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6BD1T
Workshop manual
Isuzu 6BD1T Workshop Manual
4b-6b series
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
General Repair Instructions
Symbols Used in the Manual
Main Data and Specifications
Design Features and General Outline
Main Engine Parts and Their Function
Cylinder Head
Cylinder Body
Crankshaft
Pistons
Valve Mechanism
Tightening Torque Specifications
Angular Nut and Bolt Tightening Method
Major Part Fixing Nuts and Bolts
Cylinder Head and Cover
Cylinder Body Diagram
Oil Pan and Dipstick Diagram
Camshaft and Rocker Arm Diagram
Crankshaft, Piston and Flywheel Diagram
Thermostat and Thermostat Housing Diagram
Intake and Exhaust Manifold Diagram
Timing Gear Case and Flywheel Housing Diagram
Oil Cooler, Oil Filter, and Oil Pump Diagram
Fuel System Diagram
Turbocharger Diagram
Identifications
Engine Serial Number
Injection Pump Number
Maintenance
Lubricating System Maintenance
Main Oil Filter Replacement
Center Bolt Type Removal/Installation
Cartridge (Spin-On) Type Removal/Installation
Fuel System Maintenance
Fuel Filter Replacement
Injection Nozzle Maintenance
Spray Condition Check (During Injection Nozzle Tester Operation)
Water Separator (Water Sedimentor) Check
Air Bleeding Check
Cooling System Maintenance
Valve Clearance and Adjustment
Cooling Fan Drive Belt Adjustment
Thermostat Inspection
Injection Timing
Flange Mounted Injection Pump Injection Timing Checking and Adjustment
Injection Timing Checking Procedure
Coupling Driven Injection Pump Timing Adjustment
Compression Pressure Measurement
Turbocharger Inspection
Engine Repair-Kit (for Non-Turbocharged Engines) Diagram
Engine Repair Kit (for Turbocharged Engines) Diagram
Recommended Lubricants
Engine Oil Viscosity Chart
Engine Assembly I (Disassembly)
External Parts Disassembly Steps
Model 6BD1T Right Side View/Disassembly Steps
Model 4BD1T View/Disassembly Steps
Injection Pump with Injection Pump Gear
Flange Mounted Injection Pump Removal
Coupling Mounted Injection Pump Removal
Remove of the Air Compressor (if Equipped)
Model 6BD1T Left Side View/Disassembly Steps
Model 4BD1T Left Side View/Disassembly Steps
Major Components/Disassembly Steps
Rocker Arm Shaft
Cylinder Head Bolts
Crankshaft Pulley Nut
Taper Bushing (6B Series Only)
Flywheel
Major Components II/Disassembly Steps
Idler Gear
Cam Shaft
Crankshaft Bearing Cap
Rocker Arm and Rocker Arm Shaft View/Disassembly Steps
Cylinder Head View/Disassembly Steps
Split Collar Removal
Piston and Connecting Rod View/Disassembly Steps
Piston Rings Removal
Snap Ring and Piston Pin Removal
Engine Assembly II (Inspection and Repair)
Cylinder Head Lower Face Warpage Check
Water Jacket Water Pressure Test
Valve Stem and Valve Guide Clearance
Valve Guide Replacement/Removal
Valve Depression
Valve Contact Width
Valve Seat Insert Replacement/Removal
Valve Seat Installation
Valve Seat Insert Correction
Valve Spring Free Length Measurement
Valve Spring Inclination
Valve Spring Tension
Tappet (Cam Follower or Valve Lifter) Inspection
Push Rod Inspection
Rocker Arm Correction
Rocker Arm Shaft and Rocker Arm Inspection
Rocker Arm Shaft Outside Diameter Measurement
Idler Gear and Idler Gear Shaft Inspection
Rocker Arm Shaft and Rocker Arm Clearance Check
Camshaft Inspection
Cylinder Liner Bore Measurement
Cylinder Liner Projection Inspection
Cylinder Liner Replacement
Cylinder Bore Measurement
Cylinder Liner Grade Selection
Cylinder Body Inside Diameter Measurement
Cylinder Liner Outside Diameter Measurement
Cylinder Bore and Cylinder Liner Outside Diameter Combinations
Cylinder Liner Installation
Piston Grade Selection
Cylinder Liner Bore Measurement/Piston Outside Diameter
Cylinder Liner Bore and Piston Clearance
Piston Ring and Piston Ring Groove Clearance
Piston Ring and Piston Groove Clearance
Piston Ring Gap
Piston Pin Outside Diameter
Piston Pin and Piston Clearance
Piston Pin and Piston Pin Hole Clearance
Connecting Rod Alignment
Piston Pin and Connecting Rod Small End Bushing Clearance
Connecting Rod Bushing Replacement
Connecting Rod Bearing Inspection
Crankshaft and Bearing Inspection
Crankshaft Journal and Crankpin Outside Diameter
Crankshaft Journal and Bearing Clearances
Crankshaft Journal Bearing Inside Diameter
Connecting Rod Bearing Inside Diameter
Crankshaft Run-Out
Main Bearing and Connecting Rod Bearing Tension
Crankshaft Regrinding
Crankshaft Regrinding Procedure
Crankshaft Grinding Limit
Plastigage Clearance Measurement
Crankshaft Journal Bearing Clearance
Crankshaft Pin Bearing Clearance
Crankshaft Tufftriding Inspection
Oil Seal Wear Ring Replacement (6BD1T, 6BG1, 6BG1T)
Crankshaft Gear Inspection
Crankshaft Gear Replacement
Flywheel and Flywheel Housing (Rear Oil Seal) Inspection
Rear Gear Inspection/Replacement/Installation
Flywheel Housing Oil Seal Replacement
Timing Gear Case Cover Inspection
Crankshaft Front Oil Seal Replacement
Engine Assembly III (Reassembly)
Piston and Connecting Rod Reassembly Steps - Minor Component
Pistons Heating/ Connecting Rod Installation
Piston Pin Snap Ring Installation
Piston Ring Installation
Connecting Rod Bearing Installation
Cylinder Head Reassembly Steps
Valve Stem Oil Seal Installation
Intake and Exhaust Valves Installation
Intake and Exhaust Valve Springs Installation
Spring Seat Split Collar Installation
Intake Manifold and Gasket Installation
Exhaust Manifold and Gasket Installation
Rocker Arm and Rocker Arm Shaft Reassembly Steps
Major Component Reassembly Steps I
Oil Jet Installation
Crankshaft Bearing Configuration
Crankshaft Installation
Thrust Bearing Installation
Crankshaft Bearing Cap Installation
Timing Gear Case Installation
Camshaft/Thrust Plate Bolts Tightening
Idler Gear Shaft Installation
Idler Gear Installation
Piston and Connecting Rod Installation
Oil Pump and Coupling Installation
Flywheel Housing Installation
Oil Pan Installation
Oil Cooler Installation
Major Component Reassembly Steps II
Flywheel Installation
Injection Pump and Injection Pump Gear Assembly
Air Compressor Installation
Tappet Chamber Cover Installation
Water Pump Installation
Cylinder Head Gasket/Bolt Installation
Rocker Arm and Rocker Arm Shaft Installation
External Parts Reassembly Steps (Left-Hand Side)
Cylinder Head Cover Installation
Fan Belt Adjustment
Starter Motor Installation
Turbocharger Mounting Flange Gasket Positioning
Turbocharger Nuts Tightening
Oil Drain Pipe Installation
Oil Feed Pipe Installation
Turbo Adaptor Tightening
External Parts Reassembly Steps (Right-Hand Side) - Model 6BD1T
Injection Nozzle Installation
Fuel Injection Pipe and Fuel Leak off Pipe Installation
Oil Filter Installation
Fuel Pipe, Fuel Return Pipe, Intake Pipe Installation
Injection Timing Adjustment
Engine Tuning Operation
Engine Sectional View
Lubricating System
Lubricating System - General Description
Oil Pump Disassembly
Oil Pump Drive Gear Inspection
Oil Pump Driven Gear Inspection
Main Oil Filter Disassembly/Inspection and Repair
Lubricating System Reassembly
Center Bolt and Drain Plug Installation
Oil Cooler Disassembly, Inspection and Repair
Lubricating System Reassembly Steps
Oil Cooler Element Installation
Cooling System
Cooling System - General Description
Water Pump Disassembly Steps
Impeller/Pulley Center/Snap Ring Removal
Spindle, Bearing, Spacer/Seal Unit, Washer and Seal Removal
Bearing Replacement
Cooling System Reassembly Steps
Spindle, Bearing, and Spacer Installation
Snap Ring/Pulley Center Installation
Seal Unit, Washer and Seal Installation
Impeller/Pulley Installaton
Thermostat Inspection and Repair
Fuel System
Fuel System - General Description
Fuel Filter Disassembly/Inspection and Repair
Injection Nozzle Disassembly
Push Rod Spring Check
Nozzle Holder Push Rod Check
Injection Nozzle Check
Fuel Filter Reassembly Steps
Injection Pipe Connector/Injection Nozzle/Retaining Nut Check
Injection Starting Pressure Adjustment
Nozzle Holder Cap Nut Check
Injection Pump Calibration Data
Identification Plate and Product Serial Number
Test Conditions Required for the Fuel Injection Amount Adjustment
Inj. Pump Calibration Data
Governor Adjustment
Turbocharger
Turbocharger - General Description
Turbocharger Identification
Rotor Shaft Play Inspection
Rotor Shaft Axial Play Measurement
Air Compressor
Air Compressor Sectional View/Main Data
Air Compressor Disassembly Steps
Air Compressor Inspection and Repair
Air Compressor Reassembly Steps
Connecting Rod/Bearing Cover Installation
Cylinder Body/Cylinder Head Installation
Engine Electricals
Starter Motor Identification
Nikko Identification Plate
Hitachi Identification Plate
Starter Motor Main Data and Specifications
Starter Motor Sectional View
Starter Motor Exploded View
Alternator Identification
Alternator Main Data and Specifications
Regulator Main Data and Specifications
Alternator Sectional View
Alternator Exploded View
Troubleshooting
Hard Starting
Starter Inoperative
Starter Motor Operates but Engine Does Not Turn over
Engine Turns over but Does Not Start, Fuel Is Being Delivered to the Injection Pump
Engine Turns over but Does Not Start
Unstable Low Idling
Unsufficient Power
Excessive Fuel Consumption
Overheating
White Exhaust Smoke
Dark Exhaust Smoke
Oil Pressure Does Not Rise
Abnormal Engine Noise
Engine Knocking
Gas Leakage Noise
Continuous Noise
Slapping Noise
Special Tool List
Conversion Table
Length Conversion Table
Area Conversion Table
Volume Conversion Table
Mass Conversion Table
Pressure Conversion Table
Torque Conversion Table
Temperature Conversion Table
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INDUSTRIAL
INDUSTRIAL
DIESEL ENGINE
DIESEL ENGINE
4B-6B SERIES
4B-6B SERIES
4BB1-4BD1-6BB1-6BD1-6BG1
4BB1-4BD1-6BB1-6BD1-6BG1
4BD1T-6BD1T-6BG1T
4BD1T-6BD1T-6BG1T
WORKSHOP MANUAL
ISUZU MOTORS LIMITED
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