MITSUBISHI L11.9D2B Engine Workshop Manual by engineparts2

GROUP INDEX

Shop Manual FOREWORD This shop manual contains the specification, construction, operation, adjustment and service pro cedures of the engine family L11.9D2B diesel engine for service mechanics engaged in servicing of the Mitsubishi diesel engines. Please make the most of this shop manual to perform correct servicing and wasteless operations. Note that some of the contents of this shop manual are subject to change owing to improvements, etc. that may be introduced after publication of this shop manual.

GENERAL ....................................• ENGINE ....................................... LUBRICATION ............................... FUEL AND ENGINE CONTROL ........... · ELECTRONICALLY CONTROLLED FUEL SYSTEM .............

11!1

COOLING ................................... . INTAKE AND EXHAUST .................... ENGINE ELECTRICAL ....................... CLUTCH ...................................... SPECIAL EQUIPMENT ......................

Mitsubishi L11.9D2B Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Heavy Equipment Restoration Parts LLC

COMPILATION OF THIS MANUAL CONTENTS 1. TERMS AND UNITS ............. .... ....... . ... 4 2. UNITS ........................................... 5 3. READING THE ILLUSTRATION ................. 6

COMPILATION OF THIS MANUAL - TERMS AND UNITS

1. TERMS AND UNITS The following terms and units are used throughout the entire texts of this manual. (1) Front and rear The terms "front" is the fan side and "rear" the fly wheel side of the engine. (2) Right and left The terms "right" and "left" shall be used to indi cate the side as viewed from the flywheel side of the engine. (3) Service standard terms • Nominal value Shows the nominal dimensions, dimension of an individual part, standard clearance between parts in an assembly, or the standard performance of an assembly. • Limit Shows the value of a part at which the part is no longer serviceable from the performance as well as strength viewpoints, requiring replacement or repair.

(4) lightening torque Over-or undertightening of bolts and nuts has criti cal effects on performance and functions. Tighten ing torque is therefore specified for some tighten ing points. All tightening torque specifications may be consid ered as "dry" unless "wet" is specified. Where no tightening torque is specified, use a torque value specified in the General Bolts and Nuts lightening Torque Table. (5) Units Length, weight, surface area and capacity are given in International Systems of Units with metric units indicated in ( ). Temperatures are given in degrees Celsius. For the conversion into the foot-pound system, refer to the following conversion table.

COMPILATION OF THIS MANUAL - UNITS 2. UNITS

lightening torques and other parameters are given in SI* units with metric units added in brackets { }.

*SI: Le Systeme International d'Unites Example: 390 N · m {40 kgf · m}

-r- L LSI unit

Metric unit

Unit

SI unit {metric unit}

Force

Conversion factor

N {kgf}

9.80665 N {1 kgf}

N·m {kgf·m}

9.80665 N · m {1 kgf · m}

kPa {kgf/cm2}

98.0665 kPa {1 kgf/cm2}

kPa {mmHg}

0.133322 kPa {1 mmHg}

Pa {mmH2O}

9.80665 Pa {1 mmH2O}

Volume

dm {L}

1 dm3 {1 L}

Power

kW{PS}

0. 7355kW{1 PS}

Heat quantity

J {kcal}

4186.05 J {1 kcal}

W{kcal/h}

1.16279 W{1 kcal/h}

Moment of force Positive pressure Pressure

Vacuum pressure

Heat flow

Angle

Temperature

·c

Electric current

Voltage

Foot-pound unit

Conversion rate

Resistance Electric power

SI unit

Unit Force

N (Newton)

lbf

1 N = 0.2248 lbf

Moment of force

N·m

ft.lbs

1 N · m = 0.7375 ft.lbs

Pressure

kPa (kilopascal)

psi

1 kPa = 0.145 psi 1 kPa = 0.2953 in. Hg

Volume

gal.

cm3

cu.in.

1 L = 0.2642 gal. (U.S.) 1 L = 0.220 gal. (Imp.) 1 cm3 = 0.033814 oz (U.S.) 1 cm3 = 0.035195 oz (Imp.) 1 cm3 = 0.061023 cu.in.

kW (kilowatt)

1 kW= 1.3596 PS

Temperature

·c

t•c = ( 1.8t0c + 32)° F

Mass quantity of matter

kg g

•F

lb oz

1 kg = 2.2046 lb 1 g = 0.035274 oz

Dimension

m mm

ft. in.

1 m = 3.2808 ft. 1 mm = 0.03937 in.

Power

COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION

3. READING THE ILLUSTRATION (Ex. 1: Disassembly and Inspection)

*Protrusion from crankcase to surface NV 0.10 to 0.50

Indicates the service standards.

i.----3 Carbon deposits, scratches on outer surfaces, cracks, discoloration

9 c,aok,, o;

;ng

�

*Connecting rod end play NV 0.15 to 0.45 L 0.6

Indicates visual checks.

* Indicates inspection to be made before disassembly.

1 2 3 @ @

Connecting rod cap Connecting rod bearing Piston 1st compression ring 2nd compression ring

�

@ 7 8 9

Oil ring Snap ring Piston pin Connecting rod

NV .. Nominal Value L ..... Limit

Indicates that the disassembly procedures is explained in the text. A0014A

COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION (Ex. 2: Reassembly)

Gives instruction for jobs to ho doao at raassembly. ·• "'-.

' Apply engine oil.

Piston projection NV 0.48 to 0.74

98N-m {10 kgf-m} (Wet)

Specifies the tightening torque; (Wet) meaos the part m,st be Ughteoed lo wot "1/

Indicates a typical assembly sequence.

Face the oil groove toward the crankshaft End play NV 0.10 to 0.25 L 0.4

Indicates the service standards. NV .. Nominal Value L..... Limit

Assembly sequence

3➔@➔@➔7➔@➔@➔@➔2➔1

Indicates that the assembly procedure is explained in the text.

Illustrations (exploded views and assembly drawings) shows a typical service procedures if it is identical

A0013A

among various types of available systems and units. 7

GENERAL CONTENTS 1. EXTERNAL VIEW ............................ 2. MAJOR SPECIFICATIONS ................... 2.1 Major Specifications ...................... En_gine Outputs Classified by 2.2 Application ............ . ................... 3. ENGINE NUMBER AND CAUTION PLATE ........................................

2 3 3 3

4. KEY POINTS FOR MAINTENANCE WORK ....................... 5 5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE . .. ... . . . ... . 1 2

00-1

GENERAL - EXTERNAL VIEW

1. EXTERNAL VIEW Natural-aspirated engine

Turbocharged engine

A0243A

A0244A

00-2

GENERAL - MAJOR SPECIFICATIONS 2. MAJOR SPECIFICATIONS 2.1 Major Specifications It�

6D24

6D24-T

Type

6D24-TC

Diesel, 4-cycle, water-cooled

Combustion method

Direct injection

No. and arrangement of cylinder

6, in-line

Cylinder bore x stroke mm

130 X 150

Total displacement

6D24-TL

11945

cm 3

Engine dimension (with fan) Overall length

1473

Overall width

866

881

869

Overall height

1058

1169

1209

1246

Empty weight

kg*

905

930

960

940

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

2.2 Engine Outputs Classified by Application

6D24

6D24-T Turbocharged

6D24-TC Turbocharged with Aftercooler

1500

114{115}

163{222}

182{247}

1800

136{185}

191{260}

207{282}

2000

144{196}

201{273}

217{295}

2200

151{205}

206{280}

228{310}

1500

104{141}

148{202}

165{224}

1800

124{168}

174{236}

188{256}

2000

131{178}

182{248}

197{268}

2200

137{186}

187{255}

207{282}

gine ed rpm

�

Intermittent rated kW(PS) output

Continuous rated output kW(PS)

NOTE: 1. The output (SAE, gross) is corrected to standard ambient conditions based on SAE J1349. 2. The continuous rated output allows 10% (one hour) overload operation.

00-3

GENERAL - ENGINE NUMBER AND CAUTION PLATE

3. ENGINE NUMBER AND CAUTION PLATE

(2) Caution plate

(1) Engine number

E0175 E0143

The engine number is stamped near the front of the crankcase on the left-hand side. It takes the following form:

The caution plate is attached to the portion shown in the illustration. The caution plate indicates the follow ing items.

Example: 6D24- 012345

j�---- Engine number Engine model

The engine number is important in knowing the history of the engine.

VALV E C LEARANC E (C O LD) 0.4mm(0.016in)l1 I NLET EXHAUST O.6mm(0. 02 4 in)f-1 FIRING ORDER 1-5-3-6-2-4-V--2 0 BTDC�3 FUELINJECTION TIMING

□

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

A01668

00-4

GENERAL - KEY POINTS FOR MAINTENANCE WORK

4. KEY POINTS FOR MAINTENANCE WORK

•

In order to determine the condition of the vehicle ade quately, attend the vehicle beforehand to find and keep record of the accumulated mileage, operating condi tion, what the customer's demand is, and other in formation that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure.

WARNING,&.---------Check that the wire rope and crane are sufficiently strong.

17952

•

Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary. Then follow the procedure specified by this manual. Perform maintenance work at a level area.

When removing or installing the engine, attach the lifting wire rope hooks to the engine's lifting eyes and hoist the engine slowly such that it does not touch other components.

00012

•

Be particularly careful not to work in shoes that have oily soles and are slippery. When working as a team of two or more, arrange signals in advance and keep confirming safety. Be careful not to acci dentally bump switches or levers. Check for oil leakage before cleaning the area hav ing the fault otherwise you might miss detecting the leakage. Prepare replacement part(s) beforehand.

00009

•

Prepa re general and special tools necessary for the maintenance work.

WARNING.&_---------Do not attempt to use tools other than special tools where use of special tools is specified in this manu al. This will avoid injury or damage.

00-5

GENERAL - KEY POINTS FOR MAINTENANCE WORK

/ 00015

•

Replace oil seals, packing, 0-rings and other rub ber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts.

00017

Put alignment marks on part combinations before dis assembly and arrange the disassembled parts neatly. This will help avoid mismating of the parts later. Put the alignment marks, punch marks, etc. where per formance and appearance will not be affected. Cover the area left open after removal of parts to keep it free from dust.

CAUTION_&----------

• Take care to avoid mixing up numerous parts, simi lar parts, left and right, etc. • Keep new parts for replacement and original (re moved) parts separate.

00016

On disassembly, visually inspect all parts for wear and tear, cracks, damage, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.

00018

Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly.

CAUTIONLb_---------Use only the specified oil, grease, etc. for lubricant. Remove the excess immediately after application with a piece of rag.

00-6

GENERAL - KEY POINTS FOR MAINTENANCE WORK

00022

00019

Wear goggles when using a grinder or welder. Pay full attention to safety by wearing gloves when necessary. Watch out for sharp edges, etc. that might injure your hands or fingers.

•

06701

Before carrying out maintenance work on the electric system, disconnect the negative terminals of the bat teries.

Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type con nector, first push toward arrow mark. To reconnect a lock-type connector, press the separated parts until they click together.

00023

•

When washing the vehicle, cover the electric sys tem parts and instruments with waterproof materi al beforehand (Cover with vinyl sheet or the like). Keep water away from harness wire connectors and sensors. If any of them should get wet, wipe them off immediately.

00021

•

Take care when handling sensors, relays, etc. which are vulnerable to shock and heat. 00-7

GENERAL - KEY POINTS FOR MAINTENANCE WORK Measurement Procedures Using Connectors

06702

•

To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from O volt. Do not ap ply voltage higher than the specified value. In particular, pay close attention to the electronic control unit and sensors, since they are not always supplied with 24V.

Connect the test harness and connector A between these parts

02587

Test with connectors engaged (continuity through cir cuit obtained) <Waterproof connector> Prepare a test harness and connectors A, then connect if between the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector. Never insert the test probe from the harness side of the waterproof connection, or waterproof performance might be diminished causing corrosion of the connec tor.

00027

•

When using testers or the like for continuity tests, be careful not to allow test probes to touch the wrong terminals.

02588

<Non-waterproof connector> Insert test probe C from the harness side of the connec tor. Where control units, etc. have connectors that are too small to accept the test probe, do not force the test probe into them.

00-8

GENERAL - KEY POINTS FOR MAINTENANCE WORK Connector Inspection Procedures

02589 Test with connectors disengaged

Using female pins Insert a test probe into a terminal. However, do not force the probe into the terminal, or it will cause a poor contact.

02590

Visual inspection

Check for loose connection and poor engagement.

Check if harnesses are broken by pulling gently around the terminals.

Using male pins Touch the pins directly using test probes.

CAUTION_&----------

Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the internal circuit of the electronic control unit.

02593

Check for a decrease in contact pressure between the male and female terminals.

00-9

GENERAL - KEY POINTS FOR MAINTENANCE WORK

Check for poor contact caused by connector pins hav ing fallen out, rusted terminals or foreign particles.

Remove fuse B and measure resistance between the loaded side of the fuse and ground. Turn on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0, a short has occurred between the switch and the loaded point. A value of other than zero may indicate that the fuse was blown by a temporary short but the short is no longer present. The major causes of a short circuit are as follows: • Harness stuck onto the vehicle body. • Harness sheath damaged by friction or heat. • Water in connectors or circuits. • Mistakes (accidental short circuits)

02594

Connector pin fall out inspection Damaged connector pin stoppers can cause poor en gagement of the terminals (male and female pins) even if the connector body is secured, and might cause some pins to fall out. Check if the pins have fallen out from the connector by pulling each harness gently.

A: Battery B:Fuse C: Loaded switch D:Load E: Short circuit Precautions for Handling Alternator

Inspection Procedures for Blown Fuses

A +

04746

When servicing the alternator, pay attention to the fol lowing: Do not connect the alternator with battery polari ties reversed. If the alternator is connected with re versed polarities, a large current flow from the bat tery to the alternator occurs, and the diode or regu lator might be damaged.

•

C D

02596

00-10

GENERAL - KEY POINTS FOR MAINTENANCE WORK •

Do not splash water over the alternator. If water is directly splashed over the alternator, in dividual components will be short-circuited and might be destroyed.

04747

•

While the engine is running, do not remove the bat tery terminals. If the battery terminals are removed at that time, a surge voltage is generated and the diode or regulator might be weakened.

04749

•

Do not short-circuit terminal Band terminal L while running the alternator. If the terminals are short-circuited while the alter nator is running, the diode trio might be destroyed.

02371

•

Do not use a high-voltage tester such as a megger for inspection. If a high-voltage tester is used, the diode or regulator might be destroyed.

05166

•

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

05165

00-11

- GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

5. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE • • •

Use specified bolts and nuts and tighten them with the applicable torques according to the following table, unless otherwise specified. Threads and contact seats shall be dry. Where there is difference in strength classification between nut and bolt (or stud bolt), the torque specified for bolt shall apply.

Hex-head Bolt and Stud Bolt Unit: N•m {kgf-m} Stren th classi �ication n e-

I �

(Stud)

4 to 6 {0.4to 0.6}

(Stud)

5to 7 {0.5to 0.7}

2 to 3 {0.2to 0.3}

4to 6{0.4to 0.6}

9to 14{0.9to 1.4}

M10

19to 28{1.9to 2.8}

18to 26 {1.8to 2.7}

36to 52 {3.5to 5.5}

33to 49 {3.3to 5.0}

45to 60{4.5to 6.0}

41to 59 {4.3to 6.9}

M12

35 to 50{3.4to 5.0}

31to 46 {3.1to 4.7}

70to 95{7.0to 9.5}

65to 85 {6.5to 8.5}

85to 110{8.5to 11}

75to 100 {7.5to 10}

M14

60to 85{6.0to 8.5}

55to 75 {5.5to 7.5}

120to 160{12to 16}

110to 140 {11to 14}

130to 180{13to 18}

120to 160 {12to 17}

M16

90to 130{9.5 to 13}

90to 120 {9.0to 12}

180to 240{18to 24}

160to 220 {16to 22}

200to 270{20to 27}

190to 260 {19to 26}

M18

140to 190{14to 19}

120to 160 {12to 16}

260 to 340 {25 to 35}

220to 290 {22to 30}

290to 390{30to 40}

260to 340 {26to 35}

M20

190 to 260 {19 to 26}

170to 230 {17 to 23}

350to 470{36to 48}

320to 420 {32to 43}

410to 550 {41to 56}

370to 490 {37to 50}

M22

260 to 340 {26 to 35}

230to 300 {23 to 31}

470 to 640{48to 65}

430to 570 {43to 58}

550 to 740 {56to 75}

490to 670 {50to 68}

M24

340to 450{34to 46}

290to 390 {29to 40}

630to 840{63to 86}

540to 730 {55to 74}

730 to 980 {74to 100}

630to 840 {64to 86}

7 to 11 {0.7to 1.1} 17to 26 {1.7to 2.6}

8to 12 {0.8 to 1.2}

20 to 29{2.0to 3.0}

Hex-head Flange Bolt Unit: N-m {kgf-m}

I �

Strength classification

�

8to 12 {0.8to 1.2}

0 -

� 9to 14{0.9 to 1.4}

0 -

4to 6{0.4to 0.6}

10 to 15 {1.0to 1.5}

M10

21to 30 {2.1to 3.1}

20 to 28 {1.9to 2.9}

39 to 58 {3.9 to 6.0}

37 to 53 {3.6to 5.4}

50 to 65 {5.0 to 6.5}

45 to 65 {4.5to 6.5}

M12

38 to 54 {3.8 to 5.5}

35 to 51 {3.4to 5.2}

80 to 110 {8.0 to 11}

70to 95 {7.0to 9.5}

90 to 120 {9.0to 12}

85 to 110 {8.5to 11}

00-12

19to 28 {1.9 to 2.8}

22 to 32 {2.2to 3.3}

GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE Hex-head Nut Unit: N-m {kgf-m } Strength classification

Representation

(DJ

([eJ]

Diameter symbol

Standard screw

2 to 3 {0.2 to 0.3}

4 to 6{0.4 to 0.6}

9 to 14{0.9 to 1.4}

7 to 11{0.7 to 1.1} 17 to 26{1.7 to 2.6}

M10

19 to 28{1.9 to 2.8}

18to 26{1.8to 2.7}

36to 52{3.5to 5.5}

33to 49{3.3 to 5.0}

M12

35 to 50{3.4 to 5.0}

31to 46{3.1to 4.7}

70to 95{7.0to 9.5}

65to 85{6.5 to 8.5}

M14

60 to 85{6.0 to 8.5}

55to 75{5.5to 7.5}

120to 160{12to 16}

110to 140{11to 14}

M16

90to 130{9.Sto 13}

90to 120{9.0to 12}

180to 240{18to 24}

160 to 220{16to 22}

M18

140 to 190 {14to 19}

120to 160 {12to 16}

260to 340{25to 35}

220to 290{22to 30}

M20

190 to 260 {19 to 26}

170to 230 {17to 23}

350to 470{36to 48}

320to 420{32to 43}

M22

260 to 340 {26 to 35}

230to 300 {23to 31}

470to 640{48to 65}

430to 570{43to 58}

M24

340 to 450 {34 to 46}

290to 390 {29to 40}

630to 840{63to 86}

540to 730{55to 74}

Coarse screw

Standard screw

Coarse screw

Hex-head Flange Nut Unit: N-m {kgf-m } 4T

Strength classification Representation

� Diameter symbol

Standard screw

Coarse screw

4 to 6{0.4to 0.6}

10to 15{1.0to 1.5}

M10

21to 30{2.1 to 3.1}

20to 28{1.9to 2.9}

M12

38 to 54{3.8 to 5.5}

35 to 51{3.4to 5.2}

00-13

GENERAL - GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABL E

lightening torque for flare nut for general purpose Pipe diameter

lighteningtorque

4>6.35 mm

4>4.7 6 mm

«j>Smm

39 {4.0}

25 {2.6}

17 {1.7}

«j>12mm

«j>10 mm 5

Unit: N-m {kgf-m} qi15mm

98 {10 .0}

88 {9.0}

9 {6.0}

lightening torque for air piping nylon tube for general purpose {DIN type} Standard diameter

lighteningtorque

6x1mm .9 6 20+5 { 2.0 +� } 0

10 x1.25 mm 34

10 0

{ 3.5 +�O }

Unit: N-m {kgf-m}

12x1.5 mm 10 49+ 0

{

.0 +�O }

15 x 1.5 mm 5

Tightening torque for air piping nylon tube for general purpose {SAE type} Standard diameter

lighteningtorque

00-14

1/4in . 13

{ 1.3

+g- 4 }

5 { 3.o +g- }

Unit: N-m {kgf-m}

1/2in .

3/8in. 49

5 { 5.o +g- }

5 { 5 .5 +g- }

5 +5 54 0

/8in.

5 { s.5 +g- }

ENGINE CONTENTS 1. GENERAL ................................ . ... 2 2. SPECIFICATIONS ............................ 8 3. SERVICE STANDARDS ...................... 9 Service Standards Table .................. 9 3.1 3.2 lightening Torque Table ................. 1 1 4. SPECIAL TOOLS ............................ 1 2 5. SERVICE PROCEDURES .................... 16 5.1 Measuring Compression Pressure ...... 16 5.2 Cylinder Head and Valve Mechanism ... 17 5.2.1 Disassembly ........................... 17 5.2.2 Inspection ............................. 19 5.2. 3 Reassembly ........................... 25

Flywheel, liming Gears, and Camshaft .................. ............... Disassembly ............ ............... 5.3.1 Inspection .............. ............... 5.3.2 Reassembly ............ ............... 5.3.3 5.4 Crankcase and Main Moving Parts ...... 5.4.1 Disassembly ........................ ... 5.4.2 Inspection ........ ...... ............... 5.4.3 Reassembly ...... . .................... 5.5 Inspecting and Adjusting Valve Clearances ................ ............... 6. TROUBLESHOOTING .. ...... ....... . ....... 5.3

29 29 33 39 45 45 49 59 65 67

Mitsubishi L11.9D2B Engine Parts Contact: Heavy Equipment Restoration Parts LLC 4730 118th Ave Fennville Michigan 49408 USA Phone: 269 673 1638 Fax: 269 673 7226 email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com Text message: 269 760 8652 Located in USA, Engine Parts delivery available in USA, Canada and worldwide. Mitsubishi Diesel Engine Parts Nissan Diesel Engine Parts Hino Diesel Engine Parts Isuzu Diesel Engine Parts Mercedes Benz Industrial Diesel Engine Parts

11-1

ENGINE - GENERAL

1. GENERAL

(1) Combustion chamber

Injection nozzle Cylinder head ----- 0-ring Nozzle tube Cylinder head gasket Water director

B0376A

Water directors pressed into the bottom of the cylinder head optimize cooling of the combustion chambers by directing the flow of coolant.

B0375C

The combustion chambers are formed by the cylinder head and pistons. The injection nozzles, sheathed by the nozzle tubes, are mounted on the cylinder head. The nozzle tubes hold the nozzles and protect them from cooling water. Since the nozzles are exposed to the water in the water jacket, they are sealed by 0-rings at the top and by staking at the bottom. Combustion is effected by compression of fuel injected directly into the combustion chambers.

11-2

ENGINE - GENERAL (2) Valve mechanism

Rocker cover

Rocker Valve cap Valve cotter :...----------- _____ Upper retainer _ ..- .. -- Valve spring outer ...., --· - -- Valve spring inner

Valve stem seal Oil passage

Rocker

Push rod

85040A Tappet Camshaft

B0375O

The valve mechanism is of an overhead-valve (OHV) type and is constructed as shown in the diagram. (a) Valve stem seals are fitted to the inlet and exhaust valve stems to control the amount of lubricant flowing onto the sliding surfaces of the valves and valve guides. (b) The inlet and exhaust valve springs are unevenly pitched. Two springs are mounted for each valve, and the inner and outer springs are wound in oppo site directions. (c) The rocker and rocker shaft are supported by the rocker shaft bracket and are installed indepen dently for each cylinder. The same type of rocker is used for both inlet and exhaust valves, and the cen ter of each rocker forms an oil passage. The rocker shaft is a hollow rod sealed by a thrust plate at each end. The inside of the rocker shaft forms an oil passage.

(d) A steel ball is welded to the bottom end of each push rod, and a spherical concave piece is welded to the top end. (e) The tappets are cylindrical. To help prevent local ized wear, the areas that make contact with the camshaft are curved. The overall design enables the tappets to be removed via the side of the crank case. (f) The camshaft is held by camshaft bushings that are pressed into the crankcase. The cam profiles are specially curved to achieve smooth acceleration.

11-3

ENGINE - GENERAL

(3) Crankcase and cylinder liner

(4) Piston and piston rings (a) Pistons

Weight mark

Size mark (A, B,C)

Part No.

Front indicated by "F" and arrow Cooling cavity

(a) Seven camshaft bushings are fitted in the camshaft bearing section of the crankcase. To facilitate removal and reinstallation of the camshaft, the diameter of each bearing is smaller toward the front. (b) Coolant is fed in from the water pump (located at the front left of the crankcase). After cooling the oil cooler, it flows through the water jacket holes and around the cylinders, then reaches the cylinder head.

43428

The piston is an aluminum casting, and a combustion space is recessed into its crown. A piston ring insert is cast into the 1st piston ring groove to improve durabil ity. Stamped on top of the piston are a size mark, a piston weight mark, the piston's part number, an identifica tion mark, plus an "F" and arrow, which indicate the piston installation direction. The size mark is provided to enable selection of the correct cylinder liner size. In the case of an oversize piston, the size mark shows the degree of oversize. The piston pin is fully floating and is held in position by a snap ring at either end. (b) Piston rings

� 1st compression ring � (full keystone type)

=:f ;;;;;;_;;;::;,,....____,,) (c) The cylinder liner is a removable wet type. It is press-fitted into the crankcase, with its top held by the top of the crankcase and its bottom held by the water jacket. Rubber rings and 0-rings are provided at the top and bottom of the cylinder liner to prevent the ingress of coolant. The water jacket has a water thrattling shelf to opti mize cooling performance.

11-4

2nd compression ring (typer faced inner cut type) Oil ring (dual type with an expander spring)

803740

Two compression rings and one oil ring are fitted to each piston. They are shaped as shown in the illustra tion.

ENGINE (5) Connecting rod and connecting rod bearing

GENERAL

(6) Crankshaft and crankshaft main bearings

Connecting rod bushing Balance weight

84206A

Connecting rod Connecting rod bearing (upper) Cylinder number, weight mark

"><¾?�

Connecting rod bolt

(a) The crankshaft is highly rigid and is cast in one piece with its balance. Between each journal and pin is an oil hole. Some of the main bearing oil is fed through this hole to lubricate the connecting rod bearing. <Axial lip type> Flywheel housing

45482

The connecting rod is a highly rigid I-section forging. A bushing is pressed into the small end, and a split-type plain bearing is used at the big end. Since it is a split-type bearing, the connecting rod bear ing has an upper half and a lower half. The upper half has an oil hole. This oil hole is in line with the oil pas sage inside the connecting rod. Engine oil for lubrica tion of the small end bushing is supplied via the oil hole and oil passage. An oil hole is provided at the top of the connecting rod to help cool the piston. The connecting rod and connecting rod cap are held together by four connecting rod bolts.

Slinger

43654

Flywheel housing

Crankshaft gear

O-ring

Crankshaft Retainer

803518

(b) The crankshaft gear that drives the timing gears is press-fitted onto the rear of the crankshaft. Note that a radial- or axial-lip-type oil seal is fitted to the front and rear ends of the crankshaft.

11-5

ENGINE - GENERAL (d) Main bearings Torsional damper

<Rubber type> • Single mass

,.,.

• Double mass

� Crankshaft pulley

Torsional damper Crankshaft pulley

Crankshaft pulley

Crankshaft

Upper main bearing

84489A

(c) The front end of the crankshaft is flanged, and the crankshaft pulley is bolted to the flange. A torsional damper is mounted on the crankshaft pulley to absorb the crankshaft's torsional vibration.

Thrust plate

80382A

Each main bearing is a split-type plain bearing made of special alloy-plated kelmet metal with backing mate rial. Since they are split-type bearings, the main bearings have upper halves and lower halves. Each upper half has an oil groove on its inside surface, plus an oil hole. The oil hole lines up with an oil hole in the crankcase. There are 7 main bearing pairs. A split-type thrust plate is fitted to the rearmost bearing.

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

11-6

lower main bearing

ENGINE - GENERAL (7) liming gears

Each idler gear is mounted onto the crankcase with an idler shaft bolt and is supported at the other end by the flywheel housing. The idler gears turn on the idler shafts by means of pressed-in bushings. The bushings are lubricated by oil that flows through the inside of the idler shafts via the crankcase oil holes. (8) Flywheel

Angle scale, cylinder number

11111111111)111111 ili11ili1111111fli111l1111lf111

Mr Idler gear C 2=68

inc Cylinder No.

I I I I I j I 11 I 3j

Idler gear 2=47 Oil pump gear 2=53 B0383L

The timing gears are located in the flywheel housing at the rear of the engine. The geartrain is as shown in the illustration. The timing gears are helical, and each is stamped with a timing mark. The timing marks ensure that the gears mesh correctly when reassembled.

Flywheel __,,..- housing / ----- Idler gear "A"

-=--" -

Âˇ

--Collar . Crankshaft

Thrust plate

Cylinder No.

I I I II 11 I I I 2j5

]II[

\.._ Valve timing "' check mark

j&n Hj j ! 11 t I

10355

The flywheel is made of cast iron, and at its center is a pilot bearing for the clutch shaft. The outer ring gear that meshes with the starter pinion is shrink-fitted. The ring gear teeth are chamfered on one side to ensure that the starter pinion fits easily. Cylinder numbers, an angle scale, and valve timing check marks are stamped on the outside of the flyÂ wheel, as shown in the illustration.

80384A

The crankshaft gear is press-fitted onto the crankshaft and held in place by a dowel pin. The crankshaft gear drives the other gears.

11-7

ENGINE - SPECIFICATIONS

2. SPECIFICATIONS Specification

Item Engine model Type

6D24

6D24-T

6D24-TC

6D24-TL

6-cylinder, in-line, water-cooled, 4-cycle diesel

Combustion chamber type

Direct injection

Valve mechanism

Overhead valve

130 X 150

11945

19.5

16.5

17.5

Cylinder bore x stroke (mm) Total displacement (cm ) 3

Compression ratio Fuel injection sequence Cylinder liner type Piston type

No. of piston rings

11-8

1-5-3-6 -2-4 Wet Trunk-type slipper skirt

Compression ring: 2 Oil ring: 1

.-.--

(with cooling cavity)

.--

ENGINE - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table

Unit: mm Maintenance item Compression pressure (at 200rpm)

Rocker bushing-to-rocker shaft clearance Outer valve spring

Free length Installed load/installed length

Inner valve spring

Free length Installed load/installed length Squareness

Tappet-to-crankcase clearance

Limit

2750kPa {28kgf/cm 2}

1960kPa {20kgf/cm2}

(28] 0.03to 0.08

0.2

Replace bushing

89.38

Replace

450 N {46.1kgf} / 58.35

380N {39kgf} / 58.35

65.04

115 N {12kgf} / 50.35

100N {10.2kgf} / 50.35

2.5

0.5

Replace

0.07or less

0.08

130

129.8

Replace

Inlet

11.95to 11 .96

11.85

Replace

Exhaust

11.91to 11.93

[35] 0.06to 0.10

Valve stem-tovalve guide clearance

Inlet

(12] 0.05to 0.09

Exhaust

(12] 0.09to 0.12

Valve margin

Inlet Exhaust

Correct or replace

0.2

Replace valve guide

2.2

1.7

Reface or replace

2.5

2.0

45Â°

0.25to 0.75

1.0

--0.05to 0.45

0.7

2.69to 2.96

3.5

Between crankshaft gear and idler gear B

0.08to 0.20

0.4

Inspect

Between idler gear A and camshaft gear

0.07to 0.18

0.4

Inspect

Between idler gear A and idler gearC

0.07to 0.18

0.4

Inspect

Between injection pump gear and idler gearC

0.08to 0.20

0.4

Inspect

0.05 to 0.15

0.4

Replace thrust plate

Valve seat angle Inlet Exhaust

Valve seat insert seat width

Idler gear end play

Replace valve seat insert (- shows projection)

Correct or replace

0.05to 0.22

0.4

Friction surface distortion

0.1or less

0.2

Correct or replace

Distance from clutch cover mounting surface to friction surface

47.8to 48.2

49.5

Replace

0.2

Camshaft gear end play Flywheel

Replace

Height of cylinder head from top to bottom surface

liming gear backlash

Difference between cylinders: 390 KPa {4kgf/cm 2} or less

Replace

Cylinder head bottom surface distortion

Valve sinkage from cylinder head bottom surface

Remedy and remarks

0.2

Push rod runout

Valve stem outside diameter

Nominal value (Basic diameter in [ ])

Friction surface runout (when fitted)

Correct or replace

Idler gear A-to-idler shaft A clearance

(40) 0.03to 0.06

0.2

Replace bushing

Idler gearC-to-idler shaftC clearance

[46] 0.03to 0.06

0.2

Replace bushing

11-9

ENGINE - SERVICE STANDARDS Unit: mm Limit

Inlet

8.83

8.3

Replace

Lobe height: 56.167 Base circle diameter: 47.334

Exhaust

8.82

8.3

Replace

Lobe height: 56.036 Base circle diameter: 47.216

No.1

(65.00) 0.03 to 0.08

0.25

Replace bushing

No. 2

(65.25) 0.03 to 0.08

No. 3,4

(65.50) 0.03 to 0.08

No. 5,6

(65.75) 0.03 to 0.08

No. 7

(66.00) 0.03 to 0.08 0.08

Replace

Maintenance item Cam profile (difference between lobe height and base circle diameter)

Camshaft journal-to-camshaft bushing clearance

Remedy and remarks

Nominal value (Basic diameter in [ ])

0.05 or less

Camshaft bend Camshaft gear-to-camshaft interference Flywheel housing eccentricity Connecting rod end play

(40) 0.02 to 0.05

0.2

Correct

0.2 to 0.5

1.0

Replace

Can be reassembled up to 3 times

Projection of piston from top surface of crankcase

0.87 to 1.33

Crankshaft end play

0.09 to 0.23

0.4

Replace thrust plate

0.1

Replace crankcase

0.07 or less

0.2

Correct

130.014 to 130.054

130.25

Flatness of cylinder liner supporting flange Crankcase top surface distortion Cylinder liner

Inside diameter

0.01 to 0.08

Flange projection

0.02 or less

Cylindricity Piston-to-cylinder liner clearance Piston ring groove-topiston ring clearance

1st compression ring 2nd compression ring

Inspect

Replace or grind to oversize

Correct or replace cylinder liner,or replace piston

6D24

(130) 0.178 to 0.204

6D24-T,TC,TL

(130) 0.193 to 0.219

6D24

0.09 to 0.13

0.25

Replace piston ring or piston

6D24-T,TC,TL

0.02 to 0.10

6D24

0.05 to 0.08

0.25

Replace piston ring or piston

6D24-T, TC,TL

0.07 to 0.10 0.03 to 0.06

0.15

1st compression ring

0.4 to 0.55

1.5

2nd compression ring

0.5 to 0.65

1.5

Oil ring

0.4 to 0.6

1.5

Piston pin-to-piston pin hole clearance

[50) 0.01 to 0.02

0.1

Replace piston or piston pin

Piston pin-to-connecting rod small end bushing clearance

(50) 0.02 to 0.05

0.1

Replace bushing

Oil ring Piston ring end gap

Connecting rod

Bend

0.05 or less

Replace

Correct or replace

Less than 90.5

Connecting rod bearing-to-crankshaft pin clearance

[84) 0.07 to 0.13

0.25

Replace bearing

Main bearing-to-crankshaft journal clearance

(100) 0.08 to 0.15

0.25

Replace bearing

Torsion Connecting rod bearing span when free

Main bearing span when free

Engine Parts contact phone: 269 673 1638 11-10

0.1 or fess

Less than 106.5

Replace

Email: EngineParts2@gmail.com

ENGINE - SERVICE STANDARDS

Unit: mm

Maintenance item Crankshaft pin and journal

Nominal value (Basic diameter in I ])

Limit

Roundness

0.01 or less

0.08

Cylindricity

0.006 or less

0.04 or less

0.1

Crankshaft bend Valve clearance (when cold)

Inlet

0.4

Exhaust

0.6

Remedy and remarks Correct

Correct or replace

Adjust

3.2 lightening Torque Table Location tightened

Screw size 0. D.xpitch (mm)

lightening torque N-m{kgf-m}

M14x2

Rocker shaft bracket mounting bolt

M10x1.5

59{6}

Rocker cover bolt

M8x1.25

4.9{0.5}

Rocker adjusting screw lock nut

M10 x1.25

59{6}

Flywheel mounting bolt

M16x1.5

315{32}

Cylinder head bolt

Remarks

Wet. See item (6) of section 5.2.3 for tightening procedure.

Wet

Idler shaft bolt A

M16x2

155{16}

Idler shaft bolt C

M16x2

155{16}

Idler shaft nut (for mounting collar)

M16x1.5

98{10}

Flywheel housing bolt

M12x1.75

69{7}

Oil jet check valve

M12x1.75

34{3.5}

Cannot be reused

Connecting rod cap nut

M13 X 1.25

115{12}

Wet

Main bearing cap bolt

M18x2.5

Crankshaft pulley mounting bolt

M14x1.5

175{18}

M12 X 1.75

33{3.4}

Front cover mounting bolt

Wet. See item (7) of section 5.4.3 for tightening procedure.

Mitsubishi 6D24 6D24T Engine Parts Contact: Heavy Equipment Restoration Parts LLC 4730 118th Ave Fennville Michigan 49408 USA Phone: 269 673 1638 Fax: 269 673 7226 email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com Text message: 269 760 8652 Located in USA, Engine Parts delivery available in USA, Canada and worldwide. Mitsubishi Diesel Engine Parts Nissan Diesel Engine Parts Hino Diesel Engine Parts Isuzu Diesel Engine Parts Mercedes Benz Industrial Diesel Engine Parts 11-11

ENGINE - SPECIAL TOOLS

4. SPECIAL TOOLS Unit: mm Tool name

Unit: mm Shape

Tool name

Shape

Caulking Tool Body MH061360 Installing and caulking valve seat inserts

Compression Gauge Adapter MH061461 Measuring compression presÂ sure

Caulking Tool Body

Caulking Ring (Inlet) MH061650 Installing and caulking valve seat inserts Center distance 46 Valve Lifter MH061668 Removing and installing valve cotters Valve Lifter Hook MH061679 Removing and installing valve cotters

01942

Caulking Ring For inlet: cl> 59 For exhaust: cl> 54

Caulking Ring (Exhaust) MH061651 Installing and caulking valve seat inserts

Valve Lifter B5202A Valve Lapper 30091-07500 Valve lapping

I.D. 42 Valve Lifter Hook 01956 Nozzle Tube Stamp MH061229 Installing nozzle tubes

Nozzle Tube Remover MH061232 Removing nozzle tubes cl> 12.5 cl> 8.7

Nozzle Tube Installer Flange MH061416 Installing nozzle tubes Nozzle Tube Installer Bolt MH061231 Installing nozzle tubes

13597 Rocker Bushing Puller MH061236 Replacing rocker bushings

Nozzle Tube Installer Flange

85181A Valve Stem Seal Installer ME067431 Installing valve stem seals

cl> 12

10593 Valve Guide Puller 30091-08100 Replacing valve guides

cj>24 B5111A

11-12

85191A

ENGINE - SPECIAL TOOLS Unit: mm Idler Gear Bushing Puller MH061228

Unit: mm

Camshaft Bushing Extractor Bar MH062118

Replacing idler gear bushing (for idler gear A)

Removing camshaft bushings Nos. 1 to 6

4>39.5

03532

Idler Gear Bushing Puller MH062046

B4867A

Replacing idler gear bushing (for idler gear C)

Camshaft Bushing Extractor Guide MH062119 Removing camshaft bushings Nos. 1 to 6 4>45.5

B4384A

Gear Puller MH061061 Removing gears and pulleys B4868A

Maximum pulling outside dia. 200 B5071A

Camshaft Bushing Extractor Adapter MH062120 MH062121 MH062122 MH062123 Removing camshaft bushings Nos. 1 to 6

Socket Wrench MH061540 lightening cylinder head bolts cj,A

cl> B

Applicable bushing

MH062120

69.75

No.1

MH062121

65.25

No.2

MH062122

70.25

65.5

No.3,4

MH062123

70.75

65.7

No.5,6

B4869A

B0598A Socket Wrench MH063365

Camshaft Bushing Extractor MH062124

lightening main bearing cap bolts

Removing camshaft bushing No. 7

13204

Part No.

B4870A

11-13

Ill

ENGINE - SPECIAL TOOLS Unit: mm

Unit: mm Camshaft Bushing Installer MH06213 1 MH062143 Installing camshaft bushings Nos. 1 and 7

Camshaft Bushing Installer Bar MH062125 Installing camshaft bushings Nos. 2to 6

M24x 1.5 B487 1A Camshaft Bushing Installer Guide MH062127 Installing camshaft bushings Nos. 2to 6

cl>B

Applicable bushing

Part No.

cl>A

MH062131

70.75

No.T

MH062143

72.25

No.7

B4875A Oil Seal Slinger Installer MH06 1652 Installing rear oil seal slinger

B4872A Camshaft Bushing Installer Adapter MH062133 MH062134 MH062135 MH062136 MH062137 Installing camshaft bushings Nos. 2to 6

B5 16 1B Piston Ring Tool 3 1 19 1-02900 Removing piston rings Part No.

♦A

♦B

Applicable

bushing

MH082133

MH082134

71.25

65.5

No.3

MH082135

71.5

65.5

Na.4

MH062136

71.75

85.75

No.5

MH082137

65.75

No.6

65.25

No.2

B4873A Camshaft Bushing Installer Nut MH062130 Installing camshaft bushings Nos. 2to 6

For<j,102to 178

020 13 Crankcase Table MH06 1889 Measuring flatness of cylin der-liner-supporting flanges on crankcase

M24x 1.5

B4874A

11-14

B 1480A

ENGINE - SPECIAL TOOLS Unit: mm Cylinder Liner Extractor MH061490 Removing cylinder liners

Unit: mm

Oil Seal Sleeve Installer 31191-07100 Installing rear oil seal sleeve

PE7264 B5131A Cylinder Liner Installer MH061759 Installing cylinder liners

Oil Seal Slinger Installer MH061817 Installing front oil seal slinger

85141A 80585A

Guide Plate Assembly MH063368 Removing bushings

connecting

Piston Guide Clamp MH061666

rod

Installing pistons

Mandrel 31291-75200 Removing bushings

connecting

Collar A MH063370 Removing connecting bushings Collar B MH062189 Removing bushings

connecting

Nut 31291-75500 Removing connecting bushings

Piston Guide Lever MH061658 Installing pistons

rod

I.D.: 130 rod

rod

B5171B

rod 85151A

Oil Seal Installer 31191-04300

Thickness Gauge MH061359 Measuring valve clearances

Installing rear oil seal (radial lip type)

PE7263

11605

11-15

ENGINE - SERVICE PROCEDURES

5. SERVICE PROCEDURES

5.1 Measuring Compression Pressure Compression pressure should be measured prior to disassembly of the engine. Take measurements regu larly and keep track of changes. During the engine's running-in period or after parts have been replaced, the compression pressure will increase slightly as the piston rings and valve seats fit snugly in position. T he pressure will come down as parts wear.

Compression pressure (at 200 rpm) NV 2750 kPa {28 kgf/cm2} L 1960 kPa {20 kgf/cm2} Difference between cylinders 390 kPa {4 kgf/cm2> maximum NV .. Nominal Value L ..... Limit

Measurement procedure

Compression Gauge Adapter MH061461

85561A 85554A

(1) Warm up the engine until the coolant temperature reaches 75 to 85° C, then turn off the ignition.

(3) Mount the Compression Gauge Adapter (special tool) onto an injection nozzle hole together with a gasket. Connect the compression gauge. (4) To prevent fuel from being pumped into the cylin der by the injection pump, pull the injection pump governor's stop lever fully in the "stop" direction. (5) Turn the engine over with the starter and measure the compression pressure at 200 rpm.

85560A

(2) Remove all injection nozzles from the cylinder head.

NOTE: Cover all mounting holes and injection pipes to pre vent the entry of dust and dirt.

11-16

NOTE: 1. Be sure to measure at the correct engine speed since changes in engine speed cause changes in compression pressure. 2. Since wear and other factors vary from one cylin der to another, measure the compression pressure in every cylinder.

ENGINE - SERVICE PROCEDURES 5.2 Cylinder Head and Valve Mechanism 5.2.1 Disassembly

2 Oil hole

JV/

�g vlear

Wear, damaged threads 17 Water leaks, gas leaks

Wear, damage 7

Wear, cracks

Corrosion

Disassembly sequence 1 Rocker cover 2 Rocker shaft bracket mounting bolt 3 Cylinder head bolt 4 Thrust plate Rocker Rocker shaft bracket 7 Push rod

8 Valve cap

Valve cotter Upper retainer Outer valve spring Inner valve spring Lower retainer Valve stem seal 15 Inlet valve

® 10 11 12 13 *114

16 *2 ® *218 *219 ® 21 22

Exhaust valve Nozzle tube Water director Sealing cap Cylinder head Crankcase side cover Tappet

For parts with circled numbers, refer to the following section, "Disassembly Procedure." Parts marked with "*1" should be replaced and not reused, even if only the valve is removed. Parts marked with "*2" should not be removed unless defects are evident.

Engine Parts contact phone: 269 673 1638

13208

Email: EngineParts2@gmail.com 11-17

ENGINE - SERVICE PROCEDURES

Disassembly Procedure

The cylinder head is located on the top surface of the crankcase by dowel pins. To remove the cylinder head, lift it straight upward. Rocker cover Rocker shaft bracket mounting bolt

C1543B

(1) Before removing the bolts, loosen the adjusting screw on every rocker that is being pushed up by its push rod.

NOTE: 1. Remove the injection nozzles before taking off the cylinder head. (Refer to Group 13A, Fuel and Engine Control.) If the cylinder head is placed on a work bench with the nozzles still mounted, the ends of the nozzles projecting from the bottom of the cylinder head will be damaged. 2. When removing the cylinder head gasket, take care not to scratch or dent the cylinder head and crankcase mounting surfaces. (4) Removing valve cotters

(2) Removing rocker shaft bracket assembly

Valve Lifter Hook MH061679

â&#x153;&#x201C;

Rocker shaft bracket

ďż˝as,ombly

e cotter

Spring pin

C1544B

T he rocker shaft bracket assembly is held in place in the cylinder head by a spring pin. To remove the assembly, lift it straight upward. (3) Removing cylinder head assembly

B5282B

To remove the valve cotters, use the Valve Lifter and Valve Lifter Hook (special tools) to evenly compress the valve springs. (5) Removing nozzle tubes

Nozzle Tube Remover MH061232

C1527A

B90148

11-18

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

ENGINE - SERVICE PROCEDURES 5.2.2 Inspection Item Free length Rocker bushing to-rocker shaft clearance BO 28 NV 0.03 to 0.08 L 0.2

Installed load/ installed length

Outer valve spring

89.38

Inner valve spring

65.04

Outer valve spring

450 N {46.1 kgf}/58.35

380 N {39 kgf}/58.35

Inner valve spring

115 N {12 kgf}/50.35

100 N {10.2 kgf}/50.35

Inner valve spring squareness

y � '

: --�&

2.5 BO .. Basic D iameter NV .. Nominal Value L. .... Limit

e e Runout L 0.5

I I

Tappet-to-crankcase clearance BO 35 NV 0.06 to0.10 L 0.2

C ylinder head bottom surface distortion NV 0.07 or less L 0.08 Height of cylinder head from top to bottom surface NV 130 L 129.8

Item Valve stem 0. D.

Inlet valve

11.95 to11.96

11.85

Exhaust valve

11.91 to 11.93

Valve stem-to-valve guide clearance

Inlet valve

0.05 to0.09

Exhaust valve

0.09 to0.12

Valve seat insert seat width

Inlet valve

0.2

2.69 to2.96

3.5

Exhaust valve Valve sinkage from cylinder head bottom surface

Inlet valve

0.25 to0.75

1.0

Exhaust valve

-0.05 to0.45

0.7

Valve margin

Inlet valve

2.2

1.7

Exhaust valve

2.5

2.0

Valve seat angle

C27578

11-19

ENGINE - SERVICE PROCEDURES Measure the free length and installed load of each valve spring. Replace any spring that is not up to speci fication. With inner springs, check also for squareness.

Inspection Procedure

(1) Rocker bushing-to-rocker shaft clearance Measuring position

(4) Tappet-to-crankcase tappet hole clearance <Tappet measurement>

Measuring position

�

Measuring position

c2734A C2745A

If the clearance exceeds the specified limit, replace the rocker bushing. (2) Replacing rocker bushing To install

To remove Rocker Bushing Puller MH061236

---....=."-�:;..;; �.:c. =' iu l

Adjusting screw side

_0__,�__,, Rocker oil hole

If the clearance exceeds the specified limit, replace the tappet. C27628

(5) Push rod runout

When installing a bushing, face the bushing's seam toward the rocker adjusting screw and align the bush ing and rocker oil holes. (3) Inspecting valve springs Squareness (inner spring only)

®01948

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

11-20

ENGINE

SERVICE PROCEDURES (8) Valve stem-to-valve guide clearance

(6) Cylinder head bottom surface distortion

Valve

21653

C3125A

If distortion exceeds the specified limit, correct it using a surface grinder. NOTE: Replace the cylinder head if grinding causes the height from its top surface to bottom surface to fall below 129.8mm.

Insert the valve in the valve guide and measure the play at the specified distance from the valve guide's top (as illustrated). If the amount of play exceeds the specified limit, replace the valve guide. (9) Replacing valve guide

(7) Valve stem outside diameter Valve Guide Puller 30091-08100

Measuring position

Valve guide ., Seat the collar---Â â&#x20AC;˘,! of valve guide -- -'t-11-------..securely on cylinder head

To remove

C3102A

Replace the valve if its stem's outside diameter is below specification or if it is severely worn.

To install

C3113A

To install a valve guide, insert it with the Valve Guide Puller (special tool) until its flange sits securely on the cylinder head.

11-21

ENGINE - SERVICE PROCEDURES

(10)Contact between valve and valve seat insert

(11)Rectifying valve face

Valve margin

Valve seat angle

Valve 820248

(a) Apply an even coat of minium to the valve seat insert surface that comes into contact with the valve. (b) Using the Valve Lapper (special tool), strike the valve against the valve seat insert once.

C2708A

With a valve refacer, grind the valve face to achieve the specified valve seat angle. NOTE: 1. 2.

NOTE: 1. 2.

Do not turn the valve when striking it against the valve seat insert. The contact pattern should be checked whenever a valve guide is inspected or replaced.

C2710B

Keep grinding to a minimum. If the valve margin is below specification after grinding, replace the valve. After grinding, be sure to lap the valve and valve seat insert. [See item (14) for details].

(12)Rectifying valve seat insert

000 Good

Bad

C2707A

Valve sinkage

C3127A

Valve Valve seat angle

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

Valve

11-22

C2710A

ENGINE - SERVICE PROCEDURES (al Using a valve seat cutter, cut the insert to achieve the specified valve seat angle and seat width. Use a 15° or 75 ° cutter first, followed by a 45° cutter.

NOTE:

1. 2.

Keep cutting to a minimum. If the valve sinkage exceeds the specified limit after cutting, replace the valve seat insert.

(bl After cutting, put some sandpaper of around #400 grade between the cutter and valve seat insert and grind the valve seat insert lightly.

Cylinder head 1.D. 57 +0.03 0 <Inlet>

NOTE:

Cylinder head I.D. 52 +0.03 0 <Exhaust> C3128B

After rectification, be sure to lap the valve and valve seat insert. [Refer to item (14) for details.]

Install

(13)Replacing valve seat insert Valve seats are installed by expansion fitting and should therefore be replaced according to the follow ing procedure.

Caulking

Caulking Tool Body MH061360 Caulking Ring Inlet MH061650 Exhaust MH061651

81111B

Cut off.

01973

(a) Grind the inside surface of the valve seat insert to reduce its thickness. Remove the valve seat insert at room temperature.

(b) Check that there is sufficient interference between the cylinder head and valve seat insert. (c) Cool the valve seat insert by immersing it in liquid nitrogen. Heat the cylinder head. (d) Install the valve seat insert using the Caulking Tool Body and Caulking Ring (special tools), and caulk the periphery of the valve seat insert.

NOTE:

When installing the valve seat insert, ensure that the chamfered side of the Caulking Ring faces the valve seat insert.

(el Reface the valve seat insert to achieve the specified seat width and valve sinkage. [See item (12) for details.]

11-23

ENGINE - SERVICE PROCEDURES

(14)Lapping valve and valve seat insert Contact between the valve and valve seat insert must be even over the entire contact area. Lapping should be carried out whenever the valve or valve seat insert has been rectified or replaced.

Valve stem

Compound

ÂŽ01970

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

C3130A

11-24

(b) Using the Valve Lapper (special tool), lightly strike the valve against the valve seat insert while turning it little by little. (c) Wash away the compound with gas oil or a similar fluid. (d) Apply engine oil to the contact surfaces and rub it in so that the contact surfaces are lubricated and mate together snugly. (e) Check that the valve is properly seated. [Refer to item (10) for details.]

ENGINE - SERVICE PROCEDURES 5.2.3 Reassembly

lightly wound end toward cylinder head

Tightly wound end toward cylinder head

Leak test: No leaks are allowed with 195 kPa {2 kgf/cm2} hydraulic pressure

Apply sealant to nozzle tube. (THREEBOND 1211 or equivalent) Apply sealant (HERMESEAL S-2 or equivalent)

4.9N-m {3.5 kgf-m}

Cylinder head bolt tightening sequence [refer to item (6).]

Assembly sequence @➔@➔@➔@➔®➔ 13➔12➔® ➔8➔7 ➔6➔5➔4➔3➔2➔1 16➔15j

22➔21

For parts with circled numbers, refer to the following section, "Reassembly Procedure."

10369

11-25

ENGINE - SERVICE PROCEDURES

Reassembly Procedure

(3) Valve stem seal installation

(1) Water director and sealing cap installation Water director Sealing cap Align notch with this line. F,;i.;.;z===;zf,

Valve Stem Seal Installer ME067431

Apply sealant (HERMESEAL S-2 or equivalent) 10363

Valve Stem Seal

Align each water director with the notch provided, as shown in the illustration. Cylinder head

(2) Nozzle tube installation Nozzle Tube Installer Bolt MH061231 Nozzle Tube Flange MH061416 Nozzle Tube Stamp MH061229

15 to 20 N-m {1.5 to 2.0 kgf-m} MS x 1.25

O-ring Nozzle tube ---

Apply engine oil. Apply sealant (THREEBOND 1211 or equivalent). 09178

(a) Clean the cylinder head nozzle tube holes. Take care to remove dirt, oil, water and carbon deposits from the seating surfaces. (b) Apply sealant to the new nozzle tube, and insert the nozzle tube into the cylinder head. (cl Using the Nozzle Tube Installer Flange (special tool), press the nozzle tube into the cylinder head. (d) Apply engine oil to the Nozzle Tube Stamp (special tool) and insert it into the nozzle tube. (e) Screw in the Nozzle Tube Installer Bolt (special tool) until the Nozzle Tube Stamp can be pulled out of the bottom of the cylinder head. (f) After installing the nozzle tube, carry out a leak test to verify air-tightness.

11-26

09179

To install a valve stem seal, first apply engine oil to the seal lip. T hen, push in the seal using the Valve Stem Seal Installer (special tool), striking the tool until it touches the cylinder head.

NOTE: 1. 2.

When installing a valve, apply a small amount of engine oil to its stem. After installing a valve stem seal, check that its spring has not been deformed or damaged.

ENGINE - SERVICE PROCEDURES (4) Valve cotter installation

Install the rocker shaft bracket by positioning it on the spring pin in the cylinder head. Mount the cylinder head by positioning it on the dowel pins in the crank case. (6) lightening cylinder head bolts Valve Lifter Hook MH061679 Valve cotter

852828

Install the valve cotter while evenly compressing the spring using the Valve Lifter and Valve Lifter Hook (spe cial tools).

C6649A

NOTE:

Valve springs must be installed with their tightly wound portions toward the cylinder head. (5) Mounting rocker shaft bracket and cylinder head Rocker shaft Rocker shaft bracket bolt � bracket 59 N-m {6 kgf•m} � "-, �

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

�

lighten the cylinder head bolts to 175 N-m {18 kgf-m} (wet) in the order shown. After confirming that the bolts are tightened to 175 N-m {18 kgf-m}, give each one an extra turn in accordance with the following procedure.

Cylinder head bolt Rod (lo, exteosiool

Cylinder gasket

80654A

(a) Before fitting the Socket Wrench (special tool) over a cylinder head bolt, turn the holder counter-clock wise to tension the built-in socket spring.

Knock pin 89014C

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

11-27

ENGINE - SERVICE PROCEDURES

Socket Wrench

MH061540

09182

( b) Fit the socket over the cylinder head bolt and set it such that the built-in spring forces the rod against the rocker shaft bracket, an injection pipe, or another nearby part.

Scale inscribed on socket

Lines inscribed on holder

80656A

( c) Observing the inscribed lines on the holder and socket, turn the socket clockwise by 90 to110Â° (1 pitch = 10Â°) to fully tighten the bolt.

Engine Parts contact phone: 269 673 1638

11-28

Email: EngineParts2@gmail.com

ENGINE - SERVICE PROCEDURES 5.3 Flywheel, liming Gears, and Camshaft 5.3.1 Disassembly <With axial-lip-type oil seal>

1 0A

�c (\\

:,:

�

7 Oil leaks 5 Wear/deterioration

Streaks/cracks/stepped wear on friction surface

®43651

Damage/abnormally worn gear teeth

Wear/deterioration

Disassembly sequence

Streaks/cracks/stepped wear on friction surface

1 *2 @ @ 5 @

7 Flywheel housing *8 Rear oil seal slinger <models with axial-lip type oil seal only> Sleeve <models with wet type clutch only>

Flywheel mounting bolt Pilot bearing Flywheel Oil seal retainer Oil seal Collar

*® 10 *1 OA 108

Ring gear Tachometer drive Speed sensor Cover

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

C1926L

11-29

ENGINE - SERVICE PROCEDURES

* liming gear backlash NV

Between crankshaft gear and idler gear B

0.08 to 0.20

0.4

Between idler gear A and camshaft gear

0.07 to 0.18

0.4

Between idler gear A and idler gear C

0.07 to 0.18

0.4

Between injection pump gear and idler gear C

0.08 to 0.20

0.4

Item

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

* Idler gear end play NV 0.05 to 0.15 L

0.4

* Camshaft gear end play NV 0.05 to 0.22

Wear

Disassembly sequence ® Camshaft assembly *® Camshaft *® Camshaft gear 14 Thrust plate

15 Idler shaft bolt

16 Thrust plate 17 Idler gear C 18 Idler gear A

0.4

19 Idler gear B

20 Idler shaft A 20A Idler shaft C *21 Rear plate

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

"*"

C1927D

11-30

ENGINE - SERVICE PROCEDURES (3) Removing ring gear

Disassembly Procedure

(1) Removing flywheel Threaded hole for removal

Ring gear

B2356C C19288

To remove the flywheel, screw its mounting bolts into the threaded removal hole.

To remove the ring gear, heat it evenly with an acety lene torch, then tap around its entire periphery with a hammer and rod.

(2) Removing collar and oil seal retainer

(4) Measuring gear backlash

Threaded hole � for removal

(M4x0.7)

Collar �

� ()l'l 0

�C)

Thmaded hole � for removal

Oil seal retainer

• •

C1930A

43652

To remove the collar, screw M4 x 0.7 bolts into the threaded removal holes. To remove the oil seal retainer, screw its mounting bolts into the threaded removal holes. Remove the oil seal retainer with the oil seal attached. <Radial-lip-type oil seal only>

If backlash exceeds the specified limit, inspect the idler gear bushings and gears, and replace parts as required. NOTE: For any pair of gears, measure backlash at more than 3 points to determine whether it is acceptable.

11-31

ENGINE - SERVICE PROCEDURES

(5) Measuring idler gear and camshaft gear end play Idler gear

(7) Removing camshaft gear

â&#x2122;Ś

Camshaft gear

11824

If the end play exceeds the specified limit, replace the thrust plate. (6) Removing camshaft

10992

The camshaft gear is press-fitted onto the camshaft. To separate these parts, push out the camshaft using a press. NOTE: Do not attempt to remove the gear by striking it with a hammer. Be sure to use a press .

Thrust plate

Camshaft gear

Camshaft

Remove bolts through these holes

Thrust plate mounting bolt 10991

Remove the thrust plate mounting bolts via the holes in the camshaft gear. Remove the camshaft together with the camshaft gear and thrust plate.

11-32

ENGINE - SERVICE PROCEDURES 5.3.2 Inspection

Item

Friction surface distortion

0.1 or less

0.2

Distance from clutch cover mounting surface to fric tion surface

47.8 to 48.2

49.5

®43653

Clearance BD 40 NV 0.03 to 0.06 L 0.2 Clearance BD 46 NV 0.03 to 0.06 L 0.2

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

Inlet

8.83

8.3

Exhaust

8.82

8.3

0.05 or less

0.08

0.03 to 0.08

0.25

0.02 to 0.05

Can be reassembled up to 3 times

Item Cam profile (difference between base circle diameter and lobe height) Camshaft bend Camshaft journal-to-camshaft bushing clearance

No. 1

65.00

No.2

65.25

No.3,4

65.50

No. 5,6

65.75

No. 7

66.00

Camshaft gear-to-camshaft interference

C2759D

11-33

ENGINE - SERVICE PROCEDURES (3) Idler gear-to-idler shaft clearance

Inspection Procedure

(1) Friction surface distortion Measuring position

Measuring position

Dial indicator Surface plate

C3807B C3506A

Place the flywheel on a surface plate. To measure dis tortion, pass a dial indicator over the flywheel from its periphery toward its center. If distortion exceeds the specified limit, grind the fric tion surface as necessary. NOTE: If the ring gear appears abnormal in any way, replace it before measuring distortion. [For details, refer to item (3) of section 5.3.1.]

If the clearance exceeds the specified limit, replace the bushing in the idler gear.

(4) Replacing idler gear bushing

Press

(2) Rectifying flywheel friction surface Idler Gear Bushing Puller MH061228 (for idler gear "A" MH062046 (for idler gear "C")

Clutch cover mounting surface Friction surface

Removal

Installation

C3509B

Grind the friction surface such that dimension B (the distance from the clutch cover mounting surface to the friction surface) is below the specified limit. The fric tion surface must be parallel with surface A to within 0.1 mm. If dimension B exceeds the specified limit, replace the flywheel.

11-34

C3808A

Install the bushing from the side of the idler gear whose internal diameter is chamfered. After installation, confirm that the bushing-to-idler shaft clearance is within the nominal value. If the clear ance is smaller than the nominal value, ream the bush ing.

ENGINE - SERVICE PROCEDURES (5) Cam profile (difference between base circle diame ter and lobe height)

Measuring position R1 obe �

)

9.5

(7) Replacing camshaft bushings

(a) Removal Remove the camshaft bushings in the following order: No.6 ➔ No.5 ➔ No.4 ➔ No.3 ➔ No.2 ➔ No.1 ➔ No.7. Remove them in accordance with the fol lowing instructions. 1) Removing camshaft bushings Nos. 6 to 1

he;ghl

M Base circle diameter

No. 7 camshaft bushing Camshaft Bushing Extractor Bar MH062118

C4101A

Measure the lobe heights and base circle diameters. Replace the camshaft if the difference between them is below the limit.

( Camshaft Bushing Extractor Guide MHD62119 84859A

NOTE:

Since the cams are tapered, they must be measured at the points shown in the illustration. (6) Camshaft journal-to-crankcase camshaft bushing clearance

Camshaft bushing

09166

If the clearance exceeds the specified limit, replace the camshaft bushing. [Refer to item (7) for details.]

Camshaft Bushing Extractor Adapter

No.1

MH062120

No.2

MH062121

No.3,4

MH062122

No.5,6

MH062123 84860A

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

11-35

ENGINE - SERVICE PROCEDURES

c) After removing the No. 6 bushing, remove bush ings Nos. 5 to 1 in that order using the appropriate Camshaft Bushing Extractor Adapter for each one.

2) Removing camshaft bushing No. 7

a) Mount the Camshaft Bushing Installer Adapters (special tool) and bushings Nos. 2 to 4 on the Cam shaft Bushing Installer Bar (special tool). When doing this, align the inscribed lines on the Adapters with the clinches (seams) on the bushings and position the oil holes as shown in the illustration.

Camshaft Bushin g Installer Guide MH062127

B4861A

<::' / Camshaft Bushin Installer Bar MH062125

09171

(b) Installation In accordance with the following instructions, install camshaft bushings Nos. 2, 3, and 4 simultaneously, then bushings Nos. 5 and 6 simultaneously, then bush ings Nos. 1 and 7 in that order. 1) Simultaneous installation of bushings Nos. 2, 3, and 4

No. 2 camshaft bushin g �ing

Camshaft Bushin g Installer Adapter MH062133

t:::'\ _,,- Arrow � m ark

No. 3 camshaft bushing ing pin � Camshaft Bushin g Installer Adapter MH062134

b) Fit the Camshaft Bushing Installer Guide (special tool) in the place where the No. 1 camshaft bushing is to be installed so that the Camshaft Bushing Installer Bar (special tool) may be supported by it. Then, insert the Camshaft Bushing Installer Bar into the crankcase, making sure that the arrow on it points toward the top of the crankcase. Camshaft Bushing Installer Nut MH062130

No. 2 camshaft bushin g

�� ;g � ViewA

Camshaft Bushin g Installer Adapter MH062135

� Clinch Oilhole�

ViewA

Engraved lin e (on camshaft bushin g installer adaptor) 84862D

11-36

�nm contact

09172

c) Confirm that the clinches (seams) on the bushings are aligned with the inscribed lines on the Cam shaft Bushing Installer Adapters [refer to item (a) for details]. Then, screw the Camshaft Bushing Installer Nut (special tool) onto the end of the Cam shaft Bushing Installer Bar, and tighten the Nut to press-fit the bushings. Continue turning the Nut until the Bar's flange touches the crankcase.

ENGINE - SERVICE PROCEDURES d) After installing the bushings, remove the Camshaft Bushing Installer Nut and gently withdraw the Camshaft Bushing Installer Bar.

Installation of bushings Nos. 1 and 7

-·

�""'""""'-�;�:,;l sh ;ag

NOTE: When removing the Camshaft Bushing Installer Bar, take care not to damage the inside surfaces of the bushings.

hne

2) Simultaneous installation of bushings Nos. 5 and 6

Drive in until seated

Camshaft Bushing Installer MH062143

Camshaft Bushing Installer Bar MH062125 Camshaft Bushing Installer Adaptor MH062136

Drive in until seated

Camshaft Bushing Installer Adaptor MH062137

B4865A

B4866D

Install bushings Nos. 1 and 7 as follows: Align the inscribed lines on the Camshaft Bushing Installer (spe cial tool) with the clinches (seams) on the bushing and position the oil holes as shown in the illustration. Face the arrow on the Installer toward the top of the crank case. Drive in the Installer until its flange touches the crankcase.

Follow the procedure in section 1) using the appropri ate Camshaft Bushing Installer Adapters (special tool) for bushings Nos. 5 and 6.

11-37

ENGINE - SERVICE PROCEDURES (9) Camshaft-to-camshaft gear interference

(8) Camshaft bend

10995

11834

Measure the extent of bending in the crankshaft. If it exceeds the specified limit, replace the crankshaft.

If the interference is below the specified nominal value, replace the camshaft or camshaft gear.

NOTE:

Apply a dial indicator to the camshaft and turn the camshaft through one revolution. One-half of the dial indicator reading represents the amount of bending.

Even if the interference is up to specification, reasÂ sembly should be carried out no more than 3 times.

11-38

ENGINE - SERVICE PROCEDURES 5.3.3 Reassembly

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

Flywheel housing eccentricity / L 0.2

Bend lock washer

,:J_

Camshaft gear-to-camshaft interference BD 40 NV 0.02 to 0.05 L Reassemble max. 3 times

Idler gear end play NV 0.05 to 0.15 L 0.4

L.lr...,.,_ ,,_ _,;;,.)...,,.liitlrc,ill.lM �t.ti,,-��... -1,1L�12 Camshaft gear end play lll' , NV 0.05 to 0.22 1�13 11 L 0.4 f 14

<Radial-lip-type oil seal>

r--;i_;�,..,,,C__L11 1 315 N-m {32 kgf-m} (wet) 5

4 9 8

*10A

Apply engine oil or lithium-base grease to oil seal lip

10B

20 3-----� Flywheel friction surface runout L 0.2

86013A

19 18 98 N-m {10 kgf-m} 15 155 N-m {16 kgf-m}

Backlash NV 0.07 to 0.18 L 0.4

Backlash NV 0.08 to 0.20 L 0.4

69 N-m {7 kgf-m} Assembly sequence

For parts with circled numbers, refer to the following section, "Reassembly Procedure. n For parts marked with"*" refer to Group 61, Special Equipment. B1902E

11-39

ENGINE - SERVICE PROCEDURES (3) Fitting camshaft gear

Reassembly Procedure (1) Mounting rear plate

Camshaft gear Thrust plate Camshaft

21921 C6230C

Mount the rear plate and gasket, ensuring that they are aligned with the locating pins on the crankcase. After the gasket is fitted, its bottom (oil pan mounting surface) will protrude. Cut off the protruding part of the gasket after fitting the flywheel housing. (2) Installing idler gears

155 N-m

(b) Press the camshaft gear until it sits snugly on the camshaft.

155 N:m

{16 kgf-m}

C6231D

Fit idler gear B and the crankshaft gear such that their "1" alignment marks are aligned with each other. Then, fit idler gears A and C such that their "2" alignÂ ment marks are aligned with each other. Tighten the idler shaft bolts to the specified torques. NOTE: 1. Align the "1" marks with pistons Nos. 1 and 6 at top dead center. 2. Ensure that the "1" marks are aligned before alignÂ ing the "2" marks.

11-40

B: Block

NOTE: Apply pressure to the middle part of the camshaft gear. Do not apply pressure to the gear's periphery since the gear would break.

Crankshaft gear

{16 kgf-m}

(a) With the alignment marks "4" facing away from the thrust plate, fit the camshaft gear using a press load A of 15.69 to 58.8 kN {1,600 to 6,000 kgf}.

22021

(c) Make a punch mark C on the middle part of the camshaft gear to show that reinstallation has been performed. NOTE: The camshaft gear and camshaft can be fitted together a maximum of three times. If three punch marks C have already been made, replace the camshaft gear and camshaft with new ones.

ENGINE - SERVICE PROCEDURES (4) Installing camshaft

the oil seal slinger until it is seated tightly on the crank shaft gear. (8) Fitting oil seal sleeve <With radial-lip-type oil seal> Correct sleeve position Dowel pin

Strike Camshaft gear Oil Seal Sleeve Installer 31191-07100

C6231C

Install the camshaft such that the "4" alignment marks on the camshaft gear and idler gear A are aligned with each other. NOTE: 1. When inserting the camshaft, take care not to damage the camshaft bushings. 2. Ensure that the "1" marks on the crankshaft gear and idler gear Bare aligned before aligning the "4" marks.

(5) Check the end play in the camshaft gear and idler gears. [Refer to item (5) of section 5.3.1 for details.) (6) Check the backlash in the gears. [Refer to item (4) of section 5.3.1 for details.] (7) Installing rear oil seal slinger <With axial-lip-type oil seal>

Crankshaft

85774A

Apply engine oil to the crankshaft and to the inside diameter of the sleeve. Using the Oil Seal Sleeve Installer (special tool), press the sleeve into position on the crankshaft. NOTE: 1. The sleeve's inside diameter is chamfered on one side. When fitting the sleeve, face the chamfered side toward the crankshaft. 2. Since the sleeve must be pushed into the correct position (shown in the illustration), you must use the Oil Seal Sleeve Installer. The sleeve is in the correct position when the Installer can be driven in no further.

(9) Fitting ring gear

Rear oil seal slinger Oil Seal Installer MH061652

Ring gear

Chamfered

C55298

Face the threaded groove toward the flywheel. Using the Oil Seal Slinger Installer (special tool), evenly press

Flywheel

B2357C

Using a piston heater, heat the ring gear to approxi mately 100°c for 3 minutes. Fit the ring gear with the non-chamfered side of its teeth toward the flywheel.

11-41

ENGINE - SERVICE PROCEDURES (11 )Checking flywheel housing eccentricity

(10)Fitting flywheel housing

Apply$2 mm sealant bead (THREEBOND 1207C)

B48570

(a) Apply a bead of sealant to the flywheel housing as shown in the illustration. Fit the flywheel housing within 3 minutes of applying the sealant.

NOTE: 1.

2. 3. 4. 5.

Apply a new bead of sealant whenever the fly wheel housing mounting bolts have been loos ened. Keep the flywheel housing sealing surface free of dirt and oil. Apply the sealant evenly and without breaks. When fitting the flywheel housing, hold it firmly in position to prevent spreading the sealant. After fitting the flywheel housing, wait at least 1 hour before starting the engine.

C6233B

lighten the flywheel housing mounting bolts to the specified torque. Then, rotate the flywheel and check for eccentricity at the flywheel housing joint. If eccen tricity exceeds the specified limit, remove the flywheel housing, refit it according to the instructions in item (10), and measure the eccentricity again. If the eccentricity exceeds the specified limit even after remedial measures have been taken, replace the fly wheel housing. (12)Installing oil seal <Axial-lip-type oil seal>

Locating pin

Rear oil seal

®27603 69N-m {7 kgf-m} C6230E

(b) Fit the flywheel housing such that it is aligned with the locating pins in the crankcase.

(a) Apply an even, unbroken bead of sealant A to sur face B of rear oil seal that contacts the flywheel housing when installed. (b) Fit the rear oil seal onto the flywheel housing within 3 minutes of applying the sealant A.

NOTE:

11-42

Ensure that the sealant application position on the

rear oil seal is clean before applying sealant. When fitting the rear oil seal, hold it firmly in posi tion to prevent spreading the sealant.

ENGINE - SERVICE PROCEDURES 3. 4.

After fitting the rear oil seal, wait at least an hour before starting the engine. Apply a new bead of sealant A whenever the mounting bolts of the rear oil seal have been loos ened.

(13)Checking flywheel runout

<Radial-lip-type oil seal>

315 N-m {32 kgf-m} Oil Seal Installer 31191-04300 Oil seal retainer

C6209C

(-)� Flywheel

C62368

After tightening the flywheel mounting bolts to the specified torque, rotate the flywheel and check for run out. If runout exceeds the specified limit, check the bolts' tightness and/or check the mounting surface. (14)Checking valve timing

(a) To install the oil seal, apply pressure evenly to its entire periphery using the Oil Seal Installer (special tool) until it reaches the step in the oil seal retainer.

If you need to recheck the valve timing after reassem bling the engine, do so according to the following pro cedure.

Rocker arm \ Oil Seal Installer 31191-04300

Oil seal retainer Oil seal

�

C6209D

(b) Turn the oil seal retainer over, then apply the Oil Seal Installer (special tool) to the oil seal from the opposite direction until the oil seal reaches the retainer's outer surface.

NOTE:

Different oil seals have different installation direc tions. Be sure to install the oil seal in the correct direc tion.

B5714C

(a) Bring cylinder No.1 to its compression-stroke top dead center position. (b) Insert a 3 mm shim between cylinder No.1's exhaust valve rocker arm and valve cap. Make any adjustments necessary using the adjusting screw, then tighten the lock nut.

11-43

ENGINE - SERVICE PROCEDURES

) Confirmation marks 10408

(c) Crank the engine in its normal direction of rotation (clockwise when viewed from the front). When cylÂ inder No.1 's exhaust valve begins to lift, confirm that the pointer on the flywheel housing is between the valve timing confirmation marks on the flyÂ wheel's outer periphery. If the timing marks are in the wrong position, refer to items (2) and (4), and check the timing marks again.

11-44

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

e--

ďż˝6

Damage/discoloration

'\._

t\ 'J

Cracks

* NV Connecting rod end play 0.2 to 0.5 L

1.0

NV .. Nominal Value L ..... Limit

0-- } 5

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

Damage/

aboo,malwea,

Scratches on outer periphery/ cracks on top/ 8 discoloration/melting

*topProjection of piston from surface of crankcase NV 0.87 to 1.33

JJ-10 3 Scratches/corrosion/

peeling on inner and outer peripheries

Repair kit: Liner and Piston Kit

Disassembly sequence 1 2 3 @ @

Connecting rod cap Lower connecting rod bearing Upper connecting rod bearing 1st compression ring 2nd compression ring

@ Oil ring 7 Piston pin @ Piston ÂŽ Connecting rod *10 Connecting rod bolt

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

11-45

ENGINE - SERVICE PROCEDURES

NV .. Nominal Value L ..... Limit

Clogged oil hole

/4 Scratches/co�r!sion/ peeling0!' inner and

outer penphenes

✓

L'\

�-,, ,--...::

� �� peehngon inner and

15 19

peripheries

J!i

0.4

Disassembly sequence Torsional damper Crankshaft pulley Front oil seal Front cover Front oil seal slinger Main bearing cap

�

* End play NV 0.09 to 0.23

11 12 *113 14 *115 16

�17

outer

Scratches, cracks, dents, seisure, clogged oil hole, corrosion

�

17 18 19 20 1 *®

Thrust plate Lower main bearing Crankshaft Upper main bearing Crankshaft gear

*122 *223 24 25 26

Cylinder liner Check valve Oil jet Oil spray plug Crankcase

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

11-46

ENGINE - SERVICE PROCEDURES Disassembly Procedure

(3) Removing pistons

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

Fr.o

+ •

•

Measuring point

Withdraw the piston from the crankcase together with its connecting rod, working from the top surface of the crankcase. C23398

(a) Attach a dial indicator to the top surface of the crankcase and adjust it to zero. (b) Using the dial indicator, find the piston's top dead center position. (c) Take measurements at 4 points on the piston's top surface and determine their average. (d) If the piston projection does not conform with specifications, check the clearances between pis ton/connecting rod and neighboring parts.

NOTE:

When removing a piston, take care not to damage the cylinder liner. (4) Separating piston from connecting rod

(2) Connecting rod end play

Remove the snap rings, then use a rod and hammer to tap the piston pin out. If the piston pin is hard to remove, heat the piston in hot water or with a piston heater.

C2340A

Measure each connecting rod's end play. If any mea surement exceeds the specified limit, replace the con necting rod.

11-47

ENGINE - SERVICE PROCEDURES (7) Removing main bearing caps

(5) Removing piston rings

M10 x 1.5

801838

(6) Crankshaft end play

The rearmost main bearing cap is located on dowel pins and must therefore be removed with a slide ham mer. (8) Removing crankshaft gear Rear oil seal slinger

80181C

Before removing the main' bearing caps, measure the· end play in the crankshaft. If it exceeds the specified limit, replace the thrust plate with an oversized one. [Refer to item (3) of section 5.4.3 for details.]

(a) Split the rear oil seal slinger with a chisel and remove it from the crankshaft. (b) Remove the crankshaft gear from the crankshaft using the Gear Puller (special tool).

NOTE: Do not attempt to remove the crankshaft gear by strik• ing it.

Engine Parts contact phone: 269 673 1638

11-48

Email: EngineParts2@gmail.com

ENGINE - SERVICE PROCEDURES 5.4.2 Inspection End gap Item

Clearance BO 50 NV 0.01 to 0.02 L 0.1

0 0 0

1st compression ring

0.4 to 0.55

1.5

2nd compression ring

0.5 to 0.65

1.5

Oil ring

0.4 to 0.6

1.5

Piston ring groove-to-piston ring clearance Item NV

Clearance BO 50 NV 0.02 to 0.05 L 0.1 Bend L 0.05 or less Torsion L 0.1 or less

1st compression ring 2nd compression ring

6024

0.09 to 0.13

6024-T, TC, TL

0.02 to 0.10

6024

0.05 to 0.08

6024-T, TC, TL

0.07 to 0.10

Oil ring

L 0.25

0.25

0.15

0.03 to 0.06

Crankcase top surface distortion NV 0.07 or less L 0.2 Flatness of cylinder liner supporting flange L 0.1 6024-T, TC, TL

130

0.178 to 0.204 0.193 to 0.219

Projection of cylinder liner from top surface of crankcase NV 0.01 to 0.08 Inside diameter NV 130.014 to 130.054 L 130.25 Cylindricity NV 0.02 or less

BO . . Basic Diameter NV .. Nominal Value L ..... Limit Connecting rod bearing-to-crankshaft pin clearance BO 84 NV 0.07 to 0.13 L 0.25 Connecting rod bearing span when free L Less than 90.5

C2760C

11-49

ENGINE - SERVICE PROCEDURES

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

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

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

Inspection Procedure

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

If the measured value is out of specification, replace the crankcase. 11-50

ENGINE

SERVICE PROCEDURES

(2) Distortion of crankcase top surface

(4) Cylinder liner flange projection

Measurement points

C If distortion of the crankcase top surface exceeds the specified limit, correct it with a surface grinder.

NOTE: When grinding the crankcase, take care thatthe piston projection does not exceed the specified nominal value. [Refer to item { 1) of section 5.4.1 for details.]

If any cylinder liner projection does not conform with its specified nominal value, replace the cylinder liner or crankcase. [Refer to item (5) for details of cylinder liner replacement.] (5) Replacing cylinder liner (a) Removal

(3) Cylinder liner inside diameter Cylinder Liner Extractor MH061490 Size mark 30 or more ---lh"7H .,.__ -t

or more

A: Direction of crankshaft axis B: Direction of right angle to crankÂ shaft axis

C4414B

C4424A

Measure each cylinder liner's inside diameter at 6 points, as shown in the illustration. If the inside diameÂ ter exceeds the specified limit, replace the cylinder liner or bore it to oversize. [Refer to item (5) for details of cylinder liner replacement.]

11-51

ENGINE - SERVICE PROCEDURES

(b) Installation Strike in.

Cylinder Liner Instal e l r MH061759 Cylinder liner

Piston Cylinder liner

C44278

C4813C

Make sure the new cylinder liner bears the same size mark as that of the piston. Piston size mark

Cylinder liner size mark

B C

A--------A

0-ring-=-➔ Rubber packing 0-ring --=::::iii I

Do not stretch 0-rings more than is necessary, and be careful not to damage them. 2. Contact with gas oil, kerosene, anti-corrosion oil, and similar fluids causes 0-rings to swell. Immedi ately wipe off any such fluids that come into con tact with the 0-rings. 3. After installing a cylinder liner, carry out a leak test to check for air-tightness. Apply thrust force to the cylinder liner flange.

Soapsuds to be applied

C44268

Fit new 0-rings and rubber packing to the cylinder liner, and apply soap suds to the crankcase and cyl inder liner at the points where they will touch each other.

11-52

Using the Cylinder Liner Installer (special tool), gently tap the cylinder liner down until its flange is securely seated on the crankcase.

NOTE: 1.

Soap suds to be applied

ENGINE

SERVICE PROCEDURES

(6) Selection of pistons and cylinder liners A piston may be either standard or oversized. Cylinder liners are selected accordingly. (a) Standard piston

(b) Oversized piston In accordance with the following instructions, bore the cylinder liner to suit the oversized piston to be used (+0.5, +0.75, or +1.00 mm). Cylinder liner I.D. Size mark stamped

or more

--4.......,.�..,--..i

j\ Size mark (A, B,C)

A:Axial direction of crank shaft 8: Direction at right angles to crankshaft

or more

Oversize piston O.D.

C4424A

102 <6D24>

<6D24-T, TC,TL>

Cylinder liner Piston

43429

1) The piston must bear the same size mark as that stamped on the cylinder liner. 2) The weight of all 6 of an engine's pistons must be within 10 g of the weight that is stamped on each piston's crown. NOTE: Whenever a piston is replaced, the piston rings must also be replaced. Never use old piston rings.

C4428A

1) Determine the amount of metal to bore out. To do this, measure the inside diameter of every cylinder liner and find the most worn point. 2) Bore and hone-finish the cylinder liner to achieve the specified nominal clearance between the over sized piston and cylinder liner. NOTE: 1. Even if only one cylinder requires boring, bore every cylinder to the same oversized inside diame ter. 2. Replace the piston rings with oversized piston rings that correspond to the increased cylinder liner dimension.

11-53

ENGINE

SERVICE PROCEDURES

(7) Piston-to-cylinder liner clearance

(9) Piston ring gap

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

Piston ring

0 Cylinder liner C4807B

C4806B

If the clearance exceeds the specified limit, replace the piston or piston rings.

NOTE: 1. 2.

After removing any carbon deposits, measure the clearance around the piston's entire periphery. Always replace piston rings as a set, never individ ually.

Measure the piston ring gaps with the piston rings hor izontally pushed into a standard cylinder liner, either in or out of the crankcase. Replace the rings if any gap exceeds the specified limit. Standard cylinder liner inside diameter: 130 ± 0 mm

NOTE: Use a piston to push the piston rings into the cylinder liner for measurement.

(10)Piston pin-to•piston pin hole clearance Piston

1st compression ring

Piston �

C4810D

Measure the 1st compression ring clearance while pressing the ring against the piston with a straight edge.

11-54

If the clearance exceeds the specified limit, replace the piston pin or piston.

NOTE: Whenever a piston is replaced, the piston rings must also be replaced. Never use old piston rings.

ENGINE - SERVICE PROCEDURES (11) Piston pin-to-connecting rod small end bushing clearance

(a) Removing bushing

Guide Plate Assembly MH063368

Connecting rod bushing

Piston pin

C5203A

If the clearance exceeds the specified limit, replace the connecting rod bushing. (12)Replacing connecting rod bushing

1) Remove the bearing from the connecting rod's big end, then mount the connecting rod on the Base (special tool). 2) Fit the Mandrel and Collar A (special tools) onto the connecting rod's small end as shown in the illustra tion. Slowly apply pressure with a press that has a capacity of at least 49 kN {5,000 kgf}. (b) Press-fitting bushing Approx. 49 kN {5,000 kgf}

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

10976

Replace the bushing using the Connecting Rod Bush ing Puller (special tool). 10977

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

Set up the Mandrel, Collar B, Collar A, and the Nut (special tools) on the bushing as shown in the illustration. 2) Apply engine oil to the connecting rod's small end and to the bushing. 3) Using the press, apply pressure of approximately 49 kN {5,000 kgf} such that the bushing is pressed into the connecting rod's small end. 4) After press-fitting the bushing, remove the special tools. Then, ream the bushing to achieve the speci fied nominal clearance between the bushing and piston pin. 1)

11-55

ENGINE - SERVICE PROCEDURES

NOTE: When press-fitting the bushing, align the oil hole in the bushing with the oil hole in the connecting rod. 2. When the piston pin is inserted, ensure that it turns easily and without play. 1.

(13)Connecting rod bend and twist Bend

e = 100

C5209A

Connecting rod aligner

If the span is less than the specified requirement, replace the upper and lower bearings as a set.

NOTE: Do not attempt to manually expand a bearing if its span is insufficient.

Piston pin

C5205A

C5206A

(15)Connecting rod bearing-to-crankshaft pin clear ance Connecting rod bearing inside diameter Measuring position

C5207A

C5208A

Measure the amount of bend and twist in the connect ing rod using a special connecting rod aligner. If the measurements exceed the specified limits, replace the connecting rod or rectify it using a press.

NOTE: 1. Measurements must be made with the connecting rod bushing and upper and lower connecting rod bearings fitted in their respective positions. 2. Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. (14)Span of connecting rod bearings and main bear ings when free

01996 Crankshaft pin outside diameter Measuring position Measuring direction

C5223A

If the clearance exceeds the specified limit, replace the upper and lower bearings as a set.

NOTE: Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. 11-56

ENGINE - SERVICE PROCEDURES (16) Main bearing-to-crankshaft journal clearance

(18)Crankshaft bend

Main bearing inside diameter

Measuring direction

C5526A

C5524A

Crankshaft journal outside diameter

Measuring position

Measure the extend of bending in the crankshaft at the middle journal. If the measurement exceeds the speci fied limit, grind to undersize or replace the crankshaft.

NOTE:

C5523A

If the clearance exceeds the specified limit, replace the upper and lower bearings as a set.

With the dial indicator applied to the middle journal, turn the crankshaft through one revolution. One-half of the dial indicator reading represents the extent of bending in the crankshaft.

(19)Grinding crankshaft to undersize

42.0

(17)Roundness and cylindricity of crankshaft pin and journal Roundness

Cylindricity

Measuring direction

Measuring position

75±0.07

C5527A

C5523A

If roundness and cylindricity do not conform with the specified limits, grind to undersize. [Refer to item (19) for details.]

Any damaged or scorched journal or pin must be ground in accordance with the following instructions. If grinding is carried out, the main bearing must be replaced with an undersized one. (a) Grind such that the center distance between the journal and pin does not change. (b) Grind such that the width of the journal and pin does not change. (c) Finish the corner fillet smoothly and to the speci fied radius.

11-57

Ill

ENGINE - SERVICE PROCEDURES (e) When grinding, turn the crankshaft counter-clockÂ wise as viewed from its front end. The grinder should also rotate counter-clockwise as viewed from the crankshaft's front end. (f) When finishing the crankshaft with sandpaper or a whetstone, turn the crankshaft clockwise.

(d) Use magnetic flaw detection to check for ground cracks. Also, check that the Shore hardness of the surface has not dropped below Hs 75.

Grinding

Finishing

Whetstone or sand paper

C5509A

Amount of undersize

Journal 0. D. finished dimension

Pin 0. D. finished dimension

Roundness

Cylindricity

--0.25

--0.08 99.75 --0.10

--0.06 83.75 --0.09

0.01 or less

0.006 or less

--0.50

-0.08 99.50 --0.10

--0.06 83.50 --0.09

--0.75

--0.08 99.25 --0.10

--0.06 83.25 --0.09

-1.00

--0.08 99.00 --0.10

-0.06 83.00 --0.09

Engine Parts contact phone: 269 673 1638

11-58

Email: EngineParts2@gmail.com

ENGINE - SERVICE PROCEDURES 5.4.3 Reassembly

Assembly sequence 26➔22➔®l➔@➔@➔(®J➔@➔@➔@➔@

NV .. Nominal Value L. .... Limit Cylinder liner flange projection NV 0.01 to 0.08

�@➔CD

@➔@➔7➔@➔@➔@➔@ -----�

@-1 ➔@➔14➔@➔12➔11 For parts with circled numbers, refer to the following section, "Reassembly Procedure."

10 Locating pin 34N-m {3.5kgf-m} 23

3 -"!----Hle-=::::::..,_JJ,

24 Lug direction 1-��.....c......-4- --""-t-"'--f-t--.- �CW--

2-�---,l--f!-, Expander spring ends

1st compression ring gap

Piston projection NV 0.87 to 1.33

115 N-m {12kgf-m}+60" (wet)

115N-m{12kgf-m} (wet)

33N-m {3.4kgf-m}

Rear oil seal slinger [Refer to item (7) of section 5.3.3] Oil seal sleeve [Refer to item (8) of section 5.3.3]

Locating pin 175 N,m {18kgf-m}

11 17 Side with oil groove faces sliding surface

13 Apply lithium-base grease to lip

Connecting rod end play NV 0.2 to 0.5 L 1.0

Crankshaft end play NV 0.09 to 0.23 L 0.4

C5835F

11-59

ENGINE - SERVICE PROCEDURES (3) Installing upper main bearing and thrust plate

Reassembly Procedure

(1) Installing oil spray plug

Thrust _plate_

C23358

Install the oil spray plug such that the arrow stamped on it points toward the top of the engine. (2) Installing oil jet and check valve

Install the upper main bearing such that the bearing lug is aligned with the lug groove on the crankcase. Install the rearmost thrust plate with its grooveless side facing the crankcase. NOTE: 1. The main bearing's upper part has an oil groove. The lower part does not have a groove. Take care

(

I �.:

C5836C

Insert the oil jet's locating pin into the hole on the crank case, and tighten the check valve to the specified torque.

not to confuse the upper and lower parts. Oversized thrust plates are available for adjust ment of crankshaft end play [refer to item (6) of section 5.4.1 for details]. The oversized thrust plates available are +0.15, +0.30, and +0.45 mm. If any of these is used, ensure that the correct size thrust plate is fitted to the bearing cap [refer to item (7) for details].

(4) Installing crankshaft gear Dowel pin

NOTE: Check valves cannot be reused. Be sure to use a new one.

Crankshaft gear 84202A

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

11-60

ENGINE - SERVICE PROCEDURES (b) Locate the gear such that the dowel pin on the crankshaft will fit into the notch in the gear. Fit the gear by lightly striking it with a soft hammer. (c) Fit the rear oil seal slinger (refer to item (7) of sec tion 5.3.3) or oil seal sleeve (refer to item (8) of sec tion 5.3.3). (5) Fitting front oil seal slinger <Axial-lip-type oil seal>

Oil Seal Slinger Installer MH061817

(7) Installing lower main bearings and main bearing caps Install the lower main bearings and main bearing caps in accordance with the following procedure.

i �� 7 cPI

Joo

Cr�nkshaft

axial

direction

Dowel pin 13192

80596A

(a) Drive the locating dowel pins into the rearmost main bearing cap in the direction shown in the illustration.

Fit the front oil seal slinger using the Oil Seat Slinger Installer (special tool). Main bearing cap

(6) Installing crankshaft

C5838G C5833A

Lift the crankshaft with a hoist. Keeping it horizontal, gently lower it into the crankcase.

B4222E

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

11-61

ENGINE - SERVICE PROCEDURES counter-clockwise to tension the built-in socket spring.

(c) Only to the rearmost main bearing cap, install a thrust plate on each side, with the thrust plates' grooveless sides facing the main bearing cap.

NOTE: Thrust p l ate for front side of the bearing cap Thrust plate for rear -�·,,_� �deofthebeadag �,

��lw.7fi)'

"�,__ -�f,,�/J::, ---. \ . '{

'"-':.� )

r \, 1 \1

w£

�:�� i::.

the

fc clc/

10505

\.!'./"

Thrust plate for rear side of the crankcase

C5838H

If an oversized thrust plate is used, ensure that the bearing cap rear thrust plate and the rearmost thrust plate in the crankcase [refer to item (3)) are the same size. Note, however, that the bearing cap front and rear thrust plates may be of different sizes. (d) Fit the main bearing caps in the order of the num bers that are embossed on them, working from the front of the engine. Fit them such that the sides with lug grooves are toward the right of the engine. (e) Press down the main bearing caps until they touch the crankcase. lighten the main bearing cap mounting bolts to 115 N-m {12 kgf-m} (wet). After confirming that the bolts are tightened to the specified torque, give each one an extra turn in accordance with the following procedure.

13205

Before fitting the Socket Wrench (special tool) over a main bearing cap mounting bolt, turn the holder

11-62

Fit the socket over the main bearing cap mounting head bolt. Set it such that the built-in spring forces the rod against the side of the crankcase.

Scale inscribed on socket

Lines inscribed on holder

09183

Observing the inscribed lines on the holder and socket, turn the socket 60° clockwise (1 pitch= 10°) to fully tighten the bolt. After assembly, check that the crankshaft can be turned easily by hand. Also, check that the crankshaft's end play conforms with the specified nominal value. [Refer to item (6) of section 5.4.1 for details.]

ENGINE

SERVICE PROCEDURES NOTE:

(8) Installing connecting rod bolts

All the connecting rods in an engine must have the same weight mark. Weight marks are as follows:

Flattened side toward connecting rod

Heavy --------------- Light B C D E F G H J K

(10)Fitting piston rings

:::3/f::: Ends

Check for damage/burrs

890078

Checkthat there are no burrs or damage in the connectÂ ing rod's bolt holes. Apply engine oil to the connecting rod bolts, then press fit the bolts such that the flattened side of their heads face inward. (9) Reassembling piston and connecting rod

\ Manufacturer mark stamped (Compression ring only)

C58418 Expander spring ends

Piston

Oil ring ends Connecting rod

Snap ring

Piston pin

C5843A

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

Weight mark Lug groove mark

10361

Connect the piston to the connecting rod with the pisÂ ton pin such that the piston's front mark "F" is on the same side as the connecting rod's lug groove mark. If the piston pin is difficult to insert, heat the piston in hot water or with a piston heater. 11-63

ENGINE - SERVICE PROCEDURES

(11)Installing upper and lower connecting rod bear足 ings Align these.

Align these.

NOTE: 1. Check that the size mark on the piston matches the size mark on the cylinder liner. 2. Ensure that the piston ring ends stay in their cor足 rect positions. 3. Slip some plastic tube over the connecting rod bolts to prevent them from damaging the cylinder liner and crankshaft pin. <Using the Piston Guide Clamp and Piston Guide Lever (special tools)> Piston Guide Clamp

B4223A

Install the upper connecting rod bearing such that its lug is aligned with the connecting rod's lug groove. Install the lower connecting rod bearing such that its lug is aligned with the connecting rod cap's lug groove. NOTE: The upper connecting rod bearing has an oil hole. The lower bearing does not have an oil hole. Take care not to confuse the upper and lower parts. Align the Piston Guide with the piston skirt and set the Piston Guide Lever in position. Turn the adjusting bolt such that the Clamp's inside diameter matches the pis足 ton's outside diameter. Next, remove the Clamp from the piston and apply engine oil to the outside of the pis足 ton, to the inside of the Clamp, and to the inside of the cylinder liner. Fit the Clamp over the piston such that it is flush with the piston's crown. Using a wooden mallet or block, tap the piston into the cylinder, taking care not to damage it.

(12)Installing piston and connecting rod

Piston Guide Lever MH061658

C5834B

Using the Piston Guide Clamp and Piston Guide Lever (special tools), install the piston and connecting rod such that the front mark on the piston's crown faces the front of the engine.

11-64

ENGINE - SERVICE PROCEDURES (13)Fitting connecting rod caps Connecting rod cap

5.5 Inspecting and Adjusting Valve Clearances

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

)

Front of engine

C5844B

Ensure that the alignment marks and lug groove marks on the connecting rod caps and connecting rods are aligned with each other. (14)Check the connecting rod's end play. [Refer to item (2) of section 5.4.1 for details.] (1 S)Check that the piston projections conform with specifications. [Refer to item (1) of section 5.4.1 for details.]

10404

(1) Crank the engine until the inscribed "1-6" mark on the flywheel is aligned with the pointer in the flyÂ wheel housing inspection window. When this hapÂ pens, the pistons whose push rods are not pushing up their rockers are at the top-dead-center (TDC) position of their compression stroke.

(16)Fitting front oil seal

Front oil seal

Press-fit Oil seal flange

B4187A

Press evenly around the oil seal's entire periphery until its flange is seated securely on the front cover.

11-65

ENGINE - SERVICE PROCEDURES

(2) When piston No. 1 is at the TDC position of its com pression stroke, check and adjust the clearances of the valves marked "o" in the following table. When piston No. 6 is at the TDC position of its com1

Cylinder No.

Valve arrangement

In.

Ex.

In.

No. 1 at TDC of compression stroke

No. 6 at TDC of compression stroke

Ex.

Valve clearance (when cold) 59 N-m {6 kgf-m}

pression stroke, check and adjust the clearances of the valves marked "x" in the table. Be sure to check and adjust every valve.

Inlet NV 0.4 Exhaust NV0.6

857148

In.

4 Ex.

In.

Ex.

In.

6 Ex.

In.

Ex.

0 X

(3) Using the Thickness Gauge (special tool), check that the rocker arm-to-valve cap clearance con forms to specifications. To measure the clearance, insert a gauge of the same thickness as the speci fied nominal clearance between the rocker arm and valve cap. The gauge should be able to move in the gap, but not loosely. If the clearance is incorrect, loosen the lock nut and turn the adjusting screw as required. When the clearance is correct, tighten the lock nut to the spe cified torque to secure the adjusting screw.

NOTE: After tightening the lock nut, confirm that the clear ance is still correct.

Mitsubishi 6D24 6D24T Engine Maintenance Service Kits Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts. Replace thermostats and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, replace valve cover gaskets, Replace filters, Replace V-belts. Mitsubishi 6D24 6D24T Engine Parts www.6D24.com Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Located in USA, Engine Parts Delivery in USA, Canada and worldwide.

11-66

Ill

ENGINE - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Engine will not start

Probable cause Incorrect oil viscosity

Remedy Replace

Incorrect/defective fuel Low compression pressure • Incorrect valve clearance(s) • Defective cylinder head gasket

Reference Group 12 Group 13A

Adjust Replace

• Worn valve and valve seat/carbon deposits • Weakened valve spring • Worn/damaged piston ring(s) • Worn/damaged piston ring groove(s) • Worn piston(s)/cylinder liner(s) Defective preheater • Defective starter switch

Change to oversize Repair or replace

Group 16

Adjust

Group 13A

• Defective heater relay Incorrect injection timing Insufficient fuel injection volume • Defective injection pump

Repair or replace

Group 13A, E

Repair or replace

Group 14

Replace

Group 12

• Incorrect fuel injection volume Defective cooling system Rough idling

Incorrect oil viscosity Incorrect/defective fuel Defective cooling system

Group 13A Repair or replace

Group 14

Low compression pressure (see "Engine will not start") Incorrect injection timing Defective fuel system • Defective injection pump

Adjust Repair or replace

Group 13A Group 13A, E

• Defective injection nozzle • Air trapped in fuel system Abnormal exhaust gas color

Incorrect/defective fuel

Replace

Group 13A

Cooling system malfunctioning

Repair or replace

Group 14

Intake/exhaust system malfunctioning • Clogged air cleaner

Repair or replace

Group 15

Repair or replace

Group 13A, E

• Clogged muffler • Oil leaking into intake/exhaust pipes Low compression pressure (see "Engine will not start") Defective fuel system • Malfunctioning injection pump • Defective injection nozzle Incorrect injection timing

Adjust

Excessive engine oil

Adjust

Seizure of major moving parts

Group 12

Repair or replace

11-67

ENGINE - TROUBLESHOOTING Probable cause

Symptom Low power output

Incorrect oil viscosity

Remedy Replace

Reference Group 12 Group 13A, E

Incorrect/defective fuel Cooling system malfunctioning

Repair or replace

Group 14

Intake/exhaust system malfunctioning • Clogged air cleaner

Repair or replace

Group 15

Repair or replace

Group 13A, E

• Clogged muffler Low compression pressure (see "Engine will not start") Fuel system malfunctioning • Malfunctioning injection pump • Defective injection nozzle • Air trapped in fuel system Incorrect injection timing Excessive oil consumption

Oil leaking from lubrication system Oil leaking from engine and related parts • Defective gasket/oil seal

Adjust Inspect and/or repair Replace

Oil entering combustion chamber past piston • Worn cylinder liner(s)/piston(s)

Rectify or replace

• Piston ring(s) worn, damaged, or seized

Replace whole set

• Clogged piston/oil ring oil hole(s) Oil entering combustion chamber via valves • Worn valve stem(s)/valve guide(s)

Group 12

Clean Replace

• Worn valve stem seal(s) Abnormal engine noise

Noise emanating from outside parts of engine • Loose piping/hose connection(s) • Injection pump, alternator, other auxiliary unit(s) incorrectly mounted • Loose/damaged V-belt • Incorrectly mounted crankshaft pulley • Malfunctioning air cleaner and/or muffler Noise emanating from vicinity of rocker cover • Incorrect valve clearance(s) • Defective valve spring(s) • Defective rocker shaft/bracket • Improper lubrication of rocker shaft

11-68

Inspect Inspect and/or adjust Replace

Groups 13A, E and 16 Group 14

Inspect and/or adjust Repair or replace Adjust Replace Inspect and/or repair Inspect

Group 15

ENGINE - TROUBLESHOOTING Symptom Abnormal engine noise

Probable cause Noise emanating from vicinity of flywheel housing • Incorrect timing gear backlash • Incorrect lubrication of timing gears and idler shaft

Remedy

Reference

Replace Inspect

Noise emanating from cylinder head/crankcase • Low compression pressure lsee "Engine will not start") • Incorrect injection timing • Incorrect spray of injection nozzles • Worn connecting rod small end bushing(s) and piston pin(s)

Adjust

Group 13A

Repair or replace Replace

• Worn/damaged crankshaft pin(s) and connecting rod big end bearing(s) • Worn/damaged crankshaft journal(s) and main bearing(s) • Excessive crankshaft/camshaft end play • Worn tappet(s)/camshaft Turbocharger malfunctioning

Replace thrust plate(s) Replace worn part(s) Inspect and/or rectify

Group 15

11-69

LUBRICATION CONTENTS 1. GENERAL ............................... . ... 2 2. SPECIFICATIONS ............................ 9 3. SERVICE STANDARDS ..................... 10 3.1 Service Standards Table ................. 10 3.2 lightening Torque Table ................. 10 4. SERVICE PROCEDURE ..................... 1 1 4.1 Oil Pump ................................. 1 2 4.1.1 Removal and installation ............. 1 2

4.1.2 Disassembly and inspection .......... 4.1.3 Reassembly ........................... 4.2 Oil Filter and Oil Cooler .. . ..... . ..... . ... 4.2.1 Removal and installation ............. 4.2.2 Oil filter .......................... ...... 4.2.3 Oil cooler .............................. 4.3 Regulator Valve .......................... 5. TROUBLESHOOTING .......................

1 31 15 15 15 16 17 18 19

12-1

LUBRICATION - GENERAL

1. GENERAL Oil pressure gauge Warning lamp

0---··---,

Oil pressure Oil pressure ,__ ________s_ wit_c_h_�U-L.........J gauge unit Main oil gallery Regulator valve

Water pump

* Models with turbocharger Engine lubrication is accomplished by forced lubrica tion system using gear pump. The engine oil in the oil pan is drawn up th rough the oil strainer by the oil pump and force-fed to the oil filter and oil cooler to lubricate all parts.

B1539H

(1) Oil pump

Oil pump (with built-in relief valve}

B1540A

12-2

LUBRICATION - GENERAL The oil pump, of a gear pump type, is mounted in the rear bottom portion of the crankcase, driven by the crankshaft gear. The oil strainer at the suction port prevents entry of forÂ eign matter in the oil pan and air. The engine oil is routed to the crankcase by the oil pipe connected to the delivery port.

Relief valve

Drive gear

81541A

The crankshaft gear drives the oil pump idler gear and oil pump gear to transmit rotation to the oil pump drive gear.

Delivery_ side

_ Suction side (oil strainer side)

B5693A

The oil pump is driven at a speed proportionate to the engine speed. Therefore, it is provided with a relief valve that prevents excessive pressure from being applied to the lubrication system when the engine is started in cold weather involving a surge in oil pump delivery pressure.

"::c::....1- Driven gear

B1505A

Inside the oil pump case, there are oil pump drive gear and driven gear which are in mesh with each other. When the drive gear is driven, the driven gear is caused to turn in an opposite direction. As the gears rotate with the gear teeth sliding on the inner surfaces of pump case, the resultant negative pressure causes the engine oil to enter the oil pump and the oil trapped in the space formed by the teeth and gear case inner wall is forced out through the delivÂ ery port.

12-3

LUBRICATION - GENERAL (3) Oil bypass alarm

(2) Oil filter

Element

Center bolt {Bypass filter) Center boltÂ {Full-flow filter)

81543A

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

815448

When the oil filter element is plugged resulting in the difference in pressures between before and after the element exceeding a predetermined level, the valve overcomes the spring tension to move. As a result, unfiltered oil flows directly to the oil cooler. The oil bypass alarm has electric contacts that are closed to turn on the pilot lamp, warning the driver of clogged element when the valve is opened.

12-4

LUBRICATION - GENERAL (4) Oil cooler

Bypass valve

B1545C

The oil cooler is of the shell-and-plate (multi-plate) type. It is mounted in the coolant path on the left of the crankcase. Engine oil that has been forced through the oil filter flows through the inside of the oil cooler element. At

the same time, coolant from the water pump flows around the outside of the element. The engine oil in the element is thus cooled or heated before flowing to the main oil gallery.

Bypass valve

Regulator valve

Bypass valve

To main oil gallery

81530B

When the oil's viscosity is high at low temperatures or when the element is clogged and resists the oil's flow, the oil cooler's bypass valve opens, thus allowing oil to flow to the main gallery without passing through the cooler.

81529A

The regulator valve is fitted to the main oil gallery in the crankcase. If the oil pressure in the main gallery exceeds a specified level, the regulator valve allows the oil to escape to the oil pan, thereby protecting the lubrication system from excessive pressure. 12-5

LUBRICATION - GENERAL (b) Camshaft

(5) Lubrication of components

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

6D24-T, TC, TL

·•.

Crankshaft main bearing

81547A

The camshaft bushings are lubricated via the crank case oil holes that extend to them from the periphery of the crankshaft main bearings. (c) Valve mechanism Conn ecting rod b earing

Rocker shaft bracket � ocker � �� Rocker bushin·g Rocker shaft From cylinder head

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

.,,,...

43674

·�

Main�il.�v galle Ii' ?

l r�;\ � <lf'

An oil passage extends from the main oil gallery to the crankshaft main bearing and lubricates the main bear ing. Part of the oil that has lubricated the main bearing passes through the hole in the crankshaft and lubri cates the connecting rod bearing. It then goes through an oilway inside the connecting rod and lubricates the connecting rod small end bushing. In the 6D24-T, TC and TL, there is also an oil hole in the top of the connecting rod. Oil spurts out of this hole onto the inside of the piston.

12-6

.....,..... \ ,

81548A

Engine oil that has lubricated the No. 7 camshaft bush ing flows to the cylinder heads via an oilway and holes in the top of the crankcase. Engine oil that is bound for the cylinder heads flows through oil holes in the rocker shafts and lubricates the rocker bushings. It then spurts out of a hole in the top of each rocker to lubricate the sliding surfaces of the valve caps, the valve stems, and the contact points of the valve stems, push rods, and adjusting screws. The oil then flows through the push rod holes in the cylinder head and crankcase to lubri cate the tappets and camshaft cams. Finally, the oil returns to the oil pan.

LUBRICATION - GENERAL

oil volume and the loss of oil pressure when the pres sure is already low. In the 6024-T, TC and TL, each piston has a cooling cav ity. Oil sprayed out of the oil jets enters these cavities to further cool the pistons.

(d) liming gears

Oil spray plug

Idler shaft installation section

(6) Lubrication of turbocharger Piston ring

Main oil gallery �-

-�"' B1549A

As shown in the illustration, the timing gear idler shaft bushings are lubricated via oil holes that extend from the main oil gallery and from the rearmost crankshaft main bearing. The gears are lubricated by the oil spray plug. {e) Cooling of pistons (oil jet)

Air int::::>

Piston ring

B4363A

Part of the engine oil is directed through the oil pipe from the crankcase into the turbocharger. The engine oil passes through the oil hole in the turbocharger bearing housing to lubricate the bearings. It is then returned through the oil outlet at the bottom of the bearing housing back to the crankcase and to the oil pan. A piston ring is installed on the outside of each bearing, serving as an oil seal.

6D24-T, TC, TL only Piston

11921

An oil jet is fitted under the main oil gallery for each cyl inder. These oil jets spray engine oil onto the inside sur faces of the pistons to help cool the pistons. Each oil jet has a check valve that opens and closes at specified oil pressures, thus preventing decreases in 12-7

LUBRICATION - GENERAL The injection pump and air compressor are lubricated as follows:

(7) Injection pump and air compressor

Main oil gallery From oil cooler

I I

"-.

From crankcase oil main gallery To oil pan', '

Injection pum p

Oil cooler

Crankcase

Air compressor

I I

(.2

'o.

Gear train

B4364B

Oil pan �j�( -----� �--- _ _ _ _ ___

(8) Lubrication of water pump

Section B-B To oil pan

Section A-A From oil main gallery

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

12-8

D0052A

LUBRICATION - SPECIFICATIONS

2. SPECIFICATIONS Specification

Item

API classification class CC or better (without turbocharger) API classification class CD or better (with turbocharger)

Quality

Engine oil

Capacity

Oil pan

Approx. 27 L (for general use} Approx. 25 L (for construction machinery)

Oil filter

Approx. 4 to 4.5 L

Lubrication method

Forced lubrication by oil pump

Oil pump

Type

Forced lubrication by gear pump (integral relief valve)

Relief valve

Type

Ball valve

Full-flow filter element

Type

Filter paper type

Bypass filter element

Type

Filter paper type

Oil filter

Oil bypass alarm

Type

Piston valve type (integral electric contact)

Oil cooler

Type

Shell and plate type (multi-plate type)

Oil bypass valve

Type

Piston valve type

Regulator valve

Type

Piston valve type

Oil jet check valve

Type

Piston valve type

12-9

LUBRICATION - SERVICE STANDARDS

3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item

Nominal value (Basic diameter in I ))

Limit

Remedy and remarks Inspection

Oil pressure (Oil temperature 70° C to 9 0° C)

At idle

145 kPa {1.5 kgf/cm 2} or more

49 kPa {0.5 kgf/cm 2}

At maximum speed

295 to 490 kPa {3 to 5 kgf/cm 2}

195 kPa {2 kgf/cm 2}

Oil pump

Backlash between crankshaft gear and oil pump idler gear

0.08 to 0.2

0.4

Replace

Backlash between oil pump idler gear and oil pump gear

0.08 to 0.2

0.4

Replace

Difference between pump case depth and gear height

0.05 to 0.12

0.15

Replace

Gear tooth tip to pump case clearance

0.20 to 0.29

0.35

Replace

Drive gear shaft to cover clearance

(20) 0.04 to 0.07

0.15

Replace

Driven gear shaft to driven gear bushing clearance

(20) 0.04 to 0.07

0.15

Replace

Idler gear shaft to idler gear bushing clearance

(22) 0.03 to 0.05

0.15

Replace bushing

Relief valve opening pressure Relief valve spring load

Installed length: 47.7

Oil bypass alarm valve opening pressure (on start pressure)

1080 to 1270 kPa {11 to 13 kgf/cm2}

Replace spring

180 to 200 N {18.3 to 20.5 kgf}

340 to 390 kPa {3.5 to 4 kgf/cm2}

Replace

Oil cooler bypass valve

Valve opening pressure

420 to 460 kPa {4.3 to 4.7 kgf/cm2}

Regulator valve

Valve opening pressure

360 to 420 kPa {3.7 to 4.3 kgf/cm 2}

Spring load (Installed length: 48.3)

76 to 80 N V.8 to 8.2 kgf}

3.2 Tightening Torque Table Screw size 0. D.x pitch mm

Tightening torque N-m {kgf-m}

Oil pump idler shaft nut

M12x1.25

59 to 78 {6 to 8}

Apply LOCTITE No. 262

Oil pump cover mounting bolt

Ml0x1.25

39 to 49 {4 to 5}

Wet

Oil bypass alarm

M20x1.5

44 to 54 (4.5 to 5.5)

Oil filter center bolt

M16x1.5

59 to 69 (6 to 7)

Oil filter drain plug

Ml0xl.25

20 ± 4.9 {2 ± 0.5}

Oil cooler bypass valve plug

M20x1.5

15 to 20 (1.5 to 2.0)

Regulator valve

M27x1.5

98 to 115 {10 to 12}

Oil pan drain plug

M18x1.5

690}

Location tightened

12-10

Remarks

LUBRICATION - SERVICE PROCEDURE 4. SERVICE PROCEDURE

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

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

(1) With the oil pressure switch removed and pressure gauge installed, warm up the engine until the oil temperature reaches 70°C to 90 °C. (2) Measure the oil pressure at idle and maximum speeds. If the measurement is below the limit, overhaul the lubricating system.

12-11

LUBRICATION - SERVICE PROCEDURE 4.1 Oil Pump 4.1.1 Removal and installation Apply sealant to inner bead. NV .. Nominal Value L ..... Limit

Apply sealant (Threebond 1207C) and fit it within 3 minutes.

*Backlash from crankshaft gear NV 0.08 to 0.2 L 0.4 Section B

Section A-A

Pour engine oil into pump

C1160C

1 *2 *3 4

Oil pan Oil strainer Oil pipe Flange

11923

5 Relief valve 6 Oil pump 7 Drain plug

Bolt tightening sequence CD-+ÂŽ-+@ After installation, check that the oil pump gear can be turned smoothly by hand. Service items marked with* should be checked before and after the removal. Part marked with * should not be removed unless defects are evident. (Remove it with the oil pump as an assembly.)

NOTE: 1. Sealant application portion on the oil pan should be free of oil. 2. Apply sealant evenly without break. 3. When fitting the oil pan, do not move the oil pan to spread the sealant. 12-12

4. 5.

After installation, wait at least one hour before starting the engine. Reapply sealant whenever the oil pan mounting bolts have been loosened.

LUBRICATION - SERVICE PROCEDURE 4.1.2 Disassembly and inspection

3 Clogged oil hole *Backlash NV 0.08 to 0.2 L 0.4 Relief valve opening pressure NV 1080 to 1270 kPa {11 to 13 kgf/cm 2} Spring installed load (installed length: 47.7) NV 180 to 200 N {18.3 to 20.5 kgf}

Clearance BO 22 NV 0.03 to 0.05 L 0.15

Clearance BD 20 NV 0.04 to 0.07 L 0.15

Wear on bushing 1

Wear and damage on teeth, wear on bushing

Clearance BD 20 NV 0.04 to 0.07 L 0.15

*Difference between oil pump case depth and gear height NV 0.05 to 0.12 L 0.15 *Gear tooth tip to oil pump case clearance NV 0.2 to 0.29 L 0.35

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

Disassembly sequence G) 2 3 4

Oil pump cover Driven gear assembly Idler shaft Idler gear

5 Spring seat 6 Valve spring 7 Ball valve 8 Case and gear assembly

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

12-13

LUBRICATION

SERVICE PROCEDURE

Disassembly and Inspection Procedures

(3) Gear tooth end to oil pump case clearance

(1) Removal of oil pump cover

C9521A 10375

T he oil pump cover is positioned with the dowel pin of the oil pump case. To remove the oil pump cover, tap on it with a plastic hammer or the like.

If the measurement exceeds the limit, replace the gear. Note, however, that the drive gear must be replaced with a case and gear assembly. (4) Gear shaft to case, cover, and driven gear clearÂ ance

(2) Difference between oil pump case depth and gear height

ÂŽ45484

C9520A

If the measurement exceeds the limit, replace the gear. Note, however, that the drive gear must be replaced with a case and gear assembly.

12-14

If the measurement exceeds the limit, replace the part to which bushing is installed.

LUBRICATION - SERVICE PROCEDURE 4.1.3 Reassembly 39to 49N-m {4 to 5 kgf-m} Backlash NV 0.08 to 0.2

Section B-B

0.4

a u, -

�

Apply thread-lock cement (LOCTITE 262) to threads after degreasing

'-----------'4 59to 78 N•m {6 to 8 kgf-m}

Arrow and HUP" mark must face upward and align oil holes

Assembly sequence

5 6

/sect;on A-A\

8➔7➔6➔5➔4➔3➔2➔1

Shaft end surface must be flush with case

Section C-C NOTE: Hold the oil strainer 1 in position temporarily for subsequent attachment to the crankcase. ®45485

4.2 Oil Filter and Oil Cooler 4.2.1 Removal and installation

1 Oil filter 2 Oil cooler 3 Gasket

NOTE: Do not apply oil or grease to the 0-rings at the 1. oil cooler's water inlet and outlet. 2. After installation, run the engine and check for possible oil and water leak. C1158E

12-15

LUBRICATION - SERVICE PROCEDURE 4.2.2 Oil filter NOTE: The elements in the bypass and full-flow oil filters

replaced. For specific replacement intervals, refer to

should be replaced every other time the engine oil is

the Owner's Handbook.

(1) Disassembly and reassembly

1 Drain plug Clogging, deformation

Clogging, deformation

Hardening splitting

Cracks, deformation

Center bolt Washer Oil filter case Element retainer 6 Oil filter element 7 Oil filter head 8 Oil bypass alarm

2 3 4 5

59to 69 N-m {6 to 7kgf-m}

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

C9705 C

Inspection of oil bypass alarm Pressure gauge Valve opening pressure NV 340to 390kPa {3.5 to 4kgf/cm2}

U0700C

12-16

W ith no air pressure applied, check for continuity across the terminals as shown and replace the oil bypass alarm if there is continuity. Next, with the air pressure applied and gradually increasing, measure the air pressure when there is continuity. If the measurement is out of specification, replace the oil bypass alarm.

LUBRICATION - SERVICE PROCEDURE 4.2.3 Oil cooler

(1) Disassembly and reassembly 1 Scale, damage, cracks, oil leaks 3 Scale, cracks Valve opening pressure NV 420 to 460 kPa {4.3 to 4.7 kgf/cm 2}

1 Oil cooler element 2 Bypass valve 3 Oil cooler cover C9804E

(2) Cleaning (a) Check for carbon or sludge deposited in the oil pasÂ sage of the oil cooler element and bypass valve. If contamination is evident, wash in a cleaning oil. (b) If there is a lot of scale on the element and cover, wash it away with tap water (preferably hot). (3) Pressure resistance test

NOTE: Never attempt to apply pressure exceeding the speciÂ fied test pressure.

Check for possible leak by applying a 1470 kPa {15 kgf/ cm2} air pressure to the element. Replace the element if air or oil leak or any other faulty condition is evident as a result of the test.

Conduct the pressure resistance test to check for oil leak caused by damaged or cracked element.

12-17

IEI

LUBRICATION - SERVICE PROCEDURE

4.3 Regulator Valve 98to 115 N-m {1O to 12 kgf-m}

Set load (set length: 48.3) NV 76to 80 N {7.8to 8.2 kgf} Lost tension

1 1 2 3 4

Snap ring Valve Spring Body

ï¿½er

Regulator valve installation position: Left side of crankcase

12-18

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

C9902A

LUBRICATION - TROUBLESHOOTING 5. TROUBLESHOOTING Probable cause

Symptom Overheating

Abnormal oil level • Oil leaks into coolant • Oil leaks Incorrect oil viscosity • Oil out of life • Fuel in oil

Oil pressure does not increase

Oil pressure switch not functioning properly Loaded oil filter element Loaded oil strainer, loose oil pump joint, cracked pipe

Remedy

Ref. group

Correct and fill to specified level

Replace Change oil after repair of faulty parts Replace Replace element Correct or replace

Relief valve, bypass valve not functioning properly Worn or damaged oil pump proper Excessive oil consumption

Replace

Oil leaks from engine

Correct or replace

Oil leaks from crankshaft front or rear oil seal

Correct or replace

Leaks to cooling system • Defective oil cooler water jacket

Correct or replace

Abnormal compression pressure

Check

Group 11

12-19

FUEL AND ENGINE CONTROL CONTENTS 1. 2. 3. 3.1 3.2 4. 5. 5.1

GENERAL .................................... 2 SPECIFICATIONS ........................... 2 5 SERVICE STANDARDS ..................... 26 Service Standards Table ................. 26 lightening Torque Table ................. 27 SPECIAL TOOLS ............................ 28 SERVICE PROCEDURE ..................... 29 Removal and Installation of Injection Pump Assembly ......................... 29 5.2 Bleeding of Fuel System ..... ............ 32 5.3 Inspection and Adjustment after Installing the Injection Pump ...................... 32 5.3.1 Inspection and adjustment of fuel injection start timing ............. 32 5.3.2 Inspection and adjustment of minimum and maximum no-load speeds ..... . . 34

5.4

Pump Drive Case ....................... . . Removal and installation ............. Disassembly and inspection ... ....... Reassembly ..................... . .. . .. 5.5 Injection Nozzle ................... . ...... 5.5.1 Removal and installation ... . . . . ... . .. 5.5.2 Disassembly ........................... 5.5.3 Cleaning and inspection .... . ... ..... . 5.5.4 Reassembly and adjustment <KBL2.1 injection nozzle> ............ 5.5.5 Reassembly and adjustment <KBL2.4 injection nozzle> .... ........ 5.6 Fuel Filter ............ :............. . ..... 5.7 Water Separator .................... ..... 6. TROUBLESHOOTING ............ . ..........

5.4.1 5.4.2 5.4.3

35 35 35 361 37 37 37 38

40 46 52 54

13A-1

FUEL AND ENGINE CONTROL - GENERAL

1. GENERAL

---

Injection pipe

Injection nozzle

Governor Fuel leak-off--.., pipe

Fuel feed pipe

Fuel filter

Automatic timer

Fuel feed pipe

i-----

Feed pump

Water separator (option)

Fuel tank

82115A

The fuel system consists of the injection pump general assembly (injection pump proper, governor, automatic timer, feed pump and coupling), fuel filter, water sepa rator, injection nozzle, fuel leak-off pipe, etc.

13A-2

The injection pump is connected with the air compres sor or pump drive case by a coupling and driven at one half the engine speed.

FUEL AND ENGINE CONTROL - GENERAL (1) Injection pump proper (a) Injection pump

Delivery valve holder

Deflector Oil sump Control rod Control lPLI---sleeve �---- Upper spring seat Plunger spring Lower spring seat Tappet

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

Cam chamber Camshaft

Fuel drawn in 89083C

The camshaft driven at half the engine speed is sup ported by taper roller bearings at both ends. The cam shaft has a cam for operating the plunger and a cam for operating the feed pump. A tappet operating with the pump housing as the guide is in contact with the camshaft. The tappet changes the rotary motion of the cam to up-and-down motion which is transmitted to the plunger. The P type injection pump offers the following fea tures.

Beginning of pressure feed

Pressure feed

End of pressure feed 82204A

When the plunger moves down from the top dead cen ter and opens the suction/discharge ports in the plunger barrel, fuel is not only drawn into the barrel by a vacuum created during the plunger's downward stroke but also sent into the barrel under pressure by the feed pump. On the upward stroke, the plunger begins to compress fuel as it completely closes the suctional discharge ports in the plunger barrel. With the plunger further going up and with the fuel pressure increasing, the plunger overcomes the force of delivery valve spring, pushing up the delivery valve. This causes fuel to be sent under pressure through the injection pipe to the injection nozzle. 13A-3

FUEL AND ENGINE CONTROL - GENERAL

Effective stroke

Control rod

:,-:

B2205A

Driving face

B2206A

The amount of fuel injected will be changed according to the engine operating loads by turning the plunger a given angle to increase or decrease the effective stroke. To be more precise, operation of the control lever or governor moves the control rack (or control rod) to the right or left, which results in the control sleeve being turned. The bottom end of the control sleeve meshes with the driving face of the plunger; thus, as the control sleeve rotates, the plunger also rotates to vary the effective stroke, thereby increasing or decreasing the amount of fuel injected.

13A-4

As the plunger rises and its oblique groove (the reed) meets the inlet/outlet hole, fuel flows into the plunger's vertical groove and is expelled from the inlet/outlet hole. No pressure feed takes place thereafter, regardÂ less of how much the plunger rises. The stroke length during which pressure feed takes place (from when the plunger closes the plunger barÂ rel's inlet/outlet hole until the plunger's oblique groove opens them) is known as the effective stroke.

FUEL AND ENGINE CONTROL - GENERAL (d) Overflow valve

Suction stroke Spring Spring seat To overflow pipe Beginning of Injection injection

Steel ball

End of End of injection injection (beginning of suction)

01827

The fuel highly pressurized by the plunger pushes the delivery valve up and gushes out. When delivery of the fuel under pressure by the plunger is completed, the delivery valve is pushed back by the delivery valve spring and closes the fuel passage to prevent counter flow of the fuel. The delivery valve is further brought down until it is held against the seat surface tightly. The amount of fuel corresponding to the stroke during the period is drawn back from above to instantly lower the residual pressure in the line between the delivery valve and nozzle. The draw-back effect improves the cutting of fuel from the nozzle and prevents after-injection drip足 ping. A delivery valve stopper, provided on the top of the delivery valve spring, limits the lift of the delivery valve to prevent the surging of the valve during high speed operation. It also reduces the dead volume between the delivery valve and nozzle and stabilizes the injec足 tion rate.

82208A

When the fuel pressure in the injection pump exceeds a predetermined pressure, the steel ball in the overflow valve is pushed up to let the fuel flow out from the injec足 tion pump and return to the fuel tank, thereby stabiliz足 ing the fuel temperature and temperature distribution in the injection pump and maintaining the injection rate into each cylinder constant.

13A-5

FUEL AND ENGINE CONTROL - GENERAL

(2) Governor

The construction and operation of the governor are the same regardless of the applicable model of the injecÂ tion pump. (a) RSV type governor

Supporting lever shaft Guide lever

Governor housing

Tension lever

Start spring

Control lever

Governor spring

Camshaft,

Ungleich spring or idling spring

Stop lever Full-load stopper bolt

B2657B

The RSV type governor is a centrifugal type all-speed governor coupled to the camshaft of the injection pump. The governor not only controls the maximum and minimum speeds but also automatically controls the engine speed at any intermediate speed position.

13A-6

FUEL AND ENGINE CONTROL - GENERAL

whereas the top of the lever is coupled through the shackle to the control rack. The start spring, attached to the top end of the control lever, always pulls the control rack in the direction that fuel is increased.

Slider

Ball bearing

Guide lever

Governor sleeve

Flyweight

Flyweight supporting shaft

Start spring

Control rack

Control lever

Pressure spring Governor shaft

Return spring

Adjusting screw

82658C

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

Supporting Pin lever

djusting lever

Stop lever

82659A

The control lever is mounted to the middle of the guide lever by the shaft with the bottom end as the fulcrum,

Governor spring

�-- Ungleich spring or idling spring

The turning shaft of the swivel lever is fitted into the bushing of the governor cover and' its center is eccen tric with respect to the mounting position of the gover nor spring installed to the tension lever. The governor spring is installed to the end of the swivel lever. When the governor spring receives tension, the bot tom end of the tension lever touches the adjustable full-load stopper bolt. When the angle of the adjusting lever is changed, the angle of the swivel lever is also changed and the ten sion of the governor spring changed. This is because the turning center of the swivel lever and the mounting position of the governor spring installed to the tension lever are eccentric to each other as mentioned above. An adjusting screw is also mounted to the swivel lever. Adjustment of the screw changes the tension of the governor spring, thereby making it possible to adjust the speed regulation. An Ungleich spring (or idling spring} is provided in the bottom portion of the tension lever. Adjust the tension of the spring by adding or removing shims. An idling sub spring adjustable from outside is pro vided in the middle of the governor cover. During 13A-7

FUEL AND ENGINE CONTROL - GENERAL idling, the spring always keeps in contact with the ten sion lever to maintain a constant idling speed. The stop lever, mounted through the supporting lever to the bottom end of the control lever, returns the con trol rack to the stop position with a slight pressure irre spective of the adjusting lever position.

2) Idling control

Start spring Idling

1) Start of engine

Governor spring Adjusting lever Starting

s=, l Shifter Guide lever

B2661A

B2660A

When the adjusting lever is moved to the start position (until it touches the maximum speed stopper), the swivel lever which moves with the adjusting lever pulls the governor spring and moves the tension lever until it touches the full-load stopper bolt. At that time, the flyweights are stationary, and the start spring with weak tension pulls the control lever in the direction that fuel is increased. At the same time, the shifter and governor sleeve push the flyweight slider to the left. As the result, the tension lever and shifter are spaced that much apart, and the corresponding amount of fuel is supercharged to facilitate starting.

13A-8

Once the engine is started and the adjusting lever returned to the idling position, the tension of the gover nor spring is drastically reduced. Now the flyweights can move outward even at a low speed, so the tension lever is pushed back until it touches the idling sub spring and places the control rack at the idling position. In this state, the centrifugal force of the flyweights and the weak-state governor spring and idling sub spring achieve balance and main tain smooth idling. When the speed falls, the centrifugal force decreases, the flyweights move inward, and the idling sub spring pushes the tension lever to the left and moves the con trol rack in the direction that fuel is increased. If the speed falls radically, the start spring with weak tension acts and moves the control rack in the direction that fuel is increased to maintain the idling speed.

FUEL AND ENGINE CONTROL - GENERAL 3)

position, thereby preventing over-speed operation of the engine. The RSV type governor controls the entire speed range from idling to maximum speed. If load increases or decreases at a certain speed determined by the posi tion of the adjusting lever, the governor automatically functions and maintains the engine speed constant at all times.

Maximum speed control

No-load Adjusting lever (Idling)

Ungleich operation When max. injection is set at low-speed operation

---------

Idling sub spring

--=

Injection/ stroke

Ac;,,A'

Injection matched with air intake rate -

:..;...---'-----�.() 8'

When max. injection is set at high-speed operation Shifter

Full-load stopper bolt Engine speed 82662A

When the adjusting lever is moved to the full-load posi tion, the tension of the governor spring is increased and pulls the tension lever until it touches the full-load stopper bolt. When the engine exceeds the specified speed, the cen trifugal force of flyweights becomes larger than the force of the governor spring pulling the tension lever. So the tension lever is moved to the right and moves the control rack in the direction that fuel is reduced, thereby preventing the engine from exceeding the spe cified speed. If the speed further increases, the centrifugal force of flyweight increases and pushes the tension lever to the right and also compresses the idling sub spring to pull the control rack back to the no-load maximum speed

82663A

The air intake rate of the engine falls as the engine speed increases. The injection pump, on the other hand, increases the per-stroke injection as the speed increases, even with the control rack at the same posi tion. Therefore, if full-load is set at point A to derive enough output at low speeds, the injection will reach B as the speed increases, and the engine will produce black smoke. If full-load is set at point B' to prevent black smoke, the low speed injection will come down to A', allowing combustion of more fuel. So the Ungleich device accomplishes the function of setting full-load at point A to derive the largest possible torque in the low speed range, and changing it to adjust the injection to point B' in the high speed range.

13A-9

FUEL AND ENGINE CONTROL - GENERAL As the engine speed increases, the centrifugal force of flyweight increases. If it becomes larger than the pres sure of the Ungleich spring, the Ungleich spring is slowly compressed before the start of high speed con trol, and the control rack moves in the direction that fuel is reduced. The Ungleich stroke is completed at the position where the shifter directly touches the ten sion lever.

E E

·;;; 0 0. ..>< (.)

0::

N2 N1 Pump speed (rpm) ---

Stopping of engine Stop position

�l'"'1' -t-........�

Adjusting lever

"'---:-

Without Ungleich effect

Control rack

N2 N1 Engine speed (rpm) --

B2664A

When the engine speed is low and the centrifugal force of flyweight smaller than the pressure of the Ungleich spring, the shifter is moved as much as the Ungleich stroke to the left, so the control rack moves in the direc tion that fuel is increased to increase the torque of the engine at low speeds. Full-load

ill!illy·----..,....-==-�::::::-.-.

Control rack

Ungleich spring

Shifter

13A-10

B2665A

Stop Stop lever

B2666A

When the stop lever is moved to the stop position, the control rack is moved to the stop position to stop the engine regardless of the position of the adjusting lever.

FUEL AND ENGINE CONTROL - GENERAL 6)

Operation of torque spring

in � � -"'

E C:

.g 'iii

Governor operating range

....a.:,

-"'

P1 -1---, i.,tp2 Engine speed (rpm)

P1 P2 Pump speed (rpm) -

Construction machinery engines are often subjected to a large load during operation, and reduced speeds often lead to stalls. To prevent this, a torque spring is provided. When the adjusting lever is fixed in the lever set posi tion, a sudden increase of load, if no torque spring is provided, will move the control rack along the 8-D curve as the speed falls. The rotational displacement at the time may be expressed as P1.

Torque spring

82667A

If a torque spring is provided, the control rack moves along 8-C, and the rotational displacement at the time may be expressed as P2. Therefore, large changes occur in P2 and engine speed, and because of increased fuel injection, the engine torque increases, and large combustion noise warns the operator of the increased load, enabling him to take proper action to prevent stopping the engine. In an abrupt increase of load occurs when the engine is running at continuous rating, the engine speed falls. So the flyweights are moved inward and the tension lever pulled to left by the control spring, causing the control rack to move in the direction that fuel is increased. At the time, the tension lever pin pushes the bottom of the torque control lever, and the lever moves with the pin "A" as the fulcrum, whereas the portion "B" is pushed to right. As the result, the torque spring per forms the function of reducing movement of the ten sion lever.

Full-load stopper

82668A

13A-11

FUEL AND ENGINE CONTROL - GENERAL

(b) RFD type governor

Governor cover

Stop lever

Governor housing

Flyweight Floating lever

Sliding lever

826828

The RFD type governor is a minimum-maximum gov ernor which controls only the minimum and maximum speeds. The RFD type governor make it possible to increase or reduce fuel by the load control lever which operates the control rod. Any desired speed can be set as a dis placement of the speed control lever changes the ten sion of the governor spring. Because of the construction described above, the RFD governor can be operated as an all-speed governor by holding the load control lever in the full position and operating the speed control lever. Flyweights are mounted on the injection pump cam shaft. Each of the flyweights pivots about a pin press fitted in the flyweight holder. When the flyweights move out, the slider fitted to the end of the flyweight arms pushes the sleeve end face axially. The sleeve which contacts the flyweight slider is coupled to the shifter by a snap ring. The guide lever suspended from 13A-12

the tension lever shaft holds the shifter, preventing it from turning. The guide lever has an intermediate shaft, on each side of which there is a floating lever mounted. A block is press-fitted in the bottom end of one floating lever and this block is fitted in the bottom of the sliding lever. The load control lever is fitted to this sliding lever through an eccentric shaft. The floating lever can be moved by operating the load control lever. At the upper end of the floating lever placed on the other side via a shaft, there is an injection pump control rack fitted via a floating lever link. A start spring is hooked at the lower end of the floating lever and the other end of the start spring is hooked at the spring eye on the governor housing side. The tension lever is suspended from the tension lever shaft from which the guide lever is suspended. A gov ernor spring is fitted across this tension lever and the swivel lever. Its tension is determined by the speed control lever mounted on the swivel lever shaft. Within

FUEL AND ENGINE CONTROL - GENERAL normal speed ranges, therefore, the lower end of the tension lever is always in contact with the stroke adjusting bolt. A pin is press-fitted in the side of the lower end of the tension lever. It fits into the groove in the upper part of the sliding lever. During high speed control, therefore, a greater lever ratio is obtained from the linkage formed by the pin, sliding lever, and floating lever. Built into the lower end of the tension lever is the idling spring that provides low speed control. 1)

The engine stop lever is fitted to the top of the gover nor, that moves the control rack to the non-injection position to stop the engine. The cancel spring is installed to prevent excessive force from being applied to the control rack at this time. Mounted on top of the governor cover is the smoke set assembly. It functions to ensure good starting by increasing the amount of fuel injected at starting and improve smoke condition in the practical full-load low speed range.

Control of engine start and idling Speed control lever Maximum speed position Guide lever

Control rack 11111111 Swivel lever Governor spring Load control lever Full position

Shifter

Idling spring B2670A

When the engine is not running, the flyweights are in the closed position, pushed by the governor spring, idling spring, and start spring. If, in this condition, the load control lever is moved all the way to the full posi tion (in the direction of greater fuel delivery), the start spring and idling spring cause the control rack to move to a point which is beyond the full-load position and provides the maximum amount of fuel injected, thus making it easier to start the engine. When the load control lever is returned to the idling position after the engine has started, the flyweights increase or decrease their centrifugal force as the engine speed changes. In the idle speed range, the cen trifugal force is such that it just compresses the idling spring. The centrifugal force of the flyweights balances the combined force of the idling spring and start

spring, which keeps the control rack at a given position. This results in the engine running at smooth idle speed. If the engine speed increases at this time, the centrifu gal force of the flyweights increases causing the fly weights to move out to push the shifter to the right. As a result, the guide lever and floating lever are moved, which in turn moves the control rack in the direction of smaller fuel delivery (to the right). If the engine speed decreases, on the other hand, the control rack is moved in the direction of greater fuel delivery. The governor controls the amount of fuel injected in this way to stabi lize the engine at idle speed.

13A-13

FUEL AND ENGINE CONTROL - GENERAL 3) Control of maximum speed

Normal speed operation

Speed control lever Maximum speed position

Floating lever 11111111

Sliding lever 82671A

If the load control lever is moved in the full direction (for greater fuel delivery), the eccentric shaft coupled to the load control lever causes the sliding lever to pivot about pin D fitted in the bottom of the tension lever. At the same time, the floating lever pivots about point B to push the control rack in the direction of greater fuel delivery, which results in the engine speed increasing. When the engine speed reaches a point over the idling control range, the idling spring is completely com pressed in the tension lever, causing the shifter to be in direct contact with the tension lever. The tension lever, however, is in contact with the stroke adjusting bolt by the tension of the governor spring which is tightened by the speed control lever. Since the centrifugal force of the flyweights is small in the normal speed range, the tension lever is unable to move. This means that point B can not move either, and the operation of the load control lever is directly transmitted through the eccentric shaft, sliding lever, and floating lever to the control rack, thereby increasing and decreasing the amount of fuel injected.

13A-14

82672A

As the engine load varies and engine speed reaches a predetermined maximum speed, the centrifugal force of the flyweights overcomes the governor spring ten sion, causing the flyweights to start moving out. This motion results in the shifter and tension lever being moved to the right. Then, point B is moved to B' and point D in tension lever to D', which prevents the engine speed from exceeding the predetermined max imum level. If this governor is used as an all-speed governor, the engine speed is varied by operating the speed control lever with the load control lever fixed at the full posi tion. That is, a given engine speed is maintained as the speed control lever is tilted; if load changes, however, the governor automatically controls to keep the given speed. For example, suppose the speed control lever is tilted to a position which provides the maximum out put (where it contacts the maximum speed stopper bolt). When the engine speed increases in this condi tion, the centrifugal force of the flyweights becomes greater.

FUEL AND ENGINE CONTROL - GENERAL As the force becomes greater than the force of the govÂ ernor spring which pulls the tension lever, the flyÂ weights start moving out. This motion of the flyÂ weights causes the shifter and tension lever to be moved to the right. At the same time, point Bis moved to B', point D to D', and point C to C'. This results in the control rack being pulled in the direction of smaller fuel delivery, thus reducing the engine speed. If load increases to cause the speed to decrease, the centrifugal force of the flyweights becomes smaller than the governor spring tension. Then, point B' is moved to 8, point D' to D, and point C' to C. This results in the control rack being moved in the direction of greater fuel delivery. The governor automatically activates as load changes to maintain a given speed at all times. 4)

With smoke set assembly

Without smoke set ambi'

,,i

Rs.,____

Re \

Rack position (mm)

Start booster (smoke set assembly)

Pump speed (rpm) _,..

11111111

82673A

The smoke set assembly installed to the rear of the governor has a spring with setting force and a stopper as functional parts. It also has sleeve, stroke adjusting nut, spring adjusting nut and cap.

826748

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

13A-15

FUEL AND ENGINE CONTROL - GENERAL (3) Feed pump

Engine stop lever

Normal position

Stop -. -,::: O ''�'

Priming pump

\ ®'

�

Stop lever assembly Inlet check valve

To fuel filter

82675A

To stop the engine, the stop lever on top of the gover nor must be operated to cut off the fuel. The stop lever is cable-connected to the engine stop button on the driver's seat. The stop lever is operated by pulling the button. When the stop lever is rotated, the internal lever pushes the tab on the floating lever link, forcing the control rack to the non-injection posi tion to stop the engine. The stop lever returns to the normal position by the reaction of a built-in spring.

13A-16

83006A

Supply of fuel to the injection pump proper is accom plished by the feed pump mounted to the side of the injection pump proper and driven by the cam of the injection pump camshaft provided for the purpose. The priming pump mounted to the feed pump makes it possible to lift fuel manually when the engine is sta tionary.

FUEL AND ENGINE CONTROL - GENERAL (a) Suction stroke

01837

01835

When the camshaft of the injection pump forces the push rod up, the fuel in the suction chamber is com pressed and opens the outlet check valve. Most of the fuel forced out is drawn into the pressure chamber above the position.

When the pressure in the pressure chamber exceeds specification, the piston cannot be brought back by the pressure of the piston spring and stops the pump func tion. So the pressure in the fuel filter is adjusted not to rise more than necessary.

(b) Pressure feed stroke

(4) Automatic timer

Piston spring

Pressure chamber

01836

When the cam, moved away by rotation of the cam shaft, ceases to push up, the piston is pushed back by the pressure of the piston spring and forces out the fuel from the pressure chamber and forces it into the fuel filter. At the time, the outlet check valve closes, and the inlet check valve opens, so the fuel is drawn into the suction chamber.

The interval between fuel injection into the cylinder and its ignition is called the ignition delay interval. The ignition delay interval is constant regardless of the engine speed. If the ignition timing is always constant, changes in the engine speed will vary the relation between the piston position and ignition timing, mak ing it impossible to obtain the best engine perfor mance. To maintain the relation between the piston position and ignition timing constant at all times, the injection timing must be changed to match the engine speed. The automatic timer is a device which automatically changes the injection timing according to the engine speed.

13A-17

FUEL AND ENGINE CONTROL - GENERAL

(a) SP type automatic timer <6D24, TC>

Injection pump side

Oil seal

0-ring

Flange

Cover

Spring seat Flyweight Timer housing

B3201A

Two flyweights are fitted on the pins of the timer housÂ ing and are held in the timer housing. On the other hand, the inject ion pump connection side flange has a curved surface, and the roller fitted on the pin installed in the flyweight touches the curved surface. Timer 1imer spring

When the engine is running at a low speed, the timer spring pressure is stronger than the centrifugal force of flyweight, so the roller of flyweight is held down by the flange, creating no advance state. When the engine reaches a high speed, the centrifugal force of flyweight becomes stronger, the roller of flyÂ weight pushes the curved surface of flange with the timer housing pin as the fulcrum, and the flyweight opens outward, while compressing the timer springs. In this manner, the roller installed on the flyweight moves the flange in the turning direction and advances the injection timing.

Flange

Timer housing pin \

Advance angle

83202A

13A-18

springs are held between the spring seats fitted on the timer housing pins which extend through the flange and flyweight. These parts are housed in the timer housing and are totally enclosed with a cover, 0-ring and oil seal.

FUEL AND ENGINE CONTROL - GENERAL (b) SPG type automatic timer <6D24-T>

\; \/

Cover Pilot pin

Timer holder

Timer housing

80023A

� � ��,�Flywo;ght _'.

Flywo;ght p;, =-� Eccentric cam (larger) � Timer holder � Eccentric cam (smaller) �

I�

� Housing pin -,---U ···

Timer housing

Timer spring 80024A

The timer housing receives rotating motion of the engine through a coupling. The timer holder is directly connected to the injection pump camshaft. Two oppos ing pins are press-fitted in the timer housing. A small eccentric cam is mounted on each of the pins and a large eccentric cam is slid over the periphery of the small cam. The two holes in the timer holder fit over the large eccentric cams. Pins are pressed into the undersides of the flyweights. These flyweight pins fit into holes in the larger eccen tric cams. When the timer housing is rotated, the timer holder is rotated at the same time driving the injection pump.

80025A

The two flyweights have the timer holder in between and are provided with timer springs having the same set tension to keep the flyweights evenly in position. When the engine is not running or running at low speeds, the flyweights are pressed against the timer holder by the set tension of the springs.

13A-19

FUEL AND ENGINE CONTROL - GENERAL (5) Boost compensator <engine with turbocharger> Point A Boost pressure

Flyweight

Timer spring Inlet manifold Timer housing pin (point Cl

Flyweight pin cam

Small eccentric cam

Flyweight in fully lifted position

--tt--t--+-+� �-1-+--+-....1.L_.1.

Retard angle

43932

When the engine is not running, the flyweights are pressed against the timer holder by the timer spring set tension. When the engine is started, a centrifugal force is pro duced by the flyweights; however, it is less than the timer spring set tension keeping the flyweights remaining the original positions, without lifting. As the engine speed increases, the centrifugal force of the flyweights also increases and will be balanced with the spring tension. When the engine speed further increases, the centrifugal force overcomes the timer spring set tension, causing the flyweights to lift out ward. This causes the center (point B) of the large eccentric cam pivot about the center (point A) of the timer, moved in the rotating direction, by the small eccentric cam pivoting about the timer housing pin (point C). Since the large eccentric cam is fitted to the timer holder, that motion of the large eccentric cam is imparted to the timer holder. The maximum retard angle is obtained when the backs of the flyweights are against the inner wall of the timer housing.

13A-20

86012A

The boost compensators increase the engine's power output by increasing the rate of fuel injection to match increases in air intake caused by the turbocharger. To increase the amount of fuel injected, the boost com pensators utilize the boost pressure in the inlet man ifold. There are two boost compensators. One is fitted to the governor, and the other is fitted to the drive side of the injection pump.

FUEL AND ENGINE CONTROL - GENERAL (b) Drive-side boost compensator

(a) Governor-side boost compensator

Boost compensator set spring Connection pipe Boost Boost compensator

Inlet manifold

Floating lever

B2693C

Control rod. 82691A

As the boost pressure overcomes the compensator spring, the diaphragm and push rod are pushed to the left. Movement of the diaphragm is pivoted on point "A" of the compensator lever and moves the compen sator lever in the direction shown by the dotted lines. As the diaphragm and compensator lever move, the floating lever pivots counter-clockwise about point "B," thereby pushing the control rod in the fuel-in crease direction. The system is thus able to increase the fuel quantity irrespective of the governor.

Load control lever idling position

�

tingl�oc . CanceI sprmg Floatmg . I ever 1.mk Load control lever full position (turbocharger off) Control rod

[JC: :,.•.o �

Load control lever full position (turbocharger on)

¥? [jt#:;;:g,_nn �

82693A

When the boost pressure rises above the boost com pensator spring set pressure by the action of the turbo charger, the diaphragm forces out the push rod. The cancel spring installed between the control rod and floating lever on the governor side is set so that it pushes, at all times, the control rod in the direction of greater fuel supply. This means that, when the push rod moves in the direction shown by the arrow, the control rod moves in the direction of greater fuel sup ply. This boost compensator also has a spring that increases fuel supply at engine start.

13A-21

FUEL AND ENGINE CONTROL - GENERAL (7) Injection nozzle Two models of hole type injection pumps are used. Their constructions are as follows. (a) KBL2.1 injection nozzle

Cap nut Adjusting screw Lock nut---

�..._.,,.,.,

Set screw---��=!�

�::;..._- Spacer

Control rod

82692A

Before the engine is started, the idling spring in the governor, forcing the control rod in the direction of more fuel supply overcomes the force of the smoke set spring and therefore the control rod moves to the start fuel increase position while forcing the arm. When the engine is started, the idling spring is compressed by the shifter and as a result, it loses the force to push out the control rod. Then, the smoke set spring forces the control rod back to the normal position. (6) Pump drive case

Pump drive shaft

Injection pump side

Flywheel housing side 84191A

The pump drive case, installed at the left of the fly wheel housing, is driven by the timing gear of the engine at half the engine speed. The pump drive shaft, with its end connected to the coupling of the injection pump, drives the injection pump. 13A-22

No. 2 spring

No. 2 push rod MU�--- Nozzle holder

No. 1 spring No. 1 push rod Nozzle Retaining nut

83406A

The nozzle has two springs and push rods, and a clear ance (prelift) is provided between two rods. When the high pressure fuel fed from the injection pump overcomes the 1st spring which determines the valve opening pressure, the needle valve opens to start the pre-injection and simultaneously moves the 1st push rod upward. When the 1st push rod moves through the prelift and contacts the 2nd push rod, the needle valve stops mov ing momentarily. As the fuel pressure further increases and overcomes the resultant force of the 1st and 2nd springs, the needle valve restarts moving upward for the main injection. Some of the high-pressure fuel is used to lubricate the needle valve and other components and is returned to the fuel tank via the leak-off pipe. Fuel injection pressure adjustments are made using the shim.

FUEL AND ENGINE CONTROL - GENERAL (b} KBL2.4 injection nozzle

No. 1 spring

From injection pump

OJ No. 1 valve opening pressure,--++�� adjusting shim

Push rod

No. 1 spring seat

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

No. 2 valve opening pressure adjusting shim No. 2 spring seat

Lift-piece Needle valve

Lift-piece

11933

With this nozzle, a prelift clearance is provided between the lift-piece and No. 2 spring seat, and the nozzle's injection starting pressure is determined by the force of the No. 1 spring.

Needle valve

01846

As the pressure of the fuel fed from the injection pump (i.e., the pressure in the nozzle tube} overcomes the No. 1 spring, the needle valve rises by the prelift distance. When the lift-piece rises by the prelift distance, it meets the No. 2 spring seat. Since the lift-piece and No. 1 spring seat are pressing together, the spring force at this time is that of the No. 1 and No. 2 springs com bined, and the needle valve momentarily stops rising. As the fuel pressure rises and the pressure in the nozzle tube overcomes the two springs, the needle valve rises further and the nozzle injects the remaining larger quantity of fuel. Fuel injection pressure adjustments are made using the shim.

13A-23

FUEL AND ENGINE CONTROL - GENERAL (9) Water separator

(8) Fuel filter

<6D24, T, TC>

-- Element

835018

83551A

83501C

<6D24-TL>

速28757

The fuel filter may be either the element replace type or the spin-on type which facilitates replacement of ele足 ment. It separates water content in the fuel fed under pres足 sure from the fuel feed pump of injection pump and eliminates dirt in the fuel by the element. 13A-24

The sedimenter type water separator separates gas oil and water centrifugally by taking advantage of their difference in specific gravity. The fuel that has flowed in from the inlet connector is squeezed by the fuel path of the head to increase the flow velocity and spins. The separated water is sedi足 mented in the case, whereas the water-separated fuel is drawn through the fuel path in the center of the head into the feed pump. The water separator sediments not only water but also mud components. A red float goes up and down with the water level in the semi-transparent case, making it possible to visually check the water quantity.

FUEL AND ENGINE CONTROL - SPECIFICATIONS 2. SPECIFICATIONS (1) Injection pump Specification

Item

BOSCH AUTOMOTIVE SYSTEMS

Manufacturer Injection

<6024>

<6D24-T>

Pump

(Standard)

(Optional)

(Standard)

(Optional)

Type

Bosch in-line type

Plunger diameter

<6O24-TL>

Bosch in-line type

Clockwise

RSV all-speed mechanical governor

RFD minimummaximumspeed mechanical governor

RSV all-speed mechanical governor

RFD minimummaximumspeed mechanical governor

RSV all-speed mechanical governor

RED-4 electronically controlled governor

SP mechanical automatic timer

SPG mechanical automatic timer

SP mechanical automatic timer

SPGH electronic timer

Model Direction of rotation (seen from drive side)

<6D24-TC>

Governor Model and type

Feed pump model Model Automatic timer Model and type

(2) Injection nozzles Item

Specification

Manufacturer

BOSCH AUTOMOTIVE SYSTEMS <6D24>

<6O24-TC>

<6O24-TL>

Hole-type (2-spring nozzle: KBL2. 1)

Hole-type (2-spring nozzle: KBL2.4)

OLLA

0.32

0.36

0.30

157°

154°

150°

151°

Nozzle Type

(Optional)

Hole-type (2-spring nozzle: KBL2.4)

OLLA 5

model No. of holes Hole diameter

<6O24-T> (Standard)

Spray angle

(3) Others items Item

Specification

· Fuel filter type

Spin-on filter-paper type

Water separator type

Precipitation type

13A-25

FUEL AND ENGINE CONTROL - SERVICE STANDARDS

3. SERVICE STANDARDS 3.1 Service Standards Table (1) Injection pump Unit: mm Nominal value (Basic diameter in I ])

Maintenance item

Dependent on specification

Fuel injection start timing (BTDC) Eccentricity with respect to air compressor crankshaft (or pump drive shaft)

0.2 or less

Limit

Remedy and remarks

Adjust

Adjust shims

(2) Injection nozzle Unit: mm Nominal value (Basic diameter in I ])

Maintenance item 1st valve opening pressure

Prelift

All except 6O24-TL 6O24-TL

15.7 MPa {160 kgf/cm }

KBL 2.1

0.10 ± 0.02

KBL 2.4 2nd valve opening pressure ("open" pressure) 2nd valve opening pressure with 0.05mm needle valve lift ("cover" pressure)

13A-26

17.7 MPa {180 kgf/cm2} 2

0.07 ± 0.02 24.8 to 25.4 MPa {253 to 259 kgf/cm2}

KBL 2.1

23.0 to 23.5 MPa {235 to 240 kgf/cm2}

KBL2.4

22.6 to 23.6 MPa {230 to 240 kgf/cm2}

Limit

Remedy and remarks

Adjust

FUEL AND ENGINE CONTROL - SERVICE STANDARDS 3.2 lightening Torque Table Location tightened

Screw size O.D. x pitch (mm)

Tightening torque N-m {kgf-m}

Injection pump bracket mounting bolt

M10 x 1.5

35 to 53 {3.6 to 5.4}

Injection pipe union nut

On pump side

M14 x 1.5

29 to 49 {3 to 5}

On nozzle side

M12 x 1.5

29 {3}

Injection pump

Overflow valve

20 to 29 {2 to 3}

Injection pump fuel inlet side eyebolt

20 to 29 {2 to 3}

Lubricant (inlet) side eyebolt Lubricant (outlet) side eyebolt

20 to 29 {2 to 3} 12 to 15 {1.2 to 1 .5}

Fuel inlet side eyebolt

20 to 25 {2 to 2.5}

Fuel outlet side eyebolt

20 to 25 {2 to 2.5}

A bolt

B bolt

6D24, T, TC

74 to 83 {7.5 to 8.5}

6D24-TL

83 to 93 {8.5 to 9.5} 59 to 64 {6 to 6.5}

6D24, T, TC 6D24-TL

C bolt B3401A

6D24-TL

Air vent plug

Water separator

83 to 93 {8.5 to 9.5} 215 {22}

M8x1

9.8 to 15 {1 to 1.5}

M8 x 1.25

15 {1.5}

M19 X1

59 to 78 {6 to 8}

Cap nut

M22x 1.5

39 to 49 {4 to 5}

Inlet connector

M14 x1.5

69 to 78 {7 to 8}

Set screw

M22 x 1.5

49 to 59 {5 to 6}

Lock nut

M14 x1

20 to 25 {2 to 2.5}

Leak-off connector

M14x1

29 to 39 {3 to 4}

Retaining nut

M19x0.75

59 to 78 {6 to 8}

All except 6D24-TL

M14 x 1.5

25 {2.5}

6D24-TL

M14 x 1.5

25 to 35 {2.5 to 3.5}

All except 6D24-TL

MS x 1.25

7.8 to 12 {0.8 to 0.12}

6D24-TL

MS x1.25

9.8 ± 2 {1.0 ± 0.2}

Eye bolt

M14 x 1.5

25 {2.5}

Air plug

MS x 1.25

7.8 to 12 {0.8 to 1.2}

Injection nozzle bolt (for attaching to cylinder head)

Fuel filter connector bolt

59 to 64 {6 to 6.5}

M24x 1.5

Leak-off pipe eyebolt

2-spring nozzle

83 to 93 {8.5 to 9.5}

6D24, T, TC

Injection pump gear mounting nut of pump drive case Injection nozzle

Retaining nut

Remarks

12 to 15 {1.2 to 1.5}

Boost compensator eyebolt Fuel feed pump

13A-27

FUEL AND ENGINE CONTROL - SPECIAL TOOLS

4. SPECIAL TOOLS Unit: mm Tool name

Shape

Filter Wrench MH061572 <All except 6D24-TL> Removal of fuel filter element

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

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

22338

13A-28

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5. SERVICE PROCEDURE

(2) Installation procedure

5.1 Removal and Installation of Injection Pump Assembly (1) Removal procedure (a) Ready a fluid receiver and waste cloth to ensure that the engine is not contaminated by fuel or engine oil. (b) Remove all pipes and harness connectors that make the removal job difficult or impossible.

NOTE: The following procedures assume that the injection pump is equipped with an air compressor. The same procedures apply to one with a pump drive case.

(a) Adjustment of injection pump bracket

Dial gauge Injection Pump Centering Tool MH061340 Air compressor $ 30 position 43739

Injection pump bracket

NOTE: 11929

Make zero-point adjustment with Injection Pump Centering Tool (special tool) placed on the injecÂ tion pump bracket and a dial gauge set on the manÂ drel of the special tool.

C0557A

Keep the injection pump removed on wooden blocks so as to protect the automatic timer area from impact.

(e) Do not remove the injection pump bracket unless defects, such as cracks, are evident.

13A-29

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE <When the measured value at point 8 is positive

(+)>

Insert shims evenly to four places. <When the measured value at point A is positive

(+)>

Insert shims to the lower side of point C. <When the measured value at point C is positive

(+)>

Insert shims to the upper side of point A.

Shim inserting requirements • C0597A

• 2)

Slide the dial gauge toward the air compressor and measure the misalignment between the mandrel of the special tool and the air compressor crank shaft at points shown in the figure.

Eccentricity NV 0.2 or less

•

The number of shims used in a single location must not exceed three. Top and bottom shims both at front and rear must be equal in thickness. The difference in number between the top and bottom shims must not exceed one.

4) After adjustment, tighten injection pump bracket to the specified torque before confirmation. (b) Installation of injection pump 1)

Crank the engine to bring the No. 1 cylinder piston to the fuel injection timing position. (Refer to Section 5.3.1.) Keyway

Dowel pin

NV .. Nominal Value

C0598A

If the eccentricity between the mandrel and air compressor crankshaft is in excess of the nominal value, adjust by adding or removing injection pump bracket shims.

13A-30

2) At that time, verify that the keyway of air compres sor crankshaft faces upward. If not, rotate the crankshaft one complete turn.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE • •

•

C0562A

3) Align the pointer of the injection pump and the inscribed mark on the automatic timer. 4)

Installation of injection pump

Fit the injection pump onto the injection pump bracket. Temporarily fit the timing adjustment bolt onto the driving coupling. Slide the driving coupling until there is clearance of 0.5 mm or less between it and the coupling plate. Then, tighten the cotter bolt to the specified torque. Confirm that the injection starting timing is cor rectly adjusted as per items (b) 1) to 3), then tighten the timing adjustment bolt to the specified torque.

20to29N-m {2to3 kgf-m}

20to29N -m {2to 3 kgf-m}___

_r,./

�/

20to25N•m {2to2.5 kgf- m}

29to49N-m {3to5 kgf-m} 20to29N-m k

/&1,.�

tt�: gfm}

'20to25 N-m 12to15N-m {2to2.5 kgf-m} {1.2to 1.5 kgf-m} 43741

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

liming adjustment bolt

Clearance

•

85893A

Loosen the cotter bolt and remove the timing adjustment bolt. Remove the driving coupling from the coupling plate. Fit the driving coupling onto the air compressor crankshaft and push it toward the air compressor.

13A-31

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.2

Bleeding of Fuel System

5.3

Perform fuel system air bleeding as follows.

Inspection and Adjustment after Installing the Injection Pump

5.3.1

Inspection and adjustment of fuel injection start timing

) .. ; j!!

85909A

(1) Loosen air plug of fuel filter.

r I

B6118A

(1) Crank the crankshaft more than 180° in forward direction to line up the pointer with the fuel injec tion start timing angle scale inscribed on the out side periphery of the flywheel. NOTE:

B4324A

(2) Turn counterclockwise the priming pump knob of injection pump so that it comes loose. (3) Move priming pump knob up and down to feed fuel until air bubble does not come out from air plug. (4) With no air bubble coming out in fuel, tighten air plug. (5) Move priming pump knob up and down several times, then screw in knob. NOTE: Sop up fuel spilt around.

(6) Actuate starter to discharge air in injection pump and pipe. NOTE: Do not actuate starter for more than 15 seconds.

13A-32

If the engine is turned in reverse direction (either when the engine is stopped or by cranking), the automatic timer will stay advanced and may not return to normal even if the engine is slightly cranked in the normal direction. Make sure that the engine is cranked manu ally more than 180° in the normal direction.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

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

86117C

21839

If the timer is electronic, check at this time whether the inscribed lines are aligned. If they are not aligned, the timer is advanced; give the engine two turns in the for ward direction to return the timer to a non-advanced condition. If this action does not return the timer to a non-advanced condition, first loosen the eyebolt (see the drawing) to make it easier for residual hydraulic pressure in the timer to escape to the injection pump.

(3) If they are out of alignment, loosen the timing adjusting bolt of the coupling and adjust by turning the automatic timer. After adjustment, recheck by the procedures of steps (1) and (2), and tighten the timing adjusting bolt to the specified torque. NOTE: Do not loosen the bolts of the coupling except the tim ing adjusting bolt.

C0562A

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

13A-33

5.3.2

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Inspection and adjustment of minimum and maximum no-load speeds

(2) RFD type governor

Start and idle the engine until it reaches normal operat ing temperature. Then, make the following checks. Stopper bolt

(1) RSV type governor Idling Full-speed position 1------, position Adjusting lever

Idling stopper bolt Full-load stopper bolt

Load control lever B63068

(a) Minimum speed

B6310B

(a) Minimum speed Make sure that the adjusting lever is in contact with the stopper bolt. In this condition, check that the minimum speed is within the specification. If the specification is not met, adjust with the stopper bolt. (b) Maximum speed Place the adjusting lever to the full-speed position. If the maximum speed is outside the specification in this condition, adjust with the maximum speed stopper bolt. NOTE: Quickly move the adjusting lever from the full-speed position to the idling position to make sure that the engine does not stall or develop hunting. If defects are evident, adjust within the specification.

13A-34

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

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.4 Pump Drive Case 5.4.1

Removal and installation

Pump drive case

84194A

(1) For removal and installation of the pump drive case, refer to Section 5.1 in Group 61 Special Equipment.

5.4.2

Disassembly and inspection 6

10 Deterioration, damage

Cracks, wear 84196A

Disassembly sequence 1 2 3 4

Sensor plate Injection pump gear Collar Bearing holder

5 Oil seal 6 Shaft 7 Bearing

8 Bearing 9 Cover 10 Crank case

13A-35

5.4.3

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Reassembly

Assembly sequence 10➔8➔6➔3➔®➔<D➔9 4➔7➔5 -1'

For parts with an encircled number, refer to Reassembly Procedure that follows.

7 B4197A

(1) Installation of injection pump gear Install the injection pump gear, sensor plate (or guide plate) and nut as shown. Align uo" and "U" marks

D9274B

13A-36

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

5.5 Injection Nozzle

5.5.2

5.5.1

<KBL2.1 injection nozzle>

Removal and installation

Disassembly

,-{j

Gasket -0 3� Cracks, deterioration

2--18111

4---=1 5

Nozzle identification mark stamped position

Wear6� � Shim (for prelift) _ � 1

1 Injection pipe 2 Leak-off pipe 3 Injection nozzle

4 Dust seal 5 Nozzle tip gasket C0577B

1 Cap nut 2 Adjusting screw 3 Lock nut 4 2nd spring 5 Set screw 6 2nd push rod 7 Spacer

12 11

Carbon deposits

--rf :---t./

Shim (for valve opening ---® pressure) ______§ Cracks, 8 -g dete,;o,at;oo g

Wear

o-,o

8 1st spring 9 1st push rod 10 Retaining nut 1l Nozzle 12 Needle valve 13 Nozzle holder 14 Inlet connector D7015A

13A-37

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE <KBL2.4 injection nozzle>

Disassembly Procedure

T he following special tools should be used in disas sembly: Identification mark position

11-ij r-

Tool name

�10

Part No. (Zexel product No.)

Plate

157944-9520

Special Wrench

157914-2800

Removing retaining nut

:--- 9 8 � ©-

--·· Special Wrench (157914-2800)

15--® 14�

1a__i 12 01888 15449

G) 2 3 4 5 6 7 8 9

Retaining nut Needle valve Nozzle Pin (lj>3) Spacer Lift piece Pin (lj>2.5) Spring seat Shim (For adjust ment of second ary valve opening pressure)

10 11 12 13 14 15

2nd spring Push rod Callar Spring seat 1st spring Shim (For adjust ment of primary valve opening pressure) 16 Nozzle holder 17 Leak-off connector

NOTE: 1. Clean off any carbon deposits before disassem bling, reassembling, or adjusting any nozzle assembly. Note, however, that the spray pressure and shape should be inspected and the assembly checked for oil leaks first. If no abnormalities are apparent, do not commence disassembly. 2. Under no circumstances change the combination of needle valves and nozzles used. 13A-38

Secure the Plate (special tool) in a vise and fit the injec tion nozzle onto it. Loosen and remove the retaining _ nut using the Special Wrench (special tool). 5.5.3

Cleaning and inspection

(1) Cleaning

Nozzle Cleaning Tool 105789-0010

01891

After washing the nozzle in gas oil, remove deposited carbon using Nozzle Cleaning Tool (special tool) by the following procedures. NOTE: Never change the combination of the nozzle and needle valve.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (2) Inspection

O7003A

(a) Remove the needle valve from the nozzle and clean the needle valve with the needle valve cleaning wood piece.

070058

Clean and immerse the nozzle in gas oil, slide the needle valve and check that it moves smoothly. Next, pull up the needle valve vertically about 1/3 of its entire stroke and check that it falls under its own weight. If it does not fall, replace the nozzle.

O7004A

(bl Insert, while turning, a cleaning needle into the injection orifice of the nozzle to remove carbon.

O7029A

(c) Clean the nozzle seat using the cleaning needle. (d) To remove burnt and hardened carbon, use FUSO Carbon Remover or equivalent. 13A-39

5.5.4

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Reassembly and adjustment <KBL2.1 injection nozzle>

Adjust while assembling the parts by the following procedures. As the prelift is adjusted in 1/100 mm increments, use clean detergent to thoroughly remove dust and dirt before adjustment. The following special tools should be used when mak ing adjustments: Tool name Adjusting Device

1 39 to 49 N-m {4 to 5 kgf-m} 2 20to 25 N-m 3 {2 to 2.5 kgf-m} 5 49to 59 N-m {5 to 6 kgf-m}

Shim (for prelift)

Zexel product No .

7 6 13

u....-+--Shim (for valve opening pressure}

105789-0500

8 9 Adjusting Device (105789-0500) components

11 10

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

D 7016C

Assembly sequence 13➔9➔8➔7➔5➔6-+4➔2➔3, 11➔12

____r 1O➔ 14➔1

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

Adjusting Steps

83942A 1

Adjusting device assembly

157892-0220

Dial gauge

157954-3800

Pint= 50 mm

157892-1200

Pin e = 60.5 mm

157892-1100

Connector assembly

157892-1320

Base

157892-1800

Gasket <for Retaining nut>

157892-1500

Retaining nut for adjustment

157892-1420

Gasket <for bolt of retaining nut>

026508-1140

13A-40

CD Adjustment of 1st valve opening pressure ® Selection of prelift adjusting shims @ Adjustment of 2nd valve opening pressure ("open" pressure) *@ Check of needle valve full lift @ Installation of prelift shims *@ Checking of prelift *(/) Adjustment of 2nd valve opening pressure ("cover" pressure) @ Inspection Inspection make operations marked with sary for inspection or confirmation.

* as neces

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (1) Adjustment of 1st valve opening pressure Set screw 49 to 59 N-m {5 to 6 kgf-m}

Nozzle holder

Spacer Shim (for 2nd valve opening pressure adjustment) 1st spring 1st push rod

Gasket A 157892-1500

D7018A D7017A

(a) Using the Retaining Nut for Adjustment (special tool), install the nozzle and needle valve to the nozzle holder.

(b) Insert 1st push rod, 1st spring, 1st valve opening pressure adjusting shim (first use about 1 mm thick one) and spacer to the nozzle holder. Then tighten the set screw to specified torque.

NOTE: 1. Make sure that the knock pin has seated comÂ pletely in the nozzle before tightening the RetainÂ ing Nut for Adjustment. Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench. 2. Remove the bolt from the tip of the retaining nut.

Operate lever at 60 to 100 strokes/minute Injection pressure NV 17.7 MPa {180 kgf/cm2} NV .. Nominal Value

Keep bolt removed

D7019D

(c) Install the nozzle holder to nozzle tester and adjust the shim thickness for nominal injection pressure. 0.50 to 1.54 mm (in 0.02 mm steps)

13A-41

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

NOTE:

1. 2. 3.

When using a shim, be sure to check its thickness by a micrometer. Use same shim for prelift adjustment. Use of a 0.02 mm thick shim changes the valve opening pressure by about 235 kPa {2.4 kgf/cm2}.

(2) Selection of prelift adjusting shim

Dial Gauge holder

(a) "O" point adjustment of adjusting device

Intermediate screw of Adjusting Device

Dial Gauge 157954-3800

Set screw

Adjusting Device 157892-0220 Pin 157892-1100 2nd push rod 2nd push rod Base 157892-1800 O7031A

D7030A

(c) Install the adjusting device to the set screw using its intermediate screw. After installation, holding the Dial Gauge at its holder, move it up and down to check that the gauge operates smoothly. Push down the gauge, holding its holder and read its lift h. NOTE:

Install Dial Gauge (special tool) to Adjusting Device (special tool). Install the 2nd push rod to Base (special tool) and install the assembly to a vice. Set the pin and Adjusting Device as indicated in the above illustration and adjust "O" point of the Dial Gauge. Use a 60.5 mm long pin. (b) Install the 2nd push rod to the nozzle holder. NOTE: Do not install the 2nd spring and prelift adjusting shim.

13A-42

Read to 1/100 mm.

(d) Selection of prelift adjusting shim t=t'+h where t: Shim thickness (measured) t': Prelift (0.10 Âą 0.02 mm) h: Dimension selected in step (c) T=t Âą 0.015 mm T: Thickness of shim to be used Shim thickness: 0.75 to 1.50 mm (in 0.01 mm steps) (e) Remove the Adjusting Device from the nozzle holder.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (3) Adjustment of 2nd valve opening pressure ("open" pressure) 20 to 25 N-m {2 to 2.5 kgf-m}----1 Lock nut Adjusting screw----c;:;i

(4) Checking full lift of needle valve

DialGauge 157954-3800 39 to 49 N-m {4 to 5 kgf-m} Connector 157892-1320 Pin C= 50 mm 157892-1200

2nd spring ----flll

'Retaining Nut for Adjustment 157892-1420

Gasket B 026508-1140 ---® �Bolt

D7033A 07032A

Install the 2nd spring, adjusting screw and lock nut to the nozzle holder. NOTE: Do not install the prelift adjusting shim. Operate lever at 60 to 100 strokes/minute Injection pressure NV 24.8 to 25.4 MPa {253 to 259 kgf/cm2} NV .. Nominal Value

(a) Install the special tools indicated in above illustra tion and set "O" point of the Dial Gauge. (b) Install the nozzle to the nozzle tester and operate the tester lever to bleed the inside of the retaining nut. Also check for fuel leaks. (c) Operate the tester lever to increase the pressure to about 34.3 to 44.1 MPa {350 to 450 kgf/cm2} so that the needle valve of the nozzle is fully lifted. Read this lift dimension "L" off the Dial Gauge. (d) Remove the Dial Gauge, Connector and Pin (spe cial tools). (5) Installation of prelift shim Adjusting screw Lock nut

Keep bolt removed 070190

Using a nozzle tester and turning the adjusting screw, adjust the 2nd valve opening pressure ("open" pres sure) until it complies with the nominal value. After adjustment, tighten the lock nut to specified torque.

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

07034A

13A-43

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(a) Remove the set screw, lock nut and adjusting screw as an assembly from the nozzle holder.

(7) Checking 2nd valve opening pressure ("cover" pressure)

NOTE: Never loosen the lock nut as loosening it changes the 2nd valve opening pressure.

2nd valve opening pressure (lift 0.05) NV 23.0 to 23.5 MPa {235 to 240 kgf/cm 2}

(b) Install the prelift shim selected in Item (2) between the spacer and 2nd push rod. (c) Install the 2nd push rod and 2nd spring and tighten the set screw, lock nut and adjusting screw as an assembly to specified torque. (d) Check again that the needle valve full lift dimen sion "S" with the Dial Gauge by the procedures described in Item (4).

NV .. Nominal Value

O7035A

(6) Checking prelift Check the prelift based on dimension "L" measured in Item (4) and dimension "S" measured in Item (5). L-S=b.e where

e - 0.02 mm � b. e � e + 0.02 mm b. e: Prelift (measured) e: Prelift (0.1 mm)

L: Needle valve full lift dimension (measured) S: Needle valve lift dimension (measured) with prelift subtracted

(a) After checking the prelift in Item (6), increase the pressure again to about 34.3 to 44.1 MPa {350 to 450 kgf/cm 2} so that the needle valve of the nozzle is fully lifted.

NOTE: Retaining Nut for Adjustment (special tool) must have a bolt fitted at its tip.

t' =t + (f - b. f)

(b) When the nozzle tester lever operation is stopped with the nozzle needle valve fully lifted, the pres sure will start to drop and the needle valve will go down. (c) At the moment the nozzle lift has dropped to 0.05 mm, read the pressure gauge indication. (d) If the 2nd valve opening pressure ("open" pres sure) is out of specification, adjust it in accordance with item (3).

T=t' ± 0.015 mm

NOTE:

where t: Thickness of existing shim t': Shim thickness T: Thickness of shim to actually replace exist ing shim f: Prelift (0.1 mm)

Adjust without installing prelift shim.

If b. is outside of specified dimension ± 0.02 mm, replace the prelift adjusting shim as described in (5) and repeat steps (4) and (5) so that b. e will fall within f ± 0.02 mm. Select thickness t' of shim to be used as follows.

(e) Remove special tools. (8) Inspection (a) lighten the retaining nut and cap nut to specified torque.

NOTE: 1. 2.

13A-44

Make sure that the knock pin has seated com pletely before tightening the retaining nut. Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE (b) Spray condition 1

Good

Poor I

Evenly sprayed from five injection orifices Even and symmetrical

Poor

�

Good 1

Poor

( �

Poor

�

Poor 3 4 5 6

Asymmetrical Branched Thin Irregular

O7009A

When adjusting the pressure with a nozzle tester, check also for clogged injection orifices, spray condition, and fuel leaks from the orifices. Replace the nozzle if defec tive. (c) Fuel tightness test

Test pressure

15.7 MPa {160 kgf/cm2}

O7010A

Install a nozzle that has been adjusted to specified injection start pressure to the nozzle tester. Slowly increase the pressure to the test pressure and keeping this condition, check for fuel leaks from the bottom of the nozzle. The nozzle is functioning normally if there is no leak.

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

13A-45

5.5.5

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Reassembly and adjustment <KBL2.4 injection nozzle>

The adjustment should be performed during reasÂ sembly as described below. The prelift should be adjusted in 1/100 mm unit. Therefore the parts must be Tool name and shape

cleaned with the clear cleaning fluid to remove dust and foreign materials completely. For the adjustment, following special tools are required. Application

Part No. (Zexel product No.)

Adjusting Device

157892-4920

*1 Adjusting Device

157892-4420

*2 Holder

157892-4400

*2 Nut

157892-1000

*1 Dial Gauge

157954-3800

Securing Dial Gauge

*1 Pin

157892-4700

*1 Retaining Nut for Adjustment

157892-4020

*3 Retaining Nut for Adjustment

157892-4000

*3 Gasket

026508-1140

*3 Plug

157892-1600

*1 Gasket

157892-1500

Plate

157944-9520

Securing nozzle holder

Special Wrench (SW19)

157914-2800

Removal and installation of retaining nut

Special Wrench (SW22)

157914-0500

Removal and installation of Retaining Nut for Adjustment

Items marked "*1" are parts of Adjusting Device 157892-4920. Items marked "*2" are parts of Adjusting Device 157892-4420. Items marked "*3" are parts of Retaining Nut for Adjustment 157892-4020.

13A-46

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE Reassembly and Adjustment Procedure

(1) Reassembly

29to 39 N-m {3 to 4 kgf-m}

17 16

Nozzle holder_

Plate / 157944-9520

15 14

11 9

13 01895

1,....-.;---12 H---r---10

(a) Secure the Plate (special tool) in a vise, then mount the nozzle holder on the Plate. Carry out reasÂ sembly in the opposite of the disassembly sequence.

8 6

3 Gasket 157892-1500

1 59to 78 N-m {6 to 8 kgf-m} For reassembly, reverse the order of disassembly. NOTE: Do not touch the needle valve's sliding surfaces.

__ Special ,__ Wrench 157914-0500

11937

During reassembly, make adjustments and checks in the following sequence: (1) Adjust the No. 1 valve's opening pressure (2) Check the needle valve's total lift (3) Check the prelift amount

01896

(b) Fit the Gasket (special tool) onto the nozzle. Then, secure the nozzle on the nozzle holder using the Retaining Nut for Adjustment (special tool). Turn the Retaining Nut for Adjustment as far as possible by hand, then tighten it to the specified torque using the Special Wrench (special tool).

(4) Check the No. 2 valve's opening pressure (5) Adjust the No. 2 valve's opening pressure (6) Replace the retaining nut j (7) Make an overall inspection 13A-47

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

(2) Adjusting No. 1 valve opening pressure

Plate 157944-9520 //

Injection nozzle assembly Injection pressure <All except 6D24-TL> NV 17.7 MPa {180 kgf/cm2} <6D24-TL> NV 15.7 MPa {160 kgf/cm2}

.. Nominal Value

15263 15262

(a) Fit the injection nozzle assembly onto the tester and measure the valve opening pressure.

(b) Mount the injection nozzle assembly upside-down on the Plate (special tool). Then, fit the Holder and Nut (special tools).

NOTE: Do not touch the spray that comes out of the nozzle.

(b) If the spray pressure is out of specification, adjust it using No. 1 valve opening pressure adjustment shim. (This shim has an outside diameter of 8.9 mm.) A 0.02 m m change in shim thickness causes a 235 kPa {2.4 kgf/cm 2} change in valve opening presÂ sure. Shim thickness: 0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70 (3) Checking needle valve total lift

Dial Gauge 1579543800

Pin 1578924700

Nut 157892-1000 Holder 157892-4400

Spring seat

15264

(a) Fit the Gasket and Plug (special tools) onto the Retaining Nut for Adjustment (special tool).

13A-48

(c) Fit the Pin (special tool) into the Dial Gauge (special tool). (d) Fit the Dial Gauge (special tool) onto the injection nozzle assembly and secure it with the Nut (special tool) such that the Pin (special tool) is touching the top surface of the No. 1 spring seat.

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE NOTE: 1. Secure the Dial Gauge such that a stroke of approximately 1.2 mm can be measured. 2. Do not overtighten the Nut. If the Nut is too tight, the Dial Gauge shaft will stick in one position.

(4) Checking prelift

E E

!t "' >

� -0 (1) Q)

Retaining Nut for Adjustment 157892-4000

"�" -�

Pressure gauge

Pipe pressure (MPa {kgf/cm2}) 01903

Plug 157892-1600

15265

(e) Fit the injection nozzle assembly onto the Nozzle Tester, then zero the Dial Gauge. Loosen the Plug (special tool) and operate the Nozzle Tester. Bleed the Retaining Nut for Adjust ment, and check for fuel leaks at the same time. After fully bleeding the Retaining Nut for Adjust ment, securely tighten the Plug.

(a) Once the needle valve is in its fully lifted position, the pipe pressure will start to drop if the Nozzle Tes ter handle is not moved. The needle valve lift mea surement (as shown by the Dial Gauge) will drop concomitantly. In the graph, A: Needle valve total lift amount

No_ 2 spring

E E

:lE �

NV 0.07

0.02

l'l=!::::�l,__l!::;i�:::::(I

Needle valve

NV .. Nominal Value

iii >

Q) -0 Q) Q)

:lE 34.3 to 44.1 {350 to 450}

Pipe pressure (MPa {kgf/cm }) 2

01902

(f) Operate the Nozzle Tester. When the pipe pressure is raised to 34.3 to 44.1 MPa {350 to 450 kgf/cm2}, the needle valve should lift completely. When this happens, make a note of the total lift measure ment. In the graph, A: Needle valve total lift amount C: No. 1 valve opening pressure NOTE: This check is necessary to check for abnormal wear on the nozzle seat.

> >

� Q) Q)

---

C Pipe pressure (MPa {kgf/cm2}) 01904

(b) Read the Dial Gauge indication when the No. 2 spring stops acting and the needle valve stops dropping. T his point is labeled "F" in the above graph. Confirm that the reading conforms with the specified nominal value. 13A-49

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

T he prelift measurement point (labeled "G" in the graph) corresponds to C + approx. 980 kPa {10 kgf/ cm2}, where "C" is the No. 1 valve opening pres sure. In the graph,

E E Q) >

F+0.05

iij

A: Needle valve total lift amount C: No. 1 spring opening pressure F: Prelift G: Prelift measurement point

� a,

F i------,�-

34.3 to 44.1 {350 to 450}

Pipe pressure (MPa {kgf/cm2})

F+0.05

Needle valve

r----- Capsule

Nozzle

�---

01905

(c) If the prelift measurement is out of specification, replace the pin, lift-piece, spacer, nozzle, and needle valve with the Nozzle Service Kit. (5) Checking No. 2 valve opening pressure

Dial Gauge

Pressure gauge 01907

(b) Read the pressure gauge indi(?ation at the instant when the Dial Gauge indicates the specified nomi nal needle valve lift (normally prelift F + 0.05 mm). In the graph, A: Needle valve total lift amount C: No. 1 valve opening pressure F: Prelift J: No. 2 valve opening pressure (6) Adjusting No. 2 valve opening pressure

No. 2 valve opening pressure

NV .. Nominal Value

Shim--tfl J 15266

(a) After checking the prelift, operate the Nozzle Tester and raise the pipe pressure to 34.3 to 44.1 MPa {350 to 450 kgf/cm2} such that the needle valve lifts fully. If the Nozzle Tester handle is not moved, the pipe pressure will drop. T he needle valve lift measure ment (shown by the Dial Gauge) will drop concom itantly.

13A-50

01908

If the No. 2 valve opening pressure is out of specifica tion, disassemble the nozzle mounting side of the injection nozzle assembly and change the No. 2 valve

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE opening pressure adjustment shim. (This shim has an outside diameter of 9.9 mm.) Shims are available in the following thicknesses: 0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, and 0.70 mm. A 0.02 mm change in shim thickness causes a change in valve opening pressure of 196 kPa {2 kgf/cm2}.

(8) Inspection

NOTE: 1. 2.

Do not touch the spray that comes out of the nozzle. Changing the No. 1 valve opening pressure causes the No. 2 valve opening pressure to also change.

(7) Replacing retaining nut 15268 59to 78 N-m {6 to 8 kgf-m}

Fit the injection nozzle assembly onto the Nozzle Tes ter. Check the No. 1 valve opening pressure, the spray shape, and the oil-tightness of the seat. Check also that there are no leaks. NOTE:

- Retaining Nut for Adjust ment

If the No. 1 valve opening pressure does not con form to its specified nominal value, go through the adjustment procedure again from step (1). Do not touch the spray that comes out of the nozzle.

15267

Remove the Dial Gauge, Pin, Nut, and Holder. T hen, take off the Plug, the Gasket, and the Retaining Nut for Adjustment and its Gasket. Fit the regular retaining nut and tighten it to the specified torque using the Special Wrench (special tool). Special tools: 1. Special Wrench 2. Gasket 3. Retaining Nut for Adjustment 4. Gasket 5. Plug 6. Holder 7. Nut 8. Pin 9. Dial Gauge

(157914-0500) (157892-1500) (157892-4000) (026508-1140) (157892-1600) (157892-4400) ( 157892-1000) (157892-4700) (157954-3800)

13A-51

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE 5.6 Fuel Filter <6D24, T, TC>

7.8 to 12 N-m {0.8 to 1.2 kgf-m}

�

i®

1§1(@)

25 N-m {2.5 kgf,m} 2 Cracks, threaded portion ()

Filter Wrench MH061572

Apply thin coat of engine oil when mounting.

43766

'-' I

43336

®28756

Cracks, threaded portion

7.Bto 12 N-m {0.8 to 1.2 kgf-m}

The element can be removed easily using the Filter Wrench (special tool).

{2.5 kgf-m}

43337

1 Fuel filter element 2 Fuel filter head

13A-52

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

<6D24-TL> 25 to 35 N-m {2.5 to 3.5 kgf,m} � 9.Sto 2 N-m {1.0 to 0.2 kgf-m}

2 Cracks, threaded portion

�

1 Fuel filter element 2 Fuel filter head

Apply thin coat of engine oil when mounting.

®43333

NOTE: 1. 2.

3. 4.

When removing the element, check for the gasket left behind on the head side. To mount, apply a thin coat of engine oil to the gas ket, and then secure the element by tightening 3/4 to 1 turn after the gasket comes in contact with the fuel filter head. After installation, bleed the fuel system. After bleeding the air, start the engine and check for fuel leaks.

13A-53

5.7

FUEL AND ENGINE CONTROL - SERVICE PROCEDURE

Water Separator

10 � 25N-m {2.5 kgf-m}

@ G-- 11

7.8 to 12 N-m {0.8 to 1.2 kgf-m}

�=w>�� 8�·

6 --&----ii

:� 9

�

� 10 25N-m {2.5 kgf-m}

2-<S

1�

1--43745

43744

1 Drain plug 2 0-ring 3 Ring nut 4 Case 5 0-ring 6 Baffle plate

®43369

7 Isolation plate 8 Screen assembly 9 Water level ring 10 Eyebolt 11 Air plug 12 Cover If the red water level ring in the translucent case rises to the level of the red line marked on the outer circumfer ence of the case, immediately loosen the drain plug to discharge water. It is not necessary to completely remove the drain plug, as water is discharged gradually through the groove of the loosened plug.

Red line Water level ring

NOTE: After draining, tighten firmly the drain plug before

Drain plug

bleeding the fuel system. 09278

13A-54

FUEL AND ENGINE CONTROL - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Engine will not start

Probable cause Defective feed pump • Loaded gauze filter

Replace

• Seized or worn piston

Replace

• Seized push rod

Replace

• Worn tappet

Replace

• Incorrect installation (incorrect adjustment of injection timing) • Malfunctioning overflow valve Defective injection nozzle • Seized needle valve

Adjust Replace Replace Adjust

• Clogged injection orifice

Clean

Fuel tank empty Clogged fuel pipe or fuel leaks from connection Air or water trapped in fuel system

Correct or replace Supply fuel Correct or replace Bleed or replace

Loaded fuel filter

Replace

Open circuit, short circuit, or poor connection in engine speed sensor or backup engine speed sensor

Replace

Defective main relay or blown fuse

Replace

Clogged fuel filter Air or water trapped in fuel system Defective feed pump Defective injection pump operation • Defective pump

Engine knocks

Replace

• Valve opening pressure too low

• Nozzle not air-tight

Correct or replace Bleed or replace Check Replace

• Defective governor

Replace

• Clogged gauze filter

Clean

Injection timing too advanced

Adjust

Defective injection nozzle • Valve opening pressure too high

Adjust

• Clogged injection orifice • Nozzle not air-tight

Ref. group

Clean

• Check valve inoperative

Defective injection pump • Defective pump

Engine starts but soon stops

Remedy

Clean Correct or replace

Low quality fuel in use

Replace

Defective injection pump operation • Defective pump

Replace

• Defective governor

Replace

• Defective prestroke actuator

Replace

Poor connection in injection quantity adjusting resistor

Replace

Poor contact in idle speed adjustment variable resistor

Replace

13A-55

FUEL AND ENGINE CONTROL - TROUBLESHOOTING Probable cause

Symptom

Smoky engine exhaust and knocking

Defective injection pump • Incorrect injection timing • Worn plunger • Defective valve seat

Replace

Low quality fuel in use

Replace

Defective injection nozzle • Valve opening pressure too low

Adjust

• Clogged injection orifice Defective injection pump operation • Defective pump • Incorrect installation (incorrect adjustment of injection timing)

Replace Adjust

• Defective governor

Replace Replace

• Broken spring

Replace

• Incorrect valve opening pressure

Adjust

• Worn piston Air or water trapped in fuel system Loaded fuel filter Defective injection nozzle • Defective main body • Broken spring • Clogged injection orifice Defective injection pump operation • Defective main body

Replace Replace Bleed or replace Replace Correct or replace Replace Clean Replace

• Incorrect installation (incorrect adjustment of injection timing)

Adjust

• Defective prestroke actuator

Replace

• Defective governor

Replace

• Overflow valve malfunctioning

Replace

Accelerator pedal stopper bolt poorly adjusted

Adjust

Poor quality fuel in use

Replace

Defective injection nozzle • Clogged injection orifice • Nozzle not air-tight • Valve opening pressure too low Defective injection pump operation • Defective pump • Defective governor Accelerator pedal stopper bolt poorly adjusted

13A-56

Clean

Replace

Defective feed pump • Check valve not functioning properly

Engine not reaching max. speed

Replace

• Defective prestroke actuator

Defective injection nozzle • Poor sliding of needle valve

Insufficient engine output

Adjust Replace

• Broken spring

Unstable engine output

Remedy

Clean Correct or replace Adjust Replace Replace Adjust

Ref. group

FUEL AND ENGINE CONTROL - TROUBLESHOOTING Probable cause

Symptom Engine max. speed too high

Defective injection pump operation • Defective pump

Unstable engine idling

Defective injection pump operation

• Defective governor

• Incorrect installation (incorrect adjustment of injection timing)

Adjust

• Overflow valve malfunctioning

Replace

• Defective prestroke actuator

Replace

• Defective governor

Replace Bleed or replace

Poor-quality fuel in use

Replace

Defective feed pump • Defective check valve

Replace

• Loaded gauze filter Loaded fuel filter Defective injection nozzle • Clogged injection orifice

Fuel supply failure

Correct Replace

• Worn piston

Ref. group

Replace

• Defective pump

• Air or water trapped in fuel system

Engine cannot be stopped

Remedy

Replace Clean Replace Clean

• Deteriorated spring

Replace

• Nozzle not air-tight

Correct or replace

Broken or stretched engine stop cable

Replace

Poorly adjusted engine stop cable

Adjust

Damaged governor stop mechanism

Replace

Defective injection pump

Replace

Cracked fuel hose, pipe

Replace

Leaky fuel tank

Replace

13A-57

ELECTRONICALLV CONTROLLED FUEL SYSTEM CONTENTS

1. GENERA L ....................... . ............. 2 1.1 Principle of operation ...................... 2 1.2 Electronic Governor ....................... 3 Electronic Timer ............................ 4 1.3 Timer Control Valve . ....................... 5 1.4 1.5 Electronic Control System ........... ...... 6 1.6 ECU Terminal Configuration .............. 10 2. SPECIFICATIONS ............................ 1 4 3. T ROUBLESHOOTING ................... ..... 15 3.1 Inspection Procedures . ................... 15 3.1.1 Diagnostic function .................... 15 3.1.2 Inspection flowchart ................... 16 3.2 Connection of Multi-Use Tester II ........ 1 7 3.2.1 Special tools .......................... . 1 7 3.3 Reading and Elasing Diagnostic Trouble Codes ................ 19

Causes of Diagnostic Trouble Code Issue, and Inspection Items ...... ............... Diagnostic trouble codes ............. . 3.4.1 Diagnostic trouble code issue 3.4.2 conditions, and check items ........... Multi-Use Tester II Service Data ......... . 3.5 3.6 A ctuator Tests Using Multi-Use Tester II ................................... . lnspec-tion Using ECU Connector ....... . 3.7 3.7.1 ECU terminal configuration ........... . Inspection instructions ................ 3.7.2 3.8 Checks on Transient Troubles ........... . 4. INSPECTION OF ELECTRICï¿½L EQUIPMENT ..... ........ . ........... . ....... 3.4

21 21 21

28 271

29 29 29 31

13E-1

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1. GENERAL

With the electronically controlled injection pump sys tem, electronic control is applied to the governor and timer (the components of the injection pump assem bly) to realize the optimum fuel injection timing and fuel injection rate.

The electronic governor ECU optimally controls the governor and timer in accordance with data signals from sensors mounted on the engine and other parts of the vehicle.

1.1 Principle of operation

1 2 3 4

.____,I: : --- : �:

Fuel supply line Fuel return line Electric line Hydraulic fine

RED-4 internal circuit Control rack position sensor Control rack Engine speed sensor 2 5 Electronic timer 6 Engine speed sensor 1 7 Engine ECU

8 Timer control valve 9 Injection nozzle 10 Combustion chamber 11 Fuel tank 12 Feed pump 13 Control sleeve

The extent of operation of the linear motor 17 and timer control valve 8 are determined by signals from the engine ECU 7. The linear motor 17 moves the control rack 3, thereby changing the fuel injection quantity. The timer control valve 8 controls the hydraulic pres sure applied to the electronic timer 5, thus adjusting the fuel injection timing. The RED-4 internal circuit 1 is incorporated into the electronic governor actuator 18. It contains a control 13E-2

14 Plunger 15 Camshaft 16 Injection pump

17 Linear DC motor 18 Electronic governor actuator 19 Fuel filter ®43638

rack position sensor processing circuit and a linear DC motor drive circuit, which are conventionally incorpo rated into the engine ECU. This arrangement elimi nates noise in the harness and thus prevents erro neous ECU operation. More accurate electronic control is possible as a result. The engine speed is sensed by engine speed sensor 1 6 and engine speed sensor 2 4. Each of these sensors acts as a backup if the other fails.

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.2 Electronic Governor

1 Cover

2 3 4 5 6 7 8 9

RED-4 internal circuit Control rack position sensor Housing Sensing gear Emergency engine stop lever Link Coil assembly Linear DC motor ®38928

(2) Control rack position sensor . The control rack position sensor 3 senses whether the control rack A is moved to the correct position by the linear DC motor 9. In the event of a discrepancy between the actual control rack position and the target control rack position (this is determined by the engine ECU and RED-4 internal circuit 2), the engine ECU causes the linear DC motor 9 to perform a corrective movement.

24952

(1) Linear DC motor The linear DC motor 9 moves the coil assembly 8 verti cally in accordance with signals from the engine ECU and RED-4 internal circuit. Via the link 7, this movement is transmitted to the control rack A, which moves longi tudinally to increase and decrease the fuel quantity.

(3) Emergency engine stop lever The emergency engine stop lever 6 is connected to the link 7. Via a wire, it enables the link to be moved from the driver's seat. In the event of a system fault that pre vents the engine from being stopped normally, opera tion of the emergency engine stop lever forces the con trol rack A to move to the position at which fuel injec tion is terminated. This operation takes place irrespec tive of the position of the linear DC motor 9.

13E-3

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1.3 Electronic 1imer 1 15

�1 a

11-

L,.-

J 7

6 4

1 Cover Engine speed sensor 2 liming sensor Cap Disc Disc 7 Flange 8 Large eccentric cam 9 Small eccentric cam 10 Plate 11 Spring seat 12 Timer spring 13 Pilot pin 14 Cylinder 15 Piston 24960

The electronic timer uses an eccentric cam arrange ment to adjust the injection timing. The eccentric cams 8, 9 in the electronic timer are moved by hydraulic pres sure supplied from the timer control valve assembly.

02720

02721

13E-4

(1) The timer incorporates four pistons 15, which are activated by hydraulic pressure A. The pistons are arranged as two pairs, and each piston slides vertically in a cylinder 14. (2) Each pair of pistons 15 is linked to a plate 10. The two plates are pressed against each other by the timer springs 12. (3) When hydraulic pressure A acts upon the pistons 15, the pistons move toward the outside of the timer flange 7. (4) As the pistons 15 move outward, the plates 10 (thus far pressed together by the timer springs 12) also move outward. (5) The eccentric cams 8, 9 move in conjunction with the plates 10, thereby altering the fuel injection timing.

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.4 limer Control Valve

1 2 3 4 5 6 7

Seat Valve Plunger Spring Coil Pump-side solenoid valve Release-side solenoid valve

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

24961

The timer control valve controls the hydraulic pressure (engine oil) that activates the electronic timer assemÂ bly. Internal oil passages emerge at port P (where engine oil enters the assembly), port A (which supplies engine oil to the timer), and port R (which returns engine oil to the oil pan). The oil passages are interrupted by two solenoid valves 6, 7, one on the pump side and the other on the release side. The solenoid valves control the hydraulic pressure reaching the timer. Each solenoid valve incorÂ porates a plunger 3 and coil 5. When the solenoid valve is activated, the coil 5 attracts the plunger 3, which moves the valve 2 away from the seat 1, thereby openÂ ing the oil passage. Opening and closing timing of the solenoid valves is controlled by the electronic timer control unit.

(1) Advancement of fuel injection timing

7 24963

The pump-side solenoid valve 6 is activated. The release-side solenoid valve 7 is not activated. With the solenoid valves in these conditions, ports P and A are connected, allowing the supply of hydraulic pressure to the timer. Thus, the fuel injection timing is advanced.

13E-5

ELECTRONICALLV CONTROLLED FUEL SYSTEM - GENERAL

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

(3) Retardation of fuel injection timing

6 6 7 24964

The pump-side solenoid valve 6 is not activated. The release-side solenoid valve 7 is not activated. With the solenoid valves in these conditions, the ports are isolated from each other. Thus, the hydraulic pres sure in the timer stays constant and the timer remains in its current condition.

24965

The pump-side solenoid valve 6 is not activated. The release-side solenoid valve 7 is activated. With the solenoid valves in these conditions, ports A and R are connected, allowing oil in the timer to return to the oil pan. Thus, the fuel injection timing is retarded.

1.5 Electronic Control System (1) System block diagram Input signals

Control rack position signal 1

�

RED-4 internal circuit (incorporated into electronic governor)

Engine ECU Engine speed signal 2 Engine start signal 3 Coolant temperature signal 4 Accelerator pedal position signal 5 Fault diagnosis signal 6 Fuel injection quantity signal 7 Boost pressure signal 8

Linear DC motor drive 9

]

Fuel injection quantity control j Fuel injection timing control Preheat control

Timer control valve drive 10 Warning lamp Heater relay Preheat lamp

Fault diagnosis function

13E-6

-1I,

Output signals

Tachometer output

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

Signal

Part

Control rack position signal

Engine speed signal

Engine start signal

---

Coolant temperature signal

Accelerator pedal position signal

Fault diagnosis signal

Fuel injection quantity signal

Boost pressure signal

Sensing of control rack position

.• Sensing of engine speed Use of two sensors allows for backup if one sensor fails. --·-·Recognition of engine startup with starter Starter switch switch in START position ---·- - --· -·-- ---- ----· ----------·--· -·-··-·----·· ·--Sensing of coolant temperature Coolant temperature sensor ------ -- -- . Sensing of extent of depression of accelerator Accelerator pedal position sensor pedal ---· ---····- .. - . . . . Detection o f pedal depressed/released condiAccelerator pedal switch tion (ON with pedal released) ·-·· · -... .. -------··········-·-·--· Callup of diagnosis codes Diagnosis switch -·-----·----- --------- - ·- -- . ----- .. --·· - -----··· - -- . . ..• - - Deletion of diagnosis codes; callup of past Memory clear switch diagnosis codes Engine speed sensors 1, 2

Control rack position sensor

Main function/operation

Fuel injection quantity adjusting resis- Correction of fuel injection quantity tor - -------· ··--·Detection of boost pressure Boost pressure sensor ---- ----· Moving of control rack Linear DC motor Timer control valve

Control of hydraulic pressure applied to electronic timer

Injection quantity adjusting resistor

A A: Resistor No.

02734

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

13E-7

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

(2) Control of fuel injection quantity

Control rack position sensor

• • • • •

Engine ECU

I I I I I

Engine speed sensor 1 Engine speed sensor 2 I Coolant temperature sensor Accelerator pedal position sensor Fuel injection quantity adjusting resistor

RED-4 internal circuit -

I I

Target rack position Idling characteristics

�

Linear DC motor

Running characteristics

I I

Full rack characteristics Starting characteristics

(a) Control effected by engine ECU and RED-4 internal circuit

(b) Feedback control effected using control rack position sensor

The RED-4 internal circuit processes control rack posi tion signals and transmits the results to the engine ECU. The engine ECU effects control during engine opera tion using the stored idling characteristics or running characteristics, and it determines the target control rack position in accordance with signals issued by the RED-4 internal circuit. The control rack position signal issued by the engine ECU is returned to the RED-4 internal circuit. Via the servo circuit and drive circuit, it causes activation of the linear DC motor such that the control rack is moved.

The control rack position sensor enables the RED-4 internal circuit to calculate whether the linear DC motor has moved the control rack to the target position. This arrangement enables the RED-4'to ensure that the con trol rack position always corresponds to the target val ue. The engine ECU receives signals indicating the control rack's actual position from the RED-4 internal circuit and uses them to evaluate control rack position errors.

(3) Control of fuel injection timing Control rack position sensor Engine ECU

• • • •

Engine speed sensor 1 i----Engine speed sensor 2 Coolant temperature sensor Accelerator pedal position sensor

13E-8

I I

RED-4 internal circuit

Load timer characteristics Cold idling characteristics

I I

Timer control valve

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL (a) The engine ECU controls the fuel injection timing by controlling the activation of the timer control valve, which applies hydraulic pressure to the elec tronic timer. (b) The engine ECU controls the timer control valve by determining the target and actual advance angles, comparing them with each other and with charac teristics stored in its memory, and issuing drive signals to the timer control valve in accordance with the results. 1) Target advance angle: calculated by comparison of data signals from sensors with characteristics stored in engine ECU's memory 2) Actual advance angle: determined in accordance with signals from engine speed sensor 1 and engine speed sensor 2. (c) When the engine is cold, startability and post-start warmup are optimized by the use of cold idling characteristics in determination of the fuel injec tion timing.

(4) Preheat control Preheat control improves startability engine's coolant temperature is low.

when the

(a) Operating modes 1)

Engine coolant temperature higher than 0°C

Starter switch

STAR ON � OFF

Preheat lamp

OFF----------

Running Not running ______.

Engine

ON OFF----------

Heater relay

®43717

No preheating is necessary at the time of engine startup, so the heater relay is kept OFF. 2)

Engine coolant temperature 0°C or lower

�rl�----

Starter switch

S T ART ,.___ ON OFF_j

Preheat lamp

g�F_j

Engine

Running Not running _____

Heater relay

g�F _j

I 7� ----.L

--------1 Preheat

Afterheat

®43718

"ts" seconds after the starter switch is turned ON, the heater relay is turned ON, causing preheating to begin. The preheat lamp illuminates simultaneously. When preheating finishes, the preheat lamp goes off to indicate that the engine can be started. The heater relay remains ON until the engine is started. When the engine is started, the engine ECU determines whether afterheating is necessary in accordance with the engine coolant temperature. If the engine ECU determines that afterheating is not necessary, preheat control is terminated. If it deems that afterheating is necessary, the heater relay remains ON for a certain period after engine startup to cause afterheating. 13E-9

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL 1.6 ECU Terminal Configuration

A:CW32A

B:CW25A

C: CW31A

D: CW16A

Â®43639

A: CW32A Terminal No.

ltem(s) to which terminal is connected

1 2 3

RED-4 ECU (PULL DOWN)

Terminal No.

ltem(s) to which terminal is connected

17 18

Boost pressure sensor (SIG)

Engine speed sensor 2 (GND), RED-4 ECU (SIGNAL GND-2)

Engine speed sensor 1 (GND)

Boost pressure sensor (+5V)

Engine speed sensor 2 (SIG)

Engine speed sensor 1 (SIG)

11 12 13

14 15 16

13E-10

Heater relay

RED-4 ECU (LIMP HOME)

26 27 28 29

Boost pressure sensor (GND)

Coolant temperature sensor (GND)

Timer control valve (ADV)

Timer control valve (RTD)

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

8: CW25A Terminal No.

ltem(s) to which terminal is connected

Terminal No.

ltem(s) to which terminal is connected

Warning lamp (orange)

RED-4 ECU (+5 VCC-2)

Accelerator pedal switch

RED-4 ECU (PWM SOL-2)

RED-4 ECU (V-IST)

Injection quantity adjusting resistor (SIG)

Frame ground (MN POWER GND)

3 5

RED-4 ECU (+5 VCC-1)

RED-4 ECU (PWM SOL-1)

RED-4 ECU (VB2)

RED-4 ECU (VB1)

Accelerator pedal position sensor 2 (SIG)

Shield (SHIELD) of VB-1, VB-2, GND-1, and GND-2

RED-4 ECU (SIGNAL GND-1)

Injection quantity adjusting resistor (GND)

------

MUT-11 connector (K-LINE)

RED-4 ECU (GND-2)

RED-4 ECU (GND-1)

---

C: CW31A Terminal No.

ltem(s) to which terminal is connected

Terminal No. 17

Engine speed output signal (NE OUT SIG)

Starter switch S terminal (STARTER SW S)

ltem(s) to which terminal is connected Accelerator pedal position sensor 1 (SIG)

Diagnosis switch

20 21 22

Battery relay (STARTER SW M-2)

Battery relay (STARTER SW M-1)

Battery ground (CASE GND)

MUT-11 connector (DCT)

26 27

Accelerator pedal position sensor 2 (GND)

Control rack position output signal (RAC OUT SIG)

Accelerator pedal position sensor 1 (GND)

Memory clear switch

11 12

14 15

Coolant temperature sensor (SIG)

Terminal No.

ltem(s) to which terminal is connected

-----30

Preheat lamp (PREHEAT LAMP)

D:CW16A Terminal No.

Engine ECU main power relay (+VB-2)

Engine ECU main power relay (+VB-1)

Warning lamp (red)

DDS-3 connector (DDS3)

Battery ground (GND-2)

Battery ground (GND-1)

Engine ECU main power relay (MAIN RELAY-1)

ltem(s) to which terminal is connected

Engine ECU main power relay (MAIN RELAY-2)

13E-11

ELECTRONICALLY CONTROLLED FUEL S YSTEM - GENERAL

Starter switch �· B 1-t,cc M 81 82 Sl OFF ACC ON START

Engine ECU main power relay

Battery�

.- :I

---

f -, ;

"''It_:" Battery

: ::-,

STARTER SWISI STARTER SWIM)-1 STARTER SWIMl-2 MAIN RELAY-1 MAIN RELAY-2 ECU P OWERl+VBl-1 ECU POWER(+VBl-2

CJ ca C? OB 013 Dl 02

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

-=-

Engine speed sensor 1

Ill

Engine speed sensor 2 (TIMING)

Ill

Battery Frame ground ground

SIG AB GND A2l SIG A? GND AlS I

V 1ST PWM-SOL-1 PWM-SOL-2 PULL DOWN LIMP HOME VB-1 VB-2 I GND-1 GND·2 SHIELD +SV(VCCJ-1 +5V(VCC)·2 '-" "" "" o.-=-1 - l�----S-l_G_N�AL-'GN 1 - SIGNAL GN0-2

....

RED-4 internal circuit

RED-4 ECU

� L_::_-_-_::_-_::_-�-_-u_!_�_=_�_�_'"':_4_,1 -

:::

m-m

Timer control valve (ADV) Timer control valve (RTD)

Coolant temperature sensor

:�

Al4 BB 87 825 824 022 BS 814 823

A31 A32

Ill

Injection quantity adjusting resistor

816 BS

SIG GNO

B13

SIG C15 GND AJO

Ill l:r---w-----==-i Ill

Boost pressure sensor

Ill

-��-

=l;---:i:

+SV A6 SIG A18 GND A29

::: .:::

Warning lamp (red) Warning lamp (orange) Memory clear switch L--------fli.--5-llll-------w w Diagnosis switch

03 B1 C29 C19

DATA DDS-3 connector oos-31-----m---------'='-' 05

K·Line

B20 w--------:..::. OCT C10

MUT-11 connector IL1M_u_-r 21 1 ___Ill

Rack position output signal +------------ C12 Engine speed output signal ..-�------------i C2 '----

®45865-1

13E-12

ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

En ine ECU

Preheat lamp "Tn..;----_.

�+

A111--------'-''

Heater relay

�

Heater relay Air heater

SIG Cl7 GND C28

r------

89 SIG GND C27

Accelerator pedal position sensor 2

o-,

B21----------'-o Depressed: OPEN, l Released: GND :, _____ _� _

CASEGND

Accelerator pedal position sensor 1

Accelerator pedal switch

®45865-2

13E-13

ELECTRONICALLY CONTROLLED FUEL SYSTEM - SPECIFICATIONS 2. SPECIFICATIONS Item Injection pump assembly

Specification BOSCH AUTOMOTIVE SYSTEMS

Manufacturer

Electronically controlled in-line pump

Model

NP-PE6P120

Injection pump model

RED-4 (RED-4 with internal circuit)

Governor model Timer model

SPGH KD

Feed pump model Timer control valve

BOSCH AUTOMOTIVE SYSTEMS

Manufacturer V

Rated voltage Pressure range kPa {kgf/cm } ECU

Manufacturer Rated voltage

13E-14

24 49 to 980 {0.5 to 10}

BOSCH AUTOMOTIVE SYSTEMS V

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3. TROUBLESHOOTING 3.1 Inspection Procedures 3.1.1 Diagnostic function Whenever the starting switch is placed at ON, the diag nostic function is activated to check all the sensors, etc. If any of them is found faulty, the warning lamp in the meter cluster is lit to alert the driver. At the same time, the fault location is stored in memory, and the system enters the backup mode. The stored fault location can be read as a diagnostic trouble code by the Multi-Use Tester II or the diagnostic switch. Warning lamp indications Warning lamp Safety-critical error (Vehicle must not be driven) Non-safety-critical error (Vehicle can be driven despite poor control feeling)

Red Orange

NOTE: • Check to ensure that the battery voltage is within the specified range. • Check all the harness and device connectors for looseness. Always remove a connector at least 20 seconds after placing the starting switch at the LOCK position.

• Do not forget to clear the diagnostic trouble code by the Multi-Use Tester II or memory clear switch after a fault has been rectified. • As a rule, inspection operations should be per formed with the starting switch at the LOCK posi tion. Some checks, however, may have to be made with the starting switch at the ON position. In such a case, use care to make sure that no short circuit develops between pins of the connectors or with the body. • The resistance value of each component is affected by the temperature and the accuracy of the tester. The reading, therefore, does not always fall within the standard limits. Note that the check values shown in the text are the values obtained at normal temperature (10 to 35°C). • Whether or not the system automatically returns to normal from the backup mode after a fault has been removed depends on the diagnostic trouble code (fault location). • Even when the fault has been removed and the sys tem has been automatically returned to the normal mode, the diagnostic trouble code of the fault remains stored in the engine control unit. • When a fault occurs at a point where the system is not automatically reset, perform the memory clear procedure to let the system exit from the backup mode. [O P13E-19

13E-15

- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.1.2 Inspection flowchart T he system inspection can be performed effectively by use of the Multi-Use Tester II. The types of system inspections may be broadly divided as shown below in accordance with the trouble symptoms and diagnostic trouble code outputs.

(1) Inspections based on diagnostic trouble codes stored in the engine control unit (2) Inspections of transient troubles

Vehicle brought into workshop

I I

Read diagnostic trouble codes CO P13E-19

No communications can be made with Multi-Use Tester II.

Normal code output

Trouble code output

Normal code output after erasure Check for ' Identify cause for diagnostic transient troubles trouble code issue and recP13E-31 tify P13E-21 \

I â&#x20AC;˘ â&#x20AC;˘

Driving test

If no communications can be made with all the other systems, it is highly likely that the diagnostic circuit is f8'Ulty. If no communications can be made with this system only, an open circuit in the diagnostic output circuit or power supply circuit (including the ground circuit) of this system is suspected.

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

Erace the dianostic trouble codes. ffi P13E-19

13E-16

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.2 Connection of Multi-Use Tester II

3.2.1 Special tools Unit: mm

Unit: mm Tool name

Shape

Tool name

Multi-Use Tester II MB991496 Inspection of system

Shape

Multi-Use Tester II harness MB991499 To use Multi-Use Tester II as a circuit tester

19492 Multi-Use Tester II harness (for communications) MC887252 To supply power to Multi-Use Tester II proper and commu nicate with vehicle side elec trical devices

20536 Battery clamp harness MK320193 Power supply to Multi-Use Tester II in vehicle without cigarette lighter; detection of start signal in vehicle without cigarette lighter

19141

20537

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

� �

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

20538

13E-17

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

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

With cigarette lighter socket Starter switch type A*a

Cigarette lighter socket Battery *a *b

Starter switch type A*b

(2) Power supplied to Multi-Use Tester II from battery

Without cigarette lighter socket

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

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

F ®35849

®41163

(a) Place the starting switch at the LOCK position. (b) Connect the � Multi-Use Tester II harness to� Multi-Use Tester II and insert the � read-only memory in the tester. (c) Connect the connector A to the cigar lighter socket. (d) Connect the Multi-Use Tester II connector C (16 pins) to the data link connector B (16 pins). NOTE: For the operating procedures for the Multi-Use Tester II, refer to the instruction manual for the Multi-Use Tes ter II.

13E-18

(a) Place the starter switch in the LOCK position. (b) Connect the � Multi-Use Tester II harness (for communication) to the� Multi-Use Tester II, then insert the� ROM pack. (c) Connect the EB clamp D (red) of the � battery clamp harness to the EB terminal E of the battery and the 8 clamp F (black) to the 8terminal G of the battery. (d) Fit the connector A into the socket Hof the� bat tery clamp harness. (e) Fit together the Multi-Use Tester II connector B (16 pins) and connector C (16 pins). NOTE: Connect the EB clamp D (red) of the � battery clamp harness before connecting the 8 clamp F (black).

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.3 Reading and Erasing Diagnostic Trouble Codes

(b) Reading diagnostic trouble code

Two types of methods are available for reading or eras ing a diagnostic trouble code; one using the Multi-Use Tester II and one using the vehicle side diagnostic func tions.

10s digit

(1) Method using Multi-Use Tester II OFF

(a) Current diagnostic trouble code 1)

Check to see that the memory clear switch 1 is con nected. 2) Set the starting switch to ON. 3) Operate the Multi-Use Tester II to read the current diagnostic trouble code and determine the fault location.

0.4 0.4

Set the starting switch to ON. Disconnect the memory clear switch 1. Operate the Multi-Use Tester II to read the past reg istered diagnostic trouble codes and determine the fault location.

Set the starting switch to ON. Operate the Multi-Use Tester II to erase all of the diagnostic trouble codes stored in the engine con trol unit.

(2) Method Not Using Multi-Use Tester II (Method Using Diagnostic Switch and Memory Clear Switch) (a) Current diagnostic trouble code 1) Set the starting switch to ON. 2) Disconnect the diagnostic switch 2. 3) T he diagnostic trouble code is displayed by flashes of the warning lamp 3.

0.4

Diagnostic switch disconnected

First diagnostic trouble code displayed (Diagnostic trouble code 12)

2.4

H 2.4

Second ---• diagnostic 1 trouble code displayed 2.8

Ii-----J·

®13705

-----I I nJl

�

1.2

(b) Past diagnostic trouble code 1) 2) 3)

Units digit

�

Diagnostic trouble codes are indicated by the num ber of times the warning lamp 3 flashes and their duration. • T he flashing intervals also differ between the 10s digit and units digit. • 10s digit: 1.2 second interval • Units digit: 0.4 second interval • Each diagnostic trouble code is displayed from the 10s digit followed by the units digit. As for a code which has no 1Os digit, units digit only is displayed. 2) Each diagnostic trouble code is displayed three times in succession. 3) If there is no more code stored, the sequence is then repeated from the beginning with each code indicated three times. 4) When the diagnostic switch 2 is connected, the engine control unit will immediately stop display ing codes.

13E-19

- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING (c) Past diagnostic trouble codes 1) After reading the current diagnostic trouble codes (with the diagnostic switch 2 disconnected), dis connect the memory clear switch 1. Then the O warning lamp 3 will restart flashing. 2) This time, the warning lamp displays the past diag nostic trouble codes. Determine the fault locations based on the indicated codes. (d) Erasing diagnostic trouble codes

◄

A second 3 seconds or more

Connected

J I ,

•

Released .... ___._

•

Memory cleared at this point

®02739

13E-20

Disconnect the memory clear switch 1 and the diag nostic switch 2 then reconnect them. Then all the diag nostic trouble codes stored in the engine control unit will be cleared. NOTE: • If the contents of memory are not to be cleared after display of the stored codes, set the starting switch to OFF with the memory clear switch 1 discon nected. Thereafter, connect the memory clear switch. • When you change the combination of the injection pump and engine control unit, you must rewrite the pump data stored in the engine control unit. For this purpose, be sure to perform the diagnostic trouble code erasing procedure. • Whenever the engine control unit has been replaced with a new one, be sure to erase the diagnostic trouble codes by disconnecting the memory clear switch 1 and diagnostic switch 2 after connecting all the connectors. Upon completing the procedure, confirm that no diagnostic trouble codes is stored.

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.4 Causes of Diagnostic Trouble Code Issue, and Inspection Items

3.4.1 Diagnostic trouble codes Multi-Use Tester II display Diagnostic trouble code

Message

OVER REV.

GOV. SERVO

SUB NE SNSR

NE SNSR

ACCEL. SNSR-2

TCV FEEDBACK

AIR PRES SNSR

WTR TEMP SNSR

RACKSNSR

Page of reference

Ll:i P13E-21

Multi-Use Tester II display Diagnostic trouble code

Message

T CV

ACCEL. SNSR-1

� P13E-22

BST PRES SNSR

ECU SYSTEM

CL P13E-23

Q RESISTOR

ENG.REVERSE

[Cl P13E-24

ACCELSW

HEATER RELAY

Page of reference

!J] P13E-24

2J P13E-25

LiJ P13E-26

3.4.2 Diagnostic trouble code issue conditions, and check items Perform service operations with reference to the diagnostic trouble code issue conditions and probable causes shown below. 07 OVER REV. Code issue condition [Reset condition]

Diagnostic trouble code 07 indicates that the engine speed is too high. [The code is reset when the engine speed returns to a specified range.]

Action taken by ECU

Governor operation is stopped.

Probable cause and check item

Injection pump assembly's control sleeve faulty • Over-revving of engine (for example, on downhill road) • ECU faulty

Inspection of injection pump assembly (Have inspection performed by Bosch Automotive Systems service station.)

11 GOV. SERVO Code issue condition [Reset condition)

Diagnostic trouble code 11 indicates that the difference between the target control rack position and actual control rack position is too large.

Action taken by ECU

Governor operation is stopped.

Probable cause and check item

• Control rack position sensor faulty

[No reset condition)

• ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. (D P13E-27 No. 09: Measurement of target rack position No. 0A: Measurement of actual rack position • Inspection of control rack position sensor (Have inspection performed by Bosch Automotive Systems ser vice station.)

13E-21

- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

14 SUB NE SNSR (injection pump side) Code issue condition [Reset condition]

Diagnostic trouble code 14 indicates that the number of pulses from engine speed sensor 2 (on the injec tion pump) is smaller than the number of pulses from engine speed sensor 1 (on the flywheel housing). [The code is reset when engine speed sensor 1 is normal and the number of pulses from engine speed sensor 2 returns to normal).

Action taken by ECU

• Normal control is effected using only engine speed sensor 1. • If engine speed sensor 1 is also faulty, governor operation is stopped.

Probable cause and check item

• Open circuit or short circuit in harness between ECU and engine speed sensor 2 • Engine speed sensor 2 faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. [D P13E-27 No. 02: Measurement of engine speed • Inspection using ECU connector P13E-29

LL:

m : Measurement of resistance of engine speed sensor 2

• Inspection of engine speed sensor 2 P13E-32: Inspection of Electrical Equipment�

• Check of circuit between ECU and engine speed sensor 2 14 SUB NE SNSR (injection pump side) 15 NE SNSR (flywheel housing side) Code issue condition [Reset condition]

Diagnostic trouble codes 14 and 15 are both issued if engine speed sensor 1 (on the flywheel housing) and engine speed sensor 2 (on the injection pump) fail at the same time. [The code is reset when pulses are applied from engine speed sensor 1 or engine speed sensor 2 following engine startup.]

Action taken by ECU

Fuel injection timing control is stopped, and governor operation is stopped.

Probable cause and check item

• Open circuit or short circuit in harness between ECU and engine speed sensors 1 and 2 • Engine speed sensors 1 and 2 faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. (DP13E-27 No. 02: Measurement of engine speed

• Inspection using ECU connector P13E-29 Measurement of resistance of eng1ne speed sensor 2 C!D : Measurement of resistance of engine speed sensor 1 • Inspection of engine speed sensors 1 and 2 P13E-32: Inspection of Electrical Equipment� • Check of circuit between ECU and engine speed sensors 1 and 2

m: ffi

15 NE SNSR (flywheel housing side) Code issue condition [Reset condition]

Diagnostic trouble code 15 indicates that the number of pulses from engine speed sensor 1 (on the fly wheel housing) is smaller than the number of pulses from engine speed sensor 2 (on the injection pump). [The code is reset when engine speed sensor 2 is normal and the number of pulses from engine speed sensor 1 returns to normal.]

Action taken by ECU

• Normal control is effected using only engine speed sensor 2. • If engine speed sensor 2 is also faulty, governor operation is stopped.

Probable cause and check item

• Open circuit or short circuit in harness between ECU and engine speed sensor 1 • Engine speed sensor 1 faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. QJ P13E-27 No. 02: Measurement of engine speed • Inspection using ECU connector P13E-29

C!D : Measurement of resistance of engine speed sensor 1 • Inspection of engine speed sensor 1 [l} P13E-32 Inspection of Electrical Equipment� • Check of circuit between ECU and engine speed sensor 1

13E-22

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

16 ACCEL. SNSR-2 Code issue condition (Reset condition]

Diagnostic trouble code 16 indicates short or open circuit in accelerator position sensor 2 harness and faulty sensor proper. (If diagnostic trouble code 16 is issued, inspections for diagnostic trouble code 24 must also be performed.) The code is issued when accelerator position sensor 2 voltage is out of specified limits. [When accelerator position sensor 2 voltage is back within specified limits, a reset is made.]

Action taken by ECU

• Normal control is effected using only non-faulty accelerator pedal position sensor 1. • If accelerator pedal position 1 is also faulty, control is effected using assumptions of 100% with the pedal depressed and 0% with the pedal released.

Probable cause and check item

• Open or short circuit in harness between ECU and accelerator position sensor 2 • Accelerator position sensor 2 faulty or poorly adjusted • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. P13E-27

No. 03, 04: Measurement of throttle opening indicated by accelerator pedal position sensor No. 5: Measurement of accelerator pedal position sensor's output voltage • Inspection of accelerator pedal position sensor • Check of circuit between ECU and accelerator pedal position sen sor 2

17 TCV FEEDBACK Code issue condition (Reset condition]

Diagnostic trouble code 11 indicates that the difference between the target and actual timer positions exceeds a specified limit. [After a return to a normal condition, the code is reset when the starter switch is turned from OFF to ON.]

Action taken by ECU

Fuel injection timing control is stopped.

Probable cause and check item

• Timer control valve faulty • Electronic timer faulty • Engine hydraulic system faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. [jJ P13E-27 No. 12: Measurement of timer angle difference • Inspection of timer control valve main body P13E-32: Inspection of Electrical EquipmentE

• Inspection of engine hydraulic system Gr 12 • Inspection of electronic timer (Have inspection performed by Bosch Automotive Systems ser vice station.)

19 AIR PRES SNSR Code issue condition [Reset condition]

Diagnostic trouble code 19 indicates short or open circuit in air pressure sensor harness and faulty air pressure sensor (built in ECU). The code is issued when air pressure sensor voltage is out of specified limits. [When air pressure sensor voltage falls back within specified limits, a reset is made.]

Action taken by ECU

Air pressure is defaulted to 100 kPa {760 mmHg}.

Probable cause and check item

• Air pressure sensor (built in ECU) faulty. • ECU faulty

• Perform checks on the basis of Multi-Use Tester II service data. (D P13E-27 No. 18: Air pressure measurement

13E-23

IBll

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

21 WTR TEMP SNSR Code issue condition [Reset condition)

Diagnostic trouble code 21 indicates open circuit in water temperature sensor harness and faulty sensor proper. The code is issued when water temperature sensor voltage is out of specified limits. [When water temperature sensor voltage falls back within specified limits, a reset is made.)

Action taken by ECU

Controls are continued assuming that coolant temperature is -20°C when engine is started and B0 °C when engine is running.

Probable cause and check item

• Open or short circuit in harness between ECU and water temperature sensor • Water temperature sensor faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. P13E-27 No. 16: Measurement of engine coolant temperature • Inspection using ECU connector CD P13E-29

C.iJ

(1D : Measurement of resistance of coolant temperature sensor • Inspection of coolant temperature sensor

P13E-32: Inspection of Electrical Equipment P.lml • Check of circuit between ECU and coolant temperature sensor 22 RACKSNSR Code issue condition [Reset condition]

Diagnostic trouble code 22 indicates that the control rack position sensor's output voltage is outside speci fied limits. [No reset condition]

Action taken by ECU

Governor is temporarily stopped. (Feedback control is resumed after the engine is restarted.)

Probable cause and check item

• Control rack position sensor faulty • Control rack not moving smoothly • Governor actuator's link faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. (D P13E-27 No. 0A: Measurement of actual rack position • Inspection of control rack position sensor and control rack (Have inspection performed by Bosch Automotive Systems ser vice station.)

23TCV Code issue condition [Reset condition]

Diagnostic trouble code 23 is issued in the following circumstances: The ECU issues a command to turn the timer control valve OFF following a short circuit in the timer control valve. [The code is reset when the timer control valve returns to normal.]

(1)

(2)

The ECU issues a command to turn the timer control valve ON following an open circuit in the timer control valve. [After the open circuit is rectified, the code is reset when the starter switch is turned from OFF to ON.]

Action taken by ECU

Fuel injection timing control is stopped.

Probable cause and check item

• Open circuit or short circuit in harness between ECU and timer control valve • Timer control valve faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. OJ P13E-27 No. 12: Measurement of timer angle difference • Inspection of timer control valve [O P13E-32: Inspection of Electrical Equipment� • Check of circuit between ECU and timer control valve

13E-24

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 24 ACCEL. SNSR-1 Code issue condition [Reset condition]

Diagnostic trouble code 24 indicates short or open circuit in accelerator position sensor 1 harness and faulty sensor proper. (If diagnostic trouble code 24 is issued, inspections for diagnostic trouble code 16 must also be performed.) The code is issued when accelerator position sensor 1 voltage is out of specified limits. [When accelerator position sensor 1 voltage falls back within specified limits, a reset is made.)

·------------+----------------- -------·--·----·--------------

Action taken by ECU

• Normal control is effected using only non-faulty accelerator pedal position sensor 2.

• If accelerator pedal position 2 is also faulty, control is effected using assumptions of 100 % with the pedal depressed and O % with the pedal released. Probable cause and check item

• Open or short circuit in harness between ECU and accel erator position sensor 1

• Perform checks on basis of Multi-Use Tester II service di.tl1J. L J P13E-27 No. 03, 04: Measurement of throttle opening indic1Jtr:d IJy accelerator pedal position sensor

• Accelerator position sensor 1 faulty or poorly adjusted

No. 5: Measurement of accelerator pedal position sensor's output voltage

• ECU faulty

• Inspection of accelerator pedal position sensor • Check of circuit between ECU and accelerator pedal position sen sor 1

32 BST PRES SNSR Code issue condition [Reset condition]

Diagnostic trouble code 32 indicates short or open circuit in boost pressure sensor harness and faulty sen sor proper. The code is issued when boost pressure sensor voltage is out of specified limits. [When boost pressure sensor voltage falls back within specified limits, a reset is made.)

Action taken by ECU

Control is effected with the boost pressure assumed to be fixed at O kPa {O mmHg}.

Probable cause and check item

• Open or short circuit in harness between ECU and boost pressure sensor

• Perform checks on basis of Multi-Use Tester II service data. lJ.J P13E-27 No. 20: Measurement of boost pressure

• Boost pressure sensor faulty

• Inspection of boost pressure sensor main body

• ECU faulty

L(j P13E-32: Inspection of Electrical Equipment Dill • Check of circuit between ECU and boost pressure sensor

33 ECU SYSTEM Code issue condition

Diagnostic trouble code 33 indicates a processing error or memory error in the ECU.

[Reset condition]

[No reset condition]

Action taken by ECU

Governor operation is stopped.

Probable cause and check item

ECU faulty

34 Q RESISTOR Code issue condition [Reset condition]

Diagnostic trouble code 34 indicates short or open circuit in injection quantity adjusting resistor harness and faulty adjusting resistor. The code is issued when injection quantity adjusting resistor voltage is out of specified limits. [When injection quantity adjusting resistor voltage falls back within specified limits, a reset is made.]

Action taken by ECU

Injection quantity correction value is fixed at No. 1 value.

Probable cause and check item

• Open or short circuit in har ness between ECU and injec tion quantity adjusting resistor • Injection quantity adjusting re sistor faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. (D P13E-27 No. 14: Check of resistor number of fuel injection quantity adjusting resistor • Inspection using ECU connector CD P13E-29

Measurement of resistance of fuel injection quantity adjusting resistor

• Inspection of fuel injection quantity adjusting resistor

.:m

W P13E-32: Inspection of Electrical Equipment1:f,.

• Check of circuit between ECU and fuel injection quantity adjusting resistor

13E-25

ELECTRONICALLY CONTROLLED FUEL S YSTEM - TROUBLESHOOTING

45 ENG. REVERSE Code issue condition [Reset condition)

Diagnostic trouble code 45 indicates that an extremely low engine speed (a speed lower than that result ing from cranking with the starter) has been detected with the starter switch in the OFF position. [The code is reset when the engine speed is no longer detected with the starter switch in the OFF position or when the starter switch is turned to the ON position.)

Action taken by ECU

Governor operation is stopped

Probable cause and check item

• Operating error at time of engine startup • Poor matching of connected devices • ECU faulty

65ACCELSW Code issue condition [Reset condition)

Diagnostic trouble code 65 indicates short or open circuit in accelerator pedal switch harness and faulty accelerator switch. The code is issued when accelerator pedal is released (accelerator switch ON) and accelerator pedal open ing signal is input. [When accelerator pedal opening signal returns to normal, a reset is made.)

Action taken by ECU

Normal control is effected.

Probable cause and check item

• Open or short circuit in har ness between ECU and accel erator pedal switch • Accelerator pedal switch faulty • ECU faulty

• Perform checks on basis of Multi-Use Tester II service data. (D P13E-27 No. 03, 04: Measurement of throttle opening indicated by accelerator pedal position sensor No. 69: Check of operation of accelerator pedal switch • Inspection using ECU connector P13E-29

(!D : Check of continuity of accelerator pedal switch • Inspection of accelerator pedal switch • Check of circuit between ECU and acceler,ator pedal switch 78 HEATER RELAY Code issue condition [Reset condition)

Diagnostic trouble code 78 is issued in the following circumstances: The ECU issues a command to turn the heater relay OFF following a short circuit in the heater relay. [The code is reset when the heater relay returns to normal.)

(1) (2)

The ECU issues a command to turn the heater relay ON following an open circuit in the heater relay. [No reset condition]

Action taken by ECU

Preheat control is stopped.

Probable cause and check item

• Open circuit or short circuit in harness between ECU and heater relay • Heater relay faulty • ECU faulty

13E-26

• Perform checks on basis of Multi-Use Tester II service data. QJ P13E-27 No. 92: Check of operation of heater relay

• Actuator test using Multi-Use Tester II Pl 3E-28 No. BC: Check of operation of heater relay • Inspection of heater relay CO Gr 16 • Check of circuit between ECU and heater relay

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING 3.5 Multi-Use Tester II Service Data Multi-Use Tester II display No.

Item BATT VOLTAGE

ENGINE SPEE D

■■.■■v ■■■■.rpm

ACCEL (%)

■■■.■ %

ACCEL (%) REAL

ACCEL (V)

TARGET RACK

REAL RACK

TCV ANG. DIFF.

Q RESISTOR

WATER TEMP

AIR PRESS

BOOST PRESS

DIAGNOSIS SW

■■■.■ % ■.■■■v ■■.■■ mm ■■.■■ mm ■■.■■ °CA ■■.■■ deg

•••••

■■■.■ oc ■••.• OF ■■■■. kPa ■■■■.mmHg ■■■■. kPa ■■■■.mmHg ON/OFF

DIAG LAMP (U)

ON/OFF

DIAG LAMP (R)

ON/OFF

KEY SW

DIAG RESET SW

PULL DOWN

ON/OFF

Normal condition

Condition at time of inspection

Data

Idling

20to 30V

Racing (with engine running)

Same as tachometer indication

Accelerator pedal released

Accelerator pedal gradually depressed

Gradually increases

Accelerator pedal fully depressed

100%

Accelerator pedal released

Accelerator pedal gradually depressed

Gradually increases

Accelerator pedal fully depressed

100 %

Accelerator pedal gradually depressed from released position

Depends on vehicle specifications

Starter switch ON

3mm

Starter switch ON

3mm

Depends on vehicle specifications

Engine cold During engine warmup Engine stopped after warmup Altitude

□m

Same as number marked on fuel injection quantity adjusting resistor Approximately same as ambient temperature Gradually increases Gradually decreases 101kPa

Altitude 600m

95kPa

Altitude 1,200m

88 kPa

Running at high idle speed

Depends on vehicle specifications

Diagnosis switch ON (connected to connector)

Diagnosis switch OFF (disconnected from connector)

OFF

Starter switch in ON position (engine not started)

Starter switch in OFF position

OFF

Starter switch in ON position (engine not started)

Starter switch in OFF position

OFF

Starter switch in ON position

Starter switch in any position except ON

OFF

Memory clear switch ON (connected to connector)

Memory clear switch OFF (disconnected from connector)

OFF

Normal condition

OFF

Abnormal condition (during pulldown control)

13E-27

- ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING Multi-Use Tester II display No.

69 73

Data

I tem ACCELSW STAR T SW

PRE-HEAT LAMP

HEATER RELAY

ON/OFF ON/OFF

ON/OFF

Normal condition

Condition at time of inspection Accelerator pedal depressed

Accelerator pedal released

OFF

E ngine cranked with starter switch in STAR T position

Starter switch in any position except STAR T

OFF

Starter switch ON

Coolant temperature low

Coolant temperature high

OFF

Coolant temperature low

Coolant temperature high

OFF

3.6 Actuator Tests Using Multi-Use Tester II Multi-Use Tester II display Item

No. AC

Method of checking operation

DIAG LAMP (U)

• Create warning lamp illumination conditions. • Perform test with engine speed of zero and vehicle speed of zero. • Cause warning lamp five times to be on for one second then off for one second.

DIAG LAMP (R)

PRE-HEAT LAMP

• Create indicator lamp illumination conditions. • Perform test with engine speed of zero and vehicle speed of zero. • Cause indicator lamp five times to be on for one second then off for one second.

HEATER RELAY

• Create air heater operating conditions. • Perform test with engine speed of zero and vehicle speed of zero. • Cause air heater five times to be on for one second then off for one second.

13E-28

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.7 Inspection Using ECU Connector

These checks allow correct transmission of ECU signals via vehicle harnesses and connectors to be verified. They are intended to assist in troubleshooting. The numbers ( C!D, etc.) in the tables correspond to reference num

bers in section 3.4, "Causes of Diagnostic Trouble Code Issue, and Inspection Items". 3.7.1 ECU terminal configuration

A:CW32A

8: CW25A

C: CW31A

D: CW16A

®43639

No.

(!II

m m m m

Item

Page of reference

Resistance of engine speed sensor 2 Resistance of engine speed sensor 1 Resistance of coolant temperature sensor

lil P13E-30

Resistance of fuel injection quantity adjusting resistor Continuity of accelerator pedal switch

3.7.2 Inspection instructions NOTE: Some inspections are performed with the connector removed, and others are performed with the connec tor fitted. Note the following instructions: • Do not touch any terminal other than the ones spe cified for the inspections. Be particularly careful not to cause short circuits between terminals using the tester probes. • Terminal numbers shown in the tables are the num bers of terminals on the ECU. Be careful not to select the wrong terminals for inspections. 13E-29

11]1 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING Method

Check item (!JI Resistance of engine speed sensor 2

ffl

[Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal condition) Between terminals A 7 and A 19: 2.1 to 2.5 n

Resistance of engine speed sensor 1

[Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal condition) Between terminals A a and A 21: 2.1 to 2.5 kn

Resistance of coolant temperature sensor

(Check conditions] • Starter switch OFF • Connector removed. Check performed on vehicle-side harness. [Normal conditions) Between terminals C 1s and A 30: 2.3 to 2.6 kn (at 20°C) 0.3 to 0.34 kn (at 80°C)

Resistance of fuel injec tion quantity adjusting resistor

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

ffl

13E-30

Continuity of accelera tor pedal switch

Resistance

No.

Resistance

2700

13000

5100

20000

8200

330011

No.

Resistance

15000 o

5&0on

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

ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING •

3.8 Checks on Transient Troubles

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

7""

02598

lI)l I I

02599

A transient trouble often occurs in a specific condition. Therefore, pinpointing the condition will make it easy to estimate the cause. To pinpoint the condition for a transient trouble, ask the customer in detail about the driving condition when the trouble occures, weather, occurrence frequency and symptoms, and reproduce the symptoms of the trouble. Depending on the condition where the trouble occurs, determine whether the cause of the trouble is vibra tion, temperature or any other factor. If the probable cause is vibration, perform the following checks on the relevant connectors harnesses, etc. and check whether the symptoms of the trouble are reproduced.

13E-31

- ELECTRONICAUY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT 4. INSPECTION OF ELECTRICAL EQUIP MENT lmfl Checking Water Temperature Sensor

2.3 ± 0.2 kn

Standard value (at 20° C)

(2) If the reading is out of the standard value range, replace the engine speed sensor. CC Gr 11 NOTE: If the sensor is not tightened sufficiently, it may not issue signals. Make sure the sensor's tightening torque is correct.

<Engine speed sensor 2> [Inspection]

®34629

(1) Put the water temperature sensor in a container filled with engine oil. (2) Heat the engine oil to various specified tempera tures while stirring the engine oil. (3) Measure the resistance value between pins 1 and 2 (body). Standard value

20°c

2.3 to 2.6 kQ

80°C

0.30 to 0.34 kQ

Referance value in parentheses

(4) If the reading is out of the standard value, replace the water temperature sensor.[() Gr 14

l:ml Checking Engine Speed Sensor

24984

(1) Measure the resistance between terminals if_. and l�:. Standard value

2.1 to 2.5 n

(2) Check for continuity between terminals ,J and:'�; between terminals��' and

:a,.

Standard value

Continuity exists

(3) If either result is out of specification, replace the sensor. [Installation]

D 05049

(1) Measure the resistance value between pins 1 and 2.

13E-32

24985

ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT (1) Screw in engine speed sensor 2 A until it touches the protrusion on the timer flange 8. (2) Back off engine speed sensor 2 A by 0.8 to 1.0 turn to create a clearance C (1.2 to 1.5 mm) between the sensor and the protrusion B. (3) Tighten the lock nut D on engine speed sensor 2 A.

Unit:mm Shape

Tool name Inspection Harness MC854336

1JE1 Checking Boost Pressure Sensor <Checking by use of Multi-Use Tester II> CO P13E-27 NOTE: The boost pressure checking conditions differ be tween when the boost pressure is checked by use of the Multi-Use Tester II and when it is checked without use of the Multi-Use Tester II. So the standard values also differ.

8 A

02806

(2) Mount pressure gauge A for measurement of the boost pressure. C: To inlet manifold (3) Set the starting switch to ON. (4) Measure the output voltage of the boost pressure sensor 8 according to the following table. Connector Pin

Item

1 Power(+) Power voltage *Output voltage (Refer to the output characteristics shown at left.)

*·

2GND(-)

3 Output(+)

Start the engine before measurement.

®42415

(1) Disconnect the chassis side harness D and connect the � inspection harness between them.

13E-33

- ELECTRONICALLY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT (1) Remove the connector from the timer control valve then connect a 24V DC power supply A and selector switch B. (2) Slightly loosen the eyebolt D on port C. (3) Run the engine at idling speed. (4) Turn the selector switch B to the port E setting and check that oil leaks from the eyebolt D of port C. (5) Turn the selector switch B to the port F setting and check that oil stops leaking. (6) After confirming that oil stops leaking, tighten the eyebolt D to the specified torque.

Output Characteristics

Temperature 25° C

� Ql

�

4.9 4.5 3.22 1.86 0.5 0 -34.3 33.7 {-255} {250}

98.7 163.7 {740} {1230}

lightening torque

Boost pressure (kPa {mmHg}) 02783

Standard Value

2-3

1-2

0.5V/-34.3 kPa {-255 mmHg} 1.86V/33.7 kPa {250 mmHg} 3.22V/98.7 kPa {740 mmHg} 4.5V/163.7 kPa {1230 mmHg}

(5) If the results of the above mentioned checks show

any deviation from the standard values, replace the boost pressure sensor B.

ml Inspection of timer control valve

C: Engine oil outlet (hydraulic pressure supply to electronic timer) E: Engine oil inlet F: Engine oil return outlet (7) If this inspection reveals any abnormality, replace

the timer control valve. (D Gr 13A <Checking valve resistances> (1) Take resistance measurements between terminals :1 and '3 and between terminals ·4_ and :.i,. Deter mine whether the measurements comply with the standard value.

Standard value

DD Inspection of fuel injection quantity adjusting re

(DC24V)

[iJ

21.9 to 24.1

(2) Make sure that there is not continuity between ter minaIs r3. and ii:; between terminal::) and the body; and between terminal :4. and the body. (3) If these checks reveal any abnormality, replace the timer control valve. CO Gr 13A

(2) @

20 to 25 Nm (2 to 2.5 kgfm)

sistor No. ®24981

AL2A

02786 24982

13E-34

ELECTRONICAUY CONTROLLED FUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT (1) Measure the resistance of the fuel injection quan tity adjusting resistor. The standard value corre sponds to the resistor number marked on the case. Standard value (at 20°c)

Resistor No.

2700

510Q

a2on

1300Q

20000

3300fl

5600fl

150000

(2) If the measurement is out of specification, replace the fuel injection quantity adjusting resistor.

NOTE: The fuel injection quantity adjusting resistor is matched to the injection pump. Replace it only with one that has the same resistor number.

13E-35

COOLING CONTENTS 1. GENERAL .......... . ........................ 2 2. SPECIFICAT IONS ........................... 6 3. SERVICE STANDARDS ..................... 7 3.1 Service Standards Table ................. 7 lightening Torque Table ................. 7 3.2 4. SPECIAL T OOLS ............................ 8 5. SERVICE PROCEDURE ...................... 9 Removal and Installation of Cooling 5.1 Fan ......................................... 9 5.2 Water Pump ................................ 9 5.2.1 Removal and installation .............. 9 5.2.2 Disassembly and inspection .......... 10 5.2.3 Reassembly ........................... 13 5.3 Thermostat .............................. 14 5.3.1 Removal and installation ............. 14 5.3.2 Inspection .. ...... . .................... 14

Fan Drive .......................... ....... 5.4 5.4.1 Disassembly and inspection ..... . .... 5.4.2 Reassembly ........................... 5.5 Tension Pulley ........................... 5.5.1 Disassembly and inspection .......... 5.5.2 Reassembly .. .................. ....... 5.6 Inspection of Auto Cool Fan Coupling ................................. 5.7 Inspection of Radiator ................... 5.8 V-belt Tension ............................ 5.8.1 Inspection . ............................ Adjustment ........................... 5.8.2 5.9 Cleaning of Cooling System ............. 5.10 Gas Leak Test ........................... . 5.11 Bleeding the Cooling System ........... 6. T ROUBLESHOOTING ...................... .

15 15 16 16 16 17 17 18

191 20 19

21 23 23 24

14-1

Ill

COOLING - GENERAL

1. GENERAL

(2) Thermostat

The cooling system is of the water-cooling forced cirÂ culation type consisting of a radiator, water pump, thermostat, and related parts.

When coolant temperature is high (bottom bypass valve is closed) \.

Radiator

When coolant temperature is low (bottom bypass valve is open)

817450

(1) Water pump

Impeller

From radiator

B1746C

The water pump, of the centrifugal type, is driven by V-belt from the crankshaft pulley. Mounted at one end of the water pump shaft is an impeller with blades and the coolant is sealed up by unit seal. For lubrication of the water pump, see Group 12 Lubrication.

14-2

81747A

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

COOLING - GENERAL (3) Radiator

(4) Pressure cap

<With pressure release lever> Radiator

Pressure release lever Pressure spring

Reserve tank Pressure valve// Vent valve spring

B1716B 81740A

<Without pressure release lever> Pressure spring

The radiator, with a tube-and-corrugated-fin type core (and with a reserve tank on some models), not only cools the engine coolant but also separates vapor from liquid water and regulates pressure in the cooling sysÂ tem.

Vent valve When vent valve is opened

B0295B

The pressure cap regulates the pressure in the cooling system. When the pressure builds up in the system that exceeds a predetermined level, the pressure valve compresses the pressure spring, releasing the excesÂ sive pressure through the overflow pipe into the atmoÂ sphere. 14-3

COOLING - GENERAL

If equipped with a reserve tank, the coolant that has overflowed is channeled into it. When the coolant temperature drops and negative pressure builds up in the system, the vent valve opens to take in air to prevent the radiator from becoming deformed. If equipped with a reserve tank, coolant is taken from the reserve tank to prevent the radiator from becoming deformed and to keep the quantity of coolant in the system constant. If equipped with a pressure release lever on the cap, raising the lever upright opens the pressure valve and releases the pressure in the cooling system.

is controlled by a bimetallic strip that moves in response to temperature changes. <When the temperature of the air passing through the radiator is low>

Operating chamber Control hole

(5) Auto cool fan coupling 80243A

Rotor Storage chamber

The valve fully closes the control hole of the divider plate. As a result, the silicone oil forced back from the pump hole is stored in the storage chamber and is not sent into the operating chamber. In the meantime, the silicone oil in the operating chamber decreases, and consequent slippage between the case and cover and the rotor causes the fan to rotate at a lower speed. <When the temperature of the air passing through the radiator rises>

Divider plate

80574C

Depending on the temperature of the air passing through the radiator, the auto cool fan coupling autoÂ matically controls the rotating speed of the fan. The autocool fan coupling is constructed as follows: The rotor is mounted on the shaft and rotates between the case and cover. Viscous coupling material (silicone oil) enters the gap and turns the fan. A control hole in the divider plate allows silicone oil to pass from the storage chamber to the operating chamber. The hole is controlled by a valve. Opening and closing of the valve

14-4

B0244A

As the temperature rises, the valve slowly opens the control hole of the divider plate, allowing silicone oil to flow into the operating chamber. Therefore, the siliÂ cone oil contacting area between the case and cover and the rotor slowly increases. So more torque is transÂ mitted to the fan, causing it to rotate at a higher speed.

COOLING - GENERAL <When the temperature of the air passing through the radiator is high> Direct-couple fan

Autocool fan coupling (at high temperature) Autocool fan coupling (at medium temperature)

"0 Q) Q) C. <I)

C u..

Autocool fan coupling (at low temperature)

Crankshaft speed (rpm)

80245A

The valve fully opens the control hole of the divider plate, and more silicone oil flows into the operating chamber. As a result, a maximum torque is transmitted from the shaft to the fan, causing the fan to rotate at a given maximum speed.

B1728B

"0 Q) Q) C. <I)

C u..

Temperature passing through the radiator (Â°C)

B0575A

14-5

COOLING - SPECIFICATIONS

2. SPECIFICATIONS Item

Specification

Cooling system

Water-cooling forced circulation type

Coolant quantity (Engine-proper only)

6D24, T

Approx. 22 L

6D24-TC, TL

Approx. 24 L

Water pump

Type Drive method

V-belt

Radiator

Type

Tube-and-corrugated-fin type or Tube-and-plate-fin type

Thermostat

Type

Wax pellet/bottom bypass type

Valve opening temperature x O'ty

Without jiggle valve: 76.5Â°C x 2

Type x Number of belts

Without fan drive

Low edge cog Btype x 1 or Btype x 2

With fan drive

Low-edge cogged type Bx 1 (for water pump) Low-edge cogged type C x 2 (for alternator)

Cooling fan V-belt

Centrifugal type

Suction type or blower type

Low-edge cogged type Bx 1 (for water pump) Low-edge cogged type Bx 2 (for alternator)

14-6

COOLING - SERVICE STANDARDS

3. SERVICE STANDARDS

3.1 Service Standards Table Unit: mm Maintenance item

Nominal value (Basic diameter in I ))

Interference between pump shaft and flange Interference between pump shaft and impeller Thermostat

Valve opening temperature

(22) 0.05 to 0.08

(11.8) 0.03 to 0.06

74.5 to 78.5° C

10 or more/90 C

Valve lift/temperature Radiator inspection pressure (air pressure)

98 kPa {1 kgf/cm }

Pressure valve opening pressure

39 to 59 kPa {0.4 to 0.6 kgf/cm2}

V-belt deflection [with a push force of about 98 N (10 kgf)]

Without fan drive

17 to 22

With fan drive

10 to 15

Remedy and remarks

Limit

Up to second reassembly Up to second reassembly Replace

Correct or replace Pressure cap, replace Adjust

3.2 Tightening Torque Table Screw size O.D. x pitch (mm)

Tightening torque N-m {kgf,m}

Water pump pulley mounting bolt

M10 x 1.5

44 ± 8.8 {4.5 ± 0.9}

Fan drive flange mounting nut

M20 x 1.5

145 {15}

Tension pulley mounting nut

M16 x 1.5

98 {10}

Location tightened

14-7

Ill

COOLING - SPECIAL TOOLS

4. SPECIAL TOOLS Unit: mm Tool name

Shape

Unit: mm Tool name

Impeller Puller MH062192 Removal of water pump impeller

Shape

Water Pump Pulley Puller MH062411 Removing water pump flange

B5252C Unit Seal Installer MH062195 Water pump unit seal instal lation

�,A

�.c

9.6±0.03

12.5

85258A Belt Tension Gauge MH062345 Measuring V-belt tension

85094A 03612

14-8

COOLING - SERVICE PROCEDURE 5. SERVICE PROCEDURE

5.2 Water Pump

5.1 Removal and Installation of Cooling Fan

5.2.1 Removal and installation

89019B

2 O0914A

1 Plate 2 Fan 3 Spacer * Fan pulley

14-9

COOLING - SERVICE PROCEDURE

5.2.2 Disassembly and inspection

<6D24,T, TL>

Repair kit: Water pump repair kit

7Corrosion, damage 13 Damage, wear

Cracks, wear in surface over which bearing fits, water leak, rust

BD .. Basic Diameter NV .. Nominal Value

Disassembly sequence 1 Water pump pulley ÂŽ Flange 3 Oil seal 4 Snap ring 5 Snap ring 6 Water pump cover (J) Impeller

Water pump shaft Bearing Spacer Bearing Oil seal Unit seal 14 Water pump case

8 9 10 11 12 13

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

14-10

D0044G

COOLING - SERVICE PROCEDURE

BD .. Basic Diameter NV .. Nominal Value

<6D24-TC>

Bend, rust, wear in surface over which bearing fits 8 Rotation

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

Interference BD 25 NV 0.05 to 0.08 Reassembly no more than 2 times

Disassembly sequence 1 Water pump pulley @ Flange 3 Oil seal 4 Snap ring 5 Snap ring 6 Water pump cover (]) Impeller

8 9 10 11 12 13 14

Water pump shaft Bearing Spacer Bearing Oil seal Unit seal Water pump case

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

D0044H

14-11

Ill

COOLING

SERVICE PROCEDURE (3) Flange to water pump shaft tightening margin

Disassembly and Inspection Procedures

(1) Removal of flange /

Water Pump ---1,ďż˝ďż˝ Flange

13480

D0031B

If the tightening margin exceeds specification, replace the flange or water pump shaft.

Remove the water pump flange using the Water Pump Pulley Puller and Bolt (special tools). Slip an iron pipe or similar item over the handle to gain the necessary leverage.

NOTE: Do not reassemble more than three times even when the specification is met.

(2) Removal of impeller

(4) Impeller to water pump shaft tightening margin

09192

Using two threaded holes (MB x 1.25) in the impeller and the Water Pump Impeller Puller {special tool), pull off the impeller.

14-12

D0031C

If the tightening margin exceeds specification, replace the impeller or water pump shaft. NOTE: Do not reassemble more than three times even when the specification is met.

COOLING - SERVICE PROCEDURE 5.2.3 Reassembly

Apply engine oil to lips.

12 Apply engine oil to external cylinder.

Installation load 39.2 kN {4000 kgf}

44±8.8 N-m {4.5 ± 0.9 kgf-m}

Assembly sequence

,,::..- -�

Apply engine oil to lips.

'----�!-+------

\ , ..., ,'

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

I I

127, 8➔11➔10➔9➔14➔7

d}_j For parts with an encircled number, refer to Reassembly Procedure that follows. D0047O

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

Reassembly Procedure <Installation of unit seal>

Unit seal Unit Seal Installer MH062195

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

09194

14-13

COOLING - SERVICE PROCEDURE 5.3.2 Inspection

5.3 Thermostat

5.3.1 Removal and installation Thermostat marking For 76.5°C Valve opening temperature (°C)

74.Sto 78.5

Valve lift/ temperature (mml°C)

10 or more/90

Valve lift Stirring rod

Thermostat

�� Heat source

--1J

D0301B B9021B

Agitate water in the container with the stirrer to obtain uniform temperature. For the inspection, use the fol lowing procedures. ( 1) Slowly heat water to the thermostat valve opening temperature. The valve opening temperature is stamped on the thermostat. Its nominal value is the stamped tem perature ± 2° c. (2) Keep this condition for about five minutes and make sure that the valve is open. (3) Raise the temperature further to heat the water to the valve lift measuring temperature correspond ing to the valve opening temperature. (See the table above.) Keep this state for five minutes and measure the bypass valve lift. (4) Lower temperature down to 65° C or below and ensure that the valve is fully closed. If the thermostat is found defective in any of the above items, replace it with a new one.

14-14

COOLING - SERVICE PROCEDURE 5.4 Fan Drive 5.4.1 Disassembly and inspection

7 Rotation

6 2

Disassembly sequence 1 2 3 4

Fan pulley Flange Snap ring Fan drive shaft

5 Bearing 6 Spacer 7 Bearing 8 Bearing case

B9023O

14-15

Ill

COOLING - SERVICE PROCEDURE

5.4.2 Reassembly

5.5 Tension Pulley 5.5.1 Disassembly and inspection

Sealing side to be faced outward. To be packed with grease (multipurpose grease)

Rotation

B9023E

· Disassembly sequence

1 Adjusting bolt 2 Tension pulley bracket 3 Snap ring 4 Tension pulley shaft 5 Tension pulley 6 Bearing

6 To be packed with approx. 86 g of grease (multipurpose grease)

Assembly sequence 8-+5➔3➔2➔1

4-+7-+6] 89024D

14-16

COOLING - SERVICE PROCEDURE

5.6 Inspection of Auto Cool Fan Coupling

5.5.2 Reassembly

Sealing side to be faced outward. To be packed with grease (multipurpose grease)

98N-m {10 kgf-m}

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

Fan axial runout or play, continuous high noise or unusually high noise of fan B9024E

NOTE:

Since the autocool fan coupling js constructed as a single unit, the silicone oil does not require mainÂ tenance. The autocool fan coupling cannot be dismantled. If defects become evident, the whole autocool fan coupling assembly must be replaced.

818558

14-17

Ill

COOLING - SERVICE PROCEDURE

5. 7 Inspection of Radiator

(1) Play in axial direction

(1) Cleaning

O1213A

When engine is cold, pinch the fan fitting portion and move it in axial direction. If the fan blade tip has exces sive runout or play is observed, replace the auto cool fan coupling, because the ball bearing is defective. (2) Cleaning bimetal

O0402A

Remove mud, bugs, etc., if present on the radiator core front surface, with a copper wire. During the removal work, use care to prevent damage to the tubes. Radiator inspection pressure (air pressure) NV 98 kPa {1 kgf/cm2} NV .. Nominal Value

O0409A D1214C

If dirt or dust is adhering to the bimetal, remove it care fully with a wire brush or the like. NOTE: Use care not to apply excessive force to the bimetal.

14-18

(2) Attach hose to the inlet of the radiator and cap the outlet. Then, immerse the radiator in a waterfilled tank . Using a radiator cap tester, send compressed air at the specified inspection pressure through the hose to check for leaks. If leaks are evident, re-solder or replace the radia tor.

COOLING - SERVICE PROCEDURE 5.8 V-belt Tension

(3) Inspection of radiator cap

5.8.1 Inspection Adjust the belt tension to obtain the specified belt deflection when the center of each belt is pressed with a force of approximately 98 N (10 kgf). <Without fan drive> Water pump Pressure valve opening pressure NV 39 to 59 kPa {0.4 to 0.6 kgf/cm 2}

Radiator cap tester Alternator

Crankshaft

Radiator cap

NV .. Nominal Value

B6525B

<With fan drive> 10 to 15 mm

D0420A

Check the spring tension and sealing condition of the pressure valve and vent valve. If defective, replace. Check the pressure valve opening pressure, using a radiator cap tester.

Alternator

Crankshaft B6527B NOTE: 1.

A slack belt can be a cause of overheating and undercharge. An excessively tight belt may result in damaged bearings and belts.

14-19

COOLING - SERVICE PROCEDURE â&#x20AC;˘

5.8.2 Adjustment

Using Belt Tension Gauge (special tool)

( 1) Alternator 0-ring A

Belt Tension Gauge

Depression load scale

MH062345

0-ring B

Deflection gauge

03613

E0165

Loosen the upper and lower mounting bolts of the alternator. T hen, fit a wrench handle and move the alternator as necessary.

( 1) Set 0-ri ng A at the 98 N {10 kg} mark on the depresÂ sion load scale. (2) Set 0-ring B at the V-belt's specified nominal deflection value (max.) on the lower scale.

NOTE: When moving the alternator, use care not to damage the stator coil between the front and rear brackets, and the through bolt.

(2) Tension pulley

Top of gauge Flange V-belt

Adjusting bolt

03614

(3) Apply the Belt Tension Gauge (special tool) to the V-belt's tension measurement point. Depress the top of the gauge until 0-ring A reaches the flange.

Mounting nut

E0166

Loosen the idler puller mounting nut, then turn the adjusting bolt to adjust the belt tension. (Turning the adjusting bolt moves the idler pulley.)

14-20

COOLING - SERVICE PROCEDURE 3.

If much rust is found, water may leak from the ra diator after cleaning. Check carefully each section of the radiator after cleaning. If the coolant temperature is still very high, never attempt to remove the pressure cap. Coolant in use

03615

Cleaning interval

FUSO Diesel Long Life Coolant

Every 2 years

Anti-rust, anti-freeze

At time of coolant replacement of every 6 months or before and after use of anti-freeze

(1) Washing with water

(4) Measure the amount of deflection in the V-belt. Adjust the V-belt's tension if the amount of deflec tion is out of specification.

5.9 Cleaning of Cooling System

80426A

80429A

If the radiator is used for a long time, rust, scale, mud, etc. are deposited inside, resulting in overheat. Clean the cooling system with city water by using the follow ing procedures.

NOTE: 1.

Use a cleaning solution if the radiator is seriously obstructed or coolant is seriously contaminated. When the cooling system is cleaned or washed with water, make sure that the coolant tempera ture is maintained at 90°C; the coolant tempera ture below the valve opening temperature closes the thermostat, resulting in poor coolant circula tion.

(a) Discharge coolant from the radiator, crankcase, and reserve tank. (b) After draining the system, fill it with tap water (pre ferably hot water) and, with the water temperature kept at around 90° C, run the engine at idle for about 10 minutes. Then, drain water. Continue flushing until the drained water runs clear. (2) Washing with cleaning solution (When radiator clogging or coolant contamination are serious) (a) Discharge coolant from the radiator, crankcase, and reserve tank.

14-21

COOLING - SERVICE PROCEDURE (d) After discharging the solution, fill the system with tap water (preferably hot water) and with the water temperature kept at around 90°C, run the engine at idle for about 10 minutes. Then, drain water. Continue flushing until drained water runs clear.

(b) Ready a mixture of FUSO Radiator Cleaner (Radi pet-7 or equivalent: 5 to 10%) and cooling water. Pour the specified amount of mixture into the radiator.

NOTE: 1. If the inside is heavily stained, washing with tap water before charging radiator detergent will be effective. 2. Running the engine at idle for longer than an hour with detergent left in engine could cause damage to the cooling system. Be sure to observe specified cleaning time. 3. After cleaning with detergent, fill with coolant as soon as possible.

(3) Cooling water (a) When Long Life Coolant is used:

B0428A

(c) Run the engine to raise the solution temperature to around 90°C. Let the engine run at idle for another 30 minutes, then remove the solution.

D1322B

In order to prevent freezing of cooling water and corro sion of the cooling system, add FUSO Diesel Long Life Coolant at a ratio of 30 to 60% of quantity of water. Replace the coolant once every two years to retain its anti-freeze and anti-rust effects. For usage of Long Life Coolant, refer to its instruction manual. NOTE: 1. Be sure to use FUSO Diesel Long Life Coolant. 2. Never mix it with DIAQUEEN Long Life Coolant or other commercial long life coolants, anti-freezes or anti-rusts.

B0426A

14-22

COOLING

SERVICE PROCEDURE 5.10 Gas Leak Test

(b) When anti-rust and anti-freeze are used:

Air or exhaust gas leaked into the coolant promotes corrosion and rust formation. Perform the following check and, if defects are found, take remedial action. (1) Inspection

01310A

1) After cleaning, add Fuso Radiator Anti-rust (Radi pet-98 or equivalent) at a ratio of 5% to the coolant quantity to prevent corrosion in summer. (a) Remove the pressure cap from the radiator. (b) Run the engine to raise the coolant temperature up to around 90 °C. (c) If bubbles continue forming in the coolant under the condition, it indicates that air or exhaust gas has leaked into the coolant. (2) Causes

D1322A

In winter, add the Fuso Anti-freeze or equivalent at a ratio of 30 to 60% to prevent freezing. For usage of anti-rust and anti-freeze, see respec tive instruction manuals.

NOTE: When the anti-rust or anti-freeze is used, never use with other long life coolants.

(a) If air is trapped in coolant, check cylinder head bolts, water pump mounting bolts, and hose and its connections for looseness. Check also hoses for damage. (b) If the exhaust gas has leaked into coolant, check the cylinder head gasket or nozzle tube end stake for damage. Check also cylinder head for cracks.

5.11 Bleeding the Cooling System (1) With the pressure cap removed from the radiator, let the engine run at idle with coolant temperature of about 90° C to bleed the system completely. (2) After the system has been bled of air, add coolant to radiator and reserve tank as required.

14-23

Ill

COOLING - TROUBLESHOOTING

6. TROUBLESHOOTING Probable cause

Symptom Overheat

Defective V-belt • Incorrect tension • Broken belt Clogged cooling system

Remedy Adjust Replace Clean

Defective thermostat

Replace

Defective water pump • loose shaft to impeller engagement

Replace

• Loose shaft to flange engagement

Replace

• Improper clearance between impeller and water pump case

Correct

• Damaged impeller

Replace

Clogged radiator fins Defective autocool fan coupling • Damaged bimetal • Clogged bimetal • Defective autocool fan coupling proper Damaged cooling fan low coolant level

Clean Replace Clean Replace Replace Replenish

Overcool

Defective thermostat

Replace

Quick loss of coolant

Defective radiator hose • loose hose connection

Correct

• Worn or damaged hose

Replace

Defective radiator • Radiator proper not tight

Correct or replace

• Pressure cap not tight

Replace

14-24

Ref. group

Defective water pump • Defective unit seal

Replace

• Defective oil seal

Replace

• Pump mounted improperly

Correct

Defective oil cooler

Replace

Thermostat case or cover mounted improperly

Correct

Defective heater hose • loose hose connection

Correct

• Worn or damaged hose

Replace

Defective cylinder head gasket

Replace

Group 12

Group 11

INTAKE AND EXHAUST CONTENTS 1. 2. 3. 3.1 3.2 4. 5. 5.1

GENERAL ................................... 2 SPECIFICATIONS ........................... 6 SERVICE STANDARDS ..................... 7 Service Standards Table ................. 7 lightening Torque Table ................. 7 SPECIAL TOOL .. ............ . ............... 8 SERVICE PROCEDURE ...................... 9 Removal and Installation of Intake System .................................... 9 5.2 Removal and Installation of Exhaust System ................................... 13 5.3 Air Cleaner ............................... 15

5.3.1 Disassembly and reassembly ......... Inspection and cleaning .............. 5.3.2 5.4 Turbocharger ...... ...................... . 5.4.1 Disassembly ........................... 5.4.2 Cleaning and inspection .............. ReasseÂ·mbly .. .......... ........ ....... 5.4.3 5.5 Aftercooler ......... ........ ............... 5.5.1 Disassembly and reassembly ......... Air pressure test ...................... 5.5.2 5.6 Bleeding of Aftercooler Coolant Circuit <6 D24-TC :Standard> ..................... 6. T ROUBLESHOOTING .......................

15 16 17 17 20 23 27 27 28 28 29

15-1

INTAKE AND EXHAUST - GENERAL

1. GENERAL

(1) Air cleaner <Single element type>

B0618A Outside air

The cyclone type air cleaner uses a filter paper type ele足 ment. Because of plastic coating and heat treatment, the ele足 ment is highly resistant to water and oil. Even if it is contaminated, its functions can be regained by clean足 ing. The intake air is given a spin by the vanes for centrifu足 gal separation of large particles of dust and dirt. Small particles of dust and dirt are filtered out by the filter paper element so that a clean air is drawn into the engine. The standard air cleaner is a single element type, and the double element type can be effective for operation safety under unusual conditions with a lot of dust and dirt. (2) Precleaner

Guide vane

B0619A

Inner element

B0608C Outside air

B0620A

15-2

To air cleaner

80610A

The precleaner, coupled with the air cleaner, collects relatively large particles of dust contained in the air drawn in by engine. The air entering the precleaner is made to spin by the guide vanes of the precleaner to centrifugally separate large particles of dust before the air is drawn into the air cleaner. These dusts are collected in the precleaner.

INTAKE AND EXHAUST - GENERAL

body, indicating that it is time to clean or replace the element. After the element has been cleaned or replaced, depress the reset button on the top, and the signal will return to its original position.

(3) Vacuator valve

Warning lamp

Starter switch

Electrical dust indicator

-=- Battery

Valve to be opened by repulsion of rubber

806048

Centrifuged dust collects at the bottom of the air cleaner. A vacuator valve made of rubber is mounted to the bottom, which pulsates to automatically dis charges dust and water when the engine speed is below about 800 rpm. Namely when the engine is run ning at a speed higher than 800 rpm, the negative pres sure in the air cleaner keeps this valve closed but when the negative pressure drops as the engine speed decreases, the valve is made to open by rubber action, thereby discharging dust and water.

Air cleaner

81824A

With the electric dust indicator, its electric contact points close when the vacuum reaches 6.2 kPa {635 mmH20}. This turns on the warning lamp, warning the driver that it is time to clean or replace the element.

(4) Dust indicator

Reset button Indicator body Signal Transparent section

•

Negative pressure

806058

The dust indicator is mounted near the outlet of the air cleaner. The dust indicator operates on the negative pressure of the air drawn into the engine performing the function of indicating the time to clean or replace the element. When the element is plugged with dust and dirt, the suction resistance increases. When this vacuum reaches 6.2 kPa {635 mmH20}, the signal (red) is pulled down against the spring tension. The signal (red) is then visible through the transparent section in the 15-3

INTAKE AND EXHAUST - GENERAL (5) Turbocharger Bearing housing Compressor wheel

Exhaust outlet

Compressor cover "'

Air inlet

Compressor wheel Exhaust manifold

Inlet manifold

B1215A

The turbocharger utilizes the energy of the engine exhaust gas to feed more air into the engine, thereby offering advantages such as boosted engine power output, thrifter fuel consumption, and reduced engine noise. The exhaust gases discharged from the cylinder of the engine are led through the exhaust manifold into the turbocharger and are accelerated in the turbine hous ing and are blown against the turbine wheel. Accordingly, the turbine is made to rotate at a speed of scores of thousands of revolutions a minute, and turns the compressor wheel mounted on the same shaft as the turbine wheel. By rotation of the compressor wheel, a larger amount of air than without supercharg ing is forced into the cylinder of the engine, so a corre spondingly larger amount of fuel can be burnt. This increases the effective pressure during combustion (the pressure forcing the piston down) and thus increases the output.

15-4

Shaft-and turbine-wheel

Turbine housing

B1213A

The turbocharger can be divided into three basic sec tions: the turbine wheel that is driven by the exhaust gases, the compressor wheel which forces intake air into cylinders and the bearing housing which supports the shaft of these wheels. The shaft connecting the turbine wheel with the com pressor wheel is supported in floating type bearings, which absorb vibrations during high speed operation that are caused by slight imbalance of the shaft. The shaft axial load is borne by the thrust bearing. The bearing housing has its inside cooled and lubri cated by engine oil to prevent seizure and other troubles of the sliding parts. (Refer to Group 12 Lubrication.)

INTAKE AND EXHAUST - GENERAL (6) Aftercooler <6D24-TL>

<6D24-TC>

Turbocharger

Plate-and-corrugated-fin type water-cooling heat exchanger

lntercooler

80627A

The intake air cooling system, incorporating a plate and-corrugated-fin type heat exchanger, transfers heat from the intake air to the engine coolant. It has the same function as the intercooler on automobile engines. The system cools off the intake air, whose temperature has gone high due to compression by the turbochar ger, through heat exchanging with the engine coolant. This allows the density of intake air to be increased, admitting more air into the engine, which in turn increases the fuel injection rate and improves the com bustion efficiency. Thus the fuel economy and output are improved and the exhaust gases are reduced to a minimum.

®43534

The intercooler (attached to the front of the radiator) is a tube-and-corrugated-fin, air-to-air heat exchanger. It cools the intake air, which is hot, after being com pressed by the turbocharger, thereby making the intake air denser before it enters the cylinders. Com bustion efficiency is thus improved, resulting in higher fuel efficiency and output and in lower emissions of harmful gases.

15-5

INTAKE AND EXHAUST - SPECIFICATIONS

2. SPECIFICATIONS ï¿½ Air cleaner element

Type

Supercharger

Type

Model

Model Aftercooler

6D24

6D24-T

6O24-TC

Cyclone type paper element (Nippon Donaldoson Ltd. products) Turbocharger

Mitsubishi TD08H Plate and corrugated fin type, water-cooling (built in the inlet manifold, cooled by the engine coolant)

Engine Parts contact phone: 269 673 1638

15-6

6D24-TL

Tube-and-corrugated-fin type, air-cooling

C60

Email: EngineParts2@gmail.com

INTAKE AND EXHAUST - SERVICE STANDARDS 3. SERVICE STANDARDS 3.1 Service Standards Table Unit: mm Maintenance item

Nominal value (Basic diameter in I ])

---·-�----

Dust indicator operating resistance Turbocharger

Bearing journal O.D. Shaft runout

Bearing

O.D. I.D.

---

Length Piston ring end gap in insert

Replace

20.506

Replace

11.996

Replace

0.015 20.382

0.08 to 0.28

Shaft-and-turbine-wheel axial play

0.075 to 0.155

Shaft-and-turbine-wheel to turbine back plate clearance

Replace

11.94

0.39 to 1.0

Compressor wheel to compressor cover clearance

Replace

- ---

12.042

0.05 to 0.25

Shaft-and-turbine-wheel to turbine housing clearance

Aftercooler

Remedy and remarks

6.2 ± 0.6 kPa {635 ± 58 mmH 2 O}

I.D. of section in bearing housing receiving bearing Shaft-and-turbine-wheel

Limit

0.48 to 0.92

-------

Core assembly air-tightness

6D24-TC

No leak is allowed with a 195 kPa {2 kgf/cm 2 } air pressure

lntercooler air-tightness

6D24-TL

No leak is allowed with a 150 kPa {1.5 kgf/cm2 } air pressure

Replace Replace Replace Replace Replace

---

Replace

3.2 lightening Torque Table Location tightened

Screw size O.D. x pitch (mm)

lightening torque N-m {kgf-m}

Inlet manifold mounting bolt <except 6O24-TC>

M10 x 1.5

35 {3.6}

Exhaust manifold mounting bolt

M10 x 1.25

41 {4.2}

Turbocharger mounting nut

Mounting nut

M10 x 1.25

26 {2.7}

Lock nut

M10 x 1.25

35 {3.6}

Turbocharger

Coupling mounting nut Shaft-and-turbine-wheel mounting lock nut

5.9 {0.6} 20 {2}

Remarks

Apply MOLYKOTE grease to threads.

15-7

INTAKE AND EXHAUST - SPECIAL TOOL

4. SPECIAL TOOL Unit: mm Tool name

Shape

Socket MH061242 For exhaust manifold attachÂ ing nut

Width across flats 14 85341A

15-8

INTAKE AND EXHAUST - SERVICE PROCEDURE 5. SERVICE PROCEDURE 5.1 Removal and Installation of Intake System <6D24>

� � •

Install with the arrow mark facing toward the inlet manifold.

35N-m {3.6 kgf-m}

2 1 Ground plate

2 Inlet pipe 3 Air heater 4 Inlet manifold NOTE:

1. 2. 3.

Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater. For details of air heater inspections, refer to Group 16.

84556A

15-9

INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D24-T> 3

35N-m {3.6 kgf-m}

1 2 3 4 5

�� gdown.

Ground plate Inlet pipe Rubber hose Air heater Inlet manifold

NOTE:

1. 2. 3.

Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installin g the air heater. For details of air heater inspections, refer to Group 16.

84557A

15-10

INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D24-TC: Standard>

Install with the arrow mark facing toward the cylinder head.

1 2 3 4 5

Inlet pipe Air escape pipe Water inlet pipe Water return pipe Air cooler assembly

6 7 8 9

Ground plate Heater harness Air heater Rubber hose

NOTE:

1. 2. 3.

Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater. For details of air heater inspections, refer to Group 16.

B4558C

15-11

INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D24-TL>

6 5

35 N-m {3.6 kgf-m}

1 Ground plate 2 Air inlet pipe B 3 Air heater

� �wfacing down.

4 Inlet manifold 5 Air inlet pipe A 6 Rubber hose

NOTE:

1. 2. 3.

Remove harnesses before disassembly. Ensure that the arrow points in the correct direction when installing the air heater. For details of air heater inspections, refer to Group 16.

®43535

15-12

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.2 Removal and Installation of Exhaust System

<6D24>

2 41 N-m {4.2 kgf-m}

Exhaust Seal rings manifold

"TOP" mark Install with stamped "TOP" mark facing manifold

Expansion rings

Gap

Seal ring

Install the seal rings such that their gaps are staggered by 180'. Install the expansion rings such that their gaps are opposite the seal ring gaps.

1 Heat insulator 2 Exhaust manifold 3 Seal ring

4 Expansion ring 5 Center exhaust manifold

84560A

Socket, MH061242 (special tool) is available to faciliÂ tate fitting of the exhaust manifold mounting nuts. Use

of this tool is recommended. 15-13

INTAKE AND EXHAUST - SERVICE PROCEDURE

<6D24-T, TC, TL>

4 35 N-m {3.6 kgf-m} 26 N-m {2.7 kgf-m}

� =-8

L. 5

"TOP" mark Install with stamped "TOP" mark facing manifold

Expansion rings

Seal ring Gap • Install the seal rings such that their gaps are staggered by 1ao·. • Install the expansion rings such that their gaps are opposite the seal ring gaps.

1 2 3 4

Heat insulator Oil pipe Oil return pipe Turbocharger

5 6 7 8

Exhaust manifold Seal ring Expansion ring Center exhaust manifold B4561A

Socket, MH061242 (special tool) is available to facili tate fitting of the exhaust manifold mounting nuts. Use of this tool is recommended.

15-14

NOTE: Some types of turbocharger fit onto the top of the exhaust manifold, while other types fit onto the bot tom of the exhaust manifold. Maintenance procedures for both types are the same.

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.3 Air Cleaner 5.3.1 Disassembly and reassembly Dust cup

<Single element type> Air cleaner body

e-,-- Dust indicator Air cleaner body

84563A

Dust cup

. ,·. Installation ,__direction mark

�ir cleaner body _ Dust md1cato

Outer element Inner element

�

NOTE:

,.. •,:1.

Wing nut

e-- Vacuator valve

Remove the inner element only for replacement.

Gasket

��

�:�i:iI�:: \ , � ,, •:::;;:,:•: •::- • •:. ·

Clamp

Wing nut

�

Cover

Wing nut

84564A

15-15

INTAKE AND EXHAUST

5.3.2 Inspection and cleaning

SERVICE PROCEDURE (4) Clean the inside of the air cleaner body and dust cup, and discharge the deposited dust.

(1) When there is dry dust on the element

(5) Dust indicator

Operating resistance NV 6.2 ± 0.6 kPa {635 ± 58 mmH20}

Window (red signal) C7 207A

NV .. Nominal Value

If there is dry dust on the element, clean the dust by blowing 685 kPa {7 kgf/cm2} or lower compressed air against the element. Blow the compressed air from inside the element up and down along the frills of the filter paper and clean the whole element evenly. NOTE: 1. 2.

Do not strike the element or strike it against a hard object to loosen the dust. Do not clean, but replace, the inner element.

(2) When there is moist dust on the element If the element is contaminated with moist soot, replace it regardless of the specified replacement frequency. (3) Inspection of element

C7 209A

After the element has been cleaned, put an electric lamp inside the element to check for damage and pin holes. If there are thin portions in the filter paper, replace the element. If the packing on the top surface of the element is broken, replace the element. 15-16

C7210B

Start the engine and close the inlet port of air cleaner gradually to increase negative pressure. If the red sig nal is displayed at the dust indicator, or warning lamp lights for the electric type dust indicator, the dust indi cator is normal. NOTE: Perform this inspection after cleaning or replacement of the air cleaner element if the element is heavily clogged.

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4 Turbocharger 5.4.1 Disassembly

Wear in surface receiving thrust

Wear 1 16 7

B�de bend and damag� corrosion, marks of interference on back surface

Interference with compressor wheel, cracks, damege

Interference with turbine wheel, cracks due to overheat, pitching, deformation

Blade bend and damage, corrosion, marks of interference on back sur face, damage on piston ring groove, damage on bearing journal

Interference with turbine wheel, damage

Bearing hole surface roughness, damage, gas corrosion, clogged oil hole, turbine side flange deformation

Disassembly sequence

1 Coupling assembly

(?)

3 @ @ 6 (J)

8 9

Turbine housing Snap ring Compressor cover Compressor wheel Snap ring Insert Piston ring Oil deflector

10 Thrust sleeve 11 Thrust bearing

12 Thrust ring 13 Shaft-and-turbine-wheel 14 Piston ring 15 Turbine back plate 16 Bearing 17 Snap ring 18 Bearing housing

For parts with an encircled number, refer to Disassembly Procedure that follows. C8965B

15-17

INTAKE AND EXHAUST - SERVICE PROCEDURE (3) Removal of compressor cover

Disassembly Procedure Alignment mark

Compressor cover

Turbine housing Bearing housing

C8982C

B2819D

(1) Before disassembling the turbocharger, make alignment marks on the compressor cover, bearing housing, and turbine housing so that they can be properly reassembled. (2) Removal of turbine housing

Remove the compressor cover by tapping it with . plastic hammer or similar tool which will not damag, the cover, with the snap ring loosened. NOTE: Use care not to damage the compressor wheel durin! the removal procedure.

(4) Removal of compressor wheel

Bearing housing

Turbine housing

Turbine housing B3946B

To remove the turbine housing, remove the coupling assembly and tap the housing with a plastic hammer or similar tool to prevent damage to it. NOTE: The turbine wheel blades are easy to bend. Use care not to damage them.

15-18

B2820C

(a) Clamp the turbine housing in a vise and fit the bearÂ ing housing into the turbine housing with the turâ&#x20AC;˘ bine wheel side of the bearing housing facing the turbine housing.

INTAKE AND EXHAUST - SERVICE PROCEDURE (5) Removal of insert

Snap ring

Shaft-and-turbine-wheel boss C8983C

(b) While holding the shaft-and-turbine-wheel boss, remove the lock nut that secures the compressor wheel.

C89788

(a) Snap off the snap ring that secures the insert onto the bearing housing.

NOTE: Retain the snap ring by hand to prevent it from spring ing out when slipping off the snap ring pliers.

� Comp,osso, wh"I

C8984C

(b) Fit the tip of a screwdriver into the portion of the insert shown and carefully remove it from the bear ing housing.

15-19

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4.2 Cleaning and inspection

Piston ring end gap NV 0.05 to 0.25

Clean Bearing 0.0. L 20.382 1.0. L

12.042

Length L 11.94

BearingjournalO.O. L 11.996 Shaft runout (total indi cator reading) L 0.0,5

Clean Bearing inserting portion 1.0. L 20.506

NOTE:

Before cleaning, visually inspect each component to find any scorching or rubbing that will not be apparent after cleaning. For details, refer to section 5.4.1.

C8988B

(a) Immerse all parts in a non-flammable solvent (DAIDO CHEMICAL INDUSTRY CO., LTD DAI CLEANER T-30 or equivalent) to clean oily contami nation.

(1) Cleaning

13628

15-20

NV .. Nominal Value L ..... Limit

INTAKE AND EXHAUST - SERVICE PROCEDURE (2) Inspection of bearing housing

C8990A

(b) Blow clean compressed air against the entire interÂ nal and external surfaces.

C8993A

Measure I.D. of the area receiving the bearing. Replace the bearing housing if the measurement exceeds the limit. (3) Inspection of bearing

Measuring direction

Measuring position

C8991A

(c) Clean deposits, using a plastic scraper or bristle brush. After deposits have been removed, soak parts in a non-flammable solvent again; then, blow comÂ pressed air against them.

C8971A

Measure I.D., O.D., and length of the bearing. If the measured values exceed the limit, replace.

NOTE: Use care to prevent damage to parts.

15-21

INTAKE AND EXHAUST - SERVICE PROCEDURE (5) Inspection of insert

(4) Inspection of shaft

(a) Journal 0.0. Insert

B0467A 80465A

Measure the shaft-and-turbine-wheel journal diameÂ ter. If the measured value is less than the limit, replace the shaft-and-turbine-wheel. (b) Shaft runout

B0466A

Set a dial indicator to the shaft as shown and turn the turbine wheel slowly to measure shaft runout. If the measurement exceeds the limit, replace the shaft-and-turbine-wheel. If the shaft journal is rough, clamp both centers on a lathe and lightly grind the journal surface with a sand paper #400 and engine oil with a spindle speed at 300 to 600 rpm. NOTE: After polishing the journal, measure its outside diameÂ ter (the part that rotates in the bearing). If the outside diameter is beyond the service limit, replace the shaft and turbine wheel.

15-22

Fit a new piston ring in the insert bore and measure the end gap of the piston ring using a feeler gauge. If the end gap is out of the nominal value, replace the insert.

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.4.3 Reassembly

Apply engine ott]

5.9 N-m {0.6 kgf-m} • Molykote grease or equivalent to be applied to screw and seating surface in lock nut. • Hammer entire periphery. 2

15 14 j Apply engine oil

20 N-m {2 kgf-m} Molykote grease or equiva lent to be applied to screw

Apply engine oil

Compressor wheel to com pressor cover clearance NV 0.08 to 0.28

Shaft-and-turbine-wheel to turbine housing clearance NV 0 .39 to 1.0

13 Shaft-and-turbine-wheel axial play NV 0.075 to 0.155

Assembly sequence 18➔17➔16➔15 14➔13

}+12

9➔10➔r.a.➔7

�

. �;➔(�➔r4;-➔3-/2➔:1_.

NV .. Nominal Value

For parts with an encircled number, refer to Reassembly Procedure that follows.

C89748

Set the thrust sleeve into the oil deflector, and install the piston ring.

Reassembly Procedure (1) Installation of piston ring

NOTE: When mounting piston ring to the thrust sleeve, ensure that the ring is not expanded and ring ends are not twisted.

Thrust sleeve

Oil deflector Piston ring

80472C

15-23

INTAKE AND EXHAUST - SERVICE PROCEDURE (3) Measurement of clearance between shaft-and-tur bine-wheel and turbine housing

(2) Installation of snap ring

Shaft-and turbine-wheel

C8978C C9001B

Set a dial indicator to the end of the shaft and move the shaft in the axial direction to measure the clearance. If the measurement is out of specification, disassemble and isolate the cause. (4) Installation of compressor wheel

Install the snap ring to the bearing housing with its taper up. After installation, using a screwdriver, drive the snap ring into the groove in the bearing housing by hum mering. NOTE: 1. Retain the snap ring by hand to prevent it from springing out when slipping off the snap ring pli ers. 2. Special care must be exercised, when tapping the snap ring into position, to prevent damage to the bearing housing by the screwdriver.

Bearing housing

Turbine housing

B2820C Lock nut �

20 N-m {2.0 kgf-m} ____._..,

Compressor wheel� " " Shaft-and-turbine=----fl wheel

C9002C

(a) Holding the turbine housing in a vice, set the tur bine wheel side of the bearing housing into the tur bine housing.

15-24

INTAKE AND EXHAUST - SERVICE PROCEDURE (bl Coat threads in the shaft-and-turbine-wheel with molybdenum disulfide base grease Li soap and mount the compressor wheel onto the shaft. (c) Holding the boss on the turbine wheel side, tighten the compressor wheel lock nut to the specified torque.

(6) Measurement of clearance between the turbine back plate and shaft-and-turbine-wheel back sur face

NOTE:

Set the bearing housing carefully to prevent damage on the turbine wheel blades.

.,,..-Bearing housing

(5) Measurement of axial play in shaft-and-turbine wheel Compressor cover

B2830C

Shaft-and turbine-wheel

Shaft-and turbine wheel

""'�,:;::--

Compressor wheel

Compressor cover

C90038

Set a dial gauge on the shaft-and-turbine-wheel end. With compressor wheel moved in the axial direction, measure the end play. If the play is out of specification, disassemble and check to locate the cause.

C9004A

Temporarily mount the bearing housing to the com pressor cover from the compressor wheel side. Mea sure the clearance between the turbine back plate and shaft-and-turbine-wheel back surface. If the clearance is out of specification, disassemble and isolate the cause. NOTE: Be sure to use two thickness gauges and take mea surement at the tip of the blades.

15-25

INTAKE AND EXHAUST (7) Compressor wheel to compressor cover clearance

SERVICE PROCEDURE (8) Installation of turbine housing and compressor cover

Alignment mark

84468A

Coupling assembly Snap ring Compressor cover 5.9 N•m (0.6 kgf·m) B2819E

Check by the following procedures. (a) Move up and down the compressor wheel to measure runout (R). NOTE: Do not measure runout by turning the compressor wheel.

(b) Measure compressor cover inside diameter (D) and compressor wheel outside diameter (d) at places indicated in the illustration. (c) Calculate the clearance by the equation given below. If it is out of specification, disassemble and check again. Clearance= 1/2 (D - d - R)

15-26

Make sure that the alignment marks are aligned and secure the parts with the coupling assembly and snap ring. Install the coupling assembly by the following proce dures. (a) lighten the coupling assembly to specified torque. (b) Hammer the coupling assembly all around. (cl lighten again the coupling assembly to specified torque. (9) After reassembly, turn the turbine wheel and com pressor wheel by hand and check for smooth rota tion. If the wheels turn heavily, or bind, disassemble, and locate the cause of trouble.

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.5 Aftercooler 5.5.1 Disassembly and reassembly ( 1) Water-cooled type <6D24-TC :Low profile type>

<6D24-TC :Standard>

1 Connector 2 Cover 3 Plate

4 Core assembly 5 Inlet manifold

Damage, water leaks, dirt on fins, water scale and rust inside core C9305C

(2) Air-cooled type <6D24-TL>

1 Air intake hose 2 lntercooler

84157A

15-27

INTAKE AND EXHAUST - SERVICE PROCEDURE 5.6 Bleeding of Aftercooler Coolant Circuit <6024-TC :Standard>

5.5.2 Air pressure test (1) Inspection of core assembly <6D24-TC> Conduct the air pressure test to check for water leaks due to damaged element. To check, apply an air pres sure of 390 kPa {4 kgf/cm2} to the core assembly. Replace the core assembly if it is leaking air or other wise defective.

� Air vent plug � Water return pipe

NOTE: Never apply pressure over specification.

(2) Inspection of intercooler <6D24-TL>

E0329

C9303A

(a) Remove the intercooler and use copper wire or the like to remove mud, insects, etc. from the front side of intercooler core, using care not to damage the tube. (c) Air-tightness check

Pressure for inspection of intercooler (compressed air) NV 150 kPa {1.5 kgf/cm2}

NV .. Nominal Value C9009A

Immerse the intercooler in a water tank with one open ing for air closed and with the other opening connected to a hose. Send compressed air at specified test pres sure through the hose and make sure that there is no air leak. 15-28

(a) Remove the air vent plug from the water outlet pipe. (b) Pour coolant into the radiator until coolant flows out from the air vent. Install the air vent plug. (c) With the pressure cap left removed from the radia tor, run the engine at idle, keeping coolant temper ature of about 90°C, to thoroughly bleed the sys tem. (d) After the air in the coolant circuit has been thor oughly bled, add coolant as necessary to the radia tor and reservoir tank.

INTAKE AND EXHAUST - TROUBLESHOOTING 6. TROUBLESHOOTING Symptom Low output

Probable cause Insufficient intake air • Loaded air cleaner element

Remedy

---·--- ..

• Air suction (with dust and other foreign matter) from intake system

Clean

---�--- --·

Correct

• Defective turbocharger • Turbocharger rotation failure • Seized bearing • Carbon deposit on turbine wheel

Check Check

• Seized thrust sleeve and/or thrust bearing • Incorrect sliding between inside parts due to clogged lubrieating oil pipe

Clean

·-

Replace

Check Replace

Incorrect injection timing

Adjust

Group 13A, E

Low compression pressure

Check

Group 11

Poor quality fuel

Replace

Defective turbocharger • Oil leaks due to worn piston ring, and/or insert

Replace

• Damaged oil seal due to clogged oil return pipe

Abnormal noise and/or vibration from intake and exhaust system

Clean, check

Replace

• Damaged turbine wheel

Dark and much exhaust gas

·-·

Replace

• Damaged turbine wheel

• Defective turbocharger • Turbocharger rotation failure (See above.)

Check

Replace

Low exhaust efficiency • Deformed front pipe, muffler and/or tail pipe (large exhaust resistance)

·-

Replace

• Damaged compressor wheel

• Foreign matter on front surface of intercooler core <6D24-TL>

gas

Clean

• Turbine wheel and turbine back plate interfering

• Compressor wheel and compressor housing interfering

Whitish and much exhaust

Replace

• Turbine wheel and turbine housing interfering • Bent shaft-and-turbine-wheel

Ref. group

Loaded air cleaner element

Group 13A

Replace Clean

Trouble in engine proper

Check

Group 11

Nonuniform fuel injection amount to cylinders

Adjust

Group 13A, E

Incorrect injection timing

Adjust

Group 13A, E

Poor connection of intake and exhaust systems

Correct

Deformed front pipe, muffler or tail pipe (large exhaust resistance)

Replace

Defective turbocharger (See above.)

Check

15-29

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Mitsubishi 6D24-TLA2B 6D24TLA2B Mitsubishi 6D24-TLA2C 6D24TLA2C Mitsubishi 6D24-TLA2D 6D24TLA2D Mitsubishi 6D24-TLA2E 6D24TLA2E Mitsubishi 6D24-TLA2F 6D24TLA2F Mitsubishi 6D24-TLA2J 6D24TLA2J Mitsubishi 6D24-TLA2K 6D24TLA2K Mitsubishi 6D24-TLA2O 6D24TLA2O Mitsubishi 6D24–TLA2E.01 Mitsubishi 6D24–TLA2E.02 Mitsubishi 6D24–TLA2E.03 Mitsubishi 6D24-TL2 6D24TL2 Mitsubishi 6D24-TLE 6D24TLE Mitsubishi 6D24-TLEA 6D24TLEA Mitsubishi 6D24-TLE Series 1 Mitsubishi 6D24-TLE1 6D24TLE1 Mitsubishi 6D24-TLE2 6D24TLE2 Mitsubishi 6D24-TLE2A 6D24TLE2A Mitsubishi 6D24-TLE2A .20 Mitsubishi 6D24-TLE2A .21 Mitsubishi 6D24-TLE2A .22 Mitsubishi 6D24-TLE2A .23 Mitsubishi 6D24-TLE2A .24 Hitachi Sumitomo Mitsubishi 6D24-TLE2A .25 Hitachi Sumitomo Mitsubishi 6D24TLE2A .56 Hitachi Sumitomo Mitsubishi 6D24TLE2A .57 Hitachi Sumitomo Mitsubishi 6D24-TLE2B 6D24TLE2B Mitsubishi 6D24-TLE2B.01 6D24TLE2B.01 AIRMAN Mitsubishi 6D24-TLE2B.02 6D24TLE2B.02 Mitsubishi 6D24-TLE2B.03 6D24TLE2B.03 Mitsubishi 6D24-TLQ2C Mitsubishi 6D24-TLU Mitsubishi 6D24-TLUA Mitsubishi 6D24-TLUB Mitsubishi 6D24-TLUC Mitsubishi 6D24-TLUD Mitsubishi 6D24-TLUE Mitsubishi 6D24-TLUF Mitsubishi 6D24-TLUG Mitsubishi 6D24-TLU2 6D24TLU2 Mitsubishi 6D24-TLU2A Mitsubishi 6D24-TLU2B Mitsubishi 6D24-TLU2C

Mitsubishi 6D24-TLU2D Mitsubishi 6D24-TLU2E Mitsubishi 6D24-TLU2F Mitsubishi 6D24-TLU2G SANY Mitsubishi 6D24-TLU20 Mitsubishi 6D24-0AT Mitsubishi 6D24-0AT1 Mitsubishi 6D24-0AT2 Mitsubishi 6D24-0AT3 Mitsubishi 6D24-0AT4 Mitsubishi 6D24-1AT Mitsubishi 6D24-1AT1 Mitsubishi 6D24-1AT2 Mitsubishi 6D24-1AT3 Mitsubishi 6D24T Series 13 Mitsubishi 6D24-T- 4405998 Hitachi Mitsubishi 6D24T.50 Mitsubishi 6D24T.55 Mitsubishi 6D24T-1AT.1 Mitsubishi 6D24T-1AT1.1 Mitsubishi 6D24T-1AT1.2

Notes: Mitsubishi L11.9D2B Engine Parts

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