Isuzu 6BB1 Diesel Engine Service & Repair Manual

FOREWORD The Model 6BBI desel engine, mounted on the Isuzu Model SBR Truck, has been designed and manufactured based on the outstanding technique and rich experience cultivated during long years. This high performance engine features its high durability and economy. To allow the engine displaying its high performance and to maintain optimum condition, a full knowledge of correct repair method and technique is very important. This manual covers the construction, and repair and adjustment methods for the overall 6BBI diesel engine. Many photographs and figures shown in the individual section will assist readers in understanding the engine. Please read this manual carefully and take full advantage of the information given. Note that values and other data shown in manual may be changed due to the future design change or modification. )

TABLE OF CONTENT Outline of model 6BBI diesel engine Model 6BBI diesel engine in sec tio nal view Main engine data and specifications T orqu e specification table SECTION 1. ENGINE 2. LUBRICATING SYSTEM AND COOLI NG SYSTEM 3. ENGINE AUXILIARIES 4. FUEL SYSTEM 5. ENGINE ELECTRICALS SUPPLEMENT ENGINE TROUBLE-SHOOTING AND CORRECTION

Outline of Model GBBI Diesel Engine The model 6BB1 is a direct-injection type diesel engine incorporating efficient combustion chambers (patent applied) which have recently been developed by the Isuzu engineers. The model 6BB1 diesel engine develops a maximum output of 145 PS and features an excellent operating economy, dependability, low operating noise and exhaust gas control systems of advanced design. Engineering features of the model 6BB1 diesel engine include the following: 1. Designed and built compact yet powerful-piston displacement is 5.393 Itrs with the bore and stroke of 102mm and 110mm, respectively. 2. Advanced direct-injection method, Isuzu's exclusively designed combustion chambers, efficient intake parts and direct-injection system ensure a high engine performance. 3. Adopts Isuzu's exclusively designed square-type troidal swirl combustion chambers (patent applied). 4. Utilizes an efficient RAD injection pump governor and overflow valve is installed on the fuel pump side. 5. Cylinder head, cylinder liner and piston cooling method has been improved to gain durability of engine components.

Model 6BBI Diesel Engine in External View

Model 6BB1 Diesel Engine in Sectional View

Model 6BBI Engine Data and Specifications Item Specifications Pressurized circulation 18 00 V-belt driven impeller type Wax-pellet type Dry cycron type with dust indi cator NS70 -12 x2 24-15 24 -3.75 lit. lit. Model 6BB I diesel engine Water-cooled -l-cycle direct-injection type mm 6-102¢ x 110 cc 5393 17.5 mm 1088x772x760 kg 441 (In cluding weight of fan and air cleaner) 22° (When engine is stationary) 1-5-3 -6 -2--4 NP-PES6A85C412R S NP-EP/RAD220 NP-EP /SCD500 - 1650A NP-OLLA 152S344 Over-head valve type 10° (B.T.D.C) 42° (A.B.D.C) 50° (BoB.DoC) 10° (A.T .D.C) Gear type Water-cooled (Fuel-flow side) Paper element type (Partial-flow side) Cen trifugal type Max.TZ Min. 10 Engine model Engine type Number of cylinders - bore x stroke Total piston displacement Compression ratio Engine dimensions (length x.width x height ) Engine weight (when fully equipped) Fuel injection timing B.T.D.C. Fuel injecting order Injection pump model Governor model Timer Injection nozzles Valve arrangement Intake valves,open at Intake valves close at Exhaust valves open at Exhaust valves close at Oil pump type Oil cooler type Oil filter type Oil pan capacity Cooling method Cooling system capacity Water pump type Thermostat type Air cleaner type Battery type -Nominal voltage x Number of batteries Generator voltage - Capacity V-A Starter voltage - Output V-KW

Torque Specification Table Name Torque m-kg (I) Cylinder head bolts ,. . -,- 11.5 .t) /-t , c" fl (2) Glow plugs 2.5 (3) Injection pipe sleeve nuts 2.9-3.2 (high pressure side) (4) Nozzle holder flange nuts 2.6 (5) Crankshaft bearing cap bolts 24 (6) Idle gear bolts 5.3 (7) Camshaft gear bolts 16 (8) Flywheel bolts 16 (9) Flywheel housing bolts 16 (10) Engine foot bolts 6.3 (II) Connecting-rod bearing cap bolts 10.5 (12) Crankshaft front nut 44 (13) Timing gear case bolts 2.6 (14) Timing gear case cover bolts 2.6 (15) Rocker arm bracket bolts 3.1 (16) Tappet chamber cover bolts 2.1 (17) Camshaft thrust plate 2.1 (18) Oil pump mounting bolts 5.3 (19) Water pump mounting bolts 4.3 (20) Oil pan fixing bolts 2.6 (21) Starter mounting nuts 8.6 Remarks Lubricate with oil and torque in two steps (See Note 2). Final torque should be limited to 9.5 m-kg for new bolts. Lubricate with oil Lubricate with oil Lubricate with oil 1. Thick lett ers indicate vital parts of engine . 2. Cylinder head bolt torque procedure consists of the following steps: When installing new cylinder head and bolts, first torque the entire bolts evenly to 6 m-kg and loosen them completely and then retorque to the final torque of 9.5 m-kg, When reusing cylinder head bolts torque them to the final torque of 11.5 m-kg. ~Strength 4T 7T 19T (Special \ Strength 4T 7T 9T (Special Designation\ (Soft steel) Hard steel), steel) Designation\ (Soft steel) (Hard steel) steel) M 6 x 1.0 0.4- 0.8 0.5- 1.0 - MI6 x I.5 10.6-16.0 13.8-20.8 16.3-24.5 M 8 x 1.25 0.8- 1.8 1.2- 2.3 1.7- 3.1 MI8 x 1.5 12.0-18.0 i6.0-24 .0 20.0-30 .0 MIO x 1.25 2.1- 3.5 2.8- 4.7 3.8- 6.4 M20 x 1.5 13.5-20.0 18.0-26 .0 22.5-33.5 MI2x 1.25 5.0- 7.5 6 .2- 9.3 7.7-11.6 M22x1.5 18.0-27.0 24.9-36.0 30.0-45.0 M14 x 1.5 7.8-11.7 9.5-14 .2 11.6-17.4 M24 x 2.0 23.0-34 .0 30.5-45.5 38 .0-57.0 Bolt identification - B--§+ - --- b- 4T 7T 9T Note: The torques in the above table generally apply where stdndard torques are no t specified.

SECTION 1 ENGINE CONTENTS ENGINE REMOVAL 1- 1 ENGINE INSTALLATION 1- 3 1. MAJOR DISASSEMBLy 1- 3 2. SERVICING OF ENGINE COMPONENTS 1- 9 2-1 Cylinder Body : 1- 9 2-2 Crankshaft 1-13 2-3 Pistons and Connecting-Rods 1-18 2-4 Cylinder Head 1-23 2-5 Rocker Arm Shaft and Relative Parts : 1-30 2-6 Camshaft 1-33 2-7 Timing Gears 1-35 3. MAJOR REASSEMBLY 1 -36 4. ADJUSTMENT OF ENGINE CONTROLS 1-44

ENGINE 1-1 Engine Removal I TOOLS REQUIRED: I A set of general tools, wire, hoist (chain block) (1) Apply the parking brake firmly and place the transmission in neutral. (2) Unlock the cab mounting lock lever on the right side of the cab. Then, unlock the cab mounting lock lever on the left side of the cab. Release the safety hook lever, while exerting a pressure onto the cab to prevent the cab from raising abruptly. When the cab is raised to a stop support it in position with the cab stay . (3) Disconnect the battery negative (-) cable. (4) Drain the cooling system through the drain cock on the radiator and on the cylinder block then drain engine oil completely. (5) Disconnect the cable connecting the starter to the battery. Disconnect the grounding cable to chassis frame. (6) Disconnect the generator cable at the connector then disconnect generator grounding cable. Fig. 1-1 (7) Disconnect the thermometer unit cord, oil filter switch cord and glow plug wiring. (8) Loosen the clips and remove the vacuum hose . (9) Disconnect the exhaust pipe from the exhaust manifold. (10) Disconnect the air cleaner rubber hoses from the intake manifold. (11) Disconnect the engine control rod and engine stop cable connected to the intake shutter. Fig. 1-2 (12) Disconnect the fuel pipes (between fuel tank and feed pump and between fuel tank and fuel filter.) (13) Disconnect the radiator inlet and out - let rubber hoses and heater hoses. (14) Disconnect the fan drive shaft at the water pump pulley. Fig. 1-3 (15) Disconnect the transmission control rods from the gearshift lever on the floor side and from the gearshift lever joint on the quadrant box side. (16) Disconnect the Ist propeller shaft at the flange yoke on the rear of the transmission. (17) Disconnect the parking brake control cable at the parking brake cam lever

1-2 ENGINE behind the transmission . (18) Disconnect the speedometer drive cable and back-up lamp switch cord . (19) Remove the clutch slave cylinder from the flywheel housing. (20) Place a transmission jack under the transmission and remove the bolts fixing the clutch housing then , withdraw the transmission rearward (or lift the transmission out of position through the inspection hole in the rear body using a hoist). (21) Slightly raise the engine with a hoist and remove the front and rear mountings. Fig. 1-4 (22) To remove the rear mountings, proceed as follows : Remove the 3rd crossmem- ber from the frame and take out the rear mounting bolts from the cross- member . Fig. 1-5 (23) Hoist the engine, adjusting tension so that front end of the engine is elevated slightly above the rear of the engine. Then, swing the engine to either side and lift it out of position. Fig. 1-6

Specification	Details
Displacement	5.8 liters
Horsepower	120 HP @ 2600 RPM
Torque	330 Nm @ 1600 RPM
Compression Ratio	17:1
Applications	Heavy-duty trucks, industrial generators

Isuzu 6BB1 Diesel Engine Service & Repair Manual

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