Engine Manual 6HK1 PDF

PART NO.
EDDE-EN-00
6HK1
TIER 2
Engine Manual
ENGINE MANUAL
6HK1
Tier 2
URL:http://www.hitachi-c-m.com
Service Manual consists of the following separate Part No.

EDDE-EN-00
Technical Manual (Operational Principle) : Vol. No.TODDE-EN

Technical Manual (Troubleshooting) : Vol. No.TTDDE-EN
Workshop Manual : Vol. No.WDDE-EN
PRINTED IN JAPAN (K) 2012, 05 Engine Manual : Vol. No.EDDE-EN
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 1
GENERAL INFORMATION 0A–1
GENERAL INFORMATION
CONTENTS
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B
GENERAL INFORMATION
CONTENTS
General Repair Instruction . . . . . . . . . . . . . . . . . . . . 0A-1 External View Drawing . . . . . . . . . . . . . . . . . . . . . . 0A-12
Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-13
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 0A-17
Nut and Bolt Angular Tightening Method. . . . . . . . . 0A-4 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-25
Standard Bolt Torque Specifications . . . . . . . . . . . . 0A-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-26
Recommended Thread Locking Agents . . . . . . . . . 0A-8 Lubricant Application . . . . . . . . . . . . . . . . . . . . . . . 0A-36
Main Data and Specifications. . . . . . . . . . . . . . . . . . 0A-9 Sealant Application . . . . . . . . . . . . . . . . . . . . . . . . . 0A-36
Performance Curve. . . . . . . . . . . . . . . . . . . . . . . . . 0A-11
General Repair Instruction 12. When a service operation is completed, make a final
check to be sure the service has been done properly
1. Before performing service operations, disconnect the and the problem has been corrected.
ground cable from the battery to reduce the chance of 13. Allow the engine to cool before beginning any service
cable damage and burning due to short circuiting. procedure.
2. Use a cover on body, seats and floor to protect them This will eliminate the danger of fire and possible
against damage and contamination. injury.
3. Brake fluid and anti-freeze solution must be handled 14. Hot steam under pressure may escape from the
with care because they can cause paint damage. radiator if the coolant is drained while the engine is
4. The use of proper tools and special tools, where hot. This can result in serious burns. Allow the engine
specified, is important for efficient and reliable to cool before draining the coolant.
performance of service repairs. 15. Hot engine oil can cause severe skin burns. Allow the
5. Use genuine Isuzu parts. engine to cool before draining the engine oil.
6. Used cotter pins, plastic clips, gaskets, O-rings oil 16. While working around a running engine, avoid contact
seals, lock washers, and self-locking nuts should be with moving parts and hot surfaces to prevent injury.
discarded and new ones should be installed. Normal 17. Wear safety glasses when using compressed air.
function of the parts cannot be maintained if these Flying particles may cause eye injury.
parts are reused.
18. Always wear safety goggles when working with fuel to
7. To facilitate proper and smooth reassembly protect the eyes from fuel splash.
operation, keep disassembled parts neatly in groups.
19. Test fluid from the injection nozzle tester will spray out
Keeping fixing nuts and bolts separate is very
of the injection nozzle under great pressure.
important, as they vary in hardness and design
depending on position of installation. It can easily puncture a person’s skin.
8. Clean the parts before inspection or reassembly. Also Keep your hands away from the injection nozzle at all
clean oil ports, etc. using compressed air, and make times.
certain they are free from restrictions. 20. Do not use your fingers to feel for fuel leaks at fittings.
9. Lubricate rotating and sliding faces of the parts with Fuel pressure is high enough to penetrate the skin.
oil or grease before installation. 21. Be careful when changing fuel system components:
10. When necessary, use a sealer on gaskets to prevent Diesel fuel is flammable. Be sure that the ignition key
leakage. of OFF. Do not smoke or allow open flame in the area
while changing fuel system components.
11. Carefully observe all specifications for nut and bolt
torques.
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 2
0A–2 GENERAL INFORMATION
Illustration Arrows
Arrows help you to understand technical illustrations.
Arrow Type Application Arrow Type Application
• Ambient/Clean air flow

Front of Engine
• Cool air flow
• Gas other than

Up ambient air
• Hot air flow
• Ambient air mixed with

Task Related another gas
• Temperature change
View Detail Direction
Lubrication point (Oil or

View Angle
A fluid)
Dimension (1:2) Lubrication point (Grease)
Sectioning (1:3) Lubrication point (Jelly)

69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 3
Abbreviations lb in – Inch Pounds

LF – Left Front
List of abbreviations which may be used in this
LH – Left Hand
manual
LR – Left Rear
A – Ampere(s) LS – Left Side
AC – Alternating Current L-4 – In-Line Four Cylinder Engine
ACL – Air Cleaner Max – Maximum
Adj – Adjust Min – Minimum
AMP – Ampere(s) mm – Millimeter
ASM –Assembly N – Newtons
ATDC – After Top Dead Center NA – Naturally Aspirated
Auto – Automatic NC – Normally Closed
Bat – Battery N·m – Newton Meters
B+ – Battery Positive Voltage NO – Normally Open
BHP – Brake Horsepower NOX – Nitrogen oxides
BTDC – Before Top Dead Center OD – Outside Diameter
°C – Degrees Celsius OHC – Overhead Camshaft
cc – Cubic Centimeter PCV – Positive Crankcase Ventilation
CID – Cubic Inch Displacement PRESS – Pressure
CO – Carbon Monoxide PROM – Programmable Read Only Memory
Conn – Connector psi – Pounds per Square Inch
Crank – Crankshaft PSP – Power Steering Pressure
Cu. In. – Cubic Inch Pt. – Pint
Cyl – Cylinder(s) PWM – Pulse Width Modulate
DOHC – Double Overhead Camshaft Qt. – Quart
DTC – Diagnostic Trouble Code REF – Reference
DTM – Diagnostic Test Mode RF – Right Front
DTT – Diagnostic Test Terminal RH – Right Hand
ECM – Engine Control Module RPM – Revolutions Per Minute
ECT – Engine Coolant Temperature RPM Sensor – Engine Speed Sensor
EGR – Exhaust Gas Recirculation RR – Right Rear
Exh – Exhaust RS – Right Side
°F – Degrees Fahrenheit RTV –Room Temperature Vulcanizing
FL – Fusible Link SAE – Society of Automotive Engineers
FLW – Fusible Link Wire Sec – Secondary
FP – Fuel Pump SI – System International
FRT – Front SOHC – Single Overhead Camshaft
ft – Foot Sol – Solenoid
Gal – Gallon SPEC – Specification
GND – Ground Speedo – Speedometer
Gov – Governor ST – Start / Scan Tool
g – Gram Sw – Switch
Harn – Harness SYN – Synchronize
HC – Hydrocarbons Tach – Tachometer
HD – Heavy Duty TDC – Top Dead Center
Hg – Hydrargyrum (Mercury) Term – Terminal
IC – Integrated Circuit / Ignition Control TEMP – Temperature
ID – Identification / Inside Diameter TURBO – Turbocharger
IGN – Ignition V – Volt(s)
INJ – Injection VAC – Vacuum
Int – Intake V-ref – ECM Reference Voltage
kg – Kilograms VSS – Vehicle Speed Sensor
km – Kilometers VSV – Vacuum Switch Valve
km/h – Kilometer per Hour V-6 – Six Cylinder “Vee” Engine
kPa – Kilopascals V-8 – Eight Cylinder “Vee” Engine
kV – Kilovolts (thousands of volts) W – Watt(s)
kW – Kilowatts w/ – With
L – Liter w/o – Without
lb ft – Foot Pounds WOT – Wide Open Throttle
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 4
Nut and Bolt Angular Tightening

Method
The angular tightening method uses the plastic region of
high tensile steel nuts and bolts to precision tighten Line
important engine fasteners.
Because of the method's nature, there is a limit to the
number of times a particular fastener may be reused. This
limit is specified in this Manual where applicable. C D
1. Carefully wash the nuts and bolts to remove all oil and
grease.
2. Apply a coat of molybdenum disulfide grease to the
threads and setting faces of the nuts and bolts.
3. Tighten the nuts and bolts to the specified torque
(snug torque) with a torque wrench.
4. Draw a line A–B across the center of each nut or bolt.
F00EY00002
Center line
6. Draw another line F – G on the face of each of the
parts to be clamped. This line will be in the direction
of the specified angle Q across the center E of the
nut or bolt.
A B
Specified angle Q
F
F00EY00001
5. Draw another line C – D on the face of each of the

parts to be clamped. This line should be an extension
of the line A – B.
G
Coincide line
F00EY00003
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7. Use a socket wrench to tighten each nut or bolt to the

point where the line A – B is aligned with the line F
– G.
Tighten
C D
B
F
F00EY00005
Example: Specified Angle and Tightening Rotation

A 30° 1 / 12 of a turn
B 60° 1 / 6 of a turn
C 90° 1 / 4 of a turn
D 180° 1 / 2 of a turn
E 360° One full turn
A B C D
E
F00EY00004
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Standard Bolt Torque Specifications

The tightening torque values given in the table below are applicable to all bolts unless otherwise specified.
STANDARD BOLT N·m (kgf·m/lb.ft)

Bolt
Identification
Bolt
Diameter ×
pitch (mm)
M6 × 1.0 4 – 8 (0.4 – 0.8/3 – 6) 5 – 10 (0.5 – 1.0/4 – 7)
M8 × 1.25 8 – 18 (0.8 – 1.8/6– 13) 12 – 23 (1.2 – 2.3/9 – 17) 17 – 30 (1.7 – 3.1/12 – 22)
M10 × 1.25 21 – 34 (2.1 – 3.5/5 – 25) 28 – 46 (2.8 – 4.7/20 – 33) 37 – 62 (3.8 – 6.4/28 – 46)
* M10 × 1.5 20 – 33 (2.0 – 3.4/15 – 25) 28 – 45 (2.8 – 4.6/20 – 33) 36 – 60 (3.7 – 6.1/27– 44)
M12 × 1.25 49 – 74 (5.0 – 7.5/36 – 54) 61 – 91 (6.2 – 9.3/45 – 67) 76 – 114 (7.7 – 11.6/56 – 84)
* M12 × 1.75 45 – 69 (4.6 – 7.0/33 – 51) 57 – 84 (5.8 – 8.6/42 – 62) 72 – 107 (7.3 – 10.9/53 – 79)
M14 × 1.5 77 – 115 (7.8 – 11.7/56 – 85) 93 – 139 (9.5 – 14.2/69 – 103) 114 – 171 (11.6 – 17.4/84 – 126)
* M14 × 2.0 72 – 107 (7.3 – 10.9/53 – 79) 88 – 131 (9.0 – 13.4/65 – 97) 107 – 160 (10.9 – 16.3/79 – 118)
M16 × 1.5 104 – 157 (10.6 – 16.0/77 – 116) 135 – 204 (13.8 – 20.8/100 – 150) 160 – 240 (16.3 – 24.5/118 – 177)
* M16 × 2.0 100 – 149 (10.2 – 15.2/74 – 110) 129 – 194 (13.2 – 19.8/96 – 143) 153 – 230 (15.6 – 23.4/113 – 169)
M18 × 1.5 151 – 226 (15.4 – 23.0/110 – 166) 195 – 293 (19.9 – 29.9/144 – 216) 230 – 345 (23.4 – 35.2/169 – 255)
* M18 × 2.5 151 – 226 (15.4 – 23.0/110 – 166) 196 – 294 (20.0 – 30.0/145 – 217) 231 – 346 (23.6 – 35.5/171 – 255)
M20× 1.5 206 – 310 (21.0 – 31.6/152 – 229) 270 – 405 (27.5 – 41.3/199 – 299) 317 – 476 (32.3 – 48.5/234 – 351)
* M20× 2.5 190 – 286 (19.4 – 29.2/140 – 211) 249 – 375 (25.4 – 38.2/184 – 276) 293 – 440 (29.9 – 44.9/216 – 325)
M22× 1.5 251 – 414 (25.6 – 42.2/185 – 305) 363 – 544 (37.0 – 55.5/268 – 401) 425 – 637 (43.3 – 64.9/313 – 469)
* M22× 2.5 218 – 328 (22.2 – 23.4/161 – 242) 338 – 507 (34.5 – 51.7/250 – 374) 394 – 592 (40.2 – 60.4/291 – 437)
M24× 2.0 359 – 540 (36.6 – 55.0/265 – 398) 431 – 711 (43.9 – 72.5/318 – 524) 554 – 831 (56.5 – 84.7/409 – 613)
* M24× 3.0 338 – 507 (34.5 – 51.7/250 – 374) 406 – 608 (41.4 – 62.0/299 – 448) 521 – 782 (53.1 – 79.7/384 – 576)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such
as cast iron.
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 7
The tightening torque values given in the table below are applicable to all bolts unless otherwise specified.
FLANGED HEAD BOLT N·m (kgf·m/lb.ft)

Bolt
Identification
Bolt
Diameter ×
pitch (mm)
M6 × 1.0 5 – 9 (0.5 – 0.9/4 – 7) 6 – 12 (0.6 – 1.2/4 – 9)
M8 × 1.25 11 – 20 (1.1 – 2.0/8 – 15) 15 – 28 (1.6 – 2.9/12 – 21) 18 – 34 (2.1 – 3.4/15 – 25)
M10 × 1.25 23 – 39 (2.4 – 3.9/17 – 28) 35 – 59 (3.6 – 6.1/26 – 44) 42 – 71 (4.3 – 7.2/31 – 52)
* M10 × 1.5 22 – 37 (2.3 – 3.8/17 – 28) 35 – 58 (3.5 – 5.8/25 – 42) 40 – 67 (4.1 – 6.8/30 – 49)
M12 × 1.25 55 – 82 (5.6 – 8.4/40 – 61) 77 – 117 (7.9 – 11.9/57 – 86) 85 – 128 (8.7 – 13.0/63 – 94)
* M12 × 1.75 51 – 77 (5.2 – 7.8/38 – 56) 71 – 107 (7.3 – 10.9/53 – 79) 80 – 119 (8.1 – 12.2/59 – 88)
M14 × 1.5 83 – 125 (8.5 – 12.7/62 – 92) 115 – 172 (11.7 –17.6/85 – 127) 123 – 185 (12.6 – 18.9/91 – 137)
* M14 × 2.0 77 – 116 (7.9 – 11.8/57 – 85) 108 – 162 (11.1 – 16.6/80 – 120) 116 – 173 (11.8 – 17.7/85 – 128)
M16 × 1.5 116 – 173 (11.8 – 17.7/85 – 128) 171 – 257 (17.4 – 26.2/126 – 190) 177 – 265 (18.0 – 17.1/130 – 196)
* M16 × 2.0 109 – 164 (11.2 – 16.7/81 – 121) 163 – 244 (16.6 – 24.9/120 – 180) 169 – 253 (17.2 – 25.8/124 – 187)
A bolt with an asterisk (*) is used for female screws that are made of soft materials such as cast iron.
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 8
Recommended Thread Locking

Agents
LOCTITE Type LOCTITE Color
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red
Application Steps
1. Completely remove all lubricant and moisture from the

bolts and the female-threaded surfaces of the parts to
be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
Apply LOCTITE to at least 1/3 of the

bolt's threaded area
F00RW014
3. Tighten the bolts to the specified torque.

After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until the
LOCTITE hardens.
NOTE: When the application procedures are specified in
this manual, follow them.
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 9
Main Data and Specifications

ITEMS 6HK1
Engine type Four cycle, water cooled, in-line, overhead camshaft
direct injection
Combustion chamber Open type in piston crown
Cylinder liner Dry
Timing drive system Gear drive
No. of cylinders – bore × stroke mm (in) 6 – 115 × 125 (4.53 × 4.92)
No. of piston rings Four rings (Compression rings: 3, Oil ring: 1)
Total piston displacement L (cid) 7.790 (475.4)
Compression ratio (to 1) 17.3
Compression pressure at 200 min–1
MPa (kg/cm2/psi) 3.24 (33/469) or more
Engine dimensions mm (in) 1,332 × 995 × 1,143 (52.4 × 39.2 × 45.0)
Engine weight (Dry) kg (lb) 650 (1,433)
Fuel injection order 1–5–3–6–2–4
Fuel injection timing (TDC) deg 9
Specified fuel type SAE No.2 diesel fuel
Idling speed min–1 1000
Valve clearances Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Intake valves Open at (BTDC) deg 15
Close at (ABDC) deg 44
Exhaust valves Open at (BBDC) deg 58
Close at (ATDC) deg 11
Injection pump Bosch, in-line P-Type
Governor type Mechanical
Injection nozzles Multi-hole
Injection nozzle opening pressure
MPa (kg/cm2/psi) 1st stage: 18.1 (185/2630)
2nd stage: 22.1 (225/3200)
Main fuel filter Paper element
Lubrication system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CD
Oil pressure (at oil gallery)
kPa (kg/cm2/psi)/min–1 290 – 490 (3.0 – 5.0/43–71)/2000
Condition: SAE 30 API CD grade engine oil at an
oil temperature of 80°C (176°F)
Oil pump type Gear (Timing gear drive)
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 10
ITEMS 6HK1
Relief valve opening pressure
kPa (kg/cm2/psi)
780 (8.0/114)
Oil pressure switch operating pressure
kPa (kg/cm2/psi) 29 (0.3/4)
Main oil filter Paper element
Bypass valve opening pressure
kPa (kg/cm2/psi) 200 (2.0/28.4)
Oil volume L (qts) 41 (43) with combined main and partial oil filter
Oil cooler Plate type – Water cooled in water jacket
Cooling system Pressured compulsory circulation water
Coolant volume L (qts) 14.5 (15.3)
Water pump Centrifugal impeller, gear drive
Delivery volume
Lit/min. (Imp. gal/US gal) 167 (37/44) Pump speed a 1,600 min-1
Thermostat Wax pellet
Valve initial opening temperature °C (°F) AA-6HK1XQA 82 (180)
AA-6HK1XQA-03 82 (180), with jiggle valve
76.5 (170), without jiggle valve
Valve lift mm (in) 8 (0.315)
Air cleaner
Alternator capacity V–A 24 – 50
Regulator IC (Built-in)
Brush length mm (in) Brushless
Starter motor output V – kW 24 – 5
Number of poles 4
Turbocharger model RHG 6
Manufacturer Ishikawajima-Harima Heavy Industries (IHI)
Note: Some values are different due to the difference of the models and the specifications.
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 11
Performance Curve
1. MODEL AA-6HK1XQA
Condition
Break-in period Complete Air cleaner Not installed
Cooling fan φ 850 Exhaust silencer Not installed
Alternator No load Ambient conditions Standard
1000
200 800
Torque (N·m)
600
180 400
200
160
Power output (kW)
140
120
100
80 240
SFC (g/kWh)
230
60 220
210
40
1200 1400 1600 1800 2000
Engine speed (min-1)

F06EY00111
Note: Some values are different due to the difference of the models and the specifications.
ENGINE EXTERNAL DRAWING
0A–12
MODEL AA-6HK1XQA
Cooling fan Cylinder head
300
210
F08EY00008
I/M 6HK1(H) 五面図
DOM
Owner's Manual
0 1 2 E Y 0 0 0 0 4
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 12
GENERAL INFORMATION
Cylinder head cover

Flywheel
Oil filler cap
Oil dipstick Fuel filter

Inlet pipe
Exhaust manifold Fan guide
Turbocharger
Intake duct
Alternator
Water pump
Starter motor
Oil port cover
Injection pump
Note: Some components and shapes are different due to the difference of the models and the specifications.
Oil pan Crank pulley
Flywheel housing
Oil drain plug Oil level sensor
012EY00004
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 13
Service Standards
ITEMS SERVICE STANDARD SERVICE LIMIT
Cylinder Head
Lower Face Warpage mm (in) 0.05 (0.002) or less 0.20 (0.008)
Do not regrind the lower face.
Valve Guide
Valve Stem Clearance
Intake mm (in) 0.04 – 0.06 0.20
(0.0016 – 0.0024) (0.008)
Exhaust mm (in) 0.06 – 0.10 0.25
(0.0024 – 0.0039) (0.010)
Valve Stem Outside Diameter
Intake mm (in) 7.95 – 7.96 7.89
(0.3130 – 0.3134) (0.3106)
Exhaust mm (in) 7.92 – 7.94 7.89
(0.3118 – 0.3126) (0.3106)
Valve Guide Upper End Height mm (in) 14.1 (0.56) —
Valve and Valve Seat Insert
Valve Thickness
Intake mm (in) 1.71 (0.067) 1.30 (0.051)
Exhaust mm (in) 1.75 (0.069) 1.30 (0.051)
Valve Depression
Intake mm (in) 1.0 (0.039) 2.5 (0.098)
Exhaust mm (in) 1.3 (0.051) 2.8 (0.110)
Valve Contact Width
Intake mm (in) 2.5 (0.098) 3.2 (0.126)
Exhaust mm (in) 2.0 (0.079) 2.8 (0.110)
Valve Face Angle
Intake deg 30 —
Exhaust deg 45 —
Valve Spring
Spring Height
Intake mm (in) 65.9 (2.59) 64.6 (2.54)
Exhaust mm (in) 68.1 (2.68) 66.7 (2.63)
Spring Squareness
Intake mm (in) 2.9 (0.114) 3.4 (0.134)
Exhaust mm (in) 3.0 (0.118) 3.4 (0.134)
Intake Valve Spring Tension /
Compression Height N (kg / lb) 348 (35.5 / 78) / 46
Exhaust Valve Spring Tension /
Compression Height N (kg / lb) 383 (39.0 / 86) / 46
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 14
Rocker Arm Shaft and Rocker Arm

Rocker Arm Shaft Run-Out mm (in) 0.30 (0.012)
Rocker Arm Shaft Outside Diameter
mm (in) 21.979 – 22.000 21.85
(0.865 – 0.866) (0.860)
Rocker Arm Inside Diameter mm (in) 22.010 – 22.035
(0.867 – 0.868)
Rocker Arm Shaft and
Rocker Arm Clearance mm (in) 0.010 – 0.056 0.20
(0.0004 – 0.0022) (0.008)
Rocker Arm Pin and Roller Clearance
mm (in) 0.068 – 0.099 0.50
(0.0027 – 0.0039) (0.02)
Valve Cap Worn mm (in) 0.10 (0.004)
Camshaft
Camshaft Journal Diameter mm (in) 39.950 – 39.975 39.85
(1.5728 – 1.5738) (1.5689)
Cam Lobe Height Intake mm (in) 7.851 (0.3091) 7.351 (0.2894)
Exhaust mm (in) 9.540 (0.3756) 9.040 (0.3559)
Camshaft Run-Out mm (in) 0.025 (0.001) 0.05 (0.002)
Camshaft Bearing Inside Diameter
mm (in) 40.00 – 40.037
(1.575 – 1.576)
Camshaft Bearing Clearance mm (in) 0.025 – 0.087 0.15
(0.001 – 0.003) (0.006)
Crankshaft
Crankshaft End Play mm (in) 0.040 – 0.205 0.54
(0.0026 – 0.008) (0.021)
Crankshaft Run-Out mm (in) 0.06 (0.002) or less 0.45 (0.016)
Crankshaft Journal Diameter
See section 6A crankshaft
journal diameter in this
manual.
Crankshaft Journal and
Bearing Clearance mm (in)
No. 4 Bearing 0.093 – 0.124 0.14
(0.00366 – 0.00488) (0.0055)
Other Bearings 0.063 – 0.094 0.14
(0.00248 – 0.00370) (0.0055)
Crankshaft Journal and
Crankpin Uneven Wear mm (in) 0.05 (0.0020)
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 15
Piston and Piston Ring

Piston Grade Non
Cylinder Liner and Piston Clearance
mm (in) 0.122 – 0.156 —
(0.0048 – 0.0061)
Piston Ring and Piston Ring
Groove Clearance mm (in)
1st Compression Ring 0.057 – 0.097 0.20
(0.0022 – 0.0038) (0.008)
2nd and 3rd Compression Ring 0.085 – 0.120 0.20
(0.0033 – 0.0047) (0.008)
Oil Ring 0.02 – 0.06 0.15
(0.0008 – 0.0024) (0.006)
Piston Ring Gap mm (in)
1st Compression Ring 0.18 – 0.28 1.20
(0.0071 – 0.0110) (0.047)
2nd and 3rd Compression Ring 0.35 – 0.50 1.20
(0.0138 – 0.0197) (0.047)
Oil Ring 0.15 – 0.35 1.20
(0.0059 – 0.0138) (0.047)
Piston Pin
Piston Pin Diameter mm (in) 35.995 – 36.000 35.95
(1.4171 – 1.4173) (1.4154)
Piston Pin Hole Diameter mm (in) 36.004 – 36.012
(1.4175 – 1.4178)
Piston Pin and Piston Pin
Hole Clearance mm (in) 0.004 – 0.017
(0.00016 – 0.00067)
Connecting Rod
Connecting Rod Alignment mm (in) 0.05 (0.002) or less 0.20 (0.008)
Connecting Rod Small End
Bushing Diameter mm (in) 36.012 – 36.022
(1.4178 – 1.4182)
Piston Pin and Connecting Rod
Small End Bushing Clearance mm (in) 0.012 – 0.027 0.05
(0.00047 – 0.00106) (0.002)
Crankpin and Bearing Clearance
mm (in) 0.037 – 0.076 0.10
(0.0015 – 0.0030) (0.004)
Connecting Rod Big End and
Crankpin Side Face Clearance mm (in) 0.17 – 0.30 0.35
(0.0067 – 0.0118) (0.014)
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 16
Flywheel
Flywheel Friction Surface Roughness
mm (in) Less than
0.05 (0.0020)
Idler Gear
Idler Gear Shaft A
Outside Diameter mm (in) 49.950 – 49.975 49.90
(1.9665 – 1.9675) (1.9646)
Idler Gear Shaft B and C
Outside Diameter mm (in) 29.959 – 29.980 29.9
(1.1795 – 1.1803) (1.1772)
Idler Gear Shaft A and
Idler Gear Clearance mm (in) 0.025 – 0.075
(0.00098 – 0.00295)
Idler Gear Shaft B and C and
Idler Gear Clearance mm (in) 0.020 – 0.062 0.20
(0.0008 – 0.0024) (0.008)
Idler Gear Backlash mm (in) 0.10 – 0.17 0.30
(0.0039 – 0.0067) (0.012)
Idler Gear End Play
Gear A and B mm (in) 0.08 – 0.140 0.20
(0.00315 – 0.0052) (0.008)
Gear C mm (in) 0.07 – 0.135 0.20
(0.0027 – 0.0053) (0.008)
Oil Pump
Gear Teeth and Cover
Inner Wall Clearance mm (in) 0.125 – 0.221 0.221
(0.0049 – 0.0087) (0.0087)
Gear and Body Clearance mm (in) 0.064 – 0.109 0.109
(0.0025 – 0.0043) (0.0043)
Gear Shaft Outside Diameter mm (in) 15.989 – 16.000 15.9
(0.6295 – 0.6299) (0.626)
Gear Shaft and Pump Body or
Bushing Clearance mm (in) 0.04 – 0.07 0.07
(0.0016 – 0.0028) (0.0028)
Drive Gear and Drive Gear
Shaft Interference mm (in) 0.015 – 0.044
(0.0006 – 0.0017)
Cylinder Block
Cylinder Block Upper Face Warpage
mm (in) 0.05 (0.002) or less 0.20 (0.008)
Cylinder Liner Projection mm (in) 0.06 – 0.10 —
(0.0024 – 0.0039)
Cylinder Block Bore and
Cylinder Liner Outside
Diameter Clearance mm (in) 0.001 – 0.029 —
(0.00004 – 0.0011)
Cylinder Liner Grade (Reference)
See Section 6A (Cylinder liner
grade selection & Clearance)
in this manual.
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 17
Torque Specifications
Auxiliary Parts N·m (kgf·m/lb ft)
40(4.1/30)
97(9.9/72)
39(4.0/29)
Cooling fan
40(4.1/30)
40(4.1/30)
83(8.5/61)
Starter
F06EY00104
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 18
Engine External Parts

N·m (kgf·m/lb ft)
39(4.0/29) 19(1.9/14)
Fuel filter Oil cooler
88(9.0/65)
Coupling
39(4.0/29)
Oil port cover
44(4.5/32)
Injection pump
52(5.3/38)
Turbocharger
F06EY00105
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 19
Cylinder Head
N·m (kgf·m/lb ft)
13(1.3/9.4)
27(2.8/20)
56(5.7/41)
142(14.5/105)
27(2.8/20)
27(2.8/20) 12(1.2/8.7)
Apply engine oil
30(3.1/22)
M14: 98(10/72)}→147(15.0/108)
Apply molybdenum →30°∼60°
disulfide grease M10: 38(3.9/28)
M14: Apply molybdenum
20(2.0/14) disulfide grease
M10: Apply engine oil
Apply engine oil
Apply ThreeBond
No1207B
Apply ThreeBond
No1207C
52168A
01/01/10
一般輸
Workshop
F06EY00143
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 20
Cylinder Head
N·m (kgf·m/lb ft)
Apply engine oil
Apply engine oil
95(9.7/70)
48(4.9/35)
48(4.9/35)
15(1.5/11)
20(2.0/14)
19(1.9/14)
Apply engine oil
20(2.0/14)
52(5.3/38)
34(3.5/25)
54416A
01/6/28
DOM
W k F06E100074
h M
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 21
Oil Pan
N·m (kgf·m/lb ft)
24(2.4/17)
48(4.9/35)
25(2.5/18)
25(2.5/18)
52168A 粟田
01/01/10 01/01/12
FS
一般輸出
Workshop ManualF06EY00144
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 22
Timing Gears
N·m (kgf·m/lb ft)
Apply engine oil
Apply engine oil
29(3.0/22)→60-90°
Apply molybdenum
disulfide grease Apply engine oil
24(2.4/17)
Apply engine oil 95(9.7/70)
Apply ThreeBond No.TB1201
Apply ThreeBond No TB1201

31(3.2/23)
Apply engine oil
78(8.0/58)→60°→60-90°
Apply molybdenum
disulfide grease
119(12.1/88)
54416A
01/6/28
DOM
Workshop
F 0 6 E 1 0
F06E100075
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 23
Water Pump
N·m (kgf·m/lb ft)
39(4.0/29)
20(2.0/14)
240(24/174)
20(2.0/14)
20(2.0/14) 20(2.0/14)
52(5.3/38)
54416A F06E100076
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 24
Piston, Connecting Rod and Crankshaft

N·m (kgf·m/lb ft)
Apply ThreeBond No1207C
Apply molybdenum
disulfide grease
Apply engine oil
19(1.9/14)
39(4.0/29)→60 →30-60
Apply molybdenum
21(2.1/15) disulfide grease
48(4.9/35)
200(20.4/148)
Apply engine oil
Apply engine oil
M14: 98(10.0/72)→132(13.5/98)→30-60°
M10: 37(3.8/27)
M14: Apply molybdenum

disulfide grease Apply ThreeBond No1207B
PAW0Z0LF001601
PAW0Z0LF001601
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 25
Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME
8-94396-858-0 8-94396-819-0
Replacer; Slinger Installer; Crankshaft gear
901LX049
5-88402-627-0
8-94396-856-0
Installer; Cylinder head
Setting tool; Oil seal
oil seal
5-8840-2621-0 5-8840-2623-0
Remover; Valve spring Remover; Nozzle sleeve
901MW002
5-8840-2628-0
5-8840-2624-0
Remover/Installer;
Installer; Nozzle sleeve
Valve guide
011EY00037
1-85221-029-0 5-8840-2626-0
Setting tool; Piston ring Installer; Bridge guide
901MX007
5-8840-2625-0
8-94396-818-0
Installer; Valve guide
Remover; Crankshaft gear
oil seal
901LX048
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 26
Troubleshooting
1. Hard starting
Condition Possible Cause Correction
Starter motor does not turn over Loose battery cable terminals
Poor battery connections due to rusting Clean and/or retighten the battery cable
terminals
Battery discharged or weak Recharge or replace the battery
Fusible link shorted Replace the fusible link
Defective starter switch or starter relay Replace the starter switch or starter relay
Defective magnetic switch of starter Repair or replace the magnetic switch
motor or starter relay or starter relay
Defective starter motor Repair or replace the starter motor
Starter motor operates but Loose battery cable terminals
engine does not turn over Poor battery connections due to rusting Clean and/or retighten the battery cable
terminals
Battery discharged or weak Recharge or replace the battery
Loose fan belt Adjust the fan belt tension
Defective starter motor pinion gear Replace pinion gear
Defective magnetic switch of the starter Repair or replace the magnetic switch
motor
Worn starter motor Replace the brush and /or brush spring
Weak brush spring
Piston,crank bearing seizure,or other Repair or replace the related parts
damage
Engine turns over but does not Air in the fuel system Bleed air from the fuel system
start Defective engine stop mechanism Replace the engine stop mechanism
Control wire improperly adjusted Adjust the control wire
Fuel tank is empty Fill the fuel tank
Clogged or damaged fuel lines Repair or replace the fuel lines
Loose fuel line connections Retighten the fuel line connections
Clogged fuel filter element Replace the fuel filter element or cartridge
Fuel feed pump strainer is clogged Clean the fuel pump strainer
Defective feed pump Repair or replace the feed pump
Poor return of the engine stop button Completely return the engine stop button
Use of the wrong fuel Use the recommended fuel
Water particles in the fuel Change fuel
Air in the injection pump Bleed air from the fuel system
Injection nozzle sticking Replace the injection nozzle
Injection nozzle starting pressure too low Adjust or replace the injection nozzle
Improper spray condition
Improper injection pump control rack Repair or replace the injection pump
operation control rack
Injection pump plunger worn or stuck Replace the injection pump plunger
assembly
Injection pump camshaft seizure or Replace the injection pump camshaft
other damage
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 27
2. Unstable Idling
Trouble in the engine stop Poor return of the engine stop button Completely return the engine stop
mechanism button
Trouble in the fuel system Fuel system leakage or blockage Repair or replace the fuel system
Air in the fuel system Bleed the air from the fuel system
Water particles in the fuel Replace fuel
Clogged fuel filter element Replace the fuel filter element or
cartridge
Injection nozzle starting pressure too Adjust or replace the injection nozzle
low
Defective delivery valve resulting in fuel Replace the delivery valve
drippage after fuel injection
Injection timing improperly adjusted Adjust the injection timing
Insufficient injection volume Adjust the injection volume
Broken plunger spring of the injection Replace the plunger spring
pump
Worn plunger of the injection pump Replace the plunger assembly
Worn camshaft of the injection pump Replace the camshaft
Worn roller tappet of the injection pump Replace the roller tappet
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the valve clearance
Worn camshaft Replace the camshaft
Low compression pressure Blown out cylinder head gasket Replace the related parts
Worn cylinder liner
Piston ring sticking or broken
Improper seating between the valve and
valve seat
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 28
3. Insufficient Power
Trouble in the air intake system Clogged air cleaner element Clean or replace the air cleaner element
Trouble in the fuel system Water particles in fuel system Replace fuel
Clogged fuel filter element Replace the fuel filter element or
cartridge
Clogged strainer or defective fuel feed Repair or replace the feed pump
pump
low
Improper spray condition Adjust or replace the injection nozzle
Fuel injection pipes damaged or Replace the injection pipes
obstructed
Defective delivery valve Replace the delivery valve
Repair or replace the timing advancer
Worn plunger of the injection pump Replace the plunger assembly
Worn camshaft of the injection pump Replace the camshaft
Trouble in the turbocharger Exhaust gas leakage from the exhaust Repair or replace the related parts
system system
Air leakage from the intake system Repair or replace the related parts
Defective turbocharger assembly Replace the turbocharger assembly
Worn cylinder liner
valve seat
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the valve clearance
Worn camshaft lobe Replace the camshaft
Valve spring weak or broken Replace the valve spring
Trouble in the intercooler Clogged intercooler Clean the intercooler
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 29
4. Excessive Fuel Consumption

Trouble in the fuel system Fuel leakage Repair or replace the fuel system
related parts
low
Improper spray condition Adjust or replace the injection nozzle
Trouble in the air intake system Clogged air cleaner element Clean or replace air cleaner element
Improper idle speed Poorly adjusted idling speed Adjust idling speed
Trouble in the cooling system Defective thermostat Replace
Trouble in the lubricating system Improper engine oil viscosity Replace engine oil
Trouble in turbocharger system Air leakage from the turbocharger intake Repair the turbocharger intake side
side
Defective turbocharger assembly Replace the turbocharger assembly
Worn cylinder liner
valve seat.
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the camshaft
Worn camshaft lobe Replace the camshaft
Valve spring weak or broken Replace the valve spring
5. Excessive Oil Consumption

Trouble in the lubricating system Engine oil unsuitable Replace engine oil
Too much engine oil Correct engine oil volume
Leakage Oil leakage from the oil seal and/or Replace the oil seal and/or gasket
gasket
Oil leaking into the combustion Worn valve stems and valve guides Replace the intake and exhaust valves
chamber due to poor seal in the and valve guides
valve system Worn valve stem oil seal Replace the oil seal
Improper sealing Worn or broken seal ring in the Replace the seal ring
turbocharger
Worn cylinder liner
valve seat.
Poor engine ventilation Clogged air breather Clean the air breather
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 30
6. Engine Cooling Trouble

Overheating Insufficient coolant Replenish coolant
Defective pressure cap or clogged Replace the radiator pressure cap or
radiator core clean radiator core
Defective water pump Repair or replace the water pump
Defective sealing cap resulting in the Replace the sealing cap
cooling water leakage
Defective thermostat Replace the thermostat
Cooling system clogged by foreign Remove foreign material from the
material cooling system
Fuel injection timing improperly Adjust the fuel injection timing
adjusted
7. White Exhaust Smoke

Trouble in the fuel system Water particles in fuel Replace the fuel
Retarded fuel injection timing Adjust the fuel injection timing
Worn cylinder liner
valve seat.
Trouble in the cooling system Defective thermostat Replace the thermostat
Trouble in the turbocharger Defective turbocharger Repair or replace
system
8. Black Exhaust Smoke

Trouble in the fuel system Clogged air cleaner element Clean or replace the air cleaner element
Trouble in the fuel injection Injection nozzle starting pressure tool Adjust or replace the injection nozzle
system low
Advanced fuel injection timing Adjust the fuel injection timing
Excessive injection volume Adjust the injection volume
Trouble in the valve train Worn camshaft lobe Replace the camshaft
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 31
9. Lubrication Problems
Oil pressure does not rise Improper engine oil viscosity Replace the engine oil
Insufficient engine oil Add engine oil
Defective oil pressure gauge or unit Repair or replace the oil pressure gauge
or unit
Clogged oil filter element Replace the oil filter element or
cartridge
Relief valve sticking and/or weak by- Replace the relief valve and/or by-pass
pass valve spring valve spring
Clogged oil pump strainer Clean the oil pump strainer
Worn oil pump related parts Replace the oil pump related parts
Worn rocker arm bushing Replace the rocker arm bushing
Worn camshaft and camshaft bearing Replace the camshaft and camshaft
bearing
Worn crankshaft and bearings Replace the crankshaft and/or bearing
Oiling jet valve does not close Replace the oiling jet
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 32
10. Abnormal Engine Noise

Start the engine and allow it to warm up before beginning the troubleshooting procedure.

Engine knocking Use of wrong fuel Use correct fuel
Fuel injection timing improperly Adjust the injection timing
adjusted
Improper injection nozzle starting Adjust or replace the injection nozzle
pressure
Broken piston ring resulting in low Replace the piston ring
compression pressure
Defective fuel injection nozzle resulting Replace the fuel injection nozzle
in fuel drippage after fuel injection
Gas leakage noise Loosely connected exhaust pipes Tighten the exhaust pipe connections
Broken exhaust pipes Replace the exhaust pipes
Loose injection nozzles and/or glow Tighten the injection nozzles and/or
plugs glow plugs
Replace the washers
Loosely connected exhaust manifold Tighten the exhaust manifold
connections
Damaged cylinder head gasket Replace the cylinder head gasket
Continuous noise Loose fan belt Readjust the belt tension
Loose cooling fan Retighten cooling fan
Worn or damaged water pump bearing Replace the water pump bearing
Worn or damaged alternator bearing Replace the alternator bearing
Valve clearance improperly adjusted Adjust the valve clearance
Slapping noise Valve clearance improperly adjusted Adjust the valve clearance
Damaged rocker arm Replace the rocker arm
Worn or damaged crankshaft and/or Replace the crankshaft and/or thrust
thrust bearings bearings
Worn or damaged crankshaft and/or Replace the crankshaft and/or
connecting rod bearings connecting rod bearings
Worn or damaged connecting rod Replace the connecting rod bushing
bushing and piston pin and/or piston pin
Worn or damaged piston and cylinder Replace the piston and cylinder liner
liner
Foreign material in the cylinder
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 33
11. Alternator
Battery dead Loose alternator drive belt Adjust
Low battery fluid Replenish
Defective battery terminals Replace
Blown fuse Replace
Poor contact between the fuse holder Repair
and fuse
Low battery fluid specific gravity Adjust
Broken or poorly connected starter Repair
switch and regulator terminal wire
Broken or poorly connected regulator Repair
terminal and alternator terminal wire
Defective alternator ground circuit Repair
Defective voltage regulator Replace
Defective diode Replace
Grounded or broken alternator stator Repair or replace
coil
Broken rotor coil Replace
Excessive electrical load Check the alternator output at normal
operating speed
Battery overcharged Poor connections or open circuit Correct
Poor ground connection of voltage Correct
regulator
Voltage set of regulator too high Replace
Defective voltage regulator Replace
Flashing charge light or Loose belt Adjust
fluctuating ammeter indication Defective starter switch contacts Replace
Broken or poorly connected wiring Replace or reconnect
Charge light on but dim during Loose starter switch terminal wiring Retighten
operation Excessive resistance of alternator and Replace the wire with a larger one
fuse holder terminal wire
Defective starter switch contacts Replace
Alternator noise Defective alternator bearing Replace or regrease
Exposed stator coil wires Replace
Short circuit of the stator coil Replace
Charge circuit fuse blown Grounded terminal wiring Repair
Defective alternator end flame diode Replace the end flame assembly
Out of voltage regulator adjustment Replace
Reversed battery connections Correct
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 34
12. Starter Motor

Starter and magnetic switch Low battery fluid level Replenish
does not operate Low battery specific gravity Recharge or replace
Poor battery switch contacts Replace
Defective starter switch Replace
Defective magnetic switch pull-in coil Replace
and plunger
Broken armature coil Replace
Broken field coil Replace
Broken magnetic switch Replace
Broken holding coil Replace
Magnetic switch operates but Low battery fluid level Replenish
the starter does not turn Low battery specific gravity Recharge or replace
Poor starting circuit contacts Repair
Poor contacts of magnetic switch Replace
terminal
Worn brushes Replace
Shorted armature Repair or replace
Starter runs slowly Bad contact of magnetic terminal circuit Repair
switches
Excessive brush wear Replace
Shorted starter motor armature Repair or replace
Starter operates but the engine Pinion and ring gear not engaged Repair or replace the running clutch and
does not start driving lever
Overrunning clutch slippage Replace
Abnormal operating noise Excessive bushing wear Replace
Excessive pinion gear wear Replace overrunning clutch and pinion
gear
Rough sliding action pinion gear Lubricate or replace the overrunning
clutch
Excessive ring gear wear Replace overrunning clutch and ring
gear
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 35
13. Turbocharger
Engine has less than normal Restricted air cleaner Clean or replace
power Restricted intake pipe and hose Clean or replace
Loose connection of the turbocharger inlet and Repair
outlet
Restricted exhaust and silencers Repair
Restricted air breather Clean or replace
Compressor wheel damage Replace
Turbine wheel damage Replace
Carbon build-up on the turbine wheel Replace
Dragging or seized rotating assembly Replace
Blue or black smoke Restricted air cleaner Clean or replace
Leakage from turbocharger oil seal Replace
Restricted turbocharger oil drain pipe Repair or replace
Restricted air breather Clean
Restricted center housing oil drain passage Clean or replace
Excessive oil consumption Restricted air breather Clean
Leakage from turbocharger oil seal Replace
Excessive oil pressure Repair
Excessive turbocharger noise Restricted intake and exhaust system joints Repair
Damaged intake and exhaust system gaskets Repair
Rough rotation of turbocharger parts Replace
Compressor wheel rubbing against housing Replace
Damaged compressor wheel Replace
Turbine wheel rubbing against housing Replace
Damaged turbine wheel Replace
Carbon build-up on the turbine wheel Clean or replace
Low engine oil level Correct
Contaminated oil Replace oil
Restricted turbocharger oil feed pipe Repair or replace
Carbon build-up on the turbine housing Clean
Dirty compressor housing Clean
Worn turbine shaft bearings Replace
Excessive rotating part wear Contaminated engine oil Change
Wrong grade or type of engine oil Change
Restricted turbocharger oil feed pipe Clean or replace
Defective turbocharger oil seal Replace
Turbine shaft sludge and/or coking Replace
Inadequate oil supply Correct
69945_ESS-185A_SEC0A 2011.8.10 1:37 PM ページ 36
Lubricant Application
Name of Lubricant Lubrication area
Engine Oil Turbocharger bearings

Cylinder head bolts (M10 bolt)
Rocker arm rollers
Camshaft cam nose and journal
Camshaft fixing bolts and stud bolts
Valve ends
Oil seal lips
Idle gear shaft & fixing bolts
Cylinder liner bores
Connecting rod bearing sliding surfaces
Crank bearing sliding surfaces
Thrust bearings
Piston rings
Molybdenum disulfide grease Cylinder head bolts
Crankcase fixing bolts
Flywheel bolts
Connecting rod bolts
Piston skirts
Sealant Application
Location
Name of sealant
Name of part Name of mating part
1 Rubber plug Cylinder head & cover
ThreeBond No. 1207B
2 Crankcase Cylinder block
3 Oil cooler Cylinder block
4 Cylinder block Flywheel housing
ThreeBond No. 1207C or No.1216C
5 Cylinder block Front cover
6 Water pump Front cover
7 Oil pump Cylinder block ThreeBond No. 1207C or TB1141E
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 1
SERVICE INFORMATION 0B–1
GENERAL INFORMATION
SERVICE INFORMATION
CONTENTS
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . 0B-6
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-2 Compression Pressure Measurement . . . . . . . . . . . 0B-8
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-2 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . 0B-9
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-6 Engine Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . 0B-9
Identification
Engine Serial Number
The engine serial number is stamped on the front of the cylinder block.
Engine model & serial No.
Engine model Serial number
6HK1 000000
F06EY00016
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 2
0B–2 SERVICE INFORMATION
Lubrication System 2. Before installing a new fuel filter, apply fuel to the
gasket of the cartridge.
Oil filter replacement 3. Turn the fuel filter until the filter gasket comes in
The oil filter is mounted on the equipment side. contact with the sealed face.
1. Set a filter wrench to the cartridge and remove the oil 4. Use the filter wrench to turn in the fuel filter an
filter. additional 2/3 of a turn.
Discard the used cartridge.
2. Before installing the new oil filter, apply engine oil to
the gasket of the cartridge.
3. Turn the oil filter until the filter gasket comes in contact
with its sealed face.
4. Use the filter wrench to turn in the oil filter an additional
one full turn.
Cartridge
Set the filter

wrench here
NOTE: Be careful not to spill the fuel remaining in the fuel
filter when the filter is removed. After changing the fuel
filter element, conduct fuel air bleeding and check for fuel
leaks.
Injection Timing Adjustment

050EY00063
Injection Timing Inspection

Fuel System 1. Disconnect the negative battery cable.
Fuel filter replacement procedure 2. Rotate the crankshaft in the normal direction of engine
rotation to align the injection timing mark on the
1. Use a filter wrench to remove the cartridge.
damper with the timing pointer on the front cover.
Discard the used cartridge.
• Injection Timing (Static-TDC): 9 degree
Cartridge
Pointer
Set the filter
wrench here
Drain plug
041EY00019
020EY00006
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 3
3. Check that the timing advancer notched line is aligned

with the injection pump notched line.
If the notched lines are out of alignment, the injection
timing must be adjusted.
040EY00013
4. Move the timing advancer to the correct timing.

5. Tighten the two coupling bolts.
Torque: 88 N·m (9.0 kgm)
040EY00016
6. Rotate the crankshaft two turns in the normal direction
of engine rotation.
Injection Timing Adjustment
7. Verify the new setting is the correct injection timing.
1. Rotate the crankshaft in the normal direction of engine
8. Connect the negative battery cable.
rotation until the timing mark on the timing advancer
can be seen.
2. Align the injection timing mark on the damper with the
pointer on the front cover.
Pointer
040EY00016
020EY00006
3. Loosen the two coupling bolts.

69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 4
Injection Nozzle
Opening Pressure and Spray Condition
Check
1. Use an injection nozzle tester to check the nozzle
opening pressure. 1 2 3
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or
adjusted.
Refer to “Adjustment of Injection Nozzle Opening
Pressure.”
Injection Nozzle Opening Pressure:
1st stage: 18.1 MPa (185 kg/cm2 / 2630 psi)
2nd stage: 22.1 MPa (225 kg/cm2 / 3200 psi)
040EY00030
Nozzle tester Injection Nozzle Adjustment

Nozzle holder
Refer to “Injection Nozzle” in this manual.
040MV030
WARNING:
Test fluid from the injection nozzle tester will spray
out of the injection nozzle under great pressure. It can
easily puncture a person’s skin.
Keep your hands away from the injection nozzle at all
times.
2. Check the spray condition.

If the spray condition is bad, the injection nozzle must
be replaced or reconditioned.
(1) Correct
(2) Incorrect (Restrictions in orifice)
(3) Incorrect (Dripping)
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 5
Air Bleeding Feed pump strainer

When the fuel filters are serviced or the fuel tank emptied, 1. Remove the joint bolt (feed pump intake side).
air enters the fuel system. 2. Remove the strainer by turning it counterclockwise.
The air will block the smooth flow of fuel to the engine. It 3. Clean the strainer.
must be removed by bleeding the fuel system. 4. Reinstall the strainer and joint bolt.
1. Loosen the priming pump cap. 5. Bleed the fuel system (refer to the previous item).
2. Manually operate the priming pump (1) to force fuel
into the injection pump.
040EY00011
1
042EY00016
Fuel tank draining
3. Use a wrench to loosen the air plug (2) on the fuel filter. 1. Remove the drain plug at the bottom of the fuel tank.
4. Operate the priming pump until there are no bubbles 2. Allow sufficient time for the sediment and water to
in the fuel being discharged from the air plug (the fuel drain completely.
is discharged in a solid stream).
3. Reinstall the drain plug.
5. Tighten the priming pump cap and the air plug.
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 6
Cooling System Valve Clearance Adjustment

Fan Belt Inspection The following instructions assume that valve clearance is
adjusted beginning with the No. 1 piston at top dead
Check the drive belt tension.
center (TDC) on the compression stroke.
Depress the drive belt mid-portion with a 100 N (10kg/22
Check the alignment timing mark between the timing
lb) force.
advancer and the mark line on the injection pump body.
Drive Belt Deflection
If the timing marks are aligned, the No. 1 piston is at TDC
Single belt: 8 – 11 mm (0.31 – 0.43 in) on the compression stroke.
Scrum belt: 6 – 8 mm (0.23 – 0.31 in) Valve clearance must be adjusted when the engine is
cold.
When removing the head cover, wipe off spilled oil with a
rag.
1. Bring the piston in the No. 1 or No. 6 cylinder to the
top dead center on the compression stroke by turning
Water pump the crankshaft until the T.D.C. line on the damper is
Alternator aligned with the timing pointer on the front cover.
Check the rocker arm shaft bracket nuts for looseness
and retighten as necessary before adjusting the valve
clearance.
Crankshaft
Pointer
033EY00004
Check the drive belts for cracking and other damage.
020EY00006
2. Check that the No. 1 intake and exhaust rocker arms

have play. If they have play, it indicates that the No. 1
piston is at TDC (Top Dead Center) on the
compression stroke. If the No. 1 exhaust valves are
depressed, the No. 6 piston is at TDC on the
compression stroke.
3. Adjust valve clearances for the No. 1 or No. 6 cylinder
which its piston is at TDC on compression stroke.
1. Loosen each adjusting screw on the bridge and
033EY00009 rocker arm.
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 7
Valve Clearance: 0.4 mm (0.0016 in) 4. In this condition, the opposite end of the bridge is
2. Insert a feeler gauge between the rocker arm and raised. Readjust by loosening the adjusting screw
the bridge and adjust the valve clearance by on the bridge until there is a slight drag on the
turning the adjusting screw on the rocker arm until feeler gauge. Tighten the lock nut securely.
there is a sight drag on the feeler gauge. Tighten
the lock nut securely.
No.1 cylinder T. D. C.
(compression stroke)
1 2 3 4 5 6
I E I E I E I E I E I E
Front
014EY00178
4. Rotate the crankshaft 360 degrees and realign the

014MV001
T.C. mark on the flywheel with the pointer. Adjust
clearance for remaining valves.
The “●” mark in the illustration indicates the cylinders
and valves to be adjusted.
Gauge
No.6 cylinder T. D. C.
(compression stroke)
1 2 3 4 5 6
I E I E I E I E I E I E
Front
014MX032
3. With a feeler gauge inserted, screw in the

adjusting screw on the bridge gradually until it 014EY00179
touches the end of the valve stem. Make sure that

the movement of the feeler gauge becomes stiff. NOTE: Be sure to move the No. 1 cylinder to TDC on the
compression stroke after completing the valve clearance
adjustment procedure.
Torque: 22 N·m (2.2 kg·m/16 lb·ft)
Rocker Arm Adjusting Screw Nut
Torque: 22 N·m (2.2 kg·m/16 lb·ft)
Bridge Adjusting Screw Nut
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 8
Intake and Exhaust Valve Arrangement

Cylinder No. 1 2 3 4 5 6
Valve Names I E I E I E I E I E I E
No. 1 cyl. at TDC on compression ● ● ● ● ● ●
No. 6 cyl. at TDC on compression ● ● ● ● ● ●
I : Intake valve. E: Exhaust valve
Compression Pressure Measure

To measure the compression pressure, the engine must
be cold. Engine coolant temperature should be at 20°C.
Battery and starter motor condition must be normal.
1. Remove the glow plug and the injection fuel pipe from
each cylinder.
2. Install the compression gauge adapter 5-8840-2622-
0 to the glow plug installation hole.
3. Install the compression gauge to the compression
gauge adapter.
040EY00003
4. Crank the engine with starter motor (about 200 min–1)

and take the compression gauge reading.
5. Repeat the procedure (Steps 2 to 4) for the remaining
cylinders.
Compression Pressure
Standard : 3.24 MPa (33 kg/cm2 / 470 psi)
Limit : 2.26 MPa (23.0 kg/cm2 / 327 psi)
Compression pressure should be approximately the
same for each cylinder.
A variation exceeding 200 kPa (2.0 kg/cm2 / 28 psi) is
unacceptable.
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 9
Recommended Lubricants
ENGINE TYPE TYPE OF LUBRICANT (API)
Diesel engine oil

With or without turbocharger
CD grade
Engine Oil Viscosity Chart
ENGINE OIL VISCOSITY GRADE-AMBIENT TEMPERATURE
[Single grade]
SAE 20,20W SAE 40,50
SAE 10W SAE 30
Ambient -30ºC -15ºC -0ºC 15ºC 25ºC 30ºC

temperature (-22ºF) (0ºF) (32ºF) (60ºF) (80ºF) (90ºF)
[Multi-grade] SAE 10W-30
SAE 15W-40,20W-40,20W-50
F00EY00006
69945_ESS-185A_SEC0B 2011.8.5 2:53 PM ページ 10
MEMO
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 1
ENGINE MECHANICAL 6A–1
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . 6A Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . 6D3
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B Engine Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . 6G
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C Engine Induction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
ENGINE MECHANICAL
CONTENTS
Service Precautions. . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41
General Description. . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-45
Engine Cleanliness and Care . . . . . . . . . . . . . . . 6A-2 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-48
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54
Engine Components . . . . . . . . . . . . . . . . . . . . . . 6A-2 Crank Pulley and Flywheel . . . . . . . . . . . . . . . . . 6A-62
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-63
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-64
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-64
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Intake Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-67
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-68
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . 6A-71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-72
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-76
Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-78
Bearing Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-85
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91
Rocker Arm and Shaft Assembly. . . . . . . . . . . . . 6A-23 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-94
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-28 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-101
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-32 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-107
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-36 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-108
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-37 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-109
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-39
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 2
6A–2 ENGINE MECHANICAL
Service Precautions • After removing the intake air duct or air cleaner,
immediately cover the intake opening with a clean
• Be sure to use the correct fastener in the proper cloth. This prevents the entry of foreign material
location. If a used fastener is replaced with a new one, capable of causing serious engine damage.
the new fastener must be identical to the previous
one.
Engine Components
• Some fasteners must always be replaced with new
ones following removal. These fasteners are specified The 6HK1 engine is a 4-cycle, 6-cylinder in-line, diesel
in this Manual. engine with direct fuel injection. Engine displacement is
7.79 liters (475 cubic inches).
• Some fasteners require thread locker or thread
The engine uses a gear-driven overhead camshaft
sealant. These fasteners are specified in this Manual.
timing train.
• Supplemental fastener coatings (paint, grease, or The engine is quiet, economical, and durable.
corrosion inhibitor) affect fastener torque and
clamping force. They may damage the fastener. Do
Cylinder Head
not use them unless specifically called for.
• Tighten all fasteners to the specified torque. If there is The cross-flow cylinder head is constructed of cast iron.
a tightening sequence, follow it exactly. The intake system is at the left side of the engine and the
exhaust system is at the right side. This configuration
reduces resistance in the two systems.
General Description A laminated cylinder head gasket is used to minimize
fatigue. The head and gasket are secured to the block
Engine Cleanliness and Care using the angular tightening method. This provides a
An industrial engine is a combination of many machines reliable seal against gas and water leakage.
that have been honed and polished. Tolerances are
measured in 1,000ths of millimeters (10,000ths of Cylinder Block and Cylinder Liners
inches). The cast iron cylinder block has 7 bearings. Bearing
When servicing engine assemblies and parts, care and caps have a ladder frame construction to integrate them
cleanliness are extremely important. Proper cleaning with the crankcase and increase engine rigidity.
and the protection of friction areas and delicate parts are Cylinder liners are constructed of very thin, special-use
part of the service procedure. iron alloys. In combination with the chrome-plated 1st
and 3rd piston rings, they provide excellent wear
• Apply engine oil to all friction areas during reassembly resistance.
to provide protection and lubrication when the engine
is started.
Pistons
• When valve train components, pistons, piston rings,
connecting rods, connecting rod bearings, and The aluminum alloy pistons have a ring trigger cast into
crankshaft bearings are removed, they must be the 1st ring groove. The outer sliding surface of the 1st
reinstalled to their original positions. To ensure this, and 3rd piston rings are chrome plated to provide
mark the parts at disassembly and store them neatly. strength and wear resistance.
• Disconnect battery cables before working on the
engine. This prevents damage to wire harnesses and Crankshaft
other electrical parts. The forged steel crankshaft is soft nitride treated for
• Engine cylinders are numbered 1-2-3-4-5-6 from the additional strength. The 7 bearings together with the 4
front of the engine (crankshaft pulley) to the rear counterweights result in reduced bearing rotational load.
(flywheel).
Gear Train
Engine Service (General information) The gear train is at the rear of the engine (flywheel side).
Read the following carefully to avoid engine damage This minimizes torsion vibration from the crankshaft and
and ensure reliable engine performance and a long reduces noise.
service life. To further reduce noise, the crankshaft gear is shrink-
• The electrical system is capable of damaging delicate fitted to the crankshaft. Precise gear arrangement, gear
electrical circuits. Be absolutely certain that the ratio, backlash, and bearing rigidity also contribute to a
ground cable is disconnected at the battery when quieter engine.
servicing the engine.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 3
Combustion Chambers
Isuzu’s unique combustion chamber design provides
easy starting, maximum power output, and operating
economy.
Direct fuel injection is used. Each cylinder has an
injection nozzle placed precisely at the center of the
cylinder.
Intake ports generate maximum swirl effect for the air-
fuel mixture. Exhaust ports provide minimum exhaust
resistance.
Valve Arrangement
Each cylinder has 2 intake valves and 2 exhaust valves.
The intake valves use Isuzu’s unique inlet ports to
provide high efficiency and complete combustion.
The exhaust valves are connected to a single exhaust

port.
Lubricating System
All moving engine parts are lubricated by a gear pump
pressure circulation system.
Oil is pumped from the crankcase through the oil filter to
the oil cooler where it is cleaned. From the oil cooler, the
oil travels to the cylinder block main oil gallery from
where it circulates to lubricate the engine parts.
Oil jets in the oil gallery spray oil to the inside surfaces of
the pistons to provide optimum lubrication and cooling.
Oil Pump and Oil Filter

The gear-type oil pump with relief valve is driven by the
timing gear.
A full-flow oil filter with a highly efficient paper element is
used.
If the oil filter element becomes clogged, a by-pass valve
opens to route the oil directly to the oil gallery.
Oil Cooler
Oil temperature rises as the engine warms up with a
resulting decrease in lubricating efficiency. The oil
cooler operates to maintain low oil temperature and high
lubricating efficiency.The oil cooler consists of a body
and cooling element.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 4
Turbocharger
Removal
1. Remove the oil feed pipe.
• Discard the gaskets.
2. Remove the oil drain pipe.
• Discard the gaskets.
3. Remove the turbocharger.
NOTE: Plug the turbocharger body oil ports and
openings to prevent the entry of foreign material. 1 2
Installation
1. Install the turbocharger assembly with the new
gasket to the exhaust manifold and tighten the nuts
to the specified torque.
NOTE: Lubricate the turbine shaft. Pour oil into the oil
feed hole while rotating the turbine wheel with your 052EY00007
hand.
036EY00002
2. Install the oil drain pipe (2) to the turbocharger and

tighten the bolts to the specified torque.
3. Install the oil feed pipe (1) to the turbocharger and
tighten the bolts to the specified torque.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 5
Exhaust Manifold
Removal Tighten the nuts to the specified torque in the order
shown in the illustration below.
1. Remove the turbocharger oil feed pipe. Torque: 34 N·m (3.5 kgm)
2. Remove the turbocharger oil drain pipe.
3. Remove the turbocharger.
Refer to “Turbocharger Removal” in this manual.
4. Remove the exhaust manifold.
Clean the sealing surfaces of the exhaust manifold.
4 2
11 8 7 6 9
12 3 1 5 10
027EY00024
2. Install the turbocharger assembly with the new

gasket to the exhaust manifold.
Refer to “Turbocharger Installation” in this manual.
027EY00010
Installation
1. Install the exhaust manifold assembly with the new
gasket to the cylinder head.
• Install the distance tube (1), plain washer (2), and
spring washer (3).
• Install the distance tube (1) and distance nut (4) to
the front stud of No. 5 cylinder (indicated by arrow
A).
1
2
036EY00002
3. Install the oil drain pipe to the turbocharger.

3 4. Install the oil feed pipe to the turbocharger.
1 4
027EY00023
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 6
1 2
052EY00007
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 7
Intake Cover
Removal
1. Remove the fuel pipes.
2. Remove the booster air pipe.
3. Remove the injection pipes.
4. Remove the fuel filter and bracket.
5. Remove the intake pipe.
6. Remove the intake cover.
7. Clean the sealing surfaces of the intake cover.
Installation
1. Install the intake cover with new gaskets.
• Tighten the bolts to the specified torque.
025EY00017
3. Install the fuel filter and bracket to the intake cover.

Tighten the fixing bolts to the specified torque.
Torque:
Fuel Filter: 39 N·m (4.0 kgm)
Bracket : 20 N·m (2.0 kgm)
025EY00016
2. Install the intake pipe with new gasket.

Tighten the fixing nuts to the specified torque.
041EY00003
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 8
4. Install the injection pipes and tighten the sleeve nuts 6. Install the fuel leak off pipe (1) with new gasket.
to the specified torque. Tighten the eye bolts to the specified torque.
Torque: 29 N·m (3.0 kgm) Torque:
Cylinder head side: 29 N·m (3.0 kgm)
Fuel filter side: 25 N·m (2.5 kgm)
040EY00009
5. Install the fuel pipe and tighten the bolts to the

specified torque as follows. 041EY00015
Torque:
Fuel return pipe: 37 N·m (3.2 kgm)
Fuel pipe (Fuel filter to Injection pump):
39 N·m (4.0 kgm)
Fuel pipe (Feed pump to fuel filter):
39 N·m (4.0 kgm)
041EY00011
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 9
Water Pump
Removal 4
1. Loosen the fan fixing nuts to remove the cooling fan. 3
2
1
033EY00029
Legend
(1) Bolt
033EY00003 (2) Washer
(3) Rubber mount
2. Remove the fan guard and fan guide.
(4) Rubber mount
(5) Guide tube
(6) Fan guide
3. Loosen the fan pulley fixing bolts.

4. Remove the fan belt.
• Loosen the mounting bolt (2) and the sliding piece
nut (1).
• Pivot the alternator at the mounting bolt toward the
center of the engine.
3
1
033EY00007
066EY00003
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 10
5. Remove the adapter and fan pulley.
1 6
030EY00023
Legend (4) Bypass hose

(1) Adapter (5) Water duct
(2) Fan pulley (6) Water duct
(3) Water pump
6. Disconnect the bypass hose.

7. Loosen the fixing nuts and bolts from the water
pump.
8. Remove the water pump from the front plate.
9. Discard the gaskets.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 11
Installation 4. Install the water duct with new gasket to the oil cooler
and water pump.
1. Install the water pump with new gaskets to the front Tighten the bolts to the specified torque.
plate. Use the locating pin.
2. Tighten the fixing nuts and bolts to the specified
5. Connect the bypass hose.
torque.
6. Clamp the bypass hose.
Torque:
7. Install the fan pulley and adaptor to the water pump.
Nut A: 39 N·m (4.0 kgm)
Bolt: 20 N·m (2.0 kgm)
030EY00003
030EY00025
3. Install the water duct with new gasket to the cylinder

8. Install the fan belt.
head.
9. Adjust the fan belt tension.
Tighten the bolts to the specified torque.
• Depress the drive belt midway between the
Torque:
alternator and fan pulley.
Bolt (1) : 240 N·m (24 kgm)
Drive Belt Deflection
Bolt (2) : 20 N·m (2.0 kgm)
Single belt: 8 – 11 mm (0.31 – 0.43 in)
Scrum belt: 6 – 8 mm (0.23 – 0.31 in)
Water pump
Alternator
2
Crankshaft
032EY00011
033EY00004
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 12
10. Install the cooling fan. 12. Install the fan guard.
Tighten the fixing nuts to the specified torque. Tighten the fixing bolts to the specified torque.
Torque: 39 N·m (4.0 kgm) Torque: 40 N·m (4.1 kgm)
033EY00003 033EY00007
11. Install the fan guide. 13. Adjust the fan tip clearance.
Tighten the fixing bolts to the specified torque. Clearance: 7 - 13 mm (0.28 - 0.51 in)
3
2
1
033EY00029
Legend
(1) Bolt
(2) Washer
(3) Rubber mount
(4) Rubber mount
(5) Guide tube
(6) Fan guide
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 13
Alternator
Removal
1. Remove the sliding piece nut (1).
2. Remove the alternator mounting bolt (2).
3. Remove the fan belt.
4. Remove the alternator.
3
1
2
3
1
066EY00003
Water pump
066EY00003
Alternator
Installation
1. Install the alternator.
2. Install the adjusting plate.
3. Install the fan belt.
4. Adjust the belt tension by turning bolt (3). Crankshaft
• Depress the fan belt midway between the
alternator and the water pump.
Belt Deflection:
Single belt: 8 – 11 mm (0.31 – 0.43 in)
033EY00004
Scrum belt: 6 – 8 mm (0.23 – 0.31 in)
5. Tighten the adjusting plate fixing bolts to the
specified torque.
6. Tighten the alternator mounting bolt (2) to the
specified torque.
7. Tighten the slide piece nut (1) to the specified torque.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 14
Injection Pump
Removal 3. Remove the injection pipe.
1. Remove the leak off pipe (1).
040EY00009
041EY00015
NOTE: Protect the joint openings of the injection pipe to
prevent the entry of foreign material.
2. Remove the fuel pipes (1), (2) and (3).
4. Remove the fuel filter.
2
1
042EY00013
041EY00003
Legend
(1) Fuel Pipe: Feed Pump to filter
(2) Fuel Pipe: Filter to Injection Pump
(3) Fuel Pipe: Return
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 15
5. Remove the oil feed pipe (1) from the injection pump.
6. Remove the oil return pipe (2).
1
2
040EY00057
10. Remove the injection pump.

052EY00005 11. Remove the injection pump bracket.
7. Loosen the coupling bolts (1).
1
2
040EY00001
040EY00055
8. Remove the booster air pipe (injection pump

governor to intake cover).
9. Loosen the injection pump fixing bolts (1).
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 16
Installation
1. Install the injection pump bracket to the cylinder
block. Use the locating pin.
• Tighten the fixing bolts in the numerical order
1
shown in the illustration.
2
2 5 1
040EY00006
• Install the injection pump to the injection pump

bracket. Use the locating dowel pin.
4 3 • Tighten the injection pump fixing bolts to the
specified torque.
Torque : 44 N·m (4.5 kgm)
4. Loosen the adjusting bolt (2) and fasten the coupling
040EY00048
bolt (3) to the timing advancer.
2. Align the injection timing mark on the damper with Tighten the adjusting bolt (2) and fixing bolt (1).
the pointer on the front cover. Torque : 88 N·m (9.0 kgm)
Injection Timing : 9° BTDC • Verify that the injection timing is correct by turning
the crankshaft two turns in the normal direction of
engine rotation.
3 2
Pointer
1
020EY00006
3. Install the injection pump . 040EY00058
• Bring No. 1 cylinder to top dead center on the

compression stroke.
• Align the injection timing mark on the timing
advancer with the injection pump body pointer.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 17
5. Install the oil feed pipe (1) to the injection pump. 10. Install the fuel return pipe.
Torque: 27 N·m (2.8 kgm) • Tighten the bolts to the specified torque.
6. Install the oil return pipe (2). Torque: 37 N·m (3.8 kgm)
Torque: 34 N·m (3.5 kgm) 11. Install the fuel pipe (fuel filter to injection pump).
12. Install the fuel pipe (fuel pump to fuel filter).
Torque: 39 N·m (4 kgm)
052EY00005
7. Install the air boost pipe (injection pump governor to

intake cover).
8. Install the fuel filter to the bracket. 041EY00011
• Tighten the bolts to the specified torque. 13. Install the fuel leak off pipe (1).
Torque: 39 N·m ( 4.0 kgm) • Tighten the bolts to the specified torque.
9. Install the injection pipes. Torque:
• Tighten the sleeve nuts to the specified torque. Cylinder head side: 29 N·m (3.0 kgm)
Torque: 29 N·m (3.0 kgm) Filter side: 25 N·m (2.5 kgm)
040EY00009
041EY00015
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 18
Bearing Case
Removal Installation
1. Remove the injection pump . 1. Bring No. 1 piston to top dead center on the
Refer to “Injection Pump Removal” in this manual. compression stroke.
2. Remove the coupling.
• Loosen the bolt (1).
Pointer
1
020EY00006
2. Install the bearing case with new gasket to the

040EY00059 cylinder block.
3. Remove the oil feed pipe from the bearing case. • Apply Three Bond No. 1208 or equivalent to the
gasket.
4. Remove the bearing case.
This will hold the gasket in place during
installation.
• Install the gasket to the bearing case groove.
• Install the coupling to the bearing case shaft.
• Align the S mark on the coupling with the pointer
as shown in the illustration.
• Install the bearing case to the cylinder block.
• Confirm S mark position after installation.
S
039EY00004 S
Before installation After installation
F06EY00146
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 19
• Tighten the fixing nuts and bolts to the specified

torque:
Torque:
Bolt (1): 73 N·m (7.4 kgm)
Nut (2): 73 N·m (7.4 kgm)
Nut (3), (4) : 40 N·m (4.1 kgm)
POINTER
039EY00006
3. Install the injection pump.

Refer to “Injection Pump Installation” in this manual.
4. Install the oil feed pipe to the bearing case.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 20
Oil Cooler
Removal
1. Remove the fuel leak off pipe.
2. Remove the fuel pipes.
3. Remove the injection pipe.
Gasket Gasket
4. Remove the fuel filter.
5. Remove the oil feed pipe from the injection pump.
6. Remove the oil return pipe.
7. Loosen the coupling bolts
8. Remove the boost air pipe (intake cover to injection
pump governor).
9. Loosen the injection pump fixing bolts.
10. Remove the injection pump.
Refer to “Injection Pump Removal” in this manual.
11. Remove the stay for the fan guide.
12. Loosen the oil cooler fixing bolts evenly from the
outside to inside. 050EY00055
13. Remove the oil cooler assembly from the cylinder

• Tighten the oil cooler fixing bolts to the specified
block.
torque in the numerical order shown in the
• Install the removed bolts to the replacer hole and illustration.
remove the oil cooler.
• Clean the sealing surface of the block and remove
sealant residue.
21 17 13 9 5 1 4 8 12 16 20
22
25
26 28 24
27 18 14 10 6 2 3 7 11 15 19
23
050EY00001
050MX003 2. Install the stay for the fan guide.

3. Install the injection pump.
Installation Refer to “Injection Pump Installation” in this manual.
1. Install the oil cooler assembly with new gaskets to 4. Install the oil feed pipe (1) to the injection pump.
the cylinder block. Torque: 27 N·m (2.8 kgm)
• Clean the sealing surface of the oil cooler . 5. Install the oil return pipe (2).
• Apply ThreeBond No. 1207C/1216C or equivalent Torque: 34 N·m (3.5 kgm)
to the groove of the oil cooler assembly.
NOTE: Install the oil cooler within 15 minutes of applying
sealant.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 21
052EY00005 040EY00009
6. Install the air boost pipe (injection pump governor to 9. Install the fuel return pipe.
the intake cover). • Tighten the bolts to the specified torque.
7. Install the fuel filter to the bracket. Torque: 37 N·m (3.8 kgm)
• Tighten the bolts to the specified torque. 10. Install the fuel pipe (fuel filter to injection pump).
Torque: 39 N·m (4.0 kgm) 11. Install the fuel pipe (fuel pump to fuel filter).
041EY00003
8. Install the injection pipes.

• Tighten the sleeve nuts to the specified torque. 041EY00011
Torque: 29 N·m (3.0 kgm) 12. Install the fuel leak off pipe (1).
Torque:
Cylinder head side: 29 N·m (3.0 kgm)
Filter side: 25 N·m (2.5 kgm)
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 22
041EY00015
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 23
Rocker Arm Assembly

Removal
2
3
6
4
011EY00060
Legend (5) Bearing

(1) Cylinder head cover (6) Camshaft
(2) Gasket (7) Rubber plug
(3) Rocker arm assembly (8) Cylinder head
(4) Cam bearing cap
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 24
1. Remove the head cover.

2. Remove the cylinder head cover gasket.
Discard the gasket.
NOTE : Be careful not to lose the collars inserted into the
cylinder head cover assembly.
014EY00051
Installation
1. Apply engine oil to the bridge cap.
010EY00001
3. Remove the rocker arm shaft assembly.

Loosen the camshaft bracket fixing nuts on both
sides.
Loosen the rocker arm shaft bracket fixing bolts
evenly from the outside to the inside.
011MX042
2. Install the rocker arm assembly.

1. Apply engine oil to the front and rear camshaft
bracket sliding surfaces.
2. Apply engine oil to the camshaft bracket stud
threads and nut setting faces.
3. Install the rocker arm shaft assembly to the
014EY00156
cylinder head.
NOTE :Do not remove the rocker arm fixing bolts

(indicated by an arrow).
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 25
Sealant
014MX016 015EY00171
4. Tighten the rocker arm bracket nuts and bolts to the 5. Install the cylinder head cover with new gasket.
specified torque in the numerical order shown in the 1. Clean the head cover gasket groove and the head
illustration. cover gasket.
After tightening the camshaft cap nuts, tighten the 2. Install the new head cover gasket and collar to the
rocker arm shaft bracket bolts. head cover.
Torque: 3. Install the cylinder head cover to the cylinder
Bolts 1 through 4: 27 N·m (2.8 kgm) head.
Bolts 5 through 13 : 56 N·m (5.7 kgm)
4 6 8 9 7 5 3 1
2
11 12 13 10
010EY00001
011MX014
4.Tighten the cylinder head cover bolts to the
specified torque a little at a time in the numerical
3. Adjust the valve clearance.
order shown in the illustration.
Refer to “Valve Clearance Adjustment” in this
manual.
4. Apply ThreeBond 1207B or equivalent to the rubber
plug surfaces.
NOTE : Immediately (within ten (10) minutes of applying
the sealant) install the cylinder head cover to the
cylinder head.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 26
8 4 1 5 9
11
7 3 2 6 10
010EY00008
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 27
Disassembly
2 3
014EY00157
Legend (3) Spring washer

(1) Camshaft bracket (4) Bracket
(2) Rocker arm (5) Rocker arm shaft
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 28
1. Disassemble the rocker arm and shaft assembly.

• Loosen the rocker arm shaft fixing bolts (1).
• Disassemble the bracket, rocker arm, washer and
rocker arm shaft.
NOTE: Keep each rocker arm and bracket in order so
that they can be reinstalled to their original positions.
2
014EY00073
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting
portion outside diameter.
If the measured value is less than the specified limit, the
014EY00158 rocker arm shaft must be replaced.
Rocker arm shaft outside diameter
Inspection and Repair Standard: 21.979 – 22.000 mm (0.865 – 0.866 in.)
Make the necessary adjustments, repairs, and part Limit: 21.85 mm (1.0860 in.)
replacements if excessive wear or damage is
discovered during inspection.
Rocker Arm Shaft Run-Out

1. Place the rocker arm shaft on V-blocks.
2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm
shaft run-out with a bench press. The rocker arm
must be at cold condition.
If the measured rocker arm shaft run-out exceeds
the specified limit, the rocker arm shaft must be
replaced.
Rocker arm shaft run-out
Limit: 0.3 mm (0.012 in.)
014EY00074
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 29
Rocker Arm Bushing Inside Diameter

Use either a vernier caliper or a dial indicator to measure
the rocker arm bushing inside diameter.
Rocker arm bushing inside diameter
Standard: 22.010 – 22.035 mm (0.867 – 0.868 in.)
Rocker arm and rocker arm shaft clearance
Standard: 0.01 – 0.056 mm (0.0004 – 0.0022 in.)
Limit: 0.2 mm (0.0079 in.)
014EY00097
014EY00098
Rocker arm shaft and rocker arm clearance

Standard: 0.010 – 0.056 mm (0.0004 – 0.0022 in)
Limit: 0.20 mm (0.008 in)
Check that the rocker arm and rocker arm shaft oil port
are free of obstructions.
If necessary, use compressed air to clean the rocker
arm and rocker arm shaft oil port.
014EY00159
WARNING: Compressed air can cause personal

injury when using for cleaning. Wear safety glasses
and protective clothing.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 30
Rocker arm roller and rocker arm pin 7. Check the rocker arm roller and camshaft contact
surfaces for excessive wear and damage.
1. Pass a piece of string between the rocker arm and
the rocker arm roller.
2. Pull on either end of the string in the directions
3. Measure the rocker arm protrusion (1).
4. Mark the measuring point and remove the string.
5. Press the rocker arm roller against the rocker arm
with your fingers. Measure the rocker arm protrusion
again.
6. Calculate the difference between the 2 protrusions
(roller out and roller in). This is the roller and pin
clearance.
If the clearance exceeds the limit, the rocker arm must

be replaced.
Rocker arm roller and pin clearance

Standard: 0.068 – 0.099 mm (0.0027 – 0.0039 in)
014EY00096
Limit: 0.5 mm (0.02 in)
Rocker arm bracket

Check that the oil hole in the rocker arm shaft bracket is
free of obstructions.
014EY00076
014EY00095
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 31
Bridge gap
Check the valve cap and rocker arm contact surfaces for
excessive wear and damage.
If the wear exceeds the limit, the valve cap must be
replaced.
Valve cap wear
Limit: 0.1 mm (0.004 in)
Front
014MX028
5. Install the rocker arm.

• Apply engine oil to the rocker arm roller and pin.
6. Install the spring washer and camshaft bracket.
014EY00160
Reassembly
1. Apply engine oil to the rocker arm shaft.
2. Install the camshaft bracket to the rocker arm shaft.
3. Temporarily tighten the camshaft bracket bolt (1).
014EY00162
014EY00161
4. Install the rocker arm shaft bracket as shown in the

installation.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 32
Camshaft
Removal
2
3
6
4
011EY00060
Legend (5) Bearing

(1) Cylinder head cover (6) Camshaft
(2) Gasket (7) Rubber plug
(3) Rocker arm assembly (8) Cylinder head
(4) Cam bearing cap
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 33
1. Remove the head cover. Installation

2. Remove the cylinder head cover gasket.
1. Install the camshaft with camshaft gear to the
Discard the gasket.
cylinder head.
NOTE : Be careful not to lose the collars inserted into the
1. Align the crankshaft damper pulley TDC mark with
cylinder head cover assembly.
the pointer by rotating the crankshaft in the normal
direction of engine rotation. Check the position of
the alignment timing mark on the injection pump
for No. 1 piston of TDC.
Pointer
010MX004
3. Remove the rubber plug.

020EY00006
Refer to “Rocker Arm Assembly Removal” in this
manual. 2. Install the camshaft bearings to the cylinder head
5. Remove the camshaft bearing caps. bearing grooves and bearing caps.
• Loosen the camshaft bearing cap nuts and bolts 3. Apply engine oil to the camshaft bearing sliding
evenly from the outside to the inside. surfaces before installing the camshaft.
NOTE : If the camshaft bearings are to be reinstalled, 4. Install the camshaft with camshaft gear to the
keep them in order for installation to their original cylinder head.
location. 5. Carefully align the camshaft gear “B” mark and the
upper cylinder head face as shown in the
illustration.
011MV009-1
6. Remove the camshaft with camshaft gear.

014EY00060
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 34
6. If the “B” mark and upper cylinder head face are

not aligned, No.1 piston is not on the compression
stroke.
Remove the camshaft.
Rotate the crankshaft one full turn and realign the
crankshaft damper pulley TDC mark with the
pointer by rotating the crankshaft in the normal
direction of engine rotation.
7. Reinstall the camshaft assembly repeating steps 3
to 5.
2. Install the camshaft bearing caps.
1. Apply engine oil to the camshaft bearing sliding
surfaces.
2. Install the camshaft bearing caps with the
bearings in numerical order with the cap stamped
mark facing forward.
015EY00077
3. Apply ThreeBond 1207B or equivalent to the

rubber plug surfaces.
NOTE : Immediately (within ten (10) minutes of applying
the sealant) install the cylinder head cover to the
cylinder head.
Sealant
011MV009-1
3. Apply engine oil to the bearing cap bolt threads

and setting faces.
4. Tighten the bearing cap bolts to the specified
torque. Work from the center of the cylinder head
toward the outside.
015EY00171
3. Apply engine oil to the bridge cap.
4. Install the rocker arm assembly. 7. Install the cylinder head cover with new gasket.
Refer to “Rocker Arm Assembly Installation” in this 1. Clean the head cover gasket groove and the head
manual. cover gasket.
5. Adjust the valve clearance. 2. Install the new head cover gasket and collar to the
Refer to “Valve Clearance Adjustment” in this head cover.
manual. 3. Install the cylinder head cover to the cylinder
6. Install the rubber plug to the cylinder head. head.
1. Apply ThreeBond 1207B or equivalent to the
rubber plug as shown in the illustration.
2. Install the rubber plug to the cylinder head.
NOTE : Clean the cylinder head and remove sealant
residue.
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 35
010MX004
4. Tighten the cylinder head cover bolts to the

8 4 1 5 9
11
7 3 2 6 10
010MX003
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 36
Disassembly
014EY00102
Legend
(1) Camshaft gear
(2) Knock pin
(3) Camshaft
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 37
1. Remove the camshaft gear. 2. Use a micrometer to measure each camshaft journal
• Check the gear for excessive wear or damage. diameter in two directions ((1) and (2)). If the
• Use an universal puller to pull out the camshaft measured value is less than the specified limit, the
gear. camshaft must be replaced.
Camshaft journal diameter
Standard: 39.950 – 39.975 mm (1.5728 – 1.5738 in.)
Limit: 39.85 mm (1.5689 in.)
014EY00174
Inspection and Repair

014EY00078
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is 3. Measure the cam height A and B with a micrometer.
If the measured value is less than the specified limit,
1. Measure the dimension between the camshaft thrust
the camshaft must be replaced.
surface and the camshaft gear.
Cam height (A – B)
Camshaft and camshaft gear dimension
Inlet
Standard: 25.015 – 28.055 mm (1.103 – 1.105 in)
Standard: 7.851 mm (0.3091 in.)
Limit: 7.351 mm (0.2894 in.)
Exhaust
Standard: 9.540 mm (0.3756 in.)
Limit: 9.040 mm (0.3559 in.)
014EY00105
014EY00079
69945_ESS-185A_SEC6A-1 2011.8.11 11:21 AM ページ 38
4. Mount the camshaft on V-blocks. Reassembly

Measure the run-out with a dial indicator at the No. 4
camshaft journal. 1. Install the gear alignment pin to the camshaft.
If the measured value exceeds the specified limit, the 2. Install the camshaft gear to the camshaft.
camshaft must be replaced. 1. The gear hub large side must be facing the
Camshaft run-out camshaft.
2. Apply engine oil to the camshaft bolt threads and
Standard: 0.025 mm (0.0010 in.)
the setting faces.
Limit: 0.05 mm (0.0020 in.)
3. Tighten the camshaft gear bolt to the specified
torque.
5. Use an inside dial indicator to measure the camshaft

bearing inside diameter. 014EY00164
Camshaft bearing inside diameter

Standard: 40.0 – 40.037 mm (1.575 – 1.576 in.)
If the clearance between the camshaft bearing inside
diameter and the journal exceeds the specified limit,
the camshaft bearing must be replaced.
Camshaft bearing clearance
Standard: 0.025 – 0.087 mm (0.00098 – 0.00342 in.)
Limit: 0.15 mm (0.0059 in.)
014EY00163
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 39
Cylinder Head
Removal
1
2 10
4
13
6
11
5
7 12
9
14
15
011EY00001
Legend (8) Glow plug connector

(1) Cylinder head cover (9) Glow plug
(2) Gasket (10) Rocker arm assembly
(3) Rubber plug (11) Bridge cap
(4) Leak off pipe (12) Bridge
(5) Injection nozzle bracket (13) Camshaft
(6) Injection nozzle (14) Cylinder head
(7) Gasket (15) Head gasket
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 40
1. Remove the head cover. 10. Remove the bridge.

2. Remove the cylinder head cover gasket. NOTE: Keep the bridges in order for reassembly to their
Discard the gasket. original positions.
NOTE: Be careful not to lose the collars inserted into the 11. Remove the cylinder head.
cylinder head cover assembly. • Loosen the cylinder head bolts a little at a time in
the numerical order shown in the illustration.
• Clean the cylinder head surfaces and remove the
sealant residue.
CAUTION: Failure to loosen the cylinder head bolts in
numerical order a little at a time will damage the cylinder
head lower surfaces.
3 7 11 15 19 23 27 26 22 18 14 10 6 2
010MX004 4 8 12 16 20 24 28 25 21 17 13 9 5 1
3. Remove the rubber plug.

Refer to “Rocker Arm Assembly Removal” in this
manual.
5. Remove the camshaft with the gear. 011EY00064
Refer to “Camshaft Removal” in this manual.

CAUTION: The idle gear C (1) projects from the cylinder
6. Remove the leak off pipe. head lower side and is easily damaged. Great care must
7. Remove the injection nozzle holder. be taken to avoid damaging the idle gear C when the
cylinder head is removed from the engine.
040MX042
011EY00061
8. Remove the glow plug connector.

• Remove the injection nozzles and glow plugs 13. Remove the cylinder head gasket.
before removing the cylinder head. Discard the gasket.
9. Remove the bridge cap.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 41
Installation • Apply molybdenum disulfide grease to the cylinder

head bolts (M14) threads and setting faces.
1. Install the new cylinder head gasket. • Apply engine oil to the cylinder head bolts (M10)
• Clean the cylinder block surface and remove (Number (1) to (26)) threads and setting faces.
sealant residue. • Tighten the M14 cylinder head bolts in three steps
• Apply ThreeBond No. 1207C or equivalent to the using the angular tightening method.
cylinder block and the timing gearcase fitting faces. Follow the tightening order shown in the
The sealant must be 2.0 mm (0.08 in) thick and 3.0 illustration.
mm (0.12 in.) wide. • Tighten the M10 (Number (27) to (28)) cylinder
The sealant must not obstruct the cylinder oil port. head bolts to the specified torque.
NOTE: Cylinder head bolts may be reused 6 times
before replacement.
Replace if any doubt exists.
M14 bolt
Torque:
1st step 98 N·m (10 kgm)
2nd step 147 N·m (15 kgm)
3rd step 30 – 60 deg.
M10 bolt
NOTE: Cover the timing gear hole with a clear cloth to
prevent the entry of foreign material.
012MV001
• Install the new cylinder head gasket to the cylinder 26 22 18 14 10 6 2 3 7 11 15 19 23 27

block.
2. Install the cylinder head assembly over the locating
dowel pins.
M10
• Carefully place the cylinder head on the cylinder Bolt
head gasket.
25 21 17 13 9 5 1 4 8 12 16 20 24 28
011EY00065
011EY00024
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 42
3. Install the camshaft with gear to the cylinder head. 5. Install the bridge cap.
Refer to “Camshaft Installation” in this manual. 1. Apply engine oil to the bridge cap.
2. Install the bridge cap to the bridge,
014EY00060
011MX042
4. Install the camshaft bearing cap
6. Install the rocker arm assembly.
Refer to “Rocker Arm Assembly Installation” in this
manual.
011MV009-1
014MX016
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 43
7. Install the glow plugs to the cylinder head. 10. Adjust the valve clearance.
Tighten the glow plugs to the specified torque. Refer to “Valve Clearance Adjustment” in this
Torque: 20 N·m (2.0 kgm) manual.
8. Install the glow plug connector. 11. Install the rubber plug.
1. Apply Threebond 1207B or equivalent to the
rubber plug as shown in the illustration.
2. Install the rubber plug to the cylinder head.
NOTE: If the cylinder head is to be reinstalled, be sure to
remove, clean, and reseal the rubber plug.
011MX041
9. Install the injection nozzle holders.

1. Install the injection nozzle holders with the new
gaskets to the cylinder head.
CAUTION: Take care not to damage the injection 015EY00077
nozzle and gasket during nozzle holder installation.

2. Install the nozzle holder flange to the nozzle 3. Apply ThreeBond 1207B or equivalent to the
holder bolts. rubber plug surfaces.
3. Temporarily tighten the nozzle holder bolts. NOTE: Immediately (within 10 minutes of applying the
The bolts will be finally tightened after injection sealant) install the cylinder head cover to the cylinder
pipe and leak off pipe installation. head.
6HH1
Sealant
015EY00171
040MX041
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 44
12. Install the cylinder head cover and gasket.

1. Clean the head cover gasket groove and the head
cover gasket.
2. Install the new head cover gasket and collar to the
head cover.
3. Install the cylinder head cover to the cylinder
head.
010MX004
4. Tighten the cylinder head cover bolts to the

8 4 1 5 9
11
7 3 2 6 10
010MX003
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 45
Disassembly
25
24
12
11 4 14
13
10
3
8
6 19
7
2
19 1
17
15 5 23
22
9
18
16
20
21
011EY00062
Legend (13) Idler gear C

(1) Cylinder head cover (14) Idler gear cover
(2) Oil seal (15) Gasket
(3) Bridge guide (16) Thermostat
(4) Nozzle sleeve (17) Water outlet pipe
(5) Valve seat insert (18) Overheat warning switch
(6) Valve guide (19) Hanger
(7) Lower spring seat (20) Gasket
(8) Valve stem seal (21) Exhaust manifold
(9) Valve (22) Gasket
(10) Valve spring (23) Inlet cover
(11) Upper spring seat (24) Bridge
(12) Split collar (25) Bridge cap
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 46
1. Remove the bridge cap and bridge.

NOTE: Keep the bridges and caps in order for
reassembly to their original positions.
2. Remove the intake cover and gasket.
Discard the gasket.
3. Remove the exhaust manifold and gasket.
Discard the gasket.
4. Remove the overheat warning switch.
5. Remove the water outlet pipe.
6. Remove the thermostat and gasket.
Discard the gasket.
7. Remove the idle gear cover.
• Tap the outside of the cover with a screwdriver (1)
to deform one end of it and pull it free with pliers.
NOTE : Do not scratch the sealing surfaces of the
cylinder head.
011MX017
10. Remove the spring seat, spring, valve stem seal, and
lower spring seat.
011EY00063
8. Remove the idler gear C.

9. Remove the split collar.
1. Place the cylinder head on a flat wooden surface. 011MX027
2. Use the valve spring compressor 5-8840-2621-0

to remove the split collar.
Do not allow the valves to fall from the cylinder
head.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 47
11. Remove the valve guide. 13. Remove the injection nozzle sleeve.
• Use the valve guide remover 5-8840-2628-0 to Use the nozzle sleeve remover 5-8840-2623-0 to
remove the valve guide. drive the nozzle sleeve from the lower side cylinder
head.
011MX015
040MX038
12. Remove the valve seat insert.
1. Heat (about 600 – 700°C) two points on the valve 14. Remove the bridge guide.
seat insert with a gas torch and then allow the The bolt is electrically welded to the bridge guide.
valve seat insert to cool for a few minutes. Use a sliding hammer to remove it.
2. This will invite contraction and make removal of
the valve seat insert easier.
3. Use a screwdriver to pry the valve seat insert free.
Take care not to damage the cylinder head.
4. Carefully remove carbon built-up and other foreign
materials from the cylinder head insert bore.
Electric welding
011EY00075
011MX016
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 48
15. Remove the injection pipe oil seal.
011EY00066
011MX026

A
Cylinder Head
E F
Cylinder Head Lower Face Warpage C D
Use a straight edge and a feeler gauge to measure the B

four sides and the two diagonals of the cylinder head
lower face.
If the measured values exceed the specified limit, the
cylinder head must be replaced.
Cylinder Head Lower Face Warpage
Standard: 0.05 mm (0.002 in) or less
011EY00067
Limit: 0.20 mm (0.008 in)
NOTE: Do not attempt to regrind the cylinder head lower
face. Valve Guide
Check the cylinder head lower face for cracking and Valve Stem and Valve Guide Clearance
other damage.
Measuring method-I
1. Insert the valve to the cylinder head.

2. Set the dial indicator to the valve stem at measuring
point as shown in the illustration.
Measuring Point: 10 mm (0.4 in)
3. Set the dial indicator needle to “0”.
4. Move the valve head from side to side.
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit, the
valve and the valve guide must be replaced as a set.
Valve Stem Clearance
Intake Valve
Standard: 0.04 – 0.06 mm (0.0016 – 0.0024 in)
Limit: 0.20 (0.008 in)
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 49
Exhaust Valve Valve Stem Outside Diameter

Standard: 0.06 – 0.10 mm (0.0024 – 0.0039 in)
Measure the valve stem diameter at three points.
Limit: 0.25 mm (0.010 in) If the measured value is less than the specified limit, the
Valve Stem Outside Diameter
Intake Valve
Standard: 7.95 – 7.96 mm (0.3130 – 0.3134 in)
Limit: 7.89 mm (0.3106 in)
Exhaust Valve
Standard 7.92 – 7.94 mm (0.3118 – 0.3126 in)
10mm(0.4in)
Limit: 7.89 mm (0.3106 in)
014EY00062
Measuring Method-II
1. Measure the valve stem outside diameter.

2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
3. Calculate the clearance between the valve guide
inside diameter and the valve stem outside diameter.
If the clearance exceeds the specified limit, the valve
and the valve guide must be replaced as a set. 014EY00165
Valve Guide Replacement
Valve Guide Removal
Use a hammer and the valve guide replacer to drive the

valve guide from the cylinder head lower 5-8840-2623-0
face.
011EY00068
011MX015
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 50
Valve Guide Installation Valve and Valve Seat Insert

1. Apply engine oil to the valve guide outer Valve Thickness
circumference.
Measure the valve thickness.
2. Set the ring to the valve guide replacer 5-8840-2628- If the measured value is less than the specified limit, the
0. valve and the valve guide must be replaced as a set.
3. Attach the valve guide replacer with ring to the valve Intake and Exhaust Valve Thickness
guide. Intake Valve
4. Use a hammer to drive the valve guide into position
Standard: 1.71 mm (0.067 in)
from the cylinder head upper face.
Limit: 1.30 mm (0.051 in)
Exhaust Valve
Limit: 1.30 mm (0.051 in)
011MX024
5. Measure the height of the valve guide upper end

from the upper face of the cylinder head.
Valve Guide Upper End Height (Reference): 14.1
mm (0.56 in)
NOTE: If the valve guide has been removed, both the Valve Depression
1. Install the new valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule
to measure the valve depression from the cylinder
head lower surface.
If the measured value exceeds the specified limit, the
valve seat insert must be replaced.
Valve Depression
H Intake Valve
Limit: 2.5 mm (0.098 in)
Exhaust Valve
Limit: 2.8 mm (0.110 in)
011EY00069
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 51
3. Use a screwdriver (3) to pry the valve seat insert

free.
Take care not to damage the cylinder head (4).
3
2
4
014EY00064
Valve Contact Width
1. Check the valve contact faces for roughness and

unevenness. 011EY00070
Make smooth the valve contact surfaces. Valve Seat Insert Installation
2. Measure the valve contact width.
1. Carefully place the attachment (1) (having a smaller
If the measured value exceeds the specified valve outside diameter than the valve seat insert) on the
contact width, the valve seat insert must be replaced. valve seat insert (2).
Valve Contact Width CAUTION: The smooth side of the attachment must
Intake Valve contact the valve seat insert.
Standard: 2.5 mm (0.098 in) Carefully remove carbon built-up and other foreign
Exhaust Valve material from the cylinder head insert bore.
2. Use a bench press (3) to gradually apply pressure to
Standard: 2.0 mm (0.079 in) the attachment and press the valve seat insert into
place.
CAUTION: Do not apply an excessive amount of
pressure with the bench press. Damage to the valve
seat insert will result.
014EY00065
Valve Seat Insert Removal
1. Arc weld the entire inside circumference (1) of the

valve seat insert (2). 011EY00071
2. Allow the valve seat insert to cool for a few minutes.

This will invite contraction and make removal of the
valve seat insert easier.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 52
Valve Seat Insert Correction Valve Face Angle

Intake: 30 degree
1. Remove the carbon from the valve seat insert
surface. Exhaust: 45 degree
NOTE: Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
Check that valve depression is within the specified limit
150° after valve seat insert correction.
90°
30°
011EY00032
2. Use a valve cutter (14, 45, 60 and 75 degree blades)

to minimize scratches and other rough areas. This
will bring the contact width back to the standard
value. 014E100069
Remove only the scratches and rough areas. Do not

cut away too much. Take care not to cut away 3. Apply abrasive compound to the valve seat insert
unblemished areas of the valve seat surface. surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
011EY00072
011MX018
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 53
Valve Spring
Valve Spring Free Height
Use a vernier caliper to measure the valve spring free

height.
valve spring must be replaced.
Spring Free Height
Intake
Limit: 64.6 mm (2.54 in)
Exhaust
Limit: 66.7 mm (2.63 in)
Valve Spring Tension
Use a spring tester to measure the valve spring tension.

Valve Spring Tension / Compression Height
Intake
Standard: 348 N (35.5 kg / 78 lb / 46 mm)
Exhaust
Standard: 383 N (39.0 kg / 86 lb / 46 mm)
Valve Spring Squareness
Use a surface plate and a square to measure the valve

spring squareness.
Spring Squareness
Intake
Limit: 3.4 mm (0.134 in)
Exhaust
Limit: 3.4 mm (0.134 in)
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 54
Reassembly
25
24
12
11 4 14
13
10
3
8
6 19
7
2
19 1
17
15 5 23
22
9
18
16
20
21
011EY00062
Legend (13) Idler gear C

(1) Cylinder head cover (14) Idler gear cover
(2) Oil seal (15) Gasket
(3) Bridge guide (16) Thermostat
(4) Nozzle sleeve (17) Water outlet pipe
(5) Valve seat insert (18) Overheat warning switch
(6) Valve guide (19) Hanger
(7) Lower spring seat (20) Gasket
(8) Valve stem seal (21) Exhaust manifold
(9) Valve (22) Gasket
(10) Valve spring (23) Inlet cover
(11) Upper spring seat (24) Bridge
(12) Split collar (25) Bridge cap
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 55
1. Use the oil seal installer 5-8840-2627-0 to install the 2. Tighten the engine hangers to the specified torque.
oil seals to the cylinder head. Torque: 48 N·m (4.9 kgm)
011MX026
011MX044
3. Install the bridge guides to the cylinder head.

1. Apply engine oil to the valve bridge guide outer
circumference.
2. Attach the valve bridge guide installer 5-8840-
2626-0 to the bridge guide.
3. Use a brass hammer to tap the guide into position
from the cylinder head upper face.
122.5±0.5
37.5
011MX036
011MX012
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 56
4. Install the injection nozzle sleeves to the cylinder

head.
1. Install the gasket (2) to the nozzle sleeve and
apply engine oil.
2. Apply sealer to the tapered part (1) of the nozzle
sleeve.
LOCTITE No. TL290
040MX039
5. Install the valve seat inserts into the cylinder head.

1. Carefully place the attachment (1) (having a
smaller outside diameter than the valve seat
insert) on the valve seat insert (2).
2 NOTE: The smooth side of the attachment must contact
the valve seat insert.
040MV040-1
2. Use a bench press (3) to gradually apply pressure
to the attachment and press the valve seat insert
3. Install the nozzle sleeve to the cylinder head and into place.
insert the guide sleeve. CAUTION: Do not apply an excessive amount of
4. Push in the nozzle sleeve with the guide sleeve pressure with the bench press. Damage to the valve
installer 5-8840-2624-0 so that the bottom surface seat insert will result.
of the cylinder head is reached.
5. Insert the nozzle sleeve and fix it with the clamp
and bolt.
6. Press a 9.525 mm steel ball into the guide sleeve
5-8840-2624-0. Use a hammer and punch bar to
drive the ball through the sleeve. 3
NOTE:
• Remove chips from the threaded part of the cylinder 1
head.
• Keep the cylinder head raised so that the ball can 2
escape from the bottom surface.
011EY00071
3. The valve should be lapped before final assembly

to ensure a good valve seal.
Refer to “Valve Seat Insert Correction” in this
section.
6. Install the valve guides into the cylinder head.
1. Apply engine oil to the valve guide outer
circumference.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 57
2. Attach the valve guide replacer 5-8840-2628-0 to 2. Install the valve springs with their fine pitched end
the valve guide. (painted) facing down.
3. Use a hammer to drive the valve guide into Colored
position from the cylinder head upper face. Intake Valve: Light blue
4. Measure the height of the valve guide upper end Exhaust Valve: Yellow
from the upper face of the cylinder head.
Valve Guide Upper End Height (Reference):
19 mm (0.748 in)
014EY00067
11. Install the valve spring upper seats.

011MX024 12. Install the split collars.
1. Use the spring compressor 5-8840-2621-0 to
7. Install the spring seats.
compress the valve spring.
8. Install the valve stem seals on the valve guide.
2. Install the split collars to the valve stem.
1. Apply engine oil to the oil seal inner face.
Do not allow the valve to fall from the cylinder
2. Use the oil seal installer 5-8840-2625-0 to install head.
the oil seal to the valve guide.
3.Set the split collars by tapping around the head of
each collar with a rubber hammer.
011MX020
9. Install the valves. 011MX017
Apply engine oil to the intake valves and exhaust

valves.
10. Install the valve springs.
1. Place the cylinder head on a flat wooden surface.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 58
13. Install the idler gear C.

1. Apply engine oil to the idler gear shaft and idler
gear C bushing before installation.
2. Install the idler gear C with the boss side facing 1
the front of the engine as shown in the illustration.
Front 3
031EY00023
BOSS
16. Install the water outlet pipe to the cylinder head.
Tighten the water outlet pipe bolts to the specified
torque.
011EY00074
14. Install the sealing cup to the cylinder head.

1. Apply LOCTITE No. 962T or equivalent to the
sealing cup hole circumference.
2. Drive the sealing cup into position from the
cylinder head side as shown in the illustration.
0.5∼1.5
031EY00024
011EY00034
15. Install the thermostats to the cylinder head.

1. Install the thermostat gaskets (1) to the flange of
thermostats.
2. Install the thermostat (without jiggle valve) (2) and
thermostat (with jiggle valve) (3) to the cylinder
head.
NOTE: The jiggle valves of the thermostat must be
facing the rear of the engine.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 59
17. Install the exhaust manifold gaskets. 18. Install the exhaust manifold to the cylinder head.
Install the gasket with the protruding part of the 1. Install the three gas seal rings to the rear exhaust
gasket facing down. manifold.
NOTE: Check and see that the gasket is correctly Position the ring gaps 120 degrees apart from
installed to the cylinder head. The gasket, if installed in each other.
the wrong way, can overlap the casting skin of the
cylinder head.
027EY00010
011MX021
Note: Be absolutely sure that the gaskets are correctly
installed to the cylinder head. An incorrectly installed
gasket will result in engine damage.
2. Install the front exhaust manifold to the rear
exhaust manifold.
3. Install the exhaust manifold to the cylinder head.
4. Install the distance tube (1) and washer (2) to the
1 stud bolts.
5. Install the distance tube (1), washer (2), and
distance nut to the stud bolt at the front side of No.
5 cylinder (arrow “A” mark).
6. Tighten the exhaust manifold nuts to the specified
torque.
Torque: 34 N·m (3.5 kg·m)
027EY00027
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 60
1
2
Intake cover
3 10 6 2 7 11 14
3
1 4
13 9 5 1 4 8 12
027EY0023 025MX016
20. Install the intake pipe with new gasket to the intake
cover.
Tighten the intake pipe bolts to the specified torque.
4 2
11 8 7 6 9
12 3 1 5 10
027EY0024
19. Install the intake cover with new gasket to the

cylinder head.
1. Install the intake cover bolts with the distance pipe
and the mounting rubber. 025EY00018
2. Tighten the intake cover bolts to the specified 22. Install the bridge to the bridge guide.
torque a little at a time in the numerical order
Apply engine oil to the bridge.
26. Install the bridge cap to the bridge.
Apply engine oil to the bridge cap.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 61
011MX014
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 62
Crank Pulley and Flywheel

Removal
015EY00193
Legend (4) Ring gear

(1) Crank pulley (5) Flywheel
(2) Damper (6) Washer
(3) Crankshaft
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 63
1. Remove the cooling fan.

2. Remove the fan belts.
3. Remove the crankshaft damper pulley from the
crankshaft.
1
• Block the crankshaft with a piece of hard wood to
prevent the damper pulley from turning.
• Diagonally loosen the damper pulley bolts.
4. Remove the flywheel from the crankshaft. 3 4
Installation
2
1. Install the crankshaft damper pulley to the
crankshaft.
1. Apply engine oil to the threads and setting faces of
the crankshaft damper pulley bolts.
2. Block the crankshaft with a piece of hard wood to
prevent the damper pulley from turning. 015EY00174
3. Install the crankshaft damper pulley. Use the

locating dowel pin. 2. Install the flywheel and washer to the crankshaft.
4. Tighten the crankshaft damper pulley bolts to the 1. Block the crankshaft with a piece of hard wood to
specified torque a little at a time in the numerical prevent the flywheel from turning.
order shown in the illustration. 2. Apply molybdenum disulfide grease to the
Torque: 200 N·m (20.4 kgm) flywheel bolt threads.
3. Install the flywheel. Use the locating pin.
4. Tighten the fixing bolts to the specified torque in
three steps.
Follow the numerical order shown in the
illustration.
Torque :
1st step : 78 N·m (8.0 kgm)
2nd step : 60 deg.
3rd step : 60 – 90 deg.
NOTE : The flywheel housing bolts can be reused 6
times.
015EY00006
1
6 4
3 7
8 2
5
015EY00079
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 64
3. Install the fan belts. 2. Inspect the crankshaft damper for cracking or
4. Adjust the fan belt tension. separation. If any abnormality on the crankshaft
Refer to “Fan Belt Inspection” in this manual. damper is found, inspect the crankshaft and the
flywheel fixing bolts.
Disassembly
Ring Gear
1. Strike around the edges of the ring gear with a

hammer and brass bar to remove it.
014EY00117
Reassembly
Ring Gear
015EY00075 1. Install the ring gear to the flywheel.
Damper 1. Heat the ring gear evenly with a gas burner to
invite thermal expansion.
1. Remove the damper from the crankshaft pulley. Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
Inspection and Repair WARNING: Take care not to burn yourself on the
heated ring gear.
1. Inspect the ring gear for damage or excessive wear. 2. Install the ring gear when it is sufficiently heated.
If the ring gear teeth are broken or excessively worn The ring gear must be installed with the chamfer
the ring gear must be replaced. facing outside.
014EY00116 015LX103
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 65
3. Install the damper to the crankshaft pulley.
015EY00074
Diagonally tighten the damper fixing bolts to the

specified torque.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 66
Timing Gear
Removal
10 11
14
13
12
3 6
7
5
2 4
020EY00004
Legend (8) Slinger

(1) Washer (9) Idler gear shaft A
(2) Flywheel (10) Idler gear A
(3) Cover (11) Thrust collar
(4) Idler gear D (12) Oil pump
(5) Idler gear shaft D (13) Idler gear B
(6) Flywheel housing (14) Idler gear shaft B
(7) Oil seal
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 67
1. Remove the flywheel housing.

Refer to “Flywheel Housing Removal” in this manual.
2. Measure the idler gear backlash.
1. Set a dial indicator to the idler gear.
Hold both the gear to be checked and the
adjoining gear stationary.
Move the gear to be checked as far as possible
both to the right and to the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit,
the idler gear must be replaced.
Idler Gear Backlash

Standard : 0.10 – 0.17 mm (0.0039 - 0.0067 in)
Limit : 0.30 mm (0. 12 in)
014EY00053
4. Remove the idler gear A, shaft, and thrust collar.

Inspect the idler gear for damage or wear.
Inspect the thrust collar for wear.
5. Remove the oil pump from the cylinder block.
Inspect the gear shaft for abnormal play.
Clean the fitting surfaces of the oil pump and remove
the sealant residue.
6. Remove the idler gear B, shaft, and thrust collar.
Inspect the shaft and thrust collar for wear.
Clean the front surfaces of the cylinder block and
remove the sealant residue.

014EY00052

3. Measure the gear end play. replacements if excessive wear or damage is
Insert a feeler gauge between the idler gear and the discovered during inspection.
thrust collar to measure the gap and determine the 1. Use a micrometer to measure the idler gear shaft
idler gear end play. outside diameter.
If the measured value exceeds the specified limit, the If the measured value is less than the specified limit,
idler gear must be replaced. the idler gear shaft and/or shaft must be replaced.
Idler Gear End Play Idler gear shaft outside diameter
Gear A and B Shaft A
Standard : 0.08 - 0.14 mm (0.0032 - 0.0055 in) Standard: 49.950 – 49.975 mm (1.9665 – 1.9675 in)
Limit : 0.20 mm (0.008 in) Limit: 49.90 mm (1.9646 in)
Gear C Shaft B and C
Standard : 0.07 - 0.135 mm (0.0027 - 0.0053 in) Standard: 29.959 – 29.980 mm (1.1795 – 1.1803 in)
Limit : 0.20 mm (0.008 in) Limit: 29.9 mm (1.1772 in)
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 68
2. Tighten the idler gear shaft bolts to the specified

torque.
014EY00175
2. Use an inside dial indicator or an inside micrometer

to measure the idler gear inside diameter.
If the clearance between the idler gear shaft outside 014EY00054
diameter and the idler gear inside diameter exceeds 2. Install the idler gear B to the idle gear shaft.
the limit, the idler gear and/or shaft must be 1. Apply engine oil to the idler gear B inside and
replaced. thrust areas.
Idler gear shaft and Idler gear clearance 2. Install the idler gear to the idler gear shaft.
Shaft A 3. Tighten the idler gear bolts to the specified torque.
Standard: 0.025 – 0.075 mm (0.00098 – 0.00295 in) Torque: 95 N·m (9.7 kgm)
Limit: 0.2 mm (0.008 in)
Shaft B and C
Standard: 0.020 – 0.062 mm (0.0008 – 0.0024 in)
Limit: 0.2 mm (0.008 in)
014EY00055
3. Install the oil pump to the cylinder block.

1. Carefully wipe any foreign material from the
cylinder body rear surface.
014EY00176
2. Apply engine oil to the cylinder body inside
bushing.
Installation
1. Install the idler gear B shaft.
1. Install the idler gear B shaft to the cylinder body.
The idler gear shaft oil port must be facing the
cylinder head.
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 69
051EY00010 014EY00056
3. Apply ThreeBond TB1201 (or 1141E) or 4. Install the idler gear A and Idler gear shaft to the
equivalent to the shaded areas shown in the cylinder block.
illustration. 1. Install the idler gear shaft (1) to the cylinder body.
CAUTION: The sealant must not obstruct the gear The idler gear shaft oil port must be facing the
and oil ports (indicated by arrows). cylinder head.
2. Apply engine oil to the idler gear A inside and
thrust areas.
051EY00011
4. Install the oil pump to the cylinder body within 15

minutes of sealant application. 014EY00168
5. Tighten the oil pump bolts to the specified torque. 3. Install the idler gear A (1) to the idler gear shaft.
Torque: 24 N·m (2.4 kgm) 4. Align the crankshaft gear (2) L mark and the idler
gear (1) 0 marks.
5. Tighten the idler gear bolts to the specified torque.
Torque: 29 N·m (3.0 kgm) → 60 – 90°
69945_ESS-185A_SEC6A-2 2011.8.10 1:43 PM ページ 70
2
1
1
2
014EY00169 014EY00170
5. Install the flywheel housing. 7. Install the cover with new gasket to the flywheel
1. Apply ThreeBond No. TB1201 (or TB1207C) or housing.
equivalent to the flywheel housing fitting faces and
the area marked with an arrow in the illustration.
Do not apply sealant
020MX008
8. Install the rear oil seal.

020EY00063
Refer to “Flywheel Housing Installation” in this

2. Install the flywheel housing to the cylinder block. manual.
Refer to “Flywheel Housing Installation” in this 9. Install the flywheel to the crankshaft.
manual. Refer to “Flywheel Installation” in this manual.
6. Install the idle gear D to the cylinder block.
1. Apply engine oil to the idler gear shaft (2).
2. Apply engine oil to the idler gear (1) inside and
thrust areas.
3. Install the gear to the gear shaft.
4. Install the gear and shaft to the cylinder block.
5. Tighten the bolts over the thrust collar to the
specified torque.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 71
Flywheel Housing
Removal
3 6
7
5
2 4
020EY00060
Legend (5) Idler gear shaft D

(1) Washer (6) Flywheel housing
(2) Flywheel (7) Oil seal
(3) Cover (8) Oil slinger
(4) Idler gear D
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 72
1. Remove the oil pan. 9. Use the slinger remover 894396-8580 to remove the
Refer to “Oil Pan Removal” in this manual. slinger.
2. Loosen the flywheel fixing bolts to remove the Take care not to damage the crankshaft.
flywheel. CAUTION : Be careful not to damage the crankshaft
1. Block the crankshaft with a piece of hard wood to oil seal contact surface during the removal
prevent the flywheel from turning. procedure.
2. Loosen the flywheel bolts a little at a time in the
numerical order shown in the illustration. NOTE : If the oil seal has been removed, both the oil
seal and slinger must be replaced as a set.
2
1
6 4
3 7
8 2
5
015EY00079
020EY00061
3. Remove the cover for the idler gear D and the
gasket.
Discard the gasket
4. Loosen the idler gear shaft bolt.
5. Remove the idler gear and shaft.
6. Remove the idler gear shaft supporting bolts.
7. Loosen the flywheel housing fixing bolts to remove
the flywheel housing.
8. Remove the rear oil seal.
020EY00021
Installation
1 Install the flywheel housing to the cylinder block.
1. Apply ThreeBond No. TB1201 or TB1207C or
equivalent to the flywheel housing fitting faces
and the area marked with an arrow in the
illustration.
2. Tighten the flywheel housing bolts to the specified
torque.
020MX011
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 73
Torque :
Bolt A : 73 N·m (7.4 kgm/54 lbft)
Bolt B : 96 N·m (9.8 kgm/71 lbft)
Bolt C : 73 N·m (7.4 kgm/54 lbft)
Bolt D : 87 N·m (8.9 kgm/64 lbft)
1
Bolt E : 119 N·m (12.1 kgm/88 lbft)
Bolt F : 26 N·m (2.7 kgm/20 lbft)
NOTE:
1. Mark B and D : Tighten the bolts together with the
washers.
2 Mark G : Tighten from the cylinder block side.
2
B B
D
B B
B 014EY00170
C 3. Install the cover with new gasket.

B
F E
A
G B E
B
B
B
B
020EY00057
2. Install the idler gear shaft to the cylinder block.

1. Apply engine oil to the idler gear shaft D.
2. Apply engine oil to the inside diameter and thrust
portion of the idler gear D.
3. Install the idler gear with the shaft and the thrust
collar.
020MX008
4. Tighten the idler gear shaft bolts to the specified

torque. 4. Install the rear slinger using the oil seal installer
Torque : 119 N·m (12.1 kgm) 894396-8560.
1. Install the slinger (1) to the end of adapter (2).
Install the adapter to the crankshaft (3).
NOTE : The rear slinger is gray and the front slinger is
black.
2. Install the slinger sleeve (4) to the adapter.
Tighten the center bolt (5) until the sleeve comes
in contact with the adapter stopper.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 74
5. Use the oil seal installer 894396-8560 to install the

oil seal.
5
3
2
020EY00058
3. After pressing in the slinger, make sure that the

distance between crankshaft end surface and the 020EY00023
slinger is A as specified.
1. Apply engine oil to the oil seal lip.
Distance (A) : 16.7 - 17.3mm (0.657 - 0.681 in)
Do not allow engine oil to come in contact with the
NOTE : Be sure to replace the slinger and oil seal as a outside oil seal and felt ring.
set.
2. Insert the oil seal (1) into the adapter (2) .
3. Insert the oil seal sleeve (3) to the adapter.
4. Tighten the center bolt until the sleeve comes into
contact with the adapter stopper.
5. After pressing the oil seal, make sure that the
distance between crankshaft end surface and the
oil seal is B as specified.
Distance (B) : 7.35 - 7.65 mm(0.289 - 0.301 in)
A
015MT002
020EY00064
6. Install the flywheel and washer to the crankshaft.

prevent the flywheel from turning .
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 75
015EY00175
2. Apply molybdenum disulfide grease to the

flywheel bolt threads.
3. Install the flywheel. Use the locating pin.
4. Tighten the fixing bolts to the specified torque in
three steps.
Follow the numerical order shown in the
illustration.
Torque :
1st step : 78 N·m (8.0 kgm)
2nd step : 60 deg.
3rd step : 60 - 90 deg.
NOTE : The flywheel housing bolts can be reused 6
times.
1
6 4
3 7
8 2
5
015EY00079
7. Install the oil pan with new gasket to the cylinder

block.
Refer to “Oil Pan Installation” in this manual.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 76
Oil Pan
Removal
013EY00038
Legend (3) Gasket

(1) Clip (4) Oil strainer
(2) Oil pan (5) Gasket
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 77
1. Remove the breather hose clip. 2. Apply a 3 mm bead of sealant (Three Bond
2. Loosen the fixing nuts and bolts to remove the oil No.1207B or equivalent) to the cylinder block and
pan and gasket. flywheel housing fitting faces (1) and the crankcase
Clean the lower cylinder block surfaces and remove fitting faces (2).
the sealant residue.
013EY00040
013EY00002
NOTE: Do not damage the oil pan gasket as it is coated
3. Discard the oil pan gasket. with rubber.
3. Install the oil pan with new gasket to the cylinder
4. Remove the oil strainer from the cylinder block.
block.
Clean the oil strainer.
Tighten the oil pan nuts and bolts to the specified
torque.
Installation Torque : 25 N·m (2.5 kgm)
1. Install the oil strainer with new gasket.
Torque:
M8 Bolt : 24 N·m (2.4 kgm)
M10 Bolt: 48 N·m (4.9 kgm)
013EY00039
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 78
Front Cover
Removal
3 4 5
015EY00177
Legend (5) Gasket

(1) Damper pulley (6) Slinger
(2) Oil seal (7) Crankshaft
(3) Adjusting plate (8) Crankcase
(4) Front plate
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 79
1. Remove the water pump. 7. Use the slinger remover 8-94396-858-0 to remove
Refer to “Water Pump Removal” in this manual. the slinger.
2. Remove the alternator. • Discard the removed oil seal and slinger.
Refer to “Alternator Removal” to this manual. NOTE: If the oil seal has been removed, both the oil seal
3. Remove the adjusting plate from the front cover. and slinger must be replaced as a set.
4. Remove the crankshaft damper pulley from the
crankshaft.
• Block the crankshaft with a piece of hard wood to
• Diagonally loosen the damper pulley bolts.
015MX018
Installation
1. Install the front cover to the cylinder block.
1. Apply a 2 - 3 mm bead of sealant ThreeBond
015EY0006 1207C or equivalent to the front cover grooves.
2. Install the gasket (1).
5. Remove the front plate.
3. Immediately (within 10 minutes of applying the
• Insert bolts into the remover holes on the front
sealant) set the front cover to the cylinder block.
plate to remove it.
020EY00062
020MX020
4. Tighten the front cover bolts to the specified

6. Remove the front oil seal from the front plate.
torque.
Use a screwdriver to pry the oil seal from the front
plate.
Take care not to damage the oil seal fitting faces.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 80
A
3
5
2
020EY00008 015EY00178
2. Install the adjusting plate to the front plate. 4. Install the front oil seal to the front plate.
Use the oil seal installer kit 8-94396-856-0 to install
the oil seal.
1. Apply engine oil to the oil seal lip.
2. Insert the oil seal (1) into the adapter (2).
3. Install the oil seal sleeve (3) to the adapter.
4. Tighten the center bolt until the sleeve comes into
contact with the adapter stopper (marked with an
arrow).
5. After pressing in the oil seal, make sure that the
distance between the crankshaft end surface and
oil seal (B) is the specified value.
Distance (B): 8.35 - 8.65 mm (0.33 - 0.34 in)
020EY00007
1
3. Install the slinger to the crankshaft.
• Use the oil seal installer 8-94396-856-0 to install 2
the slinger. B
NOTE: The front slinger is black and the rear slinger is
gray. 3
1. Insert the slinger (1) to the end of adapter (2), and
install the adapter to the crankshaft.
2. Install the slinger sleeve (4) to the adapter and
tighten the center bolt (5) until the sleeve comes
into contact with the adapter stopper (marked with
an arrow).
3. After pressing in the slinger, make sure that the 015EY00179
distance between the crankshaft end surface and

5. Install the crankshaft damper pulley to the
the slinger is the specified value.”
crankshaft.
Distance (A): 17.7 - 18.3 mm (0.70 - 18.3 in)
1. Apply engine oil to the threads and setting faces of
NOTE: Be sure to replace the slinger and oil seal as a the crankshaft damper pulley bolts.
set.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 81
3. Install the crankshaft damper pulley. Use the

locating dowel pin.
4. Tighten the crankshaft damper pulley bolts to the
015EY00006
3 4
015EY00174
6. Install the water pump to the front plate.

Refer to “Water Pump Installation” in this manual.
Refer to “Alternator Installation” in this manual.
Refer to “Fan Belt Inspection” in this manual.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 82
Piston
Removal
1
2
015EY00180
Legend (3) Bearings

(1) Bearing cap (4) Piston with connecting rod
(2) Bolt
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 83
1. Remove the cylinder head assembly. Installation

Refer to “Cylinder Head Removal” in this manual.
1. Install the piston with connecting rod.
2. Remove the oil pan.
1. Clean the piston in solvent to remove all sludge.
Refer to “Oil Pan Removal” in this manual.
2. Wipe away any foreign material in the cylinder
3. Remove the piston with connecting rod.
bores and on the pistons and connecting rods.
1. Remove carbon deposits from the upper position
3. Install the upper connecting rod bearings to the
of the cylinder wall with a scraper.
connecting rods.
4. Install the lower connecting rod bearings to the
bearing caps.
012EY00018
2. Loosen the connecting rod cap bolts.
5. Apply engine oil to the cylinder wall, upper/lower

bearing surfaces and crank pins of the crankshaft.
Apply engine oil to the entire circumference of the
piston rings.
6. Position the piston ring gap as shown in the
illustration.
Gap position:
(1) 1st compression ring
(2) 2nd compression ring
(3) 3rd compression ring
(4) Oil ring
(5) Coil expander
015EY00083
3. Move the piston to the top of the cylinder and tap

it with a hammer grip or similar object from the
connecting rod lower side to drive it out.
CAUTION : Take care not to damage the oil jets.
4. Remove the connecting rod bearings.
• Keep the connecting rod bearings in order for
reinstallation to their original positions.
• Inspect the connecting rod bearings for damage
and wear.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 84
Front mark
1 2,5
4 3
012HW002 015EY00095
7. Position the piston head front mark (1) so that it is 11. Apply molybdenum disulfide grease to the threads
facing the front of the engine. and setting faces of each connecting rod bolt.
NOTE : The connecting rod forging mark (projecting) (2) 12. Install the connecting rod bearing cap.
must be facing the opposite direction. 13. Align the bearing cap cylinder number mark and the
connecting rod cylinder number mark.
015EY00181
8. Apply engine oil or molybdenum disulfide grease to 015EY00182
the piston skirt. 14. Tighten the connecting rod cap bolts in three steps
9. Bring the piston to which the crankpin is to be using the angular tightening method.
installed to top dead center. Torque:
10. Use a piston setting tool to install the piston with 1st step : 39 N·m (4.0 kgm)
connecting rod to the cylinder block. At this time,
rotate the crankshaft until the piston is at bottom 2nd step : 60 deg.
dead center. 3rd step : 30 - 60 deg.
CAUTION : Do not bend or damage the oil jet. 1. Check that the crankshaft rotates smoothly.
2. Install the oil pan to the cylinder block.
3. Install the cylinder head to the cylinder block.
Refer to “Cylinder Head Installation” in this
manual.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 85
Disassembly
4
3
015EY00119
Legend (5) Connecting rod

(1) Piston rings (6) Connecting rod cap
(2) Snap ring (7) Bearings
(3) Piston pin
(4) Piston
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 86
CAUTION: Do not bend or damage the oil jet.
NOTE: When removing the piston and connection rod

assembly, pull the connecting rod parallel to the cylinder
bore.
1. Remove the connecting rod cap.
2. Remove the bearings.
• Take out the connecting rod bearing cap bolts and
disassemble the bearing cap with the lower
bearing.
• Keep the connecting rod bearings in order for
reinstallation to their original position.
3. Remove the piston rings.
• Clamp the connecting rod in a vise. 1
Take care not to damage the connecting rod.
• Use a piston ring replacer to remove the piston
rings.
Do not use some other tool to remove the piston 015EY00098
rings. Piston ring stretching will result in reduced

5. Remove the piston pin.
piston ring tension.
6. Remove the piston.
7. Remove the connecting rod.
Tap out the piston pin with a hammer and a brass
bar.
Keep the piston and piston rings in order for
installation to their original position.

Piston Ring Gap

1. Insert the piston ring horizontally (in the position it
would assume if it were installed to the piston) into
the cylinder liner bore.
2. Push the piston ring into the cylinder liner bore until it
reaches the point where the cylinder liner bore is the
smallest.
4. Remove the snap ring (1).
Do not allow the piston ring to slant to one side or the
Use a pair of snap ring pliers to remove the snap
rings. other. It must be perfectly horizontal.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 87
Piston Ring and Piston Ring Groove

Clearance
1. Visually inspect the piston ring grooves.
If a piston ring groove is damaged or distorted, the
piston must be replaced.
2. Use a feeler gauge (1) to measure the clearance
between the piston ring and the piston ring groove at
several points around the piston.
3. When measuring the clearance for the 1st piston
ring, press the 1st piston ring with a straight gauge
(2) as shown in the illustration.
015EY00099
3. Use a feeler gage to measure the piston ring gap.

piston ring must be replaced.
2
Piston ring gap
1st ring:
Standard: 0.18 – 0.28 mm (0.0071 – 0.0110 in.)
Limit: 1.2 mm (0.047 in.)
2nd, 3rd ring:
Standard: 0.35 – 0.50 mm (0.0138 – 0.0197 in.)
Limit: 1.2 mm (0.047 in.) 015EY00101
Oil ring:
Piston ring and piston ring groove clearance
Standard: 0.15 – 0.35 mm (0.0059 – 0.0138 in.)
1st ring:
Limit: 1.2 mm (0.047 in.)
Standard: 0.057 – 0.097 mm (0.0022 – 0.0038 in.)
Limit: 0.2 mm (0.0079 in.)
2nd, 3rd ring:
1 Standard: 0.085 – 0.120 mm (0.0033 – 0.0047 in.)
Limit: 0.20 mm (0.787 in.)
Oil ring:
Standard: 0.020 – 0.060 mm (0.0008 – 0.0024 in.)
Limit: 0.15 mm (0.0059 in.)
015EY00100
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 88
Piston Pin Diameter

Use a micrometer to measure the piston pin outside
diameter at several points
piston pin must be replaced.
Piston pin diameter
Standard: 35.995 – 36.000 mm (1.4171 – 1.4173 in.)
Limit: 35.95 mm (1.4154 in.)
015HY00030
Piston Ring Expansion Force

Use an expansion force gauge to measure the piston
ring expansion force.
Piston ring expansion force
1st ring:
Standard: 22.7 – 30.7 N (2.31 – 3.13 kg)
Limit: 12 N (1.2 kg)
2nd ring:
Standard: 16.7 – 22.6 N (1.70 –2.30 kg) Piston Pin Hole and Piston Pin Clearance
Limit: 5.9 N (0.6 kg) Use a inside dial indicator to measure the piston pin hole
3rd ring: (in the piston).
Piston pin hole and piston pin clearance
Standard: 20.8 – 28.2 N (2.12 – 2.08 kg)
Standard: 0.004 – 0.017 mm (0.0003 – 0.0008 in.)
Limit: 4.9 N (0.5 kg)
Oil ring:
Standard: 43.0 – 58.1 N (4.38 – 5.92 kg) Piston Pin and Connecting Rod Small End
Limit: 41 N (4.2 kg) Bushing Clearance
Use a caliper and dial indicator to measure the
clearance between the piston pin and connecting rod
small end bushing
If the clearance between the piston pin and the
connecting rod small end bushing exceeds the specified
limit, replace the piston pin and/or the connecting rod
assembly.
Small end bushing clearance
Standard: 0.012 – 0.027 mm (0.00047 – 0.0011 in.)
Limit: 0.05 mm (0.0020 in.)
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 89
Crankshaft and Connecting Rod Bearing

Clearance
1. Clean the crankshaft, connecting rod, bearing cap,
and bearings.
2. Install the bearing to the connecting rod and bearing
cap.
3. Apply a coat of molybdenum disulfide grease to the
bearing cap bolt threads and setting faces.
4. Prevent the connecting rod from moving.
5. Tighten the bearing cap to the specified torque.
Connecting rod bearing cap bolt torque
1st step: 39 N·m (4.0 kgm)
2nd step: 60 deg.
3rd step: 30 – 60 deg.
6. Use a dial indicator to measure the connecting rod
bearing inside diameter.
015EY00102
Crankpin and connecting rod bearing clearance

Standard: 0.037 – 0.076 mm (0.0015 – 0.0030 in.)
Connecting Rod Alignment
Limit: 0.1 mm (0.0034 in.)
Use a connecting rod aligner to measure the distortion
and the parallelism between the connecting rod big end
hole and the connecting rod small end hole.
If either the measured distortion or parallelism exceeds
the specified limit, the connecting rod must be replaced.
Connecting rod alignment
Per length of 100 mm (3.94 in.)
Standard: 0.05 mm (0.002 in.) or less
Limit: 0.20 mm (0.008 in.) 1 2 B
A
A
1 2 B
7. If the clearance between the measured bearing

inside diameter and the crankpin exceeds the
specified limit, the bearing and/or crankshaft must be
replaced.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 90
Piston and Liner Bore Clearance

If the cylinder liner has been replaced, install the piston
using service parts. The cylinder liner bore and pistons
have only one grade. It is not necessary to select the
piston grade.
1 2 A 1. Measure the cylinder liner bore. (Reference)
Refer to the “Cylinder Liner Bore Measurement.”
B B
Measuring Point 130 mm (5.118 in.)
A
Cylinder liner bore
Standard: 115.031 – 115.050 mm
(4.5288 – 4.5295 in.)
Connecting Rod and Crankshaft Clearance

1. Fix the connecting rod assembly to the crankshaft
using the specified torque.
2. Use a feeler gauge to measure the clearance
between the connecting rod and crankshaft.
connecting rod must be replaced.
Connecting rod and crankshaft clearance
Standard: 0.17 – 0.30 mm (0.0067 – 0.0118 in.)
Limit: 0.35 mm (0.0138 in.) 012EY00034
2. Measure the piston outside diameter (Reference).

Piston Measuring Point: 80 mm (3.15 in.)
015EY00062
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 91
The grade mark is stamped on the top of the piston

installed at the factory, but service part pistons do not
have any grade (single grade).
Piston outside diameter
Standard: 114.894 – 114.909 mm
(4.5233 – 4.5240 in.)
Piston and Liner bore clearance
Standard: 0.122 – 0156 mm (0.0048 – 0.0061 in.)
If the piston and liner clearance exceeds the standard
value, the piston and/or liner must be replaced.
CAUTION: Cylinder liner kit clearances are preset.
However, the cylinder liner installation procedure
may result in slight decreases in cylinder liner
clearances. Always measure the cylinder liner
clearance after installation to be sure that its is
correct.
015EY00183
Reassembly
• Use the piston ring setting tool 1-85221-029-0 to
1. Install the snap ring (1). reassemble the four piston rings according to the
Use a pair of snap ring pliers to reassemble the snap top mark on the piston ring.
ring to the piston. The oil ring does not have a top mark.
2. Install the connecting rod and piston pin. NOTE: Insert the expander coil into the oil ring groove so
• Clamp the connecting rod in a vise. that there is no gap on either side of the expander coil
Take care not to damage the connecting rod. before installing the oil ring.
• Install the piston so that the piston head front mark
and the connecting rod front mark face the
opposite direction.
• Check that the piston rings rotate smoothly in the

piston ring grooves.
015EY00098
4. Install the connecting rod bearing.
• Apply engine oil to the piston pin. Carefully wipe any oil or other foreign material from
• Insert the piston pin to the connecting rod through the connecting rod bearing back faces and the
the piston pin hole in the piston. bearing fitting surfaces.
• Install the snap ring.
3. Install the piston ring.
• Apply engine oil to the piston rings.
• Install the compression rings with the stamped side
facing up.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 92
5. Install the connecting rod cap.

• Fit the lower connecting rod bearing to the
connecting rod cap.
• Apply engine oil to the circumference of each 1
piston ring, piston and crankpin.
• Position the piston ring gaps as shown in the
illustration.
Gap position
(1) 1st compression ring 2
(2) 2nd compression ring
(3) 3rd compression ring
(4) Oil ring
(5) Coil expander
015EY00181
Front mark • Use a piston ring setting tool to compress the

1 2,5 piston rings.
4 3
012HW002
• Apply molybdenum disulfide grease to the two

piston skirts.
This will facilitate smooth break-in when the engine
is first started after reassembly.
• Apply engine oil to the upper connecting rod
bearing. 015EY00095
• Apply engine oil to the cylinder wall.

• Use a hummer grip to push the piston in until the
• Position the front mark (1) on the piston head so connecting rod marks contact the crankpin.
that it is facing the front of the engine.
As the same time, rotate the crankshaft until the
crankpin is at bottom dead center.
CAUTION: Do not bend or damage the oil jet.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 93
• Align the connecting rod cap cylinder number

marks and the connecting rod cylinder number
marks.
015EY00182
• Install the connecting rod caps.

• Apply molybdenum disulfide grease to the threads
and setting faces of each connecting rod bolt.
• Tighten the connecting rod bolts to the specified
torque.
Torque:
1st step: 39 N·m (4.0 kgm)
2nd step: 60 deg.
015EY00083
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 94
Crankshaft
Removal
3 4 5
2 7
1
6
10
11 9
12
10
13
015EY00184
Legend (7) Connecting rod bearing

(1) Crank pulley (8) Thrust bearings
(2) Oil seal (9) Thrust bearings
(3) Adjusting plate (10) Crank bearings
(4) Front cover (11) Crankshaft
(5) Gasket (12) Slinger
(6) Piston with connecting rod (13) Crankcase
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 95
1. Remove the cylinder head assembly.

Refer to “Cylinder Head Removal” in this manual.
2. Remove the oil pan.
Refer to “Oil Pan Removal” in this manual.
3. Remove the flywheel housing .
4. Remove the crank pulley.
1 5 9 13 12 8 4
Refer to “Crank Pulley Removal” in this manual.
5. Remove the front cover.
2 6 10 14 11 7 3
Refer to “Front Cover Removal” in this manual.
6. Remove the timing gears.
Refer to “Timing Gear Removal “ in this manual.
7. Remove to the piston with the connecting rod.
Refer to “Piston Removal “ in this manual.
8. Measure the crankshaft end play at No. 7 crankshaft
journal before removing the crankshaft thrust
012EY00057
bearing.
Crankshaft end play 2. Loosen the crankcase bolts (M10/25 pieces)
Standard: 0.04 - 0.205 mm (0.0016 - 0. 81 in) evenly from outside to inside.
Limit : 0.54 mm (0. 021 in) 3. Screw M10 bolts (crankcase bolts) into the four
thread holes (marked with asterisks) and tighten
If the measured value exceeds the specified limit, the them evenly. Separate the crankcase from the
crankshaft thrust bearing must be replaced. cylinder block.
015EY00084
012MX006
9. Remove the crankcase. 4. Remove the thrust bearing .

1. Loosen the crankcase bolts (M14/14 pieces) a Clean the crankcase surfaces and remove the
little at a time in the numerical order shown in the sealant residue.
illustration.
10. Remove the crankshaft from the cylinder block.
11. Remove the upper crankshaft bearings.
• Keep the crankshaft bearings in order for
installation to their original position.
• Clean the cylinder block surfaces and bores.
Remove the sealant residue and carbon deposits.
• Use compressed air to thoroughly clean the inside
and outside surfaces of the cylinder block, the oil
holes, and the water jackets.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 96
WARNING: Wear safety glasses when using 3. Install the upper bearings to their original position,
compressed air as flying dirt particles may cause if they are reused.
eye injury. CAUTION: Do not apply engine oil to the bearing
back faces and cylinder block bearing surfaces.
Installation
1. Install the upper crankshaft bearings to the cylinder
block .
1. Use compressed air to thoroughly clean the inside
and outside surfaces of the cylinder block, the oil
holes, and the water jackets.
injury when used for cleaning. Wear safety glasses
012EY00059
2. Install the crankshaft thrust bearing to the cylinder

block.
1. Apply engine oil to the thrust bearing oil grooves
before installation.
2. Install the thrust bearing to the crankshaft No.7
journal.
Thrust bearing oil grooves must face the sliding
surface.
012EY00058
2. Carefully wipe any foreign material from the upper

crankshaft bearings and the cylinder block bearing
fitting surfaces.
• The upper crankshaft bearings have an oil hole
and oil groove. The lower crankshaft bearings
have only a partial oil groove.
Upper
015EY00194
3. Install the crankshaft to the cylinder block.

Lower
• Carefully wipe any foreign material from the
crankshaft.
• Apply engine oil to the crankshaft journal and the
crankshaft bearing sliding surfaces before
installing the crankshaft.
015EY00185
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 97
015EY00088 015EY00090
4. Install the upper side crankshaft thrust bearings. 6. Install the lower crankcase to the cylinder block.
1. Apply engine oil to the thrust bearing oil grooves 1. Carefully wipe any foreign material from the lower
before installation. bearing back and sliding faces.
2. Install the thrust bearing to the crankshaft No.7 2. Install the lower bearings to their original position
journal. if they are reused.
015EY00089 015EY00189
5. Install the lower side crankshaft thrust bearings. 3. Apply engine oil to the lower bearing sliding
1. Apply engine oil to the thrust bearing oil grooves surfaces.
before installation. 4. Apply unbroken strips of ThreeBond 1207B or
2. Install the thrust bearings to the crankcase. equivalent to the lower face of the cylinder block
Thrust bearing oil grooves must face the sliding as shown in the illustration.
surface. The sealant must be 3 - 4 mm (0.12 - 0.16 in)
wide.
NOTE: Immediately (within 10 minutes of applying
the sealant) set the lower crankcase to the cylinder
block.
NOTE: Do not allow the lower crankshaft bearings
and thrust bearing to fall free.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 98
D 0 6 2 3 7 A
C 9 5 1 4 8 B
012EY00014 012EY00015
5. Apply molybdenum disulfide grease to the lower 7. Check that the crankshaft rotates smoothly.
crankcase bolt threads and setting faces. NOTE: Lower crankcase bolts can be reused six (6)
times.
8. Tighten the lower crankcase M10 bolts a little at a
time in the numerical order shown in the
illustration.
23 19 15 11 7 3 1 5 9 13 17 21 25
012EY00061 24 20 16 12 8 4 2 6 10 14 18 22
6. Tighten the crankcase M14 bolts in three steps

using the angular tightening method.
Torque:
1st Step: 98 N·m (10 kgm) 012EY00062
2nd Step: 132 N·m (13.5 km)

CAUTION: The lower crankcase and the cylinder
3rd Step: 30 - 60 deg.
block are machined as a single unit. They can not be
replaced separately. Always replace the lower
crankcase and the cylinder block as a set.
7. Install the piston with the connecting rod.

Refer to “Piston Installation” in this manual.
8. Install the timing gears to the cylinder block.
Refer to “Timing Gear Installation” in this manual.
9. Install the flywheel housing to the cylinder block.
manual.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 99
10. Install the flywheel to the crankshaft.

Refer to “Flywheel Installation” in this manual.
11. Install the front cover to the cylinder block.
Refer to “Front Cover Installation” in this manual.
12. Install the crankshaft damper pulley.
Refer to “Crank Pulley and Flywheel Installation” in
this manual.
13. Install the oil pan to the cylinder block.
14. Install the cylinder head to the cylinder block.
Refer to “Cylinder Head Installation” in this manual.
15. Install the camshaft to the cylinder head.
Refer to “Camshaft Installation” in this manual.
16. Install the rocker arm assembly to the cylinder head.
Refer to “Rocker Arm Assembly Installation” in this
manual.
17. Adjust the valve clearance.
Refer to “Valve Clearance Adjustment” in this
manual.
18. Install the cylinder head cover to the cylinder head.
19. Install the water pump to the front cover.
20. Install the alternator to the engine.
Refer to “Fan Belt Tension Adjustment” in this
manual.
22. Install the turbocharger .
Refer to “Turbocharger Installation” in this manual.
23. Install the cooling fan and fan guide.
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 100
Disassembly
3
2
015EY00191
Legend (3) Crankshaft gear

(1) Crankshaft
(2) Pin
1. Use the crankshaft gear remover 8-94396-818-0 to

remove the crankshaft gear.
NOTE: Do not remove the crankshaft gear from the
crankshaft unless the gear is damaged.
014EY00115
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 101
Inspection and Repair Crankshaft Run-Out

1. Set a dial indicator to the center of the No.4
Make the necessary adjustments, repairs, and part crankshaft journal.
replacements if excessive wear or damage is 2. Gently turn the crankshaft in the normal direction of
discovered during inspection. engine rotation.
Crankshaft Read the dial indicator as you turn the crankshaft.
Inspect the surface of the crankshaft journals and If the measured value exceeds the specified limit, the
crankpins for excessive wear and damage. crankshaft must be replaced.
Inspect the oil ports for obstructions.
Standard: 0.06 mm (0.0024 in) or less
Limit: 0.45 mm (0.018 in)
014EY00118
Bearing Spread 014EY00120
Check the bearing spread.

Finger pressure should be sufficient to fit the bearing Crankshaft Journal and Crankpin Diameter
into position. 1. Use a micrometer to measure the crankshaft journal
If the bearing fits loosely, it must be replaced. diameter across points (1) – (1) and
(2) – (2).
2. Use the micrometer to measure the crankshaft
journal diameter at the two points ((3) and (4)).
3. Repeat Steps 1 and 2 to measure the crankshaft pin
diameter.
Crankshaft journal diameter
Standard:
No. 4 journal: 81.875 – 81.895 mm
(3.2234 – 3.2242 in)
Others: 81.905 – 81.925 mm (3.2246 – 3.2254 in)
Crankshaft pin diameter
Standard: 65.902 – 65.922 mm (2.5946 – 2.5953 in)
Crankshaft journal and crankpin uneven wear
Limit: 0.05 mm (0.0020 in)
015EY00189
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 102
5. Tighten the lower crankcase M10 bolts to the

specified torque.
1 3 4
2 2
23 19 15 11 7 3 1 5 9 13 17 21 25
1
24 20 16 12 8 4 2 6 10 14 18 22
015EY00195
Crankshaft Bearing Inside Diameter

1. Clean the cylinder body and lower crankcase
bearing fitting surfaces. Clean the bearing inside and 012EY00062
outside surfaces.
6. Use an inside dial indicator to measure the
2. Install the lower crankcase with the bearings to the crankshaft bearing inside diameter.
cylinder body.
3. Apply molybdenum disulfide grease to the lower Crankshaft Journal and Bearing Clearance
crankcase bolt threads and setting faces. If the clearance between the measured bearing inside
diameter and the crankshaft journal diameter exceeds
4. Tighten the lower crankcase M14 bolts in three steps
the specified limit, the crankshaft must be replaced.
using the angular tightening method.
Crankshaft journal and Bearing clearance
Torque:
Standard:
1st step : 98 N·m (10 kgm)
No.4 journal: 0.093 – 0.124 mm (0.00366 – 0.00488 in)
2nd step: 132 N·m (13.5 kgm)
Others: 0.063 – 0.094 mm (0.00248 – 0.00370 in)
Limit: 0.14 mm (0.0055 in)
NOTE: Cylinder body lower crankcase M14 bolts can be
reused 6 times.
D 0 6 2 3 7 A
C 9 5 1 4 8 B
014EY00121
012EY00015
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 103
Crankshaft Tufftriding Inspection Crankshaft Tufftriding Judgment

• Use an organic cleaner to thoroughly clean the • Wait for 30 to 40 seconds.
crankshaft. If there is no discoloration after 30 or 40 seconds,
There must be no oil on the crankshaft. the crankshaft is usable.
• Prepare a 5 – 10% solution of ammonium cuprous If discoloration appears (the surface being tested
chloride (dissolved in distilled water). will become the color of copper), the crankshaft
• Use a syringe to apply the solution to the must be replaced.
crankshaft. • Steam clean the crankshaft surface immediately
Hold the surface perfectly horizontal to prevent the after completing the test.
solution from running. NOTE: the ammonium cuprous chloride solution is
NOTE: Do not allow the solution to come in contact with highly corrosive. Because of this, it is imperative that the
the oil ports and their surrounding area. surfaces being tested by cleaned immediately after
completing the test.
The portion to be tested

must be held horizontally Test liquid should
so as not to let the test not be applied to
solution flow. the area around the
oil port.
The sliding surface
of the pin
or journal.
Approximatery
10mm (0.4in)
015EY00113
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 104
Reassembly
3
2
015EY00191
Legend (3) Crankshaft gear

(1) Crankshaft
(2) Pin
69945_ESS-185A_SEC6A-3 2011.8.10 1:55 PM ページ 105
1. Install the crankshaft gear to the crankshaft (if

necessary).
1. Install the crankshaft timing gear alignment pin.
2. Heat the crankshaft gear evenly with a gas burner
to invite thermal expansion.
Do not allow the temperature of the gas burner to
exceed 180°C (356°F).
If the crankshaft gear is not heated, it may break
during installation.
3. Use the crankshaft gear installer 8-94396-819-0 to
install the crankshaft gear.
015EY00131
The crankshaft gear timing mark L (1) must be facing

out.
015EY00192
Take care not to damage the crankshaft and crankshaft

gear.
WARNING: TAKE CARE NOT TO BURN YOURSELF

ON THE HEATED CRANKSHAFT GEAR.
69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 106
Cylinder Block
Removal
3
5
012EY00012
Legend (3) Oil jet

(1) Oil pressure switch (4) Cylinder liner
(2) Crankcase (5) Cylinder block
69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 107
1. Remove the turbocharger. 6. Install the flywheel to the crankshaft.

Refer to “Turbocharger Removal” in this manual. Refer to “Crank Pulley and Flywheel Installation” in
2. Remove the fan guide from the engine (If so this manual.
equipped.) 7. Install the front cover to the cylinder block.
3. Remove the water pump. Refer to “Front Cover Installation” in this manual.
Refer to “Water Pump” in this manual. 8. Install the crank pulley to the crankshaft.
4. Remove the alternator. Refer to “Crank Pulley and Flywheel Installation” in
Refer to “Alternator Removal” in this manual. this manual.
5. Remove the injection pump. 9. Install the oil pan to the cylinder block.
Refer to “Injection Pump Removal” in this manual. Refer to “Oil Pan Installation” in this manual.
6. Remove the bearing case. 10. Install the oil cooler to the cylinder block.
Refer to “Bearing Case Removal” in this manual. Refer to “Oil Cooler Installation” in this manual.
7. Remove the oil cooler assembly. 11. Install the injection pump to the cylinder block.
Refer to “Oil Cooler Removal” in this manual. Refer to “Injection Pump Installation” in this manual.
8. Remove the cylinder head cover 12. Install the cylinder head to the cylinder block.
Refer to “Cylinder Head Removal” in this manual. Refer to “Cylinder Head Installation” in this manual.
9. Remove the cylinder head . 13. Install the camshaft to the cylinder head.
Refer to “Cylinder Head Removal” in this manual. Refer to “Camshaft Installation” in this manual.
10. Remove the oil pan. 14. Install the rocker arm assembly to the cylinder head.
Refer to “Oil Pan Removal” in this manual. Refer to “Rocker Arm Assembly Installation” in this
11. Remove the crank pulley. manual.
Refer to “Crank Pulley Removal” in this manual. 15. Adjust the valve clearance.
12. Remove the front cover. Refer to “Valve Clearance Adjustment” in this
manual.
Refer to “Front Cover Removal” in this manual.
13. Remove the flywheel housing.
14. Remove the timing gears.
Refer to “Timing Gear Removal” in this manual.
18. Install the water pump to the front plate.
15. Remove the piston from the cylinder block.
Refer to “Piston Removal” in this manual.
16. Remove the crankshaft from the cylinder block.
Refer to “Crankshaft Removal” in this manual.
17. Use compressed air to thoroughly clean the inside
and outside surfaces of the cylinder block, the oil Refer to “Fan Belt Adjustment” in this manual.
holes, and the water jackets. 21. Install the turbocharger .
WARNING: Compressed air can cause personal Refer to “Turbocharger Installation” in this manual.
injury when used for cleaning. Wear safety glasses 22. Install the cooling fan and fan guide.
and protective clothing. Refer to “Water Pump Installation” in this manual.
Installation
Refer to “Crankshaft Installation” in this manual.
2. Install the piston into the cylinder block.
Refer to “Piston Installation” in this manual.
3. Install the timing gears to the cylinder block.
Refer to “Timing Gear Installation” in this manual.
4. Install the bearing case to the cylinder block.
Refer to “Bearing Case Installation” in this manual.
5. Install the flywheel housing to the cylinder block.
manual.
69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 108
Disassembly
3
5
012EY00012
Legend (3) Oil jet

69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 109
1. Remove the lower crankcase. Inspection and Repair

• Loosen the fixing bolts to disassemble the lower
crankcase. Make the necessary adjustment, repairs, and part
• Place the crankcase on a flat piece of wool.
2. Remove the oil jet.
Loosen the bolt to remove the oil jet. Cylinder Block Flatness
NOTE: Take care not to bend or damage the oil jet. • Remove the cylinder liners.
3. Remove the cylinder liner. • Inspect the cylinder block for cracks and other
• Use a scraper to remove carbon deposits. damage. Check the oil and water holes for
• Use a cylinder bore dial indicator to measure the clogging.
cylinder bore in the thrust and axial direction of the If possible, use dye pendant flow detector.
crankshaft before removing the cylinder liner.
Measuring point: 20 – 25 mm (0.79 – 1.0 in.)
the cylinder liner must be replaced.
Cylinder liner bore
Limit: 115.2 mm (4.5354 in.)
NOTE: If the inside of the cylinder liner is scored or
scratched, the cylinder liner must be replaced.
012EY00043
• Use a straight edge (1) and a feeler gauge (2) to

measure cylinder block upper face warpage (4
sides and 2 diagonals as shown in the illustration).
Upper face warpage
Limit: 0.2 mm (0.008 in.)
012EY00036
The cylinder liner is a loose fit type. The cylinder liner

can be removed with hands. If the cylinder liner
removal is difficult, press it from crankcase side.
Visually inspect the cylinder block for damage.
69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 110

the cylinder block must be replaced.
Liner Outside
Grade No.
2
012EY00065
012EY00064
• Apply water under pressure to the cylinder body

water jacket to check for leakages. Grade No.
Water Pressure: 490 kPa (5 kg/cm2)

If water leakage is found, the cylinder block must
be replaced.
Cylinder Liner Grade Selection and

Standard Fitting Interference
Accurately measured fitting interference and proper
cylinder liner grade selection are extremely important.
If the cylinder liner fitting interference is too small,
engine cooling efficiency will be adversely affected.
If the cylinder liner fitting interference is too large, it will
be difficult to insert the cylinder liner into the cylinder
block.
012EY00066
A mark was stamped on the left side of the cylinder block
during production to indicate the correct liner.
The liner grade (1, 2, 3) is indicated by a metal stamp.
Cylinder liner grade
Liner Cylinder Bore Service Liner Outside
Grade Diameter mm (in.) Grade Diameter mm (in.)
118.001 – 118.020 117.991 – 118.000
1, 2 1X
(4.64571 – 4.64646) (4.64531 – 4.64567)
118.021 – 118.030 118.001 – 118.010
3 3X
(4.64650 – 4.64685) (4.64571 – 4.64606)
The cylinder liner grade is stamped on the outside of the

cylinder liner.
69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 111
Cylinder Bore Measurement Oil Jet

If the marking is not clear, measure the cylinder bore Check the oil port on the oil jet for clogging.
inside diameter.
• Use a cylinder bore dial indicator to measure the
cylinder bore in the thrust and axial direction of the
crankshaft.
Measuring points: 20 mm (0.79 in)
110 mm (4.33 in)
190 mm (7.18 in)
012EY00039
Cylinder Liner Projection

• Use a dial indicator or a straight edge and feeler
gauge to measure the cylinder liner projection.
Cylinder liner projection
012EY00034 Standard: 0.06 – 0.10 mm (0.0024 – 0.0039 in.)
The difference in the cylinder liner projection height
Lower Crankcase between any adjacent cylinders must not exceed
Visually inspect the lower crankcase for cracking and the limit.
damage. Projection height between adjacent cylinders:
If possible, use dye penetrant flaw detector. 0.03 mm (0.0012 in.) or less
012EY00045
012EY00038
69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 112
Reassembly
3
5
012EY00012
Legend (3) Oil jet

69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 113
1. Install the cylinder liner to the cylinder block.

• Use new kerosene or diesel fuel to thoroughly
clean the cylinder liner and bore.
• Use compressed air to blow-dry the cylinder liner
and bore surface.
injury when used for cleaning. Wear safety glasses
NOTE: All foreign materials must be carefully removed

from the cylinder liner and the cylinder bore before
installation.
• Apply engine oil to the outside surface of the
cylinder liner.
• Install the cylinder liner to the cylinder block from
the top of the cylinder block with your hand.
• Check the cylinder liner projection.
NOTE: 012EY00045
1) Do not apply excessive force or strike the cylinder

liner during installing. 2. Install the oil jet to the cylinder block.
2) Take care to not drop the cylinder liner when the Tighten to the specified torque.
cylinder block turns over. Torque: 21 N·m (2.1 kgm)
Be sure that the oil jet tip is aligned with the piston
cooling hole.
Do not bend or damage the oil jet.
012EY00044
012EY00046

4. Install the crankcase.
69945_ESS-185A_SEC6A-4 2011.8.10 1:57 PM ページ 114
5. Install the oil pressure switch.

• Install the adapter (1) to the cylinder block and
tighten to the specified torque.
• Install the oil pressure switch (2).
Torque:
Adapter: 118 N·m (12.0 kgm)
Oil pressure switch: 18 N·m (1.8 kgm)
2
Sealant
012EY00067
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 1
ENGINE COOLING 6B–1
ENGINE COOLING
CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-6
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-6
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6B-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6B-4
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Service precaution
• Be sure to use the correct fastener in the proper
location. If a used fastener is replaced with a new
one, the new fastener must be identical to the
previous one.
• Some fasteners must always be replaced with

new ones following removal. These fasteners are
specified in this Manual.

sealant. These fasteners are specified in this
Manual.
• Supplemental fastener coatings (paint, grease, or

clamping force. They may damage the fastener.
Do not use them unless specifically called for.
• Tighten all fasteners to the specified torque. If

there is a tightening sequence, follow it exactly.
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 2
6B–2 ENGINE COOLING
General Description
Coolant Flow
Reserve
tank Water outlet pipe
Thermostat
Water jacket, Cylinder head

Radiator
Water
jacket
Water Cylinder
pump body
Oil cooler Water drain
F06EY00142
The engine cooling system consists of the radiator, the When the coolant temperature reaches 82°C (180°F),
surge tank, the water pump, the cooling fan, and the the thermostat begins to open. A gradually increasing
thermostats. amount of coolant passes through the radiator before
When the engine and coolant are cold, the thermostat returning to the cylinder block.
with jiggle valve is completely closed. The water pump When the coolant temperature reaches 95°C (203°F),
circulates the coolant through the radiator by-pass the thermostat is fully open. All coolant now passes
directly back to the cylinder body (coolant does not pass through the radiator before returning to the cylinder
through the radiator). This provides a rapid increase in block. Effective engine cooling is ensured.
coolant temperature and smooth engine operation.
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 3
Thermostat
Removal
031EY00005
Legend (3) Gaskets

(1) Water outlet pipe
(2) Thermostats
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 4
Disassembly
1. Loosen the fixing bolts to remove the water outlet
pipe. Discard the gaskets.
2. Remove the thermostats.

Make necessary adjustment, repairs, and part
1. Check the wax pellet for leakage.
2. Check the springs for damage and weakness.
Jiggle valve
3. Check the caulking for cracks.
Thermostat operation test
1. Prepare a container large enough to completely

031EY00026
contain the thermostat.
2. Fill the container with cold water.
3. Completely immerse the thermostat in the cold
water. Stirring rod
4. Place a piece of wood between the thermostat and
the bottom of the container (see illustration).
5. Place a thermometer in the water.
6. Heat the water. Stir constantly to prevent direct heat
application to the thermostat.
7. Note the temperature at which the thermostat begins
to open.
AA-6HK1XQA and AA-6HK1XQA-03 (With Jiggle
Valve) Piece of wood
Initial opening temperature: 82°C (180°F)
AA-6HK1XQA-03 (Without Jiggle Valve)
Initial opening temperature: 76.5°C (170°F)
8. Note the temperature at which the thermostat opens
completely. 031EY00027
AA-6HK1XQA and AA-6HK1XQA-03 (With Jiggle

Valve)
Full open temperature: 95°C (203°F)
AA-6HK1XQA-03 (Without Jiggle Valve)
Full open temperature: 90°C (194°F)
9. Measure the thermostat opening height at the fully
open position.
Opening height at full open: 8 mm(0.31 in)
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 5
Reassembly
1. Install the thermostats to the cylinder head.
The thermostat with the jiggle valve is installed to the left

side (intake manifold side) of the engine. The jiggle
valve faces the rear of the engine (flywheel side).
Front 3
031EY00023
2. Install new gaskets.

3. Install the water outlet pipe.
4. Tighten the fixing bolts to the specified torque.
Water outlet pipe bolt torque: 19 N·m(1.9 kgm)
031EY00024
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 6
Water Pump
Disassembly
15
14
13
11
12
16
10
8
7
6
5
3
2
1
030EY00026
Legend (9) Shaft

(1) Center (10) Water pump body
(2) Dust cover (11) Dowel pin
(3) Snap ring (12) Seal unit
(4) Bearing (13) Impeller
(5) Bearing (14) Gasket
(6) Spacer (15) Cover
(7) Bearing (16) Bolt
(8) Washer
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 7
1. Remove the rear cover from the water pump body. Inspection and Repair
2. Use a remover to remove the impeller from the water
pump. Make the necessary adjustments, repairs and part
3. Use a puller to remove the water pump center.
4. Remove the dust cover and snap ring.
5. Remove the water pump shaft with ball bearings. Water pump impeller
• Use a plastic hammer to lightly tap on the water 1. Check the impeller for corrosion.
pump shaft from the impeller side.
030EY00027
030HY00027
6. Use a bench press to remove the bearing from the Water pump shaft
shaft.
1. Measure the water pump shaft and center or impeller
interference.
If the measured interference is less than the
specified limit, the pump shaft and / or the center and
impeller must be replaced.
Pump shaft and center interference:
Limit: 0.048 – 0.078 mm (0.0019 – 0.0031 in)
Pump shaft and impeller interference:
Limit: 0.022 – 0.062 mm (0.0009 – 0.0024 in)
030HY00028
7. Remove the seal unit.
030EY00036
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 8
2. Carefully wipe away any bearing grease. 4. Use a bench press to gradually press the water
3. Listen for excessive bearing operating noise. pump shaft down until the bearings are seated
correctly.
030EY00029
030HY00033
Excessive bearing operating noise indicates severe

bearing wear. 2. Install the water pump shaft with bearings to the
water pump body.
Reassembly 1. Repack the bearings with multipurpose grease.
1. Install the ball bearing to the water pump shaft.
1. Apply engine oil to the water pump shaft.
2. Place the water pump shaft and the bearings on
the base plates.
3. Install the washer (4), ball bearing (3), spacer (2),
and bearings (1).
030EY00034
4
2. Place the water pump body on bench press base
plate.
2
NOTE : To prevent damage to the water pump shaft,
place soft brass or copper sheets between the base
plates and the water pump shaft.
030EY00030
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 9
3. Position the pump shaft with bearings to the water 4. Install the seal unit to the water pump body.
pump body. • Press in the seal unit to the specified position
4. Use a bench press to gradually press the water using a bench press and installer 1-85220-047-0.
pump shaft into the water pump body. Seal unit installation position A:
NOTE : Do not drive the bearing into position with a 11.0 – 11.6 mm (0.433 – 0.457 in)
hammer or similar object. Bearing damage will result.
030EY00035
030EY00031
5. Install the water pump impeller to the water pump

3. Install the snap ring and dust cover. shaft.
1. Use pliers to install the snap ring into water pump • Use a bench press to press in the impeller.
body groove.
• The impeller must be flush with the water pump
2. Install the dust cover with the flange facing out. shaft end.
6. Use a bench press to gradually press the water
pump center onto the water pump shaft to the
specified dimension.
030EY00032
030EY00033
Dimension A: 202.9 mm (7.988 in)

7. Install the rear cover with new gasket to the water
pump body.
69945_ESS-185A_SEC6B 2011.8.10 1:58 PM ページ 10
MEMO
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 1
ENGINE FUEL 6C–1
ENGINE FUEL
CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 Injection Nozzle Holder . . . . . . . . . . . . . . . . . . . . . 6C-7
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Nozzle and Holder Specification . . . . . . . . . . . . . 6C-7
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-9
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6C-6 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-6 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Calibration Data. . . . . . . . . . . . . . . . . . . . . . . . . 6C-19
Service precaution
previous one.


Manual.


69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 2
6C–2 ENGINE FUEL
General Description
Fuel System Operation When working on the fuel system –
• Disconnect the negative battery cable.
The fuel injection pump is driven by the crankshaft. The
fuel injection pump drives the fuel feed pump. • Have a dry chemical (Class B) fire extinguisher
The fuel feed pump draws fuel from the fuel tank. The where it can be reached quickly.
fuel is delivered to the injection pump through the • Release the fuel line pressure before servicing
fuel/water separator and the secondary fuel filter. system components.
The governor regulates the flow of fuel to the delivery • Carefully read and understand the appropriate
valves. instructions.
The plunger in the injection pump delivers fuel at high
pressure through the delivery valves to the individual
fuel injectors at precise intervals.
The pressure generated by the fuel in the fuel injector
forces open a needle valve. Fuel is injected from the
injection nozzle holes into the cylinder as a very fine
spray.
Excess fuel is returned to the fuel tank through the fuel
return line.
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 3
ENGINE FUEL 6C–3
Fuel Flow
040EY00060
Fuel system components Open the drain plug at the bottom of the sedimentor to
drain the water.
The fuel system consists of the fuel tank, the fuel feed
pump, the water sedimentor, the fuel filter, the injection • Fuel filter
pump, and the injection nozzles. The fuel filter removes solid particles from the fuel.
Fuel is drawn from the fuel tank by the fuel feed pump. It These particles, if allowed to reach the injection nozzles,
passes through the water sedimentor (water particle would cause serious abrasive damage.
removal) and the fuel filter (solid particle removal) before • Fuel feed pump
being delivered to the injection pump. The fuel feed pump draws fuel from the fuel tank and
Precisely metered amounts of fuel are forced into each delivers it to the injection pump. It maintains a high
of the injection nozzles at exact intervals to provide pressure in the fuel line.
efficient engine operation. An independent priming pump permits manual fuel feed
when the engine is off.
• Water sedimentor
The water sedimentor has a clear plastic body. There is
a warning line on the body. When the water level
reaches the warning line, the sedimentor must be
emptied.
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 4
6C–4 ENGINE FUEL
• Injection pump
Major injection pump components are the pump body,
the plungers, the governor, and the timing advancer.
The injection pump is the nucleus of the diesel engine
fuel system. It pressurizes and delivers precisely timed
and measured fuel charges to the engine cylinders.
Timing and volume are determined by engine load and
speed.
Each plunger is raised to the top of its stroke by a cam
lobe and forced to the bottom of its stroke by a return
spring.
Together, the plungers create a reciprocal motion.
Fuel enters the plunger barrel through the inlet port
when the plunger is at the bottom of its stroke.
Excess fuel leaves the plunger barrel through the outlet
port when the plunger is at the top of its stroke.
The injection pump has an identification tab attached to
its body.
• Governor
The fuel system uses an RSV variable speed governor.
Engine speed and load vary widely during normal
driving. If the engine speed is too low, the engine will be
sluggish and may stall. If engine speed is too high,
overrun occurs.
The governor operates to maintain engine speed within
acceptable limits thus preventing stalling and overrun.
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 5
ENGINE FUEL 6C–5
Fuel Filter
Disassembly
Legend
(1) Fuel filter
(2) Overflow valve
(3) Fuel filter body
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 6
6C–6 ENGINE FUEL
1. Remove the fuel filter with a filter wrench. Reassembly

CAUTION: Be careful not to spill the fuel remaining
in the fuel filter when removing the filter. 1. Install the overflow valve to the fuel filter body.
2. Install the fuel filter.
• Before install a new fuel filter, apply fuel to the
gasket.
• Turn in the new fuel filter until the filter gasket
comes in contact with its sealed face.
• Use a filter wrench to turn in the fuel filter an
additional 1/2 – 3/4 of a turn.
040EY00007
2. Remove the overflow valve.

3. Remove the fuel filter body.

Check the overflow valve for restrictions and/or leakage.
Overflow valve opening pressure 230 – 260 kPa
(33 – 38 psi).
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 7
ENGINE FUEL 6C–7
Injection Nozzle Holder

Nozzle and Holder Specification
ITEMS 6HK1
Injection nozzle & holder assembly type KBL2.4/S, two-stage injection type
Injection nozzle type Hole
Number of injection nozzle orifices Five holes
Orifices diameter mm (in) 0.30 (0.0118)
Opening pressure MPa (kg/cm2 / psi) 1st stage 18.1 (185/2,630)
2nd stage 22.1 (225/3,200)
Nozzle needle valve full-lift mm (in) 0.40 (0.0157)
Nozzle needle valve pre-lift mm (in) 0.05 (0.0020)
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 8
6C–8 ENGINE FUEL
Disassembly
11
10
9
7
15 5
6
4 3
14
13
1
12
040EY00026
Legend (8) Push rod

(1) Retaining nut (9) Adjusting shim
(2) Nozzle (10) 2nd spring
(3) Pin (11) Collar
(4) Spacer (12) Spring seat
(5) Pin (13) 1st spring
(6) Lift piece (14) Adjusting shim
(7) Spring seat (15) Nozzle holder body
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 9
ENGINE FUEL 6C–9
The 2-stage injection nozzle reduces nitrogen oxide 2. Install the adjusting shim (1), first spring (2), and
(NOx) and particulate exhaust gas emissions. spring seat (3).
1. Use a wire brush to remove carbon deposits from the
nozzle and nozzle holder (before disassembly).
CAUTION : Do not touch the nozzle holes with the 3
wire brush.
2. Wipe clean the outside surfaces of the nozzle holder 2

assembly using a clean damp rag.
1
3. Place the nozzle holder in a vise.
4. Remove the retaining nut.
5. Remove the nozzle.
6. Remove the spacer, pin, lift piece, and spring seat.
7. Remove the push rod, adjusting shim, 1st spring,
and collar (1st opening pressure control).
8. Remove the spring seat, 2nd spring, and adjusting
shim (2nd opening pressure control).
9. Clean the parts thoroughly in diesel fuel to remove all
dirt and other foreign materials.
NOTE: Injection nozzle adjustments are made in very 040EY00068
small steps (100ths of a millimeter). For this reason, it is

extremely important that all parts be immaculate. 3. Install the collar (1), 2nd spring (2), adjusting shim
(3), spring seat (4), and push rod (5).
Reassembly
1. Place the nozzle holder in a vise.
3
5
040EY00069
040E100055
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 10
6C–10 ENGINE FUEL
4. Install the pins (1), lift piece (2), and spacer (3). 7. Hand-tighten the adjustment retaining nut together
with the gasket to the nozzle holder.
Retaining nut: 157892-4000 (ZEXEL)
3 Gasket: 157892-1500 (ZEXEL)
Retaining nut
(Special tool) Nozzle
Gasket
040EY00070
5. Install the pin (1).

6. Install the nozzle (2). 040MV010
8. Tighten the adjustment retaining nut (1) to the

specified torque.
2 Torque: 29 - 39 N·m (3.0 - 4.0 kg·m)
040EY00071
040EY00075
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 11
ENGINE FUEL 6C–11
9. Set the nozzle holder to the nozzle tester. Full needle valve lift confirmation
10. Operate the nozzle tester. Measure the first nozzle
1. Install the gasket (1) and plug (2) to the adjustment
opening pressure.
retaining nut.
11. If the first nozzle opening pressure is not as
Gasket: 026508-1140 (ZEXEL)
specified, disassemble the nozzle holder and
remove the shim. Replace the shim with a new shim Plug: 157892-1600 (ZEXEL)
that adjusts the opening pressure to the specified
level.
CAUTION: Use a micrometer to measure shim
thickness.
2
Nozzle tester 1
Nozzle holder
040EY00072
2. Position the nozzle holder with the nozzle facing

down. Install the dial gauge holder to the nozzle
holder.
040MV030
Dial gauge holder: 157892-4400 (ZEXEL)
• First nozzle opening pressure adjusting shims
Part No. (ZEXEL) Thickness (mm)
150590-0600 0.40 1
150590-0700 0.50
150590-0800 0.52
150590-0900 0.54
150590-1000 0.56
150590-1100 0.58
150590-1200 0.60
150590-1300 0.70
Thickness
040EY00073
φ2.6
φ6.2
040LX010
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 12
6C–12 ENGINE FUEL
3. Install the nut (1) to the dial gauge holder (2).

Nut: 157892-1000 (ZEXEL)
6
1
5
2 4
3
040EY00074
4. Install the pin to the dial gauge.

Note: Pin lengths of the pins do not include the threaded
portions.
Pin (l=60 mm): 157892-5300 (ZEXEL)
Dial gauge: 157892-3800 (ZEXEL)
040EY00076
Legend
(1) 1st spring seat
(2) Nozzle holder
(3) Pin
Dial gauge Pin (4) Holder
(5) Nut
(6) Dial gauge
040MV029
5. Secure the dial gauge to the nozzle holder using the

nut so that the pin contacts the tip of the first spring
seat.
CAUTION:
• Secure the dial gauge so that a stroke of 2
mm can be measured.
• Do not over-tighten the nut as the dial gauge
shaft may jam. Confirm from the dial gauge
that the shaft moves smoothly.
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 13
ENGINE FUEL 6C–13
6. Set the nozzle holder to the nozzle tester and zero Pre-lift confirmation
the dial gauge.
1. With the needle valve at full lift, release the nozzle
7. Operate the nozzle tester to bleed any air from inside
tester handle.
the retaining nut and to confirm that there is no fuel
leakage. Note: The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will fall slightly.
Nozzle tester
Nozzle holder
300
200
100 400
0 500
kgf／cm2
Pressure gauge
040MV030
040MV007
8. Operate the nozzle tester to increase the in-line

pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm2). The
nozzle’s needle valve should move through its full lift.
Record full lift ‘L’. (Read dial gauge)
Full lift: 0.40 mm (0.0157 in)
L
Note: The above operation is used to determine whether
Needle Valve lift
the nozzle seat is worn and whether the nozzle

assembly is in good condition.
In-line pressure
L
Needle Valve lift
040EY00079
0 1st nozzle 34.3∼44.1MPa

opening pressure {350∼450kgf/cm 2} 2. Read the needle valve lift ‘l’ from the dial gauge
indication (once the needle valve has descended
In-line pressure when the second spring has stopped operating).
Refer to the pre-lift measuring point for ‘l’.
040EY00078
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 14
6C–14 ENGINE FUEL
Pre-lift measuring point: 3. Confirm that pre-lift ‘l’ is as specified.

Pre-lift: 0.05 mm (0.0020 in)
Read the dial gauge at first nozzle opening pressure
(approx 1 MPa (10 kg/cm2). 4. If pre-lift is not as specified, replace the pin, lift piece,
Note: This point can be determined while the pressure is spacer, and nozzle assembly as a set with the
falling. service kit.
Service kit: ZEXEL 105019-2200
Service kit: ISUZU 894392-1450
L
Measuring point
(pre-lift)
Needle valve lift
Pin
l Lift piece
Spacer
0
1st nozzle Capsule
opening pressure
Nozzle
In-line pressure assembly
040EY00082
040MV031
Second nozzle opening pressure confirmation
Push rod
1. After pre-lift confirmation, operate the nozzle tester
Second spring to increase in-line pressure to 34.3 - 44.1 MPa (350 -
Spring seat Adjusting shim 450 kg/cm2). The nozzle’s needle valve should move
through its full lift.
Spacer l
Lift piece
Nozzle tester
Needle valve Nozzle holder
040EY00080
040MV030
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 15
ENGINE FUEL 6C–15
L
Needle valve lift (mm)
300
200
100 400
l+0.05
l
0 2 500
0
2nd nozzle 34.3-44.1MPa
opening pressure (350-450kg/cm2)
Pressure gauge
In-line pressure
040EY00081 040MV026
2. Release the nozzle tester handle so that in-line Second nozzle opening pressure adjustment
pressure decreases.
If the second nozzle opening pressure is not as
Note: The in-line pressure will decrease and needle
specified, disassemble the nozzle holder and remove
valve lift (as indicated on the dial gauge) will fall slightly.
the shim. Replace the shim with a new shim that adjusts
3. Read the pressure gauge indication (second nozzle
the opening pressure to the specified level.
opening pressure) the instant that the dial gauge
indicates the specified needle valve lift (usually pre- CAUTION:
lift l + 0.05 mm). • The 2nd opening pressure changes when 1st
opening pressure changes. Therefore, 2nd
opening pressure adjustment is always required
when the 1st opening pressure is adjusted.
• Use a micrometer to measure shim thickness.
• Second nozzle opening pressure adjusting shims
When needle valve lift is
l + 0.05mm Part No. (ZEXEL) Thickness (mm)
90
10 150590-0600 0.40
80 150590-0700 0.50
20
150590-0800 0.52
70
30
150590-0900 0.54
60 150590-1000 0.56
40
50 150590-1100 0.58
Full needle valve lift
150590-1200 0.60
Dial gauge
150590-1300 0.70
040MV024
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 16
6C–16 ENGINE FUEL
Final inspection
3
5 1. Remove the dial gauge, nut, and dial gauge holder.
4 Dial gauge
Nut
Dial gauge
holder
040EY00069
Legend
(1) Collar
040MV028
(2) 2nd spring
(3) Adjusting shim 2. Remove the retaining nut and gasket.
(4) Spring seat
(5) Push rod
1
Thickness
φ3.6
φ7.2
040EY00075
3. Install but do not tighten the original retaining nut.

4. Check that the pins are fully inserted into the nozzle.
040LX009
5. Hand-tighten the retaining nut.
6. Tighten the retaining nut to the specified torque.
Retaining nut torque: 59 – 79 N·m (6 – 8 kg-m)
7. Set the nozzle holder to the nozzle tester.
8. Check the 1st nozzle opening pressure.
9. Check the spray condition.
10. Check for oil leakage.
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 17
ENGINE FUEL 6C–17
CAUTION: The nozzle, lift piece, pins, and spacers

must be replaced as a set (nozzle service kit). If
only the nozzle is replaced, pre-lift specifications
will not be applicable.
Nozzle tester
Nozzle holder
040MV030
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 18
6C–18 ENGINE FUEL
Injection Pump
Identification
Use the injection pump assembly number (stamped on
the plate at the side of the pump) to determine the
applicable injection pump calibration data (refer to the
following page).
If the applicable calibration data is not listed in this
Manual, contact the manufacturer’s nearest authorized
service facility (Bosch Automotive System Corporation
or Robert Bosch GMBH).
The Isuzu injection pump assembly number is also
included on the plate. Use this number to order a
replacement pump.
MADE IN
JAPAN
ISUZU part number

ZEXEL pump assembly number
F06HV015
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 19
ENGINE FUEL 6C–19
Injection Pump Calibration Data

Test Conditions
Injection nozzle ZEXEL No. 105780-0000

Injection nozzle holder ZEXEL No. 105780-2080
Injection starting pressure 17.2 MPa
Injection line dimensions Inside diameter = 3 mm
Outside diameter = 8 mm
Length = 600 mm
Transfer pump pressure 255 kPa
Test diesel fuel ISO4113 or SAE standard test oil (SAEJ967d)
Fuel temperature 39 – 41°C (109.2 – 114.8°F)
Pump rotation Clockwise viewed from the drive side
Overflow valve opening pressure 255 kPa (2.6 kg/cm2 / 37.0 psi)
CAUTION:
Strictly observe the above test conditions during injection pump fuel injection volume adjustment.
Failure to observe the test conditions will result in misadjustment of the injection pump fuel injection volume.
Misadjustment of the fuel injection volume will result in serious engine damage.
Injection Timing
Pre-stroke 2.9 ± 0.03 mm (0.114 ± 0.001 in.)

Injection order 1–5–3–6–2–4
Plungers are numbered from the drive side.
Tappet clearance Manually rotate the camshaft several times to make
sure that it rotates smoothly.
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 20
6C–20 ENGINE FUEL
Injection Volume and Governor Performance Diagram

6HK1XQA
Injection Pump Assembly Number
ISUZU No. ZEXEL No. Remarks ISUZU No. ZEXEL No. Remarks
1-15603-334-1 106671-6451
Injection Volume
Control rack Pump speed Injection volume Variance Boost pressure
Remarks
position (mm) (min–1) (mm3/1,000 strokes) (%) (kPa)
12.8 1000 133.5± 1 ±3 More than 160 Basic
6.8 500 9.5 ± 3.2 ± 15

69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 21
ENGINE FUEL 6C–21
Governor Performance
RACK LIMIT
IDLING SUB SPRING SET
14.0以上
BOOST COMPENSATOR STROKE ; 0.7±0.1mm
E GOVERNOR SPRING SET
12.8 B A
12.0±0.1 12.0±0.1 BOOST COMPENSATOR
RACK POSITION(mm)
RACK POSITION(mm)
11.2 11.6±0.1 ADJUSTING SPEED 550min-1
9.4
6.8 C 11.2
6.7±0.3
6.4
5.1以下
10.5
0 0 48.0±4.0
240 (670) 1000+30
+20 1125
(147)±6.7
380 500 750 (1025) {360mHG} {1102.5mHG}
(460) 840±20 BOOST PRESSURE(kPa)
040EY00077
Speed Control Lever and Stop Lever
SPEED LEVER STOP LEVER
FULL SPEED
STOP
3°±5
31°±
3
70°±
5
STOP
18°±5 15°±5
IDLING
NORMAL
040EY00062
69945_ESS-185A_SEC6C 2011.8.10 2:04 PM ページ 22
MEMO
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 1
STARTING AND CHARGING 6D3–1
STARTING AND CHARGING

CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 6D3-1 Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-11
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-2 General Description. . . . . . . . . . . . . . . . . . . . . 6D3-11
General Description. . . . . . . . . . . . . . . . . . . . . . 6D3-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-5 Inspection and Repair . . . . . . . . . . . . . . . . . . . 6D3-16
Inspection and Repair . . . . . . . . . . . . . . . . . . . . 6D3-7 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-18
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-8
Service precaution
previous one.


Manual.


69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 2
6D3–2 STARTING AND CHARGING
Alternator
General Description
5 6
4
7
8
1
9
10
060EY00002
Legend (6) Rotor

(1) Rear bracket (7) Bearing
(2) IC regulator (8) Pulley
(3) Bearing (9) Front bracket
(4) Rectifier (10) Field coil assembly
(5) Stator
The engine uses a brushless alternator. Terminal R is active only until the alternator begins to
Main alternator components are the rotor, the stator, the generate electricity.
rectifier, the front and rear brackets, the IC regulator, the Terminal L also serves as a voltage output terminal.
bearings, and the pulley. When the voltage across terminal L is equal to the
Moving parts include the rotor and the pulley. battery voltage, the indicator lamp (no charging) turns
The field coil is installed to the rear bracket. off.
6 main diodes (3 positive and 3 negative) in conjunction Sealed bearings requiring no lubrication are used
with 2 sub-diodes provide 3-phase rectification. The throughout the alternator.
diodes are installed to the stator coil. The IC regulator is a solid-state device and is serviced
An additional 3 diodes (diode trio) are used to provide as a unit. It cannot be disassembled.
field current.
The alternator has 3 terminals.
a. Terminal B: DC power output
b. Terminal L: Exciting current input
c. Terminal R: Exiting current input
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 3
Identification MITSUBISHI IDENTIFICATION PLATE

The alternator identification plate is attached to the
alternator rear bracket. The ISUZU part number, the
manufacturer’s code number, and other important A
information are stamped on the plate.
B
Refer to the identification plate together with the “Main C D
Data and Specifications” Tables and accompanying
charts in this Manual when requesting service
assistance from a qualified electrical repair shop. E
If you are unable to locate the data applicable to your
engine, please contact ISUZU MOTORS LIMITED
through your machine supplier.
A: Isuzu part number

B: Manufacturer’s abbreviated name
C: System voltage output
D: Manufacturer’s lot No.
E: Bar code
Charging Circuit
ADDITIONAL B
DIODES
DIODE TRIO INDICATOR LAMP
STATOR
L
COIL
L KEY
SWITCH
R R
BATTERY
(24V)
E
FIELD
COIL
IC REGULATOR
E
ALTERNATOR
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 4
Isuzu Part No. 181200-6035

Manufacturer’s code No. (MITSUBISHI) A004T06285
Rated voltage (V) 24
Rated output (A) 50
Rated speed (min–1) 5000
Rated output (Amp./Volt/min–1) 50/27/5000
No-load output at 0 Amp. (Volt/min–1) 24/900
Direction of rotation as viewed Clockwise
from pulley side
Ground polarity (–)
Pulley diameter mm (in.) 80 (3.15)
Coil resistance at 20°C
Field coil (Ω) 4.5 – 5.2
Isuzu part No. 1-81260-0170
Manufacturer’s code No. A866X38282
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 5
Disassembly
7
5
6
9
8
060EY00004
(1) IC regulator (6) Nut

(2) Terminal stud (7) Side entry terminal
(3) Side entry terminal (Terminal B) (8) Terminal stud
(4) Rectifier assembly (9) Tube
(5) Cap
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 6
1. Scratch setting marks between the front and rear

brackets and the alternator body (2 locations). This
1
will ensure installation to its original position.
2. Remove the 4 through bolts.
3. Use the blade of a screwdriver to pry the front
bracket and the stator apart.
2
4. Carefully separate the front bracket, pulley, and rotor
from the stator and rear bracket.
NOTE:
• Do not push the screwdriver blade too deeply into
the stator. Coil damage will result.
• A vise may be used to secure the rotor. Be sure to
clamp the vise at points A (see illustration below). Do
not clamp the vise at points B. Damage to the rotor
will result.
3
060EY00003
9. Remove the cap and nut from the rectifier terminal

Ｂ
stud.
10. Use a screwdriver to pry the rear bracket and the
side entry terminal apart.
11. Remove the side entry terminal.
NOTE: The tube will remain in the rear bracket. Take
care not to lose it.
12. Remove the rectifier retaining screw and the 2 IC
regulator retaining screws.
ＡＡ 13. Remove the stator and rectifier assembly (as a
single unit) from the rear bracket.
1
14. Remove the IC regulator.
15. Unsolder the 4 stator coil leads from the rectifier
terminals.
060EY00030
16. Remove the stator from the rectifier.
5. Remove the 2 screws (2) attaching the coil terminal NOTE: High temperature solder with a melting point of
plate to the IC regulator. 230°C connects the stator coil leads to the rectifier. Use
6. Hold the coil assembly in your hand. Be careful not to a 180~280 watt soldering iron to free the leads as
damage the terminal plate. quickly as possible. Do not apply the soldering iron for
more than 5 seconds. Diode damage will result.
7. Remove the 3 screws (3) and the coil assembly.
8. Disconnect the connector (1). Bearing removal
NOTE: It is very important that Steps 5, 6 and 7 be NOTE: Bearings are not normally removed. If they are
performed in that order. If Step 6 is performed before removed, they must be replaced with new ones.
Step 5, terminal damage will result.
• Front bracket bearing
Remove the 4 retainer screws. Press out the bearing
with a suitable tool.
• Rotor bearing
Use an ordinary bearing puller.
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 7
Inspections and Repair Rotor

1. Turn the rotor. Listen for bearing noise (a scraping
Stator sound). Feel for rough rotation. Replace the rotor if
1. Check the stator for damage, loose connections, and either of these conditions is present.
discolored windings. 2. Check for grease leakage. If leakage is minimal,
2. Use a circuit tester to check for continuity between wipe it away. If leakage is excessive, replace the
each pair of stator coil leads (1). Replace the stator if rotor.
there is no continuity. NOTE: It is recommended that inspection be made with
the bearing fitted to the rotor shaft.Coil Assembly
Coil
Use an ohmmeter to measure the coil resistance
between both terminals (1) and the terminal plate (2).
Replace the coil assembly if the resistance is outside the
1 specifications.
Coil resistance at 20°C: 4.5 – 5.2 ohms
1
060EY00007
3. Use a circuit tester to check for continuity between

each of the stator coil leads (1) and the stator core
(2). Replace the stator if there is no continuity.
060EY00005
1
Rectifier
1. Use a circuit tester to test for continuity between
each diode terminal (2) and the positive heat sink.
Test in both directions.
If there is continuity and/or an open circuit in both
directions, the rectifier must be replaced.
2. Use a circuit tester to test for continuity between
2
each diode terminal (2) and the negative heat sink.
Test in both directions.
If there is continuity and/or an open circuit in both
directions, the rectifier must be replaced.
060EY00008
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 8
3. Check the diode trio for continuity in both directions. • Bracket, rotor, and stator reassembly is difficult
If there is continuity and/or an open circuit in both because of the tight fit of the components. To make
directions, the rectifier must be replaced. reassembly easier, heat the area around the rear
bracket bearing box to approximately 55°C.
Tightening torques
1 Pulley fixing nut: 147 N·m
Through bolts: 5.1 N·m
Bearing retainer screws: 3.6 N·m
Coil retaining screws: 3.6 N·m
Rectifier retaining screws: 3.6 N·m
Regulator retaining screws: 3.4 N·m
Nuts for stud bolts: 8.8 N·m
Bench testing
Perform bench tests on the reassembled alternator.
3
2
Voltage regulation
1. Make connections as shown in the illustration on the
060EY00006
following page. Use an ammeter with a scale of 0 –
Legend 100 amperes and voltmeter with a scale of 0 – 30
volts.
(1) Positive diode
2. Close switch 1 and open switch 2. The lamp should
(2) Diode terminals
light.
(3) A part of negative diode
If the lamp does not light, check the voltage at
terminal-L.
If the voltage is nearly equal to battery voltage (24V),
Front bracket
check the alternator.
Turn the bracket. Listen for bearing noise (a scraping If the voltage is low, check for an open lamp and
sound). Feel for rough rotation. Replace the bracket if related circuitry.
either of these conditions is present.
3. Slowly increase alternator speed.
Check for grease leakage. If leakage is minimal, wipe it
away. If leakage is excessive, replace the bracket. The lamp should turn off as alternator speed
approaches 1,300 min-1.
Regulator 4. Check the voltage as alternator speed increases.
The regulator cannot be checked in the absence of the If the voltage fluctuates wildly during alternator
other components. Check regulator operation after speed increase and rises above 30 volts, the IC
alternator reassembly. regulator is probably defective.
If the voltage does not exceed battery voltage (24V),
the alternator is defective (no generation of
Reassembly electricity). Check alternator components again.
Follow the disassembly steps in the reverse order. 5. Increase alternator speed to approximately 500 min-1.
Note the following precautions. 6. Note the ammeter reading.
• No lubrication is required. Bearings are If the reading is 5 amperes or less, note the voltmeter
prelubricated. reading (be sure that alternator speed remains
• Wipe away any grease leakage from the bearing constant). This is the regulated voltage.
area. If the reading is more than 5 amperes, continue to
• Use high-temperature solder (melting point of operate the ammeter at 500 min-1 until the reading
230°C). falls to 5 amperes or less.
• Use a 180 – 280 watt soldering iron to solder the If the reading does not fall, replace the battery.
leads as quickly as possible. Do not apply the If the reading still does not fall, the alternator is
soldering iron for more than 5 seconds. Diode defective and must be repaired or replaced.
damage will result.
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 9
AMMETER SWITCH 1
A
LAMP (24V) SWITCH 2

B (3W MAX.)
L
R
V ALTERNATOR BATTERY
(24V)
LOAD
VOLTMETER RESISTOR
Current output
1. Operate the alternator at minimum speed.
2. Close switch 1. Check that the lamp lights.
3. Set the load resistor to its maximum resistance
(minimum current).
4. Close switch 2.
5. Increase the alternator speed to a constant 5,000
min-1.
6. Adjust the load resistor for maximum current output.
7. Allow the alternator to run for 15 minutes. Output
should increase as alternator temperature increases.
8. Once again, adjust the load resistor for maximum
current output.
The maximum current output must equal the
specified value. If it does not, the alternator must be
rechecked.
Alternator output:
50 amp/27 volt/5,000min-1
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 10
Troubleshooting

No output Bad terminal connection Repair
Open or shorted circuit Repair
Open field coil Replace
Defective IC regulator Replace
Low output Loose terminal connection Tighten
Loose cooling fan belt Adjust belt tension
Shorted field coil Replace
Shorted stator coil Replace
Defective regulator Replace
Defective battery Replace
Poor terminal contact Repair
Overcharging Defective regulator Replace
Defective battery Replace
Unstable current Poor terminal contact Repair
Loose cooling fan belt Adjust belt tension
Short field coil Replace
Intermittent contact in wiring Replace
Poor terminal contact Repair
Defective regulator Replace
Abnormal noise Improper alternator installation Correct
Defective bearing Replace
Contact between the rotor core and Replace the rotor core and/or stator core
stator core
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 11
Starter Motor
General Description
060EY00009
The starter motor has a reduction gear assembly that

uses planetary gears.
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 12
Isuzu Part No. 898141-2061

Mitsubishi code No. M008T60973
Rated voltage V 24
Rated output kW 5.0
Rating Sec 30
Direction of rotation Clockwise
(Viewed from the pinion side)
Terminal voltage (No load) V 23
Minimum current (No load) A 85
Starter motor minimum operating speed min–1 3300
(No load)
Pinion gear
Modules 3
Number of teeth 11
Outside diameter mm (in) 48.9 (1.93)
Yoke outside diameter mm (in) 85 (3.35)
Brush length
Standard mm (in) 18 (0.71)
Limit mm (in) 11 (0.43)
Brush spring standard fitting load N 29 – 39
Commutator
Outside diameter
Standard mm (in) 32 (1.26)
Limit mm (in) 31.4 (1.23)
Depth of undercut mica
Standard mm (in) 0.5 (0.02)
Limit mm (in) 0.2 (0.008)
Pinion projection
Standard mm (in) 0.5 – 2.0 (0.0197 – 0.079)
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 13
Identification
MITSUBISHI starter motor is identified by the name
plate attached to the yoke (illustration).
(1) Manufacturer’s type
(2) Isuzu part number
(3) Bar code
NOTE: Always check the identification number before
beginning a service operation.
Applicable service data will vary according to the
identification number. Use of the wrong service data will
result in starter damage.
MITSUBISHI
ELECTRIC CORP, JAPAN 24V
TYPE 1
NO.
2
060EY00012
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 14
Disassembly
7
6
5 20
19
27
18
17
16
15
14
4
13
3
2 12 26
1
11
25
10
24
9
23
22
21
060EX00001
Legend (14) Planetary gear

(1) Snap ring (15) Ball
(2) Stop ring (16) Gasket
(3) Pinion (17) Plate
(4) Pinion spring (18) Armature
(5) Screw (19) Washer
(6) Pinion case (20) Bearing
(7) Lever (21) Gasket
(8) Magnetic switch (22) Yoke
(9) Clutch (23) Brush
(10) Internal gear (24) Gasket
(11) Washer (25) Brush holder
(12) E-type stop ring (26) Rear cover
(13) Gear shaft (27) Through bolt
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 15
1. Place matching marks on the magnetic switch and

yoke to ensure reassembly to their original positions. 5
2. Connect the starter motor to a battery. The pinion
rises and begins to rotate. 4
3. Open switch-2 to stop pinion rotation. 3 6
2
1
SW 1
SW 2
24 V
060EY00015
Legend
(1) Pinion
(2) Clutch shaft
(3) Snap ring
060EY00014 (4) Stop ring
(5) Pipe
4. Separate the stop ring by striking it with a pipe and
bar. (6) Pinion spring
5. Remove the stop ring, the snap ring, the pinion, and
the pinion spring. 7. Remove the magnetic switch.
6. Discard the stop ring. 8. Loosen the brush holder fixing screws and the
NOTE: Pinion removal should require no more than 10 through bolt.
seconds. If more time is required, heat from the 9. Remove the rear bracket and gasket.
armature will cause the starter damage. 10. Discard the gasket.
11. Use a socket wrench with a 32 mm diameter to hold
the armature commutator in place. Remove the yoke
assembly.
12. Slide the brush on to the socket.
13. Lift the brush spring and remove the brush.
14. Remove the brush holder.
15. Pull the armature from the planetary gear.
16. Use a bearing puller to remove the bearing. Be
careful not to lose the ball.
17. Remove the plate and gasket.
18. Remove the planetary gear.
19. Hold the internal gear, the gear shaft overrunning
clutch, and the lever together. Remove them as a
unit from the front bracket.
20. Remove the lever from the gear shaft (mark its
installation position).
21. Remove the E-type stop ring from the gear shaft and
discard it.
22. Remove the overrunning clutch from the gear shaft.
23. Remove the internal gear and washers.
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 16

Armature
1. Use a circuit tester to check armature continuity.
Hold the circuit tester probes against 2 commutator
segments. Repeat the procedure for several other
segment pairs.
There must be continuity between all commutator
segments. If there is not, the commutator must be
replaced.
3. Measure the commutator outside diameter.

4. If the measured diameter is less than the specified
limit, the commutator must be replaced.
Commutator outside diameter
Standard: 32 mm (1.28) in
Limit: 31.4 mm (1.256 in)
2. Use a circuit tester to check the armature ground.

Hold one probe against a commutator segment. Hold
the other probe against the armature shaft.
If there is continuity, the armature is grounded. It
must be replaced.
5. Inspect the commutator mica segments for

excessive wear and damage.
6. Measure the depth of the commutator mica
segments.
If the depth is less than the specified limit, the
commutator must be replaced.
Commutator mica segment depth
Limit: 0.2 mm (0.008 in)
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 17
060EY00016 060EY00017
5. Inspect the gear for excessive wear and damage.

Replace if required. Brush and Brush Holder
6. Rotate the commutator with your hand. Listen for 1. Measure the brush length.
abnormal noise or rattling from the bearing. Check If the brush length is less than the specified limit, the
for grease leakage. Replace if required. brush and/or yoke must be replaced.
Brush length
Standard: 18mm (0.72 in)
Field Coil
Limit: 11 mm (0.44 in)
the field coil and the lead wire. 2. Check the brush spring for weakness and corrosion.
Replace the spring if required.
If there is no continuity, a field coil wire is broken.
The field coil must be replaced. 3. Use a spring balancer to measure the brush spring
tension.
If the spring tension is less than the specified limit,
the spring must be replaced.
Brush spring tension N
Standard: 29 – 39 N
Limit: 13.7N
4. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the field winding lead wire and
the other probe to the brush.
If there is continuity between the lead wire and the
brush, the insulation is bad. Repair or replace the
brush holder.
060EY00018
2. Check for continuity between the field coil and the

yoke.
If there is continuity, the yoke must be repaired or
replaced.
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 18
Front Bracket
Check the front bracket bearing and oil seal for damage.
Replace if required.
Internal Gear and Planetary Gear

Check the gears for excessive wear and damage.
Replace if required.
Magnetic Switch
the magnetic switch terminal-M (1) and the body (2).
If there is no continuity, the switch must be replaced.
2. Check for continuity between the magnetic switch
terminal-M (1) and terminal-B (3). If there is
continuity, the switch must be replaced.
060EY00019
2
Overrunning Clutch and Pinion
1. Wipe away dirt and grime adhering to the
overrunning clutch and pinion.
2. Check the pinion teeth for excessive wear and
damage.
3. Rotate the pinion in the direction of normal rotation. It
must turn smoothly.
4. Rotate the pinion in the opposite direction. It must
1 3
lock.
Replace the overrunning clutch if any problems are
NOTE: The inside of the overrunning clutch is packed
with grease. Do not soak the clutch in liquid cleaner or
solvent to clean it. Grease leakage will result. 060EY00021
Reassembly
To reassemble the starter motor, follow the disassembly
steps in the reverse order.
Pay close attention to the following.
• Lubrication points and recommended lubricants
No. Lubrication area Lubricant
Armature bearing area
1
(Light lubrication)
2 Plunger (Light lubrication) MUL TEMP
Gear shaft spline and sliding 0A-171 or
3
parts equivalent
4 Clutch shaft
5 Oil seal
6 Pinion (Overrunning clutch)
060EY00020
Lever sliding surfaces
7 Molycoat R
(Overrunning clutch)
AG650 or
8 Sleeve bearing and ball equivalent
Armature shaft gear, internal
9
gear, and planetary gears
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 19
5
6
1
9 8 7
060EY00010
Tightening torque N·m

Nut (1) 20 – 26
Bolt (2) 4.9 – 8.8
Bolt (3) 7.8 – 13
Bolt (4) 2.4 – 4.4 1 2
060EY00031
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 20
Armature shaft axial play
Install the ball to the top of the armature shaft.

No adjustment is required. 4
3 5
Gear shaft axial play
2
Install the washer between the internal gear and the
gear shaft. 1
No adjustment is required.
060EY00023
Pinion projection
4 1. Connect the starter motor to the battery.
2. Turn switch-1 and switch-2 on.
2
The pinion moves forward to the cranking position
1 and the armature rotates.
3. Turn switch-2 off. The armature stops rotating.
4. Measure the pinion projection.
060EY00022
Pinion projection: 0.5 – 2 mm (0.02 – 0.08 in)
Legend
(1) Overrunning clutch
(2) Internal gear
(3) Washer
(4) E-type stop ring SW 1 B
(5) Gear shaft S SW 2
M
24 V
Gear shaft
1. Install the washer, internal gear, and overrunning

clutch to the gear shaft.
2. Install the pinion spring (5), the pinion (1), and the
stop ring (4) to the clutch shaft (2).
3. Install the snap ring (3).
4. Attach the stop ring to the snap ring.
060EY00024
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 21
Overrunning clutch shaft return 2. Turn the switch on.

Press against the head of the overrunning clutch with 3. Measure the starter motor speed, the current, and
your hand. the voltage.
Measure the movement (return) of the clutch shaft. If the starter motor speed is less than the specified
If the return is outside the specified range, adjust the value, the starter motor requires further servicing.
packing between the front bracket and the magnetic Starter motor minimum speed: 3,300 min-1 (No
switch. load)
If adjustment is not possible. Replace the lever. If the measured starter motor minimum current
and/or terminal voltage is different from the specified
value, the starter motor requires further servicing.
Starter motor minimum current: 85 A (No load)
Starter motor terminal voltage: 23 V (No load)
060EY00025
Performance test
1. Connect the starter motor as shown in the
illustration.
A SW B
S
1
M
3
V
060EY00026
Legend
(1) Battery
(2) Ammeter
(3) Voltmeter
69945_ESS-185A_SEC6D3 2011.8.10 2:07 PM ページ 22
MEMO
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 1
ENGINE LUBRICATION 6G–1
ENGINE LUBRICATION
CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 6G-1 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-8
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6G-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-8
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-4 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6G-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-9
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6G-5 Oil Port Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-12
Inspection and Repair . . . . . . . . . . . . . . . . . . . . 6G-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-12
Service precaution
previous one.


Manual.


69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 2
6G–2 ENGINE LUBRICATION
General Description
Lubricating Oil Flow
The engine uses a pressure-feed lubrication system.
Oil flows from the oil pump to the oil cooler where it is
cooled. It then travels to the oil filter for cleaning.
From the oil filter, the oil moves to the cylinder block oil
gallery for distribution to the moving parts of the engine.
Oil jets are arranged in a line near the center of the
cylinder block oil gallery. The oil jets spray oil to the
inside portions of the pistons to provide the most
effective lubrication and cooling.
Oil Pump and Oil Filter

The gear-type oil pump is driven by the timing gear. The
pump is equipped with a relief valve.
The full-flow oil filter uses a highly-efficient paper
element.
If the element becomes clogged, the by-pass valve
opens to route the oil directly to the oil gallery. A warning
lamp turns on to warn the equipment operator that the oil
filter is being bypassed.
Oil cooler
Engine oil temperature rises with engine temperature
with a corresponding decrease in lubricating
efficiency.The oil cooler consists of the body and the
cooling element.
The oil cooler maintains oil temperature at the level
required for optimum engine lubrication.
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 3
Lubricating Oil Flow
Oil Filter
Starter
2 Switch Battery
Oil Pressure
Indicator Light
Oil Cooler 4
Main Oil 3 Sub Oil Gallery Main Oil Gallery

Filter
Combined
Type
Partial Check Idler Crank Idler Idler Camshaft 5
Oil Valve Gear A Shaft Gear B Gear C Bearing
Filter Bearing and
160 kPa Rocker
Arm
Piston
Cooling
Oil Jet
Idler
Gear B
Connecting
Rod
Bearing
Oil Pump
Injection Bearing
Pump Case
Oil
Strainer
1 Relief Valve Opening Pressure 780 kPa 3 Oil Thermostat Opening Temperature 90°C
2 Bypass Valve Opening Pressure 4 Oil Pressure Switch Opening Pressure 30 kPa
Separate Type Oil Filter 200 kPa 5 Relief Valve Opening Pressure 490 kPa
F06EY00127
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 4
Oil Pump
Oil Pump Construction
4
2
051EY00035
Legend (4) Cotter pin

(1) Oil pump drive gear (5) Drive gear
(2) Oil pump body (6) Driven gear and shaft
(3) Oil relief valve
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 5
Disassembly 4. Remove the oil pump drive gear.

Use a gear puller to remove the oil pump drive gear.
1. Remove the driven gear and shaft.
051EY00021
051EY00014
2. Remove the cotter pin. Inspection and Repair

3. Remove the oil relief valve. Make the necessary adjustments, repairs, and part
replacements if excessive wear of damage is discovered
during inspection.
1. Use a feeler gauge to measure the clearance
between the gear teeth and the body inner wall.
If the clearance between the gear teeth and the body
inner wall exceeds the specified limit, the gears
and/or the body must be replaced.
Gear Teeth and Cover Inner Wall Clearance
Standard: 0.125 – 0.221 mm (0.0049 – 0.0087 in)
Limit: 0.221 mm (0.0087 in)
051EY00020
051EY00018
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 6
2. Use a feeler gauge to measure the clearance 4. Use an inside dial indicator or inside micrometer to
between the body and the gear side surfaces. measure the pump body inside diameter and the
If the clearance between the gears and the body cylinder block bushing inside diameter.
exceeds the specified limit, the gears and/or the If the clearance between the gear shaft and the
body must be replaced. pump body or bushing exceeds the specified limit,
Gear and Body Clearance the oil pump assembly and/or bushing must be
replaced.
Standard: 0.064 – 0.109 mm (0.0025 – 0.0043 in)
Gear Shaft and Pump Body or Bushing
Limit: 0.109 mm (0.0043 in)
Clearance
Standard: 0.04 – 0.07 mm (0.0016 – 0.0028 in)
Limit: 0.07 mm (0.0028 in)
051EY00019
3. Use a micrometer to measure the gear shaft outside

diameter. 012EY00068
Gear Shaft Outside Diameter

5. Check the ball and the valve spring for excessive
Standard: 15.989 – 16.000 mm (0.6295 – 0.6299 in)
wear and damage.
Limit: 15.9 mm (0.626 in)
051EY00036
051EY00017
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 7
6. Use an inside and outside micrometer to measure 2. Install the oil relief valve.
the interference between the oil pump drive gear 3. Install the cotter pin.
inside diameter and drive gear shaft outside 4. Install the driven gear and shaft.
diameter.
1. Apply engine oil to the driven gear and shaft.
Drive Gear and drive Gear Shaft Interference
2. Install the driven gear and shaft to the oil pump
(Reference)
body.
Standard: 0.015 – 0.044 mm (0.0006 – 0.0017 in)
051EY00014
051EY00016
Reassembly
1. Install the drive gear and oil pump drive gear.
1. Apply engine oil to the drive gear shaft.
2. Install the oil pump drive gear to the drive gear
shaft.
The gear hub large side must be facing the
outside.
3. Use the bench press to press the drive gear onto
the drive gear shaft.
051EY00013
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 8
Oil Cooler
Disassembly
1 2
7 6
050EY00013
Legend
(1) Oil cooler element (5) Plug
(2) Gasket (6) Oil thermostat
(3) Gasket (7) Bypass pipe
(4) Body
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 9
1. Loosen the fixing nuts to remove the element. Inspection and Repair
Discard the gaskets.
1. Use the dye penetrant detector procedure to inspect
2. Remove the bypass pipe.
the element for cracking.
3. Remove the oil thermostat.
2. Use the dye penetrant detector procedure to inspect
4. Clean the inside of the oil cooler element. the oil cooler cover for cracking.
1. Use a funnel to pour cleaning solution into the oil
cooler element.
Add cleaning solution until it overflows.
2. Allow the oil cooler element to stand for ten hours
(with the cleaning solution inside).
3. Pour off approximately 1/3 of the cleaning
solution from the element.
4. Apply compressed air at 200kPa (28 psi) to the
element through the oil port. Continue to apply
compressed air until all cleaning solution has been
forced from the element.
injury. When using protective for cleaning, wear
safety glasses and protective clothing.
NOTE : As long as the oil cooler element is not damaged

or excessively dirty, it may be cleaned repeatedly at
periodic intervals.
050EY00058
Reassembly
1. Install the bypass pipe with new gasket to the body.
2. Install the oil thermostat with the rubber cap to the
body.
3. Install the plug with new gasket to the body and
tighten to the specified torque.
050EY00015
050EY00059
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 10
4. Install the oil cooler element with new gasket to the

body.
5. Tighten the element fixing nuts to the specified
torque.
050EY00016
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 11
Oil Port Cover
050EY00060
Legend (5) Plug

(1) Oil port cover (6) Gasket
(2) Gasket (7) Port cover
(3) Oil relief valve
(4) Gasket
69945_ESS-185A_SEC6G 2011.8.10 2:08 PM ページ 12
Removal
1. Remove the oil port cover from the cylinder block.
Discard the gaskets.
2. Remove the oil relief valve from the oil port cover.
Check the oil valve for restrictions.

1. Remove the plugs from the port cover.
2. Inspect the port cover for restrictions.
3. Remove all sludge and restrictions from the port
cover.
Installation
1. Install the plugs with new gasket to the port cover.
Tighten the plug to the specified torque.
2. Install the oil relief valve with new gasket to the port
cover.
Tighten the valve to the specified torque.
3. Install the oil port cover with new gasket to the
cylinder block.
050EY00019
69945_ESS-185A_SEC6J 2011.8.5 2:50 PM ページ 1
ENGINE INDUCTION 6J–1
ENGINE INDUCTION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6J-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-4
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-2 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6J-6
General Description . . . . . . . . . . . . . . . . . . . . . . . 6J-2
Service precaution
previous one.


Manual.


69945_ESS-185A_SEC6J 2011.8.5 2:50 PM ページ 2
6J–2 ENGINE INDUCTION
Turbocharger
General Description
Major turbocharger components are the center housing Turbocharger rotating parts operate at very high speeds
and rotating assembly (CHRA), the compressor and temperatures. The parts are built from carefully
housing, and the turbine housing. selected materials and machined to extremely high
Rotating parts are supported by the center housing and precision.
include the turbine shaft, the compressor wheel, the The turbocharger improves air intake efficiency resulting
shaft bearings, the thrust bearings, and the oil seal ring. in increased engine power, reduced fuel consumption,
and low engine noise.
69945_ESS-185A_SEC6J 2011.8.5 2:50 PM ページ 3
Identification Turbocharger Servicing

The turbocharger name plate gives the date of 1. Refer to TROUBLESHOOTING in this Section to
manufacturer and other important information required determine whether or not turbocharger repair or
to identify the unit when service inquiries are made. overhaul is required.
2. The following procedures should also be performed
The turbocharger name plate has the following (either with the turbocharger on the equipment or
information stamped on it. Refer to the illustration. removed from the equipment but not disassembled)
(1) Turbocharger specification, production year, and to determine whether or not turbocharger repair or
production month. overhaul is required.
Example: VIBU * Visual checks
(2) Production date, serial number, and production line * Clearance measurements
name. * End play measurements
Example: RHG6 Refer to INSPECTION AND REPAIR.
(3) Part number assigned by ISUZU MOTORS 3. The turbocharger compressor and turbine housing
LIMITED. may be removed from the center housing and
Example: 1144003281 rotating assembly (CHRA) for further visual
Part numbers indicate specific designs or inspection.
configurations.
Precaution
Turbocharger servicing requires great care and
expertise.
Faulty turbocharger servicing procedures can result in

Name plate sample serious damage to pistons, valves, cylinder liners, and
other important engine parts.
Turbo Spec. 1
ISUZU does not recommend the performance of any
Serial No.RHG6 2
servicing procedure not described in this Manual.
Part No. 3
Contact your nearest IHI service facility to have the
turbocharger assembly repaired or overhauled.
The identification plate and assembly number will be

required by the service facility.
A list of IHI Turbocharger Service Network locations is

given at the end of this Section.
69945_ESS-185A_SEC6J 2011.8.5 2:50 PM ページ 4
Troubleshooting
If the engine does not run well (insufficient output or irregular acceleration) -
1. Run the engine at idle.
2. Check for oil leakage from the turbocharger.
3. Listen for abnormal turbocharger noise.
4. Write down any abnormal conditions and their location.
5. Stop the engine.
6. Allow sufficient time for the turbocharger to cool.
7. Check the turbocharger air inlet hose and outlet hose. The bands attaching the hoses to the turbocharger must be
tight. There must be no oil leakage.
WARNING: The turbocharger generates very high temperatures during operation. It will remain dangerously
hot for some time after the engine is stopped. Allow sufficient time for the turbocharger to cool before
touching it.
Oil Leak
Leak point Cause Countermeasure
Turbine housing gas inlet and outlet

tightening area Bearing abrasion (Trouble in the oil Check the turbocharger air inlet
Turbine and bearing housing mating supply system)
surfaces
Turbocharger oil inlet tightening Loose bolts Tighten bolts
area
O-ring damage Replace O-ring
Compressor housing case Oil leak from tightening area (Air Turbocharger OK
compressor oil leak)
Abnormal Noise
Description Cause Countermeasure

Whistling sound High-speed turbocharger operation Normal sound of rotor rotation
Foreign particles in turbocharger
Grinding sound Bearing abrasion (Trouble in the oil Check the turbocharger air inlet
supply system)
Tighten bolts, screws, and/or hose
Hissing sound Loose air or gas pipe
bands as required
Insufficient output or irregular acceleration
Problem Cause Countermeasure

Poor engine performance because of Loose air and/or gas pipes running to Tighten bolts, screws, and/or hose
air and/or gas leakage the turbocharger bands as required
69945_ESS-185A_SEC6J 2011.8.5 2:50 PM ページ 5
Disconnect the air inlet hose at the turbocharger to perform the following inspection.
Checkpoint Problem Countermeasure
Oil on air inlet inside and outside surfaces

Air inlet Turbocharger OK
resulting from oil leakage
Loose or missing
Shaft end nuts
Foreign particles in turbocharger
or blades
Bearing abrasion (Trouble in the oil supply system) Replace turbocharger
Blade and housing interference
Compressor housing
Bearing abrasion (Trouble in the oil supply system)
Oil feed pipe Clogged Remove restrictions
69945_ESS-185A_SEC6J 2011.8.5 2:50 PM ページ 6
Inspection and Repair Rotor Shaft Radial Play

1. Invert the turbocharger so that the turbine exhaust
Turbocharger damage or maladjustment results in a
inlet flange is facing up.
reduced volume of air to the engine. Engine
performance suffers. 2. Install a dial indicator to the turbine housing as
If there is a marked drop in engine performance, first shown in the illustration.
check the engine. If the engine appears normal, check 3. Measure the rotor shaft axial play. Note the total
the turbocharger. indicator reading (TIR).
If excessive wear or damage is discovered during Rotor shaft radial play
turbocharger inspection, the appropriate parts must be Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in)
adjusted, repaired, or replaced. Contact your nearest IHI
Limit: 0.205 mm (0.00807 in)
Service Center to make arrangements for servicing.
Rotor Shaft Axial Play rotor shaft must be replaced.
1. Install a dial indicator to the turbine housing as
2. Move the shaft back-and-forth to measure the rotor
shaft axial play. Note the total indicator reading
(TIR).
Rotor shaft axial play:
Standard: 0.06 – 0.09 mm (0.0024 – 0.0035 in)
Limit: 0.11 mm (0.00433 in)
rotor shaft must be replaced.
036EY00009
036EY00008
MEMO
MEMO
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: [email protected]
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:
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are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
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PART NO.

Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TODDE-EN

GENERAL INFORMATION 0A–1

0A–2 GENERAL INFORMATION

Arrow Type Application Arrow Type Application

• Ambient/Clean air flow

• Gas other than

• Ambient air mixed with

View Detail Direction

Lubrication point (Oil or

Dimension (1:2) Lubrication point (Grease)

Sectioning (1:3) Lubrication point (Jelly)

GENERAL INFORMATION 0A–3

Abbreviations lb in – Inch Pounds

0A–4 GENERAL INFORMATION

Nut and Bolt Angular Tightening

5. Draw another line C – D on the face of each of the

GENERAL INFORMATION 0A–5

7. Use a socket wrench to tighten each nut or bolt to the

Example: Specified Angle and Tightening Rotation

0A–6 GENERAL INFORMATION

Standard Bolt Torque Specifications

STANDARD BOLT N·m (kgf·m/lb.ft)

M6 × 1.0 4 – 8 (0.4 – 0.8/3 – 6) 5 – 10 (0.5 – 1.0/4 – 7)

GENERAL INFORMATION 0A–7

FLANGED HEAD BOLT N·m (kgf·m/lb.ft)

M6 × 1.0 5 – 9 (0.5 – 0.9/4 – 7) 6 – 12 (0.6 – 1.2/4 – 9)

0A–8 GENERAL INFORMATION

Recommended Thread Locking

1. Completely remove all lubricant and moisture from the

Apply LOCTITE to at least 1/3 of the

3. Tighten the bolts to the specified torque.

GENERAL INFORMATION 0A–9

Main Data and Specifications

0A–10 GENERAL INFORMATION

GENERAL INFORMATION 0A–11

1200 1400 1600 1800 2000

Engine speed (min-1)

Cylinder head cover

Oil dipstick Fuel filter

Oil drain plug Oil level sensor

GENERAL INFORMATION 0A–13

0A–14 GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

Rocker Arm Shaft and Rocker Arm

GENERAL INFORMATION 0A–15

ITEMS SERVICE STANDARD SERVICE LIMIT

Piston and Piston Ring

0A–16 GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

GENERAL INFORMATION 0A–17

0A–18 GENERAL INFORMATION

Engine External Parts

GENERAL INFORMATION 0A–19

Apply engine oil

0A–20 GENERAL INFORMATION

Apply engine oil

Apply engine oil