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14 MAINTENANCE STANDARD
673501
INTAKE A N D E X H A U ST S Y S T E M Turbocharger.................................. 14- 2 Exhaust m an ifold .............................14- 4 EN G IN E PROPER Cylinder head ................................. 14- 6 Valve, valve g u id e ............................14- 8 Rocker arm shaft, push rod, tappet 14-10 Cylinder block................................. 14-12 Cylinder..........................................14-14 Crankshaft...................................... 14-16 Cam shaft........................................ 14-18 Timing ge ar.....................................14-22 Piston, piston ring, piston p in ........... 14-24 Connecting r o d ................................14-26 Vibration d a m p e r.............................14-28 Flywheel, flywheel h ou sin g............... 14-30 Fan h u b ......................................... 14-32 LUBRICATING S Y S T E M Oil p u m p ........................................ 14-33 CO O LIN G S Y S T E M Water pump, thermostat................... 14-34 FUEL S Y S T E M Fuel injection p u m p ......................... 14-35 Fuel injection nozzle......................... 14-36
14-1 from the library of Barrington Diesel Club
©
MAINTENANCE STANDARD
TURBOCHARGER
TURBOCHARGER
673501
2
620 7 F4 02
14-2 ©
from the library of Barrington Diesel Club
TURBOCHARGER
673501
MAINTENANCE STANDARD
U n it: mm No.
Check item
Criteria
1
Play of rotor in radial direction
0.30 - 0.46
2
Play of rotor in axial direction
0.03 - 0.08
3
Tightening torque of com pressor housing bolt
4
Tightening torque of tur bine housing bolt
Remedy
Repair or re place .
8.5 Nm {0.9 kgm} Tighten
Outside diameter of wheel shaft
14 Nm{1.4 kgm} B
10.97-10.98
5 Curvature of wheel shaft
Repair limit: 0.0003 (total indicator range)
6
Inside diameter of back plate
19.305-19.330
7
Inside diameter of center housing
C
15.875-15.885
D
19.305-19.330
Replace
14-3 from the library of Barrington Diesel Club
©
MAINTENANCE STANDARD
EXHAUST MANIFOLD
673501
EXHAUST MANIFOLD
U n it: mm Check item
No. 1
Flatness of exhaust manifold
Criteria
Rem edy
0.10
Replace
14-4
©
from the library of Barrington Diesel Club
from the library of Barrington Diesel Club
MAINTENANCE STANDARD
CYLINDER HEAD
CYLINDER HEAD
2
3
4 673501
1
5
14-6
©
from the library of Barrington Diesel Club
MAINTENANCE STANDARD
CYLINDER HEAD
U nit: mm C heck item
No,
1
2
R em e d y
Criteria Vertical direction
6D102: 0.305
Horizontal direction
6D102: 0.076
Distortion of cylinder head mounting surface
Protrusion of nozzle
6D102E-T SA6D102E-1: c A A c n m o c o. SAA6D102E-2.
5.10 ] 4.06 o -re 3.75 J
Reference values (These values vary with thickness of nozzle gasket of each specjflcatjon>)
Order Tightening torque of cylin der head mounting bolt 3
Grind to correct or replace
Replace nozzle gasket
Tightening torque
1st step -All
90Nm{ 9.2kgm}
2nd step - Check again
90Nm{ 9.2kgm}
3rd step (long mounting bolts only) Coat bolt seat face and thread with molybdenum 4th step (long mounting bolts only) [disulphide (LM-P) . Check again 5th step 4
Tightening torque of nozzle holder
60Nm{6.0kgm}
5
Tightening torque of head cover mounting bolt
24Nm{2.4kgm}
120Nm{12.2kgm}
Tighten in order shown in diagram on left
120Nm{12.2kgm} Turn 90°
Tighten
14-7 ®
102 SERIES
from the library of Barrington Diesel Club
MAINTENANCE STANDARD
VALVE, VALVE GUIDE
VALVE, VALVE GUIDE
2
3
4
\ s C iS . V o f o J ^ o . ° a ° 0
'o°sf°t>0C30*0
°®°
0® © © 0 ° 0 0 ° 0 © ° r>Sk - s n ° k n 9 v a n c - h
102 SERIES
© from the library of Barrington Diesel Club
MAINTENANCE STANDARD
7
VALVE, VALVE GUIDE
8
9
U nit: mm No.
Check item
1
Sunk depth of valve
2
Thickness of valve head
Criteria
R em e d y
0.99-1.52
Replace valve or valve seat Replace
0.79 Repair limit
3
Angle of valve seat
45°(Exhaust) 30°(lntake)
Outside diameter of valve stem
4
Judge condition of contact surface with vacuum test 7.98
Replace
Diameter of valve guide bore Clearance between valve guide and valve stem
Installed load of valve spring 5 Perpendicularity of valve spring
Correct or re place valve, valve seat
8.019-9.090 Intake
0.039 - 0.099
Exhaust
0.039 - 0.099
Installed length
Installed load N{kg}
49.02
282.5 - 322.5 {28.8 - 32.9}
Replace either or both valve and valve guide
Repair limit (N{kg})
Replace
Max. 1.0
6
Height to drive in valve guide
11.25-12.75
7
Depth of valve insert bore (standard insert)
10.30-10.50
8
Inside diameter of valve in sert bore (standard insert)
46.987-47.013
9
Depth of valve seat polish ing
B : 0.254
Correct
Replace
14-9
102 SERIES
from the library of Barrington Diesel Club
MAINTENANCE STANDARD
LOCKER ARM SHAFT, PUSH ROD AND TAPPET
LOCKER ARM SHAFT, PUSH ROD AND TAPPET
TFS i W RRm l7rr
14-10
—
k f 9 b r n b - h
102 SERIES
©
from the library of Barrington Diesel Club
MAINTENANCE STANDARD
673501
LOCKER ARM SHAFT, PUSH ROD AND TAPPET
U n it: mm No.
1
Check item
Criteria
Outside diameter of rocker arm shaft
18.938-18.975
Replace rocker arm shaft
Inner diameter of rocker arm shaft hole
19.000-19.051
Replace rocker arm
0.025 - 0.083
Replace rocker arm or shaft
Clearance between rocker arm shaft and rocker arm
Remedy
2
Curvature of push rod
Repair limit: 0.38 M A X (total indicator range)
3
Tightening torque of lockout for rocker arm adjustment screw
34 Nm (3.5 kgm}
4
Valve clearance (both warm and cold)
Replace push rod Tighten
Intake valve
0.25
Exhaust valve
0.51
Adjust
5
Outside diameter of tappet
15.936- 15.977
Replace tappet
6
Inside diameter of tappet hole
16.000-16.055
Replace cylinder block
7
Clearance between tappet and tappet hole
0.02 - 0.065
Replace tappet or cylinder block
8
Tightening torque of rocker arm mounting bolt
24 Nm {2.4 kgm}
Tighten
14-11 from the library of Barrington Diesel Club
©
MAINTENANCE STANDARD
CYLINDER BLOCK
CYLINDER BLOCK
673501
2
4. 5
6
7
8 i
®L
O OO
