water without adding ethylene glycol anti-
freeze to the engine cooling system, except in an emer-
gency. If plain water is added in an emergency, restore
the proper mixture of antifreeze and water as soon as
possible.
z If the coolant should get extremely low and the engine
very hot, let the engine cool before adding coolant; then,
with the engine running, add coolant slowly. Adding cold
coolant to a hot engine may crack the cylinder head or
crankcase. Never use water alone.
MA-4-10
MAINTENANCE PROCEDURE
MA-4-11
MAINTENANCE PROCEDURE
FAN CLUTCH
Ensure that the engine is off when checking the fan clutch.
1. Check the fan clutch for oil leakage. If leakage is present,
replace the fan clutch assembly.
2. Check the fan clutch for proper operation:
z Rotate the cooling fan by hand (adjacent parts should be
cool) to ensure it moves smoothly without binding.
z Then, start the engine and operate it until the pointer of the
water temperature gauge stays within the “H” range. Stop
the engine to ensure that the cooling fan no longer rotates
by hand.
NOTE
z The fan clutch operates in a manner similar to a “direct
drive” when the temperature of parts near the bimetal
located at the front center of the clutch reaches approxi-
mately NºC (NºF). For this reason, it is best to measure
the temperature of those parts to assure proper mainte-
nance during inspection.
Unit: ºC (ºF)
Run the engine con- Operating temperatures
Item
tinuously (N)
FD1800L 2,500 rpm
FD2000 On-off type 2,300 rpm 65±5 (149±9)
FD2000-C 2,300 rpm
60±10 - 75±5
FDL2000-C Linear type 2,300 rpm
(140±18 - 167±9)
MA-4-12
MAINTENANCE PROCEDURE
V-BELT
Be sure the engine is off and the transmission is in “Neutral”.
Engage the parking brake securely.
Visually check the V-belt daily for cracks and damage. If the belt is
cracked or damaged excessively, replace it.
Also check that the belt does not come in contact with the bottom of
the pulley groove.
Check the belt tension by applying approximately 98 N {10 kgf, 22
lbf} force to the belt midway between the fan [or idler (cooler com-
pressor)] pulley and the tension (or alternator) pulley.
Unit: mm (in)
Item Maintenance standard Service limit
Fan pulley - Tension pulley 8 - 12 (0.31 - 0.47)
Idler (cooler compressor) pul-
15 - 18 (0.59 - 0.71)
ley - Alternator pulley
NOTE
z The cooler compressor and alternator are driven by a
common belt. Malfunction of the cooler compressor
while in motion results in a defective charging system.
Be sure to check for the proper belt tension or the proper
operation of cooler compressor (there should be no
noise while in operation) and also conduct a cooler gas
check.
3. Tighten the lock nuts.
THERMOSTAT
1. Drain coolant completely. Refer to “CHANGE COOLANT
AND CLEAN INSIDE” for procedures.
2. Disconnect the radiator hose from the water outlet, then
remove the water outlet and rubber ring.
3. Remove the thermostat.
1 Water outlet 4 Thermostat housing
2 Thermostat 5 Rubber ring
3 Rubber ring
MA-4-13
MAINTENANCE PROCEDURE
FUEL SYSTEM
WARNING
WARNING
Observe the following when removing parts of the fuel sys-
tem:
z Post a placard that reads: “CAUTION: FLAMMABLE''.
z Prepare a fire extinguisher.
z Disconnect the ground terminal from the battery.
MA-4-14
MAINTENANCE PROCEDURE
INJECTION TIMING
1. Remove the pointer cover. Secure the pointer to the fly-
wheel housing using bolts.
2. Crank the engine in the standard direction by turning the fly-
wheel with a lever until the pointer is aligned with the timing
mark.
NOTE
z If the mark goes past the pointer, move it back past the
pointer and turn again in the standard direction until
alignment is made.
Maintenance
Item Service limit Remarks
standard
PF6 16º 1
PF6T 17º 2
NOTE
z *1 CKB454, 455, CWB454, 455
z *2 CKB453, CWB453, 455
MA-4-15
MAINTENANCE PROCEDURE
Coupling bolt
: 59 - 64 N·m {6.0 - 6.5 kgf·m, 43 - 47 ft·lbf}
Cotter bolt
: 83 - 93 N·m {8.5 - 9.5 kgf·m, 61 - 69 ft·lbf}
IDLE SPEED
NOTE
z When checking engine idle speed ensure that the engine
idle control knob inside the cab is set to the low-speed
position.
1. Start the engine and warm it up to the normal operating
temperature.
2. Allow the engine to idle and observe the engine speed on
the tachometer.
3. If idle speed is not within specified range, adjust as follows:
NOTE
z If equipped with an air conditioner, the air conditioner
switch must be turned off when checking idle speed.
Unit: rpm
Maintenance
Item Service limit Remarks
standard
500 - 530 Limit speed governor
Idle speed
550 - 600 All speed governor
MA-4-16
MAINTENANCE PROCEDURE
ACCELERATOR LINKAGE
Check accelerator linkage for bent rods, interference with adjacent
parts or looseness.
MA-4-17
MAINTENANCE PROCEDURE
3. Loosen the retaining nut, and then remove the nozzle from
the nozzle holder. Do not drop the nozzle needle.
MA-4-18
MAINTENANCE PROCEDURE
FUEL TUBING
Check the fuel rubber hose and clamp of the fuel system for instal-
lation, cracks or damage.
Replace faulty parts if necessary.
Check the fuel tubing for fractures, damage or improper installation.
Replace faulty parts if necessary. Whenever the fuel tubing is dis-
connected, be sure to bleed air from the fuel system.
FUEL LEAKAGE
Check the fuel system for leakage at tube or hose connections.
MA-4-19
MAINTENANCE PROCEDURE
Center bolt
: 20 - 29 N·m {2.0 - 3.0 kgf·m, 14 - 22 ft·lbf}
NOTE
z Do not excessively tighten bolts and plug.
1 Drain plug 6 Spring
2 Packing 7 Seat
3 Center bolt 8 Element
4 Packing 9 Packing
5 Filter case 10 Filter cover
<Cartridge type>
1. Place a container under the filter. Remove the filter with a
filter wrench (99755 00Z01). Drain any remaining fuel into
the container.
2. Apply a thin coat of clean engine oil to the gasket of the new
filter.
WARNING
WARNING
z Installation of the fuel filter without coating the gasket
with oil may damage the gasket resulting in loss of fuel
and fire hazard due to spilled fuel.
3. Install the new fuel filter by hand. After the gasket comes in
contact with the bracket sealing surface, tighten an addi-
tional three-fourths of a turn.
4. After installing the filter, purge air from the fuel system and
check for fuel leaks.
MA-4-20
MAINTENANCE PROCEDURE
Center bolt
: 59 - 69 N·m {6.0 - 7.0 kgf·m, 43 - 51 ft·lbf}
NOTE
z Do not excessively tighten bolts and plugs.
MA-4-21
MAINTENANCE PROCEDURE
Procedure 1
When the fuel pipe is disconnected or precipitates are removed,
bleed air as follows:
1. Twist the knob on the priming pump, which is connected to
the injection pump, and the knob will rise up by itself.
3. After bleeding air, return the pump knob to its original posi-
tion, and replace the cover. Start the engine, and make sure
that no fuel is leaking from the fuel system.
Fuel leaks can cause a fire.
MA-4-22
MAINTENANCE PROCEDURE
Procedure 2
When the fuel filter element or primary fuel filter element is
replaced, bleed air as follows:
1. When the primary fuel filter element is replaced, refill with
fuel through the filler plug hole.
2. Remove the priming pump cover on the injection pump, and
turn the pump knob counterclockwise to prepare the prim-
ing pump for operation.
3. Slightly loosen the connector bolt on the inlet side of the
fuel filter and move the pump up and down to bleed air from
between the fuel tank and fuel filter. Perform the above
operation until no air comes out.
NOTE
z Place a receiver under the fuel filter. Thoroughly wipe up
any spilled fuel.
4. When bleeding air from between the fuel tank and fuel filter
is completed, retighten the connector bolt and move the
priming pump up and down.
Continue this procedure until the overflow valve of the fuel
filter no longer gives off a “hissing” sound and movement of
the priming pump is difficult.
The air bleeding operation is now complete.
5. After bleeding air, return the pump knob to its original posi-
tion, and replace the cover. Start the engine, and make sure
that no fuel is leaking from the fuel system as it could cause
a fire.
MA-4-23
MAINTENANCE PROCEDURE
MA-4-24
MAINTENANCE PROCEDURE
Type II
1. Loosen the wing nut and remove the cover assembly and
adapter (if so equipped).
2. Loosen the wing nut and remove the outer element.
NOTE
z After the outer element has been thoroughly dried, shine
light through from the inside of the outer element, and
check it for damage, pin holes, and thinned areas; also
check the packing for damage and/or deformation.
Replace the elements (outer and inner) if necessary.
MA-4-25
MAINTENANCE PROCEDURE
4. First remove the wing nut and then the inner element.
NOTE
z Do not remove the inner element until the specified
replacement time. In other words, the inner element need
not be checked between replacements.
MA-4-26
MAINTENANCE PROCEDURE
6. Loosen the wing nut and remove the cover assembly and
adapter (if so equipped).
7. Loosen the wing nut and remove the outer element.
8. Place the element in a container large enough to hold the
entire element, and pour light oil into the container until the
element is covered by the oil. Wash the element by shaking
it in the oil. After washing, dry the element using com-
pressed air at 196 to 294 kPa {2 to 3 kgf/cm2, 28 to 43 psi}
from inside.
NOTE
z Be sure to use light oil for this cleaning operation.
z If the packing is damaged or deformed, replace with a
new one.
9. When installing the elements, clean the inside of the case
and the evacuator valve and assemble each part in the
reverse order of disassembly.
NOTE
z Tighten the elements and cover wing nut firmly.
CONDITION OF EXHAUST
Warm up the engine sufficiently, then visually inspect exhaust
smoke during idling, acceleration and deceleration with the vehicle
at a stop.
Color of smoke Judgment standard
Colorless or light blue Normal
Abnormal
Black
Incomplete combustion
Abnormal
Engine oil is also burning. However, exhaust
White
gases are often white when
either the air or engine temperature is low.
MA-4-27
MAINTENANCE PROCEDURE
OTHERS
STARTING MOTOR
Inspect the moving connector of the magnetic valve. Refer to the
EE section for INSPECTION procedures.
MA-4-28
MAINTENANCE PROCEDURE
ALTERNATOR
Inspect the charging system.
Refer to the EE section for INSPECTION procedures.
MA-4-29
TROUBLE DIAGNOSIS
MA
CONTENTS
DIAGNOSIS...................................... TD-1-1 DECREASED ENGINE POWER ..... TD-1-5
DIFFICULT ENGINE STARTING...... TD-1-2 EXCESSIVE OIL CONSUMPTION .. TD-1-6
BLACK EXHAUST SMOKE.............. TD-1-3 EXCESSIVE FUEL CONSUMPTION TD-1-7
WHITE EXHAUST SMOKE .............. TD-1-3 NOISY ENGINE ............................... TD-1-8
IRREGULAR ENGINE ENGINE OVERHEATS .................... TD-1-9
OPERATION..................................... TD-1-4
DIAGNOSIS
DIAGNOSIS
DIAGNOSIS GUIDE
The diagnosis guide is a table which can be used for seeking out the cause of trouble without disassembling
the engine on the basis of the symptoms of the problem complained of by the user and the result of checks
performed in the shop with the engine being mounted in the body.
TD-1-1
DIAGNOSIS
Discharged battery O O O
Electrical system
Faulty starter O O
Lack of fuel O O
Faulty nozzle O O O O
O O
Faulty clutch and subsequent power train (Check by connecting and dis-
O O O
connecting the clutch)
TD-1-2
DIAGNOSIS
Engine knocks
Irregular idling
Cause of trouble
Faulty nozzle O O O O O O
TD-1-3
DIAGNOSIS
Irregular idling
Cause of trouble
Malfunction of governor O O O O
Fuel system
TD-1-4
DIAGNOSIS
Engine knocks
Irregular idling
Cause of trouble
O O O O
Turbocharger malfunction O O O O
Seized piston O O O O
TD-1-5
DIAGNOSIS
Engine knocks
Cause of trouble
TD-1-6
DIAGNOSIS
Engine overheats
EXCESSIVE FUEL CONSUMPTION
Engine knocks
Irregular idling
Cause of trouble
Dragged brake
Clutch slips
Chassis
Prolonged idling
TD-1-7
DIAGNOSIS
Engine overheats
NOISY ENGINE
Cause of trouble
TD-1-8
DIAGNOSIS
Air bubbles appear in upper tank only when water temperature is high
Water temperature difference between water inlet and outlet is small
O O
Damaged impeller O O
Malfunction of thermostat O O
Coolant passage
Water leakage O
TD-1-9
ENGINE DISASSEMBLY
AND REASSEMBLY
DR
CONTENTS
SERVICE DATA................................ DR-1-1 ENGINE REAR PTO ........................ DR-3-4
TIGHTENING TORQUE .................. DR-1-1 DISASSEMBLY AND REASSEMBLY......... DR-4- 1
TOOLS.............................................. DR-2-1 OUTSIDE OF ENGINE ................... DR-4- 1
CONSTRUCTION ............................. DR-3-1 CYLINDER HEAD ........................... DR-4- 8
ENGINE........................................... DR-3-1 ENGINE PROPER ......................... DR-4-10
GEAR TRAIN................................... DR-3-3 ENGINE REAR PTO ...................... DR-4-21
SERVICE DATA
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque Remarks
Nozzle holder assembly mounting bolt 25 - 34 {2.5 - 3.5, 18 - 25}
Spill tube mounting bolt 10 - 18 {1.0 - 1.8, 7.2 - 13.0}
Pump side 29 - 49 {3.0 - 5.0, 22 - 36}
Injection tube
Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}
Fuel tube & fuel return tube 25 - 29 {2.5 - 3.0, 18 - 22}
1st 392 {40.0, 289}
Type I 2nd Loosen
Crank pulley nut
3rd 637 - 667 {65.0 - 68.0, 470 - 492}
Type II 177 - 196 {18.0 - 20.0, 130 - 145}
Fan pulley mounting bolt 186 - 196 {19.0 - 20.0, 137 - 145}
Cooling fan mounting nut 16 - 19 {1.6 - 1.9, 12 - 14}
Hydraulic pump drive gear mounting nut 59 - 78 {6 - 8, 43 - 58}
Alternator mounting bolt 59 - 78 {6 - 8, 43 - 58}
Oil pan drain plug 98 - 127 {10.0 - 13.0, 72 - 94}
Exhaust manifold mounting nut 29 - 44 {3.0 - 4.5, 22 - 33}
Oil outlet pipe mounting bolt 13 - 14 {1.30 - 1.45, 9.4 - 10.5}
Oil inlet tube connector bolt 13 - 14 {1.30 - 1.45, 9.4 - 10.5}
Oil cooler housing mounting bolt 20 {2.0, 14}
Turbocharger mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
Air intake manifold mounting nut 49 - 54 {5.0 - 5.5, 36 - 40}
Air compressor mounting bolt 30 - 41 {3.1 - 4.2, 22 - 30}
Starting motor mounting bolt 69 {7.0, 51}
Injection pump bracket mounting bolt 30 - 41 {3.1 - 4.2, 22 - 30}
Injection pump mounting bolt 48 - 62 {4.9 - 6.3, 35 - 46}
NOTE
z For discrimination between Type I and Type II of the crank pulley nuts, refer to page DR-3-2.
DR-1-1
SERVICE DATA
NOTE
z For discrimination between Type I and Type II of the connecting rod cap nuts, refer to page DR-
3-2.
DR-1-2
TOOLS
TOOLS
Tool name and number Description Shape
Socket wrench For removal and installation of crank pulley nut
99535 Z5007 Width across flats: 55 mm (2.17 in)
(Used for Type I only)
To confirm the crank pulley nut and crank pulley type before using
the socket wrench and crank pulley puller, refer to page DR-3-2.
DR-2-1
TOOLS
Cylinder head bolt socket wrench For removal, installation and retightening of cylin-
99664 96000 der head bolt
DR-2-2
CONSTRUCTION
CONSTRUCTION
ENGINE
DR-3-1
CONSTRUCTION
DR-3-2
CONSTRUCTION
GEAR TRAIN
DR-3-3
CONSTRUCTION
DR-3-4
DISASSEMBLY AND REASSEMBLY
OUTSIDE OF ENGINE
UPPER SIDE OF ENGINE
DR-4-1
DISASSEMBLY AND REASSEMBLY
DR-4-2
DISASSEMBLY AND REASSEMBLY
NOTE
z On PF series engines the cooler compressor and genera-
tor are driven by a common belt. Malfunction of the
cooler compressor while in motion results in a defective
charge system.
Be sure to check for the proper belt tension or the proper
operation of cooler compressor (there should be no
noise while in operation) and also conduct a cooler gas
check.
DR-4-3
DISASSEMBLY AND REASSEMBLY
DR-4-4
DISASSEMBLY AND REASSEMBLY
DR-4-5
DISASSEMBLY AND REASSEMBLY
NOTE
z *1 CKB454, 455, CWB454, 455
z *2 CKB453, CWB453, 455
DR-4-6
DISASSEMBLY AND REASSEMBLY
6. Align the mark on the injection pump with the scribed line on
the timer, then connect the coupling.
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Coupling bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Cotter bolt 83 - 93 {8.5 - 9.5, 61 - 69}
DR-4-7
DISASSEMBLY AND REASSEMBLY
CYLINDER HEAD
1 Cylinder head cover assembly 3 Cylinder head bolt 5 Cylinder head gasket
2 Valve rocker assembly 4 Cylinder head assembly
Marks “ ” and “ ” indicate that the key points of operation are explained in the text.
DR-4-8
DISASSEMBLY AND REASSEMBLY
DR-4-9
DISASSEMBLY AND REASSEMBLY
ENGINE PROPER
Key points of disassembly
z This section gives the entire procedures for disassembly
and reassembly. Numbers at the top of each step are noth-
ing to do with those attached to the part names in illustra-
tions.
z When reassembling the engine, be sure to replace all the
gasket, packings and O-rings with new ones, and apply
engine oil to the sliding surface of each component part of
the engine.
z For discrimination between Type I and Type II, refer to page
DR-3-2.
Attach the crank puller (99690 95500) to the crank pulley, then
remove the crank pulley and crank damper as a set.
2. Measure and record the lateral runout of the clutch disc sur-
face of the flywheel.
DR-4-10
DISASSEMBLY AND REASSEMBLY
DR-4-11
DISASSEMBLY AND REASSEMBLY
DR-4-12
DISASSEMBLY AND REASSEMBLY
DR-4-13
DISASSEMBLY AND REASSEMBLY
Unit: mm (in)
A 3.995 - 4.025 (0.15728 - 0.15846)
B 3.970 - 4.000 (0.15629 - 0.15748) Standard
Class of thrust
C 3.945 - 3.975 (0.15531 - 0.15649)
washer
0.15 O.S. 4.100 - 4.150 (0.16142 - 0.16339) O.S.: Over
0.30 O.S. 4.250 - 4.300 (0.16732 - 0.16929) size
NOTE
z Be sure the oil groove side of the thrust washer toward
the crankshaft.
5. Fit the main bearing lower shell into the main bearing cap,
and install the main bearing cap. Install the lower thrust
washer onto both sides of the No. 7 main bearing cap.
1 No. 7 main bearing cap 2 Lower thrust washer
NOTE
z Make sure the main bearing cap is installed following the
stamped numbers with the mark “ ” indicating the
engine front side.
z The thrust washer has an oil groove which should face
the crankshaft when installed. Be careful not to inter-
change the upper and lower washers.
DR-4-14
DISASSEMBLY AND REASSEMBLY
NOTE
z Do not install the piston rings in such a way that their
gaps face the direction of the piston pin and are in a ver-
tical direction. Moreover install them so that their gaps
are located exactly on opposite sides to each other. Also
make sure that the mark “ ” at the top of the piston
F
faces the engine front side and the stamped mark at the
large end of the connecting rod is on the injection pump
side.
NOTE
z Place each piston at its top dead center, and check to
make sure that the piston top clearance at this position is
within the maintenance standard. If any abnormality is
noted, disassemble again and inspect each part.
Unit: mm (in)
Maintenance standard Service limit
+0.32 - +0.72 (+0.0126 - +0.0284)
NOTE
z Make sure stamped mark at the large end of the connect-
ing rod aligns with that on the connecting rod cap.
Type I : 196 - 216 N·m
{20.0 - 22.0 kgf·m, 145 - 159 ft·lbf}
Type II : 230 - 245 N·m
{23.5 - 25.0 kgf·m, 170 - 181 ft·lbf}
DR-4-15
DISASSEMBLY AND REASSEMBLY
NOTE
z Side clearance for every cylinder should be measured.
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.3 (0.004 - 0.012) 1.0 (0.039)
DR-4-16
DISASSEMBLY AND REASSEMBLY
19. Measure the end play of the idler gear and oil pump idler
gear. Check that the end play is within the service limit.
Unit: mm (in)
Item Maintenance standard Service limit
Idler gear 0.05 - 0.12 (0.0020 - 0.0047) 0.3 (0.012)
Oil pump idler
0.08 - 0.15 (0.0031 - 0.0059)
gear
DR-4-17
DISASSEMBLY AND REASSEMBLY
23. Turn the engine upside down and install the oil pan. Apply a
coat of liquid gasket to the contacting surfacers. Fasten
twice.
: 15 N·m {1.5 kgf·m, 11 ft·lbf}
DR-4-18
DISASSEMBLY AND REASSEMBLY
25. Install the flywheel using two guide bolts (99687 97001).
Apply a brake to the ring gear. Then tighten the flywheel
mounting bolt.
: 255 - 304 N·m {26 - 31 kgf·m, 188 - 224 ft·lbf}
26. Measure the lateral runout of the clutch disc surface of the
flywheel. Check that the runout is within the service limit.
Unit: mm (in)
Maintenance standard Service limit
Less than 0.12 (0.0047) 0.15 (0.0059)
28. Apply a brake on the ring gear of the flywheel and install the
crank pulley.
[Type I]
Install the crank pulley nut using a socket wrench (99535
Z5007).
1st ..... : 392 N·m {40.0 kgf·m, 289 ft·lbf}
2nd.... : Loosen
3rd..... : 637 - 667 N·m {65.0 - 68.0 kgf·m,
470 - 492 ft·lbf}
DR-4-19
DISASSEMBLY AND REASSEMBLY
[Type II]
Tighten the crank pulley securing bolts diagonally to the
specified torque.
: 177- 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf}
DR-4-20
DISASSEMBLY AND REASSEMBLY
DR-4-21
DISASSEMBLY AND REASSEMBLY
23 Shaft holder
Disassemble the drive shaft assembly as shown in the following fig-
ure.
NOTE
z Press in the ball bearing with the shield plate side facing
the PTO gear.
21 PTO gear
Fit the PTO gear onto the drive shaft aligning the oil groove of the
PTO gear with the oil hole of the drive shaft.
19 Bearing
Press the large ball bearing into the oil seal holder.
NOTE
z Press in the ball bearing with the shield plate side facing
the companion flange.
DR-4-22
DISASSEMBLY AND REASSEMBLY
17 Holder
Press the bearing holder onto the drive shaft.
DR-4-23
ENGINE PROPER
EP
CONTENTS
SERVICE DATA................................. EP-1-1 REPAIR AND REPLACEMENT ......... EP-4-1
TOOLS............................................... EP-2-1 CYLINDER LINER REPLACEMENT EP-4-1
INSPECTION ..................................... EP-3-1 CAMSHAFT BUSHING
CYLINDER BLOCK ........................... EP-3-1 REPLACEMENT ............................... EP-4-1
CRANKSHAFT .................................. EP-3-2 CRANKSHAFT CORRECTION......... EP-4-2
MAIN BEARING SHELL .................... EP-3-5 CRANKSHAFT ACCESSORIES
CYLINDER LINER............................. EP-3-5 REPLACEMENT .............................. EP-4-4
PISTON AND CONNECTING ROD... EP-3-6 CONNECTING ROD
CAMSHAFT..................................... EP-3-10 REPLACEMENT .............................. EP-4-5
GEAR TRAIN................................... EP-3-11 CONNECTING ROD SMALL END
FLYWHEEL ..................................... EP-3-12 BUSHING REPLACEMENT.............. EP-4-5
FLYWHEEL HOUSING, REAR END IDLER GEAR (A) BUSHING
PLATE AND FRONT COVER.......... EP-3-13 REPLACEMENT ............................... EP-4-5
CRANK PULLEY AND DAMPER .... EP-3-13 FLYWHEEL CORRECTION.............. EP-4-6
V-BELT ............................................ EP-3-13
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Posi
Item Maintenance standard Service limit Remarks
tion
Flatness of the top sur- Longitudinal direction Less than 0.01 (0.0004) 0.10 (0.0039)
Cylinder block
1.00 U.S.
(3.8925 - 3.8933)
84.64 - 84.66
0.25 U.S.
(3.3323 - 3.3331)
84.39 - 84.41
0.50 U.S.
(3.3224 - 3.3232)
Type I U.S.: Undersize
84.14 - 84.16
0.75 U.S.
(3.3126 - 3.3134)
83.89 - 83.91
1.00 U.S.
Crank pin grinding (3.3027 - 3.3035)
dimensions 89.64 - 89.66
0.25 U.S.
(3.5291 - 3.5299)
89.39 - 89.41
0.50 U.S.
(3.5193 - 3.5201)
Type II
89.14 - 89.16
0.75 U.S.
(3.5094 - 3.5102)
88.89 - 88.91
1.00 U.S.
(3.4996 - 3.5004)
EP-1-1
SERVICE DATA
Posi-
Item Maintenance standard Service limit Remarks
tion
Journal Less than 0.03
0.01 (0.0004)
location (A) (0.0012)
Oil seal Less than 0.01
Type I 0.01 (0.0004)
location (B) (0.0004)
Flywheel Less than 0.02
0.01 (0.0004)
location (C) (0.0008) Support the No. 2 and
Runout
Journal Less than 0.07 No. 6 journals
0.01 (0.0004)
location (A) (0.0028)
Oil seal Less than 0.04
Type II 0.01 (0.0004)
location (B) (0.0016)
Flywheel Less than 0.01
0.01 (0.0004)
location (C) (0.0004)
Crankshaft
0.05 - 0.14
End play 0.50 (0.0197)
(0.0020 - 0.0055)
3.995 - 4.025
A
(0.1573 - 0.1585)
3.970 - 4.000
B Standard
(0.1563 - 0.1575)
3.945 - 3.975 (
Thrust washer types C
0.1553 - 0.1565)
4.100 - 4.150 (
0.15 O.S.
0.1614 - 0.1634)
O.S.: Oversize
4.250 - 4.300
0.30 O.S.
(0.1673 - 0.1693)
Clearance between main bearing shell and crankshaft 0.04 - 0.13
0.20 (0.0079)
journal (0.0016 - 0.0051)
NOTE
z For discrimination between Type I and Type II, refer to page DR-3-2.
EP-1-2
SERVICE DATA
Unit: mm (in)
Position Item Maintenance standard Service limit Remarks
Measure at 25, 50, 75, 125, 175
Inside diameter (without dismounting it 133.00 - 133.03 and 245 mm (0.98, 1.97, 2.95,
133.25 (5.2461)
from the cylinder block) (5.2362 - 5.2374) 4.92, 6.89 and 9.65 in) positions
from the top surface of the block
Cylinder liner
EP-1-3
SERVICE DATA
Unit: mm (in)
61.92 - 61.94
No. 5
(2.4378 - 2.4386)
Clearance between journal and bush- 0.030 - 0.116
0.20 (0.0079)
ing (0.0012 - 0.0046)
53.0275 - 53.0675
PF6
(2.0877 - 2.0893)
Height of Intake PF6T
54.080 - 54.120
cam PF6TA
(2.1291 - 2.1307)
profile PF6TB
50.505 - 50.545
Exhaust
(1.9884 - 1.9900)
Support the No. 2 and No. 4 jour-
Runout Less than 0.03 (0.0012) 0.06 (0.0024)
nals
A, B, C, 0.065 - 0.135
D, E, F (0.0026 - 0.0053)
Gear train backlash
0.085 - 0.215
G, H
(0.0033 - 0.0085)
Gear train
0.05 - 0.12
Idler gear end play 0.30 (0.0118)
(0.0020 - 0.0047)
8 - 12
A
(0.31 - 0.47)
15 - 18
B
(0.59 - 0.71)
EP-1-4
TOOLS
TOOLS
Tool name and number Description Shape
Straight edge For measuring flatness of cylinder block and cylin-
99645 Z5001 der head gasketed surfaces
EP-2-1
TOOLS
1 Oil seal replacer Used together with guide bolt when press fitting
99718 96005 crankshaft rear oil seal
2 Guide bolt
99687 96001
NOTE
z For discrimination between Type I and Type II of the collar replacer, refer to page DR-3-2.
EP-2-2
INSPECTION
INSPECTION
z Clean all the disassembled parts thoroughly with cleaning
fluid. While cleaning, inspect the parts for cracks and other
damage carefully. If faulty, replace with a new one.
z If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
CYLINDER BLOCK
Flatness of the top surface
Using a straight edge (99645 Z5001), measure the flatness of the
top surface.
Unit: mm (in)
Item Maintenance standard Service limit
Longitudinal direction Less than 0.10 (0.0039) 0.10 (0.0039)
Transverse direction Less than 0.02 (0.0008) 0.10 (0.0039)
EP-3-1
INSPECTION
CRANKSHAFT
Outside diameter of the journal
Measure and record the outside diameter of the journal. If the mea-
sured value has reached the service limit, grind the journal to the
undersize, and install the undersize main bearing shell.
Unit: mm (in)
Item Maintenance standard Service limit Remarks
S.T.D. 99.87 - 99.89 (3.9319 - 3.9327) 98.87 (3.8925)
0.25 U.S. 99.62 - 99.64 (3.9220 - 3.9228)
U.S.:
0.50 U.S. 99.37 - 99.39 (3.9122 - 3.9130)
Undersize
0.75 U.S. 99.12 - 99.14 (3.9024 - 3.9031)
1.00 U.S. 98.87 - 98.89 (3.8925 - 3.8933)
EP-3-2
INSPECTION
U.S.: Undersize
NOTE
z For discrimination between Type I and Type II, refer to
page DR-3-2.
Out-of-roundness of the crankshaft pin
If the out-of-roundness has exceeded the maintenance standard,
grind the pin to the undersize, and install the undersize bearing
shell.
Unit: mm (in)
Maintenance standard Service limit
Less than 0.01 (0.0004) 0.06 (0.0024)
EP-3-3
INSPECTION
Runout
Support the No. 2 and No. 6 journals and measure the runout of
each part.
Unit: mm (in)
Item Maintenance standard Service limit
Journal location (A) Less than 0.03 (0.0012) 0.01 (0.0004)
Type I Oil seal location (B) Less than 0.01 (0.0004) 0.01 (0.0004)
Flywheel location (C) Less than 0.02 (0.0008) 0.01 (0.0004)
Journal location (A) Less than 0.07 (0.0028) 0.01 (0.0004)
Type II Oil seal location (B) Less than 0.04 (0.0016) 0.01 (0.0004)
Flywheel location (C) Less than 0.01 (0.0004) 0.01 (0.0004)
NOTE
z For discrimination between Type I and Type II, refer to
page DR-3-2.
End play
If the end play measured during disassembly has reached the
specified service limit, replace the upper and lower thrust washers
as a unit with a suitable set of thrust washers so that the end play is
within the maintenance standard.
Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.14 (0.0020 - 0.0055) 0.50 (0.0197)
Unit: mm (in)
Size identification mark Thickness Remarks
3.995 - 4.025
A
(0.1573 - 0.1585)
3.970 - 4.000
B Standard
(0.1563 - 0.1575)
Thrust washer 3.945 - 3.975
C
type (0.1553 - 0.1565)
4.100 - 4.150
0.15 O.S.
(0.1614 - 0.1634)
O.S.: Oversize
4.250 - 4.300
0.30 O.S.
(0.1673 - 0.1693)
EP-3-4
INSPECTION
CYLINDER LINER
Measure the cylinder liner without dismounting it from the cylinder
block.
Inside diameter
Unit: mm (in)
Maintenance standard Service limit
133.00 - 133.03 (5.2362 - 5.2374) 133.25 (5.2461)
Out of roundness
Unit: mm (in)
Maintenance standard Service limit
Less than 0.10 (0.0039)
Taper
Unit: mm (in)
Maintenance standard Service limit
Less than 0.03 (0.0012)
EP-3-5
INSPECTION
NOTE
z The piston rings for all cylinders should be replaced as
an assembly during overhaul.
1 1st ring 8 Bolt
2 2nd ring 9 Connecting rod
3 Oil ring 10 Bearing shell (upper)
4 Piston 11 Bearing shell (lower)
5 Retaining ring 12 Connecting rod cap
6 Piston pin 13 Nut
7 Bushing
PISTON
Outside diameter
Measurement should be made at 20.0 mm (0.787 in) “L” position
from the bottom side of the piston at a right angle to the piston pin
axis.
Unit: mm (in)
Maintenance standard Service limit
132.920 - 132.950 (5.2331 - 5.2342)
EP-3-6
INSPECTION
PISTON RINGS
Clearance between the piston ring and ring groove
Unit: mm (in)
Item Maintenance standard Service limit
2nd ring 0.08 - 0.12 (0.0031 - 0.0047) 0.40 (0.0157)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.20 (0.0079)
NOTE
z The first ring is a keystone ring and cannot be measured.
PISTON PIN
Outside diameter
Unit: mm (in)
Maintenance standard Service limit
49.99 - 50.00 (1.9681 - 1.9685) 49.90 (1.9646)
EP-3-7
INSPECTION
CONNECTING ROD
Inside diameter of small end bushing
Unit: mm (in)
Maintenance standard Service limit
50.03 - 50.04 (1.9697 - 1.9701)
Type I
: 196 - 216 N·m {20.0 - 22.0 kgf·m, 145 - 159 ft·lbf}
Type II
: 230 - 245 N·m {23.5 - 25.0 kgf·m, 170 - 181 ft·lbf}
Calculate the clearance between the crank pin O.D. and bearing
shell I.D. from the measured values.
Unit: mm (in)
Item Maintenance standard Service limit
Type I 0.04 - 0.11 (0.0016 - 0.0043) 0.20 (0.0079)
Type II 0.05 - 0.11 (0.0020 - 0.0043) 0.20 (0.0079)
NOTE
z For discrimination between Type I and Type II, refer to
page DR-3-2.
EP-3-8
INSPECTION
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Less than 0.06
Bend
(0.0024) When the distance between
Less than 0.08 pins is 100 mm (3.94 in).
Twist
(0.0031)
EP-3-9
INSPECTION
CAMSHAFT
End play
If the end play measured during disassembly of the engine has
reached the specified service limit, replace the locating plate with a
new one.
Unit: mm (in)
Maintenance standard Service limit
0.05 - 0.25 (0.0020 - 0.0098) 0.50 (0.0197)
EP-3-10
INSPECTION
Runout
Support the No. 2 and No. 4 journals, and measure the runout of
the No. 1, No. 3 and No. 5 journals.
Unit: mm (in)
Maintenance standard Service limit Remarks
Support the No. 2 and
Less than 0.03 (0.0012) 0.06 (0.0024)
No. 4 journals.
GEAR TRAIN
Check all gears for damaged teeth or abnormal wear. Replace
faulty gears.
Gear train backlash
Check the backlash between gears measured during disassembly
of the engine proper. If it has reached the service limit, replace the
gears with new ones.
Unit: mm (in)
Type Maintenance standard Service limit
0.065 - 0.135
A, B, C, D, E, F
(0.0026 - 0.0053)
0.085 - 0.215
G, H
(0.0033 - 0.0085)
EP-3-11
INSPECTION
FLYWHEEL
Check the flywheel for scratches. Also check for abnormal wear on
the contact surface of the clutch disc, damage or wear on the ring
gear teeth, and noise, damage or seizure of the ball bearing. Repair
or replace parts if faulty.
Lateral runout of clutch disc surface
Check the lateral runout of the clutch disc surface measured during
disassembly of the engine proper.
Unit: mm (in)
Maintenance standard Service limit
Less than 0.10 (0.0039) 0.15 (0.0059)
EP-3-12
INSPECTION
V-BELT
Check the V-belt (drive belt) for cracks or damage. Replace if faulty.
If the belt contacts the bottom of the pulley groove, replace the belt.
Deflection
Check belt deflection by depressing the midpoint of the drive belt
between the alternator (or fan) and cooler (or tension) pulley with a
force of approximately 98 N {10 kgf, 22 lbf}. If belt deflection is not
within maintenance standards, adjust the belt. If beyond adjust-
ment, replace.
Unit: mm (in)
Location Maintenance standard Service limit
A 8 - 12 (0.31 - 0.47)
B 15 - 18 (0.59 - 0.71)
EP-3-13
REPAIR AND REPLACEMENT
EP-4-1
REPAIR AND REPLACEMENT
NOTE
z When driving in the bushings, be sure to align the oil
hole of each bushing to the oil way of the block, with the
cut-out portion on the chamfered side facing the right
side of the cylinder block.
NOTE
z Be careful to prevent the width of the journal and crank
pin sections from increasing.
EP-4-2
REPAIR AND REPLACEMENT
Unit: mm (in)
Item Maintenance standard Service limit
Clearance between outside diame-
0.04 - 0.13
ter of journal and inside diameter of
(0.0016 - 0.0051)
main bearing shell
Clearance between outside diame-
0.04 - 0.11
ter of pin and inside diameter of
(0.0016 - 0.0043)
bearing shell
Journal
Unit: mm (in)
Size identification
Grinding dimension of journal Remarks
mark
S.T.D.
Grinding not necessary
0.07 U.S.
0.25 U.S. 99.62 - 99.64 (3.9220 - 3.9228) S.T.D.: Standard
0.50 U.S. 99.37 - 99.39 (3.9122 - 3.9130) U.S.: Undersize
Pin
Unit: mm (in)
Size identification
Grinding dimension of journal Remarks
mark
S.T.D.
Grinding not necessary
0.07 U.S.
0.25 U.S. 84.64 - 84.66 (3.3323 - 3.3331) S.T.D.: Standard
0.50 U.S. 84.39 - 84.41 (3.3224 - 3.3232) U.S.: Undersize
EP-4-3
REPAIR AND REPLACEMENT
NOTE
z For discrimination between Type I and Type II, refer to
page DR-3-2.
CRANK GEAR
1. Warm the crank gear, then remove it.
2. Warm the crank gear in a bath of oil maintained at approx.
200ºC (390ºF), and install it onto the crankshaft by aligning
its keyway with the straight pin.
WARNING
WARNING
z Be careful not to touch the crank gear with bare hands
because it is hot; otherwise, you may be burned.
NOTE
z Be sure to install the crank gear with “X” stamped on the
end face facing toward the front side.
OIL SEAL COLLAR
1. Using a puller, remove the oil seal collar.
2. Using a collar replacer, press the oil seal collar onto the
crankshaft until it comes in contact with the crank gear.
Collar replacer:
Type I.... 99718 96000
Type II... 99718 96006
EP-4-4
REPAIR AND REPLACEMENT
EP-4-5
REPAIR AND REPLACEMENT
FLYWHEEL CORRECTION
Grind or machine the clutch disc so that the runout of the contacting
surface will be within the maintenance standards. However, replace
the flywheel with a new one when the runout of the clutch disc con-
tacting surface has exceeded the service limit.
Unit: mm (in)
Item Maintenance standard Service limit
Lateral runout of clutch disc
Less than 0.10 (0.0039) 0.15 (0.0059)
surface
Service limit of clutch disc
50.50 (1.9882) 48.50 (1.9094)
surface (A)
Standard depth from flange 47.90 - 48.10
end (B) (1.8858 - 1.8937)
EP-4-6
CYLINDER HEAD AND
VALVE MECHANISM
HV
CONTENTS
SERVICE DATA................................ HV-1-1 REPAIRING VALVE.......................... HV-6-1
SERVICE DATA................................ HV-1-1 REPAIRING VALVE INSERT ........... HV-6-2
TIGHTENING TORQUE ................... HV-1-3 REPLACING VALVE INSERT .......... HV-6-2
TOOLS.............................................. HV-2-1 LAPPING THE VALVE AND
CONSTRUCTION ............................. HV-3-1 VALVE INSERT ................................ HV-6-3
DISASSEMBLY ................................ HV-4-1 REPLACING VALVE GUIDE ............ HV-6-4
REMOVAL ........................................ HV-4-1 REPLACING VALVE ROCKER
DISASSEMBLY ................................ HV-4-3 BUSHING......................................... HV-6-4
INSPECTION .................................... HV-5-1 REASSEMBLY .................................. HV-7-1
REPAIR AND REPLACEMENT ....... HV-6-1 INSTALLATION................................. HV-8-1
REPAIRING CYLINDER HEAD ........ HV-6-1
SERVICE DATA
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Posi-
Item Maintenance standard Service limit Remarks
tion
Grinding tolerance:
Cylinder head
Seat angle
Exhaust 45º - 45º30’
Intake 2.66 (0.1047) 3.0 (0.118)
Contacting width
Exhaust 2.83 (0.1114) 3.0 (0.118)
Intake 30º - 30º15’
Valve face angle
Exhaust 45º - 45º30’
11.960 - 11.975
Intake
(0.4709 - 0.4715)
Outside diameter of valve stem
11.925 - 11.935
Exhaust
(0.4695 - 0.4699)
Intake 3.0 (0.118)
Valve head thickness
Valve
12.00 - 12.02
Exhaust 12.16 (0.4787)
(0.4724 - 0.4732)
Valve guide and valve stem 0.025 - 0.070
Intake 0.15 (0.0059)
clearance (0.0010 - 0.0028)
HV-1-1
SERVICE DATA
Unit: mm (in)
Posi-
Item Maintenance standard Service limit Remarks
tion
19.99 - 20.00
Outside diameter 19.90 (0.7835)
(0.7870 - 0.7874)
Runout Less than 0.03 (0.0012) 0.05 (0.0020)
Rocker shaft
26.945 - 26.965
Cam follower
Others
Valve clearance adjusting sequence
Cylinder No. 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12
Valve arrangement
IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 piston at TDC on compression
O O O O O O
stroke
No. 6 piston at TDC on compression
O O O O O O
stroke
HV-1-2
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Tightening point Tightening torque
Preset (snug) torque: 1st time 88 - 98 {9.0 - 10.0, 65 - 72}
Cylinder head bolt 85º - 95º (long size except for bolts marked with *)
Tightening angle: 2nd time
70º - 80º (bolts marked with * are of short size)
1st time 34 {3.5, 25}
Cylinder head sub bolt
2nd time 44 - 54 {4.5 - 5.5, 33 - 40}
Rocker shaft mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
Exhaust manifold mounting nut 29 - 44 {3.0 - 4.5, 22 - 33}
Air intake manifold mounting nut 49 - 54 {5.0 - 5.5, 36 - 40}
Injection nozzle holder mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}
Pump side 29 - 39 {3.0 - 4.0, 22 - 29}
Injection tube
Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}
Spill tube mounting bolt 10 - 18 {1.0 - 1.8, 7 - 13}
Turbocharger mounting nut 34 - 44 {3.5 - 4.5, 25 - 33}
Rocker arm adjusting screw lock nut 34 - 44 {3.5 - 4.5, 25 - 33}
Rocker shaft stopper bolt 8 - 13 {0.8 - 1.3, 5.8 - 9.4}
NOTE
z For bolts marked with *, refer to the illustration in the text under the heading “INSTALLATION”.
HV-1-3
TOOLS
TOOLS
Tool name and number Description Shape
Split collar tool Used to remove and install the split collar.
99624 Z5001
Caulking tool assembly Used to caulk after the exhaust valve insert has
99670 96002 been fitted to the cylinder head.
1 99675 96002
2 99676 96001 1 Caulking tool
3 81-20616-1A 2 Guide
3 Bolt
HV-2-1
TOOLS
Stem seal replacer Used to install the valve stem seal into the
99674 97005 valve guide.
Cylinder head bolt socket wrench For removal, installation and retightening of cylin-
99664 96000 der head bolts
HV-2-2
CONSTRUCTION
CONSTRUCTION
HV-3-1
DISASSEMBLY
DISASSEMBLY
REMOVAL
Dismount the cylinder head keeping the engine mounted in a vehicle.
1. Chock the wheels, then tilt the cab.
2. Turn the key switch off and disconnect the cable from the negative terminal of the battery.
3. Drain the engine cooling water.
4. Remove the right and left side cover for the engine room.
5. Disconnect the water hose, tube and wire harness.
6. Remove the intake hose.
7. Remove the air intake manifold with the air heater and air intake duct attached to the air intake mani-
fold.
8. Remove the fuel system.
z Remove the fuel lines.
z Remove the injection nozzle tube and spill tube.
z Remove the injection nozzle.
NOTE
z When removing fuel lines, use a pan to catch dripping fuel so that fuel does not get on engine
parts. If any fuel is spilled on engine parts, use a rag to completely remove all spilled fuel.
9. Remove the shield plate, oil pipe and other parts attached to the turbocharger, then remove the tur-
bocharger together with the actuator assembly.
10. Remove the exhaust manifold.
11. Remove the rocker cover.
12. Remove the rocker shaft assembly and push rod.
NOTE
z Loosen the rocker shaft assembly mounting bolts proceeding from the outside in.
13. Remove the cylinder head and gasket.
NOTE
z Use a crane or other devices to dismount the cylinder head.
z Loosen the cylinder head bolts proceeding from the outside in.
PF6
HV-4-1
DISASSEMBLY
PF6T
PF6TA, B
HV-4-2
DISASSEMBLY
DISASSEMBLY
CYLINDER HEAD
HV-4-3
DISASSEMBLY
HV-4-4
DISASSEMBLY
1 Split collar
Remove the split collar using a split collar tool (99624 Z5001).
NOTE
z All the parts removed should be grouped together for
each valve.
HV-4-5
INSPECTION
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
CYLINDER HEAD
Flatness
Unit: mm (in)
Item Maintenance standard Service limit
Longitudinal direction Less than 0.05 (0.0020) 0.20 (0.0079)
Transverse direction Less than 0.02 (0.0008) 0.20 (0.0079)
VALVE INSERT
Contacting width and contact pattern
Unit: mm (in)
Item Maintenance standard Service limit
Intake 2.66 (0.1047) 3.0 (0.118)
Exhaust 2.83 (0.1114) 3.0 (0.118)
VALVE
Distance between the valve and the bottom surface of the
cylinder head
Check the value measured before disassembling the cylinder head.
Unit: mm (in)
Item Maintenance standard Service limit
-0.214 - +0.314
Intake 0.7 (0.028)
(-0.0084 - +0.0124)
0.75 - 1.25
Exhaust
(0.0295 - 0.0492)
HV-5-1
INSPECTION
VALVE GUIDE
Valve guide and valve stem clearance
Unit: mm (in)
Item Maintenance standard Service limit
0.025 - 0.070
Intake 0.15 (0.0059)
(0.0010 - 0.0028)
0.065 - 0.105
Exhaust 0.15 (0.0059)
(0.0026 - 0.0041)
VALVE SPRING
Free length
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Outer 85.10 (3.3504) Intake and
Inner 80.50 (3.1693) exhaust
Tension
Unit: N {kgf, lbf}
Item Maintenance standard Service limit Remarks
When compressed to
351.1 - 388.4
Outer 50.7 mm (1.996 in) Intake
{35.8 - 39.6, 78.9 - 87.3}
and exhaust
When compressed to
199.1 - 220.7
Inner 49.0 mm (1.929 in) Intake
{20.3 - 22.5, 44.8 - 49.6}
and exhaust
HV-5-2
INSPECTION
Squareness
Measure the squareness of the outer spring by calculating the
clearance difference between A and B in the figure.
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Outer 2.5 (0.098) Intake and
Inner 2.5 (0.098) exhaust
ROCKER SHAFT
Outside diameter
Unit: mm (in)
Maintenance standard Service limit
19.99 - 20.00 (0.7870 - 0.7874) 19.90 (0.7835)
Runout
Unit: mm (in)
Maintenance standard Service limit
Less than 0.03 (0.0012) 0.05 (0.0020)
HV-5-3
INSPECTION
PUSH ROD
Deviation
Measure the deviation while supporting the center of the spherical
surfaces at both ends of the push rod.
Unit: mm (in)
Maintenance standard Service limit
Less than 0.3 (0.012) 0.5 (0.020)
Length
Unit: mm (in)
Maintenance standard Service limit
236.73 (9.3201)
CAM FOLLOWER
Outside diameter
Unit: mm (in)
Maintenance standard Service limit
26.945 - 26.965 (1.0608 - 1.0616) 26.85 (1.0571)
HV-5-4
INSPECTION
HV-5-5
REPAIR AND REPLACEMENT
REPAIRING VALVE
1. Using a valve refacer, repair the valve face portion. If the
thickness of the valve face exceeds the service limit after
repaired, replace it with a new one.
NOTE
z There should be no stepped wear on the valve face.
Unit: mm (in)
Item Maintenance standard Service limit
Intake 30º - 30º15’
Valve face angle
Exhaust 45º - 45º30’
Valve head thick- Intake 3.0 (0.118)
ness Exhaust 1.9 (0.075)
2. Using a valve refacer or oil stone, repair the valve stem end.
NOTE
z Finish the valve stem end surface so that it is perpendic-
ular to the axis. Also, the finished surface should have
no scrape marks or scratches.
HV-6-1
REPAIR AND REPLACEMENT
HV-6-2
REPAIR AND REPLACEMENT
z Take out the cylinder head and valve inserts, then fit the
valve inserts quickly into the cylinder head using a special
valve insert replacer (Intake: 99665 96002 and Exhaust:
99665 96003).
z After fitting the valve inserts, caulk four locations around the
insert (on the exhaust side only) using a special valve insert
caulking tool (99670 96002).
NOTE
z When caulking with a hammer, drop a 4-pound copper
hammer from a height of about 300 mm (11.81 in) once.
When a press is used, make the pressure 122,588 to
171,623 kPa {1,250 to 1,750 kg/cm2, 17,775 to 24,885 psi}.
2. Apply a coat of engine oil to the valve stem, then insert the
valve into the valve guide. With the lapping rod coming into
contact with the valve head, lap the valve by rotating it while
lightly tapping the valve insert.
3. After oil lapping, coat the contacting surface of the valve
with red lead and repeat lapping operation in the same
manner as previously done with the grinding compound,
then check the condition of the valve surface. Repeat lap-
ping until the valve surface is properly corrected.
Unit: mm (in)
Item Maintenance standard Service limit
Intake 2.66 (0.1047) 3.0 (0.118)
Contacting width
Exhaust 2.83 (0.1114) 3.0 (0.118)
HV-6-3
REPAIR AND REPLACEMENT
HV-6-4
REPAIR AND REPLACEMENT
HV-6-5
REASSEMBLY
REASSEMBLY
CYLINDER HEAD
Key points of reassembly
z Before reassembling, be sure to apply engine oil to each
sliding surface.
1 Split collar
1. Using a split collar tool (99624 Z5001), install the split collar.
HV-7-1
REASSEMBLY
HV-7-2
INSTALLATION
INSTALLATION
Cylinder head bolt
Insert the cylinder head bolts, then tighten them in two stages
uniformly following the sequence shown in the figure. (Use an angle
wrench and socket wrench: 99664-96000.)
: 1st time 88 - 98 N·m {9.0 - 10.0 kgf·m, 65 - 72 ft·lbf}
: 2nd time
Tightening angle
85º - 95º (long size except for bolts marked with *)
70º - 80º (bolts marked with * are of short size)
Cylinder head sub bolts (Mark )
: 1st time 34 N·m {3.5 kgf·m, 25 ft·lbf}
: 2nd time 44 - 54 N·m {4.5 - 5.5 kgf·m, 33 - 40 ft·lbf}
NOTE
z Tightening of cylinder head bolts in the PF series engine
is specified by the tightening angle. Do not tighten them
additionally.
<Using an angle wrench>
1. Set the torque graduations of the torque wrench to the pre-
set (snug) torque.
2. Connect the torque wrench to the needle flexible tube.
Secure the clip. (For reading the turning angle)
3. When reading the angle: Adjust the needle to a proper posi-
tion to read the angle in the graduations and then tighten
the bolt. When tightening reaches the preset (snug) torque,
the angle graduation plate begins to turn. Tighten the bolt
while reading the angle.
4. When presetting the angle: Adjust the needle to the prede-
termined angle and tighten the bolt. When tightening
reaches the preset (snug) torque, the angle graduation
plate begins to turn. Tighten the bolt until the needle points
to “0”.
NOTE
z If no angle wrenches are available, mark the bolts and
cylinder head after the 1st tightening. Tighten the bolt to
the specified angle, starting from the marked position.
HV-8-1
- MEMO -
LUBRICATION SYSTEM
CONTENTS
SERVICE DATA................................ LB-1-1 DISASSEMBLY ................................. LB-4-2
SPECIFICATIONS ............................ LB-1-1 INSPECTION .................................... LB-4-3 LB
SERVICE DATA................................ LB-1-2 INSTALLATION ................................. LB-4-3
TIGHTENING TORQUE ................... LB-1-3 OIL FILTER ....................................... LB-5-1
LUBRICATING SYSTEM .................. LB-1-4 CONSTRUCTION ............................. LB-5-1
TOOLS.............................................. LB-2-1 DISASSEMBLY ................................. LB-5-2
OIL PUMP......................................... LB-3-1 INSPECTION .................................... LB-5-3
CONSTRUCTION............................. LB-3-1 REASSEMBLY .................................. LB-5-3
REMOVAL ........................................ LB-3-2 OIL JET ............................................. LB-6-1
DISASSEMBLY ................................ LB-3-3 CONSTRUCTION ............................. LB-6-1
INSPECTION.................................... LB-3-4 REMOVAL......................................... LB-6-1
REASSEMBLY ................................. LB-3-5 INSPECTION .................................... LB-6-1
INSTALLATION ................................. LB-3-6 INSTALLATION ................................. LB-6-1
OIL COOLER.................................... LB-4-1
REMOVAL ........................................ LB-4-1
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
PF6 PF6T PF6TA PF6TB
Item
Lubricating method Forced lubrication
Type Gear pump
Discharge amount 138 (30-3/8)
174 (38-1/4)/2,300
Oil pump liter (Imp gal)/rpm /2,300
Relief valve opening pressure
1,079 {11.0, 156}
kPa {kgf/cm2, psi}
Full-flow Filter paper
Type
By-pass Laminated 3-plate type
Oil filter Replacement method Disassembling type
Short valve opening pressure
98 - 137 {1.0 - 1.4, 14 - 20}
kPa {kgf/cm2, psi}
Type Water cooled flat tube type
Oil cooler
Number of cores 6
Regulator valve opening pressure
392 - 432 {4.0 - 4.4, 57 - 63}
kPa {kgf/cm2, psi}
Lubricating oil refill capacity With oil filter 29 {6-3/8}
(gauge H-level)
liter {lmp gal} Without oil filter 21 {4-5/8}
LB-1-1
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Posi- Maintenance
Item Service limit Remarks
tion standard
0.05 - 0.11
Side clearance 0.15 (0.0059)
(0.0020 - 0.0043)
Pump gear
0.07 - 0.19
(Drive and Idler Tip clearance 0.20 (0.0079)
(0.0028 - 0.0075)
gear)
0.09 - 0.22
Backlash 0.50 (0.0197)
(0.0035 - 0.0087)
Clearance between idler shaft and idler gear 0.01 - 0.04
Oil pump
0.20 (0.0079)
bushing (0.0004 - 0.0016)
Valve opening pressure
1,079 {11.0, 156}
kPa {kgf/cm2, psi}
Relief valve Spring free length 50.2 (1.976)
Spring tension 352.1 - 410.9 When compressed to 44
N {kgf, lbf}} {35.9 - 41.9, 79.2 - 92.4} mm (1.73 in)
0.08 - 0.15
Side clearance between idler gear and spindle
(0.0031 - 0.0059)
Short valve opening pressure
324 {3.3, 47]
Oil cooler
177 - 216
kPa {kgf/cm2, psi} {1.8 - 2.2, 26 - 31}
LB-1-2
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}}
Tightening point Tightening torque
Oil pump cover assembly mounting bolt 25 - 39 {2.6 - 4.0, 19 - 29 }
Oil pump assembly mounting bolt 30 - 41 {3.1 - 4.2, 22 - 30 }
Oil pump idler gear mounting bolt 59 - 78 {6.0 - 8.0, 43 - 58}
Oil pan drain plug 98 - 127 {10.0 - 13.0, 72 - 94}
Oil cooler element mounting nut 20 - 30 {2.0 - 3.0, 14 - 22}
54 - 93 {5.5 - 9.5, 40 - 69}
Oil cooler housing mounting bolt
30 - 54 {3.0 - 5.5, 22 - 40}
Oil cooler housing mounting nut 54 - 93 {5.5 - 9.5, 40 - 69}
Full-flow oil filter center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
By-pass oil filter center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Oil filter drain plug (Full-flow, by-pass) 16 - 22 {1.6 - 2.2, 12 - 16}
Oil jet connector bolt 29 - 39 {3.0 - 4.0, 22 - 29}
Oil pipe, oil screen mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Oil pan mounting bolt 15 {1.5, 11}
LB-1-3
SERVICE DATA
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LB-1-4
SERVICE DATA
LUBRICATION CIRCUIT
LB-1-5
TOOLS
TOOLS
Tool name and number Description Shape
Hydraulic pump For testing water pressure of oil cooler element
99570 Z5000
Oil cooler attachment For water pressure test of oil cooler element
99573 95500
1 99578 95500
2 99578 95501
LB-2-1
OIL PUMP
OIL PUMP
CONSTRUCTION
LB-3-1
OIL PUMP
REMOVAL
1. Remove the drain plug from the oil pan and drain the engine
oil into an oil tray.
WARNING
WARNING
z Before draining engine oil, ensure the engine is cool;
otherwise, you may be burned.
CAUTION
z Be sure to support the oil pan when removing the mount-
ing bolts.
NOTE
z Be sure to support the oil pump when removing it.
z Use a copper hammer to drive out the dowel pin.
LB-3-2
OIL PUMP
DISASSEMBLY
LB-3-3
OIL PUMP
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
Clearances and backlash of pump gears
Unit: mm (in)
Item Maintenance standard Service limit
0.05 - 0.11
Side clearance 0.15 (0.0059)
(0.0020 - 0.0043)
0.07 - 0.19
Tip clearance 0.20 (0.0079)
(0.0028 - 0.0075)
0.09 - 0.22
Backlash 0.50 (0.0197)
(0.0035 - 0.0087)
LB-3-4
OIL PUMP
REASSEMBLY
Key points of reassembly
When assembling each part, apply a coat of engine oil to the rotat-
ing and sliding surfaces.
5 Idler gear
Install the idler gear.
: 59 - 78 N·m {6.0 - 8.0 kgf·m, 43 - 58 ft·lbf}
NOTE
z Apply a coat of adhesive to the threading portion.
LB-3-5
OIL PUMP
INSTALLATION
1. Install the oil pump assembly.
: 30 - 41 N·m {3.1 - 4.2 kgf·m, 22 - 30 ft·lbf}}
2. Install the oil pipe and oil screen.
: 16 - 21 N·m {1.6 - 2.1 kgf·m, 12 - 15 ft·lbf}
3. Install the oil pan with the gasket in place.
: 15 N·m {1.5 kgf·m, 11 ft·lbf}
4. Install the drain plug with the gasket in place.
: 98 - 127 N·m {10.0 - 13.0 kgf·m, 72 - 94 ft·lbf}
5. Install the oil level gauge and guide.
6. Add the specified amount of engine oil.
NOTE
z The engine oil level is correct if it is close to the H mark
on the level gauge. It takes approximately 6 minutes for
the engine oil level to stabilize.
LB-3-6
OIL COOLER
OIL COOLER
REMOVAL
1. Remove the drain plug from the oil pan and drain the engine
oil into an oil tray.
NOTE
z Do not perform removal operations while the engine is
hot, e.g. just after the engine is stopped, as you may be
scalded.
2. Drain the cooling water by loosening the water drain cock.
LB-4-1
OIL COOLER
DISASSEMBLY
LB-4-2
OIL COOLER
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
NOTE
z Do not apply a pressure higher than 1,471 kPa {15 kgf/
cm2, 213 psi} for the water pressure test.
z Apply pressure for 2 to 3 minutes.
INSTALLATION
1. Install the element into the oil cooler housing with the pack-
ing in place.
: 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf}
2. Install the oil cooler housing to the engine block with the
gasket in place.
: 29 - 34 N·m {3.0 - 3.5 kgf·m, 22 - 25 ft·lbf}
3. Install the other pipes removed.
4. Add the specified amount of engine oil from the cap of the
oil filler.
5. Close the water drain cock and refill the specified amount of
cooling water.
6. Start up the engine and check to make sure that there is no
leakage of air or engine oil.
LB-4-3
OIL FILTER
OIL FILTER
CONSTRUCTION
LB-5-1
OIL FILTER
DISASSEMBLY
LB-5-2
OIL FILTER
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
REASSEMBLY
Reassemble the oil filter using the construction drawing. For the
tightening torque, refer to the following table.
Unit: N·m {kgf·m, ft·lbf }
Tightening point Tightening torque
Full-flow oil filter center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
By-pass oil filter center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
LB-5-3
OIL JET
OIL JET
CONSTRUCTION
1 Oil jet 2 Oil jet connector bolt
NOTE
z Numbers before part names do not indicate the disas-
sembly sequence.
REMOVAL
Loosen the oil jet connector bolt and remove it together with the oil
jet.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
Valve opening pressure of oil jet
Unit: kPa {kg/cm2, psi}
Maintenance standard Service limit
177 - 216 {1.8 - 2.2, 26 - 31}
INSTALLATION
Align the straight pin of the oil jet to the pin hole, then fix the oil jet
with the oil jet connector bolt.
: 29 - 39 N·m {3.0 - 4.0 kgf·m, 22 - 29 ft·lbf}
LB-6-1
COOLING SYSTEM
CONTENTS
SERVICE DATA................................ EC-1-1 INSPECTION ................................... EC-3-1
SPECIFICATIONS ............................ EC-1-1 INSTALLATION ................................ EC-3-1
SERVICE DATA................................ EC-1-1 RADIATOR AND COOLANT
TIGHTENING TORQUE ................... EC-1-2 RESERVOIR TANK.......................... EC-4-1
EC
COOLING SYSTEM ......................... EC-1-2 FLUSHING COOLING SYSTEM...... EC-4-1
WATER PUMP.................................. EC-2-1 INSPECTION ................................... EC-4-1
REMOVAL ........................................ EC-2-1 FAN CLUTCH................................... EC-5-1
EXTERNAL APPEARANCE CHECK AND CONSTRUCTION ............................ EC-5-1
CORRECTION ................................ EC-2-1 REMOVAL........................................ EC-5-3
INSTALLATION................................. EC-2-1 INSPECTION ................................... EC-5-3
THERMOSTAT EC-3-1 INSTALLATION ................................ EC-5-3
REMOVAL ........................................ EC-3-1
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
PF6 PF6T PF6TA PF6TB
Item
Cooling method Water cooled - forced circulation
Radiator Corrugated fin
FD1800L O
Type I O O O O
On-Off type FD2000
Type II O O O O
Fan clutch FD2000-C O O
SERVICE DATA
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
Valve opening temperature 74.5 - 78.5 73.0 - 80.0
ºC (ºF) (166 - 173) (163 - 176)
Thermostat
Valve lift Greater than Greater than
mm/ºC (in/ºF) 10/90 (0.39/194) 8.5/90 (0.33/194)
Valve opening pressure of coolant reservoir tank cap 49 - 69
Pressure side
kPa {kgf/cm2, psi} {0.5 - 0.7, 7 - 10}
Radiator leak test pressure kPa {kgf/cm2, psi} 98 {1.0, 14} By compressed air
0.072 - 0.142
Clearance between bearing box and pulley bracket bushing
(0.0028 - 0.0056)
600 mm (23.6 in)
Fan clutch 60 - 70
650 mm (25.6 in) Standard type (On-off type)
changeover temper- (140 - 158)
Fan dia. 700 mm (27.6 in)
ature
ºC (ºF) 60±10 - 75±5 Linear type (Disconnecting
700 mm (27.6 in)
(140±18 - 167±9) temperature)
Entire periphery (when
Clearance between cooling fan and fan shroud 5.0 (0.197) directly mounted to
engine)
8 - 12
Cooling fan to tension pulley When applied with 98 N
(0.32 - 0.47)
V-belt tension {10.0 kgf, 22 lbf} force at
15 - 18 midpoint.
Idler pulley to alternator
(0.59 - 0.71)
EC-1-1
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}}
Tightening point Tightening torque
Cooling fan 16 - 19 {1.6 - 1.9, 12 - 14}
Fan clutch assembly (with cooling fan) 30 - 36 {3.1 - 3.7, 22 - 27}
COOLING SYSTEM
EC-1-2
WATER PUMP
WATER PUMP
z Do not disassemble the water pump. If any abnormality is noted as a result of the external appear-
ance check, replace the whole water pump assembly.
REMOVAL
1. Drain the engine cooling water.
2. Disconnect the hoses, ducts, and tubes connected to the
water pump.
3. Remove the three bolts with the rubber ring in place.
4. Is there any grease leakage from the gear side of the water
pump?
INSTALLATION
Installation is the reverse of the removal procedure.
EC-2-1
THERMOSTAT
THERMOSTAT
REMOVAL
1. Drain the engine coolant.
2. Disconnect the radiator hose from the water outlet, then
remove the water outlet and rubber ring.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
INSTALLATION
Installation is the reverse of the removal procedure.
EC-3-1
RADIATOR AND COOLANT RESERVOIR TANK
NOTE
z Cover the cap with a thick and heavy rag, and remove it
gradually.
3. Flush repeatedly with tap water until the water drained from
the cooling system is completely clean.
4. Remove any dirt and dust accumulated between the radia-
tor core fins and tubes.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
Radiator leak test pressure
Plug all openings with wooden taps or the like, dip the entire radia-
tor into a container of water, and direct compressed air of 98 kPa
{1.0 kgf/cm2, 14 psi} into the radiator to determine if air leakage is
noticed. If air leakage is noticed, repair or replace the radiator.
Valve opening pressure of coolant reservoir tank cap
Unit: kPa {kgf/cm2, psi}
Maintenance standard Service limit Remarks
49 - 69 {0.5 - 0.7, 7 - 10} Pressure side
EC-4-1
RADIATOR AND COOLANT RESERVOIR TANK
Engine coolant
Check density of anti-freeze solution or LLC (Long Life Coolant)
using a tester. If it is low, add anti-freeze solution or LLC as
required to suit the areas where the vehicle is to be operated.
EC-4-2
FAN CLUTCH
FAN CLUTCH
CONSTRUCTION
ON-OFF TYPE
Model: FD1800L
Model: FD2000
EC-5-1
FAN CLUTCH
Model: FD2000-C
LINEAR TYPE
Model: FDL2000-C
EC-5-2
FAN CLUTCH
REMOVAL
1. Remove the fan and the fan clutch assembly as a unit.
2. Remove the fan from the fan clutch assembly.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
NOTE
z Care should be taken lest the bimetal is damaged or
deformed during removal and inspection.
Operation temperature check
1. Install the fan onto the fan clutch. Then run the fan drive
shaft continuously at a constant speed in the range from
2000 to 3000 rpm.
2. Install a thermometer and a drier, then blow hot air at the
bimetal.
3. Check to make sure that the speed of the fan changes from
low to high when the thermometer is indicating the following
temperature.
Unit: ºC (ºF)
Maintenance
Item Service limit
standard
FD1800L,
Fan clutch On-off 60 - 70
FD2000 and
changeove type (140 - 158)
FD2000-C
r tempera-
Linear 60±10 - 75±5
ture FDL2000-C
type (140±18 - 167±9)
INSTALLATION
1. Install the fan onto the fan clutch assembly.
: 16 - 19 N·m {1.6 - 1.9 kgf·m, 12 - 14 ft·lbf}
2. Install the fan and the fan clutch assembly as a unit.
: 30 - 36 N·m {3.1 - 3.7 kgf·m, 22 - 27 ft·lbf}
EC-5-3
FUEL SYSTEM
CONTENTS
SERVICE DATA................................. EF-1-1 NOZZLE AND NOZZLE HOLDER .... EF-4-1
SPECIFICATIONS ............................ EF-1-1 CONSTRUCTION ............................ EF-4-1
SERVICE DATA................................ EF-1-2 REMOVAL........................................ EF-4-1
TIGHTENING TORQUE ................... EF-1-2 DISASSEMBLY ................................ EF-4-2
FUEL SYSTEM................................. EF-1-3 REASSEMBLY ................................. EF-4-4
TOOLS............................................... EF-2-1 ADJUSTMENT ................................. EF-4-4
INJECTION PUMP ASSEMBLY........ EF-3-1 INSTALLATION ................................ EF-4-5 EF
INJECTION PUMP PROPER ........... EF-3-1 FUEL FILTER .................................... EF-5-1
FEED PUMP..................................... EF-3-4 REPLACEMENT .............................. EF-5-1
TIMER .............................................. EF-3-5 ENGINE CONTROL SYSTEM .......... EF-6-1
GOVERNOR..................................... EF-3-8 CONSTRUCTION ............................ EF-6-1
ADJUSTMENT ............................... EF-3-14 ADJUSTMENT ................................. EF-6-1
INJECTION PUMP CALIBRATION
DATA ............................................... EF-3-26
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
PF6 PF6T PF6TA PF6TB
Item
Ignition system Compression ignition
Fuel injection timing B.T.D.C. 16º 17º 16º 14º *1 16º 14º *2
Ignition order 1-4-2-6-3-5
Main Filter paper x 1
Fuel filter Type x Number
Primary Filter paper x 1
Type Bosch
NOTE
z *1: CKB454, 455. CWB454, 455
z *2: CKB453, CWB453, 455
EF-1-1
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
PF6 19,614 {200, 2,844}
Valve opening pressure
PF6T, PF6TA
kPa {kgf/cm2, psi} 22,556 {230, 3,271}
PF6TB
Nozzle 20,104 - 20,889
PF6
Fuel injection pressure {205 - 213, 2,915 - 3,029}
kPa {kgf/cm2, psi} PF6T, PF6TA 23,046 - 23,831
PF6TB {235 - 243, 3,342 - 3,455}
TIGHTENING TORQUE
INJECTION PUMP
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Delivery valve holder 108 - 118 {11.0 - 12.0, 80 - 87}
Delivery valve holder lock nut 39 - 44 {4.0 - 4.5, 29 - 33}
Screw bushing 39 - 59 {4.0 - 6.0, 29 - 43}
Timer special nut 83 - 93 {8.5 - 9.5, 61 - 69}
Bearing cover setting screw 7 - 9 0.{7 - 0.9, 5.1 - 6.5}
Governor housing setting screw 5 - 6 {0.5 - 0.6, 3.6 - 4.3}
Flyweight round nut 59 - 69 {6.0 - 7.0, 43 - 51}
Governor cover setting screw 5 - 7 {0.5 - 0.7, 3.6 - 5.1}
FUEL FILTER
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Connector bolt 25 - 41 {2.5 - 4.2, 18 - 30}
Center bolt 20 - 29 {2 - 3, 14 - 22}
EF-1-2
SERVICE DATA
FUEL SYSTEM
PF6T, PF6TA & PF6TB
EF-1-3
TOOLS
TOOLS
Tool name and number Description Shape
Pin vice For cleaning nozzle orifice
99727 Z5005
EF-2-1
TOOLS
EF-2-2
INJECTION PUMP ASSEMBLY
EF-3-1
INJECTION PUMP ASSEMBLY
EF-3-2
INJECTION PUMP ASSEMBLY
15 Tappet assembly
1. Attach the tappet inserter to both end-faces of the pump
housing.
Tool Name Tool Number Remarks
Tappet insert Shaft 157921-8020 For 6 cylinders
19 Spring seat
20 Control sleeve
Using the plunger inserter (157921-5620), remove the control
sleeve and the upper spring seat together.
NOTE
z If the ball attached to the sleeve and the pump housing's
tappet guide groove are not aligned during control sleeve
removal, the control sleeve and upper spring seat cannot
be removed.
EF-3-3
INJECTION PUMP ASSEMBLY
21 Screw bushing
Using the special wrench (157915-6500), remove the governor side
screw bushing.
FEED PUMP
DISASSEMBLY
EF-3-4
INJECTION PUMP ASSEMBLY
TIMER
DISASSEMBLY & REASSEMBLY
SP timer
EF-3-5
INJECTION PUMP ASSEMBLY
SPG timer
EF-3-6
INJECTION PUMP ASSEMBLY
<SP timer>
10 Roller
11 Bushing
Turn the wrench (157916-8320) to compress the timing device
spring and remove the washer, roller and bushing from the fly-
weight pin.
<SPG timer>
6 Flyweight assembly
EF-3-7
INJECTION PUMP ASSEMBLY
GOVERNOR
DISASSEMBLY & REASSEMBLY
Whole view
EF-3-8
INJECTION PUMP ASSEMBLY
Governor cover
EF-3-9
INJECTION PUMP ASSEMBLY
EF-3-10
INJECTION PUMP ASSEMBLY
Governor housing
EF-3-11
INJECTION PUMP ASSEMBLY
Boost compensator
EF-3-12
INJECTION PUMP ASSEMBLY
Aneroid compensator
NOTE
z Numbers before part names do not indicate the disassembly sequence.
EF-3-13
INJECTION PUMP ASSEMBLY
ADJUSTMENT
When the injection pump has been disassembled, plungers or
plunger springs have been replaced, or other reasons exist, use a
pump tester and adjust the injection pump.
EF-3-14
INJECTION PUMP ASSEMBLY
5. When fuel injection does not stop even when the tappet has
risen more than 3.65±0.05 mm (0.1437±0.0020 in) (PF6
and PF6T) or 3.90±0.05 mm (0.1535±0.0020 in) (PF6TA,
B), pull out the plunger block assembly, and remove adjust-
ing shims until the fuel flow stops at a lift of 3.65±0.05 mm
(0.1437±0.0020 in) (PF6 and PF6T) or 3.90±0.05 mm
(0.1535±0.0020 in) (PF6TA, B).
6. When the fuel flow stops before the tappet is raised
3.65±0.05 mm (0.1437±0.0020 in) (PF6 and PF6T) or
3.90±0.05 mm (0.1535±0.0020 in) (PF6TA, B), pull out the
plunger block assembly and add adjusting shims until the
fuel flow stops at a lift of 3.65±0.05 mm (0.1437±0.0020 in)
(PF6 and PF6T) or 3.20±0.05 mm (0.1535±0.0020 in)
(PF6TA, B).
Injection
--------- 1 — 4 — 2 — 6 — 3 — 5 — 1
order
Injection
--------- 60º 60º 60º 60º 60º 60º
interval
Scale plate
--------- 0º — 60º — 120º — 180º — 240º — 300º — 360º
indication
EF-3-15
INJECTION PUMP ASSEMBLY
NOTE
z If a boost compensator is installed on the pump's drive
side, remove it and then mount the measuring device.
EF-3-16
INJECTION PUMP ASSEMBLY
3. Increase the pump speed to “Na rpm” and adjust using the
full load stopper bolt so that the control rod position is “Ra”.
4. Next, lower the pump speed to “Nb rpm” and adjust the
high-speed lift to “L” using the stroke adjusting screw.
NOTE
z When the high-speed droop confirmation point is at the
point where the damper spring is operating, adjust the
idling and damper springs and then make the above
adjustments and confirmations.
z Replace the governor spring if the specified values can-
not be obtained.
4. Further increase the pump speed and confirm that the con-
trol rod is in the non-injection zone [or 3 mili-liter (0.11 Imp fl
oz)/1,000 st or less) at “Nm rpm”.
EF-3-17
INJECTION PUMP ASSEMBLY
Idling
1. Drive the pump at “Nc rpm” (Nd + 100 rpm).
2. Adjust the control rod position to “Rc” using the idle adjust-
ing screw.
3. Decrease the pump speed to “Ne rpm” and adjust the idling
spring capsule using the wrench (157916-2620) so that the
control rod position is “Rd”.
EF-3-18
INJECTION PUMP ASSEMBLY
Damper spring
1. Hold the load control lever at the idling position.
2. Slowly increase the pump speed from idling speed “Ne
rpm”, and maintain the pump speed of “Nc rpm” where the
control rod position is “Rf - 0.2mm”.
Stopper bolt
If idling performance is included in calibration data, as represented
by the dotted line in the illustration at right, adjust the setting of the
idle adjusting screw.
1. After adjusting the damper spring, the control rod position
should be “Re” when the pump is stopped.
EF-3-19
INJECTION PUMP ASSEMBLY
3. Slowly increase the pump speed from “Nc rpm” and adjust
the screw so that the torque control spring starts to take
effect at “Nf rpm”.
NOTE
z When shims are used, adjust by varying the shim thick-
ness.
4. Increase the pump speed and confirm that the torque con-
trol spring stops taking effect at “Nh rpm”.
5. Increase and decrease the pump speed between “Nc rpm”
and “Nb rpm” and confirm that the torque control stroke is
NOTE the specified value.
z If the torque control stroke is not the specified value,
readjust using the spring capsule screw.
z If the torque control spring does not stop taking effect at
the specified speed, replace the spring capsule.
EF-3-20
INJECTION PUMP ASSEMBLY
z Variable-speed governor
1. Fix the load control lever in the full load position.
2. Return the speed control lever in the fuel-decrease direction
and drive the pump at “Ny rpm”, slightly faster than idling
speed.
EF-3-21
INJECTION PUMP ASSEMBLY
NOTE
z The plug on the side of the governor cover is used to
hold the torque lever. Thus, this plug has no relationship
to torque spring adjustment and should not be touched.
The plug is coated with paint to draw attention to it at
repair shops. If this paint seal should be broken, disas-
semble the governor, check the torque lever position and
then repaint it.
Smoke limiter
1. Hold the load control lever in the full load position.
2. Maintain the pump speed at “Nn rpm”.
3. Screw in the spring capsule or screw and lock it at point E,
where the specified fuel injection quantity may be obtained.
NOTE
z There is no rack limiter when a boost compensator is
mounted on the drive side.
EF-3-22
INJECTION PUMP ASSEMBLY
3. Hold the load control lever in the full load position and drive
the pump at a speed of “Nu rpm” (500 rpm unless otherwise
specified).
EF-3-23
INJECTION PUMP ASSEMBLY
6. Increase the boost pressure and confirm that the control rod
is in position R1 at P1. Also confirm that the control rod is at
the R2 position at P2.
7. If not as specified, replace the boost compensator spring.
EF-3-24
INJECTION PUMP ASSEMBLY
EF-3-25
INJECTION PUMP ASSEMBLY
NOTE
z The injection quantity and the governor must be adjusted at an ambient temperature of at least
15ºC (59ºF) (as the boost compensator start spring is a shape-memory alloy).
EF-3-26
INJECTION PUMP ASSEMBLY
NOTE
z The injection quantity and the governor must be adjusted at an ambient temperature of at least
15ºC (59ºF) (as the boost compensator start spring is a shape-memory alloy).
z ZEXEL No. 106671-5101
Pump Injection q'ty mili- Max. var
Adjusting Rack Position
Speed liter (Imp fl oz)/ bet. cyl Fixed Remarks
Point mm (in)
rpm 1,000 strokes (%)
159.5±2
A 10.8 (0.425) 600 ±4 Rack
(5.61±0.07)
Basic
Approx. 6.2 14±1.3
H 260 ±10 Rack
(0.244) (0.49±0.05)
Basic
159.5±2
A 10.8 (0.425) 600 Lever Boost press. kPa {mmHg, inHg}
(5.61±0.07)
Above 34.7 {260, 10.3}
Boost press. kPa {mmHg, inHg}
B 10.8 (0.425) 1,050 Lever
Above 34.7 {260, 10.3}
125±3
C 9.5 (0.374) 400 Lever Boost press. 0
(4.40±0.11)
Boost press. kPa {mmHg, inHg}
D 10.8 (0.425) 40 Lever
Above 34.7 {260, 10.3}
Boost press. kPa {mmHg, inHg}
E 10.3 (0.406) 500 Lever 16.0±1.3
{120±10, 4.72±0.39}
Approx. 6.2
F 290 Lever Boost press. 0
(0.244)
EF-3-27
INJECTION PUMP ASSEMBLY
The injection quantity and the governor must be adjusted at an ambient temperature of at least 15ºC
(59ºF) (as the boost compensator start spring is a shape-memory alloy).
The injection quantity and the governor must be adjusted at an ambient temperature of at least 15ºC
(59ºF) (as the boost compensator start spring is a shape-memory alloy).
EF-3-28
INJECTION PUMP ASSEMBLY
NOTE
z The injection quantity and the governor must be adjusted at an ambient temperature of at least
15ºC (59ºF) (as the boost compensator start spring is a shape-memory alloy).
NOTE
z The injection quantity and the governor must be adjusted at an ambient temperature of at least
15ºC (59ºF) (as the boost compensator start spring is a shape-memory alloy).
EF-3-29
INJECTION PUMP ASSEMBLY
EF-3-30
INJECTION PUMP ASSEMBLY
EF-3-31
INJECTION PUMP ASSEMBLY
EF-3-32
INJECTION PUMP ASSEMBLY
EF-3-33
INJECTION PUMP ASSEMBLY
EF-3-34
INJECTION PUMP ASSEMBLY
EF-3-35
INJECTION PUMP ASSEMBLY
EF-3-36
INJECTION PUMP ASSEMBLY
EF-3-37
INJECTION PUMP ASSEMBLY
TESTING TIMER
In general, measurement of the timer advance angle is performed
on the pump tester after completing an adjustment of the injection
timing, injection quantity and governor.
EF-3-38
NOZZLE AND NOZZLE HOLDER
NOTE
z Type I: Nozzle holder assembly abbreviation No. 31-4370
z Type II: Nozzle holder assembly abbreviation No. 30-4540
REMOVAL
1. Chock the wheels and tilt the cab.
2. Turn the key switch off and disconnect the cable from the
negative terminal of the battery.
3. Disconnect the injection nozzle tube and spill tube, remove
the nozzle holder assembly from the cylinder head.
EF-4-1
NOZZLE AND NOZZLE HOLDER
DISASSEMBLY
EF-4-2
NOZZLE AND NOZZLE HOLDER
7 Retaining nut
Reverse the nozzle holder position by facing the nozzle-side up,
and remove the retaining nut with a appropriate wrench.
8 Nozzle assembly
Remove the nozzle needle from the nozzle body.
NOTE
z Do not use the nozzle needle in another nozzle body.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
NOTE
z Remove carbon from around nozzle jets using a wire
brush.
Clearance between nozzle body and nozzle
1. Remove carbon from around nozzle jets using the pin vise
(99727 Z5005).
Unit: mm (in)
Nozzle identifica- Number of injection Injection nozzle
Wire diameter
tion mark nozzle holes hole diameter
F8 6 0.310 (0.0122) 0.29 (0.0114)
H4 5 0.350 (0.0138) 0.29 (0.0114)
H2 5 0.360 (0.0142) 0.35 (0.0138)
H5 6 0.315 (0.0124) 0.29 (0.0114)
K1 6 0.320 (0.0126) 0.29 (0.0114)
NOTE
z Do not extend tip of the holder more than 2 to 2.5 mm
(0.079 to 0.098 in). Otherwise, it may bend inside the noz-
zle body and it cannot be removed.
z Carefully push the holder into the inside of the nozzle to
remove carbon.
z Use an oil stone to grind the wire tip of the holder until it
is shaped as shown in the figure.
EF-4-3
NOZZLE AND NOZZLE HOLDER
2. Clean remaining carbon off the back of the nozzle jet using
the nozzle cleaner (99726 Z5000).
NOTE
z Be careful not to scratch the seating surface of the noz-
zle jet and the nozzle needle.
Do not use compressed air to remove carbon because
this may introduce foreign matter into the jet.
3. Install the needle on the nozzle body while immersing both
in clean diesel fuel.
4. Visually check the needle valve seat, guide shaft and injec-
tion shaft for damage or carbon accumulation.
5. Position the nozzle body vertically. Pull out the needle so
that it protrudes approximately 1/3 its total length beyond
the top of the nozzle body. Then release it to ensure that it
drops to the valve seat under its own weight.
REASSEMBLY
1. To reassemble, reverse the order of the above removal pro-
cedures. Observe the following:
NOTE
z Clean the mating surfaces of the nozzle and nozzle
holder and the retaining nut in clean diesel fuel before
installation.
z Use new gaskets.
ADJUSTMENT
1. Loosen the adjusting screw and install the nozzle on a noz-
zle tester. Operate the hand lever forcefully two or three
times to remove foreign matter.
2. Adjust fuel injection pressure using the adjusting screw.
Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit Remarks
20,104 - 20,889
Fuel injec- PF6
{205 - 213, 2,915 - 3,029}
tion pres-
sure 23,046 - 23,831
PF6T PF6TA PF6TB
{235 - 243, 3,342 - 3,455}
EF-4-4
NOZZLE AND NOZZLE HOLDER
WARNING
WARNING
z Be extremely careful not to direct fuel spray to hands,
etc. while adjusting fuel injection. It may penetrate into
blood vein through the skin and cause toxic symptoms.
Type I
: 39 - 49 N·m {4 - 5 kgf·m, 29 - 36 ft·lbf}
Type II
: 29 - 39 N·m {3 - 4 kgf·m, 22 - 29 ft·lbf}
INSTALLATION
1. Install the nozzle holder assembly on the cylinder head.
: 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf}
2. Connect the spill tube and injection nozzle tube.
3. Bleed air from the fuel system. (Refer to the “MA” section
for procedures.)
EF-4-5
FUEL FILTER
FUEL FILTER
REPLACEMENT
REPLACE FUEL FILTER ELEMENT
Method of replacement
Cartridge type
1. Place a container under the filter. Remove the filter with a
filter wrench. Drain any remaining fuel into the container.
2. Apply a thin coat of clean engine oil to the gasket of the new
filter.
CAUTION
z Installation of the fuel filter without coating the gasket
with oil may damage the gasket resulting in leakage of
fuel and fire hazard due to spilled fuel.
3. Install the new fuel filter. After the gasket comes in contact
with the bracket sealing surface, tighten an additional three-
fourths of a turn.
NOTE
z When installing the fuel filter, securely tighten it three-
fourths of a turn using the exclusive filter wrench pro-
vided in the vehicle.
EF-5-1
FUEL FILTER
NOTE
z Do not excessively tighten bolts and plugs.
Disassembly sequence (Reassembly sequence is in the
reverse order of disassembly.)
1 Drain plug 6 Spring
2 Packing 7 Seat
3 Center bolt 8 Element
4 Packing 9 Packing
5 Filter case 10 Filter cover
EF-5-2
FUEL FILTER
EF-5-3
ENGINE CONTROL SYSTEM
ADJUSTMENT
ENGINE CONTROL WIRE
1. Turn the engine control knob counterclockwise all the way.
Under this condition, install the engine control wire to lever
B.
2. Install the engine control wire clamp to the accelerator link-
age assembly.
3. With the accelerator pedal contacting lever B, make sure
the accelator pedal angle is 50º to the floor.
EF-6-1
ENGINE CONTROL SYSTEM
ACCELERATOR WIRE
1. Connect one end of the accelerator wire to lever. Securely
fit the clip on the wire in the panel.
NOTE
z Be careful not to break the boot.
EF-6-2
- MEMO -
AIR INTAKE AND EXHAUST
SYSTEM
CONTENTS
SERVICE DATA.................................. IE-1-1 INSTALLATION ................................ IE-3-15
SPECIFICATIONS ............................. IE-1-1 INTERCOOLER.................................. IE-4-1
SERVICE DATA................................. IE-1-2 CONSTRUCTION .............................. IE-4-1
TIGHTENING TORQUE .................... IE-1-3 AIR CLEANER ................................... IE-5-1
INTAKE AND EXHAUST SYSTEM.... IE-1-4 DISASSEMBLY .................................. IE-5-1
TOOLS................................................ IE-2-1 ELEMENT REPLACEMENT .............. IE-5-1
TURBOCHARGER ............................. IE-3-1 EXHAUST BRAKE ............................. IE-6-1
CONSTRUCTION .............................. IE-3-1 CONSTRUCTION .............................. IE-6-1 IE
REMOVAL ......................................... IE-3-1 DISASSEMBLY .................................. IE-6-4
DISASSEMBLY ................................. IE-3-2 INSPECTION ..................................... IE-6-7
INSPECTION..................................... IE-3-7 REASSEMBLY ................................... IE-6-7
REASSEMBLY ................................ IE-3-11
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
AIR CLEANER
Engine model PF6 PF6T PF6TA PF6TB
Type Cyclone
Element Paper element (Dry) or Metallic element Paper element (Dry)
TURBOCHARGER
Engine model PF6 PF6T PF6TA PF6TB
Model and (Type) T51 (Type I) T51 (Type I), T51 (Type II)
External dimensions
(Length x Width x Height) 220 x 209.5 x 178 (8.66 x 8.25 x 7.01)
mm (in)
Max. permissible continu-
ous speed 105,000
rpm
Direction of rotation Counterclockwise as viewed from the exhaust turbine side
Air volume
21 (46) 22.8 (50.3)
kg/min (lb/min)
Compression ratio 3.2
NOTE
z Type I: No O-ring on back plate
z Type II: O-ring provided on back plate
Refer to the illustration on page IE-3-2.
INTERCOOLER
Engine model PF6 PF6T PF6TA PF6TB
Type Air to air
Intercooler Corrugated fin
EXHAUST BRAKE
Engine model PF6 PF6T PF6TA PF6TB
Type Cylinder type
Operating method Air type
Exhaust shutter type Type II Type I
IE-1-1
SERVICE DATA
SERVICE DATA
TURBOCHAGER
Unit: mm (in)
Item Maintenance standard Service limit Remarks
0.025 - 0.080
Play in shaft axial direction
(0.0010 - 0.0031)
INTERCOOLER
Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit Remarks
Intercooler check pressure (air) 196 {2.0, 28}
EXHAUST BRAKE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
When compressed to 105
Air intake shutter side 94.1 {9.6, 21.2}
Spring tension mm (4.13 in)
Air cylinder
N {kgf, lbf} When compressed to 113.2
Exhaust shutter side 77.5 {7.9, 17.4}
mm (4.46 in)
More than
Valve movement in the Type I
0.7 (0.028)
axial direction when clos-
ing the valve More than
Type II
0.5 (0.020)
Exhaust shutter
0.1 - 0.4
One side
Clearance between valve (0.004 - 0.016)
and body 0.2 - 0.5
Both sides
(0.008 - 0.020)
More than
Clearance between air cylinder shaft and clevis
1.0 (0.04)
IE-1-2
SERVICE DATA
TIGHTENING TORQUE
TURBOCHARGER
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Oil inlet adapter mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Oil drain pipe mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Thrust bearing mounting screw 3.4 - 3.9 {0.35 - 0.40, 2.5 - 2.9}
Back plate and center housing mounting bolt 10.2 - 11.9 {1.04 - 1.21, 7.5 - 8.8}
Compressor wheel mounting nut 3.6 - 4.7 {0.37 - 0.48, 2.7 - 3.5} -> Tighten (120º)
Clamp mounting bolt 9.0 - 11.3 {0.92 - 1.15, 6.7 - 8.3}
Turbine housing and center housing mounting V-band lock nut 17.0 {1.73, 12.5} -> Loosen -> 13.7 {1.40, 10.1}
Turbocharger assembly mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
EXHAUST BRAKE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Air cylinder mounting nut Exhaust shutter side 21 - 25 {2.1 - 2.6, 15 - 19}
Air cylinder mounting bolt Air intake shutter side 36 - 50 {3.7 - 5.1, 27 - 37}
Air cylinder cover mounting bolt 10 - 16 {1.0 - 1.6, 7 - 12}
Air cylinder shaft nut 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter shaft nut 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter shaft cover mounting nut 21 - 25 {2.1 - 2.6, 15 - 19}
Lever mounting nut (Exhaust shutter only) 10 - 16 {1.0 - 1.6, 7 - 12}
Stopper bolt lock nut (Exhaust shutter only) 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter mounting bolt 21 - 25 {2.1 - 2.6, 15 - 19}
IE-1-3
SERVICE DATA
With turbocharger
IE-1-4
SERVICE DATA
IE-1-5
SERVICE DATA
EXHAUST SYSTEM
NOTE
z The above illustration is an example. It differs according to model and specifications.
IE-1-6
TOOLS
TOOLS
TURBOCHARGER
Tool name and number Description Shape
Turbocharger tool kit Used when disassembling and reassembling the
99760 96004 turbocharger.
Deep socket Used to tighten and remove the nut of the V-band.
99535 96000
Piston ring guide Used when inserting the piston ring to the
99763 96000 turbine wheel.
IE-2-1
TURBOCHARGER
TURBOCHARGER
CONSTRUCTION
REMOVAL
WARNING
WARNING
z To avoid being burned, do not touch the exhaust pipe,
turbocharger and muffler while the engine is running or
immediately thereafter. Check that the engine has cooled
before starting work.
IE-3-1
TURBOCHARGER
DISASSEMBLY
TYPE I & TYPE II
IE-3-2
TURBOCHARGER
NOTE
z When measuring the axial play, do not turn the turbine
wheel as this will cause the measurement error to
become large.
Unit: mm (in)
IE-3-3
TURBOCHARGER
5 Compressor housing
Remove the compressor housing.
Loosen the compressor bolt and remove the clamp.
NOTE
z Be careful not to damage the compressor wheel.
NOTE
z The compressor wheel and turbine wheel are precisely
dynamically balanced and cannot be repaired. Therefore,
they must be handled with extra special care.
6 Rotating assembly
Place Holding Fixture (99768 96009) in a vise, and set the turbine
wheel on it with the compressor wheel on it with the turbine wheel
side facing downward.
8 Compressor wheel
1. Remove the compressor wheel.
z Using a T-handle (99773 96000), remove the lock nut, and
then remove the compressor wheel by hand.
NOTE
z Since bending of the turbine wheel is also related to the
life of the turbocharger, be careful not to bend it.
z Support the turbine wheel by hand while loosening the
lock nut.
IE-3-4
TURBOCHARGER
10 Piston ring
Remove the piston ring.
NOTE
z Once removed, the piston ring must always be replaced
with a new piston ring when reassembling.
However, since the turbine wheel can be reused, be care-
ful not to damage it.
12 Back plate
Remove the backplate. Loosen the backplate bolt, remove the
washer and remove the backplate.
NOTE
z When the backplate cannot be removed by hand, tap the
center housing lightly with a wooden mallet and then
remove.
IE-3-5
TURBOCHARGER
19 Journal bearing
1. Remove the journal bearing.
NOTE
z Be careful not to damage the center housing when
removing the retainer ring.
IE-3-6
TURBOCHARGER
INSPECTION
INSPECTION BEFORE CLEANING
Turbocharger failure may sometimes be due to faulty engine parts.
It is, therefore advisable to closely inspect parts for accumulation of
carbon, presence of dirt or dust, obstruction of oil passages, etc.
prior to cleaning, so that the cause of problems may be located
easily.
CLEANING
After soaking all the parts in clean detergent for about 20 to 30 min-
utes, remove dirt and grime with a rough brush and then blow dry
with compressed air.
NOTE
z Be extremely careful not to damage parts. Avoid filing
any rotating parts. Also be sure to clean parts com-
pletely. Failure to observe these points may cause the
parts to become imbalanced.
IE-3-7
TURBOCHARGER
INSPECTION
Inspect parts visually, replacing as necessary.
IE-3-8
TURBOCHARGER
NOTE
z If the measured value exceeds the maintenance stan-
dard, replace the part.
Inside diameter of center housing
Unit: mm (in)
Item Maintenance standard Service limit
Bearing part (A) 20.19 (0.7949)
Piston ring part (B) 20.93 (0.8240)
Runout of shaft
Unit: mm (in)
Maintenance standard Service limit
0.01 (0.0004)
IE-3-9
TURBOCHARGER
Thrust collar
Unit: mm (in)
Item Maintenance standard Service limit
Groove width (A) 4.44 (0.1748)
IE-3-10
TURBOCHARGER
Journal bearing
Unit: mm (in)
Item Maintenance standard Service limit
Outside diameter 20.07 (0.7902)
Inside diameter 13.04 (0.5134)
REASSEMBLY
PREPARATIONS BEFORE REASSEMBLY
Repair light damage by polishing. Aluminum parts must be polished
with a polishing cloth using silicon carbide.
Moreover, steel parts must be polished with a polishing cloth using
polishing powder. Always replace the following parts.
IE-3-11
TURBOCHARGER
NOTE
z Ensure that the open end of the retaining ring faces the
oil outlet and the round portion faces the journal bearing.
z Be careful not to damage the center housing when
installing the retaining ring.
z Coat the inner and outer periphery of journal bearing
with engine oil.
z Replace the journal bearing with a new one.
IE-3-12
TURBOCHARGER
10 Piston ring
Using a piston ring guide (99763 96000), insert the piston ring into
the turbine wheel.
9 Turbine wheel
1. Place the center housing assembly on the compressor
housing.
2. Apply a coat of engine oil to the turbine wheel journal, and
carefully insert the turbine wheel into the bore in the center
housing.
Use a pick (99767 96003) to compress the piston ring and
install it while rotating the wheel shaft.
NOTE
z Be careful not to scratch or break the piston ring.
z Ensure that the open end of the piston ring faces the oil
inlet.
8 Compressor wheel
z Before installing the compressor wheel, clean the parts and
check carefully the tightening surface for dust or foreign
matter.
IE-3-13
TURBOCHARGER
5 Compressor housing
Attach the compressor housing to the back plate by properly align-
ing their marks, then tighten the bolts with the clamps.
: 9.0 - 11.3 N·m {0.92 - 1.15 kgf·m, 6.7 - 8.3 ft·lbf}
3 Turbine housing
1. Install the turbine housing to the center housing by aligning
the alignment marks. Using a deep socket (99535 96000),
tighten the V-band.
1st ... 17.0 N·m {1.73 kgf·m, 12.5 ft·lbf}
2nd ... Loosen
3rd ... 13.7 N·m {1.4 kgf·m, 10.1 ft·lbf}
IE-3-14
TURBOCHARGER
INSTALLATION
1. Install the turbocharger assembly on the exhaust manifold
using a gasket.
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
NOTE
z Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
2. Install the exhaust connector using a gasket and spacer to
the turbocharger assembly.
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
NOTE
z Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
3. Install the oil pipe.
: 21 - 26 N·m {2.1 - 2.7 kgf·m, 15 - 20 ft·lbf}
4. Connect the oil drain pipe to the turbocharger.
: 21 - 26 N·m {2.1 - 2.7 kgf·m, 15 - 20 ft·lbf}
5. Install the turbocharger shield plate, shield bracket and
exhaust connector shield plate.
6. Connect the air intake duct and exhaust pipe using a gas-
ket.
7. After installing the turbocharger assembly, crank the engine
using the sub-starter switch. Crank for approximately 10 to
20 seconds while pulling the engine stop lever. Crank the
engine until the oil pressure gauge activates, since oil is not
distributed to the oil line.
IE-3-15
INTERCOOLER
INTERCOOLER
CONSTRUCTION
INSPECTION
Remove the intercooler. If mud, insects, etc. are attached to the front surface of the intercooler core, remove
them using a copper wire or the like exercising care not to damage the tube.
Water pressure test
Seal one of the air intakes on the intercooler with a lid and connect a hose to the other intake. Then submerge
the intercooler under water in a tank and blow compressed air through the hose to the specified pressure to
check for air leakage.
Intercooler check pressure (air): 196 kPa {2.0 kgf/cm2, 28 psi}
IE-4-1
AIR CLEANER
AIR CLEANER
DISASSEMBLY
ELEMENT REPLACEMENT
For inspection and maintenance procedures, refer to the “MA” section.
IE-5-1
EXHAUST BRAKE
EXHAUST BRAKE
CONSTRUCTION
EXHAUST SHUTTER
Type I
IE-6-1
EXHAUST BRAKE
Type II
IE-6-2
EXHAUST BRAKE
IE-6-3
EXHAUST BRAKE
DISASSEMBLY
WARNING
WARNING
z Before disassembling the exhaust system, ensure that
the engine is cool. If it is hot, wait until it cools off to pre-
vent scalding yourself.
EXHAUST SHUTTER
Type I and Type II
Mark “+” and “,” indicates that the key points of operation are explained in the text.
IE-6-4
EXHAUST BRAKE
IE-6-5
EXHAUST BRAKE
AIR CYLINDER
IE-6-6
EXHAUST BRAKE
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
AIR CYLINDER
Spring tension
Unit: N {kgf, lbf}
Maintenance Service
Item Remarks
standard limit
Air intake shutter When compressed to 105 mm
94.1 {9.6, 21.2}
side (4.13 in)
Exhaust shutter When compressed to 113.2 mm
77.5 {7.9, 17.4}
side (4.46 in)
EXHAUST SHUTTER
Valve movement in the axial direction when closing the
valve
Unit: mm (in)
Item Maintenance standard Service limit
PF6T, PF6TA, B Type I More than 0.7 (0.028)
PF6 Type II More than 0.5 (0.020)
REASSEMBLY
EXHAUST SHUTTER
Key point of reassembly
10 11 12 13 Seal ring
Install the seal rings so that rings with different shapes are placed
next to each other.
IE-6-7
EXHAUST BRAKE
8 Stopper bolt
Turn the lever open all the way until it hits the stopper bolt.
Adjust the stopper bolt with the lever in this position, so that the
valve and the body flange surface make a 90 degree angle. Then,
turn the lever shut all the way until it hits the stopper bolt again.
Adjust the stopper bolt with the lever in this position, so that the
valve-to-body clearance is 0.1 to 0.4 mm (0.004 to 0.016 in) for one
side, and 0.2 to 0.5 mm (0.008 to 0.020 in) when both sides are
added.
After adjustment, fasten the stopper bolt with the lock nut.
Unit: mm (in)
Item Maintenance standard Service limit
0.1 - 0.4
Clearance One side
(0.004 - 0.016)
between valve
and body 0.2 - 0.5
Both sides
(0.008 - 0.020)
IE-6-8
- MEMO -
ELECTRICAL SYSTEM
CONTENTS
SERVICE DATA................................ EE-1-1 ALTERNATOR EE-4-1
SPECIFICATIONS ............................ EE-1-1
SERVICE DATA................................ EE-1-1 = UNIT NAME LR240-602, LR240-603,
TIGHTENING TORQUE ................... EE-1-3 LR250-602 AND LR250-603 =
STARTING MOTOR ......................... EE-2-1 CONSTRUCTION ............................ EE-4-1
TROUBLESHOOTING ..................... EE-4-2
= UNIT NAME S210-112 = DISASSEMBLY ................................ EE-4-3
CONSTRUCTION............................. EE-2-1 INSPECTION ................................... EE-4-5
TROUBLESHOOTING ..................... EE-2-2 PERFORMANCE TEST ................... EE-4-8
DISASSEMBLY ................................ EE-2-3
INSPECTION.................................... EE-2-4 = UNIT NAME 0201 102 2920,
ADJUSTMENT ................................. EE-2-7 0201 102 2973, 0201 152 0020
EE
PERFORMANCE CHECK ................ EE-2-8 AND 0201 152 0053 =
CONSTRUCTION ............................ EE-5-1
= UNIT NAME 0350 602 0260 TROUBLESHOOTING ..................... EE-5-2
AND 0350 602 0330 = DISASSEMBLY ................................ EE-5-4
CONSTRUCTION............................. EE-3-1 INSPECTION ................................... EE-5-6
TROUBLESHOOTING ..................... EE-3-2 PERFORMANCE TEST ................... EE-5-7
DISASSEMBLY ................................ EE-3-3 AIR HEATER ..................................... EE-6-1
INSPECTION.................................... EE-3-4 CONSTRUCTION ............................ EE-6-1
ADJUSTMENT ................................. EE-3-8 INSPECTION ................................... EE-6-1
PERFORMANCE CHECK ................ EE-3-8
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
STARTING MOTOR
Model 0350 602 0260
S210-112
Item 0350 602 0330
Type Shift
Output V-kW 24-6.0
Rated time Second 30
Manufacturer Hitachi Sawafuji
ALTERNATOR
Model LR240-602 LR250-602 0201 102 2920 0201 152 0020
Item LR240-603 LR250-603 0201 102 2973 0201 152 0053
Output V-A 24-40 24-50 24-40 24-50
Type of regulator IC type
Manufacturer Hitachi Sawafuji
AIR HEATER
Type Ribbon
Rated current V-A 11.2-85
Rated time Second Less than 60
SERVICE DATA
STARTING MOTOR
Model S210-112
Unit: mm (in)
Part Item Maintenance standard Service limit Remarks
Runout 0.05 (0.0020) 0.4 (0.016)
Commutator 0.5 - 0.8
Undercut depth 0.2 (0.008)
(0.020 - 0.031)
Brush height 14.0 (0.551)
Brush Brush spring tension
34.3 {3.5, 7.7} 24.5 {2.5, 5.5} When spring is set
N {kgf, lbf}
Shaft diameter 14.9 (0.587)
EE-1-1
SERVICE DATA
Insulation resis- Armature, field MΩ More than 1.0 Less than 0.5
tance Brush holder MΩ More than 1.0 Less than 0.5
Clearance between pinion gear and pinion
Pinion gear 0.5 - 3.0 (0.020 - 0.118)
stopper
Terminal voltage
Current A Less than 100
24V
Performance test
(no load) Motor speed rpm More than 4,000
Pinion pop out voltage V Less than 16
ALTERNATOR
Model LR240-602, LR240-603, LR250-602 and LR250-603
Part Item Maintenance standard Service limit Remarks
LR240-602
0.14
LR240-603 Single phase [At
Resistance Starter coil
LR250-602 20ºC (68ºF)]
Ω 0.09
LR250-603
Coil Field coil 11
LR240-602
More than 40
Output current LR240-603 27V
A LR250-602 At 20ºC (68ºF)
More than 50
LR250-603
Regulating voltage
28.0 - 29.0 At 20ºC (68ºF)
V
Speed required to increase voltage to 27 volts
Less than 950 At 20ºC (68ºF)
rpm
EE-1-2
SERVICE DATA
Model 0201 102 2920, 0201 102 2973, 0201 152 0020
and 0201 152 0053
Unit: mm (in)
Maintenance
Part Item Service limit Remarks
standard
0201 102 2920
0.36 - 0.44
0201 102 2973 Between two phases
Starter coil
0201 152 0020 [At 20ºC (68ºF)]
0.19 - 0.24
Resistance 0201 152 0053
Coil
W 0201 102 2920
7.0 - 9.0
0201 102 2973
Field coil At 20ºC (68ºF)
0201 152 0020
5.0 - 7.0
0201 152 0053
Less than
Shaft outside diameter of the front part 25.0 (0.9843)
24.98 (0.9835)
Rotor
Less than
Shaft outside diameter of the rear part 17.0 (0.6693)
16.98 (0.6685)
More than
Inside diameter of front bearing fitting hole 62.0 (2.441)
62.1 (2.445)
Bracket
More than
Inside diameter of rear bearing fitting hole 23.8 (0.937)
23.80 (0.9370)
0201 102 2920
More than 40
Output current 0201 102 2973 28V, 5,000 rpm
A 0201 152 0020 [At 20ºC (68ºF)]
More than 50
0201 152 0053
Regulating voltage
28.0 - 29.0 At 20ºC (68ºF)
V
Speed required to increase voltage to 27 volts
Less than 900 At 20ºC (68ºF)
rpm
TIGHTENING TORQUE
STARTING MOTOR
Model S210-112
Unit: N·m {kgf·m, ft·lbf}
Part Tightening torque Remarks
C terminal 2.5 - 2.9 {0.25 - 0.30, 1.8 - 2.2}
B terminal 20 - 22 {2.0 - 2.2, 15 - 16}
EE-1-3
SERVICE DATA
ALTERNATOR
Model LR240-602, LR240-603, LR250-602 and LR250-603
Unit: N·m {kgf·m, ft·lbf}
Part Tightening torque Remarks
Alternator mounting nut 13.7 - 25.5 {1.40 - 2.60, 10.1 - 18.8}
B and E terminals 3.9 - 4.9 {0.4 - 0.5, 2.9 - 3.6}
Model 0201 102 2920, 0201 102 2973, 0201 152 0020 and 0201 152 0053
Unit: N·m {kgf·m, ft·lbf}
Part Tightening torque Remarks
Size M4 1.0 - 1.4 {0.10 - 0.14, 0.7 - 1.0}
Screw
Size M5 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
Pulley mounting nut 96 - 127 {9.8 - 13.0, 71 - 94}
B and E terminals 3.2 - 4.4 {0.33 - 0.45, 2.4 - 3.3}
Through bolt 6 - 9 {0.6 - 0.9, 4.3 - 6.5}
EE-1-4
STARTING MOTOR S210-112
STARTING MOTOR
= UNIT NAME S210-112 =
CONSTRUCTION
EE-2-1
Engine does not
start.
*A
Does engine turn No Does starting motor turn? No Check battery for charging condition N.G. z Charge or replace battery.
by cranking? and battery terminals for connections z Repair connections and corrosion of
and corrosion. battery terminals.
Yes Yes
O.K.
Yes No
TROUBLESHOOTING
Does gear shaft turn? Check pinion roller Can you hear starter relay operating? Check and repair wiring system of block
clutch for damage. (Block relay equipped model only) relay.
Replace if neces- z Key switch.
No sary. Yes z Starter relay.
z Connections.
Check reduction gear Can you hear magnetic switch operating No z Check and repair wiring up to mag-
parts (armature, gear sound? netic switch.
shaft). Replace if neces- z Repair or replace magnetic switch.
sary. Yes
N.G.
(Turns
Does starting motor slowly) Check battery for charging N.G. Is meshing condition of pinion and ring N.G. z Check lever assembly for deforma-
turn normally? condition and battery ter- *A gear normal? tion, weak return spring and pinion
minals for connections and for sliding condition.
O.K. corrosion. O.K. z Correct meshing condition of pinion
EE-2-2
and ring gear. Replace if necessary.
O.K.
N.G. No
STARTING MOTOR
Check ignition sys- Replace engine Remove starting motor from engine. Replace motor (field coil or armature).
Check engine oil viscosity. oil.
tem and fuel sys- Does starting motor turn under no load
tem. by connecting battery (+) terminal to M
O.K. terminal of starting motor and battery
(–) terminal to starting motor body?
Yes
Does engine turn by Yes Repair or replace Check magnetic switch contacts.
replacing starting motor starting motor. Replace if necessary.
with a new one?
No
DISASSEMBLY
EE-2-3
STARTING MOTOR S210-112
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
COMMUTATOR
Runout
Unit: mm (in)
Maintenance standard Service limit
0.05 (0.0020) 0.4 (0.016)
NOTE
z If the commutator surface is rough, grind with No. 500 to
600 sandpaper and then measure the runout.
Undercut depth
Unit: mm (in)
Maintenance standard Service limit
0.5 - 0.8 (0.020 - 0.031) 0.2 (0.008)
BRUSH
Brush height
Unit: mm (in)
Maintenance standard Service limit
14.0 (0.551)
EE-2-4
STARTING MOTOR S210-112
ARMATURE SHAFT
Shaft diameter
Measure the armature shaft diameter at the “A” point.
Unit: mm (in)
Maintenance standard Service limit
14.9 (0.587)
NOTE
z Check the tooth profile of the armature shaft for wear or
damage. If worn or damaged, replace the armature shaft.
GEAR SHAFT
Clearance between pinion sliding shaft and pinion
Unit: mm (in)
Maintenance standard Service limit
0.2 (0.008)
EE-2-5
STARTING MOTOR S210-112
Shaft runout
Turn the gear shaft and measure the run-out of the shaft by reading
the movement of the dial gauge pointer. The bend is 1/2 of this
reading.
Unit: mm (in)
Maintenance standard Service limit
Less than 0.5 (0.020) 0.1 (0.004)
ARMATURE COIL
Continuity test
Make sure there is no continuity between the commutator and
armature assembly.
Insulation test
Check the insulation between commutator and shaft. If there is con-
tinuity, the armature coil and shaft insulation is faulty, and should
therefore be replaced.
FIELD COIL
Continuity test
Make sure there is continuity between the field coil terminals.
Insulation test
Check for continuity between the yoke and any one of the field
coil's terminals. If no continuity exists, the field coil is broken and
should be replaced.
EE-2-6
STARTING MOTOR S210-112
BRUSH HOLDER
Insulation test
Check for continuity between the positive (insulated) and the nega-
tive (base) sides of the brush holder, using an insulation tester. If
continuity exists, it indicates faulty insulation, and the brush holder
should be replaced.
MAGNETIC SWITCH
Continuity test (Series coil resistance)
Check the continuity between the magnetic switch terminal C and
terminal M and replace when there is no continuity.
PINION
1. Check the pinion teeth for wear or damage. If necessary,
replace the pinion assembly.
2. Ensure that the pinion slides smoothly. Replace when the
pinion bushing is scratched, burned or otherwise damaged.
BALL BEARING
Check the ball bearing for noise, play, thermal discoloration or dam-
age. If there is any abnormality, replace the ball bearing together
with the armature as an assembly.
ADJUSTMENT
The pinion position dimension pushed out by the magnetic switch is
called dimension L.
1. Pass current between the magnetic switch terminal C and
ground.
EE-2-7
STARTING MOTOR S210-112
PERFORMANCE CHECK
1. Connect as shown in the illustration. Turn off the key switch
and turn the starting motor. Under these conditions, mea-
sure the current and the number of rotations. (Terminal volt-
age: 24 volts)
Item Maintenance standard Service limit
Current
Less than 170
A
Number of rotations
More than 2,000
rpm
2. Check that the pinion gear pops smoothly out and in when
the switch is turned on and off.
3. Measure the minimum voltage which is necessary for the
pinion to pop out. Prepare a variable resistor and battery
voltmeter as testing equipment. Set the resistance higher at
first so that a lower voltage applies to the starting motor.
Then, slowly lower the resistance and measure the voltage
when the pinion pops out.
Unit: V
Maintenance standard Service limit
Less than 18
EE-2-8
STARTING MOTOR 0350 602
STARTING MOTOR
= UNIT NAME S350 602 0260 AND 0350 602 0330 =
CONSTRUCTION
EE-3-1
Engine does not
start.
*A
Does engine turn No Does starting motor turn? No Check battery for charging condition N.G. z Charge or replace battery.
by cranking? and battery terminals for connections z Repair connections and corrosion of
and corrosion. battery terminals.
Yes Yes
O.K.
Yes No
TROUBLESHOOTING
Does gear shaft turn? Check pinion roller Can you hear starter relay operating? Check and repair wiring system of block
clutch for damage. (Block relay equipped model only) relay.
Replace if neces- z Key switch.
No sary. Yes z Starter relay.
z Connections.
Check reduction gear Can you hear magnetic switch operating No z Check and repair wiring up to mag-
parts (armature, gear sound? netic switch.
shaft). Replace if neces- z Repair or replace magnetic switch.
sary. Yes
N.G.
(Turns
Does starting motor slowly) Check battery for charging N.G. Is meshing condition of pinion and ring N.G. z Check lever assembly for deforma-
turn normally? condition and battery ter- *A gear normal? tion, weak return spring and pinion
minals for connections and for sliding condition.
O.K. corrosion. O.K. z Correct meshing condition of pinion
EE-3-2
and ring gear. Replace if necessary.
O.K.
N.G. No
STARTING MOTOR
Check ignition sys- Replace engine Remove starting motor from engine. Replace motor (field coil or armature).
Check engine oil viscosity. oil.
tem and fuel sys- Does starting motor turn under no load
tem. by connecting battery (+) terminal to M
O.K. terminal of starting motor and battery
(–) terminal to starting motor body?
Yes
Does engine turn by Yes Repair or replace Check magnetic switch contacts.
replacing starting motor starting motor. Replace if necessary.
with a new one?
No
DISASSEMBLY
EE-3-3
STARTING MOTOR 0350 602
12 Pinion stopper
Move the pinion stopper toward the pinion. Using a screwdriver, pry
off the pinion stopper clip. Then, extract the pinion assembly and
center plate.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
BRUSH
Brush height
Unit: mm (in)
Maintenance standard Service limit
20.0 (0.787) 14.0 (0.551)
EE-3-4
STARTING MOTOR 0350 602
COMMUTATOR
Outside diameter
Unit: mm (in)
Maintenance standard Service limit
40.0 (1.575) 38.0 (1.496)
NOTE
z If the commutator surface is rough, grind with No. 500 to
600 sandpaper and then measure the outside diameter.
Runout
Unit: mm (in)
Maintenance standard Service limit
Less than 0.05 (0.0020) 0.1 (0.004)
Undercut depth
Unit: mm (in)
Maintenance standard Service limit
0.5 - 0.8 (0.020 - 0.031) 0.2 (0.008)
GEAR SHAFT
Shaft runout
Unit: mm (in)
Maintenance standard Service limit
Less than 0.05 (0.0020) 0.1 (0.004)
Thrust gap
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.5 (0.004 - 0.020)
EE-3-5
STARTING MOTOR 0350 602
BRACKET
Metal inside diameter (Front)
Unit: mm (in)
Maintenance standard Service limit
17.0 (0.669) 17.2 (0.677)
ARMATURE COIL
Continuity test
Make sure there is no continuity between the commutator and
armature assembly.
Insulation test
Unit: MΩ
Maintenance standard Service limit
More than 1.0 0.5
EE-3-6
STARTING MOTOR 0350 602
FIELD COIL
Continuity test
Make sure there is continuity between the field coil terminals.
Insulation test
Unit: MΩ
Maintenance standard Service limit
More than 1.0 0.5
BRUSH HOLDER
Insulation test
Unit: MΩ
Maintenance standard Service limit
More than 1.0 0.5
MAGNETIC SWITCH
Continuity test (Series coil resistance)
Perform the continuity test between the M and C terminals.
Unit: Ω
Maintenance standard Service limit
0.13 - 0.15
EE-3-7
STARTING MOTOR 0350 602
PINION GEAR
Clearance between pinion gear and pinion stopper
Unit: mm (in)
Maintenance standard Service limit
0.5 - 3.0 (0.020 - 0.118)
ADJUSTMENT
Measure dimension L moved towards the thrust direction of the pin-
ion when the magnetic switch pushes out the pinion.
1. Connect the S terminal to the battery positive terminal
through the magnetic switch. Ground the M terminal mid-
way and then connect it to the battery negative terminal.
PERFORMANCE CHECK
1. Connect as shown in the illustration. Turn off the key switch
and turn the starting motor. Under these conditions, mea-
sure the current and the number of rotations. (Terminal volt-
age: 24 volts)
Item Maintenance standard Service limit
Current A More than 100
Motor speed rpm More than 4,000
EE-3-8
STARTING MOTOR 0350 602
2. Check that the pinion gear pops smoothly out and in when
the switch is turned on and off.
EE-3-9
ALTERNATOR LR240, LR250
ALTERNATOR
= UNIT NAME LR240-602, LR240-603, LR250-602 AND LR250-603 =
CONSTRUCTION
EE-4-1
OFF
Turn the key switch ON. OFF Replace the charge lamp.
Does the charge lamp come on with the chassis coupler removed and
Does the charge lamp Inspect or replace the
the wiring harness terminal "L~ grounded to the chassis?
come on? charge lamp relay.
ON ON
NOTE:
Charge lamps are available from the
Turn the key switch to chassis maker.
START position. Put the coupler into ALT.
TROUBLESHOOTING
(Engine starts.)
ON Replace RG.
Does the charge lamp come on with the ALT terminal “F” grounded to the
chassis?
Does the charge lamp ON Check the fan belt and ALT.
go out?
EE-4-2
OFF
Lamp flashes. Check the diode (positive side).
ALTERNATOR
VB = 28 - 29 All in order
* Remarks ABBREVIATION:
1) Full charged battery must be used. ALT: Alternator
2) DC voltmeter: 0 to 75V, class 0.5 RG: Regulator
3) Checking method also applies to the bench test. VB: Voltage at the battery terminal
LR240, LR250
ALTERNATOR LR240, LR250
DISASSEMBLY
REMOVAL
Key point of removal
z Before removing the alternator from the engine, be sure to
turn the key switch off, then disconnect the battery cable
from the negative terminal of the battery.
EE-4-3
ALTERNATOR LR240, LR250
DISASSEMBLY
EE-4-4
ALTERNATOR LR240, LR250
9 Regulator assembly
Remove regulator assembly by removing its mounting screws and
bolts.
NOTE
z No shocks nor loads should be applied onto the regula-
tor cooling fins at the time of disassembly and reassem-
bly.
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
STATOR COIL
Continuity test of the stator coil
Unit: Ω
Maintenance
Item Service limit Remarks
standard
LR240-602
0.14
LR240-603
Single phases [At 20ºC (68ºF)]
LR250-602
0.09
LR250-603
EE-4-5
ALTERNATOR LR240, LR250
FIELD COIL
Continuity test of the field coil
Unit: Ω
Maintenance standard Service limit
11
ROTOR
Check the ball bearings for proper rotation and abnormal noise.
Replace the ball bearings if necessary.
EE-4-6
ALTERNATOR LR240, LR250
OIL SEAL
Be sure to replace the oil seals with new ones whenever the alter-
nator is disassembled.
NOTE
z Oil seals must be pressed into position after oil seal to
rotor shaft contact surface is wiped clean. Use a cloth
dampened with alcohol for this purpose.
z Care must be taken not to damage surface “D” when
replacing the oil seals.
z Oil seals should never be reused.
DIODE
Use a tester to check to see if continuity is present between the ter-
minals.
The diode is acceptable for use if continuity exists and they are
defective or damaged if continuity does not exist.
Next, connect a tester reversely. This time, the diode is acceptable
for use if continuity does not exist, and it is defective or damaged if
continuity exists. Replace diode assembly if one diode is found
defective as a result of the test mentioned above.
Negative diode
E side
(+) (-)
U, V and W sides
Positive (+) Continuity exists
Negative (\-) No continuity
NOTE
z High tension insulation resistance tester such as Megger
etc. should never be used for this test, because the diode
could be damaged.
EE-4-7
ALTERNATOR LR240, LR250
IC REGULATOR UNIT
Using instruments listed below, connect them as shown in Figure.
Instruments to be prepared:
1. Variable resistor (RV): 0 to 300Ω, 50W............... 1 ea
2. Resistor (R1): 100Ω, 10W .................................. 1 ea
3. Batteries (BAT1, BAT2, BAT3): 12V ................... 3 ea
4. DC voltmeter: 0 to 50V, class 0.5 ....................... 1 ea
(Used for measurement at three places.)
Measuring procedures
1. Check for V3 (Voltage resulted from BAT1 + BAT2 + BAT3).
The batteries are normal if 30 to 29V is registered on the
gauge.
2. Using a variable resistor, check for V2 (Voltage between ter-
minal “F” and “E”) by gradually changing resistance from
zero. Check to see if V2 voltage changes from less than
2.0V 20 thru 26V. Replace the regulator with a new one if no
voltage change is registered.
3. Check for V1 (Voltage between variable resistor intermedi-
ate tap and terminal “E”). Check for variable RV fixed (not
changing the position) to see if voltage is in the specified
range. The regulator is normal if it is within the range.
Replace regulator with new one if it is out of range as it is
defective.
PERFORMANCE TEST
z Use leads with a cross-sectional area greater than 8 mm2
(0.0124 sq in) and a length less than 2.5 m (8.2 ft) to con-
nect the line between the alternator's B terminal and posi-
tive battery terminal, the E terminal and battery ground
terminal, and the L terminal and battery ground terminal.
z Use switches with as small a contact resistance as possible
in the circuit.
z Conduct performance test in areas where ambient tempera-
ture is maintained at 20ºC (68ºF).
Start-up revolution
1. Install the alternator on a vehicle or connect to a variable
velocity motor and connect the leads as shown in the figure.
2. Turn switches SW1 and SW2 “ON”, then gradually increase
alternator speed.
3. When the voltmeter registers a voltage higher than the volt-
age when the alternator is stopped, turn switch SW1 “OFF”.
4. While observing the voltmeter, increase alternator speed.
5. Read alternator speed (rpm) when the voltmeter registers
27 volts.
EE-4-8
ALTERNATOR LR240, LR250
Unit: rpm
Maintenance standard Service limit
Less than 950
EE-4-9
ALTERNATOR 0201 102, 0201 152
ALTERNATOR
= UNIT NAME 0201 102 2920, 0201 102 2973, 0201 152 0020 AND 0201 152 0053 =
CONSTRUCTION
EE-5-1
The battery runs down.
No Abnormal
Check the battery relay. Replace the battery relay.
Normal Abnormal
Check the wiring. Repair the wiring.
To *A
No No Abnormal
Is the voltage across alternator termi- Does voltage exist? O Is the fuse blown? O Replace the fuse.
TROUBLESHOOTING
nals B and E above 22V? O Is the wiring between the alterna- O Repair the wiring.
(When the key switch is ON and Yes tor and battery normal?
engine is stopped.)
Normal
Yes
To *A
*A Abnormal
Is the belt broken? O Change the belt.
Is the belt slipping? O Adjust the belt tension.
Normal
To *A
No Abnormal
Does voltage exist across alternator Is the key switch normal? O Replace the key switch
terminals IG and E?
(Key switch is ON) Normal Abnormal
Is the fuse blown? O Replace the fuse.
EE-5-2
Yes
*B Normal
ALTERNATOR
To *B
No
Is the voltage across alternator termi- Faulty alternator O Repair the alternator.
nals B and E over 27V? (Replace the diode, stator or
(Engine speed: 1,000 rpm) regulator.)
Yes
No No
Measure the alternator charging cur- Increase the electrical load (Turn on Faulty alternator
rent at B terminal. Is it over 35A? all the lights.)
(Engine speed: 2,000 rpm) Is the charging current over 35A?
Yes Yes
Normal alternator
Yes
Is the voltage across alternator termi- Faulty alternator (Regulator) O Repair the alternator
nals B and E over 29V? (Faulty regulator)
(Engine speed: 1,000 rpm) (Broken internal wiring)
No
Normal alternator
EE-5-3
ALTERNATOR
0201 102, 0201 152
ALTERNATOR 0201 102, 0201 152
DISASSEMBLY
REMOVAL
Key point of removal
z Before removing the alternator from the engine, be sure to
turn the key switch off, then disconnect the battery cable
from the negative terminal of the battery.
EE-5-4
ALTERNATOR 0201 102, 0201 152
DISASSEMBLY
EE-5-5
ALTERNATOR 0201 102, 0201 152
5 Pulley assembly
When separating the pulley assembly, secure the rotor periphery
with a vise. Then, remove the pulley nut, pulley assembly and
spacer. If the pulley assembly is difficult to remove, use a general-
purpose puller.
INSPECTION
STATOR COIL
Continuity test of the stator coil
Unit: Ω
Maintenance stan-
Part number Service limit Remarks
dard
0201 102 2902
0.36 - 0.44 At 20ºC (68ºF)
0201 102 2973
Between two
0201 152 0020 phases
0.19 - 0.24
0201 152 0053
EE-5-6
ALTERNATOR 0201 102, 0201 152
FIELD COIL
Continuity test of the field coil
Unit: Ω
Maintenance stan-
Part number Service limit Remarks
dard
0201 102 2902
7.0 - 9.0
0201 102 2973
At 20ºC (68ºF)
0201 152 0020
5.0 - 7.0
0201 152 0053
PERFORMANCE TEST
NOTE
z Use leads with a cross-sectional area greater than 8 mm2
(0.0124 sq in) and a length less than 2.5 m (8.2 ft) to con-
nect the line between the alternator's B terminal and pos-
itive battery terminal, the E terminal and battery ground
terminal, and the L terminal and battery ground terminal.
z Use switches with as small a contact resistance as possi-
ble in the circuit.
z Conduct performance test in areas where ambient tem-
perature is maintained at 20ºC (68ºF).
Start-up revolution
1. Install the alternator on a vehicle or connect to a variable
velocity motor and connect the leads as shown in the figure.
2. Turn switches SW1 and SW2 “ONÛ, then gradually
increase alternator speed.
3. When the voltmeter registers a voltage higher than the volt-
age when the alternator is stopped, turn switch SW1 “OFF”.
4. While observing the voltmeter, increase alternator speed.
5. Read alternator speed (rpm) when the voltmeter registers
27 volts.
EE-5-7
ALTERNATOR 0201 102, 0201 152
Unit: rpm
Maintenance standard Service limit Remarks
Less than 900 At 20ºC (68ºF)
EE-5-8
AIR HEATER
AIR HEATER
CONSTRUCTION
INSPECTION
z Check the condition of the wiring for breaks. If broken,
replace the air heater assembly with a new one.
z Check the ribbon element for accumulation of carbon. If
necessary, clean it. Also check it for breaks. If broken,
replace the air heater assembly with a new one.
EE-6-1
AUXILIARY EQUIPMENT
CONTENTS
SERVICE DATA................................ EA-1-1 AIR COMPRESSOR (F9560W12).... EA-3-1
SPECIFICATIONS ............................ EA-1-1 CONSTRUCTION ............................ EA-3-1
SERVICE DATA................................ EA-1-1 DISASSEMBLY ................................ EA-3-1
TIGHTENING TORQUE .................... EA-1-2 INSPECTION ................................... EA-3-4
TOOLS.............................................. EA-2-1 REASSEMBLY ................................. EA-3-6
EA
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Model F9560W12
Type Reciprocating type
Bore x stroke — No. of cylinders mm (in) 95 x 60 — 1 (3.74 x 2.36 - 1)
3 425 (25.93)
Theoretical discharge cm (cu in)/rev
Normal maximum speed rpm 2,400
SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit Remarks
400 Tank capacity:
Less than 124 sec.
Air charging perfor- Engine rpm 30 liter (6-5/8 Imp gal)
mance speed 2,000 0 → 785 kPa {0 → 8 kg/cm2, 0 →
Less than 32 sec.
rpm 114 psi}
0.18 - 0.25
Piston top 0.28 (0.0110)
Clearance between (0.0071 - 0.0098)
piston and cylinder 0.08 - 0.15
Piston skirt 0.18 (0.0071)
(0.0031 - 0.0059)
0.15 - 0.30
Compression ring 1.00 (0.0394)
(0.0059 - 0.0118)
Piston ring end gap
0.20 - 0.70
Oil ring 1.00 (0.0394)
(0.0079 - 0.0276)
Clearance between piston ring and ring 0.010 - 0.045
0.08 (0.0031) Compression ring only
groove (0.0004 - 0.0018)
Clearance between piston pin hole and pis- 0.01 T - 0.02 L T: Tight
0.08 L (0.003 L)
ton pin (0.0004 T - 0.0008 L) L: Loose
Clearance between connecting rod small 0.02 - 0.04
0.07 (0.0028)
end and piston pin (0.0008 - 0.0016)
Clearance between connecting rod large end 0.02 - 0.09
0.10 (0.0039)
bushing and crank pin (0.0008 - 0.0035)
0.1 - 0.7
Crankshaft end play 1.0 (0.0039)
(0.004 - 0.028)
EA-1-1
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
Item Tightening torque
Suction valve holder 137 - 157 {14.0 - 16.0, 101 - 116}
Delivery valve holder 137 - 157 {14.0 - 16.0, 101 - 116}
Unloader valve connector 98 - 118 {10.0 - 12.0, 72 - 87}
Cylinder head mounting bolts and nut 25 - 29 {2.5 - 3.0, 18 - 22}
Bearing holder securing screws 2.5 - 4 {0.25 - 0.40, 1.8 - 2.9}
Cylinder liner mounting bolts 25 - 29 {2.5 - 3.0, 18 - 22}
Connecting rod cap mounting nuts 23 - 25 {2.3 - 2.6, 17 - 19}
Air compressor drive gear mounting nut (Left-hand screw) 186 - 206 {19.0 - 21.0, 137 - 152}
Air compressor mounting bolts 30 - 41 {3.1 - 4.2, 22 - 30}
EA-1-2
TOOLS
TOOLS
AIR COMPRESSOR
Tool name and number Description Shape
Valve holder tool For removal and installation of suction valve holder
99744 97003
EA-2-1
AIR COMPRESSOR F9560
AIR COMPRESSOR
CONSTRUCTION
DISASSEMBLY
REMOVAL
Key point of removal
Remove the three bolts and one nut, then pull out the air compres-
sor to the back side along the stud being careful not to drop the O-
ring.
EA-3-1
AIR COMPRESSOR F9560
DISASSEMBLY
EA-3-2
AIR COMPRESSOR F9560
EA-3-3
AIR COMPRESSOR F9560
INSPECTION
z Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
z If measurement indicates that the service limit has
exceeded, repair or replace faulty parts.
EA-3-4
AIR COMPRESSOR F9560
EA-3-5
AIR COMPRESSOR F9560
REASSEMBLY
Key point of reassembly
34 Suction valve holder
1. Install the suction valve packing, suction valve seat, suction
valve and suction valve spring, then, using a valve holder
tool (99744 97003), tighten the suction valve holder into the
cylinder head.
: 137 - 157 N·m {14.0 - 16.0 kgf·m, 101 - 116 ft·lbf}
2. After tightening the valve holder, push the suction valve with
your fingers or a rod from the unloader valve side. When
doing so, make sure the suction valve and suction valve
spring operate smoothly.
EA-3-6
AIR COMPRESSOR F9560
32 Unloader valve
1. Install the O-ring and unloader valve spring to the unloader
valve. After inserting them into the cylinder head, tighten the
connector with the packing in place.
: 98 - 118 N·m {10.0 - 12.0 kgf·m, 72 - 87 ft·lbf}
NOTE
z Before installing, be sure to coat the O-ring and O-ring
groove in the valve with grease.
EA-3-7
AIR COMPRESSOR F9560
16 Crankshaft
Press-fit the crankshaft assembly to the crankcase.
EA-3-8
AIR COMPRESSOR F9560
13 Oil ring
12 Compression ring
Install the piston rings in the ring grooves, and attach the connect-
ing rod to the piston.
NOTE
z Install the piston rings so that their joints are neither par-
allel nor normal to the piston pin and the manufacturer's
mark faces up.
6 Cylinder liner
Install the O-ring onto the cylinder liner, then, using a piston
insert tool kit (99750 97001), install them into the crankcase with
the O-ring in place.
: 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf}
99750 97001 (Piston insert tool kit)
1: 99754 97002 (Piston insert tool)
2: 99756 97001 (Crankshaft holder)
z Make sure that the end play of the crankshaft is within the
service limit.
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.7 (0.004 - 0.028) 1.00 (0.0394)
EA-3-9