Isuzu 6UZ1X Engine OEM Service & Repair Manual

CNH Copyright © 2006 CNH France S.A. Printed in France November 2006 Lep 87606798A SERVICE MANUAL 6UZ1X ISUZU ENGINE NOT FOR PRINT

Lep 87606798A Issued 11/06 NOT FOR PRINT

General Information OA-1 General Information General Information Contents General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2 Reading the Model . . . . . . . . . . . . . . . . . . . . . . . 0A-6 General Information . . . . . . . . . . . . . . . . . . . . . . 0A-6 NOT FOR PRINT

General Information OA-2 General Information Service Precautions In order to work safely 1. Use an engine stand when lowering the engine from the machine. Do not put the engine on the ground directly. And put it so that the oil pan is not affected. 2. When performing by two persons or more, confirm safety each other. 3. If performing repair on the electrical system, always disconnect the negative cable from the battery terminal beforehand. Before removing the battery cover, keep fire away. 4. In badly ventilated indoor workshop, do not run the engine for a long time or perform painting work. 5. Be sure to use special tools as instructed. Use of other than the specified tool may cause damage of parts or injury. 6. Maintain tools, measuring equipment and special tools in good condition, and prepare them before use. Do not use worn wrenches, hammers that has the rounded striking surface of the head or chipped chisels, etc. 7. When using devices such as a grinder, crane and welder, follow the instructions and use a special care. Also, when performing other works, protect yourself with clothes and other safety tools. WSHK0190 WSHK0191 NOT FOR PRINT

General Information OA-3 8. After servicing the fuel system, always check for fuel leakage. (This may cause a fire.) 9. When handling highly-volatile material, take extreme care not to let it catch fire. Be sure to wipe off spilled oil and grease on rubbers, as this may cause the rubber to deteriorate. Replacement parts and part numbers 1. Always replace the packing, oil seal, O-ring, caulking lock nut, folding type lock plate, split pin, etc. with new ones every time they are disassembled. 2. The part number information in this manual may not represent availability of supply, or the numbers may have been changed due to revision. Always check the numbers with the part catalog before use. Liquid gasket 1. Remove old liquid gasket completely from liquid gasket applied area on each part using a scraper during disassembly. Wipe off oil, water, dust, etc. with cloth and apply specified liquid gasket on each area before assembly. 2. If the gasket remover (ThreeBond, Pando 391D) is used to clean easily, it is recommended that you wait for about 10 minutes after application, and then remove it. However, do not use it for resin or painted parts. 3. Be careful to apply appropriate amount, not excessively or insufficiently. Always, the start and end of the application should be overlapped. 4. Take care not to misalign the applied part and opposite one when assembling it after application. If the parts are misaligned, apply the liquid gasket again. Especially for the oil pan, use the same size of studs as a guide since it has no positioning such as a knock pin. 5. Apply liquid gasket and assemble it within 7 minutes. If more than 7 minutes have elapsed, remove the existing liquid gasket and apply again. 6. Start the engine more than 30 minutes after each part is assembled. Liquid gasket WSHK0192 Sealed Location Product Name Manufacturer Upper surface of the mating portion between cylinder block – flywheel housing 1207B ThreeBond Between front cover – cylinder block 1201 ThreeBond Between cylinder block – flywheel housing – crank case 1201 ThreeBond Between cylinder block – crank case FMD –127 Loctite Lower surface of the mating portion between crankcase – flywheel housing 1207B ThreeBond NOT FOR PRINT

General Information OA-4 • Be sure to use liquid gasket of product name described above or equivalent product. • Use the appropriate amount of liquid gasket. Follow the instructions of products. Method of application 1. Wipe off water, oil or grease from contact surface. The contact surface should be dry. 2. Apply liquid gasket of specified bead width on the one side of contact surfaces. At this time, there should be no gap in bead. Note: If the method of application is described in service manual, follow the description. Work procedure 1. Wipe off oil, grease and water completely from the contact surface of bolt, bolt hole and threads portion of nut. The contact surface should be dry. 2. Apply Loctite on 1/3 of the tip of threads. 3. Tighten the bolt to the specified torque. Important: After tightening, do not give excessive torque or vibration for at least 1 hour until Loctite hardens. How to use Plastigauge (Example) Measurement of clearance between connecting rod bearing and crank pin • Clean the connecting rod and the bearing, and assemble the bearing to the connecting rod. • Cut the Plastigauge in the width of the crank pin, and place it parallel, away from the oil hole of the pin. • Align the stamp mark of connecting rod with that of cap, and assemble them to the crank pin. Apply molybdenum disulphide to the threads and the seating surface of the tightening bolts, and tighten the bolts on the cap alternately to the specified torque. Important: Never move the connecting rod while using the Plastigauge. • Carefully remove the cap and the connecting rod, and measure the width (clearance) of flattened Plastigauge using the scale printed on the bag. Lower surface of the mating portion between crankcase – front cover 1207B Three Bond Contact part of cylinder head that nozzle sleeve is pushed to TL290 Loctite Sealing cup push part between cylinder block – head 962T 123T Loctite Hermetic seal Plug nipple of oil cooler #575 Loctite O-ring omission prevention agent 1208 CH Dyne #290 Three Bond Cement dyne Sealed Location Product Name Manufacturer Type Measurable Range (mm) PG-1 (Green) 0.025 — 0.076 PR-1 (Red) 0.051 — 0.152 PB-1 (Blue) 0.102 — 0.229 NOT FOR PRINT

General Information OA-5 (Example) Measurement of clearance between crankshaft bearing and crankshaft journal. • Clean the bearing installation surfaces on the crankcase and on the cylinder block, and the bearings. Then assemble each bearing to the cylinder block and the crankcase. • Put the crankshaft on the cylinder block carefully, and rotate the crankshaft for approx. 30 degrees to fit in. • Cut the Plastigauge in the width of the crankshaft journal, and place it parallel, away from the oil hole of the journal. • Put the crankcase on the cylinder block carefully, and apply molybdenum disulphide to the threads and the seating surface of the tightening bolts. Then tighten them to the specified torque in the specified order. Important: Never rotate the crankshaft while using the Plastigauge. • Carefully remove the crankcase, and measure the width (clearance) of the flattened Plastigauge using the scale printed on the bag. NOT FOR PRINT

General Information OA-6 Reading the Model Stamping position of engine number Name 1. Engine Number Stamp (6UZ)1-······) General Information Description of terms and abbreviations Definition of terms WSUZ0142 Term Description Specifications General term for the specified values that are necessary for service work, such as nominal dimension, assembly specifications and service limit. Nominal dimension It indicates the value without tolerance at the time of manufacture. Assembly specifications It indicates the specified value after assembly, repair or adjustment. Service limit It indicates the limit value that the part must be repaired or replaced when it reaches this value (dimension). Front/Rear, Right/Left, Top/Bottom These indicate directions same as those of the vehicle when mounted on. Units In addition to SI unit, conventional unit is also shown (toque, pressure, force, in particular). [Example] Length: mm, Torque: N⋅m {kgf⋅m} Warning It means the items that danger of personal life or serious injury may occur if you do not follow. NOT FOR PRINT

General Information OA-7 Abbreviation SI (International System of Unit) About changeover to SI (International System of Unit) This was introduced with the aim to internationally unify the metric system and the units (Shakkanho (Japanese measuring system), Foot-pound system, etc.) which are used conventionally in various countries, and to control the confusion among each unit (conversion by calculation etc.) Caution It means the items that injury or accident may occur if you do not follow. Important It means the items that related parts and system may lose the normal performance, or a fault may occur in vehicle. Note It means the items which is noted in procedures. Term Description Abbreviation Description AC Alternating Current ACC Accessory ACG Alternating Current Generator API American Petrol Institute ASM (Assy) Assembly ATDC After Top Dead Center BAT, BATT Battery BRG, Brg Bearing BKT, BRKT Bracket BTDC Before Top Dead Center CO Carbon Oxide CONN Connector CPU Central Processing Unit C/U Control Unit DC Direct Current DI Direct Injection ECU Engine Control Unit/Electronic Control Unit ECM Engine Control Module EGR Exhaust Gas Recirculation Exh, EXH Exhaust Ft, FRT Front FWD Forward F/C Fuel Cut GND Ground IC Integrated Circuit ID plate Identification Plate IN Intake, Inlet ISO International Organization for Standardization I/PUMP Injection Pump JIS Japanese Industrial Standards L/H, LH Left Hand M/V Magnetic Valve NOx Nitrogen Oxide N-TDC Number - Top Dead Center OPT Option P Pole(S) PCV Pump Control Valve/Positive Crankcase Ventilation PM Particulate Matter PS Pre-Stroke PTO Power Take Off QOS Quick On System Rr, RR Rear R/H, RH Right Hand R/L Relay STD Standard SW Switch TICS Timing & Injection rate Control System A type of injection system VGS Turbo Variable Geometry turbocharger System Variable turbo, VGS turbo W/L Warning Lamp Abbreviation Description NOT FOR PRINT

General Information OA-8 In Japan, the new calculation method that fully adopts SI unit was issued in 1992 and standardized in JIS-Z- 8203. In this manual, SI units which are international unit system are described, and conventional units are also described in { }. SI Abbreviation of French word “Le S ysteme I nternational d’Unites” Relationship between SI and conventional units *1 Some service data which have been issued already use “kg” instead of “kgf” to represent force and weight (mass) for convenience sake. *2 The results of the conversion may be rounded to one or two decimal places. Conversion of numeric representation Prefixes such as “k (kiro)” or “m (milli)” are used for numeric conversion. • 200 kgf/cm 2 = 19,620 kPa = 19.6 MPa • 40 mmHg = 5,332 Pa = 5.3 kPa Table of Isuzu standard tightening torque The tightening torque values in the following table are applied to the places where tightening torque is not specified. SI Conventional Unit Item, Unit Conversion Length m m Same as conventional one Weight (mass) kg kg Same as conventional one Force N * kg, kgf 1 kgf = 9.80665 N Torque N⋅m * kg⋅m, kgf⋅m 1 kgf⋅m = 9.80665 N⋅m Pressure Pa * kg/cm 2 , mmHg 1 kgf/cm 2 = 9.80665 kPa, 1 mmHg = 133.3 Pa Power output, horsepower W PS 1 PS = 0.74 kW Cubic volume, displacement m 3 Liter, L, cc 1 Liter = 1 dm 3 , 1 cc = 1 mLiter = 1 cm 3 Fuel consumption g/(kW⋅h) g/(PS⋅h) 1 g/(PS⋅h) = 1.360 g/(kW⋅h) M Mega 10 6 1,000,000 k Kiro 10 3 1,000 h Hecto 10 2 100 d Deci 10 -1 0.1 c Centi 10 -2 0.01 m Milli 10 -3 0.001 μ Micro 10 -6 0.000001 NOT FOR PRINT