Mecanica de Motor 6HK1-TC

WORKSHOP MANUAL
FVR, FVM, FVZ
ENGINE
6HK1-TC MODELS
SECTION 6
International Service & Parts

Tokyo, Japan
NOTICE
Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
“GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS
MANUAL”.
All material contained in this Manual is based on latest product

information available at the time of publication.
All rights are reserved to make changes at any time without
prior notice.
Applicable Model: FVR, FVM, FVZ
0This manual is applicable to 2000~2001 year model.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION CONTENTS
00 Service Information
6A Engine Mechanical
6B Cooling System
6C Fuel System
6D Engine Electrical
6E –
6F Exhaust System
6G Turbocharger
SERVICE INFORMATION 00 - 1
SECTION 00
SERVICE INFORMATION
CONTENTS
PAGE
Troubleshooting..........................................................................................................................00 - 3
Main Data and Specifications ....................................................................................................00 - 51
Service Standard ........................................................................................................................00 - 54
Servicing......................................................................................................................................00 - 58
Fixing Torque ..............................................................................................................................00 - 78
Special Tools...............................................................................................................................00 - 86
00 - 2 SERVICE INFORMATION
MEMO
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TROUBLESHOOTING
CONTENTS
PAGE
Engine Mechanical .....................................................................................................................00 - 4
Hard Starting ..........................................................................................................................00 - 4
Unstable Idling .......................................................................................................................00 - 10
Insufficient Power ..................................................................................................................00 - 14
Excessive Fuel Consumption ................................................................................................00 - 18
Excessive Oil Consumption...................................................................................................00 - 21
Overheating ............................................................................................................................00 - 22
White Exhaust Smoke............................................................................................................00 - 24
Black Exhaust Smoke ............................................................................................................00 - 25
Oil Pressure Does Not Rise...................................................................................................00 - 26
Abnormal Engine Noise .........................................................................................................00 - 28
Turbocharger..........................................................................................................................00 - 32
Engine Electrical .........................................................................................................................00 - 41
Generator................................................................................................................................00 - 41
Starter Motor..........................................................................................................................00 - 46
ENGINE MECHANICAL
HARD STARTING
1) STARTER MOTOR DOES NOT OPERATE
Checkpoint Trouble Cause Countermeasure

2) STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER

3) ENGINE TURNS OVER BUT DOES NOT START

1 Fuel is Not Being Delivered to The Injection Pump

2 Fuel is Being Delivered to The Injection Pump


UNSTABLE IDLING




INSUFFICIENT POWER




EXCESSIVE FUEL CONSUMPTION



EXCESSIVE OIL CONSUMPTION

OVERHEATING


WHITE EXHAUST SMOKE

BLACK EXHAUST SMOKE

OIL PRESSURE DOES NOT RISE


ABNORMAL ENGINE NOISE
1) ENGINE KNOCKING
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.
2) GAS LEAKAGE NOISE

3) CONTINUOUS NOISE

4) SLAPPING NOISE

TURBOCHARGER
1) ENGINE HAS LESS THAN NORMAL POWER


2) BLUE OR BLACK SMOKE


3) EXCESSIVE OIL CONSUMPTION


4) EXCESSIVE TURBOCHARGER NOISE


5) EXCESSIVE ROTATING PART WEAR

ENGINE ELECTRICAL
GENERATOR
1) BATTERY DEAD


2) BATTERY OVERCHARGED
3) FLASHING CHARGE LIGHT OR FLUCTUATING AMMETER INDICATION

4) CHARGE LIGHT ON BUT DIM WHILE DRIVING
5) GENERATOR NOISE

6) CHARGER CIRCUIT FUSE BLOWN

STARTER MOTOR
1) STARTER AND MAGNETIC SWITCH DO NOT OPERATE


2) MAGNETIC SWITCH CLOSES BUT STARTER DOES NOT OPERATE

3) STARTER MOTOR RUNS SLOWLY
4) STARTER MOTOR OPERATES BUT THE ENGINE DOES NOT TURN OVER

5) ABNORMAL OPERATING NOISE

MAIN DATA AND SPECIFICATIONS

ENGINE MODEL
6HK1TC
ITEM
Engine type Four-cycle, overhead camshaft, water cooled,
Combustion chamber type Direct injection
Cylinder liner type Dry liner
Timing drive system Gear drive
No. of cylinders - Bore x stroke mm (in) 6 — 115 x 125 (4.53 x 4.92)
No. of piston rings Compression rings: 2 Oil ring: 1
Total piston displacement cc (in3) 7,790 (475.2)
Compression ratio (To 1) EURO I: 17.5 EURO II: 16.9
Compression pressure at 200 rpm
kPa (kg/cm2 / psi) 3,236 (33 / 469)
Engine weight N (kg / lb) 6,021 (614 / 1,354)
Fuel injection order 1—5—3—6—2—4
Fuel injection timing (BTDC) deg EURO I: 8 EURO II: 2
Specified fuel type SAE No. 2 diesel fuel
Idling speed rpm 550 — 600
Valve clearances Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Intake valves Open at (BTDC) deg 15
Close at (ABDC) deg 44
Exhaust valves Open at (BBDC) deg 58
Close at (ATDC) deg 11
Fuel system
Injection pump type EURO I: PE-6P type EURO II: MD-TICS
Governor type EURO I: EP / RLD-J EURO II: Electronic control
Injection nozzle type EURO I: Six holes EURO II: Five holes
Injection nozzle opening pressure
MPa (kg/cm2 / psi) 1st EURO I: 15.7 (160 / 2,275) EURO II: 22.1 (225 / 3,199)
2nd EURO I: 22.1 (225 / 3,199)
Main fuel filter Paper element
Lubricating system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CC or CD
Oil pressure (at oil gallery)
kPa (kg/cm2 / psi) / rpm Approx. 98 ( 1.0 / 14) / 550
Approx. 245 (2.5 / 35.6) / 1750 more than
Oil pump type Gear (Crankshaft drive)
Main oil filter type Cartridge (Spin-on)
Partial oil filter type Cartridge (Spin-on)
Oil capacity lit (US gal / imp gal) 14 (3.7 / 3.1)
ENGINE MODEL
6HK1TC
ITEM
Oil cooler Plate type-Water cooled in water jacket
Cooling system
Cooling capacity lit (US gal / imp gal) 14.5 (3.8 / 3.2)
Water pump type Centrifugal impeller
Thermostat type Wax pallet
Generator capacity V — A (W) 24 — 40 (960)
Starter motor output V — kW 24 — 4.5
ENGINE COOLING
ENGINE MODEL
6HK1TC
ITEM
Water pump type Centrifugal impeller
Thermostat type Wax pellet
Valve initial opening temperature oC (oF) 82.0 (179.6)
Valve full opening temperature oC (oF) 95.0 (203.0)
Valve lift at fully open position mm (in) 8 (0.31)
FUEL SYSTEM
ITEM EURO I EURO II
Injection pump type Bosch in-line PE-6P type Bosch in-line MD-TICS
Plunger outside diameter mm (in) 11.5 (0.453) 11.0 (0.433)
Governor type RLD variable-speed mechanical Electronic control
governor
Timer type Electronic
Injection nozzle type Hole
Number of injection nozzle orifices Six holes Five holes
Opening pressure MPa (kg/cm2 / psi)
1st 15.7 (160 / 2,275) 22.1 (225 / 3,199)
2nd 22.1 (225 / 3,199)
Fuel filter
Main fuel filter Paper element, cartridge (spin-on) type
ENGINE ELECTRICAL
GENERATOR
Type Brushless
Manufacturer’s NIKKO or DENSO
Rated voltage V 24
Output current A 40
Load output A / V / rpm 35 or more / 27 / 5,000
Rotation (Viewed from the pulley) Clockwise
Ground polarity Negative
Pulley diameter mm (in) 80
Regulator IC type (Built-in)
STARTER MOTOR
Voltage V 24
Output kW 4.5
Number of poles 4
Manufacturer NIKKO or DENSO
Type Magnetic switch controlled
Drive gears Reduction
No. Of pinion gear teeth 11
No-load characteristics
Voltage V 24
Current A 100 or less
Operating speed (Rotor) rpm 4,000 or more
Rotation Clockwise viewed from the drive pinion gear
SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT
Cylinder Head
Lower Face Warpage mm (in) 0.05 (0.002) or less 0.20 (0.008)
Do not attempt to regrind the
lower face.
Valve Guide
Valve Stem Clearance
Intake: mm (in) 0.04 — 0.07 0.20
(0.0016 — 0.0028) (0.008)
Exhaust: mm (in) 0.06 — 0.10 0.25
(0.0024 — 0.0039) (0.010)
Valve Stem Outside Diameter
Intake: mm (in) 7.95 — 7.96 7.88
(0.3130 — 0.3134) (0.3102)
Exhaust: mm (in) 7.92 — 7.94 7.88
(0.3118 — 0.3126) (0.3102)
Valve Guide Upper End Height mm (in) 19 (0.75) –
Valve and Valve Seat Insert
Valve Thickness
Intake: mm (in) 1.80 (0.071) 1.30 (0.051)
Exhaust: mm (in) 1.80 (0.071) 1.30 (0.051)
Valve Depression A
Intake: mm (in) 1.0 (0.039) 2.5 (0.098)
Exhaust: mm (in) 1.3 (0.051) 2.8 (0.110)
Valve Contact Width
Intake: mm (in) 2.5 (0.098) 3.2 (0.126)
Exhaust: mm (in) 2.0 (0.079) 2.8 (0.110)
Valve Face Angle
Intake: deg 45 –
Exhaust: deg 45 –
Valve Spring
Spring Height
Intake: mm (in) 65.9 (2.59) 64.8 (2.55)
Exhaust: mm (in) 68.1 (2.68) 66.9 (2.63)
Spring Squareness
Intake: mm (in) 2.9 (0.114) 3.4 (0.134)
Exhaust: mm (in) 3.0 (0.118) 3.4 (0.134)
Intake Valve Spring Tension
Compression Height N (kg / lb) 348.1 (35.5 / 78) 296 (30.2 / 67)
Exhaust Valve Spring Tension
Compression Height N (kg / Ib) 382.5 (39.0 / 86) 329 (33.5 / 74)

Rocker Arm Shaft and Rocker Arm
Rocker Arm Shaft Run-Out mm (in) 0.30 (0.012)
Rocker Arm Shaft Outside Diameter mm (in) 21.979 — 22.000 21.85
(0.865 — 0.866) (0.860)
Rocker Arm Inside Diameter mm (in) 22.010 — 22.035
(0.867 — 0.868)
Rocker Arm Shaft and
Rocker Arm Clearance mm (in) 0.010 — 0.056 0.20
(0.0004 — 0.0022) (0.008)
Rocker Arm Pin and Roller Clearance
mm (in) 0.068 — 0.099 0.50
(0.0027 — 0.0039) (0.02)
Valve Cap Worn mm (in) 0.10 (0.004)
Camshaft
Camshaft Journal Diameter mm (in) 39.950 - 39.975 39.85
(1.5728 - 1.5738) (1.569)
Cam Lobe Height mm (in) 53.59 (2.11) 53.17 (2.093)
Camshaft Run-Out mm (in) 0.05 (0.002)
Camshaft Bearing Inside Diameter mm (in) 40.00 — 40.04
(1.575 — 1.576)
Camshaft Bearing Clearance mm (in) 0.025 — 0.087 0.15
(0.001 — 0.003) (0.006)
Camshaft and Camshaft Gear
Clearance mm (in) 28.015 — 28.055
(1.103 — 1.105)
Crankshaft
Crankshaft End Play mm (in) 0.040 — 0.205 0.54
(0.0016 — 0.008) (0.021)
Crankshaft Run-Out mm (in) 0.06 (0.002) or less 0.45 (0.018)
Crankshaft Journal Diameter See section 6A crankshaft
journal diameter in this manual.
Crankshaft Journal and
Bearing Clearance mm (in)
No. 4 Bearing 0.093 — 0.124 0.14
(0.00366 — 0.00488) (0.0055)
Other Bearings 0.063 — 0.094 0.14
(0.00248 — 0.00370) (0.0055)
Crankshaft Journal and
Crankpin Uneven Wear mm (in) 0.05 (0.0020)

Piston and Piston Ring
Piston Grade See section 6A piston grade
selection in this manual.
Cylinder Liner and Piston Clearance mm (in) 0.042 — 0.076
–
(0.00165 — 0.00299)
Piston Ring and Piston Ring
Glove Clearance mm (in)
1st Compression Ring 0.080 — 0.105 0.20
(0.0031 — 0.0041) (0.008)
2nd Compression Ring 0.050 — 0.080 0.15
(0.0020 — 0.0031) (0.006)
Oil Ring 0.02 — 0.06 0.15
(0.0008 — 0.0024) (0.006)
Piston Ring Gap mm (in)
1st Compression Ring 0.18 — 0.28 1.20
(0.0071 — 0.0110) (0.047)
2nd Compression Ring 0.35 — 0.50 1.20
(0.0138 — 0.0197) (0.047)
Oil Ring 0.15 — 0.35 1.20
(0.0059 — 0.0138) (0.047)
Piston Pin
Piston Pin Diameter mm (in) 35.995 — 36.000 35.95
(1.4171 — 1.4173) (1.4154)
Piston Pin Hole Diameter mm (in) 36.004 - 36.012
(1.4175 - 1.4178)
Piston Pin and Piston Pin
Hole Clearance mm (in) 0.004 — 0.017
(0.00016 — 0.00067)
Connecting Rod
Connecting Rod Alignment mm (in) 0.05 (0.002) or less 0.20 (0.008)
Connecting Rod Small End
Bushing Diameter mm (in) 36.012 — 36.022
(1.4178 — 1.4182)
Piston Pin and Connecting Rod
Small End Bushing Clearance mm (in) 0.012 — 0.027 0.05
(0.00047 — 0.00106) (0.002)
Crankpin and Bearing Clearance mm (in) 0.037 — 0.076 0.10
(0.0015 — 0.0030) (0.004)
Connecting Rod Big End and
Crankpin Side Face Clearance mm (in) 0.17 — 0.30 0.35
(0.0067 — 0.0118) (0.014)

Flywheel
Flywheel Friction Surface Depth mm (in) 43.0 (1.69) for 14 in clutch 44.0 (1.73) for 14 in clutch
48.0 (1.89) for 15 in clutch 49.0 (1.93) for 15 in clutch
Flywheel Friction Surface Roughness mm (in) Less than
0.05 (0.0020)
Idler Gear
Idler Gear Shaft “A”,
Outside Diameter mm (in) 49.950 - 49.975 49.9
(1.9665 — 1.9675) (1.965)
Idler Gear Shaft “B”,“C” and “D”
Outside Diameter mm (in) 29.959 - 29.980 29.9
(1.1795 - 1.1803) (1.177)
Idler Gear Backlash mm (in) 0.10 — 0.17 0.30
(0.0039 — 0.0067) (0.012)
Idler Gear End Play
Gear “A”, “B” and “D” mm (in) 0.08 — 0.140 0.20
(0.00315 — 0.0052) (0.008)
Gear “C” mm (in) 0.09 — 0.144 0.20
(0.00354 — 0.00567) (0.008)
Oil Pump
Gear Teeth and Cover
Inner Wall Clearance mm (in) 0.125 — 0.221
(0.0049 — 0.0087)
Gear and Body Clearance mm (in) 0.064 — 0.109
(0.0025 — 0.0043)
Gear Shaft Outside Diameter mm (in) 15.989 — 16.000 15.9
(0.6295 — 0.6299) (0.626)
Gear Shaft and Pump Body or
Bushing Clearance mm (in) 0.04 — 0.07
(0.0016 — 0.0028)
Drive Gear and Drive Gear
Shaft Interfere mm (in) 0.015 — 0.044
(0.0006 — 0.0017)
Cylinder Body
Cylinder Body Upper Face Warpage
mm (in) 0.05 (0.002) or less 0.20 (0.008)
Cylinder Liner Projection mm (in) 0.06 — 0.10
–
(0.0024 — 0.0039)
Cylinder Body Bore and Cylinder Liner
Outside Diameter Clearance mm (in) 0.001 — 0.029 –
(0.00004 — 0.00114)
Cylinder Liner Grade (Reference)
See section 6A cylinder liner
grade selection & clearance in
this manual.
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
WARNING:
ALLOW THE ENGINE TO COOL BEFORE BEGINNING
ANY SERVICING PROCEDURE. THIS WILL
ELIMINATE THE DANGER OF FIRE AND POSSIBLE
INJURY.
Nut and Bolt Angular Tightening Method

The angular tightening method uses the plastic region of
high tensile steel nuts and bolts to precision tighten
important engine fasteners.
Because of the method’s nature, there is a limit to the
number of times a particular fastener may be reused. This
limit is specified in this Manual where applicable.
1. Carefully wash the nuts and bolts to remove all oil and
grease.
2. Apply a coat of molybdenum disulfide grease to the
threads and setting faces of the nuts and bolts.
3. Tighten the nuts and bolts to the specified torque (snug

torque) with a torque wrench.
4. Draw a line A — B across the center of each bolt.

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

parts to be clamped. This line should be an extension of
the line A — B.
6. Draw another line F — G on the face of each of the

parts to be clamped. This line will be in the direction of
the specified angle E across the center of the nut or
bolt.
7. Use a socket wrench to tighten each nut or bolt to the

point where the line A — B is aligned with the line F —
G.
Example: Specified Angle and Tightening Rotation

A 30° 1 / 12 of a turn
B 60° 1 / 6 of a turn
C 90° 1 / 4 of a turn
D 180° 1 / 2 of a turn
E 360° One full turn
Nut and Bolt Angular Tightening Method

(Using The Special Tool)
1. Carefully wash the nuts and bolts to remove all oil and
grease.
2. Apply molybdenum disulfide grease to the threads and
setting faces of the nuts and bolts.
3. Use a torque wrench to tighten the nuts and bolts to
the specified torque (snug torque).
4. Attach the angle gauge to the socket wrench. Angle

Gauge: 5-88400-266-0
5. Attach a magnet to some part to hold the angle gauge
stationary.
6. Tighten the nuts and bolts to the specified angle, noting
the angle gauge indication.
Air Cleaner
Element Cleaning and Replacement
Element cleaning procedures will vary according to the
condition of the element.
130MW001
Washable Paper Element (Dry Type)

1. Dust Fouled Element
Rotate the element with your hand while applying
compressed air to the inside of the element.
This will blow the dust free.
NOTE:
Compressed air pressure must not exceed 688kPa
(7kg/cm2 / 99.5psi).
If the element damaged, the element must be replaced.
Avoid giving a shock to the element when removing dust,

or distortion or damage will result.
2. Carbon and Dust Fouled Element

1) Prepare cleaning solution of 300 grams (0.66lb / 10.59
ounes) of Donaldson ND1500 or N1400 element
cleaner diluted in 20 liters (5.3US / 4.4imp gallons) of
lukewarm.
2) Immerse the element in the solution for thirty minutes.
Periodically shake the element within the solution to
thoroughly clean it.
3) Remove the element from the solution and rinse it well

with running water.
NOTE:
Water pressure must not exceed 274.7kPa
(2.8 kg/cm2 / 39.8psi).
4) Dry the element in a well ventilated area. An electric

fan will hasten drying.
NOTE:
Do not use compressed air or an open flame to dry
the element quickly. Damage to the element will
result.
It will usually take one week for the element to dry
completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.
5) Use an inspection light to check the inside of the

element and the gasket for damage.
If the element damaged, the element must be
replaced.
Air Cleaner Body

Wipe the air cleaner body inside surfaces and the gasket
fitting surfaces free of foreign material.
Do not allow foreign material to enter the air intake pipes or
the manifold.
Lubricating System
WARNING:
HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS.
ALLOW THE ENGINE TO COOL BEFORE DRAINING
THE ENGINE OIL.
Combined Type Oil Filter (Cartridge (Spin-on))

1. Removal the drain plugs to drain the engine oil from the
oil filter.
2. Wait a few minutes and them retighten the drain plugs
to specified torque.
N·m (kg·m / lb·ft)
20 (2.0 / 14.5)
3. Use a oil filter wrench to remove the oil filter.

Filter Wrench: 1-85221-097-0
4. Clean the oil filter fitting face.
This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use a oil filter wrench to turn in the filter an additional
one full turn.
Oil Filter Wrench: 1-85221-097-0
NOTE:
Oil leaks cause distortion the cartridge due to
excessive tight the cartridge.
8. Check the engine oil level and replenish to the specified

level if required.
Oil Pan Capacity lit (US / imp gal)
Without combined partial oil filter 14 (3.7 / 3.1)
With combined partial oil filter 15 (4.0 / 3.3)
9. Start the engine and check for oil leakage from main oil
filter and partial oil filter.
Fuel System
Fuel Filter
Cartridge Type
1. Use a fuel filter wrench to remove the fuel filter.
080MX00006
080M100002
2. Clean the fuel filter fitting face.

This will allow the new fuel filter to seat properly.
3. Apply a light coat of diesel fuel to the O-ring.
4. Turn in the new fuel filter until the filter O-ring is fitted
against the sealing face.
5. Further turn in the filter 2 / 3 turn by hand.
Breed fuel system and check for fuel leakage.
Refer to “Air Bleeding”.
Water Separator (Water Sedimentor)

Visible Type
Drain water from the water separator in the following
manner when the red float reaches drain level.
1. Place a container (Approximately 0.2 liters (0.76 US /
0.09118 imp gallons capacity) at the end of the vinyl
hose beneath the drain plug on the separator.
2. Loosen the air intake plug ➀ and drain plug ➁ by
turning it counterclockwise, until the water is drained.
041MX004
3. After draining, securely tighten the drain plug and air
intake plug.
Tighten the plug to the specified torque.
Air Intake Plug Torque N·m (kg·m / lb·ft)
12 (1.2 / 9)
Drain Plug Torque N·m (kg·m / lb·ft)

15 (1.5 / 11)
Operate the priming pump on the injection pump to
bleed the fuel system.
Refer to “Air bleeding”.
4. After starting the engine, check to see that no fuel leak
from the drain plug.
The pre fuel filter should be serviced in the following

manner.
It is strongly advisable to use ISUZU genuine fuel filter
element kit for replacement.
1. Loosen the transparent cover and remove the element
together with the cover.
2. Discard the used element and install new ones.
Securely tighten the cover.
➀ Cover
➁ Element
After servicing, bleed the fuel system and check for fuel
leaks.
Injection Nozzle
Opening Pressure and Spray Condition Check
1. Use an injection nozzle tester to check the nozzle
opening pressure.
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or
adjusted.
Refer to “REASSEMBLY AND OPENING PRESSURE
ADJUSTMENT” in Section 6C of this Manual.
Injection Nozzle Opening Pressure kPa (kg/cm2 / psi)
EURO I: 1st 15.7 (1.60 / 2,275)
040MV030
EURO II: 22.1 (225/3,199)
2nd 22.1 (225 / 3,199)
WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT OF THE INJECTION NOZZLE
UNDER GREAT PRESSURE. IT CAN EASILY
PUNCTURE A PERSON’S SKIN.
KEEP YOUR HANDS AWAY FROM THE INJECTION
NOZZLE AT ALL TIMES.
2. Check the spray condition.

If the spray condition is bad, the injection nozzle must
be replaced or reconditioned.
➀ Correct
➁ Incorrect (Restrictions in orifice)
➂ Incorrect (Dripping)
Air Bleeding
1. Loosen the priming pump cap ➀ at the side of the
injection pump.
2. Loosen the joint bolt ➁ at the top of the fuel filter.
3. Operate the priming pump until there are no more
bubbles visible in the fuel being discharged from the
joint bolt.
4. Tighten the joint bolt.
5. Check for fuel leakage from around the injection pump
and fuel filter.
6. Tighten the priming pump cap.
080MX00007
Fuel Tank Strainer Cleaning (If Required)

1. Remove the fuel tank drain plug ➀.
2. Completely drain the water and sediment from the fuel
tank.
3. Remove the strainer ➁.
4. Wash the strainer in clean diesel oil.
5. Reinstall the strainer and the drain plug to the fuel tank.
Cooling System
WARNING:
HOT STEAM UNDER PRESSURE MAY ESCAPE
FROM THE RADIATOR IF THE RADIATOR SURGE
TANK CAP IS OPENED WHILE THE ENGINE IS HOT.
THIS CAN RESULT IN SERIOUS BURNS.
ALLOW THE ENGINE TO COOL BEFORE OPENING
THE RADIATOR SURGE TANK CAP.
Coolant Level
Check the coolant level and replenish the radiator surge
tank if necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then, add additional
coolant to raise the level over the “MIN” line.
1. Make sure that the engine is cool

WARNING:
WHEN THE COOLANT IS HEATED TO A HIGH
TEMPERATURE, BE SURE NOT TO LOOSEN OR
REMOVE THE RADIATOR CAP. OTHERWISE YOU
MIGHT GET SCALDED BY HOT VAPOR OR BOILING
WATER. TO OPEN THE RADIATOR CAP, PUT A
PIECE OF THICK CLOTH ON THE CAP AND LOOSEN
THE CAP SLOWLY TO REDUCE THE PRESSURE
WHEN THE COOLANT HAS BECOME COOLER.
2. Open radiator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to “MAX” line
4. Tighten radiator cap and start the engine. After idling for
2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.
Radiator Surge Tank Cap Inspection

WARNING:
FROM THE RADIATOR IF THE RADIATOR SURGE
TANK CAP IS OPENED WHILE THE ENGINE IS HOT.
THIS CAN RESULT IN SERIOUS BURNS.
ALLOW THE ENGINE TO COOL BEFORE OPENING
THE RADIATOR SURGE TANK CAP.
Cooling System Leakage Check
1. Remove the radiator filler cap from the radiator.
2. Install the radiator filler cap tester to the radiator.
3. Apply the specified test pressure to the cooling system
to check for leakage.
Do not exceed the specified test pressure.
Cooling System Test Pressure kPa (kg/cm2 / psi)
98 (1 / 14)
Repair or replace the radiator if required.

Radiator Cap Leakage Check
The radiator filler cap maintains cooling system pressure.
It must tightly seal the cooling system.
2. Install the radiator cap to the radiator filler cap tester.
3. Apply the specified test pressure to the cap to check for
leakage.
Radiator Filler Cap Test Pressure kPa (kg/cm2 / psi)
49 — 59 (0.5 — 0.6 / 7.11 — 8.53)
Negative Valve Pressure kPa (kg/cm2 / psi)

2 — 5 (0.02 — 0.05 / 0.28 — 0.71)
Replace the radiator filler cap if it fails to hold the

specified test pressure.
Drive Belt Inspection
Check the drive belt tension.
Depress the drive belt mid-portion with a 98N (10 kg / 22
Ib) force.
Drive Belt Deflection mm (in)
A 13 (0.51)
B 10 (0.39)
Check the drive belts for cracking and other damage.
033MW001 ➀ Crankshaft damper pulley
➁ Generator
➂ Cooling fan pulley
➃ Tension pulley
➄ Compressor pulley
Cooling Fan Pulley Drive Belt Adjustment

Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10 kg / 22
lb) force.
A 13 (0.51)
➀ Crankshaft damper pulley
➁ Generator pulley
➂ Cooling fan pulley
Compressor Pulley Drive Belt Adjustment
(Air Conditioner Equipped Vehicle)
Move the tension pulley as required to adjust the .
compressor drive belt tension.
Depress the drive belt mid-portion with a 98n (10 kg / 22
lb) force.
B 10 (0.39)
➀ Crankshaft damper pulley
➁ Tension pulley
033MW002
➂ Compressor pulley
Engine Control
Idling Speed Inspection (EURO I only)
1. Set the vehicle parking brake and chock the drive
wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to warm up.
4. Disconnect the idling control cable from the idling

control lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed.
If the engine idling speed is outside the specified range,
it must be adjusted.
Engine Idling Speed rpm
550 — 600
Idling Control Cable Adjustment (EURO I only)

1. Disconnect the engine control cable from the injection
pump control lever.
2. Rotate the idling control knob ➀ counterclockwise as
far as possible.
3. Loosen the idling control outer cable ➁ at the clip ➂.
4. Hold the engine control link ➅ against the link stopper
➆ as shown in the A area of the illustration.
5. Hold the idling control lever against the engine control
link as shown in the B area of the illustration.
6. Set the idling control outer cable ➁ to the clip ➂. There
must be no slack in the inner cable.
7. Reconnect the engine control cable to the injection
pump.
Accelerator Pedal Stopper Adjustment (EURO I only)

1. Set the stopper bolt cap height to 79 mm (3.1 in).
2. Temporarily tighten the stopper bolt lock nut.
The lock nut will be finally tightened after completion of
the engine control adjustment procedure below.
Accelerator Pedal Stopper Adjustment (EURO II)

Adjust the accelerator stopper bolt.
1. Depress the accelerator pedal and hold it.
2. Bring the pedal stopper bolt cap into contact with the
full stopper.
3. Turn in the pedal stopper bolt 1-1-1/2 turns to adjust
the clearance between the accelerator pedal and the
stopper bolt cap to 1-2 mm (0.0394 - 0.0787 in).
4. Tighten the stopper bolt lock nut.
060H100007
Accelerator Switch Adjustment (EURO I only)

1. Check that the engine control link and the link stopper
are in contact with each other.
2. Adjust the height of the accelerator switch.
Accelerator Switch Height mm (in)
16 — 17 (0.630 — 0.669)
Engine Control Adjustment (for EURO I only)

1. Connect the engine control cable to the injection pump
control lever ➀.
2. Adjust the cable length between the control lever and
the cable clip ➁ to the specified value.
mm (in)
Control cable length (L) 213 (8.39)
3. Adjust the accelerator stopper bolt.

1) Depress the accelerator pedal ➂ and hold it.
2) Bring the pedal stopper bolt cap ➃ into contact
with the full stopper.
3) Turn in the pedal stopper bolt 1—1-1/2 turns to
adjust the clearance between the accelerator
pedal and the stopper bolt cap to 1—2 mm.
4) Tighten the stopper bolt lock nut ➄.
600
Final Engine Control Adjustment Check (for EURO I only)

1. Start the engine and allow it to warm up.
2. Turn the idling control knob fully to the left.
3. Check that the idling speed is within the specified
range.
600
If the idling speed is outside the specified range, loosen the

engine control cable end turnbuckle (arrow) to adjust it.
4. Depress the accelerator pedal until it reaches the

accelerator pedal stopper.
Check that the injection pump control lever is making
contact with the full load stopper.
If the injection pump control lever is not making contact
with the full load stopper, readjust the accelerator pedal
stopper and the engine control cable.
Valve Clearance Adjustment

The following instructions assume that valve clearance is
adjusted beginning with the No. 1 piston at top dead
center (TDC) on the compression stroke.
Check alignment timing mark between automatic timer and
mark line on injection pump body. In this position indicate
T.D.C. of No. 1 piston.
Valve clearance must be adjusted when the engine is cold.
When remove the head cover, wipe off spilled oil with a
rag.
1. Bring the piston in the No. 1 or No. 6 cylinder to the top

dead center on the compression stroke by turning the
crankshaft until the T.D.C line on the flywheel is aligned
with the timing pointer.
Check the rocker arm shaft bracket nuts for looseness
and retighten as necessary before adjusting the valve
clearance.
2. Check that the No. 1 intake and exhaust push rods
have play. If they have play, it indicates that the No. 1
piston is at TDC (Top Dead Center) on the compression
stroke. If the No. 1 exhaust valves are depressed, the
No. 6 piston is at TDC on the compression stroke.
3. Adjust valve clearances for the No. 1 or No. 6 cylinder
which its piston is at TDC on compression stroke.
1) Loosen each adjusting screw on the bridge and
rocker arm.
Valve Clearance mm (in)
0.4 (0.0016)
2) Insert a feeler gauge between the rocker arm and

the cam and adjust by turning the adjusting screw
on the rocker arm until there is a slight drag on the
014MV001
feeler gauge. Tighten the lock nut securely.
3) With a feeler gauge inserted, screw in the adjusting
screw on the bridge gradually until it touches to the
end of the valve stem, and make sure that the
movement of the feeler gauge becomes hard.
014MX032
4) In this condition, the opposite end of the bridge is

raised. Readjust by loosening the adjusting screw on
the bridge until there is a slight drag on the feeler
gauge and tighten the lock nut securely.
011MY00037
4. Rotate the crankshaft 360° and realign the T.C. mark

on the flywheel with the pointer and adjust clearance for
remaining valves.
•
The “ ” mark in the illustration indicates the cylinders
and valves to be adjusted.
NOTE:
Be sure to move the No. 1 cylinder to TDC on the
compression stroke after completing the valve
clearance adjustment procedure.
011MY00038
Tightening Torque N·m (kg·m / lb·ft)
Position Torque
Rocker Arm Adjusting Screw Nut 22 (2.2 / 16)
Intake and Exhaust Valve Arrangement

Cylinder No. 1 2 3 4 5 6
Valve Names I E I E I E I E I E I E
No. 1 cyl. at TDC on compression
No. 6 cyl. at TDC on compression
I: Intake valve. E: Exhaust valve
00 - 76-1 SERVICE INFORMATION
Injection Timing Adjustment (for EURO I)

Injection Timing Inspection
1. Disconnect the negative battery cable.
2. Rotate the crankshaft in the normal direction of engine
rotation to align the crankshaft damper pulley notched
line with the timing notched line.
Injection Timing (Static-BTDC) deg
8
3. Check that electronic timer notched line is aligned with

the injection pump notched line.
If the notched lines are out of alignment, the injection
timing must be adjusted.
Injection Timing Adjustment

1. Rotate the crankshaft in normal direction of rotation until
the timing mark on the electronic timer housing can be
seen.
2. Align the injection timing notched line on the crankshaft
damper pulley with the timing notched line.
3. Loosen the two coupling bolts.
4. Move the electronic timer to the correct timing.

5. Tighten the two coupling bolts.
6. Rotate the crankshaft two turns in normal direction of
rotation.
7. Check the new setting.
SERVICE INFORMATION 00 - 76-2
Injection Timing Adjustment (for EURO II)

Injection Timing Inspection
1. Disconnect the negative battery cable.
2. Rotate the crankshaft in the normal direction of engine
rotation to align the crankshaft damper pulley notched
line with the timing notched line.
Injection Timing (Static-BTDC) deg
2
3. Check that flyweight notched line is aligned with the

injection pump notched line A.
If the notched lines are out of alignment, the injection
timing must be adjusted.
040M100023
Injection Timing Adjustment

1. Rotate the crankshaft in normal direction of rotation until
the timing mark on the electronic timer housing can be
seen.
2. Align the injection timing notched line on the crankshaft
damper pulley with the timing notched line.
3. Loosen the two coupling bolts D.
4. Move the flyweight to the correct timing.

5. Tighten the two coupling bolts D.
Tightening Torque N.m (kg.m / lb.ft)
61 (6.2 / 45)
6. Rotate the crankshaft two turns in normal direction of

rotation.
7. Check the new setting.
040M100023
Compression Pressure Measurement

To measure the compression pressure, the engine must be
cold. Engine coolant temperature should be at 20°C.
Battery and starter motor condition must be normal.
1. Remove the glow plug and the injection pipe from each
cylinder.
2. Install the compression gauge adapter to the No. 1

cylinder glow plug installation hole.
Compression Gauge Adapter: 5-8840-2622-0
3. Install the compression gauge to the compression
gauge adapter.
4. Crank the engine with the starter motor (about 200 rpm)
and take the compression gauge reading.
5. Repeat the procedure (Step 2 — 4) for the remaining

cylinder.
Compression Pressure kPa (kg/cm2 / psi)
Standard 3,236 (33 / 469)
Limit 2,551 (26 / 370)
Compression pressure should be approximately the same

for each cylinder. A variation exceeding 196 kPa (2.0
kg/cm2 / 28 psi) is unacceptable.
FIXING TORQUE
Cylinder Head, Rocker Arm Shaft and Camshaft N·m (kg·m / Ib·ft)
Intake and Exhaust Manifold N·m (kg·m / Ib·ft)

Crankshaft Pulley, Timing Gear Case, Lower Crankcase

and Connecting Rod N·m (kg·m / Ib·ft)
Flywheel, Timing Gear, Oil Pump, Oil Pan, and Oil Cooler N·m (kg·m / Ib·ft)
Fuel Filter and Fuel Water Sedimenter N·m (kg·m / Ib·ft)

Oil Filter, Oil Cooler and Oiling Jet N·m (kg·m / Ib·ft)
Engine Electrical
Engine Foot, Exhaust Pipe N·m (kg·m / Ib·ft)

SPECIAL TOOLS
ILLUSTRATION PART NO. PARTS NAME
5-8840-2622-0 Compression gauge adapter
Crankshaft front and rear slinger

8-94396-858-0 remover
901MY00032
Crankshaft front and rear oil seal

8-94396-856-0 installer
8-94396-819-0 Crankshaft gear installer
5-8840-2628-0 Valve guide replacer
5-8840-2625-0 Valve stem oil seal installer
901MX010
5-88402-621-0 Valve spring compressor
901MX012
1-85221-097-0 Oil filter wrench
901MX012
5-88402-623-0 Nozzle sleeve remover
040RW022
5-88402-624-0 Nozzle sleeve installer

MEMO
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ENGINE MECHANICAL 6A - 1
SECTION 6A
ENGINE MECHANICAL
CONTENTS
PAGE
General Description....................................................................................................................6A - 3
Engine..........................................................................................................................................6A - 6
Removal..................................................................................................................................6A - 6
Installation ..............................................................................................................................6A - 11
Engine External Parts.................................................................................................................6A - 15
Removal..................................................................................................................................6A - 15
Inspection and Repair............................................................................................................6A - 19
Installation ..............................................................................................................................6A - 21
Cylinder Head and Valve Mechanism........................................................................................6A - 34
Removal..................................................................................................................................6A - 34
Installation ..............................................................................................................................6A - 37
Disassembly ...........................................................................................................................6A - 44
Inspection and Repair............................................................................................................6A - 51
Reassembly ............................................................................................................................6A - 61
Crankshaft, Piston and Connecting Rod...................................................................................6A - 72
Disassembly ...........................................................................................................................6A - 72
Reassembly ............................................................................................................................6A - 77
Disassembly (Crankshaft)......................................................................................................6A - 87
Inspection and Repair (Crankshaft) ......................................................................................6A - 88
Reassembly (Crankshaft) ......................................................................................................6A - 91
Disassembly (Piston and Connecting Rod)..........................................................................6A - 93
Inspection and Repair (Piston and Connecting Rod)...........................................................6A - 95
Reassembly (Piston and Connecting Rod)...........................................................................6A-100
Flywheel, Timing Gear, Oil Pump and Oil Pan ..........................................................................6A-103
Disassembly ...........................................................................................................................6A-103
Inspection and Repair............................................................................................................6A-106
Reassembly ............................................................................................................................6A-109
6A - 2 ENGINE MECHANICAL
PAGE
Disassembly (Oil Pump) ........................................................................................................ 6A-116
Inspection and Repair (Oil Pump)......................................................................................... 6A-118
Reassembly (Oil Pump) ......................................................................................................... 6A-120
Cylinder Body ............................................................................................................................. 6A-122
Disassembly........................................................................................................................... 6A-122
Inspection and Repair ........................................................................................................... 6A-124
Reassembly............................................................................................................................ 6A-127
ENGINE MECHANICAL 6A - 3-1
GENERAL DESCRIPTION
EURO I MODEL
F06MX00078
F06MX00079
6A - 3-2 ENGINE MECHANICAL
EURO II MODEL
F06M100021
F06M100022
The 6HK1TC engine is a four-cycle, six-cylinder, in-line,

direct fuel injection type diesel engine with the piston
displacement of 7,790cm2 (475 in3). It features a gear-
driven OHC (overhead camshaft) timing train and unique
mechanisms and systems designed for outstanding
quietness, economy and durability.
The cylinder head is made of cast iron and has a cross-
flow layout with the intake system in the left side and the
exhaust system in the right side, designed to reduce
resistance in the intake and exhaust system.
The cylinder head gasket is of the laminated of least
fatigue in combination with the angular cylinder head
bolt tightening method, equally designed to increase
reliability against gas and water leakage and eliminates
the need for cylinder head bolt retightening.
The cylinder body is made of cast iron having dry
cylinder liner and seven bearings. The bearing cap has a
ladder frame construction integrating the crankcase to
increase rigidity.
The cylinder liner is made of thin iron plus special alloys
and is combined with the chrome-plate piston ring to
ensure good resistance against wear.
The piston is made of aluminum alloy. A ring trigger is
cast into the top ring groove and chrome plating is
applied to the top ring to ensure sufficient strength and
wear resistance of the ring and the ring groove.
The crankshaft is made of forge steel with seven
bearings and four counter weights to reduce revolution
load to the bearing.
The gear train is located at the end of cylinder body to
minimize influence of the torsional vibration of the
crankshaft and the radiant sound.
Noise is further reduced, to the same level as a timing
belt driven system, by integrating the crankshaft gear
with the crankshaft by shrink fit careful tuning of the gear
precision, contact gear ratio, backlash, bearing rigidity
neutral frequency, etc.
There are 2 types of the fuel injection system for 6HK1-
TC engine.
The EURO I type engine has the mechanical governor
and the electric timer for the fuel injection system. The
injection nozzle is the two-spring type nozzle.
The EURO II type engine has the electronic control
governor and the electric timer for the fuel injection
system. The injection nozzle is the single-spring type
nozzle.
The EURO II or I are the name of emission regulation in
Europe.
Lubricating Oil Flow

ENGINE
REMOVAL
Read this section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Removal Steps
• Carefully remove the piping, hoses, wiring harness
connectors, engine control cables, and control rods
from the engine.
• Remove the clutch slave cylinder or clutch booster
(Mini-pack), the control cables, the back up light
switch, and the speedometer cable from the
transmission.
WARNING:
ALLOW THE ENGINE TO COOL BEFORE REMOVE
ANY PARTS. THIS WILL ELIMINATE THE DANGER OF
FIRE AND POSSIBLE INJURY.
Battery
1. Disconnect the grounding cable ➀ and the battery
cable ➁ from the battery terminals.
Be careful not to short the battery with your wrench or
another tool at this time.
2. Disconnect the battery cable at the starter motor and

the grounding cable at the chassis frame.
Air Cleaner
Remove the air intake hose from the intake cover.
Coolant
Remove the water drain plug (at the right side of the
engine) and the radiator drain plug and allow the coolant to
drain completely.
WARNING:
FROM THE RADIATOR IF THE COOLANT IS
DRAINED WHILE THE ENGINE IS HOT. THIS CAN
RESULT IN SERIOUS BURNS.
THE COOLANT.
If long life coolant is used, drain the coolant into a clean
container so that it can be reused.
Refer to the Maintenance Schedule in Section 00,
“GENERAL INFORMATION”.
Radiator
1. Disconnect the radiator overflow rubber hose from the
radiator and the reserve tank.
2. Remove the radiator overflow pipe from the engine.
3. Pull the radiator upper hose and the radiator lower hose
from the engine.
4. Disconnect the radiator front stay at the radiator.

5. Disconnect the radiator fan shroud stays (three
positions) at the engine.
6. Remove the radiator cushion rubber nuts.
7. Remove the radiator with the fan shroud from the
chassis frame.
Be careful not to damage the radiator core.
8. Remove the cooling fan and the fan coupling from the
water pump.
Engine Control Cable

Disconnect the engine control cable from the injection
pump.
Engine Oil Draining
Oil Pan Drain Plug
1. Remove the oil pan drain plug ➀ to drain the engine oil.
WARNING:
HOT ENGINE OIL CAN CAUSE SEVERE SKIN BURNS.
THE ENGINE OIL.
2. Reinstall the drain plug and tighten to the specified
torque.
Oil Pan Drain Plug Torque N·m (kg·m / lb·ft)
78 (8.0 / 58)
Combined Type Oil Filter

1. Loosen the main and partial oil filter drain plug ➃ to
drain the engine oil.
2. Reinstall the drain plug and tighten to the specified
torque.
Oil Pan Drain Plug Torque N·m (kg·m / lb·in)
12 (1.2 / 104)
Propeller Shaft
1. Disconnect the 1st propeller shaft flange yoke from the
parking brake drum.
2. Lower the propeller shaft carefully to the ground.
Parking Brake
Refer to Section 05, “PARKING BRAKE,” “Removal and
Installation.”
Radiator Reserve Tank
Cab Mounting Rear Member
1. Remove the radiator reserve tank from the cab
mounting rear member.
2. Remove the cab mounting rear member from the
chassis frame.
Exhaust Brake Assembly

Disconnect the exhaust brake control air hose.
Transmission
Refer to Section 7, “TRANSMISSION,” “Removal and
Installation”.
Clutch Pressure Plate and Driven Plate

Refer to Section 7, “CLUTCH”, “Removal and Installation”.
Exhaust Pipe
1. Loosen the front exhaust pipe, silencer and exhaust
pipe clamp bolts and nuts.
2. Disconnect the front exhaust pipe and exhaust brake
assembly from the exhaust manifold.
Front Engine Mounting

Rear Engine Mounting
1. Attach lifting wires to the engine lifting hangers.
2. Raise the hoist until there is no slack in the lifting wires.
3. Remove the front engine mounting nuts ➀ and the rear
mounting bolts.
Engine
1. Operate the hoist to slowly raise the engine until it is
clear of the chassis frame.
Make sure that the connecting pipes, hoses, and
cables have all been removed from the engine.
The front of the engine should be held slightly higher
than the rear at this time.
2. Rotate the engine 90 degrees.

3. Continue to lift the engine from the chassis.
4. Carefully move the hoist and engine.
5. Place the engine on an engine stand.
INSTALLATION
Installation Steps
Follow the removal procedure in the reverse order to
perform the installation procedure.
Pay careful attention to the important points during the
installation procedure.
Engine
1. Attach a lifting wire to the engine lifting hangers.
2. Operate the hoist to position the engine above the
chassis frame.
3. Carefully lower the engine until it is just above the
chassis frame.
4. Rotate the engine 90 degrees to position it for final

installation.
5. Carefully lower the engine into the chassis.
The front of the engine should be held higher than the
rear at this time.
Be careful not to damage the exposed parts and the
cab.
6. Lower the engine until it contacts the engine mounting

rubbers.
7. Set the engine mounting bracket to the mounting
rubbers.
Front Engine Mounting

Rear Engine Mounting
Tighten the mounting nuts and bolts to the specified
torque.
Front Mounting Nut Torque N·m (kg·m / lb·ft)
83 (8.5 / 61)
Rear Mounting Bolt Torque N·m (kg·m / lb·ft)
294 (30 / 217)
Clutch Pressure Plate and Driven Plate

Refer to Section 7, “CLUTCH”, “Removal and Installation”.
Transmission
Refer to Section 7, “TRANSMISSION,” “Removal and
Installation”.
Propeller Shaft
1. Install the 1st propeller shaft flange yoke to the parking
brake drum.
2. Tighten the propeller shaft flange nuts to the specified
torque.
Propeller Shaft Flange Nut
Torque N·m (kg·m / lb·ft)
M12 103 (10.5 / 76)
M14 157 (16.0 / 116)
M16 With spring washer 215 (22.0 / 159)
M16 With plain washer 255 (26.0 / 188)
M16 Flange nut 255 (26.0 / 188)
Parking Brake
Refer to Section 5, “PARKING BRAKE,” “Removal and
Installation”.
Radiator
1. Install the fan coupling and the cooling fan to the water
pump.
2. Install the radiator with the fan shroud to the mounting
cushion rubbers.
Be careful not to damage the radiator core.
3. Connect the radiator front stay to the radiator.
4. Tighten the radiator cushion rubber nuts.
5. Connect the radiator upper and lower hoses.
6. Connect the radiator fan shroud stays (three positions)
to the engine.
7. Install the radiator overflow pipe to the engine.

8. Connect the radiator overflow rubber hose to the
radiator and the reserve tank.
Exhaust Pipe
1. Connect the front exhaust pipe and exhaust brake
assembly to the exhaust manifold.
2. Temporarily tighten the front exhaust pipe silencer and
exhaust pipe clamp bolts and nuts.
3. Tighten front exhaust pipe flange nuts evenly to the
specified torque.
Exhaust Pipe Nut Torque N·m (kg·m / lb·ft)
30 (4 / 29)
NOTE:
When tightening the flange nuts, the clearance
between collar ➀ of D.J.M. device and flange ➁ must
be even.
4. Full tighten the each exhaust pipe clamp bolts and nuts.
Cab Mounting Rear Member

Radiator Reserve Tank
1. Install the cab mounting member to the chassis frame.
2. Tighten the rear member nuts to the specified torque.
Rear Member Nut Torque N·m (kg·m / lb·ft)
69 (7 / 51)
3. Install the radiator reserve tank with the bracket to the

cab rear mounting member.
Engine Control Cable

Connect the engine control cable to the injection pump.
Air Cleaner
Install the air intake hose to the intake cover.
Coolant Replenishment
Replenish the coolant to the specified capacity.
Coolant Capacity lit (US / imp gal)
19 (5.02 / 4.18)
NOTE:
Make sure that the connecting pipes, hoses, and
cables have all been installed to the engine.
Battery
1. Check the battery fluid level and the specific gravity.
2. Connect the battery cable to the starter motor.
3. Connect the grounding cable to the chassis frame.
4. Connect the battery cable ➁ and the grounding cable

➀ to the battery terminals.
5. Apply grease to the battery terminals.
Engine Oil Replenishment

1. Replenish the engine oil from the filler port with new
engine oil of the specified grade.
2. Start the engine and let it idle for a few minutes.

3. Stop the engine and wait five minutes.
4. Recheck the oil level and replenish if necessary.
ENGINE EXTERNAL PARTS

REMOVAL
EURO I MODEL
F06MX00073
F06MX00074
EURO II MODEL
F06M100028
F06M100029
Removal Steps
1. Cooling fan guide 20. Water duct (By-pass)
2. Cooling fan 21. Fuel injection pipe
3. Cooling fan drive belt 22. Injection pump assembly
4. Generator 23. Injection pump bracket
5. Starter motor 24. Bearingcase
6. Power steering oil pipe 25. N-TDC sensor
7. Power steering oil pump 26. Oil level guide tube
8. Air duct 27. Water pipe
9. Air intake pipe 28. Air pipe
10. Boost compensator hose 29. Oil feed pipe
11. Fuel return pipe 30. Air compressor assembly
12. Fuel feed pipe 31. Air intake pipe
13. Fuel filter assembly 32. Oil feed pipe
14. Oil feed pipe 33. Oil return pipe
15. Oil return pipe 34. Water return pipe
16. Oil feed pipe (EURO I only) 35. Turbocharger assembly
17. Solenoid valve assembly (EURO I 36. Engine foot (front)
only) 37. Engine foot (rear)
18. Oil filter assembly
19. Water duct (Suction)
Removal Steps
1. Cooling Fan Guide
2. Cooling Fan
3. Cooling Fan Drive Belt
4. Generator
5. Starter Motor
6. Power Steering Oil Pipe
7. Power Steering Oil Pump
Remove the power steering oil pump.
NOTE:
Plug the power steering oil pump to prevent the entry
of foreign material.
8. Air Duct
9. Air Intake Pipe
10. Boost Compensator Hose
11. Fuel Return Pipe
12. Fuel Feed Pipe
13. Fuel Filter Assembly
14. Oil Feed Pipe
15. Oil Return Pipe
16. Oil Feed Pipe (EURO I only)
17. Solenoid Valve Assembly (EURO I only)
18. Oil Filter Assembly
19. Water Duct (Suction)
20. Water Duct (By-pass)
21. Fuel Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery
valve side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
NOTE:
Plug the delivery holder ports with the shipping caps
or equivalent to prevent the entry of foreign material.
040MX00048
22. Injection Pump Assembly

1) Remove the two injection pump coupling joint bolts
from the injection pump side.
2) Use a universal wrench to remove the four injection
pump mounting bolts.
3) Remove the injection pump.
23. Injection Pump Bracket
080MX00004
040M100023
24. Bearingcase
25. N-TDC Sensor
26. Oil Level Guide Tube
27. Water Pipe
28. Air Pipe
29. Oil Feed Pipe
30. Air Compressor Assembly
Plug the air compressor ports to prevent the entry of foreign
material.
039MX00013
31. Air Intake Pipe

32. Oil Feed Pipe
33. Oil Return Pipe
34. Water Return Pipe
35. Turbocharger Assembly
36. Engine Foot (Front)

37. Engine Foot (Rear)
INSPECTION AND REPAIR (EURO I only)

ELECTRONIC TIMER
Timing control valve operation check
1. Check the timing control electrical circuit.
2. Install an oil pressure gauge to the timer port (top of the
timing control valve).
3. Start the engine and allow it to idle at 500 rpm.
040MY00022
4. Increase engine speed from 500 rpm to 2,000 rpm.
5. Check that timer port oil pressure increases with engine
speed (oil pressure must not exceed 392 kPa
(4 kg/cm2).
6. Decrease the engine speed to 500 rpm.
7. Check that timer port oil pressure decreases with
engine speed.
8. Repeat Steps 4~7 several times.
9. If the timer port oil pressure does not increase and
decrease with engine speed, the timing control valve is
defective and must be replaced.
040MY00021
Timing control valve resistance measurement

If the timing control valve resistance is outside the specified
value, the timing control valve is defective and must be
replaced.
Timing control valve harness nomenclature
Connector pin No. Wire designation
➀ Return (+)
➁ Return (-)
040MY00021 ➂ Pump (+)
➃ Pump (-)
Timing control valve resistance

Connector pin Nos. Resistance valve
➀↔➁ 21~25 Ω
➂↔➃ 21~25 Ω
Connector pin ↔ Body ∞
040HA00002
Injection pump timing sensor replacement

Removal
Loosen the sensor fixing nut and remove the sensor.
040MX00050
Installation
1. Be certain that the projecting portion of the timer is at
the center of the sensor installation hole (viewed through
the installation hole).
2. Screw the sensor into the installation hole until the
sensor tip barely touches the projecting portion of the
timer.
CAUTION:
Do not force the tip of the sensor against the
080HA00005 projecting portion of the timer. The sensor will be
damaged.
3. Unscrew the sensor ¾ of a turn.
4. Tighten the sensor fixing nut to the specified torque.
Sensor Fixing Nut Torque N·m (kg·m / lb·ft)
49 (5.0 / 36)
This procedure may be used for Timing sensor installed.
080HA00006
INSTALLATION
EURO I MODEL
F06MX00076
F06MX00075
EURO II MODEL
F06M100030
F06M100031
Installation Steps
1. Engine foot (rear) 20. Oil filter assembly
2. Engine foot (front) 21. Solenoid valve assembly (EURO I only)
3. Turbocharger assembly 22. Oil feed pipe (EURO I only)
4. Water return pipe 23. Oil return pipe
5. Oil return pipe 24. Oil feed pipe
6. Oil feed pipe 25. Fuel filter
7. Air intake pipe 26. Fuel feed pipe
8. Air compressor 27. Fuel return pipe
assembly 28. Boost compensator hose
9. Oil feed pipe 29. Air intake pipe
10. Air pipe 30. Air duct
11. Water pipe 31. Power steering oil pump
12. Oil level guide tube 32. Power steering oil pipe
13. N-TDC sensor 33. Starter motor
14. Bearingcase 34. Generator
15. Injection pump bracket 35. Cooling fan drive belt
16. Injection pump 36. Cooling fan
assembly
37. Cooling fan guide
17. Fuel injection pipe
18. Water duct (By-pass)
19. Water pipe (Suction)
Installation Steps
1. Engine Foot (Rear)

2. Engine Foot (Front)
1) Apply molybdenum disulfide grease to the engine foot
bolt threads.
2) Tighten the engine foot bolts to the specified torque.
Engine Foot Bolt Torque N·m (kg·m / lb·ft)
Rear 76 (7.7 / 56)
Front 79 (8.0 / 58)
3. Turbocharger Assembly
Supply oil to turbocharger turbine
Vesco Super Engine Oil
• Supply a proper quantity of oil through the oil filling port

of the turbocharger and give the turbine shaft a few
turns for lubrication of the bearing parts.
Install the turbocharger assembly.

Tightening torque N·m (kg·m / lb·ft)
52 (5.3 / 38)
Install adapter to the turbocharger.

Adapter; 25 (2.6 / 19)
• Install the adapter to the turbocharger through gasket,

and tighten nuts. Used gasket should not be reused.
4. Water Return Pipe For Water Cooling Type

(To Thermo Unit)
Water Feed Pipe For Water Cooling Type
(From Air Compressor)
1. Install the water return pipe and feed pipe.
Tightening torque
Water Return Pipe (To Turbocharger) N·m (kg·m / lb·ft)
Turbocharger side Thermo unit side
39 (4 / 29) 44 (4.5 / 33)
Water Feed Pipe (To Turbocharger) N·m (kg·m / lb·ft)

036L100001
Turbocharger side Cylinder body side
39 (4 / 29) 39 (4 / 29)
NOTE:
Gasket should not be reused.
2. Install the piping clip.

: 20 (2 / 14)
: 73 (7.4 / 54)
: 10 (1 / 7)
5. Oil Return Pipe (To Cylinder Body)

6. Oil Feed Pipe (From Cylinder Body)
1. Install the oil return pipe and feed pipe.
Tightening torque
Oil Return Pipe (To Cylinder Body) N·m (kg·m / lb·ft)
Turbocharger side Cylinder Body side
20 (2 / 14) 39 (4 / 29)
Oil Feed Pipe (To Turbocharger) N·m (kg·m / lb·ft)

Turbocharger side Cylinder body side
34 (3.5 / 25) 34 (3.5 / 25)
NOTE:
036MX00001
Gasket should not be reused.
2. Install the piping clip.

: 20 (2 / 14)
NOTE:
After tightening the pipe, install the clips.
7. Air Intake Pipe

Install the air intake pipe
• Install with the rubber hose heat protector directed as
illustrated.
025M100008
8. Air Compressor
1) Apply liquid gasket to the O-ring.
This will hold the O-ring in place during installation.
2) Install the O-ring to the air compressor body groove.
Air Compressor Bolt and Nut Torque N·m (kg·m / lb·ft)
73 (7.4 / 54)
039MX00013
9. Oil Feed Pipe
10. Air Pipe

• Apply oil to the governor pipe during disassembly to
prevent pipe deformation. Do not use soapy water
because it will cause corrosion.
• Apply oil and tighten the bolts to the specified torque.
Air Pipe Torque N·m (kg·m / lb·in)
25 (2.5 / 18)
• Tighten to the specified torque in dry condition.
Air Pipe Torque N·m (kg·m / lb·in)
41 (4.2 / 30)
11. Water Pipe

Set the water pipes to the air compressor and the
turbocharger.
12. Oil Level Guide Tube

Install the O-ring to the guide tube groove.
13. N-TDC Sensor

• Carefully clean the N-TDC sensor to remove all iron
filling before installing it.
• Remove the N-TDC sensor before removing the
flywheel.
14. Bearingcase
1) Apply liquid gasket to the O-ring.
This will hold the O-ring in place during installation.
2) Install the O-ring to the bearingcase body groove.
040MX0050
3) Check that the No. 1 cylinder is at TDC on the

compression stroke.
4) To install the bearingcase, follow the installation
procedure below.
• Prior to installation, align the “S” marked on the

coupling with the pointer on the bearingcase body side
as illustration.
F06MX00077
• On completion of installation, make sure the mark “S”

and pointer are aligned with each other as illustration
(After bearingcase installation).
CAUTION:
If the “S” and pointer are not aligned as illustration
after bearingcase installation, the timing gear is out
of position by one (1) tooth, reinstallation is required.
4) Tighten the bearingcase nuts and bolts to the specified
torque.
Bearingcase Nut and Bolt Torque N·m (kg·m / lb·ft)
M10 Nut 40 (4.1 / 30)
M12 Nut and Bolt 73 (7.4 / 54)
15. Injection Pump Bracket

1) Align the injection pump bracket with the cylinder body
dowel pin.
2) Install the injection pump bracket to the cylinder body.
3) Tighten the injection pump bracket bolts to the
specified torque.
4) Install the brackets to the areas marked with an
asterisk (*).
Injection Pump Bracket Bolt Torque N·m (kg·m / lb·ft)
38 (3.9 / 28)
16. Injection Pump Assembly

1) Check that No.1 cylinder is on the compression stroke.
2) Rotate the crankshaft in the normal direction of engine
rotation to align the damper pulley notched line and the
timing notched line.
Injection Timing (Static — BTDC) deg
EURO I: 8
EURO II: 2
3) Install the injection pump to the pump bracket.

Semi-tighten the injection pump bolts.
4) Align the injection pump body notched line and the
timing notched line.
5) Use a wrench to tighten the injection pump bolts
(arrow marked) to the specified torque a little at a time.
Injection Pump Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
040MX00050
080M100003
040M100023
NOTE:
• Tighten the bolts diagonally, keep to the
specified tightening torque.
6) Tighten the pump timer (EURO I) or flyweight (EURO II)
from the coupling side E.
61 (6.2 / 45)
NOTE:
• Do not forget to tighten the bolts on the opposite
side, too.
040MX00049
• If coupling laminate (iron plate) looks slack when
viewed from aside, loosen the cotter bolt B and
adjust.
88 (9.0 / 65)
7) Rotate the pump in normal direction again and make

sure that there is no problem in fuel injection timing A.
040M100023
I7. Fuel Injection Pipe

1) Temporarily tighten the injection pipe sleeve nuts.
2) Set the clip in the prescribed position.
NOTE:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
040MX00048
3) Tighten the injection pipe clip bolts to the specified

torque.
Injection Pipe Clip Bolt Torque N.m (kg.m / Ib.in)
6 (0.6 / 52)
4) Tighten the injection pipe sleeve nuts to the specified

torque.
Injection Pipe Sleeve Nut Torque N.m (kg.m / lb.ft)
32 (3.3 / 23.9)
18. Water Duct (By-pass)

19. Water Duct (Suction)
20. Oil Filter Assembly

21. Solenoid Valve Assembly (EURO I only)
Solenoid Valve Bolt Torque N·m (kg·m / lb·ft)
38 (3.9 / 28)
22. Oil Feed Pipe (EURO I only)

Set the oil pipes to the timer and the solenoid valve.
23. Oil Return Pipe

Set the oil return pipe ➀ to the injection pump and the
timer.
24. Oil Feed Pipe

Set the oil feed pipe ➁ to the injection pump and the
bearingcase.
040MX00051
040M100022
25. Fuel Filter

1) Install the fuel filter to the cylinder head.
2) Tighten the fuel filter bolts to the specified torque.
Fuel Filter Bolt Torque N·m (kg·m / lb·ft)
41 (4.1 / 30)
Fuel Filter Bolt Torque N·m (kg·m / lb·ft)

38 (3.9 / 28)
041MX00001
26. Fuel Feed Pipe

27. Fuel Return Pipe
1) Set the fuel pipes to the injection pump and the fuel
filter.
2) Temporarily tighten the joint bolts.
3) Tighten the fuel pipe joint bolts to the specified torque.
Fuel Pipe Joint Bolt Torque N·m (kg·m / lb·ft)
Nozzle Leak Off Pipe Bolt 12 (1.2 / 8.7)
Other Joint Bolt 41 (4.2 / 30)
4) Set the pipe clip to the prescribed position.
NOTE:
Do not reuse gasket for fuel piping, oil piping.
080MX00006
080M10002
28. Boost Compensator Hose

29. Air Intake Pipe
Install the air intake pipe.
Intake Pipe Bolt Torque N·m (kg·m / lb·ft)
38 (3.9 / 28)
30. Air Duct

Install the air duct.
22 (2.2 / 16)
31. Power Steering Oil Pump

32. Power Steering Oil Pipe
1) Install the O-ring to the pump body.
2) Apply grease to the O-ring.
3) Tighten the power steering oil pump bolts to the

specified torque.
Power Steering Oil Pump Bolt Torque N·m (kg·m / lb·ft)
38 (3.9 / 28)
33. Starter Motor

1) Install the starter motor to the flywheel housing.
2) Tighten the starter motor nuts to the specified torque.
Starter Motor Nut Torque N·m (kg·m / lb·ft)
82 (8.4 / 61)
34. Generator
1) Install the generator and adjusting plate to the engine.
2) Temporarily tighten the generator bolt ➀.
The bolt will be finally tightened after installing and
adjusting the cooling fan belt.
3) Tighten the cooling fan drive belt adjusting plate bolt ➁
to the specified torque.
Adjusting Plate Bolt Torque N·m (kg·m / lb·ft)
48 (4.9 / 35)
35. Cooling Fan Drive Belt

1) Install the cooling fan belt.
2) Turn the adjusting bolt ➀ to move the generator and
adjust the cooling fan drive belt tension.
Apply a force of 98N (10kg / 22lb) to the drive belt mid-
portion to check the belt deflection.
Cooling Fan Drive Belt Deflection mm (in)
10 — 15 (0.4 — 0.6)
Crankshaft pulley
Generator pulley
Cooling fan pulley
3) Tighten the generator bolt ➁ and the adjusting plate
nut ➂ to the specified torque.
Generator Bolt Torque N·m (kg·m / lb·ft)
127 (13 / 94)
Adjusting Plate Nut Torque N·m (kg·m / lb·ft)

76 (7.7 / 56)
36. Cooling Fan

37. Cooling Fan Guide
CYLINDER HEAD AND VALVE MECHANISM

REMOVAL
Removal Steps
1. Cylinder head cover 10. Plate
2. Gasket 11. Water duct
3. Rubber plug 12. O-ring
4. Nozzle leak off pipe 13. O-ring
5. Nozzle clamp 14. Rocker arm assembly
6. Injection nozzle holder 15. Bridge cap
7. Gasket 16. Camshaft assembly
8. Glow plug connector 17. Cylinder head assembly
9. Glow plug 18. Head gasket
Removal Steps
1. Cylinder Head Cover
2. Gasket
Remove the cylinder head cover and gasket.
NOTE:
Be careful not to miss the collars inserted in the
cylinder head cover assembly.
010MX004
3. Rubber Plug
4. Nozzle Leak off Pipe
5. Nozzle Clamp
6. Injection Nozzle Holder
7. Gasket
8. Glow Plug Connector
9. Glow Plug
Remove the injection nozzles and glow plugs before
removing the cylinder head.
040MX042
10. Plate
11. Water Duct
12. O-Rring
13. O-Ring
14. Rocker Arm Assembly
Loosen the rocker arm shaft bracket and rocker arm and
shaft assembly bolts evenly from the outside to inside.
NOTE:
Leave the A indicated bolts (both side) unremoved
on the occasion, since it is the rocker arm fixing
bolts.
15. Bridge Cap

16. Camshaft Assembly
Loosen the camshaft bearing cap bolts and nuts evenly
from both side.
NOTE:
If the camshaft bearings (upper and lower) are to be
reinstalled, mark their fitting positions by tagging
each bearing with the camshaft bearing cap number
from which it was removed.
011MX009-1
17. Cylinder Head Assembly

Loosen the cylinder head bolts a little at a time in the
numerical order shown in the illustration.
CAUTION:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the
cylinder head lower surfaces.
CAUTION:
The idler gear “C” projects from the cylinder head
lower side and easily damaged. Great care must be
taken to avoid damaging the idler gear “C” if the
cylinder head is removed from the engine.
18. Cylinder Head Gasket

INSTALLATION
Installation Steps
1. Head gasket 10. Glow plug
2. Cylinder head assembly 11. Glow plug connector
3. Camshaft assembly 12. Gasket
4. Bridge cap 13. Injection nozzle holder
5. Rocker arm assembly 14. Nozzle clamp
6. O-ring 15. Nozzle leak off pipe
7. O-ring 16. Rubber plug
8. Water duct 17. Gasket
9. Plate 18. Cylinder head cover
Installation Steps
1. Cylinder Head Gasket
1) Clean the cylinder body surface.
2) Apply ThreeBond 1207C or equivalent to the

cylinder body and the flywheel housing fitting faces
➀ ➁.
The liquid gasket must be 2.0 — 3.0mm (0.08 — 0.118
in) thick and 2.0 — 4.0mm (0.08 — 0.157 in) wide.
The liquid gasket must not obstruct the cylinder oil
port ➂.
3) Install the cylinder head gasket to the cylinder body.

The part number (indicated by arrow in the illustration)
must be facing up.
2. Cylinder Head Assembly

1) Align the cylinder body dowel pins and the cylinder
head dowel holes.
Carefully place the cylinder head on the cylinder head
gasket.
2) Apply molybdenum disulfide grease to the cylinder

head bolts (M14) threads and setting faces.
3) Apply engine oil to the cylinder head bolts (M10)
threads and setting faces.
4) Tighten the M14 cylinder head bolts (Number ➀ to )
in three steps using the angular tightening method.
Follow the numerical order shown in the illustration.
Cylinder Head Bolt Torque N·m (kg·m / lb·ft)
1st Step 2nd Step 3rd Step
98 (10 / 72) 147 (15 / 108) 30 — 60 deg
5) Tighten the M10 cylinder head bolts (Number to )

to the specified torque.
Cylinder Head Bolt Torque N·m (kg·m / lb·ft)
38 (3.9 / 28)
NOTE:
1. The cylinder head bolts can be reused six (6)
times.
2. Cover the timing gear hole by cloth for prevent
into foreign materials.
3. Camshaft with Gear

1) Align the crankshaft damper pulley TDC mark with the
pointer by rotating the crankshaft normal direction.
Same time check alignment timing mark on injection
pump for No.1 piston TDC.
2) Install the camshaft bearing to the cylinder head
bearing groove and the bearing caps.
3) Apply engine oil to the camshaft bearing sliding
surfaces before installing the camshaft.
4) Install the camshaft with gear assembly to the cylinder

head.
5) Carefully align the camshaft gear “B” mark and the
cylinder head upper face shown in the illustration.
6) If the “B” mark and cylinder head upper face are not
aligned, No. 1 piston is not on the compression stroke.
Remove the camshaft.
Rotate the crankshaft one full turn and realign the
crankshaft damper pulley TDC mark with the pointer
by rotating the crankshaft normal direction.
7) Reinstall the camshaft assembly same as step 3.-5)
above.
Camshaft Bearing Cap

1) Apply engine oil to the camshaft bearing sliding
surfaces.
2) Install the camshaft bearing caps with the bearings in
the numerical order with the cap stamped mark facing
forward.
011MV009-1
3) Apply engine oil to the bearing cap bolts threads and

setting faces.
4) Tighten the bolt prior to the nut in each bearing cap to
the specified torque evenly from center to outside of
cylinder head.
Camshaft Bearing Cap Bolt Torque N·m (kg·m / lb·ft)
27 (2.8 / 20)
4. Bridge Cap
1) Apply engine oil to the bridge cap.
2) Install the bridge cap to the bridge.
011MX042
5. Rocker Arm Assembly

1) Apply engine oil to the front and rear camshaft bracket
sliding surfaces.
2) Apply engine oil to the camshaft bracket studs thread
and nuts setting faces.
3) Install the rocker arm and shaft assembly to the
cylinder head.
014MX016
4) Tighten the rocker arm bracket bolts and nuts to the

specified torque.
First of all tighten star mark 1 nut and star mark 3 nut
then tighten star mark 2 nut and star mark 4 nut.
Star mark Nuts 27 (2.8 / 20)
Then tighten number 5 bolt to number 9 bolt.
011MY00039 Bolts 5 through 9 56 (5.7 / 41)
Tighten valve rocker arm shaft bracket bolts.

Bolts 10 through 13 27 (2.8 / 20)
6. O-ring
7. O-ring
8. Water Duct and O-ring
9. Plate
1) Apply soapsuds to the O-ring.
2) Install the O-ring to the water duct O-ring groove.
3) Install the water duct to the water pump body.
4) Tighten the water duct bolts to the specified torque.
Water Duct Bolt Torque N·m (kg·m / lb·ft)
M8 Bolt 19 (1.9 / 14)
10. Glow Plug

11. Glow Plug Connector
1) Install the glow plug to the cylinder head.
2) Tighten the glow plug to the specified torque.
Glow Plug Torque N·m (kg·m / lb·ft)
20 (2.0 / 14)
011MX041
12. Gasket
13. Injection Nozzle Holder
14. Nozzle Clamp
15. Nozzle Leak off Pipe
1) Install the injection nozzle holders with the new gaskets
and the O-rings to the cylinder head.
CAUTION:
Take care not to damage the injection nozzle tops
040MX00048
and O-ring during nozzle holder installation.
2) Install the nozzle holder flange to the nozzle holder
bolts.
3) Temporarily tighten the nozzle holder bolts.
The bolts will be finally tightened after injection pipe
and leak off pipe installation.
Refer to external parts installation.
16. Rubber Plug

1) Apply ThreeBond 1207B or equivalent to the rubber
plug as shown in the illustration.
2) Install the rubber plugs to the cylinder head.
NOTE:
If the cylinder head is to be reinstalled, be sure to
remove, clean, and reseal the rubber plug.
3) Apply ThreeBond 1207B or equivalent to the rubber

plug surfaces.
NOTE:
Immediately (within ten (10) minutes of applying the
liquid gasket) install the cylinder head cover to the
cylinder head.
17. Gasket
18. Cylinder Head Cover
1) Clean the head cover gasket groove and the head
cover gasket.
2) Install the head cover gasket and collar to the head
cover.
3) Install the cylinder head cover to the cylinder head.
010MX004
4) Tighten the cylinder head cover bolts to the specified

torque a little at a time in the numerical order shown in
the illustration.
Cylinder Head Cover Bolt Torque N·m (kg·m / lb·in)
13 (1.3 / 113)
010MX003
DISASSEMBLY
Cylinder Head
Disassembly Steps
1. Bridge cap 16. Idler gear “C”
2. Bridge 17. Split collar
4. Intake cover 18. Valve spring upper seat
5. Gasket 19. Valve spring
6. Heat protector 20. Valve
7. Exhaust manifold 21. Valve stem seal
8. Gasket 22. Spring seat
9. Heat protector 23. Valve guide
10. Engine hanger 24. Valve seat insert
11. Thermometer unit 25. Injection nozzle sleeve
12. Water outlet pipe 26. Bridge guide
13. Thermostat 27. Oil seal
14. Gasket 28. Cylinder head
15. Scaling cup
Disassembly Steps
1. Bridge Cap
2. Bridge
4. Intake Cover
5. Gasket
6. Heat Protector
7. Exhaust Manifold
8. Gasket
9. Heat Protector
10. Engine Hanger
11. Thermometer Unit
12. Water Outlet Pipe
13. Thermostat
14. Gasket
15. Sealing Cup
Tap the outside of the sealing cup with a screw driver to
deform one end of it and draw it out with pliers.
Note:
Do not make scratch on seal surface of cylinder
head.
16. Idler Gear “C”

17. Split Collar
1) Place the cylinder head on a flat wooden surface.
2) Use the valve spring compressor to remove the split
collar.
Do not allow the valve to fall from the cylinder head. Valve
Spring Compressor: 5-8840-2621-0
011MX017
18. Valve Spring Upper Seat

19. Valve Spring
20. Valve
21. Valve Stem Seal
22. Spring Seat
011MX027
23. Valve Guide

Use valve guide remover to remove the valve guide.
Valve Guide Remover: 5-8840-2628-0
011MX015
24. Valve Seat Insert

1) Heat up (about 600 — 700°C) two point on the valve
seat insert by gas torch, allow the valve seat insert to
cool for few minutes.
2) This will invite contraction and make removal of the
valve seat insert easier.
3) Use screwdriver to pry the valve seat insert free. Take
care not to damage the cylinder head.
4) Carefully remove carbon and other foreign materials
011MX016
from the cylinder head inert bore.
25. Injection Nozzle Sleeve

Use nozzle sleeve remover to hit nozzle sleeve from lower
side cylinder head.
Nozzle Sleeve Remover: 5-8840-2623-0
040MX038
26. Bridge Guide

Electric welding the bolt to bridge guide, use sliding
hammer to remove the bridge guide.
011MX043
27. Oil Seal
011MX026
28. Cylinder Head
Rocker Arm and Shaft Assembly
014MX018
Disassembly Steps
1. Camshaft bracket 4. Rocker arm shaft bracket
2. Rocker arm 5. Rocker arm shaft
3. Spring washer
Disassembly Steps
1. Camshaft Bracket
2. Rocker Arm
If the rocker arms and rocker arm shaft brackets are to be
reinstalled, mark their installation positions by tagging each
rocker arm and rocker arm shaft bracket with the cylinder
number from which it was removed.
014MX027
3. Spring Washer
4. Rocker Arm Shaft Bracket
5. Rocker Arm Shaft
Camshaft
Disassembly Steps
1. Camshaft gear 3. Camshaft
2. Gear alignment pin
Disassembly Steps
1. Camshaft Gear
Replace the camshaft gear if it is excessively worn or
damage or if the camshaft end play is excessive.
1) Remove the camshaft gear bolt.
2) Use a gear remover ➀ to remove the camshaft gear ➁.
2. Gear Alignment Pin

3. Camshaft
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Cylinder Head
Cylinder Head Lower Face Warpage
Use a straight edge and a feeler gauge to measure the four
sides and the two diagonals of the cylinder head lower
face.
If the measured values exceed the specified limit, the
cylinder head must be replaced.
Cylinder Head Lower Face Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)
NOTE:
Do not attempt to regrind the cylinder head lower
face.
Check cracking on damage on the cylinder head
lower face.
Valve Guide
Valve Stem and Valve Guide Clearance
Measuring Method-I
1. Insert the valve to the cylinder head.
2. Set the dial indicator to the valve stem at measuring
point ➀ as shown in the illustration.
Measuring Point ➀: 10mm (0.4in)
3. Set the dial indicator needle to “0”.
4. Move the valve head from side to side. Read the dial
indicator.
Note the highest dial indication.
valve and the valve guide must be replaced as a set.
Valve Stem Clearance mm (in)
Standard Limit
Intake Valve 0.04 — 0.07 0.20
(0.0016 — 0.0028) (0.008)
Exhaust Valve 0.06 — 0.10 0.25
(0.0024 — 0.0039) (0.010)
Measuring Method-II
1. Measure the valve stem outside diameter.
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
3. Calculate the clearance between the valve guide inside
diameter and the valve stem outside diameter.
If the clearance exceeds the specified limit, the valve
and the valve guide must be replaced as a set.
Valve Stem Outside Diameter

Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the
Valve Stem Outside Diameter mm (in)
Standard Limit
Intake Valve 7.95 — 7.96 7.88
(0.3130 — 0.3134) (0.3102)
Exhaust Valve 7.92 — 7.94 7.88
(0.3118 — 0.3126) (0.3102)
Valve Guide Replacement

Valve Guide Removal
Use a hammer and the valve guide replacer to drive out the
valve guide from the cylinder head lower face. Valve Guide
Replacer: 5-8840-2628-0
011MX015
Valve Guide Installation
1. Apply engine oil to the valve guide outer circumference.

2. Set the ring to the valve guide replacer.
3. Attach the valve guide replacer with ring to the valve
guide.
4. Use a hammer to drive the valve guide into position
from the cylinder head upper face.
Valve Guide Replacer: 5-8840-2628-0
011MX024
5. Measure the height of the valve guide upper end from

the upper face of the cylinder head.
Valve Guide Upper End Height (Reference) mm
(in)
19 (0.75)
NOTE:
If the valve guide has been removed, both the valve
and the valve guide must be replaced as a set.
Valve and Valve Seat Insert

Valve Thickness
Measure the valve thickness.
If the measured valve is less than the specified limit, the
Intake and Exhaust Valve Thickness mm (in)
Standard Limit
Intake Valve 1.80 (0.071) 1.30 (0.051)
Exhaust Valve 1.80 (0.071) 1.30 (0.051)
Valve Depression
1. Install the new valve ➀ to the cylinder head ➁.
2. Use a depth gauge or a straight edge with steel rule to
measure the valve depression from the cylinder head
lower surface.
If the measured value exceeds the specified limit, the
valve seat insert must be replaced.
Valve Depression A mm (in)
Standard Limit
Intake Valve 1.0 (0.039) 2.5 (0.098)
Exhaust Valve 1.3 (0.051) 2.8 (0.110)
Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness.
2. Measure the valve contact width.
If the measured value exceeds the specified valve
contact width, the valve seat insert must be replaced.
Valve Contact Width mm (in)
Standard
Intake Valve 2.5 (0.098)
Exhaust Valve 2.5 (0.079)
Valve Seat Insert Replacement

Valve Seat Insert Removal
1. Arc weld the entire inside circumference ➀ of the valve
seat insert ➁.
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the
valve seat insert easier.
3. Use a screwdriver ➂ to pry the valve seat insert free.
Take care not to damage the cylinder head ➃.
Valve Seat Insert Installation

1. Carefully place the attachment ➀ (having a smaller
outside diameter than the valve seat insert) on the valve
seat insert ➁.
CAUTION
The smooth side of the attachment must contact the
valve seat insert.
Carefully remove carbon and other foreign material
from the cylinder head insert bore.
2. Use a bench press ➂ to gradually apply pressure to the
attachment and press the valve seat insert into the
place.
CAUTION:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15, 45, 60 and 75 degree blades) to

minimize scratches and other rough areas. This will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do not cut
away too much. Take care not to cut away
unblemished areas of the valve seat surface.
Valve Face Angle deg

Intake and exhaust 45
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside
the valve guide.
Check valve depression within the specified limit
after valve seat insert correction.
3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
011MX018
Valve Spring
Valve Spring Free Height
Use a vernier caliper to measure the valve spring free
height.
valve spring must be replaced.
Spring Free Height mm (in)
Standard Limit
Intake 65.9 (2.59) 64.8 (2.55)
Exhaust 68.1 (2.68) 66.9 (2.63)
Valve Spring Squareness

Use a surface plate and a square to measure the valve
spring squareness.
If the measured value exceeds the specified limit, the valve
spring must be replaced.
Inner and Outer Spring Squareness mm (in)
Standard Limit
Intake 2.9 (0.114) 3.4 (0.134)
Exhaust 3.0 (0.118) 3.4 (0.134)
Valve Spring Tension

Use a spring tester to measure the valve spring tension.
valve spring must be replaced.
Intake Valve Spring Tension N (kg / Ib)
Compression Height Standard Limit
46mm (1.81in) 348.1 (35.5 / 78) 296 (30.2 / 67)
Exhaust Valve Spring Tension N (kg / Ib)

Compression Height Standard Limit
46mm (1.81in) 382.5 (39.0 / 86) 329 (33.5 / 74)
Rocker Arm Shaft and Rocker Arm

Rocker Arm Shaft Run-Out
1. Place the rocker arm shaft on a V-block.
2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm shaft
run-out with a bench press. The rocker arm must be at
cold condition.
If the measured rocker arm shaft run-out exceeds the
specified limit, the rocker arm shaft must be replaced.
Rocker Arm Shaft Run-Out mm (in)
Limit
0.3 (0.012)
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting portion
outside diameter.
rocker arm shaft must be replaced.
Rocker Arm Shaft Outside Diameter mm (in)
Standard Limit
21.979 — 22.000 (0.865 — 0.866) 21.85 (0.860)
Rocker Arm Shaft and Rocker Arm Clearance

1. Use either a vernier caliper or a dial indicator to
measure the rocker arm inside diameter.
Rocker Arm Inside Diameter mm (in)
Standard
22.010 — 22.035 (0.867 — 0.868)
2. Measure the rocker arm shaft outside diameter.
If the measured value exceeds the specified limit,
replace either the rocker arm or the rocker arm shaft.
Rocker Arm Shaft and Rocker Arm Clearance mm (in)
Standard Limit
0.010 — 0.056 0.20
(0.0004 — 0.0022) (0.008)
3. Check that the rocker arm oil port is free of

obstructions.
If necessary, use compressed air to clean the rocker
arm oil port.
Rocker Arm
Visually inspect the rocker arm camshaft contact surfaces
of the roller for excessive wear and damage.
Rocker Arm Roller and Pin Clearance

1. Pass the string through the rocker arm-roller clearance
and measure the roller protrusion while pulling both
ends of the string in the arrow-indicated directions to
push out the roller.
Mark the measuring point and draw out the string.
2. Measure the roller protrusion again while the roller is

pushed in.
3. Note the difference in the above measurements is the
standard roller-rocker arm pin clearance.
Should the clearance exceed the limit, replace the
rocker arm.
Rocker Arm Pin and Roller Clearance mm (in)
Standard Limit
0.068 — 0.099 0.5
(0.0027 — 0.0039) (0.02)
Bridge Cap
Inspect the valve cap surface contacting the rocker arm for
excessive wear and damage.
If the wear exceeds the limit, replace the valve cap with
new one.
Valve Cap Worn mm (in)
Limit 0.1 (0.004)
Camshaft
Visually inspect the journal, the cams, and the camshaft
bearings for excessive wear and damage. The camshaft
and the camshaft bearings must be replaced if these
conditions are discovered during inspection.
Camshaft Journal Diameter

Use a micrometer to measure each camshaft journal
diameter in two directions ➀ and ➁. If the measured value
is less than the specified limit, the camshaft must be
replaced.
Camshaft Journal Diameter mm (in)
Standard Limit
39.950 — 39.975 39.85
(1.5728 — 1.5738) (1.569)
Cam Lobe Height

Measure the cam lobe height with a micrometer.
If the measured value is less than the the specified limit,
the camshaft must be replaced.
Cam Lobe Height mm (in)
Standard Limit
53.59 (2.11) 53.17 (2.093)
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
camshaft must be replaced.
Camshaft Run-Out mm (in)
Limit
0.05 (0.002)
Camshaft and Camshaft Bearing Clearance

Measure the outside diameter of camshaft.
Camshaft Outside Diameter mm (in)
Standard Limit
40.0 (1.5748) 39.85 (1.569)
Use an inside dial indicator to measure the camshaft
bracket inside diameter.
Camshaft Bearing Inside Diameter mm (in)
Standard
40.00 — 40.04 (1.575 — 1.576)
If the clearance between the camshaft bracket inside
diameter and the journal exceeds the specified limit, the
camshaft bracket bearing, and/or camshaft must be
replaced.
Camshaft Bearing Clearance mm (in)
Standard Limit
0.025 — 0.087 (0.001 — 0.003) 0.15 (0.006)
Camshaft and Camshaft Gear Clearance

Measure the clearance between the camshaft and
camshaft gear.
Camshaft and Camshaft Gear Clearance mm (in)
Standard
28.015 — 28.055 (1.103 — 1.105)
Camshaft Gear
Visually inspect the camshaft for excessive wear and
damage.
If the camshaft gear for excessive wear or damaged it must
be replaced.
Camshaft Bracket
Check that the camshaft bracket oil port is free of
obstructions.
If necessary, use compressed air to clean the camshaft
bracket oil port.
REASSEMBLY
Cylinder Head
Reassembly Steps
1. Cylinder head 14. Idler gear “C”
2. Oil seal 15. Sealing cup
3. Engine hanger 16. Thermostat
4. Bridge guide 17. Water outlet pipe
5. Injection nozzle sleeve 18. Thermometer unit
6. Valve seat insert 19. Heat protector
7. Valve guide 20. Gasket
8. Spring seat 21. Exhaust manifold
9. Valve stem seal 22. Heat protector
10. Valve 23. Intake cover
11. Valve spring 25. Bridge
12. Valve spring upper seat 26. Bridge cap
13. Split collar
Reassembly Steps
1. Cylinder Head
2. Oil Seal
Use the oil seal installer to install the cylinder head.
Oil Seal Installer: 5-8840-2627-0
011MX026
011MX036
3. Engine Hanger
Install the engine hanger bolts to the specify torque.
Engine Hanger Bolts Torque N.m (kg.m / lb.ft)
94 (9.6 / 69)
011MX044
4. Bridge Guide
1) Apply engine oil to the valve bridge guide outer
circumference.
2) Attach the valve bridge guide installer to the bridge
guide.
Valve Bridge Guide Installer: 5-8840-2626-0
3) Use a brass hammer to tap the guide into position
O11MX012
5. Injection Nozzle Sleeve

1) Install O-ring to nozzle sleeve and apply engine oil to
cylinder head ➁.
2) Apply liquid gasket the tapered part ➀ of nozzle
sleeve.
LOCTITE No. TL290
040MV040-1
3) Install nozzle sleeve to cylinder head and insert guide

sleeve.
4) Push in nozzle sleeve with guide sleeve so that the
bottom surface of cylinder head can be reached.
5) Insert nozzle sleeve and fix with clamp and bolt.
6) Push a ball (bearing steel ball 9.525 mm) into guide
sleeve, and let the ball go through by hammering
through punch bar.
NOTE:
040MX039 • Remove chips from the threaded part of cylinder
head.
• Keep the cylinder head afloat so that the ball can
go out of the bottom surface.
Nozzle Sleeve Setting Tool: 5-8840-2624-0
6. Valve Seat Insert

1) Carefully place the attachment ➀ (having a smaller
outside diameter than the valve seat insert) on the
valve seat insert ➁.
NOTE:
The smooth side of the attachment must contact the
valve seat insert.
2) Use a bench press ➂ to gradually apply pressure to
the attachment and press the valve seat insert into
place.
CAUTION:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.
3) The valve should be lapped before final assembly to

ensure a good valve seal.
Refer to “Valve Seat Insert Correction” in this section.
7. Valve Guide
1) Apply engine oil to the valve guide outer
circumference.
2) Attach the valve guide replacer to the valve guide.
3) Use a hammer to drive the valve guide into position
Valve Guide Remover: 5-8840-2628-0
4) Measure the height of the valve guide upper end from
the upper face of the cylinder head.
011MX024 Valve Guide Upper End Height (Reference) mm (in)
19 (0.748)
8. Spring Seat
9. Valve Stem Seal
1) Apply engine oil to the oil seal inner face.
2) Use the oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2625-0
011MX020
10. Valve
Apply engine oil to intake valves and exhaust valves.
11. Valve Spring
1) Place the cylinder head on a flat wooden surface.
2) Install the valve springs with their fine pitched end
(painted) facing down.
Colored
Intake Valve Light blue
Exhaust Valve Yellow
12. Spring Upper Seat

13. Split Collar
1) Use the spring compressor to compress the valve
spring.
Spring Compressor: 5-8840-2621-0
2) Install the split collars to the valve stem.
Do not allow the valve to fall from the cylinder head.
3) Set the split collars by tapping around the head of
each collar with a rubber hammer.
011MX017
14. Idler Gear “C”

1) Apply engine oil to the idler gear shaft and idler gear
“C” bushing before installation.
2) Install the idler gear “C” with the boss side facing to
the front of engine as shown in the illustration.
Idle Gear “C” Bolt Torque N·m (kg·m / lb·ft)
95 (9.7 / 70)
15. Sealing Cup

1) Apply LOCTITE No. 962T or equivalent to sealing cup
hole circumference.
2) Drive the sealing cup into position from the cylinder
head side as shown in the illustration.
16. Thermostat
1) Install the thermostat gaskets ➀ to the flange of
thermostats.
2) Install the thermostat (without jiggle valve) ➁ and
thermostat (with jiggle valve) ➂ to the cylinder head.
NOTE:
The jiggle valves of thermostat must be facing the
rear of the engine.

1) Install the water outlet pipe to the cylinder head.
2) Tighten the water outlet pipe bolts to the specified
torque.
Water Outlet Pipe Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
18. Thermometer Unit

1) Apply LOCTITE No. 271 or equivalent to the
thermometer unit threads portion.
2) Install the thermometer unit ➀ to the cylinder head and
tighten to the specified torque.
Thermostat Unit Torque N·m (kg·m / lb·ft)
20 (2.0 / 14)
032MX023
19. Head Cover Heat Protector

1) Install the heat protector to the cylinder head.
2) Tighten the heat protector bolts to the specified torque.
Heat Protector Bolt Torque N·m (kg·m / lb·ft)
24 (2.4 / 17)
011MX022
20. Gasket : Exhaust Manifold

Install with the protruding part of gasket facing down.
011MX021
NOTE:
Check and see that the gasket is correctly installed
to the cylinder head. The gasket, if installed in a
wrong way, could get over the casting skin of the
cylinder head.
21. Exhaust Manifold

1) Install the three gas seal ring to the rear exhaust
manifold.
Position the ring gaps 120 degrees apart from each
other.
NOTE:
Make sure, the gaskets are installed completely on
the cylinder head, if the gaskets are mis-install the
gasket onto the surface of did not make machined.
027M100009
2) Install the front exhaust manifold to the rear exhaust
other.
3) Install the exhaust manifold to the cylinder head.

4) Install the distance tube, washer to the stud bolts.
5) Nuts marked with an asterisk (*) are installed to the
exhaust manifold no.7 and no.12 positions.
6) Tighten the exhaust manifold nuts to the specified
torque.
Exhaust Manifold Nut Torque N·m (kg·m / lb·ft)
34 (3.5 / 25)
027M100008
22. Heat Protector

23. Intake Cover
1) Install the intake cover bolts with distance pipe and the
mounting rubber.
2) Tighten the intake cover bolts to the specified torque a
little at a time in the numerical order shown in the
illustration.
Intake Cover Bolt Torque N·m (kg·m / lb·ft)
15 (1.5 / 11)
025MX016
25. Bridge
Apply engine oil to the bridge.
26. Bridge cap
Apply engine oil to the bridge cap.
014MX014
Rocker Arm and Shaft Assembly
014MY00011
Reassembly Steps
1. Rocker arm shaft 4. Spring washer
2. Rocker arm shaft bracket 5. Rocker arm
3. Rocker arm 6. Camshaft bracket
Reassembly Steps
1. Rocker Arm Shaft
1) Apply engine oil to the rocker arm shaft.
2) Install the camshaft bracket to the rocker arm shaft.
3) Temporarily tighten the camshaft bracket bolt A.
2. Rocker Arm Shaft Bracket

Install the parts as shown in the installation.
014MX028
3. Rocker Arm
Apply engine oil to the rocker arm roller and pin.
4. Spring Washer
5. Rocker Arm
6. Camshaft Bracket
Camshaft
Reassembly Steps
1. Camshaft 3. Camshaft gear
2. Gear alignment pin
Reassembly Steps
1. Camshaft
2. Gear Alignment Pin
3. Camshaft Gear
1) Fit the gear alignment pin into the camshaft pin hole.
2) Install the camshaft gear to the camshaft.
The gear hub large side must be facing the camshaft.
3) Apply engine oil to the camshaft gear bolt threads and

the setting faces.
4) Tighten the camshaft gear bolt to the specified torque.
Camshaft Gear Bolt Torque N·m (kg·m / lb·ft)
142 (14.5 / 105)
CRANKSHAFT, PISTON AND

CONNECTING ROD
DISASSEMBLY
Disassembly Steps
1. Crankshaft damper pulley 9. Connecting rod bearing cap with lower
2. Water duct and O-ring bearing
3. Timing gear case cover 10. Piston and connecting rod with upper bearing
4. Crankshaft front oil seal 11. Cylinder body lower crankcase
5. Crankshaft front slinger 12. Crankshaft lower bearing
6. Power steering oil pump idler gear 13. Crankshaft thrust bearing (Lower side)
shaft 14. Crankshaft thrust bearing (Upper side)
7. Power steering oil pump idler gear 15. Crankshaft
8. Timing gear case 16. Crankshaft upper bearing
17. Cylinder body
Disassembly Steps
1. Crankshaft Damper Pulley
1) Block the crankshaft with a piece of hard wood to
prevent the damper pulley from turning.
2) Diagonally loosen the damper pulley bolts.

3. Timing Gear Case Cover
Use bolts into the replacer holes on timing gear case cover
for remove the timing gear case cover.
4. Crankshaft Front Oil Seal
Use a screwdriver to pry the oil seal from the timing gear
case cover.
Take care not to damage the oil seal fitting surface.
5. Crankshaft Front Slinger

Use the slinger remover to remove the slinger.
Slinger Remover: 8-94396-858-0
Take care not to damage the crankshaft.
NOTE:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
6. Power Steering Oil Pump Idler Gear Shaft

7. Power Steering Oil Pump Idler Gear
1) Use a TORX® wrench to loosen the idler gear shaft
bolts.
2) Remove the idler gear shaft together with idler gear.
8. Timing Gear Case

Use bolts into the replacer holes on timing gear case to
remove the timing gear case as illustration.
9. Connecting Rod Bearing Cap with Lower Bearing

1) If the connecting rod bearing assembly original marks
can not be clearly seen, remark the assemblies with a
punch or a numbering stamps.
This will ensure reassembly to their original positions.
2) Loosen the connecting rod bearing cap bolts a little at
a time.
If the connecting rod lower bearings are to be

reinstalled, mark their fitting positions by tagging each
bearing with the cylinder number from which it was
removed.
10. Piston and Connecting Rod with Upper Bearing

1) Remove carbon deposits from the upper portion of the
cylinder wall with a scraper before removing the piston
and connecting rod.
2) Move the piston to the top of the cylinder and tap it
with a hammer grip or similar object from the
connecting rod lower side to drive it out.
NOTE:
Take care not to damage the oiling jet.
If the connecting rod upper bearings are to be reinstalled,

mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
11. Cylinder Body Lower Crankcase

12. Crankshaft Lower Bearing
1) Measure the crankshaft end play at the No. 7
crankshaft journal.
Do this before removing the cylinder body lower
crankcase.
crankshaft thrust bearing must be replaced.
Crankshaft End Play mm (in)
Standard Limit
0.04 — 0.205 (0.0016 — 0.008) 0.54 (0.021)
2) Loosen the cylinder body lower crankcase bolts (M14

14 pieces) a little at a time in the numerical order
shown in the illustration.
3) Loosen the cylinder body lower outside crankcase
bolts (M10 25 pieces) evenly from outside to inside.
4) Screw M10 bolts (Lower crankcase bolts) into the four
threaded holes (asterisked) and tighten these evenly,
and separate the lower crankcase from the cylinder
body.
012MX006
If the crankshaft lower bearings are to be reinstalled, mark

their fitting positions by tagging each baring with the journal
number from which it was removed.
13. Crankshaft Thrust Bearing (Lower Side)

14. Crankshaft Thrust Bearing (Upper Side)
15. Crankshaft
16. Crankshaft Upper Bearing
If the crankshaft upper bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
journal number from which it was removed.
17. Cylinder Body

REASSEMBLY
Reassembly Steps
1. Cylinder body 10. Connecting rod bearing cap with lower
2. Crankshaft upper bearing bearing
3. Crankshaft thrust bearing 11. Timing gear case
(Upper side) 12. Power steering oil pump idler gear
4. Crankshaft 13. Power steering oil pump idler gear shaft
5. Crankshaft thrust bearing 14. Timing gear case cover
(Upper side) 15. Crankshaft front slinger
6. Crankshaft thrust bearing 16. Crankshaft front oil seal
(Lower side, 1 piece)
17. Water duct and O-ring
7. Crankshaft lower bearing
18. Crankshaft damper pulley
8. Cylinder body lower crankcase
9. Piston and connecting rod with
upper bearing
Crankshaft Bearing Selection

Refer to the following table when replacing the crankshaft
and/or the crankshaft bearings.
Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing housing.
Match the crankshaft bearing housing grade marks and the
crankshaft journal grade marks in the table below to determine
the correct crankshaft bearing size.
Crankshaft Bearing Insert Grade Mark

Position
The crankshaft bearing housing grade marks (1 or 2) are
stamped collectively for all cylinders on the underside of
the left front portion of the crankcase.
012HY00004
Crankshaft Journal Grade Mark Position

The crankshaft journal grade marks (1 or 2) are stamped
collectively for all cylinders on the front side of the crankshaft
No.1 balancer.
The clearance between the crankshaft journal and the bearing
must be the same for each position after installation of the
crankshaft and the crankshaft bearings.
015HY00037
Crankshaft Bearing Combination

Bearing Housing Crankshaft Journal Crankshaft Bearing
Grade Mark Grade Mark Color Code
1 1 Green
1 2 Pink
2 1 Yellow
2 2 Green
015HY00041 Oil Clearance

mm (in)
Crankshaft Main Bearing No.4 0.093 — 0.124
(center) (0.0037 — 0.0049)
Crankshaft Main Bearing 0.063 — 0.094
(except No.4) (0.0025 — 0.0037)
Connecting Rod Bearing Selection

Refer to the following table when installing or replacing the
connecting rod bearings.
Pay close attention to the grade mark (2) on the big end of the
connecting rod.
Do not confuse the grade mark on the big end of connecting
rod with the alignment cylinder No. mark (1).
015HY00039
Connecting Rod Bearing Combination

mm (in)
Connecting Rod Connecting Rod
Big End Bearing Oil Clearance
Grade Mark Color Code
A Green 1 0.037 — 0.077
B Yellow (0.0015 — 0.0030)
015HY00041
Installation Steps
1. Cylinder Body
Use compressed air to thoroughly clean the inside and
outside surfaces of the cylinder body, the oil holes, and the
water jackets.
2. Crankshaft Upper Bearing

The crankshaft upper bearings have an oil hole and oil
groove. The lower bearings have only a partial oil groove.
1) Carefully wipe any foreign material from the crankshaft
upper bearing and the crankshaft upper bearing fitting
surfaces.
2) Install the bearings to the cylinder body.

Note the tags attached at disassembly if the removed
crankshaft upper bearings are to be reused.

1) Apply engine oil to the thrust bearing oil grooves side
before installation.
2) Install the thrust bearing to inside of the crankshaft No.
7 journal.
The thrust bearing oil grooves must be facing the
sliding face.
4. Crankshaft
Apply engine oil to the crankshaft journal and the
crankshaft bearing sliding surfaces before installing the
crankshaft.

2) Install the thrust bearing to outside of the crankshaft
No. 7 journal.
sliding face.
6. Crankshaft Thrust Bearing (Lower Side)

2) Install the thrust bearing to the crankcase.
sliding face to crankshaft side.
7. Crankshaft Lower Bearing

8. Cylinder Body Lower Crankcase
1) Carefully wipe any foreign material from the crankcase
lower bearing back and the sliding surfaces.
2) Install the lower bearings to the lower crankcase.
Note the tags attached at disassembly if the removed
crankshaft lower bearings are to be reused.
3) Apply engine oil to the lower bearing sliding surfaces.
4) Apply unbroken strips of the ThreeBond 1 207C or
equivalent to the cylinder body lower face as shown in
the illustration.
The liquid gasket must be 3.0 — 4.0mm
(0.12 — 0.16in) wide.
NOTE:
liquid gasket) set the cylinder body lower crankcase
to the cylinder body.
NOTE:
Do not allow the crankshaft lower bearings and
thrust bearings to fall free.
6) Apply molybdenum disulfide grease to the cylinder

body
lower crankcase bolt threads and setting faces.
7) Tighten the lower crankcase M14 bolts in three steps

using the angular tightening method.
Lower Crankcase M14 Bolt Torque N.m (kg.m / Ib.ft)
98 (10 / 72) 132 (13.5 / 98) 30 — 60 deg
8) Check that the crankshaft rotates smoothly.

NOTE:
Cylinder body lower crankcase M14 bolts can be
reused six (6) times.
9) Tighten the lower crankcase M10 bolts a little at a time
in the numerical order shown in the illustration.
Lower Crankcase M10 Bolt Torque N·m (kg·m / lb·ft)
37 (3.8 / 27)
CAUTION:
The lower crankcase and the cylinder body are
machined as a single unit. They cannot be replaced
as separate unit.
Always replace the lower crankcase and the cylinder
body as a set.
9. Piston and Connecting Rod with Upper Bearing

10. Connecting Rod Bearing Cap with Lower Bearing
1) Apply engine oil to the circumference of each piston
ring and piston.
2) Position the piston ring gaps as shown in the
illustration.
➀ 1st compression ring
➁ 2nd compression ring
➂ Oil ring
3) Apply molybdenum disulfide grease to the piston skirts.

This will facilitate smooth break-in when the engine is
first started after reassembly.
4) Apply engine oil to the upper bearing surfaces.
5) Apply engine oil to the cylinder wall.
6) Position the piston head front mark ➀ so that it is

facing the front of the engine.
7) Use the piston ring compressor to compress the piston

rings.
8) Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC (Bottom Dead Center).
NOTE:
Take care not to strike the oiling jet and crankpin
with the connecting rod big end during the
installation procedure.
Damage to the oiling jet will result.
9) Install the connecting rod bearing caps.

10) Align the bearing cap cylinder number marks and the
connecting rod cylinder number marks.
The cylinder number marks must be turned toward the
intake cover side.
11) Apply molybdenum disulfide grease to the threads and

setting faces of each connecting rod cap bolt.
12) Tighten the connecting rod bearing cap bolts in three
steps using angular tightening method.
Connecting Rod Bearing Cap Bolt
Torque N.m (kg.m / lb.ft)
Standard Limit
39 (4 / 29) 60 deg 30 — 60 deg
NOTE:
Connecting rod bearing cap bolts can be reused six
(6) times.
13) Check that the crankshaft rotates smoothly.
11. Timing Gear Case

1) Apply ThreeBond 1207C or equivalent to the timing
gear case grooves. (Including arrow mark portion.)
The liquid gasket must be 2.0 — 3.0mm
(0.08 — 0.12in) wide.
2) Install the O-ring.
3) Immediately (within ten (10) minutes of applying the
liquid gasket) set the timing gear case to the cylinder
body.
4) Tighten the timing gear case bolts to the specified
torque.
Timing Gear Case Body Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
12. Power Steering Oil Pump Idler Gear

13. Power Steering Oil Pump Idler Gear Shaft
1) Apply engine oil to the idler gear and the idler gear
shaft.
2) Set the idler gear to the idler gear shaft.
3) Install the idler gear and idler gear shaft to the timing
gear case.
NOTE:
Cutting portion on idle gear shaft must be facing the
crankshaft.
4) Tighten the idler gear shaft bolts to the specified
torque.
Idler Gear Shaft Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
14. Timing Gear Case Cover

1) Apply ThreeBond 1207C or equivalent to the timing
gear case cover grooves.
The liquid gasket must be 2.0 — 3.0mm (0.08 — 0.12in)
wide.
2) Immediately (within 15 minutes of applying the liquid
gasket) set the timing gear case cover to the timing
gear case.
3) Tighten the timing gear case cover bolts to the

specified torque a little at a time in the numerical order
Timing Gear Case Cover Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
15. Crankshaft Front Slinger

Use the Oil seal installer kit to install the slinger.
Oil Seal Installer Kit: 8-94396-856-0
NOTE:
For visual identification, front slinger is black colored
and rear slinger gray colored.
1) Insert the slinger ➀ into the end of adapter ➁, and

install the adapter to the crankshaft ➂.
2) Install the slinger sleeve ➃ to the adapter, and tighten
center bolt ➄ until the sleeve comes into contact with
the adapter stopper (arrow marked).
3) After pressing in the slinger, make sure that the
distance between the crankshaft end surface and the
slinger is A. (Check 8 position on the circumference)
A: 18.0 ± 0.3 mm (0.709 ± 0.012 in)
015MT003
NOTE:
Be sure to replace the slinger and oil seal as a set.
16. Crankshaft Front Oil Seal

Use the oil seal installer kit to install the oil seal.
1) Apply engine oil to the oil seal lip.
2) Insert the oil seal ➀ into the adapter ➁.
3) Install the oil seal sleeve ➂ to the adapter.
4) Install the oil seal sleeve to the adapter, and tighten the
center bolt until the sleeve comes into contact with
adapter stopper (arrow marked).
5) After pressing in oil seal, make sure that the distance
between the crankshaft end surface and oil seal B.
This check should be conducted at eight different
points dividing the circumference into as many equal
parts.
B: 8.5 ± 0.15mm (0.335 ± 0.006in)
Front Oil Seal Installer Kit Applicable mm (in)

Part Name Stamp Slinger Oil Seal
Front use adapter FTR
Front use slinger sleeve FT –
Front use oil seal sleeve FT –
Center bolt –
Adapter bolt –

1) Install the water duct ➀ and gasket ➁ to the cylinder
body.
2) Tighten the water duct bolts to the specified torque.
Water Duct Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
18. Crankshaft Damper Pulley

1) Apply engine oil to the threads and setting faces of the
crankshaft damper pulley bolts.
prevent the damper pulley from turning.
3) Align the Crankshaft dowel and the crankshaft damper
pulley dowel hole.
4) Tighten the crankshaft damper pulley bolts to the
specified torque a little at a time in the numerical order
Pulley Bolt Torque N·m (kg·m / lb·ft)
196 (20/ 145)
DISASSEMBLY
Crankshaft
Disassembly Steps
1. Crankshaft Gear (Front) 3. Crankshaft
2. Crankshaft Gear (Rear)
Disassembly Steps
1. Crankshaft Gear (Front)
Use a gear pulley to remove the crankshaft gear.
3. Crankshaft

inspection.
Crankshaft and bearing

Crankshaft
Inspect the surface of the crankshaft journals and
crankpins for excessive wear and damage.
Inspect the oil ports for obstructions.
Bearing Spread
Check the bearing spread.
Finger pressure should be required to fit the bearing into
position.
If the bearing fits loosely, it must be replaced.
Crankshaft Run-Out
1. Set a dial indicator to the center of the No.4 crankshaft
journal.
2. Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
crankshaft must be replaced.
Crankshaft Run-Out mm (in)
Standard Limit
0.06 (0.002) or less 0.45 (0.018)
Crankshaft Journal and Crankpin Diameter

1. Use a micrometer to measure the crankshaft journal
diameter across points ➀ — ➀ and ➁ — ➁.
2. Use the micrometer to measure the crankshaft journal
diameter at the two points (➂ and ➃).
3. Repeat Steps 1 and 2 to measure the crankpin
diameter.
Crankshaft Journal Diameter mm (in)
Journal No. Standard
4 81.875 — 81.895
(3.2234 — 3.2242)
Others 81.905 — 81.925

(3.2246 — 3.2254)
Crankpin Diameter mm (in)

Standard
65.902 — 65.922 (2.5946 — 2.5953)
Crankshaft Journal and Crankpin Uneven Wear mm (in)

Limit
0.05 (0.0020)
Crankshaft Bearing Inside Diameter

1. Clean the cylinder body and lower crankcase bearing
fitting surfaces, and the bearing inside and outside
surfaces.
2. Install the lower crankcase with the bearings to the
cylinder body.
3. Apply molybdenum disulfide grease to the lower
crankcase bolt threads and setting faces.
4. Tighten the lower crankcase M14 bolts in three step
using the angular tightening method.
Lower Crankcase M14 Bolt Torque N.m (kg.m/Ib.ft)
98 (10 / 72) 132 (13.5 / 98) 30 — 60 deg
NOTE:
Cylinder body lower crankcase M14 bolts can be
reused six (6) times.
5. Tighten the lower crankcase M10 bolts to the specified
torque.
Lower Crankcase M10 Bolt Torque N·m (kg·m / lb·ft)
37 (3.8 / 27)
6. Use an inside dial indicator to measure the crankshaft

bearing inside diameter.
Crankshaft Journal and Bearing Clearance

If the clearance between the measured bearing inside
diameter and the crankshaft journal diameter exceeds the
specified limit, the crankshaft must be replaced.
Crankshaft Journal and Bearing Clearance mm (in)
Bearing No. Standard Limit
4 0.093 — 0.124
(0.00366 — 0.00488)
0.063 — 0.094 0.14 (0.0055)
Others
(0.00248 — 0.00370)
Crankshaft Tufftriding Inspection

1. Use an organic cleaner to thoroughly clean the
crankshaft.
There must be no traces of oil on the surfaces to be
inspected.
2. Prepare a 5 — 10% solution of ammonium cuprous
chloride (dissolved in distilled water).
3. Use a syringe to apply the solution to the surface to be
inspected.
Hold the surface to be inspected perfectly horizontal to
prevent the solution from running.
NOTE:
Do not allow the solution to come in contact with the
oil ports and their surrounding area.
Judgment
1. Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty seconds,
the crankshaft is usable.
If discoloration appears (the surface being tested will
become the color of copper), the crankshaft must be
replaced.
2. Steam clean the crankshaft surface immediately after
completing the test.
NOTE:
The ammonium cuprous chloride solution is highly
corrosive.
Because of this, it is imperative that the surfaces
being tested be cleaned immediately after
completing the test.
REASSEMBLY
Reassembly Steps
1. Crankshaft 3. Crankshaft gear (Front)
2. Crankshaft gear (Rear)
Reassembly Steps
1. Crankshaft
1) Install the crankshaft timing gear alignment pin.
2) Heat the crankshaft gear evenly with a gas burner to
invite thermal expansion.
Do not allow the temperature of the gas burner to
exceed 180° C (356° F).
There is broken the crankshaft gear without heat up
when install the crankshaft gear to crankshaft.
3) Use the crankshaft gear installer to install the
crankshaft gear.
Crankshaft Gear Installer: 8-94396-819-0
The crankshaft gear timing mark “L” must be facing out.
Take care not to damage the crankshaft and crankshaft
gear.
WARNING:
TAKE CARE NOT TO BURN YOURSELF ON THE
HEATED CRANKSHAFT GEAR.
3. Crankshaft Gear (Front)

Install by following the same procedure as for crankshaft
gear (rear). There is no direction of gear installation.
DISASSEMBLY
Piston and Connecting Rod
Disassembly Steps
1. Connecting rod bearing 5. Piston pin
2. Piston ring 6. Connecting rod
3. Piston pin snap ring 7. Piston
4. Piston pin snap ring
Disassembly Steps
1. Connecting Rod Bearing
If the connecting rod bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
2. Piston Ring
1) Clamp the connecting rod in vise.
Take care not to damage the connecting rod.
2) Use a piston ring replacer to remove the piston rings.
Do not attempt to use some other tool to remove the
piston rings. Piston ring stretching will result in reduced
piston ring tension.
3. Piston Pin Snap Ring

Use pliers to remove the piston pin snap rings.
5. Piston Pin
6. Connecting Rod
7. Piston
Use your hand to push the piston pin out.
If the pistons are to be installed, mark their installation
positions by tagging each piston with the cylinder number
from which it was removed.

Make the necessary adjustments, repairs, and part replacements if excessive wear of damage is discovered during
inspection.
Piston
Visual Inspection
Inspect the piston after removing carbon, sludge, etc, and
rinsing. Be sure to inspect with special care the piston
parts which may escape your notice.
Cylinder Liner and Piston Clearance

1. Measure the cylinder liner bore.
1) Measure the cylinder liner bore at measuring points ➀,
➁ and ➂ in direction a right angle to the crankshaft.
2) Calculate the average value of the three (3)
measurements to determine the cylinder liner bore.
Measuring Point ➀ : 20mm (0.79in)
➁ : 110mm (4.33in)
➂ : 190mm (7.48in)
Cylinder Liner Bore Diameter (Non Grade) mm (in)
115.031 — 115.050 (4.5288 — 4.5295)
2. Measure the piston outside diameter.

Measuring Point : 88mm (3.46in)
Piston Outside Diameter (Non Grade) mm (in)
114.974 — 114.989 (4.5265 — 4.5271)
Cylinder Liner and Piston Clearance mm (in)

0.042 — 0.076 (0.00165 — 0.00299)
CAUTION:
It is most important that the correct piston clearance
be used.
Piston Ring and Piston Ring Groove Clearance

1. Use a feeler gauge to measure the clearance between
the piston ring and piston ring groove at several points
around the piston.
If the clearance between the piston ring and the piston
ring groove exceeds the specified limit, replace either
the piston and/or piston ring.
Piston Ring and Piston Ring Groove Clearance mm (in)
Standard Limit
1st Compression 0.08 — 0.105
0.20 (0.008)
Ring (0.0031 — 0.0041)
2nd Compression 0.05 — 0.08
Ring (0.0020 — 0.0031) 0.15 (0.006)
0.02 — 0.06
Oil Ring
(0.0008 — 0.0024)
2. Visually inspect the piston ring grooves.
If a piston ring groove is damaged or distorted, the
piston must be replaced.
Piston Pin
Piston Pin Diameter
Use a micrometer to measure the piston pin diameter at
several points.
piston pin must be replaced.
Piston Pin Hole Diameter mm (in)
Standard Limit
35.995 — 36.000 (1.4171 — 1.4173) 35.95 (1.4154)
Piston Pin and Piston Pin Hole Clearance

Use an inside dial indicator to measure the piston pin hole
diameter (in the piston).
If the clearance between the piston pin and the piston pin
holes exceeds the specified limit, replace the piston pin
and/or the piston.
Front Mounting Nut Torque mm (in)
Standard
36.004 — 36.012 (1.4175 — 1.4178)
Piston Pin and Piston Pin Hole Clearance mm (in)

Standard
0.004 — 0.017 (0.00016 — 0.00067)
Piston Ring
Piston Ring Gap
1. lnsert the piston ring horizontally (in the position it would
assume if it was installed to the piston) into the cylinder
liner.
2. Push the piston ring into the cylinder liner bore until it
reaches the measuring point (where the cylinder liner
bore is the smallest).
Do not allow the piston ring to slant to one side or the
other. It must be perfectly horizontal.
3. Use a feeler gauge to measure the piston ring gap.

lf the measured value exceeds the specified limit, the
piston ring must be replaced.
Piston Ring Gap mm (in)
Standard Limit
1st Compression 0.18 — 0.28
Ring (0.0071 — 0.0110)
2nd Compression 0.35 — 0.50 1.20
Ring (0.0138 — 0.0197) (0.047)
0.15 — 0.35
Oil Ring
(0.0059 — 0.0138)
Connecting Rod
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion and
the parallelism between the connecting rod big end hole
and the connecting rod small end hole.
If either the measured distortion or parallelism exceeds the
specified limit, the connecting rod must be replaced.
Connecting Rod Alignment
Per length of 100 mm (3.94 in) mm (in)
Standard Limit
Distortion and
0.05 (0.002) or less 0.20 (0.008)
Parallelism
Piston Pin and Connecting Rod Small End Bushing

Clearance
Use a caliper calibrator and a dial indicator to measure the
piston pin and connecting rod small end bushing
clearance.
Connecting Rod Small End Bushing Diameter mm (in)
Standard
36.012 — 36.022 (1.4178 — 1.4182)
If the clearance between the piston pin and the connecting
rod small end bushing exceeds the specified limit, replace
the piston pin and/or the connecting rod assembly.
Piston Pin and Connecting Rod Small End
Bushing Clearance mm (in)
Standard Limit
0.12 — 0.027 (0.00047 — 0.00106) 0.05 (0.002)
Crankpin and Bearing Clearance

1. Clean the crankshaft, the connecting rod, the bearing
cap and the bearings.
2. Install the bearings to the connecting rod and bearing
cap.
3. Apply molybdenum disulfide grease to the bearing cap
bolt threads and setting faces.
4. Tighten the bearing cap bolts in three steps using the
angular tightening method.
Connecting Rod Bearing Cap Bolt
Torque N.m (kg.m / lb.ft)
Standard Limit
39 (4 / 29) 60 deg 30 — 60 deg
NOTE:
Connecting rod bearing cap bolts can be reused six
(6) times.
5. Use an inside dial indicator to measure the connecting

rod bearing inside diameter.
Measuring position shown in the illustration.
6. Use a micrometer to measure the crankpin diameter

across points ➀ — ➀ and ➁ — ➁.
7. Use the micrometer to measure the crankpin diameter
at the two points (➂ and ➃).
If the clearance between the measured bearing inside
diameter and the crankpin exceeds the specified limit,
the crankshaft must be reground or replaced.
If the crankshaft reground, under size bearings must be
installed.
Crankpin and Bearing Clearance mm (in)
Standard Limit
0.037 — 0.076 0.10
(0.0015 — 0.0030) (0.004)
Connecting Rod Side Face Clearance

1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance etween
the connecting rod big end side face and the crankpin
side face.
connecting rod must be replaced.
Connecting Rod Big End and Crankpin Side
Face Clearance mm (in)
Standard Limit
0.17 — 0.30 (0.0067 — 0.0118) 0.35 (0.014)
Bearing Spread
Check the bearing spread.
Finger pressure should be required to fit the bearing into
position.
If the bearing fits loosely, it must be replaced.
REASSEMBLY
Reassembly Steps
1. Piston 5. Piston pin snap ring
2. Piston pin snap ring 6. Piston ring
3. Connecting rod 7. Connecting rod bearing
4. Piston pin
Reassembly Steps
1. Piston
Use pliers to install the piston pin snap ring to the piston.
3. Connecting Rod
1) clamp the connecting rod in a vise.
2) Install the piston to the connecting rod.
The piston head front mark ➀ and the connecting rod
forging mark (projecting) ➁ must be facing the
opposite direction.
NOTE:
If the old connecting rods are to be replaced with
new ones, the connecting rod weight must be
identical for all cylinders.
4. Piston Pin
1) Apply engine oil to the piston pin.
2) Use hand pressure to force the piston pin into the
piston until it makes contact with the snap ring.
3) Use pliers to install the other snap ring.
NOTE:
Take care not to damage the piston and the piston
pin.
4) Check that the connecting rod moves smoothly on the
piston pin.
6. Piston Ring
1) Use a piston ring replacer to install the three piston
rings.
Install the piston rings in the order shown in the
illustration.
➀ Oil ring
➁ 2nd compression ring
➂ 1st compression ring
NOTE:
Insert the expander coil into the oil ring groove so
that there is no gap on either side of the expander
coil before installing the oil ring.
2) Apply engine oil to the piston ring surfaces.

3) Check to see if the piston rings rotate smoothly in the
piston ring grooves.
7. Connecting Rod Bearing

Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.
FLYWHEEL, TIMING GEAR,

OIL PUMP AND OIL PAN
DISASSEMBLY
Disassembly Steps
1. Spacer rubber 8. Crankshaft rear slinger
2. Oil pan cover 9. Flywheel housing
3. Oil pan 10. Idler gear “A” and idler gear shaft
4. Oil strainer and O-ring 11. Oil pump
5. Pilot bearing and snap ring 12. Idler gear “B”
6. Flywheel and washer 13. Idler gear “B” shaft
7. Crankshaft rear oil seal
Disassembly Steps
1. Spacer Rubber
2. Oil Pan Cover
3. Oil Pan
4. Oil Strainer and O-ring
5. Pilot Bearing and Snap Ring
1) Use a snap ring pliers to remove the snap ring.
2) Remove the pilot bearing.
6. Flywheel and Washer
prevent the flywheel from the turning.
2) Loosen the flywheel bolts a little at a time in the
numerical order shown in the illustration.
7. Crankshaft Rear Oil Seal

8. Crankshaft Rear Slinger
Use the slinger remover to remove the slinger.
Slinger Remover: 8-94396-858-0
Take care not to damage the crankshaft.
CAUTION:
Be careful not to damage the crankshaft oil seal
contact surface during the removal procedure.
NOTE:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
9. Flywheel Housing
10. Idler Gear “A” and Idler Gear Shaft
11. Oil Pump
12. Idler Gear “B”
13. Idler Gear “B” Shaft
1) Measure the idler gear backlash and the crankshaft
gear backlash before removing the idler gear.
020EY00021
2) Measure the idler gear end play before removing the
idler gear.
NOTE:
Refer to the following items for details on the
backlash and end play measurement procedure.
Idler Gear Backlash Measurement

1. Set a dial indicator to the idler gear to be measured.
Hold both the gear to be checked and the adjoining
gear stationary.
2. Move the gear to be checked as far as possible both to
the right and to the left.
Take the dial indicator reading.
idler gear must be replaced.
Idler Gear Backlash mm (in)
Standard Limit
0.10 — 0.17 0.30
(0.0039 — 0.0067) (0.012)
Idler Gear End Play Measurement

Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear end
play.
If the measured value exceeds the specified limit, the idler
gear must be replaced.
Standard Limit
Idler Gear “A”
0.08 — 0.155 0.20
Idler Gear “B” (0.00315 — 0.00610) (0.008)
Idler Gear “D”
0.09 — 0.144 0.20
Idler Gear “C”
(0.00354 — 0.00566) (0.008)

inspection.
Idler Gear Shaft and Idler Gear

Idler Gear Shaft Outside Diameter
Use a micrometer to measure the idler gear shaft outside
diameter.
idler gear shaft and/or shaft must be replaced.
Idler Gear Shaft Outside Diameter mm (in)
Standard Limit
49.950 — 49.975 49.9
Shaft “A”
(1.9665 — 1.9675) (1.965)
Shaft “B” 29.959 — 29.980 29.9
Shaft “C”, “D” (1.1795 — 1.1803) (1.177)
Idler Gear Inside Diameter

Use an inside dial indicator or an inside micrometer to
measure the idler gear inside diameter.
If the clearance between the idler gear shaft outside
diameter and the idler gear inside diameter exceeds the
limit, the idler gear and/or shaft must be replaced.
Idler Gear Shaft and Idler Gear Clearance mm (in)
Standard Limit
0.025 — 0.075 0.20
Shaft “A”
(0.0010 — 0.0030) (0.008)
Shaft “B” 0.020 — 0.062 0.20
Shaft “C”, “D” (0.0008 — 0.0024) (0.008)
Flywheel and Ring Gear

Flywheel
1. Inspect the flywheel friction surface for excessive wear
and heat cracks.
2. Measure the flywheel friction surface depth ➀.
If the measured value is between the standard and the
specified limit, the flywheel may be reground.
flywheel must be replaced.
Flywheel Friction Surface Depth ➀ mm (in)

Clutch Size Standard Limit
350 (14) 43.0 (1.69) 44.0 (1.73)
380 (15) 48.0 (1.89) 49.0 (1.93)
Flywheel Friction Surface Roughness mm (in)

0.05 (0.002)
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the
ring gear must be replaced.
Ring Gear Replacement

Ring Gear Removal
Strike around the edges of the ring gear with a hammer
and brass bar to remove it.
Ring Gear Installation

1. Heat the ring gear evenly with a gas burner to invite
thermal expansion.
Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
WARNING:
TAKE CARE NOT TO BURN YOURSELF ON THE
HEATED RING GEAR.
2. Install the ring gear when it is sufficiently heated.
The ring gear must be installed with the chamfer facing
the clutch.
Crankshaft Pilot Bearing

Check the pilot bearing for excessive wear and damage
and replace it if necessary.
REASSEMBLY
Reassembly Steps
1. Idler gear “B” shaft 7. Crankshaft rear oil seal
2. Idler gear “B” 8. Flywheel and washer
3. Oil pump 9. Oil strainer and O-ring
4. Idler gear “A” and idler gear shaft 10. Oil pan
5. Flywheel housing 11. Oil pan cover
6. Crankshaft rear slinger 12. Spacer rubber
13. Pilot bearing and snag ring
Reassembly Steps
1. Idler Gear “B” Shaft
1) Install the idler gear “B” shaft to the cylinder body.
The idler gear shaft oil port must be facing the cylinder
head.
2) Tighten the idler gear shaft bolts to the specified
torque.
Idler Gear “B” Shaft Bolt Torque N·m (kg·m / lb·ft)
24 (2.4 / 17)
2. Idler Gear “B”

1) Apply engine oil to the idler gear “B” inside and thrust
areas.
2) Install the idler gear to the idler gear shaft.
3) Tighten the idler gear bolts to the specified torque.
Idler Gear “B” Bolt Torque N·m (kg·m / lb·ft)
95 (9.7 / 70)
3. Oil Pump
1) Carefully wipe any foreign material from the cylinder
body rear surface.
2) Apply engine oil to the cylinder body bushing inside.
3) Apply ThreeBond No. 1141E or equivalent to the

shaded areas shown in the illustration.
CAUTION:
The liquid gasket must not obstruct the gear and oil
ports (arrow marked).
4) Install the oil pump to the cylinder body within 15

minute.
5) Tighten the oil pump bolts to the specified torque.
Oil Pump Bolt Torque N·m (kg·m / lb·ft)
24 (2.4 / 17)
4. Idler Gear “A” and Idler Gear Shaft

1) Install the idler gear shaft ➀ to the cylinder body.
The idler gear shaft oil port must be facing the cylinder
head.
2) Apply engine oil to the idler gear “A” inside and thrust
areas.
3) Install the idler gear “A” ➁ to the idler gear shaft.

4) Align the crankshaft gear ➂ “L” mark and the idler gear
➁ “0” marks.
5) Tighten the idler gear bolt to the specified torque.
Idler gear “A” Bolt Torque N·m (kg·m / lb·ft)
29 (3.0 / 22) → 75 deg
Geartrain
Alignment timing marks on each gear shown in the
illustration above.
A06MX00022
5. Flywheel Housing
1) Apply ThreeBond No. BB401 or equivalent to the
flywheel housing fitting faces and the one area marked
with arrow in the illustration.
2) Install the flywheel housing to the cylinder body.

3) Tighten the flywheel housing bolts to the specified
torque.
Flywheel Housing Bolt Torque N·m (kg·m / lb·ft)
: 73 (7.4 / 54)
: 96 (9.8 / 71)
: 119 (12.1 / 88)
: 86 (8.8 / 64)
020MY00022 : 26 (2.7 / 20)
4) Idle Gear D
Install the idle gear D.
119 (12.1 / 88)
Apply oil to the inside diameter and thrust of the idle gear
and install the idle gear in such a direction as illustrated.
5) Cover
Install the cover.
18 (1.8 / 13)
020MX008
6. Crankshaft Rear Slinger

Use the oil seal installer to install the slinger.
1) Insert the slinger ➀ into the end of adapter ➁, and
install the adapter to the crankshaft ➂.
NOTE:
For visual identification, the rear slinger is gray
colored, while the front slinger is black colored.
2) Install the slinger sleeve ➃ to the adapter, and tighten

the center bolt ➄ until the sleeve comes into contact
with the adapter stopper.
015MT002
3) After pressing in the slinger, make sure that the

distance between crankshaft end surface and the
slinger is A as specified.
A: 17.0 ± 0.3mm (0.669 ± 0.012 in)
NOTE:
Be sure to replace the slinger and oil seal as a set.
7. Crankshaft Rear Oil Seal

Use the oil seal installer to install the oil seal.
1) Apply engine oil to the oil seal lip.
Do not stain by engine oil outside oil seal and felt ring.
2) Insert the oil seal ➀ into the adapter ➁.
3) Install the oil seal sleeve ➂ to the adapter.
4) Install oil seal sleeve to the adapter, and tighten the
center bolt until the sleeve comes into contact with the
adapter stopper.
5) After pressing the oil seal, make sure that the distance
between crankshaft end surface and the oil seal is B
as circumferential points which divide the
circumference into eight equal parts.
B : 7.5 ± 0.15 mm (0.295 ± 0.006 in)
Rear Oil Seal Installer Kit Applicable

Part Name Stamp Slinger Oil Seal
Rear use adapter RR
Rear use slinger sleeve RR –
Rear use oil seal sleeve RR –
Center bolt –
Adapter bolt –
8. Flywheel and Washer

prevent the flywheel from turning.
2) Apply molybdenum disulfide grease to the flywheel bolt
threads and setting faces.
3) Align the flywheel with the crankshaft dowel pin.
4) Install the flywheel and washer to the crankshaft.

5) Tighten the flywheel bolts to the specified torque in
three steps using the angular tightening method.
Follow the numerical order shown in the illustration.
Flywheel Bolt Torque mm (in)
1st step 2nd step 3rd step
78 (8 / 58) 60 deg 60 — 90 deg
NOTE:
The flywheel bolts can be reused six (6) times.
9. Oil Strainer and O-ring
1) Apply engine oil to the O-ring.
2) Install the oil strainer and O-ring to the cylinder body.
Oil Strainer Bolt Torque N·m (kg·m / lb·ft)
M8 BoIt 24 (2.4 / 17)
M10 Bolt 48 (4.9 / 35)
10. Oil Pan

1) Apply ThreeBond 1207C or equivalent to the cylinder
body and flywheel housing fitting faces ➀ and the gear
case fitting faces ➁.
The liquid gasket must be 2.0mm (0.08in) thick and
3.0mm (0.12in) wide.
2) Apply ThreeBond 1207C or equivalent to the oil pan.

The liquid gasket must be 1.0 — 2.0 mm (0.04 — 0.08
in) thick and 4.0 — 5.0 mm (0.16 — 0.20in) wide.
3) Install the oil pan to the cylinder body.
NOTE:
liquid gasket) set the oil pan to the cylinder body.
4) Tighten the oil pan bolts to the specified torque a little

at a time in the numerical order shown in the
illustration.
Oil Pan Bolt Torque N·m (kg·m / lb·ft)
24 (2.4 / 17)
11. Oil Pan Cover

Install the oil pan cover.
Oil Pan Cover Bolt Torque N·m (kg·m / lb·ft)
13 (1.3 / 113)
12. Spacer Rubber

13. Pilot Bearing and Snap Ring
DISASSEMBLY
Oil Pump
Disassembly Steps
1. Driven gear and shaft 4. Oil pump drive gear
2. Cotter pin 5. Drive gear
3. Oil relief valve 6. Oil pump body
Disassembly Steps
1. Driven Gear and Shaft
2. Cotter Pin
3. Oil Relief Valve
4. Oil Pump Drive Gear
Use a gear puller to remove the oil pump drive gear.
5. Drive Gear
6. Oil Pump Body

inspection.
Oil Pump
Gear Teeth and Body Inner Wall Clearance
Use a feeler gauge to measure the clearance between the
gear teeth and the body inner wall.
If the clearance between the gear teeth and the body inner
wall exceeds the specified limit, the gears and/or the body
must be replaced.
Gear Teeth and Cover Inner Wall Clearance mm (in)
Standard Limit
0.125 — 0.221 0.221
(0.0049 — 0.0087) (0.0087)
Gear and Body Clearance

Use a feeler gauge to measure the clearance between the
body and the gear side surfaces.
If the clearance between the gears and the body exceeds
the specified limit, the gears and/or the body must be
replaced.
Gear and Body Clearance mm (in)
Standard Limit
0.064 — 0.109 0.109
(0.0025 — 0.0043) (0.0043)
Driven Gear Shaft and Oil Pump Body Clearance

1. Use a micrometer to measure the gear shafts outside
diameter.
Gear Shaft Outside Diameter mm (in)
Standard Limit
15.989 — 16.000 15.9
(0.6295 — 0.6299) (0.626)
2. Use an inside dial indicator or inside micrometer to

measure the pump body inside diameter and the
cylinder body bushing inside diameter.
If clearance between the gear shaft and the pump body
or bushing exceeds the specified limit, the oil pump
assembly and/or bushing must be replaced.
Gear Shaft and Pump Body or Bushing
Clearance mm (in)
Standard Limit
0.04 — 0.07 0.07
(0.0016 — 0.0028) (0.0028)
Oil Relief valve

Check the ball and the valve spring for excessive wear and
damage.
Oil Pump Drive Gear and Drive Gear Shaft

Interference
Use an inside and outside micrometer to measure the
interference between the oil pump drive gear inside
diameter and drive gear shaft outside diameter.
Drive Gear and drive Gear Shaft
Interference (Reference) mm (in)
Standard
0.015 — 0.044 (0.0006 — 0.0017)
REASSEMBLY
Reassembly Steps
1. Oil pump body 4. Oil relief valve
2. Drive gear 5. Cotter pin
3. Oil pump drive gear 6. Driven gear and shaft
Reassembly Steps
1. Oil Pump Body
2. Drive Gear
3. Oil Pump Drive Gear
1) Apply engine oil to the drive gear shaft.
2) Install the oil pump drive gear to the drive gear shaft.
The gear hub large side must be facing the outside.
3) Use the bench press to press the drive gear to drive
gear shaft.
4. Oil Relief Valve

5. Cotter Pin
6. Driven Gear and Shaft
1) Apply engine oil to the driven gear and shaft.
2) Install the driven gear and shaft to the oil pump body.
CYLINDER BODY
DISASSEMBLY
Disassembly Steps
1. Cylinder liner 8. Oil cooler element
2. Oiling jet and check valve 9. Element gasket
3. Oil pressure unit 10. O-ring
4. Water drain cock 11. Oil thermostat and cover
5. Oil relief valve 12. Oil cooler case
6. Oil cooler assembly 13. Cylinder body
7. O-ring
Disassembly Steps
1. Cylinder Liner
If could not be removed cylinder liner, it is recommended to
remove it by following procedure.
1) Set the cylinder liner remover to the cylinder liner.
2) Check to see if the remover shaft ankle is firmly
gripping the cylinder liner bottom edge.
3) Slowly turn the remover shaft handle clockwise to pull
the cylinder liner free.
Cylinder Liner Remover: 5-88402-397-0
CAUTION:
Take care not to damage the cylinder body upper
face during the cylinder liner removal procedure.
Measure the cylinder liner bore and projection before
disassembling the cylinder liner.
Refer to the “Cylinder Liner Bore Measurement” and
“Cylinder Liner Projection Measurement” on the
“INSPECTION AND REPAIR”.
2. Oiling Jet and Check Valve

3. Oil Pressure Unit
4. Water Drain Cock
5. Oil Relief Valve
6. Oil Cooler Assembly
Screw M8 bolts into the four threaded holes and tighten
these evenly, and separate the oil cooler assembly from the
cylinder body.
050MX003
7. O-ring
8. Oil Cooler Element
9. Element Gasket
10. O-ring
11. Oil Thermostat and Cover
12. Oil Cooler Case
13. Cylinder Body

inspection.
Cylinder Body
Cylinder Body Upper Face Warpage
Use a straight edge ➀ and a feeler gauge ➁ to measure
the four sides and the two diagonals of the cylinder body
upper face.
cylinder body must be replaced.
Cylinder Body Upper Face Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)
NOTE:
Do not attempt to regrind the cylinder body upper
surfaces.
Cylinder Liner Projection Inspection

1. Hold a straight edge ➀ along the top edge of the
cylinder liner to be measured.
2. Use a feeler gauge ➁ to measure each cylinder liner
projection A.
Cylinder Liner Projection A mm (in)
Standard
0.06 — 0.10 (0.0024 — 0.0039)
The difference in the cylinder liner projection height
between any two adjacent cylinders must not exceed
0.03 mm (0.0012 in).
Cylinder Liner Grade Selection and Clearance

1. The cylinder body upper left side has been marked
during production to indicate the correct liner.
The liner grade (1, 2, or 3) is indicated in stamped.
2. Replacement cylinder liners have their grade (1X or 3X)
marked outside.
3. Select same grade of cylinder liners as are marked on
the upper left side of the cylinder body.
Measuring Point mm (in)
➀ 20 (0.79) ➁ 110 (4.33) ➂ 190 (7.48)
in direction a right angle and cross angle to the crankshaft.
(average value)
Outside Diameter Clearance mm (in)
Standard
0.001 — 0.029 (0.00004 — 0.00114)
NOTE:
Clearance refers to the gap between the larger
cylinder body bore and the smaller cylinder liner
outside diameter.
Cylinder Liner Grade
Line Cylinder Bore Service Liner Outside
Grade Diameter mm (in) Grade Diameter mm (in)
118.001 — 118.010
1
(4.6457 — 4.6461) 1X 117.991 — 118.000
118.011 — 118.020 (4.6453 — 4.6457)
2
(4.6461 — 4.6465)
118.021 — 118.030 118.001 — 118.010
3 3X
(4.6465 — 4.6469) (4.6457 — 4.6461)
Oiling Jet and Check Valve

Check to see if the oiling jet and check valve oil ports free
of obstructions.
Oil Cooler Assembly

Oil Cooler Element Cleaning Procedure
1. Use a funnel to pour cleaning solution into the oil cooler
element.
Add cleaning solution until it overflows.
2. Allow the oil cooler element to stand for ten hours (with
the cleaning solution inside).
3. Pour off approximately 1/3 of the cleaning solution from
the element.
4. Apply compressed air at 196 kPa (2.0 kg/m2 / 28 psi) to
the element through the oil port.
Continue to apply compressed air until all of the
cleaning solution has been forced from the element.
NOTE:
As long as the oil cooler element is not damaged or
excessively dirty, it may be cleaned repeatedly at
periodic intervals.
Oil Cooler Cover

Use the dye penetrate flaw detector procedure to inspect
the oil cooler cover for cracking.
REASSEMBLY
Reassembly Steps
1. Cylinder body 8. Oil thermostat and cover
2. Cylinder liner 9. O-ring
3. Oiling jet and check valve 10. Element gasket
4. Oil pressure unit 11. Oil cooler element
5. Water drain cock 12. O-ring
6. Oil relief valve 13. Oil cooler assembly
7. Oil cooler case
REASSEMBLY STEPS
1. Cylinder Body
2. Cylinder Liner
1) Use new kerosene or diesel fuel to thoroughly clean
the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder liner and
bore surfaces.
NOTE:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.
3) Install the cylinder liner ➀ into the cylinder body ➁
from the top of the cylinder body.
Outside Diameter Clearance mm (in)
Standard
0.001 — 0.029 (0.00004 — 0.00114)
NOTE:
Clearance refers to the gap between the larger
cylinder body bore and the smaller cylinder liner
outside diameter.
4) Install the cylinder liner retaining bolts and washers as

The bolts and washers will prevent the liners from
falling free.
Cylinder Liner Retaining Bolt mm (in)
Size and Pitch Length
M14 — 2.0 30 (1.181)
Cylinder Liner Retaining Washer mm (in)

Thickness Outside Diameter
3 — 5 (0.118 — 0.197) 40 (1.575)
NOTE:
Piston and cylinder liner retaining washer
interference can result in piston and piston ring
damage.
Either remove the washers or slide out of the way
when replacing the piston and connecting rod
assemblies.
3. Oiling Jet and Check Valve

1) Install the oiling jet and check valve to the cylinder
body.
2) Tighten the check valve to the specified torque.
Oiling Jet and Check Valve Torque N·m (kg·m / lb·ft)
21 (2.1 / 15)
CAUTION:
Take care not to bending the oiling jet.
4. Oil Pressure Unit

1) Install the adapter ➀ to the cylinder body, tighten the
adapter to the specified torque.
2) lnstall the oil pressure unit ➁ to the adapter with
tighten the oil pressure unit by the specified torque.
NOTE:
(1) Apply ThreeBond No.1241 or equivalent on
screw of pressure unit.
(2) The water drain should be directed to
downward.
Adapter Torque N·m (kg·m / lb·ft)
44 (4.5 / 32.5)
Oil Pressure Torque N·m (kg·m / lb·ft)

13 (1.3 / 9.4)
5. Water Drain Cock

6. Oil Relief Valve
7. Oil Cooler Case
8. Oil Thermostat and Cover
9. O-ring
10. Element Gasket
11. Oil cooler element

12. O-ring
1) Install the O-ring, element, element gasket and oil
cooler element to the oil cooler case.
2) Tighten the oil cooler element nuts to the specified
torque.
Oil Cooler Element Nut Torque N·m (kg·m / lb·ft)
20 (2.0 / 14.5)
13. Oil Cooler Assembly

1) Install the oil cooler assembly to the cylinder body.
2) Tighten the oil cooler assembly bolts evenly from the
inside to outside.
Oil Cooler Assembly Bolt Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
NOTE:
(1) Apply ThreeBond No.1207C/1216C or equivalent
on groove of oil cooler assembly.
(2) Assemble within 15 minute after apply liquid
gasket.
MEMO
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COOLING SYSTEM 6B - 1
SECTION 6B
COOLING SYSTEM
CONTENTS
PAGE
General Description....................................................................................................................6B - 2
Water Pump ................................................................................................................................6B - 6
Removal..................................................................................................................................6B - 6
Installation ..............................................................................................................................6B - 6
Disassembly ...........................................................................................................................6B - 8
Inspection and Repair............................................................................................................6B - 10
Reassembly ............................................................................................................................6B - 12
Thermostat..................................................................................................................................6B - 15
Disassembly ...........................................................................................................................6B - 15
Reassembly ............................................................................................................................6B - 17
Radiator.......................................................................................................................................6B - 19
6B - 2 COOLING SYSTEM
GENERAL DESCRIPTION
Coolant Flow
The engine cooling system consists of the radiator, the (179.6° F) for general export and 76.5° C (170.0° F) for
surge tank, the water pump, the cooling fan, and the special region, the thermostat will begin to open and a
thermostat. gradually increasing amount of coolant will circulate
To quickly increase cold engine coolant temperature through the radiator.
for smooth engine operation, the coolant is circulated The thermostat will be fully open when the coolant
by the water pump and the thermostat through the temperature reaches 95° C (203° F) for general export
radiator bypass and directly back to the cylinder body. and 90° C (194° F) for special region.
The coolant does not circulate through the radiator at All of the coolant is now circulating through the radiator
this time. When the coolant temperature reaches 82° C for effective engine cooling.
Engine coolant change procedure 5. After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system is
1. To change engine coolant, make sure that the
disclogged and the coolant level goes down. Should
engine is cool.
the coolant level go down, repeat topping-up until
WARNING there is no more drop in the coolant level.
6. After directly filling the radiator, fill the reservoir to the
When the coolant is heated to a high
maximum level.
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by 7. Install and tighten radiator cap and start the engine.
hot vapor or boiling water. To open the radiator After idling for 2 to 3 minutes, stop the engine and
cap, put a piece of thick cloth on the cap and reopen radiator cap. If the water level is lower,
loosen the cap slowly to reduce the pressure replenish.
when the coolant has become cooler. WARNING
When the coolant is heated to a high
2. Open radiator cap and drain the cooling system by
temperature, be sure not to loosen or remove the
loosening the drain valve on the radiator and on the
radiator cap. Otherwise you might get scalded by
cylinder body.
hot vapor or boiling water. To open the radiator
NOTE cap, put a piece of thick cloth on the cap and
loosen the cap slowly to reduce the pressure
For best result it is suggested that the engine
when the coolant has become cooler.
cooling system be flushed at least once a year. It
is advisable to flash the interior of the cooling
system including the radiator before using anti- 8. After tightening radiator cap, warm up the engine at
freeze (ethylene-glycol based). about 2,000 rpm.
Set heater adjustment to the highest temperature
Replace damaged rubber hoses as the engine
position, and let the coolant circulate also into
anti-freeze coolant is liable to leak out even
heater water system.
minor cracks.
9. Check to see the thermostat has opened through
Isuzu recommends to use lsuzu genuine anti-
the needle position of water thermometer, conduct a
freeze (ethylene-glycol based) or equivalent, for
5-minute idling again and stop the engine.
the cooling system and not add any inhibitors or
additives. 10. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
CAUTION extreme shortage of coolant is found, check the
A failure to correctly fill the engine cooling coolant system and reservoir tank hose for leakage.
system in changing or topping up coolant may 11. Fill the coolant into the reservoir tank up to “MAX”
sometimes cause the coolant to overflow from line.
the filler neck even before the engine and radiator
are completely full.
If the engine runs under this condition, shortage
of coolant may possibly result in engine
overheating. To avoid such trouble, the following
precautions should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck

using a filling hose which is smaller in outside
diameter of the filler neck. Otherwise air between the
filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over
this maximum rate may force air inside the engine
and radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
Thermostat
A wax pellet type thermostat is used.

Water Pump
030MX014
A centrifugal type water pump forcefully circulates the

coolant through the cooling system.
WATER PUMP
Removal Steps Installation Steps

1. Plate 4. Water pump assembly
2. Water duct 1. Plate
3. O-ring: Water duct 5. O-ring: Water pump assembly
4. Water pump assembly 3. O-ring: Water duct
5. O-ring: Water pump assembly 2. Water duct
Installation Steps
4. Water pump assembly
1) Apply liquid gasket to water pump assembly Three
bond 1207C or equivalent.
• Apply liquid gasket to make bead width 2 ~ 3 mm on
the fitting surface as shown in the illustration.
Do not apply liquid gasket if there is some groove.
NOTE:
The water pump must be installed within 15 minutes
after apply liquid gasket.
Torque N·m (kg·m / Ib·ft)
19.0 (1.9 / 14.0)
1. Plate
• Tighten the bolt temporary of the plate fixing bolt.
5. O-ring to inlet port of water pump assembly

• After install O-ring to apply soap water for easy install
the water duct.
3. O-ring to the water duct
2. Water duct to the cylinder head

1) Tighten the bolt to the specified torque.
Torque N·m (kg·m / Ib·ft)
M8 M10
19.0
For water duct bolts –
(1.9 / 14.0)
19.0 38.0
For plate bolts
(1.9 / 14.0) (3.9 / 28.0)
NOTE:
Do not make damage the O-ring on the inlet port of
water pump when install the water duct.
DISASSEMBLY
Disassembly Steps
1. Impeller 6. Water pump shaft and ball bearing
2. Seal unit 7. Oil seal
3. Pulley 8. O-ring
4. Dust cover 9. Water pump body
5. Snap ring
Disassembly Steps
1. Impeller
1) Clamp the pump body in a vise.
2) Use the remover to remove the impeller.
NOTE:
Insert a 5mm (0.20 in) rod into the center hole
(6mm / 0.24 in) of the impeller and push the remover
center bolt to remove the impeller.
2. Seal Unit
3. Pulley
Use a remover to remove the water pump pulley.
4. Dust Cover
5. Snap Ring
6. Water Pump Shaft and Ball Bearing
Use a plastic hammer to lightly tap the water pump shaft
free.
Tap on the shaft from the impeller side.
7. Oil Seal
8. O-ring
9. Water Pump Body

inspection.
Water Pump
Water Pump Impeller
1. Check the impeller for corrosion.
2. Check the seal unit fitting faces for excessive wear and
other damage.
Water Pump Shaft and Ball Bearing

1. Check the oil seal fitting face for excessive wear and
damage.
2. Measure the water pump shaft and pulley and impeller
interference.
If the measured interference is less than the specified
limit, the pump shaft and / or the pulley and impeller
must be replaced.
Pump Shaft and Pulley Interference mm (in)
Limit
0.048 — 0.078 (0.0019 — 0.0031)
Pump Shaft and Impeller Interference mm (in)

Limit
0.022 — 0.062 (0.0009 — 0.0024)
3. Carefully wash away any bearing grease.

4. Listen for excessive bearing operating noise.
Excessive bearing operating noise indicates severe
bearing wear.
Ball Bearing Replacement

Ball Bearing Removal
1. Place the water pump shaft ➀ with the bearings
attached between the base plates ➁ of a bench press.
2. Use the bench press and a rod ➂ to gradually apply
pressure to the water pump shaft to remove the ball
bearings from the water pump shaft.
Take care not to damage the water pump shaft.
Ball Bearing Installation

1. Apply engine oil to the water pump shaft and bearings
inner race shaft contact surfaces.
2. Place the water pump shaft ➀ and the bearings ➁
between the base plates ➂.
Place soft brass or copper sheets between the base
plates and the water pump shaft to protect the water
pump shaft.
3. Install the washer ➃, the ball bearing ➄, the spacer ➅

and the bearing ➆ to the water pump shaft ➇.
4. Use the bench press to gradually press the water pump

shaft down until the ball bearings are seated correctly.
Be absolutely sure that the bearing inner race is
supported by the base plates.
REASSEMBLY
Reassembly Steps
1. Water pump body 6. Dust cover
2. O-ring 7. Pulley
3. Oil seal 8. Seal unit
4. Water pump shaft and ball bearing 9. Impeller
5. Snap ring
Reassembly Steps
1. Water Pump Body

2. O-ring
3. Oil Seal
1) Clean the water pump body.
Be absolutely sure that the oil ports are free of
restrictions.
2) Install the O-ring to the water pump body.
3) Apply engine oil to the oil seal inside circumference.
4) Apply engine oil to the oil seal outside circumference.
5) Install the oil seal to the water pump body.
The oil seal lip must be facing the ball bearing.
6) Press the oil seal into place.
4. Water Pump Shaft and Ball Bearing

1) Repack the bearings with multipurpose grease.
2) Place the water pump body on the bench press base

plate.
3) Position the pump shaft and the bearings to the pump
body.
4) Use a bench press to gradually press the water pump
shaft into the water pump body.
NOTE:
Take care not to damage the oil seal when pressing
the water pump shaft into the water pump body.
Do not attempt to drive the bearing into position with
a hammer or similar object. Damage to the bearing
will result.
5. Snap Ring
6. Dust Cover
1) Use pliers to install the snap ring into the water pump
body groove.
2) Install the dust cover with the flange facing out.
7. Pulley
Use a bench press to gradually press the water pump
pulley into the water pump shaft.
NOTE:
To protect the bearings, be sure to press in the
pulley with the impeller side pump shaft end surface
held against the bench press.
Pulley Installation Position A (Reference) mm (in)

19.1 (0.752)
8. Seal Unit
1) As seal unit surfaces (which are to contact the shaft
and pump body) are coated with liquid gasket, press
the seal unit as it is position.
2) Press in the unit to the specified position using a
bench press and installer.
Seal Unit Installation Position A mm (in)
11.0 — 11.6 (0.433 — 0.457)
9. Water Pump Impeller

Using a bench press, press in the impeller until its stopper
surface comes into contact.
NOTE:
To protect the bearings, press in the impeller with
the pulley side shaft end surface held against the
bench press.
THERMOSTAT
DISASSEMBLY
Disassembly Steps
1. Water outlet pipe 3. Thermostat (with jiggle valve)
2. Thermostat (without jiggle valve) 4. Gasket
Disassembly Steps
1. Water outlet pipe
2. Thermostat (without jiggle valve)
3. Thermostat (with jiggle valve)
4. Gasket

inspection.
Thermostat
Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Measure the thermostat initial opening temperature.
Thermostat Initial Opening Temperature °C (°F)
Standard
82.0 (180)
4. Measure the thermostat full opening temperature.

Thermostat Full Opening Temperature °C (°F)
Standard
95 (203)
➀ Thermometer
➁ Agitating rod
➂ Wooden piece
5. Measure the valve lift at the valve’s fully open position.
Valve Lift At Fully Open Position mm (in)
Approximately 8 (0.31)
REASSEMBLY
Reassembly Steps
1. Thermostat (without jiggle valve) 3. Gasket
2. Thermostat (with jiggle valve) 4. Water outlet pipe
6B - 18 ENGINE COOLING
Reassembly Steps
1. Thermostat
Install the thermostats to the cylinder head.
The thermostat with jiggle valve must be facing the engine
intake side and the jiggle valves must be facing the engine
rearward.
2. Gasket
1) Install the water outlet pipe to the cylinder head.
2) Tighten the water outlet pipe bolts to the specified
torque.
Water Outlet Pipe Bolt Torque N.m (kg.m / lb.ft)
19 (1.9 / 14)
ENGINE COOLING 6B - 19
RADIATOR
inspection.
Radiator
Cooling System Leakage Check
2. Install the radiator filler cap tester to the radiator.
3. Apply the specified test pressure to the cooling system
to check for leakage.
Cooling System Test Pressure kPa (kg/cm2 / psi)
98 (1 / 14)
Repair or replace the radiator if required.
Radiator Cap Leakage Check

The radiator filler cap maintains cooling system pressure.
It must tightly seal the cooling system.
2. Install the radiator cap to the radiator filler cap tester.
3. Apply the specified test pressure to the cap to check for
leakage.
Radiator Filler Cap Test Pressure kPa (kg/cm2 / psi)
49 — 59 (0.5 — 0.6 / 7.11 — 8.53)
Negative Valve Pressure kPa (kg/cm2 / psi)

2 — 5 (0.02 — 0.05 / 0.28 — 0.71)
Replace the radiator filler cap if it fails to hold the specified

test pressure.
MEMO
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FUEL SYSTEM 6C - 1
SECTION 6C
FUEL SYSTEM
CONTENTS
PAGE
Main Data and Specifications ....................................................................................................6C - 2
General Description....................................................................................................................6C - 3
Mechanical Governor (for EURO I model).................................................................................6C - 4
RED IV Governor (for EURO II model) .......................................................................................6C - 5
Injection Pump (for EURO II model) ..........................................................................................6C - 6
System Overview (for EURO II model) ......................................................................................6C - 7
Feed Pump ..................................................................................................................................6C - 8
Injection Nozzle (for EURO I model)..........................................................................................6C - 9
Injection Nozzle (for EURO II model).........................................................................................6C - 20
Injection Pump Adjustment (for EURO I model).......................................................................6C - 26
Identification Plate and Assembly Number ..........................................................................6C - 26
Fuel Injection Volume Ratio and Symbol Mark ....................................................................6C - 26
Symbol Mark Location...........................................................................................................6C - 26
Introduction for PE-6P Type..................................................................................................6C - 28
Injection Pump Calibration Data Test Conditions ...............................................................6C - 29
Injection Timing......................................................................................................................6C - 29
Injection Volume and Governor Performance Diagram ......................................................6C - 30
6C - 2 FUEL SYSTEM
MAIN DATA AND SPECIFICATIONS

ITEM EURO-I EURO-II
Injection pump type PE-6P type MD-TICS

Plunger outside diameter mm (in) 11.5 (0.453) 11.0 (0.433)
Governor type EP / RLD-J
Timer type Electronic control Electronic control
Injection nozzle type Hole Hole
(Two-Spring Nozzle Holder) (Single Spring Nozzle Holder)
Number of injection nozzle orifices Six holes Five holes
Orifices diameter 0.24 0.22
2
Opening pressure MPa (kg/cm / psi)
1st 15.7 (160 / 2,275) 22.1 (225 / 3,199)
2nd 22.1 (225 / 3,199)
FUEL SYSTEM 6C - 3
GENERAL DESCRIPTION
040M100025
The fuel system consists of the fuel tank, the water It pressurizes and delivers a metered volume of fuel to
separator, the prefuel filter, the fuel filter, the injection the engine cylinders at the optimum time for the
pump, and the injection nozzle. The fuel from the fuel current engine load and speed.
tank passes through the water separator, the pre-fuel The injection pump plungers are pushed up by cam
filter and the fuel filter. lobes. They are returned to their original position by the
Water particles and other foreign material are removed plunger springs. This action creates a reciprocal
from the fuel. motion.
Fuel, fed by the injection pump plunger, is delivered to The plunger barrel receives fuel from the feed ‘pump
the injection nozzle in the measured volume at the and fuel filter through its inlet port when the injection
optimum timing for efficient engine operation. pump plunger is on the down stroke.
Major components of the injection pump are the pump Surplus fuel is delivered to the injection pump fuel
body and plunger unit, the governor, the timer (EURO I) chamber through the plunger outlet port when the
or the flyweight (EURO II), and the feed pump. plunger is on its up stroke.
The injection pump is the nucleus of the diesel engine
fuel system.
6C - 4 FUEL SYSTEM
MECHANICAL GOVERNOR (for EURO I model)
The 6HK1TC engine (EURO I) is equipped with an RLD If engine speed becomes too high, engine overrun will
type variable-speed mechanical governor. result.
Diesel engine operating speed and load will vary widely The governor acts to maintain engine speed within
during the course of normal driving. If the engine speed acceptable limits, thus protecting against engine stall
falls too low, the engine may run sluggishly or stall. and / or overrun.
FUEL SYSTEM 6C - 5
RED IV GOVERNOR (for EURO II model)
081H100001
Description
The Red IV electronic control governor for EURO II Main components are the housing, the actuator, and
model features a programmable control unit. This the cover. Control circuits (servo, drive, and sensor) are
allows it to function as an all-speed governor, a high built-in to the actuator. This minimizes noise
speed/low speed governor, or a combination of the interference.
two.
6C - 6 FUEL SYSTEM
INJECTION PUMP (for EURO II model)
080M100001
Major components of the injection pump are the pump Surplus fuel is delivered to the injection pump fuel
body and plunger unit, the electronic governor, the chamber through the plunger outlet port when the
electronic timer, and the feed pump. plunger is on its up stroke.
A boost compensator is available as an option for A further development is the Timing and Injection rate
turbocharged engines and provide aneroid Control System (TICS).
compensator as an option for both type of engines. TICS controls the injection timing and injection rate by
The injection pump is the nucleus of the diesel engine varying the pre-stroke position (start of static injection).
fuel system. It pressurizes and delivers a metered This enables high injection rates in the low-and
volume of fuel to the engine cylinders at the optimum medium-speed ranges through a short injection
time for the current engine load and speed. interval, thus contributing to higher torque and cleaner
The injection pump plungers are pushed up by cam exhaust emissions and improving the performance of
lobes. They are returned to their original position by the direct-injection diesel vehicles.
plunger springs. This action creates a reciprocal Note:
motion. Injection rate is the fuel injection quantity
The plunger barrel receives fuel from the feed pump injected from the nozzle per cam angle one
and fuel filter through its intake port when the injection degree.
pump plunger is on the down stroke.
FUEL SYSTEM 6C - 7
SYSTEM OVERVIEW (for EURO II model)
040M100014
The illustration shows a diagram of the TICS system

combined with the RED IV governor.
6C - 8 FUEL SYSTEM
FEED PUMP
The fuel feed pump tappet is driven by an eccentric The fuel feed pump draws fuel from the fuel tank
cam in the injection pump camshaft. Tappet movement through the fuel filter. It delivers the fuel, under
is relayed the piston through the push rod. pressure, to the injection pump.
An independent priming pump permits manual fuel
feed when the engine is not running.
FUEL SYSTEM 6C - 9
INJECTION NOZZLE (For EURO I model)

DISASSEMBLY
The two-spring nozzle holder has been developed to reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
080LX002
Disassembly Steps
1. Retaining nut 9. Collar
2. Nozzle &pin 10. Spring seat
3. Spacer & pin 11. First spring
4. Lift piece 12. Shim (First nozzle opening pressure adjustment)
5. Spring seat 13. Nozzle holder body
6. Push rod 14. Eye bolt
7. Shim (Second nozzle opening 15. Gasket
pressure adjustment)
8. Second spring
6C - 10 FUEL SYSTEM
Disassembly Steps
1. Retaining nut
2. Nozzle & pin
3. Spacer & pin
4. Lift piece
5. Spring seat
6. Push rod
7. Shim (Second nozzle opening pressure adjustment)
8. Second spring
9. Collar
10. Spring seat
11. First spring
12. Shim (First nozzle opening pressure adjustment)
13. Nozzle holder body
14. Eye bolt
15. Gasket
(1) Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
CAUTION:
Do not touch nozzle holes with the wire brush during
cleaning it.
(2) Disassemble the nozzle holder assembly to numerical
order.
FUEL SYSTEM 6C - 11
REASSEMBLY AND OPENING PRESSURE ADJUSTMENT
080LX003
Reassembly Steps
1. Nozzle holder body 8. Shim (Second opening pressure adjustment)
2. Shim (First opening pressure 9. Spring seat
adjustment) 10. Lift piece
3. First spring 11. Spacer & pin
4. Spring seat 12. Nozzle &pin
5. Collar 13. Retaining nut
6. Second spring 14. Gasket
7. Push rod 15. Eye bolt
6C - 12 FUEL SYSTEM
Reassembly Steps
1. Retaining nut
2. Nozzle & pin
3. Spacer & pin
4. Lift piece
5. Spring seat
6. Push rod
7. Shim (Second nozzle opening pressure adjustment)
8. Second spring
9. Spring seat
10. Lift piece
11. Spacer & pin
12. Nozzle & pin
13. Retaining nut
14. Gasket
15. Eye bolt
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in light
oil to completely remove any dirt or foreign matter.
REASSEMBLY AND ADJUSTMENT PROCEDURE
Adjust the first nozzle opening pressure using the shim.
Confirm the full needle valve lift in accordance with the

closed method.
Confirm pre-Iift in accordance with the closed method.

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

shim.
Confirm the condition of the fuel spray with the nozzle

and nozzle holder assembled.
FUEL SYSTEM 6C - 13
First nozzle opening pressure adjustment
1. Claim the nozzle holder in a vise.
040MV015
2. Install the shim, first spring and spring seat in the nozzle
holder.
040MC016
3. Install the collar, second spring, shim, spring seat and

pushrod in the nozzle holder.
040MV017
4. Install the pins, lift piece and spacer in the nozzle

holder.
040MV018
5. Install the pins in the spacer.

6. Install the nozzle on the spacer.
040MV019
6C - 14 FUEL SYSTEM
7. Hand-tighten the adjustment retaining nut together with

the gasket to the nozzle holder.
Retaining nut: 5-86777-145-0
Gasket: 5-86777-146-0
040MV010
8. Tighten the adjustment retaining nut to the specified

torque.
Torque: 29 — 39 N.m (3.0 — 4.0 kg.m)
040MV014-1
9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first nozzle
opening pressure.
11. If the first nozzle opening pressure is not as specified,
disassemble the nozzle holder and replace the shim
until the pressure is as specified.
CAUTION:
Use a micrometer to measure shim thickness.
040MV030
• First nozzle opening pressure adjusting shims

Part No. Thickness (mm)
1153491120 0.40
1153491130 0.50
1153491140 0.52
1153491150 0.54
1153491160 0.56
040MY00023
1153491170 0.58
1153491180 0.60
1153491190 0.70
FUEL SYSTEM 6C - 15
Full needle valve lift confirmation

1. Install the gasket and plug on the adjustment retaining
nut.
Gasket: 8942276020
Plug: 5-86777-141-0
040MV013
2. Position the nozzle holder with the nozzle facing down

and install the dial gauge holder on the nozzle holder.
Dial gauge holder: 5-86777-148-0
040MV012
3. Install the nut on the dial gauge holder.

Nut: 5-86777-143-0
040MV011
4. Install the pin to the dial gauge.

NOTE:
The lengths of the pins do not include the
threaded portions.
Pin ( = 60 mm): 5-86777-150-0
Dial gauge: 157892-3800 (ZEXEL)
040MV029
6C - 16 FUEL SYSTEM
5. Secure the dial gauge to the nozzle holder using the nut
so that the pin contacts the tip of the first spring seat.
CAUTION:
• Secure the dial gauge so that a stroke of 2
mm can be measured.
• Do not over-tighten the nut as the dial gauge
shaft may jam. (Confirm from the dial gauge
that the shaft moves smoothly.)
040MV009
6. Set the nozzle holder to the nozzle tester and put

needle to zero on the dial gauge.
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.
040MV030
8. Operate the nozzle tester and increase the in-line

pressure to 34.3 — 44.1 MPa (350 — 450 kg/cm2) so that
the nozzle’s needle valve moves through its full lift.
Record full lift ‘L’. (Read dial gauge)
NOTE:
The above operation is used to determine
whether the nozzle seat is worn and whether the
nozzle assembly is in good condition.
040MV008
FUEL SYSTEM 6C - 17
Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle tester
handle.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV007
040MV006
2. Read the needle valve lift ‘ ’ from the dial gauge

indication (once the needle valve has descended when
the second spring has stopped operating). Refer to the
pre-lift measuring point for ‘ ’.
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure
+approx 1 MPa (10 kg/cm2).
Note:
This point can be found while the pressure is
040MV025-1 decreasing.
3. Confirm that pre-lift ‘ ’ is as specified.
Pre-lift mm
0.05
040MV005
4. If pre-lift is not as specified, replace the pins, lift piece,

spacer and nozzle assembly as a set with the service
kit.
Service kit: ISUZU
894392-1450
040MV031
6C - 18 FUEL SYSTEM
Second nozzle opening pressure confirmation

1. After pre-lift confirmation, operate the nozzle tester to
increase in-line pressure to 34.3 — 44.1 MPa (350 — 450
kg/cm2) so that the nozzle’s needle valve moves
through its full lift.
040MV030
2. Release the nozzle tester handle so that in-line pressure

decreases.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV022
3. Then, read the pressure gauge indication (second

nozzle opening pressure) the instant that the dial gauge
indicates the specified needle valve lift (usually pre-lift
+ 0.05 mm).
040MV026
FUEL SYSTEM 6C - 19
Second nozzle opening pressure adjustment

If the second nozzle opening pressure is not as specified,
disassemble the nozzle from the nozzle holder and replace
the shim until the pressure is as specified.
CAUTION:
• Because the second opening pressure changes
when the first opening pressure changes, the
second opening pressure must be adjusted when
the first opening pressure changes.
• Use a micrometer to measure shim thickness.
040MV017
• Second nozzle opening pressure adjusting shims
Part No. Thickness (mm)
1153491200 0.40
1153491210 0.50
1153491220 0.52
1153491230 0.54
1153491240 0.56
1153491250 0.58
1153491260 0.60
040MY00024 1153491270 0.70
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028
2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins are
inserted fully into the nozzle, and then hand-tighten the
retaining nut. Then, tighten the original retaining nut to
the specified torque.
Torque 59 — 79 N.m (6.0 — 8.0 kg.m)
040MV014-1
4. Set the nozzle holder to the nozzle tester and check first
nozzle opening pressure, spray condition, seat oil
tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift piece,
pins and spacer as a set with the nozzle service kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.
040MV030
6C - 20 FUEL SYSTEM
INJECTION NOZZLE (For EURO II model)

DISASSEMBLY
040M100021
Disassembly Steps
1. Retaining nut 5. Nozzle spring
2. Nozzle & pin 6. Adjusting shim
3. Spacer 7. Nozzle holder
4. Spring seat
FUEL SYSTEM 6C - 21
Disassembly Steps
1. Retaining Nut
2. Nozzle & pin
1) Clamp the injection nozzle holder in a vice.
2) Use a wrench to remove the injection nozzle retaining
nut.
3) Remove the injection nozzle holder from the vice.
4) Remove the injection nozzle, the spacer, the spring
seat, the nozzle spring and the adjusting shim.
NOTE:
Tag the nozzle assemblies and nozzle holders so
that they can be reinstalled to their original positions.
040MV020
Nozzle assembly and nozzle holder combinations
must be not changed.
5) Immerse the injection nozzle in a tool tray filled with
clean diesel oil.
This will protect the nozzles from dust.
040R100036
3. Spacer
4. Spring Seat
5. Nozzle Spring
6. Adjustment Shim
7. Nozzle Holder
6C - 22 FUEL SYSTEM

inspection.
Injection Nozzle
1. Check the injection nozzle needle valve, the valve seat,
and the injection nozzle hole for carbon deposits.
If carbon deposits are present, the injection nozzle and
the needle valve must be cleaned or replaced.
2. Hold the nozzle body vartically.
3. Lift the needle valve about 1/3 of the way out of the
nozzle body.
4. Release the needle valve.
The needle valve should fall back into the nozzle body
as far as the valve seat.
040LX036
If the needle valve does not fall back into the nozzle
body as far as the valve seat, the injection nozzle and
the needle valve must be replaced.
FUEL SYSTEM 6C - 23
Injection Nozzle Operating Test

Opening Pressure and Spray Condition Check
1. Use a nozzle tester to check the injection nozzle
opening pressure.
If the opening pressure is above or below the specified
valve, the injection nozzle must be replaced or adjusted.
Refer to “Injection Nozzle Adjustment”.
Injection Nozzle Opening Pressure MPa (kg/cm2 / psi)
22.1 (225 / 3,200)
040MV030
WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT OF THE INJECTION NOZZLE
UNDER GREAT PRESSURE. IT CAN EASILY
PUNCTURE A PERSON’S SKIN. KEEP YOUR HANDS
AWAY FROM THE INJECTION NOZZLE AT ALL
TIMES.
2. Check the spray condition.

If the spray condition is bad, the injection nozzle must
be replaced or reconditioned.
➀ Correct
➁ Incorrect (Restrictions in orifice)
➂ Incorrect (Dripping)
040EY00030
6C - 24 FUEL SYSTEM
REASSEMBLY
040M100024
Reassembly Steps
1. Nozzle holder 5. Spacer
2. Adjusting shim 6. Nozzle & pin
3. Nozzle spring 7. Retaining nut
4. Spring seat
FUEL SYSTEM 6C - 25
Reassembly Steps
1. Nozzle Holder
2. Adjustment Shim
3. Nozzle Spring
4. Spring Seat
5. Spacer
6. Nozzle & pin
7. Retaining Nut
1) Install the adjusting shim, the nozzle spring, the spring
seat, the spacer, the injection nozzle and the retaining
nut.
2) Clamp the injection nozzle holder in a vice.
3) Tighten the injection nozzle retaining nut to the
specified torque.
Injection Nozzle Holder Retaining
Nut Torque N.m (kg.m / lb.ft)
39 (4.0 / 29)
040H100020
4) Remove the injection nozzle holder from the vice.

5) Attach the injection nozzle holder to the injection
nozzle tester.
6) Apply pressure to nozzle tester.
Note the pressure at which the injection nozzle opens.
7) If required, install or remove the appropriate number of
adjusting shims to adjust it.
Reference:
Installing or removing 0.10mm (0.004in) will increase or
decrease the nozzle opening pressure approximately
040MV030
1638kPa (16.7 kg/cm2 / 237 psi).
Adjusting Shim Availability mm (in)
Increment 0.10 (0.004), 0.20 (0.008)

0.30 (0.012), 0.40 (0.016)
(0.10mm (0.004in))
0.50 (0.0196)
Increment 0.52 (0.0205) 0.54 (0.0213)
(0.02mm (0.008in)) 0.56 (0.0220) 0.58 (0.0228)
Total Number of Shims 9
6C - 26 FUEL SYSTEM
INJECTION PUMP ADJUSTMENT

(For EURO I model)
IDENTIFICATION PLATE AND ASSEMBLY NUMBER
1. It is important that you refer to the Injection Pump
Assembly Number on the identification plate to
determine the applicable calibration data in this
Section for the injection pump being serviced.
2. In the event this Section does not contain
calibration data applicable to the injection pump
being serviced, contact the nearest
manufacturer’s authorized service facility (ZEXEL
Corporation or Robert Bosch GMBH).
3. Refer to the Isuzu Injection Pump Assembly
Number stamped on the injection pump
assembly Identification Plate to order a
replacement injection pump.
FUEL INJECTION VOLUME RATIO AND SYMBOL MARK

In order for a diesel engine to operate at full efficiency, Failure to do so will result in black exhaust smoke,
fuel must be injected into the combustion chamber in increased fuel consumption, reduced engine power,
such a way that it burns completely. and shorter engine life. Injection volume is initially set at
When a vehicle is operated at high altitudes of 1,000 the Isuzu factory according to the anticipated fuel and
meters (3,200 feet) or more, the air is thinner. To altitude related operating conditions of the area to
maintain an optimum air-fuel ratio, fuel injection volume which the vehicle is to be delivered.
must be reduced. A symbol mark indicating the injection volume setting is
Some vehicles are operated in regions or countries then stamped on the injection pump assembly. This is
where a grade of fuel having a higher specific gravity is done to prevent the above engine problems after
used. Because this fuel creates more heat in the vehicle delivery.
combustion chamber, the fuel injection volume must Injection pumps whose injection volume is set 100% of
be proportionately reduced. the basic volume do not have a symbol mark.
Injection pump adjustment requires that careful
attention be given to engine operating conditions.
SYMBOL MARK LOCATION

FUEL SYSTEM 6C - 27
Symbol Mark Altitude Fuel Specific Gravity Q-Set Rating
R — Less than 0.85 105%

Not marked 0 — 1,000 – 100%
S 1,001 — 2,000 – 86%
T 2,001 — 3,000 – 73%
U 3,001 — 4,000 – 59%
All calibration data contained in this section is * Symbol Mark

calculated at 100% of the basic injection volume. 1. Set the fuel injection volume as shown in the
Should readjustment of the injection volume be calibration data.
required, check the symbol mark (stamped in the 2. Adjust the governor.
injection pump body) to determine further injection 3. Use the full load stopper bolt (smoke set screw) to
volume setting applicable to your area of operations. adjust the fuel injection volume at control rack
position A mm only according to the symbol mark.
* No. Symbol Mark
Follow the application data completely.
6C - 28 FUEL SYSTEM
INTRODUCTION FOR PE-6P TYPE

ELECTRONIC VARIABLE TIMER
• OUTLINE • FEATURES
Various efforts have been made to comply with The variable timer body differs from previous
diesel engine exhaust regulations and to reduce fuel mechanical timers in that it is operated hydraulically.
costs. As it is operated by engine oil, no special power
In particular, because fuel injection timing greatly source is necessary.
influence fuel injection quantity, exhaust emissions Because the variable timer is controlled by a
and fuel cost, extremely exact control of injection computer, operating conditions and advance
timing is demanded to respond to varied engine characteristics can be freely and easily set to enable
operating conditions. The SAGH type variable timer extremely accurate injection timing characteristics.
was developed to satisfy these demands through
electronic control of fuel injection timing in response
to engine speed and load conditions.
080MX00004
FUEL SYSTEM 6C - 29
INJECTION PUMP CALIBRATION DATA TEST CONDITIONS

Injection nozzle & nozzle holder ASM ZEXEL No. 105780-8250
Injection nozzle ZEXEL N o. 105780-0120
Injection nozzle holder ZEXEL No. 105780-2190
Injection starting pressure 20.7 MPa (211 kg/cm2 / 3,000 psi)
Injection line dimensions Inside diameter = 3mm (0.118in)
Outside diameter = 8mm (0.315in)
Length = 600 mm (23,62in)
Transfer pump pressure 157 kPa (1.6 kg/cm2 / 23 psi)
Overflow valve opening pressure 206 kPa (2.1 kg/cm2 / 30 psi)
Test diesel fuel ISO4113 or SAE standard test oil (SAE J967 d)
Fuel temperature 40 — 45°C (104 — 113°F)
Pump rotation Counterclockwise viewed from the drive side
CAUTION:
Strictly observe the above test conditions during Misadjustment of the fuel injection volume will
injection pump fuel injection volume adjustment. result in serious engine damage.
Failure to observe the test conditions will result in
misadjustment of the injection pump fuel
injection volume.
INJECTION TIMING
Pre-stroke No. 1 Plunger 3.6 ± 0.03 mm
Injection order and interval 1-5-3-6-2-4 (60° ± 15’)

Plungers are numbered from the governor side.
Tappet clearance Manually rotate the camshaft 2 ~ 3 times to make
sure that it rotates smoothly.
6C - 30 FUEL SYSTEM
INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Injection Pump Assembly Number
ISUZU No. ZEXEL No. Remarks
8-94392-0570 106693-6270
Injection Volume
Adjusting Rack Pump speed Injection volume Variance
Fixed Remarks
point position mm rpm cc/ 1,000 strokes %
– 11.4 850 97.5 ± 2 ±4 Rack Basic
Adjust injection q’ty
at N = 495
Z 8.0 ± 0.5 495 12.5 ± 3.2 ± 13 Rack
Adjust governor as
per gov. adj. spec
Basic Boost press
.kPa (mmHg)
A R1 (11.4) 850 97.5 ± 1 – Lever
Above 76.0
(Above 570)
Boost press
.kPa (mmHg)
B R1 + 0.8 1,350 93.5 ± 4 – Lever
Above 76.0
(Above 570)
Pre stroke
No. 1 plunger 3.6 ± 0.03 mm (0.14 in)
FUEL SYSTEM 6C - 31
Governor Adjustment
B06MX00011
Idle Adjustment Boost Compensator Adjustment
B06MX00010 B06MX00009
Timing Device Adjustment Stop Lever Angle
B06MX00005 B06MX00007
6C - 32 FUEL SYSTEM
Speed Control Lever Angle Timing Setting
B06MX00008 B06MX00006
FUEL SYSTEM 6C - 33
Rack Sensor Adjustment

Amp — equipped rack sensor adjustment (154610 -5*20)
• Threaded type rack sensor (without rack limit: for P type TICS)
Supply voltage 5 ± 0.01 (V)

Speed NO = 1350 (r / min)
Rack position RO = R1 + 0.8 (min)
Output voltage VR = 3.00 ± 0.01 (V)
• Rack sensor adjustment
(1) Screw in bobbin ➀ until it contacts the joint ➁.
(2) Fix the pump lever at full and at Np = NO and R = RO screw in the bobbin ➀ to adjust the depth so that
the amp’s output voltage V = VR.
Then, fix the rack sensor using the nut ➂.
(3) Move the pump lever 2 or 3 times reset at full and confirm that the amp’s output voltage V = VR.
(4) Attach the caution plate to the top of the joint ➁ and apply red paint to the joint ➁ — nut ➂ joint, and the
pump end face — joint ➁ joint.
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ENGINE ELECTRICAL 6D - 1
SECTION 6D
ENGINE ELECTRICAL
CONTENTS
PAGE
General Description....................................................................................................................6D - 2
Generator................................................................................................................................6D - 2
Starter .....................................................................................................................................6D - 3
Wire Coding............................................................................................................................6D - 4
Symbols and Abbreviations...................................................................................................6D - 6
Fuses.......................................................................................................................................6D - 8
Generator ....................................................................................................................................6D - 9
Disassembly ...........................................................................................................................6D - 9
Inspection and Repair............................................................................................................6D - 11
Reassembly ............................................................................................................................6D - 14
Starter..........................................................................................................................................6D - 16
Disassembly ...........................................................................................................................6D - 16
Reassembly ............................................................................................................................6D - 21
Prehearing, Starting and Electrical Engine Control Systems ..................................................6D - 23
Wiring Circuit Diagram ..........................................................................................................6D - 23
6D - 2 ENGINE ELECTRICAL
GENERAL DESCRIPTION
Generator
066HT001
Starter Motor
WIRE CODING
Description
Codes used in the circuit diagram represent wire size and
color.
Example: 0.5 R
Wire color (Red)
Wire size (0.5 mm2)
Wire Size
Wire size is specified in the metric system.
The metric system gives the wire size in cross-sectional
area measured in square millimeters.
Wire Size Specifications

Nominal Size Cross section area Outside diameter Maximum allowable
(mm) (mm) Current (A)
0.3 0.372 1.8 9
0.5 0.563 2.0 12
0.85 0.885 2.2 16
1.25 1.287 2.5 21
2 2.091 2.9 28
3 3.296 3.6 37.5
5 5.227 4.4 53
8 7.952 5.5 67
15 13.36 7.0 75
20 20.61 8.2 97
Wire Color
All wires have color-codes insulation.
Wires belonging to a system’s main harness have a single
color ➀.
Wires belonging to a system’s sub-circuits have a colored
stripe (tracer) ➁.
Striped wires use the following code to show wire size and
colors.
Example: 0.5 G R
Red (Stripe (tracer) color)
Green (Base color)
Wire size (0.5 mm2)
Abbreviations are used to indicate wire color within a circuit

diagram.
Refer to the following table.
Wire Color-Coding
Color-coding Meaning Circuits
B Black Starter circuit and grounding circuit
W White Charging circuit
R Red Lighting circuit
G Green Signal circuit
Y Yellow Instrument circuit
L Blue Wiper circuit
O Orange
Br Brown
Lg Light green
Gy Gray Other circuits
P Pink
Sb Sky blue
V Violet
SYMBOLS AND ABBREVIATIONS
Description
The symbols and abbreviations used in the circuit diagram
make the diagram easier to read and understand.
Symbols
The illustration at the left shows typical symbols used in
circuit diagrams.
These same symbols may also appear in the text.
Symbol and Meaning

Symbol Meaning Symbol Meaning
Fuse Single filament bulb
Main fuse Double filament bulb
Fusible link wire Motor
Switch Variable resistor
Switch Coil (Inductor)
Contact wiring Relay

NOTE:
Relay contact shown
in the wiring diagram
indicates condition
Battery
before actuation.
821RT007
Diode Connector
Symbol Meaning Symbol Meaning
Electronic part Light emitting diode
Resistor Reed switch
Speaker Condenser
Ground
Abbreviations
The illustration at the left shows typical abbreviation ➀ used in
the circuit diagrams.
These same abbreviations may also appear in the text.
Abbreviation and Meaning

Abbreviation Meaning Abbreviation Meaning
RH Right-hand side STD Standard equipment

LH Left-hand side OPT Optional equipment
SW Switch W/ With
M/T Manual transmission WO / Without
A/T Automatic transmission OD Overdrive
FT Front ACC Accessories
RR Rear A/C Airconditioner
FLW Fusible link wire ATF Automatic transmission fluid
TEMP Temperature VSV Vacuum switch valve
FUSES
Fuse (Blade Type with Polymeric Housing)

Fuses are located in the fuse box.
This type of fuse is highly resistant to both heat and shock.
It is lighter in weight than conventional glass tube fuses.
All fuses are transparent so that a blown fuse is easily
identified.
Fuse Specifications
Current (A) Housing Color
5 Yellow-brown
7.5 Brown
10 Red
15 Blue
20 Yellow
Fusible Link Wires

Fusible link wires are connected near the starter motor.
Fusible link wires are designed to melt in the event of
circuit overload. This protects the wiring harnesses from
damage.
Melted fusible links cannot be visually identified. A circuit
tester is required to check them.
Precautions
1. Always determine the cause of an overload before
replacing a fuse.
2. Always replace a blown fuse with a new fuse of the
same amperage rating.
Never replace a blown fuse with a new fuse of a
different amperage rating. An electrical fire with serious
circuit damage can result.
GENERATOR
DISASSEMBLY
Disassembly Steps
1. Pulley nut 12. Rotor assembly
2. Pulley 13. Bearing retainer
3. Fan 14. Ball bearing
4. Collar 15. Bearing cover
5. Bushing 16. Ring
6. Cover 17. Front frame
7. Rectifier holder assembly 18. Rear end frame assembly
8. Regulator 19. Ball bearing
9. Rectifier holder 20. Rotor coil
10. Through bolt 21. Stator assembly
11. Front frame and rotor assembly 22. Rectifier assembly
Disassembly steps
1. Pulley Nut
2. Pulley
3. Fan
4. Collar
5. Bushing
6. Cover
7. Rectifier Holder Assembly
8. Regulator
9. Rectifier Holder
10. Through Bolt
11. Front Frame and Rotor Assembly
12. Rotor Assembly
13. Bearing Retainer
14. Ball Bearing
15. Bearing Cover
16. Ring
17. Front Frame
18. Rear End Frame Assembly
19. Ball Bearing
20. Rotor Coil
21. Stator Assembly
22. Rectifier Assembly

inspection.
It is most important that electrical components be kept clean and dry at all times.
Always visibly check the fusible links, the fuses, and the indicator lights for damage as the first step in the inspection
and repair procedure.
Rotor Coil
Rotor Coil Resistance
Use a circuit tester to measure the rotor coil resistance
between the terminals.
Rotor Coil Resistance ohm
Standard
9
If the measured resistance is above or below the specified

standard, the rotor coil assembly must be replaced.
Stator
Stator Continuity
Check for continuity across the stator coils.
If there is no continuity, the stator assembly must be
replaced.
Stator Insulation
Use a circuit tester to check that there is no continuity
between the stator coils and the core.
If there is continuity between the stator coils and the core,
the stator assembly is defective and must be replaced.
Rectifier Holder Assembly

Rectifier Check
Use a circuit tester to check the battery side rectifiers (+)
and the ground side rectifiers (—).
1. Touch one circuit tester lead to the battery side terminal
(+).
2. Touch the other circuit tester lead to one of the battery
side rectifiers.
Note the circuit tester gauge reading (continuity or
infinite resistance).
3. Reverse the position of the circuit tester leads. The

circuit tester gauge reading should be the opposite of
Steps 2.
4. Continue the procedure for the remaining battery side
rectifiers.
If the circuit tester gauge reading at any point is
abnormal, the rectifier holder assembly must be
replaced.
5. Touch one circuit tester lead to the ground side terminal

(—).
6. Touch the other circuit tester lead to one of the ground
side rectifiers.
Note the circuit tester gauge reading (continuity or
infinite resistance).
7. Continue as in Steps 3-4 above for the remaining

ground side rectifiers.
Pulley
Check the pulley for excessive wear and cracking.
Fan
Check the fan for cracking and distortion.
Ball Bearing
Check the ball bearings for binding, drag, roughness, and
noise.
REASSEMBLY
Reassembly Steps
1. Rectifier assembly 12. Front frame and rotor assembly
2. Stator assembly 13. Through bolt
3. Rotor coil 14. Rectifier holder
4. Rear end frame assembly 15. Regulator
5. Ball bearing 16. Rectifier holder assembly
6. Front frame 17. Cover
7. Ring 18. Bushing
8. Bearing cover 19. Collar
9. Ball bearing 20. Fan
10. Bearing retainer 21. Pulley
11. Rotor assembly 22. Pulley nut
Reassembly Steps
1. Rectifier Assembly
2. Stator Assembly
3. Rotor Coil
4. Rear End Frame Assembly
5. Ball Bearing
6. Front Frame
7. Ring
8. Bearing Cover
9. Ball bearing
10. Bearing Retainer
11. Rotor Assembly
12. Front Frame and Rotor Assembly
13. Through Bolt
14. Rectifier Holder
15. Regulator
16. Rectifier Holder Assembly
17. Cover
18. Bushing
19. Collar
20. Fan
21. Pulley
22. Pulley Nut
STARTER
DISASSEMBLY
Disassembly Steps
1. Lead wire 8. Yoke assembly
2. Magnetic switch assembly and 9. Armature
gasket 10. Front bracket
3. Brush holder screw 11. Center bracket
4. Through bolt 12. Idle gear assembly
5. Rear bracket 13. Ball
6. Brush 14. Return spring
7. Brush holder and spring 15. Over running clutch
Disassembly Steps
1. Lead Wire
2. Magnetic Switch Assembly and Gasket
3. Brush Holder Screw
Loosen the brush holder screws at the rear bracket.
4. Through Bolt
5. Rear Racket
6. Brush
7. Brush Holder and Spring
8. Yoke Assembly
9. Armature
Remove the brush holder ➀ the yoke assembly ➁ and the
armature assembly ➂.
10. Front Bracket

11. Center Bracket
1. Loosen the bolts fixing the front bracket ➀ to center
bracket ➁.
2. Remove the front bracket from the center bracket.
12. Idle Gear Assembly

13. Ball
14. Return Spring
15. Over Running Clutch

inspection.
Armature
Commutator Face
Check the commutator face for roughness.
If necessary, dress the commutator face with fine
sandpaper (#500 or #600).
Be absolutely sure that there are no metal filings in the
segment gaps.
Commutator Run-Out
1. Mount the armature assembly on V-blocks.
2. Use a dial indicator to measure the commutator run-
out.
If the run-out is greater than the specified standard but
less than the specified limit, the commutator may be
turned on a lathe to correct it.
If the run-out exceeds the specified limit, the armature
assembly must be replaced.
Commutator Run-Out mm (in)
Standard Limit
0.06 (0.002) or less 0.1 (0.004)
Commutator Segment Groove Depth

Use the V-blocks and the dial indicator to measure the
depth D of each of the commutator segment grooves.
Replace the armature assembly if the commutator segment
groove depth is less than the specified limit.
Commutator Segment Groove Depth D mm (in)
Standard Limit
0.5 — 0.8 (0.020 — 0.031) 0.2 (0.008)
Armature Coil
1. Place the armature in a growler tester.
2. Hold a hacksaw blade against the armature core.
Slowly rotate the armature.
If the armature is shorted, the hacksaw blade will
vibrate.
Replace the armature assembly if it is shorted.
Armature Continuity
Use a circuit tester to check for continuity between the
commutator segments.
If there is no continuity between any two points on the
commutator, the armature assembly must be replaced.
Armature Insulation
between the commutator segments and the coil core.
If there is continuity between the commutator segments
and the coil core, the armature assembly is defective and
must be replaced.
Yoke
Field Coil Continuity
Use a circuit tester to check for continuity between the
connecting leads and the brushes.
Replace the yoke assembly if there is no continuity at any
point.
Yoke Insulation
between the field coil and the yoke body.
If there is continuity between the field coil and the yoke
body, the yoke assembly is defective and must be
replaced.
Pinion Clutch
1. Clean the pinion clutch with a clean rag.
2. Check the pinion clutch and pinion gear for excessive
wear and damage.
3. Turn the pinion gear clockwise.
The gear should turn smoothly with no resistance.
If the gear does not turn smoothly, the pinion clutch
4. Turn the pinion gear counterclockwise.
The gear should lock firmly.
If the gear does not lock firmly, the pinion clutch
Bearing
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
Magnetic Switch
CAUTION:
Do not apply an operating test to the magnetic
switch as a single unit.
Coil Inspection
Inspect the continuity between M terminal and case of the
magnetic switch using a circuit tester.
REASSEMBLY
Reassembly Steps
1. Center bracket 9. Rear bracket
2. Over running clutch 10. Brush holder screw
3. Idle gear assembly 11. Through bolt
4. Front bracket 12. Ball
5. Yoke assembly 13. Return spring
6. Brush holder and spring 14. Magnetic switch assembly and gasket
7. Armature 15. Lead wire
8. Brush
Reassembly Steps
1. Center Bracket
2. Over Running Clutch
3. Idle Gear Assembly
Adjust the over running clutch front bracket and bearing
clearance with adjusting washer so that the clearance may
become as specified.
Front Bracket and Bearing Clearance mm (in)
0.2 — 0.8 (0.008 — 0.031)
4. Front Bracket
5. Yoke Assembly
6. Brush Holder and Spring
7. Armature
Adjust the armature center bracket and bearing clearance
with adjusting washer so that the clearance may become
as specified.
Center Bracket and Bearing Clearance mm (in)
0.2 — 0.8 (0.008 — 0.031)
8. Brush
9. Rear Bracket
10. Brush Holder Screw
11. Through Bolt
Tighten the through bolts to the specified torque.
Through Bolt Torque N.m (kg.m / Ib.in)
9 (0.9 / 78)
12. Ball
13. Return Spring
14. Magnetic Switch Assembly
1) Install the magnetic switch assembly to the center
bracket.
2) Tighten the magnetic switch assembly bolts to the
specified torque.
Magnetic Switch Bolt Torque N.m (kg.m / Ib.in)
9 (0.9 / 78)
15. Lead Wire

PREHEATING, STARTING, AND

ELECTRICAL ENGINE CONTROL SYSTEMS
WIRING CIRCUIT DIAGRAM

inspection.
Preheating System
Glow Plug
Check each of the glow plugs for continuity.
Replace the glow plugs as a set if one or more of the glow
plugs does not have continuity.
Glow Relay
Check the glow relay operation.
Terminal Positions
A From the fusible link
B To the control resistor
➀ From the fuse box
➁ To ground
Control Resistor
Check the heat coil for breakage and fusing.
Replace the control resistor if the heat coil is broken or
fused.
NOTE:
Common Control Resistor Problem are:
1. Broken wires caused by vibration
2. Fusing caused by overheating
This is usually the result of mismatching the glow
plug and the control resistor.
When Installing the Control Resistor:
1. Be sure that you are installing a control resistor of
the proper rating.
2. Be sure that the glow plug is compatible with the
control resistor.
3. Be sure that the control resistor is securely
connected.
Control Resistor Continuity

Use a circuit tester to check that there is continuity
between terminal ➀ and terminal ➁.
If there is no continuity between terminal ➀ and terminal
➁, the control resister is defective and must be replaced.
Starting System
Circuit diagram terminal positions are shown in the illustration.
Starter Relay
Check the starter relay operation.
Terminal Positions
To starter terminal “C”
B To starter terminal “B”
C To starter switch
E To ground
Electrical Engine Control System

(If so equipped)
Stop Control Motor and Actuator Cable Assembly
Check the stop control motor operation.
➀ Armature assembly
➁ Worm wheel assembly
➂ Starter switch
➃ Fuse
Connector Terminal Positions

A To actuator “L”
B To fuse box “LR”
E To actuator ground “B”
To actuator “LY”
To actuator “LW”
Actuator Cable
1. Check that the actuator cable moves smoothly when
the stop control motor is operating.
If the cable does not move smoothly, the stop control
motor and actuator cable assembly must be replaced.
2. Check the actuator cable end stroke during stop
control motor operation.
Actuator Cable End Stroke mm (in)
35 (1.38) or more
If the cable end stroke is less than the specified value,

the stop control motor and actuator cable assembly
must be replaced.
EXHAUST SYSTEM 6F - 1
SECTION 6F
EXHAUST SYSTEM
CONTENTS
PAGE
General Description....................................................................................................................6F - 2
Removal..................................................................................................................................6F - 3
Inspection and Repair............................................................................................................6F - 7
Installation ..............................................................................................................................6F - 8
6F - 2 EXHAUST SYSTEM
GENERAL DESCRIPTION
150MW002
The exhaust system consists of the vibnon assembly, The exhaust pipes are connected to each other by
the exhaust pipes and the silencer. series of sleeve clamp and / or flange bolts. They are
In the horizontal system, the exhaust pipes run from the attached to the vehicle frame by clamps and brackets.
exhaust manifold, beneath the vehicle frame, to the rear Rubber bushings are used at support points.
of the vehicle. Vibnon assembly is a joint system called D.J.M. which is
In the vertical exhaust system, the exhaust pipes run used to prevent the leakage of exhaust noise and gases
from the exhaust manifold beneath the vehicle frame, to from the engine.
the top of the vehicle just behind the cab.
REMOVAL
Horizontal Outlet Type
150MW001
Removal Steps
1. Exhaust pipe clamp (A) 4. Exhaust pipe clamp (B)
2. Exhaust pipe clamp (A) 5. Exhaust silencer
3. Rear exhaust pipe 6. Front exhaust pipe with D.J.M.
REMOVAL STEPS
1. Exhaust Pipe Clamp (A)
3. Rear Exhaust Pipe
4. Exhaust Pipe Clamp (B)
5. Exhaust Silencer
6. Front Exhaust Pipe with D.J.M.
Vertical Outlet Type
Removal Steps
1. Heat protector (A) 6. Rear exhaust pipe
2. Heat protector (B) 7. Exhaust pipe clamp (A)
3. Rear exhaust pipe U-bolt, upper 8. Front exhaust pipe with D.J.M.
4. Rear exhaust pipe U-bolt, lower 9. Exhaust silencer clamp
5. Exhaust pipe clamp (B) 10. Exhaust silencer
Removal Steps
1. Heat Protector (A)
2. Heat Protector (B)
3. Rear Exhaust Pipe U-bolt, Upper
4. Rear Exhaust Pipe U-bolt, Lower
9. Exhaust Silencer Clamp
10. Exhaust Silencer

inspection.
Exhaust Pipes and Exhaust Silencer

1. Check the exhaust pipes and the exhaust silencer for
corrosion and damage.
Repair or replace as required.
2. Check the pipe and silencer connections for looseness
and misalignment.
Align and tighten as required.
3. Check the pipe support rubber rings for deterioration.
Replace as required.
INSTALLATION
Horizontal Outlet Type
Installation Steps
1. Front exhaust pipe with D.J.M. 4. Rear exhaust pipe
2. Exhaust pipe clamp (B) 5. Exhaust pipe clamp (A)
3. Exhaust silencer 6. Exhaust pipe clamp (B)
Installation Steps
1) Connect the front exhaust pipe with D.J.M. device to
the exhaust manifold.
2) Temporarily tighten the front exhaust pipe flange nuts.
NOTE:
Retighten the front exhaust pipe flange nuts to the
specified torque after installing the exhaust silencer,
rear exhaust pipe, and exhaust clamp.
Exhaust Pipe Flange Nut Torque N.m (kg.m / lb.ft)

39 (4 / 29)
NOTE:
Tighten the flange nuts carefully so that the
clearance between the D.J.M. device collar ➀ and
flange ➁ is even.

Apply muffler sealer to the exhaust pipe and exhaust
silencer joints.
The sealer should extend approximately 50mm (2in) from
each side of the joint.
3. Exhaust Silencer
Be absolutely sure that the exhaust pipe clamps and / or
the flange bolts are securely fastened to the exhaust pipes
and the silencer.
If the vehicle is equipped with an exhaust brake, be
absolutely sure that the exhaust brake valve is correctly
installed to the exhaust pipes.
Exhaust System Check

1. Start the engine and allow it to idle.
2. Check for gas leakage from the exhaust pipe joints.
3. Check for noise and vibration.
Vertical Outlet Type
Installation Steps
1. Exhaust silencer 6. Exhaust pipe clamp (B)
2. Exhaust silencer clamp 7. Rear exhaust pipe U-bolt, lower
3. Front exhaust pipe with D.J.M. 8. Rear exhaust pipe U-bolt, upper
4. Exhaust pipe clamp (A) 9. Heat protector (B)
5. Rear exhaust pipe 10. Heat protector (A)
Installation Steps
1. Exhaust Silencer
2. Exhaust Silencer Clamp
1) Connect the front exhaust pipe with D.J.M. device to
the exhaust manifold.
2) Temporarily tighten the front exhaust pipe flange nuts.
NOTE:
Retighten the front exhaust pipe flange nuts to the
specified torque after installing the exhaust silencer,
rear exhaust pipe, and exhaust clamp.
Exhaust Pipe Flange Nut Torque N.m (kg.m /lb.ft)
39 (4 / 29)
NOTE:
Tighten the flange nuts carefully so that the
clearance between the D.J.M. device collar ➀ and
flange ➁ is even.

Apply muffler sealer to the exhaust pipe and exhaust
silencer joints.
The sealer should extend approximately 50 mm (2 in) from
each side of the joint.
7. Rear Exhaust Pipe U-bolt, Lower
8. Rear Exhaust Pipe U-bolt, Upper
Be absolutely sure that the exhaust pipe clamps and / or
the flange bolts are securely fastened to the exhaust pipes
and the silencer.
If the vehicle is equipped with an exhaust brake, be
absolutely sure that the exhaust brake valve is correctly
installed to the exhaust pipes.
9. Heat Protector (B)
10. Heat Protector (A)
Exhaust System Check

1. Start the engine and allow it to idle.
2. Check for gas leakage from the exhaust pipe joints.
3. Check for noise and vibration.
MEMO
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TURBOCHARGER 6G - 1
SECTION 6G
TURBOCHARGER
CONTENTS
PAGE
General Description....................................................................................................................6G - 2
Identification Plate and Assembly Number...............................................................................6G - 3
Turbocharger Servicing..............................................................................................................6G - 3
Precautions .................................................................................................................................6G - 3
Inspection and Repair ................................................................................................................6G - 4
Turbine Shaft End Play ..........................................................................................................6G - 4
6G - 2 TURBOCHARGER
GENERAL DESCRIPTION
Turbocharger
F06MV026
Major turbocharger components are constituted the The turbocharger increase air intake efficiency, the
Center Housing and Rotating Assembly (CHRA), the results increased engine power, reduced fuel
compressor housing, and the turbine housing. consumption and minimal engine noise.
Rotating parts include the turbine shaft, the compressor Turbocharger rotating parts operate at very high speeds
wheel, the shaft bearings, the thrust bearings and the oil and temperatures. The parts materials have been
seal rings. These parts are supported by the center carefully selected and machined to extremely high
housing. precision.
TURBOCHARGER 6G - 3
IDENTIFICATION PLATE AND ASSEMBLY

NUMBER
The turbocharger nameplate gives the date of manufacture
and other important information required to identify the unit
when service inquiries are made.
The turbocharger nameplate has the following information

stamped on it. Refer to the illustration.
➀ Turbocharger specification, production year and
production month.
➁ Production date, serial number and production line
name.
➂ Part number assigned by ISUZU MOTORS LIMITED.
Example: 8976019740
Part numbers ➂ indicate specific designs or
configurations.
TURBOCHARGER SERVICING
1. Refer to TROUBLESHOOTING in this Manual to determine whether or not turbocharger repair or overhaul is
required.
2. The following procedures should also be performed (either with the turbocharger repair on the vehicle or removed
from the vehicle but not disassembled) to determine whether or not turbocharger repair or overhaul is required.
* Visual checks
* End play measurements
Refer to INSPECTION AND REPAIR
PRECAUTIONS
Turbocharger servicing requires great care and expertise.
Faulty turbocharger servicing procedures can result in serious damage to pistons, valves, cylinder liners, and other
important engine parts.
ISUZU does not recommended the performance of any servicing procedure not specified described in this Manual.
Contact your nearest GARETT TUBO INC. service facility to have the turbocharger assembly repaired or overhaul.
The identification plate and assembly number will be required by the service facility.
6G - 4 TURBOCHARGER

Make the necessary adjustment, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Minor servicing operations are described in this Section.

Contact the nearest GARRETT SERVICE FACILITY for major
repairs and maintenance.
Inspect following items before starting the repair.

• Turbocharger housing for cracks or damage.
• Gasket surfaces for damage.
• Seals and gaskets for damage.
• Turbine and compressor blades for damage or
carbon buildup.
• Air and exhaust exit openings for oil or wetness.
• For grinding or roughness when spinning turbine
and compressor wheels by hand.
• For evidence of turbine or compressor blades
contacting the shroud or housing. If any of the
above conditions exits, the turbocharger must be
replaced or repaired.
Turbine Shaft End Play

1. Set a dial indictor to the turbine shaft end.
2. Apply a force of alternately to the compressor wheel
end and the turbine wheel end.
3. Read the dial indicator.
Turbine Shaft End Play mm (in)
Standard
0.045 — 0.090 (0.0018 — 0.0035)
If excessive, replace the turbocharger.
MG6HK-WE-0219PC
You are requested to order this manual using the manual

number that is shown above.
This manual is applicable for vehicles in China.
All rights reserved. This manual may not be reproduced

in whole or in part, without the permission in writing of
ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED

INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Aug., 2001

No.MG6HK-WE-0219PC PRINTED IN JAPAN

Mecanica de Motor 6HK1-TC

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WORKSHOP MANUAL

FVR, FVM, FVZ

International Service & Parts

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on latest product

Applicable Model: FVR, FVM, FVZ

0This manual is applicable to 2000~2001 year model.

Checkpoint Trouble Cause Countermeasure

2) STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER

Checkpoint Trouble Cause Countermeasure

3) ENGINE TURNS OVER BUT DOES NOT START

Checkpoint Trouble Cause Countermeasure

1 Fuel is Not Being Delivered to The Injection Pump

Checkpoint Trouble Cause Countermeasure

2 Fuel is Being Delivered to The Injection Pump

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

EXCESSIVE FUEL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

EXCESSIVE OIL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

WHITE EXHAUST SMOKE

Checkpoint Trouble Cause Countermeasure

BLACK EXHAUST SMOKE

Checkpoint Trouble Cause Countermeasure

OIL PRESSURE DOES NOT RISE

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

ABNORMAL ENGINE NOISE

Checkpoint Trouble Cause Countermeasure

2) GAS LEAKAGE NOISE

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

2) BLUE OR BLACK SMOKE

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

3) EXCESSIVE OIL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

4) EXCESSIVE TURBOCHARGER NOISE

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

5) EXCESSIVE ROTATING PART WEAR

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

Checkpoint Trouble Cause Countermeasure

3) FLASHING CHARGE LIGHT OR FLUCTUATING AMMETER INDICATION