servic d r motor nissan fe6 fe6t fe6ta

FE series FE6,FE6T & FE6TA

Pub.No. SMEFES2E01

ENGINE

ENGINESERVICE MANUAL

Applicable Engine NumbersFE6-200001 —

FOREWORDThis manual describes the service, by system, of theengine of FE6A, FE6B, FE6T and FE6TA models. In order for a vehicle to perform at its best, and toextend vehicle life, maintenance should be performedproperly. Also, overhaul and repair should beeffected in accordance with prescribed service stan-dards.This manual should be kept readily available in theworkshop as a helpful reference for those engaged inservicing vehicles.Nissan Diesel Motor Co., Ltd. reserves the right tomake changes for improvement at any time withoutnotice.This manual is based on vehicles that were manufac-tured on or before April.1, 1998. Revisions, if any, willbe introduced in the Technical Bulletin.

QUICK REFERENCE INDEX

FM edition: Mar. 20051st edition: Jun. 19989904K30-14203-100-SZ1(M)

MAINTENANCE

TROUBLE DIAGNOSIS

ENGINE PROPER

MA

TD

EP

GENERAL GE

CYLINDER HEAD AND VALVE MECHANISM HV

LUBRICATION SYSTEM LB

COOLING SYSTEM EC

FUEL SYSTEM EF

AIR INTAKE AND EXHAUST SYSTEM IE

ELECTRICAL SYSTEM EE

AUXILIARY EQUIPMENT EA

© 1999 NISSAN DIESEL MOTOR CO., LTD.

ENGINE DISASSEMBLY AND REASSEMBLY DR

MODELFE6 series

- 1 -

HOW TO USE THIS MANUALA quick reference index, a black tab is provided on the first page, so you can quickly find the firstpage of each chapter by mating it to the chapter’s black tab.

The contents are listed on the first page of each chapter.

Construction illustration: The assembled unit is indicated. The construction illustration includes the names of the major compo-nents, items requiring adjustment after reassembling and their maintenance standards.

[EXAMPLE]

- 2 -

Exploded illustration: The number given to each part in the illustration corresponds to the number attached to each partname, and the number is determined according to the operation sequence.

No. 1, 2, 3 Disassembly sequence Reassembly sequence is in the reverse order of disassembly. The marks “ ” and “ ” affixed to the part name number indicate that the key points of operation (pre-cautions, technique, use of special tools, and other maintenance information) are explained in the text.

: Key points of disassembly : Key points of reassembly

The tightening torque necessary for maintenance and lubricating points are indicated by symbols in theillustration.

NOTEDisassembly and reassembly sequences show general examples and in some operations itmay be possible to change sequences.

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Marks “ ” and “ ” indicate that the key points of operation are explained in the text.

1. Plug 4. Ball 7. Driven gear assembly2. Gasket 5. Cover 8. Pump gear assembly3. Spring 6. Gasket

- 3 -

Removal and installation, disassembly and reassembly: Explanation of removal and installation, disassembly and reassembly is limited to the parts indicated bythe star marks “ ” and “ ” affixed to the sequence number in the exploded illustration.

NOTEIf there are no “ ” and “ ” marks affixed to the parts, general explanation is given for thoseparts.

The following marks and abbreviations are used in this manual. Marks:

: Tightening torque : Should be lubricated with grease. Unless otherwise indicated, use recommended multi-pur-pose grease.

: Should be lubricated with oil.: Sealing point: Always replace after every disassembly.

Abbreviations

Engine position:

Unit: This manual uses mainly SI units with metric and yard/pound system equivalents in braces.

Specific terms related to the maintenance standard Maintenance standard “Maintenance standard” indicates the standard clearance when parts are assembled or the standardperformances of assembly parts. Service limit “Service limit” indicates the limit value where adjustment, correction or parts replacement must bedone.

The captions WARNING and CAUTION warn you about procedures that must be followed to pre-vent personal injury and/or damage to some parts of the vehicle.

T.D.C.: Top dead center I.D.: Inside diameterB.T.D.C.: Before top dead center Dia.: Diameter A.T.D.C.: After top dead center S.T.D.: StandardB.B.D.C.: Before bottom dead center O.S.: Oversize A.B.D.C.: After bottom dead center U.S.: UndersizeO.D.: Outside diameter Ass’y: Assembly

- 4 -

Engine model:

Engine models specified for TAIWAN are different from those for general markets. Hereinafter, engine mod-els will be described by specifications for general markets. For TAIWAN specifications, use the above table toidentify the engine model specification for TAIWAN when reading this service manual. NOTE

Only maintenance interval information includes information for TAIWAN engine models.

Max. gross output (JIS)kW PS/rpm

Engine modelFor general markets For TAIWAN

118 160/3,000 FE6A —119 162/3,000 FE6B FE6132 180/3,000 FE6B —135 183/3,000 FE6T FE6T151 205/2,800 FE6T FE6T-Z162 220/2,800 FE6T —157 213/2,800 FE6TA —173 235/2,800 FE6TA FE6TA

- 5 -

- MEMO -

GENERAL

CONTENTSSPECIFICATIONS .................................. GE-1-1

ENGINE SPECIFICATIONS............................. GE-1-1ENGINE NUMBERS......................................... GE-1-9

LUBRICATION........................................ GE-2-1PRECAUTIONS ...................................... GE-3-1

PREPARATION ................................................ GE-3-1GENERAL REMARKS REGARDING IN DISASSEMBLY OPERATIONS ................... GE-3-1CLEANING AND INSPECTION........................ GE-3-2

STANDARD TIGHTENING TORQUE ..... GE-4-1

GE

SPECIFICATIONS

GE-1-1

SPECIFICATIONSENGINE SPECIFICATIONSEngine models FE6A and FE6B

Engine modelItem FE6A FE6B

Max. gross output (JIS) kW PS/rpm 118 160/3,000 119 162/3,000 132 180/3,000Type DieselCooling method Water cooledNumber of cylinders and cylinder arrangement 6, in-lineStroke cycle 4Combustion chamber Direct fuel injectionValve mechanism Overhead valveCylinder liner DryBore x stroke mm (in) 108 x 126 (4.25 x 4.96)Compression ratio 18.0

Cylinder compression kPa kgf/cm2, psi/rpm 2,942 30, 427/200

Idling speed 600

Valve timingIntake

Open (B.T.D.C.) 15ºClosed (A.B.D.C.) 40º

ExhaustOpen (B.B.D.C.) 53ºClosed (A.T.D.C.) 9º

Valve clearance mm (in)Intake 0.3 - 0.4 (0.012 - 0.016)Exhaust 0.3 - 0.4 (0.012 - 0.016)

Lubr

icat

ion

sys

tem

Lubrication system Forced-circulation typeOil pump Gear pumpOil filter Cartridge typeOil cooler Water cooled flat tube type

Regulator valve opening pressure kPa kgf/cm2, psi 422 - 461 4.3 - 4.7, 61 - 67

Coo

ling

syst

em

Cooling system Forced-circulation typeRadiator type Corrugated fin

Cooling fan Outside diameter - Number of finsmm (in)

480 (18.90) - 6485 (19.09) - 8

510 (20.08) - 6485 (19.09) - 8 510 (20.08) - 7530 (20.87) - 6 530 (20.87) - 6

Water pump Centrifugal, belt-driven typeThermostat Wax pellet type

SPECIFICATIONS

GE-1-2


Fuel

sys

tem

Ignition system Compression ignitionFuel injection timing (B.T.D.C.) 14º 15º 12ºIgnition order 1-4-2-6-3-5Fuel feed pump Plunger typeFuel filter Cartridge type and primary fuel filter

Fuel injection pump

Type BoschPlunger diameter mm (in) 9.5 (0.374) 9.0 (0.354) 9.5 (0.374)Plunger lead Right lead

Cam lift mm (in)Injection pump 8.0 (0.315) 9.0 (0.354)Feed pump 6.0 (0.236)

GovernorType CentrifugalType name RAD/RLD/RFD RLD RAD/RLD/RFD

TimerType Centrifugal

Type name SA SA (RAD, RLD)/SAG (RFD)

Fuel injectionnozzle

Type Conventional typeNozzle holder Flange typeNozzle Multi-jetIdentification mark Z D2 ZNumber of nozzle holes 5

Injection pressure kPa kgf/cm2, psi 19,614 200, 2,844

Overflow valve opening pressurekPa kgf/cm2, psi

Injection pump outlet 157 1.6, 23

Fuel filter 108 - 147 1.1 - 1.5, 16 - 21

Air i

ntak

e an

d ex

haus

t sys

tem

Air cleaner Paper element (Dry: Single or dual type)

Turbocharger

Model —External dimensions(Length x Width x Height) mm (in) —

Maximum permissible continuous speed —

Direction of rotation —Air volume kg (lb)/min —Compression ratio —

Exhaust brakeType Chamber type Cylinder typeOperating method Vacuum type Air type

SPECIFICATIONS

GE-1-3


Elec

trica

l sys

tem

Starting motorType Shift typeModel 0350 502 0310/0350 502 0321Output V-kW 24-4.5

Alternator

Type AC, diode-rectified

Model0202 152 0310

0201 152 0420/0201 152 04210202 152 0311

Output V-A 24-50Regulator IC-transistor type

Air heaterType RibbonVoltage x Current - Number V-A 22 x 85 - 1

Auxi

liary

equ

ipm

ent Air compressor

Type Reciprocating typeBore x stroke - Number of cylinders

mm (in) 85 x 40 - 1 (3.35 x 1.57 - 1)

Cooling system Water cooled

Engine rear PTO

Allowable maximum torqueN·m kgf·m, ft·lbf 343 35, 253

Direction of rotation Clockwise (as viewed from the rear)Gear ratio (PTO gear : crankshaft gear) 1.264 (67 : 53)

Vacuum pumpType Vane —Model VD-120 —

SPECIFICATIONS

GE-1-4

Engine model FE6TEngine model

Item FE6T

Max. gross output (JIS) kW PS/rpm 135 183/3,000 151 205/2,800 162 220/2,800Type DieselCooling method Water cooledNumber of cylinders and cylinder arrangement 6, in-lineStroke cycle 4Combustion chamber Direct fuel injectionValve mechanism Overhead valveCylinder liner DryBore x stroke mm (in) 108 x 126 (4.25 x 4.96)Compression ratio 18.0 17.5


Idling speed 600

Valve timingIntake

Open (B.T.D.C.) 15ºClosed (A.B.D.C.) 30º



Lubr

icat

ion

sys

tem



Coo

ling

syst

em


Cooling fan Outside diameter - Number of finsmm (in) 510 (20.08) - 7

510 (20.08) - 7580 (22.83) - 7580 (22.83) - 6

580 (22.83) - 7Water pump Centrifugal, belt-driven typeThermostat Wax pellet type

SPECIFICATIONS

GE-1-5

Engine modelItem FE6T

Fuel

sys

tem

Ignition system Compression ignitionFuel injection timing (B.T.D.C.) 12º 10º 9ºIgnition order 1-4-2-6-3-5Fuel feed pump Plunger typeFuel filter Cartridge type and primary fuel filter

Fuel injection pump

Type BoschPlunger diameter mm (in) 9.0 (0.354)Plunger lead Right lead

Cam lift mm (in)Injection pump 9.0 (0.354) 10.0 (0.394)Feed pump 6.0 (0.236)

GovernorType CentrifugalType name RLD

TimerType CentrifugalType name SA SAG


Type Conventional typeNozzle holder Flange typeNozzle Multi-jetIdentification mark D3 A5 A6Number of nozzle holes 5

Injection pressure kPa kgf/cm2, psi19,614

200, 2,84421,575

220, 3,12819,614

200, 2,844Overflow valve opening pressurekPa kgf/cm2, psi

Injection pump outlet 157 1.6, 23

Fuel filter 108 - 147 1.1 - 1.5, 16 - 21

Air i

ntak

e an

d ex

haus

t sys

tem


Turbocharger

Model T04B RHC62E

External dimensions(Length x Width x Height) mm (in)

220 x 190 x 160(8.66 x 7.48 x

6.30)

218 x 238 x 145(8.58 x 9.37 x 5.71)

Maximum permissible continuous speed 138,000 150,000

Direction of rotation Counterclockwise as viewed from the exhaust tur-bine side

Air volume kg (lb)/min 21 (46) 18.8 (41.5)Compression ratio 3.2

Exhaust brakeType Cylinder typeOperating method Air type

SPECIFICATIONS

GE-1-6

Engine modelItem FE6T

Elec

trica

l sys

tem

Starting motorType Shift typeModel 0350 502 0310/0350 502 0321 0350 502 0321Output V-kW 24-4.5

Alternator


Model 0201 152 0420/0201 152 04210201 152 04210201 222 0273

Output V-A0201 152 04200201 152 0421 24-50

0201 222 0273 — 24-80Regulator IC-transistor type


Auxi

liary

equ

ipm

ent

Air compressor

Type Reciprocating type

Bore x stroke - Number of cylin-ders

mm (in)

408738-560085 x 40 - 1 (3.35 x 1.57 - 1)

—408738-5601 85 x 40 - 1

(3.35 x 1.57 - 1)408738-5611 — —408738-5741 — 85 x 60 - 1 (3.35 x 2.36 - 1)


Engine rear PTO



SPECIFICATIONS

GE-1-7

Engine model FE6TAEngine model

Item FE6TA

Max. gross output (JIS) kW PS/rpm 157 213/2,800 173 235/2,800Type DieselCooling method Water cooledNumber of cylinders and cylinder arrangement 6, in-lineStroke cycle 4Combustion chamber Direct fuel injectionValve mechanism Overhead valveCylinder liner DryBore x stroke mm (in) 108 x 126 (4.25 x 4.96)Compression ratio 17.5


Idling speed 600

Valve timingIntake

Open (B.T.D.C.) 15ºClosed (A.B.D.C.) 30º 40º



Lubr

icat

ion

sys

tem



Coo

ling

syst

em


Cooling fan Outside diameter - Number of finsmm (in)

510 (20.08) - 7 580 (22.83) - 6580 (22.83) - 7 580 (22.83) - 7

Water pump Centrifugal, belt-driven typeThermostat Wax pellet type

SPECIFICATIONS

GE-1-8

Engine modelItem FE6TA

Fuel

sys

tem

Ignition system Compression ignitionFuel injection timing (B.T.D.C.) 3º 12ºIgnition order 1-4-2-6-3-5Fuel feed pump Plunger typeFuel filter Cartridge type and primary fuel filter

Fuel injection pump

Type TC-MD BoschPlunger diameter mm (in) 11.0 (0.433) 9.0 (0.354)Plunger lead Right lead

Cam lift mm (in)Injection pump 10.0 (0.394)Feed pump 6.0 (0.236)

GovernorType CentrifugalType name RLD

TimerType — CentrifugalType name — SAG

Injection timing control Electronic (MD-TICS) —


Type Conventional typeNozzle holder Flange typeNozzle Multi-jetIdentification mark F4 or C1 A3Number of nozzle holes 5Injection pressure

kPa kgf/cm2, psi19,614 200, 2,844 1st: 16,672 170, 2,417

2nd: 21,575 220, 3,128

Overflow valve opening pressurekPa kgf/cm2, psi

Injection pump outlet 255 2.6, 37 157 1.6, 23

Fuel filter 108 - 147 1.1 - 1.5, 16 - 21

Air i

ntak

e an

d ex

haus

t sys

tem


Turbocharger

Model T04E RHC6VExternal dimensions(Length x Width x Height) mm (in)

230 x 195 x 265(9.06 x 7.68 x 10.43)

246 x 214 x 196(9.69 x 8.43 x 7.72)

Maximum permissible continuous speed 125,000 150,000

Direction of rotation Counterclockwise as viewed from the exhaust tur-bine side

Air volume kg (lb)/min 20 (44) 19.4 (42.8)Compression ratio 3.2

Exhaust brakeType Cylinder typeOperating method Air type

SPECIFICATIONS

GE-1-9

ENGINE NUMBERSThe engine serial number is stamped on the right side of the cylin-der block.

*Engine specificationA: Natural aspirated engineB: Natural aspirated engineC: Turbocharged engineD: Turbocharged engine with intercooler

Engine modelItem FE6TA

Elec

trica

l sys

tem

Starting motor

Type Shift type

Model 0350 502 0321 0350 502 0310/0350 502 0321

Output V-kW 24-4.5

Alternator


Model 0201 152 0421 0202 152 0220/0202 152 0221

Output V-A 24-50Regulator IC-transistor type


Auxi

liary

equ

ipm

ent Air compressor

Type Reciprocating type

Bore x stroke - Number of cylin-ders

mm (in)

408738-5610408738-5611 — 85 x 40 - 1

(3.35 x 1.57 - 1)

408738-5780 85 x 40 - 1(3.35 x 1.57 - 1) —

F8040 80 x 40 - 1(3.15 x 1.57 - 1) —


Engine rear PTO



Vacuum pumpType Vane —Model VD-30 —

FE6-XXXXXXC*

Engine serial numberEngine model

LUBRICATION

GE-2-1

LUBRICATIONRECOMMENDED FUEL AND LUBRICANTS

NOTEIt is recommended that API CD class multi-grade oil be used as engine oil for turbochargedengines.

RECOMMENDED SAE VISCOSITY NUMBERUse oil having the proper viscosity beforehand which meets tem-peratures forecast for areas where you are planning to drive.

CAPACITIES (APPROXIMATELY)

NOTECapacities shown are for reference only. When filling, observe the specified level. * Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).

Lubricant Specifications Remarks

Engine oil API CC or CD For further details, refer to the recom-mended SAE viscosity chart.

Power steering fluid DEXRON® or DEXRON® II GM ATF type

Bearing grease NLGI No. 2 Lithium soap baseAntifreeze — Ethylene glycol base

FuelAbove –7ºC (20ºF) 2-D Diesel fuel or equivalent blended diesel fuel Check with the service establishment to

be sure you get the properly blended fuel.Below –7ºC (20ºF) 1-D Diesel fuel or equivalent blended diesel fuel

Item Liter (Imp measure)

Engine oilEngine oil pan (H-level)

FE6A, FE6B, FE6T, FE6TA 12 (2-5/8 gal)FE6TA* 14 (3-1/8 gal)

TotalFE6A, FE6B, FE6T, FE6TA 15 (3-1/4 gal)FE6TA* 17 (3-3/4 gal)

Power steering systemMK and LK series 3 (2-5/8 qt)PK series 5.5 (4-7/8 qt)

Cooling system 22 (4-7/8 gal)

Fuel tank

Square type

100 (22 gal)130 (28-5/8 gal)

200 (44 gal)100 + 100 (22 gal + 22 gal)

Round type109 (24 gal)150 (33 gal)227 (50 gal)

PRECAUTIONS

GE-3-1

PRECAUTIONSPREPARATIONObserve the following when servicing the vehicle.

Park the vehicle on a flat surface; otherwise, the correct oil level cannot be checked and the vehiclemay move abruptly.Engage the parking brake and chock the wheels securely.If the engine is hot, wait until it cools off.Set the transmission gear shift lever to “NEUTRAL”.Turn the key switch to “OFF”. Disconnect the ground cable when servicing the electrical system.Do not touch rotating parts of the engine if servicing requires engine operation. Always operate theengine in a well-ventilated area.When tilting the cab indoors, make sure that there is aclearance of at least 4 m (13.1 ft) in H and a clearance of 1m (3.3 ft) in F.

GENERAL REMARKS REGARDING IN DISAS-SEMBLY OPERATIONSChecks before disassemblyBefore starting to disassemble a system or unit, familiarize yourself with the cause of the problem. Forinstance, if the engine is to be disassembled, the problem may be due to an unusual noise, lack of power or oilleakage. Recognizing the problem in advance will be extremely helpful in locating which part of the engineneeds to be disassembled and which part does not. It will also save time and labor.

Work required during disassemblyScribe alignment marks on parts where necessary so that they can be easily reinstalled in their original posi-tions. When repairs involve the electrical system, disconnect the ground cable from the battery.

Checks during disassemblyWhenever each part is disassembled, check for mounting condition, scratches, dirt, damage, etc. Work effi-ciency will be degraded after all parts have been disassembled.

Keeping disassembled parts in orderKeep all disassembled parts in order so that they can be readily reinstalled. Separate parts which must bereplaced with new ones and those which should be reinstalled. Replace packings, gaskets, cotter pins, etc.Do not touch electrical parts, rubber parts, V-belt, etc., with dirty hands. These parts should not be contami-nated with water or oil. Keep them in one place and away from those having engine oil on them.

Cleaning disassembled partsClean all disassembled parts in cleaning solvent immediately before reassembly. If they are not cleaned,scratches, cracks or damage may be overlooked. This may result in entry of dirt or dust, causing problemsafter reassembly.

ReinstallationInstall parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.).Apply a coat of grease, liquid packing or sealer to designated parts.

Adjustment and operational checksUse gauges or testers to adjust the parts within specifications if so designated. Also check movable parts forproper operation.

PRECAUTIONS

GE-3-2

CLEANING AND INSPECTIONCLEANINGThe parts will be coated with dirty oil and sludge. Cleaning is mandatory. Suitable cleaning methods includesteam cleaning, light oil cleaning, acidic or alkaline solution cleaning, neutral agent cleaning, trichloroethylenesteam cleaning, and magnus solution cleaning. The cleaning process may reveal damage. So check closelywhile the cleaning is in process.

METAL PARTSLight oilUnlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless thesurface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with twowashings.

Alkaline solutionDo not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steeland cast iron parts quite well.NOTE

If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent(such as boric acid solution), since the alkaline solution must be immediately washed from theskin or eyes in the event of contact.

RUBBER PARTSDo not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.

OIL PASSAGESPass a wire through oil passages to make sure that they are free. Clean the oil passages with solvent that isinjected under pressure from a nozzle.

PROTECTION AGAINST CORROSIONAfter removing all traces of old oil and grease from the surfaces of the parts, apply a coat of clean oil to them toprevent corrosion.

INSPECTIONParts should be inspected using designated measuring instruments or tools. Whether the parts are suitable forfurther use should be determined by consulting the specified Maintenance Standards chart. Faulty partsshould be corrected or replaced as required. If one of the mating parts is found to be worn to such an extentthat the specified clearance is exceeded, replace it and/or its mate as the occasion demands.Parts which are still within the repair or wear limit should sometimes be replaced before they exceed the limitfrom preventive maintenance viewpoint.All parts should be checked carefully by looking at their appearance or by using the “red” (penetration) method,whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities,the affected part(s) should be repaired or replaced, as required.All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed.Abnormalities

Uneven wearGraded wearScratchesCracksDeformityFatigue or weakness (for springs and rubbers, etc.)BendsLoose fitUnusual noise (for bearings)Discoloration or jammingRust formationDeterioration (for brake linings, etc.)

STANDARD TIGHTENING TORQUE

GE-4-1

STANDARD TIGHTENING TORQUEThe tightening torque of the bolts and other fasteners that secure the major components parts is specified inthe text. In case there is no mention of tightening torque, these bolts and fasteners should be tightened accord-ing to the following table of bolt standard tightening torque.NOTE

All bolts and nuts are sized using the metric system. Do not use parts other than those desig-nated.

NOTESpecial parts are excluded.This standard is applicable to bolts having the following marks embossed on the bolt head.

Mark4T .............................. 47T .............................. 79T .............................. 9

Standard tightening torque of tubing connector

Nominal size

Bolt dia.mm

Pitchmm

Standard tightening torque (Without lubricant)4T 7T 9T

N·m kgf·m ft·lbf N·m kgf·m ft·lbf N·m kgf·m ft·lbfM6 6.0 1.0 5.1 0.52 3.8 8.4 0.86 6.2 12 1.2 9

M8 8.01.25 13 1.3 9 21 2.1 15 29 3.0 221.0 13 1.3 9 22 2.2 16 31 3.2 23

M10 10.01.5 25 2.5 18 41 4.2 30 59 6.0 43

1.25 25 2.6 19 43 4.4 32 62 6.3 46

M12 12.01.75 42 4.3 31 71 7.2 52 98 10.0 721.25 46 4.7 34 77 7.9 57 108 11.0 80

M14 14.0 1.5 74 7.5 54 127 13.0 94 177 18.0 130M16 16.0 1.5 108 11.0 80 186 19.0 137 275 28.0 203M18 18.0 1.5 167 17.0 123 275 28.0 203 392 40.0 289M20 20.0 1.5 226 23.0 166 382 39.0 282 549 56.0 405M22 22.0 1.5 304 31.0 224 510 52.0 376 736 75.0 542

ItemStandard tightening torque

N·m kgf·m ft·lbf

Flared nut Tube O.D. mm (in)

4.76 (0.1874) 13 - 18 1.3 - 1.8 9 - 136.35 (0.2500) 16 - 24 1.6 - 2.4 12 - 17

8.0 (0.315) 29 - 39 3.0 - 4.0 22 - 2910.0 (0.394) 39 - 49 4.0 - 5.0 29 - 3612.0 (0.472) 59 - 78 6.0 - 8.0 43 - 5815.0 (0.591) 69 - 93 7.0 - 9.5 51 - 69

Nipple nut [Tube O.D. 6.35 mm (0.2500 in)] 21 - 28 2.1 - 2.9 15 - 21Eye connector [Tube O.D. 6.35 mm (0.2500 in)] 42 - 57 4.3 - 5.8 31 - 42

- MEMO -

MAINTENANCE

CONTENTSSERVICE DATA...................................... MA-1-1

SERVICE DATA ............................................... MA-1-1TIGHTENING TORQUE ................................... MA-1-2

TOOLS .................................................... MA-2-1PERIODIC MAINTENANCE SCHEDULES .......................................... MA-3-1

MAINTENANCE INTERVALS........................... MA-3-2PERIODIC PARTS REPLACEMENT ............... MA-3-4

MAINTENANCE PROCEDURE............... MA-4-1BASIC MECHANICAL SYSTEM....................... MA-4-1LUBRICATION SYSTEM.................................. MA-4-4COOLING SYSTEM.......................................... MA-4-9FUEL SYSTEM................................................. MA-4-17INTAKE AND EXHAUST SYSTEM................... MA-4-27OTHERS........................................................... MA-4-32

MA

SERVICE DATA

MA-1-1

SERVICE DATASERVICE DATA

Item Maintenancestandard Service limit Remarks

Basi

c m

echa

nica

l sys

tem

Valve clearancemm (in)

Intake 0.3 - 0.4(0.012 - 0.016) —

When engine is coldExhaust 0.3 - 0.4

(0.012 - 0.016) —

Cylinder compression pressurekPa kgf/cm2, psi

2,942 30, 427 1,961 20, 284 At 200 rpm withengine warm

Difference between cylinders kPa kgf/cm2, psiLess than392 4, 57 —

Valve timing

FE6AFE6BFE6TA173 kW235 PS

IntakeOpen 15° B.T.D.C. —

Closed 40° A.B.D.C. —

ExhaustOpen 53° B.B.D.C —

Closed 9° A.T.D.C. —

FE6TFE6TA157 kW213 PS

IntakeOpen 15° B.T.D.C. —

Closed 30° A.B.D.C. —

ExhaustOpen 53° B.B.D.C —

Closed 9° A.T.D.C. —

Coo

ling

syst

em

V-belt deflectionmm (in)

Fan pulley -alternator pulley 10 - 15 (0.39 - 0.59) — With a force of about

98 N 10 kgf, 22 lbf applied to the mid part

Fan pulley -cooler compressor pulley 7 - 12 (0.28 - 0.47) —

Radiator cap operating pressurekPa kgf/cm2, psi

39 - 590.4 - 0.6, 6 - 9 — Pressure side

Thermostat

Valve opening temperature°C (°F)

76.5 (170) 74.5 - 78.5 (166 - 173)

71.5 - 81.5 (161 - 179)

82 (180) 80 - 84 (176 - 183) 77 - 87 (171 - 189)

88 (190) 86 - 90 (187 - 194) 85 - 93 (185 - 199)

Valve lift/ tem-perature

mm/°C (in/°F)

76.5 (170) More than 10/90(0.39/194)

Less than 9/90(0.35/194)

82 (180) More than 10/95(0.39/203)

Less than 9/95(0.35/203)

88 (190) More than 10/100(0.39/212)

Less than 9/100(0.35/212)

SERVICE DATA

MA-1-2

TIGHTENING TORQUEUnit: N·m kgf·m, ft·lbf

Fuel

sys

tem

Fuel injection timing (B.T.D.C.)

FE6A 14° —

FE6B119 kW 162 PS 15° —

132 kW 180 PS 12° —

FE6T

135 kW 183 PS 12° —

151 kW 205 PS 10° —

162 kW 220 PS 9° —

FE6TA157 kW 213 PS 3° — “MD-TICS” system

173 kW 235 PS 12° —

Idle speed rpm

FE6A, FE6B, FE6T 600 —

FE6TA157 kW 213 PS 650 —

173 kW 235 PS 550 —

Maximum speed rpm 3,200 —

No-load maximum engine speed rpm 3,600 —


Item Tightening torque

Basicmechanicalsystem

Valve clearance adjusting screw lock nut 34 - 44 3.5 - 4.5, 25 - 33Cylinder head mounting bolt 177 - 196 18.0 - 20.0, 130 - 145Air intake manifold mounting bolt and nut 16 - 20 1.6 - 2.0, 12 - 14Exhaust manifold mounting nut 34 - 44 3.5 - 4.5, 25 - 33Compression gauge mounting bolt 25 - 29 2.5 - 3.0, 18 - 22Crank damper mounting bolt 59 - 69 6.0 - 7.0, 43 - 51

Lubricationsystem Oil pan drain plug 59 - 69 6.0 - 7.0, 43 - 51

Coolingsystem

Alternator adjusting bolt 34 - 44 3.5 - 4.5, 25 - 33Alternator anchor bolt and nut 59 - 74 6.0 - 7.5, 43 - 54Cooler tension pulley lock nut 35 - 47 3.6 - 4.8, 26 - 35

SERVICE DATA

MA-1-3

Fuelsystem

Injection pump drive coupling bolt and nut

FE6A, FE6B, FE6T, FE6TA173 kW 235 PS

29 - 34 3.0 - 3.5, 22 - 25

FE6TA157 kW 213 PS 59 - 64 6.0 - 6.5, 43 - 47

Injection pump drive coupling cot-ter bolt


59 - 64 6.0 - 6.5, 43 - 47

FE6TA157 kW 213 PS 83 - 93 8.5 - 9.5, 61 - 69

Delivery valve holder


49 - 54 5.0 - 5.5, 36 - 40

FE6TA157 kW 213 PS 103 - 113 10.5 - 11.5, 76 - 83

Injection nozzle retaining nut 59 - 78 6.0 - 8.0, 43 - 58Nozzle holder mounting bolt 25 - 29 2.5 - 3.0, 18 - 22Injection pump bleeder screw 7 - 9 0.7 - 0.9, 5.1 - 6.5Fuel filter (center bolt type) center bolt 20 - 29 2.0 - 3.0, 14 - 22

Primary fuel filter center boltType I 20 - 29 2.0 - 3.0, 14 - 22Type II 59 - 69 6.0 - 7.0, 43 - 51

Primary fuel filter drain plug (Type II only) 16 - 22 1.6 - 2.2, 12 - 16Fuel strainer center bolt 15 - 20 1.5 - 2.0, 11 - 14Fuel filter eye bolt 25 - 41 2.5 - 4.2, 18 - 30

Air intakeand exhaustsystem

Compressor housing and back plate mounting bolt

N·m kgf·cm, in·lbf

T04BT04E 11.3 - 14.7 115 - 150, 100 - 130

RHC62ERHC62V 7.4 - 8.3 75 - 85, 65 - 74

Turbine housing and center hous-ing mounting bolt

N·m kgf·cm, in·lbf

T04BT04E 18.0 - 21.5 184 - 219, 160 - 190

RHC62ERHC62V 27.0 - 28.9 275 - 295, 239 - 256


TOOLS

MA-2-1

TOOLS

* Tool number designated by Zexel Co.

Tool name and number Description ShapeFeeler gauge99541 Z5000

For adjusting valve clearance Thickness mm (in): 0.25 (0.0098), 0.3 (0.012), 0.35 (0.0138), 0.4 (0.016), 0.45 (0.0177), 0.5 (0.020)

Timing plate99646 Z5001

For measuring valve timing

Compression gauge99640 Z5500

For measuring compression pressure

Compression gauge hose99644 97000

Used with the compression gauge (99640 Z5500) when the gauge cannot be installed directly due to interference with the air duct, etc.

*Plate157944-9520

For fixing nozzle holder

TOOLS

MA-2-2

Tool name and number Description ShapePin vice99727 Z5005

For cleaning nozzle injection hole.

Nozzle cleaner99726 Z5000

For cleaning injector tip.

PERIODIC MAINTENANCE SCHEDULES

MA-3-1

PERIODIC MAINTENANCE SCHEDULESAbbreviations: A = Adjust, R = Replace, I = Inspect. Correct, adjust or replace if necessary.

C = Cleaning, RB = Rebuilding, T = Tighten to specified torque, = Initial maintenance

NOTEThe maintenance or lubrication service shown below are to be performed at the indicated inter-vals (km, miles or months, whichever occurs first).Scheduled maintenance services beyond 60,000 km (36,000 miles) or 12 months should be con-tinued at the same intervals as before except the initial maintenance.Under the following severe operating conditions, more frequent servicing will be required.– Operation in heavy dust conditions– Operation at extremely low or high ambient temperature– Extended high-speed operation with vehicle fully-loaded to its GVW (Gross Vehicle Weight)– Extended low-speed operation– Frequent stop-and-go operationAny replacement parts used for required maintenance service or repairs should be genuineNissan Diesel parts.

EMISSIONS CONTROL SYSTEMS MAINTENANCE (FOR TAIWAN ONLY)To maintain efficient emissions control systems operation, have themaintenance services shown in this section performed at the inter-vals indicated.CAUTION

Do not modify, alter, disconnect or remove any part of the vehicle which could affect, directly orindirectly, vehicle emissions.


MA-3-2

MAINTENANCE INTERVALS

Remarks:(1) Replace the engine oil and oil filter whenever the oil filter warning light comes on, even before the sched-

uled replacement.(2) If the warning light comes on even before the scheduled replacement, clean or replace element.(3) Service every 6 months.(4) Service every 12 months.(5) With turbocharger engine equipped vehicles only.

Items

Maintenance intervals

Remarks

Kilometers x 1,000

Daily

1 5 10 15 20 25 30 35 40 45 50 55 60

Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36

Months — 1 2 3 4 5 6 7 8 9 10 11 12

Valve clearance I

Cylinder head and manifold bolts T

Crank damper : After 200,000 km (125,000 miles)I: Every 100,000 km (62,500 miles)

Cylinder compression pressure I

Oil leakage I I I I I I I I I I I I I

Oil level and contamination I I I I I I I I I I I I I

Engine oil and filter

Full-flow type R: Every 10,000 km (6,000 miles) or 6 months (1)

Full-flow and bypass type R: Every 15,000 km (9,000 miles) or 6 months (1)

Coolant leakage I I I I I

Coolant level I I I I I I I I I I I I I

Coolant (incl. anticorrosive) R R (3)

Coolant (incl. antifreeze) R (4)

Radiator cap I

Fan clutch I

V-belt I I I I I I I I I I I I I

Thermostat I

Injection timing I

Nozzle (injection pressure and pattern) I

Fuel leakage I I I I I I I I I I I I I

Fuel filter element R

Primary fuel filter IDrain

IDrain

IDrain

IDrain

IDrain

IDrain

IDrain

IDrain

IDrain

IDrain

IDrain

IDrain

Primary fuel filter element R R

Fuel strainer IDrain

IDrain

IDrain

IDrain

IDrain

I/CDrain

Fuel level I

Air cleaner element I/C I/C I/C I/C I/C I/C (2)

Air cleaner element (Dry type) R (2)

Condition of exhaust I I I I I I I I I I I I I

Turbocharger I (5)

I

T

I

I

I

R

R

I

I


MA-3-3

For Taiwan only

“*” refers to items related to the Emission Control System Maintenance.

Maintenance Item

Maintenance intervals

RemarksKilometers x 1,000

Daily

1 5 10 15 20 25 30 35 40 45 50 55 60

Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36

Months — 1 2 3 4 5 6 7 8 9 10 11 12

*Idle speed I

Acceleration and deceleration I

*Air intake system (duct, hose and clamp) I I I I I I

Intake* and exhaust manifold I

*Air cleaner element I/C I/C I/C I/C I/C R

Cylinder compression pressure I

*Valve clearance A

*Engine oil and oil filters

Oil CC or CD class Every 10,000 km (6,000 miles) or 6 months : R FE6 engine

Oil CD class Every 10,000 km (6,000 miles) or 6 months : RFE6T, FE6T-Z and FE6TA engines

*Engine oil and bypass oil filter (if equipped)

Oil CD class Every 15,000 km (9,000 miles) or 6 months : R

Oil level and contamination I

Oil pressure I

Coolant and fuel level I

Coolant, oil and fuel leakage I

Strainer (if equipped) I

*Fuel filter element R

*Primary fuel filter element (if equipped)

IDrain

IDrain

IDrain

IDrain

IDrain R I

DrainI

DrainI

DrainI

DrainI

Drain R

*Governor setting (checking seals) Every 30,000 km (18,000 miles) or 6 months : I

*Nozzle (injector tip) Every 80,000 km (50,000 miles) : C

*Nozzle holder (injector) Every 240,000 km (145,000 miles) : RB

*Injection timing Every 60,000 km (36,000 miles) or 12 months : I

Fuel tubing I

Accelerator linkage I

Drive belt (V-belt) I

Crank damper Every 24 months : I

Cooling system (hose and clamp) I

Engine coolant R

Water filter (if equipped) R

Thermostat I

Fan clutch I

Fan and fan shroud I

Exhaust tubing and muffler I

Alternator I

Starter I

*PCV valve Every 80,000 km (50,000 miles) : R I FE6 engine

*PCV system(hose and clamp) I I I I I I FE6 engine

(piping) I FE6 engine

*Turbocharger Every 240,000 km (145,000 miles) : CFE6T, FE6T-Z and FE6TA engines

I

I

R

R

R

I


MA-3-4

PERIODIC PARTS REPLACEMENTPeriodic replacement parts are rubber parts such as the fuel hose, etc. which deteriorate with the lapse of timeand require maintenance. It is absolutely necessary to replace those parts periodically to maintain drivingsafety.

Remarks: (1) AOH brake vehicles.

ItemsPERIODIC PARTS REPLACEMENT INTERVAL

RemarksNumber of years 1 2 3 4 5 6 7 8 9 10

ENGINEFuel hose (engine side) R R R R RFuel hose (fuel tank side) R RAir compressor rubber hose R R R R R (1)

MAINTENANCE PROCEDURE

MA-4-1

MAINTENANCE PROCEDUREBASIC MECHANICAL SYSTEM

VALVE CLEARANCE

NOTEEnsure the engine is cool when checking and adjustingthe valve clearance.

1. Remove the rocker cover.2. Remove the pointer cover from the upper section of the fly-

wheel housing. Secure the pointer to the flywheel housingusing bolts.

3. Using a lever, rotate the ring gear on the outer edge of theflywheel in the standard direction (or counterclockwise asviewed from the flywheel side) until the mark “1·6” stampedon the outer edge of the flywheel is aligned with the pointer.If the mark goes past the pointer, back it off past the pointerand then rotate in the standard direction until the mark isaligned with the pointer. At this point, if the mark stampedon the fuel injection pump timer is nearly aligned with themark on the pump housing, the No. 1 cylinder is at TDC(Top Dead Center) on the compression stroke. If the markon the timer is not visible, the No. 6 cylinder is at TDC onthe compression stroke.

4. Valve clearances (1), (2), (4), (5), (8) and (9) can bechecked and adjusted when No. 1 cylinder is at TDC on thecompression stroke; valve clearances (3), (6), (7), (10), (11)and (12) can be checked and adjusted when the No. 6 cyl-inder is at TDC on the compression stroke.

5. Place a feeler gauge between the valve stem and rockerarm to ensure that the gauge fits snugly.

Unit: mm (in)

Item Maintenance standard Service limit Remarks

Valve clearance

Intake 0.3 - 0.4 (0.012 - 0.016) — When engine is coldExhaust 0.3 - 0.4 (0.012 - 0.016) —


MA-4-2

Valve clearance adjustment1. If the valve clearance is not correct, loosen the lock nut for

the adjusting screw and adjust the screw until the specifiedclearance is obtained.

2. After adjusting the valve clearance, hold the adjustingscrew and tighten the lock nut.

: 34 - 44 N·m 3.5 - 4.5 kgf·m, 25 - 33 ft·lbf3. Recheck the valve clearance.4. Rotate the flywheel one complete turn until the mark “1·6” is

aligned with the pointer. Next, check and adjust the remain-ing valve clearances.If the engine operates erratically or vibrates even thoughthe valve clearances are properly adjusted, problems maybe due to improperly adjusted valve timing which resultsfrom incorrect assembling of the timing gear train, etc. Iferratic operation is noticed, check the valve timing asdescribed below.

Procedure for checking valve timing1. Remove the V-belt, cooling fan and crank pulley assembly.2. Turn the flywheel in the normal direction until the No. 1 pis-

ton is at the TDC on the compression stroke.NOTE

If the flywheel has been rotated excessively, rotate itbackwards beyond the desired position then graduallyrotate it back in the normal direction until it is set in theproper position.

3. Attach the timing plate (99646 Z5001) to the end of thecrankshaft. Also attach a needle pointer utilizing the frontcover mounting bolt, and align the needle to “0”.

4. Set a dial gauge so that the contact arm is in contact withthe upper valve spring seats of the intake valve and exhaustvalve.


MA-4-3

5. If the needle of the dial gauge begins to move, it means thatthe valve is beginning to open; the movement of the needlewill stop as the valve closes. Read the needle position onthe timing plate on each occasion.

CYLINDER HEAD AND MANIFOLD BOLTSCheck the cylinder head, air intake and exhaust manifold mountingbolts and nuts for proper torque. Also check the manifolds for dam-age or traces of leakage at the cylinder head connections.

Cylinder head mounting bolt: 177 - 196 N·m 18.0 - 20.0 kgf·m, 130 - 145 ft·lbf

Air intake manifold bolt: 16 - 20 N·m 1.6 - 2.0 kgf·m, 12 - 14 ft·lbf

Exhaust manifold bolt: 34 - 44 N·m 3.5 - 4.5 kgf·m, 25 - 33 ft·lbf

CRANK DAMPERCheck the crank damper for cracks or flaking, and the mountingbolts for looseness. Replace faulty parts if necessary.

Crank damper mounting bolt: 59 - 69 N·m 6.0 - 7.0 kgf·m, 43 - 51 ft·lbf

CYLINDER COMPRESSION PRESSURE1. Warm up the engine.2. Disconnect all nozzle tubes and remove all nozzle holders.

Refer to the “DR” section for details.

Item Maintenance standard

Service limit Remarks

Valve timing

FE6AFE6BFE6TA173 kW235 PS

IntakeOpen 15° B.T.D.C. — (1)

Closed 40° A.B.D.C. — (2)

ExhaustOpen 53° B.B.D.C. — (3)

Closed 9° A.T.D.C. — (4)

FE6TFE6TA157 kW213 PS

IntakeOpen 15° B.T.D.C. — (1)

Closed 30° A.B.D.C. — (2)

ExhaustOpen 53° B.B.D.C. — (3)

Closed 9° A.T.D.C. — (4)


MA-4-4

3. Install a compression gauge (99640 Z5500) on the nozzlehole using a nozzle holder gasket. Press the gauge bleederto set the pointer to “zero”.Compression gauge mounting bolt

: 25 - 29 N·m 2.5 - 3.0 kgf·m, 18 - 22 ft·lbfNOTE

Be careful to prevent foreign matter from getting into theother nozzle holder holes.Be sure to remove the old nozzle holder gasket.

4. Move the engine stop lever completely in the “FUEL CUT”direction and hold it at that position.

5. Crank the engine until the gauge pointer stabilizes. Readthe cylinder compression pressure. Measure compressionpressure for the remaining cylinders as described above. Ifthe measured values or the differences in compressionpressure between cylinders are not within specifications,pistons and/or piston rings may be worn or the valve mech-anism may be faulty. Overhaul the engine and repair asnecessary.

Unit: kPa kgf/cm2, psi

NOTEThe above engine rpm range refers to that when the bat-tery is fully charged and the starting motor is in goodcondition.

LUBRICATION SYSTEM

OIL LEAKAGECheck the cylinder head, timing gear case cover, oil pan, oil filtersand other related parts for sign of leakage. If necessary, replacegaskets. After replacing the gasket, check that point to ensure thereis no leakage.

OIL LEVEL AND CONTAMINATIONWARNINGWARNINGTo help avoid serious personal injury from hot engine oil,perform lubrication system checks and maintenanceonly after the engine has cooled.

Item Maintenance stan-dard Service limit Remarks

Compression pressure 2,942 30, 427 1,961

20, 284

At 200 rpm with engine warm

Difference between cylinders Less than 392 4, 57 —


MA-4-5

Check the engine oil level and for contamination of engine oilbefore driving the vehicle each day and when you stop for fuel.Check the oil level with the engine off. When checking the oil levelafter stopping the engine, wait at least 15 minutes to allow the oil toreturn to the oil pan.

To check the engine oil level1. Park the vehicle on a flat surface.2. Remove the oil dipstick located on the left hand side of the

engine. Wipe the dipstick clean with a rag and reinsert it.Remove the dipstick and check the oil level. Maintain the oillevel between the H and L marks on the dipstick.

3. If oil level is low, add engine oil of the proper viscosity forthe anticipated temperature range during the service inter-val through the oil filler port located on the valve cover ontop of the engine. Do not add oil above the H mark on thedipstick.

CAUTIONUse care to keep dirt and debris from entering the crank-case through the oil filler port when adding engine oil.Avoid spilling oil. Clean up any engine oil that spills acci-dentally.

4. Change the oil if it shows signs of contamination such asdiscoloration and changes in oil texture. See the instruc-tions in this manual under the caption CHANGING ENGINEOIL.

5. After adding oil, wait at least 6 minutes, then recheck the oillevel.

6. After checking, securely insert the oil dipstick.CAUTION

Do not drive the vehicle with the oil level below the Lmark on the oil dipstick. An insufficient quantity ofengine oil can cause engine seizure.

To check for engine oil contaminationRemove the oil dipstick and check the oil on it for signs of contami-nation such as discoloration and changes in texture. See theinstructions in this manual under the caption ENGINE OIL AND OILFILTER.


MA-4-6

CHANGING ENGINE OIL AND OIL FILTEREngine oil

WARNINGWARNINGTo help avoid serious personal injury from hot engine oil,perform lubrication system checks and maintenanceonly after the engine has cooled.

NOTETry to avoid direct skin contact with used oil. If skin con-tact is made, wash thoroughly with soap or hand cleaneras soon as possible.

The engine oil and oil filter change interval varies with the type ofengine oil used and vehicle driving conditions. If the vehicle isdriven for extended periods of time at high or low speeds, in dustyareas, with frequent idling or carrying heavy loads, engine oil willdeteriorate faster and require more frequent changing.As the temperature rises, the engine oil’s viscosity decreases,reducing its lubricating effect. To choose an oil with the proper vis-cosity for the anticipated ambient temperature range, refer to theviscosity chart in the “GE” section of this manual.To change the engine oil1. Loosen the oil filler cap.

2. Undo the four engine undercover catchers (on the left andright sides of the engine), and remove the undercoverassembly (if equipped).

3. Place a container under the drain plugs in the bottom of theoil pan and oil filter. Remove the plugs and drain the oil intothe container.


MA-4-7

4. When all the oil has been drained from the oil pan and oil fil-ter, replace the drain plugs in the drain hole and tighten thedrain plug.Oil pan drain plug

: 59 - 69 N·m 6.0 - 7.0 kgf·m, 43 - 51 ft·lbf5. Replace the oil filter. See the instructions under the caption

OIL FILTER.6. Add engine oil through the oil filler port to the specified

level.7. After refilling the engine oil, wait for at least 6 minutes, then

using the dipstick check the oil level. If the oil level is low,add additional oil. Wait 6 minutes, then recheck the oil level.Repeat this procedure until the engine oil reading on thedipstick is between H and L.

8. Install the engine undercover (if equipped).

Oil filterWARNINGWARNINGDo not handle hot oil filter without hand protection. Fail-ure to do so may result in burn injury.

NOTEUse genuine filter or equivalent in quality and design.Use of an inferior filter could hinder engine operation andemission controls.Always replace the oil filter at the same time engine oil isreplaced.


MA-4-8

To replace the oil filter1. Undo the four engine undercover catchers (on the left and

right sides of the engine), and remove the undercoverassembly (if equipped).

2. Place a container under the oil filter and remove the drainplug in the bottom of the oil filter. Drain oil from the filter.

3. Remove the filter with a filter wrench and drain all oil intothe container.

4. Apply a thin coat of clean engine oil to the packing of a newoil filter.

CAUTIONInstallation of the oil filter without coating the packingwith oil may damage the packing, resulting in loss ofengine oil and damage to the engine and/or lubricationsystem.

5. Install the new filter by hand. After the packing comes incontact with the bracket sealing surface, tighten an addi-tional 3/4 turn (Full flow only type) or 1-1/8 to 1-1/8 turn (Fullflow & bypass combination type).

CAUTIONWhen installing an oil filter, tighten it by hand. Do not usea wrench or other tools which could result in overtighten-ing and damage to the filter.

6. Run the engine. Check the filter and seal for leaks.7. After checking, install the under cover.


MA-4-9

COOLING SYSTEMThe engine cooling system was filled at the factory with a high-qual-ity, year-round, coolant solution with a 50/50 antifreeze/water mix-ture. The antifreeze solution contains rust and corrosion inhibitors.The solution provides protection against freezing to approximately -30°C (-22°F). The solution must remain in the system year round toprovide protection against freezing, boiling, rust and corrosion. Donot use additional cooling system additives or inhibitors. They mayinterfere with the proper operation of the cooling system.Check the engine, radiator, hoses and pipes daily. Repair anyleaks. Replace swollen and worn hoses and tighten loosen clamps.Check the OVERHEATING AND COOLANT LEVEL warning lightdaily to be sure that it does not operate.

WARNINGWARNINGTo help avoid serious personal injury from hot coolant orsteam release:

Do not open the radiator filler cap while the engine cool-ing system is hot. Wait until it cools down.Be extremely careful when opening the radiator filler cap.Place a thick cloth on the cap and slowly loosen it toallow a reduction in pressure in the cooling system.

COOLANT LEAKAGE

Check the cooling system for leakage, especially at tube and hoseconnections. Also check piping for fractures, cracks or damage.Replace parts if faulty.If water leaks through the small hole in the water pump body, thewater seal may be faulty.Disassemble and repair the water pump.


MA-4-10

WATER HOSE AND CLAMPCheck the water rubber hose and clamp of the cooling system forinstallation, cracks or damage. Replace faulty parts if necessary.

COOLANT LEVELWARNINGWARNING

To help avoid serious personal injury from hot coolant orsteam release:

Do not open the radiator filler cap while the engine cool-ing system is hot; wait until it cools.Be extremely careful when opening the radiator filler cap.Place a thick cloth on the cap and slowly loosen it toallow a reduction in pressure in the cooling system.If the coolant is accidentally ingested, force the person tovomit and secure medical help immediately. If the cool-ant gets in the eye, flood the eye with lots of water andget medical attention immediately.

Open the front lid.Check the coolant level daily only when the engine is cool.Check the coolant level in the coolant reservoir tank located behindthe front lid.The coolant level should be between the HIGH and LOW lines. Ifthe coolant level is below the LOW line, add the proper coolantsolution to the HIGH line. Be sure to use an ethylene glycol antifreeze with water at theproper mixture ratio. To ensure the proper mixture ratio, carefullyread the instructions on the container or obtain the instructions fromthe antifreeze manufacturer. Examples are shown below.

Antifreeze concentration greater than 60 to 70% will adverselyaffect freezing protection, corrosion inhibitor additives and heattransfer rates. Follow the instructions on the container or obtain theinstructions from the antifreeze manufacturer for proper concentra-tion.A complete drain, flush and refill with proper antifreeze and coolantis recommended once a year. This recommendation applies to allvehicles including those with low total annual mileage.

Outside temperature down to Antifreeze Soft water°C (°F)-10 (14) 30% 70%-20 (-4) 40% 60%

-30 (-22) 50% 50%


MA-4-11

CAUTIONAntifreeze made with methoxy propanol or propyleneglycol is not recommended for use with Nissan Dieselengines. These types of antifreeze can damage engineinternal seals and coolant hoses and create a potentialfire hazard due to lower flash points than ethylene glycoltype antifreeze.Use only municipally supplied water (tap water) in thecooling system. River, well or other water produces scalein the cooling system, which may cause damage to theengine or cooling system.Do not add water without adding ethylene glycol anti-freeze to the engine cooling system, except in an emer-gency. If plain water is added in an emergency, restorethe proper mixture of antifreeze and water as soon aspossible.If the coolant should get extremely low and the enginevery hot, let the engine cool before adding coolant; then,with the engine running, add coolant slowly. Adding coldcoolant to a hot engine may crack the cylinder head orcrankcase. Never use water alone.

CHECKING AND CLEANING RADIATORTo maintain cooling system efficiency and keep the engine fromoverheating, always keep the front surface of the radiator coreclean. Remove insects, dirt and other debris by directing pressur-ized air at the rear surface of the radiator core.CAUTION

Do not direct pressurized air to the front surface of theradiator (that is, with the air hose pointed toward theengine). Doing so will force insects, dirt and other debrisinto the radiator core and possibly cause engine over-heating.

CHANGING COOLANTWARNINGWARNING

To help avoid serious personal injury from hot coolant orsteam release:

Do not open the radiator filler cap while the engine cool-ing system is hot. Wait until it cools down.Be extremely careful when opening the radiator filler cap.Place a thick cloth on the cap and slowly loosen to allowa reduction in pressure in the cooling system.


MA-4-12

Once a year the cooling system should be drained and thoroughlyflushed.Unless the cooling system is treated with a corrosion preventive,rust and scale will eventually clog up passages in the radiator andwater jackets. This condition is aggravated in some localities by for-mation of insoluble salts from the water used.CAUTION

Do not use chemical mixtures to stop radiator leaksexcept in an emergency. Never use such solutions inplace of needed radiator repair.

To clean the cooling system1. Move the heater control temperature lever to the HOT posi-

tion.2. Open the radiator filler cap.3. Place containers under the radiator drain cock and the cyl-

inder block drain cock.

4. Connect a drain hose to the radiator drain cock.

5. Open the radiator drain cock and the cylinder block draincock.

6. Drain all coolant solution from the system into the contain-ers.

7. Shut the drain cocks. Fill the cooling system with a propermixture of water and a good quality cooling system deter-gent. (Refer to the additional instructions on the detergentcontainer.)

8. Start the engine and run it at a high idling speed until theindicator points to the middle region of the coolant tempera-ture gauge. Maintaining the above coolant temperature withthe thermostat open, run the engine and allow the detergentto circulate throughout the cooling system for at least 15minutes.

9. Stop the engine. Open the drain cocks and completely drainthe detergent from the system.


MA-4-13

10. Shut the drain cocks and fill the cooling system with plainwater. Start the engine and run it at a moderate speed inthe same manner as described in step 8.

11. Stop the engine. Open the drain cocks and drain the rinsingwater.

12. Repeat rinsing procedure 2 or 3 times until the dischargedrinsing water appears clean.

13. Drain the coolant from the coolant reservoir tank as neces-sary.

14. Close the drain cocks and remove the drain hose from theradiator drain cock.

To fill up the cooling system (with coolant)Use the following refill procedure to remove air from the system andprovide proper coolant level.1. Fill the radiator slowly with the proper coolant solution up to

the filler opening.Add coolant solution up to the HIGH level of the coolant res-ervoir tank.The cooling system holds approximately 22 liters (4-7/8 Impgal) of coolant solution.Then properly close the radiator filler cap and the reservoirtank cap.

2. Operate the engine at a slightly higher than normal idlingspeed with the engine idling control button until the coolanttemperature indicator points the middle region of the gauge.Run the engine an additional 10 minutes to allow the air toescape from the engine cooling system.

3. Stop the engine. After the engine has completely cooleddown, remove the radiator filler cap and check the coolantlevel in the radiator. If low, add coolant to the radiator filleropening.Reinstall the radiator filler cap.

4. Check the coolant level in the coolant reservoir tank. If thelevel is between the LOW and HIGH lines, it is normal. If it isbelow the LOW level, add coolant solution up to the HIGHlevel.

5. If the added coolant solution is more than 500 milliliter (17.6Imp fl oz), check and correct for any sign of leakage, thenrepeat steps 1 to 4.

6. Check the drain cock for leaks.

COOLIG FAN AND FAN SHROUDCheck the cooling fan and fan shroud for proper installation, cracksor damage. Replace faulty parts.

WARNINGWARNINGNever get your hand near the fan, when the engine isoperated.If fan clutch is equipped, the fan rotating speed mayseem to slow when the coolant is cool, but never try totouch the fan and other rotating parts while the engine isrunning.


MA-4-14

RADIATOR CAPAttach the radiator cap to a cap tester, and measure the operatingpressure of the radiator cap valve. If the measured value exceedsthe maintenance standard, replace.


FAN CLUTCHEnsure that the engine is off when checking the fan clutch.1. Check the fan clutch for oil leakage. If leakage is present,

replace the fan clutch assembly.2. Check the fan clutch for proper operation:

Rotate the cooling fan by hand (adjacent parts should becool) to ensure it moves smoothly without binding.Then, start the engine and operate it until the pointer of thewater temperature gauge stays within the “H” range. Stopthe engine to ensure that the cooling fan no longer rotatesby hand.

NOTEThe fan clutch operates in a manner similar to a “directdrive” when the temperature of parts near the bimetallocated at the front center of the clutch reaches approxi-mately TºC (TºF). For this reason, it is best to measurethe temperature of those parts to assure proper mainte-nance during inspection.

Unit: ºC (ºF)

Maintenance standard Service limit39 - 59 0.4 - 0.6, 6 - 9 —

Item

Run the engine

continu-ously

Operating tempera-ture (T)

FE6AFE6B 119 kW 162 PSFE6B 132 kW 180 PS

FD1300L ON - OFF type

3,000 rpm

75±5 (167±9)

FE6B 132 kW 180 PSFE6T 135 kW 183 PSFE6T 151 kW 205 PSFE6TA 157 kW 213 PS

FDL1700

Linear type

3,400 rpm

65±10 - 80±5

(149±18 - 176±9)

FE6T 151 kW 205 PSFE6T 162 kW 220 PSFE6TA 157 kW 213 PSFE6TA 173 kW 235 PS

FDL2000

50±10 - 80±5

(122±18 - 176±9)


MA-4-15

V-BELTBe sure the engine is off and the transmission is in “Neutral”.Engage the parking brake securely.1. Visually check the V-belt daily for cracks and damage. If the

belt is cracked or damaged excessively, replace it. Alsocheck that the belt does not come in contact with the bottomof the pulley groove. Replace the belt if necessary.

2. Check the drive belt for proper deflection by depressing themidpoint with a force of 98 N 10 kgf, 22 lbf.

Unit: mm (in)

<To adjust V-belt deflection>Fan belt1. Loosen the alternator anchor bolt and the adjusting bolt.

2. Adjust the alternator position so that the belt deflects asspecified and tighten the adjusting bolt.

: 34 - 44 N·m 3.5 - 4.5 kgf·m, 25 - 33 ft·lbf3. Tighten the alternator anchor bolt.

: 59 - 74 N·m 6.0 - 7.5 kgf·m, 43 - 54 ft·lbf

Cooler belt1. Loosen the lock nut.2. Adjust the belt tension to the specified value by the adjust-

ing bolt.3. Tighten the lock nut.

: 35 - 47 N·m 3.6 - 4.8 kgf·m, 26 - 35 ft·lbf

Item Maintenance standard Service limitFan pulley - alternator pulley 10 - 15 (0.39 - 0.59) —Fan pulley - cooler pulley 7 - 12 (0.28 - 0.47) —


MA-4-16

THERMOSTAT1. Drain coolant completely. Refer to the “CHANGING COOL-

ANT” for procedures.2. Remove the upper radiator hose, water outlet and thermo-

stat.

3. Check the thermostat as described below, and replace iffaulty.Ensure that the valve contacts the seat at room tempera-ture.Check the valve opening temperature and the “lift” of thevalve.

NOTEThe valve opening temperature (82, 88, etc.) is marked onthe thermostat.

Ensure that the difference between the valve opening andclosing temperatures is less than 5ºC (9ºF).

4. Install the thermostat, the outlet and the gasket. Connectthe upper radiator hose. Three types of thermostats, whichopen at different temperatures, are used.

5. Add coolant to the radiator. Refer to “CHANGING COOL-ANT” for procedures.

Item Maintenancestandard Service limit

Ther-mostat

Valve opening temperature

ºC (ºF)

76.5 (170) 74.5 - 78.5(166 - 173)

71.5 - 81.5(161 - 179)

82 (180) 80 - 84(176 - 183)

77 - 87(171 - 189)

88 (190) 86 - 90(187 - 194)

85 - 93(185 - 199)

Valve lift/ tem-perature

mm/ºC (in/ºF)

76.5 (170) More than 10/90(0.39/194)

Less than 9/90(0.35/194)

82 (180) More than 10/95(0.39/203)

Less than 9/95(0.35/203)

88 (190) More than 10/100(0.39/212)

Less than 9/100(0.35/212)


MA-4-17

FUEL SYSTEMWARNINGWARNING

Observe the following when removing parts of the fuel sys-tem:

Post a placard that reads: “CAUTION: FLAMMABLE”.Prepare a fire extinguisher.Disconnect the ground terminal from the battery.

GOVERNOR SETTINGMake sure that the parts shown in the figure below are secured withsealing caps and wires. If the cap or wire is broken, check andadjust the injection pump and governor.CAUTION

Any unauthorized adjustments in the injection pump andgovernor settings, other than as specified, can causeserious damage to the engine.

INJECTION TIMING1. Remove the pointer cover. Secure the pointer to the fly-

wheel housing using bolts.2. Crank the engine in the standard direction by turning the fly-

wheel with a lever until the pointer is aligned with the timingmark.

NOTEIf the mark goes past the pointer, move it back past thepointer and turn again in the standard direction untilalignment is made.

ItemMainte-nance

standard


Fuel injec-tion timing

FE6A 14º —

FE6B119 kW 162 PS 15º —132 kW 180 PS 12º —

FE6T135 kW 183 PS 12º —151 kW 205 PS 10º —162 kW 220 PS 9º —

FE6TA

157 kW 213 PS 3º — “MD-TICS” system

173 kW 235 PS 12º —


MA-4-18

3. The flywheel is correctly positioned if the timing mark is setas shown in the figure.

4. If the timing mark is slightly out of alignment, crank theengine until the correct alignment is made. There is noproblem as long as the timing mark on the flywheel is some-where between the following value.

If the timing mark is not within this range, adjust as follows:

Adjustment of fuel injection timing ..... Method 1Loosen the coupling bolts (two places).

Engine model Timing mark RemarksFE6A 13º - 15º

FE6B119 kW 162 PS 14º - 16º132 kW 180 PS 11º - 13º

FE6T135 kW 183 PS 11º - 13º151 kW 205 PS 9º - 11º162 kW 220 PS 8º - 10º

FE6TA157 kW 213 PS 2º - 4º “MD-TICS” system173 kW 235 PS 11º - 13º


MA-4-19

Slightly back the timer off in the direction opposite to that inwhich the engine rotates, then move it in the standard direc-tion until the timer mark is aligned.Tighten the coupling bolts (nut) and cotter bolt.Coupling bolt and nut

: FE6A, FE6B, FE6T and FE6TA 173 kW 235 PS29 - 34 N·m 3.0 - 3.5 kgf·m, 22 - 25 ft·lbf

: FE6TA 157 kW 213 PS59 - 64 N·m 6.0 - 6.5 kgf·m, 43 - 47 ft·lbf

Cotter bolt: FE6A, FE6B, FE6T and FE6TA 173 kW 235 PS59 - 64 N·m 6.0 - 6.5 kgf·m, 43 - 47 ft·lbf


Adjustment of Fuel Injection Timing ..... Method 2If the engine continues erratic operation even though method 1above is conducted, the camshaft or bearings, etc. may be worn tosuch an extent that fuel injection timing is not properly adjusted. Tocheck and adjust fuel injection timing, proceed as follows:

1. Remove the nozzle pipe.2. Remove the delivery valve holder of the No. 1 cylinder, take

out the delivery valve spring, and tighten the delivery valveholder to the specified torque.



3. Rotate the flywheel in reverse direction until the No. 1 pis-ton is 25º B.T.D.C. on compression stroke.

4. Set the fuel control lever in the full-injection position.5. Slowly rotate the flywheel in the normal direction while feed-

ing fuel by the priming pump.6. Fuel injection starts when fuel stops discharging from the

delivery valve holder. At this point, the timing mark on theflywheel should be somewhere between the following value.

NOTEPerform this measurement at least three times, and cal-culate the average value.

Engine model Timing mark RemarksFE6A 13º - 15º

FE6B119 kW 162 PS 14º - 16º132 kW 180 PS 11º - 13º

FE6T135 kW 183 PS 11º - 13º151 kW 205 PS 9º - 11º162 kW 220 PS 8º - 10º

FE6TA157 kW 213 PS 2º - 4º “MD-TICS” system173 kW 235 PS 11º - 13º


MA-4-20

IDLE SPEED

NOTEWhen checking engine idle speed, make sure that theengine idle control knob inside the cab is set to the low-speed position.The state of the exhaust shutter (open or closed) is notspecified.

1. Start the engine and warm it up to the normal operatingtemperature.

2. Allow the engine to idle and observe the engine speed onthe tachometer.

3. If idle speed is not within specified range, adjust as follows:Unit: rpm

NOTEIf equipped with an air conditioner, the air conditionerswitch must be turned off when checking idle speed.Be sure to adjust the idling with the magnetic valve wir-ing of the exhaust shutter disconnected. If the wiring isconnected, the idling cannot be adjusted correctly as theexhaust shutter is closed.

Idle speed adjustment1. Loosen the lock nut on the idle adjusting bolt.2. Turn the idle adjusting bolt to obtain the correct idle speed.3. Tighten the lock nut.


Accelerate the engine two or three times. Allow theengine to return to idle speed and observe the tachome-ter reading. If the idle speed is not within the specifiedrange, check the accelerator linkage for binding andrepeat idle adjustment.

4. After adjustment, connect the magnetic valve wiring of theexhaust shutter.

ACCELERATION AND DECELERATION1. Start the engine and warm it up to the normal operating

temperature.2. Depress the accelerator pedal to check that engine speed

smoothly increases from idle to the maximum and that itreturns to idle.

Item Maintenance standard Service limit

Idle speed

FE6A, FE6B, FE6T 600 —

FE6TA

157 kW 213 PS 650 —173 kW 235 PS 550 —


MA-4-21

NOTEIf the engine does not accelerate smoothly, disengagethe accelerator linkage from the injection pump andoperate the fuel control lever of the injection pump tocheck engine acceleration. If the engine rotatessmoothly, the accelerator linkage may be faulty. Checkand repair the linkage. If engine operation is erratic, theinjection pump or governor may be faulty. Check andrepair these parts.

3. Attach the pickup of the tachometer to the No. 1 injectiontube, and measure the no-load maximum engine rpm.

Unit: rpm

ACCELERATOR LINKAGECheck accelerator linkage for bent rods, interference with nearbyparts or looseness.

NOZZLE (INJECTOR PRESSURE AND PATTERN)Cleaning nozzle1. Remove the nozzle holder assembly from the engine. Refer

to the “ENGINE DISASSEMBLY AND REASSEMBLY” sec-tion for details.

2. Clamp the nozzle holder in a vise with a holder plate(157944-9520).

3. Loosen the retaining nut, and then remove the nozzle fromthe nozzle holder. Do not drop the nozzle needle.

4. Pull the nozzle needle from the nozzle body.NOTE

Do not use the nozzle needle in another nozzle body.

5. Remove carbon from around the openings by using the cor-ner of a hard piece of wood. Do not use waste or any othermaterial to push carbon into the openings.

Item Maintenance standard Service limitNo-load maximum engine speed 3,600 —


MA-4-22

6. Removing carbon in openingsUse the pin vice (99727 Z5005) and wire to clean the open-ings.

Unit: mm (in)

Allowing too much wire to protrude at the tip of the holderwill permit the wire to bend inside the nozzle, and with-drawal becomes difficult. The wire should protrude lessthan 2 to 2.5 mm (0.079 to 0.098 in).Carefully push the carbon into the nozzle. Too much forcewill bend the wire. Proceed slowly.Remove carbon at the inside end of the openings with thenozzle cleaning tool (99726 Z5000).Exercise care to avoid damaging the surface which the noz-zle needle contacts. The use of compressed air may clogthe openings with foreign particles.

7. Tighten the retaining nut.: 59 - 78 N·m 6.0 - 8.0 kgf·m, 43 - 58 ft·lbf

NOZZLE HOLDER (INJECTOR)Rebuild the nozzle holder at the specified interval. Check andadjust the nozzle opening pressure and spray pattern. Refer to the“EF” section for rebuilding procedures.

WARNINGWARNINGFuel from the injection nozzle is injected under extremelyhigh pressure. If it is directed at your hand, etc., seriousinjury may result. KEEP YOUR HANDS AWAY FROM THENOZZLE DURING TESTS.

FUEL LEAKAGECheck the fuel system for leakage at tube or hose connections.

Nozzle identifi-cation mark

Number of injec-tion nozzle hole

Injection nozzle hole diameter Wire diameter

ZD3 5 0.29 (0.0114) 0.26 (0.0102)

D2A5A6A3

5 0.30 (0.0118) 0.29 (0.0114)

C1 5 0.245 (0.0096) 0.23 (0.0091)


MA-4-23

REPLACEMENT OF FUEL FILTER

NOTEUse genuine filter or equivalent in quality and design.Use of an inferior filter could hinder engine operation andemission controls.

Cartridge type1. Remove the engine side cover (left side).2. Place a container under the filter. Remove the filter with a

filter wrench. Drain any remaining fuel into the container.

3. Apply a thin coat of clean engine oil to the gasket of the newfilter.

WARNINGWARNINGInstallation of the fuel filter without coating the gasketwith oil may damage the gasket resulting in loss of fueland fire hazard due to spilled fuel.

4. Install the new fuel filter by hand. After the gasket comes incontact with the bracket sealing surface, tighten an addi-tional 3/4 of a turn.

CAUTIONWhen installing the fuel filter, tighten by hand. Do notuse a wrench or other tools which could result in over-tightening and damage to the filter.

5. After installing the filter, purge air from the fuel system andcheck for fuel leaks.For air purging details, refer to “PURGING AIR FROMFUEL SYSTEM”.

Center bolt type1. Place a container under the filter.2. Remove the drain plug, and empty out fuel and sediments.


MA-4-24

3. Loosen the center bolt and remove the filter case, setspring, element and other parts.

4. Check the element for clogging and contamination.5. Clean the filter parts in light oil.6. Replace the packings.7. Reassemble the parts correctly.

Center bolt: 20 - 29 N·m 2.0 - 3.0 kgf·m, 14 - 22 ft·lbf

WARNINGWARNINGMake sure fuel leaks are not present after installingparts. Leaks will not only waste fuel but also create a firehazard.

NOTEDo not excessively tighten bolts.

Disassembly sequence (Reassembly sequence is in thereverse order of disassembly.)

8. After installing the filter, purge air from the fuel system andcheck for fuel leaks.For air purging details, refer to “PURGING AIR FROMFUEL SYSTEM”.

PRIMARY FUEL FILTERDraining sediment from primary fuel filterNOTE

It is not necessary to drain all the fuel in the primary fuelfilter case.

Place a receiver under the filter, then loosen the drain plug to drainsediment.Put the drained precipitates in a glass container such as a test tube.If there is fuel on top of the water, dust and precipitates, it indicatesthat the precipitates have been removed.Bleed air from the fuel system after draining sediments.

1. Drain plug 6. Seat spring2. Packing 7. Retainer3. Center bolt 8. Element4. Packing 9. Packing5. Filter case 10. Filter cover


MA-4-25

Replacing primary fuel filter element1. Place a container under the filter.2. Place a suitable oil can under the drain cock, and drain the

fuel and sediment.Also loosen the plug to speed up draining.

3. Loosen the center bolt, and remove the filter case, set sprigand element.

4. Clean each part in light oil.5. Replace the element packings.6. Reassemble each part correctly.

Center bolt: Type I20 - 29 N·m 2.0 - 3.0 kgf·m, 14 - 22 ft·lbf

: Type II59 - 69 N·m 6.0 - 7.0 kgf·m, 43 - 51 ft·lbf

Drain plug (Type II only): 16 - 22 N·m 1.6 - 2.2 kgf·m, 12 - 16 ft·lbf

Do not excessively tighten the bolts and plugs.Disassembly sequence (Reassembly sequence is in thereverse order of disassembly.)

Type I

Type II

7. After installing the filter, purge air from the fuel system andcheck fuel leaks.For air purging details, refer to “PURGING AIR FROMFUEL SYSTEM”.

1. Plug 7. Set spring2. Packing 8. Retainer3. Drain cock 9. Element4. Center bolt 10. Packing5. Packing 11. Filter cover6. Filter case

1. Drain plug 7. Seat2. Packing 8. Element3. Center bolt 9. Packing4. Packing 10. Filter cover5. Filter case 11. Filter plug6. Spring 12. O-ring


MA-4-26

FUEL STRAINERDraining sediment from fuel strainer1. Place a container under the drain plug.2. Loosen the drain plug, and drain sediment and water from

the fuel strainer.3. After draining, securely tighten the drain plug.

Cleaning procedure1. Place a suitable oil can under the drain plug, and drain the

fuel and sediment.2. Loosen the center bolt, and remove the case, set spring

baffle and other parts.3. Clean each part in light oil.4. Replace the packings.5. Reassemble each part correctly.

Center bolt: 15 - 20 N·m 1.5 - 2.0 kgf·m, 11 - 14 ft·lbf

NOTEDo not excessively tighten the bolts and plugs.

NOTENumbers before part names do not indicate the disas-sembly sequence.

6. After installing the filter, purge air from the fuel system andcheck fuel leaks.For air purging details, refer to “PURGING AIR FROMFUEL SYSTEM”.

PURGING AIR FROM FUEL SYSTEM Air entrapped in the fuel system will cause poor injection of the fuel,thus resulting in difficult starting, jerking, or even stoppage of theengine. After completing any service procedure on the fuel system(inspection, replacement of fuel filter element, or reconnection ofany fuel pipe), be sure to bleed air from the fuel system.

1. Strainer cover 6. Spring retainer 2. Packing 7. Strainer case3. Screen 8. Packing4. Baffle 9. Center bolt5. Set spring 10. Drain plug


MA-4-27

1. Twist the knob on the priming pump, which is connected tothe injection pump, and the knob will rise up by itself.

2. Loosen the bleeder screw on the injection pump front upperside. (MKB and LKC212 series only)Keep moving the priming pump knob up and down untilmoving it becomes difficult and you can no longer hear thesound of air hissing from the bleeder screw.Retighten the bleeder screw.

: 7 - 9 N·m 0.7 - 0.9 kgf·m, 5.1 - 6.5 ft·lbf

3. Move the priming pump’s knob up and down to send fuelfrom fuel tank into the filter.Continue this procedure until the overflow valve of the fuelfilter no longer gives off a “hissing” sound and movement ofthe priming pump is difficult. The air bleeding operation isnow complete.

4. After bleeding air, return the pump knob to its original posi-tion. Start the engine, and make sure that no fuel is leakingfrom the fuel system.Fuel leaks can cause a fire. If a leak is discovered, immedi-ately repair the affected part.

INTAKE AND EXHAUST SYSTEM

AIR CLEANER ELEMENTPrecautions for handling cleaner1. Be sure to install the element and cover securely. Loose or

improper installation will allow dust to enter, preventing nor-mal functioning of the air cleaner.

2. Do not touch the filter paper of the element directly withyour hand. Wear gloves. Use special care not to stain theelement with oils.

To inspect the air cleaner elementStart the engine and check if the air cleaner warning light comeson. If the warning light comes on frequently, clean or replace theelement as follows:NOTE

If the air cleaner element reaches a checking or replacingperiod, clean or replace the element regardless ofwhether the warning light comes on or not.


MA-4-28

<FE6A, FE6B, FE6T and FE6TA>Disassembly sequence (Reassembly sequence is in thereverse order of disassembly.)

1. Unlock the clips and remove the cover assembly.2. Pull out and remove the outer element.

3. Check the outer element and packing, and replace if brokenor deformed.If there is dirt or dust on the outer element, clean it by blow-ing compressed air at 196 to 294 kPa 2.0 to 3.0 kgf/cm2,28 to 43 psi from inside.

4. Pull out and remove the inner element.NOTE

Do not remove the inner element until the specifiedreplacement time. In other words, the inner element neednot be checked between replacements.

5. When installing the elements, clean the inside of the bodyassembly and evacuator valve and assembly each part inthe reverse order of disassembly.

1. Cover assembly 4. Inner element2. Packing 5. Evacuator valve3. Outer element 6. Body assembly


MA-4-29

<FE6T 151 kW 205 PS/162 kW 220 PS and FE6TA>Disassembly sequence (Reassembly sequence is in thereverse order of disassembly.)

1. Loosen the wing nut and remove the cover assembly.2. Loosen the wing nut securing the outer element and

remove the outer element.

3. Check the outer element and packing, and replace if brokenor deformed.If there is dirt or dust on the outer element, clean it by blow-ing compressed air at 196 to 294 kPa 2.0 to 3.0 kgf/cm2,28 to 43 psi from inside.

4. First remove the wig nut and then the inner element.NOTE

Do not remove the inner element until the specifiedreplacement time. In other words, the inner element neednot be checked between replacements.

AIR INTAKE SYSTEM (DUCT, HOSE AND CLAMP)Check the air intake duct connections for loose clamps or crackedhoses. Check the connection between the air cleaner and air intakemanifold especially. Tighten loose clamps, if any.

1. Wing nut 7. Outer element2. Packing 8. Wing nut3. Cover assembly 9. Packing4. Packing 10. Inner element5. Wing nut 11. Evacuator valve6. Packing 12. Body assembly


MA-4-30

EXHAUST TUBING AND MUFFLERCheck the various connections of the exhaust tubing for looseness.Tighten loose parts as necessary. Also check for any sign of gasleakage from connections or muffler.

CONDITION OF EXHAUSTWarm up the engine sufficiently, then visually inspect exhaustsmoke during idling, acceleration and deceleration with the vehicleat a stop.

TURBOCHARGER (FE6T AND FE6TA)

NOTEBefore attempting any servicing of the turbocharger,clean its entire exterior surface.Never use a caustic solution. Caustic solutions attackaluminum.

To clean the compressor side1. Remove the turbocharger from the engine.2. Remove the compressor housing and check the condition

of the impeller (compressor wheel). If it is not excessivelydirty, clean the impeller and the inner surface of the housingwith a brush and a cloth dampened with diesel fuel.

CAUTIONDo not use a wire brush or scraper.

3. If the impeller is excessively dirty, overhaul and clean. Referto the ENGINE “IE” section for cleaning instructions.

4. When the impeller is wet with cleaning solvent, dry withcompressed air.

CAUTIONHold the impeller by hand to prevent it from turning whiledrying.

Color of smoke Judgment standardColorless or light blue Normal

Black AbnormalIncomplete combustion

White

AbnormalEngine oil is also burning. However, exhaust gases are often white when either the air or engine temperature is low.


MA-4-31

5. Install the compressor housing in its original position.T04B and T04E

: 11.3 - 14.7 N·m 115 - 150 kgf·cm, 100 - 130 in·lbfRHC62E and RHC6V

: 7.4 - 8.3 N·m 75 - 85 kgf·cm, 65 - 74 in·lbf

To clean the turbine side1. Remove the turbine housing and check the condition of the

turbine. If the turbine is not excessively dirty, clean the tur-bine and the inner surface of the turbine housing in a man-ner similar to that outlined under “To clean the compressorside”.

2. If the turbine is excessively dirty, overhaul and clean.3. When the impeller is wet with cleaning solvent, dry with

compressed air.CAUTION

Hold the impeller with your hand to prevent it from turn-ing while cleaning.

4. Install the turbine housing in its original position.T04B and T04E

: 18.0 - 21.5 N·m 184 - 219 kgf·cm, 160 - 190 in·lbfRHC62E and RHC62V

: 27.0 - 28.9 N·m 275 - 295 kgf·cm, 239 - 256 in·lbf5. Check that the turbine wheel rotates smoothly by your

hand. Install the turbocharger on the engine and check forgas or air leakage.

PCV VALVEPoint of inspection

Cover the hole at the center of the bottom of the valve withmasking tape and suck on the valve outlet to check that airis sucked into the inlet hole on the bottom of the valve.Next, cover the inlet hole on the bottom of the valve andsuck on the outlet pipe to check that the diaphragm opensand closes properly. This can be confirmed by the operatingsound which the diaphragm makes when opening and clos-ing.If there are any abnormalities, replace the valve.

NOTEWhen sucking on the valve, be careful not to get any oilin mouth. First remove the oil from inside the valve.


MA-4-32

PCV SYSTEMHose and clampCheck hose connections for signs of chafing, leaks or deterioration.Replace faulty hoses or tighten clamps, as necessary.

PipingCheck piping and connections for improper installation, cracks ordamage. Remove the hose when the PCV valve is replaced andclean the inside of the hose with compressed air.Replace faulty hoses or retighten clamps, as necessary.

OTHERS

ALTERNATORCheck the ball bearings for proper rotation and abnormal noise.

STARTING MOTORInspect the moving contactor of the magnetic switch.

- MEMO -

TROUBLE DIAGNOSIS

CONTENTSDIAGNOSIS ............................................ TD-1-1

DIFFICULT ENGINE STARTING ..................... TD-1-2BLACK EXHAUST SMOKE.............................. TD-1-3WHITE EXHAUST SMOKE .............................. TD-1-3IRREGULAR ENGINE OPERATION................ TD-1-4

DECREASED ENGINE POWER ...................... TD-1-5EXCESSIVE OIL CONSUMPTION................... TD-1-6EXCESSIVE FUEL CONSUMPTION ............... TD-1-7NOISY ENGINE................................................ TD-1-8ENGINE OVERHEATS..................................... TD-1-9

TD

DIAGNOSIS

TD-1-1

DIAGNOSISDIAGNOSIS GUIDEThe diagnosis guide is a table which can be used for seeking out the cause of trouble without disassemblingthe engine on the basis of the symptoms of the problem complained of by the user and the result of checksperformed in the shop with the engine mounted in the body.

HOW TO USE THE GUIDE1. Open the page of the guide corresponding to the trouble symptom complained of by the user.2. Check all of the points listed in the page.3. If there is any applicable item in the checking points, the cause of the trouble may be assumed in the

following manner.Each item in the “Symptoms and checking points” section corresponds to one or more items in the“Cause of trouble” section through the dot mark “ ”. If there are more than one applicable “Cause oftrouble” items, the item having the largest number of dot marks should be regarded as the centralcause of the trouble.The “cause” items having no dot mark can be regarded as not being the cause of the trouble.

NOTEIf more than one cause is assumed, the repair should begin with the simplest operation.

DIAGNOSIS

TD-1-2

DIFFICULT ENGINE STARTING

Sym

ptom

s an

d ch

ecki

ng p

oint

s

Star

ter f

ails

to ro

tate

Slow

sta

rter r

otat

ion

(less

than

100

rpm

)

Insu

ffici

ent s

tarte

r rot

atio

n

Soun

d of

mag

netic

sw

itch

is h

eard

with

sta

rter s

witc

h O

N

Littl

e ex

haus

t sm

oke

Mod

erat

e ex

haus

t sm

oke

Exce

ssiv

e ex

haus

t sm

oke

Engi

ne c

anno

t be

cran

ked

man

ually

Engi

ne la

cks

pow

er

Poor

fuel

con

sum

ptio

n or

oil

cons

umpt

ion

Cause of trouble

Elec

trica

l sys

tem

Discharged batteryPoor connection of connector and terminalBreaks in electrical wireFaulty starterFaulty starter switch and starter relayFaulty air heater

Fuel

sys

tem

Lack of fuelFaulty feed pumpIncorrectly installed fuel pipeFaulty injection pumpFaulty nozzleClogged fuel filter elementAir in fuel systemIncorrect injection timingBroken or damaged fuel pipeClogged gauge filter

Engi

ne p

rope

r and

oth

ers

Damaged ring gearDamaged or seized rotating engine partsHigh engine oil viscosityIncorrect valve clearanceInadequate compression pressureIncorrect valve timingClogged air cleaner element Faulty clutch and subsequent power train(Check by connecting and disconnecting the clutch)

DIAGNOSIS

TD-1-3

BLACK EXHAUST SMOKE

Sym

ptom

s an

d ch

ecki

ng p

oint

s

Poor

eng

ine

star

ting

Poor

fuel

con

sum

ptio

n or

oil

cons

umpt

ion

Engi

ne la

cks

pow

er

Exha

ust s

mok

e gr

adua

lly tu

rns

blac

k

Exha

ust s

mok

e su

dden

ly tu

rns

blac

k

Hig

h bl

ow-b

y ga

s pr

essu

re

Irreg

ular

idlin

g

Engi

ne k

nock

s

Low

com

pres

sion

pre

ssur

e

Cause of trouble

Inta

kesy

stem

Accumulation of sludge in air heaterClogged air cleaner elementTurbocharger failure (jamming, etc.)Oil leakage from compressor side of turbocharger

Fuel

sys

tem

Excessive injection quantityUneven plunger wearMalfunction of delivery valveFaulty nozzlePoor fuel qualityExcessively advanced injection timingFaulty boost compensator

Engi

nepr

oper Wear on piston rings, and cylinder liner

Excessive oil in oil pan

WHITE EXHAUST SMOKE

Engi

ne p

rope

ran

d ot

hers

Delayed injection timingEngine temperature too lowEngine oil leakage down through valve stemWear on piston ring or cylinder linerExcessive oil in oil panIncorrect valve clearance

DIAGNOSIS

TD-1-4

IRREGULAR ENGINE OPERATION

Sym

ptom

s an

d ch

ecki

ng p

oint

s

Blac

k ex

haus

t sm

oke

Whi

te e

xhau

st s

mok

e

Engi

ne la

cks

pow

er

Diff

icul

ty in

sta

rting

eng

ine

Poor

fuel

con

sum

ptio

n

Engi

ne k

nock

Engi

ne s

tabi

lizes

at t

wo

spee

ds

Engi

ne o

ften

stal

ls

Irreg

ular

idlin

g

Spec

ified

max

imum

rpm

is n

ot a

chie

ved

Spec

ified

max

imum

rpm

is e

xcee

ded

Low

com

pres

sion

pre

ssur

e

Cause of trouble

Fuel

sys

tem

Incorrect adjustment of link or rodFuel leakage from injection pipeUneven injection quantityMalfunction of governorUneven injection pressure of nozzleImproper fuel spray of nozzleImproper adjustment of idle springImproper adjustment of damper springMalfunction of delivery valveAir in fuel system

Engi

ne p

rope

r

Improper placement of valve seatImproper valve clearanceIncorrect valve timingIncorrect compression pressureEngine temperature too low

Oth

ers Deteriorated engine mount rubber

Improper adjustment of idlingRusted control wire

DIAGNOSIS

TD-1-5

DECREASED ENGINE POWER

Sym

ptom

s an

d ch

ecki

ng p

oint

s

Littl

e ex

haus

t sm

oke

Blac

k ex

haus

t sm

oke

Whi

te e

xhau

st s

mok

e

Poor

fuel

con

sum

ptio

n

Poor

oil

cons

umpt

ion

Diff

icul

ty in

sta

rting

eng

ine

Engi

ne o

verh

eats

Low

boo

st p

ress

ure

Exce

ssiv

e bl

ow-b

y ga

s

Spec

ified

max

imum

rpm

is n

ot a

chie

ved

Engi

ne k

nock

Irreg

ular

idlin

g

Low

com

pres

sion

pre

ssur

e

Low

spe

cific

gra

vity

of f

uel

Cause of trouble

Fuel

sys

tem

Improper fuel qualityImproper adjustment of injection quantityClogged fuel filter elementWater or air in fuel systemLow fuel pressure (overflow valve)Improper fuel spray from nozzleImproper injection timingMalfunction of delivery valveMalfunction of feed pumpMalfunction of injection pumpFaulty boost compensator

Inta

ke a

nd e

xhau

stsy

stem

Clogged air cleaner elementThin or hot intake airAccumulation of carbon to air heaterClogged or crushed exhaust pipe or mufflerHalf-opened exhaust shutterTurbocharger malfunction

Engi

ne p

rope

r Wear on piston rings and cylinder linerWorn, sticking, or broken piston ringSeized pistonWorn or seized valve stemImproper seating of valve insert

Oth

ers Improper selection of gear while traveling

Improper adjustment of control linkagePoor returning of engine stop wire

DIAGNOSIS

TD-1-6

EXCESSIVE OIL CONSUMPTION

Sym

ptom

s an

d ch

ecki

ng p

oint

s

Con

tinuo

us e

mis

sion

of w

hite

sm

oke

at h

igh-

spee

d ru

nnin

g

Engi

ne e

mits

whi

te s

mok

e af

ter i

dlin

g

Engi

ne la

cks

pow

er

Diff

icul

ty in

sta

rting

eng

ine

Poor

fuel

con

sum

ptio

n

Engi

ne o

verh

eate

d pr

evio

usly

Oil

atta

chin

g to

exh

aust

pip

e an

d m

anifo

ld

Hig

h bl

ow-b

y ga

s pr

essu

re

Low

com

pres

sion

pre

ssur

e

Engi

ne k

nock

Engi

ne o

il m

easu

ring

met

hod

inco

rrect

Cause of trouble

Engi

ne p

rope

r

Worn piston rings and cylinder linerAligned piston ring end gapsInsufficient piston ring tensionImproper break-in of piston ringInversely fitted piston ringsBroken or seized piston ringsWorn piston ringScuffing of cylinder linerWorn valve stem or guideWorn valve stem seal

Turb

o-ch

arge

r Worn or broken seal ringOil return hole obstructed by carbonImproper installation of seal ring

Oth

ers

Leakage of engine oilExcess of engine oilImproper quality of engine oilClogged air cleaner element

DIAGNOSIS

TD-1-7

EXCESSIVE FUEL CONSUMPTION

Sym

ptom

s an

d ch

ecki

ng p

oint

s

Engi

ne la

cks

pow

er

Blac

k ex

haus

t sm

oke

Whi

te e

xhau

st s

mok

e

Engi

ne k

nock

Engi

ne o

verh

eats

Poor

oil

cons

umpt

ion

Hig

h bl

ow-b

y ga

s pr

essu

re

Low

boo

st p

ress

ure

Low

com

pres

sion

pre

ssur

e

Irreg

ular

idlin

g

Cause of trouble

Fuel

sys

tem

Maladjusted nozzle injection pressureImproper fuel spray from nozzleMaladjusted injection quantityImproper seating of delivery valve seatImproper injection timingFaulty boost compensator

Engi

nepr

oper

Worn or seized piston, or piston ringWorn cylinder linerImproper seating between valve seat and insertMaladjusted valve clearance

Oth

ers

Clogged air cleaner elementHalf-opened exhaust shutterClogged or crushed exhaust pipe or mufflerEngine temperature too high

Cha

ssis

Dragged brakeClutch slipSeizure in drive lineInsufficient tire inflation pressure

Driv

ing

habi

ts

Unnecessary acceleration and decelerationImproper gear shiftingProlonged idling

DIAGNOSIS

TD-1-8

NOISY ENGINE

Sym

ptom

s an

d ch

ecki

ng p

oint

s

Engi

ne la

cks

pow

er

Blac

k ex

haus

t sm

oke

Whi

te e

xhau

st s

mok

e

Poor

fuel

con

sum

ptio

n

Engi

ne o

verh

eats

Hig

h bl

ow-b

y ga

s pr

essu

re

Low

boo

st p

ress

ure

Low

com

pres

sion

pre

ssur

e

Cause of trouble

Fuel

sys

tem

Improper timer advance angleUneven injection quantityInjection timing too earlyInjection timing delayedUneven nozzle injection pressureImproper fuel spray from nozzleMalfunction of delivery valvePoor fuel quality

Oth

ers

Wear or seizure on rotating and sliding portionsInsufficient intake air quantityImproper valve clearance, or seizure of valveLow intake air temperatureEngine too cold, or overheatedInsufficient compression pressure and compression air temperatureExcessive oil coming up into cylinder

DIAGNOSIS

TD-1-9

ENGINE OVERHEATS

Sym

ptom

s an

d ch

ecki

ng p

oint

s

Exce

ssiv

e re

duct

ion

of c

oolin

g w

ater

Engi

ne c

oola

nt re

duce

s in

qua

ntity

onl

y af

ter h

igh-

spee

d op

erat

ion

Engi

ne la

cks

pow

er

Engi

ne n

oisy

in o

pera

tion

Hig

h bl

ow-b

y ga

s pr

essu

re

Wat

er te

mpe

ratu

re d

iffer

ence

bet

wee

n w

ater

inle

t and

out

let i

s sm

all

Wat

er te

mpe

ratu

re d

iffer

ence

bet

wee

n w

ater

inle

t and

out

let i

s gr

eat

Rad

iato

r rem

ains

col

d ev

en a

fter e

ngin

e w

arm

up

Air b

ubbl

es a

ppea

r in

wat

er ta

nk o

nly

whe

n w

ater

tem

pera

ture

is h

igh

Air b

ubbl

es a

ppea

r in

wat

er ta

nk o

nly

afte

r eng

ine

raci

ng

Air b

ubbl

es is

radi

ator

Engi

ne c

oola

nt a

cidi

fied

Cause of trouble

Wat

er p

ump

Improper fan belt tensionWorn or seized bearingAir drawn from suction sideImproper water sealDamaged impeller

Coo

lant

pass

age

Malfunction of thermostatCoolant leakage from engine coolant passageOverflow of engine coolant due to blow-out of gasAccumulation of water scale in cylinder block

Rad

iato

r

Clogging by oxide of ironClogging by water sealCoolant leakageMalfunction of radiator capClogged core due to accumulation of mud and insects

Stat

e of

com

bust

ion Improper fuel spray from nozzle

Improper injection timingHalf-opened exhaust shutterClogged or crushed exhaust pipe or mufflerGas leakage from cylinder head nozzle tubeGas leakage from head gasket

Oth

ers

Continuous operation under heavy load, or other improper operationImproper selection of gears while travelingIncorrect indication of thermometer

- MEMO -

ENGINE DISASSEMBLYAND REASSEMBLY

CONTENTSSERVICE DATA...................................... DR-1-1

TIGHTENING TORQUE ................................... DR-1-1TOOLS .................................................... DR-2-1CONSTRUCTION.................................... DR-3-1

ENGINE............................................................ DR-3-1GEAR TRAIN.................................................... DR-3-5ENGINE REAR PTO ........................................ DR-3-6

DISASSEMBLY AND REASSEMBLY ........................................ DR-4-1

OUTSIDE OF ENGINE ..................................... DR-4-1CYLINDER HEAD............................................. DR-4-11ENGINE PROPER............................................ DR-4-17ENGINE REAR PTO......................................... DR-4-27

DR

SERVICE DATA

DR-1-1

SERVICE DATATIGHTENING TORQUE

Unit: N·m kgf·m, ft·lbfItem Tightening torque Remarks

Air intake manifold mounting bolt 16 - 20 1.6 - 2.0, 12 - 14Alternator adjusting bolt 34 - 44 3.5 - 4.5, 25 - 33Alternator anchor bolt and nut 59 - 74 6.0 - 7.5, 43 - 54

Camshaft gear mounting nut 186 - 226 19.0 - 23.0, 137 - 166 Secure camshaft before tight-ening.

Connecting rod bearing cap nut 132 - 142 13.5 - 14.5, 98 - 105Cooling fan mounting bolt 10 - 12 1.0 - 1.2, 7 - 9Crank damper mounting bolt 59 - 69 6.0 - 7.0, 43 - 51

Crank pulley nut1st 275 - 294 28.0 - 30.0, 203 - 2172nd Loosen the nut.3rd 834 - 883 85.0 - 90.0, 615 - 651

Cylinder head bolt1st 98 10.0, 722nd 177 - 196 18.0 - 20.0, 130 - 145

Engine mounting bolt and nut

Front sideBracket 29 3.0, 22Cushion 49 5.0, 36

Rear side Cushion 49 5.0, 36Exhaust manifold connector mounting nut 34 - 44 3.5 - 4.5, 25 - 33Exhaust manifold mounting nut 34 - 44 3.5 - 4.5, 25 - 33Fan pulley mounting nut 20 - 25 2.0 - 2.5, 14 - 18

Flywheel housing mounting bolt and nut

M8 15 - 20 1.5 - 2.0, 11 - 14M12 69 - 74 7.0 - 7.5, 51 - 54

Flywheel mounting bolt and nut 235 - 255 24.0 - 26.0, 174 - 188 Tighten diagonally.Front end plate mounting bolt 16 - 21 1.6 - 2.1, 11.6 - 15Hydraulic pump drive gear mounting nut 49 - 64 5.0 - 6.5, 36 - 47Idler gear plate mounting bolt 34 - 39 3.5 - 4.0, 25 - 29Idler gear shaft mounting bolt 34 - 39 3.5 - 4.0, 25 - 29Injection bracket mounting bolt 37 - 42 3.8 - 4.3, 27 - 31Injection nozzle tube 23 - 27 2.3 - 2.8, 17 - 20

Injection pump drive coupling cotter bolt


59 - 64 6.0 - 6.5, 43 - 47

FE6TA157 kW 213 PS 83 - 93 8.5 - 9.5, 61 - 69

Injection pump drive coupling bolt and nut


29 - 34 3.0 - 3.5, 22 - 25

FE6TA157 kW 213 PS 59 - 64 6.0 - 6.5, 43 - 47

SERVICE DATA

DR-1-2

Unit: N·m kgf·m, ft·lbfItem Tightening torque Remarks

Injection pump drive gear mounting nut 147 - 167 15.0 - 17.0, 108 - 123Injection pump mounting bolt 20 - 25 2.0 - 2.5, 14 - 18

Injection pump stay mounting bolt

Cylinder block side 21 - 26 2.1 - 2.7, 15 - 20Injection pump side 29 - 39 3.0 - 4.0, 22 - 29

Locating plate mounting bolt 21 - 26 2.1 - 2.7, 15 - 20

Main bearing cap bolt 177 - 196 18.0 - 20.0, 130 - 145 Apply oil to the bolt seat and thread.

Nozzle holder mounting bolt 25 - 29 2.5 - 3.0, 18 - 22Oil cooler mounting bolt 25 2.5, 18Oil filter mounting bolt 25 2.5, 18Oil jet connector bolt 34 - 49 3.5 - 5.0, 25 - 36Oil pan drain plug 59 - 69 6.0 - 7.0, 43 - 51Oil pan mounting bolt and nut 18 - 25 1.8 - 2.5, 13 - 18Oil pipe mounting bolt 20 2.0, 14Oil pump mounting bolt 20 2.0, 14Oil screen mounting bolt 9 - 12 0.9 - 1.2, 6.5 - 8.7PTO companion flange mounting nut 392 - 412 40.0 - 42.0, 289 - 304PTO idler gear mounting bolt 98 10.0, 72Rocker cover mounting bolts 10 - 15 1.0 - 1.5, 7 - 11 Do not overtighten.

Rocker shaft bracket mounting bolt 44 - 54 4.5 - 5.5, 33 - 40 Tighten center bolts first then move toward outer bolts.

Spill tube connector 8 - 10 0.8 - 1.0, 5.8 - 7.2 Tighten nut before tightening connector.

Starting motor mounting bolt 59 - 78 6.0 - 8.0, 43 - 58Timing gear case mounting bolt and nut 21 - 26 2.1 - 2.7, 15 - 20Water pump mounting bolt and nut 10 - 13 1.0 - 1.3, 7 - 9Cooler tension pulley lock nut 35 - 47 3.6 - 4.8, 26 - 35Turbocharger assembly mounting nut 34 - 44 3.5 - 4.5, 25 - 33Turbocharger oil pipe 12 - 15 1.2 - 1.5, 9 - 11Turbocharger oil drain pipe 18 - 22 1.8 - 2.2, 13 - 16

TOOLS

DR-2-1

TOOLSTool name and number Description Shape

Socket wrench99535 Z5007

Used to remove and install crank pulley nut.Width across flats: 55 mm (2.17 in)

Guide bolt99687 97001

Used to remove and install flywheel.

Engine stand attachment99554 97001

Used as an attachment for engine stand when installing engine.

Engine stand99550 96001

Used when disassembling and reassembling engine.

Piston insert tool99631 Z5502

Used as a guide when inserting piston into cyl-inder liner.

TOOLS

DR-2-2

Tool name and number Description ShapeCylinder head bolt socket wrench99664 Z5000

Used to remove, install and tighten cylinder head bolts.

Engine jack99890 Z0001

Used to remove and install engine assembly.

CONSTRUCTION

DR-3-1

CONSTRUCTIONENGINE

ENGINE MODEL FE6

CONSTRUCTION

DR-3-2

CONSTRUCTION

DR-3-3

ENGINE MODEL FE6T(Refer to FE6T for FE6TA construction)

CONSTRUCTION

DR-3-4

CONSTRUCTION

DR-3-5

GEAR TRAIN

CONSTRUCTION

DR-3-6

ENGINE REAR PTO

DISASSEMBLY AND REASSEMBLY

DR-4-1

DISASSEMBLY AND REASSEMBLYOUTSIDE OF ENGINE

FRONT SIDE OF ENGINE



1. Fan and fan pulley 4. Alternator 6. Thermostat housing2. V-belt 5. Hydraulic pump 7. Water pump3. Crank pulley assembly


DR-4-2

Key point of disassembly3 Crank pulley assemblyRemove the pointer cover and pointer from the flywheel housing.Lock the flywheel ring gear to prevent it from turning. Loosen thecrank pulley nuts using the socket wrench (99535 Z5007).NOTEIf the crankshaft thread is staked, perform as follows:

Loosen the pulley nut and remove it. (The removed nutcannot be reused.)Correct the staked portion of the crankshaft thread with atriangular rod file.Using a new pulley nut, make sure that the nut turnssmoothly on the crankshaft thread.

Key point of reassembly6 Thermostat housingInstall the thermostat housing using liquid gasket (THREE BOND1216 or equivalent) and connect the hose.NOTE

Ensure the flange surface is clean and free from oil,water, dust, etc. before applying liquid gasket.During application, be sure to overlap the start and endpoints of the liquid gasket. The gasket should be contin-uous.Install parts properly and within 20 minutes after gasketapplication.Do not apply pressure to parts for at least 40 minutesafter installation.


DR-4-3

3 Crank pulley assembly1. Install the crank pulley assembly and temporarily tighten the

crank pulley nut.NOTE

Be sure to install the key.If the crank pulley is reused, remove the adhesive agentcoated on the tapered surface.Apply one or two drops of Loctite “221” or “222” to thetapered surface of the crankshaft.Be sure not to apply adhesive agent to the crankshaft tipthread.

2. Lock the flywheel ring gear. Using the socket wrench(99535 Z5007), install the crank pulley nut.

: 1st : 275 - 294 N·m 28.0 - 30.0 kgf·m, 203 - 217 ft·lbf2nd: Loosen the nut.3rd : 834 - 883 N·m 85.0 - 90.0 kgf·m, 615 - 651 ft·lbf

NOTEFirst, tighten the nut then loosen it. Secondly, retightenthe nut to the specified torque.Do not leave the pulley temporarily installed withouttightening the nut.


DR-4-4

RIGHT SIDE OF ENGINE



Key point of reassembly8 Oil filterInstall the oil filter using an O-ring.NOTE

Be careful not to damage the O-ring.Tighten the filter by hand. (Refer to the MA section of “Toreplace the oil filter”.)

1. Air pipe 4. Exhaust manifold cover 7. Oil pipe2. Alternator 5. Exhaust connector 8. Oil filter3. Turbocharger 6. Exhaust manifold 9. Oil cooler


DR-4-5

7 Oil pipeConnect the oil pipe using an O-ring.NOTE

Be careful not to damage the O-ring.: 20 N·m 2.0 kgf·m, 14 ft·lbf

6 Exhaust manifoldInstall the exhaust manifold using a gasket.NOTE

Start by tightening the middle nut and then alternatebetween the upper and lower ones.

These nuts are heat-resistant and should not be con-fused with other types.

: 34 - 44 N·m 3.5 - 4.5 kgf·m, 25 - 33 ft·lbf


DR-4-6

LEFT SIDE OF ENGINE



Key point of disassembly12 Air compressor or injection pump supportRemove the air compressor (AOH model only) or injection pumpsupport. (VAC model only)NOTE

Measure the backlash of the front gear train beforeremoving the air compressor (AOH model only) or injec-tion pump support. (VAC model only)

1. Air duct 6. Intake manifold 11. Drain cock2. Fuel tube 7. Nozzle assembly 12. Air compressor or injection pump3. Fuel filter 8. Timer coupling support4. Air heater 9. Injection pump assembly and stay 13. Oil pan5. Breather tube 10. Starting motor


DR-4-7

Key point of reassembly12 Air compressor or injection pump supportInstall the air compressor (AOH model only) or injection pump sup-port (VAC model only) using an O-ring (if removed after measuringfront gear train backlash).

1. Rotate the flywheel in the standard direction to determinethe 1.6 point at TDC of No. 1 cylinder on the compressionstroke. (TDC is the point at which both intake and exhaustvalves for No. 1 cylinder are closed and there is a valveclearance.)

2. Align the scribe mark on the injection pump drive gear toothwith the pointer at the check window on the upper side ofthe timing gear case. Then, install the compressor or injec-tion pump support.

9 Injection pump assembly and stay, 8 Timer coupling1. Install the injection pump stay on the injection pump body

and tighten to the specified torque. :29 - 39 N·m 3.0 - 4.0 kgf·m, 22 - 29 ft·lbf

2. Put the injection pump body on the injection pump bracketand temporarily tighten the injection pump stay-to-cylinderblock securing bolts.


DR-4-8

3. Temporarily tighten the injection pump body securing bolts(1), (2), (3) and (4).

NOTEBe sure to equally tighten the bolts in the order enumer-ated above.

4. Tighten the injection pump stay-to-cylinder block securingbolts to the specified torque. :21 - 26 N·m 2.1 - 2.7 kgf·m, 15 - 20 ft·lbf

5. Set a dial gauge probe to the periphery of the injection timerperpendicularly and horizontally as shown in the figure atright, then reset the pointer to zero (0).

6. Equally tighten the bolts (1), (2), (3) and (4) in that order sothat the dial gauge pointer stays in the 0±0.05 mm(0±0.0020 in) range. Then tighten these bolts to the speci-fied torque.

NOTEBe sure to equally tighten the bolts in the order enumer-ated above.

:20 - 25 N·m 2.0 - 2.5 kgf·m, 14 - 18 ft·lbf


DR-4-9

7. Loosen the plate (coupling half side) and cross couplingsecuring bolts.

8. Make sure the plate (coupling half side) is smoothly insertedinto the cross coupling spigot joint. If it is not, loosen theinjection pump securing bolts (1), (2), (3) and (4), readjustby repeating from step 3 above.

9. Tighten the plate (coupling half side)-to-cross couplingsecuring bolts to the specified torque.



10. Rotate the flywheel so that the pointer is aligned with thespecified fuel injection timing mark. If the timing marks onthe injection pump body and injection pump timer are notclose each other, rotate the flywheel an additional turn untilthe No. 1 cylinder is set at TDC on the compression stroke.

ItemMainte-nance

standard


Fuel injec-tion timing

FE6A 14º —

FE6B119 kW 162 PS 15º —132 kW 180 PS 12º —

FE6T135 kW 183 PS 12º —151 kW 205 PS 10º —162 kW 220 PS 9º —

FE6TA

157 kW 213 PS 3º — “MD-TICS” system

173 kW 235 PS 12º —


DR-4-10

11. Align the line scribed on the injection pump timer with theline on the injection pump body.

12. Tighten the bolts to the specified torque.: FE6A, FE6B, FE6T and FE6TA 173 kW 235 PS29 - 34 N·m 3.0 - 3.5 kgf·m, 22 - 25 ft·lbf


13. Tighten the coupling half cotter bolts to the specified torque.: FE6A, FE6B, FE6T and FE6TA 173 kW 235 PS59 - 64 N·m 6.0 - 6.5 kgf·m, 43 - 47 ft·lbf



DR-4-11

CYLINDER HEAD

DISASSEMBLY AND REASSEMBLYStep 1


1. Breather hose 3. Gasket 7. Oil filler cap2-A. Breather (Type Z5506) 4. O-ring 8. Rocker cover2-B. Breather (Type Z5507) 5. Breather adapter 9. Baffle plate2-C. Air control valve 6. O-ring 10. Cover gasket


DR-4-12

Step 2



11. Stopper bolt 14. Rocker shaft 16. Exhaust valve12. Rocker shaft bracket 15. Push rod 17. Intake valve13. Rocker arm


DR-4-13

Step 3



18. Cylinder head bolt 23. O-ring 27. Stay19. Cylinder head bolt 24. Valve guide 28. Rear engine slinger20. Cylinder head bolt 25. Push rod pipe 29. Cylinder head21. Nozzle sleeve 26. Front engine slinger 30. Head gasket22. Nozzle tube


DR-4-14

Key point of disassembly14 Rocker shaftRemove the rocker shaft assembly and push rods.NOTE

Loosen the rocker shaft assembly mounting bolts, start-ing with the outer bolt and moving toward the center.

29 Cylinder headRemove the cylinder head assembly. Attach chains or cables to theengine lifters and lift the cylinder head away from the cylinder blockusing a hoist.NOTE

Loosen the head bolts diagonally, starting with the outerone and moving toward the center.

Key point of reassembly29 Cylinder headInstall the cylinder head using gaskets.NOTE

Ensure that the stamped part number side faces upwardwhen installing the gasket.

20, 19, 18 Cylinder head boltTighten the cylinder head bolts to the specified torque using thesocket wrench (99664 Z5000). Note that seven of the head boltsare also secured to the rocker shaft bracket.

: 1st : 98 N·m 10.0 kgf·m, 72 ft·lbf2nd: 177 - 196 N·m 18.0 - 20.0 kgf·m, 130 - 145 ft·lbf

: Refers to the bolts which are also secured to the rockershaft bracket. [L = 180 mm (7.09 in)]

: Circled numbers refer to tightening sequence of head bolts.O


DR-4-15

14 Rocker shaftInsert the push rod and install the rocker shaft assembly.NOTE

Be sure to align the end of the rocker arm with that of thepush rod.

12 Rocker shaft bracketTighten seven rocker shaft bracket bolts.


Tighten the middle bolt first and move toward the outerones.


DR-4-16

- MEMO -


DR-4-17

ENGINE PROPERDISASSEMBLY AND REASSEMBLY


DR-4-18


DR-4-19


DR-4-20



Key point of disassemblyInstall the engine stand attachment (99554 97001).

Lift the engine with a hoist and attach it to the engine stand(99550 96001).

1 Flywheel1. Measure and record the surface runout of the flywheel that

engages with the clutch disc. (Manual transmission modelonly)

1. Flywheel 13-A. Air compressor (AOH model) 22. Piston assembly2. Oil pan 13-B. Injection pump support (VAC model) 23. Crankshaft assembly3. Gasket 14. O-ring 24. Idler gear4. Oil screen 15. Stiffener (If so equipped) 25. Idler gear shaft5. Gasket 16. Flywheel housing 26. Camshaft assembly6. Timing gear case 17. Oil seal 27. Cam follower7. O-ring 18. Gasket 28. Gasket8. Oil seal 19. Gasket 29. Front end plate9. Revolution sensor 20. Gasket 30. Gasket

10. Hydraulic pump 21. Connecting rod cap and bearing shell 31. Oil jet11. Gasket 12. O-ring


DR-4-21

2. Remove the bolts. Using the two guide bolts (9968797001), remove the flywheel.

10 Hydraulic pump, (13)-A Air compressor, (13)-B Injectionpump support

Measure and record the backlash of the front gear train.NOTE

Before measuring the backlash, install the air compres-sor (AOH model only) or injection pump support (VACmodel only), if previously removed.Before measuring the backlash of the hydraulic pumpgear, install the timing gear case. Apply grease to a fuseand affix the fuse to a tooth of the pump gear. Install thepump gear on the timing gear case. Rotate the gear andmeasure the thickness of the smashed fuse to determinethe backlash.

16 Flywheel housingRemove the flywheel housing.NOTE

Before removing the flywheel housing, remove theengine rear PTO (if so equipped).

22 Piston assembly1. Measure the side clearance of the large end of the connect-

ing rod.


DR-4-22

2. Remove the piston assembly and connecting rod as a unit.NOTE

Before removing these parts, remove carbon from theupper inside wall of the cylinder liner.

23 Crankshaft assembly1. Measure and record the end play of the crankshaft.

2. Remove the crankshaft, thrust washer and upper mainbearing shell.

NOTEKeep the upper and lower thrust washers together as aset.Keep the upper and lower main bearing halves and mainbearing cap as a set.

24 Idler gearMeasure and record the end play of the idler gear.

26 Camshaft assemblyRemove the camshaft gear and camshaft.NOTE

Turn the oil pan sideways so that the cam follower can-not drop into the oil pan when removing the camshaft.


DR-4-23

Key point of reassemblyCAUTION

Before reassembling the engine, replace all gaskets,packings and O-ring with new ones and apply a coat ofengine oil to the frictional surfaces of all parts.

22 Crankshaft1. Install upper main bearing shells.NOTE

Be sure to reinstall all shells in their original positions.

2. Attach the upper thrust washer to both sides of No. 6 bear-ing.

NOTEFace the side with the stamped mark toward the cylinderblock.

3. Position the lower main bearing shell in the main bearingcap and install the bearing cap.


Ensure that all main bearing shells are reinstalled in theiroriginal positions.

Install the main bearing cap with the arrow mark facingthe front of the engine in the order of embossed num-bers.

4. Be sure to attach the lower thrust washer to both sides ofNo. 6 bearing.

NOTEFace the side with the stamped mark of the thrust washertoward the main bearing cap.


DR-4-24

5. Measure the end play of the crankshaft.Unit: mm (in)

22 Piston assembly1. Insert the piston assembly (including the connecting rod,

upper bearing shell and bolts) into the cylinder liner usingthe piston insert tool (99631 Z5502).

NOTEWhen installing the piston rings, ensure that their gapsare 180º opposite of each other and are not positioned inthe direction of the piston pin and at a right angle to it.Face the arrow mark on the piston toward the front of theengine when inserting the piston assembly.Ensure that the number stamped on the large end ofeach connecting rod is the same as that on the cylinderwhen installing the piston assembly.

Maintenance standard Service limit0.06 - 0.14 (0.0024 - 0.0055) 0.40 (0.0157)

Engine model Piston assembly typeFE6T 151 kW 205 PS

Type IFE6TAFE6A

Type IIFE6B

FE6T135 kW 183 PS162 kW 220 PS Type III


DR-4-25

2. Install the connecting rod cap on which the lower bearingshell has already been installed.


Ensure that the stamped mark on the end face of the con-necting rod cap is the same as that stamped on the largeend of the connecting rod.

3. Measure the side clearance of the large end of the connect-ing rod.

Unit: mm (in)

24 Idler gear1. Install the idler gear.NOTE

Align the timing mark on the camshaft gear with that onthe crank gear.

: 34 - 39 N·m 3.5 - 4.0 kgf·m, 25 - 29 ft·lbf

2. Measure the end play of the idler gear.Unit: mm (in)

13-A Air compressor, 13-B Injection pump support1. Install the air compressor (AOH model only) or injection

pump support (VAC model only).: 147 - 167 N·m 15.0 - 17.0 kgf·m, 108 - 123 ft·lbf

NOTEAlign the timing mark on the injection pump drive gearwith that on the idler gear.Installing the air compressor in this step may facilitatesubsequent operations.

Maintenance standard Service limit0.10 - 0.30 (0.0039 - 0.0118) —

Maintenance standard Service limit0.03 -0.12 (0.0012 - 0.0047) 0.3 (0.012)


DR-4-26

2. Measure the backlash of the front gear train (Refer to keypoint (10) for measurement of backlash of the hydraulicpump gear).

Unit: mm (in)

10 Hydraulic pumpUsing grease, affix a fuse to a tooth of the hydraulic pump gear andinstall the hydraulic pump on the timing gear case. Rotate the pumpgear and measure the thickness of the smashed fuse to determinethe backlash.

Unit: mm (in)

16 Flywheel housingInstall the flywheel housing using a gasket.NOTE

On models equipped with the PTO, remove the idler gearbracket in advance.

1 Flywheel assembly1. Install the flywheel using the two guide bolts (99687 97001),

and tighten the bolts.: 235 - 255 N·m 24.0 - 26.0 kgf·m, 174 - 188 ft·lbf

2. Measure the surface runout of the flywheel that engageswith the clutch disc.

Unit: mm (in)



Maintenance standard Service limit0.15 (0.0059) (max.) 0.18 (0.0071)


DR-4-27

ENGINE REAR PTO



1. Connector bolt 13. Tray 24. Drive shaft2. Gasket 14. PTO holder 25. PTO cover3. Oil tube 15. O-ring 26. Cover gasket4. Gasket 16. Ball bearing 27. Housing cover5. Pointer cover 17. Retaining ring 28. Gasket6. Gasket 18. O-ring 29. Idler shaft7. Pointer 19. Retaining ring 30. Bushing8. Gasket 20. Sub gear 31. Idler gear9. Nut 21. Retaining ring 32. Idler gear bracket

10. Companion flange 22. PTO gear 33. Flywheel housing11. Slinger 23. Ball bearing 34. Housing gasket12. Oil seal


DR-4-28

Key point of disassemblyMeasure and record the backlash between the idler gearand crankshaft gear.Measure and record the backlash between the PTO gearand idler gear.

Key point of reassembly31 Idler gearMake sure that the backlash between the idler gear and crankshaftgear is within the maintenance standard.

Unit: mm (in)

22 PTO gear, 20 Sub gear1. Install the spring into the PTO gear. Hang the tip of the

spring from the 11 mm (0.43 in) diameter hole in the PTOgear and the other tip from the 11 mm (0.43 in) diameterhole in sub gear, and install the sub gear.

NOTEWhen installing the sub gear, face the F mark toward theoutside and lock it with a retaining ring.

2. Secure the PTO gear and turn the sub gear in the directionwhere the spring opens. When the 8 mm (0.31 in) diameterhole in the PTO gear aligns with that in the sub gear, insertan 8 mm (0.31 in) diameter pin.



DR-4-29

3. Assemble the PTO gear, aligning the oil hole of the driveshaft with the oil hole of the PTO gear.

4. Align the pin position with the M24 threaded hole in thePTO holder and install the pin.

5. Install the holder assembly into the flywheel housing andextract the pin.

NOTEBe sure to extract the pin.

6. With the gasket in place, plug the M24 threaded hole.

7. Make sure that the backlash between the PTO gear andidler gear is within the maintenance standard.

Unit: mm (in)Maintenance standard Service limit

0.05 - 0.15 (0.0020 - 0.0059) 0.3 (0.012)

- MEMO -

ENGINE PROPER

CONTENTSSERVICE DATA...................................... EP-1-1TOOLS .................................................... EP-2-1INSPECTION........................................... EP-3-1

CYLINDER BLOCK .......................................... EP-3-1CRANKSHAFT ................................................. EP-3-2MAIN BEARING SHELL ................................... EP-3-4CYLINDER LINER............................................ EP-3-4PISTON AND CONNECTING ROD.................. EP-3-5CAMSHAFT...................................................... EP-3-10GEAR TRAIN.................................................... EP-3-11FLYWHEEL ...................................................... EP-3-12FLYWHEEL HOUSING AND TIMING GEAR CASE ....................................... EP-3-13CRANK PULLEY AND DAMPER ..................... EP-3-13

V-BELT ............................................................. EP-3-13REPAIR AND REPLACEMENT .............. EP-4-1

CYLINDER LINER REPLACEMENT ................ EP-4-1CAMSHAFT BUSHING REPLACEMENT......... EP-4-2CRANKSHAFT CORRECTION ........................ EP-4-3CONNECTING ROD REPLACEMENT............. EP-4-4REPLACING CONNECTING ROD SMALL-END BUSHING.................................... EP-4-4REPLACING IDLER GEAR BUSHING ............. EP-4-5OIL SEAL COLLAR REPLACEMENT............... EP-4-5FLYWHEEL CORRECTION ............................. EP-4-6REPLACING INJECTION PUMP BRACKET.... EP-4-6REAR OIL SEAL REPLACEMENT................... EP-4-7

EP

SERVICE DATA

EP-1-1

SERVICE DATA Unit: mm (in)


Cylinder block

Upper surface warpage

Longitudinal direction Less than 0.10 (0.0039) —

Transverse direc-tion Less than 0.05 (0.0020) —

Inner wall roundness at liner 0.02 (0.0008) —

Clearance between main bearing cap and cylinder block 0.05T - 0.02L(0.0020T - 0.0008L) — T = Tight

L = Loose

Crankshaft

Journal outside diameter 77.930 - 77.950(3.0681 - 3.0689) 77.82 (3.0638)

Refinishing allowance:1.0 (0.039)

Crank pin outside diameter 64.925 - 64.945(2.5561 - 2.5569) 64.80 (2.5512)

Journal out-of-roundness Less than 0.01 (0.0004) 0.02 (0.0008)

Crank pin out-of-roundness Less than 0.01 (0.0004) 0.02 (0.0008)

Taper of journal Less than 0.01 (0.0004) —

Taper of crank pin Less than 0.01 (0.0004) —

Runout

Journal Less than 0.07 (0.0028) —

Indicator readingContacting surface with oil seal Less than 0.01 (0.0004) —

Flywheel mounting surface Less than 0.02 (0.0008) —

End play 0.06 - 0.14(0.0024 - 0.0055) 0.40 (0.0157)

Main bear-ing shell Clearance to crankshaft journal 0.03 - 0.09

(0.0012 - 0.0035) 0.15 (0.0059)

Cylinder liner

Inside diameter (when installed in cylinder block) 108.00 - 108.03(4.2520 - 4.2531) 108.23 (4.2610)

Measuring positionFrom top25, 50, 75, 100, 150, 200 (0.98, 1.97, 2.95, 3.94, 5.91, 7.87)

Out-of-roundness Less than 0.02 (0.0008) —

Taper Less than 0.025 (0.0010) —

Flange protrusion from block upper surface 0 - 0.07(0 - 0.0028) —

Difference between adja-cent cylinders 0.03 (0.0012) —

Piston

Outside diameter

FE6AFE6BFE6T 135 kW 183 PS

107.825 - 107.855(4.2451 - 4.2463) — Lateral to piston pin

Measure at 18.5 (0.728) posi-tion from bottom surface, per-pendicular to piston pin

FE6T 151 kW 205 PSFE6T 162 kW 220 PSFE6TA

107.940 - 107.970(4.2496 - 4.2508) —

Clearance to cylinder liner


0.145 - 0.205(0.0057 - 0.0081) —


0.050 - 0.070(0.0020 - 0.0028) —

Piston pin bore inside diameter 36.00 - 36.02(1.4173 - 1.4181) —

SERVICE DATA

EP-1-2

Unit: mm (in)


Piston ring

Clearance between piston ring and ring groove

2nd 0.04 - 0.08(0.0016 - 0.0031) 0.4 (0.016)

Oil 0.02 - 0.06(0.0008 - 0.0024) 0.2 (0.008)

Joint gap

1st2nd

0.30 - 0.45(0.0118 - 0.0177) 1.5 (0.059)

Oil


0.15 - 0.35(0.0059 - 0.0138) 1.5 (0.059)


0.25 - 0.45(0.0098 - 0.0177) 1.5 (0.059)

Piston pinOutside diameter 35.993 - 36.000

(1.4170 - 1.4173) —

Clearance to piston pin hole 0 - 0.03L(0 - 0.0012L) 0.05 (0.0020) L = Loose

Connecting rod

Small-end bushing inside diameter 36.025 - 36.041(1.4183 - 1.4189) —

Clearance between small-end bushing and piston pin 0.03 - 0.05(0.0012 - 0.0020) 0.10 (0.0039)

Twist Less than 0.15 (0.0059) —

Bend Less than 0.10 (0.0039) —

Crank pin side clearance 0.10 - 0.30(0.0039 - 0.0118) —

Clearance between big-end bearing and crank pin 0.035 - 0.095(0.0014 - 0.0037) 0.15 (0.0059)

Camshaft

Journal outside diameter

No. 1 57.33 - 57.35(2.2571 - 2.2579) —

No. 2 57.13 - 57.15(2.2492 - 2.2500) —

No. 3 56.93 - 56.95(2.2413 - 2.2421) —

No. 4 56.73 - 56.75(2.2335 - 2.2342) —

Height of cam profile

FE6AFE6BFE6TA 173 kW235 PS

IN 48.47 - 48.51(1.9083 - 1.9098) 47.99 (1.8894)

EXH 48.41 - 48.45(1.9059 - 1.9075) 47.93 (1.8870)

FE6TFE6TA 157 kW213 PS

IN 48.79 - 48.83(1.9209 - 1.9224) 48.31 (1.9020)

EXH 48.41 - 48.45(1.9059 - 1.9075) 47.93 (1.8870)

Journal-to-bushing clearance 0.02 - 0.10(0.0008 - 0.0039) 0.15 (0.0059)

Runout (indicator reading) Less than 0.03 (0.0012) 0.06 (0.0024)Runout of No. 1 & No. 4 with No. 2 & No. 3 supported V-blocks

End play 0.08 - 0.28(0.0031 - 0.0110) 0.3 (0.012)

Gear train

Front gear train backlash 0.06 - 0.16(0.0024 - 0.0063) 0.3 (0.012)

Idler gear end play 0.03 - 0.12(0.0012 - 0.0047) 0.3 (0.012)

Clearance between idler gear bushing and shaft 0.02 - 0.06(0.0008 - 0.0024) 0.2 (0.008)

SERVICE DATA

EP-1-3

Unit: mm (in)


Flywheel

Clutch disc contact surface runout Less than 0.15 (0.0059) 0.18 (0.0071) Manual transmission model only

Reduced size of worn surface

Thickness (A)Type I

FE6A, FE6BFE6T 135 kW 183 PS

20.5 (0.807) 18.5 (0.728)

Refer to page EP-3-12 (FLY-WHEEL). Manual transmission model only

21.5 (0.846) 19.5 (0.768)

Type II FE6B, FE6T, FE6TA 23.0 (0.906) 21.0 (0.827)

Height (H) Type II

FE6B, FE6T, FE6TA 43.0 (1.693) 45.0 (1.772)

FE6T 162 kW 220 PSFE6TA 157 kW 213 PS

48.0 (1.890) 50.0 (1.969)

V-belt DeflectionFan pulley - alternator pulley (A) 10 - 15 (0.39 - 0.59) — Refer to page EP-3-13

(V-BELT).When midpoint is pressed with 98 N 10 kgf, 22 lbfFan pulley - cooler compressor pulley (B) 7 - 12 (0.28 - 0.47) —

Engine rear PTO

Backlash of PTO gear 0.05 - 0.15(0.0020 - 0.0059) 0.3 (0.012)

Backlash of idler gear 0.06 - 0.14(0.0024 - 0.0055) 0.3 (0.012)

TOOLS

EP-2-1


Straightedge99645 Z5001

Used to measure flatness of cylinder block

Piston ring tool99630 Z5001

Used to remove and install piston rings

Cylinder liner tool99600 Z5002

Used to remove and install cylinder liners

Cam bushing remover99590 Z5002

Used to remove camshaft bushings

Tool kit cam bushing replacer99590 Z5003

Used to install camshaft bushingsCam bushing replace(1) For No. 1(2) For No. 4(3) For No. 2(4) For No. 3Cam bushing replace bar(5) For No. 2 and No. 3

(1) 99594 Z5002(2) 99594 Z5003(3) 99595 Z5004(4) 99595 Z5005(5) 99597 Z5001

TOOLS

EP-2-2

Tool name and number Description ShapeOil seal collar replacer99718 Z5002

Used to press-fit oil seal collars

Injection pump bracket set-ting tool99720 Z5500

Used to center injection pump bracket[For 25 mm (0.98 in) air compressor crankshaft rear edge outside diameter]

Injection pump bracket set-ting tool99720 Z5501

Used to center injection pump bracket[For 30 mm (1.18 in) air compressor crankshaft rear edge outside diameter]

Oil seal and sleeve replacer99691 Z5500(1) 99718 Z5500(2) 99687 97002

Used to press-fit rear oil seal and sleeve(1) Oil seal replacer(2) Guide bolt[For 110 mm (4.33 in) crankshaft rear edge outside diameter and 115 mm (4.53 in) oil seal sleeve outside diameter

Oil seal and sleeve replacer99691 Z5501(1) 99718 Z5504(2) 99687 97002

Used to press-fit rear oil seal(1) Oil seal replacer(2) Guide bolt[For 120 mm (4.72 in) crankshaft rear edge outside diameter and 145 mm (5.71 in) oil seal outside diameter]

Oil seal replacer(1) 99718 Z5501(2) 99687 97002

Used to press-fit rear oil seal(1) Oil seal replacer(2) Guide bolt[For 145 mm (5.71 in) and 148 mm (5.83 in) oil seal outside diameters]

Puller assembly99718 Z5502

Used to remove oil seal sleeve[For 115 mm (4.53 in) oil seal sleeve outside diameter]

Puller assembly99718 Z5503

Used to remove oil seal sleeve[For 125 mm (4.92 in) oil seal sleeve outside diameter]

INSPECTION

EP-3-1

INSPECTIONClean all disassembled parts in cleaning solvent. Check forscratches, cracks or damage and replace faulty parts.If measurement indicates that the service limit hasexceeded, repair or replace faulty parts.

CYLINDER BLOCKUpper surface warpageMeasure using the straightedge (99645 Z5001).

Unit: mm (in)

Inner wall roundness of linerUnit: mm (in)

Camshaft bushing inside diameterMeasure the inside diameter of the camshaft bushing.

Item Maintenance standard Service limitLongitudinal direction Less than 0.10 (0.0039) —Transverse direction Less than 0.05 (0.0020) —

Maintenance standard Service limit0.02 (0.0008) —

INSPECTION

EP-3-2

Clearance between main bearing cap and cylinderblock

Unit: mm (in)

CRANKSHAFTJournal outside diameterWhen the journal outside diameter exceeds the service limit, it mustbe corrected by grinding and undersized main bearing shells mustbe installed.

Unit: mm (in)

Journal out-of-roundnessWhen the journals exceeds the service limit in out-of-roundness,they must be corrected by grinding. Install new undersized mainbearing shells.

Unit: mm (in)

Taper of journalWhen the journals exceeds the service limit in taper, they must becorrected by grinding. Install new undersized main bearing shells.

Unit: mm (in)

Crank pin outside diameterWhen the outside diameter of the crank pin exceeds the servicelimit, it must be corrected by grinding, and install new undersizedbearing shells.

Unit: mm (in)

Maintenance standard Service limit Remarks0.05T - 0.02L

(0.0020T - 0.0008L) — T: Tight L: Loose

Maintenance standard Service limit Remarks77.930 - 77.950

(3.0681 - 3.0689) 77.82 (3.0638) Refinishing allowance:1.0 (0.039)

Maintenance standard Service limitLess than 0.01 (0.0004) 0.02 (0.0008)

Maintenance standard Service limitLess than 0.01 (0.0004) —

Maintenance standard Service limit Remarks64.925 - 64.945

(2.5561 - 2.5569) 64.80 (2.5512) Refinishing allowance:1.0 (0.039)

INSPECTION

EP-3-3

Crank pin out-of-roundnessWhen the crank pin out-of-roundness exceeds the service limit, thecrank pins must be ground and used with new undersized bearingshells.

Unit: mm (in)

Taper of crank pinWhen the crank pin taper exceeds the service limit, the crank pinmust be ground and used with new undersized bearing shells.

Unit: mm (in)

RunoutSupport the crankshaft at No. 2 and 6 journals, and measure therunout of each part.

Unit: mm (in)

End playWhen end play measured at the time of engine disassemblyexceeds the service limit, replace the thrust washers selectively asa set.

Unit: mm (in)

Types of thrust washer




Journal A Less than 0.07 (0.0028) —

Indicator readingContacting sur-face with oil seal B

Less than 0.01 (0.0004) —

Flywheel mount-ing surface C

Less than 0.02 (0.0008) —


Size symbol Thickness mm (in) Remarks

STD A 2.965 - 2.995 (0.1167 - 0.1179)

STD: StandardB 2.930 - 2.965 (0.1154 - 0.1167)C 2.900 - 2.930 (0.1142 - 0.1154)

0.20 OS 3.150 - 3.200 (0.1240 - 0.1260)OS: Oversize

0.40 OS 3.350 - 3.400 (0.1319 - 0.1339)

INSPECTION

EP-3-4

MAIN BEARING SHELLClearance to crankshaft journalInstall the main bearing shell in the cylinder block, and tighten themain bearing cap to the specified torque. Then measure the shellinside diameter and calculate the shell clearance from the journaloutside diameter.

: 177 - 196 N·m 18.0 - 20.0 kgf·m, 130 - 145 ft·lbfUnit: mm (in)

CYLINDER LINERMeasure the cylinder liners with installed in the cylinder block. [Themeasuring positions are 25, 50, 75, 100, 150 and 200 mm (0.98,1.97, 2.95, 3.94, 5.91 and 7.87 in) from the block upper surface.]

Inside diameterUnit: mm (in)

Out-of-roundnessUnit: mm (in)

TaperUnit: mm (in)

Flange protrusion from block upper surface Unit: mm (in)

Difference between adjacent cylindersUnit: mm (in)





Maintenance standard Service limit0 - 0.07 (0 - 0.0028) —


INSPECTION

EP-3-5

PISTON AND CONNECTING RODBefore inspection, disassemble the piston and connecting rodassemblies. Keep the disassembled parts of each cylinder togetherso that they may be reinstalled in the cylinder from which they wereremoved.NOTE

The piston rings for all cylinders should be replaced asan assembly during overhaul.

Disassembling piston and connecting rodRemove the snap rings and piston pin.

Remove the piston rings using the piston ring tool (99630Z5001).

1. 1st ring 8. Bolt2. 2nd ring 9. Connecting rod3. Oil ring 10. Bearing shell (upper)4. Piston 11. Bearing shell (lower)5. Snap ring 12. Connecting rod cap6. Piston pin 13. Nut7. Bushing

INSPECTION

EP-3-6

PISTONOutside diameterThe piston outside diameter should be checked at 18.5 mm (0.728in) from the piston bottom and perpendicular to the piston pin.

Unit: mm (in)

Clearance to cylinder linerCalculate the clearance from the cylinder liner inside diameter andpiston outside diameter.

Unit: mm (in)

Piston pin bore inside diameterUnit: mm (in)

Item Maintenance standard Service limitFE6A, FE6B,FE6T 135 kW 183 PS

107.825 - 107.855(4.2451 - 4.2463) —


107.940 - 107.970(4.2496 - 4.2508) —

Item Maintenance standard Service limitFE6A, FE6B,FE6T 135 kW 183 PS

0.145 - 0.205(0.0057 - 0.0081) —


0.050 - 0.070(0.0020 - 0.0028) —


INSPECTION

EP-3-7

PISTON RINGClearance between piston ring and ring grooveNOTE

The 1st ring clearance cannot be measured because ofthe ring groove shape.

Unit: mm (in)

Joint gapUnit: mm (in)

PISTON PINOutside diameter

Unit: mm (in)

Item Maintenance standard Service limit2nd 0.04 - 0.08 (0.0016 - 0.0031) 0.4 (0.016)Oil 0.02 - 0.06 (0.0008 - 0.0024) 0.2 (0.008)

Item Maintenance standard Service limit1st2nd

0.30 - 0.45 (0.0118 - 0.0177) 1.5 (0.059)

Oil


0.15 - 0.35 (0.0059 - 0.0138) 1.5 (0.059)


0.25 - 0.45 (0.0098 - 0.0177) 1.5 (0.059)


INSPECTION

EP-3-8

Clearance to piston pin holeCalculate the clearance from the piston pin outside diameter andpin hole inside diameter.

Unit: mm (in)

CONNECTING RODSmall-end bushing inside diameter

Unit: mm (in)

Clearance between small-end bushing and piston pinUnit: mm (in)

Clearance between big-end bearing and crank pinFit each bearing shell to the connecting rod having the same cylin-der No., then the connecting rod and cap to the specified torque.

: 132 - 142 N·m 13.5 - 14.5 kgf·m, 98 - 105 ft·lbfCalculate the clearance between the crank pin O.D. and bearingshell I.D. from the measured values.

Unit: mm (in)

Maintenance standard Service limit Remarks0 - 0.03L (0 - 0.0012L) 0.05 (0.0020) L = Loose




INSPECTION

EP-3-9

Bend and twistTo check connecting-rod alignment, install the piston pin in thesmall-end bushing. Mount the connecting rod with the cap on thealigner. Then measure the clearance at aligner pin A or B to deter-mine the bend and twist of the rod. If the distance between pins Aand B is not 200 mm (7.87 in), make the following calculation.

Unit: mm (in)

Crank pin side clearanceCheck the measurements made during engine overhaul.

Unit: mm (in)

Assembling piston and connecting rod1. Install the piston rings using the piston ring tool (99630

Z5001).NOTE

Install the rings with the mark facing up.

Amount of bendor twist =

200 (7.87)x Measured value [mm (in)]

Distance between pins


Bend Less than 0.10 (0.0039) — Distance between pins: 200 (7.87)Twist Less than 0.15 (0.0059) —


Piston ring design Engine model

1st ringType I FE6A, FE6B, FE6T [135 kW 183 PS]

Type II FE6T [151 kW 205 PS], FE6T [162 kW 220 PS], FE6TA

2nd ring FE6A, FE6B, FE6T, FE6TA

Oil ringType I FE6A, FE6B, FE6T [135 kW 183 PS]Type II FE6T [151 kW 205 PS], FE6TAType III FE6T [162 kW 220 PS]

INSPECTION

EP-3-10

2. Assemble the piston, piston pin, snap rings and connectingrod.

NOTEAssemble so that the triangular mark on the piston headpoints to the left side with respect to the cylinder number(facing the front) stamped on the connecting rod.

CAMSHAFTEnd play

Unit: mm (in)

Removing camshaft gear

Journal outside diameterUnit: mm (in)

Journal-to-bushing clearanceCalculate the clearance from the journal outside diameter andbushing inside diameter.

Unit: mm (in)


1. Nut 5. Locating plate2. Lock washer 6. Key3. Plain washer 7. Camshaft4. Camshaft gear

EEP3-025

Item Maintenance standard Service limitNo. 1 57.33 - 57.35 (2.2571 - 2.2579) —No. 2 57.13 - 57.15 (2.2492 - 2.2500) —No. 3 56.93 - 56.95 (2.2413 - 2.2421) —No. 4 56.73 - 56.75 (2.2335 - 2.2342) —


INSPECTION

EP-3-11

Height of cam profileUnit: mm (in)

RunoutSupport the camshaft at No. 2 and 3 journals and measure therunout of No. 1 and 4 journals.

Unit: mm (in)

Installing camshaft gear1. Install the locating plate on the camshaft.2. Insert the key into the keyway and install the camshaft gear.3. Install the plain washer, lock washer and nut in sequence.

: 186 - 226 N·m 19.0 - 23.0 kgf·m, 137 - 166 ft·lbf

GEAR TRAINFront gear train backlash

Unit: mm (in)

Item Maintenance standard Service limitFE6AFE6BFE6TA 173 kW 235 PS

IN 48.47 - 48.51 (1.9083 - 1.9098) 47.99 (1.8894)

EXH 48.41 - 48.45 (1.9059 - 1.9075) 47.93 (1.8870)

FE6TFE6TA 157 kW 213 PS

IN 48.79 - 48.83 (1.9209 - 1.9224) 48.31 (1.9020)

EXH 48.41 - 48.45 (1.9059 - 1.9075) 47.93 (1.8870)

Maintenance standard Service limit RemarksLess than 0.03

(0.0012) 0.06 (0.0024) Indicator reading


INSPECTION

EP-3-12

Clearance between idler gear bushing and shaftUnit: mm (in)

Idler gear end playUnit: mm (in)

FLYWHEELClutch disc contact surface runout

Unit: mm (in)

REDUCED SIZE OF WORN SURFACE

NOTEBe careful since dimension “A” may exceed service lim-its. Dimension “H” is within service limits on type II fly-wheel where the clutch contacting surface was ground tothe specification.

Unit: mm (in)





Thickness (A)Type I

FE6A, FE6BFE6TA 135 kW 183 PS

20.5 (0.807) 18.5 (0.728)

21.5 (0.846) 19.5 (0.768)

Type II FE6B, FE6TFE6TA 23.0 (0.906) 21.0 (0.827)

Height (H) Type II

FE6B, FE6TFE6TA 43.0 (1.693) 45.0 (1.772)


48.0 (1.890) 50.0 (1.969)

INSPECTION

EP-3-13

FLYWHEEL HOUSING AND TIMING GEARCASENOTE

Oil seals should be replaced each time the engine isoverhauled.

CRANK PULLEY AND DAMPERCheck the entire assembly for cracks or damage. Also, check forseparation of the damper from the disc.

V-BELTCheck the V-belt for cracks or damage. Also check if it is out of con-tact with the pulley grooves.

Unit: mm (in)


DeflectionA 10 - 15 (0.39 - 0.59) — When midpoint is

pressed with98 N 10 kgf, 22 lbfB 7 - 12 (0.28 - 0.47) —

REPAIR AND REPLACEMENT

EP-4-1

REPAIR AND REPLACEMENTCYLINDER LINER REPLACEMENT1. Remove and install the cylinder liners using the cylinder

liner tool (99600 Z5002).NOTE

When installing the cylinder liners, clean the cylinderblock inner walls and cylinder liner outer surfaces. Thencoat them with a thin coat of engine oil.

2. When replacing the cylinder liners, use liners whose markson the outer skirts coincide with the stamp (“0” or “1”) on theupper surface of the cylinder block.


EP-4-2

3. After press-fitting the cylinder liners, check the inside diam-eter, out-of-roundness, taper and flange protrusion.

NOTEThe main bearing caps should be tightened to the speci-fied torque.

: 177 - 196 N·m 18.0 - 20.0 kgf·m, 130 - 145 ft·lbfUnit: mm (in)

CAMSHAFT BUSHING REPLACEMENTRemoving bushingsUsing the cam bushing remover (99590 Z5002), remove bushingsNo. 1 and No. 2 toward the rear of the engine and No. 3 and No. 4toward the front.

Item Maintenancestandard

Servicelimit Remarks

Inside diameter 108.00 - 108.03 (4.2520 - 4.2531)

108.23 (4.2610)

Measuring positionFrom top25, 50, 75, 100, 150, 200 (0.98, 1.97, 2.95, 3.94, 5.91, 7.87)

Out-of-roundness Less than 0.02 (0.0008) —

Taper Less than 0.025 (0.0010) —

Flange protrusion from block upper surface

0 - 0.07(0 - 0.0028) —

Difference between adjacent cylinders 0.03 (0.0012) —


EP-4-3

Installing bushings1. Install bushings No. 2 and No. 3 using the Cam Bushing

Replacer (3), (4) and (5).2. Install bushings No. 1 and No. 4 using the Cam Bushing

Replacer (1) and (2).99590 Z5003 (Tool kit cam bushing replacer)

NOTEInstall the bushing with their notched section on the rightside of the block, facing to the front. Make sure that theoil passages are aligned with the oil holes in the bush-ings.

CRANKSHAFT CORRECTIONJournalsWhen correcting the crankshaft journals by grinding, they must beground undersized so that the clearance between the new under-sized bearing shell and the journal is within the maintenance stan-dard.

Crank pinsWhen correcting the crank pins by grinding, they must be groundundersized so that the clearance between the new undersizedbearing shell and the crank pin is within the maintenance standard.

NOTEBe careful not to extend the width of the journal andcrank pin.Finish both shoulders by rounding, referring to the figureto the right.Crankshaft journals R 3.5 mm (0.138 in)Crank pins R 4.0 mm (0.157 in)

(1) 99594 Z5002 (for No. 1)(2) 99594 Z5003 (for No. 4)(3) 99595 Z5004 (for No. 2)(4) 99595 Z5005 (for No. 3)(5) 99597 Z5001 (for No. 2 and No. 3)


EP-4-4

US: Undersized

US: Undersized

CONNECTING ROD REPLACEMENTWhen a connecting rod is replaced, stamp the cylinder No. on it inthe same position as before.

REPLACING CONNECTING ROD SMALL-ENDBUSHING1. Drive the bushing into the chamfered side of the connecting

rod small end.NOTE

Align the oil holes. The difference in height of the bush-ing above or below the chamfered surface should be lessthan 1 mm (0.04 in).

Size symbol Journal grinding standard mm (in)STD Grinding not required

0.25US 77.680 - 77.700 (3.0583 - 3.0590)0.50US 77.430 - 77.450 (3.0484 - 3.0492)0.75US 77.230 - 77.250 (3.0405 - 3.0413)1.00US 76.930 - 76.950 (3.0287 - 3.0295)

Size symbol Crank pin grinding standard mm (in)STD Grinding not required

0.25US 64.675 - 64.695 (2.5463 - 2.5470)0.50US 64.425 - 64.445 (2.5364 - 2.5372)0.75US 64.175 - 64.195 (2.5266 - 2.5274)1.00US 63.925 - 63.945 (2.5167 - 2.5175)

Engine model Connecting rod typeFE6AFE6BFE6T 135 kW 183 PSFE6T 151 kW 205 PSFE6TA

Type I

FE6T 162 kW 220 PS Type II


EP-4-5

2. After driving in the bushing, cut both ends of it by aligningwith the tapered surface of the connecting rod. (Type IIonly)

3. Measure the inside diameter of the busing and outsidediameter of the piston pin to determine the bushing-to-pis-ton pin clearance. If the clearance is less than maintenancestandards, grind the inside diameter of the bushing to withinthe specified maintenance standard.

Unit: mm (in)

REPLACING IDLER GEAR BUSHING1. Press-fit the bushing so that the end face of the boss on the

front of the engine is level with the end face of the bushing.NOTE

The fitted face of the boss at the front should be 1.5 mm(0.059 in) lower than the rear end face (H).

2. After fitting the bushing, finish the inside diameter so thatthe clearance with the idler gear shaft is within the mainte-nance standard.

Unit: mm (in)

OIL SEAL COLLAR REPLACEMENT1. Remove the oil seal collar by heating.2. Using the collar replacer (99718 Z5002), press-fit the oil

seal collar until it contacts the crank gear.NOTE

Face the side with a groove on the end to the front.




EP-4-6

FLYWHEEL CORRECTIONThe runout of the surface which contacts the clutch disc should becorrected to the maintenance standard by grinding and/or cutting.NOTE

The flywheel is serviceable until wear on the contactingsurface with the clutch disc is 2.0 mm (0.079 in) andthickness (A) reaches the service limit. However, if theflywheel is to be ground, do not grind more than 1.5 mm(0.059 in).When grinding, also grind the flange so that height (H) iswithin the maintenance standard.If the flywheel has to be ground more than 1.5 mm (0.059in), replace the flywheel.

Unit: mm (in)

REPLACING INJECTION PUMP BRACKETWhen replacing the cylinder block or injection pump bracket, centerthe injection pump bracket.1. Temporarily install a shim (of the same thickness as the one

removed) to the pump bracket.Types (thickness) of shim: 0.05, 0.10, 0.20 and 0.30 mm(0.0020, 0.0039, 0.0079 and 0.0118 in)


Thickness (A)Type I

FE6A, FE6BFE6TA 135 kW 183 PS

20.5 (0.807) 18.5 (0.728)

21.5 (0.846) 19.5 (0.768)

Type II FE6B, FE6TFE6TA 23.0 (0.906) 21.0 (0.827)

Height (H) Type II

FE6B, FE6TFE6TA 43.0 (1.693) 45.0 (1.772)


48.0 (1.890) 50.0 (1.969)


EP-4-7

2. Using the injection pump bracket setting tool, install thecoupling A to the shaft of the air compressor. Then hold thesetting tool C, slide the shaft B, and insert it into the cou-pling A. If the shaft can be fitted in place, it is properly cen-tered. If it interfaces, adjust with shim(s).

3. After centering, tighten the pump bracket to the specifiedtorque.

: 37 - 42 N·m 3.8 - 4.3 kgf·m, 27 - 31 ft·lbf

4. After reaming, driven in the dowel pin and caulk the dowelpin hole. The dowel pin should be driven in so that it isslightly below 1 mm (0.04 in) or so the bracket surface.

REAR OIL SEAL REPLACEMENT<Without oil seal sleeve>1. Remove the oil seal.2. Apply engine oil to the lip of the oil seal.3. Using the oil seal replacer, press-fit the oil seal to the fly-

wheel housing.Unit: mm (in)

Tool name Tool number Remarks

Injection pump bracket setting tool

99720 Z5500 For 25 mm (0.98 in) air compressor crankshaft rear edge outside diameter

99720 Z5501 For 30 mm (1.18 in) air compressor crankshaft rear edge outside diameter

Oil seal andsleeve replacerassembly No.

Oil seal orsleeve

replacer No.

Guide bolt No.

Outsidediameter of

oil seal

Outside diameterof the rear edge of

the crankshaft99691 Z5500 99718 Z5500

9968797002

135 (5.31) 110 (4.33)

— 99718 Z5501 145 (5.71)148 (5.83) 120 (4.72)


EP-4-8

<With oil seal sleeve>1. Remove the oil seal.2. Using the puller assembly, pull out the oil seal sleeve.

Unit: mm (in)

3. Apply sealant (LOCTITE 962T or equivalent) to the insidesurface of the oil seal sleeve.

4. Using the oil seal sleeve replacer, press-fit the oil sealsleeve to the crankshaft.

Unit: mm (in)

5. Apply engine oil to the lip of the oil seal.6. Using the oil seal replacer, press-fit the oil seal to the fly-

wheel housing.Unit: mm (in)

Puller assembly No. Outside diameter of sleeve

Outside diameter of the rear edge of the

crankshaft99718 Z5502 115 (4.53) 110 (4.33)99718 Z5503 125 (4.92) 120 (4.72)

Oil seal and sleeve

replacer assembly No.

Oil seal or sleeve

replacer No.

Guide bolt No.

Outside diameter of

sleeve

Outside diameter of

the rear edge of the crank-

shaft99691 Z5500 99718 Z5500

99687 97002115 (4.53) 110 (4.33)

99691 Z5501 99718 Z5504 125 (4.92) 120 (4.72)

Oil seal and sleeve

replacer assembly No.

Oil seal or sleeve

replacer No.

Guide bolt No.

Outside diameter of

oil seal

Outside diameter of

the rear edge of the crank-

shaft99691 Z5500 99718 Z5500

99687 97002135 (5.31) 110 (4.33)

99691 Z5501 99718 Z5504 145 (5.71) 120 (4.72)

- MEMO -

CYLINDER HEAD AND VALVE MECHANISM

CONTENTSSERVICE DATA...................................... HV-1-1

SERVICE DATA ............................................... HV-1-1TIGHTENING TORQUE ................................... HV-1-3

TOOLS .................................................... HV-2-1CONSTRUCTION.................................... HV-3-1REMOVAL............................................... HV-4-1DISASSEMBLY....................................... HV-5-1

CYLINDER HEAD ............................................ HV-5-1ROCKER SHAFT ............................................. HV-5-2

INSPECTION........................................... HV-6-1CYLINDER HEAD ............................................ HV-6-1VALVE INSERT................................................ HV-6-1VALVE .............................................................. HV-6-1VALVE GUIDE.................................................. HV-6-2VALVE SPRING ............................................... HV-6-2

VALVE ROCKER PARTS................................. HV-6-3PUSH ROD....................................................... HV-6-4CAM FOLLOWER............................................. HV-6-4

REPAIR AND REPLACEMENT .............. HV-7-1REPAIRING CYLINDER HEAD........................ HV-7-1REPAIRING VALVE AND VALVE INSERT ...... HV-7-1REPLACING VALVE INSERT .......................... HV-7-2LAPPING VALVE AND VALVE INSERT .......... HV-7-3REPLACING VALVE GUIDE ............................ HV-7-3REPLACING VALVE ROCKER BUSHING....... HV-7-4REPLACING NOZZLE TUBE ........................... HV-7-4

REASSEMBLY ........................................ HV-8-1CYLINDER HEAD............................................. HV-8-1ROCKER SHAFT.............................................. HV-8-2

INSTALLATION....................................... HV-9-1

HV

SERVICE DATA

HV-1-1

SERVICE DATASERVICE DATA

Unit: mm (in)


Cyl

inde

r hea

d

Height of cylinder head 89.9 - 90.1(3.539 - 3.547) 89.7 (3.531)

Max. allowablegrinding limit:0.3 mm (0.012 in)

Flatness

Longitudinal direction

Less than 0.05(0.0020) 0.2 (0.008)

Transverse direc-tion

Less than 0.05(0.0020) 0.2 (0.008)

Diameter of valve insert bore

Intake 50.0 - 50.02(1.9685 - 1.9693) —

Exhaust 41.0 - 41.02(1.6142 - 1.6150) —

Thickness of head gasket 1.25 - 1.35(0.0492 - 0.0531) — When bolts are tightened

to specified torque

Valv

e in

sert Seat face angle

Intake 30º - 30º30’ —Exhaust 45º - 45º30’ —

Contact width of valve and valve insert

Intake 2.2 - 2.4(0.087 - 0.094) 3.5 (0.138)

Exhaust 2.0 - 2.3(0.079 - 0.091) 3.5 (0.138)

Valv

e

Valve face angleIntake 29º30’ - 30º —Exhaust 44º30’ - 45º —

Outside diameter of valve stem

Intake 8.96 - 8.98(0.3528 - 0.3535) —

Exhaust 8.92 - 8.94(0.3512 - 0.3520) —

Valve head thicknessIntake 2.16 (0.0850) 1.8 (0.071)Exhaust 1.65 (0.0650) 1.3 (0.051)

Depth of valve below lower surface of cylinder head

Intake 1.33 - 1.83(0.0524 - 0.0720) 2.8 (0.110)

Exhaust 1.03 - 1.53(0.0406 - 0.0602) 2.3 (0.091)

Valve clearanceIntake 0.3 - 0.4

(0.012 - 0.016) —When engine is cold

Exhaust 0.3 - 0.4(0.012 - 0.016) —

SERVICE DATA

HV-1-2

Unit: mm (in)


Valv

e gu

ide

Inside diameter of valve guide

Intake 9.00 - 9.02(0.3543 - 0.3551) —

Exhaust 9.00 - 9.02(0.3543 - 0.3551) —

Clearance to valve stemIntake 0.02 - 0.05

(0.0008 - 0.0020) 0.15 (0.0059)

Exhaust 0.05 - 0.09(0.0020 - 0.0035) 0.20 (0.0079)

Protrusion above “drive-in” surface of cylinder head 15 (0.59) — Intake and exhaust

valves

Valv

e sp

ring

Free lengthOuter 62.8 (2.472) 55.0 (2.165) Intake and exhaust

valvesInner 60.9 (2.398) 58.0 (2.283)

Tension N kgf, lbf

Outer246.2 - 271.725.1 - 27.7,55.3 - 61.1

—When spring is com-pressed to 44.6 mm (1.756 in)

Inner126.5 - 140.212.9 - 14.3,28.4 - 31.5

—When spring is com-pressed to 41.6 mm (1.638 in)

Squareness Less than 2.0 (0.079) — Inner and outer springs

Valv

e ro

cker

par

ts

Outside diameter of rocker shaft 19.98 - 20.00(0.7866 - 0.7874) 19.90 (0.7835)

Rocker shaft runout 0.06 (0.0024) 0.1 (0.004)

Inside diameter of valve rocker bushing 20.02 - 20.04(0.7882 - 0.7890) 20.10 (0.7913)

Clearance between valve rocker bushing and rocker shaft

0.02 - 0.06(0.0008 - 0.0024) 0.2 (0.008)

Inside spring

Free length 60.0 (2.362) 49.0 (1.929)

TensionN kgf, lbf

21.6 - 31.42.2 - 3.2,4.9 - 7.1

16.7 1.7, 3.7When spring is com-pressed to 33.5 mm (1.319 in)

Runout of push rod Less than 0.30(0.0118) —

When measured with each spherical end sup-ported

Cam

follo

wer Outside diameter 19.96 - 19.98

(0.7858 - 0.7866) 19.85 (0.7815)

Clearance to cylinder block cam follower bore 0.02 - 0.06(0.0008 - 0.0024) 0.12 (0.0047)

SERVICE DATA

HV-1-3



Oth

er

Valve clearance adjustment sequence:Cylinder No. 1 2 3 4 5 6

Valve arrangement1 2 3 4 5 6 7 8 9 10 11 12IN EX IN EX IN EX IN EX IN EX IN EX

No. 1 piston at TDC on com-pression strokeNo. 6 piston at TDC on com-pression stroke

Item Tightening torque RemarksEngine slinger mounting bolt 29 - 49 3.0 - 5.0, 22 - 36Nozzle sleeve 34 - 38 3.5 - 3.9, 25 - 28

Cylinder head bolts1st 98 10.0, 722nd 177 - 196 18.0 - 20.0, 130 - 145

Rocker shaft bracket mounting bolts 44 - 54 4.5 - 5.5, 33 - 40 Tighten center bolts first then move toward outer bolts.

Exhaust manifold mounting nuts 34 - 44 3.5 - 4.5, 25 - 33Air intake manifold mounting bolts 16 - 20 1.6 - 2.0, 12 - 14Nozzle holder mounting bolt 25 - 29 2.5 - 3.0, 18 - 22Injection nozzle tube 23 - 27 2.3 - 2.8, 17 - 20Spill tube connector 8 - 10 0.8 - 1.0, 5.8 - 7.2

TOOLS

HV-2-1


Split collar tool99624 Z5001

Used to remove and install split collar

Valve insert remover99660 Z5503

Used to remove intake and exhaust valve insert(1) Puller (for inlet)(2) Puller (for exhaust)(3) Bridge(4) Puller bolt(5) Bolt (M8 x 1.25)(6) Nut (M16 x 1.5)(7) Plain washer

Valve insert replacer99665 Z5002

Used to install valve insert on cylinder head (cold-fit)

Valve insert caulking tool(1) 99675 Z5002(2) 99676 Z5000(3) 81-20616-1A

Used to caulk valve insert (for exhaust)(1) Caulking tool(2) Guide(3) Bolt

Valve guide remover99667 Z5000

Used to remove valve guide

(1) 99669 Z5502(2) 99669 Z5503(3) 99668 95000(4) 99532 95000(5) 99531 Z6000(6) 89-11246-1A(7) 89-15446-1A

TOOLS

HV-2-2

Tool name and number Description ShapeValve guide replacer99666 Z5001

Used to press valve guide into place

Reamer99662 Z5500

Used to finish I.D. of valve guide

Nozzle holder sleeve wrench99656 Z5501

Used to remove and install nozzle holder sleeve

Nozzle tube remover99655 Z5500

Used to remove nozzle tube

Nozzle tube setting tool99651 Z5500

Used to press nozzle tube into place

Stem seal replacer99674 Z5001

Used to press valve stem seal into place

CONSTRUCTION

HV-3-1

CONSTRUCTION

REMOVAL

HV-4-1

REMOVAL1. Remove the following parts:

Fuel tubesFuel filter assembly and bracket as a unitInjection nozzle tubes and spill tubesInjection nozzles

NOTEUse a container to catch fuel. Wipe up any fuel spilled onthe exterior of the engine with a rag.

2. Remove the rocker shaft assembly and push rods.NOTE

Loosen the rocker shaft assembly mounting bolts, start-ing with the outer bolts and moving toward the center.

3. Remove the cylinder head assembly. Attach chains orcables to the engine lifter and lifters and lift the cylinderhead away from the cylinder block using a hoist.

NOTELoosen the head bolts diagonally, starting with the outerone and moving toward the center.

DISASSEMBLY

HV-5-1

DISASSEMBLYCYLINDER HEAD



1. Push rod 7. Lower spring seat 13. Intake valve insert2. Split collar 8. Intake valve 14. Push rod pipe3. Upper spring seat 9. Exhaust valve 15. Valve guide4. Outer valve spring 10. Water jet 16. Nozzle sleeve5. Inner valve spring 11. Water jet 17. Nozzle tube6. Valve stem seal 12. Exhaust valve insert 18. O-ring

DISASSEMBLY

HV-5-2

Key point of disassemblyBefore disassembling the cylinder head, measure the depth of thevalve head below the cylinder head.NOTE

Be sure to remove carbon from these parts before mea-surement.

2 Split collarRemove the split collar using the split collar tool (99624 Z5001).

8 Intake valve, 9 Exhaust valveRemove the upper spring seat, outer and inner valve springs, valvestem seal and lower spring seat from each cylinder.NOTE

Arrange all removed parts for each valve.

ROCKER SHAFTDisassembly sequence (Reassembly sequence is in thereverse order of disassembly.)

1. Stopper bolt 6. Inside spring2. Shaft bracket 7. Exhaust valve rocker3. Adjusting screw 8. Bushing4. Intake valve rocker 9. Rocker shaft5. Bushing

INSPECTION

HV-6-1


CYLINDER HEADFlatness

Unit: mm (in)

VALVE INSERTContact width of valve and valve insert

Unit: mm (in)

VALVEDepth of valve below lower surface of cylinder headCheck that the depth is the same as that measured before disas-sembly.

Unit: mm (in)

Valve head thicknessUnit: mm (in)

Item Maintenance standard Service limitLongitudinal direction Less than 0.05 (0.0020) 0.2 (0.008)Transverse direction Less than 0.05 (0.0020) 0.2 (0.008)

Item Maintenance standard Service limitIntake 2.2 - 2.4 (0.087 - 0.094) 3.5 (0.138)Exhaust 2.0 - 2.3 (0.079 - 0.091) 3.5 (0.138)


Item Maintenance standard Service limitIntake 2.16 (0.0850) 1.8 (0.071)Exhaust 1.65 (0.0650) 1.3 (0.051)

INSPECTION

HV-6-2

Outside diameter of valve stemUnit: mm (in)

VALVE GUIDEClearance to valve stem

Unit: mm (in)

VALVE SPRINGFree length

Unit: mm (in)

TensionUnit: N kgf, lbf

SquarenessFor the outer spring, measure clearance at points A and B shown inthe figure.

Unit: mm (in)

Item Maintenance standard Service limitIntake 8.96 - 8.98 (0.3528 - 0.3535) —Exhaust 8.92 - 8.94 (0.3512 - 0.3520) —


Item Maintenance standard Service limit RemarksOuter 62.8 (2.472) 55.0 (2.165) Intake and

exhaustInner 60.9 (2.398) 58.0 (2.283)


Outer 246.2 - 271.725.1 - 27.7, 55.3 - 61.1 — When compressed to

44.6 mm (1.756 in)

Inner 126.5 - 140.212.9 - 14.3, 28.4 - 31.5 — When compressed to

41.6 mm (1.638 in)

Maintenance standard Service limit RemarksLess than 2.0 (0.079) — Inner and outer springs

INSPECTION

HV-6-3

VALVE ROCKER PARTSOutside diameter of rocker shaft

Unit: mm (in)

Rocker shaft runoutUnit: mm (in)

Inside diameter of valve rocker bushingUnit: mm (in)

Clearance between valve rocker bushing and rockershaft

Unit: mm (in)

Inside springUnit: mm (in)


Maintenance standard Service limit0.06 (0.0024) 0.1 (0.004)



Item Maintenance standard Service limit RemarksFree length 60.0 (2.362) 49.0 (1.929)

TensionN kgf, lbf

21.6 - 31.42.2 - 3.2, 4.9 - 7.1

16.71.7, 3.7

When compressed to 33.5 mm (1.319 in)

INSPECTION

HV-6-4

PUSH RODRunoutMeasure push rod runout while supporting the center of the spheri-cal surface at each end of the push rod as shown.

Unit: mm (in)

CAM FOLLOWEROutside diameter

Unit: mm (in)

Clearance to cylinder block cam follower boreUnit: mm (in)





HV-7-1

REPAIR AND REPLACEMENTREPAIRING CYLINDER HEADGrind the cylinder head using a surface grinder. The maximumallowable grinding limit is 0.3 mm (0.012 in).

Unit: mm (in)

REPAIRING VALVE AND VALVE INSERT1. Dress the valve face using a valve refacer. If thickness of

the valve head after dressing reaches the service limit,replace the valve.

NOTEEnsure that the valve face is free from stepped wear, etc.

Unit: mm (in)

2. Dress the end of the valve stem using a valve refacer or oilstone.

NOTEEnsure that the end of the valve stem is dressed at aright angle to the axis and is free from roughness ordamage.

3. Dress the surface (A) of the valve insert using a valve seatgrinder.

NOTEEnsure that the surface (A) is free from stepped wear,etc.

Maintenance standard (B) Service limit (A)89.9 - 90.1 (3.539 - 3.547) 89.7 (3.531)


Valve face angle

Intake 29º30’ - 30º —Exhaust 44º30’ - 45º —

Valve head thickness

Intake 2.16 (0.0850) 1.8 (0.071)Exhaust 1.65 (0.0650) 1.3 (0.051)


Seat face angle

Intake 30º - 30º30’ —Exhaust 45º - 45º30’ —


HV-7-2

REPLACING VALVE INSERT1. Remove both the intake and exhaust valve inserts using

valve insert removers (99660 Z5503).2. Install the intake and exhaust valve inserts using a cold-fit

method.

Cold-fit procedurea. Immerse the valve inserts in dry ice for at least five minutes

before fitting. Some alcohol may be added to the dry ice forbetter results.

WARNINGWARNINGDo not touch the valve insert or dry ice with bare handsto prevent injury.

b. Immerse the cylinder head in hot water of at least 80ºC(176ºF).

WARNINGWARNINGDo not touch the cylinder head or hot water with barehands to prevent injury.

c. Remove the valve inserts and the cylinder head. Using thevalve insert replacer (99665 Z5002), press the inserts intoplace on the cylinder head.

3. After positioning the valve inserts, caulk only the exhaustvalve at four points using the insert caulking tool.

NOTEWhen caulking the exhaust valve, use a press pressureof 14,711 N 1,500 kgf, 3,308 lbf.

Tool name Tool number

Valve insert caulking toolCaulking tool 99675 Z5002Guide 99676 Z5000Bolt 81-20616-1A


HV-7-3

LAPPING VALVE AND VALVE INSERTWhen the valve or valve insert is repaired or replaced, lap bothparts using a grinding compound.1. Apply grinding compound evenly to the mating surface of

the valve.

2. Apply engine oil to the valve stem and insert the valve intothe valve guide. Attach a suction cup to the top of the valvehead and turn the valve while lightly tapping the insert withthe valve.

3. After properly lapping these parts, thoroughly clean thecompound off the parts. Then apply oil to the mating sur-faces of the parts and relap.

4. Clean oil from the mating surfaces. Apply Prussian blue andrepeat lapping both parts until they are lapped properly.

Unit: mm (in)

REPLACING VALVE GUIDE1. Drive the valve guide from the lower surface of the cylinder

head using the valve guide remover (99667 Z5000).

2. Using the valve guide replacer (99666 Z5001), drive thevalve guide form the upper surface of the cylinder head untilthe replacer contacts the head surface.

NOTEClean the valve guide hole in the cylinder head. Applyengine oil beforehand.

Item Maintenance standard Service limitContact width of valve and valve insert

Intake 2.2 - 2.4 (0.087 - 0.094) 3.5 (0.138)

Exhaust 2.0 - 2.3 (0.079 - 0.091) 3.5 (0.138)


HV-7-4

3. Press the valve guide into place. Ream it using the reamer(99662 Z5500) so that the inside diameter is within themaintenance standard.

Unit: mm (in)

REPLACING VALVE ROCKER BUSHING1. While supporting the valve rocker, drive out the bushing

with a 23 mm (0.91 in) dia. rod.NOTE

Scribe alignment marks on the mating surfaces of thebushing and valve rocker before driving out the bushing.Be careful not to damage the mating surfaces.

2. Align the marks and drive the bushing into place.NOTE

Also check that the oil holes in the bushing and valverocker are aligned.

3. Ream the bushing so that the inside diameter is within themaintenance standard.

Unit: mm (in)

REPLACING NOZZLE TUBE1. Remove the nozzle holder sleeve using the nozzle holder

sleeve wrench (99656 Z5501).


Insidediameter

Intake 9.00 - 9.02(0.3543 - 0.3551) —

Exhaust 9.00 - 9.02(0.3543 - 0.3551) —



HV-7-5

2. Drive the nozzle tube form the lower surface of the cylinderhead using the nozzle tube remover (99655 Z5500).

3. Remove the O-ring from the nozzle tube.

4. Attach a new O-ring to the nozzle tube.NOTE

Apply soapy water to the O-ring before installation. Toavoid breaking or deforming the O-ring, install the O-ring8 mm (0.31 in) below the top of the tube (see “A” in thefigure).

5. Apply LOCTITE #601 to the mating periphery of the tube.NOTE

Clean the mating surface of the cylinder head. Be carefulnot to apply excess Loctite to the tube.

6. Attach the guide of the nozzle tube setting tool (99651Z5500) to the nozzle tube and insert the tube into the cylin-der head by hand.

NOTEBe careful not to damage the O-ring.

7. Using the nozzle holder mounting bolts, install the bridge ofthe nozzle tube setting tool (99651 Z5500) on the cylinderhead. Tighten the set bolt and press the nozzle tube intoplace.

8. When the nozzle tube contacts the seat of the cylinderhead, resistance is felt on the bolt. From the point whereresistance is felt, further tighten the set bolt approximately10º.

9. Apply THREE BOND #1344 to the thread of the nozzleholder sleeve.

10. Tighten the nozzle holder sleeve using the nozzle holdersleeve wrench (99656 Z5501).

: 34 - 39 N·m 3.5 - 4.0 kgf·m, 25 - 29 ft·lbf

REASSEMBLY

HV-8-1

REASSEMBLYCYLINDER HEADKey point of reassemblyBefore assembling parts, apply engine oil to the sliding surfaces.9 Exhaust valve, 8 Intake valveInstall the intake and exhaust valves.NOTE

Be sure to install the valves in their original positions.

6 Valve stem sealInstall the stem seal on the valve guide using the stem seal replacer(99674 Z5001).NOTE

Insert the stem seal by hand.

5 Inner valve spring, 4 Outer valve springInstall the inner and outer valve springs and the upper spring seat.NOTE

Face the narrow pitch sides (painted blue) of the innerand outer springs toward the lower spring seats.

2 Split collar1. Install the split collar using the split collar tool (99624

Z5001).

2. Check that the depth of the valve below the lower surface ofthe cylinder head is correct.

Unit: mm (in)Item Maintenance standard Service limit

Intake 1.33 - 1.83 (0.0524 - 0.0720) 2.8 (0.110)Exhaust 1.03 - 1.53 (0.0406 - 0.0602) 2.3 (0.091)

REASSEMBLY

HV-8-2

ROCKER SHAFTKey point of reassemblyBefore assembling parts, apply engine oil to the sliding surfaces.Assemble the rocker shaft assembly.NOTE

Face the oil hole downward when assembling.1. Stopper bolt 6. Inside spring2. Shaft bracket 7. Exhaust valve rocker3. Adjusting screw 8. Bushing4. Intake valve rocker 9. Rocker shaft5. Bushing

INSTALLATION

HV-9-1

INSTALLATION1. Install the cylinder head gasket and cylinder head.NOTE

Ensure that the stamped part number side faces upwardwhen installing the gasket.

2. Tightening the cylinder head bolts to the specified torqueusing the socket wrench (99664 Z5000). Note that seven ofthe head bolts are also secured to the rocker shaft bracket.

: 1st : 98 N·m 10.0 kgf·m, 72 ft·lbf2nd: 177 - 196 N·m 18.0 - 20.0 kgf·m, 130 - 145 ft·lbf

: Refers to the bolts which are also secured to the rockershaft bracket. [L = 180 mm (7.09 in)]

: Circled numbers refer to tightening sequence of head bolts.

3. Position the rocker shaft assembly on the head.NOTE

Be careful that the rocker arm tip and push rod do notdislocate.

4. Install the rocker shaft mounting bolts.NOTE

Be sure to tighten the bolts, starting from the inside andworking outside.

: 34 - 44 N·m 3.5 - 4.5 kgf·m, 25 - 33 ft·lbf5. Install the following parts:

Injection nozzlesInjection nozzle tubes and spill tubesFuel filter assembly and bracket as a unitFuel tubes

Unit: N·m kgf·m, ft·lbf

6. Start the engine. Check connections and other parts forsigns of water leakage. Recheck the cooling water level andadd cooling water if necessary.

Location Tightening torqueInjection nozzle holder 25 - 29 2.5 - 3.0, 18 - 22Injection nozzle tube 23 - 27 2.3 - 2.8, 17 - 20Spill tube 8 - 10 0.8 - 1.0, 5.8 - 7.2

O

- MEMO -

LUBRICATION SYSTEM

CONTENTSSERVICE DATA...................................... LB-1-1

SPECIFICATIONS............................................ LB-1-1SERVICE DATA ............................................... LB-1-1TIGHTENING TORQUE ................................... LB-1-2LUBRICATION SYSTEM.................................. LB-1-3

TOOLS .................................................... LB-2-1OIL PUMP ............................................... LB-3-1

CONSTRUCTION............................................. LB-3-1REMOVAL ........................................................ LB-3-1DISASSEMBLY ................................................ LB-3-2INSPECTION.................................................... LB-3-3REASSEMBLY ................................................. LB-3-4

OIL COOLER........................................... LB-4-1CONSTRUCTION............................................. LB-4-1REMOVAL ........................................................ LB-4-2DISASSEMBLY................................................. LB-4-2INSPECTION.................................................... LB-4-3

OIL FILTER.............................................. LB-5-1CONSTRUCTION............................................. LB-5-1REPLACING OIL FILTER................................. LB-5-2INSPECTION.................................................... LB-5-3

OIL JET.................................................... LB-6-1CONSTRUCTION............................................. LB-6-1REMOVAL ........................................................ LB-6-1

LB

SERVICE DATA

LB-1-1

SERVICE DATASPECIFICATIONS

NOTE*Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).

SERVICE DATAUnit: mm (in)

Lubrication type Forced-circulation typeOil pump Gear pump

Oil filter Cartridge type (Full flow only type and full flow & by pass combination type)

Oil cooler Water cooled flat tube type

Engine oil capacities (Approximately)

liter (lmp gal)

Engine oil pan (H-level)

FE6A, FE6B, FE6T, FE6TA 12 (2-5/8)

FE6TA* 14 (3-1/8)

TotalFE6A, FE6B,FE6T, FE6TA 15 (3-1/4)

FE6TA* 17 (3-3/4)


Oil pump

Side clearance 0.04 - 0.10(0.0016 - 0.0039) 0.15 (0.0059)

Tip clearance 0.04 - 0.10(0.0016 - 0.0039) 0.20 (0.0079)

Backlash between pump gears 0.16 - 0.27(0.0063 - 0.0106) 0.50 (0.0197)

Clearance between O.D. of driven gear shaft and gear bushing

0.03 - 0.08(0.0012 - 0.0031) 0.20 (0.0079)

Relief valve

Relief pressurekPa kgf/cm2, psi

1,03010.5, 149 — Fully opening pressure

1,765 18, 256

Free length of spring 40.0 (1.575) —

Spring tensionN kgf, lbf

260.9 - 288.326.6 - 29.4,58.7 - 64.8

— When spring is compressed to 46.0 mm (1.811 in)

Oil cooler Water pressure test kPa kgf/cm2, psi 981 10, 142 —

SERVICE DATA

LB-1-2

Unit: mm (in)



Oil filter

Type I

Oil cooler short valve


275 - 3142.8 - 3.2, 40 - 46 —



47.515 - 52.5164.845 - 5.355,

10.683 - 11.808— When spring is compressed

to 42.0 mm (1.654 in)

Oil filter short valve


98 - 1371.0 - 1.4, 14 - 20 —



28.882 - 31.9222.945 - 3.255,6.494 - 7.177


Regulating valve


422 - 4614.3 - 4.7, 61 - 67 —



102.48 - 113.2710.45 - 11.55,23.04 - 25.47


Type II

Oil pipe

Oil cooler short valve


275 - 3142.8 - 3.2, 40 - 46 —

Free length of spring 58.5 (2.303) —Spring tension

N kgf, lbf 50.0 5.1, 11.2 — When spring is compressed to 42.0 mm (1.654 in)

Oil filter short valve


98 - 1371.0 - 1.4, 14 - 20 —



Regulating valve


422 - 4614.3 - 4.7, 61 - 67 —



Location Tightening torqueOil pump relief valve mounting plug 47 - 71 4.8 - 7.2, 35 - 52Oil pump mounting bolt 20 2.0, 14Oil pump cover mounting bolt 14 - 20 1.4 - 2.0, 10 - 14Oil filter short valve mounting cap 25 - 34 2.5 - 3.5, 18 - 25Regulating valve mounting cap 25 - 34 2.5 - 3.5, 18 - 25Oil jet bolt 34 - 49 3.5 - 5.0, 25 - 36Cooler element mounting nut 20 - 29 2.0 - 3.0, 14 - 22Oil cooler mounting bolt and nut 25 2.5, 18

SERVICE DATA

LB-1-3

LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM

LUBRICATION CIRCUIT

TOOLS

LB-2-1


Hydraulic pump99570 Z5000

For testing oil pressure of oil cooler element.

Oil cooler attachment99573 Z5500

Used when performing the oil cooler core oilpressure test.(1) Leak test attachment(2) Leak test attachment

(1) 99578 Z5500(2) 99578 Z5501

OIL PUMP

LB-3-1

OIL PUMPCONSTRUCTION

REMOVALKey point of removalRemove the drain plug from the oil pan and drain engine oil into acontainer.

WARNINGWARNINGDo not drain oil while engine is hot to avoid scaldingyourself.

NOTEDo not disassemble the oil pump except for the removalof the valve and driven gear.

OIL PUMP

LB-3-2

DISASSEMBLY



Key point of disassemblyThe oil pump gears and the drive gear are shrink-fitted to the driveshaft. Disassembly of the oil pump must be limited to the valve anddriven gear assembly.8 Pump gear assembly1. Measure the side clearances between the pump gears

(drive and driven) and cover.

2. Measure the clearance between tips of the pump gears(drive and driven) and pump body.

1. Plug 4. Ball 7. Driven gear assembly2. Gasket 5. Cover 8. Pump gear assembly3. Spring 6. Gasket

OIL PUMP

LB-3-3

3. Measure the backlash between the drive and driven gearsusing a fuse.


Side clearanceUnit: mm (in)

Tip clearanceUnit: mm (in)

Backlash between pump gearsUnit: mm (in)

Clearance between O.D. of driven gear shaft and gearbushing

Unit: mm (in)

Relief valve







1,03010.5, 149 —

Fully opening pressure 1,765 18, 256

Free length of spring mm (in) 40.0 (1.575) —


260.9 - 288.326.6 - 29.4,58.7 - 64.8

—When spring is compressed to 46.0 mm (1.811 in)

OIL PUMP

LB-3-4

REASSEMBLYKey point of reassembly8 Pump gear assemblyAttach the driven gear to the pump gear assembly. Measure theclearances and backlash to ensure that they do not exceed themaintenance standard.

Unit: mm (in)Item Maintenance standard Service limit

Side clearance 0.04 - 0.10 (0.0016 - 0.0039) 0.15 (0.0059)Tip clearance 0.04 - 0.10 (0.0016 - 0.0039) 0.20 (0.0079)Backlash between pump gears 0.16 - 0.27 (0.0063 - 0.0106) 0.50 (0.0197)

OIL COOLER

LB-4-1

OIL COOLERCONSTRUCTIONType I

Type II

Type I: FormerType II: New

OIL COOLER

LB-4-2

REMOVALKey point of removalRemove the drain plug from the oil pan and drain engine oil into acontainer.

WARNINGWARNINGDo not drain while the engine is hot to prevent scaldingyourself.

DISASSEMBLYType I and Type II


1. Cooler housing 3. Cooler element 4. Housing gasket2. Gasket

OIL COOLER

LB-4-3


Water pressure testConduct hydraulic tests on the element using the oil cooler attach-ment (99573 Z5500) and hydraulic pump (99570 Z5000). If anyabnormality is noticed, replace the element.NOTE

After completing the test, discharge the water completelyand dry the oil cooler.

Maintenance standard Service limitWater leakage should not occur when a pressure of 981 kPa 10kgf/cm2, 142psi, is directed to the element

—

OIL FILTER

LB-5-1

OIL FILTERCONSTRUCTIONType I (Full flow only type)

Type II (Full flow & by pass combination type)

OIL FILTER

LB-5-2

REPLACING OIL FILTERRefer to the “MA” section for LUBRICATION SYSTEM.

Type I (Full flow only type)


1. Regulating valve cap 8. Short valve spring 15. Contactor spring2. Packing 9. Short valve 16. Short valve3. Regulating valve spring 10. Clog warning switch 17. Snap ring4. Regulating valve 11. Packing 18. Oil cooler short valve5. Bracket 12. Short valve spring 19. Oil cooler short valve spring6. Short valve cap 13. Contactor case 20. Oil filter element assembly7. Packing 14. Contactor

OIL FILTER

LB-5-3

Type II (Full flow & by pass combination type)



Oil cooler short valveUnit: mm (in)

1. Regulating valve cap 7. Packing 13. Contactor case2. Packing 8. Short valve spring 14. Contactor3. Regulating valve spring 9. Oil filter short valve 15. Contactor spring4. Regulating valve 10. Clog warning switch 16. Short valve5. Bracket 11. Packing 17. Oil filter element assembly6. Short valve cap 12. Short valve spring



Free length of spring

Type IType II 58.5 (2.303) —


Type I47.515 - 52.516 4.845 - 5.355,

10.683 - 11.808— When compressed to

42.0 mm (1.654 in)

Type II 50.0 5.1, 11.2 — When compressed to 42.0 mm (1.654 in)

OIL FILTER

LB-5-4

Oil filter short valveUnit: mm (in)

Regulating valveUnit: mm (in)




Type I 62.0 (2.441) —Type II 97.0 (3.819) —


Type I28.882 - 31.9222.945 - 3.255, 6.494 - 7.177

— When compressed to 38.0 mm (1.496 in)

Type II 60.8 6.2, 13.7 — When compressed to 40.5 mm (1.594 in)




Type I 61.0 (2.402) —Type II 62.0 (2.441) —


Type I102.48 - 113.2710.45 - 11.55, 23.04 - 25.47

— When compressed to 47.25 mm (1.8602 in)

Type II 115.711.8, 26.0 — When compressed to

47.25 mm (1.8602 in)

OIL JET

LB-6-1

OIL JETCONSTRUCTION

NOTENumbers before part names do not indicate the disas-sembly sequence.

REMOVALKey point of removalRemove the oil jet bolt, being careful not to drop the gasket into thecylinder block.

1. Straight pin 3. Oil jet bolt2. Oil jet

- MEMO -

COOLING SYSTEM

CONTENTSSERVICE DATA...................................... EC-1-1

SPECIFICATIONS............................................ EC-1-1SERVICE DATA ............................................... EC-1-2TIGHTENING TORQUE ................................... EC-1-3COOLING SYSTEM ......................................... EC-1-4

TOOLS .................................................... EC-2-1WATER PUMP ........................................ EC-3-1

CONSTRUCTION............................................. EC-3-1EXTERNAL APPEARANCE CHECK AND CORRECTIONEC-3-1DISASSEMBLY ................................................ EC-3-2INSPECTION.................................................... EC-3-4

REASSEMBLY.................................................. EC-3-4THERMOSTAT ........................................ EC-4-1

REMOVAL ........................................................ EC-4-1INSPECTION.................................................... EC-4-1INSTALLATION ................................................ EC-4-1

RADIATOR AND COOLANT RESERVOIR TANKEC-5-1

FLUSHING COOLING SYSTEM ...................... EC-5-1INSPECTION.................................................... EC-5-1

FAN CLUTCH .......................................... EC-6-1CONSTRUCTION............................................. EC-6-1INSPECTION.................................................... EC-6-2

EC

SERVICE DATA

EC-1-1


Type of water pumpUnit: mm (in)

Type of thermostatUnit: mm (in)

Cooling system Forced-circulation typeWater pump Centrifugal, belt-driven typeThermostat Wax pellet typeFan clutch Refer to the description in this manual.

Item Type I Type IV Type II Type V Type III Type VI

A 100 (3.94) 116 (4.57)

B 80 (3.15) 96 (3.78)

C 36 (1.42) 55 (2.17)

Screw hole in impeller Provided None Provided None Provided NonePacked grease General specification Cold resistant specificationDisassembly and reassembly OK NG OK NG OK NGFormer and new Former New Former New Former New

Remarks —

Packed grease

differs from that for Type II.

Packed grease

differs from that for Type V.

Item Type I Type II Type III Type IV Type V Type VI

A 51 (2.01) 46 (1.81)

B 27 (1.06) 33 (1.30)

C 10 (0.39) 15 (0.59)

Valve opening temperatureºC (ºF) 76.5 (170) 82 (180) 88 (190) 76.5 (170) 82 (180) 88 (190)

Former and new Former New

SERVICE DATA

EC-1-2

Fan clutch

SERVICE DATAUnit: mm (in)

Item Run the enginecontinuously

Operating temperatureºC (ºF)

FE6AFE6B 119 kW 162 PSFE6B 132 kW 180 PS

FD1300L ON-OFF type 3,000 rpm 75±5 (167±9)


FDL1700

Linear type 3,400 rpm

65±10 - 80±5(149±18 - 176±9)

FE6T 151 kW 205 PSFE6T 162 kW 220 PSFE6TA 157 kW 213 PSFE6TA 173 kW 235 PS

FDL2000 50±10 - 80±5(122±18 - 176±9)


Water pump(Type I, Type II and Type III only)

Clearance between housing and impeller

Type I 0.4 - 2.0 (0.016 - 0.079) —Side clearanceType II

Type III 0.3 - 2.1 (0.012 - 0.083) —

Outside diameter of shaft at impeller location

13.03 - 13.05(0.5130 - 0.5138) —

Fit of impeller and shaft 0.03T - 0.06T(0.0012T - 0.0024T) — T: Tight

Thermostat

Valve port diameter 45 (1.77) —

Valve opening tem-perature

ºC (ºF)

76.5ºC (170ºF)

74.5 - 78.5(166 - 173)

71.5 - 81.5(161 - 179)

82ºC (180ºF)

80 - 84(176 - 183)

77 - 87(171 - 189)

88ºC (190ºF)

86 - 90(187 - 194)

85 - 93(185 - 199)

Valve lift/temperaturemm/ºC (in/ºF)

76.5ºC (170ºF) More than 10/90 (0.39/194) Less than

9/90 (0.35/194)82ºC (180ºF) More than 10/95 (0.39/203) Less than

9/95 (0.35/203)

88ºC (190ºF) More than 10/100 (0.39/212)

Less than9/100 (0.35/

212)Radiator cap operating pressure

kPa kgf/cm2, psi39 - 59 0.4 - 0.6, 6 - 9 — Pressure side

Test air pressure for radiator leakagekPa kgf/cm2, psi

157 1.6, 23 —

V-belt deflec-tion

Fan pulley - alternator pulley 10 - 15 (0.39 - 0.59) — With a force of about 98 N 10 kgf, 22 lbf applied to the mid partFan pulley - cooler pulley 7 - 12 (0.28 - 0.47) —

SERVICE DATA

EC-1-3


Item Tightening torqueWater pump grease nipple 10 - 15 1.0 - 1.5, 7 - 11Water pump mounting bolt 10 - 13 1.0 - 1.3, 7 - 9Fan pulley mounting nut 20 - 25 2.0 - 2.5, 14 - 18Cooling fan mounting bolt 10 - 12 1.0 - 1.2, 7 - 9Fan clutch mounting nut 20 - 25 2.0 - 2.5, 14 - 18

SERVICE DATA

EC-1-4

COOLING SYSTEM

TOOLS

EC-2-1

TOOLSWATER PUMPType I

Tool name and number Description ShapePulley hub puller99749 Z5503

Used to remove flange and impeller

Drive shaft remover99758 Z5500

Used to remove drive shaft

Bearing replacer99759 Z5503

Used to remove and install ball bearing

Water seal replacer99759 Z5504

Used to remove water seal

Drive shaft guide99789 Z5500

Used to install drive shaft

Fan pulley hub replacer99788 Z5501

Used to drive flange into place

TOOLS

EC-2-2

Type II and Type IIITool name and number Description Shape

Pulley hub puller99749 Z5504

Used to remove flange and impeller

Drive shaft remover99758 Z5500

Used to remove drive shaft


Used to remove ball bearing


Used to install ball bearing

Water seal replacer99759 Z5507

Used to remove and install water seal

Drive shaft guide99789 Z5501

Used to install drive shaft

Fan pulley hub replacer99788 Z5503

Used to drive flange into place

WATER PUMP

EC-3-1

WATER PUMPCONSTRUCTION

EXTERNAL APPEARANCE CHECK AND COR-RECTIONThe water pump should not be disassembled if no defects arefound by visual inspection.1. If coolant leaks at the hole on the lower side of the water

pump housing or if there are signs of coolant leakage on thepump housing, check the seal and impeller and replaceboth at the same time if necessary.

2. If grease leaks at the hole on the lower side of the waterpump housing or on the pulley side, replace the ball bearingon that side.

3. If the impeller interferes with the pump housing due to aworn ball bearing, or if the axial play of the ball bearing isexcessive, replace both ball bearings as a unit.

WATER PUMP

EC-3-2

DISASSEMBLYType I, Type II and Type III


*Before installing the water seal, install the flange. Marks “ ” and “ ” indicate that the key points of operation are explained in the text.Type IV, Type V and Type VI

Disassembly is not possible as there are no screw holes inthe impeller. If any abnormality is found by checking theexterior appearance, replace the assembly.

1. Grease nipple 5. Drive shaft assembly 9. Washer2. Impeller 6. Ball bearing 10. Drive shaft3. Flange 7. Spacer 11. Water seal*4. Retaining ring 8. Ball bearing

WATER PUMP

EC-3-3

Key point of disassembly2 ImpellerSecure the flange and remove the impeller using the puller bolt.NOTE

To secure the flange and puller bolt, use the pulley hubpuller.

3 FlangeDrive out the flange using the pulley hub puller.

5 Drive shaft assemblyRemove the retaining ring and drive shaft assembly from the impel-ler side using the drive shaft remover (99758 Z5500).

6, 8 Ball bearingDrive out the ball bearing together with the spacer and washerusing the bearing replacer.


Pulley hub pullerType I 99749 Z5503Type II, Type III 99749 Z5504


Pulley hub pullerType I 99749 Z5503Type II, Type III 99749 Z5504


Bearing replacerType I 99759 Z5503Type II, Type III 99759 Z5505

WATER PUMP

EC-3-4

10 Water sealDrive out the water seal using the water seal replacer.


Outside diameter of shaft at impeller locationUnit: mm (in)

Fit of impeller and shaftUnit: mm (in)

REASSEMBLYKey point of reassembly10 Drive shaft Attach the drive shaft guide to the pump body, and press the driveshaft assembly into place.

8 Ball bearingInstall the washer and press the ball bearing into place on theimpeller side using the bearing replacer.NOTE

Apply bearing grease to the rolling surface of the bear-ing.


Water seal replacerType I 99759 Z5504Type II, Type III 99759 Z5507


Maintenance standard Service limit Remarks0.03T - 0.06T

(0.0012T - 0.0024T) — T = Tight


Drive shaft guideType I 99789 Z5500Type II, Type III 99789 Z5501



WATER PUMP

EC-3-5

6 Ball bearingInstall the spacer and press the ball bearing into place on the flangeside using the bearing replacer.NOTE

Apply bearing grease to the rolling surface of the bear-ing.

3 FlangePress the flange onto the drive shaft using the fan pulley hubreplacer.

11 Water sealApply a coat of THREE BOND #1702 to the outer periphery of thewater seal. Press the water seal into the pump body using the waterseal replacer.

2 ImpellerPress the impeller into place so that the clearance between thepump housing and impeller is within maintenance standards.

Unit: mm (in)

1 Grease nipplePour bearing grease into the grease nipple.

Unit: g (oz)




Fan pulley hub replacerType I 99788 Z5501Type II, Type III 99788 Z5503


Water seal replacerType I 99759 Z5504Type II, Type III 99759 Z5507


Clearance between pump housing and impeller

Type I 0.4 - 2.0 (0.016 - 0.079) —Type II,Type III 0.3 - 2.1 (0.012 - 0.083) —

Item Amount of greaseType I 38 (1.34)Type II, Type III 42 (1.48)

THERMOSTAT

EC-4-1

THERMOSTATREMOVAL

INSPECTIONCheck thermostat operation as shown in the figure on the right.

INSTALLATIONInstall a new gasket so that it covers the periphery of the thermostatas shown in the figure.


Valve opening temperature

ºC (ºF)

76.5ºC (170ºF)

74.5 - 78.5(166 - 173)

71.5 - 81.5 (161 - 179)

82ºC (180ºF) 80 - 84 (176 - 183) 77 - 87 (171 - 189)

88ºC (190ºF) 86 - 90 (187 - 194) 85 - 93 (185 - 199)

Valve lift/temperature

mm/ºC (in/ºF)

76.5ºC (170ºF)

More than 10/90(0.39/194)

Less than 9/90(0.35/194)

82ºC (180ºF)

More than 10/95(0.39/203)

Less than 9/95(0.35/203)

88ºC (190ºF)

More than 10/100(0.39/212)

Less than 9/100(0.35/212)

RADIATOR AND COOLANT RESERVOIR TANK

EC-5-1

RADIATOR AND COOLANT RESERVOIR TANKFLUSHING COOLING SYSTEM1. Drain approximately 5% of the engine coolant from the cool-

ing system and replenish with the same amount of cleaningsolvent (genuine product. Cooling Mate). Allow the engineto idle for approximately 30 minutes.

NOTEEngine coolant temperature should be maintained atapproximately 80ºC (176ºF).

2. Drain the cooling system and replenish with tap water.WARNINGWARNINGDo not remove the radiator cap quickly. Otherwise, youmay be sprayed and scalded with hot flashing fluid.Cover the cap with a thick and heavy rag, and remove itgradually.

3. Start the engine again and continue to flush the cooling sys-tem. Repeat the flushing operation until drained water isclean.

4. Remove dust, leaves, and other foreign matter from theradiator core fins, water tubes, etc.

INSPECTIONCheck the radiator and coolant reservoir tank for cracks or damage.If necessary, repair or replace.

Water leakage testPlug the inlet and outlet of the radiator with suitable taps andimmerse the entire radiator in water. While holding the radiator inwater, apply 157 kPa 1.6 kgf/cm2, 23 psi of compressed air to theradiator core to check for air leakage. If leakage is present, repair orreplace as necessary.Radiator cap operating pressure

Unit: kPa kgf/cm2, psiMaintenance standard Service limit Remarks39 - 59 0.4 - 0.6, 6 - 9 — Pressure side

RADIATOR AND COOLANT RESERVOIR TANK

EC-5-2

Engine coolantCheck density of anti-freeze solution or LLC (Long Life Coolant)using a tester. If it is low, add anti-freeze solution or LLC asrequired to suit the areas where the vehicle is to be operated.

FAN CLUTCH

EC-6-1

FAN CLUTCHCONSTRUCTION

FD1300L

FDL1700

FAN CLUTCH

EC-6-2

FDL2000

INSPECTIONAfter removing the fan clutch, inspect it visually, and if there are anycracks or oil leakage (silicone oil), replace the fan clutch assembly.

OPERATING TEMPERATURE CHECK1. Remove the fan and fan shroud.2. Reinstall the fan.3. Set a thermometer between the fan and radiator.4. Start the engine and keep it running at a steady N rpm.5. As the thermometer reaches the range for TºC (TºF) ascer-

tain that fan speed gradually increases from low speed tohigh speed. If there is any abnormality, replace the fanclutch.

FAN CLUTCH

EC-6-3

Unit: ºC (ºF)

ItemRun the engine

continuously

Operating temperature

(T)FE6AFE6B 119 kW 162 PSFE6B 132 kW 180 PS

FD1300L ON-OFF type 3,000 rpm 75±5

(167±9)


FDL1700

Linear type 3,400 rpm

65±10 - 80±5 (149±18 -

176±9)

FE6T 151 kW 205 PSFE6T 162 kW 220 PSFE6TA 157 kW [213 PSFE6TA 173 kW 235 PS

FDL200050±10 - 80±5

(122±18 - 176±9)

- MEMO -

FUEL SYSTEM

CONTENTSSERVICE DATA...................................... EF-1-1

SPECIFICATIONS............................................ EF-1-1SERVICE DATA ............................................... EF-1-2TIGHTENING TORQUE ................................... EF-1-4FUEL SYSTEM................................................. EF-1-6

TOOLS .................................................... EF-2-1

= FE6A, FE6B, FE6T AND FE6TA[173 kW 235 PS] =

INJECTION PUMP ASSEMBLY ............. EF-3-1INJECTION PUMP PROPER ........................... EF-3-1FEED PUMP..................................................... EF-3-6TIMER .............................................................. EF-3-7GOVERNOR..................................................... EF-3-16ADJUSTMENT ................................................. EF-3-24INITIAL INJECTION TIMING ADJUSTMENT... EF-3-25FUEL INJECTION QUANTITY ADJUSTMENT EF-3-27

= FE6TA [157 kW 213 PS] =

INJECTION PUMP ASSEMBLY ............. EF-4-1CONSTRUCTION............................................. EF-4-1REMOVAL ........................................................ EF-4-11FUEL FEED PUMP AND PRIMING PUMP ...... EF-4-12INSTALLATION ................................................ EF-4-15FUEL INJECTION QUANTITY ADJUSTMENT EF-4-16

NOZZLE AND NOZZLE HOLDER.......... EF-5-1

= CONVENTIONAL TYPE =CONSTRUCTION............................................. EF-5-1REMOVAL ........................................................ EF-5-1DISASSEMBLY................................................. EF-5-2INSPECTION.................................................... EF-5-3REASSEMBLY.................................................. EF-5-4ADJUSTMENT.................................................. EF-5-4INSTALLATION ................................................ EF-5-5

= TWO-SPRING TYPE =CONSTRUCTION............................................. EF-5-6REMOVAL ........................................................ EF-5-6DISASSEMBLY................................................. EF-5-7INSPECTION.................................................... EF-5-8REASSEMBLY.................................................. EF-5-9ADJUSTMENT.................................................. EF-5-9INSTALLATION ................................................ EF-5-16

FUEL FILTER .......................................... EF-6-1CONSTRUCTION............................................. EF-6-1REPLACING FUEL FILTER ELEMENT............ EF-6-3

ENGINE CONTROL SYSTEM................. EF-7-1

= FE6A, FE6B, FE6T AND FE6TA[173 kW 235 PS] =

CONSTRUCTION............................................. EF-7-1ADJUSTMENT.................................................. EF-7-1

= FE6TA [157 kW 213 PS] =CONSTRUCTION............................................. EF-7-4ADJUSTMENT.................................................. EF-7-4

“MD-TICS” SYSTEM............................... EF-8-1

EF

SERVICE DATA

EF-1-1


NOTE*1: For HONG KONG only (“F4” FE6-206670—)*2: For NORWAY only

Engine model FE6A FE6B FE6T FE6TA

Max. gross output kW PS/rpm 118 160/3,000

119 162/3,000

132 180/3,000

135 183/3,000

151205/2,800

162 220/2,800

173 235/2,800

157 213/2,800

Fuel injection timing (B.T.D.C.) 14º 15º 12º 10º 9º 12º 3º

Ignition order 1-4-2-6-3-5

Fuel injection pump

Type Bosh (PE-A type) Bosch(TC-MD type)

Plunger diametermm (in)

9.5(0.374)

9.0(0.354)

9.5(0.374) 9.0 (0.354) 11.0

(0.433)

Cam liftmm (in)

Injection pump

8.0(0.315) 9.0 (0.354) 10.0 (0.394)

Feed pump 6.0 (0.236)

Governor

Type Centrifugal

Type name

RAD-BRLD-ERFD-B

RLD-ERAD-BRLD-ERFD-B

RLD-E RLD-F RLD-J

TimerType Centrifugal

Type name SA SA/SAG SA SAG —

Injection timing con-trol — Electronic

(MD-TICS)

Fuel injection nozzle

Nozzle holder Flange type

Nozzle Multi-jet

Identification mark Z D2 Z D3 A5 A6 A3 *1C1/F4

*2C1

Number of nozzle holes 5

Injection opening pressure

kPa kgf/cm2, psi19,614 200, 2,844

21,575220,

3,128

19,614 200, 2,844

1st stage:16,672 170, 2,417

2nd stage:21,575220, 3,128

19,614200, 2,844

SERVICE DATA

EF-1-2

SERVICE DATA

INJECTION PUMP ASSEMBLYFE6A, FE6B, FE6T AND FE6TA [173 KW 235 PS]

Unit: mm (in)


Housing and associated parts

I.D. of housing tappet 24.00 - 24.03(0.9449 - 0.9461) 24.15 (0.9508)

Pump housing to tappet clearance 0.03 - 0.07(0.0012 - 0.0028) 0.2 (0.008)

Pump housing to bearing cover clearance 0.01 - 0.05(0.0004 - 0.0020) 0.1 (0.004)

Camshaft

O.D. of contact surface of oil seal 20.0 (0.787) 19.8 (0.780)

Runout Less than 0.05 (0.0020) 0.15 (0.0059) Support center holes at both

ends.

End play of camshaft 0 - 0.02(0 - 0.0008) 0.1 (0.004)

Tappet

Tappet O.D. 23.95 - 23.97(0.9429 - 0.9437) 23.9 (0.941)

Play of tappet roller — 0.2 (0.008) Measure at right angle to roller pin.

Depth of tappet roller adjusting bolt — 0.2 (0.008)

Plunger and delivery valve

Control rack to pinion backlash 0.15 (0.0059) 0.3 (0.012)

Control sleeve to plunger flange play 0.03 - 0.08(0.0012 - 0.0031) 0.12 (0.0047)

Sliding resistance of control rack — Less than 1.471 N 150 g, 5.29 oz When static

Static fuel injection starting (Cam lift) 3.0±0.05(0.1181±0.0020) —

Difference in injection interval among cyl-inders ±0.5º ±1º

Governor

Clearances between pins and holes in tension lever, speed setting lever and guide lever

0.01 - 0.09(0.0004 - 0.0035)

0.2(0.008)

Clearance of flyweight pin bushing 0.02 - 0.05(0.0008 - 0.0020)

0.08(0.0031)

Rod control lever-to-bushing clearance 0.03 - 0.08(0.0012 - 0.0031)

0.15(0.0059)

Feed pump

Roller I.D.-to-roller pin O.D. clearance 0.04 - 0.08(0.0016 - 0.0031) Total play

0.3 (0.012)Tappet roller pin hole-to-roller pin O.D. 0.02 - 0.07

(0.0008 - 0.0028)

Roller I.D. 14.98 - 15.00(0.5898 - 0.5906) 14.6 (0.575)

Housing-to-piston clearance 0.03 - 0.06(0.0012 - 0.0024) 0.15 (0.0059)

Discharge pressureLess than 30 sec. (Time required for oil pressure to reach 177 kPa 1.8 kgf/cm2, 26 psi with the engine running at 600 rpm

When suction pipe of 8.0 mm (0.315 in) I.D. and 2.0 m (6.56 ft) length is used

Discharge flow rate Less than 300 milliliter (10.6 Imp fl oz) (Oil discharged for 15 seconds with engine running at 1,000 rpm)

Priming pump 25 times (Number of cycles required for priming pump running at a stroke of 60 - 100 per minute)

When cam lift is 6.0 mm (0.236 in)

Overflow valve opening pres-sure

Injection pump outlet kPa kgf/cm2, psi 157 1.6, 23 —

Fuel filter kPa kgf/cm2, psi108 - 147

1.1 - 1.5, 16 - 21 —

SERVICE DATA

EF-1-3

FE6TA [157 kW 213 PS]Unit: mm (in)


Housing and associated parts

I.D. of housing tappet 28.000 - 28.021(1.1024 - 1.1032) 28.15 (1.1083)

Pump housing to tappet clearance 0.020 - 0.062(0.0008 - 0.0024) 0.2 (0.008)

Pump housing to bearing cover clearance 0 - 0.06(0 - 0.0024) 0.1 (0.004)

Camshaft

O.D. of contact surface of oil seal 25.0 (0.984) 19.8 (0.780)

Runout Less than 0.05 (0.0020) 0.15 (0.0059) Support center holes at both

ends.

End play of camshaft 0.02 - 0.06(0.0008 - 0.0024) 0.1 (0.004)

Tappet

Tappet O.D. 27.959 - 27.980(1.1007 - 1.1016) 27.9 (1.098)

Play of tappet roller — 0.2 (0.008) Measure at right angle to roller pin.

Depth of tappet roller adjusting bolt — 0.2 (0.008)

Plunger and delivery valve

Control rack to pinion backlash 0 - 0.056(0 - 0.0022) 0.3 (0.012)

Control sleeve to plunger flange play 0.025 - 0.083(0.0010 - 0.0033) 0.12 (0.0047)

Sliding resistance of control rack 1.275 N130 g, 4.59 oz

1.471 N150 g, 5.29 oz At standstill

Static fuel injection starting (Cam lift) 5.6±0.03(0.2205±0.0012) —

Difference in injection interval among cyl-inders ±0.25º ±1º

Governor

Clearances between pins and holes in tension lever, speed setting lever and guide lever

0.01 - 0.09(0.0004 - 0.0035) 0.2 (0.008)

Shaft to tension lever guide 0.05 - 0.08 (0.0020 - 0.0031)Lever shaft to bushing0.022 - 0.051(0.0009 - 0.0020)

Clearance of flyweight pin bushing 0.018 - 0.039(0.0007 - 0.0015) 0.08 (0.0031)

Rod control lever-to-bushing clearance 0.031 - 0.075(0.0012 - 0.0030) 0.15 (0.0059)

Feed pump

Housing and push rod clearance 0.003 - 0.018(0.0001 - 0.0007) 0.1 (0.004)

Housing and piston clearance 0.014 - 0.056(0.0006 - 0.0022) 0.15 (0.0059)

Discharge pressureLess than 30 sec. (Time required for oil pressure to reach 177 kPa 1.8 kgf/cm2, 26 psi with the engine running at 600 rpm)

when suction pipe of 8.0 mm (0.315 in) I.D. and 2.0 m (6.56 ft) length is used

Discharge flow rate Less than 300 milliliter (10.6 Imp fl oz) (Oil discharged for 15 seconds with engine running at 1,000 rpm)

Priming pump 25 times (Number of cycles required for priming pump running at a stroke of 60 to 100 per minute)

when cam lift is 6.0 mm (0.236 in)

Overflow valve opening pres-sure kPa kgf/cm2, psi

Injection pump outlet 255 2.6, 37 —

Fuel filter 108 - 1471.1 - 1.5, 16 - 21 —

SERVICE DATA

EF-1-4

NOZZLE AND NOZZLE HOLDERUnit: kPa kgf/cm2, psi

TIGHTENING TORQUE

INJECTION PUMP ASSEMBLYUnit: N·m kgf·m, ft·lbf


Valve opening pressure(Regulated pressure)

Conventional type

Z, D2, A5A6, C1, F4

20,104 - 20,595205 - 210, 2,915 - 2,986 —

D3, F4 22,066 - 22,556225 - 230, 3,200 - 3,271 —

Two-spring type A3

1st stage

17,162 - 17,947175 - 183, 2,489 - 2,602 —

2nd stage

23,046 - 23,537235 - 240, 3,342 - 3,413 — Nozzle cover method

24,321 - 24,910248 - 254, 3,527 - 3,612 — Push rod contacting

method


Injection pump assembly

Delivery valve holderPE-A type

M20 39 - 44 4.0 - 4.5, 29 - 33M24 49 - 54 5.0 - 5.5, 36 - 40

TC-MD type 103 - 113 10.5 - 11.5, 76 - 83Bearing cover mounting bolt 7 - 9 0.7 - 0.9, 5.1 - 6.5

Timer Timer round nutSAG type 54 - 59 5.5 - 6.0, 40 - 43SA type 83 - 98 8.5 - 10.0, 61 - 72

Governor

RAD-BRLD-E, FRFD-B

Flyweight round nut 59 - 69 6.0 - 7.0, 43 - 51

Governor housing mounting bolt

M6 7 - 9 0.7 - 0.9, 5.1 - 6.5M8 15 - 18 1.5 - 1.8, 11 - 13

Governor cover mounting bolt 7 - 9 0.7 - 0.9, 5.1 - 6.5Idle spring assembly lock nut 18 - 22 1.8 - 2.2, 13 - 16Ungleich spring assembly lock nut 16 - 20 1.6 - 2.0, 12 - 14Speed setting bolt lock nut 10 - 14 1.0 - 1.4, 7 - 10

RLD-J

Flyweight round nut 49 - 59 5.0 - 6.0, 36 - 43Governor housing mounting bolt 7 - 9 0.7 - 0.9, 5.1 - 6.5Governor cover mounting bolt 7 - 9 0.7 - 0.9, 5.1 - 6.5Idle spring assembly lock nut 39 - 59 4.0 - 6.0, 29 - 43Speed setting bolt lock nut 10 - 14 1.0 - 1.4, 7 - 10

Actuator hous-ing Actuator housing mounting bolt 1.0 - 1.5 0.10 - 0.15, 0.7 - 1.1

SERVICE DATA

EF-1-5

NOZZLE AND NOZZLE HOLDERUnit: N·m kgf·m, ft·lbf

FUEL FILTERUnit: N·m kgf·m, ft·lbf


Conventional type

Cap nutZ, D2, D3, A5, A6 39 - 49 4.0 - 5.0, 29 - 36C1, F4 29 - 39 3.0 - 4.0, 22 - 29

Retaining nut 59 - 78 6.0 - 8.0, 43 - 58Inlet connector 59 - 69 6.0 - 7.0, 43 - 51

Two-spring type

Cap nut 39 - 49 4.0 - 5.0, 29 - 36Retaining nut 59 - 78 6.0 - 8.0, 43 - 58Inlet connector 59 - 69 6.0 - 7.0, 43 - 51Nut 20 - 25 2.0 - 2.5, 14 - 18Set screw 49 - 59 5.0 - 6.0, 36 - 43

Nozzle holder assembly mounting bolt 25 - 29 2.5 - 3.0, 18 - 22

Item Tightening torqueFuel filter (center bolt type) center bolt 20 - 29 2.0 - 3.0, 14 - 22

Primary fuel filter center boltType I 20 - 29 2.0 - 3.0, 14 - 22Type II 59 - 69 6.0 - 7.0, 43 - 51

Primary fuel filter drain plug (Type II only) 16 - 22 1.6 - 2.2, 12 - 16Fuel strainer center bolt 15 - 20 1.5 - 2.0, 11 - 14

SERVICE DATA

EF-1-6

FUEL SYSTEM

TOOLS

EF-2-1

TOOLSInjection pump (Part numbers designated by ZEXEL)

Tool name and number Description ShapeMeasuring device105782-4080

For measuring camshaft in the axial direction

Measuring device105782-4330

For measuring plunger pre-stroke

Adjusting device105782-6170

For measuring control lever angle (RLD governor)


For measuring governor control lever


For measuring control rack travel

Timing checker157830-3320

For testing timer advance angle

Sensor157830-3420

TOOLS

EF-2-2

Tool name and number Description ShapeLamp157830-3520

For testing timer advance angleCut the reflection plate to a size of 5.0 x 7.0 mm (0.197 x 0.276 in)

Holder157842-5220

Reflection plate157951-1100

Handle157910-1120

Used together with socket wrench and special wrench

Socket wrench157914-0500

For dismounting and mounting delivery valve holder

Wrench157915-0100

For dismounting and mounting flyweight fixing nut

Socket wrench157914-0300

For dismounting and mounting round nut(SA type timer)

TOOLS

EF-2-3

Tool name and number Description ShapeWrench157915-0300

For dismounting and mounting round nut(SAG type timer)

Spanner157916-4620

For fixing coupling for timer

Extractor157926-6210

For removing timer assembly

Seal guide157920-5400

For protecting lip of camshaft oil seal

Tappet insert157921-0120

For inserting tappet assembly

Plunger insert157921-5620

For inserting plunger


For removing oil seal


For removing bearing

TOOLS

EF-2-4

Tool name and number Description ShapeExtractor157926-5120

For removing flyweight

Holder157931-2500

For holding tappet

Holder157931-4100

For holding plunger spring

Tappet inserter157931-6120

For installing tappet

Universal vise assembly105794-0090

Vise157944-8520Bracket197944-8720

For disassembling and reassembling pump vise

Lock157976-3100

For locking control rack

Wrench157916-2620

For adjusting idling(RAD and RFD governors)

TOOLS

EF-2-5

Tool name and number Description ShapeWrench157913-3520

For adjusting boost compensator stroke

Wrench157913-3620

For adjusting governor torque cam (RLD governor)

Wrench157913-5320

For adjusting governor shaft(RLD governor)

Wrench157913-5400

For adjusting idling(RLD governor)

Rod157923-5800 [18 mm, (0.71 in)] dia.157923-5900 [22 mm, 0.87 in)] dia.157923-6000 [26 mm, (1.02 in)] dia.

For press-fitting plate plug(RLD governor)

Plug029111-4050

For adjusting injection timing (M14 x 1.5)(RLD governor)


For measuring the load control lever angle (RAD governor)

TOOLS

EF-2-6

Tool name and number Description ShapeMeasuring device105782-6090

For measuring control rack

Coupling105784-0510

For measuring timing device advance angle

Coupling157842-4420

For driving injection pump

Box wrench157916-2800

For removing and installing timing device round nut

Spanner157916-5420

For fixing timing device and pump coupling


For removing governor flyweight

TOOLS

EF-2-7

Timer (Part numbers designated by ZEXEL)SAG type

SA type

Tool name and number Description ShapeTappet holder157931-7320

Pin157931-7300Holder157931-7400

For holding tappet

Tool name and number Description ShapeBase157924-2520

For disassembling and reassembling the timer

Spring compressor157921-9820

For disassembling and reassembling the fly-weight assembly

Tool name and number Description ShapeBlock157924-0800

For inserting the oil seal on the flange side

Thrust bushing157924-0500

For disassembling the timer

TOOLS

EF-2-8

Tool name and number Description ShapeGuide157924-0900

For inserting the oil seal on timer case side

Guide bolt157924-1100

For inserting the oil seal

Oil seal guide157924-0700

For inserting the oil seal

Guide bushing157924-1200

For inserting the oil seal on flange side

Guide bushing157924-1300or157924-1400

For inserting the oil seal on timer case side

Supporter157932-0100

For supporting the timer spring

Bolt029001-2220

Washer029301-2260

For reassembling the timer

Band spanner157916-6120

For removing or installing the timer case

TOOLS

EF-2-9

Nozzle and nozzle holder

* Part numbers designated by ZEXEL

Tool name and number Description ShapeBase157924-0110

For disassembling and reassembling the timer

Guide bolt157924-0300


Guide157924-0400


Thrust bushing157924-1500

For inserting the oil seal on flange and timer case side

Tool name and number Description ShapePin vise99727 Z5005

For cleaning nozzle injection hole

Nozzle cleaner99726 Z5000

Used to remove carbon from rear of nozzle

* Nozzle tester105785-0960

Used to measure nozzle opening pressure and to check spray characteristics and oil leakage from nozzle seat(Conventional type)

* Nozzle tester105785-1010

Used to confirm the first and second valve opening pressures (regulated pressures) of the nozzleUsed to bleed air from the retaining nut and to check fuel leakage (Two-spring type)

TOOLS

EF-2-10

* Part numbers designated by ZEXEL

Tool name and number Description Shape* Plate157944-9520

For fixing nozzle holder

Retaining nut157892-2020

Used to adjust the first valve opening pressure (regulated pressure) and the overall lift of the needle valve (Two-spring type)(1) Retaining ring(2) Gasket(3) Plug

Dial gauge157954-3800

Used to adjust the pre-lift and the overall lift of the needle valve (Two-spring type)

Pin157892-1100

Used to adjust the pre-lift (Two-spring type)L = 60.5 mm (2.382 in)

Pin157892-1200

Used to adjust the overall lift of the needle valve(Two-spring type)

Base157892-1800

Used to adjust the pre-lift (Two-spring type)


Used to adjust the pre-lift and the overall lift of the needle valve (Two-spring type)(1) Adjusting device(2) Connector

(1) 157892-2000(2) 026508-1140(3) 157892-1600

(1) 157892-0220(2) 157892-1320

- MEMO -

INJECTION PUMP ASSEMBLY

EF-3-1

A, B, T, TA 173 kW 235 PS

= FE6A, FE6B, FE6T AND FE6TA [173 kW 235 PS] =INJECTION PUMP ASSEMBLY

INJECTION PUMP PROPER




1. Gasket 13. Camshaft 24. Control sleeve2. Cover 14. Ball bearing 25. Lock plate3. Eyebolt 15. Shim 26. Delivery valve holder4. Gasket 16. Ring 27. O-ring5. Adapter 17. Gasket 28. Stopper6. Overflow valve 18. Center bearing 29. Delivery valve spring7. Gasket 19. Tappet assembly 30. Gasket8. Adapter 20. Shim 31. Delivery valve9. Plug 21. Spring seat 32. Plunger assembly

10. Bearing cover 22. Plunger spring 33. Rack limiter11. O-ring 23. Upper spring seat 34. Rack guide screw12. Oil seal 35. Control rack


EF-3-2

A, B, T, TA 173 kW 235 PS

Key point of disassemblySet the injection pump on the universal vise assembly (105794-0090).

2 CoverRemove the pump cover plate and, using the special wrench(157916-4620), turn the camshaft. When the tappet reaches topdead center, insert the tappet holder (157931-7320) into the tappethole, so that the tappet can be released from the cam.

9 PlugRemove the screw plug at bottom of the housing using the handle(157910-1120).

13 CamshaftRotate the camshaft until its drive side key groove is facing verti-cally upward. Then attach the seal guide (157920-5400) to thecamshaft.

14 Ball bearing1. Use the extractor (159725-0520) and remove the outer race

from the bearing cover. Install the outer race extractor andtighten the nut to force the flared portion of the tool betweenthe outer race and the oil seal. Hold the bearing cover andtap the tool with a hammer.


EF-3-3

A, B, T, TA 173 kW 235 PS

2. Place the extractor (157925-6520) over the inner race ofthe bearing and pull the inner race from the camshaft. Atthe same time remove the shim plate and washer.

19 Tappet assembly1. Insert the tappet insert (157921-0120) from the screw plug

hole, compress the plunger spring by pushing the tappet upand pull the plunger spring holder out.

2. After pulling the tappet holder, insert the tappet inserter(157931-6120) from the bearing insertion hole of the pumphousing and pull the tappet out with the shim.

3. After removing the tappet, insert the plunger insert (157921-5620) from the screw plug hole and pull the plunger with thelower spring seat.

26 Delivery valve holderUsing a socket wrench (157914-0500), remove the delivery valveholder, stopper and delivery spring.


EF-3-4

A, B, T, TA 173 kW 235 PS

Key point of reassemblyBefore assembling the fuel injection pump, clean parts thoroughlyand apply a thin coat of engine oil to rotating and sliding parts.

35 Control rackTilt the pump housing onto its side and set the punch mark at bothsides of the control rack to the same dimension from the ends ofthe pump housing.

32 Plunger assemblyInstall the plunger to the special tool plunger insert (157921-5620)and assemble to the barrel.At this time, the lower spring seat must be installed to the plunger.NOTE

Since the plunger and barrel are precision manufacturedas pair, they must not be matched with those of anothercylinder.Assemble the plunger with the matching mark facing thefront (cover side) of the pump housing.

19 Tappet assemblyAssemble the tappet to the pump housing using the tappet inserter(157931-6120) and tappet insert (157921-0120) the same as whendisassembling. Push the tappet itself forcefully and install the tap-pet holder.

13 Camshaft1. Install the camshaft, together with the center bearing, to the

pump housing so that the “assembly mark” is at the timerside. (This work can be facilitated by coating the centerbearing with a small amount of grease and sticking it to thecamshaft.)


EF-3-5

A, B, T, TA 173 kW 235 PS

2. Install the bearing cover to the pump housing.NOTE

Since the oil seal may be damaged by the key groove ofthe camshaft when installing the bearing cover, installthe seal guide (157920-5400) to the threaded part of thecamshaft.

3. Measure the end play of the camshaft with the measuringdevice (105782-4080). Adjust the end play by changing thethickness of the adjusting shim at the inside of the bearing.In this case, first measure the end play of the camshaft withthe measuring device and then adjust to 0 to 0.02 mm (0 to0.0008 in) dividing the end play equally at the front and rearwith the shim.

Unit: mm (in)

4. After injection pump reassembly, use a spring balance tocheck that the control rack moves smoothly over its com-plete stroke.

Unit: N g, oz

5. Ensure control rack stroke is 21.0 mm (0.827 in), from theposition where the control rack is fully pushed toward thegovernor to the position where it is fully pulled toward thedrive side.Use a vernier caliper or depth gauge to perform measure-ment.

NOTEIf the control rack stroke is not within 21.0 mm (0.827 in)reengage the control pinion with the control rack toobtain the control rack stroke of 21.0 mm (0.827 in).

Maintenance standard Service limit0 - 0.02 (0 - 0.0008) 0.1 (0.004)


Sliding resistance of control rack — Less than 1.471

150, 5.29 When static


EF-3-6

A, B, T, TA 173 kW 235 PS

FEED PUMP

CONSTRUCTION


1. Priming pump 7. Adapter 12. Gasket2. O-ring 8. Gasket 13. Piston spring3. Spring 9. Spring 14. Piston4. Valve 10. Valve 15. Straight pin5. Eyebolt 11. Plug 16. Housing6. Eyebolt


EF-3-7

A, B, T, TA 173 kW 235 PS

TIMER

CONSTRUCTIONSAG type

SA type


EF-3-8

A, B, T, TA 173 kW 235 PS

DISASSEMBLY AND REASSEMBLYSAG type



Key point of disassembly1. Using a socket wrench (157915-0300), handle (157910-

1120) and special wrench (157916-4620), remove theround nut and then remove the timer assembly, using anextractor (157926-6210).

1. Plug 8. Snap ring 14. Seat2. Gasket 9. Seat 15. Pilot pin3. Screw 10. Shim 16. Spacer4. Cover 11. Shim 17. Flyweight5. Flange 12. Spring 18. O-ring6. Eccentric cam (large) 13. Spring 19. Housing7. Eccentric cam (small)


EF-3-9

A, B, T, TA 173 kW 235 PS

2. Record the relationship between the housing punch markand the location of the holder key groove before disassem-bly.

3. Clamp the base (157924-2520) in a vise and set it on thetimer assembly.

4 CoverRemove the six screws holding the cover and then remove thecover.NOTE

At this time, be careful not to damage the lip of the oilseal.

5 FlangeRemove the holder together with the flyweight assembly from thehousing.NOTE

Sometimes large and small cams may be left in the hous-ing.Do not change the order of those cams at this time.Install them in the holder correctly, and note the direc-tions and locations of the key groove and cams.

8 Snap ringCompress springs using the spring compressor (157921-9820) anddraw out the snap ring.


EF-3-10

A, B, T, TA 173 kW 235 PS

Key point of reassemblyInstall large and small cams in the position specified. The specifiedposition for cams can be identified by the Bosch No. marked on theouter periphery of the housing.

17 FlyweightInstall the flyweight as shown in the figure so that the holder keygroove faces the upper portion, and the right-hand flyweight pinfaces the upper portion. (The left-hand flyweight pin will face thebottom portion.)

6, 7 Eccentric cam1. Install the large and small cams in each specified position.

Large cams: t1 is wider than t2Small cams: t3 is narrow

2. Measure the pitch of the housing pin.

3. Set the pitch of the small cam housing pin hole to the mea-sured value found in step 2.


EF-3-11

A, B, T, TA 173 kW 235 PS

4. Make sure that the distance between both the small camhole and holder center is the same.

NOTEIf not, repeat step 2.

5 Flange1. With both housing punch mark and holder key groove in

position, install the housing into the holder. At this time, becareful not to damage the oil seal.

NOTEIf the housing pin cannot be inserted into the small camhole, repeat step 1 and subsequent steps.

2. Check that cams are assembled correctly. The figure showsthe cams from the cover side.

4 CoverLubrication of timing device.Lubricating oil: Mobil oil #20Oil level: Approximately 1 mm (0.04 in) below the upper surface offlyweights.


EF-3-12

A, B, T, TA 173 kW 235 PS

SA type



Key point of disassemblyUsing a socket wrench (157914-0300), handle (157910-1120) andspecial wrench (157916-4620), remove the round nut and thenremove the timer assembly, using an extractor (157926-6210).

1. Plug 5. O-ring 9. Flyweight2. Gasket 6. Flange 10. Oil seal3. Timer case 7. Timer spring 11. Flyweight holder4. Oil seal 8. Adjusting shim


EF-3-13

A, B, T, TA 173 kW 235 PS

3 Timer case1. Clamp the base (157924-0110) in a vise and thread in the

guide bolt (157924-0300).

2. Remove one of the screw from the flyweight holder. Attachthe flyweight to the base (157924-0110) and secure withthe guide (157924-0400).

3. Unscrew the staked section of the timer case and flyweightholder. Remove the timer case by turning it clockwise withthe band spanner (157916-6120).

Key point of reassembly1. Clamp the base (157924-0110) in a vise and install in the

guide bolt (157924-1100).

2. Place the block (157924-0800) over the base pin.

3. Fit the oil seal to the flange hole. With the guide bushing(157924-1200) intervening, thread in the thrust bushing(157924-1500) to force in the oil seal.


EF-3-14

A, B, T, TA 173 kW 235 PS

10 Oil seal1. Clamp the base (157924-0110) in a vise and install the

guide bolt (157924-1100).2. Place the block (157924-0800) over the base and install the

guide (157924-0900).

3. Insert the oil seal, fit the guide bushing (157924-1300 or157924-1400), and thread in the thrust bushing (157924-1500), completing the job.

8 Adjusting shim1. Clamp the base (157924-0110) in a vise and install the

guide bolt (157924-0300).2. Place the flyweight holder over the pin of the base (157924-

0110) and fit the rubber ring.

3. Insert the adjusting shim at one end of the timer spring atthe seat portion of the flyweight holder pin. Insert the sup-porter (157932-0100) beneath the spring, and thread theguide (157924-0400) over the guide bolt.

6 FlangeMount the flange, apply a special wrench (157916-4620) to theflange claw, and fit the thrust bushing (157924-0500), washer(029301-2260), and bolt (029001-2220) to the flange.


EF-3-15

A, B, T, TA 173 kW 235 PS

3 Timer casePosition the oil seal guide (157924-0700). Install the timer case andtighten it with the band spanner (157916-6120).


EF-3-16

A, B, T, TA 173 kW 235 PS

GOVERNOR

DISASSEMBLY AND REASSEMBLYRAD type


EF-3-17

A, B, T, TA 173 kW 235 PS



Key point of disassembly20 Governor cover assembly1. Removal of governor cover assembly

Remove the governor shaft plate plug (1) then loosenthe lock nut with the wrench (157913-5320).

Remove the idling spring plate plug (2) then loosen thelock nut with the wrench (157913-5400).Next, use a Phillips screwdriver to remove the idlingspring assembly.

1. Bracket 20. Governor cover assembly 38. Snap ring2. Cover 21. Gasket 39. Floating lever3. O-ring 22. Speed adjusting bolt 40. Collar4. Cap nut 23. Spring 41. Shim5. Gasket 24. Tube 42. Sleeve assembly6. Cap nut 25. Torque control spring assembly 43. Rack limiter7. Gasket 26. Nut 44. Start spring8. Damper spring 27. Idling spring assembly 45. Spring eye9. Plug 28. Stroke adjusting bolt 46. Round nut

10. Gasket 29. Tension lever 47. Lock washer11. Idling stopper bolt 30. Speed setting lever 48. Flyweight assembly12. Full-load stopper bolt 31. Governor spring 49. Key13. Control lever 32. Guide lever assembly 50. Snap ring14. Shim 33. Lever shaft 51. Governor housing15. Oil seal 34. Snap ring 52. Gasket16. Bushing 35. Snap ring 53. Impeller17. Plug 36. Spring seat 54. Adapter18. Tension lever shaft 37. Spring seat 55. Control lever19. Plug


EF-3-18

A, B, T, TA 173 kW 235 PS

2. Using a Phillips screwdriver, remove the seven bolts to sep-arate the governor cover from the governor housing. Thenremove the governor cover.

NOTEBe sure to keep an oil pan under the governor to receivelubricating oil.

27 Idling spring assemblyLoosen the lock nut with a socket wrench (157914-0500) and han-dle (157910-1120). Then loosen the nut and remove the idlingspring assembly.

46 Round nut, 48 Flyweight assembly1. Using the special wrench (157916-4620), hold the timer so

that the camshaft will not turn. Then, using the wrench(157915-0100) and handle (157910-1120), remove theround nut securing the flyweight.

2. Screw the extractor (157926-5110) onto the threaded partof the flyweight holder to pull out the flyweight assembly.

Key point of reassembly48 Flyweight assemblyUsing the spanner (157916-5420), hold the timer so that the camshaft will not turn. Then, using the wrench (157915-0100) and han-dle (157910-1120), install the round nut securing the flyweight.

- MEMO -


EF-3-20

A, B, T, TA 173 kW 235 PS

RLD type


EF-3-21

A, B, T, TA 173 kW 235 PS



Key point of reassembly51 Flyweight assemblyUsing the special wrench (157916-4620), hold the timer so that thecam shaft will not turn. Then, using the wrench (157915-0100) andhandle (157910-1120), install the lock nut securing the flyweight.

3 Idling spring assemblyInstall the idling spring assembly using the Phillips screwdriver andtighten the lock nut using the wrench (157913-5400).

1. Plate plug 26. Snap ring 51. Flyweight assembly2. Lock nut 27. Floating lever 52. Woodruff key3. Idling spring assembly 28. Guide lever 53. Full-load set lever4. Plate plug 29. Cancel spring 54. Return spring5. Lock nut 30. Lock screw 55. Shim6. Plate plug 31. Adjusting nut 56. O-ring7. Plate plug 32. Spring inner 57. Full-load lever shaft8. Lock nut 33. Spring outer 58. Cancel spring9. Idling-speed setting bolt 34. Rod 59. Snap ring

10. Maximum-speed setting bolt and lock nut

35. Snap ring 60. Sensor lever36. Torque cam 61. U-shaped lever

11. Spring 37. Snap ring 62. Stop lever12. Tube 38. Pin 63. Cap13. Support 39. Tension lever 64. Return spring14. Control lever 40. Shifter 65. Shim15. Adjusting shim 41. Adjusting shim 66. O-ring16. Adjusting shim 42. Sleeve sub-assembly 67. Bushing17. Oil seal 43. Governor shaft 68. Collar18. Bushing 44. Spring seat 69. Shaft19. Plate plug 45. Governor spring outer 70. Guide screw20. Tension lever shaft 46. Round nut 71. Lock nut21. Governor cover 47. Rack connecting link 72. Full-load setting bolt22. Gasket 48. Start spring 73. Governor housing23. Control lever shaft 49. Spring eye 74. Gasket24. Cancel spring 50. Round nut 75. Adapter25. Supporting lever


EF-3-22

A, B, T, TA 173 kW 235 PS

RFD type


EF-3-23

A, B, T, TA 173 kW 235 PS



Key point of disassembly37 Idling spring assemblyLoosen the lock nut with a socket wrench (157914-0500), andremove the idling spring assembly.

53 Flyweight assembly1. Using a box wrench (157916-2800) and handle (157910-

1120), remove the round nut and then remove timer assem-bly using an extractor (157926-6210).

2. Attach the coupling (151842-4420) for disassembly andreassembly to the pump camshaft.

3. Hold the timer, using a special wrench (157916-4620), andremove the round nut from the flyweight side, using awrench (157915-0100) and handle (157910-1120).

1. Bracket 21. O-ring 41. Lever shaft2. Closing cover 22. Snap ring 42. Sliding lever3. O-ring 23. Lever 43. Snap ring4. Cap nut 24. Woodruff key 44. Snap ring5. Gasket 25. Collar 45. Floating lever6. Damper spring 26. Shim 46. Collar7. Plug 27. Oil seal 47. Smoke limiter8. Gasket 28. Bushing 48. Adjusting shim9. Stopper bolt 29. O-ring 49. Sleeve assembly

10. Idling stopper bolt 30. Snap ring 50. Start spring11. Full load stopper bolt 31. Plug 51. Spring eye12. Spring 32. Tension lever shaft 52. Round nut13. Tube 33. Governor cover 53. Flyweight assembly14. Lock washer 34. Gasket 54. Control lever15. Control lever 35. Governor spring 55. Stopper bolt16. Shim 36. Swivel lever 56. Governor housing17. Oil seal 37. Idling spring assembly 57. Impeller18. Bushing 38. Stroke adjusting bolt 58. Adapter19. Plug 39. Tension lever 59. Gasket20. Bushing 40. Guide lever assembly


EF-3-24

A, B, T, TA 173 kW 235 PS

4. Screw the extractor (157926-5110) onto the threaded partof the flyweight holder to pull out the flyweight assembly.

Key point of reassembly53 Flyweight assembly1. Hold the timer, using a spanner (157916-5420).

2. Using the wrench (157915-0100) and torque wrench,tighten the flyweight with the lock washer and round nut.

37 Idling spring assemblyInstall the idling spring assembly with the socket wrench (157914-0500) and handle (157910-1120).

ADJUSTMENTWhen the injection pump has been disassembled, plungers orplunger springs have been replaced, or other reasons exist, use apump tester and adjust the injection pump.


EF-3-25

A, B, T, TA 173 kW 235 PS

Injection pump preparationsRemove the cap of the control rack and install the measuringdevice (105782-6280).

INITIAL INJECTION TIMING ADJUSTMENTThe start of injection is considered as the time at which the top ofthe plunger covers the fuel intake hole of the barrel. The pumptester must be capable of developing a pressure in the range of2,942 to 3,923 kPa 30 to 40 kgf/cm2, 427 to 569 psi in order toovercome tension of the delivery valve spring (to force the deliveryvalve open).

Adjusting the injection timing of the standard cylinder1. Fix the control rack to full rack position.2. Removing the 1st cylinder delivery valve holder. To do this,

use the socket wrench (157914-0500).3. Install the measuring device (105782-4330) to the No. 1 cyl-

inder as viewed from the drive side.


EF-3-26

A, B, T, TA 173 kW 235 PS

4. Set the tappet to top dead center of the camshaft and setthe scale of the dial gauge to “0”.

5. Loosen the bleeder screw of the pump and bleed the airfrom the fuel system.

6. When the drive shaft of the tester is slowly turned in thedrive direction while feeding fuel to the fuel inlet of thepump, the fuel will stop flowing from the pipe of the test usenozzle holder. This is the injection start position. The injec-tion timing is normal if the tappet has risen by the specifiedvalue from bottom dead center.

7. When the flow of fuel does not stop when the tappet hasbeen lifted within 3.35 to 3.45 mm (0.1319 to 0.1358 in)from bottom dead center, adjust the adjusting shim usingthe plunger spring holder (157931-4100).

8. When the fuel flow stops before the tappet is raised 3.45mm (0.1358 in), add adjusting shims until the fuel flow stopsat a life of 3.35 mm (0.1319 in).

Adjusting injection interval1. After completing adjustment of initial injection timing of the

reference No. 1 cylinder (timer side), turn the camshaft tothe right (as viewed from the drive end) and set the injectioninterval for the remaining cylinders by adjusting shims.See the table below.

2. Adjust the cylinder injection intervals within ±30’Injection order ........................... 1 — 4 — 2 — 6 — 3 — 5 — 1

Injection interval........................|||

60º |||

60º |||

60º |||

60º |||

60º |||

60º |||

Scale plate indication................ 0º — 60º — 120º — 180º — 240º — 300º — 360º


EF-3-27

A, B, T, TA 173 kW 235 PS

FUEL INJECTION QUANTITY ADJUSTMENTTesting conditionsFailure of pump to deliver fuel evenly throws the engine out of balance so that roughness and loss of power isevident. In calibrating a pump, observe the following:

Injection quantity standards (“ZEXEL No.” is Inj. Pump ass’y No.)RAD governor

ZEXEL No. 101607-9351

ZEXEL No. 101607-9331

Item Test conditionNozzle 105780-0000 (BOSCH Type No. DN12SD12T)Nozzle holder 105780-2080 (BOSCH Type No. EF8511/9)

Nozzle opening pressure kPa kgf/cm2, psi 17,162 175, 2,489

Feed pump oil pressure kPa kgf/cm2, psi 157 1.6, 23

Injection pipe (OD x ID – L) mm (in) 6 x 2 – 600 (0.24 x 0.08 – 23.62)Test oil IS04113 or SAE standard test oil (SAE J967d)Test oil temperature ºC (ºF) 40 - 45 (104 - 113)

Adjusting point

Rack positionmm (in)

Pump speed

rpm

Injection q’tymilliliter (Imp fl oz)/

1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

A 8.2 (0.323) 600 42±1 (1.48±0.04) ±3.5 Lever BasicB 8.0 (0.315) 1,000 53±1 (1.9±0.04) ±10 Lever

Approx. 7.0 (0.276) 300 9±1.8 (0.32±0.06) ±10 Rack

Adjust max. var. bet. cyl. at R 7.0 mm (0.276 in).Adjust governor as per gov. adj. spec.

D — 100 Above 80 (2.8) — Lever After setting excessive fuel for starting

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

A 9.8 (0.386) 600 58.9±1 (2.07±0.04) ±3.5 Lever Basic

BR1 [10.0 (0.394)]

1,500 80.6±1 (2.84±0.04) ±5 Lever

C Approx. 7.9 (0.311) 300 8.3±1.8 (0.29±0.06) ±10 Rack



EF-3-28

A, B, T, TA 173 kW 235 PS

RLD governorZEXEL No. 101607-9270

ZEXEL No. 101696-9410

ZEXEL No. 101607-9260

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

11.3 (0.445) 600 48.2±1.6 (1.70±0.06) ±3.5 Rack Basic

Approx. 9.8 (0.386) 300 9±1.8 (0.32±0.06) ±10 Rack


AR1 [11.3 (0.445)]

600 48.2±1 (1.70±0.04) — Lever

BR1 –0.2 (–0.008)

1,000 [62.0 - 65.2 (2.2 - 2.3)] — Lever

I — 100 80+10 (2.8+0.4) — Lever Rack limit

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

12.6 (0.496) 1,500 77.5±1.6 (2.73±0.06) ±3.5 Rack Basic

Approx. 9.7 (0.382) 300 9.5±1.8 (0.33±0.06) ±10 Rack


AR1 [12.6 (0.496)]

1,500 77.5±1 (2.73±0.04) — Lever Basic

BR1 –1.65

(–0.0650)600 [40 - 44 (1.4 - 1.55)] — Lever

I — 150 77.5+20 (2.73+0.7) — Lever Rack limit

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

11.8 (0.465) 600 66.3±1.6 (2.33±0.06) ±3.5 Rack Basic

H Approx. 9.5 (0.374) 300 9.5±1.8 (0.33±0.06) ±10 Rack

AR1 [11.8 (0.465)]

600 66.3±1 (2.33±0.04) — Lever Basic

BR1 –0.2 (–0.008)

900 [71.4 - 74.6 (2.51 - 2.63)] — Lever

CR1 [11.8 (0.465)]

1,500 [81.9 - 85.9 (2.88 - 3.02)] — Lever



EF-3-29

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9380

ZEXEL No. 101696-9370

ZEXEL No. 101696-9390

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

12.5 (0.492) 1,500 83.7±1.6 (2.95±0.06) ±3.5 Rack Basic

H Approx. 9.5 (0.374) 300 9.5±1.8 (0.33±0.06) ±10 Rack

AR1 [12.5 (0.492)]

1,500 83.7±1 (2.95±0.04) — Lever Basic

BR1 –0.55 (–0.0217)

900 68.7±2 (2.42±0.07) — Lever


Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

12.5 (0.492) 1,500 83.7±1.6 (2.95±0.06) ±3.5 Rack Basic

H Approx. 9.5 (0.374) 300 9.5±1.8 (0.33±0.06) ±10 Rack

AR1 [12.5 (0.492)]

1,500 83.7±1 (2.95±0.04) — Lever Basic Boost press. kPa mmHg, inHgAbove 23.3 175, 6.89

BR1 –0.55 (–0.0217)

900 68.7±2 (2.42±0.07) — Lever Boost press. kPa mmHg, inHgAbove 23.3 175, 6.89

I — 150 85+20 (3.0+0.7) — Lever Boost press.0 Rack limit

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

12.4 (0.488) 700 77.5±2 (2.73±0.07) ±3.5 Rack Basic

H Approx. 9.5 (0.374) 300 9.5±1.8 (0.33±0.06) ±10 Rack

AR1 [12.4 (0.488)]

700 77.5±1 (2.73±0.04) — Lever Basic Boost press. kPa mmHg, inHgAbove 24.0 180, 7.09

BR1 +0.15 (+0.0059)

1,400 [89.4 - 92.6 (3.15 - 3.26)] — Lever Boost press. kPa mmHg, inHg

Above 24.0 180, 7.09

CR2 [R1 –0.3

(–0.012)]550 [66.9 - 70.1 (2.35 -

2.47)] — Lever Boost press. kPa mmHg, inHgAbove 24.0 180, 7.09

DR2 –0.9 (–0.035)

550 [46.5 - 48.5 (1.64 - 1.71)] — Lever Boost press.

0



EF-3-30

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9200

ZEXEL No. 101696-9360

ZEXEL No. 101696-9210

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

12.4 (0.488) 700 77.5±2 (2.73±0.07) ±3.5 Rack Basic

H Approx. 9.5 (0.374) 300 9.5±1.8 (0.33±0.06) ±10 Rack

AR1 [12.4 (0.488)]


BR1 +0.15 (+0.0059)


Above 23.3 175, 6.89

CR2 [R1 –0.3

(–0.012)]550 [66.9 - 70.1 (2.35 -

2.47)] — Lever Boost press. kPa mmHg, inHgAbove 23.3 175, 6.89

DR2 –0.6 (–0.024)


0


Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

12.5 (0.492) 1,500 83.7±1.6 (2.95±0.06) ±3.5 Rack Basic

H Approx. 9.5 (0.374) 300 9.5±1.8 (0.33±0.06) ±10 Rack

AR1 [12.5 (0.492)]

1,500 83.7±1 (2.95±0.04) — LeverBasic

BR1 –0.55 (–0.0217)

900 68.7±2 (2.42±0.07) — Lever


Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

13.3 (0.524) 700 97.5±2 (3.43±0.07) ±3.5 Rack Basic

Approx. 10.1 (0.398) 275 10±1.8 (0.35±0.06) ±10 Rack

Adjust max. var. bet. cyl.at R 10.1 mm (0.398 in).Adjust governor as per gov. adj. spec.

AR1 [13.3 (0.524)]


BR1 +0.1 (+0.004)


Above 26.7 200, 7.87

CR1 –2.0 (–0.079)


0



EF-3-31

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9400

RFD governorZEXEL No. 101607-9361

ZEXEL No. 101607-9341

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

13.3 (0.524) 700 97.5±2 (3.43±0.07) ±3.5 Rack Basic

Approx. 10.1 (0.398) 275 10±1.8 (0.35±0.06) ±10 Rack


AR1 [13.3 (0.524)]


BR1 +0.1 (+0.004)


Above 26.7 200, 7.87

CR1 –2.0 (–0.079)


0


Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

A 8.1 (0.319) 600 42.2±1 (1.49±0.04) ±3.5 Lever BasicB 7.8 (0.307) 1,000 53.3±1 (1.88±0.04) ±10 Lever

Approx. 7.0 (0.276) 300 9±1.8 (0.32±0.06) ±10 Rack



Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

A 9.8 (0.386) 600 58.9±1 (2.07±0.04) ±3.5 Lever Basic

BR1 [10.0 (0.394)]

1,500 80.6±1 (2.84±0.04) ±5 Lever

C Approx. 7.9 (0.311) 300 8.3±1.8 (0.29±0.06) ±10 Rack



EF-3-32

A, B, T, TA 173 kW 235 PS

RLD governorZEXEL No. 101608-9030

ZEXEL No. 101697-9000

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

11.8 (0.465) 600 66.3±1.6 (2.33±0.06) ±3.5 Rack Basic

H Approx. 9.5 (0.374) 300 9.5±1.8 (0.33±0.06) ±10 Rack

AR1 [11.8 (0.465)]

600 66.3±1 (2.33±0.04) — LeverBasic

BR1 –0.2 (–0.008)

900 [73±1.6 (2.57±0.06)] — Lever

CR1 [11.8 (0.465)]

1,500 [83.9±2 (2.95±0.07)] — Lever


Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

12.4 (0.488) 700 86.4±2 (3.04±0.07) ±3.5 Rack Basic

H Approx. 9.5 (0.374) 300 9.5±1.8 (0.33±0.06) ±10 Rack

AR1 [12.4 (0.488)]


BR1 +0.15 (+0.0059)

1,400 [86.5±1.6 (3.04±0.06)] — Lever Boost press. kPa mmHg, inHg

Above 23.3 175, 6.89

CR2 [R1 –0.3

(–0.012)]550 [76±1.6 (2.68±0.06)] — Lever Boost press. kPa mmHg, inHg

Above 23.3 175, 6.89

DR2 –0.6 (–0.024)

550 [65±1 (2.29±0.04)] — Lever Boost press.0



EF-3-33

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9920

ZEXEL No. 101696-9751

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

13.6 (0.535) 700 92.5±2 (3.26±0.07) ±3.5 Rack Basic

H Approx. 9.7 (0.382) 275 17±1.8 (0.60±0.06) ±10 Rack

AR1 [13.6 (0.535)]

700 92.5±1 (3.26±0.04) — LeverBasic Boost press. kPa mmHg, inHg

Above 40.0 300, 11.81

B[R1 +0.3

(+0.0118 )]

1,400 [99.5±1.6 (3.50±0.06)] — Lever

Boost press. kPa mmHg, inHgAbove 40.0 300, 11.81

CR2 [R1 –0.2

(–0.008)]420 [80±1.6 (2.82±0.06)] — Lever


DR2 –1.8 (–0.071)

420 [46±1 (1.62±0.04)] — LeverBoost press.0


+0.05–0.15

+0.0020–0.0059

Adjusting point


Pump speed

rpm


1,000 strokes

Max. var. bet. cyl.

(%)Fixed Remarks

13.6 (0.535) 700 92.5±2 (3.26±0.07) ±3.5 Rack Basic

H Approx. 9.7 (0.382) 275 17±1.8 (0.60±0.06) ±10 Rack

AR1 [13.6 (0.535)]


B[R1 +0.3

(+0.0118 )]

1,400 [99.5±1.6 (3.50±0.06)] — Lever


CR2 [R1 –0.2

(–0.008)]420 [80±1.6 (2.82±0.06)] — Lever


DR2 –1.15 (–0.0453)

420 [56.5±1 (1.99±0.04)] — LeverBoost press.0


+0.05–0.15

+0.0020–0.0059


EF-3-34

A, B, T, TA 173 kW 235 PS

Injection quantity adjustment procedure1. Check the control rack “0” position.

2. Remove the control rack guide screw.3. Attach the lock screw instead of the control rack guide

screw (to secure the control rack) to the pump housing.

4. Set the pump speed, control rack position and plungerstrokes as specified in the service data.

5. Measure the fuel injection quantity for each cylinder.If the fuel injection quantity is not as specified, adjust as fol-lows.

(1) Loosen the control pinion clamp screw.

(2) Rotate the control sleeve clockwise or counterclockwiseusing an appropriate tool. The control sleeve is rotatedtoward the governor side to increase fuel injection quantity.


EF-3-35

A, B, T, TA 173 kW 235 PS

GOVERNOR ADJUSTMENTThis section is divided into 3 parts according to the governor type.Each part describes the general adjustment procedure first andthen each governor’s performance chart.

RAD typePreparations1. Mount the injection pump assembly securely on a pump test

stand. Then, attach the test nozzle and nozzle holderassembly, test lines and measuring device to measure con-trol rack travel, to the injection pump.

2. Remove the damper spring, cover, torque control springusing a socket wrench (157914-0500) and Idling spring.Loosen adjusting screw.

3. Fill governor chamber and camshaft chamber with injectionpump oil.Cam chamber: 15 milliliter (0.5 Imp fl oz) for every cylinderGovernor chamber: 200 milliliter (7.0 Imp fl oz)

4. Mount a measuring device (105782-6030) to measure theload control lever angle.

5. With injection pump “off”, ensure that control rack travelssmoothly by moving load control lever in both “fuel-increase” and “fuel-decrease” directions.


EF-3-36

A, B, T, TA 173 kW 235 PS

Setting the control rack zero point1. After fixing load control lever in the “idling” position, tempo-

rarily set speed adjusting screw so that governor begins tomove the control rack in the “fuel-decrease” direction atpump speed of 500 to 600 rpm.

2. Increase the pump speed so that the control rack travels tothe non-injection position.Then, press the control pinion with a screw driver until con-trol rack stops. Make this position the “zero” point of thecontrol rack, and set the measuring device pointer to corre-spond with “zero” of the scale.

NOTEThe operation of the stopping lever will not cause thecontrol rack to travel to “zero” point.

Flyweight lift and full load positionThe total lift of the flyweight is divided into two categories; one forhigh-speed control and the other for idling control. Firstly, adjust theflyweight lift for high-speed control.1. Fix the load control lever at “full” position (control rack posi-

tion “Rb”), and temporarily set speed setting screw so thatgovernor begins to move the control rack in the “fuel-decrease” direction at pump speed of 700 to 800 rpm.

2. While raising pump speed to “Na”, make adjustments bymeans of full-load stopper bolt so that control rack positioncorresponds with “Ra”.

NOTEThe control rack position “Ra” equals control rack posi-tion “Rb” minus the travel “L”.If “Ra” is below “zero”, set the control rack to the “Raplus 2.0 mm (0.079 in)” position.

3. Next, decrease pump speed to “Nb” and, by means ofstroke adjusting screw adjust flyweight lift for high-speedcontrol “L” (control rack position “Rb”).

NOTEIf the control rack is set to the “Ra plus 2.0 mm (0.079 in)”position in Step 2, set the stroke adjusting screw to the“Rb plus 2.0 mm (0.079 in)” position.


EF-3-37

A, B, T, TA 173 kW 235 PS

4. Readjust the full-load stopper bolt to the “full-load fuel injec-tion quantity” position according to the service data.

Idling1. Run injection pump at “Nc” (Nd plus 100 rpm) rpm.2. Make adjustments by means of idling adjusting screw, so

that control rack position corresponds with “Rc”.

3. Decrease pump speed so as to maintain “Ne” rpm.4. Incorporate idling spring assembly into tension lever. Screw

in the assembly until control rack position corresponds with“Rd”, and then lock it at this point, with a wrench (157916-2620).

NOTEAt this time, pump speed may sometimes drop.Ascertain that “Ne” rpm is maintained.


EF-3-38

A, B, T, TA 173 kW 235 PS

5. Make sure control rack position remains above “Re” evenwhen pump speed is decreased to 0 rpm.

6. Next, increase pump speed slowly and ensure that whencontrol rack reaches position “Rc” the corresponding speedis “Nd” rpm.

7. Measure the load control lever angle at the idling position.When load control lever is depressed toward the “full” posi-tion side, replace shifter shim with a thicker one.When load control lever is depressed toward the “idling”position side, replace shifter shim with a thinner one.

Damper spring1. Fix the load control lever at “idling” control position.2. Increase pump speed slowly from “idling” speed (Ne rpm) to

the speed where control rack position corresponds with Rfminus 0.2 mm (0.008 in), and maintain this speed.

3. Screw in damper spring until control rack position corre-sponds with Rf minus 0.1 mm (0.004 in) and lock the springat this point.

ZEF109A


EF-3-39

A, B, T, TA 173 kW 235 PS

Stopper boltIf idling performance is included in service data, as represented bydotted line, adjust stopper bolt setting.1. After setting damper spring when pump speed is decreased

to 0 rpm, control rack position moves to “Re”.

2. After loosening stopper bolt, move the load control leveruntil control rack position is “Rg” and set stopper bolt at thispoint.

High-speed control starting point and speed droopcheck1. Fix the load control lever at “full” position.2. Raise pump speed slowly to “Nh” rpm. Make adjustments to

setting screw so that control rack starts to travel from posi-tion “Rb”.

3. Ensure by raising pump speed that it remains below “Ni”rpm when control rack position reaches “Rh”.

NOTEWhen “Ni” rpm exceeds the standard value, the no-loadmaximum speed of the engine is also increased, which isdangerous. Recheck both “Rb”, (full-load rack position)and “Rf” –0.1 mm (0.004 in), (the set position of damperspring).

4. Further increase the pump speed to “Nj” rpm and ensurethe control rack is positioned at “Ri” mm (in).

Stopping lever1. Fix the load control lever at “full” position.2. Maintain the pump speed at approximately 800 rpm.3. Move the stopping lever to the “fuel-decrease” position and

ensure the control rack reaches the non-injection zone[injection quantity of less than 3 milliliter (0.11 Imp fl oz) per1,000 strokes].

4. Check that the control rack moves smoothly to the “full-load” position when releasing the stopping lever.


EF-3-40

A, B, T, TA 173 kW 235 PS

Smoke limiter1. Attach the measuring device (105782-6090) to the plunger

spring chamber.

2. Fix the load control lever at “full” position.3. Maintain the pump speed at “Nb” rpm.4. Fix the measuring device scale plate with the indicator at

control rack position “Rb” mm (in).

5. Remove the measuring device (105782-6280) attached tothe control rack tip and attach the smoke limiter.

6. Maintaining the pump speed at “Nk” rpm, adjust and set thecontrol rack in “Rj” mm position [normally “Rb” plus 0.2 mm(0.008 in) with the smoke limiter spring capsule].

7. Reduce the pump speed to 80 to 100 rpm, then check thatthe control rack position is “Rk”. Check the fuel injectionquantity for “engine start” at point E.


EF-3-41

A, B, T, TA 173 kW 235 PS

Governor adjustment diagram (“ZEXEL No.” is Inj. pump ass’y No.)


EF-3-42

A, B, T, TA 173 kW 235 PS

RLD typePreparationFollow the instructions below to prepare for adjustment.1. Secure the fuel injection pump on the pump test stand and

fill both the governor chamber and cam chamber with lubri-cating oil (injection pump oil 131453-0120 is recom-mended).

2. Mounting the adjusting device (105782-6170)1) Align the mark on the supporting bracket with the match-

ing mark on the scale plate, then tighten the locknut.NOTE

The angle scale plate has three matching marks; use anythat is convenient.

2) Move the supporting bracket to position pin A over thecenter hole of the control lever shaft and bolt the sup-porting bracket. Then, insert pin B into the rod connect-ing hole of the control lever.

Setting the control rack’s zero position1. Mount the control rack travel measuring device (105782-

6280) on the end of the control rack.2. Setting the control rack’s “0” position.

1) Screw in the governor shaft fully, and hold the controllever at the idling position.

2) Raise the pump speed gradually until it reaches point((06)), where the governor spring stops operating. Then,push the rack fully in the “fuel decrease” direction. Theposition where it stops moving is the control rack’s “0”position.

3) Set the indicator of the measuring device’s dial gauge to“0”.


EF-3-43

A, B, T, TA 173 kW 235 PS

NOTEThe control rack of the RLD type governor-mounted fuelinjection pump cannot be set at zero unless the pump isoperated at point (06). If the control rack is pushed to thenon-injection position while the injection pump is run-ning at less than point (06), the governor links may bedamaged.

Cautions on adjustment[Governor performance chart]


EF-3-44

A, B, T, TA 173 kW 235 PS

1. Locking the control rackAt this time it is necessary to fix the control rack. Normally,injection timing adjustment and fuel injection quantityadjustment are performed before governor adjustment.Fix the control rack according to the following procedure:Increase the pump speed to 500 to 600 rpm with the controllever held at the idling position, then shift the lever to themaximum-speed position. Next, set the control rack 3 mm(0.12 in) beyond the full-speed position using the full-loadsetting bolt. Various adjustments can now be made with thecontrol rack locked in the specified position.

2. Control lever operationBefore shifting the control lever to the maximum-speedposition, increase the pump speed to 500 to 600 rpm whilethe control lever is held at the idling position.

3. The performance of the governor depends on the enginespecifications.The performance chart given above is typical of this gover-nor.

Idling adjustment1. With the pump speed maintained at 80 to 100 rpm, tempo-

rarily set the control lever so that the control rack position isRs mm (in).

2. Maintain pump speed at Nb rpm and screw in the idlingspring assembly. When the rack position is Rb mm (in),tighten the locknut.

: 18 - 22 N·m1.8 - 2.2 kgf·m, 13 - 16 ft·lbf


EF-3-45

A, B, T, TA 173 kW 235 PS

3. Increase the pump speed until the control rack position is atRi mm (in) and then check that the pump speed is Ni rpm.

NOTEIf the pump speed Ni rpm is not as specified, adjust byaltering the shim thickness.

Adjusting shims

4. Adjustment of the governor springs1) Maintain pump speed at Nh1 rpm and adjust the amount

the governor shaft is screwed in so that the rack positionis Rh1 mm (in)].

2) Check that the control rack position is Rh2 mm (in) whenthe pump speed is Nh2 rpm. If it is not as specified,replace the governor springs with new ones.

NOTEThe adjustment sequence may be reversed. [Set to Rh2mm (in) at Nh2 rpm, check that speed is Nh1 rpm at Rh1mm (in)].

3) Further increase the pump speed until the control rackreaches position “0” mm (in), and ensure the pumpspeed is Ne rpm.

5. Idling adjustment1) Decrease the pump speed to Nb’ rpm and adjust the

idling setting bolt so that the control rack will be at posi-tion Rc mm (in). Then lock the nut.

Part No. Thickness mm (in) Remarks

029310-9240029310-9250029310-9260029310-9270

0.10 (0.0039)0.20 (0.0079)0.25 (0.0098)1.00 (0.0394)

ZEF119A


EF-3-46

A, B, T, TA 173 kW 235 PS

2) Further decrease the pump speed to 80 to 100 rpm, andensure the control rack is positioned at Ra mm (in).

3) Check that the control lever angle is as specified withthe adjusting device (105782-6170).

Full-load rack position adjustmentWhen adjusting the boost compensator-equipped governor, per-form the full-load rack position adjustment using the values for aboost-compensator equipped governor, as shown in the servicedata.1. With the pump speed maintained at Nf rpm, temporarily set

the control lever at the position where the lever contacts themaximum-speed setting bolt.

2. Adjust the maximum-speed setting bolt so that the controlrack begins moving toward the fuel decrease direction at apump speed of Ng rpm. Then, lock the maximum-speedsetting bolt with the nut.

3. Adjust the full-load setting bolt so that the control rack posi-tion is Rf mm (in) when the pump speed is Nf rpm.

NOTEWhen the full-load setting bolt is turned clockwise, thecontrol rack position value decreases.


EF-3-47

A, B, T, TA 173 kW 235 PS

4. Adjusting the torque cam1) Using wrench (157913-3620), adjust the adjusting nut

so that the control rack position is Rf4 mm (in) when thepump speed is Ni rpm. Lock the adjusting nut with a lockscrew.

NOTETorque cam adjustment can be performed at a pumpspeed of either Nk rpm or Ni rpm, whichever is conve-nient.

2) Decrease the pump speed to Nj minus approximately100 rpm, then increase it to Ng rpm to ensure that thetorque cam stroke is within the specified range. If thetorque cam stroke is not as specified, readjust the full-load setting bolt and torque cam. If this adjustment can-not be performed to obtain the specified control rackposition, replace the torque cam.

NOTEBefore installing a new torque cam, ensure the stampingmark is the same as the number given in the servicedata.

3) Next, increase the pump speed from Nj minus approxi-mately 100 rpm to Ng rpm, then ensure the pump speedis as specified for each control rack position. If the pumpspeed is not as specified, the torque cam has not beenadjusted properly. Readjust it. If the torque cam cannotbe adjusted to obtain the specified pump speed, replacethe torque cam.

5. Measure the fuel injection quantity at each of the adjustingpoints (as specified; that is, the fuel injection characteristicsfor full-load). If the fuel injection quantity is not as specified,adjust the full-load setting bolt and the torque cam adjustingnut carefully. Lock the nut and bolt after adjustments.

NOTEIf this adjustment is not executed properly, the specifiedfuel injection quantity cannot be obtained, there will bedecreased engine output and black smoke may be pro-duced.


EF-3-48

A, B, T, TA 173 kW 235 PS

Maximum-speed control adjustment1. Lock the control lever when it contacts the maximum-speed

setting bolt.2. With the pump speed maintained at Ng rpm, adjust the

maximum-speed setting bolt so that the control rack beginsmoving from Rf3 mm (in) in the fuel decrease direction.Then, lock the bolt with the nut.

3. Checking the speed droopGradually increase the pump speed and ensure the pumpspeed is Nh rpm when the control rack reaches Rg mm (in).

4. Increase the pump speed further to ensure the control rackreaches 0 mm (0 in).

5. Check that the control lever angle is as specified with theadjusting device (105782-6170).

Boost compensator adjustment (If so equipped)If the governor does not have a boost compensator, proceed to“confirmation of the excess fuel limit for engine starting”.1. Install the spacer (1A); refer to the illustration on page EF-3-

49 (EEF3-177) on the governor cover, and ensure thepushrod can move smoothly.


EF-3-49

A, B, T, TA 173 kW 235 PS

2. Checking pushrod protrusion1) Fix the control lever in the maximum-speed position.2) Operate the injection pump at the specified speed,

marked BASIC in the injection quantity table of the injec-tion pump calibration data (usually adjusting point A).

3) In this condition, use calipers to measure the protrusion(dimension L) of push rod B from the end face of thespacer. If dimension L is not within the specified range,replace pushrod B so that L is as specified.

Pushrod table

3. Install the boost compensator assembly, then attach thecompressed-air pipe.

4. Boost compensator stroke adjustment1) Confirm that the screw (62) position is the same as that

before disassembly.2) Remove the plug (46) and gasket (45).3) Maintain the pump speed at N1 rpm.4) Fully loosen the screw (55) with the wrench (157913-

3520), and then confirm that the control rack position R2mm (in) can be obtained.If the control rack position R2 mm (in) is not as specified,readjust the full-load setting bolt and torque cam.

Part No. Lengthmm (in) Part No. Length

mm (in) Remarks

159274-0120159274-0220159274-0320159274-0420159274-0520159274-0620159274-0720159274-0820159274-0920159274-1120159274-1220159274-1320159274-1420159274-1520

125.0 (4.92)127.5 (5.02)128.0 (5.04)127.0 (5.00)126.0 (4.96)129.0 (5.08)128.5 (5.06)125.5 (4.94)126.5 (4.98)119.5 (4.70)120.0 (4.72)120.5 (4.74)121.0 (4.76)121.5 (4.78)

159274-1620159274-1720159274-1820159274-1920159274-4220159274-4320159274-4420159274-4520159274-4620159274-4720159274-4820159274-4920159274-5020

122.0 (4.80)122.5 (4.82)123.0 (4.84)123.5 (4.86)129.5 (5.10)130.0 (5.12)130.5 (5.14)131.0 (5.16)131.5 (5.18)132.0 (5.20)132.5 (5.22)133.0 (5.24)133.5 (5.26)


EF-3-50

A, B, T, TA 173 kW 235 PS

5) Shift the control rack position from R2 mm (in) to R1 mm(in) using the screw (55), and then lock it with the nut(54).

NOTEDuring boost compensator stroke adjustment, it is notnecessary to supply compressed air.

5. Setting the boost compensator spring force1) With the pump speed maintained at N1 rpm, gradually

increase the boost pressure.2) Adjust the screw (62) so that the control rack begins

moving from R1 mm (in) in the fuel increase directionwhen the boost pressure reaches P1 kPa mmHg, inHg.Lock the screw with the nut (63).

3) Increase the boost pressure, and ensure it reaches P2kPa mmHg, inHg when the control rack is at R2 mm(in). If the boost pressure is not as specified, replace theboost compensator spring (16).

4) Recheck the boost compensator stroke, and if not asspecified, readjust the screw (55).


EF-3-51

A, B, T, TA 173 kW 235 PS

Confirming the excess fuel limit for engine starting1. With the pump speed maintained at Ns rpm, lock the control

lever when the control rack position is Rc mm (in) (point J).2. Ensure the control rack moves beyond Ra’ mm (in) when

the pump speed is reduced to 0 rpm.3. Maintaining a pump speed of less than N liter rpm, ensure

the control rack moves beyond Rs mm (in) when the controllever is shifted toward the maximum-speed position.

The above confirmation ensures that the sensor lever and torquecam are positioned as shown in the figure when the control rackmoves beyond Rs mm (in).NOTE

The control rack must not move to Rs mm (in) if thepump speed is decreased to N liter rpm with the controllever locked at the maximum-speed position.If control rack positions Ra’ Aa and Rs mm (in) are notindicated in the calibration data, confirmation of theexcess fuel limit is unnecessary.

Confirming the black smoke limit1. With the pump speed maintained above N liter (that is, Nb’)

rpm, fix the control lever at the idling position.2. Ensure the control rack does not move beyond Rf5 mm (in)

when the control lever is shifted toward the maximum-speed position.

3. Keep the control lever at the maximum-speed position andgradually increase the pump speed.

4. Confirm that the control rack begins moving from Rf5 mm(in) in the fuel decrease direction when the pump speedexceeds Nj rpm.

The above confirmation ensures that the sensor lever and torquecam are as shown in the figure when the control lever is shiftedtoward the maximum-speed position during engine operation.

Control rack limiter adjustmentScrew type1. Using the lock (157976-3100), lock the control rack at the

position given with the calibration data, maintaining thepump speed at 0 rpm.


EF-3-52

A, B, T, TA 173 kW 235 PS

2. Measure the depth “liter” of the rack cap.

3. Attach both the bolt and nut to the end of the control rack.4. Adjust the bolt so that the distance between the end face of

the pump housing and the bolt top is “liter”, that is, the rackcap depth. Tighten the nut to lock the bolt.

5. Install the rack cap.

Installation of plate plugsAfter adjusting the governor, check that there is no damage to theinside surfaces where the governor cover plates are press fitted. Inaddition, remove as much oil as possible from inside.

1) Push in new plate plugs with a finger, and drive themsecurely into place with the rods (157923-5800, -5900, -6000).

2) After press-fitting each plug, thoroughly coat the outsidesurface with adhesive (THREE BOND No. 1405D).


EF-3-53

A, B, T, TA 173 kW 235 PS

SealingAll adjusting stoppers (bolts, nuts) that directly affect engine perfor-mance are sealed after adjustment. Do not readjust any stopperwithout using the pump test stand or the engine test bench, as thiswill adversely effect the engine, which will then be unable to oper-ate at peak performance. In addition, the engine may overrun oroverheat, causing damage.

1 On full-load stopperSealing cap part No.: 154062-1900

Unit: mm (in)

2 On maximum-speed stopperSealing cap part No.: 154062-1700

Unit: mm (in)

Stopper bolt protrusion L1 = 21 - 24 (0.83 - 0.94)

Stopper bolt protrusion L2 = 29 - 36 (1.14 - 1.42)


EF-3-54

A, B, T, TA 173 kW 235 PS

Governor adjustment diagram (“ZEXEL No.” is Inj. pump ass’y No.)ZEXEL No. 101607-9270


EF-3-55

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9410


EF-3-56

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101607-9260


EF-3-57

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9380


EF-3-58

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9370


EF-3-59

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9390


EF-3-60

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9200


EF-3-61

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9360


EF-3-62

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9210


EF-3-63

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9400


EF-3-64

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101608-9030


EF-3-65

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101697-9000


EF-3-66

A, B, T, TA 173 kW 235 PS

Aneroid compensator kit adjustment1. Aneroid compensator adjustment (Before governor installa-

tion).Select a suitable push rod so that L is as follows:

10.5 - 11.5 mm (0.413 - 0.453 in)NOTE

As “L” cannot be measured after the spacer is installed,select the push rod 2 before installing the spacer.

2. Adjustment at governor installation.With the control lever at the full position and Np = 1,400rpm/min, screw in the aneroid compensator kit body so thatpush rod 1 contacts push rod 2 and the performance asshown is obtained.

NOTEAs there is some hysteresis, measure the injection quan-tity when the absolute pressure is decreasing.Screw the aneroid compensator into the spacer and con-firm that the performance is as shown (adjust the begin-ning of operation by adjusting the amount that theaneroid compensator is screwed in).

Rack variation characteristics when negative pressure is applied tothe inside of the case.


EF-3-67

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9920


EF-3-68

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101696-9751


EF-3-69

A, B, T, TA 173 kW 235 PS

RFD typePreparations1. Remove damper spring, cover, torque control springs and

idling spring, and loosen adjusting screws.2. Mount injection pump assembly securely on a pump test

stand. Then, attach the test nozzle and nozzle holderassembly, test lines and measuring device to measure con-trol rod travel, to injection pump.

3. Fill governor chamber and camshaft chamber with injectionpump oil.

4. Mount measuring device (105782-6030) to measure theangle of load control lever.

5. With injection pump off, assure by moving load control leverin the directions of both “increase fuel” and “decrease fuel”,that control rack travels smoothly.

Setting the control rack zero point1. After fixing load control lever in the idling position, tempo-

rarily set speed control lever so that governor begins tomove the control rack to the fuel decrease direction at pumpspeed of 500 to 600 rpm.


EF-3-70

A, B, T, TA 173 kW 235 PS

2. Increase pump speed so that control rack travels to thenon-injection position. Then, press with a screw driver thetip of control rack or control pinion until it stops. Make thisposition the “zero” point of control rack, and set the indicat-ing pointer of measuring device to correspond with “zero” ofscale.

NOTEThe operation of stopping lever will not cause controlrack to travel to “zero” point.

Torque control stroke1. Fix load control lever in the full load position.2. Temporarily hold speed control lever in position so that gov-

ernor begins to move the control rack to the fuel decreasedirection at pump speed of approximately 800 rpm.

3. Using a wrench (157913-3520) make adjustments bymeans of adjustment screws, while raising and loweringpump speed within the range of 500 to 600 rpm, so thatcontrol rack position corresponds with the specified value“liter”.

Flyweight lift and full load positionThe total lift of flyweight is divided into two categories: one for highspeed control and the other for idling control. Firstly, adjust the fly-weight lift for high speed control.1. Fix load control lever at full position (control rack position

“Rb”), and temporarily set speed control lever so that gover-nor begins to move the control rack to the fuel decreasedirection at pump speed to 700 to 800 rpm.


EF-3-71

A, B, T, TA 173 kW 235 PS

2. While raising pump speed to “Na”, make adjustments bymeans of full load stopper bolt so that control rack positioncorresponds with “Ra”.

NOTEThe control rack position “Ra” is the result of controlrack position “Rb” minus the travel “L”.If “Ra” is below “zero”, set the control rack to “Ra plus 2mm (0.08 in)” position.

3. Next, decrease pump speed to “Nb” and by means of strokeadjusting screw adjust flyweight lift for high speed control“L” (control position “Rb”).

NOTEIf the control rack is set to the “Ra” plus 2.0 mm (0.079in)” position in Step 2, set the stroke adjusting screw tothe “Rb plus 2.0 mm (0.079 in) position.


EF-3-72

A, B, T, TA 173 kW 235 PS

Idling1. Run injection pump at “Nc” (Nd + 100 rpm) rpm.2. Make adjustments by means of idling adjusting screw so

that control rack position corresponds with “Rc”.

3. Decrease pump speed so as to maintain “Ne” rpm.4. Incorporate idling spring assemblies into tension lever.

Screw in the assemblies until control rack position corre-sponds with “Rd”, and then lock them at this point using awrench (157916-2620).

NOTEAt this time, pump speed may sometimes drop. Ascertainthat the “Ne” rpm is maintained.

5. Make sure control rack position remains above “Re” evenwhen pump speed is brought down to 0 rpm.

6. Next, raise pump speed slowly and ensure that when con-trol rack reaches the position “Rc”, the corresponding speedis “Nd” rpm.

7. Measure the load control lever angle.When load control lever is depressed toward the “full” posi-tion, replace shifter shim with a thicker one.When load control lever is depressed toward the “idling”position side, replace shifter shim with a thinner one.

Damper spring1. Fix load control lever at “idling” control position.2. Raise pump speed slowly from “idling” speed (Ne rpm) to

the speed where control rack position corresponds with “Rf”minus 0.2 mm (0.008 in), and maintain this speed.


EF-3-73

A, B, T, TA 173 kW 235 PS

3. Screw in damper spring until control rack position corre-sponds with “Rf” minus 0.1 mm (0.004 in) and lock thespring at this point.

Stopper bolt1. After setting damper spring, when pump is brought to 0

rpm, control rack position moves to “Re”.

2. After loosening the stopper bolt, move the load control leveruntil control rack position is “Rg” and set stopper bolt at thispoint.

EEF3-222


EF-3-74

A, B, T, TA 173 kW 235 PS

High-speed control starting point and speed droopcheck1. Fix load control lever at “full” position.2. Raise pump speed slowly to “Nk” rpm. Make adjustments to

stopper bolt so that control rack starts to travel from theposition “Rb”.

3. Ensure by raising pump speed that it remains below “N liter”rpm when control rack position reaches “Ri”.

NOTEIf “N liter” rpm exceed the standard value, the no-loadmaximum speed of the engine is also increased, creatingdangerous conditions. Recheck both “Rb”, (full-loadrack position) and “Rf” 0.1 mm (0.004 in) (the set positionof damper spring).

4. Further increase the pump speed to Nm rpm and ensurethe control rack reaches in the non-injection zone [injectionquantities are less than 3 milliliter (0.11 Imp fl oz) per 1,000strokes].

Stopper boltWhen used as variable speed governor.1. After making adjustments as described in the figure, fix load

control lever at full-load position.2. Then, run the injection pump at speed “Ny” rpm which is

slightly higher than the idling speed.3. Return stopper bolt to the low-speed position side and lock

it with nut, at control rack position Rd mm (in).

Full-load fuel deliveryReadjust the full-load stopper bolt to the full-load fuel injectionquantity position according to the service data.


EF-3-75

A, B, T, TA 173 kW 235 PS

Smoke limiter1. Fix load control lever at full position.2. Maintain pump speed at “Nn” rpm.3. Screw in spring capsule or screw and lock it at point E,

where the specified fuel delivery may be obtained.


EF-3-76

A, B, T, TA 173 kW 235 PS



EF-3-77

A, B, T, TA 173 kW 235 PS

ZEXEL No. 101607-9341


EF-3-78

A, B, T, TA 173 kW 235 PS

TESTING TIMERIn general, measurement of the timer advance angle is performedon the pump tester after completing an adjustment of the injectiontiming, injection quantity and governor.

Timing Advance Specification

ZEXEL No. 101607-9351, 101607-9270, 101607-9361

ZEXEL No. 101607-9331, 101607-9260, 101607-9341,101608-9030

ZEXEL No. 101696-9410

ZEXEL No. 101696-9380, 101696-9370, 101696-9360

ZEXEL No. 101696-9390, 101696-9200, 101697-9000

ZEXEL No. 101696-9210, 101696-9400

ZEXEL No. 101696-9920, 101696-9751

Pump speed (rpm) (1,140) 1,500Advance angle (º) Start Finish 4.0±0.5

Pump speed (rpm) Below 850 800 1,500Advance angle (º) Start Below 0.5 Finish 4.0±0.5

Pump speed (rpm) Below 1,250 1,200 1,500Advance angle (º) Start Below 0.5 Finish 1.0±0.5


Pump speed (rpm) 1,400Advance angle (º) Finish 2.0±0.3




EF-3-79

A, B, T, TA 173 kW 235 PS

Measuring equipment handling precautions1. Be sure not to apply any large shock or vibration to the tim-

ing checker.2. Do not use the reflection plate excessively. Carefully store

the remaining plate to avoid discoloration.3. Never use the equipment in any location where inflammable

gases or any other explosive atmosphere may existbecause very high pulse voltages are generated in theequipment.

4. This equipment has a built-in DC high-tension circuit. Donot use the equipment at any location where it may get wet;otherwise, equipment may be damaged and electric shockto the human body may result.

5. The sensor generates an intense flash of light. Do not lookstraight at the light source of this equipment; otherwise,eyesight may be harmed.

6. The light source unit is separate from the power supply unitof this equipment. Before disconnecting or connecting thelamp cable, be sure to turn OFF the power switch to avoidelectrical shock.

7. This equipment uses high tension current. Be sure to con-nect the ground terminal of the equipment to the ground byusing a proper ground cable.

Installation1. Attach the coupling (105784-0510) to the injection pump

camshaft.NOTE

At this time, note that both the camshaft and couplingshaft unit key groove must face in the same direction.

2. Attach the timer to the coupling shaft unit and fix it firmly.3. Fix the timer to the test stand flywheel firmly. At this time,

make sure that there is no eccentricity in the center of therotating portion.

Reflection plate attaching position1. With attaching the reflection plate (157951-1100), avoid the

stamped portion and the caution plate on the timer causing.2. Cut the reflection plate to a 5 x 7 mm (0.20 x 0.28 in) size

each time the timer advance characteristics are checked.


EF-3-80

A, B, T, TA 173 kW 235 PS

Measuring equipment installation1. Securely fix the holder (157842-5220) to the groove in the

pump tester bed.2. Temporarily tighten the sensor (157830-3420) to the holder

with the sensor light source facing the timer.3. Connect the sensor cable to the INPUT terminal of the tim-

ing checker (157830-3320).4. Connect the lamp (157830-3520) cable to the LAMP termi-

nal of the checker.5. With the checker POWER switch set to OFF, connect the

power cable to a power outlet (AC 100V 50/60 Hz).6. The distance between the reflection plate and the sensor

must be 10 to 55 mm (0.39 to 2.17 in).

Operating procedure for timing check1. Run the injection pump at a low speed and change the

selector switch of the timing checker (157830-3320) fromthe OFF to ON position.

2. Direct the light from the sensor (157830-3420) to the reflec-tion plate (157951-1100) and be sure the angle scale grad-uation on the pump tester flywheel can be read by use ofthe lamp (157830-3520).

3. Set the pump at a speed approximately 100 rpm below thebeginning rpm of the timer advance. Move the dial plate anddetermine the zero point at any desired position whiledirecting the lamp light to the pump tester flywheel.

4. Increase the pump speed from low to high, and read thetimer advance angle at each representative rpm position.

5. Upon completing measurement, stop the rotation of theinjection pump after turning the timing selector switch to theOFF position.

ADJUSTMENT OF TIMING DEVICESUsing a timing checker, measure the advance angle characteristicsof the timer. The measurement should be taken both when pumpspeed increases and when it reduces. In any case, its performancemust satisfy the specified value. The governor control lever at thistime must be at full speed status, unless any special instruction isgiven.1. The figure shows the timer performance line. Ensure that

the specified advance angle characteristics can be obtainedas the pump speed is increased gradually, according to cal-ibration data of the injection pump (including timer).

2. If the specified characteristics cannot be satisfied, adjustthe thickness of the shim built into the spring end, orreplace the spring. (Refer to Section on Disassembly/Reas-sembly timer.) After reassembling, perform a verificationtest once again.

- MEMO -


EF-4-1

TA 157 KW 213 PS

= FE6TA [157 kW 213 PS] =INJECTION PUMP ASSEMBLY

For information on disassembly, inspection, reassembly, adjusting and testing of the injection pump,refer to the service manual published by Zexel Co.

CONSTRUCTION

INJECTION PUMP ASSEMBLYType I (for HONG KONG)


EF-4-2

TA 157 KW 213 PS

Type II (for NORWAY)


EF-4-3

TA 157 KW 213 PS

INJECTION PUMP PROPERType I (for HONG KONG)

NOTENumbers before part names do not indicate the disassembly sequence.

1. Sleeve 22. Nut 42. Roller2. Oil seal 23. Washer 43. Screw3. Bolt 24. Delivery valve holder 44. Gasket4. Cover 25. O-ring 45. Center bearing5. Pointer 26. Spring 46. Stud6. Socket head bolt 27. Valve assembly 47. Gasket7. Shim 28. O-ring 48. Nut8. O-ring 29. O-ring 49. Overflow valve9. Bearing 30. Stopper 50. Control rack

10. Camshaft 31. Plunger assembly 51. Pin11. Woodruff key 32. Control sleeve 52. Bushing12. Bushing 33. Spring seat 53. Bushing13. Socket head bolt 34. Plunger spring 54. Gasket14. Connector 35. Spring seat 55. Plug15. Bushing 36. Shim 56. Plug16. Bearing 37. Guide 57. Bearing17. Washer 38. Snap ring 58. Ring18. Control rod 39. Bushing 59. Shim19. Plug 40. Plug 60. Eye bolt20. Gasket 41. Pin 61. Eye bolt21. Stud


EF-4-4

TA 157 KW 213 PS

Type II (for NORWAY)


1. Sleeve 22. Nut 42. Roller2. Oil seal 23. Washer 43. Screw3. Bolt 24. Delivery valve holder 44. Gasket4. Cover 25. O-ring 45. Center bearing5. Pointer 26. Spring 46. Stud6. Socket head bolt 27. Valve assembly 47. Gasket7. Shim 28. O-ring 48. Nut8. O-ring 29. O-ring 49. Overflow valve9. Bearing 30. Stopper 50. Control rack

10. Camshaft 31. Plunger assembly 51. Pin11. Woodruff key 32. Control sleeve 52. Bushing12. Bushing 33. Spring seat 53. Bushing13. Socket head bolt 34. Plunger spring 54. Gasket14. Connector 35. Spring seat 55. Plug15. Bushing 36. Shim 56. Plug16. Bearing 37. Guide 57. Bearing17. Washer 38. Snap ring 58. Ring18. Control rod 39. Bushing 59. Shim19. Plug 40. Plug 60. Eye bolt20. Gasket 41. Pin 61. Eye bolt21. Stud


EF-4-5

TA 157 KW 213 PS

GOVERNOR


EF-4-6

TA 157 KW 213 PS


1. Nut 46. Sleeve 91. Nut2. Lever 47. Shim 92. Bolt3. Spring 48. Shifter 93. Cover cap4. Shim 49. Rack sensor assembly 94. Bolt5. O-ring 50. Snap ring 95. Nut6. Nut 51. Washer 96. Screw7. Spring washer 52. Shaft 97. Plug8. Lever 53. Spring 98. Bracket9. Washer 54. Washer 99. Bolt

10. Oil seal 55. Lever 100. Nut11. Bolt 56. Lever 101. Plug12. Gasket 57. Snap ring 102. Plug13. Governor housing 58. Lock screw 103. Governor cover14. Nut 59. Adjusting nut 104. Bolt15. Bolt 60. Guide lever 105. Spring16. Cover cap 61. Spring 106. Washer17. Shaft 62. Snap ring 107. Spring assembly18. Oil seal 63. Tension lever assembly 108. Screw19. Washer 64. Plug 109. Plug20. Shim 65. Snap ring 110. Tube21. Snap ring 66. Shaft 111. Spring22. Lever 67. Snap ring 112. Nut23. Snap ring 68. Pin 113. Spring washer24. Bolt 69. Rod 114. Disk25. Lever 70. Spring 115. Plate26. Plug 71. Spring 116. Bushing27. Nut 72. Spring 117. Nut28. Shaft 73. Nut 118. Spring29. Spring 74. Shifter 119. Diaphragm30. Woodruff key 75. Screw 120. Gasket31. Bolt 76. Snap ring 121. Screw32. Flyweight assembly 77. Snap ring 122. Cover33. Lever 78. Cam plate 123. Gasket34. Shaft 79. Snap ring 124. Eye bolt35. Spring seat 80. Snap ring 125. Bolt36. Governor spring 81. Plug 126. Spring washer37. Governor spring 82. Gasket 127. Bolt38. Spring seat 83. Gasket 128. Nut39. Plate 84. Bolt 129. Gasket40. Bolt 85. Lever 130. Cap nut41. Spring 86. Nut 131. Push rod42. Socket head bolt 87. Lever 132. Bolt43. Link 88. Oil seal 133. Guide plate44. Spring washer 89. Snap ring 134. Bolt45. Nut 90. Shim 135. Lever assembly


EF-4-7

TA 157 KW 213 PS

COUPLINGType I (for HONG KONG) and Type II (for NORWAY)


1. Bolt 9. Coupling 16. Nut2. Plate 10. Bolt 17. Washer3. Bolt 11. Bolt 18. Plate4. Nut 12. Plate 19. Bolt5. Lock washer 13. Bolt 20. Washer6. Coupling 14. Cross coupling7. Nut 15. Sensor 15 - 20. Type II only8. Washer


EF-4-8

TA 157 KW 213 PS

ACTUATOR HOUSING


1. Socket head bolt 8. Socket head bolt 15. Bolt2. Spring washer 9. Spring washer 16. Seal ring3. Harness clamp 10. Cover 17. Eye bolt4. Washer 11. Seal ring 18. Bolt5. Socket head bolt 12. Socket head bolt 19. Gasket6. Spring washer 13. Spring washer 20. Seal ring7. Washer 14. Washer 21. Housing


EF-4-9

TA 157 KW 213 PS

FEED PUMP


EF-4-10

TA 157 KW 213 PS


1. Plug 7. Check valve spring 12. Push rod2. Gasket 8. Check valve 13. Piston3. Check valve spring 9. Eye bolt 14. Piston spring4. Check valve 10. Eye bolt 15. Gasket5. Priming pump 11. Housing 16. Plug6. Gasket


EF-4-11

TA 157 KW 213 PS

REMOVAL1. Apply chocks to the front and rear wheels and tilt open the

cab.2. Turn the key switch OFF and disconnect the ground cable

from the battery.3. Remove the left side cover.4. Disconnect the fuel line.

Disconnect the fuel tube.Remove the fuel filter assembly and bracket as a unit.Disconnect the injection nozzle tube.

NOTEUse a container or a clean cloth to catch and wipe oil asrequired.

5. Disconnect the accelerator wire and auto-stop solenoidplate.


EF-4-12

TA 157 KW 213 PS

6. Disconnect the harness connector of engine speed sensor,rack sensor and pre-stroke sensor of MD-TICS.

7. Disconnect the inlet and outlet oil tubes from the injectionpump.

8. Remove the bolts which secure the coupling.

9. Remove the bolts which secure the injection pump.Remove the injection pump assembly from the stay.

FUEL FEED PUMP AND PRIMING PUMP

DISASSEMBLY1. Removing the push rod

Pull out the push rod.


EF-4-13

TA 157 KW 213 PS

2. Place the fuel feed pump in a vise, remove the plug, gasketand pull out the piston spring and piston.

3. Disassembling the priming pumpIt is recommended that the priming pump not be disassem-bled unless the rubber seat in the piston part of the pumphas become defective or the piston has seized or is rusty.Apply a wrench to the Hex section at the bottom of the cylin-der and remove the priming pump assembly.Remove the check valve spring and check valve.

INSPECTIONWash all disassembled parts in cleaning solvent. Carefully checkfor scratches, cracks or damage. Replace faulty parts as neces-sary.

Housing and push rod clearanceUnit: mm (in)

Housing and piston clearanceUnit: mm (in)

Gauze filterCheck the gauze filter for clogging.




EF-4-14

TA 157 KW 213 PS

REASSEMBLYBefore assembling the feed pump, replace old gaskets and O-ringswith new ones.1. Insert the piston, piston spring and gasket, and tighten the

plug.2. Install the discharge side check valve, check valve spring

and gasket, and tighten adapter and priming pump.3. Install the push rod in the housing. NOTE

Coat the threads of the plug with the adhesive agent.

SUPPLY PUMP TESTSuction test1. Attach a hose to the supply pump suction port and insert

the other end into a fuel oil container.NOTE

Ensure suction head of approx. 1 m (3 ft).

2. Operate the injection pump at 100 rpm.3. Fuel oil must be discharged in less than 40 seconds.Priming pump test1. Fully loosen the priming pump’s screw cap.2. Operate the priming pump using the screw cap, at 60 to 100

strokes per minute.3. Fuel oil must be discharged in less than 25 strokes.

Capacity test1. Place discharge hose in a measuring cylinder (157970-

0500).2. Operate the injection pump and check the supply rate,

referring to the following table:Pump speed Supply rate

100 rpm More than 60 m liter (2.1 Imp fl oz)/15 seconds500 rpm More than 340 m liter (12.0 Imp fl oz)/15 seconds1,000 rpm More than 405 m liter (14.3 Imp fl oz)/15 seconds1,500 rpm More than 430 m liter (15.1 Imp fl oz)/15 seconds


EF-4-15

TA 157 KW 213 PS

Feed pressure measurement1. Connect the hose (157984-8400) between the supply pump

discharge port and the pressure gauge.2. Operate the injection pump at 600 rpm.3. Ensure that the supply pump maintains a feed pressure of

333 to 412 kPa 3.4 to 4.2 kgf/cm2, 48 to 60 psi.

Air tightness test1. Plug the supply pump discharge port using the plug

(029111-4050).2. Apply 196 kPa 2 kgf/cm2, 28 psi air pressure to the suc-

tion port.3. Immerse the supply pump in a container of fuel oil, and

check for air leakage. There must be no air leakage.

INSTALLATION1. Install the injection pump assembly. (Refer to the “DR” sec-

tion for procedures.)

2. Connect the inlet and outlet oil tubes to the injection pump.

3. Connect the accelerator wire and auto-stop solenoid plate.For adjustment procedures, refer to the instructions underthe “ENGINE CONTROL SYSTEM” in this manual.


EF-4-16

TA 157 KW 213 PS

4. Connect the fuel system parts:Connect the injection nozzle tube.Install the fuel filter assembly.Connect the fuel tube.

5. Connect the harness connector of engine speed sensor,rack sensor and pre-stroke sensor of MD-TICS.

6. Bleed air from the fuel system. (Refer to the “MA” sectionfor procedures.)

FUEL INJECTION QUANTITY ADJUSTMENTTesting conditionsFailure of pump to deliver fuel evenly throws the engine out of balance so that roughness and loss of power isevident. In calibrating a pump, observe the following:

Injection quantity standards (“ZEXEL No.” is Inj. pump ass’y No.)RLD governor

ZEXEL No. 107692-0831

Item Test conditionNozzle & Nozzle holder assembly 105780-8250 (BOSCH Type No. 1 688 901 101)Pump rotation Clockwise (Viewed from driver side)Nozzle 105780-0120 (BOSCH Type No. 1 688 901 990)Nozzle holder 105780-2190

Nozzle opening pressure kPa kgf/cm2, psi 20,693 211, 3,000

Feed pump oil pressure kPa kgf/cm2, psi 157 1.6, 23

Injection pipe (OD x ID - L) mm (in) 8 x 2 - 600 (0.31 x 0.08 - 23.62)Test oil IS04113 or SAE standard test oil (SAE J967d)Test oil temperature ºC (ºF) 40 - 45 (104 - 113)Type of selector switch setting 11

Adjustingpoint

Rackpositionmm (in)

Pumpspeedrpm

Injection q’tym liter (lmp fl oz)

1,000 strokes

Max. var.bet. cyl.

(%)Fixed Remarks

A 13.8(0.543) 1,400 112±1 (3.94±0.04) — Lever Basic Boost press. kPa mmHg, inHg

Above 37.3 280, 11.02

B 12.1(0.476) 900 105±2 (3.70±0.07) — Lever Boost press. kPa mmHg, inHg

Above 37.3 280, 11.02

C 9.85(0.3878) 350 33±2 (1.16±0.07) — Lever Boost press.

0

IApprox.11.45

(0.4508)100 89 (3.1) — Lever Boost press.

0


EF-4-17

TA 157 KW 213 PS

ZEXEL No. 107692-0832 and 107692-0920

ZEXEL No. 107069-1220

Adjustingpoint

Rackpositionmm (in)

Pumpspeedrpm


1,000 strokes

Max. var.bet. cyl.

(%)Fixed Remarks

AR1 [13.8 (0.543)]

1,400 112±1 (3.94±0.04) — LeverBasic Boost press. kPa mmHg, inHg

Above 26.7 200, 7.87

BR1 -1.7 (0.067)

900 105±2 (3.70±0.07) — Lever Boost press. kPa mmHg, inHgAbove 26.7 200, 7.87

CR2 -0.6 (0.024)

350 25±2 (0.88±0.07) — Lever Boost press.0

IApprox.

R1 -2.0 (0.079)

100 90 (3.17) — Lever Boost press.0

Adjustingpoint

Rackpositionmm (in)

Pumpspeedrpm


1,000 strokes

Max. var.bet. cyl.

(%)Fixed Remarks


Above 24.0 180, 7.09


Above 24.0 180, 7.09


0

IApprox.11.45


0


EF-4-18

TA 157 KW 213 PS



EF-4-19

TA 157 KW 213 PS

ZEXEL No. 107692-0832 and 107692-0920


EF-4-20

TA 157 KW 213 PS

ZEXEL No. 107069-1220


EF-4-21

TA 157 KW 213 PS

Injection timingPre-stroke: No. 1 Plunger 5.6±0.03 mm (0.2205±0.0012 in)

NOTE1. Adjust using the shim (1).2. Adjust with the rack in the full-load position.

3. Adjust with the connector (2) contacting the stopper pin(3).

4. Plungers are numbered from the drive side.Injection order:

Tappet clearance:Manually rotate the camshaft 2 to 3 times and confirm that itrotates smoothly.

Pre-stroke actuator adjustmentPre-stroke Actuator type: RetardPower supply voltage: 24±0.5VAmbient temperature: 23±5°C (73±9°F)

ZEXEL No. 107692-0831

1—4, 1—2, 1—6, 1—3, 1—5,60º±15′ 120º±15′ 180º±15′ 240º±15′ 300º±15′

Pre-strokemm (in)

Pre-stroke sensorOutput Voltage

VRemarks

2.5±0.05(0.0984±0.0020) 2.83±0.01 Pre-stroke actuator adjustment

5.6±0.03(0.2205±0.0012)

V1=1.2±0.2 Confirmation

— Above 3.05 Confirmation (Pre-stroke actua-tor operating range)


EF-4-22

TA 157 KW 213 PS

ZEXEL No. 107692-0832, 107069-1220 and 107692-0920

NOTE1. Move the pre-stroke actuator fully counterclockwise

(viewed from the drive side), and temporarily secure it tothe actuator housing using the bolts.

: 1.0 - 1.5 N·m 0.10 - 0.15 kgf·m, 0.7 - 1.1 ft·lbf2. Move the pre-stroke actuator clockwise (viewed from the

drive side) to adjust it.3. After pre-stroke actuator adjustment, stamp both the pre-

stroke actuator and the housing with an aligning mark.

Injection quantity variation rate adjustmentNOTE

At adjustment

Pre-strokemm (in)

Pre-stroke sensorOutput Voltage

VRemarks

2.5±0.01 (0.0984±0.0004) 2.83±0.01 Pre-stroke actuator adjustment

5.6±0.01 (0.2205±0.0004) V1=1.2±0.2 Confirmation

— Above 3.05 Confirmation (Pre-stroke actua-tor operating range)

Item Pre-stroke

Adjustment point “—” 3.6±0.05 mm (0.1417±0.0020 in)(V = 2.25±0.01)

Adjustment point Z5.5±0.03 mm (0.2165±0.0012 in)

(V = [V1+0.05]±0.01)

Adjustingpoint

Rackpositionmm (in)

Pumpspeedrpm


1,000 strokes

Max. var.bet. cyl.

(%)Fixed Remarks

— 13.8(0.543) 1,400 112±2 (3.94±0.07) ±4 Rack Basic

ZApprox.

8.0(0.315)

465 10.6±1.8 (0.37±0.06) ±10 Rack Adjust injection q’ty at N=465.

Adjust governor as per gov. adj. spec.


EF-4-23

TA 157 KW 213 PS

Injection quantity adjustment (after governor adjustment)Adjustment the injection quantity at a pre-stroke of 3.6±0.05 mm (0.1417±0.0020 in) (pre-stroke sensor outputvoltage: 2.25±0.01V).

ZEXEL No. 107692-0831

ZEXEL No. 107692-0832 and 107692-0920

ZEXEL No. 107069-1220

Adjustingpoint

Rackpositionmm (in)

Pumpspeedrpm


1,000 strokes

Max. var.bet. cyl.

(%)Fixed Remarks


Above 24.0 180, 7.09


Above 24.0 180, 7.09

C 9.85(0.3878) 350 [6.9±2 (0.24±0.07)] — Lever Boost press.

0

IApprox.

11.45(0.4508)

100 [80 (2.8)] — Lever Boost press.0

Adjustingpoint

Rackpositionmm (in)

Pumpspeedrpm


1,000 strokes

Max. var.bet. cyl.

(%)Fixed Remarks

AR1 [13.8(0.543)]

1,400 112±1 (3.94±0.04) — LeverBasic Boost press. kPa mmHg, inHg

Above 26.7 200, 7.87

BR1 -1.7(0.067)

900 105±2 (3.70±0.07) — Lever Boost press. kPa mmHg, inHgAbove 26.7 200, 7.87

CR2 -0.6(0.024)

350 25±2 (0.88±0.07) — Lever Boost press.0

IApprox.R1 -2.0(0.079)

100 90 (3.17) — Lever Boost press.0

Adjustingpoint

Rackpositionmm (in)

Pumpspeedrpm


1,000 strokes

Max. var.bet. cyl.

(%)Fixed Remarks


Above 24.0 180, 7.09


Above 24.0 180, 7.09


0

IApprox.11.45


0


EF-4-24

TA 157 KW 213 PS

RACK SENSOR1. Do not operate the aneroid compensator if installed. Secure

the speed control lever in the full position and set the pumpspeed at 1,400 rpm.(If equipped with a boost compensator, first apply boostpressure.)

Adjust the rack sensor after determining VR from the control unitpart no.

2. Adjust the bobbin (1) so that the rack sensor’s output volt-age is VR±0.01.

3. After adjustment, mark the area where the joint (2) and thenut (3) contact and the area where the joint (2) and thepump housing contact with red paint.

Injection timing setting1. Turn the pre-stroke actuator OFF.2. Position the camshaft in the No. 1 plunger’s beginning of

injection position.

VR Control unit part No.

2V407912-1742105782-6320

3V

407910-2901407910-3032407910-6010407910-7210


EF-4-25

TA 157 KW 213 PS

3. Confirm that the injection pump pointer aligning mark andthe flywheel aligning mark are aligned.

4. If not aligned, remove the incorrect flywheel aligning mark,and remark the flywheel aligning mark.

5. Confirm that the center of the coupling key groove is asspecified.

Speed sensorZEXEL No. 107069-1220 and 107692-0920

Install the speed sensor so that the gap between the sensor andthe coupling (flywheel) projection is 0.8 to 1.0 mm (0.031 to 0.039in), and then secure it using the lock nut (i.e. the position when thespeed sensor is returned 1 revolution from the point where it con-tacts the coupling (flywheel) projection).

ZEXEL No. 107692-0831 and 107692-0832Install the speed sensor so that the gap between the sensor andthe drive gear (air compressor) projection is 0.7 to 1.3 mm (0.028 to0.051 in), and then secure it using the lock nut (i.e. the positionwhen the speed sensor is returned 1 revolution from the pointwhere it contacts the drive gear (air compressor) projection).

NOZZLE AND NOZZLE HOLDER

EF-5-1

NOZZLE AND NOZZLE HOLDER= CONVENTIONAL TYPE =CONSTRUCTION

REMOVAL1. Chock wheels and tilt open the cab.2. Turn the key switch OFF and disconnect the ground cable

from the battery.3. Disconnect the injection nozzle tube and spill tube, remove

the nozzle holder assembly from the cylinder head.

CONVENTIONAL TYPE


EF-5-2

DISASSEMBLY



Key point of disassembly1 Cap nut1. Clamp the nozzle holder into a vise with holder plate

(157944-9520).2. Set the nozzle holder in the plate and remove the cap nut.

Loosen the adjusting screw until the nozzle spring no longerhas tension on it.

3. Remove the adjusting screw and separate the nozzle springand push rod.

8 Retaining nut1. Reverse the nozzle holder position by facing the nozzle-

side up, and remove the retaining nut with a appropriatewrench.

2. Remove the nozzle from the nozzle holder. Do not drop thenozzle needle.

1. Cap nut 5. Push rod 9. Nozzle2. Gasket 6. Inlet connector 10. Pin3. Adjusting screw 7. Gasket 11. Nozzle holder4. Nozzle spring 8. Retaining nut

CONVENTIONAL TYPE


EF-5-3


NOTERemove carbon from around nozzle jets using a wirebrush.

1. Remove carbon from around nozzle jets using the pin vice(99727 Z5005).

Unit: mm (in)

NOTEDo not extend tip of the holder more than 2 to 2.5 mm(0.079 to 0.098 in). Otherwise, it may bend inside the noz-zle body so that it cannot be removed.Carefully push the holder into the inside of the nozzle toremove carbon.Use an oil stone to grind the wire tip of the holder until itis shaped as shown in the figure.

2. Clean remaining carbon off the back of the nozzle jet usingthe nozzle cleaner (99726 Z5000).

NOTEBe careful not to scratch the seating surface of the noz-zle jet and the nozzle needle.Do not use compressed air to remove carbon becausethis may introduce foreign matter into the jet.

3. Install the needle on the nozzle body while immersing bothin clean diesel fuel.

4. Visually check the needle valve seat, guide shaft and injec-tion shaft for damage or carbon accumulation.

5. Position the nozzle body vertically. Pull out the needle sothat it protrudes approximately 1/3 its total length beyondthe top of the nozzle body. Then release it to ensure that itdrops to the valve seat under its own weight.


Number of injec-tion nozzle holes


Z, D35

0.29 (0.0114) 0.26 (0.0102)D2, A5, A6 0.30 (0.0118) 0.29 (0.0114)C1, F4 0.245 (0.0096) 0.23 (0.0091)

CONVENTIONAL TYPE


EF-5-4

REASSEMBLYTo reassemble, reverse the order of the above removal proce-dures. Observe the following:NOTE

Clean the mating surfaces of the nozzle and nozzleholder and the retaining nut in clean diesel fuel beforeinstallation.Use new gaskets.

ADJUSTMENT1. Loosen the adjusting screw and install the nozzle on a noz-

zle tester (105785-0960). Operate the hand lever forcefullytwo or three times to remove foreign matter.

2. Adjust fuel valve opening pressure using the adjustingscrew.


WARNINGWARNINGBe extremely careful not to direct fuel spray to handwhile adjusting fuel injection. It may penetrate into bloodvein to the skin and cause toxic symptoms.

3. After adjusting injection pressure to specifications, installthe cap nut. Recheck injection pressure.Z, D2, D3, A5 and A6

: 39 - 49 N·m 4.0 - 5.0 kgf·m, 29 - 36 ft·lbfC1 and F4

: 29 - 39 N·m 3.0 - 4.0 kgf·m, 22 - 29 ft·lbf

4. While adjusting injection pressure, check the spray pattern.Also check for signs of fuel leakage or obstruction. Ifinspection reveals slight wear on the seating surfaces of thenozzle body and needle, lap both using lapping compound.If either part requires replacement, replace both parts as aunit.


Valve opening pressure(Regulated pressure)

Z, D2, A5, A6, C1, F4

20,104 - 20,595205 - 210, 2,915 - 2,986 —

D3, F4 22,066 - 22,556225 - 230, 3,200 - 3,271 —

1. Equal, symmetrical fuel spray pattern

4. Lean fuel spray pattern

2. Asymmetrical fuel spray pattern

5. Stepped fuel spray pat-tern

3. Incorrect fuel spray pat-tern

6. Equal fuel spray (from 5 jets)

CONVENTIONAL TYPE


EF-5-5

INSTALLATION1. Install the nozzle holder assembly on the cylinder head.

: 25 - 29 N·m 2.5 - 3.0 kgf·m, 18 - 22 ft·lbf2. Connect the spill tube and injection nozzle tube.3. Bleed air from the fuel system. (Refer to the “MA” section

for procedures.)4. Connect the ground cable to the battery.

CONVENTIONAL TYPE


EF-5-6

= TWO-SPRING TYPE =CONSTRUCTION

REMOVAL1. Chock wheels and tilt open the cab.2. Turn the key switch OFF and disconnect the ground cable

from the battery.3. Disconnect the injection nozzle tube and spill tube, remove

the nozzle holder assembly from the cylinder head.

TWO-SPRING TYPE


EF-5-7

DISASSEMBLY


Key point of disassemblyNozzle and nozzle holder assembly1. Secure nozzle in vice by holding nozzle holder portion with

nozzle holes facing down.2. Loosen cap nut and remove gasket.3. Loosen nut, and remove adjusting nut, and then take out

No. 2 spring, No. 2 push rod and pre-lift adjusting shim.4. Remove set screw, and take out spacer, valve opening

pressure adjusting shim, No. 1 spring and No. 1 push rod.5. Secure nozzle by holding nozzle holder in vice with nozzle

hole facing up, and loosen retaining nut, then remove noz-zle assembly and pin.

6. Remove nozzle needle from nozzle body.NOTE

Be sure to keep nozzle needle and nozzle body as amatched set.

1. Cap nut 8. Setscrew 13. Retaining nut2. Gasket 9. Spacer 14. Nozzle assembly3. Nut 10. Shim (for valve opening pressure 15. Pin4. Adjusting screw adjustment) 16. Connector5. No. 2 spring 11. No. 1 spring 17. Gasket6. No. 2 push rod 12. No. 1 push rod 18. Nozzle holder7. Shim (for pre-lift adjustment)

TWO-SPRING TYPE


EF-5-8


NOTERemove carbon from around injection hole using wirebrush.

1. Using pin vise (99727 Z5005), remove carbon from nozzlehole.

Unit: mm (in)

NOTEDo not extend tip of the holder more than 2 to 2.5 mm(0.079 to 0.098 in). Otherwise, it may bend inside the noz-zle body so that it cannot be removed.Carefully push the holder into the inside of the nozzle toremove carbon.Use an oil stone to grind the wire tip of the holder until itis shaped as shown in the figure.

2. Clean remaining carbon off the back of the nozzle jet usingthe nozzle cleaner (99726 Z5000).

NOTEBe careful not to scratch the seating surface of the noz-zle jet and the nozzle needle.Do not use compressed air to remove carbon becausethis may introduce foreign matter into the jet.

3. Install the needle on the nozzle body while immersing bothin clean diesel fuel.

4. Visually check the needle valve seat, guide shaft and injec-tion shaft for damage or carbon accumulation.

5. Position the nozzle body vertically. Pull out the needle sothat it protrudes approximately 1/3 its total length beyondthe top of the nozzle body. Then release it to ensure that itdrops to the valve seat under its own weight.


Number of injec-tion nozzle holes


A3 2 0.30 (0.0118) 0.29 (0.0114)

TWO-SPRING TYPE


EF-5-9

REASSEMBLYTo reassemble, reverse the sequence of disassembly, payingattention to the following points.NOTE

When assembling nozzle to nozzle holder, be sure toclean each contacting surface and retaining nut withclean light oil.Replace gasket with a new one each time nozzle is disas-sembled.

See section “Adjustment” when reassembling.Unit: N·m kgf·m, ft·lbf

ADJUSTMENT

OVERHAULING TYPEAdjusting nozzle opening pressure1. Using retaining nut (157892-2020), fix nozzle assembly on

nozzle holder.: 59 - 78 N·m 6.0 - 8.0 kgf·m, 43 - 58 ft·lbf

NOTETighten retaining nut after confirming that dowel pin isentered fully into nozzle.

2. Remove screw from end of retaining nut (157892-2020).

3. Install No. 1 push rod, No. 1 spring, opening pressureadjusting shim and spacer to nozzle holder, and tighten withset screw.

: 49 - 59 N·m 5.0 - 6.0 kgf·m, 36 - 43 ft·lbf

Item Tightening torqueCap nut 39 - 49 4.0 - 5.0, 29 - 36Retaining nut 59 - 78 6.0 - 8.0, 43 - 58Nut 20 - 25 2.0 - 2.5, 14 - 18Set screw 49 - 59 5.0 - 6.0, 36 - 43Inlet connector 59 - 69 6.0 - 7.0, 43 - 51

TWO-SPRING TYPE


EF-5-10

4. Using nozzle tester (105785-1010) [with 49,035 kPa 500kgf/cm2, 7,110 psi gauge], measure valve opening pres-sure (regulated pressure) of nozzle.


5. If the valve opening pressure is out of standard, changethickness of valve opening pressure adjusting shim so thatspecified pressure is obtained.

NOTEBefore installing a shim, be sure to measure its thick-ness with a micrometer.If necessary, use a set of two shims.Select proper shims, noting that a 0.02 mm (0.0008 in)thick shim changes the valve opening pressure by 235kPa 2.4 kgf/cm2, 34 psi.

Pre-lift adjustment1. Install a 60.5 mm (2.382 in) pin (157892-1100) to the dial

gauge (157954-3800) and connect it to the adjusting device(157892-0220).

2. Secure base (157892-1800) in vise, assemble No. 2 pushrod, and set adjusting device (157892-0220), then align dialgauge needle with “0”.

3. Assemble push rod into nozzle holder.NOTE

Do not assemble No. 2 spring and pre-lift adjusting shim.

Maintenance standard Service limit17,162 - 17,947

175 - 183, 2,489 - 2,602 —

Adjusting shimthickness

mm (in)

0.10 (0.0039), 0.20 (0.0079), 0.30 (0.0118),0.40 (0.0157), 0.50 (0.0197), 0.52 (0.0205),0.54 (0.0213), 0.56 (0.0220), 0.58 (0.0228),0.60 (0.0236), 0.70 (0.0276), 0.80 (0.0315),0.90 (0.0354), 1.00 (0.0394)

TWO-SPRING TYPE


EF-5-11

4. Fit adjusting device to nozzle holder set screw, secure withintermediate screw, and move dial gauge holder up anddown to check for smooth dial gauge movement.

5. Push down by holding dial gauge holder, and read dialgauge needle deflection (lift: h).

NOTERead dial gauge indication in units of 1/100 mm.

6. Select proper thickness of pre-lift adjusting shim.t = (l + h)

t: Thickness of shim (measured value)l: Pre-lift (standard value)h: Lift (measured value in step 5) above)

Thickness of shim to be selected must be T = t±0.015 mm.

7. Remove adjusting device from nozzle holder.

Adjustment of No. 2 spring1. Assemble No. 2 spring adjusting screw and nut on nozzle

holder.NOTE

Do not assemble pre-lift adjusting shim at this stage.Accordingly, No. 1 and No. 2 push rods are in contact.

2. Using nozzle tester, adjust No. 2 spring by turning adjustingscrew, and lock with nut.


Reconfirm the valve opening pressure after adjustment;it changes by securing with the lock nut.


NOTEPush rod contacting method means that the plug at thetip of the special tool’s retaining nut has been removed.

Adjusting shimthickness

mm (in)

0.10 (0.0039), 0.20 (0.0079), 0.30 (0.0118), 0.40 (0.0157),0.50 (0.0197), 0.52 (0.0205), 0.54 (0.0213), 0.56 (0.0220),0.58 (0.0228), 0.60 (0.0236), 0.70 (0.0276), 0.80 (0.0315),0.90 (0.0354), 1.00 (0.0394)

Item Maintenance standard Service limit RemarksValve opening pressure(Regulated pressure)

24,321 - 24,910248 - 254, 3,527 - 3,612 — Push rod con-

tacting method

TWO-SPRING TYPE


EF-5-12

Checking total lift of nozzle (needle valve)1. Install screw on retaining nut (157892-2020).2. Install connector (157892-1320) on nozzle holder set screw.

: 39 - 49 N·m 4.0 - 5.0 kgf·m, 29 - 36 ft·lbf

3. Install a 50.0 mm (1.969 in) pin (157892-1200) to the dialgauge (157954-3800) and connect it to the connector.

NOTESecure the dial gauge so that it can measure a stroke ofabout 1.2 mm (0.047 in).Be careful not to tighten the nut excessively as the dialgauge shaft may seize causing malfunction.

4. Set dial gauge to “0” point.5. Using nozzle tester, bleed air from retaining nut, and also

check for fuel leaks.6. Operate nozzle tester (105785-1010), pressurize up to

34,325 to 44,132 kPa 350 to 450 kgf/cm2, 4,977 to 6,399psi, and read total lift “L” of nozzle needle indicated on dialgauge.

NOTEDimension “L” indicated at this time is pre-lift plus pre-lift adjusting shim thickness.

7. Remove connector (with dial gauge) from nozzle holder.

Assembling pre-lift adjusting shim1. Remove set screw assembly (consisting of set screw,

adjusting screw and nut) and No. 2 push rod from nozzleholder.

NOTENever attempt to loosen nut, otherwise, No. 2 springadjusting pressure will change.

TWO-SPRING TYPE


EF-5-13

2. Insert pre-lift adjusting shim selected in step 6 (under “Pre-lift adjustment”) between spacer and No. 2 push rod, andassemble spacer and rod onto nozzle holder, and fit No. 2spring; then tighten with set screw assembly.


At this stage, No. 1 and No. 2 push rods are separated byspace equivalent to pre-lift.

3. Install connector (157892-1320) on nozzle holder set screw,install dial gauge, and set dial gauge needle to “0” point.

: 39 - 49 N·m 4.0 - 5.0 kgf·m, 29 - 36 ft·lbf4. Using nozzle tester, bleed air from within retaining nut.

5. Operate nozzle tester (105785-1010), pressurize up to34,325 to 44,132 kPa 350 to 450 kgf/cm2, 4,977 to 6,399psi, and read total lift “S” of nozzle needle on dial gauge.

NOTEDimension S is total lift of needle valve minus pre-lift.

Checking pre-lift1. Confirm amount of pre-lift from dimension L measured in

step 4 (under “Checking total lift of nozzle”) and dimensionS measured in step 5 (under “Assembling pre-lift adjustingshim”).

liter = L - S mm (in)liter: Pre-lift (measured value)

L: Total lift of needle valve (measured value)S: Needle valve lift after subtracting pre-lift (mea-

sured value)2. Confirm that dimension liter is within pre-lift range of

0.12±0.02 mm (0.0047±0.0008 in).3. If dimension liter is not within range of specified dimen-

sion 0.12±0.02 mm (0.0047±0.0008 in), replace pre-liftadjusting shim, and perform operations 4 and 5 (under“Assembling pre-lift adjusting shim”). Select thickness (t’) ofshim, proceeding as follows:t’ = t + (liter - liter)

t’: Shim thicknesst: Thickness of shim assembled.

T = t’±0.015T: Thickness of shim to be used

Checking No. 2 spring adjusting pressure1. After checking for pre-lift, pressurize up to 34,325 to 44,132

kPa 350 to 450 kgf/cm2, 4,977 to 6,399 psi to fully stroke(total lift) nozzle needle valve.

TWO-SPRING TYPE


EF-5-14

2. After needle valve is lifted up fully, release nozzle testerhandle to allow pipe pressure to lower spontaneously.When 0.05 mm (0.0020 in) drop in needle valve lift is indi-cated on dial gauge, read pressure on pressure gauge.


NOTENozzle cover method means that the special tool’s retain-ing nut and the plug at the tip are attached.

3. If No. 2 spring adjusting pressure is not within specifiedvalue, perform adjustment as explained in step Adjustmentof No. 2 spring “Push rod contacting method”, then checkNo. 2 spring adjusting pressure again.

4. Remove connector (157892-1320) together with dial gauge.Finish inspection1. Remove retaining nut (157892-2020), and install standard

retaining nut.: 59 - 78 N·m 6.0 - 8.0 kgf·m, 43 - 58 ft·lbf

NOTEBefore tightening retaining nut, confirm that dowel pin iscompletely fitted into nozzle.

2. Install cap nut.: 39 - 49 N·m 4.0 - 5.0 kgf·m, 29 - 36 ft·lbf

3. Install nozzle on nozzle tester (105785-1010), and checkinjection opening pressure.


NOTENever spray injected fuel on hand: otherwise, fuel sprayunder high pressure will penetrate deeply into the skin,causing blood poisoning.


23,046 - 23,537235 - 240, 3,342 - 3,413 — Nozzle cover

method

Item Maintenance standard Service limitInjection opening pressure(1st stage)

16,672 170, 2,417 —

TWO-SPRING TYPE


EF-5-15

4. Check spray pattern, injection holes for clogging, and for oiltightness. If nozzle body seat face and nozzle needle arescratched or worn by chips or carbon in fuel, repair by lap-ping with compound, provided damage is very small.If replacement is needed, be sure to replace nozzle needleand body as a matched set.

SIMPLIFIED INSPECTIONChecking injection beginning pressure and spray pat-tern1. Install nozzle on nozzle tester, and check injection opening

pressure.Unit: kPa kgf/cm2, psi

NOTENever spray injected fuel on hand: otherwise, fuel sprayunder high pressure will penetrate deeply into the skin,causing blood poisoning.

2. Check spray pattern, injection holes for clogging, and oiltightness.

3. If nozzle is found to be faulty, replace or overhaul nozzle,and perform adjustment according to step 1 above.

1. Even and symmetrical 4. Too thin2. Asymmetrical 5. Stepped3. Branching 6. Uniform injection from

five nozzle holes

Item Maintenance standard Service limitInjection opening pressure (1st stage) 16,672 170, 2,417 —

1. Even and symmetrical 4. Too thin2. Asymmetrical 5. Stepped3. Branching 6. Uniform injection from

five nozzle holes

TWO-SPRING TYPE


EF-5-16

Checking No. 2 spring adjusting pressure1. Remove retaining nut, and install retaining nut (157892-

2020) for adjustment.: 59 - 78 N·m 6.0 - 8.0 kgf·m, 43 - 58 ft·lbf

NOTEBe sure to tighten retaining nut after making sure thatdowel pin is fitted completely into nozzle.

2. Remove cap nut, and install connector (157892-1320)together with dial gauge. Use dial gauge pin of 50.0 mm(1.969 in) in length.

: 39 - 49 N·m 4.0 - 5.0 kgf·m, 29 - 36 ft·lbf3. Install nozzle holder on nozzle tester, and purge air from

inside of retaining nut, then raise pressure in pipe to 34,325to 44,132 kPa 350 to 450 kgf/cm2, 4,977 to 6,399 psi tomove nozzle needle valve to maximum lift position.

4. After moving needle valve to maximum lift position, leavenozzle tester handle as it is to allow pressure to lower. Aspressure drops, needle valve lift will decrease. Read pres-sure gauge indication when dial gauge indicates a needlevalve drop of 0.05 mm (0.0020 in).


5. If adjusting pressure of No. 2 spring is not within specifiedrange, perform adjustment according to step 1 above.

Finish inspectionCheck injection beginning pressure, spray condition and oil tight-ness according to steps 1 and 2 (under “Checking injection begin-ning pressure and spray pattern”).

INSTALLATION1. Install the nozzle holder assembly on the cylinder head.

: 25 - 29 N·m 2.5 - 3.0 kgf·m, 18 - 22 ft·lbf2. Connect the spill tube and injection nozzle tube.3. Bleed air from the fuel system. (Refer to the “MA” section

for procedures.)4. Connect the ground cable to the battery.


23,046 - 23,537235 - 240, 3,342 - 3,413 — Nozzle cover

method

TWO-SPRING TYPE

FUEL FILTER

EF-6-1

FUEL FILTERCONSTRUCTIONCartridge type

Center bolt type

FUEL FILTER

EF-6-2

Primary fuel filter<Type I>

<Type II>

FUEL FILTER

EF-6-3

Fuel strainer

REPLACING FUEL FILTER ELEMENTRefer to the “MA” section for replacement of the fuel filter.

Cartridge typeDisassembly sequence (Reassembly sequence is the reverseorder of disassembly.)

1. Cartridge assembly 2. Cover

FUEL FILTER

EF-6-4

Center bolt typeDisassembly sequence (Reassembly sequence is the reverseorder of disassembly.)

Primary fuel filter<Type I>Disassembly sequence (Reassembly sequence is the reverseorder of disassembly.)

1. Drain plug 6. Seat spring2. Packing 7. Retainer3. Center bolt 8. Element4. Packing 9. Packing5. Filter case 10. Filter cover

1. Plug 7. Set spring2. Packing 8. Retainer3. Drain cock 9. Element4. Center bolt 10. Packing5. Packing 11. Filter cover6. Filter case

FUEL FILTER

EF-6-5

<Type II>Disassembly sequence (Reassembly sequence is the reverseorder of disassembly.)

Fuel strainerDisassembly sequence (Reassembly sequence is the reverseorder of disassembly.)

1. Drain plug 7. Seat2. Packing 8. Element3. Center bolt 9. Packing4. Packing 10. Filter cover5. Filter case 11. Filter plug6. Spring 12. O-ring

1. Drain plug 6. Set spring2. Center bolt 7. Baffle3. Packing 8. Screen4. Strainer case 9. Packing5. Spring retainer 10. Strainer cover

ENGINE CONTROL SYSTEM

EF-7-1

ENGINE CONTROL SYSTEM= FE6A, FE6B, FE6T AND FE6TA [173 kW 235 PS] =CONSTRUCTION

ADJUSTMENT

ENGINE CONTROL WIRETurn the engine control knob fully counterclockwise and connectthe engine control wire to lever.Securely fit the clips (2 places on the wire end) in the bracket.

Dimension L: 78.0 - 80.0 mm (3.071 - 3.150 in)


EF-7-2

ACCELERATOR WIRE1. Connect one end of the accelerator wire to lever. Securely

fit the clip on the wire in the panel.NOTE

Be careful not to break the boot.

2. Connect the other end of the accelerator wire to the engineside. Check that the control lever of the injection pumptouches the stopper bolt and that there is no free play at thewire connection. Then, tighten the nut.

3. Depress the accelerator pedal until the control lever of theinjection pump contacts the stopper bolt. While holding thecontrol lever in that position, adjust the clearance betweenthe pedal and stopper to “H” and secure the stopper bolt.Clearance H: 0 - 4.0 mm (0 - 0.157 in)

ENGINE STOP LINKAGEManual stop typeConnect the engine stop wire on the fuel injection pump side. Theknob should be positioned at “load” position. Before securing thethreaded section of the wire, ensure that the adjusting section ofthe wire has no slack, and that dimension L is maintained.

Auto stop type1. Turn the ignition switch OFF and stop the motor.NOTE

Make sure the wire inner cable is retracted on the motorside.Stroke A: 35.0 mm (1.378 in)Set length B: 90.0 mm (3.543 in)

Item Dimension L mm (in)Except vacuum brake vehicle 118.0 (4.646)Vacuum brake vehicle only 128.0 (5.039)


EF-7-3

2. Connect the clevis of the cable tip to the stop lever of theinjection pump. Pull the stop lever to the stop position andtemporarily install the wire adjusting nut on the support.

3. Turn the wire adjusting nut in the wire tensioning direction,approximately one turn additionally from the condition underwhich there is no slack in the wire.


EF-7-4

= FE6TA [157 kW 213 PS] =CONSTRUCTION

ADJUSTMENT

ENGINE CONTROL WIRETurn the engine control knob fully counterclockwise and connectthe engine control wire to lever.Securely fit the clips (2 places on the wire end) in the bracket.

L length: 78.0 - 81.0 mm (3.071 - 3.189 in)


EF-7-5

ACCELERATOR WIRE1. Connect one end of the accelerator wire to lever. Securely

fit the clip on the wire in the panel.NOTE

Be careful not to break the boot.

2. Connect the other end of the accelerator wire to the engineside. Check that the control lever of the injection pumptouches the stopper bolt and that there is no free play at thewire connection. Then, tighten the nut.

3. Depress the accelerator pedal until the control lever of theinjection pump contacts the stopper bolt. While holding thecontrol lever in that position, adjust the clearance betweenthe pedal and stopper to “H” and secure the stopper bolt.Clearance H: 0 - 4.0 mm (0 - 0.157 in)


EF-7-6

ENGINE STOP LINKAGETo install and adjust the engine auto-stop system, proceed as fol-low:1. Temporarily install the solenoid assembly on bracket and

connect wiring.2. Install the rod between the stop lever on the injection pump

and on the solenoid on the injection pump side. Tighten thelock nuts.

3. Turn the key switch ON. Current flows so that the solenoidretracts.

NOTEEnsure that solenoid retracts completely.

4. Turn the swivel one more turn in the direction of the arrow,and move the stop lever approximately 3.0 mm (0.118 in)towards the stop side.

5. After stop lever adjustment, tighten the lock nut and sole-noid mounting bolts.

- MEMO -

“MD-TICS” SYSTEM

EF-8-1


CONTENTSSYSTEM OVERVIEW ................................................................................................. EF-8-2

SYSTEM DIAGRAM ............................................................................................................................. EF-8-2LOCATION OF EQUIPMENT .............................................................................................................. EF-8-4FUNCTION OF EQUIPMENT ............................................................................................................. EF-8-5

FUNCTION AND CONSTRUCTION .......................................................................... EF-8-7OUTLINE ............................................................................................................................................. EF-8-7FUEL INJECTION RATE CONTROL .................................................................................................. EF-8-8PRE-STROKE CONTROL MECHANISM ........................................................................................... EF-8-9FUEL INJECTION TIMING CONTROL ............................................................................................... EF-8-13SELF-DIAGNOSIS AND “BACK UP” FUNCTION ............................................................................... EF-8-14

Trouble Display and “Back-up” ....................................................................................................... EF-8-14Trouble Diagnosis .......................................................................................................................... EF-8-14

TROUBLE DIAGNOSIS AND TROUBLE-SHOOTING ............................................. EF-8-16[1] TROUBLE DISPLAY ...................................................................................................................... EF-8-17[2] TROUBLE DIAGNOSIS ................................................................................................................. EF-8-18[3] TROUBLE-SHOOTING .................................................................................................................. EF-8-21

(1) Checking Diagnosis Light System ............................................................................................ EF-8-29(2) Checking Control Unit Power Supply System .......................................................................... EF-8-33(3) Checking Rack Sensor System ................................................................................................ EF-8-36(4) Checking Engine Speed Sensor System ................................................................................. EF-8-43(5) Checking Engine Coolant Temperature Sensor System .......................................................... EF-8-49(6) Checking Pre-stroke Sensor System ....................................................................................... EF-8-54(7) Checking Pre-stroke Servo System ......................................................................................... EF-8-58(8) Checking Pre-stroke Power Supply System ............................................................................ EF-8-62

[4] CLEARING DIAGNOSTIC MEMORY ............................................................................................ EF-8-64

APPENDIX ................................................................................................................. EF-8-65Table 1 Failure Judgement Conditions For “MD-TICS” System .................................................... EF-8-65Table 2 “BACK-UP” Operations For “MD-TICS” System ............................................................... EF-8-66Terminal Connection Drawing ....................................................................................................... EF-8-67Wiring Diagram .............................................................................................................................. EF-8-70

NOTEThere are two types of “MD-TICS SYSTEM”; one is destined for HONG KONG and the other forNORWAY. On the following pages, “Type I” refers to HONG KONG specifications and “Type II”refers to NORWAY specifications.


EF-8-2

SYSTEM OVERVIEWThe “MD-TICS” system is a system that optimizes the fuel injection rate and fuel injection timing by using elec-tronic control.

The MD-TICS system consists of the control unit, the pre-stroke actuator that is actuated by the signal from thecontrol unit, the sensors (engine speed sensor, rack sensor, engine coolant temperature sensor, and pre-stroke sensor) that read the operating condition of the engine and give signals to the control unit, the switchesand lights, and the electrical wiring.This is an electronic control system in which the action of these units is used to compare the ideal values pro-grammed beforehand into the microcomputer (control unit) with the actual values. In this way, the injection tim-ing and fuel feed rate are controlled, the exhaust gas is cleaned, and the output is improved.

SYSTEM DIAGRAM<Type I>

MD - TICS

Code Timing & Injection rate Control System


EF-8-3

<Type II>


EF-8-4

LOCATION OF EQUIPMENT


EF-8-5

FUNCTION OF EQUIPMENTControl UnitMain function

Fuel injection rate controlFuel injection timing control

Supplementary functionSelf-diagnosis function“Back up” function

Pre-stroke Actuator/SensorThe pre-stroke actuator is installed at the front of the injectionpump. It consists of the pre-stroke sensor and pre-stroke servo thatis actuated by signals from the control unit.The pre-stroke sensor is inside the pre-stroke actuator. It comparesthe target position instructed from the pre-stroke control unit withthe actual position to detect if the position is correct, and feeds thisinformation back to the control unit.

Engine Speed Sensor<Type I>The engine speed sensor is installed to the gear case and detectsthe engine speed with a magnetic pick-up.The engine speed sensor detects the potential difference gener-ated when gear teeth traverse the tip of the engine speed sensorand sends the potential difference to the control unit (25 pulses byone rotation of the engine).

<Type II>The engine speed sensor is installed to the injection pump anddetects the engine speed with a magnetic pick-up.It detects the potential difference generated when the protrusions(12 places at equal distances) on the coupling (flywheel) of theinjection pump pass the tip of the engine speed sensor and sendsthis to the control unit.

Engine Coolant Temperature SensorThe engine coolant temperature sensor is a variable resistor (ther-mistor type) in which the resistor changes according to the changein the temperature of the engine cooling water. It reads the enginecoolant temperature as the change in the resistance, and inputs anelectrical signal to the control unit.The engine coolant temperature sensor is installed at the watermanifold.


EF-8-6

Rack SensorThe rack sensor is a non-contact displacement meter that acts tosend the movement of the control rack of the injection pump to thecontrol unit.The rack sensor sends out an alternating wave current (sine wave)from the OSC terminal (oscillation terminal) of the control unit. Itdetects the position of the rack from the MDL (middle) signal gener-ated by the change in the impedance (self-induction) between thetwo coils, and sends this to the control unit.

Diagnostic SwitchThe diagnostic switch is the switch used to carry out trouble-shoot-ing of the electronic control system.The diagnostic switch consists of one pair of male and female ter-minals. These are normally connected; they are disconnected onlywhen carrying out trouble-shooting.The diagnostic switch is installed behind the electrical unit boardand labeled with a “DIAGNOSIS” tag.

Memory Reset SwitchThis switch is used to delete the control unit trouble data from mem-ory. To delete the data, short circuit the connector terminals forabout ten seconds.The memory reset switch is installed behind the electrical unitboard and labeled with a “MEMORY” tag.


EF-8-7

FUNCTION AND CONSTRUCTIONOUTLINEThe “MD-TICS” system is a system that optimizes the fuel injection rate and fuel injection timing by using elec-tronic control.In more concrete terms, it controls the pre-stroke of the injection pump, and changes the injection timing andinjection rate.The concept of the pre-stroke control is shown in the diagram below.Pre-stroke Characteristic


EF-8-8

FUEL INJECTION RATE CONTROLWith the present type of injection pump, the pre-stroke is fixed.However, with the variable injection rate injection pump, the operat-ing condition of the engine and control condition of the driver aredetected by various sensors, and the information signal is pro-cessed by the control unit. Based on the control signal from thecontrol unit, the control sleeve installed in the fuel chamber of thebarrel portion is moved up and down by the pre-stroke actuator tochange the pre-stroke and control the fuel injection rate.NOTE

Hereafter in this text, from the point of explaining theaction with the operation diagrams, the expression “fuelinjection rate” is not used. The term “fuel feed rate” isused instead.

<Fuel Feed Rate (proportion of fuel supplied per unit oftime)>When supplying a fixed amount of fuel, if the feed timing is long, asmaller amount of fuel is supplied per unit time, and this gives a lowfuel feed rate. On the other hand, if the feed timing is short, a largeramount of fuel is supplied per unit time, and this gives a high fuelfeed rate.

<Pre-stroke>The amount of cam lift when the injection pump cam rotates andmoves from the plunger lift starting point a to the fuel feed startingpoint A is called the pre-stroke.


EF-8-9

PRE-STROKE CONTROL MECHANISM<Fuel Feed Mechanism>The operation of the fuel feed for the variable fuel feed rate injection pump is as follows.

1. Before fuel feedUntil the plunger rises and the suction port is blocked by the control sleeve, the fuel in the pressurechamber passes through the suction port and flows out to the fuel chamber. Therefore, the pressurein the pressure chamber does not rise.

2. Start of fuel feedWhen the plunger rises further and the suction port is blocked by the bottom end of the controlsleeve, the fuel feed operation starts.

3. During fuel feedWhile the suction port is between the bottom of the control sleeve and the spill port, the fuel contin-ues to be fed.

4. Completion of fuel feedWhen the suction port and the notched groove (lead) of the plunger are connected with the spill portof the control sleeve, the high pressure fuel in the pressure chamber is drained through the spill portto the fuel chamber, and this completes the fuel feed.


EF-8-10

<Relation between Fuel Feed Rate and Position of Control Sleeve>

Change in fuel feed rate for same fuel feed amountWhen the control sleeve is at the top, the pre-stroke is at its maximum, and as the plunger lift speed is fast, thefuel feed time can be made shorter. This means that the amount of fuel fed per unit time is larger and the fuelfeed rate is higher.On the other hand, when the control sleeve is at the bottom, the pre-stroke is at its minimum, and as theplunger lift speed is slow, the fuel feed time is longer. This means that the amount of fuel fed per unit time issmaller and the fuel feed rate is lower.Under normal operating conditions, for low speed, the control sleeve is at the top to give a high fuel feed rate,and at high speed, the control sleeve is moved to the bottom to prevent the fuel feed rate from becoming toohigh.

<Pre-stroke Control Mechanism>The pre-stroke control mechanism consists of the following.(1) The control sleeve that is moved up and down by the control rod

inside the barrel(2) The control rod that rotates and moves the control sleeve with a

pin(3) The rotary solenoid that rotates the control rod

(4) The pre-stroke sensor that always feeds back the movement ofthe rotary solenoid to the control unit

When the control sleeve goes up, the pre-stroke becomes larger,and when it goes down, the pre-stroke becomes smaller.


EF-8-11

<Pre-stroke Actuator>

The pre-stroke actuator has a shape that forms three sides of a square, and consists of an iron core with a coilwound around it. A rotor is placed between the jaws of the actuator, and a magnetic force proportional to thecontrol signal (current) from the control unit is generated by the rotary solenoid. The action of this magneticforce then causes the rotor to rotate. The control sleeve is interconnected, so it moves up or down.


EF-8-12

<Power Circuit>The power source for the pre-stroke actuator has a separate circuit. If there is any abnormality in the pre-strokeservo system, this circuit functions to stop the control, and at the same time it opens the pre-stroke cut relay tocut the power for the pre-stroke actuator.At the same time, the boost compensator cut 3-way magnetic valve is switched OFF, and the maximum injec-tion amount is limited to prevent any secondary damage being caused when the control of the injection pumpis stopped.


EF-8-13

<Pre-stroke Sensor>The pre-stroke sensor compares the target position sent from thecontrol unit and detects if the pre-stroke actuator is actually in thecorrect position.Like the rack sensor, it is a non-contact displacement meter, andsends out an alternating wave current (sine wave) from the OSCterminal (oscillation terminal) of the control unit. It detects the posi-tion of the pre-stroke actuator (control sleeve) from the MDL (mid-dle) signal generated by the change in the impedance (self-induction) between the two coils, and sends this to the control unit.The pre-stroke sensor harness is equipped with a shielding wire toprevent noise.The shielding wire acts to prevent the influence of any outside inter-ference, thereby protecting the signal detected by the sensor; italso acts to set the measurement standard. If there is improperconnection of the shielding wire (particularly at the connector), orthere is improper grounding of the control unit case, this may causedisconnections or resistance (increased or reduced) which willcause abnormalities in the pre-stroke control. To prevent this,please be sure to carry out the grounding connection of the controlunit and the pre-stroke sensor wiring harness properly.

FUEL INJECTION TIMING CONTROLThe timing for the start of fuel injection from the variable fuel feed rate injection pump is interconnected with thecontrol of the pre-stroke.If the fuel feed rate is made high, the pre-stroke will become larger, so this well result in retarding the timing forthe start of fuel injection; if the fuel feed rate is made low, the pre-stroke will become smaller, so this will resultin advancing the timing for the start of fuel injection.Under actual operating conditions, the fuel feed rate is set high when the engine is rotating at low speed, suchas during warming-up operations, and is set low when the engine is rotating at high speed. Therefore, the tim-ing for the start of fuel injection is also delayed when the engine speed is low and is advanced when the enginespeed is high, which is more or less the same action as with the present timer. In addition, when the weather iscold, to prevent white smoke, control is carried out by the control unit in accordance with the operating condi-tion of the engine to give the optimum fuel feed rate and timing for the start of injection.


EF-8-14

SELF-DIAGNOSIS AND “BACK-UP” FUNCTIONThe control unit always uses the signals input from each sensor todiagnose whether there is any abnormality inside the system. If itjudges that there is an abnormality, it lights up the Engine Controlwarning light inside the cluster meter to warn the drive of the abnor-mality.At the same time, it carries out a back-up function to move the sys-tem to a safe zone where there is no excessive load on the engine.By using the diagnostic switch, the Diagnosis Display Code is dis-played on the diagnosis light (Engine Control warning light andOverheat warning light), and trouble-shooting is carries out.

Trouble display and “back-up”If a failure occurs in the MD-TICS system (refer to Table 1 “FailureJudgement Conditions” at the end of the chapter), the Engine Con-trol warning light comes on and displays the occurrence of a failure.[User mode]At the same time, the back-up system is actuated to keep the sys-tem in the safety zone so that there is no excessive load on theengine, while making it possible to continue to travel. Table 2 at theend of the chapter gives details of the back-up operation.

Trouble diagnosisTrouble diagnosis can be carried out by releasing the diagnosticswitch. The results of the diagnosis are displayed by the diagnosislight (Engine Control warning light and Overheat warning light)(flashing light: Diagnosis Display Code). [Dealer mode]When the Overheat warning light flashes, the buzzer also sounds atthe same time.


EF-8-15

Engine Control warning light: displays present trouble

Overheat warning light: displays the past trouble (*)

NOTE (*)To carry out analysis of past troubles, the system isequipped with a diagnostic memory function. This func-tion stores in the memory any failure signals for abnor-mality that occurred during travel. It acts to replay thesesignals when carrying out analysis of the trouble.The signals stored in the memory are retained even whenthe ignition key switch is turned OFF.Normally, the Overheat warning light lights up when theengine overheats or when the coolant level becomes toolow. However, when the diagnostic switch is released, itdisplays the result of the diagnosis of past troubles inthe MD-TICS system.The overheat warning function is not incorporated in thecontrol unit.


EF-8-16

TROUBLE DIAGNOSIS AND TROUBLE-SHOOTINGThe “MD-TICS” system always uses the signals input from each sensor to diagnose whether there is anyabnormality inside the system.If it judges that there is an abnormality (for judgement standards, refer to Table 1 at the end of the chapter), itlights up the Engine Control warning light inside the cluster meter to warn the driver of the abnormality. Theabnormality is displayed by the lighting up of the Engine Control warning light in the cluster meter. If any abnor-mality occurs, the back-up function is automatically carried out to move the system to a safe zone where thereis no excessive load on the engine. (For details of the back-up operation, refer to Table 2 at the end of thechapter.)When the Engine Control warning light lights up to display an abnormality, carry out trouble diagnosis and trou-ble-shooting using the procedure given below.


EF-8-17

[1] TROUBLE DISPLAYIf it is judged that there is an abnormality in the MD-TICS system,the Engine Control warning light comes on to display trouble.NOTE

This is called the “User mode”. The user mode is dis-played when the diagnostics switch is ON (connected).

<Trouble Display Chart>Item

MD-TICSIgnition key switch “ON”

RemarksEngine stopped Engine running

Normal Light “ON” Light “OFF” Lights come ON to check for blown bulbs

AbnormalLight “ON” Light “ON” Abnormality in MD-TICSLight “OFF” Light “OFF” Light bulb blown or other abnormality


EF-8-18

[2] TROUBLE DIAGNOSISIf the trouble display shows that there is an abnormality in the MD-TICS system, carry out trouble diagnosisaccording to the following procedure.1) TURN THE DIAGNOSTIC SWITCH OFF.2) IGNITION KEY SWITCH

1. OFF → ON: Do not run the engine.2. After cranking, stop the engine.

With the ignition key switch ON.3. Run the engine.Carry out diagnosis under the above three conditions.

NOTEThe reason for using these three positions of the ignition key switch is to allow diagnosis to becarries out under all three conditions so that all troubles can be located.Refer to Diagnosis Display Code and Trouble Location table.

3) DISPLAY OF RESULT OF TROUBLE DIAGNOSISThe result of the trouble diagnosis is displayed by the flashing (Diagnosis Display Code) of the diag-nosis light (Engine Control warning light and Overheat warning light)

NOTEThis is called the “Dealer mode”. The dealer mode is displayed when the diagnostic switch isOFF (released).

<Diagnosis Light Display>

NOTE (*)The diagnostic memory of the control unit has a memory that stores the past trouble condi-tions, and displays them. When the diagnostic switch is released, it does not show the engineoverheating condition; instead of this, it displays the results of diagnosis of past troubles.If the trouble that occurred in the past is the same as the trouble that is occurring at thepresent, only the present condition (Engine Control warning light) is displayed.

Diagnosis light

MD-TICSEngine control warning light Overheat warning light & buzzer

Displays present trouble Displays past trouble (*)

Normal Displays Diagnosis Display Code <0-1> Key ON: Light ON, Buzzer shows <0-1> codeEng. ON: Light & Buzzer show Diagnosis Code

Abnormal Displays Diagnosis Display Code Displays Diagnosis Display Code


EF-8-19

<Diagnosis Display Code and Location of Trouble>

Note (*)“O”: Displayed“X”: Not displayed

User mode[MD-TICS normal or

abnormal]

Dealer mode

Loca

tion

of tr

oubl

e (tr

oubl

e-sh

ootin

g ite

m n

umbe

r)

Diagnosis light(Engine control warning light

Overheat warning light)

Position of igni-tion key switch (*)

OFF

→ O

N

ON

(a

fter c

rank

ing,

sto

p en

gine

)

ON

(e

ngin

e ru

nnin

g)

Diagnosis display code Lighting pattern

Normal 0 — 1 O O O — —

Abnormal

OFF OFF — — — Light bulb blown, etc. (1)

ON

ON — — — C.U. power supply system (2)

1 — 3 X O O Rack sensor system (3)

1 — 5 O O O Engine speed sensor sys-tem (disconnection)

(4)

1 — 6 X O X Engine speed sensor sys-tem (no pulse)

2 — 1 O O O Engine coolant tempera-ture sensor system (5)

2 — 3 O O O Pre-stroke sensor system (6)

1 — 2 O O O Pre-stroke servo system (7)

2 — 2 O O O Pre-stroke power supply system (8)

2 — 4 O X X Pre-stroke learning func-tion (6)


EF-8-20

<Explanation of Diagnosis Display Code>Meaning of Diagnosis Display Code

Actual Display Method for Diagnosis Display CodeThe diagnosis light displays the diagnosis continuously as follows.

Example: Compound trouble (1-2 and 1-3 occur together)After displaying 1-2 three times, 1-3 is displayed three times. After this, 1-2 and 1-3 are displayedthree times each in turn.


EF-8-21

[3] TROUBLE-SHOOTINGIf the trouble diagnosis makes the condition of the trouble clear, go on to trouble-shooting.The explanation below gives the procedure for trouble-shooting for each trouble location (this forms a pair withthe diagnosis display code).

[Precautions when carrying out trouble-shooting](1) Precautions when checking the wiring harness

There is a high probability that problems with the wiring harnesses, such as disconnections, short cir-cuits, and improper contact, will occur at the connector. It is rare for disconnections or short circuits tooccur in the wiring inside the wiring harness, but these problems can occur if there is interferencebetween the wiring harness and other parts, causing it to ground with the body. When checking forabnormalities in the wiring harness, be particularly careful to check the following.1) Is the connector properly connected?2) Are any pins deformed?3) Is there any dirt or dust stuck in the terminal, or is there

any corrosion?4) Is there any disconnection or short circuit at the joint of

the connector.5) Has the grounding been carries out properly?6) Is there any interference between the wiring harness

and other parts, or any improper insulation?

(2) Precautions when measuring resistance at connector andchecking continuity1) When checking the resistance at the connector terminal

and checking the continuity, the terminal hole is small,so strip the lead wire, insert two or three copper wires,and make sure that the terminal and lead wire are prop-erly in contact. (For female terminals)

2) Do not insert the test lead of the tester directly into theconnector terminal. If it is pushed in by force, the termi-nal inside the connector will be expanded and this willcause improper contact.

3) After completing this operation, check the connection ofthe connectors. Be particularly careful with the Z con-nectors for the engine because these can easily remainincompletely connected.


EF-8-22

[Preparation]Parts name and parts number Use Shape

Memory clear connector(24004 00Z09)

To clear diagnostic memory

Circuit tester(Commercially available; use tester with digital display)

Inspecting MD-TICS component and circuit

Lead wire x 2 (make yourself) Connecting tester lead


EF-8-23

[How to read wiring diagram]<Connector No. and terminal No.>

<Abbreviation>C.U. : Control UnitU : Unit HarnessCF : Cab Front HarnessM : Main HarnessC : Chassis Harness


EF-8-24

<Connector symbol>

All connector symbols are shown from the terminal side.The number inside the box shows the number of the pins.

<Connector joint indication>For single lines, a connector is indicated in the midway of the line.For plural lines, a connector and connector terminal position areshown in the midway of the lines. In this vicinity, connector shapesare shown and terminal positions are indicated by numbers.


EF-8-25

<How to match connectors>

<Wire size and color code>Wire size: sectional area (mm2)

Color code:Unicolor

When the wire color is striped, the base color is given first, followed by the stripe color as shown below:Example: L/W = Blue with White Stripe

Alphabetical symbol ColorW WhiteB BlackR RedY YellowG GreenL BlueP Pink

BR BrownLG Light greenOR OrangePU PurpleGR GraySB Sky Blue


EF-8-26

[Position of harnesses and connectors]

A. Under the passenger seatPull out the control unit from under the front passenger seat.

Locations for inspection1. Control unit proper2. Unit harness connector U-12 (18 pin, black)3. Unit harness connector U-13 (12 pin, black)


EF-8-27

B. Inside of glove compartmentRemove the lid and front cover of the glove compartment.Locations for inspection1. Fuse block

C. Under the cabTilt the cab and remove the cover.Locations for inspection<Type I>1. Unit harness connector U-4 (6, 12 pin)2. Unit harness connector U-5 (5, 12 pin)3. Unit harness connector U-1 (4, 16 pin)4. Chassis harness connector C-3 (6, 12 pin)5. Chassis harness connector C-4 (5, 12 pin)6. Cab front harness connector CF-18 (4, 16 pin)<Type II>1. Unit harness connector U-18 (6, 12 pin)2. Unit harness connector U-17 (5, 8 pin)3. Unit harness connector U-16 (4, 12 pin)4. Chassis harness connector C-82 (6, 12 pin)5. Chassis harness connector C-81 (5, 8 pin)6. Cab front harness connector CF-23 (4, 12 pin)

D. Front of engineLocation for inspection1. Engine coolant temperature sensor harness connector C-

27 (2 pin)NOTE

There are two engine coolant temperature sensors of thesame type beside each other.The one for the MD-TICS is distinguished by the wiring atthe engine harness end (blue/red, blue/black).


EF-8-28

2. Pre-stroke actuator harness connector C-85 (8 pin)3. Rack sensor harness connector C-24 (4 pin)4. Engine speed sensor harness connector C-22 (3 pin)

E. Inside of electric unit boardLocations for inspection1. Rack sensor harness connector M-83 (2 pin)

[Service data]Item Terminals to measure Maintenance standard

Control unit power voltage V U-12 (3) - (12) U-12 20 - 28

Rack sensor resistance ΩC-24 (3) - (2) C-24C-24 (2) - (1) C-24C-24 (3) - (1) C-24

92.5 - 101.592.5 - 101.5

186

Pre-stroke sensor resistance ΩC-85 (2) - (5) C-85C-85 (2) - (4) C-85C-85 (5) - (4) C-85

5 - 75 - 7

10 - 14

Pre-stroke actuatorResistance Ω C-85 (7) - (6) C-85 2.5 - 2.9Power source voltage V U-12 (2) - Body ground 20 - 28

Engine speed sensor

Type IGap from protrusion mm (in) 0.7 - 1.3 (0.028 - 0.051)Resistance Ω C-22 (2) - (1) C-22 867 - 1,073

Type IIGap from protrusion mm (in) 0.8 - 1.0 (0.031 - 0.039)Resistance Ω C-22 (3) - (2) C-22 2.1 - 2.5

Engine coolant temperature sensor resistance Ω C-27 (1) - (2) C-27

Refer to EF-8-51.[Engine coolant temperature

and resistance of engine coolant temperature sensor]

Alignment of lines (B.T.D.C.) 3ºRack sensor output voltage (Rack out voltage)— when idling (630 - 670 rpm) — V M-83 (2) - (1) M-83 MTM 1.77


EF-8-29

(1) Checking Diagnosis Light System (light do not light up)

CHECK (1) Check fuses1. Check if the other lights on the cluster meter light up.2. Judgement

If it lights up → fuse is normal → go to CHECK (2).If it does not light up → replace fuse

CHECKFUSE

1

Stays OFF

CHECKCheck continuity between ter-minal (12) and body ground

3OK

CHECKLIGHT

2

CHECKCheck continuity between ter-

minal (4) - light - fuse4

NG

Repair or replace wiring har-ness for light system, or replace blown light bulb

Carry out troubleshooting using the diagnostic light, and check that there is no abnormality

OK

NG

OK

NG

NG

Replace fuse Replace C.U. Repair or replace C.U. GND line harness

OK


EF-8-30

CHECK (2) Check lights1. Turn the ignition key switch OFF, then remove control unit

harness connector U-12.2. Turn the ignition switch ON, then use the lead wire to

ground terminal (4) of connector U-12, and check if the lightlights up.

3. JudgementIf it lights up → lamp is normal → go to CHECK (3).If it does not light up → go to CHECK (4).

CHECK (3) Check continuity between control unit andbody ground1. Check the continuity between the body and terminal (12) of

control unit harness U-12.2. Judgement

Continuity → abnormality in control unit → replace con-trol unitNo continuity → abnormality in harness → repair orreplace harness


EF-8-31

CHECK (4) Check continuity between control unit —light — fuse <Type I>

1. Check the continuity between the fuse (monitor panel 10A) and terminal (4) of control unit harnessconnector U-12.

2. JudgementContinuity → check again from CHECK (2).No continuity → light bulb blown or disconnection in harness → replace light, or repair or replaceharness

NOTEAfter completing each operation, carry out trouble-shooting with the diagnostic light and con-firm that there is no abnormality.


EF-8-32

CHECK (4) Check continuity between control unit —lamp — fuse <Type II>

1. Check the continuity between the fuse (monitor panel 10A) and terminal (4) of control unit harnessconnector U-12.

2. JudgementContinuity → check again from CHECK (2).No continuity → lamp bulb blown or disconnection in harness → replace lamp, or repair or replaceharness

NOTEAfter completing each operation, carry out trouble-shooting with the diagnostic lamp and con-firm that there is no abnormality.


EF-8-33

(2) Checking Control Unit Power Supply System (lights do not go out)

Lights stay lighted up

C.U. abnormal, replace

CHECKFUSE

1

NG

CHECKCheck power circuit

3

Replace fuse.Locate cause of blown fuse

CHECKDoes light go

out?2


Repair or replace harness for diag-nostic light system

Repair or replace unit harness

CHECKCheck power circuit (+end)

4

CHECKCheck continuity of unit harness

2

OKNG

NG

NO

YES

NG

OK

OK

OK


EF-8-34

CHECK (1) Check fuse1. Check that the fuse for the control unit power is not blown.

When doing this, measure the voltage at the fuse also.Voltage values Unit: V

2. JudgementFuse is blown → replace fuse (voltage is normal)

Fuse is normal → go to CHECK (2).Voltage is not as specified → disconnection in harnessbetween battery and fuse, abnormality in battery →repair harness or inspect battery

CHECK (2) Check that lights go out1. Remove connector U-12 from control unit.2. Turn the ignition key switch ON.3. Judgement

Lamp stays ON → abnormality in wiring harness ofdiagnostic light system → repair or replace harnessLamp goes out → go to CHECK (3).

CHECK (3) Check power circuit1. Turn the ignition key switch ON.2. Measure voltage between terminal (3) (+end) and terminal

(12) (–end) of control unit harness connector U-12.Values for voltage of control unit power Unit: V

3. JudgementVoltage normal → replace control unitVoltage abnormal → go to CHECK (4).

Place of measurement Standard valueFuse for control unit power 20 - 28

Measurement location Standard valueConnector U-12, (3) (+end) - (12) (–end) 20 - 28


EF-8-35

CHECK (4) Check power circuit (+end)1. Turn the ignition key switch ON.2. Measure voltage between terminal (3) (+end) of control unit

harness connector U-12 and body ground (–end).Voltage of control unit power Unit: V

3. JudgementVoltage normal → go to CHECK (5)Voltage abnormal → harness abnormal → repair orreplace

CHECK (5) Check continuity of unit harness1. Check the continuity between the body and terminal (12) of

control unit harness connector U-12.2. Judgement

Continuity → check again from CHECK (3).No continuity→ harness abnormal → repair of replace

NOTEAfter completing each operation, carry out trouble-shoot-ing with the diagnostic light and confirm that there is noabnormality.

Measurement location Standard valueConnector U-12, (3) (+end) - body (–end) 20 - 28


EF-8-36

(3) Checking Rack Sensor System

CHECKCheck harness of C.U. portion

1

DIAGNOSIS DISPLAY CODE1 - 3


Repair or replace harnessC.U. abnormal, replace Replace injection pump

CHECKCheck resistance of rack sensor

3

CHECKCheck rack sensor output voltage

2

CHECKCheck each harness

4

NG

NG

OK

OK

NG

OK

OK

NG

or


EF-8-37

CHECK (1) Check harness at control unit end1. Turn the ignition key switch OFF.2. Measure the resistance between terminals (22) and (21),

(21) and (27), (22) and (27) of connector U-13.3. Check the insulation of each terminal and the rack sensor

body.Resistance and insulation of rack sensor Unit: Ω

4. JudgementResistance value normal → rack sensor harness nor-mal → go to CHECK (2).Resistance value abnormal → check resistance of racksensor body → go to CHECK (3).

CHECK (2) Check output voltage of rack sensor1. Start the engine and run the engine at idling speed.2. Measure the voltage between terminal (2) (–end) and termi-

nal (1) (+end) of rack out connector M-83 inside the controlunit cover.

Rack out voltage (when idling) Unit: V

3. JudgementOutput voltage normal → rack sensor position normal→ carry out CHECK (1) again or replace C.U.Output voltage abnormal → replace injection pumpassembly

Measurement location Standard value

Connector U-13

(22) - (21) 92.5 - 101.5(21) - (27) 92.5 - 101.5(22) - (27) 186

(21), (22), (27) Injection pump body Min. MΩ

Measurement location Standard reference value

Connector M-83, (2) (–end) - (1) (+end) MTM 1.77(630 - 670 rpm)


EF-8-38

CHECK (3) Check rack sensor body1. Measure the resistance between terminals (3) and (2), (2)

and (1), (3) and (1) of connector C-24.2. Check the insulation of each terminal and the rack sensor

body.Resistance and insulation of rack sensor Unit: Ω

3. JudgementResistance value is as specified → go to CHECK (4).Disconnection, short circuit, or resistance value is notas specified → rack sensor abnormal → replace injec-tion pump


Connector C-24

(3) - (2) 92.5 - 101.5(2) - (1) 92.5 - 101.5(3) - (1) 186

(2), (3), (1) - Injection pump body Min. MΩ


EF-8-39

CHECK (4) Check harness <Type I>

1. Turn the ignition key switch OFF.2. Refer to the table below and check for continuity, short circuit, and insulation between harness con-

nector C-24 of the rack sensor and harness connector U-13 of the control unit.Harness Chassis harness Unit harness

Connector No. C-24 C-3 U-4 U-13

Terminal

Check 1 (1) (6) (6) (27)Check 2 (2) (5) (5) (21)Check 3 (3) (4) (4) (22)Check 4 Shield (7) (7) (27)


EF-8-40

3. JudgementIf the harness is abnormal (disconnection, short circuit,etc.) → repair or replace the harnessIf the harness is not abnormal → improper output volt-age of rack sensor or abnormality in control unit →contact ZEXEL sales for repair

NOTEIf there is no abnormality in the harness or resistancevalue of the rack sensor, the rack sensor output voltagemay be defective or the may be an abnormality in thecontrol unit. However, the set condition cannot be re-enacted when the equipment is mounted on the machine,so it is difficult to check.After completing each operation, carry out trouble-shoot-ing with the diagnostic light and confirm that there is noabnormality.


EF-8-41

CHECK (4) Check harness <Type II>

1. Turn the ignition key switch OFF.2. Refer to the table below and check for continuity, short circuit, and insulation between harness con-

nector C-24 of the rack sensor and harness connector U-13 of the control unit.Harness Chassis harness Unit harness

Connector No. C-24 C-82 U-18 U-13

Terminal

Check 1 (1) (6) (6) (27)Check 2 (2) (5) (5) (21)Check 3 (3) (4) (4) (22)Check 4 Shield (7) (7) (27)


EF-8-42

3. JudgementIf the harness is abnormal (disconnection, short circuit,etc.) → repair or replace the harnessIf the harness is not abnormal → improper output volt-age of rack sensor or abnormality in control unit →contact ZEXEL sales for repair

NOTEIf there is no abnormality in the harness or resistancevalue of the rack sensor, the rack sensor output voltagemay be defective or the may be an abnormality in thecontrol unit. However, the set condition cannot be re-enacted when the equipment is mounted on the machine,so it is difficult to check.After completing each operation, carry out trouble-shoot-ing with the diagnostic lamp and confirm that there is noabnormality.


EF-8-43

(4) Checking Engine Speed Sensor System

ReferenceIf the Diagnosis Display Code is 1-5, it can be taken that there is a disconnection, and if it is 1-6, the prob-lem is something other than disconnection (short circuit, improper adjustment of gap, etc.).

DIAGNOSIS DISPLAY CODE1 - 5, 1 - 6


Replace C.U.

NG

NG

OK

OK

NG

OK

OK

NG

or

Adjust gapReplace engine speed sensor Repair or replace harness

CHECKCheck harness of C.U.

portion1

CHECKCheck engine speed sensor

gap4

CHECKCheck resistance of engine

speed sensor body2


3


EF-8-44

CHECK (1) Check harness at control unit end1. Turn the ignition key switch OFF and remove connector U-

12.2. Measure the resistance between terminal (9) and terminal

(18) of unit harness connector U-12.

3. Check the insulation between terminal (9) of connector U-12 and the body.

4. Check the insulation between terminal (18) of connector U-12 and the body.

Resistance of engine speed sensor Unit: kΩ

5. JudgementResistance value is as specified → sensor normal →go to CHECK (4).Disconnection, short circuit, defective insulation, orresistance value is not as specified → go to CHECK(2).

CHECK (2) Check engine speed sensor body <Type I>1. Measure the resistance between terminal (1) and terminal

(2) of harness connector C-22 of engine speed sensor.2. Check the insulation between the body and terminals (3),

(2), and (1) of connector C-22.Resistance of engine speed sensor Unit: Ω


Connector U-12(9) - (18) 2.1 - 2.5(9) - Body

∝(18) - Body


Connector C-22

(2) - (1) 867 - 1,073(3) - Body

∝(2) - Body(1) - Body


EF-8-45

3. JudgementResistance value is as specified → sensor normal →go to CHECK (3).Disconnection, short circuit, defective insulation, orresistance value is not as specified → replace sensor→ go to CHECK (4).

CHECK (2) Check engine speed sensor body <Type II>1. Measure the resistance between terminal (3) and terminal

(2) of harness connector C-22 of engine speed sensor.2. Check the insulation between the body and terminals (3),

(2), and (1) of connector C-22.Resistance of engine speed sensor Unit: kΩ

3. JudgementResistance value is as specified → sensor normal →go to CHECK (3).Disconnection, short circuit, defective insulation, orresistance value is not as specified → replace sensor→ go to CHECK (4).


Connector C-22

(3) - (2) 2.1 - 2.5(3) - Body

∝(2) - Body(1) - Body


EF-8-46

CHECK (3) Check for abnormality in harness <Type I>

1. Refer to the table below and check for continuity, short circuit, and insulation between harness con-nector C-22 of the engine speed sensor and harness connector U-12of the control unit.

2. JudgementIf the harness is abnormal (disconnection, short circuit, etc.) → repair or replace the harnessIf the harness is not abnormal → abnormality in control unit → replace control unit

Harness Chassis harness Unit harnessConnector No. C-22 C-3 U-4 U-12

TerminalCheck 1 (2) (2) (2) (18)Check 2 (3) (1) (1) (9)Check 3 (1) (3) (3) (18)


EF-8-47

CHECK (3) Check for abnormality in harness <Type II>

1. Refer to the table below and check for continuity, short circuit, and insulation between harness con-nector C-22 of the engine speed sensor and harness connector U-12of the control unit.

JudgementIf the harness is abnormal (disconnection, short circuit, etc.) → repair or replace the harnessIf the harness is not abnormal → abnormality in control unit → replace control unit


TerminalCheck 1 (2) (2) (2) (18)Check 2 (3) (1) (1) (9)Check 3 (1) (3) (3) (18)


EF-8-48

CHECK (4) Check engine speed sensor gap <Type I>1. Check the gap between the engine speed sensor and the

drive gear (Air compressor).Standard value for engine speed sensor gap Unit: mm (in)

2. JudgementGap normal → check again from CHECK (1), orreplace C.U.Gap defective → adjust as follows

1) Align the centers of the engine speed sensor and theprotrusions on the drive gear (Air compressor).

2) Set so that the end face of the sensor contacts the pro-trusions, then turn back one turn and lock with the lock-nut.

NOTEAfter completing each operation, carry out trouble-shoot-ing with the diagnostic light and confirm that there is noabnormality.

CHECK (4) Check engine speed sensor gap <Type II>1. Check the gap between the engine speed sensor and the

protrusions on the coupling (flywheel) of the injection pump.Standard value for engine speed sensor gap Unit: mm (in)

2. JudgementGap normal → check again from CHECK (1), orreplace C.U.Gap defective → adjust as follows

1) Align the centers of the engine speed sensor and theprotrusions on the coupling (flywheel) of the injectionpump.

2) Set so that the end face of the sensor contacts the pro-trusions, then turn back one turn and lock with the lock-nut.

NOTEAfter completing each operation, carry out trouble-shoot-ing with the diagnostic lamp and confirm that there is noabnormality.

0.7 - 1.3 (0.028 - 0.051)

0.8 - 1.0 (0.031 - 0.039)


EF-8-49

(5) Checking Engine Coolant Temperature Sensor System

CHECKCheck harness at C.U. portion

1



Repair or replace harnessReplace C.U.Replace engine coolant tem-perature sensor


3

NG

OK

OK

NG

OK

NG

or

CHECKCheck engine coolant tempera-

ture sensor2


EF-8-50

CHECK (1) Check harness between engine coolanttemperature sensors at control unit1. Turn the ignition key switch ON.2. Remove control unit harness connectors U-12 and U-13.3. Measure the resistance between terminal (14) of connector

U-12 and terminal (19) of connector U-13.

4. Check for insulation and short circuit between the body andterminal (14) of connector U-12 and terminal (19) of con-nector U-13.

Resistance of engine coolant temperature sensor

5. JudgementResistance corresponds to engine coolant temperature→ sensor normalDisconnection, short circuit, or defective insulation, orresistance does not correspond to engine coolant tem-perature → go to CHECK (2).

Sensor resistance (x102Ω) ∝ 454 270 55

Engine coolant temperature ºC (ºF)

Sensor error

–40 (–40)

–39 (–38) –1 (30)

24 12 6 3.2 1.8 0.9 0

20 (68) 40 (104) 62 (144) 86 (187) 111(232)

130(266)

Sensor error


EF-8-51

CHECK (2) Check engine coolant temperature sensorbody1. Measure the resistance between terminals (1) and (2) of

engine coolant temperature sensor harness connector C-27.For details of the resistance value of the engine coolanttemperature sensor, see the table for CHECK (1).

2. JudgementResistance corresponds to engine coolant temperature→ engine coolant temperature sensor normal → go toCHECK (3).Disconnection, short circuit, or defective insulation, orresistance does not correspond to engine coolant tem-perature → engine coolant temperature sensor abnor-mal → replace engine coolant temperature sensor


EF-8-52


1. Check for continuity, short circuit, and insulation between control unit harness connectors U-12 andU-13 and harness connector C-27 of the engine coolant temperature sensor.

2. JudgementIf harness is abnormal (disconnection, short circuit) → repair or replace harnessIf there is no abnormality in the harness → carry out CHECK (1) again → if it is normal, the con-trol unit is abnormal → replace unit


Harness Chassis harness Unit harnessConnector No. C-27 C-4 U-5 U-13 U-12

TerminalCheck 1 (1) (5) (5) (14)Check 2 (2) (4) (4) (19)


EF-8-53


1. Check for continuity, short circuit, and insulation between control unit harness connectors U-12 andU-13 and harness connector C-27 of the engine coolant temperature sensor.

2. JudgementIf harness is abnormal (disconnection, short circuit) → repair or replace harnessIf there is no abnormality in the harness → carry out CHECK (1) again → if it is normal, the control unit is abnormal → replace unit


Harness Chassis harness Unit harnessConnector No. C-27 C-81 U-17 U-13 U-12



EF-8-54

(6) Checking Pre-stroke Sensor System

CHECKCheck each

harness3

CHECKCheck wiring harness at C.U. portion

1


Repair or replace harnessReplace C.U. Replace injection pump

DIAGNOSIS DISPLAY CODE2 - 3 or 2 - 4

OK

NG

or

If error is 1-2, check pre-stroke actuator

CHECKCheck pre-stroke

sensor2

If abnormality is 1-2 or 2-4, operation of pre-stroke actuator is probably defective

NG

NG

OK

OK


EF-8-55

CHECK (1) Check harness between pre-stroke sensorsat control unit1. Turn the ignition key switch OFF.2. Measure the resistance between terminals (23) and (24),

(23) and (29), and (24) and (29) of control unit harness con-nector U-13.

Resistance value for pre-stroke sensor Unit: Ω

3. JudgementResistance is as specified → pre-stroke sensor normal→ check pre-stroke actuator (refer to (7) Check pre-stroke servo system)Resistance value is not as specified → disconnection,short circuit, or pre-stroke sensor abnormal → go toCHECK (2).

CHECK (2) Check pre-stroke sensor body1. Turn the ignition key switch OFF.2. Measure the resistance between terminals (2) and (5), (2)

and (4), and (5) and (4) of pre-stroke sensor harness con-nector C-85.

Resistance value for pre-stroke sensor Unit: Ω

3. JudgementResistance is as specified → pre-stroke sensor normal→ check harness → go to CHECK (3).Resistance value is not as specified → pre-stroke sen-sor abnormal → replace pre-stroke sensor (injectionpump assembly)


Connector U-13(23) - (24) 5 - 7(23) - (29) 5 - 7(24) - (29) 10 - 14


Connector C-85(2) - (5) 5 - 7(2) - (4) 5 - 7(5) - (4) 10 - 14


EF-8-56


1. Turn the ignition key switch OFF.2. Check continuity between pre-stroke sensor harness connector C-85 and control unit harness con-

nector U-13.

3. JudgementContinuity is as specified → control unit abnormal → replace control unitContinuity is not as specified → harness abnormal → repair or replace harness



Terminal

Check 1 (1) (12) (12) (30)Check 2 (2) (11) (11) (23)Check 3 (3) (10) (10) (29)Check 4 (4) (9) (9) (29)Check 5 (5) (8) (8) (24)


EF-8-57


1. Turn the ignition key switch OFF.2. Check continuity between pre-stroke sensor harness connector C-85 and control unit harness con-

nector U-13.

3. JudgementContinuity is as specified → control unit abnormal → replace control unitContinuity is not as specified → harness abnormal → repair or replace harness



Terminal

Check 1 (1) (12) (12) (30)Check 2 (2) (11) (11) (23)Check 3 (3) (10) (10) (29)Check 4 (4) (9) (9) (29)Check 5 (5) (8) (8) (24)


EF-8-58

(7) Checking Pre-stroke Servo System

CHECKCheck each

harness3

CHECKCheck wiring harness at C.U. portion

1


Repair or replace harnessReplace C.U. Replace injection pump


OK

NG

or

Check pre-stroke actuator also

CHECKCheck resistance

of pre-stroke actuator

2

Operation of pre-stroke actuator is probably defective

NG

NG

OK

OK


EF-8-59

CHECK (1) Check harness between pre-stroke actuatorat control unit end1. Turn the ignition key switch OFF, then remove control unit

harness connector U-12.2. Measure the resistance between terminals (1) and (10) of

harness connector U-12.Resistance value for pre-stroke sensor Unit: Ω

3. JudgementResistance is as specified → check pre-stroke sensorResistance value is not as specified → pre-stroke actu-ator or harness abnormal → go to CHECK (2).

CHECK (2) Check pre-stroke actuator body1. Turn the ignition key switch OFF, then remove the harness

connector of the pre-stroke actuator.2. Measure the resistance between terminals (7) and (6) of

connector C-85 at the pre-stroke actuator end.Resistance value for pre-stroke sensor Unit: Ω

3. JudgementResistance is as specified → pre-stroke actuator nor-mal → check harness → go to CHECK (3).Resistance value is not as specified → replace injec-tion pump

Measurement location Standard valueConnector U-12 (1) - (10) 2.5 - 2.9

Measurement location Standard valueConnector U-85 (7) - (6) 2.5 - 2.9


EF-8-60


1. Turn the ignition key switch OFF.2. Check continuity between pre-stroke actuator connector C-85 and control unit connector U-12.

3. JudgementContinuity is normal → check for CHECK (1) again → replace control unit or replace injectionpumpContinuity is not normal → harness abnormal → repair or replace harness





EF-8-61


1. Turn the ignition key switch OFF.2. Check continuity between pre-stroke actuator connector C-85 and control unit connector U-12.

3. JudgementContinuity is normal → check for CHECK (1) again → replace control unit or replace injectionpumpContinuity is not normal → harness abnormal → repair or replace harness





EF-8-62

(8) Checking Pre-stroke Power Supply System

CHECKFUSE

1



Replace fuseRepair or replace harness or pre-stroke cut relay

OK

NG

or

CHECKCheck continuity between fuse

and connector2

Replace C.U.

OK

NG

or


EF-8-63

CHECK (1) Check fuse1. Check that the power fuse for the pre-stroke actuator is not

blown.2. Measure the voltage at the fuse portion.Value for power source voltage Unit: V

3. JudgementFuse is blown (voltage is normal) → after findingcause, replace fuseFuse is normal → go to CHECK (2).Voltage is not as specified → disconnection in harnessbetween battery and fuse, battery abnormal → repairharness or check battery

CHECK (2) Check harness between unit and powersource for pre-stroke actuator system1. Remove all harness connectors from the control unit, turn

the ignition key switch ON, then measure the voltage thebody(–end) and between terminal (2) (+end) of connectorU-12.

Value for power source voltage Unit: V

2. JudgementVoltage is as specified → control unit abnormal →replace control unitVoltage is not as specified → abnormality in power har-ness between power harness connectors, or pre-strokecut relay abnormal → repair or replace harness, orreplace pre-stroke cut relay

Measurement location Standard valuePower source fuse for pre-stroke actuator 20 - 28

Measurement location Standard valueConnector U-12, (2) (+end) - body (–end) 20 - 28


EF-8-64

[4] CLEARING DIAGNOSTIC MEMORYTo clear the diagnostic memory, short circuit the memory resetswitch at the behind the electrical unit board.

<Procedure for Clearing>1. Release the diagnostic switch.2. Turn the ignition key switch ON.3. Check that the Overheat warning light is displaying the

Diagnosis Display Code.4. Connect the harness or memory clear connector (24004

00Z09) to the memory reset switch terminal, and short cir-cuit the switch.

NOTEWhen connecting the harness, the battery voltage isapplied to the Y/R cord side, so be careful not to shortcircuit any other part.

5. Check that the Overheat warning light and buzzer displayshows the normal Diagnosis Display Code (0-1). The mem-ory will be erased in about ten seconds.

6. Remove the special connector or harness from the memoryreset switch terminal.

7. Connect the diagnostic switch.8. Turn the ignition key switch OFF, then turn the ignition key

switch ON again and check that the Overheat warningbuzzer shows code <0-1>.

NOTEIf the ignition key switch is turned ON with the sensor ter-minals still disconnected, a trouble signal will berecorded in the memory.


EF-8-65

APPENDIXTable 1 Failure Judgement Conditions For “MD-TICS” System

Trouble system Failure judgement conditions Judgement time (sec) Reset condition

C.U. power voltage sys-tem

When voltage at C.U. power terminal (3) is less than approx. 0V Immediate When control unit power source

voltage recovers

Rack sensor system

1) When detected voltage is 3.5V or more at all speed ranges

1

When the detected voltage has become normal, or when the engine speed is no longer under judgement conditions.

2) When detected voltage is less than 0.2V at 300 - 1,600 rpm

Engine speed sensor system

1) When resistance for all engine speed sensors (including harness) is more than 50 kΩ (disconnection)

1 Reset when pulse is input

2) When the pulse cannot be recognized with the ignition key switch at the START position

Immediate

Reset when pulse is input After error judgement is reset, and igni-tion key switch is turned again to START, then start again

Engine coolant tempera-ture sensor system

When detected voltage (resistance) is 0.1V (30Ω) or less, or 4.9V (73.5Ω) or more

3 When the detected voltage has become normal

Pre-stroke sensor sys-tem

When detected voltage is 0.9V or less, or 3.4V or more 1 When the detected voltage has

become normal

Pre-stroke servo systemWhen difference between target value and detected value is more than 3.9º at pre-stroke actuator angle

20 Do not reset while power remains ON

Pre-stroke power voltage system

When detected voltage at pre-stroke actuator power terminal (2) is 1.5V or less

1 When power voltage is reset

Pre-stroke learning func-tion system

When electricity is not passing through pre-stroke actuator, detected voltage of pre-stroke sensor is 1.0V or less or 1.4V or more

2.4 Do not reset while power remains ON


EF-8-66

Table 2 ”BACK-UP” Operations For “MD-TICS” System

Trouble system Diagnosis dis-play code

Back-up operation

Expected resultPre-stroke control

Max. injection limit by boost

compensator cut (Yes: O, No: X)

C.U. power voltage system

Stays lighted up

Control stopped (pre-stroke: injection timing fixed at most retarded angle)

O Lack of power, excessive white smoke

Rack sensor system 1-3Pre-stroke control characteristic fixed at characteristic for full load

X No abnormality is felt

Engine speed sensor system 1-5 or 1-6 Fixed at a constant pre-stroke

value X Slight lack of power

Engine coolant temper-ature sensor system 2-1

Control is carried out assuming engine coolant temperature of 80ºC (176ºF)

X Excessive white smoke when cold.

Pre-stroke sensor sys-tem 2-3

Control stopped (pre-stroke: injection timing fixed at most retarded angle)

O Lack of power, excessive white smoke

Pre-stroke servo sys-tem 1-2 Same as above O Same as above

Pre-stroke power volt-age system 2-2 Same as above O Same as above

Pre-stroke learning function system 2-4 Controlled with learning com-

pensation at 0 XEngine performance changes slightly but no abnormality is felt


EF-8-67

Terminal Connection Drawing <Type I>


EF-8-68

Terminal Connection Drawing <Type II>


EF-8-69

- MEMO -


EF-8-70

Wiring Diagram <Type I>


EF-8-71


EF-8-72

Wiring Diagram <Type II>


EF-8-73

- MEMO -

AIR INTAKE AND EXHAUST SYSTEM

CONTENTSSERVICE DATA...................................... IE-1-1

SPECIFICATIONS............................................ IE-1-1SERVICE DATA ............................................... IE-1-3TIGHTENING TORQUE ................................... IE-1-4INTAKE AND EXHAUST SYSTEM .................. IE-1-6

TOOLS .................................................... IE-2-1AIR CLEANER ........................................ IE-3-1

CONSTRUCTION............................................. IE-3-1REPLACING AIR CLEANER ELEMENT.......... IE-3-3

TURBOCHARGER.................................. IE-4-1= MODELS T04B AND T04E =

CONSTRUCTION............................................. IE-4-1REMOVAL ........................................................ IE-4-1DISASSEMBLY ................................................ IE-4-2INSPECTION.................................................... IE-4-6REASSEMBLY ................................................. IE-4-9INSTALLATION ................................................ IE-4-13

= MODELS RHC62E AND RHC6V =CONSTRUCTION............................................. IE-4-14REMOVAL ........................................................ IE-4-15DISASSEMBLY ................................................ IE-4-16INSPECTION.................................................... IE-4-20REASSEMBLY ................................................. IE-4-22

INSTALLATION ................................................ IE-4-24EXHAUST SYSTEM ................................ IE-5-1

REMOVAL ........................................................ IE-5-1DISASSEMBLY................................................. IE-5-2INSPECTION.................................................... IE-5-2INSTALLATION ................................................ IE-5-3INSPECTION AFTER INSTALLATION............. IE-5-4

EXHAUST BRAKE .................................. IE-6-1= CHAMBER TYPE =

CONSTRUCTION............................................. IE-6-1REMOVAL ........................................................ IE-6-1DISASSEMBLY................................................. IE-6-2INSPECTION.................................................... IE-6-4REASSEMBLY.................................................. IE-6-4INSTALLATION ................................................ IE-6-5

= CYLINDER TYPE =CONSTRUCTION............................................. IE-6-6REMOVAL ........................................................ IE-6-8DISASSEMBLY................................................. IE-6-9INSPECTION.................................................... IE-6-14REASSEMBLY.................................................. IE-6-15INSTALLATION ................................................ IE-6-16

IE

SERVICE DATA

IE-1-1


AIR CLEANER

TURBOCHARGERModels T04B and T04E

Engine model FE6A FE6BMax. gross output kW PS/rpm 118 160/3,000 119 162/3,000 132 180/3,000

Type

Paper element (Dry type)Type I (Single) or Type II (Dual)

— Type III (Single)or Type IV (Dual) —

Engine model FE6TMax. gross output kW PS/rpm 135 183/3,000 151 205/2,800 162 220/2,800

Type

Paper element (Dry type)Type I (Single) or Type II (Dual) —

— Type III (Single)or Type IV (Dual) —

— Type V (Single) or Type VI (Dual)

Engine model FE6TAMax. gross output kW PS/rpm 173 235/2,800 157 213/2,800

Type

Paper element (Dry type)Type I (Single) or Type II (Dual)

Type III (Single) or Type IV (Dual)— Type VII (Single)

Model T04B T04EExternal dimensions (Length x Width x Height) mm (in)

220 x 190 x 160(8.66 x 7.48 x 6.30)

230 x 195 x 265(9.06 x 7.68 x 10.43)

Max. permissible continuous speedrpm 138,000 125,000

Direction of rotation Counterclockwise as viewed from the exhaust turbine sideAir volume kg (lb)/min 21 (46) 20 (44)Compression ratio 3.2 3.0

SERVICE DATA

IE-1-2

Models RHC62E and RHC6V

EXHAUST BRAKE

NOTE*286-04446 (New) ← 286-04442 (Former)*286-04453 (New) ← 286-04441 (Former)

Model RHC62E RHC6VExternal dimensions (Length x Width x Height) mm (in)

218 x 238 x 145(8.58 x 9.37 x 5.71)

246 x 214 x 196(9.69 x 8.43 x 7.72)

Max. permissible continuous speedrpm 140,000

Direction of rotation Counterclockwise as viewed from the exhaust turbine sideAir volume kg (lb)/min 18.8 (41.5) 19.4 (42.8)Compression ratio 3.2

Engine model FE6A FE6BMax. gross output kW PS/rpm 118 160/3,000 119 162/3,000 132 180/3,000Type Chamber type Cylinder typeOperating method Vacuum type Air typeModel 286-04505 *286-04446 (286-04442)

Engine model FE6TMax. gross output kW PS/rpm 135 183/3,000 151 05/2,800 162 220/2,800Type Cylinder typeOperating method Air type

Model*286-04446 (286-04442)*286-04453 (286-04441)

286-06109

*286-04446(286-04442) 286-06109

Engine model FE6TAMax. gross output kW PS/rpm 157 213/2,800 173 235/2,800Type Cylinder typeOperating method Air type

Model *286-04446 (286-04442)*286-04453 (286-04441)

SERVICE DATA

IE-1-3

SERVICE DATA


Unit: mm (in)

Models RHC62E and RHC6VUnit: mm (in)

Item Maintenance standard Service limit RemarksPlay in shaft axial direction 0.025 - 0.080 (0.0010 - 0.0031) —Play in shaft radial direction 0.08 - 0.15 (0.0031 - 0.0059) —Runout of shaft 0.011 (0.0004) —

Outside diameter of shaftJournal part 10.16 (0.4000) —Piston ring part 17.34 (0.6827) —

Inside diameter of back plate 12.71 (0.5004) —Distance between contact surface of thrust collar and end of plate 11.66 (0.4591) —

Inside diameter of center housingBearing part 15.81 (0.6224) —Piston ring part 18.06 (0.7110) —

Thrust bearing thickness 4.36 (0.1717) —


Turbine wheel shaft

Outside diameter of journal — 10.39 (0.4091)Outside diameter of seal ring groove — 1.33 (0.0524)

Runout — 0.011 (0.0004)

Thrust bushing, Oil thrower,Thrust bearing

Distance between thrust bushing grooves — 4.08 (0.1606)

Seal ring groove width

Small diameter — 1.25 (0.0492)Large diameter — 1.46 (0.0575)

Thrust bearing width — 3.98 (0.1567)

Floating bearingInside diameter — 10.44 (0.4110)Outside diameter — 14.98 (0.5898)

Center housingInside diameter — 15.10 (0.5945)Seal ring insertion hole — 17.03 (0.6705)

Seal plate Seal ring insertion hole

Small diameter — 12.45 (0.4902)Large diameter — 14.05 (0.5531)

Play in shaft axial direction 0.05 - 0.08 (0.0020 - 0.0031) 0.10 (0.0039)Play in shaft radial direction 0.08 - 0.12 (0.0031 - 0.0047) 0.17 (0.0067)

SERVICE DATA

IE-1-4

EXHAUST BRAKEChamber type

Unit: mm (in)

Cylinder type<Models 286-04446 (286-04442), 286-04453 (286-04441) and 286-06109>

Unit: mm (in)

TIGHTENING TORQUE


Unit: N·mkgf·cm, in·lbf


Clearance between valve and body

Only one side 0.80 - 1.05(0.0315 - 0.0413) — When 86.6 - 93.3 kPa

650 - 700 mmHg, 25.59 - 27.56 inHgVacuum pressure is applied to power chamberBoth total 1.6 - 2.1

(0.063 - 0.083) —


Spindle O.D. 286-04446 (286-04442)286-04453 (286-04441) 16.50 (0.6496) 16.43

(0.6468)Clearance between spindle and bushing

286-04446 (286-04442)286-04453 (286-04441)

0.3 - 0.4(0.012 - 0.016) —

Clearance between bushing and body

286-04446 (286-04442)286-04453 (286-04441)

0.015 - 0.090(0.0006 - 0.0035) —


286-04446(286-04442)286-04453(286-04441)

Only one side 0.80 - 1.05(0.0315 - 0.0413) — When an air pressure of 637

kPa 6.5 kgf/cm2, 92 psi is applied to the air cylinder and the valve is fully closedBoth total 1.6 - 2.1

(0.063 - 0.083) —

Air cylinder spring

286-04446(286-04442)286-04453(286-04441)286-06109

Free length 151.5 (5.965) —

TensionN kgf, lbf

134.4 - 161.213.70 - 16.44,

30.2 - 36.3— When compressed to

107.8 mm (4.244 in)

Item Tightening torque RemarksCompressor wheel lock nut 2.1 - 2.3 21 - 23, 18 - 20 → Tighten (110º)Back plate and center housing mounting bolt 8.4 - 10.2 86 - 104, 75 - 90Turbine housing and center housing mounting bolt 18.0 - 21.5 184 - 219, 160 - 190Compressor housing and back plate mounting bolt 11.3 - 14.7 115 - 150, 100 - 130

SERVICE DATA

IE-1-5

Models RHC62E and RHC6VUnit: N·m kgf·cm, ft·lbf

EXHAUST BRAKEChamber type


Cylinder type<Models 286-04446 (286-04442), 286-04453 (286-04441) and 286-06109>


Item Tightening torque RemarksTurbine housing mounting bolt 27.0 - 28.9 275 - 295, 239 - 256Compressor housing mounting bolt 7.4 - 8.3 75 - 85, 65 - 74Thrust bearing mounting screw 1.2 - 1.4 12 - 14, 10 - 12

With Torx driverSeal plate mounting screw 3.4 - 4.0 35 - 41, 30 - 36Compressor impeller mounting nut 5.1 - 5.9 52 - 60, 45 - 52

Item Tightening torqueStopper bolt lock nut 5 - 7 0.5 - 0.7, 3.6 - 5.1Cover mounting bolt (at body) 10 - 16 1.0 - 1.6, 7 - 12Body-to-bracket mounting bolt 10 - 16 1.0 - 1.6, 7 - 12Lever mounting nut 10 - 16 1.0 - 1.6, 7 - 12Clevis adjusting nut 10 - 16 1.0 - 1.6, 7 - 12Power chamber mounting nut 10 - 16 1.0 - 1.6, 7 - 12Cover mounting bolt 5 - 7 0.5 - 0.7, 3.6 - 5.1


Stopper bolt lock nut 286-04446 (286-04442)286-04453 (286-04441) 10 - 16 1.0 - 1.6, 7 - 12

Cover mounting bolt (at body) 286-04446 (286-04442)286-04453 (286-04441) 21 - 26 2.1 - 2.7, 15 - 20

Body-to-plate mounting bolt 286-04446 (286-04442)286-04453 (286-04441) 21 - 26 2.1 - 2.7, 15 - 20

Lever mounting nut 286-04446 (286-04442)286-04453 (286-04441) 10 - 16 1.0 - 1.6, 7 - 12

Cylinder shaft nut286-04446 (286-04442)286-04453 (286-04441)286-06109

10 - 16 1.0 - 1.6, 7 - 12

Air cylinder cover mounting bolt286-04446 (286-04442)286-04453 (286-04441)286-06109

10 - 16 1.0 - 1.6, 7 - 12

Insulator (air cylinder) to shield plate bolt and nut

286-04446 (286-04442)286-04453 (286-04441)286-06109

21 - 25 2.1 - 2.6, 15 - 19

SERVICE DATA

IE-1-6

INTAKE AND EXHAUST SYSTEM

INTAKE SYSTEMFE6A, FE6B and FE6TFor suction under the cab

For suction behind the cab

SERVICE DATA

IE-1-7

FE6TA

EXHAUST SYSTEM (EXAMPLE)

TOOLS

IE-2-1

TOOLSTURBOCHARGERModels T04B and T04E

Tool name and number Description ShapeTurbocharger tool kit99760 Z5500

Used when disassembling and reassembling the turbocharger.

Radial play measuring tool99764 96000

Used to measure play in the radial direction of the turbine wheel.

Radial play adapter99765 96000

Adapter mounted to the end of the dial gauge when measuring radial play.

End play measuring tool99766 96000

Used when measuring axial play of the turbine wheel.

End play adapter99765 96001

Adapter mounted to the end of the dial gauge when measuring end play

Pick99767 96003

Used when fitting the piston ring of the shaft to the center housing

TOOLS

IE-2-2

Tool name and number Description ShapeT-handle99773 96000

Used to remove and install the compressor wheel lock nut.

Torque wrench99537 96001

Used to tighten and disassemble the center housing and back plate.Torque 9.3 N·m 95 kgf·cm, 82 in·lbf

Piston ring guide99763 Z5500

Used when inserting the piston ring to the tur-bine wheel.

Retaining ring plier99546 Z5500

Used when removing the retaining ring at the center housing.

Holding fixture99768 Z5500

Used when disassembling and assembling the rotating assembly.

Torque wrench99537 Z5500

Used to tighten and remove the turbine hous-ing and center housing.Torque 16.7 N·m 170 kgf·cm, 148 in·lbf

TOOLS

IE-2-3

Models RHC62E and RHC6V

Tool name and number Description ShapeTorque wrench99537 Z5501

Used to tighten and remove the turbine hous-ing and center housing.Torque 16.7 N·m 170 kgf·cm, 148 in·lbf

Torque wrench99537 Z5502

Used to tighten and remove the compressor housing and back plate.Torque 12.7 N·m 130 kgf·cm, 113 in·lbf

Hex socket head bolt14220 Z9001

Used when mounting the radial play measur-ing tool.

Tool name Description ShapeBar Used to remove the thrust bearing and bushing

Measuring needle Attached to the dial gauge for measurement of free play in both axial and radial directions.

TOOLS

IE-2-4

Tool name Description ShapePlier Used to remove or install the retaining ring

Plier Used to remove or install the seal ring.

Torx driver Used to install the thrust bearing and seal plate.

Torque wrench Used to tighten bolts and nuts.M8 ... 13 mm (0.51 in) – 27.9 N·m 285 kgf·cm, 247 in·lbfM6 ... 10 mm (0.39 in) – 7.8 N·m 80 kgf·cm, 69 in·lbfM6 ... 10 mm (0.39 in) – 5.3 N·m 54 kgf·cm,

47 in·lbf

Box spanner Used to prevent turbine wheel from turning during installation.11 mm (0.43 in) x 12 angular type

Measuring needle Used to measure free play in both axial and radial direction.

AIR CLEANER

IE-3-1

AIR CLEANERCONSTRUCTIONType I

Type II

AIR CLEANER

IE-3-2

Type III and Type IV

Type V, Type VI and Type VII

AIR CLEANER

IE-3-3

REPLACING AIR CLEANER ELEMENTFor inspection and maintenance procedures, refer to the “MA” section.

Type I and Type II


1. Clip 4. Inner element (Type II only) 6. Evacuator valve2. Cover 5. Outer element 7. Body assembly3. Packing

AIR CLEANER

IE-3-4

Type III and Type IV


Type V, Type VI and Type VII


1. Clip 4. Inner element (Type IV only) 6. Evacuator valve2. Cover 5. Outer element 7. Body assembly3. Packing

1. Wing nut 5. Wing nut 9. Packing2. Packing 6. Packing 10. Inner element3. Cover 7. Outer element 11. Evacuator valve4. Packing 8. Wing nut 12. Body assembly

TURBOCHARGER

IE-4-1

TURBOCHARGER

= MODELS T04B AND T04E =CONSTRUCTION

REMOVALKey point of removal

WARNINGWARNINGTo avoid being burned, do not touch the exhaust pipe,turbocharger and muffler while the engine is running orimmediately thereafter. Check that the engine has cooledbefore starting work.

T04B, T04E

TURBOCHARGER

IE-4-2

DISASSEMBLY



1. Retaining ring 10. Lock nut 19. Piston ring2. Actuator 11. Compressor wheel 20. Seal ring3. Lock plate 12. Turbine wheel 21. Retaining ring4. Clamp 13. Piston ring 22. Journal bearing5. Turbine housing 14. Shroud wheel 23. Retaining ring6. Lock plate 15. Lock plate 24. Retaining ring7. Clamp 16. Back plate 25. Journal bearing8. Compressor housing 17. Thrust collar 26. Retaining ring9. Rotating assembly 18. Thrust bearing 27. Center housing

T04B, T04E

TURBOCHARGER

IE-4-3

OPERATIONS BEFORE DISASSEMBLYWhen disassembling or reassembling the turbocharger, use specialtool kits (99760 Z5500) designed for that purpose.

INSPECTION BEFORE DISASSEMBLYPlace the turbocharger on a level surface, and turn the compressorwheel with finger tip to determine whether it operates smoothly,then use the following procedure to measure both axial and radialplay.

Measuring play in the axial direction1. Set the dial gauge to the end play measuring tool (99766

96000). Replace the dial gauge adapter with the end playadapter (99765 96001).

2. Set the end play measuring tool so that the end of theadapter is contacting the compressor wheel end of theshaft.

3. Measure the play in the axial direction.Unit: mm (in)

Measuring play in the radial direction1. Set the dial gauge to the radial play measuring tool (99764

96000) and replace the dial gauge adapter with the radialplay adapter (99765 96000).

2. Tighten the measuring tool with hex socket head bolt(14220 Z9001). Make sure the measuring element contactsthe center of the shaft.

3. Measure the play in the radial direction.Unit: mm (in)



T04B, T04E

TURBOCHARGER

IE-4-4

Key point of disassemblyBefore disassembly, spread a piece of clean oil paper or cardboardon the work bench and make matching marks at the connectionsections of the turbine housing, center housing, and compressorhousing so that there will be no mistakes during reassembly. Sincethe turbocharger is a precision device, disassemble it with theutmost care.

3 Lock plate, 4 ClampUnbend the lock plate, remove the lock plate, clamp, bolt and tur-bine housing.NOTE

If the bolt has seized, apply “thread-release” oil to thebolt, then remove it, being careful not to damage the tur-bine wheel. If necessary, tap the turbine housing with awooden hammer.

6 Lock plate, 7 ClampUnbend the lock plate, and remove the lock plate, clamp and bolt.NOTE

Make a matching mark on the compressor housing andback plate.

8 Compressor housingRemove the compressor housing being careful not to damage thecompressor wheel.NOTE

The compressor wheel and turbine wheel are preciselydynamically balanced and cannot be repaired. Therefore,they must be handled with extra special care.

9 Rotating assemblyPlace holding fixture (99768 Z5500) in a vise, and set the turbinewheel on it with the compressor wheel on it with the turbine wheelside facing downward.

T04B, T04E

TURBOCHARGER

IE-4-5

11 Compressor wheelRemove the compressor wheel.

Using a T-handle (99773 96000), remove the lock nut, andthen remove the compressor wheel by hand.

NOTESince bending of the shaft is also related to the life of theturbocharger, be careful not to bend it.Support the turbine wheel by hand while loosening thelock nuts.

13 Piston ringRemove the piston ring.NOTE

Once removed, the piston ring must always be replacedwith a new ring when reassembling. However, since theturbine wheel can be reused, be careful not to damagedit.

16 Back plateUnbend the lock plate and remove the back plate.NOTE

When the back plate cannot be removed by hand, tap thecenter housing lightly with a wooden mallet and thenremove it.

17 Thrust collar, 18 Thrust bearing,19 Piston ringPull out the thrust collar and thrust bearing from the center of theback plate and remove the piston ring from the thrust collar. Thepiston ring can be removed by hand.

22, 25 Journal bearingNOTE

Be careful not to damage the center housing whenremoving the retaining ring.

1. Using retaining ring pliers (99546 Z5500), remove the com-pressor wheel side retaining ring and journal bearing.

T04B, T04E

TURBOCHARGER

IE-4-6

2. Using retaining ring pliers (99546 Z5500), remove the tur-bine side retaining ring and journal bearing.

3. Remove the two retaining rings located in the rear of thecenter housing.

INSPECTION

INSPECTION BEFORE CLEANINGTurbocharger failure may sometimes be due to faulty engine parts.It is, therefore advisable to closely inspect parts for accumulation ofcarbon, presence of dirt or dust, obstruction of oil passages, etc.prior to cleaning, so that the cause of problems may be locatedeasily.

CLEANINGAfter soaking all the parts in clean detergent for about 20 to 30 min-utes, remove dirt and grime with a rough brush and then blow drywith compressed air.NOTE

Be extremely careful not to damage parts. Avoid filingany rotating parts. Also be sure to clean parts com-pletely. Failure to observe these points may cause theparts to become imbalanced.

EIE3048A

Contents of inspection Inspection pointCarbon accumulation (check whether parts are jammed) Turbine wheel journal parts.

Outside periphery of center housing.Inside periphery of heat shroud.Inside wall of center housing.Surface of blades of turbine wheel.

Lubrication (wear, burning, discoloration etc.) Turbine wheel journal parts.Journal bearing.Center housing bore part.Thrust collar.Thrust bearing.

Oil leakage Inside and outside periphery of turbine housing.Inside periphery of heat shroud.Inside of compressor housing.Surface of back plate.Surface of blades of turbine wheel.Rear surface of compressor wheel.

Foreign matter (Also check for obstruction while cleaning parts.)

Inside of center housing.Inside of turbine case.Inside of compressor case.

Clogging Center housing of oil hole.Oil inlet adapter.Oil outlet adapter.Thrust bearing of oil hole.

T04B, T04E

TURBOCHARGER

IE-4-7

INSPECTIONInspect parts visually, replacing as necessary.

Runout of shaftNOTE

Since the turbine side is heavy and the front end of theshaft will lift when the shaft is supported by V-block, usea magnet V-block or place another V-block to keep thejournal part in place.

Unit: mm (in)

Inspection position Inspection itemCompressor housing Scratches caused by interference with compressor

wheel.Scratches on contact surfaces with back plate.Cracks and dents.

Clamp Corrosion, deterioration and damage.Turbine housing Scratches caused by interference with turbine wheel.

Burrs caused by rust formation.Thermal deformity and cracks.

Compressor wheel Corrosion.Scratches caused by interference with housing.Blade breakage and deformity.Clogging in shaft holes.

Turbine wheel Scratches from interference with turbine housing.Blade breakage, deformity and cracks.Shaft bent.Discolored journals and blades.Worn and scratched journals.Worn and damaged piston rings.

Back plate Worn bore.Wear and damage on contact surface of thrust collar.Scratches on rear face of compressor wheel.

Thrust collar Wear and scratches on contact surface.Worn and damaged piston ring groove.

Thrust bearing Thermal discoloration.Wear and scratches on contact surface.

Center housing Wear and scratches on journal bores and inner surfaces of piston rings.Obstruction in oil hole

Heat shroud Scratches caused by contact.Thermal discoloration and corrosion.


T04B, T04E

TURBOCHARGER

IE-4-8

Inside diameter of back plate (A)Unit: mm (in)

Outside diameter of shaftUnit: mm (in)

Distance between contact surface of thrust collar andend of plate (B)

Unit: mm (in)

Inside diameter of center housingUnit: mm (in)

Thrust bearing thicknessUnit: mm (in)


Item Maintenance standard Service limitJournal part 10.16 (0.4000) —Piston ring part 17.34 (0.6827) —


Item Maintenance standard Service limitBearing part (1) 15.81 (0.6224) —Piston ring part (2) 18.06 (0.7110) —


T04B, T04E

TURBOCHARGER

IE-4-9

REASSEMBLY

PREPARATIONS BEFORE REASSEMBLYRepair light damage by polishing. Aluminum parts must be polishedwith a polishing cloth, using silicon carbide. Moreover, steel partsmust be polished with a polishing cloth, using polishing powder.

Key point of reassembly25, 22 Journal bearingUsing retaining ring pliers (99546 Z5500), install the retaining ringsin the rear of the center housing, then install the journal bearing andthe outer retaining ring.NOTE

Ensure that the open end of the retaining ring faces theoil outlet and the round portion faces the journal bearing.Be careful not to damage the center housing wheninstalling the retaining ring.Coat the inner and outer periphery of journal bearingwith engine oil.

16 Back plate1. Install the back plate.

Install the piston ring to the thrust collar.Coat the thrust bearing with engine oil and then install thethrust bearing and thrust collar.

2. Fit the thrust collar into the groove pin of the center hous-ing, and fit the seal ring to the peripheral groove of the cen-ter housing.

NOTEWhen installing the thrust collar, align the portions indi-cated by dotted lines in the figure at right.

T04B, T04E

TURBOCHARGER

IE-4-10

3. Use bolt and lock plate to install the back plate to the centerhousing and bend the lock plate.

: 8.4 - 10.2 N·m 86 - 104 kgf·cm, 75 - 90 in·lbfNOTE

Ensure that the bosses are ready to be detached from theflanged portions of the inlet and outlet.

13 Piston ringInstall the piston ring to the turbine wheel using the piston ringguide (99763 Z5500).

12 Turbine wheelApply a coat of engine oil to the turbine wheel journal, and carefullyinsert the turbine wheel into the bore in the center housing. Usepick (99767 96003) to compress the piston ring and install it whilerotating the wheel shaft.NOTE

Be careful not to scratch or break the piston ring.

11 Compressor wheelNOTE

Before installing the compressor wheel, clean the partsand check carefully the tightening surface for dust or for-eign matter.When tightening the nut, be careful not to give the bend-ing force to the shaft.Keep the rated tightening torque and tightening angle.

1. Coat the compressor wheel mounting and screw section ofthe turbine wheel and the surface of the lock nut seat with athin coat of seizure preventative.

2. Fit the compressor wheel into the turbine wheel and tightenthe lock nut temporarily.

3. Attach the rotating assembly to a holding fixture (99768Z5500) which has been placed in a vise.

T04B, T04E

TURBOCHARGER

IE-4-11

4. Using a torque wrench, tighten the lock nut temporarily.: 2.1 - 2.3 N·m 21 - 23 kgf·cm, 18 - 20 in·lbf

5. Tighten the lock nut completely with T-handle (9977396000) by turning nut 110º further than the temporary posi-tion.

Measuring play in shaft axial direction and radial direction1. Seat the dial gauge to the radial play measuring tool (99764

96000) and replace the dial gauge adapter with the radialplay adapter (99765 96000).

2. Attach the measuring element to the center bearing, andmeasure its radial play.

Unit: mm (in)

3. Seat the dial gauge to the end play measuring tool (9976696000). At this time, replace the dial gauge adapter with theend play adapter (99765 96001).


T04B, T04E

TURBOCHARGER

IE-4-12

4. Temporarily install the compressor housing. Attach themeasuring element to the compressor housing and mea-sure the end play of the shaft.

Unit: mm (in)

8 Compressor housing1. Attach the compressor housing to the back plate by prop-

erly aligning their marks, then tighten the bolts with theclamps and lock plates in place.

: 11.3 - 14.7 N·m 115 - 150 kgf·cm, 100 - 130 in·lbf

2. Compressor housing assembly angle (View from the airintake side)T04Bβ = 292º

T04Eβ = 170º

5 Turbine housing1. Align the marks on the turbine housing and center housing,

attach the turbine housing to the rotating assembly, thentighten bolts with a clamp and lock plate in place.

: 18.0 - 21.5 N·m 184 - 219 kgf·cm, 160 - 190 in·lbfNOTE

Apply a “gauge-preventive” compound to bolts. Do notconfuse these bolts (designed especially for high tem-perature use) with other conventional bolts.

2. Turbine housing assembly angle (View from exhaust outletside)


T04B, T04E

TURBOCHARGER

IE-4-13

INSTALLATIONKey point of installation1. Install the turbocharger assembly on the exhaust manifold

using a gasket.NOTE

Mounting nuts are heat-resistant types. Do not confusethem with conventional nuts.

2. Install the exhaust connector using a gasket and spacer tothe turbocharger assembly.

NOTEMounting nuts are heat-resistant types. Do not confusethem with conventional nuts.

3. After installing the turbocharger assembly, crank the engineusing the sub-starter switch. Crank for approximately 10 to20 seconds while pulling the engine stop lever. Crank theengine until the oil pressure gauge activates, since oil is notdistributed to the oil line.

NOTEDo not crank the engine for more than 20 seconds at atime; otherwise, the starter motor may be damaged.Repeat cranking several times.

4. Start the engine. Check that no oil leaks.

T04B, T04E

TURBOCHARGER

IE-4-14

= MODELS RHC62E AND RHC6V =CONSTRUCTIONModel RHC62E

RHC62E, RHC6V

TURBOCHARGER

IE-4-15

Model RHC6V

REMOVALKey point of removal

WARNINGWARNINGTo avoid being burned, do not touch the exhaust pipe,turbocharger and muffler while the engine is running orimmediately thereafter. Check that the engine has cooledbefore starting work.

RHC62E, RHC6V

TURBOCHARGER

IE-4-16

DISASSEMBLYModel RHC62E



1. Holder plate 9. Sealed wheel 17. Torx screw2. Compressor housing 10. Snap ring 18. Thrust bearing3. Holder plate 11. Floating metal 19. Seal ring (small)4. Turbine housing 12. Center housing 20. Seal ring5. Nut 13. Torx screw 21. Snap ring6. Compressor impeller 14. Seal plate 22. Actuator7. Seal ring (large) 15. Oil thrower 23. Clip8. Turbine shaft 16. Thrust bearing 24. Hose

RHC62E, RHC6V

TURBOCHARGER

IE-4-17

Model RHC6V



1. Holder plate 8.Turbine shaft 15. Oil thrower2. Compressor housing 9. Sealed wheel 16. Thrust bushing3. Holder plate 10. Snap ring 17. Torx screw4. Turbine housing 11. Floating metal 18. Thrust bearing5. Nut 12. enter housing 19. Seal ring6. Compressor impeller 13. Torx screw 20. Seal ring7. Seal ring 14. Seal plate

RHC62E, RHC6V

TURBOCHARGER

IE-4-18

INSPECTION BEFORE DISASSEMBLYOn-board inspectionTurbine shaft rotationCheck for abnormal noise from the turbine shaft while rotating theturbocharger.1. If a sound-detecting rod is used, firmly attach the tip of the

rod to the turbocharger case, then increase engine speed.2. If a high-pitch sound is heard every 2 to 3 seconds during

turbocharger rotation, the metal and/or turbine shaft may bedamaged. Disassemble and repair the turbocharger orreplace it as required.

Turbocharger assembly1. Cover the oil inlet and outlet using masking tape.2. Check if the turbine vane is in contact with the compressor

impeller or if there is evidence of leaking oil.3. Check the actuator for improper movement or wear.4. Check that the impeller spins smoothly by hand.5. Measure the turbine shaft axial play.

Fix the dial gauge to the turbocharger by the magneticbase.Move the tip of the turbine shaft by hand in the axial direc-tion so that the dial gauge registers the maximum deflec-tion.

Unit: mm (in)

6. Measure the turbine shaft radial play.Fix the dial gauge to the turbocharger assembly by themagnetic base.Replace the dial gauge measuring probe with a measuringneedle. While holding both ends of the turbine shaft in both hands,move the turbine shaft in the radial direction. Read the max-imum dial gauge deflection.

Unit: mm (in)



RHC62E, RHC6V

TURBOCHARGER

IE-4-19

Key point of disassemblyCAUTION

The VNT actuator is set to the specified boost pressurebefore shipment. Do not attempt to remove the actuatorin the field.The variable exhaust nozzle mechanism is complex indesign since it slides without lubrication under high tem-perature conditions. Never attempt to disassemble thenozzle mechanism in the field.

2, 12 (RHC62E) 2, 12 (RHC6V) Compressor housing, Centerhousing1. Before disassembling, place an alignment mark on the join-

ing surfaces of the compressor housing, center housing andturbine housing so that they can be installed in their originalpositions during reassembly.

2. Liquid gasket is applied to the mating surfaces of the com-pressor housing and center housing. When removing theseparts, be careful not to damage impeller.

4 (RHC62E) 4 (RHC6V) Turbine housingBefore removing the turbine housing, place it parallel with the cen-ter housing.

5 (RHC62E) 5 (RHC6V) NutUsing a 17-mm (0.67-in) box wrench, remove the nut from the end(turbine side) of the turbine shaft.NOTE

The nut is a left-hand thread type.

10 (RHC62E) 10 (RHC6V) Snap ringUse snap ring pliers when removing or installing snap rings.13 (RHC62E) 13 (RHC6V) Torx screwUse a Torx driver when removing the Torx T type screws whichsecure the seal plate.NOTE

The seal plate can be driven out by equally and firmlytightening the two screws by hand.

RHC62E, RHC6V

TURBOCHARGER

IE-4-20

17 (RHC62E) 17 (RHC6V) Torx screwUse a Torx driver when removing the Torx T type screws whichsecure the thrust bearing.

INSPECTIONCheck all parts for scratches (frictional), scratches (on the joiningsurfaces), cracks, corrosion, bends, wear, thermal deformation, pit-ting, discoloration, breakage, oil clogging, etc. Replace faulty partswith new ones.

INSPECTION BEFORE CLEANINGBefore cleaning, visually check various parts for seizure, wear orforeign particles (including carbon) to determine if they are suitablefor further use.

Cleaning procedure

NOTEClean all other parts in kerosene.Clean the oil passage using dry compressed air.After cleaning, check all parts as specified under the topic “INSPECTION”.

Turbine shaft Turbine housing and center housing Compressor housing and compressor impeller

Pour cleaning liquid (decarbonizing agent) into the cleaning basket. Immerse parts in the liquid, then heat them.NOTE

Protect the turbine shaft journal surface and seal ring groove from damage in advance.

Wait until foreign particles are loose.

Using a scraper or hard brush, clean the parts.NOTE

Do not use a wire brush.

Check all parts as specified under the topic “INSPECTION”.

RHC62E, RHC6V

TURBOCHARGER

IE-4-21

TURBINE WHEEL SHAFTOutside diameter of journal (A) and outside diameter ofseal ring groove (E)

Unit: mm (in)

RunoutUnit: mm (in)

THRUST BUSHING, OIL THROWER AND THRUSTBEARINGDistance between thrust bushing grooves (K)

Unit: mm (in)

Oil thrower seal ring groove widths (G1 and G2)Unit: mm (in)

Thrust bearing width (J)Unit: mm (in)

Item Maintenance standard Service limitOutside diameter of journal (A) — 1.33 (0.0524)Outside diameter of seal ring groove (E) — 10.39 (0.4091)

Maintenance standard Service limit— 0.011 (0.0004)


Item Maintenance standard Service limitSmall diameter (G2) — 1.25 (0.0492)

Large diameter (G1) — 1.46 (0.0575)


RHC62E, RHC6V

TURBOCHARGER

IE-4-22

FLOATING BEARINGInside diameter (C) and outside diameter (D)

Unit: mm (in)

CENTER HOUSINGInside diameter (B) and seal ring insertion hole (F) (onturbine side)

Unit: mm (in)

SEAL PLATESeal ring insertion hole (H1 and H2) (on impeller side)

Unit: mm (in)

REASSEMBLYKey point of reassemblyNOTE

After reassembling the turbocharger, measure the axialand radial play of the turbine shaft.

17 (RHC62E) 17 (RHC6V) Torx screwUse a Torx driver when installing the Torx T type screws whichsecure the thrust bearing.

15 (RHC62E) 15 (RHC6V) Oil throwerFit the two seal rings to their grooves on the oil thrower, as shown inthe figure.

Item Maintenance standard Service limitInside diameter (C) — 10.44 (0.4110)Outside diameter (D) — 14.98 (0.5898)

Item Maintenance standard Service limitInside diameter (B) — 15.10 (0.5945)Seal ring insertion hole (F) — 17.03 (0.6705)

Item Maintenance standard Service limitSmall diameter (H1) — 12.45 (0.4902)

Large diameter (H2) — 14.05 (0.5531)

RHC62E, RHC6V

TURBOCHARGER

IE-4-23

13 (RHC62E) 13 (RHC6V) Torx screwUse a Torx driver when installing the Torx T type screws whichsecure the seal plate.

7 (RHC62E) 7 (RHC6V) Seal ringFit the seal ring to the groove on the turbine shaft, as shown in thefigure.

10 (RHC62E) 10 (RHC6V) Snap ringNote the direction of the snap ring gap during installation. Refer tothe figure.NOTE

Face the tapered side of the snap ring toward the bear-ing.

5 (RHC62E) 5 (RHC6V) NutUsing a 17 mm (0.67 in) box wrench, tighten the nut on the end (tur-bine side) of the turbine shaft.NOTE

The nut is a left-hand thread type.Align the alignment marks on the turbine shaft, compres-sor impeller and nut (on the end of the turbine shaft) dur-ing reassembly.

2, 12 (RHC62E) 2, 12 (RHC6V) Compressor housing, Centerhousing1. Before installation, apply 0.1 to 0.2 mm (0.004 to 0.008 in)

thick liquid gasket (THREE BOND #1215 or equivalent) tothe mating surfaces of the compressor housing and centerhousing.

2. Align the alignment marks on the joining surfaces of thecompressor housing, center housing and turbine housingduring reassembly.

RHC62E, RHC6V

TURBOCHARGER

IE-4-24

INSTALLATIONKey point of installation1. Install the turbocharger assembly on the exhaust manifold

using a gasket.NOTE

Mounting nuts are heat-resistant types. Do not confusethem with conventional nuts.

2. Install the exhaust connector, connector support and sealplate.

NOTEMounting nuts or bolts are heat-resistant types. Do notconfuse them with conventional nuts or bolts.

3. After installing the turbocharger assembly, crank the engineusing the sub-starter switch. Crank for approximately 10 to20 seconds while pulling the engine stop lever out. Crankthe engine until the oil pressure gauge activates, since oil isnot distributed to the oil line.

NOTEDo not crank the engine for more than 20 seconds at atime; otherwise, the starter motor may be damaged.Repeat cranking several times.

4. Start the engine. Check that no oil leaks.

RHC62E, RHC6V

EXHAUST SYSTEM

IE-5-1

EXHAUST SYSTEMREMOVALKey point of removal

WARNINGWARNINGBefore removing the exhaust system, ensure that theengine is cool. If it is hot, wait until it cools off to preventscalding yourself.

Tail pipe1. Disconnect the tail pipe clamp and hanger.2. Remove the tail pipe by loosening the bolts which secure

the rear pipe of the muffler to the tail pipe.

Muffler1. Remove the bolt from the exhaust shutter, and separate the

exhaust brake from the muffler.2. Separate the hanger from the bracket which secures the

rear pipe of the muffler. Remove the muffler.

Exhaust pipe1. Disconnect the pipes from the exhaust manifold.2. Disconnect the exhaust pipe bracket from the hanger.3. Remove the hanger and clamp from the exhaust pipe.

EXHAUST SYSTEM

IE-5-2

DISASSEMBLY(Example)

NOTENumbers before part name do not indicate the disassembly sequence.

INSPECTIONCarefully check all disassembled parts for scratches, cracks ordamage. Repair or replace faulty parts if necessary.

1. Gasket 5. Sleeper exhaust tube assembly 8. Muffler2. Exhaust tube assembly 6. Gasket 9. Hanger3. Hanger 7. Exhaust shutter assembly 10. Tail tube assembly4. Rubber

EXHAUST SYSTEM

IE-5-3

INSTALLATION1. Replace all gaskets with new ones.

2. Install the hanger and rubber pad on the tail pipe bracket.NOTE

Always install the hanger using the hole at the outer endof the bracket.Make sure that the convex end of the rubber pad facesdown and that the bolt is inserted from the lower side.Make sure that the nut which secures the rubber padmakes contact with the graded portion of the bolt whentightened.

3. Install the exhaust pipe on the exhaust manifold using agasket. Fasten it with the clamp. Install the assembled uniton the hanger.

4. Temporarily install the clamp, sleeper and rubber pad on thebracket which secures the rear of the muffler.

5. Insert the rear pipe of the muffler into the clamp. Connectthe front pipe to the exhaust pipe by using the exhaustbrake assembly and gasket.

NOTEInstall the muffler so that the bent part is 30 degreestowards the vehicle from the bottom of the muffler.

6. Insert the tail pipe between the clamp (which was installedtemporarily in step 4 above) and the rear pipe of the muffler.

7. Secure the tail pipe hanger to the tail pipe clamp.

EXHAUST SYSTEM

IE-5-4

8. Adjust the position of the tail pipe and tighten the clamp.NOTE

Make sure that the tail pipe clamp is tightened at a pointapproximately 5 mm (0.20 in) from the end of the tail pipe.

INSPECTION AFTER INSTALLATION1. Check that the exhaust pipe, muffler and tail pipe are suffi-

ciently clear of adjacent parts for safety. Also check thatthere is sufficient clearance between the exhaust pipes andthe seats and ropes.

2. Start the engine. Check the muffler for proper function andconnections for signs of air leakage.

EXHAUST BRAKE

IE-6-1

EXHAUST BRAKE

= CHAMBER TYPE =CONSTRUCTION

REMOVALPosition the vehicle on a flat surface and apply chocks to the frontand rear wheels.

WARNINGWARNINGDo not remove the exhaust brake parts while the engineis hot to prevent scalding yourself.

CHAMBER TYPE

EXHAUST BRAKE

IE-6-2

DISASSEMBLY

EXHAUST SHUTTER AND POWER CHAMBER ASSEM-BLY



1. Cover 4. Clevis 7. Gasket2. Pin 5. Power chamber assembly 8. Insulator3. Clevis pin 6. Bearing 9. Exhaust shutter assembly

CHAMBER TYPE

EXHAUST BRAKE

IE-6-3

EXHAUST SHUTTER



1. Lever 4. Cover 6. Body2. Seal ring 5. Gasket 7. Bracket assembly3. Seal ring

CHAMBER TYPE

EXHAUST BRAKE

IE-6-4


REASSEMBLY

EXHAUST SHUTTERKey point of reassembly3, 2 Seal ringPosition the spindle, valve and bushing in the body. Install the sealrings on the spindle.NOTE

Make sure that the different seal rings are installed alter-nately.

Adjustment of clearance between the valve and bodyApply a vacuum pressure of 86.6 to 93.3 kPa 650 to 700 mmHg,25.59 to 27.56 inHg to the power chamber with the valve fullyclosed. Check to ensure that the clearance between the body andvalve is in the specified range indicated in the table below. If it isnot, adjust the stopper bolt and tighten the lock nut.

: 5 - 7 N·m 0.5 - 0.7 kgf·m, 3.6 - 5.1 ft·lbfUnit: mm (in)

EXHAUST SHUTTER AND POWER CHAMBER ASSEM-BLYKey point of reassembly4 ClevisInstall the clevis on the push rod, and connect the lever using a pin.Adjust the position of the clevis so that the push rod can be set inposition when pushed 2 mm (0.08 in) against the power chamber.Check that clearances A and B between the valve and body areequal and that the push rod makes contact with the stopper bolt onthe “full-open” side. If no contact is made, adjust it as outlined in“Adjustment of clearance between the valve and body”.



Only one side 0.80 - 1.05(0.0315 - 0.0413) —

Both total 1.6 - 2.1(0.063 - 0.083) —

CHAMBER TYPE

EXHAUST BRAKE

IE-6-5

: Clevis adjusting nut10 - 16 N·m 1.0 - 1.6 kgf·m, 7 - 12 ft·lbf

: Stopper bolt lock nut5 - 7 N·m 0.5 - 0.7 kgf·m, 3.6 - 5.1 ft·lbf

INSTALLATIONKey point of installation1. Connect the vacuum hoses.NOTE

Be careful not to twist the hoses.

2. Start the engine. When vacuum pressure reaches the spec-ified value, turn the exhaust brake switch “ON” to ensurethat the exhaust brake operates properly. Also check to besure there is no air leakage.

CHAMBER TYPE

EXHAUST BRAKE

IE-6-6

= CYLINDER TYPE =CONSTRUCTION

EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLYModels 286-04442 and 286-04441

CYLINDER TYPE

EXHAUST BRAKE

IE-6-7

Models 286-04446 and 286-04453

CYLINDER TYPE

EXHAUST BRAKE

IE-6-8

Model 286-06109

REMOVALKey point of removalPosition the vehicle on a flat surface and apply chocks to the frontand rear wheels.

WARNINGWARNINGDo not remove the exhaust brake parts while the engineis hot to prevent scalding yourself.

CYLINDER TYPE

EXHAUST BRAKE

IE-6-9

Remove the exhaust shutter assembly.Separate the exhaust brake air-hose connection, andremove the hose. When removing, hold the hose stationaryand loosen the nut.

NOTEBe careful not to twist the hose when removing.

DISASSEMBLY

EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLYModels 286-04442 and 286-04441



1. Pin 4. Shield plate 6. Insulator2. Clevis pin 5. Air cylinder assembly 7. Exhaust shutter assembly3. Clevis

CYLINDER TYPE

EXHAUST BRAKE

IE-6-10

Models 286-04446, 286-04453 and 286-06109



1. Pin 4. Shield plate 6. Insulator2. Clevis pin 5. Air cylinder assembly 7. Exhaust shutter assembly3. Clevis

CYLINDER TYPE

EXHAUST BRAKE

IE-6-11

EXHAUST SHUTTERModels 286-04442, 286-04441, 286-04446 and 286-04453


Marks “ ” and “ ” indicate that the key points of operation are explained in the text.CAUTION

Do not disassemble the exhaust shutter in model 286-06109. Never loosen the stopper bolt.

1. Cover 4. Plate 6. Seal ring2. Gasket 5. Seal ring 7. Exhaust shutter3. Lever

CYLINDER TYPE

EXHAUST BRAKE

IE-6-12

AIR CYLINDER ASSEMBLYModels 286-04442 and 286-04441



1. Cover 6. Packing 11. Shaft2. O-ring 7. Plate 12. Guide3. Nut 8. Wear ring 13. Cover4. Washer 9. Protector 14. Dust seal5. Retainer 10. Spring 15. Cylinder

CYLINDER TYPE

EXHAUST BRAKE

IE-6-13

Models 286-04446, 286-04453 and 286-06109



Key point of disassembly10 SpringRemove the cover and detach the spring and shaft assembly fromthe cylinder.NOTE

Be careful not to allow the shaft assembly to jump outbecause the cover is spring-loaded.

1. Cover 7. Plate 13. Washer2. O-ring 8. Wear ring 14. Cover3. Nut 9. Protector 15. Dust seal4. Washer 10. Spring 16. Retaining ring5. Retainer 11. Shaft 17. Filter6. Packing 12. Guide 18. Cylinder

CYLINDER TYPE

EXHAUST BRAKE

IE-6-14


Spindle O.D.Unit: mm (in)

Clearance between spindle and bushingUnit: mm (in)

Clearance between bushing and bodyUnit: mm (in)

SpringUnit: mm (in)





Free length 151.5 (5.965) —

TensionN kgf, lbf

134.4 - 161.213.70 - 16.44,

30.2 - 36.3—

When com-pressed to 107.8 mm (4.244 in)

CYLINDER TYPE

EXHAUST BRAKE

IE-6-15

REASSEMBLY

EXHAUST SHUTTERKey point of reassembly6, 5 Seal ringPosition the spindle, valve and bushing in the body and attach theseal rings on the spindle.NOTE

Alternately install different types of seal rings.

Adjustment of clearance between the valve and bodyMove the lever toward the full-open side. When the lever contactsthe stopper bolt, adjust the stopper bolt so that clearances A and Bare equal. Move the lever toward the full-close side. When the levercontacts the stopper bolt, adjust the stopper bolt so that the clear-ance between the valve and body is within specifications. Afteradjusting the clearance, tighten the stopper bolt with the lock nut.

: 10 - 16 N·m 1.0 - 1.6 kgf·m, 7 - 12 ft·lbf

Unit: mm (in)

(*) When an air pressure of 637 kPa 6.5 kgf/cm2, 92 psi is applied to the air cylinder and the valve is fully closed

EXHAUST SHUTTER AND AIR CYLINDER ASSEMBLYKey point of reassembly3 ClevisConnect the shaft of the cylinder assembly and clevis using a pin.Move the lever toward the full-open side until it contacts the stopperbolt. From that position, pull out the shaft less than 1 mm (0.04 in)to ensure that the hole in the shaft is aligned with the clevis hole.

Stopper bolt lock nut (at spindle): 10 - 16 N·m 1.0 - 1.6 kgf·m, 7 - 12 ft·lbf



One side 0.80 - 1.05(0.0315 - 0.0413) —

(*)Both total 1.6 - 2.1

(0.063 - 0.083) —

CYLINDER TYPE

EXHAUST BRAKE

IE-6-16

INSTALLATIONKey point of installationInstall the connector so that its hose mounting hole faces upward.NOTE

Wind two turns of sealing on the threads of the connec-tor in the opposite direction of the threads.

CYLINDER TYPE

- MEMO -

ELECTRICAL SYSTEM

CONTENTSSERVICE DATA...................................... EE-1-1

SPECIFICATIONS............................................ EE-1-1SERVICE DATA ............................................... EE-1-1TIGHTENING TORQUE ................................... EE-1-2

STARTING MOTOR................................ EE-2-1CONSTRUCTION............................................. EE-2-1DISASSEMBLY ................................................ EE-2-3INSPECTION.................................................... EE-2-4ADJUSTMENT ................................................. EE-2-7

PERFORMANCE CHECK ................................ EE-2-8ALTERNATOR ........................................ EE-3-1

CONSTRUCTION............................................. EE-3-1 DISASSEMBLY................................................ EE-3-5INSPECTION.................................................... EE-3-7PERFORMANCE CHECK ................................ EE-3-8

AIR HEATER ........................................... EE-4-1CONSTRUCTION............................................. EE-4-1INSPECTION.................................................... EE-4-1

EE EE

SERVICE DATA

EE-1-1

SERVICE DATASPECIFICATIONS STARTING MOTOR

ALTERNATOR

AIR HEATER

SERVICE DATASTARTING MOTORModels 0350 502 0310 and 0350 502 0321

Unit: mm (in)

Model 0350 502 0310 0350 502 0321Type ShiftOutput V-kW 24-4.5

Model0202 152 0201 152 0201 222

0202 152 0310 0202 152 0311 0202 152 0220 0202 152 0221 0201 152 0420 0201 152 0421 0201 222 0273With vacuum pump Without vacuum pump

Output V-A 24-50 24-80Type ofregulator IC transistor (Built-in)

Vacuum pump model 1290 011 00 (VD-120) 1290 009 00 (VD-30) —

Type RibbonRated current V-A 22-85Rated time Second Less than 50


Com

mut

ator

Outside diameter 36.0 (1.417) 34.0 (1.339)

Runout Less than0.09 (0.0035)

More than0.10 (0.0039)

Undercut depth 0.5 - 0.8(0.020 - 0.031) 0.2 (0.008)

Brus

h Brush height 18.0 (0.709) 13.0 (0.512)

Brush spring tension N kgf, lbf 29.4 3.0, 6.6 20.6 2.1, 4.6 When spring is set

Mag

netic

switc

h Continuitytest

Pull coil resistance Ω 0.70 - 0.86 —

Hold coil resistance Ω 0.85 - 1.05 —

Gea

r sha

ft Shaft runout Less than0.09 (0.0035)

More than0.10 (0.0039)

Thrust gap 0.1 - 0.5(0.004 - 0.020) —

Armature, field coil Insulation resistance MΩ More than 1.0 0.5Brush holder Insulation resistance MΩ More than 1.0 0.5

SERVICE DATA

EE-1-2

Unit: mm (in)

ALTERNATOR

TIGHTENING TORQUE

STARTING MOTOR Unit: N·m kgf·m, ft·lbf


Brac

ket

Front bearing (metal) inside diameter 15.0 (0.591) 15.2 (0.598)Commutator bearing fit section inside diameter 28.0 (1.102) 28.1 (1.106)

Gear bearing fit section inside diame-ter 35.0 (1.378) 35.1 (1.382)

Adju

stm

ent

Clearance between pinion gear and pinion stopper (Dimension L)

0.5 - 3.0(0.020 - 0.118) —

Perfo

rman

cech

eck

Current A Less than 100 — Terminal voltage 24VNumber of rotations rpm More than 4,000 — Terminal voltage 24V

Measure minimum voltage which is necessary for pinion to pop out V Less than 16 —


Star

ter c

oil

Resistance Ω

0202 1520201 152 0.18 - 0.22 —

Between two phases at 20ºC (68ºF)

0201 222 0.14 - 0.18 —

Fiel

d co

il

Resistance Ω0202 1520201 152 5.6 - 6.8 —

At 20ºC (68ºF)

0201 222 5.0 - 7.0 —

Perfo

rman

ce c

heck No-load speed rpm

0202 1520201 152 Less than 950 —

0201 222 Less than 900 —Regulating voltage V 28 - 29 —

Output current A0202 1520201 152 Less than 50 —

0201 222 Less than 80 —

Item Tightening torqueC terminal 1.9 - 2.5 0.19 - 0.25, 1.4 - 1.8B terminal 8 - 11 0.8 - 1.1, 5.8 - 8.0M terminal 6 - 11 0.6 - 1.1, 4.3 - 8.0Magnetic switch mounting bolt 16 - 18 1.6 - 1.8, 12 - 13Through bolt 16 - 18 1.6 - 1.8, 12 - 13Brush holder mounting screw 3.6 - 4.9 0.37 - 0.50, 2.7 - 3.6Gear case mounting bolt 16 - 18 1.6 - 1.8, 12 - 13

SERVICE DATA

EE-1-3

ALTERNATOR Unit: N·m kgf·m, ft·lbf


Pulley mounting nut 0202 1520201 152 127 - 157 13.0 - 16.0, 94 - 116

0201 222 113 - 147 11.5 - 15.0, 83 - 108

STARTING MOTOR

EE-2-1

STARTING MOTORCONSTRUCTION

0350 502

STARTING MOTOR

EE-2-2

TROUBLESHOOTING

Rem

ove

star

ting

mot

or fr

om e

ngin

e.

Doe

s st

artin

g m

otor

turn

und

er n

o lo

ad

by c

onne

ctin

g ba

ttery

(+) t

erm

inal

to M

te

rmin

al o

f sta

rting

mot

or a

nd b

atte

ry

(–) t

erm

inal

to s

tarti

ng m

otor

bod

y?

Engi

ne d

oes

not

star

t.

Doe

s en

gine

turn

by

cra

nkin

g?D

oes

star

ting

mot

or tu

rn?

Che

ck b

atte

ry fo

r cha

rgin

g co

nditi

on

and

batte

ry te

rmin

als

for c

onne

ctio

ns

and

corro

sion

.

Cha

rge

or re

plac

e ba

ttery

.R

epai

r con

nect

ions

and

cor

rosi

on o

f ba

ttery

term

inal

s.

N.G

.

O.K

.Ye

s

No

No

Doe

s ge

ar s

haft

turn

?C

an y

ou h

ear s

tarte

r rel

ay o

pera

ting?

(B

lock

rela

y eq

uipp

ed m

odel

onl

y)C

heck

and

repa

ir w

iring

sys

tem

of b

lock

re

lay. Key

sw

itch.

Sta

rter r

elay

. C

onne

ctio

ns.

No

Yes

No

Yes

Che

ck p

inio

n ro

ller

clut

ch fo

r dam

age.

R

epla

ce if

nec

es-

sary

.

Che

ck re

duct

ion

gear

pa

rts (a

rmat

ure,

gea

r sh

aft).

Rep

lace

if n

eces

-sa

ry.

Can

you

hea

r mag

netic

sw

itch

oper

atin

g so

und?

Che

ck a

nd re

pair

wiri

ng u

p to

mag

-ne

tic s

witc

h.R

epai

r or r

epla

ce m

agne

tic s

witc

h.

No

Yes

Doe

s st

artin

g m

otor

tu

rn n

orm

ally

?C

heck

bat

tery

for c

harg

ing

cond

ition

and

bat

tery

ter-

min

als

for c

onne

ctio

ns a

nd

corro

sion

.

Is m

eshi

ng c

ondi

tion

of p

inio

n an

d rin

g ge

ar n

orm

al?

Che

ck le

ver a

ssem

bly

for d

efor

ma-

tion,

wea

k re

turn

spr

ing

and

pini

on

for s

lidin

g co

nditi

on.

Cor

rect

mes

hing

con

ditio

n of

pin

ion

and

ring

gear

. Rep

lace

if n

eces

sary

.

N.G

.

O.K

.

O.K

.

N.G

.

N.G

. (T

urns

sl

owly

)*A

Che

ck ig

nitio

n sy

s-te

m a

nd fu

el s

ys-

tem

.C

heck

eng

ine

oil v

isco

sity

.R

epla

ce m

otor

(fie

ld c

oil o

r arm

atur

e).

No

Yes

O.K

.

N.G

.R

epla

ce e

ngin

e oi

l.

Doe

s en

gine

turn

by

repl

acin

g st

artin

g m

otor

w

ith a

new

one

?

Che

ck m

agne

tic s

witc

h co

ntac

ts.

Rep

lace

if n

eces

sary

.

No

Yes

Rep

air o

r rep

lace

st

artin

g m

otor

.

Star

ting

mot

or d

oes

not

stop

whe

n ke

y sw

itch

is

turn

ed o

ff.

Che

ck in

side

of e

ngin

e.

Rep

air o

r rep

lace

key

sw

itch,

blo

ck re

lay

or m

ag-

netic

sw

itch.

: Che

ck it

em: P

robl

em o

r cor

rect

ive

actio

n

If an

y ab

norm

ality

is fo

und,

imm

edia

tely

dis

conn

ect b

atte

ry n

egat

ive

term

inal

.

Yes

O.K

.

*A

0350 502

STARTING MOTOR

EE-2-3

DISASSEMBLY



1. Magnetic switch assembly 9. Packing 16. Center holder2. Rear bracket 10. Retaining ring 17. Shim washer3. Brush holder assembly 11. Hook 18. Pinion assembly4. O-ring 12. Pinion stopper 19. Pinion case5. Yoke assembly 13. Holder 20. Felt6. Armature assembly 14. Shaft 21. Cover7. O-ring 15. Lever assembly 22. Metal8. Gear case

0350 502

STARTING MOTOR

EE-2-4

Key point of disassembly3 Brush holder assemblyContact the negative side of the brush spring to the side of thebrush. Lift the brush from the armature commutator surface. Extractthe positive side of the brush from the brush holder. Then, removethe brush holder assembly.

12 Pinion stopperMove the pinion stopper toward the pinion. Using a screwdriver, pryoff the pinion stopper clip. Then, extract the pinion assembly andcenter plate.


COMMUTATOROutside diameter

Unit: mm (in)

NOTEIf the commutator surface is rough, grind with No. 500 to600 sandpaper and then measure the outside diameter.

RunoutUnit: mm (in)


Maintenance standard Service limitLess than 0.09 (0.0035) More than 0.10 (0.0039)

0350 502

STARTING MOTOR

EE-2-5

Undercut depthUnit: mm (in)

BRUSHBrush height

Unit: mm (in)

Brush spring tensionUnit: N kgf, lbf

MAGNETIC SWITCHContinuity test (Pull coil resistance)Perform the continuity test between the M and C terminals.

Unit: Ω

Continuity test (Hold coil resistance)Check the continuity between the C terminal and coil case.

Unit: Ω



Maintenance standard Service limit Remarks29.4 3.0, 6.6 20.6 2.1, 4.6 When spring is set

Maintenance standard Service limit0.70 - 0.86 —


0350 502

STARTING MOTOR

EE-2-6

GEAR SHAFTShaft runout

Unit: mm (in)

Thrust gapUnit: mm (in)

ARMATURE COILContinuity testMake sure there is no continuity between the commutator andarmature assembly.

Insulation resistanceUnit: MΩ

FIELD COILContinuity testMake sure there is continuity between the field coil terminals.

Maintenance standard Service limitLess than 0.09 (0.035) More than 0.10 (0.0039)


Maintenance standard Service limitMore than 1.0 0.5

0350 502

STARTING MOTOR

EE-2-7

Insulation resistanceUnit: MΩ

BRUSH HOLDERInsulation resistance

Unit: MΩ

BRACKETFront bearing (metal) inside diameter

Unit: mm (in)

Commutator bearing fit section inside diameterUnit: mm (in)

Gear bearing fit section inside diameterUnit: mm (in)

ADJUSTMENTMeasure dimension L moved towards the thrust direction of the pin-ion when the magnetic switch pushes out the pinion.1. Connect the S terminal to the battery positive terminal

through the magnetic switch. Ground the M terminal mid-way and then connect it to the battery negative terminal.






0350 502

STARTING MOTOR

EE-2-8

2. Turn on the switch and make sure the magnetic switchpushes out the pinion. Then, push back the pinion lightlyand measure dimension L.

Unit: mm (in)

3. If dimension L exceeds the maintenance standard, replacethe starting motor assembly with a new one.

PERFORMANCE CHECK1. Connect as shown in the illustration. Turn off the key switch

and turn the starting motor. Under these conditions, mea-sure the current and the number of rotations. (Terminal volt-age: 24 volts)

2. Check that the pinion gear pops smoothly out and in whenthe switch is turned on and off.

3. Measure the minimum voltage which is necessary for thepinion to pop out. Prepare a variable resistor and batteryvoltmeter as testing equipment. Set the resistance higher atfirst so that a lower voltage applies to the starting motor.Then, slowly lower the resistance and measure the voltagewhen the pinion pops out.

Unit: V

Item Maintenance standard Service limitDimension L 0.5 - 3.0 (0.020 - 0.118) —

Item Maintenance standard Service limitCurrent A Less than 100 —Number of rotations rpm More than 4,000 —

Maintenance standard Service limitLess than 16 —

0350 502

- MEMO -

ALTERNATOR

EE-3-1

ALTERNATORCONSTRUCTIONModels 0202 152 0310 and 0202 152 0311

Models 0201 152 0420 and 0201 152 0421

0202 152, 0201 152, 0201 222

ALTERNATOR

EE-3-2

Models 0202 152 0220 and 0202 152 0221

Model 0201 222 0273

0202 152, 0201 152, 0201 222

ALTERNATOR

EE-3-3

TROUBLESHOOTING

To *A

No

Yes

The

batte

ry ru

ns d

own.

Is th

e vo

ltage

acr

oss

alte

rnat

or te

rmi-

nals

B a

nd E

abo

ve 2

2V?

(Whe

n th

e ke

y sw

itch

is O

N a

nd

engi

ne is

sto

pped

.)

Che

ck th

e ba

ttery

rela

y.

Che

ck th

e w

iring

.

Rep

lace

the

batte

ry re

lay.

Doe

s vo

ltage

exi

st a

cros

s al

tern

ator

te

rmin

als

IG a

nd E

?(K

ey s

witc

h is

ON

)

Mea

sure

the

alte

rnat

or c

harg

ing

cur-

rent

at B

term

inal

. Is

it ov

er 3

5A?

(Eng

ine

spee

d: 2

,000

rpm

)

Doe

s vo

ltage

exi

st?

Faul

ty a

ltern

ator

Incr

ease

the

elec

trica

l loa

d (T

urn

on

all t

he li

ghts

.)Is

the

char

ging

cur

rent

ove

r 35A

?

OIs

the

fuse

blo

wn?

OIs

the

wiri

ng b

etw

een

the

alte

rna-

tor a

nd b

atte

ry n

orm

al?

Is th

e fu

se b

low

n?

Faul

ty a

ltern

ator

Is th

e be

lt br

oken

?Is

the

belt

slip

ping

?

Is th

e ke

y sw

itch

norm

al?

Rep

air t

he w

iring

.

OR

epla

ce th

e fu

se.

OR

epai

r the

wiri

ng.

OR

epla

ce th

e fu

se.

OR

epla

ce th

e ke

y sw

itch

OR

epai

r the

alte

rnat

or.

(Rep

lace

the

diod

e, s

tato

r or

regu

lato

r.)

Nor

mal

OC

hang

e th

e be

lt.O

Adju

st th

e be

lt te

nsio

n.

Nor

mal

alte

rnat

or

(Che

ck th

e ba

ttery

and

its

rela

ted

parts

.)

Abno

rmal

Is th

e vo

ltage

acr

oss

alte

rnat

or te

rmi-

nals

B a

nd E

ove

r 27V

?(E

ngin

e sp

eed:

1,0

00 rp

m)

Abno

rmal

Abno

rmal

Abno

rmal

Abno

rmal

Abno

rmal

To *B

To *A

Nor

mal

No

To *A

Nor

mal

Nor

mal

Nor

mal

Yes

No

No

No

No

No

Yes

Yes

Yes

Yes

*A *B

0202 152, 0201 152, 0201 222

ALTERNATOR

EE-3-4

The

batte

ry b

ecom

es o

verc

harg

ed.

(The

bat

tery

flui

d de

crea

ses.

).

Is th

e vo

ltage

acr

oss

alte

rnat

or te

rmi-

nals

B a

nd E

ove

r 29V

?(E

ngin

e sp

eed:

1,0

00 rp

m)

Faul

ty a

ltern

ator

(Reg

ulat

or)

OR

epai

r the

alte

rnat

or(F

aulty

regu

lato

r)(B

roke

n in

tern

al w

iring

)

Nor

mal

alte

rnat

or

(Che

ck th

e ba

ttery

and

its

rela

ted

parts

.)No

(Bat

tery

flui

d de

crea

ses)

Yes

: Che

ck it

em: P

robl

em o

r cor

rect

ive

actio

n

0202 152, 0201 152, 0201 222

ALTERNATOR

EE-3-5

DISASSEMBLYModels 0202 152 and 0201 152

Marks “ ” and “ ” indicate that the key points of operation are explained in the text.NOTE

Numbers before part names do not indicate the disassembly sequence.

1. Nut 9. Ball bearing 17. Rubber cap2. Lock washer 10. Washer 18. Heat sink3. Washer 11. Oil seal 19. Terminal4. Pulley assembly 12. Cover 20. Through bolt5. Spacer 13. Rotor assembly 21. Charge light circuit assembly6. Front cover 14. Stator assembly 22. Cover7. Oil seal 15. Field coil assembly 23. Regulator8. Washer 16. Housing

0202 152, 0201 152, 0201 222

ALTERNATOR

EE-3-6

Model 0201 222

Marks “ ” and “ ” indicate that the key points of operation are explained in the text.NOTE

Numbers before part names do not indicate the disassembly sequence.

1. Nut 8. Ball bearing 15. Through bolt2. Lock washer 9. Retainer 16. Needle bearing3. Washer 10. Cover 17. Regulator4. Pulley assembly 11. Rotor assembly 18. Heat sink5. Front cover 12. Stator assembly 19. Terminal6. Bearing felt 13. Field coil assembly 20. Cover7. Retainer 14. Housing

0202 152, 0201 152, 0201 222

ALTERNATOR

EE-3-7

Key point of disassembly

To separate the front cove assembly, insert a screwdriver into theclearance between the front cover and stator core.NOTE

Be careful not to damage the stator coil with the screw-driver tip.

When separating the pulley assembly, secure the rotor peripherywith a vise. Then, remove the pulley nut, pulley assembly andspacer. If the pulley assembly is difficult to remove, use a general-purpose puller.


STATOR COILContinuity test of the stator coil

Unit: Ω

If there is no continuity, the stator coil may be broken. Replace thestator coil as an assembly.

Insulation test of the stator coilMake sure there is no continuity. If there is continuity, the stator coilmay be shorted. Replace the stator coil as an assembly.

6 Models 0202 152 and 0201 152 Front cover

5 Model 0201 222

4 Models 0202 152 and 0201 152 Pulley assembly

4 Model 0201 222



Resistance0202 1520201 152 0.18 - 0.22 — Between two

phases at 20ºC (68ºF)0201 222 0.14 - 0.18 —

0202 152, 0201 152, 0201 222

ALTERNATOR

EE-3-8

FIELD COILContinuity test of the field coil

Unit: Ω

If there is no continuity, the field coil may be broken. Replace thefield coil as an assembly.

Insulation test of the field coilMake sure there is no continuity. If there is continuity, the field coilmay be shorted. Replace the field coil as an assembly.

PERFORMANCE CHECKNOTE

Use leads with a cross-sectional area greater than 8 mm2

(0.0124 sq in) and a length less than 2.5 m (8.2 ft) to con-nect the line between the alternator’s B terminal and pos-itive battery terminal, the E terminal and battery groundterminal, and the L terminal and battery ground terminal.Use switches with as small a contact resistance as pos-sible in the circuit.Conduct performance test in areas where ambient tem-perature is maintained at 20ºC (68ºF).

Start-up revolution1. Install the alternator on a vehicle or connect to a variable

velocity motor and connect the leads as shown in the figure.2. Turn switches SW1 and SW2 “ON”, then gradually increase

alternator speed.3. When the voltmeter registers a voltage higher than the volt-

age when the alternator is stopped, turn switch SW1 “OFF”.4. While observing the voltmeter, increase alternator speed.5. Read alternator speed (rpm) when the voltmeter registers

27 volts.



Resistance0202 1520201 152 5.6 - 6.8 —

At 20ºC (68ºF)0201 222 5.0 - 7.0 —

0202 152, 0201 152, 0201 222

ALTERNATOR

EE-3-9

Unit: rpm

Measuring of regulating voltageTurn switch SW1 off and turn switch SW2 on. Increase the alterna-tor speed up to the rated rpm of 5,000. Then, measure the voltage.

Unit: V

Measuring output current1. Adjust the variable resistor to zero and turn switches SW1

and SW2 on.2. Keep the alternator speed at the rated rpm and adjust the

variable resistor so that the terminal voltage is at the speci-fied value. Then, read the current.Terminal voltage: 28V - 5,000 rpm

Unit: A



No-load speed

0202 1520201 152 Less than 950 —

At 20ºC (68ºF)0201 222 Less than 900 —




0202 1520201 152 Less than 50 —

At 20ºC (68ºF)0201 222 Less than 80 —

0202 152, 0201 152, 0201 222

AIR HEATER

EE-4-1

AIR HEATERCONSTRUCTION


1. Check wiring for improper connections or discontinuity. Ifthere is no continuity, replace the air heater assembly.

2. If carbon builds up on the ribbon heater, clean. Check theheater for discontinuity. If there is discontinuity, replace theair heater assembly.

- MEMO -

AUXILIARY EQUIPMENT

CONTENTSSERVICE DATA...................................... EA-1-1

SPECIFICATIONS............................................ EA-1-1SERVICE DATA ............................................... EA-1-2TIGHTENING TORQUE ................................... EA-1-4

TOOLS .................................................... EA-2-1AIR COMPRESSOR......................................... EA-2-1

AIR COMPRESSOR ............................... EA-3-1= MODEL F8040 =

CONSTRUCTION............................................. EA-3-1REMOVAL ........................................................ EA-3-1DISASSEMBLY ................................................ EA-3-2INSPECTION.................................................... EA-3-3REASSEMBLY ................................................. EA-3-5

= MODEL 408738 =CONSTRUCTION............................................. EA-3-7REMOVAL ........................................................ EA-3-9DISASSEMBLY................................................. EA-3-10INSPECTION.................................................... EA-3-13REASSEMBLY.................................................. EA-3-14

VACUUM PUMP...................................... EA-4-1CONSTRUCTION............................................. EA-4-1DISASSEMBLY................................................. EA-4-2INSPECTION.................................................... EA-4-2REASSEMBLY.................................................. EA-4-3

PUMP SUPPORT .................................... EA-5-1CONSTRUCTION............................................. EA-5-1REMOVAL ........................................................ EA-5-1DISASSEMBLY AND REASSEMBLY............... EA-5-2INSTALLATION ................................................ EA-5-2

EA

SERVICE DATA

EA-1-1


AIR COMPRESSOR<SANWA make>

<ZEXEL make>

VACUUM PUMP

Model F8040Bore x Stroke - No. of cylinders mm (in) 80 x 40 - 1 (3.15 x 1.57 - 1)

Theoretical discharge cm3 (cu in)/rev 201 (12.27)

Operating speed (max. service revolutions) rpm 1,600

Working pressure (max. service pressure) kPa kgf/cm2, psi 834 8.5, 121

Model408738

5600 5601 5610 5611 5741 5780Bore x Stroke - No. of cylinders

mm (in)85 x 40 - 1

(3.35 x 1.57 - 1)85 x 60 - 1

(3.35 x 2.36 - 1)

Theoretical discharge cm3(cu in)/rev 227 (13.85) 340 (20.75)

Operating speed (max. service revolu-tions) rpm

1,600

Working pressure (max. service pres-sure) kPa kgf/cm2, psi

834 8.5, 121

Model 1290 009 00 (VD-30) 1290 011 00 (VD-120)Type Vane

Theoretical discharge cm3 (cu in)/rev 30 (1.83) 120 (7.32)

Max. operating speed rpm 7,800

Vacuum perfor-mance

Time required to reach 66.7 kPa 500 mmHg, 19.69 inHg/Engine speed

Less than 40 seconds/1,000 rpmLess than 27 seconds/1,500 rpm

Less than 10 seconds/5,000 rpm

Max. degree of vacuum/Engine speed More than 90.6 kPa 680 mmHg, 26.77 inHg/5,000 rpm

More than 80.0 kPa 600 mmHg, 23.62 inHg/900 rpm

Alternator model 0202 152 0220/0202 152 0221 0202 152 0310/0202 152 0311

SERVICE DATA

EA-1-2

SERVICE DATA

AIR COMPRESSORModel F8040

Unit: mm (in)



Air c

ompr

esso

r pro

per

Charging perfor-mance

Engine speed

800 rpm 290 sec. — Tank capacity: 30 liter (6-5/8 Imp gal)Tank pressure:0 - 785 kPa 0 - 8 kgf/cm2,0 - 114 psi

3,200 rpm 85 sec. —

Piston-to-cylinder clearance

Piston top 0.25 - 0.35(0.0098 - 0.0138)

0.38(0.0150)

Replace piston or cylinder.Piston skirt 0.10 - 0.20

(0.0039 - 0.0079)0.25

(0.0098)

Piston ring joint gap

Compression ring 0.30 - 0.50(0.0118 - 0.0197)

1.0(0.039)

Replace ring.Oil ring 0.30 - 0.50

(0.0118 - 0.0197)1.0

(0.039)

Piston ring-to-ring groove clearance


0.08(0.0031)

Replace piston or cylinder.Oil ring 0.01 - 0.05

(0.0004 - 0.0020)0.08

(0.0031)

Piston pin hole-to-piston pin clearance 0.01L - 0.02T(0.0004L - 0.0008T)

0.08(0.0031)

L: LooseT: Tight

Clearance between connecting rod small-end piston pin hole and piston pin

0.015 - 0.045(0.0006 - 0.0018)

0.07(0.0028) Replace piston pin or connecting rod.

Clearance between connecting rod big-end bushing and crank pin

0.015 - 0.085(0.0006 - 0.0033)

0.1(0.004)

Replace bushing if worn so that cop-per color shows.Replace crankshaft in the cases.

End play of crankshaft 0 - 0.22(0 - 0.0087) — Replace.

Cyl

inde

r hea

d

Tension of valve spring

N kgf, lbf

Suction valve 4.410.45, 0.99

3.530.36, 0.79 Measured length 7.0 mm (0.276 in)

Delivery valve 4.510.46, 1.01

3.630.37, 0.82 Measured length 9.5 mm (0.374 in)

Valve liftDelivery valve 3.0 (0.118) —Unloader valve 1.0 (0.039) —Suction valve 2.6 (0.102) —

SERVICE DATA

EA-1-3

Model 408738Unit: mm (in)



Air c

ompr

esso

r pro

per

Chargingperfor-mance

5600560156105611

Engine speed

500 rpm 448 sec. —Tank capacity:30 liter (6-5/8 Imp gal)Tank pressure:0 - 785 kPa 0 - 8 kgf/cm2,0 - 114 psi

3,200 rpm 66 sec. —

57415780

Engine speed

500 rpm 264 sec. —3,200 rpm 46 sec. —

Piston-to-cylinder clearance Piston skirt 0.07 - 0.12

(0.0028 - 0.0047)0.25

(0.0098) Replace piston or cylinder.

Piston ring joint gapCompression ring 0.15 - 0.30

(0.0059 - 0.0118)0.6

(0.024)Replace ring.

Oil ring 0.15 - 0.35(0.0059 - 0.0138)

0.7(0.028)

Piston ring-to-ring groove clearance


0.08(0.0031)

Replace piston or cylinder.Oil ring 0.03 - 0.07

(0.0012 - 0.0028)0.10

(0.0039)

Piston pin hole-to-piston pin clearance 0.006 - 0.026(0.0002 - 0.0010)

0.08(0.0031)

Clearance between connecting rod small-end piston pin hole and piston pin

0.006 - 0.026(0.0002 - 0.0010)

0.08(0.0031)

Replace piston pin or connecting rod.

Clearance between connecting rod big-end crank pin hole and crank pin

0.034 - 0.075(0.0013 - 0.0030)

0.1(0.004)

Replace connecting rod if worn so that copper color shows. Replace crankshaft in other cases.

End play of crankshaft 0 - 0.50(0 - 0.0197)

1.0(0.039) Replace.

Cyl

inde

r hea

d TensionN kgf, lbf

Suction valve spring 1.18 0.12, 0.26 1.0

0.1, 0.2When compressed to8.2 mm (0.323 in)

Delivery valve spring 7.65 0.78, 1.72 6.08

0.62, 1.37When compressed to12.5 mm (0.492 in)

Valve liftSuction valve 2.0 (0.079) —Delivery valve 1.5 (0.059) —

SERVICE DATA

EA-1-4

VACUUM PUMPUnit: mm (in)

TIGHTENING TORQUE

AIR COMPRESSORModel F8040


Model 408738Unit: N·m kgf·m, ft·lbf


Vane height1290 009 00 (VD-30) 13.5 (0.531) 13.0 (0.512)1290 011 00 (VD-120) 21.5 (0.846) 21.0 (0.827)

Item Tightening torqueSuction valve holder 98 - 118 10.0 - 12.0, 72 - 87Unloader valve connector 29 - 34 3.0 - 3.5, 22 - 25Delivery valve holder 98 - 118 10.0 - 12.0, 72 - 87Nut for connecting rod cap 23 - 25 2.3 - 2.6, 17 - 19Cylinder head mounting bolt 25 - 29 2.5 - 3.0, 18 - 22Cylinder mounting bolt 25 - 29 2.5 - 3.0, 18 - 22Lock plate mounting bolt 14 - 18 1.4 - 1.8, 10 - 13

Item Tightening torqueUnloader valve connector 44 - 54 4.5 - 5.5, 33 - 40Cylinder head bolt 44 - 54 4.5 - 5.5, 33 - 40Bearing holder mounting bolt Except model 5780 13.2 - 16.2 1.35 - 1.65, 9.8 - 11.9Bearing holder mounting screw Model 5780 only 5.3 - 6.5 0.54 - 0.66, 3.9 - 4.8Cylinder bolt 26 - 32 2.7 - 3.3, 20 - 24

TOOLS

EA-2-1

TOOLSAIR COMPRESSORModel F8040

Model 408738

Tool name and number Description ShapePiston inserting kit99750 Z5500

Used to install piston in air compressor(1) Piston inserting tool(2) Crankshaft holder(3) Bolt (M10 x 1.5)(4) Bolt (M8 x 1.25)

Valve holder tool99744 97000

Used to remove and install air compressor suction valve holder

(1) 99754 96002(2) 99756 Z5500(3) 81-11025-1A(4) 81-10825-1A

Tool name and number Description ShapePiston inserting kit99750 Z5501

Used to install piston in air compressor(1) Piston inserting tool(2) Crankshaft holder(3) Bolt (M10 x 1.5)(4) Bolt (M8 x 1.25)

Oil seal replacer99753 Z5501

Used to install sleeve and oil seal in air com-pressor[Air compressor crankshaft rear endoutside diameter: 25 mm (0.98 in)]

(1) 99754 96001(2) 99756 Z5500(3) 81-11025-1A(4) 81-10825-1A

AIR COMPRESSOR

EA-3-1

AIR COMPRESSOR

= MODEL F8040 =CONSTRUCTION

REMOVAL1. Release air from the air reservoir tank.2. Drain the cooling water from the radiator through the drain

cock.3. Remove the injection pump (see section “ENGINE DISAS-

SEMBLY AND REASSEMBLY”).

F8040

AIR COMPRESSOR

EA-3-2

DISASSEMBLY



1. Cylinder head 16. Ball bearing 30. Delivery valve2. O-ring 17. Bearing holder 31. Valve seat3. Cylinder 18. O-ring 32. Unloader valve assembly4. O-ring 19. Crankshaft 33. Unloader valve connector5. Piston and connecting rod assembly 20. Ball bearing 34. O-ring6. Snap ring 21. Oil seal collar 35. Unloader valve7. Piston pin 22. Oil seal 36. Valve guide8. Connecting rod cap 23. Crankcase 37. Valve spring9. Connecting rod 24. Delivery valve assembly 38. Suction valve assembly

10. Bushing 25. Delivery valve holder 39. Suction valve holder11. Compression ring 26. O-ring 40. Valve spring12. Oil ring 27. Spring holder 41. Suction valve13. Piston 28. Valve spring 42. Valve seat14. Injection pump drive gear 29. O-ring 43. Packing15. Lock plate

F8040

AIR COMPRESSOR

EA-3-3

Key point of disassemblyBefore disassembling the air compressor, measure the end play ofthe crankshaft.

Unit: mm (in)

16, 20 Ball bearingUsing a puller, remove the ball bearing from the crankshaft.NOTE

Remove the ball bearing on the oil seal side together withthe oil seal collar.


Piston-to-cylinder clearanceUnit: mm (in)

Piston ring joint gapUnit: mm (in)

Maintenance standard Service limit0 - 0.22 (0 - 0.0087) —

Item Maintenance standard Service limitPiston top 0.25 - 0.35 (0.0098 - 0.0138) 0.38 (0.0150)Piston skirt 0.10 - 0.20 (0.0039 - 0.0079) 0.25 (0.0098)


Compression ring 0.30 - 0.50(0.0118 - 0.0197) 1.0 (0.039)

Oil ring 0.30 - 0.50(0.0118 - 0.0197) 1.0 (0.039)

F8040

AIR COMPRESSOR

EA-3-4

Piston ring-to-ring groove clearanceUnit: mm (in)

Piston pin hole-to-piston pin clearance Unit: mm (in)

Clearance between connecting rod small-end pistonpin hole and piston pin

Unit: mm (in)

Clearance between connecting rod big-end bushingand crank pin

Unit: mm (in)

NOTEReplace the bearing if its lining is worn to the extent thatcopper color shows. In other cases, replace the crank-shaft.

Tension of valve spring Unit: N kgf, lbf


Compression ring 0.01 - 0.05(0.0004 - 0.0020) 0.08 (0.0031)

Oil ring 0.01 - 0.05(0.0004 - 0.0020) 0.08 (0.0031)

Maintenance standard Service limit Remarks0.01L - 0.02T

(0.0004L - 0.0008T) 0.08 (0.0031) L: LooseT: Tight




Suction valve 4.41 0.45, 0.99 3.53 0.36, 0.79 Measured length 7.0 mm (0.276 in)

Delivery valve 4.51 0.46, 1.01 3.63 0.37, 0.82 Measured length 9.5 mm (0.374 in)

F8040

AIR COMPRESSOR

EA-3-5

REASSEMBLY38 Suction valve assembly, 32 Unloader valve assembly,24 Delivery valve assembly1. Install the suction valve assembly (using special tool 99744

97000), unloader valve assembly, and delivery valveassembly to the cylinder head through the packing or O-ring.


NOTEApply 0.1 to 0.2 milliliter (0.003 to 0.007 Imp fl oz) of ascrew lock (TB1323B) to the threads on the cylinder headside of the delivery valve holder.

2. Using an inspection rod, measure the lift of each valve tosee if it is within the maintenance standard.

Unit: mm (in)

39 Suction valve holderLock the suction valve holder with a punch.NOTE

Do not caulk in the same position as before.

22 Oil sealInstall the oil seal to the crankcase.NOTE

Coat the oil seal lip with engine oil.

20 Ball bearingInstall the ball bearings on the crankshaft by press-fitting.NOTE

The ball bearing on the oil seal side should be installedwith its shield plate facing outward (oil seal side).

Item Tightening torqueSuction valve holder 98 - 118 10.0 - 12.0, 72 - 87Unloader valve connector 29 - 34 3.0 - 3.5, 22 - 25Delivery valve holder 98 - 118 10.0 - 12.0, 72 - 87

Item Maintenance standard Service limitDelivery valve (A) 3.0 (0.118) —Unloader valve (B) 1.0 (0.039) —Suction valve (C) 2.6 (0.102) —

F8040

AIR COMPRESSOR

EA-3-6

12 Oil ring, 11 Compression ringInstall the piston rings in the ring grooves, and attach the connect-ing rod to the piston.NOTE

Install the piston rings so that their joints are neither par-allel nor normal to the piston pin and the manufacturer’smark faces up.

10 Bushing, 9 Connecting rod, 8 Connecting rod capFit the bushings in the connecting rod and connecting rod cap, andinstall the connecting rod to the crankshaft through the springwasher.


Match the alignment marks on the connecting rod andconnecting rod cap, and ensure the marks face the drivegear.

3 CylinderUsing the piston inserting kit (99750 Z5500), install the cylinder withthe O-ring in place.

: 25 - 29 N·m 2.5 - 3.0 kgf·m, 18 - 22 ft·lbfPiston insert kit (99750 Z5500)

(1) Piston inserting tool (99754 96002)(2) Crankshaft holder (99756 Z5500)(3) Bolt (81-11025-1A)(4) Bolt (81-10825-1A)

F8040

AIR COMPRESSOR

EA-3-7

= MODEL 408738 =CONSTRUCTIONModel 5600, 5601, 5610 and 5611

408738

AIR COMPRESSOR

EA-3-8

Model 408738-5741

408738

AIR COMPRESSOR

EA-3-9

Model 408738-5780

REMOVAL1. Release air from the air reservoir tank.2. Drain the cooling water from the radiator through the drain

cock.3. Remove the injection pump (see section “ENGINE DISAS-

SEMBLY AND REASSEMBLY”).

408738

AIR COMPRESSOR

EA-3-10

DISASSEMBLYModel 5600, 5601, 5610 and 5611



1. Cylinder head assembly 8. Piston 14. Sleeve2. O-ring 9. Connecting rod 15. Ball bearing3. Cylinder 10. Piston rings 16. Ball bearing4. O-ring 11. Oil seal 17. Crankshaft5. Piston and connecting rod assembly 12. Bearing holder 18. Crank case6. Retaining ring 13. O-ring 19. Unloader valve7.Piston pin

408738

AIR COMPRESSOR

EA-3-11

Model 5741



1. Cylinder head assembly 8. Piston 14. Sleeve2. O-ring 9. Connecting rod 15. Ball bearing3. Cylinder 10. Piston rings 16. Ball bearing4. O-ring 11. Oil seal 17. Crankshaft5. Piston and connecting rod assembly 12. Bearing holder 18. Crank case6. Retaining ring 13. O-ring 19. Unloader valve7. Piston pin

408738

AIR COMPRESSOR

EA-3-12

Model 5780



1. Cylinder head assembly 8. Piston 14. Sleeve2. O-ring 9. Connecting rod assembly 15. Ball bearing3. Cylinder 10. Piston rings 16. Ball bearing4. O-ring 11. Oil seal 17. Crankshaft5. Piston and connecting rod assembly 12. Bearing holder 18. Crank case6. Retaining ring 13. O-ring 19. Unloader valve7. Piston pin

408738

AIR COMPRESSOR

EA-3-13

Key point of disassemblyBefore disassembling the air compressor, measure the end play ofthe crankshaft.

Unit: mm (in)

15, 16 Ball bearingUsing a puller, remove the ball bearing from the crankshaft.NOTE

Remove the ball bearing on the oil seal side together withthe oil seal collar.


Piston-to-cylinder clearanceUnit: mm (in)

Piston ring joint gapUnit: mm (in)

Piston ring-to-ring groove clearanceUnit: mm (in)


Item Maintenance standard Service limitPiston skirt 0.07 - 0.12 (0.0028 - 0.0047) 0.25 (0.0098)

Item Maintenance standard Service limitCompression ring 0.15 - 0.30 (0.0059 - 0.0118) 0.6 (0.024)Oil ring 0.15 - 0.35 (0.0059 - 0.0138) 0.7 (0.028)

Item Maintenance standard Service limitCompression ring 0.02 - 0.05 (0.0008 - 0.0020) 0.08 (0.0031)Oil ring 0.03 - 0.07 (0.0012 - 0.0028) 0.10 (0.0039)

408738

AIR COMPRESSOR

EA-3-14

Piston pin hole-to-piston pin clearanceUnit: mm (in)

Clearance between connecting rod small-end pistonpin hole and piston pin

Unit: mm (in)

Clearance between connecting rod big-end crank pinhole and crank pin

Unit: mm (in)

Tension of valve springUnit: N kgf, lbf

REASSEMBLYKey point of reassembly14 SleevePress-fit the ball bearing onto the crankshaft, and using the oil sealreplacer (99753 Z5501), install the sleeve.

11 Oil sealUsing the oil seal replacer (99753 Z5501), install the oil seal.





Suction valve spring

1.180.12, 0.26

1.00.1, 0.2

When compressed to8.2 mm (0.323 in)

Delivery valve spring

7.650.78, 1.72

6.080.62, 1.37

When compressed to12.5 mm (0.492 in)

408738

AIR COMPRESSOR

EA-3-15

10 Piston ringsInstall the piston rings in the ring grooves, and attach the connect-ing rod to the piston.NOTE

Install the piston rings so that their joints are neither par-allel nor normal to the piston pin and the manufacturer’smark faces up.

3 CylinderUsing the piston inserting kit (99750 Z5501), install the cylinder withthe O-ring in place.

: 26 - 32 N·m 2.7 - 3.3 kgf·m, 20 - 24 ft·lbfPiston insert kit (99750 Z5501)

1 Cylinder head assemblyUsing a checking rod, etc., measure the valve lift of each valve.Make sure it is within the maintenance standard and install the cyl-inder head assembly.

Unit: mm (in)

Make sure that the end play of the crankshaft is within themaintenance standard.

Unit: mm (in)

Item Maintenance standard Service limitSuction valve 2.0 (0.079) —Delivery valve 1.5 (0.059) —

(1) Piston inserting tool (99754 96001)(2) Crankshaft holder (99756 Z5500)(3) Bolt (81-11025-1A)(4) Bolt (81-10825-1A)


408738

VACUUM PUMP

EA-4-1

VACUUM PUMPCONSTRUCTIONModel 1290 009 00 (VD-30)

Model 1290 011 00 (VD-120)

VACUUM PUMP

EA-4-2

DISASSEMBLY




VANEUnit: mm (in)

CENTER PLATECheck for damage at the sliding surface with the rotor and replacewhen worn or damaged.

HOUSINGInspect the sliding surface with the rotor for damage and replacewhen worn or damaged, especially when the inside diameter isworn or damaged.

1. Housing 6. Connector 10. Center plate2. Valve 7. Packing 11. O-ring3. Packing 8. Retaining ring 12. Rotor assembly4. Connector 9. Oil seal 13. Vane5. Packing


Height1290 009 00 13.5 (0.531) 13.0 (0.512)1290 011 00 21.5 (0.846) 21.0 (0.827)

VACUUM PUMP

EA-4-3

OTHERSReplace the O-ring at each disassembly.Replace and discolored copper packing. Moreover, checkthe threads of each part for damaged and replace whendamaged beyond use.

REASSEMBLYKey point of reassembly13 VaneAssemble the four vanes with the end having the round chamfer atthe outside.

12 Rotor assembly, 10 Center plate1. Insert the rotor into the housing. The side which has “no

crossed oil groove” should face the center plate.2. Position the center plate on the housing. Make sure a gas-

ket is used between both parts.

3. Position the vacuum pump assembly so that it is horizontalwhen the center plate is placed downward.Make sure that the hole in the center plate is aligned withthe hole in the rotor shaft when looking through the rotor’shole from the floor side.

PUMP SUPPORT

EA-5-1

PUMP SUPPORTCONSTRUCTION

REMOVALRemove the injection pump support.NOTE

Measure the backlash of the front gear train beforeremoving the injection pump support.

PUMP SUPPORT

EA-5-2



INSTALLATIONInstall the injection pump support using an O-ring (if removed aftermeasuring front gear train backlash).

1. Rotate the flywheel in the standard direction to determinethe 1.6 point at TDC of No. 1 cylinder on the compressionstroke. (TDC is the point at which both intake and exhaustvalves for No. 1 cylinder are closed and there is a valveclearance.)

1. Key 4. Drive shaft assembly 7. Drive shaft2. O-ring 5. Ball bearing 8. Oil seal3. Retaining ring 6. Ball bearing 9. Bearing holder

PUMP SUPPORT

EA-5-3

2. Align the scribe mark on the injection pump drive gear toothwith the pointer at the check window on the upper side ofthe timing gear case. Then, install the injection pump sup-port.

- MEMO -

servic d r motor nissan fe6 fe6t fe6ta

Documents

disassembly sequence

key points of disassembly

engine disassembly

notez disassembly

sequence number

reverse order of disassembly

operation sequence

x construction illustration