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![Manual Manual](/uploads/1/3/3/2/133281801/886085894.jpg)
![Manual Manual](/uploads/1/3/3/2/133281801/143343610.png)
Workshop Manual Free
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2Table of Contents
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3General Information
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4General Repair Instructions
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6Symbols Used in the Manual
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8Main Data and Specifications
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11Design Features and General Outline
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11Main Engine Parts and Their Function
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11Cylinder Head
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12Cylinder Body
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12Crankshaft
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13Pistons
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13Valve Mechanism
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14Tightening Torque Specifications
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15Angular Nut and Bolt Tightening Method
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17Major Part Fixing Nuts and Bolts
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17Cylinder Head and Cover
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18Cylinder Body Diagram
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19Oil Pan and Dipstick Diagram
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20Camshaft and Rocker Arm Diagram
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21Crankshaft, Piston and Flywheel Diagram
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22Thermostat and Thermostat Housing Diagram
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23Intake and Exhaust Manifold Diagram
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24Timing Gear Case and Flywheel Housing Diagram
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25Oil Cooler, Oil Filter, and Oil Pump Diagram
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26Fuel System Diagram
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27Turbocharger Diagram
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28Identifications
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28Engine Serial Number
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28Injection Pump Number
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29Maintenance
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30Lubricating System Maintenance
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30Main Oil Filter Replacement
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30Center Bolt Type Removal/Installation
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30Cartridge (Spin-on) Type Removal/Installation
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31Fuel System Maintenance
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31Fuel Filter Replacement
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32Injection Nozzle Maintenance
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33Spray Condition Check (During Injection Nozzle Tester Operation)
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34Water Separator (Water Sedimentor) Check
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34Air Bleeding Check
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35Cooling System Maintenance
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35Valve Clearance and Adjustment
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35Cooling Fan Drive Belt Adjustment
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35Thermostat Inspection
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37Injection Timing
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37Flange Mounted Injection Pump Injection Timing Checking and Adjustment
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38Injection Timing Checking Procedure
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41Coupling Driven Injection Pump Timing Adjustment
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43Compression Pressure Measurement
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44Turbocharger Inspection
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45Engine Repair-kit (For Non-turbocharged Engines) Diagram
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46Engine Repair Kit (For Turbocharged Engines) Diagram
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47Recommended Lubricants
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47Engine Oil Viscosity Chart
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49Engine Assembly I (Disassembly)
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50External Parts Disassembly Steps
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50Model 6BD1T Right Side View/Disassembly Steps
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51Model 4BD1T View/Disassembly Steps
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52Injection Pump With Injection Pump Gear
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52Flange Mounted Injection Pump Removal
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52Coupling Mounted Injection Pump Removal
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52Remove of the Air Compressor (If Equipped)
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53Model 6BD1T Left Side View/Disassembly Steps
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54Model 4BD1T Left Side View/Disassembly Steps
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55Major Components/Disassembly Steps
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56Rocker Arm Shaft
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56Cylinder Head Bolts
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56Crankshaft Pulley Nut
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57Taper Bushing (6B Series Only)
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57Flywheel
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58Major Components II/Disassembly Steps
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59Idler Gear
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59Cam Shaft
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59Crankshaft Bearing Cap
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60Rocker Arm and Rocker Arm Shaft View/disassembly Steps
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61Cylinder Head View/Disassembly Steps
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61Split Collar Removal
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62Piston and Connecting Rod View/Disassembly Steps
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63Piston Rings Removal
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63Snap Ring and Piston Pin Removal
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65Engine Assembly II (Inspection and Repair)
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66Cylinder Head Lower Face Warpage Check
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66Water Jacket Water Pressure Test
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67Valve Stem and Valve Guide Clearance
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67Valve Guide Replacement/Removal
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68Valve Depression
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68Valve Contact Width
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68Valve Seat Insert Replacement/Removal
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69Valve Seat Installation
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69Valve Seat Insert Correction
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70Valve Spring Free Length Measurement
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71Valve Spring Inclination
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71Valve Spring Tension
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71Tappet (Cam Follower or Valve Lifter) Inspection
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72Push Rod Inspection
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72Rocker Arm Correction
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72Rocker Arm Shaft and Rocker Arm Inspection
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72Rocker Arm Shaft Outside Diameter Measurement
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73Idler Gear and Idler Gear Shaft Inspection
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73Rocker Arm Shaft and Rocker Arm Clearance Check
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74Camshaft Inspection
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75Cylinder Liner Bore Measurement
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76Cylinder Liner Projection Inspection
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76Cylinder Liner Replacement
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77Cylinder Bore Measurement
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77Cylinder Liner Grade Selection
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77Cylinder Body Inside Diameter Measurement
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78Cylinder Liner Outside Diameter Measurement
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78Cylinder Bore and Cylinder Liner Outside Diameter Combinations
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79Cylinder Liner Installation
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79Piston Grade Selection
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80Cylinder Liner Bore Measurement/Piston Outside Diameter
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81Cylinder Liner Bore and Piston Clearance
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82Piston Ring and Piston Ring Groove Clearance
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82Piston Ring and Piston Groove Clearance
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82Piston Ring Gap
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83Piston Pin Outside Diameter
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83Piston Pin and Piston Clearance
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83Piston Pin and Piston Pin Hole Clearance
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84Connecting Rod Alignment
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84Piston Pin and Connecting Rod Small End Bushing Clearance
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84Connecting Rod Bushing Replacement
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85Connecting Rod Bearing Inspection
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86Crankshaft and Bearing Inspection
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86Crankshaft Journal and Crankpin Outside Diameter
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87Crankshaft Journal and Bearing Clearances
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88Crankshaft Journal Bearing Inside Diameter
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88Connecting Rod Bearing Inside Diameter
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89Crankshaft Run-Out
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89Main Bearing and Connecting Rod Bearing Tension
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89Crankshaft Regrinding
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90Crankshaft Regrinding Procedure
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90Crankshaft Grinding Limit
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91Plastigage Clearance Measurement
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91Crankshaft Journal Bearing Clearance
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92Crankshaft Pin Bearing Clearance
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92Crankshaft Tufftriding Inspection
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93Oil Seal Wear Ring Replacement (6BD1T, 6BG1, 6BG1T)
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93Crankshaft Gear Inspection
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94Crankshaft Gear Replacement
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94Flywheel and Flywheel Housing (Rear Oil Seal) Inspection
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94Rear Gear Inspection/Replacement/Installation
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94Flywheel Housing Oil Seal Replacement
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95Timing Gear Case Cover Inspection
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95Crankshaft Front Oil Seal Replacement
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97Engine Assembly III (Reassembly)
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98Piston and Connecting Rod Reassembly Steps - Minor Component
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99Pistons Heating/ Connecting Rod Installation
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99Piston Pin Snap Ring Installation
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99Piston Ring Installation
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99Connecting Rod Bearing Installation
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100Cylinder Head Reassembly Steps
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101Valve Stem Oil Seal Installation
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101Intake and Exhaust Valves Installation
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101Intake and Exhaust Valve Springs Installation
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101Spring Seat Split Collar Installation
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102Intake Manifold and Gasket Installation
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102Exhaust Manifold and Gasket Installation
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104Rocker Arm and Rocker Arm Shaft Reassembly Steps
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105Major Component Reassembly Steps I
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106Oil Jet Installation
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106Crankshaft Bearing Configuration
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106Crankshaft Installation
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106Thrust Bearing Installation
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107Crankshaft Bearing Cap Installation
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107Timing Gear Case Installation
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107Camshaft/Thrust Plate Bolts Tightening
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107Idler Gear Shaft Installation
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108Idler Gear Installation
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108Piston and Connecting Rod Installation
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109Oil Pump and Coupling Installation
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109Flywheel Housing Installation
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110Oil Pan Installation
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110Oil Cooler Installation
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111Major Component Reassembly Steps II
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112Flywheel Installation
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112Injection Pump and Injection Pump Gear Assembly
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112Air Compressor Installation
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113Tappet Chamber Cover Installation
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113Water Pump Installation
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113Cylinder Head Gasket/Bolt Installation
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115Rocker Arm and Rocker Arm Shaft Installation
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116External Parts Reassembly Steps (Left-hand Side)
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117Cylinder Head Cover Installation
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117Fan Belt Adjustment
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117Starter Motor Installation
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118Turbocharger Mounting Flange Gasket Positioning
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118Turbocharger Nuts Tightening
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118Oil Drain Pipe Installation
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119Oil Feed Pipe Installation
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119Turbo Adaptor Tightening
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120External Parts Reassembly Steps (Right-hand Side) - Model 6BD1T
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121Injection Nozzle Installation
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121Fuel Injection Pipe and Fuel Leak Off Pipe Installation
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121Oil Filter Installation
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122Fuel Pipe, Fuel Return Pipe, Intake Pipe Installation
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122Injection Timing Adjustment
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123Engine Tuning Operation
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125Engine Sectional View
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127Lubricating System
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128Lubricating System - General Description
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129Oil Pump Disassembly
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130Oil Pump Drive Gear Inspection
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130Oil Pump Driven Gear Inspection
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131Main Oil Filter Disassembly/Inspection and Repair
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132Lubricating System Reassembly
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132Center Bolt and Drain Plug Installation
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133Oil Cooler Disassembly, Inspection and Repair
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134Lubricating System Reassembly Steps
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134Oil Cooler Element Installation
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135Cooling System
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136Cooling System - General Description
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137Water Pump Disassembly Steps
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138Impeller/Pulley Center/Snap Ring Removal
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138Spindle, Bearing, Spacer/Seal Unit, Washer and Seal Removal
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139Bearing Replacement
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140Cooling System Reassembly Steps
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141Spindle, Bearing, and Spacer Installation
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141Snap Ring/Pulley Center Installation
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141Seal Unit, Washer and Seal Installation
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142Impeller/Pulley Installaton
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142Thermostat Inspection and Repair
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143Fuel System
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144Fuel System - General Description
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145Fuel Filter Disassembly/Inspection and Repair
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147Injection Nozzle Disassembly
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148Push Rod Spring Check
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148Nozzle Holder Push Rod Check
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148Injection Nozzle Check
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149Fuel Filter Reassembly Steps
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150Injection Pipe Connector/Injection Nozzle/Retaining Nut Check
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150Injection Starting Pressure Adjustment
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151Nozzle Holder Cap Nut Check
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152Injection Pump Calibration Data
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152Identification Plate and Product Serial Number
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152Test Conditions Required for the Fuel Injection Amount Adjustment
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153Inj. Pump Calibration Data
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154Governor Adjustment
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155Turbocharger
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156Turbocharger - General Description
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157Turbocharger Identification
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158Rotor Shaft Play Inspection
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158Rotor Shaft Axial Play Measurement
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159Air Compressor
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160Air Compressor Sectional View/Main Data
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161Air Compressor Disassembly Steps
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162Air Compressor Inspection and Repair
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164Air Compressor Reassembly Steps
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165Connecting Rod/Bearing Cover Installation
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165Cylinder Body/Cylinder Head Installation
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167Engine Electricals
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168Starter Motor Identification
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168Nikko Identification Plate
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168Hitachi Identification Plate
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169Starter Motor Main Data and Specifications
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171Starter Motor Sectional View
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172Starter Motor Exploded View
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173Alternator Identification
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174Alternator Main Data and Specifications
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176Regulator Main Data and Specifications
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177Alternator Sectional View
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178Alternator Exploded View
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179Troubleshooting
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180Hard Starting
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180Starter Inoperative
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181Starter Motor Operates but Engine Does Not Turn Over
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182Engine Turns Over but Does Not Start, Fuel Is Being Delivered to the Injection Pump
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183Engine Turns Over but Does Not Start
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184Unstable Low Idling
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187Unsufficient Power
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190Excessive Fuel Consumption
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193Overheating
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195White Exhaust Smoke
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196Dark Exhaust Smoke
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197Oil Pressure Does Not Rise
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199Abnormal Engine Noise
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199Engine Knocking
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199Gas Leakage Noise
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200Continuous Noise
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201Slapping Noise
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203Special Tool List
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207Conversion Table
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207Length Conversion Table
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209Area Conversion Table
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209Volume Conversion Table
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211Mass Conversion Table
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212Pressure Conversion Table
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213Torque Conversion Table
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214Temperature Conversion Table