Service Manual

6D16 Diesel Engine

DP80 T32B-00011-up
DP90 T32B-50001-up
DP100 3DP-00001-up
DP115 4DP-00001-up
DP135 5DP-00001-up
DP150 6DP-00011-up

For use with Chassis Service Manual. 99709-68130

Downloaded from www.Manualslib.com manuals search engine

 diesel engine GROUP INDEX

Shop Manual HOW TO READ THIS MANUAL

GENERAL ........................................... 00
(for industrial use)
ENGINE............................................... 11

LUBRICATION .................................... 12
FOREWORD
FUEL AND ENGINE CONTROL .......... 13
This Shop Manual is published for the information and
COOLING............................................ 14
guidance of personnel responsible for maintenance of
6D16 diesel engine, and includes procedures for
adjustment and maintenance services. INTAKE AND EXHAUST ...................... 15
We earnestly look forward to seeing that this manual
is made full use of in order to perform correct service ELECTRICAL SYSTEM ....................... 54
with no wastage.
SPECIAL EQUIPMENT ....................... 61
For more details, please consult your nearest
authorized CatTM dealer or distributor.
Kindly note that the specifications and maintenance
service figures are subject to change without prior
notice in line with improvement which will be effected
from time to time in the future.

Applicable models
6D16
6D16-TLE

Pub. No. 99709-68130

Downloaded from www.Manualslib.com manuals search engine

 HOW TO READ THIS MANUAL
How This Manual Is Compiled

• This manual is compiled by classifying various systems into certain groups.

• Each group contains specifications; troubleshooting; maintenance service standards; tightening torque;
lubricant, fluid and sealant; special tools; and service procedure.

• Page enumeration is independent by every group where first page is always 1.

Group No. Group denomination Contents

00 General General specifications, engine No. and name plate, precautions for
maintenance operations, table of standard tightening torques
11 Engine Engine body
12 Lubrication Lubrication system
13 Fuel and engine control Fuel system
14 Cooling Cooling system
15 Intake and exhaust Intake and exhaust system, intercooler
54 Electrical system Alternator, starter, preheating system, engine start system, automatic
stop system
61 Special equipment Air compressor

ii
Downloaded from www.Manualslib.com manuals search engine
 General Explanation of This Manual

● Specifications
Particulars relative to maintenance service are made.

● Structure and operation

(1) Regarding conventional equipment, descriptions are made in brief.
(2) Regarding new equipment, descriptions of system and operating condition are made in detail.

● Troubleshooting
Symptoms of troubles and possible causes are described comparatively.

● Inspection and adjustment mounted in vehicle

Descriptions are made regarding inspection and adjustment of units mounted in vehicle.

● Service procedure
In principle, an explanation is given at the spread title page so that the service procedure can be understood.
Servicing points are explained as a supplementary explanation.

Regarding the design of this manual

4
1a
1

1b
6

3
1. ............... Illustration for disassembly and assembly or removal and installation: 3-D exploded view of component
parts is displayed.
1a. ........ Names of parts show an example of the disassembly (removal) sequence.
1b. ........ When the assembly (installation) sequence differs from the disassembly (removal) sequence, an
example of the assembly (installation) sequence is shown.
2. ............... Service standards are shown collectively, classified by location.
3. ............... Tightening torques are shown collectively, classified by location.
4. ............... Points of lubricant, fluid and sealant application are shown collectively, classified by location.
5. ............... Special tools to be used are shown collectively, classified by location.
6. ............... When it is considered hard to understand the service procedure, just by the foregoing description, a
supplementary description of the service procedure is given.
iii
Downloaded from www.Manualslib.com manuals search engine
 HOW TO READ THIS MANUAL
1. Illustration for disassembly and assembly or removal and installation

This shows that the appropriate service This shows the key No. of the part. In the text,
procedure is described in the text. this No. is referred to uniformly throughout.

This shows an example of

the disassembly (removal)
sequence.

This shows that the service

procedure is described in
another section.
P. -
: shows reference page
within the same group.
Gr
: shows reference group
within the same book.

No service procedure is
referred to in this section,
but the item can be an
Meaning of symbols objective of various
: shows that the tightening torque is procedures.
specified.
This is shown when the assembly (installation)
: shows that application of lubricant,
sequence is not the reverse of the disassembly
fluid or sealant is required.
(removal) sequence.
: shows that the part should not be
reused.
This shows that a repair kit is available.

iv
Downloaded from www.Manualslib.com manuals search engine
 2. Service standards table
Only the relevant service standards are shown.

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
1, 11 Clearance between strap bolt and strap 0.01 to 0.16 0.3 (0.0118) Replace
plate (0.0039 to 0.0629)
7 Pressure spring Installed load 835 N 710 N Replace
(Installed length 49.1) (85 kgf) (72.3 kgf)
[187.7 lbf] [159.6 lbf]
Tilt 2.9 (1.1417) or less 5.0 (0.197) Replace

This shows the key No. of the relevant part.

3. Tightening torque table

This shows specified tightening torque.

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks

1 Strap bolts (Strap bolt mounting) 39 to 59 (4 to 6) [28.8 to 43.5] –
4 Bolt (Lock plate mounting) 5.9 to 7.8 (0.6 to 0.8) [4.3 to 10.5] Wet

This shows the key No. of the relevant part. This shows that the item
is to be tightened wet.

4. Lubricants and sealant table

Only the relevant lubricants and sealant are shown.

This shows the application point.

Lubricants and sealant
Location Points of application Kinds Quantity
1 Thread area of bolt LOCTITE 272 As required
10, 16 Friction surfaces of release lever plate and release Molybdenum disulfide grease As required
lever [NLGI No. 2 (Li soap)]

This shows the key No. of the relevant part. This shows the specified brand.

v
Downloaded from www.Manualslib.com manuals search engine
 HOW TO READ THIS MANUAL
5. Special tools table
Only the relevant special tools are shown. Purpose of special tools is shown.

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Removal and installation of

11 Clutch installer MH061051
clutch cover

01277

Adjust release lever

16 Master plate MH062291
heights

01278

This shows the key No. of the relevant part. Quote this number when placing
an order for the part.

6. Service procedure

This indicates a special This shows the key No. of the relevant part.
service tool.

11 Removal and installation of clutch cover

• Depress pressure spring 7 using clutch installer, then remove
the following parts:
Strap bolt 1, washer 2, washer 3, bolt 4, lock plate 5, support nut 6
• Loosen the clutch installer gradually, then remove clutch cover 11
when the pressure spring is fully released.
• For installation, follow the removal sequence in reverse.

01281

The key No. referred to in the text is always the Servicing procedures of disassembly (removal),
same as the key No. shown in the illustration. assembly (installation), inspection, adjustment,
etc. are shown collectively.

vi
Downloaded from www.Manualslib.com manuals search engine
 Terms and Units
The terms and units in this manual are defined as follows.

● This service manual contains important cautionary instructions and supplementary information under the following
four headings which identify the nature of the instructions and information:

DANGER Precautions that should be taken in handling potentially dangerous substances such
as battery fluid and coolant additives.

WARNING Precautionary instructions, which, if not observed, could result in serious injury or
death.

CAUTION Precautionary instructions, which, if not observed, could result in damage to or

destruction of equipment or parts.

NOTE Suggestions or supplementary information for more efficient use of equipment or a

better understanding.

● Front and rear

The terms “front” is the fan side and “rear” the flywheels side of the engine.

● Left and right

The terms “right” and “left” shall be used to indicate the side as viewed from the flywheel side of the engine.

● Terms of service standards

(1) Standard value
Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard
clearance between two parts when assembled, and the standard value for an assembly part, as the case may be.
The figure in [ ] is the basic diameter.
(2) Limit
When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and
must be replaced or repaired.

● Tightening torque
Excessive or insufficient tightening torque has particular importance in respect of performance. Accordingly,
tightening torque is specified in locations that are to be tightened.
Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.
When the item is to be tightened in a wet state, wet is indicated. Where there is no indication, read it as dry, and
tighten at specified torque.

● Unit
Length, weight, surface area and capacity are in SI units with foot-pound units are given in brackets.
Tightening torques and other parameters are given in SI units with metric and foot-pound units added in brackets ( )
and [ ].
Example: 390 N·m (40 kgf·m) [289 lbf·ft]
Foot-pound unit
Metric unit
SI unit
Temperatures are given in degrees Celsius with degrees Fahrenheit given brackets.
For the conversion into the foot-pound system, refer to the following conversion table.
vii
Downloaded from www.Manualslib.com manuals search engine
 HOW TO READ THIS MANUAL
Unit SI unit {metric unit} Conversion factor
Force N {kgf} 9.80665 N {1 kgf}
Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m}
2
Positive pressure kPa {kgf/cm } 98.0665 kPa {1 kgf/cm2}
Pressure kPa {mmHg} 0.133322 kPa {1 mmHg}
Vacuum pressure
Pa {mmH2O} 9.80665 Pa {1 mmH2O}
Volume dm3 {L} 1 dm3 {1 L}
Power kW {PS} 0.7355 kW {1 PS}
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W {kcal/h} 1.16279 W {1 kcal/h}
Angle ° –
Temperature °C –
Electric current A –
Voltage V –
Resistance Ω –
Electric power W –

Unit SI unit Foot-pound unit Conversion rate

Force N (Newton) lbf 1 N = 0.2248 lbf
Moment of force N·m ft.lbs 1 N·m = 0.7375 ft.lbs
Pressure kPa (kilopascal) psi 1 kPa = 0.145 psi
1 kPa = 0.2953 in. Hg
Volume L gal. 1 L = 0.2642 gal. (U.S.)
1 L = 0.220 gal. (Imp.)
cm3 oz 1 cm3 = 0.033814 oz (U.S.)
1 cm3 = 0.035195 oz (Imp.)
cm3 cu.in. 1 cm3 = 0.061023 cu.in.
Power kW (kilowatt) PS 1 kW = 1.3596 PS
Temperature °C °F t°C = (1.8t°C + 32)°F
Mass quantity of matter kg lb 1 kg = 2.2046 lb
g oz 1 g = 0.035274 oz
Dimension m ft. 1 m = 3.2808 ft.
mm in. 1 mm = 0.03937 in.

viii
Downloaded from www.Manualslib.com manuals search engine
 GENERAL SPECIFICATIONS
Item Specifications
Engine model 6D16 6D16-TLE
Type 6-cylinder in-line, water-cooled 4-cycle diesel
Combustion chamber type Direct injection type
Valve mechanism Overhead valve (OHV) type
Bore × Stroke mm (in.) 118 × 115 (4.65 × 4.53)
Total displacement cc (cu. in.) 7545 (460.4)
Compression ratio 17.5
Empty mass kg (lb)* 500 (1.102) 560
* Empty mass as measured according to Mitsubishi Motors Corporation standard.

Engine Outputs Classified By Application

Engine model 6D16 6D16-TLE
Middle-speed High-speed
Application specification specification
Intermittent rated output kW (HP) 71 (95)/1500 106 (142)/1500 101 (136)/1500
85 (114)/1800 123 (165)/1800 121 (163)/1800
93 (125)/2000 131 (176)/2000 131 (175)/2000
101 (135)/2200 140 (188)/2200 139 (186)/2200
111 (149)/2500 147 (197)/2500
120 (161)/2800 151 (203)/2800
Coutinuous rated output kW (HP) 65 (87)/1500 96 (129)/1500 92 (123)/1500
77 (103)/1800 111 (149)/1800 110 (148)/1800
84 (113)/2000 119 (160)/2000 118 (158)/2000
93 (125)/2200 127 (170)/2200 125 (168)/2200
101 (135)/2500 133 (178)/2500
110 (147)/2800 137 (184)/2800

NOTE
1. The output (SAE, gross) is corrected to standard ambient conditions based on SAE J1349.
2. The continuous rated output allows 10% (one hour) overload operation.

00-2
Downloaded from www.Manualslib.com manuals search engine
 ENGINE NUMBER AND NAME PLATE 00

The serial number for engine is assigned to the respective engine in manufacturing sequence: every engine has its
own number. This number is required for incidental inspection of the engine. Please do not fail to mention this
number to the dealers when ordering spare parts.

Engine Number
Engine number 1 is punch-marked on the left of the crankcase.

Example: 6D16–

Engine
Engine number
model

18769

Name Plate
The name plate is attached to the portion shown in the illustration, and
indicate the following items.

18779

1 Engine model
2 Total displacement
3 Maximum output
4 Valve clearance
5 Firing order
6 Fuel injection timing

18780

00-3
Downloaded from www.Manualslib.com manuals search engine
 PRECAUTIONS FOR MAINTENANCE OPERATION
In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record
of the accumulated mileage, operating condition, what the customer's demand is, and other information that may be
necessary.
Prepare the steps to be taken and perform efficient and wasteless maintenance procedure.

Determine where the fault exists and check for the cause to see
whether removal or disassembly of the part is necessary. Then follow
the procedure specified by this manual.

18770

Perform maintenance work at a level area.

Prepare the following.
• Prepare general and special tools necessary for the maintenance
work.

WARNING
Do not attempt to use tools other than special tools where use
of special tools is specified in this manual. This will avoid
00009
injury or damage.

Pay special attention to safety when removing or installing heavy items

such as engines, transmissions.

When lifting up heavy items using cables, pay special attention to the
following points:
• Check the mass of the item to be lifted and use a cable capable of
lifting that mass.

14194

• If you do not have the specified lifting hanger, secure the item using
cable taking the point-of-balance of the item into consideration.

14195

• You must work in a position where you will not be injured even if the
cable comes undone and the lifted item falls.

00-4
Downloaded from www.Manualslib.com manuals search engine
 00

Be particularly careful not to work in shoes that have oily soles and are
slippery. When working as a team of two or more, arrange signals in
advance and keep confirming safety. Be careful not to accidentally
bump switches or levers.

00012

Check for oil leakage before cleaning the area having the fault
otherwise you might miss detecting the leakage.
Prepare replacement part(s) beforehand.

00014

Replace oil seals, packing, O-rings and other rubber parts; gaskets and
split pins with new parts whenever any of them has been removed. Use
only genuine MITSUBISHI replacement parts.

00015

On disassembly, visually inspect all parts for wear and tear, cracks,
damage, deformation, degradation, rust, corrosion, smoothness in
rotation, fatigue, clogging and any other possible defect.

00016

00-5
Downloaded from www.Manualslib.com manuals search engine
 PRECAUTIONS FOR MAINTENANCE OPERATION
Put alignment marks on part combinations before disassembly and
arrange the disassembled parts neatly. This will help avoid mismating
of the parts later.
Put the alignment marks, punch marks, etc. where performance and
appearance will not be affected.
Cover the area left open after removal of parts to keep it free from dust.

CAUTION
00017
• Take care to avoid mixing up numerous parts, similar parts, left
and right, etc.
• Keep new parts for replacement and original (removed) parts
separate.

Apply the specified oil or grease to U-packings, oil seals, dust seals
and bearings during assembly.
Use only the specified oil, grease, etc. for lubricant, remove the excess
immediately after application with a piece of waste, etc.

CAUTION
When the specified lubricant, fluid and sealant is not available,
you may use an equivalent.
00018

Wear goggles when using a grinder or welder. Pay full attention to

safety by wearing gloves when necessary. Watch out for sharp edges,
etc. that might injure your hands or fingers.

00019

Before carrying out maintenance work on the electric system,

disconnect the negative terminals of the batteries to prevent them from
short-circuiting and burning-out.

CAUTION
Be sure to turn starter and lighting switches, etc. off before
disconnecting or connecting battery terminals, because the
semiconductors can be damaged.
14184

00-6
Downloaded from www.Manualslib.com manuals search engine
 00

Take care when handling sensors, relays, etc. which are vulnerable to
shock and heat. Do not attempt to remove the cover from, or apply
paint to, the electronic control unit.

00021

Pull the connector, and not the harness lead, to separate connectors.
To separate a lock-type connector, first push toward arrow mark. To
reconnect a lock-type connector, press the separated parts until they
click together.

00022

When washing the vehicle, cover the electric system parts and
instruments with waterproof material beforehand (Cover with vinyl
sheet or the like). Keep water away from harness wire connectors and
sensors. If any of them should get wet, wipe them off immediately.

00023

When using an electric welder, such electronic parts that are directly
connected to the batteries might be damaged due to the flow of current
from the welder that flows through the negative circuit. Parts that have
switches might be subject to the same danger if the switches are left
on.
Therefore, do not fail to observe the following.
• Connect the negative terminal of the welder as near as possible to
the area that is to be welded.
• Disconnect the negative terminals of batteries.

To apply voltage for testing, check that the positive and negative cables
are connected properly, then increase voltage gradually from 0 volt. Do
not apply voltage higher than the specified value.
In particular, pay close attention to the electronic control unit and
sensors, since they are not always fed the battery voltage.

14185

00-7
Downloaded from www.Manualslib.com manuals search engine
 PRECAUTIONS FOR MAINTENANCE OPERATION
When using testers or the like for continuity tests, be careful not to
allow test probes to touch the wrong terminals.

00027

Measurement Procedures Using Connectors

Test with connectors engaged (continuity through circuit obtained)
<Waterproof connector>
Prepare a test harness and connectors A, then connect if between the
two parts of harness B that is to be tested. Check the circuit by
touching test probe C to the test connector.
Never insert the test probe from the harness side of the waterproof
connection, or waterproof performance might be diminished causing
corrosion of the connector.
02587

<Non-waterproof connector>
Insert test probe C from the harness side of the connector. Where
control units, etc. have connectors that are too small to accept the test
probe, do not force the test probe into them.

02588

Test with connectors disengaged

Using female pins
Insert a test probe into a terminal. However, do not force the probe into
the terminal, or it will cause a poor contact.

02589

00-8
Downloaded from www.Manualslib.com manuals search engine
 00

Using male pins

Touch the pins directly using test probes.

CAUTION
Be sure that you do not short circuit the connector pins when
you use the test probe because this could damage the internal
circuit of the electronic control unit.

02590

Connector Inspection Procedures

Visual inspection
Check for loose connection and poor engagement.

02591

Check if harnesses are broken by pulling gently around the terminals.

02592

Check for a decrease in contact pressure between the male and female
terminals.

02593

Check for poor contact caused by connector pins having fallen out,
rusted terminals or foreign particles.

00-9
Downloaded from www.Manualslib.com manuals search engine
 PRECAUTIONS FOR MAINTENANCE OPERATION
Connector pin fall out inspection
Damaged connector pin stoppers can cause poor engagement of the
terminals (male and female pins) even if the connector body is secured,
and might cause some pins to fall out. Check if the pins have fallen out
from the connector by pulling each harness gently.

02594

Inspection Procedures for Blown Fuses

Remove fuse B and measure resistance between the loaded side of the
fuse and ground.
Turn on all circuit switches (connected to the fuse). If the resistance
value reading is approximately 0, a short has occurred between the
switch and the loaded point. A value of other than zero may indicate
that the fuse was blown by a temporary short but the short is no longer
present.

The major causes of a short circuit are as follows:

• Harness stuck onto the vehicle body.
• Harness sheath damaged by friction or heat.
• Water in connectors or circuits.
• Mistakes (accidental short circuits)

A: Battery
B: Fuse
C: Loaded switch
D: Load
E: Short circuit
02596

Precautions for Handling Alternator

When servicing the alternator, pay attention to the following:
• Do not connect the alternator with battery polarities reversed.
If the alternator is connected with reversed polarities, a large current
flow from the battery to the alternator occurs, and the diode or
regulator might be damaged.

04746

00-10
Downloaded from www.Manualslib.com manuals search engine
 00

• While the engine is running, do not remove the battery terminals. If

the battery terminals are removed at that time, a surge voltage is
generated and the diode or regulator might be weakened.

04747

• Do not use a high-voltage tester such as a megger for inspection. If

a high-voltage tester is used, the diode or regulator might be
destroyed.

02371

• Do not splash water over the alternator.

If water is directly splashed over the alternator, individual
components will be short-circuited and might be destroyed.

05165

• Do not short-circuit terminal B and terminal L while running the

alternator.
If the terminals are short-circuited while the alternator is running, the
diode trio might be destroyed.

04749

• Disconnect the battery terminals before quick-charging the battery.

Quick-charging without disconnecting the battery terminals might
damage the diode or regulator.

05166

00-11
Downloaded from www.Manualslib.com manuals search engine
 BUY NOW

Downloaded from www.Manualslib.com manuals search engine

 TABLE OF STANDARD TIGHTENING TORQUES
• Use specified bolts and nuts and tighten them at specified torques according to the following table, unless
otherwise specified.
• Threads and contact seats shall be dry.
• Where there is a difference in strength classification between the nut and bolt (or stud bolt), the torque specified
for the bolt shall apply.

Hex-head Bolt and Stud Bolt Unit: N·m (kgf·m) [lbf·ft]

Strength
4T 7T 8T
classification
Repre-
sentation
Diameter
symbol (Stud) (Stud) (Stud) 02154

2 to 3 4 to 6 5 to 7
M5 (0.2 to 0.3) – (0.4 to 0.6) – (0.5 to 0.7) –
[1.48 to 2.21] [2.95 to 4.43] [3.69 to 5.16]
4 to 6 7 to 11 8 to 12
M6 (0.4 to 0.6) – (0.7 to 1.1) – (0.8 to 1.2) –
[2.95 to 4.43] [5.16 to 8.11] [5.90 to 8.85]
9 to 14 17 to 26 20 to 29
M8 (0.9 to 1.4) – (1.7 to 2.6) – (2.0 to 3.0) –
[6.64 to 10.3] [12.5 to 19.2] [14.8 to 21.4]
19 to 28 18 to 26 36 to 52 33 to 49 45 to 60 41 to 59
M10 (1.9 to 2.8) (1.8 to 2.7) (3.5 to 5.5) (3.5 to 5.0) (4.5 to 6.0) (4.3 to 6.9)
[14.0 to 20.6] [13.3 to 19.2] [26.6 to 38.4] [24.3 to 36.1] [33.2 to 44.3] [30.2 to 43.5]
35 to 50 31 to 46 70 to 95 65 to 85 85 to 110 75 to 100
M12 (3.4 to 5.0) (3.1 to 4.7) (7.0 to 9.5) (6.5 to 8.5) (8.5 to 11) (7.5 to 10)
[25.8 to 36.9] [22.9 to 33.9] [51.6 to 70.1] [47.9 to 62.7] [62.7 to 81.1] [55.3 to 73.8]
60 to 85 55 to 75 120 to 160 110 to 140 130 to 180 120 to 160
M14 (6.0 to 8.5) (5.5 to 7.5) (12 to 16) (11 to 14) (13 to 18) (12 to 17)
[44.3 to 62.7] [40.6 to 55.3] [88.5 to 118] [81.1 to 103] [95.9 to 133] [88.5 to 118]
90 to 130 90 to 120 180 to 240 160 to 220 200 to 270 190 to 260
M16 (9.5 to 13) (9.0 to 12) (18 to 24) (16 to 22) (20 to 27) (19 to 26)
[66.4 to 95.9] [66.4 to 88.5] [133 to 177] [118 to 162] [148 to 199] [140 to 192]
140 to 190 120 to 160 260 to 340 220 to 290 290 to 390 260 to 340
M18 (14 to 19) (12 to 16) (25 to 35) (22 to 30) (30 to 40) (26 to 35)
[103 to 140] [88.5 to 118] [192 to 251] [162 to 214] [214 to 288] [192 to 251]
190 to 260 170 to 230 350 to 470 320 to 420 410 to 550 370 to 490
M20 (19 to 26) (17 to 23) (36 to 48) (32 to 43) (41 to 56) (37 to 50)
[140 to 192] [125 to 170] [251 to 347] [236 to 310] [302 to 406] [273 to 361]
260 to 340 230 to 300 470 to 640 430 to 570 550 to 740 490 to 670
M22 (26 to 35) (23 to 31) (48 to 65) (43 to 58) (56 to 75) (50 to 68)
[192 to 251] [170 to 221] [347 to 472] [317 to 420] [406 to 546] [361 to 494]
340 to 450 290 to 390 630 to 840 540 to 730 730 to 980 630 to 840
M24 (34 to 46) (29 to 40) (63 to 86) (55 to 74) (74 to 100) (64 to 86)
[251 to 332] [214 to 288] [465 to 620] [398 to 538] [538 to 723] [465 to 620]

00-12
Downloaded from www.Manualslib.com manuals search engine
 00

Hex-head Flange Bolt Unit: N·m (kgf·m) [lbf·ft]

Strength
4T 7T 8T
classification
Repre-
sentation
Diameter
symbol 02154

4 to 6 8 to 12 9 to 14
M6 (0.4 to 0.6) – (0.8 to 1.2) – (0.9 to 1.4) –
[2.95 to 4.43] [5.90 to 8.85] [6.64 to 10.3]
10 to 15 19 to 28 22 to 32
M8 (1.0 to 1.5) – (1.9 to 2.8) – (2.2 to 3.3) –
[7.38 to 11.1] [14.0 to 20.6] [16.2 to 23.6]
21 to 30 20 to 28 39 to 58 37 to 53 50 to 65 45 to 65
M10 (2.1 to 3.1) (1.9 to 2.9) (3.9 to 6.0) (3.6 to 5.4) (5.0 to 6.5) (4.5 to 6.5)
[15.5 to 22.1] [14.8 to 20.6] [28.8 to 42.8] [27.3 to 39.1] [66.8 to 47.9] [33.2 to 47.9]
38 to 54 35 to 51 80 to 110 70 to 95 90 to 120 85 to 110
M12 (3.8 to 5.5) (3.4 to 5.2) (8.0 to 11) (7.0 to 9.5) (9.0 to 12) (8.5 to 11)
[28.0 to 39.8] [25.8 to 37.6] [59.0 to 81.1] [51.6 to 70.1] [66.4 to 88.5] [62.7 to 81.1]

00-13
Downloaded from www.Manualslib.com manuals search engine
 TABLE OF STANDARD TIGHTENING TORQUES
Hex-head Nut Unit: N·m (kgf·m) [lbf·ft]
Strength
4T 6T
classification
Repre-
sentation

Diameter 02155
symbol Standard screw Coarse screw Standard screw Coarse screw
2 to 3 4 to 6
M5 (0.2 to 0.3) – (0.4 to 0.6) –
[1.48 to 2.21] [2.95 to 4.43]
4 to 6 7 to 11
M6 (0.4 to 0.6) – (0.7 to 1.1) –
[2.95 to 4.43] [5.16 to 8.11]
9 to 14 17 to 26
M8 (0.9 to 1.4) – (1.7 to 2.6) –
[6.64 to 10.3] [12.5 to 19.2]
19 to 28 18 to 26 36 to 52 33 to 49
M10 (1.9 to 2.8) (1.8 to 2.7) (3.5 to 5.5) (3.5 to 5.0)
[14.0 to 20.6] [13.3 to 19.2] [26.6 to 38.4] [24.3 to 36.1]
35 to 50 31 to 46 70 to 95 65 to 85
M12 (3.4 to 5.0) (3.1 to 4.7) (7.0 to 9.5) (6.5 to 8.5)
[25.8 to 36.9] [22.9 to 33.9] [51.6 to 70.1] [47.9 to 62.7]
60 to 85 55 to 75 120 to 160 110 to 140
M14 (6.0 to 8.5) (5.5 to 7.5) (12 to 16) (11 to 14)
[44.3 to 62.7] [40.6 to 55.3] [88.5 to 118] [81.1 to 103]
90 to 130 90 to 120 180 to 240 160 to 220
M16 (9.5 to 13) (9.0 to 12) (18 to 24) (16 to 22)
[66.4 to 95.9] [66.4 to 88.5] [133 to 177] [118 to 162]
140 to 190 120 to 160 260 to 340 220 to 290
M18 (14 to 19) (12 to 16) (25 to 35) (22 to 30)
[103 to 140] [88.5 to 118] [192 to 251] [162 to 214]
190 to 260 170 to 230 350 to 470 320 to 420
M20 (19 to 26) (17 to 23) (36 to 48) (32 to 43)
[140 to 192] [125 to 170] [251 to 347] [236 to 310]
260 to 340 230 to 300 470 to 640 430 to 570
M22 (26 to 35) (23 to 31) (48 to 65) (43 to 58)
[192 to 251] [170 to 221] [347 to 472] [317 to 420]
340 to 450 290 to 390 630 to 840 540 to 730
M24 (34 to 46) (29 to 40) (63 to 86) (55 to 74)
[251 to 332] [214 to 288] [465 to 620] [398 to 538]

00-14
Downloaded from www.Manualslib.com manuals search engine
 00

Hex-head Flange Nut Unit: N·m (kgf·m) [lbf·ft]

Strength
4T
classification
Repre-
sentation

Diameter 02155
symbol Standard screw Coarse screw
4 to 6
M6 (0.4 to 0.6) –
[3.69 to 5.16]
10 to 15
M8 (1.0 to 1.5) –
[2.95 to 4.43]
21 to 30 20 to 28
M10 (2.1 to 3.1) (1.9 to 2.9)
[7.38 to 11.1] [28.0 to 39.8]
38 to 54 35 to 51
M12 (3.8 to 5.5) (3.4 to 5.2)
[15.5 to 22.1] [14.8 to 20.6]

00-15
Downloaded from www.Manualslib.com manuals search engine
 TABLE OF STANDARD TIGHTENING TORQUES
Tightening torque for flare nut for general purpose Unit: N·m (kgf·m) [lbf·ft]
φ4.76 mm φ6.35 mm φ8 mm φ10 mm φ12 mm φ15 mm
Pipe diameter
(φ0.187 in.) (φ0.250 in.) (φ0.315 in.) (φ0.394 in.) (φ0.472 in.) (φ0.591 in.)
Tightening torque 17 25 39 59 88 98
(1.7) (2.6) (4.0) (6.0) (9.0) (10.0)
[12.5] [18.4] [28.8] [43.5] [64.9] [72.3]

Tightening torque for air piping nylon tube for general purpose
{DIN type} Unit: N·m (kgf·m) [lbf·ft]
6 × 1 mm 10 × 1.25 mm 12 × 1.5 mm 15 × 1.5 mm
Standard diameter
(0.236 × 0.0394 in.) (0.394 × 0.0492 in.) (0.472 × 0.0591 in.) (0.591 × 0.0591 in.)
Tightening torque
+6 +10 +10 +5
20 29 49 54
−0 −0 −0 −0
+0.6 +1.0 +1.0 +1.0
2.0 3.0 5.0 5.5
−0 −0 −0 −0
+0.4 +0.7 +0.7 +0.7
14.8 21.4 36.1 39.8
−0 −0 −0 −0

Tightening torque for air piping nylon tube for general purpose
{SAE type} Unit: N·m (kgf·m) [lbf·ft]
Standard diameter 1/4 in. 3/8 in. 1/2 in. 5/8 in.
Tightening torque
+4 +5 +5 +5
13 29 49 64
−0 −0 −0 −0
+0.4 +0.5 +0.5 +0.5
1.3 3.0 5.0 6.5
−0 −0 −0 −0
+0.30 +0.4 +0.4 +0.4
9.59 21.4 36.1 47.2
−0 −0 −0 −0

00-16
Downloaded from www.Manualslib.com manuals search engine
 SPECIFICATIONS
Item Specifications
Engine model 6D16 6D16-TLE
Type 6-cylinder, in-line, water-cooled, 4-cycle diesel
Combustion chamber type Direct injection
Valve mechanism Overhead valve
Cylinder bore × stroke mm (in.) φ118 × 115 (φ4.65 × 4.53)
Total displacement cc (cu. in.) 7545 (460.4)
Compression ratio 17.5

11-2
Downloaded from www.Manualslib.com manuals search engine
 STRUCTURE AND OPERATION 11

1. Cylinder Head and Crankcase

1 Connecting plate
2 Glow plug
3 Cylinder liner
4 Crankcase
5 Water jacket
6 Piston
7 Injection nozzle
8 Cylinder head

A: Cylinder liner size mark

Outer diameter mark: 1, 2, 3
Inner diameter mark: A, B

• The cylinder liners 3 are a dry type liners

that are easier to remove than wet liners.
Liners are press-fitted into the crankcase 4.
• The cylinder liners 3, crankcase 4, and
pistons 6 have size marks. They should be
combined as specified according to the size
marks. P.11-36
01925

11-3
Downloaded from www.Manualslib.com manuals search engine
 STRUCTURE AND OPERATION
2. Valve Mechanism
1 Exhaust valve
2 Inlet valve
3 Camshaft
4 Tappet
5 Push rod
6 Rocker shaft
7 Rocker shaft spring
8 Rocker
9 Rocker shaft bracket
10 Valve cap
11 Valve cotter
12 Upper retainer
13 Outer valve spring
14 Inner valve spring
15 Valve stem seal
16 Valve guide

• The valve stem seals 15 are fitted onto the

01926 valves 1, 2 to control the amount of
lubricant flowing onto the sliding surfaces of
the valves 1, 2 and valve guides 16.
• The valve springs 13, 14 are unevenly
pitched to prevent abnormal vibration at
high speeds. To prevent the inner and outer
springs from meshing with each other, the
springs are wound in opposite directions.
• To facilitate removal and reinstallation of
the camshaft from the rear end of the
crankcase, the diameter of each bushing is
smaller toward the front of the engine.
3. Connecting Rods
<6D16> <6D16-TLE> 1 Connecting rod bushing
2 Connecting rod
3 Connecting rod bearing
4 Connecting rod cap
5 Connecting rod bolt

A: Alignment mark
B: Weight mark stamp
(A, B, C, D, E, F, G, H, I, V, W, X, Y, Z:
<6D16>)
(A, B, C, D, E, F: <6D16-TLE>)

13622

11-4
Downloaded from www.Manualslib.com manuals search engine
 11

4. Pistons
A: Part number
B: “T” mark <6D16-TLE>
C: Size mark (A, B: <6D16, 6D16-TLE>)
D: Weight mark
: Front mark

16936

5. Timing Gears
1 Camshaft gear
2 No. 2 idler gear
3 No. 1 idler gear
4 Oil pump gear
5 Crankshaft gear
6 Air compressor drive gear or injection
pump drive gear
7 No. 1 idler gear

Each gear is stamped with a timing gear

alignment mark (“1”, “2”, “3”, or “4”) to facilitate
reassembly.

16937

6. Flywheel
1 Flywheel
2 Pilot bearing
3 Ring gear

A: Angle scale, cylinder number

01934

11-5
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING

Symptoms

Abnormal engine noise

Remarks

Low power output

Possible causes

Incorrect oil viscosity Gr 11

Incorrect/defective fuel Gr 13
Incorrect valve clearance
Defective cylinder head gasket
Worn valve/valve seat, and carbon deposits
Weakened valve spring
Worn/damaged piston ring(s)
Worn/damaged piston ring groove(s)
Incorrect injection timing Gr 13
Defective injection pump Gr 13
Defective cooling system Gr 14
Defective injection nozzle(s) Gr 13
Air trapped in fuel system Gr 13
Clogged air cleaner Gr 15
Clogged muffler Gr 15
Defective turbocharger Gr 15
Incorrectly fitted pipe(s)/hose(s) Gr 13
Injection pump, alternator, or other auxiliary device(s) defective/incorrectly fitted Gr 13, 54
Loose/damaged V-belt Gr 14
Incorrectly fitted crankshaft pulley
Defective air cleaner or muffler Gr 15
Defective valve spring(s)
Defective rocker shaft and bracket
Incorrect lubrication of rocker shaft bracket
Incorrect backlash in timing gears
Incorrect lubrication of timing gear peripheries and idler shafts
Worn connecting rod small end bushing and piston pin
Worn/damaged crankshaft pin and connecting rod big end bearing
Worn/damaged crankshaft journal and main bearing
Excessive end play in crankshaft and camshaft
Worn tappet(s) and camshaft

11-6
Downloaded from www.Manualslib.com manuals search engine
 ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Measuring Compression Pressure
Service standards
Location Maintenance item Standard value Limit Remedy
– Compression Each cylinder (at 200 rpm) 2550 kPa 1960 kPa Inspect
pressure (26 kgf/cm2) (20 kgf/cm2)
[370 psi] [284 psi]
Cylinder-to-cylinder – 390 kPa Inspect
pressure difference (4 kgf/cm2)
[56.6 psi]

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Compression Measuring compression

– MH061461
Gauge Adapter pressure

01942

Reductions in compression pressure should be used as a guide in determining the timing of engine overhauls. Take
measurements regularly and keep track of changes; an overview of pressure variations can be useful in fault
diagnosis.
During the engine's run-in period and after parts have been replaced, the compression pressure will increase slightly
as piston rings, valve seats, and other parts fit snugly in position. The pressure will then normalize as parts wear.
• Before inspections, check that the engine oil, starter, and battery are normal.
• Warm up the engine until the coolant temperature reaches 75 to 85°C (167 to 185°F).
• Turn off all lights and auxiliary devices.
• To prevent injection of fuel while cranking the engine by the starter, perform the following steps.
• Set the stop lever of the injection pump governor to the stop position. <Mechanical governor>
• Remove fuse 1 shown in the diagram below. For the terminal arrangement of the engine ECU, refer to Gr 13E.
<Electronic governor>

P 47396

11-8
Downloaded from www.Manualslib.com manuals search engine
 11

• Remove the injection nozzle A.

Gr 13

CAUTION
Cover the mounting holes and injection pipes to prevent the
entry of dust and dirt.

01938

• Cover the injection nozzle mounting hole B with a cloth C. Then,

turn the engine over with the starter and check that no foreign
matter adheres to the cloth.

WARNING
If any cylinder is cracked, coolant, engine oil, and fuel will
enter the cylinder through the crack. When the engine is
turned over, these substances will spray out of the nozzle
11735
mounting hole B at a high temperature. For safety, move away
from the nozzle mounting hole before turning over the engine.

• Fit the Compression Gauge Adapter onto an injection nozzle

mounting hole B together with a nozzle gasket. Then, connect the
compression gauge 1.
• Turn the engine over and measure the compression pressure.
• Measure the compression pressure in every cylinder and determine
the pressure differences between cylinders.
• If any compression pressure or cylinder-to-cylinder pressure
difference exceeds the specified limit, pour a little engine oil into the
01939 cylinder via the injection nozzle mounting hole B then take the
measurement again.
• If the compression pressure increases, there may be wear or
damage on piston rings and inner surfaces of cylinders.
• If the compression pressure does not increase, valves may be
seized or incorrectly seated, or the cylinder head gasket may be
defective.

11-9
Downloaded from www.Manualslib.com manuals search engine
 ON-VEHICLE INSPECTION AND ADJUSTMENT
2. Inspecting and Adjusting Valve Clearances
Service standards Unit: mm (in.)
Location Maintenance item Standard value Limit Remedy
– Valve clearance (when cold) 0.4 (0.0158) – Adjust

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
2, 3 Rocker arm adjusting screw lock nut 34 (3.5) [25.1] –

Valve clearances should be checked and adjusted when the engine is cold.

[Inspection]
• Bring piston No. 1 or piston No. 6 to the top-dead-centre (TDC)
position of its compression stroke. To do this, crank the engine until
the “1.6” mark inscribed on the flywheel is aligned with the pointer A
in the flywheel housing inspection window.
NOTE
Pistons whose push rods are not pushing up their rockers are at
top-dead-centre (TDC) of their compression strokes.
01940

• When piston No. 1 or piston No. 6 is at the TDC position of its

compression stroke, measure the clearance B of every valve
marked “ ” in the following table.

Piston No. 1 2 3 4 5 6

Valve arrangement In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.

No. 1 piston at TDC of compression

stroke
11620
No. 6 piston at TDC of compression
stroke

NOTE
To measure the clearance, insert a feeler gauge 1. The gauge
should be able to move in the gap, albeit not loosely. Accurate
measurements cannot be taken if the gauge moves loosely in the
gap.

11-10
Downloaded from www.Manualslib.com manuals search engine
 11

• If any measurement is out of specification, make adjustments as

follows:

[Adjustment]
• To adjust the valve clearance B, loosen the lock nut 2 and turn the
adjusting screw 3 until the feeler gauge 1 moves more stiffly in the
gap.
• After adjusting the clearance, tighten the lock nut 2. At this time, use
a screwdriver C to stop the adjusting screw 3 from turning. Next,
insert the feeler gauge 1 once more to confirm that the clearance B
is correct.
11621

11-11
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD AND VALVE MECHANISM

04134

● Disassembly sequence
1 Joint 8 Cylinder head bolt 12 Push rod
2 Oil filler cap 9 Rocker and bracket assembly 13 Tappet
3 Bolt P.11-16
4 Plate 10 Cylinder head and valve
*: Crankcase P.11-66
5 Rubber assembly P.11-20 A: Locating pin
6 Rocker cover gasket 11 Cylinder head gasket : Non-reusable part
7 Rocker cover

● Assembly sequence
Follow the disassembly sequence in reverse.

11-12
Downloaded from www.Manualslib.com manuals search engine
 11

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
12 Push rod runout – 0.4 (0.0157) Replace
13, Tappet-to-crankcase clearance 6D16 0.06 to 0.10 0.2 Replace
* [Basic diameter: (0.00237 to 0.00394) (0.00787) tappet
31 mm (1.220 in.)]
6D16-TLE 0.03 to 0.07 0.1
(0.00118 to 0.00276) (0.00394)

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
1 Joint 29 (3.0) [21.4] –
3 Rocker cover bolt 3.9 (0.4) [2.88] –
8 Cylinder head bolt M14 bolt 78 (8) [57.5] + 180° • Wet
(installation of rocker and • Can be reused
bracket assembly and cylinder up to 3 times
head and valve assembly)
M10 bolt 17 (1.75) [12.5] + 34 (3.5) [25.1] –

Lubricant
Location Points of application Specified lubricant Quantity
2 Rubber seal of oil filler cap Engine oil As required
8 Threads of cylinder head bolts Engine oil As required
12 Both ends of push rods Engine oil As required
13 Outer surfaces of tappets Engine oil As required

Special tools
Location Tool name and shape Part No. Application

Tightening cylinder head bolts

10 Socket Wrench MH063388
(M14 bolt only)

01984

◆ Service procedure
10 Cylinder head and valve assembly
[Removal]
• Before loosening the cylinder head bolts 8, loosen the adjusting
screw C on every rocker A that is compressing its valve spring B.

13021

11-13
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD AND VALVE MECHANISM
• Loosen and remove the cylinder head bolts 8 in the sequence
shown. Each cylinder head bolt should be loosened a little at a time.

01945

[Installation]
CAUTION
Before fitting any cylinder head bolt 8, check the punch marks
A on its head. Do not use the bolt if there are more than two
punch marks. The punch marks indicate the number of times
each bolt has been tightened using the plastic area tightening
method. Any bolt that already has three punch marks must be
replaced.
P 21229

• Tighten the cylinder head bolts 8 to the specified torque {M14 bolts:
78 N·m (8 kgf·m) [57.5 lbf·ft]; M10 bolts: 17 N·m (1.75 kgf·m) [12.5
lbf·ft]} in the sequence shown. Then, turn the bolts further in
accordance with the following procedure.

*: Tighten together with rocker and bracket assembly

➀ to : M14 bolt (wet)
to : M10 bolt
01945

<M14 Bolts>
• Before fitting the Socket Wrench over a cylinder head bolt, turn
the holder D counter-clockwise to tension the built-in spring.

E: Socket
F: Rod
G: Rod (extension)

01991

• Set the socket such that the built-in spring force forces the rod G
against the rocker shaft bracket, an injection pipe, or another nearby
part.
• On the holder D, select the inscribed line H that is easiest to see.
• Using the selected line as a reference, turn the socket E 180°
clockwise. (One gradation on the scale J represents 5°.)

CAUTION
12825
Since the M14 cylinder head bolts 8 utilize the plastic region
tightening method, they must not be tightened further after this
procedure.

11-14
Downloaded from www.Manualslib.com manuals search engine
 11

<M10 Bolts>
• After fitting the M14 cylinder head bolts 8, tighten the M10 bolts to
the specified torque {34 N·m (3.5 kgf·m) [25.1 lbf·ft]} in the
sequence shown.

01945

11 Cylinder head gasket

[Removal]

CAUTION
When removing the cylinder head gasket 11, be careful not to
scratch the cylinder head and valve assembly 10 and the
crankcase .
*

[Fitting]
• Fit the cylinder head gasket 11 onto the crankcase
* as shown.

13582

12 Push rod runout

If any measurement exceeds the specified limit, replace the defective
part(s).

01948

13
* Tappet-to-crankcase clearance
If any measurement exceeds the specified limit, replace the defective
part(s).

01949

11-15
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD AND VALVE MECHANISM
Rocker and Bracket Assembly
● Disassembly sequence
1 Rocker assembly
2 Rocker bushing
3 Lock nut
4 Adjusting screw
5 Rocker
6 No. 6 rocker shaft bracket
7 Set screw
8 No. 5 rocker shaft bracket
9 No. 4 rocker shaft bracket
10 No. 3 rocker shaft bracket
11 No. 2 rocker shaft bracket
12 No. 1 rocker shaft bracket
13 Rocker shaft spring
14 Rocker shaft

● Assembly sequence
Reverse the order of disassembly.
13022

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
2, 14 Rocker bushing-to-rocker shaft clearance 0.01 to 0.08 0.12 Replace
[Basic diameter: 24 mm (0.945 in.)] (0.000394 to 0.00315) (0.00472)

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
3 Adjusting screw lock nut 34 (3.5) [25.1] –
7 Rocker shaft set screw 3.9 (0.4) [2.88] –

Lubricant
Location Points of application Specified lubricant Quantity
2 Rocker bushing inner surface Engine oil As required

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Rocker Removing and installing rocker

2 MH061777
Bushing Puller bushings

01951

11-16
Downloaded from www.Manualslib.com manuals search engine
 11

◆ Service procedure
2 14 Rocker bushing and rocker shaft
[Inspection]
If any clearance exceeds the specified limit, replace the defective
part(s).

01952

Rocker bushing
[Removal]

12994

[Installation]
• Align the oil hole A in the rocker bushing 2 with the oil hole B in the
rocker 5.
• Position the notch C and seam D on the rocker bushing 2 as shown.
• Install the rocker bushing 2 into the rocker 5 from the chamfered
side F.

12995

6 8 to 12 14 Installing rocker shaft brackets and rocker shaft

Rocker shaft brackets
Be sure to fit the rocker shaft brackets 6, 8, 12 in their correct positions.

A: Oil hole
B: Threaded hole (for M8 rocker cover bolt)
C: Threaded hole (for M6 set screw)
D: No threaded hole

13023

11-17
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD AND VALVE MECHANISM
Rocker shaft
Align the oil hole G in the No. 6 rocker shaft bracket 6 with the oil hole
H in the rocker shaft 14.

13024

11-18
Downloaded from www.Manualslib.com manuals search engine