SERVICE DATA

SERVICE DATA
TIGHTENING TORQUE
Unit: Nzm {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 - 49 {3.0 - 5.0, 22 - 36}
Injection tube
Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}
Fuel tube & fuel return tube 25 - 29 {2.5 - 3.0, 18 - 22}
1st 392 {40.0, 289}
Type I 2nd Loosen
Crank pulley nut
3rd 637 - 667 {65.0 - 68.0, 470 - 492}
Type II 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 - 8, 43 - 58}
Alternator mounting bolt 59 - 78 {6 - 8, 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 20 {2.0, 14}
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 59 - 69 {6.0 - 7.0, 43 - 51}
mounting bolt Cotter bolt 83 - 93 {8.5 - 9.5, 61 - 69}
Feed side 10 - 18 {1.0 - 1.8, 7.2 - 13.0}
Injection pump oil tube con-
Return Pump side 15 - 34 {1.5 - 3.5, 11 - 25}
nector
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}
Water pump gear nut 59 - 69 {6 - 7, 43 - 51}
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}
! = 147 mm
Tightening 85° - 95°
Cylinder head bolt (5.79 in)
angle
! = 119 mm
(2nd) 70° - 80° Only bolts marked with *
(4.69 in)
Rocker shaft bracket mounting bolt 34 - 49 {3.5 - 5.0, 25 - 36}

NOTE
For discrimination between Type I and Type II of the crank pulley nuts, refer to page DR-3-2.

DR-1-1
 SERVICE DATA

Unit: Nzm {kgfzm, ftzlbf}

Item Tightening torque Remarks
Oil jet connector bolt 29 - 39 {3.0 - 4.0, 22 - 29}
Main bearing cap bolt 265 - 284 {27.0 - 29.0, 195 - 210}
Type I 196 - 216 {20.0 - 22.0, 145 - 159}
Connecting rod cap nut
Type II 230 - 245 {23.5 - 25.0, 170 - 181}
Front gear case mounting bolt 54 - 74 {5.5 - 7.5, 40 - 54}
Injection pump drive gear mounting nut 392 - 441 {40 - 45, 289 - 325}
Camshaft gear mounting nut 245 - 265 {25.0 - 27.0, 181 - 195}
Camshaft locating plate mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}
Cam chamber cover mounting bolt 10 - 13 {1.0 - 1.3, 7.2 - 9.4}
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 - 21, 137 - 152}
Oil pump mounting bolt 30 - 41 {3.1 - 4.2, 22 - 30}
Oil screen & oil outlet pipe mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
M8 15 - 20 {1.5 - 2.0, 11 - 14}
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 15 {1.5, 11}
Flywheel mounting bolt 255 - 304 {26 - 31, 188 - 224}
Crank damper mounting bolt 98 - 108 {10 - 11, 72 - 80}
Electrical timer magnetic valve eye bolt 25 - 41 {2.5 - 4.2, 18 - 30}
Rear PTO idler shaft mounting bolt 127 {13.0, 94}
Engine rear PTO companion flange nut 392 - 412 {40.0 - 42.0, 289 - 304}

NOTE
For discrimination between Type I and Type II of the connecting rod cap nuts, refer to page
DR-3-2.

DR-1-2
 CONSTRUCTION

WDR001A

* This illustration is of the PF6TA model.

DR-3-2
 DISASSEMBLY AND REASSEMBLY

6. Align the mark on the injection pump with the scribed line on
the timer, then connect the coupling.
Unit: Nzm {kgfzm, ftzlbf}
Item Tightening torque
Coupling bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Cotter bolt 83 - 93 {8.5 - 9.5, 61 - 69}

EMA1002E

DR-4-7
 DISASSEMBLY AND REASSEMBLY

Key points of disassembly

2 Valve rocker assembly
j
Be sure to loosen the mounting bolts proceeding from the
outside in.
j3 Cylinder head bolt

Be sure to loosen the bolts diagonally proceeding from the

outside in.

Key points of reassembly

3 Cylinder head bolt
j
Insert cylinder head bolts and tighten them evenly in 2 steps and
in the sequence shown in the figure. (Use an angle wrench and
socket wrench 99664 96000.)
1st .... : 88 - 98 Nzm {9.0 - 10.0 kgfzm, 65 - 72 ftzlbf}
2nd ............................................. Tightening
angle
85°-95°(Exceptboltsmarkedwith
70° - 80° (Bolts marked with * )) WHV005A

NOTE
*
• If no angle wrenches are available, mark the bolt and
cylinder head after the 1st tightening. Tighten the bolt to
the specified angle, starting from the marked position.
For sub bolt (Mark j)
1st .... : 34 Nzm {3.5 kgfzm, 25 ftzlbf}
2nd .... : 44 - 54 Nzm {4.5 - 5.5 kgfzm, 33 - 40 ftzlbf}
j2 Valve rocker assembly

Be sure to tighten the mounting bolts starting with inner ones

and proceeding to the outer ones.
: 34 - 49 Nzm {3.5 - 5.0 kgfzm, 25 - 36 ftzlbf}

DR-4-9
 DISASSEMBLY AND REASSEMBLY

3. Apply a brake to the ring gear. Then loosen the flywheel

mounting bolt and remove the flywheel using two guide bolts
(99687 97001).

EDR2-063

4. Attach the engine stand attachment (99554 96001), then

raise the engine using a crane or other devices, and mount
it on the engine stand (99550 96001).

EP3-30

5. Measure and record the misalignment of the crankshaft and

flywheel housing.

EP3-31

6. Remove the rear oil slinger and flywheel housing.

NOTE
• When an engine rear PTO is equipped, be sure to
remove the special PTO parts prior to removing the
flywheel housing.
• Remove the flywheel housing by suspending it with a
belt using a hoist.

EP3-33

7. Measure and record the backlash of the gear train.

NOTE
• Measure the backlash by inserting fuse wire between
the gears.
• When the air compressor and water pump has been
removed, temporarily install them and measure the gear
backlash.

WDR019A

DR-4-11
 DISASSEMBLY AND REASSEMBLY

8. Measure and record the end play of the idler gears.

9. Measure and record the side clearance at the large end of

the connecting rod.
NOTE
• Side clearance for every cylinder should be measured.

EP3-47

10. Remove the connecting rod cap and bearing shell.

NOTE
• Keep the bearing shells for each connecting rod being
careful not to interchange the upper and lower shells.

EDR1-093

11. Remove the piston together with the connecting rod.

NOTE
• Be sure to remove carbon accumulated at the top of the
cylinder before removing the piston.

EP3-49

12. Measure and record the end play of the crankshaft.

EDR1-096

DR-4-12
 DISASSEMBLY AND REASSEMBLY

13. Remove the crankshaft, thrust washer and upper main

bearing shell.
NOTE
• Be sure to keep the upper and lower thrust washers as
a set.
• Be sure to keep the upper and lower main bearing shells
as a set for each bearing cap.

EP3-51

Key points of reassembly

• For discrimination between Type I and Type II, refer to page
DR-3-2.

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 Nzm {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-4-13
 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

C 3.945 - 3.975 (0.1553 - 0.1565)
Class of
thrust washer 0.15
4.100 - 4.150 (0.1614 - 0.1634)
O.S. O.S.: Over
0.30 size
4.250 - 4.300 (0.1673 - 0.1693)
O.S.

NOTE
• Be sure the oil groove side of the thrust washer toward
EDR1-096
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.

EP3-50

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

: 265 - 284 Nzm {27.0 - 29.0 kgfzm, 195 - 210 ftzlbf}

EN3-067

NOTE
• Make sure the main bearing cap is installed following
the stamped numbers with the mark ‘‘À’’ indicating the
engine front side.
• The thrust washer has an oil groove which should face
the crankshaft when installed. Be careful not to inter-
change the upper and lower washers.

EP4-3

DR-4-14
 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.

EDR022A

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 - ⊕ 0.0284) —

WDR011A

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

EDR1-093

NOTE
• Make sure stamped mark at the large end of the con-
necting rod aligns with that on the connecting rod cap.
Type I ... : 196 - 216 Nzm
{20.0 - 22.0 kgfzm, 145 - 159 ftzlbf}
Type II .. : 230 - 245 Nzm
{23.5 - 25.0 kgfzm, 170 - 181 ftzlbf}

EP4-5

DR-4-15
 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
: 54 - 74 Nzm {5.5 - 7.5 kgfzm, 40 - 54 ftzlbf}

10. Install the injection pump gear.

NOTE
• When installing, align the timing marks ‘‘Y’’ and ‘‘YY’’.
: 392 - 441 Nzm {40 - 45 kgfzm, 289 - 325 ftzlbf}

WDR012A

11. Install the camshaft assembly together with the gears.

NOTE
• When installing, align the timing marks ‘‘V’’ and ‘‘VV’’.
Locating plate mounting bolt
: 25 - 29 Nzm {2.5 - 3.0 kgfzm, 18 - 22 ftzlbf}
Camshaft gear mounting nut
: 245 - 265 Nzm {25.0 - 27.0 kgfzm, 181 - 195 ftzlbf}

WDR013A

12. Install the cover for the cam chamber.

: 10 - 13 Nzm {1.0 - 1.3 kgfzm, 7.2 - 9.4 ftzlbf}

EDR1042B

DR-4-16
 DISASSEMBLY AND REASSEMBLY

13. Install the oil jet.

NOTE
• It should be installed with the injection orifices facing
the crank gear and idler gear contacting point (so that
they point 30 degrees below the horizontal).

WDR014A

14. Install the idler gear and idler gear shaft.

NOTE
• Install the idler gear aligning the timing marks ‘‘W’’ and
‘‘WW’’.
Mounting bolt
: 18 - 22 Nzm {1.8 - 2.2 kgfzm, 13 - 16 ftzlbf}
Idler gear shaft
: 49 - 57 Nzm {5.0 - 5.8 kgfzm, 36 - 42 ftzlbf}
WDR015A

15. Install the air compressor drive gear.

: 186 - 206 Nzm {19 - 21 kgfzm, 137 - 152 ftzlbf}

16. Install the oil pump assembly.

: 30 - 41 Nzm {3.1 - 4.2 kgfzm, 22 - 30 ftzlbf}
17. Install the oil outlet pipe.
: 16 - 21 Nzm {1.6 - 2.1 kgfzm, 12 - 15 ftzlbf}
18. Install the oil screen.
: 16 - 21 Nzm {1.6 - 2.1 kgfzm, 12 - 15 ftzlbf}

ELB1002B

19. Measure the end play of the idler gear and oil pump idler
gear. Check that the end play is within the service limit.
Unit: mm (in)
Item Maintenance standard Service limit
Idler gear 0.05 - 0.12 (0.0020 - 0.0047) 0.3 (0.012)
Oil pump idler
0.08 - 0.15 (0.0031 - 0.0059) —
gear

DR-4-17
 DISASSEMBLY AND REASSEMBLY

20. Measure the backlash of the gear train.

NOTE
• Measure the backlash by inserting fuse wire between
the gears.
• When the air compressor and water pump have been
removed, temporarily install them and measure the gear
backlash.
• Check that the backlash for each gear is within the
service limit.
Unit: mm (in) WDR019A
Location Maintenance standard Service limit
A.B.C.D.E.F 0.065 - 0.138 (0.0026 - 0.0054) —
G.H 0.085 - 0.215 (0.0033 - 0.0085) —

21. Install the rear oil slinger and flywheel housing.

: M8 ............... 15 - 20 Nzm {1.5 - 2.0 kgfzm, 11 - 14 ftzlbf}
: M12 .......... 78 - 98 Nzm {8.0 - 10.0 kgfzm, 58 - 72 ftzlbf}
NOTE
• When an engine rear PTO is equipped, be sure to install
the special PTO parts prior to installing the flywheel
housing.
• Install the flywheel housing by suspending it with a belt
using a hoist.
EP3-33

22. Install the right and left stiffeners.

On the housing side
: 74 - 88 Nzm {7.5 - 9.0 kgfzm, 54 - 65 ftzlbf}
On the block side
: 98 - 137 Nzm {10.0 - 14.0 kgfzm, 72 - 101 ftzlbf}

EDR1-078

23. Turn the engine upside down and install the oil pan. Apply a
coat of liquid gasket to the contacting surfacers. Fasten
twice.
: 15 Nzm {1.5 kgfzm, 11 ftzlbf}

EP3-32

DR-4-18
 DISASSEMBLY AND REASSEMBLY

[Type II]
Tighten the crank pulley securing bolts diagonally to the
specified torque.
: 177 - 196 Nzm {18.0 - 20.0 kgfzm, 130 - 145 ftzlbf}

WDR016A

EDR2061B

DR-4-20
 DISASSEMBLY AND REASSEMBLY

- MEMO -

DR-4-24
 DISASSEMBLY AND REASSEMBLY

- MEMO -

EP-4-25