H6 CEV Stage IV / TREM Stage IV

Engine

AUGUST 2021
H6 CEV Stage IV / TREM Stage IV Engine
Service Manual
 H6 CEV Stage IV / TREM Stage IV Engine
Service Manual
CONTENTS

Section Subject Page No.

1.0 GENERAL ..................................................................................................................... 1.01

1.0.0 Engine Type and Number .............................................................................................. 1.01
1.0.1 Design and Operation ................................................................................................... 1.01
1.0.2 General Data ................................................................................................................. 1.01
1.0.3 Repair Data ................................................................................................................... 1.02
1.0.4 Tightening Torques ........................................................................................................ 1.09
1.0.5 Crank Shaft Main Journals and Crank Journals Dimensions ........................................ 1.11
1.0.6 Main and Crank Journals Grinding Sizes ...................................................................... 1.11
1.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness) ........................................... 1.11
1.0.8 Crankcase Parent Bore and Cylinder Liner Outer Dia .................................................. 1.11
1.0.9 Fuel Oil (High Speed Diesel) ......................................................................................... 1.12
1.0.10 Recommended coolant ................................................................................................. 1.13
1.0.11 Recommended Lubricants ............................................................................................ 1.13
1.0.12 Filling Capacity .............................................................................................................. 1.13
1.0.13 Liquid Gasket and Application Points ............................................................................ 1.14
1.0.14 Description of Leading Engine Components ................................................................. 1.15
1.0.15 Trouble shooting ............................................................................................................ 1.18
1.0.16 Special Tools ................................................................................................................. 1.22
1.0.17 Factors Which Determine When an Engine Overhaul is Needed ................................. 1.26
1.2 CRANKCASE ............................................................................................................... 1.27
1.2.0 To Remove and Refit Cylinder Liners ............................................................................ 1.27
1.2.1 To Remove and Refit Timing Casing Cover and Back Plate ......................................... 1.28
1.2.2 To Remove and Refit Flywheel Housing ....................................................................... 1.29
1.2.3 Install the Oil Seal in the Flywheel Housing .................................................................. 1.29
1.2.4 To Remove and Refit Flywheel ..................................................................................... 1.29
1.2.5 To Remove Ring Gear ................................................................................................... 1.29
1.2.6 To Install Ring Gear ....................................................................................................... 1.29
1.2.7 Install Flywheel .............................................................................................................. 1.30
1.3 CRANKSHAFT ............................................................................................................. 1.31
1.3.0 To Remove and Refit Crankshaft .................................................................................. 1.31
1.3.1 To Renew Crankshaft Gear ........................................................................................... 1.31
1.3.2 To Refit the Crankshaft Gear ......................................................................................... 1.31
1.3.3 To Check Crankshaft Bend ........................................................................................... 1.31
1.3.4 Installation ..................................................................................................................... 1.32
1.3.5 To Renew Crankshaft Main & Connecting Rod Bearing and Check Main &
Connecting Rod Bearing Spread .................................................................................. 1.32
1.3.6 To Check and Grind Crankshaft .................................................................................... 1.33
1.3.7 To Remove and Refit Vibration Damper ........................................................................ 1.33
 H6 CEV Stage IV / TREM Stage IV Engine
Service Manual
CONTENTS

Section Subject Page No.

1.4 PISTON AND CONNECTING RODS ............................................................................ 1.34

1.4.0 To Remove Piston Assembly ......................................................................................... 1.34
1.4.1 To Dismantle and Assemble Piston and connecting rod ............................................... 1.34
1.4.2 Connecting Rod Bush ................................................................................................... 1.34
1.4.3 Piston and Piston Rings ................................................................................................ 1.36
1.5 CYLINDER HEAD ASSEMBLY .................................................................................... 1.38
1.5.0 To Remove Cylinder Head ............................................................................................ 1.38
1.5.1 To Grind Valves and Valve Seats .................................................................................. 1.38
1.5.2 To Refit the Valve Seat and To Check and Reface Valve Seat ..................................... 1.39
1.5.3 Valve Seat Installation ................................................................................................... 1.39
1.5.4 To Assemble the Cylinder Head .................................................................................... 1.40
1.6 TIMING .......................................................................................................................... 1.42
1.6.0 To Remove and Refit Rocker Levers ............................................................................ 1.42
1.6.1 To Remove, Refit and Check Push Rod and Tappets ................................................... 1.42
1.6.2 Removal and Replacement of Camshaft Bushes ......................................................... 1.42
1.6.3 Camshaft Bush Dimensions (in mm) ............................................................................. 1.43
1.6.4 Installation ..................................................................................................................... 1.43
1.6.5 Install the camshaft gear on the shaft ........................................................................... 1.44
1.6.6 To Refit the Camshaft .................................................................................................... 1.45
1.6.7 To Remove and Refit Intermediate Timing Gear ........................................................... 1.45
1.6.8 Install the Idler Gear Shaft (Spindle) ............................................................................. 1.45
1.6.9 Install the Idler Gear ...................................................................................................... 1.45
1.6.10 To Re-bush Intermediate Gear ...................................................................................... 1.46
1.6.11 To Position Timing Gears for Valve Timing and FIP Timing ........................................... 1.46
1.6.12 Timing Gear Backlash Checking ................................................................................... 1.46
1.6.13 To Fit Air Compressor .................................................................................................... 1.46
1.6.14 To Remove and Refit Fuel Injection Pump .................................................................... 1.47
1.7 ENGINE LUBRICATION ............................................................................................... 1.61
1.7.0 Design and Operation ................................................................................................... 1.61
1.7.1 To Remove and Refit Oil Pump ..................................................................................... 1.61
1.7.2 To Overhaul Oil Pump ................................................................................................... 1.62
1.7.3 To Refit the Oil Pump .................................................................................................... 1.62
1.7.4 To Overhaul Oil Cooler and Filter Assy ......................................................................... 1.62
1.7.5 Engine Piston Cooling Nozzle ....................................................................................... 1.66
1.7.6 Inspection Method for Piston Cooling Nozzle ............................................................... 1.66
 H6 CEV Stage IV / TREM Stage IV Engine
Service Manual
1.8 COOLING SYSTEM ...................................................................................................... 1.67
1.8.0 General ......................................................................................................................... 1.67
1.8.1 To Flush Cooling System .............................................................................................. 1.67
1.8.2 Baffle Plate .................................................................................................................... 1.67
1.8.3 Thermostat .................................................................................................................... 1.68
1.8.4 To Test Thermostat ........................................................................................................ 1.68
1.8.5 To Remove and Refit Water Pump ................................................................................ 1.69
1.8.6 To Overhaul Water Pump Dismantling .......................................................................... 1.69
1.8.7 To Remove and Refit Fan Belt ...................................................................................... 1.70
1.9 EXHAUST AND INTAKE MANIFOLD .......................................................................... 1.72
1.9.0 To Remove and Refit Exhaust Manifold ........................................................................ 1.72
1.9.1 To Remove and Refit Intake Manifold ........................................................................... 1.72
1.9.2 Maintenance and Servicing of Dry Type Air cleaner ...................................................... 1.72
1.9.3 Guidelines for replacing Opti air filter ............................................................................ 1.72
1.10 OCV - OPEN CRANK CASE VENTILATION ............................................................... 1.75
1.11 TURBOCHARGER ....................................................................................................... 1.76
1.11.0 General ......................................................................................................................... 1.77
1.11.1 Precautions to be taken for Turbocharger Installation ................................................... 1.78
1.11.2 Do’s and Don’ts ............................................................................................................. 1.78
1.11.3 Turbo charger trouble shooting ..................................................................................... 1.79
1.12 EDC ............................................................................................................................... 1.80
1.13 MAINTENANCE ACTIVITY ........................................................................................... 1.84
H6 CEV Stage IV / TREM Stage IV Engine
Service Manual
 H6 CEV Stage IV / TREM Stage IV Engine
1.01
Service Manual
1.0 GENERAL 1.0.1 Design and Operation

1.0.0 Engine Type and Number HA57L165 is a 6 cylinder, water cooled 4 stroke
BSIII CRS Diesel Engine with direct fuel injection.

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

The engine number is punched on the left side rear
of the energy contained in the fuel, because the cooling
top corner of the crankcase.
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.

1.0.2 General Data

Description H6C413322 H6C416022 H6C418022 H6C422522
Max output 133 HP @ 2300 rpm 160HP @ 2200 rpm 180HP @ 2200 rpm 225HP @ 2200 rpm
Max torque 475 @ 1400-1900 650 @1400-1600 700 @ 1400-1700 800 @ 1400-1600
Type Diesel four stroke, 6 cylinder water cooled, direct injection, in line over head valve
Aspiration Turbo charged Turbo charged with Inter cooler
Bore and Stroke 104 x 113 mm
Piston displacement 5.76 liters
Compression Ratio 16.2 : 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 wet (Minimum - 24 kg/cm²)
EATS DOC + Air-assisted SCR ( Modular)
AdBlue tank 24/40 liters
Idling revolution 850 ± 50 rpm
Engine Weight (with oil) 515 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
 H6 CEV Stage IV / TREM Stage IV Engine
1.02
Service Manual
1.0.2 General Data

Description H6C413322 H6C416022 H6C418022 H6C422522

Engine oil cooler Multi plates type (No. of plates - 8) water cooled
Fuel Injection Equipment Common Rail System, CB 18 (CRS) Common Rail System, CB 28 (CRS)
Injection Timing Not applicable. Pump to be fitted when 1st cylinder is at TDC on the compression stroke
High Pressure Pipe
8 x 3 x 250 mm - 6 Nos (From Rail to Injector)
(ODXIDXLength)
Injection Nozzle
Type CRS Electronic type -CB18 CRS Electronic type -CB28
Coolant Pump
Type Forced circulation by volute pump, 55 mm dia ball and roller bearing
Drive By Poly V-belt
Impeller dia 100 mm
Thermostat Single thermostat, Wax type, Bottom bypass system, opens at 82° ± 2°C
Injection Not applicable. Pump to be fitted when 1st cylinder is at TDC on the compression stroke
Turbo Charger With waste gate
Electrical
Starter motor 24V, pre-engaged
Alternator 24V - 55/85 / 100 Amps
1.0.3 Repair Data
Specification (Measurements in mm) Measuring Device and
Description
H6C413322 H6C416022 H6C418022 H6C422522 Remarks

Crankcase
Straight edge and feeler
Cylinder block flatness 0.05 (limit 0.1)
gauge
W,X,Y,Z, punch marked
Crankcase bore for on crank case LH side /
Refer section 1.0.8
cylinder liner fitment starter motor side adjacent
to each bore
Ovality / taper 0.020 (limit)
W,X,Y,Z, paint mark given
Cylinder liner outside
Refer section 1.0.8 on cylinder liner OD for
diameter
identification
Fitment of cylinder liner in Selective assy (only MLS
Mild interference fit
crankcase bore gasket to be used)
Bore dial gauge (To be
Cylinder liner bore: Size 104.008 - 104.040 (limit 104.15) measured at 80mm from
top)
Liner projection 0.01 - 0.08 Dial gauge with fixture
Block Top Surface to
300 ± 0.05
Crankshaft Centre

Block Top Surface to

370 ± 0.1
sump face height

Micro meter and bore dial

Main bearing bore dia 77.985 - 78.00
gauge
 H6 CEV Stage IV / TREM Stage IV Engine
1.03
Service Manual
1.0.3 Repair Data

Specification (Measurements in mm) Measuring Device and

Description
H6C413322 H6C416022 H6C418022 H6C422522 Remarks

Ovality / taper
0.005 (limit)
(Main bearing bore)
Cylinder liner collar 7.98 - 8.015 Vernier depth gauge
Micro meter and bore dial
Cylinder counter bore dia 112.12 - 112.29
gauge
Piston and Connecting Rod Assembly
Micrometer (measure at
Piston diameter
103.96 skirt area perpendicular to
Standard size
pin axis)
Cylinder axis should be in
Piston projection 0.35 to 0.75
vertical position
Diametral piston clear-
0.140 - 0.172 Micrometer and dial gauge
ance (at skirt)
Piston ring Groove Width
Top — Vernier caliper
Second 2.53 -2.55
Oil Ring 3.02 - 3.04
Piston ring width
Top — Micrometer
Second 2.47 -2.49
Oil Ring 2.97 - 2.99
Piston ring side clearance in groove
Top 0.08 - 0.12 Feeler gauge
Second 0.04 - 0.08
Oil Ring 0.03 - 0.07
Piston Ring gap (Butt clearance)
Top 0.30 - 0.45 Feeler gauge
2nd 0.30 - 0.45
Oil 0.30 - 0.50
Maximum permissible No need to check weight
piston weight difference 5 gms difference as Pistons are
per set services as set
Piston pin hole inside
36.998 - 37.003 (limit - 37.030) Bore dial gauge
diameter
Micrometer (Push fit in
Gudgeon pin outside
36.989 - 37.00 (limit 36.980) piston heated to 80 deg
diameter
cent)
Micrometer (Push fit in
Clearance between Piston
– 0.002 - 0.014 ( limit -0.04) piston heated to 80 deg
pin and Piston Pin hole
cent)

Con rod small end bush

41.000 - 41.025 Bore dial gauge
bore
 H6 CEV Stage IV / TREM Stage IV Engine
1.04
Service Manual
1.0.3 Repair Data

Specification (Measurements in mm) Measuring Device and

Description
H6C413322 H6C416022 H6C418022 H6C422522 Remarks

Diametral clearance
between gudgeon pin
Bore dial gauge and
and conrod small end 0.015 - 0.036 (limit 0.08)
micrometer
bush bore Max.
permissible clearance
Interference fit of small
Bore dial gauge and
end bush in connecting 0.035 - 0.092
micrometer
rod
Connecting rod center to
181.480 - 181.520
center distance
Connecting rod bend /
0.1 per 200
twist limit
Connecting rod big end
68.985 - 69 Bore dial gauge
dia
Connecting rod side
0.20 - 0.52 (limit 0.6) Feeler gauge
clearance
Connecting rod Big end Bore dial gauge and
0.004
ovality / taper micrometer
Connecting rod big end
78.75 -79.75 Vernier caliper
bearing spread
A : 1790 - 1830 Grades A, B, C, D, E are
Max. permissible B : 1830 - 1870 punched on big end of the
connecting rod weight C : 1870 - 1910 connecting rod. An engine
(gms) D : 1910 - 1950 should have connecting
E : 1950 - 1990 rod of same grade.
Crankshaft
Crankshaft journals and
Refer section 1.0.6 Micrometer dimensions
crankpin grinding
Hardness Tester. No
Surface hardness of
580 - 600 HV further heat treatment
journals and crank pins
recommended
Maximum permissible
limit 0.02 V-Blocks and dial gauge
bend at 4td journal
Journals and crank pins Refer section 1.0.5 Micrometer
Crankshaft Main Bearing
0.06
Cap roundness
Main and connecting
Refer section 1.0.6 (Standard and undersize)
journal sizes
Crankshaft end play
Dial gauge with magnetic
Maximum permissible end 0.05 - 0.125 limit 0.4
stand
play
Diametral clearance
between main journal and Bore dial gauge and mi-
0.039 - 0.09 0.13 (limit)
bearing Maximum crometer
permissible clearance
Main bearing spread
78.75 - 79.75 Vernier Caliper
(upper / lower)
 H6 CEV Stage IV / TREM Stage IV Engine
1.05
Service Manual
1.0.3 Repair Data

Specification (Measurements in mm) Measuring Device and

Description
H6C413322 H6C416022 H6C418022 H6C422522 Remarks

Diametral clearance
between Connecting Rod 0.031 - 0.082 Bore dial gauge and
Big End Bearing & (limit 0.12) micrometer
Crank pin
Dial gauge with magnetic
Flywheel face out limit 0.08
stand
Flywheel runout
(concentricity for the 0.13 Dial gauge
clutch setting)
Cylinder Heads and Valves
Straight edge and feeler
Cylinder head flatness 0.05 (limit 0.1)
gauge
Cylinder head height 87 ± 0.1 Vernier caliper
Nozzle protrusion from
2.5 ± 0.25 Depth Gauge
cylinder head
Valve Projection / ink
(Valve head depth below
cylinder head face) Dial gauge
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
9.000 - 9.015 Internal micro meter
Guide inner dia
Diametral valve stem
clearance in guide Plug gauge and
Inlet 0.030 - 0.065 Micrometer
Exhaust 0.035 - 0.085
Valve seat angle Bevel Protractor
Intake 30° - 30° 15' (for both inlet and Exhaust
Exhaust 45° - 45° 15' 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 to +0.130)
Exhaust 41.0 (+0.145 to 0.130)
 H6 CEV Stage IV / TREM Stage IV Engine
1.06
Service Manual
1.0.3 Repair Data

Specification (Measurements in mm) Measuring Device and

Description
H6C413322 H6C416022 H6C418022 H6C422522 Remarks

Valve angle
29° 45' - 30°15' Protractor (for both inlet
Inlet
44° 45' - 45°15' and exhaust)
Exhaust
Valve head diameter 45.3 - 45.5
Micrometer
Inlet 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 Plug gauge and

0.010 - 0.039
guide in cylinder head micrometer
Height of valve guide
14.5
above spring seat
Maximum permissible out
of true of valve seat to 0.03
guide
Valve spring straightness 2.0 (limit) Tri Square
Valve spring initial load
27.4 ± 1.4 kg at 45.5 mm Valve spring scale
Outer
8.8 ± 0.4 kg at 43.0 mm (inlet and exhaust)
Inner
Valve lift
Intake 12.40 mm
Exhaust 13.80mm
Timing
Rocker arm shaft diameter 18.966 - 18.984 Micro meter
Diametral clearance
Micro meter and bore
between rocker lever on 0.036 - 0.079 (limit 0.15)
gauge
rocker shaft
Push Rod Bend 0.3 Centers and dial gauge
Tappet Diameter 26.95 - 26.97 Micro meter
Tappet guide inside
27.00 - 27.02 Internal micro meter
diameter
Diametral tappet clearance
0.025 - 0.071 Bore dial gauge and
in crankcase bore
0.1 (limit) micrometer
Maximum permissible limit
Camshaft Bend 0.05 (limit) Dial gauge and V blocks
Vernier height gauge & V
Camshaft Cam lift (Intake) -6.4413 (limit)
blocks
Camshaft Cam lift Vernier height gauge & V
-7.1552 (limit)
(Exhaust) blocks
Dial gauge with magnetic
Camshaft end play 0.10 - 0.18 (limit 0.3)
base
Camshaft Joural Diameter
Journal 1 56.95 - 56.97 (limit 56.85)
Journal 2 56.75 - 56.77 (limit 56.65) Micro meter
Journal 3 56.55 - 56.57 (limit 56.45)
Journal 4 56.35 - 56.37 (limit 56.25)
 H6 CEV Stage IV / TREM Stage IV Engine
1.07
Service Manual
1.0.3 Repair Data

Specification (Measurements in mm) Measuring Device and

Description
H6C413322 H6C416022 H6C418022 H6C422522 Remarks

Camshaft Journal
Bearing inside Diameter
after pressing the bushes
Journal 1 57.0 (limit 57.070) Bore dial gauge
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
Max. permissible 0.15 (limit) and micrometer
clearance
Idler Shaft Diameter 49.95 - 49.975 (limit 49.94) Micrometer
Idler Gear bushing inside
50.00 - 50.025 (limit 50.05) Internal micro meter
Diameter
Diametral clearance
Internal measuring gauge
between Idler Gear shaft 0.03 to 0.08 (limit 0.1)
and micrometer
and Bush
Idler Gear end play 0.04 - 0.10 (limit 0.15) Dial gauge
Tooth Backlash between Feeler gauge or dial
0.068 - 0.194
Crank gear & Idler gear gauge
Tooth Backlash between
Feeler gauge or dial
Idler gear & Oil Pump 0.065 - 0.182 (limit 0.3)
gauge
gear
Tooth Backlash between
Feeler gauge or dial
Injection Pump gear & 0.065 - 0.232
gauge
Idler gear
Tooth Backlash between
Feeler gauge or dial
Cam gear & Oil Pump 0.065 - 0.182 (limit 0.3)
gauge
gear (limit 0.3)
Engine lubrication
Max. oil pressure:
Full-load 4.5 / 4.8 kg/cm²
Pressure gauge
Idling 1.2 - 1.6 kg/cm²
Minimum oil pressure 1.2 kg/cm² (engine idling) Pressure gauge
Oil flow rate 29.5 liters per minute at 4 kg/cm² pr @ 1000 rpm
Valve opening
pressure: (Oil filter)
Oil pressure relief valve
Hydraulic pump with
By-pass valve for 4 bar, 1.5 bar, 4 bar
pressure gauge
paper element
By-pass valve for heat
exchanger
Oil Pump Gear Height 33.0 - 32.04
Oil Pump Gear Outer
53.2 - 0.15 to - 0.20
Diameter
Oil Pump Gear Backlash
between Oil Pump Drive
0.12 ± 0.06 Feeler gauge
Gear, Camshaft and Idler
Gear
 H6 CEV Stage IV / TREM Stage IV Engine
1.08
Service Manual
1.0.3 Repair Data

Specification (Measurements in mm) Measuring Device and

Description
H6C413322 H6C416022 H6C418022 H6C422522 Remarks

Oil Pump Gear Backlash

between Drive and 0.15 ± 0.06 Feeler gauge
Driven Gear
Drive Gear shaft Diameter 20.088 - 20.106 (limit 20.06) Micro meter
Drive Gear inside
20.037 - 20.054 Internal micro meter
Diameter
Drive Shaft Bushing
20.146 - 20.173 Internal micro meter
Inside Diameter
Clearance between Drive Bore dial gauge/Micro
0.040 - 0.085 (limit 0.1)
Shaft & Bushing meter
Driven Gear shaft
19.979 - 19.997 (limit 19.97) Micro meter
Diameter
Driven Gear Bush Inside
20.037 - 20.054 Dial Gauge
Diameter
Clearance between driven
0.040 - 0.075 (limit 0.1)
gear and shaft
Oil Cooler air pressure
6 kg/cm²
testing
Cooling System
Maximum Permissible
102°C Temperature gauge
coolant temp
Maximum water pump
240 lpm @ 1.5 kg/cm² Test tank
output
Commencement of Test tank thermometer &
82°C +/- 2°C
thermostat opening Vernier caliper
Thermostat working Test tank thermometer &
10 mm
stroke at 95°C Vernier caliper
 H6 CEV Stage IV / TREM Stage IV Engine
1.09
Service Manual
1.0.4 Tightening Torques

Max. allowed
Description Kgm lb.ft Nm
No.of tightening
Liner Pressing Special Tool 5-6 36 - 42 49 - 59
14 ± 1.5 & 103 ± 11 & 140 ± 15 &
Main Bearing Cap Bolts 4
90° ± 5° 90° ± 5° 90° ± 5°
Flywheel Housing Fitting Bolts (13 mm bolt) 1.9 - 2.6 14 - 18 19 - 26
Flywheel Housing Fitting Bolts (22 mm bolt) 11 - 13 80 - 94 108 - 128
10 ± 1 & 73 ± 7.3 & 100 ± 10 &
Flywheel Fitting Bolts 3
60° ± 5° 60° ± 5° 60° ± 5°
10 ± 1 & 73 ± 7.3 & 100 ± 10 &
Connecting Rod Cap Bolts 3
60° ± 5° 60° ± 5° 60° ± 5°
Timing Gear Plate Bolts 1.9 - 2.6 14 - 18 19 - 26
Oil Pump Assembly Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
10 ± 1 & 73 ± 7.3 & 100 ± 10 &
Camshaft Drive Gear Fitting Bolt 4
60° ± 5° 60° ± 5° 60° ± 5°
Camshaft Thrust Plate Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
10.2 ± 10 73.8 ± 7.3 & 100 ± 10 &
Idler Gear Fitting Bolt (Refer page 09.53) 4
& 90° ± 5° 90° ± 5° 90° ± 5°
Timing Gear Cover Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Crankshaft Pulley Fitting Nut 56 ± 12 405.7 ± 88.5 550 ± 120
Oil Strainer Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Oil Pan Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Oil Pan Drain Plug 4-5 29 - 32 39 - 49
FIP Drive gear bolt 3.7 - 4.5 26 - 32 36 - 44
10 ± 1 & 73 ± 7.3 & 100 ± 10 &
Crankshaft to Flywheel Adaptor bolt
60° ± 5° 60° ± 5° 60° ± 5°
Flywheel Mounting Bolts (With Crankshaft Adaptor) 12 - 13 85 -92 115 - 125
Air Compressor Fitting Bolts 4.5 - 5.0 33 - 36 44 - 49
Alternator Bracket 4.5 - 5.0 33 - 36 44 - 49
Alternator Supporting Bolt & Nut. 4.5 - 5.0 33 - 36 44 - 49
Fan Belt Adjusting Bracket 4.5 - 5.0 33 - 36 44 - 49
Water Jacket Elbow 4.5 - 5.0 33 - 36 44 - 49
Water Drain Plug on Elbow 4.5 - 5.0 33 - 36 44 - 49
Centre Bolt - Oil Filter 4-5 29 - 32 39 - 49
Oil Cooler Element Fitting Nuts 1 - 1.5 8 -10 10 -15
Oil Cooler Assembly Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Water Pump Assembly Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Water Pump Pulley Bolt 1.9 - 2.6 14 - 18 19 - 26
Fan to Spacer Bolts 2.0 - 3.0 15 - 21 20 - 29
Cooling Fan Fitting Bolts 1.5 - 2.2 16-Nov 15 - 22
7.1 ± 0.5 & 52 ± 4 & 70 ± 5 &
Cylinder Head Bolts (M12) with Marusan gasket
90° ± 5° 90° ± 5° 90° ± 5°
 H6 CEV Stage IV / TREM Stage IV Engine
1.10
Service Manual
1.0.4 Tightening Torques

Max. allowed
Description Kgm lb.ft Nm
No.of tightening
Cylinder Head Bolts (M10) 4.5 - 5.0 33 - 36 44 - 49
Rocker Shaft Locking Bolts 0.6 - 0.74 4-5 6 -7
Rocker Shaft Assembly Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Rocker Shaft Assembly Main Bolts 13 - 14 94 - 102 128 - 137
Rocker Arm Adjusting Screw Nuts 1.9 - 2.6 14 - 18 19 - 26
Thermostat Case 4.5 - 5.0 33 - 36 44 - 49
Thermostat Cover 1.9 - 2.6 14 - 18 19 - 26
Glow Plugs Fitting Nuts 2.25 - 2.75 17 - 19 22 - 27
Flare Nuts on Injector Pipes 1.5 - 2.5 11 - 18 15 - 25
Exhaust Manifold 4.5 - 5.0 33 - 36 44 - 49
Inlet Manifold Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Cylinder Head Cover Bolts 1.3 -1.8 10 -13 13 - 18
Mass Balancer Bolts 5.0 - 5.6 37 - 41 50 - 55
Water cooled Compressor Banjo Fitment
5.7 - 6.3 42.04 - 46.46 57 - 63
(On TG case) - Water line
CR pump oil filling allen plug 3-4 22.12 - 29.5 30 - 40
CR pump Lower Mounting brackets (M10 Bolts) 4 - 4.5 29.5 - 33.2 40-45
Filter mounting bracket bolts 4 - 4.5 29.5 - 33.2 40-45
CR pump Mounting on Timing Casing 1.9 - 2.6 14 - 18 19 - 26
Common Rail Fitment (M8 nuts) 3.1 - 3.7 22.1 - 25.8 30 - 35
CR injector holding clamp nut 3.1 - 3.7 22.1 - 25.8 30 - 35
Leak off line banjo bolt fitting 1.5 - 2.5 11 - 18 15 - 25
Leak off banjo from rail to pump 3.1 ± 0.5 22.1 ± 3.68 30 ± 5
Leak off banjo from pump to tank 3.1 ± 0.5 22.1 ± 3.68 30 ± 5
Gear pump inlet banjo fitment 3.1 ± 0.5 22.1 ± 3.68 30 ± 5
Fuel Filter inlet banjo 3.1 ± 0.5 22.1 ± 3.68 30 ± 5
Fuel filter outlet banjo 3.1 ± 0.5 22.1 ± 3.68 30 ± 5
FIP Drive Gear Bolt 28 ± 2.5 202 ± 18 275 ± 25
High Pressure Pipe Cap Nut 3.1 - 3.8 22.1 - 25.8 30 ± 5
 H6 CEV Stage IV / TREM Stage IV Engine
1.11
Service Manual
1.0.5 Crank Shaft Main Journals and Crank Journals Dimensions

Description mm
1.Std diameter of main journals 72.94 - 72.96
2.Std diameter of conrod journals 64.94 - 64.96
3.Fillet Radius main journal 2.75 - 3.25
4.Con. rod journal fillet radius 2.75 - 3.25
5.Wear limits
Taper (across total width) - cylindricity 0.0035
Ovality - circularity 0.0035
Bend - perpendicularity 0,04
Wear limit 0.2
Concentricity - eccentricity 0.05
Maximum permissible out of round 0,02
6. Available under sizes (only 4 under sizes) 0.25/0.50/0.75/1.00
1.0.6 Main and Crank Journals Grinding Sizes
Under size (mm) Crank pin (mm) Main Journal (mm)
0.25 64.69 - 64.71 72.69 - 72.71
0.50 64.44 - 64.46 72.44 - 72.46
0.75 64.19 - 64.21 72.19 - 72.21
1.0 63.94 - 63.96 71.94 - 71.96
Width of crank pin - 36.00 - 36.25 mm
Correct by regrinding if worn unevenly more than 0.10 mm
Regrind if the wear is more than 0.2 mm
Replace crankshaft if wear is more than 1.2 mm
1.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness)
Under size (mm) Thickness (mm) Tolerance
STANDARD 2.00
0.25 2.125
0.50 2.250 -0.003 To -0.013
0.75 2.375
1.0 2.500
1.0.8 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 + 0 W 107 + 0.011 + 005
X 107 + 0.0125 + 0.0060 X 107 + 0.011 + 018
Y 107 + 0.0190 + 0.0125 Y 107 + 0.024 + 018
Z 107 + 0.0250 + 0.0190 Z 107 + 0.030 + 024
Z+ 107 + 0.0550 + 0.0490 Z+ 107 + 0. 063 + 057
Interchangeability is allowed w.r.t. next oversize or undersize liners.
Only Multi Layered Gasket (MLS) should be used along with Mild Interference Liners (MIF).
 H6 CEV Stage IV / TREM Stage IV Engine
1.12
Service Manual
1.0.9 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.

Fuel Specifications - as per IS 1460 : 2000

1. Acidity, inorganic ... Nil

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

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

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

percent by Mass, Max ... 0.30

5. Cetane Number (Minimum) ... 51

6. Cetane index (Minimum) ... 46

7. Pour point (Max.) ... 3°C for Winter & 15ºC

for Summer

8. Copper Strip Corrosion for 3 hours @ 100°C., Max., rating ... Not worse than No.1

9. Distillation, percent v/v, recovered:

a) at 350°C, Min ... 85

b) at 370°C, Min ... 95

10. Flash point (Min.)

a) Abel, °C, Min ... 35

b) Pensky-Martens, °C, Min ... 66

11. Kinematic viscosity, cSt, @ 40°C ... 2.0 to 4.5

12. Sediment, percent by mass (Max.) ... 0.05

13. Density; at 15ºC., kg/m3 ... 820 -845

14. Total Sulphur, percent by mass (Max.) ... 0.035

15. Water content percent by mass (Max.) ... 0.020

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

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

18. Total contaminations (Particulate matter) mg/kg. (max) ... 24

19. Oxidation stability, g/m3, (max) ... 25

20. Polycyclic Aromatic Hydrocarbon (PAH), percent by mass, Max ... 11

21. Lubricity, corrected wear scar diameter (wsd) 1.4) at 60°C,

microns, Max ... 460
 H6 CEV Stage IV / TREM Stage IV Engine
1.13
Service Manual
1.0.10 Recommended coolant

Gulf LEYPOWER COOL 40

Gulf LEYPOWER COOL 40 pre mixed coolant (pre mixed with water at 50% ratio) and has been formulated with
a view to offer extended service life. No addition of water is required.

The recommended coolant change interval is 5000 hours or 2 years whichever is earlier. Both are available in
convenient pack sizes of 1, 3, 20, 50 liters & also as 210 liter barrel.

Minimum Ambient Temp. °C Gulf Oil India

H6 CEV Stage IV / TREM

-35 Gulf LEYPOWER COOL 40
Stage IV Engine

For topping up use only Gulf LEYPOWER COOL 40 directly. Do not dilute with plain or demineralised
water for top up.

1.0.11 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.

Minimum Ambient Temp. °C Gulf Oil India

H6 CEV Stage IV / TREM

-20 Gulf LEYPOWER XLE Engine Oil
Stage IV Engine

Note: Do not mix lubricants of different brands/grades.

1.0.12 Filling Capacity

Aggregates Qty (ltr.)

Engine (Including Oil Filter) 18

Engine Cooling System Capacity 22 (Approx - based on Application / Customer it may change)
 H6 CEV Stage IV / TREM Stage IV Engine
1.14
Service Manual
1.0.13 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

COATING
PARTS NAME APPLICATION
WIDTH
Flange face which mate with cylinder block, timing gear cover and
a) Oil pan 1.5 - 2.5 mm
flywheel housing
b) Timing gear cover Faces which mates with timing gear plate (flange face, boss face) 1.5 - 2.5 mm
c) Flywheel housing Faces which mate with cylinder block (flange face, boss face) 1.5 - 2.5 mm
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) 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

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.
 H6 CEV Stage IV / TREM Stage IV Engine
1.15
Service Manual
1.0.14 Description of Leading Engine
Components

Crankshaft - an alloy steel forging, mounted in seven

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

Vibration Damper - is mounted on the front end of the

crankshaft. Care should be taken while handling the
vibration damper.
Cylinder Liners (dry, pre finished, hard, easy fit type)
- made of cast iron. There are four selectable grades Do not drop hammer on the damper.
available i.e. W, X, Y, Z based on liner outer diameter. Do not hammer the damper while
disassembling it. Do not let the engine
rest on the damper.

Cylinder Head - made of high-grade cast iron,

accommodating all cylinders, fitted with exchangeable,
pre finished valve seats and valve guides. Alfin Pistons - made of special grade aluminium alloy
with cast iron insert to form the first compression ring
seat. The combustion chamber design is reentrant type
for better combustion.
 H6 CEV Stage IV / TREM Stage IV Engine
1.16
Service Manual

2
1. Main Bearing
2. Thrust washer

Main and Big End Bearing Shells - thin-walled, Valve Spring - made of spring steel, constant pitch coil
with aluminium and tin or lead bronze linings for sliding type springs.
surfaces.

FUEL PUMP
DRIVE GEAR

Timing Gear Train - higher drive torque requirement

Camshaft - made of steel, mounted in the cylinder of VE pump, wider gears are provided for crank gear,
block in four exchangeable bearing bushes. Drive is idler gear and FIP gear.
supplied from the engine crankshaft through a gear
train.

Flywheel - machined with 58 holes on the periphery

to facilitate engine speed sensing by engine speed
Valves - made of high-grade alloy steel. Valve stem sensor. These holes are equi-spaced and dimensions
seals prevent oil leakage into combustion chamber. are controlled to achieve perfect speed pulse output
waveform from the speed sensor.
 H6 CEV Stage IV / TREM Stage IV Engine
1.17
Service Manual
Output signals from ECU triggers the governor there by
controls the quantity of fuel injected and the start of
injection.

Flywheel housing - fitted with sensor mounting holder

facilitates fitment of engine speed sensor over the
flywheel for engine speed sensing. Aluminium is used
for the holder as a non-magnetic base is required for
the magnetic pulse pickup to avoid signal disturbances.
Engine Coolant Temperature Sensor - It is a thermistor,
mounted on coolant return line from cylinder head.
It measures the engine operating temperature.

Injectors - CRS Injectors are high precision and

sensitive components and hence care should be taken
during handling. The injectors should be preserved in a Engine speed sensor - Engine speed sensor is a
dry, non salty and clean environment and it should be inductive type sensor. It is mounted on the flywheel
protected against weather (rain, snow and sunshine) housing. Electric pulses are generated when the
and impact. formed slots on the flywheel pass through the sensor
axis. The Electric pulse - Frequency (Sine Wave)
Electronic Control Unit (ECU) : The ECU is the heart of
generated by the sensor is proportional to the engine
the system that compares the requirements thru
speed.
sensors and the accelerator pedal movement with the
fuel mappings already stored in the ECU and decides
on the fuel delivery. It operates on 24V DC.

Engine Boost Pressure Sensor - Engine Boost

Pressure sensor is mounted on the intake manifold
to measure the absolute intake manifold pressure.
CRS Fuel Injection Pump - This pump is mechanically
Colour Identification - Blue coloured name plate.
driven and electronically controlled by ECU.
 H6 CEV Stage IV / TREM Stage IV Engine
1.18
Service Manual
1.0.15 Trouble shooting

1.0.15.0 Engine

Symptom Possible Cause Remedy/Prevention

Engine overheating Coolant
* Insufficient coolant Add coolant
* Defective thermostat Replace the thermostat
* Overflow of coolant due to leakage of Repair
exhaust into cooling system
* Coolant leakage from cylinder head Replace gasket
gasket
* Defective coolant pump Repair or replace

Radiator
* Clogged with rust and scale Clean radiator
* Clogged with iron oxide due to leakage Clean coolant passage and correct
of exhaust into cooling system exhaust leakage
* Clogged radiator core due to mud or Clean radiator
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
* CAC & Radiator fins out side for dust Clean
deposit.

Abnormal combustion
* Poor fuel Use good quality fuel
* Poor nozzle spray Replace nozzle

Other problems
* Defective or deteriorated engine oil Change engine oil
* Unsatisfactory operation of oil pump Replace or repair
* Insufficient oil Add oil

Excessive oil Piston, cylinder liners and piston rings

consumption * 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
* 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 Reassemble piston rings
other

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
 H6 CEV Stage IV / TREM Stage IV Engine
1.19
Service Manual

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 high speed
* 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 Repair oil pump
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 Replace element
Fuel and nozzle
* Poor nozzle spray Replace injector with new one
* Clogged nozzle with carbon Replace injector with new one
* Wear or seizure of nozzle Replace injector with new one
* Air in fuel system Repair and bleed air from fuel system
* Clogged fuel filter Replace fuel filter element
* Use of poor fuel Use good quality fuel

Abnormal combustion See symptom:”Piston Seizure”

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

Other problems
* Breakage of turbine or blower Repair
* EDC system defective Use diagnostic tool for trouble shooting
and rectify
 H6 CEV Stage IV / TREM Stage IV Engine
1.20
Service Manual

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
Injection pump Repair

Air cleaner
* Clogged element 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 fuel Tighten fuel line connections
line connections
* Clogged fuel filter Replace element
* Loose connection in high-pressure line 1. First loosen both sleeve nuts of high
pressure pipes.
2. Hand tighten both the sleeve nuts to
ensure that the seating of HP pipe is
proper
3. Apply the specified torque
* Water in fuel Drain and clean fuel system
Nozzle
* Seized nozzle Replace injector with new one

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 pinion Replace the ring gear and/or starter
* Check relays and fuses of EDC system Replace defective parts.
Rough idling Injection pump Repair

Nozzles
* Poor nozzle spray Replace injector with new one
* Carbon deposit on nozzle tip Replace injector with new one

Engine
* 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
 H6 CEV Stage IV / TREM Stage IV Engine
1.21
Service Manual
1.0.15.1 Fuel Injection Pump
Symptom Possible Cause Remedy/Prevention
Engine does not Fuel not reaching injection pump
start * 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

Nozzle faulty
* Fuel leakage caused by loosened Inspect and tighten it. If it is not OK, replace
nozzle clamp injector with new one.
Excessive smoke Black smoke
* Bad nozzle fuel spray characteristics Check and correct them
* Faulty booster sensor Check and replace

White smoke
* Water in fuel Check and clean fuel lines
* Faulty coolant temperature sensor Check and replace
* Fuel starvation Check and correct
Engine always runs
at high speed Accelerator pedal sensor sticky Check and replace
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

* Feed pressure too low Repair the feed pump located on the FIP
* EDC system faulty Check with diagnostic tool and rectify

Nozzle faulty
* Fuel leakage from nozzle holder Replace injector with new one
 H6 CEV Stage IV / TREM Stage IV Engine
1.22
Service Manual
1.0.16 Special Tools
P2607047 - Drift oil seal gear case

To press oil seal on

timing gear case

0102001 (3802)
P2607147 - Adapter idler gear spindle

To be used with
0102003 - sliding
hammer, to extract
idler gear spindle

0102002 (3803)
P2607247 - Sliding hammer

To remove injectors,
idler gear spindle
etc., With their
respective adaptors

0102003 (3804)
P2607347 - Drift (1) oil seal flywheel hsg
(4 mm step height)

To press oil seal

- crankshaft rear
end in flywheel
housing

0102004 (3805)
P2607447 - Compressor valve spring

To assemble and
disassemble inlet
& exhaust valves

0102005 (3806)
P2608247 - Drift valve stem seal

To install valve stem

seal

0102006 (3807)
 H6 CEV Stage IV / TREM Stage IV Engine
1.23
Service Manual
1.0.16 Special Tools
P2600441 - Gauge compression checking

Check the
compression
pressure in each
cylinder

0102021 (3801)
P2608947 - Drift valve guide

To install valve guide

0102009 (3811)
P2607747 - Special socket cylinder head bolt

To tighten cylinder
head bolts after
fixing rocker shaft
assembly

0102010 (3812)
P2607847 - Extractor cylinder liner

To extract cylinder
liners

0102011 (3813)
P2607947 - Guide cylinder liner

To guide the cylinder

liners while inserting
it in to bore

0102012 (3814)
P2608047 - Retainer cylinder liner (3 nos.)

To hold the cylinder

liners while removing
the piston assembly

0102013 (3815)
 H6 CEV Stage IV / TREM Stage IV Engine
1.24
Service Manual
1.0.16 Special Tools
P2610647 - Compressor piston ring

To compress piston
rings during
assembly

0102014 (3816)
P2608147 - Drift & extractor con-rod bushes

To extract and install

connecting rod
bushes

0102017 (3836)
P2609147 - Drift & extractor cam bushes

To extract and install

cam shaft bushes

0102018 (3839)
P2609247 - Wrench engine cranking

To rotate the
crankshaft

0102019 (3840)
Injector removal tool

To remove injector

0000000 (0000)
P2613247 - Adapter compression checking

To be used with
0102021 - gauge
compression
checking, to check
the compression
pressure of each
cylinder

0102023 (3822)
 H6 CEV Stage IV / TREM Stage IV Engine
1.25
Service Manual
1.0.16 Special Tools
Open end torque wrench

To torque tighten
100
5
10
injector high
pressure pipes
15

Torque screw driver

To torque tighten
0
12
0

injector wiring
11
0
10
Nm

terminals
 H6 CEV Stage IV / TREM Stage IV Engine
1.26
Service Manual
1.0.17 Factors Which Determine When an pressure. If the compression pressure increases, wear
Engine Overhaul is Needed in piston rings/cylinder bore is indicated. If it does not,
1. Low compression pressure leak is through the valves. If compression pressure of
adjacent cylinder is on lower side it may be due to
cylinder head gasket.

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.

Make sure no leakage through the sealing

face.

a. Before the measurement c. Compression pressure recommended values

1. Warm up the engine to operating temperature Minimum : 24 kg/cm² @ 280 rpm
(bring the coolant temp. to about 80°C) Maximum : 29 - 32 kg/cm² @ 280 rpm
2. Check and correct valve tappet clearance.
Pressure difference between each cylinders should
3. Change the battery full
be below 3 kg/cm²
4. Remove the air cleaner
2. Low oil pressure
5. Remove all injectors
6. Install the gauge adaptor in place of one of the Check the oil pressure warning lamp when the oil and
injectors. coolant temperature is hot about 80°C.
7. Connect Special Tool 0102023 - Gauge a. If the warning lamp is lighted , check the oil level.
Compression Adaptor and Special Tool
0102021 - Gauge Compression. b. Check oil deterioration.
a. Measurement 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 : Idling 1.2 kg/cm²
for Turbo engines 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.
Crank the engine with starter motor (ensure min. d. Fuel consumption increases.
cranking speed of 280 rpm). The gauge needle will
e. Engine makes greater noise.
start rising. Cranking should be continued until the
needle in the gauge stops, without any further rising. f. Excessive oil consumption.
Note the reading. Loose gauge vent knob to ensure the
needle returns to zero.
Repeat the procedure to the remaining cylinder.
Min. compression pressure in each cylinder should
be 29 – 32 kg/cm².
Low compression pressure may be due to leakage
past thru piston rings / valves / blown cylinder head
gasket. To find out the exact point of leakage, a small
amount of engine oil may be sprayed into the cylinder
through nozzle hole and recheck the compression
 H6 CEV Stage IV / TREM Stage IV Engine
1.27
Service Manual
1.2 CRANKCASE markings W, X, Y or Z of the OD. These indicate the
size of the O.D. of the liner. Similarly, the matching
1.2.0 To Remove and Refit Cylinder Liners
I.D. markings of the cylinder bore is indicated by
Use Special Tool 0102011 - Extractor Cylinder Liner W, X, Y or Z on crank case LH side top for each Bore.
for removal of cylinder liners.
Gently press the liner with hand.
Place a plate of dia 107 mm and thickness 15 mm
of PTFE material over the liner top and gently tap with
nylon mallet at the centre to drive the liner into the bore.
Liner projections has to be maintained as mentioned
(0.01 - 0.08 mm)
Only (Multi Layered Gasket) MLS gasket
should be used along with Mild
Interference Liners (MIF).

Make sure no leakage through the sealing

face

When reusing a liner, insert the liner in its original

position aligning the markings marked before
disassembly. Use Special Tool 0102012 - Guide
Cylinder Liner.
Measure the projection of the cylinder liner.

Incase you want to reuse the liner be sure to put

matching marks with marker pen on the cylinder block
and liner flange for repositioning.
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 one of the following
 H6 CEV Stage IV / TREM Stage IV Engine
1.28
Service Manual

Fix Special Tool 0102013 - Retainer Cylinder Liner and Timing back plate mounting bolt holes, in which one
measure the amount of projection of the liner from the mounting hole provided with a counter bore, use
cylinder block with a dial gauge and magnetic stand. special bolt with a thread sealent (without washer).

1.2.1 To Remove and Refit Timing Casing

Cover and Back Plate

Remove timing cover and Replace new oil seal using

Special Tool 0102001 - Drift Oil Seal Gear Case.
Installation should only take place with engine in
Back out fixing screws of the Timing back plate. normal upright position.

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) with new

gasket to crank case face of the Timing Back plate.
Screw down Timing Back plate with hex screws and
spring washers.
 H6 CEV Stage IV / TREM Stage IV Engine
1.29
Service Manual
1.2.2 To Remove and Refit Flywheel Housing 1.2.4 To Remove and Refit Flywheel

Back out fixing screws and remove flywheel.

Remove speed sensor along with the cable.
Check ring gear, if necessary replace.
Remove sensor mounting block.
Do not damage the slots on the flywheel.
Back out fixing screws of the flywheel housing.
Start with M8 bolts (6 nos.) and then M14 bolts (8 nos.). 1.2.5 To Remove Ring Gear
Take off the flywheel housing, taking care of rear main
oil seal.
1.2.3 Install the Oil Seal in the Flywheel
Housing

Heat the ring gear with a blow torch in a uniform

manner (approx. 180°C).
Using a metal rod as pad and strike all around the ring
gear in uniform manner and remove the ring gear.
1.2.6 To Install Ring Gear
Using a special tool, press in the oil seal in the flywheel
housing.
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.
Fit flywheel housing and tighten it securely with
hex screw. Start with M14 bolts (8 nos.) and
M8 bolts (6 nos).

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.
 H6 CEV Stage IV / TREM Stage IV Engine
1.30
Service Manual
1.2.7 Install Flywheel

Align the ‘O’ mark on the flywheel and crankshaft collar

knock pin.

Install the flywheel and tighten the bolts through

several repetition of the tightening 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. Angle torque the mounting bolts as
recommended.
When tightening the bolt, apply engine oil to the threads
and flywheel surface of the bolts.
Crank shaft Adaptor for Flywheel to be fitted wherever
applicable.
Check the flywheel run out and face out as per
recommendation.
Ensure there is no fouling of speed
sensor with flywheel after fitment of
sensor. Also ensure gap between
flywheel and speed sensor should be
1.00 ± 0.1 mm by using depth gauge
method.
 H6 CEV Stage IV / TREM Stage IV Engine
1.31
Service Manual
1.3 CRANKSHAFT The bearing caps are match mark with the crankcase
by the punch mark 1 - 7, commencing from timing
The crankshaft is supported by 7 main bearings. gear side.
Thrust is taken up by the thrust washer at the fourth
journal.
Two oil holes on the main journal.

Lift the crankshaft out of the crankcase.

1.3.1 To Renew Crankshaft Gear

Punch mark on the crankshaft web. Uprated engine

crankshaft - all main journal fillets are induction
hardened.
1.3.0 To Remove and Refit Crankshaft

Backout collared bolts and remove bearing caps.

By using Conventional puller remove crankshaft gear

from crankshaft.
1.3.2 To Refit the Crankshaft Gear

Heat the gear upto 130°C and fix it.

1.3.3 To Check Crankshaft Bend
Remove thrust bearing cap (4th) last.

2
1. Main Bearing
2. Thrust washer

Arrange all the caps bearing and thrust washer in Check crankshaft bend as shown in figure. Refer repair
order. data for Maximum permissible bend.
 H6 CEV Stage IV / TREM Stage IV Engine
1.32
Service Manual
1.3.4 Installation

Clean crankcase, crankshaft and bearing shells by

blowing compressed air through the lubrication holes.
1.3.5 To Renew Crankshaft Main & Connecting
Rod Bearing and Check Main &
Connecting Rod Bearing Spread

Tighten cap collared bolts uniformly in the three stages

in tightening order 4-5-3-6-2-7-1. Angle torque the bolts
as recommended.

Hold the bearing shell without applying any pressure

and measure the outside diameter. Refer repair data
(bearing spread) for dimensions.
Install the crankshaft, main bearing on the crankcase
and bearing caps.
Lubricate crankshaft journals, bearing shells, cap bolt
threads and under the bolt heads with the engine oil.
Carefully lower the crankshaft into position.

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.
Check end play of crankshaft as follows:
Force crankshaft in one axial direction and measure
the gap between thrust bearing side and crank web
face. This can be done using magnetic stand and dial
gauge.

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.
Bearing cap set identification no punched on the
bearing cap and LH side rear end of the crankcase.

The initial end clearance with new thrust and main

bearings should amount to 0.05 to 0.125 mm.
 H6 CEV Stage IV / TREM Stage IV Engine
1.33
Service Manual
1.3.6 To Check and Grind Crankshaft 1.3.7 To Remove and Refit Vibration Damper

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.

No further heat treatment is recommended.

Support crankshaft at front and rear journals. The bend

must not exceed 0.02 mm.

Check journals & crankpins for ovality and Taperness

(Refer Repair Data).
Back out the hex nut with box spanner 46 mm.
Grind the crankshaft according to the available Withdraw the vibration damper.
replacement bearing shells. This work may only be
If found external damage, replace with new one.
performed by experienced crankshaft grinders.
For repair data of undersize big end bearings and main Fit the new O ring on the inner dia of the hub.
bearings refer section 1.0.6 and 1.0.7.
To refit vibration damper reverse the procedure for
removal.

Torque for damper bolts

(9 Nos. M10 x 1.5 = 50-55Nm

 H6 CEV Stage IV / TREM Stage IV Engine
1.34
Service Manual
1.4 PISTON AND CONNECTING RODS 1.4.2 Connecting Rod Bush

1.4.0 To Remove Piston Assembly 1.4.2.0 To Remove Bush

Fix Special Tool 0102013 - Retainer Cylinder Liner to Using a special tool 0102017 - Drift and extractor.
hold the liner.
Align supporting surfaces of the guide and press sub
Back out connecting rod bolts and remove bearing cap. assembly flush on the flat plain.

Set the connecting rod assembly without crank pin

Scrape off carbon deposit from the upper end of the bearing on the guide and press assembly.
cylinder liner with the help of emery paper or scraper.

Extract all the pistons and connecting rod assemblies

through top of the cylinders.

1.4.1 To Dismantle and Assemble Piston and

connecting rod

Install the spindle into the bushing. Align the grooving

of the spindle with the oil hole of the bush.

Remove gudgeon pin circlip with the circlip plier.

Using a hydraulic press, remove the bush slowly and

smoothly.

Place a copper drift on the pin and strike it out with the
hammer.
 H6 CEV Stage IV / TREM Stage IV Engine
1.35
Service Manual
1.4.2.1 Installation of Connecting Rod Bush

If there is any deviation in the alignment of the oil holes

correct it with a drill of 3 mm dia. If drilling is carried out,
Chamfer one edge of the bush hole at the small end take care to remove the machined burrs clears off the
of the connecting rod uniformly by C 0.5 - 1.0 mm. connecting rod small end bore and oil holes.
Set the bush and guide on the spindle then secure 1.4.2.3 Check for Bend of Connecting Rod
them with the bolt.
Lubricate the bush guide and bush bore on the
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
Always operate the press slowly and smoothly. from the longitudinal axis of connecting rod.
1.4.2.2 Inspect the Bushing Position after 1.4.2.4 Install the Connecting Rod Bearing
Installation

Confirm the notch are aligned both in the connecting

Make sure that the oil holes of the bushing and rod and bearing.
connecting rod are aligned.
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.
 H6 CEV Stage IV / TREM Stage IV Engine
1.36
Service Manual
1.4.3 Piston and Piston Rings Insert the gudgeon pin into the piston with connecting
rod.
1.4.3.0 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.

O mark on the piston top and connecting rod match

mark should remain opposite to each other, while
assembling the piston to connecting rod.
1.4.3.3 Install Piston rings

The pistons have been provided with a relief at the skirt

to accommodate PCN.
Max. difference in the weight of the piston is an engine
set of 6 pistons not to exceed 5 gms.
Weight group identification mark punched on the piston
crown.
1.4.3.1 To Remove 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.
Apply oil over the piston ring. use a piston ring
expander while fitting the piston rings.
Install the piston ring in sequence viz; oil ring, second
ring and top ring with the identification mark at the top
of the ring facing upwards.
Remove compression rings and oil scraper rings with
the aid of piston ring plier.
Remove carbon deposits from piston ring grooves.
1.4.3.2 Assemble Piston and Connecting Rod

Heat the piston to approximately 80°C temperature.

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.
 H6 CEV Stage IV / TREM Stage IV Engine
1.37
Service Manual

Insert piston with connecting rod assembly into

the cylinder bore compressing the piston rings by
Check the side clearance of the piston rings. means of Special Tool - Compressor Piston Ring.
Push the piston into the crankcase until the big end
bearing is seated on the crankpin.

Stagger the piston ring gaps so that they are not in

line, approximately at 120o away from each other. Align the punch mark on the connecting rod and cap.

1.4.3.4 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. Rotate crankshaft so that the
crankpin of the respective piston is in B.D.C. position.

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. Angle torque as recommended.
Check connecting rod axial play (side clearance) using
feeler gauge. It should be within specified limits as
given in repair data.
 H6 CEV Stage IV / TREM Stage IV Engine
1.38
Service Manual
1.5 CYLINDER HEAD ASSEMBLY Remove the inlet and exhaust valves.

1.5.0 To Remove Cylinder Head Before removal of all valves, punch the serial nos of
cylinder numbers on the valve face, to avoid mixing of
valves.
Clean the cylinder head, valves, valve cap, spring and
all other parts thoroughly with the suitable solvent.

Loosen the cylinder head bolts / rocker arm support

bolts as per sequence shown. Start with M10 bolts and
then M12 bolts.
Using a special tool 0102010 - Wrench Cylinder Head Check cylinder head surface unevenness.
Bolt.
Hand lap valve and valve seat.

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 Lightly apply lapping compound to the valve face.
protrusion from the cylinder head surface (Refer Repair Install the valve with a Valve Lapping Tool, tap and
Data). rotate valve against the seat.
Ensure that all the nozzles are removed from the 1.5.1 To Grind Valves and Valve Seats
cylinder head.
Remove valve caps, valve split cone lock, collar and
spring from cylinder head.

Using Special Tool 0102005 - Compressor Valve

Spring.
 H6 CEV Stage IV / TREM Stage IV Engine
1.39
Service Manual
Valve seat section machining specifications
Intake (mm) Exhaust (mm)
Cylinder A 46.5 - 46.516 41 - 41.016
Head
Dimension B 8.8 - 9 7.2 - 7.4
Valve C 46.63 - 46.645 41.13 - 41.145
Seat
Dimension D 7.5 - 7.7 6 - 6.2

1.5.3.0 To Check the Valve Guide

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.

After grinding, always recheck the valve sink.

For repair data refer section 1.0.3.
1.5.2 To Refit the Valve Seat and To Check
and Reface Valve Seat

Cut the circumference of a valve head at three places The Valve guide may require replacement if stem to
with a grinder and install it into seat and weld valve to valve guide clearance exceeds
seat. Then drive out valve and seat with a hammer and
a brass block. Intake - 0.035 - 0.068 mm
1.5.3 Valve Seat Installation Exhaust - 0.050 - 0.083 mm
1.5.3.1 To Renew Valve Guide

Remove the valve stem seal.

Using a brass rod and hammer, drive out the valve
guide.
Install the valve guide.
Special Tool 0102009 - Drift Valve Guide.
Apply engine oil lightly to the valve
guide outer circumference before
installation.
1.5.3.2 To Refit Valve and Valve Stem Seals
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.

Install the valves and lower spring seat.

Use plastic sleeve (X1102160) before inserting the
valve stem seal to avoid oil seal lip damage.
 H6 CEV Stage IV / TREM Stage IV Engine
1.40
Service Manual

Apply engine oil to the lip of the valve stem seal and Using Special Tool 0102005 - Compressor Valve
insert by hand force. Spring.

Remove and scrap the fitment sleeve. Install the Cylinder Head
Only (Multi Layered Gasket) MLF
gasket should be used along with Mild
Interference Liners (MIF)
After cleaning the surfaces of the cylinder head and
cylinder block free from dirt, water and grease, install
the cylinder head gasket (always use new cylinder
head gasket).

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.
Use correct tool to ensure proper seating of valve
Stem Seal on guide. Install the cylinder head over the dowels on the cylinder
block.
Drive the suitable special tool until it hits the lower
spring seat. Insert push rod in correct order.
Special Tool Z06DH0430025 - Drift Valve Stem Seal. Spiral Tightening Sequence indicating with bolt
number
1.5.3.3 To Check Valve Springs

Check valve springs on a valve spring scale for

reusability. Refer Repair Data.

1.5.4 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, if the same valves were used.

Valve springs are constant pitch in place of progressive

spring (Equal pitch coil).

Press valve spring and collar to install split cone lock.

Recommend to replace the existing bolts with new with

new cylinder head bolts while reassembly.
 H6 CEV Stage IV / TREM Stage IV Engine
1.41
Service Manual
Procedure for Yield point tightening of Cylinder head
mounting bolts:

- Ensure the cleanliness of the mating components

Exhaust manifold side
before assembly.

- Dip the cylinder head mounting bolt in oil to the

length of 30mm minimum to ensure availability of
oil on the threads of bolt and also apply oil on the
bolt head before inserting into cylinder head Intake manifold side

- Locate and fix 3-4 threads of the cylinder head

bolts by hand.

- Tighten the bolts as per the sequence given below: The 6 numbers M10 bolts are to be tightened in the
sequence shown above.
- Apply a pre-torque of 120Nm. (88 lb-ft)
Retightening of cylinder head bolt is not
- Loosen the bolt by 360˚ (i.e. one complete turn). recommended.
- Re-tighten the bolts by applying a torque of 70Nm. CAUTION
Only one reuse of the Cylinder head bolts
(52lb-ft) is accepted, thereafter replace new.
Mount the rocker arm assembly on the cylinder head,
- The long and the short Cylinder head bolts to be make sure that the push rods interlock with the
angle tightened to 180˚ and 150˚ respectively. adjusting screws.
 H6 CEV Stage IV / TREM Stage IV Engine
1.42
Service Manual
1.6 TIMING Examine push rod ends for wear. Replace if necessary
and check rocker lever and tappet lubrication in this
1.6.0 To Remove and Refit Rocker Levers case.

Back out fixing bolt and remove rocker shaft assembly. Check diametral clearance of tappet in crankcase bore
and inspect sliding surface and push rod seat for wear.
Reassemble rocker arm assy. in the order as follows:-
If necessary replace worn out parts.
Bracket, Inlet valve lever, Spacer, Exhaust valve lever, To refit push rods and tappets, reverse the procedure
Bracket and so on, for removal.
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.

Confirm that oil hole of rocker arm assembly No.7

support aligns with shaft oil hole.
Improper installation of rocker will result in seizure of
the entire valve assembly.
1.6.1 To Remove, Refit and Check Push Rod
and Tappets

Remove push rods and tappets. Pull out the camshaft slowly turning it, so that the
Check out of true of push rods between centres. bushes are not damaged.
Maximum permissible out of true = 0.3 mm.

1.6.2 Removal and Replacement of Camshaft Bushes

Use Special Tool 0102018 - Drift & Extractor Camshaft Bushes to remove and refit camshaft bushes.
 H6 CEV Stage IV / TREM Stage IV Engine
1.43
Service Manual
Extraction 6. Arrange the guiding bunk, support bracket, thrust
The cylinder block is designed with minimum aperture, bearing and nut & handle assembly at the front end
the camshaft bushes are not approachable from the of the engine on the puller shaft and extract the 3rd
LH side or bottom side of the engine. Hence the parent bush. The 3rd bush will fall between the 3rd and
bores of camshaft bushes in the cylinder block have 2nd parent bores of the camshaft bushes now.
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.
1.6.3 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
Proceed in the following manner to remove the 7. Guide the extractor bunk along with the extracted
camshaft bushes. 3rd bush in to the 2nd bush and continue to rotate
the nut & handle assembly until the 2nd bush is
extracted.
8. Take out the puller arrangement along with the 2nd
and 3rd bushes carefully through the 1st bush
parent bore of the camshaft.
1.6.4 Installation:
The camshaft bushes are pre-finished; hence handle
them carefully.

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

using collapsible puller assembly and support
bracket from front and rear respectively.
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 bunk
so that the bunk does not collapse when the bush
is being pulled out.
4. Place the support bracket and thrust bearing in 1. Fix the drift bunk on the puller shaft in the
place and using the nut and handle assembly, pull appropriate groove on the longer puller shaft as
out the bush. shown. Place the 3rd camshaft bush on the
extractor and carefully insert the 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.
2. Remove the puller from the cylinder block and
place the 2nd camshaft bush on the drift bunk.
Insert the puller from the front side of the engine
until the front portions of the drift bunk sufficiently
5. Fix the extractor bunk on the appropriate groove on enter the 2nd camshaft bush parent bore. Arrange
the puller shaft, insert the puller shaft from rear side the guide bunk, support bracket, thrust bearing and
of the engine carefully locating the bunk inside the nut & handle assembly at the rear end of the
3rd bush.
 H6 CEV Stage IV / TREM Stage IV Engine
1.44
Service Manual
figure, centralize the puller shaft at the rear and
tighten the nut & handle assembly until the 1st
camshaft bush is in its place.

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.

cylinder block as shown and tighten the nut & handle

assembly until the 2nd camshaft bush is in its place.

Remove the nut, then using a gear puller, remove the

gear.

1.6.5 Install the camshaft gear on the shaft

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 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.

Install the camshaft bearing with a thrust bearing. When

installing the gear to the camshaft, heat the gear in hot
water (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.

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
 H6 CEV Stage IV / TREM Stage IV Engine
1.45
Service Manual
1.6.6 To Refit the Camshaft 1.6.8 Install the Idler Gear Shaft (Spindle)

Install idler gear shaft with thrust plate using a plastic

hammer.

Set the no. 1 piston to Top Dead Centre of the

compression stroke.
Lubricate all journals of the camshaft and insert the Make sure that the two oil holes is facing downward
camshaft assembly into the cylinder block, by slowly (oil pan side) so that it does not become clogged due to
turning, so that the bearing will not be damaged. accumulation of sludge and other foreign material in
the oil.
Align the camshaft timing gear matching mark with the
oil pump gear mark. 1.6.9 Install the Idler Gear

1.6.7 To Remove and Refit Intermediate

Timing Gear

FUEL PUMP
DRIVE GEAR

Install the Idler gear, be sure that the matching marks

of 1,1 of idler gear align with corresponding ‘1’ on the
crankshaft gear, 2,2 align with oil pump drive gear and
Back out fixing bolt and remove it with thrust washer, 3,3 align with the corresponding 3 on the FIP gear.
withdraw intermediate gear.
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 bolt by
half turn.
- Retighten applying a snug torque of 40 Nm.

To remove the spindle use special tool 0102003 -

Sliding Hammer and special tool 0102002 - Adaptor
Idler Gear Shaft.
 H6 CEV Stage IV / TREM Stage IV Engine
1.46
Service Manual
1.6.11 To Position Timing Gears for Valve
Timing and FIP Timing

FUEL PUMP
DRIVE GEAR

- Mark alignment lines on bolt head & washer as

shown.
Angle torque aligning both marks by 60°
The gear train to be matched as per matching punch
This operation will result in final torque level of marks on gear circumference.
140 - 190 Nm
1.6.12 Timing Gear Backlash Checking
1.6.10 To Re-bush Intermediate Gear

Press out the worn bush with a suitable drift. Check tooth backlash with feeler gauge.
Drive in the new bush. Backlash between driving gear and intermediate gear.
Max. limit = 0.3 mm.
The idler gear bush is pre-finished.
1.6.13 To Fit Air Compressor (wherever
applicable otherwise dummy plate to be
fitted)

Max. oil clearance between

spindle and bush = 0.1 mm
While assembling, keep engine first cylinder at TDC,
Intermediate gear align ‘l‘ punch mark on the gear teeth with the bottom
endplay = 0.15 mm mounting hole, then assemble the compressor and
Bush internal diameter = 50.00 mm tighten the mounting bolts.
Spindle dia = 49.95-49.97 mm
 H6 CEV Stage IV / TREM Stage IV Engine
1.47
Service Manual
1.6.14 To Remove and Refit Fuel Injection Pump

27 24
33
25
38 22
32 31
20

23 15
21
26
17
18
19
16

36

12

13
8 34
4 14
35 39
11 28 30
3 29
2 7 41 37
9
5 6
1
40
10

ILL. ILL.
DESCRIPTION QTY DESCRIPTION QTY
NO NO

1 GEAR,FUEL INJECTION PUMP DRIVE 1 22 S/A OF 3.6 MM ID HP PIPE CYL-4 1

2 O RING 1 23 S/A OF 3.6 MM ID HP PIPE CYL-3 1

3 SPECIAL WASHER 1 24 S/A OF 3.6 MM ID HP PIPE CYL-6 1

4 HOUSING, CB28 FIP DRIVE 1 25 S/A OF 3.6 MM ID HP PIPE CYL-5 1

5 BUSH 2 26 STANDARD FLANGED SCREW 1

6 TRIGGER WHEEL, CAM SPEED SENSOR FOR CB28 1 27 PIPE-INJECTOR LEAK OFF 1

7 SHAFT, CB28 FIP DRIVE 1 28 CLIP FOR COMPRESSOR LUB OIL PIPE MOUNTING 1

29 S/A OF FUEL LEAK OFF PIPE FROM COMMON RAIL TO TANK 1

8 SPECIAL CIRCLIP - EXTERNAL 1
THROUGH PUMP

9 STUD - COVER TIMER ,STARTER MOTOR MOUNTING M10 4 30 LUBE OIL PIPE FROM FIP HOUSING TO CB28 PUMP 1

10 STANDARD FLANGED SCREW 8 31 SPECIAL WASHER 2

11 SPLINED BUSH, CB28 CRS FIP 1 32 SPECIAL WASHER 6

12 NIPPLE FOR CR PUMP INLET 1 33 BANJO CONNECTION 1

13 SPECIAL WASHER 1 34 S/A OF PIPE, OIL 1

14 HIGH PRESSURE FUEL PUMP, CB28 1 35 PIPE OIL 1

15 COMMON RAIL 1 36 SPECIAL BOLT 2

16 HIGH PRESSURE PIPE, LINE 2 FROM CB28 PUMP TO RAIL 1 37 ENGINE SPEED SENSOR FOR CRS ENGINES 1

17 CLIP , PIPES- RAIL INLET 1 38 BANJO BOLT 6

18 CLIP WITH NUT, PIPES-RAIL INLET 1 39 BANJO BOLT 1

19 HIGH PRESSURE PIPE, LINE 1 FROM CB28 CR PUMP TO RAIL 1 40 SPECIAL WASHER 8

20 S/A OF 3.6 MM ID HP PIPE CYL-1 1 41 SPACER 4

21 S/A OF 3.6 MM ID HP PIPE CYL-2 1

 H6 CEV Stage IV / TREM Stage IV Engine
1.48
Service Manual
1.6.14.0 To Remove Fuel Injection Pump To Assemble Pump Drive Housing

Isolate battery.
Remove high pressure pipes, injector pipes and low
pressure leak off pipes.
Remove the speed sensor holder fitted on the flywheel
timing window. Also remove connectors and cables
from the FIP.
Bring the No.1 Cylinder at TDC on the compression
stroke.
Loosen the 4 nuts holding the FIP on to the pump drive
housing and remove the FIP Loosen the pump shaft
nut and remove Spline bush.

Do not damage the pump shaft. Ensure this oil hole in the housing is not covered by
bush. If so please don’t use, replace.
CAUTION

Do not misplace shaft key.

There is no need to remove the pump housing.

If required flow the below steps.
To Remove Pump Drive Housing
Remove 5 numbers of mounting bolts

Take out the drive housing remove circlip to remove

strigger wheel.
Take out Drive shaft.
Assemble the Shaft FIP drive with thrust washer into
Remove 8 M8 bolt to separate gear.
the housing.
6
4
3
1

10
5
7
9
8

Groove provided for identification of Drive shaft.

1. S/A housing for 7. Gear INJ Pump
INJ pump drive Drive
2. O-Ring 8. Bolt
3. Stud 9. Washer
4. Trigger wheel 10. Thrust Washer
5. Shaft FIP Drive
6. Circlip
 H6 CEV Stage IV / TREM Stage IV Engine
1.49
Service Manual
Assemble drive housing assembly to the engine

Assemble the Trigger wheel and circlip

Ensure 3mm cut in trigger wheel faces towards the Assemble drive housing assembly into TG case by
shaft as shown above. matching 3-3 mark in idler gear with 3 mark on the
FIP gear.

To Refit the Fuel Injection Pump

Pump mounting procedure

Assemble the gear with fasteners.

After assembly of the gear ensure free rotation of drive
unit
End play of drive assembly = 0.3 to 0.8mm
Assemble studs for FIP fitment. At receipt of Pump keyway will be at 12’o clock
position. Ensure Key is available for spline bush
assembly.
 H6 CEV Stage IV / TREM Stage IV Engine
1.50
Service Manual

Clean up cam cone surface to remove dust. Assemble FIP by matching splined bush to the drive
shaft which is in the drive housing assembly.
Do not apply any grease to cam shaft taper.
Splined bush continuous tooth and drive shaft missing
Assemble Spline Bush into pump shaft by matching
tooth to be matched.
the keyway with woodruff key.

Mount the nuts to the mounting studs and tighten to

Use Special tool for torque tightening of spline bush
recommended torque.
Torque for Pump Nut - 160 to 165 Nm.
Fit the camshaft sensor.

Assemble Fuel-in adaptor into FIP.

Ensure engine is in 1st cylinder TDC.

 H6 CEV Stage IV / TREM Stage IV Engine
1.51
Service Manual
1.6.14.1 To remove and refit common rail Removal of common rail (Injector pipes removed)
(Injector pipes removed) Follow the above procedure in reverse order to remove
Fitment of common rail the common rail from the inlet manifold.

Clean the threaded mounting holes. 1.6.14.1 To remove and refit CRS injectors
To remove injectors

Apply thread sealant AL 683 on both the threaded

potion of the stud. Remove CRS wiring connections.
Mount three nos M8 studs on the intake manifold. Remove all high pressure pipes connected with the
Clean the contact surfaces and Mount the common injectors.
rail on the engine intake manifold. Remove Low pressure pipe connections.
Loosen injector clamping nut with spherical washer
and take off clamps from the injector.

Place plain washer, spring washer in sequence and

tighten the nut to the recommended torque.
This is a high precision and sensitive Use the injector removal tool shown in the diagram to
component and hence care should be remove the injector along with the clamp from the
taken during handling. cylinder head.
CAUTION
Both the original & spare parts Support the tool on the cylinder head mounting bolt
component can be preserved for a head and mount it across the clamp.
maximum period of 1 year. The ideal
storage conditions are -30°C to 60°C
with 0-80% humidity.
The component should be protected against rain,
snow and sun impacts.
 H6 CEV Stage IV / TREM Stage IV Engine
1.52
Service Manual
The component should be preserved
in a dry, non salty and clean
environment and it should be
protected against weather (Rain, Snow
and Sunshine) and impact.
Safe handling of injectors
Do’s

Apply leverage force on the tool to push the injector

out of the cylinder head along with the clamp.

Ensure the injector is secured with proper protection

cap to avoid dust entry at the following areas.
High pressure pipe connector
Leak off pipe connector
All Electrical terminals
Nozzle tip.
Remove the protection caps only during the time of
Move away the clamp from the injector after bringing
assembling the injectors on cylinder head.
the assembly out of the mounting stud.
Assemble all the protection caps immediately after
removing the injectors.

Common rail injector is very sensitive for

contamination / particles.
CAUTION

Don’ts
Don’t damage the Nozzle tip, Electrical connector or
high pressure connector while assembling or removing
the injectors from the engine.
Don’t allow the injector to fall-off or hit with other
component.
Don’t use the same copper washer after removal.
Check whether the copper washer has come out along Don’t try to assemble or remove electrical connectors
with the injector. If you find it still inside the injector when ignition key is in ON position.
bore, take out the washer gently.
Don’t try to dismount the HP connector or nozzle body.
Take out the injector, clean it and keep it safely.
This is a high precision and sensitive
component and hence care should be
CAUTION
taken during handling. Both the
original equipment can be preserved
for a period of 1 year and the spare
parts component can be preserved for
a maximum period of 2 years. The ideal
storage conditions are -40°C to 60°C
with 0-80% humidity.
 H6 CEV Stage IV / TREM Stage IV Engine
1.53
Service Manual
To refit the injectors

Insert the spherical washer after cleaning the mating

Apply sealant (AL683) to the threaded portion (10 mm area.
thread length) of the stud. Tighten with M8 nut to the recommended torque values
Drive the stud to cylinder head using M8 stud driver (30 to 35Nm)
(Recommended torque : 20 to 30 Nm) 1.6.14.2 Fitment of High pressure pipes and leak
off assembly.
There are totally 10 piping’s used for connecting
common rail, Fuel pump and injectors.

Insert the clamp in to the injector clamping area Ensure

the integrity of O ring with the injector.
Ensure the integrity of copper washer with the injector
(use new washer each time. Don’t re use old Washers) Out of the 10 pipes, two are high pressure pipes
Ensure the injector bore is clean before assembly. connecting fuel pump and common rail and six pipes
are use for connecting common rail and injectors.
Remaining two are leak off pipes.
Leak off assembly consists of two pipes , the first one
is connecting injectors and common rail whereas the
second one is connecting common rail and fuel tank
through fuel pump.

Assemble the injector in to the cylinder head orienting

the leak off side towards the rocker cover.
Position the injector clamps and ensure proper seating
of the injector clamps on the head surface.
 H6 CEV Stage IV / TREM Stage IV Engine
1.54
Service Manual
Follow the below sequence for high pressure pipe Mounting the leak off from rail to pump:
assembly.

A 1 B 2 3 4 5 6

1. Pipe from pump to rail port A

2. Pipe from rail port 1 to injector 1
3. Pipe from pump to rail port B
4. Pipe from rail port 2 to injector 2
5. Pipe from rail port 3 to injector 3
6. Pipe from rail port 4 to injector 4
Mount the leak off assembly connecting common rail
7. Pipe from rail port 5 to injector 5 and pump with one no M14 Banjo bolt and two nos M14
copper washers.
8. Pipe from rail port 6 to injector 6
Mounting High pressure pipe “A” from pump to
Mounting the injector leak off assembly: rail:

Mount the high pressure pipes from pump to common

rail. Hand tighten both the ends.

Mount the injector leak off assembly connecting all the

injectors and common rail with 6 nos M8 banjo bolts
and 12 nos M8 copper washers as indicated in the
diagram.
Apply recommended tightening torque at both the ends
(Max 35 Nm and Min 25 Nm). While tightening always
hold the injector nut & tighten the high pressure pipe
nut as shown in the figure.
 H6 CEV Stage IV / TREM Stage IV Engine
1.55
Service Manual
Mounting High pressure pipes from common rail Hand tighten both the ends.
to injector 1:
Apply recommended tightening torque at both the ends
(Max 35Nm and Min 25Nm)

Follow the procedure given below for the fitment of

High pressure pipes connecting common rail and
Mount the high pressure pipe 3 from common rail to
injector.
injector 3.
Mount the high pressure pipe 1 from common rail to
Hand tighten both the ends.
injector 1.
Apply recommended tightening torque at both the ends
Hand tighten both the ends.
(Max 35Nm and Min 25Nm)
Apply recommended tightening torque at both the
ends (Max 35Nm and Min 25Nm)
Mounting High pressure pipe “B” from pump to
rail:

Mount the high pressure pipe 4 from common rail to

injector 4.
Hand tighten both the ends.
Apply recommended tightening torque at both the ends
Mount the high pressure pipes from pump to common
(Max 35Nm and Min 25Nm)
rail. Hand tighten both the ends.
Apply recommended tightening torque at both the ends
(Max 35Nm and Min 25Nm)

Mount the high pressure pipe 5 from common rail to

injector 5.

Mount the high pressure pipe 2 from common rail to

injector 2.
 H6 CEV Stage IV / TREM Stage IV Engine
1.56
Service Manual
Hand tighten both the ends.
Apply recommended tightening torque at both the ends
(Max 35Nm and Min 25Nm)

Mount the hose from common rail to pump, pump to

tank with M16 banjo bolt and M16 dowtee washers.

Mount the high pressure pipe 6 from common rail to

injector 6.
Hand tighten both the ends.
Apply recommended tightening torque at both the ends
(Max 35Nm and Min 25Nm).

While tightening always hold the pump nut & tighten

the leak off and high pressure pipes banjo bolt as
shown in the fig. to avoid thread damage at the
pump end.
1.6.14.3 Fitment of Fuel filter
Effective fuel filtration is absolutely essential for
trouble free operation of the fuel injection equipment.
Fuel filters have been designed to retain even the
Place pipe clips as shown in the above figure.
smallest of the impurities and protect the extremely
Fitment of Low pressure pipings sensitive precision parts of the injection pump and
nozzle from damage.

Mount the hose from common rail to the pump by using

M16 banjo bolt and M16 copper washers. Mount the fuel filter mounting bracket on the cylinder
block.
 H6 CEV Stage IV / TREM Stage IV Engine
1.57
Service Manual
Assemble one end of the hose at the filter outlet and Effective fuel filtration is absolutely essential for
the other end at the pump as shown in the diagram. trouble free operation of the fuel injection equipment.
Banjo bolt with filter should be fitted at the pump inlet Fuel filters have been designed to retain even the
end. smallest of the impurities and protect the extremely
Assemble one end of the hose at the filter and the sensitive precision parts of the injection pump and
other end at the Gear pump as shown in the diagram. nozzle from damage.
Maintenance
Filter inserts must be replaced at regular intervals.
For replacement period refer Maintenance Schedule.
Renewal procedure for Fuel Filter

Insert the main and return line hoses into the

respective pipes as shown in the arrow. Ensure that
the hoses inserted does not to exceed the projection
given in the pipe to avoid damage to the hoses.
Maintenance
Change both the filter elements as mentioned in the - Remove old filter using a filter wrench.
maintenance schedule. - Clean filter base and ensure that all the old
The filter elements should never be cleaned. Both the gasket material is completely removed.
filter elements should be replaced at the same time. - Check the filter mounting adaptor for tightness.
Sometime the filter inserts get clocked in a very short
time due to asphaltene or waxy compounds present in - Apply thread seal.
the fuel. In such cases the filter inserts have to be - Apply a thin coat of clean engine oil to the gasket
replaced. sealing surface of the new filter. Press the
Fuel filter gaskets firmly into the gasket retainer groove
while lubricating the sealing gasket. Do Not Use
CB18 PUMP
Grease.
- Pre-fill the new filter with clean fuel.
- Spin on the new filter until the sealing gasket
makes contact with the sealing surface on the
fuel filter head.
- Mark a reference point on the filter and head to
identify the point that the sealing gasket first
makes contact with the sealing surface of the
head.
PRE FILTER MAIN FILTER
- Rotate the filter 3/4 number of turns past gasket
CB28 PUMP contact.
- Start the engine and check for fuel leakage
around the sealing gasket and filter assembly.

PRE FILTER MAIN FILTER

 H6 CEV Stage IV / TREM Stage IV Engine
1.58
Service Manual
Functional description 1. Undo drain plug (2) on the base of the water
collecting vessel (1) and allow the water to
The PreLine filter system is installed in the fuel line
drain off.
downstream of the fuel tank. Here, it separates water
and ultra-fine particles from the diesel fuel which flows 2. Re-tighten the drain plug.
through it, by virtue of its multilayer media construction.
Changing the water collecting vessel (bowl)
The separated water collects in the vessel (1) (bowl)
located beneath the filter. The collected water is
drained off via the drain plug (2).
Ventilating the system with the hand pump

Procedure:
1. Turn off the engine.
2. Drain the water from the water collecting vessel.
It is necessary to ventilate the filter if the spinon filter 3. Unscrew the vessel (1) by hand, if possible. If the
has been replaced and work has been performed on vessel is secured too tightly, use the assembly
the fuel line. tool.
Procedure 4. Dispose of vessel properly. Do not throw away.
1. Turn off the engine. 5. Lightly lubricate the seal (2) on the new water
collecting vessel with several droplets of oil.
2. Undo the vent screw (3).
6. Screw on the vessel by hand. Tighten with the
3. Pump with the hand pump (4) until only fuel
assembly tool.
emerges from the vent screw.
7. Check the removed bowl for damage if the bowl
4. Re-tighten the vent screw.
is reused with a new spin-on filter.
Draining the water from the water collecting vessel
8. Mount the assembly tool on a torque wrench and
(bowl)
torque the bowl to 20 Nm.
It is necessary to drain the collected water if the water
The bowl can be tightened together with the spin-on
collecting vessel is full and when the spin-on filter has
filter using the assembly tool. Do not damage the
been changed.
spin-on filter when assembling the bowl.
Fuel leakage contaminates the environment. When
Changing the pre-filter
working on the filter, place a collecting vessel below
the engine and dispose of collected fuel properly. Only install undamaged spin-on filters. The old spin-on
filter may stuck to the filter head. Release the filter
Procedure:
using a suitable tool.
 H6 CEV Stage IV / TREM Stage IV Engine
1.59
Service Manual
To remove the spin-on filter, follow this procedure: 6. Loosen bleed screw on the main filter.
1. Turn off the engine. 7. Crank engine till fuel comes out of bleed screw
but do not operate the starter motor for more
2. Remove the old spin-on filter (3). than 10 seconds continuously. Wait 30 - 60
3. If the bowl (4) is to be reused, unscrew the bowl. seconds before next attempt.
8. Tighten bleed screw
4. Dispose of the old filter.
Do not operate the starter motor for
To mount the spin-on filter, follow this procedure: more than 10 seconds continuously.
1. Lubricate the seal. Wait 30 - 60 seconds before next
CAUTION
attempt.
2. Screw on filter (3) by hand until the seal is in
contact with the joint. CB18 Fuel Pump

3. Continue to screw filter by hand until filter is

tightly fitted (approx. ¾ turn).
4. Ventilate until air bubbles are no longer visible.
5. Carry out a leakage test.
Mounting the pre-filter system

B
A
A - Fuel inlet to Fuel Pump
1. Look and align for hole spacings B - Fuel return to tank
C - Fuel return from injector and rail to pump fuel return
2. Attach mounting flange (7) to frame (10) with
two screws (6).
CB28 Fuel Pump
3. Remove the covering caps from the inlet (1) and
outlet (3) and/or (9). The standard outlet is (3).
4. Disconnect the fuel line and attach threaded
couplings
5. Connect the fuel lines (2/4) to the inlet (1) and
outlet (3) and/or (9).
6. Check the filter and the water collecting vessel
(bowl) for leakage.
7. Check the entire filter for snug fit (vibration free).
8. Open the vent screw (5).
9. Operate the hand pump (8) and prime with fuel.
10. Actuate the pump until no more air emerges
from the vent screw.
11. Close the vent screw.
12. Start the engine.
Bleeding the fuel system
1. Ensure that diesel (min. 10 litres) is available in
the tank. If leakages are there arrest it and
ensure there is no blockage in the filter/pipe lines.
2. Open the vent screw (5) of pre-filter.
3. Operate the hand pump (8) and prime with fuel. 9. Crank engine till fuel leaks out of injector leak
4. Actuate the pump until no more air emerges off connection (C) to the banjo on rail but do not
from the vent screw. operate the starter motor for more than 10
5. Close the vent screw. seconds continuously. Wait 30 - 60 seconds
before next attempt.
 H6 CEV Stage IV / TREM Stage IV Engine
1.60
Service Manual
10. Tighten leak off connection. 1.6.14.4 To Adjust the Valve Clearance
11. Crank engine till engine starts but do not operate Method for determining if the No. 1 or No.6 piston
the starter motor for more than 10 seconds is at the Top Dead Center on compression stroke.
continuously. Wait 30 - 60 seconds before next Turning the crankshaft, align the mark “1-6” on the
attempt. flywheel pointer on the flywheel housing.
12. Ensure there is no leak anywhere in the fuel line. In this position either the No. 1 or No. 6 piston is at the
top dead center on compression stroke.
Do not open high pressure lines for If both No. 1 intake and exhaust rocker arms can be
bleeding Before bleeding ensure that moved easily by hand, the No. 1 piston is at top dead
CAUTION center on compression stroke.
1. Adequate diesel is available in fuel tank. With the No. 1 piston positioned at top dead center on
compression stroke, adjust the No. 1 valve clearance
2. There are no damaged fuel pipes. using a feeler gauge.
3. The copper washer at all the joints must be ok, The feeler gauge should move with a very slight pull.
otherwise priming takes more time due to entry Valve clearance
of air and hence bleeding is not proper.
4. The pipe fittings are tight.
5. The suction strainer in fuel tank is clean.
6. Both the fuel filters and their seals are in good
condition.
Fuel additives should not be used.
Use good quality diesel. Use always low
CAUTION
sulphur diesel fuel (BS III Fuel) as
specified in Annexure - IVF of CMV Rules.
115 (14). Keep fuel clean and prevent
water from entering the fuel system.
When filling the fuel tank in the rain or
snow care should be taken not to allow
water in the fuel tank. Do not forget to
close the fuel tank cap securely.
Since the tip of the nozzle is very
sensitive, extreme care to be exercised in
handling the injection nozzles at all
level. Do not use emery sheet or any hard
material to clean the tip of nozzles.

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 order.
 H6 CEV Stage IV / TREM Stage IV Engine
1.61
Service Manual
1.7 ENGINE LUBRICATION

1. Piston

2. Connecting rod

3. Idler gear

4. Crank shaft

5. Cam shaft

6. Rocker shaft

7. Oil cooler

8. Turbo charger

9. Turbo feed

10. Oil filter

11. Oil cooler by pass valve

12. Oil filter by pass valve

13. Relief valve

15. Strainer

16. Oil sump

17. Oil pump

18. Fuel injection pump drive housing

19. Air compressor

20. FIP Front Cover

SCHEMATIC LAYOUT OF OIL FLOW DIAGRAM

1.7.0 Design and Operation 1.7.1 To Remove and Refit Oil Pump

The above figure illustrates the arrangement of the

equipment, and the flow of oil through the systems.
The engine is arranged for forced feed lubrication.
The oil pump supplies the lubricating oil for engine.
The oil pump is located within timing gear cover and
driven by Intermediate gear, the oil pump gear in turn
drives the engine camshaft.
The oil pump forces the oil from the sump to the oil
cooler 7. The oil is then filtered through full flow paper
type oil filter, there are by pass valves (11) and (12)
for cooler and filter respectively. After cleaning the
oil passes to the main gallery via oil pressure relief
valve it is forced through oil ducts to the crankshaft Remove oil pump from front face of Crank case after
and camshaft bearings. The connecting rod big end removing intermediate gear and camshaft.
bearings are supplied with lubricant from the
crankshaft main bearings, through inclined oil ducts.
The lubricating oil rises from the camshaft bush (5) to
the rocker shaft assembly. The intermediate gear pin is
lubricated from the 1st main Journal Bearing & Aux.
gallery. This oil also lubricates the other timing gears.
The lubricating oil for the injection pump drive housing
and Air compressor is tapped off from the duct feeding
1st main journal and carried to the injection pump drive
housing and Air compressor by the pipe arranged
outside the crankcase.
 H6 CEV Stage IV / TREM Stage IV Engine
1.62
Service Manual
1.7.2 To Overhaul Oil Pump 1.7.3 To Refit the Oil Pump

Check Gear backlash between oil pump gears

standard 0.009 - 0.21 mm (limit - 0.30 mm). 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 is shown in the diagram.
Make sure adequate clearance between idler gear
and oil pump cover, in view of the increased width
of idler gear.
1.7.4 To Overhaul Oil Cooler and Filter Assy

Remove the entire assy of oil cooler and oil filter from
engine after draining coolant from cylinder block and
oil from filter drain plug.
Replace the gear if backlash exceeds the limit. All Bolts are of 13 mm size, But of Varied
Drive gear shaft diameter to drive gear Bushing Inner length. Be careful to identify the bolts to
diameter clearance should not exceed 0.040 mm - its original place during reassembly.
0.085 mm. Remove & refit O-rings 4 nos during
reassembly.
The drive gear shaft diameter dimension 20.088 -
20.106 mm (limit - 20.06 mm). Replace drive gear Clean the oil filter head and oil cooler plate.
shaft or bush whichever is wornout excessively. Clean the oil cooler.
Check clearance between driven gear bush and driven Assemble the oil cooler by-pass valve.
shaft 0.040 - 0.075 mm (limit - 0.1mm). Replace driven
Assemble the oil filter by-pass valve.
gear bush or shaft whichever is worn excessively.
Assemble oil pressure regulator valve.
Driven gear Shaft Diameter 19.979 - 19.997 mm
(limit - 19.970 mm). Assemble oil pressure gauge adaptor.
Driven gear inside diameter 20.037 - 20.054 mm
(limit - 20.070 mm).

Ensure height of the oil pump gear is 33.00 - 33.04 mm.

 H6 CEV Stage IV / TREM Stage IV Engine
1.63
Service Manual
Renewal procedure for spin on oil filter

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.
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. Remove the old filter using a filter wrench. Clean
filter base (adaptor) and ensure that all the old
Fit filter bowl with filter element to the filter head tighten ‘O’ Ring is removed.
the centre bolt.
Check the filter mounting adaptor for tightness, if leak
Also tighten the drain plug. is observed remove the adaptor bolt from oil filter
Spin on type filter element adaptor.
Take out the oil filter adaptor from oil cooler unit and
discard the old ‘O’ Ring.
Clean the ‘O’ Ring seating surface of the oil cooler unit.
OIL COOLER
GASKET
OUTER
‘O’ RING

OIL COOLER
CASE

Smear thin coat of engine oil onto the outer ‘O’ Ring
and press the gasket firmly into ‘O’ Ring retainer
portion of the oil cooler unit. Do not use grease.
 OIL PRESSURE SENSOR CONNECTOR PIPE 1.64
ELEMENT OIL COOLER OIL COOLER GASKET BOLT

‘O’ RING
BOLT
WASHER
NUT
Service Manual

VALVE FILTER SAFETY

‘O’ RING
OIL COOLER CASE
FLANGED BOLT

PLUG VALVE SPRING SPRING OIL VALVE

GASKET INNER GASKET OUTER
H6 CEV Stage IV / TREM Stage IV Engine

SPIN ON FILTER ADAPTOR

WASHER
WASHER

BOLT

OIL FILTER

OIL COOLER WITH FILTER ASSEMBLY

 H6 CEV Stage IV / TREM Stage IV Engine
1.65
Service Manual
OIL COOLER Fit the filter adaptor unit onto the oil cooler unit.
GASKET
OIL COOLER

GASKET

OIL FILTER ADAPTOR

OIL COOLER
CASE

OIL COOLER

Ensure whether the ‘O’ Ring is evenly seated onto the CASE

oil cooler unit by applying hand pressure. Remove and refit if any irregularities observed after
assembling the unit.
OIL COOLER

GASKET
OIL FILTER
ADAPTOR BOLT
OIL FILTER ADAPTOR

OIL COOLER
CASE

Smear thin coat of engine oil onto the inner ‘O’ Ring
and press the gasket firmly into ‘O’ Ring retainer groove Fit the adaptor bolt onto the adaptor and torque tighten
of the oil filter adaptor unit. Do not use grease. to 40-50 Nm.
Carefully read the installation instructions printed on
the outside of the filter to determine the number of turns
the filter must to be rotated past ‘O’ Ring contact for
OIL FILTER
ADAPTOR proper installation and ‘O’ Ring compression.
Pre-fill the new filter with clean engine oil.

Ensure whether the ‘O’ Ring is evenly seated onto

the oil filter adaptor unit by applying hand pressure.

OIL COOLER

GASKET

OIL FILTER ADAPTOR

Spin on the new filter until the ‘O’ Ring makes contact
with the sealing surface on the filter head.
Mark a reference point on the filter and head to identify
the point that the sealing ‘O’ Ring first makes contact
with the sealing surface of the head.
PRESSED
Rotate the filter by 3/4th number of turns past ‘O’ Ring
OIL COOLER contact.
CASE

Start the engine and check for oil leakage around the
sealing ‘O’ Ring and filter assembly.
 H6 CEV Stage IV / TREM Stage IV Engine
1.66
Service Manual
To Refit Oil Cooler Make sure to install O ring guide and O ring on adaptor.
Install all lubrication pipes from crankcase to FIP and
to compressor.
1.7.5 Engine Piston Cooling Nozzle
In order to improve the piston crown cooling of engines,
Piston Cooling Nozzles are fitted. This arrangement is
expected to improve the cooling of the piston crown.

Clean the gasket sealing faces thoroughly.

1. Cooling jet body 4. Ball

2. Jet pipe 5. Spring
3. Cap

The piston cooling nozzles are mounted directly on the

main oil gallery. These nozzles are set to operate at oil
pressures 1.5 ksc and above.
1.7.6 Inspection Method for Piston Cooling
Nozzle

In order to increase the heat dissipation capacity of

engine oil the no. of plates on the oil cooler is increased
from 5 to 8.

At a pressure of 4 bar, the oil jet from the nozzle should

penetrate a hole of dia 10 mm placed at a height of
170 mm.
At 1.5 bar, no oil should flow out of the nozzle.
A compressed asbestos gasket (steel plate
When pressure is increased to 2.75 bar oil jet should
sandwiched) is used in oil cooler/oil filter assembly.
issue from nozzle.
This will prevent oil cooler casing from direct contact
with coolant, in turn aluminium surface erosion. During complete / semi overhauling of the engine, the
following care to be taken in the field.
- Do not assemble the engine with non - PCN
Install Oil Cooler with filter. piston which will cause damage to the piston,
cooling nozzles etc.
- Care to be taken while installing piston assembly
Install the Oil Strainer
along with connecting rod. If the connecting rods
are not properly directed towards crank pins, will
damage piston cooling nozzle.
- Nozzle should be free from dust and dirt while
assembling.
- Position of Piston cooling nozzle is taken care by
the reamed mounting hole in the crankcase.
- In case any damage noticed on the piston cooling
nozzle, the same should be replaced with a new
one. Please do not try to repair, as it will lead to
improper installation with respect to angle and
pressure.
 H6 CEV Stage IV / TREM Stage IV Engine
1.67
Service Manual
1.8 COOLING SYSTEM

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

1.8.0 General
Make sure that solution does not
The engine is water cooled, and forced circulated by a contain any acid as even the smallest
water pump. amount of it in the cleaning fluid is
likely to affect the cooling system
The coolant, drawn by the pump from the radiator or unfavourably.
the thermostat control by-pass enters the crankcase
after getting filtered by the coolant filter and passes Having drained off the solvents, flush the system
through the oil cooler. It is then passed to the cylinder several times whilst the engine is running.
head. The coolant returns to the radiator via thermostat The use of hard water fosters the formation of fur
housing. which may be removed with aid of an acid free solvent.
During vehicle operation the thermostat maintains the The fur removing agent must not be aggressive to
operating temperature between 80° and 84°C. copper brass and zinc materials used in the cooling
systems.
The thermostat installed in the cooling system controls
not only the flow of coolant to the radiator but also Also flush the cooling system several times after
regulates the by-pass flow alternately i.e when it allows application of a fur solvent.
the coolant to flow back to the radiator it closes the by Should lime has deposited too heavily in the
pass fully and vice versa. radiator tubes remove radiator and have it cleaned
mechanically by a specialised workshop.
The sensing unit of the coolant temperature is provided
at thermostat housing. It shows the engine coolant 1.8.2 Baffle Plate
outlet temperature.
1.8.1 To Flush Cooling System

Flushing of the cooling system might become

necessary because of impurities in the coolant itself.
The cooling system may also be clogged by rust
deposits, grease or other impurities in the coolant.
This should be removed by flushing the system several
times with hot water containing a grease dissolving
agent.
Let the engine run when flushing the system.
Baffle plates are provided for increasing the oil cooler
Replace the coolant filter during flushing. efficiency by guiding the water through the oil cooler
plates.
These plates are fitted behind the cooler plates.
 H6 CEV Stage IV / TREM Stage IV Engine
1.68
Service Manual
1.8.3 Thermostat 1.8.4 To Test Thermostat

Remove hose connection and take out thermostat.

Inspection of thermostat function

Thermostat housing is modified for accommodating

twin thermostat (parallel) of current engine to achieve
recommended flow restrictions.
Place the thermostat in hot water and check the valve
Consequently thermostat cover is also modified for opening temperature and valve lift. The thermostat
accommodating twin thermostat and position changed valve opening temperature is punched on the
from vertical to horizontal. thermostat seat, and it should be confirmed.
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.
Commencement of opening = 82°C ± 2°C.
Measure the stroke with the aid of special device and
vernier calliper.

1. Thermostat housing 8. Water Temperature sensor

2. Thermostat assembly 9. Screw Check full working stroke.
3. Gasket Thermostat 10. Screw
Working stroke = 7.5 mm at 95°C
4. Thermostat housing cover 11. Copper washer
Install the thermostat
5. Connecting pipe 12. Adaptor
Remove dirt adhering to the thermostat casing.
6. O ring 13. Washer
7. Temperature transducer 14. Washer Replace the gasket without fail, if it is corroded,
damaged or flattened.
Before installing the casing cover apply the liquid
gasket or the casing joint.
 H6 CEV Stage IV / TREM Stage IV Engine
1.69
Service Manual
1.8.5 To Remove and Refit Water Pump pitch bolts in the water pump casing at locations
A and B.
Drain off coolant and collect it in a clean container.
Unscrew fan and remove V belt for water pump fan
and alternator.
Remove hose connection from water pump and back
out attaching bolts.

Remove the water pump vane from shaft by screwing

in a bolt of 10 mm dia, 1.5 mm pitch.

Using a conventional puller remove the pulley from the

shaft.
Remove the circlip before removing the shaft and the
To refit water pump reverse the procedure for removal.
bearing.
1.8.6 To Overhaul Water Pump Dismantling

Using a steel pipe and press, remove the water pump

shaft along with sealed bearings from water pump
Unscrew water pump mounting Hex screws, remove body.
water pump by screwing in two 10 mm dia, 1.5 mm
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.
 H6 CEV Stage IV / TREM Stage IV Engine
1.70
Service Manual
To install Vane. (Impeller) 1.8.7 To Remove and Refit Fan Belt
Using a press install the Vane to the shaft. To Adjust Fan Belt Tension

Apply a little engine oil to the seal face.

Maintain distance between water pump mounting face

to impeller outer dia end tip as given in the table.

Dimension (in mm)

A B C
17 100 dia 95

Rotate the nut (2) anticlockwise of link rod (1). Loosen

alternator bottom mounting fasteners, slacken the
pulleys and then remove the belt (5).
Check pulley grooves for wear / damage and replace
the pulley if required.
Clean the pulley grooves for debris and ensure not to
Refit the water pump assy after applying fresh liquid apply oil or grease on the pulley grooves.
sealant over clean surface.
Check alignment of the pulleys. Misalignment of
pulleys will produce noise and shorten the belt life.
Mount the belt over pulleys and ensure that the belt
ribs are seated in the respective pulley grooves.
Tension the belt by rotating the nut (2) clockwise thus
moving the adaptor piece (3) and alternator away from
the engine. Tighten the outer lock nut (4) after
achieving required belt tension. Also tighten the
alternator bottom fastener.
Run the engine for 3 to 5 minutes with the applied
tension to allow the belt to seat in the respective pulley
grooves properly. Reset tension.
Apply initial belt tension of 700N by adjusting the
alternator position.
Using a press install the pulley drive flange.
To ensure the applied tension, measure it in the middle
Maintain distance C from coolant pump installation of span between water-pump pulley and alternator
face to flange outer face. using electronic type tension gauge.
Verify the initial tension after running the engine for
24 hours.
Tensioning of fan belt
A tight belt results in rapid wear of
a) Fan belt
b) Alternator and Water pump bearings
A loose fan belt result in
a) Squeaking noise
b) An undercharged battery
c) Engine overheating
 H6 CEV Stage IV / TREM Stage IV Engine
1.71
Service Manual
Belt tension Procedure
Hold the sensing head steadily across the belt span
within 5~10 mm distance above the top surface of the
belt.
Tap the belt gently near the mid span using a rod
or with similar tool to cause the belt span to vibrate.
Check the required tension display on the LCD panel of
the Tension Meter.
If a reading is not obtained, check the sensing head for
correct positioning and ensure that it is positioned
properly.
Repeat the same procedure to recheck.
DO’s:
- Check belt tension at regular intervals and adjust
as needed.
- Check for any abnormal wear and damage in
pulleys / Belt
- Check for pulley alignment
- Make belts free of fluffs and dirt.
DONT’s:
- Don’t over tension the belt
- Don’t apply oil/grease or paint on pulley grooves
- Don’t fix the belt improperly aligned
- Don’t use worn out belts
- Don’t pry the belt using sharp tools.
Visually inspect the belt.

Replace the belt if it is frayed or pieces of

material missing or longitudinal cracks
intersect with transverse cracks.
 H6 CEV Stage IV / TREM Stage IV Engine
1.72
Service Manual
1.9 EXHAUST AND INTAKE MANIFOLD Replace the secondary filter element at the time of
every third replacement of the primary filter element.
1.9.0 To Remove and Refit Exhaust Manifold
Replace primary filter element as soon as vacuum
indicator shows red band.
For opening or closing of the air cleaner,
instructions given on the sticker (pasted
on air cleaner) need to be followed.

1.9.3 Guidelines for replacing Opti air filter

Disconnect front exhaust pipe from the turbocharger

outlet elbow.
Backout manifold attaching screws from cylinder heads
and remove the exhaust manifold taking care of the
gaskets.
To refit manifold, reverse the procedure for removal.
1.9.1 To Remove and Refit Intake Manifold 1. Lift the lever as indicated on the cover label

Back out fixing screws and remove the vertical intake

pipe. Back out manifold attaching screws from cylinder
head and remove intake manifold.
To refit intake manifold, reverse the procedure for
removal.

Use liquid gasket. Take care that the

gasket does not get into the inside
surfaces.
Tighten down the attaching screws evenly.
1.9.2 Maintenance and Servicing of Dry Type
Air cleaner 2. Twist the cover to the left in the open position

Maintenance of Air cleaner plays a major role in engine

performance and life. Poor air cleaner maintenance will
result in complaints like excess liner wear, high engine
oil consumption, excess blow by and poor pick up.

Maintenance and Servicing

Following maintenance recommendations need to be
strictly followed.
Remove dust deposit weekly by squeezing the dust
evacuator valve.
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.

Do not clean the air filter primary &

secondary elements.
CAUTION
 H6 CEV Stage IV / TREM Stage IV Engine
1.73
Service Manual
3. Remove the cover 6. Insert the new element in the housing.

4. Twist the end of the filter to disengage the seal. 7. Place the cover back on the housing. Make sure
Gently remove the filter element from the dust evacuator valve is oriented downwards.
housing. Inspect the element for the foreign
material on the sealing surface and potential
marks of dust at the clean air side.
Repeat the above step at the time of change
interval for safety element.

Also unlocked symbol marking on end cover

should match with the marking on air cleaner
housing.

5. Thoroughly clean the sealing surface and the

inside of the housing.

8. Twist the cover to the right and put into the

closed position.
 H6 CEV Stage IV / TREM Stage IV Engine
1.74
Service Manual
Ensure that the arrow mark on air cleaner housing matches with the locked symbol on air cleaner end cap.

9. Once the elements have been changed,make sure that you reset the restriction indicator.
1. Never pull the latch

2. Lift the latch and rotate the end cover for opening of air cleaner

3. Ensure that the latch is sitting in the slot. This condition only ensures air cleaner end cover is
properly fitted with the air cleaner housing otherwise end cover may fall off and damage.

4. Dust evacuator on the end cover should always point vertically down.
 H6 CEV Stage IV / TREM Stage IV Engine
1.75
Service Manual
1.10 OCV - OPEN CRANK CASE VENTILATION Principle

Diaphragm and spring

inside for maintaining
positive pressure in crank
case

Blow by gases from TG case

Separated oil return to sump

Filtered Blowby gases to Atmosphere

Blow By contains aerosol (oil+air), CO, NOX, HC,H2O,

soot.
Diaphragm
Spring

Blowby from TG
case entering
tangentially

Condensed oil
drains to sump

OUTLET

VENT PIPE

SEPARATED OIL
TO SUMP

Blow by gases from TG case enter tangentially in the

cyclonic chamber in the oil separator. The heavier oil
particles settle down and the lighter gases escape to
Oil is lost in the form of vapor through the blow by the environment. The diaphragm and the spring always
gases. By the use of oil separators, this loss of oil can maintain a positive pressure in the crank case.
be reduced.
Emission regulations make it mandatory to control the Don’t try to open the oil separators cap.
crankcase emissions. There is no serviceable part inside.
CAUTION

ADDED MATERIAL
CUTS MADE
FOR TAPPING
BLOWBY GAS

SPACE FOR TIMING

WINDOW PROFILE IS CHANGED

Blow by path modification in oil to ensure preseparation

 H6 CEV Stage IV / TREM Stage IV Engine
1.76
Service Manual
1.11 TURBOCHARGER

Re entrant Turbocharger

1. Air Outlet from Compressor

2. Back Plate
3. Compressor Wheel
4. Thrust Bearing
5. Center Bearing Housing
6. Turbine Wheel
7. Journals
 H6 CEV Stage IV / TREM Stage IV Engine
1.77
Service Manual
1.11.0 General 1.11.0.2 For Enhancing Turbocharger Life
In exhaust gas turbo charging, the thermal energy in Turbocharger needs CLEAN ENGINE OIL & CLEAN
the exhaust gas, which would normally be wasted, AIR (from the air filter.) for it’s proper functioning
is used to drive a turbine. and durability for the following reasons.
The turbine drives a compressor, which draws in 1. Oil contaminated with dirt or foreign material will
filtered air and feeds this, at a higher pressure, to the wear the journals and journal seating area.
engine.
2. Dirt in the oil also blocks the oil holes in the
This enables more fuel to be burnt with a greater mass journals (bearings) and bearing housing leading
of charge air, increasing engine power output. to oil starvation to the turbocharger.
Better air availability enhances better combustion, 3. Filtered oil at required pressure is essential to
thus leading to lower fuel consumption and less lubricate and cool the journals.
emission.
4. The clearances between the rotating parts are
1.11.0.0 Design and Operation very close(in microns)
Turbocharger is operated on the exhaust gas, which 5. Turbocharger rotor assembly rotates at high
is normally wasted. speeds up to 1,00,000 rpm at the rated engine
power. Therefore turbocharger rotating parts are
Turbocharger consists of:
balanced to very high accuracy for optimum
1. Turbine wheel performance.
2. Turbine housing 6. Since turbocharger compressor wheel is made
3. Compressor wheel of aluminum alloy rotating at very high speeds,
dust, sand or any foreign particle entering in to
4. Compressor housing the turbocharger compressor housing will
5. Journals damage the compressor wheel blades, which
will lead to turbocharger failure.
6. Bearing housing
7. Damaged blades will lead to imbalance in the
7. Waste gate (When provided) rotor assembly resulting in shaft or bearing
8. Actuator (moved by the boost pressure opens failure.
or closes the waste gate valve)
Exhaust gas is used to drive the turbine wheel. Turbine
wheel rotates the compressor wheel, which is mounted
on the same shaft. Compressor wheel sucks the clean
air through the air filter. The clean air is compressed
and sent into the engine.
Due to more air in the engine more fuel can be burnt.
Due to more fuel and more air, we get more power from
the same engine. When waste gate valve is fitted, at
higher engine speeds the waste gate limits the exhaust
gas flow through the turbine by diverting a portion of
the exhaust gas direct to the exhaust pipe.
1.11.0.1 Benefits of Turbo charging
Lower fuel consumption
Lower emission
Better torque characteristics
Lower weight and a smaller engine package
Lower engine noise
Altitude compensating
 H6 CEV Stage IV / TREM Stage IV Engine
1.78
Service Manual
1.11.1 Precautions to be taken for 1.11.2 Do’s and Don’ts
Turbocharger Installation
Do’s
Check air cleaner (filter element) and it’s connecting
- Regular change of engine oil / oil filter.
pipes for blockage, distortion etc, and should be
cleaned / replaced. - Regular change / cleaning of air filter element.
Check and clean engine intake and exhaust manifold - Check for oil pressure at engine idling condition.
pipes. The oil feed and drainpipe to the turbocharger (Minimum oil pressure to be as per
should be examined for dirt, cracks, distortion, etc. recommendation during idling.)
pipes should be thoroughly cleaned before fitment.
- Idle the engine for two minutes after starting
If found damaged it should be replaced.
the engine.
Remove any tape or cover used as temporary cover
- Idle the engine for two minutes before switching
to the pipe inlet.
off the engine.
Examine the engine oil and the oil filter condition.
- Periodic cleaning of crankcase breather is
Replace the oil and the filter element if necessary. necessary to allow free flow of oil from
(Adhere to Ashok Leyland’s recommendation for turbocharger outlet.
correct grade & change period).
- Regularly check all air, oil and exhaust
Use recommended new gaskets for fitment of the connections for leaks and abnormal dust / oil /
turbocharger to the engine. Do not apply gasket carbon build up.
sealant (Shellac, Anabond, grease etc.,) at the oil inlet
Don’ts
and the oil outlet flanges for pasting the gaskets.
- Don’t run the engine with low oil pressure.
Do not use a strainer type gasket . (This is a temporary
gasket used only for the initial testing in the Factory). - Don’t put the engine under full load immediately
after starting. (Always run the engine/vehicle
Ensure correct fitment of the turbocharger to the
at moderate speed and load for a few minutes
engine (rotate the turbine shaft and check for its free
before going to full load and speed.)
rotation).
- Don’t switch off the engine under full load.
Fitment of inlet and outlet pipes (to turbocharger)
under strain may result in turbocharger failure. - Don’t run the engine with DAMAGED
- Oil feed and drain pipes
After long storage before starting the
engine, fill-up the oil feed hole of the - Pipes between air filter and turbocharger
turbocharger with clean engine oil to - Exhaust pipes
ensure lubrication during start-up.
- Don’t run with Leaky connections from the air
- Crank the engine till you notice oil pressure in cleaner to the turbocharger and turbocharger
the gauge before you start the engine. to the inlet manifold.
- Start the engine and idle for two minutes before
accelerating the engine. Don’t open the Turbocharger yourself.
CAUTION
- Check the engine oil pressure.
- Do not run the engine if oil pressure is found - Please contact the Ashok Leyland Authorised
less than that recommended. Dealers for any turbocharger problems.
- When the engine in running, check all air, oil and - As the turbocharger is precision built, assembled
exhaust connections for leaks. and tested by highly skilled personnel, we do not
recommend opening of the Turbocharger for
Do not accelerate the engine immediately servicing by unauthorised persons.

CAUTION
after start. - However, if need be, please contact Turbo
Energy Ltd Service centres for assistance for
- Idle the engine for at least two minutes after start servicing Turbochargers.
and before the engine is stopped.
 H6 CEV Stage IV / TREM Stage IV Engine
1.79
Service Manual
1.11.3 Turbo charger trouble shooting

High oil consumption

Oil leak from turbine

Engine Lacks power

Turbocharger noisy

compressor side
Black smoke

Oil leak from

Possible Cause

Blue Smoke

seal
Dirty air cleaner 3 3 3 3

Restricted compressor intake duct / piping 3 3 3 3 3

Restricted air duct from compressor to intake manifold 3 3 3

Air leak in pipe from air cleaner to turbocharger 3

Air leak in pipe from compressor to inlet manifold 3 3 3 3

Air leak from inlet manifold 3 3 3 3

Foreign object in exhaust manifold (from engine) 3 3 3 3 3

Restricted exhaust system 3 3 3

Exhaust manifold cracked, gaskets blown or missing 3 3 3

Gas leak at turbine inlet/exhaust manifold joint 3 3 3

Gas leak in exhaust piping 3

Restricted turbocharger oil drain line 3 3 3

Restricted/blocked/distorted crankcase breather 3 3 3

Turbocharger bearing housing sludged or coked 3 3 3

Fuel Injection System defective / incorrectly adjusted 3 3

Engine valve timing incorrect 3 3

Worn engine piston / piston rings / liners 3 3 3 3

Eroded valves and / or pistons 3 3 3 3 3

Excessive dirt build up on compressor wheel and housing 3 3 3 3 3 3

Boost pressure control swing valve / poppet valve doesn’t close/damaged 3 3

Boost pressure pipe to actuator leaking / damaged 3

Piston ring sealing defective 3 3 3

Turbocharger journal (bearing) defective 3 3 3 3 3 3 3

Foreign body damage on compressor / turbine wheels 3 3 3 3

Insufficient oil supply to turbocharger 3 3 3 3

 H6 CEV Stage IV / TREM Stage IV Engine
1.80
Service Manual
1.12 EDC Injector Solenoid connection - Integrated with
injectors.
Electronic fuel injection equipment is used along with
sensors for precise control of injected fuel quantity. Intermediate Connector - Fitted on a bracket
(on Intake manifold)
HA57L165 common rail BS III engine has the following
electronic components and sensors. Above components on the engine are coupled with the
connectors in Engine Wiring Harness which terminates
Crankshaft Speed Sensor (CrS - DG6) - Mounted
at an Intermediate Connector. This is recoupled with
on flywheel housing.
the mating connector of Vehicle Wiring Harness.
Camshaft Speed Sensor (CaS - DG6) - Integrated
Through Intermediate Connector sensors / actuators
with FIP
on engine are connected to Electronic Control Unit
Fuel Temperature Sensor (FTS) - Integrated with FIP (ECU), which is mounted on chassis.
Rail Pressure Sensor (RDS4) - Integrated with The fuel injection system is electronically controlled
common rail by the ECU. It receives signal from the sensors on
engine / vehicle and actuates the Metering Unit and
Coolant Temperature Sensor (CTS) - Mounted on
Injectors for optimum fuel injection to achieve desired
thermostat housing
performance.
Boost Pressure cum Temperature Sensor (LDFT6) -
For satisfactory and safe operation of Electronic Diesel
Mounted on intake manifold
Control System, proper connection of sensors,
Metering Unit (MeUn) - Integrated with FIP actuators and wiring harness is necessary.

LOCATION OF SENSORS, ACTUATORS AND CONNECTORS ON ENGINE

Boost Pressure Sensor

Injectors
Rail Pressure Sensor
Engine Speed
Sensor

Coolant
Temperature
Sensor Intermediate
Connector

Fuel
Temperature
Sensor

Camshaft
Speed Metering
Sensor Unit
 H6 CEV Stage IV / TREM Stage IV Engine
1.81
Service Manual
Assembly of EDC Engine Wiring Harness
Assemble the bracket for intermediate connector on
intake manifold.

1. Injector Terminals
2. Injector cap
3. Yellow Sticker marked with cylinder no.

Tighten the wiring harness terminal on the injectors.

1. Bracket intermediate connector (Tightening Torque 1.5 Nm). Make sure that the
2. Wiring Harness intermediate connector cylinder no. on the sticker matches with the
corresponding injectors.
Assemble the intermediate connector of wiring harness
as shown above. The two terminals for an injector can be connected
on any of the two terminals on that injector.

1. Injector Cap

Route the corrugated sleeve containing injector cables

to the top of intake manifold through clip on the bracket After tightening of injector terminals, ensure that the
of intermediate connector. caps are properly fitted on all the injectors.

The corrugated sleeve contains 6 branches for 6 Tie all the injector branches on the bracket using cable
injectors. Each branch contains a sticker with cylinder straps as shown above.
no. printed on it (Ex. Cyl 1, Cyl 2 & etc.,).
 H6 CEV Stage IV / TREM Stage IV Engine
1.82
Service Manual

1. Fuel Temperature Sensor Harness

2. Camshaft Speed Sensor Harness

Route the corrugated sleeve containing connectors Connect the wiring harness for Fuel temperature
for Boost Pressure Sensor, Coolant Temperature sensor and Camshaft Speed sensor to the respective
Sensor, Cam Speed Sensor and Fuel Temperature sensors on FIP.
Sensor towards front side of engine taking it behind
the intermediate connector.

1. Fuel Metering Unit (MeUn) Connection on FIP

1. Boost Pressure Sensor Cable
2. Coolant Temperature Sensor Cable
Connect the wiring harness for Fuel Metering Unit,
branching from intermediate connector to the metering
Connect the wiring harness for boost pressure sensor Unit on FIP.
and coolant temp sensor to the respective sensors on
engine. The wiring harness cables contain the sticker
marked with labels BPS, CTS for identification.

1. Rail Pressure Sensor Cable

2. Grid heater cable tied with bracket

Route the corrugated sleeve containing branch for

Rail Pressure sensor, crankshaft speed sensor, grid
heater and vehicle speed sensor towards rear side of
Tie the cable for coolant temp sensor using cable strap the engine along with the bracket fitted with intake
on the bracket fitted with intake manifold. manifold.
Tie the cable on the bracket using cable strap.
 H6 CEV Stage IV / TREM Stage IV Engine
1.83
Service Manual

1. Rail Pressure Sensor Harness

Connect the wiring harness branch for Rail Pressure sensor to the sensor integrated with rail.

1. Crankshaft Speed Sensor Harness

Connect the Crankshaft Speed Sensor branch to the Speed sensor mounted on the flywheel housing.
Wrap the cable branching for vehicle speed sensor and tie it using cable strap.
For detailed working, maintenance and trouble shooting of EDC, refer EDC (CRS) service manual.
 H6 CEV Stage IV / TREM Stage IV Engine
1.84
Service Manual
1.13 MAINTENANCE PROGRAMME

The operations described here as “Regular Maintenance” involve such service operations as inspection,
lubrication, adjustment, and replacement which should be carried out at specified intervals.
The periods under which the various items are listed are intended to apply to engine engaged on normal operating
conditions. More frequent attention will be necessary to engine working under adverse conditions. The regular
maintenance periods, therefore, should be altered to suit the local conditions.
More frequent attentions will be necessary to engines working under adverse conditions such as Mine,
sand quarry , gravel pit work or under severe hilly terrains / projects.

Weekly
Daily
PDI
MAINTENANCE ACTIVITY Remarks

A General

1 Check and adjust valve clearance on cold engine Every 1,000 hours

Every 1,000 hours

Check and tighten front and rear engine mounting rubber
2 or Six months
pads, mounting bracket fasteners
whichever is earlier

Every 1,000 hours

3 Check and replace engine mounting rubber pads, if necessary or Six months
whichever is earlier

4 Check engine fly up RPM / High speed RPM as per spec √ √

Check and secure wiring harness away from temperature

5 √
zones on the engine/equipment

B Lubrication system

1 Check engine oil level and top up if necessary √ √

2 Check for oil leakage and correct if any leak found √ √

Every 500 hours or

6 months,
whichever is earlier
3 Change engine oil and oil filter element with AL PSB
recommended
Engine Oil, Parts &
consumables

C Cooling System

1 Check engine coolant level and top up if necessary. √ √

Every 500 hours or

2 Check and tighten fan mounting bolts √ 6 months,
whichever is earlier

Every 500 hours or

Check radiator hoses and clamps for leakages and tightness /
3 6 months,
re-place if necessary
whichever is earlier

Every 250 hours or

Check fan belt tension / condition and adjust /
4 3 months,
replace if necessary
whichever is earlier
 H6 CEV Stage IV / TREM Stage IV Engine
1.85
Service Manual

Weekly
Daily
PDI
MAINTENANCE ACTIVITY Remarks

Every 500 hours or

5 Check & Tighten radiator stay rod and radiator mounting bolts √ 6 months,
whichever is earlier

Every 5000 hours

6 Drain cooling system and fill recommended coolant. or 2 years,
whichever is earlier

Every 500 hours or

Check Charge air cooler hoses and clamps for leakages and
7 6 months,
tightness / replace if necessary
whichever is earlier

Every 6 months
or whenever is
8 Clean radiator fins
chocked, whichever
is earlier

D Fuel System

Every 500 hours

or 6 months or
Replace both fuel filters ( Pre Filter & Main Filter) & Fuel
1 whenever fuel filter
Strainer.
is choked,
whichever is earlier

2 Check water separator and drain water if necessary √ √

Every 1,000 hours

3 Clean Fuel tank and suction strainer of Fuel tank or 6 months,
which-ever is earlier

Every 1,500 hours

4 Check and replace fuel hoses if necessary or 1 year,
whichever is earlier

Every 1500 hours

5 Check fuel piping routing for any kink and fouling √ or 1 year, whichev-
er is earlier

E Air Intake and Exhaust

Check the vacuum

indicator and
replace
1 Replace air cleaner primary filter element √
primary filter
element whenever
red band appears

At the time of every

third replacement
2 Replace air cleaner secondary filter element
of primary filter
element

Check air inlet hose for any puncture/damage and replace if

3 √
re-quired
 H6 CEV Stage IV / TREM Stage IV Engine
1.86
Service Manual

Weekly
Daily
PDI
MAINTENANCE ACTIVITY Remarks

Every 1,000 hours

4 Check Turbocharger mounting for tightness or 1 year,
whichever is earlier

Every 1,000 hours

Check charge air cooler for any blockage of fins and clean the
5 or 1 year,
cooler if necessary (2.5 kg/cm²)
whichever is earlier

Every 1,000 hours

Check Charge air cooler hoses and clamps for leakages and
6 or 1 year,
tightness , replace if necessary
whichever is earlier

Every 1,000 hours

Check and tighten exhaust manifold and silencer for leaks and
7 or 1 year,
tightness
whichever is earlier

F Electronic Diesel Control (EDC)

1 Check for engine full acceleration (Throttle response) √

Check tightness of all mating connectors and ensure they are

2 √
connected properly including A & K connectors of ECU

Check and secure wiring harness away from temperature

3 √
zones on the engine / vehicle

Check tightness of engine speed sensors and clean the

4 √ Every 1,000 hours
sensor tip for any dirt / dust deposits

Every 1,000 hours

Check functioning of EDC and sensors with diagnostic tool & - To be checked
5 clear error codes if any. Also check the correctness of √ by Authorized AL
data set ID Service personnel
only

Check proper functioning of NOx Sensor lamp and EDC lamp.

6 √ √
Both lamp should turn off in Engine running condition

Check and note - Idle rpm and fly up rpm achieved with 100%
7 √ √
accelerator position in static condition.

Switch off Ignition key and isolator switch - Check and ensure
8 √ √
proper locking of all ECU and Sensor connectors

G Air Compressor

1 Clean compressor fins from oil sludge and dust Monthly

2 Check for leakages in lub oil connection and rectify if any √ √

Every 1,000 hours

Check compressor Inlet & delivery rubber hoses and pipes for
3 or 6 months,
deterioration and renew, if required
which-ever is earlier

Remove cylinder head assembly and check for excessive Every 2,000 hours
4 carbon deposit and reed valve rivet loosening, de carbonize or 1 Year,
cylinder head and overhaul if necessary. whichever is earlier
 H6 CEV Stage IV / TREM Stage IV Engine
1.87
Service Manual

Weekly
Daily
PDI
MAINTENANCE ACTIVITY Remarks

Every 2,000 hours

5 Check for carbon deposit in delivery pipe and clean or 1 Year,
whichever is earlier

Every 5,000 hours

6 Overhaul the assembly, if required or 2 Year,
whichever is earlier

H ELECTRICAL SYSTEM

Check the battery electrolyte level. Top up if necessary with

1 √ √
dis-tilled water only.

2 Check battery terminals. Apply petroleum jelly √ √

Check for function of instrument panel for engine parameter

3 √ √
dis-play

Every 500 hours or

Check battery cells - voltage and specific gravity, rectify /
4 3 months
service if necessary
whichever is earlier

Wiring harness shall not rub against any sharp edges / hot
5 √ Every 1,000 hours
zones / rotating or moving parts

6 Wiring harness shall not be routed and clamped with fuel lines √ Every 1,000 hours

7 Check for proper fitment of all earthing points √ Every 1,000 hours

Visually check the wiring harness for any fouling and correct
8 √ Every 1,000 hours
the same

I EATS (Exhaust After Treatment System)

Every 1,000 hours

1 Check Exhaust gas leak on all V band clamps √ or One year
whichever is earlier

Check Urea Dozing System working using Scan tool

2 √
(ACU --> Ac-tuator Test --> Pump Override test and Purging)

Check for Air leak in Urea Dozing system at all joints and at
3 √
the filter

At the time of
4 Replace the V-clamp nuts and gaskets in EATS √
removal

At the time of
5 Replace UDS injector nozzle Gasket √
removal

Under Validation,
Will confirm after
6 Replace the DEF Air filter √
completion of
validation.

Under Validation,
Will confirm after
7 Replace Urea suction filter (Inside the tank on suction unit) √
completion of
validation
 H6 CEV Stage IV / TREM Stage IV Engine
1.88
Service Manual

Weekly
Daily
PDI
MAINTENANCE ACTIVITY Remarks

Under Validation,
Will confirm after
8 Clean the DEF Tank neck filter (Replace if found damaged) √
completion of
validation

Under Validation,
Ensure DEF tank cap proper locking. Rotate the Cap anti Will confirm after
9 √
clockwise for 2 rotations and verify the cap doesn't come out completion of
validation

Under Validation,
Will confirm after
10 Check for any leak in Urea & Air pipe lines and replace/rectify √
completion of
validation

Under Validation,
Visually check Exhaust gas Leakage on bellow and Will confirm after
11 √
V band integrity completion of
validation

Under Validation,
Check tightness of U Clamp mounting of 1st Exhaust Pipe and Will confirm after
12 √
also EATS mounting by removing top cover completion of
validation.

13 Check for leakages in Urea Dozer coolant line √

14 Check quality of DEF through Refractometer or Diagnostic tool √

15 Check proper routing of wiring Harness of EATS Sensors √

Check Exhaust tail pipe for any traces of white powder

16 √
deposition