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.

—1—
 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
Engine model PF6TB-21 PF6TB-22 PF6TC
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 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
Compression ring 2
Number of piston rings
Oil ring 1
Open (B.T.D.C.) 16°
Intake
Closed (A.B.D.C.) 20°
Valve timing
Open (B.B.D.C.) 52°
Exhaust
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
kPa {kgf/cm2, psi} 1,177 {12.0, 171}

Full-flow Paper element type

Lubrication system

Type
By-pass Paper element type
Oil filter Replacement method Disassembly type
Short valve opening pressure
kPa {kgf/cm2, psi} 98 - 137 {1.0 - 1.4, 14 - 20}

Type Water cooled flat tube type

Oil cooler Number of cores 5

Short valve opening pressure
kPa {kgf/cm2, psi} 304 - 343 {3.1 - 3.5, 44 - 50}

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

Engine model PF6TB-21 PF6TB-22 PF6TC

Item
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)
Fan clutch
Cooling system

Changeover temperature °C (°F) 60 - 70 (140 - 158) 60±10 - 75±5

(140±18 - 167±9)
Type Centrifugal
Water pump 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
Main Cartridge type
Fuel filter
Primary Center bolt type
Type Bosch
Plunger diameter mm (in) 12.0 (0.472)
Fuel system

Fuel injection pump

Governor Electrical RED-III type
Timer Centrifugal (Mechanical SDG type)
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
kPa {kgf/cm2, psi} 22,556 {230, 3,271}

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)
Model TD45 GT45 GT42
Air intake and exhaust system

Radial-flow turbine
Turbine type (With variable Radial-flow turbine
plate)
Turbocharger
Compressor type Centrifugal
Lubrication method Engine oil circulation type
Bearing type Full floating
Type Air to air
Intercooler
Intercooler Corrugated fin
Type Cylinder
Exhaust shutter
Operation Air

GE-1-2
 SPECIFICATIONS

Engine model PF6TB-21 PF6TB-22 PF6TC

Item
Type Shift
0350 602 0381
Starting motor Model 350 602 0460
0350 602 0460
Output V-kW 24-6.0
Type AC, diode-rectified
0202 102 1943
Electrical system

Model 0202 152 0044 0201 152 1130 0201 102 4510
(0202 152 0043)
0202 102 1943 24-40
Alternator — —
0202 152 0044 24-50
Output V-A (0202 152 0043)
0201 152 1130 — 24-50 —
0201 102 4510 — — 24-40
Regulator IC-transistor type
Type Ribbon
Air heater Voltage (V) x Current (A) - Number 11.0 x 85 - 2
Model F9560W12
3
Theoretical discharge cm (cu in) 425 (26)
Auxiliary equipment

Normal maximum discharge pressure

Air compressor kPa {kgf/cm2, psi} 834 {8.5, 121}

Cooling system Water cooled (Forced circulation type)

Type Vane —
Vacuum pump
Model VD-30 —

GE-1-3
 MAINTENANCE

CONTENTS
SERVICE DATA .......................................... MA-1- 1 BASIC MECHANICAL SYSTEM ................. MA-3- 1
SERVICE DATA .......................................... MA-1- 1 FAN CLUTCH ............................................. MA-3- 1
TIGHTENING TORQUE ............................. MA-1- 2 FUEL SYSTEM ........................................... MA-3- 2
TOOLS ........................................................... MA-2- 1 INTAKE AND EXHAUST SYSTEM ............. MA-3- 5
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.
 SERVICE DATA

SERVICE DATA
SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit Remarks
0.30 - 0.40
Intake —
(0.012 - 0.016)
Valve clearance When engine is cold
0.30 - 0.40
Exhaust —
Basic mechanical system

(0.012 - 0.016)
Open 16° B.T.D.C. —
Intake
Closed 20° A.B.D.C. —
Valve timing
Open 52° B.B.D.C. —
Exhaust
Closed 12° A.T.D.C. —
Cylinder compression pressure At 180 to 220 rpm
3,040 {31, 441} 1,961 {20, 284}
kPa {kgf/cm2, psi} (With engine warm)
Compression pressure difference
Less than 392 {4, 57} —
kPa {kgf/cm2, psi}
Water tank cap operating pressure 49 - 69
— Pressure side
kPa {kgf/cm2, psi} {0.5 - 0.7, 7 - 10}
Fan pulley
8 - 12 (0.31 - 0.47) —
- Tension pulley
Cooling system

With a force of about

Deflection of V-belt Idler (cooler compres- 98 N {10 kgf, 22 lbf}
sor) pulley 15 - 18 (0.59 - 0.71) — applied to the mid part
- Alternator pulley
Valve opening tem- 74.5 - 78.5 73.0 - 80.0
perature °C (°F) (166 - 173) (163 - 176)
Thermostat
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° —
Fuel injection timing
PF6TB-22 2° —
Fuel system

B.T.D.C.
PF6TC 0° —
PF6TB-21 430 - 530 —
Idle speed
PF6TB-22 550 - 570 —
rpm
PF6TC 510 - 610 —

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}
Cylinder head
Basic mechanical system

Tightening L = 147 mm (5.79 in) 85° - 95°

bolt
angle (2nd) L = 119 mm (4.69 in) 70° - 80°

Cylinder head 1st 34 {3.5, 25}

sub bolt 2nd 44 - 54 {4.5 - 5.5, 33 - 40}
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}
Oil pan drain plug 98 - 127 {10.0 - 13.0, 72 - 94}
Lubrication system

Center bolt 59 - 69 {6.0 - 7.0, 43 - 51}

Full-flow type
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
Oil filter
Center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Bypass type
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}

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}
Fuel system

Nozzle holder assembly mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}

Apply film of engine oil to gasket and
screw on until gasket contacts en-
Cartridge type
gine, then tighten 3/4 turn by hand
Fuel filter or UD genuine filter wrench
Center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Bypass type
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
Compressor housing and back plate
Air intake and exhaust system

clamp mounting bolt 9.0 - 11.3 {0.92 - 1.15, 6.7 - 8.3}

N·m {kgfzm, ftzlbf}
Turbine housing and center housing
mounting V-band lock nut 12.7 - 14.7 {130 - 150, 113 - 130}
Turbocharger N·m {kgfzcm, inzlbf}
Model GT45
Compressor housing and back plate
10.3 - 12.3 {105 - 125, 91 - 109}
mounting bolt N·m {kgfzcm, inzlbf}
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.

EP12-3

WMA149A

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

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 WDR151A

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

WDR167A

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

EP4-23

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} EMA1002E
Cotter bolt
: 147 - 167 N·m {15.0 - 17.0 kgfzm, 108 - 123 ftzlbf}

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 read-
ing. 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.

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.

WMA017A

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 0.31 (0.0122) 0.29 (0.0114)
6
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 WMA018A

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}

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}
Pump side 29 - 39 {3.0 - 4.0, 22 - 29}
Injection tube
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}
Bolt 29 - 54 {3.0 - 5.5, 22 - 40}
Oil cooler housing mounting bolt and nut
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}
Feed side 10 - 18 {1.0 - 1.8, 7.2 - 13.0}
Injection pump oil tube
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}
1st 34 {3.5, 25}
Cylinder head sub bolt
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}
Housing side 74 - 88 {7.5 - 9.0, 54 - 65}
Stiffener mounting bolt
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.)

j
1 Air intake duct j
4 Fuel filter j
7 Air intake manifold
j
2 Air intake j
5 Water manifold j
8 Nozzle holder assembly
j
3 Water tube j
6 Nozzle tube j
9 PCM valve

DR-4-1
 DISASSEMBLY AND REASSEMBLY

RIGHT SIDE OF ENGINE

WDR150A

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

j
1 Air intake duct j
5 Turbocharger j9 Car heater pipe
j
2 Exhaust outlet j
6 Exhaust manifold j
10 Oil filter
j
3 Exhaust shutter j
7 Water duct j
11 Oil cooler
j
4 Air pipe j
8 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.

EDR1151A

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)

WDR008A

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
PF6TB-21 3° —
Fuel injection
PF6TB-22 2° —
timing (B.T.D.C.) WDR151A
PF6TC 0° —

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}

EMA1002E

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).

EP3-30

2. Install the oil jet.

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

EN3-065

3. Install the main bearing upper shell.

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

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)
EN3-066
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.

EDR1-096

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}

EP3-50

j
1 No. 7 main bearing cap
j
2 Lower thrust washer

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.

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.

EDR1-101

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.

WDR152A

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) —

WDR011A

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

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}

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