Mitsubishi 6d24 Workshop Manual PDF

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Mitsubishi 6D24
/barringtondieselclub.
Work5hupi\lanual
00
GENERAL
■
CONTENTS
1. E X T E R N A L V IE W ............ 2 4. KEY P O IN T S FOR

2. M A J O R S P E C IF IC A T IO N S ....................... 3 M A IN T E N A N C E W O R K .............................. 5
2.1 M ajor Specifications .............................. 3 5. G E N E R A L BO LTS A N D N U T S
2.2 Engine O utputs Classified by T IG H T E N IN G T O R Q U E T A BLE ................ 12
Application ......................................... 3
3. E N G IN E N U M B E R A N D C A U T IO N
PLATE ............................................... 4
00-1
https://barringtondieselclub.co.za/
00 GENERAL - EXTERNAL VIEW
1. EXTERNAL VIEW
Natural-aspirated engine
A0244A
00-2
GENERAL - MAJOR SPECIFICATIONS 00
2. MAJOR SPECIFICATIONS
2.1 Major Specifications
------^ E n g in e m odel 6D24 6D24-T 6D24-TC 6D24-TL
Item
Type Diesel, 4-cycle, w ater-cooled
C o m b u stio n m ethod Direct injection
No. and arrangem e n t of 6 , in-line

cylinder
Cylinder bore x stroke 130x150

mm
Total displacem ent 11945

cm 3
E ngin e dim e nsion

(with fan)
Overall length mm 1473 1473 1473 1473
Overall w idth mm 866 881 881 869
Overall height mm 1058 1169 1209 1246
Em p ty w eigh t kg* 905 930 960 940
* Em p ty w eigh t as m e asure d according to M itsu b ish i M o to rs Corporation standard.
2.2 Engine Outputs Classified by Application
^ --------- E n g in e m odel 6D24 6D24-T 6D24-TC

T urbocharged Turbocharged
with Aftercooler
Engin e
Application \ ^ e d rpm
intermittent rated 1500 114(115} 163 {222} 182(247}

output kW (PS)
1800 136(185} 191 {260} 207{282}
2000 144(196} 201 {273} 217(295}
2200 151 {205} 206(280} 228(310}
C on tinu ou s rated 1500 104(141} 148 { 202} 165(224}

output kW (PS)
1800 124(168} 174(236} 188(256}
2000 131 {178} 182 {248} 197(268}
2200 137 {186} 187(255} 207 {282}
NOTE:
1. The output (SAE, gross) is corrected to standard
ambient conditions based on S A E J1349.
2. The continuous rated output allows 10% (one
hour) overload operation.
00-3
00 GENERAL - ENGINE NUM BER AND CAUTION PLATE
3. ENGINE NUMBER AND CAUTION PLATE (2) Caution plate
(1) Engine num ber
The caution plate is attached to the portion show n in

the illustration. The caution plate indicates the follow
The engine num ber is stamped near the front of the
ing items.
crankcase on the left-hand side. It takes the follow ing
form:
Example: 6 D 2 4 - 012345
---------------Engine num ber

— -------------- E ngine model V A L V E C L E A R A N C E (COLD)
INLET 0.4mm(0.016in)- -1
The engine num ber is important in know ing the history
E X H A U S T 0 . 6 m m ( 0. 0 2 4 i n) - -1
o fth e engine.
FIRING O R D E R 1-5-3-6-2-4- 2
FUEL INJECTION T IM IN G I 1° BTD C -3
1 Valve clearance
2 Firing order
1 -5 -3 -6 -2 -4
3 Fuel injection timing
A0166B
00-4
GENERAL - KEY POINTS FOR MAINTENANCE WORK 00
4. KEY POINTS FOR MAINTENANCE WORK • W hen rem oving or installing the engine, attach the
lifting wire rope hooks to the engine's lilting eyes
In order to determine the condition ofthe vehicle ade
and hoist the engine slow ly such that it does hot
quately, attend the vehicle beforehand to find and keep
touch other components.
record of the accumulated mileage, operating condi
tion, what the custom er's dem and is, and other in WARNING A --------------------------------------
formation that m ay be necessary. Check that the wire rope and crane are sufficiently
Prepare the steps to be taken and perform efficient and strong.
wasteless maintenance procedure.
• Determine where the fault exists and check for the Be particularly careful not to work in sh o e s that
cause to see whether removal or d isassem bly of have oily soles and are slippery. W hen w orking as a
the part is necessary. Then follow the procedure team of two or more, arrange signals in advance
specified by this manual. and keep confirming safety. Be careful not to acci
• Perform maintenance work at a level area. dentally bump switches or levers.
Check for oil leakage before cleaning the area hav
ing the fault otherwise you m ight m iss detecting
the leakage.
Prepare replacement part(s) beforehand.
• Prepare general and special tools necessary forthe

maintenance work.
W ARNING A ---------------------------- ----------

Do not attempt to use tools other than special tools
where use of special tools is specified in this manu
al. This will avoid injury or damage.
00-5
•II GENERAL - KEY POINTS FOR MAINTENANCE WORK
00015
Replace oil seals, packing, O-rings and other rub Put alignment m arks on part com binations before d is
ber parts; gaskets and split pins with new parts assem bly and arrange the disassem bled parts neatly.
w henever any of them has been removed. This will help avoid m ism ating of the parts later.
Use only genuine M IT S U B IS H I replacement parts. Put the alignment marks, punch marks, etc. where per
formance and appearance will not be affected.
Coverthe area left open after removal of parts to keep it
•
free from dust.
(D O CAUTION A ----------------------------------
• Take care to avoid mixing up numerous parts, simi
lar parts, left and right, etc.
• Keep new parts for replacement and original (re
moved) parts separate.
00016
On disassem bly, visually inspect all parts for wear and

tear, cracks, damage, deformation, degradation, rust,
corrosion, sm o o th n e ss in rotation, fatigue, clogging
and any other possible defect.
Apply the specified oil or grease to U-packings, oil

seals, dust seals and bearings during assembly.
C A U T IO N ^ ----------------------------------------
Use only the specified oil, grease, etc. for lubricant.
Remove the excess immediately after application
with a piece of rag.
00-6
00019 00022
W ear goggles when using a grinder or welder. Pay full • Pull the connector, and not the harness lead, to
attention to safety by wearing gloves w hen necessary. - separate connectors. To separate a lock-type con
Watch out for sharp edges, etc. that m ight injure your nector, first push toward arrow mark. To reconnect
hands or fingers. a lock-type connector, press the separated parts
until they click together.
Before carrying out maintenance w ork on the electric

system, disconnect the negative term inals of the bat • W hen w ashing the vehicle, cover the electric s y s
teries. tem parts and instruments with waterproof materi
al beforehand (Cover with vinyl sheet or the like).
Keep water away from harness wire connectors
and sensors. If any of them should get wet, wipe
them off immediately.
• Take care when handling sensors, relays, etc.

which are vulnerable to shock and heat.
00-7
00 GENERAL - KEY POINTS FOR MAINTENANCE WORK
Measurem ent Procedures U sin g Connectors
• To apply voltage for testing, check that the positive

and negative cables are connected properly, then Test with connectors engaged (continuity through cir
increase voltage gradually from 0 volt. Do not ap cuit obtained)
ply voltage higher than the specified value. <Waterp roof co n n ecto r>
In particular, pay close attention to the electronic Prepare a test harness and connectors A, then connect
control unit and sensors, since they are not alw ays if between the two parts of harness B that is to be
supplied with 24V. tested. Check the circuit by touching test probe C to the
test connector.
Never insertthe test probe from the harness side ofthe
waterproof connection, or waterproof performance
might be dim inished causing corrosion ofthe connec
tor.
• W hen using testers or the like for continuity tests,

be careful not to allow test probes to touch the
w rong terminals.
<Non-waterproof connector>
Insert test probe C from the harness side ofthe connec
tor. Where control units, etc. have connectors that are
too small to accept the test probe, do not force the test
probe into them.
00-8
Connector Inspection Procedures
Test with connectors disengaged

U sing female pins Visual inspection
Insert a test probe into a terminal. However, do not Check for loose connection and poor engagem ent.
force the probe into the terminal, or it will cause a poor
contact.
Check if harnesses are broken by pulling gently around

the terminals.
U sing male pins
Touch the pins directly using test probes.
CAUTION A — -------------------------------------
Be sure that you do not short circuit the connector
pins when you use the test probe because this could
damage the internal circuit ofthe electronic control
unit.
Check for a decrease in contact pressure between the

male and female terminals.
00-9
00 GENERAL - KEY POINTS FOR MAINTENANCE WORK
Check for poor contact caused by connector pins hav Rem ove fuse B and measure resistance between the
ing fallen out, rusted terminals or foreign particles. loaded side of the fuse and ground.
Turn on all circuit switches (connected to the fuse). If
the resistance value reading is approximately 0, a short
has occurred between the switch and the loaded point.
A value of other than zero m ay indicate that the fuse
w as blown by a temporary short but the short is no
longer present.
The major causes of a short circuit are as follows:
• Harness stuck onto the vehicle body.
• Harness sheath dam aged by friction or heat.
• Water in connectors or circuits.
• Mistakes (accidental short circuits)
A: Battery
B: Fuse
Connector pin fall out inspection C: Loaded switch
Dam aged connector pin stoppers can cause poor en D :Load
gagem ent ofthe terminals (male and female pins) even E: Short circuit
if the connector body is secured, and m ight cause
Precautions for Handling Alternator
som e pins to fall out. Check if the pins have fallen out
from the connector by pulling each harness gently.
Inspection Procedures for Blow n Fuses
W hen servicing the alternator, pay attention to the fol

lowing:
• Do not connect the alternator with battery polari
ties reversed. If the alternator is connected with re
versed polarities, a large current flow from the bat
tery to the alternator occurs, and the diode or regu
lator m ight be damaged.
02596
00-10
• Do not splash water over the alternator.
If water is directly splashed over the alternator, in
dividual com ponents will be short-circuited and
might be destroyed.
• W hile the engine is running, do not rem ove the bat

tery terminals. Ifthe battery terminals are rem oved
at that time, a surge voltage is generated and the
diode or regulator might be weakened.
• Do notshort-circuitterminal B an d te rm in al Lw hile
running the alternator.
Ifthe terminals are short-circuited while the alter
nator is running, the diode trio m ight be destroyed.
• Do not use a high-voltage tester such as a m egger

for inspection. If a high-voltage tester is used, the
diode or regulator m ight be destroyed.
• Disconnect the battery terminals before quick-

charging the battery. Quick-charging without d is
connecting the battery terminals m ight dam age
the diode or regulator.
05165
00-11
00 GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE
5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

• U se specified bolts and nuts and tighten them with the applicable torques according to the following table,
unless otherwise specified.
• Threads and contact seats shall be dry.
• W here there is difference in strength classification between nut and bolt (or stud bolt), the torque specified for
bolt shall apply.
Hex-head Bolt and Stud Bolt
Unit: N-m {kgf-m}
Stren gth 4T 7T 8T
classification
\ Repre-
\ sentation
D ia m e -\.
ter s y m - \
bol \.
© o (s) ® © © (Stud) (Stud) (Stud)
©
M5 2 to 3 {0.2 to 0.3} - 4 to 6 {0.4 to 0.6} - 5 to 7 {0.5 to 0.7} -
M6 4 to 6 {0.4 to 0.6} - 7 to 11 {0.7 to 1.1} - 8 to 12 {0.8 to 1.2} -
M8 9 to 14 {0.9 to 1.4} - 17 to 26 {1.7 to 2.6} - 20 to 29 {2.0 to 3.0} -
M 10 19 to 28 {1.9 to 2.8} 18 to 26 36 to 52 {3.5 to 5.5} 33 to 49 45 to 60 {4.5 to 6.0} 41 to 59

{1.8 to 2.7} {3.3 to 5.0} {4.3 to 6.9}
M 12 35 to 50 {3.4 to 5.0} 31 to 46 70 to 95 {7.0 to 9.5} 65 to 85 85 to 110 {8.5 to 11} 75 to 100

{3.1 to 4.7} {6.5 to 8.5} {7.5 to 10}
M 14 60 to 85 {6.0 to 8.5} 55 to 75 120 to 160 {12 to 16} 110 to 140 130 to 180 {13 to 18} 120 to 160
{5.5 to 7.5} {11 to 14} {12 to 17}
M16 90 to 130 {9.5 to 13} 90 to 120 180 to 240 {18 to 24} 160 to 220 200 to 270 {20 to 27} 190 to 260
{9.0 to 12} {16 to 22} {19 to 26}
M18 140 to 190 {14 to 19} 120 to 160 260 to 340 {25 to 35} 220 to 290 290 to 390 {30 to 40} 260 to 340
{12 to 16} {22 to 30} {26 to 35}
M20 190 to 260 {19 to 26} 170 to 230 350 to 470 {36 to 48} 320 to 420 410 to 550 {41 to 56} 370 to 490
{17 to 23} {32 to 43} {37 to 50}
M 22 260 to 340 {26 to 35} 230 to 300 470 to 640 {48 to 65} 430 to 570 550 to 740 {56 to 75} 490 to 670
{2 3 to 3 1 } {43 to 58} {50 to 68}
M24 340 to 450 {34 to 46} 290 to 390 630 to 840 {63 to 86} 540 to 730 730 to 980 630 to 840
{29 to 40} {55 to 74} {74 to 100} {64 to 86}
Hex-head Flange Bolt

Unit: N-m {kgf-m}
Stren gth 4T 7T 8T
c lassification
\. Repre-
\s e n t a t io n
D ia m e -\ .
ter s y m - \
bol N.
© ® ®
M6 4 to 6 {0.4 to 0.6} - 8 to 12 {0.8 to 1.2} - 9 to 14 {0.9 to 1.4} -
M8 10 to 15 - 19 to 28 - 22 to 32 -
{1.0 to 1.5} {1.9 to 2.8} {2.2 to 3.3}
M10 21 to 30 20 to 28 39 to 58 37 to 53 50 to 65 45 to 65
{2.1 to 3.1} {1.9 to 2.9} {3.9 to 6.0} {3.6 to 5.4} {5.0 to 6.5} {4.5 to 6.5}
M 12 38 to 54 35 to 51 80 to 110 70 to 95 90 to 120 85 to 110

{3.8 to 5.5} {3.4 to 5.2} {8.0 to 11} {7.0 to 9.5} {9.0 to 12} {8.5 to 11}
00-12
GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE 00
Hex-head Nut
Unit: N-m {kgf-m}
Strength 4T 6T
classification
\ Repre-
(O) E_: am
\ sentation
© (03
Diam eter \
sy m b o l \ Sta n d ard screw Coarse screw Standard screw C oarse screw
M5 2 to 3 {0.2 to 0.3} - 4 to 6 {0.4 to 0.6} -
M6 4 to 6 {0.4 to 0.6} - 7 to 11 {0.7 to 1.1} -
M8 9 to 14 {0.9 to 1.4} - 17 to 26 {1.7 to 2.6} -
M 10 19 to 28 {1.9 to 2.8} 18 to 26 {1.8 to 2.7} 36 to 52 {3.5 to 5.5} 33 to 49 {3.3 to 5.0}
M 12 35 to 50 {3.4 to 5.0} 31 to 46 {3.1 to 4.7} 70 to 95 {7.0 to 9.5} 65 to 85 {6.5 to 8.5}
M 14 60 to 85 {6.0 to 8.5} 55 to 75 {5.5 to 7.5} 120 to 160 {12 to 16} . 110 to 140 {11 to 14}
M 16 90 to 130 {9.5 to 13} 90 to 120 {9.0 to 12} 180 to 240 {18 to 24} 160 to 220 { 1-6 to 22 }
140 to 190 120 to 160 260 to 340 {25 to 35} 220 to 290 {22 to 30}
M 18
{14 to 19} {12 to 16}
190 to 260 170 to 230 350 to 470 {36 to 48} 320 to 420 {32 to 43}
M 20
{19 to 26} {17 to 23}
260 to 340 230 to 300 470 to 640 {48 to 65} 430 to 570 {43 to 58}
M 22
{26 to 35} {23 to 31}
340 to 450 290 to 390 630 to 840 {63 to 86 } 540 to 730 {55 to 74}
M24
{34 to 46} {29 to 40}
Hex-head Flange Nut

Unit: N-m {kgf-m}
Strength 4T
classification
\ Repre-
\ sentation
(§)
Diam eter \
sy m b o l \ Sta n d a rd screw C oarse screw
M6 4 to 6 {0.4 to 0.6} -
M8 10 to 15 {1.0 to 1.5} -
M 10 21 to 30 {2.1 to 3.1} 20 to 28 {1.9 to 2.9}
M12 38 to 54 {3.8 to 5.5} 35 to 51 {3.4 to 5.2}
00-13
00 GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE
Tightening torque for flare nut for general purpose

Unit: N-m {kgf-m}
Pipe diam eter 4>4.76 m m 4)6.35 m m 4>8 m m 4>10 m m 4>12 m m 4>15 m m
T igh te nin g torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10.0}
Tightening torque for air piping nylon tube for general purpose {DIN type}
Unit: N-m {kgf-m}
S ta n d a rd diam eter 6 x 1 mm 10 x 1.25 m m 12 x 1:5 m m 15 x 1.5 m m
T igh te nin g torque

2o +5-9
0.
u « « } 34+1°
0 “ "o 0 ! I 7!
“
54+^
0
I 5.5 + ° '5
| 0
Tightening torque for air piping nylon tube for general purpose {SAE type}
Unit: N-m {kgf-m}
S ta n d a rd diam eter 1/4 in. 3/8 in. 1/2 in. 5/8 in.
T igh te nin g torque

13+4 1.3 + ° '4 I 29+ "’ ( 3.0 +° ‘5 49+n 5-° +^'5 « 1 (6 .5 *» -5 )
0 0 j 0 | 0 j 0 0
00-14
11
ENGINE
1. G E N E R A L .......................................... ... 2 5.3 Flywheel, Tim ing Gears, and

2. S P E C IF IC A T IO N S . . ......... ................... ... 8 Cam shaft ...................................... ... 29
3. S E R V IC E S T A N D A R D S ........................ ... 9 5.3.1 D isasse m bly .............................. ... 29
3.1 Service Stan dards Table ................... ... 9 5.3.2 Inspection ................................. ... 33
3.2 Tightening Torque Table ................... .. 11 5.3.3 R eassem bly .............................. ... 39
4. S P E C IA L T O O L S ................................. .. 12 5.4 Crankcase and M ain M o v in g Parts ... ... 45
5. S E R V IC E P R O C E D U R E S ....................... ... 16 5.4.1 D isasse m bly .............................. ... 45
5.1 M easuring Com pression Pressure — .. 16 5.4.2 Inspection .................. .............. . . . 4 9
5.2 Cylinder Head and Valve M ech anism .. 17 5.4.3 Reassem bly .............................. . . . 5 9
5.2.1 D isasse m bly ................................ .. 17 5.5 Inspecting and Adjusting Valve
5.2.2 Inspection .................................. .. 19 Clearances .................................... . . . 6 5
5.2.3 R eassem bly ................................ .. 25 6. T R O U B L E S H O O T IN G ......................... ... 67
n -1
11 ENGINE - GENERAL
1. GENERAL
(1) Com bustion chamber
Injection nozzle
C ylin de r head
O -rin g
Nozzle tube
C ylin de r head
ga sk e t
C o m b u stio n
ch am b e r
■ Piston
Water directors pressed into the bottom of the cylinder

head optimize cooling of the com bustion chambers by
directing the flow of coolant.
B0375C
The com bustion cham bers are formed by the cylinder

head and pistons. The injection nozzles, sheathed by
the nozzle tubes, are m ounted on the cylinder head.
The nozzle tubes hold the nozzles and protect them
from cooling water. Since the nozzles are exposed to
the water in the water jacket, they are sealed by O -rings
atthe top and by staking atthe bottom. C om bustion is
effected by com pression of fuel injected directly into
the com bustion chambers.
11-2
ENGINE - GENERAL 11
(2) Valve m echanism
The valve m echanism is of an overhead-valve (OHV) (d) A steel ball is welded to the bottom end of each
type and is constructed as sh ow n in the diagram. push rod, and a spherical concave piece is welded
(a) Valve stem seals are fitted to the inlet and exhaust to the top end.
valve stem s to control the am ount of lubricant (e) The tappets are cylindrical. To help prevent local
flow ing onto the sliding surfaces ofthe valves and ized wear, the areas that make contact with the
valve guides. cam shaft are curved. The overall design enables
(b) The inlet and exhaust valve sprin gs are unevenly the tappets to be removed via the side ofthe crank
pitched. Two springs are m ounted for each valve, case.
and the.inner and outer sp rings are w ound in op po If) The camshaft is held by cam shaft b u sh in gs that are
site directions. pressed into the crankcase. The cam profiles are
(c) The rocker and rocker shaft are supported by the specially curved to achieve sm ooth acceleration.
rocker shaft bracket and are installed indepen
dently for each cylinder. The sam e type of rocker is
used for both inlet and exhaust valves, and the cen
ter of each rocker form s an oil passage.
The rocker shaft is a hollow rod sealed by a thrust
plate at each end. The inside of the rocker shaft
form s an oil passage.
11-3
11 ENGINE - GENERAL
(3) Crankcase and cylinder liner (4) Piston and piston rings
(a) Pistons
(a) Se ve n cam shaft bushings are fitted in the cam shaft

bearing section of the crankcase. To facilitate The piston is an aluminum casting, and a com bustion
rem oval and reinstallation of the camshaft, the space is recessed into its crown. A piston ring insert is
diameter of each bearing is sm aller toward the cast into the 1st piston ring groove to im prove durabil
front. ity.
(b) Coolant is fed in from the water pum p (located at Stam ped on top of the piston are a size mark, a piston
the front left of the crankcase). After cooling the oil weight mark, the piston's part number, an identifica
cooler, it flow s through the water jacket holes and tion mark, plus an " F " and arrow, which indicate the
around the cylinders, then reaches the cylinder piston installation direction. The size mark is provided
head. to enable selection of the correct cylinder liner size. In
the case of an oversize piston, the size mark sh ow s the
degree of oversize.
The piston pin is fully floating and is held in position by
a snap ring at either end.
(b) Piston rings
(c) The cylinder liner is a rem ovable wet type. It is

press-fitted into the crankcase, with its top held by
the top of the crankcase and its bottom held by the
water jacket.
Rubber rings and O-rings are provided at the top
and bottom of the cylinder liner to prevent the
Two com pression rings and one oil ring are fitted to
in gre ss of coolant.
each piston. They are shaped as show n in the illustra
The water jacket has a waterthrottling shelf to opti
tion.
mize cooling performance.
11-4
ENGINE - GENERAL 11
(5) Connecting rod and connecting rod bearing (6) Crankshaft and crankshaft main bearings
(a) The crankshaft is highly rigid and is cast in one

piece with its balance.
Between each journal and pin is an oil hole. So m e
of the main bearing oil is fed through this hole to
lubricate the connecting rod bearing.
The connecting rod is a highly rigid l-section forging. A

bushing is pressed into the sm all end, and a split-type
plain bearing is used at the big end.
Since it is a split-type bearing, the connecting rod bear
ing has an upper half and a lower half. The upper half
has an oil hole. This oil hole is in line with the oil pas
sage inside the connecting rod. Engine oil for lubrica
tion ofthe small end bushing is supplied via the oil hole
and oil passage. A n oil hole is provided at the top ofthe
connecting rod to help cool the piston.
The connecting rod and connecting rod cap are held
together by four connecting rod bolts.
(b) The crankshaft gear that drives the timing gears is

press-fitted onto the rear of the crankshaft. Note
that a radial- or axial-lip-type oil seal is fitted to the
front and rear ends ofthe crankshaft.
11-5
11 ENGINE - GENERAL
(d) M ain bearings
(c) The front end of the crankshaft is flanged, and the

crankshaft pulley is bolted to the flange. A torsional Each main bearing is a split-type plain bearing made of
d am per is m ounted on the crankshaft pulley to special alloy-plated kelmet metal with backing mate
a b so rb the crankshaft's torsional vibration. rial.
Since they are split-type bearings, the main bearings
have upper halves and lower halves. Each upper half
has an oil groove on its inside surface, plus an oil hole.
The oil hole lines up with an oil hole in the crankcase.
There are 7 main bearing pairs. A split-type thrust plate
is fitted to the rearmost bearing.
11-6
ENGINE - GENERAL 11
Each idler gear is m ounted onto the crankcase with an
idler shaft bolt and is supported at the other end by the
flywheel housing.
The idler gears turn on the idler shafts by m eans of
pressed-in bushings. The b u shings are lubricated by
oil that flows through the inside of the idler shafts via
the crankcase oil holes.
(8) Flywheel
The timing gears are located in the flywheel housing at

the rear of the engine. The geartrain is as show n in the
illustration.
The timing gears are helical, and each is stam ped with
a timing mark. The tim ing marks ensure that the gears
m esh correctly when reassembled.
Idler ge ar " B " The flywheel is made of cast iron, and at its center is a
pilot bearing for the clutch shaft. The outer ring gear
that m eshes with the starter pinion is shrink-fitted.
The ring gear teeth are chamfered on one side to
ensure that the starter pinion fits easily.
Cylinder numbers, an angle scale, and valve timing
check marks are stamped on the outside of the fly
wheel, as show n in the illustration.
T h ru st plate
B0384A
The crankshaft gear is press-fitted onto the crankshaft

and held in place by a dowel pin. The crankshaft gear
drives the other gears.
11-7
11 ENGINE - SPECIFICATIONS
2. SPECIFICATIONS
Item Specification
E n g in e m o del 6D24 6D24-T 6D24-TC 6D24-TL
Type 6-cylinder, in-line, w ater-cooled, <— «— <—

4-cycle diesel
C o m b u stio n c h am b e r type Direct injection 4—
Valve m e ch a n ism O verhead valve i - <— <—
Cylinder bore x stroke (m m ) 130x150 <- 4 r- <—
Total disp la ce m e n t (cm 3) 11945 4— <- <—
C o m p re ssio n ratio 19.5 16.5 <— 17.5
Fuel injection se q u e n ce 1-5-3-6-2-4 «— «—
Cylinder liner type W et <- <—
Piston type Trunk-type slip p e r skirt 4r— <-

(with cooling
cavity)
N o. of piston rin gs C o m p re ssio n ring: 2 «—

Oil ring: 1
11-8
ENGINE - SERVICE STANDARDS 11
3. SERVICE STANDARDS
3.1 Service Standards Table
Unit: m m
M ainten ance item N o m inal value Limit R em e dy a nd rem arks

(Basic diam eter in [ ])
C o m p re ssio n pressure (at 200 rpm) 2750 kPa 1960 kPa {20 kgf/cm 2} Difference between cylin
{28 kgf/cm2} ders: 390 KPa {4 kgf/cm 2}
or less
Rocker bushing-to-rocker shaft clearance (28) 0.03 to 0.08 0.2 Replace b u sh in g
Outer valve sprin g Free length 88.38 85 Replace
Installed load/installed length 450 N 380 N

{46.1 k g f } / 58.35 {39 k g f } / 58.35
Inner valve sprin g Free length 65.04 62 Replace
Installed load/installed length 115 N 100 N

{12 k g f } / 50.35 {10.2 k g f } / 50.35
Sq u a re n e ss - 2.5
Tappet-to-crankcase clearance [35) 0.06 to 0.10 0.2 Replace
Push rod runout - 0.5 Replace
Cylinder head bottom surface distortion 0.07 or le ss 0.08 Correct or replace
H eight of cylinder head from top to bottom surface 130 129.8 Replace
Valve stem outside Inlet 11.95 to 11.96 11.85 Replace

diam eter
Exhaust 11.91 to 11.93
Valve stem -to- Inlet [12] 0.05 to 0.09 0.2 Replace valve gu ide
valve guide
clearance Exhaust [12] 0.09 to 0.12
Valve m argin Inlet 2.2 1.7 Reface or replace
Exhaust 2.5 2.0
Valve seat angle 45° -
Valve sin kage Inlet 0.25 to 0.75 1.0 Replace valve seat insert
from cylinder ( - sh o w s projection)
head bottom
Exhaust -0.05 to 0.45 0.7
surface
Valve seat insert seat w idth 2.69 to 2.96 3.5 Correct or replace
T im ing ge ar Between crankshaft gear and idler 0.08 to 0.20 0.4 Inspect
backlash ge arB
Between idler ge a r A and 0.07 to 0.18 0.4 Inspect

cam shaft gear
Between idler ge ar A and idler 0.07 to 0.18 0.4 Inspect

gear C
Between injection p um p ge ar and 0.08 to 0.20 0.4 Inspect

idler ge ar C
Idler gear end play 0.05 to 0.15 0.4 Replace thrust plate
C am sh aft gear end play 0.05 to 0.22 0.4
Flywheel Friction surface distortion 0.1 or less 0.2 Correct or replace
Distance from clutch cover m oun t 47.8 to 48.2 49.5 Replace

ing surface to friction surface
Friction surface runout (when - 0.2 Correct or replace

fitted)
Idler ge a r A-to-idler shaft A clearance [40] 0.03 to 0.06 0.2 Replace bu sh in g
Idler ge ar C-to-idler shaft C clearance [46] 0.03 to 0.06 0.2 Replace bu sh in g
11-9
11 ENGINE - SERVICE STANDARDS
Unit: m m
M ainten ance item N o m in a l value Limit R em e dy and rem arks

(B a sic diameter in [ ])
C a m profile (difference Inlet 8.83 8.3 Replace Lobe height:

betw een lobe height and base 56.167
circle diam eter) B ase circle
diameter: 47.334
E xhaust 8.82 8.3 Replace Lobe height:

56.036
B ase circle
diameter: 47.216
C a m sh a ft journal-to-cam shaft No. 1 [65.00] 0.03 to 0.08 0.25 Replace bu sh in g

b u sh in g clearance
No. 2 [65.25] 0.03 to 0.08
No. 3, 4 [65.50] 0.03 to 0.08
No. 5, 6 [65.75] 0.03 to 0.08
No. 7 [66.00] 0.03 to 0.08
C am sh aft bend 0.05 or less 0.08 Replace
C a m sh a ft ge ar-to-cam shaft interference [40] 0.02 to 0.05 - C an be reassem b led up to

3 tim es
Flywheel h o u sin g eccentricity - 0.2 Correct
Con ne cting rod end play 0.2 to 0.5 1.0 Replace
Projection o f p iston from top surface of crankcase 0.87 to 1.33 - Inspect
Crankshaft end play 0.09 to 0.23 0.4 Replace thrust plate
Flatness of cylinder liner su p portin g flange - 0.1 Replace crankcase
C rankcase top surface distortion 0.07 or less 0.2 Correct
C ylinder liner Inside diam eter 130.014 to 130.054 130.25 Replace or grind to oversize
F lange projection 0.01 to 0.08 -
Cylindricity 0.02 or less -
Piston-to-cylinder liner clear 6D24 [130] 0.178 to 0.204 - Correct or replace cylinder
ance liner, or replace piston
6D24-T, TC, T L [130] 0.193 to 0.219 -
Piston 1st c o m p re ssio n 6D24 0.09 to 0.13 0.25 Replace piston ring or piston
ring ring
groove-to- 6D24-T, TC, TL 0.02 to 0.10
piston
ring 2 nd c o m p re ssio n 6D24 0.05 to 0.08 0.25 Replace piston ring or piston
clearance ring
6D24-T, TC, TL 0.07 to 0.10
Oil ring 0.03 to 0.06 0.15
Piston 1st c o m p re ssio n ring 0.4 to 0.55 1.5 Replace

ring end
ga p 2 nd co m p re ssio n ring 0.5 to 0.65 1.5
Oil ring 0.4 to 0.6 1.5
Piston pin-to-piston pin hole clearance [50] 0.01 to 0.02 0.1 Replace piston or piston pin
Piston pin-to-connecting rod sm all end bu sh in g clearance [50] 0.02 to 0.05 0.1 Replace bu sh in g
C on ne cting rod Bend - 0.05 or less Correct or replace
Torsion - 0.1 or less
C on ne cting rod bearing sp an w hen free - Less than 90.5 Replace
C on ne cting rod bearing-to-crankshaft pin clearance [84] 0.07 to 0.13 0.25 Replace bearing
M a in bearing-to-crankshaft journal clearance [100] 0.08 to 0.15 0.25 Replace bearing
M a in bearing sp an w hen free - Le ss than 106.5 Replace
11-10
ENGINE - SERVICE STANDARDS 11
Unit: m m
Maintenance item N o m inal value Limit R em edy a n d rem arks

(B asic diam eter in [ ])
Crankshaft pin and journal R oun dn ess 0.01 or less 0.08 Correct
Cylindricity 0.006 or less -
Crankshaft bend 0.04 or le ss 0.1 Correct or replace
Valve clearance (w hen cold) Inlet 0.4 - Adjust
Exhaust 0.6 -
3.2 Tightening Torque Table

Location tightened Screw size Tightening torque R em arks
O. D. x pitch N-m {kgf-m}
(m m)
C ylin der head bolt M14 x 2 Wet. See item (6 ) of

section 5.2.3 for
tightening
procedure.
Rocker shaft bracket m oun tin g bolt M 10 x 1.5 59 {6}
Rocker cover bolt M 8 x 1.25 4.9 {0.5}
Rocker adjusting screw lock nut M 1 0 x 1.25 59 {6}
Flywheel m o u n tin g bolt M 1 6 x 1.5 315 {32} W et
Idler shaft bolt A M 16 x 2 155 {16}
Idler shaft bolt C M 16 x 2 155 {16}
Idler shaft nut (for m ounting collar) M 1 6 x 1.5 98 {10}
Flywheel h o u sin g bolt M12 x 1.75 69 {7}
Oil jet check valve M 1 2 x 1.75 34 {3.5} Cannot be reused
C on ne cting rod cap nut M 1 3 x 1.25 115 {12} Wet
M a in bearing cap bolt M 18 x 2.5 Wet. S e e item (7) of

section 5.4.3 for
tightening
procedure.
Crankshaft pulley m oun tin g bolt M 14 x 1.5 175 {18}
Front cover m o u n tin g bolt _ M 1 2 x 1.75 33 {3,4}
11-11
11 ENGINE - SPECIAL TOOLS
4. SPECIAL TOOLS
Unit: m m Unit: m m
Tool nam e Shape Tool nam e S h ap e
C o m p re ssio n G a u g e Adapter Caulking Tool B o dy

MH061461 MH061360
M e a su rin g c o m p re ssio n pres Installing and caulking valve
sure seat inserts
C au lking Tool
Caulking R in g (Inlet) Bo dy
MH061650
C aulking Ring
Installing and caulking valve
seat inserts For inlet: $ 59
For exhaust: <|>54
Caulking Rin g (Exhaust)
•Center MH061651
distance 46
Installing and caulking valve
01942 seat inserts
Valve Lifter Valve Lifter
MH 061668
if 12
R e m o v in g and installin g valve
cotters B5202A
Valve Lapper
Valve Lifter H ook
30091-07500
M H 061679
Valve lapping
R e m o v in g and installin g valve
cotters
Valve Lifter
H ook
01956 01958
Nozzle Tube R e m o ve r Nozzle Tube S ta m p

M H 061232 MH061229
R e m o v in g nozzle tub es Installing nozzle tubes Nozzle Tube

Installer Bol'
112.5 Nozzle Tube Installer Flange
MH061416
Installing nozzle tubes
<>8.7
Nozzle Tube Installer Bolt
MH061231 Center-
Installing nozzle tubes to-center
distance:
13597
46
Rocker B u sh in g Puller Nozzle Tube - Nozzle Tube
M H 061236 Installer S ta m p
R e p lacin g rocker b u sh in g s Flange
'<t>8
B5181A
Valve Ste m Seal Installer

ME067431 4> 12
Installing valve stem seals
10593
Valve G u id e Puller
30091-08100
R ep lacing valve gu id e s
(|> 24
B 5111A B5191A
11-12
ENGINE - SPECIAL TOOLS 11
Unit: m m Unit: m m
Idler G ear B u sh in g Puller C am sh aft B u shin g Extractor

MH061228 Bar
MH062118
Replacing idler gear b u sh in g
(for idler ge ar A) R e m o vin g cam shaft bu sh in gs
N o s. 1 to 6
Idler G ear B u sh in g Puller

MH062046
B4867A
Replacing idler gear b u sh in g
(for idler ge ar C) C am sh aft Bu sh in g Extractor
Guide
MH062119
R e m o vin g cam shaft bu sh in gs
N o s. 1 to 6
Gear Puller
MH061061
R em o vin g ge ars and pulleys
B4868A
C am sh aft B u sh in g Extractor
A dapter
MH062120
MH062121
MH062122
M H 062123
M a x im u m pulling outside
R e m o vin g cam shaft bu sh in gs
dia. 200 B5071A
N o s. 1 to 6
Socket W rench
MH061540
Tightening cylinder head bolts
Part No. 4> A 4>B Applicable

b u sh in g
M H0G212O 69.75 65 No.1

M H 062121 70 65.25 No.2
M H 0 62 1 22 70.25 65.5 No.3, 4
M H 0 62 1 23 70.75 65.7 No.5, 6
B0598A B4869A
Socket W rench C am sh aft B u shin g Extractor

MH063365 MH 062124
Tightening m ain bearing cap R e m o vin g cam shaft bushing
bolts No. 7
$71.25
13204 B4870A
11-13
11 ENGINE - SPECIAL TOOLS
Unit: m m Unit: m m
C a m sh a ft B u s h in g Installer C am sh aft B u sh in g Installer

Bar MH062131
M H 062125 MH062143
In sta llin g c a m sh a ft b u sh in gs Installing cam shaft b u sh in g s
N o s. 2 to 6 N os. 1 and 7
M 2 4 x 1.5
B4871A Part No. 4> A <)> B Applicable

b u shing
C a m sh a ft B u s h in g Installer M H 062131 70.75 65 No.1
G u id e
M H 0 62 1 43 72.25 66 No.7
M H 062127
In stallin g c a m sh a ft b u sh in gs B4875A
N o s. 2 to 6
Oil S eal S lin g e r Installer
MH061652
Installing rear oil seal slin ge r
B4872A
C a m sh a ft B u s h in g Installer
A dapter <t>123
M H 062133
M H 062134
M H 062135
M H 062136
M H 062137
In sta llin g c a m sh a ft b u sh in gs B5161B
N o s. 2 to 6
Piston R in g Tool
31191-02900
R e m o vin g piston rings For<|>102 to 178
Pan No. «>A 4 B *C Applicable

bushing
MH062133 71 65.25 27 No.2
MH062134 71.25 65.5 35 No.3
MH062135 71.5 65.5 43 No.4
MH062136 71.75 65.75 51 No.5
MH062137 72 65.75 59 No.6
B4873A
02013
C a m sh a ft B u sh in g installer
Nut C rankcase Table
M H 062130 M H 061889
In stallin g c a m sh a ft b u sh in gs M e a su rin g flatn ess of cylin
N o s. 2 to 6 der-liner-supporting flan ges
on crankcase
M 24 x 1.5
B4874A B1480A
11-14
ENGINE - SPECIAL TOOLS 11
Unit: m m Unit: m m
Cylinder Liner Extractor

MH 061490
R e m o vin g cylinder liners
129.5
B5131A
Cylinder Liner Installer
M H 061759
Installing cylinder liners
4>129.5
B5141A
G uide Plate A sse m b ly
M H 063368
R e m o vin g connecting rod
b u sh in g s
M an drel
31291-75200
R e m o v in g connecting rod G u id e Plate
b u sh in g s A s se m b ly
C ollar A
M H 063370
R e m o v in g connecting rod
b u sh in gs
C ollar B
MH062189
Nut
R e m o v in g connecting rod
b u sh in g s
Nut
31291-75500
R e m o vin g connecting rod
b u sh in g s
B5151A
Oil S e a l Installer
31191-04300
Installing rear oil seal (radial
lip type)
PE7263
11-15
11 ENGINE - SERVICE PROCEDURES
5. SERVICE PROCEDURES
5.1 M e a s u rin g C o m p re ssio n P ressure
C om p re ssion pressure should be m easured prior to
d isa ssem b ly of the engine. Take m easurem ents regu
larly and keep track of changes. During the engine's
running-in period or after parts have been replaced,
the com pression pressure will increase slightly as the
piston rings and valve seats fit sn u gly in position. The
pressure will come dow n as parts wear.
Measurem ent procedure
C M
x> ■ha y
B5554A
(3) M ount the Com pression Gauge Adapter (special

(1) W arm up the engine until the coolant temperature tool) onto an injection nozzle hole together with a
reaches 75 to 85°C, then turn off the ignition. gasket. Connect the com pression gauge.
(4) To prevent fuel from being pumped into the cylin
der by the injection pump, pull the injection pump
governor's stop lever fully in the "sto p " direction.
(5) Turn the engine over with the starter and measure
the com pression pressure at 200 rpm.
NOTE:
1. Be sure to measure at the correct engine speed
since changes in engine speed cause changes in
compression pressure.
2. Since wear and other factors vary from one cylin-
derto another, measure the compression pressure
in every cylinder.
(2) Rem ove all injection nozzles from the cylinder
head.
NOTE:
Cover all mounting holes and injection pipes to pre
vent the entry of dust and dirt.
11-16
ENGINE - SERVICE PROCEDURES 11
5.2 Cylinder Head and Valve Mechanism
5.2.1 Disassembly
Oil hole
clogging
Wear, damage
22 Wear, cracks
Carbon deposition,
cracks, scale deposition,
dam age 2Q
Corrosion 18
1 6 ' 15
Carbon deposition
cracks, damage,
ridge wear
Water leaks, oil leaks,

gas leaks
Disassem bly sequence

1 Rocker cover 8 Valve cap 16 Exhaust valve
2 Rocker shaft bracket ® Valve cotter * 2 ® Nozzle tube
mounting bolt 10 Upper retainer * 218 Water director
3 Cylinder head bolt 11 Outer valve spring * 219 Sealing cap
4 Thrust plate 12 Inner valve spring ® Cylinder head
5 Rocker 13 Lower retainer 21 Crankcase side cover
© Rocker shaft bracket * 114 Valve stem seal
22 Tappet
7 Push rod 15 Inlet valve
For parts with circled numbers, refer to the following section, "Disassem bly Procedure."
Parts marked with * * 1 " should be replaced and not reused, even if only the valve is removed.
Parts marked with " * 2 " should not be removed unless defects are evident.
13208
11-17
Disassem bly Procedure The cylinder head is located on the top surface of the
crankcase by dowel pins. To rem ove the cylinder head,
lift it straight upward.
NOTE:
1. Remove the injection nozzles before taking off the
cylinder head. (Refer to Group 13A, Fuel and
Engine Control.) Ifthe cylinder head is placed on a
work bench with the nozzles still mounted, the
ends of the nozzles projecting from the bottom of
the cylinder head will be damaged.
2. When removing the cylinder head gasket, take
care not to scratch or dent the cylinder head and
crankcase mounting surfaces.
(4) Rem oving valve cotters
(1) Before rem oving the bolts, loosen the adjusting
screw on every rocker that is being pushed up by
its push rod.
(2) R em oving rocker shaft bracket assem bly
To remove the valve cotters, use the Valve Lifter and

Valve Lifter Hook (special tools) to evenly com press the
valve springs.
(5) Rem oving nozzle tubes
The rocker shaft bracket assem bly is held in place in the
cylinder head by a spring pin. To rem ove the assembly,
lift it straight upward.
(3) R em oving cylinder head assem bly
§ Injection nozzle
A ,
Cylinder head-
Cylinder head
gasket
Knock pin NOTE:

Whenever a nozzle tube is removed, it must be
B9014B replaced with a new one.
11-18
ENGINE - SERVICE PROCEDURES
5.2.2 Inspection
Item NV L
Free length Outer valve sprin g 89.38 85
Rocker bu sh in g- Inner valve spring 65.04 62

to-rocker shaft
clearance installed load/installed length Outer valve sprin g 450 N {46.1 kgf}/58.35 380 N {39 kgf}/58.35
BO 28
N V 0.03 to 0.08 Inner valve spring 115 N {12 kgf}/50.35 100 N {10.2 kgf}/50.35
L 0.2
Inner valve sp rin g sq u are ne ss - 2.5
B D .. B a sic D iam eter

N V .. N o m in a l Value
L Lim it
Cylinder head bottom

surface distortion
N V 0.07 or less
L 0.08
H eight of cylinder
head from top to
bottom surface
N V 130
L 129.8
Item BD NV L
Valve stem O. D. Inlet valve - 11.95 to 11.96 11.85
E xh a u st valve - 11.91 to 11.93
Valve stem -to-valve gu ide Inlet valve 12 0.05 to 0.09 0.2

clearance
E xh a u st valve 12 0.09 to 0.12
Valve seat insert seat width Inlet valve “■ 2.69 to 2.96 3.5
E xh au st valve
Valve sin kage from cylinder Inlet valve - 0.25 to 0.75 1.0
head bottom surface
E xh a u st valve - -0.05 to 0.45 0.7
Valve m argin Inlet valve - 2.2 1.7
E xh a u st valve - 2.5 2.0
Valve seat angle - 45° -

C2757B
Inspection Procedure M easure the free length and installed load of each
(1) Rocker bushing-to-rocker shaft clearance valve spring. Replace any spring that is not up to speci
fication. With inner springs, check also for squareness.
(4) Tappet-to-crankcase tappet hole clearance
If the clearance exceeds the specified limit, replace the

rocker bushing.
(2) Replacing rocker bushing

tappet.
(5) Push rod runout
W hen installing a bushing, face the b u sh in g 's seam

toward the rocker adjusting screw and align the bu sh
ing and rocker oil holes.
(3) Inspecting valve springs
©01948,
Check for runout and replace the push rod if the dial
reading exceeds the specified limit.
11-20
(6) Cylinder head bottom surface distortion (8) Valve stem-to-valve guide clearance
If distortion exceeds the specified limit, correct it using Insert the valve in the valve guide and m easure the play
a surface grinder. at the specified distance from the valve guide's top (as
NOTE: illustrated). If the am ount of play exceeds the specified
Replace the cylinder head if grinding causes the height limit, replace the valve guide.
from its top surface to bottom surface to fall below (9) Replacing valve guide
129.8 mm.
(7) Valve stem outside diameter
Valve Guide
Puller
30091-08100
Valve guide
Seat the collar

of valve guide
securely on
cylinder head
To rem ove To install C3113A
To install a valve guide, insert it with the Valve Guide

Puller (special tool) until its flange sits securely on the
Replace the valve if its stem 's outside diameter is cylinder head.
below specification or if it is severely worn.
(10)Contact between valve and valve seat insert (11)Rectifying valve face
Valve seat
C2708A C2710B
(a) A p p ly an even coat of m inium to the valve seat With a valve refacer, grind the valve face to achieve the
insert surface that com es into contact with the specified valve seat angle.
valve. NOTE:
(b) U sin g the Valve Lapper (special tool), strike the 1. Keep grinding to a minimum.
valve against the valve seat insert once. 2. if the valve margin is below specification after
NOTE: grinding, replace the valve.
1. Do not turn the valve when striking it against the 3. After grinding, be sure to lap the valve and valve
valve seat insert. seat insert. [See item (14) for details].
2. The contact pattern should be checked whenever (12)Rectifying valve seat insert
a valve guide is inspected or replaced.
o oGood Bad Bad
C3127A
C2707A Valve Valve
Ifthe m inium indicates a poor contact pattern, rectify it

as follows:
M in o r defect: Lapping
Se rio u s defect: Rectify valve and valve seat
11-22
(a) U sin g a valve seat cutter, cut the insert to achieve
the specified valve seat angle and seat width. Use a
15° or 75° cutter first, followed by a 45° cutter.
NOTE:
1. Keep cutting to a minimum.
2. If the valve sinkage exceeds the specified limit
after cutting, replace the valve seat insert.
(b) After cutting, put som e sandpaper of around #400
grade between the cutter and valve seat insert and +0.03 52
+0.03
57
o
grind the valve seat insert lightly. <lnlet> <Exhaust>
NOTE: C3128B
After rectification, be sure to lap the valve and valve Install Caulking
seat insert. [Refer to item (14) for details.]

(13)Replacing valve seat insert
0 Caulking
Tool Bo dy
MH061360
Valve seats are installed by expansion fitting and C aulking R in g

1 E L ^ Inlet
should therefore be replaced according to the follow __E M H 061650
—fit. Exhaust
ing procedure. C ham fe r MH061651
B1111B
(b) Check that there is sufficient interference between

the cylinder head and valve seat insert.
(c) Cool the valve seat insert by im m ersing it in liquid
nitrogen. Heat the cylinder head.
(d) Install the valve seat insert using the Caulking Tool
Body and Caulking Ring (special tools), and caulk
01973 the periphery ofthe valve seat insert.
NOTE:
(a) Grind the inside surface ofthe valve seat insert to When installing the valve seat insert, ensure that the
reduce its thickness. Rem ove the valve seat insert chamfered side of the Caulking Ring faces the valve
at room temperature. seat insert.
(e) Reface the valve seat insert to achieve the specified
seat width and valve sinkage. [See item (12) for
details.]
11-23
(14)Lapping valve and valve seat insert (b) Using the Valve Lapper (special tool), lightly strike
Contact between the valve and valve seat insert m ust the valve against the valve seat insert while turning
be even overthe entire contact area. Lapping should be it little by little.
carried out w henever the valve or valve seat insert has (c) W ash away the com pound with gas oil or a sim ilar
been rectified or replaced. fluid.
(d) Ap p ly engine oil to the contact surfaces and rub it
in so that the contact surfaces are lubricated and
mate together snugly.
(e) Check that the valve is properly seated. [Refer to
item (10) for details.]
© 01970
(a) A p p ly a thin, even coat of lapping com pound to the

seating surface o fth e valve.
NOTE:
1. Ensure that no compound adheres to the valve
stem.
2. Start w ith intermediate-mesh compound (120 to
150 mesh), and finish with fine-mesh compound
(200 m esh or more).
3. The addition of a small amount of engine oil makes
lapping com pound easier to apply.
C3130A
11-24
5.2.3 Reassem bly
Tightly w o u n d end tow ard

cylinder head
59 N-m
{6 kgf-m) - 1 « Tightly w o u n d end
tow ard cylinder head
Leak test: N o leaks are allow ed

with 195 kPa {2 kgf/cm2}
hydraulic pressure
A p p ly sealant to nozzle tube.

(T H R E E B O N D 1211 or equivalent)
18 19 2
A p p ly sealant
(H E R M E S E A L S-2 or equivalent)
4.9 N-m
{3.5 kgf-m) 59 N-m
21 - 3 {6 kgf-m)
16 Cylinder head bolt tightening

15 sequence (refer to item (6 ).)
A sse m b ly sequence
@ - > ® - > ® - > © _ > ® - > 1 3-412 -> ® -> 8 —>7-46-45-44—>3—>2—>1
16—>15? 22->21 -T
For parts with circled num bers, refer to the follow in g section, "R e a sse m b ly Procedure."
10369
11-25
Reassem bly Procedure (3) Valve stem seal installation

(1) Water director and sealing cap installation
A lig n each water director with the notch provided, as

sh o w n in the illustration.
(2) Nozzle tube installation
To install a valve stem seal, first apply engine oil to the

seal lip. Then, push in the seal using the Valve Stem
Seal Installer (special tool), striking the tool until it
touches the cylinder head.
NOTE:
1. W h e n in stallin g a valve, a p p ly a sm a ll a m o u n t of
engine oil to its stem.
(a) Clean the cylinder head nozzle tube holes. Take 2. After installing a valve stem seal, check that its
care to remove dirt, oil, water and carbon deposits spring has not been deformed or damaged.
from the seating surfaces.
(b) A p p ly sealantto the new nozzle tube, and insertthe
nozzle tube into the cylinder head.
(c) U sin g the Nozzle Tube Installer Flange (special
tool), press the nozzle tube into the cylinder head.
(d) A p p ly engine oil to the Nozzle Tube Stam p (special
tool) and insert it into the nozzle tube.
(e) Screw in the Nozzle Tube Installer Bolt (special
tool) until the Nozzle Tube Stam p can be pulled out
ofthe bottom ofthe cylinder head.
(f) After installing the nozzle tube, carry out a leak test
to verify air-tightness.
11-26
(4) Valve cotter installation Install the rocker shaft bracket by positioning it on the
spring pin in the cylinder head. M ount the cylinder
head by positioning it on the dowel pins in the crank
case.
(6) Tightening cylinder head bolts
Install the valve cotter while evenly com pressing the

spring u sin g the Valve Lifter and Valve Lifter Hook {spe
cial tools).
NOTE:
Valve springs must be installed with their tightly Tighten the cylinder head bolts to 175 N-m {18 kgf-m}
wound portions toward the cylinder head. (wet) in the order shown.
(5) M ou ntin g rocker shaft bracket and cylinder head Afterconfirm ingthatthe bolts are tightened to 175 N-m
{18 kgf-m}, give each one an extra turn in accordance
with the follow ing procedure.
(a) Before fitting the SocketW rench (specialtool) over

a cylinder head bolt, turn the holder counter-clock
wise to tension the built-in socket spring.
11-27
(b) Fit the socket over the cylinder head bolt and set it
such that the built-in spring forces the rod against
the rocker shaft bracket, an injection pipe, or
another nearby part.
S c a le inscribed
on socket
Lines inscribed
on holder
B0656A
(c) O bserving the inscribed lines on the holder and

socket, turn the socket clockwise by 90 to 110° (1
pitch = 10°) to fully tighten the bolt.
11-28
5.3 Flywheel, Timing Gears, and Camshaft
5.3.1 Disassembly
<W ith axial-lip-type <W ith m echanical <W ith electric

.. . tachom eter drive> speed sensor>
Oil seal>
5 7 o il leaks
W ear/deterioration
Streaks/cracks/stepped w ear
on friction surface
<With radial-lip-type ©43651
<W ith m echanical tachom eter
oil seal> drive>
D a m age /ab n o rm ally

w orn ge ar teeth
9
5 Wear/deterioration
Streaks/cracks/stepped w ear
D isasse m bly sequence on friction surface
1 Flywheel m ounting bolt 7 Flywheel housing Ring gear

*2 Pilot bearing *8 Rear oil seal slinger 10 Tachometer drive
© Flywheel cm odels with axiai-lip- *1 0 A Speed sensor
® Oil seal retainer type oil seal only> 10B Cover
5 Oil seal Sleeve cm odels with
© Collar wet type clutch only>
For parts with circled num bers, refer to the follow in g section, "D isa ss e m b ly Procedure."
Parts marked w ith sh o u ld not be rem oved u n less defects are evident.
C1926L
11-29
5F T im in g gear backlash
Item NV L
Between crankshaft ge ar and idler ge a r B 0.08 to 0.20 0.4
Between idler gear A and cam sh aft ge a r 0.07 to 0.18 0.4
Between idler ge ar A and idler g e a r C 0.07 to 0.18 0.4
Betw een injection p u m p ge ar and idler ge ar C 0.08 to 0.20 0.4
Injection p u m p ge a r
(Refer to G rou p 61, Sp e cia l Equ ipm en t)
D isasse m bly sequence

© Cam shaft assem bly 15 Idler shaft bolt 19 Idler gear B
Cam shaft 16 Thrust plate 20 Idler shaft A
Cam shaft gear 17 Idler gear C 20A Idler shaft C
14 Thrust plate 18 Idler gear A *21 Rear plate
For parts with circled num bers, refer to the fo llo w in g section, "D isa ss e m b ly Procedure."
Parts marked with sh o u ld be inspected prior to disassem bly.
Parts m arked with sh o u ld not be rem oved u n le ss defects are evident.
C1927D
11-30
Disassem bly Procedure (3) Rem oving ring gear
(1) R em oving flywheel
To remove the ring gear, heat it evenly with an acety

To rem ove the flywheel, screw its m ounting bolts into lene torch, then tap around its entire periphery with a
the threaded removal hole. ham m er and rod.
(2) Rem oving collar and oil seal retainer (4) M easuring gear backlash
• To rem ove the collar, screw M 4 x 0.7 bolts into the If backlash exceeds the specified limit, inspect the idler
threaded removal holes. gear b u shings and gears, and replace parts as
• To rem ove the oil seal retainer, screw its m ounting required.
bolts into the threaded removal holes. Rem ove the NOTE:
oil seal retainer with the oil seal attached. For any pair of gears, measure backlash at more than 3
<Radial-lip-type oil seal only> points to determine whether it is acceptable.
11-31
(5) M e a su rin g idler gear and cam shaft gear end play (7) Rem oving camshaft gear
If the end play exceeds the specified limit, replace the The camshaft gear is press-fitted onto the camshaft. To
thrust plate. separate these parts, push out the camshaft using a
(6) R em ovin g cam shaft press.
NOTE:
Do not attempt to rem ovethegearby striking it with a
hammer. Be sure to use a press.
Thrust plate
10991
R em ove the thrust plate mounting bolts via the holes in

the cam shaft gear. Rem ove the cam shaft together with
the cam shaft gear and thrust plate.
11-32
5.3.2 inspection
Item BD NV L
C a m profile (difference Inlet - 8.83 8.3

between base circle diam eter
an d lobe height) Exh au st - 8.82 8.3
C am sh aft bend - 0.05 or less 0.08
C am sh aft journal-to-cam shaft No. 1 65.00 0.03 to 0.08 0.25

b u sh in g clearance
No. 2 65.25
No. 3, 4 65.50
No. 5, 6 65.75
No. 7 66.00
C am sh aft gear-to-cam shaft interference 40 0.02 to 0.05 Can be reassem bled

up to 3 tim es
C2759D
11-33
Inspection Procedure (3) Idler gear-to-idler shaft clearance

(1) Friction surface distortion

Place the flywheel on a surface plate. To m easure d is bushing in the idler gear.
tortion, p ass a dial indicator over the flywheel from its (4) Replacing idler gear bushing
periphery tow ard its center.
If distortion exceeds the specified limit, grind the fric
tion surface as necessary.
NOTE:
Press Press
If the ring gear appears abnormal in any way, replace it
before measuring distortion. [For details, refer to item
(3) of section 5.3.1.]
(2) Rectifying flywheel friction surface
Idler G ear
B u sh in g Puller
B- ■ Clutch cover
m o u n tin g surface
MH061228
(for idler ge a r " A "
MH062046
(for id le r g e a r " C " )
■Friction surface
B u sh in g
Idler ge a r
D im e n sio n B
IE Rem oval Installation
Surface A
C3509B
C3808A
Grind the friction surface such that dim ension B (the
distance from the clutch cover m ounting surface to the
Install the bushing from the side of the idler gear
friction surface) is below the specified limit. The fric
w h ose internal diameter is chamfered.
tion surface m ust be parallel with surface A to within
After installation, confirm that the bushing-to-idler
0.1 mm.
shaft clearance is within the nominal value. If the clear
If dim ension B exceeds the specified limit, replace the
ance is sm allerthan the nominal value, ream the bush
flywheel.
ing.
11-34
(5) Cam profile (difference between base circle diame (7) Replacing camshaft b u shings
ter and lobe height) (a) Removal
Remove the camshaft b u shings in the follow ing
order: No.6 —> No.5 —> N o .4 —¥ No.3 —» No.2 -» No.1
-> No.7. Rem ove them in accordance with the fol
lowing instructions.
1) Rem oving camshaft b u shings Nos. 6 to 1
No. 6 cam shaft b u sh in g N°- 7 cam shaft bu sh in g

Crankcase / C am shaft Bushing
( __ / Extractor Bar
J ----------n L MH062118
M easure the lobe heights and base circle diameters.

Replace the camshaft if the difference between them is C am shaft B u sh in g Extractor G u id e
C am shaft Bu sh in g MH062119
below the limit. Extractor Adapter
MH062123 B4859A
NOTE:
Engine
Since the cams are tapered, they m ust be measured at front 'Cj,
the points shown in the illustration.

(6) Camshaft journal-to-crankcase cam shaft bushing
clearance
C am shaft C am sh aft B u sh in g
bu sh in g Extractor A dapter
No.1 MH 062120
No.2 MH062121
No.3, 4 MH062122
No.5, 6 M H 062123
B4860A

camshaft bushing. [Refer to item (7) for details.] a) M ount the Cam shaft B ushing Extractor Adapter
and Camshaft B ushing Extractor Guide (special
tools) onto the Cam shaft Bushing Extractor Bar
(special tool). Insert this assem bly into the crank
case. W hen doing this, fit the Guide onto the No. 7
camshaft bushing to support the Bar.
b) Hold the Cam shaft B ushing Extractor Adapter
against the No. 6 camshaft bushing. A s sh o w n in
the illustration, remove the No. 6 bushing by strik
ing the Bar with a hammer.
11-35
c) After rem oving the No. 6 bushing, rem ove bush a) M o u n t the Camshaft Bushing Installer Adapters
in g s Nos. 5 to 1 in that order using the appropriate (special tool) and bushings Nos. 2 to 4 on the Cam
Cam shaft B ushing Extractor Adapter for each one. shaft Bushing Installer Bar (special tool). W hen
doing this, align the inscribed lines on the Adapters
2) R em oving cam shaft bushing No. 7
with the clinches (seams) on the bushings and
position the oil holes as show n in the illustration.
No. 7 cam shaft bu sh in g
C am sh aft B u sh in g
/ Extractor
MH062124
i? 7
B4861A
(b) Installation
In accordance with the follow ing instructions, install
b) Fit the Camshaft Bushing Installer Guide (special
cam shaft b u sh in g s Nos. 2, 3, and 4 simultaneously,
tool) inthe place where the No. 1 camshaft bushing
then b u sh in g s Nos. 5 and 6 sim ultaneously, then bush
is to be installed so that the Camshaft Bushing
in gs Nos. 1 and 7 in that order.
Installer Bar (special tool) m ay be supported by it.
1) Sim ultaneous installation of b u sh in gs Nos. 2, 3, Then, insert the Camshaft B ushing Installer Bar
and 4 into the crankcase, making sure that the arrow on it
points toward the top of the crankcase.
N o. 2 cam sh aft bu sh in g N o. 3 cam shaft b u sh in g

L ocating Locating pin
fpin
C am sh aft B u sh in g C am sh aft B u sh in g
Installer Adapter Installer Adapter
M H 062133 M H 062134
===o =y O ===C|3™
No. 4 c am sh aft bu sh in g
Locating
pin
J C am shaft B u sh in g
Installer Bar
MH062125
View A
C am sh aft B u sh in g
Installer A dapter Oil hole
o Clinch
M H 062135
c) Confirm that the clinches (seams) on the bushings
View A -
are aligned with the inscribed lines on the Cam
shaft Bushing Installer Adapters [refer to item (a)
for details]. Then, screw the Camshaft Bushing
Clinch Installer Nut (special tool) onto the end ofthe Cam
Engraved line shaft Bushing Installer Bar, and tighten the Nut to
(on cam shaft b u sh in g
installer adaptor) . press-fit the bushings. Continue turning the Nut
B4862D until the Bar's flange touches the crankcase.
11-36
d) After installing the bushings, remove the Cam shaft 3) Installation of b u shings Nos. 1 and 7
B ushing Installer Nut and gently w ithdraw the
Cam shaft Bushing Installer Bar.
NOTE:
When removing the Camshaft Bushing Installer Bar,
take care not to damage the inside surfaces of the
bushings.
2) Sim ultaneous installation of bushings Nos. 5 and 6
Cam shaft B u sh in g
Installer G uide
MH062127
No. 5 cam shaft bu sh in g

C am shaft B u sh in g No. 6 cam shaft
Installer Bar bu shin g ^ .A rro w
MH062125 ^ mark
Cam shaft B u sh in g
Installer A daptor Install bushings Nos. 1 and 7 as follows: Align the
MH062136
Cam shaft B u sh in g inscribed lines on the Cam shaft Bushing Installer (spe
Installer A daptor
MH062137 cial tool) with the clinches (seams) on the b ushing and
position the oil holes as show n in the illustration. Face
the arrow on the Installer toward the top of the crank
case. Drive in the Installer until its flange touches the
B4865A
crankcase.
Follow the procedure in section 1) using the appropri

ate Cam shaft Bushing Installer Adapters (special tool)
for b u shings Nos. 5 and 6.
11-37
(8) Cam shaft bend (9) Camshaft-to-camshaft gear interference
M easure the extent of bending in the crankshaft. If it Ifthe interference is below the specified nominal value,
exceeds the specified limit, replace the crankshaft. replace the camshaft or cam shaft gear.
NOTE: NOTE:
Apply a dial indicator to the camshaft and turn the Even if the interference is up to specification, reas
camshaft through one revolution. One-half of the dial sembly should be carried out no more than 3 times.
indicator reading represents the amount of bending.
11-38
5.3.3 Reassem bly
B D .. B a sic D iam eter

Flywheel h ou sin g N V .. N o m in a l Value
eccentricity L Limit
L 0.2
Idler ge ar end play

Bend lock w asher N V 0.05 to 0.15
L 0.4
C am sh aft gear-to-cam shaft
interference
B D 40
N V 0.02 to 0.05
L R ea sse m b le m ax. 3 tim es
C am sh aft ge ar end play 17

<Radial-lip-type oil seal> N V 0.05 to 0.22
L 0.4 20A
Locating pin 16
1 5 155 N-m {16 kgf-m}
1 315 N-m {32 kgf-m} (wet) •98 N-m {10 kgf-m}
6
19
18
A p p ly engine oil or ■98 N-m {10 kgf-m}
lithium -base grease 15 155 N-m {16 kgf-m}
to oil seal lip 6
16
Flywheel friction
surface runout
B6013A
L 0.2
1 0 B -V I0 A
@ —»20->20A-»© —» © - > © —»16—>1
I
—> ® — »5-»4—»3-»2-»1
T T
<ID (12-^14—>03))— 1 10 ®
For parts with circled num bers, refer to the follow in g section, "R e a sse m b ly Procedure."
For parts marked with " * " refer to G ro u p 61, Special Equipm ent.
B1902E
11-39
R eassem bly Procedure (3) Fitting camshaft gear

(1) M ounting rear plate
_______________________________________________ 21921
(a) With the alignment marks " 4 " facing away from
M o u ntth e rear plate and gasket, ensuring that they are the thrust plate, fit the camshaft gear using a press
aligned with the locating pins on the crankcase. load A of 15.69 to 58.8 kN {1,600 to 6,000 kgf}.
After the gasket is fitted, its bottom (oil pan m ounting B: Block
surface) will protrude. Cut off the protruding part ofthe (b) Press the camshaft gear until it sits sn u gly on the
gasket after fitting the flywheel housing. camshaft.
(2) Installing idler gears NOTE:
A p p ly pressure to the middle part of the cam shaft
gear. Do not apply pressure to the gear's periphery
since the gear w ould break.
Fit idler gear B and the crankshaft gear such that their
" 1 " alignm ent marks are aligned with each other.
22021
Then, fit idler gears A and C such that their " 2 " align
ment marks are aligned with each other. Tighten the (c) M ake a punch mark C on the middle part of the
idler shaft bolts to the specified torques.
camshaft gear to show that reinstallation has been
NOTE: performed.
1. Align the " 1 " m arks w ith pistons Nos. 1 and 6 at NOTE:
top dead center.
The cam shaft gear and cam shaft can be fitted together
2. Ensure t h a t t h e " ! " m arks are aligned before align a m axim um of three times. If three punch m arks C
ing the " 2 " marks.
have already been made, replace the cam shaft gear
and cam shaft with new ones.
11-40
(4) Installing camshaft the oil seal siinger until it is seated tightly on the crank
shaft gear.
(8) Fitting oil seal sleeve <With radial-lip-type oil seal>
Install the camshaft such that the " 4 " alignment marks
on the camshaft gear and Idler gear A are aligned with
each other. Apply engine oil to the crankshaft and to the inside
NOTE: diameter of the sleeve. Using the Oil Seal Sleeve
1. When inserting the camshaft, take care not to Installer (special tool), press the sleeve into position on
dam age the camshaft bushings. the crankshaft.
2. Ensure that the "1 " marks on the crankshaft gear NOTE:
and idler gear B are aligned before aligning the "4 " 1. The sleeve's inside diameter is chamfered on one
marks. side. When fitting the sleeve, face the chamfered
(5) Check the end play in the camshaft gear and idler side toward the crankshaft.
gears. [Refer to item (5) of section 5.3.1 for details.] 2. Since the sleeve must be pushed into the correct
position (shown in the illustration), you m ust use
(6) Check the backlash in the gears. [Refer to item (4)
the Oil Seal Sleeve Installer. The sleeve is in the
of section 5.3.1 for details.]
correct position when the Installer can be driven in
(7) Installing rear oil seal siinger <With axial-lip-type no further.
oil seal>
(9) Fitting ring gear
Rear oil seal siinger

Oil Se a l Installer
M H 061652
Seat th is surface
tightly all around
Threaded groo ve
C5529B
Face the threaded groove toward the flywheel. U sing U sing a piston heater, heat the ring gear to approxi
the Oil Seal Siinger Installer (special tool), evenly press mately 100°C for 3 minutes. Fit the ring gear with the
non-chamfered side of its teeth toward the flywheel.
11-41
(10) Fitting flywheel housing (H )C h e ckin g flywheel housing eccentricity
Flywheel h ou sin g
C6233B
(a) A p p ly a bead of sealant to the flywheel housing as Tighten the flywheel housing mounting bolts to the
sh o w n in the illustration. Fit the flywheel housing specified torque. Then, rotate the flywheel and check
w ithin 3 m inutes of applying the sealant. for eccentricity at the flywheel housing joint. If eccen
NOTE: tricity exceeds the specified limit, remove the flywheel
1. A p p ly a new bead of sealant w henever the fly housing, refit it according to the instructions in item
w heel hou sing m ounting bolts have been loos (10), and m easure the eccentricity again.
ened. If the eccentricity exceeds the specified limit even after
2. Keep the flywheel hou sing sealing surface free of remedial m easures have been taken, replace the fly
dirt and oil. wheel housing.
3. A p p ly the sealant evenly and w ithout breaks. (12)lnstalling oil seal
4. W h e n fitting the flywheel housing, hold it firmly in
<Axial-lip-type oil seal>
position to prevent spreading the sealant.
5. After fitting the flywheel housing, w ait at least 1
h o u r before starting the engine.
(a) Apply an even, unbroken bead of sealant A to su r

face B of rear oil seal that contacts the flywheel
housing when installed.
(b) Fit the flywheel housing such that it is aligned with (b) Fit the rear oil seal onto the flywheel housing
the locating pins in the crankcase. within 3 minutes of applying the sealant A.
11-42
3. After fitting the rear oil seal, wait at least an hour (13)Checking flywheel runout
before starting the engine.
4. Apply a new bead of sealant A whenever the
mounting bolts ofthe rear oil seal have been loos
ened.
<Radial-lip-type oil sea!>
After tightening the flywheel m ounting bolts to the

specified torque, rotate the flywheel and check for run
out. If runout exceeds the specified limit, check the
bolts' tightness and/or check the m ounting surface.
(14)Checking valve timing
(a) To install the oil seal, apply pressure evenly to its If you need to recheck the valve tim ing after reassem
entire periphery using the Oil Seal Installer (special bling the engine, do so according to the follow ing pro
tool) until it reaches the step in the oil seal retainer. cedure.
(b) Turn the oil seal retainer over, then apply the Oil (a) Bring cylinder No.1 to its com pression-stroke top
Seal Installer (special tool) to the oil seal from the dead center position.
opposite direction until the oil seal reaches the (b) Insert a 3 m m shim between cylinder N o.Ts
retainer's outer surface. exhaust valve rocker arm and valve cap. M ake any
NOTE: adjustments necessary using the adjusting screw,
Different oil seals have different installation direc then tighten the lock nut.
tions. Be sure to install the oil seal in the correct direc
tion.
11-43
10408
(c) Crank the engine in its normal direction of rotation

(clockwise w hen viewed from the front). W hen cyl
inder N o . I's exhaust valve begins to lift, confirm
thatthe pointer on the flywheel h ousing is between
the valve tim ing confirmation marks on the fly
w h e el's outer periphery. Ifthe timing m arks are in
the w ro n g position, refer to items (2) and (4), and
check the tim ing m arks again.
11-44
5.4 Crankcase and Main Moving Parts
5.4.1 Disassembly
L Limit
5 . D am age/
abnorm al w ear
6J
Dam age/discoloration
Scratches on outer periphery/
7 cracks on top/
\ 8 discoloration/m elting
* Projection of piston from

top surface of crankcase
N V 0.87 to 1.33
Cracks 9
& Connecting rod end play

N V 0.2 to 0.5
L 1.0
3 Scratches/corrosion/
peeling on inner and
outer peripheries
Repair kit:
Liner and Piston Kit
Scratches/corrosion/
2 peeling on inner and
outer peripheries
o r1
D isassem bly sequence
1 Connecting rod cap (D Oil ring
2 Lower connecting rod bearing 7 Piston pin
3 Upper connecting rod bearing ® Piston
@ 1st com pression ring ® Connecting rod
© 2nd com pression ring '10 Connecting rod bolt
For parts with circled num bers, refer to the follow ing section, "D isa ss e m b ly Procedure.”
Parts marked w ith sh o u ld be inspected prior to disassem bly.
Parts marked w ith sh o u ld not be rem oved unless defects are evident.
C2337G
11-45
NV N o m in a l Value
L ... Limit 25 C lo g g e d oil hole
Rear oil seal siinger

(Refer to 5.3.)
D isasse m b ly sequence
11 Torsional damper 17 Thrust plate * 122 Cylinder liner
12 Crankshaft pulley 18 Low er main bearing * 223 Check valve
#113 Front oil seal 19 Crankshaft 24 Oil jet
14 Front cover 20 Upper main bearing 25 Oil spray plug
* 115 Front oil seal siinger n (0) Crankshaft gear 26 Crankcase
16 M a in bearing cap
For parts with circled num bers, refer to the fo llo w in g section, "D is a s s e m b ly Procedure."
Parts marked with "fK" sh o u ld be inspected prior to disassem bly.
Parts marked with * * 1 " sh o u ld not be rem oved u n le ss defects are evident.
Parts marked with " * 2 " m u st not be reused sin ce they are held in place by thread-lock cem ent a nd m a y be deform ed
du rin g disassem b ly.
B0599G
11-46
Disassem bly Procedure (3) Rem oving pistons
(1) Piston projection
The piston projection m easurem ents m ust conform
with specifications, partly since they affect engine per
formance, and partly since the pistons m ust not inter
fere with the valves.
W ithdraw the piston from the crankcase together with

its connecting rod, w orking from the top surface ofthe
crankcase.
NOTE:
When removing a piston, take care not to dam age the
(a) Attach a dial indicator to the top surface of the cylinder liner.
crankcase and adjust it to zero. (4) Separating piston from connecting rod
(b) U sing the dial indicator, find the piston's top dead
center position.
(c) Take m easurem ents at 4 points on the piston's top
surface and determine their average.
(d) If the piston projection d oes not conform with
specifications, check the clearances between pis
ton/connecting rod and neighboring parts.
(2) Connecting rod end play
Rem ove the snap rings, then use a rod and ham m er to
tap the piston pin out. If the piston pin is hard to
remove, heat the piston in hot water or with a piston
heater.
M easure each connecting rod's end play. If any mea

surem ent exceeds the specified limit, replace the con
necting rod.
11-47
(5) R em oving piston rings (7) Rem oving main bearing caps
(6) Crankshaft end play The rearmost main bearing cap is located on dowel
pins and m ust therefore be removed with a slide ham
mer.
(8) Rem oving crankshaft gear
Before rem oving the main bearing caps, m easure the

end play in the crankshaft. If it exceeds the specified
limit, replace the thrust plate with an oversized one.
[Refer to item (3) of section 5.4.3 for details.]
(a) Split the rear oil seal slinger with a chisel and
remove it from the crankshaft.
(b) Rem ove the crankshaft gear from the crankshaft
using the Gear Puller (special tool).
NOTE:
Do not attempt to remove the crankshaft gear by strik
ing it.
11-48
5.4.2 Inspection
End g a p
Item NV L
1st com p ressio n ring 0.4 to 0.55 1.5
2 nd com p ressio n ring 0.5 to 0.65 1.5
Oil ring 0.4 to 0.6 1.5
Clearance
B D 50
N V 0.01 to 0.02
L 0.1
Piston ring groove-to-piston ring clearance

Item NV L
1st c o m 6D24 0.09 to 0.13 0.25

pression
Clearance ring 6D24-T, TC, T L 0.02 to 0.10
B D 50
N V 0.02 to 0.05 2 nd c o m 6D24 0.05 to 0.08 0.25
L 0.1 pression
ring 6D24-T, TC. TL 0.07 to 0.10
Bend
L 0.05 or less Oil ring 0.03 to 0.06 0.15
Torsion
L 0.1 or less
Crankcase top surface

distortion
N V 0.07 or less
L 0.2
Flatness of cylinder liner Clearance

su p portin g flange
L 0.1 Item BD NV
6D24 130 0.178 to 0.204
6D24-T, TC, 0.193 to 0.219

TL
Projection of cylinder liner from

top surface of crankcase
N V 0.01 to 0.08
B D .. B a sic Diam eter
inside diam eter
N V 130.014 to 130.054 N V .. N o m inal Value
L 130.25 L Limit
Cylindricity
N V 0.02 or less C onnecting rod bearing-to-crankshaft
pin clearance
B D 84
N V 0.07 to 0.13
L 0.25
C onnecting rod bearing sp an w hen

free
L Le ss than 90.5
C2760C
11-49
free
L L e ss than 106.5
B0599H
Inspection Procedure
(1) Flatness of cyiinder-liner-supporting flange on
crankcase
If the m easured value is out of specification, replace

the crankcase.
11-50
(2) Distortion of crankcase top surface (4) Cylinder liner flange projection
If distortion of the crankcase top surface exceeds the If any cylinder liner projection does not conform with
specified limit, correct it with a surface grinder. its specified nominal value, replace the cylinder liner or
NOTE: crankcase. [Refer to item (5) for details of cylinder liner
When grinding the crankcase, take care that the piston replacement.]
projection does not exceed the specified nominal (5) Replacing cylinder liner
value. [Refer to item (1) of section 5.4.1 for details.] (a) Removal
(3) Cylinder liner inside diameter
M easure each cylinder liner's inside diameter at 6

points, as show n in the illustration. Ifthe inside diam e
ter exceeds the specified limit, replace the cylinder
liner or bore it to oversize. [Refer to item (5) for details
of cylinder liner replacement.]
11-51
(b) Installation
Strike in.
J Cylinder Liner Installer
MH061759
Size m ark (A, B, C) Piston
C4427B
C4813C
3) Using the Cylinder Liner Installer (special tool),

1) M ake sure the new cylinder liner bears the sam e gently tap the cylinder liner down until its flange is
size mark as that of the piston. securely seated on the crankcase.
Piston size mark Cylinder liner size mark NOTE:
A ------------------------------- A 1. Do not stretch O-rings more than is necessary, and
B ------------------------------- B be careful not to damage them.
C ------------------------------- C 2. Contact with gas oil, kerosene, anti-corrosion oil,
and similar fluids causes O-rings to swell. Immedi
ately wipe off any such fluids that come into con
tact with the O-rings.
3. After installing a cylinder liner, carry out a leak test
to check for air-tightness. Apply thrust force to the
cylinder liner flange.
2) Fit new O -rings and rubber packing to the cylinder

liner, and apply soap suds to the crankcase and cyl
inder liner at the points where they will touch each
other.
11-52
(6) Selection of pistons and cylinder liners (b) Oversized piston
A piston m ay be either standard or oversized. Cylinder In accordance with the follow ing instructions, bore the
liners are selected accordingly. cylinder liner to suit the oversized piston to be used
(+0.5, +0.75, or +1.00 mm).
(a) Standard piston
Cylinder liner I.D.
C4424A
Oversize piston O.D.
1) The piston m ust bear the sam e size mark as that 1) Determine the am ount of metal to bore out. To do
stam ped on the cylinder liner. this, measure the inside diameter of every cylinder
2) The weight of all 6 of an engine's pistons m ust be liner and find the m ost worn point.
within 10 g of the weight that is stam ped on each 2) Bore and hone-finish the cylinder liner to achieve
piston's crown. the specified nominal clearance between the over
sized piston and cylinder liner.
NOTE:
Whenever a piston is replaced, the piston rings must NOTE:
also be replaced. Never use old piston rings. 1. Even if only one cylinder requires boring, bore
every cylinder to the same oversized inside diame
ter.
2. Replace the piston rings with oversized piston
rings that correspond tp the increased cylinder
liner dimension.
11-53
(7) Piston-to-cylinder liner clearance (9) Piston ring gap

If the clearance is out of specification, replace the p is
ton or cylinder liner. [Refer to item (6) for details.]
(8) Piston-to-piston ring clearance
M easure the piston ring gaps with the piston rings hor
izontally pushed into a standard cylinder liner, either in
or out of the crankcase.
Replace the rings if any gap exceeds the specified limit.
Standard cylinder liner inside diameter: 130 ± 0 mm
piston or piston rings.
NOTE:
NOTE:
Use a piston to push the piston rings into the cylinder
1. After removing any carbon deposits, measure the
liner for measurement.
clearance around the piston's entire periphery.
2. A lw ays replace piston rings as a set, never individ (10)Piston pin-to-piston pin hole clearance
ually.
C4810D
M easure the 1st com pression ring clearance while piston pin or piston.
pressing the ring against the piston with a straight NOTE:
edge. Whenever a piston is replaced, the piston rings must
also be replaced. Never use old piston rings.
11-54
(11) Piston pin-to-connecting rod small end bushing (a) Rem oving bushing
clearance
Mandrel
31291-75200,
G uide Plate
A sse m b ly
MH063368
Larger dim e nsion

facing d o w n w ard
y /V /y //7 7 7/7777777/ / / / / /
'/ Press bench
C5203A
1) Rem ove the bearing from the connecting rod's big

If the clearance exceeds the specified limit, replace the end, then m ount the connecting rod on the Base
connecting rod bushing. (special tool).
(12)Replacihg connecting rod bushing 2) Fit the Mandrel and Collar A (special tools) onto the
connecting rod's small end as show n in the illustra
tion. Slow ly apply pressure with a press that has a
capacity of at least 49 kN {5,000 kgf}.
(b) Press-fitting bushing
Approx. 49 kN {5,000 kgf}
J L
Guide Plate A s se m b ly
Collar B MH063368
MH062189
B u sh in g.
Collar A Larger dim ension
M H 063370- facing d ow n w ard
\
-=cjV f
Replace the bushing using the Connecting Rod B u sh
ing Puller (special tool). 77777777777
I Press bench
10977
1) Set up the Mandrel, Collar B, Collar A, and the Nut

(special tools) on the bushing as sh o w n in the
illustration.
2) Apply engine oil to the connecting rod's sm all end
and to the bushing.
3) U sing the press, apply pressure of approximately
49 kN {5,000 kgf} such that the bushing is pressed
into the connecting rod's small end.
4) After press-fitting the bushing, remove the special
tools. Then, ream the bushing to achieve the speci
fied nominal clearance between the bushing and
piston pin.
11-55
NOTE:
1. When press-fitting the bushing, align the oil hole
in the bushing with the oil hole in the connecting
rod.
2. W hen the piston pin is inserted, ensure that it
turns easily and without play.
(13)Connecting rod bend and twist
If the span is less than the specified requirement,

replace the upper and lower bearings as a set.
NOTE:
Do not attempt to manually expand a bearing if its
span is insufficient.
(15)Connecting rod bearing-to-crankshaft pin clear
ance
M easure the am ount of bend and twist in the connect

ing rod using a special connecting rod aligner. If the
m easurem ents exceed the specified limits, replace the
connecting rod or rectify it using a press.
NOTE:
1. Measurem ents m ust be made with the connecting
rod bushing and upper and lower connecting rod
bearings fitted in their respective positions.
2. Measurem ents m ust be made with the connecting
rod cap mounting nuts tightened to their specified
torque.
(14)Span of connecting rod bearings and main bear
in g s when free If the clearance exceeds the specified limit, replace the
upper and lower bearings as a set.
NOTE:
Measurements must be made with the connecting rod
cap mounting nuts tightened to their specified torque.
11-56
(16)Main bearing-to-crankshaft journal clearance (18) Crankshaft bend
M a in bearing inside diameter
P
£l
C5524A
Crankshaft journal outside diameter
M e asu rin g direction M e asu rin g position

M easure the extend of bending in the crankshaft at the
middle journal. If the measurement exceeds the speci
fied limit, grind to undersize or replace the crankshaft.
NOTE:
With the dial indicator applied to the middle journal,
turn the crankshaft through one revolution. One-half
of the dial indicator reading represents the extent of
bending in the crankshaft.
(19)Grinding crankshaft to undersize

upper and lower bearings as a set.
(17)Roundness and cylindricity of crankshaft pin and
journal
R oun dn ess Cylindricity
M e asu rin g position
A n y dam aged or scorched journal or pin m ust be

ground in accordance with the following instructions.
If grinding is carried out, the main bearing m ust be
C5523A
replaced with an undersized one.
(a) Grind such that the center distance between the
If roundness and cylindricity do not conform with the
journal and pin does not change.
specified limits, grind to undersize. [Refer to item (.19)
for details.] (b) Grind such that the width of the journal and pin
does not change.
(c) Finish the corner fillet sm oothly and to the speci
fied radius.
11-57
(d) U se m agnetic flaw detection to check for ground (e) W hen grinding, turn the crankshaft counter-clock
cracks. Also, check that the Shore hardness of the wise as viewed from its front end. The grinder
surface has not dropped below Hs 75. should also rotate counter-clockwise as viewed
from the crankshaft's front end.
(f) W hen finishing the crankshaft with sandpaper or a
whetstone, turn the crankshaft clockwise.
A m o u n t of Jou rn al O. D. Pin O. D. finished R o u n d n e ss Cylindricity

undersize finished d im e n sio n dim ension
-0.25 0.01 or less 0.006 or less

99.75 I £ h ) - ° ' 06
83 75 -0.09
-0.50
99.50 l £ ? o 83.50 lo 'o g
-0.75
99.25 ^ 83.25 if t g g -
- 1.00
99.00 83.00
11-58
5.4.3 Reassem bly
A sse m b ly sequence L Lim it
Cylinder liner
flange projection
@-*<D N V 0.01 to 0.08
->©->14-+<0W l2->11
For parts w ith circled num bers, refer to the follow in g section,
"R e a sse m b ly Procedure."
Locating pin
34 N-m
{3.5 kgf-m}
23
24
Lug direction
Expander
1st
com pression
sp rin g ends
ring ga p
n .. - 115 N-m
Oil ring ga p {12 kgf-m }+ 60 115 N-m {12 kgf-m}
(wet) (wet)
(Tj) Face arrow head up.
.Rear oil seal siinger

[Refer to item (7) of
section 5.3.3)
Oil seal sleeve
[Refer to item (8 ) of
section 5.3.3]
17 Side w ith oil groove

faces slid in g surface
Crankshaft end
play
N V 0.09 to 0.23
L 0.4
C5835F
11-59
Reassembly Procedure (3) Installing upper main bearing and thrust plate
(1) Installing oil spray plug
Upper m ain bearing
Thrust plate
m ounting pin
■Thrust plate
Oil groove
C5837A
Installthe uppermain bearing suchthatthe bearing lug

Install the oil spray plug such that the arrow stamped is aligned with the lug groove on the crankcase.
on it points toward the top of the engine. Install the rearmost thrust plate with its grooveless
side facing the crankcase.
(2) Installing oil jet and check valve
NOTE:
1. The main bearing's upper part has an oil groove.
The lower part does not have a groove. Take care
not to confuse the upper and lower parts.
2. Oversized thrust plates are available for adjust
ment of crankshaft end play [refer to item (6) of
section 5.4.1 for details]. The oversized thrust
plates available are +0.15, +0.30, and +0.45 mm. If
o any of these is used, ensure that the correct size
© thrust plate is fitted to the bearing cap [refer to
item (7) for details].
o \
C5836C
(4) Installing crankshaft gear
Insertthe oil jet's locating pin into the hole on the crank
case, and tighten the check valve to the specified
torque.
NOTE:
Check valves cannot be reused. Be sure to use a new
one.
(a) Heat the gear to approximately 100°C using a pis

ton heater.
11-60
(b) Locate the gear such that the dowel pin on the (7) Installing lower main bearings and main bearing
crankshaft will fit into the notch in the gear. Fit the caps
gear by lightly striking it with a soft hammer. Install the lower main bearings and main bearing caps
(c) Fit the rear oil seal slinger (refer to item (7) of sec in accordance with the following procedure.
tion 5.3.3) or oil seal sleeve (refer to item (8) of sec
tion 5.3.3).
(5) Fitting front oil seal slinger <Axial-lip-type oil seai>
(a) Drive the locating dowel pins into the rearm ost
main bearing cap in the direction sh o w n in the
illustration.
Fit the front oil seal slinger using the Oil Seal Slinger
Installer (special tool).
T hrust plate
/ M a in bearing cap
(6) Installing crankshaft
T hrust plate
m o u n tin g pin
Lug groove
/ O i l groo ve
T hrust
plate
Low er m ain bearing
- Lug
C5838G
E m b o sse d main bearing
cap num ber
Lift the crankshaft with a hoist. Keeping it horizontal,

Front of*,
gently lower it into the crankcase. engine s P
Tx_
B4222E
(b) Mate each main bearing with its m ain bearing cap,
ensuring that the lugs on the bearings are aligned
with the lug grooves in the caps.
11-61
(c) O nly to the rearm ost main bearing cap, install a counter-clockwise to tension the built-in socket
thrust plate on each side, with the thrust plates' spring.
grooveless sides facing the main bearing cap.
NOTE:
2) Fit the socket over the main bearing cap m ounting

head bolt. Set it such that the built-in spring forces
If an oversized thrust plate is used, ensure that the the rod against the side ofthe crankcase.
bearing cap rear thrust plate and the rearmost thrust
plate in the crankcase [refer to item (3)] are the sam e
size. Note, however, that the bearing cap front and
rear thrust plates m ay be of different sizes.
(d) Fit the main bearing caps in the order of the n u m
bers that are em b ossed on them, working from the
front of the engine. Fit them such that the sides
with lug gro o ve s are toward the right ofthe engine.
(e) Press dow n the main bearing caps until they touch
the crankcase. Tighten the main bearing cap
m ounting bolts to 115 N-m {12 kgf-m} (wet).
After confirm ing that the bolts are tightened to the
specified torque, give each one an extra turn in
accordance with the following procedure. 3) Observing the inscribed lines on the holder and
socket, turn the socket 60° clockwise (1 pitch = 10°)
to fully tighten the bolt. After assembly, check that
the crankshaft can be turned easily by hand. Also,
check that the crankshaft's end play conform s with
the specified nominal value. [Refer to item (6) of
section 5.4.1 for details.)
13205
1) Before fitting the Socket Wrench (special tool) over

a m ain bearing cap mounting bolt, turn the holder
11-62
(8) Installing connecting rod bolts NOTE:
All the connecting rods in an engine m ust have the
same w eight mark. Weight marks are as follows:
Heavy <------------------------------------------------- — > Light
A B C D E F G H J K
{10)Fitting piston rings
Checkthat there are no burrs or dam age in the connect

ing rod's bolt holes. Apply engine oil to the connecting
rod bolts, then press fit the bolts such that the flattened
side of their heads face inward.
(9) Reassem bling piston and connecting rod
U sing the Piston Ring Tool (special tool), fit the piston
rings in the positions show n in the illustration. Ensure
that the manufacturer's marks on the com pression
rings face upward. Fit the rings in the follow ing order:
1. Oil ring
2. 2nd com pression ring
3. 1st com pression ring
Connect the piston to the connecting rod with the pis

ton pin such that the piston's front m ark " F " is on the
sam e side as the connecting rod's lug groove mark.
Ifthe piston pin is difficult to insert, heat the piston in
hot water or with a piston heater.
11-63
(11)Installing upper and lower connecting rod bear- NOTE:

1. Check that the size mark on the piston matches
the size mark on the cylinder liner.
2. Ensure that the piston ring ends stay in their cor
rect positions.
3. Slip some plastic tube over the connecting rod
bolts to prevent them from dam aging the cylinder
liner and crankshaft pin.
c U sin g the Piston Guide Clamp and Piston Guide Lever
(special tools)>
Install the upper connecting rod bearing such that its

lug is aligned with the connecting rod's lug groove.
Install the lower connecting rod bearing such that its
lug is aligned with the connecting rod cap's lug groove.
NOTE:
The upper connecting rod bearing has an oil hole. The
lower bearing does not have an oil hole. Take care not
to confuse the upper and lower parts.
(12)lnstalling piston and connecting rod A lign the Piston Guide with the piston skirt and set the
Piston Guide Lever in position. Turn the adjusting bolt
such that the Clam p's inside diameter matches the pis
ton's outside diameter. Next, rem ove the Clamp from
the piston and apply engine oil to the outside ofthe pis
ton, to the inside ofthe Clamp, and to the inside ofthe
cylinder liner.
Fit the Clamp over the piston such that it is flush with
the piston's crown. Using a w ooden mallet or block, tap
the piston into the cylinder, taking care not to damage
it.
U sin g the Piston Guide Clamp and Piston Guide Lever

(special tools), install the piston and connecting rod
such that the front mark on the piston's crown faces the
front of the engine.
11-64
(13) Fitting connecting rod caps 5.5 inspe cting and A d ju stin g V alve C learance s
Valve clearances should be checked and adjusted
when the engine is cold.
Ensure thatthe alignment m arks and lug groove marks

on the connecting rod caps and connecting rods are
aligned with each other.
(1) Crank the engine until the inscribed "1-6 " mark on
(14)Checkthe connecting rod's end play. [Referto item
the flywheel is aligned with the pointer in the fly
(2) of section 5.4.1 for details.]
wheel housing inspection window. W hen this hap
(15)Check that the piston projections conform with pens, the pistons w hose push rods are not pushing
specifications. [Referto item (1) of section 5.4.1 for up their rockers are at the top-dead-center (TDC)
details.] position of their com pression stroke.
(16) Fitting front oil seal
Press evenly around the oil seal's entire periphery until

its flange is seated securely on the front cover.
11-65
(2) W hen piston No. 1 is at the T D C position of its compression stroke, check and adjust the clearances of
pression stroke, check and adjust the clearances of the valves marked " x " in the table. Be sure to
the valves marked "o" ' n the follow ing table. check and adjust every valve.
W hen piston No. 6 is at the T D C position of its com-
Cylinder No. 1 2 3 4 5 6
Valve arrangem ent In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
No. 1 at T D C of c o m p re ssio n stroke o o o o 0 0

N o . 6 at T D C of c o m p re ssio n stroke X X X X X X
(3) U sing the Thickness Gauge (special tool), check

Valve clearance that the rocker arm-to-valve cap clearance con
(w hen cold)
form s to specifications. To measure the clearance,
Inlet
N V 0.4 insert a gauge ofthe same thickness as the speci
Exhaust fied nom inal clearance between the rocker arm
N V 0.6
and valve cap. The gauge should be able to move
in the gap, but not loosely.
If the clearance is incorrect, loosen the lock nut and
Th ickne ss turn the adjusting screw as required. W hen the
Gauge
MH061359 clearance is correct, tighten the lock nut to the spe
cified torque to secure the adjusting screw.
N V .. N o m in a l Value B5714B NOTE:
After tightening the lock nut, confirm that the clear
ance is still correct.
11-66
ENGINE - TROUBLESHOOTING 11
6. TROUBLESHOOTING
S y m p to m Probable cause R em edy Reference
E n g in e will not Incorrect oil viscosity Replace G roup 12

start
Incorrect/defective fuel G rou p 13A
Low c om p ressio n pressure

• Incorrect valve clearance(s) Adjust
• Defective cylinder head gasket Replace
• W orn valve and valve seat/carbon deposits
• W eakened valve sp rin g
• W orn/dam age d piston ring(s)
• W orn/dam age d piston ring groove(s)
• W orn piston(s)/cylinder liner(s) C h an ge to oversize
Defective preheater
• Defective starter sw itch Repair or replace G rou p 16
• Defective heater relay
Incorrect injection tim in g Adjust G rou p 13A
Insufficient fuel injection vo lu m e

• Defective injection p u m p Repair or replace G rou p 13A, E
• Incorrect fuel injection v olu m e
Defective co o lin g sy ste m Repair or replace G rou p 14
R o u g h idling Incorrect oil viscosity Replace G rou p 12
Incorrect/defective fuel G rou p 13A
Defective coolin g system Repair or replace G rou p 14
Low c om p ressio n pressu re (see "E n g in e will not start")
Incorrect injection tim in g Adjust G rou p 13A
Defective fuel system

• Defective injection p u m p Repair or replace G rou p 13A, E
• Defective injection nozzle
• Air trapped in fuel sy ste m
A b n o rm a l Incorrect/defective fuel Replace G rou p 13A

exh au st g a s
color ■ Cooling sy ste m m alfu nction ing Repair or replace G rou p 14
Intake/exhaust sy ste m m alfunctioning

• C lo gg e d air cleaner Repair or replace G rou p 15
• C lo gg e d muffler
• Oil leaking into intake/exhaust pipes
Low com p ression pressure (see "E n g in e will not start")
Defective fuel system

• M alfunctioning injection p u m p Repair or replace G rou p 13A, E
Incorrect injection tim in g Adjust
Excessive engine oil Adjust G rou p 12
Seizure of m ajor m o vin g parts Repair or replace
11-67
11 ENGINE - TROUBLESHOOTING
S y m p to m Probable cau se Rem edy Reference
Lo w p ow e r Incorrect oil viscosity Replace Group 12

output
Incorrect/defective fuel G roup 13A, E
C oolin g system m alfunctioning Repair or replace Group 14
Intake/exhaust sy ste m m alfunctioning

• C lo g g e d air cleaner Repair or replace G roup 15
• C lo g g e d muffler
Low com p ressio n pressure (see "E n g in e will not start")
Fuel sy ste m m alfunctioning

• M alfu nction in g injection p u m p Repair or replace Group 13A, E
• A ir trapped in fuel system
Incorrect injection tim ing Adjust
E x c e ssiv e oil Oil leaking from lubrication system Inspect and/or repair G roup 12
c o n su m p tio n
Oil leaking from en gin e and related parts
• Defective gasket/oil seal Replace
Oil entering com b ustion ch am ber p ast piston

• W orn cylinder liner(s)/piston(s) Rectify or replace
• Piston ring(s) w orn, d a m a ge d , or seized Replace w h o le set
• C lo g g e d piston/oil ring oil hole(s) Clean
Oil entering com bustion ch am ber via v alv e s

• W orn valve stem (s)/valve gu ide(s) Replace
• W orn valve stem seal(s)
A b n o rm a l N o ise em an atin g from outside parts of e n gin e

e n gin e noise
• Lo o se p iping/hose connection(s) Inspect
• Injection pum p, alternator, other auxiliary unit(s) incorrectly Inspect and/or adjust G rou ps 13A, E and
m ounted 16
• Lo ose /dam age d V-belt Replace Group 14
• Incorrectly m ounted crankshaft pulley Inspect and/or adjust
• M alfu nction in g air cleaner and/or m uffler Repair or replace Group 15
N o ise em anating from vicinity of rocker cover

• Incorrect valve clearance(s) Adjust
• Defective valve sp rin g(s) Replace
• Defective rocker shaft/bracket Inspect and/or repair
• Im proper lubrication of rocker shaft Inspect
11-68
ENGINE - TROUBLESHOOTING 11
S y m p to m Probable cau se Rem edy Reference
A b n o rm a l Noise em an atin g from vicinity of flyw heel h ou sin g

e ngine noise
• Incorrect tim ing gear backlash Replace
• Incorrect lubrication o f tim ing ge a rs and idler shaft inspect
N o ise em an atin g from cylinder head/crankcase

• Low com p ression p ressure (see "E n g in e will not start")
• Incorrect injection tim in g Adjust G rou p 13A
• Incorrect spray of injection nozzles Repair or replace
• W orn connecting rod sm all end b u sh in g(s) and piston pin(s) Replace
• W orn /dam age d crankshaft pin(s) and connecting rod big end
bearing(s)
• W orn /dam age d crankshaft journal(s) and m ain bearing(s)
• E xcessive crankshaft/cam shaft end play Replace thrust plate(s)
• W orn tappet(s)/cam shaft Replace w orn part(s)
Turbocharger m alfunctioning Inspect and/or rectify G rou p 15
11-69
12
LUBRICATION
CONTENTS
1. G E N E R A L ...................................... 2 4.1.2 D isasse m bly and inspection ............. 13

2. SP E C IF IC A T IO N S ................................... 9 4.1.3 Reassem bly ................................... 15
3. S E R V IC E S T A N D A R D S .......................... 10 4.2 Oil Filter and Oil Cooler ....................... 15
3.1 Service Standards Table ...................... 10 4.2.1 Rem oval and installation ................. 15
3.2 Tightening Torque Table ...................... 10 4.2.2 Oil filter ......................................... 16
4. S E R V IC E P R O C E D U R E .......................... 11 4.2.3 Oil cooler ....................................... 17
4.1 Oil Pum p ........................................ . . . 1 2 4.3 Regulator Valve ................................. 18
4.1.1 Rem oval and installation ................ 12 5. T R O U B L E S H O O T IN G ............................. 19
12-1
12 LUBRICATION - GENERAL
1. GENERAL
Oil p ressure
gauge
* M o d e ls with turbocharger B1539H
Engine lubrication is accom plished by forced lubrica (1) Oil pump

tion system using gear pump. The engine oil in the oil
pan is drawn up through the oil strainer by the oil pum p
and force-fed to the oil filter and oil cooler to lubricate
all parts.
12-2
LUBRICATION - GENERAL 12
The oil pump, of a gear pum p type, is mounted in the
rear bottom portion of the crankcase, driven by the
crankshaft gear.
The oil strainer at the suction port prevents entry of for
eign matter in the oil pan and air. The engine oil is
routed to the crankcase by the oil pipe connected to the
delivery port.
The crankshaft gear drives the oil pum p idler gear and
oil pum p gearto transmit rotation to the oil pum pdrive B5693A
gear.
The oil pum p is driven at a speed proportionate to the
engine speed. Therefore, it is provided with a relief
valve that prevents excessive pressure from being
Drive gear applied to the lubrication system when the engine is
started in cold weather involving a surge in oil pum p
delivery pressure.
Delivery , , Suction side
side (oil strainer side)
Driven gear
Oil p u m p case
B1505A
Inside the oil pum p case, there are oil pum p drive gear
and driven gear which are in m esh with each other.
W hen the drive gear is driven, the driven gear is caused
to turn in an opposite direction.
A s the gears rotate with the gear teeth sliding on the
inner surfaces of pum p case, the resultant negative
pressure causes the engine oil to enter the oil pum p
and the oil trapped in the space formed by the teeth
and gear case inner wall is forced out through the deliv
ery port.
12-3
(2) Oil filter (3) Oil bypass alarm
The oil filter a ssem b ly consists of a full-flow filter and a

b ypass filter. Paper elements are used.
Engine oil fed under pressure from the oil pum p passes
through the oil hole in the crankcase and enters the full-
flow and b yp a ss filters via the oil filter head. Engine oil
that p a sse s through the full-flow filter is routed from
the oil filter head to the oil cooler via the crankcase oil
hole. E ngine oil that passes through the b y p a ss filter
returns to the oil pan.
W hen the oil filter element is plugged resulting in the

difference in pressures between before and after the
element exceeding a predetermined level, the valve
overcom es the spring tension to move. A s a result,
unfiltered oil flow s directly to the oil cooler.
The oil bypass alarm has electric contacts that are
closed to turn on the pilot lamp, warning the driver of
clogged element when the valve is opened.
12-4
The oil cooler is of the shell-and-plate (multi-plate) the sam e time, coolant from the water pum p flow s
type. It is mounted in the coolant path on the left of the around the outside of the element. The engine oil in the
crankcase. element is thus cooled or heated before flow ing to the
Engine oil that has been forced through the oil filter main oil gallery.
flows through the inside of the oil cooler element. At
B ypass valve Regulator valve
W hen the oil's viscosity is high at low temperatures or The regulator valve is fitted to the main oil gallery in the
when the element is clogged and resists the oil's flow, crankcase. If the oil pressure in the main gallery
the oil cooler's bypass valve opens, thus allowing oil to exceeds a specified level, the regulator valve allows
flow to the main gallery without passing through the the oil to escape to the oil pan, thereby protecting the
cooler. lubrication system from excessive pressure.
12-5
(5) Lubrication of com ponents (b) Camshaft

Engine oil routed to the main oil gallery lubricates the
engine's va rio u s com ponents as follows:
(a) M ain bearings, connecting rod bearings, and con
necting rod b u shings
The camshaft bushings are lubricated via the crank

case oil holes that extend to them from the periphery of
the crankshaft main bearings.
(c) Valve m echanism
A n oil p assage extends from the main oil gallery to the

crankshaft m ain bearing and lubricates the m ain bear
ing. Part ofthe oil that has lubricated the m ain bearing
p asses th rou gfrthe hole in the crankshaft and lubri Engine oil that has lubricated the No. 7 camshaft bush
cates the connecting rod bearing. It then go e s through ing flows to the cylinder heads via an oilway and holes
an oilw ay inside the connecting rod and lubricates the in the top ofthe crankcase. Engine oil that is bound for
connecting rod sm all end bushing. the cylinder heads flows through oil holes in the rocker
In the 6D24-T, T C and TL, there is also an oil hole in the shafts and lubricates the rocker bushings. It then spurts
top of the connecting rod. Oil spurts out of this hole out of a hole in the top of each rocker to lubricate the
onto the inside ofthe piston. sliding surfaces ofthe valve caps, the valve stems, and
the contact points ofthe valve stems, push rods, and
adjusting screws. The oil then flow s through the push
rod holes in the cylinder head and crankcase to lubri
cate the tappets and camshaft cams. Finally, the oil
returns to the oil pan.
12-6
(d) Timing gears oil volum e and the loss of oil pressure w hen the pres
sure is already low.
In the 6D24-T, TC and TL, each piston has a cooling cav
ity. Oil sprayed out ofthe oil jets enters these cavities to
further cool the pistons.
(6) Lubrication of turbocharger
A s show n in the illustration, the timing gear idler shaft

b u shings are lubricated via oil holes that extend from
the main oil gallery and from the rearmost crankshaft
main bearing. The gears are lubricated by the oil spray
plug.
(e) Cooling of pistons (oil jet) Part ofthe engine oil is directed through the oil pipe
from the crankcase into the turbocharger. The engine
oil passes through the oil hole in the turbocharger
bearing housing to lubricate the bearings. It is then
6D24-T, TC, T L
returned through the oil outlet at the bottom of the
bearing housing back to the crankcase and to the oil
pan. A piston ring is installed on the outside of each
bearing, serving as an oil seal.
11921
A n oil jet is fitted underthe main oil gallery for each cyl
inder. These oil jets spray engine oil onto the inside sur
faces of the pistons to help cool the pistons.
Each oil jet has a check valve that opens and closes at
specified oil pressures, thus preventing decreases in
12-7
(7) Injection pum p and air com pressor The injection pum p and air com pressor are lubricated
as follows:
B4364B
(8) Lubrication of water pum p
The engine oil drawn by the pum p is routed through

the crankcase oil passage to the water pump. The
engine oil delivered to the water pum p flow s through
the oil hole of the water pum p and lubricates the bear
ings.
The engine oil is then forced backfrom the drain portto
the crankcase and returns to the oil pan.
12-8
LUBRICATION - SPECIFICATIONS 12
2. SPECIFICATIONS
Item Specification
E ngin e oil Quality A P I classification cla ss CC or better (without turbocharger)

A PI classification class C D or better (with turbocharger)
Capacity Oil pan Approx. 27 L

(for general use)
Approx. 25 L
(for construction m achinery)
Oil filter Approx. 4 to 4.5 L
Lubrication m ethod Forced lubrication by oil p u m p
Oil p u m p Type Forced lubrication by gear p u m p

(integral relief valve)
Relief valve Type Ball valve
Oil filter Full-flow filter elem ent Type Filter paper type
B y p a ss filter elem ent Type Filter paper type
Oil b y p a ss alarm Type Piston valve type (integral electric contact)
Oil cooler Type Shell and plate type (multi-plate type)
Oil b y p a ss valve Type Piston valve type
Regulator valve Type Piston valve type
Oil jet check valve Type Piston valve type
12-9
12 LUBRICATION - SERVICE STANDARDS
3.1 S e rvice S ta n d a r d s Table
Unit: m m
M a in te n a n ce item N o m in a l value Limit Rem edy and

(B asic diam eter in [)) remarks
Oil pres A t idle 145 kPa {1.5 kgf/cm 2} or m ore 49 kPa Inspection
sure (Oil {0.5 kgf/cm 2}
tem pera
ture 70°C to A t m a x im u m speed 295 to 490 kPa {3 to 5 kgf/cm 2} 195 kPa
90°C) {2 kgf/cm2}
Oil p u m p B a cklash betw een crankshaft gear and 0.08 to 0.2 0.4 Replace
oil p u m p idler ge ar
B a c klash betw een oil p u m p idler gear 0.08 to 0.2 0.4 Replace
an d oil p u m p gear
Difference betw een p u m p case depth 0.05 to 0.12 0.15 Replace

an d ge ar height
G e a r tooth tip to p um p case clearance 0.20 to 0.29 0.35 Replace
D rive ge ar shaft to cover clearance [20] 0.04 to 0.07 0.15 Replace
D riven ge ar shaft to driven ge ar bushing [20] 0.04 to 0.07 0.15 Replace

clearance
Idler ge a r shaft to idler ge a r bu shin g [22] 0.03 to 0.05 0.15 Replace bu sh in g

clearance
Relief valve o p e n in g pressure 1080 to 1270 kPa - Replace spring

{11 to 13 kgf/cm2}
Relief valve Installed length: 47.7 180 to 200 N {18.3 to 20.5 kgf} -
sp rin g load
Oil b y p a s s alarm valve o p e n in g pressure (on start 340 to 390 kPa {3.5 to 4 kgf/cm 2} - Replace
pressure)
Oil cooler Valve o p e n in g pressure 420 to 460 kPa Replace

b y p a ss {4.3 to 4.7 kgf/cm 2}
valve
R egu lator Valve o p e n in g pressure 360 to 420 kPa - Replace

valve {3.7 to 4.3 kgf/cm 2}
S p r in g load (Installed length: 48.3) 76 to 80 N {7.8 to 8.2 kgf} -
3.2 T igh te n in g Torque Table
Location tightened Scre w size T ightening torque Rem arks

O. D. x pitch N-m {kgf-m}
mm
Oil p u m p idler sh aft nut M 1 2 x 1.25 59 to 78 {6 to 8} A p p ly LO CTITE

No. 262
Oil p u m p cover m o u n tin g bolt M 1 0 x 1.25 39 to 49 {4 to 5} W et
Oil b y p a s s alarm M 2 0 x 1.5 44 to 54 (4.5 to 5.5)
Oil filter center bolt M 1 6 x 1.5 59 to 69 (6 to 7)
Oil filter drain p lu g M l O x 1.25 20 ± 4.9 {2 ± 0.5}
Oil cooler b y p a ss valve plug M 2 0 x 1.5 15 to 20(1.5 to 2.0)
R egu lato r valve M 2 7 x 1.5 98 to 115 {10 to 12}
Oil pan drain p lu g M 1 8 x 1.5 69 {7}
12-10
LUBRICATION - SERVICE PROCEDURE 12
4. SERVICE PROCEDURE
Oil Pressure Measurement
A t idle
N V 145 kPa
{1.5 kgf/cm 2} o r more
L 49 kPa (0.5 kgf/cm 2}
A t m a x im u m speed
N V 295 to 490 kPa
{3 to 5 kgf/cm2}
L 195 kPa
{2 kgf/cm 2}
Limit B9016A
(1) With the oil pressure switch rem oved and pressure
gauge installed, warm up the engine until the oil
temperature reaches 70°C to 90°C.
(2) Measure the oil pressure at idle and m axim um
speeds. If the m easurem ent is below the limit,
overhaul the lubricating system.
12-11
12 LUBRICATION - SERVICE PROCEDURE
4.1 Oil P u m p
4.1.1 R em oval and installation
A p p ly sealant to inner bead.
N V .. N o m in a l Value A p p ly sealant (Threebond 1207C)

L Lim it 69 N-m {7 kgf-m} and fit it within 3 minutes.
^ B a c k la sh from
crankshaft g e a r
N V 0.08 to 0.2
L 0.4
Pou r e n gin e
oil into p u m p
11923
C1160C
1 Oil pan 5 Relief valve

*2 Oil strainer 6 0il Pu m P
*3 Oil pipe 7 Drain P lu9
4 Flange
Bolt tighte nin g sequence
After installation, check that the oil p u m p ge a r can be turned sm o o th ly by

hand.
S e rv ic e item s m arked with fK sh o u ld be checked before and after the rem oval.
Part m arked w ith * sh o u ld not be rem oved u n less defects are evident.
(R e m o v e it w ith the oil pum p as an assem bly.)
NOTE: 4. After installation, wait at least one hour before

1. Sealant application portion on the oil pan should starting the engine.
be free of oil. 5. Reapply sealant whenever the oil pan mounting
2. Apply sealant evenly without break. bolts have been loosened.
3. When fitting the oil pan, do not move the oil pan to
spread the sealant.
12-12
4.1.2 D isasse m b ly and inspection
W ear on bu shin g C lo g g e d oil hole

“■Backlash 4
N V 0.08 to 0.2
L 0.4
Relief valve opening pressure

N V 1080 to 1270 kPa
{11 to 13 kgf/cm2}
S p r in g installed load Clearance

(installed length: 47.7) B D 22
N V 180 to 200 N N V 0.03 to 0.05
{18.3 to 20.5 kgf} L 0.15
W ear on bushing,
w ear and dam age on teeth
‘ Difference between oil pum p

case depth and ge ar height
N V 0.05 to 0.12
W ear on bu shin g 1 L 0.15
‘ G ear tooth tip to oil p um p

case clearance
N V 0.2 to 0.29
L 0.35
B D .. Basic Diam eter

N V .. N o m in al Value
L Limit

© Oil pum p cover 5 Spring seat
2 Driven gear assem bly 6 Valve spring
3 Idler shaft 7 Ball valve
4 Idler gear 8 Case and gear assem bly
For parts with an encircled number, refer to D isa sse m b ly and Inspection Procedures
that follow.
Service item s m arked with * should be checked before disassem bly.
10374
12-13
Disassem bly and Inspection Procedures (3) Gear tooth end to oil pum p case clearance
(1) Rem oval of oil pum p cover
If the measurem ent exceeds the limit, replace the gear.

The oil pum p cover is positioned with the dowel pin of Note, however, that the drive gear m ust be replaced
the oil pum p case. with a case and gear assembly.
To rem ove the oil pum p cover, tap on it with a plastic (4) Gear shaft to case, cover, and driven gear clear
ham m er or the like. ance
(2) Difference between oil pum p case depth and gear
height
If the measurem ent exceeds the limit, replace the part

to which bushing is installed.
If the m easurem ent exceedsthe limit, replace the gear.
Note, however, that the drive gear m ust be replaced
with a case and gear assembly.
12-14
4.1.3 Reassem bly
39 to 49 N-m
{4 to 5 kgf-m }_
Backlash
N V 0.08 to 0.2
L 0.4
*
A s se m b ly sequence
5 6
be flush with case
8-»7 —>6—>5—>4—>3-»2-* 1
Section C -C
N O TE:
Hold the oil strainer 1 in position temporarily for subsequent attachment
to the crankcase.
© 45 4 85
4.2 Oil Filter and Oil Cooler
4.2.1 Rem oval and installation
1 Oil filter
2 Oil cooler
3 Gasket
NOTE:
1. Do not apply oil or grease to the O-rings at the
oil cooler’s water inlet and outlet.
2. After installation, run the engine and check for
possible oil and water leak.
C1158E
12-15
4.2.2 Oil filter
NOTE:
The elements in the bypass and full-flow oil filters replaced. For specific replacement intervals, refer to
should be replaced every other time the engine oil is the Owner's Handbook.
(1) D isasse m bly and reassem bly
Cracks 8 44 to 54 N-m
{4.5 to 5.5 kgf-m}
1 Drain plug
0 C lo gg in g, deformation 2 Center bolt
C lo g g in g , deform ation g 3 W asher
4 Oil filter case
5 H ardening splitting
5 Element retainer
H arde nin g splitting 5
6 Oil filter element
4 Cracks, deform ation
7 Oil filter head
Cracks, deform ation 4
8 Oil bypass alarm
1 20 ± 4.9 N-m {2 + 0.5 kgf-m}

20 ± 4.9 N-m {2 + 0.5 kgf-m} 1 3
3
59 to 69 N-m
59 to 69 N-m {6 to 7 kgf-m}
{6 to 7 kgf-m}
C9705C
Inspection of oil bypass alarm With no air pressure applied, check for continuity
across the terminals as show n and replace the oil
b ypass alarm if there is continuity.
Next, with the air pressure applied and gradually
increasing, measure the air pressure when there is
continuity.
If the measurem ent is out of specification, replace the
oil bypass alarm.
12-16
4.2.3 Oil cooler
(1) Disassem bly and reassem bly
(2) Cleaning NOTE:

(a) Check for carbon or sludge deposited in the oil pas Never attempt to apply pressure exceeding the speci
sage of the oil cooler element and bypass valve. If fied test pressure.
contamination is evident, w ash in a cleaning oil. Check for possible leak by applying a 1470 kPa {15 kgf/
(b) If there is a lot of scale on the element and cover, cm 2} air pressure to the element. Replace the element if
wash it away with tap water (preferably hot). air or oil leak or any other faulty condition is evident as
(3) Pressure resistance test a result of the test.
Conduct the pressure resistance test to check for oil
leak caused by dam aged or cracked element.
12-17
4.3 R e g u la to r Valve
98 to 115 N-m
{10 to 12 kgf-m}
1 Sn a p ring
2 Valve
3 Spring
4 Body C9902A
Regulator valve installation position:

Left side of crankcase
12-18
LUBRICATION - TROUBLESHOOTING 12
5. TROUBLESHOOTING
S y m p to m Probable cause R em edy Ref. gro u p
Overheating A bn orm al oil level

• Oil leaks into coolant Correct and fill to specified
level
• Oil leaks
Incorrect oil viscosity

• Oil out o f life Replace
• Fuel in oil C h an ge oil after repair of

faulty parts
Oil pressure Oil pressure sw itch not functioning properly Replace

do e s not
increase Loaded oil filter elem ent Replace elem ent
Loaded oil strainer, loose oil p u m p joint, cracked pipe Correct or replace
Relief valve, b y p a ss valve not fun ction ing properly
W orn or d a m a ge d oil pum p proper Replace
Excessive oil Oil leaks from engine Correct or replace G rou p 11

con su m ption
Oil leaks from crankshaft front or rear oil seal Correct or replace
Leaks to coolin g system

• Defective oil cooler w ater jacket Correct or replace
A bn orm al com p ressio n pressure Check G rou p 11
12-19
13A
FUEL AND ENGINE CONTROL
CONTENTS
1. G E N E R A L ................. ............................. 2 5.4 Pum p Drive Case ................................ 35

2. S P EC IF IC A T IO N S .................................. 25 5.4.1 Rem oval and installation ................ 35
3. S E R V IC E S T A N D A R D S ........................... 26 5.4.2 D isasse m bly and inspection ............ 351
3.1 Service Standards Table ..................... 26 5.4.3 Reassem bly .................................. 36
3.2 Tightening Torque Table ..................... 27 5.5 Injection Nozzle ................................. 37\
4. S P E C IA L T O O L S .................................... 28 5.5.1 Rem oval and installation ............. 37
5. S E R V IC E P R O C E D U R E ....................... 29 5.5.2 D isassem bly .................................. 37
5.1 Rem oval and Installation of Injection 5.5.3 Cleaning and inspection ................. 38
Pump A ssem b ly ................................ 29 5.5.4 R eassem bly and adjustm ent
5.2 Bleeding of Fuel Sy ste m ..................... 32 <KBL2.1 injection nozzle> ............... 40
5.3 Inspection and Adjustm ent after Installing 5.5.5 Reassem bly and adjustm ent
the Injection Pum p ............................ 32 <KBL2.4 injection nozzle> ............... 46
5.3.1 Inspection and adjustm ent of 5.6 Fuel Filter ................'........................ 52
fuel injection start tim in g ................ 32 5.7 W ater Separator ................................ 54
5.3.2 Inspection and adjustm ent of m inim um 6. T R O U B L E S H O O T IN G ............................. 55
and m axim um no-load sp e e d s ........ 34
13A-1
13A FUEL AND ENGINE CONTROL - GENERAL
1. GENERAL
B2115A
The fuel system consists ofthe injection pum p general T h e in je c tio n p u m p is c o n n e c te d w it h t h e a ir c o m p re S '
assem bly (injection pum p proper, governor, automatic s o r o r p u m p d r iv e c a s e b y a c o u p lin g a n d d r iv e n a to n e '
timer, feed pum p and coupling), fuel filter, water sepa h a lf t h e e n g in e s p e e d .
rator, injection nozzle, fuel leak-off pipe, etc.
13A-2
FUEL AND ENGINE CONTROL - GENERAL 13A
(1) Injection pump proper 1) The pum p housing is a totally enclosed type.
(a) Injection pump 2 ) The plunger barrel has an oblique hole m ade to
return the fuel that has leaked to the oil su m p to
minimize the leakage of the fuel into the cam cham
ber.
Delivery valve holder
3} To prevent the fuel in the oil sum pfrom leaking into
the cam chamber, an O-ring is provided on the
Delivery valve spring
outer circumference of the plunger barrel, thereby
maintaining its tightness.
, Delivery valve
Stop p e r- 4) A deflector is provided on the outer circumference
^Delivery valve seat of the plunger barrel to prevent erosion of the
pum p housing that m ay be caused by counter flow
of fuel at the end of an injection.
Plunger barrel - ^ Deflector
(b) Plunger and plunger barrel
-Oil su m p
The plunger has an obliquely cut groove (lead) and a
-Control rod
>< vertical groove as illustrated. The plunger barrel has
Leak hole - . Control two fuel suction/discharge ports.
sleeve
. Upper Fuel fed into the injection pump is sent under pressure
sprin g seat
■ Plunger
by the camshaft rotation, or the reciprocating motion
spring of the plunger as follows.
■ Lower
sp rin g seat
-Tappet
— cham ber
a ;m f
1 (I — Cam shaft
S*1 1 v -1 /
B9083C
The camshaft driven at half the engine speed is sup

ported by taper roller bearings at both ends. The cam W hen the plunger m oves down from the top dead cen
shaft has a cam for operating the plunger and a cam for ter and opens the suction/discharge ports in the
operating the feed pump. plunger barrel, fuel is not only drawn into the barrel by
A tappet operating with the pum p housing as the guide a vacuum created during the plunger's dow nw ard
is in contact with the camshaft. The tappet changes the stroke but also sent into the barrel under pressure by
rotary motion of the cam to up-and-down motion the feed pump.
which is transmitted to the plunger. On the upward stroke, the plunger begins to com press
The P type injection pum p offers the following fea fuel as it completely closes the suctional discharge
tures. ports in the plunger barrel.
With the plunger further going up and with the fuel
pressure increasing, the plunger overcomes the force
of delivery valve spring, pushing upthe delivery valve.
This causes fuel to be sent under pressure through the
injection pipe to the injection nozzle.
13A-3
FUEL AND ENGINE CONTROL - GENERAL
Effective stroke
B2205A
A s the plunger rises and its oblique groove (the reed)

meets the inlet/outlet hole, fuel flow s into the plunger's
vertical groove and is expelled from the inlet/outlet
hole. N o pressure feed takes place thereafter, regard
less of how much the plunger rises.
The stroke length during which pressure feed takes
place (from when the plunger closes the plunger bar
rel's inlet/outlet hole until the plunger's oblique groove
opens them) is known as the effective stroke.
The am ount of fuel injected will be changed according

to the engine operating loads by turning the plunger a
given angle to increase or decrease the effective
stroke. To be more precise, operation of the control
lever or governor m oves the control rack (or control
rod) to the right or left, which results in the control
sleeve being turned. The bottom end of the control
sleeve m eshes with the driving face of the plunger;
thus, as the control sleeve rotates, the plunger also
rotates to vary the effective stroke, thereby increasing
or decreasing the am ount of fuel injected..
13A-4
(c) Delivery valve (d) Overflow valve
Suction stroke
B e gin n in g of Injection End of End of

injection injection injection
(beginning
of suction)
01827
The fuel highly pressurized by the plunger pushes the W hen the fuel pressure in the i ejection pum p exceeds a
delivery valve up and gushes out. W hen delivery ofthe predetermined pressure, the steel ball in the overflow
fuel under pressure by the plunger is completed, the valve is pushed up to let the fuel flow out from the injec
delivery valve is pushed back by the delivery valve tion pum p and return to the fuel tank, thereby stabiliz
spring and closes the fuel passage to prevent counter ing the fuel temperature and temperature distribution
flow of the fuel. in the injection pump and maintaining the injection
The delivery valve is further brought down until it is rate into each cylinder constant.
held against the seat surface tightly. The am ount of
fuel corresponding to the stroke during the period is
drawn back from above to instantly lower the residual
pressure in the line between the delivery valve and
nozzle. The draw-back effect im proves the cutting of
fuel from the nozzle and prevents after-injection drip
ping.
A delivery valve stopper, provided on the top of the
delivery valve spring, limits the lift ofthe delivery valve
to prevent the surging ofthe valve during high speed
operation. It also reduces the dead volum e between
the delivery valve and nozzle and stabilizes the injec
tion rate.
13A-5
(2) G overnor
The construction and operation ofthe governor are the
sam e regardless of the applicable model ofth e injec
tion pump.
(a) R S V type governor
The R S V type governor is a centrifugal type all-speed

governor coupled to the camshaft of the injection
pump. The governor not only controls the m axim um
and m inim um speeds but also automatically controls
the engine speed at any intermediate speed position.
13A-6
whereas the top of the lever is coupled through the
shackle to the control rack.
The start spring, attached to the top end ofthe control
lever, always pulls the control rack in the direction that
fuel is increased.
The governor, as shown, consists of flyweights

m ounted to the injection pum p camshaft. W hen the
flyweights turning on the flyweight supporting shaft
open outward, the slider mounted to the end of fly
weight arm pushes the end ofthe sleeve in the axial
direction. The governor sleeve, being made integral
with the shifter through a bearing, m oves only in the
axial direction. The shifter is fixed to the end of the
guide lever with a pin to prevent its rotation.
The turning shaft of the swivel lever is fitted into the

bushing ofthe governor cover and'its center is eccen
tric with respect to the m ounting position ofthe gove r
nor spring installed to the tension lever. The governor
spring is installed to the end ofthe swivel lever.
W hen the governor spring receives tension, the bot
tom end of the tension lever touches the adjustable
full-load stopper bolt.
W hen the angle ofthe adjusting lever is changed, the
angle ofthe swivel lever is also changed and the ten
sion ofthe governor spring changed. This is because
the turning center ofthe swivel lever and the m ounting
position ofthe governor spring installed to the tension
lever are eccentric to each other as mentioned above.
A n adjusting screw is also mounted to the swivel lever.
Adjustment of the screw changes the tension of the
governor spring, thereby making it possible to adjust
the speed regulation.
A n Ungleich spring (or idling spring) is provided in the
bottom portion ofthe tension lever. Adjust the tension
ofthe spring by adding or removing shims.
The control lever is mounted to the middle ofthe guide An idling sub spring adjustable from outside is pro
lever by the shaft with the bottom end as the fulcrum. vided in the middle of the governor cover. During
13A-7
idling, the spring alw ays keeps in contact with the ten 2) Idling control
sion lever to maintain a constant idling speed.
The stop lever, m ounted through the supporting lever
to the bottom end ofthe control lever, returns the con
trol rack to the stop position with a slight pressure irre
spective ofthe adjusting lever position.
1) Start of engine
Once the engine is started and the adjusting lever

returned to the idling position, the tension ofthe gover
nor spring is drastically reduced.
N ow the flyweights can m ove outward even at a low
speed, so the tension lever is pushed back until it
touches the idling sub spring and places the control
W hen the adjusting lever is m oved to the start position rack at the idling position. In this state, the centrifugal
(until it touches the m axim um speed stopper), the force of the flyweights and the weak-state governor
swivel lever which m oves with the adjusting lever pulls spring and idljng sub spring achieve balance and m ain
the governor spring and m oves the tension lever until tain sm ooth idling.
it touches the full-load stopper bolt. W hen the speed falls, the centrifugal force decreases,
At that time, the flyweights are stationary, and the start the flyweights move inward, and the idling sub spring
spring with weak tension pulls the control lever in the pushes the tension lever to the left and m oves the con
direction that fuel is increased. trol rack in the direction that fuel is increased.
At the sam e time, the shifter and governor sleeve push If the speed falls radically, the start spring with weak
the flyweight slider to the left. tension acts and m oves the control rack in the direction
A s the result, the tension lever and shifter are spaced that fuel is increased to maintain the idling speed.
that m uch apart, and the corresponding am ount of fuel
is supercharged to facilitate starting.
13A-8
3) M axim um speed control position, thereby preventing over-speed operation of
the engine.
The R SV type governor controls the entire speed range
from idling to m axim um speed. If load increases or
decreases at a certain speed determined by the posi
tion ofthe adjusting lever, the governor automatically
functions and maintains the engine speed constant at
all times.
4) Ungleich operation
W hen max. injection is set

at low -speed operation
Injection matched
w ith air intake rate
A o-
Injection/
stroke
A '(
T
W hen max. injection is set
at high-speed operation
Engine speed B2663A
The air intake rate of the engine falls as the engine

speed increases. The injection pump, on the other
W hen the adjusting lever is moved to the full-load posi
hand, increases the per-stroke injection as the speed
tion, the tension of the governor spring is increased
increases, even with the control rack at the sam e p osi
and pulls the tension lever until it touches the full-load tion.
stopper bolt.
Therefore, if full-load is set at point A to derive enough
W hen the engine exceeds the specified speed, the cen
output at low speeds, the injection will reach B as the
trifugal force of flyweights becomes larger than the
speed increases, and the engine will produce black
force of the governor spring pulling the tension lever.
smoke.
S o the tension lever is m oved to the right and m oves
If full-load is set at point B ’ to prevent black smoke, the
the control rack in the direction that fuel is reduced, low speed injection will come dow n to A', allowing
thereby preventing the engine from exceeding the spe
combustion of more fuel.
cified speed.
S o the Ungleich device accom plishes the function of
If the speed further increases, the centrifugal force of
setting full-load at point A to derive the largest possible
flyweight increases and pushes the tension lever to the torque in the low speed range, and changing it to
right and also com presses the idling sub spring to pull
adjust the injection to point B ' in the high speed range.
the control rack back to the no-load m axim um speed
13A-9
A s the engine speed increases, the centrifugal force of

flyweight increases. If it becomes larger than the pres
sure of the Ungleich spring, the Ungleich spring is
slow ly compressed before the start of high speed con
trol, and the control rack m oves in the direction that
fuel is reduced. The Ungleich stroke is completed at
the position where the shifter directly touches the ten
sion lever.
5) Stopping of engine
P u m p speed (rpm) — ►
Engine speed (rpm)

B2664A
W hen the engine speed is low and the centrifugal force

of flyweight sm aller than the pressure of the Ungleich
spring, the shifter is m oved as much as the Ungleich
stroke to the left, so the control rack m oves in the direc
tion that fuel is increased to increase the torque of the W hen the stop lever is m oved to the stop position, the
engine at low speeds. control rack is m oved to the stop position to stop the
e n g in e re g a r d le s s o ft h e p o s itio n o ft h e a d ju s tin g lever.
13A-10
6) Operation of torque spring
E
E
c
o
-P I
•P2
Pu m p speed (rpm) •
B2667A
Construction machinery engines are often subjected to If a torque spring is provided, the control rack m oves
a large load during operation, and reduced speeds along B-C, and the rotational displacement at the time
often lead to stalls. To prevent this, a torque spring is m ay be expressed as P2. Therefore, large changes
provided. occur in P 2 and engine speed, and because of
W hen the adjusting lever is fixed in the lever set posi increased fuel injection, the engine torque increases,
tion, a sudden increase of load, if no torque spring is and large com bustion noise w arns the operator of the
provided, will m ove the control rack along the B-D increased load, enabling him to take proper action to
curve as the speed falls. The rotational displacement at prevent stopping the engine.
the time m ay be expressed as P^
In an abrupt increase of load occurs when the engine is

running at continuous rating, the engine speed falls.
S o the flyweights are m oved inward and the tension
lever pulled to left by the control spring, causing the
control rack to m ove in the direction that fuel is
increased.
At the time, the tension lever pin pushes the bottom of
the torque control lever, and the lever m oves with the
pin " A " as the fulcrum, whereas the portion " B " is
pushed to right. A s the result, the torque spring per
form s the function of reducing movement of the ten
sion lever.
13A-11
(b) RFD type governor
Governor\cover Sto p lever

Governor housing
Guide lever
Governor spring
Tension lever
Floating Control rack
lever link
Start spring
Dam per spring

Cam shaft
Speed
control
lever
Sm ok
set
assem bly
Load control
lever
Torque
spring
Idling spring
Flyweight
Stroke adjusting bolt
Sliding lever
Floating lever
B2682B
T h e R F D ty p e g o v e r n o r is a m in im u m - m a x im u m g o v th e te n s io n lever s h a ft h o ld s th e shifter, p re v e n tin g it

ernor which controls only the m inim um and m axim um from turning.
speeds. The guide lever has an intermediate shaft, on each side
The RFD type gove rn or make it possible to increase or of which there is a floating lever mounted.
reduce fuel by the load control lever which operates A block is press-fitted in the bottom end of one floating
the control rod. A n y desired speed can be set as a d is lever and this block is fitted in the bottom of the sliding
placement of the speed control lever changes the ten lever. The load control lever is fitted to this sliding lever
sion of the governor spring. through an eccentric shaft. The floating lever can be
Because of the construction described above, the R FD moved by operating the load control lever. Atthe upper
governor can be operated as an all-speed governor by end of the floating lever placed on the other side via a
holding the load control lever in the full position and shaft, there is an injection pum p control rack fitted via a
operating the speed control lever. floating lever link. A start spring is hooked atthe lower
Flyweights are m ounted on the injection pum p cam end of the floating lever and the other end of the start
shaft. Each of the flyweights pivots about a pin press- spring is hooked at the spring eye on the governor
fitted in the flyweight holder. W hen the flyw eights housing side.
m ove out, the slider fitted to the end of the flyweight The tension lever is suspended from the tension lever
arm s p ushes the sleeve end face axially. The sleeve shaft from which the guide lever is suspended. A g o v
which contacts the flyweight slider is coupled to the ernor spring is fitted across this tension lever and the
shifter by a snap ring. The guide lever suspended from swivel lever. Its tension is determined by the speed
control lever mounted on the swivel lever shaft. Within
13A-12
normal speed ranges, therefore, the lower end of the The engine stop lever is fitted to the top of the gover
tension lever is always in contact with the stroke nor, that m oves the control rack to the non-injection
adjusting bolt. position to stop the engine. The cancel spring is
A pin is press-fitted in the side ofthe lower end ofthe installed to prevent excessive force from being applied
tension lever. It fits into the groove in the upper part of to the control rack at this time.
the sliding lever. During high speed control, therefore, Mounted on top ofthe governor cover is the sm oke set
a greater lever ratio is obtained from the linkage assembly. It functions to ensure good starting by
form ed by the pin, sliding lever, and floating lever. Built increasing the am ount of fuel injected at starting and
into the lower end of the tension lever is the idling improve sm oke condition in the practical full-load low
spring that provides low speed control. speed range.
1) Control of engine start and idling
Speed control lever
B2670A
W hen the engine is not running, the flyweights are in spring, which keeps the control rack at a given position.
the closed position/pushed by the governor spring, This ,results in the engine running at sm ooth idle
idling spring, and start spring. If, in this condition, the speed.
load control lever is moved all the way to the full posi If the engine speed increases at this time, the centrifu
tion (in the direction of greater fuel delivery), the start gal force ofthe flyweights increases causing the fly
spring and idling spring cause the control rack to move weights to m ove out to push the shifter to the right. A s
to a point which is beyond the full-load position and a result, the guide lever and floating lever are moved,
provides the m axim um am ount of fuel injected, thus which in turn m oves the control rack in the direction of
making it easier to start the engine. smaller fuel delivery (to the right). If the engine speed
W hen the load control lever is returned to the idling decreases, on the other hand, the control rack is m oved
position after the engine has started, the flyweights in the direction of greater fuel delivery. The governor
increase or decrease their centrifugal force as the controls the am ount of fuel injected in this w ay to stabi
engine speed changes. In the idle speed range, the cen lize the engine at idle speed.
trifugal force is such that it just com presses the idling
spring. The centrifugal force ofthe flyweights balances
the com bined force of the idling spring and start
13A-13
FUEL AND ENGINE CONTROL - GENERAL
3) Control of m axim um speed
If the load control lever is m oved in the full direction

(for greater fuel delivery), the eccentric shaft coupled
to the load control lever causes the sliding lever to
pivot about pin D fitted in the bottom of the tension
lever. At the sam e time, the floating lever pivots about
point B to push the control rack in the direction of A s the engine load varies and engine speed reaches a
greater fuel delivery, which results in the engine speed predetermined m axim um speed, the centrifugal force
increasing. ofthe flyweights overcom es the governor spring ten
W hen the engine speed reaches a point over the idling sion, causing the flyweights to start m oving out. This
control range, the idling spring is completely com motion results in the shifter and tension lever being
p r e s s e d in the te n s io n lever, c a u s in g the s h ifte r to be in moved to the right. Then, point B is moved to B ' and
direct contact with the tension lever. The tension lever, point D in tension lever to D', which prevents the
however, is in contact with the stroke adjusting bolt by engine speed from exceeding the predetermined max
the tension o fth e governor spring which is tightened imum level.
by the speed control lever. Since the centrifugal force If this governor is used as an all-speed governor, the
o fth e flyweights is small in the normal speed range, engine speed is varied by operating the speed control
the tension lever is unable to move. This m eans that lever with the load control lever fixed at the full posi
point B can not m ove either, and the operation ofthe tion. That is, a given engine speed is maintained as the
load control lever is directly transmitted through the speed control lever is tilted; if load changes, however,
eccentric shaft, sliding lever, and floating lever to the the governor automatically controls to keep the given
control rack, thereby increasing and decreasing the speed. For example, suppose the speed control leveris
am ount of fuel injected. tilted to a position which provides the m axim um out
put (where it contacts the m axim um speed stopper
bolt). W hen the engine speed increases in this condi
tion, the centrifugal force of the flyweights becomes
greater.
13A-14
A s the force becomes greater than the force of the g o v
ernor spring which pulls the tension lever, the fly
weights start m oving out. This motion of the fly With sm oke set
assem bly
w eights causes the shifter and tension lever to be
m oved to the right. At the sam e time, point B is m oved
to B', point D to D', and point C to C'. This results in the
control rack being pulled in the direction of smallerfuel
delivery, thus reducing the engine speed.
If load increases to cause the speed to decrease, the
centrifugal force of the flyweights becom es smaller
than the governor spring tension. Then, point B ' is
m oved to B, point D ' to D, and point C ' to C. This results
in the control rack being m oved in the direction of
greater fuel delivery.
The governor automatically activates as load changes
to maintain a given speed at all times.
4) Start booster (smoke set assem bly)
Pu m p speed (rpm)
B2674B
A s indicated by the governor characteristics sh o w n

above, when without the sm oke set assem bly, the
shifter and floating lever are pushed back by the idling
spring force, m oving the control rack toward fuel
increasing direction when pum p speed reaches N-|.
Namely, Ni is the smoke limit in this case.
W hen with the sm oke set assembly, the spring force of
the sm oke set assem bly overcom es that of the idling
spring so that the floating lever motion is inhibited
until the speed reaches N 2. Thus, the sm oke limit
decreases from Nt to N 2.
It is also possible to secure rack position Rs needed at
The sm oke set assem bly installed to the rear of the time of start.
governor has a spring with setting force and a stopper
as functional parts. It also has sleeve, stroke adjusting
nut, spring adjusting nut and cap.
13A-15
5) Engine stop lever (3) Feed pump
Norm al
position
S to p lever asse m b ly
B2675A
To stop the engine, the stop lever on top ofthe gover Su p p ly of fuel to the injection pum p proper is accom
nor m ust be operated to cut off the fuel. plished by the feed pum p mounted to the side ofthe
The stop lever is cable-connected to the engine stop injection pum p proper and driven by the cam of the
button on the driver's seat. The stop lever is operated injection pum p camshaft provided for the purpose.
by pulling the button. W hen the stop lever is rotated, The priming pum p mounted to the feed pum p makes it
the internal lever pushes the tab on the floating lever possible to lift fuel m anually when the engine is sta
link, forcing the control rack to the non-injection posi tionary.
tion to stop the engine. The stop lever returns to the
normal position by the reaction of a built-in spring.
13A-16
(a) Suction stroke (c) Stop
01835 01837
W hen the camshaft of the injection pum p forces the W hen the pressure in the pressure cham ber exceeds
push rod up, the fuel in the suction cham ber is com specification, the piston cannot be brought back by the
pressed and opens the outlet check valve. M o st of the pressure of the piston spring and stops the pum p func
fuel forced out is drawn into the pressure chamber tion. S o the pressure in the fuel filter is adjusted not to
above the position. rise more than necessary.
(b) Pressure feed stroke (4) Automatic timer
The interval between fuel injection into the cylinder
and its ignition is called the ignition delay interval. The
ignition delay interval is constant regardless of the
engine speed. Ifthe ignition timing is alw ays constant,
changes in the engine speed will vary the relation
between the piston position and ignition timing, m ak
ing it im possible to obtain the best engine perfor
mance. To maintain the relation between the piston
position and ignition timing constant at all times, the
injection timing must be changed to match the engine
speed.
The automatic timer is a device which automatically
changes the injection timing according to the engine
W hen the cam, moved away by rotation of the cam speed.
shaft, ceases to push up, the piston is pushed back by
the pressure of the piston spring and forces out the fuel
from the pressure chamber and forces it into the fuel
filter.
At the time, the outlet check valve closes, and the inlet
check valve opens, so the fuel is drawn into the suction
chamber.
13A-17
(a) S P type automatic timer <6D24, TC>
B3201A
Two flyweights are fitted on the pins ofthe timer hou s sp rin gs are held between the spring seats fitted on the
ing and are held in the timer housing. On the other timer housing pins which extend through the flange
hand, the injection pum p connection side flange has a and flyweight. These parts are housed in the timer
curved surface, and the roller fitted on the pin installed housing and are totally enclosed with a cover, O-ring
in the flyweight touches the curved surface. Timer and oil seal.
W hen the engine is running at a low speed, the timer
spring pressure is strongerthan the centrifugal force of
flyweight, so the roller of flyweight is held down by the
flange, creating no advance state.
W hen the engine reaches a high speed, the centrifugal
force of flyweight becomes stronger, the roller of fly
weight p ushes the curved surface of flange with the
timer housing pin as the fulcrum, and the flyweight
opens outward, while com pressing the timer springs.
In this manner, the roller installed on the flyweight
m oves the flange in theturning direction and advances
the injection timing.
13A-18
(b) SP G type automatic timer <6D24-T>
B 0023A
The timer housing receives rotating motion of the The two flyweights have the timer holder in between
engine through a coupling. The timer holder is directly and are provided with timer springs having the sam e
connected to the injection pum p camshaft. Two op p os set tension to keep the flyweights evenly in position.
ing pins are press-fitted in the timer housing. A small W hen the engine is not running or running at low
eccentric cam is mounted on each of the pins and a speeds, the flyweights are pressed against the timer
large eccentric cam is slid over the periphery of the holder by the set tension of the springs.
small cam .The two holes in the timer holderfit overthe
large eccentric cams.
Pins are pressed into the undersides ofthe flyweights.
These flyweight pins fit into holes in the larger eccen
tric cams.
W hen the timer housing is rotated, the timer holder is
rotated at the same time driving the injection pump.
13A-19
(5) Boost compensator <engine with turbocharger>
The boost com pensators increase the engine's power

W h en the engine is not running, the flyweights are
output by increasing the rate of fuel injection to match
pressed againstthetim er holder b ythetim erspring set
increases in air intake caused by the turbocharger. To
tension.
W h en the engine is started, a centrifugal force is pro increase the amount of fuel injected, the boost com
pensators utilize the boost pressure in the inlet m an
duced by the flyweights; however, it is less than the
tim er spring set tension keeping the flyweights ifold.
There are two boost compensators. One is fitted to the
rem aining the original positions, without lifting.
governor, and the other is fitted to the drive side of the
A s the engine speed increases, the centrifugal force of
injection pump.
the flyweights also increases and will be balanced with
the spring tension. W hen the engine speed further
increases, the centrifugal force overcom es the timer
sp ring set tension, causing the flyweights to lift out
ward. This causes the center (point B) of the large
eccentric cam pivot about the center (point A) of the
timer, m oved in the rotating direction, by the sm all
eccentric cam pivoting about the timer housing pin
(point C). Since the large eccentric cam is fitted to the
tim er holder, that motion ofthe large eccentric cam is
imparted to the timer holder. The m axim um retard
angle is obtained when the backs of the flyweights are
against the inner wall of the timer housing.
13A-20
(a) Governor-side boost com pensator (b) Drive-side boost com pensator
B o o st com pen sator set spring
D iap h rag m
Pressurization
cham ber
1Boost
' pressure
Pu sh rod
A rm
Start fuel
increase stroke
Control rod.
B2691A
A s the boost pressure overcom es the com pensator Load control lever idling position
spring, the diaphragm and push rod are pushed to the
left. Movem ent of the diaphragm is pivoted on point
" A " of the com pensator lever and m oves the com pen Floating lever
Control rod
sator lever in the direction show n by the dotted lines. Cancel sp rin g Floating lever link
Load control lever full position (turbocharger off)
A s the diaphragm and com pensator lever move, the
floating lever pivots counter-clockwise about point
"B , " thereby pushing the control rod in the fuel-in- CD =
crease direction. The system is thus able to increase Load control lever full position (turbocharger on)
the fuel quantity irrespective of the governor. T O

CD 3=
B2693A
W hen the boost pressure rises above the boost com

pensator spring set pressure by the action of the turbo
charger, the diaphragm forces out the push rod. The
cancel spring installed between the control rod and
floating lever on the governor side is set so that it
pushes, at all times, the control rod in the direction of
greater fuel supply. This m eans that, w hen the push
rod m oves in the direction sh ow n by the arrow, the
control rod m oves in the direction of greater fuel sup-
ply-
This boost com pensator also has a spring that
increases fuel supply at engine start.
13A-21
(7) Injection nozzle

Two models of hole type injection pum ps are used.
Their constructions are as follows.
(a) KBL2.1 injection nozzle
Before the engine is started, the idling spring in the

governor, forcing the control rod in the direction of
more fuel supply overcom es the force ofthe sm oke set
spring and therefore the control rod m oves to the start
fuel increase position while forcing the arm. W hen the
engine is started, the idling spring is com pressed by
the shifter and as a result, it loses the force to push out
the control rod. Then, the sm oke set spring forces the
control rod back to the normal position.
(6) Pum p drive case
The nozzle has two springs and push rods, and a clear
ance (prelift) is provided between two rods.
W hen the high pressure fuel fed from the injection
pum p overcomes the 1st spring which determines the
valve opening pressure, the needle valve opens to start
the pre-injection and sim ultaneously m oves the 1st
push rod upward.
W hen the 1st push rod m oves through the prelift and
contacts the 2nd push rod, the needle valve stops m ov
ing momentarily. A s the fuel pressure further increases
and overcom es the resultant force of the 1st and 2nd
springs, the needle valve restarts m oving upward for
the main injection.
So m e ofthe high-pressure fuel is used to lubricate the
needle valve and other com ponents and is returned to
the fuel tank via the leak-off pipe.
The pum p drive case, installed at the left o fth e fly Fuel injection pressure adjustments are made using
wheel housing, is driven by the timing gear of the the shim.
engine at half the engine speed. The pum p drive shaft,
with its end connected to the coupling ofthe injection
pump, drives the injection pump.
13A-22
(b) KBL2.4 injection nozzle
A s the pressure ofthe fuel fed from the injection pum p

With this nozzle, a prelift clearance is provided (i.e., the pressure in the nozzletube) overcom esthe No.
between the lift-piece and No. 2 spring seat, and the 1 spring, the needle valve rises by the prelift distance.
nozzle's injection starting pressure is determined by W hen the lift-piece rises by the prelift distance, it meets
the force ofthe No. 1 spring. the No. 2 spring seat. Since the lift-piece and No. 1
spring seat are pressing together, the spring force at
this time is that of the No. 1 and No. 2 sp rin gs com
bined, and the needle valve momentarily stops rising.
A s the fuel pressure rises and the pressure in the nozzle
tube overcom es the two springs, the needle valve rises
further and the nozzle injects the rem aining larger
quantity of fuel.
Fuel injection pressure adjustments are m ade using
the shim.
13A-23
(8) Fuel filter (9) Water separator
The sedimenter type water separator separates gas oil

and water centrifugally by taking advantage of their
difference in specific gravity.
The fuel that has flowed in from the inlet connector is
squeezed by the fuel path of the head to increase the
flow velocity and spins. The separated water is sedi-
mented in the case, whereas the water-separated fuel
is drawn through the fuel path in the center ofthe head
into the feed pump.
The water separator sedim ents not only water but also
m ud components.
A red float goes up and down with the water level in the
semi-transparent case, m aking it possible to visually
check the water quantity.
The fuel filter m ay be eitherthe element replace type or

the spin-on type which facilitates replacement of ele
ment.
It separates water content in the fuel fed under pres
sure from the fuel feed pum p of injection pum p and
eliminates dirt in the fuel by the element.
13A-24
FUEL AND ENGINE CONTROL - SPECIFICATIONS 13A
2. SPECIFICATIONS
(1) injection pump
Item Specification
M anufacturer B O S C H A U T O M O T IV E S Y S T E M S
Injection <6D24> <6D24-T> <6D24-TC> <6D24-TL>
Pum p (Standard) (Optional) (Standard) (Optional)
Type B o sch in-line B o sch in-line Bosch in-line Bosch in-line Bo sch in-line B o sch in-line
type type type type type type
M odel P P P P P P
Direction of rotation Clockw ise Clockw ise Clockw ise Clockw ise Clockw ise C lockw ise
(seen from drive side)
Plunger diam eter mm 12 12 12 12 12 12
G overn or
M o d e l and type R S V all-speed R FD m in im u m - R S V all-speed RFD m inim um - R S V all-speed RED -4
m echanical m a xim u m - mechanical m axim u m - m echanical electronically
go ve rnor speed m echani governor speed m echani go ve rnor controlled
cal go ve rnor cal governor go ve rn o r
Feed p u m p m odel
M o del K K K K K KD
A utom atic tim er
M o d e l and type S P m echanical S P m echanical SPG SPG S P m echanical SPGH
autom atic tim er autom atic timer m echanical mechanical autom atic tim er electronic timer
autom atic timer automatic timer
(2) Injection nozzles
Item Specification
Manufacturer B O S C H A U T O M O T IV E S Y S T E M S
<6D24> . <6D24-T> <6D24-TC> <6D24-TL>
Nozzle (Standard) (Optional)
Type Hole-type (2-spring Hole-type (2 -spring Hole-type (2-spring Hole-type (2-spring Hole-type (2-spring
nozzle: KBL2.4) nozzle: KBL2.4) nozzle: KBL2.1) nozzle: KBL2.4) nozzle: KBL2.4)
m odel D LL A DLLA DLLA DLLA DLLA
No. of holes 5 5 5 5 5
Hole diam eter mm 0.32 0.36 0.36 0.36 0.30
S p ra y a n gle 157° 154° 150° 150° 151°
(3) Others items
Item Specification
Fuel filter
type Spin -on filter-paper type
W ater separator
type Precipitation type
13A-25
13A FUEL AND ENGINE CONTROL - SERVICE STANDARDS
3.1 S e rvic e S ta n d a r d s Table
(1) Injection pum p
Unit: m m
M aintenance item N o m in a l value Limit Rem edy and remarks

Fuel injection start tim in g (BTDC) Dependent on - Adjust

specification
Eccentricity w ith respect to air co m p re sso r crankshaft 0.2 or less - A dju st sh im s

(or p u m p drive shaft)
(2) Injection nozzle

Unit: m m
M aintenance item N o m inal value Limit Rem edy and remarks

1st v a lv e o p e n in g pressure All except 6D24-TL 17.7 M P a {180 kgf/cm 2} - Adjust
6D24-TL 15.7 M P a {160 kgf/cm 2} -
Prelift KBL2.1 0.10 ± 0.02 - Adjust
K B L 2.4 0.07 ± 0.02 -
2 nd valv e o p e n in g pressure ("o p e n " pressure) 24.8 to 25.4 M P a - Adjust

{253 to 259 kgf/cm 2}
2nd valve o p e n in g p ressure with 0.05mm KBL2.1 23.0 to 23.5 M P a - Adju st

needle valve lift ("c o v e r " pressure) {235 to 240 kgf/cm 2}
K B L 2.4 22.6 to 23.6 M P a - Adjust

{230 to 240 kgf/cm 2}
13A-26
FUEL AND ENGINE CONTROL - SERVICE STANDARDS 13A
3.2 T igh ten ing Torque Table
Location tightened Screw size Tightening torque Rem arks

O.D. x pitch (m m) N-m (kgf-m)
Injection p u m p bracket m ounting bolt M l O x 1.5 35 to 53 (3.6 to 5.4}
Injection pipe union On p um p side M 1 4 x 1.5 29 to 49 (3 to 5}

nut
On nozzle side M 12 x 1.5 29(3}
Injection O verflow valve - 20 to 29 (2 to 3}

pum p
Injection p um p fuel inlet side eyebolt - 20 to 29 (2 to 3}
Lubricant (inlet) side eyebolt - 12 to 15(1.2 to 1.5}
Lubricant (outlet) side eyebolt - 20 to 29 (2 to 3}
B o o st com pensator eyebolt - 12 to 15 (1.2 to 1.5}
Fuel feed Fuel inlet side eyebolt - 20 to 25 (2 to 2.5}

pum p
Fuel outlet side eyebolt - 20 to 25 (2 to 2.5}
A bolt 6D24, T, TC - 74 to 83 (7.5 to 8.5}
6D24-TL - 83 to 93 (8.5 to 9.5}
B bolt 6D24, T, TC - 59 to 64 (6 to 6.5}
6D24-TL - 83 to 93 (8.5 to 9.5}
C bolt 6D24, T, TC - 59 to 64 (6 to 6.5}
B3401A 6D24-TL - 83 to 93 (8.5 to 9.5}
Injection p u m p gear m ounting nut of p u m p drive case M 24 x 1.5 215(22}
Injection Leak-off pipe eyebolt M8x 1 9.8 to 15(1 to 1.5}

nozzle
Injection nozzle bolt M 8 x 1.25 15(1.5}
(for attaching to cylinder head)
2 -spring Retaining nut M 19 x 1 59 to 78 (6 to 8 }

nozzle
C ap nut M 22 x 1.5 39 to 49 (4 to 5}
Inlet connector M 1 4 x 1.5 69 to 78 (7 to 8}
Set screw M 22 x 1.5 49 to 59 (5 to 6)
Lock nut. M14 x 1 20 to 25 (2 to 2.5}-
Leak-off connector M 14 x 1 29 to 39 (3 to 4}
Retaining nut M 19 x 0.75 59 to 78 (6 to 8}
Fuel filter connector A ll except 6D24-TL M 1 4 x 1.5 25 (2.5}

bolt
6D24-TL M 1 4 x 1.5 25 to 35 (2.5 to 3.5}
A ir vent plug A ll except 6D24-TL M 8 x 1.25 7.8 to 12(0.8 to 0.12}
6D24-TL M 8 x 1.25 9.8 ± 2 (1.0 ±0.2}
W ater separator Eye bolt M 1 4 x 1.5 25 {2.5}
A ir plug M 8 x 1.25 7.8 to 12(0.8 to 1.2}
13A-27
13A FUEL AND ENGINE CONTROL - SPECIAL TOOLS
4. SPECIAL TOOLS
Unit: m m
Tool nam e Sh a p e
Filter W rench
M H 061572
< A II except 6D24-TL>
R e m o va l of fuel filter elem ent
B5222A
Filter W rench
M H 061572
<6D 24>
R e m o v a l of fuel filter elem ent
© 01503
Injection P u m p Centering
Tool
M H 061340
C entering of bracket of
injection p um p
22338
13A-28
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 13A
5. SERVICE PROCEDURE (2) Installation procedure
5.1 R e m oval and Installation of Injection Pum p NOTE:

A s s e m b ly The follow ing procedures assum e that the injection
pump is equipped with an air compressor. The sam e
(1) Removal procedure
procedures apply to one with a pum p drive case.
(a) Ready a fluid receiver and waste cloth to ensure
(a) Adjustment of injection pum p bracket
that the engine is not contaminated by fuel or
engine oil.
(b) Rem ove all pipes and harness connectors that
make the removal job difficult or im possible.
(c) Rem ove the bolt show n from the coupling.

(d) Rem ove the injection pum p from the injection
pum p bracket.
NOTE:
1) Make zero-point adjustment with Injection Pum p

Centering Tool (special tool) placed on the injec
i tion pum p bracket and a dial gauge set on the m an
drel of the special tool.
n _ 5
r -------W o o d b lo c k
////////////////////////////////////////////
C0557A
Keep the injection pum p rem oved on w o o d e n blocks

so as to protect the automatic tim er area from impact.
(e) Do not remove the injection pum p bracket unless
defects, such as cracks, are evident.
13A-29
13A FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
<W hen the measured value at point B is positive

(+)>
Insert shim s evenly to four places.
<W hen the measured value at point A is positive
(+)>
Insert shim s to the lower side of point C.
<W hen the measured value at point C is positive
(+)>
Insert shim s to the upper side of point A.
Shim inserting requirements
• The number of sh im s used in a single location
must not exceed three.
• Top and bottom sh im s both at front and rear
2) Slide the dial gauge toward the air com p re ssor and must be equal in thickness.
m easure the m isalignm ent between the mandrel • The difference in num ber between the top and
of the special tool and the air com p re ssor crank bottom shim s m ust not exceed one.
shaft at points show n in the figure. 4) After adjustment, tighten injection pum p bracket
to the specified torque before confirmation.
Eccentricity (b) Installation of injection pum p

NV 0.2 or less
1) Crank the engine to bring the No. 1 cylinder piston
to the fuel injection timing position.
(Refer to Section 5.3.1.)
2) At that time, verify that the keyway of air com pres

sor crankshaft faces upward. If not, rotate the
N V .. N o m in a l Value C0598A crankshaft one complete turn.
3) If the eccentricity between the mandrel and air

co m p re sso r crankshaft is in excess of the nom inal
value, adjust by adding or rem oving injection
pum p bracket shims.
13A-30
• Fit the injection pum p onto the injection pum p
bracket.
• Temporarily fit the tim ing adjustment bolt onto the
driving coupling. Slide the driving coupling until
there is clearance of 0.5 mm or less between it and
the coupling plate. Then, tighten the cotter bolt to
the specified torque.
• Confirm that the injection starting timing is cor
rectly adjusted as per items (b) 1) to 3), then tighten
the timing adjustment bolt to the specified torque.
20 to 29 N-m
29 to 49 N-m
{2 to 3 kgf-m}
{3 to 5 kgf-m}
20 to 29 N-m
3) Align the pointer of the injection pum p and the {2 to 3 kgf-m}. A f W V t f i ! / 20 to 29 N-m
}J D / {2 to 3 kgf-m}
inscribed mark on the automatic timer.
4) Installation of injection pump
20 to 25 N-m /
{2 to 2.5 kgf-m}
T im ing adjustm ent bolt 20 to 25 N-m
<6D24, T, T C > 58 to 64 N-m {6 to 6.5 kgf-m} 12 to 15 N-m <2 to 2.5 kgf-m}
<6D24-TL> 83 to 93 N-m {8.5 to 9.5 kgf-m} {1.2 to 1.5 kgf-m}
C ro ss coupling Driving cou plin g 43741
C ou p lin g plate /
m o un tin g bolt
<6D24, T, T C >
59 to 64 N-m A ir c o m p re sso r (c) Tighten each pipe to specification.
{6 to 6.5 kgf-m} crankshaft
(d) After the injection pum p has been installed, be
<6D24-TL>
83 to 93 N-m sure to check and adjust, if necessary, the fuel
{8.5 to 9.5 kgf-m}
injection start timing. (Refer to Section 5.3.1.)
C ou p lin g plate /
Cotter bolt
83 to 93 N-m {8.5 to 9.5 kgf-m}
43740
• Loosen the cotter bolt and remove the timing

adjustment bolt. Rem ove the driving coupling
from the coupling plate.
• Fit the driving coupling onto the air com pressor
crankshaft and push it toward the air compressor.
13A-31
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE
5.2 Bleeding of Fuel System 5.3 Inspection and Adjustment after Installing
Perform fuel system air bleeding as follows. the Injection Pump
5.3.1 Inspection and adjustment of fuel injection
start tim ing
(1) Loosen air plug of fuel filter.
(1) Crank the crankshaft more than 180° in forward

direction to line up the pointer with the fuel injec
tion start timing angle scale inscribed on the out
side periphery of the flywheel.
NOTE:
If the engine is turned in reverse direction (either when
the engine is stopped or by cranking), the automatic
timer will stay advanced and may not return to normal
even if the engine is slightly cranked in the normal
direction. Make sure that the engine is cranked m anu
B4324A ally more than 180° in the normal direction.
(2) Turn counterclockwise the priming pum p knob of

injection pum p so that it com es loose.
(3) M o ve prim ing pum p knob up and down to feed fuel
until air bubble does not com e out from air plug.
(4) With no air bubble com ing out in fuel, tighten air
plug.
(5) M o ve priming pum p knob up and down several
times, then screw in knob.
NOTE:
Sop up fuel spilt around.
(6) Actuate starter to discharge air in injection pum p
and pipe.
NOTE:
Do not actuate starter for more than 15 seconds.
13A-32
If the timer is electronic, check at this time whether the (3) If they are out of alignment, loosen the tim ing
inscribed lines are aligned. If they are not aligned, the adjusting bolt of the coupling and adjust by turning
timer is advanced; give the engine two turns in the for the automatic timer.
ward direction to return the timer to a non-advanced After adjustment, recheck by the procedures of
condition. If this action does not return the timer to a steps (1) and (2), and tighten the timing adjusting
non-advanced condition, first loosen the eyebolt (see bolt to the specified torque.
the drawing) to make it easier for residual hydraulic NOTE:
pressure in the timer to escape to the injection pump. Do not loosen the bolts ofthe coupling except the tim
ing adjusting bolt.
(2) If the inscribed mark ofthe injection pum p and the

inscribed mark ofthe automatic timer are in align
ment in the above condition (1), the fuel injection
start timing is correct.
13A-33
5.3.2 Inspection and adjustment of minimum and

maximum no-load speeds
Start and idle the engine until it reaches normal operat
ing temperature. Then, make the follow ing checks.
(1) R S V type governor
(a) M inim um speed

Check to see that the load control lever is in contact
with the idling stopper bolt. In this state, check that the
m inim um speed is within specified limits. If not, adjust
with the idling stopper bolt.
(a) M in im u m speed
(b) M axim um speed
M ake sure that the adjusting lever is in contact with the
Set the load control lever at the full-load position
stopper bolt. In this condition, check that the m inim um
(where it contacts the full-load stopper bolt). If the m ax
speed is within the specification. If the specification is
imum speed is outside specified limits in this state,
not met, adjust with the stopper bolt.
adjust with the m axim um speed stopper bolt and stop
(b) M axim u m speed
per bolt.
Place the adjusting lever to the full-speed position. If
NOTE:
the m axim um speed is outside the specification in this
1. Never attempt to change the locked position of
condition, adjust with the m axim um speed stopper
the full-load stopper bolt.
bolt.
2. Quickly move the load control lever from the full-
NOTE: load position to the idling position to make sure
Quickly move the adjusting lever from the full-speed that the engine does not stall or develop hunting.
position to the idling position to make sure that the If defects are evident, adjust within the specifica
engine does not stall or develop hunting. If defects are tion.
evident, adjust within the specification.
13A-34
5.4 P u m p Drive Case
(1) For removal and installation o ft h e pum p drive

case, refer to Section 5.1 in Group 61 Special
Equipment.
5.4.2 D isasse m b ly and inspection
13A-35
5.4.3 Reassem bly
(1) Installation of injection pum p gear

install the injection pum p gear, sensor plate (or guide
plate) and nut as shown.
13A-36
5.5 Injection N o zzle 5.5.2 D isa sse m b ly
5.5.1 R em oval and installation <KBL2.1 injection nozzle>
Cracks,
deterioration 4
Nozzle
identification
mark stam pe d
position
W ear 6 11
Carbon
S h im d e po sits
(for prelift)
Sh im
(for valve opening
pressure)
Cracks, g
deterioration
1 Cap nut 8 1st spring

2 Adjusting 9 1st push rod
screw 10 Retaining nut
3 Lock nut IT Nozzle
4 2nd spring 12 Needle valve
5 Set screw 13 Nozzle holder
6 2nd push rod 14 Inlet connector
7 Spacer
D7015A
13A-37
<KBL2.4 injection nozzle> Disassembly Procedure

The following special tools should be used in d isas
sembly:
Identification
m ark position Tool nam e Part No. (Zexel product No.)
Plate 157944-9520
Special W rench 157914-2800
Rem oving retaining nut
ten?
15449
Secure the Plate (special tool) in a vise and fit the injec
© Retaining nut 10 2nd spring
tion nozzle onto it. Loosen and remove the retaining
2 Needle valve 11 Push rod
nut using the Special Wrench (special tool).
3 Nozzle 12 Callor
4 Pin (4>3) 13 Sprin g seat 5.5.3 Cleaning and inspection
5 Spacer 14 1st spring (1) Cleaning
6 Lift piece 15 Sh im (For adjust
7 Pin (4>2.5) ment of primary
8 Sp rin g seat valve opening
9 Sh im (For adjust pressure)
ment of second -16 Nozzle holder
ary valve opening 17 Leak-off
pressure) connector
NOTE:
1. Clean off any carbon deposits before disassem
bling, reassembling, or adjusting any nozzle After w ashing the nozzle in gas oil, remove deposited
assembly. Note, however, that the spray pressure carbon using Nozzle Cleaning Tool (special tool) by the
and shape should be inspected and the assembly following procedures.
checked for oil leaks first. If no abnormalities are NOTE:
apparent, do not commence disassembly. Never change the combination of the nozzle and
2. Under no circumstances change the combination needle valve.
of needle valves and nozzles used.
13A-38
(2) Inspection
(a) Rem ove the needle valve from the nozzle and clean
the needle valve with the needle valve cleaning Clean and im m erse the nozzle in gas oil, slide the
w ood piece. needle valve and check that it m oves smoothly.
Next, pull up the needle valve vertically about 1/3 of its
entire stroke and check that it falls under its ow n
weight. If it does not fall, replace the nozzle.
(b) Insert, while turning, a cleaning needle into the

injection orifice ofthe nozzle to remove carbon.
(c) Ciean the nozzle seat using the cleaning needle.

(d) To remove burnt and hardened carbon, use F U SO
Carbon Rem over or equivalent.
13A-39
5.5.4 Reassem bly and adjustm ent <KBL2.1 injec

tion nozzle>
Adjust while assem bling the parts by the follow ing
procedures.
A s the prelift is adjusted in 1/100 m m increments, use
clean detergent to thoroughly remove dust and dirt
before adjustment.
The follow ing special tools should be used when m ak
ing adjustments:
Tool n am e Zexel product No.
A d ju stin g Device 1D5789-0500
A d ju stin g S te p s
© Adjustment of 1st valve opening pressure
© Selection of prelift adjusting shim s
® Adjustment of 2nd valve opening pressure
("o p e n " pressure)
*© Check of needle valve full lift
© Installation of prelift sh im s
*© Checking of prelift
1 A d ju stin g device a sse m b ly 157892-0220
*® Adjustment of 2nd valve opening pressure
2 Dial g a u g e 157954-3800
("cover" pressure)
3 Pin £ = 50 m m 157892-1200 ® Inspection
4 Pin £ = 60.5 m m 157892-1100
Inspection make operations marked with * as neces
5 C onnector a sse m b ly 157892-1320
sary for inspection or confirmation.
6 B ase 157892-1800
7 G asket <for Retaining nut> 157892-1500
8 R etaining nut for adjustm ent 157892-1420
g G asket <for bolt of retaining nut> 026508-1140
13A-40
(1) Adjustment of 1st valve opening pressure
(b) Insert 1st push rod, 1st spring, 1st valve opening
(a) U sing the Retaining Nut for Adjustment (special pressure adjusting shim (first use about 1 m m thick
tool), install the nozzle and needle valve to the one) and spacer to the nozzle holder.
nozzle holder. Then tighten the set screw to specified torque.
NOTE:
1. Make sure that the knock pin has seated com
pletely in the nozzle before tightening the Retain
ing Nut for Adjustment. Tighten the retaining nut
finger tight and then tighten to specified torque
using a torque wrench.
2. Remove the bolt from the tip of the retaining nut.
(c) Install the nozzle holder to nozzle tester and adjust

the shim thickness for nominal injection pressure.
0.50 to 1.54 mm (in 0.02 mm steps)
13A-41
NOTE:
1. When using a shim, be sure to check its thickness
by a micrometer.
2. Use same shim for preiift adjustment.
3. Use of a 0.02 mm thick shim changes the valve
opening pressure by about 235 kPa {2.4 kgf/cm2}.
(2) Selection of prelift adjusting shim
(a) " 0 " point adjustment of adjusting device
(c) Install the adjusting device to the set screw using

its intermediate screw.
After installation, holding the Dial Gauge at its
holder, m ove it up and down to check that the
gauge operates smoothly.
Push down the gauge, holding its holder and read
its lift h.
NOTE:
Install Dial Gauge (special tool) to Adjusting Device Read to 1/100 mm.
(special tool). (d) Selection of prelift adjusting shim
Install the 2nd push rod to Base (special tool) and
t= €+ h
install the assem bly to a vice.
Set the pin and Adjusting Device as indicated in the where t: Sh im thickness (measured)
above illustration and adjust " 0 " point of the Dial ( : Prelift (0.10 ± 0.02 mm)
Gauge. U se a 60.5 m m long pin. h: Dim ension selected in step (c)
(b) Install the 2nd push rod to the nozzle holder. T = t ± 0.015 mm
NOTE: T: Thickness of shim to be used

Do not install the 2nd spring and prelift adjusting Shim thickness: 0.75 to 1.50 mm (in 0.01 mm steps)
shim.
(e) Rem ove the Adjusting Device from the nozzle
holder.
13A-42
(3) Adjustment of 2nd valve opening pressure (4) Checking full lift of needle valve
("o p e n " pressure)
(a) Install the special tools indicated in above illustra

Install the 2nd spring, adjusting screw and lock nut to tion and set " 0 " point of the Dial Gauge.
the nozzle holder. (b) Install the nozzle to the nozzle tester and operate
NOTE: the tester lever to bleed the inside of the retaining
Do not install the prelift adjusting shim. nut.
A lso check for fuel leaks.
(c) Operate the tester leverto increase the pressure to
about 34.3 to 44.1 M Pa {350 to 450 kgf/cm2} so that
the needle valve of the nozzle is fully lifted. Read
this lift dim ension " L " off the Dial Gauge.
(d) Remove the Dial Gauge, Connector and Pin (spe
cial tools).
(5) Installation of prelift shim
Using a nozzle tester and turning the adjusting screw,

adjust the 2nd valve opening pressure ("o p e n " pres
sure) until it complies with the nom inal value.
After adjustment, tighten the lock nut to specified
torque.
13A-43
(a) Rem ove the set screw, lock nut and adjusting (7) Checking 2nd valve opening pressure ("cover"
screw as an assem bly from the nozzle holder. pressure)
NOTE:
Never loosen the lock nut as loosening it changes the
2nd valve opening pressure.
(b) Install the prelift shim selected in Item (2) between
the spacer and 2nd push rod.
(c) Install the 2nd push rod and 2nd spring and tighten
the set screw, lock nut and adjusting screw as an
assem bly to specified torque.
(d) Check again that the needle valve full lift dimen
sion " S " with the Dial G auge by the procedures
described in Item (4).
(6) Checking prelift
Check the prelift based on dim ension " L " m easured in (a) After checking the prelift in Item (6), increase the
Item (4) and dim ension " S " m easured in Item (5). pressure again to about 34.3 to 44.1 M Pa {350 to
L- S = A € 450 kgf/cm2} so that the needle valve ofthe nozzle
is fully lifted.
where € - 0.02 m m Hk A t ^ t + 0.02 mm
NOTE:
A t:Prelift (measured)
Retaining Nut for Adjustment (special tool) must have
t : Prelift (0.1 mm)
a bolt fitted at its tip.
L: Needle valve full lift dim ension (measured)
S: Needle valve lift dim ension (measured) with (b) W hen the nozzle tester lever operation is stopped
prelift subtracted with the nozzle needle valve fully lifted, the pres
sure will start to drop and the needle valve will go
If A € is outside of specified dim ension t ± 0.02 mm,
down.
replace the prelift adjusting shim as described in (5)
(c) At the m om ent the nozzle lift has dropped to 0.05
and repeat steps (4) and (5) so that A € will fall within €
mm, read the pressure gauge indication.
± 0.02 mm.
(d) If the 2nd valve opening pressure ("o p e n " pres
Select thickness t' of shim to be used as follows,
sure) is out of specification, adjust it in accordance
t' = t + (t - A t) with item (3).
T = t ' ± 0.015 mm NOTE:
where t: Thickness of existing shim Adjust without installing prelift shim.
t': Shim thickness (e) Rem ove special tools.
T: Thickness of shim to actually replace exist
(8) Inspection
ing shim
t : Prelift (0.1 mm) (a) Tighten the retaining nut and cap nut to specified
torque.
NOTE:
1. Make sure that the knock pin has seated com
pletely before tightening the retaining nut.
2. Tighten the retaining nut finger tight and then
tighten to specified torque using a torque wrench.
13A-44
(b) Sp ray condition
1 2 3 4 5 6
Good G ood Poor Poor Poor Poor
Good Poor
1 Evenly sprayed from 3 Asym m etrical
five injection orifices 4 Branched
2 Even and symmetrical 5 Thin
6 Irregular
D7009A
W hen adjusting the pressure with a nozzle tester, check

also for clogged injection orifices, spray condition, and
fuel leaks from the orifices. Replace the nozzle if defec
tive.
(c) Fuel tightness test
D7010A
Install a nozzle that has been adjusted to specified

injection start pressure to the nozzle tester. Slow ly
increase the pressure to the test pressure and keeping
this condition, check for fuel leaks from the bottom of
the nozzle. The nozzle is functioning norm ally if there is
no leak.
13A-45
5.5.5 R e asse m b ly and adjustm ent <KBL2.4 injection nozzle>

The adjustment should be performed during reas- cleaned with the clear cleaning fluid to remove dust
sem bly as described below. The prelift should be and foreign materials completely. For the adjustment,
adjusted in 1/100 m m unit. Therefore the parts m ust be following special tools are required.
Tool n am e and sh ap e Part No. A pplication

(Zexel product No.)
A d ju stin g Device 157892-4920
*1 A d ju stin g Device 157892-4420
*2 H older 157892-4400
*2 Nut 157892-1000 Se cu rin g Dial G a u g e
*1 Dial G a u g e 157954-3800
*1 Pin 157892-4700
*1 R etainin g N ut for A dju stm e nt 157892-4020
*3 R etainin g Nut for A dju stm e nt 157892-4000
*3 G asket 026508-1140
*3 Plu g 157892-1600
*1 G asket 157892-1500
Plate 157944-9520 Secu rin g nozzle holder
Spe cial W ren ch (SW 1 9 ) 157914-2800 R em o val and installation of retaining nut
Spe cial W rench (SW 2 2 ) 157914-0500 R em oval and installation of Retaining Nut for Adjustm ent
Item s m arked " * 1 " are parts of Adjusting Device 157892-4920.

Item s m arked " * 2 " are parts of A djusting Device 157892-4420.
Item s m arked “ * 3 " are parts o f Retaining Nut for A dju stm ent 157892-4020.
13A-46
Reassembly and Adjustment Procedure
(1.) Reassem bly
(a) Secure the Plate (special tool) in a vise, then m ount

the nozzle holder on the Plate. Carry out reas
sem bly in the opposite of the disassem bly
sequence.
During reassembly, make adjustments and checks in

the following sequence-:
(b) Fit the Gasket (special tool) onto the nozzle. Then,
secure the nozzle on the nozzle holder using the
Retaining Nut for Adjustment (special tool). Turn
the Retaining Nut for Adjustment as far as possible
by hand, then tighten it to the specified torque
using the Special Wrench (special tool).
13A-47
(2) Adjusting No. 1 vaive opening pressure
(b) M ount the injection nozzle assem bly upside-down

(a) Fit the injection nozzle assem bly onto the tester on the Plate (special tool). Then, fit the Holder and
and m easure the valve opening pressure. Nut (special tools).
NOTE:
Do not touch the spray that comes out of the nozzle.
(b) If the spray pressure is out of specification, adjust it
using No. 1 valve opening pressure adjustment
shim. (This shim has an outside diameter of 8.9
mm.)
A 0.02 m m change in shim thickness causes a 235
kPa {2.4 kgf/cm2} change in valve opening pres
sure.
Sh im thickness:
0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70
(3) Checking needle valve total lift
(c) Fit the Pin (special tool) into the Dial Gauge (special
tool).
(d) Fit the Dial Gauge (special tool) onto the injection
(a) Fit the Gasket and Plug (special tools) onto the nozzle assem bly and secure it with the Nut (special
Retaining Nut for Adjustment (special tool). tool) such that the Pin (special tool) is touching the
top surface of the No. 1 spring seat.
13A-48
NOTE: (4) Checking prelift
1. Secure the Dial Gauge such that a stroke of
approximately 1.2 mm can be measured.
2. Do not overtighten the Nut. If the Nut is too tight,
the Dial Gauge shaft will stick in one position.
01903
(a) Once the needle valve is in its fully lifted position,

the pipe pressure will startto drop if the Nozzle Tes
ter handle is not moved. The needle valve lift m ea
surement (as show n by the Dial Gauge) will drop
(e) Fit the injection nozzle assem bly onto the Nozzle concomitantly. In the graph,
Tester, then zero the Dial Gauge. A: Needle valve total lift am ount
Loosen the Plug (special tool) and operate the
Nozzle Tester. Bleed the Retaining Nut for Adjust
ment, and check for fuel leaks at the sam e time.
After fully bleeding the Retaining Nut for Adjust
ment, securely tighten the Plug.
Pipe pressure (M P a {kgf/cm 2}) 01902
(f) Operate the Nozzle Tester. W hen the pipe pressure

is raised to 34.3 to 44.1 M Pa {350 to 450 kgf/cm2},
the needle valve should lift completely. W hen this
happens, make a note of the total lift m easure
ment. In the graph,
A: Needle valve total lift am ount (b) Read the Dial Gauge indication when the No. 2
C: No. 1 valve opening pressure spring stops acting and the needle valve stops
NOTE: dropping. This point is labeled " F " in the above
graph. Confirm that the reading conform s with the
This check is necessary to check for abnormal wear on
the nozzle seat. specified nominal value.
13A-49
The prelift measurement point (labeled " G " in the

graph) corresponds to C + approx. 980 kPa {10 kgf/
cm 2}, where " C " is the No. 1 valve opening pres
sure.
In the graph,
A: Needle valve total lift am ount
C: No. 1 spring opening pressure
F: Prelift
G: Prelift measurem ent point
(c) If the prelift measurement is out of specification,

(b) Read the pressure gauge indication at the instant
replace the pin, lift-piece, spacer, nozzle, and
when the Dial Gauge indicates the specified nom i
needle valve with the Nozzle Service Kit.
nal needle valve lift (normally prelift F + 0.05 mm).
(5) Checking No. 2 valve opening pressure In the graph,
A: Needle valve total lift am ount
C: No. 1 valve opening pressure
F: Prelift
J: No. 2 valve opening pressure
(6) Adjusting No. 2 valve opening pressure
(a) After checking the prelift, operate the Nozzle Tester

and raise the pipe pressure to 34.3to 44.1 M Pa {350
to 450 kgf/cm2}suc h thatthe needle valve lifts fully.
If the Nozzle Tester handle is not m oved, the pipe
pressure will drop. The needle valve lift m easure
ment (show n by the Dial Gauge) will drop concom
If the No. 2 valve opening pressure is out of specifica
itantly.
tion, disassem ble the nozzle m ounting side of the
injection nozzle assem bly and change the No. 2 valve
13A-50
opening pressure adjustment shim. (This shim has an (8) Inspection
outside diameter of 9.9 mm.)
S h im s are available in the following thicknesses: 0.40,
0.50. 0.52, 0.54, 0.56, 0.58, 0.60, and 0.70 mm. A 0.02
mm change in shim thickness causes a change in valve
opening pressure of 196 kPa {2 kgf/cm2}.
NOTE:
1. Do not touch the spray that comes out of the
nozzle.
2. Changing the No. 1 valve opening pressure causes
the No. 2 valve opening pressure to also change.
(7) Replacing retaining nut
15268
59 to 78 N m
{6 to 8 kgf-m} Fit the injection nozzle assem bly onto the Nozzle Tes
ter. Check the No. 1 valve opening pressure, the spray
shape, and the oil-tightness of the seat. Check also that
there are no leaks.
NOTE:
R etaining 1. Ifthe No. 1 valve opening pressure does not con
N ut for form to its specified nominal value, go through the
A d ju st
m ent adjustment procedure again from step (1).
2. Do not touch the spray that comes out of the
nozzle.
- 3
" 4
- 5
15267
Rem ove the Dial Gauge, Pin, Nut, and Holder. Then,
take off the Plug, the Gasket, and the Retaining Nut for
Adjustment and its Gasket. Fitthe regular retaining nut
and tighten it to the specified torque using the Special
W rench (special tool).
Special tools:
1. Special Wrench (157914-0500)
2. Gasket (157892-1500)
3. Retaining Nut for Adjustment (157892-4000)
4. Gasket (026508-1140)
5. Plug (157892-1600)
6. Holder (157892-4400)
7. Nut (157892-1000)
8. Pin (157892-4700)
9. Dial Gauge (157954-3800)
13A-51
5.6 Fuel Filter

<6D24, T, T C>
25 N-m
{2.5 kgf-m}
43336
7.8 to 12 N-m
Cracks, {0.8 to 1.2 kgf-m)
threaded
portion 2
The element can be removed easily using the Filter 25 N-m

{2.5 kgf-m}
W rench (special tool).
A p p ly thin coat
of engine oil
) w hen m ounting.
25 N-m /
{2.5 kgf-m}
U JLJ$
43337
1 Fuel filter element
2 Fuel filter head
13A-52
<6D24-TL>
25 to 35 N-m
{2.5 to 3.5 kgf-m}.
2 Cracks,
9.8 to 2 N-m threaded
{ 1.0 to 0.2 kgf-m} portion
25 to 35 N-m
{2.5 to 3.5 kgf-m}
A p p ly thin coat
of e ngine oil
w hen m ounting.
© 43333
1 Fuel filter element
2 Fuel filter head
NOTE:
1. When removing the element, check for the gasket
left behind on the head side.
2. To mount, apply a thin coat of engine oil to the ga s
ket, and then secure the element by tightening 3/4
to 1 turn afterthe gasket comes in contact with the
fuel filter head.
3. After installation, bleed the fuel system.
4. After bleeding the air, start the engine and check
for fuel leaks.
13A-53
5.7 W a te r S e p a ra to r
1 0 25 N-m
{2.5 kgf-m}
11 @
7.8 to 12 N-m 10 -
{0.8 to 1.2 kgf-m } @
7.8 to 12 N-m @
10 {0.8 to 1.2 kgf-m} ©
7.8 to 12 N-m
25 N-m {0.8 to 1.2 kgf-m}
{2.5 kgf- 1 0 25 N-m
{2.5 kgf-m}
25 N-m
11 {2.5 kgf-m}
7.8 to 12 N-m 10
{ 0.8 to 1.2 kgf-m}
7 — <!
8 - M
10
25 N-m
{2.5 kgf-m}
43745 ©43369
Drain plug 7 Isolation plate

0-ring 8 Screen assem bly
Ring nut 9 Water level ring
Case 10 Eyebolt
0-ring 11 Air plug
Baffle plate 12 Cover
If the red water level ring in the translucent case rises to

the level of the red line marked on the outer circumfer
ence of the case, immediately loosen the drain plug to
discharge water.
It is not necessary to completely remove the drain plug,
as water is discharged gradually through the groove of
the loosened plug.
NOTE:
After draining, tighten firmly the drain plug before
bleeding the fuel system.
09278
13A-54
FUEL AND ENGINE CONTROL - TROUBLESHOOTING 13A
6. TROUBLESHOOTING
S y m p to m Probable cause R em e dy Ref. grou p
E ngin e will not Defective feed p u m p

start
• Loaded ga u z e filter Clean
• Check valve inoperative Replace
• Seized or w o rn piston Replace
• Seized push rod Replace
• W orn tappet Replace
Defective injection pum p

• Defective p u m p Replace
• Incorrect installation (incorrect adjustm ent of injection tim Adjust

ing)
• M alfu nction in g overflow valve Replace
Defective injection nozzle

• Seized needle valve Replace
• Valve o p e n in g pressure too low Adjust
• C lo gg e d injection orifice Clean
• Nozzle not air-tight Correct or replace
Fuel tank em pty S u p p ly fuel
C lo g g e d fuel pipe or fuel leaks from connection Correct or replace
Air or water trapped in fuel system Bleed or replace
Loaded fuel filter Replace
Open circuit, sh o rt circuit, or p oor connection in engine speed Replace

se n sor or backup engine speed se n sor
Defective m ain relay or blow n fuse Replace
E n gin e starts C lo gg e d fuel filter Correct or replace

but so o n stop s
A ir or w ater trapped in fuel system Bleed or replace
Defective feed p u m p Check
Defective injection p u m p operation

• Defective go ve rn o r Replace
• C lo gg e d gau ze filter Clean
E ngin e knocks Injection tim ing to o advanced Adjust

• Valve o p e n in g pressure too high A dju st
• C lo gg e d injection orifice Clean
Low quality fuel in use Replace

• Defective go ve rn o r Replace
• Defective prestroke actuator Replace
Poor connection in injection quantity adjusting resistor Replace
Poor contact in idle speed adjustm ent variable resistor Replace
13A-55
FUEL AND ENGINE CONTROL - TROUBLESHOOTING
Sym p tom Probable cause Rem edy Ref. group
S m o k y e n gin e Defective injection p um p

exh au st and Adjust
• Incorrect injection tim in g
knocking
• W orn plunger Replace
• Defective valve seat Replace
Low quality fuel in use Replace

• Valve opening p ressure too low Adjust
• Broken spring Replace
• C lo g g e d injection orifice Clean
U n sta b le engine Defective injection p u m p operation

output
• Defective pum p Replace

ing)
• Defective governor Replace

• Poor slid in g of needle valve Replace
• Incorrect valve op en ing pressure Adjust
Defective feed pum p

• Check valve not fun ction ing properly Replace
• W orn piston Replace
A ir or w ater trapped in fuel system Bleed or replace
Insufficient Defective injection nozzle

e n gin e output • Defective m ain body Correct or replace
* C lo g g e d injection orifice Clean

• Defective main body Replace

ing)
• Overflow valve m alfunctioning Replace
Accelerator pedal stopper bolt poorly adjusted Adjust
Poor quality fuel in use Replace
E n g in e not Defective injection nozzle

reach in g max.
speed
• Valve opening pressure too low Adjust
Defective injection p um p operation

Accelerator pedal stopper bolt poorly adjusted Adjust
13A-56
FUEL AND ENGINE CONTROL - TROUBLESHOOTING 13A
S y m p to m Probable cause Rem edy Ref. grou p
Engin e max, Defective injection p u m p operation

speed too high Replace
• Defective pum p
• Defective governor Correct
U n stable engine Defective injection p u m p operation

idling

ing)
• Overflow valve m alfunctioning Replace
• Air or water trapped in fuel system Bleed or replace
Poor-quality fuel in use Replace
Defective feed pum p

• Defective check valve Replace
• W orn piston Replace
• Loaded gauze filter Clean

• Deteriorated sprin g Replace
E ngin e cannot Broken or stretched engine stop cable Replace

be stopped
Poorly adjusted engine stop cable Adjust
D a m a g e d governor stop m e chan ism Replace
Fuel su p p ly Defective injection p um p Replace

failure
Cracked fuel hose, pipe Replace
Leaky fuel tank Replace
13A-57
13E
ELECTRONICALLY
CONTROLLED FUEL SYSTEM
CONTENTS
1. G E N E R A L ......................................... ..... 2 3.4 C auses of Diagnostic Trouble Code Issue,

1.1 Principle of o p e ra tio n ..................... ..... 2 and Inspection Item s ........................... 21
1.2 Electronic Governor ....................... ..... 3 3.4.1 D iagnostic trouble codes ................. 21
1.3 Electronic T im e r............................. ..... 4 3.4.2 D iagnostic trouble code issue
1.4 Timer Control V a lv e ........................ ..... 5 conditions, and check i t e m s ............. 21
1.5 Electronic Control S y s t e m ............... ..... 6 3.5 M ulti-U se Tester II Service D a t a ............ 27
1.6 ECU Terminal C o n figu ra tio n ............ .... 10 3.6 Actuator Tests U sing M ulti-U se
2. SP E C IF IC A T IO N S .............................. .... 14 Tester I I .............................................. 28
3. T R O U B L E S H O O T IN G ....................... .... 15 3.7 Inspection U sin g EC U Connector ......... 29
3.1 Inspection P ro ce d u re s.................... .... 15 3.7.1 EC U terminal co n figu ration ............... 29
3.1.1 Diagnostic function .................... .... 15 3.7.2 Inspection instructions .................... 29
3.1.2 Inspection flo w c h a rt................... .... 16 3.8 Checks on Transient Troubles ............... 31
3.2 Connection of M ulti-U se Tester II __ .... 17 4. IN SP E C T IO N OF ELECTRICAL
3.2.1 Special tools ............................. .... 17 E Q U IP M E N T .......................................... 32
3.3 Reading and Elasing
Diagnostic Trouble Codes ............... .... 19
13E-1
13E ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL
1. GENERAL
W ith the electronically controlled injection pum p sy s The electronic governor ECU optimally controls the
tem, electronic control is applied to the governor and governor and timer in accordance with data signals
timer (the com ponents of the injection pum p assem from sensors mounted on the engine and other parts of
bly) to realize the optimum fuel injection tim ing and the vehicle.
fuel injection rate.
1.1 Principle of operation
1 RED-4 internal circuit 8 Timer control valve 14 Plunger

2 Control rack position sensor 9 Injection nozzle 15 Cam shaft
3 Control rack 10 C om bustion chamber 16 Injection pump
4 Engine speed sensor 2 11 Fuel tank 17 Linear DC motor
5 Electronic timer 12 Feed pum p 18 Electronic governor actuator
6 Engine speed sensor 1 13 Control sleeve 19 Fuel filter
7 Engine ECU © 43638
The extent of operation of the linear m otor 17 and timer rack position se nsor processing circuit and a linear DC
control valve 8 are determined by sign als from the motor drive circuit, which are conventionally incorpo
engine ECU 7. rated into the engine ECU. This arrangement elimi
The linear motor 17 m oves the control rack 3, thereby nates noise in the harness and thus prevents erro
changing the fuel injection quantity. neous ECU operation. M ore accurate electronic control
The timer control valve 8 controls the hydraulic pres is possible as a result.
sure applied to the electronic timer 5, thus adjusting The engine speed is sensed by engine speed sensor 1 6
the fuel injection timing. and engine speed sensor 2 4. Each of these sensors
The RED-4 internal circuit 1 is incorporated into the acts as a backup if the other fails.
electronic governor actuator 18. It contains a control
13E-2
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 13E
1.2 Electronic G overn or
1 Cover
2 RED-4 internal circuit
3 Control rack position sensor
4 Housing
5 Se n sin g gear
6 Em ergency engine stop lever
7 Link
8 Coil assem bly
9 Linear DC motor
©38928
(2) Control rack position sensor .

The control rack position sensor 3 senses whether the
control rack A is m oved to the correct position by the
linear DC motor 9. In the event of a discrepancy
between the actual control rack position and the target
control rack position (this is determined by the engine
ECU and RED-4 internal circuit 2), the engine ECU
causes the linear DC motor 9 to perform a corrective
movement. .
(3) Em ergency engine stop lever
The em ergency engine stop lever 6 is connected to the
link 7. Via a wire, it enables the link to be m oved from
(1) Linear DC motor the driver's seat. In the event of a system fault that pre
The linear DC motor 9 m oves the coil assem bly 8 verti vents the engine from being stopped normally, opera
cally in accordance with signals from the engine ECU tion of the emergency engine stop lever forces the con
and RED-4 internal circuit. Via the link 7, this m ovem ent trol rack A to move to the position at which fuel injec
is transmitted to the control rack A, which m oves longi tion is terminated. This operation takes place irrespec
tudinally to increase and decrease the fuel quantity. tive o f the p o s itio n o f th e lin e a r D C m o to r 9.
13E-3
B3E ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL
1.3 Electronic Tim er
Cover
Engine speed sensor 2
Tim ing sensor
Cap
Disc
Disc
Flange
8 Large eccentric cam
9 Sm all eccentric cam
10 Plate
11 Spring seat
12 Timer spring
13 Pilot pin
14 Cylinder
15 Piston
24960
The electronic timer uses an eccentric cam arrange

ment to adjust the injection timing. The eccentric cam s
8,9 in the electronic timer are m oved by hydraulic pres
sure supplied from the timer control valve assembly.
(1) The timer incorporates four pistons 15, which are
activated by hydraulic pressure A. The pistons are
arranged as two pairs, and each piston slides verti
cally in a cylinder 14.
(2) Each pair of pistons 15 is linked to a plate 10. The
two plates are pressed against each other by the
timer springs 12.
(3) W hen hydraulic pressure A acts upon the pistons
15, the pistons m ove toward the outside of the
timer flange 7.
(4) A s the pistons 15 move outward, the plates 10
(thus far pressed together by the timer springs 12)
also move outward.
(5) The eccentric cam s 8, 9 m ove in conjunction with
the plates 10, thereby altering the fuel injection
timing.
13E-4
ELECTRONICALLY CONTROLLED FUEL SYST EM - GENERAL 13E
1.4 Tim er C ontrol Valve
p 1 Seat
2 Valve
3 Plunger
4 Spring
► 5 Coil
-3 6 Pump-side solenoid valve
-4 7 Release-side solenoid valve
-5
A: Port A
P: Port P
R: Port R
24961
The timer control valve controls the hydraulic pressure (1) Advancem ent of fuel injection timing
(engine oil) that activates the electronic timer assem
bly.
Internal oil passages emerge at port P (where engine
oil enters the assembly), port A (which supplies engine
oil to the timer), and port R (which returns engine oil to
the oil pan).
The oil passages are interrupted by two solenoid
valves 6,7, one oh the pump side and the other on the
release side. The solenoid valves control the hydraulic
pressure reaching the timer. Each solenoid valve incor
porates a plunger 3 and coil 5. W hen the Solenoid valve
is activated, the coil 5 attracts the plunger 3, which
m oves the valve 2 away from the seat 1 .thereby open
ing the oil passage. Opening and closing timing of the The pum p-side solenoid valve 6 is activated.
solenoid valves is controlled by the electronic timer The release-side solenoid valve 7 is not activated.
control unit. With the solenoid valves in these conditions, ports P
and A are connected, allowing the supply of hydraulic
pressure to the timer. Thus, the fuel injection tim ing is
advanced.
13E-5
(2) Maintenance of advanced (or retarded) fuel injec- (3) Retardation of fuel injection timing
tion timing
The pum p-side solenoid valve 6 is not activated.

The pum p-side solenoid valve 6 is not activated. The release-side solenoid valve 7 is activated.
The release-side solenoid valve 7 is not activated. With the solenoid valves in these conditions, ports A
With the solenoid valves in these conditions, the ports and R are connected, allowing oil in the timer to return
are isolated from each other. Thus, the hydraulic pres to the oil pan. Thus, the fuel injection timing is
sure in the timer stays constant and the timer rem ains retarded.
in its current condition.
1.5 Electronic C o n tro l S y s t e m

(1) System block diagram
Input signals Output signals
13E-6
Sign a l Part M a in function/operation
1 Control rack position sign al Control rack position sensor S e n sin g of control rack position
2 E ngin e speed sign al E ngin e speed se n so rs 1, 2 S e n sin g of e ngine speed

U se of two se n so rs a llow s for backup if one
se n so r fails.
3 E n gin e start sign al Starter sw itch Recognition of engine startup with starter
sw itch in S T A R T position
4 C oolan t temperature sign al Coolant temperature se nsor S e n sin g of coolant temperature
5 Accelerator pedal position signal Accelerator pedal position se n sor S e n sin g of extent of depression of accelerator
pedal
Accelerator pedal switch Detection of pedal depressed/released con d i

(O N with pedal released) tion
6 Fault d ia g n o sis signal D ia g n o sis switch C allup of d ia g n o sis codes
M e m o ry clear switch Deletion of d ia g n o sis codes; callup of p ast

d ia g n o sis codes
7 Fuel injection quantity sign a l Fuel injection quantity adjusting resis Correction of fuel injection quantity
tor
8 B o o st pressure signal B o o st pressure se n sor Detection of bo ost pressure

9 - Linear D C m otor M o v in g of control rack
10 - Tim er control valve Control of hydraulic pressure applied to elec
tronic timer
Injection quantity adjusting resistor
02734
The injection quantity adjusting resistor makes fine ad

justments to achieve optimal com m ensuration of in-
jectied fuel quantity with fuel feed from the com m on
rail.
NOTE:
This resistor, selected as the best from am ong several
types, determines the final injection quantity. DO N O T
change it for any other type.
13E-7
(2) Control of fuel injection quantity
Control rack position sensor
Engine ECU RED-4 inter

nal circuit
Engine speed sensor 1
Engine speed sensor 2 Target rack position
Linear DC
Coolant temperature sensor
Idling characteristics motor
Accelerator pedal position
se nsor
Fuel injection quantity adjust Running characteristics
ing resistor
Full rack characteristics
Starting characteristics
(a) Control effected by engine ECU and RED-4 internal (b) Feedback control effected using control rack posi
circuit tion sensor
The RED -4 internal circuit processes control rack posi The control rack position se nsor enables the RED-4
tion sign als and transmits the results to the engine internal circuitto calculate whetherthe linear DC motor
ECU. has m oved the control rack to the target position. This
The engine ECU effects control during engine opera arrangement enables the R ED -4to ensure thatthe con
tion u sing the stored idling characteristics or running trol rack position always corresponds to the target val
characteristics, and it determines the target control ue.
rack position in accordance with sign als issued by the The engine ECU receives signals indicating the control
RED-4 internal circuit. rack's actual position from the RED-4 internal circuit
The control rack position signal issued by the engine and uses them to evaluate control rack position errors.
ECU is returned to the RED-4 internal circuit. Via the
servo circuit and drive circuit, it causes activation of the
linear D C m otor such that the control rack is moved.
(3) Control of fuel injection timing
13E-8
(a) The engine ECU controls the fuel injection timing (4) Preheat control
by controlling the activation of the timer control Preheat control im proves startability w hen the
valve, which applies hydraulic pressure to the elec engine's coolant temperature is low.
tronic timer.
(a) Operating m odes
(b) The engine ECU controls the timer control valve by
determining the target and actual advance angles, 1) Engine coolant temperature higher than 0°C
com paring them with each other and with charac
teristics stored in its memory, and issuing drive
START
signals to the timer control valve in accordance ON
Starter switch O F F ----
with the results.
1) Target advance angle: calculated by com parison of ON
Preheat lamp OFF
data signals from sensors with characteristics
stored in engine E C U 's m em ory Running ... .
Engine Not ru n n in g__
2) Actual advance angle: determined in accordance
with signals from engine speed sensor 1 and ON
Heater relay OFF
engine speed se nsor 2.
(c) W hen the engine is cold, startability and post-start
warm up are optimized by the use of cold idling © 43717
characteristics in determination of the fuel injec
tion timing.
No preheating is necessary at the time of engine
startup, so the heater relay is kept OFF.
2) Engine coolant temperature 0°C or lower
START m
ON |
Starter switch OFF— >
_ . ON 1
Preheat lamp OFF —1
Running
Enaine Nnt running I......................
i
ON I-------------
Heater relay OFF— 1 - T ------------------ L
1- ------------- 4 .----------------~l ,
Preheat Afterheat
©43718
" t s " seconds after the starter switch is turned ON, the
heater relay is turned ON, causing preheating to begin.
The preheat lamp illuminates simultaneously.
W hen preheating finishes, the preheat lamp goes off to
indicate that the engine can be started. The heater relay
remains ON until the engine is started.
W hen the engine is started, the engine ECU determines
whether afterheating is necessary in accordance with
the engine coolant temperature. If the engine ECU
determines that afterheating is not necessary, preheat
control is terminated. If it deems that afterheating is
necessary, the heater relay remains ON for a certain
period after engine startup to cause afterheating.
13E-9
1.6 E C U Term inal C o n figu ratio n
A: C W 3 2 A
I . f
10 6 3 T 6 S 4 3 2 1
24 23 22 21 20 10 16 17 16 1b 14 13 12
32 31 30 20 20 27 26 2b
B: C W 2 5 A
II I
6 7 T b 4 3 2 r h
18 17 16 15 14 13 12 11 10 9
25 24 23 22 21 20 10
C: C W 3 1 A
r
10 0 8 7 -(T 5 4 V 2 1
22 21 20 10 Ifi 17 16 1i 14 13 12 11
3i 30 20 28 27 26 2b 24 23
D: C W 16A
I | 1J
5 4 3 2 1
12 11 10 0 6 7 6
16 1b 14 13
© 43639
A: C W 3 2 A
Terminal No. ltem(s) to which terminal is connected Terminal No. ltem(s) to which terminal is connected
1 - 17 -
2 - 18 Boost pressure sensor (SIG)
3 RED-4 ECU (PULL DOW N) 19 Engine speed sensor 2 (GND), RED-4 ECU (SIG N A L
GND-2)
4 - 20 -
5 - 21 Engine speed sensor 1 (GND)
6 Boost pressure sensor (+5V) 22 -
7 Engine speed sensor 2 (SIG) 23 -
8 Engine speed sensor 1 (SIG) 24 -

9 - 25 -
10 - 26 -
11 Heater relay 27 -
12 - 28 -
13 - 29 Boost pressure sensor (GND)
14 RED-4 ECU (LIMP HOME) 30 Coolant temperature sensor (GND)
15 - 31 Timer control valve (ADV)
16 - 32 Timer control valve (RTD)
13E-10
B: C W 25A
Terminal No. ltem(s) to w hich terminal is connected Terminal No. ltem(s) to which terminal is connected
1 W arn ing lam p (orange) 14 RED-4 E C U (+5 VCC-2)
2 Accelerator pedal sw itch 15 RED-4 E C U (P W M SOL-2)
3 - 16 RED-4 E C U (V-IST)
4 Injection quantity adjusting resistor (S IG ) 17 Frame grou n d (M /V P O W E R G N D )
5 R ED-4 ECU (+5 VCC-1) 18 -
6 R ED -4 E C U (P W M SOL-1) 19 -
7 R ED-4 E C U (VB2) 20 M U T -II connector (K-LINE)
8 R ED -4 E C U (VB1) 21 -
9 Accelerator pedal position se nsor 2 (S IG ) 22 Shie ld (S H IEL D ) of VB-1, VB-2, GND-1, and G N D -2
10 - 23 R ED-4 E C U (S IG N A L G ND-1)
11 - 24 RED-4 E C U (GN D-2)
12 - 25 RED-4 E C U (G N D-1)
13 Injection quantity adjusting resistor (G N D ) '— ------------- --------
C: C W 31A
Terminal No. ltem(s) to w hich terminal is connected Terminal No. ltem(s) to w hich terminal is connected
1 - 17 Accelerator pedal position se nsor 1 (SIG )
2 E n gin e speed output sign a l (N E O U T S IG ) 18 -
3 Starter switch S term inal (S T A R T E R S W S) 19 D ia g n o sis switch
4 - 20 -
5 - 21 -
6 - 22 -
7 Battery relay (ST A R T E R S W M-2) 23 -
8 Battery relay (ST A R T E R S W M -1 ) 24 Battery grou n d (C A S E G N D )
9 - 25 -
10 M U T -II connector (DCT) 26 Preheat lam p (P R E H E A T LA M P )
11 - 27 Accelerator pedal position sensor 2 (G N D )
12 Control rack p osition output sign al (R A C O U T 28 Accelerator pedal position sensor 1 (G N D )

S IG )
13 - 29 M e m o ry clear sw itch
14 - 30 -
15 C oolan t temperature se n so r (SIG ) 31
16 ----------------------------- ----------------- --------------------
D: C W 1 6 A
Terminal No. ltem(s) to w hich term inal is connected Terminal No. ltem(s) to w hich terminal is connected
1 E ngin e ECU m ain pow er relay (+VB-2) 9 -
2 E ngin e E C U m ain pow er relay (+VB-1) 10 -
3 W arn ing lam p (red) 11 -
4 - 12 -
5 D D S-3 connector (D D S 3 ) 13 E ngin e E C U m ain pow er relay (M A IN RELAY-2)
6 Battery ground (GN D-2) 14 -
7 Battery ground (GN D-1) 15 -

8 E ngin e E C U m ain p ow er relay (M A IN RELAY-1) 16 -
13E-11
13E-12
E n gin e E C U
C 25 Preheat lam p
-csrr-
Heater relay
Heater relay
T -m h A ir heater
i i
SIG r
C 17
GND
Accelerator pedal
C28 p osition se n sor 1
S IG
B9 Accelerator pedal
GND
C27 position se n sor 2
B2 Accelerator pedal
Depressed: OPEN,
Released: G N D
“i sw itch
X
CASE GND ©45865-2
13E-13
13E ELECTRONICALLY CONTROLLED FUEL SYSTEM - SPECIFICATIONS
2. SPECIFICATIONS
Item Specification
Injection p u m p a sse m b ly M anufacturer B O S C H A U T O M O T IV E S Y S T E M S
Model Electronically controlled in-line pum p
Injection p u m p m odel NP-PE6P120
G ove rn or m odel R ED -4 (RED-4 with internal circuit)
Tim er m odel SPGH
Feed p u m p m odel KD
Tim er control valve M anufacturer B O S C H A U T O M O T IV E S Y S T E M S
Rated voltage V 24
Pressure ran ge kPa {kgf/cm2} 49 to 980 {0.5 to 10}
ECU M anufacturer B O S C H A U T O M O T IV E S Y S T E M S
Rated voltage V 24
13E-T4
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 13E
3. TROUBLESHOOTING Do not forget to clear the diagnostic trouble code by
the Multi-Use Tester II or memory clear switch after
3.1 Inspection Procedures
a fault has been rectified.
3.1.1 Diagnostic function A s a rule, inspection operations should be per
W heneverthe starting switch is placed at ON, the diag formed with the starting switch at the LOCK posi
nostic function is activated to check all the sensors, etc. tion. Some checks, however, may have to be made
with the starting switch at the O N position. In such
If any of them is found faulty, the warning lamp in the
a case, use care to make sure that no short circuit
meter cluster is lit to alert the driver. At the sam e time,
develops between pins of the connectors or with
the fault location is stored in memory, and the system
the body.
enters the backup mode.
The resistance value of each component is affected
The stored fault location can be read as a diagnostic by the temperature and the accuracy of the tester.
trouble code by the Multi-Use Tester II orthe diagnostic The reading, therefore, does not always fall within
switch. the standard limits. Note that the check values
shown in the text are the values obtained at normal
Warning lamp indications
temperature (10 to 35°C).
' ---------— ______ W arn in g lam p Whether or not the system automatically returns to
Safety-critical error Red
normal from the backup mode after a fault has been
(Vehicle m ust not be driven) removed depends on the diagnostic trouble code
Non-safety-critical error O range (fault location).
(Vehicle can be driven despite poor
control feeling)
Even when the fault has been removed and the sy s
tem has been automatically returned to the normal
NOTE: mode, the diagnostic trouble code of the fault
• Check to ensure that the battery voltage is within remains stored in the engine control unit.
the specified range. When a fault occurs at a point where the system is
• Check all the harness and device connectors for not automatically reset, perform the memory clear
looseness. Alw ays remove a connector at least 20 procedure to let the system exit from the backup
seconds after placing the starting switch at the mode. CD P13E-19
LOCK position.
13E-15
13E ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
3.1.2 Inspection flow chart

The system inspection can be performed effectively by (1) Inspections based on diagnostic trouble codes
use of the M ulti-Use Tester II. The types of system stored in the engine control unit
inspections m ay be broadly divided as show n below in (2) Inspections of transient troubles
accordance with the trouble sym p tom s and diagnostic
trouble code outputs.
13E-16
3.2 Connection of M u lti-U s e Tester II
3.2.1 Special tools

Unit: m m Unit: m m
Tool nam e Sh ap e Tool nam e S h ap e
M ulti-U se Tester II M u lti-U se Tester II harness

MB991496 MB991499
Inspection of system To use M ulti-U se Tester II as
a circuit tester
19492 20536
M ulti-U se Tester II harness Battery clam p harness

(for com m unications) MK320193
MC887252
Pow er su p ply to M u lti-U se
To supply pow er to M ulti-U se Tester II in vehicle w ithout
Tester II proper and co m m u cigarette lighter; detection of
nicate with vehicle side elec start sign al in vehicle w ithout
trical devices cigarette lighter f)
19141 20537
Read-only m em ory pack

(M RI-E1)
MK369392
Data for inspection and con
trol of engine control unit
19493
M e m o ry card (set in Multi-

U se Tester II proper)
MB991500
To write data
20538
13E-17
The M ulti-U se Tester II typically draw s power from the (2) Power supplied to Multi-Use Tester II from battery
cigarette lighter. In a vehicle without a cigarette lighter,
the pow er connection ofthe Multi-Use Tester II is differ
ent depending on the type ofthe starter switch as fol
lows:
M u lti-U se W ith cigarette lighter socket W ith o u t ciga

Tester II rette lighter
p ow e r s u p p ly Starter switch Starter switch socket
connection type A *a type A * b
C igarette O - -
lighter socket
Battery - O O
*a W ith starter sw itch type A, pow er su p p ly to cigarette lighter

co n tin u e s w hile engine is being cranked.
*b W ith starter sw itch type B, pow er su p p ly to cigarette lighter is
su sp e n d e d w hile engine is being cranked.
(1) Pow er supplied to Multi-Use Tester II from ciga

rette lighter
___________________________________ ©35849
(a) Place the starter switch in the LOCK position.

(b) Connect the |£b) Multi-Use Tester II harness (for
communication) to the |£a) Multi-Use Tester II, then
insert the (jCc) R O M pack.
(c) Connect the © clamp D (red) of the (£d) battery
clamp harness to the © terminal E ofth e battery
(a) Place the starting switch at the LO C K position.
and the © clamp F (black) to the ©term inal G ofthe
(b) Connect the (£a) Multi-Use Tester II harness to jCb]
battery.
M ulti-U se Tester II and insert the jcT] read-only
(d) Fit the connector A into the socket H ofthe j£d) bat
m em ory in the tester.
tery clamp harness.
(c) Connect the connector A to the cigar lighter socket.
(e) Fit together the Multi-Use Tester II connector B (16
(d) Connect the Multi-Use Tester II connector C (16
pins) and connector C (16 pins).
pins) to the data link connector B (16 pins).
NOTE:
NOTE:
Connect the © clamp D (red) ofthe (£d) battery clamp
For the operating procedures for the M ulti-Use Tester
harness before connecting the © clamp F (black).
II, refer to the instruction manual for the M ulti-Use Tes
ter II.
13E-18
3.3 R e ad in g and Erasin g D ia g n o stic Trouble (b) Reading diagnostic trouble code
Codes
Two types of methods are available for reading or eras 10s digit Units digit
ing a diagnostic trouble code; one using the Multi-Use
Tester II and one using the vehicle side diagnostic func
ON
tions.
(1) M ethod using Multi-Use Tester II
OFF
(a) Current diagnostic trouble code
1) Check to see that the m em ory clear switch 1 is con 1.2 1.2
nected. 0.4------
2) Set the starting switch to ON.
0.4-
3) Operate the Multi-Use Tester II to read the current
diagnostic trouble code and determine the fault 0.4-
location. D iagnostic switch
disconnected
(b) Past diagnostic trouble code. First diagnostifc trouble code displayed
1) Set the starting switch to ON. I (Diagnostic trouble code 12)
2) Disconnect the m em ory clear switch 1.

STL-rum rum rum Second
U
d ia gn o stic
3) Operate the Multi-Use Tester II to read the past reg I trouble
istered diagnostictrouble codes and determinethe
J code
2.4 2.4 2.4 2.8 d isp laye d
fault location.
©13705
(c) Erasing diagnostic trouble codes
1) Set the starting switch to ON. Diagnostictrouble codes are indicated by the n u m
2) Operate the Multi-Use Tester II to erase all of the ber of times the warning lamp 3 flashes and their
diagnostic trouble codes stored in the engine con duration.
trol unit. The flashing intervals also differ between the 10s
(2) Method Not Using Multi-Use Tester II (Method digit and units digit.
U sing Diagnostic Switch and M e m o ry Clear 10s digit: 1.2 second interval
Switch) Units digit: 0.4 second interval
Each diagnostictrouble code is displayed from the
(a) Current diagnostic trouble code
10s digit followed by the units digit. A s for a code
1) Set the starting switch to ON. which has no 10s digit, units digit only is displayed.
2) Disconnect the diagnostic switch 2. 2) Each diagnostic trouble code is displayed three
3) The diagnostictrouble code is displayed byflashes times in succession.
of the warning lamp 3. 3) If there is no more code stored, the sequence is
then repeated from the beginning with each code
indicated three times.
4) W hen the diagnostic switch 2 is connected, the
engine control unit will immediately stop display
ing codes.
13E-19
(c) Past diagnostic trouble codes Disconnect the m em ory clear switch 1 and the diag
1) After reading the current diagnostic trouble codes nostic switch 2 then reconnect them. Then all the diag
(with the diagnostic switch 2 disconnected), d is nostic trouble codes stored in the engine control unit
connect the m em ory clear switch 1. Then the O will be cleared.
w arning lamp 3 will restart flashing. NOTE:
2) This time, the warning lamp displays the past diag- • If the contents of memory are not to be cleared after
nostictrouble codes. Determine the fault locations display of the stored codes, set the starting switch
based on the indicated codes. to OFF with the memory clear switch 1 discon
nected. Thereafter, connect the memory clear
(d) Erasing diagnostic trouble codes
switch.
• When you change the combination of the injection
pump and engine control unit, you must rewrite the
pump data stored in the engine control unit. For this
A second purpose, be sure to perform the diagnostic trouble
or more 3 seconds code erasing procedure.
• Wheneverthe engine control unit has been replaced
Connected — —
with a new one, be sure to erase the diagnostic
t trouble codes by disconnecting the memory clear
Released Memory cleared switch 1 and diagnostic switch 2 after connecting all
at this point
the connectors. Upon completing the procedure,
confirm that no diagnostic trouble codes is stored.
________________________________ © 0 2739
13E-20
3.4 C a u se s of D ia g n o stic Trouble C ode Issue, and Inspection Item s
3.4.1 Diagn ostic trouble codes
Multi-Use Tester II display Page of Multi-Use Tester 11 display Page of

reference reference
Diagnostic Message Diagnostic Message
trouble code trouble code
07 OVER REV. L1IP13E-21 23 TCV Lili P13E-24
n GOV. SERVO 24 ACCEL. SNSR-1 u j P13E-25

14 SUB NE SNSR •_Lj P13E-22 32 BST PRES SNSR
15 NE SNSR 33 ECU SYSTEM
16 ACCEL. SNSR-2 U'-i P13E-23 34 Q RESISTOR
17 TCV FEEDBACK 45 ENG.REVERSE i_.Q P13E-26
19 AIR PRES SNSR 65 ACCEL SW
21 WTR TEMP SNSR HQ P13E-24 78 HEATER RELAY
22 RACK SNSR
3.4.2 Diagnostic trouble code issue conditions, and check items

Perform service operations with reference to the diagnostic trouble code issue conditions and probable causes
show n below.
07 O V ER REV.
Code issue condition Diagnostic trouble code 07 indicates that the engine speed is too high.
[Reset condition] [The code is reset when the engine speed returns to a specified range.]
Action taken by ECU Governor operation is stopped.
Probable cause and check item Injection pump assembly's Inspection of injection pump assembly
control sleeve faulty (Have inspection performed by Bosch Automotive Systems service
station.)
• Over-revving of engine (for
example, on downhill road)
• ECU faulty
11 GOV. SER V O
Code issue condition Diagnostic trouble code 11 indicates that the difference between the target control rack position and
[Reset condition] actual control rack position is too large.
[No reset condition)
Action taken by ECU Governor operation is stopped.
Probable cause and check item • Control rack position sensor • Perform checks on basis of Multi-Use Tester II service data.
faulty CQP13E-27
• ECU faulty No. 09: Measurement of target rack position
No. 0A: Measurement of actual rack position
• Inspection of control rack position sensor
(Have inspection performed by Bosch Automotive Systems ser
vice station.)
13E-21
14 SUB NE SNSR (injection pump side)
Code issue condition Diagnostictrouble code 14 indicates that the number of pulses from engine speed sensor 2 (on the injec
tion pump) is smaller than the number of pulses from engine speed sensor 1 (on the flywheel housing).
[Reset condition]
[The code is reset when engine speed sensor 1 is normal and the number of pulses from engine speed
sensor 2 returns to normal].
Action taken by ECU • Normal control is effected using only engine speed sensor 1.
• If engine speed sensor 1 is also faulty, governor operation is stopped.
Probable cause and check item • Open circuit or short circuit in • Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and Q3P13E-27
engine speed sensor 2
No. 02: Measurement of engine speed
• Engine speed sensor 2 faulty
• Inspection using ECU connector Q_[ P13E-29
• ECU faulty
C D : Measurement of resistance of engine speed sensor 2
• Inspection of engine speed sensor 2
Q j P13E-32: Inspection of Electrical Equipment EH9
• Check of circuit between ECU and engine speed sensor 2
14 SUB NE SNSR (injection pump side)

15 NE SNSR (flywheel housing side)
Code issue condition Diagnostic trouble codes 14 and 15 are both issued if engine speed sensor 1 (on the flywheel housing)
and engine speed sensor 2 (on the injection pump) fail at the same time.
[Reset condition]
[The code is reset when pulses are applied from engine speed sensor 1 or engine speed sensor 2 following
engine startup.)
Action taken by ECU Fuel injection timing control is stopped, and governor operation is stopped.
harness between ECU and Q3 P13E-27
engine speed sensors 1 and 2
• Engine speed sensors 1 and 2
• Inspection using ECU connector Q j P13E-29
faulty
C D : Measurement of resistance of engine speed sensor 2
• ECU faulty
jiH : Measurement of resistance of engine speed sensor 1
• Inspection of engine speed sensors 1 and 2
Q3 P13E-32: Inspection of Electrical Equipment B33
• Check of circuit between ECU and engine speed sensors 1 and 2
15 NE SNSR (flywheel housing side)
Code issue condition Diagnostic trouble code 15 indicates that the number of pulses from engine speed sensor 1 (on the fly
wheel housing) is smaller than the number of pulses from engine speed sensor 2 (on the injection pump).
[Reset condition]
[The code is reset when engine speed sensor 2 is normal and the number of pulses from engine speed
sensor 1 returns to normal.]
Action taken by ECU • Normal control is effected using only engine speed sensor 2.
• If engine speed sensor 2 is also faulty, governor operation is stopped.
harness between ECU and (33 P13E-27
engine speed sensor 1
• Engine speed sensor 1 faulty
• ECU faulty
: Measurement of resistance of engine speed sensor 1
• Inspection of engine speed sensor 1
Q j P13E-32 Inspection of Electrical Equipment E 19
• Check of circuit between ECU and engine speed sensor 1
13E-22
16 ACCEL. SN SR -2
Code issue condition Diagnostic trouble code 16 indicates short or open circuit in accelerator position sensor 2 harness and
faulty sensor proper. (If diagnostic trouble code 16 is issued, inspections for diagnostic trouble code 24
(Reset condition]
must also be performed.)
The code is issued when accelerator position sensor 2 voltage is out of specified limits.
[When accelerator position sensor 2 voltage is back within specified limits, a reset is made.]
Action taken by ECU • Normal control is effected using only non-faulty accelerator pedal position sensor 1.
• If accelerator pedal position 1 is also faulty, control is effected using assumptions of 100% with the
pedal depressed and 0% with the pedal released.
Probable cause and check item • Open or short circuit in har • Perform checks on basis of Multi-Use Tester II service data.
ness between ECU and Q j P13E-27
accelerator position sensor 2
No. 03, 04: Measurement of throttle opening indicated by
• Accelerator position sensor 2 accelerator pedal position sensor
faulty or poorly adjusted No. 5: Measurement of accelerator pedal position sensor's
• ECU faulty output voltage
• Inspection of accelerator pedal position sensor
• Check of circuit between ECU and accelerator pedal position sen
sor 2
17 T C V FEEDBACK
Code issue condition Diagnostic trouble code 11 indicates that the difference between the target and actual timer positions
exceeds a specified limit.
(Reset condition]
[After a return to a normal condition, the code is reset when the starter switch is turned from OFF to ON.]
Action taken by ECU Fuel injection timing control is stopped.
Probable cause and check item • Timer control valve faulty • Perform checks on basis of Multi-Use Tester II service data.
Qj] P13E-27
• Electronic timer faulty
No. 12: Measurement of timer angle difference
• Engine hydraulic system faulty
• Inspection of timer control valve main body
• ECU faulty
Q j P13E-32: Inspection of Electrical Equipment KTIA
• Inspection of engine hydraulic system [Tj Gr 12
• Inspection of electronic timer
(Have inspection performed by Bosch Automotive Systems ser
vice station.)
19 A IR PRES S N S R
Code issue condition Diagnostic trouble code 19 indicates short or open circuit in air pressure sensor harness and faulty air
[Reset condition] pressure sensor (built in ECU).
The code is issued when air pressure sensor voltage is out of specified limits.
[When air pressure sensor voltage falls back within specified limits, a reset is made.]
Action taken by ECU Air pressure is defaulted to 100 kPa {760 mmHg).
Probable cause and check item • Air pressure sensor (built in • Perform checks on the basis of Multi-Use Tester II service data.
ECU) faulty. QL) P13E-27
• ECU faulty No. 18: Air pressure measurement
13E-23
21 W TR T E M P S N S R
Code issue condition Diagnostic trouble code 21 indicates open circuit in water temperature sensor harness and faulty sensor
proper.
[Reset condition]
The code is issued when water temperature sensor voltage is out of specified limits.
[When water temperature sensor voltage falls back within specified limits, a reset is made.]
Action taken by ECU Controls are continued assuming that coolant temperature is -20°C when engine is started and B0°C
when engine is running.
Probable cause and check item • Open or short circuit in har • Perform checks on basis of Multi-Use Tester II service data.
ness between ECU and water CQ P13E-27
temperature sensor
No. 16: Measurement of engine coolant temperature
• Water temperature sensor
faulty
m : Measurement of resistance of coolant temperature sensor
• ECU faulty
• Inspection of coolant temperature sensor
ffl P13E-32: Inspection of Electrical Equipment tofel
• Check of circuit between ECU and coolant temperature sensor
22 R A C K S N S R
Code issue condition Diagnostictrouble code 22 indicates that the control rack position sensor's output voltage is outside speci
fied limits.
[Reset condition]
[No reset condition]
Action taken by ECU Governor is temporarily stopped. (Feedback control is resumed after the engine is restarted.)
Probable cause and check item • Control rack position sensor • Perform checks on basis of Multi-Use Tester II service data.
faulty LQ P13E-27
• Control rack not moving No. OA: Measurement of actual rack position
smoothly
• Inspection of control rack position sensor and control rack
• Governor actuator's link faulty (Have inspection performed by Bosch Automotive Systems ser
vice station.)
• ECU faulty
23 T C V
C o d e issu e condition D iagnostic trouble code 23 is issu e d in the follow ing circumstances:
[Reset condition] (1) The E C U issu e s a c o m m a n d to turn the tim er control valve OFF follow in g a short circuit in the
tim er control valve.
[The code is reset w hen the tim er control valve returns to normal.]
(2) The E C U issu e s a c o m m a n d to turn the tim er control valve O N follow in g an open circuit in the
tim er control valve.
[After the open circuit is rectified, the code is reset w hen the starter sw itch is turned from OFF to ON.]
Action taken by E C U Fuel injection tim in g control is stopped.
Probable cau se a n d check item • O pen circuit or short circuit in • Perform checks on b a sis of M u lti-U se Tester II service data.
harness between E C U and LU P13E-27
tim er control valve
No. 12: M e asu re m e n t o f timer angle difference
• Tim er control valve faulty
• Inspection of tim er control valve
• E C U faulty
ff] P13E-32: Inspection of Electrical Equipm ent @B3
• Check of circuit between E C U and tim er control valve
13E-24
24 A C C E L S N S R -1
Code issu e condition Diagnostic trouble code 24 indicates short or open circuit in accelerator position se n sor 1 h arn ess and
faulty se nsor proper. (If diagn ostic trouble code 24 is issued, inspections for d iagn ostic trouble code 16
[Reset condition)
m ust also be performed.)
The code is issu e d w hen accelerator position se n sor 1 voltage is out of specified limits.
[When accelerator position se n so r 1 voltage falls back within specified limits, a reset is made.)
Action taken by E C U • N orm al control is effected u sing only non-faulty accelerator pedal position se n sor 2.
• If accelerator pedal position 2 is also faulty, control is effected u sin g a ssu m p tion s of 100 % with the
pedal depressed and 0 % with the pedal released.
Probable cause and check item • Open or short circuit in har • Perform checks on basis of M u lti-U se Tester II service dula.
n ess between E C U and accel Li i P13E-27
erator position se n so r 1
No. 03, 04: M easurem ent of throttle opening indicated by
• Accelerator position se n so r 1 accelerator pedal position se nsor
faulty or poorly adjusted
No. 5: M easurem ent of accelerator pedal position
• E C U faulty sensor's output voltage
• Inspection of accelerator pedal position se nsor
• Check of circuit between E C U and accelerator pedal position se n
so r 1
32 B S T P R E S S N S R
C ode issu e condition Diagnostic trouble code 32 indicates short or open circuit in bo ost pressure se n sor harness and faulty se n
so r proper.
[Reset condition)
The code is issu e d w hen bo ost pressure se n sor voltage is out of specified limits.
[W hen boost pressu re se n so r voltage falls back within specified limits, a reset is made.l
Action taken by E C U Control is effected with the bo ost pressure assu m e d to be fixed at 0 kPa {0 m m Hg}.
Probable cause and check item • Open or short circuit in har • Perform checks on basis of M u lti-U se Tester II service data.
n ess between E C U and bo ost LLI P13E-27
pressure se n so r
No. 2D: M easurem ent of b o o st pressure
• B o ost pressure se n so r faulty
• Inspection of boost pressure se n sor m ain body
• E C U faulty
[Xi P13E-32: Inspection of Electrical Equipm ent tfilil
• Check of circuit between E C U and boost pressure se n sor
33 E C U S Y S T E M
C ode issu e condition D iagnostic trouble code 33 indicates a processing error or m e m o ry error in the ECU.
[Reset condition) [No reset condition]
Action taken by E C U Governor operation is stopped.
Probable cause and check item E C U faulty -
34 Q R E S IS T O R
C ode issu e condition D iagn ostic trouble code 34 indicates short or open circuit in injection quantity adjusting resistor h arness
and faulty adjusting resistor.
[Reset condition]
The code is issu e d w hen injection quantity adjusting resistor voltage is out of specified limits.
[W hen injection quantity adjusting resistor voltage falls back within specified limits, a reset is made.)
Action taken by E C U Injection quantity correction value is fixed at No. 1 value.
Probable cause and check item • Open or short circuit in har • Perform checks on basis of M u lti-U se Tester II service data.
n ess between E C U and injec [IQ P13E-27
tion quantity adjusting resistor
No. 14: Check of resistor n um ber of fuel injection quantity
• injection quantity adjusting re adjusting resistor
sistor faulty
• Inspection u sin g E C U connector |l[j P13E-29
• E C U faulty
<iCT : M easurem ent of resistance of fuel injection quantity
adjusting resistor
• Inspection of fuel injection quantity adjusting resistor
f fl P13E-32: Inspection of Electrical Equipm ent E E S
• Check of circuit between E C U and fuel injection quantity adjusting
resistor
13E-25
45 E N G . R E V E R S E
Code issu e condition D iagn ostic trouble code 45 indicates that an extremely low engine speed (a speed lower than that result
ing from cranking w ith the starter) has been detected with the starter switch in the OFF position.
[Reset condition]
[The code is reset w h e n the e n gin e speed is no longer detected with the starter switch in the O FF position
or w hen the starter sw itch is turned to the O N position.)
Action taken by E C U G ove rn or operation is stopped
Probable cau se and check item • O perating error at tim e of en

gine startup
• Poor m atching of connected
devices
• E C U faulty
65 A C C E L S W
C ode issu e condition D iagn o stic trouble c o d e 65 indicates short or open circuit in accelerator pedal sw itch harness and faulty
accelerator switch.
[Reset condition]
The code is issued w h e n accelerator pedal is released (accelerator sw itch O N ) and accelerator pedal o p e n
ing sign a l is input.
[W hen accelerator pedal o p e n in g sign a l returns to norm al, a reset is made.]
Action taken b y E C U N orm al control is effected.
Probable cau se and check item • O pen or short circuit in har • Perform checks on basis of M u lti-U se Tester II service data.
n ess between E C U and accel CQ P13E-27
erator pedal sw itch
No. 03, 04: M e asure m en t of throttle op en ing indicated by
• Accelerator pedal sw itch faulty accelerator pedal position se n sor
• E C U faulty No. 69: Check of operation of accelerator pedal switch
• Inspection u sin g E C U connector f]I| P13E-29
n t - l : Check of continuity of accelerator pedal switch
• Inspection of accelerator pedal switch
• Check of circuit between ECU and accelerator pedal sw itch
78 H E A T E R R E L A Y
C ode issu e condition D iagn o stic trouble code 78 is issu e d in the follow in g circum stances:
[Reset condition] (1) The E C U issu e s a c o m m a n d to turn the heater relay OFF fo llow in g a short circuit in the heater
relay.
[The code is reset w hen the heater relay returns to normal.]
(2) The E C U issu e s a c o m m a n d to turn the heater relay O N follow in g an open circuit in the heater
relay.
[No reset condition]
Action taken by E C U Preheat control is stopped.
Probable cau se and check item • Open circuit or sh o rt circuit in • Perform checks on b a sis of M u lti-U se Tester II service data.
harness between E C U and C£1P13E-27
heater relay
No. 92: Check of operation of heater relay
• Heater relay faulty
• Actuator test u sin g M u lti-U se Tester II CQ P13E-28
• E C U faulty
No. BC: Check of operation of heater relay
• Inspection of heater relay CO G r 16
• Check of circuit between E C U and heater relay
13E-26
3.5 Multi-Use Tester II Service Data
M u lti-U se Tester II disp lay Condition at time of Norm al condition
No. Item Data
01 BATT V O LTA G E Idling 20 to 30 V
02 E N G IN E S P E E D ■ ■ ■ ■ . rpm Racing S a m e a s tachom eter indication

(with engine running)
03 A C C E L {%) ■ ■ ■. ■ % Accelerator pedal released 0%
Accelerator pedal gradu ally depressed Gradually increases
Accelerator pedal fully depressed 100%
04 A C C E L ( % ) R EA L ■ ■ ■. ■ % Accelerator pedal released 0%
Accelerator pedal gradu ally depressed G radually increases
Accelerator pedal fully depressed 100 %

05 A C C E L (V) ■. ■ ■ ■ V Accelerator pedal gradu ally d epressed D ep en ds on vehicle specifica
from released position tions
09 TARGET RACK 1 1 .1 1 m m Starter switch O N 3 mm

0A R EA L R A C K ■ ■•■■m m Starter sw itch O N 3 mm
12 T C V A N G . DIFF. ■ ■ °CA Depends on vehicle specifications

■ ■ de g
14 Q R E S IS T O R S a m e as n um ber m arked on fuel

injection quantity adjusting
resistor
16 W ATER T EM P ■ ■ a. ■ °c Engine cold A pproxim ately sa m e a s am bient

temperature
■ ■ ■ I F
During engine w arm up Gradually increases
Engine stopped after w arm u p Gradually decreases
18 A IR P R E S S a a a a. kPa Altitude 0 m 101 kPa

B B a a .m m H g Altitude 600 m 95 kPa
Altitude 1.200 m 88 kPa

2D BO O ST PRESS a a a a. kPa Running at high idle speed D ep en ds on vehicle specifica
tions
B B B a. mm Hg
4F D IA G N O S IS S W O N /O F F D iagn osis sw itch O N ON

(connected to connector)
D iagn o sis switch OFF OFF

- (disconnected from connector)
51 D IA G L A M P (U) O N /O F F Starter sw itch in O N position ON

(engine not started)
Starter sw itch in OFF position OFF
52 D IA G L A M P (R) O N /O F F Starter sw itch in O N position ON

(engine not started)
Starter switch in OFF position OFF

56 KE Y S W O N /O F F Starter sw itch in O N position ON
Starter sw itch in any position except OFF

ON
62 D IA G R E S E T S W O N /O FF M e m ory clear sw itch O N ON

(connected to connector)
M e m ory clear sw itch OFF OFF

(disconnected from connector)
67 PU LL D O W N O N /O F F Norm al condition OFF
Abnorm al condition ON
'(during pulldow n control)
13E-27
M u lti-U se Tester II display Condition at tim e of N o rm al condition

inspection
No. Item Data
69 ACCEL SW O N /O FF Accelerator pedal depressed ON
Accelerator pedal released OFF
73 START SW O N /O FF E ngin e cranked with starter sw itch in ON

S T A R T position
Starter switch in any position except OFF

STA RT
91 P R E -H E A T L A M P O N /O FF Starter Coolant temperature ON

sw itch O N low
Coolant temperature OFF

high
92 HEATER RELAY O N /O FF Starter Coolant temperature ON

sw itch O N low
C oolan t temperature OFF

high
3.6 A c tu a to r T e sts U s in g M u lti-U se Tester II
M u lti-U se Tester II d isp lay M e tho d of checking operation
No. Item
AC D IA G L A M P (U) • Create w arning lam p illum ination conditions.

• Perform test with engine speed of zero and vehicle speed of zero.
• C au se w arning lam p five tim es to be on for on e second then off for
one second.
AD D IA G L A M P (R) • Create w arning lam p illum ination conditions.

• Perform test with e n gin e speed of zero and vehicle speed of zero.
• C au se w arn ing lam p five tim es to be on for one second then off for
one second.
BB P R E -H E A T L A M P • Create indicator lam p illum ination conditions.

• Perform test with engine speed of zero and vehicle speed of zero.
• C au se indicator lam p five tim es to be on for on e second then off for
one second.
BC HEATER RELAY • Create air heater operating conditions.
• Perform test with en gin e speed of zero and vehicle speed of zero.
• C au se air heater five tim es to be on for one se co n d then off for one
second.
13E-28
3.7 In sp ectio n U sin g E C U C onnector
These checks allow correct transm ission of ECU signals via vehicle harnesses and connectors to be verified. They
are intended to assist in troubleshooting. The num bers (g i ll , G 0 , etc.) in the tables correspond to reference n u m
bers in section 3.4, "C au se s of Diagnostic Trouble Code Issue, and Inspection Items".
3.7.1 ECU terminal configuration
A: C W 3 2 A
1 f
11 10 9 "7 0 TT 3 2 1
24 22 22 21 20 19 16 17 16 1b 14 13 12
32 31 30 29 26 27 26 2b
B: C W 2 5 A
-n n
B 7 3 2 1
18 17 16 15 14 13 12 11 10 9
25 24 23 22 21 20 19
C: C W 3 1 A
[V I 9 6 7 T 5 4 V 2 V]
22 21 20 19 16 17 16 1b 14 13 12 11
31 30 29 26 27 26 2b 24 23
D: C W 1 6 A
I I
V 4 3 2 1
12 11 10 9 6 7 6
16 15 14 13
© 4 36 3 9
No. Item Page of reference
Resistance of engine speed se n so r 2

O B
Resistance of engine speed se n so r 1
lifl Resistance of coolant tem perature se n sor iXl P13E-30
Resistance of fuel injection quantity adjusting resistor

m
Continuity of accelerator pedal switch
3.7.2 Inspection instructions

NOTE:
Som e inspections are performed with the connector
removed, and others are performed with the connec
tor fitted. Note the following instructions:
• Do not touch any terminal other than the ones spe
cified for the inspections. Be particularly careful not
to cause short circuits between terminals using the
tester probes.
• Terminal numbers shown in the tables are the num
bers of terminals on the ECU. Be careful notto select
the wrong terminals for inspections.
13E-29
Check item M ethod
CD Resistan ce of e ngine [Check conditions)

sp ee d se n so r 2 • Starter sw itch OFF
• Connector rem oved. Check perform ed on vehicle-side harness.
[N orm al condition)
Between term inals A ^ and A '«: 2.1 to 2.5 Cl
f lil R esistance of e ngine [Check conditions]

speed se n s o r 1 • Starter sw itch OFF
[N orm al condition]
Between term in als A b and A 2': 2.1 to 2.5 k ii
fijc l R esistan ce o f coolant [Check conditions]

tem perature se n so r • Starter sw itch OFF
[N orm al conditions]
Between term inals C >5 and A »: 2.3 to 2.6 kD (at 20°C)
0.3 to 0.34 k£2 (at 80°C)
fiTtk R esistan ce of fuel injec- [Check conditions]

tion quantity adjusting • Starter sw itch OFF
resistor • Connector rem oved. Check perform ed on vehicle-side harness.
Between term inals B * and B n:
No. Resistance No. Resistance No. Resistance
1 270 n A 1300 n 7 5600 ft

2 510 n 5 2000 n B 15000ft
3 620 n 6 3300 n ■— —
fip m Continuity of accelera- [Check conditions]

tor pedal sw itch • Starter sw itch OFF
Between term inals ( © and © ) B 2 and D 6: • Accelerator pedal depressed: C ontinuity d o es not exist.
• Accelerator pedal released: Continuity exists.
13E-30
3.8 Checks on Transient Troubles • Lightly move the connector up and dow n and to
the right and left.
• Lightly move the harness up and dow n and to the
right and left.
• Lightly shake the sensors and other devices by
hand.
• Lightly shake the wiring harness located in the
m oving com ponents such as the suspension.
The connectors and other parts to be checked are iden
tifiable from the descriptions in the Probable C auses or
the Checking Procedures for the displayed diagnostic
trouble code.
A transient trouble often occurs in a specific condition.

Therefore, pinpointing the condition will make it easy
to estimate the cause. To pinpoint the condition for a
transient trouble, ask the custom er in detail about the
driving condition when the trouble occures, weather,
occurrence frequency and sym ptom s, and reproduce
the sym ptom s ofthe trouble.
Depending on the condition where the trouble occurs,
determine whether the cause of the trouble is vibra
tion, temperature or any other factor. If the probable
cause is vibration, perform the following checks on the
relevant connectors harnesses, etc. and check whether
the sym ptom s ofthe trouble are reproduced.
13E-31
13E ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT
4. INSPECTION OF ELECTRICAL EQUIP

Sta n d ard value 2.3 ± 0.2 kQ
MENT (at 20°C)
islifel Checking Water Temperature Sensor (2) If the reading is out ofthe standard value range, re
place the engine speed sensor. (X: Gr 11
NOTE:
If the sensor is not tightened sufficiently, it may not
issue signals. Make sure the sensor's tightening
torque is correct.
<Engine speed sensor 2>

[Inspection]
©34629
(1) Put the water temperature se nsor in a container

filled with engine oil.
(2) Heat the engine oil to various specified tempera
tures while stirring the engine oil.
(3) M easure the resistance value between pins 1 and 2
(body).
S ta n d ard value 20°C 2.3 to 2.6 kQ
80°C 0.30 to 0.34 kQ

(1) M easure the resistance between terminals ’I- and
Referance v alu e in parentheses
(4) If the reading is out ofthe standard value, replace
Stand ard value 2.1 to 2.5 Cl
the water temperature sensor. Gr 14
idrfcl Checking Engine Speed S e n so r (2) Check for continuity between terminals i' and <Z;
between terminals and &.
<Engine speed se nsor 1>
Sta n d ard value Continuity exists
(3) If either result is out of specification, replace the

sensor.
[Installation]
(1) M easure the resistance value between pins 1 and

2.
13E-32
ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT 13E
(1) Screw in engine speed se n sor 2 A until it touches Unit: m m
the protrusion on the timer flange B.

(2) Back off engine speed se nsor 2 A by 0.8 to 1.0 turn
to create a clearance C (1.2 to 1.5 mm) between the
sensor and the protrusion B.
(3) Tighten the lock nut D on engine speed se nsor 2 A.
E E Checking Boost Pressure Se n so r
cChecking by use of Multi-Use Tester ll> Q j P13E-27

NOTE:
The boost pressure checking conditions differ be
tween when the boost pressure is checked by use of
the M ulti-Use Tester II and w hen it is checked w ithout (2) M ount pressure gauge A for measurem ent of the
use of the Multi-Use Tester II. S o the standard values boost pressure.
also differ. C: To inlet manifold
(3) Set the starting switch to ON.
(4) Measure the output voltage of the boost pressure
sensor B according to the following table.
Item Connector Pin
1 Pow er (+) 2 G N D (-) 3 Output (+)
Pow er voltage O ------- -------0

'"'Output voltage
(Refer to the out
put characteris O ------ ------ 0
tics show n at
left.)
*: Start the engine before m easurem ent.
(1) Disconnect the chassis side harness D and connect

the g) inspection harness between them.
13E-33
13E ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT
Output Characteristics (1) Rem ove the connector from the timer control valve
then connect a 24V DC power supply A and selector
switch B.
(2) Slightly loosen the eyebolt D on port C.
(3) Run the engine at idling speed.
(4) Turn the selector switch B to the port E setting and
check that oil leaks from the eyebolt D of port C.
(5) Turn the selector switch B to the port F setting and
check that oil stops leaking.
(6) After confirming that oil stops leaking, tighten the
eyebolt D to the specified torque.
Tightening torque 20 to 25 Nm (2 to 2.5 kgfm)
C: Engine oil outlet

(hydraulic pressure supply to electronic timer)
S ta n d ard Value 2 -3 5V
E: Engine oil inlet
1 -2 0.5V/-34.3 kPa {-255 m m H g ) F: Engine oil return outlet
1.86V/33.7 kPa {250 m m H g )
3.22V/98.7 kPa {740 m m H g }

(7) If this inspection reveals any abnormality, replace
4.5V/163.7 kPa {1230 m m H g }
the timer control valve. CD Gr 13A
(5) Ifthe results of the above mentioned checks show <Checking valve resistances>
any deviation from the standard values, replace (1) Take resistance measurements between terminals
the boost pressure se nsor B. 'T and <% and between terminals '? and -4. Deter
mine whether the measurem ents com ply with the
E 2 3 Inspection of timer control valve
standard value.
<Checking valve operation>
Stand ard value 21.9 to 24.1 n
(2) Make sure that there is not continuity between ter

m inals^- and 4'; between terminal 3. and the body;
and between terminal ;4: and the body.
(3) If these checks reveal any abnormality, replace the
timer control valve. CD Gr 13A
Inspection of fuel injection quantity adjusting re

sistor
13E-34
ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT 13E
(1) M easure the resistance ofthe fuel injection quan
tity adjusting resistor. The standard value corre
sp onds to the resistor number marked on the case.
Stand ard value R esistor No. 1 270 n

(at 20°C)
2 5 io n
3 820 a
4 i3 o on
5 2000 a
6 3300 n
7 5600 Cl
8 15000 0
(2) If the measurement is out of specification, replace

the fuel injection quantity adjusting resistor.
NOTE;
The fuel injection quantity adjusting resistor is
matched to the injection pump. Replace it only with
one that has the same resistor number.
13E-35
14
COOLING
CONTENTS
1. G E N E R A L .......................................... ... 2 5.4 Fan Drive .......................................... 15

2. SP E C IF IC A T IO N S ........................ ... 6 5.4.1 D isasse m bly and inspection ............ 15
3. S E R V IC E S T A N D A R D S ........................... 7 5.4.2 Reassem bly .................................. 16
3.1 Service Standards Table .................. ... 7 5.5 Tension Pulley .................................. 16
3.2 Tightening Torque Table .................. ... 7 5.5.1 D isassem bly and inspection ............ 16
4. S P E C IA L T O O LS ................................. ... 8 5.5.2 Reassem bly .................................. 17
5. S E R V IC E P R O C E D U R E ..................... ... 9 5.6 Inspection of Auto Cool Fan
5.1 Rem oval and Installation of Cooling Coupling .......................................... 17
Fan ................................................. ... 9 5.7 Inspection of Radiator ........................ 18
5.2 W ater P u m p ..................................... ... 9 5.8 V-belt Tension ................................... 19|
5.2.1 Rem oval and installation ............. ... 9 5.8.1 Inspection ..................................... 19l
5.2.2 D isassem bly and inspection ......... ... 10 5.8.2 Adjustm ent .................................. 20
5.2.3 Reassem bly ................................... 13 5.9 Cleaning of Cooling Sy ste m ................ 21
5.3 Therm ostat .................................... .. 14 5.10 G as Leak Test ................................... 23
5.3.1 Rem oval and installation ............. .. 14 5.11 Bleeding the Cooling System ............. 23
5.3.2 Inspection .................................. .. 14 6. T R O U B L E SH O O T IN G ............. ............. 24
14-1
14 COOLING - GENERAL
1. GENERAL (2) Thermostat
The cooling system is of the water-cooling forced cir

W hen coolant temperature is high
culation type consisting of a radiator, water pump, (bottom b y p a ss valve is closed) \ - From
i r cylinder
thermostat, and related parts. head
Radiator T herm ostat
To water pum p
W h en coolant tem perature is low
(bottom b y p ass v alv e is open) B1747A
The thermostat is of bottom bypass type with a valve

W ater p um p controlled by special w ax enclosed in a pellet. W hen
B1745D
the wax is heated, it p asse s from a solid to a liquid state
with its volum e changing. This change in volum e regu
(1) Water pump
lates the am ount of coolant flowing into the radiator
and water pum p (bypass side), thereby controlling
coolant temperature.
To engine
From therm ostat ___

Im peller
t
From radiator
B1746C
The water pump, of the centrifugal type, is driven by

V-belt from the crankshaft pulley.
M ounted at one end of the water pum p shaft is an
impeller with blades and the coolant is sealed up by
unit seal.
For lubrication of the water pump, see Group 12
Lubrication.
14-2
COOLING - GENERAL 14
(3) Radiator (4) Pressure cap
Radiator
B1740A
The radiator, with a tube-and-corrugated-fin type core

(and with a reserve tank on som e models), not only
cools the engine coolant but also separates vapor from
liquid water and regulates pressure in the cooling sy s
tem.
The pressure cap regulates the pressure in the cooling

system. W hen the pressure builds up in the system that
exceeds a predetermined level, the pressure valve
com presses the pressure spring, releasing the exces
sive pressure through the overflow pipe into the atmo
sphere.
14-3
14 COOLING - GENERAL
If equipped with a reserve tank, the coolant that has is controlled by a bimetallic strip that m oves in
overflowed is channeled into it. response to temperature changes.
W hen the coolant temperature drops and negative <W hen the temperature ofthe air passing through the
pressure builds up in the system, the vent valve opens radiator is low>
to take in air to prevent the radiator from becom ing
deformed.
If equipped with a reserve tank, coolant is taken from
the reserve tankto prevent the radiatorfrom becom ing
deformed and to keep the quantity of coolant in the
system constant.
If equipped with a pressure release lever on the cap,
raising the lever upright opens the pressure valve and
releases the pressure in the cooling system.
(5) Auto cool fan coupling
The valve fully closes the control hole of the divider

plate. A s a result, the silicone oil forced back from the
pum p hole is stored in the storage chamber and is not
sent into the operating chamber. In the meantime, the
silicone oil in the operating chamber decreases, and
consequent slippage between the case and cover and
the rotor causes the fan to rotate at a lower speed.
<W hen the temperature ofthe air passing through the
radiator rises>
. \__r
•
I iV *
Im
Depending on the temperature of the air passing
B0244A
through the radiator, the auto cool fan coupling auto
matically controls the rotating speed of the fan.
A s the temperature rises, the valve slow ly opens the
The autocool fan coupling is constructed as follows:
control hole ofthe divider plate, allowing silicone oil to
The rotor is m ounted on the shaft and rotates between
flow into the operating chamber. Therefore, the sili
the case and cover. V iscous coupling material (silicone
cone oil contacting area between the case and cover
oil) enters the gap and turns the fan. A control hole in
and the rotor slow ly increases. S o more torque is trans
the divider plate allows silicone oil to pass from the
mitted to the fan, causing it to rotate at a higher speed.
storage cham berto the operating chamber. The hole is
controlled by a valve. Opening and closing ofthe valve
14-4
COOLING - GENERAL 14
<W hen the temperature of the air passing through the
radiator is high>
The valve fully opens the control hole of the divider

plate, and more silicone oil flow s into the operating
chamber.
A s a result, a m axim um torque is transmitted from the
shaft to the fan, causing the fan to rotate at a given
m axim um speed.
14-5
14 COOLING - SPECIFICATIONS
2. SPECIFICATIONS
Item Specification
C o o lin g sy ste m W ater-coo ling forced circulation type
C oolan t quantity (Engine-proper only) 6D24, T Approx. 22 L
6D24-TC, TL Approx. 24 L
W ater p u m p Type C entrifugal type
Drive m ethod V-belt
Radiator Type Tube-and-corrugated-fin type or Tube-and-plate-fin type
T h erm ostat Type W a x pellet/bottom b y p a ss type
Valve op en ing W ith ou t jiggle valve: 76.5“C x 2

tem perature x Q'ty
C o o lin g fan Su ction type or blow er type
V-belt Type x N u m b er of belts W ith ou t fan drive Low edge cog B type x 1 or B type x 2
W ith fan drive Low -edge co gge d type B x 1 (for w ater pum p)
Low -edge co gge d type C x 2 (for alternator)
Low -edge co gge d type B x 1 (for water pum p)

Low -edge co gge d type B x 2 (for alternator)
14-6
COOLING - SERVICE STANDARDS 14
3.1 Service Sta n d a rd s Table
Unit: m m
M aintenance item N o m inal value Limit R em edy and rem arks

Interference between p um p shaft and flange [22] 0.05 to 0.08 - U p to second

reassem bly
Interference between pum p shaft and impeller [11.8] 0.03 to 0.06 - U p to second
reasse m b ly
T h erm ostat Valve op en in g temperature 74.5 to 78.5°C - Replace
Valve lift/temperature 10 or more/90°C -
Radiator inspection pressure (air pressure) 98 kPa {1 kgf/cm 2} - Correct or replace
Pressure valve op en ing pressure 39 to 59 kPa - Pressure cap, replace

{0.4 to 0.6 kgf/cm 2}
V-belt deflection [with a push W ithout fan drive 17 to 22 - A dju st

force of about 98 N (10 kgf)]
W ith fan drive 10 to 15
3.2 T igh ten ing Torque Table
Location tightened Screw size Tightening torque

O.D. x pitch N-m {kgf:m}
(m m)
W ater p um p pulley m ounting bolt M 10 x 1.5 44 + 8.8 {4.5 ± 0.9}
Fan drive flange m ounting nut M 2 0 x 1.5 145 {15}
T ension pulley m ounting nut M 16 x 1.5 98 {10}
14-7
14 COOLING - SPECIAL TOOLS
4. SPECIAL TOOLS
Unit: m m Unit: m m
Tool nam e S h ap e
Im peller Puller
M H 062192
R e m o va l of w ater pum p
im peller
B5252C
U nit Se a l Installer
M H 062195
W ater p u m p unit seal instal
lation
4 A B 4C
28 9.6±0.03 12.5
B 5094A
14-8
COOLING - SERVICE PROCEDURE 14
5. SERVICE PROCEDURE 5.2 Water Pump
5.1 Removal and Installation of Cooling Fan 5.2.1 Removal and installation
14-9
14 C O O L IN G - S E R V IC E P R O C E D U R E
5.2.2 D isa sse m b ly and inspection
<6D24, T, TL> Bend, rust, w ear in Dam age,

surface over w hich wear
bearing fits
Rotation 8^
Rotation i q 11
D a m age, ® Interference
w ear a
B D 11.8
3, ‘ N V 0.03 to 0.06
R easse m b ly no m ore
than 2 tim es
Interference
B D 22
N V 0.05 to 0.08
R easse m b ly no m ore
than 2 tim es 7 C o rro sio n , d am age
1 3 D a m age, w ear
Repair kit: N V .. N o m inal Value
Cracks, w ear in surface
W ater p u m p repair kit
over w hich bearing fits,
w ater leak, rust

1 Water pum p pulley 8 Water pum p shaft
@ Flange 9 Bearing
3 Oil seal 10 Spacer
4 Sn ap ring 11 Bearing
5 Snap ring 12 Oil seal
6 Water pum p cover 13 Unit seal
® Impeller 14 Water pum p case
For parts with an encircled num ber, refer to D isa sse m b ly and Inspection Procedures that follow.
D0044G
14-10
B D .. B a sic Diam eter
<6D24-TC> N V .. N o m in a l Value
over w hich bearing fits,

w ater leak, rust

1 Water pump pulley 8 Water pum p shaft
D Flange 9 Bearing
3 Oil seal 10 Spacer
4 Sn a p ring 11 Bearing
5 Sn a p ring 12 Oil seal
6 Water pum p cover 13 Unit seal
7) Impeller 14 Water pum p case
F o r p a rt s w ith a n e n c irc le d n u m b e r , re fe r to D is a s s e m b l y a n d
Inspection Procedures that follow.
D0044H
14-11
14 COOLING - SERVICE PROCEDURE
Disassem bly and inspection Procedures (3) Flange to water pum p shaft tightening margin
(1) Rem oval of flange
If the tightening margin exceeds specification, replace

Rem ove the water pum p flange using the Water Pum p the flange or water pum p shaft.
Pulley Puller and Bolt (special tools). Slip an iron pipe NOTE:
or sim ilar item over the handle to gain the necessary Do not reassemble more than three times even when
leverage. the specification is met.
(2) Rem oval of impeller (4) Impeller to water pum p shaft tightening margin
U sin g two threaded holes (M8 x 1.25) in the impeller If the tightening margin exceeds specification, replace
and the Water Pum p Impeller Puller (special tool), pull the impeller or water pum p shaft.
off the impeller.
NOTE:
Do not reassemble more than three times even when
the specification is met.
14-12
5.2.3 R e a sse m b ly
A p p ly engine
oil to lips.
12
—>6-»5—>4-»3—>2—^1
NOTE:
1. After reassembly, rotate the w ater pump pulley by hand
For parts with an encircled number,
to confirm that the impeller does not interfere w ith the
refer to R e a sse m b ly Procedure that
w ater pump cover and w ater pump case.
follow s.
2. When the impeller and flange are installed, confirm that
they are not installed with a load of 4900 N {500 kgf}.
D0047D
Reassem bly Procedure To install the unit seal, use the Unit Seal Installer (spe-
clnstallation of unit seal> cial tool) as show n and press-fit the unit seal until the
installed dim ensions show n are obtained.
Unit seal
Unit Seal Installer

MH062195
Installation load
31 to 44 N
{3 .2 to 4 .5 k g f}
Installation speed
14 to 28 mm /sec.
09194
14-13
5.3 T h e rm o sta t 5.3.2 Inspection
Therm ostat m arking For 76.5°C
Valve opening 74.5 to 78.5

temperature (°C)
Valve lift/ 10 or more/90
temperature
(mm/°C)
Valve lift
Heat source - i n
D0301B
B9021B
Agitate water in the container with the stirrer to obtain
uniform temperature. For the inspection, use the fol
lowing procedures.
(1) Slow ly heat water to the thermostat valve opening
temperature.
The valve opening temperature is stamped on the
thermostat. Its nominal value is the stamped tem
perature ± 2°C.
(2) Keep this condition for about five minutes and
make sure that the valve is open.
(3) Raise the temperature further to heat the water to
the valve lift m easuring temperature correspond
ing to the valve opening temperature. (See the
table above.)
Keep this state for five m inutes and measure the
bypass valve lift.
(4) Lower temperature dow n to 65°C or below and
ensure that the valve is fully closed.
If the thermostat is found defective in any of the
above items, replace it with a new one.
14-14
5.4 Fan Drive
5.4.1 D isassem bly and inspection
Rotation
5
7
Rotation

1 Fan pulley 5 Bearing
2 Flange 6 Spacer
3 Snap ring 7 Bearing
4 Fan drive shaft 8 Bearing case B9023D
14-15
5.4.2 Reassem bly 5.5 Tension Pulley

5.5.1 D isasse m bly and inspection
6
Rotation
B9023E

1 Adjusting bolt
2 Tension pulley bracket
3 Sn a p ring
4 Tension pulley shaft
5 Tension pulley
6 Bearing
A s s e m b ly sequence
8—»5—»3—>2—>1
1
B9024D
14-16
5.5.2 Reassem bly 5.6 Inspection of A u to C o o l Fan C o u p lin g
Sealing side to be faced

outward.
To be packed with grease
(multipurpose grease)
98 N-m
{10 kgf-m}
To be packed with
approx. 6 g of grease
(multipurpose grease)
B9024E
NOTE:
1. Since the autocool fan coupling is constructed as a
single unit, the silicone oil does not require main
tenance.
2. The autocool fan coupling cannot be dismantled. If
defects become evident, the w hole autocool fan
coupling assembly must be replaced.
B1855B
14-17
(1) Play in axial direction 5.7 Insp ectio n of Radiator
(1) Cleaning
D0402A
W hen engine is cold, pinch the fan fitting portion and
m ove it in axial direction. If the fan blade tip has exces
Rem ove mud, bugs, etc., if present on the radiator core
sive runout or play is observed, replace the auto cool
front surface, with a copper wire. During the removal
fan coupling, because the ball bearing is defective.
work, use care to prevent damage to the tubes.
(2) Cleaning bimetal
(2) Attach hose to the inlet ofthe radiator and cap the
If dirt or dust is adhering to the bimetal, rem ove it care outlet. Then, immerse the radiator in a waterfilled
fully with a wire brush or the like. tank.
NOTE: U sin g a radiator cap tester, send com pressed air at
Use care not to apply excessive force to the bimetal. the specified inspection pressure through the hose
to check for leaks.
If leaks are evident, re-solder or replace the radia
tor.
14-18
(3) inspection of radiator cap 5.8 V-belt Tension
5.8.1 Inspection
Adjust the belt tension to obtain the specified belt
deflection when the center of each belt is pressed with
a force of approximately 98 N (10 kgf).
Check the spring tension and sealing condition ofthe

pressure valve and vent valve. If defective, replace.
Check the pressure valve opening pressure, using a
radiator cap tester.
14-19
5.8.2 A dju stm en t Using Belt Tension Gauge (special tool)
(1) Alternator
O-ring A
■ Depression
load scale
Belt Tension G a u g e .
MH062345
1
„0-ring B
-Deflection gau ge
03613
(1) Set O-ring A at the 98 N {10 kg} mark on the depres

sion load scale.
Loosen the upper and lower m ounting bolts of the
(2) Set O-ring B at the V-belt's specified nominal
alternator. Then, fit a wrench handle and m ove the
deflection value (max.) on the lower scale.
alternator as necessary.
NOTE:
When m oving the alternator, use care not to dam age
the stator coil between the front and rear brackets,
and the through bolt.
(2) Tension pulley
03614
(3) Apply the Belt Tension Gauge (special tool) to the

V-belt's tension measurem ent point. Depress the
top ofthe gauge until O-ring A reaches the flange.
E0166
Loosen the idler puller mounting nut, then turn the

adjusting bolt to adjust the belt tension. (Turning the
adjusting bolt m oves the idler pulley.)
14-20
3. If much rust is found, water may leak from the ra
diator after cleaning. Check carefully each section
of the radiator after cleaning.
4. If the coolant temperature is still very high, never
attempt to remove the pressure cap.
Coolant in use Cleaning interval
F U S O Diesel Every 2 years

L o n g Life Coolant
Anti-rust, anti-freeze At time of coolant replacem ent

of every 6 m o nth s or before
and after use of anti-freeze
(1) W ashing with water
(4) M easure the amount of deflection in the V-belt.

Adjust the V-belt's tension if the am ount of deflec
tion is out of specification.
5.9 C le a n in g of C o o lin g S y ste m
(a) Discharge coolant from the radiator, crankcase,

and reserve tank.
(b) After draining the system, fill it with tap water (pre
ferably hot water) and, with the water temperature
kept at around 90°C, run the engine at idle for about
10 minutes. Then, drain water. Continue flushing
Ifthe radiator is used for a long time, rust, scale, mud,
until the drained water runs clear.
etc. are deposited inside, resulting in overheat. Clean
the cooling system with city water by using the follow (2) W ashing with cleaning solution (When radiator
ing procedures. clogging or coolant contamination are serious)
NOTE: (a) Discharge coolant from the radiator, crankcase,

1. Use a cleaning solution ifthe radiator is seriously and reserve tank.
obstructed or coolant is seriously contaminated.
2. When the cooling system is cleaned or washed
with water, make sure that the coolant tempera
ture is maintained at 90°C; the coolant tempera
ture below the valve opening temperature closes
the thermostat, resulting in poor coolant circula
tion.
14-21
(d) After discharging the solution, fill the system with

tap water (preferably hot water) and with the water
temperature kept at around 90°C, run the engine at
idle for about 10 minutes. Then, drain water.
Continue flushing until drained water runs clear.
NOTE:
1. If the inside is heavily stained, washing with tap
water before charging radiator detergent will be
effective.
2. Running the engine at idle for longer than an hour
with detergent left in engine could cause damage
to the cooling system. Be sure to observe specified
cleaning time.
(b) Ready a mixture of F U SO Radiator Cleaner (Radi- 3. After cleaning with detergent, fill with coolant as
pet-7 or equivalent: 5 to 10%) and cooling water. soon as possible.
Pour the specified am ount of mixture into the (3) Cooling water
radiator. (a) W hen Long Life Coolant is used:
(c) Run the engine to raise the solution temperature to In orderto prevent freezing of cooling water and corro
around 90°C. Let the engine run at idle for another sion of the cooling system, add F U S O Diesel Long Life
30 minutes, then remove the solution. Coolant at a ratio of 30 to 6 0 % of quantity of water.
Replace the coolant once every two years to retain its
anti-freeze and anti-rust effects.
For usage of Long Life Coolant, refer to its instruction
manual.
NOTE:
1. Be sure to use FU SO Diesel Long Life Coolant.
2. Never mix it with D IAQ U EEN Long Life Coolant or
other commercial long life coolants, anti-freezes
or anti-rusts.
14-22
(b) W hen anti-rust and anti-freeze are used: 5.10 G a s Leak Test
Air or exhaust gas leaked into the coolant prom otes
corrosion and rust formation. Perform the follow ing
check and, if defects are found, take remedial action.
(1) Inspection
1) After cleaning, add Fuso Radiator Anti-rust (Radi-

pet-9B or equivalent) at a ratio of 5 % to the coolant
quantity to prevent corrosion in summer.
(a) Remove the pressure cap from the radiator.

(b) Run the engine to raise the coolant temperature up
to around 90°C.
(c) If bubbles continue form ing in the coolant under
the condition, it indicates that air or exhaust gas
has leaked into the coolant.
(2) Causes
(a) If air is trapped in coolant, check cylinder head
bolts, water pum p m ounting bolts, and hose and
its connections for looseness. Check also hoses for
damage.
2) In winter, add the Fuso Anti-freeze or equivalent at (b) If the exhaust gas has leaked into coolant, check
a ratio of 30 to 6 0 % to prevent freezing. the cylinder head gasket or nozzle tube end stake
For usage of anti-rust and anti-freeze, see respec for damage. Check also cylinder head for cracks.
tive instruction manuals.
5.11 Bleeding the C o o lin g S y ste m
NOTE:
(1) With the pressure cap removed from the radiator,
When the anti-rust or anti-freeze is used, never use
let the engine run at idle with coolant temperature
with other long life coolants.
of about 90°C to bleed the system completely.
(2) After the system has been bled of air, add coolant
to radiator and reserve tank as required.
14-23
14 COOLING - TROUBLESHOOTING
6. TROUBLESHOOTING
S y m p to m Probable cause Rem edy Ref. group
Overheat Defective V-belt

• Incorrect tension Adjust
• Broken belt Replace
C lo g g e d coolin g system Clean
Defective therm ostat Replace
Defective w ater p u m p
• Lo o se shaft to im peller e n ga ge m e n t Replace
• Lo o se shaft to flange e n ga ge m e n t Replace
• Im proper clearance between im peller and w ater p u m p case Correct
• D a m a g e d im peller Replace
C lo g g e d radiator fins Clean
Defective autocool fan cou plin g .

• D a m a g e d bimetal Replace
• C lo g g e d bimetal Clean
• Defective autocool fan c o u p lin g proper Replace
D a m a g e d coolin g fan Replace
Low coolant level Replenish
O vercool Defective therm ostat Replace
Quick lo ss Defective radiator hose

o f coolant • Lo ose hose connection Correct
• W orn or d a m a ge d hose Replace
Defective radiator
• Radiator proper not tight Correct or replace
• Pressure cap not tight Replace
Defective w ater p um p
• Defective unit seal Replace
• Defective oil seal Replace
• Pu m p m ounted im properly Correct
Defective oil cooler Replace G roup 12
T h erm ostat case or cover m oun ted im properly Correct
Defective heater hose

• Lo ose hose connection Correct
• W orn or d a m a ge d hose Replace
Defective cylinder head gasket Replace Group 11
14-24
15
INTAKE AND EXHAUST
CONTENTS
1. G E N E R A L .......................................... .. 2 5.3.1 D isassem bly and reassem bly ......... , 15

2. SP EC IF IC A T IO N S ................................ .. 6 5.3.2 Inspection and cleaning ................ 16
3. S E R V IC E S T A N D A R D S ........................ .. 7 5.4 Turbocharger ................................... 17
3.1 Service Standards Table .................. .. 7 5.4.1 D isassem bly ................................. , 17
3.2 Tightening Torque Table .................. .. 7 5.4.2 Cleaning and inspection ................ 20
4. S P E C IA L TO O L .................................. ... 8 5.4.3 Reassem bly ................................. 23
5. S E R V IC E P R O C E D U R E ........................ ... 9 5.5 A fte rco o le r....................................... 27
5.1 Rem oval and Installation of intake 5.5.1 D isassem bly and reassem bly ......... 27
System .......................................... ... 9 5.5.2 Air pressure test .......................... 28
5.2 Rem oval and Installation of Exhaust 5.6 Bleeding of Aftercooler Coolant Circuit
System .......................................... .. 13 <6D24-TC :S ta n d a rd > ......................... 28
5.3 Air Cleaner ..................................... .. 15 6. T R O U B L E SH O O T IN G ........................... 29
15-1
15 INTAKE AND EXHAUST - GENERAL
1. GENERAL The cyclone type air cleaner uses a filter paper type ele
ment.
(1) Air cleaner
Because of plastic coating and heat treatment, the ele
ment is highly resistant to water and oil. Even if it is
< Sin gle element type>
Outside air
contaminated, its functions can be regained by clean
ing.
The intake air is given a spin by the vanes for centrifu
gal separation of large particles of dust and dirt. Sm all
particles of dust and dirt are filtered out by the filter
paper element so that a clean air is drawn into the
engine.
The standard air cleaner is a single element type, and
the double element type can be effective for operation
safety under unusual conditions with a lot of dust and
B0618A
dirt.
Outside air
(2) Precleaner
To e n gin e
Vacuator valve
G uide vane
B0619A
<Double element type>
O utside air
Inner elem ent
T h e precleaner, coupled w ith the air cleaner, collects

relatively large particles of dust contained in the air
drawn in by engine.
The air entering the precleaner is made to spin by the
Outer elem ent guide vanes of the precleaner to centrifugally separate
To e n gin e large particles of dust before the air is drawn into the air
B0608C cleaner. These dusts are collected in the precleaner.
Outside air
B 0620A
15-2
INTAKE AND EXHAUST - GENERAL 15
(3) Vacuator valve body, indicating that it is time to clean or replace the
element.
After the element has been cleaned or replaced,
depress the reset button on the top, and the signal will
return to its original position.
W arning lam p
Q j Starter switch
Electrical
dust indicator
$
J— L
Centrifuged dust collects at the bottom of the air

SL A ir cleaner
cleaner. A vacuator valve made of rubber is mounted to
the bottom, which pulsates to automatically dis B1824A
charges dust and water when the engine speed is
below about 800 rpm. Nam ely w hen the engine is run With the electric dust indicator, its electric contact
ning at a speed higherthan 800 rpm, the negative pres points close when the vacuum reaches 6.2 kPa {635
sure in the air cleaner keeps this valve closed but when mmH20}. This turns on the warning lamp, w arning the
the negative pressure drops as the engine speed driver that it is time to clean or replace the element.
decreases, the valve is made to open by rubber action,
thereby discharging dust and water.
(4) Dust indicator
The dust indicator is mounted near the outlet of the air

cleaner.
The dust indicator operates on the negative pressure of
the air drawn into the engine performing the function
of indicating the time to clean or replace the element.
W hen the element is plugged with dust and dirt, the
suction resistance increases. W hen this vacuum
reaches 6.2 kPa {635 mml-^O}, the signal (red) is pulled
down against the spring tension. The signal (red) is
then visible through the transparent section in the
15-3
15 INTAKE AND EXHAUST - GENERAL
(5) Turbocharger
The turbocharger can be divided into three basic sec

tions: the turbine wheel that is driven by the exhaust
gases, the com pressor wheel which forces intake air
into cylinders and the bearing housing which supports
the shaft of these wheels.
The shaft connecting the turbine wheel with the com
pressor wheel is supported in floating type bearings,
which absorb vibrations during high speed operation
that are caused by slight imbalance ofthe shaft.
The shaft axial load is borne by the thrust bearing.
The bearing housing has its inside cooled and lubri
The turbocharger utilizes the energy of the engine
cated by engine oil to prevent seizure and other
exhaust gas to feed more air into the engine, thereby troubles ofthe sliding parts.
offering advantages such as boosted engine power (Refer to Group 12 Lubrication.)
output, thrifterfuel consumption, and reduced engine
noise.
The exhaust gases discharged from the cylinder ofthe
engine are led through the exhaust m anifold into the
turbocharger and are accelerated in the turbine h o u s
ing and are blown against the turbine wheel.
Accordingly, the turbine is made to rotate at a speed of
scores of thousands of revolutions a minute, and turns
the com pressor wheel mounted on the sam e shaft as
the turbine wheel. By rotation of the com pressor
wheel, a larger am ount of airthan without supercharg
ing is forced into the cylinder ofthe engine, so a corre
sp o n d in gly larger am ount of fuel can be burnt. This
increases the effective pressure during com bustion
(the pressure forcing the piston down) and thus
increases the output.
15-4
INTAKE AND EXHAUST - GENERAL 15
(6) Aftercooler
The intercooler (attached to the front ofthe radiator) is

The intake air cooling system, incorporating a plate- a tube-and-corrugated-fin, air-to-air heat exchanger. It
and-corru gated-fin type heat exchanger, transfers heat cools the intake air, which is hot. after being com
from the intake air to the engine coolant. It has the pressed by the turbocharger, thereby making the
sam e function as the intercooler on automobile intake air denser before it enters the cylinders. C o m
engines. bustion efficiency is thus improved, resulting in higher
The system cools off the intake air, w hose temperature fuel efficiency and output and in lower e m issions of
has gone high due to com pression by the turbochar harmful gases.
ger, through heat exchanging with the engine coolant.
This allows the density of intake air to be increased,
admitting more air into the engine, which in turn
increases the fuel injection rate and im proves the com
bustion efficiency. Thus the fuel econom y and output
are im proved and the exhaust gases are reduced to a
minimum.
15-5
15 INTAKE AND EXHAUST - SPECIFICATIONS
2. SPECIFICATIONS
Model 6D24 6D24-T 6D24-TC 6D24-TL
Item '—
Air cleaner Type Cyclone type paper elem ent

elem ent (N ippon D o n ald oson Ltd. products)
Su p erch arge r Type - T urbocharger
M odel - M itsu b ish i TD08H
Aftercooler Type Plate and corrugated fin Tube-and-corrugated-fin

type, w ater-cooling (built type, air-cooling
in the inlet manifold,
cooled by the engine
coolant)
Model - - - C60
15-6
INTAKE AND EXHAUST - SERVICE STANDARDS 15
Unit: m m
M aintenance item N o m in a l value Limit R e m e d y and

(Basic diam eter in [ ]) rem arks
D u st indicator operating resistance 6.2 ± 0.6 kPa - Replace

{635 ± 58 m m H 20}
T urbocharger I.D. of section in bearing h o u sin g receiving bearing - 20.506 Replace
Shaft-and-turbine-wheel Be arin g journal O.D. - 11.996 Replace
Sh aft runout - 0.015 Replace
Bearing O.D. 20.382 Replace
I.D. - 12.042
Length - 11.94
Piston ring end ga p in insert 0.05 to 0.25 - Replace
Shaft-and-turbine-wheel to turbine h o u sin g clearance 0.39 to 1.0 - Replace
Com p ressor wheel to c o m p re sso r cover clearance 0.08 to 0.28 - Replace
Shaft-and-turbine-wheel axial play 0.075 to 0.155 - Replace
Shaft-and-turbine-wheel to turbine back plate clearance 0.48 to 0.92 - Replace
Aftercooler Core a sse m b ly air-tightness 6D24-TC N o leak is allow ed with a 195 Replace
kPa {2 kgf/cm 2} air pressure
Intercooler air-tightness 6D24-TL N o leak is allow ed with a 150 -

kPa {1.5 kgf/cm 2} air pressure

Location tightened Screw size Tightening torque R em arks
O.D. x pitch N-m {kgf-m}
(m m)
Inlet m an ifold m ounting bolt <except 6D24-TC> M 10 x 1.5 35 {3.6}
Exh au st m an ifold m ounting bolt M 10 x 1.25 41 {4.2}
T urbocharger M ou n tin g nut M 1 0 x 1.25 26 {2.7}

m o u n tin g nut
Lock nut M l O x 1.25 35 {3.6}
T urb och arger C ou plin g m ounting nut - 5.9 {0.6} A p p ly M O L Y -

KO TE gre ase to
Shaft-and-turbine-w heel m o u n tin g - 20 {2} threads.
lock nut
15-7
15 INTAKE AND EXHAUST - SPECIAL TOOL
4. SPECIAL TOOL
Unit: m m
Tool nam e Shape
Socket
MH 061242
For ex h au st m an ifold attach
ing nut
W idth a cross
flats 14
B5341A
15-8
INTAKE AND EXHAUST - SERVICE PROCEDURE 15
5.1 Removal and Installation of Intake System
<6D24>
Install with the arrow

mark facing toward
the inlet manifold.
35 N-m
{3.6 kgf-m}
1 Ground plate
2 Inlet pipe
3 Air heater
4 Inlet manifold
NOTE:
1. Remove harnesses before disassembly.
2. Ensure th at the arrow points in the correct direction when installing the air heater.
3. For details of air heater inspections, refer to Group 16.
B4556A
15 INTAKE AND EXHAUST - SERVICE PROCEDURE
<6D24-T>
1 Ground piate
2 Inlet pipe
3 Rubber hose
4 A ir heater
5 Inlet manifold
NOTE:
2. Ensure that the arrow points in the correct direction when installing the air heater.
B4557A
15-10
<6D24-TC: Standard>
l ^ l l Install with the arrow

^ / / mark facing tow ard
r the cylinder head.
1 Inlet pipe 6 Ground plate

2 Air escape pipe 7 Heater harness
3 Water inlet pipe 8 Air heater
4 Water return pipe 9 Rubber hose
5 Air cooler assem bly
N O TE:
B4558C
15-11
<6D24-TL>
1 Ground plate 4 Inlet manifold

2 Air inlet pipe B 5 Air inlet pipe A
3 Air heater 6 Rubber hose
NOTE:
© 43535
15-12
5.2 R e m o val and Installation of E x h au st S y ste m
<6D24>
1 Heat insulator 4 Expansion ring

2 Exhaust manifold 5 Center exhaust manifold
3 Seal ring
B4560A
Socket, MH061242 (special tool) is available to facili- of this tool is recommended,

tate fitting of the exhaust manifold m ounting nuts. Use
15-13
<6D24-T, TC, TL>
1 H e a t in s u la t o r 5 Exhaust manifold
2 Oil pipe 6 Seal ring
3 Oil return pipe 7 Expansion ring
4 Turbocharger 8 Center exhaust manifold
B4561A
Socket, M H061242 (special tool) is available to facili NOTE:

tate fitting ofthe exhaust manifold mounting nuts. Use Som e types of turbocharger fit onto the top of the
of this tool is recommended. exhaust manifold, while other types fit onto the bot
tom ofthe exhaust manifold. Maintenance procedures
for both types are the same.
15-14
5.3 Air Cleaner
5.3.1 D isassem bly and reassem bly
<Single element type> Clam p

Element Dust cup
Air cleaner body

Installation direction mark
Installation
direction mark
D ust cup
Buffle
W in g nut
Air cleaner body
Gasket
A ir cleaner body
D ust indicator W in g nut
Cover
B 4563A
<Double element type>
Dust cup
Clam p
Outer e le m e n t,
. . . Inner Installation
Dust indicator A ir cleaner e|ement I-direction mark
I body
D ust cup
Clam p
W in g nut v acuator valve
Outer element
A ir . ^^= 0 .
cleaner O-ring p \
D ust indicator body; Installation
-• — Wi ng nut direction mark
W in g nut Clam p
Inner
element
Gasket
Outer element
Inner
element
Air cleaner bo d y
Dust indicator
W in g nut
W in g nut
6-5— Vacuator valve
NOTE:
Remove the inner element only for replacement.
B4564A
15-15
5.3.2 Inspection and cleaning (4) Clean the inside of the air cleaner body and dust
(1) W hen there is dry dust on the element cup, and discharge the deposited dust.
(5) Dust indicator
If there is dry dust on the element, clean the dust by

blowing 685 kPa {7 kgf/cm2} or lower com pressed air Start the engine and close the inlet port of air cleaner
against the element. gradually to increase negative pressure. If the red sig
B low the com pressed air from inside the element up nal is displayed at the dust indicator, or warning lamp
and down along the frills of the filter paper and clean lights for the electric type dust indicator, the dust indi
the whole element evenly. cator is normal.
NOTE: NOTE:
1. Do not strike the element or strike it against a hard Perform this inspection after cleaning or replacement
object to loosen the dust. of the air cleaner element if the element is heavily
2. Do not clean, but replace, the inner element. clogged.
(2) W hen there is m oist dust on the element
If the element is contaminated with moist soot, replace
it regardless of the specified replacement frequency.
(3) Inspection of element
After the element has been cleaned, put an electric

lam p inside the element to check for dam age and pin
holes. If there are thin portions in the filter paper,
replace the element. If the packing on the top surface of
the element is broken, replace the element.
15-16
5.4 Turbocharger
5.4.1 Disassembly
W ear in surface W ear

receiving thrust «c
force 12
Wear-i
Blade bend and dam age,

corrosion, marks of
interference on back surface 6
Interference with
c o m p re sso r wheel,
cracks, da m e ge
Interference w ith
turbine wheel, cracks
due to overheat, pitching,
deformation
Blade bend and dam age, corrosion,

17 m arks of interference on back sur
15 face, d a m a ge on piston ring groove,
d a m a ge on bearing journal
Interference with
turbine wheel, d am age
Bearing hole surface roughness,

dam age, g a s corrosion, clo gge d oil
hole, turbine side fla n ge deform ation

1 Coupling assem bly 10 Thrust sleeve
® Turbine housing 11 Thrust bearing
3 Snap ring 12 Thrust ring
(?) Com pressor cover 13 Shaft-and-turbine-wheel
® Com pressor wheel 14 Piston ring
6 Snap ring 15 Turbine back plate
Insert 16 Bearing
8 Piston ring 17 Snap ring
9 Oil deflector 18 Bearing housing
For parts with an encircled number, refer to D isa sse m b ly Procedure that follow s.
C8965B
15-17
Disassem bly Procedure (3) Removal of com pressor cover
(1) Before disassem bling the turbocharger, make Rem ove the com pressor cover by tapping it with .
alignm ent m arks on the com pressor cover, bearing plastic hammer or similar tool which will not damag<
housing, and turbine housing so that they can be the cover, with the snap ring loosened.
properly reassembled. NOTE:
(2) Rem oval of turbine housing Use care not to damage the compressor wheel durim
the removal procedure.
(4) Removal of com pressor wheel
To rem ove the turbine housing, remove the coupling

assem bly and tap the hou sing with a plastic ham m er or
similar tool to prevent dam age to it. (a) Clamp the turbine housing in a vise and fit the bear
NOTE: ing housing into the turbine housing with the tur
The turbine wheel blades are easy to bend. Use care bine wheel side of the bearing housing facing the
not to dam age them. turbine housing.
15-18
(5) Removal of insert
(b) While holding the shaft-and-turbine-wheel boss,

remove the lock nut that secures the com pressor (a) Snap off the snap ring that secures the insert onto
wheel. the bearing housing.
NOTE:
Retain the snap ring by hand to prevent it from spring
ing out when slipping off the snap ring pliers.
(c) Slow ly slide off the com pressor wheel upward.
(b) Fit the tip of a screwdriver into the portion of the

insert show n and carefully remove it from the bear
ing housing.
15-19
5.4.2 Cleaning and inspection
Clean
Clean
Clean
Shaft-and-turbine-w heel
Bearing journal O.D.
L 11.996
Shaft runout (total indi

cator reading)
L 0.015
Bearing inserting
portion I.D.
L 20.506 N V .. N o m inal Value
L Limit
NOTE:
Before cleaning, visually inspect each component to find
any scorching or rubbing that will not be apparent after
cleaning. For details, refer to section 5.4.1.
C8988B
(1) Cleaning (a) Immerse all parts in a non-flammable solvent

(DAIDO C H E M IC A L IN D U S T R Y CO., LTD DAI
C LE A N E R T-30 or equivalent) to clean oily contami
nation.
15-20
(2) Inspection of bearing housing
C8993A
(b) Blow clean com pressed air against the entire inter
nal and external surfaces. M easure I.D. of the area receiving the bearing. Replace
the bearing housing if the measurem ent exceeds the
limit.
(3) Inspection of bearing
M e asu rin g M e asu rin g

direction position
(c) Clean deposits, using a plastic scraper or bristle

brush. C 8971A
After deposits have been removed, soak parts in a

non-flammable solvent again; then, blow com M easure I.D., O.D., and length of the bearing. If the
pressed air against them. measured values exceed the limit, replace.
NOTE:
Use care to prevent damage to parts.
15-21
(4) Inspection of shaft (5) Inspection of insert

(a) Journal O.D.
B0465A
Fit a new piston ring in the insert bore and measure the
M easure the shaft-and-turbine-wheel journal diam e end gap of the piston ring using a feeler gauge.
ter. If the end gap is out ofthe nominal value, replace the
If the m easured value is less than the limit, replace the insert.
shaft-and-turbine-wheel.
(b) Shaft runout
Set a dial indicator to the shaft as show n and turn the

turbine wheel slow ly to measure shaft runout.
If the m easurem ent exceeds the limit, replace the
shaft-and-turbine-wheel.
If the shaft journal is rough, clamp both centers on a
lathe and lightly grind the journal surface with a sand
paper #400 and engine oil with a spindle speed at 300
to 600 rpm.
NOTE:
After polishing the journal, measure its outside diame
ter {the part that rotates in the bearing). If the outside
diameter is beyond the service limit, replace the shaft
and turbine wheel.
15-22
5.4.3 Reassem bly
5.9 N-m {0.6 kgf-m}
A sse m b ly sequence Shaft-and-turbine-w heel

axial play
18—>17—»16—>15l—1 N V 0.075 to 0.155
U l2->11 —
14 - » 13 — ' >(4)—>3—>'2 —>!.i.: N V .. N o m in a l Value
9 -» 1 0 -> # -> 7 —
For parts w ith an encircled num ber, refer to R ea sse m b ly Procedure that follow s.
C8974B
Reassembly Procedure Set the thrust sleeve into the oil deflector, and install
the piston ring.
(1) Installation of piston ring
NOTE:
When mounting piston ring to the thrust sleeve,
ensure that the ring is not expanded and ring ends are
not twisted.
15-23
(2) Installation of snap ring (3) M easurem ent of clearance between shaft-and-tur-
bine-wheel and turbine housing
Se ta dial indicator to the end of the shaft and move the

shaft in the axial direction to measure the clearance. If
the m easurem ent is out of specification, disassem ble
and isolate the cause.
(4) Installation of com pressor wheel
Install the sn a p ring to the bearing housing with its

taper up.
After installation, using a screwdriver, drive the snap
ring into the groove in the bearing housing by hum-
mering.
NOTE:
1. Retain the snap ring by hand to prevent it from
springing out when slipping off the snap ring pli
ers.
2. Special care must be exercised, when tapping the
snap ring into position, to prevent dam age to the
bearing housing by the screwdriver.
(a) Holding the turbine housing in a vice, set the tur

bine wheel side of the bearing housing into the tur
bine housing.
15-24
(b) Coat threads in the shaft-and-turbine-wheel with (6) Measurem ent of clearance between the turbine
m olybdenum disulfide base grease Li soap and back plate and shaft-and-turbine-wheel back su r
mount the com pressor wheel onto the shaft. face
(c) Holding the boss on the turbine wheel side, tighten
the com pressor wheel lock nut to the specified
torque.
NOTE:
Set the bearing housing carefully to prevent damage
on the turbine wheel blades.
(5) M easurem ent of axial play in shaft-and-turbine-
wheel
Set a dial gauge on the shaft-and-turbine-wheel end.

With com pressor wheel m oved in the axial direction,
Temporarily mount the bearing housing to the co m
measure the end play. If the play is out of specification,
pressor cover from the com pressor wheel side. M e a
disassem ble and check to locate the cause.
sure the clearance between the turbine back plate and
shaft-and-turbine-wheel back surface. If the clearance
is out of specification, disassem ble and isolate the
cause.
NOTE:
Be sure to use two thickness gauges and take m ea
surement at the tip of the blades.
15-25
(7) C o m p re sso r wheel to com pressor cover clearance (8) Installation of turbine housing and com pressor
cover
C oupling
asse m bly
A lign m e n t mark
Turbine h o u sin g
C o u p lin g a sse m b ly S n a p ring C o m p re sso r cover

5.9 N-m (0.6 kgf-m)
B2819E
Check by the follow ing procedures.
(a) M o v e up and dow n the com pressor wheel to mea M ake sure that the alignment marks are aligned and
sure runout (R). secure the parts with the coupling assem bly and snap
ring.
NOTE:
Install the coupling assem bly by the following proce
Do not measure runout by turning the compressor
dures.
wheel.
(a) Tighten the coupling assem bly to specified torque.
(b) M easure com p ressor cover inside diameter (D)
(b) Ham m er the coupling assem bly all around.
and co m p re sso r wheel outside diameter (d) at
(c) Tighten again the coupling assem bly to specified
places indicated in the illustration.
torque.
(c) Calculate the clearance by the equation given
below. (9) After reassembly, turn the turbine wheel and com
If it is out of specification, disassem ble and check pressor wheel by hand and check for sm ooth rota
again. tion.
If the wheels turn heavily, or bind, disassemble,
Clearance = 1/2 (D - d - R)
and locate the cause of trouble.
15-26
5.5 Aftercooler
5.5.1 D isasse m bly and reassem bly

(1) Water-cooled type
<6D24-TC :Standard> <6D24-TC :Low profile type>
5 D am age, water leaks,

Dam age, w ater leaks, dirt on fins, water scale
dirt on fins, water scale and rust inside core
and rust inside core
C9305B C9305C
1 Connector 4 Core assem bly
2 Cover 5 Inlet manifold
3 Plate
(2) Air-cooled type
15-27
5.5.2 Air pressure test 5.6 Bleeding of Aftercooler C o o la n t Circuit

(1) Inspection of core assem bly <6D24-TC> ' <6D24-TC :Stan dard >
Conduct the air pressure test to check for water leaks

due to dam aged element. To check, apply an air pres
sure of 390 kPa {4 kgf/cm2} to the core assem bly.
Replace the core assem bly if it is leaking air or other
wise defective.
NOTE:
Never apply pressure over specification.
(2) Inspection of intercooler <6D24-TL>
(a) Remove the air vent plug from the water outlet
pipe.
(b) Pour coolant into the radiator until coolant flows
out from the air vent. Install the air vent plug.
(c) With the pressure cap left removed from the radia
tor, run the engine at idle, keeping coolant temper
ature of about 90°C, to thoroughly bleed the s y s
tem.
(d) After the air in the coolant circuit has been thor
(a) Rem ove the intercooler and use copper wire or the oughly bled, add coolant as necessary to the radia
like to rem ove mud, insects, etc. from the front side tor and reservoir tank.
of intercooler core, using care not to dam age the
tube.
(c) Air-tightness check
Pressure for inspection of

intercooler (co m p re sse d air)
N V 150 kPa {1.5 kgf/cm 2}
C9009A
Im m erse the intercooler in a water tank with one open

ing for air closed and with the other opening connected
to a hose. Se n d com pressed air at specified test pres
sure through the hose and make surethatthere is no air
leak.
15-28
INTAKE AND EXHAUST - TROUBLESHOOTING 15
6. TROUBLESHOOTING
S y m p to m Probable cause Rem edy Ref. grou p
Low output Insufficient intake air

• Loaded air cleaner elem ent Clean
• A ir suction (with dust and other foreign matter) from intake Correct
system
• Defective turbocharger
• Turbocharger rotation failure
• Seized bearing Replace
• Carbon deposit on turbine wheel Clean
• Turbine w heel and turbine back plate interfering Check
• Turbine w heel and turbine h ou sin g interfering Check
• Bent shaft-and-turbine-w heel Replace
• C o m p re sso r w heel and com p ressor hou sin g interfering Check
• Seized thrust sleeve and/or thrust bearing Replace
• Incorrect slid in g between inside parts due to clo gg e d lubri Clean, check
cating oil pipe
• D a m a g e d co m p re sso r wheel Replace
• D a m a g e d turbine wheel Replace
• Foreign matter on front surface of intercooler core <6D24-TL> Clean
Low exhaust efficiency

• Deform ed front pipe, m uffler and/or tail pipe (large exhaust Replace
resistance)
• Defective turbocharger
• Turbocharger rotation failure (See above.) Check
• D a m ag e d turbine w heel Replace
W hitish and Incorrect injection tim in g Adjust G rou p 13A, E

m uch exhaust
gas Low c om p ression pressure Check G rou p 11
Poor quality fuel Replace G rou p 13A
Defective turbocharger
• Oil leaks due to w orn piston ring, and/or insert Replace
• D a m age d oil seal due to clo gg e d oil return pipe Replace
Dark and m uch Loaded air cleaner elem ent Clean
Trouble in engine proper Check G rou p 11
Nonuniform fuel injection am ou nt to cylinders Adjust G rou p 13A, E
Incorrect injection tim in g Adjust G rou p 13A, E
A bn orm al noise Poor connection of intake and exhaust system s Correct
from intake and Deform ed front pipe, m uffler or tail pipe (large exhaust resistance) Replace
Defective turbocharger (See above.) Check
15-29
16
ENGINE ELECTRICAL
CONTENTS
1. G E N E R A L ..................... 2 5.4.4 Reassem bly .................................... 66

1.1 Starter ...................... 3 5.4.5 inspection and adjustm ent after
1.2 Alternator ................. 5 installation ..................................... 68
1.3 Safety Relay .............. 10 5.5 40 A, 50 A Alternators
1.4 Intake Air Heater ........ 11 (brushless type) ................................ 73
1.5 Autom atic S to p Sy ste m 12 5.5.1 Rem oval and installation ................ 73
1.5.1 Sh utd ow n type ...... 13 5.5.2 D isassem bly .................................. 73
1.5.2 Run-on type .......... 15 5.5.3 Inspection ..................................... 76
2. SP E C IF IC A T IO N S ........ . 18 5.5.4 Reassem bly .................................. 79
3. S E R V IC E S T A N D A R D S ... 20 5.5.5 Inspection and adjustm ent after
3.1 Service Standards Table 20 installation ................................... 80
3.2 Tightening Torque Table 23 5.6 80 A Alternator
4. SP E C IA L TO O L ............. 24 (brushless type) 1.................... 81
5. S E R V IC E P R O C E D U R E ... 24 5.6.1 Rem oval and installation ................ 81
5.1 Starter <24 V - 6 kW: M5T50276> ........ 24 5.6.2 D isassem bly .................................. 81
5.1.1 Rem oval and installation ................ 24 5.6.3 Inspection ..................................... 83
5.1.2 D isassem bly .................................. 25 5.6.4 Reassem bly .................................. 87
5.1.3 Inspection ..................................... 28 5.6.5 Inspection and adjustm ent after
5.1.4 Reassem bly .................................. 34 reassem bly ...... 88
5.1.5 Inspection and adjustm ent after 5.7 150 A Alternator .................................. 90
reassem bly .................................... 37 5.7.1 Rem oval and installation ................. 90
5.2 Starter <24 V - 5.5 kW: M9T60171, 5.7.2 D isassem bly .................................... 90
24 V - 7.0 kW: M9T80771> .................. 38 5.7.3 Inspection ...................................... 93
5.2.1 Rem oval and installation ................ 38 5.7.4 Ressem bly ...................................... 97
5.2.2 D isassem bly ................ .................. 39 5.7.5 Inspection and adjustm ent after
5.2.3 Inspection ..................................... 43 reassem bly ..................................... 98
5.2.4 Reassem bly .................................. 48 5.8 Safety Relay Inspection ...................... 100
5.2.5 Inspection and adjustm ent 5.9 Preheater ......................................... 101
after reassem bly ............................ 50 5.9.1 Intake air heater ............................ 101
5.3 Starter Relay ..................................... 53 5.9.2 Heater relay .................................. 101
5.4 30 A, 35 A, 80 A Alternators 5.10 Autom atic Sto p Sy ste m .................... 102
(with brush type) .............................. 54 5.10.1 Sh ut dow n type .................. 102
5.4.1 Rem oval and installation ................ 54 5.10.2 Run-on type .................................. 107
5.4.2 D isassem bly .................................. 55 6. T R O U B L E S H O O T IN G .................. 112
5.4.3 Inspection ..................................... 59
16-1
16 ENGINE ELECTRICAL - GENERAL
1. GENERAL
Starter
Alternator
Oil p ressure
gauge
Code size
0.85 0.85 m m 2 or more
5 m m 2 or m ore
15 m m 2 or more
Oil pressu re 60 m m 2 or more
unit
j Oil I
|____pressure [
B1646F
16-2
ENGINE ELECTRICAL - GENERAL 16
1.1 Starter (2) Overrunning clutch section
<24V - 6kW>
The overrunning clutch is of roller type.

Each roller is set in the wedge-shaped groove provided
The starter is a reduction starter with a built-in reduc
by the outer and inner races (pinion) and is pressed by
tion gear. Its motor has been downsized with even
a spring.
higher speed capability.
The roller is pressed against the narrower side of the
Major com ponents of the starter are: motor section
groove by the spring transmitting outer race rotation to
generating power; the overrunning clutch section
the pinion by its wedge action. On the other hand, no
transmitting armature torque and preventing the
torque is transmitted from the pinion as the roller
engine from overrunning after startup; the magnetic
m oves to the wider side releasing the wedge action.
switch section which puts the pinion in mesh with the
ring gear and feeds load current into the motor; and,
the reduction gear and transmitting torque to the pin
ion.
(1) Reduction gear section
The end ofthe armature shaft is shaped as a gear and is

in m esh with the internal gear.
16-3
(3) Operation
B3709A
W hen the pinion com es into complete m esh with the

While the starter switch is ON, current flows from the ring gear, the contact " P i " closes and the large current
terminal " S W " ofthe starter relay to the terminal " L " ofthe battery directly flow s to the motor section to turn
and closes the contact " P 2 ". the pinion powerfully.
W hen the contact " P 2" closes, current from the battery In this condition, no current flow s to the pull-in coil.
flows from the terminal " S " ofthe magnetic switch to
The plunger is retained by the holding coil alone.
the pull-in coil " P " and holding coil "H ".
Furthermore, the current that has decreased flows
from the terminal " M " to the motor section.
The plunger, attracted by the" magnetic flux of the
pull-in coil and holding coil, pushes out the pinion
through a lever.
16-4
1.2 Alternator
(1) 30 A, 35 A, 80 A alternator (with brush type)
Setting the starter switch to OFF position causes the

contact " P 2" to open.
At the moment the starter switch is opened, the " P i " The alternator is a brush type in which a current flow s
still rem ains closed and the battery current flows from from the brushes through the slip ring to the field coil in
the terminal " B " to the pull-in coil " P " and holding coil the rotor.
"H ". Since the coil are w ound in opposite direction to M ajor com ponents include: the rotor (field coil) that
each other, the magnetic fluxes cancel each other so generates magnetic field; the stator that generates
that the return spring can m ove the plunger back to its electromotive force; the rectifier that rectifies electro
original position. At the sam e time, the contact " P i " motive force so generated; the regulator that keeps
opens to shut down the current flow to the motor. generated voltage constant.
16-5
(a) Rotor (c) Rectifier
<30 A, 80 A Alternator> <30 A, 80 A Alternator>
S lip ring
Field coil
Rotor core
<35 A Alternator>
B2702D B2704A
<35 A Alternator>
' Field coil
S lip ring Rotor core

B4392B B4393A
W hen the rotor is driven by the pulley rotation, a cur The rectifier m ainly consists of 3 diode trios, 6 diodes
rent flow s from the brushes, through the slip ring, to and 2 heat sinks. It rectifies the A C stator output to DC
the field coil. The rotor core tabs then become m a g power.
netic poles. Each heat sink has the (+) or (-) leads from 3 diodes
(b) Stator attached to it, performing full wave rectification for
3-phase AC.
Two rectifiers are used in the 80 A alternator.
(d) Regulator
Together with the rotor core, the stator core form s the
magnetic flux path. The magnetic flux lines in the sta
tor core are affected by the passage of the rotor core
field and generate electricity. The regulator alters the strength of the field coil field to
stabilize output power which varies with engine speed
fluctuations.
16-6
The regulator is integral with the brush holder. The 2) Starting the engine
assem bly com bines the IC regulator, the brushes and
the brush springs.
(e) Charging circuit
1) Turning O N the starter switch
W hen the engine is started and the alternator starts

generation so that the voltage at the alternator " B " ter
minal becomes higher than the battery voltage, the
current flows as show n below.
In this way, battery charge is started and at the sam e

time, the charge lamp goes out.
16-7
(2) 50A, 150A alternator (brushless type) (b) Neutral point diode operation
• W hen the neutral point's peak electric potential is
28V or below, only the six normal rectification
diodes function.^
This brushless alternator has neutral point diodes.

That is, two diodes are added to the neutral point
where three stator coils are connected.
This configuration provides higher DC voltage at high • W hen the neutral point's peak electric potential
speeds of alternator rotation when compared with the exceeds 28V, the neutral point diode arrangement
alternator without neutral point diode. supplements the regular DC output to the vehicle's
(a) Changes in neutral point electric potential on-board electrical systems.
(3) 40A, 80A alternator (brushless type)
A s illustrated, the neutral point's electric potential rises

and falls on either side ofth e neutral point's average A s its name implies, the 40A brushless alternator
DC voltage. (The neutral point's DC voltage is one-half allows current to flow directly to the field coil without
ofth e alternator's DC output voltage.) At high speeds the use of brushes.
of rotation, the peak emf generated greatly exceeds the The alternator's key com ponents are as follows: the
alternator's output voltage. A neutral point diode field coil (which generates the required magneticfield);
arrangem ent eliminates the excess emf. the stator (which generates electromotive force), the
rectifier (which converts the generated A C waveform
into direct current); and the regulator (which maintains
the generated emf at a constant level).
16-8
(a) Field coil Together with the rotor coil, the stator core form s the
magnetic flux path. The magnetic flux lines in the sta
tor core are affected by the passage of the rotor core
field and generate electricity.
(d) Rectifier
The field coil, secured onto the rear bracket, receives

current from the terminal and generates magnetic
field.
(b) Rotor
The rectifier m ainly consists of 3 diode trios, 6 diodes
and 2 heat sinks. It rectifies the A C stator output to DC
power.
Each heat sink has the {+) or (-) leads from 3 diodes
attached to it, performing full wave rectification for
3-phase AC.
(e) Regulator
The rotor is rotated by the pulley to surround the field

coil. By the magnetic field generated by the field coil,
the rotor core tabs become magnetic poles.
(c) Stator
The regulator alters the strength of the field coil field to

stabilize output power which varies with engine speed
fluctuations.
(f) Charging circuit
Refer to Item (1) (e) Alternator with brush.
Stator coil Stator core

B2703A
16-9
1.3 S a fe ty Relay The alternator rpm is detected and when it exceeds the
reference level, the safety relay prevents the starter
<R8T30171, R8T30172, R8T30174, R8T30274>
from operating even if its switch is accidentally turned
on during engine revolution.
Operation
Alternator
Battery
sw itch
{ Battery
B1454A
(1) W h en the starter switch is set to ON, current flow (3) W hen the pulse frequency at terminal " P " exceeds
from the starter relay to terminal " S " and to termi the specified value, continuity between terminals
nal " E " of the safety relay, closing contact "P i" . " S " and " E " is lost. Then, the starter does notoper-
The charge lamp also illuminates if provided. ate even ifthe starter switch is set to O N while the
(2) A s the starter runs and the engine starts running, engine is running.
pulses of frequency 1/10 of the alternator speed
appear at terminal " P " of the alternator. The
charge lamp goe s out.
16-10
1.4 Intake Air Heater
A ir heater
jr w
Starter switch
<6D24, T, TL>
OFF
HEAT
0 N 4- <6D24-TC>
START
Rl ACC R2
Heater relay
Fuse
Air heater
Battery switch J
0/ indicator <t>
Battery
DB803C
The intake air heater is an electric heater which heats

the intake air to facilitate engine starting.
Place the starter switch to HEAT position to operate the
heater. If current is supplied forabout 40 to 60 seconds
by keeping the starter switch at HEAT position, the tem-
perature ofthe intake air heater will exceed 800°C.
The intake air heater circuit has an indicator to let the
driver recognize the heat condition.
16-11
1.5 Automatic Stop System
Solenoid operation
<Shutdow n type>
Battery sw itch
W hen the solenoid status changes from OFF to ON,
the stop lever is pulled to the S T O P side.
Sto p lever
(returned to R U N side by return sp rin g when
B5883A
<Run-on type>
W hen the solenoid status changes from O N to OFF, a
stop lever pulls the stop lever back to the ST O P side.
S to p lever
(pulled to R U N side by solenoid when
B5883B
16-12
The automatic stop system automatically stops the
engine ifthe oil pressure drops to an abnorm ally low
level or the coolant temperature reaches an abnor
mally high level. The system 's key com ponents include
an oil pressure switch, a thermostatic switch, a sole
noid relay, and a solenoid.
A n y abnormal drop in oil pressure is sensed by the oil
pressure switch, which then activates the solenoid.
Similarly, any abnorm al increase in coolant tempera
ture is sensed by the thermostatic switch, which then
A tthis time, the oil pressure switch contacts are closed
activates the solenoid.
since the engine has not been started. Current thus
W hen actuated, the solenoid m oves the injection
flow s as follows:
pum p governor's stop lever in the ST O P direction and
thereby stops the engine.
There are two types of automatic stop system: shut
dow n type and run-on type. The solenoid operation
with each type is as illustrated.
1.5.1 Shutdown type
(1) Before engine is started
Since there is no alternator voltage at the solenoid

relay's A terminal, however, the solenoid relay is not
actuated and does not supply current to the solenoid.
With the solenoid not actuated, the governor's stop
lever is positioned to allow the engine to be started.
(2) W hen engine is started
W hen the engine is started, alternator voltage is
applied to the solenoid relay's A terminal. At this time,
the oil pressure is still low, so the oil pressure switch
contacts are closed, current is flowing to the solenoid
relay's W terminal, and the solenoid relay is actuated.
However, the capacitor inside the solenoid relay
charges up using the voltage at terminal A, so current
does not immediately flow to the solenoid relay's
actuation circuit. Charging of the capacitorthus delays
actuation of the solenoid relay. During this time delay,
the engine's oil pressure increases and the oil pressure
switch contacts open. This cuts the supply of current to
the solenoid relay's W terminal, rendering the solenoid
relay totally inactive.
W hen the battery switch is turned ON, current flow s as
follows:
16-13
(3) Autom atic engine stop
At this time, output voltage from the alternator is pres

If the oil pressure drops abnorm ally orthe coolanttem - ent at the solenoid relay's A terminal and current is
perature increases abnorm ally while the engine is run flowing to the solenoid relay's internal circuit. The sole
ning, the output current from the alternator flow s as noid relay is thus actuated, causing further current to
sh ow n below and the engine is stopped. flow, as follows:
With the solenoid thus actuated, the injection pum p

governor's stop lever is pulled in the ST O P direction.
Until the engine stops completely, the solenoid is kept
activated by current from the solenoid relay's internal
capacitor.
16-14
1.5.2 Run-on type
(1) Before engine is started
If the stop switch is turned O N while the engine is run

ning, battery current flows as follow s and the engine is
stopped.
W hen current flows to the solenoid relay's S T terminal,

the solenoid relay is actuated and the engine is
stopped in the way described in item (3).
16-15
W hen the battery switch is turned ON, current flow s as

follows:
(* : C on tacts are op en with stop sw itch O N and closed with stop

sw itch OFF)
Although there is a voltage at the solenoid relay's B ter

minal, there is no input at any other terminal so the
solenoid relay does not actuate. The gove rn or's stop
lever is therefore in the S T O P position. W hen the starter switch is turned to the ST A R T p osi
tion, current flow s as follows:
W hen current flows to the solenoid relay's S terminal,

the solenoid relay is actuated and further current flows,
as follows:
Sole n oid relay C terminal
1
Sole noid
>>
G round
The solenoid is thus actuated and positions the gover

nor's stop lever such thatthe engine can be started. The
engine then starts.
(3) If starter switch is turned ON after engine is started
W hen current flow s to the solenoid relay's H terminal,

the solenoid relay actuates, thereby keeping the sole
noid actuated.
(4) Automatic stop
Ifthe oil pressure drops abnorm ally and/or the coolant
temperature increases abnorm ally while the engine is
running, the oil pressure switch and/or thermostatic
switch contacts open, cutting the supply of current to
the solenoid relay. The solenoid relay thus stops oper
ating, causing the solenoid to also stop operating.
W hen it stops operating, the solenoid m oves the g o v
ernor's stop lever in the S T O P direction, thus stopping
the engine.
(5) M anual engine stop
If the engine stop sw itch* is turned O N while the
engine is running, the supply of current to the solenoid
relay's B terminal is cut, thus stopping the solenoid
W hen the starter switch is turned to the O N position, relay from operating. The engine is thus stopped in the
the connection between the starter switch C terminal w ay described in item (4).
and the solenoid relay's S terminal is broken. However, (* : Contacts are open with stop switch ON and closed
the solenoid relay is kept actuated by its internal capac with stop switch OFF)
itor. During this period, the engine's oil pressure
increases and the oil pressure switch contacts close.
Current generated by the alternator flow s as follows:
16-17
16 ENGINE ELECTRICAL - SPECIFICATIONS
2. SPECIFICATIONS
(1) Starter
Item Specification
V oltage - Polarity 24 V - © ground
Starter Type Electrom agnetic push-in type reduction starter

(M anufacturer
M itsu b ish i M odel M9T60171 M5T50276 M9T80771
Electric Corp.)
Output 24 V - 5.5 kW 24 V - 6 kW 24 V - 7 kW
Reduction S in g le reduction internal teeth spur gear

ge a rs
(2) Starter relay
Item Specification
Starter relay Model U1T35089 U1T06074 U1T07076

(M an u factu rer
M itsu b ish i
Electric Corp.)
(3) Alternator
Item Specification
A lternator Type Alternator with built-in 1C regulator

(M an u factu rer
M itsu b ish i W ith brushes
Electric Corp.)
M odel A2T72987 A3TN5387 A6T76087
O utput 24 V - 30 A 24 V - 35 A 24 V - 80 A
Item Specification
Alternator Type Alternator with built-in 1C regulator

(M an u factu rer
M itsu b ish i Brushless
Electric Corp.)
Model A4T40287 A4T40385 A4T40387 A4T70066 A4T70087 A9TU5097
Output 24 V - 40 A 24 V - 50 A 24 V - 80 A 24 V - 150 A
(4) Safety relay
Item Specification
Safety relay Model R8T30171 R8T30172 | R8T30174 R8T30274
16-18
ENGINE ELECTRICAL - SPECIFICATIONS 16
(5) Intake air heater
Item Specification
Intake air Type Electric heating type

heater
Capacity x 0.3 kW x 6 0.476 kW x 6 2 kW x 1 2.86 k W x 1
q'ty
Heater relay M odel U1T06671 U1T06672 U1T06671 U1T06672
Fuse capacity 91 A 127 A 91 A 127 A
(6) Automatic stop system (option)
Item Specification
For shu tdow n For run-on
S to p solenoid Type Electrom agnetic Electrom agnetic

(Synchro-Start Products)
Sole n oid relay Type 0-25000-5592 0-25000-6720

(Nikko Denki Produkts)
Oil pressure switch D iaphragm -type with built-in electric contacts
T herm o switch W ax-type with built-in electric contacts
16-19
16 ENGINE ELECTRICAL - SERVICE STANDARDS
3.1 Service S ta n d a rd s Table
(1) Starter
Unit: m m
M aintenance item N o m inal value Limit Rem edy and remarks

M9T60171, C om m utator O.D. 38.7 38.1 Replace

M9T80771
M5T50276 43.2 42.6
C o m m u tato r outside circum ference runout - 0.1 Correct or replaces
M o u ld depth between se gm e n ts 0.8 0.2 Correct or replaces
M5T50276 B rush spring pressure 25 to 34 N 17.7 N {1.8 kgf} Replace

(2.5 to 3.5 kgf}
M9T60171 33 to 45 N 17.7 N {1.8 kgf}

{3.4 to 4.6 kgf}
M9T80771 33 to 45 N 19.6 N {2.0 kgf}

{3.4 to 4.6 kgf}
M5T50276 B ru sh length 23 14 R eplace
M9T60171 18 11
M9T80771 23 12
M5T50276 N o -lo ad characteristics 110 A or less Check

(Voltage 3300 rpm or m ore
23 V)
M9T60171 110 A or less ”

23.5 V)
M9T80771 125 A o r less

23.5 V)
M 5T50276 M a gn e tic sw itch operating voltage 15 V - Replace
M9T60171 16 V or m ore -
M9T80771 16 V -
M 5T50276 Pinion ga p 4 to 6 - A dju st w ashers
M9T60171, 0.5 to 2.0 -

M9T80771
Gear shaft thrust ga p 0.1 to 0.5 - A dju st w ashers
16-20
ENGINE ELECTRICAL - SERVICE STANDARDS 16
(2) Alternator
Unit: m m
M aintenance item N om inal value Limit Rem edy and rem arks
(Basic diameter in [ ])
Alternator Field coil resistance (at 20*0) Approx. 8.7 Q - Replace

30 A
(A2T72987) Slip ring O.D. 40.8 to 41.2 40.4
Brush sprin g tension 3.1 to 4.3 N 2 N {0.2 kgf}

{0.32 to 0.44 kgf}
Brush length 23 8
Load characteristics 1500 rpm. 17 A or m ore — Check

(W hen cold) Terminal
voltage 27V
2500 rpm. 26 A or m ore —

Terminal
voltage 27V
IC regulator regulated voltage range 28 to 29 V - Replace

(5000 rpm, 5 A or less)
Alternator Field coil resistance (at 20°C) 9 to 10.4 O - Replace

35 A
(A3TN5387) S lip ring O.D. 33 32.4
Brush length 18.5 5
Load characteristics 1600 rpm. 20 A or m ore ~~ Check

(W hen hot) Terminal
voltage 27V
2500 rpm, 29 A or m ore

Terminal
voltage 27V
IC regulator regulated voltage range 28 to 29 V - Replace

Alternator Field coil resistance (at 20°C) Approx. 7.2 Q - Replace

80 A
(A6T76087) S lip ring O.D. 40.8 to 41.2 40.4
Brush sp rin g tension 3.1 to 4.3 N 2 N {0.2 kgf}

{0.32 to 0.44 kgf}
Brush length 23 8
Load characteristics 1500 rpm, 39 A or m ore Check

(W hen cold) Terminal
voltage 27V
2500 rpm. 71 A or m ore

Terminal
voltage 27V
IC regulator regulated voltage range 28 to 29 V “ Replace

Alternator Field coil resistance (at 20°C) 6.1 to 7.2 D - Replace

40 A ( b r u s h
less) Load characteristics 1500 rpm. 30 A or more Check
(A4T40287) (W hen cold) Terminal
v o ltage 27V
2500 rpm. 41 A or m ore

Terminal
voltage 27V
IC regulator regulated voltage range 28 to 29 V Replace

16-21
16 ENGINE ELECTRICAL - SERVICE STANDARDS
M ain ten an ce item N o m in a l value Limit R em edy and remarks

Alternator Field coil resistance (at 20°C) 6.1 to 7.2 - Replace

50 A (b rush
less) Load characteristics 1500 rpm. 30 A or m ore Check
(A4T40385 (W hen cold) Terminal
A4T40387) v o ltag e 27V
2500 rpm. 47 A or more "■

Term inal
voltage 27V
1C regulator regulated voltage range 28 to 29 V Replace

Alternator Field coil resistance (at 20°C) 6.8 to 8.0 Cl * Replace

80 A ( b r u s h
less) Lo ad characteristics 1500 rpm. 56 A or m ore — Check
(A4T70066 (W hen cold) Terminal
A4T70087) v o ltag e 27V
2500 rpm. 86 A or more

Terminal
voltage 27V
1C regulator regulated voltage ran ge 28 to 29 V - Replace

A lternator Field coil resistance (at 20°C) A pp rox. 4.4 to 5.2 f l - Replace
150 A
(brushless) Lo ad characteristics 1500 rpm. 104 A or m ore Check
(A9TU5097) (W h e n cold) Term inal
v o ltage 27V
2500 rpm. 154 A or more

Term inal
v o ltage 27V
1C regulator regulated voltage ran ge 28 to 29 V Replace

(3) Regulator
Unit: m m
M a in te n a n ce item N o m in a l value Limit R em edy and remarks

(B asic diam eter in [))
V o lta g e r e g u la to r re g u la te d v o lt a g e 28 to 29 V (20°C) - R e p la c e
(4) Safety relay

Unit: mm
M ain ten an ce item N o m in a l value Limit R em edy and rem arks

(B asic diam eter in [))
R esistance between " L " and " R " term inals A pp rox. 200 £1 - Replace
(5) Intake air heater

Unit: m m
M ain ten an ce item N o m in a l value Limit Rem edy and remarks

Tim e required for indicator to be com e red-hot 40 to 60 sec. - Check
16-22
ENGINE ELECTRICAL - SERVICE STANDARDS 16
(6) Automatic stop system
(a) Shutdow n type
Unit: m m
Maintenance item N om inal value Limit R em e dy and rem arks

(Basic diameter in ())
Sole n oid Clearance between ba se lever and case 1.2 ± 0.2 - Replace
stopper
H olding coil current 0.5 A or less -
S o le n o id Delay time at starting (after 28.5 V applied 13 to 23 sec. “ Replace

relay to term inals “B " and " W " and 28.5 V to
terminal " A " )
Delay time at stop p in g (after 24 V applied 25 to 35 sec.

to term inals " B " and " W " and no voltage
to terminal " A " )
T h erm o sw itch actuating tem C o o le d with tap w ater 93 to 97°C - Replace

perature
C oole d by radiator 99 to 103°C -
Oil pressure sw itch actuating pressure 69 to 98 KPa ” Replace

{0.7 to 1.0 kgf/cm 2}
or less
Oil pressure sw itch relay (24 V) Coil resistance 190 to 280 D - Replace
M in . operating voltage 16 V or less -
(b) Run-on type

Unit: m m
Maintenance item N o m inal value Limit R e m e d y and rem arks

S o le n o id S to p lever to external stopper clearance 0.7 + 0.2 - Replace
H old in g coil current 0.5 A or less -
S o le n o id relay delay time 26 to 34 sec. - Replace
T herm o Actuating temperature Tap w ater 93 to 97°C - Replace

sw itch co o lin g type
R adiator 99 to 103°C -
c o o lin g type
Oil pressure sw itch actuating pressure 79 to 115 KPa Replace

{0.8 to 1.2 kgf/cm 2}
or le ss
3.2 T igh ten in g Torque Table
Location tightened S cre w size Tightening torque Rem ark

O.D. x pitch N m {kgf-m}
(m m )
A lternator pulley tightening nut M 1 7 x 1.5 83 to 105 {8.5 to 11} -
M 20 x 1.5 132 to 162 {13.5 to 16.5} -
Alternator shaft nut - 345 to 360 {35 to 37} -
16-23
16 ENGINE ELECTRICAL - SPECIAL TOOL / SERVICE PROCEDURE
4. SPECIAL TOOL
Unit: m m
Tool nam e S h ap e
Socket
31191-06100
R e m o va l and installation of
starter
W idth a cross flats 17 B 502 i a
NOTE:
Whenever removing electrical parts from the vehicle,
be sure to place the starter switch in OFF position, dis
connect the negative battery cable, and wind the cable
end with vinyl insulation tape.
5.1 Sta rte r <24 V - 6 kW : M 5T50276>

To rem ove the starter m ounting nut inside (on the

crankcase end), use Socket (special tool: 31191-06100).
16-24
ENGINE ELECTRICAL - SERVICE PROCEDURE 16
5.1.2 D is a s s e m b ly
C om m utator surface rou gh n ess, seizure,

stepped wear, w orn or d a m a g e d ge ar
Rotating
G ear shaft thrust gap
condition
Brush pow er deposits, uneven wear,

brush m otion in holder
B9071C
Pole and field coil installation condition

© Yoke assem bly *8 Rear bearing 15 Lever
2 Rear bracket (9) M agnetic switch *1 6 Gear shaft bearing
3 Brush holder 10 Center bracket © Ring
© Brush spring © Gear bracket © Pinion stopper
© Brush © Gear shaft 19 Front bracket
6 Armature © Overrunning clutch *2 0 Sleeve bearing
*7 Front bearing 14 Packing
Parts marked with * sh o u ld not be rem oved u n less defects are evident.
16-25
16 ENGINE ELECTRICAL - SERVICE PROCEDURE
D isasse m b ly Procedure (3) Rem oval of overrunning clutch

(1) Rem oval of yoke assem bly
Rem ove the magnetic switch and separate the front

bracket assem bly and yoke assembly.
NOTE:
D o n o t d ro p the arm ature.
E sp e c ia lly w h e n d is a s s e m b lin g w ith th e arm atu re
s t a y in g in th e yoke, d o n o t tilt th e y o k e asse m b ly.
(2) Inspection of gear shaft thrust gap
(a) Rem ove the gear bracket mounting bolt and

rem ove the overrunning clutch, to which the gear
shaft and gear bracket remain installed, from the
front bracket.
Before disassem bly, set the dial indicator as show n to

m easure the thrust gap in the gear shaft. If the m ea
surem ent is out of specification, use adjusting w ashers
to obtain correct gap. [For adjustment procedure, refer
to Item (8), Section 5.1.3.]
(b) A pply atubulartooltothe pinion stopperand ham
mer the pinion stopper out toward the pinion side.
Then rem ove the ring.
16-26
(4) Removal of brush spring
(c) Rem ove the ring from the ring groove of the gear
shaft. Remove the pinion stopper from the gear To remove the brush spring, first release the brush
shaft. spring and remove the brush.
(d) Rem ove the overrunning clutch and gear bracket

from the gear shaft.
16-27
5.1.3 In s p e c t io n
Item NV L
C o m m u ta to r O.D. 43.2 42.6
C o m m u ta to r outside circumference runout - 0.1
Depth o f g ro o v e between segm ent - 0.2
S h o rt circuit test, coil grou n d test, —
open circuit test
Item NV L
Brush spring 25 to 34 N 17.7 N
pressure {2.5 to 3.5 kgf} { 1.8 kgf}
Brush length 23 14
Insulation test - -
B1104E
16-28
inspection Procedure (c) Inspection of commutator
(1) Armature inspection
(a) Coil short circuit test
M easure the runout of commutator using a dial gauge

and turning the armature by hand.
If the runout exceeds the limit, correct, ensuring that
Place the armature on a growler tester. Hold a piece of
the O.D. limit is not exceeded.
iron in parallel with the armature and slow ly turn arma
If the commutator surface is rough developing ridge
ture by hand. If the iron piece is attracted or vibrates, it
wear, correct with sandpaper (No. 300 to 500).
m eans there is a short circuit. Replace the armature.
After correction, make sure to check the runout again.
(b) Coil ground test
(d) Com m utator O.D.
Check for continuity across the com mutator and shaft

M easure the commutator O.D. If the m easurem ent
(or core). If there is a continuity, indicating that the coil
exceeds the limit, replace the armature.
is grounded, replace the armature.
16-29
(e) M ould depth between segm ents If there is no continuity, indicating an open circuit,
replace the yoke assembly.
(b) Coil ground test
M easure the m ould depth between segm ents. If it does

not reach the limit, correct the armature.
Check that there is no continuity between the yoke and
brush (+).
If there is continuity, indicating that the coil is
grounded, check for poor insulation.
If repair is impossible, replace the yoke assembly.
NOTE:
T h e coil can be g ro u n d e d to th e y o k e a sse m b ly due to
c o n tin u ity created betw een the coil an d yo ke a sse m
b ly by m etal particles th at h av e w o r n off th e b ru sh e s
a n d /o r arm ature.
(3) Inspection of brush
If the segm ent indicates the faulty condition as show n

in the illustration, replace the armature.
(2) Inspection of field coil
(a) Coil open circuit test
(a) Measure the brush length and, if the measurement

is less than the limit, replace the brush as an
assem bly [(+) side: yoke assem bly; (-) side: brush
holder assembly].
(b) If the brush is unevenly worn or develops rough
surfaces, correct with sandpaper (No. 300 to 500).
Check that there is continuity between the terminal
lead and brush (+).
16-30
NOTE: (6) Inspection of magnetic switch
C orrect the b ru sh con tact su rface to a curve of the (a) Coil open circuit test
com m utator.
(4) Inspection of brush spring
" M " term inal 1^
-s-
term inal ,
¥
43446
• Checkthat there is a continuity across " S " and " M "

terminals. If there isn't, replace the magnetic
M easure the installed load of the brush spring. Using a switch.
new brush read the load at the m om ent the spring
leaves the brush.
(5) Brush holder insulation test
G round
- s - / £
terminal
43447
• Check to ensure that there is a continuity across

" S " and ground terminals. If there isn't, replace the
magnetic switch.
Check to ensure that there is no continuity between the

(+) brush holder and (-) holder plate.
If there is continuity, replace the brush holder.
16-31
(b) Fused contact check • In this condition, check that there is a continuity
across " B " and " M " terminals. If there isn't,
replace the magnetic switch.
(7) Inspection of overrunning clutch
_____________________ 43448
• Check that there is no continuity across " B " and

" M " terminals. If there is, replace the magnetic
switch.
(c) Contact test Install the gear shaft to the overrunning clutch and
check to see if the gear shaft turns sm oothly when
turned clockwise (in the drive direction) and locks
when turned counterclockwise.
If any unusual condition is noted, replace the overrun
ning clutch.
With the overrunning clutch fitted into the gear shaft,
check also that the overrunning clutch m oves
sm oothly along the splines.
NOTE:
Do not clean the overrunning clutch with cleaning oil.
If the overrunning clutch is cleaned with cleaning oil,
the grease inside it will come out.
(8) Adjustment of gear shaft thrust gap
• Close the contacts of th e . magnetic switch as
sh o w n in the illustration.
If the thrust gap is out of specification, insert the adjust

ing w asher into the position shown.
[For adjusting procedures, refer to Item (2), Section
5.1.2.]
16-32
(Adjusting washer: 0.25, 0.5 mm) (b) Replacement of front and rear bearings
(9) Replacement of bearings (Removal)
(a) Replacement of gear bearing

(Removal)
(Installation)
If the bearing of the gear shaft is defective, put a pin or

bolt in each of the four holes (6 m m in diameter) in the
internal gear and press down the bearing out of posi
tion with a press.
(Installation)
• Install the rear bearing by striking its inner race uni

formly with a soft hammer.
Apply a tubulartool to the bearing inner race and ham

mer it into position.
• Install the front bearing applying a tubular tool

diameter as its inner race and striking it into posi
tion.
16-33
N V .. N o m inal Value
A p p ly a
thin coat
of g re a se
*1 to
outer
periphery.
A p p ly gre ase *2 .
A p p ly gre ase *1.
A p p ly grease *1.
G ear shaft thrust g ap
N V 0.1 to 0.5
<Recom m ended greases>

B9073B
*1 M U L T E M P #6129 (Kyodo Yushi) or equivalent
*2 M O LY K O T E A S-1 9 (Dow Corning) or equivalent
R e a sse m b ly sequence
19->2
6-»7—>8 J- ->2
3 -* 5 -» 4 -V i
For parts w ith an encircled number, refer to R e a sse m b ly Procedure that follow s.
16-34
Reassem bly Procedure (c) Fit the ring into the ring groove in the gear shaft.
(1) Reassem ble the gear shaft, overrunning clutch,
and gear bracket in the following way.
B2969A
(d) Pull hard the pinion gear toward the ring and
secure it by fitting the ring into the ring groove in
(a) Coat the portions in gear shaft sh ow n with the spe pinion stopper.
cified greases and install the gear bracket and over (2) Installation of lever
running clutch over the gear shaft.
Insert the lever in the direction show n and m ount it

(b) Install the pinion stopper to the gear shaft in the with the pin from outside the front bracket.
direction shown.
B2968A
16-35
(3) Installation of overrunning clutch and gear shaft (4) Installation of magnetic switch
B term inal terrnin a | M a gn etic switch

C reacP
(M U L T E M P #6129
or equivalent)
Lever
B2952C
" S " term inal
" M ” terminal
“B " terminal
43449
Before installing the overrunning clutch and gear shaft Apply grease to the part of the magnetic switch show n
to the front bracket, be sure to apply the specified in the illustration, then fit the magnetic switch onto the
greases to the portions indicated. lever. Type M 3 T magnetic switches should be fitted
U pon installation, make sure that the lever is w edged with the B terminal on top. Types M 4 T and M 5 T should
into the overrunning clutch. be fitted with the S terminal on top.
(5) In s ta lla tio n o f y o k e a s s e m b ly
Apply the specified grease to the armature splines,

then install the yoke assem bly to the center bracket.
16-36
(a) Wire the reassembled starter as show n above.
(b) Turn ON switches Kt and «2 to project the pinion.
(c) Turn OFF switch K2 to stop pinion from rotating.
Fit the yoke assem bly such that the yoke terminal fits
into the center bracket notch.
5.1.5 Inspection and adjustm ent after reassem bly
(1) Inspection of pinion gap
(d) Measure the axial m ovem ent (pinion gap) when

the pinion is pushed lightly toward the armature
side.
(e) If the measurement is out of specification, increase

ordecreasethe num ber of w ashers used atthe por
tion to which magnetic switch is mounted.
Washers: 0.25, 0.5, 1.0 mm
16-37
(2) Inspection of no-load characteristics and magnetic 5.2 Starter <24 V - 5.5 kW: M9T60T71. 24 V - 7.0
switch operating voltage kW: M9T80771>
(a) Set up a circuit as show n including the ammeter,

voltmeter and transformer.
NOTE:
1. Use a wire as thick as possible and secure each
connection firmly.
2. Apply voltage gradually from 0 V up to 24 V.
(b) W ith the specified voltage applied, m easure the
current and speed of rotation. If the m easurem ents
are out of specification, inspect the starter again
and replace any faulty com ponents.
M easure the rotating speed by illuminating the
pinion with strobe light. The starter mounting bolts at the inside (crankcase)
Nom inal values (no-load characteristics) end can be removed and fitted m ost easily using the
Socket (special tool: 31191-06100).
V oltage N o m in a l v alue s
Current S pe ed of rotation
23.5 V 110 A or less 3,300 rpm

or above
(c) W hen a potential of 15to 1 6V is applied,the pinion

should spring out and turn. If the pinion does not
spring out and turn unless the voltage is above the
specified nominal level, inspect the starter again
and replace any faulty components.
N o m in a l v alue s 16 V or less
(m agne tic sw itch operating voltage)
16-38
5.2.2 D isasse m bly
<M 9T80771> R ou gh n e ss, burns, or stepped w ear on com m u tator

surface; w ear or d a m a ge on gear
14
Rotating
condition
1 2 3 Brush pow der deposition;

W e a r or d a m a g e on ge ar uneven wear; brush m o v e
m ent in holder
Installed condition of pole

pieces and field coils
©43364

1 Stopper ring 11 B r u s h © 21 Plate
2 Pinion stopper 12 Brush holder 22 E-ring
<D Pinion 13 B r u s h ® 23 Gear shaft assem bly
4 Spring *1 4 Rear bearing 24 W asher
5 Electromagnetic switch ® Armature 25 Internal gear
6 Shim 16 Ball . Overrunning clutch
7 Rear bracket 17 Cover 27 Lever assem bly
8 O-ring 18 Packing *28 Front bearing
<D Yoke assem bly 19 Planetary gears 29 Oil seal
10 Brush spring 20 Packing 30 Front bracket
Parts m arked with * should not be rem oved u nless defects are evident.
16-39
Disassem bly Procedure

(1) R em oving pinion
Front Lever -P in ion

E lectro m agne tic
sw itch
bracket a sse m b ly
\ / 'S to p p e r
=1 Pinion
ring <=[
C=[
■=[
D
© 39617
Battery
(DC 24 V)
©39618
A ,
— 1° °i—*—is
H
C E -41'
|— 1°—°l— H2 B4 y ~ w i
r 1°]
\
© 14259
©14257 (b) Connect the starter as shown.in the drawing.

A: Switch
(a) Rem ove the pinion with the starter energized and C: Switch
the pinion in its pushed-out position. D: Cable
P: Pull-in coil M: Starter M terminal
H: Holding coil S: Starter S terminal
NOTE: (c) The following steps m ust be performed with the
• The pinion will spring out and turn when the starter starter energized. Complete the pinion removal
is energized. Be careful not to touch it. procedure within 30 seconds.
• The electromagnetic switch may be hot after being Energize the starter by turning O N switches A and
inspected. Be careful when touching it. C; the pinion will spring out and turn.
• Do not energize the pull-in coil P for longer than 10
seconds. Do not energize the holding coil H for
longer than 30 seconds. Exceeding these tim es
could cause the coils to overheat and burn out.
• Cause the pinion to spring out by energizing the
starter and not by any other means. If you cause the
pinion to spring out by pulling the lever assem bly
{with the starter not energized), shock when the
stopper ring is removed can damage the front
bracket and lever.
• A current in excess of 100A flow s when the starter
is energized. Connect the parts using booster cables
or similarly thick wires, and make sure all connec
tions are secure.
16-40
into the ring groove in the pinion stopper. If this hap
pens, re-energizethe starter and repeat the procedure.
(2) Rem oving yoke assem bly
(d) W hen the pinion starts turning, promptly (within

five seconds) turn OFF switch C to stop it.
P: Pull-in coil
H: Holding coil To prevent the brushes from dam aging the arm ature's
NOTE: commutator, it is necessary to remove the yoke a sse m
With switches A and C turned ON, the pull-in coil and bly as follows:
holding coil are both energized. No voltage is applied • Raise the brushes from the commutator, then
to the starter's B terminal, so current flows in the apply the brush sp rin gsto the sides of their respec
pull-in coil while the pinion 3 is turning. To prevent the tive brushes to hold the brushes in position.
pull-in coil from burning out, it is essential to turn OFF
switch C promptly (within five seconds) when the pin
ion starts turning.
• Pull each brush spring at point A and lift the brush.

• After lifting each brush, hold it in place with the
brush spring as show n in the drawing.
(e) Apply a pipe-shaped jig to the pinion stopper. • Remove the yoke assembly.
(f) Lightly tap the jig with a ham m er to remove the
stopper ring from the ring groove in the pinion
stopper.
(g) Remove the stopper ring, then remove the pinion.
(h) Turn OFF switch A to de-energize the starter.
NOTE:
If the starter is de-energized prematurely, the pinion
m ay be pulled in, causing the stopper ring to go back
16-41
(3) Rem oving gear shaft assem bly
Internal ge a r
O ve rru n nin g
clutch
16917
Sp lin e s
16915
Rem ove the E-rings, then remove the gear shaft

assem b ly from the overrunning clutch. If the splines on
the gear shaft catch on the inside of the overrunning
clutch and prevent removal of the gear shaft, take the
follow ing steps:
(a) Push the gear shaft assem bly against the overrun
ning clutch.
(b) Give the gear shaft assem bly 1/8ofaturnto reposi
tion the splines, then remove the gearshaft a sse m
bly.
16-42
5.2.3 Inspection
Item NV L
C om m utator outside diameter 38.7 38.1
C om m utator runout - 0.1
M o u ld depth betweent se gm e nts 0.8 0.2
Coil short circuit test, grou n d in g test - -
Item NV L
Brush spring M9T60171 33 to 45 N 17.7 N
pressure {3.4 to 4.6.kgf} {1.8 kgf}
M9T80771 33 to 45 N 20 N
{3.4 to 4.6 kgf} {2.0 kgf}
Brush length 18 11
Insulation test - -
© 43365
16-43
Inspection Procedure (c) Comm utator runout

(1) Inspection of armature
(a) Coil short circuit test
45495
M easure the extent of commutator runout by turning

©45493
the commutator by hand with a dial indicator applied
to it. If the measurement exceeds the limit, rectify it
Place the armature on an armature tester. Then, hold a
within the limit specified for the outside diameter (see
strip of iron parallel to the armature and slow ly turn the
(d)). If the com mutator's surface is rough or has
armature by hand. If the iron strip is pulled toward the
stepped wear, rectify it using sandpaper (#300 to 500).
armature or starts to vibrate, there is a short circuit in
Be sure to check the commutator runout after eliminat
the coil and the armature must be replaced.
ing roughness or stepped wear in this way.
(b) Coil gro u n d in g test
(d) Comm utator outside diameter
45494
Check whether continuity exists between the com m u

M easure the commutator's outside diameter. If the
tator and shaft (or core). If continuity exists, the coil is
measurem ent is smaller than the specified minimum,
grounded and the armature must be replaced.
replace the armature.
16-44
(e) M ould depth between segm ents (2) Inspection of field coil
(a) Coil open circuit test
Measure the mould depth between segments. If any

measurement is smaller than the specified minimum, Check whether continuity exists between the terminal
replace the armature. lead and the (+) brush. If continuity does not exist, there
is an open circuit in the field coil and the yoke assem bly
m ust be replaced.
(b) Coil grounding test
If the mould is defective as sh ow n in the drawing, rec

tify it or replace the armature.
Check whether continuity exists between the yoke and

the(+) brush. If continuity exists, indicating that the coil
is grounded, inspect the insulation. If repair is im p o ssi
ble, replace the yoke assembly.
NOTE:
The coil can be g ro u n d e d to the yo ke a s s e m b ly d ue to
con tin u ity created b etw een th e coil and y o k e a s s e m
bly by m etal particles th a t h ave w o rn off th e b ru sh e s
a n d /o r arm ature.
16-45
(3) Inspection of brushes (5) Brush holder insulation test
(a) M ea su re the brush length. If the m easurem ent is Check whether continuity exists between the (+) brush
sm aller than the specified minimum, replace the holder and the (-) holder plate. If continuity exists, the
brush as an assem bly [(+) brush: yoke assem bly; brush holder is grounded and m ust be replaced.
(-) brush: brush holder assembly].
(6) Inspection of electromagnetic switch
(b) Ifthe brush surfacethattouchesthecom m utatoris
rough or unevenly worn, rectify it using sandpaper (a) Coil open circuit test
(#300 to 500).
NOTE:
W h e n rectifying th e b ru sh co n ta ct surface, m a k e su re
it r e m a in s cu rved to m atch the curvature of th e c o m
m utator.
(4) Inspection of brush springs
43446
Check whether continuity exists between the S and

M terminals. If continuity does not exist, replace
the electromagnetic switch.
Pull the brush spring away from the brush (a new one)
as sh o w n in the drawing. Note the load at the m om ent
w hen the brush spring separates from the brush. Ifthe
m easurem ent is sm aller than the specified m inim um ,
replace the brush spring.
16-46
• Close the electromagnetic switch's contacts as
show n in the drawing.
B2586B
• Check whether continuity exists between the M ter
minal and the body. If continuity does not exist,
replace the electromagnetic switch. • With the electromagnetic switch in this condition,
check whether continuity exists between the B and
(b) Inspection for fused contacts
M terminals. If continuity does not exist, replace
the electromagnetic switch.
(7) Inspection of overrunning clutch
• Check whether continuity exists between the B and

M terminals. If continuity exists, replace the elec
tromagnetic switch.
(c) Inspection of contact action Perform the following checks. Replace the overrunning
clutch if any abnormality is evident.
(a) Check that the shaft can be turned sm oothly in the
B direction.
(b) Check that the shaft locks when turned in the A
direction.
B2587B
16-47
5.2.4 R e a s s e m b ly
*2 A p p ly grease A p p ly grease
30 22 29
*1 A p p ly grease
'1 A p p ly gre ase
Pinion ga p
N V 0.5 to 2
M A p p ly grease
*2 A pply grease
© 43426
Recom m ended greases

*1: M U L T E M P # 6 1 2 9 (KyodoYushi) or equivalent
*2: M O LYK O TE® AG 650 (Dow Corning) or equivalent
Follow the d isa sse m b ly sequence in reverse.
For parts 3, 27, and 28, refer to the R e a sse m b ly Procedure that follow s.
16-48
R e a ss e m b ly Procedure (2) Installation of lever assem bly
(1) Installation of pinion
O verrunning
clutch
/ Pinion
/ - •
■*
:T r | r i/ Sto p p e r ring
- M /i
/
1
1
J. _ 4 -
7—
Ring groo ve
© 1 0 77 8
©10781
Install the lever assem bly (aligned as show n in the
It is not necessary to energize the starter while instal drawing) on the overrunning clutch.
ling the pinion.
(3) Installation of front bearing
(a) Install the pinion stopper and pinion (aligned as
show n in the drawing) on the overrunning clutch.
(b) Install the stopper ring in the ring groove in the
overrunning clutch.
© 13 3 25
(a) Install the oil seal before press-fitting the front

bearing.
(b) Use a pipe-shaped jig and a press to press-fit the
front bearing into the front bracket.
(c) Pull the pinion with significant force to fully seat
the stopper ring in the ring groove in the pinion
stopper.
16-49
NOTE:
• The pinion will spring out and turn when the starter
is energized. Be careful not to touch it.
• The electromagnetic switch may become hot dur
ing the inspection. Be careful when touching it.
• Do not energize the pull-in coil for longer than 10
seconds. Do not energize the holding coil for longer
than 30 seconds. Exceeding these times could cause
the coils to overheat and burn out.
• A current in excess of 100A flows when the starter
is energized. Connectthe parts using booster cables
or similarly thick wires, and make sure all connec
tions are secure.
(1) Inspection of pinion gap

(c) New ly clinch the front bracket.
NOTE:
Choose points that are well away from the old clinched
points.
5.2.5 Inspection and adjustm ent after reassem bly

=t Pinion
nt
Electrom agnetic
sw itch
© 39617
Battery
(D C 24 V)
©39615
© 14259
(a) Connect the starter as show n in the drawing.

C: Switch
E: Switch
F: Cable
© 14257
M: Starter M terminal
S: Starter S terminal
Post-assem bly inspection of the starter m ust be per
(b) The following steps m ust be performed with the
formed with the starter energized.
starter energized. Finish m easuring the pinion gap
P: Pull-in coil
within 30 seconds.
H: Holding coil
1) Energize the starter by turning ON switches C and
E; the pinion will spring out and turn.
16-50
2) W hen the pinion starts turning, promptly (within

five seconds) turn OFF switch E to stop it.
P: Pull-in coil
FI: Flolding coil
NOTE:
With switches C and E turned ON, the pull-in coil and
holding coil are both energized. No voltage is applied
to the starter's B terminal, so current flows in the
pull-in coil while the pinion is turning. To prevent the
pull-in coil from burning out, it is essential to turn OFF
switch E promptly (within five seconds) when the pin
ion starts turning.
3) M anually pull outthe end ofthe overrunning clutch
and gently push it back in. M easure the extent of
axial m ovem ent G (the pinion gap).
4) Turn OFF switch C to de-energize the starter.
(c) If the measurement is out of specification, replace
the lever.
16-51
(2) Performance test (c) The following steps must be performed with the
starter energized. Finish m easuring the current
and rotation speed within 30 seconds.
1) Energize the starter by turning ON switch C; the
pinion will spring out and turn.
NOTE:
With switch C turned ON, the pull-in coil and holding
coil are both energized. When a large current supplied
by the DC power supply flow s from the starter's B ter
minal to the starter's M terminal, the supply of current
to the pull-in coil is terminated such that current flows
© 39616
only in the holding coil. To prevent the holding coil
from burning out, it is essential to complete all steps
A V within 30 seconds.
.ft. % 2} M easure the current and the starter's speed of rota

tion. (Measure the speed of rotation by pointing a
P strobe-type timing light at the pinion.)
3) Turn OFF switch C to de-energize the starter.
(d) If either m easurem ent is out of specification, d isas
semble and inspect the starter again.
© 14258
(a) Connect the starter as show n in the drawing.

A: Am m eter
B: Starter B terminal
C: Switch
D: DC pow er supply
S: Starter S terminal
V: Voltmeter
(b) Set the voltage to 23 V.
NOTE:
Do not apply a voltage greater than 24 V.
16-52
5.3 Starter Relay
(a) Check for continuity between the " S W " and " L "
S B
terminals and check to ensure that the coil resis
nc =~r —Tz=3] i
tance is up to specification.
(b) Check to ensure that when the battery voltage (24
V) is applied across the " S W " and " L " terminals,
there is continuity between the " B " and " S " termi
nals.
D8002A
16-53
5.4 30 A, 35 A, 80 A A lte rn ators (w ith b rush type)

After installation, adjust the V-belt tension by referring

to Section 5.8 of Group 14 Cooling.
16-54
5.4.2 D isasse m bly
<30 A, 80 A Alternators>

© Rear bracket assem bly 7 Rear bracket *14 Rear bearing
® Stator 8 Pulley and fan # Rotor
3 Rectifier (9) Pulley (16' Front bracket assem bly
®A Rectifier <80A> (§> Fan 17 Cover
4 Regulator 11 Spacer 18 Cover
5 Brush 12 Rotor assem bly *19 Front bearing
6 Brush spring 13 Spring @ Front bracket
Parts marked with * sh o u ld not be rem oved u nless defects are evident.
For parts with an encircled num ber, refer to D isa sse m b ly Procedure that follow s.
16-55
<35 A Alternator>
B6000A
D isasse m bly sequence

© Rear bracket assem bly 7 Sringa Front bracket
© Stator 8 Rectifier 15 Rotor assem bly
3 Plate @ Rear bracket *16 Rear bearing
4 Brush © Pulley © Rotor
5 Brush spring 11 Front bracket assem bly
6 Regulator and brush 12 Cover
holder *13 Front bearing
Parts marked with * sh o u ld not be rem oved u n less defects are evident.
For parts w ith an encircled number, refer to D isa sse m b ly Procedure that follow s.
16-56
Disassembly Procedure
The inspection procedure is alm ost the sam e for all
alternators. For clarity, the instructions in this section
are written for 30 A alternators, and extra notes are pro
vided for other models where necessary.
(1) Separation of front bracket assem bly from rear
bracket assem bly
2. At time of separation, use care not to lose the

spring fitted to the Outside of the rear bearing.
(2) Removal of pulley
Rem ove the through bolt and, using a screwdriver, pry

off the front bracket assem bly from the rear bracket
assembly.
NOTE:
Hold the rotor in a vice, etc. and remove the pulley, fan
and front bracket.
NOTE:
1. The rear bearing is tightly fitted. Before separa

tion, therefore, preheat the bearing box of the rear
bracket by an air dryer to facilitate separation.
When holding the rotor in a vice, be sure to hold at

illustrated portion.
16-57
(3) Rem oval of stator coil (4) Separation of rectifier
<30 A Alternator> <35 A Alternator>
04787
Stator <80 A Alternator>
B1031C
<35 A Alternator>
Rectifier diode area
B3909A
Stator coil leads

Separate the rectifier by unsoldering the area shown.
Stator NOTE:
W hen unsoldering, finish it in a short time {less than 5
04760 seconds) w ith a soldering iron.
<80 A Alternator>
Rectifier diode area
Stator coil leads

B1950A
To rem ove the stator coil, unsolder the stator coil leads
soldered to the rectifier.
NOTE:
W hen unsoldering, finish it in a short time (less than 5
seconds) with a soldering iron.
16-58
5.4.3 Inspection
<30 A, 80 A Alternator>
Item NV L
Field coil resistance 30 A Approx. 8.7 A -
80 A Approx. 7.2 A -
Slip ring O.D. 40.8 to 41.2 40.4
Ground test - -
Brush length
Open circuit test
Ground test
Short circuit test

Brush spring tension
Open circuit test
NV 3.1 to 4.3 N
{0.32 to 0.44 kgf} B3907F
NV .. Nominal Value L 2 N {0.2 kgO
L Limit
<35 A Alternator>
Item NV L
Field coil resistance 9 to 10.4 A -
Slip spring O.D. 33 32.4
Ground test - -
Brush length
NV 18.5
L 5
Open circuit test
Ground test
Short circuit test
Open circuit test
B6000B
16-59
Inspection Procedure (2) Inspection of rotor

The inspection procedure is alm ost the sam e for all (a) Continuity between slip ring and core
alternators. For clarity, the instructions in this section
are written for 30A alternators, and extra notes are pro
vided for other m odels where necessary.
(1) Inspection of stator
(a) Continuity across leads
Check that there is no continuity between the slip ring

and core.
If there is, replace the rotor as it is grounded.
(b) Field coil resistance
Check that there is continuity across stator leads. If

there is no continuity, indicating a broken wire, replace
the stator.
(b) Continuity across stator leads and core
M easure the resistance across slip rings. Replace the

rotor if the resistance is not within the specification.
Check that there is continuity across the stator leads

and core.
If there is, replace the stator as it is grounded.
16-60
(c) Slip ring O.D.
Measure the slip ring O.D. If the slip ring has rough sur
face or is unevenly worn, correct with sandpaper or
lathe.
Correction must be made within the limit of slip ring
O.D.
(3) Inspection of brush and brush spring
(a) Inspection of brush
If the spring pressure is lower than the limit, replace,

(c) Replacement of brush and brush spring
• Unsolderthe position show n in the illustration and

remove the brush and brush spring.
Replace the brush if it is w orn beyond the limit.
16-61
• Insert the brush into the regulator and brush

holder, making sure it faces in the direction shown.
Then, resolder the unsoldered points.
NOTE:
Be sure to use a soldering iron to remove and replace
the solder. Apply the soldering iron for as short a time
as possible (within 5 seconds).
(4) Inspection of rectifier
M easure resistance of each diode. M easure both when
with the circuit tester (+) probe applied to the diode and
when with the (-) probe applied to the diode.
• If resistance is infinite in both cases, the diode is
open.
• W hen soldering the brush, insert a pin into the
• If resistance is close to zero in both cases, the diode
brush hole and fix to the regulator assembly.
is shorted.
NOTE: In the case of open or shorted diode, replace the recti
When soldering or unsoldering, work quickly (within fier.
about 5 seconds) with a soldering iron. M easure according to the following procedures.
<35 A Alternator>
B6001A
• U nsolder the parts of the regulator and brush

a ssem b ly sh o w n in the illustration. Then, with
draw the brush and brush spring.
04785
16-62
(a) M easurem ent of diode mounted to heat sink (6 Measure between the heat sink and stator coil lead
places) connections.
(b) Measurem ent of diode trio (3 places)
Stator coil lead
wire connections
(3 places)
B2720A
B2721A
<35 AAIternator> M easure between the plate connecting to the regulator

and the stator coil lead connections.
(5) Inspection of bearings
Replace the bearing if defect is evident.
(a) Replacement of front bearing
(Removal)
B2724A
04788 1) Remove the bearing cover.
16-63
B 2725A
2) A p p ly a rod to the spacer on the front side of the 2) Install the cover and strike the spacer with a soft
front bracket and strike out the bearing. hammer, etc. to make sure that the bearing and
(Installation) cover are in contact with each other. If not, strike
the spacer to bring them into contact.
(b) Replacement of rear bearings
(Removal)
Rear bearing
B2731D
NOTE:
Use care not to cause damage to the slip ring by the
bearing puller.
1) A p p ly a light coat of engine oil to the outside of the

bearing and install to the inside of the front bracket
u sin g a press.
Install flush with the cover m ounting portion.
16-64
(Installation)
Apply a light coat of engine oil to the inside ofthe bear

ing and using a press, install with the spring fitting
groove ofthe bearing facing the rotor field coil side.
16-65
5.4.4 Reassem bly
<30 A Alternators>
B2990L
<80 A Alternator>
C om p onents R ea sse m b ly se q ue nce
1: 3 , 3 A < 80 A only>, 4, 5, 6, 7 11 “ |
12: 13, 14, 15 16 (20— ^->19—>18-*17)->12 {15—»14— »8 (10-^9)-*2-»!.i(7 -» ft'-» 6 -» 5 -» < S-^ fA < 8 0 A o n ly > )
16: 17, 18, 19, 2 0 For parts with an encircled number, refer to R easse m b ly Procedure that follow s.
16-66
<35 A Alternator>
Com ponents R ea sse m b ly sequence
1: 3, 4, 5, 6, 7, 8, 9 11 (14->13->12)->15 (17-»16)->10->2-»1 (9->7-+6-*5->4->8->3)
11. 12, 13, 1 4 por parts w jth an encircled number, refer to R ea sse m b ly Procedure that follow s.
15: 16, 17
B6002A
16-67
Reassem bly Procedure (3) Installation of front bracket and rear bracket
(1) Installation of rectifier <80 A alternator> assem bly
W hen the rectifiers are to be connected together by sol (a) Push in the brush by hand and insert the pin into
dering, do the soldering with the regulator as well as the brush hole from the rear of the rear bracket to
the rectifiers mounted to the rear bracket. fix the brush.
NOTE: (b) Keeping this condition, install the rear bracket
W hen soldering, finish it in a short tim e (less than 5 assem bly to the front bracket assembly.
seconds). NOTE:
(2) Installation of spring (30 A, 80 A Alternators) After completion of reassembly, be sure to remove the
pin and close the hole.
5.4.5 Inspection and adjustm ent after installation
(1) Handling precautions
W hen servicing the alternator, observe the following
precautions.
Install the spring with its highest point seated in the

deepest of the spring fitting groove of the bearing.
02369
(a) Never connect the battery reversely.

If the polarity of the battery is reversed when con
nections are made, a large current flows from the
battery to alternator, dam aging the diode and 1C
. regulator.
16-68
(b) D o not disconnect the battery terminal connec (e) Operating the alternator with its " B " and " L " termi
tions while the engine is running, or a surge volt nals shorted results in the dam aged diode trio.
age develops deteriorating the diode and regula
tor.
(f) W hen quick-charging the battery with a quick char

ger, be sure to disconnect terminal connections in
(c) Do not use a m egger or other high-voltage multi advance. Otherwise, a dam aged diode and regula
meter, or dam aged'diode and regulator will result. tor will result. .
(d) Do not expose the alternator to the water. If the

alternator is exposed to water, short circuit may
result, causing damaged alternator.
16-69
(2) Performance test • W hile gradually increasing the alternator speed

(a) Test bench inspection and reducing the load resistance, measure the cur
rent value with the specified terminal voltage and
speed.
If the measurement is below the specification,
check alternator parts.
Output current
30 A alternator 1,500 rpm, 27 V 17 A or more

(when cold)
2,500 rpm, 27 V 26 A or more

(w hen hot)
2,500 rpm, 27 V 29 A or more

(when cold)
2,500 rpm, 27 V 71 A or more
Perform the test using the circuit show n above.

• W ith the load resistance set at m axim um (m eaning
that there is alm ost no load current flowing), close
sw itches K-| and K2.
16-70
(b) On-vehicle inspection (3) Inspection of regulator
(a) Test bench inspection
• Provide a switch between the battery and alterna

tor " B " terminal. With the switch turned off, con
nect an ammeter (with 60 A full-scale to the 30 A
alternator and 100 A full-scale to the 35 A, 80 A
alternator) and voltmeter.
• Turn on the switch and make sure that the voltme
ter indicates the battery voltage.
• Start up the engine and immediately turn on all
lamp switches. Then, increase the engine speed
and read the m axim um current value when the
alternator speed reaches 5000 rpm.
• If the current reading is 7 0 % or more ofthe nominal
output, the alternator m ay be regarded as in good
condition.
NOTE:
The on-vehicle test is an easier w ay of inspection; the
test bench inspection is necessary for more accurate
results.
Inspect the regulator regulated voltage as follows

using the circuit shown above.
• Use a fully-charged battery. Turn on the switch.
• Gradually increase the alternator speed up to 5000
rpm. Check that the current value at this speed is 5
A or less.
16-71
The regulator is in good condition ifthe regulated

voltage underthis condition is within specification.
If not, replace the regulator assembly.
Nom inal value 28 to 29 V
(b) On-vehicle inspection
• C o n n e c t a voltm eter and a m m e te r and provid e a

switch as shown.
• The regulator is in good condition ifthe voltmeter
registers 0 w hen the switch turns ON. Ifthe voltm e
ter pointer deflects, the alternator or w iring is
defective.
• W ith the ammeterterminal shorted to preventflow
of the starter current through it, start the engine.
• Increase the engine speed to around 2000 rpm and
read the regulated voltage value ifthe charge cur
rent is 5 A or less. If the charge current is 5 A or
more, continue charging for a while or replace the
battery with a fully-charged one. Or 1/4 Q. (25 W)
resistor m ay be connected in series to the battery
to limit the charge current.
• If the m easurem ent is out of specification, replace
the regulator assembly.
16-72
5.5 40 A, 50 A Alternators (b ru sh le ss type)
5.5.1 Rem oval and installation [Refer to the instruction in Section 5.4.1]
5.5.2 Disassem bly
43439

© Rotor assem bly *0.1.) Stator
1 Nut
7 Cover 0?) Regulator
® Pulley
*8 Front bearing 0.3) Rectifier
© Fan
4 Sp ace r © Front bracket Oi) Rear bracket
*5 Rear bearing 0.0) Field coil
Parts marked with * should not be removed unless defects are evident.
For parts with an encircled number, refer to Disassem bly Procedure that follows.
16-73
Disassem bly Procedure (2) Removal of pulley

(1) Separation of front bracket assem bly from rear
bracket assem bly
Hold the rotor in a vice, etc. and remove the pulley, fan
and front bracket.
Rem ove the through bolt. Using a screwdriver, pry off NOTE:
the front bracket assem bly from the rear bracket
assembly.
NOTE:
When holding the rotor in a vice, be sure to hold at

illustrated portion.
The rear bearing is tightly fitted. Before separation,

therefore, preheat the bearing box of the rear bracket
by an air dryer to facilitate separation.
16-74
(3) Rem oval of stator coil (4) Separation of rectifier from regulator
Rectifier
Stator 02335 _____________________________________________________ B3866A
To remove the stator coil, unsolder the stator coil lead To separate the rectifier from the regulator, unsolder
wires from the rectifier at three places. ing the connection shown.
NOTE: NOTE:
Unsolder within as short a time as possible (within 5 Unsolder within as short a time as possible (within 5
seconds) using a soldering iron. seconds) using a soldering iron.
16-75
5.5.3 Inspection
Item NV
Field coil resistance 40A 6.1 to 7.2 O
50A 6.1 to 7.2 0
G rou nd test -
S h o rt circuit test
O pen circuit test
Open circuit test
G rou nd test
43442
16-76
Inspection Procedure In the case of open or shorted diode, replace the
(1) Inspection of stator rectifier.
(a) Continuity across leads M easure according to the following procedures.
(a) Measurem ent of diode mounted to heat sink (40 A:
6 places, 50 A: 8 places)
Check that there is continuity across stator leads. If

there is no continuity, indicating a broken wire, replace
the stator.
(b) Continuity across stator leads and core
M easure between the heat sink and stator coil lead

connections.
(b) Measurem ent of diode trio (3 places)
Check thatthere is no continuity across the stator leads

and core.
If there is, replace the stator as it is grounded.
M easure resistance of each diode. M easure both when
with the circuit tester (+) probe applied to the diode and
when with the (-) probe applied to the diode.
• If resistance is infinite in both cases, the diode is
open.
• If resistance is close to zero in both cases, the diode
is shorted.
M easure between the plate connecting to the regulator
and the stator coil lead connections.
16-77
(3) Inspection of field coil 2) Apply a rod to the spacer on the front side of the
front bracket and strike out the bearing.
<lnstallation>
M easure the resistance across field coil terminals and,

if the m easurem ent is out of specification, replace the
field coil.
(4) Inspection of bearing
Replace the bearing if defect is evident.
(a) Replacement of front bearing
<Rem oval>
1) Apply a light coat of engine oil to the outside of the

bearing and install to the inside of the front bracket
using a press.
In sta ll flu s h w ith th e c o v e r m o u n t in g portion.
2) Install the cover and strike the spacer with a soft

hammer, etc. to make sure that the bearing and
■ cover are in contact with each other. If not, strike
the spacer to bring them into contact.
16-78
(b) Replacement of rear bearing <lnstallation>
<Rem oval>
Rear bearing
02330
Apply a light coat of engine oil to the inside of the bear
ing and using a press, install with the spring fitting
groove of the bearing facing the rotor side.
13
R easse m b ly sequence
1 4 -> ® 9->8->7.
6- >
For parts with an encircled number, refer to R ea sse m b ly Procedure that follows.
43440
16-79
Reassem bly Procedure 5.5.5 Inspection and adjustm ent after installation
(1) Installation of regulator and rectifier The inspection and adjustment procedures for the 30
A, 80 A alternator are applicable. Refer to Section 5.4.5
and use the following specifications.
<Alternator output current>
Output current
40 A alternator 1,500 rpm, 27 V 30 A or m ore

(when cold)
2,500 rpm, 27 V 41 A or m ore

(when cold)
2,500 rpm, 27 V 47 A or m ore
<IC regulator regulated voltage>
N o m in al value 28 to 29 V
(5000 rpm.
Solder the regulator to the rectifier with the two parts 5 A or less)
installed to the rear bracket.
NOTE:
Solder within as short a time as possible (within 5
seconds) using a soldering iron.
(2) To install the stator coil, reverse the order of d isas
sembly. [Refer to Item (3), Section 5.5.2.]
(3) Installation of spring
Install the spring with its highest point seated in the

deepest of the spring fitting groove of the bearing.
16-80
5.6 80 A Alternator (brushiess type)
5.6.1 Rem oval and installation [Refer to the instruction in section 5.4.1]
5.6.2 Disassembly

® Pulley and fan 5 Cover (9) Stator
@ Front bracket *6 Front bearing # Regulator
(3) Rotor 7 Oil seal •It.’ Rectifier
*4 Rear bearing 8 Field coil © Rear bracket
Parts marked with * should not be rem oved u n less defects are evident.
For parts with an encircled number, refer to the D isa sse m b ly Procedure that follows.
16-81
Disassem bly Procedure Be sure the vise grips the rotor only at the points illus
(1) Separation of front bracket and rear bracket trated.
(3) Removal of rotor
Rem ove the through bolt. Then, pry apart the front
bracket and rear bracket using a screwdriver. The rotor and front bracket are held together by a nut.
(2) Rem oval of pulley and fan Take off the nut before rem oving the rotor.
(4) Rem oving stator
Secure the rotor in a vise, then- remove the pulley and

fan.
Unsolder the stator coil leads from the rectifier (3
NOTE: places) before rem oving the stator.
NOTE:
16-82
(5) Separation of rectifier and regulator Separate the rectifier and regulator by unsoldering the
joint show n in the illustration.
NOTE:
5.6.3 Inspection
Item NV
Field coil resistance 6.8 to 8.0 Cl
N V .. N om inal Value
S h o rt circuit test
O pen circuit test
O pen circuit test
G rou n d test
43444
16-83
Inspection Procedure If any diode is either open-circuited or short-cir

(1) Stator inspection cuited, the rectifier m ust be replaced. Take m ea
surements in accordance with the following
(a) Continuity of leads
instructions.
(a) Measurem ent across heat sink and diodes (8
places)
Check for continuity between each pair of stator coil

leads. If any test sh o w s
a lack of continuity, a lead is broken and the stator m ust
be replaced
(b) Continuity between stator leads and core
M easure the resistance between the heat sink and sta

tor coil lead connection points.
(b) Diode trio m easurem ents (3 places)
Confirm that there is no continuity between the stator

leads and core. If continuity exists between any lead
and the core, the stator is grounded and m ust be
replaced.
M easure the resistance of each diode. Take m easure
ments first with the tester's (+) probe applied to the
diode, then with the tester's (-) probe applied to the
diode.
• If both m easurem ents show infinite resistance, the
relevant diode is open-circuited.
M easure the resistance between the stator coil lead
• If both m easurem ents show resistance of close to
connection points and the plate that leads to the regu
zero, the relevant diode is short-circuited.
lator connections.
16-84
(3) Field coil inspection 1) Rem ove the bearing cover.
M easure the resistance between the field coil termi 2) Apply a ro d to th e sp a ce ro n th e fro n tsu rfa ce o fth e
nals. If the m easurem ents are out of specification, front bracket. Tap out the bearing with a hammer.
replace the field coil. <lnstallation>
(4) Bearing inspection
Replace any bearing that appears defective.
NOTE:
If the front bearing is replaced, the oil seal must also be
replaced.
(a) Front bearing replacement
<Rem oval>
1) In se rt the oil seal in the position show n and pack its

lip with grease. Next, apply a thin film of engine oil
to the bearing's outer periphery. Finally, press-fit
the bearing until it is flush with the cover m ounting
surface.
16-85
<lnstallation>
2) Fit the cover.

(b) Rear bearing replacement
<Rem oval>
Rear bearing
02330
16-86
43438
12—» ® — »8-»2—>7—>6->5-»3-»4—
For parts with an encircled number, refer to R e a sse m b ly Procedure that follow s.
Reassembly Procedure Fit the regulator and rectifier into the rear bracket
(1) Regulator and rectifier installation before soldering them.
NOTE:
Be sure to use a soldering iron and apply it for as short
a time as possible (within 5 seconds).
(2) Install the stator. The stator installation sequence is
the opposite of the disassem bly sequence (refer to
item (4) of section 5.6.2).
(3) Install the pulley and fan. The pulley and fan instal
lation sequence is the opposite of the d isassem bly
sequence (refer to item (2) of section 5.6.2).
16-87
5.6.5 Inspection and adjustm ent after reassem bly (b) On-vehicle test
(1) Read and adhere to the precautions given in item
(1) of section 5.4.5.
(2) Performance test
(a) Bench test
• Connect a switch between the battery and terminal

B ofthe alternator. With the switch open, connect
an ammeter (with a capacity of at least 90 A) and
voltmeter.
• Close the switch and confirm that the voltmeter
indicates the battery voltage.
• Start the engine and immediately switch on all the
vehicle's lam ps to increase the engine speed.
Observe the m axim um ammeter reading when the
alternator speed reaches 5,000 rpm.
• If the ammeter reading is at least 7 0 % ofthe alter
nator's rated output current, the alternator m ay be
considered usable.
NOTE:
On-vehicle tests provide only a rough indication of
Carry out testing with the circuit connected as show n
altern ator perform ance. M o r e precise te s t s on a bench
above.
must also be carried out.
• Setthe load resistorfor m axim um resistance (such
that alm ost no current flows), then close switches
Ki and K2.
• Gradually increase the alternator speed and
reduce the load resistance. M easure the current
flowing w hen the alternator's terminal voltage and
speed reach the specified nom inal values. If the
m easurem ent is out of specification, inspect the
alternator.
Output current

(w hen cold)
2,500 rpm, 27 V 86 A or m ore
16-88
(3) Regulator tests (b) On-vehicle test
(a) Bench test
Connect an ammeter, voltmeter, and switch

between the harness and alternator, as illustrated.
Close the switch and confirm that the voltmeter
reading is zero. If the voltmeter needle m oves, the
alternator or wiring is defective.
So that no current flow s through the ammeter
when the engine is started, short-circuit the am m e
ter terminals. Then, start the engine.
If the charging current is 5 A or less w hen the
engine speed reaches 2,000 rpm, observe the regu
lated voltage reading. If the charging current
Check the regulated voltage with the circuit connected exceeds 5 A, either wait for the battery to charge or
as show n above. replace the battery with a fully charged one. Alter
• Using a fully charged battery, close the switch. natively, connect a 0.25 Q (25 W) resistor in series
Gradually increase the alternator speed. Confirm with the battery to su ppress the charging current.
that the current flowing is 5 A or less when the If the regulated voltage does not conform with the
alternator speed reaches 5,000 rpm. specified nominal value, replace the regulator
• If the voltage (regulated voltage) at this time con assembly.
form s with the specified nominal value, the regula
tor is usable. If the voltage does not conform with
the nominal value, replace the regulator assembly.
N o m in a l value 28 to 29 V
16-89
5.7 150 A A lte rn ator

5.7.1 Rem oval and installation (Refer to the instructions in section 5.4.1)
5.7.2 D isasse m b ly
12 \
3
43436

© Rear bracket assem bly 7 Pulley and fan Rotor
(2) Field coil (8) Pulley Front bracket assem bly
<D Stator ® Fan 15 Cover
Rectifier ($> Nut *16 Front bearing
© Regulator 11 Rotor assem bly 17 Oil seal
6 Rear bracket *12 Rear bearing © Front bracket
Parts m arked with * sh o u ld not be rem oved u n le ss defects are evident.

For parts w ith an encircled num ber, refer to the D isa sse m b ly Procedure that follow s.
16-90
D isassem bly Procedure (2) Rem oval of stator
(1) Separation of front bracket assem bly and rear
bracket assembly
Before rem oving the stator, unsolder the stator coil

leads from the rectifier (eight places).
Rem ove the through-bolts, then separate the front NOTE:
bracket assem bly and rear bracket a ssem b ly by prying Unsolder the connections using a soldering iron. Do
them apart at the point show n in the draw ing with a not apply the soldering iron for longer than five
screwdriver. seconds.
NOTE: (3) Separation of rectifier and regulator
Rectifier
02326
1. When removing the field coils, remove the tw o Separate the rectifier and regulator by unsoldering
" A " screws and the three " B " screws in that them at the point show n in the drawing.
sequence. Removing the screws in the opposite
NOTE:
sequence would result in dam age to the field coils'
Unsolderthe connection using a soldering iron. Do not
leads.
apply the soldering iron for longer than five seconds.
2. When removing the three " B " bolts, support the
coils by hand to prevent them from falling under
their own weight.
3. When the coils are removed, their leads may catch
on the stator coils. Do not pull the coils out with
excessive force.
16-91
(4) Rem oval of pulley (5) Removal of rotor
Hold the rotor in a vise before rem oving the pulley, fan, The rotor is retained on the front bracket by a nut.
and front bracket. Rem ove the nut before removing the rotor.
NOTE:
Hold the rotor in the vise at the points show n in the

drawing.
16-92
5.7.3 Inspection
Item NV L
Field coil resistance 4.4 to 5.2 Cl -
G rou nd test -
^ M i , -
Short circuit test
Open circuit test
L Limit O pen circuit test
G rou nd test
43445
Inspection Procedure Check for continuity between each pair of leads. If any
(1) Inspection of stator check sh ow s a lack of continuity, a lead is broken and
(a) Continuity between leads the stator m ust be replaced.
NOTE:
Each of the stator's two coils has four leads.
1. Continuity should exist between any pair of leads
in each four-lead set.
2. Continuity should not exist between any lead in a
four-lead set and any lead in the other four-lead
set.
16-93
(b) Continuity between leads and core Take m easurem ents in accordance with the following
instructions:
(a) Measurem ent across heat sink and diodes (8
places)
Check for continuity between the stator leads and core.

If continuity exists, the stator is grounded and m ust be
replaced.

M easure the resistance of each diode. Take m easure
m ents first with the tester's (+) probe applied to the
diode and then with the tester's (-) probe applied to the
diode.
• If both m easurem ents sh o w infinite resistance, the
relevant diode is open-circuited.
• If both m easurem ents sh ow resistance of close to
zero, the relevant diode is short-circuited.
If any diode is open-circuited orshort-circuited.the rec
Measure the resistance between the heat sink and the
tifier m ust be replaced.
stator coil lead connection points.
(b) Diode trio m easurem ents (3 places)
M easure the resistance between the stator coil lead

connection points and the plate that leads to the regu
lator connections. .
16-94
(3) Field coil inspection
16585
2) Apply a rod to the spacer on the front surface of the

M easure the resistance between the field coil termi front bracket. Tap out the bearing with a hammer.
nals. If any measurement is out of specification,
<lnstallation>
replace the field coil.
(4) Bearing inspection

Replace any bearing that appears defective.
(a) Front bearing replacement
<Rem oval>
1) Rem ove the bearing cover.
Press-fit the front bearing into the inside of the front

bracket. Press the bearing until its surface is flush with
the cover m ounting surface.
16-95
(b) Rear bearing replacement

<Rem oval>
Rear bearing
B2731C
<lnsta!lation>
Press-fit the inner race with a press until it m oves no

further.
16-96
5.7.4 Reassembly
Com ponents R e a sse m b ly sequence
1: 4 ,5 ,6 14 (15—>16—>17—»18)-»11 (13->12)—>7 (10—»9—>8) —>1—^(6— 4- — 5') —>'3 —>2
7. 8, 9, 10 por parts wjth an encircled number, refer to R easse m b ly Procedure that follow s.
11: 12,13
14: 15,16,17,18
43437
Reassembly Procedure Solder the regulator and rectifier after installing them
(1 ) Installation of rectifier and regulator in the rear bracket.
NOTE:
Solder the connections using a soldering iron. Do not
apply the soldering iron for longer than five seconds.
(2) Install the stator coils by following the removal
procedure in reverse (see 5.7.2 (2)).
(3) Install the pulley and fan by following the removal
procedure in reverse (see 5.7.2 (4)).
16-97
5.7.5 Inspection and adjustm ent after reassem bly (b) On-vehicle test
(1 ) Cautions for handling (see 5.4.5 (1)).
(2) Performance tests

(a) Bench test
Voltmeter
B3623S
NOTE:
Turn OFF the battery switch before disconnecting the
harness from the alternator's B terminal.
• Connect a switch between the battery and the alter
Carry out testing with the circuit connected as sh o w n in nator's B terminal. With the switch open, connect
the draw ing above. an ammeter (with a capacity of at least 100 A) and a
• Setthe load resistorfor m axim um resistance (such voltmeter.
that alm ost no current flows), then close switches • Close the switch and confirm that the voltmeter
«i and K 2. indicates the battery voltage.
• Gradually increase the alternator speed and • Start the engine then promptly switch on all the
reduce the load resistance. M easure the current vehicle's lam ps and increase the engine speed.
flow ing w hen the alternator's terminal voltage and Observe the m axim um ammeter reading when the
speed reach the specified nominal values. If either alternator speed reaches 5,000 rpm (with an
m easurem ent is out of specification, inspect the engine speed of approximately 1,890 rpm).
alternator. • If the ammeter reading is at least 7 0 % of the alter
nator's rated output, the alternator m ay be consid
Nom inal values
ered usable.
---------- ------------ Output current NOTE:
Alternator 1,500 rpm; 27 V 104 A or higher On-vehicle tests provide only a rough indication of
(when cold)
2,500 rpm; 27 V 154 A or higher alternator performance. An accurate indication can be
obtained only from a bench test.
16-98
(3) Regulator tests (b) On-vehicle test
(a) Bench test
• Pull the cover off the B terminal, then connect the

(+) terminal of a voltmeter to the exposed B term i
nal.
• Set the engine speed at approximately 2,000 rpm.
Provided the charging current is 5 A or less at this
time, read the voltage at the B terminal. If the
charging current is higher than 5 A, either wait for
the battery to charge or replace the battery with a
fully charged one.
• If the regulated voltage is out of specification,
check the alternator again on a test bench.
Check the regulated voltage with the circuit connected NOTE:
as show n in the drawing above. Perform this test with all electrical loads turned off.
• U sing a fully charged battery, close the switch.
Gradually increase the alternator speed. Confirm
that the current flowing is 5 A or less w hen the
alternator speed reaches 5,000 rpm.
• If the voltage (regulated voltage) at this time is.
within specification, the regulator is normal. If the
voltage is out of specification, replace the alterna
tor assembly.
N o m in a l value 28 to 29 V
5.8 Safety Relay Inspection Measure voltage at each terminal in the sequence
<R8T30171, R8T30172, R8T30174, R8T30274> show n below to identify faulty parts.
(a) On-vehicle test
S e q u e n ce E ngin e operation V oltage at term inal " P " Voltage at terminal " S " Voltage at term inal " R " or " L "
1 Starter sw itch O N • 1 V or le ss Term inal " R "

• (+) diode shorted if clo se to • A pp rox. 24 V
battery voltage • If 0 V, w iring is faulty
Terminal " L " (with charge
lam p)
• A pprox. 24 V
Terminal “L " (with charge
lam p)
• A pprox. 3 V or less
• If close to battery voltage,
w irin g alternator is faulty
2 D u rin g cranking • Approx. 1 V or less

• If close to battery voltage,
safety relay is faulty (crank
ing im possible)
3 Idlin g (600 rpm or higher) • A pp rox. 13 to 16 V • A bulb connected between

(Be sure to use a n a lo g type battery and term inal " S "
tester) d oes not com e on
• If bulb c o m e s on despite
norm al terminal " P " voltage
(show n to left), replace
safety relay and test again
(b) C om ponent test

The resistance value between terminals " R " and " L "
shall be within specified range.
16-100
5.9 Preheater 5.9.2 Heater relay
5.9.1 Intake air heater Inspection
(1) Rem oval and installation

(Refer to Group 15 intake and Exhaust.)
(2) Inspection
Air heater
Starter switch
w
<6D22j_22-T, 24-T>
OFF
HEAT
O
o— -o —
o—
O - - o
- o
—o
rM SSS® -
<6D22-TC, 24-TC>
O
o -|
n >
START
B R1 ACC R2 C
Heater relay
\
Fuse
A ir heater
Battery switch J indicator
Battery
(1) Inspection of fuse

If there is any abnormality, replace the fuse A (127A).
D8803C
(2) Inspection of relay
Perform the following inspection and check the func Perform continuity and operation checks in accor
tion of each part or the wiring if necessary. dance with the following table.
(a) Time required before indicator becom es red-hot:
1 2 3 4 5
Standard time: 40 to 60 seconds (S i termi (S 2 termi (B term i (S W ter (B ody)
nal) nal) nal) minal)
(b) Check each terminal of the air heaterfor looseness
Not L> ■■ ■* O
and the heater element for dam age and contact ener
with other parts. gized
Ener U '.... . , (j u D
gized
0 - 0 Continuity exists between terminals.

© - © Term inals a cross w hich 24 V D C is applied
A: Fuse (127 A)
• Replace the relay if the result of any check is unsat
isfactory.
16-101
5.10 A u to m a tic S to p S y ste m

5.10.1 S h u t dow n type
(1) Adjustm ent and inspection of stop solenoid
Sole n oid N V .. N o m in a l Value
Sw itch
18822 ©43931
(a) Adjustm ent of stroke (b) Check of operation

1) Connect the rod between the stop lever and the After adjusting the stroke, energize and de-energize
solenoid. the solenoid two or three times then perform the fol
2) Turn on the switch to activate the solenoid, then lowing checks:
adjustthe rod length so thatthe clearance between 1) Check that the stop lever, rod, and solenoid move
the base lever and case stopper is within specifica sm oothly between the run and stop positions.
tion. Finger-tighten the lock, nut at each end of the 2) Check that the clearance between the base lever
rod. and case stopper is within specification.
NOTE: 3) Check that the check lamp illuminates or that the
D o n o t s u p p ly current to th e so le n o id for lo n g e r th a n current flowing to the solenoid is within specifica
20 se c o n d s. E n e rg iz in g th e so le n o id fo r lo n g e r cou ld tion.
m a k e th e so le n o id burn out. NOTE:
3) Turn off the switch. D o n o t sw itc h the so le n o id b ack an d forth betw een its
energized and de-energized sta te s rapidly.
16-102
(2) Solenoid relay 3) Manual stop timer
(a) Unit test W hen the push switch C (stop switch) is set to ON,
the solenoid will be operated. Operate a stop
watch as soon as the stop switch C is set to OFF, and
measure the time required before the solenoid is
Sole n oid relay reset.
Terminal voltage
Checking oil
Afterthe tests of the above items 1) and 2), allow 5
pressure timer: B C ST W A
7777
minutes before m aking retests. It takes 5 m inutes
DC28.5V SW ®
Lsw ® before the capacitor C t which is an element of the
Checking
stop timer: I Terminal time constant of the oil pressure timer finishes dis
I— voltage
DC24V SW © DC28.5V
charging.
Sole n oid or coil load:

30 A + 3 A
SW ®
SW ®
ON
18±5" c" n c c
Oil pressure timer
SW ® ----------
30a=5“ ,
Sto p tim er I
Test schedule
Legend
SW ® Sn a p sw itch A
SW ® S n a p switch B
SW ® S n a p switch C
D9558A
Make connections as show n above and perform the

following checks.
1 ) Oil pressure timer
Set the snap switch A to ON. Operate a stop watch
as soon as the snap switch B is set to ON, and mea
sure the time required before the solenoid is oper
ated.
2) Stop timer
Set the snap switch B to OFF 5 seconds after the
solenoid has been operated. At the sam e time,
using a stop watch, m easure the time required
before the solenoid is reset.
The snap switch B is set to OFF 5 seconds after
operation of the solenoid because if the solenoid is
operated, it takes 5 seconds before the alternator
voltage disappears.
16-103
(b) On-vehicle inspection

Check the solenoid relay according to the following
flowcharts and determine whether it is good or not on
the basis of the terminal voltage, etc. m easured in the
individual states.
• The terminal sym b ols denote those of the solenoid
relay.
• The voltage 24 V m eans the battery voltage.
Perform m e asure m en ts w ith engine running
16-104
Perform m e asure m en ts with engine running
(3) Therm o switch (b) Confirm that there is no continuity between the ter
The thermo switch w on't operate if the tempera minals, then begin heating the test fluid.
ture-sensing portion is not in contact with coolant. NOTE:
If the coolant level is low or if there is only steam, S tir the liquid to e nsu re th a t it h e a ts up uniform ly.
the thermo switch w on't operate completely.
(c) Measure the fluid temperature when the therm o
static switch operates and continuity appears
between its terminals.
N O T E:
Increase th e fluid te m p e ratu re very s lo w ly a s it
a p p ro a ch e s the o p e ra tin g te m perature of th e th e r m o
static sw itch. (W he n th e fluid te m pe rature is 5°C
b e lo w the o p e ratin g tem perature, m ain tain th is t e m
perature for 5 m inu te s. Then, increase th e te m p e r a
ture b y 1°C every 2 to 3 m inutes.)
(d) Briefly continue increasing the fluid temperature,

then allow the fluid to cool. Measure the fluid tem
perature when the thermostatic switch operates
and continuity between its terminals disappears.
Calculate the difference between the upper and
lower operating temperatures, and check that it is
correct.
B5329A
Inspection
(a) Set a circuit tester to measure resistance, then
apply its probes to the thermostatic switch termi
nals. Put the thermostatic switch into glycerin upto
the end of its threaded section.
16-105
Inspection
(a) Connect the pipes as show n in the above illustra
tion. Then, set a tester to m easure resistance and
apply its probes to the oil pressure switch termi
nals.
(b) With cocks A and B closed, start the engine. W hen
the oil pressure increases, fully open cock A to
apply pressure to the oil pressure switch.
(c) Close cock A to cut the oil passage from the engine
and maintain the accumulated pressure in the oil
sump.
(d) Confirm that there is no continuity between the oil
pressure switch terminals.
(e) Gradually open cock B to reduce the oil pressure.
O bserve the test oil pressure gauge indication
w hen the oil pressure switch operates and continu
ity appears between its terminals.
16-106
5.10.2 Run-on type
(1) Stop solenoid
Sole noid
position
18822 043930
(a) Adjustment of stroke (b) Check of operation

1) Connect the rod between the stop lever and the After adjusting the stroke, energize and de-energize
solenoid. the solenoid two or three times then perform the fol
2) Turn on the switch to activate the solenoid, then lowing checks:
adjust the rod length so thatthe clearance between 1 ) Check that the stop lever, rod, and solenoid m ove
the base lever and case stopper is within specifica sm oothly between the run and stop positions.
tion. Finger-tighten the lock nut at each end of the 2) Check that the clearance between the base lever
rod. and case stopper is within specification.
NOTE: 3) Check that the check lamp illuminates or that the
D o n o t su p p ly current to the so le n o id fo r lo n g e r th a n current flowing to the solenoid is within specifica
20 se co n d s. E n e rgiz in g the so le n o id fo r lo n g e r co u ld tion.
m a k e the so le n o id burn out. NO TE:
3) Turn off the switch. D o not sw itch th e so le n o id back and forth b e tw e e n its
energized and de-energized sta te s rapidly.
16-107
(2) Solenoid relay

(a) Unit test
B C H S
SW 2
SW 3
SW i
u
Term inal voltage
24V
D e lay time So le n o id or coil load 30A±3A

N V 26 to 34 sec.
77T
D9564A
W ire as show n and check the following.

1) Relay operation and delay time
a) Check if the solenoid is energized when switches
S W i and S W 2 are turned ON.
b) U sing a stop watch, m easure the time required for
the solenoid to return after switch S W 2 is turned
OFF.
2) Relay holding
a) Turn O N switches S W i and S W 2 and, afterthe sole
noid is activated, turn O N the switch S W 3.
b) Turn OFF the switch S W 2 and make sure that the
solenoid rem ains activated for more than 34
seconds.
c) After verifying b) above, turn OFF the switch S W 3
to ensure that the solenoid returns.
16-108
(b) On-vehicle inspection • Terminal sym b ols denote those of the solenoid
Check the solenoid relay according to the following relay.
flowchart and determine whether it is good or not on * Voltage 24 V m eans the battery voltage,
the basis of the terminal voltage, etc. m easured in the
individual states.
16-109
Perform m e asu re m en ts with e n gin e running
Perform m e asu re m en ts with engine running
16-110
(3) Therm o switch (d) Briefly continue increasing the fluid temperature,
The thermo switch w on't operate if the temperature- then allow the fluid to cool. M easure the fluid tem
sensing portion is not in contact with coolant. If the perature w hen the thermostatic switch operates
coolant level is low or if there is only steam, the thermo and continuity appears between its terminals. Cal
switch w on't operate completely. culate the difference between the upper and lower
operating temperatures, and check that it is cor
rect.
(4) Oil pressure switch
Inspection
(a) Set a circuit tester to measure resistance, then
apply its probes to the thermostatic switch termi
nals. Put the thermostatic switch into glycerin up to Inspection
the end of its threaded section. (a) Connect the pipes as show n in the above illustra
(b) Confirm thatthere is no continuity between the ter tion. Then, set a tester to measure resistance and
minals, then begin heating the test fluid. apply its probes to the oil pressure switch termi
NOTE: nals.
Stir the liquid to ensure that it heats up uniformly. (b) With cocks A and B closed, start the engine. W hen
(c) M easure the fluid temperature when the therm o the oil pressure increases, fully open cock A to
static switch operates and the continuity between apply pressure to the oil pressure switch.
its terminals disappears. (c) Close cock A to cut the oil passage from the engine
and maintain the accumulated pressure in the oil
NOTE:
sump.
Increase the fluid temperature very slowly as it
(d) Confirm that there is continuity between the oil
approaches the operating temperature of the thermo
pressure switch terminals.
static switch. (When the fluid temperature is 5°C
(e) Gradually open cock B to reduce the oil pressure.
below the operating temperature, maintain this tem
Observe the test oil pressure gauge indication
perature for 5 minutes. Then, increase the tempera
when the oil pressure switch operates and the con
ture by 1°C every 2 to 3 minutes.)
tinuity between its terminals disappears.
16-111
16 ENGINE ELECTRICAL - TROUBLESHOOTING
6. TROUBLESHOOTING
Sym p tom Probable cause R em edy Ref. grou p
Starter w ill not Defective battery or low capacity Replace or charge

start
Defective w iring Correct
• Defective starter w irin g
• Defective starter relay w irin g
• Defective m agnetic sw itch w irin g
• Defective heater relay w irin g
• Defective starter sw itch w irin g
• Defective battery or battery sw itch w iring
Defective m agnetic sw itch Replace
Defective starter relay
W orn or d a m a ge d bin din g brush
Defective m otor Replace arm ature or yoke
Defective overrunning clutch Replace
Defective heater relay
Defective starter switch
Starter starts Pinion not m e sh in g with ring ge a r Replace starter relay or

but e n gin e d o es starter switch
not • Incorrect voltage at m agn etic sw itch " S " term inal
• Incorrect voltage at starter relay " S W " term inal
• W orn or d a m aged pinion Replace
• W orn or d a m a ge d ring ge ar Replace G roup 11
Pinion m e sh e s with ring ge a r but d o e s not turn C h arge or replace battery
• Defective battery or insufficient battery v oltage
• Insufficient brush contact Replace brush and/or brush

sprin g
• Defective overrunning clutch Replace
A lternator is Low V-belt tension Adjust G rou p 14

fun ction ing
n o rm a lly but D a m a g e d V-belt Replace
battery is
o v e rd isch a rge d Defective w iring Correct
• Defective alternator w iring
Defective battery Replace
16-112
ENGINE ELECTRICAL - TROUBLESHOOTING 16
S ym ptom 2 5 Probable cause Rem edy Ref. grou p
Battery is Defective alternator Replace

normal but is
overdischarged • Open circuit in stator coil
• Stator coil and core grou n ded
• S lip ring and rotor core grou n d e d (excluding brushless alter

nators)
• Defective field coil
• W orn slip ring (excluding bru sh le ss alternators)
• W orn brush (excluding b ru sh le ss alternators)
• Defective brush sp rin g (excluding b ru shless alternators)
• Defective rectifier
• Defective regulator
Charge lam p Defective regulator Replace

does not com e
on w hen engine
is stopped
(starter sw itch
ON)
Premature lo ss Defective alternator (See "Battery is n orm al but is overdis Replace

of battery elec charged".)
trolyte
H igh battery
electrolyte tem Defective regulator
perature
Engin e is hard Defective w iring Correct

to start
• Defective air heater w iring
• Defective heater relay w iring
• Defective water temperature se n s o r w iring
Defective heater relay or blow n fuse Replace
16-113
21
CLUTCH
CONTENTS
1. G E N E R A L ............................................. 2 5.2 Clutch Proper .......................... 9

2. SP EC IF IC A T IO N S ................................... 3 5.2.1 D isassem bly and inspection ............. 9
3. S E R V IC E S T A N D A R D S ........................... 4 5.2.2 Reassem bly ................................... 13
3.1 Service Standards Table ....................... 4 5.3 Bearing Case ..................................... 15
3.2 Tightening Torque Table ....................... 4 5.3.1 D isassem bly and inspection ............. 15
4. SP E C IA L T O O LS .................................... 5 5.3.2 Reassem bly .................... 16
5. S E R V IC E P R O C ED U R E ....................... 6 6. T R O U B L E S H O O T IN G ............................. 17
5.1 Rem oval and Installation ...................... 6
21-1
21 CLUTCH - GENERAL
1. GENERAL
The clutch consists of a clutch disc to transm it engine W hen the clutch lever is operated, the release fork will
p o w e rto th e bearing case and a pressure plate to press push forward the release bearing. The release bearing
the clutch disc against the engine flywheel. will then push the inner end of the release lever which
W hen the clutch lever is in the released state, the force pivots on the release lever support pin. The outer end
of the pressure sp rin gs act on the pressure plate. The of the release lever is connected to and will pull the
clutch disc is pressed against the flywheel by the pres pressure plate away from the flywheel.
sure plate. At this time, there will be a clearance between the
The clutch disc pressed against the flywheel turns with clutch disc and flywheel. The engine power will not be
the flywheel and transm its power to the clutch shaft in sent to the bearing case.
the bearing case.
21-2
CLUTCH - SPECIFICATIONS 21
2. SPECIFICATIONS
(1) Clutch
Engin e model
6D24 6D24-T, TC
Item
M odel C10W41 C12W 43
Clutch drive Strap drive
Type Dry single disc coil sprin g type
Material W oven
Facing
O.D. x I.D. (mm) 410x250 430 x 250
Pressure plate type Coil spring
(2) Bearing case
E ngin e m odel
6D24, T, TC
Item
Type Direct-coupled type
Model PCI 2
21-3
21 CLUTCH - SERVICE STANDARDS
Unit: m m
Maintenance item N o m inal value Limit R em edy and rem arks

Clutch proper
Clutch d isc Depth from facing surface to rivet head 2.2 to 2.8 0.2 Replace
F latness 0.3 to 1.2 - Correct or replace
Lateral runout 1.3 or less -
Vertical runout 1.5 or less -
Clearance of hub spline turning direction 0.06 to 0.195 0.42 Replace
Pressure T h ick n e ss 59.7 to 59.9 56.8 Replace

plate
Flatness 0.05 or less 0.2 Correct or replace
S trap bolt fitting hole 12.21 to 12.22 12.5 Replace
C learance between strap plate and strap bolt [12.2] 0.006 to 0.024 0.3 Replace
P ressu re Free length C10W41 99.5 - Replace

sp rin g
C12W 43 92.1 -
Installed load (Installed length: 63) C10W41 1200 to 1330 N 1070 N

{122.6 to 135.4 kgf} {109 kgf}
C12W 43 1420 to 1570 N 1270 N

{145 to 160.2 kgf} (129 kgf)
S p r in g sq u are n e ss (In free length state) C10W41 3.5 or less 5.2 Replace
C12W 43 3.2 or less 4.8
R ele ase lever height 36.5 to 37.5 — Adjust

(D im e n sio n from clutch cover top surface) (Difference a m o n g four
levers: 0.7 or less)
C learan ce betw een release lever pin and bu sh in g 0.016 to 0.111 0.3 Replace
B e arin g case
C learan ce betw een release fork shaft and needle roller bearing [30] 0.03 to 0.08 0.2 Replace
Location tightened Scre w size T ighte nin g torque

O.D. x pitch N m {kgf-m}
(m m )
S trap bolt M 12 x 1.5 39 to 49 {4 to 5}
Lock plate m o u n tin g bolt M 8 x 1.25 9.8 to 15 {1 to 1.5}
Pressu re plate and lever a sse m b ly m o un tin g bolt M l O x 1.5 32 to 49 {3.3 to 5.0}
B e arin g case m o u n tin g bolt M 1 6 x 2.0 140 {14.2}
21-4
CLUTCH - SPECIAL TOOLS 21
4. SPECIAL TOOLS
Unit: mm Unit: m m
Tool nam e Sh ap e Tool nam e S h ap e
Clutch A lign m e n t A rb or Clutch Lever A lign e r

03726-21000 M H061330
< C 10W 41,C 12W 43> A djustm ent of release lever
43490-00100 height
<C12W43: for disc with 12
splines>
A lign m en t of clutch disc at
installation
Part No. Dim ension A 3 7 i0 .5
03726-21000 4>42
E0013A
43490-00100 <j>36
Needle Roller Bearing
08903 Installer
44590-12600
Clutch Installer
MH061331 Installation of needle roller
bearing of bearing case
Rem oval and installation of
clutch cover
01306 09326
21-5
21 CLUTCH - SERVICE PROCEDURE
5. SERVICE PROCEDURE NOTE:

1. Before removing the clutch, be sure to install the
5.1 Removal and Installation
stopper bolt and plain washer to prevent the strap
(1) Rem oval plate from being damaged.
2. Use the stopper bolt (M1 Ox 1.25-85 with effective
length 30 mm or more) and plain washer (for M12
threads) commercially available.
(2) Installation
Part n um be r
stam pe d here
Pilot Clutch disc

bearing
Flywheel Clutch A lign m e n t A rb or

03726-21000
<C10W 4 1,C 12W 4 3 >
43490-00100
<C12W43: for disc with
12 sp lin es> E 0 18 ?A
(a) Install the clutch disc using Clutch Alignm ent Ar
1 Bearing case assem bly
bor (special tool).
2 Pressure plate & lever assem bly
3 Clutch disc assem bly NOTE:
E0755A
When installing the clutch disc, make sure that it is
installed in the correct direction: install it so that its
side with the part number stamped is visible.
Clutch A lign m en t Arbor

03726-21000
<C10W 41, C12W 43>
43490-00100
<C12W43: for disc with
12 splines>
Stopper bolt.
Plain w asher (4 places) E0119B
W h e n rem oving the pressure plate and leverassem bly,

secure the pressure plate with Stopper Bolt and Plain
W a sh e r (special tools).
Before rem oving the pressure plate and lever a ssem
bly, install Clutch Alignm ent Arbor (special tool) to pre
vent the clutch disc from dropping.
21-6
CLUTCH - SERVICE PROCEDURE 21
(c) Inspection of release lever height
(b) Secure the pressure plate of the pressure plate and

lever assem bly with the stopper bolts, then install U sin g Clutch Lever Aligner (special tool), check the
the clutch, aligning it with the knock pins in the fly heights of the clutch cover and release lever.
wheel. Use the support nut for adjustment.
NOTE:
1. Before installing the clutch, check and clean the
flywheel and repair or replace as necessary.
2. Tighten bolts evenly, in the diagonal order.
3. After installation, be sure to remove the set bolt.
21-7
CLUTCH - SERVICE PROCEDURE
(d) Adjustment after installation of clutch and bearing

case
The clutch should be set in the m ost w orn position as

wear of the clutch disc during service causes the clutch
to slip.
1) M ove the lever in the direction that the clutch en
gages. At a position where a click is heard in the
clutch, turn the adjusting bolt A until it is blocked
by the stopper, and lock it by turning dow n the bolt
another two or three threads.
2) From the position where the release bearing has
touched the release lever, turn the adjusting bolt B
in the direction that the clutch disengages, check
to see that the clutch is in disengaged position, and
then lock the bolt.
21-8
5.2 Clu tch Proper
Depth to clutch disc rivet head Clearance of hub spline turning

N V 2.2 to 2.8 direction
L 0.2 N V 0.06 to 0.195
L 0.42
<C10W 41>
Clutch disc runout
Free length
Flatness N V 99.5
N V 0.3 1.2
Installed load (installed length: 63)
Lateral runout N V 1200 to 1330 N {122.6 to 135.4 kgf}
N V 1.3 or less L 1070 N {109 kgf}
Vertical runout Strap bolt fitting hole Sq u a re n e ss

N V 1.5 or less N V 12.21 to 12.22 N V 3.5 or less
L 12.5 L 5.2
Thickness <C12W 43>

N V 59.7 to 59.9
Free length
L 56.8
N V 92.1
Flatness
Installed load (Installed length: 63)
N V 0.05 or less
N V 1420 to 1570 N {145 to 160.2 kgf}
L 0.2
L 1270 N {129 kgf}
Sq u a re n e ss
N V 3.2 or less
L 4.8
Clearance between strap

plate and strap bolt
B D 12.2
N V 0.006 to 0.024
Clearance between release L 0.3
lever pin and bu sh in g
N V 0.016 to 0.111
L 0.3
5 4 3 BD .. B asic D iam eter

L Limit

© Clutch disc assem bly 9 Release lever pin
(D Strap bolt 10 Return spring
® Lock bolt 11 Release lever support
@ Lock plate 12 Release lever pin
© Support nut 13 Release lever subassem bly
© Clutch cover (with strap plate) 14 Bushing
© Pressure spring @ Pressure plate
8 Spring seat
For parts with an encircled number, refer to D isa sse m b ly and Inspection Proce
dures that follow.
N O TE:
1. S in c e the clutch cover and pressure plate are balanced, m ake a lign m en t m arks
before disassem b ly.
2. D o n ot rem ove th e strap plate.
E0757B
21-9
Disassem bly and Inspection Procedures (2 ) Inspection of clutch disc

(1) Rem oval of clutch cover (a) Facing wear
M easure the assem bly thickness of facing and the

depth from facing surface to rivet head or cup head. If
the measurement is below the limit, replace the clutch
disc assembly.
(4 places)
(b) Flatness of clutch disc
08913
(a) C om press the pressure spring with the stopper

bolts and, atthe sam e time, remove the strap bolts,
support nut, and other parts.
M easure the flatness of facing surface. If it is beyond

the limit, correct or replace.
(b) Put alignm ent m arks on the clutch cover and pres
sure plate. C om p ress the pressure spring using
Clutch Installer (special tool), and the sam e time,
rem ove the stopper bolt.
(c) Gradually loosen the handle of Clutch Installer to
remove the clutch cover.
21-10
(c) Clutch disc runout (3) Inspection of pressure plate
(a) M easurem ent of thickness
U sing the runout tester, measure the clutch disc run

out. If the measurement exceeds specification, correct M easure the pressure plate thickness and, if it is below
or replace the clutch disc. the limit, replace.
(d) Spline play in turning direction (b) M easurem ent of flatness
U sing a piano wire, m easure the play in the turning M easure the flatness of the pressure plate friction sur
direction of the clutch disc hub splines and bearing face. Regrind or replace if the limit is exceeded.
case clutch shaft. If the limit is exceeded, replace the
clutch disc.
21-11
(c) Strap bolt fitting hole I.D. (5) Inspection of pressure spring
M easure I.D. of strap bolt fitting hole in the pressure Measure the free length, squareness, and installed
plate and, if the limit is exceeded, replace. load of the pressure spring. If the measurement is be
(4) Inspection of release lever low the limit, replace the spring.
M easu re the release lever pin O.D. and b ushing I.D. Re
place if clearance exceeds specification.
21-12
5.2.2 Reassem bly
9.8 to 15 N-m
{1 to 1.5 kgf-m}
-S tra p plate
- 2 39 to 49 N-m
{4 to 5 kgf-m}
-S tra p support w ash er

-S tra p plate
1 15
® 1
14
; I->12 “ I
|->11—>9—>10—>8—>7—>'1?—>5—>4—>3—->2—>1
© 1
For parts with an encircled num ber, refer to R e a sse m b ly Procedure
that follows.
E0754B
Reassembly Procedure (1 ) W henever the pressure plate friction surface is cor

rected, insert adjusting w ashers of thickness
equivalent to correction amount.
Friction surface correction am ou nt A dju stin g w ash e r thick

(m m ) n e ss (m m)
Less than 1 N o n e required
1 or m ore to less than 2 O n e 1.2
2 or m ore to less than 3 Two 1.2 or one 2.3
21-13
(2) To install the clutch cover, align the alignm ent (4) After installing the clutch, check the clutch cover
m arks and, using Clutch Installer (special tool), and release lever for height using Clutch Lever
tem porarily tighten the stopper bolts. Aligner (special tool).
(3) With the pressure spring com pressed by the stop

per bolts, install the strap bolt, support nut, and
other parts.
21-14
5.3 B earin g C ase
5.3.1 D isassem bly and inspection
Cracks, d a m a g e

1 Clutch shifter 7 Clutch release fork 12 Ball bearing
*2 Clutch release bearing 8 Drive shaft front cover 13 Bearing case
3 Return spring 9 Oil seal 14 Oil seal
4 Stopper plate 10 Clutch shaft *15 Needle roller bearing
5 Stopper 11 Sn ap ring 16 Clutch housing
6 Clutch release fork shaft
NO TE:
Parts m arked * sh o u ld n ot be rem oved u nless they are to be replaced. E0760A
21-15
5.3.2 R eassem bly
Pack gre ase Pack gre ase

Tem plex N-3 gre ase M itsu b ish i wheel
bearing gre ase Oil g ro o v e to be placed in
up p e rm o st position
A p p ly grease
M o ly ko te BR2 Plus
140 N -m
{14.2 kgf-m )
Pack gre ase

A p p ly sealant Tem plex N-3 grease
T H R E E B O N D 1102C A sse m b ly sequence
13->14 —
10—>12—>11
16—>'15 —>6->7—>5 3—>4
1—>2
For parts with an encircled number, refer to Installation of Needle
Roller Bearing that follow s. E0761A
Reassem bly Procedure

Installation of Needle Roller Bearing
U sing Needle Roller Bearing Installer (special tool),

install the needle roller bearing in the housing.
The needle roller bearing should be pressed in up to
th e s p e c ifie d d im e n s io n w ith th e oil s e a l s id e in w a rd
and the inscribed side outward.
NOTE:
N eedle roller bearing When installing the needle roller bearing, direct the lip
Inscribed sid e
(dust seal side) in the correct direction.
N eedle Roller B e arin g Installer
44590-12600
E0123A
Needle roller bearing
Installing
direction "
D u st seal
3 to 5 m m
E0762A
21-16
CLUTCH - TROUBLESHOOTING 21
6. TROUBLESHOOTING
S y m p to m Probable cause Rem edy Ref. g ro u p
Clutch drags Defective clutch proper

w hen dise n (D isassem b le and check clutch assem bly.)
ga g e d
• D a m a g e d or poorly lubricated pilot bearing Replace or lubricate
• D a m a g e d release bearing Replace
• Uneven height of release lever or its d a m a ge Adjust height or replace
• Defective clutch disc Replace
• D a m age d or deform ed clutch d isc
• W orn or rusty sp lin es and clutch disc hub Replace or correct defective
parts
• Distored or d a m a ge d p ressure plate Grind or replace
Distored or d a m a ge d flywheel G rou p 11
Clutch slip s Defective clutch proper

(D isassem b le and check clutch assem bly.)
• Uneven height of release’lever Adjust
• Pressure sp rin g lo sing proper tension Replace
• Defective clutch disc
• W orn facing
• Deform ed clutch disc
• Hardened facing R em ove hardened surface

or replace
• Oil on facing R em o ve oil or replace
• Distored or d a m a ge d p ressure plate Grind or replace
Clutch is not Defective clutch proper

sm o o th ly en (D isassem b le and check clutch assem bly.)
gaged
• Defective clutch disc Replace
• Distored facing
• Hardened facing R em o ve hardened surface

or replace
• Loose rivet Replace
• Oil on facing R em o ve oil or replace
• Binding clutch disc splines Correct or lubricate splines
• Clutch disc torsion sp rin g lo sin g proper tension or broken Replace
• Uneven height of release lever Adjust
• Pressure sp rin g lo sin g proper tension Replace
• Distored or d a m a ge d p ressure plate G rind or replace
21-17
21 CLUTCH - TROUBLESHOOTING
S y m p to m Probable cau se R em edy Ref. group
Clutch is n o isy W orn, dam a ge d , or p o o rly lubricated pilot bearing Replace or lubricate
w h en d ise n
gaged W orn, dam a ge d , or p o o rly lubricated release bearing
Defective clutch disc

• W orn clutch d isc sp lin e s Replace
• Clutch disc torsion sp rin g lo sin g proper tension or broken
Bent strap plate Replace clutch cover
Clutch is n o isy Defective clutch disc

w hen e n g a g in g
• Clutch disc torsion sp rin g lo sin g proper tension or broken Replace
• W orn clutch disc hu b sp lin es
W orn sp lin es of clutch shaft
Pressure sp rin g lo sin g proper tension
L o w idle speed A dju st Group 13A, E
21-18
SPECIAL EQUIPMENT
CONTENTS
1. G E N E R A L ............................................ 2 5.1 Air Com pressor ................................ . 9

1.1 Air Com pressor .................................. 2 5.1.1 Rem oval and installation .................. 9
1.2 Air Pressure Governor ......................... 4 5.1.2 D isassem bly ................................... 12
2. SP E C IF IC A T IO N S .............................. 5 5.1.3 Inspection ...................................... 15
3. S E R V IC E S T A N D A R D S .......................... 6 5.1.4 Reassem bly ................................... 19
3.1 Service Standards Table ...................... 6 5.2 Air Pressure Governor ..................... 22
3.2 Tightening Torque Table .................. 7 5.2.1 D isassem bly and inspection ............. 22
4. SP E C IA L T O O L S ................................... 8 5.2.2 Reassem bly and adjustm ent ............ 23
5. S E R V IC E P R O C E D U R E ........................... 9
61 SPECIAL EQUIPMENT - GENERAL
1. GENERAL
1.1 A ir C o m p re s s o r
The air com p ressor is driven by the injection pum p

gear in m esh with the tim ing gear of the engine at a
speed one half of the engine speed. On the cylinder
head of the air com pressor, a suction valve, delivery
valve and unloader valve are provided which respec
tively accom plishes the suction, delivery and exhaust
functions. The air com pressor com es in two types; the
1 - and 2 -cylinder types.
A s e n s o r plate forthetachom eter is provided on the in

jection pum p gear side of the air compressor. The sen
sor plate has se n so r bars.
61-2
SPECIAL EQUIPMENT - GENERAL 61
(1 ) How air is drawn in
The air is drawn in by the negative pressure which is The air, com pressed in the cylinder as the piston m oves
produced in the cylinder as the piston m oves down. down, gets over the action of the valve spring on the
W hen the negative pressure is produced in the cylin delivery side and forces up the delivery valve stopping
der, the suction valve that has been stopping up the up the delivery port of the valve seat. S o the air is
suction port of the valve seat com presses the valve routed under pressure to the air tank.
spring to open the suction port. S o the air is drawn into W hen the piston enters the down stroke, the delivery
the cylinder. valve is forced back by the valve spring to close the air
W hen the piston enters-the up stroke, the suction valve delivery port of the valve seat.
is forced back by the valve spring to close the air suc
tion port of the valve seat.
61-3
61 SPECIAL EQUIPMENT - GENERAL
(3) H ow unloader valve operates 1.2 A ir P ressure G overnor
W hen the air pressure in the air tank exceeds the speci The pressure governor controls com pressor operation
fied pressure (pressure governor operating pressure), to keep the air tank pressure within specified limits.
the pressure gove rn or opens to send the com pressed To the high pressure valve of the diaphragm, the sam e
air to the unloader valve. The com pressed air not only air pressure as in the air tank acts always through the
depresses the unloader valve, but keeps the suction filter, thereby balancing with the adjusting spring
valve open, causing the air com pressor to operate un force. W hen the pressure in the airtank increases to ex
der no load. ceed that opening pressure of the high pressure valve,
W hen the air pressure in the air tank falls below specifi the airforces upthe high pressure valve seat ofthe dia
cation, the pressure governor resum es operation, dis phragm. T h is causes increase of acting area so that the
charging com pressed air present at top of the unload diaphragm m oves up quickly to close the seat of the
er. Then the unloader valve spring puts the unloader low pressure valve.
valve back to its original position, causing the suction W hen the low pressure valve is closed, air now flow s
valve to begin operation. through the valve body to force down the unloader
valve ofthe air compressor, thereby stopping air su p
ply to the air tank.
A s the air pressure in the air tank gradually drops, the
diaphragm is forced down by the adjusting spring and
the low pressure valve opens and the high pressure
one closes. A s a result, the air on the unloader side is
exhausted through the exhaust hole and air supply to
the airtank is resumed.
61-4
SPECIAL EQUIPMENT - SPECIFICATIONS 61
2. SPECIFICATIONS
Unit: m m
Item Specification
A ir c o m p re sso r Type W ater-cooled 1-cylinder type W ater-cooled 2-cylinder type
Cylinder diam eter x stroke 85x50 80x50
Cylinder capacity 284 cm 3 502 c m 3
Turning direction Clockw ise

(as view ed from drive side)
Pressure governor Type D iap h ragm type
61-5
61 SPECIAL EQUIPMENT - SERVICE STANDARDS
(1) A ir com pressor
Unit: m m
M aintenance item N o m in a l value Limit R em e dy and remarks

1-cylinder Su c tio n valve sprin g Installed load/ 4.4 N {0.45 kgf}/5 3.5 N {0.36 kgf}/5 Replace
type deterioration installed length
D elivery valve sprin g 4.5 N {0.46 kgf}/9.5 3.6 N {0.37 kgf}/9.5

deterioration
Piston ring open end clearance (m easu red - 1.0 Replace all piston rings as a
inside cylinder liner) set
Clearance between p is C o m p re ssio n ring “T 0.08 Replace all piston rings a s a
ton ring and ring groo ve only set
o f piston
Piston pin to piston clearance [18) 0.08 Replace
Piston pin to connecting rod sm all end clear [18] 0.07 Replace piston pin or con
ance necting rod
Piston to cylinder liner Top portion [85] 0.27 Replace piston or cylinder
clearance liner
Skirt portion [85] 0.18
Be arin g to crankshaft clearance [42] 0.1 Replace crankshaft or crank

case
C rankshaft to connecting rod bearing clear [34] 0.1 Replace bearing

ance
C on n e ctin g rod bearing W hen copper color Replace bearing

is ex po sed be
cause o f w orn in
ternal plated layer
Crankshaft end play - 1.0 Replace crankshaft
C o n n e ctin g rod end play - 0.5 Replace crankshaft or c o n

necting rod
2-cyiinder Su c tio n valve sprin g Installed load/ 4.4 N {0.45 kgf}/5 3.5 N {0.36 kgf}/5 Replace
type deterioration installed length
D elivery valve sprin g 4.5 N {0.46 kgf}/9.5 3.6 N {0.37 kgf}/9.5

deterioration
Piston ring open end clearance (m easu red - 1.0 Replace all piston rings as a
inside cylinder liner) ~ •• * ■ set
C learance between p is C o m p re ssio n ring 0.08 Replace all piston rings as a
ton ring and ring gro o ve only set
o f piston
Piston pin to piston clearance [16] 0.08 Replace
Piston pin to connecting rod sm all end clear [16] 0.07 Replace piston pin or c o n
ance necting rod
Piston to cylinder liner Top portion [80] 0.29 Replace piston or cylinder
clearance liner
Skirt portion [80] 0.17
C rankshaft to connecting rod bearing clear [34] 0.1 Replace bearing

ance
C on ne cting rod bearing W hen copp er color Replace bearing

is exposed be
cause of w orn in
ternal plated layer
Crankshaft end play - 1.0 Replace crankshaft
Con ne cting rod end play - 0.5 Replace crankshaft or con

necting rod
SPECIAL EQUIPMENT - SERVICE STANDARDS 61
(2) Air pressure governor
Unit: kPa {kg/cm 2}
M aintenance item Nom inal value Limit R em edy and rem arks
High pressure valve open MC802148 n 3 +0.35 \ - A djust or replace

ing pressure 715^ . 9 -0.05 ‘
MC802150 ro o +0.35 i -
7 8 4 ^
{8,0 -0.05 ‘
Low pressure valve open MC802148 re a +0.05 \ -

ing pressure 625+-34 -0.35
M CB02150 n 1 +0.05 \ —
6® 5-34 -0.35 '

(1) A ir com pressor

O.D. x pitch N-m {kgf-m)
(m m)
Cylinder head nut <1-cylin dertype> M l O x 1.25 23 to 27 {2.3 to 2.8}
Cylinder head bolt <2-cylin dertyp e> M 1 0 x 1.5 39 to 49 {4 to 5)
C ylinder liner nut <2-cylin dertyp e> M l O x 1.5 25 to 29 {2.5 to 3.0)
Injection pum p ge ar m ounting nut M 2 4 x 1.5 215(22}
Bearing holder bolt <1-cylin dertyp e> M 8 x 1.25 14 to 18{1.4 to 1.8}
Bearing holder nut <2-cylin dertyp e> M 8 x 1.25 14 to 18(1.4 to 1.8}
Connecting rod cap nut M 8 x 1.25 23 to 25 (2.3 to 2.6}
Joint PT1/8 15 to 20 (1.5 to 2.0}
U n loader valve gu ide M 2 8 x 1.5 98 to 115 (10 to 12}
Delivery valve holder M 3 6 x 1.5 98 to 115 (10 to 12)
Suction valve holder M 4 5 x 1.5 98 to 115 (10 to 12)
Tachom eter se n so r N on-adjustable - 29 + 5.9 {3 + 0.6}
Tachom eter se n so r lock nut A djustable - 29 ± 5.9 (3 ± 0.6}
(2) Air pressure governor

O.D. x pitch N-m {kgf-m}
(m m )
Sleeve lock nut - 15 to 20 (1.5 to 2}
A d ju stin g screw lock nut - 9.8 to 15{1 to 1.5}
61-7
61 SPECIAL EQUIPMENT - SPECIAL TOOLS
4. SPECIAL TOOLS
Air com pressor
Unit: m m Unit: m m
61-8
SPECIAL EQUIPMENT - SERVICE PROCEDURE 61
5.1 Air Compressor
NOTE:
1. To remove the air compressor, remove the injec
tion pump beforehand.
2. At installation, the injection pump gear installed
on the air compressor should be in mesh as speci
fied.
(1 -cylinder type air compressor) (2 -cylinder type air compressor)
1 Water outlet pipe 6 Air suction hose (1-cylinder type)

2 Air outlet pipe Air suction pipe (2-cylinder type)
3 Unloader pipe A 7 Oil pipe
4 Unloader pipe B (2-cylinder type only) 8 Air com pressor
5 Water inlet pipe
B9050B B9051B
Removal Procedure
With the piston at any other position, the injection
pum p gear guide plate cannot be rem oved as it is
caught by the idler gear.
61-9
61 SPECIAL EQUIPMENT - SERVICE PROCEDURE
Installation Procedure
(1) Crank the engine until the " 1 6 " marked on the out
er periphery of the flywheel is aligned with the
pointer of the inspection w ind ow of the flywheel
housing to place the piston in the No. 1 cylinder of
the engine at the top dead center on the com pres
sion stroke. If the piston in the No. 1 cylinder is at
the top dead center on the com pression stroke, the
valve clearance should exist in the No. 1 cylinder. If
there is no valve clearance, the piston in the No. 6
cylinder is at the top dead center on the com pres (2) Insert bolts (M 10 x 1.5 about 100 mm long) from
sion stroke. Therefore, rotate the engine 360°. the rear end plane of the flywheel housing to su p
NOTE: port the air compressor. Insert the air com pressor
When the engine is to be cranked, crank it by hand 180° in the hole provide in flywheel housing until its
or more in the direction of normal rotation. gear end m akes contact with the end surfaces of
both injection pum p gear and camshaft gear. Align
the inscribed lines on rear plate and injection pum p
gear and push the air com pressor inward.
61-10
(4) Installation of tachometer sensor
(a) Adjustment-free type
A p p ly a sealant
(T H R E E B O N D 1211
or 1212) to the
threaded portion
z
29 ± 5.9 N -m {3 * 0.6 kgf-m)
09640
To install the tachometer sensor, apply sealant to the

threaded portion ofthe sensor and screw the se nsor in
until the hexagonal portion of the sensor seats.
(b) Adjustment type
(3) Rem ove the tachometer sensor or plug. Look

through the threaded hole to confirm that the pro
jection on the sensor plate is positioned at the cen
ter of the threaded hole, and then secure the air Clearance Flywheel h o u sin g
0.5 to 1.5
compressor. If the projection on the se n so r plate is
not positioned at the center of the threaded hole,
remove the air com pressor and perform Item (2)
again. S e n so r
plate
NOTE:
If the meshing teeth of the injection pump gear and Tachom eter se n so r
idler gear C are one tooth different, about one half of
■"> / Tachom eter se n so r lock nut
the sensor plate bar will be hidden from the threaded
A pp ly a sealan t 29 ± 5'9 <3 ± °‘6 kS f'm >
hole. (T H R E E B O N D 1211
or 1212) to the
threaded portion
N2 8 2 5A
To m ount the tachometer sensor, apply a sealant to the

threaded portion ofthe sensor and turn down the se n
sor until it com es in contact with the sensor plate. Then
back it off 2/3 of a turn (240°) (Clearance 1.0 mm).
Secure it by tightening the lock nut to specification.
61-11
5.1.2 D isa sse m b ly
(1 -cylinder type)
11
Sagging spring 8 12 Sagging spring
9 13 Wear, damage
1 4 Wear, damage
18 Wear, damage
17 Wear, damage
-16 Sagging spring
Crack, worn bushing, 2 7

clogged oil hole
Circumference damaged 2 9 2
or worn Crack, wear
Wear, damage
26 3 0 Scratch, clogged oil hole
Circum
ference 28 End play
damaged L 1.0
or worn I Limit
D isasse m b ly sequence
1 S e n so r plate 10 Delivery valve holder 19 Cylinder liner 27 Connecting rod
2 Injection pum p gear 11 Spring holder Com pression ring 28 Connecting rod cap
3 Collar 12 Delivery valve spring <3> Oil ring 29 Connecting rod bear
4 Cylinder head 13 Delivery valve 22 Snap ring ing
5 Stud bolt 14 Delivery valve seat 23 Piston pin 30 Crankshaft
6 Sn a p ring © Suction valve holder 24 Piston 31 Crankcase
7 U nloader valve 16 Suction valve spring 25 Bearing holder *32 Bearing
8 Valve spring 17 Suction valve 26 Oil seal *33 Bearing
9 Valve guide 18 Suction valve seat
For parts with an encircled number, refer to Disassembly Procedure that follows.
Parts marked with * should not be removed unless defects are evident.
D9252A
61-12
(2 -cylinder type)
S a g g in g sp rin g 6 - - f f -10
-1 1 S a g g in g sp rin g
-1 2 Wear, d a m a g e
-1 3 Wear, d a m a g e
17 Wear, d a m a ge
16 Wear, d a m a ge
Crack, scratch 2 3 21 15 S a g g in g spring
14
22
Crack, w orn bushing, 2 6

clo gge d oil hole
Circum ference d a m a g e d 28
or w orn
If O * 28
Circum ference d a m a ge d or w orn
— 27
2 9 Scratch, c lo g g e d oil hole

25
W ear, d a m a ge End play I Limit
L 1.0

1 Sensor plate 9 Delivery valve hold 16 Suction valve 25 Oil seal
2 Injection pum p gear er 17 Suction valve seat 26 Connecting rod
3 Collar 10 Sp rin g holder 18 Cylinder liner 27 Connecting rod cap
4 11 Delivery valve © Com pression ring 28 Connecting rod
Cylinder head
5 Snap ring spring @ Oil ring bearing
6 Unloader valve 12 Delivery valve 21 Snap ring 29 Crankshaft
7 Valve spring 13 Delivery valve seat 22 Piston pin 30 Crankcase
8 Valve guide @ Suction valve holder 23 Piston 31 Bearing
15 Suction valve spring 24 Bearing holder 32 Bearing
For parts w ith an encircled number, refer to D isa sse m b ly Procedure that follows.
09641
61-13
SPECIAL EQUIPMENT - SERVICE PROCEDURE
Disassem bly Procedure (2) D isassem bly of piston ring

(1) D isassem bly of suction valve holder
NOTE:
NOTE: When a piston ring is removed, do not widen the open
Since the suction valve holder is staked by punching, ends ofthe piston ring more than 28 mm for 1-cylinder
do not attempt disassembly unless trouble is evident. type and more than 26 mm for 2-cylinder type.
61-14
5.1.3 Inspection
(1 -cylinder type)
S a g g in g sp rin g
Installed load/installed
length
Clearance betw een piston N V 4.5 N {0.46 kgf>/9.5
ring and ring gro o ve of piston L 3.6 N {0.37 kgf}/9.5
C om p re ssio n ring only
L 0.08
Clearance
B D 42
L 0.1
End play
L 1.0

L Limit
D 9252B
(2 -cylinder type)
S a g g in g sp rin g
Installed load/installed
length
N V 4.5 N {0.46 kgf}/9.5
L 3.6 N {0.37 kgf}/9.5

L Limit
09646
61-16
Inspection Procedures (3) Piston ring open end clearance
(1) Piston to cylinder clearance
Fit the piston ring over a standard gauge or new cylin

der liner and measure the open end clearance. If the
clearance is over the limit, replace the piston ring.
NOTE:
Push the piston in and measure the clearance with the
piston ring in horizontal position.
(4) Piston to piston pin clearance
If the clearance is over the limit, replace the piston or

cylinder liner.
(2) Piston ring and piston ring groove clearance
Calculate the clearance. If it is in excess ofthe limit, re

place the piston or piston pin.
If the clearance is over the limit, replace the com pres

sion ring or piston.
NOTE:
Measure the clearance all around the piston.
61-17
(5) Piston pin and connecting rod clearance (7) Clearance between crankshaft journal and bearing
D9267A
If the clearance is over the limit, replace the piston pin Calculate the clearance. If it is in excess of the limit, re
or connecting rod. place the parts.
(6) Crankshaft and connecting rod bearing clearance (8) Connecting rod end play
If the play exceeds the limit, replace the connecting

rod.
(9) Unloader valve assem bly
Calculate the clearance. If it is in excess of the limit, re

place the bearing or crankshaft.
If the unloader valve in unloader valve assem bly is

badly worn, replace the unloader valve assembly.
61-18
(1 -cylinder type)
98 to 115 N-m 98 to 115 N-m
31 -}32—>33—>30—>29-»®-*®,-*25^26->24—>23^22— 9->5->4->3-»;'?'-»'i ' j

_________ t
14-»l 3-»12-»1 1 -»10->18—>17-» 1
8—»7->6—>9—
For parts with an encircled number, refer to R e a sse m b ly Procedure that follow s.
B3256B
61-19
61-20
R eassem bly Procedure
(1) A sse m b ly of connecting rod
the connecting rod cap end
09645 Install each piston ring in place and locate their ends as
show n in the illustration.
M ake sure that the alignment mark on the connecting (3) Installation of suction valve holder
rod is aligned with that on the connecting rod cap.
(2 ) Installation of piston rings
Stake the cylinder head at three places sh o w n over the

suction valve holder.
61-21
(4) Installation of injection pum p gear 5.2 A ir Pressure G ove rn or

1 D a m age, corrosion
3 Sagging, dam age
10 Damage, corrosion
9 Damage,
deterioration
Repair kit:
Pressure governor kit
Install the injection pum p gear, sensor plate (guide

plate), and nut as instructed in the illustration. Disassem bly sequence
1 Cover 6 Filter
2 Adjusting screw 7 Screen
3 Spring 8 Cap
4 Sleeve 9 Diaphragm
5 Sn ap ring 10 BodV B4081A
61-22
5.2.2 R eassem bly and adjustm ent Testing
A ir pressure go ve rn o r A ir g a u g e
9.8 to 15 N-m
B4082A
(1) Connect an air gauge between the air pressure

governor and air tank.
(2) Start the engine and increase air pressure slow ly
while observing the air gauge. Check that the read
ing of the gauge when it has stabilized is as speci
fied (high pressure valve opening pressure).
If not, adjust by adjusting tightening am ount of the
R easse m b ly sequence sleeve. After adjustment, tighten firmly with the
10— >9— >8— > 7 — > 6— ^ 5— >4— > 3 — > 2— >1 lock nut.
B4080B
(3) Slow ly decrease the air tank pressure and check
High and low pressure valve opening pressure that the air gauge reading starts to increase when
the nominal pressure (low pressure valve opening
Part No. N o m in a l value pressure) is reached.
H igh pressure valve Low pressure valve
For adjustment, use the adjusting screw. After ad
op en ing pressure op en ing pressure justment, tighten firmly with the lock nut.
(4) After tightening the lock nut, check again the high
7 1 5 ^ kPa 6 2 5 ^ '| k P a
MC802148 and low pressure valve opening pressures. If they
■O'-3 t o 3! kg/cm 2} {6.4 !° ;° !k g /c m 2} are out of specification, adjust again.
(5) Install and seal the cover.
784 ^ k P a 695 +34 kPa
MC802150
{8.0 kg/cm 2} {7.1 kg/cm 2}
—U.ob
61-23

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1. E X T E R N A L V IE W ............ 2 4. KEY P O IN T S FOR

Type Diesel, 4-cycle, w ater-cooled

C o m b u stio n m ethod Direct injection

No. and arrangem e n t of 6 , in-line

Cylinder bore x stroke 130x150

Total displacem ent 11945

E ngin e dim e nsion

Overall w idth mm 866 881 881 869

Overall height mm 1058 1169 1209 1246

Em p ty w eigh t kg* 905 930 960 940

* Em p ty w eigh t as m e asure d according to M itsu b ish i M o to rs Corporation standard.

2.2 Engine Outputs Classified by Application

^ --------- E n g in e m odel 6D24 6D24-T 6D24-TC

intermittent rated 1500 114(115} 163 {222} 182(247}

2000 144(196} 201 {273} 217(295}

2200 151 {205} 206(280} 228(310}

C on tinu ou s rated 1500 104(141} 148 { 202} 165(224}

2000 131 {178} 182 {248} 197(268}

2200 137 {186} 187(255} 207 {282}

3. ENGINE NUMBER AND CAUTION PLATE (2) Caution plate

(1) Engine num ber

The caution plate is attached to the portion show n in

---------------Engine num ber

• Prepare general and special tools necessary forthe

W ARNING A ---------------------------- ----------

On disassem bly, visually inspect all parts for wear and

Apply the specified oil or grease to U-packings, oil

Before carrying out maintenance w ork on the electric

• Take care when handling sensors, relays, etc.

Measurem ent Procedures U sin g Connectors

• To apply voltage for testing, check that the positive

• W hen using testers or the like for continuity tests,

Test with connectors disengaged

Check if harnesses are broken by pulling gently around

Check for a decrease in contact pressure between the

W hen servicing the alternator, pay attention to the fol­

• W hile the engine is running, do not rem ove the bat­

• Do not use a high-voltage tester such as a m egger

• Disconnect the battery terminals before quick-

5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

M6 4 to 6 {0.4 to 0.6} - 7 to 11 {0.7 to 1.1} - 8 to 12 {0.8 to 1.2} -

M8 9 to 14 {0.9 to 1.4} - 17 to 26 {1.7 to 2.6} - 20 to 29 {2.0 to 3.0} -

M 10 19 to 28 {1.9 to 2.8} 18 to 26 36 to 52 {3.5 to 5.5} 33 to 49 45 to 60 {4.5 to 6.0} 41 to 59

M 12 35 to 50 {3.4 to 5.0} 31 to 46 70 to 95 {7.0 to 9.5} 65 to 85 85 to 110 {8.5 to 11} 75 to 100

Hex-head Flange Bolt

M 12 38 to 54 35 to 51 80 to 110 70 to 95 90 to 120 85 to 110

M5 2 to 3 {0.2 to 0.3} - 4 to 6 {0.4 to 0.6} -

M6 4 to 6 {0.4 to 0.6} - 7 to 11 {0.7 to 1.1} -

M8 9 to 14 {0.9 to 1.4} - 17 to 26 {1.7 to 2.6} -

M 10 19 to 28 {1.9 to 2.8} 18 to 26 {1.8 to 2.7} 36 to 52 {3.5 to 5.5} 33 to 49 {3.3 to 5.0}

M 12 35 to 50 {3.4 to 5.0} 31 to 46 {3.1 to 4.7} 70 to 95 {7.0 to 9.5} 65 to 85 {6.5 to 8.5}

Hex-head Flange Nut

M 10 21 to 30 {2.1 to 3.1} 20 to 28 {1.9 to 2.9}

M12 38 to 54 {3.8 to 5.5} 35 to 51 {3.4 to 5.2}

Tightening torque for flare nut for general purpose

Pipe diam eter 4>4.76 m m 4)6.35 m m 4>8 m m 4>10 m m 4>12 m m 4>15 m m

T igh te nin g torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10.0}

S ta n d a rd diam eter 6 x 1 mm 10 x 1.25 m m 12 x 1:5 m m 15 x 1.5 m m

T igh te nin g torque

T igh te nin g torque

1. G E N E R A L .......................................... ... 2 5.3 Flywheel, Tim ing Gears, and

Water directors pressed into the bottom of the cylinder

W hen servicing the alternator, pay attention to the fol

• W hile the engine is running, do not rem ove the bat

Distance from clutch cover m oun t 47.8 to 48.2 49.5 Replace