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WORKSHOP MANUAL

WORKSHOP MANUAL ENGINE (6HK1 model)

ENGINE
(6HK1 model)

No.MG6HK-WE-0871
MG6HK-WE-0871_69199前書 2011.5.7 9:41 AM ページ 1

This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
1L Power Take-Off (PTO)
2 SUSPENSION 2A1 Air Suspension Control System
2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4 BRAKES 4A2 Brake Control System (Air Over)
4A3 Brake Control System (Full Air)
4B2 Brake (Air Over)
4B3 Brake (Full Air)
4C Anti-Lock Brake (ABS)
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
4F Speed Retarder System
4G Trailer Brake
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G Power Take-Off (PTO)
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME AND FRAME ACCESSORIES 11A Frame
MG6HK-WE-0871_69199前書 2011.5.7 9:41 AM ページ 2
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-1

ENGINE
Engine Mechanical
(6HK1)
TABLE OF CONTENTS
6HK1-TC Engine (Euro 4 specification) . . . . . . . . 1B-3 Phenomenon: No engine revolutions . . . . . . . 1B-71
Precautions for Servicing . . . . . . . . . . . . . . . . . 1B-3 Phenomenon: Engine rotates but does not
Technical Service Information . . . . . . . . . . . . . . 1B-3 start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-72
Explanation of Types. . . . . . . . . . . . . . . . . . . . . 1B-5 Phenomenon: Lots of black exhaust gas . . . . 1B-73
Explanation of Functions and Operations . . . . . 1B-6 Phenomenon: Lots of white exhaust gas . . . . 1B-74
Function Inspection List . . . . . . . . . . . . . . . . . 1B-12 Phenomenon: Engine is knocking . . . . . . . . . . 1B-75
Function Inspection: . . . . . . . . . . . . . . . . . . . . 1B-13 Phenomenon: Poor engine revolutions . . . . . . 1B-76
Compression Pressure Measurement. . . . . . . 1B-15 Phenomenon: Poor charge . . . . . . . . . . . . . . . 1B-77
Judgment of Overhaul Timing . . . . . . . . . . . . . 1B-18 Main Specifications . . . . . . . . . . . . . . . . . . . . . 1B-77
Failure Phenomenon List . . . . . . . . . . . . . . . . 1B-19 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-79
Phenomenon: No engine revolutions . . . . . . . 1B-20 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
Phenomenon: Engine rotates but does not Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-83
Phenomenon: Lots of black exhaust gas . . . . 1B-22 Engine Accessory Parts (Euro 4 specification) . 1B-87
Phenomenon: Lots of white exhaust gas . . . . 1B-23 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1B-87
Phenomenon: Engine is knocking. . . . . . . . . . 1B-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-92
Phenomenon: Poor engine revolutions . . . . . . 1B-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-93
Phenomenon: Poor charge . . . . . . . . . . . . . . . 1B-26 Tightening Torque Table . . . . . . . . . . . . . . . . . 1B-96
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1B-26 Engine Accessory Parts (Euro 3 specification) 1B-102
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-28 Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-102
6HK1-TC Engine (Euro 3 specification) . . . . . . . 1B-30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-105
Precautions for Servicing . . . . . . . . . . . . . . . . 1B-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-106
Technical Service Information . . . . . . . . . . . . . 1B-30 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-108
Explanation of Types. . . . . . . . . . . . . . . . . . . . 1B-32 Engine Accessory Parts (Euro 2 specification) 1B-112
Explanation of Functions and Operations . . . . 1B-33 Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-112
Function Inspection List . . . . . . . . . . . . . . . . . 1B-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-115
Function Inspection: . . . . . . . . . . . . . . . . . . . . 1B-39 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-116
Compression Pressure Measurement. . . . . . . 1B-41 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-118
Judgment of Overhaul Timing . . . . . . . . . . . . . 1B-43 Engine Exterior Parts (Euro 4/3 specifications) 1B-122
Failure Phenomenon List . . . . . . . . . . . . . . . . 1B-44 Component Parts: Variable Nozzle
Phenomenon: No engine revolutions . . . . . . . 1B-45 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . 1B-122
Phenomenon: Engine rotates but does Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-128
not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-137
Phenomenon: Lots of black exhaust gas . . . . 1B-47 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-156
Phenomenon: Lots of white exhaust gas . . . . 1B-48 Engine Exterior Parts (Euro 3 specification). . . 1B-162
Phenomenon: Engine is knocking. . . . . . . . . . 1B-49 Component Parts: With waste gate control
Phenomenon: Poor engine revolutions . . . . . . 1B-50 valve turbocharger . . . . . . . . . . . . . . . . . . . . 1B-162
Phenomenon: Poor charge . . . . . . . . . . . . . . . 1B-51 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-166
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1B-51 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-174
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-53 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-190
6HK1-TC Engine (Euro 2 specification) . . . . . . . 1B-55 Engine Exterior Parts (Euro 2 specification). . . 1B-196
Precautions for Servicing . . . . . . . . . . . . . . . . 1B-55 Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-196
Technical Service Information . . . . . . . . . . . . . 1B-55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-200
Explanation of Types. . . . . . . . . . . . . . . . . . . . 1B-57 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-207
Explanation of Functions and Operations . . . . 1B-58 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-222
Function Inspection List . . . . . . . . . . . . . . . . . 1B-63 Cylinder Head (Euro 4 specification) . . . . . . . . 1B-226
Function Inspection: . . . . . . . . . . . . . . . . . . . . 1B-64 Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-226
Compression Pressure Measurement. . . . . . . 1B-66 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-227
Judgment of Overhaul Timing . . . . . . . . . . . . . 1B-69 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-232
Failure Phenomenon List . . . . . . . . . . . . . . . . 1B-70 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-235
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-2 Engine Mechanical (6HK1)

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-240
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-247
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-259
Cylinder Head (Euro 3 specification) . . . . . . . . 1B-260
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-260
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-261
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-266
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-269
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-274
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-281
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-293
Cylinder Head (Euro 2 specification) . . . . . . . . 1B-294
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-294
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-295
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-301
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-304
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-309
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-316
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-326
Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-327
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-327
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-328
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-328
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-330
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-331
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-331
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-331
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-332
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-334
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-335
Timing Gears, Flywheel and Flywheel Housing 1B-336
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-336
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-336
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-339
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-340
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-341
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-342
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-350
Crank Pulley, Gearcase Cover and Crankshaft 1B-351
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-351
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-351
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-354
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-354
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-359
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-359
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-370
Piston and Connecting Rod . . . . . . . . . . . . . . . 1B-371
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-371
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-371
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-372
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-373
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-377
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-380
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-382
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1B-383
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-383
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-383
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-384
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-385
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-389
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-3

6HK1-TC Engine (Euro 4 specification)

Precautions for Servicing Technical Service Information
Pay close attention to the following points when How to use a plastigage
servicing the engine to prevent damage to the engine,
and to preserve reliability of engine performance.
• When lifting up or supporting the engine, do not Type Measurable range mm(in)
apply the jack to the oil pan. PG-1 (green) 0.025 – 0.076 (0.001– 0.003)
When lowering the engine to the ground, use an
engine palette or wooden frame to support the PR-1 (red) 0.051 – 0.152 (0.002 – 0.006)
engine foot and flywheel housing. PB-1 (blue) 0.102 – 0.229 (0.004 – 0.009)
• When removing the air intake system, cover the air
intake opening to prevent debris from entering the <Example> How to measure the gap between the
cylinder. If debris is allowed to enter, it may cause connecting rod bearing and crank pin
severe damage to the cylinder etc when the engine
• Clean the connecting rod and bearing, and
is running.
assemble the connecting rod.
• When carrying out service work on the main body
• Cut the plastigage on the pin width of the crank,
of the engine, always remove the battery earth
and lay it parallel while avoiding the crank pin oil
cable. Failing to remove the battery earth cable
hole.
during such work may cause damage to the wire
harness or electrical parts. If the electricity supply • Line up the connecting rod mark and cap mark and
is required for inspections etc, make sure you do assemble the crank pin, apply molybdenum-
not cause a short circuit etc. disulfide to the thread section and seating surface
of the tightening bolt, and tighten the cap
• Apply a sufficient amount of engine oil to the
alternately to the specified torque.
rotational movement surfaces to lubricate and
protect them during initial engine running. NOTE:
• When removing valve related parts, pistons, piston Never move the connecting rod when using a
rings, connecting rods, connecting rod bearings plastigage.
and crank shaft journal bearings, be sure to
organize and keep the parts in order. • Gently remove the gap and connecting rod, and
• When re-assembling the parts, assemble the same measure the crushed width of the plastigage (gap)
parts in the same location they were in when they with the scale printed on the bag.
were removed.
• Replace gaskets, oil seals, O-rings etc. with new
ones each time they are disassembled.
• Completely remove any old liquid gasket from
locations that use liquid gasket, and clean the
locations so there is no oil, water, or dirt on those
locations. Apply the specified liquid gasket then
reassemble the parts.
• Re-assemble the parts within 5 minutes of applying
the liquid gasket.
If more than 5 minutes pass before reassembly,
remove the liquid gasket and re-apply it.
• Tighten to the specified torque strength when
assembling or attaching parts, and make sure that
the parts are attached correctly.

Specific precautions for working on this engine HCW30ASH002001

All of the holes and gaps in the fuel lines within the fuel
system injectors are made to extremely precise
specifications. These parts are highly sensitive to dust
or debris, and dust or debris entering these parts may
cause damage to the fuel lines. Therefore, you should
aim to completely prevent any dust or debris from
entering these parts.
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-4 Engine Mechanical (6HK1)

HCW30ASH002101 HCW30ASH002301

<Example> Measuring the gap between the crank

bearing and crank journal
• Clean the cylinder block, crankcase bearing
mounting face, and bearing, and attach the
cylinder block to the crankcase.
• Gently rest the crankshaft on the cylinder block,
rotate approx. 30 until it falls into place.
• Cut the plastigage on the journal width of the
crank, and lay it parallel while avoiding the journal
oil hole.
• Gently place the crankcase on the cylinder block,
apply molybdenum disulphide to the thread section
and seating surface of the tightening bolt, and
tighten to the specified torque in order.

NOTE:
Never rotate the crankshaft when using a plastigage.

• Gently remove the crankcase, and measure the

crushed width of the plastigage (gap) with the
scale printed on the bag.

HCW30ASH002201
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-5

Explanation of Types

MFWB1BMF001501

Legend
1. Engine number imprint location (6HK1-……)
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-6 Engine Mechanical (6HK1)

Explanation of Functions and Operations
Engine structural diagram
Left side (day cab)

MFW81BMF000101
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-7

Right side (day cab)

MFW71BMF000601

Upper surface (day cab)

MFW71BMF000501
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-8 Engine Mechanical (6HK1)

Left side (full cab)

MFW71BMF002501

Right side (full cab)

MFW71BMF002401
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-9

Upper surface (full cab)

MFW71BMF002301

Left side (wide cab)

MFW81BMF000601
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-10 Engine Mechanical (6HK1)

Right side (wide cab)

MFW81BMF001101

Upper surface (wide cab)

MFW81BMF001801
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-11

Electronic engine control Preheating system
Control units control fuel injection volume, fuel injection The QOS-II system has been adopted for the
timing, EGR, idling speed etc. and intake/exhaust gas preheating system. Furthermore, the controller has
from injection. been integrated with the Engine Control Module (ECM).
Cylinder block Lubricating system
The cylinder block, which is made of cast iron, has a The full flow bypass single-unit oil filter uses the water-
symmetrical, rigid construction centered on the cooled oil cooler and oil jet for piston cooler.
crankshaft center, with equal center distances from
Diesel Particulate Defuser (DPD) (Euro 4
each bore. The bearing cap is of a ladder frame
specification)
construction, and is attached using the angle method.
An integrated Diesel Particulate Defuser (DPD)
Cylinder liner oxidation catalyst is installed for reducing exhaust gas.
The cylinder liner is lined-up with the internal diameter
of the cylinder block, and the cylinder liner is grade
marked on the left hand side of the cylinder performing
cylinder liner selection attachment.
Piston
The pistons are constructed from aluminum alloy, and
the combustion chamber is a round-shaped reentrant
type.
Cylinder head
The cylinder heads are constructed of cast iron, and
there are 4 valves per each cylinder. The head bolt is
attached using the angle method.
Crankshaft
TUFFTRIDE treatment process is applied, and the
grades of each journal diameter are marked on the
No.1 balance weight.
EGR device
The ECM performs control based on information such
as water temperature, engine r/min, and engine load,
and exhaust gasses are cleaned by recycling part of
the exhaust gas.
The main components are EGR valve, EGR cooler,
exhaust brake valve, and various sensors.
Connecting rod cap bolt
The connecting rod cap attachment bolt is attached
using the angle method.
Common rail electronic fuel injection system
The common rail electronic fuel injection system
consists of a supply pump that sets the target pressure
and supplies high-pressure fuel, a common rail that
accumulates the high-pressure fuel, and injectors that
reduce the amount of high-pressure fuel and then inject
it. Each of the controls is based on various signals, and
the Engine Control Module (ECM) controls the injection
timing and quantity for every kind of driving condition.
Injectors
The injectors use 7 multi-hole nozzles, and the opening
and closing of an electromagnetic valve in the injector
head to adjust the injection timing and quantity.
Fuel filter with sedimenter
The filter has a sedimenter that removes moisture
content by the difference in the specific gravity of diesel
fuel and water, and it is also equipped with an indicator
that informs when water has accumulated.
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-12 Engine Mechanical (6HK1)

Function Inspection List
• Valve clearance inspection and adjustment
• Compression pressure measurement
• Judgment of overhaul timing
MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-13

Function Inspection:
Valve clearance inspection and adjustment • Completely loosen each adjustment screw for
1. Remove the head cover. the bridge and rocker arm.
2. Valve clearance inspection.
• Rotate the crankshaft forwards and line up the
top compression dead point of the 1st cylinder.
• Insert a 0.4 mm (0.0157 in) thickness gauge
into the space between the rocker arm and
bridge to inspect the clearance, and adjust the
clearance if required.

Valve clearance
Intake valve 0.4 mm (0.0157 in)
Exhaust valve 0.4 mm (0.0157 in)

NOTE:
Adjust while cold.
BLW51BSH005501

1
• Insert a 0.4 mm (0.0157 in) thickness gauge
between the rocker arm tip (valve side) and cap
(attached to the top of the bridge), tighten the
adjustment screw on the rocker arm, then fix
the rocker arm adjustment screw nut at the
point where it is hard to insert and remove the
thickness gauge.

Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)

2
MFWB1BSH003301

Legend
1. Gearcase cover marks
2. Crankshaft damper 0 degree mark

3. Valve clearance adjustment.

NOTE:
Make sure that the bridge is adjusted so that it is level
(touching the ends of the 2 valve shafts).

BLW51BSH005601
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-14 Engine Mechanical (6HK1)

• With the thickness gauge inserted, check that
the tip of the adjustment screw and edge of the
valve shafts touch and the movement of the
thickness gauge becomes hard when the
bridge adjustment screw is gently tightened.
• Next, check that the opposite side of the valve
shaft is not floating and not slanting. If it is
floating or slanting, slightly loosen the bridge
adjustment screw and adjust the valve shaft
ends on both sides so that they touch correctly.
Valve bridge clearance: Less than 0.1 mm
(0.0040 in).
• Once both sides of the valve shaft edges are
adjusted to touch correctly, while fixing with a
flat head (minus) screwdriver so that the bridge
adjustment screw does not rotate, tighten the
bridge adjustment screw nut.
BLW51BSH005701

Tightening torque Tightening torque

22 N⋅m (2.2 kg⋅m/16 lb⋅ft) Rocker arm adjustment
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Screw/nut:
NOTE: Bridge adjustment
Precise adjustments must be performed. If adjustment 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Screw/nut:
of the bridge adjustment screw is not performed, faults
such as the bridge inclining and being pressed down,
burn, bridge guide chipping etc. will occur.

Valve clearance adjustment table

Cylinder No. 1 2 3 4 5 6
Arrangement
Condition IN EXH IN EXH IN EXH IN EXH IN EXH IN EXH
of valve
When the #1
cylinder is set
at the { { { { { {
compression
Valve to be top dead center
adjusted When the #6
cylinder is set
at the { { { { { {
compression
top dead center

Injection sequence (1 - 5 - 3 - 6 - 2 - 4)

4. Install the head cover.

MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-15

Compression Pressure Measurement
1. Start the engine to warm it up to the normal • Remove the harness connector for the boost
operating temperature, and stop it. sensor.
2. Disconnect the negative terminal of the battery. • Remove the fixing bracket and clip for the
3. Remove all the grow plugs. injection pipe.
• Remove the 2 fixing clips for radiator overflow
water pipe.
1 2 3

4
5

1 MFW71BSH015301

Legend
MFW71BSH015201 1. Intake throttle
2. Gasket
Legend
3. Inlet pipe
1. Fixing clips
4. Bracket
5. Gasket
4. Remove the intake pipe.
• Remove the nut for the bracket.
• Loosen the 2 clamps for the rubber hoses at the 7. Remove the harness connector for the injector
intercooler outlet and the intake pipe (1). attached to the cylinder head cover; lower (No fuel
injection).
1
NOTE:
• When the harness connector is removed, the ECM
judges a malfunction and records a DTC.
Always clear the ECM memory after completing the
measurements. (Refer to the Engine Control
System section for the ECM memory clear
procedure).

MFW61BSH000801

5. Remove the 4 fixing bolts for the intake throttle.

• Remove the harness connector for the intake
throttle.
• Remove the fixing bracket for the harness.
6. Remove the 3 fixing nuts for the inlet pipe.
MG6HK-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-16 Engine Mechanical (6HK1)

11. Install the special tools; the compression gauge (5-
8840-2675-0) and the compression gauge adaptor
(5-8840-2815-0).

0 0 0
0 0
0 0
0
0
0
0
0 0
0 0

HCW46BSH002201

8. Remove the 4 fixing nuts for the harness connector MFW410SH000201

bracket.
• Remove the stud bolt (1) at the left hand side
of the connector bracket. 12. Turn the starter to test the compression pressure.

Compression
MPa (kgf/cm2/psi) / 200r/min
pressure
Standard value 3.2 (33 / 469)
Limit 2.3 (23 / 327)
Difference between
290 kPa (3.0 / 43)
each cylinder

13. Measure the compression for each cylinder.

1 NOTE:
Use a fully charged battery in order to keep the engine
r/min more than 200r/min.

14. Disconnect the negative terminal of the battery.

15. Remove the special tools; the compression gauge
MFW71BSH015401
and the adaptor.
16. Install the stud bolt at the left-hand side of the
connector bracket.
9. Connect the negative terminal of the battery.
17. Install the harness connector bracket with the 4
10. Turn the starter and discharge foreign matter
nuts.
inside the cylinders.
18. Install the harness connector for the injector at the
cylinder head; lower.
19. Install the inlet pipe with the 3 nuts.
• Install the fixing bracket for the injection pipe
and the clip.
• Connect the harness connector for the boost
sensor.
MG6HK-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-17

20. Install the intake throttle.
• Install the fixing bracket for the harness.
• Connect the harness connector for the intake
throttle.
21. Install the intake pipe.
• Install the bolt for the bracket.
• Tighten the 2 clamps for the rubber hoses at the
intercooler outlet and the intake pipe.
22. Install all the grow plugs.

Tightening torque
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

• Install the 2 fixing clips for radiator overflow

water pipe.
23. Connect the negative terminal of the battery.
MG6HK-WE-0871.book 18 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-18 Engine Mechanical (6HK1)

Judgment of Overhaul Timing
Rate of increase of engine oil consumption
If the rate of consumption (the number of km that the
vehicle can drive on 1L) is taken as 100% for a new
vehicle, the vehicle needs overhauling when the rate
drops less than 50%.

Rate of increase of fuel consumption rate

If the rate of consumption (km/L) is taken as 100% for a
new vehicle, the vehicle needs overhauling when the
rate drops less than 60%.

Abnormal noises from within the engine

If the cause of the abnormal noises is from inside the
engine, perform an early overhaul and remedy the
problem.
There are many causes for abnormal noises to come
from the engine. However, it seems that most cases of
burning or debris in the engine occur when there is a lot
of wear on engine parts.
MG6HK-WE-0871.book 19 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-19

Failure Phenomenon List
• No engine revolutions
• Engine revolutions do not start
• Lots of black exhaust gas
• Lots of white exhaust gas
• Engine is knocking
• Poor engine revolutions
• Poor charge
MG6HK-WE-0871.book 20 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-20 Engine Mechanical (6HK1)

Phenomenon: No engine revolutions

Condition Possible Cause Correction

No starter revolutions Bad battery relay Replace
Bad wiring Connect or repair
Insufficient battery capacity Recharge or replace
Fixing, or wear/damage to the starter Repair or replace
brush
Starter internal functional failure Disassemble and repair
Starter rotates but doesn’t engage the Flywheel starter gear wear Repair or replace
flywheel Poor adjustment of start magnetic Adjust or repair
switch
Starter pinion engages the link gear but Poor battery capacity Recharge or repair
does not rotate Insufficient connection pressure Disassemble and repair
between starter brush and commutator
Starter armature fixed Disassemble and repair
Engine internal seizure Disassemble and repair
MG6HK-WE-0871.book 21 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-21

Phenomenon: Engine rotates but does not start

Condition Possible Cause Correction

Fuel is not arriving in the supply pump Air mixed in the fuel system Air removal
Air intake from the fuel pipe Air removal or replace
Out of fuel Add fuel
Blocked strainer in fuel suction section Clean or replace
Blocked fuel pipe Clean or replace
Functional failure in supply pump Disassemble and repair
Extreme cold period( fuel is not for cold Replace with suitable fuel
regions)
Blocked fuel filter Replace
Engine control system fault Diagnose the engine control system
Fuel is arriving in the supply pump Loose connection in injection pipe Tighten each section
Overflow valve not airtight Replace
Supply pump internal malfunction Replace
Bad wiring connection or broken wire Repair or replace
Revolution sensor failure Replace
Engine control system fault Diagnose the engine control system
Insufficient or unstable fuel injection Air mixed in the fuel system Air removal
quantity Blocked fuel pipe Clean or replace
Functional failure in supply pump Replace
Injector nozzle fixing Replace
Bad wiring connection or broken wire Repair or replace
Fuel filter blocked Replace
Engine control system fault Diagnose the engine control system
MG6HK-WE-0871.book 22 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-22 Engine Mechanical (6HK1)

Phenomenon: Lots of black exhaust gas

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Injector poor injection condition Nozzle fixing Replace
Engine control system fault Diagnose the engine control system
Poor compression pressure Excessive valve clearance Adjustments
Valve stem fixing (valve open condition) Disassemble and repair
Poor valve spring Replace
Valve seat wear Disassemble and repair
Compression leak due to poor piston Disassemble and repair
ring etc.
Bad gasket Disassemble and repair
Piston burning Disassemble and repair
Bad fuel Water is mixed with the fuel Replace
Inferior fuel used Replace
Intake air failure Air duct blocked Repair or replace
Air cleaner element blocked Clean or replace
DPD failure Melted or broken filter Replace
Fault detected by engine control system Each sensor etc. malfunction Repair or replace
Engine control system fault Diagnose the engine control system
EGR or intake throttle valve failure EGR valve seizure Repair or replace
Exhaust brake valve seizure Repair or replace
Engine control system fault Diagnose the engine control system
Fixing of the intake throttle valve Repair or replace
MG6HK-WE-0871.book 23 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-23

Phenomenon: Lots of white exhaust gas

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Fault detected by engine control system Each sensor etc. malfunction Replace
Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Poor compression pressure Excessive/too little valve clearance Adjustments
Valve stem fixing (valve open condition) Disassemble and repair
Poor valve spring Replace
Valve seat wear Disassemble and repair
Compression leak due to poor piston Disassemble and repair
ring etc.
Bad gasket Disassemble and repair
Piston burning Disassemble and repair
Bad fuel Water is mixed with the fuel Replace
Excessive oil consumption Piston ring worn or broken Disassemble and repair
Bad valve stem oil seal Disassemble and repair
MG6HK-WE-0871.book 24 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-24 Engine Mechanical (6HK1)

Phenomenon: Engine is knocking

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Fault detected by engine control system Each sensor etc. malfunction Replace
Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Fuel Inferior fuel used Replace
Intake air failure Air duct blocked Repair or replace
Engine control system fault Diagnose the engine control system
Engine malfunction Debris inside the cylinder Repair or replace
Piston, bearing etc. burning Repair or replace
MG6HK-WE-0871.book 25 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-25

Phenomenon: Poor engine revolutions

Condition Possible Cause Correction

Revolutions do not increase Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Unstable revolutions Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Fuel filter element blocked Replace element
Injector failure Replace
Water is mixed with the fuel Replace
Air mixed in the fuel system Air removal
Exhaust brake valve fixing Repair or replace
MG6HK-WE-0871.book 26 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-26 Engine Mechanical (6HK1)

Phenomenon: Poor charge

Condition Possible Cause Correction

Does not charge Broken wire, short circuit, bad Repair or replace
connection in the wiring
Generator internal functional failure Disassemble and repair
Insufficient charge Short circuit, bad connection in the Connect or repair
wiring
Generator internal functional failure Disassemble and repair
Loose generator drive belt Adjust or repair
Bad battery Replace
Overcharge Wiring short circuit Connect or repair
Generator internal functional failure Disassemble and repair

Main Specifications

Model 6HK1-TCN 6HK1-TCC 6HK1-TCS

Water-cooled 4-cycle in-line 6-cylinder 24-valve
Engine type
OHC direct-injection diesel engine
Cylinder layout and
number - inside diameter mm (in) L6 - Dia 115 (4.53) - 125 (4.92)
- stroke
Total displacement L (in3) 7.79 (475.35)
Compression ratio 17.5
kPa (kgf/
Compression pressure cm2 / psi) / 3,240 (33 / 469) / 200
r/min
Day cab: 1,330 / 841 / 995 (52.4 / 33.1 / 39.2)
Dimensions (length /
mm (in) Full cab: 1,280 / 841 / 970 (50.4 / 33.1 / 38.2)
width / height)
Wide cab: 1,311 / 841 / 1,003 (51.6 / 33.1 / 39.5)
Drying weight (excluding
N (kg/lb) 6,011 (613 / 1,352)
air cleaner)
Fuel injection timing BTDC 0°
Fuel injection sequence 1-5-3-6-2-4
Injection pump type Electronically controlled fuel injection system (common-rail type)
Inlet and exhaust valve
mm (in) 0.4 (0.016)
clearance (when cold)
Inlet valve opening and
Open 17° (BTDC)
closing timing
Inlet valve opening and
Close 42° (ABDC)
closing timing
Exhaust valve opening
Open 48° (BBDC)
and closing timing
Exhaust valve opening
Close 14° (ATDC)
and closing timing
Fuel filter type Filter paper type
Oil filter type Full-flow Filter paper type
MG6HK-WE-0871.book 27 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-27

Model 6HK1-TCN 6HK1-TCC 6HK1-TCS

Oil pump type Gear type
Oil cooler type
Water-cooled type
(Incorporated transaxle EGR cooler)
Total capacity: Shallow pan type 13.5 (2.97) ,
Deep pan type 19.5 (4.29);
Engine oil amount L (Imp.gal)
oil pan: Shallow pan type 11.0 (2.42), Deep pan type 16.0 (3.52)
with combined oil filter
Cooling unit system Water-cooled forced circulation type
TCN, TCC 29.0 (6.38)
Total cooling water
L (Imp.gal) TCS 29.5 (6.49)
capacity
Fire fighting vehicle: 32.0 (7.04)
Water pump type Centrifugal belt type
Thermostat type Wax pellet type(with jiggle valve, without jiggle valve(one for each))
Air cleaner type Cyclone filter paper type
Type -
Battery type 65D23L or 80D26L or 115E41L - 2
number
Generator capacity V-A 24 - 50, 24 - 60, 24 - 90
Starter V-kW 24 - 5.0
Idle speed r/min 500 to 550
Turbocharger type GTA40V (Honeywell)
Inter-cooler type Aluminum tube and end plate type
Thermostat open valve
ºC (°F) 82 (180)
temperature
Thermostat totally open ºC/mm
95 / 8 (203 / 0.315)
temperature/lift amount (°F/in)
Exhaust gas recirculation (EGR) Provided
MG6HK-WE-0871.book 28 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-28 Engine Mechanical (6HK1)

Special Tools
Illustration Tool Number/ Description Illustration Tool Number/ Description

5-8840-2815-0
5-8840-2628-0
Compression gauge
Valve guide replacer
adaptor

5884028150

5-8840-2675-0 5-8840-2623-0
Compression gauge Injector sleeve remover

5884026750

5-8840-2826-0 5-8840-2627-0
Injector remover Oil seal installer

5884028260 5884026270

5-8840-0019-0 5-8840-2626-0
Sliding hammer small Bridge guide setting tool

5884026260

5-8840-2624-0
5-8840-2621-0
Injector sleeve setting
Valve spring replacer
tool

5884026210 5884026240

5-8840-2625-0
8-9439-6862-0
Valve stem seal setting
Pivot
tool

8943968620
MG6HK-WE-0871.book 29 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-29

Illustration Tool Number/ Description Illustration Tool Number/ Description

8-9439-6858-0 5-8840-2397-0
Slinger replacer Cylinder liner remover

5884023970

9-8521-0157-0 1-8521-0050-0
Pilot bearing replacer Pulley puller

9852101570 1852100500

8-9439-6856-0 1-8522-0047-0
Oil seal setting tool kit Seal unit setting tool

1852200470

8-9439-6818-0 1-8522-1097-0
Crankshaft gear puller Oil filter wrench

8943968180 1852210970

8-9439-6819-0
9-8522-1310-0
Crankshaft gear setting
Oil seal installer
tool

9852213100

1-8522-1029-0 5-8840-2930-0
Piston ring setting tool Valve guide installer

1852210290 5884029300
MG6HK-WE-0871.book 30 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-30 Engine Mechanical (6HK1)

6HK1-TC Engine (Euro 3 specification)

Precautions for Servicing Technical Service Information
Pay close attention to the following points when How to use a plastigage
servicing the engine to prevent damage to the engine,
and to preserve reliability of engine performance.
• When lifting up or supporting the engine, do not Type Measurable range mm(in)
apply the jack to the oil pan. PG-1 (green) 0.025 – 0.076 (0.001– 0.003)
When lowering the engine to the ground, use an
engine palette or wooden frame to support the PR-1 (red) 0.051 – 0.152 (0.002 – 0.006)
engine foot and flywheel housing. PB-1 (blue) 0.102 – 0.229 (0.004 – 0.009)
• When removing the air intake system, cover the air
intake opening to prevent debris from entering the <Example> How to measure the gap between the
cylinder. If debris is allowed to enter, it may cause connecting rod bearing and crank pin
severe damage to the cylinder etc when the engine
• Clean the connecting rod and bearing, and
is running.
assemble the connecting rod.
• When carrying out service work on the main body
• Cut the plastigage on the pin width of the crank,
of the engine, always remove the battery earth
and lay it parallel while avoiding the crank pin oil
cable. Failing to remove the battery earth cable
hole.
during such work may cause damage to the wire
harness or electrical parts. If the electricity supply • Line up the connecting rod mark and cap mark and
is required for inspections etc, make sure you do assemble the crank pin, apply molybdenum-
not cause a short circuit etc. disulfide to the thread section and seating surface
of the tightening bolt, and tighten the cap
• Apply a sufficient amount of engine oil to the
alternately to the specified torque.
rotational movement surfaces to lubricate and
protect them during initial engine running. NOTE:
• When removing valve related parts, pistons, piston Never move the connecting rod when using a
rings, connecting rods, connecting rod bearings plastigage.
and crank shaft journal bearings, be sure to
organize and keep the parts in order. • Gently remove the gap and connecting rod, and
• When re-assembling the parts, assemble the same measure the crushed width of the plastigage (gap)
parts in the same location they were in when they with the scale printed on the bag.
were removed.
• Replace gaskets, oil seals, O-rings etc. with new
ones each time they are disassembled.
• Completely remove any old liquid gasket from
locations that use liquid gasket, and clean the
locations so there is no oil, water, or dirt on those
locations. Apply the specified liquid gasket then re-
assemble the parts.
• Re-assemble the parts within 5 minutes of applying
the liquid gasket.
If more than 5 minutes pass before reassembly,
remove the liquid gasket and re-apply it.
• Tighten to the specified torque strength when
assembling or attaching parts, and make sure that
the parts are attached correctly.

Specific precautions for working on this engine HCW30ASH002001

All of the holes and gaps in the fuel lines within the fuel
system injectors are made to extremely precise
specifications. These parts are highly sensitive to dust
or debris, and dust or debris entering these parts may
cause damage to the fuel lines. Therefore, you should
aim to completely prevent any dust or debris from
entering these parts.
MG6HK-WE-0871.book 31 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-31

HCW30ASH002101 HCW30ASH002301

<Example> Measuring the gap between the crank

bearing and crank journal
• Clean the cylinder block, crankcase bearing
mounting face, and bearing, and attach the
cylinder block to the crankcase.
• Gently rest the crankshaft on the cylinder block,
rotate approx. 30 until it falls into place.
• Cut the plastigage on the journal width of the
crank, and lay it parallel while avoiding the journal
oil hole.
• Gently place the crankcase on the cylinder block,
apply molybdenum disulphide to the thread section
and seating surface of the tightening bolt, and
tighten to the specified torque in order.

NOTE:
Never rotate the crankshaft when using a plastigage.

• Gently remove the crankcase, and measure the

crushed width of the plastigage (gap) with the
scale printed on the bag.

HCW30ASH002201
MG6HK-WE-0871.book 32 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-32 Engine Mechanical (6HK1)

Explanation of Types

MFWB1BMF001501

Legend
1. Engine number imprint location (6HK1-……)
MG6HK-WE-0871.book 33 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-33

Explanation of Functions and Operations
Engine structural diagram
Left side (with MZW transmission)

MFWB1BMF001601
MG6HK-WE-0871.book 34 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-34 Engine Mechanical (6HK1)

Right side (with MZW transmission)

MFWB1BMF001701

Upper surface (with MZW transmission)

MFWB1BMF001801
MG6HK-WE-0871.book 35 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-35

Left side (without MZW transmission)

MFWB1BMF001901

Right side (without MZW transmission)

MFWB1BMF002001
MG6HK-WE-0871.book 36 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-36 Engine Mechanical (6HK1)

Upper surface (without MZW transmission)

MFWB1BMF002101

Electronic engine control EGR device

Control units control fuel injection volume, fuel injection The ECM performs control based on information such
timing, EGR, idling speed etc. and intake/exhaust gas as water temperature, engine r/min, and engine load,
from injection. and exhaust gasses are cleaned by recycling part of
the exhaust gas.
Cylinder block
The main components are EGR valve, EGR cooler,
The cylinder block, which is made of cast iron, has a
exhaust brake valve, and various sensors.
symmetrical, rigid construction centered on the
crankshaft center, with equal center distances from Connecting rod cap bolt
each bore. The bearing cap is of a ladder frame The connecting rod cap attachment bolt is attached
construction, and is attached using the angle method. using the angle method.
Cylinder liner Common rail electronic fuel injection system
The cylinder liner is lined-up with the internal diameter The common rail electronic fuel injection system
of the cylinder block, and the cylinder liner is grade consists of a supply pump that sets the target pressure
marked on the left hand side of the cylinder performing and supplies high-pressure fuel, a common rail that
cylinder liner selection attachment. accumulates the high-pressure fuel, and injectors that
reduce the amount of high-pressure fuel and then inject
Piston
it. Each of the controls is based on various signals, and
The pistons are constructed from aluminum alloy, and
the Engine Control Module (ECM) controls the injection
the combustion chamber is a round-shaped reentrant
timing and quantity for every kind of driving condition.
type.
Injectors
Cylinder head
The injectors use 7 multi-hole nozzles, and the opening
The cylinder heads are constructed of cast iron, and
and closing of an electromagnetic valve in the injector
there are 4 valves per each cylinder. The head bolt is
head to adjust the injection timing and quantity.
attached using the angle method.
Fuel filter with sedimenter
Crankshaft
The filter has a sedimenter that removes moisture
TUFFTRIDE treatment process is applied, and the
content by the difference in the specific gravity of diesel
grades of each journal diameter are marked on the
fuel and water, and it is also equipped with an indicator
No.1 balance weight.
that informs when water has accumulated.
MG6HK-WE-0871.book 37 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-37

Preheating system
The QOS-II system has been adopted for the
preheating system. Furthermore, the controller has
been integrated with the Engine Control Module (ECM).
Lubricating system
The full flow bypass single-unit oil filter uses the water-
cooled oil cooler and oil jet for piston cooler.
MG6HK-WE-0871.book 38 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-38 Engine Mechanical (6HK1)

Function Inspection List
• Valve clearance inspection and adjustment
• Compression pressure measurement
• Judgment of overhaul timing
MG6HK-WE-0871.book 39 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-39

Function Inspection:
Valve clearance inspection and adjustment • Completely loosen each adjustment screw for
1. Remove the head cover. the bridge and rocker arm.
2. Valve clearance inspection.
• Rotate the crankshaft forwards and line up the
top compression dead point of the 1st cylinder.
• Insert a 0.4 mm (0.0157 in) thickness gauge
into the space between the rocker arm and
bridge to inspect the clearance, and adjust the
clearance if required.

Valve clearance
Intake valve 0.4 mm (0.0157 in)
Exhaust valve 0.4 mm (0.0157 in)

NOTE:
Adjust while cold.
BLW51BSH005501

1
• Insert a 0.4 mm (0.0157 in) thickness gauge
between the rocker arm tip (valve side) and cap
(attached to the top of the bridge), tighten the
adjustment screw on the rocker arm, then fix
the rocker arm adjustment screw nut at the
point where it is hard to insert and remove the
thickness gauge.

Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)

2
MFWB1BSH003301

Legend
1. Gearcase cover marks
2. Crankshaft damper 0 degree mark

3. Valve clearance adjustment.

NOTE:
Make sure that the bridge is adjusted so that it is level
(touching the ends of the 2 valve shafts).

BLW51BSH005601
MG6HK-WE-0871.book 40 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-40 Engine Mechanical (6HK1)

• With the thickness gauge inserted, check that
the tip of the adjustment screw and edge of the
valve shafts touch and the movement of the
thickness gauge becomes hard when the
bridge adjustment screw is gently tightened.
• Next, check that the opposite side of the valve
shaft is not floating and not slanting. If it is
floating or slanting, slightly loosen the bridge
adjustment screw and adjust the valve shaft
ends on both sides so that they touch correctly.
Valve bridge clearance: Less than 0.1 mm
(0.0040 in).
• Once both sides of the valve shaft edges are
adjusted to touch correctly, while fixing with a
flat head (minus) screwdriver so that the bridge
adjustment screw does not rotate, tighten the
bridge adjustment screw nut.
BLW51BSH005701

Tightening torque Tightening torque

22 N⋅m (2.2 kg⋅m/16 lb⋅ft) Rocker arm adjustment
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Screw/nut:
NOTE: Bridge adjustment
Precise adjustments must be performed. If adjustment 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Screw/nut:
of the bridge adjustment screw is not performed, faults
such as the bridge inclining and being pressed down,
burn, bridge guide chipping etc. will occur.

Valve clearance adjustment table

Cylinder No. 1 2 3 4 5 6
Arrangement
Condition IN EXH IN EXH IN EXH IN EXH IN EXH IN EXH
of valve
When the #1
cylinder is set
at the { { { { { {
compression
Valve to be top dead center
adjusted When the #6
cylinder is set
at the { { { { { {
compression
top dead center

Injection sequence (1 - 5 - 3 - 6 - 2 - 4)

4. Install the head cover.

MG6HK-WE-0871.book 41 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-41

Compression Pressure Measurement
1. Start the engine to warm it up to the normal
operating temperature, and stop it.
2. Disconnect the negative terminal of the battery. 1 2 3
3. Remove all the grow plugs.
• Remove the 2 fixing clips (1) for radiator
overflow water pipe (2). 4
5

MFW71BSH015301

Legend
1. Intake pipe
2. Gasket
3. Inlet pipe
1 2
4. Bracket
MFW81BSH010401
5. Gasket

4. Remove the inlet pipe.

• Remove the nut for the bracket. 6. Remove the harness connector for the injector
attached to the cylinder head cover; lower (No fuel
• Loosen the 2 clamps for the rubber hoses at the injection).
intercooler outlet and the inlet pipe (1).
NOTE:
• When the harness connector is removed, the ECM
1
judges a malfunction and records a DTC.
Always clear the ECM memory after completing the
measurements. (Refer to the Engine Control
System section for the ECM memory clear
procedure).

MFWB1BSH003901

5. Remove the 3 fixing nuts for the intake pipe.

• Remove the harness connector for the boost
sensor.
• Remove the fixing bracket and clip for the
injection pipe.

HCW46BSH002201
MG6HK-WE-0871.book 42 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-42 Engine Mechanical (6HK1)

11. Turn the starter to test the compression pressure.
7. Remove the 4 fixing nuts for the harness connector
bracket. Compression
MPa (kgf/cm2/psi) / 200 r/min
• Remove the stud bolt (1) at the left-hand side pressure
of the connector bracket.
Standard value 3.2 (33 / 469)
Limit 2.3 (23 / 327)
Difference between
290 kPa (3.0 / 43)
each cylinder

12. Measure the compression for each cylinder.

NOTE:
Use a fully charged battery in order to keep the engine
r/min more than 200 r/min.

1 13. Disconnect the negative terminal of the battery.

14. Remove the special tools; the compression gauge
and the adaptor.
15. Install the stud bolt at the left-hand side of the
connector bracket.
MFW71BSH015401 16. Install the harness connector bracket with the 4
nuts.
17. Install the harness connector for the injector at the
8. Connect the negative terminal of the battery. cylinder head; lower.
9. Turn the starter and discharge foreign matter 18. Install the intake pipe with the 3 nuts.
inside the cylinders. • Install the fixing bracket for the injection pipe
10. Install the special tools; the compression gauge (5- and the clip.
8840-2675-0) and the compression gauge adaptor • Connect the harness connector for the boost
(5-8840-2815-0). sensor.
19. Install the inlet pipe.
• Install the bolt for the bracket.
0 0

• Tighten the 2 clamps for the rubber hoses at the

0
0 0
0 0
0
0
0

intercooler outlet and the inlet pipe.

0
0 0
0 0

20. Install all the grow plugs.

Tightening torque
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

• Install the 2 fixing clips for radiator overflow

water pipe.
21. Connect the negative terminal of the battery.

MFW410SH000201
MG6HK-WE-0871.book 43 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-43

Judgment of Overhaul Timing
Rate of increase of engine oil consumption
If the rate of consumption (the number of km that the
vehicle can drive on 1L) is taken as 100% for a new
vehicle, the vehicle needs overhauling when the rate
drops less than 50%.

Rate of increase of fuel consumption rate

If the rate of consumption (km/L) is taken as 100% for a
new vehicle, the vehicle needs overhauling when the
rate drops less than 60%.

Abnormal noises from within the engine

If the cause of the abnormal noises is from inside the
engine, perform an early overhaul and remedy the
problem.
There are many causes for abnormal noises to come
from the engine. However, it seems that most cases of
burning or debris in the engine occur when there is a lot
of wear on engine parts.
MG6HK-WE-0871.book 44 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-44 Engine Mechanical (6HK1)

Failure Phenomenon List
• No engine revolutions
• Engine revolutions do not start
• Lots of black exhaust gas
• Lots of white exhaust gas
• Engine is knocking
• Poor engine revolutions
• Poor charge
MG6HK-WE-0871.book 45 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-45

Phenomenon: No engine revolutions

Condition Possible Cause Correction

No starter revolutions Bad battery relay Replace
Bad wiring Connect or repair
Insufficient battery capacity Recharge or replace
Fixing, or wear/damage to the starter Repair or replace
brush
Starter internal functional failure Disassemble and repair
Starter rotates but doesn’t engage the Flywheel starter gear wear Repair or replace
flywheel Poor adjustment of start magnetic Adjust or repair
switch
Starter pinion engages the link gear but Poor battery capacity Recharge or repair
does not rotate Insufficient connection pressure Disassemble and repair
between starter brush and commutator
Starter armature fixed Disassemble and repair
Engine internal seizure Disassemble and repair
MG6HK-WE-0871.book 46 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-46 Engine Mechanical (6HK1)

Phenomenon: Engine rotates but does not start

Condition Possible Cause Correction

Fuel is not arriving in the supply pump Air mixed in the fuel system Air removal
Air intake from the fuel pipe Air removal or replace
Out of fuel Add fuel
Blocked strainer in fuel suction section Clean or replace
Blocked fuel pipe Clean or replace
Functional failure in supply pump Disassemble and repair
Extreme cold period( fuel is not for cold Replace with suitable fuel
regions)
Blocked fuel filter Replace
Engine control system fault Diagnose the engine control system
Fuel is arriving in the supply pump Loose connection in injection pipe Tighten each section
Overflow valve not airtight Replace
Supply pump internal malfunction Replace
Bad wiring connection or broken wire Repair or replace
Revolution sensor failure Replace
Engine control system fault Diagnose the engine control system
Insufficient or unstable fuel injection Air mixed in the fuel system Air removal
quantity Blocked fuel pipe Clean or replace
Functional failure in supply pump Replace
Injector nozzle fixing Replace
Bad wiring connection or broken wire Repair or replace
Fuel filter blocked Replace
Engine control system fault Diagnose the engine control system
MG6HK-WE-0871.book 47 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-47

Phenomenon: Lots of black exhaust gas

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Injector poor injection condition Nozzle fixing Replace
Engine control system fault Diagnose the engine control system
Poor compression pressure Excessive valve clearance Adjustments
Valve stem fixing (valve open condition) Disassemble and repair
Poor valve spring Replace
Valve seat wear Disassemble and repair
Compression leak due to poor piston Disassemble and repair
ring etc.
Bad gasket Disassemble and repair
Piston burning Disassemble and repair
Bad fuel Water is mixed with the fuel Replace
Inferior fuel used Replace
Intake air failure Air duct blocked Repair or replace
Air cleaner element blocked Clean or replace
Fault detected by engine control system Each sensor etc. malfunction Repair or replace
Engine control system fault Diagnose the engine control system
EGR or intake throttle valve failure EGR valve seizure Repair or replace
Exhaust brake valve seizure Repair or replace
Engine control system fault Diagnose the engine control system
Fixing of the intake throttle valve Repair or replace
MG6HK-WE-0871.book 48 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-48 Engine Mechanical (6HK1)

Phenomenon: Lots of white exhaust gas

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Fault detected by engine control system Each sensor etc. malfunction Replace
Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Poor compression pressure Excessive/too little valve clearance Adjustments
Valve stem fixing (valve open condition) Disassemble and repair
Poor valve spring Replace
Valve seat wear Disassemble and repair
Compression leak due to poor piston Disassemble and repair
ring etc.
Bad gasket Disassemble and repair
Piston burning Disassemble and repair
Bad fuel Water is mixed with the fuel Replace
Excessive oil consumption Piston ring worn or broken Disassemble and repair
Bad valve stem oil seal Disassemble and repair
MG6HK-WE-0871.book 49 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-49

Phenomenon: Engine is knocking

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Fault detected by engine control system Each sensor etc. malfunction Replace
Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Fuel Inferior fuel used Replace
Intake air failure Air duct blocked Repair or replace
Engine control system fault Diagnose the engine control system
Engine malfunction Debris inside the cylinder Repair or replace
Piston, bearing etc. burning Repair or replace
MG6HK-WE-0871.book 50 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-50 Engine Mechanical (6HK1)

Phenomenon: Poor engine revolutions

Condition Possible Cause Correction

Revolutions do not increase Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Unstable revolutions Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Fuel filter element blocked Replace element
Injector failure Replace
Water is mixed with the fuel Replace
Air mixed in the fuel system Air removal
Exhaust brake valve fixing Repair or replace
MG6HK-WE-0871.book 51 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-51

Phenomenon: Poor charge

Condition Possible Cause Correction

Does not charge Broken wire, short circuit, bad Repair or replace
connection in the wiring
Generator internal functional failure Disassemble and repair
Insufficient charge Short circuit, bad connection in the Connect or repair
wiring
Generator internal functional failure Disassemble and repair
Loose generator drive belt Adjust or repair
Bad battery Replace
Overcharge Wiring short circuit Connect or repair
Generator internal functional failure Disassemble and repair

Main Specifications

Model 6HK1-TCN 6HK1-TCS

Water-cooled 4-cycle in-line 6-cylinder 24-valve
Engine type
OHC direct-injection diesel engine
Cylinder layout and
number - inside diameter mm (in) L6 - Dia 115 (4.53) - 125 (4.92)
- stroke
Total displacement L (in3) 7.79 (475.35)
Compression ratio 17.5
kPa (kgf/
Compression pressure cm2 / psi) / 3,240 (33 / 469) / 200
r/min
Dimensions (length / Full cab: 1,280 / 841 / 970 (50.4 / 33.1 / 38.2)
mm (in)
width / height) Wide cab: 1,311 / 841 / 1,003 (51.6 / 33.1 / 39.5)
Drying weight (excluding
N (kg/lb) 6,178 (630 / 1,389)
air cleaner)
Fuel injection timing BTDC 0°
Fuel injection sequence 1-5-3-6-2-4
Injection pump type Electronically controlled fuel injection system (common-rail type)
Inlet and exhaust valve
mm (in) 0.4 (0.016)
clearance (when cold)
Inlet valve opening and
Open 17° (BTDC)
closing timing
Inlet valve opening and
Close 42° (ABDC)
closing timing
Exhaust valve opening
Open 48° (BBDC)
and closing timing
Exhaust valve opening
Close 14° (ATDC)
and closing timing
Fuel filter type Filter paper type
Oil filter type Full-flow Filter paper type
Oil pump type Gear type
MG6HK-WE-0871.book 52 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-52 Engine Mechanical (6HK1)

Model 6HK1-TCN 6HK1-TCS

Oil cooler type
Water-cooled type
(Incorporated transaxle EGR cooler)
Total capacity: Shallow pan type 13.5 (2.97),
Deep pan type 19.5 (4.29);
Engine oil amount L (Imp.gal)
oil pan: Shallow pan type 11.0 (2.42), Deep pan type 16.0 (3.52)
with combined oil filter
Cooling unit system Water-cooled forced circulation type
For FTS 29.5 (6.49)
Total cooling water TCN:
L (Imp.gal) Except for FTS 29.0 (6.38)
capacity
TCS: 29.5 (6.49)
Water pump type Centrifugal belt type
Thermostat type Wax pellet type(with jiggle valve, without jiggle valve(one for each))
Air cleaner type Cyclone filter paper type
Type -
Battery type 65D23L or 80D26L or 115E41L - 2
number
Generator capacity V-A 24 - 50, 24 - 60, 24 - 90
Starter V-kW 24 - 5.0
Idle speed r/min 500 to 550
Turbocharger type VIEH (IHI)
Inter-cooler type Aluminum tube and end plate type
Thermostat open valve
ºC (°F) 82 (180)
temperature
Thermostat totally open ºC/mm
95 / 8 (203 / 0.315)
temperature/lift amount (°F/in)
Exhaust gas recirculation (EGR) Provided
MG6HK-WE-0871.book 53 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-53

Special Tools
Illustration Tool Number/ Description Illustration Tool Number/ Description

5-8840-2815-0
5-8840-2628-0
Compression gauge
Valve guide replacer
adaptor

5884028150

5-8840-2675-0 5-8840-2623-0
Compression gauge Injector sleeve remover

5884026750

5-8840-2826-0 5-8840-2627-0
Injector remover Oil seal installer

5884028260 5884026270

5-8840-0019-0 5-8840-2626-0
Sliding hammer small Bridge guide setting tool

5884026260

5-8840-2624-0
5-8840-2621-0
Injector sleeve setting
Valve spring replacer
tool

5884026210 5884026240

5-8840-2625-0
8-9439-6862-0
Valve stem seal setting
Pivot
tool

8943968620
MG6HK-WE-0871.book 54 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-54 Engine Mechanical (6HK1)

Illustration Tool Number/ Description Illustration Tool Number/ Description

8-9439-6858-0 5-8840-2397-0
Slinger replacer Cylinder liner remover

5884023970

9-8521-0157-0 1-8521-0050-0
Pilot bearing replacer Pulley puller

9852101570 1852100500

8-9439-6856-0 1-8522-0047-0
Oil seal setting tool kit Seal unit setting tool

1852200470

8-9439-6818-0 1-8522-1097-0
Crankshaft gear puller Oil filter wrench

8943968180 1852210970

8-9439-6819-0
9-8522-1310-0
Crankshaft gear setting
Oil seal installer
tool

9852213100

1-8522-1029-0 5-8840-2930-0
Piston ring setting tool Valve guide installer

1852210290 5884029300
MG6HK-WE-0871.book 55 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-55

6HK1-TC Engine (Euro 2 specification)

Precautions for Servicing Technical Service Information
Pay close attention to the following points when How to use a plastigage
servicing the engine to prevent damage to the engine,
and to preserve reliability of engine performance.
• When lifting up or supporting the engine, do not Type Measurable range mm(in)
apply the jack to the oil pan. PG-1 (green) 0.025 – 0.076 (0.001– 0.003)
When lowering the engine to the ground, use an
engine palette or wooden frame to support the PR-1 (red) 0.051 – 0.152 (0.002 – 0.006)
engine foot and flywheel housing. PB-1 (blue) 0.102 – 0.229 (0.004 – 0.009)
• When removing the air intake system, cover the air
intake opening to prevent debris from entering the <Example> How to measure the gap between the
cylinder. If debris is allowed to enter, it may cause connecting rod bearing and crank pin
severe damage to the cylinder etc when the engine
• Clean the connecting rod and bearing, and
is running.
assemble the connecting rod.
• When carrying out service work on the main body
• Cut the plastigage on the pin width of the crank,
of the engine, always remove the battery earth
and lay it parallel while avoiding the crank pin oil
cable. Failing to remove the battery earth cable
hole.
during such work may cause damage to the wire
harness or electrical parts. If the electricity supply • Line up the connecting rod mark and cap mark and
is required for inspections etc, make sure you do assemble the crank pin, apply molybdenum-
not cause a short circuit etc. disulfide to the thread section and seating surface
of the tightening bolt, and tighten the cap
• Apply a sufficient amount of engine oil to the
alternately to the specified torque.
rotational movement surfaces to lubricate and
protect them during initial engine running. NOTE:
• When removing valve related parts, pistons, piston Never move the connecting rod when using a
rings, connecting rods, connecting rod bearings plastigage.
and crank shaft journal bearings, be sure to
organize and keep the parts in order. • Gently remove the gap and connecting rod, and
• When re-assembling the parts, assemble the same measure the crushed width of the plastigage (gap)
parts in the same location they were in when they with the scale printed on the bag.
were removed.
• Replace gaskets, oil seals, O-rings etc. with new
ones each time they are disassembled.
• Completely remove any old liquid gasket from
locations that use liquid gasket, and clean the
locations so there is no oil, water, or dirt on those
locations. Apply the specified liquid gasket then re-
assemble the parts.
• Re-assemble the parts within 5 minutes of applying
the liquid gasket.
If more than 5 minutes pass before reassembly,
remove the liquid gasket and re-apply it.
• Tighten to the specified torque strength when
assembling or attaching parts, and make sure that
the parts are attached correctly.

Specific precautions for working on this engine HCW30ASH002001

All of the holes and gaps in the fuel lines within the fuel
system injectors are made to extremely precise
specifications. These parts are highly sensitive to dust
or debris, and dust or debris entering these parts may
cause damage to the fuel lines. Therefore, you should
aim to completely prevent any dust or debris from
entering these parts.
MG6HK-WE-0871.book 56 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-56 Engine Mechanical (6HK1)

HCW30ASH002101 HCW30ASH002301

<Example> Measuring the gap between the crank

bearing and crank journal
• Clean the cylinder block, crankcase bearing
mounting face, and bearing, and attach the
cylinder block to the crankcase.
• Gently rest the crankshaft on the cylinder block,
rotate approx. 30 until it falls into place.
• Cut the plastigage on the journal width of the
crank, and lay it parallel while avoiding the journal
oil hole.
• Gently place the crankcase on the cylinder block,
apply molybdenum disulphide to the thread section
and seating surface of the tightening bolt, and
tighten to the specified torque in order.

NOTE:
Never rotate the crankshaft when using a plastigage.

• Gently remove the crankcase, and measure the

crushed width of the plastigage (gap) with the
scale printed on the bag.

HCW30ASH002201
MG6HK-WE-0871.book 57 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-57

Explanation of Types

MFW81BMF003201

Legend
1. Engine number imprint location (6HK1-……)
MG6HK-WE-0871.book 58 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-58 Engine Mechanical (6HK1)

Explanation of Functions and Operations
Engine structural diagram
Left side (with MZW transmission)

MFW81BMF003301
MG6HK-WE-0871.book 59 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-59

Right side (with MZW transmission)

MFW81BMF003401

Upper surface (with MZW transmission)

MFW81BMF003501
MG6HK-WE-0871.book 60 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-60 Engine Mechanical (6HK1)

Left side (without MZW transmission)

MFW81BMF003601

Right side (without MZW transmission)

MFW81BMF003701
MG6HK-WE-0871.book 61 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-61

Upper surface (without MZW transmission)

MFW81BMF003801

Electronic engine control EGR device

Control units control fuel injection volume, fuel injection The ECM performs control based on information such
timing, EGR, idling speed etc. and intake/exhaust gas as water temperature, engine r/min, and engine load,
from injection. and exhaust gasses are cleaned by recycling part of
the exhaust gas.
Cylinder block
The main components are EGR valve, EGR cooler,
The cylinder block, which is made of cast iron, has a
exhaust brake valve, and various sensors.
symmetrical, rigid construction centered on the
crankshaft center, with equal center distances from Connecting rod cap bolt
each bore. The bearing cap is of a ladder frame The connecting rod cap attachment bolt is attached
construction, and is attached using the angle method. using the angle method.
Cylinder liner Common rail electronic fuel injection system
The cylinder liner is lined-up with the internal diameter The common rail electronic fuel injection system
of the cylinder block, and the cylinder liner is grade consists of a supply pump that sets the target pressure
marked on the left hand side of the cylinder performing and supplies high-pressure fuel, a common rail that
cylinder liner selection attachment. accumulates the high-pressure fuel, and injectors that
reduce the amount of high-pressure fuel and then inject
Piston
it. Each of the controls is based on various signals, and
The pistons are constructed from aluminum alloy, and
the Engine Control Module (ECM) controls the injection
the combustion chamber is a round-shaped reentrant
timing and quantity for every kind of driving condition.
type.
Injectors
Cylinder head
The injectors use 7 multi-hole nozzles, and the opening
The cylinder heads are constructed of cast iron, and
and closing of an electromagnetic valve in the injector
there are 4 valves per each cylinder. The head bolt is
head to adjust the injection timing and quantity.
attached using the angle method.
Fuel filter with sedimenter
Crankshaft
The filter has a sedimenter that removes moisture
TUFFTRIDE treatment process is applied, and the
content by the difference in the specific gravity of diesel
grades of each journal diameter are marked on the
fuel and water, and it is also equipped with an indicator
No.1 balance weight.
that informs when water has accumulated.
MG6HK-WE-0871.book 62 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-62 Engine Mechanical (6HK1)

Preheating system
The QOS-II system has been adopted for the
preheating system. Furthermore, the controller has
been integrated with the Engine Control Module (ECM).
Lubricating system
The full flow bypass single-unit oil filter uses the water-
cooled oil cooler and oil jet for piston cooler.
MG6HK-WE-0871.book 63 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-63

Function Inspection List
• Valve clearance inspection and adjustment
• Compression pressure measurement
• Judgment of overhaul timing
MG6HK-WE-0871.book 64 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-64 Engine Mechanical (6HK1)

Function Inspection:
Valve clearance inspection and adjustment • Completely loosen each adjustment screw for
1. Remove the head cover. the bridge and rocker arm.
2. Valve clearance inspection.
• Rotate the crankshaft forwards and line up the
top compression dead point of the 1st cylinder.
• Insert a 0.4 mm (0.0157 in) thickness gauge
into the space between the rocker arm and
bridge to inspect the clearance, and adjust the
clearance if required.

Valve clearance
Intake valve 0.4 mm (0.0157 in)
Exhaust valve 0.4 mm (0.0157 in)

NOTE:
Adjust while cold.
BLW51BSH005501

1
• Insert a 0.4 mm (0.0157 in) thickness gauge
between the rocker arm tip (valve side) and cap
(attached to the top of the bridge), tighten the
adjustment screw on the rocker arm, then fix
the rocker arm adjustment screw nut at the
point where it is hard to insert and remove the
thickness gauge.

Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)

2
MFWB1BSH003301

Legend
1. Gearcase cover marks
2. Crankshaft damper 0 degree mark

3. Valve clearance adjustment.

NOTE:
Make sure that the bridge is adjusted so that it is level
(touching the ends of the 2 valve shafts).

BLW51BSH005601
MG6HK-WE-0871.book 65 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-65

• With the thickness gauge inserted, check that
the tip of the adjustment screw and edge of the
valve shafts touch and the movement of the
thickness gauge becomes hard when the
bridge adjustment screw is gently tightened.
• Next, check that the opposite side of the valve
shaft is not floating and not slanting. If it is
floating or slanting, slightly loosen the bridge
adjustment screw and adjust the valve shaft
ends on both sides so that they touch correctly.
Valve bridge clearance: Less than 0.1 mm
(0.0040 in).
• Once both sides of the valve shaft edges are
adjusted to touch correctly, while fixing with a
flat head (minus) screwdriver so that the bridge
adjustment screw does not rotate, tighten the
bridge adjustment screw nut.
BLW51BSH005701

Tightening torque Tightening torque

22 N⋅m (2.2 kg⋅m/16 lb⋅ft) Rocker arm adjustment
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Screw/nut:
NOTE: Bridge adjustment
Precise adjustments must be performed. If adjustment 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Screw/nut:
of the bridge adjustment screw is not performed, faults
such as the bridge inclining and being pressed down,
burn, bridge guide chipping etc. will occur.

Valve clearance adjustment table

Cylinder No. 1 2 3 4 5 6
Arrangement
Condition IN EXH IN EXH IN EXH IN EXH IN EXH IN EXH
of valve
When the #1
cylinder is set
at the { { { { { {
compression
Valve to be top dead center
adjusted When the #6
cylinder is set
at the { { { { { {
compression
top dead center

Injection sequence (1 - 5 - 3 - 6 - 2 - 4)

4. Install the head cover.

MG6HK-WE-0871.book 66 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-66 Engine Mechanical (6HK1)

Compression Pressure Measurement
1. Start the engine to warm it up to the normal
operating temperature, and stop it.
2. Disconnect the negative terminal of the battery.
3
3. Remove all the grow plugs.
• Remove the 2 fixing clips (1) for radiator
overflow water pipe (2). 2

1 2

MFW81BSH010401

4. Remove the inlet pipe. MFW81BMH000101

• Remove the nut for the bracket.
Legend
• Loosen the 2 clamps for the rubber hoses at the 1. Intake pipe
intercooler outlet and the inlet pipe (1). 2. Boost sensor
3. Bracket
4. Gasket
1

6. Remove the harness connector for the injector

attached to the cylinder head cover; lower (No fuel
injection).

NOTE:
• When the harness connector is removed, the ECM
judges a malfunction and records a DTC.
Always clear the ECM memory after completing the
measurements. (Refer to the Engine Control
System section for the ECM memory clear
procedure).

MFW81BSH010301

5. Remove the 3 fixing nuts for the intake pipe.

• Remove the harness connector for the boost
sensor.
• Remove the fixing bracket and clip for the
injection pipe.
MG6HK-WE-0871.book 67 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-67

10. Install the special tools; the compression gauge (5-
8840-2675-0) and the compression gauge adaptor
(5-8840-2815-0).

0 0 0
0 0
0 0
0
0
0
0
0 0
0 0

HCW46BSH002201

7. Remove the 4 fixing nuts for the harness connector MFW410SH000201

bracket.
• Remove the stud bolt (1) at the left-hand side
of the connector bracket. 11. Turn the starter to test the compression pressure.

Compression
MPa (kgf/cm2/psi) / 200 r/min
pressure
Standard value 3.2 (33 / 469)
Limit 2.3 (23 / 327)
Difference between
290 kPa (3.0 / 43)
each cylinder

12. Measure the compression for each cylinder.

1 NOTE:
Use a fully charged battery in order to keep the engine
r/min more than 200 r/min.

13. Disconnect the negative terminal of the battery.

14. Remove the special tools; the compression gauge
MFW71BSH015401
and the adaptor.
15. Install the stud bolt at the left-hand side of the
connector bracket.
8. Connect the negative terminal of the battery.
16. Install the harness connector bracket with the 4
9. Turn the starter and discharge foreign matter
nuts.
inside the cylinders.
17. Install the harness connector for the injector at the
cylinder head; lower.
18. Install the intake pipe with the 3 nuts.
• Install the fixing bracket for the injection pipe
and the clip.
• Connect the harness connector for the boost
sensor.
MG6HK-WE-0871.book 68 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-68 Engine Mechanical (6HK1)

19. Install the inlet pipe.
• Install the bolt for the bracket.
• Tighten the 2 clamps for the rubber hoses at the
intercooler outlet and the inlet pipe.
20. Install all the grow plugs.

Tightening torque
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

• Install the 2 fixing clips for radiator overflow

water pipe.
21. Connect the negative terminal of the battery.
MG6HK-WE-0871.book 69 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-69

Judgment of Overhaul Timing
Rate of increase of engine oil consumption
If the rate of consumption (the number of km that the
vehicle can drive on 1L) is taken as 100% for a new
vehicle, the vehicle needs overhauling when the rate
drops less than 50%.

Rate of increase of fuel consumption rate

If the rate of consumption (km/L) is taken as 100% for a
new vehicle, the vehicle needs overhauling when the
rate drops less than 60%.

Abnormal noises from within the engine

If the cause of the abnormal noises is from inside the
engine, perform an early overhaul and remedy the
problem.
There are many causes for abnormal noises to come
from the engine. However, it seems that most cases of
burning or debris in the engine occur when there is a lot
of wear on engine parts.
MG6HK-WE-0871.book 70 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-70 Engine Mechanical (6HK1)

Failure Phenomenon List
• No engine revolutions
• Engine revolutions do not start
• Lots of black exhaust gas
• Lots of white exhaust gas
• Engine is knocking
• Poor engine revolutions
• Poor charge
MG6HK-WE-0871.book 71 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-71

Phenomenon: No engine revolutions

Condition Possible Cause Correction

No starter revolutions Bad battery relay Replace
Bad wiring Connect or repair
Insufficient battery capacity Recharge or replace
Fixing, or wear/damage to the starter Repair or replace
brush
Starter internal functional failure Disassemble and repair
Starter rotates but doesn’t engage the Flywheel starter gear wear Repair or replace
flywheel Poor adjustment of start magnetic Adjust or repair
switch
Starter pinion engages the link gear but Poor battery capacity Recharge or repair
does not rotate Insufficient connection pressure Disassemble and repair
between starter brush and commutator
Starter armature fixed Disassemble and repair
Engine internal seizure Disassemble and repair
MG6HK-WE-0871.book 72 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-72 Engine Mechanical (6HK1)

Phenomenon: Engine rotates but does not start

Condition Possible Cause Correction

Fuel is not arriving in the supply pump Air mixed in the fuel system Air removal
Air intake from the fuel pipe Air removal or replace
Out of fuel Add fuel
Blocked strainer in fuel suction section Clean or replace
Blocked fuel pipe Clean or replace
Functional failure in supply pump Disassemble and repair
Extreme cold period( fuel is not for cold Replace with suitable fuel
regions)
Blocked fuel filter Replace
Engine control system fault Diagnose the engine control system
Fuel is arriving in the supply pump Loose connection in injection pipe Tighten each section
Overflow valve not airtight Replace
Supply pump internal malfunction Replace
Bad wiring connection or broken wire Repair or replace
Revolution sensor failure Replace
Engine control system fault Diagnose the engine control system
Insufficient or unstable fuel injection Air mixed in the fuel system Air removal
quantity Blocked fuel pipe Clean or replace
Functional failure in supply pump Replace
Injector nozzle fixing Replace
Bad wiring connection or broken wire Repair or replace
Fuel filter blocked Replace
Engine control system fault Diagnose the engine control system
MG6HK-WE-0871.book 73 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-73

Phenomenon: Lots of black exhaust gas

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Injector poor injection condition Nozzle fixing Replace
Engine control system fault Diagnose the engine control system
Poor compression pressure Excessive valve clearance Adjustments
Valve stem fixing (valve open condition) Disassemble and repair
Poor valve spring Replace
Valve seat wear Disassemble and repair
Compression leak due to poor piston Disassemble and repair
ring etc.
Bad gasket Disassemble and repair
Piston burning Disassemble and repair
Bad fuel Water is mixed with the fuel Replace
Inferior fuel used Replace
Intake air failure Air duct blocked Repair or replace
Air cleaner element blocked Clean or replace
Fault detected by engine control system Each sensor etc. malfunction Repair or replace
Engine control system fault Diagnose the engine control system
MG6HK-WE-0871.book 74 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-74 Engine Mechanical (6HK1)

Phenomenon: Lots of white exhaust gas

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Fault detected by engine control system Each sensor etc. malfunction Replace
Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Poor compression pressure Excessive/too little valve clearance Adjustments
Valve stem fixing (valve open condition) Disassemble and repair
Poor valve spring Replace
Valve seat wear Disassemble and repair
Compression leak due to poor piston Disassemble and repair
ring etc.
Bad gasket Disassemble and repair
Piston burning Disassemble and repair
Bad fuel Water is mixed with the fuel Replace
Excessive oil consumption Piston ring worn or broken Disassemble and repair
Bad valve stem oil seal Disassemble and repair
MG6HK-WE-0871.book 75 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-75

Phenomenon: Engine is knocking

Condition Possible Cause Correction

Injection timing fault Engine control system fault Diagnose the engine control system
Fault detected by engine control system Each sensor etc. malfunction Replace
Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Fuel Inferior fuel used Replace
Intake air failure Air duct blocked Repair or replace
Engine control system fault Diagnose the engine control system
Engine malfunction Debris inside the cylinder Repair or replace
Piston, bearing etc. burning Repair or replace
MG6HK-WE-0871.book 76 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-76 Engine Mechanical (6HK1)

Phenomenon: Poor engine revolutions

Condition Possible Cause Correction

Revolutions do not increase Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Unstable revolutions Control unit malfunction Replace
Engine control system fault Diagnose the engine control system
Fuel filter element blocked Replace element
Injector failure Replace
Water is mixed with the fuel Replace
Air mixed in the fuel system Air removal
Exhaust brake valve fixing Repair or replace
MG6HK-WE-0871.book 77 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-77

Phenomenon: Poor charge

Condition Possible Cause Correction

Does not charge Broken wire, short circuit, bad Repair or replace
connection in the wiring
Generator internal functional failure Disassemble and repair
Insufficient charge Short circuit, bad connection in the Connect or repair
wiring
Generator internal functional failure Disassemble and repair
Loose generator drive belt Adjust or repair
Bad battery Replace
Overcharge Wiring short circuit Connect or repair
Generator internal functional failure Disassemble and repair

Main Specifications

Model 6HK1-TCN 6HK1-TCS

Water-cooled 4-cycle in-line 6-cylinder 24-valve
Engine type
OHC direct-injection diesel engine
Cylinder layout and
number - inside diameter mm (in) L6 - Dia 115(4.53) - 125(4.92)
- stroke
Total displacement L(in3) 7.79 (475.35)
Compression ratio 17.5
kPa (kgf/
Compression pressure cm2 / psi) / 3,240 (33 / 469) / 200
r/min
Dimensions (length /
mm (in) 1,311 / 848 / 935 (51.61 / 33.39 / 36.81)
width / height)
Drying weight (excluding
N (kg/lb) 5,894 (601 / 1,325)
air cleaner)
Fuel injection timing BTDC 0°
Fuel injection sequence 1-5-3-6-2-4
Injection pump type Electronically controlled fuel injection system (common-rail type)
Inlet and exhaust valve
mm (in) 0.4 (0.016)
clearance (when cold)
Inlet valve opening and
Open 17° (BTDC)
closing timing
Inlet valve opening and
Close 42° (ABDC)
closing timing
Exhaust valve opening
Open 48° (BBDC)
and closing timing
Exhaust valve opening
Close 14° (ATDC)
and closing timing
Fuel filter type Filter paper type
Oil filter type Full-flow Filter paper type
Oil pump type Gear type
MG6HK-WE-0871.book 78 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-78 Engine Mechanical (6HK1)

Model 6HK1-TCN 6HK1-TCS

Oil cooler type Water-cooled type
Total capacity: Shallow pan type 13.5 (2.97),
Deep pan type 19.5 (4.29)
Engine oil amount L (Imp.gal)
oil pan: Shallow pan type 10.5 (2.31), Deep pan type 16.5 (3.63)
with combined oil filter
Cooling unit system Water-cooled forced circulation type
For FTS 29.5 (6.49)
TCN:
Total cooling water Except for FTS 29.0 (6.38),
L (Imp.gal)
capacity TCS: 29.5 (6.49)
A/T(ALLISON 3***), TCS A/T, FTS A/T: 33.0 (7.26)
Water pump type Centrifugal belt type
Thermostat type Wax pellet type(with jiggle valve, without jiggle valve(one for each))
Air cleaner type Cyclone filter paper type
Type -
Battery type 65D23L or 80D26L or 115E41L - 2
number
Generator capacity V-A 24 - 50, 24 - 60
Starter V-kW 24 - 5.0
Idle speed r/min 500 to 550
Turbocharger type RHE62 (IHI)
Inter-cooler type Aluminum tube and end plate type
Thermostat open valve
ºC (°F) 82 (180)
temperature
Thermostat totally open ºC/mm
95/8 (203 / 0.315)
temperature/lift amount (°F/in)
Exhaust gas recirculation (EGR) Disengaging
MG6HK-WE-0871.book 79 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-79

Special Tools
Illustration Tool Number/ Description Illustration Tool Number/ Description

5-8840-2815-0
5-8840-2628-0
Compression gauge
Valve guide replacer
adaptor

5884028150

5-8840-2675-0 5-8840-2623-0
Compression gauge Injector sleeve remover

5884026750

5-8840-2826-0 5-8840-2627-0
Injector remover Oil seal installer

5884028260 5884026270

5-8840-0019-0 5-8840-2626-0
Sliding hammer small Bridge guide setting tool

5884026260

5-8840-2624-0
5-8840-2621-0
Injector sleeve setting
Valve spring replacer
tool

5884026210 5884026240

5-8840-2625-0
8-9439-6862-0
Valve stem seal setting
Pivot
tool

8943968620
MG6HK-WE-0871.book 80 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-80 Engine Mechanical (6HK1)

Illustration Tool Number/ Description Illustration Tool Number/ Description

8-9439-6858-0 5-8840-2397-0
Slinger replacer Cylinder liner remover

5884023970

9-8521-0157-0 1-8521-0050-0
Pilot bearing replacer Pulley puller

9852101570 1852100500

8-9439-6856-0 1-8522-0047-0
Oil seal setting tool kit Seal unit setting tool

1852200470

8-9439-6818-0 1-8522-1097-0
Crankshaft gear puller Oil filter wrench

8943968180 1852210970

8-9439-6819-0
9-8522-1310-0
Crankshaft gear setting
Oil seal installer
tool

9852213100

1-8522-1029-0 5-8840-2930-0
Piston ring setting tool Valve guide installer

1852210290 5884029300
MG6HK-WE-0871.book 81 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-81

Engine Assembly
Removal 10. Remove the air cleaner assembly installation nuts.
NOTE: 11. Remove the two connectors of the cab tilt hydraulic
Precautions when installing or removing the engine. pump.
• Always apply chock blocks to the vehicle wheels. 12. Remove the connector of the voice alarm speaker.
• Select an engine hoist that is able to withstand the 13. Remove the cab tilt hydraulic pump assembly.
weight of the engine. • Use the removed bolt to attach the removed
• Do not get under the engine while it is hoisted. hydraulic pump to the frame hole when
removing the cab back member, so the pump
• Never put your hands where they can get easily
does not get in the way.
caught.
14. Remove the reservoir tank hose clip.
1. Disconnect the negative terminal of the battery 15. Remove the power steering reservoir tank to free
cable. it.
2. Remove the engine side noise cover. 16. Disconnect the exhaust brake air hose. (for
3. Remove the front exhaust pipe. Indonesia)
• Refer to "Exhaust Pipe" in Section 1G, Engine
Exhaust.
4. Remove the transmission assembly.
• Refer to "Transmission ASM" in Section 5B,
Automatic Transmission. or "Transmission
ASM" in Section 5C, Manual Transmission.
5. Drain the coolant.

MFWB1BSH009601

17. Remove the oil level gauge.

18. Remove the rubber hose clip of the oil level gauge
1
2 guide tube and the rubber hose.
3
19. Remove the cab back member.
20. Remove the connector and terminal of the starter.
Also remove the bracket of the harness.
MFW61BSH006001
21. Disconnect the wiring of the generator.
Legend 22. Remove the turbocharger out rubber hose
1. Intercooler (turbocharger – intercooler).
2. Radiator
23. Remove the radiator breather hose.
3. Drain Plug
24. Remove the radiator hose (upper side).
25. Disconnect the unipolar connector of the A/C
compressor.
6. Remove the air compressor charge hose on the air 26. Loosen the A/C compressor idle pulley lock nut,
dryer side. and move the pulley with the adjust bolt to remove
7. Remove the MAF sensor connector and harness the cooler belt.
clip. 27. Remove the mounting bolts of the A/C
8. Loosen the clamp of the air cleaner duct (air compressor, and then remove it from the engine
cleaner – turbocharger). side without disconnecting the pipes and secure it
9. Remove the clip of the air compressor suction to the chassis side with a belt, etc.
hose. 28. Remove the power steering oil pump.
MG6HK-WE-0871.book 82 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-82 Engine Mechanical (6HK1)

• Remove the power steering oil pump, and 35. Remove the fan guide.
suspend it on the vehicle side with a belt, etc. 36. Remove the fan drive. (with fan)
29. Remove the radiator hose (lower side). 37. Remove the hose of the fuel filter assembly. (feed
and return).
• Plug the hose so that fuel does not leak.
38. Remove the left and right noise covers on the cab
side, and the engine noise cover and mud-guard
on the right side.
39. Remove the engine mount.
• Before removing the engine mount, use the
hoist to suspend the engine.
• Remove the mounting nut and bolt of the
engine mount.
1
40. Remove the engine assembly.
• Slowly operate the hoist to raise the engine to
the top surface of the chassis frame.
2
3

MFW41CSH002101

Legend
1. Intercooler
2. Radiator
3. Radiator hose (lower side).

30. Remove the two connectors on the near side of the

ECM (noise cover side) and the two ECM
connectors.
31. Remove the engine harness and harness bracket
on the near side of the ECM.
32. Remove the heater hose.
33. Remove the clamp of the intercooler outlet rubber MFW71BSH006801
hose, and then remove the inlet pipe (1)
(intercooler – intake pipe).
• Turn the engine 90° and move it from the top
surface of the chassis frame to remove the
1 engine assembly.

MFWB1BSH003901

34. Remove the radiator rubber ring. MFW71BSH006901

MG6HK-WE-0871.book 83 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-83

Installation • Tighten the front side and rear side engine
mounts at the specified torque.
1. Install the engine assembly.
• Install the hoist wire to the engine hook and
hoist to install the engine. Tightening torque
• Operate the hoist to move the engine to the Front side
installation position. 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
(Engine foot side nut)
215 N⋅m (22 kg⋅m/159lb⋅ft)
< with DRY condition >
Rear side * w/o MZW transmission
(Engine foot side bolt) 116 N⋅m (11.8 kg⋅m/85lb⋅ft)
< with WET condition >
* MZW transmission

3. Install the fuel filter.

• Install the fuel filter assembly.
• Install the fuel hose.
• Connect the connector of the sedimenter.

MFW71BSH006901

• Turn the engine 90° and slowly lower the

engine to the installation position.

CAUTION:
Never get under the engine while it is hoisted.

MFW61DSH000101

4. Install the heater hose.

5. Install the bracket of the harness on the engine left
side (vehicle left side), and connect the connector.
6. Install the inlet pipe (1) (intercooler – intake pipe).
• Tighten the clip.

Tightening torque
ABA W4
6.4 N⋅m (0.65 kg⋅m/52 lb⋅in)
MFW71BSH006801
Stainless clamp
NORMA W1
2. Install the engine mount. 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
Steel clamp
• After temporarily tightening the installation nut
of the engine mount, remove the hoist.
MG6HK-WE-0871.book 84 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-84 Engine Mechanical (6HK1)

2
3

MFWB1BSH003901 MFW41CSH002101

Legend
1. Intercooler
7. Install the cooling fan. 2. Radiator
8. Install the bell mouth stay. 3. Radiator hose (lower side)
9. Install the radiator hose (upper side).

12. Install the power steering reservoir tank and

Tightening torque
tighten it at the specified torque.
5 N⋅m (0.5 kg⋅m/43 lb⋅in)
13. Install the intake pipe (turbocharger – intercooler),
and then install the heat protector of the
10. Install the radiator breather hose. turbocharger rubber hose.
11. Install the radiator hose (lower side). 14. Install the guide tube of the oil level gauge and the
oil level gauge.

Tightening torque
5 N⋅m (0.5 kg⋅m/43 lb⋅in)
MG6HK-WE-0871.book 85 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-85

• Install the rubber hose to the second spool or 15. Connect the exhaust brake air hose. (for
the bracket of guide tube, and fix the clip. Indonesia)
Insertion target: spool (second)

Tightening torque
37 N⋅m (3.8 kg⋅m/27 lb⋅ft)

16. Install the power steering oil pump.

1 • Install the power steering oil pump and tighten
2 the bolts at the specified torque.
• Install the bracket of the power steering oil pipe.
17. Install the A/C compressor.
• Adjust the adjust bolt so that the amount of flex
is approximately 6 to 7 mm (0.24 to 0.28 in)
when the center of the belt between the crank
pulley and idle pulley is pushed with a force of
3 approximately 98 N (10 kgf / 22 lb).
5 4
After adjustment, tighten the center nut of the
idle pulley.
MFWB1BSH007801
18. Install the wiring of the generator.
Legend 19. Connect the starter wiring, and install the bracket
1. Second spool of the C terminal.
2. Guide tube
20. Connect the flexible joint section of the air
3. Clip
compressor charge hose.
4. First spool
5. Rubber hose 21. Install the cab back member and tighten it at the
specified torque.
Insertion target: guide tube bracket • Install the cab back member, and connect the
connectors of the relay connected to the cab
back member and the magnetic valve.

Tightening torque
94 N⋅m (9.6 kg⋅m/69 lb⋅ft)

22. Install the power steering reservoir tank.

1
23. Install the cab tilt hydraulic pump assembly.
24. Install the air cleaner assembly.
25. Install the air cleaner duct (air cleaner –
turbocharger).
2 • Tighten the clip.
5 4 3

Tightening torque
MFWB1BSH007701
ABA W4
Legend 6.4 N⋅m (0.65 kg⋅m/52 lb⋅in)
Stainless clamp
1. Second spool
2. Guide tube NORMA W1
8 N⋅m (0.8 kg⋅m/69 lb⋅in)
3. Clip Steel clamp
4. First spool
5. Rubber hose 26. Install the air compressor suction hose.
27. Install the harness connectors.
• Connect the wiring connectors of the switches,
sensors, and units.
MG6HK-WE-0871.book 86 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-86 Engine Mechanical (6HK1)

28. Install the transmission assembly.
• Refer to "Transmission ASM" in Section 5B,
Automatic Transmission.
Also, refer to "Transmission ASM" in Section
5C, Manual transmission.
29. Install the front exhaust pipe.
• Refer to "Exhaust Pipe" in Section 1G, Engine
Exhaust.
30. Install the engine side noise cover.
31. Pour the coolant.
32. Connect the negative terminal of the battery cable.

NOTE:
Perform the following inspection when installing the
engine.

• Check the amount of engine oil and coolant.

• Adequately remove the air from the fuel system.
• Check the pulling margin of the parking brake
lever.
• Remove rags and all items that may get caught
which are near the engine, and wipe off any fuel or
engine oil stuck to the engine.
• Confirm that the DTC light is not lit.
• Confirm that the shift lever is in the neutral
position, and start the engine after announcing it to
those in the vicinity.
• Confirm that there is no oil or water leakage from
the engine parts.
• Confirm that there is no fuel, oil, or air leakage
from the connection of each pipe.
• Confirm that there is no abnormal noise coming
from each part.
• Confirm that no exhaust gas is leaking and that the
exhaust gas is colorless.
• After stopping the engine, inspect whether the oil
and coolant are at the specified level.
• Perform a test drive and confirm that there are no
abnormalities.
MG6HK-WE-0871.book 87 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-87

Engine Accessory Parts (Euro 4 specification)

Component Parts
Day cab (left side)

5 4 3
MFW81BMF000201

Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive
3. Power steering oil pump
MG6HK-WE-0871.book 88 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-88 Engine Mechanical (6HK1)

Day cab (right side)

4 3 2 1
MFW71BMF000201

Legend
1. Drive belt 3. Generator
2. A/C compressor 4. Starter motor
MG6HK-WE-0871.book 89 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-89

Full cab (left side)

4 3

MFW71BMF003301

Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive
3. Power steering oil pump
MG6HK-WE-0871.book 90 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-90 Engine Mechanical (6HK1)

Full cab (right side)

4 3 2 1
MFW71BMF003201

Legend
1. Drive belt 3. Generator
2. A/C compressor 4. Starter motor
MG6HK-WE-0871.book 91 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-91

Wide cab (left side)

4 3

MFW81BMF000701

Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive
3. Power steering oil pump
MG6HK-WE-0871.book 92 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-92 Engine Mechanical (6HK1)

Wide cab (right side)

4 3 2

MFW81BMF001201

Legend
1. Drive belt 3. Generator
2. A/C compressor 4. Starter motor

Removal
1. Remove the fan cover assembly.
2. Remove the cooling fan.
3. Remove the fan drive.
4. Remove the drive belt (for fan, A/C compressor).
5. Remove the A/C compressor.
6. Disconnect the generator.
7. Remove the power steering oil pipe.
8. Remove the power steering oil pump.

NOTE:
Stopper the pump internal section so that debris cannot
enter.

MFW41BSH001501

9. Disconnect the starter.

MG6HK-WE-0871.book 93 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-93

Installation
1. Install the starter motor. 1

Tightening torque 2

82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

2. Install the power steering oil pump.

Tightening torque
50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)

MFW41BSH032301

6. Adjust the drive belt tension.

• Loosen the top and bottom mounting bolts of
the generator, and adjust the belt tension with
the adjusting bolt so that the tension is kept
within the standard values when the middle
section of the belt is pressed with the force of
about 98 N (10 kgf /22 lb).
• When adjusting the A/C compressor belt,
loosen the nut of the idle pulley and use an
adjust bolt to adjust the belt.

MFW41BSH001501 Belt tension adjustment value

Amount of Frequency Tension

3. Install the power steering oil pipe. Generator flex of N
4. Install the generator. drive belt mm vibrations (kgf / lb)
5. Install the A/C compressor (2), and tighten the bolt (in) Hz
(3). When 980 – 1,176
4–5
using 191 – 209 (100 – 120 /
NOTE: (0.16 – 0.2)
new belt 221 – 265)
Do not forget to insert spacer (1) between the bracket
and A/C compressor. 706 – 804
When 6–7 (72 – 82
162 – 172
readjusted (0.24 – 0.28) /
Tightening torque 159 – 181)
40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
MG6HK-WE-0871.book 94 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-94 Engine Mechanical (6HK1)

7. Install the fan drive.
Amount of Frequency Tension
A/C
flex of N
compressor Tightening torque
mm vibrations (kgf / lb)
drive belt 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(in) Hz
392 – 588
When using 10 – 13 (40 – 60 8. Install the cooling fan.
115 – 141
new belt (0.39 – 0.51) /
88 – 132)
Tightening torque
294 – 392
When 13 – 15 (30 – 40 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
101 – 115
readjusted (0.51 – 0.59) /
66 – 88) Full cab and wide cab

NOTE:
• A V-rib belt is used for the generator drive belt. It is
necessary to adjust the tension more accurately 2
compared to conventional V belts. If the tension is 1
improper, the belt life will be reduced, or the belt can
squeak. Therefore, be sure to set the exact tension.
A method for checking whether the precise tension
has been set is to use a sonic tension meter to
confirm that the frequency of vibrations is within the
above values. Check whether the frequency of
vibrations is within the above values, and readjust
the belt if the value is improper.
• Securely tighten the bolt after the adjustment. 3

2 MFW61BSH001401

Legend
1
1. Fan bolts
2. Coupling bolts
3. Water pump pulley

3
4
MFW71BSH005801

Legend
1. Generator
2. Water pump
3. Crankshaft
4. Idle pulley
5. A/C compressor
MG6HK-WE-0871.book 95 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-95

Day cab

5 4

MFWA1BSH002601

Legend
1. Coupling
2. Cooling fan
3. Coupling bolts
4. Crank pulley
5. Fan bolts

9. Install the fan cover assembly.

MG6HK-WE-0871.book 96 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-96 Engine Mechanical (6HK1)

Tightening Torque Table
Day cab (left side)

c
MFW81BMF000301

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
MG6HK-WE-0871.book 97 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-97

Day cab (right side)

b a
MFW710MF000201

(a) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

(b) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
MG6HK-WE-0871.book 98 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-98 Engine Mechanical (6HK1)

Full cab (left side)

MFW71BMF003101

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
MG6HK-WE-0871.book 99 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-99

Full cab (right side)

b a
MFW71BMF003001

(a) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

(b) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
MG6HK-WE-0871.book 100 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-100 Engine Mechanical (6HK1)

Wide cab (left side)

MFW81BMF000801

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
MG6HK-WE-0871.book 101 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-101

Wide cab (right side)

b a

MFW81BMF001301

(a) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

(b) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
MG6HK-WE-0871.book 102 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-102 Engine Mechanical (6HK1)

Engine Accessory Parts (Euro 3 specification)

Component Parts
Left side (with MZW transmission)

3
4

MFWB1BMF002201

Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive
3. Power steering oil pump
MG6HK-WE-0871.book 103 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-103

Right side (with MZW transmission)

4
1 2 3

MFWB1BMF002301

Legend
1. Starter motor 3. A/C compressor
2. Generator 4. Drive belt
MG6HK-WE-0871.book 104 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-104 Engine Mechanical (6HK1)

Left side (without MZW transmission)

4 3

MFWB1BMF002401

Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive
3. Power steering oil pump
MG6HK-WE-0871.book 105 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-105

Right side (without MZW transmission)

4
2
3
1
MFWB1BMF002501

Legend
1. Starter motor 3. A/C compressor
2. Generator 4. Drive belt

Removal
1. Remove the fan cover assembly.
2. Remove the cooling fan. 3
3. Remove the fan drive.
4. Remove the drive belt (for fan, A/C compressor).
5. Remove the A/C compressor.
6. Disconnect the generator. 2
7. Remove the power steering oil pipe.
1
8. Remove the power steering oil pump.

NOTE:
Stopper the pump internal section so that debris cannot
enter.

MFW81BSH010901

Legend
1. Power steering oil pump
2. O- ring
3. Gearcase cover
MG6HK-WE-0871.book 106 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-106 Engine Mechanical (6HK1)

9. Disconnect the starter.

1

Installation 2
1. Install the starter motor.

Tightening torque
82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

2. Install the power steering oil pump.

Tightening torque
39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) 3

MFW41BSH032301

6. Adjust the drive belt tension.

3
• Loosen the top and bottom mounting bolts of
the generator, and adjust the belt tension with
the adjusting bolt so that the tension is kept
within the standard values when the middle
2 section of the belt is pressed with the force of
about 98 N (10 kgf / 22 lb).
1 • When adjusting the A/C compressor belt,
loosen the nut of the idle pulley and use an
adjust bolt to adjust the belt.
Belt tension adjustment value

Amount Frequency Tension

MFW81BSH010901 Generator of flex of N
drive belt mm vibrations (kgf / lb)
Legend (in) Hz
1. Power steering oil pump
2. O- ring When 4–5 980 – 1,176
3. Gearcase cover using (0.16 – 191 – 209 (100 – 120 /
new belt 0.2) 221 – 265)
6–7 706 – 804
When
(0.24 – 162 – 172 (72 – 82 /
3. Install the power steering oil pipe. readjusted
0.28) 159 – 181)
4. Install the generator.
• Refer to “Drive Belt” in Engine Cooling.
5. Install the A/C compressor (2), and tighten the bolt Amount of Frequency Tension
(3). A/C
flex of N
compressor
mm vibrations (kgf / lb)
NOTE: drive belt
(in) Hz
Do not forget to insert spacer (1) between the bracket
and A/C compressor. 10 – 13 392 – 588
When using
(0.39 – 115 – 141 (40 – 60 /
new belt
0.51) 88 – 132)
Tightening torque 13 – 15 294 – 392
When
40 N⋅m (4.1 kg⋅m / 30 lb⋅ft) (0.51 – 101 – 115 (30 – 40 /
readjusted
0.59) 66 – 88)
MG6HK-WE-0871.book 107 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-107

NOTE:
• A V-rib belt is used for the generator drive belt. It is
necessary to adjust the tension more accurately
compared to conventional V belts. If the tension is
improper, the belt life will be reduced, or the belt can 2
squeak. Therefore, be sure to set the exact tension. 1
A method for checking whether the precise tension
has been set is to use a sonic tension meter to
confirm that the frequency of vibrations is within the
above values. Check whether the frequency of
vibrations is within the above values, and readjust
the belt if the value is improper.
• Securely tighten the bolt after the adjustment.
3
2

MFW61BSH001401
1
Legend
1. Fan bolts
2. Coupling bolts
3. Water pump pulley

9. Install the fan cover assembly.

3
4
MFW71BSH005801

Legend
1. Generator
2. Water pump
3. Crankshaft
4. Idle pulley
5. A/C compressor

7. Install the fan drive.

Tightening torque
36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)

8. Install the cooling fan.

Tightening torque
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
MG6HK-WE-0871.book 108 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-108 Engine Mechanical (6HK1)

Tightening Torque Table
Left side (with MZW transmission)

MFWB1BMF002601

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
MG6HK-WE-0871.book 109 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-109

Right side (with MZW transmission)

a b

MFWB1BMF002701

(a) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
MG6HK-WE-0871.book 110 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-110 Engine Mechanical (6HK1)

Left side (without MZW transmission)

MFWB1BMF002801

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
MG6HK-WE-0871.book 111 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-111

Right side (without MZW transmission)

b
a
MFWB1BMF002901

(a) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
MG6HK-WE-0871.book 112 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-112 Engine Mechanical (6HK1)

Engine Accessory Parts (Euro 2 specification)

Component Parts
Left side (with MZW transmission)

4 3

MFW81BMF003901

Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive
3. Power steering oil pump
MG6HK-WE-0871.book 113 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-113

Right side (with MZW transmission)

4
2
3
1

MFW81BMF004001

Legend
1. Starter motor 3. A/C compressor
2. Generator 4. Drive belt
MG6HK-WE-0871.book 114 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-114 Engine Mechanical (6HK1)

Left side (without MZW transmission)

4 3

MFW81BMF004101

Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive
3. Power steering oil pump
MG6HK-WE-0871.book 115 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-115

Right side (without MZW transmission)

2 4
3
1

MFW81BMF004201

Legend
1. Starter motor 3. A/C compressor
2. Generator 4. Drive belt

Removal
1. Remove the fan cover assembly.
2. Remove the cooling fan. 3
3. Remove the fan drive.
4. Remove the drive belt (for fan, A/C compressor).
5. Remove the A/C compressor.
6. Disconnect the generator. 2
7. Remove the power steering oil pipe.
1
8. Remove the power steering oil pump.

NOTE:
Stopper the pump internal section so that debris cannot
enter.

MFW81BSH010901

Legend
1. Power steering oil pump
2. O- ring
3. Gearcase cover
MG6HK-WE-0871.book 116 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-116 Engine Mechanical (6HK1)

9. Disconnect the starter.

1

Installation 2
1. Install the starter motor.

Tightening torque
82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

2. Install the power steering oil pump.

Tightening torque
39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) 3

MFW41BSH032301

6. Adjust the drive belt tension.

3
• Loosen the top and bottom mounting bolts of
the generator, and adjust the belt tension with
the adjusting bolt so that the tension is kept
within the standard values when the middle
2 section of the belt is pressed with the force of
about 98 N (10 kgf / 22 lb).
1 • When adjusting the A/C compressor belt,
loosen the nut of the idle pulley and use an
adjust bolt to adjust the belt.
Belt tension adjustment value

Amount Frequency Tension

MFW81BSH010901 Generator of flex of N
drive belt mm vibrations (kgf / lb)
Legend (in) Hz
1. Power steering oil pump
2. O- ring When 4–5 980 – 1,176
3. Gearcase cover using (0.16 – 191 – 209 (100 – 120 /
new belt 0.2) 221 – 265)
6–7 706 – 804
When
(0.24 – 162 – 172 (72 – 82 /
3. Install the power steering oil pipe. readjusted
0.28) 159 – 181)
4. Install the generator.
• Refer to “Drive Belt” in Engine Cooling.
5. Install the A/C compressor (2), and tighten the bolt Amount of Frequency Tension
(3). A/C
flex of N
compressor
mm vibrations (kgf / lb)
NOTE: drive belt
(in) Hz
Do not forget to insert spacer (1) between the bracket
and A/C compressor. 10 – 13 392 – 588
When using
(0.39 – 115 – 141 (40 – 60 /
new belt
0.51) 88 – 132)
Tightening torque 13 – 15 294 – 392
When
40 N⋅m (4.1 kg⋅m / 30 lb⋅ft) (0.51 – 101 – 115 (30 – 40 /
readjusted
0.59) 66 – 88)
MG6HK-WE-0871.book 117 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-117

NOTE:
• A V-rib belt is used for the generator drive belt. It is
necessary to adjust the tension more accurately
compared to conventional V belts. If the tension is
improper, the belt life will be reduced, or the belt can 2
squeak. Therefore, be sure to set the exact tension. 1
A method for checking whether the precise tension
has been set is to use a sonic tension meter to
confirm that the frequency of vibrations is within the
above values. Check whether the frequency of
vibrations is within the above values, and readjust
the belt if the value is improper.
• Securely tighten the bolt after the adjustment.
3
2

MFW61BSH001401
1
Legend
1. Fan bolts
2. Coupling bolts
3. Water pump pulley

9. Install the fan cover assembly.

3
4
MFW71BSH005801

Legend
1. Generator
2. Water pump
3. Crankshaft
4. Idle pulley
5. A/C compressor

7. Install the fan drive.

Tightening torque
36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)

8. Install the cooling fan.

Tightening torque
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
MG6HK-WE-0871.book 118 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-118 Engine Mechanical (6HK1)

Tightening Torque Table
Left side (with MZW transmission)

MFW81BMF004301

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
MG6HK-WE-0871.book 119 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-119

Right side (with MZW transmission)

b
a

MFW81BMF004401

(a) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
MG6HK-WE-0871.book 120 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-120 Engine Mechanical (6HK1)

Left side (without MZW transmission)

MFW81BMF004501

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
MG6HK-WE-0871.book 121 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-121

Right side (without MZW transmission)

a
b

MFW81BMF004601

(a) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
MG6HK-WE-0871.book 122 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-122 Engine Mechanical (6HK1)

Engine Exterior Parts (Euro 4/3 specifications)

Component Parts: Variable Nozzle Turbocharger
Day cab (left side)
5 6
2 3 4 7

10

11

18 17 16 15 12

14 13 MFW81BMF000401

Legend
1. Intake pipe 10. Supply pump
2. EGR cooler water feed pipe 11. Crankshaft position sensor
3. EGR valve 12. Oil filter
4. EGR cooler water return pipe 13. Fuel suction pipe
5. Oil separator hose 14. Guide tube
6. Injection pipe 15. Oil separator
7. EGR pipe 16. Common rail (Fuel rail)
8. Pressure feed pipe 17. EGR valve duct
9. Leak-off pipe 18. Water duct
MG6HK-WE-0871.book 123 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-123

Day cab (right side)
2 3
1 4 5 6

13

12 11 10 9 8 7
MFW710MF000301

Legend
1. Heat protector 8. Ft engine foot
2. EGR cooler 9. Turbocharger oil return pipe
3. Turbocharger 10. Air compressor oil feed pipe
4. Exhaust manifold 11. Air compressor
5. Exhaust pipe adaptor 12. Rr engine foot
6. EGR cooler water feed pipe 13. Charge air pipe
7. Generator bracket
MG6HK-WE-0871.book 124 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-124 Engine Mechanical (6HK1)

Full cab (left side)

1 2 3 4 5 6 7

10

11

18 17 16 15 14 13 12
MFW71BMF002901

Legend
1. Intake pipe 10. Supply pump
2. EGR cooler water feed pipe 11. Crankshaft position sensor
3. EGR valve 12. Oil filter
4. EGR cooler water return pipe 13. Fuel suction pipe
5. Oil separator hose 14. Guide tube
6. Injection pipe 15. Oil separator
7. EGR pipe 16. Common rail (Fuel rail)
8. Pressure feed pipe 17. EGR valve duct
9. Leak-off pipe 18. Water duct
MG6HK-WE-0871.book 125 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-125

Full cab (right side)

1 2 3 4 5 6

13

12

11 10 9 8 7
MFW71BMF002801

Legend
1. Heat protector 8. Ft engine foot
2. EGR cooler 9. Turbocharger oil return pipe
3. Turbocharger 10. Air compressor oil feed pipe
4. Exhaust manifold 11. Air compressor
5. Exhaust pipe adaptor 12. Rr engine foot
6. EGR cooler water feed pipe 13. Charge air pipe
7. Generator bracket
MG6HK-WE-0871.book 126 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-126 Engine Mechanical (6HK1)

Wide cab (left side)

1 2 3 4 5 6 7

10

11

12

18 17 16 15 14 13
MFW81BMF000901

Legend
1. Intake pipe 10. Supply pump
2. EGR cooler water feed pipe 11. Crankshaft position sensor
3. EGR valve 12. Oil filter
4. EGR cooler water return pipe 13. Fuel suction pipe
5. Oil separator hose 14. Guide tube
6. Injection pipe 15. Oil separator
7. EGR pipe 16. Common rail (Fuel rail)
8. Pressure feed pipe 17. EGR valve duct
9. Leak-off pipe 18. Water duct
MG6HK-WE-0871.book 127 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-127

Wide cab (right side)

1 2 3 4 5 6

13

12

11 10 9 8

MFW81BMF001401

Legend
1. Heat protector 8. Ft engine foot
2. EGR cooler 9. Turbocharger oil return pipe
3. Turbocharger 10. Air compressor oil feed pipe
4. Exhaust manifold 11. Air compressor
5. Exhaust pipe adaptor 12. Rr engine foot
6. EGR cooler water feed pipe 13. Charge air pipe
7. Generator bracket
MG6HK-WE-0871.book 128 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-128 Engine Mechanical (6HK1)

Removal Full cab and Wide cab (coil spring cab
mounting model)
1. Remove the intake duct.
day cab
1

2
2

MFW71BSH006101

MFW71JSH000901 Legend
1. Air cleaner
Legend
2. Intake duct
1. Air cleaner
2. Intake duct

Full cab and Wide cab (rigid cab mounting

2. Remove the engine harness.
model)
• Remove the harnesses from the sensors and
accessories.
1
NOTE:
Before removing the harnesses, clearly indicate the clip
positions. (with paint, etc.)

MFW71BSH006001

Legend
1. Air cleaner
2. Intake duct

MFW71BSH003101

3. Remove the oil level gauge.

MG6HK-WE-0871.book 129 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-129

4. Remove the stays of the guide tube, and remove 6. Remove the fan guide stays (1).
the guide tube (1) from the crankcase. Day cab

1
1

MFW71BSH003001
MFW71BSH001901
Full cab and Wide cab

5. Remove the intake pipe.

• Loosen the hose clip, remove the nut at the
stay section, and remove the intake pipe (1).

NOTE:
After removing the pipe, seal it to prevent foreign
materials from getting into it.

MFW71BSH004301

MFW61BSH000801
MG6HK-WE-0871.book 130 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-130 Engine Mechanical (6HK1)

7. Remove the oil separator hose (1).

1 2

MFW71BSH000301
MFW81BSH007001
Legend
1. Bracket
1 2. Oil separator
3. Oil drain hose

9. Remove the water hose (1). (day cab only)

MFW81BSH007101

8. Remove the oil separator from the cylinder block

with the bracket attached to it.
• Remove the drain hose of the oil separator from
the oil pan. MFW71BSH000401

Legend
1. Water hose (reservoir tank to radiator)
2. Bolts

10. Remove the fastening clip of the water pipe. Next,

remove the hoses at the water pump side and the
EGR cooler side, and remove the water feed pipe
(1) for the EGR cooler.
MG6HK-WE-0871.book 131 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-131

11. Remove the fastening clip of the water pipe. Next, 13. Remove the EGR cooler.
remove the hose at the EGR cooler side, and
remove the water return pipe (2) for the EGR
cooler. 1

MFW71BSH000701

Legend
1. EGR cooler
MFW71BSH000501
2. Exhaust manifold
Legend
1. EGR cooler water feed pipe
2. EGR cooler water return pipe
14. Remove the suction air hose (air compressor).
15. Remove the charge air pipe (air compressor)
together with the bracket.
12. Remove the EGR pipe from the EGR cooler and
the oil cooler.

1 2

MFW71BSH008501

MFW71BSH000601
Legend
1. Charge air pipe
Legend 2. Air compressor
1. EGR cooler
2. EGR pipe
MG6HK-WE-0871.book 132 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-132 Engine Mechanical (6HK1)

16. Remove the water pipe (1) (cylinder block – air c. Remove the oil feed pipe (turbocharger).
compressor). d. Remove the water return pipe (turbocharger).
e. Remove the water feed pipe (turbocharger).
f. Remove the oil return pipe.
g. Remove the turbocharger assembly.

NOTE:
Plug the ports of the oil and the coolant to prevent
foreign material from getting into them. Plug the
compressor and the turbine side as well.

1 2 3 4
1 2

MFW71BSH008601

Legend
1. Water pipe (feed)
2. Compressor
3. Water pipe (return to turbocharger) 5

17. Remove the air compressor from the flywheel

housing.
MFW61BSH006301

NOTE: Legend
After removing the air compressor, plug it to prevent 1. Intake pipe
foreign materials from getting into it. 2. Water return pipe
3. Connector
4. Oil feed pipe
5. Water feed pipe

MFW61BSH005501

18. Remove the exhaust pipe adapter.

19. Remove the turbocharger.
a. Disconnect the oil pressure switch connector.
b. Remove the intake pipe.
MG6HK-WE-0871.book 133 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-133

20. Remove the heat protector from the exhaust 22. Remove the intake throttle and inlet pipe.
manifold.

1 2 3
1

3 2

MFW71BSH000801
BLW71BSH007901
Legend
Legend 1. Intake throttle
1. Exhaust manifold assembly 2. Gasket
2. Heat protector (front) 3. Inlet pipe
3. Heat protector (rear) 4. Gasket

21. Remove the boost sensor (1). 23. Remove the injection pipe.

1 NOTE:
Plug the common rail and the injector to prevent foreign
material from getting into them.

BLW71JSH001301
MG6HK-WE-0871.book 134 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-134 Engine Mechanical (6HK1)

26. Remove the fuel leak-off pipe (1) from the various
parts.

5 6
3 4
2
1

MFW71BSH000901

Legend
MFW71BSH001101
1. Injection pipe # 1
2. Injection pipe # 2
3. Injection pipe # 3
4. Injection pipe # 4 27. Remove the common rail.
5. Injection pipe # 5
6. Injection pipe # 6 NOTE:
7. Common rail (Fuel rail) Careful handing of the sensor is needed to avoid
interference with other objects.
Plug it to prevent foreign materials from getting into it.

24. Remove the pressure feed pipe (1) from the

common rail and the supply pump.
25. Remove the fuel suction pipe (2) from the supply 1
pump.

2
1 3

2 MFW71BSH001201

Legend
1. Nuts
2. Common rail (Fuel rail)
MFW71BSH001001 3. Bolts
MG6HK-WE-0871.book 135 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-135

28. Remove the crankshaft position sensor (1) from d. Remove the bracket (2) and O-ring (7) from the
the flywheel housing (2). supply pump.

1 2 3 4 5

10

9
1 2
8 7 6
MFW71BSH002501 BLW71BSH000701

Legend
1. Supply pump
29. .Remove the oil filter from the cylinder block. 2. Bracket
• Remove the oil filter after removing oil from the 3. Gear
oil drain hose. 4. Nut
5. Bolts
6. O-ring
7. O-ring
8. Nuts
9. Bolts
10. Nuts

31. Remove the EGR valve duct.

MFW71BSH001601

30. Remove the supply pump (1) together with the

bracket (2).
a. Remove the O-ring (6) from the supply pump.
b. Remove the nut (4) and gear (3) from the
supply pump. 3 2
c. Remove the bolts (9) from the supply pump.
MFW71BSH001301

Legend
1. EGR valve
2. EGR valve duct
3. Gaskets
MG6HK-WE-0871.book 136 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-136 Engine Mechanical (6HK1)

34. Remove the inlet cover (1).
32. Remove the EGR valve.

MFW71BSH001801

MFW71BSH001401

Legend
1. EGR valve 35. Remove the water duct from the oil cooler.
2. Gasket 36. Remove the noise cover from the cylinder block.
3. EGR valve duct assembly
1

33. Remove the EGR valve duct assembly from the

inlet cover.

2 MFW71BSH001701

Legend
1. Space rubber
1 2. Noise cover

MFW71BSH001501

Legend 37. Remove the oil cooler from the cylinder block.
1. EGR valve duct assembly • Remove the mounting bolts of the oil cooler. Put
2. Gasket the removed bolts into the replacer holes (the parts
indicated by arrows) and remove the cooler by
tightening all the bolts equally.
MG6HK-WE-0871.book 137 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-137

4. Install the oil pressure switch.
Refer to “Cylinder Block”.
5. Install the oil cooler.
1
• Apply liquid gasket (ThreeBond 1207C or
1216C) in the groove of the oil cooler to have
2
the bead width of 2 – 3 mm (0.08 – 0.12 in).
3 Insert the O-ring (1) and install it.

NOTE:
• Clean the O-ring groove, as it is difficult to fit in the
O-ring if liquid gasket remains in the groove.
• After applying the liquid gasket, install within 5
minutes.

• When installing the oil cooler to the cylinder

block, it is easier to perform the installation if
you temporarily attach M8 studs to the front and
MFW41BSH024201 back of the mounting screw holes to use as a
Legend guide.
1. Cylinder block
2. Oil cooler
3. Bolts

1
38. Remove the oil pressure switch from the cylinder
block.
39. Remove the generator bracket from the cylinder
block.
40. Remove the front engine foot from the cylinder
block.
41. Remove the rear engine foot from the flywheel
housing.

Installation
MFW41BSH002001
1. Install the rear engine foot, and tighten it at the
specified torque.

• Tighten the oil cooler fixing bolts in the order

Tightening torque N⋅m (kg⋅m / lb⋅ft) shown in the diagram.
76 (7.7 / 56)
Tightening torque N⋅m (kg⋅m / lb⋅ft)
2. Install the front engine foot, and tighten it at the
specified torque. 25 (2.5 / 18)

Tightening torque N⋅m (kg⋅m / lb⋅ft)

78 (8.0 / 58)

3. Install the generator bracket, and tighten it at the

specified torque.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

38 (3.9 / 28)
MG6HK-WE-0871.book 138 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-138 Engine Mechanical (6HK1)

• Rotate the engine in the forward direction. Align
the positions of the TDC (0°) mark (2) on the
outer circumference of the damper and the
pointer (1).

NOTE:
Confirm that the first cylinder is at the compression top
21 17 13 9 5 1 4 8 12 16 20 dead center.
22
25
26
24
1
18 14 10 6 2 3 7 11 15 19
27 23

MFW41BSH024101

6. Install the water duct (suction) to the oil cooler.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

19 (1.9 / 14) 2
MFWB1BSH003301
7. Install the crankshaft position sensor (1) to the
flywheel housing (2).
• Before assembling the supply pump, align the
alignment marks (slits) on the gear.
Tightening torque N⋅m (kg⋅m / lb⋅in)
8 (0.8 / 69)

MFW41BSH023701
1 2

MFW71BSH002501

8. Install the supply pump, gear and bracket together

to the cylinder block.
MG6HK-WE-0871.book 139 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-139

• Make sure to paint in white the gear edge • Tighten the supply pump with a nut and bolt.
surface (1) that corresponds to 2-point marks
(2) on the gear side surface.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Nuts (10) 50 (5.1 / 37)
Nut (8), Bolt (5) 77 (7.9 / 57)
Nut (4) 64 (6.5 / 47)
Bolts (9) 19 (1.9 / 14)

1
1 2 3 4 5
2

10

MFWB1BSH003001

• Horizontally insert the supply pump into the

cylinder block. 9

• Confirm that the white paint of the alignment

mark appears as indicated in the illustration 8 7 6
when you look at the gear from upslope, MFW61BSH001001

through the timing check hole on top of the Legend

flywheel housing. 1. Supply pump
2. Bracket
3. Gear
2
4. Nut
5. Bolt
6. O-ring
7. O-ring
8. Nut
1 9. Bolts
10. Nuts

• Re-confirm again that the ruling alignment mark

of the timing mark (crank damper) is aligned to
0°, and the alignment mark of the supply pump
gear is aligned.
• If the marks are misaligned, reassemble the
BLW71BSH005701 parts.
Legend • Install the plug to the flywheel housing after
1. Timing check hole checking the timing.
2. Supply pump gear 9. Install the oil filter.
• Assemble an O-ring to the groove of the
bracket, and install it to the cylinder block.

NOTE:
• ThreeBond 1208 or CH Dine 290 can be used to
prevent O-rings from falling off.
MG6HK-WE-0871.book 140 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-140 Engine Mechanical (6HK1)

• Confirm that the O-ring is firmly in place without 12. Install the space rubber between the inlet manifold
protrusion or misalignment. and the oil cooler.

1
Tightening torque N⋅m (kg⋅m / lb⋅ft)
38 (3.9 / 28)

2 MFW71BSH001701

Legend
1. Space rubber
2. Noise cover

MFW71BSH001601

13. Install the EGR valve duct assembly (1) to the inlet
cover.
10. Install the noise cover.
• Install the gasket (2) to the inlet cover side.
11. Install the inlet cover (1).

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Tightening torque N⋅m (kg⋅m / lb⋅ft)
M8 25 (2.5 / 18)
25 (2.5 / 18)
M10 46 (4.7 / 34)

1
1

MFW71BSH001801
MFW71BSH001501

14. Temporarily install the EGR valve (1) to the EGR

valve duct assembly (3).
MG6HK-WE-0871.book 141 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-141

• Install the gasket (2) to the EGR valve duct Tightening torque N⋅m (kg⋅m / lb⋅ft)
assembly side.
EGR valve duct
46 (4.7 / 34)
(EGR valve side)

1 EGR valve duct

22 (2.2 / 16)
(oil cooler side)

3 1

MFW71BSH001401

15. Temporarily install the EGR valve duct to the EGR

valve and oil cooler.
MFW61BSH001901
• Install a gasket to the EGR valve side and oil
cooler side.

17. Install the common rail.

• Order for temporal tightening: nuts (1) before
bolts (2).
1
• Order for complete tightening: bolts (2) before
nuts (1).

Tightening torque N⋅m (kg⋅m / lb⋅ft)

25 (2.5 / 18)

1
3 2
MFW71BSH001301

Legend
1. EGR valve
2. EGR valve duct
3. Gaskets

16. Completely tighten the EGR valve.

• Securely tighten the EGR valve duct (2) and
EGR valve (1). 2

Tightening torque N⋅m (kg⋅m / lb⋅ft) MFW61BSH001301

EGR valve 46 (4.7 / 34)
MG6HK-WE-0871.book 142 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-142 Engine Mechanical (6HK1)

18. Install the pressure feed pipe (1).

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Supply pump side 44 (4.5 / 33)
Common rail side 44 (4.5 / 33)

19. Install the fuel suction pipe (2) to the supply pump
and fix it with a clip.
1

Tightening torque N⋅m (kg⋅m / lb⋅ft)

18 (1.8 / 13)

MFW71BSH001101

21. Install the injection pipe and tighten the sleeve nut.

1
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Injector side 30 (3.1 / 22)
Common rail side 25 (2.6 / 19)

2
3 4
2
5
1

MFW71BSH001001 6
Legend
1. Pressure feed pipe
2. Suction pipe 7

20. Install the fuel leak-off pipe (1).

• Assemble a new gasket to each connecting
section.
• Fix each part with a clip after tightening it.

Tightening torque N⋅m (kg⋅m / lb⋅ft) BLW71BSH004901

Supply pump side 10 (1.0 / 87 lb⋅in) Legend

1. Injection pipe # 1
Common rail side 20 (2.0 / 14)
2. Injection pipe # 2
3. Injection pipe # 3
4. Injection pipe # 4
5. Injection pipe # 5
6. Injection pipe # 6
7. Common rail (Fuel rail)
MG6HK-WE-0871.book 143 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-143

22. Install the inlet pipe and intake throttle. 24. Install the heat protector to the exhaust manifold.

Tightening torque N⋅m (kg⋅m / lb⋅ft) 1

Inlet pipe 25 (2.5 / 18)
Intake throttle 24 (2.4 / 17)

1 2 3

3 2
4

BLW71BSH007901

Legend
1. Exhaust manifold assembly
2. Heat protector (front)
3. Heat protector (rear)

MFW71BSH000801

Legend 25. Install the turbocharger.

1. Intake throttle • Refuel the appropriate amount of oil from the oil
2. Gasket inlet hole (1) of the turbocharger, and rotate the
3. Inlet pipe turbine shaft to lubricate the shaft bearing
4. Gasket section.

1
23. Install the boost sensor (1).

MFW61BSH005901

BLW71JSH001301
• Fasten the gasket (2), and install the
turbocharger (1) to the exhaust manifold.

Tightening torque N⋅m (kg⋅m / lb⋅in)

Tightening torque N⋅m (kg⋅m / lb⋅ft)
2 (0.2 / 17)
52 (5.3 / 38)
MG6HK-WE-0871.book 144 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-144 Engine Mechanical (6HK1)

NOTE:
Make sure to use a new gasket to prevent oil leakage.
1

2 Tightening torque N⋅m (kg⋅m / lb⋅ft)

Turbocharger side 34 (3.5 / 25)
Cylinder block side 41 (4.2 / 30)

MFW71BSH008201 2

26. Install the oil return pipe.

• Install the oil pipe to the turbocharger and 2
cylinder block. 1

NOTE:
Make sure to use a new gasket to prevent oil leakage.
MFWA1BSH002801

Tightening torque N⋅m (kg⋅m / lb⋅ft)

28. Install the water feed pipe.
Turbocharger side
23 (2.3 / 17)
Cylinder block side NOTE:
Make sure to use a new gasket to prevent coolant
leakage.
1

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Turbocharger side 41 (4.2 / 30)
Air compressor side 50 (5.1 / 37)

29. Install the water return pipe.

NOTE:
Make sure to use a new gasket to prevent coolant
leakage.
2

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Turbocharger side
41 (4.2 / 30)
Cylinder head side
MFWA1BSH002701

Legend
1. Turbocharger
2. Oil return pipe

27. Install the oil feed pipe.

• Install the turbocharger oil feed pipe (2)
perpendicularly to the cylinder block (1).
MG6HK-WE-0871.book 145 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-145

2
1
3
1 2

3
4
MFWA1BSH002901 MFW71BSH008401

Legend Legend
1. Water return pipe 1. Gasket
2. Turbocharger 2. Exhaust pipe adapter
3. Water feed pipe 3. Heat protector
4. Bracket

30. Install the inlet pipe (turbocharger out).

• Assembly procedure
- Tighten by following the procedure below.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
a. Temporarily tighten the adapter and bracket.
22 (2.2 / 16)
b. Temporarily tighten the bracket and cylinder
block.
31. Connect the connector of the oil pressure switch.
c. Temporarily tighten the adapter and
32. Install the exhaust pipe adapter (2). turbocharger.
• Fasten the gasket (1) between the turbocharger d. Perform the same procedure to completely
and the adapter (2) and install it. tighten the parts.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Bolts (2) 26 (2.7 / 20)
Bolt (1) 45 (4.6 / 33)
Bolt (3) 45 (4.6 / 33)
Bolt (4) 22 (2.2 / 16)
MG6HK-WE-0871.book 146 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-146 Engine Mechanical (6HK1)

2
4

4 3
MFW81BSH006101 MFW71BSH006201

33. Install the intake duct (1) to the turbocharger (3), 34. Install the air compressor to the flywheel housing.
and tighten it with a V-band (2) while aligning it with • Tap the key into the shaft of the air compressor,
the marking (4). and tighten the installation nut of the drive gear
at the specified torque.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
16 (1.6 / 12) Tightening torque N⋅m (kg⋅m / lb⋅ft)
147 (15 / 108)

1
2

2
1

MFW61BSH005401

Legend
1. Gear
2. Key

MFW71BMH000101
MG6HK-WE-0871.book 147 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-147

• Apply liquid gasket (ThreeBond 1208 or CH
Dine 290) equally to three parts on the Tightening torque N⋅m (kg⋅m / lb⋅ft)
circumference of the O-ring, and install the O- Cylinder block side 41 (4.2 / 30)
ring in the groove of the air compressor.
Air compressor side 28 (2.9 / 21)

Tightening torque N⋅m (kg⋅m / lb⋅ft)

73 (7.4 / 54)
1

MFW71BSH002101

Legend
1. Air compressor
2. Oil feed pipe
MFW61BSH005501

36. Install the air compressor water pipes (1) and (3).
1
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Air compressor side 50 (5.1 / 37)
Water pipe adaptor side 41 (4.2 / 30)
2

4 BLW71BSH015501

Legend
1. Air compressor
2. Bolt (long)
3
3. Bolts
4. Nut
1 2
35. Install the oil feed pipe (air compressor) to the air MFW71BSH008601
compressor and the cylinder block.
Legend
• Use a new gasket. 1. Water pipe (feed)
2. Compressor
3. Water pipe (return to turbocharger)
MG6HK-WE-0871.book 148 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-148 Engine Mechanical (6HK1)

37. Install the charge air pipe (1) to the air compressor
1
(2).
• Install the charge pipe with a clip.

NOTE:
Apply oil so that it does not turn together with the
eyebolt. Never use soapy water, etc.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Charge air pipe side (dry) 64 (6.5 / 47)
2

MFW71BSH000701

Legend
1. EGR cooler
2. Exhaust manifold
1

2
2 1

MFW71BSH008501

38. Install the EGR cooler.

• Fasten the gasket at the exhaust manifold side
and install it. 3

NOTE:
Make sure to use a new gasket to prevent oil leakage. MFW71BSH002001

Legend
1. Bolts
2. EGR cooler
3. Bracket

39. Install the EGR pipe.

MG6HK-WE-0871.book 149 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-149

•

1 2

MFW71BSH000601

Legend
1. EGR cooler
2. EGR pipe

40. EGR cooler and EGR pipe tightening.

procedure.
• Numbers alone indicate the order for temporal
tightening.
• Numbers enclosed in squares indicate the
order for complete tightening.
MG6HK-WE-0871.book 150 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-150 Engine Mechanical (6HK1)

5 8

1 3

2 4

6 7

BLW61BMF000101
MG6HK-WE-0871.book 151 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-151

d
BLW61BMF000201

(a) 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(c) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(d) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(e) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)

• The bolt (b) is not reusable.

MG6HK-WE-0871.book 152 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-152 Engine Mechanical (6HK1)

41. Install the EGR cooler water pipe hose and fix it 43. Install the oil separator hoses (1).
with the clips.

MFW81BSH007001

MFW71BSH000501

Legend 1
1. Water feed pipe
2. Water return hose

42. Put the bracket on the oil separator, and install it to

the cylinder block.

2 MFW81BSH007101

MFW71BSH000301

Legend
1. Bracket
2. Oil separator
3. Oil drain hose
MG6HK-WE-0871.book 153 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-153

44. Install the water hose (1). (day cab only) Full cab and Wide cab

MFW71BSH004301
MFW71BSH000401

Legend
1. Water hose (reservoir tank to radiator)
2. Bolts 47. Install the intake pipe (1).

Tightening torque N⋅m (kg⋅m / lb⋅ft)

45. Install the suction air pipe to the air compressor. M8 nut 18 (1.8 / 13)
46. Install the fan guide stay (1). ABA W4 Stainless clamp 6.4 (0.65 / 56 lb⋅in)
Day cab
NORMA W1 Steel clamp 8 (0.8 / 69 lb⋅in)

MFW71BSH003001

MFW61BSH000801

48. Install the guide tube (1) into the crankcase, and fix
the stay section.
• Insert the O-ring into the guide tube, and press
it in until it touches the hole of the crankcase.

NOTE:
Take care not to cut the O-ring.
MG6HK-WE-0871.book 154 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-154 Engine Mechanical (6HK1)

Day cab

MFW71BSH001901
MFW71JSH000901

Legend
49. Insert the oil level gauge. 1. Air cleaner
50. Install the engine harness to each connector, and 2. Intake duct
clip it in the designated position. Full cab and Wide cab (rigid cab mounting
model)

MFW71BSH003101
MFW71BSH006001

Legend
51. Install the intake duct. 1. Air cleaner
2. Intake duct

Tightening torque N⋅m (kg⋅m / lb⋅in)

ABA W4 Stainless clamp 6.4 (0.65 / 56)
NORMA W1 Steel clamp 8 (0.8 / 69)
MG6HK-WE-0871.book 155 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-155

Full cab and Wide cab (coil spring cab
mounting model)

MFW71BSH006101

Legend
1. Air cleaner
2. Intake duct
MG6HK-WE-0871.book 156 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-156 Engine Mechanical (6HK1)

Tightening Torque Table
Day cab (left side)

e d

MFW81BMF000501

(a) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side

25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side
(b) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft) M10 Nut
77 N⋅m (7.9 kg⋅m / 57 lb⋅ft) Bolt, M12 Nut
(d) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(e) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
MG6HK-WE-0871.book 157 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-157

Day cab (right side)

a b

g f e d
MFW91BMF001901

(a) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(c) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(d) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(e) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(f) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(g) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
MG6HK-WE-0871.book 158 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-158 Engine Mechanical (6HK1)

Full cab (left side)

a b

e d c
MFW71BMF002701

(a) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side

25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side
(b) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft) M10 Nut
77 N⋅m (7.9 kg⋅m / 57 lb⋅ft) Bolt, M12 Nut
(d) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(e) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
MG6HK-WE-0871.book 159 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-159

Full cab (right side)

a b

g
f e d

MFWB1BMF000701

(a) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(c) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(d) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(e) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(f) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(g) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
MG6HK-WE-0871.book 160 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-160 Engine Mechanical (6HK1)

Wide cab (left side)

a b

e d c
MFW81BMF001001

(a) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side

25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side
(b) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft) M10 Nut
77 N⋅m (7.9 kg⋅m / 57 lb⋅ft) Bolt, M12 Nut
(d) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(e) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
MG6HK-WE-0871.book 161 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-161

Wide cab (right side)

a b c

g f

MFW81BMF001501

(a) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(c) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(d) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(e) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(f) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(g) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
MG6HK-WE-0871.book 162 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-162 Engine Mechanical (6HK1)

Engine Exterior Parts (Euro 3 specification)

Component Parts: With waste gate control valve turbocharger
Left side (with MZW transmission)
5 6
3 4 7 8
2

10

11

18 17 16 15
19 14 13
12
MFWB1BMF003001

Legend
1. Intake pipe 11. Crankshaft position sensor
2. EGR valve 12. Oil filter
3. EGR cooler water return pipe 13. Fuel suction pipe
4. Common rail (Fuel rail) 14. Guide tube
5. Oil separator hose 15. Pressure feed pipe
6. Inlet pipe 16. Oil separator
7. Injection pipe 17. Oil cooler
8. EGR pipe 18. EGR valve duct
9. Leak-off pipe 19. Water duct
10. Supply pump
MG6HK-WE-0871.book 163 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-163

Right side (with MZW transmission)
3
1 2 4 5 6
7

16
15

14

8
11 10 9
13 12
MFWB1BMF003101

Legend
1. Exhaust manifold 9. Ft engine foot
2. Turbocharger feed water pipe 10. Turbocharger return oil pipe
3. Turbocharger feed oil pipe 11. Air compressor feed water pipe
4. Turbocharger 12. Air compressor feed oil pipe
5. Exhaust pipe adaptor 13. Air compressor
6. Turbocharger return water pipe 14. Rr engine foot
7. Turbocharger outlet inlet pipe 15. Governor air pipe
8. Generator bracket 16. Charge air pipe
MG6HK-WE-0871.book 164 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-164 Engine Mechanical (6HK1)

Left side (without MZW transmission)
5 8
3 4 6
7
2
1

10

11

18 17 16
19 15
14 12
13
MFWB1BMF003201

Legend
1. Intake pipe 11. Crankshaft position sensor
2. EGR valve 12. Oil filter
3. EGR cooler water return pipe 13. Fuel suction pipe
4. Common rail (Fuel rail) 14. Guide tube
5. Oil separator hose 15. Pressure feed pipe
6. Inlet pipe 16. Oil separator
7. Injection pipe 17. Oil cooler
8. EGR pipe 18. EGR valve duct
9. Leak-off pipe 19. Water duct
10. Supply pump
MG6HK-WE-0871.book 165 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-165

Right side (without MZW transmission)
3
2 4
1 5 6 7

16

15

14

13 11 10 9 8
12
MFWB1BMF003301

Legend
1. Exhaust manifold 9. Ft engine foot
2. Turbocharger feed water pipe 10. Turbocharger return oil pipe
3. Turbocharger feed oil pipe 11. Air compressor feed water pipe
4. Turbocharger 12. Air compressor feed oil pipe
5. Exhaust pipe adaptor 13. Air compressor
6. Turbocharger return water pipe 14. Rr engine foot
7. Turbocharger outlet inlet pipe 15. Governor air pipe
8. Generator bracket 16. Charge air pipe
MG6HK-WE-0871.book 166 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-166 Engine Mechanical (6HK1)

Removal
1. Remove the intake duct.
Full cab and Wide cab (rigid cab mounting
model)

2
MFWB1BSH004001

3. Remove the oil level gauge.

MFW71BSH006001
4. Remove the stays of the guide tube, and remove
Legend the guide tube (1) from the crankcase.
1. Air cleaner
2. Intake duct

Full cab and Wide cab (coil spring cab

mounting model)

2
MFW71BSH001901

5. Remove the intake pipe.

MFW71BSH006101 • Loosen the hose clip, remove the nut at the
stay section, and remove the intake pipe (1).
Legend
1. Air cleaner NOTE:
2. Intake duct After removing the pipe, seal it to prevent foreign
materials from getting into it.

2. Remove the engine harness.

• Remove the harnesses from the sensors and
accessories.

NOTE:
Before removing the harnesses, clearly indicate the clip
positions. (with paint, etc.)
MG6HK-WE-0871.book 167 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-167

7. Remove the oil separator hose (1).

1
2

MFWB1BSH003901
MFWB1BSH004101

6. Remove the fan guide stays (1). 1

Full cab and Wide cab

1
MFW81BSH007101

MFW71BSH004301
8. Remove the oil separator from the cylinder block
with the bracket attached to it.
• Remove the drain hose of the oil separator from
the oil pan.
MG6HK-WE-0871.book 168 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-168 Engine Mechanical (6HK1)

10. Remove the EGR pipe (1) from the exhaust
manifold (2) and the oil cooler.

2 2

MFW71BSH000301

Legend
MFWB1BSH004301
1. Bracket
2. Oil separator
3. Oil drain hose
11. Remove the suction air hose (air compressor).
12. Remove the charge air pipe and governor air pipe
(air compressor) together with the bracket.
9. Remove the EGR cooler water pipe (1).
1 2
1

4 3
MFWB1BSH004401
MFWB1BSH004201
Legend
1. Charge air pipe
2. Governor air pipe
3. Air compressor
4. Bracket
MG6HK-WE-0871.book 169 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-169

13. Remove the turbocharger outlet inlet pipe (1). 15. Remove the air compressor feed oil pipe (1).

1
MFWB1BSH004501 MFWB1BSH004701

14. Remove the water pipe (3) (adapter – air 16. Remove the air compressor from the flywheel
compressor). housing.

NOTE:
1 After removing the air compressor, plug it to prevent
foreign materials from getting into it.

4 3 2
MFWB1BSH004601

Legend
1. Water pipe (return to turbocharger)
2. Adapter
3. Water pipe (feed) MFW61BSH005501
4. Compressor

17. Remove the exhaust adapter bracket.

18. Remove the exhaust pipe adapter.
19. Remove the turbocharger.
a. Disconnect the oil pressure switch connector.
b. Remove the oil feed pipe (turbocharger).
c. Remove the water return pipe (turbocharger).
d. Remove the water feed pipe (turbocharger).
e. Remove the oil return pipe.
f. Remove the turbocharger assembly.
MG6HK-WE-0871.book 170 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-170 Engine Mechanical (6HK1)

NOTE:
Plug the ports of the oil and the coolant to prevent 21. Remove the boost sensor (1).
foreign material from getting into them. Plug the
compressor and the turbine side as well. 1

4
3
2

BLW71JSH001301

MFWB1BSH004801
22. Remove the intake throttle and inlet pipe.
Legend
1. Exhaust manifold
2. Turbocharger
3. Gasket 1 2 3
4. Exhaust pipe adapter
5. Exhaust pipe adapter bracket

20. Remove the heat protector from the exhaust

manifold and air duct bracket.

MFW71BSH000801

Legend
1. Intake throttle
2. Gasket
3 3. Inlet pipe
4. Gasket

23. Remove the injection pipe.

MFWB1BSH004901
NOTE:
Legend Plug the common rail and the injector to prevent foreign
1. Air duct bracket material from getting into them.
2. Exhaust manifold (front)
3. Exhaust manifold (rear)
4. Heat protector
MG6HK-WE-0871.book 171 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-171

26. Remove the fuel leak-off pipe (1) from the various
parts.

5 6
3 4
2
1

MFW71BSH000901

Legend
MFW71BSH001101
1. Injection pipe # 1
2. Injection pipe # 2
3. Injection pipe # 3
4. Injection pipe # 4 27. Remove the common rail.
5. Injection pipe # 5
6. Injection pipe # 6 NOTE:
7. Common rail (Fuel rail) Careful handing of the sensor is needed to avoid
interference with other objects.
Plug it to prevent foreign materials from getting into it.

24. Remove the pressure feed pipe (1) from the

common rail and the supply pump.
25. Remove the fuel suction pipe (2) from the supply 1
pump.

2
1 3

2 MFW71BSH001201

Legend
1. Nuts
2. Common rail (Fuel rail)
MFW71BSH001001 3. Bolts
MG6HK-WE-0871.book 172 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-172 Engine Mechanical (6HK1)

28. Remove the crankshaft position sensor (1) from d. Remove the bracket (2) and O-ring (7) from the
the flywheel housing (2). supply pump.

1 2 3 4 5

10

9
1 2
8 7 6
MFW71BSH002501 BLW71BSH000701

Legend
1. Supply pump
29. .Remove the oil filter from the cylinder block. 2. Bracket
• Remove the oil filter after removing oil from the 3. Gear
oil drain hose. 4. Nut
5. Bolts
6. O-ring
7. O-ring
8. Nuts
9. Bolts
10. Nuts

31. Remove the EGR valve duct.

MFW71BSH001601

30. Remove the supply pump (1) together with the

bracket (2).
a. Remove the O-ring (6) from the supply pump.
b. Remove the nut (4) and gear (3) from the
supply pump. 3 2
c. Remove the bolts (9) from the supply pump.
MFW71BSH001301

Legend
1. EGR valve
2. EGR valve duct
3. Gaskets
MG6HK-WE-0871.book 173 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-173

34. Remove the inlet cover (1).

32. Remove the EGR valve.

MFW71BSH001801

MFW71BSH001401

Legend 35. Remove the water duct from the oil cooler.
1. EGR valve 36. Remove the noise cover from the cylinder block.
2. Gasket
3. EGR valve duct assembly 1

33. Remove the EGR valve duct assembly from the

inlet cover.

2 MFW71BSH001701

Legend
1. Space rubber
2. Noise cover
1

MFW71BSH001501 37. Remove the oil cooler from the cylinder block.
Legend • Remove the mounting bolts of the oil cooler. Put
1. EGR valve duct assembly the removed bolts into the replacer holes (the parts
2. Gasket indicated by arrows) and remove the cooler by
tightening all the bolts equally.
MG6HK-WE-0871.book 174 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-174 Engine Mechanical (6HK1)

4. Install the oil pressure switch.

1 Tightening torque N⋅m (kg⋅m / lb⋅ft)

18 (1.8 / 13)
2
3 5. Install the oil cooler.
• Apply liquid gasket (ThreeBond 1207C or
1216C) in the groove of the oil cooler to have
the bead width of 2 – 3 mm (0.08 – 0.12 in).
Insert the O-ring (1) and install it.

NOTE:
• Clean the O-ring groove, as it is difficult to fit in the
O-ring if liquid gasket remains in the groove.
• After applying the liquid gasket, install within 5
minutes.
MFW41BSH024201

Legend • When installing the oil cooler to the cylinder

1. Cylinder block block, it is easier to perform the installation if
2. Oil cooler you temporarily attach M8 studs to the front and
3. Bolts back of the mounting screw holes to use as a
guide.

38. Remove the oil pressure switch from the cylinder

block.
39. Remove the generator bracket from the cylinder
block. 1
40. Remove the front engine foot from the cylinder
block.
41. Remove the rear engine foot from the flywheel
housing.

Installation
1. Install the rear engine foot, and tighten it at the
specified torque.

Tightening torque N⋅m (kg⋅m / lb⋅ft}) MFW41BSH002001

76 (7.7 / 56)

2. Install the front engine foot, and tighten it at the • Tighten the oil cooler fixing bolts in the order
specified torque. shown in the diagram.

Tightening torque N⋅m (kg⋅m / lb⋅ft) Tightening torque N⋅m (kg⋅m / lb⋅ft)

78 (8.0 / 58) 25 (2.5 / 18)

3. Install the generator bracket, and tighten it at the

specified torque.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

38 (3.9 / 28)
MG6HK-WE-0871.book 175 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-175

21 17 13 9 5 1 4 8 12 16 20
22
25
26
24

18 14 10 6 2 3 7 11 15 19
27 23

1 2

MFW41BSH024101 MFW71BSH002501

6. Install the water duct (suction) to the oil cooler. 8. Install the supply pump, gear and bracket together
to the cylinder block.
• Rotate the engine in the forward direction. Align
Tightening torque N⋅m (kg⋅m / lb⋅ft) the positions of the TDC (0°) mark (2) on the
19 (1.9 / 14) outer circumference of the damper and the
pointer (1).

NOTE:
Confirm that the first cylinder is at the compression top
dead center.

2
3

MFW81BSH009901

Legend
1. Oil cooler
2
2. O-ring
3. Water duct (suction) MFWB1BSH003301

7. Install the crankshaft position sensor (1) to the

flywheel housing (2).

Tightening torque N⋅m (kg⋅m / lb⋅in)

8 (0.8 / 69)
MG6HK-WE-0871.book 176 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-176 Engine Mechanical (6HK1)

• Before assembling the supply pump, align the • Confirm that the white paint of the alignment
alignment marks (slits) on the gear. mark appears as indicated in the illustration
when you look at the gear from upslope,
through the timing check hole on top of the
flywheel housing.
1

2 2

MFW41BSH023701

• Make sure to paint in white the gear edge BLW71BSH005701

surface (1) that corresponds to 2-point marks Legend

(2) on the gear side surface. 1. Timing check hole
2. Supply pump gear

• Tighten the supply pump with a nut and bolt.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Nuts (10) 50 (5.1 / 37)
Nut (8), Bolt (5) 77 (7.9 / 57)
1 Nut (4) 64 (6.5 / 47)
2 Bolts (9) 19 (1.9 / 14)

MFWB1BSH003001

• Horizontally insert the supply pump into the

cylinder block.
MG6HK-WE-0871.book 177 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-177

1 2 3 4 5

10

8 7 6
MFW61BSH001001 MFW71BSH001601

Legend
1. Supply pump
2. Bracket 10. Install the noise cover.
3. Gear 11. Install the inlet cover (1).
4. Nut
5. Bolt
6. O-ring Tightening torque N⋅m (kg⋅m / lb⋅ft)
7. O-ring 25 (2.5 / 18)
8. Nut
9. Bolts
10. Nuts

• Re-confirm again that the ruling alignment mark

of the timing mark (crank damper) is aligned to
0°, and the alignment mark of the supply pump
gear is aligned.
• If the marks are misaligned, reassemble the
parts.
• Install the plug to the flywheel housing after
checking the timing.
9. Install the oil filter.
• Assemble an O-ring to the groove of the
bracket, and install it to the cylinder block. 1

NOTE:
MFW71BSH001801
• ThreeBond 1208 or CH Dine 290 can be used to
prevent O-rings from falling off.
• Confirm that the O-ring is firmly in place without
protrusion or misalignment.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

38 (3.9 / 28)
MG6HK-WE-0871.book 178 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-178 Engine Mechanical (6HK1)

12. Install the space rubber between the inlet manifold
and the oil cooler.
1
1

MFW71BSH001401

2 MFW71BSH001701

Legend 15. Temporarily install the EGR valve duct to the EGR
1. Space rubber valve and oil cooler.
2. Noise cover • Install a gasket to the EGR valve side and oil
cooler side.

13. Install the EGR valve duct assembly (1) to the inlet
cover.
1
• Install the gasket (2) to the inlet cover side.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

M8 25 (2.5 / 18)
M10 46 (4.7 / 34)

3 2
2 MFW71BSH001301

Legend
1. EGR valve
2. EGR valve duct
3. Gaskets

16. Completely tighten the EGR valve.

• Securely tighten the EGR valve duct (2) and
1 EGR valve (1).

MFW71BSH001501

14. Temporarily install the EGR valve (1) to the EGR

valve duct assembly (3).
• Install the gasket (2) to the EGR valve duct
assembly side.
MG6HK-WE-0871.book 179 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-179

Tightening torque N⋅m (kg⋅m / lb⋅ft) 18. Install the pressure feed pipe (1).
EGR valve 46 (4.7 / 34)
EGR valve duct Tightening torque N⋅m (kg⋅m / lb⋅ft)
46 (4.7 / 34)
(EGR valve side) Supply pump side 44 (4.5 / 33)
EGR valve duct Common rail side 44 (4.5 / 33)
22 (2.2 / 16)
(oil cooler side)
19. Install the fuel suction pipe (2) to the supply pump
and fix it with a clip.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

1 18 (1.8 / 13)

MFW61BSH001901

2
17. Install the common rail.
• Order for temporal tightening: nuts (1) before
bolts (2).
• Order for complete tightening: bolts (2) before MFW71BSH001001
nuts (1).
Legend
1. Pressure feed pipe
Tightening torque N⋅m (kg⋅m / lb⋅ft) 2. Suction pipe

25 (2.5 / 18)

20. Install the fuel leak-off pipe (1).

• Assemble a new gasket to each connecting
section.
1 • Fix each part with a clip after tightening it.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Supply pump side 10 (1.0 / 87 lb⋅in)
Common rail side 20 (2.0 / 14)

MFW61BSH001301
MG6HK-WE-0871.book 180 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-180 Engine Mechanical (6HK1)

22. Install the inlet pipe and intake throttle.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Inlet pipe 25 (2.5 / 18)
Intake throttle 24 (2.4 / 17)

1
1 2 3

MFW71BSH001101

21. Install the injection pipe and tighten the sleeve nut.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Injector side 30 (3.1 / 22) MFW71BSH000801
Common rail side 25 (2.6 / 19) Legend
1. Intake throttle
2. Gasket
3 4 3. Inlet pipe
2
5 4. Gasket
1

23. Install the boost sensor (1).

7 1

BLW71BSH004901

Legend
1. Injection pipe # 1
2. Injection pipe # 2
3. Injection pipe # 3
4. Injection pipe # 4
5. Injection pipe # 5
BLW71JSH001301
6. Injection pipe # 6
7. Common rail (Fuel rail)
Tightening torque N⋅m (kg⋅m / lb⋅in)
2 (0.2 / 17)
MG6HK-WE-0871.book 181 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-181

24. Install the heat protector to the exhaust manifold • Refuel the appropriate amount of oil from the oil
and air duct bracket. inlet hole (1) of the turbocharger, and rotate the
• It thrusts and temporary tightening of the upper turbine shaft to lubricate the shaft bearing
part bolt of heat protector attachment is carried section.
out until.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Air duct bracket side 20 (2.0/14)
Exhaust manifold side 41 (4.2/30) 1

MFW41BSH026401

3
• Fasten the gasket (2), and install the
turbocharger (1) to the exhaust manifold.
4

Tightening torque N⋅m (kg⋅m / lb⋅ft)

MFWB1BSH004901
52 (5.3 / 38)
Legend
1. Air duct bracket
2. Exhaust manifold (front)
3. Exhaust manifold (rear)
4. Heat protector

25. Install the turbocharger.

MFW41BSH026501

26. Install the exhaust pipe adapter.

• Fasten the gasket (2) between the turbocharger
(1) and the exhaust pipe adapter (3) and install
it.
MG6HK-WE-0871.book 182 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-182 Engine Mechanical (6HK1)

• The bolt is previous tightened. 28. Install the turbocharger oil return pipe.
• Install the oil pipe to turbocharger and cylinder
block.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Nut and Bolt 26 (2.7/20) NOTE:
Make sure to use a new gasket to prevent oil leakage.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

3 Turbocharger side 28 (2.9/21)
2 Cylinder block side 18 (1.8/13)
1

3
MFW81JSH000901 4

27. Install the exhaust pipe adapter bracket.

5
• Tighten A previously (A to B).

MFW81HSH001201
Tightening torque N⋅m (kg⋅m / lb⋅ft) Legend
71 (7.2/52) 1. Cylinder block
2. Turbocharger
3. Gasket
4. Oil return pipe
5. Gasket
A

B
29. Install the turbocharger oil feed pipe.
• Install the turbocharger oil feed pipe (2) to the
cylinder block (1).

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Turbocharger side 34 (3.5/25)
Cylinder block side 41 (4.2/30)

1
2
3
MFW81BSH009601

Legend
1. Turbocharger
2. Exhaust pipe adapter bracket
3. Exhaust manifold
MG6HK-WE-0871.book 183 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-183

4
1 2
3

2
1

3
5
MFW81HSH001101 MFW81CSH001001

Legend Legend
1. Cylinder block 1. Water pipe bracket
2. Turbocharger oil return pipe 2. Turbocharger water feed pipe
3. Turbocharger 3. Water pipe bracket
4. Turbocharger
5. Air compressor
30. Install the turbocharger water feed pipe.

NOTE:
Make sure to use a new gasket to prevent coolant 31. Install the turbocharger water return pipe.
leakage.
NOTE:
Make sure to use a new gasket to prevent coolant
Tightening torque N⋅m (kg⋅m / lb⋅ft) leakage.
Turbocharger side 41 (4.2 / 30)
Air compressor side 50 (5.1 / 37) Tightening torque N⋅m (kg⋅m / lb⋅ft)
Turbocharger side 50 (5.1 / 37)
Cylinder head side 41 (4.2 / 30)
MG6HK-WE-0871.book 184 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-184 Engine Mechanical (6HK1)

3 4
2

MFW81BSH009701

Legend
1. Inlet pipe
2. Turbocharger
4
3. Heat protector
4. Rubber hose
5

33. Connect the connector of the oil pressure switch.

MFW81CMH000301
34. Install the air cleaner outlet duct (1) to the
Legend turbocharger (3), and tighten it with a air duct
1. Cylinder head cover clamp (2).
2. Cylinder head
3. Rubber hose
4. Turbocharger water return pipe
5. Turbocharger
3
2

32. Install the inlet pipe (turbocharger out). 1

Tightening torque N⋅m (kg⋅m / lb⋅ft)

18 (1.8 / 13)

MFW81BSH009801

35. Install the air compressor to the flywheel housing.

• Tap the key into the shaft of the air compressor,
and tighten the installation nut of the drive gear
at the specified torque.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

147 (15 / 108)
MG6HK-WE-0871.book 185 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-185

2
2
1

MFW61BSH005401
4 BLW71BSH015501

Legend Legend
1. Gear 1. Air compressor
2. Key 2. Bolt (long)
3. Bolts
4. Nut

• Apply liquid gasket (ThreeBond 1208 or CH

Dine 290) equally to three parts on the 36. Install the air compressor oil feed pipe (2) to the air
circumference of the O-ring, and install the O- compressor (3) and the cylinder block (1).
ring in the groove of the air compressor.
NOTE:
Use a new gasket.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
73 (7.4 / 54)
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Cylinder block side 41 (4.2 / 30)
Air compressor side 28 (2.9 / 21)

MFW61BSH005501
3

MFW81HSH001301
MG6HK-WE-0871.book 186 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-186 Engine Mechanical (6HK1)

37. Install the air compressor water pipes (1) and (3).
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Tightening torque N⋅m (kg⋅m / lb⋅ft) Charge air pipe side (dry) 64 (6.5 / 47)
Air compressor side 50 (5.1 / 37) Governor air pipe side 27 (2.8 / 20)
Water pipe adaptor side 41 (4.2 / 30) Bracket 19 (1.9 / 14)
Water pipe clip bracket 18 (1.8 / 13)
Water pipe clip 9 (0.9 / 78 lb⋅in)
1 2

4 4 3
MFWB1BSH004401

Legend
1. Charge air pipe
3 2. Governor air pipe
2 3. Air compressor
4. Bracket

39. Install the EGR pipe (1) from the exhaust manifold
(2) and the oil cooler.

MFW81BMH000301
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Legend
Exhaust manifold side 25 (2.5 / 18)
1. Water pipe (return to turbocharger)
2. Air compressor Oil cooler side 25 (2.5 / 18)
3. Water pipe (feed)
4. Water feed adapter

38. Install the charge air pipe (1) and governor air pipe
(2) to the air compressor (3).
• Install the charge pipe and governor with a clip.

NOTE:
Apply oil so that it does not turn together with the
eyebolt. Never use soapy water, etc.
MG6HK-WE-0871.book 187 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-187

MFWB1BSH004301 MFW71BSH000301

Legend
1. Bracket
40. Install the EGR cooler water pipe (1). 2. Oil separator
3. Oil drain hose

Tightening torque N⋅m (kg⋅m / lb⋅ft)

M6 9 (0.9 / 78 lb⋅in)
42. Install the oil separator hoses (1).
M8 25 (2.5 / 18)

Tightening torque N⋅m (kg⋅m / lb⋅ft)

1 Bracket 25 (2.5 / 18)
Oil separator hose clip 9 (0.9 / 78 lb⋅in)

1
2

MFWB1BSH004201

41. Put the bracket on the oil separator, and install it to

the cylinder block.
MFWB1BSH004101

Legend
Tightening torque N⋅m (kg⋅m / lb⋅ft) 1. Bracket
40 (4.1 / 30) 2. Oil separator hose
MG6HK-WE-0871.book 188 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-188 Engine Mechanical (6HK1)

1
1

MFW81BSH007101 MFWB1BSH003901

43. Install the suction air pipe to the air compressor. 46. Install the guide tube (1) into the crankcase, and fix
44. Install the fan guide stay (1). the stay section.
Full cab and Wide cab • Insert the O-ring into the guide tube, and press
it in until it touches the hole of the crankcase.

NOTE:
Take care not to cut the O-ring.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

24 (2.4 / 17)

MFW71BSH004301

45. Install the intake pipe (1).

Tightening torque N⋅m (kg⋅m / lb⋅ft)

1
M8 nut 18 (1.8 / 13)
ABA W4 Stainless clamp 6.4 (0.65 / 56 lb⋅in)
MFW71BSH001901
NORMA W1 Steel clamp 8 (0.8 / 69 lb⋅in)

47. Insert the oil level gauge.

MG6HK-WE-0871.book 189 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-189

48. Install the engine harness to each connector, and Full cab and Wide cab (coil spring cab
clip it in the designated position. mounting model)

MFW71BSH006101
MFWB1BSH004001
Legend
1. Air cleaner
49. Install the intake duct. 2. Intake duct

Tightening torque N⋅m (kg⋅m / lb⋅in)

ABA W4 Stainless clamp 6.4 (0.65 / 56)
NORMA W1 Steel clamp 8 (0.8 / 69)

Full cab and Wide cab (rigid cab mounting

model)

MFW71BSH006001

Legend
1. Air cleaner
2. Intake duct
MG6HK-WE-0871.book 190 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-190 Engine Mechanical (6HK1)

Tightening Torque Table
Left side (with MZW transmission)

d e
c f
b

u
l

t
s q p o
r m
n
MFWB1BMF003401

(n) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)

(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft) (o) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(b) 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft) (p) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
M8: 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) (q) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(c)
M10: 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft) (r) 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
44 N⋅m (4.5 kg⋅m / 33 lb⋅ft) Common rail side M6: 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)
(d) (s)
44 N⋅m (4.5 kg⋅m / 33 lb⋅ft) Supply pump side M8: 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side (t) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(e)
25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side (u) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(f) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(g) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
10 N⋅m (1.0 kg⋅m / 87 lb⋅in) Supply pump side
(h)
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) Common rail side
(i) 77 N⋅m (7.9 kg⋅m / 57 lb⋅ft)
M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M10: 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(j)
M12: 77 N⋅m (7.9 kg⋅m / 57 lb⋅ft)
M14: 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
(k) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(l) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(m) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
MG6HK-WE-0871.book 191 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-191

Right side (with MZW transmission)

e f g h i
d j

o k
t n m l
s r q p
MFWB1BMF003501

(a) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)

(b) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(d) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(e) 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
(f) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(g) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(h) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
(i) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(j) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(k) 38 N⋅m (9.9 kg⋅m / 28 lb⋅ft)
(l) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(m) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
(n) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(o) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(p) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(q) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(r) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(s) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(t) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(u) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
MG6HK-WE-0871.book 192 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-192 Engine Mechanical (6HK1)

Upper surface (with MZW transmission)

c d
a b

e
j
f
i h g

MFWB1BMF003601

(a) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)

(b) 2 N⋅m (0.2 kg⋅m / 17 lb⋅in)
(c) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(e) 71 N⋅m (7.2 kg⋅m / 52 lb⋅ft)
(f) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)
(g) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(h) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(i) 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)
(j) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
MG6HK-WE-0871.book 193 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-193

Left side (without MZW transmission)

c d e f
b

g
h

u
m
t
s r q p o n

MFWB1BMF003701

(n) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)

(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft) (o) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(b) 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft) (p) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
M8: 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) (q) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(c)
M10: 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft) (r) 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
44 N⋅m (4.5 kg⋅m / 33 lb⋅ft) Common rail side M6: 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)
(d) (s)
44 N⋅m (4.5 kg⋅m / 33 lb⋅ft) Supply pump side M8: 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side (t) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(e)
25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side (u) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(f) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(g) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
10 N⋅m (1.0 kg⋅m / 87 lb⋅in) Supply pump side
(h)
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) Common rail side
(i) 77 N⋅m (7.9 kg⋅m / 57 lb⋅ft)
M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M10: 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(j)
M12: 77 N⋅m (7.9 kg⋅m / 57 lb⋅ft)
M14: 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
(k) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(l) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(m) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
MG6HK-WE-0871.book 194 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-194 Engine Mechanical (6HK1)

Right side (without MZW transmission)

f g h i
e
d j

u k
o n
t s m l
r p
q MFWB1BMF003801

(a) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)

(b) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(d) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(e) 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
(f) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(g) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(h) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
(i) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(j) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(k) 38 N⋅m (9.9 kg⋅m / 28 lb⋅ft)
(l) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(m) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
(n) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(o) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(p) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(q) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(r) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(s) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(t) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(u) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
MG6HK-WE-0871.book 195 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-195

Upper surface (without MZW transmission)

a b c d

j f
i g
h

MFWB1BMF003901

(a) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)

(b) 2 N⋅m (0.2 kg⋅m / 17 lb⋅in)
(c) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(e) 71 N⋅m (7.2 kg⋅m / 52 lb⋅ft)
(f) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)
(g) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(h) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(i) 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)
(j) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
MG6HK-WE-0871.book 196 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-196 Engine Mechanical (6HK1)

Engine Exterior Parts (Euro 2 specification)

Component Parts
Left side (with MZW transmission)

4
1 2 3 5

13 12
14 11
10 9

MFW81BMF004701

Legend
1. Inlet pipe 8. Crankshaft position sensor
2. Turbocharger return water pipe 9. Oil filter
3. Common rail (Fuel rail) 10. Fuel suction pipe
4. Breather hose 11. Guide tube
5. Injection pipe 12. Pressure feed pipe
6. Leak-off pipe 13. Oil cooler
7. Supply pump 14. Suction water duct
MG6HK-WE-0871.book 197 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-197

Right side (with MZW transmission)

2 3 4 5
1 6

15
14

13

10 9 8 7
12 11

MFW81BMF004801

Legend
1. Air compressor suction hose 9. Turbocharger oil feed pipe
2. Heat protector 10. Turbocharger oil return pipe
3. Turbocharger 11. Air compressor oil feed pipe
4. Exhaust pipe adaptor 12. Air compressor
5. Exhaust manifold 13. Rr engine foot
6. Turbocharger outlet intake pipe 14. Governor air pipe
7. Generator bracket 15. Charge air pipe
8. Ft engine foot
MG6HK-WE-0871.book 198 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-198 Engine Mechanical (6HK1)

Left side (without MZW transmission)

1 3
2 4

12 11
13 10
9 8

MFW81BMF004901

Legend
1. Inlet pipe 8. Oil filter
2. Common rail (Fuel rail) 9. Fuel suction pipe
3. Breather hose 10. Guide tube
4. Injection pipe 11. Pressure feed pipe
5. Leak-off pipe 12. Oil cooler
6. Supply pump 13. Suction water duct
7. Crankshaft position sensor
MG6HK-WE-0871.book 199 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-199

Right side (without MZW transmission)

2 3 4 5
1 6

16
15

14

11 10 9 8
13 12

MFW81BMF005001

Legend
1. Air compressor suction hose 9. Ft engine foot
2. Heat protector 10. Turbocharger oil feed pipe
3. Turbocharger 11. Turbocharger
4. Exhaust pipe adaptor 12. Air compressor oil feed pipe
5. Turbocharger water return pipe 13. Air compressor oil return pipe
6. Exhaust manifold 14. Rr engine foot
7. Turbocharger outlet intake pipe 15. Governor air pipe
8. Generator bracket 16. Charge air pipe
MG6HK-WE-0871.book 200 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-200 Engine Mechanical (6HK1)

Removal
1. Remove the intake duct.
Full cab and Wide cab (rigid cab mounting 1
model)

2
MFW81BSH010101

3. Remove the oil level gauge.

MFW71BSH006001
4. Remove the stays of the guide tube, and remove
Legend the guide tube (1) from the crankcase.
1. Air cleaner
2. Intake duct

Full cab and Wide cab (coil spring cab

mounting model)

1
2
MFW81BSH008301

5. Remove the inlet pipe.

MFW71BSH006101 • Loosen the hose clip, remove the nut at the
stay section, and remove the inlet pipe (1).
Legend
1. Air cleaner NOTE:
2. Intake duct After removing the pipe, seal it to prevent foreign
materials from getting into it.

2. Remove the engine harness.

• Remove the harnesses (1) from the sensors
and accessories.

NOTE:
Before removing the harnesses, clearly indicate the clip
positions. (with paint, etc.)
MG6HK-WE-0871.book 201 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-201

7. Remove the air breather hose.

1
2

MFW81BSH010301
3

6. Remove the fan guide stays (1).

Full cab and Wide cab

MFW81BMH000201

Legend
1. Head cover
2. Air breather hose
3. Intake pipe

1 8. Remove the fastening clip of the water pipe. Next,

remove the hoses at the water pump side .
9. Remove the suction air hose (air compressor).
MFW71BSH004301
MG6HK-WE-0871.book 202 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-202 Engine Mechanical (6HK1)

10. Remove the charge air pipe and governor air pipe 11. Remove the water pipe (1) (cylinder block – air
(air compressor) together with the bracket. compressor).

1 2 3

MFW81BSH010601
3
Legend 2
1. Charge air pipe
2. Governor air pipe
3. Air compressor

MFW81BMH000301

Legend
1. Water pipe (return to turbocharger)
2. Air compressor
3. Water pipe (feed)
4. Water feed adaptor

12. Remove the air compressor from the flywheel

housing.

NOTE:
After removing the air compressor, plug it to prevent
foreign materials from getting into it.
MG6HK-WE-0871.book 203 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-203

4
3
2

MFW61BSH005501 MFW81BSH009101

Legend
1. Exhaust manifold
13. Remove the exhaust pipe adapter. 2. Turbocharger
14. Remove the turbocharger. 3. Gasket
a. Disconnect the oil pressure switch connector. 4. Exhaust pipe adapter
5. Exhaust pipe adapter bracket
b. Remove the intake pipe.
c. Remove the oil feed pipe (turbocharger).
d. Remove the water return pipe (turbocharger).
15. Remove the heat protector from the exhaust
e. Remove the water feed pipe (turbocharger).
manifold and air duct bracket.
f. Remove the oil return pipe.
g. Remove the turbocharger assembly. 1

NOTE:
Plug the ports of the oil and the coolant to prevent 2
foreign material from getting into them. Plug the
compressor and the turbine side as well.

MFW81BSH009501

Legend
1. Air duct bracket
2. Exhaust manifold (front)
3. Exhaust manifold (rear)
4. Heat protector
MG6HK-WE-0871.book 204 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-204 Engine Mechanical (6HK1)

16. Remove the boost sensor (1).

5
4 6
3
1 2
1

MFW81BSH008901
MFW81BSH008601
Legend
1. Injection pipe # 1
2. Injection pipe # 2
17. Remove the intake pipe. 3. Injection pipe # 3
4. Injection pipe # 4
5. Injection pipe # 5
2 6. Injection pipe # 6
7. Common rail (Fuel rail)
1

19. Remove the pressure feed pipe (5) from the

3 common rail and the supply pump.
20. Remove the fuel suction pipe (4) from the supply
4 pump.

MFW81BSH008701

Legend
1. Intake pipe
2. Bracket
3. Gasket
4. Inlet cover

18. Remove the injection pipe.

NOTE:
Plug the common rail and the injector to prevent foreign
material from getting into them.
MG6HK-WE-0871.book 205 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-205

21. Remove the fuel leak-off pipe (3) from the various
parts.

2 2
1
3
3

4 4

MFW81BSH009201
5 Legend
MFW81BSH009001
1. EGR valve duct assembly
Legend 2. Common rail (Fuel rail)
1. Common rail (Fuel rail) 3. Nuts
2. Pressure limiter 4. Bolts
3. Fuel leak-off pipe
4. Fuel suction pipe
5. Pressure feed pipe
23. Remove the crankshaft position sensor (1) from
the flywheel housing (2).
Manual transmission specifications
22. Remove the common rail.

NOTE:
Careful handing of the sensor is needed to avoid
interference with other objects.
Plug it to prevent foreign materials from getting into it.

1 2

MFW71BSH002501
MG6HK-WE-0871.book 206 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-206 Engine Mechanical (6HK1)

Automatic transmission specifications d. Remove the bracket (2) and O-ring (7) from the
supply pump.

2 1 2 3 4 5
1

10

MFW81BSH010501 8 7 6
BLW71BSH000701

Legend
24. .Remove the oil filter from the cylinder block. 1. Supply pump
• Remove the oil filter after removing oil from the 2. Bracket
oil drain hose. 3. Gear
4. Nut
5. Bolts
6. O-ring
7. O-ring
8. Nuts
9. Bolts
10. Nuts

26. Remove the Duct cover.

MFW81BSH011401

25. Remove the supply pump (1) together with the

bracket (2). 1

a. Remove the O-ring (6) from the supply pump.

b. Remove the nut (4) and gear (3) from the
supply pump.
c. Remove the bolts (9) from the supply pump.

MFW81BSH009301

Legend
1. EGR valve duct assembly
2. Gasket
3. Duct cover
MG6HK-WE-0871.book 207 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-207

27. Remove the EGR valve duct assembly from the

inlet cover. 1

1 2
3

MFW81BSH008801

Legend
1. Cylinder block
MFW81BSH009401 2. Oil cooler
Legend 3. Bolts
1. Inlet cover
2. Gasket
3. EGR valve duct assembly
31. Remove the oil pressure switch from the cylinder
block.
32. Remove the generator bracket from the cylinder
28. Remove the inlet cover (1). block.
33. Remove the front engine foot from the cylinder
block.
34. Remove the rear engine foot from the flywheel
housing.

Installation
1. Install the rear engine foot, and tighten it at the
specified torque.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

76 (7.7 / 56)

1 2. Install the front engine foot, and tighten it at the

specified torque.
MFW71BSH001801

Tightening torque N⋅m (kg⋅m / lb⋅ft)

29. Remove the water duct from the oil cooler. 78 (8.0 / 58)
30. Remove the oil cooler from the cylinder block.
3. Install the generator bracket, and tighten it at the
• Remove the mounting bolts of the oil cooler. Put specified torque.
the removed bolts into the replacer holes (the parts
indicated by arrows) and remove the cooler by
tightening all the bolts equally. Tightening torque N⋅m (kg⋅m / lb⋅ft)
38 (3.9 / 28)
MG6HK-WE-0871.book 208 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-208 Engine Mechanical (6HK1)

4. Install the oil pressure switch.
Refer to “Cylinder Block”.
5. Install the oil cooler.
• Apply liquid gasket (ThreeBond 1207B) in the
groove of the oil cooler to have the bead width
of 2 – 3 mm (0.08 – 0.12 in).
Insert the O-ring (1) and install it. 21 17 13 9 5 1 4 8 12 16 20
22 27
23
NOTE:
26
• Clean the O-ring groove, as it is difficult to fit in the
O-ring if liquid gasket remains in the groove. 18 14 10
25 6 2 3 7 11 15 19
• After applying the liquid gasket, install within 5 24
minutes.

• When installing the oil cooler to the cylinder

block, it is easier to perform the installation if
you temporarily attach M8 studs to the front and
back of the mounting screw holes to use as a MFW81BSH005901

guide.

6. Install the water duct (suction) to the oil cooler.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

19 (1.9 / 14)
1

MFW41BSH002001
2
3
• Tighten the oil cooler fixing bolts in the order
shown in the diagram.

Tightening torque N⋅m (kg⋅m / lb⋅ft) MFW81BSH009901

19 (1.9 / 14) Legend

1. Oil cooler
2. O- ring
3. Water duct (suction)

7. Install the crankshaft position sensor (1) to the

flywheel housing (2).

Tightening torque N⋅m (kg⋅m / lb⋅in)

8 (0.8 / 69)
MG6HK-WE-0871.book 209 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-209

Manual transmission specifications

1 2
2
MFWB1BSH003301
MFW71BSH002501

Automatic transmission specifications

• Before assembling the supply pump, align the
alignment marks (slits) on the gear.
2
1

MFW81BSH010501

MFW41BSH023701
8. Install the supply pump, gear and bracket together
to the cylinder block.
• Rotate the engine in the forward direction. Align
the positions of the TDC (0°) mark (2) on the
outer circumference of the damper and the
pointer (1).

NOTE:
Confirm that the first cylinder is at the compression top
dead center.
MG6HK-WE-0871.book 210 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-210 Engine Mechanical (6HK1)

• Make sure to paint in white the gear edge • Tighten the supply pump with a nuts and bolts.
surface (1) that corresponds to 2-point marks
(2) on the gear side surface.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Nuts (10) 50 (5.1 / 37)
Nut (8), Bolt (5) 77 (7.9 / 57)
Nut (4) 64 (6.5 / 47)
Bolts (9) 19 (1.9 / 14)

1
1 2 3 4 5
2

10

MFWB1BSH003001

• Horizontally insert the supply pump into the

cylinder block. 9

• Confirm that the white paint of the alignment

mark appears as indicated in the illustration 8 7 6
when you look at the gear from upslope, MFW61BSH001001

through the timing check hole on top of the Legend

flywheel housing. 1. Supply pump
2. Bracket
3. Gear
2
4. Nut
5. Bolt
6. O-ring
7. O-ring
8. Nuts
1 9. Bolts
10. Nuts

• Re-confirm again that the ruling alignment mark

of the timing mark (crank damper) is aligned to
0°, and the alignment mark of the supply pump
gear is aligned.
• If the marks are misaligned, reassemble the
BLW71BSH005701 parts.
Legend • Install the plug to the flywheel housing after
1. Timing check hole checking the timing.
2. Supply pump gear 9. Install the oil filter.
• Assemble an O-ring to the groove of the
bracket, and install it to the cylinder block.

NOTE:
• ThreeBond 1208 or CH Dine 290 can be used to
prevent O-rings from falling off.
MG6HK-WE-0871.book 211 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-211

• Confirm that the O-ring is firmly in place without
protrusion or misalignment.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
M8 25 (2.5 / 18)
Tightening torque N⋅m (kg⋅m / lb⋅ft) M10 46 (4.7 / 34)
38 (3.9 / 28)

MFW91BSH003301

MFW81BSH011401

12. Install the duct cover (3) to the EGR valve duct
10. Install the inlet cover (1). assembly (1).
• Install the gasket (2) to the EGR valve duct
assembly side.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
25 (2.5 / 18)
Tightening torque N⋅m (kg⋅m / lb⋅ft)
46 (4.7 / 34)

MFW71BSH001801

11. Install the EGR valve duct assembly (3) to the inlet
MFW81BSH009301
cover (1).
• Install the gasket (2) to the inlet cover side. 13. Install the common rail.
• Order for temporal tightening: nuts (1) before
bolts (2).
MG6HK-WE-0871.book 212 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-212 Engine Mechanical (6HK1)

• Order for complete tightening: bolts (2) before
nuts (1).

Tightening torque N⋅m (kg⋅m / lb⋅ft) 2

1
25 (2.5 / 18)

5
MFW81BSH009001

Legend
1. Common rail (Fuel rail)
2. Pressure limiter
2 3. Fuel leak-off pipe
4. Fuel suction pipe
5. Pressure feed pipe
MFW61BSH001301

17. Install the injection pipe and tighten the sleeve nut.
14. Install the pressure feed pipe (5).

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Tightening torque N⋅m (kg⋅m / lb⋅ft)
Injector side 30 (3.1 / 22)
Supply pump side 44 (4.5 / 33)
Common rail side 25 (2.6 / 19)
Common rail side 44 (4.5 / 33)

15. Install the fuel suction pipe (4) to the supply pump
and fix it with a clip.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

18 (1.8 / 13)

16. Install the fuel leak-off pipe (3).

• Assemble a new gasket to each connecting
section.
• Fix each part with a clip after tightening it.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Supply pump side 10 (1.0 / 87 lb⋅in)
Common rail side 20 (2.0 / 14)
MG6HK-WE-0871.book 213 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-213

2
5
4 6 1
3
2
1
3

7
4

MFW81BSH008901 MFW81BSH008701

Legend Legend
1. Injection pipe # 1 1. Intake pipe
2. Injection pipe # 2 2. Bracket
3. Injection pipe # 3 3. Gasket
4. Injection pipe # 4 4. Inlet cover
5. Injection pipe # 5
6. Injection pipe # 6
7. Common rail (Fuel rail)
19. Install the boost sensor (1).

18. Install the intake pipe . Tightening torque N⋅m (kg⋅m / lb⋅in)
2 (0.2 / 17)

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Intake pipe 25 (2.5 / 18)

MFW81BSH008601

20. Install the heat protector to the exhaust manifold

and air duct bracket.
MG6HK-WE-0871.book 214 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-214 Engine Mechanical (6HK1)

• It thrusts and temporary tightening of the upper
part bolt of heat protector attachment is carried • Fasten the gasket, and install the turbocharger
out until. to the exhaust manifold.
• The plain washer (2) and the dish washer (3) in
a lower stud and it tightens.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Air duct bracket side 20 (2.0 / 14)
Exhaust manifold side 41 (4.2 / 30) Tightening torque N⋅m (kg⋅m / lb⋅ft)
52 (5.3 / 38)

3
2

3
4

MFW81BSH009501

Legend MFW41BSH026501

1. Air duct bracket

2. Exhaust manifold (front)
3. Exhaust manifold (rear) 22. Install the exhaust pipe adapter.
4. Heat protector • Fasten the gasket (2) between the turbocharger
(1) and the exhaust pipe adapter (3) and install
it.
21. Install the turbocharger. • The bolt is previous tightened.
• Refuel the appropriate amount of oil from the oil
inlet hole (1) of the turbocharger, and rotate the Tightening torque N⋅m (kg⋅m / lb⋅ft)
turbine shaft to lubricate the shaft bearing
section. Nut and Bolts 26 (2.7 / 20)

MFW41BSH026401
MG6HK-WE-0871.book 215 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-215

NOTE:
Make sure to use a new gasket to prevent oil leakage.

3
2 Tightening torque N⋅m (kg⋅m / lb⋅ft)
1 Turbocharger side 28 (2.9 / 21)
Cylinder block side 18 (1.8 / 13)

MFW81JSH000901

3
4
23. Install the exhaust pipe adapter bracket.
• Tighten A previously (A to B).

5
Tightening torque N⋅m (kg⋅m / lb⋅ft)
71 (7.2 / 52) MFW81HSH001201

Legend
1. Cylinder block
2. Turbocharger
3. Gasket
A
4. Oil return pipe
5. Gasket
B

25. Install the turbocharger oil feed pipe.

• Install the turbocharger oil feed pipe (2) to the
cylinder block (1).

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Turbocharger side 34 (3.5 / 25)
1
2 Cylinder block side 41 (4.2 / 30)
3
MFW81BSH009601

Legend
1. Turbocharger
2. Exhaust pipe adapter bracket
3. Exhaust manifold

24. Install the turbocharger oil return pipe.

• Install the oil pipe to the turbocharger and
cylinder block.
MG6HK-WE-0871.book 216 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-216 Engine Mechanical (6HK1)

4
1 2
3

2
1

3
5
MFW81HSH001101 MFW81CSH001001

Legend Legend
1. Cylinder block 1. Water pipe bracket
2. Turbocharger oil return pipe 2. Turbocharger water feed pipe
3. Turbocharger 3. Water pipe bracket
4. Turbocharger
5. Air compressor

26. Install the turbocharger water feed pipe.

NOTE: 27. Install the turbocharger water return pipe.

Make sure to use a new gasket to prevent coolant
leakage. NOTE:
Make sure to use a new gasket to prevent coolant
leakage.
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Turbocharger side 41 (4.2 / 30)
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Air compressor side 50 (5.1 / 37)
Turbocharger side 41 (4.2 / 30)
Cylinder head side 50 (5.1 / 37)
MG6HK-WE-0871.book 217 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-217

3 4
2

MFW81BSH009701

Legend
1. Inlet pipe
2. Turbocharger
4
3. Heat protector
4. Rubber hose
5

29. Connect the connector of the oil pressure switch.

MFW81CMH000301
30. Install the air cleaner outlet duct (1) to the
Legend turbocharger (3), and tighten it with a air duct
1. Cylinder head cover clamp (2).
2. Cylinder head
3. Rubber hose
4. Turbocharger water return pipe
5. Turbocharger
3
2

28. Install the inlet pipe (turbocharger out). 1

Tightening torque N⋅m (kg⋅m / lb⋅ft)

18 (1.8 / 13)

MFW81BSH009801

31. Install the air compressor to the flywheel housing.

• Tap the key into the shaft of the air compressor,
and tighten the installation nut of the drive gear
at the specified torque.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

147 (15 / 108)
MG6HK-WE-0871.book 218 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-218 Engine Mechanical (6HK1)

2
2
1

MFW61BSH005401
4 BLW71BSH015501

Legend Legend
1. Gear 1. Compressor
2. Key 2. Bolt (Long)
3. Bolts
4. Nut

• Apply liquid gasket (ThreeBond 1208 or CH

Dine 290) equally to three parts on the 32. Install the air compressor oil feed pipe (2) to the air
circumference of the O-ring, and install the O- compressor (3) and the cylinder block (1).
ring in the groove of the air compressor. • Use a new gasket.

Tightening torque N⋅m (kg⋅m / lb⋅ft) Tightening torque N⋅m (kg⋅m / lb⋅ft)
73 (7.4 / 54) Cylinder block side 41 (4.2 / 30)
Air compressor side 28 (2.9 / 21)

3
MFW61BSH005501

MFW81HSH001301
MG6HK-WE-0871.book 219 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-219

33. Install the air compressor water pipes (1) and (3).

1 2 3
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Air compressor side 50 (5.1 / 37)
Water pipe adaptor side 41 (4.2 / 30)

MFW81BSH010601

35. Install the air breather hose (2).

4

Tightening torque N⋅m (kg⋅m / lb⋅ft)

M6 Bolt 9 (0.9 / 78 lb⋅in)
3
M10 Bolt 40 (4.1 / 30 )
2

MFW81BMH000301

Legend
1. Water pipe (return to turbocharger)
2. Air compressor
3. Water pipe (feed)
4. Water feed adaptor

34. Install the charge air pipe (1) and governor air
pipe(2) to the air compressor (3).
• Install the charge pipe and governor pipe with a
clip.

NOTE:
Apply oil so that it does not turn together with the
eyebolt. Never use soapy water, etc.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

Charge air pipe side (Dry) 64 (6.5 / 47)
Governor air pipe side 27 (2.8 / 20)
MG6HK-WE-0871.book 220 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-220 Engine Mechanical (6HK1)

38. Install the inlet pipe (1).

2 Tightening torque N⋅m (kg⋅m / lb⋅ft)

M8 Nut 18 (1.8 / 13)
ABA W4 Stainless clamp 6.4 (0.65 / 56 lb⋅in)
NORMA W1 Steel clamp 8 (0.9 / 69 lb⋅in)

1
1
2

MFW81BSH010301
MFW81BMH000201

Legend
1. Head cover 39. Install the guide tube (1) into the crankcase, and fix
2. Air breather hose the stay section.
3. Intake pipe
• Insert the O-ring into the guide tube, and press
it in until it touches the hole of the crankcase.

36. Install the suction air pipe to the air compressor.

Tightening torque N⋅m (kg⋅m / lb⋅ft)
37. Install the fan guide stay (1).
Full cab and Wide cab 24 (2.4 / 17)

NOTE:
Take care not to cut the O-ring.

MFW71BSH004301
MG6HK-WE-0871.book 221 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-221

Full cab and Wide cab (rigid cab mounting
model)

1
MFW81BSH008301

MFW71BSH006001

40. Insert the oil level gauge. Legend

41. Install the engine harness (1) to each connector, 1. Air cleaner
and clip it in the designated position. 2. Intake duct

Full cab and Wide cab (coil spring cab

mounting model)
1

MFW81BSH010101

MFW71BSH006101

42. Install the intake duct. Legend

1. Air cleaner
2. Intake duct
Tightening torque N⋅m (kg⋅m / lb⋅in)
ABA W4 Stainless clamp 6.4 (0.65 / 56)
NORMA W1 Steel clamp 8 (0.8 / 69)
MG6HK-WE-0871.book 222 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-222 Engine Mechanical (6HK1)

Tightening Torque Table
Left side (with MZW transmission)

d
b c
a

k j i

MFW81BMF005101

(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

(b) 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
(c) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(d) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side
25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side
(e) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(f) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in) Supply pump side
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) Common rail side
(g) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
77 N⋅m (7.9 kg⋅m / 57 lb⋅ft)
(h) 6 N⋅m (0.6 kg⋅m / 52 lb⋅in)
(i) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(j) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(k) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
MG6HK-WE-0871.book 223 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-223

Right side (with MZW transmission)

d e
c
b

f
a

h g
k i
j

MFW81BMF005201

(a) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(b) 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
(c) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)
(d) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft) Turbocharger side
41 N⋅m (4.2 kg⋅m / 30 lb⋅ft) Cylinder block side
(e) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(f) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(g) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(h) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(i) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft) Turbocharger side
18 N⋅m (1.8 kg⋅m / 13 lb⋅ft) Cylinder block side
(j) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft) Cylinder block side
28 N⋅m (2.9 kg⋅m / 21 lb⋅ft) Air compressor side
(k) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(l) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
MG6HK-WE-0871.book 224 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-224 Engine Mechanical (6HK1)

Left side (without MZW transmission)

c d
b
a

k j i
h

MFW81BMF005301

(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

(b) 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
(c) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(d) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side
25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side
(e) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(f) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in) Supply pump side
20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) Common rail side
(g) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
77 N⋅m (7.9 kg⋅m / 57 lb⋅ft)
(h) 6 N⋅m (0.6 kg⋅m / 52 lb⋅in)
(i) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(j) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(k) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
MG6HK-WE-0871.book 225 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-225

Right side (without MZW transmission)

d e
c
b

a
f

h g
i
j

MFW81BMF005401

(a) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(b) 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
(c) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)
(d) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft) Turbocharger side
41 N⋅m (4.2 kg⋅m / 30 lb⋅ft) Cylinder block side
(e) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(f) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(g) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(h) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(i) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft) Turbocharger side
18 N⋅m (1.8 kg⋅m / 13 lb⋅ft) Cylinder block side
(j) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft) Cylinder block side
28 N⋅m (2.9 kg⋅m / 21 lb⋅ft) Air compressor side
(k) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(l) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
MG6HK-WE-0871.book 226 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-226 Engine Mechanical (6HK1)

Cylinder Head (Euro 4 specification)

Component Parts

5
1

2
6
25
7
3 24 8

4 23
9
10
22
11
12

13
21

20

18
19 14
17
16

15
MFW71BLF001401

Legend
1. Noise cover 14. Head gasket
2. Head cover 15. Water duct
3. Gasket 16. Plate
4. Bracket 17. O-ring (water pump)
5. Connector 18. O-ring
6. Harness assembly 19. Rubber plug
7. Injector leak-off pipe 20. Glow plug connector (with glow plug)
8. Injector clamp 21. Glow plug (or dummy glow plug)
9. Injector assembly 22. Camshaft
10. Gasket 23. Rocker arm assembly
11. Bridge cap 24. Gasket
12. Bridge 25. Lower case
13. Cylinder head assembly
MG6HK-WE-0871.book 227 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-227

Removal
NOTE:
Seal the inlet duct hole, supply pump and other such
places so that debris cannot enter.

1. Remove the engine exterior parts. Refer to “Engine

Exterior Parts”.
2. Remove the injection pipe.
1
3. Remove the noise cover. 2

3
1

BLW71BSH008901

Legend
1. Bracket
2. Head cover
2 3. Bolt

5. Remove the head cover.

BLW71BSH008301 NOTE:
Legend Make sure you do not lose the collar that is inside the
1. Noise cover head cover.
2. Head cover
6. Remove the gasket.

4. Remove the noise cover bracket.

NOTE:
If the bracket is not damaged, do not remove it.

BLW71BSH009001

7. Remove the lower case.

MG6HK-WE-0871.book 228 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-228 Engine Mechanical (6HK1)

8. Remove the gasket.

MFW41BSH026201
MFW71BSH005001

• Take out the injector harness terminal.

9. Remove the glow plug connector. (with glow plug)
10. Remove the glow plug. (or dummy glow plug) 3

LNW71DSH003601

Legend
LNW21BSH055301 1. Injector
2. Injector harness
3. Terminal nut
11. Remove the harness assembly.
• Push the arrowed section of the connector with
your fingers to remove it.

NOTE:
Do not pull the wires or pry the connector with a
screwdriver.
MG6HK-WE-0871.book 229 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-229

• Remove the harness bracket with the harness • If it is difficult to remove the injector, set the
still attached. injector remover (5-8840-2826-0) on the
injector, tighten the bolt into the leak- off pipe
fitting, and using the sliding hammer small (5-
8840-0019-0) pull the injector out in an upward
direction.
2
1 NOTE:
• When removing the injector using this special tool,
make sure that the injector sleeve is not removed as
well.
• The ID plate is unique to each injector, so install a
number tag to it before storing it to ensure that it is
not used on a different injector.
• He injector and glow plug protrude from first to
prevent them from being damaged.

MFW41BSH027101

Legend
1. Harness terminal 1
2. Harness bracket

2
12. If there are no malfunctions with the connector, do
not remove it.
13. Remove the rubber plug.
14. Remove the injector leak-off pipe.
15. Remove the injector clamp.
• Loosen the injector clamp bolt using a torque
wrench (T-40).

LNW46CMH000301

Legend
1. Sliding hammer small
2. Injector remover
3. Injector assembly

MFWA1BSH003101

NOTE:
16. Remove the injector assembly.
• Indicate the cylinder No. on the removed injector
• Loosen the clamp, and use the replacer to
before storing the injector.
remove the injector.
• Be careful not to strike the injection nozzle against a
hard surface.
MG6HK-WE-0871.book 230 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-230 Engine Mechanical (6HK1)

24. Remove the camshaft.

NOTE:
After inspecting the removed bearing, temporarily
install the removed cap and bearing in their previous
locations so as not to confuse them with other parts.

MFW71BSH005301

17. Remove the gasket.

18. Remove the plate.
19. Remove the water duct.
BLW51BSH001501
20. Remove the O-ring.
21. Remove the O-ring (water pump).
22. Remove the rocker arm assembly.
25. Remove the cylinder head assembly.
• Loosen both sides of the cam rocker arm shaft
• Loosen and remove the attachment bolts from
bracket and rocker arm assembly bracket
the outside in the numerical order shown in the
attachment bolts equally and remove them.
diagram.
NOTE:
NOTE:
If the attachment bolts (arrow) on both ends of the cam
Before lifting the cylinder head, check that all of the
rocker arm shaft brackets are removed, the rocker arm
bolts have been removed.
and bracket may spring out. Therefore, they should not
be removed.

MFW61BSH000301

23. Remove the bridge and bridge cap.

• Keep them in the order they were attached.
MG6HK-WE-0871.book 231 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-231

3 7 11 15 19 23 27 26 22 18 14 10 6 2

4 8 12 16 20 24 28 25 21 17 13 9 5 1

MFW41BSF000101

NOTE:
When the cylinder head is removed, idle gear C (1)
protrudes from the bottom of the cylinder head. Ensure
that the gear is not damage.

MFW41BSH002901

26. Remove the head gasket.

• Check for the presence of gas or water leaks.
MG6HK-WE-0871.book 232 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-232 Engine Mechanical (6HK1)

Disassembly

1
2
29 4 6
28 5
3
27
26
25
24
7
22 23
8
9

21

20

10
18

19 16
17

11

12

15

14

13
MFWB1BLF002601

Legend
1. Bridge cap 16. Engine coolant temperature sensor
2. Bridge 17. Valve
3. Bridge guide 18. Valve seat insert
4. Nozzle sleeve 19. Thermostat
5. Idle gear C 20. Gasket
6. Idle gear C cover 21. Water outlet pipe
7. Engine hanger 22. Engine hanger
8. Oil seal 23. Cylinder head
9. Gasket 24. Spring seat
10. Inlet cover 25. Valve guide
11. Exhaust manifold (Front) 26. Valve stem oil seal
12. Heat protector 27. Valve spring
13. Heat protector 28. Spring upper seat
14. Exhaust manifold (Rear) 29. Split collar
15. Gasket

NOTE: rest it on wooden planks to prevent the idle gear C that

When placing the cylinder head assembly on the floor, protrudes from the bottom from getting damaged.
MG6HK-WE-0871.book 233 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-233

1. Remove the bridge cap.
2. Remove the bridge.
3. Remove the intake cover.
4. Remove the gasket (intake cover).
5. Remove the heat protector.
6. Remove the exhaust manifold.
7. Remove the gasket (exhaust manifold).
8. Remove the bracket.
9. Remove the heat protector. 2
10. Remove the engine hanger.
11. Remove the engine coolant temperature sensor. 1
12. Remove the water outlet pipe.
13. Remove the thermostat.
14. Remove the gasket (thermostat).
15. Remove the camshaft position sensor. BLW51BSH000101
16. Remove the idle gear C cover. Legend
• Gently tap the outer perimeter of the sealing 1. Idle gear C
cup with the tip of a screwdriver (1) as shown in 2. Shaft
the diagram, then invert the cup and use pliers
etc. to extract it.

NOTE: 18. Remove the split collar.

Be sure not to damage the cover insertion section. • Place the cylinder head on wooden planks.
• Use a valve spring replacer (5-8840-2621-0)
and pivot (8-9439-6862-0) remove the split
collar, then remove the spring seat, spring,
seal, and valve. At this time, also remove the
spring seat that is inserted in the lower side of
the spring.
• Install tickets numbered according to cylinder to
the removed valves.

MFW41BSH009701

17. Remove idle gear C.

• Extract the idle gear shaft and remove the
gears.

MFW41BSH009801

19. Remove the valve spring upper seat.

20. Remove the valve spring.
21. Remove the valve.
MG6HK-WE-0871.book 234 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-234 Engine Mechanical (6HK1)

22. Remove the valve stem oil seal.
23. Remove the valve spring seat.

MFW41BSH010101

MFWB1BSH003201
26. Remove the nozzle sleeve. Place a injector sleeve
remover (5-8840-2623-0) against the bottom side
24. Remove the valve guide. of the head, and hit it to extract the sleeve.
• Insert the valve guide replacer (5-8840-2628-0) NOTE:
into the valve guide from the bottom of the
head, and hit it with a hammer to extract it. • Make sure you do not damage the bottom side of
the head.
• Do not re-use extracted nozzle sleeves.

MFW41BSH010001

MFW41BSH010201
25. Remove the valve seat insert.
• Use a welding burner to burn 2 sections (700 to
800°C / 1292 to 1472°F) on the inner surface of
27. Remove the bridge guide.
the insert, leave it to self cool for between 3 to 5
minutes, then extract it with a screwdriver. • Electrically weld the bridge guide head section
nut (1), install a sliding hammer and extract it.
CAUTION: • Do remove it if there is no wear.
Do not rapidly cool it. Do not damage the cylinder head
when extracting.
MG6HK-WE-0871.book 235 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-235

• Check there is no hesitance in the bridge and
bridge guide.
• Measure the gap between the bridge and
bridge guide.

Gap
1
Assembly standard Limitations for use
0.020 – 0.056 mm 0.1 mm
(0.0008 – 0.0022 in) (0.004 in)

MFW41BSH010301

28. Remove the oil seal.

Place a dolly against the inside of the head, and hit
it to extract the seal.

Inspection
1. Inspect the bridge cap.
• Inspect the cap and rocker arm adjustment bolt
strike surface for wear or damage. MFW41BSH010601
• If the amount of wear is greater than 0.1 mm
(0.004 in), or if linear wear has occurred,
replace it. 3. Measure the idle gear C (1) axial direction gap.
• Measure idle gear C axial direction gap and the
Bridge cap wear limit shaft diameter.
0.1 mm (0.004 in)
Axial direction gap
Nominal Assembly Limitations
dimensions standard for use
0.09 – 0.144 mm 0.2 mm
—
(0.004 – 0.0057 in) (0.008 in)

Shaft diameter
Nominal Assembly Limitations
dimensions standard for use
30 mm 29.85 mm
—
(1.18 in) (1.175)

MFW41BSH010501

2. Inspect the bridge.

MG6HK-WE-0871.book 236 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-236 Engine Mechanical (6HK1)

Free length
Nominal Limitations for
dimensions use
Inlet 59.9 mm 58.7mm
(2.36 in) (2.31 in)
Exhaust 70.3 mm 68.9 mm
(2.77 in) (2.71 in)

BLW51BSH002301

4. Measure the valve spring.

• Measure the squareness of the valve spring.

Squareness
Assembly Limitations for use
standard
Inlet — 3.4 mm (0.13 in)
MFW41BSH010901
Exhaust — 3.4 mm (0.13 in)
• Measure the load of the valve spring when
attached.

Attached load/attached length N (kgf / lb)

Assembly Limitations for
standard use
333 (34.0 / 75.0) / 315 (32.1 / 70.8) /
Inlet
47 mm (1.85 in) 47 mm (1.85 in)
490 (50.0 / 110.0) 463 (47.2 / 104) /
Exhaust
/47 mm (1.85 in) 47 mm (1.85 in)

MFW41BSH010801

• Measure the free length of the valve spring.

MG6HK-WE-0871.book 237 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-237

• Insert a valve into the valve guide, and
measure the looseness of the valve at a
position (a) 10 mm (0.3937 in) from the top of
the guide.

Gap between valve guide and valve stem

Assembly standard Limitations
for use
0.039 – 0.071 mm 0.2 mm
Inlet valve
(0.0015 – 0.0028 in) (0.008 in)
0.064 – 0.096 mm 0.25 mm
Exhaust valve
(0.0025 – 0.0038 in) (0.01 in)

MFW41BSH011001

5. Inspect the valve.

• Measure the valve stem abrasion. 1
• Measure the 3 locations in the diagram.
a

Valve stem outer diameter

Nominal dimensions Limitations for use 2

8 mm (0.315 in) 7.88 mm (0.310 in)

• If the amount of valve stem abrasion exceeds

the limit, replace both the valve and the valve
guide. MFW61BSH001501

Legend
1. Valve
2. Valve guide

• Measure the thickness of the valve.

Valve thickness
Nominal Limitations for
dimensions use
Inlet valve 1.71 mm
(0.0673 in) 1.3 mm
Exhaust valve 1.75 mm (0.051 in)
(0.0689 in)
MFW41BSH011101
MG6HK-WE-0871.book 238 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-238 Engine Mechanical (6HK1)

Amount of valve depression

Nominal dimensions Limitations
for use
0.73 – 1.10 mm 2.3 mm
Inlet valve
(0.0287 – 0.0433 in) (0.091 in)
1.16 – 1.54 mm 2.8 mm
Exhaust valve
(0.0457 – 0.0606 in) (0.110 in)

MFW41BSH011301

• Inspect and repair the valve seat striking 3

surface. 2
• Apply red lead paint to the valve insert, and
inspect the width of the seat striking surface.
Also, inspect for lack of strike, and that the
strike position is in the center of the valve seat
face.
MFW51BSH003501

Width of seat striking surface Legend

1. Striking width
Assembly standard 2. Amount of depression
Inlet valve 2.7 mm (0.106 in) 3. Seat angle
Exhaust valve 2.7 mm (0.106 in)

• If there is a defect in the valve striking width or Perform valve slide matching
the striking surface, use a seat cutter that • Apply compound to the valve striking surface,
matches the stem diameter to repair it. and perform sufficient slide matching between
the valve seat and valve striking surface.

Valve seat angle (deg)

Inlet valve 30
Exhaust valve 45

Valve stem diameter

8 mm (0.315 in)

• After valve seat grinding, measure the amount

of valve depression to be sure that it is within
the useable limit.

MFW41BSH011601
MG6HK-WE-0871.book 239 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-239

• After valve slide matching, clean the cylinder

head and valve.
6. Inspect the valve seat insert.
• Measure the amount of valve depression (1).
• Insert a new valve into the valve guide, and
measure the dimensions from the bottom of the
cylinder head to the valve surface.

Amount of valve depression

Nominal dimensions Limitations
for use
0.73 – 1.10 mm 2.3 mm
Inlet valve
(0.0287 – 0.0433 in) (0.091 in)
1.16 – 1.54 mm 2.8 mm
Exhaust valve
(0.0457 – 0.0606 in) (0.110 in) MFW41BSH011801

• Inspect the cylinder head for cracks and

damage.
• Inspect using a magnetic flaw detector or dye
penetrant testing method if necessary.

NOTE:
When magnetizing using the magnetic flaw detector,
always demagnetize when the test is complete.
(Remnant magnetism is less than 5G)

MFW41BSH011701

7. Inspect the cylinder head.

• Measure the amount of distortion of the cylinder
head.
• Clean off the carbon without damaging the
processing surfaces of the cylinder head, valve
seat, insert etc.
• Place a straightedge against the mounting
surface of the cylinder head, and measure the MFW41BSH011901
amount of distortion in locations A to F on the
diagram using a thickness gauge.
• With the hydraulic test, apply 490 kPa (5 kgf/
Amount of distortion cm2/71 psi) of water pressure for 3 minutes,
and inspect each section of the head for water
Limitations for use 0.2 mm (0.008 in) leaks.

NOTE: NOTE:
Cannot be repaired because the timing gear backlash Perform the hydraulic test with the nozzle holder
will change. attached.
MG6HK-WE-0871.book 240 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-240 Engine Mechanical (6HK1)

Reassembly • Apply engine oil to the outer periphery of the
guide, and use a bridge guide setting tool (5-
1. Install the oil seal to the cylinder head.
8840-2626-0) to hammer it in to the finishing
• Use a oil seal installer (5-8840-2627-0). depth of the cylinder head hole. (Reference:
• Hit the seal evenly so that it does not slant. The bridge guide height is approx. 37.5 mm
(1.476 in) (b) from the head upper surface)
NOTE:
Take care not to damage the lip section.

b
a
MFW61BSH000901

MFW41BSH012001 (a) 122.5 mm (4.823 in)

(b) 37.5 mm (1.476 in)

3. Install the nozzle sleeve.

• Install the O-ring (1) and (2) to the nozzle
sleeve, and apply engine oil.
1 2
3 • Apply sealant (LOCTITE LT620) to the nozzle
sleeve tapered section (3).

MFW81BSH006201

Legend
1. Cylinder head
2. Oil seal
3. Oil seal installer

2. Install the bridge guide.

MG6HK-WE-0871.book 241 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-241

• Apply engine oil (4) to nozzle sleeve installation
side.

1
2

2
3 6
5 3

LNW21BMH001001

Legend
MFW61BMH000101
1. Punch bar
Legend 2. Ball
1. O-ring (white paint) 3. Guide sleeve
2. O-ring 4. Nozzle sleeve
3. Apply LOCTITE 5. Injector clamp
4. Apply engine oil 6. Injector clamp bolt

4. Install the valve seat insert.

• Install the injector sleeve setting tool (5-8840- • Carefully clean off the carbon, rust, etc. from
2624-0) and install nozzle sleeve to the cylinder the mounting surface of the insert, and press fit
head. the insert using a press.
• Push the nozzle sleeve in with a guide sleeve
so that it is firmly seated at the bottom side of
the cylinder head.
• After inserting the guide sleeve, fix it with the
injector clamps and injector clamp bolts.
• Insert the ball (bearing steel ball 9.525 mm/
0.375 in) into the guide sleeve, and use a
punch bar and hammer to knock the ball out.

NOTE:
• After carefully removing the shavings from the
cylinder head screw section, insert the sleeve.
• Lift the cylinder head so that the ball can come out
from the bottom.

MFW41BSH012401
MG6HK-WE-0871.book 242 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-242 Engine Mechanical (6HK1)

1
a

LNW21BSH018601 LNW71BSH001701

Legend
1. Dolly
2. Insert 6. Install the lower spring seat.
3. Press 7. Install the valve stem oil seal.
• Apply oil to the oil seal, and use a valve stem
seal setting tool (5-8840-2625-0) to tap in the
5. Install the valve guide.
valve guide.
• Hammer in the valve guide from the upper
surface of the cylinder head, using the valve NOTE:
guide replacer (5-8840-2628-0) and valve guide Check the valve seal for shape deformation and
installer (5-8840-2930-0). cracks, and that the spring has not detached.

NOTE:
Replace the valve guide as a set with the valve.

MFW41BSH012601

MFW41BSH012501 8. Install the valve.

• Apply engine oil to the valve stem, and insert
the cylinder head.
Dimensions (a) of the valve guide surface from the
cylinder head upper surface NOTE:
Check the assembly of the valve.
17.1 – 17.9 mm (0.6732 – 0.7047 in)
“ E “ Mark : Exhaust
“ I “ Mark : Inlet
MG6HK-WE-0871.book 243 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-243

MFW41BSH012701 MFW41BSH009801

9. Install the valve spring. 12. Install a gasket in the thermostat flange part.
• Place the cylinder head on wooden planks. 13. Install the thermostat.
• Install the valve spring with the side that has the • Install the rubber gasket to the flange section.
identification paint facing the cylinder head • Line up the position of the jiggle valve (1) as
surface. shown in the diagram.

Identification paint
Inlet valve spring Blue
Exhaust valve spring Red

10. Install the spring upper seat.

11. Install the split collar.
• Use a valve spring replacer (5-8840-2621-0)
and pivot (8-9439-6862-0) to push the valve
1
spring in, then install the split collar.
• After attaching, gently hit the valve stem head
section with a rubber mallet so the split collar
falls into place.

NOTE:
Check that the split collar is firmly in the valve stem MFW91BSH000801
slot.

14. Install the water outlet pipe.

• Install the thermostat as shown in the diagram,
and install the water outlet pipe.

Tightening torque
24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

NOTE:
If you install the thermostat in the wrong position, you
will not be able to install the water outlet pipe.
MG6HK-WE-0871.book 244 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-244 Engine Mechanical (6HK1)

1
2

3 2

MFW41BSH013101 MFW71BSH006301

Legend Legend
1. Water outlet pipe 1. Plug
2. Incorrect attachment prevention stopper 2. Engine coolant temperature sensor
3. Thermostat with jiggle valve 3. Plug

15. Install the engine coolant temperature sensor.

• Install the Plug in position (1), (3) shown in the 16. Install the rear side engine hanger (2) to the
diagram. cylinder head.
• Apply ThreeBond 1207C or LOCTITE 271 to
the thread section and attach. Tightening torque
94 N⋅m (9.6 kg⋅m/69 lb⋅ft)
Tightening torque
•

Plug (1) 108 N⋅m (11 kg⋅m/80 lb⋅ft)

Plug (3) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
1
• Install the engine coolant temperature sensor in
position (2) shown in the diagram.
• The thread section of the new plug switch is
treated with plating processing.
When reusing plug switches, apply ThreeBond
1207C or LOCTITE 271, and install to the
location shown in the diagram.
• Apply LOCTITE 262 or 962 to the engine
coolant temperature sensor threaded portion
and tighten at the specified torque.

Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft) MFW61BSH000701

17. Install the bracket.

Tightening torque
28 N⋅m (2.9 kg⋅m/21 lb⋅ft)
MG6HK-WE-0871.book 245 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-245

NOTE:
Install before assembling the exhaust manifold.

MFW41BSH013501

Legend
1. Casting surface side
MFW71BSH005501
2. Gasket

18. Install the exhaust manifold gaskets.

• Install so that the protruding section of the 19. Install the exhaust manifold.
gaskets is down. • Move each of the seal ring alignment holes
120° and assemble them to the rear exhaust
manifold.

1 2 3

MFW41BSH013401

NOTE: MFWB1BSH003401
Check that the gasket is securely attached to the Legend
cylinder head. If it is attached incorrectly, it will ride up 1. Exhaust manifold (rear side)
on the casting surface side of the cylinder head as 2. Seal ring
shown in the diagram. 3. Exhaust manifold (front side)
MG6HK-WE-0871.book 246 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-246 Engine Mechanical (6HK1)

• Install the exhaust manifold. • Tighten them in the order shown in the diagram.
Exhaust nut (10 pieces)
Tightening torque
55 N⋅m (5.6 kg⋅m/41 lb⋅ft)

Exhaust distance nut (2 pieces)

Tightening torque
34 N⋅m (3.5 kg⋅m/25 lb⋅ft) 1
4
11 8 69
• Assemble the distance tube, flat washer and 7 3 2 5 10
coned disc spring washer as shown in the 12
diagram, and tighten the exhaust manifold.
• Only the distance nut can be re-used.

1 2
MFW61BSH000601

20. Install the heat protector.

21. Install the inlet cover.
3
• Install the gasket to the inlet cover (1), and
tighten in the order shown in the diagram.

4
Tightening torque
25 N⋅m (2.5 kg⋅m/18 lb⋅ft)

MFWB1BSH003501

Legend
1. Distance tube
2. Nut
3. Coned disc spring washer
4. Distance nut

• Tighten the distance nut (arrow) in the 7th and

12th attachment positions shown in the
diagram.
1

MFWA1BSH001901
MG6HK-WE-0871.book 247 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-247

NOTE:
Remove any deposits, carbon, sealing compound, etc.
from the upper surface and lower surface of the
cylinder block.

Reamer bolt

13 9 6 7 10 14
3

12 2 5 1 4 8 11

MFWB1BSH003601

22. Apply engine oil to the bridge and install it.

NOTE: MFW41BSH003001
Move it up and down to check that it moves smoothly.
2. Install the cylinder head assembly.
23. Apply engine oil to the bridge cap and install it. • Install the dowel to the cylinder block, line up
the cylinder head bolt holes and gently rest it
on.

MFW41BSH014001

MFW41BSH003101
Installation
1. Install the head gasket.
• Apply approx. 2 mm (0.0787 in) thickness, • Apply molybdenum-disulfide to the thread
approx. 3 mm (0.1181 in) width of liquid gasket section and seating surface of the M14 bolts,
(ThreeBond 1207C) to the alignment sides of and engine oil to the thread section of the M10
the cylinder block and flywheel housing, and bolts, and tighten them to the specified torque
install the head gasket. and angle in the order shown in the diagram.
• After applying the liquid gasket, install the
cylinder head within 5 minutes.
MG6HK-WE-0871.book 248 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-248 Engine Mechanical (6HK1)

Tightening torque
98 N⋅m (10.0 kg⋅m/72 lb⋅ft) →
M14 bolt 147N⋅m (15.0 kg⋅m/108 lb⋅ft) →
Angle method 30° to 60°
M10 bolt
38 N⋅m (3.9 kg⋅m/ 28 lb⋅ft)
(#27, 28)

26 22 18 14 10 6 2 3 7 11 15 19 23 27

25 21 17 13 9 5 1 4 8 12 16 20 24 28

BLW71BSF000101

NOTE: 1. Position the marked line (2) on the crank

To check the tightness of the M14 bolts, rotate the tool pulley and the alignment mark (1) on the
in the tightening direction. gearcase cover and set to compression top
dead center of the first cylinder.

Checking tightening torque

142 N⋅m (14.5 kg⋅m/105 lb⋅ft) 1

3. Install idle gear C.

a. Assembly of the idle gear C

NOTE:
When disassembling the idle gear C, assemble it while
paying attention to the following points because it is
difficult to position the idle gear C shaft.

2
MFWB1BSH003301

2. With the idle gear B assembled, insert the

idle gear C from above the cylinder head.
• Apply engine oil to the inner
circumference of the idle gear C bushing
and the thrust bearing surface.
MG6HK-WE-0871.book 249 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-249

3. Apply engine oil to the outer circumference 2. Assemble the camshaft with the gear
of the shaft and pass from the cylinder head installed to mesh with the idle gear C
rear surface hole to the gear center hole. installed to the cylinder head.
4. Apply engine oil to the both surfaces of the At this time, when the marked line on the
thrust collar, and molybdenum disulfide to crank pulley and alignment mark on the front
the threaded portion of the bolt and seat cover are positioned compression top dead
surface. Assemble the bolt which is installed center of the first cylinder), install so that the
to the thrust collar. alignment mark B on the camshaft gear
However, the bolt should be tightened at a matches the top surface of the cylinder
torque of 40 N⋅m (4.1 kg⋅m/30 lb⋅ft), and head.
loosen by 30° – 90° after tightening.
(Confirm that the idle gear C moves.)

1
2 3

MFW41BSH003201
6

3. Set the cam bearing upper to the camshaft

cap, and apply engine oil to the bearing
inner circumference.
4. Assemble the #2, #3, and #4 caps (1).

Apply engine oil to the threaded portion and seat

surface
BLW71BMH000501 Tightening torque
Legend Cap bolts 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
1. Insertion Direction Cap nuts 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
2. Shaft
3. Thrust Collar NOTE:
4. Bolt Do not assemble the rocker arm.
5. Idle Gear C
6. Bushing

b. Installation of the camshaft gear.

1. Set the cam bearing lower to the cylinder
head. Apply engine oil to the bearing inner
circumference.
MG6HK-WE-0871.book 250 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-250 Engine Mechanical (6HK1)

2. Hold down the camshaft gear by hand and
tighten the idle gear C bolt at the specified
torque.

1
Apply molybdenum disulfide to the threaded
portion and seat surface
Tightening torque
Idle gear C bolt 71 N⋅m (7.2 kg⋅m/ 52 lb⋅ft)

NOTE:
When tightening, be careful that the idle gear C shaft
position does not move a lot.

3. After tightening the idle gear C, check the

backlash to ensure that it is within the
standard value below.
BLW71BSH009901

Between the idle gear C and camshaft gear

c. Tightening the idle gear C. 0.015 – 0.146 mm (0.0006 – 0.0057 in)
1. Manually rotate the camshaft gear in the left
direction (when looking from the engine If the camshaft gear does not move with
rear) (2), gently mesh the idle gear C to the rattling when manually moving it, there is the
direction of the arrow (1) in the diagram, and possibility that the backlash has excessively
set the idle gear C shaft position. built up. Check the backlash and readjust.

NOTE: NOTE:
Be careful as backlash can excessively build up if too If the backlash cannot be adjusted, assembly with the
much force is applied when rotating the camshaft gear. service idle gear C shaft (8-97186-398-1).

4. Remove the cam cap and camshaft.

5. Use a flat blade screwdriver (large size),
etc., to check the backlash of the idle gear C
2 while holding down the idle gear B.

1
1 Between the idle gear C and idle gear B
0.015 – 0.217 mm (0.0006 – 0.0085 in)

2 4. Install the idle gear C cover.

BLW71BSH009801

Legend
(1) Lightly engage the idle gear C.
(2) Rotate the camshaft gear counterclockwise.
1. Camshaft Gear
2. Idle Gear C
3. Idle Gear B
MG6HK-WE-0871.book 251 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-251

• Apply liquid gasket (ThreeBond 1386 or
LOCTITE 962T) to the entire circumference of • Clean the camshaft bearing and mounting
the insertion hole, and tap in the cover so that section, install the bearing, and apply engine oil
the edge is 0.5 to 1.5 mm (0.0197 to 0.0591 in) to the rotational movement surface of the
inside the cylinder head beveling as shown in bearing.
the diagram.
• Engage idle gear C with the camshaft gear so
that the camshaft gear B mark lines up with the
top surface of the cylinder head as shown in the
diagram, then gently install the camshaft.

NOTE:
• Make sure you do not damage the camshaft
bearing.
a • Check that the camshaft gear B mark is on the top
surface of the cylinder head.
• If the camshaft gear B mark is not in line with the
cylinder head top surface, realign the B mark.

BLW51BSH002401

Legend
(a) 0.5 to 1.5 mm (0.0197 to 0.0591 in)

5. Install the camshaft.

• At this time, check that the alignment mark
white paint can be seen as shown in the
diagram (#1 cylinder is in the top compression
dead point) from the flywheel housing side
timing check hole when looking from above the
slanting surface of the supply pump gear.
MFW41BSH003201

2
• Clean the camshaft bearing and cap, assemble
the bearing and cap, and apply engine oil to the
rotational movement surface.
• Face the arrow on the top surface of the
1 camshaft bearing cap towards the engine front
side, and install in numerical order. Tighten both
sides of the cap at the same time as the rocker
arm.

NOTE:
Point the arrow on the top surface of the cap towards
the engine front side, and check that they are attached
in numerical order.

BLW71BSH005701

Legend
1. Timing check hole
2. Supply pump gear
MG6HK-WE-0871.book 252 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-252 Engine Mechanical (6HK1)

• Apply engine oil to the thread and seating
section, and tighten uniformly from the center 7. Install the bridge (2) and bridge cap (1).
outwards.
• Apply engine oil to the bridge and bridge cap
and install them.
Tightening torque
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)

MFW61BSH000401

8. Install the rocker arm assembly.

BLW51BSH001501 • Clean the camshaft bearing and cam rocker
arm shaft bracket, assemble the bearing and
bracket, and apply engine oil to the rotational
movement surface.
• Extract the gear alignment pin and take care
not to drop it inside the engine. • Fully tighten the rocker arm adjustment screw,
and apply engine oil to the roller section.
NOTE: • Install the rocker arm assembly.
Do not forget to remove the gear alignment pin.

6. Install the camshaft position sensor.

3

Tightening torque
8 N⋅m (0.8 kg⋅m/69 lb⋅in) 2

MFW51BSH003601

Legend
1. Front cam bracket
2. Rocker arm bracket
3. Rear cam bracket

MFW71BSH004101
MG6HK-WE-0871.book 253 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-253

• Tighten them in the numerical order shown in
the diagram.

Tightening torque
Cam rocker arm shaft
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
bracket
Rocker arm bracket 56 N⋅m (5.7 kg⋅m/41 lb⋅ft)

NOTE:
• Only for the camshaft bearing mounting section,
apply oil to the stud bolt screw section, and nut
thread part and seating surface, and tighten them.
• Refer to “Valve clearance adjustment” section for
details on valve clearance adjustment.

MFW41BSH003801

• Apply liquid gasket (1) (ThreeBond 1207B) to

the top surface of the rubber plug.
4 6 8 9 7 5 3 1
2 NOTE:
Install the lower case within 5 minutes of applying the
liquid gasket.

11 12 13 10

MFW41BSH003501

9. Install the rubber plug.

• Apply liquid gasket (ThreeBond 1207B) to the
rubber plug, and install it to the cylinder head.

NOTE:
If there are cracks in the rubber plug, do not re-use it.

MFW41BSH003901

10. Install the injector.

• Insert gasket into the tip of the injector and
insert it into the cylinder head.
• Insert the injector clamp at the same time.

NOTE:
• The injector ID plate is unique to that particular
injector. Do not confuse it with a different injector
ID plate.
• When the injector assembly is replaced, use a
scan tool to write the ID code to the ECM. Refer to
“Engine Control Section” for the writing procedure.
MG6HK-WE-0871.book 254 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-254 Engine Mechanical (6HK1)

• Tighten the injection pipe clip (1) at the
specified torque.

Tightening torque
6 N⋅m (0.6 kg⋅m/52 lb⋅in)

1
1
1

1
MFW71BSH005301

a
1
11. Apply engine oil to the thread section and seating
section of the injector clamp bolt, and temporarily
tighten it.

MFW81BSH010001

2 3
13. Tighten the injector clamp (temporarily tightened
4 earlier) at the specified torque.

1
Tightening torque
30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
5
14. Tighten the injection pipe at the specified torque.

6
Tightening torque
Injector side 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
BLW71BSH020401 Common rail side 25 N⋅m (2.6 kg⋅m/19 lb⋅ft)
Legend
1. O-ring
2. Injector assembly
3. Injector clamp bolt
4. Injector clamp
5. O-ring
6. Gasket

12. Install the injection pipe.

• Thinly apply engine oil to the outer
circumference of the injector side sleeve nut
and install it.
• Lightly tighten the sleeve nut with spanner so
that it is airtight to the injector and common rail
side.
MG6HK-WE-0871.book 255 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-255

16. Insert gasket into the lower case slot and install it
to the cylinder head.

Tightening torque
5 6
3 4 13 N⋅m (1.3 kg⋅m/113 lb⋅in)
2
1

MFW71BSH000901

Legend
1. Injection pipe #1
2. Injection pipe #2
3. Injection pipe #3
4. Injection pipe #4
5. Injection pipe #5
6. Injection pipe #6
7. Common rail (Fuel rail) MFW41BSH027201

15. Install the leak-off pipe to the injector. 17. Install the injector harness assembly.
• Install the harness bracket with the harness still
attached.
Tightening torque
12 N⋅m (1.2 kg⋅m/104 lb⋅in)
Tightening torque
NOTE: 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
• Always use brand new gasket.
• Re-check to make sure you didn’t forget to tighten • Install the terminal nut to the injector, and
anything. tighten to the specified torque strength.

Tightening torque
2 N⋅m (0.2 kg⋅m/17 lb⋅in)

NOTE:
• As the terminal is a single unit, tighten the nuts 2 to
3 turns each until fully tightened.
• Over tightening the nuts will cause damage to the
terminal stud. Therefore, they should never be over
tightened.

MFW41BSH023501
MG6HK-WE-0871.book 256 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-256 Engine Mechanical (6HK1)

NOTE:
•

Check that there is no debris on the upper surface of

the cylinder head.

2
1

8 4 1 5 9

11

7 3 2 6 10

MFW71BSH007101

Legend
1. Harness terminal
2. Harness bracket
MFW41BSH035801

18. Install the gasket.

20. Install the bracket.
• Clean the head cover gasket attachment slot
and gasket, and install the gasket to the head • Install the noise cover bracket to the cylinder
cover. head cover.

NOTE:
Check that the collar has not fallen out. Tightening torque
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

1
2

BLW71BSH009001

BLW71BSH008901

19. Install the head cover. Legend

1. Bracket
• After temporarily tightening all of the bolts,
2. Head cover
tighten them in the order shown in the diagram.
3. Bolt

Tightening torque
13 N⋅m (1.3 kg⋅m/113 lb⋅in) 21. Install the noise cover.
MG6HK-WE-0871.book 257 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-257

• Install the noise cover (1) to the head cover (2),
and tighten the nut and bolt.

Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

MFW41BSH003701

2
24. Install the O-ring.
• Install the O-ring to the water pump.
• Apply soapy water (1) to the perimeter of the O-
ring.
BLW71BSH008301

1
22. Install the glow plug. (or dummy glow plug)

Tightening torque
20 (2.0 kg⋅m/14 lb⋅ft)

NOTE:
Take care not to over tighten the glow plugs, as
doing so will damage them.

23. Install the glow plug connector. (with glow plug)

Tightening torque
1 N⋅m (0.1 kg⋅m/9 lb⋅in) MFW61CSH001101

25. Install the water duct.

• Install the O-ring to the water duct, but be
careful not to damage the water pump O-ring.

Tightening torque
M8 bolt 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
M16 bolt 103 N⋅m (10.5 kg⋅m/76 lb⋅ft)

26. Install the plate.

MG6HK-WE-0871.book 258 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-258 Engine Mechanical (6HK1)

• Install after tightening the water duct.

Tightening torque
M8 bolt 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
M10 bolt 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)

MFW61CSH001201

Legend
1. Water duct
2. Plate

27. Install the engine exterior parts.

• Refer to “Engine Exterior Parts”.
28. Pour in cooling water.
MG6HK-WE-0871.book 259 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-259

Tightening Torque Table

a
c
d

b e

p g

q n
m h

l k

i
j

MFWB1BLF002901

(n) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) (o) 56 N⋅m (5.7 kg⋅m / 41 lb⋅ft)
(b) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in) (p) 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
(c) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in) (q) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(d) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(e) 2 N⋅m (0.2 kg⋅m / 17 lb⋅in)
(f) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
(g) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(h) M14: 98 N⋅m (10 kg⋅m / 72 lb⋅ft) →
147 N⋅m (15 kg⋅m / 108 lb⋅ft) →
Angle method 30° to 60°
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(i) M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M16: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
(j) M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(k) 1 N⋅m (0.1 kg⋅m / 9 lb⋅in)
(l) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(m) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
MG6HK-WE-0871.book 260 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-260 Engine Mechanical (6HK1)

Cylinder Head (Euro 3 specification)

Component Parts

5
1

2
6
25
7
3 24 8

4 23
9
10
22
11
12

13
21

20

18
19 14
17
16

15
MFW71BLF001401

Legend
1. Noise cover 14. Head gasket
2. Head cover 15. Water duct
3. Gasket 16. Plate
4. Bracket 17. O-ring (water pump)
5. Connector 18. O-ring
6. Harness assembly 19. Rubber plug
7. Injector leak-off pipe 20. Glow plug connector (with glow plug)
8. Injector clamp 21. Glow plug (or dummy glow plug)
9. Injector assembly 22. Camshaft
10. Gasket 23. Rocker arm assembly
11. Bridge cap 24. Gasket
12. Bridge 25. Lower case
13. Cylinder head assembly
MG6HK-WE-0871.book 261 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-261

Removal
NOTE:
Seal the inlet duct hole, supply pump and other such
places so that debris cannot enter.

1. Remove the engine exterior parts. Refer to “Engine

Exterior Parts”.
2. Remove the injection pipe.
1
3. Remove the noise cover. 2

3
1

BLW71BSH008901

Legend
1. Bracket
2. Head cover
2 3. Bolt

5. Remove the head cover.

BLW71BSH008301 NOTE:
Legend Make sure you do not lose the collar that is inside the
1. Noise cover head cover.
2. Head cover
6. Remove the gasket.

4. Remove the noise cover bracket.

NOTE:
If the bracket is not damaged, do not remove it.

BLW71BSH009001

7. Remove the lower case.

MG6HK-WE-0871.book 262 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-262 Engine Mechanical (6HK1)

8. Remove the gasket.

MFW41BSH026201
MFW71BSH005001

• Take out the injector harness terminal.

9. Remove the glow plug connector. (with glow plug)
10. Remove the glow plug. (or dummy glow plug) 3

LNW71DSH003601

Legend
LNW21BSH055301 1. Injector
2. Injector harness
3. Terminal nut
11. Remove the harness assembly.
• Push the arrowed section of the connector with
your fingers to remove it.

NOTE:
Do not pull the wires or pry the connector with a
screwdriver.
MG6HK-WE-0871.book 263 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-263

• Remove the harness bracket with the harness • If it is difficult to remove the injector, set the
still attached. injector remover (5-8840-2826-0) on the
injector, tighten the bolt into the leak- off pipe
fitting, and using the sliding hammer small (5-
8840-0019-0) pull the injector out in an upward
direction.
2
1 NOTE:
• When removing the injector using this special tool,
make sure that the injector sleeve is not removed as
well.
• The ID plate is unique to each injector, so install a
number tag to it before storing it to ensure that it is
not used on a different injector.
• He injector and glow plug protrude from first to
prevent them from being damaged.

MFW41BSH027101

Legend
1. Harness terminal 1
2. Harness bracket

2
12. If there are no malfunctions with the connector, do
not remove it.
13. Remove the rubber plug.
14. Remove the injector leak-off pipe.
15. Remove the injector clamp.
• Loosen the injector clamp bolt using a torque
wrench (T-40).

LNW46CMH000301

Legend
1. Sliding hammer small
2. Injector remover
3. Injector assembly

MFWA1BSH003101

NOTE:
16. Remove the injector assembly.
• Indicate the cylinder No. on the removed injector
• Loosen the clamp, and use the replacer to
before storing the injector.
remove the injector.
• Be careful not to strike the injection nozzle against a
hard surface.
MG6HK-WE-0871.book 264 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-264 Engine Mechanical (6HK1)

24. Remove the camshaft.

NOTE:
After inspecting the removed bearing, temporarily
install the removed cap and bearing in their previous
locations so as not to confuse them with other parts.

MFW71BSH005301

17. Remove the gasket.

18. Remove the plate.
19. Remove the water duct.
BLW51BSH001501
20. Remove the O-ring.
21. Remove the O-ring (water pump).
22. Remove the rocker arm assembly.
25. Remove the cylinder head assembly.
• Loosen both sides of the cam rocker arm shaft
• Loosen and remove the attachment bolts from
bracket and rocker arm assembly bracket
the outside in the numerical order shown in the
attachment bolts equally and remove them.
diagram.
NOTE:
NOTE:
If the attachment bolts (arrow) on both ends of the cam
Before lifting the cylinder head, check that all of the
rocker arm shaft brackets are removed, the rocker arm
bolts have been removed.
and bracket may spring out. Therefore, they should not
be removed.

MFW61BSH000301

23. Remove the bridge and bridge cap.

• Keep them in the order they were attached.
MG6HK-WE-0871.book 265 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-265

3 7 11 15 19 23 27 26 22 18 14 10 6 2

4 8 12 16 20 24 28 25 21 17 13 9 5 1

MFW41BSF000101

NOTE:
When the cylinder head is removed, idle gear C (1)
protrudes from the bottom of the cylinder head. Ensure
that the gear is not damage.

MFW41BSH002901

26. Remove the head gasket.

• Check for the presence of gas or water leaks.
MG6HK-WE-0871.book 266 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-266 Engine Mechanical (6HK1)

Disassembly

1
2
29 4 6
28 5
3
27
26
25
24 7
22 23
8
9

21

20

10
18

11
19
17
16
12

13

15

14 MFWB1BLF002701

Legend
1. Bridge cap 16. Engine coolant temperature sensor
2. Bridge 17. Valve
3. Bridge guide 18. Valve seat insert
4. Nozzle sleeve 19. Thermostat
5. Idle gear C 20. Gasket
6. Idle gear C cover 21. Water outlet pipe
7. Engine hanger 22. Engine hanger
8. Oil seal 23. Cylinder head
9. Gasket 24. Spring seat
10. Inlet cover 25. Valve guide
11. Exhaust manifold (Front) 26. Valve stem oil seal
12. Heat protector 27. Valve spring
13. Heat protector 28. Spring upper seat
14. Exhaust manifold (Rear) 29. Split collar
15. Gasket

NOTE: rest it on wooden planks to prevent the idle gear C that

When placing the cylinder head assembly on the floor, protrudes from the bottom from getting damaged.
MG6HK-WE-0871.book 267 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-267

1. Remove the bridge cap.
2. Remove the bridge.
3. Remove the intake cover.
4. Remove the gasket (intake cover).
5. Remove the heat protector.
6. Remove the exhaust manifold.
7. Remove the gasket (exhaust manifold).
8. Remove the bracket.
9. Remove the heat protector. 2
10. Remove the engine hanger.
11. Remove the engine coolant temperature sensor. 1
12. Remove the water outlet pipe.
13. Remove the thermostat.
14. Remove the gasket (thermostat).
15. Remove the camshaft position sensor. BLW51BSH000101
16. Remove the idle gear C cover. Legend
• Gently tap the outer perimeter of the sealing 1. Idle gear C
cup with the tip of a screwdriver (1) as shown in 2. Shaft
the diagram, then invert the cup and use pliers
etc. to extract it.

NOTE: 18. Remove the split collar.

Be sure not to damage the cover insertion section. • Place the cylinder head on wooden planks.
• Use a valve spring replacer (5-8840-2621-0)
and pivot (8-9439-6862-0) remove the split
collar, then remove the spring seat, spring,
seal, and valve. At this time, also remove the
spring seat that is inserted in the lower side of
the spring.
• Install tickets numbered according to cylinder to
the removed valves.

MFW41BSH009701

17. Remove idle gear C.

• Extract the idle gear shaft and remove the
gears.

MFW41BSH009801

19. Remove the valve spring upper seat.

20. Remove the valve spring.
21. Remove the valve.
MG6HK-WE-0871.book 268 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-268 Engine Mechanical (6HK1)

22. Remove the valve stem oil seal.
23. Remove the valve spring seat.

MFW41BSH010101

MFWB1BSH003201
26. Remove the nozzle sleeve. Place a injector sleeve
remover (5-8840-2623-0) against the bottom side
24. Remove the valve guide. of the head, and hit it to extract the sleeve.
• Insert the valve guide replacer (5-8840-2628-0) NOTE:
into the valve guide from the bottom of the
head, and hit it with a hammer to extract it. • Make sure you do not damage the bottom side of
the head.
• Do not re-use extracted nozzle sleeves.

MFW41BSH010001

MFW41BSH010201
25. Remove the valve seat insert.
• Use a welding burner to burn 2 sections (700 to
800°C / 1292 to 1472°F) on the inner surface of
27. Remove the bridge guide.
the insert, leave it to self cool for between 3 to 5
minutes, then extract it with a screwdriver. • Electrically weld the bridge guide head section
nut (1), install a sliding hammer and extract it.
CAUTION: • Do remove it if there is no wear.
Do not rapidly cool it. Do not damage the cylinder head
when extracting.
MG6HK-WE-0871.book 269 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-269

• Check there is no hesitance in the bridge and
bridge guide.
• Measure the gap between the bridge and
bridge guide.

Gap
1
Assembly standard Limitations for use
0.020 – 0.056 mm 0.1 mm
(0.0008 – 0.0022 in) (0.004 in)

MFW41BSH010301

28. Remove the oil seal.

Place a dolly against the inside of the head, and hit
it to extract the seal.

Inspection
1. Inspect the bridge cap.
• Inspect the cap and rocker arm adjustment bolt
strike surface for wear or damage. MFW41BSH010601
• If the amount of wear is greater than 0.1 mm
(0.004 in), or if linear wear has occurred,
replace it. 3. Measure the idle gear C (1) axial direction gap.
• Measure idle gear C axial direction gap and the
Bridge cap wear limit shaft diameter.
0.1 mm (0.004 in)
Axial direction gap
Nominal Assembly Limitations
dimensions standard for use
0.09 – 0.144 mm 0.2 mm
—
(0.004 – 0.0057 in) (0.008 in)

Shaft diameter
Nominal Assembly Limitations
dimensions standard for use
30 mm — 29.85 mm
(1.18 in) (1.175)

MFW41BSH010501

2. Inspect the bridge.

MG6HK-WE-0871.book 270 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-270 Engine Mechanical (6HK1)

• Measure the free length of the valve spring.

Free length
Nominal Limitations for
dimensions use
Inlet 59.9 mm 58.7mm
(2.36 in) (2.31 in)
Exhaust 70.3 mm 68.9 mm
(2.77in) (2.71 in)
1

BLW51BSH002301

4. Measure the valve spring.

• Measure the squareness of the valve spring.

Squareness
Assembly Limitations for use
standard
Inlet — 3.4 mm (0.13 in)
Exhaust — 3.4 mm (0.13 in)
MFW41BSH010901

• Measure the load of the valve spring when

attached.

Attached load/attached length N (kgf / lb)

Assembly Limitations for
standard use
333 (34.0 / 75.0) / 315 (32.1 / 70.8) /
Inlet
47 mm (1.85 in) 47 mm (1.85 in)
490 (50.0 / 110.0) 463 (47.2 / 104) /
Exhaust
/47 mm (1.85 in) 47 mm (1.85 in)

MFW41BSH010801
MG6HK-WE-0871.book 271 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-271

• Insert a valve into the valve guide, and
measure the looseness of the valve at a
position (a) 10 mm (0.3937 in) from the top of
the guide.

Gap between valve guide and valve stem

Assembly standard Limitations
for use
0.039 – 0.071 mm 0.2 mm
Inlet valve
(0.0015 – 0.0028 in) (0.008 in)
0.064 – 0.096 mm 0.25 mm
Exhaust valve
(0.0025 – 0.0038 in) (0.01 in)

MFW41BSH011001

5. Inspect the valve.

• Measure the valve stem abrasion. 1
• Measure the 3 locations in the diagram.
a

Valve stem outer diameter

Nominal dimensions Limitations for use 2

8 mm (0.315 in) 7.88 mm (0.310 in)

• If the amount of valve stem abrasion exceeds

the limit, replace both the valve and the valve
guide. MFW61BSH001501

Legend
1. Valve
2. Valve guide

• Measure the thickness of the valve.

Valve thickness
Nominal Limitations for
dimensions use
Inlet valve 1.71 mm
(0.0673 in) 1.3 mm
Exhaust valve 1.75 mm (0.051 in)
(0.0689 in)
MFW41BSH011101
MG6HK-WE-0871.book 272 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-272 Engine Mechanical (6HK1)

Amount of valve depression

Nominal dimensions Limitations
for use
0.73 – 1.10 mm 2.3 mm
Inlet valve
(0.0287 – 0.0433 in) (0.091 in)
1.16 – 1.54 mm 2.8 mm
Exhaust valve
(0.0457 – 0.0606 in) (0.110 in)

MFW41BSH011301

• Inspect and repair the valve seat striking 3

surface. 2
• Apply red lead paint to the valve insert, and
inspect the width of the seat striking surface.
Also, inspect for lack of strike, and that the
strike position is in the center of the valve seat
face.
MFW51BSH003501

Width of seat striking surface Legend

1. Striking width
Assembly standard 2. Amount of depression
Inlet valve 2.7 mm (0.106 in) 3. Seat angle
Exhaust valve 2.7 mm (0.106 in)

• If there is a defect in the valve striking width or Perform valve slide matching
the striking surface, use a seat cutter that • Apply compound to the valve striking surface,
matches the stem diameter to repair it. and perform sufficient slide matching between
the valve seat and valve striking surface.

Valve seat angle (deg)

Inlet valve 30
Exhaust valve 45

Valve stem diameter

8 mm (0.315 in)

• After valve seat grinding, measure the amount

of valve depression to be sure that it is within
the useable limit.

MFW41BSH011601
MG6HK-WE-0871.book 273 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-273

• After valve slide matching, clean the cylinder
head and valve.
6. Inspect the valve seat insert.
• Measure the amount of valve depression (1).
• Insert a new valve into the valve guide, and
measure the dimensions from the bottom of the
cylinder head to the valve surface.

Amount of valve depression

Nominal dimensions Limitations
for use
0.73 – 1.10 mm 2.3 mm
Inlet valve
(0.0287 – 0.0433 in) (0.091 in)
1.16 – 1.54 mm 2.8 mm
Exhaust valve
(0.0457 – 0.0606 in) (0.110 in)
MFW41BSH011801

• Inspect the cylinder head for cracks and

damage.
• Inspect using a magnetic flaw detector or dye
penetrant testing method if necessary.

NOTE:
When magnetizing using the magnetic flaw detector,
always demagnetize when the test is complete.
(Remnant magnetism is less than 5G)
1

MFW41BSH011701

7. Inspect the cylinder head.

• Measure the amount of distortion of the cylinder
head.
• Clean off the carbon without damaging the
processing surfaces of the cylinder head, valve
seat, insert etc.
• Place a straightedge against the mounting
surface of the cylinder head, and measure the
amount of distortion in locations A to F on the
MFW41BSH011901
diagram using a thickness gauge.

Amount of distortion • With the hydraulic test, apply 490 kPa (5 kgf/
cm2/71 psi) of water pressure for 3 minutes,
Limitations for use 0.2 mm (0.008 in)
and inspect each section of the head for water
leaks.
NOTE:
Cannot be repaired because the timing gear backlash NOTE:
will change. Perform the hydraulic test with the nozzle holder
attached.
MG6HK-WE-0871.book 274 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-274 Engine Mechanical (6HK1)

Reassembly • Apply engine oil to the outer periphery of the
guide, and use a bridge guide setting tool (5-
1. Install the oil seal to the cylinder head.
8840-2626-0) to hammer it in to the finishing
• Use a oil seal installer (5-8840-2627-0). depth of the cylinder head hole. (Reference:
• Hit the seal evenly so that it does not slant. The bridge guide height is approx. 37.5 mm
(1.476 in) (b) from the head upper surface)
NOTE:
Take care not to damage the lip section.

b
a
MFW61BSH000901

MFW41BSH012001 (a) 122.5 mm (4.823 in)

(b) 37.5 mm (1.476 in)

3. Install the nozzle sleeve.

• Install the O-ring (1) and (2) to the nozzle
sleeve, and apply engine oil.
1 2
3 • Apply sealant (LOCTITE LT620) to the nozzle
sleeve tapered section (3).

MFW81BSH006201

Legend
1. Cylinder head
2. Oil seal
3. Oil seal installer

2. Install the bridge guide.

MG6HK-WE-0871.book 275 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-275

• Apply engine oil (4) to nozzle sleeve installation
side.

1
2

2
3 6
5 3

LNW21BMH001001

Legend
MFW61BMH000101
1. Punch bar
Legend 2. Ball
1. O-ring (white paint) 3. Guide sleeve
2. O-ring 4. Nozzle sleeve
3. Apply LOCTITE 5. Injector clamp
4. Apply engine oil 6. Injector clamp bolt

4. Install the valve seat insert.

• Install the injector sleeve setting tool (5-8840- • Carefully clean off the carbon, rust, etc. from
2624-0) and install nozzle sleeve to the cylinder the mounting surface of the insert, and press fit
head. the insert using a press.
• Push the nozzle sleeve in with a guide sleeve
so that it is firmly seated at the bottom side of
the cylinder head.
• After inserting the guide sleeve, fix it with the
injector clamps and injector clamp bolts.
• Insert the ball (bearing steel ball 9.525 mm/
0.375 in) into the guide sleeve, and use a
punch bar and hammer to knock the ball out.

NOTE:
• After carefully removing the shavings from the
cylinder head screw section, insert the sleeve.
• Lift the cylinder head so that the ball can come out
from the bottom.

MFW41BSH012401
MG6HK-WE-0871.book 276 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-276 Engine Mechanical (6HK1)

1
a

LNW21BSH018601 LNW71BSH001701

Legend
1. Dolly
2. Insert 6. Install the lower spring seat.
3. Press 7. Install the valve stem oil seal.
• Apply oil to the oil seal, and use a valve stem
seal setting tool (5-8840-2625-0) to tap in the
5. Install the valve guide.
valve guide.
• Hammer in the valve guide from the upper
surface of the cylinder head, using the valve NOTE:
guide replacer (5-8840-2628-0) and valve guide Check the valve seal for shape deformation and
installer (5-8840-2930-0). cracks, and that the spring has not detached.

NOTE:
Replace the valve guide as a set with the valve.

MFW41BSH012601

MFW41BSH012501 8. Install the valve.

• Apply engine oil to the valve stem, and insert
the cylinder head.
Dimensions (a) of the valve guide surface from the
cylinder head upper surface NOTE:
Check the assembly of the valve.
17.1 – 17.9 mm (0.6732 – 0.7047 in)
“ E “ Mark : Exhaust
“ I “ Mark : Inlet
MG6HK-WE-0871.book 277 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-277

MFW41BSH012701 MFW41BSH009801

9. Install the valve spring. 12. Install a gasket in the thermostat flange part.
• Place the cylinder head on wooden planks. 13. Install the thermostat.
• Install the valve spring with the side that has the • Install the rubber gasket to the flange section.
identification paint facing the cylinder head • Line up the position of the jiggle valve (1) as
surface. shown in the diagram.

Identification paint
Inlet valve spring Blue
Exhaust valve spring Red

10. Install the spring upper seat.

11. Install the split collar.
• Use a valve spring replacer (5-8840-2621-0)
and pivot (8-9439-6862-0) to push the valve
1
spring in, then install the split collar.
• After attaching, gently hit the valve stem head
section with a rubber mallet so the split collar
falls into place.

NOTE:
Check that the split collar is firmly in the valve stem MFW91BSH000801
slot.

14. Install the water outlet pipe.

• Install the thermostat as shown in the diagram,
and install the water outlet pipe.

Tightening torque
24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

NOTE:
If you install the thermostat in the wrong position, you
will not be able to install the water outlet pipe.
MG6HK-WE-0871.book 278 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-278 Engine Mechanical (6HK1)

1
2

3 2

MFW41BSH013101 MFW71BSH006301

Legend Legend
1. Water outlet pipe 1. Plug
2. Incorrect attachment prevention stopper 2. Engine coolant temperature sensor
3. Thermostat with jiggle valve 3. Plug

15. Install the engine coolant temperature sensor.

• Install the Plug in position (1), (3) shown in the 16. Install the rear side engine hanger (1) to the
diagram. cylinder head.
• Apply ThreeBond 1207C or LOCTITE 271 to
the thread section and attach. Tightening torque
M12 bolt 94 N⋅m (9.6 kg⋅m/69 lb⋅ft)
Tightening torque
•

Plug (1) 108 N⋅m (11 kg⋅m/80 lb⋅ft)

Plug (3) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)

• Install the engine coolant temperature sensor in

position (2) shown in the diagram.
• The thread section of the new plug switch is
treated with plating processing.
When reusing plug switches, apply ThreeBond 1
1207C or LOCTITE 271, and install to the
location shown in the diagram.
• Apply LOCTITE 262 or 962 to the engine
coolant temperature sensor threaded portion
and tighten at the specified torque.

Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft) MFWB1BSH005001

17. Install the bracket (1) and heat protector (2).

Tightening torque
24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
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Engine Mechanical (6HK1) 1B-279

NOTE:
Install before assembling the exhaust manifold.

2
1

MFW41BSH013501

Legend
1. Casting surface side
MFWB1BSH005101
2. Gasket

18. Install the exhaust manifold gaskets.

• Install so that the protruding section of the 19. Install the exhaust manifold.
gaskets is down. • Move each of the seal ring alignment holes
120° and assemble them to the rear exhaust
manifold.

1 2 3

MFW41BSH013401

NOTE: MFWB1BSH005201
Check that the gasket is securely attached to the Legend
cylinder head. If it is attached incorrectly, it will ride up 1. Exhaust manifold (rear side)
on the casting surface side of the cylinder head as 2. Seal ring
shown in the diagram. 3. Exhaust manifold (front side)
MG6HK-WE-0871.book 280 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-280 Engine Mechanical (6HK1)

• Install the exhaust manifold. • Tighten them in the order shown in the diagram.
Exhaust nut (10 pieces)
Tightening torque
55 N⋅m (5.6 kg⋅m/41 lb⋅ft)

Exhaust distance nut (2 pieces)

Tightening torque
34 N⋅m (3.5 kg⋅m/25 lb⋅ft)

8 4
• Assemble the distance tube, flat washer and 12 11 7 2 6 9
3 1 5 10
coned disc spring washer as shown in the
diagram, and tighten the exhaust manifold.
• Only the distance nut can be re-used.

1 2
MFWB1BSH005301

20. Install the heat protector.

21. Install the inlet cover.
3
• Install the gasket to the inlet cover (1), and
tighten in the order shown in the diagram.

4
Tightening torque
25 N⋅m (2.5 kg⋅m/18 lb⋅ft)

MFWB1BSH003501

Legend
1. Distance tube
2. Nut
3. Coned disc spring washer
4. Distance nut

• Tighten the distance nut (arrow) in the 7th and

12th attachment positions shown in the
diagram.
1

MFWA1BSH001901
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Engine Mechanical (6HK1) 1B-281

NOTE:
Remove any deposits, carbon, sealing compound, etc.
from the upper surface and lower surface of the
cylinder block.

Reamer bolt

13 9 6 7 10 14
3

12 2 5 1 4 8 11

MFWB1BSH003601

22. Apply engine oil to the bridge and install it.

NOTE: MFW41BSH003001
Move it up and down to check that it moves smoothly.
2. Install the cylinder head assembly.
23. Apply engine oil to the bridge cap and install it. • Install the dowel to the cylinder block, line up
the cylinder head bolt holes and gently rest it
on.

MFW41BSH014001

MFW41BSH003101
Installation
1. Install the head gasket.
• Apply approx. 2 mm (0.0787 in) thickness, • Apply molybdenum-disulfide to the thread
approx. 3 mm (0.1181 in) width of liquid gasket section and seating surface of the M14 bolts,
(ThreeBond 1207C) to the alignment sides of and engine oil to the thread section of the M10
the cylinder block and flywheel housing, and bolts, and tighten them to the specified torque
install the head gasket. and angle in the order shown in the diagram.
• After applying the liquid gasket, install the
cylinder head within 5 minutes.
MG6HK-WE-0871.book 282 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-282 Engine Mechanical (6HK1)

Tightening torque
98 N⋅m (10.0 kg⋅m/72 lb⋅ft) →
M14 bolt 147N⋅m (15.0 kg⋅m/108 lb⋅ft) →
Angle method 30° to 60°
M10 bolt
38 N⋅m (3.9 kg⋅m/ 28 lb⋅ft)
(#27, 28)

26 22 18 14 10 6 2 3 7 11 15 19 23 27

25 21 17 13 9 5 1 4 8 12 16 20 24 28

BLW71BSF000101

NOTE: 1. Position the marked line (2) on the crank

To check the tightness of the M14 bolts, rotate the tool pulley and the alignment mark (1) on the
in the tightening direction. gearcase cover and set to compression top
dead center of the first cylinder.

Checking tightening torque

142 N⋅m (14.5 kg⋅m/105 lb⋅ft) 1

3. Install idle gear C.

a. Assembly of the idle gear C

NOTE:
When disassembling the idle gear C, assemble it while
paying attention to the following points because it is
difficult to position the idle gear C shaft.

2
MFWB1BSH003301

2. With the idle gear B assembled, insert the

idle gear C from above the cylinder head.
• Apply engine oil to the inner
circumference of the idle gear C bushing
and the thrust bearing surface.
MG6HK-WE-0871.book 283 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-283

3. Apply engine oil to the outer circumference 2. Assemble the camshaft with the gear
of the shaft and pass from the cylinder head installed to mesh with the idle gear C
rear surface hole to the gear center hole. installed to the cylinder head.
4. Apply engine oil to the both surfaces of the At this time, when the marked line on the
thrust collar, and molybdenum disulfide to crank pulley and alignment mark on the front
the threaded portion of the bolt and seat cover are positioned compression top dead
surface. Assemble the bolt which is installed center of the first cylinder), install so that the
to the thrust collar. alignment mark B on the camshaft gear
However, the bolt should be tightened at a matches the top surface of the cylinder
torque of 40 N⋅m (4.1 kg⋅m/30 lb⋅ft), and head.
loosen by 30° – 90° after tightening.
(Confirm that the idle gear C moves.)

1
2 3

MFW41BSH003201
6

3. Set the cam bearing upper to the camshaft

cap, and apply engine oil to the bearing
inner circumference.
4. Assemble the #2, #3, and #4 caps (1).

Apply engine oil to the threaded portion and seat

surface
BLW71BMH000501 Tightening torque
Legend Cap bolts 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
1. Insertion Direction Cap nuts 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
2. Shaft
3. Thrust Collar NOTE:
4. Bolt Do not assemble the rocker arm.
5. Idle Gear C
6. Bushing

b. Installation of the camshaft gear.

1. Set the cam bearing lower to the cylinder
head. Apply engine oil to the bearing inner
circumference.
MG6HK-WE-0871.book 284 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-284 Engine Mechanical (6HK1)

2. Hold down the camshaft gear by hand and
tighten the idle gear C bolt at the specified
torque.

1
Apply molybdenum disulfide to the threaded
portion and seat surface
Tightening torque
Idle gear C bolt 71 N⋅m (7.2 kg⋅m/ 52 lb⋅ft)

NOTE:
When tightening, be careful that the idle gear C shaft
position does not move a lot.

3. After tightening the idle gear C, check the

backlash to ensure that it is within the
standard value below.
BLW71BSH009901

Between the idle gear C and camshaft gear

c. Tightening the idle gear C. 0.015 – 0.146 mm (0.0006 – 0.0057 in)
1. Manually rotate the camshaft gear in the left
direction (when looking from the engine If the camshaft gear does not move with
rear) (2), gently mesh the idle gear C to the rattling when manually moving it, there is the
direction of the arrow (1) in the diagram, and possibility that the backlash has excessively
set the idle gear C shaft position. built up. Check the backlash and readjust.

NOTE: NOTE:
Be careful as backlash can excessively build up if too If the backlash cannot be adjusted, assembly with the
much force is applied when rotating the camshaft gear. service idle gear C shaft (8-97186-398-1).

4. Remove the cam cap and camshaft.

5. Use a flat blade screwdriver (large size),
etc., to check the backlash of the idle gear C
2 while holding down the idle gear B.

1
1 Between the idle gear C and idle gear B
0.015 – 0.217 mm (0.0006 – 0.0085 in)

2 4. Install the idle gear C cover.

BLW71BSH009801

Legend
(1) Lightly engage the idle gear C.
(2) Rotate the camshaft gear counterclockwise.
1. Camshaft Gear
2. Idle Gear C
3. Idle Gear B
MG6HK-WE-0871.book 285 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-285

• Apply liquid gasket (ThreeBond 1386 or
LOCTITE 962T) to the entire circumference of • Clean the camshaft bearing and mounting
the insertion hole, and tap in the cover so that section, install the bearing, and apply engine oil
the edge is 0.5 to 1.5 mm (0.0197 to 0.0591 in) to the rotational movement surface of the
inside the cylinder head beveling as shown in bearing.
the diagram.
• Engage idle gear C with the camshaft gear so
that the camshaft gear B mark lines up with the
top surface of the cylinder head as shown in the
diagram, then gently install the camshaft.

NOTE:
• Make sure you do not damage the camshaft
bearing.
a • Check that the camshaft gear B mark is on the top
surface of the cylinder head.
• If the camshaft gear B mark is not in line with the
cylinder head top surface, realign the B mark.

BLW51BSH002401

Legend
(a) 0.5 to 1.5 mm (0.0197 to 0.0591 in)

5. Install the camshaft.

• At this time, check that the alignment mark
white paint can be seen as shown in the
diagram (#1 cylinder is in the top compression
dead point) from the flywheel housing side
timing check hole when looking from above the
slanting surface of the supply pump gear.
MFW41BSH003201

2
• Clean the camshaft bearing and cap, assemble
the bearing and cap, and apply engine oil to the
rotational movement surface.
• Face the arrow on the top surface of the
1 camshaft bearing cap towards the engine front
side, and install in numerical order. Tighten both
sides of the cap at the same time as the rocker
arm.

NOTE:
Point the arrow on the top surface of the cap towards
the engine front side, and check that they are attached
in numerical order.

BLW71BSH005701

Legend
1. Timing check hole
2. Supply pump gear
MG6HK-WE-0871.book 286 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-286 Engine Mechanical (6HK1)

• Apply engine oil to the thread and seating
section, and tighten uniformly from the center 7. Install the bridge (2) and bridge cap (1).
outwards.
• Apply engine oil to the bridge and bridge cap
and install them.
Tightening torque
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)

MFW61BSH000401

8. Install the rocker arm assembly.

BLW51BSH001501 • Clean the camshaft bearing and cam rocker
arm shaft bracket, assemble the bearing and
bracket, and apply engine oil to the rotational
movement surface.
• Extract the gear alignment pin and take care
not to drop it inside the engine. • Fully tighten the rocker arm adjustment screw,
and apply engine oil to the roller section.
NOTE: • Install the rocker arm assembly.
Do not forget to remove the gear alignment pin.

6. Install the camshaft position sensor.

3

Tightening torque
8 N⋅m (0.8 kg⋅m/69 lb⋅in) 2

MFW51BSH003601

Legend
1. Front cam bracket
2. Rocker arm bracket
3. Rear cam bracket

MFW71BSH004101
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Engine Mechanical (6HK1) 1B-287

• Tighten them in the numerical order shown in
the diagram.

Tightening torque
Cam rocker arm shaft
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
bracket
Rocker arm bracket 56 N⋅m (5.7 kg⋅m/41 lb⋅ft)

NOTE:
• Only for the camshaft bearing mounting section,
apply oil to the stud bolt screw section, and nut
thread part and seating surface, and tighten them.
• Refer to “Valve clearance adjustment” section for
details on valve clearance adjustment.

MFW41BSH003801

• Apply liquid gasket (1) (ThreeBond 1207B) to

the top surface of the rubber plug.
4 6 8 9 7 5 3 1
2 NOTE:
Install the lower case within 5 minutes of applying the
liquid gasket.

11 12 13 10

MFW41BSH003501

9. Install the rubber plug.

• Apply liquid gasket (ThreeBond 1207B) to the
rubber plug, and install it to the cylinder head.

NOTE:
If there are cracks in the rubber plug, do not re-use it.

MFW41BSH003901

10. Install the injector.

• Insert gasket into the tip of the injector and
insert it into the cylinder head.
• Insert the injector clamp at the same time.

NOTE:
• The injector ID plate is unique to that particular
injector. Do not confuse it with a different injector
ID plate.
• When the injector assembly is replaced, use a
scan tool to write the ID code to the ECM. Refer to
“Engine Control Section” for the writing procedure.
MG6HK-WE-0871.book 288 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-288 Engine Mechanical (6HK1)

• Tighten the injection pipe clip (1) at the
specified torque.

Tightening torque
6 N⋅m (0.6 kg⋅m/52 lb⋅in)

1
1
1

1
MFW71BSH005301

a
1
11. Apply engine oil to the thread section and seating
section of the injector clamp bolt, and temporarily
tighten it.

MFW81BSH010001

2 3
13. Tighten the injector clamp (temporarily tightened
4 earlier) at the specified torque.

1
Tightening torque
30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
5
14. Tighten the injection pipe at the specified torque.

6
Tightening torque
Injector side 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
BLW71BSH020401 Common rail side 25 N⋅m (2.6 kg⋅m/19 lb⋅ft)
Legend
1. O-ring
2. Injector assembly
3. Injector clamp bolt
4. Injector clamp
5. O-ring
6. Gasket

12. Install the injection pipe.

• Thinly apply engine oil to the outer
circumference of the injector side sleeve nut
and install it.
• Lightly tighten the sleeve nut with spanner so
that it is airtight to the injector and common rail
side.
MG6HK-WE-0871.book 289 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-289

16. Insert gasket into the lower case slot and install it
to the cylinder head.

Tightening torque
5 6
3 4 13 N⋅m (1.3 kg⋅m/113 lb⋅in)
2
1

MFW71BSH000901

Legend
1. Injection pipe #1
2. Injection pipe #2
3. Injection pipe #3
4. Injection pipe #4
5. Injection pipe #5
6. Injection pipe #6
7. Common rail (Fuel rail) MFW41BSH027201

15. Install the leak-off pipe to the injector. 17. Install the injector harness assembly.
• Install the harness bracket with the harness still
attached.
Tightening torque
12 N⋅m (1.2 kg⋅m/104 lb⋅in)
Tightening torque
NOTE: 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
• Always use brand new gasket.
• Re-check to make sure you didn’t forget to tighten • Install the terminal nut to the injector, and
anything. tighten to the specified torque strength.

Tightening torque
2 N⋅m (0.2 kg⋅m/17 lb⋅in)

NOTE:
• As the terminal is a single unit, tighten the nuts 2 to
3 turns each until fully tightened.
• Over tightening the nuts will cause damage to the
terminal stud. Therefore, they should never be over
tightened.

MFW41BSH023501
MG6HK-WE-0871.book 290 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-290 Engine Mechanical (6HK1)

NOTE:
•

Check that there is no debris on the upper surface of

the cylinder head.

2
1

8 4 1 5 9

11

7 3 2 6 10

MFW71BSH007101

Legend
1. Harness terminal
2. Harness bracket
MFW41BSH035801

18. Install the gasket.

20. Install the bracket.
• Clean the head cover gasket attachment slot
and gasket, and install the gasket to the head • Install the noise cover bracket to the cylinder
cover. head cover.

NOTE:
Check that the collar has not fallen out. Tightening torque
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

1
2

BLW71BSH009001

BLW71BSH008901

19. Install the head cover. Legend

1. Bracket
• After temporarily tightening all of the bolts,
2. Head cover
tighten them in the order shown in the diagram.
3. Bolt

Tightening torque
13 N⋅m (1.3 kg⋅m/113 lb⋅in) 21. Install the noise cover.
MG6HK-WE-0871.book 291 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-291

• Install the noise cover (1) to the head cover (2),
and tighten the nut and bolt.

Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

MFW41BSH003701

2
24. Install the O-ring.
• Install the O-ring to the water pump.
• Apply soapy water (1) to the perimeter of the O-
ring.
BLW71BSH008301

1
22. Install the glow plug. (or dummy glow plug)

Tightening torque
20 (2.0 kg⋅m/14 lb⋅ft)

NOTE:
Take care not to over tighten the glow plugs, as
doing so will damage them.

23. Install the glow plug connector. (with glow plug)

Tightening torque
1 N⋅m (0.1 kg⋅m/9 lb⋅in) MFW61CSH001101

25. Install the water duct.

• Install the O-ring to the water duct, but be
careful not to damage the water pump O-ring.

Tightening torque
M8 bolt 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
M16 bolt 103 N⋅m (10.5 kg⋅m/76 lb⋅ft)

26. Install the plate.

MG6HK-WE-0871.book 292 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-292 Engine Mechanical (6HK1)

• Install after tightening the water duct.

Tightening torque
M8 bolt 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
M10 bolt 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)

MFW61CSH001201

Legend
1. Water duct
2. Plate

27. Install the engine exterior parts.

• Refer to “Engine Exterior Parts”.
28. Pour in cooling water.
MG6HK-WE-0871.book 293 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-293

Tightening Torque Table

a
c
d

b e

p g

q n
m h

l k

i
j

MFWB1BLF002901

(n) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) (o) 56 N⋅m (5.7 kg⋅m / 41 lb⋅ft)
(b) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in) (p) 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
(c) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in) (q) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(d) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(e) 2 N⋅m (0.2 kg⋅m / 17 lb⋅in)
(f) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
(g) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(h) M14: 98 N⋅m (10 kg⋅m / 72 lb⋅ft) →
147 N⋅m (15 kg⋅m / 108 lb⋅ft) →
Angle method 30° to 60°
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(i) M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M16: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
(j) M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(k) 1 N⋅m (0.1 kg⋅m / 9 lb⋅in)
(l) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(m) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
MG6HK-WE-0871.book 294 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-294 Engine Mechanical (6HK1)

Cylinder Head (Euro 2 specification)

Component Parts

1
5

2 3 4 6
25
7
24 8

23
9
10
22
11
12

13
21

20

18
19 14
17
16

15
MFW81BLF002801

Legend
1. Head cover 14. Head gasket
2. Gasket 15. Water duct
3. Bracket 16. Plate
4. Bracket 17. O-ring (water pump)
5. Connector 18. O-ring
6. Harness assembly 19. Rubber plug
7. Injector leak-off pipe 20. Glow plug connector (with glow plug)
8. Injector clamp 21. Glow plug (or dummy glow plug)
9. Injector assembly 22. Camshaft
10. Gasket 23. Rocker arm assembly
11. Bridge cap 24. Gasket
12. Bridge 25. Lower case
13. Cylinder head assembly
MG6HK-WE-0871.book 295 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-295

Removal 3. Remove the air pipe. (for Indonesia)
NOTE:
Seal the inlet duct hole, supply pump and other such
places so that debris cannot enter.

1. Remove the air breather hose (2)

1 MFWB1BSH009801
2
4. Remove the air pipe bracket. (for Indonesia)

MFW81BMH000201

Legend
1. Head cover
2. Air breather hose
3. Intake pipe
MFWB1BSH009901

5. Remove the cover bracket.

2. Remove the injection pipe. NOTE:

If the bracket is not damaged, do not remove it.
MG6HK-WE-0871.book 296 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-296 Engine Mechanical (6HK1)

9. Remove the gasket.

1
2

BLW71BSH008901
MFW71BSH005001
Legend
1. Bracket
2. Head cover
3. Bolt 10. Remove the glow plug connector. (with glow plug)
11. Remove the glow plug. (or dummy glow plug)

6. Remove the head cover.

NOTE:
Make sure you do not lose the collar that is inside the
head cover.

7. Remove the gasket.

LNW21BSH055301

12. Remove the harness assembly.

• Push the arrowed section of the connector with
your fingers to remove it.

NOTE:
BLW71BSH009001 Do not pull the wires or pry the connector with a
screwdriver.

8. Remove the lower case.

MG6HK-WE-0871.book 297 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-297

• Remove the harness bracket with the harness
still attached.

2
1

MFW41BSH026201

MFW41BSH027101

• Take out the injector harness terminal. Legend

1. Harness terminal
3 2. Harness bracket

13. If there are no malfunctions with the connector, do

not remove it.
14. Remove the rubber plug.
15. Remove the injector leak-off pipe.
16. Remove the injector clamp.
• Loosen the injector clamp bolt using a torque
wrench (T-40).
2

LNW71DSH003601

Legend
1. Injector
2. Injector harness
3. Terminal nut

MFWA1BSH003101

17. Remove the injector assembly.

• Loosen the clamp, and use the replacer to
remove the injector.
MG6HK-WE-0871.book 298 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-298 Engine Mechanical (6HK1)

• If it is difficult to remove the injector, set the
injector remover (5-8840-2826-0) on the
injector, tighten the bolt into the leak- off pipe
fitting, and using the sliding hammer small (5-
8840-0019-0) pull the injector out in an upward
direction.

NOTE:
• When removing the injector using this special tool,
make sure that the injector sleeve is not removed as
well.
• The ID plate is unique to each injector, so install a
number tag to it before storing it to ensure that it is
not used on a different injector.
• He injector and glow plug protrude from first to
prevent them from being damaged.

MFW71BSH005301

18. Remove the gasket.

1 19. Remove the plate.
20. Remove the water duct.
21. Remove the O-ring.
2
22. Remove the O-ring (water pump).
23. Remove the rocker arm assembly.
• Loosen both sides of the cam rocker arm shaft
bracket and rocker arm assembly bracket
attachment bolts equally and remove them.

NOTE:
If the attachment bolts (arrow) on both ends of the cam
rocker arm shaft brackets are removed, the rocker arm
3 and bracket may spring out. Therefore, they should not
be removed.

LNW46CMH000301

Legend
1. Sliding hammer small
2. Injector remover
3. Injector assembly

NOTE:
• Indicate the cylinder No. on the removed injector
before storing the injector.
• Be careful not to strike the injection nozzle against a MFW61BSH000301
hard surface.

24. Remove the bridge and bridge cap.

• Keep them in the order they were attached.
MG6HK-WE-0871.book 299 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-299

25. Remove the camshaft.
26. Remove the cylinder head assembly.
NOTE:
After inspecting the removed bearing, temporarily • Loosen and remove the attachment bolts from
install the removed cap and bearing in their previous the outside in the numerical order shown in the
locations so as not to confuse them with other parts. diagram.

NOTE:
Before lifting the cylinder head, check that all of the
bolts have been removed.

BLW51BSH001501

3 7 11 15 19 23 27 26 22 18 14 10 6 2

4 8 12 16 20 24 28 25 21 17 13 9 5 1

MFW41BSF000101

NOTE:
When the cylinder head is removed, idle gear C (1)
protrudes from the bottom of the cylinder head. Ensure
that the gear is not damage.
MG6HK-WE-0871.book 300 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-300 Engine Mechanical (6HK1)

MFW41BSH002901

27. Remove the head gasket.

• Check for the presence of gas or water leaks.
MG6HK-WE-0871.book 301 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-301

Disassembly

1
2
29 4 6
28 5
3
27
26
25
24
7
22 23
8
9

21

20

10
18

11
19
17
16
12

13

15

14 MFWB1BLF002801

Legend
1. Bridge cap 16. Engine coolant temperature sensor
2. Bridge 17. Valve
3. Bridge guide 18. Valve seat insert
4. Nozzle sleeve 19. Thermostat
5. Idle gear C 20. Gasket
6. Idle gear C cover 21. Water outlet pipe
7. Engine hanger 22. Engine hanger
8. Oil seal 23. Cylinder head
9. Gasket 24. Spring seat
10. Inlet cover 25. Valve guide
11. Heat protector 26. Valve stem oil seal
12. Heat protector rear bracket 27. Valve spring
13. Exhaust manifold (Front) 28. Spring upper seat
14. Heat protector 29. Split collar
15. Gasket

NOTE: rest it on wooden planks to prevent the idle gear C that

When placing the cylinder head assembly on the floor, protrudes from the bottom from getting damaged.
MG6HK-WE-0871.book 302 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-302 Engine Mechanical (6HK1)

1. Remove the bridge cap.
2. Remove the bridge.
3. Remove the intake cover.
4. Remove the gasket (intake cover).
5. Remove the heat protector.
6. Remove the exhaust manifold.
7. Remove the gasket (exhaust manifold).
8. Remove the bracket.
9. Remove the heat protector. 2
10. Remove the engine hanger.
11. Remove the engine coolant temperature sensor. 1
12. Remove the water outlet pipe.
13. Remove the thermostat.
14. Remove the gasket (thermostat).
15. Remove the camshaft position sensor. BLW51BSH000101
16. Remove the idle gear C cover. Legend
• Gently tap the outer perimeter of the sealing 1. Idle gear C
cup with the tip of a screwdriver (1) as shown in 2. Shaft
the diagram, then invert the cup and use pliers
etc. to extract it.

NOTE: 18. Remove the split collar.

Be sure not to damage the cover insertion section. • Place the cylinder head on wooden planks.
• Use a valve spring replacer (5-8840-2621-0)
and pivot (8-9439-6862-0) remove the split
collar , then remove the spring seat, spring,
seal, and valve. At this time, also remove the
spring seat that is inserted in the lower side of
the spring.
• Install tickets numbered according to cylinder to
the removed valves.

MFW41BSH009701

17. Remove idle gear C.

• Extract the idle gear shaft and remove the
gears.

MFW41BSH009801

19. Remove the valve spring upper seat.

20. Remove the valve spring.
21. Remove the valve.
MG6HK-WE-0871.book 303 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-303

22. Remove the valve stem oil seal.
23. Remove the valve spring seat.

MFW41BSH010101

MFWB1BSH003201 26. Remove the injector sleeve. Place a injector

sleeve remover (5-8840-2623-0) against the
bottom side of the head, and hit it to extract the
24. Remove the valve guide. sleeve.
• Insert the valve guide replacer (5-8840-2628-0) NOTE:
into the valve guide from the bottom of the
head, and hit it with a hammer to extract it. • Make sure you do not damage the bottom side of
the head.
• Do not re-use extracted injector sleeves.

MFW41BSH010001

MFW41BSH010201

25. Remove the valve seat insert.

• Use a welding burner to burn 2 sections (700 to
27. Remove the bridge guide.
800°C / 1,292 to 1,472°F) on the inner surface
of the insert, leave it to self cool for between 3 • Electrically weld the bridge guide head section
to 5 minutes, then extract it with a screwdriver. nut (1), install a sliding hammer and extract it.
• Do remove it if there is no wear.
CAUTION:
Do not rapidly cool it. Do not damage the cylinder head
when extracting.
MG6HK-WE-0871.book 304 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-304 Engine Mechanical (6HK1)

• Check there is no hesitance in the bridge and
bridge guide.
• Measure the gap between the bridge and
bridge guide.

Gap
1
Assembly standard Limitations for use
0.020 – 0.056 mm 0.1 mm
(0.0008 – 0.0022 in) (0.004 in)

MFW41BSH010301

28. Remove the oil seal. Place a dolly against the

inside of the head, and hit it to extract the seal.

Inspection
1. Inspect the bridge cap.
• Inspect the cap and rocker arm adjustment bolt
strike surface for wear or damage.
• If the amount of wear is greater than 0.1 mm MFW41BSH010601
(0.004 in), or if linear wear has occurred,
replace it.
3. Measure the idle gear C (1) axial direction gap.
Bridge cap wear limit • Measure idle gear C axial direction gap and the
shaft diameter.
0.1 mm (0.004 in)

Axial direction gap

Nominal Assembly Limitations
dimensions standard for use
0.09 – 0.144 mm 0.2 mm
—
(0.004 – 0.0057 in) (0.008 in)

Shaft diameter
Nominal Assembly Limitations
dimensions standard for use
30 mm (1.18 in) — 29.85 m (1.175 in)

MFW41BSH010501

2. Inspect the bridge.

MG6HK-WE-0871.book 305 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-305

Free length
Nominal Limitations for
dimensions use
59.9 mm 58.7 mm
Inlet
(2.36 in) (2.31 in)
67.0 mm 65.7 mm
Exhaust
(2.64 in) (2.59 in)

BLW51BSH002301

4. Measure the valve spring.

• Measure the squareness of the valve spring.

Squareness
Assembly Limitations for use
standard
Inlet — 3.4 mm (0.13 in) MFW41BSH010901

Exhaust — 3.4 mm (0.13 in)

• Measure the load of the valve spring when
attached.

Attached load/attached length N (kgf / lb)

Assembly Limitations for
standard use
333 (34.0 / 75.0) / 315 (32.1 / 70.8) /
Inlet
47 mm(1.85 in) 47 mm (1.51 in)
383 (39.0 / 86.0) / 363 (37.0 / 81.6) /
Exhaust
46 mm (1.81 in) 46 mm (1.81 in)

MFW41BSH010801

• Measure the free length of the valve spring.

MG6HK-WE-0871.book 306 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-306 Engine Mechanical (6HK1)

• Insert a valve into the valve guide, and
measure the looseness of the valve at a
position (a) 10 mm (0.3937 in) from the top of
the guide.

Gap between valve guide and valve stem

Assembly standard Limitations
for use
0.039 – 0.072 mm 0.2 mm
Inlet valve
(0.0015 – 0.0028 in) (0.008 in)
0.064 – 0.096 mm 0.25 mm
Exhaust valve
(0.0025 – 0.0038 in) (0.01 in)

MFW41BSH011001

5. Inspect the valve.

• Measure the valve stem abrasion. 1
• Measure the 3 locations in the diagram.
a

Valve stem outer diameter

Nominal dimensions Limitations for use 2

8 mm (0.315 in) 7.88 mm (0.310 in)

• If the amount of valve stem abrasion exceeds

the limit, replace both the valve and the valve
guide. MFW61BSH001501

Legend
1. Valve
2. Valve guide

• Measure the thickness of the valve.

Valve thickness
Nominal Limitations
dimensions for use
1.71 mm
Inlet valve
(0.0673 in) 1.3 mm
1.75 mm (0.051 in)
Exhaust valve
(0.0689 in)
MFW41BSH011101
MG6HK-WE-0871.book 307 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-307

Amount of valve depression

Nominal dimensions Limitations
for use
0.73 – 1.10 mm 2.3 mm
Inlet valve
(0.0287 – 0.0433 in) (0.091 in)
1.16 – 1.54 mm 2.8 mm
Exhaust valve
(0.0457 – 0.0606 in) (0.110 in)

MFW41BSH011301

• Inspect and repair the valve seat striking 3

surface. 2
• Apply red lead paint to the valve insert, and
inspect the width of the seat striking surface.
Also, inspect for lack of strike, and that the
strike position is in the center of the valve seat
face.
MFW51BSH003501

Width of seat striking surface Legend

1. Striking width
Assembly standard 2. Amount of depression
Inlet valve 3. Seat angle
2.7 mm (0.106 in)
Exhaust valve

• If there is a defect in the valve striking width or Perform valve slide-matching

the striking surface, use a seat cutter that • Apply compound to the valve striking surface,
matches the stem diameter to repair it. and perform sufficient slide matching between
the valve seat and valve striking surface.

Valve seat angle (deg)

Inlet valve 30
Exhaust valve 45

Valve stem diameter

8 mm (0.315 in)

• After valve seat grinding, measure the amount

of valve depression to be sure that it is within
the useable limit.

MFW41BSH011601
MG6HK-WE-0871.book 308 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-308 Engine Mechanical (6HK1)

• After valve slide-matching, clean the cylinder

head and valve.
6. Inspect the valve seat insert.
• Measure the amount of valve depression (1).
• Insert a new valve into the valve guide, and
measure the dimensions from the bottom of the
cylinder head to the valve surface.

Amount of valve depression

Nominal dimensions Limitations
for use
0.73 – 1.10 mm 2.3 mm
Inlet valve
(0.0287 – 0.0433 in) (0.091 in)
1.16 – 1.54 mm 2.8 mm
Exhaust valve
(0.0457 – 0.0606 in) (0.110 in) MFW41BSH011801

• Inspect the cylinder head for cracks and

damage.
• Inspect using a magnetic flaw detector or dye
penetrant testing method if necessary .

NOTE:
When magnetizing using the magnetic flaw detector,
always demagnetize when the test is complete.
(Remnant magnetism is less than 5G)

MFW41BSH011701

7. Inspect the cylinder head.

• Measure the amount of distortion of the cylinder
head.
• Clean off the carbon without damaging the
processing surfaces of the cylinder head, valve
seat, insert etc.
• Place a straightedge against the mounting
surface of the cylinder head, and measure the MFW41BSH011901
amount of distortion in locations A to F on the
diagram using a thickness gauge.
• With the hydraulic test, apply 490 kPa (5 kgf/
Amount of distortion cm2/71 psi) of water pressure for 3 minutes,
and inspect each section of the head for water
Limitations for use 0.2 mm (0.008 in) leaks.

NOTE: NOTE:
Cannot be repaired because the timing gear backlash Perform the hydraulic test with the nozzle holder
will change. attached.
MG6HK-WE-0871.book 309 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-309

Reassembly • Apply engine oil to the outer periphery of the
guide, and use a bridge guide setting tool (5-
1. Install the oil seal to the cylinder head.
8840-2626-0) to hammer it in to the finishing
• Use a oil seal installer (5-8840-2627-0). depth of the cylinder head hole. (Reference:
• Hit the seal evenly so that it does not slant. The bridge guide height is approx. 37.5 mm
(1.476 in) (b) from the head upper surface.)
NOTE:
Take care not to damage the lip section.

b
a
MFW61BSH000901

MFW41BSH012001 (a) 122.5 mm (4.823 in)

(b) 37.5 mm (1.476 in)

3. Install the injector sleeve.

• Install the O-ring (1) and (2) to the injector
1 2 sleeve, and apply engine oil.
• Apply sealant (LOCTITE LT620) to the injector
sleeve tapered section (3).

MFW41BSH012101

Legend
1. Oil seal
2. Oil seal installer

2. Install the bridge guide.

MG6HK-WE-0871.book 310 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-310 Engine Mechanical (6HK1)

• Apply engine oil (4) to injector sleeve
installation side .

1
2

2
3 6
5 3

LNW21BMH001001

Legend
MFW61BMH000101
1. Punch bar
Legend 2. Ball
1. O-ring (white paint) 3. Guide sleeve
2. O-ring 4. Injector sleeve
3. Apply LOCTITE 5. Injector clamp
4. Apply engine oil 6. Injector clamp bolt

4. Install the valve seat insert.

• Install the injector sleeve setting tool (5-8840- • Carefully clean off the carbon, rust, etc. From
2624-0) and install injector sleeve to the the mounting surface of the insert, and press-fit
cylinder head. the insert using a press.
• Push the injector sleeve in with a guide sleeve
so that it is firmly seated at the bottom side of
the cylinder head.
• After inserting the guide sleeve, fix it with the
injector clamps and injector clamp bolts.
• Insert the ball (bearing steel ball 9.525 mm/
0.375 in) into the guide sleeve, and use a
punch bar and hammer to knock the ball out.

NOTE:
• After carefully removing the shavings from the
cylinder head screw section, insert the sleeve.
• Lift the cylinder head so that the ball can come out
from the bottom.

MFW41BSH012401
MG6HK-WE-0871.book 311 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-311

1
a

LNW21BSH018601 LNW71BSH001701

Legend 6. Install the lower spring seat.

1. Dolly 7. Install the valve stem oil seal.
2. Insert
• Apply oil to the oil seal, and use a valve stem
3. Press
seal setting tool (5-8840-2625-0) to tap in the
valve guide.
5. Install the valve guide.
NOTE:
• Hammer in the valve guide from the upper Check the valve seal for shape deformation and
surface of the cylinder head, using the valve cracks, and that the spring has not detached.
guide replacer (5-8840-2628-0) and valve guide
installer (5-8840-2930-0).

NOTE:
Replace the valve guide as a set with the valve.

MFW41BSH012601

8. Install the valve.

• Apply engine oil to the valve stem, and insert
MFW41BSH012501 the cylinder head.

NOTE:
Dimensions (a) of the valve guide surface from the Check the assembly of the valve.
cylinder head upper surface “ E “ Mark : Exhaust
17.1 – 17.9 mm (0.6732 – 7047 in) “ I “ Mark : Inlet
MG6HK-WE-0871.book 312 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-312 Engine Mechanical (6HK1)

MFW41BSH012701 MFW41BSH009801

9. Install the valve spring.

• Place the cylinder head on wooden planks. 12. Install a gasket in the thermostat flange part.
• Install the valve spring with the side that has the 13. Install the thermostat.
identification paint facing the cylinder head • Install the rubber gasket to the flange section.
surface. • Line up the position of the jiggle valve (1) as
shown in the diagram.
Identification paint
Inlet valve spring Blue
Exhaust valve spring White

10. Install the spring upper seat.

11. Install the split collar.
• Use a valve spring replacer (5-8840-2621-0)
and pivot (8-9439-6862-0) to push the valve
spring in, then install the split collar.
1
• After attaching, gently hit the valve stem head
section with a rubber mallet so the split collar
falls into place.

NOTE:
Check that the split collar is firmly in the valve stem
slot.
MFW91BSH000801

14. Install the water outlet pipe.

• Install the thermostat as shown in the diagram,
and install the water outlet pipe.

Tightening torque N⋅m (kg⋅m/lb⋅ft)

24 (2.4 / 17)

NOTE:
If you Install the thermostat in the wrong position, you
will not be able to install the water outlet pipe.
MG6HK-WE-0871.book 313 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-313

1
2

3 2

MFW41BSH013101 MFW71BSH006301

Legend Legend
1. Water outlet pipe 1. Plug
2. Incorrect attachment prevention stopper 2. Engine coolant temperature sensor
3. Thermostat with jiggle valve 3. Plug

15. Install the engine coolant temperature sensor.

• Install the Plug in position (1) shown in the 16. Install the rear side engine hanger (1) to the
diagram. cylinder head.
• Apply ThreeBond 1207C or LOCTITE 271 to
the thread section and attach. Tightening torque N⋅m (kg⋅m/lb⋅ft)
94 (9.6 / 69)
Tightening torque N⋅m (kg⋅m/lb⋅ft)
•

Plug (1) 108 (11.0 / 80)

Plug (3) 25 (2.5 / 18)
1
• Install the engine coolant temperature sensor in
position (2) shown in the diagram.
• The thread section of the new plug switch is
treated with plating processing. When re-using
plug switches, apply ThreeBond 1207C or
LOCTITE 271, and install to the location shown
in the diagram.
• Apply LOCTITE 262 or 962 to the engine
coolant temperature sensor threaded portion
and tighten at the specified torque.

Tightening torque N⋅m (kg⋅m/lb⋅ft)

20 (2.0 / 14) MFW61BSH000701

17. Install the heat protector rear bracket and heat

protector.

Tightening torque N⋅m (kg⋅m/lb⋅ft)

24 (2.4 / 17)
MG6HK-WE-0871.book 314 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-314 Engine Mechanical (6HK1)

NOTE:
Install before assembling the exhaust manifold.

1 MFW41BSH013501

Legend
1. Casting surface side
MFW81BSH007201
2. Gasket
Legend
1. Heat protector rear bracket
2. Heat protector
19. Install the exhaust manifold.
• Move each of the seal ring alignment holes
120° and assemble them to the rear exhaust
18. Install the exhaust manifold gaskets. manifold.
• Install so that the protruding section of the
gaskets is down.

1 2 3

MFW81BSH005601

Legend
MFW41BSH013401
1. Exhaust manifold (rear side)
2. Seal ring
NOTE:
3. Exhaust manifold (front side)
Check that the gasket is securely attached to the
cylinder head. If it is attached incorrectly, it will ride up
on the casting-surface side of the cylinder head as
shown in the diagram.
MG6HK-WE-0871.book 315 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-315

• Install the exhaust manifold. • Tighten them in the order shown in the diagram.
Exhaust nut (10 pieces)
Tightening torque N⋅m (kg⋅m/lb⋅ft)
55 (5.6 / 41)

Exhaust distance nut (2 pieces)

Tightening torque N⋅m (kg⋅m/lb⋅ft)
34 (3.5 / 25)
2
11 8 4 6 9
7 3 1 5
• Assemble the distance tube, flat washer and 12 10
coned disc spring washer as shown in the
diagram, and tighten the exhaust manifold.
• Only the distance nut can be re-used.

1 2
MFW81BSH005701

20. Install the heat protector.

21. Install the inlet cover.
3
• Install the gasket to the inlet cover (1), and
tighten in the order shown in the diagram.

4
Tightening torque N⋅m (kg⋅m/lb⋅ft)
25 (2.5 / 18)

MFWB1BSH003501

Legend
1. Distance tube
2. Nut
3. Coned disc spring washer
4. Distance nut

• Tighten the distance nut (arrow) in the 7th and

12th attachment positions shown in the
diagram.
1

MFW71BSH001801
MG6HK-WE-0871.book 316 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-316 Engine Mechanical (6HK1)

Reamer bolt

13 9 5 3 8 12
4

14 10 6 1 2 7 11

MFW81BSH005501 MFW41BSH003001

22. Apply engine oil to the bridge and install it. 2. Install the cylinder head assembly.
• Install the dowel to the cylinder block, line up
NOTE: the cylinder head bolt holes and gently rest it
Move it up and down to check that it moves smoothly. on.
23. Apply engine oil to the bridge cap and install it.

MFW41BSH003101

MFW41BSH014001

• Apply molybdenum-disulfide to the thread

Installation section and seating surface of the M14 bolts,
and engine oil to the thread section of the M10
1. Install the head gasket.
bolts, and tighten them to the specified torque
• Apply approx. 2 mm (0.0787 in) thickness, and angle in the order shown in the diagram.
approx. 3 mm (0.1181 in) width of liquid gasket
(ThreeBond 1207C) to the alignment sides of
the cylinder block and flywheel housing, and Tightening torque N⋅m (kg⋅m/lb⋅ft)
install the head gasket.
98 (10.0 / 72) →
NOTE: M14 bolt 147 (15.0 / 108) →
Remove any deposits, carbon, sealing compound, etc. angle method 30° to 60°
from the upper surface and lower surface of the M10 bolt
38 (3.9 / 28)
cylinder block. (#.27, 28)
MG6HK-WE-0871.book 317 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-317

26 22 18 14 10 6 2 3 7 11 15 19 23 27

25 21 17 13 9 5 1 4 8 12 16 20 24 28

BLW71BSF000101

NOTE:
To check the tightness of the M14 bolts, rotate the tool 2
1
in the tightening direction.

Checking tightening torque N⋅m (kg⋅m/lb⋅ft)

142 (14.5 / 105)

3. Install the idle gear C.

• Apply engine oil on the idle gear C shaft and 4
the inner diameter of the idle gear. 3
Apply molybdenum-disulfide grease to the
thread and seating surface of the bolt.
Install the idle gear C so that the side with gear
groove is on the side of the rear surface of the
engine.
• Tighten the idle gear C with the designated
LNW61BSH003901
torque.
• Do not use impact wrench and like. Legend
1. Idle gear C
2. Idle gear C shaft
Tightening torque N⋅m (kg⋅m/lb⋅ft) 3. Washer
4. Bolt
77 (7.9 / 57)

4. Install the idle gear C cover.

• Apply liquid gasket (ThreeBond 1386 or
LOCTITE 962T) to the entire circumference of
the insertion hole, and tap in the cover so that
the edge is 0.5 – 1.5 mm (0.0197 – 0.0591 in)
inside the cylinder head beveling as shown in
the diagram.
MG6HK-WE-0871.book 318 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-318 Engine Mechanical (6HK1)

• Engage idle gear C with the camshaft gear so
that the camshaft gear B mark lines up with the
top surface of the cylinder head as shown in the
diagram, then gently install the camshaft.

NOTE:
• Make sure you do not damage the camshaft
bearing.
a • Check that the camshaft gear B mark is on the top
surface of the cylinder head.
• If the camshaft gear B mark is not in line with the
cylinder head top surface, realign the B mark.

BLW51BSH002401

Legend
(a) 0.5 – 1.5 mm (0.0197 – 0.0591 in)

5. Install the camshaft.

• At this time, check that the alignment mark
white paint can be seen as shown in the
diagram (#1 cylinder is in the top compression
dead point) from the flywheel housing side
timing check hole when looking from above the
slanting surface of the supply pump gear.
MFW41BSH003201

• Clean the camshaft bearing and cap, assemble

the bearing and cap, and apply engine oil to the
rotational movement surface.
• Face the arrow on the top surface of the
1
camshaft bearing cap towards the engine front
side, and install in numerical order. Tighten both
sides of the cap at the same time as the rocker
arm.

NOTE:
Point the arrow on the top surface of the cap towards
the engine front side, and check that they are attached
in numerical order.
BLW71BSH005701 • Apply engine oil to the thread and seating
Legend section, and tighten uniformly from the center
1. Timing check hole outwards.
2. Supply pump gear

Tightening torque N⋅m (kg⋅m/lb⋅ft)

27 (2.8 / 20)
• Clean the camshaft bearing and mounting
section, install the bearing, and apply engine oil
to the rotational movement surface of the
bearing.
MG6HK-WE-0871.book 319 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-319

• Apply engine oil to the bridge and bridge cap
and install them.

BLW51BSH001501

MFW61BSH000401

• Extract the gear alignment pin and take care

not to drop it inside the engine. 8. Install the rocker arm assembly.
NOTE: • Clean the camshaft bearing and cam rocker
Do not forget to remove the gear alignment pin. arm shaft bracket, assemble the bearing and
bracket, and apply engine oil to the rotational
6. Install the camshaft position sensor. movement surface.
• Fully tighten the rocker arm adjustment screw,
and apply engine oil to the roller section.
Tightening torque N⋅m (kg⋅m/lb⋅in)
• Install the rocker arm assembly.
8 (0.8 / 69)

MFW51BSH003601

Legend
MFW71BSH004101 1. Front cam bracket
2. Rocker arm bracket
3. Rear cam bracket
7. Install the bridge (2) and bridge cap (1).
MG6HK-WE-0871.book 320 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-320 Engine Mechanical (6HK1)

• Tighten them in the numerical order shown in
the diagram.

Tightening torque N⋅m (kg⋅m/lb⋅ft)

Cam rocker arm shaft
27 (2.8 / 20)
bracket
Rocker arm bracket 56 (5.7 / 41)

NOTE:
• Only for the camshaft bearing mounting section,
apply oil to the stud bolt screw section, and nut
thread part and seating surface, and tighten them.
• Refer to “Valve clearance adjustment” section for
details on valve clearance adjustment.

MFW41BSH003801

• Apply liquid gasket (1) (ThreeBond 1207B) to

the top surface of the rubber plug.
4 6 8 9 7 5 3 1
2 NOTE:
Install the lower case within 5 minutes of applying the
liquid gasket.

11 12 13 10

MFW41BSH003501

9. Install the rubber plug.

• Apply liquid gasket (ThreeBond 1207B) to the
rubber plug, and install it to the cylinder head.

NOTE:
If there are cracks in the rubber plug, do not re-use it.

MFW41BSH003901

10. Install the injector.

• Insert gasket into the tip of the injector and
insert it into the cylinder head.
• Insert the injector clamp at the same time.

NOTE:
• The injector ID plate is unique to that particular
injector. Do not confuse it with a different injector
ID plate.
• When the injector assembly is replaced, use a
scan tool to write the ID code to the ECM. Refer to
“Engine Control Section” for the writing procedure.
MG6HK-WE-0871.book 321 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-321

• Tighten the injection pipe clip (1) at the
specified torque.

Tightening torque N⋅m (kg⋅m/lb⋅in)

6 (0.6 / 52)

1
1
1

1
MFW71BSH005301

a
1
11. Apply engine oil to the thread section and seating
section of the injector clamp bolt, and temporarily
tighten it.

MFW81BSH010001

(a) 6 N⋅m (0.6 kg⋅m / 52 lb⋅in)

2 3

4 13. Tighten the injector clamp.

(temporarily tightened earlier) at the specified
1
torque.

Tightening torque N⋅m (kg⋅m/lb⋅ft)

5
30 (3.1 / 22)
6
14. Tighten the injection pipe at the specified torque.

BLW71BSH020401 Tightening torque N⋅m (kg⋅m/lb⋅ft)

Legend Injector side 30 (3.1 / 22)
1. O-ring Common rail side 25 (2.5 / 18)
2. Injector assembly
3. Injector clamp bolt
4. Injector clamp
5. O-ring
6. Gasket

12. Install the injection pipe.

• Thinly apply engine oil to the outer
circumference of the injector side sleeve nut
and install it.
• Lightly tighten the sleeve nut with spanner so
that it is airtight to the injector and common rail
side.
MG6HK-WE-0871.book 322 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-322 Engine Mechanical (6HK1)

16. Insert gasket into the lower case slot and install it
to the cylinder head.
5
4 6
3 Tightening torque N⋅m (kg⋅m/lb⋅in)
2
1
13 (1.3 / 113)

MFW81BSH008901

Legend
1. Injection pipe #1
2. Injection pipe #2
3. Injection pipe #3
4. Injection pipe #4
5. Injection pipe #5
6. Injection pipe #6
7. Common rail (Fuel rail) MFW41BSH027201

15. Install the leak-off pipe to the injector. 17. Install the injector harness assembly.
• Install the harness bracket with the harness still
attached.
Tightening torque N⋅m (kg⋅m/lb⋅in)
12 (1.2 / 104)
Tightening torque N⋅m (kg⋅m/lb⋅ft)
NOTE: 22 (2.2 / 16)
• Always use brand new gasket.
• Re-check to make sure you didn’t forget to tighten • Install the terminal nut to the injector, and
anything. tighten to the specified torque strength.

Tightening torque N⋅m (kg⋅m/lb⋅in)

2 (0.2 / 17)

NOTE:
• As the terminal is a single unit, tighten the nuts 2 to
3 turns each until fully tightened.
• Over-tightening the nuts will cause damage to the
terminal stud. Therefore, they should never be over-
tightened.

MFW41BSH023501
MG6HK-WE-0871.book 323 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-323

NOTE:
•

Check that there is no debris on the upper surface of

the cylinder head.

2
1

8 4 1 5 9

11

7 3 2 6 10

MFW71BSH007101

Legend
1. Harness terminal
2. Harness bracket
MFW41BSH035801

18. Install the gasket.

20. Install the bracket.
• Clean the head cover gasket attachment slot
and gasket, and install the gasket to the head • Install the cover bracket to the cylinder head
cover. cover .

NOTE:
Check that the collar has not fallen out. Tightening torque N⋅m (kg⋅m/lb⋅ft)
19 (1.9 / 14)

1
2

BLW71BSH009001

BLW71BSH008901

19. Install the head cover. Legend

1. Bracket
• After temporarily tightening all of the bolts,
2. Head cover
tighten them in the order shown in the diagram.
3. Bolt

Tightening torque N⋅m (kg⋅m/lb⋅in)

13 (1.3 / 113)
MG6HK-WE-0871.book 324 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-324 Engine Mechanical (6HK1)

21. Install the air pipe bracket. (for Indonesia)

1
Tightening torque N⋅m (kg⋅m/lb⋅ft)
24.5 (2.5 / 18)

22. Install the air pipe. (for Indonesia)

Tightening torque N⋅m (kg⋅m/lb⋅ft)

Exhaust brake side 30 (3.1 / 22)
Air hose side 37 (3.8 / 27)
Clamp nut 10.8 (1.1 / 95 lb⋅in)

23. Install the glow plug. (or dummy glow plug)

MFW61CSH001101
Tightening torque N⋅m (kg⋅m/lb⋅ft)
20 (2.0 / 14)
26. Install the water duct.
NOTE: • Install the O-ring to the water duct, but be
Take care not to over-tighten the glow plugs, as careful not to damage the water pump O-ring.
doing so will damage them.

24. Install the glow plug connector. (with glow plug) Tightening torque N⋅m (kg⋅m/lb⋅ft)
M8 bolt 19 (1.9 / 14)
Tightening torque N⋅m (kg⋅m/lb⋅in) M16 bolt 103 (10.5 / 76)
1 (0.1 / 9)
27. Install the plate.
• Install after tightening the water duct.

Tightening torque N⋅m (kg⋅m/lb⋅ft)

M8 bolt 19 (1.9 / 14)
M10 bolt 38 (3.9 / 28)

MFW41BSH003701

25. Install the O-ring.

• Install the O-ring to the water pump.
• Apply soapy water (1) to the perimeter of the O-
ring.
MG6HK-WE-0871.book 325 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-325

1
2

MFW61CSH001201
3

Legend
1. Water duct
2. Plate

28. Install the air breather hose.

MFW81BMH000201
Tightening torque N⋅m (kg⋅m / lb⋅ft)
M6 Bolt 9 (0.9 / 78 lb⋅in) Legend
1. Head cover
M10 Bolt 40 (4.1 / 30 ) 2. Air breather hose
3. Intake pipe

29. Install the engine harness.

30. Pour in cooling water.
MG6HK-WE-0871.book 326 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-326 Engine Mechanical (6HK1)

Tightening Torque Table

c
d

b
e

p g

n
m h

l k

i
j

MFW81BLF002901

(n) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(a) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in) (o) 56 N⋅m (5.7 kg⋅m / 41 lb⋅ft)
(b) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft) (p) 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
(c) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
(d) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(e) 2 N⋅m (0.2 kg⋅m / 17 lb⋅in)
(f) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
(g) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(h) M14: 98 N⋅m (10 kg⋅m / 72 lb⋅ft) →
147 N⋅m (15 kg⋅m / 108 lb⋅ft) →
Angle method 30° to 60°
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(i) M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M16: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
(j) M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(k) 1 N⋅m (0.1 kg⋅m / 9 lb⋅in)
(l) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(m) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
MG6HK-WE-0871.book 327 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-327

Rocker Arm
Component Parts

3
2

MFW41BLF001301

Legend
1. Front cam bracket 4. Bracket
2. Rocker arm 5. Rocker arm shaft
3. Washer
MG6HK-WE-0871.book 328 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-328 Engine Mechanical (6HK1)

Disassembly
1. Remove the front cam bracket and rear cam
bracket.
Remove the rocker arm shaft tightening bolt (1)
while pressing down on the front cam bracket (2),
and remove the rocker arm, washer, and bracket in
this order.

2
MFW41BSH014301

• When measuring the distance between the

roller pin and roller, pass string etc.
Between the rocker arm and roller as shown in
the diagram, pull hard on the string in the
MFW41BSH014101 direction of the arrow, and measure the step
between the rocker arm and roller when the
roller is in the pushed out condition (A
Inspection dimension).
Next, mark the measurement points and extract
1. Inspect the rear cam bracket oil hole for blockages. the string, and with the roller pushed to the
back, measure the step between the mark
positions on the rocker arm and roller (B
dimension).
Check that the measured value of A dimension
minus B dimension is within the standard value.

Gap between the roller pin and roller

Assembly standard Limitations for use
0.068 – 0.100 mm
0.2 mm (0.008 in)
(0.0027– 0.004 in)

MFW41BSH014201

2. Inspect the rocker arm roller section for wear or

damage.
• Inspect the roller surface for damage.
MG6HK-WE-0871.book 329 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-329

5
6
1

2
4

5
3

MFW51BSH003301 MFW41BSH014601

Legend
1. Roller
2. B dimension • Measure the diameter of the rocker arm shaft
3. Slide calipers and the gap between the shaft and rocker arm.
4. A dimension
5. Direction for pulling the string
6. Direction for pushing the roller in Nominal Assembly Limitations
dimensions standard for use
Gap
between 0.01 –
3. Inspect the rocker arm shaft oil hole for blockages. the rocker 0.056 mm 0.2 mm
—
arm shaft (0.0004 – (0.008 in)
and rocker 0.0022 in)
arm
Rocker arm
22 mm 21.85 mm
shaft —
(0.87 in) (0.86 in)
diameter

MFW41BSH014501

• Measure the run out of the rocker arm shaft.

Amount of Run out

Limitations for use 0.3 mm (0.012 in)
MFW41BSH014701
MG6HK-WE-0871.book 330 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-330 Engine Mechanical (6HK1)

Reassembly
1. Install the rear cam bracket to the rocker arm shaft.
Temporarily tighten installment bolt (1) so that it
does not slip out.

NOTE:
Fully fixing bolt when installing the cylinder head.

2
1

MFW41BSH015001

3. Install the front cam bracket.

• Install the front cam bracket to the rocker arm
shaft.
• Temporarily tighten installment bolt so that the
front cam bracket does not slip out.
MFW41BSH014801

NOTE:
Fully tighten the bolts when installing the cylinder head.
2. Install the rocker arm, washer, and bracket
sequentially as shown in the diagram.

MFW41BSH015101

MFW41BSH014901

• Apply engine oil to the rocker arm bushing (2)

and roller section (1) and install the rocker arm.
MG6HK-WE-0871.book 331 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-331

Camshaft
Component Parts

2
1

MFW61BLF000601

Legend
1. Bolt 4. Knock pin
2. Washer 5. Camshaft
3. Camshaft gear

Disassembly
1. Remove the camshaft gear.
• Fix the hexagonal section of the camshaft in a
vice through an aluminum adaptor, and
remove.
MG6HK-WE-0871.book 332 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-332 Engine Mechanical (6HK1)

• Remove the camshaft gear attachment bolts,
insert wood chippings into the puller, and
remove the camshaft gear.

1
MFW41BSH015401

3. Visually inspect the camshaft and inspect for run

out.
LNW21BSH056201
• Inspect the journal section and cam section for
Legend wear, and replace any that have faults.
1. Wood chippings
• Use a V block to hold #1 and #7 journal
2. Remove the knock pin. sections, put a dial gauge against the #4
journal, gently rotate the camshaft through 1
rotation and measure the amount of run out.
Inspection
1. Inspect the gear teeth section, breakaway, pitching Camshaft amount of Run out
etc.
Limitations for use 0.05 mm (0.002 in)

MFW41BSH015301

MFW41BSH015501

2. Measure the dimensions from the camshaft thrust

surface to the camshaft gear.
4. Measure the amount of cam lift.
• Inspect the cam surface for damage, and
Dimensions from camshaft thrust surface to the measure the amount of cam lift.
camshaft gear
27.945 – 27.985 mm
Assembly standard
(1.1002 – 1.1018 in)
MG6HK-WE-0871.book 333 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-333

• Measure with 1 – 2 in the diagram.
Repair any slight damage or wear with an oil
stone.

Amount of cam lift (2 – 1)

Assembly Limitations for
standard use
7.851 mm 7.351 mm
Inlet
(0.309 in) (0.2894 in)
9.491 mm 9.040 mm
Exhaust
(0.3737 in) (0.3559 in)

MFW41BSH015701

1
6. Measure the gap between the journal and bearing.
2
• Measure the inner diameter of the camshaft
bearing using a cylinder gauge.
• Read the difference between the bearing inner
diameter and journal diameter.
If the oil clearance has exceeded the limit,
replace the bearing.

Clearance between the journal and bearings

MFW41BSH015601 Assembly standard Limitations for use
0.025 – 0.087 mm 0.15 mm
(0.0010 – 0.0034 in) (0.0059 in)
5. Measure the cam journal.
• Measure the positions shown in the diagram
with a micrometer.

Diameter
Nominal dimensions Limitations for use
40 mm (1.575 in) 39.85 mm (1.569 in)

MFW41BSH015801
MG6HK-WE-0871.book 334 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-334 Engine Mechanical (6HK1)

Reassembly
1. Install the knock pin.
2. Install the camshaft gear.
• With the camshaft gear center boss section
protruding side on the camshaft side, line up
the knock pin, and install the camshaft gear.

Tightening torque
142 N⋅m (14.5 kg⋅m/105 lb⋅ft)

NOTE:
• Take care not to damage the cam section and
journal section when tightening the gear.

LNW21BSH020301
MG6HK-WE-0871.book 335 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-335

Tightening Torque Table

MFW61BMF000201

(a) 142 N⋅m (14.5 kg⋅m / 105 lb⋅ft)

MG6HK-WE-0871.book 336 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-336 Engine Mechanical (6HK1)

Timing Gears, Flywheel and Flywheel Housing

Component Parts

2
1

5
4

13

11 12 3

9
7

10 8

MFW81BLF003301

Legend
1. Idle gear A 8. Air compressor idle gear
2. Idle gear A shaft 9. Oil seal
3. Oil pump 10. Flywheel
4. Idle gear B 11. Cover
5. Idle gear B shaft 12. Flywheel housing
6. Slinger 13. Crankshaft position sensor
7. Air compressor idle gear shaft

Removal • Refer to “Oil Pan” in Lubrication System.

1. Lower the engine assembly from the vehicle. 4. Remove the Crankshaft Position Sensor (CKP).
• Refer to “Engine Assembly”.
2. Remove the cylinder head.
• Refer to “Cylinder Head”.
3. Remove the oil pan.
MG6HK-WE-0871.book 337 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-337

• Remove it before removing the flywheel. 3. Remove the flywheel.
Manual transmission model

1
2
3
4
5

1 2

MFW81BSH010701
MFW71BSH002501
Legend
Legend 1. Flywheel housing
1. Crankshaft position sensor 2. Flywheel
2. Flywheel housing 3. Pilot bearing
4. Snap ring
Automatic transmission model
5. Washer

2
1 b. It is a specification of the automatic
transmission.
1. The flexible plate installation bolt is
removed.
2. Washer and flexible plate and flexible plate
adaptor are removed.
3. The installation bolt is removed.
4. Washer is removed.

MFW81BSH010501

Legend
1. Crankshaft position sensor
2. Flywheel housing

5. Remove the flywheel.

a. It is a specification of the manual transmission.
1. The installation bolt is removed.
2. Washer is removed.
MG6HK-WE-0871.book 338 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-338 Engine Mechanical (6HK1)

5. Remove the flywheel.

1
2
3

4
5
6

MFW41BSH028801
MFW81BSH010801

Legend
1. Flywheel housing 10. Remove the oil seal.
2. Flywheel • Remove the flywheel housing oil seal while
3. Washer being careful not to damage the flywheel
4. Flexible plate adaptor housing surface to press fit the oil seal.
5. Flexible plate
6. Flexible plate washer NOTE:
• Always replace it when disassembling.
• Replace the slinger as a set along with the oil seal.
6. Remove the cover.
7. Remove air compressor idle gear .
8. Remove air compressor idle gear shaft.
9. Remove the flywheel housing.

NOTE:
• The bolts in the diagram tighten the flywheel
housing from the cylinder body side. Do not forget to
remove them.
• Three M8 bolts are used to install the idle gear A
shaft and flywheel housing. Do not forget to remove
them.
• After removing air compressor idle gear, there is
one M14 bolt installed.
Do not forget to remove it.

MFW41BSH004501

11. Remove the slinger, and measure the backlash of

each idle gear.
• Use a Slinger replacer (8-9439-6858-0) to
remove the slinger.

NOTE:
Replace the slinger as a set along with the oil seal.
MG6HK-WE-0871.book 339 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-339

Axial direction gap

Limitations for
Assembly standard
use
0.15 – 0.225 mm 0.3 mm
Idle gear A
(0.006 – 0.009 in) (0.012 in)
0.08 – 0.155 mm 0.2 mm
Idle gear B
(0.003 – 0.006 in) (0.008 in)

MFW41BSH004601

a. Measure the backlash.

• Measure the backlash of each idle gear.

Backlash
Assembly standard Limitations for use
0.1 – 0.17 mm 0.3 mm
(0.004 – 0.007 in) (0.012 in) MFW41BSH004801

12. Remove idle gear A.

13. Remove idle gear A shaft.
14. Remove the oil pump.
15. Remove idle gear B.
16. Remove idle gear B shaft.

Disassembly
1. Remove the snap ring from the flywheel.

MFW41BSH004701

b. Measure the axial direction gap.

• Measure the axial direction gap for each idle
gear.
MG6HK-WE-0871.book 340 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-340 Engine Mechanical (6HK1)

2. Use a Pilot bearing replacer (9-8521-0157-0) to NOTE:
remove the pilot bearing. Do not clean it as it is a grease seal type.

MFW41BSH017901
MFW41BSH018201

3. Remove the flywheel starter gear from the

flywheel. 2. Inspect the flywheel.
• Place wood chips on the flywheel, place an • Inspect the flywheel for cracks and impact
application bar on the edge surface of the marks, and measure the amount of wear.
flywheel starter gear, and tap it evenly to Either repair or replace it if there are any
remove it. abnormalities.

NOTE:
Inspect the flywheel starter gear for damage first, and if Nominal Limitations
there are no problems, do not remove it. dimensions for use
Dimensions 43 mm 44 mm
14 inch
from the clutch (1.693 in) (1.732 in)
disc friction
surface to the
crankshaft 48 mm 49 mm
15 inch
mounting (1.890 in) (1.929 in)
surface (a)

MFW41BSH018001

Inspection
1. Inspect the pilot bearing.
• Inspect the pilot bearing for wear and abnormal
noises. a
MFW81BSH008101
MG6HK-WE-0871.book 341 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-341

3. Inspect the flywheel starter gear wear. mm (in)

NOTE: Nominal Limitations
Inspect the tooth surface, and replace the flywheel dimensions for use
starter gear if it is damaged or excessively worn. Idle gear shaft A, B 29.959 – 29.980 29.8
circumference (1.1795 –1.1803) (1.1732)
Idle gear shaft C 29.959 – 29.980 29.8
circumferences (1.1795 –1.1803) (1.1732)
Air compressor
29.959 – 29.980 29.8
idle gear shaft
(1.1795 –1.1803) (1.1732)
circumferences
Gap between idle
0.020 – 0.062 0.2
gear A, B shafts and
(0.0008 –0.0024) (0.008)
gears
Gap between idle
0.020 – 0.062 0.2
gear C shaft and
(0.0008 –0.0024) (0.008)
gears
Gap between air
0.020 – 0.062 0.2
compressor idle
(0.0008 –0.0024) (0.008)
shaft gear

MFW41BSH018401

4. Inspect each gear teeth section, breakaway,

pitching etc. 1

MFW41BSH019601

Reassembly
1. Install the flywheel ring gear to the flywheel.
MFW41BSH019501 • Place the flywheel starter gear on a metal grill,
heat the inner surface of the gear evenly with a
gas burner, point the larger side of the gear
5. Measure the diameter of each idle gear shaft (1) beveling (1) towards the flywheel side and
and the gap between the shaft and idle gear. install it.

NOTE:
• The temperature for the ring gear shrinkage fit is
less than 200°C (392°F).
• During the shrink fit, put the load of 68.6 kN (6995
kg / 15424 lb) on the ring gear to keep flatness.
• After shrink fit, check that the ring gear is firmly
seated in the flywheel.
MG6HK-WE-0871.book 342 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-342 Engine Mechanical (6HK1)

• Apply oil to the inner circumference of the idle
gear and the thrust section, and tighten the bolt
through the thrust collar.

Tightening torque
95 N⋅m (9.7 kg⋅m/70 lb⋅ft)

NOTE:
After installing, check that it rotates when turned gently
by hand.
1

MFW41BSH019401

2. Install the pilot bearing to the flywheel.

3. Install the snap ring to the flywheel.

Installation
Completely remove the gasket from the flywheel
housing and cylinder block mounting surfaces.
1. Install idle gear B shaft.
• Install with the shaft oil hole towards the MFW41BSH005001
cylinder head side.

3. Install the oil pump.

Tightening torque
• Apply engine oil to the oil pump gear insertion
31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
section.
• Remove any liquid gasket that has overflowed
from the oil pump mounting surface, and apply
engine oil to the crankcase and cylinder block
bushing.

NOTE:
Do not allow oil to get onto the oil pump mounting
surface.

MFW41BSH004901

2. Install idle gear B.

MG6HK-WE-0871.book 343 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-343

• Install the oil pump before installing idle gear A.

MFW41BSH005101

MFW41BSH005301

• Apply liquid gasket (ThreeBond TB 1201 or

1207C) to the oil pump mounting surface as 4. Install idle gear A shaft.
shown in the diagram. • Apply engine oil to the gear inner circumference
section and thrust section.
NOTE:
• Insert idle gear A shaft into the arrow section.
• Install within 5 minutes of applying the liquid gasket.
• Do not allow liquid gasket to get onto the gears or
arrow section hole.
• Make sure the driven gear does not fall out.

MFW51BSH001401

• Insert the gear into the shaft, and fit in the

collar.
MFW41BSH005201

NOTE:
• Rotate the crankshaft and set the #1 cylinder to the
• Line up the dowel and install the oil pump. top dead point.

Tightening torque
24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

NOTE:
• There are no alignment marks on the gears.
MG6HK-WE-0871.book 344 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-344 Engine Mechanical (6HK1)

• After installing the flywheel housing, install the shaft
using 3 bolts.

1
2
11

10
3
2

9
BLW51BSH002501
5

6
7 6. Install the flywheel housing.
8
• Apply liquid gasket (ThreeBond 1207C or 1201)
to the flywheel housing as shown in the
MFW41BMH001101
diagram.

Legend NOTE:
1. Camshaft gear • Apply liquid gasket to the arrow sections of the
2. Positioning diagram.
3. Idle B gear
4. Positioning • Install within 5 minutes of applying the sealing
5. Air compressor gear compound.
6. Air compressor idle gear
7. Crank gear
8. Oil pump gear
9. Supply pump gear
10. Idle A gear
11. Idle C gear

5. Install idle gear A.

• Line up the shaft knock pin and cylinder body
knock hole, and install so that the crank gear
(1) “L” mark and idle gear A (2) “O” mark also
line up. 1
• Apply molybdenum-disulfide paste to the
threaded section and seating section of the
bolts and the washer, and tighten them.

MFWA1BSH003001

Tightening torque Legend

134 N⋅m (13.7 kg⋅m/99.1 lb⋅ft) 1. Do not apply gasket to this location

NOTE:
• After installing, re-check that the marks are in line. • Install the flywheel housing.
MG6HK-WE-0871.book 345 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-345

• Tighten the knock pin location first. Tighten the
remaining sections in any order.

Tightening torque
1, 2, 4, 7, 9 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
1
5, 6 119 N⋅m (12.1 kg⋅m/87.5 lb⋅ft)
3 73 N⋅m (7.4 kg⋅m/54 lb⋅ft)
8 75 N⋅m (7.6 kg⋅m/55 lb⋅ft)
10 86 N⋅m (8.8 kg⋅m/64 lb⋅ft)
11 53 N⋅m (5.4 kg⋅m/39 lb⋅ft)
2
NOTE:
• Tighten sections (10) and (11) in the diagram from
the cylinder block side.
MFW41BSH005601

1
2 9. Insert and install the O-ring to the cover.
3

Tightening torque
8
4 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)

5
6
9
7

10

11

MFW41BSH030701
MFW71BMH000401

7. Install air compressor idle gear shaft (2).

8. Install air compressor idle gear (1).
• Apply engine oil to the idle gear inner
circumference and thrust section, insert the
gear into the shaft to assemble it.
• Tighten the bolts through the thrust collar.

Tightening torque
119 N⋅m (12.1 kg⋅m/87.5 lb⋅ft)
MG6HK-WE-0871.book 346 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-346 Engine Mechanical (6HK1)

10. Install the slinger to the crankshaft.
• Installment of the slinger and oil seal should be
performed with the separate oil seal setting tool
kits (8-9439-6856-0).
• Make sure the slinger direction is correct. 5
6 1

Slinger Oil seal

Product name
Front Rear Front Rear
Front adaptor { — { —
Rear adaptor — { — {
2
Sleeve slinger { { — — 4 3

Sleeve seal — — { {
Bolt adaptor { { { {
Bolt center { { { { MFW41BSH005801

Bolt PTO — { — { Legend

1. Center bolt
2. Sleeve
• Insert the slinger into the adaptor tip, and set
3. Adaptor (rear)
the adaptor on the crankshaft.
4. Crankshaft
• Cover the adaptor with the sleeve, and tighten 5. Rear slinger
the center bolt until the sleeve touches the 6. Adaptor fixing bolts
adaptor.

NOTE:
• As the slinger 4 lead thread section rotationally
moves the seal lip section, take care not to damage
it.
• The Installment locations of the slinger are set by
the 4 lead threads, and are separated by color.

Engine front side ; silver

(4 evenly provided thread grooves from the inside to
the outside in a counter-clockwise direction).

Engine rear side ; gray

(4 evenly provided thread grooves from the inside to
the outside in a counter-clockwise direction).

MFW71BSH006401

• Measure the eight equal periphery divisions to

check that the slinger is press fitted in within the
specified dimensions.

Slinger press fit dimensions (rear side)

16.7 – 17.3 mm
Assembly standard
(0.66 – 0.68 in)

NOTE:
Measure from the crankshaft edge surface to the oil
seal lip section working face.
MG6HK-WE-0871.book 347 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-347

MFW41BSH006001 MFW71BSH006401

Legend
1. Slinger press fit dimensions
2. Crankshaft • Measure the eight equal periphery divisions to
3. Slinger check that the oil seal is press fit within the
specified dimensions.

11. Install the oil seal.

• Always apply engine oil to the lip section before Oil seal press fit dimensions (rear side)
press fitting the oil seal, and use a oil seal 7.35 – 7.65 mm
Assembly standard
setting tool kit (8-9439-6856-0) to install it. (0.29 – 0.301 in)

NOTE: NOTE:
Do not allow oil to touch the oil seal perimeter and felt
section. • If damage is left on the shaft section after extracting
the slinger, apply liquid gasket (ThreeBond 1207C)
•
to the inner surface of the slinger and install it.
• If oil is oozing out after installment, wipe it off.

5 6 1

4 3 2

MFW41BSH006101

Legend
1. Sleeve
2. Center bolt
3. Adaptor ring
4. Oil seal
5. Adaptor (rear)
6. Adaptor bolts
MG6HK-WE-0871.book 348 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-348 Engine Mechanical (6HK1)

The tightening order is the same.

1
2

4
3

MFWB1BSH009001
BLW51BSH004901
Legend
1. Flywheel housing
2. Slinger
3. Oil seal press fit dimensions a. Flexible plate, Adaptor installation.
4. Crankshaft 1. Flexible plate adaptor is installed according
to the knock pin of the flywheel.
2. Install the flexible plate.
12. Install the flywheel.
3. Flexible plate washer is set, and it installs it
• Line up the knock pin with the flywheel and
with the bolt.
install it.
• Apply molybdenum-disulphide to the thread
section and seating section of the installment Tightening torque
bolts, assemble the washers, and tighten in the
87 N⋅m (8.9 kg⋅m/64 lb⋅ft)
order shown in the diagram.
• Insert the pilot bearing, and set the snap ring.

Tightening torque
1st time 78 N⋅m (8.0 kg⋅m/58 lb⋅ft) 1
2
3
Angle method
2nd time
60° → 60° to 90° 4
5
NOTE:
6
Always check all of the bolts to make sure you didn’t
forget to tighten one.

MFW81BSH010801

Legend
1. Flywheel housing
2. Flywheel
3. Washer
4. Flexible plate adaptor
5. Flexible plate
6. Flexible plate washer
MG6HK-WE-0871.book 349 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-349

• Refer to “Cylinder Head”.
13. Install the crankshaft position sensor (CKP). 16. Load the engine assembly into the vehicle.
• Refer to “Engine Assembly”.
Tightening torque
8 N⋅m (0.8 kg⋅m/69 lb⋅in)

Manual transmission model

1 2

MFW71BSH002501

Legend
1. Crankshaft position sensor
2. Flywheel housing

Automatic transmission model

2
1

MFW81BSH010501

Legend
1. Crankshaft position sensor
2. Flywheel housing

14. Install the oil pan.

• Refer to “Oil Pan” in Lubrication System.
15. Install the cylinder head.
MG6HK-WE-0871.book 350 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-350 Engine Mechanical (6HK1)

Tightening Torque Table

b
h
c

d
g

f e
MFW71BLF002801

(a) 134 N⋅m (13.7 kg⋅m / 99.1 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 95 N⋅m (9.7 kg⋅m / 70 lb⋅ft)
(d) 31 N⋅m (3.2 kg⋅m / 23 lb⋅ft)
(e) 119 N⋅m (12.1 kg⋅m / 87.5 lb⋅ft)
(f) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
Angle method 60° → 60° to 90°
(g) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(h) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
MG6HK-WE-0871.book 351 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-351

Crank Pulley, Gearcase Cover and Crankshaft

Component Parts

1
2
3

19 20
18
17
16 8

15
6

7
14
9
10

13

12

11

MFWB1BLF001801

Legend
1. Adjustment plate 11. Crankcase
2. Gearcase 12. Slinger
3. O-ring 13. O-ring
4. Piston, connecting rod 14. Water duct
5. Connecting rod bearing 15. Crank pulley
6. Thrust bearing 16. Damper
7. Thrust bearing 17. Oil seal
8. Crankshaft bearing 18. Gearcase cover
9. Crankshaft 19. Idle gear shaft
10. Crankshaft bearing 20. Idle gear

Removal 2. Remove the cylinder head.

Refer to “Cylinder Head”.
1. Lower the engine assembly from the vehicle.
Refer to “Engine Assembly”. 3. Remove the water pump.
Refer to “Water Pump” in Cooling System.
MG6HK-WE-0871.book 352 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-352 Engine Mechanical (6HK1)

4. Remove the oil pan.
Refer to “Oil Pan” in Engine Lubrication.
5. Remove the crank pulley and damper.
6. Remove the water duct.
7. Remove the O-ring.
8. Remove the adjustment plate.
9. Remove the gearcase cover.
10. Remove idle gear and idle gear shaft.
11. Remove the gearcase.
• Screw bolts into the gearcase replacer holes
(more than 2 locations), tighten them uniformly
and remove it.

MFW41BSH006501

15. Remove the piston and connecting rod.

• Remove the carbon from the top surface of the
liner using a scraper, etc.

MFW41BSH029601

12. Remove the O-ring.

13. Remove the oil seal.
• Remove the gearcase cover oil seal while being
careful not to damage the press fit surface.

NOTE:
Replace the slinger as a set along with the oil seal.
MFW41BSH006601

14. Remove the slinger.

• Use as Slinger replacer (8-9439-6858-0) to
remove the slinger. • Rotate the crankshaft, move the piston of the
cylinder to be removed to the bottom dead point
NOTE: position, and remove the cap.
Replace the slinger as a set along with the oil seal. • Rotate the crankshaft, and move the piston of
the cylinder to be removed to the top dead point
position. Use the shank of a hammer, etc. to
push out the bearing from the bottom of the
connecting rod so as not to damage it.

NOTE:
• Be careful not to damage the oil jet and cylinder
liner when pushing out the connecting rod.
• Keep the removed cap, bearing and connecting rod
separately according to the cylinder they came from.
MG6HK-WE-0871.book 353 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-353

NOTE:
After removing the oil pump, remove the crankcase.

MFW41BSH006701

16. Remove the connecting rod bearing. MFW81BSH011501

17. Measure the play in the crankshaft axial direction.
19. Remove the thrust bearings.
• Measure at the #7 bearing.
20. Remove the crankshaft bearings.

NOTE:
Play in the axial direction:
• When removing the crankcase, do not let the
Assembly standard Limitations for use bearing drop out.
0.04 – 0.205 mm 0.34 mm • Always clarify the cylinder number for the bearings.
(0.0016 – 0.0081 in) (0.0134 in)

• If the value exceeds the useable limit, replace

the thrust bearing.

MFW41BSH007001

MFW41BSH006801 21. Remove the crankshaft.

• Lift the crankshaft horizontally and remove it.

18. Remove the crankcase. NOTE:

• Remove the crankcase fixing bolts in the order It is easier to lift if the end thrust bearing is removed
from the outside to the inside. before lifting.
• Screw bolts into the crankcase replacer holes 22. Remove the thrust bearings.
(1) (4 locations), tighten them uniformly and
23. Remove the crankshaft bearings.
remove it.
MG6HK-WE-0871.book 354 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-354 Engine Mechanical (6HK1)

NOTE:
Always clarify the cylinder number for the bearings.

Disassembly
Remove the gear.
Use a gear puller (Crankshaft gear puller: 8-9439-
6818-0) to remove it.

MFW41BSH031501

2. Inspect the crankshaft.

a. Inspect the crankshaft for cracks and the
bearing striking surface for damage.
• Inspect using a magnetic flaw detector or
dye penetrant testing method if necessary.
MFW41BSH018101

Inspection
1. Inspect the damper.
• Inspect the damper for cracks and breakaway.

NOTE:
• It must always be replaced if an abnormality is
found, as a faulty damper may cause damage to the
crankshaft.
• If there is an abnormality with the damper, inspect
the crankshaft and flywheel bolts.

MFW41BSH018501

b. Measure the wear of the crankshaft journal and

pin.

MFW41BSH031601
MG6HK-WE-0871.book 355 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-355

• Measure the 4 locations each as shown in • Hold the #1 and #7 journal sections with a
the diagram for the journal and pin locations. crankshaft aligner or V block. Place a dial
gauge against the crankshaft #4 journal,
gently rotate the crankshaft position, and
measure the dial gauge run out.

A 1 2

B B

MFW41BSH018601

Crankshaft outer diameter mm (in) MFW41BSH018701

Nominal Assembly Limitations

dimensions standard for use
Crankshaft deflection
#4 journal
Dia 81.851 – Assembly standard Limitations for use
81.871 0.06 mm (0.0024 in) 0.45 mm (0.0177 in)
(3.2225 –
Journal 3.2233) d. Measure the gap between the bearing and
82 0.05
outer Other than crankshaft journal.
(3.2283) (0.0020)
diameter #4
Dia 81.881 –
81.901 Tightening torque
(3.2237 – 98 N⋅m (10 kg⋅m/72 lb⋅ft) →
3.2244) M14 bolt 132 N⋅m (13.5 kg⋅m/98 lb⋅ft) →
Dia 72.902 – Angle method 30° to 60°
Pin outer 73 72.922 0.05
diameter (2.874) (2.8702 – (0.0020) • Measure the bearing inner circumference
2.8709) (when installed in the crankcase) and outer
diameter of the crankshaft journal, and
c. Measure the crankshaft run out. calculate the gap.
• Clean the bearing and bearing mounting
surface, assemble the bearing, and tighten
the crankcase to the specified torque. Use a
cylinder gauge to measure the bearing inner
diameter at the 4 locations shown in the
diagram.
• Measure the outer diameter of the
crankshaft at the 4 locations shown in the
diagram using a micrometer.
MG6HK-WE-0871.book 356 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-356 Engine Mechanical (6HK1)

Existence of a TAFTRIDE layer
• Clean the crankshaft. Remove oil using an organic
solvent etc. on the inspection sections (except for
the area within 10 mm (0.3937 in) around the oil
hole).

MFW41BSH018801

MFW41BSH018501

Inspect for the existence of a TAFTRIDE layer

12 • Drip the inspection solution onto the inspection
A
section using a syringe or glass rod, etc. At this
B B
time, keep the inspection section flat so that
inspection solution does not run off.
*Inspection fluid 5 to 10% solution of Ammonium
A
copper (II) chloride dihydrate in distilled water.

MFW41BSH018901 2
1

Assembly Limitations 3
standard for use
#4 journal
0.093 – 0.124 mm
Crank bearing (0.0037– 0.0049 in)
0.14 mm
and crankshaft Other than #4 (0.0055 in)
Journal gap journal
0.063 – 0.094 mm
(0.0025 – 0.0037 in)
LNW21BSH038001

Refer to general information if measuring with a Legend

plastigage. 1. Do not inspect within the 10 mm (0.3937 in)
around the oil hole
2. Inspection solution
3. Crankshaft
MG6HK-WE-0871.book 357 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-357

Judgment
• Crankshaft re-usable
There is no change in the inspection area after 30
to 40 seconds.
• Crankshaft not re-usable
The inspection solution (1) (light blue color)
became transparent, then changed to copper color
after 30 to 40 seconds.

MFW41BSH018501

1. Inspect the bearing.

Inspect the bearing for wear, damage, breakaway,
striking, etc.

HCW31BSH020701

Process after inspection

• As the inspection solution is highly corrosive, wipe
it off after the inspection is complete, and wash the
area with water, steam, etc.

NOTE:
The crankshaft has been treated with TAFTRIDE and
therefore cannot be repaired.

CAUTION:
Do not allow the inspection solution to come in contact
with your eyes, hands, clothing, etc. If for any reason
the fluid gets into someone’s eye, immediately wash it
with a lot of fresh water and seek immediate medical
attention. MFW41BSH019001

2. Crankshaft bearing selection procedure.

• When installing a new bearing, or when re-
placing a bearing that is already in use, refer to
the bearing selection table to select the correct
ones.
• Check the cylinder block journal hole inner
diameter grade and the crankshaft journal
diameter grade, select a new bearing and
install it.
MG6HK-WE-0871.book 358 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-358 Engine Mechanical (6HK1)

• The journal numbers are in #1 to #7 order from NOTE:
the left side when viewed in the readable When installing, be aware of the differences in bearing
direction. configuration.

1 2
3
4

6
MFW41BSH035101
LNW21BSH024901

Legend
1. Upper bearing
2. Oil hole
3. Grade identification color
4. Oil groove
5. Lower bearing
6. Grade identification color

MFW81BSH006401

Bearing selection table

Grade combination Oil clearance
Cylinder block Crank journal Bearing
#1,2,3,5,6,7 #4
Grade Grade identification color
0.065 – 0.092 mm 0.095 – 0.122 mm
1 1 Black
(0.0026 – 0.0036 in) (0.0037 – 0.0048 in)
0.063 – 0.089 mm 0.093 – 0.119 mm
1 2 Brown
(0.0025 – 0.0035 in) (0.0037 – 0.0047 in)
0.067 – 0.094 mm 0.097 – 0.124 mm
2 1 Blue
(0.0026 – 0.0037 in) (0.0038 – 0.0049 in)
0.065 – 0.091 mm 0.095 – 0.121 mm
2 2 Black
(0.0026 – 0.0036 in) (0.0037 – 0.0048 in)
MG6HK-WE-0871.book 359 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-359

3. Inspect the crankshaft gear teeth section for • Install the damper to the crank pulley.
contact breakaway, wear, etc.

Tightening torque
48 N⋅m (4.9 kg⋅m/35 lb⋅ft)

IMPORTANT:
• Tighten the bolts diagonally across.
• Do not allow oil or lubricants to touch the damper.

MFW41BSH019101

Reassembly
Install the crank gear.
• Warm the gear to 175°C (347°F).
• Point the timing gear mark towards the flywheel
side, and insert the warmed gears together before
they cool. Also, while the gears are cold, line up MFW41BSH031501

the crankshaft rear side pin position and gear

groove, and use a crankshaft gear setting tool (8-
9439-6819-0) to insert until it hits the collar section. Installation
Carefully clean and wash all parts before assembly.
1. Install the crankshaft bearing.
• If you are attaching a new bearing, refer to the
bearing selection table when selecting the new
bearing (refer to inspection section).
• Install the bearing to the cylinder block and
crankcase.
• Apply ample of engine oil to the bearing.

NOTE:
• The cylinder block side bearing has grooves on its
entire circumference and an oil hole (1).
The crankcase side bearing has grooves partially
and no oil hole.
• Install the bearings with their outer side dry.

MFW41BSH019201

Install the damper.

MG6HK-WE-0871.book 360 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-360 Engine Mechanical (6HK1)

• Bring the crankshaft near to the #7 journal side
so that it contacts with the thrust bearing.

MFW41BSH007101

MFW41BSH007301

2. Install the thrust bearings.

• Install the thrust bearings to the cylinder
block. • Install the thrust bearing to the cylinder block.
• Apply engine oil to the sliding surface of the • Apply engine oil to the sliding surface of the
bearing, face the oil groove (1) towards the bearing, face the oil groove towards the sliding
sliding surface of the crankshaft, line up with surface of the crankshaft, line up with the
the cylinder block #7 journal inside groove and cylinder block #7 journal outer groove and push
install the bearing. At this time, applying a thin it in by hand.
layer of grease to the cylinder block bearing
mounting surface allows the operation to be
performed more smoothly without anything
falling out.

MFW41BSH007401

4. Install the crankshaft bearing (lower).

MFW41BSH007201
5. Install the thrust bearing.
• Install the thrust bearing to the crankcase outer
side.
3. Install the crankshaft.
• Apply engine oil to the crankshaft journal, lift the
crankshaft horizontally and gently lower it on.
MG6HK-WE-0871.book 361 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-361

• Apply engine oil to the sliding surface of the
bearing, face the oil groove towards the sliding
surface of the crankshaft, line up with the
crankcase #7 journal external indentation and
install the bearing. At this time, applying a thin
layer of grease to the crankcase bearing
mounting surface allows the operation to be
performed more smoothly without anything
falling out.

NOTE:
Only use the thrust bearing lower on the crankcase
outer.

MFW41BSH007601

• Apply engine oil to the sliding surface of the

bearing.
• Point the thrust bearing oil hole to the cylinder
block rear, and gently install the so that the
thrust bearing does not fall out.

MFW41BSH007501

6. Install the crankcase.

• Line up the cylinder block groove, and apply a
bead of liquid gasket (ThreeBond 1207B)
approx. 3 to 4 mm (0.1181 to 0.1575 in) wide.

NOTE:
• Apply the gasket seamlessly without breaks in the
bead.
• Install within 5 minutes of applying the liquid gasket.
MFW41BSH007701

• Tighten the crankcase.

• Apply molybdenum-disulfide to the thread and
seating section of the M14 bolts, and tighten in
the numerical sequence shown in the diagram.
• Do not apply molybdenum-disulfide or engine
oil to the M10 bolts.
MG6HK-WE-0871.book 362 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-362 Engine Mechanical (6HK1)

• Install the M10 bolts after tightening the M14
bolts. (no fixed order)

Tightening torque
98 N⋅m (10 kg⋅m/72 lb⋅ft) →
M14 bolt 132 N⋅m (13.5 kg⋅m/98 lb⋅ft) →
Angle method 30° to 60°
M10 bolt 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)

• Clean off any overflowing liquid gasket.

NOTE:
Check that the crankshaft rotates smoothly.

MFW41BSH007901

8. Install the piston and connecting rod.

• Apply oil to the entire circumference of the
piston ring, and offset the open end 120° as
14 10 6 2 3 7 11
shown in the diagram avoiding side pressure
13 9 5 1 4 8 12
direction.
• Apply molybdenum-disulfide or engine oil to the
piston as shown in the diagram.

2
MFW41BSH007801
1

7. Install the connecting rod bearing.

• If you are Installing new bearings, refer to the
bearing selection table when selecting the new
2
bearings (refer to inspection section).
• Clean the connecting rod and cap, line up the 3
groove and install the bearings. 2
• Apply engine oil to the sliding surface of the
bearing.

NOTE:
MFW61BSH000201
Install the bearings with their outer side dry.
Legend
1. Front mark
2. Ring gap 120° apart
3. Molybdenum-disulfide or Engine oil application
MG6HK-WE-0871.book 363 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-363

• Move the crankpin that assembles the piston • Set the crankpin to top dead center with each
and connecting rod to the upper dead point of cylinder, when inserting piston / connecting rod.
the cylinder. When inserting piston / connecting rod if the
crankpin is set to the bottom dead center, the oil jet
might hit connecting rod and if might break.

MFW41BSH008101

• Apply engine oil to the cylinder liner (1).

MFW41BSH008301

• Apply ample engine oil to the connecting rod

bearings.
1 • Line up the connecting rod markings and cap
markings and install the cap.
• Apply molybdenum-disulfide to the thread and
seating section of the bolts, and tighten
alternately to the specified torque.

Tightening torque
39 N⋅m (4.0 kg⋅m/29 lb⋅ft) →
Angle method 60° → 30°

MFW41BSH008201

• Check the connecting rod cylinder number,

point the piston head front mark section to the
front side of the cylinder block, and insert it into
the cylinder.
• Use a piston setting tool, and use the shank of
a hammer, etc. to push the piston in until it hits
the crankpin.

NOTE:
• When pushing in the piston, push it in so that the
setting tool is in contact with the cylinder block.
Pushing in without adequate contact will damage
the piston ring.
• Take care not to damage the crankpin and oil jet.
MFW41BSH008401
• After inserting the piston connecting rod, install a
stopper so that the liner does not come out.
MG6HK-WE-0871.book 364 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-364 Engine Mechanical (6HK1)

• Rotate the crankshaft by hand and check that it

does not catch against anything and rotates
smoothly. Also check that the oil jet is not 1
distorted, and that it does not interfere with
other parts.

MFW71BSH015101

• Tighten the gearcase.

NOTE:
MFW41BSH008501 Remove any overflowing liquid gasket from the power
steering idle gear shaft mounting holes.

9. Install the gearcase.

• Line up the gearcase groove, and apply a bead Tightening torque
of liquid gasket (ThreeBond 1207B) approx. 2 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
to 3 mm (0.0787 to 0.1181 in) wide.
• Assemble the O-ring (1).

NOTE:
• Do not forget to apply liquid gasket to the arrow
sections of the diagram.
• Install within 5 minutes of applying the liquid gasket.
• It is also OK to use ThreeBond 1208 or CH Dyne
290 to prevent the O-ring from falling out.
• This engine does not have an oil thermo valve
installed. Installing one would cause a blockage in
the oil line and cause burning.

MFW41BSH029901

• Fasten the adjustment plate together at the

arrowed position shown in the diagram.

Tightening torque
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
MG6HK-WE-0871.book 365 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-365

NOTE:
• No liquid gasket should be attached to the bolt holes
during the application.
• Install within 5 minutes of applying the liquid gasket.

MFW41BSH030401

10. Install the power steering pump idle gear.

Tightening torque MFW41BSH030001

19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

1
• Apply oil to the idle gear rotational movement
section and install it to the shaft.
• Point the shaft notch section towards the
crankshaft side, and install it to the gearcase.

2
4

MFW41BSH029201
4
NOTE:
Take care not to damage the idle gear metal. MFW71BMH000501

Legend
11. Install the idle gear shaft.
1. Gearcase cover
12. Install the gearcase cover. 2. Applying liquid gasket (Correct)
Apply liquid gasket (ThreeBond 1207C) to the 3. Applying liquid gasket (Wrong)
gearcase cover. 4. Parts that need extra caution (as oil may leak)
• Line up the gearcase groove, and apply a bead 5. Bolt holes
of liquid gasket approx. 2 to 3 mm (0.0787 to
0.1181 in) wide.
MG6HK-WE-0871.book 366 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-366 Engine Mechanical (6HK1)

• Tighten the gearcase cover. • Tighten the water pump assembly.

Tightening torque Tightening torque

19 N⋅m (1.9 kg⋅m/14 lb⋅ft) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

• Tighten the knock pin position first, and tighten

it either clockwise or counter-clockwise.

MFW61CSH001301

MFW41BSH030101 NOTE:
Remove any overflowing liquid gasket from the power
steering idle gear shaft mounting holes.
13. Install the water pump.
For details, refer to the cooling system. 14. Install the slinger to the crankshaft front side.
NOTE: • Insert the slinger into the adaptor tip, and set
the adaptor on the crankshaft.
• After tightening the gearcase, install the water
Use a oil seal setting tool kit (8-9439-6856-0)
pump. (to prevent the liquid gasket from drying)
and press fit the slinger to the specified
• Install within 5 minutes of applying the liquid gasket. dimensions.
•

MFW61CSH000101

Legend
1. Do not apply gasket even if there is a groove.
MG6HK-WE-0871.book 367 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-367

• Cover the adaptor with the sleeve, and tighten
the center bolt until the sleeve touches the
adaptor.

1 2 4
5

MFW41BSH030201

MFW41BSH035001 • Measure the dimensions from the crankshaft

Legend edge surface to the oil seal lip section working
1. Slinger face.
2. Adaptor
3. Adaptor bolts
4. Sleeve Slinger press fit dimensions (front side)
5. Center bolt 17.7 – 18.3 mm
Assembly standard
(0.70 – 0.72 in)
NOTE:
• As the slinger 4 lead thread section rotationally NOTE:
moves the seal lip section, take care not to damage After press fitting the slinger, check that there is no
it. deflection.
• The installment locations of the slinger are set by
the 4 lead thread, and are separated by color.

Engine front side ; silver

(4 evenly provided thread grooves from the inside to
the outside in a counter- clockwise direction). 1

Engine rear side ; gray

(4 evenly provided thread grooves from the inside 2
to the outside in a counter- clockwise direction).

MFW41BSH009301

Legend
1. Slinger pressure fit dimensions
2. Slinger
3. Crankshaft
MG6HK-WE-0871.book 368 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-368 Engine Mechanical (6HK1)

15. Install the oil seal. • Measure from the crankshaft edge to the oil
• Apply a thin layer of oil to the oil seal lip section, seal surface.
and set it to the crankshaft.
• Insert the adaptor ring into the sleeve and press
Oil seal press fit dimensions (front side)
fit it.
8.35 – 8.65 mm
Assembly standard
NOTE: (0.33 – 0.34 in)
Always apply oil to the oil seal lip section.
NOTE:
Special tool Check that the oil seal is press fit with no deflection.
Oil seal setting tool kit: 8-9439-6856-0

2
1
1 2 3 4 5

4 3

MFW41BSH009501

MFW41BSH031201
Legend
1. Oil seal pressure fit dimensions
Legend 2. Front cover
1. Front adaptor 3. Oil seal
2. Oil seal 4. Crankshaft
3. Adaptor bolt
4. Sleeve
5. Center bolt
16. Install the crank pulley.
Line up the knock pin with the crank pulley and
install it.

Tightening torque
200 N⋅m (20.4 kg⋅m/147.6 lb⋅ft)

NOTE:
• Tighten the bolts in diagonal lines.
• Do not allow oil or grease to touch the crank pulley
damper.

MFW41BSH030201
MG6HK-WE-0871.book 369 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-369

MFW41BSH031601

17. Install the oil pan.

Refer to “Oil Pan” in Lubrication System.
18. Install the cylinder head.
Refer to “Cylinder Head”.
19. Load the engine assembly into the vehicle.
Refer to “Engine Assembly”.
MG6HK-WE-0871.book 370 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-370 Engine Mechanical (6HK1)

Tightening Torque Table

MFWB1BLF005801

(a) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)

(b) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(c) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) →
Angle method 60°→ 30°
(d) M14 : 98 N⋅m (10 kg⋅m / 72 lb⋅ft) →
132 N⋅m (13.5 kg⋅m / 98 lb⋅ft) →
Angle method 30° to 60°
(e) M10 : 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(f) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(g) 200 N⋅m (20.4 kg⋅m / 147.6 lb⋅ft)
MG6HK-WE-0871.book 371 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-371

Piston and Connecting Rod

Component Parts

1 2

2
3

6
4

MFWB1BLF005001

Legend
1. Piston ring 5. Connecting rod cap
2. Snap ring 6. Connecting rod
3. Piston 7. Piston pin
4. Bearing 8. Connecting rod bolt

Removal 4. Remove the cylinder head.

1. Remove the oil pan. Refer to “Cylinder Head”.
Refer to “Oil Pan” in Lubrication System. 5. Remove the piston and connecting rod.
2. Remove the rocker arm shaft assembly.
Refer to “Rocker Arm ”.
3. Remove the camshaft assembly.
Refer to “Camshaft ”.
MG6HK-WE-0871.book 372 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-372 Engine Mechanical (6HK1)

• Completely remove the carbon from the top of Disassembly
the liner using a scraper etc.
1. Remove the bearing.

NOTE:
If the bearings are to be re-used, keep them according
to the cylinder number.

2. Use a replacer piston ring setting tool (1-8522-

1029-0) to remove the piston ring (1).

NOTE:
After moving, keep the bearing outer race etc.
According to cylinder number.

LNW21BSH005001

• Rotate the crankshaft, move the piston of the

cylinder to be removed to the bottom dead point
position, and remove the cap. 1
• Rotate the crankshaft, and move the piston of
the cylinder to be removed to the top dead point
position. Use the shank of a hammer etc. to
push out the bearing from the bottom of the
connecting rod so as not to damage it.
MFW41BSH016001
NOTE:
• Be careful not to damage the oil jet and cylinder
liner when pushing out the connecting rod.
3. Remove the snap ring.
• Keep the removed cap, bearing and connecting rod
4. Remove the piston pin (1).
separately according to the cylinder they came from.
NOTE:
After removing, keep the parts according to cylinder
number.

MFW41BSH006701

MFW41BSH016101
MG6HK-WE-0871.book 373 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-373

5. Remove the connecting rods from the pistons.
6. Clean the piston. b. Measure the gap between the piston ring
• Carefully clean carbon from the piston heads groove and piston ring.
and piston ring grooves. • Clean the carbon from the piston head
section and ring groove. Next, insert a ring
NOTE: into the ring groove, and measure the gap
Do not use a wire brush to clean the pistons. with a thickness gauge.
Visually inspect the pistons for cracks, seizure or other
excessive wear. If there is an abnormality, replace the
piston. Gap between ring groove and ring
Limitations for
Assembly standard
Inspection use
Top ring — —
1. Measure the piston ring.
a. Inspect the piston ring for damage, and 0.015 – 0.055 mm
Second ring
measure the open end gap. (0.0006 – 0.0022 in) 0.15 mm
0.030 – 0.070 mm (0.0059 in)
• Insert the piston ring into the cylinder liner, Oil ring
and press in the ring with the piston head to (0.0012 – 0.0028 in)
the minimum wear section of the liner (liner
upper or lower section). Next, insert a
thickness gauge into the ring open end
alignment hole gap, and measure the gap.

NOTE:
When measuring, completely remove all carbon from
the open end, and set the ring at a right angle in the
cylinder liner.

Piston ring gap

Limitations for
Assembly standard
use
0.27 – 0.46 mm
Top ring
(0.0106 – 0.0181 in)
0.37 – 0.61 mm 1.2 mm
Second ring
(0.0146 – 0.0240 in) (0.0472 in)
BLW61BSH000701
0.27 – 0.56 mm
Oil ring
(0.0106 – 0.0220 in)

c. Measure the tensile strength of the piston ring.

• Use a piston ring tension meter to measure
the tensile strength.

NOTE:
• Measure the oil ring with the coil expander attached.
• Take the open end gap and measure it.

MFW41BSH016201
MG6HK-WE-0871.book 374 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-374 Engine Mechanical (6HK1)

Tensile strength N (kgf/lb)

Assembly Limitations for
standard use
26 – 34 (2.65 – 3.47/ 11.8
Top ring
5.84 – 7.64) (1.2 / 2.65)
21.7 – 28.7 (2.21 – 5.9
Second ring
2.93/4.88 – 6.45) (0.6 / 1.33)
30 – 40 (3.06 – 4.08/ 28
Oil ring
6.74 – 8.99) (2.86 / 6.29)

MFW41BSH016501

• When inserting the piston pin into the piston

under normal temperatures, check that there is
enough resistance to require gentle pushing of
the pin.
• If the pin is very loose or slack under normal
temperatures, replace the piston or the piston
pin.

MFW41BSH016401

2. Measure the piston pin.

• Measure the outer diameter of the piston pin,
and measure the gap between the piston pin
and piston pin hole, and the piston pin and
connecting rod bushing.
• Measure the 6 piston pin locations in the
diagram with a micrometer.

mm (in)
Nominal Assembly Limitations
dimensions standard for use LNW21BSH009701

- 0.005 –
Piston pin
40 0.000 39.95
outer
(1.5748) (-0.0002 (1.5728) 3. Inspect and measure the piston.
circumference
–0.000) a. Inspect for impact marks and cracks in the
0.009 – piston.
Gap between
0.022 • Completely remove any carbon or sludge
piston pin and — —
(0.0004 – from the piston and clean it thoroughly
piston pin hole
0.0009) before inspection. Carefully inspect difficult
Gap between 0.012 – to see places, such as the piston ring
piston pin and 0.027 0.05 groove, etc.
—
connecting rod (0.0005 – (0.002) • Inspect using a dye penetrant testing
bushing 0.0011) method if necessary.
MG6HK-WE-0871.book 375 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-375

• Clean the bearing and bearing mounting
surface, and install the bearing.
Next, apply molybdenum-disulfide to the
thread section, tighten the connecting rod
cap, and measure the 4 locations of the
connecting rod bearing shown in the
diagram with a cylinder gauge.

Cap bolt tightening torque

39 N⋅m (4.0 kg⋅m/29 lb⋅ft) →
Angle method 60° → 30°

• Measure the outer diameter of the crankpin

in the 4 locations shown in the diagram
using a micrometer.

BLW61BSH000601
Gap between connecting rod bearing and crank pin
Assembly standard Limitations for use
b. Measure the piston outer diameter. 0.037 – 0.076 mm 0.1 mm
• Measure the piston pin at the location 85 (0.0015 – 0.0030 in) (0.004 in)
mm (3.35 in) from the piston head section,
and measure the piston outer diameter in Refer to “How to use a plastigage” in general
the right angle direction with a micrometer. information if measuring with a plastigage.

Piston outer diameter service replacement

114.944 – 114.979 mm (4.5254 – 4.5267 in)

Inner circumference gap between piston

and cylinder liner service replacement
0.052 – 0.106 mm (0.0020 – 0.0042 in) 1 2
A
B

A
NOTE: 1 2 B

If, as a result of the measurements, the piston liner gap

exceeds the standard value, replace the piston or
cylinder liner.
• The dimensions above are of the liner and piston for
service replacement.
MFW41BSH016701
4. Measure the connecting rod.
a. Measure the gap between the connecting rod
bearing and crank pin.
• Measure the connecting rod bearing inner
diameter and crank pin outer diameter.
MG6HK-WE-0871.book 376 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-376 Engine Mechanical (6HK1)

• Assemble the connecting rod to the crank
pin, and measure the gap in the axial
direction.

Gap between connecting rod large edge section and

1 2
A crankshaft axial direction
B B Assembly standard Limitations for use
A 0.17 – 0.3mm 0.35 mm
(0.0067 – 0.0118 in) (0.0138 in)

MFW41BSH016801

b. Measure the distortion of the connecting rod.

• Use a connecting rod aligner to measure the
torsion and the parallelism of the big and
small end bores.

NOTE:
The measurements are taken based on the bearing, so
make sure the bearing is not worn.
MFW41BSH017001

Torsion and parallelism of big and small end bores (for

100 mm/3.937 in)
5. Inspect the connecting rod bearing for wear,
Assembly standard Limitations for use
damage and breakaway.
0.05 mm (0.002 in) 0.2 mm (0.008 in)

MFW41BSH017101

MFW41BSH016901

6. Select the connecting rod bearing.

• When installing a new connecting rod or
c. Measure the axial direction gap on the replacing a bearing that is in use, do so in
connecting rod big end. accordance with the bearing selection table.
MG6HK-WE-0871.book 377 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-377

• Pay attention to the big end bore diameter Reassembly
grade, select a bearing, and install it.
Piston selection
• When replacing the piston, there is only one grade
for service, and therefore no need to select a
piston.
• Piston and liner can be supplied as a set. In that
case, there is need to match the liner outer
diameter and cylinder block bore inner diameter
grades.

1
2 3

MFW41BSH035701

Legend
1. Front/back distinction boss
2. Big end bore diameter grade mark
3. Cylinder number

Grade combination BLW61BSH000601

Connecting
Bearing Grade Oil
rod
(identification color) Clearance (for reference) Liner grade selection procedure
Grade
0.037 – 0.076 mm • Matching the cylinder block bore inner diameter
A Green and liner outer diameter grades.
(0.0015 – 0.003 in)
• From the number etched on the top surface of the
0.037 – 0.076 mm
B Yellow cylinder block, select liner 1X for 1 and 2, 3X for 3
(0.0015 – 0.003 in)
and assemble them.

Combination of cylinder block and liner outer diameter

Block etching
Liner grade
number
1X; 117.991 – 118.000 mm
1, 2
(4.6453 – 4.6457 in)
3X; 118.001 – 118.010 mm
3
(4.6457 – 4.6461 in)

Cylinder block bore grade

Block etching
Bore inner diameter
number
1
118.001 – 118.020 mm
1, 2
(4.6457 – 4.6464 in)
LNW21BSH010801
118.021 – 118.030 mm
3
Legend (4.6465 – 4.6468 in)
1. Bearing grade (identification color)
MG6HK-WE-0871.book 378 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-378 Engine Mechanical (6HK1)

• Measure the outer diameter of the piston at the
grade location. Clean carbon etc. From the liner,
measure at an equivalent location to the cylinder
block bore, and inspect whether the gap between
the piston and liner is within the standard value.
1

Grade selection measurement position

(from the longer-axis direction piston head)
85 mm (3.35 in)

Gap between piston and liner (longer-axis direction)

0.052 – 0.106 mm
Assembly standard
(0.002 – 0.0042 in)

BLW71BSH009201

Legend
1. Grade etching location

• Measure the maximum and the minimum bores at

the three different positions from the top surface of
the cylinder block and obtain the average value of
the six measurements.

Measuring locations (from the top surface) 1

A B C
20 mm 110 mm 190 mm
(0.787 in) (4.331 in) (7.480 in)

MFW41BSH017401

• (For reference) Dimensions of piston for service.

Piston outer diameter 114.944 – 114.979 mm

(grade position) (4.5254 – 4.5267 in)

1. Install the piston to the connecting rod.

• Install the snap ring to one side of the piston.
• Apply oil to the piston pin.
• Assemble with the piston head front side mark
(1) and connecting rod indented mark (rear side
mark) in reverse, fully insert the piston pin and
fix with the snap ring.

MFW41BSH017301 NOTE:
Measuring procedure when re-using pistons Check that the snap ring is securely installed to the ring
groove. At this time, make sure the ring opening
• When re-using pistons, measure the gap between section is vertical. Also, check that the piston moves
the piston and liner. smoothly.
MG6HK-WE-0871.book 379 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-379

MFW61BSH001601 BLW51BSH005301

• Point the 2T mark on the second ring upwards,

and use a piston ring setting tool (1-8522-1029-
1 0) to install it.
• Point the T1 mark on the top ring upwards, and
use a piston ring setting tool (1-8522-1029-0) to
install it.
• Apply oil to the entire periphery of the rings,
rotate the rings, and check that they rotate
2 smoothly without catching.
• The part ring gap of 1st piston ring, 2nd piston
ring, and oil ring is things that the direct shifts
by 120°.

NOTE:
• When re-using the piston ring, make sure it is not
MFW41BSH017601 inserted upside down.
Legend • There is no up or down side with the oil ring.
1. Front mark
2. Indented mark

2. Install the piston ring.

• Assemble the expander ring onto the piston,
and engage them so there is no gap, then
install the oil ring.

NOTE:
Set the expander ring gap and piston ring gap at 180
opposite directions.
MG6HK-WE-0871.book 380 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-380 Engine Mechanical (6HK1)

2. Install the piston and connecting rod assembly.
• Apply oil to the entire circumference of the
piston ring, and avoid side pressure on the gap
as shown in the diagram.
• Apply molybdenum-disulfide or engine oil to the
1 piston locations shown in the diagram.

3 2
1

2
MFWB1BSH008501
3
Legend 2
1. Top ring
2. Second ring
3. Oil ring

MFW61BSH000201

Installation Legend
1. Install the connecting rod bearing. 1. Front mark
2. Ring gap 120° apart
• When replacing the connecting rod or bearing, 3. Molybdenum disulfide or Engine oil application
replace the bearing based on the bearing
replacement table (refer to inspection).
• Clean the connecting rod and cap, line up the
prongs and install the bearing. • Move the crankpin that assembles the piston
• Apply oil to the rotational movement surface of and the connecting rod to the lower dead point
the bearing. of the cylinder.

NOTE:
Install the bearing with its back dry.

MFW41BSH008101

MFW41BSH007901
MG6HK-WE-0871.book 381 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-381

• Apply oil to the cylinder liner.

MFW41BSH008301
MFW41BSH008201

Legend
1. Oil application • Apply ample oil to the connecting rod cap
bearing.
• Line up the connecting rod cap marks and
install them.
• Check the connecting rod cylinder number,
point the piston head front mark to the front side • Apply molybdenum-disulfide to the thread and
of the cylinder block, and insert it into the seating section of the bolts, and tighten
cylinder. alternately to the specified torque.
• Use a piston setting tool, and use the shank of
a hammer, etc. to push the piston in until it hits Tightening torque
the crankpin.
39 N⋅m (4.0 kg⋅m/29 lb⋅ft) → Angle method 60° → 30°
NOTE:
• When pushing in the piston, push it in so that the
setting tool is in contact with the cylinder block.
Pushing in without adequate contact damages the
piston ring.
• Take care not to damage the crankpin and oil jet.
• Install a stopper so that the liner does not drop out.
• Set the crankpin to top dead center with each
cylinder, when inserting piston / connecting rod.
When inserting piston / connecting rod if the
crankpin is set to the bottom dead center, the oil jet
might hit connecting rod and if might break.

MFW41BSH008401

• Rotate the crankshaft by hand and check that it

does not catch against anything and rotates
smoothly. Also check that the oil jet is not
distorted, and that it does not interfere with
other parts.
MG6HK-WE-0871.book 382 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-382 Engine Mechanical (6HK1)

NOTE:
Set the crankpin to the bottom dead center when 3. Install the cylinder head.
tighten connecting rod cap. (Because if doesn’t hit the
tightening tool to the oil jet.) Refer to “Cylinder Head”.
4. Install the camshaft.
Refer to “Camshaft ”.
5. Install the rocker arm shaft.
Refer to “Rocker Arm ”.
6. Install the oil pan.
Refer to “Oil pan” in Lubrication System.

MFW41BSH008501

Tightening Torque Table

MFW61BMF000101

(a) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) →

Angle method 60° → 30°
MG6HK-WE-0871.book 383 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-383

Cylinder Block
Component Parts

MFW41BLF001701

Legend
1. Cylinder liner 4. Cylinder block
2. Oil jet 5. Oil pressure switch
3. Crankcase

Disassembly 4. Remove the crankshaft.

1. Lower the engine assembly from the vehicle. Refer to “Crank Pulley, Gearcase Cover and
Refer to “Engine Assembly”. Crankshaft”.
2. Remove the cylinder head. 5. Remove the oil pressure switch.
Refer to “Cylinder Head”. 6. Remove the oil jet.
3. Remove the supply pump, air compressor, and oil 7. Remove the cylinder liner.
cooler. Measure the inner circumference of the cylinder
liner, and remove it after judging whether it is OK
Refer to “Engine Exterior Parts”. or not. Refer to the liner wear section.
• If the cylinder liner cannot be extracted by hand, follow the following procedure.
MG6HK-WE-0871.book 384 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-384 Engine Mechanical (6HK1)

• Securely hang the cylinder liner remover (5-
8840-2397-0) anchor on the lower edge of the
liner, insert a turret into the center bolt so that it
does not catch on the collar section of the liner
for above, and tighten it with a bearing
mounting nut. Next, fix a handle to the nut, and
rotate the handle to extract the liner.

NOTE:
Take care not to damage the cylinder block bore
surface when extracting the liner.

MFW41BSH019901

5. Inspect the oil jet.

• Inspect the oil jet for blocked oil hole, bent pipe,
and check valve operation.

Check valve opening pressure

160 kPa (1.6 kgf/m2/23 psi)

MFW41BSH019801

Inspection
1. Carefully remove an deposits and other debris
from the upper surface of the cylinder block.

NOTE:
Take care not to damage the cylinder block.

2. Carefully remove and liquid gasket from the

crankcase mounting surface.
3. Clean the cylinder block and crankcase.
4. Inspect the crankcase.
• Inspect the crankcase for cracks and damage.
• Inspect using a magnetic flaw detector or dye
penetrant testing method if necessary.
MFW41BSH020001

6. Measure the wear of the cylinder liner.

• Measure the largest wear at around 20 mm
(0.7874 in) from the liner upper surface, and
replace the liner if it exceeds the specified
value.

Maximum wear on cylinder liner

Limitations for use 0.2 mm (0.008 in)
MG6HK-WE-0871.book 385 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-385

• Inspect the cylinder block for cracks and
damage.
• Inspect using a dye penetrant testing method if
necessary.
• Check the screw thread for damage or faults.
• With the hydraulic test, apply 490 kPa (5 kgf/
cm2 / 71 psi) of water pressure for 3 minutes,
and inspect each section of the cylinder block
for water leaks.

MFW41BSH019701

7. Inspect and measure the cylinder block.

• Measure the amount of distortion of the cylinder
block.
• Place a straightedge diagonally on the cylinder
block surface, and measure 4 locations with a
thickness gauge (1).
MFW41BSH020201

Amount of distortion of cylinder block

Limitations for use 0.1 mm (0.0039 in) Reassembly
1. Select a liner grade for the cylinder block and
NOTE: assemble them.
Cannot be repaired with grinding because the timing
gear backlash will change. CAUTION:
Do not use a thermo valve in the oil hole on the front
side of the cylinder block. Installing would may cause
burning.

a. Cylinder liner grade selection.

• Matching the cylinder block bore inner
diameter and liner outer diameter grades.
• From the number printed on the top surface
of the cylinder block, select liner 1X for 1
and 2, 3X for 3 and assemble them.

CAUTION:
• As the liners are very thin, do not use one that has
been dropped.
1 • If the liner grade is not selected correctly, there will
be insufficient cooling (gap size) which may cause
seizure.

MFW41BSH020101

• Inspect the cooling water pipes and oil pipes

between each of the cylinders for blockages or
corrosion.
MG6HK-WE-0871.book 386 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-386 Engine Mechanical (6HK1)

• The dimensions for the liner grade are controlled
when the liner is produced, and are stamped onto
the upper side surface of the liner.

Cylinder block measurement location

1
(From cylinder block upper surface)
A B C
20mm 110 mm 190 mm
(0.79 in) (4.33 in) (7.48 in)

MFW41BSH020301

Legend
1. Grade print location

Matching cylinder block and liner outer diameter

grade
Block print 1 2 3
Liner outer
1X 3X
diameter
MFW41BSH020501

Cylinder block inner circumference, liner mm (in)

outer circumference grade
Grade (1) . (1X) (2) . (1X) (3) . (3X)
118.001 118.011 118.021
1
– – –
Block inner 118.010 118.020 118.030
circumference (4.6457 (4.6461 (4.6465
– – –
4.6460) 4.6464) 4.6468)
118.001
–
Liner outer 117.991– 118.000 118.010
diameter (4.653 – 4.6457) (4.6457
–
4.6460)
BLW71BSH009201
NOTE:
Legend
• The cylinder block grade is determined by 1. Grade etching
measuring the following 3 locations and a total of 6
locations on the cylinder block upper surface and
calculating the average value.
2. Install the cylinder liner.
• Wash the cylinder block and liner.
• After washing the cylinder block and liner, air
blow them.
MG6HK-WE-0871.book 387 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-387

NOTE: • Use a dial gauge and measure the amount of
Handle the liner carefully as it is very thin. Do not store liner protrusion.
the liner flat.

Assembly standard
0.06 – 0.1 mm
Amount of liner protrusion
(0.0024 – 0.004 in)
Difference of liner protrusion 0.03 mm
1 with next liner (0.0012 in)

MFW81BSH007901

Legend
1. Correct
2. Wrong

• Apply a thin layer of engine oil to the bottom MFW41BSH020801

surface of the outer perimeter of the cylinder

liner, and install it straight against the cylinder
3. Install the oil jet.
block.

NOTE:
Tightening torque
• When inserting the liner, do not strike it or use
excessive force. 21 N⋅m (2.1 kg⋅m/15 lb⋅ft)
• After inserting the liner, prevent the liner from falling
out when inverting the cylinder block. NOTE:
Do not bend the oil jet tip.

MFW41BSH020701
MFW41BSH020901
MG6HK-WE-0871.book 388 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1B-388 Engine Mechanical (6HK1)

4. Install the oil pressure switch.

• Install the adaptor to the cylinder block.
• Apply ThreeBond 1241 to the adaptor for the oil
pressure switch, and install them to the cylinder
block.

Tightening torque
Adaptor 117 N⋅m (11.9 kg⋅m/86 lb⋅ft)
Oil pressure switch 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)

MFW41BSH021001

Legend
1. Adaptor
2. Oil pressure switch

5. Install the crankshaft.

Refer to “Crank Pulley, Gearcase Cover and
Crankshaft”.
6. Install the supply pump, air compressor, and
oil cooler.
Refer to “Engine Exterior Parts”.
7. Install the oil pan.
Refer to “Oil Pan” in Lubrication System.
8. Install the cylinder head.
Refer to “Cylinder Head”.
9. Load the engine assembly into the vehicle.
Refer to “Engine Assembly”.
MG6HK-WE-0871.book 389 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Mechanical (6HK1) 1B-389

Tightening Torque Table

a
b

MFWB1BLF005901

(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

(b) 117 N⋅m (11.9 kg⋅m / 86 lb⋅ft)
(c) 21 N⋅m (2.1 kg⋅m / 15 lb⋅ft)
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

MEMO
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MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-1

ENGINE
Engine Cooling
(6HK1)
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1C-2
Explanation of Functions and Operations . . . . . 1C-3
Coolant Inspection . . . . . . . . . . . . . . . . . . . . . . 1C-6
Radiator Inspection . . . . . . . . . . . . . . . . . . . . . . 1C-8
Engine Cooling Water Replacement Procedure 1C-9
Failure Phenomenon List . . . . . . . . . . . . . . . . 1C-10
Phenomenon: Engine overheats. . . . . . . . . . . 1C-11
Phenomenon: Engine overcools . . . . . . . . . . . 1C-12
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1C-12
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1C-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-16
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Tightening Torque Table . . . . . . . . . . . . . . . . . 1C-19
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1C-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Tightening Torque Table . . . . . . . . . . . . . . . . . 1C-25
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-26
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1C-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-29
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-32
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-2 Engine Cooling (6HK1)

Cooling System
Precautions for Servicing
WARNING:
Do not loosen or remove the radiator cap when the
cooling water is hot. Steam or hot water may spurt out,
which may cause serious scalding injuries. When
opening the radiator cap, do so when the cooling water
is cool, cover the cap with a thick cloth, and rotate it
slowly to release pressure before removing it.
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-3

Explanation of Functions and Operations
Cooling water circulation system diagram
This diagram shows a vehicle with a Euro 4 specification

2 3 10

1
11
5
6
9
7
8
19

13 12

18

14

17
16 15

MFW71CLF000401

Legend
1. Radiator cap 11. Turbocharger
2. Reserve tank 12. Air compressor
3. Reserve tank filling hole 13. Water jacket
4. EGR cooler 14. Oil cooler
5. Water outlet pipe 15. Water pump
6. Thermostat 16. Lower hose
7. Engine coolant temperature sensor 17. Drain plug
8. Bypass passage 18. Cooling fan
9. Water jacket 19. Radiator
10. Heater core
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-4 Engine Cooling (6HK1)

This diagram shows a vehicle with a Euro 2 specification and Euro 3 specification

2 3 4

1
10
5
6
9
7
8
18

12 11

17

13

16
15 14

MFW71CLF000901

Legend
1. Radiator cap 10. Turbocharger
2. Reserve tank 11. Air compressor
3. Reserve tank filling hole 12. Water jacket
4. Heater core 13. Oil cooler
5. Water outlet pipe 14. Water pump
6. Thermostat 15. Lower hose
7. Engine coolant temperature sensor 16. Drain plug
8. Bypass passage 17. Cooling fan
9. Water jacket 18. Radiator
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-5

Water pump structural diagram

3 4
2

10 8
9

MFW81CLF000601

Legend
1. Shaft 6. Impeller
2. Snap ring 7. Seal unit
3. Bearing 8. Spacer
4. Grease nipple 9. Pulley
5. Washer 10. Dust cover
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-6 Engine Cooling (6HK1)

Coolant Inspection
1. Coolant Concentration
Inspect the coolant level in the reserve tank . If the
Coolant
level is within its MAX (upper limit) and MIN (lower Region where used
Concentration
limit), it is the appropriate amount. Note that if
there is insufficient coolant, remove the reserve General regions, regions where the
tank cap and pour in a mixture of tap water and lowest temperature is -12°C (10.4°F) 30%
engine coolant at the appropriate proportion and fill or above
the tank to the MAX line.
Cold regions, regions where the
lowest temperature is -30°C (-22°F) 50%
For FTS or above
TCN, TCS: 29.5 (6.49)
Regions where the lowest
Except for FTS temperature is -30°C (-22°F) 55%
Coolant TCN, TCC: 29.0 (6.38), or below
Amount
Standard L (lmp⋅gal) Fire fighting vehicle:
value 32.0 (7.04) CAUTION:
• For the coolant, make sure to use the products
A/T (ALLISON 3***):
specified (recommended) by Isuzu.
33.0 (7.26)
• If the coolant specified (recommended) by Isuzu is
Replacement not used, the engine, radiator or heater core may be
Every 2 years
period damaged.
• Never use the coolant which contains borate or
• Because the freezing temperature of the engine silicate. The engine, radiator or heater core may
coolant is changed with the concentration of the corrode, causing a water leakage.
engine coolant. The concentration should
conform to the lowest temperatures. 2. Measurement of coolant concentration (specified
• The engine coolant is made by mixing the product of Isuzu or equivalent)
coolant and water (distilled water or deionized • Use an antifreeze hydrometer or thermometer,
water) at the specified concentration ratio. and measure the specific gravity and coolant
• Calculation to obtain the engine coolant temperature.
concentration: Take care if the temperature is hot, as cooling
Concentration of Engine Coolant (%) = Volume water may spurt out when the cap is removed.
of Engine Coolant (L) / [Volume of Engine • After measuring the temperature and specific
Coolant (L) + Volume of Tap Water (L)] x 100 gravity, calculate the concentration from the
• If the mixing ratio of the engine coolant is higher table below.
than 60%, overheats easily occur. If it is less • Use a container that is deeper that the length of
than 30%, corrosion cannot be prevented the hydrometer to be used.
sufficiently. • The temperature of the cooling water to be
• It is recommended to directly use the "50/50 measured should be within the 0 – 50°C (32 –
Prediluted" or "50/50 Pre-Mixed" or equivalent 122°F) range.
products which are already diluted to 50%
concentration.
• When diluting the coolant, use the distilled or
deionized water.
• When it is used at the temperature of -30°C (-
22°F) or below, make the concentration to 55%.
• If the coolant is used at any other concentration
than specified, the anti-freezing performance
may decrease, and freezing may result.
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-7

MFW41CSH000201

• Coolant tester
Use a coolant tester to measure the
concentration.
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-8 Engine Cooling (6HK1)

Radiator Inspection
Radiator cap Inspection for cooling water leaks
• Use a radiator cap tester to inspect the injection • Using a radiator cap tester, apply 200 kPa (2.0 kgf/
valve opening pressure. If the inspection valve cm2 / 28 psi) of pressure and inspect the following
opening pressure exceeds the standard value, parts for leaks. Also inspect the radiator hose and
replace the radiator cap. heater hose for damage and deterioration, and
inspect the hose clamps for looseness.
Inspection locations
kPa (kgf/cm2 / psi) • Radiator assembly, water pump assembly, radiator
Positive pressure : 93 – 122 hose, heater hose.
Cap operating (0.9 – 1.2 / 13 – 17)
pressure Negative pressure : Min. 4.9
(0.05 / 0.7)

MFW41CSH000901

MFW41CSH000801

• Inspect the condition of the negative pressure

valve at the center of the cap valve seat side.
If the valve seat does not operate smoothly
because of rust, dirt, etc, clean or replace the
radiator cap.

Radiator core
• A distorted radiator fin may lead to a reduction in
heat dissipation effectiveness, which may in turn
cause overheating. Therefore, the fin must be
repaired. Take care not to damage the joint section
of the fin when repairing it.
• Remove dirt and other debris.

NOTE:
Do not perform high-pressure washing to the radiator
or intercooler, and the parts surrounding it.

Cleaning the radiator

• Clean the inside of the radiator and cooling water
passages with tap water. Remove all rust and
incrustations.
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-9

Engine Cooling Water Replacement Procedure
NOTE:
Replace the coolant every 2 years.
Wash the radiator cap, radiator and coolant passage at
the same time.

1. Check that the engine is cool.

WARNING:
Do not loosen or remove the radiator cap when the
cooling water is hot. Steam or hot water may spurt out,
which may cause serious scalding injuries. When
opening the radiator cap, do so when the cooling water
is cool, cover the cap with a thick cloth, and rotate it
slowly to release pressure before removing it.

2. Remove the radiator cap.

3. Loosen the radiator cooling water drain plug, and
drain the cooling water.
4. Close the drain plug.
5. Completely fill the radiator with tap water.
6. Inspect and clean the radiator cap. Replace the
cap if there are any abnormalities.
7. Securely close the radiator cap.
8. Fill the reserve tank with tap water up to the [MAX]
line.
9. Close the reserve tank cap.
10. Start the engine, allow it to idle for 20 minutes, then
stop the engine and drain tap water after the
engine has cooled enough.
11. Completely fill the radiator with coolant.
12. Close the radiator cap securely.
13. Fill the reserve tank to its [MAX] line with coolant.
14. Close the reserve tank cap.
15. Start the engine.
16. After running the engine at a normal idling
revolution speed for 2 to 3 minutes, stop the
engine.
17. Once it has been confirmed that the coolant has
cooled down, remove the radiator cap and top up if
the level is low.
18. Close the radiator cap securely, and then warm up
the engine by running it at approximately 2,000 r/
min.
19. When the coolant temperature gauge’s needle
exceeds the gauge’s midway point, let the engine
idle for approximately 5 minutes, and then stop the
engine and let it rest.
20. Once it has been confirmed that the coolant has
cooled down, remove the radiator cap and top up if
necessary. If the coolant’s level is extremely low,
check for leaks.
21. Close the radiator cap securely.
22. Once again, fill the reserve tank to its [MAX] line
with coolant.
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-10 Engine Cooling (6HK1)

Failure Phenomenon List
• Engine overheats
• Engine overcools
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-11

Phenomenon: Engine overheats

Condition Possible Cause Correction

Engine overheats Insufficient amount of cooling water Add more
Thermostat malfunction Replace
Water pump malfunction Replace
Radiator blocked Clean or replace
Radiator cap malfunction Replace
Insufficient engine oil, or an incorrect Add or replace the engine oil
engine oil is being used
Cylinder head gasket malfunction Replace
Loose fan belt Adjust
Exhaust system blockage Clean or replace
Excess fuel injection volume Diagnose the engine control system
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-12 Engine Cooling (6HK1)

Phenomenon: Engine overcools

Condition Possible Cause Correction

Engine overcools Thermostat malfunction Replace

Main Specifications
Vehicle with a Euro 3 specification and Euro 4 specification
Item Specifications
Cooling method Water cooled preload forced-
circulation type
Radiator Colgate type
Water pump Type V-ribbed belt drive-swirl, type
82 (180),
With jiggle valve °C (°F)
(Fire fighting vehicle: 76.5 (170))
Temperature for Primary: 82 (180), (Fire fighting
thermostat open start vehicle; 76.5 (170))
Without jiggle valve °C (°F)
Secondary: 85 (185),
(Fire fighting vehicle; 79.5 (175.1))
For FTS
TCN, TCS: 29.5 (6.49)
Cooling water volume Except for FTS
L (Imp⋅gal)
TCN, TCC: 29.0 (6.38),
Fire fighting vehicle:
32.0 (7.04)
Reserve tank capacity L (Imp⋅gal) 2.0 (0.44)

Vehicle with a Euro 2 specification

Item Specifications
Cooling method Water cooled preload forced-
circulation type
Radiator Colgate type
Water pump Type V-ribbed belt drive-swirl, type
With jiggle valve °C (°F) 82 (180)
Temperature for
thermostat open start Primary: 82 (180)
Without jiggle valve °C (°F)
Secondary: 85 (185)
For FTS
TCN, TCS: 29.5 (6.49)
Except for FTS
Cooling water volume L (Imp⋅gal) TCN: 29.0 (6.38)
A/T (ALLISON 3***)
TCS A/T, FTS A/T:
33.0 (7.24)
Reserve tank capacity L (Imp⋅gal) 2.0 (0.44)
MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-13

Radiator
Component Parts

1 2

6 5
MFW71CLF000201

Legend
1. Reserve tank hose 4. Intercooler
2. Upper hose 5. Fan shroud
3. Radiator 6. Turbocharger out intercooler hose

Removal
1. Drain off the cooling water from the radiator.
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-14 Engine Cooling (6HK1)

• Remove the drain plug, and drain off the cooling 4. Remove the lower hose.
water from within the radiator.

3 2 1 1 2 3

MFW71CSH001001
MFW71CSH001101
Legend
Legend 1. Intercooler
1. Intercooler 2. Radiator
2. Radiator 3. Lower hose
3. Drain plug

5. Remove the reserve tank hose.

2. Remove the intercooler hose (1). 6. Remove the fan.
• Remove the fan shroud bracket (1) in three
location, and remove the fan guide with the fan
coupling attached.
1

MFW71CSH000901

1
3. Remove the upper hose. MFW71CSH000801

7. Remove the radiator assembly.

• Remove the rubber from the radiator.
MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-15

• Remove the radiator stay (1).
• Inspect the condition of the negative pressure
valve at the center of the cap valve seat side. If the
1 valve seat does not operate smoothly because of
rust, dirt, etc, clean or replace the radiator cap.

Radiator core
• A distorted radiator fin may lead to a reduction in
heat dissipation effectiveness, which may in turn
cause overheating. Therefore, the fin must be
repaired. Take care not to damage the joint section
of the fin when repairing it.
• Remove dirt and other debris.

Inspection for cooling water leaks

• Using a radiator cap tester, apply 200 kPa (2.0 kgf/
cm2 / 28 psi) of pressure and inspect the following
MFW71CSH000701
parts for leaks. Also inspect the radiator hose and
heater hose for damage and deterioration, and
inspect the hose clamps for looseness.
Inspection locations
• Remove the radiator assembly.
• Radiator assembly, water pump assembly, radiator
• Take care not to damage the radiator fin. hose, heater hose.

Inspection
Radiator cap
• Use a radiator cap tester to inspect the injection
valve opening pressure. If the inspection valve
opening pressure exceeds the standard value,
replace the radiator cap.

kPa (kgf/cm2 / psi)

Positive pressure : 93 – 122
Cap operating (0.90 – 1.20 / 13 – 17)
pressure Negative pressure : Min. 4.9
(0.05 / 0.7)

MFW41CSH000901

Cleaning
Washing inside the radiator and the water passage.
Wash the inside of the radiator and coolant path with
tap water.
Wash away all scales and rust.

Washing the radiator core

CAUTION:
Do not perform high-pressure washing onto the
radiator, intercooler and surrounding parts when they
are still installed on the vehicle.

1. Seal the hose connecting section with a cap or

MFW41CSH000801
fabric tape.
MG6HK-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-16 Engine Cooling (6HK1)

2. Sufficiently wet the front and back surfaces of the NOTE:
radiator. If some dirt is still left, fine black particles attached on
• Adhering matter which easily comes off with a the fins can be seen.
splash of tap water should be washed off
sufficiently in advance. 7. Rinse off the detergent constituents on the fins and
resin parts using the tap water.
NOTE: 8. Remove the seal on the hose connecting section.
Do not use a high-pressure washer or brush. 9. Clean and dry the hose connecting section
sufficiently.
3. Prepare a mild detergent.
• Use a type which contains approx. 8% of
surface acting agent. Installation
1. Install the radiator assembly.
NOTE:
Do not use anything other than a mild detergent. Use of
any product other than a mild detergent may cause Tightening torque
corrosion.
Upper side nut 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
4. Spray the mild detergent onto both sides of the Lower side nut 85 N⋅m (8.7 kg⋅m/63 lb⋅ft)
fins, and leave them as is for 10 minutes.
5. Rinse off the mild detergent using a high-pressure • When Installing the radiator, take care not to
washer. damage the fin.
• Start washing from the engine side of the
radiator.

NOTE:
• Apply the high-pressure water in a direction
perpendicular to the fins.
• Do not bring the high-pressure water too close to
the fins.
• Be careful not to deform the fins.

MFW71CSH001201

• Install the radiator stay (1).

Tightening torque
13.4 N⋅m (1.37 kg⋅m/119 lb⋅in)

MFWA1CSH001101

Legend
1. Radiator

6. After washing is finished, inspect the fins to

confirm that the dirt is removed sufficiently.
• If washing is not sufficient, wash them again.
MG6HK-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-17

5. Install the upper hose.

1
Tightening torque
5 N⋅m (0.5 kg⋅m/43 lb⋅in)

NOTE:
Make sure the head of the clamp bolt does not protrude
above the hose.

6. Install the intercooler hose (1).

• Tighten a clamp bolt.

Tightening torque
ABA W4
6.4 N⋅m (0.65 kg⋅m/56 lb⋅in)
Stainless clamp
MFW71CSH000701
NORMA W1
8 N⋅m (0.8 kg⋅m/69 lb⋅in)
Steel clamp
2. Install the fan.

Tightening torque
1
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

3. Install the reserve tank hose.

4. Install the lower hose.

Tightening torque
5 N⋅m (0.5 kg⋅m/43 lb⋅in)

MFW71CSH000901

7. Close the drain plug, and fill with cooling water.

1 2 3

MFW71CSH001001

Legend
1. Intercooler assembly
2. Radiator assembly
3. Radiator lower hose
MG6HK-WE-0871.book 18 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-18 Engine Cooling (6HK1)

Drive Belt
Inspection • Securely tighten each bolt after the adjustment.
• Inspect the drive belt for wear or damage, and
Generator drive belt tension adjustment value
replace it as necessary.
• Inspect the belt tension, and adjust it as necessary.
Amount Frequency Tension
of flex of N
mm vibrations (kgf / lb)
(in) (Hz)
When 980 – 1176
4–5
using new 191 – 209 (100 – 120 /
(0.16 – 0.2)
belt 221 – 265)
706–804
When 6–7
162 – 172 (72 – 82 /
readjusted (0.24 – 0.28)
159 –181)

A/C drive belt tension adjustment value

Amount Frequency Tension

of flex of N
mm vibrations (kgf / lb)
MFW71CSH001401
(in) (Hz)

Inspection guidelines When 392–588

10 – 13
using new 115 – 141 (40 – 60 /
• Press the middle section of each belt with the force (0.39 – 0.51)
belt 88 – 132)
of approx. 98 N (10 kgf / 22 lb), and inspect the
amount of flex / frequency of vibrations of the belt. 294 – 392
When 13 – 15
101 – 115 (30 – 40 /
readjusted (0.51 – 0.59)
66 – 88)

1 2

MFW71CSH002501

Reference 3
MFW71CSH001301
NOTE:
Legend
• Since a V-rib belt is used for the generator drive
1. Adjust bolt
belt and it is necessary to adjust the tension more
2. Installation nut
accurately than conventional V belts, use a sonic
3. Mounting bolt
tension meter to confirm that the measured
frequency of vibrations is within the adjustment
values and readjust the tension if the value is
improper.
MG6HK-WE-0871.book 19 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-19

Adjustment Adjusting A/C compressor drive belt
When adjusting the tension of the drive belt, do so for 1. Loosen the lock nut of the idle pulley.
both the generator drive belt and the A/C compressor 2. Turn the adjust bolt of the idle pulley to adjust the
drive belt. belt.
3. Tighten the lock nut at the specified torque after
Adjusting generator drive belt the adjustment.
1. Loosen the adjust plate lock nut and through bolt.
2. Turn the adjust bolt to adjust the generator drive
belt. Tightening torque
3. After the adjustment, tighten the adjust plate lock Lock nut 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
nut and through bolt at the specified torque.

Tightening torque
Lock nut 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
Through bolt 127 N⋅m (12.9 kg⋅m/93 lb⋅ft)

Tightening Torque Table

c
MFW71CMF000601

(a) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

(b) 127 N⋅m (12.9 kg⋅m / 93 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
MG6HK-WE-0871.book 20 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-20 Engine Cooling (6HK1)

Thermostat
Component Parts

MFW61CLF000601

Legend
1. Water outlet pipe 4. Without thermostat
2. Gasket 5. Spacer
3. Thermostat 6. Sealing cup

Removal 4. Remove the thermostat. (Spacer is removed for

the specification without thermostat)
1. Drain the cooling water. Prepare a receptacle, and
drain at a rate so that the cooling water does not
spill onto the thermostat housing. Inspection
2. Remove the radiator air extraction hose from the
1. Inspect the water outlet pipe for corrosion etc.
radiator side.
2. Inspect the thermostat.
• Remove the radiator upper hose at the radiator
side. • Inspect the thermostat pellet, spring, shaft,
jiggle valve and caulking section for damage.
3. Remove the water outlet pipe.
MG6HK-WE-0871.book 21 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-21

1
1

MFW41CSH001301 MFW41CSH001401

Legend Legend
1. Jiggle valve 1. Wood chippings
2. Stirring rod

• Inspect the operation of the thermostat.

• Place the thermostat into water, and gradually 3. Inspect the gasket for cracks and damage.
raise the water temperature to inspect the
temperature at which the it starts opening,
temperature at which it is fully open, and
Installation
amount of lift. 1. Install the gasket.

NOTE:
Temperature at which it Replace the gasket as it can cause water leakage.
80 to 84°C (176 to 183°F)
starts to open
2. Install the thermostat. (Install the spacer)
Temperature at which it
More than 95°C (203°F) • Install the gasket to the thermostat, and install it
is fully open
as shown in the diagram.
Amount of lift More than 8 mm (0.315 in)
NOTE:
• As the heat capacity for wax type thermostats is Do not install in the wrong location or in the wrong
great, there is some difference between the direction.
valve operation with changes in water
temperature.

NOTE:
To avoid direct heat on the thermostat, either cover the
bottom of the container with a plate, or suspend it. At
this time, continue to stir the water to ensure a constant
water temperature.
MG6HK-WE-0871.book 22 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-22 Engine Cooling (6HK1)

4. Install the radiator upper hose.

Tightening torque
5 N⋅m (0.5 kg⋅m/43 lb⋅in)

5. Install the radiator air extraction hose.

6. Fill with cooling water.

MFW91BSH000801

Legend
1. Jiggle valve position

3. Install the water outlet pipe.

Tightening torque
24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

NOTE:
If you install the thermostat in the wrong position, you
will not be able to install the water outlet pipe.

MFW41CSH001601

Legend
1. Water outlet pipe
2. Positioning stopper
3. Thermostat
MG6HK-WE-0871.book 23 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-23

Fan Drive
Inspection
This diagram shows a vehicle with a day cab model.

MFWA1CLF000101

1. Fan coupling
• Inspect for abnormal noises and oil leaks.
• Rotate by hand to inspect for abnormal noises.
MG6HK-WE-0871.book 24 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-24 Engine Cooling (6HK1)

4 3
MFW61CMH000101

Legend
1. Cooling fan
2. Fan drive
3. Bimetal
4. Cooling fin
MG6HK-WE-0871.book 25 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-25

Tightening Torque Table

MFW71CLF000601

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
MG6HK-WE-0871.book 26 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-26 Engine Cooling (6HK1)

Water Pump
Component Parts

12
11

10

6
5

MFW81CLF000501

Legend
1. Pulley 7. Washer
2. Dust cover 8. Shaft
3. Snap ring 9. Water pump body
4. Bearing 10. O-ring
5. Spacer 11. Seal unit
6. Bearing 12. Impeller
MG6HK-WE-0871.book 27 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-27

Removal
1. Remove the plate.

2
MFWB1CSH000101

Legend
1. M8 bolt
2. M10 bolt

2. Remove the water duct.

3. Remove the O-ring (water duct).
4. Remove the O-ring (water pump).
5. Remove the water pump.
MG6HK-WE-0871.book 28 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-28 Engine Cooling (6HK1)

1 3

MFW61CLF000401

Legend
1. Water pump assembly 4. O-ring (water pump)
2. O-ring (water duct) 5. Plate
3. Water duct

Disassembly
If more than 10cc/100 hours of water is leaking from
the water drain hole when the pump assembly is
assembled, disassemble and adjust.
1. Remove the impeller.
MG6HK-WE-0871.book 29 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-29

2. Use a puller (Pulley puller: 1-8521-0050-0) to 6. Use a press to remove the bearing.
remove the pulley.

MFW41CSH002401

MFW61CSH000501

7. Remove the spacer.

3. Remove the dust cover. 8. Remove the washer.
4. Remove the snap ring. 9. Push the seal unit out from the pulley side to
5. Remove the shaft. remove it.
• Remove the snap ring from the pulley side, and 10. Remove the O-ring.
gently tap the shaft from the impeller side with a 11. Only for the water pump body.
hammer to remove it.

Inspection
1. Inspect the impeller for wear etc.
2. Inspect the pulley for abrasion and wear.
3. Inspect the dust cover for deformation and
damage.
4. Inspect the snap ring for damage.
5. Inspect the shaft.
• Inspect the shaft oil seal striking surface for
wear or damage.

MFW41CSH002301

BLW71CSH000801
MG6HK-WE-0871.book 30 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-30 Engine Cooling (6HK1)

• Measure the inner diameter of the pulley shaft 7. Inspect the spacer for damage.
insertion section and the outer diameter of the 8. Inspect the washer for damage.
shaft, and inspect to make sure that the
9. Replace the seal unit with a new seal unit.
interference is within the standard value.
10. Replace the oil seal with a new oil seal.
11. Replace the o-ring with a new O-ring.
12. Inspect the water pump body for rust and damage.

Reassembly
1. Set the water pump body.
2. Install the O-ring.
3. Install the washer.
4. Install the bearing.
• Apply engine oil to the shaft.
• Assemble the washer, bearing, spacer and
bearing in order to the shaft, and use a press to
press-fit them.

NOTE:
MFW71CSH001901 2 bearings are placed at the front side.

Pulley and shaft interference

0.048 – 0.078 mm
Assembly standard
(0.0019 – 0.0031 in)

6. Inspect the bearing.

• Inspect the bearing for breakaway, wear, and
abnormal noises.
• Inspect the entire periphery from the ball gap to
the lace for scratches and breakaway.
• Inspect the ball and race sections for abnormal
looseness caused by wear.
• Rotate the bearing by hand to check whether or
not its movement is smooth, and if there are
any abnormal noises.
MFW41CSH002401

NOTE:
The spacer is placed between the bearings.

5. Install the spacer.

6. Install the shaft to the water pump body.
• Fill the bearing with grease (BESCO L-3 or
BESCO L-2 grease or equivalent).
• Install the shaft to the water pump body, put a
pipe, etc. against the bearing outer race, and
use a press to press-fit it.

NOTE:
Make sure you do not damage the oil seal.

MFW41CSH002701
MG6HK-WE-0871.book 31 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-31

MFW61CSH000801 MFW61CSH000301

Legend
1. Impeller insertion section
7. Install the snap ring.
8. Install the dust cover to the water pump body in the
direction shown in the diagram.
10. Install the seal unit.
• Install the seal unit to the water pump body.
• Using a press, press-fit the seal unit (Seal unit
setting tool: 1-8522-0047-0) until its collar
section hits the pump body.

Seal unit press-fit dimensions

11 – 11.6 mm
Assembly standard
(0.43 – 0.46 in)

• The seal unit has liquid gasket burned-on to the

water pump body and shaft striking surface.
• To make a seal unit setting tool, refer to the
diagram on the bottom.

MFW61CSH000601

9. Install the pulley to the shaft.

• Use a press to press-fit the pulley, while taking
care not to damage the dust cover.

NOTE:
In order to prevent damage to the bearing, use the tip
a

of the impeller side shaft to press-fit it.

BLW51CSH000601
MG6HK-WE-0871.book 32 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-32 Engine Cooling (6HK1)

(a) 11.0 to 11.6 mm (0.43 to 0.46 in)

2
2

4
MFW61CSH000201
5
12. Inspect after reassembly.
• Rotate the pump, and check that it rotates
MFW41CSH003301 smoothly.
Legend • Perform a pressure test with water pressure
1. Dia 17 mm (0.67 in) 100 kPa (1.0 kgf/cm2 / 14 psi) equivalent, and
2. 11.2 to 11.4 mm (0.44 to 0.45 in) check the seal unit section for water leaks.
3. 50 mm (1.97 in)
4. Dia 33 mm (1.30 in)
5. Dia 44 mm (1.73 in) Installation
1. Install the water pump assembly.
• Uniformly apply a bead of liquid gasket
11. Install the impeller. (ThreeBond 1207B) approx. 2 to 3 mm (0.0787
to 0.1181 in) in width as shown in the diagram.
• Using a press, press-fit until the shaft tip (1) and
impeller edge surface (2) become the same NOTE:
level. Install within 5 minutes of applying the liquid gasket.
NOTE:
In order to prevent damage to the bearing, use the tip
of the pulley side shaft to press-fit it.

Gap between body and impeller

0.4 – 1.2 mm (0.02 – 0.05 in)

MFW61CSH000101

Legend
1. Do not apply gasket even if there is a groove
MG6HK-WE-0871.book 33 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Cooling (6HK1) 1C-33

• Install the water pump assembly. • Press in the duct while taking care not to
damage the O-ring.

Tightening torque
19 N⋅m (1.9 kg⋅m/14 lb⋅ft) Tightening torque
M8 bolt 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
• Temporarily install the bolt to the plate M16 bolt 103 N⋅m (10.5 kg⋅m/76 lb⋅ft)
attachment section (1) bolt.

MFW61CSH001001
MFW61CSH001201

Legend
1. Water duct
2. Install the O-ring (water pump).
2. Plate
• After installing the O-ring, apply soapy water to
the outer perimeter of the O-ring. 5. Install the plate.

1 Tightening torque
M8 bolt 19 N⋅m (1.9 (kg⋅m/ 14lb⋅ft)
M10 bolt 36 N⋅m (3.9 (kg⋅m/ 28lb⋅ft)

MFW61CSH001101

Legend
1. Soapy water

3. Install the O-ring (water duct).

4. Install the water duct.
MG6HK-WE-0871.book 34 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1C-34 Engine Cooling (6HK1)

2
MFWB1CSH000101

Legend
1. M8 bolt
2. M10 bolt
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-1

ENGINE
Engine Fuel
(6HK1)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-47
Precautions for Servicing . . . . . . . . . . . . . . . . . 1D-2 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-47
Explanation of Functions and Operations . . . . . 1D-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-51
Function Inspection: . . . . . . . . . . . . . . . . . . . . . 1D-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-51
Failure Phenomenon List . . . . . . . . . . . . . . . . . 1D-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-55
Phenomenon: Starting difficulties . . . . . . . . . . 1D-10
Phenomenon: Hunting when idling . . . . . . . . . 1D-11
Phenomenon: Lack of output . . . . . . . . . . . . . 1D-12
Phenomenon: Engine does not stop . . . . . . . . 1D-13
Phenomenon: Exhaust gas is blue or black . . 1D-14
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1D-14
Fuel Pressure Sensor (Common Rail) . . . . . . . . 1D-15
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-15
Maintenance Precautions . . . . . . . . . . . . . . . . 1D-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Pressure Limiter (Common Rail) . . . . . . . . . . . . 1D-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Fuel Filter Assembly. . . . . . . . . . . . . . . . . . . . . . 1D-18
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-18
Fuel Filter Element Replacement Procedure . . . 1D-19
Maintenance Precautions . . . . . . . . . . . . . . . . 1D-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-19
Water Sedimenter Switch. . . . . . . . . . . . . . . . . . 1D-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-21
Pre-fuel Filter Element . . . . . . . . . . . . . . . . . . . . 1D-22
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-23
Fuel Rail Pressure (FRP) Regulator . . . . . . . . . 1D-24
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-24
Maintenance Precautions . . . . . . . . . . . . . . . . 1D-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-24
Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . 1D-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-26
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-29
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-34
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-40
Tightening Torque Table . . . . . . . . . . . . . . . . . 1D-42
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-2 Engine Fuel (6HK1)

Fuel System
Precautions for Servicing Work procedure
All of the holes and gaps in the fuel lines within the fuel • When removing the fuel pipe, injection pipe,
system injectors are made to extremely precise injector, supply pump, and common rail, seal all of
specifications. These parts are highly sensitive to dust the fuel openings immediately.
or debris, and dust or debris entering these parts may • Store eyebolts and gaskets in a parts box with a lid
cause damage to the fuel lines. Therefore, you should so that debris and foreign matter do not adhere to
aim to completely prevent any dust or debris from them.
entering these parts. The injector ID plate is unique to • As fuel leaks can cause fire, always clean up any
that particular injector. Do not confuse it with a different spilled fuel after completing work, and after starting
injector ID plate. When the injector assembly is the engine, always check that there are no fuel
replaced, use a scan tool to write the ID code to the leaks.
ECM. Refer to “Engine Control Section” for the writing
procedure. Furthermore, as fuel water removing
agents cause diesel fuel to absorb water, which in turn
may cause rust, do not use water-removing agents in
the fuel tank.

Explanation of Functions and Operations

Fuel system diagram
Vehicle with a Euro 4 specification

2 5
3
1

13

11
12 10 7
9

MFW91DMF003801

Legend
1. Common rail (Fuel rail) 8. Fuel feed pipe
2. Common rail pressure sensor 9. Fuel filter assembly (Sedimenter assembly)
3. Leak-off pipe 10. Recirculation valve (with a built-in fuel filter)
4. ECM 11. Supply pump
5. Injector 12. Fuel rail pressure (FRP) regulator / Suction
6. Fuel return pipe control valve (SCV)
7. Fuel tank 13. Fuel temperature sensor
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-3

Fuel system diagram
Vehicle with a Euro 2 specification and Euro 3 specification

2 5
3
1

14

12 9
13 11 7
10

MFWB1DMF000601

Legend
1. Common rail (Fuel rail) 9. Pre-fuel filter
2. Common rail pressure sensor 10. Fuel filter assembly
3. Leak-off pipe 11. Recirculation valve (with a built-in fuel filter)
4. ECM 12. Supply pump
5. Injector 13. Fuel rail pressure (FRP) regulator / Suction
6. Fuel return pipe control valve (SCV)
7. Fuel tank 14. Fuel temperature sensor
8. Fuel feed pipe
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-4 Engine Fuel (6HK1)

Common rail

BLW71DMF000201

Legend
1. Common rail (Fuel rail) assembly 3. Fuel inlet
2. Pressure limiter 4. Pressure sensor
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-5

Supply Pump

1 1
4
2

7
6

MFWB1DMF000201

Legend
1. Fuel outlet (return) 5. Camshaft
2. Fuel rail pressure (FRP) regulator / Suction 6. Supply pump assembly
control valve (SCV) 7. High pressure pipe
3. Fuel inlet 8. High pressure fuel outlet
4. Fuel temperature sensor
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-6 Engine Fuel (6HK1)

Injectors Fuel filter assembly

1
1 2

8
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00
7 3

6 4 6

3
5 4
5
MFW71DMH000201 MFW61DMH000101

Legend Legend
1. ID plate 1. Priming pump
2. Terminal stud 2. Element
3. Injector drive section 3. Drain plug
4. Injector assembly 4. Float
5. Gasket 5. Switch connector
6. O-ring 6. Case
7. Fuel outlet port 7. Body assembly
8. Recirculation valve
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-7

Pre-fuel filter

4
3

MFW81DMF000601

Legend
1. Filter body 3. Float switch connector
2. Clear element case 4. Drain plug
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-8 Engine Fuel (6HK1)

Function Inspection:
Air bleeding • Insert a vinyl hose into the drain plug tip and
1. Loosen the fuel filter air removal plug. prepare a container to receive the water.
2. Move the priming pump and pressure feed fuel. • Loosen the drain plug.
Check that fuel mixed with bubbles comes out of • In order to drain the water, operate the priming
the air removal plug. pump a few times.
3. When bubbles stop coming out, tighten the air • After draining, tighten the drain plug.
removal plug. • Operate the priming pump a few times, and check
that there are no fuel leaks.
• Check that the warning lamp in the meter has gone
Tightening torque
out.
7 N⋅m (0.7 kg⋅m/61 lb⋅in)
NOTE:
4. After tightening the plug, move the priming pump • The drained water contains fuel. Therefore, follow
until it becomes heavy enough or approx. 150 processing regulations established by your local
times. area when discarding the water.
5. Wipe up any spilt fuel. • If fuel sticks to the vehicle body etc, wipe it clean.
6. Start the engine.
Check that there are no fuel leaks. If it does not
start, repeat from procedure 1.

MFW81DMH000101

Legend
1. Priming pump
2. Air removal plug

Water drain
If there is more water than the specified amount in the
sedimenter, a warning lamp lights. In this situation,
follow the procedure below to remove the water.
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-9

Failure Phenomenon List
• Starting difficulties
• Hunting when idling
• Engine top speed is too slow
• Engine does not stop
• Exhaust gas is blue or black
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-10 Engine Fuel (6HK1)

Phenomenon: Starting difficulties

Condition Possible Cause Correction

Starting difficulties Fuel tank is empty Fill the tank
Clogging of the fuel tank breather Clean the fuel tank breathe
Air in the fuel system Remove the air
Clogging or damaged fuel line. Loose Repair or replace the fuel line. Re-
fuel line connection tighten the connection
The fuel is frozen (wax blocked) Pour hot water on the fuel pump or fuel
filter to heat it up, or wait for the
temperature to rise
Clogging of the fuel filter element Replace the cartridge
Feed pump malfunction Replace the supply pump
Regulating valve is open Replace the supply pump
Injector nozzle fixing Replace the injector
Engine control system fault Diagnose the engine control system
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-11

Phenomenon: Hunting when idling

Condition Possible Cause Correction

Hunting when idling Air in the fuel system Remove the air from the fuel system
Leak or clogging of the fuel system Repair or replace the fuel system
Water in the fuel system Replace the fuel
Clogging of the fuel filter element Replace the cartridge
Injector nozzle fixing Replace the injector
Low injector opening valve pressure, Replace the injector
poor injection condition
Incomplete supply pump functioning Replace the supply pump
Engine control system fault Diagnose the engine control system
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-12 Engine Fuel (6HK1)

Phenomenon: Lack of output

Condition Possible Cause Correction

Lack of output Clogging of the fuel tank breather Clean the fuel tank breather
Air in the fuel system Remove the air from the fuel system
Blockage or leak in the fuel system Repair or replace the fuel system
Water in the fuel system Replace the fuel
Clogging of the fuel filter element Replace the cartridge
Injector nozzle fixing Replace the injector
Engine control fault Diagnose the engine control system
MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-13

Phenomenon: Engine does not stop

Condition Possible Cause Correction

Engine does not stop Engine control system fault Diagnose the engine control system
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-14 Engine Fuel (6HK1)

Phenomenon: Exhaust gas is blue or black

Condition Possible Cause Correction

Exhaust gas is blue or black Low injector opening valve pressure, Replace the injector
poor injection condition
Engine control system fault Diagnose the engine control system

Main Specifications
Fuel system

Item Specifications
Engine type 6HK1-TC
Electronically controlled fuel injection system (common
Fuel system
rail type)
MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-15

Fuel Pressure Sensor (Common Rail)

Component Parts
Common rail

BLW71DMF000201

Legend
1. Common rail (Fuel rail) 3. Fuel inlet
2. Pressure limiter 4. Pressure sensor

Maintenance Precautions NOTE:

Do not re-use sensors that have been removed.
Maintenance precautions
• Put cleansing fluid into a steam cleaner and
carefully clean around the sensors and common
rail.
• Remove water completely using compressed air.
• Confirm that foreign materials have all been
removed before starting work.
• After replacement of any of the sensors, use the
scan tool to erase trouble codes and check if the
sensor is operating correctly.

Removal
Fuel pressure sensor
• Remove the fuel pressure sensor (1) using a
socket wrench 30 mm (1.1811 in).
MG6HK-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-16 Engine Fuel (6HK1)

BLW71DSH000101

Installation
Fuel pressure sensor
• Apply grease (1) to the threads and seat area of
the sensor and then install it.
• Install the connector terminals so that the terminals
do not interfere each other.

Tightening torque
98 N⋅m (10 kg⋅m/72 lb⋅ft)

NOTE:
Do not allow foreign material to stick to the threaded
area. In addition, make sure there is not foreign
material on the mounting area and then install the
sensor.

HCW31DSH000901
MG6HK-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-17

Pressure Limiter (Common Rail)

Removal
Pressure limiter
• Remove the pressure limiter using a socket
wrench 19 mm (0.75 in).

NOTE:
• Do not re-use pressure limiter or gaskets that have
been removed.
• Do not damage the seat surface when taking off
the gasket.

BLW71DSH000201

Legend
1. Pressure limiter (socket width across flats of 19
mm (0.75 in))

Installation
Pressure limiter
• Install the pressure limiter with a copper gasket.

Tightening torque
172 N⋅m (17.5 kg⋅m/127 lb⋅ft)

NOTE:
• Confirm that there is not any foreign material on
the mounting area.
• Tighten the pressure limiter using the area with a
width across flats of 19 mm (0.75 in).
MG6HK-WE-0871.book 18 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-18 Engine Fuel (6HK1)

Fuel Filter Assembly

Component Parts

2
1
3

4
5

MFW81DMF000101

Legend
1. Fuel filter assembly 4. Fuel return hose
2. Air removal plug 5. Water sedimenter switch connector
3. Fuel feed pipe (From fuel tank)

Removal Installation
1. Remove the filler cap. 1. Install the fuel filter assembly.
2. Disconnect the wiring connector of the sedimenter
switch.
Tightening Torque
3. Extract the feed hose and return hose from the fuel
filter assembly, and cork it so that fuel does not 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
leak.
2. Install the feed hose and the return hose.
WARNING: 3. Connect the sedimenter switch wiring connector.
Make sure that foreign material does not enter the fuel
feed hose (engine side) when it is removed, as this 4. Install the filler cap.
may cause the supply pump to fail. (Inserting a rusty 5. Remove the air bleeding.
bolt, etc. is strictly prohibited) • Refer to “Fuel System”.

4. Remove the fuel filter mounting bolt.

5. Remove the fuel filter assembly.
MG6HK-WE-0871.book 19 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-19

Fuel Filter Element Replacement Procedure

Maintenance Precautions
• Replace the fuel filter element timing is in the table
below. 1

2
Fuel filter element replace timing
3
Except for Indonesia 30,000 km
(18,000 mile) or every 9
4
For Indonesia 20,000 km months
(12,000 mile)

5
Removal
1. Remove the fuel in the element case.
a. Loosen the drain plug at the bottom of the
element case.
6
b. When the air removal plug of the body is 9
loosened, the fuel is run out from the drain plug.
2. Remove the harness of the water warning switch.
3. Remove the element case from the body by
rotating the case in a counterclockwise direction, 7
using a socket (width of double socket (a) : 29 mm 8
(1.142 in). After removing the case, confirm that
the float at the inside bottom can move up and a
down smoothly.
BLW61DMH000101
NOTE: Legend
Check that the float in the element case moves 1. Cap
smoothly. 2. Air removal plug
3. Filter body
4. Remove the O-ring of the body by pulling out the
4. O-ring
element downward.
5. Fuel filter element
5. If foreign material is attached on the surface of the 6. Element case
body inner circumference, wipe it with clean cloth. 7. O-ring
8. Drain plug
NOTE: 9. Switch connector
Do not use an air blower to remove foreign materials. If
you do, they can be blown into the path of the clean
side and cause failure of the supply pump.
Installation
1. Place the O-ring, packaged with the element kit,
into the groove on the outer circumference of the
body.
Careful handling of the O-ring is needed to prevent
being damaged by the threaded area of the body.
2. Apply a thin layer of fresh diesel fuel on the
gaskets, inside and outside of the element, and
then insert the gasket until it hits the end.

NOTE:
Be careful not to insert any foreign materials into the
four holes (clean side) next to the inside gasket.
MG6HK-WE-0871.book 20 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-20 Engine Fuel (6HK1)

• Make sure to use a genuine Isuzu fuel filter and
replace the O-ring at the same time.
4. Tighten the element case with a torque wrench.

Tightening torque
33 N⋅m (3.4 kg⋅m/25 lb⋅ft)

5. Tighten the drain plug of the element case, and

reconnect the connector of the water warning
switch.

Tightening torque
1
2 0.4 N⋅m (0.04 kg⋅m/3.5 lb⋅in)

6. Remove the air in the fuel.

• Refer to "Air bleeding" in Fuel System.
7
7. Start the engine and confirm that the check light is
turned off.
6
NOTE:
4 Reset the fuel filter replacement schedule (mileage
5 count) of the multi-display item on the meter side.

MFWA1DLH000101

Legend
1. Salient for socket
2. Float
3. Outside gasket
4. Inside gasket
5. Clean side hole
6. Element kit
7. O-ring grove

3. Apply a thin layer of fresh diesel fuel on the inner

circumference of the element case (or the O-ring
section at the body side). Turn the element in a
clockwise direction until it hits to the body carefully.
Biting with the O-ring must be avoided.
No hitting of the element to the case means that
the element does not have compete insertion.
Turn the element and push it in again.

WARNING:
Be careful so as not to pinch the O-ring when installing
the element case.
If the O-ring gets stuck, fuel may leak causing fire.
MG6HK-WE-0871.book 21 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-21

Water Sedimenter Switch

Inspection If a fault is discovered as a result of the inspections,
replace the switch section, and repair the bad
1. Inspect the water sedimenter switch.
connections between circuits and broken wires.
• Remove the fuel filter assembly from the
bracket.
• Connect the sedimenter switch wiring
connector, and turn the key switch ON.
• Turn the fuel filter assembly over (move the
float), and it is normal if the warning lamp in the
meter lights.
2. If the warning lamp does not light in procedure 1,
inspect the following.
• Turn the fuel filter assembly over. The switch is 1
normal if there is conductance between the
connector terminals.
• Remove the sedimenter switch connector,
connect between the vehicle side connector
terminals, then turn the starter switch ON. At
this time, if the sedimenter warning lamp lights,
the circuit is normal.
2
5

4 3

MFW61DMH000201

Legend
1. Fuel filter assembly
2. Drain plug
3. Lead switch terminal
4. Lead switch terminal
5. Water sedimenter switch assembly
MG6HK-WE-0871.book 22 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-22 Engine Fuel (6HK1)

Pre-fuel Filter Element

Component Parts

7 6

MFW81DMF001801

Legend
1. Filter body 5. Clear element case
2. Gasket 6. Float switch connector
3. Filter element 7. Drain plug
4. O- ring

Removal Inspection
1. Loosen the drain plug at the bottom of the fuel • Check any damage or scratch on the clear element
filter. case.
• Drain the fuel completely. • Check dirt, break and distortion on the filter
2. Disconnect the water separator switch connector. element.
3. Carefully turn the clear element case • Check any clog in the through hole of filter body.
counterclockwise, then remove the clear element • The O-ring of water separator is exchanging at the
case and the filter element from the filter body as a time of decomposition.
single unit.
Inspect the water in float switch
NOTE:
When remove the case, do not use any tools for the • The wires red (+) and black (-) are connected to
projection part under the case to prevent the case 24V DC.
being damaged.
Voltage DC 24V
4. Remove the filter element from the clear element Water
case. warning Float switch /
80 – 120 cc (0.0176 –
5. Remove the O-ring from the clear element case. level Direct connection
0.0264 Imp⋅gal)
(warning ON)
MG6HK-WE-0871.book 23 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-23

Installation
NOTE:
Drain out water, when fuel filter will be covered with
water. If driving is continued not draining, there is a
possibility of damaging a fuel injection system.
In addition, surely use the genuine filter for engine at
the time of element exchange.

1. Install the new O-ring to the clear element case.

NOTE:
Use care not to damage the O-ring.

2. Install the filter element.

• After light coating the gasket of the new filter
element with diesel fuel, place the element until
it touches the filter body.
3. Install the clear element case to the filter body.
• After light coating the O-ring of element case
with diesel fuel, slowly turn the clear element
case clockwise.

NOTE:
Be careful not to let the O-ring catch in the screw
threads.

• Slowly tighten the clear element case with a

filter wrench until it touches the filter body.

OK

3
2

NG

1
4

MFW91DSH002501

Legend
1. Clear element case
2. Filter body
3. No gap
4. Gap

4. Tighten the drain plug and connect the water

separator switch connector, then bleed the fuel
system.
MG6HK-WE-0871.book 24 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-24 Engine Fuel (6HK1)

Fuel Rail Pressure (FRP) Regulator

Component Parts

1
2

MFWB1DMF000501

Legend
1. Bolt 3. O-ring
2. Fuel rail pressure (FRP) regulator / Suction 4. Supply pump
control valve (SCV)

Maintenance Precautions Installation

• Add cleaning agent to the steam cleaner and 1. Install the O-rings to the supply pump
thoroughly clean the sensor and supply pump 2. Install the FRP regulator to the supply pump, and
areas. temporarily tighten 2 bolts.
• Completely remove the moisture with an air
blower. NOTE:
• Start work after checking that all foreign matter has • Be careful so as not to pinch the O-ring during
been removed. installation.
• After starting the engine, check to be sure that • Temporarily tighten by hand until the FRP regulator
there is no fuel leaking. adheres the supply pump.
• After replacing valves, use a scan tool to check
3. Tighten the FRP regulator to the specified torque.
that the trouble code is cleared and that operations
are normal.
Tightening torque
Removal 8.9 N⋅m (0.9 kg⋅m/78 lb⋅in)
1. Disconnect the connector from the FRP regulator.
4. Connect the connector to the FRP regulator.
2. Remove the FRP regulator.
3. Remove the O-rings from the FRP regulator.
MG6HK-WE-0871.book 25 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-25

Supply Pump Relearn
1. Install a scan tool.
2. Start the engine and let idle until engine coolant
temperature reads 65°C (149°F) or higher while
observing the Fuel Supply Pump Status parameter
with a scan tool. The scan tool parameter changes
status Not Learned → Learned.
MG6HK-WE-0871.book 26 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-26 Engine Fuel (6HK1)

Fuel Temperature Sensor

Removal
1. Disconnect the fuel temperature sensor connector.
2. Remove the fuel temperature sensor (1).

MFWA1DSH000701

Installation
1. Install the fuel temperature sensor.

Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)

2. Connect the wiring connector fuel temperature

sensor.
MG6HK-WE-0871.book 27 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-27

Injector
Removal
NOTE:
Seal the inlet duct hole, supply pump and other such
places so that debris cannot enter.

1. Remove the engine exterior parts. Refer to “Engine

Exterior Parts”.
2. Remove the injection pipe.
1
3. Remove the noise cover. 2

3
1

BLW71BSH008901

Legend
1. Bracket
2. Head cover
2 3. Bolt

5. Remove the head cover.

BLW71BSH008301 NOTE:
Legend Make sure you do not lose the collar that is inside the
1. Noise cover head cover.
2. Head cover
6. Remove the gasket.

4. Remove the noise cover bracket.

NOTE:
If the bracket is not damaged, do not remove it.

BLW71BSH009001

7. Remove the harness assembly.

• Push the arrowed section of the connector with
your fingers to remove it.
MG6HK-WE-0871.book 28 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-28 Engine Fuel (6HK1)

NOTE: • Remove the harness bracket with the harness
Do not pull the wires or pry the connector with a still attached.
screwdriver.

2
1

MFW41BSH027101

Legend
MFW41BSH026201
1. Harness terminal
2. Harness bracket

• Take out the injector harness terminal.

8. If there are no malfunctions with the connector, do
3 not remove it.
9. Remove the injector leak-off pipe.
10. Remove the injector clamp.
• Loosen the injector clamp bolt using a torque
wrench (T-40).

LNW71DSH003601

Legend
1. Injector
2. Injector harness
3. Terminal nut

MFWA1BSH003101

11. Remove the injector assembly.

• Loosen the clamp, and use the replacer to
remove the injector.
MG6HK-WE-0871.book 29 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-29

• If it is difficult to remove the injector, set the
injector remover (5-8840-2826-0) on the
injector, tighten the bolt into the leak- off pipe
fitting, and using the sliding hammer small (5-
8840-0019-0) pull the injector out in an upward
direction.

NOTE:
• When removing the injector using this special tool,
make sure that the injector sleeve is not removed as
well.
• The ID plate is unique to each injector, so install a
number tag to it before storing it to ensure that it is
not used on a different injector.
• He injector and glow plug protrude from first to
prevent them from being damaged.

MFW71BSH005301

1 Installation
1. Install the injector.
2
NOTE:
When injector replaced, fuel injector ID codes is written
in ECM with scan tool.

• Insert gasket into the tip of the injector and

insert it into the cylinder head.
• Insert the injector clamp at the same time.

NOTE:
3 • The injector ID plate is unique to that particular
injector. Do not confuse it with a different injector
ID plate.
• When the injector assembly is replaced, use a
scan tool to write the ID code to the ECM. Refer to
“Engine Control Section” for the writing procedure.

LNW46CMH000301

Legend
1. Sliding hammer small
2. Injector remover
3. Injector assembly

NOTE:
• Indicate the cylinder No. on the removed injector
before storing the injector.
• Be careful not to strike the injection nozzle against a
hard surface.
MFW71BSH005301
MG6HK-WE-0871.book 30 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-30 Engine Fuel (6HK1)

2. Apply engine oil to the thread section and seating

section of the injector clamp bolt, and temporarily
tighten it.

1
1
1

2 3
1
4
a
1
1

MFW81BSH010001
6

4. Tighten the injector clamp (temporarily tightened

BLW71BSH020401 earlier) at the specified torque.
Legend
1. O-ring
Tightening torque
2. Injector assembly
3. Injector clamp bolt 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
4. Injector clamp
5. O-ring 5. Tighten the injection pipe at the specified torque.
6. Gasket

Tightening torque
Injector side 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
3. Install the injection pipe.
• Thinly apply engine oil to the outer Common rail side 25 N⋅m (2.6 kg⋅m/19 lb⋅ft)
circumference of the injector side sleeve nut
and install it.
• Lightly tighten the sleeve nut with spanner so
that it is airtight to the injector and common rail
side.
• Tighten the injection pipe clip (1) at the
specified torque.

Tightening torque
6 N⋅m (0.6 kg⋅m/52 lb⋅in)
MG6HK-WE-0871.book 31 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-31

7. Install the injector harness assembly.

• Install the harness bracket with the harness still
1 2 3 4 5 6
attached.

Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)

• Install the terminal nut to the injector, and

tighten to the specified torque strength.

Tightening torque
2 N⋅m (0.2 kg⋅m/17 lb⋅in)
7
MFWA1BSH001501 NOTE:
Legend • As the terminal is a single unit, tighten the nuts 2 to
1. Injection pipe #1 3 turns each until fully tightened.
2. Injection pipe #2 • Over tightening the nuts will cause damage to the
3. Injection pipe #3 terminal stud. Therefore, they should never be over
4. Injection pipe #4 tightened.
5. Injection pipe #5
6. Injection pipe #6
•

7. Common rail (Fuel rail)

2
1
6. Install the leak-off pipe to the injector.

Tightening torque
12 N⋅m (1.2 kg⋅m/104 lb⋅in)

NOTE:
• Always use brand new gasket.
• Re-check to make sure you didn’t forget to tighten
anything.

MFW71BSH007101

Legend
1. Harness terminal
2. Harness bracket

8. Install the gasket.

• Clean the head cover gasket attachment slot
and gasket, and install the gasket to the head
cover.

NOTE:
Check that the collar has not fallen out.

MFW41BSH023501
MG6HK-WE-0871.book 32 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-32 Engine Fuel (6HK1)

• Install the noise cover bracket to the cylinder
head cover.

Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

1
2
BLW71BSH009001

9. Install the head cover.

• After temporarily tightening all of the bolts,
tighten them in the order shown in the diagram.

BLW71BSH008901
Tightening torque
Legend
13 N⋅m (1.3 kg⋅m/113 lb⋅in) 1. Bracket
2. Head cover
NOTE: 3. Bolt
Check that there is no debris on the upper surface of
the cylinder head.
11. Install the noise cover.
• Install the noise cover (1) to the head cover (2),
and tighten the nut and bolt.

Tightening torque
8 4 1 5 9 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

11

7 3 2 6 10
1

MFW41BSH035801

10. Install the bracket. 2

BLW71BSH008301
MG6HK-WE-0871.book 33 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-33

• Refer to “Programming” in Section 1A, Engine
12. Paint out fuel injector ID codes of the cylinder that Control System.
replaced injector among the fuel injector ID codes
written in the code label. 2 1
• Only when injector are replaced, it does.
• Injector ID code label is on the surface of the
noise cover. 64DA A505
2F4C 0F36
FA17 25 00
0000 8C

1
SAMPLE
6HK1
2 64 05 4F 08 F5 F5 F5 DD 0A 00 00 14
64 F0 00 12 0E 04 16 00 0A 0A 20 BA
3 64 00 31 06 0A 14 00 10 FA 00 25 82
64 E5 00 00 10 12 0F 16 0C 11 23 A4
4 64 05 3A 0C F6 D9 FB DA 00 EE EC 5B
64 32 61 1B 1C 0C 0D FA 1D 0F 0C D5
LNW76ESH002601
5
6 Legend
7 1. Fuel injector ID plate
2. Fuel injector ID code
3. Fuel injector
MFW81ASH000601

Legend
1. Cylinder #1 fuel injector ID code
2. Cylinder #1 fuel injector ID code
3. Cylinder #1 fuel injector ID code
4. Cylinder #1 fuel injector ID code
5. Cylinder #1 fuel injector ID code
6. Cylinder #1 fuel injector ID code
7. Injector ID code label

13. Install the engine exterior parts.

• Refer to “Engine Exterior Parts”.
14. Pour in cooling water.
15. Program the injector ID code.
• After installing the injector, make sure to
program the ID code indicated on the injector.
MG6HK-WE-0871.book 34 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-34 Engine Fuel (6HK1)

Fuel Tank
Component Parts
140L (30.8 Imp.gal) - Tank model

2
1

7 6

MFW81DLF001201

Legend
1. Fuel feed hose 6. Drain plug
2. Fuel return hose 7. Fuel tank
3. Fuel tank bracket 8. Fuel tank unit
4. Fuel tank band 9. Outlet breather hose
5. Filler cap
MG6HK-WE-0871.book 35 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-35

200L (44 Imp.gal) - Tank type: W

1 2

3
5

6
MFW81DLF000101

Legend
1. Fuel tank bracket 6. Drain plug
2. Fuel tank band 7. Fuel tank
3. Fuel feed hose 8. Fuel return hose
4. Outlet breather hose 9. Fuel tank unit
5. Filler cap
MG6HK-WE-0871.book 36 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-36 Engine Fuel (6HK1)

200L (44 Imp.gal) - Tank type: N

2 4
1

7
8
MFW81DMF001001

Legend
1. Fuel return hose 6. Filler cap
2. Fuel feed hose 7. Drain plug
3. Outlet breather hose 8. Fuel tank
4. Fuel tank bracket 9. Fuel tank unit
5. Fuel tank band
MG6HK-WE-0871.book 37 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-37

200L (44 Imp.gal) - Tank type: M

3
2

MFWB1DLF000501

Legend
1. Fuel tank 4. Filler cap
2. Fuel tank band 5. Drain plug
3. Fuel tank bracket
MG6HK-WE-0871.book 38 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-38 Engine Fuel (6HK1)

400L (88 Imp.gal) tank

2
3
4
1

MFW81DLF001501

Legend
1. Fuel tank unit 5. Filler cap
2. Fuel tank bracket 6. Fuel tank
3. Fuel tank band 7. Drain plug
4. Insulator

Removal Drain plug

1. Disconnect the negative terminal of the battery Tightening torque
cable. 140L Tank model 73.5 N⋅m (7.5 kg⋅m/54 lb⋅ft)
2. Loosen the fuel filler cap. 200L Tank type: W 73.5 N⋅m (7.5 kg⋅m/54 lb⋅ft)
3. Drain the fuel from the drain plug.
200L Tank type: N 73.5 N⋅m (7.5 kg⋅m/54 lb⋅ft)
4. After draining the fuel, tighten the drain plug to the
200L Tank type: M 19.6 N⋅m (2.0 kg⋅m/15 lb⋅ft)
specified torque strength.
400L tank 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)

5. Remove the fuel tank unit connector.

6. Remove the fuel feed hose.
7. Remove the fuel return hose.
MG6HK-WE-0871.book 39 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-39

• Plug the hose so that fuel does not leak, and tie 200L (44 Imp.gal) - Tank type: N
it to the frame side pointing upwards.
8. Remove the fuel tank attachment band, and
remove the frame side end of the band.
9. Extract the fuel tank to the outside. 1
2
NOTE:
If the fuel tank cannot be extracted, remove the
bracket, and extract the fuel tank from the bottom.

140L (30.8 Imp.gal) - Tank model

3

1
3

MFW81DSH001401

Legend
1. Fuel tank unit
2. Fuel tank
3. Band

200L (44 Imp.gal) - Tank type: M

1
MFW81DSH001001
2
Legend
1. Frame
2. Fuel tank unit
3. Band

200L (44 Imp.gal) - Tank type: W

2 3

MNWB1DSH000101

Legend
1. Fuel tank
2. Band

MFW81DSH000101

Legend
1. Frame
2. Fuel tank unit
3. Band
MG6HK-WE-0871.book 40 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-40 Engine Fuel (6HK1)

400L (88 Imp.gal) tank

1 a

MFW81DSH001301
MFW81DSH001501

Legend
1. Fuel tank unit (a) 855 mm (33.7 in)
2. Fuel tank
3. Band 200L (44 Imp.gal) - Tank type: N
Bracket tightening torque
47.1 N⋅m (4.8 kg⋅m/35 lb⋅ft)
Installation
1. Install the fuel tank temporarily.

NOTE:
• When removing the fuel tank, if the bracket was
removed, install the bracket to the frame at the
a
specified torque strength.
• When supporting the fuel tank in the bracket, make
sure the rubber section stuck to the fuel tank is
firmly supported in the bracket.
Bracket
140L (30.8 Imp.gal) - Tank model
Bracket tightening torque
47.1 N⋅m (4.8 kg⋅m / 35 lb⋅ft)

200L (44 Imp.gal) - Tank type: W

Bracket tightening torque MFW81DSH001201

97.1 N⋅m (9.9 kg⋅m/71.6 lb⋅ft)

(a) 1345 mm (53 in)

200L (44 Imp.gal) - Tank type: M

Bracket tightening torque
97.1 N⋅m (9.9 kg⋅m/71.6 lb⋅ft)
MG6HK-WE-0871.book 41 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-41

400L (88 Imp.gal) tank
Tightening torque
a
Inside nut 17.7 N⋅m (1.8 kg⋅m/13 lb⋅ft)
Outside nut 20.6 N⋅m (2.1 kg⋅m/15.2 lb⋅ft)

MNWB1DSH000201

(a) 720 mm (28.4 in)

2
400L (88 Imp.gal) tank
4 3
Bracket tightening torque MFW81BSH001801

97.1 N⋅m (9.9 kg⋅m/71.6 lb⋅ft) Legend

1. Band
2. Install the band to the fuel tank, and tighten the 2. Bracket
nuts to the specified torque strength. 3. Inside nut
4. Outside nut
Band nut
140L (30.8 Imp.gal) tank 3. Install the fuel return hose.
Tightening torque 4. Install the fuel feed hose.
Inside nut 17.7 N⋅m (1.8 kg⋅m/13 lb⋅ft) • Insert the hose more than 25 mm (0.9843 in)
into the pipe.
Outside nut 20.6 N⋅m (2.1 kg⋅m/15.2 lb⋅ft)
5. Connect the fuel tank unit connector.
6. Fill the fuel tank with fuel, and tighten the fuel filler
200L (44 Imp.gal) - Tank type: W
cap.
Tightening torque 7. Connect the negative terminal of the battery cable.
Inside nut 17.7 N⋅m (1.8 kg⋅m/13 lb⋅ft) 8. After starting the engine, check all of the hose
Outside nut 20.6 N⋅m (2.1 kg⋅m/15.2 lb⋅ft) connection sections to make sure there are no fuel
leaks.
200L (44 Imp.gal) - Tank type: N
Tightening torque
Inside nut 17.7 N⋅m (1.8 kg⋅m/13 lb⋅ft)
Outside nut 20.6 N⋅m (2.1 kg⋅m/15.2 lb⋅ft)

200L (44 Imp.gal) - Tank type: M

Tightening torque
Inside nut 16.5 N⋅m (1.7 kg⋅m/12 lb⋅ft)
Outside nut 16.5 N⋅m (1.7 kg⋅m/12 lb⋅ft)
MG6HK-WE-0871.book 42 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-42 Engine Fuel (6HK1)

Tightening Torque Table
140L (30.8 Imp.gal) - Tank model

b
c

MFW81DLF001301

(a) 47.1 N⋅m (4.8 kg⋅m / 35 lb⋅ft)

(b) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)
MG6HK-WE-0871.book 43 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-43

200L (44 Imp.gal) - Tank type: W

d
c

b
MFW81DLF000201

(a) 97.1 N⋅m (9.9 kg⋅m / 71.6 lb⋅ft)

(b) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
MG6HK-WE-0871.book 44 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-44 Engine Fuel (6HK1)

200L (44 Imp.gal) - Tank type: N

b
c

MFW81DMF001101

(a) 47.1 N⋅m (4.8 kg⋅m / 35 lb⋅ft)

(b) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)
MG6HK-WE-0871.book 45 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-45

200L (44 Imp.gal) - Tank type: M

c
d

MFWB1DLF000601

(a) 97.1 N⋅m (9.9 kg⋅m / 71.6 lb⋅ft)

(b) 97.1 N⋅m (9.9 kg⋅m / 71.6 lb⋅ft)
(c) 16.5 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(d) 16.5 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(e) 19.6 N⋅m (2.0 kg⋅m / 15 lb⋅ft)
MG6HK-WE-0871.book 46 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-46 Engine Fuel (6HK1)

400L (88 Imp.gal) tank

MFW81DLF001601

(a) 97.1 N⋅m (9.9 kg⋅m / 71.6 lb⋅ft)

(b) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
MG6HK-WE-0871.book 47 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-47

Fuel Tank Unit

Component Parts
140L (30.8 Imp.gal) - Tank model

MFW81DMF000901

Legend
1. Fuel tank unit 2. Fuel tank
MG6HK-WE-0871.book 48 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-48 Engine Fuel (6HK1)

200L (44 Imp.gal) - Tank type: W

MFWA1DMF000501

Legend
1. Fuel tank unit 2. Fuel tank
MG6HK-WE-0871.book 49 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-49

200L (44 Imp.gal) - Tank type: N

MFWA1DMF000601

Legend
1. Fuel tank unit 2. Fuel tank
MG6HK-WE-0871.book 50 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-50 Engine Fuel (6HK1)

200L (44 Imp.gal) - Tank type: M

1 2

MFWB1DMF001301

Legend
1. Fuel tank unit 2. Fuel tank
MG6HK-WE-0871.book 51 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-51

400L (88 Imp.gal) tank

MFWA1DMF000701

Legend
1. Fuel tank unit 2. Fuel tank

Removal Inspection
1. Disconnect the wiring connector from the fuel tank The fuel tank unit changes the internal resistance by
unit. the float position (the fuel level height) and operates the
2. Remove the installment screw, and remove the fuel meter indicator.
fuel tank unit. 1. While moving the float from "E" to "F", inspect the
resistance value between the connector terminals.
NOTE: 2. Check that the low fuel level warning light lights up
• When removing and replacing the fuel tank unit, when the float is at the "E" position.
make sure there is no interference around the If any abnormality is found in the inspection
perimeter, and be sure not to distort the shape of the results, replace the meter with a normal one.
arm.
• After removing the fuel tank unit, cover it to ensure
debris does not enter the tank.
140L (30.8 Imp.gal) - Tank model
F point 3/4 point 1/2 point 1/4 point E point SE point
Float position
(h1) (h2) (h3) (h4) (h5) (h6)
Distance from the 66.0 139.6 215.5 291.5 368.8 379.9
mm (in)
flange (2.60) (5.50) (8.48) (11.48) (14.52) (14.96)
129.0 100.5 71.0 41.5 12.0 8.0
Tank capacity L (lmp⋅gal)
(28.4) (22.1) (15.6) (9.1) (2.6) (1.8)
Resistance value (Ω)
6.0 28 50 86 141 150
(Between terminal 2 and 3)
MG6HK-WE-0871.book 52 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-52 Engine Fuel (6HK1)

200L (44 Imp.gal) - Tank type: W

F point 3/4 point 1/2 point 1/4 point E point SE point
Float position
(h1) (h2) (h3) (h4) (h5) (h6)
Distance from the 77.2 157 248.7 330.7 421.9 437.8
mm (in)
flange (3.04) (6.18) (9.79) (13.02) (16.61) (17.24)
182.8 144.5 100.4 60.8 17.2 9.8
Tank capacity L (lmp⋅gal)
(40.2) (31.8) (22.1) (13.4) (3.8) (2.2)
Resistance value (Ω)
6.0 28 50 86 141 150
(Between terminal 2 and 3)

140L (30.8 Imp⋅gal) and 200L (44 Imp.gal) - Tank type: W

2
h1

3 1

F
h2
h3

3/4
h4
h5
h6

1/2

1/4

SE

MFW81ELF000101
MG6HK-WE-0871.book 53 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-53

200L (44 Imp.gal) - Tank type: N
F point 3/4 point 1/2 point 1/4 point E point SE point
Float position
(h1) (h2) (h3) (h4) (h5) (h6)
Distance from the 53.5 114.1 171.6 233.0 295.8 303.4
mm (in)
flange (2.11) (4.49) (6.76) (9.17) (11.65) (11.94)
182.0 143.0 102.0 60.5 19.0 13.8
Tank capacity L (lmp⋅gal)
(40.0) (31.5) (22.4) (13.3) (4.2) (3.0)
Resistance value (Ω)
6.0 28 50 86 141 150
(Between terminal 2 and 3)

200L (44 Imp.gal) - Tank type: N

3 2 1
h1
h2

F
h3
h4

3/4
h5
h6

1/2

1/4

SE

MFW81ELF000601
MG6HK-WE-0871.book 54 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1D-54 Engine Fuel (6HK1)

200L (44 Imp.gal) - Tank type: M
F point 3/4 point 1/2 point 1/4 point E point
Float position
(h1) (h2) (h3) (h4) (h5)
Distance from the 32.8 139.6 255 370.3 477.2
mm (in)
flange (1.29) (5.50) (10.04) (14.58) (18.79)
Resistance value (Ω)
0 22.7 50 95.4 150
(Between terminal 1 and 2)

200L (44 Imp.gal) - Tank type: M

h1

1
2
F
h2
h3

3/4
h4
h5

1/2

1/4

MFWB1DLF000901
MG6HK-WE-0871.book 55 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Fuel (6HK1) 1D-55

400L (88 Imp.gal) tank
F point 3/4 point 1/2 point 1/4 point E point
Float position
(h1) (h2) (h3) (h4) (h5)
Distance from the 98 226 354 481 578
mm (in)
flange (3.86) (8.90) (13.94) (18.94) (22.76)
Resistance value (Ω)
0 22.7 50 95.4 150
(Between terminal 1 and 2)

400L (88 Imp.gal) tank

h1
2 1

h2

h3
3/4

h4

h5
1/2

1/4

MFW81DLF001801

Installation
Follow the disassemble procedure in reverse order to
reassemble.
1. Install the fuel tank unit.
2. Connect the wiring connector to the fuel tank unit.
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

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MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-1

ENGINE
Engine Electrical
(6HK1)
TABLE OF CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1E-2
Explanation of Functions and Operations . . . . . 1E-2
Failure Phenomenon List . . . . . . . . . . . . . . . . . 1E-4
Phenomenon: Starter does not operate even
if the starter is switched on . . . . . . . . . . . . . . . . 1E-5
Phenomenon: The pinion moves
forwards but does not engage the ring gear . . . 1E-6
Phenomenon: The pinion engages and rotates
the motor but does not rotate the engine . . . . . 1E-7
Phenomenon: The pinion engages but
does not rotate the engine . . . . . . . . . . . . . . . . 1E-8
Phenomenon: After the engine starts, the starter
does not stop even though the starter switch is
switched off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-9
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1E-9
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-10
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1E-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-15
Tightening Torque Table . . . . . . . . . . . . . . . . . 1E-19
Charge System . . . . . . . . . . . . . . . . . . . . . . . . . 1E-20
Precautions for Servicing . . . . . . . . . . . . . . . . 1E-20
Explanation of Functions and Operations . . . . 1E-21
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1E-22
Function Inspection . . . . . . . . . . . . . . . . . . . . . 1E-23
Failure Phenomenon List . . . . . . . . . . . . . . . . 1E-24
Phenomenon: Does not charge at all . . . . . . . 1E-25
Phenomenon: Insufficient charge . . . . . . . . . . 1E-26
Phenomenon: Overcharge . . . . . . . . . . . . . . . 1E-27
Phenomenon: Charging current is unstable . . 1E-28
Phenomenon: Abnormal noises coming from
the generator. . . . . . . . . . . . . . . . . . . . . . . . . . 1E-29
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-30
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1E-30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-33
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Bench Testing:. . . . . . . . . . . . . . . . . . . . . . . . . 1E-37
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-2 Engine Electrical (6HK1)

Starting System
Precautions for Servicing Starter
When performing maintenance work on the electrical The starter is a magnetic shift type, and has a
system, check that the starter switch, headlight switch circumscription engagement type reduction starter.
etc. are OFF, and always disconnect the battery minus When the starter switch is switched ON, the magnetic
terminal before starting maintenance work. switch assembly contact closes, and the armature
rotates. At the same time, the plunger draws in through
the lever assembly, the pinion is pushed out of the front
Explanation of Functions and Operations and engages with the ring gear, which then rotates
Starting circuit causing the crank shaft to rotate and the engine to
start. After the engine has started and if the starter
The starting system consists of the battery, starter, switch is switched OFF, the plunger returns, the pinion
starter switch, starter relay etc. and these main parts disengages from the ring gear, and the armature stops
are wired as shown in the starting circuit diagram. rotating. If the engine r/min are faster than the pinion,
the pinion is conversely rotated. However, as the pinion
runs idle because of the effects of the clutch, the
armature is not driven.

Starter motor
24V 5.0kW

5
8
7
6

MFW51EMF000401

Legend
1. Brush holder 5. Clutch
2. Magnetic switch assembly 6. Internal gear
3. Lever assembly 7. Armature
4. Pinion 8. Yoke
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-3

Schematics

B M

B S S

SW L
M
K.S

MFW41EMH000101

Legend
1. Momentary current: 308.4A (24V20°C / 68°F),
Holding current: 15.7A (24V20°C / 68°F)
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-4 Engine Electrical (6HK1)

Failure Phenomenon List
• Starter does not operate even if the starter switch
is switched on
• The pinion moves forwards but does not engage
the ring gear
• The pinion rotates the engagement motor but does
not rotate the engine
• The pinion engages but does not rotate the engine
• After the engine starts, the starter does not stop
even though the starter switch is switched off
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-5

Phenomenon: Starter does not operate even if the starter is switched on

Condition Possible Cause Correction

Starter does not operate even if the Battery is completely discharged Replace the battery
starter is switched on Broken wire or bad connection in the Repair it
wiring circuit
Bad contact in the starter switch Repair or replace
contact, or poor tightening of the
terminal
Bad contact in the starter relay contact, Repair or replace
or bad contact in the insertion terminal
Short circuit or broken wire in the Replace
magnetic switch coil
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-6 Engine Electrical (6HK1)

Phenomenon: The pinion moves forwards but does not engage the ring gear

Condition Possible Cause Correction

The pinion moves forwards but does Insufficient battery capacity Recharge the battery
not engage the ring gear Worn pinion or ring gear tooth tip Replace the pinion or ring gear
Dirt adhering to the pinion shaft Repair it
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-7

Phenomenon: The pinion engages and rotates the motor but does not rotate the engine

Condition Possible Cause Correction

The pinion engages and rotates the Clutch slipping Replace the clutch or starter
motor but does not rotate the engine Reduction gear damage Replace the gear or starter
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-8 Engine Electrical (6HK1)

Phenomenon: The pinion engages but does not rotate the engine

Condition Possible Cause Correction

The pinion engages but does not rotate Insufficient battery capacity Recharge the battery
the engine Bad terminal connection in the wiring Repair it
circuit
Short circuit in the armature or field coil Replace the starter
Dirt on the commutator Repair or replace the starter
Weak brush spring or worn brush Replace the brush spring or brush
Bearing lock Replace the bearing or starter
Bad contact in the magnetic switch Replace the magnetic switch
contact
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-9

Phenomenon: After the engine starts, the starter does not stop even though the starter
switch is switched off

Condition Possible Cause Correction

After the engine starts, the starter does Bad return from the starter switch Replace the starter switch
not stop even though the starter switch contact
is switched off Bad return from the starter relay contact Replace the starter relay
Short circuit in the magnetic switch coil Replace the magnetic switch

Main Specifications

Model (Manufacturer) Mitsubishi

Voltage 24 V
Output 5.0 kW
Time 30 sec.
Pinion teeth count 11
Rotational direction (see from pinion side) Clockwise
Weight (approx.) 70.1 N (7.2 kg / 16.0 lb)
No-load characteristics
Voltage/Current 23 V / Max.85 A
Rotational speed Min. 3,300 r/min
Load characteristics
Voltage/Current 18.5 V / Max.400 A
Torque Min. 26 N⋅m (2.6 kg⋅m / 19 lb⋅ft)
Rotational speed Min. 1,250 r/min
Locking characteristics
Voltage/Current 9 V / Max.1,400 A
Torque Min. 88 N⋅m (9.0 kg⋅m / 65 lb⋅ft)
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-10 Engine Electrical (6HK1)

Starter Motor
Component Parts

10

21
20
19 22
18
6
17
9 23
7 8 24 30
5

15 16

4 13
14 29
3 12 28
1 2 25 26 27
11

MFWB1ELF000601

Legend
1. Snap ring 16. Planetary gear
2. Stop ring 17. Ball
3. Pinion 18. Gasket
4. Pinion spring 19. Plate
5. Screw 20. Armature
6. Front bracket 21. Bearing
7. Lever 22. Through bolt
8. Plate 23. O-ring
9. Gasket 24. Lead wire with terminal
10. Magnet switch 25. O-ring
11. Overrunning clutch 26. Yoke assembly
12. Internal gear 27. Brush
13. Washer 28. Brush holder
14. E-form retaining ring 29. Rear bracket
15. Gear shaft 30. Screw
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-11

Disassembly
NOTE:
• Before disassembling the starter, attach
identification marks on the attachment sections
between the magnetic switch, yoke, front bracket,
SW1
and rear bracket, to make it easier to reassemble
SW2
them later.
• Remove the pinion first. If disassembly is 24V
performed without first removing the pinion, the
pinion will become un-removable, and you will not
be able to proceed with disassembly. However, the
motor section and magnetic switch can be
removed even if the pinion is not removed.

1. Remove the snap ring.

2. Remove the stop ring.
3. Remove the pinion. HCW51ESH001701
• Under normal circumstances, if the pinion or
stop ring is tapped to the front bracket side, the
front bracket will break. Therefore, tap the • Place a pipe that is the exact same size as the
stopper ring when the pinion is out to the stop ring against the stop ring, hit the pipe with
cranking position. a hammer and remove the stop ring to the
• Connect the starter to the battery as shown in pinion side. Next, remove the snap ring, then
the diagram. When switch SW1 and SW2 are remove the stop ring, pinion, and pinion spring.
closed, the pinion moves forward to the
cranking position, and the armature rotates. NOTE:
Then, switch SW2 opens and the armature Do not re-use the snap ring.
stops rotating.

NOTE:
If left with the power supply on, heat will be generated, 6
so the pinion should be removed within 10 seconds.
5

4 1

2
3

MFW41ESH000201

3 Legend
1 2 1. Clutch shaft
2. Pinion spring
3. Pinion
MFWB1ESH000301
4. Snap ring
Legend 5. Stop ring
1. Snap ring 6. Pipe
2. Stop ring
3. Pinion gear
4. Remove the pinion spring.
5. Remove the lead wire with terminal.
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-12 Engine Electrical (6HK1)

6. Remove the screw. • Pull the brush spring upwards, and remove the
7. Remove the magnetic switch. brush from the brush holder. Next, remove the
brush holder.
• Remove the magnetic switch M terminal nut,
and remove the lead wire with terminal. Next, 14. Remove the armature.
remove the magnetic switch tightening screw, 15. Remove the ball.
and remove the magnetic switch. • Remove the armature. At the same time the
ball should also come out, but sometimes it
NOTE: sticks in the grease and does not move. The
The tightening screw is tight, so use a shock driver to bearing can generally be removed with a puller.
loosen it.
16. Remove the plate.
8. Remove the screw. 17. Remove the gasket.
9. Remove the through bolt. 18. Remove the gasket.
• Remove the brush holder tightening screw and 19. Remove the plate.
through bolt. • Remove the planetary gear section plate, and
Next, remove the rear bracket. At the same time, remove the gasket.
remove the O-ring. Next, remove the lever support section gasket
and plate.
NOTE:
Do not re-use the O-ring. 20. Remove the planetary gears.
• Remove the 4 planetary gears.
10. Remove the rear bracket. • Pull out the internal gears, gear shaft,
11. Remove the yoke assembly. overrunning clutch and lever as a set from the
12. Remove the O-ring. front bracket.
• Place a socket (outer diameter 38 mm / 1.5 in) 21. Remove the lever.
against the armature commutator.
Next, let the brush slide against the socket, and NOTE:
while allowing the brush to be supported on the Remember the direction of the lever.
socket, remove the yoke assembly. At the same
22. Remove the E-shaped retaining ring.
time, remove the O-ring.
• Remove the both E- shaped retaining rings.
Rotate the overrunning clutch one spline gear
1 tooth, then remove it from the gear shaft
assembly.
2
NOTE:
Do not re-use E-shaped retaining rings after they have
been removed once.

23. Remove the internal gear.

24. Remove the washer.
• Remove the internal gear. At this time, remove
the washer that adjusts gear shaft play in the
axial direction.
25. Remove the gear shaft.
3
26. Remove the front bracket.
5 4
27. Remove the bearing.
HCW31ESH000401
28. Remove the brush.
Legend
1. Armature
2. Through bolt Inspection
3. Rear bracket 1. Inspect the armature.
4. Brush holder
5. Yoke assembly

13. Remove the brush holder.

MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-13

Growler test. Commutator inspection
• Inspect for armature coil internal short circuits • Inspect the outer circumference of the
with a growler tester. commutator for wear.
If an internal short circuit is found in the If the armature is worn beyond the limit, replace
armature, replace it. it.

HCW51ESH000701 HCW51ESH000901

Earth inspection • Measure the thickness (called “undercut”) of

• Inspect the armature coil earth (bad insulation) the commutator insulation mold. Remove the
with a circuit tester. brush wear grindings, and repair any faults.
If the armature is earthed, replace it.

1 a
2

HEW61ESH001201

HCW51ESH000801 Legend
1. Insulation mold
2. Commutator segment
3. Bad
4. Good

Gear inspection
• Inspect the gear section for damage and wear.
If a fault is found in the armature, replace it.
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-14 Engine Electrical (6HK1)

Bearing inspection • Inspect the wear of the brush length.
• Inspect the bearing for abnormal noises, If the brush is worn close to the limit, replace
looseness, and grease leakage. If a fault is the brush holder assembly for the brush holder
found in the bearing, replace it. side brush. Just replace the brush on the Yoke
assembly side.
2. Inspect the field coil.
Conduction inspection • Check that the brush moves smoothly in the
brush holder.
• Inspect the coil for broken wires with a circuit
Also inspect the pressure of the brush spring.
tester. If the there are broken wires, replace the
yoke assembly. • Inspect the brush holder earth (bad insulation)
with a circuit tester.
However, clean the brush holder before
inspection. Place one side of the circuit tester
probe against the brush holder plate (metal
section) and the other probe onto the insulated
holder (2). If there is conductance, the
insulation must be bad, so replace the brush
holder assembly.

HCW51ESH001101

Earth inspection
• Inspect the coil earth (bad insulation) with a
circuit tester. If it is earthed, either repair it, or
replace the yoke assembly.
HEW61ESH001301

Legend
1. Brush length
2. Insulated holder

4. Overrunning clutch and pinion.

Inspect the overrunning clutch.
• Hold the overrunning clutch housing section
with your hand, and when rotating the pinion by
hand, it should gently rotate in one direction
with a certain amount of resistance, but not
rotate at all in the opposite direction. If this is
not the case, replace the overrunning clutch.
Inspect the pinion, and replace the pinion if it is
damaged or worn.
HCW51ESH001201

NOTE:
3. Inspect the brush. The inside of the overrunning clutch is filled with
grease, so if it is washed using wash oil or oil removing
detergents, the grease may be washed out of it.
Therefore, simply wipe dirt off the overrunning clutch
using a cloth.
MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-15

8. Inspect the magnetic switch.
• Inspect the conductance between the M
terminal and body, and if there is no
conductance, replace the magnetic switch.
Also check that there is no conductance
between the B terminal and M terminal. If there
is conductance, replace the magnetic switch.

3 2

HCW51ESH001401

5. Inspect the front bracket.

• Inspect the bearing and oil seal, and if there are
any faults, replace the front bracket assembly
(including the bearing and oil seal).
MFW51ESH000201
6. Inspect the internal gears and planetary gears.
• Inspect the gear teeth, and replace the internal Legend
gears or planetary gears if abnormal wear or 1. S terminal
damage is found. 2. B terminal
3. M terminal
7. Inspect the lever.
• If the section that rubs against the overrunning
clutch is worn, the pinion protrusion location is
incorrect. For pinion protrusion location Reassembly
adjustments, see the assembly section. Reassembly can be performed in the reverse order to
disassembly. However, the following precautions
should be followed.

NOTE:
The following parts should be replaced with brand new
parts.

• Snap ring (fixing the stop ring)

• E-shaped retaining ring
• O- ring (gasket on both sides of the yoke, and
each screw)

MFW41ESH001101

Legend
1. Worn section
MG6HK-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-16 Engine Electrical (6HK1)

1. The following sections require lubrication. We
recommend using MULTEMP 0A-171 grease
(manufactured by Kyodo Yushi Co., Ltd.) on
sections 1, 2, 3, 4, 5, and 9 in the diagram, and
Molykote RAG650 grease (manufactured by Dow
Corning Corporation) for sections 6, 7, and 8 on
the diagram.

2
3
4

8 7 6

MFW51EMF000501

Legend
1. Plunger surface (very small quantity) 6. Lever and overrunning clutch rotational
2. Gear shaft spline section and rotational movement sections
movement section 7. Sleeve bearing and ball
3. Clutch shaft rotational movement section 8. Armature shaft gear, planetary gear, internal
4. Oil seal gear
5. Bottom of the pinion 9. Surface of the armature bearing outer
circumference (very small quantity)

• Pass the gear shaft through the washer,

2. Tightening torque internal gear, and overrunning clutch. Next,
The torque is as per the list on the separate sheet. move the overrunning clutch one spline tooth
distance, check that the overrunning clutch
3. Armature shaft axial direction play
does not slip, then attach the E-shaped
• No need to adjust. Insert the ball in to the shaft retaining ring.
tip section.
4. Gear shaft axial direction play
• By inserting one washer between the internal
gear and gear shaft, the required gap is
automatically maintained.
MG6HK-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-17

6
1

1 2
5

4
2
3

3
4
5

HCW51ESH001501 MFW41ESH001401

Legend Legend
1. Washer 1. Push the pinion down and hook-on the puller
2. Gear shaft prongs
3. E-shaped retaining ring 2. Pinion spring
4. Internal gear 3. Pinion
5. Overrunning clutch 4. Clutch shaft
5. Snap ring
6. Stop ring

5. Pinion attachment
• Before attaching the magnetic switch to the
front bracket, attach the pinion. Attach the 6. Pinion protrusion position inspection
pinion spring, pinion, and stop ring in order onto After assembling the starter, inspect the pinion
the clutch shaft, then finally tightly attach the protrusion position. The measurement and
snap ring to the clutch shaft groove. Next, use a adjustment procedures are as follows.
gear puller to firmly pull the stop ring to the stop • Connect the starter to the battery as shown in
ring side, and fix both sides. the diagram. When switches SW1 and SW2 are
closed, the pinion moves forward to the
cranking position, and the armature rotates.
Then, switch SW2 opens and the armature
stops rotating.

SW1
SW2

24V

HCW51ESH001701
MG6HK-WE-0871.book 18 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-18 Engine Electrical (6HK1)

• Gently push the end of the crankshaft by hand
(push back), and measure the crankshaft
moving dimensions (return dimensions). This
value is OK if it is between 0.5 to 2.0 mm (0.02
to 0.08 in). If the measured value is outside this 2
range, either adjust by changing the number (2
or less) of gaskets (thickness 0.5 mm (0.02 in)) A SW B
between the magnetic switch and front bracket, S
1
or replace the lever. M
3
V

PWW010SH036201

Legend
1. Battery
2
2. Ammeter
3. Voltmeter

8. Maintenance standard
MFW41ESH001601

Legend
1. Gently push the Clutch shaft by hand Standard value or limit
Item
2. Amount of shaft movement value
Unloaded Voltage 23.0 V
7. No-load test characteristics Current Less than 85 A
• After adjusting the protrusion position of the
Rotation More than 3300 r/min
pinion, connect the starter as shown in the
diagram. Commutator Outer
38.7 mm (1.52 in)
diameter
NOTE: Wear limit 38.1 mm (1.50 in)
Use a wire of adequate thickness, and adequately
tighten the connection sections. Commutator Undercut 0.8 mm (0.031 in)
Limit 0.2 mm (0.008 in)
• Close the switch, and read the r/min, current,
Brush Length 23 mm (0.91 in)
and voltage. Compare with the maintenance
standard. If the value is different to the Wear limit 12 mm (0.47 in)
maintenance standard value, disassemble Brush spring 33 – 45 N (3.4 – 4.6 kg
them again and inspect them. Pressure
/ 7.5 – 10.1 lb)
Limit 20 N (2.0 kg/4.4 lb)
Pinion drive position 0.5 – 2.0 mm
(0.02 – 0.08 in)
MG6HK-WE-0871.book 19 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-19

Tightening Torque Table

b
a

MFW81EMF000301

(a) 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft)

(b) 6 N⋅m (0.6 kg⋅m / 52 lb⋅in)
(c) 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
(d) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
(e) 3 N⋅m (0.3 kg⋅m / 26 lb⋅in)
MG6HK-WE-0871.book 20 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-20 Engine Electrical (6HK1)

Charge System
Precautions for Servicing
Be aware of the following precautions when handling
the generator.
• Connecting the plus and minus poles of the battery
to the opposite poles causes damage to the
generator diodes.
• Never disconnect the battery terminals and
charging circuit wires when the engine is running.
• The wiring for each terminal should be performed
accurately in accordance with the terminal codes.
• Do not perform a mega test on the semi -conductor
element.
• Always disconnect the battery terminal (-) when
inspecting the device.
• Do not open/close the battery relay switch when
the engine is running.
• When performing charging from external sources
such as a quick charge, always disconnect the
battery terminals first.
• Do not directly use a steam cleaner or water on the
device.
• After wiring, tighten B terminal and E terminal to
the torque strength shown below.

11 N⋅m
B terminal
50A (1.1 kg⋅m / 95 lb⋅in)
Specifications 4 N⋅m
E terminal
(0.4 kg⋅m / 35 lb⋅in)
11 N⋅m
B terminal
60A (1.1kg⋅m / 95 lb⋅in)
Specifications 4 N⋅m
E terminal
(0.4 kg⋅m / 35 lb⋅in)
11 N⋅m
B terminal
90A (1.1 kg⋅m / 95 lb⋅in)
Specifications 4 N⋅m
E terminal
(0.4 kg⋅m / 35 lb⋅in)

• Refer to the belt adjustment sections for details on

adjusting the tension of the V belt.
MG6HK-WE-0871.book 21 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-21

Explanation of Functions and Operations
Multi-function IC regulator
Trouble diagnosis function
• Trouble diagnosis is added to turn on the charge
light when the feed coil circuit is open, and there is
excessive voltage.

2 3

1 4

11

10

8
7 6

MFW61EMF000301

Legend
1. Regulator 7. Rotor
2. Field coil 8. Rear bracket
3. Stator 9. Rectifier
4. Ball bearing 10. B terminal
5. Pulley 11. Ball bearing
6. Front bracket
MG6HK-WE-0871.book 22 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-22 Engine Electrical (6HK1)

Charging circuit

1
2
7 L

B S L
P
3
F
6
MIC
4
E
E

MFW71EMF000101

Legend
1. Charge lamp (LED) 5. Generator
2. Key switch 6. Field coil
3. Battery 7. Stator coil
4. IC Regulator

Main Specifications

Official output 24V – 50A 24V – 60A 24V – 90A

Rated speed 5,000 r/min 5,000 r/min 5,000 r/min
Regulator type IC type
Adjustment voltage 28.0 to 29.0V
Mass 97 N (9.9 kg/21.83 lb) 97 N (9.9 kg/21.83 lb) 179 N (18.3 kg/40.35 lb)
MG6HK-WE-0871.book 23 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-23

Function Inspection
General vehicle inspection
The charge warning lamp indicates operating
malfunctions in the charge system. The warning lamp
lights when the starter switch is switched “ON”, and if it
goes out after the engine has started, operation is
normal. If the warning lamp indicates a malfunction, or
if there is suspicion that there is insufficient battery
charge or overcharging, perform fault diagnosis
according to the list.
MG6HK-WE-0871.book 24 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-24 Engine Electrical (6HK1)

Failure Phenomenon List
• Does not charge at all
• Insufficient charge
• Overcharging
• Charging current is unstable
• Abnormal noises coming from the generator
MG6HK-WE-0871.book 25 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-25

Phenomenon: Does not charge at all

Condition Possible Cause Correction

Does not charge at all Battery fault Replace
Broken wire in the wiring/ampere meter, Repair
short circuit, disconnected connection
section
Broken wire in one of the generator Replace
coils, earthed, short circuit and diode
damage
Regulator fault Replace
Regulator bad terminal connection Repair
MG6HK-WE-0871.book 26 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-26 Engine Electrical (6HK1)

Phenomenon: Insufficient charge

Condition Possible Cause Correction

Insufficient charge Battery fault Replace
Broken wire in the wiring, short circuit, Repair
disconnected connection section
Loose generator drive belt Adjust the tension of the belt
Stator coil layer short-circuit Replace
Diode fault Replace
Bad connection in one of the terminals Repair
Regulator fault Replace
Regulator bad terminal connection Repair
MG6HK-WE-0871.book 27 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-27

Phenomenon: Overcharge

Condition Possible Cause Correction

Overcharging Regulator fault Replace
MG6HK-WE-0871.book 28 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-28 Engine Electrical (6HK1)

Phenomenon: Charging current is unstable

Condition Possible Cause Correction

Charging current is unstable Wiring intermittent contact or partly Repair
broken wire
Loose generator drive belt Adjust the tension of the belt
Stator coil short circuit, partly broken Repair
wire
Bad contact in each terminal Repair
Regulator fault Replace
Regulator bad terminal connection Repair
MG6HK-WE-0871.book 29 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-29

Phenomenon: Abnormal noises coming from the generator

Condition Possible Cause Correction

Abnormal noises coming from the Loose belt tension Adjust the tension of the belt
generator Bearing fault Replace the bearing
Contact between the rotor core and Repair
stator core
Diode fault Replace
Stator coil short circuit, partly broken Replace
wire
MG6HK-WE-0871.book 30 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-30 Engine Electrical (6HK1)

Generator
Component Parts
50A ⋅ 60A Specifications

1
2
3
4
5
6
7
8
9
10
11
12

13
24

23
22
21
20
19 18
17 16
15
14

MFW61ELF000101

Legend
1. Nut 13. Nuts (for tightening the cover)
2. Pulley 14. Cover
3. Fan 15. Screw (for installing the regulator)
4. Through bolts 16. Screw (for tightening the regulator)
5. Collar 17. Clamp
6. Front bracket 18. Regulator
7. Front bearing 19. Nut (for fixing the rectifier)
8. Retainer 20. Rectifier
9. Screw (for tightening the retainer) 21. Screw (for fixing field coil)
10. Collar 22. Rear bracket
11. Rotor 23. Stator
12. Rear bearing 24. Field coil
MG6HK-WE-0871.book 31 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-31

90A Specifications

1
2 3
4
5
6
7 8
9
10
11
12
13

14

23

15

26

25
17
24
23
22
21
20 19
18
16

MFW61ELF000201

Legend
1. Nut 14. Rear bearing
2. Spring washer 15. Nuts (for tightening the cover)
3. Plain washer 16. Cover
4. Pulley 17. Screw (for installing the regulator)
5. Fan 18. Screw (for tightening the regulator)
6. Through bolts 19. Clamp
7. Collar 20. Regulator
8. Front bracket 21. Nut (for fixing the rectifier)
9. Front bearing 22. Rectifier
10. Retainer 23. Screw (for fixing field coil)
11. Screw (for tightening the retainer) 24. Rear bracket
12. Woodruff key 25. Stator
13. Rotor 26. Field coil

Disassembly front and rear bracket for easy reassembly.

NOTE: 1. Remove the through bolt.
Before disassembling, put an alignment mark to the
• Remove the 3 through bolts (50A&60A).
MG6HK-WE-0871.book 32 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-32 Engine Electrical (6HK1)

• Remove the 4 through bolts (90A). • Before separating, use a dryer etc. to warm up
2. Remove the cover from the rear side. the bearing housing and then dismantle.
• Remove the 3 nuts. • When separating, dismantle with a press using
the holes where the through bolts have been
• Remove the 2 B terminal nuts (90A).
removed from.
50A ⋅ 60A Specifications
NOTE:
1 Take care not to damage the stator coil.

5. Remove the pulley nut with an impact.

6. Remove the spring washer and plain washer
(90A).
7. Remove the pulley.
B 8. Remove the fan.
9. Remove the woodruff key (90A).
E 10. Remove the collar.
11. Remove the rotor from the front bracket assembly.
2
• When removing the rotor, use a pressing
4 3 machine etc.
• Do not put the rotor into a vice as it will become
distorted in shape.
MFW61ESH000501 12. Remove the collar from the rotor (50A&60A).
Legend 13. Remove the front bracket assembly’s bearing
1. Connector retainer screw.
2. B terminal 14. Remove the front bearing.
3. Nuts
• If it is necessary to remove the front bearing,
4. Cover
remove retainer fitting screw, and then use an
90A Specifications appropriate socket to push out the bearing.

NOTE:
1 Only remove the bearing if necessary.
Once the bearing has been removed, it cannot be
reused.

15. Remove the stator.

• Remove the stator lead wires from the 4 places,
and remove the stator from the rectifier.
• Remove the stator lead wires from the 7 places,
and remove the stator from the rectifier (90A).

2 NOTE:
4 When removing the stator lead wires, use the soldering
iron for a short time (not over 5 seconds) so that the
rectifier does not overheat and damage the diode.
3
16. Remove the field coil terminal lead.
MFW61ESH000701
• Remove the 2 screws (M4) that connect the
Legend lead to the rectifier.
1. Nuts
• Remove the solder from the place where the
2. B terminal
lead connects to the rectifier.
3. Cover
4. Nuts NOTE:
When removing the field coil terminal lead, use the
soldering iron for short time (not over 5 seconds) so
that the rectifier does not overheat to the rectifier.
3. Remove the B terminal (90A).
4. Separate the front and rear sides.
MG6HK-WE-0871.book 33 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-33

• Remove the lead on the side of regulator from 90A Specifications
the clamp.
2
17. Remove the regulator fitting screw.
18. Remove the regulator. 1
19. Remove the nut (1 place) that fixes the rectifier.
20. Remove the rectifier.
50A & 60A Specifications
7
2 3
1

6
7 4

5
3
MFW61ESH000901
6
Legend
4 1. Screw
2. Soldered part
3. Regulator
5
4. Rectifier
5. Nut
MFW61ESH000801
6. Screw
Legend 7. Clamp
1. Screw
2. Soldered part
3. Regulator
4. Rectifier 21. Remove the 3 field coil fitting screws (50A&60A).
5. Nut 22. Remove the 4 field coil fitting screws (90A).
6. Screw 23. Remove the field coil.
7. Clamp
24. Disconnect the rear bearing.
• If it is necessary to remove the rear bearing,
use a pressing machine.

NOTE:
Only remove the rear bearing if necessary.
Once the rear bearing has been removed, it cannot be
reused.

Inspection
Generator inspection and repair
Inspect the stator
• Perform a visual inspection for damage, slack
connections and discoloration of the stator coil.
MG6HK-WE-0871.book 34 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-34 Engine Electrical (6HK1)

• Inspect the conduction between the 2 stator coil Inspect the coil assembly
lead wires (1) with a circuit tester. • Measure the resistance between both terminals in
If there is no conduction, replace the stator. the terminal section using circuit tester. If the value
is outside the standard value, replace the coil
assembly.

MFW61ESH000301

MFW61ESH000101
• Inspect the conduction between the stator coil lead
wire (1) and core (2) with a circuit tester. Inspect the rectifier assembly
If there is conduction, replace the stator.
• Inspect the conductance between the 4 diode
terminals of the plus diode using a circuit tester. If
there is conductance in both directions, there is a
short circuit in the plus diode. In this case, replace
the rectifier assembly.
1 If there is not conductance in both directions, the
plus diode is open. In this case, replace the
rectifier assembly.
• Inspect the conductance between the 4 diode
terminals of the minus diode using a circuit tester.
If there is conductance in both directions, there is
short circuit in the minus diode. In this case,
replace the rectifier assembly. If there is not
conductance in both directions, the minus diode is
open. In this case, replace the rectifier assembly.
2

MFW61ESH000201

Inspect the rotor

• Inspect the bearing for abnormal noises,
looseness, and leaking grease (if a minute amount
of grease is present, simply wipe it off), and
replace the bearing if a fault is found. It is easier to
inspect the bearing for abnormal noises and
slackness when it is press fit into the shaft, than
inspecting it by itself.
MG6HK-WE-0871.book 35 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-35

Reassembly
As the assembly can be done in the reverse order to
disassembly, only the most important points will be
explained here. Also, pay attention to the next point.
1 1. The bearings are filled with grease and sealed,
3 therefore they do not need lubricating.

NOTE:
The bearing from the rotor shaft with resin band must
never be greased. If there is oil on the rear bracket
bearing box section, it may cause joint rotation of the
rear bearing, and must therefore be completely wiped
2 off.

2. Use high temperature solder (fusing point 230°C /

446°F specifications).
When soldering, use a 180 to 270 watt soldering
MFW61ESH000601 iron and work quickly (within approx. 5 seconds) so
as not to overheat the rectifier.
Legend
1. Positive heat sync 3. Tightening torque for each parts. Refer to the
2. One section of the negative heat sync tightening torque table.
3. Diode terminal
NOTE:
Be careful not to over tighten.

N⋅m (kg⋅m/
Tightening torque
lb⋅in)
50A & 60A 137 (14.0 /
specifications 101 lb⋅ft)
Pulley nut
245 (25.0 /
90A specifications
181 lb⋅ft)
50A & 60A
6 (0.6 / 52)
specifications
Through bolt
14 (1.4 /
90A specifications
122)
Bearing retainer 5 (0.5 / 43)
50A & 60A
Field coil 3 (0.3 / 26)
specifications
MFW61ESH000401 assembly
90A specifications 5 (0.5 / 43)
Inspect the front bearing Rectifier 3 (0.3 / 26)
• Inspect the bearing for abnormal noises, loosens Regulator 3 (0.3 / 26)
and leaking grease (if a minute amount of grease Regulator and a connection
is present, simply wipe it off), and replace the 2 (0.2 / 17)
screw of rectifier
bearing if fault is found. It is easier to inspect the
bearing for abnormal noises and slackness when it Cover 3 (0.3 / 26)
is press fit into bracket, rather than inspecting it by Terminal B nut 11 (1.1 / 95)
itself.
4. Rear bracket, stator assembly and front bracket
Inspect the regulator rotor assembly installation.
• The regulator cannot be inspected with a circuit • As the fit of the rear bearing and rear bracket is
tester. After re-assembling the generator, test the very tight, heat the bearing box section of the
generator and check that the regulator is rear bracket 50 to 60 ºC (122 to 140°F)
controlling the generator voltage. beforehand, then assembly the bearing and
bracket.
MG6HK-WE-0871.book 36 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-36 Engine Electrical (6HK1)

• After re-assembling the generator, rotate the
pulley by hand, and check that the rotor rotates
smoothly.
MG6HK-WE-0871.book 37 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Electrical (6HK1) 1E-37

Bench Testing:
Generator bench test

Ammeter SW1

Voltmeter
Lamp(24V)
(3W or less)
SW2

Battery
(24V)

Generator

Resistor

MFW81EMF000201

Voltage regulation • Run the generator to about 5,000 r/min and read
• Connect the circuit as shown in the above the ammeter.
diagram. If 5 A or less, read the indication of the voltmeter.
Use an ammeter of a rated 100 A and a voltmeter This is the regulated voltage.
of a rated 30 V. If the ammeter indicates 5A or more, either
Use a variable resistor of a rated 50 A or higher. continue charging until current drops below 5A or
replace the battery with a fully charged battery.
• Close switch 1. Open switch 2.
If the regulated voltage is outside the specified
At this point, the lamp should light.
range, replace the regulator.
If it does not light, check terminal L voltage.
If voltage is near to the battery voltage, check the Output current
generator.
If voltage is low, the lamp or lamp circuit is The output current test determines whether the
disconnected. generator outputs the rated current or not.
• Gradually raise generator rotational speed. • After checking voltage regulation, lower generator
Check that the lamp goes out before reaching speed and stop the generator.
about 1,300 r/min. • Close switch 1. The lamp should light.
Watch the voltage. If voltage cannot be kept below • Set variable resistance to the highest value
30 V, the IC regulator may be damaged. (minimum current), and close switch 2.
If voltage does not exceed battery voltage, the
generator is not generating power.
Check the generator again.
If the lamp does not light, check the generator
again.
MG6HK-WE-0871.book 38 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1E-38 Engine Electrical (6HK1)

• Raise the generator rotational speed, and, with 90A specifications
speed maintained at 5,000 r/min, adjust variable
resistance so that output current is the maximum.
Run the generator in this state for 15 minutes to Rotational 2,500 5,000
raise generator temperature. speed r/min r/min
15 minutes later, set generator rotational speed so Output Voltage 27V 27V
that it matches the specified speed (2,500 and characteristics 80A 90A
5,000 r/min). Then, adjust variable resistance in (when hot) Current
or more or more
this state so that output current is the maximum.
If the ammeter indication is within the specified Field coil resistance
6.3 – 7.5Ω
range at this time, the generator is operating (At 20 °C / At 68°F)
correctly. Regulator regulated voltage 28 – 29V
If it is outside the specified range, recheck the
Rotational direction
generator as explained in “Inspection”. Clockwise
(Seen from pulley side)
Specifications
50A specifications

Rotational 2,500 5,000

speed r/min r/min
Output Voltage 27V 27V
characteristics 42A 50A
(when hot) Current
or more or more
Field coil resistance
8.3 – 9.1Ω
(At 20 °C / At 68°F)
Regulator regulated voltage 28 – 29V
Rotational direction
Clockwise
(Seen from pulley side)

60A specifications

Rotational 2,500 5,000

speed r/min r/min
Output Voltage 27V 27V
characteristics 45A 60A
(when hot) Current
or more or more
Field coil resistance
8.3 – 9.1Ω
(At 20 °C / At 68°F)
Regulator regulated voltage 28 – 29V
Rotational direction
Clockwise
(Seen from pulley side)
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-1

ENGINE
Engine Exhaust
(6HK1 Euro4 specification)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1G-2
Explanation of Functions and Operations . . . . . 1G-2
Function Inspection: . . . . . . . . . . . . . . . . . . . . . 1G-3
Failure Phenomenon List . . . . . . . . . . . . . . . . . 1G-4
Phenomenon: Vibrations and rattling from
the exhaust system . . . . . . . . . . . . . . . . . . . . . . 1G-5
Phenomenon: Clogging of the exhaust system. 1G-6
Phenomenon: Exhaust gas leak, noise. . . . . . . 1G-7
Phenomenon: Exhaust gas is mostly black
in large quantity. . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-11
Tightening Torque Table . . . . . . . . . . . . . . . . . 1G-14
Diesel Particulate Defuser (DPD). . . . . . . . . . . . 1G-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-20
Exhaust Differential Pressure Sensor . . . . . . . . 1G-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-21
Exhaust Temperature Sensor. . . . . . . . . . . . . . . 1G-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-23
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-2 Engine Exhaust (6HK1 Euro4 specification)

Exhaust System
Precautions for Servicing Explanation of Functions and Operations
As vibrations and looseness in the exhaust system are The exhaust brake assembly adjusts the exhaust
often caused by positioning discrepancies when pressure to assist the brake, performs engine Quick
assembling the system, temporarily tighten all bolts Warm-up System (QWS), etc.
until all of the parts have been positioned, then finally The Diesel Particulate Defuser (DPD) unit is a single
tighten all bolts in order from the engine side to the rear unit construction of a filter and oxidation catalyst, which
pipe side. cleans the exhaust gas. The silencing effect is obtained
from the post silencer integrated in the tailpipe.
The main parts consist of the exhaust brake assembly,
front exhaust pipes A, B and C, DPD, exhaust throttle
assembly, throttle – silencer exhaust pipe, silencer, and
rear exhaust pipe. (Include it post silencer)

MFW71GLF000101

Legend
1. Front exhaust pipe A 5. Diesel Particulate Defuser (DPD)
2. Front exhaust pipe B 6. Exhaust throttle assembly
3. Exhaust brake assembly 7. Silencer
4. Front exhaust pipe C 8. Rear exhaust pipe
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-3

Function Inspection:
• When inspecting or repairing the exhaust system,
check that there is enough space between the floor
and the body.
• Damage to the body panel from heat or vibration
may cause the exhaust gas to leak into the room.
• Inspect the connection sections for damage or
looseness, and check that there are no exhaust
gas leaks.
• Inspect the clamps and rubber for deterioration,
abrasion, and damage.
• If the pipes, DPD or silencer are either damaged or
dented, repair or replace them.
• Inspect for the presence of dents, damage, and
holes or splitting due to corrosion, and inspect for
the presence of abnormal noises while driving.
• If a DTC related to DPD is detected, inspect and
repair according to the DPD section of “Engine
Control System”.

CAUTION:
Before disassembling the DPD assembly, always use a
scan tool to check the status and inspection /
maintenance details of the DPD pressure difference.
For details, refer to “Engine Control System”.
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-4 Engine Exhaust (6HK1 Euro4 specification)

Failure Phenomenon List
• Vibrations and rattling from the exhaust system
• Clogging of the exhaust system
• Exhaust gas leak, noise
• Exhaust gas is mostly black in large quantity
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-5

Phenomenon: Vibrations and rattling from the exhaust system

Condition Possible Cause Correction

Vibrations and rattling from the exhaust Component looseness, or mismatching Line up the connection areas and then
system re-tighten also, inspect the hanger,
attachment bracket, and clamp for
damage
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-6 Engine Exhaust (6HK1 Euro4 specification)

Phenomenon: Clogging of the exhaust system

Condition Possible Cause Correction

Clogging of the exhaust system The exhaust brake and exhaust throttle Refer to the engine control system
are ON section to inspect the electrical system,
then repair any malfunction
Inspect the exhaust brake and exhaust
throttle shaft for hesitant movement,
and replace if there is a fault
Blocked exhaust pipe Repair or replace the exhaust pipe
DPD related DTC detected Inspect and repair by following the DPD
related engine control section
troubleshooting section
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-7

Phenomenon: Exhaust gas leak, noise

Condition Possible Cause Correction

Exhaust gas leak, noise Bad attachment, or mismatch Line up the connection areas and then
re-tighten
Damage or scorching in the exhaust Replace the damaged part
pipe silencer, or DPD
Bad exhaust system component Replace the defect part
(clamp, pipe, silencer)
Silencer internal damage Replace the silencer
DPD internal damage Replace the damaged section
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-8 Engine Exhaust (6HK1 Euro4 specification)

Phenomenon: Exhaust gas is mostly black in large quantity

Condition Possible Cause Correction

DPD failure Melted or broken filter Replacement
Clogging of the filter carbon Clean or replace
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-9

Exhaust Pipe
Removal 6. Remove the exhaust pipe adaptor.
1. Remove the rear exhaust pipe.
• Remove the clamp, then remove the rear
exhaust pipe. 4

3
2 2
1 1

5
6

MFW71GSH003701

Legend
1. Gasket
MFW41GSH000801
2. Exhaust pipe adaptor
3. Gasket
Legend 4. Silencer
1. Rear exhaust pipe 5. Gasket
2. Post silencer 6. Exhaust throttle assembly

2. Disconnect the exhaust throttle air pipe. 7. Remove the 2 DPD exhaust temperature sensor
3. Remove the silencer bracket. connectors.
4. Remove the silencer. 8. Remove the 2 DPD differential pressure hoses.
5. Remove the exhaust throttle assembly.
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-10 Engine Exhaust (6HK1 Euro4 specification)

9. Remove the DPD assembly from the front pipe.

3 4

2 1
1

6 5
MFW41GSH001601
7
MFW81GSH001101
Legend
Legend 1. Exhaust differential pressure sensor assembly
1. Exhaust temperature sensor 2 (catalyst inlet) 2. Tightening screw
2. Exhaust temperature sensor 1 (catalyst outlet)
3. Differential pressure hose (Front)
4. Differential pressure hose (Rear)
5. Exhaust silencer 10. Remove the front exhaust pipe A, B, and C.
6. Exhaust throttle assembly • Remove the clamp, then remove the front
7. DPD assembly exhaust pipe.
• Remove the exhaust brake assembly.
NOTE:
If the exhaust differential pressure sensor assembly
must unavoidably be removed, pay attention to the 1
following points.
• Never loosen the 4 sensor tightening screws (2). If 2
they are loosened, replace the sensor assembly.
• Do not re-use the sensor assembly if it is ever
dropped.
3
• Do not use a tool such as an impact wrench etc.,
which causes vibrations when installing and
removing the sensor.

MFW71GSH003501

Legend
1. Front exhaust pipe A
2. Front exhaust pipe B
3. Front exhaust pipe C
4. Exhaust brake assembly
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-11

Installation
NOTE:
1
• As vibrations and looseness in the exhaust system
are often caused by positioning discrepancies
2
when assembling the system, temporarily tighten
all bolts until all of the parts have been positioned,
then finally tighten all bolts in order from the engine
side to the tail pipe side.
3
• Do not re-use the removed gasket or nuts.

1. Install the front exhaust pipe A.

• Install the front exhaust pipe A to the exhaust
manifold, and tighten to the specified torque
strength. 4

Tightening torque
MFW71GSH003501
76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
Legend
1. Front exhaust pipe A
NOTE: 2. Front exhaust pipe B
Tighten front exhaust pipe A equally, and make sure 3. Front exhaust pipe C
there are no gas leaks. 4. Exhaust brake assembly
2. Install the front exhaust pipe B.
• Install the front exhaust pipe B to the front
exhaust pipe A, and tighten to the specified 4. Install the DPD assembly to the front pipe.
torque strength.

Tightening torque
Tightening torque 85 N⋅m (8.7 kg⋅m/63 lb⋅ft)
85 N⋅m (8.7 kg⋅m/63 lb⋅ft)
5. Install the differential pressure hose to the DPD
3. Install the exhaust brake assembly. differential pressure pipe.
• Install the exhaust brake assembly and front • Securely insert the differential pressure hose to
exhaust pipe C to the front exhaust pipe B, and the pipe bulge section.
tighten to the specified torque strength. • Securely fasten the hose clip.

NOTE:
Tightening torque
• Do not mistake the front and rear directions.
41 N⋅m (4.2 kg⋅m/30 lb⋅ft) • Do not use hoses that are cracked.
• Never tighten or loosen the exhaust differential
pressure sensor assembly tightening screw.
• If gas leaks from the coupling section, it may cause
control malfunction.
After starting the engine, always check that there
are no gas leaks.
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-12 Engine Exhaust (6HK1 Euro4 specification)

3 4

1 2

4
6
5

6 5

7
MFW61GSH000801 MFW81GSH001101

Legend Legend
1. Exhaust differential pressure sensor assembly 1. Exhaust temperature sensor 2 (catalyst inlet)
2. Tightening screw (Never loosen) 2. Exhaust temperature sensor 1 (catalyst outlet)
3. Differential pressure hose (Rear) 3. Differential pressure hose (Front)
4. Differential pressure hose (Front) 4. Differential pressure hose (Rear)
5. Clip for differential pressure hose 5. Exhaust silencer
6. Bulge section 6. Exhaust throttle
7. DPD assembly

6. Install the DPD exhaust temperature sensor

connector. 7. Install the exhaust pipe adaptor to the DPD.

NOTE:
Do not mistake the front and rear directions. Tightening torque
37 N⋅m (3.8 kg⋅m/27 lb⋅ft)

8. Insert the exhaust throttle assembly into the

exhaust adaptor, and Install the silencer.

Tightening torque
41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-13

9. Install the air pipe to the exhaust throttle air
cylinder.

4 2
1

3
2
1

5
6

MFW41GSH000801

Legend
MFW71GSH003701
1. Rear exhaust pipe
Legend 2. Post silencer
1. Gasket
2. Exhaust pipe adaptor
NOTE:
3. Gasket
After assembling each part, start the engine and check
4. Silencer
that there are no gas leaks or vibration from each of the
5. Gasket
coupling sections. If the DPD assembly was
6. Exhaust throttle
disassembled, perform the following careful checks for
gas leakage.
• Sufficiently warm up the engine.
10. Install the rear exhaust pipe. • Raise the engine to its maximum r/min. In this
• Tighten the clamp. condition spray soapy water onto the differential
pressure hose connection section and sleeve nut
NOTE: connection section, and verify that there are no
• Tighten the clamp bolts in sequence, upper and gas leaks.
lower.
• Install the clamp on an even keel.

Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-14 Engine Exhaust (6HK1 Euro4 specification)

Tightening Torque Table

d
MFW71GMF000101

(a) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

(b) 85 N⋅m (8.7 kg⋅m / 63 lb⋅ft)
(c) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(d) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(e) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(f) 85 N⋅m (8.7 kg⋅m / 63 lb⋅ft)
(g) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-15

Diesel Particulate Defuser (DPD)

Removal a. Paint the arrow mark (1) on the filter case so
that exhaust gas flow direction may be
1. Remove the DPD assembly.
distinguished.
Refer to “Exhaust Pipe” in this section.

Disassembly
Disassemble the DPD assembly.
1
1. Loosen the sleeve nut that fixes the differential
pressure pipe.
2. Remove the differential pressure pipe clips (3
locations).
3. Remove the differential pressure pipe.

1 2 3

MFW81GSH004201

b. Loosen the oxidation catalyst section tightening

nut, and separate the oxidation catalyst section,
and filter section.
c. Loosen the filter section tightening nut, and
separate the filter section from the rear case.

NOTE:
5 4 Do not apply a strong impact to the DPD assembly or
drop it.
MFW61GSH000601

Legend
1. Differential pressure pipe (Front)
2. Differential pressure pipe (Rear) 4 5
3
3. Sleeve nut (Rear)
4. Clip
5. Sleeve nut (Front) 2

4. Remove the DPD exhaust temperature sensors 1

(catalyst inlet side and outlet side).
5. Disassemble the DPD assembly.

MFW41GSH001001

Legend
1. Oxidation catalyst section
2. Gasket
3. Filter section
4. Gasket
5. Rear case
MG6HK-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-16 Engine Exhaust (6HK1 Euro4 specification)

Inspection • The DPD lamp lights, then goes off after
approx. 30 seconds.
1. Perform an external inspection of the exhaust pipe
related parts. • After verifying that the DPD lamp has gone off,
turn the key OFF and leave for more than 15
• Damage to the body panel from heat or vibration
seconds.
may cause the exhaust gas to leak into the room.
• Inspect the connection sections for damage or NOTE:
looseness, and check that there are no exhaust Do not perform 0-point corrections within 2 hours after
gas leaks. regenerating DPD because the differential pressure
• Inspect the clamps and rubber for deterioration, sensor assembly is sensitive to heat.
abrasion and damage.
• Inspect the pipes and silencer for dents, and for Filter cleaning
cracks due to corrosion, and either repair or
replace the damaged sections. Ash cannot be regenerated by combustion unlike
particulate matter (PM).
2. Inspect the DPD related sections.
• Visually check the filter for melting damage, Because the ash is calcined (tightly stuck) to the DPD
damage, or blockages. filter.
In order to remove ash, use a DPD ash removal device.
• Shine a light from the opposite side of the filter.
Refer to DPD ash removal device handling manual for
If the light penetrates and can be seen, replace
the handling of DPD ash removal device.
the filter section.
1. Set the DPD filter to the DPD ash removal device.
• Visually check the catalyst section for melting
damage, damage, or blockages. NOTE:
Set the DPD assembly so that arrow mark, which was
NOTE:
painted at disassembly operation, face up.
Before disassembling the DPD assembly, always use a
scan tool to check the status and inspection/
maintenance details of the DPD differential pressure.
For details, refer to “Engine Control System”.

MFW81GSH004101
2
2. Supply air up to the given pressure of 0.4 MPa (4.0
kg/cm2 / 58 psi) in the air tank.
MFW41GSH001101 Stop supplying when the air is pressurized up to
given pressure.
Legend
1. Filter CAUTION:
2. Filter case Do not supply air exceed 0.5MPa (5.0 kg/cm2 / 73 psi)
to the tank as indicated by the manometer mounted on
the pressure regulator.
At this point, check for air leaks from the pipe without
3. If the differential pressure sensor assembly has
fail.
been replaced, perform the following actions (on
the vehicle). 3. Press the device’s mechanical valve for three
• Switch the key from OFF to ON (do not start the seconds. Implement backwashing and cleanse the
engine). DPD filter.
MG6HK-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-17

4. Repeat the work described in STEP2 and STEP3
three times.

CAUTION:
Ash may escape from the exhaust filter and
1
backwashing noises may be heard while in use.
Wear protective equipment, such as dust masks, safety
goggles and earplugs and operate the equipment while
keeping the face and hands at a safe distance.

Air-tightness check
Check for air-tightness when the DPD is disassembled
and reassembled (when installed to vehicle).
1. Warm up the engine and rev the engine to the
maximum speed with no load.
2. With the engine revved, check the pressure hoses
(1) connections, sleeve nuts (2) and (4)
connections, for gas leaks by spraying soapy MFW81GSH004301

water on them. 1. Insert a new gasket into the filter section and rear
case, and temporarily tighten with nuts and bolts.
2. Insert a new gasket into the filter section and
oxidation catalyst section, and temporarily tighten
with new nuts and bolts.

1 NOTE:
• If the DPD was disassembled, do not re- use old
gasket, nuts, and bolts (use gasket and fixing kit).

NOTE:
• Check the attachment positions of the filter section
and rear case, and the filter section and oxidation
catalyst section, and tighten both pipe brackets.
2
3. Tighten the nuts and bolts to their specified torque.
4 3
• Tighten each nut and bolt twice.

MFW81GSH004001

Legend Tightening torque

1. Pressure hoses 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
2. Sleeve nut (Rear)
3. Clips NOTE:
4. Sleeve nut (Front) After tightening each nut and bolt, with specified
tightening torque be sure to tighten once again to the
same torque (tighten twice).
Reassembly
Reassemble the DPD assembly.

NOTE:
• The DPD assembly must be installed with arrow
mark (1), which was painted at disassembly
operation, in the opposite direction of exhaust gas
flow.
• Do not reuse the removed gasket, nut and bolt.
MG6HK-WE-0871.book 18 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-18 Engine Exhaust (6HK1 Euro4 specification)

• Check for gas leakage and confirm that it is securely
sealed.
4 5
3
Screw sizes Connector
2
Color
Sensor
M12 / 1.75 mm
(catalyst inlet Dark grey
(0.47 / 0.069 in)
side)
1
Sensor
M12 / 1.25 mm
(catalyst outlet Light grey
(0.47 / 0.049 in)
side)

Tightening torque
30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
MFW41GSH001001

Legend 5. Tighten the sleeve nut of the pressure pipe (front)

1. Oxidation catalyst section (rear) with your hand.
2. Gasket
3. Filter section NOTE:
4. Gasket • Clean off the old burning prevention agent from the
5. Rear case sleeve nut, and apply new burning prevention agent
(Bostik : Never-Seez High Temperature stainless
grade 5-87411-039-0).

4. Install the DPD exhaust temperature sensor 6. Fix the differential pressure pipe with the clip.
(catalyst inlet, catalyst outlet)

NOTE: Tightening torque

• Remove the old seizing-prevention agent from the 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
threaded portion to the threaded portion of the
sensor and apply a new seizing-prevention agent
7. Tighten the differential pressure pipe sleeve nut to
(Bostik : Never- Seez High Temperature stainless
the specified torque.
grade 5-87411-039-0).
• When the sensor is replaced with a new one, the
application of the seizing-prevention agent is Tightening torque
unnecessary since it has already been pre-applied
Sleeve nut front
to the sensor. 35 N⋅m (3.6 kg⋅m/26 lb⋅ft)
Sleeve nut rear
• When assembling, do not hit the tip of the sensor to
the other boss.
• Do not use a sensor which has scratches or dents NOTE:
made by dropping or hitting. • If the differential pressure pipe attachment
procedure is not followed correctly, the nuts may
• Do not hit the protruded section against something
become loose. Always follow the procedure
after assembling the sensor to the DPD.
precisely when attaching the pipe.
• Be careful not to mix up sensors (for catalyst inlet
side and outlet side) when assembling. • Do not reuse old gaskets, nuts and bolts if the DPD
is disassembled.
MG6HK-WE-0871.book 19 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-19

1 2 3

5 4

MFW61GSH000601

Legend
1. Differential pressure pipe (Front)
2. Differential pressure pipe (Rear)
3. Sleeve nut (Rear)
4. Clip
5. Sleeve nut (Front)

Installation
1. Install the DPD assembly.
Refer to “Exhaust Pipe” in this section.
MG6HK-WE-0871.book 20 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-20 Engine Exhaust (6HK1 Euro4 specification)

Inspection
Filter Inspection
Inspect the differential pressure.
Perform after installing the DPD to the vehicle.
1. Start the engine and confirm there is no exhaust
leakage from the DPD related parts (such as DPD
sensor, differential pressure sensor, and
connecting parts of hoses).
2. Inspect the differential pressure.
a. Observe the Exhaust Temperature 1 parameter
with a scan tool. Make sure the temperature is
less than 120°C (248°F). If more than 120°C
(248°F), let increase 1000 RPM without load.
(Rotate the idle up sensor clockwise.)
b. Accelerate the engine to W.O.T. (accelerator
pedal full travel) and read the Exhaust
Differential Pressure parameter when the
Exhaust Temperature 1 parameter is reached
to 150°C (302°F).
3. If the inspection value is higher than limit value,
replace the filter.

Limit; 3.3 kPa (0.034 kgf/cm2 /0.48 psi)

NOTE:
After replacement of the DPD filter, perform DPD status
resetting.

DPD Regenerate Programming Procedure

DPD regenerate data reset
• Carry out the following steps when changing the
DPD.
1. Install the scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle
identification > Engine > 6HK1-TC (C/Rail) >
Programming > DPD Regeneration data reset.
4. Initiate the reset function in accordance with the
onscreen instructions.
5. After the reset is complete, if the “Programming
Completed Successfully” message is displayed,
follow the onscreen instructions to advance the
end procedure.
MG6HK-WE-0871.book 21 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-21

Exhaust Differential Pressure Sensor

Removal 3. Connect the differential pressure hoses (2 pieces).
1. Disconnect the differential pressure hoses (2 NOTE:
pieces).
• Do not mistake the front and rear directions.
2. Disconnect the differential pressure sensor
• Do not use cracked hoses.
harness connector.
• Absolutely do not over-tighten or remove the
3. Remove the differential pressure sensor.
differential pressure sensor assembly tightening
• Remove the installation bolts (2). screw.
• Remove the differential pressure sensor. • There is the danger of the sensor miss-operation
when there is a gas leak from the joint sections.
1 After starting the engine, check that no gas is
leaking.
2 • Do not reuse the differential pressure sensor
assembly if it was dropped.
• Do not use a tool such as an impact wrench, etc., to
3
apply vibrations when installing the differential
pressure sensor.

F
MFW81GSH001401

Legend
1. Differential pressure sensor
2. Installation bolts
3. Differential pressure hoses

4
NOTE:
3 2
If it is unavoidable to remove the differential pressure
sensor (1), be careful of the following points.
LNW76FSH001801
• Absolutely never loosen the 4 differential pressure
sensor installation screws. If they are loosened, Legend
replace the differential pressure sensor. 1. Front mark
• Do not reuse the differential pressure sensor 2. Rear side differential pressure hose insertion
assembly if it was dropped. section
3. Front differential pressure hose insertion section
• Do not use a tool such as an impact wrench, etc., to 4. Bracket
apply vibrations when installing the differential
pressure sensor.
0-point correction of the differential pressure
sensor
Installation
Perform 0-point correction on the differential pressure
1. Install the differential pressure sensor. sensor when the differential pressure sensor assembly
• Tighten installation bolt by rule torque. has been replaced. (on vehicle)
1. Turn the key from the OFF state to the ON state.
(Engine does not start.)
Tightening torque
2. DPD light turns on, and then turns off after
20 N⋅m (2.0 kg⋅m/14 lb⋅ft) approximately 30 seconds.
3. After checking that the DPD light is extinguished,
2. Connect the differential pressure sensor harness turn the key off and leave for at least 15 seconds.
connector.
MG6HK-WE-0871.book 22 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-22 Engine Exhaust (6HK1 Euro4 specification)

NOTE:
Performing 0-point correction tend to receive the
influence by heat easily. Do not perform corrections
until two hours after regenerating DPD.
MG6HK-WE-0871.book 23 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro4 specification) 1G-23

Exhaust Temperature Sensor

Removal
1. Remove the exhaust temperature sensor 4
connectors (two pieces).
2. Remove the clip that is holding the exhaust 5
temperature sensor harness in place.
2 3
3. Remove the exhaust temperature sensor (two
pieces). 1

NOTE:
• Wipe away the old seizure inhibitor and apply new
inhibitor on the sleeve nut threaded portion.

Used seizure inhibitor:

Bostik Never-Seez high temperature stainless grade
5-87411-039-0
6
However, it is not necessary to apply the anti-seize
compound when using a new sensor, as it is already
MFW81GSH001601
applied.
Legend
• When assembling, do not hit the tip of the sensor to
1. Exhaust temperature sensor 2 (catalyst
the other boss.
entrance)
• Do not use a sensor which has flaws or dents from 2. Exhaust temperature sensor 1 (filter entrance)
dropping or hitting. 3. Differential pressure hose (Front)
• Do not hit the protruded section after assembling 4. Differential pressure sensor
the sensor to the DPD assembly. 5. Differential pressure hose (Rear)
• Be careful not to mix up sensors ( catalyst entrance, 6. DPD assembly
filter entrance ) when assembling.

Installation
Screw size Connector color 1. Install the exhaust temperature sensor (two
Sensor M12 / 1.75 pieces).
Dark grey
(catalyst entrance) (0.47/0.069)
Sensor M12 / 1.25 Tightening torque
Light grey
(filter entrance) (0.47/0.049)
30 N⋅m (3.1 kg⋅m/22 lb⋅ft)

2. Install the exhaust temperature sensor connectors

(two pieces).
3. Fasten the exhaust temperature harness with the
clip.
4. Check for gas leakage and confirm that it is
securely sealed.
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

MEMO
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MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-1

ENGINE
Engine Exhaust
(6HK1 Euro3 specification and Euro2 specification)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1G-2
Description of Function and Operation . . . . . . . 1G-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1G-6
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1G-7
Phenomenon: Vibrations and Rattling Sounds
from the Exhaust System . . . . . . . . . . . . . . . . . 1G-8
Phenomenon: Clogging of the Exhaust System 1G-9
Phenomenon: Exhaust Gas Leak, Noise . . . . 1G-10
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-11
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-13
Tightening Torques Table . . . . . . . . . . . . . . . . 1G-16
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-2 Engine Exhaust (6HK1 Euro3 specification and Euro2 specification)

Exhaust System
Maintenance Precautions Description of Function and Operation
Vibrations and looseness of the exhaust system are The exhaust brake includes a valve inside the exhaust
caused by miss positioning when assembling. pipe, and closing this valve increases resistance in the
Temporarily install all bolts and nuts until all exhaust stroke, to raise the effect of the engine brake.
components are positioned. After positioning is Also, by adjusting the exhaust pressure, quick on start
completed, tighten them from the engine side to the system-II (QOS-II) is executed.
rear side. The main components are: a front exhaust pipe A, B, C,
exhaust brake, silencer and rear exhaust pipe.
This diagram shows the FRR/FSR models except for Indonesia

4
3
1 2
6

MFW81GSF000101

Legend
1. Front exhaust pipe A 4. Front exhaust pipe C
2. Front exhaust pipe B 5. Silencer
3. Exhaust brake assembly 6. Rear exhaust pipe
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-3

This diagram shows a vehicle with MZW and MLD transmission (FTR/FVR) except for Indonesia

4
3
2 6
1

MFW81GSF000201

Legend
1. Front exhaust pipe A 4. Front exhaust pipe C
2. Front exhaust pipe B 5. Silencer
3. Exhaust brake assembly 6. Rear exhaust pipe

This diagram shows a vehicle without MZW and MLD transmission except for Indonesia

6
3

MFW81GSF000301

Legend
1. Front exhaust pipe A 4. Front exhaust pipe C
2. Front exhaust pipe B 5. Silencer
3. Exhaust brake assembly 6. Rear exhaust pipe
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-4 Engine Exhaust (6HK1 Euro3 specification and Euro2 specification)

This diagram shows a vehicle with a single tire construction (4WD) except for Indonesia

6
4

3
2
1

MFW81GSF000401

Legend
1. Front exhaust pipe A 4. Front exhaust pipe C
2. Front exhaust pipe B 5. Silencer
3. Exhaust brake assembly 6. Rear exhaust pipe

This diagram shows a vehicle with a double tire construction (4WD) except for Indonesia

3 6

MFW81GSF000501

Legend
1. Front exhaust pipe A 4. Front exhaust pipe C
2. Front exhaust pipe B 5. Silencer
3. Exhaust brake assembly 6. Rear exhaust pipe
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-5

This diagram shows the Indonesia

MFWB1GSF000601

Legend
1. Front exhaust pipe 2. Silencer
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-6 Engine Exhaust (6HK1 Euro3 specification and Euro2 specification)

Functional Inspection:
• When inspecting or repairing the exhaust system,
check that there is an adequate gap between the
floor and body.
• Damage caused by heat from the body panel or
vibrations can cause exhaust gas to enter the
cabin. Be careful.
• Inspect for loose or damaged connections and
exhaust gas leaks.
• Inspect the clamp and rubber for degradation,
cracks or damage.
• If the pipes or silencer are damaged or dented,
repair or replace them.
• Inspect for dents or damage, or holes and
fractures caused by corrosion, and abnormal noise
when driving the vehicle.
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-7

Failure Symptom List
• Vibrations and Rattling Sounds from the Exhaust
System
• Clogging of the Exhaust System
• Exhaust Gas Leak, Noise
• Exhaust Gas is Mostly Black in Large Quantity
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-8 Engine Exhaust (6HK1 Euro3 specification and Euro2 specification)

Phenomenon: Vibrations and Rattling Sounds from the Exhaust System

Condition Possible Cause Correction

Vibrations and rattling sounds from the Loose components, or improper Retighten after aligning the connections
exhaust system installation Inspect the hanger, installed brackets
and clamps for damage
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-9

Phenomenon: Clogging of the Exhaust System

Condition Possible Cause Correction

Clogging of the exhaust system The exhaust brake is ON Inspect and repair the control system.
Refer to "Diagnostic Information and
Procedures" in Section 1A, Engine
Control System (6HK1)
Also, inspect the exhaust brake and
exhaust throttle shaft for strain. Replace
if there is a problem
Clogging of the exhaust pipe Repair or replace the exhaust pipe
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-10 Engine Exhaust (6HK1 Euro3 specification and Euro2 specification)

Phenomenon: Exhaust Gas Leak, Noise

Condition Possible Cause Correction

Exhaust gas leak, noise Improper installation or connection Retighten after aligning the connections
Exhaust pipe or silencer damage, Replace the damaged parts
burning
Defective exhaust system components Replace the unnecessary parts
(clamps, pipe, silencer, catalyst
converter)
Internal damage on silencer Replace the damaged parts
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-11

Exhaust Pipe
Components
Except for Indonesia
4

1 2

7
10

MFWB1GLF000901

Legend
1. Front exhaust pipe A 6. Front exhaust pipe C
2. Front exhaust pipe B 7. Exhaust pipe clamp bracket
3. Exhaust mounting bracket 8. Silencer assembly
4. Exhaust silencer bracket (to T/M) 9. Rear exhaust pipe
5. Exhaust brake assembly 10. Clamp
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-12 Engine Exhaust (6HK1 Euro3 specification and Euro2 specification)

For Indonesia

MFWB1GLF001201

Legend
1. Front exhaust pipe 3. Silencer assembly
2. Exhaust pipe clamp bracket 4. Clamp

Removal
Except for Indonesia
1. Remove the rear exhaust pipe.
• Remove the clamps and rear exhaust pipe.
2. Remove the silencer.
3. Remove the front exhaust pipe C.
4. Remove the exhaust brake assembly.
• Remove the air hose and the exhaust brake
assembly.
5. Remove the front exhaust pipe B.
• Remove the clamp, and remove the front
exhaust pipe.
6. Remove the front exhaust pipe A.
MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-13

For Indonesia Installation
1. Remove the silencer. NOTE:
• Do not reuse the removed gasket and nut.
• Visually check that there is no foreign material in
the exhaust pipe.

Except for Indonesia

1. Temporarily tighten the front exhaust pipe A,
exhaust brake assembly, and adaptor pipe.

NOTE:
Uniformly tighten the front exhaust pipe so that there is
no exhaust gas leak.

2. Temporarily tighten the front exhaust pipe B,

exhaust brake assembly, and front exhaust pipe C.
3. Install the exhaust brake air hose.
4. Temporarily tighten the silencer.
MFWB1GSH001201 5. Temporarily install the rear exhaust pipe.
2. Disconnect the air pipe.
After temporary installation, securely tighten it.

6. Exhaust pipe adaptor from the front exhaust pipe

A.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

76 (7.7 / 56)

7. Front exhaust pipe A from front exhaust pipe B.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

85 (8.7 / 63)

8. Transmission right side bracket from the clamp of

the front exhaust pipe B.
MFWB1BSH009701

3. Remove the front exhaust pipe and the exhaust

brake assembly. Tightening torque N⋅m (kg⋅m / lb⋅ft)
47 (4.8 / 35)

Inspection
1. Externally inspect the exhaust pipe components.
• Damage caused by heat from the body panel or
vibrations can cause exhaust gas to enter the
cabin. Be careful.
• Inspect for loose or damaged connections and
exhaust gas leaks.
• Inspect the clamp and rubber for degradation,
cracks or damage.
• Inspect the pipe or silencer for dents, or cracks
caused by corrosion. If damaged, repair or replace
them.
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-14 Engine Exhaust (6HK1 Euro3 specification and Euro2 specification)

10. Silencer assembly from front exhaust pipe C.

4
5 Tightening torque N⋅m (kg⋅m / lb⋅ft)
3 85 (8.7 / 63)

2
1

MFWB1GSH001001

Legend 1
1. Front exhaust pipe A
2. Front exhaust pipe B
3. Exhaust mounting bracket
4. Exhaust pipe bracket
5. Exhaust brake assembly MFW81GSH003001

Legend
9. Exhaust brake.
1. Front exhaust pipe C
2. Exhaust pipe clamp bracket
Tightening torque N⋅m (kg⋅m / lb⋅ft) 3. Silencer assembly

41 (4.2 / 30) 11. Install the rear exhaust pipe.

NOTE:
• First tighten the bolts at the upper side of the
vehicle, then tighten the bolts at the lower side.

2 Tightening torque N⋅m (kg⋅m / lb⋅ft)

20 (2.0 / 14)
1
3

MFW81GSH002901

Legend
1. Front exhaust pipe B
2. Exhaust brake assembly
3. Front exhaust pipe C
4. Gasket
MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-15

NOTE:
• First tighten the bolts at the upper side of the
vehicle, then tighten the bolts at the lower side.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

20 (2.0 / 14)
2

MFW81GSH003101

Legend
1. Silencer assembly
2. Rear exhaust pipe

12. Tighten the clamp after tightening the pipe joint.

Start the engine after tightening the parts and check for
exhaust leaks from the part joints and for vibrations. MFWB1GSH001201

For Indonesia Start the engine after tightening the parts and check for
exhaust leaks from the part joints and for vibrations.
1. Temporarily tighten the front exhaust pipe and the
exhaust brake assembly.

NOTE:
Uniformly tighten the front exhaust pipe so that there is
no exhaust gas leak.

2. Temporarily tighten the silencer.

After temporary installation, securely tighten it.

3. Exhaust pipe adaptor from the front exhaust pipe.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

76 (7.7 / 56)

4. Connect the air pipe.

Tightening torque N⋅m (kg⋅m / lb⋅ft)

30 (3.1 / 22)

5. Silencer assembly from front exhaust pipe.

MG6HK-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1G-16 Engine Exhaust (6HK1 Euro3 specification and Euro2 specification)

Tightening Torques Table
Except for Indonesia

f
d
c

h
g
i

MFWB1GLF001101

(a) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

(b) 85 N⋅m (8.7 kg⋅m / 63 lb⋅ft)
(c) 47 N⋅m (4.8 kg⋅m / 35 lb⋅ft)
(d) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(e) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(f) 85 N⋅m (8.7 kg⋅m / 63 lb⋅ft)
(g) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(h) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(i) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
MG6HK-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Exhaust (6HK1 Euro3 specification and Euro2 specification) 1G-17

for Indonesia

MFWB1GLF001301

(a) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

(b) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(c) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

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MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-1

ENGINE
Engine Lubrication
(6HK1)
TABLE OF CONTENTS
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . 1H-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1H-2
Explanation of Functions and Operations . . . . . 1H-3
Function Inspection:(Euro 4 Specification) . . . . 1H-6
Function Inspection:(Euro 2 Specification and
Euro 3 Specification) . . . . . . . . . . . . . . . . . . . . . 1H-7
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1H-8
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1H-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Tightening Torque Table . . . . . . . . . . . . . . . . . 1H-13
Oil Separator (Euro 3/4 specifications) . . . . . . . 1H-14
Maintenance Precautions . . . . . . . . . . . . . . . . 1H-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
Oil Pan (Euro 3/4 specifications) . . . . . . . . . . . . 1H-15
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1H-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-17
Tightening Torque Table . . . . . . . . . . . . . . . . . 1H-19
Oil Pan (Euro 2 specification). . . . . . . . . . . . . . . 1H-20
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1H-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-22
Tightening Torque Table . . . . . . . . . . . . . . . . . 1H-25
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-26
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1H-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-27
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-27
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-29
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-2 Engine Lubrication (6HK1)

Lubrication System
Precautions for Servicing
• Every time section that use liquid gasket are
disassembled, use a scraper to completely remove
all of the old gasket from each part and their
matching parts, clean each part with a rag etc. To
ensure there is no oil, water, dirt etc.
Adhered to them, and apply a fresh quantity of the
specified type of liquid gasket to each location
when assembling.
• Do not over apply or under apply the liquid gasket.
Always apply a suitable amount. An excess of
liquid gasket may cause blockages in the oil
gallery or oil jet, causing burning. Furthermore,
under application of liquid gasket may cause oil or
water leaks.
• Always overlap the liquid gasket when starting and
finishing application.
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-3

Explanation of Functions and Operations
Lubrication system diagram
Vehicle with a Euro 3 specification and Euro 4 specification

26

3 2
25
24 4

23
5
6
22 7
21
20
8 9

19 18

11 10
16

17
12
15

13

14
MFW71HLF000201

Legend
1. Rocker arm 15. Full flow oil filter
2. Gallery to cylinder head 16. Over flow valve
3. Idle gear C 17. Crankshaft
4. Idle gear B 18. Oil jet
5. Oil relief valve 19. Specialized gallery for oil jet
6. Air compressor 20. Idle gear (front)
7. Oil thermo 21. Oil cooler
8. Idle gear A 22. Bypass oil gallery (oil cooler)
9. PTO idle gear (only for PTO gear specification) 23. Main oil gallery
10. Turbocharger 24. Oil pressure switch
11. Oil pump 25. PTO gear oil supply (only for PTO gear
12. Oil relief valve specification)
13. Oil strainer 26. Camshaft
14. Oil pan
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-4 Engine Lubrication (6HK1)

Vehicle with a Euro 2 specification

24

3 2

23 4

22
5
6
21 7
20
19
8

18 17

10 9
15

16
11
14

12

13
MFW71HLF000701

Legend
1. Rocker arm 13. Oil pan
2. Gallery to cylinder head 14. Full flow oil filter
3. Idle gear C 15. Over flow valve
4. Idle gear B 16. Crankshaft
5. Oil relief valve 17. Oil jet
6. Air compressor 18. Specialized gallery for oil jet
7. Oil thermo 19. Idle gear (front)
8. Idle gear A 20. Oil cooler
9. Turbocharger 21. Bypass oil gallery (oil cooler)
10. Oil pump 22. Main oil gallery
11. Oil relief valve 23. Oil pressure switch
12. Oil strainer 24. Camshaft
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-5

Oil pump structural diagram

2
MFWB1HLF000801

Legend
1. Driven gear assembly 3. Drive gear assembly
2. Oil pump body 4. Oil pump drive gear
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-6 Engine Lubrication (6HK1)

Function Inspection:(Euro 4 Specification)
Oil pressure inspection
1. Inspect the engine oil level. Add more engine oil if
there is insufficient oil.
2. Remove the oil pressure switch.
3. Attach an oil pressure gauge. 1
4. Sufficiently warm up the engine.
5. Measure whether the oil pressure indicates more 7
than 210 kPa (2.1 kgf/cm2 / 30 psi) at 1,400 r/min. 2
6. Stop the engine. 6 3
7. Remove the oil pressure gauge.
8. Attach the oil pressure switch.
5
9. Start the engine, and check for oil leaks. 4

NOTE:
Inspect the engine oil for abnormal dirt, or whether fuel
or water is mixed into it. If an abnormality is found,
LNW41HSH000101
investigate the cause, take the appropriate action to
remedy the cause, and replace the oil. Legend
1. Oil change is necessary
Engine oil used 2. Good oil level
3. The supplying is possible to MAX
• Grade (API) CD Class
4. The supplying is necessary
Viscosity (SAE) 10W-30 Besco Clean
5. An MIN level
(Oil compatible with DPD)
6. Supply purpose MAX
NOTE: 7. Inspection purpose MAX
Only use one of the engine oils listed above in this
engine. Engine oil leak

Amount of engine oil • Inspect the oil seal, cylinder head cover, oil pan,
etc. For oil leaks.
• Park the vehicle on a level surface, and inspect the
amount of engine oil using a level gauge after
more than 30 minutes has passed since the engine
was stopped. If engine oil adheres to the level
gauge at a level between the upper limit and lower
limit, the oil level is OK.
However, if the level of engine oil is below the
lower limit, add more oil. Also, check how dirty the
oil is.
• Vehicles installed with this engine are equipped
with DPD, and so the method in inspecting the
engine oil level is different.
When a fixed amount of particulate matter (PM)
accumulates in the DPD filter, the DPD vehicle
automatically performs regeneration (combustion).
To perform this regeneration, a slight amount of
fuel is injected into the fuel chamber after
combustion of the engine and is fed to the DPD
filter as exhaust mixed gas.
A portion of the fuel is mixed into the engine oil, so
the engine oil increases from when it is filled, but
this is not a problem.

NOTE:
If the engine oil has increased in quantity, fuel or water
may have become mixed in it. The cause must be
investigated.
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-7

Function Inspection:(Euro 2 Specification and Euro 3 Specification)
Oil pressure inspection
1. Inspect the engine oil level. Add more engine oil if
there is insufficient oil.
2. Remove the oil pressure switch.
3. Attach an oil pressure gauge.
4. Sufficiently warm up the engine.
5. Measure whether the oil pressure indicates more
than 210 kPa (2.1 kgf/cm2 / 30 psi) at 1,400 r/min.
6. Stop the engine.
7. Remove the oil pressure gauge.
8. Attach the oil pressure switch.
1 2
9. Start the engine, and check for oil leaks.

NOTE:
Inspect the engine oil for abnormal dirt, or whether fuel
or water is mixed into it. If an abnormality is found,
LNW61HSH000401
investigate the cause, take the appropriate action to
remedy the cause, and replace the oil. Legend
1. MAX for supplying
Engine oil used 2. An MIN level
• Grade (API) CD Class
Viscosity (SAE) 10W-30 Besco Clean Engine oil leak

NOTE: • Inspect the oil seal, cylinder head cover, oil pan
Only use one of the engine oils listed above in this etc. for oil leaks.
engine.

Amount of engine oil

• Park the vehicle on a level surface, and inspect the
amount of engine oil using a level gauge after
more than 30 minutes has passed since the engine
was stopped. If engine oil adheres to the level
gauge at a level between the upper limit and lower
limit, the oil level is OK.
However, if the level of engine oil is below the
lower limit, add more oil. Also, check how dirty the
oil is.

NOTE:
If the engine oil has increased in quantity, fuel or water
may have become mixed in it. The cause must be
investigated.
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-8 Engine Lubrication (6HK1)

Main Specifications
Main Specifications

Item Specifications
Lubrication system Forced lubrication type
Type Gear type
Output volume
Pump r/min: 4,490r/min
Oil SAE #30, Oil
L (Imp⋅gal)
temperature: 50°C 115 (25.3)
Oil pump /min
(122°F)
Output pressure 400 kPa
(4.1 kgf/cm2/58 psi)
Relief valve opening kPa (kgf/cm2/
800 (8.2 / 117)
pressure psi)
kPa (kgf/cm2 /
Oil gallery relief valve opening pressure 490 (5.0 / 71)
psi)
Type Full flow, filter paper type
Bypass valve opening
Oil filter pressure kPa (kgf/cm2/
250 (2.5 / 36)
(Inlet/outlet oil pressure psi)
differential)
Oil cooler type Water-cooled multi-plate type
Temperature at which it
°C (°F) 90 (194)
starts to open
Oil thermo valve Bypass opening valve
°C (°F) 95 (203)
(Oil thermostat) temperature
Bypass opening valve
mm (in) 5 (0.197)
amount of lift
Shallow pan type: Max. 10.5 (2.31), Min. 8 (1.76)
Oil pan capacity L (Imp⋅gal)
Deep pan type: Max. 16.5 (3.63), Min. 13.5 (2.97)
Total capacity (Euro 4 & 6HK1-TCN 13.5 (2.97)
Engine oil L (Imp⋅gal)
3 specifications) 6HK1-TCC,TCS 19.5 (4.29)
Total capacity 6HK1-TCN 13.5 (2.97)
L (Imp⋅gal)
(Euro 2 specifications) 6HK1-TCN,TCS 19.5 (4.29)
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-9

Maintenance standard table

Item Nominal Assembly Limitations for

dimensions standard use
Driven gear shaft outer 16 15.9
mm (in) —
diameter (0.63) (0.626)
Gap between the driven gear
0.04 – 0.07
shaft, driven shaft, and mm (in) — —
(0.0016 – 0.0028)
bushing
Oil pump
Gap between body wall and 0.125 – 0.221
mm (in) — —
gear tooth tip (0.0049 – 0.0087)
Axial direction gap between
0.064 – 0.109
body attachment surface and mm (in) — —
(0.0025 – 0.0043)
gear
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-10 Engine Lubrication (6HK1)

Oil Filter
Component Parts

1
6

MFWB1HLF000401

Legend
1. Over flow valve 4. Oil filter plug
2. Oil filter body 5. Oil filter
3. Harness bracket 6. O-ring

Disassembly
Disassembly
1. Remove the oil filter.
• As oil has collected inside the oil filter (1)
making it heavy, support it by hand and use an
oil filter wrench (1-8522-1097-0) to remove it.
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-11

2. Assembly the O-ring to the oil filter body, and
install it to the cylinder block.

Tightening torque
38 N⋅m (3.9 kg⋅m/28 lb⋅ft)

MFW81HSH001401

2. Remove the over flow valve.

3. Remove the O-ring.
4. Remove the oil filter body.
5. Remove the O-ring.

MFW81HSH000601
Inspection
1. Inspect the oil filter.
• Replace the oil filter if it is blocked. 3. Install the O-ring.
• Inspect the oil filter for deformation etc. 4. Install the O-ring to the over flow valve, and install
2. Inspect the over flow valve for blockages. it to the oil filter body.

Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

MFW81HSH000501

3. Replace the over flow valve O-ring.

4. Replace the oil filter body attachment section O-
ring. MFW81HSH000701

Reassembly
1. Install the O-ring.
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-12 Engine Lubrication (6HK1)

5. Install the oil filter (1).
• Apply a thin layer of oil to the oil filter seal
section and screw it into the oil filter body.
When the oil filter seal section is in the position
where it contacts with the oil filter body, tighten
it one more turn.
When clamping was short, I tighten it with an oil
filter wrench (1-8522-1097-0).

NOTE:
• If it is over tightened, the oil filter will distort causing
an oil leak.
• Completely wipe off any oil that has seeped out.

MFW81HSH001401
MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-13

Tightening Torque Table

c
d

MFWB1HLF000301

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(d) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-14 Engine Lubrication (6HK1)

Oil Separator (Euro 3/4 specifications)

Maintenance Precautions 3. Connect the blow-by gas rubber hose.
Maintenance precautions
• Replace the oil separator element once a year. 1 2

Disassembly
1. Disconnect the blow-by gas rubber hose.
• Disconnect the IN and OUT ends of the rubber
hose on the oil separator side.
2. Remove the cap.
3. Remove the element. 3

1 2

4
BLW61BSH000501

Legend
1. Oil separator hose (OUT)
2. Oil separator hose (IN)
3. Oil separator
3 4. Oil drain hose

4
BLW61BSH000501

Legend
1. Oil separator hose (OUT)
2. Oil separator hose (IN)
3. Oil separator
4. Oil drain hose

Reassembly
1. Install the element.
• Install a new element.
2. Install the cap.
• Fit an O-ring onto the cap and tighten the cap
securely.
MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-15

Oil Pan (Euro 3/4 specifications)

Component Parts
Shallow pan type

5
8
6

7
MFW71BLF001201

Legend
1. O-ring 5. Bracket
2. Oil strainer 6. Rubber
3. Gasket 7. Bracket
4. Oil pan 8. Rubber spacer
MG6HK-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-16 Engine Lubrication (6HK1)

Deep pan type

6 3

MFW71BLF001501

Legend
1. O-ring 4. Bracket
2. Oil strainer 5. Rubber spacer
3. Oil pan 6. Bracket

Removal 3. Remove the attachment bolt loosening bracket.

1. Drain the engine oil. 4. Remove the attachment bolt loosening rubber.
(shallow pan type only.)
• After draining the oil, tighten the drain plug at
the specified torque. 5. Remove the oil pan.
6. Remove the oil pan gasket. (shallow pan type
Drain plug
only.)
Tightening torque 7. Remove the oil strainer.
78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) 8. Remove the O-ring.

NOTE:
Do not forget tighten the drain plug.

2. Remove the rubber spacer.

MG6HK-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-17

Installation
1. Mount the O-ring in the oil strainer, and install it to
the crankcase.

1
Tightening torque
M8 bolt 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
M10 bolt 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)

2
3

MFW41BSH004301

Legend
1. Crankcase
2. Front gearcase
3. Flywheel housing

3. Install the oil pan.

• Apply liquid gasket (ThreeBond 1207C) to the
MFW41BSH004201 oil pan flange with a thickness of approx. 1 – 2
mm (0.04 – 0.08 in), and a width of approx. 4 –
5 mm (0.16 – 0.2 in). (deep pan type.)
2. Install the oil pan gasket.
NOTE:
• Apply liquid gasket (ThreeBond 1207C) approx.
2 mm (0.08 in) thick and approx. 3 mm (0.12 in) • Clean the installation surface before applying
wide to the crankcase, flywheel housing and sealing agent.
gearcase joints. • Assemble it within 5 minutes after applying the
• Line up the oil pan gasket with the stud, and sealing agent.
install it. (shallow pan type.)

NOTE:
• Clean the mounting surfaces before applying the
sealing compound.
• Install within 5 minutes of applying the sealing
compound.

MFW71HSH000401

Legend
1. Areas which you must remember to apply the
agent to
MG6HK-WE-0871.book 18 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-18 Engine Lubrication (6HK1)

NOTE:
• When the oil pan is installed, the P/S pipe Check the tightness of the oil pan drain plug.
bracket (1) and A/C Generator stay (2) be Drain plug
tightening. (deep pan type.)
Tightening torque
78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)

4. Install the rubber. (shallow pan type.)

• Install the rubber to the plate beforehand.
• Equally tighten it with the oil pan.
1 5. Install the bracket.
• Equally tighten it with the oil pan.
6. Install the rubber spacer.
• Line up the radius of the rubber spacer with the
oil pan cover and insert it, and fix the hole
sections on both sides to the protruding section
of the housing.

2
MFW61HSH000201

• Tightening procedure tightens others after

tightening at 1, 2, 3, 4 points.
Oil pan
Tightening torque
Shallow pan type 11 N⋅m (1.1 kg⋅m / 95 lb⋅in)
Deep pan type 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
1 2

MFW61BSH001701

Legend
1 2
1. Oil pan
2. Flywheel housing

7. Fill the engine oil.

4 3

MFW61HSH000101
MG6HK-WE-0871.book 19 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-19

Tightening Torque Table

a b

c
e

d
MFW61BLF000501

(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(c) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(d) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in) Shallow pan type
24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) Deep pan type
(e) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in) Shallow pan type
24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) Deep pan type
MG6HK-WE-0871.book 20 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-20 Engine Lubrication (6HK1)

Oil Pan (Euro 2 specification)

Component Parts
Shallow pan type

6
7

MFW81HLF001201

Legend
1. O-ring 5. Bracket
2. Oil strainer 6. Rubber
3. Gasket 7. Drain plug
4. Oil pan
MG6HK-WE-0871.book 21 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-21

Deep pan type

MFW81HLF001301

Legend
1. O-ring 4. Bracket
2. Oil strainer 5. Drain plug
3. Oil pan

Removal 3. Remove the attachment bolt loosening bracket.

1. Drain the engine oil. 4. Remove the attachment bolt loosening rubber.
(shallow pan type only.)
• After draining the oil, tighten the drain plug at
the specified torque. 5. Remove the oil pan.
6. Remove the oil pan gasket. (shallow pan type
Drain plug
only.)
Tightening torque 7. Remove the oil strainer.
78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) 8. Remove the O-ring.

NOTE:
Do not forget tighten the drain plug.

2. Remove the oil pan cover. (deep pan type.)

MG6HK-WE-0871.book 22 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-22 Engine Lubrication (6HK1)

Installation
1. Mount the O-ring in the oil strainer, and install it to
the crankcase.

1
Tightening torque
M8 bolt 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
M10 bolt 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)

2
3

MFW41BSH004301

Legend
1. Crankcase
2. Front gearcase
3. Flywheel housing

3. Install the oil pan.

• Apply liquid gasket (ThreeBond 1207C) to the
MFW41BSH004201 oil pan flange with a thickness of approx. 1 – 2
mm (0.04 – 0.08 in), and a width of approx. 4 –
5 mm (0.16 – 0.2 in). (deep pan type.)
2. Install the oil pan gasket.
NOTE:
• Apply liquid gasket (ThreeBond 1207C) approx.
2 mm (0.0787 in) thick and approx. 3 mm • Clean the installation surface before applying
(0.1187 in) wide to the crankcase, flywheel sealing agent.
housing and gearcase joints. • Assemble it within 5 minutes after applying the
• Line up the oil pan gasket with the stud, and sealing agent.
install it. (shallow pan type.)

NOTE:
• Clean the mounting surfaces before applying the
sealing compound.
• Install within 5 minutes of applying the sealing
compound.

MFW71HSH000401

Legend
1. Areas which you must remember to apply the
agent to
MG6HK-WE-0871.book 23 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-23

• When the oil pan is installed, the A/C Generator

stay (1) be tightening.
Shallow pan type
1 2

4 3

MFW61HSH000101

MFW81HSH000901 NOTE:
Check the tightness of the oil pan drain plug.
Deep pan type
Drain plug
Tightening torque
78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)

4. Install the rubber. (shallow pan type.)

• Install the rubber to the plate beforehand.
• Equally tighten it with the oil pan.
5. Install the oil pan cover.

Tightening torque
10 N⋅m (1.0 kg⋅m / 87 lb⋅in)

1
MFW81HSH001001

• Tightening procedure tightens others after

tightening at 1, 2, 3 , 4 points.
Oil pan
Tightening torque
Shallow pan type 11 N⋅m (1.1 kg⋅m / 95 lb⋅in)
Deep pan type 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
MG6HK-WE-0871.book 24 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-24 Engine Lubrication (6HK1)

2
3
4

MFW81HSH000801

Legend
1. Oil pan
2. O-ring
3. Oil pan cover
4. Bolt

6. Fill the engine oil.

MG6HK-WE-0871.book 25 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-25

Tightening Torque Table

a b

f
c
e

d
MFW81HLF001401

(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(c) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(d) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in) Shallow pan type
24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) Deep pan type
(e) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in) Shallow pan type
24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) Deep pan type
(f) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in) Deep pan type
MG6HK-WE-0871.book 26 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-26 Engine Lubrication (6HK1)

Oil Pump
Component Parts

4
3
5
2

7
6

BLW71HLF000701

Legend
1. Oil pump body 5. Cotter pin
2. Oil relief valve 6. Driven gear
3. Spring 7. Drive gear
4. Spring seat

Removal 4. Remove the oil pan.

5. Remove the flywheel housing.
Refer to “Crankshaft” in the Engine Mechanical
1. Remove the cylinder head assembly.
section.
Refer to “Cylinder Head” in the Engine Mechanical
section.
2. Remove the air compressor.
Refer to “Air compressor” in Engine Exterior Parts.
3. Remove the supply pump assembly.
Refer to “Supply pump” in Engine Exterior Parts.
MG6HK-WE-0871.book 27 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-27

6. Remove idle gear A.

MFW41HSH000101
MFW41HSH002201

3. The oil pump body is a single unit.

7. Remove idle gear A shaft.
8. Remove the oil pump assembly.
Inspection
1. Measure the driven gear.
a. Measure the outer diameter of the driven gear
shaft and the gap between the shaft and
bushing.

Nominal Limitations for use

dimensions
Shaft outer 16 mm 15.9 mm
diameter (0.6299 in) (0.626 in)

Assembly standard
Gap between the shaft 0.04 – 0.07 mm
and bushing (0.0016 – 0.0028 in)
MFW41HSH002301

• Also measure the outer diameter and gap

for the drive gear side.
Disassembly
1. Remove the driven gear. NOTE:
Measure the bushing inner diameter on the cylinder
2. Remove the oil relief valve. body side in the same way.
• Remove the cotter pin, then extract the spring
seat, spring, and oil relief valve in order.

NOTE:
When the cotter pin is removed, the spring seat and
spring will spring out, so make sure you do not lose
them.
MG6HK-WE-0871.book 28 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-28 Engine Lubrication (6HK1)

3. Inspect the oil relief valve and spring for damage.

MFW41HSH000301
MFW41HSH000601

Legend
b. Measure the gap between the oil pump body 1. Oil relief valve
and gear tooth tip. 2. Spring

Assembly standard
0.125 – 0.221 mm 4. Inspect the oil pump body for damage.
Gap
(0.0049 – 0.0087 in)
Reassembly
• Also measure the gap on the drive gear side
1. Set the oil pump body assembly.
in the same way.
2. Install the oil relief valve.
• Insert the oil relief valve, spring, and spring
seat, in that order, and secure them with a
cotter pin.
3. Install the driven gear.
• Apply oil to the driven gear, and install it to the
pump body.

NOTE:
• Be careful not to drop the driven gear.
• Turn it with your hand to confirm that there are no
abnormalities.
• Install the driven gear so that the stepped surface
on the side of the driven gear is touching the
cylinder block.

MFW41HSH000401

2. Inspect the spring seat for damage.

MG6HK-WE-0871.book 29 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Lubrication (6HK1) 1H-29

NOTE:
• Install within 5 minutes of applying the sealing
compound.
• Do not allow liquid gasket to get onto the gears or
arrow section hole.
• Make sure the driven gear does not fall out.

MFW41HSH000901

Installation
Completely remove the gasket from the flywheel
housing and cylinder block mounting surfaces.
1. Install the oil pump.
MFW41BSH005201
• Apply oil to the oil pump gear insertion section.
• Remove any liquid gasket that has overflowed
from the oil pump mounting surface, and apply
oil to the crankcase and cylinder block bushing. • Line up the dowel and install the oil pump.

NOTE:
Do not allow oil to get onto the oil pump mounting Tightening torque
surface. 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

NOTE:
• There are no alignment marks on the gears.
• Install the oil pump before installing idle gear A.

MFW41BSH005101

• Apply liquid gasket (ThreeBond 1201 and

1207C) to the oil pump mounting surface as
MFW41BSH005301
shown in the diagram.

2. Install idle gear A shaft and idle gear A.

MG6HK-WE-0871.book 30 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1H-30 Engine Lubrication (6HK1)

• Apply oil to the gear inner circumference 7. Install the cylinder head.
section and thrust section.
Refer to “Cylinder Head” in the Engine Mechanical
• Insert the gear into the shaft, and fit in the section.
collar.

NOTE:
Rotate the crankshaft and set the #1 cylinder to the top
dead point.

• Line up the shaft knock pin and cylinder block

knock hole, and also line up the crank gear “L”
mark with the idle gear A “O” mark, and install
them.
• Apply molybdenum-disulfide paste to the
threaded section and seating section of the
bolts and the washer, and tighten them.

Tightening torque
134 N⋅m (13.6 kg⋅m/98.4 lb⋅ft)

MFW61BSH001801

Legend
1. Crank gear
2. Idle gear A

NOTE:
• After installing, re-check that the marks are in line.
• After installing the flywheel housing, tighten the idle
gear A shaft using 3 bolts.

3. Install the flywheel housing.

Refer to “Crankshaft” in the Engine Mechanical section.
4. Install the oil pan.
5. Install the supply pump assembly.
Refer to “Supply pump” in Engine Exterior Parts.
6. Install the air compressor.
Refer to “Air compressor” in Engine Exterior Parts.
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Speed Control System (6HK1) 1I-1

ENGINE
Engine Speed Control System
(6HK1)
TABLE OF CONTENTS
Accelerator Control Assembly . . . . . . . . . . . . . . . . 1I-2
Component Parts . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-3
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1I-2 Engine Speed Control System (6HK1)

Accelerator Control Assembly

Component Parts

1
4

MFW71IMF000201

Legend
1. Bolt 4. Pedal
2. Control link and bracket assembly 5. Pedal stopper bolt
3. Accelerator position sensor

Removal 2. Remove the control link and bracket assembly

installation nut.
NOTE:
When removing the harness connector, remove the
battery earth.

1. Turn OFF the ignition switch.

MFWB1ISH000101
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Engine Speed Control System (6HK1) 1I-3

3. Remove the accelerator pedal installation bolts.
4. Remove the harness connector to the Accelerator
Pedal Position (APP) sensor.

Installation
1. Connect the Accelerator Pedal Position (APP)
sensor harness connector.
2. Install the accelerator pedal installation bolt.
3. Install the control link and bracket assembly.

Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

MFWB1ISH000101

4. After installing the pedal, check that the gap (a) is

at the specified value when the pedal is fully
depressed.
Gap (a) [reference value]: 1.0 mm (0.039 in)
• If it needs adjustment, loosen the nut (2), turn
the bolt (1) to adjust, and then fix the nut (2).

1
2
a

MFWB1ISH000201
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

MEMO
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MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-1

ENGINE
Induction
(6HK1)
TABLE OF CONTENTS
Supercharging System. . . . . . . . . . . . . . . . . . . . . .1J-2
Precautions for Servicing . . . . . . . . . . . . . . . . . .1J-2
Explanation of Functions and Operations . . . . . .1J-2
Failure Phenomenon List . . . . . . . . . . . . . . . . . .1J-4
Phenomenon: If there is a fault or vibration . . . .1J-5
Phenomenon: If the turbocharger is thought
to be generally normal but the output is low . . . .1J-6
Phenomenon: Oil leak in the exhaust pipe or
intake pipe, and the exhaust gas color is white. .1J-7
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-8
Component Parts . . . . . . . . . . . . . . . . . . . . . . . .1J-8
Inspection : Euro 3 specification and Euro 4
specification (Variable Nozzle Turbocharger) . . .1J-9
Inspection : Euro 2 specification and Euro 3
specification (With waste gate control valve
turbocharger). . . . . . . . . . . . . . . . . . . . . . . . . . .1J-10
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-12
Component Parts . . . . . . . . . . . . . . . . . . . . . . .1J-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-12
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-13
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . .1J-14
Component Parts . . . . . . . . . . . . . . . . . . . . . . .1J-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-16
MAF (Mass Air Flow) Sensor . . . . . . . . . . . . . . . .1J-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-18
IAT (Inlet Air Temperature) Sensor. . . . . . . . . . . .1J-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-19
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-2 Induction (6HK1)

Supercharging System
Precautions for Servicing • When performing maintenance work, you should
aim to completely prevent any dust or debris from
• The turbocharger is designed to rotate at high
entering these parts.
speed (approx. 100,000 r/min), therefore if the fin,
housing, or other parts are damaged or bent just a CAUTION:
small amount, or if other faults are discovered, In order not to cause malfunction or trouble , do not
replace the turbocharger assembly. loosen the bolts and nuts of the turbocharger assembly,
or disassembly or remove the components of
turbocharger assembly.

Explanation of Functions and Operations

Euro 3 specification and Euro 4 specification (Variable Nozzle Turbocharger)

1
2
3

8
7

6 5

MFW61JLF000101

Legend
1. Actuator 5. Center housing assembly
2. Oil inlet 6. Oil outlet
3. Rod end assembly 7. Compressor housing assembly
4. Turbine housing assembly 8. Connector
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-3

Euro 2 specification and Euro 3 specification (With waste gate control valve turbocharger)

1
3

MFW81JLF000201

Legend
1. Actuator rod 4. Rubber hose
2. Waste gate actuator 5. Compressor housing assembly
3. Clip 6. Turbine housing assembly
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-4 Induction (6HK1)

Failure Phenomenon List
• If there is a fault or vibration
• If the turbocharger is thought to be generally
normal but the output is low
• Oil leak in the exhaust pipe or intake pipe, and the
exhaust gas color is white
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-5

Phenomenon: If there is a fault or vibration

Condition Possible Cause Correction

If there is a fault or vibration Caused by a damaged bearing or Replace
contact between the rotating section
and its periphery Neglecting to change
the oil, debris entering the oil supply
pipes, blocked oil filter or driving
If there are no abnormalities in the Replace
lubrication system, and damage is
found to be caused by contact between
the rotating section and its periphery, it
is probably caused by poor balance in
the rotating section, or a bent shaft This
is because a worn bearing is being
used, or because debris has flown
inside and damaged the turbine wheel
or compressor wheel
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-6 Induction (6HK1)

Phenomenon: If the turbocharger is thought to be generally normal but the output is low

Condition Possible Cause Correction

If the turbocharger is thought to be Gas leak from various parts of the Repair or replace
generally normal but the output is low exhaust
Carbon deposits or distortion in the Repair or replace
exhaust pipe silencer etc. can cause
excessive exhaust resistance
Air leak from the compressor output Clean or replace
side, dirty air cleaner
Compressor interior dirty Clean
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-7

Phenomenon: Oil leak in the exhaust pipe or intake pipe, and the exhaust gas color is white

Condition Possible Cause Correction

Oil leak in the exhaust pipe or intake Dirty air cleaner, oil leak due to Clean or replace
pipe blockage
The exhaust gas color becomes white Blocked, crushed, or deformed drain oil Repair or replace
pipe
Wear or damage in the turbine shaft Repair or replace
section
Close type PCV; blocked air breather Clean or replace
Closed type PCV; Oil suction in the Repair or replace
turbocharger compressor side due to a
faulty air breather slinger
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-8 Induction (6HK1)

Turbocharger
Component Parts
Euro 3 specification and Euro 4 specification (Variable Nozzle Turbocharger)

1
2
3

8
7

6 5

MFW61JLF000101

Legend
1. Actuator 5. Center housing assembly
2. Oil inlet 6. Oil outlet
3. Rod end assembly 7. Compressor housing assembly
4. Turbine housing assembly 8. Connector
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-9

Euro 2 specification and Euro 3 specification (With waste gate control valve turbocharger)

1
3

MFW81JLF000201

Legend
1. Actuator rod 4. Rubber hose
2. Waste gate actuator 5. Compressor housing assembly
3. Clip 6. Turbine housing assembly

Inspection : Euro 3 specification and Euro A. External inspection of each part

4 specification (Variable Nozzle Turbo- 1. Perform a visual inspection on each of the parts for
charger) cracks, interference, damage, distortion, oil leaks
from the seal section, gas leaks etc.
Inspect each part of the turbocharger, and only
exchange it if an abnormality is found. 2. Rotate the turbine shaft by hand to see if it rotates
smoothly, and at the same time inspect the turbine
NOTE: shaft play in the axial direction and rotational
It is not a malfunction if oil is adhering to the direction.
compressor port inner surface. The engine blow-by gas
is returned to the compressor inlet, so the oil content B. Turbine shaft play measurement
that is slightly contained in the blow-by gas may adhere 1. Turbine shaft axial direction measurement
to the inner wall of the compressor inlet and outlet, but
• Set the dial gauge in the turbine shaft axial
this is not a failure of the turbocharger.
direction, and adjust the gauge to zero.
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-10 Induction (6HK1)

• Move the turbine shaft forwards and
backwards, and read off the axial direction play.
The clearance should be within the table below.

Axial direction clearance

0.043 –0.094 mm
6HK1-TCN, TCC, TCS
(0.0017 – 0.0037 in)

BLW71JSH001001

Inspection : Euro 2 specification and Euro

3 specification (With waste gate control
valve turbocharger)
Inspect each part of the turbocharger, and only
exchange it if an abnormality is found.

BLW71JSH001101 NOTE:
2. Turbine shaft diameter direction measurement It is not a malfunction if oil is adhering to the
compressor port inner surface. The engine blow-by gas
• Set the dial gauge including offset pin into the is returned to the compressor inlet, so the oil content
turbine shaft, and adjust the gauge to zero. that is slightly contained in the blow-by gas may adhere
• Move the turbine shaft up and down, and read to the inner wall of the compressor inlet and outlet, but
off the diameter direction play. The clearance this is not a failure of the turbocharger.
should be within the table below.
A. External inspection of each part

Diameter direction clearance 1. Perform a visual inspection on each of the parts for
cracks, interference, damage, distortion, oil leaks
0.086 – 0.140 mm from the seal section, gas leaks etc.
6HK1-TCN, TCC, TCS
(0.0034 – 0.0055 in)
2. Rotate the turbine shaft by hand to see if it rotates
smoothly, and at the same time inspect the turbine
NOTE: shaft play in the axial direction and rotational
If the turbine shaft play is outside the specified value, direction.
and if a malfunction is discovered in the center housing
assembly, replace the turbocharger assembly. B. Turbine shaft play measurement
1. Turbine shaft axial direction measurement
• Set the dial gauge in the turbine shaft axial
direction, and adjust the gauge to zero.
• Move the turbine shaft forwards and
backwards, and read off the axial direction play.
The clearance should be within the table below.

Axial direction clearance

0.060 – 0.090 mm
6HK1-TCN, TCC, TCS
(0.0024 – 0.0035 in)
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-11

MFW41JSH000201

2. Turbine shaft diameter direction measurement

• Set the dial gauge including offset pin into the
turbine shaft, and adjust the gauge to zero.
• Move the turbine shaft up and down, and read
off the diameter direction play.
The clearance should be within the table below.

Diameter direction clearance

0.100 – 0.170 mm
6HK1-TCN, TCC, TCS
(0.0039 – 0.0067 in)

NOTE:
If the turbine shaft play is outside the specified value,
and if a malfunction is discovered in the center housing
assembly, replace the turbocharger assembly.

MFW410SH000101
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-12 Induction (6HK1)

Intercooler
Component Parts

4
3

7 6

10

MFW71JLF000201

Legend
1. Intercooler 6. Radiator hose (lower)
2. Rubber hose (IN side) 7. Drain cock
3. Nuts 8. Radiator stay
4. Radiator assembly 9. Rubber hose (OUT side)
5. Radiator hose (upper) 10. Bolts

Removal Inspection
1. Remove the radiator assembly. 1. A distorted intercooler fin may lead to a reduction
in heat dissipation effectiveness, which may in turn
Refer to “Radiator” in Engine Cooling.
cause reduced engine performance.
2. Remove the 4 intercooler fixing bolts from the Therefore, the fin must be repaired. Take care not
radiator assembly and remove the intercooler. to damage the joint section of the fin when
repairing it.
2. Inspect inside the intercooler for dirt. Clean it if it is
particularly dirty.
MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-13

NOTE: Installation
Do not perform high-pressure washing to the radiator
1. Install the intercooler to the radiator.
or intercooler, and the parts surrounding it.

Cleaning Tightening torque

19.1 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
Washing the intercooler core
CAUTION:
2. Install the radiator assembly.
Do not perform high-pressure washing onto the
radiator, intercooler and surrounding parts when they Refer to “Radiator” in Engine Cooling.
are still installed on the vehicle.

1. Seal the hose connecting section with a cap or

fabric tape.
2. Sufficiently wet the front and back surfaces of the
intercooler.
• Adhering matter which easily comes off with a
splash of tap water should be washed off
sufficiently in advance.

NOTE:
Do not use a high-pressure washer or brush.

3. Prepare a mild detergent.

• Use a type which contains approx. 8% of
surface acting agent.

NOTE:
Do not use anything other than a mild detergent. Use of
any product other than a mild detergent may cause
corrosion.

4. Spray the mild detergent onto both sides of the

fins, and leave them as is for 10 minutes.
5. Rinse off the mild detergent using a high-pressure
washer.
• Start washing from the engine side of the
intercooler.

NOTE:
• Apply the high-pressure water in a direction
perpendicular to the fins.
• Do not bring the high-pressure water too close to
the fins.
• Be careful not to deform the fins.

6. After washing is finished, inspect the fins to

confirm that the dirt is removed sufficiently.
• If washing is not sufficient, wash them again.

NOTE:
If some dirt is still left, fine black particles attached on
the fins can be seen.

7. Rinse off the detergent constituents on the fins and

resin parts using the tap water.
8. Remove the seal on the hose connecting section.
9. Clean and dry the hose connecting section
sufficiently.
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-14 Induction (6HK1)

Air Cleaner Element

Component Parts

1 2 3 4

7 6

MFW81JMF000101

Legend
1. Body assembly 5. Match mark
2. Outer element 6. Inner element
3. Wire clamp 7. Water drain valve
4. Air cleaner cover

Removal
1. Tilt the cab.
2. Remove the air cleaner cover.
• Remove the clamps (1) at 4 locations by
pressing them inside to remove the air cleaner
cover (2).
MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-15

•

MFW81JSH000201

Legend
1. Air cleaner assembly
2. MAF (Mass Air Flow) sensor

2
With waste gate control valve turbocharger
1. Inspection for IAT (Inlet Air Temperature) sensor.
Refer to Section 1A, “Engine Control System” for
MFW81JMH000401
IAT sensor inspection and replacement.
•

3. Remove the element.

• Do not remove the inner element when the 1
outer element is cleaned.
• Never clean the inner element. Replace the
inner element at the same time of replacing the
outer element.

NOTE:
• Make sure to use a genuine dry type element
because an MAF sensor (Variable nozzle
turbocharger) and IAT sensor (With waste gate
control valve turbocharger) is used.
Do not use a wet type element because it may make
the sensor dirty.
• Use a genuine air cleaner element.
If other element is used, it may cause the sensor to
output a wrong signal. MFWB1JSH000401

Legend
Inspection 1. IAT (Inlet Air Temperature) sensor
Variable nozzle turbocharger 2. Inspect the air cleaner.
1. Inspection for MAF (Mass Air Flow) sensor. • Inspect the element on a regular basis or when
Refer to Section 1A, “Engine Control System” for the air cleaner warning light turns on.
MAF sensor inspection and replacement.
3. Clean the element.
NOTE: • When it is dirty with dry dust, etc., clean it by
Do not touch the sensing section of the sensor with blowing the compressed air to it.
hand because it is heated to 170 – 300 °C (338 – • Blow the compressed air from inside the
572°F) when the sensor is turning on electricity. element while rotating the element.
MG6HK-WE-0871.book 16 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-16 Induction (6HK1)

NOTE: NOTE:
Do not hit or strike the element to clean. • Make sure to replace the element if there is an
Do not exceed an air pressure of 690 kPa (7.0 kgf/cm2 abnormality found.
/ 100 psi).
• Replace the element after using it for a year or after
cleaning it 6 times, whichever is earlier, and when it
is damaged.

HCW310SH000101

• When blackened by oily smoke such as soot.

Dissolve a mild detergent in water and soak the HCW31BSH057601
element for approximately 30 minutes.
5. Inspect the water drain valve (1) at the lower side
Then rinse the element well with running tap
of the air cleaner for clogging.
water, etc.
Moreover, it checks whether the adhesion of water
After washing the element, allow it to dry
drain valve is good.
naturally without using flames (for two to three
days).
Do not exceed a water pressure of 275 kPa (2.8
kgf/cm2 / 40 psi).

1
MFW71JSH002201

Installation
HCW31BSH057501
1. Install the element.
4. Inspect the element for breakage or damage.
2. Install the air cleaner cover.
• Place a light in the element to inspect the
element for damage or pin hole, and inspect the • Face the “ISUZU” mark on the cover upward
seal section for breakage. and engage the concave and convex sections
(3) at the left side of the cover.
MG6HK-WE-0871.book 17 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-17

• Hook the wire clamps to the body assembly (1)
at 4 locations, and pull it towards you to install
the air cleaner cover (2).

MFW91JSH000601

1
2

3
MFW71JMH000401

3. Install the intake duct.

• Install the intake duct (2) to the air cleaner and
turbo charger, and tighten it with air duct
clamps (1).

Tightening torque
ABA W4
6.4 N⋅m (0.65 kg⋅m/56 lb⋅in)
Stainless clamp
NORMA W1
8 N⋅m (0.8 kg⋅m/69 lb⋅in)
Steel clamp
MG6HK-WE-0871.book 18 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1J-18 Induction (6HK1)

MAF (Mass Air Flow) Sensor

Removal
1. Turn OFF the ignition switch .
2. Disconnect the harness connector.
3. Remove the MAF (Mass Air Flow) sensor.

MFW81JSH000101

Installation
1. Install the MAF (Mass Air Flow) sensor.

Tightening torque
1.5 N⋅m (0.15 kg⋅m / 13 lb⋅in)

2. Install the harness connector.

MG6HK-WE-0871.book 19 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Induction (6HK1) 1J-19

IAT (Inlet Air Temperature) Sensor

Removal
1. Turn OFF the ignition switch .
2. Disconnect the harness connector.
3. Remove the IAT (Inlet Air Temperature) sensor.

MFW81JSH000801

Legend
1. IAT (Inlet Air Temperature) sensor
2. Sensor adapter

Installation
1. Install the IAT (Inlet Air Temperature) sensor.

Tightening torque
3.5 N⋅m (0.36 kg⋅m / 31 lb⋅in)

2. Install the harness connector.

MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

MEMO
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MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Pre-Heating System (6HK1) 1K-1

ENGINE
Pre-Heating System
(6HK1)
TABLE OF CONTENTS
Pre-Heating System . . . . . . . . . . . . . . . . . . . . . . . 1K-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1K-2
Description of Functions and Operation . . . . . . 1K-2
Functional Inspection . . . . . . . . . . . . . . . . . . . . 1K-3
List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1K-5
Symptom: Glow indicator lamp does not turn on1K-6
Symptom: Preheating does not work . . . . . . . . 1K-7
Symptom: Preheating period is either too
long or too short . . . . . . . . . . . . . . . . . . . . . . . . 1K-8
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1K-8
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1K-2 Pre-Heating System (6HK1)

Pre-Heating System
Maintenance Precautions
Over tightening glow plugs can cause damage to them.

Description of Functions and Operation

The QOS II system has been adopted for the
preheating system. Also, the electricity supply controls
are performed by the ECM.
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Pre-Heating System (6HK1) 1K-3

Functional Inspection
Inspection and correction of QOS II • If the results of the measurement show that the
1. System inspection resistance value is outside specifications,
replace the glow relay.
• Disconnect the of the engine coolant
Glow relay resistance value :
temperature sensor (1) connector.
approximately 51.5Ω

4 1

4 3

1
2 2 1
3

MFW61KSH000201
HCW31KSH000101
• Connect a voltmeter between the glow plug and
• Glow relay (1) attachment location :
engine ground.
Chassis relay box (fix the left side of cab
• Turn the ignition switch to ON (without starting mounting).
engine) and check for the following items.
- The glow indicator turns on for 3.5 seconds.
- The voltmeter indicates the power supply
voltage for approximately 18 seconds.
• If there are any abnormalities with the
inspection, inspect the glow relay, water thermo 1
sensor and the glow plugs. If normal, inspect
the engine control system.

MFW81ESH000101

3. Inspect the engine coolant temperature sensor.

• Place the sensor part of engine coolant
temperature sensor into water, and check that
the resistance value changes as shown in the
graph when the water temperature is changed.

NOTE:
HCW31KSH000201 Be careful not to allow water in the terminal section.
Also, wipe off the water droplets on the sensor after the
2. Inspection of the glow relay
inspection.
• Using a circuit tester, measure the resistance
value (between 1 and 2) of the glow relay.
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1K-4 Pre-Heating System (6HK1)

• If the results of the measurement show that the
resistance value is outside specifications,
replace the glow plug.

Glow plug resistance value :

approximately 6.0Ω (normal temperature)

NOTE:
Use a 6-piece set of genuine glow plugs.

MFW71KSH000201

Resistance value at a certain temperature

(approximate value)
Remarks Resistance value
– 20°C (– 4°F) Approx 15.48 kΩ
0°C (32°F) Approx. 5.79 kΩ
20°C (68°F) Approx. 2.45 kΩ MFW61KSH000401
40°C (104°F) Approx. 1.15 kΩ
60°C (140°F) Approx. 0.59 kΩ
80°C (176°F) Approx. 0.32 kΩ
100°C (212°F) Approx. 0.19 kΩ

Thermistor characteristic

30

20

10
7.0
)

5.0
Resistance value(k

3.0

2.0

1.0
0.7
0.5

0.3

0.2

0.1
-20 0 20 40 60 80 100 120
Engine coolant temperature( )
MFW81CSH000901

4. Inspection of the glow plug.

• Measure the resistance value of the glow plugs
using a circuit tester.
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Pre-Heating System (6HK1) 1K-5

List of Trouble Symptoms
• Glow indicator lamp does not turn on
• Preheating does not work
• Preheating period is either too long or too short
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1K-6 Pre-Heating System (6HK1)

Symptom: Glow indicator lamp does not turn on

Condition Possible Cause Correction

Glow indicator lamp does not turn on. Slow blow fuse melts Replace the slow blow fuse
Fuse blows Replace the fuse
Burnout of indicator valve Replace the indicator valve
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Pre-Heating System (6HK1) 1K-7

Symptom: Preheating does not work

Condition Possible Cause Correction

Preheating does not work. Slow blow fuse melts Replace the slow blow fuse
Connection failure of the glow relay Re-install or replace the glow relay
connector
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1K-8 Pre-Heating System (6HK1)

Symptom: Preheating period is either too long or too short

Condition Possible Cause Correction

Preheating period is either too long or Thermo-switch failure or open or short Replace the thermo-switch. Repair the
too short. in the circuit circuit
Glow plug failure Replace or tighten the glow plug

Main Specifications

Item Model
Model with pre-heater Glow plug QOS timer
Glow plug rated voltage and current 23V - 3.5A
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Power Take-Off (PTO) (6HK1) 1L-1

ENGINE
Power Take-Off (PTO)
(6HK1)
TABLE OF CONTENTS
Flywheel PTO (Euro 3/4 specifications) . . . . . . . . 1L-2
Functional and Operational Description . . . . . . 1L-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1L-11
Tightening Torque Table . . . . . . . . . . . . . . . . . 1L-15
MG6HK-WE-0871.book 2 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1L-2 Power Take-Off (PTO) (6HK1)

Flywheel PTO (Euro 3/4 specifications)

Functional and Operational Description
The PTO crank gear is added to the end of the
crankshaft, and the flywheel PTO is tightened to the
crankshaft together with the flywheel.
Motive energy is outputted from the PTO gear located
in the upper section of the flywheel housing, from the
PTO crank gear via the idle gear. There is no
mechanism for turning the motive power ON/ OFF
partway; motive power is output by direct coupling to
the engine, regardless of the clutch and transmission
being ON/OFF.
MG6HK-WE-0871.book 3 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Power Take-Off (PTO) (6HK1) 1L-3

Components

3 4
2
5

1
6

14

10

13
11

12

MFW71LLF000401

Legend
1. Front bearing 8. Idle gear
2. PTO gear 9. Idle gear shaft
3. O-ring 10. Idle gear bearing
4. Bearing case 11. PTO crankshaft gear
5. Rear bearing 12. Flywheel housing (PTO specification)
6. PTO shaft 13. Crankshaft
7. Oil seal 14. Idle gear A
MG6HK-WE-0871.book 4 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1L-4 Power Take-Off (PTO) (6HK1)

Removal
Removal of the PTO assembly

2
3
4
5
6
7
8
9
1 10
11

21
20
19 18
17
16
15 14
13

12

MFW71LLF000701

Legend
1. Flywheel housing (PTO specification) 12. Idle gear cover
2. Front bearing 13. Bolt
3. PTO gear assembly 14. Nut
4. Rear bearing 15. Lock washer
5. Oil thrower 16. Idle gear
6. O-ring 17. Rear bearing
7. Bearing case 18. Outer spacer
8. Oil seal 19. Inner spacer
9. Flange 20. Front bearing
10. O-ring 21. Shaft
11. Nut

1. Remove the oil pipe of the PTO gear section. • Loosen the assembly case tightening bolt, and
• Remove the clip. remove the O-ring, oil seal, rear bearing, PTO
gear, front bearing inner race in an assembled
2. Remove the PTO assembly.
state.
MG6HK-WE-0871.book 5 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Power Take-Off (PTO) (6HK1) 1L-5

Removal of the PTO idle gear assembly

2 3
1 2

1
4

6
3

10

MFW71LMH000101
9
Legend MFW71LMH000501

1. PTO gear assembly Legend

2. Oil pipe 1. Idle gear A
3. Idle gear cover 2. Bearing (front)
3. Idle gear
4. Bearing (rear)
5. Lock washer
3. Remove the O-ring.
6. Shaft
7. Bolt
Removal of the PTO crank shaft gear assembly
8. Nut
1. Remove the transmission. 9. Inner spacer
• Refer to "Transmission ASM" in Section 5C, 10. Thrust collar
Manual Transmission.
2. Remove the flywheel.
• Refer to "Timing Gears, Flywheel, and Flywheel
Housing" in Section 1B, Engine Mechanical.
3. Remove the oil seal.
• Refer to "Timing Gears, Flywheel, and Flywheel
Housing" in Section 1B, Engine Mechanical.
4. Remove the PTO crankshaft gear.
MG6HK-WE-0871.book 6 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1L-6 Power Take-Off (PTO) (6HK1)

1. Remove the idle gear cover (1).
Use 2 replacer holes (M10 / 1.5) (2) to remove it.

1 1
2 3
2 4
5
6
7
8
9
10
11

MFW71LSH000201

Legend
MFW71LSH000101
1. Front bearing
2. PTO gear
3. PTO shaft
2. Remove the flywheel housing. 4. Rear bearing
3. Loosen the idle gear shaft bolt. 5. Oil thrower
4. Remove with the shaft and idle gear assembly in 6. O-ring
one piece. 7. Bearing case
8. Oil seal
9. Flange
Disassembly 10. O-ring
11. Nut
Disassembly of the PTO gear assembly
1. Remove the O-ring from the bearing case.
2. Remove the PTO gear assembly from the bearing Disassembly of the PTO idle gear assembly
case. 1. Remove the bearing tightening nut to remove the
3. Remove the oil seal from the bearing case. lock washer.
4. Remove the front bearing and rear bearing from 2. Use the press to pull the shaft out from the idle
the PTO gear assembly. gear assembly, then remove the inner bearing.
3. Remove the outer races (both front and back) from
the idle gear.
4. Remove the inner spacer (shim) and the outer
spacer (snap ring) from the idle gear.
MG6HK-WE-0871.book 7 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Power Take-Off (PTO) (6HK1) 1L-7

1
2

3
4
5
6
7
8

MFW71LSH001101 MFW41LSH000201

Legend 2. Inspect the PTO gear.

1. Shaft • Inspect the gear tooth surfaces for damage and
2. Idle gear wear.
3. Front bearing
3. Inspect the idle gear bearing.
4. Inner spacer
5. Outer spacer • Inspect the bearing for peeling, wear and
6. Rear bearing abnormal sounds.
7. Lock washer • Inspect the entire circumference from between
8. Nut the roller and ball bearing cage to the inner race
for damage or peeling.
• Inspect the roller and ball bearing cage for any
Inspection abnormal looseness caused by wear.
1. Inspect the PTO bearing. • Rotate the bearing to manually inspect for
abnormal sounds, and check for any
• Inspect the bearing for peeling, wear and irregularities in movement.
abnormal sounds.
• Inspect the entire circumference from between
the roller and ball bearing cage to the inner race
for damage or peeling.
• Inspect the roller bearing cage for looseness
caused by wear.
• Rotate the bearing to manually inspect for
abnormal sounds, and check for any
irregularities (such as bumpiness) in
movement.

MFW41LSH000301

4. Inspect the idle gear.

• Inspect the gear tooth surface for wear and
damage, and the inner circumference for
damage.
MG6HK-WE-0871.book 8 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1L-8 Power Take-Off (PTO) (6HK1)

• Firmly fit by pushing the inner race.

NOTE:
There should be no gaps between the bearing end
surface and shaft surface.

3. Install the O-ring to the bearing case and firmly fit

the rear bearing.

NOTE:
• Apply engine oil to the ball area before firmly fitting
the rear bearing.
• There should be no gaps between the bearing end
surface and case surface.

4. Firmly fit the PTO gear assembled at Procedure 2.

into the bearing case.
5. Press the oil thrower all the way in until it touches
MFW41LSH000501
the rear bearing.
6. Apply engine oil to the lip area of the oil seal, and
Reassembly use oil seal installer (9-8522-1310-0) to fit it firmly
into the bearing case.
Reassembly of the PTO gear assembly
7. Insert and fasten the O-ring with a nut after
assembling the flange to the PTO shaft.

Tightening torque
1
2 3 480 N⋅m (48.9 kg⋅m/353.7 lb⋅ft)
4
5
6
7 Reassembly of the PTO idle gear
8
9
10
11

1
2

3
4
5
MFW71LSH000201 6
7
Legend 8
1. Front bearing
2. PTO gear
3. PTO shaft
4. Rear bearing
5. Oil thrower
6. O-ring
7. Bearing case MFW71LSH001101

8. Oil seal Legend

9. Flange 1. Shaft
10. O-ring 2. Idle gear
11. Nut 3. Front bearing
4. Inner spacer
5. Outer spacer
6. Rear bearing
1. Firmly fit the PTO gear into the PTO shaft. 7. Lock washer
• Bake fit at below 250 °C (482°F). 8. Nut
2. Firmly fit the front bearing into the PTO shaft.
MG6HK-WE-0871.book 9 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Power Take-Off (PTO) (6HK1) 1L-9

a. Measure the gap in the idle gear bearing axis
1. Use the snap ring pliers to insert the outer spacer direction. Assemble the inner race of the idle
(snap ring) into the idle gear. gear bearing without the inner spacer, and
measure the thickness (1) in the bearing axis
direction on a level block.

MFW41LSH000601

LNW71LSH001001

2. Fit the outer race of the tapered roller bearing

firmly into the outer space until they touch.
b. Next, assemble the inner spacer (2) and
measure the thickness (3) in the bearing axis
direction in the same way.

LNW71LSH000201

LNW71LSH001101
3. Select the inner spacer.

• Select spacers so that the measurements

above satisfy 0 mm (0 in) < (3) - (1) < 0.07
mm (0.0028 in).
• Note that there are 21 spacer sizes in
increments of 0.07 mm (0.0028 in), ranging
from 6.05 (0.2382 in) to 7.45 mm (0.2933
in).
4. Install the front side inner race to the shaft.
MG6HK-WE-0871.book 10 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1L-10 Power Take-Off (PTO) (6HK1)

NOTE:
Apply engine oil to the bearing for assembly.

5. Install the PTO idle gear.

MFW71LSH000801

8. Tighten the nut (2) via the lock washer (1).

MFW71LSH000601

Tightening torque
6. Install the inner spacer (1). 196 N⋅m (20 kg⋅m/145 lb⋅ft)

• After tightening the nut, measure the clearance

in the PTO idle gear axis direction.
- If the clearance is not within specifications,
1 replace the spacer and readjust it.

0 – 0.05 mm
Clearance in the axis direction
(0 – 0.002 in)

Friction starting torque

0.2 N⋅m (0.02 kg⋅m / 1.74 lb⋅in)

NOTE:
MFW71LSH000701 • Apply engine oil to the bearing for assembly.
• The clearance value in the direction of the axis is
important. Make adjustments so that it always falls
7. Install the rear side inner race (1). within the specified range.
• After tightening, bend the lock washer to fasten the
NOTE: nut.
Apply engine oil to the bearing for assembly.
MG6HK-WE-0871.book 11 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Power Take-Off (PTO) (6HK1) 1L-11

Installation
Installation of the PTO idle gear assembly

2 3
1

1
4

6
2

MFW71LSH000301

10

9
MFW71LMH000501

Legend
1. Idle gear A
2. Bearing (front)
3. Idle gear
4. Bearing (rear)
5. Lock washer
6. Shaft
7. Bolt
8. Nut
9. Inner spacer
10. Thrust collar

1. Install the idle gear assembly.

• The idle gear A and crank gear should be
aligned.

NOTE:
• The idle gear assembly should be securely installed
to the cylinder block installation section.
• Apply engine oil to the bearing just before
installation.
• Apply engine oil to the inner circumference of the
bushing and the thrust contact surface of idle gear
A.
• Take sufficient care to ensure that the thrust collar
does not come off.
MG6HK-WE-0871.book 12 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1L-12 Power Take-Off (PTO) (6HK1)

2. Apply molybdenum-disulfide to the bolt seat
surface and thread section, then tighten it at the 1
specified torque.

Tightening torque
98 N⋅m (10 kg⋅m/72 lb⋅ft) →
angle method 60° to 90°

• Confirm that the bolt is tightened at 156.8 N⋅m

(16 kg⋅m / 116 lb⋅ft) or more in the tightening
direction.
3. Install the flywheel housing. 2
• Refer to "Timing Gear, Flywheel, and Flywheel
Housing" in Section 1B, Engine Mechanical.
4. Install the idle gear cover.
• Apply a thin layer of grease to the O-ring (1) to
install it.
• Apply liquid gasket (ThreeBond 1207C) to
seven places on the flange surface (2) and the
bolt seat surface (3).
• Tighten the bolt at the specified torque.

3
Tightening torque
4
40 N⋅m (4.1 kg⋅m/30 lb⋅ft) MFW71LMH000301

NOTE: Installation of the PTO crankshaft gear assembly

After firmly fitting it in, do not hammer the cover section 1. Position the crankshaft gear to the crankshaft
(4). knock pin, then tap with a rubber hammer to set it.
2. Install the oil seal retainer.
• Apply liquid gasket (ThreeBond 1207C) when
installing the part.
3. Install the slinger oil seal set to between the
crankshaft gear and oil seal retainer.
• Refer to "Timing Gear, Flywheel, and Flywheel
Housing" in Section 1B, Engine Mechanical.
4. Install the flywheel.
• Refer to "Timing Gear, Flywheel, and Flywheel
Housing" in Section 1B, Engine Mechanical.
5. Install the transmission.
• Refer to "Transmission ASM" in Section 5C,
Manual Transmission.
MG6HK-WE-0871.book 13 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Power Take-Off (PTO) (6HK1) 1L-13

Installation of the PTO assembly

2
3
4
5
6
7
8
9
1 10
11

21
20
19 18
17
16
15 14
13

12

MFW71LLF000701

Legend
1. Flywheel housing (PTO specification) 12. Idle gear cover
2. Front bearing 13. Bolt
3. PTO gear assembly 14. Nut
4. Rear bearing 15. Lock washer
5. Oil thrower 16. Idle gear
6. O-ring 17. Rear bearing
7. Bearing case 18. Outer spacer
8. Oil seal 19. Inner spacer
9. Flange 20. Front bearing
10. O-ring 21. Shaft
11. Nut

1. Apply a thin layer of engine oil to the O-ring and 3. Install the PTO assembly to the flywheel housing
install to the bearing case. and tighten the bearing case at the specified
2. Firmly fit the front bearing outer into the gearcase. torque.
• Apply engine oil to the ball part of the bearing
before firmly fitting it in.
Tightening torque
42 N⋅m (4.3 kg⋅m/31 lb⋅ft)
MG6HK-WE-0871.book 14 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

1L-14 Power Take-Off (PTO) (6HK1)

4. Install the oil pipe of the PTO gear unit.
• Install the clip.
• Tighten the oil pipe and clip at the specified
torque.

Tightening torque
(1) 27.5 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(2) 8.8 N⋅m (0.9 kg⋅m/78 lb⋅in)
(3) 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(4) 41.2 N⋅m (4.2 kg⋅m/30 lb⋅ft)

2
1

MFW71LSH001201
MG6HK-WE-0871.book 15 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

Power Take-Off (PTO) (6HK1) 1L-15

Tightening Torque Table

e d

MFW71LLF000301

(a) 42 N⋅m (4.3 kg⋅m / 31 lb⋅ft)

(b) 480 N⋅m (48.9 kg⋅m / 353.7 lb⋅ft)
(c) 98 N⋅m (10 kg⋅m / 72 lb⋅ft) → Angle method 60° to 90°
(d) 196 N⋅m (20 kg⋅m / 145 lb⋅ft)
(e) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
MG6HK-WE-0871.book 1 ページ ２０１１年５月１９日　木曜日　午後１２時１４分

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MG6HK-WE-0871_69199奥付 2011.5.7 9:24 AM ページ 1

Published: May, 2011 All rights reserved.

Seventh Edition

WORKSHOP MANUAL
ENGINE
(6HK1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
MG6HK-WE-0871_69199奥付 2011.5.7 9:24 AM ページ 2
 2008-2011MY
2008-2011MY

WORKSHOP MANUAL

WORKSHOP MANUAL ENGINE (6HK1 model)

ENGINE
(6HK1 model)

No.MG6HK-WE-0871