Nissan PF6TB, PF6TC Service Manual

ENGINE

[SUPPLEMENT]

PF series

PF6TB AND PF6TC

Pub.No. SSM615PFE2

HOW TO USE THIS MANUAL

+This supplement is designed to provide you with the new service procedures, service data and specifications for the PF6TB engine on the CKB457/459, CWB457/459 and CGB457 models and PF6TC engine on the CKB45A, CWB45A, CGB45A models.

+However, this supplement contains only new service procedures and relevant data, etc.

For information which is not included in this manual, refer to the general service manual mentioned below. Service Manual: PF series ``MODELS PF6, PF6T, PF6TA & PF6TB'' (Pub. No. SMEPFS2E00)

+Please be sure to follow the instruction below when using this supplement.

1)See the specified section titles in the QUICK REFERENCE INDEX of this supplement, and check whether the background is black or white.

2) Only those items containing supplementary information are specified in the CONTENTS of each section.

Ð 1 Ð

6n053for

0001DRD-1225-4-S(M)

6n053for

White:

No change. Please refer to the engine service manual PF series ``MODELS PF6, PF6T, PF6TA & PF6TB'' (Pub. No. SMEPFS2E00).

Black:

Service procedures and service data have been added.

Only the new or revised information is described.

-1-1

GENERAL

CONTENTS

SPECIFICATIONS .....................................

GE-1- 1

ENGINE SPECIFICATIONS ........................

GE-1- 1

SUPPLEMENTAL OUTLINE

+Addition of specifications due to introduction of the PF6TB-21 engine in the CKB, CWB and CGB457 series.

+Addition of specifications due to introduction of the PF6TB-22 engine in the CKB459 and CWB459 series.

+Addition of specifications due to introduction of the PF6TC engine in the CKB, CWB and CGB45A series.

SPECIFICATIONS

SPECIFICATIONS

ENGINE SPECIFICATIONS

Item

Engine model

PF6TB-21

PF6TB-22

PF6TC

Max. output (SAE)

kW {PS}/rpm

257 {350}/2,100

279 {380}/2,100

Type

Diesel

Aspiration system

Turbocharger with intercooler

Cooling method

Water cooled

Number of cylinders and cylinder arrangement

6, in-line

Stroke cycle

4

Combustion chamber

Direct fuel injection

Valve mechanism

Overhead

Cylinder liner

Dry

Bore x stroke

mm (in)

133.0 x 150.0 (5.24 x 5.91)

Total displacement

cm3 (cu in)

12,503 (763)

Compression ratio

16.5

Cylinder compression

kPa {kgf/cm2, psi}/rpm

3,040 {31, 441}/200±20

Max. engine speed under full load conditions

2,480

2,300

Idle speed

430 - 530

550 - 570

510 - 610

Number of piston rings

Compression ring

2

Oil ring

1

Intake

Open (B.T.D.C.)

16°

Valve timing

Closed (A.B.D.C.)

20°

Exhaust

Open (B.B.D.C.)

52°

Closed (A.T.D.C.)

12°

Valve clearance

Intake

0.30 - 0.40 (0.012 - 0.016)

mm (in)

Exhaust

0.30 - 0.40 (0.012 - 0.016)

Lubrication system

Forced-circulation type

Type

Gear pump

Oil pump

Discharge amount

! (Imp gal)/rpm

174 (38-1/4)/2,300

Relief valve opening pressure

1,177 {12.0, 171}

kPa {kgf/cm2, psi}

system

Type

Full-flow

Paper element type

By-pass

Paper element type

Oil filter

Lubrication

Replacement method

Disassembly type

Short valve opening pressure

98 - 137 {1.0 - 1.4, 14 - 20}

kPa {kgf/cm2, psi}

Type

Water cooled flat tube type

Oil cooler

Number of cores

5

Short valve opening pressure

304 - 343 {3.1 - 3.5, 44 - 50}

kPa {kgf/cm2, psi}

Regulator valve opening pressure

kPa {kgf/cm2, psi}

392 - 432 {4.0 - 4.4, 57 - 63}

System total capacity

29 (6-3/8)

Lubrication oil ca-

H-level

21 (4-5/8)

pacity

! (Imp gal)

Oil pan

L-level

14 (3-1/8)

GE-1-1

SPECIFICATIONS

Item

Engine model

PF6TB-21

PF6TB-22

PF6TC

Cooling system

Water cooled, forced circulation

Radiator type

Corrugated fin

Cooling fan

Number of fins

6

Type

ON-OFF type (FD2000-C)

Linear type

(FDL2300)

system

Fan clutch

Changeover temperature

°C (°F)

60 - 70 (140 - 158)

60±10 - 75±5

(140±18 - 167±9)

Cooling

Type

Centrifugal

Water pump

Drive

Gear drive

Number of impellers

6

Type

Wax pellet

Thermostat

Valve opening temperature

76.5 (170) - 1

°C (°F) - Number

Cooling water capacity

! (Imp gal)

37 (8-1/8)

Ignition system

Compression ignition

Fuel injection timing (B.T.D.C.)

3°

2°

0°

Ignition order

1-4-2-6-3-5

Fuel filter

Main

Cartridge type

Primary

Center bolt type

Type

Bosch

system

Fuel injection pump

Plunger diameter

mm (in)

12.0 (0.472)

Governor

Electrical RED-III type

Timer

Centrifugal (Mechanical SDG type)

Fuel

Nozzle holder

Flange type

Nozzle type

Multi-hole type

Fuel injection nozzle

Nozzle

Number

6

7

holder

Diameter

mm (in)

0.31 (0.0122) [K4]

0.27 (0.0106) [K6]

0.26 (0.0102) [K8]

Valve opening pressure

22,556 {230, 3,271}

kPa {kgf/cm2, psi}

Overflow valve opening pressure

Injection pump outlet

255 {2.6, 37}

kPa {kgf/cm2, psi}

Fuel filter

108 - 147 {1.1 - 1.5, 16 - 21}

Air cleaner

Paper element (Dry: Dual type)

system

Model

TD45

GT45

GT42

Radial-flow turbine

Turbine type

(With variable

Radial-flow turbine

plate)

exhaust

Turbocharger

Compressor type

Centrifugal

Lubrication method

Engine oil circulation type

and

Bearing type

Full floating

intake

Intercooler

Type

Air to air

Intercooler

Corrugated fin

Air

Exhaust shutter

Type

Cylinder

Operation

Air

GE-1-2

SPECIFICATIONS

Item				Engine model	PF6TB-21	PF6TB-22		PF6TC
		Type				Shift
	Starting motor	Model			0350 602 0381	350 602 0460
					0350 602 0460
		Output		V-kW		24-6.0
		Type				AC, diode-rectified
system					0202 102 1943
		Model				0201 152 1130		0201 102 4510
					0202 152 0044
					(0202 152 0043)
Electrical	Alternator			0202 102 1943	24-40
						Ð		Ð
				0202 152 0044	24-50
		Output	V-A	(0202 152 0043)
				0201 152 1130	Ð	24-50		Ð
				0201 102 4510	Ð	Ð		24-40
		Regulator				IC-transistor type
		Type				Ribbon
	Air heater	Voltage (V) x Current (A) - Number				11.0 x 85 - 2
		Model				F9560W12
equipment		Theoretical discharge		cm3 (cu in)		425 (26)
	Air compressor	Normal maximum discharge pressure				834 {8.5, 121}
				kPa {kgf/cm2, psi}
		Cooling system			Water cooled (Forced circulation type)
Auxiliary
	Vacuum pump	Type			Vane		Ð
		Model			VD-30		Ð

GE-1-3

MAINTENANCE

CONTENTS

SERVICE DATA ..........................................	MA-1- 1
SERVICE DATA ..........................................	MA-1- 1
TIGHTENING TORQUE .............................	MA-1- 2
TOOLS ...........................................................	MA-2- 1
MAINTENANCE PROCEDURE ............	MA-3- 1

SUPPLEMENTAL OUTLINE

BASIC MECHANICAL SYSTEM .................	MA-3- 1
FAN CLUTCH .............................................	MA-3- 1
FUEL SYSTEM ...........................................	MA-3-	2
INTAKE AND EXHAUST SYSTEM .............	MA-3-	5

+Addition of service data and maintenance procedure due to introduction of a new vehicle model.

+The fuel injection timing has been changed.

+The idle speed has been changed.

+The tightening torque of the injection pump coupling mounting bolt has been changed.

+Addition of fuel injection timing and idle speed maintenance standards for the PF6TB-22 and PF6TC engines.

+Addition of a model GT42, 45 turbocharger.

SERVICE DATA

SERVICE DATA

SERVICE DATA

								Unit: mm (in)
	Item				Maintenance standard		Service limit	Remarks
		Intake			0.30	- 0.40	Ð
					(0.012	- 0.016)
	Valve clearance							When engine is cold
system		Exhaust			0.30	- 0.40	Ð
					(0.012	- 0.016)
mechanical		Intake	Open		16° B.T.D.C.		Ð
	Valve timing		Closed		20° A.B.D.C.		Ð
		Exhaust	Open		52° B.B.D.C.		Ð
Basic			Closed		12° A.T.D.C.		Ð
	Cylinder compression pressure				3,040 {31, 441}		1,961 {20, 284}	At 180 to 220 rpm
		kPa {kgf/cm2, psi}						(With engine warm)
	Compression pressure difference				Less than 392 {4, 57}		Ð
		kPa {kgf/cm2, psi}
	Water tank cap operating pressure				49	- 69	Ð	Pressure side
		kPa {kgf/cm2, psi}			{0.5 - 0.7, 7 - 10}
		Fan pulley			8 - 12 (0.31 - 0.47)		Ð
system		- Tension pulley						With a force of about
	Deflection of V-belt	Idler (cooler compres-						98 N {10 kgf, 22 lbf}
Cooling		sor) pulley			15 - 18 (0.59 - 0.71)		Ð	applied to the mid part
		- Alternator pulley
		Valve opening tem-			74.5	- 78.5	73.0 - 80.0
	Thermostat	perature	°C (°F)		(166	- 173)	(163 - 176)
		Valve lift/temperature			More than		More than
		mm/°C (in/°F)			10/90 (0.39/194)		8.5/90 (0.335/194)
		PF6TB-21				3°	Ð
	Fuel injection timing
system		PF6TB-22				2°	Ð
	B.T.D.C.
		PF6TC				0°	Ð
Fuel		PF6TB-21			430	- 530	Ð
	Idle speed
		PF6TB-22			550	- 570	Ð
	rpm
		PF6TC			510	- 610	Ð

MA-1-1

SERVICE DATA

TIGHTENING TORQUE

							Unit: N´m {kgfzm, ftzlbf}
		Item				Tightening torque		Remarks
	Valve clearance adjusting screw lock nut					34 - 44	{3.5 - 4.5, 25 - 33}
		Snug torque (1st)				88 - 98 {9.0 - 10.0, 65 - 72}
system	Cylinder head
		angle (2nd)		L = 119 mm (4.69 in)			70° - 80°
	bolt	Tightening		L = 147 mm (5.79 in)			85° - 95°
mechanical
	Cylinder head	1st					34 {3.5, 25}
	sub bolt	2nd				44 - 54	{4.5 - 5.5, 33 - 40}
Basic	Air intake manifold mounting bolt and nut					49 - 54	{5.0 - 5.5, 36 - 40}
	Exhaust manifold mounting nut					29 - 44	{3.0 - 4.5, 22 - 33}
	Crank damper mounting bolt					98 - 108 {10.0 - 11.0, 72 - 80}
	Compression gauge bolt					25 - 29	{2.5 - 3.0, 18 - 22}
system	Oil pan drain plug					98 - 127 {10.0 - 13.0, 72 - 94}
		Full-flow type		Center bolt		59 - 69	{6.0 - 7.0, 43 - 51}
Lubrication
				Drain plug		16 - 22	{1.6 - 2.2, 12 - 16}
	Oil filter			Drain plug		16 - 22	{1.6 - 2.2, 12 - 16}
		Bypass type		Center bolt		59 - 69	{6.0 - 7.0, 43 - 51}
	Injection pump	Coupling bolt and nut				103 - 113	{10.5 - 11.5, 76 - 83}
	drive coupling	Cotter bolt				147 - 167 {15.0 - 17.0, 108 - 123}
	Injection nozzle retaining nut					59 - 78	{6.0 - 8.0, 43 - 58}
system
	Nozzle holder assembly mounting bolt					Apply film of engine oil to gasket and
						25 - 29	{2.5 - 3.0, 18 - 22}
Fuel		Cartridge type				screw on until gasket contacts en-
						gine, then tighten 3/4 turn by hand
	Fuel filter					or UD genuine filter wrench
		Bypass type		Center bolt		59 - 69	{6.0 - 7.0, 43 - 51}
				Drain plug		16 - 22	{1.6 - 2.2, 12 - 16}
				Turbine housing and center housing		17.0 {1.73, 12.5} → Loosen →
				mounting V-band lock nut
						13.7 {1.40, 10.1}
					N´m {kgfzm, ftzlbf}
		Model TD45
system				Compressor housing and back plate
					N´m {kgfzm, ftzlbf}	9.0 - 11.3 {0.92 - 1.15, 6.7 - 8.3}
				clamp mounting bolt
exhaust
				Turbine housing and center housing
	Turbocharger			mounting V-band lock nut		12.7 - 14.7	{130 - 150, 113 - 130}
and		Model GT45			N´m {kgfzcm, inzlbf}
				Compressor housing and back plate
intake						10.3 - 12.3 {105 - 125, 91 - 109}
				mounting bolt	N´m {kgfzcm, inzlbf}
Air				Turbine housing and center housing
				mounting V-band lock nut		12.7 - 14.7	{130 - 150, 113 - 130}
		Model GT42			N´m {kgfzcm, inzlbf}
				Compressor housing and back plate		10.3 - 12.3 {105 - 125, 91 - 109}
				mounting bolt	N´m {kgfzcm, inzlbf}

MA-1-2

TOOLS

TOOLS

Tool name and number	Description	Shape
Feeler gauge	For adjusting valve clearance
99541 Z5000	Thickness mm (in)
	0.25 (0.0098), 0.3 (0.012), 0.35 (0.0138), 0.4
	(0.016), 0.45 (0.0177), 0.5 (0.020)
		ET14-049
Feeler gauge	For adjusting valve clearance
99541 Z0001	Thickness mm (in)
	0.2 (0.008), 0.3 (0.012), 0.4 (0.016)
		ET14049A
Timing plate	For measuring valve timing
99646 Z5001
	ZMA121A
		ET14-053
Adapter	Used when measuring valve timing as a set includ-
99808 96500	ing the timing plate (99646 Z5001)
		WMA148A
Compression gauge	For measuring compression pressure
99640 96000
		ET14050B
Compression gauge hose	Used with the compression gauge (99640 96000)
99644 97000	when the gauge cannot be installed directly due to
	interference with the air duct, etc.
		ET14-051

MA-2-1

TOOLS

Tool name and number	Description	Shape
Plate	For fixing nozzle holder
157944-9520	NOTE
	+ Tool number designated by ZEXEL CORPO-
	RATION
		WMA001A
Pin vice	For cleaning nozzle orifice
99727 Z5005
		EP14-121
Nozzle cleaner	For removal of carbon from rear of nozzle orifice
99726 Z5000
		ET14-072
Filter wrench	For removal of fuel filter
99755 00Z01	(Only when replacing cartridge type element)
		WMA027A

MA-2-2

MAINTENANCE PROCEDURE

MAINTENANCE PROCEDURE

BASIC MECHANICAL SYSTEM

VALVE CLEARANCE

Procedure for checking valve timing

1.Remove the V-belt, cooling fan and crank pulley assembly.

2.Turn the flywheel in the normal direction until the No. 1 piston is at the top dead center on the compression stroke.

NOTE

+If the flywheel has been rotated excessively, rotate it backwards beyond the desired position then gradually rotate it back in the normal direction until it is set in the proper position.

3.Attach the timing plate (99646 Z5001) and adapter (99808 96500) to the end of the crankshaft. Also attach a needle pointer utilizing the front cover mounting bolt, and align the needle to ``0''.

4.Set a dial gauge so that the contact arm is in contact with the upper valve spring seats of the intake valve and exhaust valve.

FAN CLUTCH

				Unit: C° (F°)
	Item		Run the engine	Operating temperatures
			continuously
FDL2300-C		Linear type	2,300 rpm	60±10 - 75±5
				(140±18 - 167±9)

EP12-3

WMA149A

MA-3-1

MAINTENANCE PROCEDURE

FUEL SYSTEM

INJECTION TIMING

1.Remove the pointer cover. Secure the pointer to the flywheel housing using bolts.

2.Crank the engine in the standard direction by turning the flywheel with a lever until the pointer is aligned with the timing mark.

NOTE

+If the mark goes past the pointer, move it back past the pointer and turn again in the standard direction until alignment is made.

	Item		Maintenance standard	Service limit
		PF6TB-21	3°	Ð
	Fuel injection timing
		PF6TB-22	2°	Ð
	(B.T.D.C.)
		PF6TC	0°	Ð

3.If the timer marks are not aligned as shown in the figure, adjust as follows:

Adjustment of fuel injection timing

1.Make sure the pointer points to the specified injection timing graduation on the outer periphery of the flywheel and loosen the coupling bolts (2 places).

2.Back the timer off a little in the reverse direction of the normal timer direction. Turn the timer in the normal direction to adjust the pointer to the mark.

3.Tighten the coupling bolts and cotter bolt.

Coupling bolt and nut

: 103 - 113 N´m {10.5 - 11.5 kgfzm, 76 - 83 ftzlbf}

Cotter bolt

: 147 - 167 N´m {15.0 - 17.0 kgfzm, 108 - 123 ftzlbf}

WDR151A

WDR167A

EP4-23

EMA1002E

MA-3-2

MAINTENANCE PROCEDURE

IDLE SPEED

NOTE

+When checking engine idle speed ensure that the engine idle control knob inside the cab is set to the low-speed position.

1.Start the engine and warm it up to the normal operating temperature.

2.Allow the engine to idle and observe the engine speed on the tachometer.

3.If idle speed is not within specified range, adjust as follows:

NOTE

+If equipped with an air conditioner, the air conditioner switch must be turned off when checking idle speed.

				Unit: rpm
	Item		Maintenance standard	Service limit
		PF6TB-21	430 - 530	Ð
Idle speed		PF6TB-22	550 - 570	Ð
		PF6TC	510 - 610	Ð

Idle speed adjustment

1.Loosen the lock nut on the idle adjusting bolt.

2.Turn the idle adjusting bolt to obtain the correct idle speed.

3.Tighten the lock nut on the idle adjusting bolt.

NOTE

+Accelerate the engine two or three times. Allow the engine to return to idle speed and observe the tachometer reading. If the idle speed is not within the specified range, check the accelerator linkage for binding and repeat idle adjustment.

NOZZLE (INJECTOR PRESSURE AND PATTERN)

Cleaning nozzle

1.Remove the nozzle holder assembly from the engine. Refer to the ``ENGINE DISASSEMBLY AND REASSEMBLY'' section for details.

2.Clamp the nozzle holder in a vise with a holder plate (1579449520).

3.Loosen the retaining nut, and then remove the nozzle from the nozzle holder. Do not drop the nozzle needle.

EEF1160A

MA-3-3

MAINTENANCE PROCEDURE

4. Pull the nozzle needle from the nozzle body.

NOTE

+ Do not use the nozzle needle in another nozzle body.

5.Remove carbon from around the openings by using the corner of a hard piece of wood. Do not use waste or any other material to push carbon into the openings.

6.Removing carbon in openings

Use the pin vice (99727 Z5005) and wire to clean the openings.

				Unit: mm (in)
	Nozzle identifica-	Number of injec-	Injection nozzle	Wire diameter
	tion mark	tion nozzle holes	hole diameter
	K4	6	0.31 (0.0122)	0.29 (0.0114)
	K6		0.27 (0.0106)	0.26 (0.0102)
	K8	7	0.26 (0.0102)	0.25 (0.0098)

+Allowing too much wire to protrude at the tip of the holder will permit the wire to bend inside the nozzle, in which case withdrawal proves difficult. The wire should protrude no more than 2.0 to 2.5 mm (0.079 to 0.098 in).

+Carefully push the carbon into the nozzle. Too much force will bend the wire. Proceed slowly.

+Remove carbon at the inside end of the openings with the nozzle cleaner (99726 Z5000).

Exercise care to avoid damaging the surface which the nozzle

needle contacts. The use of compressed air may clog the openings with foreign particles.

7.Tighten the retaining nut.

: 59 - 78 N´m {6.0 - 8.0 kgfzm, 43 - 58 ftzlbf}

WMA017A

WMA018A

WMA019A

MA-3-4

MAINTENANCE PROCEDURE

INTAKE AND EXHAUST SYSTEM

TURBOCHARGER

NOTE

+Before attempting any servicing of the turbocharger, clean its entire exterior surface.

+Never use a caustic solution. Caustic solutions attack aluminum.

To clean the compressor side

1.Remove the turbocharger from the engine.

2.Remove the compressor housing and check the condition of the impeller (compressor wheel). If it is not excessively dirty, clean the impeller and the inner surface of the housing with a brush and a cloth dampened with diesel fuel.

CAUTION

+ Do not use a wire brush or scraper.

3.If the impeller is excessively dirty, overhaul and clean. Refer to the ENGINE ``IE'' section for cleaning instructions.

4.When the impeller is wet with cleaning solvent, dry with compressed air.

CAUTION

+Hold the impeller by hand to prevent it from turning while drying.

5. Install the compressor housing in its original position.

: Model TD45

9.0 - 11.3 N´m {0.92 - 1.15 kgfzm, 6.7 - 8.3 ftzlbf}

: Model GT42, 45

10.3 - 12.3 N´m {105 - 125 kgfzcm, 91 - 109 inzlbf}

To clean the turbine side

1.Remove the turbine housing and check the condition of the turbine. If the turbine is not excessively dirty, clean the turbine and the inner surface of the turbine housing in a manner similar to that outlined under ``To clean the compressor side''.

2.If the turbine is excessively dirty, overhaul and clean.

3.When the impeller is wet with cleaning solvent, dry with compressed air.

CAUTION

+Hold the impeller with your hand to prevent it from turning while cleaning.

4. Install the turbine housing in its original position.

: Model TD45

17.0 N´m {1.73 kgfzm, 12.5 ftzlbf}

→Loosen

→13.7 N´m {1.40 kgfzm, 10.1 ftzlbf}

: Model GT42, 45

12.7- 14.7 N´m {130 - 150 kgfzcm, 113 - 130 inzlbf}

5.Check that the turbine wheel rotates smoothly by your hand. Install the turbocharger on the engine and check for gas or air leakage.

MA-3-5

ENGINE DISASSEMBLY

AND REASSEMBLY

CONTENTS

SERVICE DATA ..........................................	DR-1- 1 DISASSEMBLY
TIGHTENING TORQUE ..............................	DR-1- 1	AND REASSEMBLY .................................	DR-4- 1
TOOLS ...........................................................	DR-2- 1	OUTSIDE OF ENGINE ...............................	DR-4- 1
CONSTRUCTION .......................................	DR-3- 1	ENGINE PROPER ......................................	DR-4- 4
ENGINE .......................................................	DR-3- 1

SUPPLEMENTAL OUTLINE

+ Addition of tightening torque due to introduction of a new vehicle model.

SERVICE DATA

SERVICE DATA

TIGHTENING TORQUE

							Unit: N´m {kgfzm, ftzlbf}
		Item		Tightening torque			Remarks
Nozzle holder assembly mounting bolt				25 - 34	{2.5 - 3.5,	18 - 25}
Spill tube mounting bolt				10 - 18 {1.0 - 1.8, 7.2 - 13.0}
Injection tube		Pump side		29 - 39	{3.0 - 4.0,	22 - 29}
		Nozzle side		25 - 34	{2.5 - 3.5,	18 - 25}
Fuel tube and fuel return tube				25 - 29	{2.5 - 3.0,	18 - 22}
Crank pulley mounting bolt				177 - 196 {18.0 - 20.0, 130 - 145}
Fan pulley mounting bolt				186 - 196 {19.0 - 20.0, 137 - 145}
Cooling fan mounting nut				16 - 19	{1.6 - 1.9,	12 - 14}
Hydraulic pump drive gear mounting nut				59 - 78	{6.0 - 8.0,	43 - 58}
Alternator mounting bolt				59 - 78	{6.0 - 8.0,	43 - 58}
Oil pan drain plug				98 - 127 {10.0 - 13.0, 72 - 94}
Exhaust manifold mounting nut				29 - 44	{3.0 - 4.5,	22 - 33}
Oil outlet pipe mounting bolt				13 - 14 {1.30 - 1.45,		9.4 - 10.5}
Oil inlet tube connector bolt				13 - 14 {1.30 - 1.45,		9.4 - 10.5}
Oil cooler housing mounting bolt and nut			Bolt	29 - 54	{3.0 - 5.5,	22 - 40}
			Nut	54 - 93	{5.5 - 9.5,	40 - 69}
Turbocharger mounting bolt				34 - 44	{3.5 - 4.5,	25 - 33}
Air intake manifold mounting nut				49 - 54	{5.0 - 5.5,	36 - 40}
Air compressor mounting bolt				30 - 41	{3.1 - 4.2,	22 - 30}
Starting motor mounting bolt					69 {7.0, 51}
Injection pump bracket mounting bolt				30 - 41	{3.1 - 4.2,	22 - 30}
Injection pump mounting bolt				48 - 62	{4.9 - 6.3,	35 - 46}
Injection pump coupling		Coupling bolt		103 - 113	{10.5 - 11.5, 76 - 83}
mounting bolt		Cotter bolt		147 - 167 {15.0 - 17.0, 108 - 123}
Injection pump oil tube		Feed side		10 - 18 {1.0 - 1.8, 7.2 - 13.0}
			Pump side	15 - 34	{1.5 - 3.5,	11 - 25}
connector		Return side
			Block side	25 - 41	{2.5 - 4.2,	18 - 30}
Engine mounting bracket mounting bolt				98 - 127 {10.0 - 13.0, 72 - 94}
Engine lifter mounting bolt				74 - 93	{7.5 - 9.5,	54 - 69}
Cylinder head sub bolt			1st		34 {3.5, 25}
			2nd	44 - 54	{4.5 - 5.5,	33 - 40}
		Snug torque (1st)		88 - 98 {9.0 - 10.0, 65 - 72}
Cylinder head bolt		Tightening	L = 147 mm (5.79 in)		85° - 95°
		angle (2nd)	L = 119 mm (4.69 in)		70° - 80°
Rocker shaft bracket mounting bolt				34 - 49	{3.5 - 5.0,	25 - 36}

DR-1-1

SERVICE DATA

					Unit: N´m {kgfzm, ftzlbf}
Item			Tightening torque		Remarks
Oil jet connector bolt			29 - 39 {3.0 - 4.0, 22 - 29}
Main bearing cap bolt		265	- 294 {27.0 - 30.0,	195 - 217}
Connecting rod cap nut		230	- 245 {23.5 - 25.0,	170 - 181}
Front gear case mounting bolt			25 - 34 {2.5 - 3.5, 18 - 25}
Injection pump drive gear mounting nut		392	- 441 {40.0 - 45.0,	289 - 325}
Camshaft gear mounting nut		245	- 265 {25.0 - 27.0,	181 - 195}
Camshaft locating plate mounting bolt			20 - 24 {2.0 - 2.4, 14 - 17}
Cam chamber cover mounting bolt			15 - 29 {1.5 - 3.0, 11 - 22}
Idler gear mounting bolt			18 - 22 {1.8 - 2.2, 13 - 16}
Idler gear shaft bolt			49 - 57 {5.0 - 5.8, 36 - 42}
Air compressor drive gear mounting nut		186	- 206 {19.0 - 21.0,	137 - 152}
Oil pump mounting bolt			30 - 41 {3.1 - 4.2, 22 - 30}
Oil screen and oil outlet pipe mounting bolt			16 - 21 {1.6 - 2.1, 12 - 15}
Flywheel housing mounting bolt	M12	78 - 98 {8.0 - 10.0, 58 - 72}
Stiffener mounting bolt	Housing side		74 - 88 {7.5 - 9.0, 54 - 65}
	Block side	98	- 137 {10.0 - 14.0,	72 - 101}
Oil pan mounting bolt			21 {2.1, 15}
Flywheel mounting bolt		255	- 304 {26.0 - 31.0,	188 - 224}
Crank damper mounting bolt		98 - 108 {10.0 - 11.0, 72 - 80}
Rear PTO idler shaft mounting bolt			127 {13.0, 94}
Engine rear PTO companion flange nut		392	- 412 {40.0 - 42.0,	289 - 304}

DR-1-2

TOOLS

TOOLS

Tool name and number	Description	Shape
Engine stand	For disassembling and reassembling engine proper
99550 96001
Head assembly
99551 96001
		ET14-001
Engine stand attachment	For disassembling and reassembling engine proper
99554 96001	To be used together with engine stand
		EDR1074A
Piston insert tool	For inserting piston into cylinder
99631 96502
		ET14045C
Injection pump bracket	For centering of injection pump bracket
setting tool
99720 95500
		ETL2-003

DR-2-1

CONSTRUCTION

CONSTRUCTION

ENGINE

WDR148A

DR-3-1

DISASSEMBLY AND REASSEMBLY

DISASSEMBLY AND REASSEMBLY

OUTSIDE OF ENGINE

UPPER SIDE OF ENGINE

WDR149A

Disassembly sequence (Reassembly sequence is the reverse of disassembly.)

j1	Air intake duct	j4	Fuel filter	j7	Air intake manifold
j2	Air intake	j5	Water manifold	j8	Nozzle holder assembly
j3	Water tube	j6	Nozzle tube	j9	PCM valve

DR-4-1

DISASSEMBLY AND REASSEMBLY

RIGHT SIDE OF ENGINE

WDR150A

Disassembly sequence (Reassembly sequence is the reverse of disassembly.)

j1	Air intake duct	j5	Turbocharger	j9	Car heater pipe
j2	Exhaust outlet	j6	Exhaust manifold	j10	Oil filter
j3	Exhaust shutter	j7	Water duct	j11	Oil cooler
j4	Air pipe	j8	Water pump

DR-4-2

DISASSEMBLY AND REASSEMBLY

LEFT SIDE OF ENGINE Key points of reassembly

j4 Injection pump

When the injection pump bracket has been removed, center it using the following procedure:

1.Fasten the injection pump bracket.

: 30 - 41 N´m {3.1 - 4.2 kgfzm, 22 - 30 ftzlbf}

2.Centering the injection pump bracket

Set a bracket setting tool (99720 95500) in place. Then check to make sure that the shaft of the injection pump support enters the hole on the end of the shaft smoothly.

3.If it does not enter smoothly, adjust by changing the thickness of the injection pump bracket shims.

Shim thickness [mm (in)]: 0.05 (0.0020)

:0.10 (0.0039)

:0.20 (0.0079)

4.Install the injection pump.

: 48 - 62 N´m {4.9 - 6.3 kgfzm, 35 - 46 ftzlbf}

5.Turn the flywheel in the standard direction of rotation to align the scribed line of the injection timer on the No. 1 cylinder with the pointer. If not aligned properly, rotate the flywheel in the reverse direction sufficiently, and realign.

	Item		Maintenance standard	Service limit
	Fuel injection	PF6TB-21	3°	Ð
		PF6TB-22	2°	Ð
	timing (B.T.D.C.)
		PF6TC	0°	Ð

EDR1151A

WDR008A

WDR151A

WDR167A

DR-4-3

DISASSEMBLY AND REASSEMBLY

6.Align the mark on the injection pump with the scribed line on the timer, then connect the coupling.

Unit: N´m {kgfzm, ftzlbf}

Item	Tightening torque
Coupling bolt	103 - 113 {10.5 - 11.5, 76	- 83}
Cotter bolt	147 - 167 {15.0 - 17.0, 108	- 123}

ENGINE PROPER

Key points of reassembly

1.Attach the engine stand attachment (99554 96001), then raise the cylinder block using a crane or other devices, and mount it on the engine stand (99550 96001).

2.Install the oil jet.

: 29 - 39 N´m {3.0 - 4.0 kgfzm, 22 - 29 ftzlbf}

3. Install the main bearing upper shell.

NOTE

+Be sure to install the main bearing upper shell in the original position before disassembly.

EMA1002E

EP3-30

EN3-065

ZDR025A

DR-4-4

DISASSEMBLY AND REASSEMBLY

4.Attach the upper thrust washer to both side of the No. 7 main bearing and measure the end play of the crankshaft. If the measured value exceeds the service limit, replace the thrust washer with a new one.

					Unit: mm (in)
Maintenance standard			Service limit
0.05 - 0.14 (0.0020 - 0.0055)			0.5 (0.020)
					Unit: mm (in)
	A	3.995 - 4.025 (0.1573 - 0.1585)
	B	3.970 - 4.000 (0.1563 - 0.1575)			Standard
Thrust washer	C	3.945 - 3.975 (0.1553 - 0.1565)
	0.15 O.S.	4.100 - 4.150 (0.1614 - 0.1634)		O.S.: Oversize
	0.30 O.S.	4.250 - 4.300 (0.1673 - 0.1693)

NOTE

+Be sure the oil groove side of the thrust washer faces toward the crankshaft.

5.Fit the main bearing lower shell into the main bearing cap, and install the main bearing cap. Install the lower thrust washer onto both sides of the No. 7 main bearing cap.

: 265 - 294 N´m {27.0 - 30.0 kgfzm, 195 - 217 ftzlbf}

j1 No. 7 main bearing cap j2 Lower thrust washer

NOTE

+Make sure the main bearing cap is installed following the stamped numbers with the mark `` '' indicating the engine front side.

+The thrust washer has an oil groove which should face the crankshaft when installed. Be careful not to interchange the upper and lower washers.

EN3-066

EDR1-096

EP3-50

EN3-067

EP4-3

DR-4-5

DISASSEMBLY AND REASSEMBLY

6.Using a piston insert tool (99631 96502) insert the piston, connecting rod and bearing upper shell into the cylinder liner.

NOTE

+Do not install the piston rings in such a way that their gaps face the direction of the piston pin and are in a vertical direction. Moreover install them so that their gaps are

located exactly on opposite sides to each other. Also make sure that the mark ``F←'' at the top of the piston faces the engine front side and the stamped mark at the large end of the connecting rod is on the injection pump side.

NOTE

+Place each piston at its top dead center, and check to make sure that the piston top clearance at this position is within the maintenance standard. If any abnormality is noted, disassemble again and inspect each part.

		Unit: mm (in)
Maintenance standard		Service limit
0.32 - 0.72 ( 0.0126 -	0.0283)	Ð

7. Install the connecting rod cap and bearing lower shell.

NOTE

+Make sure stamped mark at the large end of the connecting rod aligns with that on the connecting rod cap.

: 230 - 245 N´m {23.5 - 25.0 kgfzm, 170 - 181 ftzlbf}

EDR1-101

WDR152A

WDR011A

EDR1-093

EP4-5

DR-4-6

DISASSEMBLY AND REASSEMBLY

8.Make sure the side clearance at the connecting rod large end is within the service limit.

NOTE

+ Side clearance for every cylinder should be measured.

Unit: mm (in)

Maintenance standard	Service limit
0.1 - 0.3 (0.004 - 0.012)	1.0 (0.039)

EP3-47

9.Install the front gear case and oil jet.

Front gear case mounting bolt

: 25 - 34 N´m {2.5 - 3.5 kgfzm, 18 - 25 ftzlbf}

10. Install the injection pump gear.

NOTE

+When installing, align the timing marks ``Y'' and ``YY''.

: 392 - 441 N´m {40.0 - 45.0 kgfzm, 289 - 325 ftzlbf}

WDR012A

11. Install the camshaft assembly together with the gears.

NOTE

+When installing, align the timing marks ``V'' and ``VV''.

Camshaft locating plate mounting bolt

: 20 - 24 N´m {2.0 - 2.4 kgfzm, 14 - 17 ftzlbf}

Camshaft gear mounting nut

: 245 - 265 N´m {25.0 - 27.0 kgfzm, 181 - 195 ftzlbf}

WDR013A

12.Install the cover for the cam chamber.

: 15 - 29 N´m {1.5 - 3.0 kgfzm, 11 - 22 ftzlbf}

EDR1042B

DR-4-7