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Isuzu AA-6HK1T, Workshop Manual

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Isuzu AA-6HK1T Workshop Manual Download Page 52

ENGINE MECHANICAL

6A–1

ENGINE

CONTENTS

ENGINE MECHANICAL

CONTENTS

Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . 6A
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C

Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . 6D3
Engine Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . 6G
Engine Induction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J

Service Precautions. . . . . . . . . . . . . . . . . . . . . . . . 6A-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6A-2

Engine Cleanliness and Care . . . . . . . . . . . . . . . 6A-2
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Engine Components . . . . . . . . . . . . . . . . . . . . . . 6A-2

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4

Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5

Intake Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7

Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-11

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13

Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16

Bearing Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18

Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20

Rocker Arm and Shaft Assembly. . . . . . . . . . . . . 6A-23

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-32

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-36
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-37
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-39

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-39

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-45
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-48
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54

Crank Pulley and Flywheel . . . . . . . . . . . . . . . . . 6A-62

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-64
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-64
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-64

Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-67
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-68

Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . 6A-71

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-72

Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-76

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-77

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-78

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-78
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-79

Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-83
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-85
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-86
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-94

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-94
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100
Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-101
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104

Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-107
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-108
Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-109
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112

Summary of Contents for AA-6HK1T

Page 1: ...AA 6HK1T BB 6HK1T...

Page 2: ...ISUZU MOTORS LIMITED AA 6HK1T BB 6HK1T ENGLISH 9806 2200 ISSUE 1 MAY 05 WORKSHOP MANUAL...

Page 3: ...0 0 9806 2200 Notes...

Page 4: ...and thoroughly understand the information contained in Section 00 under the heading GENERAL INFORMATION All material contained in this Manual is based on latest product information available at the t...

Page 5: ...NUAL INCLUDES THE FOLLOWING SECTIONS SECTION NO CONTENTS 00 General Information 6A Engine Mechanical 6B Engine Cooling 6C Engine Fuel 6D Starting and Charging 6E 6F 6G Engine Lubrication 6J Engine Ind...

Page 6: ...8 Clean the parts before inspection or reassembly Also clean oil ports etc using compressed air and make certain they are free from restrictions 9 Lubricate rotating and sliding faces of the parts wit...

Page 7: ...t of Engine Up Task Related View Detail A View Angle Dimension 1 2 Sectioning 1 3 Arrow Type Application Ambient Clean air flow Cool air flow Gas other than ambient air Hot air flow Ambient air mixed...

Page 8: ...per Hour kPa Kilopascals kV Kilovolts thousands of volts kW Kilowatts L Liter lb ft Foot Pounds lb in Inch Pounds LF Left Front LH Left Hand LR Left Rear LS Left Side L 4 In Line Four Cylinder Engine...

Page 9: ...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 lin...

Page 10: ...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...

Page 11: ...38 507 34 5 51 7 250 374 5 10 0 5 1 0 4 7 12 23 1 2 2 3 9 17 28 46 2 8 4 7 20 33 28 45 2 8 4 6 20 33 61 91 6 2 9 3 45 67 57 84 5 8 8 6 42 62 93 139 9 5 14 2 69 103 88 131 9 0 13 4 65 97 135 204 13 8 2...

Page 12: ...8 5 12 7 62 92 77 116 7 9 11 8 57 85 116 173 11 8 17 7 85 128 109 164 11 2 16 7 81 121 6 12 0 6 1 2 4 9 15 28 1 6 2 9 12 21 35 59 3 6 6 1 26 44 35 58 3 5 5 8 25 42 77 117 7 9 11 9 57 86 71 107 7 3 10...

Page 13: ...ctly dry 2 Apply LOCTITE to the bolts 3 Tighten the bolts to the specified torque After tightening be sure to keep the bolts free from vibration and torque for at least an hour until the LOCTITE harde...

Page 14: ...der 1 5 3 6 2 4 Fuel injection timing TDC deg 9 Specified fuel type SAE No 2 diesel fuel Idling speed min 1 1000 Valve clearances Intake mm in 0 40 0 016 Exhaust mm in 0 40 0 016 Intake valves Open at...

Page 15: ...y circulation water Coolant volume L qts 14 5 15 3 Water pump Centrifugal impeller Delivery volume Lit min Imp gal US gal 167 37 44 Pump speed a 1 600 min 1 Thermostat Wax pellet Valve initial opening...

Page 16: ...Flywheel Fan guide Water pump Injection pump Oil level sensor Oil port cover Intake duct Inlet pipe Crank pulley Oil filler cap Exhaust manifold Oil dipstick Oil pan Alternator Oil drain plug Flywhee...

Page 17: ...m in 14 1 0 56 Valve and Valve Seat Insert Valve Thickness Intake mm in 1 71 0 067 1 30 0 051 Exhaust mm in 1 75 0 069 1 30 0 051 Valve Depression Intake mm in 1 0 0 039 2 5 0 098 Exhaust mm in 1 3 0...

Page 18: ...85 1 5728 1 5738 1 5689 Cam Lobe Height Intake mm in 7 851 0 3091 7 351 0 2894 Exhaust mm in 9 540 0 3756 9 040 0 3559 Camshaft Run Out mm in 0 025 0 001 0 05 0 002 Camshaft Bearing Inside Diameter mm...

Page 19: ...5 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...

Page 20: ...135 0 20 0 0027 0 0053 0 008 Oil Pump Gear Teeth and Cover Inner Wall Clearance mm in 0 125 0 221 0 221 0 0049 0 0087 0 0087 Gear and Body Clearance mm in 0 064 0 109 0 109 0 0025 0 0043 0 0043 Gear S...

Page 21: ...0A 16 GENERAL INFORMATION Torque Specifications Auxiliary Parts N m kgf m lb ft F06EY00104 97 9 9 72 40 4 1 30 40 4 1 30 83 8 5 61 40 4 1 30 39 4 0 29 Cooling fan Starter...

Page 22: ...AL INFORMATION 0A 17 Engine External Parts N m kgf m lb ft F06EY00105 19 1 9 14 Oil cooler 39 4 0 29 Fuel filter 39 4 0 29 Oil port cover 44 4 5 32 Injection pump 52 5 3 38 Turbocharger 88 9 0 65 Coup...

Page 23: ...4 56 5 7 41 Apply engine oil 30 3 1 22 Apply molybdenum disulfide grease 27 2 8 20 12 1 2 8 7 27 2 8 20 20 2 0 14 Apply engine oil M14 98 10 72 147 15 0 108 30 60 M10 38 3 9 28 M14 Apply molybdenum di...

Page 24: ...19 Cylinder Head N m kgf m lb ft F06E100074 5 4 4 1 6 A DOM Workshop Man 0 01 6 28 Apply engine oil Apply engine oil Apply engine oil 48 4 9 35 19 1 9 14 20 2 0 14 20 2 0 14 15 1 5 11 48 4 9 35 95 9 7...

Page 25: ...0A 20 GENERAL INFORMATION Oil Pan N m kgf m lb ft F06EY00144 5 2 1 6 8 A Workshop Manual 01 01 12 FS 01 01 10 48 4 9 35 24 2 4 17 25 2 5 18 25 2 5 18...

Page 26: ...01 6 28 Apply engine oil Apply engine oil Apply engine oil 29 3 0 22 60 90 Apply molybdenum disulfide grease 24 2 4 17 Apply engine oil Apply ThreeBond No TB1201 78 8 0 58 60 60 90 Apply molybdenum di...

Page 27: ...0A 22 GENERAL INFORMATION Water Pump N m kgf m lb ft F06E100076 5 4 4 1 6 A 01 6 28 240 24 174 20 2 0 14 20 2 0 14 20 2 0 14 20 2 0 14 39 4 0 29 52 5 3 38...

Page 28: ...19 1 9 14 39 4 0 29 60 30 60 21 2 1 15 Apply molybdenum disulfide grease 200 20 4 148 Apply engine oil Apply ThreeBond No1207C M14 98 10 0 72 132 13 5 98 30 60 M10 37 3 8 27 M14 Apply molybdenum disul...

Page 29: ...ide 1 85221 029 0 Setting tool Piston ring 8 94396 818 0 Remover Crankshaft gear ILLUSTRATION TOOL NO TOOL NAME 8 94396 819 0 Installer Crankshaft gear 5 88402 627 0 Installer oil seal cylinder head 5...

Page 30: ...njection nozzle sticking Injection nozzle starting pressure too low Improper spray condition Improper injection pump control rack operation Injection pump plunger worn or stuck Injection pump camshaft...

Page 31: ...Worn plunger of the injection pump Worn camshaft of the injection pump Worn roller tappet of the injection pump Valve clearance improperly adjusted Worn camshaft Blown out cylinder head gasket Worn c...

Page 32: ...efective turbocharger assembly Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and valve seat Valve clearance improperly adjusted W...

Page 33: ...n nozzle Adjust the injection timing Clean or replace air cleaner element Adjust idling speed Replace Replace engine oil Repair the turbocharger intake side Replace the turbocharger assembly Replace t...

Page 34: ...ng system Trouble in the turbocharger system Water particles in fuel Retarded fuel injection timing Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating b...

Page 35: ...rocker arm bushing Worn camshaft and camshaft bearing Worn crankshaft and bearings Oiling jet valve does not close Replace the engine oil Add engine oil Repair or replace the oil pressure gauge or un...

Page 36: ...d crankshaft and or connecting rod bearings Worn or damaged connecting rod bushing and piston pin Worn or damaged piston and cylinder liner Foreign material in the cylinder Use correct fuel Adjust the...

Page 37: ...n circuit Poor ground connection of voltage regulator Voltage set of regulator too high Defective voltage regulator Loose belt Defective starter switch contacts Broken or poorly connected wiring Loose...

Page 38: ...of magnetic switch terminal Worn brushes Shorted armature Bad contact of magnetic terminal circuit switches Excessive brush wear Shorted starter motor armature Pinion and ring gear not engaged Overrun...

Page 39: ...tem joints Damaged intake and exhaust system gaskets Rough rotation of turbocharger parts Compressor wheel rubbing against housing Damaged compressor wheel Turbine wheel rubbing against housing Damage...

Page 40: ...nd No 1207C or TB1141E Sealant Application Name of Lubricant Lubrication area Engine Oil Turbocharger bearings Cylinder head bolts M10 bolt Rocker arm rollers Camshaft cam nose and journal Camshaft fi...

Page 41: ...MEMO...

Page 42: ...2 Cooling System 0B 6 Valve Clearance Adjustment 0B 6 Compression Pressure Measurement 0B 8 Recommended Lubricants 0B 9 Engine Oil Viscosity Chart 0B 9 Identification Engine Serial Number The engine...

Page 43: ...ket of the cartridge 3 Turn the fuel filter until the filter gasket comes in contact with the sealed face 4 Use the filter wrench to turn in the fuel filter an additional 2 3 of a turn NOTE Be careful...

Page 44: ...he timing mark on the timing advancer can be seen 2 Align the injection timing mark on the damper with the pointer on the front cover 3 Loosen the two coupling bolts 4 Move the timing advancer to the...

Page 45: ...stage 18 1 MPa 185 kg cm2 2630 psi 2nd stage 22 1 MPa 225 kg cm2 3200 psi WARNING Test fluid from the injection nozzle tester will spray out of the injection nozzle under great pressure It can easily...

Page 46: ...e priming pump until there are no bubbles in the fuel being discharged from the air plug the fuel is discharged in a solid stream 5 Tighten the priming pump cap and the air plug Feed pump strainer 1 R...

Page 47: ...ing 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 th...

Page 48: ...ew on the bridge until there is a slight drag on the feeler gauge Tighten the lock nut securely 4 Rotate the crankshaft 360 degrees and realign the T C mark on the flywheel with the pointer Adjust cle...

Page 49: ...he glow plug and the injection fuel pipe from each cylinder 2 Install the compression gauge adapter 5 8840 2622 0 to the glow plug installation hole 3 Install the compression gauge to the compression...

Page 50: ...ICANT API With or without turbocharger Diesel engine oil CD grade ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE Single grade Multi grade Ambient temperature 30 C 22 F 0 F 32 F 60 F 80 F 90 F 15 C 0 C...

Page 51: ...MEMO...

Page 52: ...sembly 6A 27 Inspection and Repair 6A 28 Reassembly 6A 31 Camshaft 6A 32 Removal 6A 32 Installation 6A 33 Disassembly 6A 36 Inspection and Repair 6A 37 Reassembly 6A 38 Cylinder Head 6A 39 Removal 6A...

Page 53: ...ble of damaging delicate electrical circuits Be absolutely certain that the ground cable is disconnected at the battery when servicing the engine After removing the intake air duct or air cleaner imme...

Page 54: ...ssure circulation system Oil is pumped from the crankcase through the oil filter to the oil cooler where it is cleaned From the oil cooler the oil travels to the cylinder block main oil gallery from w...

Page 55: ...with the new gasket to the exhaust manifold and tighten the nuts to the specified torque Torque 52 N m 5 3 kgm 38 lbft NOTE Lubricate the turbine shaft Pour oil into the oil feed hole while rotating t...

Page 56: ...the distance tube 1 plain washer 2 and spring washer 3 Install the distance tube 1 and distance nut 4 to the front stud of No 5 cylinder indicated by arrow A Tighten the nuts to the specified torque i...

Page 57: ...6A 6 ENGINE MECHANICAL 2 1 052EY00007...

Page 58: ...Installation 1 Install the intake cover with new gaskets Tighten the bolts to the specified torque Torque 15 N m 1 5 kgm 11 lbft 2 Install the intake pipe with new gasket Tighten the fixing nuts to t...

Page 59: ...ue as follows Torque Fuel return pipe 37 N m 3 2 kgm 23 lbft Fuel pipe Fuel filter to Injection pump 39 N m 4 0 kgm 29 lbft Fuel pipe Feed pump to fuel filter 39 N m 4 0 kgm 29 lbft 6 Install the fuel...

Page 60: ...de Legend 1 Bolt 2 Washer 3 Rubber mount 4 Rubber mount 5 Guide tube 6 Fan guide 3 Loosen the fan pulley fixing bolts 4 Remove the fan belt Loosen the mounting bolt 2 and the sliding piece nut 1 Pivot...

Page 61: ...sen the fixing nuts and bolts from the water pump 8 Remove the water pump from the front plate 9 Discard the gaskets Legend 1 Adapter 2 Fan pulley 3 Water pump 4 Bypass hose 5 Water duct 6 Water duct...

Page 62: ...m 2 0 kgm 14 lbft 4 Install the water duct with new gasket to the oil cooler and water pump Tighten the bolts to the specified torque Torque 20 N m 2 0 kgm 14 lbft 5 Connect the bypass hose 6 Clamp t...

Page 63: ...the fixing bolts to the specified torque Torque 30 N m 3 1 kgm 22 lbft Legend 1 Bolt 2 Washer 3 Rubber mount 4 Rubber mount 5 Guide tube 6 Fan guide 12 Install the fan guard Tighten the fixing bolts...

Page 64: ...turning bolt 3 Depress the fan belt midway between the alternator and the water pump Belt Deflection 8 11 mm 0 31 0 43 in 5 Tighten the adjusting plate fixing bolts to the specified torque Torque 49...

Page 65: ...2 and 3 Legend 1 Fuel Pipe Feed Pump to filter 2 Fuel Pipe Filter to Injection Pump 3 Fuel Pipe Return 3 Remove the injection pipe NOTE Protect the joint openings of the injection pipe to prevent the...

Page 66: ...the oil return pipe 2 7 Loosen the coupling bolts 1 8 Remove the booster air pipe injection pump governor to intake cover 9 Loosen the injection pump fixing bolts 1 10 Remove the injection pump 11 Re...

Page 67: ...lign the injection timing mark on the timing advancer with the injection pump body pointer Install the injection pump to the injection pump bracket Use the locating dowel pin Tighten the injection pum...

Page 68: ...pipes Tighten the sleeve nuts to the specified torque Torque 29 N m 3 0 kgm 22 lbft 10 Install the fuel return pipe Tighten the bolts to the specified torque Torque 37 N m 3 8 kgm 27 lbft 11 Install t...

Page 69: ...the bearing case with new gasket to the cylinder block Apply Three Bond No 1208 or equivalent to the gasket This will hold the gasket in place during installation Install the gasket to the bearing ca...

Page 70: ...ecified torque Torque Bolt 1 73 N m 7 4 kgm 54 lbft Nut 2 73 N m 7 4 kgm 54 lbft Nut 3 4 40 N m 4 1 kgm 30 lbft 3 Install the injection pump Refer to Injection Pump Installation in this manual 4 Insta...

Page 71: ...cooler Clean the sealing surface of the block and remove sealant residue Installation 1 Install the oil cooler assembly with new gaskets to the cylinder block Clean the sealing surface of the oil coo...

Page 72: ...0 kgm 22 lbft 9 Install the fuel return pipe Tighten the bolts to the specified torque Torque 37 N m 3 8 kgm 27 lbft 10 Install the fuel pipe fuel filter to injection pump 11 Install the fuel pipe fue...

Page 73: ...6A 22 ENGINE MECHANICAL 1 041EY00015...

Page 74: ...CHANICAL 6A 23 Rocker Arm and Shaft Assembly Removal 3 2 1 6 4 5 7 8 011EY00060 Legend 1 Cylinder head cover 2 Gasket 3 Rocker arm assembly 4 Cam bearing cap 5 Bearing 6 Camshaft 7 Rubber plug 8 Cylin...

Page 75: ...en the rocker arm shaft bracket fixing bolts evenly from the outside to the inside NOTE Do not remove the rocker arm fixing bolts indicated by an arrow Installation 1 Apply engine oil to the bridge ca...

Page 76: ...uivalent to the rubber plug surfaces NOTE Immediately within ten 10 minutes of applying the sealant install the cylinder head cover to the cylinder head 5 Install the cylinder head cover with new gask...

Page 77: ...6A 26 ENGINE MECHANICAL 8 4 1 5 9 10 6 2 3 7 11 010EY00008...

Page 78: ...ENGINE MECHANICAL 6A 27 4 3 2 1 5 014EY00157 Disassembly Legend 1 Camshaft bracket 2 Rocker arm 3 Spring washer 4 Bracket 5 Rocker arm shaft...

Page 79: ...se 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 conditi...

Page 80: ...dard 0 01 0 056 mm 0 0004 0 0022 in Limit 0 2 mm 0 0079 in Rocker arm shaft and rocker arm clearance Standard 0 010 0 056 mm 0 0004 0 0022 in Limit 0 20 mm 0 008 in Check that the rocker arm and rocke...

Page 81: ...your fingers Measure the rocker arm protrusion again 6 Calculate the difference between the 2 protrusions roller out and roller in This is the roller and pin clearance If the clearance exceeds the li...

Page 82: ...y engine oil to the rocker arm shaft 2 Install the camshaft bracket to the rocker arm shaft 3 Temporarily tighten the camshaft bracket bolt 1 4 Install the rocker arm shaft bracket as shown in the ins...

Page 83: ...6A 32 ENGINE MECHANICAL Camshaft Removal 3 2 1 6 4 5 7 8 011EY00060 Legend 1 Cylinder head cover 2 Gasket 3 Rocker arm assembly 4 Cam bearing cap 5 Bearing 6 Camshaft 7 Rubber plug 8 Cylinder head...

Page 84: ...ion 6 Remove the camshaft with camshaft gear Installation 1 Install the camshaft with camshaft gear to the cylinder head 1 Align the crankshaft damper pulley TDC mark with the pointer by rotating the...

Page 85: ...ead toward the outside Torque 27 N m 2 8 kgm 20 lbft 3 Apply engine oil to the bridge cap 4 Install the rocker arm assembly Refer to Rocker Arm Assembly Installation in this manual 5 Adjust the valve...

Page 86: ...CAL 6A 35 4 Tighten the cylinder head cover bolts to the specified torque a little at a time in the numerical order shown in the illustration Torque 13 N m 1 3 kgm 9 4 lbft 010MX004 8 4 1 5 9 10 6 2 3...

Page 87: ...6A 36 ENGINE MECHANICAL Legend 1 Camshaft gear 2 Knock pin 3 Camshaft Disassembly 1 2 3 014EY00102...

Page 88: ...25 015 28 055 mm 1 103 1 105 in 2 Use a micrometer to measure each camshaft journal diameter in two directions 1 and 2 If the measured value is less than the specified limit the camshaft must be repla...

Page 89: ...40 037 mm 1 575 1 576 in If the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit the camshaft bearing must be replaced Camshaft bearing clearance Stan...

Page 90: ...3 Rubber plug 4 Leak off pipe 5 Injection nozzle bracket 6 Injection nozzle 7 Gasket 8 Glow plug connector 9 Glow plug 10 Rocker arm assembly 11 Bridge cap 12 Bridge 13 Camshaft 14 Cylinder head 15 He...

Page 91: ...Remove the bridge NOTE Keep the bridges in order for reassembly to their original positions 11 Remove the cylinder head Loosen the cylinder head bolts a little at a time in the numerical order shown i...

Page 92: ...head bolts M14 threads and setting faces Apply engine oil to the cylinder head bolts M10 Number 1 to 26 threads and setting faces Tighten the M14 cylinder head bolts in three steps using the angular...

Page 93: ...Installation in this manual 4 Install the camshaft bearing caps 5 Install the bridge caps 1 Apply engine oil to the bridge cap 2 Install the bridge cap to the bridge 6 Install the rocker arm assembly...

Page 94: ...he nozzle holder bolts The bolts will be finally tightened after injection pipe and leak off pipe installation 10 Adjust the valve clearance Refer to Valve Clearance Adjustment in this manual 11 Insta...

Page 95: ...ket 2 Install the new head cover gasket and collar to the head cover 3 Install the cylinder head cover to the cylinder head 4 Tighten the cylinder head cover bolts to the specified torque a little at...

Page 96: ...Bridge guide 4 Nozzle sleeve 5 Valve seat insert 6 Valve guide 7 Lower spring seat 8 Valve stem seal 9 Valve 10 Valve spring 11 Upper spring seat 12 Split collar 13 Idler gear C 14 Idler gear cover 15...

Page 97: ...gasket Discard the gasket 7 Remove the idle gear cover Tap the outside of the cover with a screwdriver 1 to deform one end of it and pull it free with pliers NOTE Do not scratch the sealing surfaces o...

Page 98: ...of the valve seat insert easier 3 Use a screwdriver to pry the valve seat insert free Take care not to damage the cylinder head 4 Carefully remove carbon built up and other foreign materials from the...

Page 99: ...0 008 in NOTE Do not attempt to regrind the cylinder head lower face Check the cylinder head lower face for cracking and other damage Valve Guide Valve Stem and Valve Guide Clearance Measuring method...

Page 100: ...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 and the valve guide...

Page 101: ...Valve Seat Insert Valve Thickness Measure the valve thickness If the measured value is less than the specified limit the valve and the valve guide must be replaced as a set Intake and Exhaust Valve T...

Page 102: ...d make removal of the valve seat insert easier 3 Use a screwdriver 3 to pry the valve seat insert free Take care not to damage the cylinder head 4 Valve Seat Insert Installation 1 Carefully place the...

Page 103: ...ce Angle Intake 30 degree Exhaust 45 degree NOTE Use an adjustable valve cutter pilot Do not allow the valve cutter pilot to wobble inside the valve guide Check that valve depression is within the spe...

Page 104: ...se 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 Spring Squareness Intake Standard 2 9 mm 0 11...

Page 105: ...ridge guide 4 Nozzle sleeve 5 Valve seat insert 6 Valve guide 7 Lower spring seat 8 Valve stem seal 9 Valve 10 Valve spring 11 Upper spring seat 12 Split collar 13 Idler gear C 14 Idler gear cover 15...

Page 106: ...rque Torque 48 N m 4 9 kgm 35 lbft 3 Install the bridge guides to the cylinder head 1 Apply engine oil to the valve bridge guide outer circumference 2 Attach the valve bridge guide installer 5 8840 26...

Page 107: ...of the cylinder head Keep the cylinder head raised so that the ball can escape from the bottom surface 5 Install the valve seat inserts into the cylinder head 1 Carefully place the attachment 1 havin...

Page 108: ...install the oil seal to the valve guide 9 Install the valves Apply engine oil to the intake valves and exhaust valves 10 Install the valve springs 1 Place the cylinder head on a flat wooden surface 2...

Page 109: ...Drive the sealing cup into position from the cylinder head side as shown in the illustration 15 Install the thermostats to the cylinder head 1 Install the thermostat gaskets 1 to the flange of thermos...

Page 110: ...ition the ring gaps 120 degrees apart from each other Note Be absolutely sure that the gaskets are correctly installed to the cylinder head An incorrectly installed gasket will result in engine damage...

Page 111: ...in the illustration Torque 15 N m 1 5 kg m 11 lbft 20 Install the intake pipe with new gasket to the intake cover Tighten the intake pipe bolts to the specified torque Torque 20 N m 2 0 kg m 14 lbft...

Page 112: ...ENGINE MECHANICAL 6A 61 011MX014...

Page 113: ...6A 62 ENGINE MECHANICAL Crank Pulley and Flywheel Removal 1 2 4 5 6 3 015EY00193 Legend 1 Crank pulley 2 Damper 3 Crankshaft 4 Ring gear 5 Flywheel 6 Washer...

Page 114: ...ankshaft damper pulley Use the locating dowel pin 4 Tighten the crankshaft damper pulley bolts to the specified torque a little at a time in the numerical order shown in the illustration Torque 200 N...

Page 115: ...ng gear must be replaced 2 Inspect the crankshaft damper for cracking or separation If any abnormality on the crankshaft damper is found inspect the crankshaft and the flywheel fixing bolts Reassembly...

Page 116: ...ENGINE MECHANICAL 6A 65 3 Install the damper to the crankshaft pulley Diagonally tighten the damper fixing bolts to the specified torque Torque 48 N m 4 9 kgm 35 lbft 015EY00074...

Page 117: ...2 7 5 8 4 3 6 13 14 12 1 020EY00004 Legend 1 Washer 2 Flywheel 3 Cover 4 Idler gear D 5 Idler gear shaft D 6 Flywheel housing 7 Oil seal 8 Slinger 9 Idler gear shaft A 10 Idler gear A 11 Thrust colla...

Page 118: ...mm 0 0027 0 0053 in Limit 0 20 mm 0 008 in 4 Remove the idler gear A shaft and thrust collar Inspect the idler gear for damage or wear Inspect the thrust collar for wear 5 Remove the oil pump from th...

Page 119: ...the 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 torqu...

Page 120: ...Torque 24 N m 2 4 kgm 17 lbft 4 Install the idler gear A and Idler gear shaft to the cylinder block 1 Install the idler gear shaft 1 to the cylinder body The idler gear shaft oil port must be facing...

Page 121: ...to the idler gear shaft 2 2 Apply engine oil to the idler gear 1 inside and thrust areas 3 Install the gear to the gear shaft 4 Install the gear and shaft to the cylinder block 5 Tighten the bolts ove...

Page 122: ...ENGINE MECHANICAL 6A 71 Flywheel Housing Removal 2 7 5 8 4 3 6 1 020EY00060 Legend 1 Washer 2 Flywheel 3 Cover 4 Idler gear D 5 Idler gear shaft D 6 Flywheel housing 7 Oil seal 8 Oil slinger...

Page 123: ...porting bolts 7 Loosen the flywheel housing fixing bolts to remove the flywheel housing 8 Remove the rear oil seal 9 Use the slinger remover 894396 8580 to remove the slinger Take care not to damage t...

Page 124: ...ameter and thrust portion of the idler gear D 3 Install the idler gear with the shaft and the thrust collar 4 Tighten the idler gear shaft bolts to the specified torque Torque 119 N m 12 1 kgm 88 lbft...

Page 125: ...ontact with the outside oil seal and felt ring 2 Insert the oil seal 1 into the adapter 2 3 Insert the oil seal sleeve 3 to the adapter 4 Tighten the center bolt until the sleeve comes into contact wi...

Page 126: ...eps Follow the numerical order shown in the illustration Torque 1st step 78 N m 8 0 kgm 58 lbft 2nd step 60 deg 3rd step 60 90 deg NOTE The flywheel housing bolts can be reused 6 times before replacem...

Page 127: ...6A 76 ENGINE MECHANICAL Oil Pan Removal 1 2 3 4 5 013EY00038 Legend 1 Clip 2 Oil pan 3 Gasket 4 Oil strainer 5 Gasket...

Page 128: ...new gasket Tighten the fixing bolts to the specified torque Torque M8 Bolt 24 N m 2 4 kgm 17 lbft M10 Bolt 48 N m 4 9 kgm 35 lbft 2 Apply a 3 mm bead of sealant Three Bond No 1207C or equivalent to t...

Page 129: ...6A 78 ENGINE MECHANICAL Front Cover Removal 5 4 3 7 1 2 6 8 015EY00177 Legend 1 Damper pulley 2 Oil seal 3 Adjusting plate 4 Front plate 5 Gasket 6 Slinger 7 Crankshaft 8 Crankcase...

Page 130: ...the front plate Use a screwdriver to pry the oil seal from the front plate Take care not to damage the oil seal fitting faces 7 Use the slinger remover 8 94396 858 0 to remove the slinger Discard the...

Page 131: ...o replace the slinger and oil seal as a set 4 Install the front oil seal to the front plate Use the oil seal installer kit 8 94396 856 0 to install the oil seal 1 Apply engine oil to the oil seal lip...

Page 132: ...tle at a time in the numerical order shown in the illustration Torque 200 N m 20 4 kgm 148 lbft 6 Install the water pump to the front plate Refer to Water Pump Installation in this manual 7 Install th...

Page 133: ...6A 82 ENGINE MECHANICAL Piston Removal 3 4 1 2 015EY00180 Legend 1 Bearing cap 2 Bolt 3 Bearings 4 Piston with connecting rod...

Page 134: ...der for reinstallation to their original positions Inspect the connecting rod bearings for damage and wear Installation 1 Install the piston with connecting rod 1 Clean the piston in solvent to remove...

Page 135: ...not bend or damage the oil jet 11 Apply molybdenum disulfide grease to the threads and setting faces of each connecting rod bolt 12 Install the connecting rod bearing cap 13 Align the bearing cap cyli...

Page 136: ...ENGINE MECHANICAL 6A 85 Disassembly 2 7 6 5 2 3 4 1 015EY00119 Legend 1 Piston rings 2 Snap ring 3 Piston pin 4 Piston 5 Connecting rod 6 Connecting rod cap 7 Bearings...

Page 137: ...ll result in reduced piston ring tension 4 Remove the snap ring 1 Use a pair of snap ring pliers to remove the snap rings 5 Remove the piston pin 6 Remove the piston 7 Remove the connecting rod Tap ou...

Page 138: ...ing grooves If a piston ring groove is damaged or distorted the piston must be replaced 2 Use a feeler gauge 1 to measure the clearance between the piston ring and the piston ring groove at several po...

Page 139: ...is less than the specified limit the piston pin must be replaced Piston pin diameter Standard 35 995 36 000 mm 1 4171 1 4173 in Limit 35 95 mm 1 4154 in Piston Pin Hole and Piston Pin Clearance Use a...

Page 140: ...arings 2 Install the bearing to the connecting rod and bearing cap 3 Apply a coat of molybdenum disulfide grease to the bearing cap bolt threads and setting faces 4 Prevent the connecting rod from mov...

Page 141: ...0 30 mm 0 0067 0 0118 in Limit 0 35 mm 0 0138 in Piston and Liner Bore Clearance If the cylinder liner has been replaced install the piston using service parts The cylinder liner bore and pistons hav...

Page 142: ...connecting rod in a vise Take care not to damage the connecting rod Install the piston so that the piston head front mark and the connecting rod front mark face the opposite direction Apply engine oil...

Page 143: ...ston skirts This will facilitate smooth break in when the engine is first started after reassembly Apply engine oil to the upper connecting rod bearing Apply engine oil to the cylinder wall Position t...

Page 144: ...linder number marks Install the connecting rod caps Apply molybdenum disulfide grease to the threads and setting faces of each connecting rod bolt Tighten the connecting rod bolts to the specified tor...

Page 145: ...1 2 10 12 13 9 8 7 11 015EY00184 Legend 1 Crank pulley 2 Oil seal 3 Adjusting plate 4 Front cover 5 Gasket 6 Piston with connecting rod 7 Connecting rod bearing 8 Thrust bearings 9 Thrust bearings 10...

Page 146: ...ecified limit the crankshaft thrust bearing must be replaced 9 Remove the crankcase 1 Loosen the crankcase bolts M14 14 pieces a little at a time in the numerical order shown in the illustration 2 Loo...

Page 147: ...bearings have an oil hole and oil groove The lower crankshaft bearings have only a partial oil groove 3 Install the upper bearings to their original position if they are reused CAUTION Do not apply e...

Page 148: ...ower crankcase to the cylinder block 1 Carefully wipe any foreign material from the lower bearing back and sliding faces 2 Install the lower bearings to their original position if they are reused 3 Ap...

Page 149: ...hown in the illustration Torque 37 N m 3 8 kgm 27 lbft CAUTION The lower crankcase and the cylinder block are machined as a single unit They can not be replaced separately Always replace the lower cra...

Page 150: ...aft Installation in this manual 16 Install the rocker arm assembly to the cylinder head Refer to Rocker Arm Assembly Installation in this manual 17 Adjust the valve clearance Refer to Valve Clearance...

Page 151: ...1 2 3 015EY00191 Legend 1 Crankshaft 2 Pin 3 Crankshaft gear 1 Use the crankshaft gear remover 8 94396 818 0 to remove the crankshaft gear NOTE Do not remove the crankshaft gear from the crankshaft u...

Page 152: ...l direction of engine rotation Read the dial indicator as you turn the crankshaft If the measured value exceeds the specified limit the crankshaft must be replaced Standard 0 06 mm 0 0024 in or less L...

Page 153: ...ankcase M14 bolts can be reused 6 times before replacement 5 Tighten the lower crankcase M10 bolts to the specified torque Torque 37 N m 3 8 kgm 27 lbft 6 Use an inside dial indicator to measure the c...

Page 154: ...t for 30 to 40 seconds If there is no discoloration after 30 or 40 seconds the crankshaft is usable If discoloration appears the surface being tested will become the color of copper the crankshaft mus...

Page 155: ...6A 104 ENGINE MECHANICAL Reassembly 1 2 3 015EY00191 Legend 1 Crankshaft 2 Pin 3 Crankshaft gear...

Page 156: ...t allow the temperature of the gas burner to exceed 180 C 356 F If the crankshaft gear is not heated it may break during installation 3 Use the crankshaft gear installer 8 94396 819 0 to install the c...

Page 157: ...6A 106 ENGINE MECHANICAL Cylinder Block Removal 3 2 5 1 4 012EY00012 Legend 1 Oil pressure switch 2 Crankcase 3 Oil jet 4 Cylinder liner 5 Cylinder block...

Page 158: ...block Refer to Timing Gear Installation in this manual 4 Install the bearing case to the cylinder block Refer to Bearing Case Installation in this manual 5 Install the flywheel housing to the cylinder...

Page 159: ...6A 108 ENGINE MECHANICAL Disassembly 3 2 5 1 4 012EY00012 Legend 1 Oil pressure switch 2 Crankcase 3 Oil jet 4 Cylinder liner 5 Cylinder block...

Page 160: ...4 in NOTE If the inside of the cylinder liner is scored or scratched the cylinder liner must be replaced The cylinder liner is loose fit type The cylinder liner can be removed with hands If the cylind...

Page 161: ...gine cooling efficiency will be adversely affected If the cylinder liner fitting interference is too large it will be difficult to insert the cylinder liner into the cylinder block A mark was stamped...

Page 162: ...kcase for cracking and damage If possible use dye penetrant flaw detector Oil Jet Check the oil port on the oil jet for clogging Cylinder Liner Projection Use a dial indicator or a straight edge and f...

Page 163: ...6A 112 ENGINE MECHANICAL Reassembly 3 2 5 1 4 012EY00012 Legend 1 Oil pressure switch 2 Crankcase 3 Oil jet 4 Cylinder liner 5 Cylinder block...

Page 164: ...r liner Install the cylinder liner to the cylinder block from the top of the cylinder block with your hand Check the cylinder liner projection NOTE 1 Do not apply excessuve force or strike the cylinde...

Page 165: ...oil pressure switch Install the adapter 1 to the cylinder block and tighten to the specified torque Install the oil pressure switch 2 Torque Adapter 118 N m 12 0 kgm 87 lbft Oil pressure switch 18 N m...

Page 166: ...new one the new fastener must be identical to the previous one Some fasteners must always be replaced with new ones following removal These fasteners are specified in this Manual Some fasteners requir...

Page 167: ...The water pump circulates the coolant through the radiator by pass directly back to the cylinder body coolant does not pass through the radiator This provides a rapid increase in coolant temperature...

Page 168: ...ENGINE COOLING 6B 3 Thermostat Disassembly 3 1 2 031EY00005 Legend 1 Water outlet pipe 2 Thermostats 3 Gaskets...

Page 169: ...e thermostat and the bottom of the container see illustration 5 Place a thermometer in the water 6 Heat the water Stir constantly to prevent direct heat application to the thermostat 7 Note the temper...

Page 170: ...ENGINE COOLING 6B 5 2 Install new gaskets 3 Install the water outlet pipe 4 Tighten the fixing bolts to the specified torque Torque 19 N m 1 9 kg 14 lbft 031EY00024...

Page 171: ...embly 10 11 13 15 9 8 7 6 5 4 3 2 1 16 14 12 030EY00026 Legend 1 Center 2 Dust cover 3 Snap ring 4 Bearing 5 Bearing 6 Spacer 7 Bearing 8 Washer 9 Shaft 10 Water pump body 11 Dowel pin 12 Seal unit 13...

Page 172: ...he seal unit Inspection and Repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is discovered during inspection Water pump impeller 1 Check the impeller for...

Page 173: ...ase plates 3 Install the washer 4 ball bearing 3 spacer 2 and bearings 1 4 Use a bench press to gradually press the water pump shaft down until the bearings are seated correctly 2 Install the water pu...

Page 174: ...out 4 Install the seal unit to the water pump body Press in the seal unit to the specified position using a bench press and installer 1 85220 047 0 Seal unit installation position A 11 0 11 6 mm 0 433...

Page 175: ...MEMO...

Page 176: ...ner is replaced with a new one the new fastener must be identical to the previous one Some fasteners must always be replaced with new ones following removal These fasteners are specified in this Manua...

Page 177: ...rs fuel at high pressure through the delivery valves to the individual fuel injectors at precise intervals The pressure generated by the fuel in the fuel injector forces open a needle valve Fuel is in...

Page 178: ...at exact intervals to provide efficient engine operation Water sedimentor The water sedimentor has a clear plastic body There is a warning line on the body When the water level reaches the warning li...

Page 179: ...ng Together the plungers create a reciprocal motion Fuel enters the plunger barrel through the inlet port when the plunger is at the bottom of its stroke Excess fuel leaves the plunger barrel through...

Page 180: ...ENGINE FUEL 6C 5 Fuel Filter Disassembly 2 3 1 Legend 1 Fuel filter 2 Overflow valve 3 Fuel filter body...

Page 181: ...ck the overflow valve for restrictions and or leakage Overflow valve opening pressure 230 260 kPa 33 38 psi Reassembly 1 Install the overflow valve to the fuel filter body 2 Install the fuel filter Be...

Page 182: ...y 11 8 10 9 7 5 3 2 1 4 6 15 14 13 12 040EY00026 Legend 1 Retaining nut 2 Nozzle 3 Pin 4 Spacer 5 Pin 6 Lift piece 7 Spring seat 8 Push rod 9 Adjusting shim 10 2nd spring 11 Collar 12 Spring seat 13 1...

Page 183: ...nd spring seat 7 Remove the push rod adjusting shim 1st spring and collar 1st opening pressure control 8 Remove the spring seat 2nd spring and adjusting shim 2nd opening pressure control 9 Clean the p...

Page 184: ...djustment retaining nut together with the gasket to the nozzle holder Retaining nut 157892 4000 ZEXEL Gasket 157892 1500 ZEXEL 8 Tighten the adjustment retaining nut 1 to the specified torque Torque 2...

Page 185: ...nozzle opening pressure adjusting shims Part No ZEXEL Thickness mm 150590 0600 0 40 150590 0700 0 50 150590 0800 0 52 150590 0900 0 54 150590 1000 0 56 150590 1100 0 58 150590 1200 0 60 150590 1300 0...

Page 186: ...EL 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 ov...

Page 187: ...d whether the nozzle assembly is in good condition 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...

Page 188: ...ice kit ZEXEL 105019 2200 Service kit ISUZU 894392 1450 Second nozzle opening pressure confirmation 1 After pre lift confirmation operate the nozzle tester to increase in line pressure to 34 3 44 1 MP...

Page 189: ...t adjusts the opening pressure to the specified level CAUTION The 2nd opening pressure changes when 1st opening pressure changes Therefore 2nd opening pressure adjustment is always required when the 1...

Page 190: ...l retaining nut 4 Check that the pins are fully inserted into the nozzle 5 Hand tighten the retaining nut 6 Tighten the retaining nut to the specified torque Torque 59 79 N m 6 8 kgm 43 58 lbft 7 Set...

Page 191: ...FUEL CAUTION The nozzle lift piece pins and spacers must be replaced as a set nozzle service kit If only the nozzle is replaced pre lift specifications will not be applicable Nozzle tester Nozzle hol...

Page 192: ...efer to the following page If the applicable calibration data is not listed in this Manual contact the manufacturer s nearest authorized service facility Bosch Automotive System Corporation or Robert...

Page 193: ...ckwise viewed from the drive side Overflow valve opening pressure 255 kPa 2 6 kg cm2 37 0 psi Pre stroke 2 9 0 03 mm 0 114 0 001 in Injection order 1 5 3 6 2 4 Plungers are numbered from the drive sid...

Page 194: ...Assembly Number Injection Volume Control rack position mm 12 8 6 8 Pump speed min 1 1000 500 Injection volume mm3 1 000 strokes 133 5 1 9 5 3 2 Variance 3 15 Boost pressure kPa More than 160 Remarks B...

Page 195: ...RING SET BOOST COMPENSATOR STROKE 0 7 0 1mm 12 8 11 2 9 4 6 8 6 4 5 1 12 0 0 1 6 7 0 3 BOOST COMPENSATOR ADJUSTING SPEED 550min 1 11 2 RACK POSITION mm RACK POSITION mm BOOST PRESSURE kPa 10 5 0 48 0...

Page 196: ...d fastener is replaced with a new one the new fastener must be identical to the previous one Some fasteners must always be replaced with new ones following removal These fasteners are specified in thi...

Page 197: ...3 negative in conjunction with 2 sub diodes provide 3 phase rectification The diodes are installed to the stator coil An additional 3 diodes diode trio are used to provide field current The alternato...

Page 198: ...bles and accompanying charts in this Manual when requesting service assistance from a qualified electrical repair shop If you are unable to locate the data applicable to your engine please contact ISU...

Page 199: ...ge V 24 Rated output A 50 Rated speed min 1 5000 Rated output Amp Volt min 1 50 27 5000 No load output at 0 Amp Volt min 1 24 900 Direction of rotation as viewed Clockwise from pulley side Ground pola...

Page 200: ...ING AND CHARGING 6D3 5 Disassembly 2 3 4 5 6 7 8 9 1 060EY00004 1 IC regulator 2 Terminal stud 3 Side entry terminal Terminal B 4 Rectifier assembly 5 Cap 6 Nut 7 Side entry terminal 8 Terminal stud 9...

Page 201: ...Step 6 is performed before Step 5 terminal damage will result 9 Remove the cap and nut from the rectifier terminal stud 10 Use a screwdriver to pry the rear bracket and the side entry terminal apart...

Page 202: ...xcessive replace the rotor NOTE It is recommended that inspection be made with the bearing fitted to the rotor shaft Coil Assembly Coil Use an ohmmeter to measure the coil resistance between both term...

Page 203: ...ws 3 6 N m 0 37 kgm 2 7 lbft Rectifier retaining screws 3 6 N m 0 37 kgm 2 7 lbft Regulator retaining screws 3 4 N m 0 35 kgm 2 5 lbft Nuts for stud bolts 8 8 N m 0 9 kgm 6 5 lbft Bench testing Perfor...

Page 204: ...Adjust the load resistor for maximum current output 7 Allow the alternator to run for 15 minutes Output should increase as alternator temperature increases 8 Once again adjust the load resistor for m...

Page 205: ...ive regulator Replace Defective battery Replace Poor terminal contact Repair Overcharging Defective regulator Replace Defective battery Replace Unstable current Poor terminal contact Repair Loose cool...

Page 206: ...STARTING AND CHARGING 6D3 11 Starter Motor General Description 060EY00009 The starter motor has a reduction gear assembly that uses planetary gears...

Page 207: ...A 85 Starter motor minimum operating speed min 1 3300 No load Pinion gear Modules 3 Number of teeth 11 Outside diameter mm in 48 9 1 93 Yoke outside diameter mm in 85 3 35 Brush length Standard mm in...

Page 208: ...ion 1 Manufacturer s type 2 Isuzu part number 3 Bar code NOTE Always check the identification number before beginning a service operation Applicable service data will vary according to the identificat...

Page 209: ...d 1 Snap ring 2 Stop ring 3 Pinion 4 Pinion spring 5 Screw 6 Pinion case 7 Lever 8 Magnetic switch 9 Clutch 10 Internal gear 11 Washer 12 E type stop ring 13 Gear shaft 14 Planetary gear 15 Ball 16 Ga...

Page 210: ...and the through bolt 9 Remove the rear bracket and gasket 10 Discard the gasket 11 Use a socket wrench with a 32 mm diameter to hold the armature commutator in place Remove the yoke assembly 12 Slide...

Page 211: ...utator segment Hold the other probe against the armature shaft If there is continuity the armature is grounded It must be replaced 3 Measure the commutator outside diameter 4 If the measured diameter...

Page 212: ...easure the brush length If the brush length is less than the specified limit the brush and or yoke must be replaced Brush length Standard 18mm 0 72 in Limit 11 mm 0 44 in 2 Check the brush spring for...

Page 213: ...mage Replace if required Magnetic Switch 1 Use a circuit tester to check for continuity between the magnetic switch terminal M 1 and the body 2 If there is no continuity the switch must be replaced 2...

Page 214: ...7 lbft Bolt 2 6 8 N m 0 7 kgm 5 1 lbft Bolt 3 9 8 N m 1 0 kgm 7 2 lbft Bolt 4 3 4 N m 0 35 kgm 2 5 lbft Armature shaft axial play Install the ball to the top of the armature shaft No adjustment is req...

Page 215: ...ring 4 to the clutch shaft 2 3 Install the snap ring 3 4 Attach the stop ring to the snap ring Pinion projection 1 Connect the starter motor to the battery 2 Turn switch 1 and switch 2 on The pinion m...

Page 216: ...gend 1 Battery 2 Ammeter 3 Voltmeter 2 Turn the switch on 3 Measure the starter motor speed the current and the voltage If the starter motor speed is less than the specified value the starter motor re...

Page 217: ...MEMO...

Page 218: ...e the correct fastener in the proper location If a used fastener is replaced with a new one the new fastener must be identical to the previous one Some fasteners must always be replaced with new ones...

Page 219: ...ovide the most effective lubrication and cooling Oil Pump and Oil Filter The gear type oil pump is driven by the timing gear The pump is equipped with a relief valve The full flow oil filter uses a hi...

Page 220: ...aft Bearing Idler Gear B Connecting Rod Bearing Idler Gear B 5 4 1 2 Starter Switch Battery Oil Filter Main Oil Gallery 1 Relief Valve Opening Pressure 780 kPa 2 Bypass Valve Opening Pressure Separate...

Page 221: ...6G 4 ENGINE LUBRICATION Oil Pump Oil Pump Construction 2 1 3 4 6 5 051EY00035 Legend 1 Oil pump drive gear 2 Oil pump body 3 Oil relief valve 4 Cotter pin 5 Drive gear 6 Driven gear and shaft...

Page 222: ...airs and part replacements if excessive wear of damage is discovered during inspection 1 Use a feeler gauge to measure the clearance between the gear teeth and the body inner wall If the clearance bet...

Page 223: ...Outside Diameter Standard 15 989 16 000 mm 0 6295 0 6299 in Limit 15 9 mm 0 626 in 4 Use an inside dial indicator or inside micrometer to measure the pump body inside diameter and the cylinder block...

Page 224: ...the drive gear and 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 th...

Page 225: ...6G 8 ENGINE LUBRICATION Oil Cooler Disassembly 5 6 4 3 7 2 1 050EY00013 Legend 1 Oil cooler element 2 Gasket 3 Gasket 4 Body 5 Plug 6 Oil thermostat 7 Bypass pipe...

Page 226: ...all cleaning solution has been forced from the element WARNING Compressed air can cause personal injury when used protective for cleaning Wear safety glasses and protective clothing NOTE As long as t...

Page 227: ...6G 10 ENGINE LUBRICATION 4 Install the oil cooler element with new gasket to the body 5 Tighten the element fixing nuts to the specified torque Torque 20 N m 2 0 kgm 14 lbft 050EY00016...

Page 228: ...ENGINE LUBRICATION 6G 11 Oil Port Cover 7 6 5 3 4 1 2 050EY00060 Legend 1 Oil port cover 2 Gasket 3 Oil relief valve 4 Gasket 5 Plug 6 Gasket 7 Port cover...

Page 229: ...ions 3 Remove all sludge and restrictions from the port cover Installation 1 Install the plugs with new gasket to the port cover Tighten the plug to the specified torque Torque 25 N m 2 6 kgm 19 lbft...

Page 230: ...ENGINE LUBRICATION 6G 13 Oil Filter 5 1 4 3 2 5 050EY00046 Legend 1 Oil filter 2 By pass valve 3 Gasket 4 Oil filter body 5 Gaskets...

Page 231: ...e orifice of the partial oil filter for restriction Supply compression air to the orifice indicated by a arrow Confirm that air blows out from the holes of the oil filter installation joint Reassembly...

Page 232: ...ter to the oil filter body Apply engine oil to the oil filter gasket Turn the oil filter until the filter gasket comes in contact with its sealed face Use a filter wrench to turn in the oil filter an...

Page 233: ...MEMO...

Page 234: ...l to the previous one Some fasteners must always be replaced with new ones following removal These fasteners are specified in this Manual Some fasteners require thread locker or thread sealant These f...

Page 235: ...ter housing and include the turbine shaft the compressor wheel the shaft bearings the thrust bearings and the oil seal ring Turbocharger rotating parts operate at very high speeds and temperatures The...

Page 236: ...t or removed from the equipment but not disassembled to determine whether or not turbocharger repair or overhaul is required Visual checks Clearance measurements End play measurements Refer to INSPECT...

Page 237: ...ure Abnormal Noise Description Cause Countermeasure Turbine housing gas inlet and outlet tightening area Turbine and bearing housing mating surfaces Turbocharger oil inlet tightening area Compressor h...

Page 238: ...s or blades Compressor housing Oil feed pipe Oil on air inlet inside and outside surfaces resulting from oil leakage Loose or missing Foreign particles in turbocharger Bearing abrasion Trouble in the...

Page 239: ...g as shown in the illustration 2 Move the shaft back and forth to measure the rotor shaft axial play Note the total indicator reading TIR Rotor shaft axial play Standard 0 06 0 09 mm 0 0024 0 0035 in...

Page 240: ...4997 0408 FAX 86 1 505 4350 TLX 210343 IHIPK CN TAIWAN IHI TAIPEI OFFICE Room 1202 Chia Hsin Building No 96 Chung Shan North Road Section 2 Taipei TAIWAN TEL 886 3 542 5520 5521 5523 FAX 886 2 542 436...

Page 241: ...MEMO...

Page 242: ...ten consent of ISUZU MOTORS LIMITED WORKSHOP MANUAL INDUSTRIAL INDUSTRIAL DIESEL ENGINE AA 6HK1T BB 6HK1T IDE 2394 Issued by ISUZU MOTORS LIMITED POWERTRAIN SERVICE PARTS DEPARTMENT POWERTRAIN SALES D...

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