HA6DTI2(D/N/U) ENGINES 09.

01

CONTENTS

GROUP - 09

HA6DTI2(D/N/U) ENGINES

Section Subject Page No.

09.0 General .......................................................................................................................... 09.05
09.0.0 Engine Type and Number ........................................................................................................... 09.05
09.0.1 Design and Operation .................................................................................................................. 09.05
09.0.2 General Data .................................................................................................................................... 09.06
09.0.3 Repair Data ....................................................................................................................................... 09.07
09.0.4 Tightening Torques ........................................................................................................................ 09.11
09.0.5 Crank Shaft Main Journals and Crank Journals Dimensions. ....................................... 09.13
09.0.6 Main and Crank Journals Grinding Sizes .............................................................................. 09.13
09.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness) ............................................. 09.13
09.0.8 Crankcase Parent Bore and Cylinder Liner Outer Dia ................................................. 09.13
09.0.9 Fuel Oil (High Speed Diesel) ..................................................................................................... 09.14
09.0.9.0 Fuel Specifications - as per IS 1460 : 2000 .................................................................................. 09.14
09.0.10 Recommended coolant .................................................................................................................. 09.15
09.0.11 Recommended Lubricants ............................................................................................................ 09.15
09.0.12 Filling Capacity ................................................................................................................................. 09.15
09.0.13 Liquid Gasket and Application Points ................................................................................... 09.16
09.0.14 Description of Leading Engine Components ....................................................................... 09.17
09.0.15 Trouble shooting ............................................................................................................................. 09.18
09.0.15.0 Engine .............................................................................................................................................................................. 09.18
09.0.15.1 Fuel Injection Pump .............................................................................................................................................. 09.22
09.0.16 Special Tools ..................................................................................................................................... 09.24
09.0.17 Factors Which Determine When an Engine Overhaul is Needed ........................... 09.25

09.1 To Remove and Refit Engine from Vehicle ......................................................... 09.27

09.1.0 To Remove Engine ......................................................................................................................... 09.27
09.1.1 To Refit Engine ................................................................................................................................ 09.27

09.2 Crankcase ...................................................................................................................... 09.28

09.2.0 To Remove and Refit Cylinder Liners ................................................................................... 09.28
09.2.1 To Remove and Refit Timing Casing Cover and Back Plate ....................................... 09.29
09.2.2 To Remove and Refit Flywheel Housing ............................................................................... 09.30
09.2.3 Install the Oil Seal in the Flywheel Housing ...................................................................... 09.30
09.2.4 To Remove and Refit Flywheel ................................................................................................. 09.30
09.2.5 To Remove Ring Gear .................................................................................................................. 09.31
09.2.6 To Install Ring Gear ..................................................................................................................... 09.31
09.2.7 Install Flywheel ................................................................................................................................. 09.31

09.3 Crankshaft ..................................................................................................................... 09.32

09.3.0 To Remove and Refit Crankshaft ............................................................................................. 09.32
09.3.1 To Renew Crankshaft Gear ........................................................................................................ 09.33
09.3.2 To Refit the Crankshaft Gear ................................................................................................... 09.33
09.3.3 To Check Crankshaft Bend ........................................................................................................ 09.33
09.3.4 Installation .......................................................................................................................................... 09.33
09.3.5 To Renew Crankshaft Main & Connecting Rod Bearing and
Check Main & Connecting Rod Bearing Spread ................................................................ 09.33
09.3.6 To Check and Grind Crankshaft ............................................................................................. 09.34
09.3.7 To Remove and Refit Vibration Damper .............................................................................. 09.34

PUB. NO. SM:HINO BS-II:787:1204:1000:10

09.02 HA6DTI2(D/N/U) ENGINES

CONTENTS

GROUP - 09

HA6DTI2(D/N/U) ENGINES

Section Subject Page No.

09.4 Piston and Connecting Rods ................................................................................... 09.35

09.4.0 To Remove Piston Assembly ..................................................................................................... 09.35
09.4.1 To Dismantle and Assemble Piston and connecting rod .............................................. 09.35
09.4.2 Connecting Rod Bush ................................................................................................................... 09.35
09.4.2.0 To Remove Bush ................................................................................................................................................... 09.35
09.4.2.1 Installation of Connecting Rod Bush ...................................................................................................... 09.36
09.4.2.2 Inspect the Bushing Position after Installation ................................................................................ 09.37
09.4.2.3 Check for Bend of Connecting Rod ...................................................................................................... 09.37
09.4.2.4 Install the Connecting Rod Bearing ......................................................................................................... 09.37
09.4.3 Piston and Piston Rings ............................................................................................................... 09.38
09.4.3.0 Piston General .......................................................................................................................................................... 09.38
09.4.3.1 To Remove Piston rings ................................................................................................................................... 09.38
09.4.3.2 Assemble Piston and Connecting Rod ................................................................................................. 09.38
09.4.3.3 Install Piston rings ................................................................................................................................................. 09.39
09.4.3.4 Installation ..................................................................................................................................................................... 09.40

09.5 Cylinder Head Assembly ........................................................................................... 09.41

09.5.0 To Remove Cylinder Head ......................................................................................................... 09.41
09.5.1 To Grind Valves and Valve Seats ............................................................................................ 09.42
09.5.2 To Refit the Valve Seat and To Check and Reface Valve Seat ................................. 09.42
09.5.3 Valve Seat Installation ................................................................................................................... 09.42
09.5.3.0 To Check the Valve Guide ........................................................................................................................... 09.43
09.5.3.1 To Renew Valve Guide .................................................................................................................................... 09.43
09.5.3.2 To Refit Valve and Valve Stem Seals .................................................................................................. 09.43
09.5.3.3 To Check Valve Springs ................................................................................................................................... 09.44
09.5.4 To Assemble the Cylinder Head .............................................................................................. 09.44

09.6 Timing .......................................................................................................................... 09.45

09.6.0 To Remove and Refit Rocker Levers ..................................................................................... 09.45
09.6.1 To Remove, Refit and Check Push Rod and Tappets .................................................... 09.45
09.6.2 To Remove and Refit Camshaft ................................................................................................ 09.46
09.6.3 Removal and Replacement of Camshaft Bushes ................................................................. 09.46
09.6.4 Camshaft Bush Dimensions (in mm) ....................................................................................... 09.46
09.6.5 Installation .......................................................................................................................................... 09.47
09.6.6 Install the camshaft gear on the shaft ................................................................................... 09.49
09.6.7 To Refit the Camshaft .................................................................................................................. 09.49
09.6.8 To Remove and Refit Intermediate Timing Gear .............................................................. 09.49
09.6.9 Install the Idler Gear Shaft (Spindle) ..................................................................................... 09.50
09.6.10 Install the Idler Gear ..................................................................................................................... 09.50
09.6.11 To Re-bush Intermediate Gear ................................................................................................. 09.50
09.6.12 To Position Timing Gears for Valve Timing and FIP Timing ...................................... 09.51
09.6.13 Timing Gear Backlash Checking ............................................................................................... 09.51
09.6.14 To Fit Air Compressor ................................................................................................................. 09.51
 HA6DTI2(D/N/U) ENGINES 09.03

CONTENTS

GROUP - 09

HA6DTI2(D/N/U) ENGINES

Section Subject Page No.

09.6.15 To Remove and Refit Fuel Injection Pump and To Adjust the Injection Timing ........... 09.51
09.6.16 To Adjust the Valve Clearance ................................................................................................ 09.54
09.6.17 To Assemble FIP Drive Coupling ............................................................................................ 09.55
9.6.18 To Fit Injector High Pressure Pipes ....................................................................................... 09.55
9.6.19 Fuel Filters .......................................................................................................................................... 09.56
09.6.20 Water Separator .............................................................................................................................. 09.57
09.6.21 To Remove and Refit Injector Nozzle ................................................................................... 09.57
09.6.21.0 Cleaning ......................................................................................................................................................................... 09.57
09.6.21.1 Test the nozzle sinking ...................................................................................................................................... 09.58
09.6.21.2 Test the spray profile ......................................................................................................................................... 09.58
09.6.21.3 Test the fuel leakage (Dribbling) .............................................................................................................. 09.58
09.6.21.4 Install the nozzle holder assembly. .......................................................................................................... 09.58

09.7 Engine Lubrication ..................................................................................................... 09.59

09.7.0 Design and Operation .................................................................................................................. 09.59
09.7.1 To Remove and Refit Oil Pump .............................................................................................. 09.60
09.7.2 To Overhaul Oil Pump ................................................................................................................ 09.60
09.7.3 To Refit the Oil Pump ................................................................................................................. 09.60
09.7.4 To Overhaul Oil Cooler and Filter Assy ............................................................................. 09.61
09.7.4.0 To Remove ................................................................................................................................................................. 09.61
09.7.4.1 To Refit Oil Cooler ............................................................................................................................................. 09.62
09.7.4.2 Install the Oil Strainer ........................................................................................................................................ 09.62

09.8 Cooling System ............................................................................................................ 09.63

09.8.0 General ................................................................................................................................................ 09.63
09.8.1 To Flush Cooling System ............................................................................................................. 09.63
09.8.2 External Cleaning of Radiator ................................................................................................... 09.64
09.8.3 Engine Cooling Fan and Fan Clutch ...................................................................................... 09.64
09.8.4 Service Tips for Viscous Fan / Clutch .................................................................................. 09.64
09.8.5 To Test Thermostat ....................................................................................................................... 09.64
09.8.6 To Remove and Refit Water Pump ........................................................................................ 09.65
09.8.7 To Overhaul Water Pump .......................................................................................................... 09.66
09.8.8 To Remove and Refit V Belt. To Adjust V Belt Tension. .......................................... 09.67

09.9 Exhaust and Intake Manifold ................................................................................... 09.68

09.9.0 To Remove and Refit Exhaust Manifold ............................................................................... 09.68
09.9.1 To Remove and Refit Intake Manifold ................................................................................... 09.68
09.9.2 Maintenance and Servicing of Dry Type Air cleaner ..................................................... 09.68

9.10 Aluminium Radiators and charge air cooler ...................................................... 09.70

9.10.0 Service Instruction .......................................................................................................................... 09.70
9.10.0.0 Introduction ................................................................................................................................................................. 09.70
9.10.0.1 Details of Radiator ............................................................................................................................................... 09.70
9.10.0.2 Servicing Kit ................................................................................................................................................................ 09.70
9.10.0.3 Procedure for Servicing ..................................................................................................................................... 09.71
9.10.0.4 Radiator Installation .............................................................................................................................................. 09.73
9.10.0.5 Do's and Don'ts ................................................................................................................................................... 09.73
09.04 HA6DTI2(D/N/U) ENGINES

CONTENTS

GROUP - 09

HA6DTI2(D/N/U) ENGINES
Section Subject Page No.

09.11 Turbocharger ................................................................................................................ 09.74

09.11.0 General ................................................................................................................................................ 09.74
09.11.0.0 Design and Operation .................................................................................................................. 09.74
09.11.0.1 Effects of Turbocharger ................................................................................................................ 09.74
09.11.0.2 Preliminary Checks ......................................................................................................................... 09.74
09.11.0.3 Serviceable Parts of Turbocharger .......................................................................................... 09.75
09.11.1 Precautions to be taken for Turbocharger Installation .................................................. 09.75
09.11.2 Do’s and Don’ts .............................................................................................................................. 09.76
09.11.3 List of Equipment’s and Special Tools for K 27 Turbocharger ................................. 09.77
09.11.4 Data Sheet (For 5327 970 6742 TC) ................................................................................... 09.78
09.11.5 Turbo charger trouble shooting ............................................................................................... 09.79

09.12 Maintenance Programme .......................................................................................... 09.80

IMPORTANT

Experienced personnel should carry out any repair work on the aggregate and utmost cleanliness
must be observed.

A dismantling of the aggregate should only be undertaken for the purpose of replacing or worn
components. After the aggregate has been removed from the vehicle it should be thoroughly
washed with a suitable cleansing liquid before it is opened.

Dismantling and assembly should be carried out on a clean work bench and the special tools,
manufactured for this purpose to be used.

Any old sealing compound adhering to joint surfaces of parts and cover must be removed before
the components are installed. Burrs or similar defects must be removed carefully with a oil stone.

Damaged and badly worn components must be renewed.

Sealing rings with rough, torn or hardened sealing lips must be renewed. Care must be taken that
grease\sludge or other foreign matters do not obstruct oil holes and passages.

The tightening torque and adjustment data, given in the manual must be followed very strictly
during the assembly of the aggregate. Tightening torque’s for bolts and nuts, which are not
contained in the table “ tightening torque and adjustment data” can be obtained from standard
specification tables.
 HA6DTI2(D/N/U) ENGINES 09.05

09.0 GENERAL

09.0.0 Engine Type and Number

The engine number is punched on the left

side rear top corner of the crankcase.
Fig - 1

09.0.1 Design and Operation

6 cylinder, water cooled 4 stroke Diesel

Engine with direct fuel injection into a Fig. 1
hemispherical combustion chamber arranged
in the crown.

The engine employs a re-entrant combustion

chamber which features a specially shaped
combustion chamber in the piston crown.

Another characteristics is the special shape

and arrangement of the intake ducts in the
cylinder head which allows the air to enter
only from one direction. Upon entering, the
air is given a swirling motion causing the fuel
to mix, which is injected through a multi hole
nozzle into the combustion chamber.
Combustion is initiated at the end of
compression stroke.

The shape of the combustion chamber

allows full use of the energy contained in
the fuel, because the cooling surfaces are
comparatively small in relation to the volume
of the combustion chamber whilst the air
swirls ensures that air and fuel are mixed
uniformly.
09.06 HA6DTI2(D/N/U) ENGINES

09.0.2 General Data

Description HA6DTI2D HA6DTI2N HA6DTI2U
Type Diesel four stroke, 6 cylinder water cooled, direct injection, in line over head valve.
Aspiration Turbo charged with Inter cooler.
Max output 97 kW (132 ps) @ 122 kW (165 ps) @ 130 kW (177 ps) @
2400 rpm 2400 rpm 2400 rpm
Max torque 42 kgm @ 56 kgm @ 60 kgm @
1600 - 1800 rpm 1600 rpm 1600
Bore and Stroke 104 x 113 mm
Piston displacement 5.759 l
Compression Ratio 17.5 : 1
Firing order 1-4-2-6-3-5
Direction of rotation Counter clockwise viewed from flywheel.
Compression pressure 29 - 32 kg/cm² @ 280 rpm (Limit - 24 kg/cm²)
Idling revolution 530 ± 30 rpm.
Engine Weight (with oil) 512 kg
Valve Timing
Intake opens 18° Before TDC
Intake closes 30° After BDC
Exhaust opens 57° Before BDC
Exhaust closes 15° After TDC
Valve clearance (when cold)
Intake 0.30 mm (0.012")
Exhaust 0.45 mm (0.018")
Engine Oil Pump
Type Full forced Pressure feed by gear pump
Drive By timing gear
Engine oil cooler Multi plates type (no of plates - 5) water cooled
Fuel Injection Equipment Distributor type (VE) with manifold pressure compensator (LDA) and
cold start injection advance (KSB)
High Pressure Pipe (OD x ID x Length) 6.35 x 1.8 x 650 mm
Injection Nozzle
Type Multi hole nozzle type
Valve opening pressure 247 to 260 bar
Coolant Pump
Type Forced circulation by volute pump, 55 mm dia ball and roller bearing
Drive By V-belt
Impeller dia 75 mm 75 mm 85 mm
Thermostat Wax type, Bottom bypass system
Injection timing 1.22 mm (± 0.02 mm) 1.38 mm (± 0.02 mm) 1.35 mm (+0.05 mm)
plunger lift at TDC with plunger lift at TDC with plunger lift at TDC
No.1 cylinder on No. 1 cylinder on with No. 1 cylinder on
Compression stroke compression stroke compression stroke
Turbo wastegate No Yes Yes
Electrical
Starter motor 24V, Axial type 24V, Axial type, pre-engaged
Alternator 24V - 30/44 Amps 24V - 30/44 Amps 24V - 30/44/55 Amps
 HA6DTI2(D/N/U) ENGINES 09.07

09.0.3 Repair Data

SPECIFICATION
(Measurements in mm) MEASURING DEVICE
DESCRIPTION
AND REMARKS
HA6DTI2(D/N/U)
Crankcase
Cylinder block flatness 0.05 (limit 0.1) Straight edge and feeler gauge
Crankcase bore for cylinder liner fitment Refer section 09.0.8 W,X,Y,Z, punch marked on crank
case LH side adjacent to each
bore
Cylinder liner outside diameter Refer section 09.0.8 W,X,Y,Z, paint mark given
on cylinder liner OD for
identification
Fitment of cylinder liner in crankcase bore Transition fit Selective assy
Transition Fit
Cylinder liner bore: Size 104.008 - 104.040 (limit 104.15) Bore dial gauge (To be
measured at 80 mm from top)
Liner projection 0.01 - 0.08 Dial gauge with magnetic stand
Block Top Surface to Crankshaft Centre 299.950 - 300
Block Top Surface to sump face height 370
Main parent bore dia 77.985 - 78.00 Micro meter and bore dial gauge
Cylinder counter bore depth 8.020 - 7.980 Vernier depth gauge
Cylinder counter bore dia 112.00 (+0.290 to 0.150) Micro meter and bore dial gauge
Piston and Connecting Rod Assembly
Piston diameter Standard size 103.960 Micrometer (measure at skirt
area perpendicular to pin axis)
Diametral piston clearance (at skirt) 0.140 - 0.172 Micrometer and dial gauge
Piston ring Groove Width
Top -
Second 2.53 - 2.55 (limit 2.70) Vernier caliper
Oil Ring 5.01 - 5.03 (limit 5.08)
Piston ring width
Top -
Second 2.47 - 2.49 (limit 2.32) Micrometer
Oil Ring 4.97 - 4.99 (limit 4.95)
Piston ring side clearance in groove
Top 0.08 - 0.12 (limit 0.7)
Second 0.04 - 0.08 (limit 0.2) Feeler gauge
Oil Ring 0.02 - 0.06 (limit 0.1)
Piston Ring gap
Top 0.30 - 0.45 (limit 1.2)
2nd 0.30 - 0.45 (limit 1.2)
Oil 0.30 - 0.45 (limit 1.2)
Maximum permissible piston weight 5 gms No need to check weight
difference per set difference as pistons are serviced
as set
Piston pin hole inside diameter 36.998 - 37.003 (limit 37.030) Bore dial gauge
Gudgeon pin outside diameter 36.989 - 37.000 (limit 36.980) Micrometer (Push fit in piston
heated to 80oC)
Clearance between Piston pin and Piston -0.002 - 0.014 (limit 0.040)
pin hole
09.08 HA6DTI2(D/N/U) ENGINES

09.0.3 Repair Data

SPECIFICATION
(Measurements in mm) MEASURING DEVICE
DESCRIPTION
AND REMARKS
HA6DTI2(D/N/U)
Con rod small end bush bore 37.015 - 37.025 (limit 37.07) Bore dial gauge
Diametral clearance between gudgeon 0.015 - 0.036 Bore dial gauge and
pin and con. rod small end bush bore (limit 0.08) micrometer
Max. permissible clearance
Interference fit of small end bush in 0.035 - 0.092 Bore dial gauge and micrometer
connecting rod
Connecting rod centre to centre distance 181.480 - 181.520
Connecting rod bend / twist limit 0.1 per 200
Connecting rod big end dia 65.985 - 66
Max. permissible connecting rod A : 1790 - 1830 Grades A, B, C, D, E are
weight (gms) Grading B : 1830 - 1870 punched on big end of the
C : 1870 - 1910 connecting rod. An engine
D : 1910 - 1950 should have connecting rods of
E : 1950 - 1990 same grade.
Crankshaft
Crankshaft journals and crankpin grinding Refer section 09.0.6 Micrometer
dimensions
Surface hardness of journals and crankpins 269-311 BHN Hardness Tester. No further
heat treatment recommended
Maximum permissible bend at limit 0.04 V-Blocks and dial gauge
4th journal
Journals and crankpins Refer section 09.0.5 Micrometer
Crankshaft Main Bearing Cap roundness 0.06
Main and connecting journal sizes Refer section 09.0.6 (Standard and undersizes)
Crankshaft end play 0.05 - 0.22 Magnetic stand and dial gauge
Maximum permissible clearance 0.4 (limit)
Diametral clearance between main journal 0.039 - 0.09 Bore dial gauge and micrometer
and bearing Max. permissible clearance 0.13 (limit)
Main bearing spread 79.00 - 79.60 Vernier Calliper
Connecting rod big end bearings Refer section 09.0.7 (Standard and undersize)
Connecting rod side clearance 0.20 - 0.52 (limit 0.6) Feeler gauge
Diametral clearance between Connecting 0.031 - 0.082 Bore dial gauge and micrometer
Rod Big End Bearing & Crank pin (limit 0.12)
Connecting rod Big End parent bore dia 65.985 - 66.00 Bore dial gauge
Connecting rod Big end ovality/taper 0.06 Bore dial gauge and micrometer
Connecting rod big end bearing spread 67.05 - 67.55 Vernier caliper
Flywheel face out limit 0.15 Dial gauge
Cylinder Heads and Valves
Cylinder head flatness 0.05 (limit 0.1) Straight edge and feeler gauge
Cylinder head height 87.0 (limit 86.8) Vernier caliper
Nozzle protrusion from cylinder head
surface 4.0 - 4.5 Depth gauge
 HA6DTI2(D/N/U) ENGINES 09.09

09.0.3 Repair Data

SPECIFICATION
(Measurements in mm) MEASURING DEVICE
DESCRIPTION
AND REMARKS
HA6DTI2(D/N/U)
Valve projection/sink (Valve head depth Dial gauge
below cylinder head face)
Inlet 0.05 - 0.35
Exhaust (-) 0.47 - (-) 0.77
Valve stem diameter
Inlet 8.95 - 8.97 (limit 8.9) Micrometer
Exhaust 8.93 - 8.95 (limit 8.8)
Intake and Exhaust Valve Guide inner dia 9.000 - 9.015 Internal micro meter
Diametral valve stem clearance in guide Plug gauge and Micrometer
Intake 0.035 - 0.068
Exhaust 0.050 - 0.083
Valve seat angle
Intake 30° - 30° 15' Bevel Protractor (for both inlet
Exhaust 45° - 45° 15' and exhaust)
Valve seat seating depth on cylinder head
Inlet 8.9 ± 0.1
Exhaust 7.3 ± 0.1
Valve seat thickness
Inlet 7.5 - 7.7
Exhaust 6.0 - 6.2
Valve seat seating dia on cylinder head
Inlet 46.5 (+0.016, - 0.0)
Exhaust 41.0 (+0.10, - 0.0)
Outer dia of valve seat
Inlet 46.5 (+0.145 - 0.130)
Exhaust 41.0 (+0.145 - 0.130)
Valve angle
Intake 29° 45' - 30°15' Protractor (for both inlet and
Exhaust 44° 45' - 45°15' exhaust)
Valve head diameter:
Inlet 45.3 - 45.5 Micrometer.
Exhaust 39.8 - 40.0
Maximum permissible out of true 0.03 Lathe and dial gauge
head face head to stem
Interference fit of valve guide in 0.010 - 0.039 Plug gauge and micrometer
cylinder head
Height of valve guide above spring seat 14.5
Maximum permissible out of true of 0.030
valve seat to guide
Valve spring straightness 2.0 (limit) Tri Square
Valve spring (constant pitch) load 26.5 kg at 45.5 mm Valve spring scale
(limit 24.6 kg) (inlet and exhaust)
Valve lift
Intake 11.74 mm
Exhaust 13.02 mm
09.10 HA6DTI2(D/N/U) ENGINES

09.0.3 Repair Data

SPECIFICATION
(Measurements in mm) MEASURING DEVICE
DESCRIPTION
AND REMARKS
HA6DTI2(D/N/U)
Timing
Rocker arm shaft diameter 18.966 - 18.984 Micrometer
Diametral clearance between rocker 0.036 - 0.079 Dial gauge and micrometer
lever on rocker shaft (limit 0.15)
Push Rod Bend 0.3 Centres and dial gauge
Tappet Diameter 26.95 - 26.97 Micro meter
Tappet guide inside diameter 27.00 - 27.02 Internal micro meter
Diametral tappet clearance in crankcase 0.025 - 0.071 Bore dial gauge and
bore Maximum permissible limit 0.1 (limit) micrometer
Camshaft Bend 0.05 (limit) Dial gauge and V blocks
Camshaft Cam lift (Intake) 6.5213 Vernier height gauge and V
blocks
Camshaft Cam lift (Exhaust) 7.2352 Vernier height gauge and V
blocks
Camshaft end play 0.10 - 0.18 Dial gauge with magnetic
(limit 0.3) base
Camshaft Journal Diameter Micro meter
Journal 1 56.95 - 56.97 (limit 56.85)
Journal 2 56.75 - 56.77 (limit 56.65)
Journal 3 56.55 - 56.57 (limit 56.45)
Journal 4 56.35 - 56.37 (limit 56.25)
Camshaft Journal Bearing inside Diameter Bore dial gauge
after pressing the bushes.
Journal 1 57.0 (limit 57.070)
Journal 2 56.8 (limit 56.870)
Journal 3 56.6 (limit 56.670)
Journal 4 56.4 (limit 56.470)
Diametral camshaft clearance in bushes 0.03 - 0.12 Internal measuring gauge and
Max. permissible clearance 0.15 (limit) micrometer
Idler Shaft Diameter 49.95 - 49.975 (limit 49.94) Micrometer
Idler Gear bushing inside Diameter 50.00 - 50.025 (limit 50.05) Internal micro meter
Diametral clearance between Idler Gear 0.03 to 0.08 Internal measuring gauge and
shaft and Bush (limit 0.1) micrometer
Idler Gear end play 0.04 - 0.10 (limit 0.15) Dial gauge
Tooth Backlash between Crank gear 0.068 - 0.194 Feeler gauge or dial gauge
and idler gear & Idler gear
Tooth Backlash between Idler gear and 0.065 - 0.182 (limit 0.3) Feeler gauge or dial gauge
camshaft gear
Tooth Backlash between Injection Pump 0.065 - 0.232 Feeler gauge or dial gauge
gear & Idler gear
Tooth Backlash between Cam gear 0.065 - 0.182 (limit 0.3) Feeler gauge or dial gauge
& Oil Pump gear
Engine lubrication
Max. oil pressure:
Full-load 4.5/4.8 kg/cm² Pressure gauge
Idling 1.2/1.6 kg/cm² Pressure gauge
Minimum oil pressure 1.0 kg/cm² (engine idling)
 HA6DTI2(D/N/U) ENGINES 09.11

09.0.3 Repair Data

SPECIFICATION
(Measurements in mm) MEASURING DEVICE
DESCRIPTION
AND REMARKS
HA6DTI2(D/N/U)
Oil flow rate 21 - 24 litres per minute at
4 kg/cm² at 1000 rpm
Valve opening pressure: (Oil filter)
Release valve 3.7 - 4.3 kg/cm² Hydraulic pump with pressure
By-pass valve for paper element 4 kg/cm² gauge
By-pass valve for heat exchanger 1.5 kg/cm²
Oil Pump Gear Height 27.00 - 27.04
Oil Pump Gear Outer Diameter 49.2
Oil Pump Gear Backlash(Drive & Driven) 0.09 - 0.21 (limit 0.30) Feeler gauge
Drive Gear shaft Diameter 18.088 - 18.106 (limit 18.060) Micro meter
Drive shaft Bushing inside Diameter 18.146 - 18.173 (limit 18.20) Internal micro meter
Clearance between Drive Shaft & Bushing 0.040 - 0.085 (limit 0.1) Bore dial gauge/Micro meter
Driven Gear shaft Diameter 17.979 - 17.997 (limit 17.970) Micro meter
Driven Gear Inside Diameter 18.037 - 18.054 (limit 18.070) Bore dial gauge/Internal micro
meter
Clearance between driven gear and shaft 0.040 - 0.075 (limit 0.1) Dial gauge
Oil Cooler air pressure testing 6 kg/cm²
Cooling System
Permissible maximum cooling temp. 95°C Temperature gauge
Maximum water pump output 125 l pm @ 0.5 kg/cm² for Test tank
derated and nominal engines
216 l pm @ 0.5 kg/cm² for
uprated engines
Commencement of thermostat opening 82°C + 2°C Test tank thermometer & dial
gauge
Thermostat working stroke at 95°C 10 mm or more Test tank thermometer & dial
gauge
Cooling system capacity 22.5 litres

09.0.4 Tightening Torques Spanner Size Kgm lb.ft Nm

Liner Pressing Special Tool - 5 - 6 36 - 42 49 - 59
Main Bearing Cap Bolts 19 14 - 16 102 - 115 137 - 157
Flywheel Housing Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
22 11 - 13 80 - 94 108 - 128
Flywheel Fitting Bolts 22 18 - 20 131 - 144 177 - 196
Connecting Rod Cap Bolts 17 4 + 68° Angle 29 +68° Angle 39 + 68° Angle
Timing Gear Plate Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Oil Pump Assembly Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Camshaft Drive Gear Fitting Bolt 22 11 - 13 80 - 94 108 - 128
Camshaft Thrust Plate Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Idler Gear Fitting Bolt (Refer page 09.50) 17 4 + 60° - 65° 30 + 60° - 65° 40 + 60° - 65°
Timing Gear Cover Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Crankshaft Pulley Fitting Nut 46 48 - 57 348 - 412 471 - 559
Oil Strainer Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Oil Pan Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Oil Pan Drain Plug 19 4 - 5 29 - 32 39 - 49
09.12 HA6DTI2(D/N/U) ENGINES

Tightening Torques Spanner Size Kgm lb.ft Nm

FIP Drive gear bolt 3.7 - 4.5 26 - 32 36 - 44
FIP Mounting on Timing Casing 1.9 - 2.6 14 - 18 19 - 26
FIP Cam Lock (While locking) 3.2 23 31
FIP Fuel Injector Banjo 2.0 - 2.5 15 - 18 20 - 25
Fuel Outlet Orifice Adaptor 2.5 - 3.0 18 - 22 25 - 30
High Pressure Pipe Cap Nut 2.0 - 2.5 15 - 18 20 - 25
Injector Leak of Pipe Screws 0.5 - 0.7 3.7 - 5 5 - 7
FIP Cam Lock with Interposing
Plate (After unlocking) 1 - 1.5 7 - 11 10 - 15
Air Compressor Fitting Bolts 14 4.5 - 5.0 33 - 36 44 - 49
Alternator Bracket 14 4.5 - 5.0 33 - 36 44 - 49
Alternator Supporting Bolt & Nut. 22 4.5 - 5.0 33 - 36 44 - 49
Fan Belt Adjusting Bracket 14 4.5 - 5.0 33 - 36 44 - 49
Water Jacket Elbow 14 4.5 - 5.0 33 - 36 44 - 49
Water Drain Plug on Elbow 14 4.5 - 5.0 33 - 36 44 - 49
Oil filter Drain Plug 17 5.5 - 6.2 40 - 45 54 - 61
Centre Bolt - Oil Filter 22 4 - 5 29 - 32 39 - 49
Oil Cooler Element Fitting Nuts 13 1 - 1.5 8 - 10 10 - 15
Oil Cooler Assembly Fitting Bolts 27 1.9 - 2.6 14 - 18 19 - 26
Water Pump Assembly Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Water Pump Pulley Bolt 13 1.9 - 2.6 14 - 18 19 - 26
Fan to Spacer Bolts 13 2.0 - 3.0 15 - 21 20 - 29
Cooling Fan Fitting Bolts 13 1.5 - 2.2 11 - 16 15 - 22
Cylinder Head Bolts (M12) 14 13 - 14 94 - 102 128 - 137
Cylinder Head Bolts (M10) 14 4.5 - 5.0 33 - 36 44 - 49
Rocker Shaft Locking Bolts 8 0.6 - 0.7 4 - 5 6 - 7
Rocker Shaft Assembly Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Rocker Shaft Assembly Main Bolts 13 - 14 94 - 102 128 - 137
Rocker Arm Adjusting Screw Nuts 14 1.9 - 2.6 14 - 18 19 - 26
Thermostat Case & Cover 14 4.5 - 5.0 33 - 36 44 - 49
13 1.9 - 2.6 14 - 18 19 - 26
Injector Holder Fitting Nuts 13 1.3 - 1.9 10 - 13 13 - 19
Glow Plugs Fitting Nuts 14 2.25 - 2.75 17 - 19 22 - 27
Flare Nuts on Injector Pipes 17 1.5 - 2.5 11 - 18 15 - 25
Injector Pipe Clip fasteners 10 0.5 - 1.0 3.7 - 7.2 5 - 10
Exhaust Manifold 14 4.5 - 5.0 33 - 36 44 - 49
Inlet Manifold Fitting Bolts 13 1.9 - 2.6 14 - 18 19 - 26
Cylinder Head Cover Bolts 13 1.3 - 1.8 10 - 13 13 - 18
 HA6DTI2(D/N/U) ENGINES 09.13

09.0.5 Crank Shaft Main Journals and Crank Journals Dimensions.

DESCRIPTION mm inch

1. Std diameter of main journals 72.94 - 72.96 2.871 - 2.872

2. Std diameter of conrod journals 61.94 - 61.96 2.438 - 2.439
3. Fillet Radius main journal 3.00 - 3.50 0.118 - 0.1377
4. Con. rod journal fillet radius 3.75 - 4.25 0.1477 - 0.1673
5. Wear limits
Taper (across total width) 0.1 0.004
Ovality 0.1 0.004
Bend 0.04 0.0015
Wear limit 0.2 0.008
Concentricity 0.03 0.001
Maximum permissible out of round 0.02 0.0007
6. Available under sizes (only 4 under sizes) 0.25/0.50/0.75/1.00 0.010/0.020/0.030/0.040

09.0.6 Main and Crank Journals Grinding Sizes

Under size Crank pin Main Journal
mm mm inch mm inch
0.25 61.69 - 61.71 2.4288 - 2.4295 72.69 - 72.71 2.8619 - 2.8625
0.50 61.44 - 61.46 2.4189 - 2.4196 72.44 - 72.46 2.8520 - 2.8527
0.75 61.19 - 61.21 2.4091 - 2.4098 72.19 - 72.21 2.8422 - 2.8429
1.00 60.94 - 60.96 2.3992 - 2.4000 71.94 - 71.96 2.8323 - 2.8330
Width of crank pin - 38.00 - 38.25 mm
- 1.496" - 1.506"
Note: Correct by regrinding if worn unevenly more than 0.10 mm (0.004")
Regrind if the wear is more than 0.2 mm (0.008")
Replace crankshaft if wear is more than 1.2 mm (0.048")

09.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness)

Under size (mm) Thickness (mm) Tolerance

STANDARD 2.00 -0.003 To -0.013
0.25 2.125 - do -
0.50 2.250 - do -
0.75 2.375 - do -
1.00 2.500 - do -

09.0.8 Crankcase Parent Bore and Cylinder Liner Outer Dia

Crankcase Parent Bore Cylinder Liner Outer Dia

Grade Size (mm) Grade Size (mm)
W 107 + 0.0060
W 107 - 0.0125
+ 0 - 0.0190

X 107 + 0.0125
X 107 - 0.0060
+ 0.0060 - 0.0125

Y 107 + 0.0190
Y 107 + 0
+ 0.0125 - 0.0060

Z 107 + 0.0250
Z 107 + 0.0060
+ 0.0190 + 0.

Note: Interchangeability is allowed w.r.t. next oversize or undersize liners.

09.14 HA6DTI2(D/N/U) ENGINES

09.0.9 Fuel Oil (High Speed Diesel)

Users are recommended to obtain their fuel supplies from a source which can be depended upon to
maintain a consistent standard of quality and service.

Fuel should be free from water and dirt, care should be taken by the user to protect fuel from
contamination.

09.0.9.0 Fuel Specifications - as per IS 1460 : 2000

1. Acidity, inorganic ... Nil

2. Acidity, total mg.of KOH/g (Max.) ... 0.20

3. Ash, % by Mass (Max.) ... 0.01

4. Carbon residue (Ramsbottom) on 10 percent residue,

percent by Mass, Max ... 0.30

5. Cetane Number (Minimum) ... 48

or
Cetane index (Minimum) ... 46

6. Pour point (Max.) ... 3°C for Winter &

15ºC for Summer

7. Copper Strip Corrosion for 3 hours @ 100°C ... Not worse than No.1

8. Distillation, percent v/v, recovered:

a) at 350°C, Min ... 85
b) at 370°C, Min ... 95

9. Flash point (Min.)

a) Abel, °C, Min ... 35

10. Kinematic viscosity in centistokes @ 40°C ... 2.0 to 5.0

11. Sediment % by mass (Max.) ... 0.05

12. Density at 15ºC kg/m3 ... 820 - 860

13. Total Sulphur, % by mass (Max.) ... 0.05

14. Water content % by volume (Max.) ... 0.05

15. Cold Filter Plugging Point (CFPP) max ... 6ºC for Winter and
18ºC for Summer

16. Total Sediments mg per 100 ml. (max) 1.6

 HA6DTI2(D/N/U) ENGINES 09.15

09.0.10 Recommended coolant

Recommended
Change
Name & Address Concentration
Coolant intervals
of the manufacturer For Brass- Copper For Aluminium
in km
Radiator Radiator
Gulf Oil Corporation Limited,
Lubricants Division
Gulf Euro Cool 20% 50% 75,000
IN Centre, 49/50, MIDC, 12th Road,
Andheri (E), Mumbai - 400 093. INDIA
GC 1200 Sunstar-CCI (India) Private Ltd., 30% 50% 60,000
67, Maruthi Industrial Area, Sector 18,
GCL-2000 Gurgaon - 122 015. Haryana. 20% 50% 75,000
Tejon 800 S S Industrial Corporation 20% 50% 75,000
G-10, Udyog Nagar,
Tejon 1200 Delhi - 110 041. 30% 50% 60,000
Bharat Petroleum Corporation Limited,
MAK®
ECE House, 28A Kasturba Gandhi Marg, 20% 50% 75,000
SuperKool
New Delhi - 110 001.

Note: For Sub-zero temperature application use 1 : 1 Ratio.

To Prepare the coolant, it is recommended that only potable drinking water is used.

Caution: Use of any hard water will only increase scale formation in the Engine. Also please note that coolant
does not alter the hardness level of water.

09.0.11 Recommended Lubricants

Use of correct grades of lubrication is most important to prevent the wear and tear of components.
The chart shows the oil grade recommended by AL.

ASHOK
LEYLAND
GENUINE
LUBRICANTS
Ashok Ambient Sah Valvoline
Gulf Indian Oil Hindustan Bharat Elf
Aggregate Leyland Temp. IBP Chemoleums Petroleums Cummins
Oil India Corporation Petroleum Petroleum Lubricants
Specification °C IPOL Ltd.
Bharat Gulf Elf IPOL MCG VALVOLINE
Servo HP Milcy IBP
Stage II API CG4 + -15 and Superfleet MAK®-CG4 Performance Turbo CG4 Diesel All Fleet
Premium Eurol Turbo CG4
Norm MB 228.3 above Special 15W-40 Trophy DX 15W40 Premium Premium
CG4 15W40 15W40 15W40
Engines # 15W40 15W 40 15W40 15W40

09.0.12 Filling Capacity

Aggregates Qty (ll) Change Period (km)

Engine (Including Oil Filter) 10.5 16000

Note: The drain limits indicated are only for plains operation. For Ghat operations drain interval to be halved.
09.16 HA6DTI2(D/N/U) ENGINES

09.0.13 Liquid Gasket and Application Points

Use liquid gasket (Anabond 673/Loctite 587) instead of conventional sheet gaskets. The following are
the liquid gasket application points.

Liquid gasket application points and coating width

Parts Name Application Coating width
a) Oil pan Flange face which mate with cylinder 1.5 - 2.5 mm
block, timing gear cover and flywheel housing
b) Timing gear cover Faces which mates with timing gear 1.5 - 2.5 mm
plate (flange face, boss face)
c) Flywheel housing Faces which mate with cylinder block 1.5 - 2.5 mm
(flange face, boss face)
d) Coolant pump Flange face which mates with timing gear cover 1.5 - 2.5 mm
e) Thermostat case Flange face which mates with cylinder head 1.5 - 2.5 mm
f) Intake manifold Flange face which mates with cylinder head 1.5 - 2.5 mm
g) Turbo oil drain pipe Flange face which mates with cylinder block 1.5 - 2.5 mm
h) Camshaft end plate Flange face which mates with cylinder block 1.5 - 2.5 mm

Coating Liquid Gasket and parts Assembly Procedure

1. Completely remove old liquid gasket from each part and the respective mating part, and
remove oil, water, and dirt using cloth.
2. Be careful not to apply excessive or insufficient liquid gasket. Also, be sure to overlap the start
and end of each coating.
3. When assembling coated parts, be careful that there is no misalignment between mating parts.
If there is any misalignment, coat the parts again.
4. Assemble the various parts within 20 minutes after applying liquid gasket. If more than 20
minutes have elapsed, remove the liquid gasket and apply it again.
5. After assembling the various parts wait for at least 15 minutes before starting the engine.

Applicator Gun

Fig. 2

Loading Cartridge
Press lever 1 and simultaneously pull lever 2 back completely. Insert the cartridge. The open
cartridge can be dispensed by pressing lever 3.

Unloading Cartridge
Press lever 1 and simultaneously pull lever 2 back completely - Remove cartridge from the gun.
 HA6DTI2(D/N/U) ENGINES 09.17

09.0.14 Description of Leading Engine

Components

Cylinder Block - of high grade cast iron.

Cylinders and the crankcase form an integral
casting. The crankcase is enclosed from
below by the oil sump.

Cylinder Liners (dry, pre finished, hard,

easy fit type) - made of cast iron. There
are four selectable grades available i.e. W,
X, Y, Z based on liner outer diameter.

Cylinder Head - made of high-grade cast Fig. 3

iron, accommodating all cylinders, fitted with
exchangeable, pre finished valve seats and
valve guides.

Crankshaft - an alloy steel forging,

mounted in seven shell bearings with
exchangeable shells. The main journals and
crank-journals are induction hardened.

Vibration Damper - is mounted on the

front end of the crankshaft. Care should Damper X Y
be taken while handling the vibration BS I 104.5 mm 21 mm
damper. BS II 103 mm 20.5 mm
Fig. 4
Alfin Pistons - made of special grade
aluminium alloy with cast iron insert to form
the first compression ring seat. The
combustion chamber design is re-entrant
type for better combustion. Fig - 5

Main and Big End Bearing Shells -

thin-walled, with aluminium and tin or lead
bronze linings for sliding surfaces.

Camshaft - made of steel, mounted in the

cylinder block in four exchangeable bearing
bushes. Drive is supplied from the engine
crankshaft through a gear train. Cam
Fig. 5
profiles modified for intake and exhaust
consequentially tappet adjusting screw length
increased by 1.5 mm.

Valves - made of high-grade alloy steel.

Valve stem seals prevent oil leakage into
combustion chamber.

Valve Spring - made of spring steel,

constant pitch coil type springs.

Timing Gear Train - higher drive torque

requirement of VE pump, wider gears are
provided for crank gear, idler gear and FIP
gear.
09.18 HA6DTI2(D/N/U) ENGINES

09.0.15 Trouble shooting

09.0.15.0 Engine
Symptom Possible Cause Remedy/Prevention
Engine overheating Coolant
* Insufficient coolant Add coolant
* Defective thermostat Replace the thermostat
* Overflow of coolant due to leakage Repair
of exhaust into cooling system
* Coolant leakage from cylinder head gasket Replace gasket.
* Defective coolant pump Repair or replace.

Radiator
* Clogged with rust and scale Clean radiator.
* Clogged with iron oxide due to Clean coolant passage and correct
leakage of exhaust into cooling system exhaust leakage.
* Clogged radiator core due to mud Clean radiator.
or other debris
* Defective radiator cap pressure valve Replace radiator cap
* In correct gap between radiator and fan Correct the gap
* Deration pipes blocked due to mud Clean and use coolant.

Abnormal combustion
* Incorrect injection timing Adjust injection timing.
* Reduced injection pressure Adjust injection pressure.
* Poor fuel Use good quality fuel.
* Poor nozzle spray Adjust or replace nozzle.
* Unsatisfactory automatic timer advance angle Repair or replace timer.

Other problems
* Defective or deteriorated engine oil Change engine oil.
* Unsatisfactory operation of oil pump Replace or repair
* Insufficient oil Add oil.
* Brake drag Repair or adjust.
Excessive oil
consumption Piston, cylinder liners and piston rings
* Wear of piston ring and cylinder liner Replace piston rings and cylinder liner.
* Worn, sticking or broken piston rings Replace piston rings and cylinder liner.
* Insufficient tension on piston rings Replace piston rings and cylinder liner.
* Unsatisfactory break-in of piston rings Replace piston rings and cylinder liner.
* Unsuitable oil (viscosity too low) Change oil as required and replace piston
rings and cylinder liners.
* Incorrectly fitted piston rings (upside down) Replace piston rings.
* Gaps of piston rings in line with each other Reassemble piston rings.

Valve and valve guides

* Worn valve stream Replace valve and valve guide
* Worn valve guide Replace valve guides.
* Incorrectly fitted valve stem seal Replace the stem seal.
* Excessive lubricant on rocker arm Check clearance of rocker arm and shaft.
 HA6DTI2(D/N/U) ENGINES 09.19

Symptom Possible Cause Remedy/Prevention

Excessive oil
consumption Excess oil feed
* Defective oil level gauge Replace oil level gauge
* Oil level too high Drain excess oil.

Other problems
* Overcooled engine (low temperature wear) Warm up engine before moving vehicle.
Check cooling system.
* Oil leakage from miscellaneous parts Repair.

Piston seizure Operation

* Abrupt stoppage of engine after running Operate engine properly.
at highspeed
* Hill climbing using unsuitable gear Select suitable gear

Oil
* Insufficient oil Add oil.
* Dirty oil Change oil.
* Poor quality oil Replace with proper engine oil.
* High oil temperature Repair
* Defective oil pump Repair oil pump.
* Reduced performance due to worn oil pump Repair oil pump.
* Suction strainer sucking air Add oil and/or repair strainer.

Abnormal combustion See symptom:”Engine overheating”

Coolant See symptom:”Engine overheating”

Lack of power Intake

* Clogged air cleaner Clean element or replace element.

Fuel and nozzle

* Poor nozzle spray Adjust or replace injection nozzle
* Clogged nozzle with carbon Clean nozzle
* Wear or seizure of nozzle Replace nozzle
* Air in fuel system Repair and bleed air from fuel system.
* Clogged fuel filter Replace element
* Use of poor fuel Use good quality fuel.

Abnormal combustion See symptom:”Piston Seizure”

Wrong injection timing Set as per recommendation.

Throttle not travelling fully. Correct the setting.

Piston, cylinder liners and piston rings See symptom.”Excessive Oil Consumption”

Other problems
* Breakage of turbine or blower Repair
(if so equipped turbocharger)
09.20 HA6DTI2(D/N/U) ENGINES

Symptom Possible Cause Remedy/Prevention

Difficult starting
engine Electrical system
* Discharged battery Charge battery
* Defective wiring in starter circuit Repair wiring of starter.
* Loose or open-circuit battery cable Tighten battery terminal connections or
replace battery cable.
* Break of glow plug or intake Replace
air heater (if so equipped)

Injection pump Repair

Air cleaner
* Clogged element Clean the element or replace the element.
Fuel system
* No fuel in tank Supply fuel and bleed air from fuel system.
* Clogged fuel line Clean fuel line.
* Air sucked into fuel system through Tighten fuel line connections.
fuel line connections.
* Clogged fuel filter Replace element
* Loose connection in high-pressure line Tighten sleeve nut of high pressure line.
* Water in fuel Drain and clean fuel system

Nozzle
* Seized nozzle Replace nozzle
* Broken or fatigued nozzle spring Replace spring

Oil system
* Oil viscosity too high Use proper viscosity oil, or install an oil
immersion heater and warm up oil.

Other problems
* Seized piston Replace piston, piston rings ,and liner.
* Seized bearing Replace bearing and /or crankshaft
* Reduced compression pressure overhaul engine
* Ring gear damaged or worn Replace the ring gear and/or starter pinion.
* Improperly adjusted or broken accelerator
cable Adjust or replace the accelerator cable
* Arens control struck Correct the cable.
Rough idling Injection pump Repair

Nozzles
* Uneven injection pressure Adjust
* Poor nozzle spray Adjust or replace nozzle.
* Carbon deposit on nozzle tip Remove carbon
* Seized needle valve Replace nozzle

Engine proper
* Improper valve clearance Adjust valve clearance
* Improper contact of valve seat Replace or repair valve and valve seat.
* Idling speed too low Warm up engine.
* Compression pressure of cylinders Overhaul engine
markedly different from one another
 HA6DTI2(D/N/U) ENGINES 09.21

Symptom Possible Cause Remedy/Prevention

Leakage of exhaust Cylinder head gasket

* Fatigued gasket (aging) Replace gasket

* Damage Replace gasket

* Improper installation Replace gasket

Cylinder head bolts

* Loose bolts Tighten bolt

* Elongated bolts Replace bolt

* Improper tightening torque of tightening

sequence Tighten properly

Cylinder block

* Cracking Replace cylinder block

* Surface distortion Repair or replace.

* Fretting of cylinder liner insertion portion

(in sufficient projection of cylinder liner) Replace cylinder lines or cylinder block

Cylinder head

* Cracking Replace cylinder head

* Surface distortion Repair or replaces.

Cylinder liners

* Cracking Replace cylinder liner

* Corrosion Replace cylinder liner

* Insufficient projection of cylinder liner Replace cylinder liner

Other problems

* Incorrect injection timing Adjust injection timing.

09.22 HA6DTI2(D/N/U) ENGINES

09.0.15.1 Fuel Injection Pump

Symptom Possible Cause Remedy/Prevention
Engine does not start Fuel not reaching injection pump
* Fuel lines clogged or damaged Clean or replace fuel lines.
* Fuel filter clogged Clean or replace the filter elements.
* Air in fuel caused by improper connections Repair connections.
of fuel line between fuel tank and feed pump.
* Filter incorporated in inlet side of feed Remove foreign material.
pump clogged
* Faulty feed pump check valve Repair or replace it.
* Feed pump piston spring broken Replace it.
* Feed pump push rod or tappet sticking Repair or replace it.

Fuel reaching injection pump

* Faulty connection of accelerator wire to Repair connection.
pump adjusting lever
* Control rack faulty or sticking Repair it.
* Damaged camshaft bearing Repair it.
* Plunger worn or sticking Correct or replace it
* Faulty connection of engine stop wire to Repair it.
pump stop lever.

Nozzle faulty
* Fuel leakage caused by loosened nozzle Inspect and tighten it.
holder.
* Low opening pressure of nozzle Adjust it.
* Nozzle pressure spring broken Replace it.
* Nozzle needle sticking to nozzle body Correct or replace it.

Pump out of timing

* Improperly retarded injection timing Correct injection timing.
* Incorrect timing caused by improper Check engine timing and correct it.
installation of pump.
* Woodruff key for pump camshaft cut off. Replace it.
* Improper pre-stroke adjustment Correct it to obtain specified injection
timing.
Excessive smoke Black smoke
* Excessive fuel delivery caused by in correct Adjust fuel delivery on test stand.
adjustment of fuel load stopper screw.
* Excessively advanced injection timing. Correct it.
* Large spread in fuel delivery Adjust it.
* Bad nozzle fuel spray characteristics Check and correct them.

White smoke
* Improperly retarded injection timing Advance injection timing.
* Water in fuel Check and clean fuel lines.
 HA6DTI2(D/N/U) ENGINES 09.23

Symptom Possible Cause Remedy/Prevention

Low idle speed
irregular Improper adjustment of idle button Correct it.
Bad fuel spray characteristic of nozzles. Check and repair them.
Incorrect injection timing Correct it.
Incorrect initial tension setting of idling spring Adjust or replace it.
or the spring broken.
Control rack not smoothly move Disassemble pump and repair it.
Large spread in fuel delivery Adjust it.
Plunger worn Replace it.
Governor linkage not smoothly move. Correct it.
Defective feed pump Disassemble and repair it.
Engine always runs
at high speed Accelerator cable sticking Check and correct it
Governor linkage sticking Disassemble and repair the governor.
Control rack sticking Check and correct it.
Engine starts and
stops Fuel lines clogged Clean or replace fuel lines.
Air in fuel caused by damaged fuel lines of Repair fuel lines or replace fuel lines and
improper connection of fuel lines. gaskets.
Engine has low
power Pump out of timing
* Excessive advanced timing resulting in loud Check and correct it.
knocking.
* Excessively retarded timing resulting in black Check and correct it.
smoke.
* Defective injection pump overflow valve. Repair or replace it.
* Feed pressure too low Repair the feed pump.
* Improper accelerator cable adjustment Adjust it.
Nozzle faulty
* Fuel leakage from nozzle holder Check and repair nozzle holder.
* Bad nozzle spray characteristic Repair or replace it.
* Loosened adjusting screw in nozzle Adjust it.
holder, resulting in low opening pressure
Pump faulty
* Fuel leakage from delivery valve Retighten the delivery valve holder if it is
holder. loosened or replace O-ring if the O-ring
is defective.
* Defective seat of delivery valve assembly. Repair or replace it.
* Delivery valve spring broken Replace the spring.
* Plunger worn Replace it.
* Large spread in fuel delivery Adjust it.
* Wear of tappet roller Replace the roller.
* Camshaft bearing worn or broken Replace it.
* Improper adjustment of governor fuel load
stopper screw.
Loud knocking Improper injection timing Correct it.
Bad fuel nozzle spray pattern after-dribble. Check and correct it.
High nozzle opening pressure Adjust the opening pressure.
Incorrect fuel deliveries to some nozzles. Readjust the fuel deliveries.
09.24 HA6DTI2(D/N/U) ENGINES

09.0.16 Special Tools

Special Tool 0102001 Special Tool 0102002 Special Tool 0102003 Special Tool 0102004
Drift Oil Seal Gear Case Adaptor Idler Gear Shaft Sliding Hammer Drift (I) Oil Seal Fly Wheel
Housing

Special Tool 0102005 Special Tool 0102006 Special Tool 0102007 Special Tool 0102009
Compressor Valve Spring Drift Valve stem Seal Adapter Engine Compression Drift Valve Guide

Special Tool 0102010 Special Tool 0102011 Special Tool 0102012 Special Tool 0102013
Wrench Cylinder Head Bolt Extractor Cylinder Liner Guide Cylinder Liner Retainer Cylinder Liner

Special Tool 0102014 Special Tool 0102015 Special Tool 0102017 Special Tool 0102018
Compressor Piston Ring Adaptor Injector Removal Drift & Extractor Drift and Extractor
Connecting rod Bushes Cam Bushes

Special Tool 0102019 Special Tool 0102020 Special Tool 0102021 Special Tool 0102023
Wrench Engine Cranking Drift-II Oil Seal Gauge Compression Adapter Engine
Flywheel Housing Checking Compression
 HA6DTI2(D/N/U) ENGINES 09.25

09.0.17 Factors Which Determine When an

Engine Overhaul is Needed
1. Low compression pressure.
a. Before the measurement
i) Correct the valve clearance.
ii) Warm up engine [Bring the coolant
temperature to about 80°C.
iii) Charge the battery fully.
iv) Remove the air cleaner.
b. Measurement Fig. 6

i) Measure at nozzle holder hole.

- Remove the nozzle holders.
- Install the gauge adapter in the
nozzle holder hole and connect
compression gauge.
Special Tool 0102023 - Compression
Gauge Adapter and Special Tool
0102021 Gauge Compression.
Set the engine starter key at “OFF”
position, then disconnect the engine
stop switch harness.
Fig. 7
- Drive the engine with the starter
and read the compression pressure.
Note: Do not continuously operate the starter for
more than 15 seconds at a time.
- Measure the compression pressure
for each cylinder. If the compression
pressure is low, be sure to repeat
the measuring.
Note: Make sure no leakage through the sealing
face.
c. After the measurement
Make sure the engine starter key is in
“off” position and then connect the
engine stop switch harness.
Warning: Do not connect the electric harness
with the engine stop switch while the
engine starter key at “on” position as
this operate the engine stop switch
instantaneously and the link lever of
the engine stop switch and the engine
stop lever of the fuel injection pump
move, resulting in your finger caught
by the lever.
09.26 HA6DTI2(D/N/U) ENGINES

Compression pressure
Minimum : 24 kg/cm² @ 280 rpm
Maximum : 29 - 32 kg/cm² @ 280 rpm

Pressure difference between each

cylinders should be below 3 kg/cm²

2. Low oil pressure

Check the oil pressure warning lamp when

the oil and coolant temperature is hot about
80°C.

a. If the warning lamp is lighted , check the

oil level.

b. Check oil deterioration.

If oil quality is poor, replace with a

suitable grade oil.

c. Remove the oil pressure switch and

install the oil pressure gauge.

d. Measure the oil pressure at coolant

temperature about 80°C.
Standard oil pressure
for Turbo engines : Idling 1.0 kg/cm²
Max. 4.8 kg/cm²

3. Other factors

a. The blow – by gas increases.

b. The engine does not start easily.

c. Engine output decreases.

d. Fuel consumption increases.

e. Engine makes greater noise.

f. Excessive oil consumption.

 HA6DTI2(D/N/U) ENGINES 09.27

09.1 TO REMOVE AND REFIT ENGINE

FROM VEHICLE
09.1.0 To Remove Engine
- Disconnect battery terminals and choke the
wheels.
- Drain engine oil
- Drain the coolant and remove cooling
system, radiator, pipes, hoses etc.
- Remove air intake system, turbo connection,
charge air cooler, exhaust system and fuel
pipe connections,
- Disconnect electrical connection from fuel
shut off solenoid and cold start device
(KSB).
- Disconnect the clutch / gear linkage system.
- Remove gear box and clutch.
- Unscrew engine fixing bolts of the engine
mounting pad.
- Fasten hoisting cable to the lifting eyes on
right front and left rear of engine.
- Use multipurpose jip crane SME 11001 to
lift the engine. Fig - 1
- Lift the engine slightly and move it Fig. 1
outwards.
- Place the engine on suitable platform
keeping in mind that the oil sump is not
damaged.
Note: Use Engine stand of proper dimensions to
keep the engine or use Special Maintenance
Equipment, SME No. 01006. Fig - 2
- Engine should be thoroughly washed with a
suitable cleaning liquid before it is
dismantled.
- Dismantling and assembly should be carried
out by experienced personal and atmost Fig. 2
cleanliness must be observed. Special tools
manufactured for this purpose to be used.

09.1.1 To Refit Engine

- The above mentioned procedure to be
fitted back in reverse order.
- Ensure the alignment of the engine in the
exact centre of the chassis frame.
- Before initial starting of the engine, check
whether, engine injection pump, governor,
gear box and cooling system have been
filled with lubricants and coolants according
to specifications.
09.28 HA6DTI2(D/N/U) ENGINES

09.2 CRANKCASE

09.2.0 To Remove and Refit Cylinder Liners

Use Special Tool 0102011 - Extractor
Cylinder Liner for removal of cylinder liners.

Note: Liners are of transition fit type. Special tool

to be used only when liner removal is
difficult. Fig - 1.

Incase you want to reuse the liner be sure

to put matching marks with marker pen on Fig. 1
the cylinder block and liner flange for
repositioning. Fig - 2

After removing the cylinder liners, put

numbers on their periphery or arrange them
in sequence.

Make sure that the liner grade mark has the

same mark on the cylinder block.

There are 4 different grades of liners and

cylinder block matches. Each liner has any
Fig. 2
one of the following markings W, X, Y or Z
of the OD. These indicate the size of the
O.D. of the liner. Similarly, the matching I.D.
markings of the cylinder bore is indicated by
W, X, Y or Z on crank case LH side top
for each Bore. Fig - 3

Apply a small amount of clean engine oil on

the outer periphery of liner. The special tool
should be used as liner is extremely thin and
can easily get damaged. Thin and sharp ring
on the top face of the liner is called
"FLAME ARRESTER". Any damage to this Fig. 3

flame arrester ring can cause cylinder head

gasket failures.

When reusing a liner, insert the liner in its

original position aligning the markings marked
before disassembly. Use Special Tool
0102012 - Guide Cylinder Liner. Fig - 4

Fig. 4
 HA6DTI2(D/N/U) ENGINES 09.29

Measure the projection of the

cylinder liner.

Fix Special Tool 0102013 - Retainer Cylinder

Liner (Fig - 5) and measure the amount of
projection of the liner from the cylinder block
with a dial gauge and magnetic stand. Fig
- 6

09.2.1 To Remove and Refit Timing Casing

Cover and Back Plate Fig. 5

Identification for Timing Casing. Fig - 7

Backout fixing screws of the Timing back

plate. Fig - 8

Take off the Timing back plate, taking care

of both dowel pins. Before refitting, remove
the old Liquid gasket material and clean
front face of the crankcase.

Apply fresh liquid gasket (Anabond 683)

Fig. 6
with new gasket to crank case face of the
Timing Back plate.

Screw down Timing Back plate with hex

screws and spring washers.

Timing back plate mounting bolt holes, in

which one mounting hole provided with a
counter bore, use special bolt with a thread
sealent (without washer). Fig - 9.

Fig. 7

Fig. 9 Fig. 8
09.30 HA6DTI2(D/N/U) ENGINES

Remove timing cover and Replace new oil

seal using Special Tool 0102001 - Drift Oil
Seal Gear Case. Fig - 10.

Installation should only take place with

engine in normal upright position.

Fig. 10
09.2.2 To Remove and Refit Flywheel
Housing

Backout fixing screws of the flywheel housing.

Fig - 11. Start with M8 bolts (6 nos.) and
then M14 bolts (8 nos.).

Take off the flywheel housing, taking care of

rear main oil seal.

09.2.3 Install the Oil Seal in the Flywheel

Fig. 11
Housing

Using a special tool, press in the oil seal in

the flywheel housing. Fig - 12

Special tool 0102004 : Drift for Oil Seal

Flywheel Housing.

Before refitting, remove the old Liquid gasket

material and clean rear face of the
crankcase. Apply fresh Liquid gasket to
inner side of the flywheel housing.
Fig. 12

Fit flywheel housing and tighten it securely

with hex screw. Fig - 11. Start with M14
bolts (8 nos.) and M8 bolts (6 nos).

09.2.4 To Remove and Refit Flywheel

Backout fixing screws and remove flywheel.

Fig - 13

Check ring gear, if necessary replace.

Fig. 13
 HA6DTI2(D/N/U) ENGINES 09.31

09.2.5 To Remove Ring Gear (Fig - 14a)

- Heat the ring gear with a blow torch in a

uniform manner (approx. 180°C).

- Using a metal rod as pad and strike all

Fig. 14a
around the ring gear in uniform manner and
remove the ring gear.

09.2.6 To Install Ring Gear (Fig - 14b)

Fig. 14b
- Heat the ring gear uniformly using a blow
torch (approx. 180°C).

- Drive the ring gear with its chamfered gear

teeth facing the block onto the flywheel
using a metal rod.

09.2.7 Install Flywheel

Align the 'O' mark on the flywheel and

crankshaft collar knock pin. Fig - 15.

Install the flywheel and tighten the bolts

through several repetition of the tightening Fig. 15

order so as to reach specified torque evenly

and gradually then slacken and tighten them
by one by one to the specified torque as
per sequence. Fig - 16a & 16b.

When tightening the bolt, apply engine oil to

the threads and flywheel surface of the bolts.
Fig. 16a

Install the pilot bearing and stopper.

Check the flywheel runout as per Fig. 16b

recommendation. Fig - 17

Fig. 17
09.32 HA6DTI2(D/N/U) ENGINES

09.3 CRANKSHAFT

The crankshaft is supported by 7 main

bearings.

Thrust is taken up by the thrust washer at

the fourth journal.

Identification for uprated engine

crankshaft.

'E2U' punch mark on the crankshaft 1st Fig. 1

web. Fig - 1

Uprated engine crankshaft - 1st & 6th pin

and 1st & 7th main journal fillets are
induction hardened.

09.3.0 To Remove and Refit Crankshaft

Backout collared bolts and remove bearing

caps.

Remove thrust bearing cap (4th) last.

Fig. 2
Fig - 2

Arrange all the caps bearing and thrust

washer in order. Fig - 3

The bearing caps are match mark with the

crankcase by the punch mark 1 - 7,
commencing from timing gear side. Timing Gear Side

Fig. 3

Lift the crankshaft out of the crankcase.

Fig - 4

Fig. 4
 HA6DTI2(D/N/U) ENGINES 09.33

09.3.1 To Renew Crankshaft Gear

By using Conventional puller remove

crankshaft gear from crankshaft. Fig - 5

09.3.2 To Refit the Crankshaft Gear

Heat the gear upto 130°C and fix it.

09.3.3 To Check Crankshaft Bend

Maximum permissible bend is 0.04 mm.

Fig - 6
Fig. 5
09.3.4 Installation
Clean crankcase, crankshaft and bearing
shells by blowing compressed air through the
lubrication holes.

09.3.5 To Renew Crankshaft Main &

Connecting Rod Bearing and Check
Main & Connecting Rod Bearing
Spread

Hold the bearing shell without applying any

pressure and measure the outside diameter. Fig. 6

Main bearing dimension : 79.00-79.60 mm

Connecting rod
bearing dimension : 67.05 - 67.55 mm

Fig - 7

Install the crankshaft, main bearing on the

crankcase and bearing caps.

Lubricate crankshaft journals, bearing shells,

Fig. 7
cap bolt threads and under the bolt heads
with the engine oil. Carefully lower the
crankshaft into position.

Fit bearing caps and starting off with the

thrust bearing No.4, adhering to the match
marks. Connecting faces, of bearing caps
and crankshaft should be perfectly clean.
Fig - 8.

Bearing cap set identification no punched on

the bearing cap and LH side rear end of
the crankcase. Fig. 8
09.34 HA6DTI2(D/N/U) ENGINES

Tighten cap collared bolts uniformly in the

three stages in tightening order 4-5-3-6-2-7-1.
Fig - 9
Do not attempt to rotate crankshaft
before all bearing caps have been bolted
down. The crankshaft must turn freely
without binding i.e. a strong push by hand
should make it turn atleast one revolution.
Fig - 10
Check endplay of crankshaft as follows:
Force crankshaft in one axial direction and
measure the gap between thrust bearing
side and crank web face. Fig. 9

The initial end clearance with new thrust and

main bearings should amount to 0.05 to
0.22 mm end clearance should not exceed
0.4 mm.. Fig - 11

09.3.6 To Check and Grind Crankshaft

Clean crankshaft and blow out lubrication
holes with compressed air, check journals
and crankpins for cracks.
Check wear of crankshaft if wear is more
than 1.2 mm from standard size, replace
crankshaft.
Fig. 10
No further heat treatment is recommended.
Support crankshaft at front and rear journals.
The bend must not exceed 0.04 mm.
Check journals & crankpins for ovality, Taper.
Max. permissible ovality = 0.02 mm
Max. permissible Taper = 0.02 mm
Concentricity = 0.03 mm
Grind the crankshaft according to the
available replacement bearing shells. This
work may only be performed by experienced
crankshaft grinders. For repair data of
undersize big end bearings and main Fig. 11
bearings refer section 09.0.7.

09.3.7 To Remove and Refit Vibration

Damper
Backout the hex nut with box spanner 46
mm. Fig - 12
Withdraw the vibration damper.
If found external damage, replace with new
one.
Fit the new O ring on the inner dia of the
hub.
To refit vibration damper reverse the
procedure for removal. Fig. 12
 HA6DTI2(D/N/U) ENGINES 09.35

09.4 PISTON AND CONNECTING RODS

09.4.0 To Remove Piston Assembly

Fix Special Tool 0102013 - Retainer Cylinder

Liner to hold the liner.

Backout connecting rod bolts and remove

bearing cap.

Scrape off carbon deposit from the upper

end of the cylinder liner with the help of Fig. 1
emery paper or scraper. Fig. 1

Extract all the pistons and connecting rod

assemblies through top of the cylinders.

09.4.1 To Dismantle and Assemble Piston

and connecting rod

Remove gudgeon pin circlip with the circlip

plier. Fig - 2

Fig. 2

Place a copper drift on the pin and strike it

out with the hammer. Fig - 3

09.4.2 Connecting Rod Bush

Fig. 3

09.4.2.0 To Remove Bush

Using a special tool 0102017 - Drift and

extractor.

Align supporting surfaces of the guide and

press sub assembly flush on the flat plain.

Set the connecting rod assembly without

crank pin bearing on the guide and press
assembly. Fig - 4
Fig. 4
09.36 HA6DTI2(D/N/U) ENGINES

Install the spindle into the bushing. Align

the grooving of the spindle with the oil hole
of the bush. Fig - 5

Fig. 5

Using a hydraulic press, remove the bush

slowly and smoothly. Fig - 6

Fig. 6

09.4.2.1 Installation of Connecting Rod Bush

Chamfer one edge of the bush hole at the

small end of the connecting rod uniformly by
C 0.5 - 1.0 mm. Fig - 7

Set the bush and guide on the spindle then

secure them with the bolt.

Fig. 7

Be sure to slip the bushing over the spindle

in the proper direction, so that oil hole 'A'
will later align with the rifle hole in the
connecting rod. Fig - 8

Fig. 8
 HA6DTI2(D/N/U) ENGINES 09.37

lubricate the bush guide and bush bore on

the connecting rod.

Align oil hole 'B' in the bushing with the rifle

hole of the connecting rod. Fig - 9

Always operate the press slowly and

smoothly.

Fig. 9
09.4.2.2 Inspect the Bushing Position after
Installation

Make sure that the oil holes of the bushing

and connecting rod are aligned. Fig - 10

Insert a pin of 3 mm dia into the hole at

the end of the connecting rod, and make
sure that the pin fully goes in.

If there is any deviation in the alignment of

the oil holes correct it with a drill of 3 mm Fig. 10
dia. If drilling is carried out, take care to
remove the machined burrs clears off the
connecting rod small end bore and oil holes.

09.4.2.3 Check for Bend of Connecting Rod

Check for bend of connecting rod by means

of bend checking tool and feeler gauge. The
permissible tolerance is 0.1 measured at the
distance of 200 mm from the longitudinal
axis of connecting rod. Fig - 11

Fig. 11

09.4.2.4 Install the Connecting Rod Bearing

Confirm the oil hole A & B are in line.
Fig - 12

Fig. 12
09.38 HA6DTI2(D/N/U) ENGINES

09.4.3 Piston and Piston Rings

09.4.3.0 Piston General

The piston combustion chamber is of re-

entrant type for faster and more efficient
combustion. The piston consists of two
compression Ring grooves, one oil scraper
ring groove and crown face with valve
pockets.

Max. difference in the weight of the piston is Fig. 13

an engine set of 6 pistons not to exceed 5
gms.

Weight group identification mark punched on

the piston crown.

The difference between BSI and BS II pistons

are shown in Fig - 13.

09.4.3.1 To Remove Piston rings

Remove compression rings and oil scraper

Fig. 13A
rings with the aid of piston ring plier. Fig -
13A

Remove carbon deposits from piston ring

grooves.

09.4.3.2 Assemble Piston and Connecting Rod

Heat the piston to approximately 80°C

temperature.

Insert the gudgeon pin into the piston with

connecting rod. Fig - 14 Fig. 14

O mark on the piston top and connecting

rod match mark should remain opposite to
each other, while assembling the piston to
connecting rod. Fig - 15

Fig. 15
 HA6DTI2(D/N/U) ENGINES 09.39

09.4.3.3 Install Piston rings

Before fitting new piston rings, check each

ring gap separately by inserting the ring into
the cylinder bore at right angles and
measure the ring gap with a feeler gauge.
Fig - 16

Apply oil over the piston ring. use a piston

ring expander while fitting the piston rings.

Install the piston ring in sequence viz; oil Fig. 16

ring, second ring and top ring with the
identification mark at the top of the ring
facing upwards.

Connect the ends of the coil expander and

then fit the coil inside the piston ring after
ensuring that the gap of the piston ring is
180° away from the joint of the coil. Coil
expander and piston scraper ring are
supplied together. Fig - 17

Fig. 17

Check the side clearance of the piston rings.

Fig - 18

Fig. 18

Stagger the piston ring gaps so that they

are not in line, approximately at 120 o away
from each other. Fig - 19

Fig. 19
09.40 HA6DTI2(D/N/U) ENGINES

09.4.3.4 Installation

Lubricate piston, piston rings, cylinder bore

and con rod bearing with engine oil.

Displace the piston ring gaps relative to

each other by 120°.

Make sure that 'O' mark on the piston top

is on the tappet side, when fitted.
Fig. 20
Rotate crankshaft so that the crankpin of
the respective piston is in B.D.C. position.

Insert piston with connecting rod assembly

into the cylinder bore compressing the piston
rings by means of Special Tool 0102014 -
Compressor Piston Ring. Fig - 20

Push the piston into the crankcase until the

big end bearing is seated on the crankpin.

Align the punch mark on the connecting rod

Fig. 21
and cap. Fig - 21

Fit bearing cap with bearing, taking care that

the bearing halves are seated properly in the
connecting rod and cap. Tighten con rod
bolts alternatively to recommended torque.
Fig - 22

Fig. 22
 HA6DTI2(D/N/U) ENGINES 09.41

09.5 CYLINDER HEAD ASSEMBLY

09.5.0 To Remove Cylinder Head

Loosen the cylinder head bolts / rocker

arm support bolts as per sequence shown.
Fig - 1. Start with M10 bolts and then
M12 bolts.

Using a special tool 0102010 - Wrench

Cylinder Head Bolt
Fig. 1
Lift the cylinder head from the dowels on
the cylinder block and place it on wooden
blocks (supporting on both the ends) to
avoid nozzle tip damage. Nozzle protrusion
from the cylinder head surface 4 - 4.5 mm.
Fig - 2

Ensure that all the nozzles are removed from

the cylinder head.

Remove the valve split cone lock, collar and

spring from cylinder head.
Fig. 2

Using Special Tool 0102005 - Compressor

Valve Spring. Fig - 3

Remove the inlet and exhaust valves.

Before removal of all valves, punch the serial

nos of cylinder numbers on the valve face,
to avoid mixing of valves. Fig. 3

Clean the cylinder head, valves, spring and

all other parts thoroughly with the suitable
solvent.

Check cylinder head surface unevenness.

Fig - 4.

Fig. 4
09.42 HA6DTI2(D/N/U) ENGINES

Hand lap valve and valve seat.

Lightly apply lapping compound to the valve

face. Install the valve with a Valve Lapping
Tool, tap and rotate valve against the seat.
Fig - 5.

Fig. 5

09.5.1 To Grind Valves and Valve Seats

Note : Grinding of valves and valve seats should

only be performed when handlapping does
not result in proper seating. Any
conventional valve grinding machine can be
used. Fig - 6 & 7

After grinding, always recheck the valve sink.

For repair data refer section 09.0.3.

Fig. 6

09.5.2 To Refit the Valve Seat and To

Check and Reface Valve Seat

Cut the circumference of a valve head at

three places with a grinder and install it into
seat and weld valve to seat. Then drive
out valve and seat with a hammer and a
brass block.

09.5.3 Valve Seat Installation

Fig. 7

Heat the cylinder head to about 80° -

100°C with hot water. On the other hand,
cool the valve seat with dry ice or liquid
nitrogen for about 30 minutes. Hold the
seat with pincers and place it into the
heated cylinder head. Fig - 8

Fig. 8
 HA6DTI2(D/N/U) ENGINES 09.43

Valve seat section machining specifications

Fig. 9
Fig - 9

09.5.3.0 To Check the Valve Guide

The Valve guide may require replacement if

stem to valve guide clearance exceeds
Intake - 0.035 - 0.068 mm
Exhaust - 0.050 - 0.083 mm

Fig - 10

09.5.3.1 To Renew Valve Guide

Fig. 10
Remove the valve stem seal.
Intake Exhaust
Using
(mm)a brass(mm) rod and hammer, drive out
the valve
46.500 - guide.
41.000 -
A
Cylinder Head 46.516the valve
Install 41.016
guide.
Dimension
B 8.8 - 9.0Tool7.20102009
Special - 7.4 - Drift Valve Guide.

Note 46.630 - 41.130 -

C : Apply engine oil lightly to the valve guide
Valve Seat 46.645circumference
outer 41.145 before installation.
Dimension
D 7.5 - 7.7 6.0 - 6.2
09.5.3.2 To Refit Valve and Valve Stem Seals

Install the valves and lower spring seat.

Use fitment sleeve for valve guide Fig. 11

seal to part no. X1102160.

Fig - 11

Then apply engine oil to the lip of the stem

seal and install the stem seals.

Remove and scrap the fitment sleeve.

Drive the special tool until it hits the lower

spring seat.

Special Tool 0102006 - Drift Valve Stem

Seal. Fig - 12

Fig. 12
09.44 HA6DTI2(D/N/U) ENGINES

09.5.3.3 To Check Valve Springs

Check valve springs on a valve spring scale

for re-usability

Valve spring
straightness = 2.0 mm

Setting load = 26.5 kg at 45.5 mm

limit 24.6 mm

09.5.4 To Assemble the Cylinder Head

Apply engine oil to contact surface of all the

parts. Make sure that the valves are
installed in the respective cylinders.

Valve springs are constant pitch in place of

progressive spring (Equal pitch coil).

Press valve spring and collar to install split

cone lock.

Using Special Tool 0102005 - Compressor

Valve Spring. Fig - 13.

Install the Cylinder Head Fig. 13

Install the cylinder head gasket, always use

new cylinder head gasket. After cleaning the
surfaces of the cylinder head, cylinder block
and head gasket free from dirt, water and
grease.

Fit 12 numbers valve lifters on to the

cylinder block after applying the oil to the
tappet bores on the cylinder block.

Ensure fitment of two dowel pins on the

cylinder block top, to locate cylinder head
gasket.

Install the cylinder head over the dowels on

the cylinder block.

Insert push rod in correct order.

Tighten the cylinder head bolts in three

stages as per tightening sequence and
recommended torque. Fig - 14. Start with
M12 bolts and then M10 bolts.

Mount the rocker arm assembly on the

cylinder head, make sure that the push rods
interlock with the adjusting screws.
Fig. 14
 HA6DTI2(D/N/U) ENGINES 09.45

09.6 TIMING

09.6.0 To Remove and Refit Rocker Levers

Backout fixing bolt and remove rocker shaft

assembly.

Reassemble rocker arm assy. in the order as

follows:-

Bracket, Inlet valve lever, Spacer, Exhaust

valve lever, Bracket . . . ,
Fig. 1
The tappet adjusting screws in BS II are
longer by 1.5 mm then compared to BS I
engine. Hence care should be taken to
ensure that the right screws are fitted.

Confirm that oil hole of rocker arm

assembly No.7 support aligns with shaft oil
hole.

Fig - 1

Improper installation will result in seizure of

the entire valve assembly.

09.6.1 To Remove, Refit and Check Push

Rod and Tappets

Remove push rods and tappets.

Check out of true of push rods between

centres.

Maximum permissible out of true = 0.3

mm.

Examine push rod ends for wear. Replace

if necessary and check rocker lever and
tappet lubrication in this case.

Check diametral clearance of tappet in

crankcase bore and inspect sliding surface
and push rod seat for wear.

If necessary replace worn out parts.

To refit push rods and tappets, reverse the

procedure for removal.
09.46 HA6DTI2(D/N/U) ENGINES

09.6.2 To Remove and Refit Camshaft

Unscrew 2 Nos Hex screws of 12mm size
from camshaft holding flange through
opening provided in camshaft gear.
Do not unscrew camshaft drive gear
holding bolt and try to pull the gear using
puller.
Extract camshaft after removing push rods
and tappets.
Pull out the camshaft slowly turning it, so
that the bearings are not damaged. Fig - 2

09.6.3 Removal and Replacement of Fig. 2

Camshaft Bushes
Use Special Tool 0102018 - Drift &
Extractor Camshaft Bushes to remove and
refit camshaft bushes. Fig - 3
Extraction
The HINO cylinder block is designed with
minimum aperture, the camshaft bushes are
not approachable from the LH side or
bottom side of the engine. Hence the parent
bores of camshaft bushes in the cylinder
block have been machined in different
diameters to facilitate the removal and re-
fitment of the bushes. For this reason, the
diameters of the camshaft bearing journals
are in descending order.

09.6.4 Camshaft Bush Dimensions (in mm)

Parent bore diameter
First Bush - 60 Second Bush - 59.8
Third Bush - 59.6 Fourth Bush - 59.8
Bush inner diameter
First Bush - 57 Second Bush - 56.8
Third Bush - 56.6 Fourth Bush - 56.4

Fig. 3
 HA6DTI2(D/N/U) ENGINES 09.47

Proceed in the following manner to remove

the camshaft bushes.

1. Remove the 1st and 4th bushes one after

one using collapsible puller assembly and
support bracket from front and rear
respectively. Fig - 4

2. Compress the collapsible puller and insert

the same in to the bush until the collapsible
bunk expands and holds the bush snugly.

3. Lightly tighten the nut next to the collapsible Fig. 4

bunk so that the bunk does not collapse
when the bush is being pulled out.

4. Place the support bracket and thrust bearing

in place and using the nut and handle
assembly, pull out the bush.

5. Fix the extractor bunk on the appropriate

groove on the puller shaft, insert the puller
shaft from rear side of the engine carefully
locating the bunk inside the 3rd bush.
Fig - 5
Fig. 5
6. Arrange the guiding bunk, support bracket,
thrust bearing and nut & handle assembly at
the front end of the engine on the puller
shaft and extract the 3rd bush. The 3rd
bush will fall between the 3rd and 2nd
parent bores of the camshaft bushes now.

7. Guide the extractor bunk along with the

extracted 3rd bush in to the 2nd bush and
continue to rotate the nut & handle
assembly until the 2nd bush is extracted.
Fig. 6
Fig. 6
8. Take out the puller arrangement along with
the 2nd and 3rd bushes carefully through
the 1st bush parent bore of the camshaft.

09.6.5 Installation:

The camshaft bushes are pre-finished; hence

handle them carefully.

1. Fix the drift bunk on the puller shaft in the

appropriate groove on the longer puller
shaft as shown. Place the 3rd camshaft bush
on the extractor and carefully insert the
09.48 HA6DTI2(D/N/U) ENGINES

puller shaft from rear of the engine until the

front portion of the drift bunk sufficiently
enters the 3rd camshaft bush parent bore.
Arrange the guide bunk, support bracket,
thrust bearing and nut & handle assembly
at the front end of the cylinder block as
shown and tighten the nut & handle
assembly until the 3rd camshaft bush is in
its place. Fig - 7.

2. Remove the puller from the cylinder block

and place the 2nd camshaft bush on the
drift bunk. Insert the puller from the front Fig. 7
side of the engine until the front portions of
the drift bunk sufficiently enter the 2nd
camshaft bush parent bore. Arrange the
guide bunk, support bracket, thrust bearing
and nut & handle assembly at the rear end
of the cylinder block as shown and tighten
the nut & handle assembly until the 2nd
camshaft bush is in its place. Fig - 8

3. Remove the puller from the cylinder block

and fix the drift bunk in the appropriate
groove as shown in figure. Place the 4th
camshaft bush on the bunk and insert the Fig. 8
puller shaft from rear end of cylinder block
until the front end of the bunk is sufficiently
inside the parent bore of the 4th camshaft
bush as shown. Arrange the guide bunk,
support bracket, thrust bearing and nut &
handle assembly at the frond end of the
cylinder block as shown and tighten the nut
and handle assembly until the 4th camshaft
bush is in its place. Check for the alignment
of oil holes when the bush is in its place, it
would be about 2 mm inside the parent
bore. Fig - 9
Fig. 9
4. Remove the puller from the cylinder block
and place the 1st gear bush on the drift
bunk. Insert the puller from front end until
the front portion is sufficiently inside the
parent bore of 1st camshaft bush parent
bore. . Arrange the support bracket, thrust
bearing and nut & handle assembly at the
front end of the cylinder block as shown in
the figure, centralize the puller shaft at the
rear and tighten the nut & handle assembly
until the 1st camshaft bush is in its place.
Fig - 10.

Fig. 10
 HA6DTI2(D/N/U) ENGINES 09.49

To refit camshaft reverse the procedure for

removal.
If necessary, remove the camshaft
gear
Hold the camshaft assembly with a suitable
vice through wooden supports.
Remove the nut, then using a gear puller,
remove the gear. Fig - 11
09.6.6 Install the camshaft gear on the shaft
Install the camshaft bearing with a thrust
bearing. When installing the gear to the
camshaft, heat the gear in hot water Fig. 11
(approx. 100°C), then install the gear on the
camshaft by using a press. When tightening
the bolts, apply engine oil to the threads and
bearing surface of the bolt. Fig - 12
09.6.7 To Refit the Camshaft
Identification
'E2' punch mark on the rear end of the
camshaft. Fig - 13
Set the no. 1 piston to Top Dead Centre
of the compression stroke.
Lubricate all journals of the camshaft and
insert the camshaft assembly into the
cylinder block, by slowly turning, so that the Fig. 12

bearing will not be damaged.

Align the camshaft timing gear matching
mark with the oil pump gear mark.
09.6.8 To Remove and Refit Intermediate
Timing Gear
Backout fixing bolt and remove it with
thrust washer, withdraw intermediate gear.
Fig - 14
To remove the spindle use special tool
0102003 - Sliding Hammer and special
tool 0102002 - Adaptor Idler Gear Shaft.
Fig - 15 Fig. 13

Fig. 15 Fig. 14
09.50 HA6DTI2(D/N/U) ENGINES

09.6.9 Install the Idler Gear Shaft (Spindle)

Install idler gear shaft with thrust plate using

a plastic hammer.

Make sure that the two oil holes is facing

downward (oil pan side) so that it does
not become clogged due to accumulation of
sludge and other foreign material in the oil.
Fig - 16

09.6.10 Install the Idler Gear

Install the Idler gear, be sure that the Fig.16

matching marks of the crankshaft gear, oil
pump drive gear and idler gears are aligned
correctly. Fig - 17

Check end play within 0.040 - 0.095 mm.

Ensure backlash - 0.068 - 0.194 mm.

Tightening torque procedure for

idler gear bolt

- Apply oil on bolt thread and face

- Initial torque by 100 Nm, then loosen the Fig.17

bolt.

- Then torque the bolt to 40 Nm + 60° -

65°

- Resultant torque 135 - 195 Nm.

09.6.11 To Re-bush Intermediate Gear

Press out the worn bush with a suitable

drift. Fig - 18

Drive in the new bush.

Fig.18
Note: The replacement bush is supplied finished.

Max. oil clearance

between spindle
and bush = 0.1 mm

Intermediate gear
endplay = 0.15 mm

Fig - 19

Bush internal diameter = 50.00 mm

Spindle dia = 49.95-49.97 mm

Fig. 19
 HA6DTI2(D/N/U) ENGINES 09.51

09.6.12 To Position Timing Gears for Valve

Timing and FIP Timing
1. Crankshaft Gear

2. Idler Gear
The gear train to be matched as per
3. Injection Pump
matching punch marks on gear Drive Gear
circumference. Fig - 20 4. Oil Pump
Drive Gear

09.6.13 Timing Gear Backlash Checking 5. Camshaft Gear

(Fig - 21) 6. Power Steering
Oil Pump
Check tooth backlash with feeler gauge. Drive Gear
(Option)
Backlash between driving gear and
intermediate gear.
Fig. 20
Max. limit = 0.3 mm.

09.6.14 To Fit Air Compressor

While assembling, keep engine first cylinder

at TDC, align 'N' punch mark on the gear
teeth with the bottom mounting hole, then
assemble the compressor and tighten the
mounting bolts. Fig - 22

09.6.15 To Remove and Refit Fuel Injection

Pump and To Adjust the Injection
Timing
Fig. 21
Use special Tool 0102019 - Wrench for
Engine Cranking.

A. Removal of FIP from Engine:

1. Isolate battery.

2. Remove high pressure pipe connections,

remove over flow pipe, boost compensator
pipe (black colour nylon hose) and
disconnect the 24V supply connection to
Fuel shut off solenoid and KSB. Remove the
FIP support bracket.
Fig. 22

3. Loosen the 3 nuts mounting the FIP onto

the injection pump drive housing, and
remove the FIP. There is no need to
remove the injection pump drive housing
(cover timer).

Caution: After removal ensure that the Over

flow Banjo (marked as ‘OUT’) and
the LDA connection banjo if fitted
back to the respective FIP. These are
not to be interchanged and will be
required for Bench calibration also.
09.52 HA6DTI2(D/N/U) ENGINES

B. Bench Calibration:

1. Remove the splined bush by a suitable tool.

The FIP can now be put on bench for

calibration.

2. After bench calibration, fix the splined bush

and torque tighten to the specified value.

3. Set the specified pre-stroke value by using

dial indicator and cam lock.

4. The FIP is now ready for fitment onto the

engine.

5. Ensure that the inlet adaptor on the FIP fuel

inlet, Overflow (‘OUT’) Banjo and the LDA
Banjos are fitted back onto the FIP after
bench calibration.

Note: For Calibration chart refer MICO dealer.

C. To Refit the Fuel Injection Pump and

adjusting the Fuel Injection Timing

1. Bring the no.1 cylinder at TDC on

compression stroke. Fig - 23 ( Hint: there is
no need to remove the rocker cover. At
the first cylinder compression the double
groove in the Inj. Pump drive coupling, which
can be felt with hand from the open end
rear end of the Inj. Pump drive housing, will
be vertical).

2. Check the FIP mounting Gasket.

Fig. 23

3. Fit the FIP onto the engine aligning the

double tooth with the double groove in the
injection pump drive coupling (Hint: at the
correct timing the double tooth on the
splined bush would be vertical) and cam
locked condition.

4. Tighten the 3 FIP mounting nuts, by pushing

the pump towards cylinder block. Fig - 24

Fig. 24
 HA6DTI2(D/N/U) ENGINES 09.53

5. Loosen the cam-lock, insert the interposing

plate under the camlock screw and tighten
the cam-lock screw again. (To make the
drive shaft free).

6. Remove the dummy plug on the

distributor head and fix the special tool.
Fig - 25 & 26

7. Energise the KSB by connecting the 24V

supply or Mechanically disengage the KSB
(Wait for approximately for 5 minutes to Fig. 25
allow the wax in the KSB to melt and relax).
Fig - 27

8. Rotate the engine in the opposite direction

of rotation. Stop the rotation when the
pointer of the dial indicator stops moving.

9. Set Zero on the dial.

10. Rotate the engine in the direction of rotation

and align the 1/6 mark on the engine
flywheel to the flywheel housing ref.
Fig. 26

11. The dial indicator should now read pre-

stroke specified for the engine type.

12. If not, loosen the three nuts holding the FIP

to the housing-inj. Pump drive and turn the
FIP towards or away from the engine so
that the dial reads the required pre-stroke
value.

13. Tighten the three nuts to secure the FIP

firmly.
Fig. 27

14. Remove the dial indicator and fit the dummy

plug.

15. Mechanically engage the KSB if it has been

disengaged mechanically in step 7 above.

16. Fit the Over flow pipe, boost compensator

pipe, high pressure pipes and FIP support
bracket.
09.54 HA6DTI2(D/N/U) ENGINES

FIP Timing Setting Tool

FIP rear end dummy plug sizes are M8 and
M10.
Use special tool part no.
Small Tool - M8 - Z00WEO203193
M10 - Z00WEO230528
for checking timing without high pressure
pipes. Fig - 28a
Use special tool part no.
Long Tool - M8 - Z00ZZ0031450
Fig. 28a Fig. 28b
M10 - Z00ZZ0031604
for checking timing with just loosening the
high pressure pipes at injector end. Fig -
28b.
Supplier Address:
Productive Tool Engineers,
No. 251 1st Main, 7th Cross,
New 3rd Cross, Prakash Nagar,
Bangalore - 560 021.
Ph : 080-3124606.

09.6.16 To Adjust the Valve Clearance

Method for determining if the No. 1
or No.6 piston is at the Top Dead
Center on compression stroke.
* Turning the crankshaft, align the mark
"1-6" on the flywheel pointer on the
flywheel housing.
* In this position either the No. 1 or
No. 6 piston is at the top dead
center on compression stroke.
If both No. 1 intake and exhaust rocker
arms can be moved easily by hand, the No.
1 piston is at top dead center on Fig. 29
compression stroke.
With the No. 1 piston positioned at top
dead center on compression stroke, adjust
the No. 1 valve clearance using a feeler
gauge.
The feeler gauge should move with a very
slight pull.
Valve clearance -
To adjust the other cylinder valves, by
turning the crankshaft clockwise 120°
(viewed from the front side). Adjust the
valve clearance for each cylinder as per firing Fig. 30
order. Fig - 29 & 30
 HA6DTI2(D/N/U) ENGINES 09.55

09.6.17 To Assemble FIP Drive Coupling

(Fig - 31)

Assemble the bushes (2) on to the injection

pump drive housing (1).

Pump drive shaft (3) is assembled alongwith

a thrust washer (4) into the housing (1).

Eccentric (5) is press fit on to the drive

shaft (3) and retainer circlip (6) is fitted.
Fig. 31
The IPD coupling (7) is assembled into the
drive shaft (3).

Circlip (12) is fitted into the IPD.

FIP gear (8) is fitted onto the drive shaft

(3) and retained with 8 bolt (9).

The end cover (11) with O ring (10) is

fitted.

Feed pump is fitted on the drive on the

injection pump drive housing.
Identification for FIP Splined Bush

FIP is assembled with splined bush on to

the FIP drive coupling.

Note: For derated pump, use splined push punched

"6D".
For nominal/uprated pump use splined bush
Part No. ID Mark Application
punched "6N"

Fig - 32 X1600315 6D Derated

X1600415 6N Nominal and Uprated

9.6.18 To Fit Injector High Pressure Pipes
Fig. 32
The fuel outlet at distributor head of the FIP
would be identified with alphabets A-B-C-D-
E-F as shown in Fig. 33

The fuel outlet on the pump corresponding

to each Engine cylinder is given in the table
below:
Connection Sequence
Engine
Cylinder no. 1 2 3 4 5 6

Fuel Outlet
A C E B F D
on the pump
Fig. 33
09.56 HA6DTI2(D/N/U) ENGINES

9.6.19 Fuel Filters

Effective fuel filtration is absolutely essential

for trouble free operation of the fuel
injection equipment. Fuel filters have been
designed to retain even the smallest of the
impurities and protect the extremely sensitive
precision parts of the injection pump and
nozzle from damage.

Note: Do not use star type filter inserts. Always

use coil type fuel filter. Fig - 34

Fig. 34
Maintenance
Filter inserts must be replaced at regular
intervals. Guidelines for replacement period
under normal conditions are given below.

Filter Change Period (Both Paper Coil

Type)

First stage First 16000 km and

element thereafter every 16000 km

Second stage First 24000 km and

element thereafter every 16000 km

Note: Never change both the filters at a same

time.

The filter elements (inserts) should never be

cleaned, at an interval lesser than the
recommended period. Sometimes the filter
inserts get clogged in a very short time due
to asphaltene or waxy compounds present in
fuel. In such cases the filter inserts have to
be replaced.

Renew Fuel Filter Element

- Unscrew centre bolt and withdraw the

bowl and filter, Install new sealing ring
and ensure it is correctly located.

- Clean the bowl free of sediments.

Replace a genuine filter element and
refit the bowl.

Bleed the fuel system

While bleeding the fuel system bleed the fuel
through the high pressure injector pipes upto
the injector end. It is necessary to crank
the engine intermediately.

Note: Do not disturb FIP for bleeding.

 HA6DTI2(D/N/U) ENGINES 09.57

09.6.20 Water Separator

Remove and empty the bowl and wash out

with clean fuel. Prefill the bowl with clean
fuel before refitting. Always renew the
sealing ring. Fig - 35

09.6.21 To Remove and Refit Injector Nozzle

Clean the surrounding area of the nozzle

and fuel line connections. Fig - 36

Remove injector pipes, clean and cover both

the ends of the pipes to prevent entry of Fig. 35
the dirt.

Remove nozzle assembly.

Use a special tools 0102015 - Adaptor

Injector Removal and 0102003 - Sliding
Hammer. Fig - 37

09.6.21.0 Cleaning

Important: The ball profile of DSLA nozzle is not

hardened, extreme care to be
exercised in handling the injectors and
nozzles at all levels. Do not use Fig. 36
emery sheet or hard material to clean
the nozzles.

To Clean nozzles

Use ultrasonic cleaning equipment.

Ultrasonic cleaning is a safe and effective

way of cleaning the nozzles.

Ultrasonic cleaning equipment consists of

generator capable of generating electrical
energy at an ultrasonic frequency and a
'transducerized tank' which holds the cleaning
Fig. 37
solution and the parts to be cleaned. The
Ultrasonic frequency waves are transmitted
to the cleaning solution contained in the
tank, which dislodges the dirt and soot.

The main objective of using this equipment

is to clean the spray holes of the nozzles
especially the DSLA type in which the ball
profile is soft.
09.58 HA6DTI2(D/N/U) ENGINES

09.6.21.1 Test the nozzle sinking

Wash the nozzle with the diesel then

immerse it in diesel oil.

Slide the needle inside the nozzle and ensure

moves smoothly. The needle should fall
under its own weight when withdraw
vertically about 1/3rd and released. If its
motion is sluggish, replace the nozzle with
new one. Fig - 38
Fig. 38
Adjust the injection pressure.

Connect the nozzle holder with a nozzle

tester and move the lever at the rate of
about 50 - 60 strokes per minute.

Adjust the injection pressure as

recommended. Fig - 39

If the injection pressure is not within

specifications, readjust the injection pressure
with the shims.
Fig. 39

09.6.21.2 Test the spray profile

In case of the new nozzle, operate the lever

at the rate of 30 - 60 strokes per minute
and for a used nozzle, operate the lever at
the rate of 15 - 60 strokes per minute.
Fig - 40

09.6.21.3 Test the fuel leakage (Dribbling)

When checking for fuel leakage from the

nozzle, apply a pressure of about 10 - 20 Fig. 40

kg/cm², to lower than correct injection

pressure to the nozzle. If there is no
leakage, the nozzle is normal. Fig - 41

09.6.21.4 Install the nozzle holder assembly.

Fit the new nozzle washer.

Tight the nozzle holder bolts alternatively

right and left, tightening the bolts gradually
until the specified torque is reached evenly
[Torque 150 kgcm (11 lb.ft.)]. Fig. 41
 HA6DTI2(D/N/U) ENGINES 09.59

09.7 ENGINE LUBRICATION cooler and filter respectively. After cleaning

the oil passes to the main gallery via oil
09.7.0 Design and Operation pressure relief valve it is forced through oil
ducts to the crankshaft and camshaft
Fig-1 illustrates the arrangement of the bearings. The connecting rod big end
equipment, and the flow of oil through the bearings are supplied with lubricant from
systems. the crankshaft main bearings, through
inclined oil ducts. The lubricating oil rises
The engine is arranged for forced feed from the camshaft bearing No. 6 to the
lubrication. The oil pump supplies the rocker shaft assembly. The intermediate
lubricating oil for engine. The oil pump is gear pin is lubricated from the 1st main
located within timing gear cover and driven Journal Bearing & Aux. gallery. This oil
by Intermediate gear, the oil pump gear in also lubricates the other timing gears. The
turn drives the engine camshaft. lubricating oil for the injection pump drive
housing and Air compressor is tapped off
The oil pump forces the oil from the sump from the duct feeding 1st main journal and
to the oil cooler 7. The oil is then filtered carried to the injection pump drive housing
through full flow paper type oil filter, there and Air compressor by the pipe arranged
are by pass valves (11) and (12) for outside the crankcase.

1. Piston 8. Turbo charger 15. Strainer

2. Connecting rod 9. Turbo feed 16. Oil sump
3. Idler gear 10. Oil filter 17. Oil pump
4. Crank shaft 11. Oil cooler by pass valve 18. Fuel injection pump drive housing
5. Cam shaft 12. Oil filter by pass valve 19. Air compressor
6. Rocker shaft 13. Relief valve 20. FIP Front Cover
7. Oil cooler

Fig. 1
09.60 HA6DTI2(D/N/U) ENGINES

09.7.1 To Remove and Refit Oil Pump

Remove oil pump from front face of Crank
case after removing intermediate gear and
camshaft. Fig - 2.

09.7.2 To Overhaul Oil Pump

Check Gear backlash between oil pump

gears standard 0.09 - 0.21 mm (limit -
0.30 mm). Fig - 3

Replace the gear if Backlash exceeds the

limit. Drive gear shaft diameter to drive
gear Bushing Inner diameter clearance should
not exceed 0.040 mm - 0.085 mm, If found Fig. 2
excess by measuring the Drive gear shaft
and Bushing inner dia separately. The drive
gear shaft diameter dimension - 18.088 -
18.106 mm (limit 18.06 mm). Fig - 4

Check clearance between driven gear and

shaft 0.040 - 0.075 mm (limit - 0.1mm).
Replace gear or shaft whichever is worn
excessively.

Driven gear Shaft Diameter 17.979 -

17.997mm (Limit 17.970 mm). Driven gear
inside diameter 18.037 - 18.054 mm (Limit
18.070 mm).
Fig. 3
Ensure height of the oil pump gear is
27.00 - 27.04 mm. Fig - 3A

09.7.3 To Refit the Oil Pump

The oil pump assembly is fixed by means of
7 screws, two of which are located at the
counter sunk area. The bolts used at these
2 locations have controlled head thicknesses
and are to be fitted using thread sealant
and without washers. Tightening sequence
of the oil pump. Fig - 5.

Make sure adequate clearance between idler

gear and oil pump cover, in view of the
increased width of idler gear. Fig. 3A

Fig. 5 Fig. 4
 HA6DTI2(D/N/U) ENGINES 09.61

09.7.4 To Overhaul Oil Cooler and Filter Assy

09.7.4.0 To Remove
Remove the entire assy of oil cooler and oil
filter from engine after draining coolant from
cylinder block and oil from filter drain plug.
Fig - 6
Note: All Bolts are of 13 mm size, But of Varied
length. Be careful to identify the bolts to
its original place during reassembly. Remove
& refit O-rings 4 nos during reassembly
Fig - 7 Fig. 6

Clean the oil filter head and oil cooler plate.

Clean the oil cooler.
Assemble the oil cooler by-pass valve.
Assemble the oil filter by-pass valve.
Assemble oil pressure regulator valve.
Assemble oil pressure gauge adaptor.
Assemble the oil cooler on the oil cooler
plate.
Replace the `O' ring at oil filter centre bolt
and position the bolt in oil filter bowl. Fig. 7

Replace the ‘O’ ring on the top of filter

bowl.
Refit the spring and the plate washer in the
bowl.
Fit a new oil filter element, washer, sealing
ring facing upwards.
Fit filter bowl with filter element to the filter
head tighten the centre bolt.
Also tighten the drain plug.
Fig - 8, 8A & 9
Fig. 8 Filter Correct Fitment

Fig. 9 Fig. 8A Filter Wrong Fitment

09.62 HA6DTI2(D/N/U) ENGINES

09.7.4.1 To Refit Oil Cooler

Clean the gasket sealing faces thoroughly.

Fig - 10

* Oil cooler / oil filter assembly a compressed

asbestos gasket is used.

Fig - 11

This will prevent oil cooler casing from Fig. 10

direct contact with coolant, in turn aluminium
surface erosion.

Note: Install Oil Cooler with filter.

09.7.4.2 Install the Oil Strainer

Make sure to install O ring guide and O

ring on adaptor.

Lubrication pipe connections.

Fig. 11
Lubrication pipe connection from crankcase
to FIP cover timer / Air compressor and
front cover. Fig 12, 13 & 14

Fig. 12

Fig. 14 Fig. 13
 HA6DTI2(D/N/U) ENGINES 09.63

1. Radiator
2. Cooling Fan
3. Thermostat
4. Coolant Pump
5. De-aeration Tank
6. Non-return valve

Water pump : Heavy Duty sealed 55 mm dia ball and roller bearing type.
Fig. 1 - Cooling System

09.8 COOLING SYSTEM 09.8.1 To Flush Cooling System

Flushing of the cooling system might

09.8.0 General become necessary because of impurities in
the coolant itself.
The engine is water cooled, and forced
The cooling system may also be clogged by
circulated by a water pump.
rust deposits, grease or other impurities in
the coolant. This should be removed by
The coolant, drawn by the pump from the
flushing the system several times with hot
radiator or the thermostat control by-pass
water containing a grease dissolving agent.
enters the crankcase and oil cooler. It is
then passed to the cylinder head. The Let the engine run when flushing the system.
coolant returns to the radiator via Note : Make sure that solution does not contain
thermostat housing. any acid as even the smallest amount of it
in the cleaning fluid is likely to affect the
During vehicle operation the thermostat cooling system unfavourably.
functions to maintain the operating
Having drained off the solvents, flush the
temperature of 80° to 85°C (176 to
system several times whilst the engine is
185°F). running.

The thermostat installed in the cooling The use of hard water fosters the formation
of fur which may be removed with aid of an
system controls not only the flow of coolant
acid free solvent. The fur removing agent
to the radiator but also regulates the by-
must not be aggressive to copper brass and
pass flow alternately i.e when it allows the
zinc materials used in the cooling systems.
coolant to flow back to the radiator it
closes the by pass fully and vice versa. Also flush the cooling system several times
after application of a fur solvent.
The sensing unit of the coolant temperature Should lime has deposited too heavily in the
is provided at thermostat housing. It shows radiator tubes remove radiator and have it
the engine coolant outlet temperature. cleaned mechanically by a specialised
workshop.
09.64 HA6DTI2(D/N/U) ENGINES

09.8.2 External Cleaning of Radiator

The radiator tubes/fins may be cleaned by

washing them with using a suitable hot
cleaning solutions such as 0.5ll of HP
Radiator cleaner (supplied by M/s Hindustan
Petroleum corporation).

A 5% caustic soda solution (sodium

hydroxide) may also be used for this
purpose. In addition, the radiator fins can
be blown from the inside with air or water
with less than 2 kg/cm² pressure.

09.8.3 Engine Cooling Fan and Fan Clutch

* 520 mm dia 6 bladed fan with viscous

clutch (imported). Fig - 2

* 520 mm dia 10 bladed fan with viscous

clutch (Indigenous). Fig - 2A

* Fan clutch engages when the sensor senses

at 55°C (air temperature).
Fig. 2

* Reduces fan power consumption at low

temperatures, thereby improving fuel
economy.

09.8.4 Service Tips for Viscous Fan / Clutch

* Handle the fan / fan clutch with care.

* Check the bimetallic temp sensing coil for

any mud or dust. If the coil is covered with
mud or dust, the fan performance will be
erratic. Remove any mud / dust carefully Fig. 2A

with a brush.

* Do not paint the fan / clutch.

* Do not try to dismantle the clutch, the

clutch is a sealed unit.

09.8.5 To Test Thermostat

Remove hose connection and take out

thermostat. Fig - 3
Fig. 3
 HA6DTI2(D/N/U) ENGINES 09.65

Inspection of thermostat function

Place the thermostat in hot water and

check the valve opening temperature and
valve lift. The thermostat valve opening
temperature is punched on the thermostat
seat, and it should be confirmed. Fig - 4

Check commencement of opening. This is

the temperature at which the stroke of the
thermostat has risen to 0.1 mm in a
gradually heated water bath.
Fig. 4

Commencement of opening = 80°C ± 1°C.

Measure the stroke with the aid of special

device and dial gauge.

Check full working stroke.

Working stroke = 10 mm at 92°C

Fig - 5

Install the thermostat Fig. 5

Remove the water and dirt adhering to the

thermostat casing.

Replace the gasket without fail, if it is

corroded, damaged or flattened.

Before install the casing cover apply the

liquid gasket or the casing joint.

09.8.6 To Remove and Refit Water Pump

Drain off coolant collecting it in a clean

container if anti-freeze has been added.

Unscrew fan and remove V belt for water

pump fan and alternator.

Remove hose connection from water pump

and backout attaching bolts.

To refit water pump reverse the procedure

for removal. Fig - 6

Fig. 6
09.66 HA6DTI2(D/N/U) ENGINES

09.8.7 To Overhaul Water Pump

Dismantling

Unscrew water pump mounting Hex screws,

remove water pump by prying loose with
screw driver at the 2 points on the flange.
Fig - 7

Fig. 7

Remove the water pump vane from shaft

by screwing in a bolt of 10 mm dia, 1.5
mm pitch. Fig - 8

Fig. 8

Using a conventional puller remove the

pulley from the shaft. Fig - 9

Fig. 9

Using a steel pipe and press, remove the

water pump shaft along with sealed
bearings from water pump body. Fig - 10

Fig. 10
 HA6DTI2(D/N/U) ENGINES 09.67

To install new water pump seal apply a

little liquid sealant to the water pump seal
outer circumference and water pump body.
Install the slinger and coolant seal.

To install Vane. (Impeller)

Using a press install the Vane to the shaft.

Note: Apply a little engine oil to the seal face.

Maintain distance between water

Fig. 11
pump mounting face to impeller
outer dia end tip.

Dimension (in mm)

Model
A B C
HA6DTI2D/
21 75 dia 90
HA6DTI2N
Ha6DTI2U 20.8 85 dia 99
Fig - 11 & 12

Refit the water pump assy after applying

fresh liquid sealant over clean surface. Fig. 12

Using a press install the pulley drive flange.

For distance from water pump installation
face to flange outer face refer Fig - 12.

09.8.8 To Remove and Refit V Belt. To

Adjust V Belt Tension.

Loosen the adjusting Bolt on the Alternator

and remove the V belt. Fig. 13

To refit V Belt, swing the alternator towards

the crankcase Fig. 13

To Tension the V belt swing the alternator

outwards.

Tighten the fixing screw on the alternator

adjusting bracket. Fan belt play (tension)
should be 10 - 15 mm, when applying
load of 10 kg by pressing with your finger.
Fig - 14.

The V belt should not touch the bottom of

the pulley groove. Fig - 14.
Fig. 14
09.68 HA6DTI2(D/N/U) ENGINES

09.9 EXHAUST AND INTAKE MANIFOLD

09.9.0 To Remove and Refit Exhaust

Manifold

Exhaust manifold
Disconnect front exhaust pipe from the
turbocharger outlet elbow.
Inlet manifold

Backout manifold attaching screws from

cylinder heads and remove the exhaust
manifold taking care of the gaskets.

To refit manifold, reverse the procedure for Fig. 1

removal.

09.9.1 To Remove and Refit Intake Manifold

Backout fixing screws and remove the

vertical intake pipe. Backout manifold
attaching screws from cylinder head and
remove intake manifold.

To refit intake manifold, reverse the

procedure for removal.

Note: Use liquid gasket. Take care that the

gasket does not get into the inside surfaces.
Tighten down the attaching screws evenly.

09.9.2 Maintenance and Servicing of Dry

Type Air cleaner

* Remove dust deposit weekly by squeezing the

dust evacuator valve. Fig - 2

* Replace dust evacuator valve immediately if it is

torn, cracked, remains open or missing.

* Never operate the engine, if the restriction

indicator is either broken or missing. Fig. 2

* If red band appear in restriction indicator, clean

the primary element immediately and reset the
restriction indicator by pressing the top button.

Caution: It is recommended that the primary

filter element should not be cleaned
till the red band appears. Good
cleaning practice can increase the life
of the filter element.

* Check for proper adhesion between end plate

of the element and the sealing ring. Fig - 3 Fig. 3
 HA6DTI2(D/N/U) ENGINES 09.69

* Always clean the primary element with

pressurised air. Keep a distance between the
nozzle and the element. Use the pressurised air
from inside to outside of the primary element. 
* Don't tap on the element and never try to clean
it with compressed air, flowing from outside to
inside of the primary element. Fig - 4

* Glow an electric bulb inside the primary element.

Check for any holes. If light comes out through
any hole, replace the element. Fig - 5 Fig. 4

* Change the air filter primary element only if

- due for cleaning after two consecutive

cleaning

- primary element get punctured (refer

electric bulb test) OR

- red band appears in restriction indicator

with engine stopped condition, even after
cleaning the primary element.
Fig. 5

* Replace the safety element after third

replacement of the primary element. Safety
element should never be cleaned but
always replaced.

Note: The wing bolt should be tightened

with hand alone, excessive tightening
would damage the air cleaner.

Caution: Frequent cleaning of the air filter

element leads to drop in the dust
holding capacity, weakening of the air
filter media and ruptures. This, in turn,
could result in serious damage to the
engine because of entry of dust in the
system.
09.70 HA6DTI2(D/N/U) ENGINES

9.10 ALUMINIUM RADIATORS AND

CHARGE AIR COOLER

9.10.0 Service Instruction

9.10.0.0 Introduction
This manual explains the procedure for
servicing (specifically, the sealing of leakages)
of aluminium radiators fitted with plastic
tanks that may damage in actual usage due
to improper handling before installation on
the vehicle.

The procedure covers the following aspects

of servicing :- Fig. 1 Construction of Aluminium Radiators

* Leakage spot detection

* Sealing Techniques and the tools

required

* Confirmation of proper sealing

9.10.0.1 Details of Radiator

A typical radiator is shown in Fig - 2 for

reference.

CAUTION: Users are requested to get themselves

familiar with all the parts and the
Fig. 2
assembly of radiator before
undertaking the servicing.

9.10.0.2 Servicing Kit

The radiator servicing kit consists of

following items:-

* Screw Driver

* Monkey Plier

* Sealant resin and hardener containers

(Araldite Standard of M/s Ciba Geigy
make or on equivalent Epo x y based
system)

* Alumaseal container

* Araldite applicator

* Brush

NOTE: Araldite rapid may be used in place of

Araldite standard for faster drying and curing
of seal.
 HA6DTI2(D/N/U) ENGINES 09.71

9.10.0.3 Procedure for Servicing

Removal of radiator from vehicle -
* Allow the coolant in the radiator to
reach to the room temperature.
* Drain the coolant from radiator
completely by unscrewing the drain
cock.
* Remove all the mounting fasteners,
attachments like shroud, hoses etc.
* Take out the radiator from the vehicle
carefully without damaging the core.
CAUTION: Radiator core and plastic tanks are
susceptible to cracking due to impact
and deformation.

Detection of Leakage Spot –

* Connect the inlet of the radiator to
air supply at the gauge pressure of
1.5 bar.
* Seal all other outlet points.
* Dip the radiator completely in a clean
water tank.
* Tilt the radiator and shake it
vigorously to let the air bubbles
trapped at the clinching area to
escape.
* Observe carefully for one minute and
locate the source of air leakage on
the radiator from the direction of air
bubbles that are coming out of the
radiator.
CAUTION: Do not use the water tank that is
used for copper radiators.

Sealing the leakage spot –

Following procedures shall be adopted for
arresting leakages at different locations of
the radiator.

Replacement of Plastic tank –

Fig. 3
* Take out the member supports using
13 size spanner
* Release the clinch projections of
header plate using screw driver.
Fig - 3
* After making all the clinching
projections up, take out the tank from
its seat in header plate while grasping
the outlet.
* In case, it takes more effort, pat the
tank with rubber or plastic hammer
lightly.
Fig - 4 Fig. 4
09.72 HA6DTI2(D/N/U) ENGINES

* Take off the tank packing.

* Clean the area of the header plate
where the tank sits, thoroughly.
* Insert new tank packing in the place
without twisting.

* Insert new tank (top or bottom) as

applicable.

NOTE: If the source of leakage is at the base

of the tank, i.e. area between header
plate and tank there is no need to
replace the tank.
Fig. 5
CAUTION: Tank packing shall be replaced, every
time, the tank is taken off for
servicing.

* If gap is found between the clinching

projections of header plate and tank,
softly hammer the projections.

Fig - 5

* Clinch the header plate projections

with monkey plier.

* The sequence of clinching should be

followed as illustrated in the figure.
Fig. 6

Fig - 6

* After clinching, confirm the dimension.

Fig - 7

CAUTION: If any of the clinching projections is

broken during the clinching or releasing
process, discontinue the servicing and
replace the entire radiator by a new
one.

* Fix the member supports and tighten

the bolts properly wherever applicable.
Fig. 7
Bottom Type pipe, Drain Cock and
Pressure Cap –

Bottom Type pipe -

* Take out the Bottom Type pipe using
10 size spanner.
* Remove the ‘O’ ring.
* Clean the seat of Bottom Type pipe
and the ‘O’ ring groove.
* Insert a new ‘O’ ring.
* Fit the Bottom Type pipe back,
ensuring proper tightness of the bolts.
 HA6DTI2(D/N/U) ENGINES 09.73

Drain Cock * Silver colour paint may be used for

* Unscrew the drain cock. touching up the araldite spots and
impart the aluminium type appearance.
* Remove the ‘O’ ring.
* Clean the ‘O’ ring groove. CAUTION: * Do not damage the fins during
the process.
* Insert a new ‘O’ ring.
* Confirm that fins are set properly,
* Screw the drain cock back.
if disturbed during the process.
Pressure Cap – * As the Araldite is inflammable, do
not dry it by heating.
* Replace the pressure cap with a new
one, if leakage is through if after * Proper cleaning of radiator core
cleaning the filler neck. is must for proper setting of
Araldite or else it will come off.
CAUTION: Always use recommended radiator
pressure cap. Confirmation of Proper Sealing

Radiator Core – * After the sealing work is over,

Different procedure of sealing shall be assemble the radiator properly.
followed for minor and major leaks in the * Subject the assembled radiator to
radiator core. leakage test as shown in point 4.2.
Minor Leaks : Leak spots which are very NOTE: If the problem of leakage persists, it is
minute, are to be sealed in following manner. advisable to replace the radiator with new
* Install the radiator onto the vehicle as one.
explained in section 9.10.0.4.
9.10.0.4 Radiator Installation
* Pour the contents of alumaseal in the
radiator. * Ensure that all the openings of the
radiator are closed properly except
* Fill proper quantity of coolant liquid. the inlet.
* Run the engine in idling for more than * Install the radiator on the vehicle
20 minutes to detect lekage, if any. ensuring proper alignment, damping
Major Leaks: Procedure of sealing major etc. as applicable.
leaks in the radiator is as follows : * Connect the inlet and outlet pipes
* Wash the core with clean water and and clamp them.
brush provided in the kit to remove * Fit the fan shroud.
dirt, dust etc.
Fill the radiator with proper quantity of
* To remove the greasy spot on the fresh coolant as recommended.
core, apply thinner with cotton swab
and take off the grease. 9.10.0.5 Do's and Don'ts
* Dry the core using a dryer. Do's
CAUTION: Drying by heating must be avoided. Always use the clinching tool for removing
and refitting the radiator tanks.
* Mix adequate quantity of Araldite
resin and hardener in the ratio of 1:1 Always drain the radiator fully before
and stir it thoroughly. removing it from vehicle.,
* Apply the mixture immediately at the Always refill the radiator with coolant
leakage spot with the applicator. recommended by the manufacturer.
* If required, apply the mixture to dry Always check tank packing before
and harden under the shade at room reassembly of tank to core.
temperature for 10-12 hour.
Don'ts
* Allow the mixture to dry and harden
under the shade at room temperature Never open the pressure cap when the
for 10-12 hour. radiator is hot.
Don't use acid for cleaning the tubes and
NOTE: * Araldite Rapid of M/s Ciba Geigy
tanks.
dries and hardens within one hour and
hence users may use it to minimize Don't use manual force for cleaning clogged
the down time. tubes.
09.74 HA6DTI2(D/N/U) ENGINES

09.11 TURBOCHARGER Note: For longer turbocharger life turbocharger

requires clean engine oil and clean air from
09.11.0 General the air filter. Because
In exhaust gas turbocharging the exhaust
gas which would normally be wasted, is 1. Oil contaminated with dirt or foreign
material will wear the bearings and
used to drive a turbine. The turbine drives
journal area.
a compressor which draws in filtered air
and feeds this, at a higher pressure, to the 2. Dirt in the oil also blocks the oil holes
engine. This enables more fuel to be burnt in the bearings and bearing housing
with a greater mass of charge air, leading to oil starvation to the
increasing engine power output. Better air turbocharger
availability enhances better combustion, thus
leading to lower fuel consumption and less 3. The clearances between the rotating
emission. parts are very close (in microns)

09.11.0.0 Design and Operation 4. Turbocharger rotor assembly rotates at

high speeds up to 1,25,000 rpm at the
rated engine power.
It is operated on the wasted exhaust gas
5. Since turbocharger compressor wheel is
It consists of: made of aluminium and it rotates at
1. Hot wheel (Turbine wheel) very high speeds, Dust, sand or any
foreign particle entering in to the
2. Cold wheel (Compressor wheel) turbocharger compressor housing will
3. Bearing housing damage the compressor wheel blades,
which will lead to turbocharger failure.
4. Turbine housing
5. Compressor housing 6. Damaged blades will lead to imbalance
in the rotor assembly resulting in shaft
6. Bearings or bearing failure.

Exhaust gas is used to drive the turbine 09.11.0.2 Preliminary Checks

wheel.
If your Turbo engine does not run the way
Turbine wheel rotates the compressor it should, do not start your search for
defects at the turbocharger.
wheel.
Check for the following:
Compressor wheel sucks the clean air
a. Is the air filter system blocked?
through the air filter.
b. Is the compression of the engine low?
The clean air is compressed and sent into c. Is the fuel injection system correct?
the engine. d. Does the crankcase breather system
function?
Due to more air in the engine more fuel e. Is the exhaust pipe blocked?
can be burnt. f. Does the vehicle brakes drag?

Due to more fuel and more air, we get After the above inspection now you can
more power from the same engine. look at the turbocharger for cause of
trouble
09.11.0.1 Effects of Turbocharger
Please do not try to service or repair the
Lower fuel consumption turbocharger without proper facilities
Lower emission
Turbocharger rotating parts are balanced to
Better torque characteristics
1 g. mm accuracy for good performance
Lower weight and a smaller engine package
Lower engine noise 100 g.mm imbalance leads to 65 kg imbalance
load on the bearing at 1,20,000 rpm.
Altitude compensating
 HA6DTI2(D/N/U) ENGINES 09.75

After confirming that all parameters outside 09.11.1 Precautions to be taken for
turbocharger are satisfactory as per the check Turbocharger Installation
list given earlier, inspect the turbocharger.
Check air cleaner (filter element) and it’s
Disconnect compressor inlet and turbine connecting pipes for blockage, distortion
outlet pipes and visually examine both the etc., and should be cleaned / replaced.
wheels,
Check and clean engine intake and exhaust
If no fault is found remove turbocharger from manifold pipes.
the engine and take for complete dismantling
and inspecting the individual parts. The oil feed and drainpipe to the
turbocharger should be examined for dirt,
09.11.0.3 Serviceable Parts of Turbocharger cracks, distortion, etc. pipes should be
1. Core assembly kit thoroughly cleaned before fitment. If found
damaged it should be replaced.
2. Overhaul kit
3. Secondary kit Examine the engine oil and the oil filter
4. Gasket kit condition. Replace the oil and the filter
element if necessary (adhere to engine
Overhaul Kit manufacturer recommendation for correct
SL. No. Description Qty grade & change period).

1. Journal 2 Use recommended new gaskets for fitment

2. Snap Ring 4 of the turbocharger to the engine. Don’t
3. Thrust Plate 1 apply gasket sealant (Shellac, Anabond,
grease etc.,) at the oil inlet and the oil
4. Thrust Ring 1
outlet flanges for pasting the gaskets.
5. Piston Ring T.S 2
6. Piston Ring C.S 1 Ensure correct fitment of the turbocharger
7. O’ Ring (Big) 1 to the engine (rotate the turbine shaft and
8. O’ Ring (Small) 1 check for it’s free rotation). Tilted fitment
will cause turbocharger failure.
9. Socket Head Bolt 4
10. Washer 4 Note: After long storage before starting the
11. Shaft Nut 1* engine, fill-up the oil feed hole of the
12. Segment (C.S) 4 turbocharger with clean engine oil to ensure
lubrication during start-up. Crank the
13. Bolt Hex. (C.S) 8
engine till you notice oil pressure in the
14. Segment (T.S) 3 gauge before you start the engine.
15. Bolt Hex. (T.S) 6
* To be used with LH shaft 5327 120 Start the engine and idle for two minutes
5012. before accelerating the engine.

Secondary kit Check the engine oil pressure. Do not run

the engine if oil pressure is found less than
Sl. No. Description Qty that recommended.
1. Flinger Sleeve
(Single Piece Type) 1 With the engine in running condition check
Air, Gas and Oil line connections for
Alternate (Three piece type) leakage and for their proper functioning.
1. Flinger Sleeve 1
2. Oil Deflector Ring 1 Caution: Do not accelerate the engine immediately
3. Spacer Sleeve 1 after start. Idle the engine for atleast
two minutes after start and before the
engine is stopped.
Gasket Kit
Sl.No. Description Qty
1 Gasket (Oil Inlet) 1
2 Gasket (Oil Outlet) 1
3 Gasket (Turbine inlet) 1
09.76 HA6DTI2(D/N/U) ENGINES

09.11.2 Do’s and Don’ts

Do’s

Regular change of engine oil/oil filters.

Regular change / cleaning of air filter

element.

Check for oil pressure at engine idling

condition. Minimum oil pressure to be as
per recommendation during idling.

Idle the engine for 60 seconds after

starting the engine.

Idle the engine for 60 seconds before

switching off the engine.

Periodic cleaning of crankcase breather is

necessary to allow free flow of oil from
turbocharger outlet.

Regularly check all air, oil and exhaust

connections for leaks and abnormal dust /
oil / carbon build up.

Don’ts

Don’t run the engine with low oil pressure

Don’t put the engine under full load

immediately after starting.

Don’t switch off the engine under full load.

Don’t run the engine with damaged oil feed

and drain pipes, pipes between air filter
and turbocharger and as well as exhaust
pipes.

Don't run with damaged / faulty

connections from the air cleaner to the
turbocharger and turbocharger to the inlet
manifold.

Caution: Don’t open the Turbocharger yourself.

Please contact the Ashok Leyland
authorised dealers for any turbocharger
problems.
 HA6DTI2(D/N/U) ENGINES 09.77

09.11.3 List of Equipment’s and Special Tools for K 27 Turbocharger

Sl. No Description Qty. Remarks

1 Ring spanner 10 X 11 mm 1 C H clamp plates

2 Double End Spanner 10 X 11 mm 1 C H clamp plates
3 Ring spanner 12 X 13 mm 1 T H clamp plates
4 Double End Spanner 12 X 13 mm 1 T H clamp plates
5 Socket 12 mm X ½” Square drive 1 Turbine shaft lock nut
6 T - Handle with ½” square drive 1
7 T - Handle with 3/8" square drive 1
8 Adaptor ½” (F) X 318" (M) 1
9 Centre Punch 1
10 Copper Hammer 4 Pounds 1 For removing T H
11 Steel Hammer 1 & ½ Pounds 1
12 Copper Rod 12" Length 1 For removing T H
13 Wooden Hammer 1 For removing C H
14 Chisel 6" 1
15 Steel Wire Brush 1
16 Brass Wire Brush 1
17 Screw Driver 6" 1
18 Tap Handle 1
19 Tap 6 X 1 mm 1 SET
20 Tap 8 X 1.25 mm 1 SET
21 Threaded die 8 X 1.25 1
22 Die handle 1
23 Dial gauge 0.01 mm 1 To check axial play
24 Dial gauge 0.001 mm 1 To check shaft trueness
25 Dial gauge Stand (Magnetic) 1
26 V - block (magnetic) 1 To check shaft trueness
27 Feeler gauge 1
28 Norbar torque meter 4 - 20 Nm 1 To tighten C H bolts
29 Insert AF 10 mm 1 To tighten C H bolts.
30 Adaptor with 3/8" Square drive 1 To tighten Back plate screws
31 Loctite 640 (50 ML Tin) 1 For lock nut
32 8" Special Vice Jaw plates 1 To hold the turbine shaft
33 Shaft Removing Push Rod 1
34 K 26 Dismantling tube 66 mm DIA 100 mm long 1
35 Splined wrench Insert M 6 1 For B P socket head screws
36 Connecting piece for Splined wrench 1 For B P socket head screws
37 Piston plier 1
38 Snap ring plier 0.7 mm 1
39 T-Handle Torque meter 5 - 45 Nm 1 To tighten the lock nut
40 Hot Air Blower 1 For Compressor wheel
41 Monoscope torque meter 0 - 30 Nm 1 To tighten T H bolts
42 Insert AF 13 mm 1 To tighten T H bolts
43 Never seez (100 Grams Tin) 1 For T H bolts

Remarks
- SL NO. 1 to 31 items can be brought in local market.
- SL NO. 32 to 34 are fabricated by Turbo Energy Limited.
- SL NO. 35 to 43 are imported tools from KKK - Germany.
- Degreasing & sand blasting equipment for cleaning turbocharger components are required.
- Suitable press for removing the turbine shaft is required.
- C H - Compressor Housing, T H - Turbine Housing, B P - Back Plate
09.78 HA6DTI2(D/N/U) ENGINES

09.11.4 Data Sheet (For 5327 970 6742 TC)

Size Procedure Torque (Nm)

Shaft Nut M7 x 1 Tightening torque + 3.0

LH SW 12 Angle setting 50° / 45°

Back plate M6 10

Compressor housing M6 7

Turbine Housing M8 20

Maximum (mm)

Axial Play 0.11

Gap (Turbine side) 0.90

Gap (Compressor side) 0.75

 HA6DTI2(D/N/U) ENGINES 09.79

09.11.5 Turbo charger trouble shooting

High oil consumption

Oil leak from turbine

Compressor/Turbine
Engine Lacks power

Turbocharger noisy

compressor seal

wheel defective
Boost Pressure

Oil leak from

Black smoke

Blue Smoke
Possible Cause

too high

seal
Dirty air cleaner     
Restricted compressor intake duct     
Restricted air duct from compressor to intake manifold   
Restricted intake manifold   
Air leak in feed from air cleaner to compressor 
Air lead in feed from compressor to intake manifold     
Air leak between intake manifold and engine     
Foreign object in exhaust manifold (from engine)      
Restricted exhaust system   
Exhaust manifold cracked, gaskets blown or missing   
Gas leak at turbine inlet/exhaust manifold joint   
Gas leak in ducting after turbine outlet 
Restricted turbocharger oil drain line    
Restricted engine crankcase breather/leaking or distorted    
Turbocharger bearing housing sludged or coked    
Fuel system/Injection feed system defective or incorrectly
adjusted  
Engine valve timing incorrect  
Worn engine piston rings or liners      
Burnt valves and / or pistons      
Excessive dirt build up on compressor wheel and /
or diffuser vanes       
Boost pressure control swing valve / poppet valve
doesn’t close  
Boost pressure control swing valve / poppet valve
doesn’t open 
Pipe assembly to swing valve / poppet valve defective  
Piston ring sealing defective    
Turbocharger bearing defective        
Foreign body damage on compressor or turbine    
Turbine housing / flap damaged    
Insufficient oil supply of turbocharger    
 09.80 HA6DTI2(D/N/U) ENGINES

09.12 MAINTENANCE PROGRAMME

km x 1000
Lubricant

16000 km
8000 km
Weekly
Remarks

No. of
points

Every

Every
Every
Daily
PDI
A. General
1. Check and adjust valve clearance on cold engine  
2. Check and tighten front and rear engine
mounting / other peripheral bolts 
3. Check compression pressure 60
4. Check and tighten cylinder head nut / bolts  80
for correct torque in correct sequence
B. Lubrication system
1. Check and top up engine oil O 1 
2. Change engine oil and oil filter element  
3. Clean oil cooler 60
4. Check engine oil pressure (min. 1 kg/cm² at
idling and 80°C engine temperature  
5. Check oil leakages, if any  
C. Cooling System
1. Check and tight fan mounting bolts  
2. Check coolant level and top up if necessary 
3. Check radiator hoses and clamps for
leakages and tightness   
4. Check fan belt tension and adjust If necessary  
5. Check radiator stay rod & radiator mounting bolts  
6. Drain cooling system and fill recommended
coolant. Refer section 09.0.10. 72
7. Replace cooling system hoses and radiator
rubber pads for radiator mounting & stay rod 72
D. Fuel System
1. Replace fuel filter element *
a. Primary element 
b. Secondary element  First
24000kms
& thereafter
every
16000kms
2. Check water separator and drain if necessary  
3. Clean fuel feed pump strainer 
4. Lubricate accelerator linkages G 2 
5. Lubricate accelerator link pedal shaft O 1 
6. Check FIP control lever return spring 
7. Proper functioning of KSB / Solenoid switches 
8. Check and tighten F.I.P. mountings 32
9. Check injection timing 32
* Both the fuel filter elements must not be changed at the same time
 HA6DTI2(D/N/U) ENGINES 09.81

09.12 MAINTENANCE PROGRAMME

km x 1000
Lubricant

16000 km
8000 km
Weekly
Remarks

No. of
points

Every

Every
Every
Daily
PDI
10. Clean Fuel tank and suction strainer 48
11. Adjust Fuel Injector Nozzle opening 56 First
Pressure (247 - 260 kg/cm²) 16000km
also.
12. Recalibrate fuel pump 150
13. Replace fuel hoses 150
E. Air Intake and Exhaust
1. Check and clean air cleaner - primary element
(If restriction indicator shows red band -
refer section 09.9.2)
2. Replace air cleaner primary element (After
2 consecutive cleaning).
3. Replace air cleaner safety element (At the
time of third replacement of primary element
or once in a year - whichever earlier).
4. Check restriction indicator, if necessary clean
the element 
5. Check air inlet hose for any puncture/damage 
6. Check for any blockage / breakage at 
rainhood assembly
7. Check Turbocharger mounting  24
8. Check charge air cooler for any blockage of
fins and clean the cooler if necessary  32
9. Check charge air cooler hoses for any damage 
10. Check exhaust manifold and silencer for
leaks and tightness  
11. Check intake and exhaust manifold mounting
fasteners  32