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Mitsubishi 6M60-TL, Service Manual

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Mitsubishi 6M60-TL Service Manual Download Page 165

13E

13E-7

CAUTION

• Be sure to connect the SCV (suction control valve) connector to the engine harness before starting the

engine. If the engine is started with the SCV (suction control valve) connector not connected, control of
the supply pump by the engine electronic control unit would not be possible and a fault would ensue.

• The supply pump pressurizes fuel and supplies it in a highly pressurized state.
• Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers. It is supplied first to the

common rail pressure solenoid valve, which controls the amount of fuel reaching the plungers.

• If the fuel pressure exceeds a certain level, the regulating valve returns fuel to the inlet side of the feed pump. This

operation keeps the pressure of the fuel fed to SVC (suction control valve), constant.

• Rotation of the camshaft causes (via the ring cam) up-down movement of the plungers. Fuel in the plunger cham-

bers is thus highly pressurized.

(1) SCV (suction control valve)

•

The SCV (suction control valve) receives fuel from the feed
pump and feeds fuel toward the plungers of the supply pump in
such a quantity that the fuel pressure corresponds to that re-
quired by the engine electronic control unit.

•

When the SCV (suction control valve) is not operating, i.e., when
current is not flowing, fuel flows at its maximum rate. When cur-
rent flows, the piston in the common rail pressure solenoid valve
is pressed down such that fuel is not fed toward the plungers.

•

The engine electronic control unit controls the ratio of current-off
time (duty ratio).

Summary of Contents for 6M60-TL

Page 1: ...Service Manual 99709 51100 For use with the FD80N FD160N Service Manuals 6M60 TL Diesel Engine ...

Page 2: ......

Page 3: ...eries diesel engine and includes procedures for adjustment and maintenance services We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage For more details please consult your nearest authorized Mitsubishi forklift truck dealer Kindly note that the specifications and maintenance ser vice figures are subject to change without pr...

Page 4: ... NUMBER 00 7 PRECAUTIONS FOR MAINTENANCE OPERATION 00 8 DIAGNOSTIC CODES 1 Using Multi Use Tester 00 17 2 Use of Blinking Warning Lamp for Diagnostic Code 00 19 3 Up Time Service Tool Functions 00 21 4 Troubleshooting 00 29 TABLE OF STANDARD TIGHTENING TORQUES 00 31 ...

Page 5: ...dings which identify the nature of the instructions and information Terms and Units Front and rear The forward running direction of the machine is referred to as the front and the reverse running direction is re ferred to as the rear Left and right Left hand side and right hand side when facing the forward running direction of the machine are respectively left and right Standard value Standard val...

Page 6: ...ure Positive pressure kPa kgf cm2 98 0665 kPa 1 kgf cm2 Vacuum pressure kPa mmHg 0 133322 kPa 1 mmHg Pa mmH2O 9 80665 Pa 1 mmH2O Volume dm3 L 1 dm3 1 L Heat quantity J kcal 4186 05 J 1 kcal Heat flow W kcal h 1 16279 W 1 kcal h Power kW PS 0 7355 kW 1 PS Angle Temperature C Electric current A Voltage V Resistance Ω Electric power W Unit SI unit Foot pound unit Conversion rate Force N Newton lbf 1 ...

Page 7: ...pin Parts to be positioned for installation Non reusable parts Parts not to be reused Lubricant and or sealant Parts to be coated with lubricant or sealant for assembly or installation Necessary lubricant and or sealant quantity re quired etc are specified in table Special tool Parts for which special tools are required for service operation Tool name shape and part number are shown in table a Ass...

Page 8: ...00 00 5 ...

Page 9: ... 574 MPROP1 rail pressure control valve 08 This section suggests areas to inspect for each diagnostic code TROUBLESHOOTING 1 Diagnostic Procedure 2 Diagnostic Precautions 3 Inspections Based On Diagnostic Codes 4 Multi use Tester Service Data 5 Actuator Tests Performed Using Multi use Tester 6 Inspections Performed At Electronic Control Unit Connectors There are the diagnostic code and message dis...

Page 10: ...igned to the engines in manufac turing sequence Every engine has its own number These num bers are required for registration and related inspection of the vehicle An engine nameplate indicates the following item Engine model ENGINE NUMBER ...

Page 11: ...mpt to use other tools since they could cause injuries and or truck damage Take extreme care when removing installing heavy items such as engine transmission and axle When lifting heavy items using a cable etc observe the following precautions Identify the weight of the item being lifted Use a cable that is strong enough to support the weight If lifting eyes are not provided on the item being lift...

Page 12: ...on them before disassembly and arrange disassembled parts neatly Make punch marks and other alignment marks where they will not detract from parts functionality and appearance After removing parts from the vehicle cover the area to keep it free of dust CAUTION Be careful not to mix up identical parts similar parts and parts that have left right alignments Keep new replacement parts and original re...

Page 13: ...aged Carefully handle sensors relays and other items that are sensi tive to shock and heat Do not remove or paint the cover of any control unit When separating connectors grasp the connectors themselves rather than the harnesses To separate locking connectors first push them in the direction of the arrows To reconnect locking connectors push them to gether until they click Before washing the vehic...

Page 14: ... B of the circuit to be inspected Perform the inspec tion by applying a test probe C to the connectors of the inspec tion harness Do not insert the test probe C into the wire entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust 1 2 Non waterproof connectors Perform the inspection by inserting a test probe C into the wire entry sides of the connec...

Page 15: ...use damage to the control unit s internal circuit ry When using a multimeter to check continuity do not allow the test probes to touch the wrong terminals 1 2 Inspection of connectors 1 Visual inspection Check that the connectors are fitted together securely Check whether wires have been separated from their terminals due to pulling of the harness Check that male and female terminals fit together ...

Page 16: ...he fuse If the resistance measurement between any switch and ground is ze ro there is a short circuit between the switch and the load If the resistance measurement is not zero the circuit is not currently short circuited the fuse probably blew due to a momentary short circuit The main causes of short circuits are as follows Harnesses trapped between chassis parts Harness insulation damage due to f...

Page 17: ...er could damage the diodes and regulator Keep alternators dry Water on alternators can cause internal short circuits and dam age Never operate an alternator with the B and L terminals short cir cuited Operation with the B and L terminals connected together would damage the diode trio Disconnect the battery cables before quick charging the battery with a quick charger Unless the battery cables are ...

Page 18: ... the conditions under which the fault occurs determine whether the fault is caused by vibration heat or other factors if vibration is a possible factor see if the fault can be re produced by performing the following checks on individual con nectors and other parts Gently move connectors up and down and to left and right Gently move wiring harnesses up and down and to left and right Gently wiggle s...

Page 19: ...of the welder will flow backward through the bat tery s cable and damage the battery and electrical systems directly connected to the battery Be sure to disconnect the bat tery s cable in the following procedure Turn the battery switch to the LOCK position Turn the starter switch to the LOCK position Disconnect the battery s cable Cover all parts of the machine that may be damaged by welding spark...

Page 20: ... illustrated Connect the Multi Use Tester connector on the vehicle with the connector of Mark Tool name and shape Part No Application PC FMSi E06 1 Multi Use Tester III ver sion Data transmission to from V C I V C I N A Data transmission between electronic control unit and PC MH062928 Power supply to V C I and communi cation with electronic control unit Multi Use Tester har ness A Multi Use Tester...

Page 21: ...nic control unit With the machine restored to its normal condition or the starter switch turned from OFF to ON after inspection or repair against present diagnostic codes the present diagnostic code is stored as past diagnostic codes in the memory of the electronic control unit The warning lamp is not lit because the indicated fault is not present one 2 Access of diagnostic code Set the starter sw...

Page 22: ...d digit only the first digit will be displayed The same diagnostic code will be displayed 3 times in a row be fore moving to the display of the next code After the last diagnostic code is displayed the first code will be displayed again 3 times in a row and then the subsequent codes This will be repeated 2 2 Present diagnostic codes Turn the starter switch ON Remove the diagnostic switch Diagnosti...

Page 23: ...en gine Open the memory clear switch and reconnect it all diagnostic codes stored in electronic control unit memory will be erased To erase diagnostic code after opening the memory clear switch turn the starter switch to the OFF position and then reconnect the memory clear switch DIAGNOSTIC CODES ...

Page 24: ...e fault data such as the error codes and hour meter data stored in the controller Tool menu Set up Option Indicates or sets the Setup Option data Oscilloscope Graphs the input output values The oscillograph can be stored as data Active Test Outputs the signal forcibly to check the operation of the equipment selected Connection Change Designates the controller operated by the service tool and the c...

Page 25: ...nput Monitor and Output Monitor These screens indicate the input and output values of each controller 3 2 1 VCM 3 input monitor and output monitor VCM 3 VCM 3 212339 InputUnit TABLE OF STANDARD TIGHTENING TORQUES ...

Page 26: ...00 00 23 212340 OutputUnit V OutputUnit OutputUnit ...

Page 27: ...00 24 3 2 2 VCM 3OP input monitor and output monitor VCM 3 VCM 3OP 212341 ...

Page 28: ...00 00 25 3 2 3 MP input monitor VCM 3 MP 212342 ...

Page 29: ...00 26 3 2 4 ECU input monitor and output monitor VCM 3 ECU Accel pedal position unfiltered Accel pedal position filtered Reference injection quantity 212343 ...

Page 30: ...00 00 27 3 3 Fault Status This screen indicates all error codes occurring 212344 OutputUnit Communication error InputUnit Communication error ...

Page 31: ...ontroller 212345 OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error ...

Page 32: ...4 Turn on the truck power 5 Start the service tool software 4 1 3 Diagnostic Precautions 1 Before measuring voltage check the battery for charged condition and specific gravity If system inspection is performed with the battery uncharged or reduced in specific gravity accurate measure ments cannot be achieved 2 To avoid having electrical parts damaged set the starter switch to OFF before disconnec...

Page 33: ...you have to do is just give a strong spray to wash off grime No need to wipe off the sprayed liquid 2 After checking the connector for continuity wash it as shown Then uncouple the connector and spray the contact surface activator onto contact surfaces Install and remove the connector several times to wet the surfaces thoroughly with the activator liquid After coupling up the connector check to be...

Page 34: ...150 11 to 15 100 to 140 11 to 14 130 to 170 13 to 17 120 to 160 12 to 16 M16 90 to 120 9 to 12 90 to 110 9 to 11 170 to 220 17 to 23 160 to 210 16 to 21 200 to 260 20 to 27 190 to 240 19 to 25 M18 130 to 170 14 to 18 120 to 150 12 to 16 250 to 330 25 to 33 220 to 290 23 to 30 290 to 380 30 to 39 250 to 340 26 to 35 M20 180 to 240 19 to 25 170 to 220 17 to 22 340 to 460 35 to 47 310 to 410 32 to 42...

Page 35: ... 8 0 55 to 75 5 5 to 7 5 110 to 150 11 to 15 100 to 140 11 to 14 M16 90 to 120 9 to 12 90 to 110 9 to 11 170 to 220 17 to 23 160 to 210 16 to 21 M18 130 to 170 14 to 18 120 to 150 12 to 16 250 to 330 25 to 33 220 to 290 23 to 30 M20 180 to 240 19 to 25 170 to 220 17 to 22 340 to 460 35 to 47 310 to 410 32 to 42 M22 250 to 330 25 to 33 230 to 300 23 to 30 460 to 620 47 to 63 420 to 560 43 to 57 M24...

Page 36: ...pe Unit N m kgf m Pipe diameter φ4 76 mm φ6 35 mm φ8 mm φ10 mm φ12 mm φ15 mm Tightening torque 17 1 7 25 2 6 39 4 0 59 6 0 88 9 0 98 10 Nominal diameter wall thickness 6 1 mm 10 1 25 mm 12 1 5 mm 15 1 5 mm Tightening torque 20 2 0 34 3 5 49 5 0 54 5 5 Nominal diameter 1 4 in 3 8 in 1 2 in 5 8 in Tightening torque 13 1 3 29 3 0 49 5 0 64 6 5 6 0 0 6 0 10 0 1 0 0 10 0 1 0 0 5 0 0 5 0 4 0 0 4 0 5 0 0...

Page 37: ...Rod 11 5 5 Piston 11 5 6 Timing Gears 11 6 7 Flywheel 11 7 TROUBLESHOOTING 11 8 GENERAL INSPECTION AND ADJUSTMENT 1 Measuring Compression Pressure 11 10 2 Inspection and Adjustment of Valve Clearances 11 14 ROCKER COVER ROCKER BRACKET AND CAMSHAFT 11 16 CYLINDER HEAD AND VALVE MECHANISM 11 24 PISTON AND CONNECTING ROD CYLINDER LINER 11 40 FLYWHEEL 11 54 TIMING GEARS 11 62 CRANKSHAFT AND CRANKCASE ...

Page 38: ...er Direct injection type Valve mechanism Overhead camshaft OHC system Maximum output kW PS rpm 110 150 2100 129 175 2100 145 195 2600 200 270 2600 Maximum torque N m kgf m rpm 610 62 1600 700 71 1600 740 75 1400 785 80 1400 Bore stroke mm φ118 115 Total displacement cm3 L 7545 7 545 Compression ratio 17 5 SPECIFICATIONS ...

Page 39: ...11 11 3 1 Engine Proper The 6M60 TL engine employs an overhead camshaft OHC system with the valve mechanism and the timing gears arranged as shown above STRUCTURE AND OPERATION ...

Page 40: ... rocker case and brackets have been machined together meaning that they all need to be replaced with a new set when one of them becomes defective 3 Valve Mechanism Each valve has a valve stem seal which regulates the flow of lubricating oil to the contact surface between the valve and the valve guide The valve springs have a variable pitch to prevent abnormal vibration at high engine speed The exh...

Page 41: ...on the cylinder liner and the crankcase bore all must have the same size marks to ensure a good fit between them The pistons are made of special alumi num alloy and are provided with a re cess on each end of the piston pin boss to reduce weight ...

Page 42: ...ts of the sub gear A the sub gear B and the main gear A spring is installed between the sub gear A and the main gear as well as between the sub gear B and the main gear The springs are locked in place with pins The sub gears are installed as follows The sub gear A has been turned in such a way as to compress the spring before meshing with the camshaft gear Likewise the sub gear B has been turned t...

Page 43: ...o 2 idler gears Without the non backlash mechanism the backlash changes between zero and the maximum generating gear rattle noise With the non backlash mechanism equipped on the engine the sub gears A and B maintain the backlash to zero even when the engine hunts eliminat ing gear rattle during idling 7 Flywheel ...

Page 44: ...groove s O O Worn damaged piston ring s O O Worn piston pin and connecting rod small end O Crankshaft Excessive end play in crankshaft O Incorrectly fitted crankshaft pulley O Worn damaged crankshaft pins and connecting rod bear ings O Worn damaged crankshaft journals and main bearings O Fuel system Supply pump faulty O O Gr13E Defective injector O O Air trapped in fuel system O Gr13A Cooling syst...

Page 45: ...M E M O 11 9 11 ...

Page 46: ... C Turn off the lights and auxiliaries Place the lever in neutral Remove the fuse for fuel cut to prevent fuel from being injected while the engine is cranked using the starter CAUTION When cranking the engine never shut off the power sup plied to the engine electronic control unit by disconnecting the engine electronic control unit connector or other similar methods If the engine is cranked with ...

Page 47: ...oles Then connect a compression gauge to Crank the engine and measure the compression pressure Measure the compression pressure for all the cylinders one after another Determine the compression pressure difference be tween the cylinders If the compression pressure is below the limit or the cylinder to cylinder pressure differences is not within the limit pour a small amount of engine oil into the ...

Page 48: ...by the valve clearance amounts has its piston at TDC Rotate the engine by one full turn to switch the TDCs of the No 1 and No 6 cylinder pistons With the No 1 or No 6 cylinder piston at TDC measure the clearance of the valves clearance between valve bridge and pad marked with a circle in the table below Location Maintenance item Standard value Limit Remedy Valve clearance when cold 0 6 Adjust Mark...

Page 49: ...g a flat head screwdriver or other similar tool This will create space necessary for the gauge to be inserted The measurement is correct when the feeler gauge feels slightly resisted as it is inserted The measurement is not yet correct if the feeler gauge can still be inserted smoothly If the measurement deviates from the standard value adjust as follows Adjustment Loosen the lock nuts and adjusti...

Page 50: ...omise the parallelism of the valve bridge damaging the valve mechanism Screw in or out the adjusting screw on the rocker arm until the correct feeler gauge can be inserted with a slight resistance While holding the adjusting screw in this position with a screw driver tighten the lock nut to the specified torque using Recheck the valve clearance using the correct feeler gauge Installation Install t...

Page 51: ...M E M O 11 15 11 ...

Page 52: ...11 16 ROCKER COVER ROCKER BRACKET AND CAMSHAFT ...

Page 53: ...y 0 05 to 0 20 0 4 Inspect 11 b Backlash between camshaft gear and No 3 idler gear 0 18 to 0 26 0 35 Replace Mark Parts to be tightened Tightening torque Remarks Bolt rocker cover mounting 8 8 0 9 Mark Points of application Specified lubricant and or sealant Quantity Rubber portion of oil filler cap Engine oil As required Camshaft journal supports on rocker and bracket assem bly Camshaft journals ...

Page 54: ...al Camshaft Remove the plug at the rear end of the cylinder head Insert a sub gear locking bolt M8 1 25 mm length 20 mm into the dedicated hole in the No 3 idler gear to lock the sub gears Remove the camshaft Installation procedure Installation Rocker case Tighten the rocker case bolts in the order shown in the illustra tion Installation Camshaft Make sure that the timing marks on the timing gears...

Page 55: ...or one hour after installation When removing the rocker cover after installation never fail to apply sealant again Installation Rocker case upper gasket Make sure that the gasket fitting groove in the rocker case is clear of grease and dirt Clean if necessary Before installation make sure that the gasket is free of grease etc that could cause an oil leakage Installation Rocker cover gasket Make su...

Page 56: ...combinations of its parts as before Assembly sequence Follow the disassembly sequence in reverse Service standards Unit mm Tightening torque Unit N m kgf m Lubricant and or sealant Special tools Unit mm Location Maintenance item Standard value Limit Remedy 3 7 15 Clearance between rocker shaft and bushing 0 006 to 0 076 0 114 Replace 4 8 Radial clearance of rocker roller 0 035 to 0 078 Replace Mar...

Page 57: ...pection Clearance between rocker shaft and bushing If the measurement exceeds the limit replace the bushing Replace of rocker bushing Removal Installation Assemble the bushing onto the rocker such that the oil holes are aligned as shown in the illustration After assembly recheck the clearance If the measurement is less than the standard value ream the bushing ...

Page 58: ...ot attempt to remove the camshaft gear with a hammer as damage will result Use a press or other similar tool Location Maintenance item Standard value Limit Remedy 1 3 Interference between camshaft gear and camshaft 0 017 to 0 062 Replace 3 Camshaft Cam lift Intake 5 023 4 973 Replace Lobe diame ter 45 110 Base circle diameter 40 087 Exhaust 7 084 7 034 Lobe diame ter 47 370 Base circle diameter 40...

Page 59: ...amshaft is ro tated by a full turn represents the bend of the camshaft If the measurement exceeds the limit replace the camshaft 3 Oil clearance at journal If the measurement exceeds the limit replace the defective part s CAUTION The rocker case and the brackets of the rocker and bracket assembly have been machined together which means that they all must be replaced together Installation procedure...

Page 60: ...11 24 CYLINDER HEAD AND VALVE MECHANISM ...

Page 61: ...8 3 4 to 3 9 Cylinder head bolt 78 8 90 90 Wet Reusable up to 3 times Plug 13 to 17 1 3 to 1 7 Nut collar mounting 39 to 59 4 0 to 6 0 No 3 idler bolt 59 to 78 6 0 to 8 0 Mark Points of application Specified lubricant and or sealant Quantity Threaded portion of cylinder head bolt Engine oil As required O ring Threaded portion of No 3 idler bolt Periphery of No 3 idler shaft Inside surface of No 3 ...

Page 62: ...exceeds the limit replace the defective part s Inspection Backlash between No 2 and No 3 idler gears If the measurement exceeds the limit replace the defective part s Mark Tool name and shape Part No Application Socket wrench MH063388 Installation of cylinder head Pin wrench arm MH063473 Assembly of No 3 idler gear MH061779 Removal and installation of No 3 idler gear bushing Idler gear push puller...

Page 63: ... the cylinder head crankcase and flywheel housing when removing the cylinder head gasket Inspection procedure Inspection Clearance between No 3 idler shaft and No 3 idler gear bushing If the measurement exceeds the limit replace the bushing Replacement of No 3 idler gear bushing Removal Installation Using press in the bushing until contacts the No 3 idler gear After installation measure the cleara...

Page 64: ...gear Then install a locking bolt M8 1 25 mm 20 mm long into the dedicated hole Turn over the No 3 idler gear and repeat the same procedure on the other side of the No 3 idler gear installing another sub gear a spring pins and a snap ring Installation Cylinder head CAUTION Before fitting the cylinder head bolts check the punch marks on each bolt s head Do not use the bolt if there are three punch m...

Page 65: ...e that will be fitted together Within three minutes following the sealant application install the cylinder head onto the crankcase with the cylinder head gasket in between them using the cylinder head bolts Take care so that the applied sealant is not displaced during installation Be sure to install the gasket in the illustrated position CAUTION Do not start the engine for at least an hour after i...

Page 66: ...From the reference point turn the socket by 90 in the direc tion shown Each division on the holder scale represents 5 Further turn the socket by 90 After tightening the cylinder head bolts within the plastic region punch a mark on the bolt heads to record the number of times that they have been tightened CAUTION Cylinder head bolts that have been tightened using the torque turn method must never b...

Page 67: ...M E M O 11 31 11 ...

Page 68: ...the valve stem seal 1 Adjusting screw 2 Valve bridge 3 Valve cotter 4 Upper retainer 5 Outer valve spring 6 Inner valve spring Only exhaust valve 7 Valve stem seal 8 Exhaust valve 9 Intake valve 10 Valve bridge guide 11 Exhaust valve guide 12 Intake valve guide 13 Exhaust valve seat 14 Intake valve seat 15 Stud bolt 16 Cylinder head Non reusable parts CYLINDER HEAD AND VALVE MECHANISM ...

Page 69: ... 3 0 2 1 55 Inspect Valve margin 1 5 1 2 Replace Seat angle 45 15 Correct 8 11 Exhaust valve stem to valve guide clearance 0 07 to 0 10 0 2 Replace 9 Intake valve Stem outside diameter φ8 φ7 85 Replace Sinkage from cylinder head bottom surface 1 3 0 2 1 55 Inspect Valve margin 1 5 1 2 Replace Seat angle 45 15 Correct 9 12 Intake valve stem to valve guide clearance 0 06 to 0 09 0 2 Replace 10 Valve...

Page 70: ...llation of valve bridge guides 31391 10500 Removal of valve guides MH062726 Installation of valve guides Caulking tool body 31391 13100 Installation of valve seat Installer ring MH062725 Intake valve MH063605 Exhaust valve Valve lifter seat A φ 38 Valve stem seal installer A B φ 25 φ 9 Valve bridge guide installer A B φ 10 37 2 Valve guide remover A B φ 8 φ 12 Valve guide installer A B C φ 25 5 φ ...

Page 71: ... or other foreign mat ter is in the installation hole Using install the valve bridge guide until comes into positive contact with the cylinder head CAUTION The valve bridge guide must be installed to the specified depth of the cylinder head Correct installation can only be possible by using Inspection Intake and exhaust valve 1 Valve stem outside diameter Replace the valve if the stem s outside di...

Page 72: ...snugly on the cylinder head CAUTION The valve guide must protrude from the cylinder head by the specified amount Correct installation can only be pos sible by using The valve guides for the exhaust valves are longer than the valve guides for the inlet valves Inspection Contact between valve and valve seat Before starting inspection check that the valve and valve guide are intact Apply an even coat...

Page 73: ...h diesel fuel Apply engine oil to the valve contact surface of the valve seat and rub in the valve and seat well Inspect the contact pattern of the valve and valve seat again If the contact pattern is still defective replace the valve seat Inspection Valve seats 1 Valve seat width If the measurement exceeds the limit reface or replace the valve seat After refacing or replacing the valve seat make ...

Page 74: ...he wall thick ness then remove the valve seat at room temperature Installation Check that the diameters of the valve seat holes in the cylinder head conform with the values shown below Replace the cylinder head if necessary Chill the valve seat thoroughly by immersing in it in liquid nitro gen Install the valve seat in the cylinder head using and Lap the valve seat and valve Inspection Cylinder he...

Page 75: ... check that its spring is not deformed or damaged Installation Valve spring Install the outer and inner valve springs onto the cylinder head while facing them as shown in the illustration Installation Valve cotter Using and install the valve cotter while com pressing the valve spring s evenly CAUTION Do not compress the valve spring s too much or the upper retainer will contact the valve stem seal...

Page 76: ...45 0 6 Inspect 1 3 Connecting rod bearing Oil clearance 0 034 to 0 093 0 2 Replace Span when free Less than 74 5 4 5 Piston and connecting rod to cylinder liner clearance 0 19 to 0 21 Replace 5 Cylinder liner Flange projection 0 03 to 0 10 Replace Bore φ118 to 118 03 φ118 25 Out of roundness 0 03 or less Mark Parts to be tightened Tightening torque Remarks Bolt connecting rod cap installation 29 3...

Page 77: ...alled To prevent this retain the cylinder liners by holding their flanges with bolts and washers Mark Tool name and shape Part No Application Piston guide clamp MH061760 Installation of piston and connecting rod Piston guide lever MH061658 Socket wrench MH061560 MH061761 Removal of cylinder liner MH061771 Installation of cylinder liner Cylinder liner extractor A φ117 5 Cylinder liner installer A φ...

Page 78: ...easurements If the average value is out of the standard value range check the clearances between all relevant parts Inspection Connecting rod end play Measure the end play for every connecting rod If any measurement exceeds the specified limit replace the de fective part s Inspection Cylinder liner flange projection If the measurement deviates from the standard value inspect the installation and r...

Page 79: ...d one machine the crankshaft pin to the specified undersize diameter See CRANKSHAFT AND CRANKCASE Inspection Clearance between piston and cylinder sleeve If the measurement deviates from the standard value replace the defective part s A Measuring point on the crankcase in direction of the crank case axis B Measuring point on the crankcase vertical to the crankcase axis C Measuring point on the pis...

Page 80: ...er While pushing the top surface of evenly with hands gently insert the cylinder liner into the crankcase CAUTION Cylinder liners are thinly structured Therefore they must be handled with extreme care Installation procedure Installation Connecting rod bearings CAUTION Do not reverse the positions of the lower bearing and the upper bearing with oil hole when installing as this may cause seizure in ...

Page 81: ...und the piston skirt tighten the adjusting bolt of until the inside diameter of matches the outside diameter of the piston skirt Remove and from the piston Apply engine oil to the following areas Then install and over the rings of the piston Outside surface of piston Inside surface of Cylinder liner inside surface Install the piston and connecting rod taking care not to damage the inside surface o...

Page 82: ...unterclockwise to preload the built in spring Set the tool such that the rod extension is pressed against the crankshaft by the force of the spring Align any line on the holder scale with any line on the socket scale This will be used as the reference point 0 From the reference point turn the socket by 90 5 in the direc tion shown Each division on the socket scale represents 5 With the connecting ...

Page 83: ...M E M O 11 47 11 ...

Page 84: ...ssion ring Oil ring 0 3 to 0 55 1 to 3 9 Piston ring side clear ance in piston groove 1st compression ring 0 13 to 0 18 0 2 Replace 2nd compression ring 0 065 to 0 105 0 15 Oil ring 0 025 to 0 065 5 6 Piston pin to connecting rod bushing clearance 0 02 to 0 055 0 1 Replace 5 8 Piston pin to piston clearance 0 004 to 0 022 0 05 Replace 7 Connecting rod Bend 0 05 Replace Twist 0 1 Mark Points of app...

Page 85: ...h the piston ring horizontally into a cylinder in the crankcase until it reaches the lower part of the cylinder liner where there is relatively small wear Taking care not to move the piston ring measure the end gap If any of the rings has a gap exceeding the specified limit re place all the piston rings as a set Mark Tool name and shape Part No Application Piston ring tool 30091 07100 Removal and ...

Page 86: ...is defective re place all the rings on the piston as a set The side clearance of the 1st compression ring must be mea sured using a feeler gauge while holding the ring against the pis ton ring groove with a straight edge Inspection Piston pin to piston clearance If the measurement exceeds the specified limit replace the de fective part s Inspection Piston pin to connecting rod bushing clearance If...

Page 87: ...Installation Apply engine oil to the outside surface of the connecting rod bushing and the bushing fitting surface of the connecting rod Fit collar B the bushing and collar A over the puller in the illus trated directions and lock this arrangement together with the nut Align the oil holes in the connecting rod bushing and the con necting rod Then use a press to slowly apply a pressure of ap proxim...

Page 88: ... paying attention to the following The connecting rods on the same engine must all have the same mass mark A to E Apply engine oil to the piston pin and assemble the piston and connecting rod with their marks facing in the illustrated di rections Front mark If the piston pin is difficult to insert heat the piston in hot wa ter or with a piston heater Installation Piston rings With the manufacturer...

Page 89: ...M E M O 11 53 11 ...

Page 90: ...sensor 6 Adapter a 7 Plug 8 Eyebolt 9 Air outlet pipe 10 Air suction pipe 11 Eyebolt 12 Water inlet pipe 13 Eyebolt 14 Oil pipe 15 Eyebolt 16 Water outlet pipe 17 Air compressor See Gr61 18 O ring 19 Rear oil seal 20 Stiffener 21 Flywheel housing Non reusable parts a Varies depending on specifi cations FLYWHEEL ...

Page 91: ...d at spigot joint section when fitted 0 2 Inspect or replace Mark Parts to be tightened Tightening torque Remarks Bolt flywheel mounting 98 10 150 Wet Can be reused up to 3 times Plug 88 9 Eyebolt air outlet pipe mounting 98 10 Bolt air suction pipe mounting 19 to 28 1 9 to 2 8 Eyebolt water inlet pipe mounting 50 5 0 Eyebolt water outlet pipe mounting Eyebolt oil pipe mounting 21 2 1 Mark Points ...

Page 92: ...Removal procedure Removal Flywheel To remove the flywheel use bolts M16 1 5 mm Length 60 mm inserted into the dedicated holes in the flywheel Removal Ring gear Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200 C then remove it from the flywheel WARNING You may burn yourself if you touch the heated ring gear Mark Tool name and shape Part No Application Socke...

Page 93: ... the measurement exceeds the limit rectify or replace the fly wheel If the ring gear is evidently defective replace the ring gear be fore inspecting the friction surface for distortion Rectification of friction surface Rectify the friction surface so that its height is not below the specified limit and it is parallel with surface A with an error not exceeding 0 1 mm ...

Page 94: ...at the location indicated in the illustration If the eccentricity exceeds the limit reassemble the flywheel If the eccentricity still exceeds the limit after reassembly replace the defective part s Installation Rear oil seal Clean the rear oil seal surface where sealant is to be applied Apply an even and continuous bead of sealant on the rear oil seal as shown in the illustration Install the rear ...

Page 95: ... ring gear evenly with a gas burner or the like until it reaches approximately 200 C WARNING You may burn yourself if you touch the heated ring gear Fit the ring gear with the side having non chamfered tooth edges toward the flywheel Installation Flywheel CAUTION Before installing a bolt check the number of punch marks on the bolt head Bolts with up to two punch marks can be reused The number of p...

Page 96: ...ing Align any line on the holder scale with any line on the socket scale This will be used as the reference point 0 From the reference point turn the socket by 150 clock wise Each division on the socket scale represents 5 After tightening the bolt within the plastic region make a punch mark on the bolt head for subsequent identification CAUTION The bolts should be tightened within the plastic regi...

Page 97: ...M E M O 11 61 11 ...

Page 98: ...nce in reverse 1 No 1 idler shaft 2 No 1 idler gear bushing 3 No 1 idler gear 4 O ring 5 Collar 6 O ring 7 No 2 idler bolt 8 Thrust plate 9 No 2 idler gear bushing 10 No 2 idler gear 11 No 2 idler shaft a Air compressor gear b Crankshaft gear Non reusable parts TIMING GEARS ...

Page 99: ... 10 Idler gear end play 0 05 to 0 15 0 3 Replace 9 11 Clearance between No 2 idler gear bushing and No 2 idler shaft 0 01 to 0 05 0 2 Replace Mark Parts to be tightened Tightening torque Remarks Bolt No 1 idler gear mounting 88 9 Nut collar mounting 82 8 4 No 2 idler bolt 95 9 7 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Mark Tool name and ...

Page 100: ...the specified limit replace the de fective part s Removal procedure Removal No 1 idler shaft and No 1 idler gear With the bolt loosened by approximately 15 mm pull out the No 1 idler shaft from the crankcase using Remove the bolt Remove the No 1 idler shaft and No 1 idler gear Removal No 2 idler shaft Inspection procedure Inspection Clearance between No 1 idler shaft and No 1 idler gear bushing In...

Page 101: ...he standard value ream the bushing Inspection Clearance between No 2 idler gear bushing and No 2 idler shaft Inspection If the measurement exceeds the limit replace the bushing Replacement of No 2 idler gear bushing Removal Installation Place the No 2 idler gear as shown in the illustration Using insert the bushing until contacts the chamfered tooth edge of the gear After installation measure the ...

Page 102: ...n Installation No 1 idler gear Install the No 1 idler gear such that the alignment mark 2 on the gear is aligned with the alignment mark 2 2 on the air com pressor gear When installing the No 1 idler gear also ensure that the align ment mark 1 1 on the gear is aligned with the alignment mark 1 on the crankshaft gear TIMING GEARS ...

Page 103: ...M E M O 11 67 11 ...

Page 104: ...11 68 CRANKSHAFT AND CRANKCASE ...

Page 105: ...lace 16 Distortion of crankcase top surface 0 07 or less 0 2 Replace Mark Parts to be tightened Tightening torque Remarks Bolt crankshaft pulley installation 190 19 Bolt torsional damper installation 78 8 Bolt main bearing cap installation 78 90 8 90 Wet Reusable up to 3 times Check valve 34 3 5 Mark Points of application Specified lubricant and or sealant Quantity Front cover surface to be mated ...

Page 106: ...tallation of main bearing cap MH062710 Installation of front oil seal slinger MH061470 Installation of rear oil seal slinger Gear puller MH061326 Removal of crankshaft gear Main bearing cap ex tractor A B 32 M8 1 25 Front oil seal slinger installer A φ 76 Rear oil seal slinger in staller A B C φ 104 5 φ 100 φ 14 CRANKSHAFT AND CRANKCASE ...

Page 107: ... seal slinger using a chisel or a similar tool Removal Rear oil seal slinger Taking care not to damage the crankshaft split the rear oil seal slinger using a chisel or a similar tool Removal Crankshaft gear CAUTION Do not tap off the crankshaft gear as this can damage it Inspection procedure Inspection Main bearing 1 Main bearing span when free CAUTION Do not attempt to manually expand the bearing...

Page 108: ...rankshaft journal to one of the specified undersize dimensions Inspection Crankshaft 1 Bend Measure the crankshaft at the center journal for bend while sup porting the shaft at the end journals A half of the dial gauge reading obtained as the crankshaft is ro tated by a full turn represents the bend of the crankshaft If the measurement exceeds the specified limit replace the crankshaft 2 Roundness...

Page 109: ...aft undersize dimensions Unit mm When grinding turn both the crankshaft and the grinder counter clockwise as viewed from the crankshaft front end When finishing the crankshaft with whetstone or sandpaper ro tate the crankshaft clockwise Inspection Distortion of crankcase top surface If the measurement exceeds the limit correct the crankcase top surface with a surface grinder CAUTION Do not grind t...

Page 110: ...be sure to apply sealant again upon reassembly Installation Crankshaft gear Heat the crankshaft gear to approximately 100 C with a burner or the like WARNING Be careful not to get burned Align the key fitted in the crankshaft with the slot in the crank shaft gear Drive the gear into position by lightly striking its end face with a plastic hammer Installation Rear oil seal slinger Using install the...

Page 111: ...pin NOTE If oversized thrust plates are to be used those with a mark must be the same in size Oversized thrust plates are available in the following sizes 2 6 mm 2 75 mm and 2 9 mm CAUTION If thrust plates are installed with the oil grooves facing in side the engine may seize Installation Main bearing cap CAUTION Before installing the main bearing cap bolts check the number of punch marks on the h...

Page 112: ...urn method must never be additionally tightened after the final angular tightening After installing the main bearing cap rotate the crankshaft by hand If it cannot be rotated smoothly inspect the main bearing caps for correct installation Installation Front oil seal Install the front oil seal onto the front cover while pressing the seal s entire periphery evenly to prevent it from tilting Install ...

Page 113: ...Oil Filter 12 5 5 Lubrication of Engine Components 12 6 TROUBLESHOOTING 12 9 GENERAL INSPECTION AND ADJUSTMENT 1 Oil Filter Replacement 12 10 2 Engine Oil Replacement 12 12 3 Oil Pressure Measurement 12 13 OIL PAN OIL JETS AND OIL LEVEL SENSOR 12 14 OIL PUMP OIL STRAINER 12 16 OIL FILTER 12 18 OIL COOLER 12 20 REGULATOR VALVE 12 21 ...

Page 114: ...pump type Oil filter Spin on paper filter type Oil cooler Shell and plate type multiple plate type Engine oil Grade API classification CD CD SF CE CE SF CF 4 Quantity dm3 L Oil pan Approx 11 11 12 12 16 16 28 28 Oil filter Approx 2 3 2 3 SPECIFICATIONS ...

Page 115: ...re exceeds a specified level 1 Engine oil pressure switch 2 Main oil gallery 3 Bypass valve 4 Oil cooler 5 Engine oil bypass alarm switch 6 Full flow filter element 7 Bypass filter element 8 Relief valve built into oil pump 9 Oil pump 10 Oil strainer 11 Regulator valve 12 Crankshaft main bearing 13 Connecting rod bearing 14 Connecting rod bushing 15 Check valve for oil jet 16 Piston 17 Air compres...

Page 116: ...ch and regulator valve When the pressure of the engine oil to the main oil gallery drops below the specified level an electrical contact in side the engine oil pressure switch closes This causes a warning lamp on the meter cluster to illuminate and no tify the operator of the excessive pres sure drop When the oil pressure in the main oil gallery exceeds the specified level the regulator valve open...

Page 117: ...ow of engine oil caus ing the engine to seize To prevent this the oil filter is provided with the engine oil bypass alarm switch If the oil filter clogs up the engine oil bypass alarm switch trips in such a way as to direct the engine oil straight on to the oil cooler bypassing the full flow and bypass filter elements When the switch trips the relevant warning lamp illuminates to alert the operato...

Page 118: ...d bearing of each connecting rod Simultaneously engine oil supplied through an oil passage in the connecting rod lubricates the connecting rod s small end connecting rod bushing 5 2 Timing gears Engine oil in the main oil gallery is directed through the oil passages in the crankcase and cylinder head and is used to lubricate the various gear shafts After lubricating the gear shafts the oil is used...

Page 119: ...g to the adjusting screws on the rockers also lubricates the valve bridges After lubricating the vari ous parts the oil returns to the oil pan 5 4 Check valves and oil jets An oil jet is fitted in the lower part of the main oil gallery for each cylinder Engine oil is sprayed out of the oil jet into the piston to cool the piston Each oil jet is fitted with a check valve that opens and closes at pre...

Page 120: ...shaft The rings function as oil sealing 5 6 Air compressor Engine oil in the main oil gallery is di rected through a passage in the crank shaft to the supply pump coupling and also to the big ends of the connecting rods to lubricate these parts At the same time the pistons and the small ends of the connecting rods are splash lubricated with engine oil by the rotating crankshaft STRUCTURE AND OPERA...

Page 121: ...ipe O O Clogged oil strainer O O Weakened relief valve spring O Oil filter Incorrect installation O Clogged element O O Defective O ring O Front cover timing gear case Defective front oil seal O Gr11 Incorrectly mounted front cover O Flywheel housing Defective rear oil seal O Incorrectly mounted gasket O Weakened regulator valve spring O Defective piston cooling oil jet s O Oil working its way up ...

Page 122: ...deteriorated performance of the cooling system Removal Remove the drain plug and drain the oil out of the oil filter Remove the oil filter using Mark Parts to be tightened Tightening torque Remarks Drain plug oil filter 7 8 2 0 0 8 0 2 Mark Points of application Specified lubricant and or sealant Quantity Oil filter Engine oil API classification CD CD SF CE CE SF CF 4 Approx 2 3 dm3 2 3L Mark Tool...

Page 123: ...ilter by hand until the gasket contacts the oil fil ter head Tighten further by 1 1 8 to 1 3 8 of a turn Install the drain plug With the oil filter installed start the engine and ensure that there is no oil leakage through the gasket If oil is leaking remove and reinstall the oil filter Stop the engine and check the engine oil level Add engine oil if the engine oil level is low ...

Page 124: ...ecified torque then pour a speci fied amount of new engine oil into the engine Stop the engine and check the engine oil level Add engine oil if the engine oil level is low CAUTION Do not add engine oil too much An excessive oil level can only lead to increased oil consumption or make the positive crankcase ventilation system less efficient Mark Parts to be tightened Tightening torque Remarks Drain...

Page 125: ...king the measurements wrap the threads of the engine oil pressure switch with teflon tape and then tighten the switch to the specified torque CAUTION Reinstall the oil pressure switch only when the engine is cold Location Maintenance item Standard value Limit Remedy Oil pressure oil tempera ture at 70 to 90 C No load minimum speed 145 to 295 kPa 1 5 to 3 kgf cm2 49 kPa 0 5 kgf cm2 Inspect No load ...

Page 126: ...perate properly leading to engine seizure Be sure to tighten the check valve to the specified torque Tightening torque Unit N m kgf m Lubricant and or sealant Mark Parts to be tightened Tightening torque Remarks Drain plug 69 7 Check valve 34 3 5 Mark Points of application Specified lubricant and or sealant Quantity Crankcase mounting surface of oil pan ThreeBond 1207C As required OIL PAN OIL JETS...

Page 127: ...and without any breaks Change the amount of application to A and B at four locations shown in the illustration Mount the oil pan within three minutes of applying the sealant Make sure that the sealant stays in place CAUTION Do not start the engine for one hour after installation If the oil pan mounting bolts were loosened or removed be sure to reapply sealant ...

Page 128: ... between the shaft and cover 0 04 to 0 07 0 15 Replace 6 11 Clearance between case and tooth tips of each gear 0 10 to 0 19 0 2 Replace Difference between case depth and height of each gear 0 06 to 0 11 0 15 8 Relief valve opening pressure 1 1 0 1 MPa 11 1 kgf cm2 Replace 9 Relief valve spring installed load installed length 30 84N 8 6 kgf Replace a b Backlash between crankshaft gear and oil pump ...

Page 129: ...Inspection procedure Inspection Driven gear Gear and case assembly Perform the following inspections Replace the defective part s as required 1 Difference between case depth and height of each gear 2 Clearance between case and tooth tips of each gear 3 Clearance between drive gear shaft and cover 4 Clearance between driven gear shaft and case and that between the shaft and cover Shim feeler Change...

Page 130: ...ngine is hot CAUTION When adding engine oil be careful not to allow engine oil to smear the V belt A V belt smeared with oil will slip resulting in reduced cooling efficiency Tightening torque Unit N m kgf m Lubricant and or sealant Mark Parts to be tightened Tightening torque Remarks Drain plug 7 8 2 0 8 0 2 Engine oil bypass alarm switch 49 4 9 5 0 0 5 Bolt Oil filter head mounting 37 to 53 3 6 ...

Page 131: ...oil onto the oil filter gasket Screw in the oil filter by hand until the gasket contacts the oil fil ter head Tighten further by 1 1 8 to 1 3 8 of a turn Install the drain plug With the oil filter installed start the engine and ensure that there is no oil leakage through the gasket If oil is leaking remove and reinstall the oil filter Stop the engine and check the engine oil level Add engine oil i...

Page 132: ...l inlet port Then immerse the oil cooler element in a tank of water Apply a specified air pressure for 15 seconds through the hose and check for any air leaks Replace the element if it leaks air Location Maintenance item Standard value Limit Remedy 14 Air leakage from oil cooler element air pressure 1470 kPa 15 kgf cm2 0 cm3 0 mL Replace Mark Parts to be tightened Tightening torque Remarks Bypass ...

Page 133: ...ce Follow the removal sequence in reverse Service standards Unit mm Location Maintenance item Standard value Limit Remedy Regulator valve opening pressure 392 29 kPa 4 0 0 3 kgf cm2 Replace 3 Spring installed load installed length 48 3 78 5 1 96 N 8 0 0 2 kgf Replace REGULATOR VALVE ...

Page 134: ...3A 3 2 Fuel Filter 13A 4 3 Water separator 13A 5 TROUBLESHOOTING 13A 6 GENERAL INSPECTION AND ADJUSTMENT 1 Air bleeding of Fuel System 13A 8 2 Fuel Filter Replacement 13A 10 3 Water Separator Element Replacement 13A 12 FUEL FILTER 13A 14 WATER SEPARATOR 13A 16 COMMON RAIL 13A 20 SUPPLY PUMP 13A 22 INJECTOR 13A 24 ...

Page 135: ...rochoid pump Common rail system Manufacturer DENSO Common rail capacity cm3 mL 26 26 Pressure limiter valve opening pressure MPa kgf cm2 221 9 2253 91 8 Common rail pressure sensor supply voltage V 5 Injector Manufacturer DENSO Control system Electronically controlled Maximum injection pressure MPa kgf cm2 155 1580 SPECIFICATIONS ...

Page 136: ... through the injectors into the combustion chambers If fuel leakage occurs through any of the fuel line connections between the common rail and injectors the relevant flow damper s will close shutting off fuel supply and thus preventing any further fuel leakage out of the system If the pressure of fuel in the common rail rises above the specified level the pressure limiter valve opens to allow fue...

Page 137: ...r assembly When water has accumulated to a certain level this is detected by the water separator sensor provided on the fuel filter assembly which then illu minates a warning lamp on the meter cluster The water which has collected in the water separator can be drained through the drain hole by loosening the wa ter separator sensor To bleed air from the fuel system a manually operated pump is provi...

Page 138: ...ater separator separates water in fuel The float provides visual indication of the level of the water separated from fuel This enables the water to be drained at an appropriate timing through the drain hole by loosening the drain plug ...

Page 139: ...o low O O O O O Operation of flow damper O O Common rail pressure sensor circuit open short or intermittent connection O O O O O O O Gr13E Defective sealing O O O O Incorrect injector fuel injection Injector magnetic valve open circuited short or in termittent connection O O O O O O O Gr13E or Defective injector injector magnetic valve or injec tion nozzle O O O O O O O Orifice clogged O O O O Fue...

Page 140: ...sor Cylinder recognition sensor Defective sensor Sensor open circuited short or intermit tent connection O O O O O O Gr13E Each sensor improperly mounted O O O O O Gr11 Defective boost pressure sensor Boost pressure sensor open circuited short or intermittent connection O O O Gr13E Defective coolant temperature sensor Coolant temperature sensor open cir cuited short or intermittent connection O O ...

Page 141: ...d torque Continue operating the pump until there is strong pumping resis tance CAUTION If the fuel is cold pumping resistance may not become strong Even if this is the case be sure to cycle the pump several times Wipe up all spilled fuel then start the engine Check that no fuel leakage occurs WARNING Fuel is highly flammable Keep it away from flames and sources of heat Be sure to wipe up all spill...

Page 142: ...M E M O 13A 9 13A ...

Page 143: ...ources of heat Thoroughly wipe up any spilled fuel Otherwise it may catch fire CAUTION Be careful not to damage the case Mark Parts to be tightened Tightening torque Remarks Water separator sensor 5 1 0 5 0 1 Case 30 2 3 1 0 2 Location Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Mark Tool name and shape Part No Application Filter wrench MH063203 ...

Page 144: ...n genuine filter elements will lead to engine problems Be sure to use only genuine parts To help prevent fuel injection problems keep the fuel filter and hoses free from contamination Using tighten the case to the specified torque Tighten the water separator sensor to the specified torque With the sensor correctly installed bleed air from the fuel system Start the engine and ensure that there is n...

Page 145: ...rce away from it Spilled fuel can easily catch a fire Wipe it off completely CAUTION Be careful not to damage the cover Mark Parts to be tightened Tightening torque Remarks Drain plug 1 47 0 3 0 15 0 03 Cover 19 6 2 5 2 0 0 3 Plug A 12 3 2 5 1 25 0 3 Plug B 17 2 2 5 1 75 0 3 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Mark Tool name and shap...

Page 146: ... engine prob lems Be sure to use a genuine element To prevent fuel injection problems keep the water separator and fuel hoses clear of fine dirt and other foreign matter Using the with a torque wrench attached to it tighten the cover to the specified torque Tighten the drain plug plug A and plug B to the specified torque Then bleed the fuel system of trapped air Start the engine and ensure that th...

Page 147: ...ng torque Unit N m kgf m Lubricant and or sealant Special tools Removal procedure Removal Case Drain fuel from the case by loosening the water separator sen sor Using remove the case CAUTION Be careful not to damage the case Mark Parts to be tightened Tightening torque Remarks Water separator sensor 5 1 0 5 0 1 Case 30 2 3 1 0 2 Plug 10 2 1 0 2 Mark Points of application Specified lubricant and or...

Page 148: ...ater separator sensor CAUTION The use of non genuine filter elements will lead to engine problems Be sure to use only genuine parts To help prevent fuel injection problems keep the fuel filter and hoses free from contamination Using tighten the case to the specified torque Tighten the water separator sensor to the specified torque With the sensor correctly installed bleed air from the fuel system ...

Page 149: ...mbly sequence Follow the disassembly sequence in re verse Tightening torque Unit N m kgf m Lubricant and or sealant Special tools Unit mm Mark Parts to be tightened Tightening torque Remarks Plug A 12 3 2 5 1 3 0 3 Plug B 17 2 2 5 1 8 0 3 Drain plug 1 47 0 3 0 15 0 03 Cover 19 6 2 5 2 0 0 3 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required Mark To...

Page 150: ...an the O ring contact surface of the water separator body and the O ring fitting groove in the body Replace the element and O ring with new ones Apply a thin coat of engine oil to the O ring and fit the O ring onto the cover CAUTION The use of an inappropriate element can lead to engine problems Be sure to use a genuine element To prevent fuel injection problems keep the water separator and fuel h...

Page 151: ...pecified torque Tighten the drain plug plug A and plug B to the specified torque Then bleed the fuel system of trapped air Start the engine and ensure that there is no fuel leakage If there is any fuel leakage remove the water separator and rein stall it correctly WATER SEPARATOR ...

Page 152: ...M E M O 13A 19 13A ...

Page 153: ...ther parts plug the openings with covers Wash eye bolts and gaskets in light oil and keep them away from contaminants For the maintenance of the common rail ask Denso Service Station Assembly sequence Follow the disassembly sequence in reverse 1 Fuel temperature sensor 2 O ring 3 Eyebolt 4 Fuel return pipe 5 Connector 6 Eyebolt 7 Fuel overflow pipe 8 Fuel pipe 9 Injection pipe 10 Flow damper 11 Pr...

Page 154: ...s of the connector evenly and temporarily tighten it without applying an excessive force Tighten it to the specified torque after temporary tightening Mark Parts to be tightened Tightening torque Remarks Fuel temperature sensor 17 6 to 21 5 1 8 to 2 2 Eyebolt for fuel return pipe mounting 25 2 6 Eyebolt for fuel overflow pipe mounting 17 7 to 22 6 1 8 to 2 3 Fuel pipe 49 to 58 8 5 0 to 6 0 Injecti...

Page 155: ...g pipes hoses or other parts plug the openings with covers Wash eye bolts and gas kets in light oil and keep them away from contaminants For the maintenance of the supply pump ask Denso Service Station Assembly sequence Follow the disassembly sequence in reverse 1 Eyebolt 2 Fuel return pipe 3 Eyebolt 4 Fuel suction pipe 5 Fuel pipe 6 Supply pump bracket 7 Supply pump 8 Driving disc 9 O ring 10 Key...

Page 156: ...ter in the compression stroke From that position every turn of the crankshaft will alternately bring the No 1 and No 6 pistons to the top dead center in the compression stroke See Gr11 Install the supply pump while ensuring that the stamped line on the supply pump timing cover is aligned with the stamped line on the coupling block Installation Injection pipe and fuel pipe Ensure that the pipe and ...

Page 157: ...enance of the injector ask Denso Service Station Assembly sequence Follow the disassembly sequence in reverse CAUTION Do not attempt to clean the nozzle hole with a wire brush or other similar tools or the hole can be dam aged Be sure to tighten the nozzle bridge bolts to the specified torque Overtightening the bolts can deform the injectors resulting in incorrect fuel injection Tightening torque ...

Page 158: ...surfaces of the connector are flat and free from damage Bring the pipe into intimate contact with mounting surfaces of the connector evenly and temporarily tighten it without applying an excessive force Tighten it to the specified torque after temporary tightening Mark Tool name and shape Part No Application MH062560 Removing injector use with MH061071 MH061071 Removing injector Injector extractor...

Page 159: ... 20 2 Diagnostic Precautions 13E 21 3 Inspections Based on Diagnostic Codes 13E 22 4 Multi Use Tester Service Data 13E 37 5 Reading and Erasing Diagnostic Trouble Codes 13E 39 6 Actuator Tests Performed Using Multi Use Tester 13E 41 7 Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit 13E 43 8 Inspections Performed at Electronic Control Unit Connectors 1...

Page 160: ...2473 Common rail Manufacturer DENSO Common rail volume cm3 mL 26 26 Pressure limiter opening pressure MPa kgf cm2 221 9 2250 92 Common rail pressure sensor supply voltage V 5 Injectors Manufacturer DENSO Control method Electrical type Max operating pressure MPa kgf cm2 psi 155 1580 22473 Min operating pressure MPa kgf cm2 psi 24 245 3485 Engine electronic con trol unit Manufacturer DENSO Rated vol...

Page 161: ...M E M O 13E 3 13E ...

Page 162: ... quantity fuel injection timing and fuel injection pressure in order to optimize the engine s operation The electronic control unit has a diagnostic function that enables it to recognize abnormalities in the common rail system s major components and alert the driver to them The common rail system consists mainly of an electronically controlled supply pump injectors a common rail and the electronic...

Page 163: ... valve is supplied via the inlet valves to the plunger chambers The fuel in the plunger chambers is pressurized The outlet valves are then opened and the fuel is fed under pres sure to the common rail The pressurized fuel is held in the common rail and then uniformly fed to the injectors In response to signals from the engine electronic control unit a solenoid valve in each injector causes the inj...

Page 164: ...13E 6 1 1 Supply pump STRUCTURE AND OPERATION ...

Page 165: ...alve returns fuel to the inlet side of the feed pump This operation keeps the pressure of the fuel fed to SVC suction control valve constant Rotation of the camshaft causes via the ring cam up down movement of the plungers Fuel in the plunger cham bers is thus highly pressurized 1 SCV suction control valve The SCV suction control valve receives fuel from the feed pump and feeds fuel toward the plu...

Page 166: ...ng valve thus prevents the fuel pressure from becoming higher than the set pressure CAUTION When the pressure limiter is activated the common rail system is faulty and needs an inspection 1 Flow damper During normal operation the piston moves thus pushing and compressing the spring to the extent necessary for one injection quantity to pass through The piston does not make contact with the seat at ...

Page 167: ...al timing and in the opti mal quantity The injector is divided into the control section and the injector section The control section consists of the control chamber magnet spring valve body valve ball pressure pin com mand piston and orifice plate The pressure pin is located between the control section and the injection sec tion The injection section consists of the nozzle body nozzle needle nozzl...

Page 168: ...ays in its downward pushed position and injection does not take place 1 2 Start of injection When the magnet is energized the re sulting electromagnetic force draws the valve body upward causing the ball seat to open Fuel in the control chamber passes through the orifice plate and ball seat and flows to the fuel tank With the pressure in the control cham ber reduced the fuel acting on the nozzle n...

Page 169: ... magnet is stopped the valve body is pushed downward by the spring in the magnet such that the ball seat closes At this time fuel flows into the control cham ber via orifice plate pushing down the command piston and nozzle needle such that injection finishes ...

Page 170: ...edal switch Vehicle speed sensor Fuel injection rate adjustment resistor Memory clear switch Connec tor Diagnostic switch Connector Multi Use Tester connector Transmission neutral switch Warm up acceleration function Exhaust gas recirculation valve control function See Gr17 Fault diagnostic function Starter continuous energization prevention function See Gr54 Pre heat control function See Gr54 Fue...

Page 171: ...utput of past diagnostic codes Fuel injection rate adjustment resistor Correction of fuel injection rate Boost pressure sensor Sensing of boost pressure Intake air temperature sensor Sensing of intake air temperature Multi Use Tester connector Communication between Multi Use Tester and common rail system Common rail pressure sensor Sensing of common rail pressure Injector magnetic valve Control of...

Page 172: ...ntity The basic fuel injection quantity is determined in accordance with the engine speed and throttle opening 3 Maximum injection quantity The maximum injection quantity is calculated from the engine speed and boost pressure 4 Fuel injection rate adjustment resistor correction amount To limit inconsistency in the injection quantity the injection quan tity is corrected by the fuel injection rate a...

Page 173: ... calculated from the fuel injection quantity and engine speed 2 Pre injection timing The pre injection timing is calculated from the fuel injection quantity and engine speed 2 5 Fuel injection timing control The fuel injection pressure is calculated from the fuel injection quantity and engine speed ...

Page 174: ...m seizing If the engine electronic control unit determines based on the engine speed signal it receives that the engine has run at or above the specified speed for longer than the specified time period after start up the unit trips the safety relay open 1 Operation mode 2 8 Preheating function This preheating function aims to enhance the engine start up when the engine coolant is low in cold weath...

Page 175: ...ning lamp and dis playing the error code on the meter panel At the same time the system also stores a relevant diagnostic code in the memory and starts operation in the fault mode While the fault is taking place the control limits the systems functionality to ensure vehicle and driver safety It is possible to read the memorized diagnostic code using a Multi Use Tester or from flashing of the warni...

Page 176: ...13E 18 3 Electronic Control Unit Connection Diagram STRUCTURE AND OPERATION ...

Page 177: ...13E 13E 19 ...

Page 178: ...he electronic control unit Response to transient fault Vehicle in service shop Read diagnostic code See Gr00 Check against each diagnos tic code Fault code output Normal code output Normal code output after cleared Response to transient fault See Gr00 Start the engine After starting the engine check for diagnostic code and warning lamp lighting If diagnostic code is issued and warning lamp is lit ...

Page 179: ...rs set the starter switch to LOCK or OFF then allow at least 20 seconds Voltage may remain in electric parts or connected circuit When performing measurement with the tester handle the test bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short circuit failure between terminals in connector or between connector and c...

Page 180: ... Cylinder1 P1240 E 16 72 Flow Limiter Cylinder2 P1241 E 17 73 Flow Limiter Cylinder3 P1242 E 18 74 Flow Limiter Cylinder4 P1243 E 19 75 Flow Limiter Cylinder5 P1244 E 20 76 Flow Limiter Cylinder6 P1245 E 24 15 Engine Revolution SNSR P0335 E 25 07 Engine Overrunning P0219 E 26 32 Boost Press SNSR Low P0237 E 26 32 Boost Press SNSR High P0238 E 28 22 Common Rail Pressure Defect P0253 E 29 19 Atmosph...

Page 181: ...ion Service data 22 Accel Pedal Position unfiltered 23 Accel Pedal Position filtered 24 Accel Pedal Sensor Voltage 1 Electronic control unit connector Accelerator pedal position sensor Electrical equipment 324 Accelerator pedal position sensor Generation condition Accelerator pedal position sensor 2 voltage is below standard value Recoverability System recovers if signal becomes normal with starte...

Page 182: ... condition Common rail pressure is slightly too high lower than operating pressure of pres sure limiter Recoverability System recovers power is re supplied to electronic control unit if signal be comes normal when starter switch is turned OFF ON Control effected by electronic control unit Main injections only enabled Common rail pressure upper limit provided Injection rate limited to predetermined...

Page 183: ...ol unit Main injections only enabled Common rail pressure upper limit provided Injection rate limited to predetermined value Common rail pressure and injection quantity are limited Inspection Other Inspection or replacement of supply pump Have work performed by DENSO Service Station Generation condition Fuel is leaking from high pressure part of system calculated value Recoverability System recove...

Page 184: ...Pressure 0C Difference Common Rail Pressure Electrical equipment 319 Common rail pressure sensor Generation condition Common rail pressure sensor voltage is above standard value 4 95 V Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Common rail pressure open loop control is effected Exhaust gas recirculation con...

Page 185: ...ndition Injector magnetic valve No 4 cylinder is short circuited or open circuited Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Fuel injection stopped for faulty cylinder Exhaust gas recirculation control stopped Inter cylinder injection amount correction valve FCCB learning disabled Inspection Actuator test ...

Page 186: ...alue Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit FCCB learning is disabled Inspection Service data 45 Flow Limiter 3 Other Flow damper Have work performed by DENSO Service Station Generation condition Inter cylinder injection amount correction value FCCB is higher than standard value and fluctuation in engin...

Page 187: ...on Service data 26 Boost Pressure Electrical equipment 318 Boost pressure sensor Generation condition Boost pressure sensor voltage is above standard value 4 7 V Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Control is effected with boost pressure assumed as constant 101 kPa 1 03 kgf cm2 Inspection Service dat...

Page 188: ...e is below standard value 0 1 V Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Water temperature is assumed as constant 20 C during engine startup and as constant 80 C while vehicle is being driven Exhaust emissions worsen Exhaust gas recirculation control is stopped Inspection Service data 35 Water Temperature...

Page 189: ... Exhaust gas recirculation control stopped Inter cylinder injection amount correction valve FCCB learning disabled When open circuited Exhaust gas recirculation control stopped Inter cylinder injection amount correction valve FCCB learning disabled Inspection Actuator test BB Injector Test 1 BD Injector Test 3 BF Injector Test 5 Electronic control unit connector Injector magnetic valve Electrical ...

Page 190: ...mperature inlet Electronic control unit connector Fuel temperature sensor inlet Electrical equipment 323 Fuel temperature sensor inlet Generation condition Fuel temperature sensor voltage is above standard value 4 8 V Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Fuel temperature is assumed to be constant 40 C...

Page 191: ...control unit connector Intake air temperature sensor Electrical equipment 305 Intake air temperature sensor Generation condition Fuel injection rate adjustment resistor voltage is below standard value 0 6 V Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Control is effected using fuel injection rate adjustment r...

Page 192: ...ic control unit connector SCV suction control valve system Electrical equipment 574 SCV suction control valve system Generation condition SCV suction control valve binds and fails to operate Recoverability System recovers power is re supplied to electronic control unit if signal be comes normal when starter switch is turned OFF ON Control effected by electronic control unit Main injections only en...

Page 193: ...noid valve Generation condition Exhaust gas recirculation solenoid valve M V 3 is shorted circuited to ground or open circuited Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Exhaust gas recirculation control is stopped Inspection Service data 1F EGR Position Actuator test A3 EGR 3 Electrical equipment 530 Exha...

Page 194: ...Starter safety relay Actuator test B1 Starter safety relay Electronic control unit connector Safety relay Electrical equipment 201 Safety relay Generation condition Safety relay is short circuited to ground circuit or open circuited Recoverability System recovers if signal becomes with starter switch ON position Control effected by electronic control unit Continuous energization prevention functio...

Page 195: ...ally de pressed from released position 0 85 to 4 15 V 25 Accel Pedal Sensor Voltage 2 Accelerator pedal gradually de pressed from released position 0 85 to 4 15 V 26 Boost Pressure Starter switch On engine stopped Equal to atmospheric pressure Press the accelerator pedal down after starting the engine Gradual raise 27 Intake Air Temperature Engine cold Value corresponds to ambient tem perature 35 ...

Page 196: ...n position except ON OFF 73 Accel SW ON OFF Accelerator pedal not depressed ON Accelerator pedal depressed OFF 83 Diagnostic SW ON OFF Diagnostic switch OFF fuse fit ted ON Diagnostic switch ON fuse re moved OFF 84 Memory Clear SW ON OFF Memory clear switch OFF fuse fitted ON Memory clear switch ON fuse removed OFF 8D Glow relay ON OFF Actuator test is performed ON Actuator test is not performed O...

Page 197: ...diagnostic trouble code is 0 only the units code is displayed Some diagnostic trouble codes are displayed from the 10s unit in numeral followed by alphabet in place of the numeral for the units digit in which case alphabetical letters are represented by the following numbers flashes A 10 times B 11 times C 12 times D 13 times E 14 times F 15 times Example Diagnostic trouble code 8A The lamp flashe...

Page 198: ...emory clear switch When you want to keep the memory contents after the indi cation of stored codes leave the memory clear switch dis connected and turn the starter switch in the off position Then connect the memory clear switch connector When you change the combination of the injection pump and engine control unit you must rewrite the pump data stored in the engine control unit For this purpose be...

Page 199: ...tomatic reset after six seconds Can be executed under the following conditions Vehicle stopped vehicle speed 0 km h Starter switch ON Engine Stopped ON OFF condition of indicator lamp Service data 8E Glow Relay Indicator Lamp B1 Starter safety relay Switch ON OFF safety relay automatic reset after six seconds Can be executed under the following conditions Vehicle stopped vehicle speed 0 km h Start...

Page 200: ...t diagnostic codes generated Injector magnetic valve No 1 cylinder should stop BC Injector Test 2 Injector magnetic valve No 5 cylinder should stop BD Injector Test 3 Injector magnetic valve No 3 cylinder should stop BE Injector Test 4 Injector magnetic valve No 6 cylinder should stop BF Injector Test 5 Injector magnetic valve No 2 cylinder should stop C0 Injector Test 6 Injector magnetic valve No...

Page 201: ... unit New engine electronic control unit starts automatic pump adjustment after engine warming up and various condi tions satisfied To replace the supply pump and engine electronic control unit complete all the replacement jobs other than the replacement of engine electronic control unit Then replace the new unit Replacement of engine electronic control unit with new one Start engine Allow it to w...

Page 202: ...pecified for the inspection Be particularly careful not to cause short circuits between terminals using the tester probes When the supply pump has been replaced perform the Initialization of supply pump unit difference learning value using the MUT and erase the compensation information pump learning condition in the ECU Check item Measurement method Resistance of intake air temperature sen sor Con...

Page 203: ...ements Terminals D1 or D2 D5 injector magnetic valve No 1 cylinder D1 or D2 D3 injector magnetic valve No 2 cylinder D1 or D2 D4 injector magnetic valve No 3 cylinder E1 or E2 E5 injector magnetic valve No 4 cylinder E1 or E2 E7 injector magnetic valve No 5 cylinder E1 or E2 E6 injector magnetic valve No 6 cylinder 0 45 0 1 Ω 20 C Resistance of engine speed sensor Conditions Starter switch OFF Dis...

Page 204: ...nnect connector Perform inspection on vehicle side connector Requirements Terminals E14 E16 E14 E17 E15 E16 E15 E17 7 9 0 2 Ω Glow drive relay voltage Conditions Keep the vehicle harnesses connected to the electronic control unit connector halves Inspection is made at the back of the vehicle connectors Carry out the actuator test AF Relay for Glow Relay using Multi Use Tester Normal status Termina...

Page 205: ...ine oil Heat the oil to each of the specified temperatures Stir the oil well while doing so Measure the resistance between terminals 1 and 2 If either measurement is out of specification replace the sensor 263 Inspection of engine speed sensor Measure the resistance between terminals 1 and 2 If the measurement is out of specification replace the sensor Switch position Terminals with continuity OFF...

Page 206: ... so you must evaluate it indirectly by inspection of system harnesses and re lated parts If there is no abnormality in any related part but the system is abnormal replace the common rail pressure sensor 320 Inspection of cylinder recognition sensor Measure the resistance between terminals 1 and 2 The resis tance serves as a rough indication only A pulse output monitor is needed for confirmation of...

Page 207: ...l switch connector disappears as accelerator pedal is pushed downward C Position in which lever is touching stopper bolt If any output voltage is out of specification make an adjustment If any output voltage is still out of specification when you have made an adjustment replace the sensor Adjustment To adjust the output voltage for the accelerator pedal switch op erating position A use nut D To ad...

Page 208: ...e solenoid valve s OFF ON operation from the operating sound 2 Check of continuity and airtightness Air pressure applied during check 930 kPa 9 5 kgf cm2 574 Inspection of SCV suction control valve Measure the resistance between terminals 1 and 2 If the measurement is out of specification replace the supply pump 582 Inspection of injector Measure the resistance between terminals 1 and 2 If the mea...

Page 209: ...on rate adjustment resistor with one that has the same resistor number and same specified resistance CAUTION The fuel injection rate adjustment resistor is matched to the engine If you replace it be sure to replace it with one that has the same resistor number Standard value at 20 C Resistor No 1 270 13 5 Ω 2 510 25 5 Ω 3 820 41 Ω 4 1300 65 Ω 5 2000 100 Ω 6 3300 165 Ω 7 5600 280 Ω 8 15000 750 Ω 9 ...

Page 210: ...14 5 GENERAL INSPECTION AND ADJUSTMENT 1 Coolant Replacement and Cleaning of Cooling System 14 6 2 Air Bleeding of Cooling System 14 8 3 Gas Leakage Test 14 8 4 Inspection of V belts 14 9 DISCONNECTION AND CONNECTION OF HOSES AND PIPES 14 10 RADIATOR OIL COOLER INTERCOOLER AND FAN SHROUD 14 12 COOLING FAN AND V BELT 14 24 WATER PUMP 14 28 THERMOSTAT 14 32 ...

Page 211: ...14 2 Item Specifications Cooling system Forced water circulation system Water pump Belt driven type Thermostat Wax pellet bottom bypass type with jiggle valve SPECIFICATIONS ...

Page 212: ...14 14 3 1 Cooling System Flow of Coolant STRUCTURE AND OPERATION ...

Page 213: ... changing its total volume This al lows the valve to open or close in accordance with the coolant tempera ture regulating and adjusting the flow of coolant to the radiator and to the water pump bypassing the radiator 3 Water Pump The water pump has a drain hole to prevent coolant from entering the unit bearing in case of a defect in the unit seal STRUCTURE AND OPERATION ...

Page 214: ...alve remains closed O Valve opening temperature too low valve remains open O Radiator Clogged core O Cracked core and or separation in welds O O Intercooler Foreign matter adhered on the core O Oil cooler For machinery Water leaking O EGR system Defective gasket O O Gr17 Incorrectly mounted EGR cooler O O Oil cooler Incorrectly mounted oil cooler O O Gr12 Defective gasket O O Water leaking from wa...

Page 215: ...ocedure CAUTION Water used for flushing the cooling system must be soft water that has a property meeting the require ments indicated below Using hard water will cause scale and rust to form in the system Required properties of soft water Total hardness 300 ppm or less Sulfate SO 100 ppm or less Chloride CI 100 ppm or less Total dissolved solids 500 ppm or less pH 6 to 8 Keep the coolant temperatu...

Page 216: ...the engine idle for 30 minutes with the water at approxi mately 90 C CAUTION Limit the engine idling period to one hour Operating an engine containing the cleaning solution for long er time may lead to damage of the cooling system Drain out coolant Pour tap water preferably hot into the surge tank Let the engine idle for 10 minutes with the water at approximately 90 C Cleaning is complete if drain...

Page 217: ... the engine is hot boiling coolant may spurt out from the filler port when the pressure cap is loosened To avoid burn ing yourself make sure to remove the pressure cap only when the coolant is cold Run the engine until the coolant temperature rises to approxi mately 90 C If air bubbles appear continuously through the filler port there is air or exhaust gas penetrating into the cooling system Prese...

Page 218: ...s that over which the belt has been used since the vehicle was new or since the belt was replaced whichever is more recent The driving distance over the which the belt can still be used is about half of that over which the belt has been used since the vehi cle was new or since the belt was replaced whichever is more re cent The driving distance over the which the belt can still be used is about a ...

Page 219: ...p and its surrounding parts Tightening torque Unit N m kgf m Mark Parts to be tightened Tightening torque Remarks Clamp 3 9 0 6 0 4 0 06 Clamp 4 to 5 0 4 to 0 5 Eyebolt joint pipe mounting 25 25 1 Water hose 2 Eyebolt 3 Joint pipe 4 Water hose 5 Water hose 6 EGR cooler water pipe 7 Water hose 8 Water hose 9 EGR cooler water pipe 10 Water hose EGR Exhaust gas recirculation DISCONNECTION AND CONNECT...

Page 220: ...M E M O 14 11 14 ...

Page 221: ...Air leaks from oil cooler Coolant side air pressure 20 kPa 0 2 kgf cm2 0 cm3 0 mL Replace Oil side air pressure 150 kPa 1 5 kgf cm2 0 cm3 0 mL Replace 5 Pressure cap opening pressure 49 9 8 kPa 0 5 0 1 kgf cm2 Replace Mark Parts to be tightened Tightening torque Remarks Clamp 3 9 0 6 0 4 0 06 1 Intercooler 2 Hose 3 Drain cock 4 Oil cooler 5 Pressure cap 6 Filler 7 Filler hose 8 Radiator See later ...

Page 222: ...of the oil cooler and apply a specified air pressure from the other end with the oil cooler immersed in water Be sure to check both the coolant passage and oil passage If any leakage is found replace the oil cooler Inspection Pressure cap 1 Pressure valve opening pressure If the measurement does not conform to the standard value re place the pressure cap Mark Tool name and shape Part No Applicatio...

Page 223: ...the original level noted earlier If not the vent valve is deemed faulty Replace the pressure cap CAUTION If the pressure cap is opened before the coolant tempera ture drops to the atmospheric temperature the negative pressure in the radiator is canceled out As a result it is no longer possible for coolant to flow into the reservoir tank Ensure that this does not happen Installation procedure Insta...

Page 224: ...r air pressure 150 kPa 1 5 kgf cm2 0 cm3 0 mL Replace 10 11 Pressure cap opening pressure 49 9 8 kPa 0 5 0 1 kgf cm2 Replace 17 19 Air leaks from radiator air pressure 100 kPa 1 0 kgf cm2 0 cm3 0 mL Replace 1 Plug 2 Gasket 3 Intercooler 4 Protector 5 Packing 6 Packing 7 Oil cooler 8 Shroud 9 Packing 10 Pressure cap 11 Pressure cap 12 Water hose 13 Water hose 14 Hose 15 Cushion 16 Bracket 17 Radiat...

Page 225: ...er Be sure to check both the coolant passage and oil passage If any leakage is found replace the oil cooler Inspection before removal Inspection Air leaking of radiator Install hose and radiator cap tester and plug to upper tank Insert plug in lower tank and immerse the entire body of the ra diator in water Apply a specified air pressure using radiator cap tester and check for any air leakage If a...

Page 226: ...s dropped to the atmospheric temperature check if the cool ant level in the reservoir tank has subsided to the original level noted earlier If not the vent valve is deemed faulty Replace the pressure cap CAUTION If the pressure cap is opened before the coolant tempera ture drops to the atmospheric temperature the negative pressure in the radiator is canceled out As a result it is no longer possibl...

Page 227: ...imped twice before replace the core with a new part Assembly sequence Follow the disassembly sequence in reverse Service standards Tightening torque Unit N m kgf m Location Maintenance item Standard value Limit Remedy 8 Air leakage from radiator air pressure 177 kPa 1 8 kgf cm2 0 cm3 0 mL Repair or replace Mark Parts to be tightened Tightening torque Remarks Drain cock 2 0 2 Bolt side member mount...

Page 228: ...arks on the joint between the core and upper tank or on the joint between the core and lower tank which indicates that the tank retaining tabs have been crimped twice before replace the core with a new part The number of paint marks on the upper tank joint or the lower tank joint corresponds to the number of repairs per formed on that joint Removal procedure Removal Upper tank and lower tank Use f...

Page 229: ...er hold the pipes con nected to the inlet outlet and remove tank If it is difficult to remove tank lightly hit with rubber hammer or plastic hammer to remove CAUTION Gently handle tanks since they are made of a resin that can break on impact Inspection procedure Inspection Tank surface where core is to be mounted Check the tank surface where the core is to be mounted for cleanliness damage etc Cle...

Page 230: ... entire periphery even a hair can cause leakage Repairing core CAUTION The core is repaired by means of tungsten inert gas arc welding TIG welding which should only be performed by a skilled welder It is extremely dangerous to weld on a wet core Before welding ensure that the core is completely dry Using a stainless wire brush brush both ends A of the leaky tube and the areas B around the tube end...

Page 231: ...ween the tank and core plate by tapping with a rubber or plastic hammer CAUTION To prevent adhesion of foreign matter use bare hands to in stall the packing and tank Adjust the stopper bolt until the gap dimension shown in the il lustration is obtained on the attachment of Following the sequence shown in the diagram bend tabs for caulking tank To perform this work since cannot be used to caulk sid...

Page 232: ...14 14 23 Paint a mark on the core where it can be easily noticed to indi cate that the core has been crimped CAUTION Paint a mark for each repair performed on either the upper or lower tank ...

Page 233: ...vent differences in tension between the belts 1 V belt 2 Cooling fan Type B and Type C 3 Fan spacer Type B 4 Fan spacer Type B and Type C 5 Water pump pulley 6 Inlet pipe 7 Inlet hose 8 Tube Type C 9 Straight joint Type C 10 Grease nipple Type C 11 Connector Type C 12 Grease nipple bracket Type C a Water pump b Crankshaft pulley COOLING FAN AND V BELT ...

Page 234: ...ark corresponding to 98N 10 kgf press force Place the large O ring on at the scale mark corresponding to the maximum permissible deflection value specified for the belt Location Maintenance item Service standard Limit Remedy 1 V belt tension 10 to 15 Adjust Mark Parts to be tightened Tightening torque Remarks Grease nipple 12 5 2 5 1 3 0 3 Straight joint Tube 2 25 0 25 0 2 0 03 Clamp 39 0 4 Mark P...

Page 235: ...alternator mounting bolts 2 locations then adjust the tension of V belts by moving the alternator from side to side When the adjustment is completed tighten the bolts and nuts securely CAUTION Excessive tension in V belts may damage the belts and re lated bearings When replacing the V belts replace them as a set to prevent differences in tension between the two belts Keep the V belts free of oil I...

Page 236: ...M E M O 14 27 14 ...

Page 237: ... interference 0 03 to 0 08 Reassembly allowed only twice Mark Parts to be tightened Tightening torque Remarks Bolt water pump mounting 24 2 4 Grease nipple 9 8 to 15 1 to 1 5 Mark Points of application Specified lubricant and or sealant Quantity Pack in bearing Wheel bearing grease NLGI No 2 Li soap As required Fill through grease nipple 60 g Outer periphery of unit seal ThreeBond 1102 As required...

Page 238: ...e measurement complies with the standard value reassembly must not be carried out more than twice Inspection Flange to water pump shaft interference If the measurement does not comply with the standard value re place the defective part s CAUTION Even if the measurement complies with the standard value reassembly must not be carried out more than twice Mark Tool name and shape Part No Application M...

Page 239: ...ntil it contacts the fixture CAUTION If the flange is installed without the fixture the water pump case will be damaged Installation Impeller CAUTION Before installing impeller make sure that there is no or only one punch mark in the shown location on the impeller Make an additional punch mark on the impeller to indicate that it undergoes the disassembly and reassembly process you are doing now Pu...

Page 240: ...14 14 31 Inspection after assembly Inspection Flange rotation Rotate the flange by hand The flange should rotate smoothly without any binding If the flange does not rotate freely disassemble and check ...

Page 241: ...uence in re verse Service standards Unit mm Tightening torque Unit N m kgf m Lubricant and or sealant Location Maintenance item Standard value Limit Remedy 3 Thermostat Valve opening temperature 76 5 2 C Replace Valve lift temperature 10 or more 90 C Mark Parts to be tightened Tightening torque Remarks Water temperature sensor 35 7 3 6 0 7 Cock 20 to 26 2 0 to 2 7 Mark Points of application Specif...

Page 242: ...way from the heat source Heat the water gradually to the valve opening temperature Maintain this temperature for five minutes and make sure that the valve is completely open Make sure that the valve closes completely when the water tem perature drops below 65 C 2 Valve lift Heat the water to a temperature slightly higher than the valve opening temperature Maintain this temperature for five minutes...

Page 243: ...OUP 15 INTAKE AND EXHAUST SPECIFICATIONS 15 2 STRUCTURE AND OPERATION 1 Air Cleaner 15 3 2 Turbocharger 15 4 TROUBLESHOOTING 15 5 AIR CLEANER 15 6 TURBOCHARGER 15 8 INTAKE MANIFOLD 15 14 EXHAUST MANIFOLD 15 16 ...

Page 244: ...15 2 Item Specifications Air cleaner element Cyclone filter paper type Dust indicator type Mechanical electrical Turbocharger Model TD06 Manufacturer Mitsubishi Heavy Industries SPECIFICATIONS ...

Page 245: ...u ator valve The vacuator valve automatically works in such a way that when the en gine speed drops below a specified level the valve s rubber boot which is usually subdued by internal vacuum is allowed to spring back and accumulat ed dust and dirt are discharged as a result STRUCTURE AND OPERATION ...

Page 246: ...nto the actuator s chamber A through rubber hose When the boost pressure working on the chamber A is lower than the preset level the actuator remains inactive al lowing exhaust gas to be blown against the turbine wheel with the waste gate valve closed When the boost pressure in the cham ber A becomes higher than the preset level it causes the waste gate valve to be opened and the exhaust gas being...

Page 247: ...ng O O O Bent shaft O O O Damaged turbine wheel unit O O O Interference between compressor wheel and compressor cover O O O Damaged compressor wheel O O O Compressor cover fitted poorly O O O O Turbine housing fitted poorly O O Incorrect valve clearances O Gr11 Head gasket defective O Wear carbon deposits on valves and valve seats O Valve spring weakened O Piston rings worn damaged O O Piston ring...

Page 248: ...Follow the removal sequence in reverse Service standards Tightening torque Unit N m kgf m Location Maintenance item Standard value Limit Remedy 1 Operation of dust indicator under specified negative pressure 6 2 0 6 kPa 47 4 3 mmHg Replace Mark Parts to be tightened Tightening torque Remarks Dust indicator 3 0 to 3 5 0 3 to 0 35 AIR CLEANER ...

Page 249: ... inside the element Replace the element if thin spots or broken parts are evident in the filter paper or if the packing at the top of the element is dam aged Also replace the element if the dust on the element is damp with oily smoke or soot regardless of the replacement schedule Inspection Operation of dust indicator under specified neg ative pressure Mechanical type Apply negative pressure to th...

Page 250: ...eed pipe mounting 21 2 1 Nut exhaust pipe mounting 41 4 2 Nut turbocharger mounting Mark Points of application Specified lubricant and or sealant Quantity Turbocharger to be filled with engine oil Engine oil As required 1 Air inlet pipe 2 Rubber hose 3 Eyebolt 4 Oil feed pipe 5 Oil return pipe 6 Gasket 7 Turbocharger cover 8 Exhaust pipe 9 Gasket 10 Turbocharger See later section 11 Gasket a Exhau...

Page 251: ...15 15 9 Installation procedure Installation Turbocharger Before installing the turbocharger pour engine oil into the oil hole to ensure smooth operation of the internal parts ...

Page 252: ...r sealant Work before removal Alignment mark Put alignment marks on the coupling turbine housing compres sor cover and cartridge assembly Location Maintenance item Standard value Limit Remedy 8 Cartridge assembly Play in axial direction of shaft 0 05 to 0 09 0 1 Replace Play perpendicular to axis of shaft Turbine wheel end 0 40 to 0 53 0 58 Replace Compressor wheel end 0 55 to 0 66 0 72 Replace Ma...

Page 253: ...k the disassembled parts for scorches abrasion and other marks that may be difficult to see after cleaning Replace any part that appears defective Immerse the disassembled parts in a non flammable solvent a 5 to 10 aqueous solution of Oil Clean from New Hope Co Ltd Take out the parts and blow them dry with compressed air Re move any hard deposits with a stiff brush or plastic scraper CAUTION Do no...

Page 254: ... install the snap ring into the compressor cover CAUTION Fit the snap ring into place using hands not to let it spring away Work after installation Inspection Free rotation of cartridge assembly Turn the wheels of the cartridge assembly They should turn freely without binding If not disassemble again and correct TURBOCHARGER ...

Page 255: ...M E M O 15 13 15 ...

Page 256: ... Brake Parts Cleaner In 20 to 30 seconds after spraying wipe the sensor portion clear of the sprayed cleaner using a soft waste cloth or the like CAUTION Be sure to wait for 20 to 30 seconds before wiping It takes the cleaner that long to dissolve foreign matter If the sensor portion is fouled excessively the positive crankcase ventilation PCV may be faulty Inspect the PCV valve and filter to loca...

Page 257: ...old surface where the cylinder head is to be mounted Install the intake manifold onto the cylinder head within 3 min utes following the application while taking care not to spread the sealant beyond the application area CAUTION Do not start the engine at least for an hour after the intake manifold has been installed If the intake manifold mounting bolts are subsequently loosened or removed be sure...

Page 258: ...st manifold 7 Gasket a Cylinder head See Gr11 Non reusable parts Installation sequence Follow the removal sequence in reverse Tightening torque Unit N m kgf m Installation procedure Installation Gasket Fit the gasket to the cylinder head in the illustrated direction Mark Parts to be tightened Tightening torque Remarks Nut exhaust manifold mounting 58 5 9 EXHAUST MANIFOLD ...

Page 259: ...D OPERATION 1 Exhaust Gas Recirculation System 17 2 2 Blowby Gas Return System 17 4 GENERAL INSPECTION AND ADJUSTMENT 1 Replacement of PCV Valve Element 17 5 EGR VALVE EGR SOLENOID VALVE EGR PIPE AND EGR COOLER 17 6 BLOWBY GAS RETURN SYSTEM 17 9 ...

Page 260: ...density of the inert gases thereby achieving a greater EGR ef fect The EGR system uses various sensors to detect engine operating conditions engine speed coolant temperature accelerator opening and based on the information obtained lets the engine ECU control operation of the EGR solenoid valve See Gr13E for the electronic control system and ECU connection diagram If black smoke occurs or the engi...

Page 261: ...urned ON OFF by drive signals from the engine electronic control unit to real ize a 7 stage supply of air to the EGR valve 2 EGR valve The EGR valve realizes 7 stages of valve lift in accordance with the supply of air to its input ports from the EGR solenoid valves ...

Page 262: ...rom being released to the out side air The PCV valve keeps constant the pressure inside the crankcase The oil in the blowby gas is separated by the wire mesh and the element in the PCV valve and is returned to the oil pan When the element is clogged the regulator valve opens and the blowby gas is returned to the breather hose STRUCTURE AND OPERATION ...

Page 263: ...age Removal Loosen the cap by hand CAUTION Do not use any tools to loosen the cap Otherwise the cap may become damaged Installation Clean the thread on the cap Lightly smear the O ring with engine oil and fit it on the cap Securely tighten the cap until it stops slightly above the PCV body CAUTION Be sure to use a genuine Mitsubishi Fuso element Using an inappropriate element could result in engin...

Page 264: ...et 6 Gasket 7 Plug 8 EGR cooler 9 Gasket 10 Upper EGR pipe clamp 11 EGR pipe 12 Gasket 13 Eyebolt 14 EGR air pipe 15 Connector 16 Connector 17 EGR solenoid valve 18 EGR valve 19 Gasket a EGR valve adapter Non reusable parts Arrows A to C indicate points to or from which pipes are connected EGR Exhaust Gas Recirculation EGRVALVE EGR SOLENOIDVALVE EGR PIPE AND EGR COOLER ...

Page 265: ...value Limit Remedy 18 EGR valve lift Operating stage 0 0 Replace 1 1 3 0 3 2 2 6 0 3 3 4 6 0 3 4 5 7 0 3 5 7 7 0 4 6 9 0 0 3 7 11 0 0 3 Mark Parts to be tightened Tightening torque Remarks Clamp water hose mounting 4 to 5 0 4 to 0 5 Connector air pipe mounting 15 to 29 1 5 to 3 0 Clamp water hose mounting 3 9 0 4 Eyebolt water outlet pipe mounting 25 2 6 Eyebolt EGR air pipe mounting Nut EGR adapt...

Page 266: ...Check that air does not leak from any part of the EGR cooler If there is any abnormality replace the EGR cooler 2 Coolant passage side Fit covers over the EGR cooler s exhaust gas inlet exhaust gas outlet and coolant outlet and connect a hose to the coolant in let Then submerge the EGR cooler in a container of water Apply air pressure of 294 kPa 3 kgf cm2 through the hose Check that air does not l...

Page 267: ...ghtening torque Remarks Clamp 4 9 0 5 Clamp 4 0 to 5 0 0 4 to 0 5 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required 1 Breather pipe 2 Breather hose 3 Breather hose 4 Oil hose 5 PCV valve bracket 6 Oil hose stay 7 Cap 8 O ring 9 Element 10 PCV body a Rocker cover b Breather hose Non reusable parts PCV Positive crankcase ventilation BLOWBY GAS RETUR...

Page 268: ...s to be tightened Tightening torque Remarks Clamp 4 9 0 5 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required 1 Breather hose 2 Breather hose 3 Oil hose 4 PCV valve bracket 5 Oil hose stay 6 Cap 7 O ring 8 Element 9 PCV body a Rocker cover b Air suction pipe Non reusable parts PCV Positive crankcase ventilation BLOWBY GAS RETURN SYSTEM ...

Page 269: ...o be tightened Tightening torque Remarks Clamp 4 9 0 5 Mark Points of application Specified lubricant and or sealant Quantity O ring Engine oil As required 1 Breather hose 2 Breather pipe 3 Breather hose 4 Breather hose 5 Oil hose 6 Cap 7 O ring 8 Element 9 PCV body 10 Oil hose stay 11 PCV valve bracket a Rocker cover b Air suction pipe Non reusable parts PCV Positive crankcase ventilation ...

Page 270: ... 8 INSPECTION OF ELECTRICAL EQUIPMENT 001 to 179 SWITCH 54 10 180 to 249 RELAY 54 11 250 to 349 SENSOR 54 12 350 to 409 CONTROL UNIT 54 13 750 to 859 OTHER 54 14 930 STARTER 54 15 940 ALTERNATOR 54 28 GENERAL INSPECTION AND ADJUSTMENT 950 INSPECTION OF ALTERNATOR 54 34 951 INSPECTION OF REGULATOR 54 35 955 INSPECTION OF PREHEATING SYSTEM 54 36 ...

Page 271: ...utput V kW 24 5 0 Magnetic switch operating voltage V 16 or less Starter relay Model U001X33472 Excitation current V A 24 2 3 Closing voltage V 16 or less Opening voltage V 4 or less Allowable cutoff current A 200 Glow plug Model Sheathed type Rated voltage and current V A 23 2 2 reference Glow relay Model U001T41472 Excitation current V A 24 1 8 Closing voltage V 16 or less Opening voltage V 4 or...

Page 272: ...54 54 3 1 Starter This starter uses planetary gears as its reduction gearing mech anism STRUCTURE AND OPERATION ...

Page 273: ...54 4 2 Alternator 24V 50A STRUCTURE AND OPERATION ...

Page 274: ...nt DC voltage 1 2 of output voltage as a center as shown When the alternator is operated at high speeds the voltage at the neutral point can increase to exceed the out put voltage 28 V and decrease to be come lower than the ground voltage 0 V and these voltages are lost in con ventional system The neutral diodes rectifies these over voltage and under voltage shaded portions of diagram and adds the...

Page 275: ...ositive diode oper ates and adds extra output to the DC output for supply to each electric equipment When the voltage at neutral point drops below 0 V the negative diode supplies the output from neutral point through other three diodes STRUCTURE AND OPERATION ...

Page 276: ...54 54 7 3 Circuit diagram ...

Page 277: ...th engine stopped Alternator is normal but battery over discharged Reference Gr Possible causes Connector connection faulty harness broken grounding faulty O O Fuse blown O O O V belts loose O O Gr14 V belts damaged O O Battery faulty O O Alternator Stator coil broken O Stator coil short circuited with core O Field coil broken O Rectifier faulty O Regulator faulty O O O Wiring faulty O TROUBLESHOO...

Page 278: ...O O Fuse blown O O O Battery insufficiently charged O O Starter Magnetic switch contacts stuck or fused together O Open circuit in magnetic switch coil O Overrunning clutch malfunc tioning O Pinion worn or damaged O Starter relay defective O Starter switch defective O O Flywheel ring gear worn or damaged O Gr11 Electronically controlled fuel system Engine electronic control unit defective O O O O ...

Page 279: ... cm2 Measure the degree of air pressure at the moment when conti nuity is not detected between terminal 1 and body and make sure to confirm if the value meets the standard 053 Inspection of engine oil bypass alarm switch Perform the following checks and if any fault is found replace the switch See Gr12 1 Inspection by without applying air pressure Make sure that there is no continuity between term...

Page 280: ...ay Perform continuity check and operation check and if any fault is found replace the relay 195 Inspection of glow relay Perform continuity check and operation check and if any fault is found replace the relay 201 Inspection of relay normally open type 5 pin Perform continuity check and operation check and if any fault is found replace the relay 180 to 249 RELAY ...

Page 281: ...ied one while stirring oil Measure the resistance values between terminals 1 and the body If the measured value deviates from the standard value replace the sensor See Gr14 For engine control Dip the sensor in a container filled with engine oil Raise the oil temperature to the specified one while stirring oil Measure resistance values between terminals 1 and 2 If the measured value deviates from t...

Page 282: ...50 Inspection of control unit and other units Since the units alone cannot be readily checked in the off vehi cle state check the harness switch and other related parts in each system If any fault is not found in the related parts and the problem still remains in the system replace the control units or other units Standard value at 20 C 125 5 17 Ω Condition Continuity terminal ON when coolant quan...

Page 283: ...rying the temperature around the thermostat measure the temperatures when the continuity is established and is lost between terminals 1 and 2 2 Inspection of heater Measure the resistance of heater as shown If the measured value is out of the standard value replace the heater 764 Inspection of glow plug Measure resistance value of glow plug as shown If the measured value deviates from the standard...

Page 284: ...rter dis connect the battery cable and in sulate the cable and the battery terminal with tape It is dangerous to leave the bat tery cable connected since the bat tery cable voltage is always present at terminal B Installation sequence Follow the removal sequence in reverse 930 STARTER ...

Page 285: ...spring 10 Brush 11 Brush holder 12 Brush 13 Yoke 14 Packing 15 Rear bearing 16 Washer 17 Armature 18 Ball 19 Cover 20 Rubber packing 21 Planetary gear 22 Rubber packing 23 Plate 24 E ring 25 Gear shaft 26 Washer 27 Internal gear 28 Overrunning clutch 29 Lever 30 Front bearing 31 Oil seal 32 Front bracket Non reusable parts 930 STARTER ...

Page 286: ...ion speed 3300 rpm or higher 9 Brush spring pressure 29 2 to 39 4 N 3 to 4 kgf 13 7 N 1 4 kgf Replace 10 12 Brush length 18 11 Replace 17 Commutator outside diameter 32 31 4 Replace Runout of commutator periphery 0 1 or higher Mold depth between segments 0 2 or less Correct or replace Mark Points of application Specified lubricant and or sealant Quantity Lever contact surface of magnetic switch Mu...

Page 287: ... sec onds and do not energize the holding coil H for longer than 30 seconds If these periods are exceeded the coils may overheat and burn out To make the pinion spring out be sure to energize the start er such that its parts are positioned correctly If the starter is not energized and the lever is pulled to make the pinion come out the front bracket and or lever may be damaged by the shock inflict...

Page 288: ...age is applied to starter terminal B so cur rent flows to the pull in coil while the pinion rotates To pre vent the pull in coil from burning out it is essential to turn OFF switch 2 quickly within five seconds after the pinion starts to rotate Apply a pipe shaped implement to the pinion stopper Using a hammer lightly tap the pipe shaped implement to re move the stopper ring from the ring groove o...

Page 289: ...brushes Hold the brushes in position with the brush springs as illustrat ed Remove the yoke and brush holder Disassembly Gear shaft and internal gear Remove the E rings and then the gear shaft and internal gear from the overrunning clutch Proceed as follows if the gear shaft cannot be removed due to interference of the splined section of gear shaft with internal parts of the overrunning clutch Pre...

Page 290: ...at continuity exists between terminals S and M Check that continuity exists between terminal M and the body 2 Test for fused together contacts Check that continuity does not exist between terminals B and M 3 Test for contact to contact continuity Push in the end of the magnetic switch to close the internal con tacts Then check that continuity exists between terminals B and M ...

Page 291: ...Thoroughly clean the brush holder and the holder plate then check that continuity does not exist between them If continuity exists there is a short circuit and the brush holder must be replaced Inspection Yoke 1 Test for coil open circuit Check that continuity exists between the cable and the brush If there is no continuity there is an open circuit and the yoke or brush must be replaced 2 Test for...

Page 292: ...ircuited and the armature must be replaced 2 Test for coil grounding Check that continuity does not exist between the commutator and the core or shaft If continuity exists the coil is grounded and the armature must be replaced 3 Commutator outside diameter If the measurement is out of specification replace the armature 4 Runout of commutator periphery If the reading exceeds the specified limit rec...

Page 293: ...nacceptable Inspection Overrunning clutch If the following inspections reveal any abnormality replace the overrunning clutch Turn the shaft in direction B and check that it rotates smoothly Turn the shaft in direction A and check that it locks Assembly procedure Assembly Front bearing Press fit the front bearing using A and B After the press fitting caulk the front bearing using the claws on A CAU...

Page 294: ...ever with terminal S aligned as illustrated Assembly Pinion For installation of the pinion it is not necessary to supply current to the starter Fit the pinion stopper and pinion onto the overrunning clutch making sure they are oriented as illustrated Fit the stopper ring into the ring groove of the overrunning clutch Pull the pinion hard and securely fit the stopper ring into the ring groove of th...

Page 295: ...ltage to 23 Volts DC CAUTION The voltage applied must not exceed 24 V The following operations are performed with current supplied to the starter Thus the entire test consisting of measurement of the current flowing through the starter and measurement of the starter s rotational speed must be completed within 30 seconds Turn ON the switch to supply current to the starter The pinion will spring out...

Page 296: ...hes 1 and 2 are turned ON the pull in coil P and holding coil H are both energized The circuit is connected such that no voltage is applied to starter terminal B so cur rent flows to the pull in coil while the pinion rotates To pre vent the pull in coil from burning out it is essential to turn OFF switch 2 quickly within five seconds after the pinion starts to rotate Pull out the end of the overru...

Page 297: ...standards The hot condition is that which occurs after the alternator has been running at normal ambient temperature at 5000 rpm and maximum output for 30 minutes Location Maintenance item Standard value Limit Remedy 4 Alternator output current when al ternator is hot and producing 27 V At 1500 rpm 24 A or more Inspect At 2500 rpm 38 A or more At 5000 rpm 45 A or more Adjustment voltage of regulat...

Page 298: ... current Measure the current at each specified revolution of alternator If the measured value deviates from the standard value disas semble and check alternator 2 Adjustment voltage of regulator bench test Connect the alternator as illustrated B Terminal B E Terminal E L Terminal L R Terminal R Turn switch ON Run alternator at low speeds Increase the speed of alternator to 5000 rpm and measure the...

Page 299: ...orque Unit N m kgf m Location Maintenance item Standard value Limit Remedy 8 Field coil resistance at 20 C 6 1 to 7 1 Ω Replace Mark Parts to be tightened Tightening torque Remarks Nut pulley mounting 143 to 181 15 to 18 1 Pulley fan 2 Spacer 3 Rear bearing 4 Rotor 5 Cover 6 Front bearing 7 Front bracket 8 Field coil 9 Stator 10 Regulator 11 Rectifier 12 Rear bracket 940 ALTERNATOR ...

Page 300: ...rewdriver to pry rotor and front bracket away from sta tor and rear bracket CAUTION Be careful not to insert the screwdriver too deep or it will damage coil of stator and may cause a short circuit Disassembly Pulley CAUTION Make sure to grip the root of the core claws when you hold the rotor in a vice Gripping claws can damage them ...

Page 301: ... with your hand Remove field coil CAUTION Do not remove the field coil forcibly Otherwise the portion that joins with the regulator may be caught by the stator coil Disassembly Stator Disconnect lead of stator from rectifier The lead is soldered to the diode of the rectifier at 4 places CAUTION Unsolder within as short a time period as possible within 5 seconds otherwise diode can be easily damage...

Page 302: ...stance is infinite in both cases the diode has open If resistance is close to 0 Ω in both cases the diode has shorted A B C D Lead connecting area of stator coil E G Heat sink area F Regulator connecting area Inspection should be conducted twice changing over the posi tive probe and the negative probe of the tester CAUTION When inspecting using a tester the current flowing through the rectifier is...

Page 303: ...icates battery voltage Start the engine Immediately turn on the switches for all lamps on the vehicle Immediately accelerate the engine to the speed indicated below and measure the alternator s output current Approx 1400 rpm A4T40399 Approx 1900 rpm A4T40379 crankshaft pulley PCD 193mm Approx 2100 rpm A4TU7686 Approx 2150 rpm A4T40379 crankshaft pulley PCD 168mm PCD Pitch circle diameter The alter...

Page 304: ...peres or less when the engine speed is raised to the appropriate speed indicated below then mea sure the voltage at terminal B Approx 1400 rpm A4T40399 Approx 1900 rpm A4T40379 crankshaft pulley PCD 193mm Approx 2100 rpm A4TU7686 Approx 2150 rpm A4T40379 crankshaft pulley PCD 168mm PCD Pitch circle diameter CAUTION If the output current is in the range from 5 to 10 amperes the measured value regul...

Page 305: ... vant components 1 Pre glow time checking Turn the starter switch to ON without starting the engine and confirm that the pre glow time or check lamp ON time at each water temperature conform with standard values 2 After glow time checking Start the engine and measure the check lamp ON time to en sure that the after glow time conforms with the standard val ue Location Maintenance item Standard valu...

Page 306: ...r Compressor 61 4 2 Air Dryer 61 6 TROUBLESHOOTING 61 9 GENERAL INSPECTION AND ADJUSTMENT 1 Maintenance and Inspection of Air Dryer 61 10 2 Inspection and Adjustment of Air Dryer s Air Pressure Governor 61 11 AIR COMPRESSOR 154 cm3 154 mL 61 14 319 cm3 319 mL 61 18 AIR DRYER 61 22 ...

Page 307: ...anwa Seiki Item Specifications Model DU 4 Heater capacity V W 24 70 Thermostat operating temperature C ON 4 4 OFF 16 4 Purge chamber capacity dm3 L 1 0 1 0 Required time for recycling desiccant sec 30 Air pressure governor operating pressure kPa kgf cm2 Upper threshold pressure 890 9 1 Lower threshold pressure 760 15 7 8 0 15 Manufacturer Nabtesco 29 20 0 3 0 2 SPECIFICATIONS ...

Page 308: ...M E M O 61 3 61 ...

Page 309: ...61 4 1 Air Compressor STRUCTURE AND OPERATION ...

Page 310: ... to open allowing air to be drawn into the cylinder 1 2 During compression and delivery When the piston goes up during the compression and delivery stroke cycle the suction valve is closed by air pressure Air pressure compressed by the piston forces open the delivery valve and makes its way to the air dryer and air tank ...

Page 311: ... s supply side Moisture and oil are separated from the air inside the body and collect in the bottom The air then passes through the oil filter which removes smaller oil droplets and particles of dust The air then flows into the case where the desic cant removes any remaining moisture As the air flows upward in the case it makes contact with increasingly dry desiccant and thus contains less and le...

Page 312: ...er nor continues to act upon the control port and the valve remains open Air from the air compressor thus flows through the valve through the silenc er and out into the atmosphere The regeneration process continues until air consumption causes the pres sure in the air tank to decrease to the governor lower threshold level 2 3 Operation when tank pressure reaches upper threshold level Air pressure ...

Page 313: ... pressure A from the air tank drops below the lower threshold level the piston is pushed downward by the spring such that the inlet valve closes and the exhaust valve opens As a result air pressure flows through the exhaust stem and escapes to the atmosphere STRUCTURE AND OPERATION ...

Page 314: ...perative heater causing air dryer to freeze O Malfunctioning of valve due to adherence of foreign particles O Heater circuit open and therefore no heat retention O Heater malfunction due to thermostat malfunction O Extreme lowering of temperature of air dryer main body due to ad herence of snow ice O Heater malfunction due to disconnection with thermostat O Dry air in air tank flows out in reverse...

Page 315: ...ccant down following the manners Before tapping the case against the work surface lay two or three layers of shop towel on the work surface to protect the bottom of the case from scratches Holding down the filter plate with both hands lift the case to a height of about 100 mm and tap it gently against the work sur face Tap the case about 30 more times Make sure the filter plate drops by 4 to 6 mm ...

Page 316: ...is expelled from the exhaust cover If the pressure indicated by either of the pressure gauges A B decreases air is leaking from the check valve and air pressure governor in the air dryer causing continuous charging and purg ing Carry out disassembly and inspection Location Maintenance item Standard value Limit Remedy Threshold pressure Upper threshold pressure 890 kPa Adjust 9 1 kgf cm2 Lower thre...

Page 317: ...andard value the upper threshold pressure If the indicated pressure deviates from the standard value make further adjustments With the upper threshold pressure indicated air from the air compressor is expelled from the exhaust cover continuously With the equipment in this condition open the drain cock to gradually reduce the air pressure When air stops being expelled from the exhaust cover check w...

Page 318: ...M E M O 61 13 61 ...

Page 319: ...61 14 AIR COMPRESSOR 154 cm3 154 mL ...

Page 320: ...big end and crankshaft 0 1 Replace 20 Crankshaft end play 0 7 Replace 20 21 Clearance between crankshaft and crankcase bushing inside diameter 0 2 Replace Mark Parts to be tightened Tightening torque Remarks Nut compressor gear mounting 167 to 186 17 to 19 Bolt cylinder head mounting 29 to 34 3 0 to 3 5 Bolt cylinder liner mounting 25 to 29 2 5 to 3 0 Bolt coupling mounting 53 to 65 5 4 to 6 6 Nut...

Page 321: ...erse See Removal Compression rings Installation Lock washer compressor gear Install the compressor gear onto the crankshaft ensuring that O mark on the compressor gear is aligned with O mark on the crankshaft Insert the protrusion of the lock washer such that the O mark on the compressor gear remains exposed Tighten the nut to the specified torque Bend one part at the bot tom of the lock washer to...

Page 322: ...M E M O 61 17 61 ...

Page 323: ...61 18 AIR COMPRESSOR 319 cm3 319 mL ...

Page 324: ...ay 1 0 Replace 22 23 Clearance between crankshaft and crankcase bushing inside diameter 0 12 Replace Mark Parts to be tightened Tightening torque Remarks Nut compressor gear mounting 167 to 186 17 to 19 Bolt cylinder head mounting 29 to 34 3 0 to 3 5 Nut connecting rod cap mounting 23 to 25 2 3 to 2 6 Bolt valve seat mounting Nut cylinder liner cap mounting 25 to 29 2 5 to 3 0 Bolt coupling mounti...

Page 325: ... end gaps are located as shown in the illustration Install the compression rings by following the removal sequence in reverse See Removal Compression rings Installation Lock washer compressor gear Install the compressor gear onto the crankshaft ensuring that O mark on the compressor gear is aligned with O mark on the crankshaft Insert the protrusion of the lock washer such that the O mark on the c...

Page 326: ...M E M O 61 21 61 ...

Page 327: ...61 22 AIR DRYER ...

Page 328: ...valve piston and valve body mounting 3 9 to 6 9 0 4 to 0 7 Plug 14 7 to 24 5 1 5 to 2 5 Silencer 29 4 to 39 2 3 0 to 4 0 1 Purge chamber 2 O ring 3 Check valve 4 Case cover 5 O ring 6 Set spring 7 Filter plate 8 Filter 9 Desiccant 10 Filter 11 Filter plate 12 Case 13 Oil filter 14 O ring 15 Cover 16 Gasket ring 17 Gasket ring 18 Plate 19 Seat 20 Retaining ring 21 Upper spring seat 22 Spring 23 Low...

Page 329: ...te Install the filters with their soft layers facing the desiccant Place the desiccant in the case then settle the desiccant by tap ping gently and evenly around the case with a plastic hammer Mark Points of application Specified lubricant and or sealant Quantity O ring Multipurpose grease NLGI No 2 Li soap As required Adjusting screw entire surface except thread Outer periphery of piston and O ri...

Page 330: ...y escape and create blockages in brake lines thus preventing normal brake operation Inspection after installation Inspection Air leakage Completely plug the delivery side of the air dryer then apply air pressure of 49 kPa 0 5 kgf cm2 or 780 kPa 8 kgf cm2 to the supply side and check that no air leaks from any joint Leakage from the valve assembly must not exceed 20 cm3 per minute Increase the pres...

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