Isuzu A-4BG1, A-4BG1T, A-6BG1, A-6BG1T Workshop Manual

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is his torical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand C

ompany and Doosan

Company or the products of

e

ith

er.

Revised (10-12)

GENERAL INFORMATION 1-I

SECTION

1

GENERAL INFORMATION

TABLE OF CONTENTS

ITEM

General repair instructions ...............................................................................

Notes on the format of this manual Main data and specifications Tightening torque specifications Angular nut and bolt tightening method Major parts fixing nuts and bolts

Identifications

..............................................................................................

.............................................................................

.....................................................................

........................................................................

.

I

...............................................................

PAGE

ll- 2 l1l-10 l-12 l-23

2

6 8

13 GENERAL INFORMATION

GENERAL REPAIR INSTRUCTIONS

1 .

Before performing any service operation with the engine mounted, disconnect the grounding cable

from the battery. This will reduce the chance of cable damage and

.

Always use the proper tool or tools for the job at hand.

2

.

mere specified, use the specially designed tool or tools.

L

.

3

Use genuine ISUZU parts referring ISUZU PARTS CATALOG for the engines surely.

.

4

Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you remove them. Replace them with new ones.

.

5

Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation.

It is especially important to keep fastening parts separate. These parts vary in hardness and design, depending on their installation position.

.

6

All parts should be carefully cleaned before inspection or reassembly. Oil ports and other openings should be cleaned with compressed air to make sure that they are com-

pletely free of obstructions.

.

7

Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.

.

If necessary, use a sealer on gaskets to prevent leakage.

8

.

9

Nut and bolt torque specifications should be carefully followed.

.

10

Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine or disconnecting pipes and hoses. To not do so is extremely dangerous.

11 .

Always check and recheck you work. No sewice operation is complete until you have done this.

12 .

Information contained in the “Main Data and Specifications” of the Workshop Manual and the Instruction Book may differ. In this case, the information contained in the Instruction Bo.ok should be

considered applicable.

burning

due to short circuiting.

‘.

z

‘, r. I--

NOTES ON THE FORMAT OF THIS MANUAL

This Workshop Manual is applicable to the 4BG1, 4BGlT, 6BG1, and 6BGlT family of industrial diesel engines. Unless otherwise specified, these engines have common parts and components as well as data and qqecifications.

Illustrations used in this Workshop Manual are based on the 6BGl and 6BGlT engines.

The 4BGlTengine and the 6BGlT engine are turbocharged.

1 .

Find the applicable section by referring to the Table of Contents at the beginning of the Manual.

.

2

Cdmmon technical data such as general maintenance items, service specifications, and tightening torques are included in the “General Information” section.

.

3

Each section is divided into sub-sections dealing with disassembly, inspection and repair, and

reassembly.

The section ENGINE ASSEMBLY is an exception. This part is divided into three sections to facilitates

quick indexing.

.

4

When the same servicing operation is applicable to<--everal different units, the manual will direct you

to the appropriate page.

.

5

For the sake of brevity, self-explanatory removal and installation procedures are omitted.

More complex procedures are covered in detail.

.

,

6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area. A brief explanation of the notation used follows.

Parts marked with an asterisk (*) are included in the repair kit.

Parts within a square frame are to be removed and installed as a single unit.

All parts within an irregularly shaped frame form a single assembly. They are considered ti “major component”.

Individual parts within the irregularly shaped frame are considered “minor components”.

The number tells you the service operation sequence.

Removal of unnumbered parts is unnecessary unless replacement is required.

o&sumblystaps-2

1. W8terby-passho8e

2. ThwmosUtfiou8ing

.3. WatDrpfJmp

A 4. l~rKuzleholder

5. Glow plug and gJow plug connector

6. cylllherdcowr

A 7. Rocbrarmshaftandrockerrrm

S. fbhrod

A 9. c-w

-.

10. Cylinder he8d gultet

A 11. Crankshaft damper pulley with

dust seal

12. liming gear cue cutter

13. liming gmr cover

14. Tf gear oil pipe

15. ldktr gear 3. rnd shaft

16. ldbr war -A’ l?. Mkr gear shaft

lnvwted Engine

I

I-

The ‘I* Repair Kit”

repair kit is available.

The .parts listed under “Reassembly Steps” or “Installation Steps” are in the service operation sequence.

The removal or installation of parts

marked with a triangle (A) is an import-

ant operation.

given in the text.

indicates that a

Detailed information is

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I 1

1” GENERAL INFORMATION

7. Below is a sample of the text of the Workshop Manual.

from the upper face of the cylinder head.

set.

guides.

This is the item shown in the illus-

4 tration. It is marked with a triangle

(A) on the Major Components page.

Special tools are identified by the

Letters and numbers contained in a

circle refer to the illustration.

Symbols indicate the type of service

or step to be performed. A detailed explanation of these symbols follows.

Service data and specifications are given in this table.

Y

8. The following symbols appear throughout this Workshop Manual. They tell you the type of service operation or step to perform.

-

D

. . .

CI)

q

*+ l **

Removal

Installation

0

+$+ . . .

III

$+ l l l

Disassembly

Reassembly

cl

. . .

Alignment (Marks)

ltrl

. . .

*

0

Directional Indication

II)

El l5l

?

0

V

m

bl

El

0

cl

Adjustment

Cleaning

. . .

Important Operation Requiring Extra Care

.

Specified Torque (Tighten)

. .

Special Tool Use Required or Recommended

.

. .

(lsuzu Tool or Tools)

Commercially Available Tool Use Required or

. . .

Recommended

aB

. . .

El

.

. . .

l!!il

. . .

Inspection

Measurement

Sealant Application

qy5 l l l

0

-b

cl

Lubrication (Oil)

(2

. . .

Lubrication (Grease)

B!l

I‘

.

Measurement criteria are defined by the terms “standard” and “limit”.

9

GENERAL INFORMAiiON

l-5

A measurement falling within the “standard” range indicates that the applicable part or parts are servicea ble.

“Limit” should be thought of as an absolute value. A measurement which is outside the “limit” indicates that the applicable part or parts must be either

repaired or replaced.

.

10

Components and parts are listed in the singular form throughout the Manual.

.

II

Directions used in this Manual are as follows: Front

The cooling fan side of the engine viewed from the flywheel.

Right

The injection pump side of the engine.

Left

The exhaust manifold side of the engine.

Rear The flywheel side of the engine. Cylinder numbers are counted from the front of the engine. The front most cylinder is No. 1 and rear most cylinder is No. 4 or No. 6. The’engine’s direction of rotation is counterclockwise viewed from the flywheel.

. -

b Front

t

Right

Rear W

Left

+

l-6 GENERAL INFORMATION

MAIN DATA AND SPECIFICATIONS

Item Engine type Combustion chamber type Cylinder liner type No. of cylinders - bore x stroke Total piston displacement Compression ratio

f Engine dimensions

Length x width x height

’ Engine weight (Dry)

Fuel injection order Specified fuel

Injection pump Governor Injection nozzle injection starting pressure Fuel filter type Water sedimentor

(If so equipped)

Compression pressure

(At warm)

Valve clearances (At cold) Intake

Exhaust mm (in) Lubrication method Oil pump Main oil filter type

)c Lubricating oil volume

Oil cooler Cooling method Coolant volume (engine only) Water pump Thermostat type

* Generator

* Starter * Turbocharger manufacturer * Turbocharger model

Engine Model

-

mm (in)

cm3 (cid)

mm (in)

kg

(lb)

kg/cm2( psi)

kg/cm2 (psi)

mm (in)

lit. (US gal)

i

V-A

V-KW

A-4BGl

A-4BGlT

Water cooled, four cycle, vertical in-line overhead valve

Direct injection

Dry

4 - 105 x 125 (4.13 x 4.92)

4,329 (464)

17.0 to I

842x645~775

(33.1 x 25.4 x 30.5)

325 (716)

878 x 702 x 883

(34.6 x 27.6 x 34.8)

361 (796)

I-3-4-2

Diesel fuel (ASTM D975 No. 2D)

In-line plunger, Bosch A type

Mechanical, RSV type

Multi hole

150 (2,134)

I

185 (2,630)

Center bolt or cartridge (spin-on)

Sediment/water level indicating type

31 (441) at 200 rpm at sea level

0.40 (0.016)

Pressurized circulation

Gear type

Full flow, cartridge (spin-on)

13.2 (3.5)

Water cooled integral type

Pressurized forced circulation

8.5 (2.25)

Belt driven impeller type

Wax pellet type

24-40

24-4.5

MITSUBISHI

TDO4H

:’ !

c\.?,

‘L

.@jJ I

*‘I

c

.Tp’

t,. / .

r-pa.

‘i‘

tJ

k

._

I

Note: 1. These specifications are based on the standareengine.

2. Specifications for items marked with an asterisk (*) will vary according to the type of equipment on which the engine is installed. If you are unable to locate the data applicable to these specifications, please contact lsuzu Motors LTD through your machine supplier.

MAIN DATA AND SPECIFICATIONS

Engine Model

Item Engine type Combustion chamber type Direct injection Cylinder liner type No. of cylinders - bore x stroke mm (in) Total piston displacement cm3 (cid) 6,494 (396) Compression ratio

Engine dimensions mm (in)

Length x width x height (44.2 x 25.5 x 30.5) Engine weight (Dv) Fuel injection order l-5-3-6-2-4 Specified fuel Diesel fuel (ASTM 0975 No. 20)

injection pump . In-line plunger, Bosch AD type Governor Inject& nozzle

injection starting pressure kg/cm2 (psi) 185 (2,630)

Fuel filter type Cartridge (spin-on)

kg

(lb)

Water cooled, four cycle, vertical in-line

A-6BGl

Dry

6 - 105.0 x 125.0 (4.13 x 4.92)

17.5 to 1

1122x648~775 1193X739X949

458 (1009) \ 489 (1078)

Mechanical, RSV type

Multi hole

A-6BG1T

overhead

(47.0 x 29.1 x 37.4)

valve

Water sedimentor

Compression pressure kg/cm* (psi) 31 (441) at 200 rpm, at sea level

. .(At warm)

Valve clearances (At cold) Intake mm (in) 0.40 (0.016)

Lubrication method Pressurized circulation Oil pump Main oil filter type Centerbolt, fullflow or cartridge (spin-on)

Partial oil filter

’ Lubricating oil volume

Oil cooler Water cooled integral type Cooling method Pressurized forced circulation Coolant volume (engine only) lit. (US gal) 12 (3.2) Water pump

Thermostat type Wax pellet type t Generator V-A 24-40 e Starter V-KW 24-4.5 e Turbocharger manufacturer t Turbocharger model ’

(if

so equipped) Sedimenter/water level indicating type

Exhaust mm (in)

lit. (US gal)

(yJ

a

-

0.40 (0.016)

Gear type

Equipped by OEM

21.5 (5.68)

Belt driven impeller type

IHI

RHE6

Note:

1 .

These specifications are based on the standard engine.

2. Specifications for items marked with an asterisk (*) will vary according to the type of equipment on which the engine is installed.

If you are unable to locate the data applicable to these specifications, please contact lsutu Motors LTD through your machine supplier.

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I 1pr

-4 1 I

1-8 GENERAL INFORMATION

TIGHTENING TORQUE SPECIFICATIONS

The tightening torque values given in the table below are applicable to the bolts unless otherwise

specified.

STANDARD BOLT

4.8 (4T)

(7-n

Refined

88

0

Non-Refined

9.8 (9T)

kg.m

(I b.ft/N.m)

@I @@@I @

-@@$I @

0.5-1.0

1.2-2.3

(8.7~16.6/11.8-22.6)

(12.3-22.4/16.7-30.4)

2.8-4.7

(20.3434.0/27.5-46.1)

(27.5~46.3/37.3-62.8)

6.2-9.3 (55.7~83.9/75.5-113.8)

9.5-14.2

(68.7-102.7/93.2-139.3) .

(99.8-150.4/135.3-204.0)

(143.9-216.3/195.2-391.3)

(83.9~125.6/113.8-170.6)

(118.9-177.2/159.9-240.3)

(169.34254.6/229.5-345.2)

27.5-41.3 (233.6~350.8/316.8-475.6)

(313.2-469.4/424.6-636.5)

43.9-72.5 (408.7-612.6/554.1-830.6)

2.8-4.6 (26.8-44.1/36.3-59.8)

5.8-8.6

(42.0~62.2/56.9-84.3)

(52.8-78.8/7X6-106.9)

9.0-13.4 10.9-16.3

(65.1~96.9/88.3-131.4)

(78.8~118.9/106.9-159.9)

13.2-19.8

(95.5~143.2/129.5-194.2)

(112.8-169.3/162.8-229.5)

x7-3.1

3.8-6.4

7.7-11.6

11.6-17.4

16.3-24.5

23.4-35.2

32.3-48.5

43.3-64.9

56.5-84.7

3.7-6.1

7.3-10.9

15.6-23.4

M6 x1.0

M8 xl.25

Ml0 x 1.25

M72 x 1.25

M34 x 1.5

Ml6 x 1.5

Nil8 x 1.5

nmxl.5

M22xl.5

M24 x 2.0

*Ml0 x 1.5

*Ml2 x 1.5

*Ml4 x 2.0

*Ml6 x 2.0

I r

,

.

0 77

No mark

.

0.4-0.8

(2.9-5.813.9-7.8) (3.6-7.2/4.9-9.8)

0.8-1.8

(5.8~~13.OjT.8-17.7)

2.1-3.5

(15.2-25.3/20.6-34.3)

5.0-7.5

(36.2-54.2/49.0-73.6) (44.8~67.3/60.8-91.2)

7.8-11.7

(56.4-84.6178.5-114.7)

10.6-16.0 . 13.8-20.8

(76.7~115.7/103.0--156.9)

15.4-23.0 19.9-29.9

(lll.l-166.4/151.0-225.6)

21.0-31.6

(151.9-228.6/205.9-307.9) (198.9-298.7/269.7-405.0)

25.6-42.2 37.0-55.5

(185.2-305.2/251.1-413.8) (267.6-401.4/362.9-544.3)

36.6-55.0

(264.7-397.8/358.9-539.4) (317.5~523.9/430.5-711.0)

2.0-3.4

I

(14.5-24.6/19.6-32.4) (20.3-33.3127.5-45.1)

4.6-7.0

(33.3-50.6/45.1-68.7)

7.3-10.9

(52.8-78.8/77.6-106.9)

10.2-15.2

173.8~110.0/100.0-149.1;

An asterisk (*) indicates that *he bolts are used for female threaded parts that are made of soft materials such as casting. Those shown in parentheses in the strength class indicate the classification by the old standard.

J ,I ‘\

i &~

,a,<.

‘C

A

_-r,.‘3

,Tc-\

: 3

\

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I

II

- -~-

TIGHTENING TORQUE SPECIFICATIONS

The .tightening torque values given in the table below are applicable to the bolts unless otherwise specified.

FLANGED HEAD BOLT

M6x7

M8 x1.25

M’IO x ‘I.25

*MOO x 1.5

- M12x It.25

+M12 x 1.75

Ml4 x 1.5

*Ml4 x 2

Ml6 x 1.5

*Ml6 x 2

A

bolt with an asterisk (*) is used for female screws of soft material such ascast iron.

I

(7.95-14.46/10.78-19.61)

I

(17.35-28.20/23.53--38.24)

I

(16.63-27.48/22.55--37.26) (25.31s41.95/34.32-56.87) (29.65--49.18/40.20-66.68)

I

(40.50;60.75/54.91-82.37) (57.14-86.07/77.47--116.69)

I

(37.61-56.41/50.99-76.49)

I

(61.48-91.85183.35~124.54)

I

(57.14-85.34/17.47-115.71)

I

(85.34-128.02/115.71-173.57)

I

(81.00~120.79/109.83-163.77) (120.06- 180.10/162.79--244.18)

M-0.9

(3.61-6.50/4.6-8.5)

1.1-2.0

2.3-3.9

2.3-3.8 3.5-5.8

5.6-8.4

3.5-9.5 7.3-10.9

8.5-12.7

X6-11.5 11.1-16.6

11.8-17.7

11.2-16.7 16.6-24.9

(4.33--8.67/5.88-11.76)

(26.03-44.12/35.30-59.82)

(52.80-78.83/7X58-106.89)

(84.62-127.30/114.73-

(80.28-120.06/108.85-162.79)

(125.85-

I

0.6-1.2

1.4-2.9 1.9-3.4

(4.33-8.67/5.88-11.76)

3.6-6.4 4.3-7.2

.

7.9-11.9

11.7-17.6

172.59)

I

17.1-26.5

189.50/170.63-256.93)

(130.19-196.01/176.52-265.76)

(124.40~186.61/168.67-253.01)

kg*m (Ib.ft/N*m)

(13.74%24.59/18.63-33.34)

(31.10-52.07/42.16-70.60)

4.1- 6.8

(62.92--94.02/85.31-127.48)

(58.58-88.24f79.43~119.64)

(91.13~136.70/123.56-185.34)

(85.34--128.02/l

8.7-13.0

8.1-12.2

12.6- 18.9

11.8-17.7

15.71-173.57)

18.0-27.1

17.2-25.7

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I

II

l-10

GENERAL INFORMATION

lal

ANGULAR NUT AND BOLT TIGHTENING METHOD

1. Carefully wash the nuts and bolts to remove all oil

5

2. Apply a coat of molybdenum disulfide grease to the

-3

q

and grease.

threads and setting faces of the nuts and bolts.

. .

.’ :I

::

/*-

I.

:I ‘J\

y -.

,r

,“<.

.F - x

\

Center line

3. Tighten the nuts and bolts to the specified torque (snug torque) with a torque wrench.

4. Draw a line [A-B] across the center of each bolt.

Coinciding line

5. Draw another line (C-D) on the face of each of the parts to be clamped. This line should be an extension of the line [A-B].

6. Draw another line [F-G] on the face of each of the

parts to be clamped. This line will be in the direction of the specified angle (Q) across the center [E] of the nut or bolt.

ified angle 0

Tighten

D

Example: Specified Angie and Tightening Rotation

r

A

B 60

.

C D 180° E

30

90

360’

0

l/12 of a turn l/6 of a turn

of a

turn

l/4

l/2 of a turn One full turn -

l-12

GENERAL INFORMATION

l%‘l

,-

MAJOR PART FIXING NUTS AND IBOLTS

Cylinder Head and Cover

kgam (Ib.ft)

i ‘I.

:

_-

i

1. 9

/-

.) ‘c.

.c-”

k *

.

‘k

Y-y..-.

‘f. , \.

.-

’

.( I

For laminated

steel sheet

gasket

Mosz . . . . . .

7.0+9.0*0.5

(50.6)+(65.1*3.6)

L

Apply MoS2 grease

Molybdenum disulfide paste.

+goo-1200

/,,::::if6,/

-

GENERAL INFORMATION

l-13

Cylinder Body

kgam (IbIt)

*fly

A’@ $,

J$ , I.;

I J

.’ a

/

H

e

/

/i,

23-25

(166481)

r-l

Apply engine oil

;

/

:’

1.6-2.6

(11.6-18.8)

lllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllll

1/*---\I-

I

1-14

GENERAL INFORMATION

Oil Pan and Dipstick

kgem

(Ib.ft)

. .

2.1-3.1

(15.2-22.4)

GENERAL INFORMATION

1-15

Camshaft and Rocker Arm

kgSm (Ib.ft)

Lubricate with engine oil

1

68 1 4.5-6.5 (32.5-47.0)

1

4B 1 4.3-6.3 (31.1-45.6)

1 1

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I

II

1-16

GENERAL INFORMATION

Crankshaft, Piston, and Flywheel

kgam (Ib.ft)

,-

‘/’

.f

: .

.

^ -’ F

,.

s’

,

,A.

,;.. ‘,

*.

.P ;. ’

3

L%

.4r-*

.

1, ‘1”

;

:

. .

I

6B

Apply MoS2 grease

zA .

1

4B

1

I

\,

- - --

(-los-127)

Apply engine oil

(

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I

II

GENERAL INFORMATliN

1-17

Thermostat and Thermostat Housing

kgom (lb&)

2.1-3.1

(15.2-22.4)

4.3-6.3

(31.1-45.6)

I

4.3-6.3

(31.1-45.6)

/

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I

I

1-18 ?GENERAL INFORMATION

Intake and Exhaust Manifold

1 2.1-3.1 1

(15.2-22.4)

I

-U

\

.

\

/

kgam (Ib.ft)

*. .

,:.

,..l

c

‘2

*’

/

:

6\

pi

f

y

,/c-A

/’

T

-.

*

GENERAL

INFORMATlOffI

1-19

liming Gear Case and Flywheel Housing

9

‘3

- 1,;’ \

‘- .

‘k \

\- l

lb ‘i-1 2,

-3 . ’ 5.. ‘. -. \;. ‘.i

\

9

G 3

Q . 3

n ’

@

3 9’

%%

wr

\i’q;, {

0 ’ \\,! ‘\

9

-A 3

g”

0

; ’

‘9

4

‘, ---p\\Q

T ‘>

c

j-i

\

9 1

“. 3-i

kgem (Ib.ft)

3.

if

1 2.1-3.1

1 (15.2-22.4) 1

Outer side

l(15.2~22.4) 1

inner side

l-20

GENERAL INFORMATION

Oil Coo&, Oil Filter, and Oil Pump

kaba -y-,

kgem (Ib.ft)

/ (3:::::6, /

0 40 3.14.1 (22.b36.1)

6B 1 4.3-6.3 (31.1-45.6) 1

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ets

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Refer

to the section MAINTENANCE

(15.2-22.4)

Fuel System

' 1.7-2.1

(12.3-15.2)

c

kgom (Ib.ft)

/ (l::zYo, j

3.4-5.0

(24.6-36.2)

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2.1-3.1

(15.2-22.4)

l-22 GENERAL INFORMATION

Turbocharger

1 6B 1 2.1-3.1 (15.2-22.4) 1

46

1.2-l .6

(8.7-11.6)

4.3-6.3 (3

2.2-3.2

(15.9-23.1)

kgmm (Ib.ft)

1.1-45.1)

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IDENTIFICATIONS

MODEL IDENTIFICATION

Engine Serial Number The engine number is stamped on the front left hand

side of the cylinder body.

GENERAL INFORMATION

l-23

-p-

Engine serial number

Engine serial number- \--

Pump No.

NP-PE

(LICENCE BOSCH)

a************

*******~***a******

J&;

48

INJECTION PUMP IDENTIFICATION

Injection Pump Number Injection volume should be adjusted after referring to

the adjustment data applicable to the injection pump installed.

The injection pump identification number (A) is stamped on the injection pump identification plate.

Note: Always check the identification number before begin-

ning a service operation.

Applicable service data will vary according to the identification number.

result in reduced engine performance and engine damage.

Use of the wrong service data will

@ -*identification number ’

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II I I I I

MEMO

............................................................................................................................................................................................................................................................

. . . . . . . . . . . .

. ..-....-................~...........................................................*..............................

.......................................................................................................................................................................................................................... ................................

....................................................................................................................................................................................................................

......................................................................................................................................................................................................................... ...................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

........................................

.................................................................................................................................................................................................................................... ........................

.....................................................................................................................................................................................................................

.......................................

r:

* ............... ..- ..........................................................................................................................................................................................................................................

SECTION 2

MAINTENANCE

TABLE OF CONTENTS

MAINTENANCE

2-1

ITEM

Lubricating system Fuel system Cooling system Valve clearance adjustment

Injection timing Compression pressure measurement

Turbocharger inspection

Engine repair kit Recommended lubricants Engine oil viscosity chart

Note: Maintenance intervals such as fuel or oil filter changes should be referred to INSTRUCTION BOOK.

.................................................................................................

........................................................................................

............................................................................................

.............................................................................

............................................................................................

...................................................................

..................................................................................

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. -

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PAGE

2- 2 2- 3 29 7 29 2- 9

2-15 2-16

2-17

2-19

7

2-2

MAINTENANCE

c*

0

Q

ELI

*c

cl

Paper element

r

w

m- Gasket W Spring seat

@-Spring

c>- O-ring A

Filter

body

r====h

c)-------- O-ring 6

LUBRICATING SYSTEM

Main Oil Filter Replacement Center Bolt Type Removal

1. Loosen the drain plug to drain the engine oil from the oil filter.

2. Remove the center bolt and the filter body from the filter cover along with the filter element.

3. Discard the used filter element.

4. Wipe the oil filter fitting face clean with a rag. This will allow the new oil filter to seat properly.

Installation

1. ln.stall the two O-rings A and 6 and check that they are correctly positioned.

2. Reassemble the filter body with the center bolt.

.

Center Bolt Torque

3. Check that the gasket is properly seated. This will prevent oil leakage.

. -

Drain Plug Torque

4.3-6.3 (31 .l-45.6).

1 S2.0 (11 Sl4.5)

kg.m (lb.ft)

kg.m (Ib.ft)

1

i

‘* /

a

I

Partial

filter

I-

lb-----

- Cartridge

Drain plug

Center bolt

O-ring

Drain plug

Cartridge (Spin-On) Type

Removal

Removal and Installer: Filter Wrench

*II)

I I

I

q

*c

III

1. Loosen the used oil filter by turning it counterclock-

1

2. Discard the used oil filter.

Installation

1. Wipe the oil filter mounting face with a clean rag.

2. Lightly oil the O-ring.

3. Turn in the new oil filter until the sealing face is fit-

4. Use the filter wrench to turn in the oil filter an addi-

5. beck the engine oil level and replenish to the speci-

6. Start the engine and check for oil leakage from the

wise with the filter wrench.

This will allow the new oil filter to seat properly.

ted against the O-ring.

tional 3/4 of a turn or one turn.

fied level if required.

oil fi Iter.

. 1

CIS

cl

MAINTENANCE 2-3

FUEL SYSTEM

Fuel Filter Replacement Center BoltType Removal

1. Loosen the drain plug @ to drain the fuel from the fuel filter.

2. Loosen the center bolt @ to remove the filter body 0, the spring 8, the washer 0, the gasket @, and the filter element @.

3. Discard the used element.

5l

*c

0

5l

Installation

‘I. Wash the filter body and the other parts immersing

them into clean diesel oil.

2. Reassemble the parts in reverse order. Use the new

element.

3. Check that the gaskets are properly seated.

This will prevent fuel leakage.

1. Loosen the fuel filter by turning it counterclockwise with the filter wrench or your hand. Discard the

0

used filter. Filter Wrench

2. Wipe the fuel filter fitting face clean with a rag. This will allow the new fuel filter to seat properly.

2-4

MAINTENANCE

installation

1. Apply a light coat of engine oil to the O-ring.

2. Supply fuel to the new fuel filter. This will facilitate air bleeding.

3. Turn in the new fuel filter until the filter O-ring is fitted against the sealing face.

4. Use the filter wrench to turn in the fuel filter an additional 2/3 of a turn.

Overflow Valve Check the overflow valve for clogging. Check the ball side for suction leakage

kg/cm2( psi)

r

Overflow Valve Opening Pressure (Reference)

.

Injection Nozzle Inspection procedure

1. Clamp the injection nozzle holder in a vise.

2. Use a wrench to remove the injection nozzle holder cap.

3. Remove the injection nozzle holder from the vise.

Adjusting Procedure Injection Starting Pressure Check

1. Attach the injection nozzle holder to the injection nozzle tester.

2. Loosen the adjusting screw 0.

3. Check the injection nozzle starting pressure and the spray condition by operating the injection nozzle tester.

4. Adjust the injection nozzle starting pressure. Turn the adjusting screw clockwise while operating

the injection nozzle tester handle.

1.5 (21) .

-.

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

MAINTENANCE Z-5

- -

I-

0

. J

(1)

(2)

(3)

A

&$&!+&& 52

.

: *;

l

kg/cm2 (psi)

4BGl

Injection Starting Pressure

WARNING TEST FLUID FROM THE NOZZLE TESTER WILL SPRAY

OUT UNDER GREAT PRESSURE. PUNCTURE A PERSON‘S SKIN. KEEP YOUR HANDS

AWAY FROM THE NOZZLE TESTER AT ALL TIMES.

Spray Condition Check (During Injection Operation)

1. Tighten the

cap nut.

150

(2134)

4BGlT,

6BG1,GBGlT

185

(2630)

IT

CAN EASILY

Nozzle Tester

2. Check the injection nozzle starting pressure.

3. Check the injection nozzle spray condition.

Operate the injection nozzle tester hand

lever 4 to 6

times a second while looking for abnormal injection

nozzle spray conditions. Refer to the illustration for different spray

(1) Good (2) Bad (Restrictions (3) Bad (Dripping)

in

orifice)

conditions.

Feed Pump Strainer

5l

1. Remove the joint bolt.

2. Use a screwdriver to remove the strainer. 3, Wash the strainer in clean diesel fuel.

0

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

2-6

MAINTENANCE

St raker

a Water Separator (Water Sedimentor)

1

I0

(Optional Equipment)

Check the water separator float @ level.

If the float @ has reached level 0, loosen the drain plug @ (at the bottom side of the water separator) to drain the water.

Drain Plug Torque

kg.m (Ib.ft)

0.945 (6.5-10.8)

1

i

4, G

.’

/: i ‘<.

Air Bleeding

1. Loosen the feed pump cap Q’) on the injection pump.

2. Loosen the fuel filter fuel return eye bolt 0.

3. Operate the feed pump until there are no more bubbles visible in the fuel being discharged from the fuel filter fuel return eye bolt.

4. Retighten the fuel filter fuel return eye bolt.

5. Operate the feed pump several times and check for fuel leakage around the injection pump and the fuel filter.

II

ICI

MAINTENAiiiCE 2-7

COOLING SYSTEM

Cooling Fan Drive Belt Adjustment

4

1. Check the cooling fan drive belt for cracking and

e

other damage.

2. Check the drive belt tension by exerting a force of 10 kg (221b) midway between the fan pulley @ and the generator 0.

3. Adjust the belt tension by loosening the alternator

mounting bolt and the generator adjusting bolt and pivoting the generator.

Be sure to retighten the bolts after adjusting the belt

tension.

*

Cooling Fan Drive Belt Deflection

8-O-12.0 (0.3-0.5)

mm (in)

,

4

Agitating rod

Thermometer

- Wood piece

4B

ICI

.

ISI

Thermostat

Inspection Visually inspect the thermostat.

Replace the thermostat if excessive wear or damage is discovered during inspection.

Measure the valve lift.

mm (in)

Amount of Valve Lift at 95OC (203°F)

I

c

Valve Opening Temperature

10.0 (0.39)

“C( “F)

80-84 (176483)

VALVE CLEARANCE AND ADJUSTMENT

Note: The cylinder head bolts were previously tightened with

the “Angular Tightening Method”. Therefore, it is not

onecessary to retighten the cylinder head bolts before

adjusting the valve clearance.

lcrl

1. Bring the piston in either the No. 1 cylinder or the No. 6 cylinder to Top Dead Center on the compression stroke by turning the crankshaft until the TDC notched line on the crankshaft pulley is aligned with

the timing pointer.

2. Check to see if there is play in the No. 1 intake and exhaust valve rocker arms.

If the No. 1 cylinder intake and exhaust valve rocker arms have play, the No. ‘I piston is at TDC on the compression stroke.

If the No. 1 cylinder intake and exhaust valve rocker arms are depressed, the No. 6 piston (No. 4 piston for the 4BGl) is at TDC on the compression stroke.

w front

I

0 @’

0 l * 0 0 -00 000

I n\

08’ o(g)’ O@’

-0. 00. -@

0 @i@@

6B

I

4

Bl

Adjust the No. 1 or the No. 6 (No. 4 for the 4BGl) cylinder valve clearances while their respective cylinders are at TDC on the compression stroke.

mm (in)

Intake and Exhaust Valve Clearance (cold)

3. Loosen each valve clearance adjusting screw as shown in the illustration.

4. Insert a 0.40 mm (0.016 in) feeler gauge between the

rocker arm and the valve stem end.

5. Turn the valve clearance adjusting screw until a slight drag can be felt on the feeler gauge.

6. Tighten the lock nut securely.

7. Rotate the crankshaft 360°. Realign the crankshaft pulley TDC notched

the timing pointer.

8. Adjust the clearances for the remaining valves as shown in the illustration.

0.40 (0.016)

line with

.

When No.1 cylinder at TDC

in compression stroke

i

MAINTENANCE 2-9

When

No.6

comgmession

a Front

When

No.1 cylinder

in compression

cylinder at TDC

stroke

is at

stroke

TDC

4B

I

Rocker Arm Screw Lock

Nut Torque

Note:

The valve clearance adjustment procedure for the 4BGl

engines is identical to that for the 6BGl engines. Only

the number of cylinders is different.

2.1-3.1 (15.2-22.4)

kg.m (Ib.ft)

e Front

When No.4 cylinder is at in compression stto ke

TDC

4B

7

0

V

Note:

Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made.

FLANGE MOUNTED INJECTION PUMP INJECTION TIMING CHECKING AND ADJUSTMENT

The flange mounted injection pump is installed behind the timing gear case.

2-10 WIAINTENANCE

lcll

Checking Procedure

1. Align the crankshaft pulley TDC mark with the pointer.

Remove the inspection hole cover at the front of the injection pump on the timing gear case cover.

Check the alignment between the pointer @ on the injection pump gear nut lock plate and the projection area mark @ on the injection pump gear

If ‘it is in misalignment, recheck with turning the crankshaft pulley one more turn to repeat the aforegoing procedure to mark sure that it is in alignment.

Check the alignment of the notched lines @ and @. (These notched lines were aligned at the factory to

set the injection pump body and the mounting flange.)

Next, inspect the crankangle position of the injection

starting.

2. Reversely turn the crankshaft pulley counterclockwise about 30* crankangle.

case.

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1

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c*

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c+

0

*c

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3. Disconnect the injection pipe from the No. 1 plunger.

This will allow you to visually check the full injection

starting flow at No. 1 plunger.

4. Remove the delivery valve holder 0, the valve seat 0, valve spring @ the delivery valve @ from the No.

1 plunger.

5. Reinstall the delivery holder @ and tighten it to the specified torque.

IDO not reinstall the delivery valve spring, the valve

seat and the delivery valve. These parts will be reinstalled later.

MAINTENANCE

2-11

6. Hold the

7. Slowly turn the crankshaft pulley clockwise, at the same time, continue to feed the fuel with pumping

the priming pump. When the fuel stop to flow out from the No. 1 deliv-

ery valve holder, stop the pump instantaneously.

This crankangle position is the injection starting of

the engine.

8. Observe and make sure that mark (injection starting angle line CX”) on the crankshaft pulley with the pointer.

The the

Blow out the remaining fuel from the holder.

Make

fuel

control lever at the fully open position.

timing line shows

the injection

engine.

sure that there is no fuel

is aligning

lg angle of

startir

ivery valve

del

being delivered from

the priming pump.

6BGl

4BGl

*

Damper pulley

r case

Pulley

Note 6BGl engine

the crankshaft damper pulley. 4BGl engine has eight timing notch lines punched on gear case side, and TDC

mark on

These notched timing.

Refer to the illustration.

Injection Timing B.T.D.C

I I

al Injection Timing B.T.D.C

‘I

has

eight timing notch lines punched on

crank pulley.

lines

must be aligned for correct -engine

Degree

I

GBGIT

12

Degree

12

6BGl

12

4BG1 / 4BGlT 1

14

I

2-12 MAINTENANCE

- Holder

8

- Seat

0

-Spring

f

+I)

l-l

*c

l-l

Note:

Injection pump injection timing will vary among identi-

cal engines contact your machine supplier or nearest

ISUZU engine service outlet for the specifications applicable to your engine.

These specifications have been set by

OEM manufacturer.

9. Remove the delivery valve holder from the No. 1 plunger.

10. Reinstall the delivery valve internal parts (seat, spring, and valve) to the delivery valve holder.

11. Reinstall the delivery valve holder assembly to the

No. 1 plunger and tighten it to the specified torque.

Delivery Valve Holder Torque

e

ISUZU

kg.m (lb.ft)

4-4.5 (29-33)

and the

,

.

7

0

V

12. Install the No. 1 cylinder injection pipe and tighten it to the specified torque.

_ -

kg.m (lb.ft)

Injection Pipe Nut Torque

Note:

DO NOT OVERTIGHTEN THE INJECTION PUMP BODY.

THE INJECTION PUMP BODY IS MADE OF ALUMINUM.

OVERTIGHTENING WILL DISTORT THE INJECTION PUMP BODY SHAPE AND ADVERSELY AFFECT CON-

TROL RACK OPERATION.

Adjusting Procedure

1. Align the pointer and the specified timing mark on the crank pulley.

2. Perform the operations paragraphs 3, 4,5, 6.

3. Loosen the four injection pump fixing nut.

4. To advance the timina Pivot the injection pump at the pump driveshaft

toward out. To retard the timing.

&ot the injection pump at the pump driveshaft toward in. (toward the cylinder block)

Reference; the 1 mm misalignment between the two setting mark lines corresponds to about 2’ in crankangle.

2.9-3.3 (2 l-24)

described on page

2-10, 11,

MAINTENANCE 2-13

Do a fine injection pump position

5 .

continue the pumping operation to

and stop to pivot the injection stop to flow out from the No. 1 delivery valve holder.

Tighten the four injection pump fixing nuts.

6 . 7 .

CI)

q

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cl

Once remove the No. 1 delivery valve holder, and

reinstall holder with the specified torque.

.

Install the No. 1 injection pipe and tighten it to the

8

specified torque.

the delivery valve, spring

lzl

COUPLING DRIVEN INJECTION PUMP TIMING ADJUST-

MENT

The coupling driven injection pump is installed at the

middle of the cylinder body. It is driven by the injection pump drive shaft.

1. Injection timing is initially adjusted by aligning the

IBI

a a

4

Kl

notched line 5 on the crankshaft damper pulley with the pointer 6.

Fine adjustment is made by rotating the injection

pump drive coupling. Rotating the injection pump drive coupling counter-

clockwise will

Rotating

wise will

the

retard the injection timing.

pump when the

advance the

injection pump drive

injection

adjustment, while

feed the fuel,

fuel

and the valve

timing.

coupling clock-

Notchled fines

2. Loosen the two coupling bolts on the injection pump

drive coupling.

Coupling bolt

2-14

--MAMVTENANCE

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3. Perform the operations paragraphs 3, 4, 5, 6.

4. Slowly turn the coupling counterclockwise (viewed from the timing gear case).

At the same time, operate the priming pump to feed fuel to the No. 1 injection pump plunger.

Visually check that fuel is being fed (from the top of

the delivery valve holder).

5. Continue to operate the priming pump. Turn the coupling counterclockwise until the fuel

stops flowing from the delivery valve holder. This is the fuel injection starting point at the No. ‘I

plunger.

described

on page

2-10, 11

. .

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6. Blow out the remaining fuel from the delivery valve holder.

7. Check that there is no fuel being delivered from the priming pump.

8. Retighten two coupling bolts.

9. Perform the operations described on page 2-12 paragraphs 9, 10, II, 12.

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

.

:

m

1. Operate the

2. Remove all of the glow

3. Attach a compression gauge to the No. 1 cylinder

MAINTENANCE

engine

temperature reaches to 75OC (167°F).

pipes.

glow plug installation threads.

to warm-up until the coolant

plugs

and the injection

2-15

Compression

gauge adaptor

Note:

Compression pressure may be measured starting

cylinder and in no particular cylinder order. However, it

is very important that the compression pressure be mea-

sured in Therefore, start at

this way, you will be sure to measure the compression

pressure Compression Gauge:

Compression Gauge Adapter: 5-85317-003-O (JKM-1015)

4. Crank

I

5. Repeat the procedure

each

cylinder.

the

No.1 cylinder and work back. In

in each

the

compression gauge

31 .o (441)

ing cylinders. Compression pressure should be approximately the

same for each cylinder.

kg/cm* (28

If the measured the related parts

cylinder.

engine with the starter motor and take the

reading. _

kg/cm* (psi)

Standard

psi) is unacceptable.

value exceeds the specified

must

(Steps 2 and

be

at 200

I I

A variation exceeding 2.0

checked.

rpm

Limit

26.0 (370)

3) for the remain-

at any

at sea level

limit,

I I

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

2-16

MAINTENANCE

TURBOCHARGER INSPECTION

1. Check the air intake duct connections for air leakage.

4F

It

2. Check the intake manifold connections for air Ieakage.

3. Check the exhaust duct connections for smoke leakage.

_ -

4. Check the turbocharger mounting nuts for looseness.

5. Check the oil feed pipe for oil leakage.

6. Check the oil return pipe joints for oil leakage.

ENGINE REPAIR KIT (FOR NATURALLY ASPIRATED ENGINES)

MAINTENANCE

2-17

1. Cylinder head gasket

2. Cylinder head cover gasket

3. Inlet manifold gasket

4. Exhaust manifold gasket

5. Thermostat housing gasket

6. Thermostat gasket

7. Tappet chamber cover gasket

8. Tappet cover fixing bolt gasket

9. Crankshaft rear end oil seal

10. Timing gear case oil seal

11. Valve guide

oil seal

12. Oil pan gasket

13.

Drain

plug gasket -

14.

Oil filter cover gasket

15.

Oil filter fixing bolt gasket

16.

Oil cooler gasket

17 .

Gear

case to cylinder block gasket

.

Cover to timing gear case gasket

18

.

Relief

19

.

20 21 .

.

22

.

23

.

24

.

25 26 .

.

27

.

28

.

29

.

30

0

31

.

valve O-ring

Cylinder

block side plug gasket

Water drain valve gasket

Oil pump hole cover gasket

Water

Oil pipe Oil Fuel

Leak off pipe joint

Injection nozzle gasket Injection Injection pump oil pipe gasket Cylinder head cover nut gasket

pump

gasket

pipe gasket

pipe joint

pump

bolt

gasket

bolt gasket

oil pipe gasket

.

248

MAINTENANCE

.

ENGINE REPAIR KIT (FOR TURBOCHARGED ENGINES)

1. Cylinder head gasket Cylinder head cover gasket

2.

3. Cylinder head cover nut gasket

4. Tappet chamber cover gasket

5. Chamber cover fixing bolt gasket

6. Oil pump hole cover gasket

7. Oil relief valve gasket

8. Water drain valve gasket

9. Gear case to cylinder block gasket Crank pulley to gear case oil seal

10. Gear case cover gasket

11. Crankshaft rear end oil seal

12.

13. Valve guide oil seal

14. Drain plug gasket

15. Oil pan gasket

16. Oil pipe gasket

17. Oil filter gasket ’

18. Oil filter fixing bolt gasket

19. Oil cooler gasket

20. Oil pipe joint gasket

21. Joint bolt gasket

22. Oil pipe gasket injection pump oil pipe gasket

23 . 24 .

Injection pump oil pipe gasket

25 .

Water pump gasket

26 .

i

Thermostat housing gasket

27 .

Intake manifold gasket

28 .

Inlet pipe manifold gasket

.

29

Exhaust manifold gasket

30 .

Exhaust manifold to turbocharger gasket

31 .

Oil feed pipe gasket

.

.Oil drain pipe gasket

32

.

Oil drain pipe gasket

33

34 .

Overflow fuel pipe gasket

95 .

Injection nozzle gasket

.

36

Injection nozzle leak off pipe gasket

37 .

Thermostat gasket

RECOMMENDED LUBRICANTS

..*.*.*.).~**...*

~.~.~.~.~.~.,.~.

,,...

.

::

.,.,.,.,.,.~.~.,.~.~.~.,.,.~.,.,.~.,.~.~.~.,,~.~.

MAINTENANCE 2-19

[Single grade]

_ -

Ambient

‘temperature

ENGINE TYPE

Without turbocharger

With turbocharger

ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE

AE

I

.,......................................-....

I

-3o*c

(-22°F)

-15*c (0°F)

TYPES OF LUBRICANTS (API)

20, 2()W

-0°C

(32°F)

iiiiiiiiiiiiiiiiiiiiiiiiijiiiiiiiiii

Diesel engine oil

CC or CD grade

Diesel engine oil

CD grade

I

15*c

(60°F)

~::;~~~~~~$ SAE 40, 50 5:;

.,.:.I.

v

25*C 3O*C

(80°F) (90°F)

.

. . . . .

. . . .

:.:.I.:.

[Multi grade]

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

MEMO

...... ..-.................................-

........................................... .............................................................. .........

...........

....................

................ ................

...

....... ..... .........

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................................................................-........

. . . . . . .._.....................................-....-................-...................-............................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . ..-..................................................-..............................................................................................-............................................

................................................................................................................................................................................................ ...........................

.....................................................................................................................

........................................................................

...............................................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . ..-..-.....-................

.................................

......................................................................................................................................................................................... ...................................................................

.................................................................................................................... ................................................................................

........................................................

f’

*’ *.

,! I. i. ‘?.

,

/ ‘:

.....................................................................................................................

....................................................................................................................

................................................................................................................................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............................................................................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..-..-..........-...........................................................................................................

........................................................................

......................................................................................

...............................................................

@

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..-..

...............................................................

..................................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.............................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3

ENGINE ASSEMBLY I

(DISASSEMBLY)

TABLE OF CONTENTS

ENGINE ASSEMBLY I 3-1

ITEM

External parts disassembly steps Major components Rocker arm and rocker arm shaft disassembly steps Cylinder head disassembly steps Piston and connecting rod disassembly steps

.........................................................................................

........................................................................

.........................................................

.................................................

PAGE

3- 2 3- 7 3-12 3-13 3-14

3-2 ENGINE ASSEMBLY I

+$+ EXTERNAL PARTS DISASSEMBLY STEPS

cl

MODEL 6BGlT

(Right-hand side)

Disassembly

1 .

Cooling fan

.

2

Not installed

3

Intake

l

4 .

Fuel return pipe

.

5

Fuel pipe; fuel filter to injection Pump

6 .

Fuel pipe; feed pump to filter

7 .

Injection nozzle and leak off pipe

8 .

Injection pipe

pipe

Steps

12

i

9. Oil pipe; injection pump to cylinder body

10. Not installed

11. Oil pipe; filter to oil cooler

A 12.

0

Injection pump with injection pump

gear

13. Fuel filter

14. Oil filter

15. Glow plug

MODEL 4BGlT

ENGINE ASSEMBLY I 3-3

6

15

S-

14-

Disassembly Steps

1. Cooling fan

2. Not installed

3. intake pipe

4. Fuel return pipe

5. Fuel pipe; fuel filter to injection pump

6. Fuel pipe; feed pump to filter

7. Injection nozzle and leak off pipe

8. Injection pipe

9. Oil pipe; injection pump to cylinder body

10. Not installed

11. Oil pipe; filter to oil cooler

A 12. Injection pump with injection pump

gear

13. Fuel filter

14. Oil filter

15. Glow plug

3-4 ENGINE ASSEMBLY 1

7

0

V

important Operations

12. Injection Pump with injection Pump Gear Use the shipping plugs (or something similar) to

seal the injection pump delivery valve ports. This will prevent the entry of foreign material.

Flange Mounted Injection Pump Removal

1)

Remove the injection pump flange bolts.

2) Pull the injection pump with the injection pump drive gear free.

Refer to the illustration.

Coupling Mounted Injection Pump Removal

1) Remove the two coupling bolts to disconnect the coupling.

2) Remove the injection pump mounting bolts.

3) Remove either the injection pump bracket bolts or the injection pump fixing bolts.

Mark

Remove of the Air Compressor (if so equipped)

Before the air compressor is removed the injection pump must be unfastened from the mounting bracket to permit the pump to be moved freely on the mounting

bracket.

1. Remove the injection pump coupling bolts 0.

2.

Remove the injection pump mounting bolts and shift

the pump to the rear about 50 mm (2 in).

3. Remove the air compressor mounting bolts @.

4.

Pull out the compressor to the rear about 50 mm in) to pull out the air compressor crankshaft front end spline from the injection pump drive gear.

5. After removal, visually make sure that the crankshaft end spline

pump drive gear shaft have fitting marks. Those marks are important for reassembly.

and

the female spline of the injection

(2

MODEL 6BGlT

ENGINE ASSEMBLY‘ I

+$+ EXTERNAL PARTS DISASSEMBLY STEPS

El

(Left-hand side)

3-5

Disassembly Steps ,

1.

Dipstick and guide tube

2. Air breather

3. Turbo adaptor

4. Oil feed pipe

5. Oil drain pipe

A 6. Turbocharger

7. Gasket

8. Starter

9. Fan belt

10. Generator

11. Fan pulley

12. Cylinder head cover

3-6 ENGINE ASSEMBLY I

IVfODEL 4BGlT

30

ll-

-8

Disassembly

1.

Dipstick and guide tube

2. Air breather

3. (Not installed)

4. Oil feed pipe

. 51 Oil drain pipe

A -6. Turbocharger

Steps

7. Gasket

8. Starter

9. Fan belt

10. Generator

11. Fan pulley

12. Cylinder head cover

Important Operations

6. Turbocharger

Plug oil ports in turbocharger

a&r removal of the turbocharger.

body

immediately

MAJOR COMPONENTS - I

ENGINE ASSEMBLV I

37

. t

Disassembly Steps *

1. Rubber hose ; water by-pass

A 2. Rocker arm shaft assembly

3. Push rod

A 4. Cylinder head bolt

5. Cylinder head assembly

6. Cylinder head gasket

7. Water pump assembly

8. Tappet

chamber cover

9. Oil pump driving

A

10. Starting handle

A

11. Taper bushing

12. Crankshaft pulley and dust thrower

13. Timing gear

14. Oil thrower

A

15. Flywheel

pinion

nut

cover

* : Repair-kit

3-8 ENGINE ASSEMBLY 1

6B ser.-

4B series

Front

I

6B series

I

r

‘V

n

IQI

Important

2. Rocker Arm Shaft Loosen the rocker arm shaft fixing bolts a little at a

time in numerical sequence as specified.

4.

Cylinder Head Bolts

Loosen the cylinder head bolts a little at a time in

the numerical order shown in the illustration.

Cylinder head bolt wrench:

Operations

l-851 11-003-O

4B series

1

10. Crankshaft Pulley Nut Wrench:

Wrench: 42 mm (1.65 in) for 4B series

Use an appropriate wrench to remove the crankshaft pulley nut.

@,

54

mm

(2.13

in) for 6B series

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

‘- 0 *

/’

0

t-b

O 0

/J

O@@ 0 0

0

0 0

0

O 0

zc @ cc

0

ENGINE ASSEMBLY I 3-s

11 .

Taper Bushing (6B series only) Remover: 9-852 l-01 22-O Use the taper bushing remover to remove the crank-

shaft end taper bushing.

15.

Flywheel

0

Loosen the flywheel bolt a little at a time in the numerical order as specified.

.

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

3-10 ENGINE ASSEMBLY 1

MAJOR COMPONENTS - II

* : Repair

kit

i

Disassembly Steps

1

.

Oil cooler

2

.

Oil pan

3

Oil pump and coupling

4:

Flywheel housing

5

Piston and connecting rod

A

6'

Idler gear

A

7'

.

Camshaft

8

.

Tappet

9. Timing gear case

10. Idler gear shaft

A 11. Crankshaft bearing cap

12.

Crankshaft bearing (lower half)

13.

Thrust bearing

14. Crankshaft

c 15. Crankshaft bearing (upper half)

. ’ ‘I!

16. Oiling jet

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

ENGINE ASSEMBLY I

I

7

0

v

Important Operations

6.

Idler Gear

Measure the following points before disassembly.

Standard Limit

Idler Gear End Play

0.128-0.185 02

(0.005-0.0070)

(O.d08)

3-11

mm (in)

Dial indicator ’

Feet& gauie

!

Feeler gauge

Standard

Timing Gears

Backlash

I

Includes the crankshaft gear, the camshaft gear, and the idler gear.

I

7 Camshaft

Measure the following points before disassembly.

I

c

i

OK255

w

Cam Gear End Play

.

11. Crankshaft Bearing Cap

.

Measure the crankshaft end play at the thrust bearing (center main bearing) before disassembly.

Crankshaft End Play

0.10-0.17 03

(0.004-0.007)

Standard

0.050-0.114

(0.002-0.005)

Standard

0.15-0.33

(0.006-0.014)

Limit

(O.il2)

mm (in)

Limit

02

(O.do8,

mm (in)

Limit

04

(o.dl6,

I

1

I

Crankshaft

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I 17

3-12 ENGINE ASSEMBLY I

+++ ROCKER ARM, AND ROCKER ARM SHAFT

0

+ DISASSEMBLY STEPS

Disassembly Steps

1. Bracket

2. Rocker arm

3. Spring

4. Rocker arm shaft

ENGINE ASSEMBLY I 3-13

+$+ CYLINDER HEAD DISASSEMBLY STEPS

0

Disassembly Steps

1. Exhaust manifold and gasket

2. intake manifold and gasket

3.

Water outlet pipe

4.

Thermostat

5.

Thermostat housing and

A 6. Spiit collar

gasket

77

7.

8. Valve

9.

10. Valve

11.

7

0

Important Operation

.

6. Split collar

Use the valve spring compressor to remove the split

@I

collar. Valve Spring Compressor: l-85235-006-0

Spring seat

Spring seat (lower) -.

Valve stem oil seal

(upper) or

spring

4BG1

* : Repair kit

*Valve

(if so equipped)

rotator

Valve

spring compressor

3-14 ENGINE ASSEMBLY I

+++ PISTON AND CONNECTING ROD

cl

+ DISASSEMBLY STEPS

:‘. >

.

$4

Disassembly Steps

A

1.

Piston rings

A 2. Snap ring

A 3. Piston pin and connecting rod

4. Piston

5. Connecting rod bearing

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

carbon &

7

0

V

ENGINE ASSEMBLY I 3-15

Important Operation

Note:

Remove any carbon deposits from the upper part of the cylinder bore.

This will prevent damage

rings

when they are

1 .

Piston Rings

Use a piston ring remover to rings.

Do not attempt to use

stretching

Piston

ring remover:

removed from the cylinder bore.

will result in reduced piston ring

to the piston

remove

some other

and the piston

the piston

tool. Piston ring

tension.

Piston

2,3.

Snap

Ring and Piston Pin

(1) Use a pair of snap ring pliers to remove the

snap

ring.

(2)

Tap the

bar

piston pin out with a hammer and brass

.

MEMO

....................................... ...............

......................................

......................................................... ............

..............................

.......... ...............................

........

..................................................................................................................................................................................................................... ........................

....................................

...................... ...........

............... ..................................................................................................................

..................................................................................................................................................................................

............................ ... .... ............ w ...................

.......................................................

.......................................................................................... . ................................

............................................... ...................................

..................................

..........

............................................................................................................................................................

............................................................................................................................................................................................................................................................

............................................................................................................................ ...............................................................................................

. . . . . . . . . ..I.......................................................~.......~...............................................

. . . .._..............................................................

...............................................

.................................................

.................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE ASSEMBLY II 4-1

SECTION

4

ENGINE ASSEMBLY II

(INSPECTION & REPAIR)

TABLE OF CONTENTS

Cylinder head ............................................................................................... 4-2

Valve guide .................................................................................................. 4- 3

Valve spring ................................................................................................. 4- 6

Tappet Push rod

Rocker arm shaft and rocker arm ........................................................................ 4-8

idler gear and idler gear shaft . . . . . . . . . . . . . . ..*...................*.....*................................. 49 9

........................................................................................................ 4-7

..................................................................................................... A8

Camshaft

Cylinder body and liner ...................................................................................

Piston and piston ring Piston pin

Connecting rod .............................................................................................

Crankshaft ...................................................................................................

Flywheel and flywheel housing liming gear case cover

....................................................................................................

..................................................................................... 4-18

mmmmmmmmsmmmmmmmmmmmmmmmmmmmmmmmmmmm~mmmmmmmmm~mmmmmmm~mmm~~mmmmmmmmmmmmmmmmmmmmm~mmmmm~mmm~~~~m~m~~

.......................................................................... 4-30

....................................................................................

440 4-11

A20 . A21 A23

4-31

4-2 ENGINE ASSEMBLY II

jlal INSPECTION AND REPAIR

Make the ered during inspection.

I \

~

necessary

\

“\

\

I -1-,-

\ c

0

.’

c

‘5

-- cj

3

adjustments, repairs, and part replacements if excessive wear or

CYLINDER HEAD

Cylinder Head Lower Face Warpage

1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder

head lower face.

2. Regrind the cylinder head lower face if the measured values are greater than the specified limit but

less than the maximum grinding allowance.

If the measured values exceed the maximum grinding allowance, the cylinder head must de replaced.

Cylinder Head Lower Face Warpage

=+- ‘. ?,.

. ’

E3

c;

3 . h-

0

.-Q

0

cl

=,C =g

I’ -

It

m

1’.

Standard

c,

t

I

0.05

(0.002) or less

I

Cylinder Head Height (Reference)

Standard

1 89.95 (3.541).90.05 (3.545) 1

Limit

02

(O.do8,

I

damage

Maximum Grinding

Limit

89.65 (3.530)

is

Allowance

03

co.& 2)

discov-

mm (in)

I

I I

Note:

If the cylinder head lower face is reground, valve depres-

sion must be checked.

Water Jacket Water Pressure Test

Use the hydraulic gauge to check the water jacket water pressure.

Apply water pressure to the water jacket at 5 kg/cm*

(71.1

psi) for three minutes.

a’%,)

Check the entire

cylinder head

for

water

leakage.

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

****I’%,*

‘,

..*‘\

2.

..r’

;-, ;

5..‘. (g y.:=.

\.”

‘*I

*.,.I...*

0

ENGINE ASSEMBLY II

&3

VALVE GUIDE

;

Valve Stem and Valve Guide Clearance

Measuring Method - 1

1. With the valve stem inserted in the valve guide, set the dial indicator needle to “0”.

2. Move the valve head from side to side

Note the total dial indicator reading (TIR).

This value is the clearance between the valve stem and the valve guide.

if the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set.

Valve Stem Clearance *

Intake Side TIR

Exhaust Side TIR

w

Standard

0.039-0.068

(0.001 S-0.0027)

0.064-0.096

(0.0025-0.0038)

mm (in)

Limit

0.20

(0.008)

0.25

(0.0098)

7

4

‘1.

--

Measuring Method - II”

1. Measure the valve stem outside diameter.

2. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter.

The difference between the valve stem outside

diameter and the valve guide inside diameter is equal to the valve stem clearance.

Valve Guide Replacement

c*

cl lal

/’

/

I f

i2

b

-/

V

Valve Guide Removal

Use a hammer and the valve guide remover to drive out

bl

the valve guide from the cylinder head lower face.

Valve Guide Remover: 9-8522-035-o

The height of the valve guide top edge from the cylinder

7

0

head upper face should be 14.1 mm.

-

OK

A

ENGINE

~~~

ASSEMBLY II

I 0 I /

/

,*

4

I

/,:

Valve Depression

1. install the valve @to the cylinder head 0.

2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder

head lower surface. If the measured value exceeds the specified limit,

the valve seat insert and/or valve must be replaced.

If the valve is replaced, the valve guide must be also replaced.

mm (in)

I I

Intake and Exhaust

Valve Depression

*

Standard

1 .o (0.039)

I

2.5 (0.098)

Limit

I

,f-

I

I*

\ . .

$

u:

I$

.,

\

Valve Contact Width

1. Inspect the valve contact faces for roughness and unevenness.

Make smooth the valve contact surfaces.

2. Measure the valve contact width. If the measured value exceeds the specified limit,

the valve seat insert must be replaced.

L

Valve Contact Width ( 1.5 (0.059)

1

Valve Seat insert Replacement

.

mm (in)

1 Standard 1

Limit

( 2.0 (0.078)

I

Valve Seat Insert Removal

1. Arc weld the entire inside circumference @ of the valve seat insert @.

2. %llow the valve seat insert to cool for a few minutes. This will invite contraction and make removal of the

valve seat insert easier.

5l

3. Use a screwdriver @ to pry the valve seat insert free.

Take care

4. Carefully remove carbon and other foreign material from the cylinder head insert bore.

Valve Seat Installation

1. Carefully place the attachment @ (having the smaller outside diameter than the valve seat insert)

on the valve seat insert 0.

Note:

The

smooth side of the attachment must contact the

valve seat

2. Use a bench press @ to slowly apply pressure to the

attachment and press the valve seat insert into

place. (Amount of pressure needed is more than

2,500 kg) Note: Do not apply an excessive amount of pressure with the

bench press. Damage to the valve seat insert will result.

not to damage the cylinder head @.

insert.

. -

Valve Seat Insert Correction

1. Remove insert surface.

2. Use valve scratches and other rough areas.

This will bring

dard value of 90’ @. Remove only the scratches and rough areas. Do not

cut away too much.

unblemished areas of the valve seat surfaces.

the

carbon deposits from the valve seat

cutters (15”,

the contact width

30°, or 75’ blades) to remove

back

to the stan-

Take care not to cut away

4-6 ENGINE ASSEMBLY IO

Angie Location Intake Valve Seat Angle @ Exhaust Valve Seat Angie @I

.

Note: Use an adjustable valve cutter pilot. Do not allow the cutter pilot to wobble inside the valve

guide.

3. Apply abrasive compound to the valve seat insert surface.

4. Insert the valve into the valve guide.

5. Hand lap the valve and the valve seat with a lapping cup.

This will provide optimum valve and valve seat contact for effective gas sealing.

6. Check that the valve contact width is correct.

7. Check that the valve seat insert surface is in contact

with the entire circumference of the valve.

Standard

45O

0

45

,

<

1*

i

‘.

Painted

/

port

ion

VALVE SPRING

Valve Spring Free Length

Use a vernier caliper to measure the valve spring free

.

:

lzu

length. If the measured value is less than the specified limit, the

valve spring must be replaced.

4BGl

I

1 Length

6BGl; with valve rotator

6BG I ; without valve rotator

L

1 Standard (

Exhaust and Intake

Valve Spring Free 49.0 (1.929)

~~~

1 Color 1 Standard 1

Exhaust

a’4

Exhaust

pink

1 Color I Standard 1

blue

mm (in)

Limit

47.0 (1.850)

mm (in)

Limit

55.0

(2.165) (2.087)

60.6

(2.39)

53.0

mm (in)

Limit

68.0

(2.68)

. ’

I

-.

Valve Spring inclination

Use a surface plate and a square

.

:

lIEI

@!I

spring inclination.

If

the measured value exceeds the specified

valve spring must be replaced.

Valve

Spring less than

Inclination

* Valve Spring Tension

Use a

.

spring tester to

If the measured value is less than the specified limit, the valve spring must

4BGl

Set

Length

40

mm (1.57 in)

be replaced.

.ENGlNE ASSEMBLY II 4-t

to

measure the

Standard Limit

1.3 (0.051)

measure the valve spring tension.

Standard Limit

14.5

(30.9)

(O.l.06)

13.0 (28.7)

valve

limit, the

mm (in)

27

kg (lb)

I

- 0

- I

Pitted

llll~ II

t

I II1

1

’ I

,I Ii/ii1

’

I rregu lar contact

Crack Normal contact 1

6BGl; with valve rotator .

Set Length

40 mm (1.57 in) 14.5 (30.9)

6BGl; without valve rotator

w-

Set Length Standard

44.5 mm

c

TAPPET (Cam Follower or Valve Lifter)

Inspect the tappets for excessive wear, damage and any

abnormalities.

(1.75 in) 14.5

Standard

(30.9)

13.0 (28.7)

kg (lb)

Limit

kg (lb)

Limit

1

4

Use a micrometer to measure the tappet

.

l3Ll

Tappet Diameter

Standard

27.97-27.98

(1.1020-1.1024)

diameter.

mm (in)

Limit

27.92

(1.1000)

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

d-8 ENGINE ASSEMBLY II

Use a dial indicator to measure the clearance between

.

:

@I

a

the tappet and cylinder body tappet travelling bore.

Tappet and Tappet Travelling Bore

Clearance

.

PUSH ROD

:

Use a filter gauge to measure the valve push rod run

out.

Roll the push rod along a smooth flat surface (illustra-

tion).

I

,

1 Standard 1 Limit - I

0.020-0.054

(0.001-0.002)

-Limit ~ - ~~ -1

Push Rod Run-Out 0.3

01

(O.dO4)

(0.012)

mm (in)

iI

“,

Rocker Arm Correction

Inspect the rocker arm valve stem contact surfaces for ridge @ and scoring @.

If the surfaces have light ridge or scoring, they may be honed with an oil stone.

If the ridge or scoring is severe, the rocker arm must be replaced.

ROCKER ARM SHAFT AND ROCKER ARM

Inspect all disassembled parts for wear, damage and any abnormalities.

Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm outside

.

:

El

diameter.

If the measured value is less than the specified limit, the shaft must be replaced.

Rocker Arm Shaft Diameter

@

Standard Limit

18.98-l 9.00

(0.747-0.749)

(0.743)

mm (in)

18.85

ENGINE ASSEMBLY II 4-S

Rocker Arm Shaft and Rocker Arm Clearance

1. Use a vernier caliper to measure the rocker arm bushing inside diameter.

mm (in)

F----- I

-Rocker Arm Bushing Inside Diameter

I

2. Measure the rocker arm shaft outside diameter. Replace either the rocker arm or the rocker arm shaft

if the clearance exceeds the specified limit.

Standard Limit

19.01-I 9.03

(0.749-0.750)

19.05

(0.751)

I

t

.

:

l!El

mm (in)

Standard

L +

Rocker Arm Bushing and Rocker Arm Shaft Clearance

3. Check that the rocker arm oil port is free of obstructions.

If necessary, use compressed air to clean the rocker

arm oil port.

IDLER GEAR AND IDLER GEAR SHAFT

1. Use a micrometer to measure the idler gear shaft outside diameter.

If measured diameter exceeds specified limit,

replace the idler gear shaft.

Idler Gear Shaft Outside Diameter

I

0.01-0.05

(0.0004-0.0020)

Standard

I ~

44.945-44.975 (1.7694771)

I

Limit

02

(O.Oi79)

mm (in)

Limit

44.9

(1.768)

I

J

Remover and installer

.

El

c*

0

II

Eil

2. Use a dial indicator diameter.

Idler Gear and Idler

Gear

Shaft Clearance

CAMSHAFT

1 . Use the camshaft bearing remover and installer to

remove camshaft bearing

Camshaft

1818-O

2. Measure the clearance between the camshaft bearing.

Bearing Remover and Installer: 9-8523.

r-- ~~ I

Cam Journal and Cam Bearing Clearance

I

to measure the idler

1 Standard 1 Limit 1

0.025-0.085

(0.001-0.003)

from the cylinder body.

the cam

Standard

0.03-0.09

(0.001-0.004)

gear inside

02

(O.dO8)

journal and

Limit

I

0.15

(0.006)

mm (in)

I

Cam bearing

/

8.

‘r

Al

ports

ign oil

a.$

Q

i

1

I: 18

a

Ip d I

1) /

0

a

.Q

\

1 @

/ Q

a

, y--@ i

3. Align the camshaft bearing oil holes with the mating oil ports (machined on the cylinder body camshaft bearing fitting bore).

r

4. Use a micrometer to measure If the cam lobe height

the

camshaft must be replaced.

is less than the specified limit,

the cam lobe height.

mm (in)

0

I

1 Cam

Cam

Diameter

c

Lobe

Height (C-D) 1 7.71

Journal

I

56.0

Standard

(0.304) / 7.23 (0.284) 1

(2.205)

Limit

55.6 (2.189)

I

1

0

Gig-

1 ’

5. Place the camshaft on a measuring stand.

.

lzil

.

:

@iill

Use a dial indicator to measure the camshaft runout. Note the total indicator reading (TIR). If the measured run-out exceeds the

the

.

Camshaft Run-Out TIR

l

CYLINDER BODY AND LINER

Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder liner bore at measuring position @ in line with the crankshaft

@ and across the crankshaft 0.

Measuring Point @ mm (in): 20.0 (0.79) (Maximum

If the measured value exceeds the specified limit, the cylinder liner must be replaced.

camshaft must

HwiiWE ASSEMBLY II b-11

specified limit,

be

replaced.

mm (in)

Limit

0.12 (0.005)

Wear Portion)

f

\

t

Cylinder Liner Bore Total Indicator Reading (4.1347-4.1362)

4

Note: The inside of the dry type cylinder liner is chrome

plated. It cannot be rebored or honed. If the inside of the cylinder liner is scored or scorched,

the cylinder liner must be replaced.

Standard

105.021-105.060

mm (in)

Limit

105.20

(4.1417)

4

4-12 ENGINE ASSEMBLY II

Cylinder Liner Projection Inspection

1. Hold a straight

cylinder

2.

Use

projection.

Cylinder Liner

The

between any

exceed 0.03 mm (0.001 in).

liner to be measured.

a feeler gauge @ to measure each cylinder liner

difference in the cylinder liner projection height

edge @ along the top

Projection

two

0.03-0.10 (0.001-0.004)

adjacent

edge of the

mm (in)

Standard

cylinders must not

lal

Cylinder Liner Replacement

Cylinder Liner Removal

b1

1. Set the cylinder liner remover to the cylinder liner.

2. Check that the remover shaft ankle is firmly gripping the cylinder liner bottom edge.

3. Slowly turn the remover shaft handle counterclockwise to pull the cylinder liner free.

Cylinder Liner Remover: 9-8523-1169-O

Cylinder Liner Remover Ankle: 5-8523-1004-o

Note:

Take care

during

not

the cylinder

-

to

damage

liner removal procedure.

the cylinder body

upper face

Cylinder Bore Measurement Cylinder Liner Grade Selection The term “grade” refers to the cylinder body inside diam-

.

:

l!!&I

eter and the cylinder liner outside diameter combination.

Measure the cylinder body inside diameter and select

the appropriate cylinder liner grade.

Loose fitting cylinder liners (the liner is too small for the cylinder bore) will adversely affect engine cooling efficiency and may lead to serious engine damage.

Cylinder liners which are too large for the cylinder bore will be difficult to install.

ENGINE ASSEMBLY II 443

.

Cylinder Body Inside Diameter Measurement

1. Take measurements at measuring point @ across the positions W-W, X-X, Y-Y, and Z-Z.

Measuring Point @ : 115 mm (4.531 in)

2. Calculate the average value of the four measurements to determine the correct cylinder liner grade.

A14

ENGINE

ASSEMBLY II

I

X

_c-- -----

a---

X

/

Cylinder Liner Outside Diameter Measurement

1. Take measurements at measuring point 0, @, and a

Measuring Points mm (in):

@ 20.0 (0.788)

@ 105.0 (4.137) @ 195.0 (7.683)

2. Calculate the average value of the 6 measurements

to determine the correct cylinder liner grade.

mm (in)

Cylinder Liner Fitting Clearance Standard

Cylinder Bore and Cylinder Liner Outside Diameter Combinations

(Reference) 4BGl,6BGl

Grade Cylinder Bore

I I

-

1

107.001-107.010 107.011-107.020 (4.2126-4.2130)

107.011-107.020 2 107.021-107.030 (4.2130-4.2134)

107.021-107.030 (4.2134-4.2138) (4.2138-4.2142)

0.001-0.019

(0.00004-0.0007)

mm (in)

Cylinder Liner

Outside Diameter .

(4.2130-4.2134)

(4.2134-4.2138)

107.031-107.040

_ -

i ‘:

L

i

5‘

,

ENGINE ASSEMBLY II

Cylinder Liner Installation

1.

Carefully

cylinder liner inside

cylinder bore.

2. Use

the

3. Use a clean rag to remove all traces of kerosene or

diesel

4. Insert the cylinder liner @ into the cylinder body @ from the top of the cylinder body.

5.

Set the

cylinder liner.

Cylinder

6. Position @ is directly beneath

@

7. Check that the cylinder liner is set perpendicular to

the

Check that the cylinder liner does not wobble.

8. Use the bench press to apply an initial seating force of 500 kg (1,102.5 lb) to the cylinder liner.

9. Use the bench press to apply a final seating force of

2,500 kg (5,512.5 lb) to fully seat the cylinder liner.

10.

After

der liner projection. Refer to ‘Cylinder Liner Projection Inspection.”

wipe away any foreign material from the

and

outside surfaces and the

new

kerosene or diesel oil to thoroughly clean

cylinder liner and bore

oil from the cylinder liner and bore surfaces.

cylinder liner installer @ to the top of the

Liner Installer: 5-8522-1018-O

the

cylinder body so that

cylinder.

installing the cylinder liner, measure the cylin-

surfaces.

the installer center

the

bench press shaft center

. -

4-15

0

Piston Grade Selection

The term

and cylinder liner bore combination.

Selection engine problems.

Measure the der liner.

the

installed

“piston grade” refers to the piston diameter

of

the

proper piston grade will ensure efficient

operation, free from cylinder liner and piston

cylinder liner bore after installing the cylin-

Then select the appropriate piston grade for

cylinder liner.

4-16 ENGINE ASSEMBLY II

.

:

ml

Cylinder Liner Bore Measurement

1. Locate the two measuring points. Cylinder Liner Measuring Point 0: 20 mm (0.788 in) Cylinder Liner Measuring Point 0: 105 mm (4.173 in)

2. Measure the cylinder liner bore at measuring @ and @ in four different directions (W-W, X-X,

Y-Y, and Z-Z).

3. Calculate the average value of the eight measurements.

point

mm (in)

\I

82

.

:

El

0

4

I

l!Il

Cylinder Liner Bore Total

Indicator Reading

Note:

It is most important that the correct piston grade be used. result in piston seizure.

Always measure the cylinder bore and select the appro-

priate piston grade.

Piston Outside Diameter

Measure the piston outside diameter at the measuring piston shown in the illustration.

Piston Grade

4BGl

I I

4BGlT 104.9454 04.964 104.965-104.984

6BGl 104.9554 04.974 104.975-104.994 GBGIT

Failure to select the correct piston grade will

. -

104.955-104.974 (4.1321-4.1328)

(4.1317-4.1324)

(4.1321-4.1328)

105.021-105.060 (4.1347-4.1362)

mm (in)

104.975-104.994 (4.1329-4.1336)

(4.1325-4.1332)

(4.1329-4.1336)

I

Cylinder Liner Bore and Piston Clearance

mm (in)

4BG1,

6BG1,GBGlT

-Cylinder Liner Bore and Piston Clearance

Note: Cylinder liner piston kit clearances are preset. However,

the cylinder liner installation procedure may result in slight

decreases in cylinder liner

Alwqs

installation to be sure that it is correct.

measure the cylinder

0.047-0.085

(0.0019-0.0033) (0.0022-0.0037)

bore clearances.

liner bore clearance after

4BGlT

0.057-0.095

I

.

lsl

ENGINE ASSEMBLY II

4-17

PISTON AND PISTON RING

Piston Ring and Piston Ring Groove Clearance

Use a feeler gauge to measure the clearance between

the piston ring and the piston ring groove.

Do this at several points around the piston. If the clearance between the piston ring and the

ring groove exceeds the specified limit, the piston ring must be replaced.

Piston Ring and Piston Ring Groove Clearance 4BGl mm (in)

1st Compression 0.085-O. 110 0.20

2nd Compression

Ring

I

Oil Ring

- ~~

Standard

I

(0.0033-0.0043) (0.0079)

~~-

0.030-0.055

(0.0018-0.0022)

0.030-0.070 0.15

(0.0018-0.0027)

I

(0.0059)

piston

Limit

0.15

I

4BGlT mm (in)

I

1st Compression 0.105-0.130 Ring (0.0041-0.0051)

2nd Compression 0.050-0.075

Ring (0.002&0.0029)

I

Oil Ring

I

6BGl

I-

1st Compression

Ring

I

2nd Compression 0.030-0.065

Ring

I

Oil Ring

6BGlT

1st Compression

Ring

Standard

0.030-0.070

(0.0012-0.0027)

I Standard 1

0.105-0.130

(0.0041-0.0051)

(0.0012-0.0026) (0.0059)

0.030-0.070

(0.0012-0.0027)

1 Standard 1

0.085-0.120

(0.0033-0.0047)

Limit

0.20

(0.0079)

0.15

(0.0059)

0.15

(0.0059)

mm (in)

Limit

0.20

(0.0079)

0.15

(0.0059)

Limit

0.20

(0.0079)

-

mm (in)

I

Oil Ring

0.030-0.070

(0.0012-0.0027)

0.15

(0.0059)

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

A18 ENGINE ASSEMBLY Ii

Piston Ring Gap

1. Insert the piston ring horizontally (in the position it would assume if it were installed to the piston) into the cylinder liner.

2. Use an inverted piston to push the piston ring into the cylinder liner until it reaches either measuring point @ or measuring point 0. Cylinder liner diameter is the smallest at these two points.

Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal.

Cylinder Liner Measuring Point 0: 1Omm (0.39 in) Cylinder Liner Measuring Point@:l3Omm (5.12in)

3. Use a feeler gauge to measure the piston ring gap. If the measured value exceeds the specified limit,

the piston ring must be replaced.

Piston Ring Gap

4BGl

r

1st Compression

Ring 2nd Compression

Ring

Oil Ring

I

Standard

0.25-0.45

(0.010-0.018)

0.35-0.50

(0.014-0.020) (O.d59)

0.30-0.50

(0.012-0.020)

mm (in)

Limit ,

15

8

i:

Y

L

4BGlT, 6BG1,GBGlT mm (in)

Limit

15

(O.d59)

1st Compression Ring

2nd Compression

Ring

Oil Ring

Standard

0.35-0.50

(0.014-0.020)

0.35-0.50

(0.014-0.020)

0.30-0.50

(0.014-0.020)

1

l l l

lllllllllllllllllllllllllllllllllllllllllllllllll

l l l l l l l l l l l

ENGINE ASSEMBLY

II 619

PISTON PIN

Piston Pin Outside Diameter

Use a micrometer to measure the piston pin outside

.

L!iEl

diameter at several points. If the measured piston pin outside diameter exceeds the

specified limit, the piston pin must be replace.

c

Piston Pin Outside Diameter

Piston Use an inside dial indicator to measure the piston pin

hole.

(1.3780-1.3781)

and Piston Clearance

Standard

35.000-35.005

mm (in)

Limit

34.95

(1.3760)

mm (in)

‘k

I

Piston Pin Hole Diameter

4BG1,4BGlT, 6BGl GBGIT

Piston Pin and Piston Pin Hole Clearance

Determine the clearance between the piston pin and the

piston pin hole by calculating the difference between the

piston pin hole diameter and the piston pin outside diameter.

Piston Pin and Piston Pin Hole Clearance

I

if an inside dial indicator is not available, use the following procedure to check the piston pin fit.

1. Use a piston heater to heat the piston to approxi-

0

q

,2. Push strongly against the piston pin with your

24

thumbs. The piston pin fitting should feel tight.

mately 60°C (140°F).

I

Standard

35.01 O-35.01 8

(1.3783-l .3787)

Limit

0.050 (0.002)

mm (in)

I

4-20 ENGINE ASSEMBLY II

Connecting Rod Alignment Use a connecting rod aligner to measure

between the connecting rod big necting rod small

If either the measured parallelism exceeds limit, the connecting rod must be replaced.

Connecting Rod Alignment (Per Length of 100 mm (3.94 in)

I I

Parallelism

end

hole.

Standard

0.05 (0.0002)

or less

end

hole and the con-

I

the

parallelism

the

Limit

0.20

(0.0079)

specified

mm (in)

I

C

l3il

Piston Pin and Connecting Rod Small End Bushing

Clearance ‘.

Use a caliper calibrator and a micrometer to measure

.

:

the piston pin and connecting rod small end bushing

clearance.

If the clearance between the piston pin and the connecting rod small end bushing exceeds the specified limit, replace either the piston pin or the connecting rod bushing.

mm (in) I

1 Standard 1 Limit

Piston Pin and Con-

netting Rod Small

End Bushing

.

Clearance

0.012-0.025 0.05

(0.0004-0.0010) (0.0020)

c*

cl

Connecting Rod Bushing Replacement Connecting Rod Bushing Removal

1. Clamp

2. Use a brass @remove the connecting rod bushing.

the connecting rod

bar

and a bench

in a vise.

press or hammer to

ENGINE ASSEMBLY *iI 4-29

Connecting Rod Bushing Installation

*c

t

cl

lal

lrrl

Use the connecting rod bushing installer to install the connecting rod bushing.

Connecting Rod Bushing Installer: 9-8523-1369-O

bl

Note:

The connecting rod bushing oil port must be

with the connecting rod oil port.

3, Use a piston pin hole grinder @ fitted with

@ or an adjustable pilot reamer to ream the

pin hole.

(J-29765)

aligned

a reamer

piston

mm (in)

e

El

*c

III

Standard

Connecting Rod Bushing

Inside Diameter

Connecting Rod Bearing Inspection

1. Fit the connecting rod bearing lower half connecting rod bearing cap.

2. Check the connecting rod bearing lower half tension. If the tension is insufficient, the bearing must be

replaced.

3. Tighten the connecting rod and the bearing

the specified torque.

Connecting Rod and Bearing Cap Bolt Tightening Torque

35.017-35.025

(1.37861.3789)

v

4

(28.9)

into the

cap

kgom(lb.ft)

60’090’

i

to

4. Use an inside dial indicator to measure the connect-

. :

@I

ing rod inside diameter.

Connecting Rod Bearing

e Nominal Diameter

64(2.520)

mm

(in)

A22 ENGINE ASSEMBLY II

Crankshaft and Bearing Inspection

1. Inspect the crankshaft journal surfaces and pin surfaces for excessive wear and

damage.

2. Inspect the oil seal fitting surfaces of the front and rear ends for excessive wear and

the crank

crankshaft

damage.

3. Replace or repair the crankshaft if any excessive wear or damage is discovered.

4. Inspect the crankshaft oil ports for obstructions.

5. Use high pressure air to clean the oil ports if necessary.

Crankshaft Journal and Crankpin Outside Diameter

1. Use a micrometer to measure the crankshaft journal outside diameter across points @ - @ and @ - 0.

2. Use the micrometer to measure the crankshaft journal outside diameter at the two points <@ and @).

3. Repeat steps 1 and 2 to measure the crankshaft out-

side diameter.

mm (in)

1 68 Engines only [ Position at (

Center

Crankshaft Journal Diameter

Bearing Only Other

Bearings

Standard

79.905-79.925

(3.1459-3.1467)

79.919-79.939

(3.1464-3.1472)

mm (in)

1 4B Engines only 1 Position at

Crankshaft Journal

Diameter

All Bearings

1 Standard 1

79.905-79.925

(3.145%3:1467)

I

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

mm (in)

Crankshaft Pin Diameter

63.924-63.944

(2.5167-2.5175)

4. Measure the crankshaft journal outside diameter (and/or the crankpin outside diameter) and the bearing inside diameters to determine the bearing clearance.

Crankshaft Journal and Bearing Clearances

If the bearing clearance exceeds the specified limit, the crankshaft must be reground (except 4BDlT, GBDIT, 6BGl and 6BGlT) and/or

1 6B Engines Only

Crankshaft Journal

and Main Bearing Clearance

the

bearing must be replaced.

I Position ati Standard

Center Bearing Only

Other

0.039-0.098

(0.0015-0.0039)

0.025-0.084

mm

(in)

1 Limit I

0.11

- (0.0043)

Bearings (0.0010-0.0033)

mm (in)

4B Engines Only ( Position at[ Standard

Crankshaft Journal All and Main Bearing Clearance

Bearings (0.0015-0.0039) (0.0043)

0.039-0.098 0.11

1 Limit 1

Crankpin and Connecting Rod

Bearing Clearance

1 Standard f

0.03-0.07

(0.0012-0.0028)

Limit

0.10

(0.0039)

mm (in)

I

4-24

ENGINE ASSEMBLY II

Crankshaft Journal Bearing Inside Diameter

1. install the main bearing cap with bearings to the cylinder body with the specified torque and facing the arrow mark on the bearing cap toward front.

Place them in order of punched cylinder numbers.

2. Use an inside dial indicator to measure the main bearing diameters.

kg-m(lb.ft)

Main Bearing Cap Torque

23-25

(160 - 181)

mm (in)

I

Main Bearing Nominal Diameter

80

(3.149)

Crankshaft Run-Out

.

:

Ial

I

ENGINE ASSEMBLY U:

1. Mount the crankshaft on a set of V-blocks.

2. Set a dial indicator to the center of the crankshaft journal.

3. Gently turn the crankshaft in the normal direction of

engine rotation. Read the dial indicator (TIR) as you turn the crank-

shaft. If the measured value exceeds the specified limit,

the crankshaft must

1 Model 1 Standard 1 Limit

Crankshaft Run-Out

If the crankshaft generated a crack after repair, replace the crankshaft.

Crankshaft can not be bench pressed, because it is

finished with tufftride method.

be

replaced.

4-25

mm (in)

Main Bearing and Connecting Rod Bearing Tension Check to see if the bearing has enough tension, so that

good finger pressure is needed to fit the bearing into position.

Crankshaft Regrinding Note: Crankshaft for 4BG1, 4BGlT, 6BGl and 6BGlT can not

be reground because it is finished with TUFFTRIDE method.

For the crankshaft on 4BG1, 4BGlT, 6BGl and 6BGlT, no attempt should be made to grind finish the faces of

the journals and crankpins as they are TUFFTRIDED

(Special hardening treatment). Therefore, the undersize bearings are not prepared:

Plastigage Clearance Measurements This is another method to measure the crankjournal

bearing clearance. Crankshaft Journal Bearing Clearance

1.

5l

2. Install the new journal bearing to the cylinder body.

3. Carefully place the crankshaft on the bearing.

4. Rotate the crankshaft approximately 30’ to seat the

5. Place the Plastigage (arrow) over the crankshaft

6. Install the bearing cap with the bearing.

7. Tighten the bearing cap to the specified torque.

8. Remove the bearing cap.

9. Compare the width of the plastigage attached to

.

l3zl

Clean the cylinder body, the journal bearing fitting portions, the bearing cap, and the inside the outside

surfaces of the bearing.

bearing.

journal across the full width of the bearing.

Apply engine oil to the Plastigage to keep it from falling.

Do not allow the crankshaft to turn during bearing

cap installation and tightening.

either the crankshaft or the bearing against the scale printed on the plastigage container.

If the measured value exceeds the limit, perform the

following additional steps.

1) Use a micrometer to measure the crankshaft outside diameter.

2) Use an inside dial indicator to measure the bearing inside .diameter.

3) Replace the crankshaft and/or the bearing if the measured value(s) exceed the limit.

I

J

i

.

\

lal

ENGINE ASSEMBLY II

Crankshaft Pin Bearing Clearance

3 .

Clean the crankshaft, ing cap, and the bearings.

.

2

Install Do

the

not allow

bearing to the connecting

the crankshaft to move when installing

the bearing cap.

.

Hold the connecting

3

against the crankshaft

.

Attach the plastigage to the crankshaft pin.

4

Apply engine oil to the plastigage to keep it from

falling.

.

5

Install

the

connecting rod bearing cap and tighten it

to the specified torque. Do not allow the connecting rod to move when

installing

.

Remove the bearing cap.

6

.

7

Compare the width of the plastigage attached to

and

tightening the bearing cap.

either the crankshaft or the bearing against the scale printed on the plastigage container.

If the measured value exceeds the limit, perform the

following additional steps.

1) Use a micrometer to measure the crankshaft outside diameter.

2) Use an inside dial indicator to measure the bearing inside diameter.

3) Replace the crankshaft and/or the bearing if the measured value(s) exceed the limit.

the connecting

rod

(with

the bearing

pin.

rod, the bear-

rod.

A27

installed)

Ammoniun cuprous chloride

Face in contact

Test liquid shou not be applied t area around oil

Crankshaft T&biding Inspection

Id

0

. .

Inspection

Model

4BG1, QBGlT, 6BGl

1.

Use an organic cleaner to thoroughly clean the

and

6BGlT

crankshaft. There must be no traces of oil on the surfaces to be inspected.

2. Prepare a 10% solution of ammonium cuprous chloride (dissolved in distilled water).

3. Use a spot glass rod to apply the solution to

face

to be inspected.

the sur-

Hold the surface to be inspected perfectly horizontal

to prevent the solution from running. Note: Do not allow

ports and

ci

the

solution

to come in contact with the oil

their surrounding area.

A28

ENGINE ASSEMBLY II

Judgement

1. Wait for thirty to forty seconds. If there is no discoloration after

onds, the crankshaft is usable.

If discoloration appears

will become the color of

must be replaced.

2.

Clean steam immediately

Note: The ammonium cuprous chloride solution is highly cor-

rosive. Because of this, it is imperative that the surfaces being tested be cleaned immediately after completing

the test.

the

surface

being tested with clean water of

(the surface being

after completing the test.

thirty or

copper), the crankshaft

forty sec-

tested

Oil Seal Wear Ring Replacement Removal

Use the oil seal wear ring remover to remove the oil seal

wear ring from the crankshaft front end.

Oil Seal Wear Ring Remover: l-85210-0560

Installation Use a brass bar and a hammer to drive the oil seal wear

ring into place. Oil Seal Wear Ring Installer: l-85220-031-0

Crankshaft Gear inspection Visually inspect the crankshaft gear.

Replace the crankshaft gear if excessive wear or damage is discovered.

1 nstaller

Remover

Crankshaft Gear Replacement

Irl

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t*

cl

Eil

+t

q

Removal

Use the crankshaft gear remover to remove the crank-

shaft gear. Crankshaft Gear Remover: 9-8521-0141-O

installation

M

Use the crankshaft gear installer to install the crankshaft

gear. Crankshaft Gear Installer: 9-8522-0033-o

ENGINE ASSEMBLY 91 A29

FLYWHEEL AND FLYWHEEL HOUSING

(REAR OIL SEAL)

Ring Gear Inspection Inspect the ring gear.

If the ring gear teeth are broken or excessively worn, the ring gear must be replaced.

Ring Gear Replacement

Ring Gear Removal Strike around the edges of the ring gear with a hammer

t*

tl

t

I)c

q

ml

t*

q

I)t

cl

~~~

btal ter

/’

-. 0 \

I/

/

#I /

-

3

u

and chisel to remove it. Ring Gear Installation

1. Heat the ring gear evenly with a gas-burner to invite thermal expansion.

Do not allow the temperature of the ring gear to exceed 200°C (390°F).

2. Use a hammer to install the ring gear when it is sufficiently heated.

Flywheel Housing Oil Seal Replacement

M

Removal Use a pry bar to remove the flywheel housing oil seal. Installation

c?Jse the oil seal installer to install the flywheel housing

oil seal. Oil Seal Installer: 9-8522-1254-o

4-30 ENGINE ASSEMBLY II

I nstalier

t*

El

I)c

0

TIMING GEAR CASE COVER

Crankshaft Front Oil Seal Replacement Removal

Use an adapter and a hammer to remove the crankshaft

front end oil seal. Installation

Use the crankshaft front oil seal installer to install the

crankshaft front oil seal. Crankshaft Front Oil Seal Installer: 9-8522-0034-o

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

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II I I I I I I I I

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-*

ENGINE ASSEMBLY Ill

5-1

SECTION

5

ENGINE ASSEMBLY Ill

(REASSEMBLY)

TABLE OF CONTENTS

ITEM

Piston Cylinder

and connecting rod reassembly steps

head reassembly steps .........................................................................

Rocker arm and rocker arm shaft reassembly steps

Major component reassembly steps I ...................................................................

Major component reassembly steps II ..................................................................

External

External parts Engine tuning

parts

reassembly steps (Left-Hand Side) ....................................................

reassembly steps (Right-Hand Side) operation

..................................................................................

Engine sectional view .....................................................................................

..........................................................

..................................................

. -

PAGE

59 2 5- 4

5- 8 59 9

5-14

5-19

5-23 5-26 5-28

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I

5-2 ENGINE ASSEMBLY III

*it PISTON AND CONNECTING ROD REASSEMBLY STEPS

III

MIRROR COMPONENT

3

Reassembly Steps

A 1.

A 2. Piston pin and connecting-rod

A 3. Snap ring

Piston

A 4.

Piston ring

A 5. Connecting rod bearing

:-

. .

=

ENGINE ASSEMBLY Ill 5-3

Conventional piston heater

I

Put cylinder

‘marked side in this

position.

Marked side up

number

<

\

1st camp.

2nd

Oil

i

0

camp.

PISTON AND CONNECTING ROD

Important Operations

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0

V

0

•1 lrtl

*c

0

[J

1)c

q

1. Piston Use a piston heater to heat the pistons to approxi-

mately 60°C (140°F).

2. Connecting Rod

1) install the connecting rod to the piston with setting the marks as illustrated.

2) install the piston pin into the piston and the connecting rod bushing.

Refer the description of piston pin in page 4-19.

3. Piston Pin Snap Ring

1) Use a pair of snap ring pliers to install the piston pin snap ring.

Check that the piston moves smoothly on the

2

piston pin.

8. Piston Ring

1)

Use a piston ring installer to install the three piston rings.

Piston Ring installer Install the piston rings in the following order.

‘(1) Oil ring

(2) 2nd compression ring (3) 1st compression ring

The marked side of the two compression rings must be facing up.

The undercut side of the second compression

ring will be facing down.

As the oil ring has no any facing mark, it may face in either direction.

2) Lubricate the piston ring surfaces with engine

. .

oil.

3) Check that the piston rings rotate smoothly in the piston ring grooves.

5. Connecting Rod Bearing Install the connecting rod bearings to the con-

1)

necting rod large-end and the connecting rod

cap.

Install the bearing cap to the connecting rod

with semi-tightening the cap bolts.

Lubricate the bearing with engine oil.

5-4 ENGINE ASSEMBLY 111

+ CYLINDER HEAD REASSEMBLY STEPS

0

a

Reassembly Steps

A 1. Valve stem oil seal

A 2. Intake and exhaust valves

3. Spring seat (Lower)

A

4.

Intake and exhaust valve springs

5. Spring seat (Upper) or valve rotator

A 6. Spring seat split collar

7 .

Thermostat housing and gasket

. Thermostat

8 9 Water outlet pipe

A

lb. Intake manifold and gasket

A

Exhaust manifold and gasket

11.

* : Repair kit

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

II

II I I I I I II

II

II I I I I I I I I

I

. .

t

V

7%

0

lal

9%

III

Important Operations

1. Valve Stem Oil Seal

1)

Lubricate the oil seals and valve stem sealing

areas with engine oil.

bi

2) Use a valve stem oil seal installer to install the oil seal.

Valve Stem Oil Seal Installer: l-85221-005-0

2. intake and Exhaust Valves

1) Place the cylinder head on a flat wooden surface.

2) Lubricate valve stems with engine oil.

3) Install the valves to the intake or exhaust guides.

Install the valves to their original lapped valve seats.

ENGINE ASSEMBLY III 5-s

4. Intake and Exhaust Valve Springs Install the valve springs with their painted end (the

*

cl

,/ Painted

L

DOft iOn

J

close .pitched end) facing down.

6. Spring Seat Split Collar

1) Use a spring compressor to push the valve spring into position.

2) install the spring seat split collar.

3) Set the spring seat split collar by tapping lightly around the head of the collar with a rubber hammer.

Spring Compressor: l-85235-006-0

5-6 ENGINE ASSEMBLY Ill

Unchamfered corner

Rear

c7

10. Intake Manifold and Gasket

1)

Install the intake manifold gasket.

The intake manifold gasket must be installed with its unchamfered corner facing up and to the front of the engine.

Refer to the illustration.

2) Install the intake manifold.

3) Tighten the intake manifold bolts to the specified torque a little at a time in the numerical

order shown in the illustration.

Intake Monifold 4B Bolt Torque

.

6B

1.4-2.4 (10.1-17.4)

2.1-3.1 (15.2-22.4)

kgmm (Ibft) 1

4

i

1:

:

<’ ‘,

g! $

f

4BGl

6BGl

#

0

TOP

_ -

0

i

11. Exhaust Manifold and Gasket

1) Install the exhaust manifold The “TOP” mark must be facing up.

2) install the exhaust manifold.

3) Tighten the exhaust manifold bolts to the specified torque a little at a time in the numerical

order shown in the illustration.

Exhaust Manifold 4B

Bolt Torque

Note: 4B and 6B engines use a different exhaust manifold gas-

.

ket Refer to the illustration to determine the correct gasket

for your engine.

6B

gasket.

kg*m (lb.ft)

1.6-2.6 (11.6-18.8)

2.6-3.2 (18.8-23.1)

ENGINE ASSEMBLY Ill

5-7

Spar facing

Distance tube

4) Install either end of the distance tube to facing (6B series engine only).

the spot

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

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5-8 ENGINE ASSEMBLY III

+ ROCKER ARM AND ROCKER ARM SHAFT REASSEMBLY STEPS

r-l

-

- Reassembly Steps

A

1.

Rocker arm shaft

2. Spring

7

0

V

3. Rocker arm

4. Bracket

Important Operation

1. Rocker Arm Shaft The rocker arm shaft must be installed with the oil

ports facing up.

ti

Isuzu A-4BG1, A-4BG1T, A-6BG1, A-6BG1T Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual