Isuzu Engine 6WF1-TC Commanrail Workshop Manual

WORKSHOP MANUAL
C&E SERIES
ENGINE
(6WF1-TC (Common Rail) model)
SECTION 1
NOTICE
Before using this Workshop Manual to assist you in performing

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

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model:
C&E Series
This Manual is applicable to 2006 year model and later vehicles.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTENTS

1B Engine Mechanical
1C Cooling System
1D Fuel System
1E Engine Electrical
1F —
1G Exhaust System
1H Lubrication System
1I Accelerator Pedal Assembly
1J Supercharge System
1K Preheating System
1L Power Take Off
Engine Mechanical (6WF1-TC) 1B-1
ENGINE
Engine Mechanical
(6WF1-TC)
TABLE OF CONTENTS
6WF1-TC Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Tightening Torque Table . . . . . . . . . . . . . . . . . . 1B-97
Maintenance Precautions . . . . . . . . . . . . . . . . . 1B-2 Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-98
How to Read the Model . . . . . . . . . . . . . . . . . . . 1B-3 Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1B-98
Description of Functions and Operation. . . . . . . 1B-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-98
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1B-6 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-100
List of Trouble Symptoms . . . . . . . . . . . . . . . . 1B-11 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-101
Symptom: The engine fails to turn over . . . . . . 1B-12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-102
Symptom: The engine turns over but fails to start 1B- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-102
13 Tightening Torque Table . . . . . . . . . . . . . . . . . 1B-107
Symptom: Lots of black smoke is emitted . . . . 1B-14 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 1B-108
Symptom: Lots of white smoke is emitted . . . . 1B-15 Flywheel and Flywheel housing . . . . . . . . . . . . 1B-109
Symptom: Engine knocking occurs . . . . . . . . . 1B-16 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1B-109
Symptom: The engine does not turn over properly . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-109
1B-17 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-111
Symptom: Battery charging trouble . . . . . . . . . 1B-18 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-111
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1B-18 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-111
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1B-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-112
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20 Tightening Torque Table . . . . . . . . . . . . . . . . . 1B-115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 1B-116
Engine Accessory Parts . . . . . . . . . . . . . . . . . . . 1B-31 Piston and Connecting rod . . . . . . . . . . . . . . . . 1B-117
Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1B-31 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1B-117
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-32 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-118
Engine Exterior Parts . . . . . . . . . . . . . . . . . . . . . 1B-35 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-119
Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1B-35 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-123
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-125
Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-43 Tightening Torque Table . . . . . . . . . . . . . . . . . 1B-128
Tightening Torque Table. . . . . . . . . . . . . . . . . . 1B-62 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-130
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-63 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1B-130
Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1B-63 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-130
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-63 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-132
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-68 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-132
Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-135
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-136
Tightening Torque Table. . . . . . . . . . . . . . . . . . 1B-88 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-139
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-89 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1B-139
Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-90 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1B-139
Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1B-90 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-140
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-90 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-141
Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-91 Tightening Torque Table . . . . . . . . . . . . . . . . . 1B-144
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-92
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-94
Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1B-94
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-94
Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-97
1B-2 Engine Mechanical (6WF1-TC)
6WF1-TC Engine
Maintenance Precautions Precautions for jobs inherent to this engine
Observe the following precautions when conducting In the fuel system, all the holes and clearances inside
engine maintenance in order to both safeguard against the injector that serves as the fuel passages and other
engine damage and maintain the reliability of the parts are finished to a high level of precision. For this
engine performance. reason, these parts are particularly sensitive to foreign
• When raising or supporting the engine, do not matter, and the entry of foreign matter may lead to
allow the jacks to come into contact with the oil malfunctioning or other trouble. Therefore, take every
pan. means possible to keep these holes and clearances
When lowering the engine, use an engine pallet, free from foreign matter.
wood frame or other such means to support it at
the engine foot and flywheel housing.
• When the intake system has been removed, cover
the air intake to prevent foreign matter from
entering the cylinders. If foreign matter is allowed
to enter, the cylinders and other parts may be
seriously damaged when the engine is run.
• When conducting maintenance work on the engine
body, be absolutely sure to disconnect the battery
grounding cable. When power needs to be
supplied to the engine during inspections or other
such jobs, exercise care since short-circuiting may
occur.
• Apply plenty of engine oil to the sliding surfaces in
order to protect and lubricate the sliding surfaces
during the initial operation.
• When the valve train parts, pistons, piston rings,
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 same positions where they were prior to
disassembly.
• Whenever the gaskets, oil seals, O-rings 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 oil, grease, moisture and
contamination, and then apply the designated
liquid gaskets and assemble the parts.
• Assemble the parts within 7 minutes after applying
the liquid gaskets.
If more than 7 minutes have elapsed, remove the
liquid gaskets, and re-apply them.
• During the assembly and mounting processes,
tighten the parts to the specified tightening torque,
and ensure that the parts are mounted properly.
How to Read the Model
HCW61BMF000301
Legend
1. Engine serial number (6WF1-. . . . . .)
Description of Functions and Operation
Structural view of engine
HCW6Z0MF000101
HCW6Z0MF000201
HCW6Z0MF000301
Functional Inspection:
Measurement of compression pressure
Measure the compression pressure with the battery Special tools
and starter motor in a trouble-free state while the
engine is cold (water temperature of 20°C/68°F). Compression adapter: 5-8531-7001-0
Removal of glow plugs

• Remove all the glow plugs (1).
HCW46BSH002301
Measurement of compression pressure

HCW51KSH000201
• Run the starter motor (at a speed of 200 rpm), and
read off the compression pressure when the
Disconnection of injector harness connectors
pointer of the compression gauge has stabilized.
• Disconnect the injector harness connectors from
the lower head cover (No fuel injected). 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 harness 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 Difference between

pressure cylinders
kPa (kg/cm2/psi)/ kPa (kg/cm2/psi)/rpm
rpm
HCW46BSH002201 2840 200
standard
(29 / 412 ) / 200 (2.0 / 28) / 200
Mounting of compression gauge
2260
• Insert the compression adapter into the holes limit —
(23 / 327) / 200
where the glow plugs are installed, and mount the
compression gauge.
3. Be absolutely sure to disconnect the battery
terminals in order to protect the sensors and other
electronic components from 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.
HCW31BSH009301 Adjustment of valve clearance

Setting the #1 (or #6) cylinder to the compression
Determining when overhauling is to be performed top dead center
Overhauling is required in the following cases. Turn the crankshaft in the forward direction, and align
the T/C ruled line of the flywheel to the pointer. At this
Drop in compression pressure point, check that there is a clearance between the cam
When the compression pressure has dropped below and rocker arm of the #1 (or #6) cylinder (compression
2260 kPa (23kg/cm2/327psi) according to the top dead center).
measurement method set forth in "Measurement of
compression pressure."
Increase in rate at which engine oil 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 T

C
When, if 100% serves as the amount of fuel consumer
(km/liter) by a new vehicle, 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. HCW31BSH012301
NOTE:
Adjustment of valve clearance
Examples of possible factors that may cause abnormal
noises include engine parts wear, seizures and 1. Adjust the valves listed in the valve clearance
overheating. adjustment table.
Maintenance Precautions
1. Allow the engine to cool off sufficiently since its
parts will be hot 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 tool before inspecting
the sensors.
2. Loosen the adjusting screws (1) of the rocker arm Tightening torque:N⋅m(kgf⋅m/lb⋅ft)
and bridge (2) completely. Rocker arm adjusting screw lock
78 (8.0 / 58 )
nut
Bridge adjusting screw lock nut 54 (5.5 / 40)
NOTE:
1
• 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
cover is removed, so use a rag to clean it up.
HCW31BSH008901
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.
HCW31BSH009001
4. With the thickness gauge still 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 stiff, and secure the
lock nut of the bridge.
Valve clearance mm(in) (when cold)
0.40(0.016) for both intake and exhaust

Valve clearance adjustment table
Cylinder No. 1 2 3 4 5 6
Arrangement
Condition EXH IN EXH IN EXH IN EXH IN EXH IN EXH IN
of valves
When the #1
cylinder is set
at the
{ { { { { {
compression
top dead
Valve to be center
adjusted When the #6
cylinder is set
at the
{ { { { { {
compression
top dead
center
Injection sequence (1 - 5 - 3 - 6 - 2 - 4)
Inspection and adjustment of belts 3. Deflection amount when the centers between the
Inspect the V-belt for wear and cracks. idle pulley and generator pulley (F1) and between
the crank pulley and idle pulley (F2) are pressed
with a force of 98N (10 kgf/22lb).
Reference values
New product When tension is

mm(in) re-adjusted
mm(in).
10 – 13 11 – 14
F1
(0.39 – 0.51) (0.43 – 0.55)
13 – 16 15 – 18
F2
(0.51 – 0.63) (0.59 – 071)
HCW31BSH025001
Adjustment of generator drive belt tension

1. Loosen the lock nut of the idle pulley.
2. Using the adjusting bolt of the idle pulley, adjust
the belt tension to the reference value.
1
HCW31BSH008601 HCW31BSH008701
Legend Legend
1. Adjusting bolt 1. Adjusting bolt
2. Lock nut
3. F1
4. F2
Adjustment of A/C compressor drive belt tension 1
1. Loosen the bolt and nut shown in the illustration.

2. Using the adjusting bolt, adjust the belt tension to 2
the reference value.
Reference values
Deflection amount when the center between the

crank pulley and A/C compressor is pressed with a 4 3
force of 98N (10 kgf/22lb): 10 – 13 mm(0.39 – 0.51 in)
3. Tighten the bolt and nut.

HCW31BSH065601
Legend
1. Bolt
2. A/C compressor
3. Adjusting bolt
4. Nut (rear side)
List of Trouble Symptoms
• The engine fails to turn over
• The engine turns over but fails to start
• Lots of black smoke is emitted
• Lots of white smoke is emitted
• Engine knocking occurs
• The engine does not turn over properly
• Battery charging trouble
Symptom: The engine fails to turn over
Condition Possible Cause Correction

The starter fails to turn. The battery relay is defective. Replace.
Something is wrong with the wiring. Connect or repair.
The battery capacity is insufficient. Recharge or replace.
The starter brush has stuck or is Repair or replace.
worn or damaged.
Something is wrong with the Disassemble and repair.
functions inside the starter.
The starter turns but fails to engage The ring gear is worn. Repair or replace.
with the flywheel. The magnetic switch of the starter Adjust or repair.
is not adjusted properly.
The starter pinion engages with the Something is wrong with the battery Charge or repair.
ring gear but fails to turn. capacity.
The contact pressure of the starter Disassemble and repair.
brush and commutator is
insufficient.
The armature of the starter is stuck. Disassemble and repair.
The engine has seized up inside. Disassemble and repair.
Symptom: The engine turns over but fails to start

Fuel does not reach the supply Air has found its way inside the fuel Purge the air.
pump. system.
Air has been sucked in from the fuel Purge the air or replace the pump.
pump.
The engine is out of fuel. Replenish.
The strainer in the fuel suction area Clean or replace.
is clogged.
The fuel pipe is clogged. Clean or replace.
functions of the supply pump.
In extremely cold weather, fuel Replace with the suitable fuel.
which is not designed to be used in
cold areas, is being used.
The fuel filter 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 not 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.
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.
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 filter is clogged. Replace.
Symptom: Lots of black smoke is emitted

Defective ignition timing Something is wrong with the engine Diagnose the engine control
Something is wrong with the The nozzle is stuck. Replace.
injection status of the injector. Something is wrong with the engine Diagnose the engine control
Insufficient compression pressure The valve clearance is excessive. 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. Disassemble and repair.
A piston 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 fuel is being used. Replace.
Defective air intake The intake pipe is clogged. Repair or replace.
The air cleaner element is clogged. Clean or replace.
Trouble detected by engine control Trouble in the sensors or other Repair or replace.
system parts
The EGR or exhaust valve is The EGR valve is stuck. Repair or replace.
defective. The exhaust brake valve is stuck. Repair or replace.
Symptom: Lots of white smoke is emitted

Defective ignition timing The rotation sensor is defective. Replace.
Trouble detected by engine control Trouble in the sensors or other Replace.
system parts
Something is wrong with the control Replace.
unit.
The compression pressure is The valve clearance is excessive or Adjust.
defective. insufficient.
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. Disassemble and repair.
A piston has seized up. Disassemble and repair.
The quality of the fuel is not high Moisture has become mixed in with Replace.
enough. the fuel.
High oil consumption The piston ring is worn or broken. Disassemble and repair.
The valve stem oil seal is defective. Disassemble and repair.
Symptom: Engine knocking occurs

Defective ignition timing Something is wrong with the engine Diagnose the engine control
Trouble detected by engine control Trouble in the sensors or other Replace.
system parts
unit.
Fuel A low-grade fuel is being used. Replace.
Defective air intake The intake pipe is clogged. Repair or replace.
Abnormal noises from the engine Foreign matter has found its way Repair or replace.
inside the cylinders.
A piston, bearing or other part has Repair or replace.
seized up.
Symptom: The engine does not turn over properly

The rpm does not go up. The accelerator sensor or switch is Replace.
defective.
unit.
Unstable engine turn-over Something is wrong with the control Replace.
unit.
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.
system.
The exhaust brake valve is stuck. Repair or replace.
Symptom: Battery charging trouble

No charging Broken or short-circuited wire or Repair or replace.
defective connection
functions inside the generator.
Insufficient charging Short-circuited wire or defective Connect or repair.
connection
The generator drive belt is loose. Adjust or repair.
The battery is defective. Replace.
Overcharging Wire short-circuiting Connect or repair.
Main Specifications
Model 6WF1-TC
Item
Engine type Water-cooled 4-cycle in-line 6-cylinder 24-valve
OHC direct-injection diesel engine
Cylinder layout and number - inside
(mm / in) L6 - φ147 (5.79) - 140 (5.51)
diameter – stroke
Total displacement (L / in3) 14.256 (869.9)
Compression ratio 17.0
Compression pressure kPa (kg / cm2 / psi)
2844 (29 / 412) / 200
/ rpm
Dimensions (length / width / height) (mm / in) 1693 (66.65) / 960 (37.8) / 1159 (45.63)
Maintenance weight (excluding air
(kg / lb) 1180 (2602)
cleaner)
Fuel injection timing (BTDC) 0°
Fuel injection sequence 1-5-3-6-2-4
Injection pump type Electronically controlled fuel injection system
(common-rail type)
Governor type Electronic
Timer type Electronic
Nozzle model DLL-P
Intake and exhaust valve clearance
(mm / in) 0.4 (0.016)
(when cold)
Intake valve opening and closing (Open)
21° (BTDC)
timing
Intake valve opening and closing (Close)
27° (ABDC)
timing
Model 6WF1-TC
Item
Exhaust valve opening and closing (Open)
52.5° (BBDC)
timing
Exhaust valve opening and closing (Close)
17.5° (ATDC)
timing
Fuel filter type Filter paper type
Oil filter type Pleated filter paper type
Partial oil filter type Filter paper type
Oil pump type Gear type
Oil cooler type Water-cooled type
Total capacity: 28.5 (6.27); oil pan: 23.5 (5.17)
Engine oil amount (L / Imp.gal)
with combined main and partial oil filter
Cooling unit system Water-cooled forced circulation type
Total cooling water capacity (L / Imp.gal) 41.4 (9.11)
Water pump type Centrifugal gear type
Thermostat type Wax type
Air cleaner type Filter paper type
Battery type (Type – number) 115F51 - 2
Generator capacity (V-A) 24 - 50, 24 - 60
Starter (V-kW) 24 - 7.0
Idling speed (rpm) 490 - 510
Turbocharger type Model TD08H - 27V (made by MHI)
Inter-cooler type Aluminum tube & end plate type
Thermostat open valve temperature (ºC/°F) 82 (180)
Thermostat totally open temperature/
(ºC/°F,mm/in) 95 (203) / 11 (0.433)
lift amount
Exhaust gas recirculator (EGR) Provided
Engine Assembly
Removal 3. Transmission assembly
For details on removing or installing the
CAUTION:
transmission assembly, refer to the chapter entitled
Precautions for removal and installation
"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 it is being hoisted.
• Never put your hands where they may be pinched
or 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).
1
HCW5Z0SH000401
4. Drain off the cooling water.

Drain off the cooling water from the drain plug of
the radiator and drain plug of the engine.
HCW51BSH024801
2. Exhaust pipe
HCW31BSH053401
5. Inter-cooler hose 8. Oil filler pipe
Disengage the clip of the heater hose attached to
the oil filler pipe, and remove the oil filler pipe.
HCW51BSH002701
6. Radiator hoses
HCW31BSH053701
Disconnect the harness attached to the upper
hose. At this time, remove the harness bracket 9. Side noise cover
attached to the radiator as well before proceeding. 10. Air cleaner assembly
Disconnect the air purging hose, upper hose and Disconnect the air duct and connector, and remove
lower hose. the air cleaner together with the bracket.
7. Oil level gauge

Remove the bolt for the oil level gauge attached to
the radiator assembly, and put it to one side so that
it will not get in the way.
11. Exhaust pipe front and exhaust brake 13. Cab back member
Remove the heat protector, and remove the Remove the cab back member noise cover (2).
exhaust pipe front and exhaust brake. Remove the oil tank (1) of the power steering
pump.
HCW31BSH062001
HCW31BSH054201
12. Exhaust pipe front and exhaust brake
Remove the heat protector (2) and then the
exhaust pipe front (1) and exhaust brake (3). Disconnect the air hose (1) connected to the cab
back members and its connectors (2).
2
3
2
HCW31BSH054101
HCW31BSH065701
Remove the insulator (1) and then the oil pipe (2) 19. Engine harness connector
for tilting the cab. Disconnect the connectors.
14. A/C compressor 20. Sub tank hose

Remove the belt for the A/C compressor and Disconnect the air purging hose and charge pipe.
harness connectors.
Remove the four A/C compressor mounting bolts
and the gas pipe clip, and put 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.
HCW31BSH054701
HCW31BSH054501
15. Generator wires

16. Starter wires
17. Dual thermo sensor connector
18. Oil pressure sensor connector
21. EGR valve air hose 27. Ground wire
Disconnect EGR valve air hose. Cut the connection between the starter ground and
frame ground (1).
HCW31BSH054801
HCW31BSH055201
22. Air cylinder hose
Disconnect the air cylinder hose. 28. Fuel hose
23. Air compressor hose Cut the connection between IN and OUT of the
Disconnect the air compressor hose. fuel hose. At this point in time, drain the fuel filter
as well.
24. Power steering pump
Remove the two mounting bolts, and remove the
power steering pump.
Do not remove the oil pipe of the power steering
pump at this point in time.
Release the oil pipe of the power steering pump,
and put the power steering pump with oil pipe
attached to one side.
25. Engine speed sensor connector
26. Shift selector rod
HCW31BSH055301
29. Engine mounting

Install the engine hangers from the right to front
and from the left to rear, attach wires securely, and
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.
HCW31BSH055101
Never position yourself underneath the engine
when it is being hoisted.
Installation
CAUTION:
Precautions for removal and installation
5
6
• Lock the wheels.
• Attach wires securely to the engine, and hoist it. 1
• Do not position yourself underneath the engine
while it is being hoisted.
• Never put your hands where they may be pinched
or sandwiched.
• The engine is heavy so proceed with the work with
all due care.
1. Engine assembly 3 2
Hoist the engine slowly, and install it in place. Do 4
this work while taking care to avoid interference
with other parts.
HCW31BSH055401
•CAUTION: Legend
Never position yourself underneath the engine when it 1. Engine foot
is being hoisted. 2. Nut (chassis side)
3. Bracket
2. Engine mounting 4. Frame
Install the engine mounting, and tighten it to the 5. Bolt (frame side)
specified torque. 6. Nut (engine side)
Front tightening torque: N⋅m (kgf⋅m/lb⋅ft)
Rear tightening torque: N⋅m(kgf⋅m/lb⋅ft)

Engine side (6) 228 (23.2/
168)
Rubber nut Engine side (1) 490 (50.0/362)
Chassis side 113 (11.5/83)
(2) Rubber bolt Chassis side (2) 157 (16.0/
116)
Bracket Frame side (5) 157 (16.0/
116)
HCW31BSH055501
3. Fuel hose 5. Shift selector rod
Install the IN and OUT of the fuel hose.
HCW31BSH055101
HCW31BSH055301
6. Engine speed sensor connector
4. Ground wire 7. Power steering pump
Connect the starter ground wire (1) to the frame. Install the power steering pump, and tighten it to
the specified torque.
Tightening torque: 39N⋅m (4.0kgf⋅m/29lb⋅ft)

Install the suction pipe and governor pipe of the air
1 compressor.
8. EGR valve air hose
9. Air compressor hose
10. Air cylinder hose
HCW31BSH055201
HCW31BSH054801
11. Sub tank hose Install the A/C compressor belt, 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.)
HCW31BSH054701
12. Engine harness connector

Connect the connectors securely.
HCW31BSH054501
18. Cab back member

Install the cab back member, and tighten it to the
specified torque.
Tightening torque: 155N⋅m (15.8kgf⋅m/114lb⋅ft))
HCW31BSH054601
13. Oil pressure switch

14. Dual thermo sensor connector
15. Starter wires
16. Generator connector
17. A/C compressor
Install the A/C compressor, and tighten it to the
specified torque. HCW31BSH055601

Install the oil pipe (2) for tilting the cab. Install the heat protector (2).
Connect the air hose and its connectors to the cab
back member.
2
3
2
HCW31BSH054101
20. Air cleaner assembly

HCW31BSH054401
Install the air cleaner assembly, and connect the
air duct and its connectors.
Install the oil tank (1) of the power steering pump.
Install the cab back member noise cover (2).
Purge the air in the cab tilt pump.
2 HCW31BSH061901
21. Mud guard

HCW31BSH054201 22. Side noise cover
19. Exhaust pipe front and exhaust brake 23. Oil filler pipe
Install the exhaust pipe front (1) and exhaust brake
(3), and tighten it to the specified torque.

24. Oil level gauge 26. Inter-cooler hose
25. Radiator hose 27. Pour in the cooling water.

After installing the air purging hose, upper hose 28. Transmission assembly
and lower hose, connect the harness. For details on installing the transmission assembly,
refer to the chapter on removing and installing the
transmission.
HCW31BSH053601
HCW31BSH055801
29. Exhaust pipe

30. Battery cable
Connect the battery cable (1).
HCW51BSH024801
Inspections and adjustments after installation

• Supply and check the engine oil and cooling water.
• Inspect and check the idling speed.
• Inspect and check the clutch pedal play.
• Adjust the pulling reserve of the parking brake
lever.
• Clear away the rags from around the engine and
any other items that may be snagged by the
engine parts, and wipe off any engine oil and other
substances on the engine.
• Check that the shift lever is at the neutral position,
call out to warn any persons in the vicinity, start up
the engine using the starter switch of the driver’s
seat, and check that the engine starts up and stops
properly.
• Check for leaking oil or water from the engine
parts.
• 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 gas is leaking and that the
exhaust gas is colorless.
• After stopping the engine, inspect whether the oil
and cooling water are within the prescribed levels.
• Go for a test drive, and check that there are no
problems.
Engine Accessory Parts

Component Parts
2
4 3
7 6 5
HCW61BMF000501
Legend
1. Generator 6. Cooling fan and fan drive
2. Starter 7. Fan guide
3. Oil pipe (power steering oil pump) 8. V-belt (for A/C compressor)
4. Power steering oil pump 9. V-belt (for generator)
5. A/C compressor (cab cooler)
Removal
1. Fan guide
2. Cooling fan and fan drive
3. V-belt (for A/C compressor)
4. A/C compressor
• Remove the A/C compressor from the bracket. NOTE:
After disconnecting the pump, seal it to prevent foreign
matter from entering inside.
HCW31BSH004301
Legend
1
1. Collar
HCW51BSH001501
2. A/C compressor
3. Stay 9. Starter
5. V-belt (for generator)

6. Generator
Installation
7. Oil pipe (power steering oil pump) 1. Starter
• Disconnect the oil pipe (2) at the outlet side of • Connect the starter cable as shown in the
the power steering oil pump. illustration.
1 2
HCW46BSH000401
Legend
1. Clip
HCW51ESH000101
2. Power steering oil pipe
2. Power steering oil pump (1)
8. Power steering oil pump
• With the intake side oil pipe still attached,
disconnect the oil pump (1) from the timing gear
case.
• Assemble the O-ring into the pump, apply 4. Generator
grease around the outside of the O-ring, and 5. V-belt (for generator)
install in the gear case.
• Adjust the V-belt tension.
6. A/C compressor
Tightening torque: 39N⋅m (4.0kgf⋅m/29lb⋅ft) • Install the compressor in such a way that it
sandwiches the collar (1) and stay (3).
1
HCW51BSH001501 3
3. Oil pipe (power steering oil pump)

• Connect the oil pipe at the discharge side of the
power steering oil pump. HCW31BSH004301
Legend
1. Collar
Eye- 2. A/C compressor
59N⋅m (6.0kgf⋅m/43lb⋅ft) 3. Stay
Tightening torque bolt
Union 98N⋅m (10kgf⋅m/72lb⋅ft) 7. V-belt (for A/C compressor)
• Adjust the V-belt (for the A/C compressor)
tension.
• For the adjustment procedure, refer to the
section on belt inspections and adjustments.
8. Cooling fan and fan drive
a. 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)
c. Install the adapter into the crank pulley.(3)
1 2
HCW46BSH000401
Legend
1. Clip
2. Power steering oil pipe
HCW31BSH009601
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
of the gear case.
Tightening torque
Outlet side: 39N⋅m (4.0kgf⋅m/29lb⋅ft)
Gear case side: 119N⋅m (12.1kgf⋅m/88lb⋅ft)
HCW31BSH009701
Engine Exterior Parts

Component Parts
5 6 7 8
3 4
2
9
11
10
HCW61BMF000601
Legend
1. EGR pipe (Rr) 7. EGR duct and lead valve (Ft)
2. EGR cooler (Rr) 8. Water pipe: EGR cooler (Ft)
3. EGR valve (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
2 3 4
5 6
7
1
8
18 17 16 15
14
13 10
12 11
HCW61BMF000701
Legend
1. Water pipe (OUT): EGR valve (Rr) 10. Heater pipe
2. Exhaust duct 11. Thermostat housing
3. Inlet duct 12. Water pipe: Turbocharger (IN)
4. Turbocharger 13. Oil pipe: Turbocharger (OUT)
5. Water pipe: Turbocharger (OUT) 14. Oil pipe: Turbocharger (IN)
6. Inlet pipe 15. Partial oil filter
7. Water pipe (OUT): EGR valve (Ft) 16. Oil filter
8. Water pump 17. Drain pipe: Water
9. Water pipe (IN) 18. Oil cooler
6 7 8 9
5
4
1 10
11
13 12
18 14
17 16 15
HCW61BMF000401
Legend
1. Water pipe: Air compressor 10. Air governor pipe
2. Air charge pipe 11. Fuel feed pipe
3. Water outlet pipe 12. Oil pipe: Supply pump (IN)
4. Inlet pipe 13. Oil pipe: Supply pump (OUT)
5. Fuel pipe: Common-rail to supply pump 14. Supply pump
6. Common-rail 15. Bracket: Supply pump
7. Injection pipe 16. Oil level guide tube
8. Fuel filter 17. Oil pipe: Air compressor (IN)
9. Fuel return pipe 18. Air compressor
Removal
1. Air breather hose
2. Engine harness
NOTE:
Making paint marks at the positions where the harness
clips are installed before removing these parts will
make it easier to reassemble the parts later.
3. Water pipe: Air leak

4. Water pipe: Charge
• Remove the overheat switch attached on the
cylinder head side, and disconnect the air leak
pipe.
9. EGR pipe (Rr)
3 HCW41BSH002201
HCW46BSH000101
Legend
1. Charge pipe 10. EGR pipe (Ft)
2. Air leak off pipe
3. Water outlet pipe NOTE:
Seal the two ends of the EGR pipe to prevent foreign
5. Inlet pipe matter from entering inside.
NOTE:
Seal the opening of the inlet manifold to prevent foreign
matter from entering inside.
HCW46BSH000201
11. Air pipe: EGR valve:

• Remove the eye-bolt and clip on the EGR pipe
HCW51BSH000601 side, and disconnect the air pipes (1) (2) as
assemblies.
6. 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.
17. 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.
HCW41BSH001101
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).
HCW31BSH012801
Legend
1. Water pipe:
2. EGR cooler
3. EGR valve
4. Water pipe (IN)
14. EGR valve:

15. EGR cooler
16. EGR duct and lead valve
2
1
6 4
5
HCW31BMF001801
Legend
1. Filter to supply pump 4. Fuel feed
2. Fuel filter return 5. Fuel return
3. leak off pipe return 6. Feed pump to filter
18. Fuel filter and bracket
2
3
HCW31BSH013001
HCW31BSH024801
Legend
19. Fuel feed pipe: Supply pump to common-rail 1. Fuel pipe: Common-rail to supply pump
20. Oil pipe: Supply pump 2. Oil feed pipe
3. Oil return pipe
• Disconnect the oil feed and oil return pipes.
21. Oil level gauge guide tube and bracket NOTE:
• Fit a wrench onto the flow damper (19 mm/0.75in
2 width across flats) of the common-rail to stop it from
turning, and loosen the sleeve nuts of the injection
pipes.
• Seal the pipes and pumps to prevent foreign matter
from 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.
1 • Check that the rubber parts of the clips are not
cracked or damaged.
3
HCW41BSH000301
Legend 1 2 3 4 5 6
1. Oil level gauge guide tube
2. Bracket
3. Plug
22. Supply pump

• Loosen the coupling tightening bolt, and
remove the supply pump.
HCW51BSH001801
1
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.
HCW31BSH013301
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.
Compressor, V-twin type
1
1
2
2
6
4 3
3
4
5
HCW51BSH001901
HCW41BSH000201
Legend
1. Common-rail Legend
2. Fuel pipe bracket 1. Air suction pipe
3. Common-rail bracket 2. Water pipe (OUT)
4. Fuel pipe bracket 3. Water pipe (IN)
4. Air intake pipe
25. Supply pump bracket 5. Compressor
6. Air pipe: Charge
26. Oil pipe: Air compressor
27. Water pipe: Air compressor 28. Air pipe: Charge and governor
Compressor, single type
29. Air compressor
2 3
1
5 4
HCW31BSH013801
HCW31BSH010801
Legend
1. Flare nut
2. Bracket
3. Nut
4. S/P washer
5. Union
30. Inlet pipe: Turbocharger

31. Inlet duct: Turbocharger
32. Exhaust brake
33. Turbocharger oil pipe 39. Water outlet pipe
34. Turbocharger water pipe 40. Water inlet pipe
41. Thermostat housing
42. Water pump
43. Water drain pipe
44. Oil cooler
• Remove the oil cooler tightening bolts, insert
the removed bolts into the two replacer holes,
tighten them up, and remove the oil cooler.
1
HCW31BSH010301
Legend
1. Water pipe (OUT)
2. Water pipe (IN)
35. Turbocharger
NOTE:
After removing the parts, cover the oil inlet and outlet of HCW31BSH014901
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 Inspections
entering inside. EGR lead valve
• Inspect the exterior of the valve for damage.
• Inspect whether carbon has accumulated between
the stopper and valve.
HCW31BSH009801
Legend
1. Gasket
HCW31BSH018301
36. Oil filter

37. Partial oil filter
38. Heater pipe
Installation
1. Oil cooler
• Fit the four O-rings into place. (2 types – 2 pcs
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.
2
1
3
4
1
2
HCW31BSH006001
3
Legend
1. Connector (area A)
2. Water drain pipe (area B)
3. Water drain plug(area D)
4. Bolt (area C)
4
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
HCW31BSH005901
from the gear case side using the four bolts.
Legend
1. Gasket
2. O-ring Tightening torque: 39N⋅m (4.0kgf⋅m/29lb⋅ft)
3. Oil 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.
N⋅m (kgf⋅m/lb⋅ft)
Area A: 78 (8.0/58)
Tightening Area B: 68 (6.9/50) 3
torque Area C: 43 (4.4/32)
2 1
Area D: 4 (0.4/35lb⋅in)
HCW31BSH006101
Legend
1. Water pump
2. O-ring
3. O-ring
• Mount the two thermostats onto the oil cooler.
• For details on mounting the seal rings and
thermostats, refer to the section on mounting 1 2
the thermostats.
• Fit the gasket into the thermostat housing, and
while pressing on the oil cooler side, tighten the
two bolts on the water pump side. Then tighten
the three oil cooler side bolts.
1 HCW46BSH000701
Legend
2 2. Water pump
3. Oil cooler
6. Water outlet pipe

• Assemble the two O-rings into the head gear
case, and attach the water outlet pipe.

HCW31BSH015001
Legend
1. Thermostat
5. Water inlet pipe

• Attach the inlet pipe to the oil cooler.
Tightening torque
Oil cooler side 39N⋅m (4.0kgf⋅m/29lb⋅ft)

Gear case side 88N⋅m (9.0kgf⋅m/65lb⋅ft)
HCW31BSH015101
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.
• Supply the appropriate amount of engine oil
through the oil filling port shown by the
lubrication mouth(1) of the turbocharger, and
turn the turbine shaft gently to lubricate the
bearings.
• Install the turbocharger using the double nuts.
2
1
HCW51BSH023201 1
8. Oil filter and Partial oil filter
• Install the O-ring and assemble the oil filter.
Tightening torque
Area A 43N⋅m (4.4kgf⋅m/32lb⋅ft)

Area B 50N⋅m (5.1kgf⋅m/37lb⋅ft) HCW31BSH010201
10. Turbocharger water pipe
Eye-bolt
tightening torque: 41N⋅m (4.2kgf⋅m/30lb⋅ft)
3 2
6 1
4
5
HCW61BSH000301
Legend 2
1. Bracket
2. Bolt (A)
3. Partial oil filter HCW31BSH010301
4. Bolt (A)
5. Bolt (B) Legend
6. Oil filter 1. Water pipe (return)
2. Water pipe(feed)
9. Turbocharger
11. Turbocharger oil pipe
• Secure the oil pipe (IN) to the bracket using the
clip.
Eye-bolt
tightening torque: 34N⋅m (3.5kgf⋅m/25lb⋅ft)
• Apply a small amount of the liquid gasket to two
places along the O-ring groove of the oil pipe
(OUT), and fit the O-rings into place.
1
1
HCW31BSH010501
13. Exhaust brake

14. Inlet duct: Turbocharger
• Provisionally secure the rubber hose and clip to
the turbo side, and insert the inlet duct.
2
3 • Mount the inlet duct on the bracket installed on
the lower head cover and exhaust manifold.
• Tighten the rubber hose using the two clips.
HCW31BSH010401 • Install the heat protector.
Legend 15. Inlet pipe: Turbocharger
1. Oil pipe (return) • Provisionally secure the rubber hose and clip to
2. Oil pipe brakt the turbo side, and insert the inlet pipe.
3. Oil pipe brakt • Tighten up the inlet pipe in the bolt hole on the
inlet duct side.
12. Exhaust duct: Turbo
• Tighten the rubber hose using the two clips.
• Secure the duct to the turbocharger using the V
bands (1). NOTE:
• Tighten the V bands using the two bolts from The clip screw must be pointing toward the rear.
the top of the bracket which has been tightened
onto the exhaust manifold together.
V band
tightening torque: 10N⋅m (1.0kgf⋅m/87lb⋅in)
• Align the pointer with the key of the air
1 compressor shaft, assemble the coupling, and
align the engraved “A” mark on the coupling
with the pointer (1).
2
• Fit the O-ring into the gear case mounting
flange area.
4
5 3
1
2
HCW31BSH010601
Legend
1. Bolt
2. Inlet pipe 3
3. Bolt
4. Bolt
5. Inlet duct HCW31BSH015201
Legend
16. Air compressor 1. Pointer
• Assemble the gears in the air compressor 2. “S” mark (engraved)
ahead of time. 3. “A” mark (engraved)
Apply some molybdenum disulfide to the
threaded areas and seating surface of the bolts,
and tighten the bolts to the specified torque in
the sequence shown in the illustration.
Tightening torque: 1
39N⋅m (4.0kgf⋅m/29lb⋅ft) → Angle method 90° to 120°
HCW31BSH005001
Legend
1. Pointer
2. Air compressor
PWW010SH009001
• Mount the pointer on the coupling side.

• Turn the crankshaft in the forward direction, and
align the engraved line on the flywheel with the
timing pointer in such a way that the #1 cylinder
is set at the compression top dead center. At 1
this point, check that there is a clearance
2
between the intake and exhaust valves of the
#1 cylinder.
3
T
C
HCW31BSH015201
Legend
1. Pointer
2. “S” mark (engraved)
3. “A” mark (engraved)
17. Air pipe: Charge and governor

HCW31BSH012301
• Mount the air pipe on the air compressor outlet
• Using the gear case stud as the guide, gently side.
push the air compressor in until it strike the idle
gear inside the gear case.
Eye-bolt tightening torque
• Turn the air compressor shaft very slightly, and
after engaging the gear, push the air
compressor in completely until it fits snugly in Charge pipe (M24)
the gear case. At this point, check that the 147N⋅m (15.0kgf⋅m/108lb⋅ft)
(copper gasket)
pointer (1) and the engraved “S” mark (2) on
Governor pipe (M14) 41N⋅m (4.2kgf⋅m/30lb⋅ft)
the coupling are aligned. The gear teeth will be
out of position if they are not aligned so repeat
the process. • Place a wrench up against the pipe union side,
and tighten up the flare nut while ensuring that
• Tighten up the air compressor.
the pipe is not twisted.
Flare nut 129 (13.2/95)
Charge pipe
Nut 147 (15.0/108)
Flare nut 28 (2.9/21)
Governor pipe
Nut 69 (7.0/51)
• Connect the oil pipe between the cylinder block
and compressor.

2 3 M10: 27N⋅m (2.8kgf⋅m/20lb⋅ft)
1
5 4
HCW31BSH010801
Legend
1. Flare nut
2. Bracket 1
3. Nut
4. S/P washer
5. Union HCW31BSH011001
18. Water pipe: Air compressor Legend

1. Eye-bolt
• Connect the water pipes between the cylinder
block and compressor and between the
20. Supply pump bracket
compressor and cylinder head.
• Align the bracket with the dowel holes and
attach.
M14: 41N⋅m (4.2kgf⋅m/30lb⋅ft) Bracket tightening torque
108N⋅m (11.0kgf⋅m/80lb⋅ft)
1
1
HCW31BSH010901
Legend HCW41BSH001201
1. Water pipe:
Legend
19. Oil pipe: Air compressor 1. Supply pump
2. Bracket
21. Common-rail
• Mount the bracket (3) used to attach the
common-rail, to the cylinder block.
• Mount the common-rail (1) onto the bracket (3).
At this point, tighten it up together with the fuel 1 2 3 4 5 6
pipe bracket (2).
NOTE:
Tighten up bracket (4) after mounting the pipe clips.
1
2
HCW51BSH001801
23. Supply pump

• Turn the crankshaft in the forward direction, and
timing pointer in such a way that a B.D.T.C.0° is
4 3 achieved. At this point, check that there is a
clearance between the intake and exhaust
valves of the #1 cylinder.
Fuel injection timing (B.T.D.C): 0°
HCW51BSH001901
Legend
1. Common-rail
2. Fuel pipe bracket
3. Common-rail bracket
4. Fuel pipe bracket
22. Injection pipes (1) to (6)

T
• Clip the injection pipe at the positions shown in C
the illustration.
• Before mounting the injection pipe, assemble
No.4 and No.3.
Injection pipe tightening torque

Sleeve nut: 44N⋅m (4.5kgf⋅m/33lb⋅ft)
HCW31BSH012301
• Align the engraved line on the coupling with the

engraved line on the supply pump.
• Attach the supply pump to the supply pump
bracket, and tighten up alternately at the
opposite ends along the diagonals.

• Check the supply pump index mark.
Turn the crankshaft in the forward direction, and
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
4 2 coupling side, and tighten up the coupling.
1 3
1
HCW41BSH001401 2
• Slide the coupling, check that it fits snugly on
the supply pump, and tighten up the coupling
bolt (2).

• Check that the coupling laminate is not warped,
and tighten up cotter bolt (1). 3
4

HCW31BSH015801
Legend
1. Coupling bolt
2. Engraved line on coupling side
3. Engraved line on pump side
4. Cotter bolt
1
24. Oil level gauge guide tube and bracket
• Apply a thin film of oil to the O-ring, and insert
the parts while ensuring that the O-ring is not
damaged.
HCW31BSH013301
• Assembly sequence of pipes (1) and (2) in the
2
illustration
- Provisionally secure both ends of the pipes.
- Tighten up the common-rail end.
- Tighten up the supply pump end.
Tightening torque
Sleeve nut: 44N⋅m (4.5kgf⋅m/33lb⋅ft)
1 NOTE:
• After provisionally attaching the clip, tighten the pipe
bracket, and finally tighten the clip.
1 2 3
3
HCW41BSH000301
Legend
1. Oil level gauge guide tube
2. Bracket
3. Plug
25. Oil pipe: Supply pump

• Connect the oil feed pipe and oil return pipe to
the supply pump.

M10: 28N⋅m (2.8kgf⋅m/20lb⋅ft)
M14: 41N⋅m (4.2kgf⋅m/30lb⋅ft)
HCW61BSH000401
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
fuel filter, mount it on the inlet manifold.
1 • Tighten up the bracket and fuel filter.
Tightening sequence
- Provisionally secure the bolts in the
2 sequence of (3), (2), (1) and (4).
3 - Tighten up the bolts in the sequence of (3),
(2), (1) and (4).
• Connect the vinyl hose for draining the water,
and secure it using the band clips.
HCW31BSH013001
Legend
1. Fuel pipe: Common-rail to supply pump Tightening torque: 39N⋅m (4.0kgf⋅m/29lb⋅ft)
2. Oil feed pipe
3. Oil return pipe
26. Fuel feed pipe

1
2
HCW31BSH007001
28. Fuel pipe

• Use the clips to secure the fuel pipe at the
positions shown in the illustration.
M8: 15 (1.5/11)
M10: 28 (2.8/20)
M12: 35 (3.5/25)
M14: 41 (4.2/30)
NOTE:
Do not use the rubber parts of the clips if they are
cracked or damaged.
2
1
6 4
5
HCW31BMF001801
Legend
1. Filter to supply pump 4. Fuel feed
2. Fuel filter return 5. Fuel return
3. leak off pipe return 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.
NOTE:
The duct must be assembled while checking the 2 3
identification marks at the front and rear.
1
Tightening torque
Lead valve: 10N⋅m (1.0kgf⋅m/87lb⋅in)

EGR duct: 39N⋅m (4.0kgf⋅m/29lb⋅ft)
HCW41BSH000601
Legend
1. EGR duct
2. Gasket
3. Lead valve
30. EGR cooler

• Mount the gasket, and assemble the EGR
cooler as shown in the illustration.

3
NOTE: 1 2
There are two pipes at the front and one at the rear.
Check the pipes, and assemble them.
2
1
HCW41BSH000801
Legend
1. EGR valve (front)
2. Gasket
3. EGR valve (rear)
HCW41BSH000701
1
Legend
1. EGR cooler (front)
2. Gasket
3. EGR cooler (rear)
31. EGR valve:

• Assemble the gasket into the EGR cooler, and
provisionally assemble the EGR valve."F" is
embossed on the top of the front EGR valve,
2
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. HCW31BSH024401
CAUTION: Legend
When the EGR pipe is assembled, tighten up the EGR 1. Front EGR
valves in the prescribed tightening sequence and to the 2. Rear EGR
specified torque.
At this stage, the valves must be kept provisionally 32. Water pipe: EGR cooler to EGR valve
assembled. • 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 are indicated by the arrows in the illustration.

33. Water pipe: EGR valve (IN) 35. EGR pipe (Ft)
• Connect the rubber hose (1) to the cooler side, • As shown in the illustration, provisionally
insert the water pipe (2), and clip it. assemble the gasket, EGR pipe, distance tube,
washers and bolts in this order.
NOTE: • Tighten up the bolts in a 2-step process: first,
Insert the rubber hose deeply, and attach the clip while provisionally secure them, and then tighten
ensuring that it will not ride up onto the part where the them up.
pipe bulges.
2 3
5 4
HCW51GSH000101
HCW41BSH001001 Legend
1. Gasket
34. Air pipe: EGR valve:
2. Distance tube
• Assemble the air pipes (1) and (2) into the EGR 3. Bolt
valves. 4. Washer
5. Flange (pipe area)
Eye-bolt
• Tighten up the parts in the numerical order
tightening torque: 28N⋅m (2.8kgf⋅m/20lb⋅ft) 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 locations (EGR pipe - exhaust manifold
- 3 locations (EGR pipe - EGR valve side) (1) side) (3)
- 2 locations (EGR valve - EGR cooler side)
(2) Torque for provisional securing
- 3 locations (EGR pipe - exhaust manifold 5N⋅m (0.5kgf⋅m/43lb⋅in)
side) (3)
• Order in which bolts are tightened up
Tighten up the bolts in the same sequence as
Torque for provisional securing
when they were provisionally secured.
5N⋅m (0.5kgf⋅m/43lb⋅in)
• Order in which bolts are tightened up Tightening torque: 38N⋅m (3.9kgf⋅m/28lb⋅ft)
Tighten up the bolts in the same sequence as
the one used when provisionally securing them. CAUTION:
The bolt tightening sequence and torque must be
adhered to. Following the wrong procedure may cause
Tightening torque: 38N⋅m (3.9kgf⋅m/28lb⋅ft) the exhaust gas to leak.
CAUTION:
The bolt tightening sequence and torque must be
adhered to. Following the wrong procedure may cause
the exhaust gas to leak. 2
1 2
HCW46BSH001101
37. Water pipe (OUT) (1): EGR valve (Ft)

38. Water pipe (OUT) (2): EGR valve (Rr)
3
HCW46BSH001201
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 locations (EGR pipe - EGR valve side) (1)
- 2 locations (EGR valve - EGR cooler side)
(2)
41. Water pipe air leak
2
HCW31BSH016201
3 HCW41BSH002201
39. Air compressor suction pipe
• Attach the suction pipe to the air compressor, Legend
and connect it to the turbo inlet duct via the 1. Charge pipe
rubber hose. 2. Air leak pipe
3. Water outlet pipe
42. Engine harness

• Connect the engine harness as shown in the
illustration.
HCW51BSH002101
40. Water pipe charge

4 5 6 7
11
10
9 HCW61ELF000201
Legend
1. Injector harness 7. Common-rail pressure sensor
2. Injector harness connector 8. Engine speed sensor
3. Injector L-shaped connector 9. Connector
4. Boost sensor 10. Cylinder identification sensor
5. Injector harness connector 11. PCV
6. Injector harness connector

• 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.
2
3
HCW31BSH004901
Legend
1. Harness clip
2. Harness clip
Tightening Torque Table
Engine exterior parts
39 (4.0/29)
137 (14.0/101)
39 (4.0/29)
22 (2.2/16)
39 (4.0/29)
39 (4.0/29)
58 (5.9/43)
108 (11.0/80) 31 (3.2/23)
98 (10.0/72)
62 (6.3/46) 78 (8.0/58)
HCW61BLF000701
Cylinder head
Component Parts
2
3
9
4
10 11
5
14
12 6
7
13
HCW46BLF000601
Legend
1. Head cover 8. Rocker arm assembly
2. Head cover gasket 9. Camshaft
3. Injector harness 10. Bridge
4. Nozzle leak-off pipe 11. Injector and clamp
5. Head cover lower 12. Cylinder head assembly
6. Harness connector 13. Cylinder head gasket
7. Head cover lower gasket 14. Idle gear C
Removal
1. Head cover
• After disconnecting the air breather hose,
remove the head cover.
2. Head cover gasket
3. Injector harness Legend

1. Nozzle leak-off pipe
NOTE: 2. Harness connector
When the injector harness 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 ID code plate.
NOTE:
A small amount of oil may flow when the head cover
2 3 lower is removed, so clean it up using a rag.
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00
1
HCW41BSH002401
Legend
1. Injector assembly
2. ID plate HCW41BSH002301
3. Terminal nut 8. Rocker arm assembly

4. Gasket
• Loosen the bracket tightening bolts of the
5. O-ring
rocker arm assembly uniformly at both ends,
and remove the assembly.
5. Harness connector
PWW010SH009901 PWW010SH012201
9. Bridges 10. Camshaft

• Remove the bridges (1). • Before removing the camshaft, measure the
clearance in the camshaft axial direction.
NOTE:
Attach a number label to the bridges for each cylinder.
Clearance in camshaft axial direction
standard mm(in) limit mm(in)

1 0.085 – 0.170(0.033 – 0.0067) 0.25(0.0098)
PWW010SH011201
• Inspect the contact surfaces for wear and

peeling and also the bridges for cracks and
damage.
PWW010SH010101
• Loosen the bracket tightening bolts of the • If it is difficult to remove the injector, set the
camshaft uniformly at both ends, and remove injector remover(2) on the injector, tighten the
the camshaft. 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: 5-8840-2826-0
Slideing hammer small 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
attach a number tag to it before storing it to ensure
that it is 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.
HCW31BSH011201
• Measure the clearance between the camshaft

journal and bracket.
Clearance between camshaft journal and bracket

1

0.075 – 0.125(0.0030 – 0.0049) 0.15(0.0059) 2
LNW46CMH000301
HCW31BSH011301
Legend
11. Injector and clamp 1. Sliding hammar
• Loosen the clamp, and use the replacer to 2. Injector remover
remove the injector. 3. Injector assembly
NOTE:
• Indicate the cylinder No. on the removed injector
before storing the injector.
• Be careful not to strike the injection nozzle against a 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 (29) tightening bolts first.
• Block the hole in the timing gear with a rag
beforehand.
BLW51BSH001801
29
16 8
27 1 9 17 24 23 15 7
2 10 18 25
22 14 6
26
28 3 11 19
21 13 5
4 12 20
HCW31BSF000201
13. Cylinder head gasket

Disassembly
6
4 7
5 8
3 9
10
11
2
12
2
13
1
24
14
23
22
15
16
21 18
20
17
19
HCW51BLF003601
Legend
1. Distance tube 13. O-ring
2. Seal ring 14. Valve seat insert
3. Air duct bracket 15. Valve
4. Exhaust duct bracket 16. Glow plug
5. Exhaust manifold assembly 17. Glow plug connector
6. Split collar 18. Dual thermo sensor
7. Spring seat (upper) 19. Inlet manifold
8. Valve spring 20. Idle gear shaft C
9. Valve oil seal 21. Idle gear C
10. Spring seat (lower) 22. Gear case
11. Valve guide 23. O-ring
12. Nozzle sleeve 24. Bridge guide
1. Glow plug connector 5. O-ring

2. Glow plug • Before removing the gear case, measure the
3. Dual thermo sensor clearance in the axial direction of the idle gear
C.
4. Gear case
8. Inlet manifold
Clearance in axial direction

0.05 – 0.125(0.0020 - 0.0049) 0.25(0.0098)
HCW31BSH017801
9. Air duct bracket

10. Exhaust duct bracket
11. Engine hanger (Ft)
12. Exhaust manifold assembly
13. Seal ring
PWW010SH011701
14. Split collar
6. Idle gear shaft C
15. Spring seat (upper)
7. Idle gear C
• Place the cylinder head on a wooden board,
• Draw out the idle gear shaft, and remove the use the replacer to remove the split collar, and
idle gear C from the cylinder head. remove the spring seat, valve spring and valve.
NOTE: NOTE:
Take care not to damage the bushing of the idle gear Attach a number label to the valves for each cylinder.
shaft.
Valve spring replacer: 1-8523-5013-0
HCW31BSH017501
1
1
HCW51BSH023401 PWW010SH011901
Legend 22. Valve seat insert

1. Bracket • After using a gas welding burner to heat two
2. Split collar places on the inside surface of the insert until
they are red-hot (600 to 700 ºC/1112 to
16. Valve spring 1292°F), allow these places to cool off naturally
17. Spring seat (lower) for 3 to 5 minutes, and use a screwdriver to
18. Valve draw out the insert.
19. Valve oil seal
CAUTION:
20. Valve guide Do not force the insert to cool rapidly.
• Insert the replacer into the guide from the
bottom surface of the head, and knock it out
using a hammer.
Valve guide replacer: 9-8523-1202-0
PWW010SH012001
23. Nozzle sleeve

• Removal of the nozzle sleeve
Draw it out of the sleeve by tapping from
underneath the head.
PWW010SH023001
21. Bridge guide

• Electrically weld (1) the bolt to the bridge guide,
mount a sliding hammer onto the bolt to draw
the bolt out.
PWW010SH012101 PWW010SH012401
24. O-ring
Valve spring
• Measure the squareness of the valve spring.
Inspections
Idle gear shaft C Squareness of valve spring
• Measure the outside diameter of the idle gear shaft
and the clearance between the shaft and bushing.
Inspect the bushing as well for damage. Standard Limit mm(in)
mm(in)
Outside diameter of shaft Inlet 3.5(0.1378) 4.8(0.1890)
Outer 4.5(0.1772) 6.2(0.2441)
Exhaust
Dimension mm(in) Working limit mm(in) Inner 4.2(0.1654) 5.9(0.2322)
49(1.9291) 48.85(1.9232)
Clearance between shaft and bushing
Standard mm(in) Limit mm(in)

0.04 – 0.105
0.20(0.0079)
(0.0016 – 0.0041)
HCW51BSH023301
• Measure the free length of the valve spring.
Free length of valve spring
Nominal
Working limit
dimension
mm(in)
mm(in)
Inlet 79.3(3.1220) 75.3(2.9646)
Outer 102.7(4.0433) 97.6(3.8425)
Exhaust
Inner 96.5(3.7992) 91.7(3.6102)
LNW21BSH056701
Valve
• Inspect the valve stem end for wear. Use an oil-
stone to repair minor wear.
LNW21BSH017001
• Measure the tension when the spring is mounted.
Tension of valve spring
Dimension Limit
N(kgf/lbf)/ N(kgf/lbf))/
mm(in) mm(in)
HCW31BSH022101
392 (40.0/ 372 (38.0/
Inlet 88.2)/ 83.8)/ • Measure the valve stem wear.
64(2.5200) 64(2.5200) Measure the wear in the three places shown in the
illustration.
610 (62.2/ 578 (59.0/
Outer 137.2)/ 130.1)/
69(2.7165 69(2.7165) Outside diameter of valve stem
Exhaust
223 (22.8/ 213 (21.7/
Inner 50.3)/ 47.8)/ Nominal Working limit
66(2.5984) 66(2.5984) dimension mm(in)
mm(in)
Inlet φ10(0.3937) φ 9.92(0.3906)
Exhaust φ10(0.3937) φ 9.90(0.3898)
If the amount of the valve stem wear has exceeded • Inspection of contact with valve seat surface and
the limit, replace the valve stem together with the valve thickness measurement
guide. Inspect the seat surface for damage and stepped
wear, and measure the valve thickness.
Valve thickness
Nominal Llimit
dimension mm(in)
mm(in)
Inlet 2.02(0.0795) 1.52(0.0598)
Exhaust 2.48(0.0976) 1.98(0.0780)
Width of contact with valve seat
Nominal Limit
dimension mm(in)
PWW010SH012901
mm(in)
• Measure the clearance between the valve guide Inlet 3.9(0.1535) 4.3(0.16693)
and valve stem. Exhaust 2.8(0.1102) 3.2(0.1260)
Insert the valve 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. If the wear exceeds the usable limit after polishing and
modifying the valve thickness, replace the valve.
Clearance between the guide and valve stem

0.040 – 0.077
Inlet 0.15(0.0059)
(0.0016 – 0.0030)
0.065 – 0.102
Exhaust 0.25(0.098)
(0.026 – 0.040)
10mm(0.4in) HCW31BSH022201
Legend
1. Contact width
2. Valve thickness
PWW010SH012801
Bridge guide
• Measure the clearance between the bridge guide
and bridge (1).
Clearance between guide and bridge

3

0.020 – 0.056 2
0.10(0.0039)
(0.0008 – 0.0022)
HCW31BSH016501
Legend
1. 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 straight-edge
PWW010SH011201 ruler against the head mounting surface, and
measure 1 to 4 in the illustration using a thickness
Valve seat insert gauge. Replace if the limit is exceeded.
• Measurement of recess amount of valve Distortion amount
Insert a new valve into the guide, and measure the
recess amount from the mounting surface of the
cylinder head to the valve surface. Less than
Limit:
0.2mm(0.0079in)
Recess amount of valve
NOTE:
No repairs can be undertaken since the backlash of the
Nominal Working timing gear will be altered as a result.
dimension limit
mm(in) mm(in)
Inlet 1.0(0.0394) 2.0(0.0787)
Exhaust 0.9(0.0354) 1.9(0.0748)
4
1
3 2 1
HCW31BSH016601 PWW010SH013701
• Inspection of cylinder head for cracks and damage Legend

If necessary, inspect the cylinder head using the 1. Application of Loctite
magnetic flaw detection method or red check.
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-fit
the insert using a bench press.
HCW31BSH016801
• Inspection of water jacket for cracks

Using a hydraulic tester, apply a hydraulic
pressure of 490 kPa (5 kg/cm2/71psi) for three
minutes, and inspect various parts of the head for
water leaks.
PWW010SH012001
Assembly
4. Bridge guide
1. O-ring
• Apply some engine oil to the outer surfaces of
2. Nozzle sleeve the guide. Next, use the installation tool to
• Apply some engine oil to the O-ring, assemble press-fit the guide so that the height of the
it into the sleeve, apply Loctite No.LT290 to the bridge guide is 49 mm(1.9291in) above the
outer surfaces and contact seat surface, and head top surface.
press-fit the O-ring into the cylinder head.
Bridge guide installation tool: 9-8522-1324-0

• Use the installation tool 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

1-8522-1140-1
(for inlet):
1-8522-1184-0
(for exhaust):
HCW31BSH017001
5. Valve guide
• Apply some engine oil all around the valve
guide. Next, use the replacer to press-fit the
valve guide so that it is positioned at the rated
height above the cylinder head.
Height of valve guide above cylinder head
Assembly standard mm(in)

Inlet 27.0(1.0630)
PWW010SH014101
Exhaust 29.0(1.1417)
7. Valve
Insertion of valve
Valve guide replacer: 9-8523-1202-0
• Apply some engine oil to the valve stem, and
insert the valve into the cylinder head.
1 2
HCW31BSH017201
PWW010SH014201
Legend
1. 29.0mm(1.1417in)
2. 27.0mm(1.0630in)
6. Valve seal
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
Assembly Working limit

standard mm(in) mm(in)
Inlet valve 3.9(0.1535) 4.3(0.1693)
Exhaust valve 2.8(0.1102) 3.2(0.1260)
HCW46BSH002001
• After polishing and modifying the valve seat,

measure whether the recess amount of the
valve is within the working limit.
Recess amount of valve

1
Standard Limit
mm(in) mm(in)
2 Inlet valve 1.0(0.0394) 2.0(0.0787)
Exhaust valve 0.9(0.0354) 1.9(0.0748)
Fitting the valve

• Apply some compound to the surfaces where
HCW31BSH017401
the insert and valve seat make contact with
Legend each other, and fit them together properly. After
1. Contact width fitting them together, wash the cylinder head
2. Recess amount and valve.
• If the width or surface 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: 30º

Exhaust valve: 45º
Valve stem outside

φ10.0mm(0.3937in)
diameter:
HCW31BSH022301
8. Spring seat (lower)

9. Valve spring 12. Seal ring
10. Spring seat (upper) 13. Exhaust manifold
• Place the cylinder head on a wooden board, • Install the seal rings (1) at intervals of 120°, and
and assemble the lower spring seat, valve assemble the manifold.
spring and upper spring seat in this order. Both
the inlet valve spring and exhaust valve spring NOTE:
can be placed with either end at the top. Ensure that seal rings (1) are installed with the right
side up.
HCW41BSH001701
11. Split collar HCW31BSH022501

• Use the valve spring replacer to push the valve
• Install the manifold in the cylinder head, and
spring in, and install the split collar.
tighten up the parts in the numerical sequence
After completing the installation, gently tap the
shown in the illustration.
valve stem head with a rubber hammer and
(Tighten up the flanges in the clockwise
ensure that the split collar settles into position.
direction starting with the one at the bottom.)
Valve spring replacer: 1-8523-5013-0

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
1 the gasket is positioned at the bottom right.
HCW51BSH023401
Legend
1. Bracket
2. Split collar
5 3 1 4 2 6
HCW51GSH000201
14. Engine hanger (front)

15. Exhaust pipe bracket
HCW31BSH018001
16. Air duct bracket
20. O-ring
17. Inlet manifold
21. Gear case
• Install the inlet manifold.
• Install the O-ring into the gear case.
• Apply some FMD-127 in a thickness of about
Tightening torque: 19.6N⋅m (2.0kgf⋅m/14lb⋅ft) 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.
HCW31BSH017801
18. Idle gear C

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.
NOTE:
• Check that the gear rotates smoothly.
• Take care not to damage the gear teeth surfaces
since the teeth protrude beyond the cylinder head.
• Insert the glow plug connector between the
glow plug nut and flat washer to install it.
Tightening torque: 1.0N⋅m (0.1kgf⋅m/9lb⋅in)
HCW31BSH018101
Legend
1. Application of liquid gasket
2. O-ring
HCW31BSH022901
22. Dual thermo sensor
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
mm(0.0394 to 0.0787in) and a width of about 5
mm(0.1969in) to the surface where the cylinder
block and gear case as well as the cylinder
head and head gear case are joined.
NOTE:
After applying the liquid gasket, the parts must be
assembled without delay.
HCW31BSH022801
23. Glow plug
NOTE:
Do not overtighten since doing so may damage the
parts.
24. Glow plug connector

• Block the hole in the timing gear with a rag
beforehand.
• Do not re-use the head bolts more than four times.
HCW31BSH011501
• Assembly of cylinder head

Assemble the head gasket, align the cylinder
head with the knock-pin, and place it gently on
top.
HCW31BSH011601
• Tightening of cylinder head assembly
Tightening torque
177N⋅m (18.0kgf⋅m/130lb⋅ft) →
M18: 245N⋅m (25.0kgf⋅m/181lb⋅ft) →
Angle method 60 to 90°
M10: 38N⋅m (4.0kgf⋅m/29lb⋅ft)
M12: 97N⋅m (9.9kgf⋅m/72lb⋅ft)
NOTE:
• Do not apply any of the molybdenum disulfide to the
M10 or M12 bolts.
HCW31BSF000301
Legend
1. M12 2. M10
3. Injector and clamp

• Install the injector in the cylinder 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 injectors are
not removed. If a plate has been removed, be
absolutely sure to attach it back on the same
injector.
Tightening torque
Clamp: 49N⋅m (5.0kgf⋅m/36lb⋅ft) HCW31BSH017301
Injection pipe: 39N⋅m (4.0kgf⋅m/29lb⋅ft)

• Apply some engine oil to the cam surface of the
camshaft and the cam gear teeth surfaces.
HCW46BSH001801
4. Camshaft
HCW31BSH011801
• Set the #1 cylinder to the compression top dead
center. • Installation of camshaft
Turn the crankshaft in the forward direction, and Apply some oil to the camshaft bracket. Install
align the T/C mark on the flywheel with the the camshaft in such a way that the mark on the
pointer. camshaft gear and the pointer are aligned.
At this point, check that the engraved line on Now check that the engraved lines at the rear
the coupling is aligned with the engraved line end of the camshaft are positioned horizontally
on the pump. and vertically.
T
C
HCW31BSH012301 PWW010SH011001
Legend
1. Pointer
• Installation of camshaft with lower cover

already 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.
• Installation of camshaft 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 from the camshaft
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 mounting the cylinder head bolts, the brackets
must be tightened up.
1
PWW010SH011101
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.
PWW010SH011201
HCW31BMH000401
Legend NOTE:
1. Index mark • Re-assemble the parts as per the cylinder numbers
2. Cam gear recorded at the disassembly stage.
3. Lower cover • 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.
• After provisionally securing the parts in the • Fit the gasket into the groove in the cover, and
numerical sequence shown in the illustration, tighten up the bolts indicated by the arrows.
tighten them up to secure them in the numerical
sequence shown in the illustration to the
specified torque. Tightening torque: 15N⋅m (1.5kgf⋅m/11lb⋅ft)

1
HCW31BSH012101
HCW31BSH011901
6 4 2 1 3 5 7
HCW31BSH017901
9. Harness connector
HCW31BSH012001
• Assemble the O-rings, and attach the
connectors to the lower cover.
• Adjustment of valve clearance
For the adjustment procedures, refer to the
section on adjusting the valve clearance in Tightening torque: 20N⋅m (2.0kgf⋅m/14lb⋅ft)
“Functional Inspection.”
7. Head cover lower gasket
8. Head cover lower
• Clean the top surface of the cylinder head, and
apply some liquid gasket Three Bond
No.1207B(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.
• Insert the connectors on the harness side into
the connectors attached to the lower cover until
a clicking sound is heard, and attach the
injector harness to the lower cover.
1
2
HCW31BSH018201
Legend
1. O-ring 2
2. Connector

• Mount the adapter on the lower cover rear side,
HCW31BSH018401
and install the nozzle leak off pipe in the
injector. Legend
1. Nut
2. Connector
Tightening torque
Adapter: 29N⋅m (3.0kgf⋅m/22lb⋅ft) • Insert the terminals of the harness (1) into the
Eye-bolt: 15N⋅m (1.5kgf⋅m/11lb⋅ft) heads of the cylinder injectors (2), and tighten
up the nuts to the specified torque.
Tightening torque: 2.0N⋅m (0.2kgf⋅m/17lb⋅in)
NOTE:
1 Under no circumstances must the nuts be
overtightened since this may damage the injectors.
HCW31BSH016901
Legend
2. Connector
11. Injector harness

2
HCW46BSH001901
Legend
1. Injector harness
2. Injector
12. Head cover gasket

13. Head cover
• Install the gaskets by assembling them into the
head cover.
• Tighten them up in the numerical order shown
in the illustration.
9 10 11 12 13 1 14 15 16
8
17
7
18
6 5 4 3 2 20 19
HCW46BSH001701
47 (4.8/35)
38 (3.9/28) 25 (2.5/18)
20 (2.0/14)
39 (4.0/29)
20 (2.0/14)
HCW61BLF000301
Special Tools
Cylinder head
Illustration Tool Number/ Description Illustration Tool Number/ Description
1-8523-5013-0 5-8840-0019-0
Valve spring replacer Slideing hammer small
1852350130
9-8523-1202-0
Valve guide replacer
9852312020
9-8522-1324-0
Bridge guide installation
tool
9852213240
1-8522-1140-1
(for inlet)
1852211840
1-8522-1184-0
(for exhaust)
1852211840
1-8840-2826-0
Injector remover
5884028260
Rocker arm
Component Parts
3
2
Front Mark
PWW010LF001101
Legend
1. Bracket (front) 4. Bracket (center)
2. Rocker arm 5. Rocker arm shaft
3. Spring
Disassembly • While pressing down on the bracket of the

rocker arm shaft, draw out the tightening bolts
1. Bracket (front)
(1) of the bracket (2), and remove the rocker
2. Rocker arm arm, spring and bracket.
3. Spring
4. Bracket (center) NOTE:
5. Rocker arm shaft • When the tightening bolts of the bracket are drawn
out, the force exerted by the spring will cause the
rocker arm and other parts to pop out.
• All the bolts must be loosened uniformly a little at a
time.
HCW31BSH018701
HCW31BSH018501
Inspections
Rocker arm 1
• Inspect the roller surface for wear and damage,
and measure the clearance between the roller pin
and roller.
2
With the roller of the rocker arm pushed out all the
way, make a mark at the measurement location,
and measure the difference in level (dimension A) 3
4
between the rocker arm and roller. Next, push the
roller in all the way, and measure the difference in
level (dimension B) at the marked position of the
measurement location.
The difference between dimensions A and B
HCW31BSH018901
represents the clearance between the roller pin
and roller. Legend
1. Roller
2. Dimension B
Clearance between roller pin and roller 3. Calipers
4. Dimension A
0.036 – 0.069
0.150(0.0059)
(0.0014 – 0.0027)
Rocker arm shaft • Measure the outside diameter of the rocker arm
• Inspect the oil hole in the rocker arm shaft. shaft and the clearance between the shaft and
rocker arm bushing.
Nominal Standard Llimit

dimension mm(in) mm(in)
mm(in)
Clearance 0.041 –
between shaft 0.141 0.20
—
and rocker (0.0016 – (0.0079)
arm 0.0056)
Outside
φ28 φ27.85
diameter of —
(1.1024) (1.0965)
shaft
PWW010SH015601
• Inspect the bend in the rocker arm shaft.
Shaft bend
Limit: 0.3mm(0.0118in)
HCW31BSH023001
Assembly
1. Rocker arm shaft
2. Bracket (center)
3. Rocker arm
4. Spring
5. Bracket (front)
• Apply some engine oil to the rocker arm
LNW21BSH056601
bushing, and mount it in the direction shown in
the illustration.
NOTE:
• Check the front mark on the rocker arm shaft.
HCW31BSH019001
Legend
1. Front mark
Camshaft
Component Parts
Camshaft
HCW51BLF000701
Legend
1. Camshaft gear 3. Camshaft
2. Key
Disassembly
1. Camshaft gear
• Place wood piece around so that the gear will
not be damaged, and use a puller to remove it.
NOTE:
Inspect the gear for damage: do not remove it if there
are no problems in evidence.
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 rotate the camshaft gently through a complete turn,
and measure the bend.
Camshaft run-out amount
Standard mm(in) Working limit mm(in)

0.08(0.0031) 0.1(0.0039)
PWW010SH016001
Legend
1. Wood piece
2. Key
3. Camshaft
Inspections
Camshaft gear
• Inspect the camshaft gear for damage.
PWW010SH016301
• Inspection of cam surface for damage and

measurement of lift amount of cam
Use an oil-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) 8.85(0.3484)
Exhaust 10.4(0.4094) 9.75(0.3839)
HCW31BSH021001
• Clean the camshaft bracket, check the engraved
mark on the side surface and assemble it, apply
some engine oil to its threaded area, and tighten
up the bracket to the specified torque. Next, mount
B the rocker arm shaft, apply some engine oil to its
threaded area, and tighten it up to the specified
torque.
A 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: 76N⋅m (7.7kgf⋅m/57lb⋅ft)
Rocker arm shaft: 90.0N⋅m (9.2kgf⋅m/67lb⋅ft)
PWW010SH016201
• Measurement of outside diameter of journal

Use a micrometer to measure the position shown
in the illustration.
Outside diameter of journal
Nominal dimension Working limit

mm(in) mm(in)
φ40.0(1.5748) φ39.89(1.5705)
PWW010SH016501
• The outside diameter of the camshaft journal is

obtained by measuring the four places at the
position shown in the illustration using a
2 micrometer.
1 Clearance between camshaft journal and camshaft

bracket

0.075 – 0.125 0.15
(0.0030 – 0.0049) (0.0059)
* When using a plastigauge for the measurement,

PWW010SH016101
refer to the General Information.
Measurement of clearance between camshaft
journal and camshaft bracket NOTE:
• Measure the inside diameter of the camshaft • The No.1 camshaft bracket must be assembled
bracket and outside diameter of the camshaft to securely at the No.1 position.
obtain the clearance. • The engraved mark on the camshaft bracket side
surface is not the journal number.
• Tap 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.
PWW010SH016401
Assembly
1. Camshaft
2. Key
3. Camshaft gear PWW010SH016601
Installation of camshaft gear

Camshaft
76 (7.8/56)
137 (14.0/101)
HCW61BMF000101
Timing gears
Component Parts
Timing gear
12
11
10
9
2
8
3
7
4
5
HCW51BLF000301
Legend
1. Timing gear case 7. Idle pulley
2. Gasket 8. Idle gear A
3. Gear case cover 9. Distance bolt
4. A/C compressor bracket 10. Idle gear B
5. Oil seal (crankshaft) 11. Oil pump
6. Crank pulley assembly 12. O-ring
Removal 5. Oil seal (crankshaft)

1. Crank pulley assembly • Remove the oil seal in such a way that its
press-fitting surface on the front cover will not
2. Idle pulley
damaged or marked.
3. Gear case cover
4. Gasket
• The oil seal cannot be re-used. • Measurement of backlash
Before removing the idle gears, measure the
backlash of each idle gear.
Backlash
Standard mm(in) Limit mm

0.03 – 0.13
—
(0.0012 – 0.0051)
HCW51BSH000701
• Use the remover to remove the slinger.

• The slinger cannot be re-used.
NOTE:
• When replacing the oil seal, replace it together with
the slinger 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.
PWW010SH016901
• Measure the clearance of idle gear A in the

Slinger remover: 1-8521-0027-0 axial direction.

0.165 – 0.230 0.35
(0.0065 – 0.0091) (0.0138)
• Measure the clearance of idle gear B in the

axial direction.

0.075 – 0.140 0.25
(0.0030 – 0.0055) (0.0098)
HCW31BSH019401
6. Oil pump
7. O-ring
8. Distance bolt
9. Idle gear A
10. Idle gear B
• Remove idle gear A and idle gear B.
The idle gears and thrust plate have a front and
2
back so make identifying marks on them before
removing them.
PWW010SH017001
Legend
1. Idle gear A
2. Idle gear B
PWW010SH017101
11. A/C compressor bracket

12. Timing gear case
Inspections
HCW31BMF002201
Idle gear
• Measure the outside diameter of the idle gear
spindles and the clearance between the gears and
spindles.
Outside diameter of idle gear spindles
Nominal dimension Llimit

Idle gear
mm(in) mm(in)
A φ57(2.2441) φ56.85(2.2382)
B φ142(5.5904) φ141.85(5.5846)
C φ49(1.9291) φ48.85(1.9232)
Clearance between idle gears (A, B, C) and

spindles
HCW31BSH020901

Disassembly
0.04 – 0.105 0.20
(0.016 – 0.0041) (0.0079) 1. Crank pulley assembly
Loosen the mounting bolts and remove the
damper from the crank pulley.
Outside diameter of pin of large idle gear A
Nominal dimension Limit

mm(in) mm(in) 1
8 6
φ22.2(0.8740) φ22.0(0.8661)
3 4
5 7
2
HCW51BSH000801
Inspections
1. Crankshaft pulley
• Inspect the crankshaft pulley groove for wear
and damage.
HCW31BSH020801 2. Crankshaft damper
• Inspect the damper for cracks.
Installation
1. Timing gear case
• Apply some liquid gasket Loctite No. FMD-127
in a thickness of about 0.3 mm (0.0118in) 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
PWW010SH025301 threaded areas.
• If, after the timing gear case has been installed, a
period of more than 30 minutes is left before
Assembly installing idle gears A and B, provisionally secure
1. Crankshaft damper the M10 X1.5 bolts in areas 1 to 3 shown in the
2. Crank pulley illustration to the specified torque.
• Mount the crankshaft damper on the crank
pulley.
Tighten up the parts in sequence by proceeding Tightening torque
alternately at the opposite ends along the M14: 135N⋅m (13.8kgf⋅m/100lb⋅ft)
diagonals.
M10: 43N⋅m (4.4kgf⋅m/32lb⋅ft)
NOTE:
• Place the crankshaft damper with the side on which
the caution label is adhered at the front.
• Keep all oils and greases away from the crankshaft
damper.
1
8 6
3 4
5 7
2 PWW010SH017301
HCW51BSH000801
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 flywheel with the
1 pointer. At this point, check that the engraved
line on the coupling and engraved line on the
2 pump are more or less aligned.
3
T
C
HCW31BSH013101
2. A/C compressor bracket

• Tighten the A/C compressor bracket together
with the gear case.

3. Idle gear B HCW31BSH012301
• Apply some engine oil to the inside diameter of
• Apply some engine oil to the inside diameter of
idle gear B and thrust area, check the front and
timing gear A, align the timing marks on the
back marks made when the idle gear B and
gears, and assemble timing gear A, spindle and
thrust plate (1) were disassembled, and
thrust plate.
assemble.
NOTE: Tightening torque: 108N⋅m (11.0kgf⋅m/80lb⋅ft)

If provisionally secured bolts have been installed, do
not forget to remove them.
Tightening torque: 43 N⋅m (4.4kgf⋅m/32lb⋅ft)
HCW31BSH066101
5. Distance bolt
PWW010SH017401
• Tighten up the three distance bolts at the
positions shown in the illustration.
HCW31BSH019101
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
PWW010SH017701
and seating surface of the distance bolts, and
6. O-ring install the parts without delay.
7. Oil pump Apply some Loctite No. FMD-127 to the diagonal
line area indicated by the arrows.
• Install the O-ring into the oil pump, align the
dowel position and install.
NOTE:
NOTE:
Press the protruding part of the gasket firmly into the
Do not tighten up the bolt with the heads painted yellow
groove all around its circumference.
using the above tightening torque by mistake. This bolt
is a mounting bolt of the oil pump cover only.
Tightening torque
Tightening torque: 49N⋅m (5.0kgf⋅m/36lb⋅ft) M10: 39N⋅m (4.0kgf⋅m/29lb⋅ft)
M8: 25N⋅m (2.6kgf⋅m/19lb⋅ft)
Inside hex bolt
Tightening torque: 39N⋅m (4.0 kgf⋅m/29lb⋅ft)
HCW51BSH000901
4
2
HCW51BSH001001 7
10. Oil seal (crankshaft)

• Apply a thin film of engine oil to the outer
circumference of the oil seal.
• Using the installation tool, install the oil seal and
slinger (silver color) at the same time. 6 5
• Tighten the center bolt until the sleeve touches
the adapter.
HCW31BMH000501
Oil seal installation tool: 1-8522-0043-0 Legend
• Upon completion of the press-fitting, clean up 1. Special tool (sleeve)
any oil stains. 2. Special tool (adapter)
3. Reference dimension
• After installing the oil seal, measure the
4. Crankshaft
distance from the end of the crankshaft to the
5. Slinger (silver color)
oil seal surface.
6. Oil seal
NOTE: 7. Position of special tool before press-fitting
8. Position of special tool after press-fitting
• Be absolutely sure to replace the slinger and oil seal
together as a pair. • If marks are left behind on the shaft section
• Take care not to mark or damage the oil seal lip and after the slinger has been drawn out, apply
4-ridge thread-cutting surface of the slinger. some liquid gasket (Three Bond No.1207C) to
the area shown in the illustration on the inner
circumferential surface of the slinger, and
6.7 – 7.3mm install.
Reference dimension:
(0.2638 – 0.2874)
HCW31BSH019501
11. Idle pulley

12. Crank pulley assembly
• Apply some engine oil to the threaded parts of
the tightening bolts, and tighten up the bolts in
sequence at the opposite ends along the
diagonals.
1
8 6
3 4
5 7
2
HCW51BSH023501
135 (13.8/100)
49 (5.0m/36)
43 (4.4/32)
39 (4.0/29)
108 (11.0/80)
39 (4.0/29)
25 (2.6/19)
118 (12.0/87)
267 (27.2/197)
HCW61BLF000401
Special Tools
Illustration Tool Number/ Description
1-8521-0027-0
Slinger replacer
1852100270
1-8522-0043-0
Oil seal installation tool
1852200430
Flywheel and Flywheel housing

Component Parts
12
4
11
10
9
7
6
8
5
HCW51BLF000501
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.
NOTE:
1 the slinger as a set.
HCW51BSH001201
2. Snap ring
3. Pilot bearing
• Remove the snap ring. HCW31BSH013501
• Using the bearing puller, remove the pilot 10. Slinger
bearing.
• Using the slinger remover, remove the slinger.
Bearing puller: 9-8521-0157-0 NOTE:

the slinger 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: 1-8521-0027-0
HCW31BSH013401
4. Washer
5. Flywheel
6. Engine foot
7. Flywheel housing stay
8. Flywheel housing
9. Oil seal
• Remove the oil seal without marking or HCW31BSH019401
damaging the press-fitting surface of the oil
seal of the flywheel housing.
Disassembly Flywheel
Flywheel • Inspect the flywheel for cracks and streaking, and
measure its wear.
1. Ring gear
• Inspect the ring gear for damage.
Do not remove it if nothing is wrong with it. Depth from wear surface of flywheel to installation
surface of clutch cover
• Removal of ring gear
Place the flywheel on some wooden chips,
place a bar up against the end of the ring gear, Nominal Limit
and tap it uniformly to remove the ring gear. dimension mm(in)
mm(in)
15.5" twin plate 24(0.9449) 26.5(1.0433)
NOTE:
Polish and repair the flywheel, and replace it if its wear
has exceeded the working limit.
HCW31BSH019901
Inspections
Pilot bearing
• Inspect the pilot bearing for wear and play.
NOTE: HCW31BSH020101
This is a grease-sealed bearing, so it must not be
washed.
Ring gear
• Inspect the ring gear for damage.
Do not remove it if nothing is wrong with it.
Assembly
1. Flywheel
• Warm up the ring gear uniformly using a gas
burner (lower than 200°C/392°F) and, with the
larger of the gear chamfers at the front, install
the gear in the flywheel.
HCW31BSH020001
• Ensure that none of the liquid gasket gets into the
bolt holes.
• Tighten up the bolt by the knock pin first.
PWW010SH025801
HCW31BSH014101
2. Engine foot rear

• Apply some molybdenum disulfide to the
threaded areas and seating surfaces of the
nuts, and start tightening the nuts from the
place where the dowels are provided.
Tightening torque
147N⋅m (15.0kgf⋅m/108lb⋅ft) → 274N⋅m (28.0kgf⋅m/
203lb⋅ft)
HCW31BSH020201
Installation
1. Flywheel housing
• After applying some liquid gasket Loctite No.
FMD-127 with a thickness of about 0.3
mm(0.0118in) and a width of about 4
mm(0.1575in), install the flywheel housing
without delay.
Tightening torque
M14: 123N⋅m (12.5kgf⋅m/90lb⋅ft)
M 8: 22N⋅m (2.2kgf⋅m/16lb⋅ft) HCW31BSH014201
NOTE: 3. Flywheel housing stay

• Also apply a sufficient amount of the liquid gasket to • Install the flywheel housing stay.
the surface where the cylinder block and crankcase
are joined.
4. Oil seal
• Apply a thin film of engine oil to the outer
circumference of the oil seal.
• Using the installation tool, install the oil seal and 2
slinger (gray color) at the same time.
• Tighten the center bolt until the sleeve touches 1
the adapter.
3
Oil seal installation tool: 1-8522-0043-0

4
• Upon completion of the press-fitting, clean up
any oil stains. 5
• After installing the oil seal, measure the
distance from the crank end to the seal surface.
6
6.7 – 7.3mm
Reference dimension
(0.2638 – 0.2874in)
NOTE:
• Be absolutely sure to replace the slinger and oil seal
together as a pair. 8 7
• Take care not to mark or damage the oil seal lip and
4-ridge thread-cutting surface of the slinger.
HCW31BMH000601
Legend
1. Crankshaft
2. Reference dimension
3. Special tool (adapter)
4. Special tool (sleeve)
5. Position of special tool after press-fitting
6. Position of special tool before press-fitting
7. Oil seal
8. Slinger (gray color)
• 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.
5. Flywheel 8. Pilot bearing

6. Washer 9. Snap ring
• Apply some molybdenum disulfide to the • Insert the pilot bearing, and fasten it using the
threaded areas and seating surfaces of the snap ring.
bolts, and tighten up the bolts in the numerical
sequence shown in the illustration.
Pilot bearing installation tool: 1-8522-1057-0
Tightening torque:
79N⋅m (8.1kgf⋅m/59lb⋅ft) → Angle method 60° → 30°
9 1
6 4
3 7
10 2
8 5
HCW31BSH014401
HCW31BSH014301
7. Engine speed sensor

• Mount the sensor on the flywheel housing.
NOTE:
Be absolutely sure to assemble the flywheel before
mounting the sensor.
147(15/11) 274(28/203)
M14 ; 123(12.5/90)
M 8 ; 22(2.2/16)
79(8.1/59) 60 30
HCW61BLF000501
Special Tools
1-8521-0027-0
Slinger remover
1852100270
1-8522-0043-0
Oil seal installation tool
1852200430
1-8522-1057-0
Pilot bearing installation
tool
1852210570
9-8521-0157-0
Pilot bearing puller
9852101570
Piston and Connecting rod

Component Parts
3 4
2
PWW010LF002001
Legend
1. Piston ring 5. Connecting rod
2. Snap ring 6. Connecting rod cap
3. Piston pin 7. Bearing
4. Piston
Removal •NOTE:
Fasten the liner in such a way that it will 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.
• Loosen the tightening nuts, and tap the cap

lightly with a copper hammer or other such tool
to remove it. Next, turn the crankshaft, and set
Disassembly
the piston to be drawn out to the top dead 1. Piston pin
center position. • Using the installation tool, remove the piston
ring.
NOTE:
Take care not to damage the oiling jet. NOTE:
Make marks on the removed piston rings to identify
them by cylinder.
Piston ring installation tool: 1-8522-1025-0
HCW31BSH014601
• Using an implement such as the handle of a

hammer, push out the bottom end of the
connecting rod.
NOTE: PWW010SH020601
• Ensure that the connecting rod and liner do not 2. Snap ring
interfere with each other.
3. Piston ring
• Take care not to damage the oiling jet.
• Remove the snap ring, place a bar up against
• Assemble the cap, bearing and connecting rod the piston pin (1), and tap it gently to remove it.
which have been removed into a set to ensure that
they will not be mixed up with other parts.
NOTE:
Attach number labels to the piston pins for each
cylinder.
1 PWW010SH020901
• Measurement of clearance between piston ring

groove and piston ring
Clean off the carbon on the piston head and in the
PWW010SH020701
ring groove. Next, insert the ring into the ring
4. Piston groove, and measure the clearance using the
5. Connecting rod thickness gauge.
6. Connecting rod cap For the top ring, measure the clearance using the
thickness gauge (1) while pressing down on the
7. Bearing
piston along the straight edge (2).
Inspections Clearance between ring groove and ring

Piston pin
• Inspection of piston rings and measurement of Assembly Woeking limit
closed gap standard mm(in)
Clean off the carbon on the piston rings. Insert the mm(in)
piston rings into the cylinder liners, and use the
piston heads to push in the rings as far as the least 0.058 – 0.117
Top ring —
worn sections of the liners (bottoms of the liners). (0.0023 – 0.0046)
Next, insert a thickness gauge into the joint areas 0.085 – 0.120
Second ring —
of the rings, and measure the clearance. (0.0033 – 0.0047)
0.085 – 0.120
Third ring —
Closed gaps of piston rings (0.0033 – 0.0047)
0.025 – 0.065 0.15
Oil ring
(0.0010 – 0.0026) (0.0059)
Assembly Woeking
standard limit mm(in)
mm(in)
0.35 – 0.50 1.0
Top ring
(0.0138 – 0.0197) (0.0394)
0.80 – 0.95 1.5
Second ring
(0.0315 – 0.0374) (0.0591)
0.35 – 0.50 1.0
Third ring
(0.0138 – 0.0197) (0.0394)
0.3 – 0.50 1.0
Oil ring
(0.0118 – 0.0197) (0.0394)
Standard Limit
N (kgf)/(lbf) N (kgf/lbf)
28.1 – 36.6
1 19.6
Third ring (2.87 – 3.73)
(2.0/4.41)
/(6.33 – 8.24)
46.3 – 57.7
39.2
Oil ring (4.72 – 5.88)/
(4.0/8.82)
(10.41 – 12.97)
PWW010SH021001
HCW31BSH023201
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 which are hard to see.
HCW31BSH023101
If necessary, conduct an inspection using a red
check.
• 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 Limit
N (kgf)/(lbf) N (kgf/lbf)
27.5 – 41.2
24.5
Top ring (2.81 – 4.20)
(2.5/5.51)
/(6.20 – 9.26)
22.8 – 34.1
19.6
Second ring (2.32 – 3.48)
(2.0/4.41)
/(5.12 – 7.67)
HCW31BSH023301
• Measurement of outside diameter of piston pin Connecting rod
Measure the outside diameter of the piston pin, • Measurement of clearance between connecting
and measure the clearance between the piston pin rod bearing and crank pin
and piston pin hole and also between the piston Clean the bearing and its mounting surface, and
pin and connecting rod bushing. assemble the bearing. Next, apply some
For the piston pin, perform the measurements in molybdenum disulfide to the threaded areas and
the six locations shown in the illustration. 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
bearing shown in the illustration.
mm(in)
Outside Tightening torque:
φ56 φ55.97
diameter of — 98N⋅m (10.0kgf⋅m/72lb⋅ft)→ Angle method 30°→ 30°
(2.2047) (2.2035)
piston pin
Clearance 0.008 –
between piston 0.021 0.05
—
pin and piston (0.0003 – (0.020)
pin hole 0.0008)
Clearance
0.020 –
between piston
0.037 0.10
pin and —
(0.0008 – (0.0039)
connecting rod
0.0015) 1 2
bushing B
A
A
1 2 B
PWW010SH021501
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

mm(in) mm(in)
PWW010SH021201
0.033 – 0.103 0.16
(0.013 – 0.041) (0.0063)
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.
• 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.
12 A Clearance in axial direction
B B
A Standard mm(in) Limit mm(in)
0.175 – 0.290 0.35
(0.069 – 0.0114) (0.0138)
PWW010SH021601
• 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 (per 100 mm/3.937in)
PWW010SH021701
0.05(0.0020) 0.1(0.0039) Bearing
• Inspect for wear, scratches, peeling, etc.
• Assemble the bearing, and check that there is
tension.
PWW010SH021401
HCW51BSH023601
Assembly
1. 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)
HCW31BSH023401
• Inside diameter of liner and outside diameter of

piston
Part Inside diameter Outside diameter

Grade symbol of liner mm(in) of piston mm(in)
147.000 – 146.840 –
147.010 146.849
A
(5.7874 – (5.7811 –
5.7878) 5.7814)
147.011 – 146.850 –
HCW31BSH023301
147.020 146.860
B
• When re-using the piston, measure the (5.7878 – (5.7815 –
clearance between the piston and liner. 5.7882) 5.7819)
• Measurement method 147.021 – 146.861 –
Measure the outside diameter of the piston at 147.030 146.870
C
the grade position. Clean off any carbon and (5.7882 – (5.7819 –
other foreign matter on the liner, measure the 5.7886) 5.7823)
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 the
piston and liner is within the reference value.
• When replacing only the liner, select it by
grade.
Grade selection measurement position

30mm
(from bottom of piston skirt in direction of
(1.1811in) 130mm
the longer diameter):
Clearance between piston and liner (in direction of

the longer diameter)
0.149 – 0.190mm
Assembly standard:
(0.0059 – 0.0075mm)
PWW010SH021801
(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
number engraved on the right side of the cylinder
block, and assemble.
Cylinder block and liner combinations
Part Outside
Cylinder
Grade symbol diameter of
block mm(in)
liner mm(in)
151.60 – 151.590 –
151.610 151.599
1 1X
(5.9685 – (5.9681 – HCW31BSH023501
5.9689) 5.9685)
5. Piston
151.611 –
151.620 6. Piston ring
2 7. Snap ring
(5.9689 – 151.600 –
5.9693) 151.610 • Align the arrow mark on the piston head and
3X
151.621 – (5.9685 – the front mark on the connecting rod as shown
151.630 5.9689) in the illustration (same direction) to assemble.
3 Next, apply some engine oil to the piston pin,
(5.9693 –
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 down). Finally, check
that the piston and connecting rod move
smoothly.
6W
HCW31BSH021501
Legend
1. Position where the inside diameter bore grade is HCW31BSH023601
engraved on the cylinder block
Legend
1. Front mark
2. Grade category
3. Front mark
8. Piston pin
• Installation of expander ring
Insert the expander ring so that there is no
closed gap, and fit it into the piston groove.
1 2 3
2N 3N
Red Blue Green
HCW51BSH002301
• No differentiation is made between the top and

bottom of the oil ring, but install this ring in such
LNW21BSH011201
a way that it is pointing 180 degrees in the
opposite direction from the joint area of the
Installation of piston rings expander ring.
• Place the top ring, second ring and third ring • Apply some engine oil all around the rings, and
with the identification colors of their joint areas turn the rings. At this point, check that the rings
on the right, and use the installation tool to turn smoothly without catching on anything.
install them.
• Make marks on the joint area sides of each ring
to identify the top ring, second ring and third Piston ring installation tool: 1-8522-1025-0
ring.
• Take care to ensure that the coating on the
piston skirt will not be peeled off.
1
Identification Top/bottom
No engraved
Top ring Red paint (1) 2
marks
Second ring Blue paint (2) 2N
3
Third ring Green paint (3) 3N
HCW51BSH023701
Legend
1. Top ring
2. Second ring
3. Third ring
4. Oil ring
Installation
1. Connecting rod and bearing
• Thoroughly clean the mounting surfaces of the NOTE:
cap bearing and connecting rod bearing, Fasten the liner in such a way that it will not be drawn
assemble the bearing, and apply some engine out.
oil 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 oil hole.
• The bearing on the cap side has an oil groove which
extends all the way around and no oil hole.
HCW31BSH016101
• 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.
PWW010SH020001
2. Piston and connecting rod

• Apply some engine oil all around the cylinder
liner (1).
HCW31BSH021801
• 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
HCW31BSH015901
toward the front of the cylinder block, and insert
• Turn the crankshaft, and set the crank pin of the the piston by hand. At this point, insert the
cylinder in which the piston is to be assembled, piston by turning it to the right by 5 to 10
to the top dead center position. degrees, and return it to point properly at the
position where it does not interfere with the
oiling jet.
• Using the installation tool, push in the piston
with the handle of a hammer until it makes
contact with the crank pin. Then turn 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 tool 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 jet.
PWW010SH020001
Piston installation tool: 1-8522-0059-0
• Turn 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.
PWW010SH022701
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 HCW31BSH021901
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 torque:
98N⋅m (10.0kgf⋅m/72lb⋅ft)→ Angle method 30°→ 30°
98(10.0/72) 30 30
HCW61BLF000601
Special Tools
1-8522-0059-0
Piston installation tool
1852200590
1-8522-1025-0
Piston ring installation
tool
1852210250
Crankshaft
Component Parts
5
4
3
4
3
HCW31BLF010501
Legend
1. Cylinder block 4. Main bearing
2. Crankshaft 5. Thrust bearing
3. Thrust bearing 6. Crankcase
Removal
1. Crankcase
• Before removing the crankcase, measure the • Loosen the bearing tightening bolts from the
clearance in the axial direction of the outside, and remove them. Place brass rods
crankshaft. against the ribbed area in the four corners on
Measure this at the No.1 bearing thrust surface. 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
Clearance in axial direction of crankshaft
remove.

0.04 – 0.67
—
(0.04016 – 0.0264)
NOTE:
If the working limit has been exceeded, replace the
1 5 9 13 12 8 4
thrust bearing.
2 6 10 14 11 7 3
HCW51BSH001301
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
PWW010SH023101
crankshaft bearing.
HCW31BSH015401
Disassembly Inspections
1. Crankshaft Crankshaft
2. Bearing • Inspect the crankshaft for cracks and the contact
3. Crankshaft gear surfaces of the bearing for damage.
• Use the gear puller to remove the crankshaft If necessary, inspect the parts using the magnetic
gear. flaw detection method or red check.
Gear puller: 1-8521-0064-0
Slinger remover: 1-8521-0027-0
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.
HCW31BSH020301
• Measurement of crank journal and pin wear

Perform the measurements in the four locations
shown in the illustration.
Nominal Assembly
dimension standard
mm(in) mm(in)
φ104.850
(4.1279) –
PWW010SH023901 No.4
φ104.875
Outside (4.1289)
diameter of φ105(4.1339)
journal φ104.880
(4.1291)–
Other
φ104.905
(4.130)
Outside
φ91.895(3.6179) –
diameter of φ92(3.6220)
φ91.92583.6191)
pin
NOTE:
The crankshaft has been nitrocarburized so it must not
be modified or repaired.
3 1 2
4 4
• Measurement of crankshaft run-out

Hold the No.1 journal and No.7 journal using the Crankshaft gear
crankshaft aligner or V-block. Place a dial gauge • Inspect the crankshaft gear for damage.
against the No.4 journal of the crankshaft, rotate
the crankshaft gently through one turn, and NOTE:
measure the amount of crankshaft run-out. Conduct this inspection before drawing the gear out
from the crankshaft, and do not draw it out if nothing is
wrong with it.
Amount of crankshaft run-out
Limit: 0.15 mm(0.0059in)
HCW31BSH020601
Measurement of clearance between crank bearing

and crank journal
PWW010SH024101
• With the crankcase assembled, measure the
inside diameter of the crank bearing and the
Bearing
outside diameter of the crank journal, and obtain
• Inspect for wear, scratches, peeling, etc. the clearance.
• Assemble the bearing, and check that there is
tension.
• 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 bolts, and tighten up the bolts
to the specified torque.
The crankcase tightening sequence is shown in
the illustration.
In addition, apply some engine oil 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
illustration.
Tightening torque
N⋅m (kgf⋅m/lb⋅ft) PWW010SH024401
49 (5 / 36) → 88 (9.0 / 65) →

M18:
Angle method 90° to 120°
M12: 96 (9.8/71)
M18: Application of molybdenum disulfide
M12: Application of engine oil
Standard mm(in) Limit

mm(in)
Clearance 0.075 – 0.150
No.4
between (0.0030 –
journal 0.16
bearing 0.0059) PWW010SH024301
(0.0063)
and crank 0.045 – 0.120
journal Other
(0.018 – 0.0048)
NOTE:
* When using a plastigauge for the measurement, refer
to the General Information.
Presence/absence of nitrocarburized zone • Judgment
• Washing of crankshaft Crankshaft is re-usable: No changes at all are
Wash the crankshaft. Remove the oil and grease apparent after 30 to 40 seconds.
particularly at the test locations (but not within 10 Crankshaft cannot be re-used: After 30 to 40
mm(0.3937in) around the oil holes) using an seconds, the test solution (a light blue color) turns
organic solvent or other such agent. 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, etc.
CAUTION:
• Do not allow the test solution to come into contact
with your eyes, hands, clothing, etc. If some
solution should get into your eyes, rinse them
immediately with large quantities of pure water,
and seek medical assistance.
HCW31BSH020301
• Inspection of nitrocarburized zone

1
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
2 HCW31BSH020701
3 Assembly
1. 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 ºC / 374°F to 464°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
LNW21BSH038001 the crankshaft collar.
Legend NOTE:
1. Do not test within 10 mm (0.3937in) around the Assemble the parts while paying attention to the
oil holes. direction in which the gear is pointing.
2. Test solution
3. Crankshaft
Gear installation tool: 1-8522-0045-0

• Apply some engine oil to the bearing sliding
surface, and place the crankshaft on top
horizontally.
PWW010SH025001
2. Bearing
3. Crankshaft PWW010SH023401
3. Thrust bearing
Installation • Apply some oil to the engine oil groove side of
1. Crankshaft bearing the thrust bearing, point the oil groove toward
• Check the installation positions at the the outside, and push it in by hand at both sides
disassembly stage, thoroughly clean the of the No.1 journal of the cylinder block.
bearing and its installation surface, and
assemble the parts.
NOTE: 1
• The bearing on the cylinder block side has a groove
which extends all the way around and an oil hole.
2
• The bearing on the crankcase side has a narrow
groove which extends all the way around and no oil 3
hole.
HCW31BSH015701
Legend
1. Alignment of knock pin hole
2. Oil groove
3. Application of oil
HCW51BSH006501
2. Crankshaft
• Apply some engine oil to the oil groove 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 turns smoothly.
Tightening torque
49 (5 / 36) → 88 (9.0 / 65) →
M18:
Angle method 90° to 120°
M12: 96 (9.8 / 71)
1
M18: Application of molybdenum disulfide

M12: Application of engine oil
HCW31BSH064301
4. Crankcase
• Apply some liquid gasket Loctite No. FMD-127
with a thickness of at least 0.3 mm(0.1575in)
and a width of about 4 mm(0.0118in) to the
areas on the bottom of the cylinder block
indicated as 1, 2, 3, 4, 5 and 6 in the illustration,
and install the parts without delay.
1
6{
} 2
PWW010SH023801
5 { } 3
HCW31BSH064401
• Apply some molybdenum disulfide to the

threaded areas and seating surfaces of the
M18 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.
Special Tools
1-8521-0064-0
Crankshaft gear puller
1852100640
1-8522-0045-0
Crankshaft gear
installation tool
1852200450
Cylinder block
Component Parts
3
2
HCW51BLF003901
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

liner
• Check the inside of the liner for marks and
2. Oil relief valve
damage.
3. Crankcase
• With the liner installed on the cylinder block,
4. Oiling jet measure its inside diameter by measuring
5. Cylinder liner where it is worn the most at a position about
130mm from the top surface of the liner. If the
wear has exceeded the working limit, replace
the liner.
Inside diameter of cylinder liner Inspections
Nominal dimension Working limit Crankcase
mm(in) mm(in) • Inspect the crankcase for cracks and damage.
φ147(5.7874) φ147.3(5.7992) If necessary, inspect the cylinder head using the
• 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 a way that it will not be
drawn out.
HCW31BSH021101
130mm
Oiling jet
• Inspect the oil holes in the oiling jet and joint bolts.
HCW51BSH023801
6. Cylinder block
HCW31BSH021201
Cylinder block
• Inspection of the cooling water and oil
passageways for corrosion and clogging
Carefully inspect the cooling water passageways
between the cylinders for clogging.
• Inspect the cylinder block for cracks, damage, etc.
If necessary, inspect the cylinder head using the
• Inspection of water jacket for leaking water
Using a hydraulic tester, apply a hydraulic
pressure of 490 kPa (5 kg/cm2 / 71psi) for three
minutes, and inspect various parts of the cylinder
block for water leaks. 1
6W
HCW31BSH023801
Cylinder block and liner combinations
Number engraved in Liner grade

PWW010SH026001
block
1 1X
Assembly 2⋅3 3X
1. Cylinder block
Selection of cylinder liner grade Clearance between cylinder block and liner
• The grade must be the same for both the inside
diameter (1) of the cylinder block bore and
outside diameter of the liner. 0.006 – 0.025mm
Assembly reference:
(0.0002 – 0.0010in)
• 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. • Washing of cylinder block and liner
Thoroughly wash the cylinder block and liner,
NOTE: and then wipe off all traces of the detergent.
Assembling the parts without selecting the liner grade
may lead to insufficient cooling (excessive clearance) NOTE:
or difficulties in inserting the liner (insufficient • The liner is thin so handle it carefully.
clearance) and give rise to distortion. • Position where outside diameter of liner is engraved
as indicated by arrow
• Measurement of cylinder liner protrusion
Using a dial gauge, measure the amount of the
liner protrusion.
Amount of liner protrusion
0.75 – 1.12mm
Assembly standard:
(0.0295 – 0.0441in)
Difference from adjacent cylinder
Less than
Assembly standard:
0.025 mm(0.0010in)
HCW31BSH023501
2. Cylinder 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, after inserting the liner, the cylinder block is to be
turned upside down, take steps to prevent the liner
from being drawn out.
PWW010SH026801
3. Oiling jet
• Check that the tip of the oiling jet is pointing
toward the cooling cavity inlet of the piston, and
tighten up the parts.
PWW010SH026901
Tightening torque
Adapter: 41N⋅m (4.2kgf⋅m/30lb⋅ft)
Oil pressure switch: 18N⋅m (1.8kgf⋅m/13lb⋅ft)
PWW010SH027101
NOTE:
Do not cause the tip of the oiling jet to be bent out of
shape.
4. Crankcase HCW5Z0SH000301
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.
PWW010SH027201

• Install both the adapter and oil pressure switch
through the gasket.
41(4.2/30)
20(2.0/14)
18(1.8/13)
69(7.0/51)
HCW61BMF000201
Engine Cooling (6WF1-TC) 1C-1
ENGINE
Engine Cooling
(6WF1-TC)
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2
Maintenance Precautions . . . . . . . . . . . . . . . . .1C-2
Description of Functions and Operation. . . . . . .1C-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . .1C-4
List of Trouble Symptoms . . . . . . . . . . . . . . . . .1C-7
Symptom:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-8
Symptom:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9
Main Specifications . . . . . . . . . . . . . . . . . . . . . .1C-9
Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Component Parts . . . . . . . . . . . . . . . . . . . . . . .1C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-13
Tightening Torque Table. . . . . . . . . . . . . . . . . .1C-15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16
Water pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-17
Component Parts . . . . . . . . . . . . . . . . . . . . . . .1C-17
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-17
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-19
Tightening Torque Table. . . . . . . . . . . . . . . . . .1C-22
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .1C-23
1C-2 Engine Cooling (6WF1-TC)
Cooling System
Maintenance Precautions Description of Functions and Operation
WARNING: Cooling system
Do not loosen or remove radiator cap when coolant is The cooling system has forced circulation and the main
hot. Steam or hot water may escape from the radiator components are a water pump, thermostat and a
and can cause burns. When opening the radiator cap, radiator.
make sure the coolant has cooled off, cover the cap
with a thick cloth and release pressure by turning
slowly and then remove the cap.
5 6 7
2 3 4 8
10
14 12 11
13
HCW51CMF000401
Legend
1. Radiator 8. Air compressor
2. EGR valve 9. Turbo charger
3. EGR cooler 10. Oil cooler
4. EGR cooler 11. Water pump
5. Air removal pipe 12. Water pump outlet (heater)
6. EGR valve 13. Thermostat
7. Sub tank 14. Cooling fan
Water pump
The water pump is a centrifugal impeller type and is
driven by a gear on the front of the engine.
1 2
3
4
10
HCW31CLF000101
Legend
1. Impeller 6. Rear cover
2. Seal unit 7. Bearing
3. Oil seal 8. Water pump
4. Gear 9. O-ring
5. Shaft 10. Front cover
Fan drive inspection
HCW31CMF000101
Fan drive • As freezing temperature differs with

• Check for abnormal noises and oil leaks. concentration of long life coolant super, change
Turn by hand to check for abnormal noises. the concentration according to minimum
temperature.
• Do not use coolant other than Isuzu genuine
coolant.
• Method for calculating coolant concentration:
coolant concentration (%) = 100(coolant
capacity) (L) /( coolant capacity (L) + water
capacity (L)) )
coolant capacity + water capacity = coolant
capacity = 41.4 L(9.108Imp.gal)
<Example> In regions where minimum
temperature is -20 °C(-4°F), as a coolant
concentration of approximately 35% is required.
• 41.4(35/100)= 14.5(3.19)
• Dilute 14.5 L(3.19Imp.gal) of coolant with 26.9
L(5.92Imp.gal) of water for a total volume of
41.4 L(9.108Imp.gal), giving a coolant
concentration of 35%.
HCW31CSH000301
2. Measurement of coolant concentration
• Use an antifreeze hydrometer and a
Coolant inspection
thermometer to measure the specific gravity
1. Coolant concentration and coolant temperature.
CAUTION:
Take precaution as when the cap is removed at high
temperature, the coolant may escape.
• After measuring the temperature and specific

gravity, use the following table to determine
concentration.
• Use a container that is deeper than the length
of the hydrometer.
• The temperature of the coolant to be measured
should be within 0 to 50 C(32 to 122°F).
Rough Mixing percentage Concentratio

indication of (L/Imp.gal) n of coolant
freezing
temperature coolant Tap water
°C(°F)° HCW31CSH000501
14.5 26.9
-18 (-0.4) 35%
(3.19) (5.92) Radiator inspection
17.4 24.0 Radiator, radiator valve
-25 (-13) 42%
(3.83) (5.28)
• Use a radiator cap tester to inspect the valve
20.7 20.7 opening pressure. If the valve opening pressure
-35 (-31) 50%
(4.55) (4.55) exceeds the standard value, replace the radiator
21.9 19.5 cap.
-40 (-40) 53%
(4.82) (4.29)
kPa (kg/cm2 / psi)

Positive pressure = 61.8 to 71.6
(0.63 to 0.73 /
Cap operating 8.9586 to 10.3806)
pressure:
Coolant density( )
Negative pressure = 1.96 to 4.9
(0.02 to 0.05 / 0.2844 to 0.7110)
Frozen temperature ( F)
)
0 10 20 30 40 50
Frozen temperature(
-10 14
-20 -4
-30 -22
-40 -40
-50 -58
HCW61CSH000101
HCW31CSH000601
• Inspect the condition of the negative pressure WARNING:
valve in the center of the cap valve seat. If the Do not loosen or remove sub tank cap when coolant is
valve seating does not operate smoothly due to hot. Steam or hot water may escape and can cause
rust, dust or other foreign materials, clean or burns. When opening the sub tank cap, make sure the
replace the radiator cap. coolant has cooled off, cover the cap with a thick cloth
and release pressure by turning slowly and then
Radiator core remove the cap.
• If the radiator fins are bent, heat dissipation
capability is reduced and can lead to overheating; 2. Press the sub tank cap button, and after the
therefore, straighten any bent fins. internal pressure has been released, remove the
When straightening the fins, do not damage the cap.
attachment area of the fin. 3. Open the engine and radiator cooling water drain
• Remove dust and other foreign materials. plug and drain off the cooling water.
4. Retighten the drain plug.
Cleaning the radiator 5. Pour radiator cleaner into the sub tank, and then
• Clean the inside of the radiator and coolant add tap water up to the "MAX" level.
passages with water and a neutral cleanser. 6. Inspect and clean the sub tank cap. If anything is
Remove all scale and rust. wrong with the cap, replace it.
Coolant leakage check 7. Attach the sub tank cap securely.
8. Start the engine, and let it idle for 20 minutes. Stop
• Using a radiator cap tester, apply a pressure of 90
the engine, allow the cooling water to cool off
kPa (0.9 kgf/cm2/13psi) and inspect the following
sufficiently, and then drain it.
locations for leaks. Also, inspect the radiator hoses
and heater hoses for damage and/or deterioration 9. Following the same procedure, add only tap water,
and for loosening of the clamps. idle the engine to clean it, and drain off the water.
10. Replenish the cooling water.
Locations to inspect 11. After idling the engine and raising the water
• Radiator assembly, water pump assembly, radiator temperature to the appropriate level, continue
hose, heater hose, sub tank assembly, rubber idling the engine for another 10 minutes. Adjust the
hose for air removal. heater temperature to its maximum setting, and
ensure that the cooling water is circulating inside
the heater's water line system as well.
12. Stop the engine, and after allowing it cool, inspect
the cooling water. If there is an insufficient amount,
replenish it up to the "MAX" level.
MAX
0.7
PUSH
MIN
HCU520SH007501
Engine coolant replacement procedure

1. Confirm that the engine is cool.
• Engine overheats
• Engine cools too much
Symptom:
Cooling system

Engine overheats Overload Reduce load.
Coolant level is low Fill up.
Coolant temperature gauge trouble Replace the coolant temperature
gauge.
Clogging of exhaust pipe and/or Repair the exhaust pipe and/or
silencer silencer.
Oil level is low Replenish more oil.
Fatigue, damage of radiator cap Replace the radiator cap.
Clogging or dirt in radiator core or Clean and/or repair the radiator
grill core or grill.
Clogging of radiator tube due to rust Clean or replace the radiator core.
or foreign material
Thermostat failure Replace the thermostat.
Fan clutch failure Replace the fan clutch.
Water pump failure Repair or replace the water pump.
Clogging of the water jacket Clean the water jacket.
Symptom:

Engine cools too much Thermostat failure Replace.
Main Specifications
Item Specification
Cooling method Water-cooled forced circulation
Radiator type Corrugated fin type
Radiator cap operating pressure Positive pressure valve 60 – 70 (0.6 – 0.7 / 9 – 10)
kPa (kg/cm2 / psi) Negative pressure valve 2 – 5 (0.02 – 0.05 / 0.3 – 0.7)
Type Centrifugal gear type
Water pump Amount discharged
383 / 84.26 (2840rpm)
(L/Imp.gal/min)
Thermostat initial opening temperature (°C/°F) 82 (180)
Coolant capacity (L/Imp.gal) 41.4 (9.11)
Fan belt
Adjustment Tension adjustment of the belt for driving the A/C
compressor
Tightening adjustment of belt for driving generator
1. Loosen the nut (D) and bolts (B)(C) in the
1. Loosen the lock nut for the idle pulley.
illustration.
2. Adjust the adjustment bolt of the idle pulley so the
tension of the belt achieves the standard value.
3. Amount of deflection when the centers of the belt
between the idle pulley and generator pulley (F1)
and between the crankshaft pulley and the idle 1 2
pulley (F2) are pushed on with a 98 N (10 kgf/
22.05lb) force.
3
Standard value 8
7
New part When re-tensioned

mm(in) mm(in)
8 – 10 9 – 11
F1 6 5 4
(0.315 – 0.3937) (0.3543 – 0.4331)
10 – 12 13 – 15
F2
(0.3937 – 0.4724) (0.5118 – 0.5906)
HCW31BSH008801
Legend
1. Bolt B
2. Bracket B
3. A/C compressor
1 4. Adjustment bolt
5. Nut D
6. Bracket A
7. Bolt C
3 8. Bolt A
2 2. Adjust the adjusting bolt so the tension of the belt

achieves the standard value.
4
Standard value
Amount of deflection when the center of 10 –
the belt between the crankshaft pulley 13mm
and the A/C compressor is pushed on (0.3937 –
HCW31BSH008601 with a 98 N (10 kgf/22.05lb) force: 0.5118in)
Legend
1. Adjusting bolt
2. Lock nut
3. F1
4. F2
1
HCW31BSH008701
Legend
1. Adjustment bolt
3. Tighten the nut and bolts.

Thermostat
Component Parts
4
5
PWW010LF003001
Legend
1. Seal rings 4. Thermostat housing
2. Thermostat 5. O-ring
3. Gasket 6. QOS water temperature switch
Removal 6. Seal rings

1. QOS water temperature switch
Removal of seal rings.
• Use a thermostat seal puller to remove the seal
3. Gasket rings.
4. O-ring
5. Thermostat
Thermostat seal puller: 1-8521-0067-0
NOTE:
To prevent direct heating of the thermostat, place a
plate (2) under the container or suspend the
thermostat. Continuously stir (1) the warm water to
prevent temperature differences.
PWW010SH028901
Inspection
Thermostat
• Inspect the thermostat pellet, spring and caulking PWW010SH029101
areas for damage.
Legend
1. Agitation rod
2. Wooden piece
• As the thermal capacity of a wax type thermostat is

high, there are slight differences in time to
operation of the valve.
Installation
1. Seal rings
• Install the seal ring using a setting tool with the
lip directed as in the illustration.
Thermostat seal setting tool: 1-8522-1034-0

2. Thermostat
PWW010SH029001 • Install the thermostat as shown in the
illustration to prevent damage to the seal.
• Thermostat operating test
Place the thermostat in water and gradually
increase the temperature of the water. Measure
the temperature and valve lift when the thermostat
starts to open and the fully opens.
Thermostat initial opening

82 °C(180°F)
temperature
Thermostat full opening
95 °C(203°F)
temperature
95 °C(203°F) /
Valve lift
11mm(0.4331in)
• When thermostat has a QOS, attach water
temperature switch at area A.
Installation components Comments

Water temperature
switch for plug or QOS
A Apply Loctite 271
(specification for
including QOS)
HCW31CSH000201
3. O-ring
4. Gasket
• While pressing the thermostat housing against
the oil cooler, tighten the bolt on the water
pump side and afterwards tighten the bolt on
the oil cooler side.
A
PWW010SH029501
PWW010SH029401
6. QOS water temperature switch

39 (4.0/29)
39 (4.0/29)
20 (2.0/14)
HCW61CMF000101
Special Tools
1-8521-0067-0
Thermostat seal puller
1852100670
1-8522-1034-0
Thermostat seal setting
tool
1852210340
Water pump
Component Parts
11
10
4
9
1
7
3
2
HCW31CLF001001
Legend
1. Rear cover 7. O-ring
2. Bearing (small) 8. Shaft
3. Gear 9. Seal unit
4. Bearing (large) 10. Impeller
5. Oil seal 11. Front cover
6. Water pump body
Disassembly • Mount the impeller remover in the impeller, fix

the remover in place with a wrench while
1. Front cover
twisting the bolt and remove the impeller.
2. O-ring
3. Impeller
Impeller remover: 1-8521-0062-0
• Use the bench press from the gear side and
remove the shaft.
2
1
PWW010SH027401
4. Rear cover
PWW010SH027601
5. Bearing (small)
Legend
6. Gear
1. Bearing
7. Bearing (large) 2. Gear
8. Shaft
• Using a bench press, remove the shaft from the 9. Oil seal
impeller side with the bearing. 10. Seal unit
• Remove the oil seal. Take care not to damage
its press fit area.
• Remove the seal unit. Take care not to damage
its press fit area.
2
PWW010SH027501
HCW31CSH000101
Legend
1. Seal unit
2. Oil seal
11. Water pump body

Inspection Shaft
Impeller • Inspect the shaft for damage or wear.
• Inspect for corrosion of the impeller as well as for
wear or damage to the seal unit contact surface.
PWW010SH028001
PWW010SH027801
Assembly
Bearing 1. Water pump body
2. Oil seal
• Inspect the bearing for peeling, wear, or abnormal
noise • Apply engine oil to the inner side of the lip and
external area of the oil seal. Point the lip area
• Inspect the entire circumference of the race from
up and press fit it into the water pump body.
between the balls for damage or pealing.
Take care not to distort it.
• Inspect whether or not there is abnormal clearance
due to wear between balls and bearing race.
• Rotate the bearing on your hand to check for
abnormal noises.
PWW010SH028101
3. Bearing (large)
4. Shaft
PWW010SH027901 • Apply engine oil to the shaft, and press fit the
bearing onto the shaft using a bench press.
PWW010SH028201 PWW010SH028401
5. Shaft assembly 7. Bearing (small)

• Press fit the shaft assembly onto the water 8. Rear cover
pump body using a bench press. • Press fit the rear cover using a pipe that covers
the outer race (1) of the bearing, not to damage
NOTE: the rear cover.
Do not damage the oil seal.
1
PWW010SH028501
PWW010SH028301 9. Rear cover assembly

6. Gear • Press fit the rear cover assembly into the shaft
using a pipe that covers the inner race of the
• Place the gear long boss side with a large lip
bearing (small). At the same time, align the rear
facing the seal unit. Press fit the gear onto the
cover bolt tightening location.
shaft until reaching the bearing using the bench
press.
NOTE:
To prevent damage to the bearing, press fit the shaft NOTE:
end of the impeller insertion side. To prevent damage to the bearing and rear cover, press
fit the shaft end of the impeller insertion side.
Clearance between water pump body and impeller
1.7 – 2.7mm
standard:
(0.0669 – 0.1063in)
PWW010SH028601
10. Seal unit

2
• Using a setting seal, press fit the seal unit until
its guard portion reaches the water pump body.
NOTE:
Do not damage the seal unit.
PWW010SH028801
Seal unit setting tool: 1-8522-0047-0 NOTE:

To prevent damage to the bearing, press fit the shaft
end of the impeller insertion side.
12. O-ring
13. Front cover
1
2
PWW010SH028701
Legend
1. Setting tool
2. Seal unit
11. Impeller
• Using a bench press, press fit the impeller until
the clearance between the water pump body (2)
and impeller (1) reaches the specified value.
28 (2.9/21)
HCW61CMF000201
Special Tools
1-8521-0062-0
Impeller remover
1852100620
1-8521-0067-0
Sealing puller
1852100670
1-8522-0047-0
Seal unit setting tool
1852200470
1-8522-1034-0
Seal unit setting tool
1852210340
Engine Fuel (6WF1-TC) 1D-1
ENGINE
Engine Fuel
(6WF1-TC)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-2
Maintenance Precautions . . . . . . . . . . . . . . . . .1D-2
Description of Functions and Operation. . . . . . .1D-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . .1D-6
List of Trouble Symptoms . . . . . . . . . . . . . . . . .1D-7
Symptom: Difficult to start . . . . . . . . . . . . . . . . .1D-8
Symptom: Hunting during idle . . . . . . . . . . . . . .1D-9
Symptom: Insufficient output . . . . . . . . . . . . . .1D-10
Symptom: Engine maximum speed is too low . 1D-11
Symptom: Engine does not stop . . . . . . . . . . .1D-12
Symptom: Exhaust is blue or black . . . . . . . . .1D-13
Main Specifications . . . . . . . . . . . . . . . . . . . . .1D-13
Fuel pressure Sensor (Common rail) . . . . . . . . .1D-14
Component Parts . . . . . . . . . . . . . . . . . . . . . . .1D-14
Maintenance Precautions . . . . . . . . . . . . . . . .1D-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-15
Pressure limiter (Common rail) . . . . . . . . . . . . . .1D-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-17
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1D-17
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-18
Pre-fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-19
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1D-19
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-20
1D-2 Engine Fuel (6WF1-TC)
Fuel System
Maintenance Precautions 2. Handle fuel pipe and injection pipe in a manner
similar to 1.
Precautions for handling of fuel system
components 3. In order to prevent adhesion of foreign material to
the eyebolts or gaskets used for assembly of fuel
Compared to conventional systems, electronically pipe, store them neatly in a component box that
controlled fuel injection systems (common-rail type) has a lid. And clean the box containing the
have higher injection pressure and a higher degree of components on a periodic basis.
control. To realize these, holes and gaps that provide
passage for the fuel, including inside the injector, are 4. It is desirable to handle parts and perform
formed very precisely. assembly work without gloves or using rubber
Therefore, sensitivity with respect to foreign material is gloves; however, if use of cloth gloves is
higher than for conventional systems and the entry of necessary, check for filth and slivers frequently
foreign materials may lead to serious problem such as and always use a new pair of gloves.
vehicle failure on the road. Because of this, extreme 5. As fuel leak can cause fire, clean up fuel that has
care must be taken to avoid contamination. leaked after finishing work and check to make sure
there are not any fuel leaks after starting the
Work procedure engine.
1. Seal the fuel opening as quickly as possible after
removing the injector, supply pump, or common-
rail.
Fuel system
3
2
4
7
6
8 5
HCW61DMF000101
Legend
1. Common-rail 6. Feed pump
2. Fuel filter 7. Supply pump
3. Injector 8. Feed line
4. Pre-fuel filter 9. Return line
5. Fuel tank
Common-rail
HCW46DMF000101
Legend
1. Flow damper 3. Pressure sensor
2. Pressure limiter
Supply pump
2 3
4
1 5
11
10 9 8
HCW46BMF000301
Legend
1. Overflow valve 7. Fuel inlet: feed pump
2. Fuel outlet: to common-rail 8. Air bleeder
3. Pump control valve (PCV) 9. Cylinder identification sensor
4. Fuel inlet: pump body 10. Oil outlet
5. Priming pump 11. Oil inlet
6. Fuel output: feed pump
Injector
HCW46DLF000101
Legend
1. ID code plate 3. O-ring
2. Injector assembly
Air removal from fuel
1. Loosen eyebolt for fuel filter (shown by the arrow).
2. Run the priming pump until bubbles stop coming.
1 2 3
HCW40DSH000201
Legend
1. Air bleeder: supply pump
HCW40DSH000101 2. Supply pump
3. Priming pump
3. Loosen the supply pump air bleeder (1) and run
the priming pump until air bubbles stop coming.
4. Tighten the air bleeder.
NOTE:
Do not overtighten the air bleeder plug.
5. After tightening all of the plugs, run the priming

pump more than 150 times.
6. Tighten the priming pump in its initial position and
start the engine. If the engine will not start, repeat
from step 5.
• Difficult to start
• Hunting during idle
• Insufficient output
• Engine maximum speed is too low
• Engine does not stop
• Exhaust is blue or black
Symptom: Difficult to start

Starting difficulties Fuel tank is empty Fill the tank.
Breather for fuel tank is clogged Clean the breather for the fuel tank.
Air has found its way inside the fuel Remove the air.
system
Fuel line clogging or Repair or replace the fuel line.
damageLooseness of fuel line Tighten the connection.
connection
Fuel filter element is clogged Replace the element.
Feed pump failure Replace the feed pump.
Relief valve is open Replace the relief valve.
Adherence of injector nozzle Replace the injector.
Engine control system failure Diagnose the engine control
system.
Symptom: Hunting during idle

Hunting during idle Clogging of fuel tank breather Clean the fuel tank breather.
Air has found its way inside the fuel Remove air in fuel system.
system
Leak or blockage in fuel system Repair or replace the fuel system.
Water has found its way inside the Replace fuel.
fuel system
Fuel filter element is clogged Replace the fuel filter element.
Reduction of injector valve open Replace the injector.
pressure or failure of misting
conditions
Failure of the feed pump function Replace the pump.
Relief valve is open Replace the relief valve.
system.
Symptom: Insufficient output

Insufficient output Clogging of fuel tank breather Clean the fuel tank breather.
Air has found its way inside the fuel Remove air in fuel system.
system
Leak or blockage in fuel system Repair or replace the fuel system.
Water has found its way inside the Replace fuel.
fuel system
Fuel filter element is clogged Replace the element.
system.
Symptom: Engine maximum speed is too low

Engine maximum speed is too low Clogging of fuel tank breather Clean the fuel tank breather.
Fuel line clogging or damage Repair or replace the fuel line.
system.
Symptom: Engine does not stop

Engine does not stop Engine control system failure Diagnose the engine control
system.
Symptom: Exhaust is blue or black

Exhaust is blue or black Reduction of injector valve open Replace the injector.
pressure or failure of misting
conditions
system.
Main Specifications
Fuel pump specification
Engine type 6WF1-TC

Item
Electronically controlled fuel injection system (common-
Fuel injection
rail type)
Supply pump SP160 - 6HD
Pump maximum discharge amount 490mm3 / ST
Rotation direction Right when looking from the drive side
Pump sequence 1-2-1-2-1-2 (pump cylinder number)
Plunger diameter mm(in) φ8.5 (0.335)
2
kPa (kg/cm
Overflow valve opening pressure 255 (2.6 / 37)
/psi)
Feed pump With trochoid 10.5cm3/rev
Injector specifications
Item Specification
Injector DLL - P
Injection nozzle number mm(in) φ0.19 (0.0075) - 8
Fuel pressure Sensor (Common rail)

Component Parts
Common-rail
HCW46DMF000101
Legend
1. Flow damper 3. Pressure sensor
2. Pressure limiter
Maintenance Precautions • After replacement of any of the sensors, use the

scan tool to erase trouble codes and check if the
Maintenance precautions
sensor is operating correctly.
• Put cleansing fluid into a steam cleaner and
carefully clean around the sensors and common-
rail. Removal
• Remove water completely using compressed air. Fuel pressure sensor
• Confirm that foreign materials have all been • Remove the fuel pressure sensor (1) using a
removed before starting work. socket wrench (27 mm / 1.063in).
NOTE:
Do not re-use sensors that have been removed.
HCW46BSH001501
Installation
Fuel pressure sensor
• Apply grease(1) to the threads and seat area of the
sensor and then install it.
• Install the connector terminals so that the terminals
do not interfere each other.
NOTE:
Do not allow foreign material to stick to the threaded
area. In addition, make sure there is not foreign
material on the mounting area and then install the
sensor.
HCW31DSH000901
Pressure limiter (Common rail)

Removal
Pressure limiter
• Remove the pressure limiter using a socket
wrench (19 mm / 0.748in).
1
NOTE:
• Do not re-use sensors or gaskets that have been
removed.
• Do not damage the seat surface when taking off
the gasket.
1
HCW46BSH001401
Legend
1. Pressure limiter (socket width across flats of 19
mm / 0.748in)
HCW46BSH001401
Legend
1. Pressure limiter (socket width across flats of 19
mm / 0.748in)
Installation
Pressure limiter
• Install the pressure limiter (1) with a copper gasket.
NOTE:
• Confirm that there is not any foreign material on
the mounting area.
• Tighten the pressure limiter using the area with a
width across flats of 19 mm(0.748in)
Fuel filter
Component Parts
1
2
10
8 HCW31DMF000401
Legend
1. Center bolt 6. Water strainer
2. Air removal valve 7. Overflow valve
3. Upper cover 8. Drain valve
4. O-ring 9. Fuel filter body
5. Element 10. Center tube
Disassembly • Clean all of the fuel passages such as the

center tube and filter body etc.
1. Drain valve
• Loosen the drain valve and drain fuel inside the
filter. Inspection
2. Overflow valve Overflow valve
3. Plug for air removal • Inspect the over flow valve for clogging and for
4. Center bolt leakage from the ball seat.
5. Upper cover
6. O-ring 240 – 270kPa
Overflow valve
7. Element (2.55 – 2.75kgf/cm2 /
opening pressure:
8. Water strainer 36.26 – 39.1psi)
9. Center tube
10. Fuel filter body
HCW31DSH000301 HCW31DSH000401
8. Plug for air removal

Assembly 9. Overflow valve
10. Drain valve
1. Fuel filter body
2. Center tube
3. Water strainer
4. Element
5. O-ring
6. Upper cover
7. Center bolt
• Tighten the center tube onto the body and
insert the water strainer (with a spring) and
element (with a gasket).
• Insert an o-ring into the groove of the upper
cover and tighten the center bolt onto the
center tube.
NOTE:
Do not overtighten the center bolt.
Pre-fuel filter
Component Parts
7 5
HCW61DMF000201
Legend
1. Mounting head 5. Bowl
2. Gasket 6. Water in fuel sensor
3. Filter element(cartridge) 7. Drain valve
4. Gasket
Disassembly Inspection
1. Drain valve Bowl
• Open the bowl drain at bottom of the fuel • Check any damage or scratch on the bowl.
separator.
2. Water in fuel sensor Filter element
3. Filter element • Check dirt, break and distortion on the filter
4. Gasket element.
5. Bowl
Mounting head
6. Mounting head
• Check any clog in the through hole of mounting
a. Remove the bowl and the element from the head.
mounting head as a single unit.
b. Remove the element from the bowl. Gasket
c. Remove the gasket from the bowl and • The gasket of water separatror is exchanging at
mounting head. the time of decomposition.
Water in fuel sensor
• The wires red(+) and black(-) are connected to
24V DC.
• The yellow wire send a signal when electrode
perceives water.
• The signal stop at removal of water.
Voltage DC 24V
Resistance in fuel
Water in fuel MIN.220kΩ
(warniing OFF)
senso
Resistance in water
47 to 100kΩ
(warniing ON)
Assembly
NOTE:
Drain out water, when fuel filter will be covered with
water. If driving is continued not draining, there is a
possibilityof damaging a fuel injection system.
In addition,surely use the genuine filter for engine at the
time of element exchange.
1. Bowl
• Carefull clean the bowl and gasket grooves.
2. Gasket
• Apply a light coat of clean diesel fuel or engine
oil to the new gaskets.
• Carefull insert the gaskets into the gasket
grooves.
3. Filter element
• Screw the bowl into the new element with your
hand.
• Do not use a wrench.
4. Mounting head
• Screw the bowl and element assembly into the
mounting head with you hand until it is firmly
seated.
5. Drain valve
6. Water in fuel sensor
Engine Electrical (6WF1-TC) 1E-1
ENGINE
Engine Electrical
(6WF1-TC)
TABLE OF CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1E-2
Description of Functions and Operation. . . . . . . 1E-2
List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1E-3
Symptom: The starter motor does not start when the
starter switch is engaged . . . . . . . . . . . . . . . . . . 1E-4
Symptom: The pinion advances but does not engage
the ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-5
Symptom: The pinion engages the ring gear and the
motor starts, but the engine does not turn over . 1E-6
Symptom: The pinion engages the ring gear, but the
engine does not turn over . . . . . . . . . . . . . . . . . 1E-7
Symptom: The starter motor does not stop after the
engine starts and the starter switch is released . 1E-8
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1E-8
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-9
Component Parts . . . . . . . . . . . . . . . . . . . . . . . . 1E-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-10
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-15
Tightening Torque Table. . . . . . . . . . . . . . . . . . 1E-19
Charge System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-20
Maintenance Precautions . . . . . . . . . . . . . . . . 1E-20
Description of Functions and Operation. . . . . . 1E-20
List of Trouble Symptoms . . . . . . . . . . . . . . . . 1E-22
Symptom: The battery is not charged at all . . . 1E-23
Symptom: The battery is not fully charged. . . . 1E-24
Symptom: The battery is overcharged . . . . . . . 1E-25
Symptom: The charge current is unstable . . . . 1E-26
Symptom: The generator emits abnormal noises 1E-
27
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1E-27
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-28
Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1E-28
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-29
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-32
Bench Testing: . . . . . . . . . . . . . . . . . . . . . . . . . 1E-33
Tightening Torque Table. . . . . . . . . . . . . . . . . . 1E-34
1E-2 Engine Electrical (6WF1-TC)
Starting System
Handling Precautions
• The pinion and ring gear do not properly engage if
the clearance between them is too wide or too
narrow. (Clearance: 2 ~ 5 mm)
Also, be absolutely sure to install the front bracket
to the engine side.
• Disconnect the battery ground before removing or
installing the starter.
• Make sure wiring connections are tight and secure.
Loose wire raises electrical resistance and will
affect starter motor operation.
Starter Operating Precautions

• Be sure that the battery is fully charged before
starting the engine. A weak battery makes engine
starting difficult.
• Release the starter switch immediately after the
engine starts.
• Do not continuously operate the starter for more
that 10 seconds. Be sure that the pinion has come
to a complete stop before operating the starter
again.
• If the starter does not stop when the starter switch
is released, promptly disconnect the battery
ground. In such case, check the wiring and
switches.

Wiring circuit diagram (made by Mitsubishi)
Instantaneous current
321.4 A 24V 20 /68
Holding current
17.6A 24V 20 /68
Magnetic switch
Starter relay
B M
B S S
SW L
M
K.S
HCW61ESH000201
• The starter motor does not start when the starter
switch is engaged
• The pinion advances but does not engage the ring
gear
• The pinion engages the ring gear and the motor
starts, but the engine does not turn over
• The pinion engages the ring gear, but the engine
does not turn over
• The starter motor does not stop after the engine
starts and the starter switch is released
Symptom: The starter motor does not start when the starter switch is engaged

The starter motor does not start The battery is completely Replace the battery.
when the starter switch is engaged. discharged.
Wiring circuits are disconnected or Repair.
making improper contact.
The starter switch contact is not Repair or replace parts as
making proper contact or the necessary.
terminal is loose.
The starter relay contact or the Repair or replace parts as
plug-in terminals not making proper necessary.
contact.
The magnetic switch coil is shorted Replace.
or disconnected.
Symptom: The pinion advances but does not engage the ring gear

The pinion advances but does not The battery capacity is low. Charge the battery.
engage the ring gear. The teeth on the pinion or ring gear Replace the pinion/ring gear.
are worn.
Dust is adhering to the pinion shaft. Repair.
Symptom: The pinion engages the ring gear and the motor starts, but the engine does not
turn over

The pinion engages the ring gear The clutch is slipping. Replace the clutch or the starter.
and the motor starts, but the engine The reduction gear is broken. Replace the reduction gear or the
does not turn over. starter.
Symptom: The pinion engages the ring gear, but the engine does not turn over

The pinion engages the ring gear, The battery capacity is low. Charge the battery.
but the engine does not turn over. Wiring connections are loose at the Repair.
terminals.
The armature or field coil is shorted. Replace the starter.
The commutator is dirty. Clean the commutator or replace
the starter.
The brush spring is weak or the Replace the brush spring or the
brushes are worn. brushes.
The bearing is locked. Replace the bearing or the starter.
The magnetic switch contact is Replace the magnetic switch.
Symptom: The starter motor does not stop after the engine starts and the starter switch is
released

The starter motor does not stop The starter switch contact is not Replace the starter switch.
after the engine starts and the returning all the way.
starter switch is released. The starter relay contact is not Replace the starter relay.
returning all the way.
The magnetic switch coil is shorted. Replace the magnetic switch.
Main Specifications
Model (Manufacturer) Mitsubishi

Rating
Voltage (V) 24
Output (kW) 7.0
Time (sec) 30
Pinion teeth count 11
Rotational direction (see from pinion side) Clockwise
Weight (approx.) (kg/lb) 12.7 (28)
No-load characteristics
Voltage/Current (V/A) Max. 23.5 / 125
Rotational speed (rpm) Min. 3000
Load characteristics
Voltage/Current (V/A) 15.8 / 600
Torque N⋅m (kgf⋅m/lb⋅ft) Min. 52 (5.3 / 38)
Rotational speed (rpm) Min. 900
Locking characteristics
Voltage/Current (V/A) Max. 5 / 1,600
Torque N⋅m (kgf⋅m/lb⋅ft) Min. 117 (11.9 / 86)
Starter Motor
Component Parts
24 V 7.0 kW (made by Mitsubishi)
8
20
7
19
4
3
2
1
27
9
18
13
17
16
15
14
12 26
11
25
21
10 24
22
23 PWW010LF003401
Legend
1. Snap ring 15. Planetary gear
2. Stop ring 16. Ball
3. Pinion 17. Gasket
4. Pinion spring 18. Plate
5. Screw 19. Armature
6. Front bracket 20. Bearing
7. Bearing 21. O-ring
8. Magnetic switch 22. Yoke assembly
9. Lever 23. Brush
10. Overrunning clutch 24. O-ring
11. Internal gear 25. Brush holder
12. Washer 26. Rear bracket
13. E-type retaining ring 27. Through bolt
14. Gear shaft
Disassembly
NOTE:
• Before disassembling the starter, mark the mating
surfaces of the magnetic switch, yoke, front
bracket and rear bracket. This will make
reassembly easier. SW 1
• Remove the pinion first. Unless the pinion is SW 2
removed first, it becomes impossible to remove the
pinion later and thus the starter cannot be 24 V
completely disassembled.
However, the motor and magnetic switch can be
removed without removing the pinion.
1. Snap ring
2. Stop ring
3. Pinion
Remove the pinion. PWW010SH034601
• In the normal position, tapping the pinion or • Set a pipe the exact same diameter as the stop
stop ring towards the front bracket will break ring over the stop ring and tap the pipe with a
the front bracket. Therefore, tap on the stop hammer to loosen the stop ring in the direction
ring with the pinion in the cranking position. of the pinion.
• Connect the starter to the battery as shown in Then, remove the snap ring, followed by the
the illustration. stop ring, pinion and pinion spring.
Close switches SW1 and SW2. The pinion rises
to the cranking position and the armature NOTE:
rotates. The snap ring cannot be reused.
Open switch SW2 to stop armature rotation.
NOTE:
Do not take more than 10 seconds to remove the 5
pinion. Current flow through the starter for more than
10 seconds will cause overheating. 4
3 6
2
1
1 2 3
PWW010SH034701
Legend
1. Pinion
2. Clutch shaft
3. Snap ring
4. Stop ring
HCW31ESH000201
5. Pipe
Legend 6. Pinion spring
1. Snap ring
2. Stop ring 4. Pinion spring
3. Pinion gear 5. Screw
6. Magnetic switch
• Remove the nut from terminal M of the
magnetic switch and disconnect the lead wire
with terminal. 1
Then, remove the screws that hold the
magnetic switch and remove the magnetic 2
switch.
NOTE:
The screws are tight, so use a shock screwdriver to
loosen them.
3
5 4
HCW31ESH000401
Legend
1. Armature
2. Through bolt
3. Rear bracket
4. Brush holder
5. Yoke assembly
12. Brush holder

• Pull the brush spring up and remove the
HCW31ESH000301 brushes from the brush holder.
Then, remove the brush spring.
7. Screw
13. Armature
8. Through bolt
14. Ball
• Remove the screw that holds the brush holder
and the through bolt. • Remove the armature.
Next, remove the rear bracket. At the same The ball should fall free at the same time, but it
time, remove the O-ring. may get stuck in the grease.
The bearing can be removed with a general
NOTE: bearing puller.
The O-ring cannot be reused. 15. Plate
16. Gasket
9. Rear bracket
17. Planetary gear
10. Yoke assembly
• Remove the 4 planetary gears.
11. O-ring
• Pull out the internal gear, gear shaft,
• Place a socket (Outside diameter 38 mm /
overrunning clutch and lever together from the
1.4961in) over the commutator of the armature.
front bracket.
Then, slide the brushes over the socket and,
while holding the brushes there, remove the
yoke assembly.
At the same time, remove the O-ring.
Inspection
3 4 5 1. Armature
2
Growler test
1 • Use the Growler tester to check the armature coil
internally for shorting.
If a short is detected, replace the armature.
HCW31ESH000501
Legend
1. Overrunning clutch
2. Lever
3. Internal gear
4. Gear shaft
5. Planetary gear
HCW51ESH000701
18. Lever
• Remove the lever. Grounding
• Use a circuit tester to check the armature coil for
NOTE: grounding (insulation breakdown).
Remember the direction in which the lever faces. If grounding is detected, replace the armature.
19. E-type retaining ring

• Remove the 2 E-type retaining rings. Rotate the
spline of the overrunning clutch the distance of
1 tooth and remove the clutch from the gear
shaft assembly.
NOTE:
The E-type retaining rings cannot be reused.
20. Overrunning clutch

21. Internal gear
22. Washer
• Remove the internal gear. At the same time,
remove the 1 washer that is used to adjust gear
shaft play in the axial direction.
23. Gear shaft
24. Front bracket HCW51ESH000801
25. Bearing (20)

26. Brushes
27. Bearing (7)
Commutator Bearing
• Check the commutator outside diameter for wear. • Check the bearing for abnormal noises, rattling
If wear exceeds the specified limit, replace the and grease leaks.
armature. If anything abnormal is detected, replace the
bearing.
2. Field coil
Continuity
• Use a circuit tester to check the field coil for
disconnection.
If a disconnection is detected, replace the yoke
assembly.
HCW51ESH000901
• Check the depth (undercut) of the commutator

insulation mold(a).
Clean the brush to remove abrasive particles and
other foreign material. Inspect the brush. Repair
the brush if any abnormal conditions are present.
HCW51ESH001101
Grounding
1 a • Use a circuit tester to check the field coil for
2 grounding (insulation breakdown).
If grounding is detected, repair or replace the yoke
assembly as necessary.
HEW61ESH001201
Legend
1. Insulation mold
2. Commutator segment
3. Bad
4. Good
Gear
• Check the gears for wear and damage. HCW51ESH001201
If significant wear or damage is detected, replace
the armature.
3. Brushes
• Check brush length for wear.
If brushes on the brush holder side are worn close
to the specified limit, replace the entire brush
holder assembly. With brushes on the yoke
assembly side, replace only the brushes.
• Check the brushes rotate smoothly inside the
brush holder.
Check brush spring pressure.
• Use a circuit tester to check the brush holder for
grounding (insulation breakdown).
Clean the brush holder before making the check.
Touch one probe of the circuit tester to the brush
holder plate (metal part) and the other to insulated
points of the holder. If there is continuity, insulation
has broken down, so replace the brush holder
assembly.
HCW51ESH001401
5. Front bracket
2
• Check the bearing and the oil seal. If anything
abnormal is detected, replace the front bracket
1 assembly together with the bearing and oil seal.
6. Internal gear and planetary gear

• Check the gear teeth for abnormal wear and
damage. If abnormal wear or damage is detected,
replace the internal gear or planetary gear.
7. Lever
• If parts are worn because of rubbing with the
overrunning clutch, the pinion protrusion position
can be affected.
To adjust the pinion protrusion position, refer to the
HEW61ESH001301
assembly procedure.
Legend
1. Brush longth
2. Insulated portion of brush holder
4. Overrunning clutch and pinion

Overrunning clutch
• Hold the overrunning clutch by its housing and turn
the pinion by hand. The pinion should rotate with
slight resistance in one direction and not at all in
the other. If it does not, replace the overrunning
clutch.
Check the pinion for wear and damage. If
detected, replace the pinion.
NOTE:
The overrunning clutch is internally charged with
grease, so if washed in cleaning fluid or grease HCW31ESH001201
removing detergent, the grease may run. Therefore,
wipe dirt of the clutch with a rag.
8. Magnetic switch
• Check continuity between terminal M (4) and the
body. If there is no continuity, replace the magnetic
switch.
Also, there must not be continuity between
terminal B (2) and terminal M (4).
If there is continuity, replace the magnetic switch.
4
HCW51ESH000301
Legend
1. Magnetic switch
2. Terminal B
3. Terminal S
4. Terminal M
Assembly
The starter can be reassembled by following the
disassembly steps in reverse order, but observe the
following precautions.
NOTE:
Replace the following parts with new parts.
• Snap ring (Holds the stop ring in place.)
• E-type retaining ring
• O-ring (On both yoke gaskets and all screws)
1. Lubrication is needed in the following locations.
Use MULTEMP 0A-171 (Kyodo Yushi) for parts
numbered 1 to 6 in the illustration, and
MOLYCOAT R-AG650 (Dow Corning) for parts
numbered 7 to 9 in the illustration.
3 4 5 6
9 8 7
HCW51EMF000101
Legend
1. Armature bearing outside surface (Apply very 6. Pinion (Lower side)
sparingly.) 7. Lever and overrunning clutch sliding parts
2. Plunger (Apply very sparingly.) 8. Sleeve bearing and ball
3. Gear shaft spline and sliding parts 9. Armature shaft gear, planetary gears and internal
4. Clutch shaft sliding parts gear
5. Oil seal
2. Tightening torque • Fit the washer, internal gear and overrunning

For tightening torque, refer to the Tightening clutch over the gear shaft.
Torque Table. Then, slide the overrunning clutch along the
3. Armature shaft play in the axial direction spline the distance of one tooth, make sure the
overrunning clutch does not come off and
• No adjustment is required. Install the ball to the
attach the E-type retaining rings.
end of the shaft.
4. Gear shaft play in the axial direction
• One washer in-between the internal gear and
gear shaft is all that is needed to establish the
required clearance.
2 3
1
2
5
1
3
4
5
HCW51ESH001501 HCW31ESH001401
Legend Legend
1. Washer 1. Pinion
2. Gear shaft 2. Clutch shaft
3. E-type retaining ring 3. Snap ring
4. Internal gear 4. Stop ring
5. Overrunning clutch 5. Pinion spring
5. Pinion installation 6. Pinion Protrusion Position Check

• Install the pinion before installing the magnetic After assembling the starter, check the pinion
switch to the front bracket. protrusion position.
Install the pinion spring, pinion and stop ring to Measure and adjust as follows.
the clutch shaft in that order, then firmly press • Connect the starter to the battery as shown in
the snap ring into the groove on the clutch the illustration.
shaft. Close switches SW1 and SW2. The pinion rises
Then, pull the stop ring to the stop ring side with to the cranking position and the armature
a gear puller, and secure both parts. rotates.
Open switch SW2 to stop armature rotation.
SW 1 B
S SW 2
M
24 V
PWW010SH036001
• Lightly press the end of the crankshaft with your NOTE:
hand, allow it to return and measure the return Use wire of sufficient thickness and make sure
distance of the crankshaft. connections are tight.
If 0.5 ~ 2.0 mm(0.0197 ~ 0.0787in) , it is OK. If
the return distance is outside this range, adjust
the number (2 or less) of gaskets (0.5 mm/
0.0197 in thickness) in-between the magnetic
switch and the front bracket or replace the
lever. 2
A SW B
S
1
M
3
V
PWW010SH036201
Legend
1. Battery
2. Ammeter
3. Voltmeter
HCW31ESH001501
7. No-Load test • Close the switch and read the rotational speed,
current and voltage. Then, compare readings
• After adjusting the pinion protrusion position,
against specifications.
connect the starter and measuring instruments
If readings do not meet specifications,
as shown in the illustration.
disassemble and inspect the starter again.
8. Specifications
Item Standard/Limit
Voltage (V) 23.5
No-load characteristics Current (A) Max. 125
Rotational speed r/min Min. 3000
Outer diameter mm(in) 38.7(1.5236)
Commutator
Wear limit mm(in) 38.1(1.5000)
Undercut mm(in) 0.8(0.0315)
Commutator
Limit mm(in) 0.2(0.0079)
Length mm(in) 23(0.9055)
Brushes
Wear limit mm(in) 12(0.4724)
Pressure N(lb) 33 – 45(7.4200 – 10.1181)
Brush spring
Limit N(lb) 20(4.4969)
Pinion protrusion position mm(in) 0.5 – 2.0(0.0197 – 0.0787)
Starter
6 (0.6/52 )
23 (2.3/17)
3 (0.3/26 )
10 (1.0/87 )
HCW61EMF000101
Charge System
Maintenance Precautions • Disconnect the battery terminal before charging
the battery from the outside using a quick charger,
Observe the following precautions when handling the
etc.
generator.
• Do not use steam or water to clean the generator.
• If the battery is connected backwards, the
generator diodes will be damaged. • After wiring, tighten terminal B and terminal E to
the below tightening torque.
• Do not disconnect the battery terminals or
Terminal B : 6 N⋅m (0.6kgf⋅m / 52lb⋅in)
charging circuit wires with the engine running.
Terminal E : 4 N⋅m ( 0.4kgf⋅m / 35lb⋅in)
• Be absolutely sure that terminal wires match the
• To adjust V-belt tension, refer to “Belt Adjustment.”
terminal labels.
• Do not perform a Megger test to check the
semiconductor devices. Description of Functions and Operation
• Always disconnect the negative battery terminal
when inspecting the generator.
Generator cross-section
3
2
1 4
10
6
8 7
HCW31EMF000201
Legend
1. Rectifier 6. Front bracket
2. Stator 7. Coil assembly
3. Rotor 8. Rear bracket
4. Bearing 9. IC regulator
5. Pulley 10. Bearing
Charging circuit
Stator coil
0.5 F
Key
1.8W 24V SW
R
Battery
24V
E
Field coil
R L
N
IC Regulator
HCW61EMF000201
Generator construction and functions

• This generator is brushless.
The major parts are the rotor, stator, rectifier
assembly, front bracket, rear bracket, IC regulator,
bearing and pulley.
• It uses 8 main diodes to change the 3-phase AC
generated by the stator coil to DC. Of these 8
diodes, 4 are positive diodes and 4 negative
diodes.
Moreover, it uses 3 small diodes, referred to as the
“diode trio”, to supply field current.
This generator has 3 terminals: B (DC output), L
and R.
Terminal L is connected to the field coil, so
together with Terminal R, it functions as the initial
excitation current input terminal until the generator
starts generating power.
It also functions as an output terminal.(Current
capacity is 1 A.)
When Terminal L voltage reaches the battery
voltage, the charge lamp goes out.
• The battery is not charged at all
• The battery is not fully charged
• The battery is overcharged
• The charge current is unstable
• The generator emits abnormal noises
Symptom: The battery is not charged at all

The battery is not charged at all. The battery is dead. Replace.
Wiring or the ammeter is Repair.
disconnected, shorted or making
improper contact.
A generator coil is disconnected, Replace.
grounded or shorted, or a diode is
damaged.
The regulator is broken. Replace.
The regulator terminal is not Repair.
connected or loose.
Symptom: The battery is not fully charged

The battery is not fully charged. The battery is dead. Replace.
Wiring is disconnected, shorted or Repair.
The generator drive belt is loose. Adjust belt tension.
There is a layer short in the stator Replace.
coil.
A diode is damaged. Replace.
A terminal is not making proper Repair.
contact.
connected or loose.
Symptom: The battery is overcharged

The battery is overcharged. The regulator is broken. Repair.
Symptom: The charge current is unstable

The charge current is unstable. Wiring is disconnected, making Repair.
improper contact or about to
disconnect.
The generator drive belt is loose. Adjust belt tension.
A stator coil is about to short or Repair.
disconnect.
A terminal is not making proper Repair.
contact.
connected or loose.
Symptom: The generator emits abnormal noises

The generator emits abnormal The belt is loose. Adjust belt tension.
noises. The bearing is damaged. Replace the bearing.
The rotor core and stator core are Repair.
making contact.
A diode is damaged. Replace.
A stator coil is about to short or Replace.
disconnect.
Main Specifications
Nominal output (V - A) 24 - 50 24 - 60
Rated rotational speed (rpm) 5000 5000
Regulator type IC
Regulated voltage (V) 28.0 to 29.0
Weight (kg/lb) 9.7 (21.4) 15 (33.1)
Mitsubishi Electric Mitsubishi Electric
Generator
Component Parts
10
8
7
5 13 14
4 12
11
3
2
1
15
16
17
18
19
22
23
24
25
26
20
21
27
HCW31ELF000101
Legend
1. Nut 15. Screw (for installing clamp)
2. Spring washer 16. Clamp
3. Pulley 17. Screw (for tightening coil assembly)
4. Through bolt 18. Screw (for installing regulator)
5. Screw (for tightening retainer) 19. Rear bracket
6. Front bracket 20. Screw (for installing connector)
7. Front bearing 21. Connector assembly
8. Retainer 22. Rectifier
9. Rotor 23. Regulator
10. Rear bearing 24. Plate (L)
11. Terminal B bolt 25. Screw (for tightening regulator)
12. Terminal B tightening nut 26. Stator
13. Terminal B nut (bolt) 27. Coil assembly
14. Terminal B cap
Disassembly
• This section gives only important points.
NOTE:
Before disassembling the generator, mark the mating
surfaces of the front bracket and rear bracket. This will 1
make reassembly easier.
1. Front and rear brackets

• Remove the 4 through bolts, insert the tip of a
screwdriver between the stator and the front
bracket, and very carefully pry the front bracket
from the rear bracket.
2
NOTE:
Be careful not to damage the stator coils.
HCW31ESH001701
4 3. Bearings
3 • If the front bearing must be removed, remove
2 the retainer tightening screws and push the
bearing free with a suitable socket.
1
• If the rotor bearing must be removed, remove it
with a typical bearing puller.
NOTE:
Do not remove the bearing unless necessary. The
bearing cannot be reused once removed.
8
4. Coil assembly
7 • To remove the coil assembly from the rear
bracket, first remove screw A (locks the coil
6
terminal to the IC regulator).
5
HCW31ESH001601 If screw B (holds the coil assembly to the rear
bracket) is removed before removing screw A, it
Legend may damage the terminals.
1. Pulley Support the coil assembly by hand to prevent
2. Front bracket damage to the terminals.
3. Front bearing Then, remove screw B and remove the coil
4. Rotor assembly.
5. Coil assembly
6. Stator
7. Rectifier
8. Rear bracket
2. Rotor
• Anchor the rotor in a vice being careful not to
deform the rotor balls.
Remove the pulley tightening nut, and remove
the pulley, fan, spacer and front bracket.
NOTE:
Grip the rotor in the vice at part (2). Do not grip the rotor
at part (1) as it is structurally weak.
4
1
1
3
2
HCW61ESH000401 HCW51ESH000501
Legend Legend
1. Connector 1. IC regulator
2. Screw A 2. Terminal bolt
3. Screw B 3. Terminal B
4. Terminal B
5. Terminal B assembly
Inspection
• Remove the connector and clamp.
Generator inspection and repair
• Remove the cap and nut from the rectifier
terminal bolt. Stator
Pry between the rear bracket and terminal B • Visually check for damage, loose connections and
assembly and remove the terminal B assembly. coil discoloration.
The tube remains on the rear bracket. • Use a circuit tester to check continuity between the
two stator coil lead wires (1).
NOTE:
If there is no continuity, replace the stator.
Do not lose the tube.
6. Rectifier assembly
• Remove the 1 rectifier tightening screw and the
2 regulator tightening screws.
Pull the stator and rectifier assembly together
from the rear bracket.
Then, remove the IC regulator. 1
• Disconnect the 4 stator coil lead wires and
remove from the stator rectifier.
NOTE:
The stator coil lead wires are soldered (230 ºC / 446°F
melting point specification) to the rectifier terminals.
Heat from the soldering iron will damage the diodes if
applied for too long a time. Work as quickly as possible
using a 180 to 270 W soldering iron to disconnect the
lead wires. Do not apply heat to any connection for
more than 5 seconds. PWW010SH034001
• Use a circuit tester to check continuity between the Rectifier assembly
stator coil lead wire (1) and core (2). • Use a circuit tester to check continuity between the
If there is continuity, replace the stator. 4 positive diodes and their respective terminals.
If there is continuity in both directions, the positive
diode is shorted, so replace the rectifier assembly.
If there is no continuity in either direction, positive
diode is open, so replace the rectifier assembly.
• Negative diode
Use a circuit tester to check continuity between the
1
4 negative diodes and their respective terminals.
If there is continuity in both directions, the negative
diode is shorted, so replace the rectifier assembly.
If there is no continuity in either direction, the
negative diode is open, so replace the rectifier
assembly.
• Diode Trio (3 Small Diodes)
2 Use a circuit tester to check continuity in both
directions.
If there is continuity in both directions or no
continuity in either direction, the diode is damaged,
PWW010SH034101
so replace the rectifier assembly.
Rotor
• Check the bearing for abnormal noises, rattling
and grease leaks (small quantities may be wiped 1
up). If anything abnormal is detected, replace the
bearing. It is easer to check for abnormal noises
and rattling when the bearing is press-fitted onto
the shaft rather than separated.
Coil assembly
• Use a circuit tester to measure resistance between
the two terminals of the terminal unit.
If outside the specified range, replace the coil
assembly.
3
2
PWW010SH034301
Legend
1. Positive diode
2. Diode terminals
3. Negative diode unit
HCW31ESH001901
NOTE:
Be careful not to overtighten.
4. Rear bracket, stator assembly and front bracket

rotor assembly installation
• The rotor bearing and rear bracket fit tightly
together, so heat the rear bracket bearing box
to 50 – 60 ºC(122 –140°F)before assembling
parts together.
• After reassembling the generator, turn the
pulley by hand and check that the rotor rotates
smoothly.
HCW31ESH002001
Front bearing
• Check the bearing for abnormal noises, rattling
and grease leaks (small quantities may be wiped
up). If anything abnormal is detected, replace the
bearing.
It is easer to check for abnormal noises and rattling
when the bearing is press-fitted onto the bracket
rather than separated.
Regulator
• The regulator cannot be checked with a circuit
tester.
After reassembling the generator, test the
generator and check the regulator controls
generator voltage.
Assembly
The generator can be reassembled by following the
disassembly steps in reverse order, but observe the
following precautions.
1. The bearings are charged with grease and sealed
when manufactured, therefore lubrication is
unnecessary.
NOTE:
The rotor shaft bearing has a lubrication band. Do not
apply further grease or oil. If oil is detected on the rear
bracket bearing box, it can cause creeping, so wipe it
completely off.
2. Use high temperature (230°C/446°F melting point

specification) solder.
Use a soldering iron of 180 to 270 W and quickly
(approx. 5 sec max) perform work, being careful
not to overheat the rectifier.
3. Tightening torque for parts
Refer to the tightening torque table.
Bench Testing:
Generator bench test Output current
The output current test determines whether the
generator outputs the rated current or not.
• After checking voltage regulation, lower generator
speed and stop the generator.
• Close switch 1. The lamp should light.
SW1
Ampere meter
• Set variable resistance to the highest value
Volt meter Lamp(24V) (minimum current), and close switch 2.
(3W ) SW2
• Raise the generator rotational speed, and, with
speed maintained at 5,000 rpm, adjust variable
Battery
(24V)
resistance so that output current is the maximum.
Generator
Run the generator in this state for 15 minutes to
Resistor
raise generator temperature.
15 minutes later, set generator rotational speed so
that it matches the specified speed (2,500 and
5,000 rpm). Then, adjust variable resistance in this
state so that output current is the maximum.
If the ammeter indication is within the specified
HCW61ESH000301
range at this time, the generator is operating
correctly.
Voltage regulation
If it is outside the specified range, recheck the
• Connect the circuit as shown in the above generator as explained in “Inspection”.
diagram.
Use an ammeter of a rated 100 A and a voltmeter Specifications
of a rated 30 V. ACG50 specifications
Use a variable resistor of a rated 50 A or higher.
• Close switch 1. Open switch 2.
At this point, the lamp should light. Rotational 2500rpm 5000rpm
If it does not light, check terminal L voltage. speed
If voltage is near to the battery voltage, check the O u t p u t Voltage 27V 27V
generator. characteristics
If voltage is low, the lamp or lamp circuit is (when hot) Current Min. 42 A Min. 50 A
disconnected.
Field coil resistance
• Gradually raise generator rotational speed. 4.4 – 5.2Ω
(At 20 °C)
Check that the lamp goes out before reaching
about 1,300 rpm. Regulator regulated voltage 28 – 29V
Watch the voltage. If voltage cannot be kept below Rotational direction
30 V, the IC regulator may be damaged. Clockwise
(See from pulley side)
If voltage does not exceed battery voltage, the
generator is not generating power.
Check the generator again.
If the lamp does not light, check the generator
again.
• Run the generator to about 5,000 rpm and read the
ammeter.
If 5 A or less, read the indication of the voltmeter.
This is the regulated voltage.
If the ammeter indicates 5A or more, either
continue charging until current drops below 5A or
replace the battery with a fully charged battery.
If the regulated voltage is outside the specified
range, replace the regulator.
4 (0.4/35 )
5 (0.5/43 )
6 (0.6/52 )
147 (15.0/108)
4 (0.4/35 )
4 (0.4/35 )
4 (0.4/35 )
HCW61ELF000101
Engine Exhaust (6WF1-TC) 1G-1
ENGINE
Engine Exhaust
(6WF1-TC)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . .1G-2
Maintenance Precautions . . . . . . . . . . . . . . . . .1G-2
Description of Functions and Operation. . . . . . .1G-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . .1G-3
List of Trouble Symptoms . . . . . . . . . . . . . . . . .1G-4
Symptom: Exhaust system vibration and/or rattle1G-
5
Symptom: Clogging in exhaust system . . . . . . .1G-6
Symptom: Exhaust leakage and noise. . . . . . . .1G-7
Tightening Torque Table. . . . . . . . . . . . . . . . . . .1G-7
Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1G-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1G-8
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1G-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1G-8
Exhaust brake valve . . . . . . . . . . . . . . . . . . . . . .1G-10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .1G-10
1G-2 Engine Exhaust (6WF1-TC)
Exhaust System
Maintenance Precautions Description of Functions and Operation
Looseness and vibration in the exhaust system is The exhaust brake assembly adjusts exhaust
possibly due to mis-location at time of assembly. pressures and assists braking.
Provisionally secure bolts until positioning of all The silencer is a box shape and has a built-in catalyst
components is complete and then tighten the bolts from converter.
the engine side to the rear pipe side. The main components are the exhaust brake, front
exhaust pipe, silencer assembly and rear exhaust pipe.
HCW51GMF000201
Legend
1. Exhaust valve 3. Front exhaust pipe B
2. Front exhaust pipe A 4. Silencer assembly
• When inspecting or repairing the exhaust system,
confirm that there is sufficient clearance between
the floor and the body.
• Damage caused by overheating or vibration of
body panels can lead to penetration of exhaust gas
into the vehicle cabin.
• Inspect the connection for looseness and damage
well as exhaust gas leakage.
• Inspect the clamps and rubber for deterioration,
cracks, and damage.
• If pipes or the silencer are damaged or dented,
repair or replace the damaged part(s).
• Inspect for dents, damage or holes and cracks
caused by corrosion as well as abnormal noise
during operation.
• Exhaust system vibration and/or rattle
• Clogging in exhaust system
• Exhaust leakage and noise
Symptom: Exhaust system vibration and/or rattle

Exhaust system vibration and/or Loosening or misalignment of Re-tighten after mating
rattle components connections. Also, inspect hangers,
mounting brackets, and clamps for
damage.
Symptom: Clogging in exhaust system

Clogging in exhaust system Exhaust brake is ON Inspect the exhaust brake throttle
valve shaft for misalignment and if
any abnormalities are found,
replace the shaft. Refer to the
Engine Control System for
inspection of the electrical system
and perform repairs as needed for
any abnormalities.
Clogging and deformation of Repair or replace the exhaust pipe
exhaust pipe
Symptom: Exhaust leakage and noise

Exhaust leakage and noise Mounting failure or misalignment Re-tighten after mating
connections.
Breakdown or burnout of exhaust Replace the failed components.
pipes or silencer
Exhaust system component failure Replace the failed components.
(clamp, pipe, silencer)
Silencer internal damage Replace the silencer.
59 (6.0/43)
108 (11/80)
108 (11/80)
108 (11/80)
HCW61GMF000101
Exhaust pipe
Removal
1. Remove the rear exhaust pipe.
• Remove the clamp and then remove the rear 1
exhaust pipe.
2. Remove the front exhaust pipe A.
2
3. Remove the front exhaust pipe B.
4. Remove the exhaust valve.
5. Remove the silencer.
4 3
6
5
Inspection
• Damage caused by overheating or vibration of
body panels can lead to penetration of exhaust gas
into the vehicle cabin.
• Inspect the connection for looseness and damage
well as exhaust gas leakage. HCW31GSH001501
• Inspect the clamps and rubber for deterioration,
Legend
cracks, and damage.
1. Exhaust valve
• Inspect the pipe and silencer for dents and cracks 2. Front exhaust pipe
caused by corrosion and if there is any damage, 3. Nut
repair or replace the damaged part(s). 4. Washer
5. Gasket
6. Exhaust duct
Installation
NOTE: 2. Install the silencer.
• Looseness and vibration in the exhaust system is • Fix the silencer in place using a band on the
possibly due to mis-location at time of assembly. bracket and tighten.
Provisionally secure bolts until positioning of all
components is complete and then tighten the bolts
from the engine side to the rear pipe side. Tightening torque: 20N⋅m (2.0kgf⋅m/14lb⋅ft)
• Do not re-use gaskets or nuts that have been 3. Install the front exhaust pipes A and B.
removed. • Install front exhaust pipe B onto A, install them
to the silencer and tighten to specified torque.
1. Install the exhaust brake assembly.
• Using the exhaust duct stud as the guide,
assemble a gasket, install the front exhaust Tightening torque: 108N⋅m (11.0 kgf⋅m/80lb⋅ft)
pipe, and tighten to specified torque.
NOTE:
Tighten the front exhaust pipe evenly and make sure
there are not any gas leaks.
2 3
HCW51GSH000501
Legend
1. Front exhaust pipe A
2. Front exhaust pipe B
3. Silencer assembly
4. Bolt and nut
5. Bolt and nut
4. Install the rear exhaust pipe onto the silencer

assembly.
2 3
HCW51GSH000401
Legend
1. Bracket
2. Rear exhaust pipe
3. Silencer assembly
Exhaust brake valve

Adjustment
Valve adjustment
• Loosen the full-open stopper bolt and fix the
stopper bolt in a position that is withdrawn at least
1 mm(0.0394 in) from the free state of the control
cylinder shaft and tighten the lock nut to the
specified torque.
Confirm that the valve and flange surfaces are
vertical.
2
If they are not vertical, return the stopper bolt to the
back, loosen the control cylinder assembly bolt,
1
and perform a readjustment.
HCW31GSH001301
Legend
1. A, valve gap
1 2. B, valve gap
• Clearance between valve and body with valve

closed
* Measure while pushing the valve with your hand
from the direction of the gas.
90 Item Standard value mm(in)

2 A, B Greater than 0.1(0.0039)
0.1 – 0.25
(A + B) / 2
(0.0039 – 0.0098)
HCW31GSH001201
Legend
1. Stopper bolt (full-open)
2. Stopper bolt (full-close)
Full-close stopper bolt

• Adjust the stopper bolt such that the clearance
between valve and body is within the standard
value when compressed air is sent and the valve is
fully closed. Tighten the lock nut to specified
torque.

Engine Lubrication (6WF1-TC) 1H-1
ENGINE
Engine Lubrication
(6WF1-TC)
TABLE OF CONTENTS
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . .1H-2
Maintenance Precautions . . . . . . . . . . . . . . . . .1H-2
Description of Functions and Operation. . . . . . .1H-2
Main Specifications . . . . . . . . . . . . . . . . . . . . . .1H-3
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-5
Component Parts . . . . . . . . . . . . . . . . . . . . . . . .1H-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-6
Partial oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-8
Partial Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . .1H-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-8
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-9
Oil pan and Oiling jet. . . . . . . . . . . . . . . . . . . . . .1H-10
Component Parts . . . . . . . . . . . . . . . . . . . . . . .1H-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Tightening Torque Table. . . . . . . . . . . . . . . . . .1H-13
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-14
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1H-14
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-16
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1H-19
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1H-21
1H-2 Engine Lubrication (6WF1-TC)
Lubrication System
Maintenance Precautions • Always overlap the start and end of the liquid
gasket coat.
• Every time the lubrication system is disassembled,
completely remove the old liquid gasket from all
locations that use liquid gasket using a scraper Description of Functions and Operation
and clean off all oil, water and adhering matter
using a rag. Then, newly apply the specified liquid The lubrication system employs a filter element
gasket to each location. integrated with full flow bypass, water-cooled oil cooler
and oiling jet for piston cooling.
• Apply the appropriate amount of liquid gasket
being careful not to add too much or too little. If too
much liquid gasket is applied, the oil gallery and
oiling jet can clog, leading to the engine seizure. If
too little applied, oil and water can leak.
Lubricant flow chart
Cylinder block Cylinder block left hand oil gallery

right hand oil gallery
Oil press.
Cylinder head unit Supply
&switch
pump
Oil filter Main oil Partial Turbo
relief valve filter oil filter charger
Cam shaft Idle gear Idle Idle Bearing
journal oiling jet
A gear B gear C case
(2.5)
Oil cooler Rocker Relief

arm Crank
shaft valve shaft
journal
Oil thermo Rocker

Cam shaft arm
valve journal Crank pin
&valve
(1.3 4.6)
Connecting
rod bush
Oil Relief valve
pump
Strainer
Oil pan
HCW61HLF000301
Oil pump
8 9
2
11 10
PWW010LF003601
Legend
1. Oil pump body 7. Oil pump cover
2. Oil pump drive gear 8. Relief valve
3. Ball 9. Split pin
4. Driven gear 10. Spring seat
5. Drive gear 11. Spring
6. Driven gear
Main Specifications
Item Specification
Lubrication Forced circulation
Item Specification
Type Geared(timing gear drive)
154 (Pumping speed: 3,200 rpm, pumping pressure:
Amount discharged (L/min)
Oil pump 540 kPa [5.5 kgf/cm2/ 78 psi])
Relief valve opening kPa (kg/cm2/
690 (7/100)
pressure psi)
kPa (kg/cm2/
Oil gallery relief valve opening pressure 440 (4.5/64)
psi)
Main oil filter type Full flow filter paper
Main oil filter bypass valve opening
kPa (kg/cm2/
pressure (Oil pressure differential between 196 (2/28)
psi)
intake and outlet)
Oil cooler type 6-stage water-cooled, multi-plate
Oil thermostat opening temperature (°C/°F) 103 (217)
Oil pan (L/Imp.gal) 17 – 23.5 (3.74 – 5.17)
Engine oil level
Full capacity (L/Imp.gal) 22 – 28.5 (4.84 – 6.27)
Maintenance standard
Nominal
standard limit
Item dimension
mm(in) mm(in)
mm(in)
0.050 – 0.098
Clearance between oil pump body lining and gear 0.15
— (0.002 –
tooth tip (0.0059)
0.0039)
0.040 – 0.094
Clearance between oil pump cover and gear — (0.0016 – —
0.0037)
φ20 φ19.9
Oil pump Driven gear shaft outside diameter —
(0.7874) (0.7835)
0.040 – 0.074
Clearance between driven gear shaft and pump body — (0.0015 – —
0.0029)
0.019 – 0.047
Interface between drive gear shaft and drive gear — (0.0007 – —
0.0019)
Oil filter
Component Parts
13
11
10
12
8
5
2
1 7
4
PWW010LF004101
Legend
1. Drain plug 8. O-ring
2. O-ring 9. Oil filter warning switch
3. Center bolt 10. Gasket
4. O-ring 11. Spring
5. Oil filter case 12. Valve
6. Spring 13. Bracket
7. Element
Disassembly 3. Center bolt

1. Drain plug 4. O-ring
2. O-ring 5. Oil filter case
• Loosen the drain plug and drain the oil from the 6. Spring
filter. 7. Element
8. O-ring
• Loosen the center bolt and detach the case, Tightening torque: 43N⋅m (4.4kgf⋅m/32lb⋅ft)
spring, element and O-rings.
• Clean inside the case.
PWW010SH038701
PWW010SH038501 2. Valve
9. Oil filter warning switch 3. Spring
10. Gasket 4. Gasket
11. Spring 5. Oil filter warning switch
12. Valve • Install the valve and spring in the body case
13. Bracket and install the switch.
• Clean the valve and the oil channel in the
bracket. Tightening torque: 78N⋅m (8.0kgf⋅m/58lb⋅ft)
PWW010SH038601
PWW010SH038801
6. Oil filter case

Assembly 7. O-ring
1. Bracket • Apply engine oil to the O-ring and fit it in the
• Fit the O-rings in the two locations and install groove in the case.
the bracket.
NOTE:
• Be careful not to damage the O-ring.
• Be careful not to overtighten the center bolt.
HCW31HSH000501
8. Center bolt
9. O-ring
10. Spring
11. Element
• Insert the center bolt into the case from below
and fit the spring and element over the bolt from
above.
• Install the case so that the drain plug faces to
the rear of the engine.
Tightening torque
Center bolt: 49N⋅m (5.0kgf⋅m/36lb⋅ft)
PWW010SH039001
12. O-ring
13. Drain plug

Partial oil filter

Partial Oil Filter
2
1
7
PWW010LF004201
Legend
1. Drain plug 6. Spring
2. Gasket 7. Element
3. Center bolt 8. Gasket
4. Gasket 9. Bracket
5. Oil filter case
Disassembly 3. Install the plug with new gasket and tighten to the
specified torque after draining.
1. Remove the drain plug.
Discard the gasket.
2. Drain the engine oil in the oil filter. Tightening torque: 44 N⋅m (4.5 kgf⋅m/33 lb⋅ft)
4. Remove the center bolt.
Discard the gasket.
Gasket
Drain plug
PWW010SH039101 PWW010SH039301
5. Remove the filter case. 3. Install the new element in the case and tighten the
Discard the element. center bolt to the specified torque.
Clean the filter case inside. • Install the filter case with the drain plug faced
6. Remove the bracket. rear.
Discard the gasket.
Clean the oil passage of the bracket.
Tightening torque: 98 N⋅m (10.0 kgf⋅m/72 lb⋅ft)
7. Clean the oil passage of the center bolt.
Drain plug
PWW010SH039201 PWW010SH039401
Reassembly
1. Install the bracket with the new gasket to the
cylinder block.
Tighten the fixing bolts to the specified torque.
Tightening torque: 43 N⋅m (4.4 kgf⋅m/32 lb⋅ft)

2. Apply engine oil to the gasket and install it into the
groove of the filter case.
Oil pan and Oiling jet

Component Parts
9 2
7 HCW61BLF000801
Legend
1. Oiling jet assembly 6. Oil pipe bracket
2. Oil strainer bracket 7. Rubber spacer
3. Oil pan gasket 8. Oil strainer
4. Oil pan 9. O-ring
5. Breather hose clip
Removal 5. Oil pan gasket

Oil Pan and oiling jet disassembly procedure 6. Oil strainer
1. Rubber spacer 7. Oil strainer bracket
2. Oil pipe bracket 8. O-ring
3. Breather hose clip 9. Oiling jet assembly
4. Oil pan
Installation 5. Oil pan gasket
1. Oiling jet assembly 6. Oil pan
• Set the projection on the oiling jet assembly into • Apply Three Bond 1207B liquid gasket to the
the positioning hole in the cylinder block, and cylinder block, flywheel housing and gear case
lock in place by tightening the joint bolts to the seam face (1) to a thickness and width of abut 3
specified torque.(x 6) –4 mm(0.1181 –0.1575in).
HCW31BSH012401
• Install the oil pan through the gasket and

HCW31BSH021201 tighten in the clockwise from (1) or (2).
• Lastly, tighten (1) or (2) to the specified torque.
NOTE:
Handle the oiling jet pipe carefully as it deforms easily. Tightening torque: 38N⋅m (3.9kgf⋅m/28lb⋅ft)
2. O-ring
3. Oil strainer bracket
4. Oil strainer
• Fit the O-ring onto the oil strainer and tighten
20
parts in the sequence indicated in the 1
illustration.
Tightening torque: 49N⋅m (5.0kgf⋅m/36lb⋅ft) Front 21
36
3
2
6 HCW61HSH000401
5 7. Oil pipe bracket

• Tighten the oil pan bracket with oil pan.
2 3
1 8. Breather hose clip
• Tighten the oil pan bracket with oil pan.
HCW31BSH012201
HCW61HSH000301
Legend
1. Oil pan
2. Breather hose clip
3. Oil pipe bracket
9. Rubber spacer
69(7.0/51)
49(5.0/36)
38(3.9/28)
HCW61HLF000401
Oil pump
Component Parts
2
3
11
10 4
7
9
6
8 5
HCW31HLF001501
Legend
1. Cover 7. Split pin
2. Ball 8. Oil pump drive gear
3. Oil pump cover 9. Spring seat
4. Driven gear 10. Spring
5. Drive gear shaft 11. Oil relief valve
6. Oil pump body
Disassembly 6. Oil relief valve

1. Cover • Pull out the split pin and remove the spring
seat, spring and oil relief valve.
2. Ball
3. Split pin NOTE:
4. Spring seat When the split pin is pulled out, the spring may pop out,
5. Spring so be careful not to loose it.
Inspection
Oil relief valve
• Check the oil relief valve and spring for damage.
PWW010SH036301
7. Oil pump drive gear

• Use a gear puller to remove the drive gear.
PWW010SH036701
Driven gear
• Measure the clearance between the pump body
lining and gear.
Clearance between body lining and gear
0.050 – 0.098mm
standard:
(0.002 – 0.0039in)
Measure the clearance between the body lining

and drive gear.
PWW010SH036401
8. Oil pump cover

9. Driven gear
10. Drive gear shaft
11. Oil pump body
RUW20ASH000501
• Measure the clearance between the oil pump Measure the outside diameter and clearance on
cover and gear. the drive gear side.
Clearance between oil pump cover and gear
0.040 – 0.094mm
standard:
(0.001 – 0.0037in)
PWW010SH037001
• Measure the interface between the shaft and the

drive gear.
Interface
PWW010SH036901
• Measure the outside diameter of the driven gear 0.019 – 0.047mm

standard:
shaft and the clearance between the shaft and the (0.0007 – 0.0019)
pump body.
Nominal standard limit

mm(in)
Shaft
φ20 φ19.9
outside —
(0.7874) (0.7835)
diameter
Clearance
0.04 – 0.074
between
— (0.0016 – —
shaft and
0.0029)
pump
PWW010SH037101
Assembly
1. Oil pump body
2. Drive gear shaft
3. Oil pump drive gear
• Apply engine oil to the drive gear shaft and
install it in the body.
• With the drive gear facing as shown in the
illustration, press fit the drive gear onto the
shaft until the end face of the gear is level with
shaft end face.
PWW010SH037401
6. Oil relief valve

7. Spring
PWW010SH037201 8. Spring seat
Legend 9. Split pin
1. Drive gear • Apply oil to the oil relief valve, spring and spring
2. Drive gear shaft seat, install in the given order and lock in place
with the split pin.
4. Driven gear
• Apply engine oil to the driven gear and install it
on the pump body.
PWW010SH037501
10. Ball
11. Cover
PWW010SH037301
5. Oil pump cover

• Install the oil pump cover.
Tightening torque
M10: 39N⋅m (4.0kgf⋅m/29lb⋅ft)
M8: 18N⋅m (1.8kgf⋅m/13lb⋅ft)
Oil pump operation test
• After the pump has been assembled, turn the drive
gears by hand and check they rotate smoothly.
PWW010SH037601
18 (1.8/13)
18 (1.8/13)
39 (4.0/29)
HCW61HMF000101
Oil cooler
Component Parts
2
5
6
7
8
3
4
9
10
11
HCW31HLF001601
Legend
1. Water guide 7. Oil thermo valve support
2. Oil cooler element 8. Spacer
3. Gasket 9. Oil thermo valve
4. O-ring 10. O-ring
5. Body case 11. Oil pipe
6. Seal ring
Disassembly
1. Water guide
2. Oil cooler element
3. O-ring
4. Gasket
Oil Cooler Element Cleaning Inspection
• Pour cleaning fluid into the element and let Oil cooler element
soak for about 10 hours. After that, drain about
• Inspect the oil cooler element for cracks.
1/3 of the cleaning fluid and inject compressed
air of approx. 196 kPa (2 kgf/cm2/28psi) from • Perform a red check as necessary.
the oil port to drain the rest of the cleaning fluid.
Repeat this operation several times as needed
until removing element dirt.
CAUTION:
Use the cleaning fluid in a ventilated room void of open
flames and heat sources. Wear protective goggles and
a mask when handling the fluid.
Use in undiluted Diluted with

form kerosene
High Arom 2S
{ —
(Nippon Oil)
Swasol 310
{ —
(Maruzen)
PWW010SH037701
Hisol (Showa
{ — Oil thermo valve
Shell)
Mobilsol A • Inspection of the oil thermo valve for clogging and
— { damage
(Mobile)
Inspect the piston and valve seat face for wear and
damage.
Also, inspect the spring for damage and decay.
• Oil thermo valve operating test
Check the valve opens between 96.5 and 99.5 °C
(205.7and 211.1°F) .
Oil thermo valve 96.5 – 99.5 °C

opening temperature: (205.7 – 211.1°F)
PWW010SH037701
5. Oil pipe
6. O-ring
7. Oil thermo valve
8. Spacer
9. Oil thermo valve support
10. Seal rings
11. Body case
PWW010SH037801
Assembly • Insert the O-ring and install the oil pipe.
1. Body case Tightening torque: 39N⋅m (4.0kgf⋅m/29lb⋅ft)
2. Seal rings
3. Oil thermostat support
• Install the seal ring being careful of which way it
faces.
3
PWW010SH038301
8. Gasket
9. O-ring
PWW010SH038101 10. Oil cooler element
Legend • Apply ThreeBond 1208 to the two O-ring
1. Seal ring grooves on the case and attach the O-rings.
2. Turn stopper Then, assemble the gasket onto the element
3. Oil thermo valve support and install it on the case.
• Align the turn stopper and install the oil thermo
valve (2).
PWW010SH038401
PWW010SH038201
11. Water guide
4. Spacer
5. Oil thermostat
6. O-ring
7. Oil pipe
39 (4.0/29)
50 (5.1/37)
78 (8.0/58)
39 (4.0/29)
69 (7.0/51)
39 (4.0/29)
88 (9.0/65)
43 (4.4/32)
43 (4.4/32)
43 (4.4/32)
HCW61HLF000201
Engine Speed Control System (6WF1-TC) 1I-1
ENGINE
Engine Speed Control System
(6WF1-TC)
TABLE OF CONTENTS
Accelerator pedel Assembly . . . . . . . . . . . . . . . . . 1I-2
Component Parts . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
1I-2 Engine Speed Control System (6WF1-TC)
Accelerator pedel Assembly

Component Parts
3
6
HCW31BMF004901
Legend
1. Nut 4. Accelerator pedal
2. Accelerator sensor 5. Bolt
3. Controller link and bracket assembly 6. Accelerator switch
Removal NOTE:
1. Remove the mounting nut for the controller link • Make sure to perform learning of the accelerator
and bracket assembly. pedal using a scan tool after adjusting the
accelerator pedal.
2. Remove the mounting bolt for the accelerator
pedal. • Refer to the Engine Control System for adjustment
of the accelerator sensor, accelerator switch, and
3. Remove the accelerator switch connector and
accelerator pedal.
harness connector to the accelerator position
sensor.
NOTE:
For removing the harness connector, remove battery
ground.
Installation
1. Install the harness connector.
2. Mount the accelerator pedal installation bolt.
3. Install the controller link and bracket assembly.
Induction (6WF1-TC) 1J-1
ENGINE
Induction
(6WF1-TC)
TABLE OF CONTENTS
Supercharge System. . . . . . . . . . . . . . . . . . . . . . . 1J-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1J-2
Description of Functions and Operation. . . . . . . 1J-2
List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1J-3
Symptom: When there is an abnormality or vibration
1J-4
Symptom: The turbocharger is considered to be
functioning normal but output has dropped . . . . 1J-5
Symptom: Oil leak in exhaust pipe or intake pipe or
exhaust turns white . . . . . . . . . . . . . . . . . . . . . . 1J-6
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1J-6
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-7
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-7
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-9
Component Parts . . . . . . . . . . . . . . . . . . . . . . . . 1J-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-10
Air cleaner element . . . . . . . . . . . . . . . . . . . . . . . 1J-11
Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1J-11
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J-11
1J-2 Induction (6WF1-TC)
Supercharge System
Maintenance Precautions • When replacing the turbocharger, after installing
the new turbocharger, pour in 3 to 5 cc engine oil
• As the turbocharger is manufactured and
and then attach the oil pipe.
assembled very precisely (approximately 100,000
rpm), it cannot be disassembled. If an abnormality
is found, replace the turbocharger assembly. Description of Functions and Operation
• When removing and attaching the turbocharger,
seal the turbine housing, compressor housing, oil
fill inlet, and oil drain to prevent intrusion of foreign
material.
Turbocharger
6 7 12
5
4 8
9 13
3 11
10
14
15
22 21 20 19 18 17 16
HCW31JMF000301
Legend
1. Nut 12. Piston ring
2. Insert 13. Turbine housing
3. Oil deflector 14. Shaft and Turbine wheel
4. Compressor housing 15. Turbine back plate
5. Snap ring 16. Bearing housing
6. O- ring 17. Bearing
7. Snap ring 18. Thrust ring
8. Thrust bearing 19. Sleeve
9. Thrust ring 20. O- ring
10. Bolt 21. Piston ring
11. Snap ring 22. Compressor wheel
• When there is an abnormality or vibration
• The turbocharger is considered to be functioning
normal but output has dropped
• Oil leaks into exhaust pipe or intake pipe
Exhaust turns white
Symptom: When there is an abnormality or vibration

When there is an abnormality or Cause is bearing failure or contact Inspect and replace.
vibration between rotating parts and
peripheral parts.
Failure to change oil, intrusion of
foreign material in the oil fill pipe,
driving while the oil filter is clogged
or damaged, and repeated starting
and stopping of vehicle movement
can cause damage to the bearing.
If there is no abnormality in the oil Inspect and replace.
lubrication system and damage
caused by contact between rotating
parts and peripheral parts is found,
it is likely that the rotating part is out
of balance or that the shaft is bent.
This is caused by use of a worn
bearing or damage to the turbine
wheel or compressor wheel due to
air borne foreign materials.
Symptom: The turbocharger is considered to be functioning normal but output has
dropped

The turbocharger is considered to Exhaust gas leakage Repair or replace.
be functioning normal but output Excessive exhaust resistance due Repair or replace.
has dropped to deformation of the exhaust pipe
muffler or carbon deposits
Air leakage from the discharge side Clean or replace.
of the compressor or air cleaner
getting dirty
Inside of compressor is dirty Clean.
Rotor shaft is dirty Inspect and replace.
Symptom: Oil leak in exhaust pipe or intake pipe or exhaust turns white

Oil leaks into exhaust pipe or intake Rise in oil level due to oil separator Clean or replace.
pipe being dirty or clogged
Exhaust turns white Oil drain pipe being clogged, Repair or replace.
crushed, or deformed
Piston ring wear or excessive wear Replace.
of piston ring grooves
Piston ring damage caused by Repair or replace.
bearing failure
Main Specifications
Maintenance standard
Nominal
standard limit
Maintenance item value Comments
mm(in) mm(in)
mm
0.075 – 0.11 0.12
Play in the axial direction of the shaft — —
(0.003 – 0.0043) (0.0047)
0.117 – 0.20 0.24
Gap in the rotational direction of the shaft — —
(0.0046 – 0.0079) (0.0094)
Turbocharger
Inspection
Visual/listening inspection
• Abnormal noise
Check if the turbocharger is generating abnormal
noises while running.
• Scratch or cracking
Check for any scratch marks or cracking caused
by contact between the compressor housing or
turbine housing and fins.
• Oil leak
Check for oil leakage from the seal area.
NOTE:
Confirm there are no causes for oil leakage by the
engine.
If there is a possibility of oil being leaked from the oil
separator, inspect the oil separator after releasing the HCW41JSH000401
blowby gases to the atmosphere.
• Measurement of clearance in the axial direction of
• Shaft rotation failure the shaft
Turn the shaft by hand and make sure it is not mis- Place a dial gauge on the end of the shaft and
aligned and that it does not catch. measure the clearance in the axial direction.
Measurement of bearing wear Clearance mm(in)

• Measurement of clearance in the rotational
direction of the shaft
Place a dial gauge on the shaft and measure the standard 0.075 (0.003) – 0.11 (0.0043)
clearance in the direction of rotation. limit 0.12 (0.0047)
Clearance mm(in) NOTE:

As there is oil remaining in the bearing, push the gauge
with a fair amount of force and then make the
standard 0.117 (0.0046) – 0.20 (0.0079) measurement.
limit 0.24 (0.0094)
NOTE:
As there is oil remaining in the bearing, push the gauge
with a fair amount of force and then make the
measurement.
HCW41JSH000201
CAUTION:
As the turbocharger cannot be disassembled, replace
the assembly if there is an abnormality.
Intercooler
Component Parts
HCW31BLF007701
Legend
1. Rubber hose 2. Intercooler assembly
Removal
• Remove the rubber hose.
• Remove the intercooler.
HCW51BSH002701
Installation
1. Mount the intercooler to the radiator.
NOTE:
When attaching or removing, do not damage the fins.
2. Fully insert the rubber hose until its guard portion

reaches the pipe and fix in place with two clips.
1
2
HCW31BSH062901
Legend
1. Intercooler pipe
2. Rubber hose
3. Clip
4. 5 mm(0.1969 in) from the end of the hose
Air cleaner element

Component Parts
HCW30ELF000101
Legend
1. Indicator 3. Cover
2. Element 4. Valve
Inspection
Dust indicator inspection
• Visually inspect the dust indicator and when the
surface is red, push the button to return it to normal
status and inspect the element.
HCW310SH000201 HCW31BSH057701
Inspect the element for breakdown and damage. Cleaning of element

• Insert a light into the element to inspect whether or When dirty with dry dust (from sandblast etc.).
not there are any damaged or thin areas in the
• Clean by blowing compressed air from the inside
element.
of the element.
NOTE:
Do not clean by hitting or striking the element.
Do not exceed air pressure of 690 kPa (7.0 kgf/cm2/
100psi).
HCW31BSH057601
• Inspect the water drain valve at the lower side of

the air cleaner to make sure it is not clogged.
HCW310SH000101
When dirty with oily smoke (soot etc.).

• Dissolve cleanser in water and soak the element in
this for approximately 20 minutes. Next, rinse the
element well using tap water etc. After cleaning let
air dry (2 to 3 hours) without heating.
Do not clean by hitting or striking the element.
Do not exceed water pressure of 275 kPa (2.8 kgf/cm2/
40psi).
HCW31BSH057501
MEMO
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Pre-Heating System (6WF1-TC) 1K-1
ENGINE
Pre-Heating System
(6WF1-TC)
TABLE OF CONTENTS
Preheating System . . . . . . . . . . . . . . . . . . . . . . . . 1K-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1K-2
Description of Functions and Operation. . . . . . . 1K-2
Functional Inspection . . . . . . . . . . . . . . . . . . . . . 1K-3
List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1K-5
Symptom: Glow indicator lamp does not turn on1K-6
Symptom: Preheating does not work . . . . . . . . . 1K-7
Symptom: Preheating period is either too long or too
short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1K-8
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1K-8
1K-2 Pre-Heating System (6WF1-TC)
Preheating System
Overtightening glow plugs can cause damage to them.

A QOS II system is being used for the preheating
system. Also, the controller is timer controlled.
Functional Inspection
Inspection and correction of QOS II • If the results of the measurement show that the
1. System inspection resistance value is outside specifications,
replace the glow relay.
• Disconnect the connector of the thermo switch
Glow relay resistance value = approximately
(1).
51.5Ω
4 1
4 3
2 2 1
3
HCW31KSH000601
HCW31KSH000101
• Connect a voltmeter between the glow plug and
• Installation location of glow relay (1): inside
engine ground.
center of instrument panel
• Turn the ignition switch to ON (without starting
engine) and check for the following items.
- The glow indicator turns on for 3.5 seconds.
- The voltmeter indicates the power supply
voltage for approximately 18 seconds.
• If there are any abnormalities with the
inspection, inspect the glow relay, thermo
switch and the glow plugs. If normal, inspect 1
the engine control system.
HCW31KSH000801
3. Inspection of thermo switch
HCW31KSH000201
2. Inspection of the glow relay

• Using a circuit tester, measure the resistance
value (between 1 and 2) of the glow relay.
• As a thermo-ferrite switch is used, the test
passes if continuity is found while testing with a
circuit tester with temperature above 20 ºC.
Operating temperafure
3 (37.4 F)
ON(Close)
Coolant temperature
(Open)OFF
10 3
Coolant temperature
(50 5.4 F)
HCW61KSH000201
4. Inspection of the glow plug

• Measure the resistance value of the glow plugs
using a circuit tester.
• If the results of the measurement show that the
resistance value is outside specifications,
replace the glow plug.
Glow plug resistance value = approximately

4.3Ω (normal temperature)
NOTE:
Use a 6 piece set of glow plugs from the same
manufacturer.
HCW31KSH000501
• Glow indicator lamp does not turn on
• Preheating does not work
• Preheating period is either too long or too short
Symptom: Glow indicator lamp does not turn on

Glow indicator lamp does not turn Slow blow fuse melts Replace the slow blow fuse.
on. Fuse blows Replace the fuse.
Burnout of indicator valve Replace the indicator valve.
Symptom: Preheating does not work

Preheating does not work. Slow blow fuse melts Replace the slow blow fuse.
Connection failure of the glow relay Re-install or replace the glow relay.
connector
Symptom: Preheating period is either too long or too short

Preheating period is either too long Thermo-switch failure or open or Replace the thermo-switch. Repair
or too short. short in the circuit the circuit.
Glow plug failure Replace or tighten the glow plug.
Main Specifications
Item Model
Pre-heat equipment model Glow plug QOS timer
Glow plug rated voltage and current 23V - 3.0A
Power Take-Off (PTO) (6WF1-TC) 1L-1
ENGINE
Power Take-Off (PTO)
(6WF1-TC)
TABLE OF CONTENTS
Engine Rear PTO . . . . . . . . . . . . . . . . . . . . . . . . . 1L-2
Description of Functions and Operation. . . . . . . 1L-2
Component Parts . . . . . . . . . . . . . . . . . . . . . . . . 1L-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-5
1L-2 Power Take-Off (PTO) (6WF1-TC)
Engine Rear PTO

P.T.O.
5
3
14
15 12
13
11
10 9
HCW3Z0LF000101
Legend
1. Bolt 9. Taper roller bearing
2. Washer 10. O-ring
3. Oil seal 11. Spacer
4. Bearing case 12. Shim
5. P.T.O. gear 13. Oil thrower
6. P.T.O. Shaft 14. O-ring
7. Nut 15. Flange
8. Lock washer
Component Parts
17
1 16
15
14
13
12
11
10
9
8
7
6
5
4 18
3
2
1
19
27
26
25
24
23 28
22
21
20
HCW3Z0LF000201
Legend
1. P.T.O. assembly 15. P.T.O. gear
2. Bolt 16. Lock washer
3. Washer 17. Nut
4. Flange 18. Idle gear cover
5. O-ring 19. Bolt
6. Oil seal 20. Bolt
7. Oil thrower 21. Nut
8. Bearing (rear) 22. Lock washer
9. Shim 23. Bearing (rear)
10. Spacer 24. Inner spacer
11. P.T.O. Shaft 25. Outer spacer
12. Bearing case 26. Bearing (front)
13. Bearing (front) 27. Idle gear spindle
14. O-ring 28. Idle gear
Disassembly 1. P.T.O. assembly

• After loosening the flange bolt, remove the 24. Bearing (rear)
P.T.O. assembly. 25. Inner spacer
2. Bolt 26. Bearing (front)
3. Washer 27. Outer spacer
4. Nut 28. Idle gear
• Place the flange in a vise and loosen the nut.
5. Lock washer
Inspection
6. P.T.O. gear
Bearing
7. Flange
• Inspect the whole circumference of the inner race,
8. O-ring
outer race, and rollers for damage or peeling.
9. Oil seal
• Inspect the roller and inner race for signs of wear
10. Oil thrower (looseness).
11. P.T.O. Shaft • Rotate the inner race and outer race together to
• Lightly tap the shaft with a hammer to remove check if they make abnormal noise or if they
the shaft. produce an uneven or scraping feeling.
12. Bearing (front)
13. Bearing (rear)
14. Shim (2 pieces)
15. Spacer
16. O-ring
17. Bearing case
18. Bolt
19. Idle gear cover
• Screw a bolt (M18 / P1.25) into the replacer
hole and extract.
20. Nut
21. Lock washer
22. Bolt
23. Idle gear spindle
• Screw a sliding hammer (M20 / P1.5) into the HCW3Z0SH001001
spindle and extract.
• Remove the idle gear assembly through the
P.T.O. mounting opening.
HCW3Z0SH001101
HCW3Z0SH000901
P.T.O. gear NOTE:
• Inspect the teeth surfaces for peeling, damage and • Apply engine oil to the bearing prior to assembly.
wear. • Press fit the outer race until it is in full contact with
• Inspect the spline for damage and wear. the spacer.
• Do not reverse the procedure for press fitting the
bearing outer race.
• Install the bearing inner race (7) onto the idle

gear on the housing side.
NOTE:
Use the bearing inner race and outer race in pairs.
3
4
2
5
HCS21BSH001101
6
1
7
Idle gear
• Inspect the teeth surfaces for peeling, damage and
wear.
• Inspect the inner surface for damage.
HCW3Z0SH000101
• With the discriminative groove (1) pointed

towards the rear of the engine, insert into the
P.T.O. installation opening of the flywheel
housing.
HCW3Z0SH001201
Assembly
Assembly of the idle gear
1. Bearing
• Insert the outer spacer (4) into the idle gear (3) HCS21BSH000801
using pliers.
2. Idle gear spindle
• Press fit the bearing outer race (2) by pressing
the discriminative groove (1) end in first.
• Press fit the bearing outer race (5).
• Attach the idle gear spindle (9) to the flywheel • Insert an O-ring into the idle cover and tighten with
housing and tighten the bolt (8) to the specified a bolt.
torque.
Tightening torque: 221N⋅m (22.6kgf⋅m/163.5lb⋅ft)
Assembly of the P.T.O.
1. P.T.O. Shaft
• Insert the P.T.O. gear (3) into the P.T.O. shaft
(4). Insert the lock washer (2) and tighten with
the nut (1) (width across flats - 65 mm) to the
specified torque.
9
8 Tightening torque: 294N⋅m (30.0kgf⋅m/217lb⋅ft)
NOTE:
Do not clamp P.T.O. shaft directly in a vise.
Mount the P.T.O. flange, hold the flange in place using
a vice and tighten.
HCW3Z0SH000201
• Insert the inner spacer (13) and press fit the

bearing inner race (10).
• Insert the lock washer (12) and tighten the nut
(11) to the specified torque.
1
2
Tightening torque: 147N⋅m (15kgf⋅m/108lb⋅ft)
NOTE: 3
• Press fit the bearing inner race (10) until it is in full 4
contact with the spacer.
• To maintain a clearance (0 ~ 0.05 mm) in the axial
direction, when replacing the bearing, replace as
an assembly. HCW3Z0SH000401
2. Bearing case
• Mount O-rings (5) in the bearing case (4).
• Press the bearing outer race (3) and (6) onto
the bearing case.(1),(2)
NOTE:
13 Press fit the bearing outer race until it comes into full
12 contact with the bearing case.
11
10
HCW3Z0SH000301
2 3
1 1
5
2
6
3
HCW3Z0SH000501 HCW3Z0SH000701
• Press fit the bearing inner race (2) onto the

P.T.O. shaft (3). Clearance adjustment in the axial direction
• Insert the oil thrower (3), flange (2) and washer (1)
NOTE: onto the P.T.O. shaft and tighten the bolt to the
Press fit the bearing inner race until it comes into full specified torque.
contact with the gear.
• Integrate the P.T.O. shaft (3) with the bearing Tightening torque: 343N⋅m (35.0kgf⋅m/253lb⋅ft)
race (1).
NOTE:
Do not tighten the bolt completely at once, spread
tightening out over several times. Between each time,
turn the P.T.O. shaft by hand to make sure that it turns
smoothly.
1 2 3
1 2 3
HCW3Z0SH000601
• Insert the spacer (1) and shim (2) into the

P.T.O. shaft and press fit the bearing inner race
(3) on the back end until it fully contacts (1) and
(2).
HCW3Z0SH000801
NOTE:
Apply engine oil to the bearing prior to assembly. • Measure the clearance in the axial direction using
a dial gauge.

0.01 – 0.07mm
Clearance in axial direction:
(0.0004 – 0.0028 in)
• If the clearance is not within specification, replace

the shim or spacer and adjust the clearance so
that it is within the standard value.
Adjustment shim and spacer types
Thickness Difference in
2
mm(in) thickness
mm(in)
3.50 – 3.60 1
0.01
Adjustment shim (0.1378 –
(0.0004)
0.1417)
17.95 – 19.45
0.25 HCW3Z0SH001401
Spacer (0.7067 –
(0.0098)
0.7657)
P.T.O. assembly
Assembly after adjustment of clearance in axial • Apply a thin layer of engine oil on the bearing case
direction O-ring and mount it onto the flywheel housing.
• Loosen the flange bolt and remove the flange
again. Tightening torque: 49N⋅m (5.0kgf⋅m/36lb⋅ft))
• Apply ThreeBond TB1212 to the circumference of
the oil seal.
Apply a light layer of engine oil to the lip area and
press fit.
• Mount O-rings (3) onto the back end of the P.T.O.
shaft.
2
1
1 3
HCW3Z0SH001501
HCW3Z0SH001301
• Mount the flange, insert a washer (with beveled

side (1) toward shaft) and tighten to the specified
torque.
HG6WFCG2-WE-0661
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all

countries except the USA and Canada.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Apr. 2006 6604-01K

No. HG6WFCG2-WE-0661 PRINTED IN JAPAN

Isuzu Engine 6WF1-TC Commanrail Workshop Manual

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WORKSHOP MANUAL

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on latest product

This Manual is applicable to 2006 year model and later vehicles.

SECTION No. CONTENTS

Removal of glow plugs

Measurement of compression pressure

Item Compression Difference between

Adjustment of valve clearance

HCW31BSH009301 Adjustment of valve clearance

Increase in rate at which engine oil is consumed

Increase in rate at which fuel is consumed T

Abnormal noises inside the engine

3. Insert the thickness gauge between the rocker arm

4. With the thickness gauge still inserted, tighten the

Valve clearance mm(in) (when cold)

0.40(0.016) for both intake and exhaust

Valve clearance adjustment table

New product When tension is

Adjustment of generator drive belt tension

Adjustment of A/C compressor drive belt tension 1

1. Loosen the bolt and nut shown in the illustration.

Deflection amount when the center between the

3. Tighten the bolt and nut.

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

4. Drain off the cooling water.

7. Oil level gauge

14. A/C compressor 20. Sub tank hose

15. Generator wires

29. Engine mounting

Front tightening torque: N⋅m (kgf⋅m/lb⋅ft)

Rear tightening torque: N⋅m(kgf⋅m/lb⋅ft)

Tightening torque: 39N⋅m (4.0kgf⋅m/29lb⋅ft)

12. Engine harness connector

18. Cab back member

Tightening torque: 155N⋅m (15.8kgf⋅m/114lb⋅ft))

13. Oil pressure switch

Tightening torque: 20N⋅m (2.0kgf⋅m/14lb⋅ft))

20. Air cleaner assembly

21. Mud guard

Tightening torque: 59N⋅m (6.0kgf⋅m/43lb⋅ft))

25. Radiator hose 27. Pour in the cooling water.

29. Exhaust pipe

Inspections and adjustments after installation

Engine Accessory Parts

5. V-belt (for generator)

Tightening torque: 103N⋅m (10.5kgf⋅m/76lb⋅ft)

Tightening torque: 20N⋅m (2.0kgf⋅m/14lb⋅ft)

3. Oil pipe (power steering oil pump)

Tightening torque: 58N⋅m (5.9kgf⋅m/43lb⋅ft)

Engine Exterior Parts

3. Water pipe: Air leak

11. Air pipe: EGR valve:

12. Water pipe: EGR valve (IN)

14. EGR valve:

18. Fuel filter and bracket

22. Supply pump