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)Seethespecified section titles in the QUICK REFERENCE INDEX of thissupplement,andcheck whether the background is black or white.

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

—1—

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.

6n053for

0001DRD-1225-4-S(M)

-1-1

GENERAL

CONTENTS

SPECIFICATIONS ..................................... GE-1- 1

SUPPLEMENTAL OUTLINE

+ Addition of specifications dueto 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.

ENGINE SPECIFICATIONS ........................ GE-1- 1

ENGINE SPECIFICATIONS

SPECIFICATIONS

Item 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 cm Compression ratio 16.5 Cylinder compression kPa {kgf/cm Max. engine speed under full load conditions 2,480 2,300 Idle speed 430 - 530 550 - 570 510 - 610

Number of piston rings

Valve timing

Valve clearance

Lubrication system Forced-circulation type

Oil pump

Oil filter

Lubrication system

Oil cooler

Regulator valve opening pressure kPa {kgf/cm

Lubrication oil capacity ! (Imp gal)

mm (in)

Type Gear pump Discharge amount ! (Imp gal)/rpm 174 (38-1/4)/2,300 Relief valve opening pressure

Type

Replacement method Disassembly type Short valve opening pressure

Type Water cooled flat tube type Number of cores 5 Short valve opening pressure

System total capacity 29 (6-3/8)

Oil pan

Compression ring 2 Oil ring 1

Intake

Exhaust

Intake 0.30 - 0.40 (0.012 - 0.016) Exhaust 0.30 - 0.40 (0.012 - 0.016)

Full-flow Paper element type By-pass Paper element type

H-level 21 (4-5/8) L-level 14 (3-1/8)

Engine model

(cu in) 12,503 (763)

, psi}/rpm 3,040 {31, 441}/200±20

Open (B.T.D.C.) 16° Closed (A.B.D.C.) 20° Open (B.B.D.C.) 52° Closed (A.T.D.C.) 12°

kPa {kgf/cm

, psi}

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

PF6TB-21 PF6TB-22 PF6TC

1,177 {12.0, 171}

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

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

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)

Fan clutch

Changeover temperature °C (°F) 60 - 70 (140 - 158) Type Centrifugal

Water pump

Cooling system

Drive Gear drive Number of impellers 6 Type Wax pellet

Thermostat

Valve opening temperature

°C (°F) - Number

76.5 (170) - 1

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

Fuel injection pump

Plunger diameter mm (in) 12.0 (0.472) Governor Electrical RED-III type Timer Centrifugal (Mechanical SDG type)

Fuel system

Nozzle holder Flange type Nozzle type Multi-hole type

Fuel injection nozzle

Overflow valve opening pressure

kPa {kgf/cm

, psi}

Nozzle holder

Valve opening pressure

Injection pump outlet 255 {2.6, 37} Fuel filter 108 - 147 {1.1 - 1.5, 16 - 21}

Number 6 7 Diameter mm (in) 0.31 (0.0122) [K4] 0.27 (0.0106) [K6] 0.26 (0.0102) [K8]

kPa {kgf/cm

, psi}

22,556 {230, 3,271}

Air cleaner Paper element (Dry: Dual type)

Model TD45 GT45 GT42

Radial-flow turbine

Turbine type

Turbocharger

(With variable

plate)

Radial-flow turbine

Compressor type Centrifugal Lubrication method Engine oil circulation type Bearing type Full floating

Intercooler

Air intake and exhaust system

Exhaust shutter

Type Air to air Intercooler Corrugated fin Type Cylinder Operation Air

Linear type

(FDL2300)

60±10 - 75±5

(140±18 - 167±9)

GE-1-2

SPECIFICATIONS

Item

Starting motor

Alternator

Electrical system

Air heater

Air compressor

Vacuum pump

Auxiliary equipment

Engine model

PF6TB-21 PF6TB-22 PF6TC

Type Shift

Model

0350 602 0381 0350 602 0460

350 602 0460

Output V-kW 24-6.0 Type AC, diode-rectified

0202 102 1943

Model

0202 152 0044

0201 152 1130 0201 102 4510

(0202 152 0043)

0202 102 1943 24-40

——

Output V-A

0202 152 0044

(0202 152 0043)

24-50

0201 152 1130 — 24-50 —

0201 102 4510 — — 24-40 Regulator IC-transistor type Type Ribbon Voltage (V) x Current (A) - Number 11.0 x 85 - 2 Model F9560W12

Theoretical discharge cm Normal maximum discharge pressure

kPa {kgf/cm

(cu in) 425 (26)

, psi}

834 {8.5, 121}

Cooling system Water cooled (Forced circulation type) Type Vane — Model VD-30 —

GE-1-3

MAINTENANCE

CONTENTS

SERVICE DATA .......................................... MA-1- 1

TIGHTENING TORQUE ............................. MA-1- 2

TOOLS ........................................................... MA-2- 1

MAINTENANCE PROCEDURE ............ MA-3- 1

SUPPLEMENTAL OUTLINE

+ 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.

BASIC MECHANICAL SYSTEM ................. MA-3- 1

FAN CLUTCH ............................................. MA-3- 1

FUEL SYSTEM ........................................... MA-3- 2

INTAKE AND EXHAUST SYSTEM ............. MA-3- 5

SERVICE DATA

Item Maintenance standard Service limit Remarks

Valve clearance

Valve timing

Cylinder compression pressure

Basic mechanical system

Compression pressure difference

Water tank cap operating pressure

Deflection of V-belt

Cooling system

Thermostat

Fuel injection timing

B.T.D.C.

Idle speed

Fuel system

rpm

SERVICE DATA

Intake

Exhaust

Intake

Exhaust

Fan pulley

- Tension pulley Idler (cooler compres-

sor) pulley

- Alternator pulley Valve opening tem-

perature °C (°F) Valve lift/temperature

PF6TB-21 3° — PF6TB-22 2° — PF6TC 0° — PF6TB-21 430 - 530 — PF6TB-22 550 - 570 — PF6TC 510 - 610 —

Open 16° B.T.D.C. — Closed 20° A.B.D.C. — Open 52° B.B.D.C. — Closed 12° A.T.D.C. —

kPa {kgf/cm

, psi}

mm/°C (in/°F)

0.30 - 0.40

(0.012 - 0.016)

0.30 - 0.40

(0.012 - 0.016)

3,040 {31, 441} 1,961 {20, 284}

Less than 392 {4, 57} —

49-69

{0.5 - 0.7, 7 - 10}

8 - 12 (0.31 - 0.47) —

15 - 18 (0.59 - 0.71) —

74.5 - 78.5 (166 - 173)

More than

10/90 (0.39/194)

8.5/90 (0.335/194)

—

— Pressure side

73.0 - 80.0 (163 - 176)

More than

Unit: mm (in)

When engine is cold

At 180 to 220 rpm (With engine warm)

With a force of about 98 N {10 kgf, 22 lbf} applied to the mid part

MA-1-1

SERVICE DATA

TIGHTENING TORQUE

Item Tightening torque Remarks

Valve clearance adjusting screw lock nut 34 - 44 {3.5 - 4.5, 25 - 33}

Cylinder head bolt

Cylinder head sub bolt

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}

Basic mechanical system

Crank damper mounting bolt 98 - 108 {10.0 - 11.0, 72 - 80} Compression gauge bolt 25 - 29 {2.5 - 3.0, 18 - 22} Oil pan drain plug 98 - 127 {10.0 - 13.0, 72 - 94}

Oil filter

Lubrication system

Injection pump drive coupling

Injection nozzle retaining nut 59 - 78 {6.0 - 8.0, 43 - 58} Nozzle holder assembly mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}

Fuel system

Fuel filter

Turbocharger

Air intake and exhaust system

Snug torque (1st) 88 - 98 {9.0 - 10.0, 65 - 72} Tightening

angle (2nd) 1st 34 {3.5, 25}

2nd 44 - 54 {4.5 - 5.5, 33 - 40}

Full-flow type

Bypass type

Coupling bolt and nut 103 - 113 {10.5 - 11.5, 76 - 83} Cotter bolt 147 - 167 {15.0 - 17.0, 108 - 123}

Cartridge type

Bypass type

Model TD45

Model GT45

Model GT42

L = 147 mm (5.79 in) 85° - 95° L = 119 mm (4.69 in) 70° - 80°

Center bolt 59 - 69 {6.0 - 7.0, 43 - 51} Drain plug 16 - 22 {1.6 - 2.2, 12 - 16} Center bolt 59 - 69 {6.0 - 7.0, 43 - 51} Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}

Apply film of engine oil to gasket and screw on until gasket contacts engine, then tighten 3/4 turn by hand

or UD genuine filter wrench 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

mounting V-band lock nut

N·m {kgfzm, ftzlbf}

Compressor housing and back plate clamp mounting bolt

N·m {kgfzm, ftzlbf}

Turbine housing and center housing mounting V-band lock nut

N·m {kgfzcm, inzlbf}

Compressor housing and back plate mounting bolt N·m {kgfzcm, inzlbf}

Turbine housing and center housing mounting V-band lock nut

N·m {kgfzcm, inzlbf}

Compressor housing and back plate mounting bolt N·m {kgfzcm, inzlbf}

17.0 {1.73, 12.5} → Loosen →

13.7 {1.40, 10.1}

9.0 - 11.3 {0.92 - 1.15, 6.7 - 8.3}

12.7 - 14.7 {130 - 150, 113 - 130}

10.3 - 12.3 {105 - 125, 91 - 109}

12.7 - 14.7 {130 - 150, 113 - 130}

10.3 - 12.3 {105 - 125, 91 - 109}

Unit: N·m {kgfzm, ftzlbf}

MA-1-2

TOOLS

Tool name and number Description Shape

Feeler gauge 99541 Z5000

For adjusting valve clearance 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 99541 Z0001

Timing plate 99646 Z5001

Adapter 99808 96500

For adjusting valve clearance Thickness mm (in)

0.2 (0.008), 0.3 (0.012), 0.4 (0.016)

ET14049A

For measuring valve timing

ZMA121A

ET14-053

Used when measuring valve timing as a set including the timing plate (99646 Z5001)

WMA148A

Compression gauge 99640 96000

Compression gauge hose 99644 97000

For measuring compression pressure

ET14050B

Used with the compression gauge (99640 96000) 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 157944-9520

For fixing nozzle holder

NOTE + Tool number designated by ZEXEL CORPO-

RATION

WMA001A

Pin vice 99727 Z5005

Nozzle cleaner 99726 Z5000

Filter wrench 99755 00Z01

For cleaning nozzle orifice

EP14-121

For removal of carbon from rear of nozzle orifice

ET14-072

For removal of fuel filter (Only when replacing cartridge type element)

WMA027A

MA-2-2

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

FDL2300-C Linear type 2,300 rpm

Run the engine

continuously

Operating temperatures

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

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

PF6TB-21 3° — PF6TB-22 2° —

PF6TC 0° —

WDR151A

3. If the timer marks are notaligned 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,76-83ftzlbf}

Cotter bolt

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

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 —

Idle speed

PF6TB-22 550 - 570 —

PF6TC 510 - 610 —

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 (157944-

9520).

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

MA-3-3

EEF1160A

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 ofwood. Do not use waste orany other material to push carbon into the openings.

6. Removing carbon in openings Use the pin vice (99727Z5005)and wire to clean the openings.

Unit: mm (in)

Nozzle identifica-

tion mark

K4 K6 0.27 (0.0106) 0.26 (0.0102) K8 7 0.26 (0.0102) 0.25 (0.0098)

Number of injection nozzle holes

Injection nozzle

hole diameter

0.31 (0.0122) 0.29 (0.0114)

Wire diameter

WMA017A

+ 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,43-58ftzlbf}

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 amanner 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

TIGHTENING TORQUE .............................. DR-1- 1

TOOLS ........................................................... DR-2- 1

CONSTRUCTION ....................................... DR-3- 1

ENGINE ....................................................... DR-3- 1

SUPPLEMENTAL OUTLINE

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

DISASSEMBLY AND REASSEMBLY

OUTSIDE OF ENGINE ............................... DR-4- 1

ENGINE PROPER ...................................... DR-4- 4

................................. DR-4- 1

SERVICE DATA

TIGHTENING TORQUE

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 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 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 mounting bolt

Injection pump oil tube connector

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

Cylinder head bolt

Rocker shaft bracket mounting bolt 34 - 49 {3.5 - 5.0, 25 - 36}

Pump side 29 - 39 {3.0 - 4.0, 22 - 29} Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}

Bolt 29 - 54 {3.0 - 5.5, 22 - 40} Nut 54 - 93 {5.5 - 9.5, 40 - 69}

Coupling bolt 103 - 113 {10.5 - 11.5, 76 - 83} Cotter bolt 147 - 167 {15.0 - 17.0, 108 - 123} Feed side 10 - 18 {1.0 - 1.8, 7.2 - 13.0}

Return side

Snug torque (1st) 88 - 98 {9.0 - 10.0, 65 - 72} Tightening

angle (2nd)

Pump side 15 - 34 {1.5 - 3.5, 11 - 25} Block side 25 - 41 {2.5 - 4.2, 18 - 30}

1st 34 {3.5, 25} 2nd 44 - 54 {4.5 - 5.5, 33 - 40}

L = 147 mm (5.79 in) 85° - 95° L = 119 mm (4.69 in) 70° - 80°

Unit: N·m {kgfzm, ftzlbf}

DR-1-1

SERVICE DATA

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 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}

Housing side 74 - 88 {7.5 - 9.0, 54 - 65} Block side 98 - 137 {10.0 - 14.0, 72 - 101}

Unit: N·m {kgfzm, ftzlbf}

DR-1-2

TOOLS

Tool name and number Description Shape

Engine stand 99550 96001 Head assembly 99551 96001

For disassembling and reassembling engine proper

ET14-001

Engine stand attachment 99554 96001

Piston insert tool 99631 96502

Injection pump bracket setting tool 99720 95500

For disassembling and reassembling engine proper To be used together with engine stand

EDR1074A

For inserting piston into cylinder

ET14045C

For centering of injection pump bracket

DR-2-1

ETL2-003

ENGINE

CONSTRUCTION

DR-3-1

WDR148A

DISASSEMBLY AND REASSEMBLY

OUTSIDE OF ENGINE

UPPER SIDE OF ENGINE

DISASSEMBLY AND REASSEMBLY

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

Air intake duct

Air intake

Water tube

Fuel filter

Water manifold

Nozzle tube

Air intake manifold

Nozzle holder assembly

PCM valve

DR-4-1

WDR149A

RIGHT SIDE OF ENGINE

DISASSEMBLY AND REASSEMBLY

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

Air intake duct

Exhaust outlet

Exhaust shutter

Air pipe

Turbocharger

Exhaust manifold

Water duct

Water pump

Car heater pipe

Oil filter

Oil cooler

DR-4-2

WDR150A

DISASSEMBLY AND REASSEMBLY

LEFT SIDE OF ENGINE Key points of reassembly

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,22-30ftzlbf}

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 pumpsupport 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,35-46ftzlbf}

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 timing (B.T.D.C.)

PF6TB-21 3° — PF6TB-22 2° — PF6TC 0° —

EDR1151A

WDR008A

WDR151A

DR-4-3

WDR167A

DISASSEMBLY AND REASSEMBLY

6. Alignthemarkontheinjectionpump 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).

EMA1002E

2. Install the oil jet.

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

3. Install the main bearing upper shell.

NOTE + Be sure to install the main bearing upper shell in the

original position before disassembly.

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)

StandardB 3.970 - 4.000 (0.1563 - 0.1575)

Thrust washer

C 3.945 - 3.975 (0.1553 - 0.1565)

0.15 O.S. 4.100 - 4.150 (0.1614 - 0.1634)

0.30 O.S. 4.250 - 4.300 (0.1673 - 0.1693)

O.S.: Oversize

NOTE + Be sure the oil groove side of the thrust washer faces

toward the crankshaft.

EN3-066

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}

No. 7 main bearing cap

Lower thrust washer

EDR1-096

EP3-50

EN3-067

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.

DR-4-5

EP4-3

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 waythat 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 sidesto each other.Also make sure that the mark ‘‘

←

’’ 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.

EDR1-101

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) —

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

WDR152A

WDR011A

EDR1-093

NOTE + Make sure stamped mark at the large end of the connect-

ing rod aligns with that on the connecting rod cap.

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

DR-4-6

EP4-5

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)

9. Install the front gear case and oil jet.

Front gear case mounting bolt

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

EP3-47

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}

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,14-17ftzlbf}

Camshaft gear mounting nut

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

12. Install the cover for the cam chamber.

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

WDR012A

WDR013A

DR-4-7

EDR1042B

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