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WORKSHOP MANUAL C&E SERIES ENGINE (6WF1-TC (Common Rail) model) SECTION 1 ISUeU Engine Mechanical (6WF1-IC) 18-1 (6WF1-TC) TABLE OF CONTENTS @WF1-TC Engine 182 Tightening Torque Table 18-97 Maintonance Precautions 182 Timing goars 16.98 How to Read the Model 18.3 Component Parts, 18-98 Description of Functions and Operation 18-4 Romoval : : 18-98 Functional Inspection: 18-6 Inspections. 18-100 List of Trouble Symptoms tot Disassembly 1B-101 ‘Symptom: The engine fails to turn over 18-12 Assembly 18-102 Synmpivn, The engine ture uver Lui falls iv sian 1B insialition : : iB-102 13 Tightening Torque Table. 1-107 Symptom: Lots of black smoke is emitted... .1B-14 Special Tools 18-108 Symptom: Lots of white smoke is emitted ....18-15 Flywheel and Flywheel housing 18-109 Symplomn: Engine knocking occurs 1B-16 Component Parts 1B-109 ‘Symptom: The engine does not turn over properly Removal 18-109 1B-17 Disassembly. 1-111 ‘Symptom: Battery charging trouble 18-418 Inspections 184111 ‘Main speemcations ress Assembly ae Engine Assembly 18-20 Installation 18-112 Removal 18-20 Tightening Torque Table 18118 Installation 18-25 Special Tools 18-116 Engine Accessory Parts, 18-31 Piston and Connecting rod 117 Component Parts, : 18-31 Component Parts. : 18417 Removal 18-31 Removal 18-117 Installation 18-32 Disassembly 18-118 Engine Exterior Parts : 18-35 Inspections : : 18-119 Component Parts, 18-35 Assembly 18-123 Removal : : 18-37 Installation : : 18-125 Inspections. 18-43 Tightening Torque Table. 18-128 Installation 18-44 Special Tools 18-129 Tightening Torque Table. 18-62 Crankshatt 18-130 cylinder head 18-63 Component Parts, 18-130 Component Parts, 18-63 Removal 18-130 Removal 18-63 Disassembly. 18-132 Disassembly. 18-68 Inspections 18-132 Inspections. . ... : 18-71 Assembly : : 18-135 Assembly 18-75 Installation 18-136 Installation 18-80 Special Tools 18-138 Tightening Torque Table 1B-88 Cylinder block 18-139 Special Tools 18-89 ‘Component Parts, 18-139 Rocker arm 18-90 Disassembly 18-139 Component Parts, 18-90 Inspections 18-140 Disassembly. 18-00 Assembly 1141 Inspections 18.91 Tightening Torque Table. 1144 Assembly 18-02 Camshaft, : : 18-94 Component Parts 1B.04 Disassembly. 18-94 Inspections. .. : 18.05 Assembly 18-97 18-2 __ Engine Mechanical (6WF1-1C) 6WF1-TC Engine Maintenance Precautions engine maintenance in order to both safeguard against engine damage and maintain the reliability of the engine performance. + When raising or supporting the engine, donot allow the jacks to come into contact with the oi pan. When lowering the engine, use an engine pallet, ‘wood frame of other stich means to support it at the engine foot and flywheel housing + When the intake system has been removed, cover the air intake to prevent foreian matter from entering the cylinders. If foreign matter is allowed to enter. the oviinders and other parts may be seriously damaged when the engine Is run + When condueting maintenance work on the engine body, be absolutely sure to disconnect the battery grounding cable. Whon power necds to be supplied to the engine during inspections or other such jobs, exercise care since short-circuting may occur. + Apply plenty of engine oi! to tne siting surraces in order to protect and lubricate the sliding surfaces during the initial operation + When the valve train parts, pistons. piston rinas, connecting rods, connecting rod bearings and crankshaft journal bearings have been disassembled, arrange them in sequence and store them. + When re-mounting the parts, mount the same parts in the eame positions where they were prior to disassembly. + Whenever the gaskets, ol seals, O-nngs and other such parts are disassembled, be absolutely sure to replace them with new parts + When using liquid gaskets, remove all the old ones, wash the parts where they were used to remove any il, arease, moisture and contamination, and then apply the designated liauid gaskets and assemble the parts, + Assemble the parts within 7 minutes after applying If more than 7 minutes have elapsed, remove the liquid gackete, and re-apply them, + During the assembly and mounting processes, tighten the pans to the specitied tightening torque, and ensure that the parts are mounted propery. Precautions for jobs inherent to this engine In the fuel system, all the holes and olearances inside. the injector that serves as the fuel passages and other parts are finished to a high level of precision. Far this reason, these parts are particularly sensitive to foreign matter. and the entry of foreign matter may lead to matfunctioning or other trouble. Therefore, take every means possible to keep these holes and clearances free from foreign matter. Engine Mechanical (6WF1-IC) _1B-3 How to Read the Model Legend 1. Engine serial number (6WF1-......) 18-4 _ Engine Mechanical (6WF1-1C) Description of Functions and Operation Structural view of engine Engine Mechanical (6WF1-IC) _1B-5 18-6 _ Engine Mechanical (6WF1-1C) Functional Inspection: Measurement of compression pressure Measure the compression pressure with the battery and starter motor in @ trouble-free state while the engine is cold (water temperature of 20°C/68°F) Removal of glow plugs + Remove all the glow plugs (1). Disconnection of injector harness connectors + Disconnect the injector hamess connectors from the lower head cover (No fuel injected). Mounting of compression gauge + Insert the compression adapter into the holes where the glow plugs are installed, and mount the compression gauge. Special tools ‘Compression adapter: 5-8531-7001-0 ‘Measurement of compression pressure + Run the starter motor (at a speed of 200 rpm), and. read off the compression pressure when the pointer of the compression gauge has stabilized NOTE: + Bear in mind that air will shoot out with great force from the glow hole while the motor is running + Measure the compression force for all the cylinders. + When disconnecting the hamess connectors, the ECM will identify this as a failure and record an error code. Upon completion of the measurements, be absolutely sure to clear the ECM memory.(For details on how to clear the ECM memory refer to the Troubleshooting Manual.) item | Compression | Diference between pressure oylinders Pa (kglony fps | KPa (kg/cm? fosiyrom "pm 2840 200 standard | (9/412)/200 | _(2.0/28)/ 200 2260 limit | (23/327) 200 - Engine Mechanical (6WF1-IC) _1B-7 Determining when overhauling is to be performed Overhauling is required in the following cases. Drop in camprassion pressure When the compression pressure has dropped below 2200 APa (ZGryiuW7S27ysi) awarding tw tie measurement method set forth in "Measurement of ‘compression pressure.” Increase in rate at which engine oll Is consumed When, if 100% serves as the amount of engine oil consumed (number of kilometers traveled per liter of oil) by a new vehicle, this rate has dropped below 50% Increase in rate at which fuel is consumed When, if 100% serves as the amount of fuel consumer {(krnfiter) by a new vohiclo, this rate has dropped below 60%. Abnormal noises inside the engine When abnormal noises are heard from inside the engine. Implement overhauling as soon as possible and remedy the problem. NOTE: Examples of possible factors that may cause abnormal noises include engine parts wear, seizures and overheating, Maintenance Precaut ns. 1, Allow the engine to cool off sufficiently since its Barts will be hat immediately after the engine has been run, 2, Since self-diagnosis codes are stored in the ECM memory, remember to check the codes stored in the ECM using the scanning tou! before inspecting the sensors. 3. Be absolutely sure to disconnect me battery terminals in order to protect the sensors and other electronic components trom damage and prevent a fire 4, There is a risk of electric shocks from the high voltages present in the injector harness and solenoid valve areas. Before proceeding with the maintenance work. be absolutely sure to set the starter switch to the "lock" position and pull out the key. Adjustment of valve clearance Adjust the valve clearance in two stages: first with the #1 cylinder set to the compression top dead center, and then with the #6 cylinder set to the compression top dead center. Adjustment of vaive ciearance Setting the #1 (or #6) cylinder to the compression top dead center Turn the erankcha in the forward diroetion, and align the TIC ruled line of the flywheel to the pointer. At this point, check that thore is a clearance botween the cam and rocker arm of the #1 (or #6) cylinder (compression b> | Non in Adjustment of valve clearance 1. Aglust tne vaives listes in tne vane clearance adjustment table. 18-8 _ Engine Mechanical (6WF1-1C) 2. Loosen the adjusting screws (1) of the rocker arm and bridge (2) completely. 3. Insert the thickness gauge between the rocker arm (1) and cam, make the adjustment using the adjusting screw of the rocker arm, and then secure using the lock nut. owoses01 4. With the thickness gauge stil inserted, tighten the adjusting screw of the bridge until the gauge ceases to move, 5. Gradually loosen the adjusting screw of the bridge re-adjust so that the insertion and removal of the thickness gauge feel suitably sti, and secure the lock nut of the bridge. Valve clearance mm(in) (when cold) 10.40(0.016) for Bath intake and exhaust Tightening torque:N-m(kgf mbt) Rocker arm adjusting screw lock rut Bridge adjusting screw lock nut 78 (8.0) 58) 54 (55/40) NOTE: + Before starting the work, stop the engine, and allow enough time for the engine to cool off. + A small amount of oil oozes out when the head over is removed, so use @ rag to clean it up Engine Mechanical (6WF1-IC) 18-9 Valve clearance adjustment table Cylinder No. 7 2 3 4 5 6 Arrangement! exis! in | exH| IN | eEXH| IN |EXH| IN |EXH| IN | EXH| IN of valves When the #1 cylinder is set at the compression top dead Valve to be | center Condition adjusted [When the #6 oylinder is sot ° O#|0 Ho: [Bo top dead center Injection sequence (1-5 -3-6-2-4) Inspection and adjustment of belts 3. Detection amount when the centers between the idle pulley and generator pulley (F1) and between the crank pulley and idle pulley (F2) are pressed with a force of 9BN (10 kgf/22!b). Inspect the V-halt far wear and cracks Reference values New product] When tension is mm(in) ro-adjusted mm(in). Ft 0-13 14 (0.39-051) | (0.43-0.55) F2 3-16 76-18 (051-063) | (059-071) Adjustment of generator drive belt tension 2. Using the adjusting bolt of the idle pulley, adjust the belt tension to the reference value, 18-10 _ Engine Mechanical (6WF1-1C) Legend 1. Adjusting bott 2. Lock nut 3. Ft 4. F2 Agjusiment of AIC compressor drive bei ie 41. Loosen the bolt and nut shown in the illustration. 2. Using the adjusting bolt, adjust the belt tension to the reference valie Reterence values Deflection amount when the center between the crank pulley and A/C compressor is pressed with a force of 98N (10 kgf/22Ib): 10 - 13 mm(0.39 -0.51 in) 3. Tiahten the bolt and nut Legend 1. Adjusting bott eves Legend 1. Bolt 2. AIC compressor 3. Adjusting bolt 4. Nut (rear side) Engine Mechanical (6WF1-1C) 18-11 List of Trouble Symptoms +The engine fails to turn over + The engine turns over but fails to start + Lots of biack smoke 1s emitted + Lots of white smoke is emitted + Engine knocking occurs + The engine dows not turn over properly + Battery charging trouble 18-12 _ Engine Mechanical (6WF1-IC) ‘Symptom: The engine fails to turn over Condition Possible Cause Correction ‘Something is wrong with the wiring, Connect or repair. The battery capacity is insufficient. Recharge or replace. The starter brush has stuck or is worn or damaged Repair or replace. ‘Something is wrong with functions inside the starter. the Disassemble and repair. "The starter turns but falls to engage with the flywheel ‘The starter pinion engages with the ring gear but fails to tur. The ring gear is worn Repair or replace. The magnetic switch of the starter is not adjusted properly ‘Something is wrong with the battery capacity ‘Adjust or repair, Charge or repair. The contact pressure of the starter brush and commutator is. insufficient Disassemble and repair. The armature of the starter 18 StUCK, Disassemble and repair. The enaine has seized up inside. Disassemble and repair. Engine Mechanical (6WF1-1C) 18-13 ‘Symptom: The engine turns over but fails to start Condition Possible Cause Correction pump. system, Air nas been sucked in from the fuel pump. The engine is out of fuel. Purge the air or replace the pump. Replenish, The strainer in the fa is clogged. ‘Suction area Clean or replace, “The fue! pipe is clogged, Clean or replace, ‘Somathing is wrong with the| Disassemble and rapair funetions of the supply pump. Th extiemvly GoW weather, fuel] Replace with the suitable fuel ‘which is not designed to be used in oid areas, is being used The fuel fiter is clogged. Replace ‘Something is wrong with the engine| Diagnose the engine control control system, system, Fuel reaches the supply pump. The injection pipe connections are] Tighten up the parts, loose. The overflow valve is nat] Replace completely airtight. A failure has occurred inside the| Inspect or repair. supply pump) The wiring is not connected | Repair or replace. properly or is broken The rotation sensor is defective. | Replace. Something is wrong wilh the engine| Diagnose the engine control control system, system, insufficient or unstable amount of | Air has found its way inside the fuel | Purge the air. fuel injected system. The fuel pipe is clogged Clean or replace ‘Something 18 wrong with tme| Disassemble and repair. functions of the supply pump. The injector nozzle is stuck. Replace The wiring is not connected| Repair or replace. properly or is broken The fuel iter is clogged. Replace ‘Ramething fe wenng with the angina | Niagnnee the engine _cantenl control system, system, 18-14 _ Engine Mechanical (6WF1-1C) ‘Symptom: Lots of black smoke is emitted Condition Possible Cause Correction control system, system. Something © wrong with the| The nozzle is stuck Replace injection status ofthe injector. ‘Something is wrong with he engine | Diagnose the engine control control system, system. Tnsuficiont comprossion prossure | “The valve clearance fs excosaive, | Adjust The valve stem is stuck (valve open| Disassemble and repair. status) The valve spring is defective Replace The valve seat is worn. Disassemble and repair. The compression pressure is Disassemble and repair. leaking due to a defective piston ring or other part. ‘A gasket is defective. Disassomblo and repair Apiston has seized up. Disassemble and repair. ‘The quality of the fuel is not high} Moisture has become mixed in with | Replace. enough. the fuel. ‘A low-grade fuels being used. _| Replace. Detective air intake The intake pipe is clogged Repair or replace. The air cleaner elementis clogged. | Clean or replace. ‘Trouble detected by engine control] Trouble in the sensors or other| Repair or replace. system ats ‘Something s wrong with the engine | Diagnose the engine contral control system. system, The EGR or exhaust valve ls| The EGR valve is stuck Repair or replace. defective. The exhaust brake valve is stuck | Repair or replace. ‘Something is wrong with the engine | Diagnose the engine contral control system. system. Engine Mechanical (6WF1-1C) 18-15 ‘Symptom: Lots of white smoke is emitted Condition Possible Cause Correction ‘Something is wrong with the engine control system. Diagnose the system. engine ‘control Trouble detected by engine control system Trouble in the sensors or other parts Replace. ‘Something Is wrong with the control unit Replace, ‘Something is wrong with the engine control system. Diagnose the system, engine control The compression defective pressure is The valve clearance is excessive or insufficient Adjust. The vaive stem is stuck (valve open status), The valve spring is defective, Disassemble and repair. Replace, The vaive seat is worn Disassemble and repair. The compression pressure 1S leaking due to a defective piston ring or other part Disassemble and repair, ‘A casket is defective Disassamble and rapair A piston has seized up. Disassemble and repair. The quality of the fuel is not high enough Moisture has become mixed in with the fuel Replace. High oil consumption The piston ring is worn or broken. Disassemble and repair. The vaive stem oll seals defestive, Disassemble and repair 18-16 _ Engine Mechanical (6WF1-1C) ‘Symptom: Engine knocking occurs Condition Possible Cause Correction control system. system, ‘Trouble detected by engine control| Trouble in the sensors or other| Replace, system parts ‘Something is wrong with the contro! | Replace. unit ‘Something is wrong with the engine| Diagnose the engine _ control control system, system, Fuel A low-grade fuel is being used. Replace. Defective air intake The intake pipe is clogged Repair or replace. Somelhing is wong with tie engine] Diagnose ie engine contol control system. system, ‘Abnormal noises from the engine Foreign matter has found its way inside the cylinders. Repair or replace. A piston, bearing or other part has ccized up. Repair or replace. Engine Mechanical (6WF1-1C) 18-17 ‘Symptom: The engine does not turn over properly Condition Possible Cause Correction defective. ‘Something is wrong with the control unit ‘Something is wrong with the engine control system. Replace. Diagnose the engine control system Unstable engine turn-over ‘Something is wrong with the control nit ‘Something is wrong with the engine control system, Replace. Diagnose the engine control system, “The fuel filter element is clogged Replace the element The nozzle is defective. Replace. Moisture has become mixed in with | Replace. the fuel Air has found its way inside the fuel | Purge the air. sotem, The exhaust brake valve is stuck Repair or replace. 18-18 _ Engine Mechanical (6WF1-1C) ‘Symptom: Battery charging trouble Condition Possible Cause Correction Insufficient charging defective connection a ‘Something is wrong with functions inside the generator. Short-circuited wire or defective connection the Disassemble and repair. Connect or repair, ‘Something is wrong with functions inside the generator. The generator drive belt is loose. the Disassemble and repair Adjust or repair. The battery is defective. Replace. ‘Overcharging Wire short-circuiting Connect or repalr Something is wrong with | functions inside the generator. the Disassemble and repair. Main Specifications Model WFT-TC Engine type Water-cooled 4-cycle inline 6-cyinder 24-valve OHC direct-injection diesel engine Cylinder layout and number i ] 2 r eee arse (mm /in) L6 - 6147 (6.79) - 140 (5.51) Total displacement (Lin’) 14.256 (869.9) ‘Compression ratio 17.0 Zz ‘Compression pressure Katka Von? ve 2044 (29 412)/ 200 Dimensions (engi / widih 7 height) rain 1693 (66.66) / 960 (37.6)/ 1159 (45.63) Maintananan weight fexahiding air oonaes cleaner) («gio 1180 (2602) Fuel injection ting (GTDC) o Fuel injection sequence 1.5. 3-8-2-4 Injection pump type Electronically controlled fuel injection system (common-rail type) Timer type Electronic Nozzle model DILP Intake and exhaust valve clearance Hepsi (mm fin) 0.4 (0.016) nae valve opening and closing (Open) ou ere) Intake vaive opening and closing (Close) . timing 27° (ABDC) Engine Mechanical (6WF1-IC) _1B-19 Model eWEt-TC lem Exhaust valve opening and closing (vend timing — ‘valve opening and closing (Giose) ae ATHe) Fuel fiter type Filter paper ype ‘Oiiter type Pleated titer paper type Partial il fiter type Fiter paper type Oil pump type Gear ype Gil cooler type Water-cooled type Engine ol moun (Litm.gan| "pth combined main and paral ol er Cooling unit system Water-cooled forced circulation type Total cooling water capacity Timp gal) 414 0.11) Water pump pe Centrifugal gear ype Thermostat tyoe Wax type Air cleaner type Filter paper type Battery type (Type - number) 15F51 -2 ‘Generator capacity WA) 24-50, 24-60 ‘Starter WaW) 24-70 Idling speed (rem) 490-510 Turbocharger ype Model TD0H - 27V (made by MHI) intercooler type ‘Aluminum tube & end plate type Thermostat onan valve famparahire COPF) #2 (180) Thermostat totally open temperature! oan penal itt amount 18-20 _ Engine Mechanical (6WF1-1C) Engine Assembly Removal 3. Transmission assembly CAUTION: For details on removing or installing the . transmission assembly, refer to the chapter entitied Precautions for removal and installation 7 " ‘Removing or installing the transmission, + Lock the wheels. + Attach wires securely to the engine, and hoist it + Do not position yourself underneath the engine while itis being hoisted + Never put your hands where they may be pinched of sandwiched, + The engine is heavy so proceed with the work with all due care. 1. Battery cable Disconnect the battery cable from the negative terminal (1) Drain aff the pooling water Drain off the cooling water from the drain plug of the radiator and drain plug of the engine Howstastenient 2. Exhaust pipe oweresrasot 8. Inter-cooler nose Radiator hoses Disconnect the hamess attached to the upper hose. At this time, remove the harness bracket attached to the radiator as well before proceedina, Disconnect the air purging hose, upper hose and lower hose. 7. Oil level gauge Remove the bolt for the oil level gauge attached to itwil not get in the way. Engine Mechanical (6WF1-1C) 18-21 8, Oilfiller pipe Disengage the clip of the heater hose attached to the oll tiller pipe, and remove the oil tier pipe. owareshassrot 9. Side noise cover 410. Air cleaner azsembly Disconnect the air duct and connector, and remove 18-22 _ Engine Mechanical (6WF1-1C) 11, Exhaust pipe tront and exnaust brake Remove the heat protector, and remove the exnaust pipe tront and exhaust brake. owsrastemont 42. Exhaust pipe front and exhaust brake Remove the heat protector (2) and then the exhaust pipe front (1) and exhaust brake (3) Gab back member Remove the cab back member noise cover (2). Remove the oll tank (1) of the power steering pump. Disconnect the air hose (1) connected to the cab back members and its connectors (2). 1B. Engine Mechanical (6WF1-1C) Remove tne insulator (1) and then the oll pipe (2) for tilting the cab, 19. Engine harness connector Disconnect the connectors 14. AIC compressor Remove the belt for the AIC compressor and harness connectors. Remove the four A/C compressor mounting bolts and the gas nive clip. and out the A/C compressor to one side so that it will not get in the way. At this point in time, do not disconnect the gas pipe from the A/C compressor. Howotestnstot 15, Generator wires 16. Starter wires 47. Dual thermo sensor connector 18. Oil pressure sensor connector 20. Sub tank hose Disconnect the air purging hose and charge pipe. 18-24 _ Engine Mechanical (6WF1-1C) 21, EGR valve air nose Disconnect EGR valve air hose. | | a 22. Air oylinder hose Disconnect the air cylinder hose. 23, Air compressor hose Disconnect the air compressor hose. 24, Power sivering pump Remove the two mounting bolts, and remove the power steering pump. Do not remove the cil pipe of the power steering Pump at this point in ume. Release the oll pipe of the power steering pump, and put the power steering pump with oll pipe attached to one side, 25, Engine speed sensor connector 26. Shift selector rod hg ce, y | ia 2/. Ground wire Cut the connection between the starter ground and trame ground (1) eS = exe PYLE ST AGN veworeias01 28, Fuel hose Cut the connection between IN and OUT of the fuel hose. At this point in time, drain the fuel fiter as well \ 29. Engine mounting Install the engine hangers from the right to front cut the engine mounting connections. 30. Engine assembly Hoist the engine slowly, and remove it. Do this work while taking care to avoid interference with other parts Never position yourself undemeath the engine when itis being hoisted ely, anc Engine Mechanical (6WF1-1C) _ 18: Installation CAUTION: Precautions for removal and installation + Attach wires securely to the engine, and hoist i. + Do not position yourself underneath the engine while itis being hoisted. + Never put your hands where they may be pinched cor sandwiched. + The engine is heavy so proceed with the work with all due care. 4, Engine assembly Hoist the engine slowly, and install it in place. Do this work while taking care to avoid interference with other parts, sCAUTION: Never position yourselt underneath the engine when it is being hoisted. 2. Engine mounting Install the engine mounting, and tighten it to the specified torque. Front tightening torque: Nim (kgf) Engine side (6) 208 @327 Rubber nut a uibber nu Se aE Engine side (1) 400 (6007362) a Rubber bolt Ghasaie side @) 187 (16.07 Bracket Frame side (6) 187 (16.07 16) 116) Legend Engine foot Nut (chassis side) Bracket Frame Bott (frame side) Nut (enaine side) Rear tightening torque: N-m(kgf milb-#t) 18-26 _ Engine Mechanical (6WF1-1C) 3. Fuel nose Install the IN and OUT of the fuel hose. 4, Ground wire Connect the starter ground wire (1) to the frame. ‘>, Shitt selector roa 6. Engine speed sensor connector 7. Power steering pump Install the power steering pump, and tighten it to the specified torque, Tightening torque: 39N-m (4.0kgt:m/29lb-ft) Install the suction pipe and governor pipe of the air compressor. EGR valve air hose Air compressor hose Air cylinder hose 11. Sub tank hose Nowornstost04 12, Engine hamess connector Connect the connectors securely, rowatastostot 13, Oil prossure switch 14. Dual thermo sensor connector 15. Starter wires 16. Generator connector 17. AIC compressor Install the A/C compres specified torque. Tightening torque: ‘and tighten it to the 20N-m (2.0kaf-rn/14Ib-f)) Engine Mechanical (6WF1-IC) _1B-27 Install the A/C compressor elt, harness connectors and gas pipe clips. Adjust the belt tension. (For details on adjusting the belt tension, refer to the section on inspections and maintenance.) rowareshassot 18. Cab back member Install the cab back member, and tighten it to the specified torque. Tightening torque: 155Nm (15.8kgfm/114Ib-f)) owareshassot 18-28 _ Engine Mechanical (6WF1-1C) Install ie oll pipe (2) for uiting the cab, Connect the air hose and its connectors to the cab back member. howsrastostot Install the oil tank (1) of the power steering pump. install ine cab back memoer noise cover (2) Purge the air in the cab tt pump. 19. Exhaust pipe front and exhaust brake Install the exhaust pipe front (1) and exhaust brake (3), and tiahten it to the specified toraue. Tightening torque: 89N-m (6.0kgt:m/43ib-t)) Install the neat protector (2) 20. Air cleaner assembly Install the air cleaner assembly, and connect the air duct and its connectors. 21. Mud guard 22, Side noise cover 23. Oilfiller pipe 24, Oil level gauge Engine Mechanical (6WF1-IC) 18-29 28. Inter-cooler nose 25. Radiator hose After installing the air purging hose. upper hose and lower hose, connect the harness, 27, Pour in the cooling water. 28, Transmission assembly For details on installing the transmission assembly, refer to the chapter on removing and inetalling the transmission. 29. Exhaust pipe 18-30 _ Engine Mechanical (6WF1-1C) 30, Battery cable Connect the battery cable (1). Inspections and adjustments after installation Supply and check the engine oil and cooling water. Inspect and check the idling speed. inspect aid check the clutch pedal play. Adjust the pulling reserve of the parking brake lever. Clear away the raas from around the engine and any other items that may be snagged by the engine parts, and wipe off any engine oll and other substances on the engine, Check that the shift lever ie at the neutral position, call out to warn any persons in the vicinity, start up the engine using the starter ewiteh of the driver's seat, and check that the engine starts up and stops properly Check for leaking oll or water from the engine pars. Check for leaking fuel, oil and air from the pipe connections, Check that no unusual sounds are heard from any of the parts, Check that no exhaust yas is leaking and thal the exhaust gas is colorless. After stopping the engine, inspect whether the cil and cooling water are within the prescribed levels. Go for a test drive, and check that there are no problems, Engine Mechanical (6WF1-TC) 18-31 Engine Accessory Parts Component Parts Legend “1. Generator 2. Starter 3. Oil pipe (power steering oil pump) 4. Power steering ail pump 5. AIC compressor (cab cooler) 6. Cooling fan and fan drive 7. Fan guide 8. V-belt (for AIC compressor) 9. Vebeit (for generator) Removal 1. Fan guide 2. Cooling fan and fan drive 3, Vebelt (for A/C compressor) 4. AIC compressor 18-32 _Engine Mechanical (6WF1-1C) + Remove the A/C compressor trom the bracket. Howoresosot Legend 1. Collar 2. AIC compressor 3. Stay 5. Vebelt (for generator) 6. Generator 7. Oil pipe (power steering oll pump) + Disconnect the oll pipe (2) at the outlet side of the power steering oll pump. Legend 1. Clip 2. Power steering oil pipe 8. Power steering oil pump + With the intake side cil pipe stil attached, disconnect the oll pump (1) from the timing gear NOTE: ‘After disconnecting the pump, seal it to prevent foreign matter from entering inside. 9. Starter Installation 1. Starter * Connect the starter cable as shown in the ilustration Tightening torque: 103N-m (10.5kgfnv76o) 2. Power steering oil pump (1) Engine Mechanical (6WF1-TC) _1B: + Assemble the O-ring Into the pump, apply ‘grease around the outside of the O-ring, and install in the gear case. Tightening torque: 39N-m (4.0kgFm/29b-ty Hewarastootor 3. Oilpipe (power stooring oll pump) + Connect the oil pipe at the discharge side of the power steering oil pump. 4, Generator 5. Vebelt (for generator) + Adjust the V-belt tension, 6. AIC compressor + Install the compressor in such a way that it sandwiches the collar (1) and stay (3). Tightening torque: 20N-m (2.0kgfmi4lb-tt) Legend 1. Clip 2. Power steering oil pipe rowatesi.o1 Legend 1. Collar Eye- 2. AIC compressor '5QN-m (6.0kgfm/43ib- Tightening torque | bolt (6.0kgF- t) 3. Stay Union | 98Nm (FOKgFmi7ZO | — 7 Waseit for AKC compressor) + Adjust the V-belt (for the AIG compressor) tension. + For the adjustment procedure, refer to the section on belt inspections and adjustments 8. Cooling fan and fan drive 8. Before proceeding any further, bolt the fan onto the rear of the fan drive,(1) b. Assemble the assembled fan and fan drive into the adapter (2) 6. Install the adapter into the crank pulley.(3) Tightening torque: S8N-m (5.9kgfMV43Io-tt) 18-34 _ Engine Mechanical (6WF1-IC) 9. Fan guide + Install the fan guides through the mounting rubber pieces shown in the illustration in three places on the water outlet pipe, on the bracket mounted at the front right of the gear case and ‘on the bracket mounted at the bottom left side Tightening torque Oullet side. S9Nn (4 ObyFrv28ib-N) Gear case side: 119N-m (12. 1kgfm/88ib-t) Engine Mechanical (6WF1-IC) 18-35 Engine Exterior Parts Component Parts Legend 1. EGR pipe (Rr) 7. EGR duct and lead vaive (Ft) 2. EGR cooler (Rr) 8. Water pipe: EGR cooler (Ft) 3. EGR vaive (Rr) 9. EGR pipe (Ft) 4 Air pipe: EGR valve (Rr) 10. Suction pipe: Air compressor 5. EGR duct and lead valve (Rr) 11. Ventilator hose 6. Water pipe: Air leak 18-36 _ Engine Mechanical (6WF1-1C) Legend 1. Water pipe (OUT): EGR valve (Rr) 10. Heater pipe 2, Exhaust duct 41, Thermostat housing 3, Inlet duct 12. Water pipe: Turbocharger (IN) 4. Turbocharger 19. Oil pipe: Turbocharger (OUT) 5. Water pipe: Turbocharger (OUT) 14, Oil pipe: Turbocharger (IN) 6. Inlet pipe 19. Partial oil fiter 7. Water pipe (OUT): EGR valve (Ft) 16. Oilfilter 8. Water pump 17. Drain pipe: Water 9. Water pipe (IN) 18. Oilcooler Engine Mechanical (6WF1-TC) _1B: Legend Water pipe: Air compressor Air charge pipe Water outiet pipe Injet pipe Fuel pipe: Common-rail to supply pump Common-rail Injection pipe Fuel fiter Fuel retum pipe 10. 1" 12 13. 14. 16. 16. 7 18. Air governor pipe Fuel feed pipe il pipe: Supply pump (IN) il pipe: Supply pump (OUT) ‘Supply pump Bracket: Supply pump Oil level guide tube Oil pipe: Air compressor (IN) Air compressor Removal 1. Air breather hose 2. Engine hamess NOTE: Making paint marks at the positions where the hamess clips are installed before removing these parts will make it easier to reassemble the parts later. 3. Water pipe: Alr leak 4. Water pipe: Charge + Remove the overheat switch attached on the cylinder head side, and disconnact the air leak pipe, 18-38 Engine Mechanical (6WF1-1C) Legend 4. Charge pipe 2. Airleak off pipe 3, Water outlet pipe 5. Inlet pipe: NOTE: ‘Seal the opening of the inlet manifold to prevent foreign ‘matter from entering inside ®. Air compressor suction pipe 7. Water pipe (OUT): EGR valve (Rr) 8. Water pipe (OUT): EGR valve (Ft) + Disconnect the water pipe (OUT) for cooling the EGR valve. 9. EGR pipe (Rr) 10. EGR pipe (Fty NOTE: Seal the two ends of the EGR pipe to prevent foreign ‘matter from entering inside. 11. Air pipe: EGR valve’ + Remove the eye-bolt and clip on the EGR pipe side, and disconnect the air pipes (1) (2) ae assemblies. Engine Mechanical (6WF1-1C) _ 18: 11, Fuel pipe + A'small amount of fuel will gush out so hold a rag against the pipe when removing the pipe. NOTE: ‘Seal the mounting parts of the removed pipe to prevent contamination with foreign matter. Legend 1. Air pipe 2. Air pipe 12. Water pipe: EGR valve (IN) 13. Water pipe: EGR cooler to EGR valve NOTE: ‘The eye-bolts indicated by the arrows in the illustration are special eye-bolts whose heads have a recessed hole (for purging the air). Legend +. Water pipe 2. EGR cooler 2. EGR valve 4, Water pipe (IN) 14, EGR valve 15, EGR cooler 16. EGR duct and lead valve 18-40 _ Engine Mechanical (6WF1-1C) Legend 1. Filter to supply pump 4. Fuel feed 2. Fue! filter return 5. Fuel retum 3. leak off pipe return 6. Feed pump to filter 18, Fuel filter and bracket roworestorot Legend 18, Fuel feed pipe: Supply pump to common-rall 1. Fuel pipe: Common-ail to supply pump 20. Oil pipe: Supply pump 2 Ollteed pipe + Disconnect the oil feed and ol return pipes. 3. Oil retumn pipe Engine Mechanical (6WF1-IC) 18-41 21. Oll level gauge guide tube and bracket NOTE: + Fit a wrench onto the flow damper (19 mmi0.75in Width across flats) of the common-rall to stop it from tuming, and loosen the sleeve nuts of the injection Pipes. + Seal the pipes and pumps to prevent foreign matter ‘rom entering inside. + Take care not to bend the injection pipes out of shape when disconnecting them, A small amount of fuel may flow from the head area, so clean it up using a rag + Check that the rubber parts of the clips are not cracked or darnaged Legend 1. Oil level gauge guide tube 2. Bracket 3. Plug 22. Supply pump + Loosen the coupling tightening bolt, and remove the supply pump. Legend 1. Cotter bolt 2. Coupling tightening bolt 23. Injection pipes (1) to (6) + Disengage the clips of the injection pipes, and then disconnect the injection pipes. owsrasheniot 24, Common-rail + Remove the fuel pipe clip bracket, and remove the common-rail NOTE: ‘Seal the openings where the common-rail pipes are mounted to prevent contamination with foreign matter. 18-42 __ Engine Mechanical (6WF1-1C) Legend 4, Common-rail 2. Fuel pipe bracket 3. Common-rail bracket 4, Fuel pipe bracket 25. Supply pump bracket 28. Ci pipe: Air compressor 27. Water pipe: Air compressor Compressor, single type Compressor, V-twin type Legend Air suction pipe , Water pipe (OUT) Water pipe (IN) Ar intake pipe Compressor . Air pipe: Charge 28. Air pipe: Charge and governor 29. Air compressor Legend 1. Flare nut 2. Bracket 3. Nut 4. SIP washer 5. Union 30. Inlet pipe: Turbocharger 31, Inlet duct: Turbocharger 32, Exhaust brake Engine Mechanical (6WF1-IC) 18-43 33. Turpocharger oll pipe 34. Turbocharger water pipe rowarasto1o0 Legend 41. Water pipe (OUT) 2. Water pipe (IN) 35, Turbocharger NoTE: Aiter removing the parts, cover the oil inlet and outlet of the turbocharger, inlet and outlet of the cooling water, and inlet and outlet of the compressor and turbine sides with gummed tape to prevent foreign matter from entering inside Legend 1. Gasket 36. Oil filter 37. Partial oil fiter 38. Heater pipe 39. Water outlet pipe 40. Water inlet pipe 41, Thermostat housing 42, Water pump 43, Water drain pipe 44, Oil cooler + Remove the all cooler tightening bolts, insort the removed bolts into the two replacer holes, tighten them up, and remove the oil cooler. Inspections EGR lead valve + Inspect the exterior of the valve for damage. + Inspect whether carbon has accumulated behwaen the stopper and vaive. 18-44 _ Engine Mechanical (6WF1-1C) Installation 4. Oll cooler + Fit the four O-rings into place. (2 types - 2 pes each) + Fit the gasket into the groove on the surface of the flange to be mounted into the cylinder block, and install the oil cooler. Tightening torque: SON-m (5.tkgfimn/S7Ibtt) Legend 1, Gasket 2. Orting 3. Ol cooler 4. Water drain pipe 2. Water drain pipe + Provisionally install and tighten connector (A), water drain pipe (B) and tightening bolt (C) in this order, Nin (ket mlb) Area A: 78 (8.0058) Tightening [Area 35 _(GHTBO) torque Area 4 (6432) Area D: 4 (0.4/351b-in) Legend 4. Connector (area A) 2. Water drain pipe (area B) 3. Water drain plug(area D) 4, Bolt (area C) 3, Water pump + Fit the two O-rings into the water pump, and while pressing on the gear case side, tighten the two bolts on the oil cooler side. Then tighten from the gear case side using the four bolts. Tightening torque: 39N«m (4.0kgtm/2SIb-tt) Legend 1. Water pump 2. O-ring 3. Orting 4, Thermostat housing Engine Mechanical (6WF1-IC) 18-45 + Mount the two thermostats onto the oll cooler. + For details on mounting the seal rings and thermostats, refer to the section on mounting the thermostats. + Fit the gasket into the thermostat housing, and hile pressing on the oil cooler side, tighten the ‘wo bolts on the water pump side. Then tighten the three oil cooler side bolts. Tightening torque: 39N-m (4.0kgt:m/29Ib-tty Legend 1. Thermostat housing 2. Water pump 3. Oilcooler 6. Water outlet pipe + Assembla the two O-rings into tha head gear case, and attach the water outlet pipe. Tightening torque: 39N-m (4.0kgfnv291b-f) Legend 1. Thermostat 2. Thermostat housing 5. Water inlet pipe + Attach the inlet pipe to the cil cooler. Tightening torque Oil cooler side | Senin (OKgTNZaIDT) Gear case side ‘BBN: (9-Okgt m/G5Ib ft) 7. Heater pipe + Attach the heater pipes, and tighten them up in the numerical order shown in the illustration. + Ensure that the hose is inserted securely as far as the white paint area of bead area on the pipe body. 18-46 _ Engine Mechanical (6WF1-1C) + Supply the appropriate amount of engine oil through the oil filing port shown by the lubrication mouth(1) of the turbocharger, and tum the turbine shaft gently to lubricate the bearings, + Install the turbocharger using the double nuts. ‘ Tightening torque: 4UN-m (4.1kgtm/30uIb-tt) 8. Oil filter and Partial oil filter + Install the O-ring and assemble the oil fiter. Tightening torque Area A 43N-m (4.4kgfm/S2Io‘) Area 8 BON m (6. tkghmia7IOR) pewstosoot 10. Turbocharger water pipe Eye-bolt tightening torque: 4AN-m (4.2kgf-m/30lb tt) 1. Bracket 2. Bolt (A) ao toga billie 2 Water petted) 9. Turbocharger 11, Turbocharger oll pipe Engine Mechanical (6WF1-1C) 18-47 + Secure tne ol pipe (IN) to tne bracket using the clip. Fyachalt tightening torque: 34N-m (3.5kgfm/25Ib-H) + Apply a small amount of the liquid gasket to two plaves along ie O-ting youve of the vil pipe (OUT), and fit the O-rings into place. jend 4. Oil pipe (return) 2. Oil pipe brakt 3. Oil pipe brakt 42, Exhaust duct: Turbo + Secure the duct to the turbocharger using the V bands (1), + Tighton tho V bands using the two bolts from the top of the bracket which has been tightened Vband tightening torque: 40N-m (1.0kgf m/87Ib in) 13, Exhaust brake 44, Inlet duct: Turbocharger + Provisionally secure the rubber hose and clip to the turbo side, and insert the inlet duct. + Mount the inlet duct on the bracket installed on the lower head cover and exhaust manifold + Tighten the rubber hose using the two clip. + Install the heat protector. 416. Inlet pipe: Turbocharger + Provisionally secure the rubber hose and clip to the turbo side, and insert the inlet pipe. + Tighten up the infet pipe in the bolt hole on the inlet duct side. + Tighten the rubber hose using the two clips. NOTE: ‘The clip eerew must be pointing toward the rear. 18-48 _ Engine Mechanical (6WF1-1C) Legend 1, Bolt 2. Inlet pipe 3. Bott 4, Bott 5. Inlet duct 46. Air compressor + Assemble the gears in the air compressor ahead of time, Apply some molybdenum disuifide to the threaded areas and seating surface of the bolts, land tighten the bolts to the specified torque in the sequence shown in the illustration Tightening torque: 39N-m (4.0kgf-m/29Ib tt) > Angle method 90° to 120° a4) @ © Puworesenemnt = Mount the pointer on the coupling side, + Align the pointer with the key of the alr compressor shaft, assemble the coupling, and align the engraved "A" mark on the coupling with the pointer (1) + Fit the O-ring info the gear case mounting flange area rowatestotsnt Legend 1. Pointer 2. °S* mark (engraved) 3. "A" mark (engraved) Legend 1. Pointer 2. Air compressor + Lurm the crankshattin the torward direction, and align the engraved line on the flywheel with the ‘uming pointer in such a way that the #1 cylinder is set at the compression top dead center. At this point, check that there Is a clearance between the intake and exhaust valves of the #1 cylinder. Ranh Using the gear case stud as the guide, gently push the air compressor in until it strike the idle gear inside the gear case + Tur the ait compressor shaft very slightly, and after engaging the gear, push the air compressor in completely unti it fits snugly in the gear case. At this point, check that the pointer (1) and the engraved *S* mark (2) on the coupling are aligned. The gear teeth will be ‘out of position if they are not aligned so repeat the process. + Tighten up the air compressor. Tightening torque: 137N-m (14.0kgf-nv/101Ib-) Engine Mechanical (6WF1-IC) 18-49 Legend 1. Pointer 2. *S" mark (engraved) 3. "A" mark (engraved) 17. Air pipe: Charge and governor + Mount tha air pine an the air eampracsar anitlat side. Eye-bolt tightening torque ‘Charge pipe (Mz4) (copper gasket) Govemor pipe (wii4) | 4iNm (4.2kgrm/SO1b-A) 4147N-m (15.0kgf-m/1081b-ft) + Place a wrench up against the pipe union side, ‘and tighton up the flare nut while ensuring that the pipe is not twisted. Nim (kgfimilb tty Flare nut 7 (1S) Charge pipe Nat 747 (1.07108) ee | meron 28 (29721) z Nat 8 (7.051) 18-50 _Engine Mechanical (6WF1-1C) Legend 1, Flare nut 2. Bracket 3. Nut 4, SIP washer 5. Union + Connect the oil pipe between tne cylinder black and compressor. Eye-bolt tightening torque M10: 27N-m (2.8kgFm/20ib ft) 18. Water pipe: Air compressor + Connect the water pipes between the cylinder block and compressor and between the ‘compressor and cylinder head, Eye-bolt tightening torque M14: 4ANem (4.2kgfim/9Olb-tt) roreteso1ont Legend “1. Wator pipe: 19, Oil pipe: Air compressor Legend 1, Eye-bolt 20. Supply pump bracket + Align the bracket with the dowel holes and attach Bracket tightening torque 408Nim (11, Okgfm/B0b- A) Legend 4. Supply pump 2. Bracket Engine Mechanical (6WF1-TC) 18-51 21. Gommon-rail + Mount the bracket (3) used to altach the ‘commor-rail, to the cylinder block. + Mount the commonerail (1) onto the bracket (3) At this point, tighten it up together with the fuel pipe bracket (2) Tightening torque: 22N-m (2.2kgf-m/16Ib-t) NOTE: Tighten up bracket (4) after mounting the pipe clips. Legend 4. Common-rail 2. Fuel pipe bracket 3. Common-rail bracket 4, Fuel pipe bracket 22. Injection pipes (1) to (6) + Clip the injection pipe at the positions shown in the illustration + Before mounting the injection pipe, assemble No.4 and No.3. Injection pipe tightening torque Sleeve nut: 44N-m (4.5kgtV33I6-) 23. Supply pump. + Tum the crankshaft in the forward direction, and align the engraved line on the fiywheel with the timing pointer in such a way that a B.D.T.C.0" is achieved. At this point, check that there is a clearance between the intake and exhaust valves of the #1 cylinder. Fuel injection tming (8. TDC) a Nant * Align the engraved line on the coupling with the ‘engraved line on the supply pump, + Attach the supply pump ta the supply pump bracket, and tighten up alternately at the ‘opposite ends along the diagonals. Tightening torque: 3 1N-m (3.2kgt:m/23lbtty 18-52 Engine Mechanical (6WF1-1C) * Slide the coupling, check that it fits snugly on the supply pump, and tighten up the coupling bolt (2). Tightening torque: 62N-m (6.3kgtm/a6iDsty and tighten up cotter bolt (1) Tightening torque: 91Nim (9.3kaf-m/67Ib-t) * Check the supply pump index mark Turn the crankshaft in the forward direction, and align the engraved line on the tlywneel with the timing pointer in such a way that a B.D.T.C.0° is achieved. At this point, check that the engraved line on the pump body and engraved line on the coupling side are aligned. IF the lines deviate, loosen the two bolts with the elongated heads of the coupling Turn the coupling, align the engraved line on the pump body with the engraved line on the coupling side, and tighten up the coupling, Lagend 1. Coupling bolt 2. Engraved line on coupling side 3. Engraved line on pump side 4 Cotter halt 24. Cll level gauge guide tube and bracket + Apply a thin film of oil to the O-ring, and insert tiie parts wie erisuling that damaged. fe Oring is 0k Engine Mechanical (6WF1-IC) 18-53 + Assembly sequence of pipes (1) and (2) in the illustration ~ Provisionally secure both ends of the pipes. = Tighten up the cammon-rail and = Tighten up the supply pump end, Tightening torque Sleeve nut NOTE: + After provisionally attaching the clip, tighten the pipe bracket, and finally tighten the clip, 44Nom (4.5kgtm/33lb-Mt) Legend 1. Oil level gauge guide tube 2. Bracket 3. Plug 25. Oil pipe: Supply pump + Connact the oil faed pipe and ail return pipe to the supply pump. Eye-bott tightening torque M10: 2BN-m (2.8kgf:mm/20lb tt) M14: 41Nom (4.2kof:m/30lb-tt) Legend 1, Fuel feed pipe No.2 2. Fuel feed pipe No.1 3. Clip 27. Fuel filter and bracket + After provisionally securing the bracket to the {uol filter, mount iton the inlet manifold + Tighten up the bracket and fuel fier. Tightening sequence = Provisionally secure the bolts sequence of (3), (2), (1) and (4). + Tighten up the bolts in the sequence of (3). (2), (1) and (4). in the Legend “1. Fuel pipe: Common rail to supply pump 2. Oll feed pipe 3. Oil rotum pipe 26. Fucl food pipe + Connect the vinyl hose for draining the water, and secure it using the band clips. Tightening torque: 39N-m (4,0kofm/29Ib-Rt) 18-54 _ Engine Mechanical (6WF1-IC) 28. Fuel pipe + Use the clips to secure the fuel pipe at the positions shawn in the illustration, Eye-bolt tightening torque Nem (kgfmilb-) i 75 (15/1) M0: 28 (2.0720) maz 35 (35I25) Mi: 41 (42180) NOTE: Do not use the rubber parts of the clips if they are cracked or damaged. Engine Mechanical (6WE1-1C) _1B-55 Legend 1. Filter to supply pump 4. Fuel feed 2. Fuel filter vetuin 5. Fuel retum 3. leak off pipe retum 6. Feed pump to filter 29, EGR duct and lead valve + Mount the lead valve at the position shown in the illustration, and assemble the EGR duct while sandwiching the gasket. ure: The duct must be assembled while checking the identification marks at the front and rear. Tightening torque Lead valve: TON-m (1-OkgFmi87ib in) EGR duct GON m (4.0kgf m/201b ft) owerasheonot Legend 4. EGR duct 2. Gasket 3. Lead valve 30. EGR cooler 18-56 _ Engine Mechanical (6WF1-1C) + Mount the gasket, and assemble me EGR cooler as shown in the illustration NOTE: ‘There are two pipes at the front and one at the rear. Check the pipes, and assemble thom, Legend 1. COR cooler (font) 2. Gasket 3. EGR wovter (eat) 31. EGR vale + Assemble the gasket into the EGR cooler, and provisionally assemble the EGR valve."-" is ‘embossed on the top of the front EGR valve, and "R" is embossed on the top of the rear EGR valve. + Ensure that the breather holes are facing downward at both the front and rear. CAUTION: When the EGR pipe is assembled, tighten up the EGR valves in the prescribed tightening sequence and to the specified torque. ‘At this stage. the valves must be ket orovisionally assembled Legend 1. EGR valve (front) 2. Gasket 3. EGR valve (rear) Legend 1. Front EGR 2. Rear EGR 32, Water pipe: EGR cooler to EGR valve + Assemble the water pipe into the EGR cooler. NoTE: Special eye-bolts whose heads have a recessed hole (for purging the air) must be used for the eye-bolts which ara indiaated by the arrows in the illustration Tightening torque’ 50N-m (5. 1kgf.m/37Ib-t) 18-57 Engine Mechanical (6WF1-1C) romanian | 33, Water pipe: EGR valve (IN) + Connect the rubber hose (1) to the cooler side, insert the water pipe (2), and clip it NOTE: Insert the rubber hose deeply, and attach the clip while ‘ensuring that it will not ride vin onto the part whare the pipe bulges. + Assemble the alr pipes (1) and (2) into the EGR valves. Eye-bolt tightening torque: 28N-m (2.8kgf-m/20Ib tt) I ronmesraner | 35, EGR pipe (Ft) + As shown in the illustration, provisionally assemble the gasket, EGR pipe, distance tube, washers and bolts in this order. + Tighlen up the bolls in @ 2-slep process: frst, provisionally secure them, and then tighten iver up, 2 3 | EB a) Legend 1. Gasket 2. Distance tube 3. Bolt 4. Washer 5. Flange (pipe area) + Tighten up the parts in the numerical order shown in the illustration (for both provisionally securing them and tightening them up) + Tighten up the bolts in a 2-step process: fist, provisionally secure them, and then tighten them up. 18-58 Engine Mechanical (6WF1-1C) + Order in which bolts are provisionally secured = locations (EGR pipe - EGR valve side) (1) ~ 2 locations (EGR valve - EGR cooler side) @) = 3 locations (EGR pipe - exhaust manifold side) (2) Torque for provisional securing SN-m (0.5kgt:mv43ibin) + Order in which bolts aro tightened up Tighten up the bolts in the same sequence as the one used when provisionally securing them. Tightening torque: 38N-m (3.9kgf:mm/28Ib-ft) CAUTION: The bolt tightening sequence and torque must be adhered to. Following the wrong procedure may cause the exhaust gas to leak. 36. EGR pipe (Rr) + Tighten up the parts in the numerical order shown in the illustration (for both provisionally securing them and tightening them up}. + Tighten up the bolts in a 2-step process: first, provisionally secure them, and then tighten them up. + Order in which bolts are provisionally secured = 3 ocatione (EGR pipe - EGR vaive side) (1) = 2 locations (EGR valve - EGR cooler side) @) ~ 3 locations (EGR pipe - exhaust manifold side) (3) Torque for provisional securing Nim (0.5kgf-mn/43ib in) + Order in which bolts are tightened up Tighten up the bolts in the same sequence as when they were provisionally secured Tightening torque: 38N-m (3.9kgf.m/28Ib-f) CAUTION: The bolt tightening sequence and torque must be adhered to. Following the wrong procedure may cause the exhaust gas to leak. 37, Water pipe (OUT) (1): EGR valve (Ft) 38, Water pipe (OUT) (2): EGR valve (Rr) Tightening torque: SON m (5. 1kgf nva7lb ft) Engine Mechanical (6WF1-IC) 18-59 39. Air compressor suction pipe + Attach the suction pipe to the air compressor, and connect it to the turbo inlet duct via the rubber hose. 40. Water pipe charge 41. Water pipe ar leak owstasierz0t Legend 4. Charge pipe 2. Airleak pipe 3, Water outlet pipe 42, Engine harness + Connect the engine harness as shown in the illustration 18-60 _Engine Mechanical (6WF1-1C) Legend Injector hamess Injector hares connector Injector L-shaped connector Boost sensor Injector hares connector Injector harness connector ‘Common-rail pressure sensor Engine speed sensor Connector Cylinder identification sensor Pov 43, Air breather hose + Attach the clips while ensuring that they are pointing in the direction shown in the illustration + Ensure that there is no interference between the hose and head cover. Engine Mechanical (6WF1-1C) 18-61 Legend 1. Harness clip 2. Hamess clip 3. Air breather hose 18-62 _Engine Mechanical (6WF1-1C) Tightening Torque Table Engine exterior parts 137 (14.0704) 39 (4.0729) 38 (4.0728) Eo) 6 (603) 30070) Nemacgeewtom 22 (22118) 706 (170780) (98 (10.0772) © (636) 78 (6.0758) Hewesa.roa7 Engine Mechanical (6WF1-TC) _1B-63 Cylinder head Component Parts Legend +. Head cover 8. Rocker arm assembly 2. Head cover gasket 9. Camshaft 3, Injector harness 10. Bridge 4. Nozale leak-off pipe 11. Injector and clamp 5. Head cover lower 42. Cylinder head assembly 6. Hamess connector 48. Cylinder head gasket 7. Head cover lower gasket 44, Idle gear C Removal 1, Head cover + After disconnecting the air breather hose, remove the head cover. 2. Head cover gasket 18-64 _ Engine Mechanical (6WF1-1C) I romana | romana 3, Injector harness Legend 1. Nozzle leak-off pipe NOTE: 2. Hamess connector When the injector hamess is disconnected, the ID code plate can be removed, Do not mix this plate up with the 6. Head cover lower ID code plates of the other injectors. 7. Head cover lower gasket Each injector has its own injector 1D code plate. NOTE: ‘A small amount of oil may flow when the head cover lower is removed, so clean it up using a rag, LE. Seer al Legend 1. Injector assembiv 2 IDpiate omsesternt 3. Terminal nut Rocker arm assembly oc + Loosen the bracket tightening bolts of the 5. O-ring rocker arm assembly uniformly at both ends, and remove the assembly. 4. Nozzle leak-off pine 5. Hamess connector Engine Mechanical (6WF1-IC) 184 9. Bridges + Remove the bridges (1) NOTE: Attach a number label to the bridges for each cylinder. Prmcoseott4 + Inspect the contact surfaces for wear and pooling and also the bridges for cracks and damage. 10. Camshaft + Before removing the camshaft, measure the clearance in the camshaft axial direction Clearance in camshaft axial direction standard mmjin) {0.085 — 0.170(0.033 - 0.0067) Timit mmtiny 0,25(0.0098) 18-61 Engine Mechanical (6WF1-TC) + Loosen the bracket tightening bolts of the camshaft uniformly at bath ends, and remove the camshaft. roworesronaat + It IC Is dificult to remove the injector, set the injector remover(2) on the injector, tighten the bolt into the leak-off pipe fitting, and, using the sliding hammer(1) , pull the injector(3) out in an. upward direction Special tools Injector remover: Silideing hammer small 5-8840-2826-0 5-8840-0019-0 NOTE: + When removing the injector using this special tool, make sure that the injector sleeve is not removed as well + The ID code plate is unique to each injector, so altach a number tay to it before storing it to ensure that itis not used on a different injector. + he injector and glow plug protrude from the bottom ‘face of the cylinder head, so remove them first to prevent them from being damaged. + Measure the clearance between the camshaft journal and bracket, Clearance between camshaft journal and bracket standard mmiin) 0.075 — 0.125(0.0030 - 0.0049) Timit mmin) 10.15(0.0059) 17, Injector and clamp + Loosen the clamp, and use the replacer to remove the injector. Legend 1. Sliding hammar 2. Injector remover 3. Injector assembly NOTE: + Indicate the cylinder No. on the removed injector before storing the injector. Engine Mechanical (6WF1-TC) 18-6 + Be careful not to strike the injection nozzle against ‘12. Cylinder head assembly hard surface, + After loosening and removing the (27), (28) and (29) tightening bolts, loosen uniformly and remove the tightening bolts from the outside in the numerical sequence shown in the illustration, NOTE: + Be absolutely sure to remember to remove the (27), (28) and (28) tightening bolts first. + Block the hole In the timing gear with a rag beforehand, 13. Cylinder head gasket 18-68 _ Engine Mechanical (6WF1-1C) Disassembly 6 Legend 1. Distance tube 13. O-ring 2. Seal ring 414, Valve seat insert 3. Alrduct bracket 19. Vaive 4, Exhaust duct bracket 16. Giow plug 5. Exhaust manifold assembly 11. Glow plug connector 8. Split collar 48. Dual thermo sensor 7. Spring seat (upper) 419. Inlet manifold 8. Valve spring 20. Idle gear shaft C 9. Valve oil seal 21. Idle gear C 410. Spring seat (lower) 22. Gear case 11. Valve guide 23. O-ring 12. Nozzle sleeve 24. Bridge guide 1. Glow plug connector 2. Glow plug 3, Dual thermo sensor 4, Gear case 5. O-ring + Before removing the gear case, measure the clearance in the axial direction af the idle gear Cc, Engine Mechanical (6WF1-TC) 18-6 Clearance in axial direction standard mmiin) (0.05 = 0.125(0.0020 - 0.0049) Tit mmginy 0.25(0.0090) Prmcostost704 6. Idle gear shaft C 7. Idle gear © + Draw out the idle gear shall, and remove the idle gear C from the cylinder head. NOTE: Take care not to damage the bushing of the idle gear sha, 8. Inlet manitols owatashorr0t 9. Air duct bracket 10. Exhaust duct bracket 11. Engine hanger (Ft) 12. Exhaust manifold assembly 13. Seal ring 44. Split collar 15, Spring seat (upper) + Place the cylinder head on a wooden board, use the replacer to remove the split collar, and remove the spring seat, valve spring and valve. NOTE: Attach a number label to the valves for each cylinder. Valve spring repiacer: 1-8523.5013-0 18-70 _Engine Mechanical (6WF1-1C) Legend 16. "7. 18, 19, 20, 1, Bracket 2. Split collar ‘Valve spring Spring seat (lower) Valve Valve oil seal Valve guide + Insert the replacer into the guide from the bottom surface of the head, and knock it out using a hammer. Vaive guide replacer: 9-8523-1202-0 2 Bridge guide + Electrically weld (1) the bolt to the bridge guide, mount a sliding hammer onto the bolt to draw the bolt out 22, Valve seat insert + After using a gas welding bumer to heat two places on the inside surface of the insert until they are red-hot (600 to 700°C/1112 to 1282°F), allow these places to cool off naturally for 3 to 5 minutes, and use a screwdriver to draw out the insert. CAUTION: Do not force the insert to cool rapidly. soso 23, Nozzle leave + Removal of the nozzle sleeve Draw it out of the sleeve by tapping from underneath the head. Engine Mechanical (6WF1-1C) 18-71 24, Ong Inspections Idle gear shaft C + Measure the outside diameter of the idle gear shaft und ihe clearance between the shalt and busing Inspect the bushing as well for damage. Outside diameter of shaft Dimension mm(iny) Working limit mmciny 49(7.5251) 48.85(1.9252) rance between shaft and bushing ‘Standard mmi(in) Limit mm(in) 0.04 -0.105 (0.0016 - 0.0041) 0.20(0.0079) Valve spring + Measure the squareness of the valve spring, ‘Squareness of valve spring Standard] Limit mmi(in) rain) Tnlet 3.5(0.1378) | 4.8(0.1890) Exhaust Outer | 4.5(0.1772)_| 6.2(0.2441) inner | 4.2(0.1654) | 5.9(0.2322) +F owstesharsot 18-72 __Engine Mechanical (6WF1-1C) + Measure tne free length of the valve spring. Free length of valve spring mina’ | working tim mension mene) mmiin) Thiet 79.3(8.1220) | 75.5(2.9646) Outer_| 102.714.0433) | 97.6(3.8425) Exhaust Taner | 96.5(3.7002) | 91726102) as + Measure the tension when the spring is mounted. Tension of valve spring Dimension Limit Nikatibty | Nikgtiibty mm(in) mm(in) 392 (40.07 | 372 (38.07 Inlet 88.2)/ 83.8) 64(2.5200) | 64(2.5200) 102.2) | 578 60.0) Outer 137.2)) 430.1 ea27i6s | 69(2.7165) Exhaust 223228) | 213217 Inner 50.3)/ 47.8) 66(2.5984) | 66(2.5984) Valve + Inspect the valve stem end for wear. Use an oil: stone to repair minor wear, atl powonestaz04 ‘+ Measure the valve stem wear. Measure the wear in the three places shown in the illustration, Nominal Working limit dimension mmtin) matin) Tet 7100.3857)_| 4 9:02(0.3006) Exhaust ‘p10(0.3937) | 6 9.90(0.3898) Engine Mechanical (6WF1-IC) 18-73 Itthe amount of the valve stem wear has exceeded the limit, replace the valve stem together with the guide, + Inspection of contact with valve seat surface and valve thickness measurement Inspect the seat surface for damage and stepped wear, and measure the valve thickness, Valve thickness. + Measure the clearance between the valve guide and valve stem. Nominal imi dimension mm(in) matin) inet 7202(0.0795) | _1.52(0.0598) T T Exhaust 2.48(0.0976) | 1.98(0.0780) Width of contact with valve seat Nominal Limit dimension mmtin) Prmorosror904 mmtin) Tiiet 390.1535) | 43(0.16093) Exhaust 260.1102) | 3.2(0.1260) Insert the vaive into the guide, and measure the clearance between the guide and valve at a NOTE: position 10 mm from the upper end of the guide. Clearance between the guide and valve stem Limit tammy 0.040 - 0.077 Inlet (0.0016 0.0030) | °-*8(0.0089) 0.065 — 0.102 Exhaust (0.026 0.040) | 2510-098) — "Tomo ain) If the wear exceeds the usable limit after polishing and modifying the valve thickness, replace the valve. Legend 1. Contact width 2. Valve thickness 18-74 _ Engine Mechanical (6WF1-1C) Bridge guide + Measure the clearance between the bridge auide and bridge (1). Clearance between guide and bridge ‘Slandard mama) Timitraminy 020 — 0.0856 (0.0008 0.0022) 9-10(0-0039) Valve seat insert ‘+ Measurement of recess amount of valve Insert a new valve into the guide, and measure the recess amount from the mounting surface of the cylinder head to the valve surface. Recess amount of valve Nominal Working dimansion limit mmiin) mmiin) Tet TO(o03Eq)_ | _2.000.0787) Exhaust 0.9(0.0354) | 1.9(0.0748) Legend 4. Recess amount 2. Cylinder head 3, Valve seat insert Cylinder head + Cylinder head distortion measurement Clean off the carbon without marking or damaging the machined surfaces of the head, valve seat, insert and other parts. Next, place a straightedge ruler against the head mounting surface, and measure 1 to 4 in the illustration using a thickness gauge. Replace if the limit is exceeded Distortion amount Less than Limit: 0.2mm0.0079in) NOTE: No repairs can be undertaken since the backlash of the timing gear will be altered as a result Engine Mechanical (6WF1-IC) 18-75 * Inspection of cylinder head for cracks and damage If necessary, inspect the cylinder head using the ‘magnetic flaw detection method or red check. rowarastoten * Inepection of water jacket for oracks Using a hydraulic tester, apply a hydraulic pressure of 490 kPa (6 kglom’/? psi) for throe minutes, and inspect various parts of the head for water leaks, Assembly 1. Oning 2. Nozzle sleeve + Apply some engine cil to the O-ring, assemble it into the sleeve, apply Loctte No.LT290 ta the outer surfaces and contact seat surface, and press-fit the O-ring into the cylinder head Legend 1. Application of Loctite NOTE: ‘The O-ring is assembled with the red at the top and black at the bottom, 3. Valve seat insert + Clean the insert mounting surface, and press-ft the insert using a bench press. 4, Bridge guide + Apply some engine oil to the outer surfaces of the guide, Next, use the installation tool to press-fit the guide so that the height of the bridge guide is 49 mm(1.9291in) above the head top surface Bridge quide installation tool: 9-8522-1324.0, 18-76 _ Engine Mechanical (BWF1-TC) 5. Valve quide + Apply some engine oil all around the valve guide. Next, use the replacer to press-fit tho valve guide so that itis positioned at the rated height above the cylinder head, Height of valve guide above cylinder head ‘Assembly standard mm(iny Tniet 27.0(1.0630) 28.01.1417) Exhaust Valve guide replacer: 9-8523-1202-0 Legend 4. 29.0mm(1.1417in) 2. 27,0mm(1.0830in) 6. Valve seal + Use the installation too! to install the valve seal in the valve guide NOTE: After installing the valve seal, check that the spring Is. not disengaged or deformed. Valve seal installation tool (for inlet) Valve seal installation tool (for exhaust): 1-8522-1187-0 1-8522-1184-0 Paeworooiou 7. Valve Insertion of valve + Apply some engine oil to the valve stem, and insert the valve into the cylinder head. Engine Mechanical (6WF1-1C) 18-77 Valve contact inspection + Apply some red lead to the valve insert, and inspect the width of the seat surface contact Inspect whether the contact position is at the center of the valve seat surface, Insert and valve contact width Valve contact width of valve seat surface | 2 ‘Assembly | Working limit standard mm(in) | ramin) inlet valve 390.1535) 4.3(0.1693) NY Exhaustvaive | 280.1102) | 3.201260) + After polishing and modifying the valve seat, measure whether the recess amount of the valve is within the working limit. Recess amount of valve Legend 1. Contact width 2. Recess amount ‘Standard Limit min(in) mm(in) Inlet valve 7,0(0.0394)_| _2.0(0.0787) Exhaust vaive | 0.9(0.0354) | 1.9(0.0748) Fitting the valve + Apply some compound to the surfaces where the insert and valve seat make contact with each other, and fit them together properly. After fitting them together, wash the cylinder head and valve, ‘+ IT the width or surtace of the valve contact is defective, use a seat cutter appropriate for the seat angle and stem diameter to make corrections. Valve seat angle Inlet valve: 30" Exnaust vane’ roe Valve stom outside diameter {10.0mm(0.3937in) 8. Spring seat (lower) 18-78 Engine Mechanical (6WF1-1C) 9. Valve spring 10. Spring seat (upper) + Place the cylinder head on a wooden board, and assemble the lower spring seat, valve spring and upper spring seat in this order. Both the inlet valve spring and exhaust valve spring can be placed with either end at the top. 11, Split colar + Use the valve spring replacer to push the valve spring in, and install the split collar. ‘After completing the installation, gently tap the valve stem head with a rubber hammer and ensure that the split collar settles into position Valve spring replacer: 4-8523-5013-0 rowstesrauot Legend 1, Bracket 2. Split collar 12. Seal ring 13. Exhaust manifold + Install the seal rings (1) at intervals of 120°, and assemble the manifald, NOTE: Ensure that seal rings (1) are installed with the right side up, * Install the manifold in the cylinder head, and tighten up the parts in the numerical sequence ‘shown in the illustration. (Tighten up the flanges in the clockwise direction starting with the one at the bottom.) Tightening torque: 47N-m (4.8kaf:m/35Ib-) NOTE: + Install it in such a way that the distance tube is facing the nut side. + It must be assembled so that the engraved mark on the yasket is positioned al the bottom right. Engine Mechanical (6WF1-IC) 18-79 14, Engine hanger (front) 45, Exhaust pipe bracket 46. Air duct bracket 47. Inlet manifold + Install the inlet manifold. Tightening torque: 19.6N-m (2.0kgfm/14ib-#) 18. Idle gear 19. Idle gear shaft C + Apply some engine oil to the idle gear shaft. Next, assemble the idle gear into the cylinder, and tighten the shaft Not! + Check that the gear rotates smoothly. + Take care not to damage the gear teeth surfaces since the teeth protrude beyond the cylinder head. Tightening torque: ABN m (A.7kgf m/34 lb) 20. O-ring 21. Gear case + Install the O-ring into the gear case + Apply some FMD-127 jn a thickness of about 0.3 mm and a width of about 5 mm to the surface where the gear case is mounted on the cylinder head, and install the gear case. NOTE: Ensure that none of the FMD-127 gets into the bolt holes. Tightening torque: 38N-m (3.9kgf-mn/28ib-tt) 18-80 _Engine Mechanical (6WF1-1C) Legend 1. Application of liquid gasket 2. O-ring 22. Dual thermo sensor Tightening torque 20N-m (2.0kgfm/ 14D.) rowotesnarent 23, Glow plug Tightening torque 25Nim (2.5kgfirn/1 Blt.) NOTE: Do not overtighten since doing so may damage the parts. 24, Glow plug connector + Insert the glow plug connector netween the glow plug nut and flat washer to install it. 41.0N-m (0.1kgf mb in) Tightening torque: Installation 1. Head gasket + Use a new head gasket at the re-assembly stage. 2. Cylinder head assembly + Application of liquid gasket Loctite FMD-127 Clean the top surface of the cylinder block and bottom surface of the cylinder head, and apply the liquid gasket in a thickness of 1 to 2 rmm(0.0394 to 0.0787in) and a width of about 5 ‘mm(0.1968in) to the surface where the cylinder block and gear case as wall as the cylinder head and head gear case are joined NOTE: After applying the liquid gasket, the pars must be assembled without delay. Engine Mechanical (6WF1-TC) 18-81 + Assembly of cylinder head ‘Assemble the head gasket, align the cylinder head with the knock-pin, and place it gently on. top. + Tightening of cylinder head assembly Tightening torque T77Nm (16 Okgtm/T30IR) > wi 245N-m (25.0kgt m/1 81st) > Angle method 60 to 90° wie ‘aN (4 OKghm7OIB AD Miz ‘O7Nm (9.9kgh V7 2b) NOTE: + Do net apply any of the molybdenum disulfide to the M10 or M12 bolts. + Block the hole In tne timing gear with a rag beforehand, + Do not re-use the head bolts more than four times. 18-82 _Engine Mechanical (6WF1-1C) Legend 4. M12 2. M10 3. Injector and clamp + Install the injector in the oylinder head, and provisionally secure the injection pipe. Next, tighten up the clamp using the clamp tightening bolts, and finally tighten up the injection pipe. NOTE: + Install the gaskets securely. + Do not re-use the gaskets. + Ensure that the ID code plates on the ot removed. If a plate has been absolutely sure to altach it back on the same injector. Tightening torque Clamp: 49N-m (5.0kgFm/36Ib-ft) Injection pipe: 39N-m (4.0kgf-m/29Ib-fty Engine Mechanical (6WE1-1C) 18-83 4, Camshaft + Set the #1 cylinder to the compression top dead center, Turn the crankshaft in the forward direction, and align the T/C mark on the flywheel with the pointer. the coupling is aligned with the engraved line ‘on the pump. anh + Apply some engine oii to the cam surface of ihe camshaft and the cam gear teeth surfaces. * Installation of camshaft Apply some oil to the camshaft bracket. Install the camshaft in such a way that the mark on the camshaft gear and the pointer are aligned, Now check that the engraved lines at the rear ‘end of the camshaft are positioned horizontally and vertically 1 Pe VHA Us COPE CY Ur Pointer ‘+ Installation of camshaft with alroady mounted With the lower cover already mounted, install the camshaft in such a way that one of the two index marks on the camshaft gear is hidden by the lower cover, as shown in the illustration. lower cover 18-84 Engine Mechanical (6WF1-1C) + Installation of camshamt brackets Apply some engine oil to the seating surfaces and threaded sections of the nuts, install the brackets by aligning their engraved numbers, provisionally secure them trom the camshatt ‘gear side, and then tighten them up again to the specified torque. NOTE: + The No.1 camshaft bracket must be installed securely on No.1 + After mauinting the cylinder head bolts, the brackets must be tightened up. Tightening torque: 76Nem (7.7kghm/96Ib-t) Legend 1. Index mark. 2. Cam gear 3. Lower cover Legend 1. Engraved number 5, Bridges + Loosen the adjusting screw (1) all the way. apply some engine oil to the bridge guide, and install the bridge. Prmsoscotzo. NOTE: + Re-ascemble the parts as per the oylinder numbers recorded at the disassembly stage. + Install in such a way that the adjusting screw faces the intake manifold side. 6. Rocker arm assembly + Loosen the adjusting screw all the way, apply some engine oil to roller area and tip of the adjusting screw, and assemble the rocker arm assembly. Engine Mechanical (6WF1-IC) 18-85 + After provisionally securing the parts in tne numerical sequence shown in the illustration, tighten them up to secure them in the numerical sequence shown in the illustration to the specttied torque. Tightening torque: 90N-m (9.2kgfm/67Ib-t) + Adjustment of valve clearance For the adjustment procedures, refer to the section on adjusting the valve clearance in “Functional inspection.” 7. Head cover lower gasket 8, Head cover lower + Clean the top surface of the oylinder head, and apply some liquid gasket Three Bond No.12078(1) in a thickness of about 1 to 2mm{0.0394 to 0.0787in) and a width of 5 mm(0.1969in) to the top surface where the timing gear case and cylinder head are joined. + Fit he gasket into the groove In the cover, and tighten up the bolts indicated by the arrows. Tightoning torque: 15m (1.5kgf nvttlb *t) ewateshoront 9. Hamess connector + Assemble the O-rings, and atlach the ‘connectors to the lower cover. Tightening torque: 20N-m (2.0kgt-m/tAlb-tt) 18-86 _ Engine Mechanical (6WF1-1C) Legend 1. O-ring 2. Connector 10. Nozzle leak-off pipe + Mount the adapter on the lower cover rear side, and install tha nnz7ie leak off pine in tha injector. Tightening torque Adapter: Eye-boll 29N-m (3.0kgfm/22Ib-f}) AON (1.Skyban HbA) Legend 1. Nozzle leak off pipe 2. Connector 11, Injector harness ‘+ Insert the connectors on tne hamess side into the connectors attached to the lawer cover until @ Clicking sound is neard, and attach the injector harness to the lower cover. Tightening torque: 2ON m (2.2kgf m/16Ib ft) roworastoteot Legend 4. Nut 2. Connector + Insert the terminals of the hamess (1) into the heads of the cylinder injectors (2), and tighten up the nuts to the specified torque Tightening torque’ 2.0N-m (0.2kaf-mv/17ib-in) NOTE: Under’ no circumstances must the nuts be overtiahtened since this mav damage the iniectors. Engine Mechanical (6WF1-1C) 18-87 Legend 1. Injector hanes 2. Injector 12. Head cover gasket 18. Head cover + Install the gaskets by assembling them into the head cover. + Tighten them up in the numerical order shown in the illustration, Tightening torque: 18N-m (1.5kgf rv 111b-ft) Howansroat01 18-88 _ Engine Mechanical (6WF1-IC) Tightening Torque Table Nemikgfmib-) a7 (aw) —~ 39.0729) Engine Mechanical (6WF1-TC) 18-89 Special Tools, Cylinder head Tiustration ‘Tool Number/ Description Tiustration ‘Tool Number! Description 1-8623-6013-0 ‘Valve spring replacer 5-8840-0019-0 Slideing hammer small a 9-8523-1202-0 Valve guide replacer e 9-8522-1324-0 Bridge guide installation tool ‘ 4-8522-1187-0 Valve seal installation tool (for inlet) % 1-8522-1184-0 Valve seal installation too! (for exhaust) A 1-8840-2826-0 Injector remover 18-90 _ Engine Mechanical (6WF1-1C) Rocker arm Component Parts Legend 1, Bracket (front) 4. Bracket (center) 2. Rocker arm 8. Rocker arm shaft 3. Spring Disassembly + While pressing down on the bracket of the rocker arm shaft, draw out the tightening bolts 1. Bracket (ront) (1) of the bracket (2), and remove the rocker ee arm, spring and bracket. 2. Spring 4, Bracket (center) NoTE: 5. Rocker arm shatt + When the tightening botts ofthe bracket are drawn out, the force exerted by the spring will cause the rocker atm and other parts to pop out Engine Mechanical (6WF1-TC) _18-91 + All the bolts must be loosened uniformly a litle at a time. Inspections Rocker arm + Inspect the roller surface for wear and damage, ‘and measure the clearance between the roller pin @® and roller, With the roller of the racker arm pushed out all the way, make a mark at the measurement location, and meastire the difference in level (dimension A) 4 between the rocker arm and roller. Next, push the roller in all the way, and measure the differance in level (dimension B) at the marked position of the measurement location, The difference between dimensions A and B represents the clearance between the roller pin HeNDSHONEOY and roller, Legend 1. Roller 2. Dimension B Clearance between roller pin and roller 3 Calipers 4, Dimension A Siandard mmiin} Limit mmntiny o.0a8 — 0.068 (0.0044 - 0.0027) 0.180(0.0069) 18-92 _ Engine Mechanical (6WF1-1C) Rocker arm shatt + Inspect the oil hole in the rocker arm shaft ems: + Measure the outside diameter ot the rocker arm shaft and the clearance between the shaft and rocker arm bushing, + Inspect the band in the rocker arm shaft Shaft bend Umit: ‘0.3mm(0.0778in) Nominal | Standard] Limit dimension | mmtiny | mmciny mmiin) Clearance 004T- betweenshat | _ 0.141 0.20 and rocker (0.0016- | (0.0079) arm 0.0056) cane | tl | ee cere) ac 02) (1.0965) a eo Assembly Rocker arm shaft Bracket (center) Rocker arm Spring Bracket (front) + Apply some engine cll to the rocker arm bushing, and mount itn the direction shown in NoTe: + Check the front mark on the rocker arm shaft Engine Mechanical (6WE1-1C) 18-93 Legend 1. Front mark 18-94 Engine Mechanical (6WF1-1C) Camshaft Component Parts Camshaft x Legend 1. Camshaft gear 3. Camshatt 2. Key Disassembly 4. Camshaft gear + Place wood piece around so that the gear will ot be damaged, and use a puller to remove it. NOTE: Inspect the gear for damage: do not remove it if there ‘re no probleme in evidence. Engine Mechanical (6WF1-IC) _1B-95 Camshaft + Measurement of bend in camshaft Hold the No.1 and No.7 journal areas using a V- block, place a dial gauge against the No.4 journal, 1 o rolate the camshaft gently through a complete turn, and measure the bend. Camshaft run-out amount +} ‘Blandard mm(in) Working limit mm(in) 0.08(0.0087) 0.710.039) 1 ° Legend 1. Wood piece 2. Key 3. Camshaft Inspections ‘Camshaft goar + Inspect the camshatt gear for damage. * Inspection of cam surface for damage and measurement of it amount of cam Use an oll-stone to repair minor damage and wear. Measure A-B to obtain the lift amount Lift amount (A-B) of cam Nominal dimension | Working limit mm(in) mm(in) inlet 9.4(0.3701) 6.85(0.3484) Exnaust Toaoaoeay | 9:75(0.3839) 18-96 _ Engine Mechanical (6WF1-1C) TD + Measurement of outside diameter of journal Use a micrometer to measure the position shown in the illustration Outside diameter of journal ‘Nominal dimension min) $40.0(1 5748) Working limit rmmtin) 739.89(1 5705) Measurement of clearance between camehaft Journal and camshaft bracket + Measure the inside diameter of the camshaft bracket and outside diameter of the camshaft to obtain the clearance. + Glean the camshaft bracket, check tne engraved mark on the side surface and assemble it, apply some engine ol to its threaded area, and tighten Up the bracket to the specified torque. Next, mount the rocker arm shaft, apply some engine oll to its threaded area, and tighten it up to the specified torque. Use a cylinder gauge to measure the four places at the position shown in the illustration to obtain the inside diameter of the camshaft bracket. Tightening torque Camshaft bracket: Rocker arm shaft: T6N-m (7.7kgf-miS7Ib-f) 90.0N:m (9.2kgf m/67Ib-ft) Prorosroo + The outside diameter of the camshatt journal is obtained by measuring the four places at the position shown in the illustration using a micrometer. Clearance between camshaft journal and camshaft bracket ‘Standard mm(in) Limit mmfin) 0075 = 0.125 015 (0.0030 - 0.0049) (0.0059) * When using a plastigauge for the measurement, refer to the General Information. NOTE: + The No.1 camshaft bracket must be assembled securely at the No.1 position. + The engraved mark on the camshaft bracket side surface is not the journal number. Engine Mechanical (6WF1-IC) 18-97 Tightening torque: —137Nm (14.0kgf-m/101Ib-f) + Tep the key into the camshaft, and the assemble with the larger gear center boss facing toward the camshaft side. Next, apply some oil to the threaded areas and seating surfaces of the bolts, and tighten up the bolts. Assembly 1. Camshaft 2. Key 3. Camshaft gear Installation of camshaft gear Camshaft Poroshorent Tightening Torque Table 137 (14.0708) Nemigtmnot) Howstewromto1 18-98 _ Engine Mechanical (6WF1-1C) Timing gears Component Parts Legend 1. Timing gear ease 7. Idle pulley 2. Gasket 8. Idle gear A 2. Gear ease envar 9 Ristanca halt 4. AIC compressor bracket 10. Idle gear 8 5. Oil seal (crankshaft) 41 Oilpurmp 6. Crank pulley assembly 12. O-ting Removal 5, Oil seal (crankshatty 4. Crank pulley assembly + Remove the oil seal in such a way that its press-fitting surface on the front cover will not Idle pulley damaged or marked 2 3. Gear case cover 4, Gasket Engine Mechanical (6WF1-IC) 18-99 + The oll seal cannot be re-used, Nowsrnstom704 + Use the remover to remove the singer. + The slingar cannot be re-used. NOTE: + When replacing the oil seal, replace it together with the linger as a set + If the remover tends to slip free of the slinger, tighten up the outer circumference of the tool using a clip band to make this work easier. Slinger remover: 4-8521-0027-0 6 Oil pump 7. Oring 8, Distance bot 9. Idle gear A 0. Idle gear B + Measurement of backlash Before removing the idle gears, measure the backlash of each idle gear. Backlash ‘Standard mm(iny 003-013 (0.0012 - 0.0051) Limit mmm + Measure the clearance of idle gear A in the axial direction Clearance in axial direction ‘Standard mmqiny Limit mimginy 0.165 - 0.230 0.35 (0.0065 - 0.0091) (0.0138) + Measure the clearance of idle gear B in the axial direction. Clearance in axial direction ‘Standard mm(iny Limit mmiiny 0.075 0.140 0.25 (0.0030 - 0.0055) (0.0098) 18-100 _Engine Mechanical (6WF1-1C) + Remove idle gear A and idle gear B. The idle gears and thrust plate have a front and back so make Identifying marks on them before removing them. Legend 1. Idle gear A 2. Idle gear B coor +1, AIC compressor bracket 42, Timing gear case Inspections Engine Mechanical (6WF1-TC) 18-101 lale gear * Measure the outside diameter of the idle gear spindles and the clearance between the gears and spindles. Outside diameter of Idle gear spindles idle gear Nominal dmenson Lint a $57(2.2441) {$56.85(2.2382) 8 $142(6.5004) | 0147,85(6.5846) c 4901 8257) 948.85(1.9232) Clearance between idle gears (A, B, C) and spindles. ‘Standard mmiiny Limit mmciny 0.040.105 020 (0.016 - 0.0041) (0.0079) Outside diameter of pin of large Idle gear A Nominal dimension Limit mmiin) mmiin) $22 210.8740) P2200.8667) wowatastazeot Disassembly 4. Crank pulley assembly Loosen the mounting bolts and remove the damper from the crank pulley Inspections 4. Crankshaft pulley + Inspect the crankshaft pulley groove for wear and damage. 2. Crankshaft damper + Inspect the damper for cracks. 18-102 _Engine Mechanical (6WF1-TC) Assembly 41. Crankshaft damper 2. Crank pulley + Mount the crankshaft damper on the crank pulley. Tighten up the parts in sequence by proceeding alternately at the opposite ends along the diagonals, NOTE: + Place the crankshaft damper with the side on which the caution label is adhered at the front. + Keep all cils and greases away from the crankshaft damper. Tightening torque: 118N-m (12.0kgf-m/87ibtt) rowstestoment Installation 4. Timing gear case + Apply some liquid gasket Loctite No. FMD-127 ina thickness of about 0.9 mm (0.0448in) and a width of about 4 mm(0.1575in) to the mounting surface. Also apply some to the surface where the cylinder block and crankcase are joined. + Install the timing gear case. NOTE: + Ensure that none of the liquid gasket gets into the bolt holes. + After applying the liquid gasket, install the parts without delay. + When re-using the tightening bolts in the areas marked by the arrows, apply Loctite 271 to their threaded areas, + If, after the timing gear case has been installed, a period of more than 30 minutes is lett before installing idle gears A and B, provisionally secure the M10 X1.5 bolts in areas 1 to 3 shown in the illustration to the specified torque. Tightening torque M14: 135N-m (13.8kgt:m/100lb-tt) M10: 43N-m (4.4kaFm/32ib-tt) 2. AIC compressor bracket + Tighten the A/C compressor bracket together with the gear case, Tightening torque: 135N-m (13.8kgf-mn/100Ib-t) 3. Idle gear B + Apply some engine oil to the inside diameter of idle gear B and thrust area, check the front and. back marks made when the idle gear B and thrust plate (1) were disassembled, and assemble. NOTE: If provisionally secured bolts have been installed, do not forget to remove them, Tightening torque: 43 Nem (4.4kgf.mv32ibft) Engine Mechanical (6WF1-1C) 18-103 4. Idle gear A + Set the #1 cylinder to the compression top dead center. Turn the crankshaft in the forward direction, and align the T/C mark on the fiywheel with the pointer. At this point, check that the enaraved line on the coupling and engraved line on the pump are more or less aligned. Ninn > Apply some engine ol to the inside diameter of timing gear A, align the timing marks on the goars, and assemble timing gear A, spindle and thrust plate, Tightening torque: 108N-m (11.0kgF m/80Ib-f) 5. Distance bolt 18-104 _ Engine Mechanical (6WF1-IC) + lighten up tne tnree distance bolts at tne positions shown in the illustration 6. O-ting 7. Git pup + Install the O-ring into the oll pump, align the dowel position and install NOTE: Do not tighten up the bolt with the heads painted yellow using the above ughtening torque by mistake. This bolt is a mounting bolt of the oll pump cover only. Tightening torque: 49N-m (5.0kgt:m/36lb-ft) Inside hex bolt Tigitening torque: 381V-m (4.0 kyteni2siv-Ay 8. Gasket 9. Gear case cover Apply some liquid gasket Loctite No. FMD-127 to the seating surfaces of the spindle of idle gear A and seating surface of the distance bolle, and install the parts without delay. line area indicated by the arrows. NOTE: Press the protruding part of the gasket firmly into the greove all around its cireurnference Tightening torque M10: 39N-m (4.0kgf/29Ib-M) Me: 25N-m (2.Gkgf/191b-£) Engine Mechanical (6WF1-1C) 18-105 10. Oil seal (erankshatt) + Apply a thin film of engine oil to the outer circumference of the oil seal + Using the installation too, install the oil seal and slinger (silver color) at the same time, + Tighten the center bolt unti the sleeve touches the adapter. i seal installation too! 1-8622-0043-0 + Upon completion of the press-fiting, olean up any oil stains. + After installing the oil seal, measure the distance from the end of the crankshaft to the oil seal surface, NOTE: + Be absolutely sure to replace the slinger and oil seal together as a pair. + Take care not to mark or damage the oll seal lip and 4-ridge thread-cutting surface of the slinger. Reference dimension: 67 -7-3mm (0.2638 - 0.2874) 2 os > 4 1 | = cp ; rh 7 ° 3 Legend 2 3. 4. 5 6 7, 8 ‘Special tool (sleeve) ‘Special tool (adapter) Reference dimension Crankshaft Slinger (silver color) ii seal Position of special tool before press-fitting Position of special tool after press-fiting + If marks are left behind on the shaft section after the slinger has been drawn out, apply ‘some liquid gasket (Three Bond No.1207C) to the area shown in the illustration on the inner circumferential surface of the slinger, and install 18-106 _ Engine Mechanical (6WF1-IC) 11, Idle pulley 42. Crank pulley assembly + Apply some engine oil to the threaded paits of the tightening bolts, and tighten up the botts in sequence al the opposite ends along Ue diagonals. Tightening torque: 267N-m (27.0kgt-m/195lb-A) Engine Mechanical (6WF1-1C) 18-107 Tightening Torque Table Nek) 7135 (198/100) a Qe Ow SF a 39(6028)( me ig ee (ee Koa eay Am 39 4079) yp 9 Ore 7 ECCI 267 @72NGT) 78 (2.087) 18-108 _Engine Mechanical (6WF1-1C) Special Tools Tiustration ‘Tool Number? Description 41-8521-0027-0 Slinger roplacer 1-8522-0043-0 Oil seal installation tool Engine Mechanical (6WF1-TC) 18-109 Flywheel and Flywheel housing Component Parts Legend 1. Engine foot 7. Flywheel housing 2. Engine speed sensor 8. Oil seal 3. Flywheel housing stay 9. Washer 4, Slinger 10. Snap ring 5. Flywheel housing stay 11, Pilot bearing 6. Engine foot 12. Flywheel Removal 1, Engine speed sensor + Remove the sensor together with the bracket, NOTE: Do not remove only the sensor. 18-110 __ Engine Mechanical (6WF1-1C) 2. Snap ring 3, Pilot bearing + Remove the snap ring. + Using the bearing puller, remove the pilot bearing Bearing puller: 9-8521-0157-0 “4. Washer 5. Flywheel 6. Engine foot 7. Flywheel housing stay 8. Flywheel housing 9. Ollseal + Remove the cil seal without marking or damaging the presséiting surface of the oil seal of the flywheel housing. NOTE: + When replacing the oil seal, replace it together with the slinger as a set, rewatestorsnt 10. Slinger + Using the slinger remover, remove the slinger, NOTE: + When replacing the oil seal, replace it together with the slingor as a set. + If the remover tends to slip tree of the slinger, tighten up the outer circumference of the tool using a clip band to make this work easier. Slinger remover: 18821-00270 Engine Mechanical (6WF1-TC) _1B-111 Disassembly Flywheel 1. Ring gear + Inspect the ring gear for damage. Do not remove it if nothing is wrong with it. + Removal of ring gear Place the fywheel on some wooden chips, place a bar up against the end of the ring gear, and tap it uniformly to remove the ring gear. Inspections Pilot bearing * Inspect the pilot bearing for wear and play. NOTE: This is a grease-sealed bearing, so it must not be washed, Flywheel * Inspect the flywheel for cracks and streaking, and measure its wear. Depth from wear surface of flywheel to installation surface of clutch cover Nominal Limit dimension mi(in) mm(in) 15.5" twin plate | 240.9449) | 26.5(7.0433) NOTE: Polish and repair the flywheel, and replace it fits wear has exceeded the working limit, rowateshzo0t Ring gear + Inspect the ring gear for damaye. Do not remove it if nothing is wrong with it Assembly 4. Fiywhee! + Warm up the ring gear uniformiy using a gas bumer (lower than 200°C/382°F) and, with the larger of the gear chamfers at the front, install the gear in the fywheal 18-112 _ Engine Mechanical (6WF1-TC) Ata, Installation 1. Flywheel housing + After applying some liquid gasket Loctite No FMD-127 with @ thickness of about 0.3 mm(0.0118in) and @ width of about 4 mm(0.1575in), install the flywheel housing without delay. Tightening torque ig: 423N-m (12.5kghm/90Ib-") Me: 22N-m (2.2kafrm/16\bt) NOTE: + Also apply a sufficient amount of the liquid gasket to the surface where the cylinder block and crankcase are joined. + Ensure that none of the liquid gasket gets Into ine bolt holes. + Tighten up the bolt by the knack pin first. Howatestore0t 2, Engine foot rear + Apply some molybdenum disulfide to the threaded areas and seating surfaces of the ruts, and start tightening the nuts from the place where the dowels are provided. Tightening torque 1A7N-m (15.0kgfmV/108ID-) > 274N-m (28.0Kgtm/ 20316) 3, Flywheel housing stay *+ Install the flywheel housing stay, Tightening torque: 113N-m (11.5kgEnv83lb-ft) Engine Mechanical (6WF1-TC) 18-113 4. Oli seal + Apply a thin film of engine oil to the outer circumference of the oil seal + Using the instalation too, install the oil seal and > slinger (gray color) at the same time. tg + Tighten the center bolt unti the sleeve touches 1 the adapter. 3 il seal instalation took 41-8522-0043.0 mi) 4 * Upon completion of the press-fitting, clean up any ol stains. s + After installing the oil seal, measure the distance from the crank end to the seal surface. 6.7—7.3mm Reference dimension | 9 a¢46 6 2ardin) NoTE: + Be absolutely sure to replace the slinger and oll seal together as a pair. é 7 + Take care not to mark or damage the oil seal lip and 4-ridge thread-cutting surface of the slinger. Legend 1. Crankshaft 2. Reference dimension 3. Special tool (adapter) 4. Special tool (sieeve) 5. Position of special tool after press-fitting 6. Position of special tool before press-fiting 7. Oil seal 8. Slinger (gray colar) + If marks are left behind on the shaft section after the slinger has been drawn out, apply ‘some liquid gasket (Three Bond No.1207C) to the area shown in the illustration on the inner circumferential surface of the slinger, and install 18-114 _ Engine Mechanical (6WF1-1C) 5. Flywheel 6. Washer + Apply some molybdenum disulfide to the threaded areas and seating surfaces of the bolts, and tighten up the bolts in the numerical ‘sequence shown in the illustration, Tightening torque: 79N-m (8.1 kgf-m/59lb-ft) > Angle method 60° -> 30° rowetesoMont 7, Engine speed sensor + Mount the sensor on the flywheel housing. Tightening torque: 20N-m (2.0Kgfm/4ib-N) NOTE: Be absolutely sure to assemble the flywheel! before ‘mounting the sensor, @. Pilot bearing 9, Snap ring + Insert the pilot bearing, and fasten it using the snap ring Pilot hearing installation tool: 4-8522-1057-0 Engine Mechanical (6WF1-TC) 18-115 Tightening Torque Table Nem(kgt mtn) T4751) 274128203) ata 123(17 560) M 8:22(22/16) 79(8.1158)=60"=30" 18-116 _ Engine Mechanical (6WF1-TC) Special Tools Tiustration ‘Tool Number? Description a 4-8521-0027-0 Slinger remover 1-8522-0043-0 Oil seal installation tool 4-8522-1057-0 Pilot bearing installation tool t 9-8521.0187-0 Pilot bearing puller Engine Mechanical (6WF1-1C) 18-117 Piston and Connecting rod Component Parts 3. 2 Legend 1. Piston ring 5, Connecting rod 2. Snap ring 6. Connecting rod cap 3. Piston pin 7, Bearing 4. Piston Removal “NOTE: Faston tho liner in such a way that it wll not be drawn 1. Connecting rod cap and bearing out when the crankshaft is turned or the piston 2, Piston and connecting rod removed. 3. Connecting rod and bearing + Use an implement such as a scraper to remove the carbon on the top of the liner. 18-118 _ Engine Mechanical (6WF1-TC) * Loosen the tightening nuts, and tap the cap lightly with a copper hammer or other such tool to remove it. Next, tum the orankshaft, and set the piston to be drawn out to the top dead center position. NOTE: Take care not to damage the olling jet * Using an implement such as the handle of a hammer, push out the bottom end of the connecting rod. NOTE: + Ensure that the connecting rod and liner do not interfere with each other. + Take care not to damage the oiling jet. * Assemble the cap, bearing and connecting rod Which have been removed into a set to ensure that they will not be mixed up with other parts Disassembly 4. Piston pin + Using the instalation tool, remove the piston ring NOTE: Make marks on the removed piston rings to identify them by cylinder. Piston ring installation toot! 1-8622-1025-0 2. Snap ring 3, Piston ring + Remove the snap ring, place a bar up against the piston pin (1), and tap it gently to remove it Engine Mechanical (6WF1-TC) 18-119 NOTE: ‘Attach number labels to the piston pins for each cylinder, Piston Connecting rod Conneeting rod cap Bearing Nene Inspections Piston pin + Inspection of piston rings and measurement of closed gap Clean off the carbon on the piston rings. Insert the piston rings into the cylinder liners, and use the piston heads to push in the rings as far as the least worn sections ofthe liners (bottoms of the liners) Next, insert a thickness gauge into the joint areas of the rings, and moasure the clearance. Closed gaps of piston rings Assembly Woaking standard limit mmiin) mm(in) 0:35 -0.50 7 ‘Top ring (0.0138-0.0197) | (0.0304) “Second rn 0.80 -0.95 TS 8 | o.0315-0.0374) | (0.0591) 0.35 0.50 TO Thidting | (@.0138-0.0197) | (0.0304) 03-050 7) Ollring (.0118-0.0197) | (0.0394) + Measurement of clearance between piston ring groove and piston ring Clean off the carbon on the piston head and in the ring groove. Next, insert the ring into the ring groove, and measure the clearance using the thickness gauge, For the top ring, measure the clearance using the thickness gauge (1) while pressing down on the piston along the straight edge (2). Clearance between ring groove and ring Top ring ‘Assembly ‘standard mm(in) 0.058 - 0.117 (0.0023 - 0.0046) ‘Woeking limit mmin) Second ring 0.085 — 0.120, (0.0033 - 0.0047) Third ring 0.085— 0.120, (0.0033 - 0.0047) olrning 0.025 — 0.085 (0.0010 - 0,026) 0.18 (0.0059) 18-120 _Engine Mechanical (6WF1-TC) + Measurement of piston ring tension Use a tension gauge to measure the piston ring tension, Install the coil expander ring, and measure the tension of the oil ring. Piston ring tension Standard Timi Nekapidby | _N ckofton 275-2 245 Top ring | (281-420) He.20-9.26) | 565!) 228-34.1 106 Seoond ring | (2323.48) Keia_zen | @0"an dard Tn Ntwatyilo |W kgtbe) 28.1 = 36.6 196 Thing | 287-273) 2 nea3—8.24) | 20441) ae3- 877 292 oiling | (4.72-5.88y dioai—tz97) | 0882) ee Piston + Inspection of piston for streaking and cracks Remove the carbon sludge and other foreign matter on the piston, and wash. Carefully inspect the ring groove of the piston and other places wich are hard to sec. If necessary, conduct an inspection using a red check Engine Mechanical (6WF1-TC) 18-121 + Measurement of outside diameter of piston pin Measure the outside diameter of the piston pin, and measure the clearance between the piston pin and piston pin hole and also between the piston pin and connecting rod bushing, For the piston pin, perform the measurements in the six locations shown in the ilustration, Connecting rod + Measurement of clearance between connecting rod bearing and crank pin Clean the bearing and its mounting surface, and assemble the bearing. Next, apply some molybdenum disulfide to the threaded areas and seating surfaces of the tightening nuts, tighten up the nuts alternately and, using a cylinder gauge measure the four locations on the connecting rod Nominal | Standard | Limit Romina) ] Standard 7 Unt bearing shown in the ilastration min) Tightening torque: donor | 958 _ | ¢s897 . pion 2.2035) | 98Nm (10.0kgfnv72Ib )-» Angle method 30°-» 20 biston pin Clearance 3.008 = between piston | 0.021 0.05 pin and piston: (0.0003 — | (0.020) pin hole 0.0008) ‘Clearance between piston 00F TN ot0 in and _ * (0.0008 - | (0.0038) connectina rod 00015) 5) bushing Use a micrometer to measure the outside diameter of the crank pin at the four locations shown in the illustration, Clearance between bearing and crank pin ‘Assembly standard Working limit mmatin) min) 0.033 - 0.103 0.16 (0.013 - 0.041) (0.0083) NOTE: ‘The crankshaft has been nitrocarburized so it must not be modified or repaired. * When using a plastic gauge for the measurement, refer to the General Information, 18-122 _Engine Mechanical (6WF1-TC) 12 A + Measurement of connecting rod deformation Using the connecting rod aligner, measure the torsion and parallelism of the holes at the small and big ends. NOTE: The bearing serves as the reference for the measurement so check that the bearing is not worn Torsion and parallelism (por 100 mm/3.937in) ‘Standard mm(in) 005(0.0020) Limit mm(in) 0.110.039) ‘+ Measure the clearance In the axial direction of the connecting rod at the bigger end. Assemble the connecting rod into the crank pin and, using a thickness gauge, measure the clearance in the axial direction, Clearance in axial direction ‘Standard mmtiny Limit mmtiny 0.175-0.290 0.35 (0.069 - 0.0114) (0.0138) sossatre: Bearing + Inepect for wear, scratches, peeling, ete. + Assemble the bearing, and check that there is tension, Engine Mechanical (6WF1-1C) 18-123 Assembly 4. Connecting rod 2. Bearing 3. Connecting rod cap + For details on the assembly, refer to the section ‘on installing the piston and connecting rod 4, Selection of piston grade + When using a new piston, use the designated resupply piston + When replacing the piston, there is no need to select the grade. (Since there is only one type) + When re-using the piston, measure the clearance between the piston and liner + Measurement method Measure the outside diameter of the piston at the grade position. Clean off any carbon and ‘other foreign matter on the liner, measure the average maximum and minimum values (in the lateral direction of the cylinder block) at 130, mm(5.1181in) from the top of the liner, and check whether the clearance between te piston and liner is within the reference value, + When replacing only the liner, select it by grade. * Inside diameter of ner and outside diameter of piston Part) Inside diameter | Outside diameter Grade symbol | of liner mm(in) | of piston mm(iny 147.000 - 146,840 — A 147.010 146.849 (6.7874— (6.7811 — 5.7878) 5.7814) 747.011 — 146.850 - 8 147.020 146.860 (6.7878 — (6.7815- 5.7882) 5.7819) 7a7.024 — 146.861 — c 147.030 146.870 (6.7882 — (6.7819- 5.7686) 9.7823) Grade selection measurement positon] ao, {from bottom of piston skirt in direction of| (4147 iq) the longer diameter): " Clearance between piston and liner (in direction of the longer diameter) Assembly standard oe een (0.0089 ~ 0.007Smm) 18-124 _Engine Mechanical (6WF1-1C) (Reference) Liner replacement + The grade must be the same for both the inside diameter of the cylinder block bore and outside diameter of the liner. + Select 1X for 1 or 3X for 2 and 3 according to the umber engravad on the right side of the cylinder block, and assemble. Cylinder block and liner combinations: Par) Gyinger ‘Outside Grade symbol | block mmin diameter of liner min) 151.60- 757.590— 1 151610 | 4, | 151.599 (6.9685 — (s:9681 — vemmunaceon 5.9689) 5.9685) =a , Piston > 51.620 6, Piston ring (5.9089 - 451.600— 7. Snap ring 59693) | | 151.610 * Align the arrow mark on the piston head and 151.621 (5.9685 — the front mark on the connecting rod as shown 451.620 5.9689) in the illustration (same direction) to assemble. 3 (6.9893 — Next, apply some engine oil to the piston pin, 5.9697) push the piston pin into place, and fasten it ‘securely using the snap ring (the opening of the snap ring must be up or dovin). Finally, check that the piston and connecting rod. move smoothly, 1 = S o> 3 . Legend 1, Position where the inside diameter bore grade is veoysicn engraved on the cylinder block legend 1. Front mark 2. Grade category 3, Front mark 8. Piston pin Engine Mechanical (6WF1-1C) 18-125 ‘+ Installation ot expanaer ning Insert the expander ring so that there is no closed gap, and tite into the piston groove. 1 Installation of piston rings + Place the top ring, second ring and third ring with the identification colors of their joint areas (on the right, and use the installation tool to install them, ‘+ Make marks on the joint area sides of each ring 10 identify the top ring, second ing and third ring + Take care Ww ensure thal ie coating on Une piston skirt will not be peeled off. a rewsnisrazt + No differentiation is made between the top and bottom of the oil ring, but instal this ring in such a way that it is pointing 180 dearees in the ‘opposite direction from the joint area of the expander rina, + Apply some engine cil all around the rings, and tum smoothly without catching on anything Piston ring installation too: 4-8522-1025-0 SS =” iaritcaion | —Tenaom Terme | Redan | NeeTaaNed aay | Rea] Triding [Grn ramt yf 3 SS JS Legend 1. Top ring 2. Second ring 3. Third ring, 4. Oil ring Installation 1. Connecting rod and bearing 18-126 _Engine Mechanical (6WF1-1C) + Thoroughly clean the mounting surfaces of the cap bearing and connecting rod bearing, assemble the bearing, and apply some engine il to the sliding surface + Also apply some oil to the piston pin. NOTE: + The bearing on the connecting rod side has a groove in one section and an ail hole. + The bearing on the cap side has an oil groove which extends all the way around and no oll hole. ed 2, Piston and connecting rod + Apply some engine oil all around the cylinder liner (1). Hovstesotont + Tum the crankshaft, and set the orank pin of the cylinder in which the piston is to be assembled to the top dead center position. NOTE: Fasten the liner in such @ way that it will not be drawn out. + Divide the joint area directions of the piston ring into four equal sections while ignoring the lateral pressure direction NOTE: Install the join of the oil ring on the opposite side of the Join of the expander ring onaretcntot + Apply some oil all around the piston and ring, + Check the cylinder number of the connecting rod, point the arrow mark on the piston head toward the front of the cylinder block, and insert the piston by hand. At this point, insert the piston by turing it to the right by § to 10 degrees, and return it to point properiy at the position where it does not interfore with the cling jt. Engine Mechanical (6WF1-1C) 18-127 + Using the installation tool, push in the piston with the handle of a hammer until it makes contact with the crank pin. Then tum the crankshaft while pushing in the piston head, and set it to the bottom dead center position. ‘CAUTION: + The front marks on the piston and connecting rod must be pointing in the same direction. + Use the installation too! by placing it right up against with the cylinder block. Unless it is right up against with the cylinder block, the piston ring will be damaged, + When installing the piston and connecting rod, take care not to damage the crank pin and oiling jat. Piston installation tool: 4-8522-0059-0 3. Connecting rod cap and bearing + Install the bolts so that the arrows at the end of the connecting rod bolts will be pointing in the direction shown in the illustration. + Match the cylinder number of the cap with the cylinder number of the connecting rod, apply some molybdenum disulfide to the threaded areas and seating surfaces of the nuts, tighten Up the nuts alternately. At this point, check that the cylinder numbers of the connecting rod and cap are pointing toward the right side of the cylinder block, Tightening torqu 9BN-m (10.0kgf m/72Ib ft)-» Angle method 30°» 30° + Tum the crankshaft, and check that it turns ‘smoothly without catching on anything. Also check that it does not interfere with the oiling jet. NOTE: Fasten the liner in such a way that it will not be drawn out. 18-128 _ Engine Mechanical (6WF1-1C) Tightening Torque Table 96(10.0772)--30"—30" Nemkofmtb-#) wera. Engine Mechanical (6WF1-1C) 18-129 ‘Special Tools lustration ‘Tool Number/ Description 41-8522-0059-0 Piston installation tool 1-8522-1025-0 Piston ring installation tool 18-130 _Engine Mechanical (6WF1-TC) Crankshaft Component Parts Legend 1, Gylinder block 4, Main bearing 2, Crankshaft 5, Thrust bearing 3, Thrust bearing 8. Crankcase Removal 1. Crankcase Engine Mechanical (6WF1-TC) 18-131 + Before removing the crankcase, measure the clearance in the axial direction of the crankshaft Measure this at the No.1 bearing thrust surface. Clearance in axial direction of crankshaft ‘Standard mm(in) Limit renin) 004-067 (0.04016 - 0.0264) NOTE: If the working limit has been exceeded, replace the thrust bearing, + Loosen the bearing tightening bolts trom tne outside, and remove them. Place brass rods ‘against the ribbed area in the four corners on the outside of the crankcase, tap them with a hammer to separate the Loctite, Then allow the crankcase to lift up, hoist it horizontally, and remove. 2. Crankshaft 3. Crankshaft bearing 4, Thrust bearing + Use tags or labels to mark the positions where the bearing and thrust bearing are installed NOTE: + Do not mark or damage the sliding surfaces of the crankshaft bearing, 18-132 _ Engine Mechanical (6WF1-1C) Disassembly 1. Crankshaft 2. Bearing 3. Crankshaft gear + Use the gear puller to remove the crankshaft gear. Gear puller: 1-8521-0064-0 Slinger remover: 4-8521-0027-0 NOTE: + Inspect the gear for damage: do not remove it if there are no problems in evidence. + When a slinger is installed, remove it first. Inspections Crankshaft + Inspect the crankshaft for cracks and the contact surfaces of the bearing for damage. I necessary, inspect the parts using the magnetic flaw detection method or red check. + Measurement of erank journal and pin wear Perform the measurements in the four locations shown in the illustration. Nominal Assembly dimension standard ram(in) min) 9104850 (4.1270) Nod | 'yi04.875 Outside 41286) diameter of | $105(4.1339) joumal 9104880 (4.7291)- omer | 104.905 (4.130) Outside damotorat | sozcaeaa | #238950 79)- pin NoTE: ‘The crankshaft has been nitrocarburized so it must not be modified or repaired, Engine Mechanical (6WF1-TC) 18-133 * Measurement of crankshaft run-out Hold the No.1 journal and No.7 joumal using the crankshaft aligner or V-biock. Place a dial gauge against the No.4 journal of the crankshaft, rotate the crankshaft gently through one turn, and measure the amount of crankshaft run-out. Amount of crankshaft run-out Timi 0.15 mmin(0,0059In) Prmcrosrnats Bearing + Inspect for wear, scratches, peeling, ete. + Assemble the bearing, and check that there is tension, Crankshatt gear * Inspect the crankshaft gear for damage NOTE: Conduct this inspection before drawing the gear out from the crankshaft, and do not draw it out if nothing is wrong with it ‘Measurement of clearance between crank bearing and crank journal + With the crankcase assembled, measure the inside diameter of the crank bearing and the outside diameter of the crank journal, and obtain the clearance 18-134 _Engine Mechanical (6WF1-TC) + Clean the bearing and its mounting surfaces, assemble the bearing, and then install the crankcase. Next, apply some molybdenum disulfide to the threaded areas and seating surfaces of the M18 bolls, and tighten up the bolts to the specified torque. The crankcase tightening sequence is shown in the illustration In addition, apply some engine cil to the threaded areas and seating surfaces of the M12 bolts, tighten up the bolts, and use a cylinder gauge to measure the four locations shown in the ilustration, Tightening torque Nim (kgf mab) we 49 (5/36) > 88 8.0785) > ‘Angle method 90° to 120° uta 36 GATT) TE | Application of movadenum disutide wT: ‘Application of engine ol ‘Slandard mim(in)] Limit (in) Clearance | No.4 | 0075-0150 between | joumal | (PORE) 0.16 beating 0.0059) cogs, Prasat and crank [5045 0.120 journal ther | (0.018 - 0.0048) NoTE: * When using a plastigauge for the measurement, refer to the General Information. Presence/absence of nitrocarburized zone + Washing of crankshaft Wash the crankshaft. Remove the oil and grease particularly at the test locations (but not within 10 ‘mm(0.3937in) around the oll holes) using an organic solvent or other such agent, + Inspection of nitrocarburized zone Using a dropper or glass rod, drip the test solution onto the test area. At this point, hold the drip area horizontal so that the test solution will not run down. * Test solution: Cupric ammonium chloride dissolved in distilled water to form a 5% to 10% solution Legend Do not test within 10 mm (0.3837in) around the oil holes. 2. Test solution 3. Crankshaft Engine Mechanical (6WF1-1C) 18-135 + Judgment Crankshaft is re-usable: No changes at all are apparent after 30 to 40 seconds. Crankshaft cannot be re-used: After 30 to 40 seconds, the test solution (a light blue color) turns transparent, and the place onto which it has dripped changes to a copper color, + Steps to be taken after testing The test solution (1) is highly corrosive so use a cloth to wipe it up immediately after the test, and wash the places which were exposed to it with water or steam, ete. CAUTION: * Do not allow the test solution to come into contact with your eyes, hands, clothing, ete, If some solution should get into your eyes, rinse them immediately with large quantities of pure water, and seek medical assistance. owatesh701 Assembly 4. Crankshaft gear + Assemble the knock pin in the crankshaft. + Warm up the gear using an oil heater (at an oil temperature of 190 to 240 °C / 374°F to 44°F), Next, point the 0" timing index mark on the gear toward the front, align the key groove in the gear with the knock pin of the crank, and tap it using the installation tool until it touches the crankshaft colar NOTE: Assemble the parts while paying attention to the direction in which the gear is pointina. Gear installation tool: 1-8522-0045-0 18-136 _Engine Mechanical (6WF1-1C) 2. Bearing 3. Crankshaft Installation 1. Crankshaft bearing + Check the installation positions at the disassembly stage, thoroughly clean the bearing and its installation surface, and assemble the parts NOTE: + The bearing on the cylinder block side has a groove which extends all the way around and an oil hole. + The bearing on the crankcase side has a narrow groove which extends all the way around and no ail hole. 2. Crankshaft + Apply some engine oll to the Dearing sliding surface, and place the crankshaft on top horizontally, rmsossc2u0r 3. Thrust bearing + Apply some ol to the engine oll groove side of the thrust bearing, point the oil groove toward the outside, and push it in by hand at both sides of the No.1 journal ofthe cylinder block. Legend 1. Alignment of knock pin hole 2. Oilgroove 3. Application of oll Engine Mechanical (6WF1-1C) 18-137 + Apply some engine oll to the all groave side of NOTE: the thrust bearing. Point the oil groove toward «Check that the thrust bearing has been installed the outside, align with the protrusion in the securely. crankcase, and assemble. + Check that the crankshaft tums smoothly. Tightening torque Tim (kata) Mie: 495136) > 88 (810765) > ‘Angle method 90° to 120° mia 96 88771) Mi8:_| Application of molybdenum disulfide Mia: ‘Application of engine oll 4. Crankcase + Apply some liquid gasket Loctite No. FMD-127 with a thickness of at least 0.3 mm(0.1875in) and a width of about 4 mm(0.0118in) to the areas on the bottom of the oylinder block indicated as 1, 2, 3, 4, 8 and 6 in the illustration, ‘and install the parts without delay. * Apply some molybdenum disutide to the threaded areas and seating surfaces of the Mi8 bolts, and tighten up the bolts in the numerical sequence shown in the illustration. In addition, apply some oil to the threaded areas and seating surfaces of the M12 bolts, and tighten up the bolts. 18 Special Tools 38__Engine Mechanical (6WF1-TC) Tiustration ‘Tool Number? Description 1-8521-0064-0 Crankshaft gear puller 1-8522-0045-0 Crankshaft gear installation tool Engine Mechanical (6WF1-1C) 18-139 Cylinder block Component Parts Legend 1. Oil relief valve 4, Oil pressure switch 2. Cylinder liner 5, Oiling jet 3. Cylinder block 6. Crankcase Disassembly Measurement of Inside diameter of cylinder 4. Oil pressure switch Hner 2 Oiiwlctvaive + Check the inside of the liner for marks and damage. 3. Crankease + With the liner installed on the cylinder block, 4, Oling jet measure its. inside diameter by measuring 8. Cylinder liner where it is worn the most at a position about 430mm from the top surface of the liner. If the wear has exceeded the working limit, replace the liner, 18-140 _Engine Mechanical (6WF1-TC) Inside diameter of cylinder liner Nominal dimension mm(in) 9147(6.7874) ‘Wrking limit min) 9147.3(6.7992) + When the liner is to be re-used, use an implement such as a scraper to remove the ‘carbon on the top of the liner. NOTE: + The liner cannot be repaired by boring or honing, + Fasten the liner in such @ way that it wil not be drawn out Inspections Crankease + Inspect the crankcase for cracks and damage. I necessary, inspect the cylinder head using the magnetic flaw detection method or red check. Olting jet + Inspect the oil holes in the oiling jet and joint bolts. 6. Cylinder biock Cylinder block + Inspection of the cooling water and oil passageways for corrosion and clogging Carefully inspect the covling water passageways between the cylinders for clogging. + Inspect the cylinder block for cracks, damage, etc. Wt necessary, inspect the cylinder head using the magnetic flaw detection method or red check. Engine Mechanical (6WF1-TC) 18-141 + Inspection of water jacket for leaking water Using a hydraulic tester, apply a hydraulic pressure of 490 kPa (5 kgiom* | /1psi) for three minutes, and inspect various parts of the cylinder block for water leaks. Assembly 41. Cylinder block Selection of cylinder liner grade + The grade must be the same for both the inside diameter (1) of the cylinder block bore and outside diameter of the liner. + Select 1X for 1 or 3X for 2 and 3 according to the number engraved on the right side of the cylinder block, and assemble, NOTE: Assembling the parts without selecting the liner grade may lead to insufficient cooling (excessive clearance) or difficulties in inserting the liner (insufficient clearance) and give rise to distortion Cylinder block and liner combinations. Number engraved in Liner grade black 1 1K 23 ax Clearance between cylinder block and liner 0.006 —0.025mm ‘Assembly reference: (0.0002 - 0.0010in) + Washing of cylinder block and liner Thoroughly wash the cylinder block and liner, and then wipe off all traces of the detergent. NOTE: + The liner is thin so handle it carefully, + Position where outside diameter of liner is engraved as indicated by arrow 18-142 _ Engine Mechanical (6WF1-IC) manson 2. Gylinder liner + Installation of cylinder liner Apply some engine oil around the cylinder liner ‘on the outside, and install it straight in relation to the cylinder block. NOTE: + When inserting the liner, do not tap it or apply unnecessary force. + If, afler inserting the liner, the cylinder block is to be tured upside down, take steps to prevent the liner from being drawn out. + Measurement of cylinder iiner protrusion Using a dial gauge, measure the amount of the liner protrusion Amount of liner protrusion 078-1 12mm | ‘Assembly standard: (0.0265 —004atn) Difference from adjacent cylinder Less than ee aaa 0.025 mm(0.0010in) Poses 3. Oiling jet + Check that the tip of the oiling jet fe pointing toward the cooling cavity inlet of the piston, and Tightening torque: 69N-m (7.0kgf-m/5tIb-ft) Engine Mechanical (6WF1-1C) 18-143, Tightening torque Adapter: 41N-m (4.2kgf-miS0lb-t) Oil pressure switch’ 48N-m (1.8kgt-m/3ib-t) NOTE: Do not cause the tip of the oiling jet to be bent out of shape 4. Crankcase For details on the assembly procedure, refer to the section on the crankshaft. 5. Oil relief valve + Apply some engine oil to the O-ring, and install the O-ring in the relief valve. + Apply some engine oil to the threaded part of the relief valve, and assemble the valve into the cylinder block, Tightening torque: 20N-m (2.0kaF-m/14Ib 1) 6. Oil pressure switch + Install both the adapter and oil pressure switch through the gasket, 18-144 _ Engine Mechanical (6WF1-1C) Tightening Torque Table Nemkofmib-) 41167750) 16(1.8/19) ear. 0761) 20720114)