6024

6D24T
6D24TC
6D24TL
diesel engine
GROUP INDEX
GENERAL ....................................•

Shop Manual ENGINE .......................................

LUBRICATION ...............................

Im
FOREWORD
FUEL AND ENGINE CONTROL ........... ·
This shop manual contains the specification,

11!1
construction, operation, adjustment and service pro­ ELECTRONICALLY
cedures of the Model 6024 diesel engine for CONTROLLED FUEL SYSTEM .............
service mechanics engaged in servicing of the
Mitsubishi die­sel engines.
COOLING ................................... .
Please make the most of this shop manual to perform
correct servicing and wasteless operations.
Note that some of the contents of this shop manual are INTAKE AND EXHAUST ....................
subject to change owing to improvements, etc. that
may be introduced after publication of this shop
ENGINE ELECTRICAL ....................... -
manual.

CLUTCH ......................................

SPECIAL EQUIPMENT ......................

Mitsubishi 6D24 6D24T Engine Maintenance Service Kits

Includes: thermostat set, thermostat gaskets, valve cover gaskets,
oil filters, air filters, fuel filters, V-belts.
Replace thermostats and thermostat gaskets,
Adjust intake valve clearance and exhaust valve clearance, replace valve cover gaskets,
Replace filters,
Replace V-belts.

Mitsubishi 6D24 6D24T Engine Parts www.6D24.com

Contact email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Mitsubishi 6D24 6D24T Engine Parts Contact:

Heavy Equipment Restoration Parts LLC

4730 118th Ave
Fennville Michigan 49408 USA
Phone: 269 673 1638
Fax: 269 673 7226
email: EngineParts@HeavyEquipmentRestorationParts.com
alternate email: EngineParts2@gmail.com
Text message: 269 760 8652

Located in USA, Engine Parts delivery available in USA, Canada and worldwide.
Mitsubishi Diesel Engine Parts
Nissan Diesel Engine Parts
Hino Diesel Engine Parts
Isuzu Diesel Engine Parts
Mercedes Benz Industrial Diesel Engine Parts
COMPILATION OF THIS
MANUAL
CONTENTS

1. TERMS AND UNITS ............. .... ....... . ... 4

2. UNITS ........................................... 5
3. READING THE ILLUSTRATION ................. 6

3
 COMPILATION OF THIS MANUAL - TERMS AND UNITS

1. TERMS AND UNITS (4) lightening torque

The following terms and units are used throughout the
entire texts of this manual.
(1) Front and rear
The terms "front" is the fan side and "rear" the fly­
wheel side of the engine.
(2) Right and left
The terms "right" and "left" shall be used to indi­
cate the side as viewed from the flywheel side of
the engine.
(3) Service standard terms
• Nominal value
Shows the nominal dimensions, dimension of an
individual part, standard clearance between parts
in an assembly, or the standard performance of an
assembly.
• Limit
Shows the value of a part at which the part is no
longer serviceable from the performance as well as
strength viewpoints, requiring replacement or
repair.
Over-or undertightening of bolts and nuts has criti­
cal effects on performance and functions. Tighten­
ing torque is therefore specified for some tighten­
ing points.
All tightening torque specifications may be consid­
ered as "dry" unless "wet" is specified.
Where no tightening torque is specified, use a
torque value specified in the General Bolts and
Nuts lightening Torque Table.
(5) Units
Length, weight, surface area and capacity are
given in International Systems of Units with metric
units indicated in ( ).
Temperatures are given in degrees Celsius.
For the conversion into the foot-pound system,
refer to the following conversion table.

4
 COMPILATION OF THIS MANUAL - UNITS

2. UNITS
lightening torques and other parameters are given in SI* units with metric units added in brackets { }.
*SI: Le Systeme International d'Unites
Example: 390 N · m {40 kgf · m}

-r- L
LSI unit
Metric unit

Unit SI unit {metric unit} Conversion factor

Force N {kgf} 9.80665 N {1 kgf}
Moment of force N·m {kgf·m} 9.80665 N · m {1 kgf · m}
Positive pressure kPa {kgf/cm2} 98.0665 kPa {1 kgf/cm2}
Pressure kPa {mmHg} 0.133322 kPa {1 mmHg}
Vacuum pressure
Pa {mmH2O} 9.80665 Pa {1 mmH2O}
Volume dm {L}
3
1 dm3 {1 L}
Power kW{PS} 0. 7355kW{1 PS}
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W{kcal/h} 1.16279 W{1 kcal/h}
Angle 0 -
Temperature ·c -
Electric current A -
Voltage V -
Resistance n -
Electric power w -

Unit SI unit Foot-pound unit Conversion rate

Force N (Newton) lbf 1 N = 0.2248 lbf
Moment of force N·m ft.lbs 1 N · m = 0.7375 ft.lbs
Pressure kPa (kilopascal) psi 1 kPa = 0.145 psi
1 kPa = 0.2953 in. Hg
Volume L gal. 1 L = 0.2642 gal. (U.S.)
1 L = 0.220 gal. (Imp.)
cm3 oz 1 cm3 = 0.033814 oz (U.S.)
1 cm3 = 0.035195 oz (Imp.)
cm3 cu.in. 1 cm3 = 0.061023 cu.in.
Power kW (kilowatt) PS 1 kW= 1.3596 PS
Temperature ·c •F t•c = ( 1.8t0c + 32)° F
Mass quantity of kg lb 1 kg = 2.2046 lb
matter g oz 1 g = 0.035274 oz

Dimension m ft. 1 m = 3.2808 ft.

mm in. 1 mm = 0.03937 in.

5
 COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION

3. READING THE ILLUSTRATION

(Ex. 1: Disassembly and Inspection)

*Protrusion from
crankcase to surface
NV 0.10 to 0.50

standards.
/
Indicates the service i.----3 Carbon deposits, scratches
on outer surfaces, cracks,
discoloration

9 c,aok,, o; ;ng

/
*Connecting rod end play
NV 0.15 to 0.45
L 0.6

Indicates visual checks.

* Indicates inspection to
be made before disassembly.
2

NV .. Nominal Value
1 Connecting rod cap @ Oil ring L ..... Limit

2 Connecting rod bearing 7 Snap ring

3 Piston 8 Piston pin
@ 1st compression ring 9 Connecting rod
@ 2nd compression ring

� Indicates that the disassembly

procedures is explained in the text.

A0014A

6
 COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION

(Ex. 2: Reassembly)

Gives instruction for jobs to

ho doao at raassembly. ·•
"'-.

'
Apply engine oil. Piston projection
NV 0.48 to 0.74

2 1 98N-m

/
{10 kgf-m} Face the oil groove
(Wet) toward the crankshaft
End play
NV 0.10 to 0.25
L 0.4
Specifies the tightening torque;
(Wet) meaos the part m,st be Ughteoed lo wot "1/

\
Indicates a typical assembly sequence.
Indicates the service standards.
NV .. Nominal Value
L..... Limit

Assembly sequence

3➔@➔@➔7➔@➔@➔@➔2➔1

\
Indicates that the assembly procedure is
explained in the text.
A0013A

Illustrations (exploded views and assembly drawings) among various types of available systems and units.
shows a typical service procedures if it is identical
7
 GENERAL
CONTENTS

1. EXTERNAL VIEW ............................ 2 4. KEY POINTS FOR

2. MAJOR SPECIFICATIONS ...................
2.1 Major Specifications ......................
2.2 En_gine Outputs Classified by
Application ............ . ...................
3. ENGINE NUMBER AND CAUTION
PLATE ........................................
3 MAINTENANCE WORK ....................... 5
3 5. GENERAL BOLTS AND NUTS
TIGHTENING TORQUE TABLE . .. ... . . . ... . 1 2
3
4

00-1
 -
1. EXTERNAL VIEW
GENERAL - EXTERNAL VIEW

Natural-aspirated engine

Turbocharged engine
A0243A

A0244A

00-2
 GENERAL - MAJOR SPECIFICATIONS

2. MAJOR SPECIFICATIONS
2.1 Major Specifications

It�

Type
el 6D24 6D24-T
I 6D24-TC

Diesel, 4-cycle, water-cooled

I 6D24-TL

Combustion method Direct injection

No. and arrangement of 6, in-line
cylinder

Cylinder bore x stroke 130 X 150

mm

Total displacement 11945

cm 3

Engine dimension
(with fan)
Overall length mm 1473 1473 1473 1473
Overall width mm 866 881 881 869
Overall height mm 1058 1169 1209 1246
Empty weight kg* 905 930 960 940

* Empty weight as measured according to Mitsubishi Motors Corporation standard.

2.2 Engine Outputs Classified by Application

6D24 6D24-T 6D24-TC

Turbocharged Turbocharged
with Aftercooler
gine
ed rpm
A
�
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}

Continuous 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 SAE J1349.
2. The continuous rated output allows 10% (one
hour) overload operation.

00-3
 GENERAL - ENGINE NUMBER AND CAUTION PLATE

3. ENGINE NUMBER AND CAUTION PLATE (2) Caution plate

(1) Engine number

E0175

E0143
The caution plate is attached to the portion shown in
the illustration. The caution plate indicates the follow­
The engine number is stamped near the front of the
ing items.
crankcase on the left-hand side. It takes the following
form:

1
Example: 6D24- 012345
j�---- Engine number
Engine model VALV E C LEARANC E (C O LD) 11
The engine number is important in knowing the history I NLET 0.4mm(0.016in)l1
of the engine. EXHAUST O.6mm(0. 02 4 in)f-1

□
FIRING ORDER 1-5-3-6-2-4-V--2
FUELINJECTION TIMING 0 BTDC�3

1 Valve clearance
2 Firing order
1-5-3-6-2-4
3 Fuel injection timing

A01668

00-4
 GENERAL - KEY POINTS FOR MAINTENANCE WORK
4. KEY POINTS FOR MAINTENANCE WORK
In order to determine the condition of the vehicle ade­
quately, attend the vehicle beforehand to find and keep
record of the accumulated mileage, operating condi­
tion, what the customer's demand is, and other in­
formation that may be necessary.
Prepare the steps to be taken and perform efficient and
wasteless maintenance procedure.
17952
• Determine where the fault exists and check for the
cause to see whether removal or disassembly of
the part is necessary. Then follow the procedure
specified by this manual.
• Perform maintenance work at a level area.
00009
• Prepa re general and special tools necessary for the
maintenance work.
WARNING.&_----------
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.
•
-
When removing or installing the engine, attach the
lifting wire rope hooks to the engine's lifting eyes
and hoist the engine slowly such that it does not
touch other components.
WARNING,&.----------
Check that the wire rope and crane are sufficiently
strong.
00012
• Be particularly careful not to work in shoes that
have oily soles and are slippery. When working as a
team of two or more, arrange signals in advance
and keep confirming safety. Be careful not to acci­
dentally bump switches or levers.
• Check for oil leakage before cleaning the area hav­
ing the fault otherwise you might miss detecting
the leakage.
• Prepare replacement part(s) beforehand.
00-5
 - GENERAL - KEY POINTS FOR MAINTENANCE WORK
/
00015
• Replace oil seals, packing, 0-rings and other rub­
ber parts; gaskets and split pins with new parts
whenever any of them has been removed.
Use only genuine MITSUBISHI replacement parts.
00016
On disassembly, visually inspect all parts for wear and
tear, cracks, damage, deformation, degradation, rust,
corrosion, smoothness in rotation, fatigue, clogging
and any other possible defect.
00-6
00017
Put alignment marks on part combinations before dis­
assembly and arrange the disassembled parts neatly.
This will help avoid mismating of the parts later.
Put the alignment marks, punch marks, etc. where per­
formance and appearance will not be affected.
Cover the area left open after removal of parts to keep it
free from dust.
CAUTION_&----------
• 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.
00018
Apply the specified oil or grease to U-packings, oil
seals, dust seals and bearings during assembly.
CAUTIONLb_----------
Use only the specified oil, grease, etc. for lubricant.
Remove the excess immediately after application
with a piece of rag.
 GENERAL - KEY POINTS FOR MAINTENANCE WORK
00019
Wear goggles when using a grinder or welder. Pay full
attention to safety by wearing gloves when necessary.
Watch out for sharp edges, etc. that might injure your
hands or fingers.
06701
Before carrying out maintenance work on the electric
system, disconnect the negative terminals of the bat­
teries.
00021
• Take care when handling sensors, relays, etc.
which are vulnerable to shock and heat.
-
00022
• Pull the connector, and not the harness lead, to
separate connectors. To separate a lock-type con­
nector, first push toward arrow mark. To reconnect
a lock-type connector, press the separated parts
until they click together.
00023
• When washing the vehicle, cover the electric sys­
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.
00-7
 - GENERAL - KEY POINTS FOR MAINTENANCE WORK
06702
• To apply voltage for testing, check that the positive
and negative cables are connected properly, then
increase voltage gradually from O volt. Do not ap­
ply voltage higher than the specified value.
In particular, pay close attention to the electronic
control unit and sensors, since they are not always
supplied with 24V.
00027
• When using testers or the like for continuity tests,
be careful not to allow test probes to touch the
wrong terminals.
00-8
Measurement Procedures Using Connectors
Connect the test harness
and connector A between
these parts
02587
Test with connectors engaged (continuity through cir­
cuit obtained)
<Waterproof connector>
Prepare a test harness and connectors A, then connect
if between the two parts of harness B that is to be
tested. Check the circuit by touching test probe C to the
test connector.
Never insert the test probe from the harness side of the
waterproof connection, or waterproof performance
might be diminished causing corrosion of the connec­
tor.
02588
<Non-waterproof connector>
Insert test probe C from the harness side of the 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.
 GENERAL - KEY POINTS FOR MAINTENANCE WORK

Connector Inspection Procedures

-

02589

Test with connectors disengaged

Using female pins Visual inspection
Insert a test probe into a terminal. However, do not Check for loose connection and poor engagement.
force the probe into the terminal, or it will cause a poor
contact.

02590 Check if harnesses are broken by pulling gently around

the terminals.
Using male pins
Touch the pins directly using test probes.
CAUTION_&----------
Be sure that you do not short circuit the connector
pins when you use the test probe because this could
damage the internal circuit of the electronic control
unit.

02593

Check for a decrease in contact pressure between the

male and female terminals.

00-9
 - GENERAL - KEY POINTS FOR MAINTENANCE WORK
Check for poor contact caused by connector pins hav­
ing fallen out, rusted terminals or foreign particles.
02594
Connector pin fall out inspection
Damaged connector pin stoppers can cause poor en­
gagement of the terminals (male and female pins) even
if the connector body is secured, and might cause
some pins to fall out. Check if the pins have fallen out
from the connector by pulling each harness gently.
Inspection Procedures for Blown Fuses
A
+
B
C •
D tery to the alternator occurs, and the diode or regu­
02596
00-10
Remove fuse B and measure resistance between the
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 may indicate that the fuse
was 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 damaged by friction or heat.
• Water in connectors or circuits.
• Mistakes (accidental short circuits)
A: Battery
B:Fuse
C: Loaded switch
D:Load
E: Short circuit
Precautions for Handling Alternator
04746
When 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
lator might be damaged.
 GENERAL - KEY POINTS FOR MAINTENANCE WORK
• Do not splash water over the alternator.
-
If water is directly splashed over the alternator, in­
dividual components will be short-circuited and
might be destroyed.

04747

• While the engine is running, do not remove the bat­

tery terminals. If the battery terminals are removed
at that time, a surge voltage is generated and the 04749
diode or regulator might be weakened.
• Do not short-circuit terminal Band terminal L while
running the alternator.
If the terminals are short-circuited while the alter­
nator is running, the diode trio might be destroyed.

f I
/

02371

• Do not use a high-voltage tester such as a megger

for inspection. If a high-voltage tester is used, the
diode or regulator might be destroyed. 05166

• Disconnect the battery terminals before quick­

charging the battery. Quick-charging without dis­
connecting the battery terminals might damage
the diode or regulator.

05165

00-11
- GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

• Use 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.
• Where 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 th 4T 7T BT
classi �ication

©0 0 ©0 0 ®@ 0
n

e-
-
I
� (Stud) (Stud) (Stud)

MS 2 to 3 {0.2to 0.3} - 4 to 6 {0.4to 0.6} - 5to 7 {0.5to 0.7} -

M6 4to 6{0.4to 0.6} - 7 to 11 {0.7to 1.1} - 8to 12 {0.8 to 1.2} -
MB 9to 14{0.9to 1.4} - 17to 26 {1.7to 2.6} - 20 to 29{2.0to 3.0} -
M10 19to 28{1.9to 2.8} 18to 26 36to 52 {3.5to 5.5} 33to 49 45to 60{4.5to 6.0} 41to 59
{1.8to 2.7} {3.3to 5.0} {4.3to 6.9}

M12 35 to 50{3.4to 5.0} 31to 46 70to 95{7.0to 9.5} 65to 85 85to 110{8.5to 11} 75to 100
{3.1to 4.7} {6.5to 8.5} {7.5to 10}

M14 60to 85{6.0to 8.5} 55to 75 120to 160{12to 16} 110to 140 130to 180{13to 18} 120to 160
{5.5to 7.5} {11to 14} {12to 17}

M16 90to 130{9.5 to 13} 90to 120 180to 240{18to 24} 160to 220 200to 270{20to 27} 190to 260
{9.0to 12} {16to 22} {19to 26}

M18 140to 190{14to 19} 120to 160 260 to 340 {25 to 35} 220to 290 290to 390{30to 40} 260to 340
{12to 16} {22to 30} {26to 35}

M20 190 to 260 {19 to 26} 170to 230 350to 470{36to 48} 320to 420 410to 550 {41to 56} 370to 490
{17 to 23} {32to 43} {37to 50}

M22 260 to 340 {26 to 35} 230to 300 470 to 640{48to 65} 430to 570 550 to 740 {56to 75} 490to 670
{23 to 31} {43to 58} {50to 68}

M24 340to 450{34to 46} 290to 390 630to 840{63to 86} 540to 730 730 to 980 630to 840
{29to 40} {55to 74} {74to 100} {64to 86}

Hex-head Flange Bolt

Unit: N-m {kgf-m}
Strength 4T 7T BT
classification

0 0 0
n

-
- � � �
I
�
M6 4to 6{0.4to 0.6} - 8to 12 {0.8to 1.2} - 9to 14{0.9 to 1.4} -
MB 10 to 15 - 19to 28 - 22 to 32 -
{1.0to 1.5} {1.9 to 2.8} {2.2to 3.3}

M10 21to 30 20 to 28 39 to 58 37 to 53 50 to 65 45 to 65
{2.1to 3.1} {1.9to 2.9} {3.9 to 6.0} {3.6to 5.4} {5.0 to 6.5} {4.5to 6.5}

M12 38 to 54 35 to 51 80 to 110 70to 95 90 to 120 85 to 110

{3.8 to 5.5} {3.4to 5.2} {8.0 to 11} {7.0to 9.5} {9.0to 12} {8.5to 11}

00-12
 GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE -

Hex-head Nut
Unit: N-m {kgf-m }
Strength 4T 6T
classification

©
Repre-

@ @
sentation

(DJ ([eJ]
Diameter
symbol Standard screw Coarse screw Standard screw Coarse screw

MS 2 to 3 {0.2 to 0.3} - 4 to 6{0.4 to 0.6} -

MS 4 to 6{0.4 to 0.6} - 7 to 11{0.7 to 1.1} -
MS 9 to 14{0.9 to 1.4} - 17 to 26{1.7 to 2.6} -
M10 19 to 28{1.9 to 2.8} 18to 26{1.8to 2.7} 36to 52{3.5to 5.5} 33to 49{3.3 to 5.0}
M12 35 to 50{3.4 to 5.0} 31to 46{3.1to 4.7} 70to 95{7.0to 9.5} 65to 85{6.5 to 8.5}
M14 60 to 85{6.0 to 8.5} 55to 75{5.5to 7.5} 120to 160{12to 16} 110to 140{11to 14}
M16 90to 130{9.Sto 13} 90to 120{9.0to 12} 180to 240{18to 24} 160 to 220{16to 22}
140 to 190 120to 160 260to 340{25to 35} 220to 290{22to 30}
M18 {14to 19} {12to 16}

190 to 260 170to 230 350to 470{36to 48} 320to 420{32to 43}
M20 {19 to 26} {17to 23}

260 to 340 230to 300 470to 640{48to 65} 430to 570{43to 58}
M22 {26 to 35} {23to 31}

340 to 450 290to 390 630to 840{63to 86} 540to 730{55to 74}
M24 {34 to 46} {29to 40}

Hex-head Flange Nut

Unit: N-m {kgf-m }
Strength 4T
classification

Repre-
sentation

�
Diameter
symbol Standard screw Coarse screw

MS 4 to 6{0.4to 0.6} -
MB 10to 15{1.0to 1.5} -
M10 21to 30{2.1 to 3.1} 20to 28{1.9to 2.9}
M12 38 to 54{3.8 to 5.5} 35 to 51{3.4to 5.2}

00-13
 -
GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABL E

lightening torque for flare nut for general purpose

Unit: N-m {kgf-m}
Pipe diameter 4>4.7 6 mm 4>6.35 mm «j>Smm «j>10 mm «j>12mm qi15mm
lighteningtorque 17 {1.7} 25 {2.6} 39 {4.0} 5 9 {6.0} 88 {9.0} 98 {10 .0}

lightening torque for air piping nylon tube for general purpose {DIN type}
Unit: N-m {kgf-m}
Standard diameter 6x1mm 10 x1.25 mm 12x1.5 mm 15 x 1.5 mm
lighteningtorque
.9 6 10 10
20+5 { 2.0 +� } 34 { 3.5 +�O } 49+ .0 +�O } 4 { 5 .5 +g- }
+ +5 5
0 0 0 { 5 5
0

Tightening torque for air piping nylon tube for general purpose {SAE type}
Unit: N-m {kgf-m}
Standard diameter 1/4in . 3/8in. 1/2in . 5 /8in.
lighteningtorque
13
+4
{ 1.3 +g- 4 } 29
+5
{ 3.o +g- }
5
49
+5 5
{ 5.o +g- }
+5
54 0 { s.5 +g- }
5
0 0 0

00-14
 -

ENGINE
CONTENTS

1. GENERAL ................................ . ... 2 5.3 Flywheel, liming Gears, and

2. SPECIFICATIONS ............................ 8 Camshaft .................. ............... 29
3. SERVICE STANDARDS ...................... 9 5.3.1 Disassembly ............ ............... 29
3.1 Service Standards Table .................. 9 5.3.2 Inspection .............. ............... 33
3.2 lightening Torque Table ................. 1 1 5.3.3 Reassembly ............ ............... 39
4. SPECIAL TOOLS ............................ 1 2 5.4 Crankcase and Main Moving Parts ...... 45
5. SERVICE PROCEDURES .................... 16 5.4.1 Disassembly ........................ ... 45
5.1 Measuring Compression Pressure ...... 16 5.4.2 Inspection ........ ...... ............... 49
5.2 Cylinder Head and Valve Mechanism ... 17 5.4.3 Reassembly ...... . .................... 59
5.2.1 Disassembly ........................... 17 5.5 Inspecting and Adjusting Valve
5.2.2 Inspection ............................. 19 Clearances ................ ............... 65
5.2. 3 Reassembly ........................... 25 6. TROUBLESHOOTING .. ...... ....... . ....... 67

Mitsubishi 6D24 6D24T Engine Parts Contact:

Heavy Equipment Restoration Parts LLC

4730 118th Ave
Fennville Michigan 49408 USA
Phone: 269 673 1638
Fax: 269 673 7226
email: EngineParts@HeavyEquipmentRestorationParts.com
alternate email: EngineParts2@gmail.com
Text message: 269 760 8652

Located in USA, Engine Parts delivery available in USA, Canada and worldwide.
Mitsubishi Diesel Engine Parts
Nissan Diesel Engine Parts
Hino Diesel Engine Parts
Isuzu Diesel Engine Parts
Mercedes Benz Industrial Diesel Engine Parts

11-1
 -
1. GENERAL
ENGINE - GENERAL

(1) Combustion chamber

Injection nozzle

Cylinder head

----- 0-ring
Nozzle tube
Cylinder head
gasket

Water director
B0376A

Water directors pressed into the bottom of the cylinder

head optimize cooling of the combustion chambers by
directing the flow of coolant.

B0375C

The combustion chambers are formed by the cylinder

head and pistons. The injection nozzles, sheathed by
the nozzle tubes, are mounted 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 0-rings
at the top and by staking at the bottom. Combustion is
effected by compression of fuel injected directly into
the combustion chambers.

11-2
 (2) Valve mechanism
ENGINE - GENERAL -
Rocker
Rocker cover
Valve cap
Valve cotter
:...-----------
- _____ Upper retainer
_ ..- .. -- Valve spring outer
...., --· - -- Valve spring inner

Valve stem seal

Oil passage Rocker

Push rod

85040A
Tappet

Camshaft
B0375O

The valve mechanism is of an overhead-valve (OHV)
type and is constructed as shown in the diagram.
(a) Valve stem seals are fitted to the inlet and exhaust
valve stems to control the amount of lubricant
flowing onto the sliding surfaces of the valves and
valve guides.
(b) The inlet and exhaust valve springs are unevenly
pitched. Two springs are mounted for each valve,
and the inner and outer springs are wound in oppo­
site directions.
(c) The rocker and rocker shaft are supported by the
rocker shaft bracket and are installed indepen­
dently for each cylinder. The same type of rocker is
used for both inlet and exhaust valves, and the cen­
ter of each rocker forms an oil passage.
The rocker shaft is a hollow rod sealed by a thrust
plate at each end. The inside of the rocker shaft
forms an oil passage.
(d) A steel ball is welded to the bottom end of each
push rod, and a spherical concave piece is welded
to the top end.
(e) The tappets are cylindrical. To help prevent local­
ized wear, the areas that make contact with the
camshaft are curved. The overall design enables
the tappets to be removed via the side of the crank­
case.
(f) The camshaft is held by camshaft bushings that are
pressed into the crankcase. The cam profiles are
specially curved to achieve smooth acceleration.

11-3
-(3) Crankcase and cylinder liner
ENGINE - GENERAL

(4) Piston and piston rings

(a) Pistons

Weight
mark

(A, B,C)
Ji
Size mark Part
No.

(a) Seven camshaft bushings are fitted in the camshaft
bearing section of the crankcase. To facilitate
removal and reinstallation of the camshaft, the
diameter of each bearing is smaller toward the
front.
(b) Coolant is fed in from the water pump (located at
the front left of the crankcase). After cooling the oil
cooler, it flows through the water jacket holes and
around the cylinders, then reaches the cylinder
head.
Front indicated
by "F" and arrow
Cooling cavity
43428
The piston is an aluminum casting, and a combustion
space is recessed into its crown. A piston ring insert is
cast into the 1st piston ring groove to improve durabil­
ity.
Stamped on top of the piston are a size mark, a piston
weight mark, the piston's part number, an identifica­
tion mark, plus an "F" and arrow, which indicate the
piston installation direction. The size mark is provided
to enable selection of the correct cylinder liner size. In
the case of an oversize piston, the size mark shows 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

� 1st compression ring

� (full keystone type)

2nd compression ring

=:f
;;;;;;_;;;::;,,....____,,)
(typer faced inner cut
type)

Oil ring
(dual type with an
(c) The cylinder liner is a removable wet type. It is expander spring)
press-fitted into the crankcase, with its top held by
the top of the crankcase and its bottom held by the
water jacket.
803740
Rubber rings and 0-rings are provided at the top
and bottom of the cylinder liner to prevent the
Two compression rings and one oil ring are fitted to
ingress of coolant.
each piston. They are shaped as shown in the illustra­
The water jacket has a water thrattling shelf to opti­
tion.
mize cooling performance.

11-4
 (5) Connecting rod and connecting rod bearing
ENGINE GENERAL

(6) Crankshaft and crankshaft main bearings

-

Connecting rod
bushing

Balance weight
Connecting rod 84206A

Connecting rod (a) The crankshaft is highly rigid and is cast in one
bearing (upper)
"><¾?� Connecting rod
piece with its balance.
Cylinder number,
weight mark bolt Between each journal and pin is an oil hole. Some
of the main bearing oil is fed through this hole to
lubricate the connecting rod bearing.

<Axial lip type>

Flywheel housing
45482

The connecting rod is a highly rigid I-section forging. A

bushing is pressed into the small 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 Slinger
43654
<Radial lip type>
tion of the small end bushing is supplied via the oil hole Flywheel housing
and oil passage. An oil hole is provided at the top of the
connecting rod to help cool the piston. O-ring
Crankshaft gear
The connecting rod and connecting rod cap are held
together by four connecting rod bolts. Crankshaft

Retainer

803518

(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 of the crankshaft.

11-5
 ID ENGINE - GENERAL

(d) Main bearings

<Rubber type> Torsional damper

• Single mass

� Crankshaft pulley
,.,.

• Double mass
Torsional damper

Crankshaft pulley

<Viscous type>

Crankshaft pulley

Crankshaft Upper main lower main Thrust plate

84489A
(c) The front end of the crankshaft is flanged, and the
crankshaft pulley is bolted to the flange. A torsional
damper is mounted on the crankshaft pulley to
absorb the crankshaft's torsional vibration.
bearing bearing
80382A
Each main bearing is a split-type plain bearing made of
special alloy-plated kelmet metal with backing mate­
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.

Engine Parts contact phone: 269 673 1638

Email: EngineParts2@gmail.com

11-6
 (7) liming gears
ENGINE - GENERAL

Each idler gear is mounted 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 means of
pressed-in bushings. The bushings are lubricated by
oil that flows through the inside of the idler shafts via
the crankcase oil holes.
(8) Flywheel

Angle scale, cylinder number

r
11111111111)111111
ili11ili1111111fli111l1111lf111

Mr inc
Idler gear C
2=68
Cylinder No.

=n
I I I I I j I 11 I
3j
Idler gear
2=47

Oil pump gear

2=53

B0383L

The timing gears are located in the flywheel housing at

the rear of the engine. The geartrain is as shown in the Cylinder No.
illustration. I I I II 11
I I I 2j5 / \.._ Valve timing
The timing gears are helical, and each is stamped with "' check mark
j&n Hj j !

]II[
a timing mark. The timing marks ensure that the gears 11 t I

mesh correctly when reassembled. 10355

The flywheel is made of cast iron, and at its center is a

Flywheel
pilot bearing for the clutch shaft. The outer ring gear
__,,..- housing that meshes with the starter pinion is shrink-fitted.
/
-=--" - ·
----- Idler gear "A" The ring gear teeth are chamfered on one side to
--Collar ensure that the starter pinion fits easily.
. Crankshaft Cylinder numbers, an angle scale, and valve timing
check marks are stamped on the outside of the fly­
wheel, as shown in the illustration.

Thrust plate
80384A

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
 -
2. SPECIFICATIONS
ENGINE - SPECIFICATIONS

Item Specification
Engine model 6D24 6D24-T 6D24-TC 6D24-TL
Type 6-cylinder, in-line, water-cooled, r r r
4-cycle diesel
Combustion chamber type Direct injection r r r
Valve mechanism Overhead valve r r r
Cylinder bore x stroke (mm) 130 X 150 r r r
Total displacement (cm )
3 11945 r r r
Compression ratio 19.5 16.5 r 17.5
Fuel injection sequence 1-5-3-6 -2-4 r r r
Cylinder liner type Wet .-- r .--
Piston type Trunk-type slipper skirt .-- r r
(with cooling
cavity)
No. of piston rings Compression ring: 2 .-- r r
Oil ring: 1

11-8
3. SERVICE STANDARDS
ENGINE - SERVICE STANDARDS -
3.1 Service Standards Table
Unit: mm
Maintenance item Nominal value Limit Remedy and remarks
(Basic diameter in [ ])
Compression pressure (at 200rpm) 2750kPa 1960kPa {20kgf/cm2} Difference between cylin-
{28kgf/cm 2} ders: 390 KPa {4kgf/cm 2}
or less
Rocker bushing-to-rocker shaft clearance (28] 0.03to 0.08 0.2 Replace bushing
Outer valve spring Free length 89.38 85 Replace
Installed load/installed length 450 N 380N
{46.1kgf} / 58.35 {39kgf} / 58.35
Inner valve spring Free length 65.04 62 Replace
Installed load/installed length 115 N 100N
{12kgf} / 50.35 {10.2kgf} / 50.35
Squareness - 2.5
Tappet-to-crankcase clearance [35] 0.06to 0.10 0.2 Replace
Push rod runout - 0.5 Replace
Cylinder head bottom surface distortion 0.07or less 0.08 Correct or replace
Height of cylinder head from top to bottom surface 130 129.8 Replace
Valve stem outside Inlet 11.95to 11 .96 11.85 Replace
diameter
Exhaust 11.91to 11.93
Valve stem-to- Inlet (12] 0.05to 0.09 0.2 Replace valve guide
valve guide
clearance Exhaust (12] 0.09to 0.12

Valve margin Inlet 2.2 1.7 Reface or replace

Exhaust 2.5 2.0
Valve seat angle 45° -
Valve sinkage Inlet 0.25to 0.75 1.0 Replace valve seat insert
from cylinder (- shows projection)
head bottom
surface Exhaust --0.05to 0.45 0.7

Valve seat insert seat width 2.69to 2.96 3.5 Correct or replace
liming gear Between crankshaft gear and idler 0.08to 0.20 0.4 Inspect
backlash gear B

Between idler gear A and 0.07to 0.18 0.4 Inspect

camshaft gear

Between idler gear A and idler 0.07to 0.18 0.4 Inspect

gearC

Between injection pump gear and 0.08to 0.20 0.4 Inspect

idler gearC

Idler gear end play 0.05 to 0.15 0.4 Replace thrust plate

Camshaft gear end play 0.05to 0.22 0.4

Flywheel Friction surface distortion 0.1or less 0.2 Correct or replace

Distance from clutch cover mount- 47.8to 48.2 49.5 Replace

ing surface to friction surface

Friction surface runout (when - 0.2 Correct or replace

fitted)

Idler gear A-to-idler shaft A clearance (40) 0.03to 0.06 0.2 Replace bushing

Idler gearC-to-idler shaftC clearance [46] 0.03to 0.06 0.2 Replace bushing

11-9
- ENGINE - SERVICE STANDARDS

Unit: mm
Maintenance item Nominal value Limit Remedy and remarks
(Basic diameter in [ ])

Cam profile (difference Inlet 8.83 8.3 Replace Lobe height:

between lobe height and base 56.167
circle diameter) Base circle
diameter: 47.334

Exhaust 8.82 8.3 Replace Lobe height:

56.036
Base circle
diameter: 47.216

Camshaft journal-to-camshaft No.1 (65.00) 0.03 to 0.08 0.25 Replace bushing

bushing 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
Camshaft bend 0.05 or less 0.08 Replace
Camshaft gear-to-camshaft interference (40) 0.02 to 0.05 - Can be reassembled up to
3 times

Flywheel housing eccentricity - 0.2 Correct

Connecting rod end play 0.2 to 0.5 1.0 Replace

Projection of piston 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 supporting flange - 0.1 Replace crankcase
Crankcase top surface distortion 0.07 or less 0.2 Correct
Cylinder liner Inside diameter 130.014 to 130.054 130.25 Replace or grind to oversize
Flange 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
6D24-T,TC,TL (130) 0.193 to 0.219 - liner,or replace piston

Piston 1st compression 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 2nd compression 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 compression ring 0.4 to 0.55 1.5 Replace
ring end
gap 2nd compression 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 small end bushing clearance (50) 0.02 to 0.05 0.1 Replace bushing
Connecting rod Bend - 0.05 or less Correct or replace
Torsion - 0.1 or fess

Connecting rod bearing span when free - Less than 90.5 Replace
Connecting rod bearing-to-crankshaft pin clearance [84) 0.07 to 0.13 0.25 Replace bearing
Main bearing-to-crankshaft journal clearance (100) 0.08 to 0.15 0.25 Replace bearing
Main bearing span when free - Less than 106.5 Replace

Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com

11-10
 ENGINE - SERVICE STANDARDS - Unit: mm
Maintenance item Nominal value Limit Remedy and remarks
(Basic diameter in I ])
Crankshaft pin and journal Roundness 0.01 or less 0.08 Correct
Cylindricity 0.006 or less -
Crankshaft bend 0.04 or less 0.1 Correct or replace
Valve clearance (when cold) Inlet 0.4 - Adjust
Exhaust 0.6 -

3.2 lightening Torque Table

Location tightened Screw size lightening torque Remarks
0. D.xpitch N-m{kgf-m}
(mm)
Cylinder head bolt M14x2 - Wet. See item (6) of
section 5.2.3 for
tightening
procedure.
Rocker shaft bracket mounting bolt M10x1.5 59{6}
Rocker cover bolt M8x1.25 4.9{0.5}
Rocker adjusting screw lock nut M10 x1.25 59{6}
Flywheel mounting bolt M16x1.5 315{32} Wet
Idler shaft bolt A M16x2 155{16}
Idler shaft bolt C M16x2 155{16}

Idler shaft nut (for mounting collar) M16x1.5 98{10}

Flywheel housing bolt M12x1.75 69{7}
Oil jet check valve M12x1.75 34{3.5} Cannot be reused
Connecting rod cap nut M13 X 1.25 115{12} Wet
Main bearing cap bolt M18x2.5 - Wet. See item (7) of
section 5.4.3 for
tightening
procedure.
Crankshaft pulley mounting bolt M14x1.5 175{18}
Front cover mounting bolt M12 X 1.75 33{3.4}

Mitsubishi 6D24 6D24T Engine Parts Contact:

Heavy Equipment Restoration Parts LLC

4730 118th Ave
Fennville Michigan 49408 USA
Phone: 269 673 1638
Fax: 269 673 7226
email: EngineParts@HeavyEquipmentRestorationParts.com
alternate email: EngineParts2@gmail.com
Text message: 269 760 8652

Located in USA, Engine Parts delivery available in USA, Canada and worldwide.
Mitsubishi Diesel Engine Parts
Nissan Diesel Engine Parts
Hino Diesel Engine Parts
Isuzu Diesel Engine Parts
Mercedes Benz Industrial Diesel Engine Parts

11-11
 -
4. SPECIAL TOOLS
ENGINE - SPECIAL TOOLS

Unit: mm Unit: mm
Tool name Shape Tool name Shape
Compression Gauge Adapter Caulking Tool Body
MH061461 MH061360
Measuring compression pres­ Installing and caulking valve
sure seat inserts
Caulking Tool
Caulking Ring (Inlet) Body
MH061650
Caulking Ring
Installing and caulking valve
seat inserts For inlet: cl> 59
For exhaust: cl> 54
Caulking Ring (Exhaust)
Center MH061651
distance 46 Installing and caulking valve
01942 seat inserts
Valve Lifter Valve Lifter
MH061668
Removing and installing valve
cotters B5202A

Valve Lifter Hook Valve Lapper

30091-07500
MH061679
Valve lapping
Removing and installing valve

D
cotters

I.D. 42 Valve Lifter

Hook

01956
Nozzle Tube Remover Nozzle Tube Stamp
MH061232 MH061229
Removing nozzle tubes Installing nozzle tubes

cl> 12.5 Nozzle Tube Installer Flange

MH061416
Installing nozzle tubes
cl> 8.7
Nozzle Tube Installer Bolt
MH061231
Installing nozzle tubes
13597
Rocker Bushing Puller Nozzle Tube
MH061236 Installer
Replacing rocker bushings Flange

85181A
Valve Stem Seal Installer
ME067431 cl> 12
Installing valve stem seals
10593
Valve Guide Puller
30091-08100
Replacing valve guides

cj>24
B5111A 85191A

11-12
 ENGINE - SPECIAL TOOLS

Unit: mm
- Unit: mm
Idler Gear Bushing Puller Camshaft Bushing Extractor
MH061228 Bar
Replacing idler gear bushing MH062118
(for idler gear A) Removing camshaft bushings
Nos. 1 to 6

4>39.5 03532
Idler Gear Bushing Puller
MH062046 B4867A
Replacing idler gear bushing
(for idler gear C) Camshaft Bushing Extractor
Guide
MH062119
Removing camshaft bushings
Nos. 1 to 6

4>45.5
B4384A
Gear Puller
MH061061
Removing gears and pulleys

B4868A

Camshaft Bushing Extractor

Adapter
MH062120
MH062121
MH062122
MH062123
Maximum pulling outside Removing camshaft bushings
dia. 200 B5071A Nos. 1 to 6
Socket Wrench
MH061540
lightening cylinder head bolts

Part No. cj,A cl> B Applicable

bushing
MH062120 69.75 65 No.1
MH062121 70 65.25 No.2
MH062122 70.25 65.5 No.3,4
MH062123 70.75 65.7 No.5,6

B0598A B4869A

Socket Wrench Camshaft Bushing Extractor

MH063365 MH062124
lightening main bearing cap Removing camshaft bushing
bolts No. 7

13204 B4870A

11-13
Ill ENGINE - SPECIAL TOOLS

Unit: mm Unit: mm
Camshaft Bushing Installer Camshaft Bushing Installer
Bar MH06213 1
MH062125 MH062143
Installing camshaft bushings Installing camshaft bushings
Nos. 2to 6 Nos. 1 and 7

M24x 1.5

B487 1A Part No. cl>A cl>B Applicable

bushing
Camshaft Bushing Installer MH062131 70.75 65 No.T
Guide
MH062143 72.25 66 No.7
MH062127
Installing camshaft bushings B4875A
Nos. 2to 6
Oil Seal Slinger Installer
MH06 1652
Installing rear oil seal slinger

B4872A
Camshaft Bushing Installer
Adapter
MH062133
MH062134
MH062135
MH062136
MH062137
Installing camshaft bushings B5 16 1B
Nos. 2to 6 Piston Ring Tool
3 1 19 1-02900
Removing piston rings For<j,102to 178

Part No. ♦A ♦B +c Applicable

bushing
MH082133 71 65.25 27 No.2
MH082134 71.25 65.5 35 No.3
MH082135 71.5 65.5 43 Na.4
MH062136 71.75 85.75 51 No.5
MH082137 72 65.75 59 No.6

B4873A
020 13
Camshaft Bushing Installer
Nut Crankcase Table
MH062130 MH06 1889

p
Installing camshaft bushings Measuring flatness of cylin­
Nos. 2to 6 der-liner-supporting flanges
on crankcase

M24x 1.5

B4874A B 1480A

11-14
 ENGINE - SPECIAL TOOLS

Unit: mm
-
Unit: mm
Cylinder Liner Extractor Oil Seal Sleeve Installer
MH061490 31191-07100
Removing cylinder liners Installing rear oil seal sleeve

PE7264
Oil Seal Slinger Installer
B5131A MH061817
Installing front oil seal slinger
Cylinder Liner Installer
MH061759
Installing cylinder liners

85141A
Guide Plate Assembly 80585A
MH063368
Piston Guide Clamp
Removing connecting rod MH061666
bushings
Installing pistons
Mandrel
31291-75200 Piston Guide Lever
MH061658
Removing connecting rod
bushings Installing pistons

Collar A I.D.: 130

MH063370
Removing connecting rod
bushings
Collar B
MH062189
Removing connecting rod
bushings

Nut
31291-75500
Removing connecting rod B5171B
bushings Thickness Gauge
85151A MH061359
Oil Seal Installer Measuring valve clearances
31191-04300
Installing rear oil seal (radial
lip type)

PE7263 11605

11-15
 -
5. SERVICE PROCEDURES
ENGINE - SERVICE PROCEDURES

5.1 Measuring Compression Pressure Compression pressure

(at 200 rpm)
NV 2750 kPa {28 kgf/cm2}
Compression pressure should be measured prior to L 1960 kPa {20 kgf/cm2}
disassembly of the engine. Take measurements regu­
Difference between cylinders
larly and keep track of changes. During the engine's 390 kPa {4 kgf/cm2> maximum
running-in period or after parts have been replaced, NV .. Nominal Value
the compression pressure will increase slightly as the L ..... Limit

piston rings and valve seats fit snugly in position. T he

pressure will come down as parts wear.
Measurement procedure

Compression Gauge
Adapter
MH061461

85561A
85554A
(3) Mount the Compression Gauge Adapter (special
(1) Warm 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 compression 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 "stop" direction.
(5) Turn the engine over with the starter and measure
the compression 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
der to another, measure the compression pressure
85560A
in every cylinder.
(2) Remove 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
5.2 Cylinder Head and Valve Mechanism
ENGINE - SERVICE PROCEDURES -
5.2.1 Disassembly

Oil hole

JV/
�g

vlear
Wear, damaged
threads

17 Water leaks,
Wear, damage 7 gas leaks

21
1
/

Wear, cracks

Corrosion

Disassembly 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
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, "Disassembly 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

Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com

11-17
 -
Disassembly Procedure
ENGINE - SERVICE PROCEDURES

The cylinder head is located on the top surface of the

crankcase by dowel pins. To remove the cylinder head,
lift it straight upward.
Rocker cover NOTE:
1. Remove the injection nozzles before taking off the
Rocker shaft bracket cylinder head. (Refer to Group 13A, Fuel and
mounting bolt
Engine Control.) If the 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
C1543B crankcase mounting surfaces.
(4) Removing valve cotters
(1) Before removing the bolts, loosen the adjusting
screw on every rocker that is being pushed up by
its push rod.
(2) Removing rocker shaft bracket assembly
Valve Lifter
Hook

f
✓
MH061679
Rocker shaft bracket
�as,ombly
e cotter

II
Spring pin

B5282B

To remove the valve cotters, use the Valve Lifter and

Valve Lifter Hook (special tools) to evenly compress the
C1544B valve springs.
(5) Removing nozzle tubes
T he rocker shaft bracket assembly is held in place in the
cylinder head by a spring pin. To remove the assembly,
lift it straight upward.
Nozzle Tube Remover
(3) Removing cylinder head assembly MH061232

C1527A

NOTE:
Whenever a nozzle tube is removed, it must be
B90148 replaced with a new one.

11-18
5.2.2 Inspection
ENGINE - SERVICE PROCEDURES -
Item NV L
Free length Outer valve spring 89.38 85

Rocker bushing­ Inner valve spring 65.04 62

to-rocker shaft
clearance Installed load/ installed length Outer valve spring 450 N {46.1 kgf}/58.35 380 N {39 kgf}/58.35
BO 28
NV 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 spring squareness - 2.5

BO .. Basic D iameter
NV .. Nominal Value
y � ' & L. .... Limit

- : --�&
\f

e
e

I
Runout Tappet-to-crankcase
L 0.5 clearance

I
BO 35
NV 0.06 to0.10
L 0.2

C ylinder head bottom

surface distortion
NV 0.07 or less
L 0.08

Height of cylinder
head from top to
bottom surface
NV 130
L 129.8

Item BO NV L
Valve stem 0. D. Inlet valve 11.95 to11.96 11.85

Exhaust valve 11.91 to 11.93

Valve stem-to-valve guide Inlet valve 12 0.05 to0.09 0.2
clearance
Exhaust valve 12 0.09 to0.12
Valve seat insert seat width Inlet valve 2.69 to2.96 3.5

Exhaust valve
Valve sinkage from cylinder Inlet valve 0.25 to0.75 1.0
head bottom surface
Exhaust valve -0.05 to0.45 0.7
Valve margin Inlet valve 2.2 1.7

Exhaust valve 2.5 2.0

Valve seat angle 45 °
C27578

11-19
 -
Inspection Procedure
ENGINE - SERVICE PROCEDURES

Measure 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.
Measuring
position (4) Tappet-to-crankcase tappet hole clearance

<Tappet measurement> Measuring position

Measuring position
c2734A
C2745A
If the clearance exceeds the specified limit, replace the
rocker bushing.
(2) Replacing rocker bushing

To remove To install

Rocker
Bushing
Puller
MH061236

If the clearance exceeds the specified limit, replace the

tappet.
---....=."-�:;..;;
�.:c.
=' iu
l _0__,�__,,
Adjusting screw side I' Rocker oil hole C27628 (5) Push rod runout

When installing a bushing, face the bushing's seam

toward the rocker adjusting screw and align the bush­
ing and rocker oil holes.
(3) Inspecting valve springs

Squareness
(inner spring only)

®01948

Check for runout and replace the push rod if the dial
reading exceeds the specified limit.

11-20
 ENGINE SERVICE PROCEDURES ID
(6) Cylinder head bottom surface distortion (8) Valve stem-to-valve guide clearance

Valve

C3125A 21653

If distortion exceeds the specified limit, correct it using
a surface grinder.
NOTE:
Replace the cylinder head if grinding causes the height
from its top surface to bottom surface to fall below
129.8mm.
(7) Valve stem outside diameter
Insert the valve in the valve guide and measure the play
at the specified distance from the valve guide's top (as
illustrated). If the amount of play exceeds the specified
limit, replace the valve guide.
(9) Replacing valve guide

Valve Guide
Puller

i+
30091-08100
Measuring position
Valve guide
., Seat the collar---­
•,! of valve guide -- -'t-11-------..-
securely on
cylinder head

To remove To install C3113A

C3102A
Replace the valve if its stem's outside diameter is
below specification or if it is severely worn.
To install a valve guide, insert it with the Valve Guide
Puller (special tool) until its flange sits securely on the
cylinder head.

11-21
 - ENGINE - SERVICE PROCEDURES

(10)Contact between valve and valve seat insert (11)Rectifying valve face

Valve seat
angle
Valve margin

Valve

820248 C2708A C2710B

(a) Apply an even coat of minium to the valve seat With a valve refacer, grind the valve face to achieve the
insert surface that comes into contact with the specified valve seat angle.
valve. NOTE:
(b) Using 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.

000Good Bad Bad

C3127A
C2707A Valve Valve
sinkage Valve seat
angle
If the minium indicates a poor contact pattern, rectify it
as follows:
Minor defect: Lapping
Serious defect: Rectify valve and valve seat

Valve
C2710A

11-22
 ENGINE - SERVICE PROCEDURES

(al Using 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.
(bl After cutting, put some sandpaper of around #400
Cylinder head 1.D. Cylinder head I.D.
grade between the cutter and valve seat insert and 57 +0.03 52 +0.03
0 0
grind the valve seat insert lightly. <Inlet> <Exhaust>
NOTE: C3128B

After rectification, be sure to lap the valve and valve Install Caulking

seat insert. [Refer to item (14) for details.]

D D Caulking
Tool Body
(13)Replacing valve seat insert MH061360

Valve seats are installed by expansion fitting and Caulking Ring

Inlet
should therefore be replaced according to the follow­ MH061650
Exhaust
ing procedure. MH061651

81111B

(b) Check that there is sufficient interference between

the cylinder head and valve seat insert.
(c) Cool the valve seat insert by immersing 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
Cut off.
01973 the periphery of the valve seat insert.
NOTE:
(a) Grind the inside surface of the valve seat insert to When installing the valve seat insert, ensure that the
reduce its thickness. Remove the valve seat insert chamfered side of the Caulking Ring faces the valve
at room temperature. seat insert.
(el Reface the valve seat insert to achieve the specified
seat width and valve sinkage. [See item (12) for
details.]

11-23
 ID ENGINE - SERVICE PROCEDURES

(14)Lapping valve and valve seat insert
Contact between the valve and valve seat insert must
be even over the entire contact area. Lapping should be
carried out whenever the valve or valve seat insert has
been rectified or replaced.
Valve stem
(b) Using the Valve Lapper (special tool), lightly strike
the valve against the valve seat insert while turning
it little by little.
(c) Wash away the compound with gas oil or a similar
fluid.
(d) Apply 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.]

Compound

®01970

(a) Apply a thin, even coat of lapping compound to the

seating surface of the valve.
NOTE:
1. Ensure that no compound adheres to the valve
stem.
2. Start with intermediate-mesh compound (120 to
150 mesh}, and finish with fine-mesh compound
(200 mesh or more).
3. The addition of a small amount of engine oil makes
lapping compound easier to apply.

C3130A

11-24
5.2.3 Reassembly
ENGINE - SERVICE PROCEDURES -
lightly wound end toward
cylinder head

Tightly wound end

toward cylinder head

Leak test: No leaks are allowed

7 with 195 kPa {2 kgf/cm2}
hydraulic pressure

17

Apply sealant to nozzle tube.

(THREEBOND 1211 or equivalent)

Apply sealant
(HERMESEAL S-2 or equivalent)
4.9N-m
{3.5 kgf-m}
21 3 20

16 Cylinder head bolt tightening

15 sequence [refer to item (6).]

Assembly sequence

@➔@➔@➔@➔®➔ 13➔12➔® ➔8➔7 ➔6➔5➔4➔3➔2➔1

16➔15j 22➔21 j
For parts with circled numbers, refer to the following section, "Reassembly Procedure."
10369

11-25
 -
Reassembly Procedure
ENGINE - SERVICE PROCEDURES

(3) Valve stem seal installation

(1) Water director and sealing cap installation

Water director
Sealing cap
Align notch with this line. F,;i.;.;z===;zf,

Valve Stem Seal Installer

ME067431
Apply sealant
(HERMESEAL S-2
or equivalent)
10363
Valve Stem Seal
Align each water director with the notch provided, as
shown in the illustration.
Cylinder head
(2) Nozzle tube installation

Nozzle Tube
Installer Bolt
MH061231
15 to 20 N-m
Nozzle Tube Flange {1.5 to 2.0 kgf-m} 09179
MH061416

Nozzle Tube Stamp MS x 1.25

MH061229 To install a valve stem seal, first apply engine oil to the
seal lip. T hen, push in the seal using the Valve Stem
O-ring
Seal Installer (special tool), striking the tool until it
Nozzle tube --- Apply engine oil.
touches the cylinder head.
Apply sealant
(THREEBOND 1211 NOTE:
or equivalent).
09178
1. When installing a valve, apply a small amount 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) Apply sealant to the new nozzle tube, and insert the
nozzle tube into the cylinder head.
(cl Using the Nozzle Tube Installer Flange (special
tool), press the nozzle tube into the cylinder head.
(d) Apply engine oil to the Nozzle Tube Stamp (special
tool) and insert it into the nozzle tube.
(e) Screw in the Nozzle Tube Installer Bolt (special
tool) until the Nozzle Tube Stamp can be pulled out
of the bottom of the cylinder head.
(f) After installing the nozzle tube, carry out a leak test
to verify air-tightness.

11-26
 ENGINE - SERVICE PROCEDURES ID
(4) Valve cotter installation Install the rocker shaft bracket by positioning it on the
spring pin in the cylinder head. Mount the cylinder
head by positioning it on the dowel pins in the crank­
case.
(6) lightening cylinder head bolts
Valve Lifter
Hook
MH061679

Valve cotter

852828

Install the valve cotter while evenly compressing the

spring using the Valve Lifter and Valve Lifter Hook (spe­
cial tools). C6649A
NOTE:
Valve springs must be installed with their tightly lighten the cylinder head bolts to 175 N-m {18 kgf-m}
wound portions toward the cylinder head. (wet) in the order shown.
(5) Mounting rocker shaft bracket and cylinder head After confirming that the bolts are tightened to 175 N-m
{18 kgf-m}, give each one an extra turn in accordance
with the following procedure.
Rocker shaft
bracket bolt � Rocker shaft
59 N-m bracket
{6 kgf•m}
"-, �
�

� � Cylinder
Spring pin ------<ti) o head bolt

Cylinder
head

Rod (lo, exteosiool

Cylinder 80654A
gasket

(a) Before fitting the Socket Wrench (special tool) over

a cylinder head bolt, turn the holder counter-clock­
wise to tension the built-in socket spring.
Knock
pin

Engine Parts contact phone: 269 673 1638

Email: EngineParts2@gmail.com
89014C

11-27
 - ENGINE - SERVICE PROCEDURES

Socket Wrench
MH061540

09182

( 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.

Scale inscribed
on socket

Lines inscribed
on holder
80656A

( c) Observing the inscribed lines on the holder and

socket, turn the socket clockwise by 90 to110° (1
pitch = 10°) to fully tighten the bolt.

Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com

11-28
5.3 Flywheel, liming Gears, and Camshaft
ENGINE - SERVICE PROCEDURES -
5.3.1 Disassembly

<With axial-lip-type <With mechanical <With electric

tachometer drive> speed sensor>
oil seal>
1 0A
�c
1

r
(\\
_,
:,:

\ 1 3
5 7 Oil leaks
Wear/deterioration
Streaks/cracks/stepped wear
on friction surface
<With radial-lip-type ®43651
<With mechanical tachometer
oil seal> drive>

Damage/abnormally
worn gear teeth
9

7
5 Wear/deterioration
3
Streaks/cracks/stepped wear
Disassembly sequence on friction surface
1 Flywheel mounting bolt 7 Flywheel housing *® Ring gear
*2 Pilot bearing *8 Rear oil seal slinger 10 Tachometer drive
@ Flywheel <models with axial-lip­ *1 OA Speed sensor
@ Oil seal retainer type oil seal only> 108 Cover
5 Oil seal Sleeve <models with
@ Collar wet type clutch only>
For parts with circled numbers, refer to the following section, uoisassembly Procedure."
Parts marked with "*" should not be removed unless defects are evident. C1926L

11-29
 - ENGINE - SERVICE PROCEDURES

* liming gear backlash

Item NV L
Between crankshaft gear and idler gear B 0.08 to 0.20 0.4
Between idler gear A and camshaft gear 0.07 to 0.18 0.4
Between idler gear A and idler gear C 0.07 to 0.18 0.4
Between injection pump gear and idler gear C 0.08 to 0.20 0.4

Injection pump gear

(Refer to Group 61, Special Equipment)
NV .. Nominal Value
L. .... Limit
21 Oil leaks

* Idler gear end play

NV 0.05 to 0.15
L 0.4

* Camshaft gear end play

NV 0.05 to 0.22
Wear
15 L 0.4

Disassembly sequence
® Camshaft assembly 15 Idler shaft bolt 19 Idler gear B
*® Camshaft 16 Thrust plate 20 Idler shaft A
*® Camshaft gear 17 Idler gear C 20A Idler shaft C
14 Thrust plate 18 Idler gear A *21 Rear plate

For parts with circled numbers, refer to the following section, "Disassembly Procedure."
Parts marked with "*"
should be inspected prior to disassembly.
Parts marked with "*" should not be removed unless defects are evident.

C1927D

11-30
Disassembly Procedure
ENGINE - SERVICE PROCEDURES

(3) Removing ring gear

-
(1) Removing flywheel

Threaded hole
for removal

Ring gear
B2356C
C19288
To remove the ring gear, heat it evenly with an acety­
To remove the flywheel, screw its mounting bolts into lene torch, then tap around its entire periphery with a
the threaded removal hole. hammer and rod.

(2) Removing collar and oil seal retainer (4) Measuring gear backlash

Threaded hole �
for removal
(M4x0.7)
Collar �

� ()l'l 0

Thmaded hole
for removal
�C)
�

Oil seal retainer

43652 C1930A

• To remove the collar, screw M4 x 0.7 bolts into the
threaded removal holes.
• To remove the oil seal retainer, screw its mounting
bolts into the threaded removal holes. Remove the
oil seal retainer with the oil seal attached.
<Radial-lip-type oil seal only>
If backlash exceeds the specified limit, inspect the idler
gear bushings and gears, and replace parts as
required.
NOTE:
For any pair of gears, measure backlash at more than 3
points to determine whether it is acceptable.

11-31
 - ENGINE - SERVICE PROCEDURES

(5) Measuring idler gear and camshaft gear end play (7) Removing camshaft gear

♦
Idler gear Camshaft gear

11824 10992

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) Removing camshaft press.
NOTE:
Do not attempt to remove the gear by striking it with a
hammer. Be sure to use a press .
Thrust plate

Camshaft gear

Camshaft

Remove bolts through

these holes

Thrust plate mounting bolt

10991

Remove the thrust plate mounting bolts via the holes in

the camshaft gear. Remove the camshaft together with
the camshaft gear and thrust plate.

11-32
5.3.2 Inspection
ENGINE - SERVICE PROCEDURES
-
Item NV L
Friction surface distortion 0.1 or less 0.2
Distance from clutch cover 47.8 to 48.2 49.5
mounting surface to fric­
tion surface

®43653

Clearance
BD 40
NV 0.03 to 0.06
L 0.2

Clearance
BD 46
NV 0.03 to 0.06
L 0.2

BD .. Basic Diameter
NV .. Nominal Value
L ..... Limit

Item BD NV L
Cam profile (difference Inlet 8.83 8.3
between base circle diameter
and lobe height) Exhaust 8.82 8.3
Camshaft bend 0.05 or less 0.08
Camshaft journal-to-camshaft No. 1 65.00 0.03 to 0.08 0.25
bushing clearance
No.2 65.25
No.3,4 65.50
No. 5,6 65.75
No. 7 66.00
Camshaft gear-to-camshaft interference 40 0.02 to 0.05 Can be reassembled
up to 3 times
C2759D

11-33
 -
Inspection Procedure
ENGINE - SERVICE PROCEDURES

(3) Idler gear-to-idler shaft clearance

(1) Friction surface distortion

Measuring position Measuring position

Dial indicator EB
Surface plate

C3807B

C3506A
If the clearance exceeds the specified limit, replace the
Place the flywheel on a surface plate. To measure dis­ bushing in the idler gear.
tortion, pass a dial indicator over the flywheel from its (4) Replacing idler gear bushing
periphery toward 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 Gear
Bushing Puller
Clutch cover MH061228
mounting surface (for idler gear "A"
MH062046
(for idler gear "C")
Friction surface

Removal Installation

C3509B

C3808A
Grind the friction surface such that dimension B (the
distance from the clutch cover mounting surface to the
Install the bushing from the side of the idler gear
friction surface) is below the specified limit. The fric­
whose internal diameter is chamfered.
tion surface must 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 dimension B exceeds the specified limit, replace the
ance is smaller than the nominal value, ream the bush­
flywheel.
ing.

11-34
 ENGINE - SERVICE PROCEDURES

(5) Cam profile (difference between base circle diame­ (7) Replacing camshaft bushings
-
ter and lobe height) (a) Removal
Remove the camshaft bushings in the following
order: No.6 ➔ No.5 ➔ No.4 ➔ No.3 ➔ No.2 ➔ No.1
Measuring
➔ No.7. Remove them in accordance with the fol­
position lowing instructions.

R1 obe 1) Removing camshaft bushings Nos. 6 to 1

) �
he;ghl

M
9.5 9.5 Base
circle No. 7 camshaft bushing
diameter
Camshaft Bushing
Extractor Bar
MH062118
C4101A

Measure the lobe heights and base circle diameters.

Replace the camshaft if the difference between them is ( Camshaft
MHD62119
Bushing Extractor Guide
below the limit.
84859A
NOTE:
Since the cams are tapered, they must be measured at
the points shown in the illustration.
(6) Camshaft journal-to-crankcase camshaft bushing
clearance

Camshaft Camshaft Bushing

bushing Extractor Adapter

No.1 MH062120

No.2 MH062121

No.3,4 MH062122

No.5,6 MH062123
09166
84860A

If the clearance exceeds the specified limit, replace the

camshaft bushing. [Refer to item (7) for details.]
a) Mount the Camshaft Bushing Extractor Adapter
and Camshaft Bushing Extractor Guide (special
tools) onto the Camshaft Bushing Extractor Bar
(special tool). Insert this assembly into the crank­
case. When doing this, fit the Guide onto the No. 7
camshaft bushing to support the Bar.
b) Hold the Camshaft Bushing Extractor Adapter
against the No. 6 camshaft bushing. As shown in
the illustration, remove the No. 6 bushing by strik­
ing the Bar with a hammer.

11-35
- ENGINE - SERVICE PROCEDURES

c) After removing the No. 6 bushing, remove bush­
ings Nos. 5 to 1 in that order using the appropriate
Camshaft Bushing Extractor Adapter for each one.
2) Removing camshaft bushing No. 7
a) Mount the Camshaft Bushing Installer Adapters
(special tool) and bushings Nos. 2 to 4 on the Cam­
shaft Bushing Installer Bar (special tool). When
doing this, align the inscribed lines on the Adapters
with the clinches (seams) on the bushings and
position the oil holes as shown in the illustration.

Camshaft Bushin g
Installer Guide
MH062127

<::'
/
Camshaft Bushin
B4861A g t:::'\ _,,- Arrow
Installer Bar � m ark
MH062125 /

(b) Installation 09171

In accordance with the following instructions, install

b) Fit the Camshaft Bushing Installer Guide (special
camshaft bushings Nos. 2, 3, and 4 simultaneously,
then bushings Nos. 5 and 6 simultaneously, then bush­
ings Nos. 1 and 7 in that order.
1) Simultaneous installation of bushings Nos. 2, 3,
and 4
tool) in the place where the No. 1 camshaft bushing
is to be installed so that the Camshaft Bushing
Installer Bar (special tool) may be supported by it.
Then, insert the Camshaft Bushing Installer Bar
into the crankcase, making sure that the arrow on it
points toward the top of the crankcase.

No. 2 camshaft bushin g No. 3 camshaft bushing

�ing ing pin Camshaft Bushing
� Installer Nut
MH062130
Camshaft Bushin g Camshaft Bushin g
Installer Adapter Installer Adapter
MH062133 MH062134 No. 2 camshaft
bushin g

No �� ;g
�
ViewA
�nm
contact
Camshaft Bushin g � Clinch 09172

-
Installer Adapter Oilhole�
MH062135
c) Confirm that the clinches (seams) on the bushings
ViewA
are aligned with the inscribed lines on the Cam­
shaft Bushing Installer Adapters [refer to item (a)
for details]. Then, screw the Camshaft Bushing
Installer Nut (special tool) onto the end of the Cam­
Engraved lin e shaft Bushing Installer Bar, and tighten the Nut to
(on camshaft bushin g
installer adaptor) press-fit the bushings. Continue turning the Nut
84862D until the Bar's flange touches the crankcase.

11-36
 ENGINE - SERVICE PROCEDURES

d) After installing the bushings, remove the Camshaft 3) Installation of bushings Nos. 1 and 7
-·
Bushing Installer Nut and gently withdraw the
Camshaft Bushing Installer Bar. �""'""""'-�;�:,;l sh ;ag

NOTE:
When removing the Camshaft Bushing Installer Bar,
take care not to damage the inside surfaces of the
bushings.
hne Drive in until seated
2) Simultaneous installation of bushings Nos. 5 and 6

Camshaft
Bushing
Installer
MH062143

Drive in
until seated
Camshaft Bushing B4866D
Installer Bar
MH062125
Camshaft Bushing
Installer Adaptor Install bushings Nos. 1 and 7 as follows: Align the
MH062136
Camshaft Bushing inscribed lines on the Camshaft Bushing Installer (spe­
Installer Adaptor
MH062137 cial tool) with the clinches (seams) on the bushing and
position the oil holes as shown 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 Camshaft Bushing Installer Adapters (special tool)
for bushings Nos. 5 and 6.

11-37
 -
(8) Camshaft bend
ENGINE - SERVICE PROCEDURES

(9) Camshaft-to-camshaft gear interference

10995 11834

Measure the extent of bending in the crankshaft. If it
exceeds the specified limit, replace the crankshaft.
NOTE:
Apply a dial indicator to the camshaft and turn the
camshaft through one revolution. One-half of the dial
indicator reading represents the amount of bending.
If the interference is below the specified nominal value,
replace the camshaft or camshaft gear.
NOTE:
Even if the interference is up to specification, reas­
sembly should be carried out no more than 3 times.

11-38
5.3.3 Reassembly
ENGINE - SERVICE PROCEDURES -
BD . . Basic Diameter
Flywheel housing NV .. Nominal Value
eccentricity L ..... Limit
/ L 0.2
7
Idler gear end play
Bend lock washer NV 0.05 to 0.15
L 0.4
Camshaft gear-to-camshaft
interference

,:J_
BD 40
NV 0.02 to 0.05
L.lr...,.,_L Reassemble max. 3 times 10
,,_
_,;;,.)...,,.liitlrc,ill.lM �t.ti,,-��...
-1,1L�12 Camshaft gear end play
<Radial-lip-type oil seal> , lll' NV 0.05 to 0.22
1�13 11
L 0.4
14 f

2
r--;i_;�,..,,,C__L11 1 315 N-m {32 kgf-m} (wet)
6
19
18
5 Apply engine oil or 98 N-m {10 kgf-m}
lithium-base grease 15 155 N-m {16 kgf-m}
to oil seal lip 6
4
16
9
20
3-----�
8 Flywheel friction Backlash Backlash
surface runout NV 0.07 to 0.18 NV 0.07 to 0.18
86013A
L 0.2 L 0.4 L 0.4
*10A
10B Backlash
NV 0.08 to 0.20
L 0.4

69 N-m {7 kgf-m}

Assembly sequence

For parts with circled numbers, refer to the following section, "Reassembly Procedure. n
For parts marked with"*" refer to Group 61, Special Equipment.

B1902E

11-39
 -
Reassembly Procedure
ENGINE - SERVICE PROCEDURES

(3) Fitting camshaft gear

(1) Mounting rear plate

Camshaft
gear

Thrust
plate
Camshaft

C6230C
Mount the rear plate and gasket, ensuring that they are
aligned with the locating pins on the crankcase.
After the gasket is fitted, its bottom (oil pan mounting
surface) will protrude. Cut off the protruding part of the
gasket after fitting the flywheel housing.
(2) Installing idler gears
Crankshaft gear
21921
(a) With the alignment marks "4" facing away from
the thrust plate, fit the camshaft gear using a press
load A of 15.69 to 58.8 kN {1,600 to 6,000 kgf}.
B: Block
(b) Press the camshaft gear until it sits snugly on the
camshaft.
NOTE:
Apply pressure to the middle part of the camshaft
gear. Do not apply pressure to the gear's periphery
since the gear would break.

155 N-m 155 N:m

{16 kgf-m} {16 kgf-m}
C6231D

Fit idler gear B and the crankshaft gear such that their
"1" alignment marks are aligned with each other.
Then, fit idler gears A and C such that their "2" align­
ment marks are aligned with each other. Tighten the
idler shaft bolts to the specified torques.
NOTE:
1. Align the "1" marks with pistons Nos. 1 and 6 at
top dead center.
2. Ensure that the "1" marks are aligned before align­
ing the "2" marks.
22021
(c) Make a punch mark C on the middle part of the
camshaft gear to show that reinstallation has been
performed.
NOTE:
The camshaft gear and camshaft can be fitted together
a maximum of three times. If three punch marks C
have already been made, replace the camshaft gear
and camshaft with new ones.

11-40
 (4) Installing camshaft
ENGINE - SERVICE PROCEDURES -
the oil seal slinger until it is seated tightly on the crank­
shaft gear.
(8) Fitting oil seal sleeve <With radial-lip-type oil seal>

Correct sleeve
position

Dowel pin

Strike
Camshaft gear

C6231C Oil Seal Sleeve Installer

31191-07100

Install the camshaft such that the "4" alignment marks
on the camshaft gear and idler gear A are aligned with
each other.
NOTE:
1. When inserting the camshaft, take care not to
damage the camshaft bushings.
2. Ensure that the "1" marks on the crankshaft gear
and idler gear Bare aligned before aligning the "4"
marks.
(5) Check the end play in the camshaft gear and idler
gears. [Refer to item (5) of section 5.3.1 for details.)
(6) Check the backlash in the gears. [Refer to item (4)
of section 5.3.1 for details.]
(7) Installing rear oil seal slinger <With axial-lip-type
oil seal>
Crankshaft
85774A
Apply engine oil to the crankshaft and to the inside
diameter of the sleeve. Using the Oil Seal Sleeve
Installer (special tool), press the sleeve into position on
the crankshaft.
NOTE:
1. The sleeve's inside diameter is chamfered on one
side. When fitting the sleeve, face the chamfered
side toward the crankshaft.
2. Since the sleeve must be pushed into the correct
position (shown in the illustration), you must use
the Oil Seal Sleeve Installer. The sleeve is in the
correct position when the Installer can be driven in
no further.
(9) Fitting ring gear

Rear oil seal slinger Ring gear

Oil Seal Installer
MH061652

Chamfered

C55298 Flywheel B2357C

Face the threaded groove toward the flywheel. Using Using a piston heater, heat the ring gear to approxi­
the Oil Seal Slinger 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
ENGINE - SERVICE PROCEDURES

(11 )Checking flywheel housing eccentricity

Apply$2 mm
sealant bead
(THREEBOND
1207C)

B48570 C6233B

(a) Apply a bead of sealant to the flywheel housing as
shown in the illustration. Fit the flywheel housing
within 3 minutes of applying the sealant.
NOTE:
1. Apply a new bead of sealant whenever the fly­
wheel housing mounting bolts have been loos­
ened.
2. Keep the flywheel housing sealing surface free of
dirt and oil.
3. Apply the sealant evenly and without breaks.
4. When fitting the flywheel housing, hold it firmly in
position to prevent spreading the sealant.
5. After fitting the flywheel housing, wait at least 1
hour before starting the engine.
lighten the flywheel housing mounting bolts to the
specified torque. Then, rotate the flywheel and check
for eccentricity at the flywheel housing joint. If eccen­
tricity exceeds the specified limit, remove the flywheel
housing, refit it according to the instructions in item
(10), and measure the eccentricity again.
If the eccentricity exceeds the specified limit even after
remedial measures have been taken, replace the fly­
wheel housing.
(12)Installing oil seal
<Axial-lip-type oil seal>

Locating pin

Rear
oil seal

®27603
69N-m
{7 kgf-m}
(a) Apply an even, unbroken bead of sealant A to sur­
C6230E 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.
NOTE:
1. Ensure that the sealant application position on the
rear oil seal is clean before applying sealant.
2. When fitting the rear oil seal, hold it firmly in posi­
tion to prevent spreading the sealant.
11-42
 3.
ENGINE - SERVICE PROCEDURES

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 of the rear oil seal have been loos­
ened.
<Radial-lip-type oil seal>

315 N-m
{32 kgf-m}

Oil Seal Installer

31191-04300

Oil seal retainer (-)�

Flywheel
C62368

After tightening the flywheel mounting bolts to the

C6209C
(a) To install the oil seal, apply pressure evenly to its
entire periphery using the Oil Seal Installer (special
tool) until it reaches the step in the oil seal retainer.
specified torque, rotate the flywheel and check for run­
out. If runout exceeds the specified limit, check the
bolts' tightness and/or check the mounting surface.
(14)Checking valve timing
If you need to recheck the valve timing after reassem­
bling the engine, do so according to the following pro­
cedure.

Rocker arm
\
Oil Seal Installer
31191-04300

Oil seal retainer

Oil seal

� C6209D B5714C

(b) Turn the oil seal retainer over, then apply the Oil
Seal Installer (special tool) to the oil seal from the
opposite direction until the oil seal reaches the
retainer's outer surface.
NOTE:
Different oil seals have different installation direc­
tions. Be sure to install the oil seal in the correct direc­
tion.
(a) Bring cylinder No.1 to its compression-stroke top
dead center position.
(b) Insert a 3 mm shim between cylinder No.1's
exhaust valve rocker arm and valve cap. Make any
adjustments necessary using the adjusting screw,
then tighten the lock nut.

11-43
 - ENGINE - SERVICE PROCEDURES

Confirmation marks
10408

(c) Crank the engine in its normal direction of rotation

(clockwise when viewed from the front). When cyl­
inder No.1 's exhaust valve begins to lift, confirm
that the pointer on the flywheel housing is between
the valve timing confirmation marks on the fly­
wheel's outer periphery. If the timing marks are in
the wrong position, refer to items (2) and (4), and
check the timing marks again.

11-44
5.4 Crankcase and Main Moving Parts
ENGINE - SERVICE PROCEDURES -
5.4.1 Disassembly

NV .. Nominal Value

4
L ..... Limit

e--
0-- }
5 Damage/
aboo,malwea,
�6

Damage/discoloration
Scratches on outer periphery/
7 '\._ cracks on top/

b
<;.J...__.,J.

8 discoloration/melting

t\
C) *topProjection of piston from
surface of crankcase
'J
NV 0.87 to 1.33

JJ-10
Cracks 9

* NV
Connecting rod end play
0.2 to 0.5
I

L 1.0 I
3 Scratches/corrosion/
peeling on inner and
outer peripheries

Repair kit:
Liner and Piston Kit

Disassembly sequence
1 Connecting rod cap @ Oil ring
2 Lower connecting rod bearing 7 Piston pin
3 Upper connecting rod bearing @ Piston
@ 1st compression ring ® Connecting rod
@ 2nd compression ring *10 Connecting rod bolt

For parts with circled numbers, refer to the following section,"Disassembly Procedure."
Parts marked with"*" should be inspected prior to disassembly.
Parts marked with"*" should not be removed unless defects are evident.
C2337G

11-45
 - ENGINE - SERVICE PROCEDURES

NV .. Nominal Value
L ..... Limit Clogged oil hole

26

/4 20
Scratches/co�r!sion/
peeling0!' inner and
Y ✓
outer penphenes
" L'\
,--...::
�-,, �
/\

� �17
���
peehngon �
15 inner and
outer
19 peripheries
Scratches, cracks, dents, seisure,
clogged oil hole, corrosion R
J!i

12
* End play
NV 0.09 to 0.23
L 0.4
11
Disassembly sequence
11 Torsional damper 17 Thrust plate *122 Cylinder liner
12 Crankshaft pulley 18 Lower 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
1
*® Crankshaft gear 26 Crankcase
*115 Front oil seal slinger
16 Main bearing cap

For parts with circled numbers, refer to the following section, "Disassembly Procedure."
Parts marked with u*" should be inspected prior to disassembly.
Parts marked with "*1" should not be removed unless defects are evident.
Parts marked with "*2" must not be reused since they are held in place by thread-lock cement and may be deformed
during disassembly.
80599G

11-46
 Disassembly Procedure
ENGINE - SERVICE PROCEDURES

(3) Removing pistons

-
(1) Piston projection
The piston projection measurements must conform
with specifications, partly since they affect engine per­
formance, and partly since the pistons must not inter­
fere with the valves.

Fr.o
+ •
. •

Measuring point

Withdraw the piston from the crankcase together with

its connecting rod, working from the top surface of the
crankcase.

C23398
NOTE:
When removing a piston, take care not to damage 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) Using the dial indicator, find the piston's top dead
center position.
(c) Take measurements at 4 points on the piston's top
surface and determine their average.
(d) If the piston projection does not conform with
specifications, check the clearances between pis­
ton/connecting rod and neighboring parts.
(2) Connecting rod end play

Remove the snap rings, then use a rod and hammer 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.

C2340A

Measure each connecting rod's end play. If any mea­

surement exceeds the specified limit, replace the con­
necting rod.

11-47
 -
(5) Removing piston rings
ENGINE - SERVICE PROCEDURES
(6) Crankshaft end play
80181C
Before removing the main' bearing caps, measure 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.]
Engine Parts contact phone: 269 673 1638
11-48
(7) Removing main bearing caps
M10 x 1.5
801838
The rearmost main bearing cap is located on dowel
pins and must therefore be removed with a slide ham­
mer.
(8) Removing crankshaft gear
Rear oil seal slinger
(a) Split the rear oil seal slinger with a chisel and
remove it from the crankshaft.
(b) Remove 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.
Email: EngineParts2@gmail.com
5.4.2 Inspection
ENGINE - SERVICE PROCEDURES -
End gap
Item NV L

1st compression ring 0.4 to 0.55 1.5

0 2nd compression ring 0.5 to 0.65 1.5

0
Oil ring 0.4 to 0.6 1.5

0
Clearance
BO 50
NV 0.01 to 0.02
L 0.1

Piston ring groove-to-piston ring clearance

Item NV L
1st com- 6024 0.09 to 0.13 0.25
pression
Clearance ring 6024-T, TC, TL 0.02 to 0.10
BO 50
NV 0.02 to 0.05 2nd com- 6024 0.05 to 0.08 0.25
L 0.1 pression
ring 6024-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
NV 0.07 or less
L 0.2

Flatness of cylinder liner

supporting flange
L 0.1 BO NV
130 0.178 to 0.204
6024-T, TC, 0.193 to 0.219
TL

Projection of cylinder liner from

top surface of crankcase
NV 0.01 to 0.08
BO . . Basic Diameter
Inside diameter NV .. Nominal Value
NV 130.014 to 130.054 L ..... Limit
L 130.25

Cylindricity
NV 0.02 or less Connecting rod bearing-to-crankshaft
pin clearance
BO 84
NV 0.07 to 0.13
L 0.25
Connecting rod bearing span when
free
L Less than 90.5

C2760C

11-49
 - ENGINE - SERVICE PROCEDURES

BO .. Basic Diameter
NV .. Nominal Value
L ..... Limit

Bend
NV 0.04 or less
L 0.1
Roundness
NV 0.01 or less
L 0.08
Cylindricity
NV 0.006 or less

Main bearing-to-crankshaft
journal clearance
BO 100
NV 0.08 to 0.15
L 0.25
Main bearing span when
free
L Less than 106.5
80599H

Inspection Procedure
(1) Flatness of cylinder-liner-supporting flange on
crankcase

If the measured value is out of specification, replace

the crankcase.
11-50
 (2) Distortion of crankcase top surface
ENGINE SERVICE PROCEDURES

(4) Cylinder liner flange projection

-
Measurement points

If distortion of the crankcase top surface exceeds the
specified limit, correct it with a surface grinder.
NOTE:
When grinding the crankcase, take care thatthe piston
projection does not exceed the specified nominal
value. [Refer to item { 1) of section 5.4.1 for details.]
(3) Cylinder liner inside diameter
If any cylinder liner projection does not conform with
its specified nominal value, replace the cylinder liner or
crankcase. [Refer to item (5) for details of cylinder liner
replacement.]
(5) Replacing cylinder liner
(a) Removal

Cylinder Liner Extractor

MH061490
Size mark
30
or more ---lh"7H .,.__
-t

70 A: Direction of
or more crankshaft axis
B: Direction of right
angle to crank­
shaft axis C4414B
C4424A

Measure each cylinder liner's inside diameter at 6

points, as shown in the illustration. If the inside diame­
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
ENGINE - SERVICE PROCEDURES

Strike in.
Cylinder Liner Instal e
l r
MH061759

Piston Cylinder liner

Cylinder liner

C44278
C4813C

3) Using the Cylinder Liner Installer (special tool),

1) Make sure the new cylinder liner bears the same 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 0-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 0-rings to swell. Immedi­
ately wipe off any such fluids that come into con­
0-ring-=-➔ tact with the 0-rings.
Rubber
3. After installing a cylinder liner, carry out a leak test
Soapsuds to
packing be applied to check for air-tightness. Apply thrust force to the
0-ring --=::::iii I cylinder liner flange.

Soap suds to
be applied

C44268

2) Fit new 0-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
 ENGINE

(6) Selection of pistons and cylinder liners

SERVICE PROCEDURES

(b) Oversized piston

A piston may be either standard or oversized. Cylinder
liners are selected accordingly.
(a) Standard piston
-
In accordance with the following instructions, bore the
cylinder liner to suit the oversized piston to be used
(+0.5, +0.75, or +1.00 mm).

Cylinder liner I.D.

Size mark stamped

30
or more --4.......,.�..,--..i

j\
Size mark
(A, B,C) 70 A:Axial direction of crank­
or more shaft
8: Direction at right angles
to crankshaft
C4424A
Oversize piston O.D.

102
<6D24>
97
<6D24-T,
TC,TL>

Cylinder liner

Piston
43429 C4428A

1) The piston must bear the same size mark as that
stamped on the cylinder liner.
2) The weight of all 6 of an engine's pistons must be
within 10 g of the weight that is stamped on each
piston's crown.
NOTE:
Whenever a piston is replaced, the piston rings must
also be replaced. Never use old piston rings.
1) Determine the amount of metal to bore out. To do
this, measure the inside diameter of every cylinder
liner and find the most worn point.
2) Bore and hone-finish the cylinder liner to achieve
the specified nominal clearance between the over­
sized piston and cylinder liner.
NOTE:
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 to the increased cylinder
liner dimension.

11-53
 -
(7) Piston-to-cylinder liner clearance
ENGINE SERVICE PROCEDURES

(9) Piston ring gap

If the clearance is out of specification, replace the pis­
ton or cylinder liner. [Refer to item (6) for details.]
(8) Piston-to-piston ring clearance

0
Piston

Piston ring Cylinder liner

C4807B

Measure the piston ring gaps with the piston rings hor­
izontally pushed into a standard cylinder liner, either in
C4806B
or out of the crankcase.
Replace the rings if any gap exceeds the specified limit.
If the clearance exceeds the specified limit, replace the
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. Always replace piston rings as a set, never individ­ (10)Piston pin-to•piston pin hole clearance
ually.
Piston

1st
compression ring

Piston �
EB

C4810D
If the clearance exceeds the specified limit, replace the
Measure the 1st compression 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
 ENGINE - SERVICE PROCEDURES

(11) Piston pin-to-connecting rod small end bushing (a) Removing bushing
-
clearance

Connecting Guide Plate

rod bushing Assembly
MH063368

Piston pin

C5203A

1) Remove the bearing from the connecting rod's big

If the clearance exceeds the specified limit, replace the
connecting rod bushing.
(12)Replacing connecting rod bushing
end, then mount the connecting rod on the Base
(special tool).
2) Fit the Mandrel and Collar A (special tools) onto the
connecting rod's small end as shown in the illustra­
tion. Slowly 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}

Collar B
MH062189 __...,.,__..,,,
Bushing
Collar A
MH063370
10976

Replace the bushing using the Connecting Rod Bush­

ing Puller (special tool).
10977

1) Set up the Mandrel, Collar B, Collar A, and the Nut

Engine Parts contact phone: 269 673 1638 (special tools) on the bushing as shown in the
Email: EngineParts2@gmail.com illustration.
2) Apply engine oil to the connecting rod's small end
and to the bushing.
3) Using 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:
ENGINE - SERVICE PROCEDURES

1. When press-fitting the bushing, align the oil hole

in the bushing with the oil hole in the connecting
rod.
2. When the piston pin is inserted, ensure that it
turns easily and without play.
(13)Connecting rod bend and twist

Bend
e = 100
C5209A
Connecting
rod aligner
e 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
Piston pin
span is insufficient.
(15)Connecting rod bearing-to-crankshaft pin clear­
C5205A C5206A
ance

Connecting rod bearing inside diameter

Measuring position
e

C5207A C5208A

Measure the amount of bend and twist in the connect­

ing rod using a special connecting rod aligner. If the 01996
measurements exceed the specified limits, replace the Crankshaft pin outside diameter
connecting rod or rectify it using a press. Measuring position
NOTE: Measuring direction
1. Measurements must be made with the connecting
rod bushing and upper and lower connecting rod
bearings fitted in their respective positions.
2. Measurements must be made with the connecting
rod cap mounting nuts tightened to their specified
torque.
C5223A
(14)Span of connecting rod bearings and main bear­
ings 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
 ENGINE - SERVICE PROCEDURES

(16) Main bearing-to-crankshaft journal clearance (18)Crankshaft bend

-
Main bearing inside diameter

C5524A C5526A
Crankshaft journal outside diameter
Measuring direction Measuring position
Measure 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.
C5523A
(19)Grinding crankshaft to undersize
If the clearance exceeds the specified limit, replace the
upper and lower bearings as a set. 42.0
(17)Roundness and cylindricity of crankshaft pin and
journal

Roundness Cylindricity 75±0.07

RS
Measuring direction Measuring position R5

C5527A

Any damaged or scorched journal or pin must be

ground in accordance with the following instructions.
If grinding is carried out, the main bearing must 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)
(b) Grind such that the width of the journal and pin
for details.]
does not change.
(c) Finish the corner fillet smoothly and to the speci­
fied radius.

11-57
 Ill ENGINE - SERVICE PROCEDURES

(d) Use magnetic flaw detection to check for ground
cracks. Also, check that the Shore hardness of the
surface has not dropped below Hs 75.
Grinding Finishing
(e) When grinding, turn the crankshaft counter-clock­
wise as viewed from its front end. The grinder
should also rotate counter-clockwise as viewed
from the crankshaft's front end.
(f) When finishing the crankshaft with sandpaper or a
whetstone, turn the crankshaft clockwise.

Whetstone
or sand paper

C5509A

Amount of Journal 0. D. Pin 0. D. finished Roundness Cylindricity

undersize finished dimension dimension

--0.25 --0.08 --0.06 0.01 or less 0.006 or less

99.75 --0.10 83.75 --0.09

--0.50 -0.08 --0.06

99.50 --0.10 83.50 --0.09

--0.75 --0.08 --0.06

99.25 --0.10 83.25 --0.09

-1.00 --0.08 -0.06

99.00 --0.10 83.00 --0.09

Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com

11-58
5.4.3 Reassembly
ENGINE - SERVICE PROCEDURES -
NV .. Nominal Value

7
Assembly sequence L. .... Limit

26➔22➔®l➔@➔@➔(®J➔@➔@➔@➔@ Cylinder liner

flange projection
�@➔CD NV 0.01 to 0.08
@➔@➔7➔@➔@➔@➔@ -----�
@-1
➔@➔14➔@➔12➔11
For parts with circled numbers, refer to the following section,
"Reassembly Procedure."

10
Locating pin

34N-m
{3.5kgf-m}
23
3 -"!----Hle-=::::::..,_JJ,
24
2-�---,l--f!-,
Lug direction
1-��.....c......-4- --""-t-"'--f-t--.- �CW--
Expander 1st
spring ends compression
ring gap

Piston projection 115 N-m

NV 0.87 to 1.33 {12kgf-m}+60" 115N-m{12kgf-m}
(wet) (wet)

33N-m
{3.4kgf-m}

Rear oil seal slinger

[Refer to item (7) of
section 5.3.3]
Locating pin Oil seal sleeve
[Refer to item (8) of
section 5.3.3]
175 N,m
{18kgf-m}

11
17 Side with oil groove
faces sliding surface
13 Connecting rod Crankshaft end
end play play
Apply lithium-base NV 0.2 to 0.5 NV 0.09 to 0.23
grease to lip L 1.0 L 0.4

C5835F

11-59
-
Reassembly Procedure
ENGINE - SERVICE PROCEDURES

(3) Installing upper main bearing and thrust plate

(1) Installing oil spray plug

Thrust _plate_

C23358
Install the upper main bearing such that the 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
0 0 any of these is used, ensure that the correct size
thrust plate is fitted to the bearing cap [refer to
item (7) for details].
I
�.: (4) Installing crankshaft gear
C5836C

Insert the oil jet's locating pin into the hole on the crank­ Dowel pin
case, and tighten the check valve to the specified
torque.
NOTE:
Check valves cannot be reused. Be sure to use a new
one.

Crankshaft gear
84202A

(a) Heat the gear to approximately 100° c using a pis­

ton heater.

11-60
 ENGINE - SERVICE PROCEDURES

(b) Locate the gear such that the dowel pin on the
crankshaft will fit into the notch in the gear. Fit the
gear by lightly striking it with a soft hammer.
(c) Fit the rear oil seal slinger (refer to item (7) of sec­
tion 5.3.3) or oil seal sleeve (refer to item (8) of sec­
-
(7) Installing lower main bearings and main bearing
caps
Install the lower main bearings and main bearing caps
in accordance with the following procedure.

i
tion 5.3.3).

�� 7
(5) Fitting front oil seal slinger <Axial-lip-type oil seal>

Oil Seal Slinger Installer

cPI Joo
MH061817 Cr�nkshaft
axial

0
direction

Dowel pin

13192

(a) Drive the locating dowel pins into the rearmost

80596A main bearing cap in the direction shown in the
illustration.
Fit the front oil seal slinger using the Oil Seat Slinger
Installer (special tool).
Main bearing cap
(6) Installing crankshaft

C5838G
C5833A

Lift the crankshaft with a hoist. Keeping it horizontal,

gently lower it into the crankcase.

B4222E

(b) Mate each main bearing with its main bearing cap,
ensuring that the lugs on the bearings are aligned
with the tug grooves in the caps.

11-61
 - ENGINE - SERVICE PROCEDURES

(c) Only to the rearmost 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:

Thrust p l ate for front

side of the bearing cap

Thrust plate for rear

-�·,,_�
�deofthebeadag �,

��lw.7fi)'
"�,__ -�f,,�/J::,
.
'"-':.� )
-
'{
---.
w£
\ fc clc/
l
�:�� �i::.
the

10505

r \, 1
\1 \ \.!'./"

Thrust plate for rear side of the crankcase C5838H 2) Fit the socket over the main bearing cap mounting
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 of the crankcase.
bearing cap rear thrust plate and the rearmost thrust
plate in the crankcase [refer to item (3)) are the same
size. Note, however, that the bearing cap front and
rear thrust plates may be of different sizes.
(d) Fit the main bearing caps in the order of the num­
Scale inscribed
bers that are embossed on them, working from the on socket
front of the engine. Fit them such that the sides
with lug grooves are toward the right of the engine.
(e) Press down the main bearing caps until they touch
the crankcase. lighten the main bearing cap
mounting bolts to 115 N-m {12 kgf-m} (wet). Lines inscribed
on holder
After confirming that the bolts are tightened to the 09183

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 conforms 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 main bearing cap mounting bolt, turn the holder

11-62
 (8) Installing connecting rod bolts
ENGINE SERVICE PROCEDURES

NOTE:
-
All the connecting rods in an engine must have the
Flattened side toward connecting rod
same weight mark. Weight marks are as follows:
Heavy --------------- Light
A B C D E F G H J K
(10)Fitting piston rings

:::3/f:::
Ends \
Check for damage/burrs Manufacturer
mark
890078 stamped
(Compression
ring only)
Checkthat there are no burrs or damage 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. C58418
(9) Reassembling piston and connecting rod
Expander spring ends

Piston

Oil ring ends

C5843A
Connecting
rod
Using the Piston Ring Tool (special tool), fit the piston
rings in the positions shown in the illustration. Ensure
Snap Piston
ring pin that the manufacturer's marks on the compression
rings face upward. Fit the rings in the following order:
1. Oil ring
2. 2nd compression ring
Weight mark
3. 1st compression ring

Lug groove mark

10361

Connect the piston to the connecting rod with the pis­

ton pin such that the piston's front mark "F" is on the
same side as the connecting rod's lug groove mark.
If the piston pin is difficult to insert, heat the piston in
hot water or with a piston heater.

11-63
 - ENGINE - SERVICE PROCEDURES

(11)Installing upper and lower connecting rod bear­ NOTE:

ings 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
Align these.
Align these. rect positions.
3. Slip some plastic tube over the connecting rod
bolts to prevent them from damaging the cylinder
liner and crankshaft pin.
<Using the Piston Guide Clamp and Piston Guide Lever
(special tools)>

Piston Guide Clamp

B4223A

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)Installing piston and connecting rod Align the Piston Guide with the piston skirt and set the
Piston Guide Lever in position. Turn the adjusting bolt
such that the Clamp's inside diameter matches the pis­
ton's outside diameter. Next, remove the Clamp from
Piston Guide the piston and apply engine oil to the outside of the pis­
Lever
MH061658 ton, to the inside of the Clamp, and to the inside of the
cylinder liner.
Fit the Clamp over the piston such that it is flush with
the piston's crown. Using a wooden mallet or block, tap
the piston into the cylinder, taking care not to damage
it.

C5834B

Using 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
ENGINE - SERVICE PROCEDURES -
5.5 Inspecting and Adjusting Valve Clearances

..
Valve clearances should be checked and adjusted
Connecting rod cap when the engine is cold.

)
Front of
engine

C5844B

Ensure that the alignment marks and lug groove marks

on the connecting rod caps and connecting rods are 10404
aligned with each other.
(1) Crank the engine until the inscribed "1-6" mark on
(14)Check the connecting rod's end play. [Refer to item
the flywheel is aligned with the pointer in the fly­
(2) of section 5.4.1 for details.]
wheel housing inspection window. When this hap­
(1 S)Check that the piston projections conform with pens, the pistons whose push rods are not pushing
specifications. [Refer to item (1) of section 5.4.1 for up their rockers are at the top-dead-center (TDC)
details.] position of their compression stroke.
(16)Fitting front oil seal

Front oil seal Press-fit

Oil seal flange

B4187A

Press evenly around the oil seal's entire periphery until

its flange is seated securely on the front cover.

11-65
 - ENGINE - SERVICE PROCEDURES

(2) When piston No. 1 is at the TDC position of its com­ pression 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" in the following table. check and adjust every valve.
When piston No. 6 is at the TDC position of its com-

Cylinder No. 1 2 3 4 5 6
Valve arrangement In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.
No. 1 at TDC of compression stroke 0 0 0 0 0 0
No. 6 at TDC of compression stroke X X X X X X

(3) Using the Thickness Gauge (special tool), check

Valve clearance that the rocker arm-to-valve cap clearance con­
(when cold)
forms to specifications. To measure the clearance,
Inlet
NV 0.4 insert a gauge of the same thickness as the speci­
59 N-m
{6 kgf-m} Exhaust fied nominal clearance between the rocker arm
NV0.6 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
turn the adjusting screw as required. When the
clearance is correct, tighten the lock nut to the spe­
cified torque to secure the adjusting screw.
857148 NOTE:
After tightening the lock nut, confirm that the clear­
ance is still correct.

Mitsubishi 6D24 6D24T Engine Maintenance Service Kits

Includes: thermostat set, thermostat gaskets, valve cover gaskets,
oil filters, air filters, fuel filters, V-belts.
Replace thermostats and thermostat gaskets,
Adjust intake valve clearance and exhaust valve clearance, replace valve cover gaskets,
Replace filters,
Replace V-belts.

Mitsubishi 6D24 6D24T Engine Parts www.6D24.com

Contact email:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Located in USA, Engine Parts Delivery in USA, Canada and worldwide.

11-66
 ENGINE - TROUBLESHOOTING Ill
6. TROUBLESHOOTING
Symptom Probable cause Remedy Reference
Engine will not Incorrect oil viscosity Replace Group 12
start
Incorrect/defective fuel Group 13A
Low compression pressure
• Incorrect valve clearance(s) Adjust
• Defective cylinder head gasket Replace
• Worn valve and valve seat/carbon deposits
• Weakened valve spring
• Worn/damaged piston ring(s)

• Worn/damaged piston ring groove(s)

• Worn piston(s)/cylinder liner(s) Change to oversize
Defective preheater
• Defective starter switch Repair or replace Group 16
• Defective heater relay
Incorrect injection timing Adjust Group 13A
Insufficient fuel injection volume
• Defective injection pump Repair or replace Group 13A, E
• Incorrect fuel injection volume
Defective cooling system Repair or replace Group 14
Rough idling Incorrect oil viscosity Replace Group 12
Incorrect/defective fuel Group 13A
Defective cooling system Repair or replace Group 14
Low compression pressure (see "Engine will not start")
Incorrect injection timing Adjust Group 13A
Defective fuel system
• Defective injection pump Repair or replace Group 13A, E
• Defective injection nozzle
• Air trapped in fuel system
Abnormal Incorrect/defective fuel Replace Group 13A
exhaust gas
color Cooling system malfunctioning Repair or replace Group 14
Intake/exhaust system malfunctioning
• Clogged air cleaner Repair or replace Group 15
• Clogged muffler
• Oil leaking into intake/exhaust pipes
Low compression pressure (see "Engine will not start")
Defective fuel system
• Malfunctioning injection pump Repair or replace Group 13A, E
• Defective injection nozzle
Incorrect injection timing Adjust
Excessive engine oil Adjust Group 12
Seizure of major moving parts Repair or replace

11-67
 - ENGINE - TROUBLESHOOTING

Symptom Probable cause Remedy Reference

Low power Incorrect oil viscosity Replace Group 12
output
Incorrect/defective fuel Group 13A, E
Cooling system malfunctioning Repair or replace Group 14
Intake/exhaust system malfunctioning
• Clogged air cleaner Repair or replace Group 15
• Clogged muffler
Low compression pressure (see "Engine will not start")
Fuel system malfunctioning
• Malfunctioning injection pump Repair or replace Group 13A, E
• Defective injection nozzle
• Air trapped in fuel system
Incorrect injection timing Adjust
Excessive oil Oil leaking from lubrication system Inspect and/or repair Group 12
consumption
Oil leaking from engine and related parts
• Defective gasket/oil seal Replace
Oil entering combustion chamber past piston
• Worn cylinder liner(s)/piston(s) Rectify or replace
• Piston ring(s) worn, damaged, or seized Replace whole set
• Clogged piston/oil ring oil hole(s) Clean
Oil entering combustion chamber via valves
• Worn valve stem(s)/valve guide(s) Replace
• Worn valve stem seal(s)
Abnormal Noise emanating from outside parts of engine
engine noise • Loose piping/hose connection(s) Inspect
• Injection pump, alternator, other auxiliary unit(s) incorrectly Inspect and/or adjust Groups 13A, E and
mounted 16
• Loose/damaged V-belt Replace Group 14
• Incorrectly mounted crankshaft pulley Inspect and/or adjust
• Malfunctioning air cleaner and/or muffler Repair or replace Group 15
Noise emanating from vicinity of rocker cover
• Incorrect valve clearance(s) Adjust
• Defective valve spring(s) Replace
• Defective rocker shaft/bracket Inspect and/or repair
• Improper lubrication of rocker shaft Inspect

11-68
 ENGINE - TROUBLESHOOTING -
Symptom Probable cause Remedy Reference
Abnormal Noise emanating from vicinity of flywheel housing
engine noise • Incorrect timing gear backlash Replace

• Incorrect lubrication of timing gears and idler shaft Inspect

Noise emanating from cylinder head/crankcase
• Low compression pressure lsee "Engine will not start")
• Incorrect injection timing Adjust Group 13A
• Incorrect spray of injection nozzles Repair or replace
• Worn connecting rod small end bushing(s) and piston pin(s) Replace
• Worn/damaged crankshaft pin(s) and connecting rod big end
bearing(s)

• Worn/damaged crankshaft journal(s) and main bearing(s)

• Excessive crankshaft/camshaft end play Replace thrust plate(s)
• Worn tappet(s)/camshaft Replace worn part(s)
Turbocharger malfunctioning Inspect and/or rectify Group 15

11-69
 -

LUBRICATION
CONTENTS

1. GENERAL ............................... . ... 2 4.1.2 Disassembly and inspection .......... 1 31

2. SPECIFICATIONS ............................ 9 4.1.3 Reassembly ........................... 15
3. SERVICE STANDARDS ..................... 10 4.2 Oil Filter and Oil Cooler .. . ..... . ..... . ... 15
3.1 Service Standards Table ................. 10 4.2.1 Removal and installation ............. 15
3.2 lightening Torque Table ................. 10 4.2.2 Oil filter .......................... ...... 16
4. SERVICE PROCEDURE ..................... 1 1 4.2.3 Oil cooler .............................. 17
4.1 Oil Pump ................................. 1 2 4.3 Regulator Valve .......................... 18
4.1.1 Removal and installation ............. 1 2 5. TROUBLESHOOTING ....................... 19

12-1
 -
1. GENERAL
LUBRICATION - GENERAL

Oil pressure
gauge
Warning lamp 0---··---,
Oil pressure Oil pressure
,__ ________s_ wit_c_h_�U-L.........J gauge unit

Main oil gallery

Regulator *
valve

Water
pump

* Models with turbocharger B1539H

Engine lubrication is accomplished by forced lubrica­ (1) Oil pump

tion system using gear pump. The engine oil in the oil
pan is drawn up th rough the oil strainer by the oil pump
and force-fed to the oil filter and oil cooler to lubricate
all parts.

Oil pump
(with built-in
relief valve}

B1540A

12-2
 LUBRICATION - GENERAL

The oil pump, of a gear pump 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.

Relief valve

Drive gear

81541A

The crankshaft gear drives the oil pump idler gear and
oil pump gear to transmit rotation to the oil pump drive B5693A
gear.
The oil pump is driven at a speed proportionate to the
engine speed. Therefore, it is provided with a relief
valve that prevents excessive pressure from being
applied to the lubrication system when the engine is
started in cold weather involving a surge in oil pump
delivery pressure.
Delivery_ _ Suction side
side (oil strainer side)
"::c::....1- Driven gear

B1505A

Inside the oil pump case, there are oil pump drive gear
and driven gear which are in mesh with each other.
When the drive gear is driven, the driven gear is caused
to turn in an opposite direction.
As the gears rotate with the gear teeth sliding on the
inner surfaces of pump case, the resultant negative
pressure causes the engine oil to enter the oil pump
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
 m
(2) Oil filter
LUBRICATION - GENERAL

(3) Oil bypass alarm

Element

Center bolt
{Bypass filter)
Center bolt­
{Full-flow filter) 81543A

The oil filter assembly consists of a full-flow filter and a

bypass filter. Paper elements are used.
Engine oil fed under pressure from the oil pump passes
through the oil hole in the crankcase and enters the full­
flow and bypass filters via the oil filter head. Engine oil
that passes through the full-flow filter is routed from
the oil filter head to the oil cooler via the crankcase oil
hole. Engine oil that passes through the bypass filter
returns to the oil pan. 815448

When the oil filter element is plugged resulting in the

difference in pressures between before and after the
element exceeding a predetermined level, the valve
overcomes the spring tension to move. As a result,
unfiltered oil flows 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
 (4) Oil cooler
LUBRICATION - GENERAL
The oil cooler is of the shell-and-plate (multi-plate)
type. It is mounted in the coolant path on the left of the
crankcase.
Engine oil that has been forced through the oil filter
flows through the inside of the oil cooler element. At
Bypass valve
Bypass valve
To main
oil gallery
81530B
When the oil's viscosity is high at low temperatures or
when the element is clogged and resists the oil's flow,
the oil cooler's bypass valve opens, thus allowing oil to
flow to the main gallery without passing through the
cooler.
-
Bypass valve
B1545C
the same time, coolant from the water pump flows
around the outside of the element. The engine oil in the
element is thus cooled or heated before flowing to the
main oil gallery.
Regulator valve
81529A
The regulator valve is fitted to the main oil gallery in the
crankcase. If the oil pressure in the main gallery
exceeds a specified level, the regulator valve allows
the oil to escape to the oil pan, thereby protecting the
lubrication system from excessive pressure.
12-5
m(5) Lubrication of components
LUBRICATION - GENERAL

(b) Camshaft
Engine oil routed to the main oil gallery lubricates the
engine's various components as follows:
(a) Main bearings, connecting rod bearings, and con­
necting rod bushings

6D24-T, TC, TL
·•.
Crankshaft main
bearing
81547A

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 mechanism

Conn ecting Rocker shaft bracket

rod b earing
� ocker
�

��
Rocker bushin·g
Rocker shaft From cylinder head

_ ..,.,- .-CY:.,.,,,To cylinder h ad

< e
.,,,... C I ·�
Main�il.�v
43674 galle Ii'
?

l r�;\ �
<lf'

An oil passage extends from the main oil gallery to the

crankshaft main bearing and lubricates the main bear­
ing. Part of the oil that has lubricated the main bearing
passes through the hole in the crankshaft and lubri­
cates the connecting rod bearing. It then goes through
an oilway inside the connecting rod and lubricates the
connecting rod small end bushing.
In the 6D24-T, TC and TL, there is also an oil hole in the
top of the connecting rod. Oil spurts out of this hole
onto the inside of the piston.
.....,..... \ , 81548A
Engine oil that has lubricated the No. 7 camshaft bush­
ing flows to the cylinder heads via an oilway and holes
in the top of the crankcase. Engine oil that is bound for
the cylinder heads flows through oil holes in the rocker
shafts and lubricates the rocker bushings. It then spurts
out of a hole in the top of each rocker to lubricate the
sliding surfaces of the valve caps, the valve stems, and
the contact points of the valve stems, push rods, and
adjusting screws. The oil then flows 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) liming gears
LUBRICATION - GENERAL -
oil volume and the loss of oil pressure when the pres­
sure is already low.
In the 6024-T, TC and TL, each piston has a cooling cav­
ity. Oil sprayed out of the oil jets enters these cavities to
further cool the pistons.
Oil spray
Idler shaft plug (6) Lubrication of turbocharger
installation
section
Piston ring

Main oil
gallery �-­
-�"'
B1549A Air int::::>

As shown in the illustration, the timing gear idler shaft

bushings are lubricated via oil holes that extend from
the main oil gallery and from the rearmost crankshaft
Piston ring
main bearing. The gears are lubricated by the oil spray
B4363A
plug.
{e) Cooling of pistons (oil jet) Part of the 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, TL
returned through the oil outlet at the bottom of the
only bearing housing back to the crankcase and to the oil
Piston pan. A piston ring is installed on the outside of each
bearing, serving as an oil seal.

11921

An oil jet is fitted under the 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 pump and air compressor
LUBRICATION - GENERAL

The injection pump and air compressor are lubricated

as follows:

l
Main oil gallery

From oil cooler

"-.
I
Injection pum p Oil cooler

From crankcase
oil main gallery
I
Crankcase
I
Air compressor
To oil pan',
'
'o.
(.2 I
Gear train

Oil pan
�--- _ _ _ _ ___
�j�( -----�
B4364B

(8) Lubrication of water pump

Section B-B

To oil pan

Section A-A

From oil main gallery

D0052A

The engine oil drawn by the pump is routed through

the crankcase oil passage to the water pump. The
engine oil delivered to the water pump flows through
the oil hole of the water pump and lubricates the bear­
ings.
The engine oil is then forced back from the drain port to
the crankcase and returns to the oil pan.

12-8
 LUBRICATION - SPECIFICATIONS

2. SPECIFICATIONS
Item Specification

Engine oil Quality API classification class CC or better (without turbocharger)

API classification class CD or better (with turbocharger)

Capacity Oil pan Approx. 27 L

(for general use}
Approx. 25 L
(for construction machinery)
Oil filter Approx. 4 to 4.5 L
Lubrication method Forced lubrication by oil pump
Oil pump Type Forced lubrication by gear pump
(integral relief valve)

Relief valve Type Ball valve

Oil filter Full-flow filter element Type Filter paper type
Bypass filter element Type Filter paper type
Oil bypass alarm Type Piston valve type (integral electric contact)
Oil cooler Type Shell and plate type (multi-plate type)
Oil bypass valve Type Piston valve type
Regulator valve Type Piston valve type
Oil jet check valve Type Piston valve type

12-9
 LUBRICATION - SERVICE STANDARDS

3. SERVICE STANDARDS
3.1 Service Standards Table
Unit: mm
Maintenance item Nominal value Limit Remedy and
(Basic diameter in I )) remarks

Oil pres- At idle 145 kPa {1.5 kgf/cm 2} or more 49 kPa Inspection
sure (Oil {0.5 kgf/cm 2}
tempera-
ture 70° C to At maximum speed 295 to 490 kPa {3 to 5 kgf/cm 2} 195 kPa
9 0° C) {2 kgf/cm 2}

Oil pump Backlash between crankshaft gear and 0.08 to 0.2 0.4 Replace
oil pump idler gear

Backlash between oil pump idler gear 0.08 to 0.2 0.4 Replace
and oil pump gear

Difference between pump case depth 0.05 to 0.12 0.15 Replace

and gear height

Gear tooth tip to pump case clearance 0.20 to 0.29 0.35 Replace
Drive gear shaft to cover clearance (20) 0.04 to 0.07 0.15 Replace
Driven gear shaft to driven gear bushing (20) 0.04 to 0.07 0.15 Replace
clearance

Idler gear shaft to idler gear bushing (22) 0.03 to 0.05 0.15 Replace bushing
clearance

Relief valve opening pressure 1080 to 1270 kPa - Replace spring

{11 to 13 kgf/cm2}
-
I
Relief valve Installed length: 47.7 180 to 200 N {18.3 to 20.5 kgf}
spring load

Oil bypass alarm valve opening pressure (on start 340 to 390 kPa {3.5 to 4 kgf/cm2} - Replace
pressure)

Oil cooler Valve opening pressure 420 to 460 kPa - Replace

bypass {4.3 to 4.7 kgf/cm2}
valve
Regulator Valve opening pressure 360 to 420 kPa - Replace
valve {3.7 to 4.3 kgf/cm 2}

Spring load (Installed length: 48.3) 76 to 80 N V.8 to 8.2 kgf} -

3.2 Tightening Torque Table

Location tightened Screw size Tightening torque Remarks

0. D.x pitch N-m {kgf-m}
mm

Oil pump idler shaft nut M12x1.25 59 to 78 {6 to 8} Apply LOCTITE

No. 262

Oil pump cover mounting bolt Ml0x1.25 39 to 49 {4 to 5} Wet

Oil bypass alarm M20x1.5 44 to 54 (4.5 to 5.5)
Oil filter center bolt M16x1.5 59 to 69 (6 to 7)
Oil filter drain plug Ml0xl.25 20 ± 4.9 {2 ± 0.5}
Oil cooler bypass valve plug M20x1.5 15 to 20 (1.5 to 2.0)

Regulator valve M27x1.5 98 to 115 {10 to 12}

Oil pan drain plug M18x1.5 690}

12-10
4. SERVICE PROCEDURE
LUBRICATION - SERVICE PROCEDURE -
Oil Pressure Measurement

At idle
NV 145 kPa
{1.5 kgf/cm2} or more
L 49 kPa {0.5 kgf/cm2}
At maximum speed
NV 295 to 490 kPa
{3 to 5 kgf/cm2 }
L 195 kPa
{2 kgf/cm2}

NV . . Nominal Value
L · · · · · Limit 89016A

(1) With the oil pressure switch removed 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 maximum
speeds. If the measurement is below the limit,
overhaul the lubricating system.

12-11
 LUBRICATION - SERVICE PROCEDURE

4.1 Oil Pump

4.1.1 Removal and installation

Apply sealant to inner bead.

NV .. Nominal Value Apply sealant (Threebond 1207C)
and fit it within 3 minutes.
L ..... Limit B

*Backlash from
crankshaft gear
NV 0.08 to 0.2
L 0.4

Section B Section A-A

Pour engine
oil into pump

11923
C1160C

1 Oil pan 5 Relief valve

*2 Oil strainer 6 Oil pump
*3 Oil pipe 7 Drain plug
4 Flange
Bolt tightening sequence

CD-+®-+@

After installation, check that the oil pump gear can be turned smoothly by
hand.

Service items marked with* should be checked before and after the removal.
Part marked with * should not be removed unless defects are evident.
(Remove it with the oil pump as an assembly.)

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 Disassembly and inspection
LUBRICATION - SERVICE PROCEDURE -
3 Clogged oil hole
*Backlash
NV 0.08 to 0.2
L 0.4

Relief valve opening pressure

NV 1080 to 1270 kPa
{11 to 13 kgf/cm 2}
Spring installed load Clearance
(installed length: 47.7) BO 22
NV 180 to 200 N NV 0.03 to 0.05
{18.3 to 20.5 kgf} L 0.15

Clearance
BD 20
NV 0.04 to 0.07
L 0.15

*Difference between oil pump

case depth and gear height
NV 0.05 to 0.12
Wear on bushing 1
2 L 0.15
Wear and damage on teeth,
wear on bushing *Gear tooth tip to oil pump
case clearance
NV 0.2 to 0.29
L 0.35
Clearance
BD 20
NV 0.04 to 0.07
L 0.15

BD .. Basic Diameter
NV . . Nominal Value
L..... Limit

Disassembly sequence
G) Oil pump cover 5 Spring seat
2 Driven gear assembly 6 Valve spring
3 Idler shaft 7 Ball valve
8 Case and gear assembly
4 Idler gear

For parts with an encircled number, refer to Disassembly and Inspection Procedures
that follow.
Service items marked with * should be checked before disassembly.
10374

12-13
- LUBRICATION

Disassembly and Inspection Procedures

SERVICE PROCEDURE

(3) Gear tooth end to oil pump case clearance

(1) Removal of oil pump cover

C9521A

10375
If the measurement exceeds the limit, replace the gear.
T he oil pump cover is positioned with the dowel pin of Note, however, that the drive gear must be replaced
the oil pump case. with a case and gear assembly.
To remove the oil pump cover, tap on it with a plastic (4) Gear shaft to case, cover, and driven gear clear­
hammer or the like. ance
(2) Difference between oil pump case depth and gear
height

®45484

C9520A
If the measurement exceeds the limit, replace the part
to which bushing is installed.
If the measurement exceeds the limit, replace the gear.
Note, however, that the drive gear must be replaced
with a case and gear assembly.

12-14
4.1.3 Reassembly
LUBRICATION - SERVICE PROCEDURE -
39to 49N-m Apply thread-lock cement

a
{4 to 5 kgf-m} (LOCTITE 262) to threads
� after degreasing

u, -
'-----------'4
59to 78 N•m
Backlash Section
NV 0.08 to 0.2 {6 to 8 kgf-m}
B-B Arrow and HUP" mark must
L 0.4 face upward and align oil holes

/sect;on A-A\
5 6 7 1
Assembly sequence Shaft end surface must
be flush with case
8➔7➔6➔5➔4➔3➔2➔1
Section C-C
NOTE:
Hold the oil strainer 1 in position temporarily for subsequent attachment
to the crankcase.
®45485

4.2 Oil Filter and Oil Cooler

4.2.1 Removal and installation

1 Oil filter
2 Oil cooler
3 Gasket

NOTE:
1. Do not apply oil or grease to the 0-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
 LUBRICATION - SERVICE PROCEDURE

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) Disassembly and reassembly

1 Drain plug
6 Clogging, deformation 2 Center bolt
Clogging, deformation 6 3 Washer
4 Oil filter case
Hardening splitting
5 Element retainer
6 Oil filter element
Cracks, deformation
Cracks, deformation 4 7 Oil filter head
8 Oil bypass alarm

2 59to 69 N-m
59to 69 N-m {6 to 7kgf-m}
{6 to 7kgf-m}
C9705 C

Inspection of oil bypass alarm W ith no air pressure applied, check for continuity
across the terminals as shown and replace the oil
Pressure gauge bypass alarm if there is continuity.
Valve opening pressure Next, with the air pressure applied and gradually
NV 340to 390kPa
{3.5 to 4kgf/cm2} increasing, measure the air pressure when there is
continuity.
If the measurement is out of specification, replace the
oil bypass alarm.

U0700C

12-16
4.2.3 Oil cooler
LUBRICATION - SERVICE PROCEDURE -
(1) Disassembly and reassembly

1 Scale, damage, cracks, oil leaks

3 Scale, cracks

Valve opening pressure

NV 420 to 460 kPa
{4.3 to 4.7 kgf/cm 2}

1 Oil cooler element

2 Bypass valve
3 Oil cooler cover
C9804E

(2) Cleaning NOTE:

(a) Check for carbon or sludge deposited in the oil pas­
sage of the oil cooler element and bypass valve. If
contamination is evident, wash in a cleaning oil.
(b) If there is a lot of scale on the element and cover,
wash it away with tap water (preferably hot).
(3) Pressure resistance test
Conduct the pressure resistance test to check for oil
leak caused by damaged or cracked element.
Never attempt to apply pressure exceeding the speci­
fied test pressure.
Check for possible leak by applying a 1470 kPa {15 kgf/
cm2} air pressure to the element. Replace the element if
air or oil leak or any other faulty condition is evident as
a result of the test.

12-17
 IEI LUBRICATION - SERVICE PROCEDURE

4.3 Regulator Valve

98to 115 N-m

{1O to 12 kgf-m}

Set load (set length: 48.3)

NV 76to 80 N
{7.8to 8.2 kgf}

Lost tension

�er
Valve opening pressure
NV 360to 420 kPa
{3.7 to 4.3
kgf/cm 2 }

1 2
1 Snap ring
2 Valve
3 Spring
4 Body C9902A

Regulator valve installation position:

Left side of crankcase

12-18
 LUBRICATION - TROUBLESHOOTING

5. TROUBLESHOOTING
Symptom Probable cause Remedy Ref. group

Overheating Abnormal oil level

• Oil leaks into coolant Correct and fill to specified
level
• Oil leaks
Incorrect oil viscosity
• Oil out of life Replace
• Fuel in oil Change oil after repair of
faulty parts

Oil pressure Oil pressure switch not functioning properly Replace

does not
increase Loaded oil filter element Replace element
Loaded oil strainer, loose oil pump joint, cracked pipe Correct or replace
Relief valve, bypass valve not functioning properly
Worn or damaged oil pump proper Replace
Excessive oil Oil leaks from engine Correct or replace Group 11
consumption
Oil leaks from crankshaft front or rear oil seal Correct or replace
Leaks to cooling system
• Defective oil cooler water jacket Correct or replace
Abnormal compression pressure Check Group 11

12-19
 FUEL AND ENGINE CONTROL
CONTENTS

1. GENERAL .................................... 2 5.4 Pump Drive Case ....................... . . 35

2. SPECIFICATIONS ........................... 2 5 5.4.1 Removal and installation ............. 35
3. SERVICE STANDARDS ..................... 26 5.4.2 Disassembly and inspection ... ....... 35
3.1 Service Standards Table ................. 26 5.4.3 Reassembly ..................... . .. . .. 361
3.2 lightening Torque Table ................. 27 5.5 Injection Nozzle ................... . ...... 37
4. SPECIAL TOOLS ............................ 28 5.5.1 Removal and installation ... . . . . ... . .. 37
5. SERVICE PROCEDURE ..................... 29 5.5.2 Disassembly ........................... 37
5.1 Removal and Installation of Injection 5.5.3 Cleaning and inspection .... . ... ..... . 38
Pump Assembly ......................... 29 5.5.4 Reassembly and adjustment
5.2 Bleeding of Fuel System ..... ............ 32 <KBL2.1 injection nozzle> ............ 40
5.3 Inspection and Adjustment after Installing 5.5.5 Reassembly and adjustment
the Injection Pump ...................... 32 <KBL2.4 injection nozzle> .... ........ 46
5.3.1 Inspection and adjustment of 5.6 Fuel Filter ............ :............. . ..... 52
fuel injection start timing ............. 32 5.7 Water Separator .................... ..... 54
5.3.2 Inspection and adjustment of minimum 6. TROUBLESHOOTING ............ . .......... 55
and maximum no-load speeds ..... . . 34

13A-1
 FUEL AND ENGINE CONTROL - GENERAL

1. GENERAL

--- Injection pipe

Injection nozzle

!
Fuel feed pipe Fuel
filter
Governor

Fuel Automatic timer

leak-off--..,
pipe

Fuel feed pipe

Water
Feed pump i----- separator
(option)

Fuel tank

82115A

The fuel system consists of the injection pump general The injection pump is connected with the air compres­
assembly (injection pump proper, governor, automatic sor or pump drive case by a coupling and driven at one­
timer, feed pump and coupling), fuel filter, water sepa­ half the engine speed.
rator, injection nozzle, fuel leak-off pipe, etc.

13A-2
 (1) Injection pump proper
FUEL AND ENGINE CONTROL - GENERAL

1) The pump housing is a totally enclosed type.

-
(a) Injection pump 2) The plunger barrel has an oblique hole made to
return the fuel that has leaked to the oil sump to
minimize the leakage of the fuel into the cam cham­
ber.
Delivery valve holder
3) To prevent the fuel in the oil sump from leaking into
the cam chamber, an 0-ring is provided on the
outer circumference of the plunger barrel, thereby
maintaining its tightness.
4) A deflector is provided on the outer circumference
of the plunger barrel to prevent erosion of the
pump housing that may be caused by counter flow
of fuel at the end of an injection.
Deflector
(bl Plunger and plunger barrel
Oil sump
The plunger has an obliquely cut groove (lead) and a
Control rod
vertical groove as illustrated. The plunger barrel has
Control two fuel suction/discharge ports.
lPLI---sleeve
�---- Upper Fuel fed into the injection pump is sent under pressure
spring seat
Plunger
by the camshaft rotation, or the reciprocating motion
spring of the plunger as follows.
Lower
spring seat
Tappet
Cam
chamber

Camshaft

Fuel Beginning of Pressure End of

drawn in pressure feed feed pressure
feed
89083C

The camshaft driven at half the engine speed is sup­
ported by taper roller bearings at both ends. The cam­
shaft has a cam for operating the plunger and a cam for
operating the feed pump.
A tappet operating with the pump housing as the guide
is in contact with the camshaft. The tappet changes the
rotary motion of the cam to up-and-down motion
which is transmitted to the plunger.
The P type injection pump offers the following fea­
tures.
82204A
When the plunger moves down from the top dead cen­
ter and opens the suction/discharge ports in the
plunger barrel, fuel is not only drawn into the barrel by
a vacuum created during the plunger's downward
stroke but also sent into the barrel under pressure by
the feed pump.
On the upward stroke, the plunger begins to compress
fuel as it completely closes the suctional discharge
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 up the 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

Control rod :,-:

B2205A

As the plunger rises and its oblique groove (the reed)

meets the inlet/outlet hole, fuel flows into the plunger's
vertical groove and is expelled from the inlet/outlet
hole. No pressure feed takes place thereafter, regard­
Driving face
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
B2206A opens them) is known as the effective stroke.

The amount 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 moves 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 meshes 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 amount of fuel injected.

13A-4
 (c) Delivery valve
FUEL AND ENGINE CONTROL - GENERAL

(d) Overflow valve

-
Suction stroke
Spring

Spring seat

To overflow
pipe
Steel ball

Beginning of Injection End of End of

injection injection injection
(beginning
of suction)
01827 82208A

The fuel highly pressurized by the plunger pushes the When the fuel pressure in the injection pump exceeds a
delivery valve up and gushes out. When delivery of the 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 pump 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 amount 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 improves 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 of the delivery valve
to prevent the surging of the valve during high speed
operation. It also reduces the dead volume between
the delivery valve and nozzle and stabilizes the injec­
tion rate.

13A-5
 -
(2) Governor
FUEL AND ENGINE CONTROL - GENERAL

The construction and operation of the governor are the

same regardless of the applicable model of the injec­
tion pump.
(a) RSV type governor

Supporting lever shaft

Guide lever Governor housing

Tension lever

Start spring

Control lever

Governor spring

Camshaft,

Ungleich spring or
idling spring

Stop lever

Full-load stopper bolt

B2657B

The RSV type governor is a centrifugal type all-speed

governor coupled to the camshaft of the injection
pump. The governor not only controls the maximum
and minimum speeds but also automatically controls
the engine speed at any intermediate speed position.

13A-6
 FUEL AND ENGINE CONTROL - GENERAL -
whereas the top of the lever is coupled through the
Slider shackle to the control rack.
Ball bearing
The start spring, attached to the top end of the control
lever, always pulls the control rack in the direction that
fuel is increased.

Guide
lever

Adjusting
Flyweight djusting lever screw
Governor Flyweight supporting shaft
sleeve 82658C

The governor, as shown, consists of flyweights

mounted to the injection pump camshaft. When the
flyweights turning on the flyweight supporting shaft Governor spring
open outward, the slider mounted to the end of fly­
weight arm pushes the end of the sleeve in the axial
�-- Ungleich spring
direction. The governor sleeve, being made integral or idling spring
with the shifter through a bearing, moves only in the
axial direction. The shifter is fixed to the end of the
guide lever with a pin to prevent its rotation.

Start spring
The turning shaft of the swivel lever is fitted into the
bushing of the governor cover and' its center is eccen­
tric with respect to the mounting position of the gover­
Control rack nor spring installed to the tension lever. The governor
spring is installed to the end of the swivel lever.
When the governor spring receives tension, the bot­
Control
lever tom end of the tension lever touches the adjustable
full-load stopper bolt.
When the angle of the adjusting lever is changed, the
angle of the swivel lever is also changed and the ten­
Pressure sion of the governor spring changed. This is because
spring
the turning center of the swivel lever and the mounting
Governor
shaft position of the governor spring installed to the tension
lever are eccentric to each other as mentioned above.
An 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.
Supporting Pin Return Stop An Ungleich spring (or idling spring} is provided in the
lever spring lever
82659A bottom portion of the tension lever. Adjust the tension
of the spring by adding or removing shims.
The control lever is mounted to the middle of the 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
 FUEL AND ENGINE CONTROL - GENERAL
idling, the spring always keeps in contact with the ten­
sion lever to maintain a constant idling speed.
The stop lever, mounted through the supporting lever
to the bottom end of the control lever, returns the con­
trol rack to the stop position with a slight pressure irre­
spective of the adjusting lever position.
1) Start of engine
Adjusting lever
Starting
s=, l
Guide lever
B2660A
When the adjusting lever is moved to the start position
(until it touches the maximum speed stopper), the
swivel lever which moves with the adjusting lever pulls
the governor spring and moves the tension lever until
it touches the full-load stopper bolt.
At that time, the flyweights are stationary, and the start
spring with weak tension pulls the control lever in the
direction that fuel is increased.
At the same time, the shifter and governor sleeve push
the flyweight slider to the left.
As the result, the tension lever and shifter are spaced
that much apart, and the corresponding amount of fuel
is supercharged to facilitate starting.
13A-8
2) Idling control
Start spring
Idling
Governor spring
Shifter
B2661A
Once the engine is started and the adjusting lever
returned to the idling position, the tension of the gover­
nor spring is drastically reduced.
Now the flyweights can move outward even at a low
speed, so the tension lever is pushed back until it
touches the idling sub spring and places the control
rack at the idling position. In this state, the centrifugal
force of the flyweights and the weak-state governor
spring and idling sub spring achieve balance and main­
tain smooth idling.
When the speed falls, the centrifugal force decreases,
the flyweights move inward, and the idling sub spring
pushes the tension lever to the left and moves the con­
trol rack in the direction that fuel is increased.
If the speed falls radically, the start spring with weak
tension acts and moves the control rack in the direction
that fuel is increased to maintain the idling speed.
 3) Maximum speed control
FUEL AND ENGINE CONTROL - GENERAL

position, thereby preventing over-speed operation of

-
the engine.
The RSV type governor controls the entire speed range
from idling to maximum speed. If load increases or
decreases at a certain speed determined by the posi­
No-load Adjusting lever
(Idling) tion of the adjusting lever, the governor automatically
functions and maintains the engine speed constant at
all times.
4) Ungleich operation

When max. injection is set

at low-speed operation

----
Injection matched
with air intake rate

-,
\_
Idling sub spring B

------
-
--=
Ac;,,- :..;...---'-----�.() 8'
Injection/
stroke A'

When max. injection is set

at high-speed operation
Shifter Full-load stopper bolt

Engine speed 82663A

82662A
When the adjusting lever is moved to the full-load posi­
tion, the tension of the governor spring is increased
and pulls the tension lever until it touches the full-load
stopper bolt.
When the engine exceeds the specified speed, the cen­
trifugal force of flyweights becomes larger than the
force of the governor spring pulling the tension lever.
So the tension lever is moved to the right and moves
the control rack in the direction that fuel is reduced,
thereby preventing the engine from exceeding the spe­
cified speed.
If the speed further increases, the centrifugal force of
flyweight increases and pushes the tension lever to the
right and also compresses the idling sub spring to pull
the control rack back to the no-load maximum speed
The air intake rate of the engine falls as the engine
speed increases. The injection pump, on the other
hand, increases the per-stroke injection as the speed
increases, even with the control rack at the same posi­
tion.
Therefore, if full-load is set at point A to derive enough
output at low speeds, the injection will reach B as the
speed increases, and the engine will produce black
smoke.
If full-load is set at point B' to prevent black smoke, the
low speed injection will come down to A', allowing
combustion of more fuel.
So the Ungleich device accomplishes the function of
setting full-load at point A to derive the largest possible
torque in the low speed range, and changing it to
adjust the injection to point B' in the high speed range.

13A-9
 - FUEL AND ENGINE CONTROL - GENERAL

As 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
slowly compressed before the start of high speed con­
trol, and the control rack moves in the direction that
E fuel is reduced. The Ungleich stroke is completed at
E
the position where the shifter directly touches the ten­
.g
·;;; sion lever.
0
0.
..>< 5) Stopping of engine
"'
(.)
0::
N2 N1
Pump speed (rpm) ---
Stop

�l'"'1' -t-........�
Adjusting lever
position

Without "'---:-
Ungleich effect
Control rack

N2 N1
Engine speed (rpm) --
B2664A

When the engine speed is low and the centrifugal force

Stop
of flyweight smaller than the pressure of the Ungleich
spring, the shifter is moved as much as the Ungleich Stop lever B2666A
stroke to the left, so the control rack moves in the direc­
tion that fuel is increased to increase the torque of the When the stop lever is moved to the stop position, the
engine at low speeds. control rack is moved to the stop position to stop the
engine regardless of the position of the adjusting lever.
Full-load

ill!illy·----..,....-==-�::::::-.-.
Control rack

Ungleich spring

Shifter
B2665A

13A-10
6) Operation of torque spring
FUEL AND ENGINE CONTROL - GENERAL -
t
E
E
C:
C D
t
in
�
�
D

Governor operating range

.g
'iii
-"'
0
a.
-"'
....a.:,
(J
A

Pump speed (rpm) -

P2
P1
Engine speed (rpm) --1---,
-
i.,t-
P1
p2

82667A

Construction machinery engines are often subjected to
a large load during operation, and reduced speeds
often lead to stalls. To prevent this, a torque spring is
provided.
When the adjusting lever is fixed in the lever set posi­
tion, a sudden increase of load, if no torque spring is
provided, will move the control rack along the 8-D
curve as the speed falls. The rotational displacement at
the time may be expressed as P1.
Torque spring
If a torque spring is provided, the control rack moves
along 8-C, and the rotational displacement at the time
may be expressed as P2. Therefore, large changes
occur in P2 and engine speed, and because of
increased fuel injection, the engine torque increases,
and large combustion noise warns the operator of the
increased load, enabling him to take proper action to
prevent stopping the engine.
In an abrupt increase of load occurs when the engine is
running at continuous rating, the engine speed falls.
So the flyweights are moved inward and the tension
lever pulled to left by the control spring, causing the
control rack to move 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 moves with the
pin "A" as the fulcrum, whereas the portion "B" is
pushed to right. As the result, the torque spring per­
forms the function of reducing movement of the ten­
sion lever.

Full-load stopper
82668A

13A-11
 -
(b) RFD type governor
FUEL AND ENGINE CONTROL - GENERAL
Governor cover Stop lever
Sliding lever
Floating lever
The RFD type governor is a minimum-maximum gov­
ernor which controls only the minimum and maximum
speeds.
The RFD type governor make it possible to increase or
reduce fuel by the load control lever which operates
the control rod. Any desired speed can be set as a dis­
placement of the speed control lever changes the ten­
sion of the governor spring.
Because of the construction described above, the RFD
governor can be operated as an all-speed governor by
holding the load control lever in the full position and
operating the speed control lever.
Flyweights are mounted on the injection pump cam­
shaft. Each of the flyweights pivots about a pin press­
fitted in the flyweight holder. When the flyweights
move out, the slider fitted to the end of the flyweight
arms pushes the sleeve end face axially. The sleeve
which contacts the flyweight slider is coupled to the
shifter by a snap ring. The guide lever suspended from
13A-12
Governor housing
Flyweight
826828
the tension lever shaft holds the shifter, preventing it
from turning.
The guide lever has an intermediate shaft, on each side
of which there is a floating lever mounted.
A block is press-fitted in the bottom end of one floating
lever and this block is fitted in the bottom of the sliding
lever. The load control lever is fitted to this sliding lever
through an eccentric shaft. The floating lever can be
moved by operating the load control lever. At the upper
end of the floating lever placed on the other side via a
shaft, there is an injection pump control rack fitted via a
floating lever link. A start spring is hooked at the lower
end of the floating lever and the other end of the start
spring is hooked at the spring eye on the governor
housing side.
The tension lever is suspended from the tension lever
shaft from which the guide lever is suspended. A gov­
ernor spring is fitted across this tension lever and the
swivel lever. Its tension is determined by the speed
control lever mounted on the swivel lever shaft. Within
 FUEL AND ENGINE CONTROL - GENERAL
normal speed ranges, therefore, the lower end of the
tension lever is always in contact with the stroke
adjusting bolt.
A pin is press-fitted in the side of the lower end of the
tension lever. It fits into the groove in the upper part of
the sliding lever. During high speed control, therefore,
a greater lever ratio is obtained from the linkage
formed by the pin, sliding lever, and floating lever. Built
into the lower end of the tension lever is the idling
spring that provides low speed control.
1) Control of engine start and idling
Speed control lever
Maximum speed position
Control rack
11111111
Swivel lever
Governor spring
Shifter
When the engine is not running, the flyweights are in
the closed position, pushed by the governor spring,
idling spring, and start spring. If, in this condition, the
load control lever is moved all the way to the full posi­
tion (in the direction of greater fuel delivery), the start
spring and idling spring cause the control rack to move
to a point which is beyond the full-load position and
provides the maximum amount of fuel injected, thus
making it easier to start the engine.
When the load control lever is returned to the idling
position after the engine has started, the flyweights
increase or decrease their centrifugal force as the
engine speed changes. In the idle speed range, the cen­
trifugal force is such that it just compresses the idling
spring. The centrifugal force of the flyweights balances
the combined force of the idling spring and start
-
The engine stop lever is fitted to the top of the gover­
nor, that moves the control rack to the non-injection
position to stop the engine. The cancel spring is
installed to prevent excessive force from being applied
to the control rack at this time.
Mounted on top of the governor cover is the smoke set
assembly. It functions to ensure good starting by
increasing the amount of fuel injected at starting and
improve smoke condition in the practical full-load low
speed range.
Guide lever
Load control lever
Full position
Idling spring
B2670A
spring, which keeps the control rack at a given position.
This results in the engine running at smooth idle
speed.
If the engine speed increases at this time, the centrifu­
gal force of the flyweights increases causing the fly­
weights to move out to push the shifter to the right. As
a result, the guide lever and floating lever are moved,
which in turn moves the control rack in the direction of
smaller fuel delivery (to the right). If the engine speed
decreases, on the other hand, the control rack is moved
in the direction of greater fuel delivery. The governor
controls the amount of fuel injected in this way to stabi­
lize the engine at idle speed.
13A-13
 -
2) Normal speed operation
FUEL AND ENGINE CONTROL - GENERAL
Speed control lever
Maximum speed position
Floating lever
11111111
Sliding lever
82671A
If the load control lever is moved 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 same time, the floating lever pivots about
point B to push the control rack in the direction of
greater fuel delivery, which results in the engine speed
increasing.
When the engine speed reaches a point over the idling
control range, the idling spring is completely com­
pressed in the tension lever, causing the shifter to be in
direct contact with the tension lever. The tension lever,
however, is in contact with the stroke adjusting bolt by
the tension of the governor spring which is tightened
by the speed control lever. Since the centrifugal force
of the flyweights is small in the normal speed range,
the tension lever is unable to move. This means that
point B can not move either, and the operation of the
load control lever is directly transmitted through the
eccentric shaft, sliding lever, and floating lever to the
control rack, thereby increasing and decreasing the
amount of fuel injected.
13A-14
3) Control of maximum speed
82672A
As the engine load varies and engine speed reaches a
predetermined maximum speed, the centrifugal force
of the flyweights overcomes the governor spring ten­
sion, causing the flyweights to start moving out. This
motion results in the shifter and tension lever being
moved to the right. Then, point B is moved to B' and
point D in tension lever to D', which prevents the
engine speed from exceeding the predetermined max­
imum level.
If this governor is used as an all-speed governor, the
engine speed is varied by operating the speed control
lever with the load control lever fixed at the full posi­
tion. That is, a given engine speed is maintained as the
speed control lever is tilted; if load changes, however,
the governor automatically controls to keep the given
speed. For example, suppose the speed control lever is
tilted to a position which provides the maximum out­
put (where it contacts the maximum speed stopper
bolt). When the engine speed increases in this condi­
tion, the centrifugal force of the flyweights becomes
greater.
 FUEL AND ENGINE CONTROL - GENERAL

As the force becomes greater than the force of the gov­

-
ernor spring which pulls the tension lever, the fly­
With smoke set
assembly
weights start moving out. This motion of the fly­

Without smoke set

weights causes the shifter and tension lever to be
moved to the right. At the same time, point Bis moved ambi'
to B', point D to D', and point C to C'. This results in the ,,i
control rack being pulled in the direction of smaller fuel
delivery, thus reducing the engine speed. Rs.,____ ' Re
\
If load increases to cause the speed to decrease, the
centrifugal force of the flyweights becomes smaller
than the governor spring tension. Then, point B' is
Rack
position
moved to 8, point D' to D, and point C' to C. This results
in the control rack being moved in the direction of (mm)
greater fuel delivery.
The governor automatically activates as load changes
to maintain a given speed at all times.
4) Start booster (smoke set assembly)

Pump speed (rpm) _,..

11111111 826748

As indicated by the governor characteristics shown

82673A
The smoke set assembly installed to the rear of the
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.
above, when without the smoke set assembly, the
shifter and floating lever are pushed back by the idling
spring force, moving the control rack toward fuel
increasing direction when pump speed reaches N1.
Namely, N1 is the smoke limit in this case.
When with the smoke set assembly, the spring force of
the smoke set assembly overcomes that of the idling
spring so that the floating lever motion is inhibited
until the speed reaches N 2. Thus, the smoke limit
decreases from N1 to N2.
It is also possible to secure rack position Rs needed at
time of start.

13A-15
 -
5) Engine stop lever
FUEL AND ENGINE CONTROL - GENERAL

(3) Feed pump

Normal
position
Stop
-. -,::: O
''�'
Priming pump
�
\ ®'
Stop lever assembly

Inlet check valve

To fuel filter

82675A 83006A

To stop the engine, the stop lever on top of the gover­
nor must be operated to cut off the fuel.
The stop lever is cable-connected to the engine stop
button on the driver's seat. The stop lever is operated
by pulling the button. When the stop lever is rotated,
the internal lever pushes the tab on the floating lever
link, forcing the control rack to the non-injection posi­
tion to stop the engine. The stop lever returns to the
normal position by the reaction of a built-in spring.
Supply of fuel to the injection pump proper is accom­
plished by the feed pump mounted to the side of the
injection pump proper and driven by the cam of the
injection pump camshaft provided for the purpose.
The priming pump mounted to the feed pump makes it
possible to lift fuel manually when the engine is sta­
tionary.

13A-16
 (a) Suction stroke
FUEL AND ENGINE CONTROL - GENERAL
01835
When the camshaft of the injection pump forces the
push rod up, the fuel in the suction chamber is com­
pressed and opens the outlet check valve. Most of the
fuel forced out is drawn into the pressure chamber
above the position.
(b) Pressure feed stroke
Piston spring
Pressure
chamber
01836
When the cam, moved away by rotation of the cam­
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.
(c) Stop
-
01837
When the pressure in the pressure chamber exceeds
specification, the piston cannot be brought back by the
pressure of the piston spring and stops the pump func­
tion. So the pressure in the fuel filter is adjusted not to
rise more than necessary.
(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. If the ignition timing is always constant,
changes in the engine speed will vary the relation
between the piston position and ignition timing, mak­
ing it impossible 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
speed.
13A-17
-
(a) SP type automatic timer <6D24, TC>
FUEL AND ENGINE CONTROL - GENERAL

Injection
Oil seal pump side

0-ring

Flange Cover

Spring seat
Flyweight
Timer housing

B3201A

Two flyweights are fitted on the pins of the timer hous­
ing and are held in the timer housing. On the other
hand, the inject ion pump connection side flange has a
curved surface, and the roller fitted on the pin installed
in the flyweight touches the curved surface. Timer
1imer spring Flange
Timer housing
pin
\ When the engine reaches a high speed, the centrifugal
Advance angle
springs are held between the spring seats fitted on the
timer housing pins which extend through the flange
and flyweight. These parts are housed in the timer
housing and are totally enclosed with a cover, 0-ring
and oil seal.
When the engine is running at a low speed, the timer
spring pressure is stronger than the centrifugal force of
flyweight, so the roller of flyweight is held down by the
flange, creating no advance state.
force of flyweight becomes stronger, the roller of fly­
weight pushes the curved surface of flange with the
timer housing pin as the fulcrum, and the flyweight
opens outward, while compressing the timer springs.
In this manner, the roller installed on the flyweight
moves the flange in the turning direction and advances
the injection timing.

83202A
13A-18
 FUEL AND ENGINE CONTROL - GENERAL

(b) SPG type automatic timer <6D24-T>

-
\;
Cover
Pilot pin

\/ Timer holder

Timer housing

80023A

� �
��,�Flywo;ght _'.

Flywo;ght p;, =-�

� - Eccentric cam (larger)
Timer holder �
� Eccentric cam (smaller)

I�
�
Housing pin -,---U ···
Timer housing

Timer spring
80024A 80025A

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 same
connected to the injection pump camshaft. Two oppos­ set tension to keep the flyweights evenly in position.
ing pins are press-fitted in the timer housing. A small When 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 holder fit over the
large eccentric cams.
Pins are pressed into the undersides of the flyweights.
These flyweight pins fit into holes in the larger eccen­
tric cams.
When the timer housing is rotated, the timer holder is
rotated at the same time driving the injection pump.

13A-19
 FUEL AND ENGINE CONTROL - GENERAL

(5) Boost compensator <engine with turbocharger>

Point A

Boost
Flyweight pressure

Timer spring

Inlet manifold
Flyweight pin Timer housing pin
(point Cl
Small
eccentric
cam cam

Flyweight in fully
lifted position

Retard
angle
--tt--t--+-+� �-1-+--+-....1.L_.1.

86012A
43932

When the engine is not running, the flyweights are The boost compensators increase the engine's power
pressed against the timer holder by the timer spring set output by increasing the rate of fuel injection to match
tension. increases in air intake caused by the turbocharger. To
When the engine is started, a centrifugal force is pro­ increase the amount of fuel injected, the boost com­
duced by the flyweights; however, it is less than the pensators utilize the boost pressure in the inlet man­
timer spring set tension keeping the flyweights ifold.
remaining the original positions, without lifting. There are two boost compensators. One is fitted to the
As the engine speed increases, the centrifugal force of governor, and the other is fitted to the drive side of the
the flyweights also increases and will be balanced with injection pump.
the spring tension. When the engine speed further
increases, the centrifugal force overcomes the timer
spring 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, moved in the rotating direction, by the small
eccentric cam pivoting about the timer housing pin
(point C). Since the large eccentric cam is fitted to the
timer holder, that motion of the large eccentric cam is
imparted to the timer holder. The maximum 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 compensator
FUEL AND ENGINE CONTROL - GENERAL

(b) Drive-side boost compensator

-
Boost compensator set spring
Connection pipe

Boost
Boost compensator

Inlet manifold

Floating lever

B2693C Control rod.

82691A
As the boost pressure overcomes the compensator Load control lever idling position

7
spring, the diaphragm and push rod are pushed to the
left. Movement of the diaphragm is pivoted on point �
"A" of the compensator lever and moves the compen­ = tingl�oc
Control rod .
sator lever in the direction shown by the dotted lines. CanceI sprmg Floatmg. I ever 1.mk

[JC: :,.•.o
Load control lever full position (turbocharger off)
As the diaphragm and compensator lever move, the
:+
floating lever pivots counter-clockwise about point F.
"B," thereby pushing the control rod in the fuel-in­ �
crease direction. The system is thus able to increase Load control lever full position (turbocharger on)

the fuel quantity irrespective of the governor. :+ ¥? [jt#:;;:g,_nn

� 82693A

When 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 means that, when the push
rod moves in the direction shown by the arrow, the
control rod moves in the direction of greater fuel sup­
ply.
This boost compensator also has a spring that
increases fuel supply at engine start.

13A-21
 - FUEL AND ENGINE CONTROL - GENERAL

(7) Injection nozzle

Two models of hole type injection pumps are used.
Their constructions are as follows.
(a) KBL2.1 injection nozzle

Cap nut
Adjusting screw

Lock nut---
�..._.,,.,.,
Set screw---��=!� No. 2 spring

�::;..._- Spacer
Control rod
82692A No. 2 push rod
MU�--- Nozzle holder

Before the engine is started, the idling spring in the

governor, forcing the control rod in the direction of
No. 1 spring
more fuel supply overcomes the force of the smoke set
No. 1 push rod
spring and therefore the control rod moves to the start
Nozzle
fuel increase position while forcing the arm. When the Retaining nut
engine is started, the idling spring is compressed by
the shifter and as a result, it loses the force to push out
the control rod. Then, the smoke set spring forces the
control rod back to the normal position. 83406A

(6) Pump drive case

The nozzle has two springs and push rods, and a clear­
ance (prelift) is provided between two rods.
Pump drive shaft
When the high pressure fuel fed from the injection
pump overcomes the 1st spring which determines the
valve opening pressure, the needle valve opens to start
the pre-injection and simultaneously moves the 1st
Injection
push rod upward.
pump side When the 1st push rod moves through the prelift and
contacts the 2nd push rod, the needle valve stops mov­
ing momentarily. As the fuel pressure further increases
and overcomes the resultant force of the 1st and 2nd
springs, the needle valve restarts moving upward for
the main injection.
Flywheel
housing side Some of the high-pressure fuel is used to lubricate the
84191A
needle valve and other components and is returned to
the fuel tank via the leak-off pipe.
The pump drive case, installed at the left of the 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 pump drive shaft,
with its end connected to the coupling of the injection
pump, drives the injection pump.
13A-22
(b} KBL2.4 injection nozzle
FUEL AND ENGINE CONTROL - GENERAL -
No. 1 spring
From injection pump

OJ
No. 1 valve No. 1 spring seat
opening pressure,--++�� Push rod
adjusting shim

No. 1 spring
No. 2 spring
No. 1 spring seat

No. 2 valve
opening pressure Lift-piece
adjusting shim
Needle valve
No. 2 spring seat Lift-piece
Needle valve

01846
11933

As the pressure of the fuel fed from the injection pump

With this nozzle, a prelift clearance is provided
between the lift-piece and No. 2 spring seat, and the
nozzle's injection starting pressure is determined by
the force of the No. 1 spring.
(i.e., the pressure in the nozzle tube} overcomes the No.
1 spring, the needle valve rises by the prelift distance.
When the lift-piece rises by the prelift distance, it meets
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 springs com­
bined, and the needle valve momentarily stops rising.
As the fuel pressure rises and the pressure in the nozzle
tube overcomes the two springs, the needle valve rises
further and the nozzle injects the remaining larger
quantity of fuel.
Fuel injection pressure adjustments are made using
the shim.

13A-23
 -
(8) Fuel filter
FUEL AND ENGINE CONTROL - GENERAL

(9) Water separator

<6D24, T, TC>

-- Element

835018

83551A

The sedimenter type water separator separates gas oil

and water centrifugally by taking advantage of their
difference in specific gravity.
83501C
The fuel that has flowed in from the inlet connector is
<6D24-TL> 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 of the head
into the feed pump.
The water separator sediments not only water but also
mud components.
A red float goes up and down with the water level in the
semi-transparent case, making it possible to visually
check the water quantity.

®28757

The fuel filter may be either the 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 pump of injection pump and
eliminates dirt in the fuel by the element.

13A-24
 2. SPECIFICATIONS
FUEL AND ENGINE CONTROL - SPECIFICATIONS -
(1) Injection pump
Item Specification
Manufacturer BOSCH AUTOMOTIVE SYSTEMS
Injection <6024> <6D24-T> <6D24-TC> <6O24-TL>
Pump (Standard) (Optional) (Standard) (Optional)
Type Bosch in-line Bosch in-line Bosch in-line Bosch in-line Bosch in-line Bosch in-line
type type type type type type
Model p p p p p p
Direction of rotation Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise
(seen from drive side)
Plunger diameter mm 12 12 12 12 12 12
Governor
Model and type RSV all-speed RFD minimum- RSV all-speed RFD minimum- RSV all-speed RED-4
mechanical maximum- mechanical maximum- mechanical electronically
governor speed mechani- governor speed mechani- governor controlled
cal governor cal governor governor
Feed pump model
Model K K K K K KD
Automatic timer
Model and type SP mechanical SP mechanical SPG SPG SP mechanical SPGH
automatic timer automatic timer mechanical mechanical automatic timer electronic timer
automatic timer automatic timer

(2) Injection nozzles

Item Specification
Manufacturer BOSCH AUTOMOTIVE SYSTEMS
<6D24> <6O24-T> <6O24-TC> <6O24-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)
model OLLA OLLA OLLA OLLA OLLA
No. of holes 5 5 5 5 5
Hole diameter mm 0.32 0.36 0.36 0.36 0.30
Spray angle 157° 154° 150° 150° 151°

(3) Others items

Item Specification
· Fuel filter
type Spin-on filter-paper type

Water separator
type Precipitation type

13A-25
 FUEL AND ENGINE CONTROL - SERVICE STANDARDS

3. SERVICE STANDARDS
3.1 Service Standards Table
(1) Injection pump
Unit: mm
Maintenance item Nominal value Limit Remedy and remarks
(Basic diameter in I ])

Fuel injection start timing (BTDC) Dependent on - Adjust

specification

Eccentricity with respect to air compressor crankshaft 0.2 or less - Adjust shims
(or pump drive shaft)

(2) Injection nozzle

Unit: mm
Maintenance item Nominal value Limit Remedy and remarks
(Basic diameter in I ])

1st valve opening pressure All except 6O24-TL 17.7 MPa {180 kgf/cm2} - Adjust
6O24-TL 15.7 MPa {160 kgf/cm }2 -
Prelift KBL 2.1 0.10 ± 0.02 - Adjust
KBL 2.4 0.07 ± 0.02 -
2nd valve opening pressure ("open" pressure) 24.8 to 25.4 MPa - Adjust
{253 to 259 kgf/cm2}

2nd valve opening pressure with 0.05mm KBL 2.1 23.0 to 23.5 MPa - Adjust
needle valve lift ("cover" pressure) {235 to 240 kgf/cm2}

KBL2.4 22.6 to 23.6 MPa - Adjust

{230 to 240 kgf/cm2}

13A-26
3.2 lightening Torque Table
FUEL AND ENGINE CONTROL - SERVICE STANDARDS -
Location tightened Screw size Tightening torque Remarks
O.D. x pitch (mm) N-m {kgf-m}

Injection pump bracket mounting bolt M10 x 1.5 35 to 53 {3.6 to 5.4}

Injection pipe union On pump side M14 x 1.5 29 to 49 {3 to 5}
nut
On nozzle side M12 x 1.5 29 {3}
Injection Overflow valve 20 to 29 {2 to 3}
pump
Injection pump 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}
Boost compensator eyebolt 12 to 15 {1.2 to 1 .5}
Fuel feed Fuel inlet side eyebolt 20 to 25 {2 to 2.5}
pump
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 pump gear mounting nut of pump drive case M24x 1.5 215 {22}
Injection Leak-off pipe eyebolt M8x1 9.8 to 15 {1 to 1.5}
nozzle
Injection nozzle bolt M8 x 1.25 15 {1.5}
(for attaching to cylinder head)

2-spring Retaining nut M19 X1 59 to 78 {6 to 8}

nozzle
Cap nut M22x 1.5 39 to 49 {4 to 5}
Inlet connector M14 x1.5 69 to 78 {7 to 8}
Set screw M22 x 1.5 49 to 59 {5 to 6}
Lock nut M14 x1 20 to 25 {2 to 2.5}

Leak-off connector M14x1 29 to 39 {3 to 4}

Retaining nut M19x0.75 59 to 78 {6 to 8}
Fuel filter connector All except 6D24-TL M14 x 1.5 25 {2.5}
bolt
6D24-TL M14 x 1.5 25 to 35 {2.5 to 3.5}
Air vent plug All except 6D24-TL MS x 1.25 7.8 to 12 {0.8 to 0.12}

6D24-TL MS x1.25 9.8 ± 2 {1.0 ± 0.2}

Water separator Eye bolt M14 x 1.5 25 {2.5}

Air plug MS x 1.25 7.8 to 12 {0.8 to 1.2}

13A-27
 FUEL AND ENGINE CONTROL - SPECIAL TOOLS

4. SPECIAL TOOLS
Unit: mm
Tool name Shape
Filter Wrench
MH061572
<All except 6D24-TL>
Removal of fuel filter element

85222A
Filter Wrench
MH061572
<6D24>
Removal of fuel filter element

®01503
Injection Pump Centering
Tool
MH061340
Centering of bracket of
injection pump

22338

13A-28
 5. SERVICE PROCEDURE
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(2) Installation procedure

-
5.1 Removal and Installation of Injection Pump NOTE:
Assembly The following procedures assume that the injection
pump is equipped with an air compressor. The same
(1) Removal procedure
procedures apply to one with a pump drive case.
(a) Ready a fluid receiver and waste cloth to ensure
(a) Adjustment of injection pump bracket
that the engine is not contaminated by fuel or
engine oil.
(b) Remove all pipes and harness connectors that
make the removal job difficult or impossible.

Dial gauge

Injection Pump
Centering Tool
MH061340

Air compressor

$ 30 position

43739

(c) Remove the bolt shown from the coupling. Injection pump
(d) Remove the injection pump from the injection bracket
pump bracket.
NOTE:
11929

1) Make zero-point adjustment with Injection Pump

Centering Tool (special tool) placed on the injec­
tion pump bracket and a dial gauge set on the man­
drel of the special tool.

C0557A

Keep the injection pump removed on wooden blocks

so as to protect the automatic timer area from impact.
(e) Do not remove the injection pump bracket unless
defects, such as cracks, are evident.

13A-29
 - FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

<When the measured value at point 8 is positive

(+)>
Insert shims evenly to four places.
<When the measured value at point A is positive
(+)>
Insert shims to the lower side of point C.
<When the measured value at point C is positive
(+)>
Insert shims to the upper side of point A.
Shim inserting requirements
• The number of shims used in a single location
C0597A must not exceed three.
• Top and bottom shims both at front and rear
2) Slide the dial gauge toward the air compressor and must be equal in thickness.
measure the misalignment between the mandrel • The difference in number between the top and
of the special tool and the air compressor crank­ bottom shims must not exceed one.
shaft at points shown in the figure.
4) After adjustment, tighten injection pump bracket
to the specified torque before confirmation.
Eccentricity (b) Installation of injection pump
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.)

Keyway

Dowel pin

2) At that time, verify that the keyway of air compres­

sor crankshaft faces upward. If not, rotate the
NV .. Nominal Value C0598A crankshaft one complete turn.

3) If the eccentricity between the mandrel and air

compressor crankshaft is in excess of the nominal
value, adjust by adding or removing injection
pump bracket shims.

13A-30
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

• Fit the injection pump onto the injection pump

-
bracket.
• Temporarily fit the timing 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.

u
C0562A 20to29N-m 29to49N-m
{2to3 kgf-m}
{3to5 kgf-m}
20to29N -m
3) Align the pointer of the injection pump and the {2to 3 kgf-m}___ _r,./ 20to29N-m
�/ k
inscribed mark on the automatic timer.

/&1,.�
4) Installation of injection pump tt�: gfm}
20to25N•m
{2to2.5 kgf- m} \
'20to25 N-m
12to15N-m {2to2.5 kgf-m}
{1.2to 1.5 kgf-m}
43741

(c) lighten each pipe to specification.

(d) After the injection pump has been installed, be
sure to check and adjust, if n_ecessary, the fuel
injection start timing. (Refer to Section 5.3.1.)

liming
adjustment
bolt

Clearance 85893A

• Loosen the cotter bolt and remove the timing

adjustment bolt. Remove the driving coupling
from the coupling plate.
• Fit the driving coupling onto the air compressor
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 timing

)
r
(1) Loosen air plug of fuel filter.
85909A .. ; j!!
I B6118A

(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 manu­
B4324A ally more than 180° in the normal direction.

(2) Turn counterclockwise the priming pump knob of

injection pump so that it comes loose.
(3) Move priming pump knob up and down to feed fuel
until air bubble does not come out from air plug.
(4) With no air bubble coming out in fuel, tighten air
plug.
(5) Move priming pump knob up and down several
times, then screw in knob.
NOTE:
Sop up fuel spilt around.
(6) Actuate starter to discharge air in injection pump
and pipe.
NOTE:
Do not actuate starter for more than 15 seconds.

13A-32
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Adjusting bolt
<6O24,T,TC>
59 to 64 N-m {6 to 6.5 kgf-m}
<6O24-TL>
83 to 93 N-m {8.5 to 9.5 kgf-m}

21839 86117C

If the timer is electronic, check at this time whether the
inscribed lines are aligned. If they are not aligned, the
timer is advanced; give the engine two turns in the for­
ward direction to return the timer to a non-advanced
condition. If this action does not return the timer to a
non-advanced condition, first loosen the eyebolt (see
the drawing) to make it easier for residual hydraulic
pressure in the timer to escape to the injection pump.
(3) If they are out of alignment, loosen the timing
adjusting bolt of the coupling and adjust by turning
the automatic timer.
After adjustment, recheck by the procedures of
steps (1) and (2), and tighten the timing adjusting
bolt to the specified torque.
NOTE:
Do not loosen the bolts of the coupling except the tim­
ing adjusting bolt.

C0562A

(2) If the inscribed mark of the injection pump and the

inscribed mark of the automatic timer are in align­
ment in the above condition (1), the fuel injection
start timing is correct.

13A-33
 -
5.3.2
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Inspection and adjustment of minimum and (2) RFD type governor

maximum no-load speeds
Start and idle the engine until it reaches normal operat­
ing temperature. Then, make the following checks.
Stopper bolt
(1) RSV type governor

Idling Full-speed Idling stopper bolt

position 1------, position
Adjusting lever Full-load
stopper bolt

Load control lever

B63068

(a) Minimum speed

B6310B
(a) Minimum speed
Make sure that the adjusting lever is in contact with the
stopper bolt. In this condition, check that the minimum
speed is within the specification. If the specification is
not met, adjust with the stopper bolt.
(b) Maximum speed
Place the adjusting lever to the full-speed position. If
the maximum speed is outside the specification in this
condition, adjust with the maximum speed stopper
bolt.
NOTE:
Quickly move the adjusting lever from the full-speed
position to the idling position to make sure that the
engine does not stall or develop hunting. If defects are
evident, adjust within the specification.
Check to see that the load control lever is in contact
with the idling stopper bolt. In this state, check that the
minimum speed is within specified limits. If not, adjust
with the idling stopper bolt.
(b) Maximum speed
Set the load control lever at the full-load position
(where it contacts the full-load stopper bolt). If the max­
imum speed is outside specified limits in this state,
adjust with the maximum speed stopper bolt and stop­
per bolt.
NOTE:
1. Never attempt to change the locked position of
the full-load stopper bolt.
2. Quickly move the load control lever from the full­
load position to the idling position to make sure
that the engine does not stall or develop hunting.
If defects are evident, adjust within the specifica­
tion.

13A-34
5.4 Pump Drive Case
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE -
5.4.1 Removal and installation

Pump drive case

84194A

(1) For removal and installation of the pump drive

case, refer to Section 5.1 in Group 61 Special
Equipment.

5.4.2 Disassembly and inspection

10
Deterioration,
damage

Cracks, wear
84196A
Disassembly sequence
1 Sensor plate 5 Oil seal 8 Bearing
2 Injection pump gear 6 Shaft 9 Cover
3 Collar 7 Bearing 10 Crank case
4 Bearing holder

13A-35
 -
5.4.3 Reassembly
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Assembly sequence 4
10➔8➔6➔3➔®➔<D➔9
4➔7➔5 -1'
10 7
For parts with an encircled number, refer to
Reassembly Procedure that follows.
B4197A

(1) Installation of injection pump gear

Install the injection pump gear, sensor plate (or guide
plate) and nut as shown.

Align uo" and "U" marks

D9274B

13A-36
5.5 Injection Nozzle
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.5.2 Disassembly
-
5.5.1 Removal and installation <KBL2.1 injection nozzle>

Gasket
,-{j
-0

3�

2--18111
Cracks,
deterioration 4---=1
Nozzle
identification
5 mark stamped
position Wear
12
Wear6� 11
Carbon
Shim � deposits
(for prelift) _
�
o-,o
Shim
1
--rf
(for valve opening ---®

:---t./
pressure)
______§
Cracks, 8 -- g
1 Injection pipe 4 Dust seal dete,;o,at;oo g
2 Leak-off pipe 5 Nozzle tip gasket
3 Injection nozzle 1 Cap nut 8 1st spring
C0577B
2 Adjusting 9 1st push rod
screw 10 Retaining nut
3 Lock nut 1l 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
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

<KBL2.4 injection nozzle> Disassembly Procedure

T he following special tools should be used in disas­
sembly:
Identification
mark position Tool name Part No. (Zexel product No.)
11-ij 157944-9520
Plate
11
r- Special Wrench 157914-2800

�10
Removing retaining nut
:--- 9
� 8
16 ©-

--·· Special Wrench

(157914-2800)

15--®
14�
1a__i
12

01888

15449
Secure the Plate (special tool) in a vise and fit the injec­
G) 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 Callar
4 Pin (lj>3) 13 Spring seat 5.5.3 Cleaning and inspection
5 Spacer 14 1st spring (1) Cleaning
6 Lift piece 15 Shim (For adjust­
7 Pin (lj>2.5) ment of primary
8 Spring seat valve opening Nozzle Cleaning Tool
9 Shim (For adjust­ pressure) 105789-0010

ment of second­ 16 Nozzle holder

ary valve opening 17 Leak-off
pressure) connector

NOTE: 01891
1. Clean off any carbon deposits before disassem­
bling, reassembling, or adjusting any nozzle After washing 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
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(2) Inspection
-

O7003A
(a) Remove the needle valve from the nozzle and clean
the needle valve with the needle valve cleaning
wood piece.
070058
Clean and immerse the nozzle in gas oil, slide the
needle valve and check that it moves smoothly.
Next, pull up the needle valve vertically about 1/3 of its
entire stroke and check that it falls under its own
weight. If it does not fall, replace the nozzle.

O7004A

(bl Insert, while turning, a cleaning needle into the

injection orifice of the nozzle to remove carbon.

O7029A

(c) Clean the nozzle seat using the cleaning needle.

(d) To remove burnt and hardened carbon, use FUSO
Carbon Remover or equivalent.

13A-39
-
5.5.4
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Reassembly and adjustment <KBL2.1 injec-

tion nozzle>
Adjust while assembling the parts by the following 1 39 to 49 N-m
{4 to 5 kgf-m}
procedures. 2
3 20to 25 N-m
As the prelift is adjusted in 1/100 mm increments, use {2 to 2.5 kgf-m}
clean detergent to thoroughly remove dust and dirt 5 49to 59 N-m
{5 to 6 kgf-m}
before adjustment. 4
The following special tools should be used when mak­ Shim (for prelift)
ing adjustments: 14 7
6
Tool name Zexel product No . 13
u....-+--Shim (for valve
Adjusting Device 105789-0500 opening pressure}
8
9
Adjusting Device (105789-0500) components

11
10
59to 78 N-m
{6to 8 kgf-m}

D 7016C
Assembly sequence
13➔9➔8➔7➔5➔6-+4➔2➔3,
____r 1O➔ 14➔1
11➔12

NOTE:
Never touch the sliding surface of the needle valve by hand.

Adjusting Steps
CD Adjustment of 1st valve opening pressure
® Selection of prelift adjusting shims
@ Adjustment of 2nd valve opening pressure
("open" pressure)
*@ Check of needle valve full lift
83942A
@ Installation of prelift shims
*@ Checking of prelift
1 Adjusting device assembly 157892-0220
*(/) Adjustment of 2nd valve opening pressure
2 Dial gauge 157954-3800
("cover" pressure)
3 Pint= 50 mm 157892-1200 @ Inspection
4 Pin e = 60.5 mm 157892-1100
Inspection make operations marked with * as neces­
5 Connector assembly 157892-1320
sary for inspection or confirmation.
6 Base 157892-1800
7 Gasket <for Retaining nut> 157892-1500
8 Retaining nut for adjustment 157892-1420
9 Gasket <for bolt of retaining nut> 026508-1140

13A-40
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(1) Adjustment of 1st valve opening pressure

-
Set screw
49 to 59 N-m
{5 to 6 kgf-m}

Nozzle holder

Spacer

Shim (for 2nd valve opening

pressure adjustment)
1st spring

1st push rod

Gasket A
157892-1500

D7018A
D7017A

(b) Insert 1st push rod, 1st spring, 1st valve opening
(a) Using the Retaining Nut for Adjustment (special pressure adjusting shim (first use about 1 mm 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
Operate lever at 60 to
pletely in the nozzle before tightening the Retain­ 100 strokes/minute
ing Nut for Adjustment. Tighten the retaining nut Injection pressure
finger tight and then tighten to specified torque NV 17.7 MPa
{180 kgf/cm2}
using a torque wrench.
NV .. Nominal Value
2. Remove the bolt from the tip of the retaining nut.

Keep bolt removed

D7019D

(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:
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

1. When using a shim, be sure to check its thickness

by a micrometer.
2. Use same shim for prelift 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
Dial Gauge holder
(a) "O" point adjustment of adjusting device
Intermediate screw
of Adjusting Device

Dial Gauge
157954-3800 Set screw

Adjusting Device
157892-0220
Pin
157892-1100
2nd push rod
2nd push rod

Base
157892-1800

O7031A

(c) Install the adjusting device to the set screw using

its intermediate screw.
After installation, holding the Dial Gauge at its
holder, move it up and down to check that the
gauge operates smoothly.
Push down the gauge, holding its holder and read
D7030A 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=t'+h
install the assembly to a vice.
Set the pin and Adjusting Device as indicated in the where t: Shim thickness (measured)
above illustration and adjust "O" point of the Dial t': Prelift (0.10 ± 0.02 mm)
Gauge. Use a 60.5 mm long pin. h: Dimension 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) Remove the Adjusting Device from the nozzle
holder.

13A-42
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE -
t
(3) Adjustment of 2nd valve opening pressure (4) Checking full lift of needle valve
("open" pressure)

20 to 25 N-m DialGauge
{2 to 2.5 kgf-m}----1 157954-3800
Lock nut 39 to 49 N-m {4 to 5 kgf-m}
Adjusting screw----c;:;i Connector
157892-1320
2nd spring ----flll Pin C= 50 mm
157892-1200
0

07032A
Install the 2nd spring, adjusting screw and lock nut to
the nozzle holder.
NOTE:
Do not install the prelift adjusting shim.
Operate lever at 60 to 100
strokes/minute
Injection pressure
NV 24.8 to 25.4 MPa
{253 to 259 kgf/cm2}
NV .. Nominal Value
'-
Retaining Nut for
Adjustment
Gasket B 157892-1420
026508-1140 ---®
�Bolt
D7033A
(a) Install the special tools indicated in above illustra­
tion and set "O" point of the Dial Gauge.
(b) Install the nozzle to the nozzle tester and operate
the tester lever to bleed the inside of the retaining
nut.
Also check for fuel leaks.
(c) Operate the tester lever to increase the pressure to
about 34.3 to 44.1 MPa {350 to 450 kgf/cm2} so that
the needle valve of the nozzle is fully lifted. Read
this lift dimension "L" off the Dial Gauge.
(d) Remove the Dial Gauge, Connector and Pin (spe­
cial tools).
(5) Installation of prelift shim

Adjusting screw

Lock nut

Set screw
Keep bolt removed 49 to 59 N-m
{5 to 6 kgf-m}
070190

Using a nozzle tester and turning the adjusting screw,

adjust the 2nd valve opening pressure ("open" pres­
sure) until it complies with the nominal value.
After adjustment, tighten the lock nut to specified 07034A
torque.

13A-43
- FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(a) Remove the set screw, lock nut and adjusting (7) Checking 2nd valve opening pressure ("cover"
screw as an assembly from the nozzle holder. pressure)
NOTE:
Never loosen the lock nut as loosening it changes the 2nd valve opening pressure
(lift 0.05)
2nd valve opening pressure. NV 23.0 to 23.5 MPa
{235 to 240 kgf/cm 2}
(b) Install the prelift shim selected in Item (2) between
the spacer and 2nd push rod. NV .. Nominal Value

(c) Install the 2nd push rod and 2nd spring and tighten
the set screw, lock nut and adjusting screw as an
assembly to specified torque.
(d) Check again that the needle valve full lift dimen­
sion "S" with the Dial Gauge by the procedures
described in Item (4).
(6) Checking prelift
Check the prelift based on dimension "L" measured in
Item (4) and dimension "S" measured in Item (5).
L-S=b.e
where e - 0.02 mm � b. e � e + 0.02 mm
b. e: Prelift (measured)
e: Prelift (0.1 mm)
L: Needle valve full lift dimension (measured)
S: Needle valve lift dimension (measured) with
prelift subtracted
e e
If b. is outside of specified dimension ± 0.02 mm,
replace the prelift adjusting shim as described in (5)
and repeat steps (4) and (5) so that b. e will fall within f
± 0.02 mm.
Select thickness t' of shim to be used as follows.
t' =t + (f - b. f)
T=t' ± 0.015 mm
where t: Thickness of existing shim
t': Shim thickness
T: Thickness of shim to actually replace exist­
ing shim
f: Prelift (0.1 mm)
O7035A
(a) After checking the prelift in Item (6), increase the
pressure again to about 34.3 to 44.1 MPa {350 to
450 kgf/cm 2} so that the needle valve of the nozzle
is fully lifted.
NOTE:
Retaining Nut for Adjustment (special tool) must have
a bolt fitted at its tip.
(b) When the nozzle tester lever operation is stopped
with the nozzle needle valve fully lifted, the pres­
sure will start to drop and the needle valve will go
down.
(c) At the moment the nozzle lift has dropped to 0.05
mm, read the pressure gauge indication.
(d) If the 2nd valve opening pressure ("open" pres­
sure) is out of specification, adjust it in accordance
with item (3).
NOTE:
Adjust without installing prelift shim.
(e) Remove special tools.
(8) Inspection
(a) lighten 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) Spray condition
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE -
1 2 3 4 5 6
Good Good Poor Poor Poor Poor
I
I
I \ I
� �

i
l
�
(

'
i
�

\ f

Good Poor
1 Evenly sprayed from 3 Asymmetrical
five injection orifices 4 Branched
2 Even and symmetrical 5 Thin
6 Irregular
O7009A

When 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

Test pressure
15.7 MPa
{160 kgf/cm2}

O7010A

Install a nozzle that has been adjusted to specified

injection start pressure to the nozzle tester. Slowly
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 normally if there is
no leak.

Engine Parts contact phone: 269 673 1638

Email: EngineParts2@gmail.com

13A-45
-
5.5.5
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Reassembly and adjustment <KBL2.4 injection nozzle>

The adjustment should be performed during reas­ cleaned with the clear cleaning fluid to remove dust
sembly as described below. The prelift should be and foreign materials completely. For the adjustment,
adjusted in 1/100 mm unit. Therefore the parts must be following special tools are required.

Tool name and shape Part No. Application

(Zexel product No.)

Adjusting Device 157892-4920

*1 Adjusting Device 157892-4420
*2 Holder 157892-4400
*2 Nut 157892-1000 Securing Dial Gauge
*1 Dial Gauge 157954-3800
*1 Pin 157892-4700
*1 Retaining Nut for Adjustment 157892-4020
*3 Retaining Nut for Adjustment 157892-4000
*3 Gasket 026508-1140
*3 Plug 157892-1600
*1 Gasket 157892-1500
Plate 157944-9520 Securing nozzle holder
Special Wrench (SW19) 157914-2800 Removal and installation of retaining nut
Special Wrench (SW22) 157914-0500 Removal and installation of Retaining Nut for Adjustment

Items marked "*1" are parts of Adjusting Device 157892-4920.

Items marked "*2" are parts of Adjusting Device 157892-4420.
Items marked "*3" are parts of Retaining Nut for Adjustment 157892-4020.

13A-46
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Reassembly and Adjustment Procedure

-
(1) Reassembly
29to 39 N-m
{3 to 4 kgf-m}
17

16 Nozzle holder_ Plate

/ 157944-9520

15
14

11 13
9 01895
1,....-.;---12
7 H---r---10 (a) Secure the Plate (special tool) in a vise, then mount
4 the nozzle holder on the Plate. Carry out reas­
8 sembly in the opposite of the disassembly
6 sequence.

2 5

3
Gasket
1 157892-1500
59to 78 N-m
{6 to 8 kgf-m}
__ Special
,__ Wrench
157914-0500
For reassembly, reverse the order of disassembly.
NOTE:
Do not touch the needle valve's sliding surfaces.
11937

During reassembly, make adjustments and checks in 01896

the following sequence:
(b) Fit the Gasket (special tool) onto the nozzle. Then,
(1) Adjust the No. 1 valve's opening pressure secure the nozzle on the nozzle holder using the
Retaining Nut for Adjustment (special tool). Turn
(2) Check the needle valve's total lift the Retaining Nut for Adjustment as far as possible
by hand, then tighten it to the specified torque
using the Special Wrench (special tool).
(3) Check the prelift amount

(4) Check the No. 2 valve's opening pressure

(5) Adjust the No. 2 valve's opening pressure

(6) Replace the retaining nut

j (7) Make an overall inspection

13A-47
 - FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(2) Adjusting No. 1 valve opening pressure

Plate 157944-9520

//
Injection nozzle
assembly

Injection pressure
<All except 6D24-TL>
NV 17.7 MPa
{180 kgf/cm2}
<6D24-TL>
NV 15.7 MPa
{160 kgf/cm2}
15263
NV .. Nominal Value 15262

(b) Mount the injection nozzle assembly upside-down

(a) Fit the injection nozzle assembly onto the tester on the Plate (special tool). Then, fit the Holder and
and measure 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/cm 2} change in valve opening pres­
Nut
sure. 157892-1000
Holder
Shim thickness: Dial 157892-4400
0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70 Gauge
157954-
3800
(3) Checking needle valve total lift

Pin
157892-
4700
Spring seat

15264

(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 assembly 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:
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(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,
E
-
the Dial Gauge shaft will stick in one position.
E
!t
"'
>
�
-0
(1)

z Pressure gauge
Q)

Retaining Nut
for Adjustment

"�"
157892-4000 Pipe pressure (MPa {kgf/cm2})
01903

-� Plug 157892-1600
(a) Once the needle valve is in its fully lifted position,
the pipe pressure will start to drop if the Nozzle Tes­
15265 ter handle is not moved. The needle valve lift mea­
surement (as shown by the Dial Gauge) will drop
(e) Fit the injection nozzle assembly onto the Nozzle concomitantly. In the graph,
Tester, then zero the Dial Gauge. A: Needle valve total lift amount
Loosen the Plug (special tool) and operate the
Nozzle Tester. Bleed the Retaining Nut for Adjust­
ment, and check for fuel leaks at the same time.
No_ 2 spring
After fully bleeding the Retaining Nut for Adjust­
ment, securely tighten the Plug.

E I NV 0.07 ± 0.02 I Needle valve

E l'l=!::::�l,__l!::;i�:::::(I
:lE
� NV .. Nominal Value
iii
>

---
Q)
-0
Q)
A
z
Q)

1/
-
:lE
C 34.3 to 44.1 {350 to 450} G
>
Pipe pressure (MPa {kgf/cm })
2
01902 >
� F
Q)
Q)
(f) Operate the Nozzle Tester. When the pipe pressure
is raised to 34.3 to 44.1 MPa {350 to 450 kgf/cm2},
C
the needle valve should lift completely. When this
Pipe pressure (MPa {kgf/cm2})
happens, make a note of the total lift measure­ 01904
ment. In the graph,
A: Needle valve total lift amount (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. T his point is labeled "F" in the above
graph. Confirm that the reading conforms with the
This check is necessary to check for abnormal wear on
specified nominal value.
the nozzle seat.
13A-49
 - FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

T he prelift measurement point (labeled "G" in the

graph) corresponds to C + approx. 980 kPa {10 kgf/
cm2}, where "C" is the No. 1 valve opening pres­ E
E
sure.
In the graph, Q)
>
iij
F+0.05
>
A: Needle valve total lift amount Q)

C: No. 1 spring opening pressure � F i------,�-

a,
F: Prelift z
G: Prelift measurement point
C J 34.3 to 44.1 {350 to 450}

Pin Pipe pressure (MPa {kgf/cm2})

F+0.05

Needle valve

Nozzle r----- Capsule

�--- 01905 Dial Gauge A Pressure gauge

01907

(c) If the prelift measurement is out of specification,

(b) Read the pressure gauge indi(?ation at the instant
replace the pin, lift-piece, spacer, nozzle, and
when the Dial Gauge indicates the specified nomi­
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 amount
C: No. 1 valve opening pressure
F: Prelift
J: No. 2 valve opening pressure
(6) Adjusting No. 2 valve opening pressure

No. 2 valve opening

pressure
Shim--tfl J

NV .. Nominal Value 15266

(a) After checking the prelift, operate the Nozzle Tester

and raise the pipe pressure to 34.3 to 44.1 MPa {350
to 450 kgf/cm2} such that the needle valve lifts fully.
If the Nozzle Tester handle is not moved, the pipe
01908
pressure will drop. T he needle valve lift measure­
ment (shown by the Dial Gauge) will drop concom­
If the No. 2 valve opening pressure is out of specifica­
itantly.
tion, disassemble the nozzle mounting side of the
injection nozzle assembly and change the No. 2 valve

13A-50
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

opening pressure adjustment shim. (This shim has an (8) Inspection

-
outside diameter of 9.9 mm.)
Shims 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

59to 78 N-m
{6 to 8 kgf-m} Fit the injection nozzle assembly 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:
- Retaining 1. If the No. 1 valve opening pressure does not con­
Nut for form to its specified nominal value, go through the
Adjust­
ment adjustment procedure again from step (1).
2. Do not touch the spray that comes out of the
nozzle.

15267

Remove the Dial Gauge, Pin, Nut, and Holder. T hen,

take off the Plug, the Gasket, and the Retaining Nut for
Adjustment and its Gasket. Fit the regular retaining nut
and tighten it to the specified torque using the Special
Wrench (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
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.6 Fuel Filter

<6D24, T, TC>

25 N-m
{2.5 kgf,m}

li
7.8 to 12 N-m 2 Cracks,
{0.8 to 1.2 kgf-m} threaded
� portion
i® ()
1§1(@)

Filter Wrench
MH061572
43766 Apply thin coat
of engine oil
when mounting.

'-' I U
43336
7.Bto 12 N-m
Cracks, {0.8 to 1.2 kgf-m}
®28756 threaded
portion 2

The element can be removed easily using the Filter

Wrench (special tool).

{2.5 kgf-m}

43337
1 Fuel filter element
2 Fuel filter head

13A-52
 FUEL AND ENGINE CONTROL - SERVICE PROCEDURE -
<6D24-TL>
25 to 35 N-m
{2.5 to 3.5 kgf,m}
�
9.Sto 2 N-m 2 Cracks,
{1.0 to 0.2 kgf-m} © threaded
portion
�

1
""
Apply thin coat
of engine oil
when mounting.

®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 gas­
ket, and then secure the element by tightening 3/4
to 1 turn after the 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 Water Separator
FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

10
25N-m �
{2.5 kgf-m}

@ G-- 11
7.8 to 12 N-m
{0.8 to 1.2 kgf-m}
12

�=w>��
8�- �
·
10
6 25N-m
--&----ii {2.5 kgf-m}

:�
9 �
4

2-<S
1�
1---

43745 43744 ®43369

1 Drain plug 7 Isolation plate

2 0-ring 8 Screen assembly
3 Ring nut 9 Water level ring
4 Case 10 Eyebolt
5 0-ring 11 Air plug
6 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.
Red line It is not necessary to completely remove the drain plug,
Water level ring as water is discharged gradually through the groove of
the loosened plug.
NOTE:
Drain plug After draining, tighten firmly the drain plug before
bleeding the fuel system.

09278

13A-54
6. TROUBLESHOOTING
FUEL AND ENGINE CONTROL - TROUBLESHOOTING -
Symptom Probable cause Remedy Ref. group
Engine will not Defective feed pump
start • Loaded gauze filter Clean
• Check valve inoperative Replace
• Seized or worn piston Replace
• Seized push rod Replace
• Worn tappet Replace
Defective injection pump
• Defective pump Replace
• Incorrect installation (incorrect adjustment of injection tim- Adjust
ing)

• Malfunctioning overflow valve Replace

Defective injection nozzle
• Seized needle valve Replace
• Valve opening pressure too low Adjust
• Clogged injection orifice Clean
• Nozzle not air-tight Correct or replace
Fuel tank empty Supply fuel
Clogged 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, short circuit, or poor connection in engine speed Replace
sensor or backup engine speed sensor

Defective main relay or blown fuse Replace

Engine starts Clogged fuel filter Correct or replace
but soon stops
Air or water trapped in fuel system Bleed or replace
Defective feed pump Check
Defective injection pump operation
• Defective pump Replace
• Defective governor Replace
• Clogged gauze filter Clean
Engine knocks Injection timing too advanced Adjust
Defective injection nozzle
• Valve opening pressure too high Adjust
• Clogged injection orifice Clean
• Nozzle not air-tight Correct or replace
Low quality fuel in use Replace
Defective injection pump operation
• Defective pump Replace
• Defective governor Replace
• Defective prestroke actuator Replace

Poor connection in injection quantity adjusting resistor Replace

Poor contact in idle speed adjustment variable resistor Replace

13A-55
- Symptom
FUEL AND ENGINE CONTROL - TROUBLESHOOTING

Probable cause Remedy Ref. group

Smoky engine Defective injection pump

exhaust and • Incorrect injection timing Adjust
knocking
• Worn plunger Replace

• Defective valve seat Replace

Low quality fuel in use Replace

Defective injection nozzle

• Valve opening pressure too low Adjust

• Broken spring Replace

• Clogged injection orifice Clean

Unstable engine Defective injection pump operation

output • Defective pump Replace
• Incorrect installation (incorrect adjustment of injection tim- Adjust
ing)

• Defective prestroke actuator Replace

• Defective governor Replace
Defective injection nozzle
• Poor sliding of needle valve Replace
• Broken spring Replace
• Incorrect valve opening pressure Adjust

Defective feed pump

• Check valve not functioning properly Replace
• Worn piston Replace
Air or water trapped in fuel system Bleed or replace
Loaded fuel filter Replace
Insufficient Defective injection nozzle
engine output • Defective main body Correct or replace
• Broken spring Replace
• Clogged injection orifice Clean
Defective injection pump operation
• Defective main body Replace
• Incorrect installation (incorrect adjustment of injection tim- Adjust
ing)

• Defective prestroke actuator Replace

• Defective governor Replace
• Overflow valve malfunctioning Replace
Accelerator pedal stopper bolt poorly adjusted Adjust
Poor quality fuel in use Replace
Engine not Defective injection nozzle
reaching max. • Clogged injection orifice Clean
speed
• Nozzle not air-tight Correct or replace
• Valve opening pressure too low Adjust
Defective injection pump operation
• Defective pump Replace
• Defective governor Replace
Accelerator pedal stopper bolt poorly adjusted Adjust

13A-56
 Symptom
FUEL AND ENGINE CONTROL - TROUBLESHOOTING

Probable cause Remedy

-
Ref. group
Engine max. Defective injection pump operation
speed too high • Defective pump Replace
• Defective governor Correct
Unstable engine Defective injection pump operation
idling
• Defective pump Replace
• Incorrect installation (incorrect adjustment of injection tim- Adjust
ing)

• Overflow valve malfunctioning Replace

• Defective prestroke actuator Replace
• Defective governor Replace
• Air or water trapped in fuel system Bleed or replace
Poor-quality fuel in use Replace
Defective feed pump
• Defective check valve Replace
• Worn piston Replace
• Loaded gauze filter Clean
Loaded fuel filter Replace
Defective injection nozzle
• Clogged injection orifice Clean
• Deteriorated spring Replace
• Nozzle not air-tight Correct or replace
Engine cannot Broken or stretched engine stop cable Replace
be stopped
Poorly adjusted engine stop cable Adjust
Damaged governor stop mechanism Replace
Fuel supply Defective injection pump Replace
failure
Cracked fuel hose, pipe Replace
Leaky fuel tank Replace

13A-57
 ELECTRONICALLV
CONTROLLED FUEL SYSTEM
CONTENTS

1. GENERA L ....................... . ............. 2 3.4 Causes of Diagnostic Trouble Code Issue,

1.1 Principle of operation ...................... 2 and Inspection Items ...... ............... 21
1.2 Electronic Governor ....................... 3 3.4.1 Diagnostic trouble codes ............. . 21
1.3 Electronic Timer ............................ 4 3.4.2 Diagnostic trouble code issue
1.4 Timer Control Valve . ....................... 5 conditions, and check items ........... 21
1.5 Electronic Control System ........... ...... 6 3.5 Multi-Use Tester II Service Data ......... .

271
1.6 ECU Terminal Configuration .............. 10 3.6 A ctuator Tests Using Multi-Use
2. SPECIFICATIONS ............................ 1 4 Tester II ................................... . 28
3. T ROUBLESHOOTING ................... ..... 15 3.7 lnspec-tion Using ECU Connector ....... . 29
3.1 Inspection Procedures . ................... 15 3.7.1 ECU terminal configuration ........... . 29
3.1.1 Diagnostic function .................... 15 3.7.2 Inspection instructions ................ 29
3.1.2 Inspection flowchart ................... 16 3.8 Checks on Transient Troubles ........... . 31
3.2 Connection of Multi-Use Tester II ........ 1 7 4. INSPECTION OF ELECTRIC�L
3.2.1 Special tools .......................... . 1 7 EQUIPMENT ..... ........ . ........... . ....... 32
3.3 Reading and Elasing
Diagnostic Trouble Codes ................ 19

13E-1
 -
1. GENERAL
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

With the electronically controlled injection pump sys­
tem, electronic control is applied to the governor and
timer (the components of the injection pump assem­
bly) to realize the optimum fuel injection timing and
fuel injection rate.
1.1 Principle of operation
The electronic governor ECU optimally controls the
governor and timer in accordance with data signals
from sensors mounted on the engine and other parts of
the vehicle.

f
.____,I: Fuel supply line g
19 : Fuel return line
11
--- : Electric line
�: Hydraulic fine

1RED-4 internal circuit 8 Timer control valve 14 Plunger

2Control rack position sensor 9 Injection nozzle 15 Camshaft
3Control rack 10 Combustion chamber 16 Injection pump
4Engine speed sensor 2 11 Fuel tank 17 Linear DC motor
5 Electronic timer 12 Feed pump 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 motor 17 and timer
control valve 8 are determined by signals from the
engine ECU 7.
The linear motor 17 moves the control rack 3, thereby
changing the fuel injection quantity.
The timer control valve 8 controls the hydraulic pres­
sure applied to the electronic timer 5, thus adjusting
the fuel injection timing.
The RED-4 internal circuit 1 is incorporated into the
electronic governor actuator 18. It contains a control
rack position sensor processing circuit and a linear DC
motor drive circuit, which are conventionally incorpo­
rated into the engine ECU. This arrangement elimi­
nates noise in the harness and thus prevents erro­
neous ECU operation. More accurate electronic control
is possible as a result.
The engine speed is sensed by engine speed sensor 1 6
and engine speed sensor 2 4. Each of these sensors
acts as a backup if the other fails.

13E-2
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1.2 Electronic Governor

1 1 Cover
2 RED-4 internal circuit
3 Control rack position sensor
4 Housing
5 Sensing gear
6 Emergency engine stop lever
7 Link
8 Coil assembly
9 Linear DC motor

®38928

(2) Control rack position sensor .

A The control rack position sensor 3 senses whether the
control rack A is moved 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
6 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) Emergency engine stop lever
24952 The emergency engine stop lever 6 is connected to the
link 7. Via a wire, it enables the link to be moved from
(1) Linear DC motor the driver's seat. In the event of a system fault that pre­
The linear DC motor 9 moves the coil assembly 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 movement trol rack A to move to the position at which fuel injec­
is transmitted to the control rack A, which moves longi­ tion is terminated. This operation takes place irrespec­
tudinally to increase and decrease the fuel quantity. tive of the position of the linear DC motor 9.

13E-3
-1.3 Electronic 1imer
ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

15
1 Cover
Engine speed sensor 2
2 liming sensor
Cap
Disc
1 Disc
�1
a
J
7 Flange
8 Large eccentric cam
11- iL,.-
9 Small eccentric cam
10 Plate
10 11 Spring seat
12 Timer spring
7 6 13 Pilot pin
14 Cylinder
4 15 Piston
24960

The electronic timer uses an eccentric cam arrange­

ment to adjust the injection timing. The eccentric cams
8, 9 in the electronic timer are moved 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.
02720 (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.
7 (3) When hydraulic pressure A acts upon the pistons
15, the pistons move toward the outside of the
timer flange 7.
(4) As the pistons 15 move outward, the plates 10
(thus far pressed together by the timer springs 12)
also move outward.
(5) The eccentric cams 8, 9 move in conjunction with
the plates 10, thereby altering the fuel injection
timing.
02721

13E-4
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1.4 limer Control Valve

-
1 Seat
2 Valve
3 Plunger
4 Spring
5 Coil
6 Pump-side solenoid valve
7 Release-side solenoid valve

A: Port A
P: Port P
R: Port R
7

24961

The timer control valve controls the hydraulic pressure (1) Advancement 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
p
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 on the pump side and the other on the
release side. The solenoid valves control the hydraulic
pressure reaching the timer. Each solenoid valve incor­ 7
porates a plunger 3 and coil 5. When the solenoid valve
is activated, the coil 5 attracts the plunger 3, which 24963
moves the valve 2 away from the seat 1, thereby open­
ing the oil passage. Opening and closing timing of the The pump-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 timing is
advanced.

13E-5
- ELECTRONICALLV CONTROLLED FUEL SYSTEM - GENERAL

(2) Maintenance of advanced (or retarded) fuel injec­ (3) Retardation of fuel injection timing
tion timing

6
7
24964
The pump-side solenoid valve 6 is not activated.
The release-side solenoid valve 7 is not activated.
With the solenoid valves in these conditions, the ports
are isolated from each other. Thus, the hydraulic pres­
sure in the timer stays constant and the timer remains
in its current condition.
6
24965
The pump-side solenoid valve 6 is not activated.
The release-side solenoid valve 7 is activated.
With the solenoid valves in these conditions, ports A
and R are connected, allowing oil in the timer to return
to the oil pan. Thus, the fuel injection timing is
retarded.

1.5 Electronic Control System

(1) System block diagram

Input signals Output signals

Control rack position signal 1
�
RED-4 internal circuit
(incorporated into electronic
-1I, Linear DC motor drive 9

governor)

]
Engine ECU

Engine speed signal 2

Fuel injection quantity control Timer control valve drive 10
Engine start signal 3
Coolant temperature signal 4
j Fuel injection timing control Warning lamp
Accelerator pedal position signal 5
Fault diagnosis signal 6 Heater relay
Fuel injection quantity signal 7 Preheat control
Boost pressure signal 8 Preheat lamp
Fault diagnosis function
Tachometer output

13E-6
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

Signal Part Main function/operation

1 Control rack position signal
2 Engine speed signal
3 Engine start signal
---
4 Coolant temperature signal
5 Accelerator pedal position signal
6 Fault diagnosis signal
7 Fuel injection quantity signal
8 Boost pressure signal
9 -
10 - Timer control valve
..
Control rack position sensor Sensing of control rack position
.•
Engine speed sensors 1, 2 Sensing of engine speed
Use of two sensors allows for backup if one
sensor fails.
--·-·-
Starter switch Recognition of engine startup with starter
switch in START position
---·- - --· -·-- ---- ----· ----------·--· -·-··-·----·· ·---
Coolant temperature sensor Sensing of coolant temperature
------ -- -- .
Accelerator pedal position sensor Sensing of extent of depression of accelerator
pedal
---· ---····- .. - . . . .
Accelerator pedal switch Detection o f pedal depressed/released condi-
(ON with pedal released) tion
-------··········-·-·--· ·-·· · -- ... ..
Diagnosis switch Callup of diagnosis codes
-·-----·----- --------- - ·- -- . ----- .. --·· - -----··· - -- . . ..• - - -
Memory clear switch Deletion of diagnosis codes; callup of past
diagnosis codes
Fuel injection quantity adjusting resis- Correction of fuel injection quantity
tor
- -------· ··--·- -
Boost pressure sensor Detection of boost pressure
---- ----·
Linear DC motor Moving of control rack
Control of hydraulic pressure applied to elec-
tronic timer

Injection quantity adjusting resistor

A: Resistor No.
02734

The injection quantity adjusting resistor makes fine ad­

justments to achieve optimal commensuration of in­
jectied fuel quantity with fuel feed from the common
rail.
NOTE:
This resistor, selected as the best from among several
types, determines the final injection quantity. DO NOT
change it for any other type.

13E-7
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

(2) Control of fuel injection quantity

1
Control rack position sensor

RED-4 inter- -
- Engine ECU
nal circuit -
• I I I
Engine speed sensor 1
• Engine speed sensor 2 I Target rack position
• � Linear DC

I I
Coolant temperature sensor
• Accelerator pedal position Idling characteristics motor

sensor
• Fuel injection quantity adjust-
ing resistor
I Running characteristics

I Full rack characteristics

I
I Starting characteristics
I
(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
tion signals and transmits the results to the engine
ECU.
The engine ECU effects control during engine opera­
tion using the stored idling characteristics or running
characteristics, and it determines the target control
rack position in accordance with signals issued by the
RED-4 internal circuit.
The control rack position signal issued by the engine
ECU is returned to the RED-4 internal circuit. Via the
servo circuit and drive circuit, it causes activation of the
linear DC motor such that the control rack is moved.
The control rack position sensor enables the RED-4
internal circuit to calculate whether the linear DC motor
has moved the control rack to the target position. This
arrangement enables the RED-4'to ensure that the con­
trol rack position always corresponds to the target val­
ue.
The engine ECU receives signals indicating the control
rack's actual position from the RED-4 internal circuit
and uses them to evaluate control rack position errors.

(3) Control of fuel injection timing

1
Control rack position sensor

Engine ECU RED-4 inter-

-
nal circuit
• Engine speed sensor 1
•
•
Engine speed sensor 2 i-----
I Load timer characteristics I - Timer control

I I
Coolant temperature sensor valve
• Accelerator pedal position Cold idling characteristics
sensor

13E-8
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

(a) The engine ECU controls the fuel injection timing (4) Preheat control
by controlling the activation of the timer control Preheat control improves startability when the
valve, which applies hydraulic pressure to the elec­ engine's coolant temperature is low.
tronic timer.
(a) Operating modes
(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
comparing them with each other and with charac­
teristics stored in its memory, and issuing drive
STAR
signals to the timer control valve in accordance ON �
Starter switch OFF
with the results.
1) Target advance angle: calculated by comparison of ON
Preheat lamp OFF----------
data signals from sensors with characteristics
stored in engine ECU's memory Running
Engine Not running ______.
2) Actual advance angle: determined in accordance
with signals from engine speed sensor 1 and ON
Heater relay OFF----------
engine speed sensor 2.
(c) When the engine is cold, startability and post-start
warmup 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

S T ART
,.___
�rl�----
Starter switch
ON
OFF_j I
Preheat lamp g�F_j
Running
Engine Not running _____
I
7� ----.L
Heater relay g�F _j
--------1
Preheat Afterheat

®43718

"ts" seconds after the starter switch is turned ON, the

heater relay is turned ON, causing preheating to begin.
The preheat lamp illuminates simultaneously.
When 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.
When 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
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1.6 ECU Terminal Configuration

A:CW32A

<>
B:CW25A

C: CW31A

D: CW16A

®43639

A: CW32A

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 DOWN) 19 Engine speed sensor 2 (GND), RED-4 ECU (SIGNAL
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
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

8: CW25A
-
Terminal No. ltem(s) to which terminal is connected Terminal No. ltem(s) to which terminal is connected
1 Warning lamp (orange) 14 RED-4 ECU (+5 VCC-2)
2 Accelerator pedal switch 15 RED-4 ECU (PWM SOL-2)
3 - 16 RED-4 ECU (V-IST)
4 Injection quantity adjusting resistor (SIG) 17 Frame ground (MN POWER GND)
5 RED-4 ECU (+5 VCC-1) 18 -
---
6 RED-4 ECU (PWM SOL-1) 19 -
7 RED-4 ECU (VB2) 20 MUT-11 connector (K-LINE)
8 RED-4 ECU (VB1) 21 -
9 Accelerator pedal position sensor 2 (SIG) 22 Shield (SHIELD) of VB-1, VB-2, GND-1, and GND-2
10 - 23 RED-4 ECU (SIGNAL GND-1)
-

------
11 24 RED-4 ECU (GND-2)
12 - 25 RED-4 ECU (GND-1)
13 Injection quantity adjusting resistor (GND)

C: CW31A
Terminal No. ltem(s) to which terminal is connected Terminal No. ltem(s) to which terminal is connected
1 - 17 Accelerator pedal position sensor 1 (SIG)
2 Engine speed output signal (NE OUT SIG) 18 -
3 Starter switch S terminal (STARTER SW S) 19 Diagnosis switch
4 - 20 -
5 - 21 -
6 - 22 -
7 Battery relay (STARTER SW M-2) 23 -
8 Battery relay (STARTER SW M-1) 24 Battery ground (CASE GND)
9 - 25 -
10 MUT-11 connector (DCT) 26 Preheat lamp (PREHEAT LAMP)
11 - 27 Accelerator pedal position sensor 2 (GND)
12 Control rack position output signal (RAC OUT 28 Accelerator pedal position sensor 1 (GND)
SIG)
13 - 29 Memory clear switch
- -

------
14 30
15 Coolant temperature sensor (SIG) 31 -
16 -
D:CW16A
Terminal No. ltem(s) to which terminal is connected Terminal No. ltem(s) to which terminal is connected
1 Engine ECU main power relay (+VB-2) 9 -
2 Engine ECU main power relay (+VB-1) 10 -
3 Warning lamp (red) 11 -
4 - 12 -
5 DDS-3 connector (DDS3) 13 Engine ECU main power relay (MAIN RELAY-2)

6 Battery ground (GND-2) 14 -

7 Battery ground (GND-1) 15 -
8 Engine ECU main power relay (MAIN RELAY-1) 16 -
13E-11
 - ELECTRONICALLY CONTROLLED FUEL S YSTEM - GENERAL

Starter switch
�· B 1-t,cc M 81 82 Sl

OFF
ACC
ON

START - -

STARTER SWISI CJ
STARTER SWIM)-1
ca
Engine ECU main power relay T STARTER SWIMl-2
: ::-, C?

I
MAIN RELAY-1
OB
MAIN RELAY-2
013
ECU P OWERl+VBl-1
.- :I
Dl
:
---
ECU POWER(+VBl-2
02

f -, ;

"''It_:"
GND-1
Battery O?
GND-2 06
GNOICA!':1= GNDI c 24
GNOIMN PWR GNDI
B 17

m SIG
AB
Battery� -=- Engine speed sensor 1 Ill II GND
A2l
m SIG
A?
Engine speed sensor 2 Ill II GND
AlS

\V
(TIMING) I

V 1ST 816
Battery Frame .... PWM-SOL-1
BS
ground ground PWM-SOL-2
s
PULL DOWN :�
LIMP HOME
Al4
VB-1 BB
RED-4 VB-2
87
RED-4 ECU internal I GND-1 825
circuit GND·2 824
SHIELD
022
+SV(VCCJ-1
BS
+5V(VCC)·2
- l�----S-l_G_N�AL-'- 814
'-"
"" ""
o.-=-1
GN 1
- SIGNAL GN0-2 823

� L_::_-_-_::_-_::_-�-_-u_!_�_=_�_�_'"':_4_,1
-
Timer control valve (ADV)
Timer control valve (RTD)
:::
m-m

w w
A31
A32

- SIG
B4
Injection quantity adjusting resistor -
Ill GNO
B13

- SIG
Coolant temperature sensor
l:r---w-----==-i
Ill GND
C15
AJO

+SV
A6
Ill SIG A18
Boost pressure sensor Ill GND
A29

-��-
Warning lamp (red)
Warning lamp (orange)
Memory clear switch L--------fli.--5-llll--------
Diagnosis switch w w
=l;---:i:
::: .:::
03
B1
C29
C19

DATA
DDS-3 connector oos-31-----m---------'='-' 05 -
K·Line
MUT-11 connector IL1M_u_-r 21 1 ___Ill
.r
w--------:..::.
OCT
B20
C10

Rack position output signal +------------­ C12

Engine speed output signal ..-�------------i C2
'----

®45865-1

13E-12
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL -
En ine ECU

Preheat lamp

"Tn..;----_.

�+
A111--------'-'' Heater relay

�
: '
Heater relay

Air heater

r------
SIG
Cl7
GND Accelerator pedal
C28 position sensor 1
89 SIG Accelerator pedal
GND
C27 position sensor 2

B21----------'-o o-, Accelerator pedal

Depressed: OPEN,
Released: GND
l
:, _____ _�
_J switch
_

CASEGND ®45865-2

13E-13
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - SPECIFICATIONS

2. SPECIFICATIONS

Item Specification
--
Injection pump assembly Manufacturer BOSCH AUTOMOTIVE SYSTEMS
Model Electronically controlled in-line pump
Injection pump model NP-PE6P120
Governor model RED-4 (RED-4 with internal circuit)
Timer model SPGH
Feed pump model KD
Timer control valve Manufacturer BOSCH AUTOMOTIVE SYSTEMS
Rated voltage V 24
Pressure range kPa {kgf/cm }
2 49 to 980 {0.5 to 10}
ECU Manufacturer BOSCH AUTOMOTIVE SYSTEMS
Rated voltage V 24

13E-14
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

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 • As a rule, inspection operations should be per­
Whenever the 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
If any of them is found faulty, the warning lamp in the with the starting switch at the ON position. In such
a case, use care to make sure that no short circuit
meter cluster is lit to alert the driver. At the same 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 or the 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).
Warning lamp • Whether or not the system automatically returns to
Safety-critical error Red normal from the backup mode after a fault has been
(Vehicle must not be driven) removed depends on the diagnostic trouble code
Non-safety-critical error Orange (fault location).
(Vehicle can be driven despite poor • Even when the fault has been removed and the sys­
control feeling)
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. Always remove a connector at least 20 procedure to let the system exit from the backup
seconds after placing the starting switch at the mode. [O P13E-19
LOCK position.

13E-15
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.1.2 Inspection flowchart

T he system inspection can be performed effectively by
use of the Multi-Use Tester II. The types of system
inspections may be broadly divided as shown below in
accordance with the trouble symptoms and diagnostic
trouble code outputs.
(1) Inspections based on diagnostic trouble codes
stored in the engine control unit
(2) Inspections of transient troubles

I Vehicle brought into workshop I

I Read diagnostic trouble codes CO P13E-19 I
Normal code No communications
Trouble code output output can be made with
Multi-Use Tester II.

Normal code output

after erasure \

' Check for

Identify cause for diagnostic transient troubles
trouble code issue and rec- P13E-31CO
CO
tify P13E-21
I ,,
If no communications can be made with all the other systems,

,. it is highly likely that the diagnostic circuit is f8'Ulty.

I Driving test I If no communications can be made with this system only, an open
circuit in the diagnostic output circuit or power supply circuit
(including the ground circuit) of this system is suspected.

• If the same diagnostic trouble code is issued during test driving, reexamine the cause for the
diagnostic trouble code issue and rectify. CO
P13E-21
• If none of the diagnostic trouble codes stored in the engine control unit before the test driving is
issued, perform the checks on transient troubles in addition to the checks based on the
diagnostic trouble codes.

Erace the dianostic trouble codes.

ffi P13E-19

13E-16
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.2 Connection of Multi-Use Tester II

-
3.2.1 Special tools
Unit: mm Unit: mm
Tool name Shape Tool name Shape
Multi-Use Tester II Multi-Use Tester II harness
MB991496 MB991499
Inspection of system To use Multi-Use Tester II as
a circuit tester

19492 20536
Multi-Use Tester II harness Battery clamp harness
(for communications) MK320193
MC887252
Power supply to Multi-Use
To supply power to Multi-Use Tester II in vehicle without
Tester II proper and commu­ cigarette lighter; detection of
nicate with vehicle side elec­ start signal in vehicle without
trical devices cigarette lighter

19141 20537
Read-only memory pack
(MRI-El)
MK369392
Data for inspection and con­
trol of engine control unit

19493
Memory card (set in Multi­
Use Tester II proper)
MB991500
To write data

20538

13E-17
 -
ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

T he Multi-Use Tester II typically draws power from the (2) Power supplied to Multi-Use Tester II from battery
cigarette lighter. In a vehicle without a cigarette lighter,
the power connection of the Multi-Use Tester II is differ­
ent depending on the type of the starter switch as fol­
lows:

Multi-Use With cigarette lighter socket Without ciga-

Tester II rette lighter
power supply Starter switch Starter switch socket
connection type A*a type A*b

Cigarette 0 - - E
lighter socket

Battery - 0 0

*a With starter switch type A, power supply to cigarette lighter

continues while engine is being cranked.
*b With starter switch type B, power supply to cigarette lighter is
suspended while engine is being cranked.

(1) Power supplied to Multi-Use Tester II from ciga­

rette lighter

G F
®35849

(a) Place the starter switch in the LOCK position.

(b) Connect the � Multi-Use Tester II harness (for
communication) to the� Multi-Use Tester II, then
insert the� ROM pack.
®41163
(c) Connect the EB clamp D (red) of the � battery
clamp harness to the EB terminal E of the battery
(a) Place the starting switch at the LOCK position.
and the 8 clamp F (black) to the 8terminal G of the
(b) Connect the � Multi-Use Tester II harness to�
battery.
Multi-Use Tester II and insert the � read-only
(d) Fit the connector A into the socket Hof the� bat­
memory 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 EB clamp D (red) of the � battery clamp
For the operating procedures for the Multi-Use Tester
harness before connecting the 8 clamp F (black).
II, refer to the instruction manual for the Multi-Use Tes­
ter II.

13E-18
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.3 Reading and Erasing Diagnostic Trouble (b) Reading diagnostic trouble code
-
Codes
Two types of methods are available for reading or eras­ 10s digit Units digit

-----I I nJl
ing a diagnostic trouble code; one using the Multi-Use
� �
Tester II and one using the vehicle side diagnostic func­
ON
tions.
(1) Method using Multi-Use Tester II
OFF
(a) Current diagnostic trouble code
1) Check to see that the memory clear switch 1 is con­ 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

l
diagnostic trouble code and determine the fault 0.4
location. Diagnostic switch
disconnected

(b) Past diagnostic trouble code First diagnostic trouble code displayed
(Diagnostic trouble code 12)
1) Set the starting switch to ON.
2) Disconnect the memory clear switch 1. ON Second

H
---• diagnostic
3) Operate the Multi-Use Tester II to read the past reg­ Ii-----J·
1 trouble
code
istered diagnostic trouble codes and determine the 2.4 2.4 2.4 2.8 displayed
fault location.
®13705
(c) Erasing diagnostic trouble codes
1) Set the starting switch to ON. 1) Diagnostic trouble codes are indicated by the num­
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. • T he flashing intervals also differ between the 10s
digit and units digit.
(2) Method Not Using Multi-Use Tester II (Method
• 10s digit: 1.2 second interval
Using Diagnostic Switch and Memory Clear
• Units digit: 0.4 second interval
Switch)
• Each diagnostic trouble code is displayed from the
(a) Current diagnostic trouble code 10s digit followed by the units digit. As for a code
1) Set the starting switch to ON. which has no 1Os digit, units digit only is displayed.
2) Disconnect the diagnostic switch 2. 2) Each diagnostic trouble code is displayed three
3) T he diagnostic trouble code is displayed by flashes 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) When the diagnostic switch 2 is connected, the
engine control unit will immediately stop display­
ing codes.

13E-19
 - ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

(c) Past diagnostic trouble codes
1) After reading the current diagnostic trouble codes
(with the diagnostic switch 2 disconnected), dis­
connect the memory clear switch 1. Then the O
warning lamp 3 will restart flashing.
2) This time, the warning lamp displays the past diag­
nostic trouble codes. Determine the fault locations
based on the indicated codes.
(d) Erasing diagnostic trouble codes
Disconnect the memory clear switch 1 and the diag­
nostic switch 2 then reconnect them. Then all the diag­
nostic trouble codes stored in the engine control unit
will be cleared.
NOTE:
• If the contents of memory are not to be cleared after
display of the stored codes, set the starting switch
to OFF with the memory clear switch 1 discon­
nected. Thereafter, connect the memory clear
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
purpose, be sure to perform the diagnostic trouble

◄ ◄
A second

I t1
or more 3 seconds code erasing procedure.
• Whenever the engine control unit has been replaced

J I
,
• •
with a new one, be sure to erase the diagnostic
Connected
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.

®02739

13E-20
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.4 Causes of Diagnostic Trouble Code Issue, and Inspection Items

-
3.4.1 Diagnostic trouble codes
Multi-Use Tester II display Page of Multi-Use Tester II display Page of
reference reference
Diagnostic Message Diagnostic Message
trouble code trouble code
07 OVER REV. Ll:i P13E-21 23 T CV !J] P13E-24
11 GOV. SERVO 24 ACCEL. SNSR-1 2J P13E-25
14 SUB NE SNSR � P13E-22 32 BST PRES SNSR
15 NE SNSR 33 ECU SYSTEM
16 ACCEL. SNSR-2 CL P13E-23 34 Q RESISTOR
17 TCV FEEDBACK 45 ENG.REVERSE LiJ P13E-26
19 AIR PRES SNSR 65 ACCELSW
21 WTR TEMP SNSR [Cl P13E-24 78 HEATER RELAY
22 RACKSNSR

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
shown below.

07 OVER REV.
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
Diagnostic trouble code 07 indicates that the engine speed is too high.
[The code is reset when the engine speed returns to a specified range.]
Governor operation is stopped.
Injection pump assembly's Inspection of injection pump assembly
control sleeve faulty (Have inspection performed by Bosch Automotive Systems service
• Over-revving of engine (for station.)
example, on downhill road)
• ECU faulty

11 GOV. SERVO
Code issue condition
[Reset condition)
Action taken by ECU
Probable cause and check item
Diagnostic trouble code 11 indicates that the difference between the target control rack position and
actual control rack position is too large.
[No reset condition)
Governor operation is stopped.
• Control rack position sensor • Perform checks on basis of Multi-Use Tester II service data.
faulty (D P13E-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
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
14 SUB NE SNSR (injection pump side)
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
14 SUB NE SNSR (injection pump side)
15 NE SNSR (flywheel housing side)
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
15 NE SNSR (flywheel housing side)
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
13E-22
Diagnostic trouble 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).
[The code is reset when engine speed sensor 1 is normal and the number of pulses from engine speed
sensor 2 returns to normal).
• Normal control is effected using only engine speed sensor 1.
• If engine speed sensor 1 is also faulty, governor operation is stopped.
• Open circuit or short circuit in • Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and [D P13E-27
engine speed sensor 2 No. 02: Measurement of engine speed
• Engine speed sensor 2 faulty • Inspection using ECU connector LL:
P13E-29
• ECU faulty m : Measurement of resistance of engine speed sensor 2
• Inspection of engine speed sensor 2
CD P13E-32: Inspection of Electrical Equipment�
• Check of circuit between ECU and engine speed sensor 2
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.
[The code is reset when pulses are applied from engine speed sensor 1 or engine speed sensor 2 following
engine startup.]
Fuel injection timing control is stopped, and governor operation is stopped.
• Open circuit or short circuit in • Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and (DP13E-27
engine speed sensors 1 and 2 No. 02: Measurement of engine speed
• Engine speed sensors 1 and 2 • Inspection using ECU connector CD P13E-29
faulty
• ECU faulty
m: Measurement of resistance of eng1ne speed sensor 2
C!D : Measurement of resistance of engine speed sensor 1
• Inspection of engine speed sensors 1 and 2
ffiP13E-32: Inspection of Electrical Equipment�
• Check of circuit between ECU and engine speed sensors 1 and 2
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).
[The code is reset when engine speed sensor 2 is normal and the number of pulses from engine speed
sensor 1 returns to normal.]
• Normal control is effected using only engine speed sensor 2.
• If engine speed sensor 2 is also faulty, governor operation is stopped.
• Open circuit or short circuit in • Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and QJ P13E-27
engine speed sensor 1 No. 02: Measurement of engine speed
• Engine speed sensor 1 faulty • Inspection using ECU connector CD
P13E-29
• ECU faulty
C!D : Measurement of resistance of engine speed sensor 1
• Inspection of engine speed sensor 1
[l} P13E-32 Inspection of Electrical Equipment�
• Check of circuit between ECU and engine speed sensor 1
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
16 ACCEL. SNSR-2
Code issue condition
(Reset condition]
Action taken by ECU
Probable cause and check item
17 TCV FEEDBACK
Code issue condition
(Reset condition]
Action taken by ECU
Probable cause and check item
19 AIR PRES SNSR
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
-
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
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.]
• 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.
• Open or short circuit in har- • Perform checks on basis of Multi-Use Tester II service data.
ness between ECU and CJ 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
Diagnostic trouble code 11 indicates that the difference between the target and actual timer positions
exceeds a specified limit.
[After a return to a normal condition, the code is reset when the starter switch is turned from OFF to ON.]
Fuel injection timing control is stopped.
• Timer control valve faulty • Perform checks on basis of Multi-Use Tester II service data.
[jJ 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
CO P13E-32: Inspection of Electrical EquipmentE
• Inspection of engine hydraulic system CD
Gr 12
• Inspection of electronic timer
(Have inspection performed by Bosch Automotive Systems ser­
vice station.)
Diagnostic trouble code 19 indicates short or open circuit in air pressure sensor harness and faulty air
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.]
Air pressure is defaulted to 100 kPa {760 mmHg}.
• Air pressure sensor (built in • Perform checks on the basis of Multi-Use Tester II service data.
ECU) faulty. (D P13E-27
• ECU faulty No. 18: Air pressure measurement
13E-23
IBll ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
21 WTR TEMP SNSR
Code issue condition
[Reset condition)
Action taken by ECU
Probable cause and check item
22 RACKSNSR
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
23TCV
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
13E-24
Diagnostic trouble code 21 indicates open circuit in water temperature sensor harness and faulty sensor
proper.
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.)
Controls are continued assuming that coolant temperature is -20°C when engine is started and B0 °C
when engine is running.
• Open or short circuit in har- • Perform checks on basis of Multi-Use Tester II service data.
ness between ECU and water C.iJ
P13E-27
temperature sensor No. 16: Measurement of engine coolant temperature
• Water temperature sensor • Inspection using ECU connector CD P13E-29
faulty
• ECU faulty (1D : Measurement of resistance of coolant temperature sensor
• Inspection of coolant temperature sensor
CD P13E-32: Inspection of Electrical Equipment P.lml
• Check of circuit between ECU and coolant temperature sensor
Diagnostic trouble code 22 indicates that the control rack position sensor's output voltage is outside speci­
fied limits.
[No reset condition]
Governor is temporarily stopped. (Feedback control is resumed after the engine is restarted.)
• Control rack position sensor • Perform checks on basis of Multi-Use Tester II service data.
faulty (D P13E-27
• Control rack not moving No. 0A: 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
• ECU faulty vice station.)
Diagnostic trouble code 23 is issued in the following circumstances:
(1) The ECU issues a command to turn the timer control valve OFF following a short circuit in the
timer control valve.
[The code is reset when the timer control valve returns to normal.]
(2) The ECU issues a command to turn the timer control valve ON following an open circuit in the
timer control valve.
[After the open circuit is rectified, the code is reset when the starter switch is turned from OFF to ON.]
Fuel injection timing control is stopped.
• Open circuit or short circuit in • Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and OJ P13E-27
timer control valve
No. 12: Measurement of timer angle difference
• Timer control valve faulty
• Inspection of timer control valve
• ECU faulty
[O P13E-32: Inspection of Electrical Equipment�
• Check of circuit between ECU and timer control valve
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
24 ACCEL. SNSR-1
Code issue condition
[Reset condition]
·------------+----------------- -------·--·----·--------------
Action taken by ECU
Probable cause and check item
32 BST PRES SNSR
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
33 ECU SYSTEM
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
34 Q RESISTOR
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
Diagnostic trouble code 24 indicates short or open circuit in accelerator position sensor 1 harness and
faulty sensor proper. (If diagnostic trouble code 24 is issued, inspections for diagnostic trouble code 16
must also be performed.)
The code is issued when accelerator position sensor 1 voltage is out of specified limits.
[When accelerator position sensor 1 voltage falls back within specified limits, a reset is made.)
• Normal control is effected using only non-faulty accelerator pedal position sensor 2.
• If accelerator pedal position 2 is also faulty, control is effected using assumptions of 100 % with the
pedal depressed and O % with the pedal released.
• Open or short circuit in har- • Perform checks on basis of Multi-Use Tester II service di.tl1J.
ness between ECU and accel­ L J P13E-27
erator position sensor 1
No. 03, 04: Measurement of throttle opening indic1Jtr:d IJy
• Accelerator position sensor 1 accelerator pedal position sensor
faulty or poorly adjusted
No. 5: Measurement of accelerator pedal position
• ECU faulty sensor's output voltage
• Inspection of accelerator pedal position sensor
• Check of circuit between ECU and accelerator pedal position sen­
sor 1
Diagnostic trouble code 32 indicates short or open circuit in boost pressure sensor harness and faulty sen­
sor proper.
The code is issued when boost pressure sensor voltage is out of specified limits.
[When boost pressure sensor voltage falls back within specified limits, a reset is made.)
Control is effected with the boost pressure assumed to be fixed at O kPa {O mmHg}.
• Open or short circuit in har- • Perform checks on basis of Multi-Use Tester II service data.
ness between ECU and boost lJ.J P13E-27
pressure sensor
No. 20: Measurement of boost pressure
• Boost pressure sensor faulty
• Inspection of boost pressure sensor main body
• ECU faulty
L(j P13E-32: Inspection of Electrical Equipment Dill
• Check of circuit between ECU and boost pressure sensor
Diagnostic trouble code 33 indicates a processing error or memory error in the ECU.
[No reset condition]
Governor operation is stopped.
ECU faulty I
Diagnostic trouble code 34 indicates short or open circuit in injection quantity adjusting resistor harness
and faulty adjusting resistor.
The code is issued when injection quantity adjusting resistor voltage is out of specified limits.
[When injection quantity adjusting resistor voltage falls back within specified limits, a reset is made.]
Injection quantity correction value is fixed at No. 1 value.
• Open or short circuit in har­ • Perform checks on basis of Multi-Use Tester II service data.
ness between ECU and injec­ (D P13E-27
tion quantity adjusting resistor
No. 14: Check of resistor number of fuel injection quantity
• Injection quantity adjusting re­ adjusting resistor
sistor faulty
• Inspection using ECU connector CD P13E-29
• ECU faulty m: Measurement of resistance of fuel injection quantity
adjusting resistor
• Inspection of fuel injection quantity adjusting resistor
W P13E-32: Inspection of Electrical Equipment1:f,. .:m
• Check of circuit between ECU and fuel injection quantity adjusting
resistor
13E-25
-
ELECTRONICALLY CONTROLLED FUEL S YSTEM - TROUBLESHOOTING
45 ENG. REVERSE
Code issue condition
[Reset condition)
Action taken by ECU
Probable cause and check item
65ACCELSW
Code issue condition
[Reset condition)
Action taken by ECU
Probable cause and check item
78 HEATER RELAY
Code issue condition
[Reset condition)
Action taken by ECU
Probable cause and check item
13E-26
Diagnostic trouble code 45 indicates that an extremely low engine speed (a speed lower than that result­
ing from cranking with the starter) has been detected with the starter switch in the OFF position.
[The code is reset when the engine speed is no longer detected with the starter switch in the OFF position
or when the starter switch is turned to the ON position.)
Governor operation is stopped
• Operating error at time of en-
gine startup
• Poor matching of connected
devices
• ECU faulty
Diagnostic trouble code 65 indicates short or open circuit in accelerator pedal switch harness and faulty
accelerator switch.
The code is issued when accelerator pedal is released (accelerator switch ON) and accelerator pedal open­
ing signal is input.
[When accelerator pedal opening signal returns to normal, a reset is made.)
Normal control is effected.
• Open or short circuit in har­ • Perform checks on basis of Multi-Use Tester II service data.
ness between ECU and accel­ (D P13E-27
erator pedal switch
No. 03, 04: Measurement of throttle opening indicated by
• Accelerator pedal switch faulty accelerator pedal position sensor
• ECU faulty No. 69: Check of operation of accelerator pedal switch
• Inspection using ECU connector CO P13E-29
(!D : Check of continuity of accelerator pedal switch
• Inspection of accelerator pedal switch
• Check of circuit between ECU and acceler,ator pedal switch
Diagnostic trouble code 78 is issued in the following circumstances:
(1) The ECU issues a command to turn the heater relay OFF following a short circuit in the heater
relay.
[The code is reset when the heater relay returns to normal.)
(2) The ECU issues a command to turn the heater relay ON following an open circuit in the heater
relay.
[No reset condition]
Preheat control is stopped.
• Open circuit or short circuit in • Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and QJ P13E-27
heater relay
No. 92: Check of operation of heater relay
• Heater relay faulty
• Actuator test using Multi-Use Tester II CD
Pl 3E-28
• ECU faulty
No. BC: Check of operation of heater relay
• Inspection of heater relay CO Gr 16
• Check of circuit between ECU and heater relay
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.5 Multi-Use Tester II Service Data

-
Multi-Use Tester II display Condition at time of Normal condition
inspection
No. Item Data
01 BATT VOLTAGE ■■.■■v Idling 20to 30V
02 ENGINE SPEE D ■■■■.rpm Racing Same as tachometer indication
(with engine running)
03 ACCEL (%) ■■■.■ % Accelerator pedal released 0%
Accelerator pedal gradually depressed Gradually increases
Accelerator pedal fully depressed 100%
04 ACCEL (%) REAL ■■■.■ % Accelerator pedal released 0%
Accelerator pedal gradually depressed Gradually increases
Accelerator pedal fully depressed 100 %
05 ACCEL (V) ■.■■■v Accelerator pedal gradually depressed Depends on vehicle specifica-
from released position tions
09 TARGET RACK ■■.■■ mm Starter switch ON 3mm
DA REAL RACK ■■.■■ mm Starter switch ON 3mm
12 TCV ANG. DIFF. ■■.■■ °CA Depends on vehicle specifications

•••••
■■.■■ deg
14 Q RESISTOR - Same as number marked on fuel
injection quantity adjusting
resistor
16 WATER TEMP ■■■.■ oc Engine cold Approximately same as ambient
■••.• OF temperature
During engine warmup Gradually increases
Engine stopped after warmup Gradually decreases
18 AIR PRESS ■■■■. kPa Altitude □m 101kPa
■■■■.mmHg Altitude 600m 95kPa
Altitude 1,200m 88 kPa
2D BOOST PRESS ■■■■. kPa Running at high idle speed Depends on vehicle specifica-
■■■■.mmHg tions

4F DIAGNOSIS SW ON/OFF Diagnosis switch ON ON

(connected to connector)
Diagnosis switch OFF OFF
(disconnected from connector)
51 DIAG LAMP (U) ON/OFF Starter switch in ON position ON
(engine not started)
Starter switch in OFF position OFF
52 DIAG LAMP (R) ON/OFF Starter switch in ON position ON
(engine not started)
Starter switch in OFF position OFF
56 KEY SW ON/OFF Starter switch in ON position ON
Starter switch in any position except OFF
ON
62 DIAG RESET SW ON/OFF Memory clear switch ON ON
(connected to connector)
Memory clear switch OFF OFF
(disconnected from connector)
67 PULL DOWN ON/OFF Normal condition OFF
Abnormal condition ON
(during pulldown control)

13E-27
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

Multi-Use Tester II display Condition at time of Normal condition

inspection
No. I tem Data
69 ACCELSW ON/OFF Accelerator pedal depressed ON
Accelerator pedal released OFF
73 STAR T SW ON/OFF E ngine cranked with starter switch in ON
STAR T position
Starter switch in any position except OFF
STAR T
91 PRE-HEAT LAMP ON/OFF Starter Coolant temperature ON
switch ON low
Coolant temperature OFF
high
92 HEATER RELAY ON/OFF Starter Coolant temperature ON
switch ON low
Coolant temperature OFF
high

3.6 Actuator Tests Using Multi-Use Tester II

Multi-Use Tester II display Method of checking operation

No. Item
AC DIAG LAMP (U) • Create warning lamp illumination conditions.
• Perform test with engine speed of zero and vehicle speed of zero.
• Cause warning lamp five times to be on for one second then off for
one second.
AD DIAG LAMP (R) • Create warning lamp illumination conditions.
• Perform test with engine speed of zero and vehicle speed of zero.
• Cause warning lamp five times to be on for one second then off for
one second.
BB PRE-HEAT LAMP • Create indicator lamp illumination conditions.
• Perform test with engine speed of zero and vehicle speed of zero.
• Cause indicator lamp five times to be on for one second then off for
one second.
BC HEATER RELAY • Create air heater operating conditions.
• Perform test with engine speed of zero and vehicle speed of zero.
• Cause air heater five times to be on for one second then off for one
second.

13E-28
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.7 Inspection Using ECU Connector

-
These checks allow correct transmission of ECU signals via vehicle harnesses and connectors to be verified. They
are intended to assist in troubleshooting. The numbers ( m,
C!D, etc.) in the tables correspond to reference num­
bers in section 3.4, "Causes of Diagnostic Trouble Code Issue, and Inspection Items".
3.7.1 ECU terminal configuration

A:CW32A

<>
8: CW25A

C: CW31A

B D: CW16A
C

®43639

No. Item Page of reference

(!II Resistance of engine speed sensor 2

m Resistance of engine speed sensor 1

m Resistance of coolant temperature sensor lil P13E-30

m Resistance of fuel injection quantity adjusting resistor

m Continuity of accelerator pedal switch

3.7.2 Inspection instructions

NOTE:
Some 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 not to select
the wrong terminals for inspections.

13E-29
 11]1 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
Check item Method

(!JI Resistance of engine [Check conditions]

speed sensor 2 • Starter switch OFF
• Connector removed. Check performed on vehicle-side harness.
[Normal condition)
Between terminals A 7 and A 19: 2.1 to 2.5 n
ffl Resistance of engine [Check conditions]
speed sensor 1 • Starter switch OFF
• Connector removed. Check performed on vehicle-side harness.
[Normal condition)
Between terminals A a and A 21: 2.1 to 2.5 kn
ffl Resistance of coolant (Check conditions]
temperature sensor • Starter switch OFF
• Connector removed. Check performed on vehicle-side harness.
[Normal conditions)
Between terminals C 1s and A 30: 2.3 to 2.6 kn (at 20°C)
0.3 to 0.34 kn (at 80°C)

m Resistance of fuel injec­

tion quantity adjusting
[Check conditions)
• Starter switch OFF
resistor • Connector removed. Check performed on vehicle-side harness.
(Normal conditions]
Between terminals B 4 and B 13:
No. Resistance No. Resistance No. Resistance

2700 13000 5&0on

5100 20000 8 15000 o
8200 330011

ffl Continuity of accelera­

tor pedal switch
(Check conditions]
• Starter switch OFF
• Connector removed. Check performed on vehicle-side harness.
[Normal conditions]
Between terminals (EE) and 0) B 2 and D e: • Accelerator pedal depressed: Continuity does not exist.
• Accelerator pedal released: Continuity exists.

13E-30
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING -

3.8 Checks on Transient Troubles • Lightly move the connector up and down and to
the right and left.
• Lightly move the harness up and down and to the
right and left.
• Lightly shake the sensors and other devices by
hand.
• Lightly shake the wiring harness located in the
moving components such as the suspension.
T he connectors and other parts to be checked are iden­
tifiable from the descriptions in the Probable Causes or
the Checking Procedures for the displayed diagnostic
trouble code.
02597

02598

7""
lI)l
I I
02599

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 customer in detail about the
driving condition when the trouble occures, weather,
occurrence frequency and symptoms, and reproduce
the symptoms of the 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 symptoms of the trouble are reproduced.

13E-31
- ELECTRONICAUY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT

4. INSPECTION OF ELECTRICAL EQUIP­

Standard value 2.3 ± 0.2 kn
MENT (at 20° C)

lmfl Checking Water Temperature Sensor
(2) If the reading is out of the standard value range, re-
place the engine speed sensor. CC 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 sensor in a container

filled with engine oil.
(2) Heat the engine oil to various specified tempera­
tures while stirring the engine oil.
(3) Measure the resistance value between pins 1 and 2
(body).
24984
Standard value 20°c 2.3 to 2.6 kQ
80°C 0.30 to 0.34 kQ
(1) Measure the resistance between terminals if_. and
Referance value in parentheses l�:.
(4) If the reading is out of the standard value, replace
Standard value 2.1 to 2.5 n
the water temperature sensor.[() Gr 14

l:ml Checking Engine Speed Sensor (2) Check for continuity between terminals ,J and:'�;
between terminals��' and :a,.
<Engine speed sensor 1>
Standard value Continuity exists

(3) If either result is out of specification, replace the

sensor.

[Installation]

D
05049

(1) Measure the resistance value between pins 1 and

2.

24985
13E-32
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT -

(1) Screw in engine speed sensor 2 A until it touches Unit:mm

the protrusion on the timer flange 8. Tool name Shape
(2) Back off engine speed sensor 2 A by 0.8 to 1.0 turn Inspection Harness
MC854336
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 sensor 2 A.

1JE1 Checking Boost Pressure Sensor

<Checking by use of Multi-Use Tester II> CO P13E-27
NOTE:
The boost pressure checking conditions differ be­
02806
tween when the boost pressure is checked by use of
the Multi-Use Tester II and when it is checked without (2) Mount pressure gauge A for measurement of the
use of the Multi-Use Tester II. So the standard values boost pressure.
also differ. C: To inlet manifold
<Checking without use of Multi-UseTester II> (3) Set the starting switch to ON.
(4) Measure the output voltage of the boost pressure

8
sensor 8 according to the following table.
A
Item Connector Pin

- -
C 1 Power(+) 2GND(-) 3 Output(+)

it Power voltage
*Output voltage
(Refer to the out-
put characteris-
tics shown at
-
left.)

*· Start the engine before measurement.

B

®42415

(1) Disconnect the chassis side harness D and connect

the � inspection harness between them.

13E-33
- ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT

Output Characteristics (1) Remove the connector from the timer control valve
then connect a 24V DC power supply A and selector
switch B.
Temperature 25° C (2) Slightly loosen the eyebolt D on port C.
4.9 (3) Run the engine at idling speed.
4.5 (4) Turn the selector switch B to the port E setting and
�
Ql 3.22 check that oil leaks from the eyebolt D of port C.
1.86 (5) Turn the selector switch B to the port F setting and
�
0.5 check that oil stops leaking.
(6) After confirming that oil stops leaking, tighten the
0 -34.3 33.7 98.7 163.7
{-255} {250} {740} {1230} eyebolt D to the specified torque.

Boost pressure (kPa {mmHg}) lightening torque 20 to 25 Nm (2 to 2.5 kgfm)

02783
C: Engine oil outlet
(hydraulic pressure supply to electronic timer)
Standard Value 2-3 5V E: Engine oil inlet
1-2 0.5V/-34.3 kPa {-255 mmHg} F: Engine oil return outlet
1.86V/33.7 kPa {250 mmHg}
3.22V/98.7 kPa {740 mmHg}
(7) If this inspection reveals any abnormality, replace

4.5V/163.7 kPa {1230 mmHg}

the timer control valve. (D Gr 13A

(5) If the 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 sensor B. :1 and '3 and between terminals ·4_ and :.i,. Deter­
mine whether the measurements comply with the
ml Inspection of timer control valve standard value.
<Checking valve operation>
Standard value 21.9 to 24.1 n
(2) Make sure that there is not continuity between ter­
(2) minaIs r3. and ii:; between terminal::) and the body;
B A and between terminal :4. and the body.
@ (3) If these checks reveal any abnormality, replace the
timer control valve. CO Gr 13A

(DC24V) DD Inspection of fuel injection quantity adjusting re­

[iJ
sistor

No.

®24981

AL2A

02786

24982

13E-34
 ELECTRONICAUY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT

(1) Measure the resistance of the fuel injection quan­

-
tity adjusting resistor. The standard value corre­
sponds to the resistor number marked on the case.

Standard value Resistor No. 1 2700

(at 20°c)
2 510Q
3 a2on
4 1300Q
5 20000
6 3300fl
7 5600fl
8 150000

(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
 -

COOLING
CONTENTS

1. GENERAL .......... . ........................ 2 5.4 Fan Drive .......................... ....... 15

2. SPECIFICAT IONS ........................... 6 5.4.1 Disassembly and inspection ..... . .... 15
3. SERVICE STANDARDS ..................... 7 5.4.2 Reassembly ........................... 16
3.1 Service Standards Table ................. 7 5.5 Tension Pulley ........................... 16
3.2 lightening Torque Table ................. 7 5.5.1 Disassembly and inspection .......... 16
4. SPECIAL T OOLS ............................ 8 5.5.2 Reassembly .. .................. ....... 17
5. SERVICE PROCEDURE ...................... 9 5.6 Inspection of Auto Cool Fan
5.1 Removal and Installation of Cooling Coupling ................................. 17
Fan ......................................... 9 5.7 Inspection of Radiator ................... 18
5.2 Water Pump ................................ 9 5.8 V-belt Tension ............................
191
5.2.1 Removal and installation .............. 9 5.8.1 Inspection . ............................ 19
5.2.2 Disassembly and inspection .......... 10 5.8.2 Adjustment ........................... 20
5.2.3 Reassembly ........................... 13 5.9 Cleaning of Cooling System ............. 21
5.3 Thermostat .............................. 14 5.10 Gas Leak Test ........................... . 23
5.3.1 Removal and installation ............. 14 5.11 Bleeding the Cooling System ........... 23
5.3.2 Inspection .. ...... . .................... 14 6. T ROUBLESHOOTING ...................... . 24

14-1
 Ill COOLING - GENERAL

1. GENERAL (2) Thermostat

The cooling system is of the water-cooling forced cir­

When coolant temperature is high
culation type consisting of a radiator, water pump, (bottom bypass valve is closed) \.
thermostat, and related parts.

Radiator

When coolant temperature is low

(bottom bypass valve is open) 81747A

The thermostat is of bottom bypass type with a valve

controlled by special wax enclosed in a pellet. When
817450
the wax is heated, it passes from a solid to a liquid state
with its volume changing. This change in volume regu­
(1) Water pump
lates the amount of coolant flowing into the radiator
and water pump (bypass side), thereby controlling
coolant temperature.

Impeller

From radiator
B1746C

The water pump, of the centrifugal type, is driven by

V-belt from the crankshaft pulley.
Mounted at one end of the water pump 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 Bl
(3) Radiator (4) Pressure cap

<With pressure release lever>

Radiator
Pressure release lever
Pressure spring
h

Reserve tank
Pressure valve//
Vent valve spring

B1716B

81740A <Without pressure release lever>

Pressure spring

The radiator, with a tube-and-corrugated-fin type core

(and with a reserve tank on some models), not only
cools the engine coolant but also separates vapor from
liquid water and regulates pressure in the cooling sys­
tem.

Vent valve
When vent valve is opened

B0295B

The pressure cap regulates the pressure in the cooling

system. When the pressure builds up in the system that
exceeds a predetermined level, the pressure valve
compresses the pressure spring, releasing the exces­
sive pressure through the overflow pipe into the atmo­
sphere.

14-3
 - COOLING - GENERAL

If equipped with a reserve tank, the coolant that has is controlled by a bimetallic strip that moves in
overflowed is channeled into it. response to temperature changes.
When the coolant temperature drops and negative <When the temperature of the 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 becoming
deformed.
If equipped with a reserve tank, coolant is taken from
Operating
the reserve tank to prevent the radiator from becoming chamber
deformed and to keep the quantity of coolant in the Control hole
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

Rotor 80243A
Storage
chamber
The valve fully closes the control hole of the divider
plate. As a result, the silicone oil forced back from the
pump 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.
<When the temperature of the air passing through the
radiator rises>

Divider plate

80574C

Depending on the temperature of the air passing

through the radiator, the auto cool fan coupling auto­ B0244A
matically controls the rotating speed of the fan.
The autocool fan coupling is constructed as follows: As the temperature rises, the valve slowly opens the
control hole of the divider plate, allowing silicone oil to
The rotor is mounted on the shaft and rotates between
the case and cover. Viscous coupling material (silicone flow into the operating chamber. Therefore, the sili­
oil) enters the gap and turns the fan. A control hole in cone oil contacting area between the case and cover
and the rotor slowly increases. So 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 chamber to the operating chamber. The hole is
controlled by a valve. Opening and closing of the valve

14-4
 COOLING - GENERAL DI
<When the temperature of the air passing through the
radiator is high>

Direct-couple fan

Autocool fan coupling

(at high temperature)

"0 Autocool fan coupling

Q)
Q) (at medium temperature)
C.
<I)

"'
C
u.. Autocool fan coupling
(at low temperature)

Crankshaft speed (rpm)

80245A
B1728B
The valve fully opens the control hole of the divider
plate, and more silicone oil flows into the operating
chamber.
As a result, a maximum torque is transmitted from the
shaft to the fan, causing the fan to rotate at a given E
maximum speed. e-
"0
Q)
Q)
C.
<I)

"'
C
u..

Temperature passing through

the radiator (°C)

B0575A

14-5
 ID COOLING - SPECIFICATIONS

2. SPECIFICATIONS
Item Specification
Cooling system Water-cooling forced circulation type
Coolant quantity (Engine-proper only) 6D24, T Approx. 22 L
6D24-TC, TL Approx. 24 L
Water pump Type Centrifugal type
Drive method V-belt
Radiator Type Tube-and-corrugated-fin type or Tube-and-plate-fin type
Thermostat Type Wax pellet/bottom bypass type
Valve opening Without jiggle valve: 76.5°C x 2
temperature x O'ty
Cooling fan Suction type or blower type
V-belt Type x Number of belts Without fan drive Low edge cog Btype x 1 or Btype x 2
With fan drive Low-edge cogged type Bx 1 (for water pump)
Low-edge cogged type C x 2 (for alternator)
Low-edge cogged type Bx 1 (for water pump)
Low-edge cogged type Bx 2 (for alternator)

14-6
 COOLING - SERVICE STANDARDS ID
3. SERVICE STANDARDS
3.1 Service Standards Table
Unit: mm
Maintenance item Nominal value Limit Remedy and remarks
(Basic diameter in I ))

Interference between pump shaft and flange (22) 0.05 to 0.08 - Up to second
reassembly

Interference between pump shaft and impeller (11.8) 0.03 to 0.06 - Up to second
reassembly

Thermostat Valve opening 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 opening pressure 39 to 59 kPa - Pressure cap, replace
{0.4 to 0.6 kgf/cm2}

V-belt deflection [with a push Without fan drive 17 to 22 - Adjust

force of about 98 N (10 kgf)]
With fan drive 10 to 15 -

3.2 Tightening Torque Table

Location tightened Screw size Tightening torque

O.D. x pitch N-m {kgf,m}
(mm)
Water pump pulley mounting bolt M10 x 1.5 44 ± 8.8 {4.5 ± 0.9}

Fan drive flange mounting nut M20 x 1.5 145 {15}

Tension pulley mounting nut M16 x 1.5 98 {10}

14-7
 Ill COOLING - SPECIAL TOOLS

4. SPECIAL TOOLS
Unit: mm Unit: mm
Tool name Shape Tool name Shape
Impeller Puller Water Pump Pulley Puller
MH062192 MH062411
Removal of water pump Removing water pump
impeller flange

B5252C
Unit Seal Installer 85258A
MH062195 C
Water pump unit seal instal­ Belt Tension Gauge
lation MH062345
Measuring V-belt tension

�,A B �.c
28 9.6±0.03 12.5

85094A
03612

14-8
5. SERVICE PROCEDURE
COOLING - SERVICE PROCEDURE

5.2 Water Pump

m
5.1 Removal and Installation of Cooling Fan 5.2.1 Removal and installation

89019B

2
1
O0914A

1 Plate
2 Fan
3 Spacer
* Fan pulley

14-9
 -
5.2.2 Disassembly and inspection
COOLING - SERVICE PROCEDURE

<6D24,T, TL>

7Corrosion, damage
13 Damage, wear
Repair kit:
14 BD .. Basic Diameter
Cracks, wear in surface NV .. Nominal Value
Water pump repair kit
over which bearing fits,
water leak, rust

Disassembly sequence
1 Water pump pulley 8 Water pump shaft
® Flange 9 Bearing
3 Oil seal 10 Spacer
4 Snap ring 11 Bearing
5 Snap ring 12 Oil seal
6 Water pump cover 13 Unit seal
(J) Impeller 14 Water pump case

For parts with an encircled number, refer to Disassembly and Inspection Procedures that follow.
D0044G

14-10
 COOLING - SERVICE PROCEDURE m
BD .. Basic Diameter
<6D24-TC> NV .. Nominal Value

Bend, rust, wear in

surface over
which bearing fits
8
Rotation

Interference
BD 11.8
NV 0.03 to 0.06
Reassembly no more
than 2 times

Interference
BD 25
NV 0.05 to 0.08

Reassembly no more
than 2 times

Disassembly sequence
1 Water pump pulley 8 Water pump shaft
@ Flange 9 Bearing
3 Oil seal 10 Spacer
4 Snap ring 11 Bearing
5 Snap ring 12 Oil seal
6 Water pump cover 13 Unit seal
(]) Impeller 14 Water pump case

For parts with an encircled number, refer to Disassembly and

Inspection Procedures that follow.

D0044H

14-11
 Ill COOLING SERVICE PROCEDURE

Disassembly and Inspection Procedures (3) Flange to water pump shaft tightening margin
(1) Removal of flange

Water Pump ---1,��

Flange

13480
Remove the water pump flange using the Water Pump
Pulley Puller and Bolt (special tools). Slip an iron pipe
or similar item over the handle to gain the necessary
leverage.
(2) Removal of impeller
D0031B
If the tightening margin exceeds specification, replace
the flange or water pump shaft.
NOTE:
Do not reassemble more than three times even when
the specification is met.
(4) Impeller to water pump shaft tightening margin

09192 D0031C

Using two threaded holes (MB x 1.25) in the impeller
and the Water Pump Impeller Puller {special tool), pull
off the impeller.
If the tightening margin exceeds specification, replace
the impeller or water pump shaft.
NOTE:
Do not reassemble more than three times even when
the specification is met.

14-12
 5.2.3 Reassembly
COOLING - SERVICE PROCEDURE -
Apply engine
oil to lips.
12

Apply engine oil to

external cylinder. 13
11

Installation load Installation load

39.2 kN {4000 kgf} 39.2 kN {4000 kgf}

44±8.8 N-m
{4.5 ± 0.9 kgf-m}
6

Assembly sequence

,,::..- -�
Apply engine 127,

'----�!-+------
oil to lips. Ir \
\ , ..., ,'
I
I 8➔11➔10➔9➔14➔7

d}_j

NOTE:
1. After reassembly, rotate the water pump pulley by hand
to confirm that the impeller does not interfere with the For parts with an encircled number,
water pump cover and water pump case. refer to Reassembly Procedure that
2. When the impeller and flange are installed, confirm that follows.
they are not installed with a load of 4900 N {500 kgf}.
D0047O

Reassembly Procedure To install the unit seal. use the Unit Seal Installer (spe­
<Installation of unit seal> cial tool) as shown and press-fit the unit seal until the
installed dimensions shown are obtained.

Unit seal
Unit Seal Installer
MH062195

Installation load
31 to 44 N
{3. 2 to 4.5 kgf}
Installation speed
14 to 28 mm/sec.

09194

14-13
-
5.3 Thermostat
COOLING - SERVICE PROCEDURE

5.3.2 Inspection
5.3.1 Removal and installation

Thermostat marking For 76.5°C

Valve opening 74.Sto 78.5

temperature (°C)
Valve lift/ 10 or more/90
temperature
(mml°C)

Valve lift
Stirring rod

Thermostat

��
Heat source --1J
D0301B

B9021B
Agitate water in the container with the stirrer to obtain
uniform temperature. For the inspection, use the fol­
lowing procedures.
( 1) Slowly 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 measuring temperature correspond­
ing to the valve opening temperature. (See the
table above.)
Keep this state for five minutes and measure the
bypass valve lift.
(4) Lower temperature down 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
COOLING - SERVICE PROCEDURE m
5.4.1 Disassembly and inspection

4
7
Rotation
8
6
3
2

1
Disassembly sequence
1 Fan pulley 5 Bearing
2 Flange 6 Spacer
3 Snap ring 7 Bearing
4 Fan drive shaft 8 Bearing case B9023O

14-15
Ill COOLING - SERVICE PROCEDURE

5.4.2 Reassembly 5.5 Tension Pulley

5.5.1 Disassembly and inspection

Sealing side to be faced outward.

To be packed with grease
(multipurpose grease)

Rotation
B9023E
· Disassembly sequence
1 Adjusting bolt
2 Tension pulley bracket
3 5 6 3 Snap ring
To be packed with
4 Tension pulley shaft
approx. 86 g of grease 5 Tension pulley
(multipurpose grease)
6 Bearing

Assembly sequence

8-+5➔3➔2➔1

4-+7-+6]
89024D

14-16
 COOLING - SERVICE PROCEDURE DI
5.5.2 Reassembly 5.6 Inspection of Auto Cool Fan Coupling

Sealing side to be faced

outward.
To be packed with grease
(multipurpose grease) 98N-m
{10 kgf-m}

To be packed with
approx. 6 g of grease
(multipurpose grease)

Fan axial runout or

play, continuous high
noise or unusually
high noise of fan

B9024E

NOTE:
1. Since the autocool fan coupling js 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 whole autocool fan
coupling assembly must be replaced.

818558

14-17
Ill COOLING - SERVICE PROCEDURE

(1) Play in axial direction 5. 7 Inspection of Radiator

(1) Cleaning

O1213A

O0402A
When engine is cold, pinch the fan fitting portion and
move it in axial direction. If the fan blade tip has exces­
Remove 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

Radiator inspection pressure

(air pressure)
NV 98 kPa {1 kgf/cm2}
NV .. Nominal Value

D1214C
(2) Attach hose to the inlet of the radiator and cap the
If dirt or dust is adhering to the bimetal, remove it care­
fully with a wire brush or the like.
NOTE:
Use care not to apply excessive force to the bimetal.
O0409A
outlet. Then, immerse the radiator in a waterfilled
tank .
Using a radiator cap tester, send compressed air at
the specified inspection pressure through the hose
to check for leaks.
If leaks are evident, re-solder or replace the radia­
tor.

14-18
 COOLING - SERVICE PROCEDURE Bl
(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).

<Without fan drive>

Water pump
Pressure valve opening Radiator
pressure cap tester
NV 39 to 59 kPa
{0.4 to 0.6 kgf/cm 2}
Alternator

Crankshaft B6525B

Radiator cap <With fan drive>

10 to 15 mm

NV .. Nominal Value D0420A

Check the spring tension and sealing condition of the

Alternator
pressure valve and vent valve. If defective, replace.
Check the pressure valve opening pressure, using a
radiator cap tester.

Crankshaft
B6527B

NOTE:
1. A slack belt can be a cause of overheating and
undercharge.
2. An excessively tight belt may result in damaged
bearings and belts.

14-19
 -
5.8.2 Adjustment
COOLING - SERVICE PROCEDURE

• Using Belt Tension Gauge (special tool)

( 1) Alternator
0-ring A

Depression
load scale
Belt Tension Gauge
MH062345

0-ring B

E0165
Loosen the upper and lower mounting bolts of the
alternator. T hen, fit a wrench handle and move the
alternator as necessary.
Deflection gauge
03613
( 1) Set 0-ri ng A at the 98 N {10 kg} mark on the depres­
sion load scale.
(2) Set 0-ring B at the V-belt's specified nominal
deflection value (max.) on the lower scale.

NOTE:
When moving the alternator, use care not to damage
the stator coil between the front and rear brackets, Top of gauge
and the through bolt.
Flange
(2) Tension pulley
V-belt
Adjusting bolt

03614

(3) Apply the Belt Tension Gauge (special tool) to the

Mounting nut V-belt's tension measurement point. Depress the
top of the gauge until 0-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 moves the idler pulley.)

14-20
 COOLING - SERVICE PROCEDURE

3.
m
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

FUSO Diesel Every 2 years
Long Life Coolant

Anti-rust, anti-freeze At time of coolant replacement

of every 6 months or before
and after use of anti-freeze

03615
(1) Washing with water

(4) Measure the amount of deflection in the V-belt.

Adjust the V-belt's tension if the amount of deflec­
tion is out of specification.

5.9 Cleaning of Cooling System

80426A

(a) Discharge coolant from the radiator, crankcase,

80429A
If the radiator is used for a long time, rust, scale, mud,
etc. are deposited inside, resulting in overheat. Clean
the cooling system with city water by using the follow­
ing procedures.
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
until the drained water runs clear.
(2) Washing with cleaning solution (When radiator
clogging or coolant contamination are serious)

NOTE: (a) Discharge coolant from the radiator, crankcase,

1. Use a cleaning solution if the 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
- COOLING - SERVICE PROCEDURE
(b) Ready a mixture of FUSO Radiator Cleaner (Radi­
pet-7 or equivalent: 5 to 10%) and cooling water.
Pour the specified amount of mixture into the
radiator.
B0428A
(c) Run the engine to raise the solution temperature to
around 90°C. Let the engine run at idle for another
30 minutes, then remove the solution.
B0426A
14-22
(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.
3. After cleaning with detergent, fill with coolant as
soon as possible.
(3) Cooling water
(a) When Long Life Coolant is used:
D1322B
In order to prevent freezing of cooling water and corro­
sion of the cooling system, add FUSO Diesel Long Life
Coolant at a ratio of 30 to 60% 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 FUSO Diesel Long Life Coolant.
2. Never mix it with DIAQUEEN Long Life Coolant or
other commercial long life coolants, anti-freezes
or anti-rusts.
 COOLING
(b) When anti-rust and anti-freeze are used:
SERVICE PROCEDURE
01310A
1) After cleaning, add Fuso Radiator Anti-rust (Radi­
pet-98 or equivalent) at a ratio of 5% to the coolant
quantity to prevent corrosion in summer.
D1322A
2) In winter, add the Fuso Anti-freeze or equivalent at
a ratio of 30 to 60% to prevent freezing.
For usage of anti-rust and anti-freeze, see respec­
tive instruction manuals.
NOTE:
When the anti-rust or anti-freeze is used, never use
with other long life coolants.
5.10 Gas Leak Test
-
Air or exhaust gas leaked into the coolant promotes
corrosion and rust formation. Perform the following
check and, if defects are found, take remedial action.
(1) Inspection
(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 forming 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 pump mounting bolts, and hose and
its connections for looseness. Check also hoses for
damage.
(b) If the exhaust gas has leaked into coolant, check
the cylinder head gasket or nozzle tube end stake
for damage. Check also cylinder head for cracks.
5.11 Bleeding the Cooling System
(1) With the pressure cap removed from the radiator,
let the engine run at idle with coolant temperature
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
Ill COOLING - TROUBLESHOOTING

6. TROUBLESHOOTING
Symptom Probable cause Remedy Ref. group
Overheat Defective V-belt
• Incorrect tension Adjust
• Broken belt Replace
Clogged cooling system Clean
Defective thermostat Replace
Defective water pump
• loose shaft to impeller engagement Replace
• Loose shaft to flange engagement Replace
• Improper clearance between impeller and water pump case Correct
• Damaged impeller Replace
Clogged radiator fins Clean
Defective autocool fan coupling
• Damaged bimetal Replace
• Clogged bimetal Clean
• Defective autocool fan coupling proper Replace
Damaged cooling fan Replace
low coolant level Replenish
Overcool Defective thermostat Replace
Quick loss Defective radiator hose
of coolant • loose hose connection Correct
• Worn or damaged hose Replace
Defective radiator
• Radiator proper not tight Correct or replace
• Pressure cap not tight Replace
Defective water pump
• Defective unit seal Replace
• Defective oil seal Replace
• Pump mounted improperly Correct
Defective oil cooler Replace Group 12
Thermostat case or cover mounted improperly Correct
Defective heater hose
• loose hose connection Correct
• Worn or damaged hose Replace
Defective cylinder head gasket Replace Group 11

14-24
 INTAKE AND EXHAUST
CONTENTS

1. GENERAL ................................... 2 5.3.1 Disassembly and reassembly ......... 15

2. SPECIFICATIONS ........................... 6 5.3.2 Inspection and cleaning .............. 16
3. SERVICE STANDARDS ..................... 7 5.4 Turbocharger ...... ...................... . 17
3.1 Service Standards Table ................. 7 5.4.1 Disassembly ........................... 17
3.2 lightening Torque Table ................. 7 5.4.2 Cleaning and inspection .............. 20
4. SPECIAL TOOL .. ............ . ............... 8 5.4.3 Reasse·mbly .. .......... ........ ....... 23
5. SERVICE PROCEDURE ...................... 9 5.5 Aftercooler ......... ........ ............... 27
5.1 Removal and Installation of Intake 5.5.1 Disassembly and reassembly ......... 27
System .................................... 9 5.5.2 Air pressure test ...................... 28
5.2 Removal and Installation of Exhaust 5.6 Bleeding of Aftercooler Coolant Circuit
System ................................... 13 <6 D24-TC :Standard> ..................... 28
5.3 Air Cleaner ............................... 15 6. T ROUBLESHOOTING ....................... 29

15-1
 -
1. GENERAL
INTAKE AND EXHAUST - 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
<Single element type>
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. Small
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

Guide vane
B0619A
<Double element type>

Inner element To air cleaner

80610A

The precleaner, coupled with 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
guide vanes of the precleaner to centrifugally separate
large particles of dust before the air is drawn into the air
B0608C cleaner. These dusts are collected in the precleaner.
Outside air

B0620A

15-2
 (3) Vacuator valve
INTAKE AND EXHAUST - GENERAL m
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.

Warning lamp
Starter switch
Electrical
dust indicator
-=- Battery
Valve to be opened by l
repulsion of rubber

806048

Centrifuged dust collects at the bottom of the air Air cleaner

cleaner. A vacuator valve made of rubber is mounted to
the bottom, which pulsates to automatically dis­ 81824A
charges dust and water when the engine speed is
below about 800 rpm. Namely when the engine is run­ With the electric dust indicator, its electric contact
ning at a speed higher than 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, warning 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

Reset button

Indicator body

Signal

•
Transparent
section

Negative pressure
806058

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.
When the element is plugged with dust and dirt, the
suction resistance increases. When this vacuum
reaches 6.2 kPa {635 mmH20}, the signal (red) is pulled
down against the spring tension. The signal (red) is
then visible through the transparent section in the
15-3
 INTAKE AND EXHAUST - GENERAL

(5) Turbocharger
Bearing housing

Compressor wheel Compressor

cover "' Shaft-and­
turbine-wheel

Exhaust
outlet Air inlet

Turbine housing
Compressor
wheel
B1213A
Inlet
manifold
Exhaust
manifold The turbocharger can be divided into three basic sec­
tions: the turbine wheel that is driven by the exhaust
gases, the compressor 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 of the shaft.
B1215A 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 of the sliding parts.
offering advantages such as boosted engine power (Refer to Group 12 Lubrication.)
output, thrifter fuel consumption, and reduced engine
noise.
The exhaust gases discharged from the cylinder of the
engine are led through the exhaust manifold into the
turbocharger and are accelerated in the turbine hous­
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 compressor wheel mounted on the same shaft as
the turbine wheel. By rotation of the compressor
wheel, a larger amount of air than without supercharg­
ing is forced into the cylinder of the engine, so a corre­
spondingly larger amount of fuel can be burnt. This
increases the effective pressure during combustion
(the pressure forcing the piston down) and thus
increases the output.

15-4
 (6) Aftercooler
INTAKE AND EXHAUST - GENERAL -
<6D24-TL>
<6D24-TC>

Turbocharger Turbocharger

Plate-and-corrugated-fin
type water-cooling heat
exchanger lntercooler

®43534
80627A

The intercooler (attached to the front of the radiator) is

The intake air cooling system, incorporating a plate­ a tube-and-corrugated-fin, air-to-air heat exchanger. It
and-corrugated-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
same function as the intercooler on automobile intake air denser before it enters the cylinders. Com­
engines. bustion efficiency is thus improved, resulting in higher
The system cools off the intake air, whose temperature fuel efficiency and output and in lower emissions of
has gone high due to compression 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 improves the com­
bustion efficiency. Thus the fuel economy and output
are improved and the exhaust gases are reduced to a
minimum.

15-5
-
2. SPECIFICATIONS
INTAKE AND EXHAUST - SPECIFICATIONS

el 6D24 6D24-T 6O24-TC 6D24-TL

�

Air cleaner Type Cyclone type paper element

element (Nippon Donaldoson Ltd. products)

Supercharger Type - Turbocharger

Model - Mitsubishi TD08H
Aftercooler Type - - Plate and corrugated fin Tube-and-corrugated-fin
type, water-cooling (built type, air-cooling
in the inlet manifold,
cooled by the engine
coolant)
Model - - - C60

Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com

15-6
 INTAKE AND EXHAUST - SERVICE STANDARDS

3. SERVICE STANDARDS
3.1 Service Standards Table
Unit: mm
Maintenance item Nominal value Limit Remedy and
(Basic diameter in I ]) remarks
---·-�----
Dust indicator operating resistance 6.2 ± 0.6 kPa - Replace
{635 ± 58 mmH 2 O}

Turbocharger I.D. of section in bearing housing receiving bearing - 20.506 Replace

Shaft-and-turbine-wheel Bearing journal O.D. - 11.996 Replace

Shaft runout - 0.015 Replace

--- -- - ---
Bearing O.D. - 20.382 Replace
---
I.D. - 12.042

Length - 11.94

Piston ring end gap in insert 0.05 to 0.25 - Replace

Shaft-and-turbine-wheel to turbine housing clearance 0.39 to 1.0 - Replace

Compressor wheel to compressor 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 assembly air-tightness 6D24-TC No leak is allowed with a 195 - Replace
kPa {2 kgf/cm 2 } air pressure

lntercooler air-tightness 6D24-TL No leak is allowed with a 150

kPa {1.5 kgf/cm2 } air pressure

3.2 lightening Torque Table

Location tightened Screw size lightening torque Remarks

O.D. x pitch N-m {kgf-m}
(mm)

Inlet manifold mounting bolt <except 6O24-TC> M10 x 1.5 35 {3.6}

Exhaust manifold mounting bolt M10 x 1.25 41 {4.2}

Turbocharger Mounting nut M10 x 1.25 26 {2.7}

mounting nut
Lock nut M10 x 1.25 35 {3.6}

Turbocharger Coupling mounting nut - 5.9 {0.6} Apply MOLY-

Shaft-and-turbine-wheel mounting - 20 {2}

KOTE grease to
threads.
lock nut

15-7
 -
4. SPECIAL TOOL
INTAKE AND EXHAUST - SPECIAL TOOL

Unit: mm
Tool name Shape
Socket
MH061242
For exhaust manifold attach­
ing nut

Width across
flats 14

85341A

15-8
5. SERVICE PROCEDURE
INTAKE AND EXHAUST - SERVICE PROCEDURE -
5.1 Removal and Installation of Intake System

<6D24>

�
•
Install with the arrow
mark facing toward
the inlet manifold.

35N-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 that the arrow points in the correct direction when installing the air heater.
3. For details of air heater inspections, refer to Group 16.

84556A

15-9
 INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D24-T>

3 2

35N-m ��
�gdown.
{3.6 kgf-m}

1 Ground plate
2 Inlet pipe
3 Rubber hose
4 Air heater
5 Inlet manifold

NOTE:
1. Remove harnesses before disassembly.
2. Ensure that the arrow points in the correct direction when installin g the air heater.
3. For details of air heater inspections, refer to Group 16.

84557A

15-10
 INTAKE AND EXHAUST - SERVICE PROCEDURE m
<6D24-TC: Standard>

Install with the arrow

mark facing toward
the cylinder head.
9 2

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 assembly

NOTE:
1. Remove harnesses before disassembly.
2. Ensure that the arrow points in the correct direction when installing the air heater.
3. For details of air heater inspections, refer to Group 16.

B4558C

15-11
 INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D24-TL>

�
�wfacing down.
35 N-m {3.6 kgf-m}

1 Ground plate 4 Inlet manifold

2 Air inlet pipe B 5 Air inlet pipe A
3 Air heater 6 Rubber hose

NOTE:
1. Remove harnesses before disassembly.
2. Ensure that the arrow points in the correct direction when installing the air heater.
3. For details of air heater inspections, refer to Group 16.

®43535

15-12
 INTAKE AND EXHAUST - SERVICE PROCEDURE

5.2 Removal and Installation of Exhaust System

-
<6D24>

41 N-m
{4.2 kgf-m}

Exhaust
Seal rings manifold

"TOP" mark
Install with stamped
"TOP" mark facing
manifold
l Expansion rings

Seal ring
Gap

Install the seal rings such that their gaps

are staggered by 180'.
Install the expansion rings such that their
gaps are opposite the seal ring gaps.

1 Heat insulator 4 Expansion ring

2 Exhaust manifold 5 Center exhaust manifold
3 Seal ring

84560A

Socket, MH061242 (special tool) is available to facili­ of this tool is recommended.

tate fitting of the exhaust manifold mounting nuts. Use
15-13
 m INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D24-T, TC, TL>

35 N-m {3.6 kgf-m}

�
=-8

L.
26 N-m {2.7 kgf-m}

"TOP" mark
Install with stamped
"TOP" mark facing
manifold Expansion rings

Seal ring
Gap
• Install the seal rings such that their gaps
are staggered by 1ao·.
• Install the expansion rings such that their
gaps are opposite the seal ring gaps.

1 Heat insulator 5 Exhaust manifold

2 Oil pipe 6 Seal ring
3 Oil return pipe 7 Expansion ring
4 Turbocharger 8 Center exhaust manifold

B4561A

Socket, MH061242 (special tool) is available to facili­ NOTE:

tate fitting of the exhaust manifold mounting nuts. Use Some types of turbocharger fit onto the top of the
of this tool is recommended. exhaust manifold, while other types fit onto the bot­
tom of the exhaust manifold. Maintenance procedures
for both types are the same.
15-14
 INTAKE AND EXHAUST - SERVICE PROCEDURE

5.3 Air Cleaner

5.3.1 Disassembly and reassembly

Dust cup
<Single element type>

Air cleaner body

e-,-- Dust indicator

Air cleaner body

84563A

Dust cup
<Double element type>

. ,·. Installation
,__direction mark

Clamp

Gasket
Outer element

1
�
Inner
element ��
�ir cleaner body
_
,, •:::;;:,:•:
Dust md1cato
� �:�i:iI�:: \ ,
o ,.. •::- • •:. Cover
,
•,:1. · Wing nut Wing nut
�
Wing nut

e-- Vacuator valve

NOTE:
Remove the inner element only for replacement.
84564A

15-15
 - INTAKE AND EXHAUST

5.3.2 Inspection and cleaning

SERVICE PROCEDURE

(4) Clean the inside of the air cleaner body and dust
(1) When there is dry dust on the element cup, and discharge the deposited dust.
(5) Dust indicator

Operating resistance
NV 6.2 ± 0.6 kPa
{635 ± 58 mmH20}

Window (red signal)

C7 207A
If there is dry dust on the element, clean the dust by
blowing 685 kPa {7 kgf/cm2} or lower compressed air
against the element.
Blow the compressed air from inside the element up
and down along the frills of the filter paper and clean
the whole element evenly.
NOTE:
1. Do not strike the element or strike it against a hard
object to loosen the dust.
2. Do not clean, but replace, the inner element.
(2) When there is moist dust on the element
If the element is contaminated with moist soot, replace
it regardless of the specified replacement frequency.
(3) Inspection of element
NV .. Nominal Value C7210B
Start the engine and close the inlet port of air cleaner
gradually to increase negative pressure. If the red sig­
nal is displayed at the dust indicator, or warning lamp
lights for the electric type dust indicator, the dust indi­
cator is normal.
NOTE:
Perform this inspection after cleaning or replacement
of the air cleaner element if the element is heavily
clogged.

C7 209A

After the element has been cleaned, put an electric

lamp inside the element to check for damage 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
INTAKE AND EXHAUST - SERVICE PROCEDURE -
5.4.1 Disassembly

Wear in surface Wear

receiving thrust 1
16 7

B�de bend and damag�

corrosion, marks of
interference on back surface

4
Interference with
compressor wheel,
cracks, damege

Interference with
turbine wheel, cracks
due to overheat, pitching,
deformation
13
Blade bend and damage, corrosion,
marks of interference on back sur­
face, damage on piston ring groove,
damage on bearing journal
Interference with
turbine wheel, damage

18
Bearing hole surface roughness,
damage, gas corrosion, clogged oil
hole, turbine side flange deformation

Disassembly sequence
1 Coupling assembly 10 Thrust sleeve
(?) Turbine housing 11 Thrust bearing
3 Snap ring 12 Thrust ring
@ Compressor cover 13 Shaft-and-turbine-wheel
@ Compressor wheel 14 Piston ring
6 Snap ring 15 Turbine back plate
(J) Insert 16 Bearing
8 Piston ring 17 Snap ring
9 Oil deflector 18 Bearing housing
For parts with an encircled number, refer to Disassembly Procedure that follows.

C8965B

15-17
 m
Disassembly Procedure
INTAKE AND EXHAUST - SERVICE PROCEDURE

(3) Removal of compressor cover

Alignment mark

Turbine Compressor cover

housing

Bearing housing
B2819D C8982C

(1) Before disassembling the turbocharger, make
alignment marks on the compressor cover, bearing
housing, and turbine housing so that they can be
properly reassembled.
(2) Removal of turbine housing
Remove the compressor cover by tapping it with .
plastic hammer or similar tool which will not damag,
the cover, with the snap ring loosened.
NOTE:
Use care not to damage the compressor wheel durin!
the removal procedure.
(4) Removal of compressor wheel

Turbine housing Bearing housing

Turbine housing

B3946B

To remove the turbine housing, remove the coupling B2820C

assembly and tap the housing with a plastic hammer or
similar tool to prevent damage to it.
NOTE:
The turbine wheel blades are easy to bend. Use care
not to damage them.
(a) Clamp the turbine housing in a vise and fit the bear­
ing housing into the turbine housing with the tur•
bine wheel side of the bearing housing facing the
turbine housing.

15-18
 INTAKE AND EXHAUST - SERVICE PROCEDURE

(5) Removal of insert

m
Snap ring

Shaft-and-turbine-wheel boss
C8983C
(b) While holding the shaft-and-turbine-wheel boss,
remove the lock nut that secures the compressor
wheel.
C89788
(a) Snap off the snap ring that secures the insert onto
the bearing housing.
NOTE:
Retain the snap ring by hand to prevent it from spring­
ing out when slipping off the snap ring pliers.

� Comp,osso, wh"I

C8984C

(c) Slowly slide off the compressor wheel upward.

(b) Fit the tip of a screwdriver into the portion of the

insert shown and carefully remove it from the bear­
ing housing.

15-19
 INTAKE AND EXHAUST - SERVICE PROCEDURE

5.4.2 Cleaning and inspection

Piston ring end gap

NV 0.05 to 0.25

Clean
Bearing
0.0.
L 20.382

1.0.
L 12.042
Length
L 11.94

BearingjournalO.O.
L 11.996
Shaft runout (total indi­
cator reading)
L 0.0,5

Clean
Bearing inserting
portion 1.0.
L 20.506 NV .. Nominal 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 CHEMICAL INDUSTRY CO., LTD DAI
CLEANER T-30 or equivalent) to clean oily contami­
nation.

13628

15-20
 INTAKE AND EXHAUST - SERVICE PROCEDURE

(2) Inspection of bearing housing

-

C8990A
C8993A
(b) Blow clean compressed air against the entire inter­
nal and external surfaces. Measure I.D. of the area receiving the bearing. Replace
the bearing housing if the measurement exceeds the
limit.
(3) Inspection of bearing

Measuring Measuring
direction position

C8991A

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

brush. C8971A

After deposits have been removed, soak parts in a

non-flammable solvent again; then, blow com­ Measure 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
 m
(4) Inspection of shaft
INTAKE AND EXHAUST - SERVICE PROCEDURE

(5) Inspection of insert

(a) Journal 0.0.

Insert

B0467A
80465A
Fit a new piston ring in the insert bore and measure the
Measure the shaft-and-turbine-wheel journal diame­ end gap of the piston ring using a feeler gauge.
ter. If the end gap is out of the nominal value, replace the
If the measured value is less than the limit, replace the insert.
shaft-and-turbine-wheel.
(b) Shaft runout

B0466A

Set a dial indicator to the shaft as shown and turn the

turbine wheel slowly to measure shaft runout.
If the measurement 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
 INTAKE AND EXHAUST - SERVICE PROCEDURE

5.4.3 Reassembly

5.9 N-m {0.6 kgf-m}

11 12 I Apply engine ott]

• Molykote grease or equivalent
to be applied to screw and
seating surface in lock nut.
• Hammer entire periphery.

15
14 j Apply engine oil I

20 N-m {2 kgf-m}
Molykote grease or equiva­
lent to be applied to screw

I Apply engine oil I 8

Compressor wheel to com­

pressor cover clearance
NV 0.08 to 0.28 Shaft-and-turbine-wheel to
turbine housing clearance
NV 0 .39 to 1.0

13
Assembly sequence Shaft-and-turbine-wheel
axial play
18➔17➔16➔15 NV 0.075 to 0.155
}+12 11 .
14➔13 � �;➔(�➔r4;-➔3-/2➔:1_. NV .. Nominal Value
9➔10➔r.a.➔7
For parts with an encircled number, refer to Reassembly Procedure that follows.
C89748

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.

Thrust sleeve

Oil deflector

Piston ring
80472C

15-23
Bl INTAKE AND EXHAUST - SERVICE PROCEDURE

(2) Installation of snap ring (3) Measurement of clearance between shaft-and-tur­

bine-wheel and turbine housing

Shaft-and­
turbine-wheel

C8978C

C9001B

Set a dial indicator to the end of the shaft and move the
shaft in the axial direction to measure the clearance. If
the measurement is out of specification, disassemble
and isolate the cause.
(4) Installation of compressor wheel

Install the snap ring to the bearing housing with its

Bearing housing
taper up.
After installation, using a screwdriver, drive the snap
ring into the groove in the bearing housing by hum­ Turbine housing
mering.
NOTE:
1. Retain the snap ring by hand to prevent it from
B2820C
springing out when slipping off the snap ring pli­
ers. Lock nut
� 20 N-m
2. Special care must be exercised, when tapping the {2.0 kgf-m} ____._..,
Compressor wheel�
snap ring into position, to prevent damage to the "
bearing housing by the screwdriver. Shaft-and-turbine=----fl "
wheel

C9002C

(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
 INTAKE AND EXHAUST - SERVICE PROCEDURE

(bl Coat threads in the shaft-and-turbine-wheel with (6) Measurement of clearance between the turbine
m
molybdenum disulfide base grease Li soap and back plate and shaft-and-turbine-wheel back sur­
mount the compressor wheel onto the shaft. face
(c) Holding the boss on the turbine wheel side, tighten
the compressor wheel lock nut to the specified
torque.
NOTE:
Set the bearing housing carefully to prevent damage
'
.,,..-Bearing housing
on the turbine wheel blades.
(5) Measurement of axial play in shaft-and-turbine­
wheel

Compressor cover

B2830C
Shaft-and­
turbine-wheel Shaft-and­

t ""'�,:;::--
turbine wheel

Compressor wheel
Compressor cover
C90038

Set a dial gauge on the shaft-and-turbine-wheel end.
With compressor wheel moved in the axial direction,
measure the end play. If the play is out of specification,
disassemble and check to locate the cause.
C9004A
Temporarily mount the bearing housing to the com­
pressor cover from the compressor wheel side. Mea­
sure the clearance between the turbine back plate and
shaft-and-turbine-wheel back surface. If the clearance
is out of specification, disassemble and isolate the
cause.
NOTE:
Be sure to use two thickness gauges and take mea­
surement at the tip of the blades.

15-25
 INTAKE AND EXHAUST
(7) Compressor wheel to compressor cover clearance
84468A
Check by the following procedures.
(a) Move up and down the compressor wheel to mea-
sure runout (R).
NOTE:
Do not measure runout by turning the compressor
wheel.
(b) Measure compressor cover inside diameter (D)
and compressor wheel outside diameter (d) at
places indicated in the illustration.
(c) Calculate the clearance by the equation given
below.
If it is out of specification, disassemble and check
again.
Clearance= 1/2 (D - d - R)
15-26
SERVICE PROCEDURE
(8) Installation of turbine housing and compressor
cover
Alignment mark
Coupling assembly Snap ring Compressor cover
5.9 N•m (0.6 kgf·m)
B2819E
Make sure that the alignment marks are aligned and
secure the parts with the coupling assembly and snap
ring.
Install the coupling assembly by the following proce­
dures.
(a) lighten the coupling assembly to specified torque.
(b) Hammer the coupling assembly all around.
(cl lighten again the coupling assembly to specified
torque.
(9) After reassembly, turn the turbine wheel and com­
pressor wheel by hand and check for smooth rota­
tion.
If the wheels turn heavily, or bind, disassemble,
and locate the cause of trouble.
 INTAKE AND EXHAUST - SERVICE PROCEDURE

5.5 Aftercooler
5.5.1 Disassembly and reassembly
( 1) Water-cooled type

<6D24-TC :Standard> <6D24-TC :Low profile type>

4
5 Damage, water leaks,
dirt on fins, water scale
and rust inside core

C9305C
1 Connector 4 Core assembly
2 Cover 5 Inlet manifold
3 Plate

(2) Air-cooled type

<6D24-TL>

1 Air intake hose

2 lntercooler

84157A

15-27
 m
5.5.2 Air pressure test
INTAKE AND EXHAUST - SERVICE PROCEDURE

5.6 Bleeding of Aftercooler Coolant Circuit

(1) Inspection of core assembly <6D24-TC> <6024-TC :Standard>
Conduct the air pressure test to check for water leaks
due to damaged element. To check, apply an air pres­ � Air vent plug
sure of 390 kPa {4 kgf/cm2} to the core assembly. �
Replace the core assembly if it is leaking air or other­
wise defective. Water return
pipe
NOTE:
Never apply pressure over specification.
(2) Inspection of intercooler <6D24-TL>

E0329

(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 sys­
C9303A tem.
(d) After the air in the coolant circuit has been thor­
(a) Remove the intercooler and use copper wire or the oughly bled, add coolant as necessary to the radia­
like to remove mud, insects, etc. from the front side tor and reservoir tank.
of intercooler core, using care not to damage the
tube.
(c) Air-tightness check

Pressure for inspection of

intercooler (compressed air)
NV 150 kPa {1.5 kgf/cm2}

NV .. Nominal Value
C9009A

Immerse the intercooler in a water tank with one open­

ing for air closed and with the other opening connected
to a hose. Send compressed air at specified test pres­
sure through the hose and make sure that there is no air
leak.

15-28
 INTAKE AND EXHAUST - TROUBLESHOOTING

6. TROUBLESHOOTING
Symptom Probable cause Remedy Ref. group
Low output Insufficient intake air
• Loaded air cleaner element Clean
---·--- .. ---�--- --·
• Air 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 wheel and turbine back plate interfering Check
• Turbine wheel and turbine housing interfering Check
• Bent shaft-and-turbine-wheel Replace
• Compressor wheel and compressor housing interfering Check
·-·
• Seized thrust sleeve and/or thrust bearing Replace
• Incorrect sliding between inside parts due to clogged lubri- Clean, check
eating oil pipe

• Damaged compressor wheel Replace

• Damaged turbine wheel Replace
• Foreign matter on front surface of intercooler core <6D24-TL> Clean
·-
Low exhaust efficiency
• Deformed front pipe, muffler and/or tail pipe (large exhaust Replace
resistance)

• Defective turbocharger
• Turbocharger rotation failure (See above.) Check
• Damaged turbine wheel Replace
Whitish and Incorrect injection timing Adjust Group 13A, E
much exhaust
gas Low compression pressure Check Group 11
Poor quality fuel Replace Group 13A
Defective turbocharger
• Oil leaks due to worn piston ring, and/or insert Replace
• Damaged oil seal due to clogged oil return pipe Replace
Dark and much Loaded air cleaner element Clean
exhaust gas
Trouble in engine proper Check Group 11
Nonuniform fuel injection amount to cylinders Adjust Group 13A, E
Incorrect injection timing Adjust Group 13A, E
Abnormal noise Poor connection of intake and exhaust systems Correct
and/or vibration
from intake and Deformed front pipe, muffler or tail pipe (large exhaust resistance) Replace
exhaust system
Defective turbocharger (See above.) Check

15-29
Notes: Mitsubishi 6D24

Engine Parts contact phone: 269 673 1638 Email: EngineParts2@gmail.com