https://truckmanualshub.

com/

HA6DTI Engine (B platform)

SERVICE MANUAL

05:2015
 https://truckmanualshub.com/
HA6DIT B Platform Engine
Service Manual

CONTENTS

GROUP - 17

HA57L165 CRS BSIII ENGINE

Section Subject Page No.

17.0 G E N E R A L ....................................................................................................... 17.01

17.0.0 Engine Type and Number............................................................................ 17.01
17.0.1 Design and Operation.................................................................................. 17.01
17.0.2 General Data............................................................................................... 17.01
17.0.3 Repair Data................................................................................................. 17.02
17.0.4 Tightening Torques....................................................................................... 17.07
17.0.5 Crank Shaft Main Journals and Crank Journals Dimensions...................... 17.09
17.0.6 Main and Crank Journals Grinding Sizes.................................................... 17.09
17.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness)......................... 17.09
17.0.8 Crankcase Parent Bore and Cylinder Liner Outer Dia................................ 17.10
17.0.9 Fuel Oil (High Speed Diesel)....................................................................... 17.10
17.0.10 Recommended coolant................................................................................. 17.11
17.0.11 Recommended Lubricants............................................................................ 17.11
17.0.12 Filling Capacity............................................................................................ 17.11
17.0.13 Liquid Gasket and Application Points.......................................................... 17.12
17.0.14 Description of Leading Engine Components................................................ 17.13
17.0.15 Trouble shooting.......................................................................................... 17.16
17.0.16 Special Tools............................................................................................... 17.20
17.0.17 Factors Which Determine When an Engine Overhaul is Needed................ 17.24
17.1 TO REMOVE AND REFIT ENGINE FROM VEHICLE....................................... 17.25
17.1.0 To Remove Engine...................................................................................... 17.25
17.1.1 To Refit Engine............................................................................................ 17.25
17.2 CRANKCASE.................................................................................................... 17.26
17.2.0 To Remove and Refit Cylinder Liners.......................................................... 17.26
17.2.1 To Remove and Refit Timing Casing Cover and Back Plate....................... 17.27
17.2.2 To Remove and Refit Flywheel Housing...................................................... 17.28
17.2.3 Install the Oil Seal in the Flywheel Housing............................................... 17.28
17.2.4 To Remove and Refit Flywheel.................................................................... 17.28
17.2.5 To Remove Ring Gear................................................................................. 17.28
17.2.6 To Install Ring Gear.................................................................................... 17.28
17.2.7 Install Flywheel............................................................................................ 17.29
17.3 CRANKSHAFT.................................................................................................. 17.30
17.3.0 To Remove and Refit Crankshaft................................................................. 17.30
17.3.1 To Renew Crankshaft Gear......................................................................... 17.30
17.3.2 To Refit the Crankshaft Gear....................................................................... 17.30
17.3.3 To Check Crankshaft Bend.......................................................................... 17.30
17.3.4 Installation.................................................................................................... 17.31
17.3.5 To Renew Crankshaft Main & Connecting Rod Bearing and Check Main &
Connecting Rod Bearing Spread ........................................................................ 17.31
17.3.6 To Check and Grind Crankshaft.................................................................. 17.32
17.3.7 To Remove and Refit Vibration Damper...................................................... 17.32
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
Service Manual

CONTENTS

GROUP - 17

HA57L165 CRS BSIII ENGINE

Section Subject Page No.

17.4 PISTON AND CONNECTING RODS................................................................. 17.33

17.4.0 To Remove Piston Assembly....................................................................... 17.33
17.4.1 To Dismantle and Assemble Piston and connecting rod............................. 17.33
17.4.2 Connecting Rod Bush.................................................................................. 17.33
17.4.3 Piston and Piston Rings.............................................................................. 17.35

17.5 CYLINDER HEAD ASSEMBLY......................................................................... 17.37

17.5.0 To Remove Cylinder Head........................................................................... 17.37
17.5.1 To Grind Valves and Valve Seats................................................................ 17.37
17.5.2 To Refit the Valve Seat and To Check and Reface Valve Seat.................. 17.38
17.5.3 Valve Seat Installation................................................................................. 17.38

17.6 TIMING.............................................................................................................. 17.41

17.6.0 To Remove and Refit Rocker Levers........................................................... 17.41
17.6.1 To Remove, Refit and Check Push Rod and Tappets................................. 17.41
17.6.2 Removal and Replacement of Camshaft Bushes........................................ 17.41
17.6.3 Camshaft Bush Dimensions (in mm)........................................................... 17.42
17.6.4 Installation:................................................................................................... 17.42
17.6.5 Install the camshaft gear on the shaft......................................................... 17.43
17.6.6 To Refit the Camshaft.................................................................................. 17.44
17.6.7 To Remove and Refit Intermediate Timing Gear......................................... 17.44
17.6.8 Install the Idler Gear Shaft (Spindle)........................................................... 17.44
17.6.9 Install the Idler Gear.................................................................................... 17.44
17.6.10 To Re-bush Intermediate Gear.................................................................... 17.45
17.6.11 To Position Timing Gears for Valve Timing and FIP Timing........................ 17.45
17.6.12 Timing Gear Backlash Checking.................................................................. 17.45
17.6.13 To Fit Air Compressor.................................................................................. 17.45
17.6.14 To Remove and Refit Fuel Injection Pump................................................ 17.46
17.6.14.0 To Remove Fuel Injection Pump............................................................ 17.47
17.6.15 To Adjust the Valve Clearance.................................................................... 17.59

17.7 ENGINE LUBRICATION.................................................................................... 17.60

17.7.0 Design and Operation.................................................................................. 17.60
17.7.1 To Remove and Refit Oil Pump................................................................... 17.60
17.7.2 To Overhaul Oil Pump................................................................................. 17.61
17.7.3 To Refit the Oil Pump.................................................................................. 17.61
17.7.4 To Overhaul Oil Cooler and Filter Assy..................................................................... 17.61
17.7.5 Engine Piston Cooling Nozzle .................................................................... 17.65
17.7.6 Inspection Method for Piston Cooling Nozzle.............................................. 17.65
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.03
Service Manual

CONTENTS

GROUP - 17

HA57L165 CRS BSIII ENGINE

Section Subject Page No.

17.8 COOLING SYSTEM........................................................................................... 17.66

17.8.0 General........................................................................................................ 17.66
17.8.1 To Flush Cooling System............................................................................. 17.66
17.8.2 Baffle Plate.................................................................................................. 17.66
17.8.3 Pipe Coolant Pump Outlet........................................................................... 17.67
17.8.4 Coolant filter................................................................................................ 17.67
17.8.5 External Cleaning of Radiator...................................................................... 17.67
17.8.6 Engine Cooling Fan and Fan Clutch........................................................... 17.67
17.8.7 Service Tips for Viscous Fan / Clutch......................................................... 17.67
17.8.8 Thermostat................................................................................................... 17.68
17.8.9 To Test Thermostat...................................................................................... 17.68
17.8.10 To Remove and Refit Water Pump.............................................................. 17.69
17.8.11 To Overhaul Water Pump............................................................................ 17.69
17.8.12 To Remove and Refit Fan Belt.................................................................... 17.70

17.9 EXHAUST AND INTAKE MANIFOLD................................................................ 17.72

17.9.0 To Remove and Refit Exhaust Manifold...................................................... 17.72
17.9.1 To Remove and Refit Intake Manifold......................................................... 17.72
17.9.2 Maintenance and Servicing of Dry Type Air cleaner................................... 17.72
17.9.3 Guidelines for replacing Opti air filter.......................................................... 17.72

17.10 OIL SEPARATOR.............................................................................................. 17.75

17.11 ALUMINIUM RADIATORS AND CHARGE AIR COOLER................................. 17.76

17.11.0 Service Instruction....................................................................................... 17.76
17.11.0.0 Introduction.................................................................................................. 17.76
17.11.0.1 Details of Radiator....................................................................................... 17.76
17.11.0.2 Servicing Kit................................................................................................. 17.76
17.11.0.3 Procedure for Servicing............................................................................... 17.76
17.11.0.4 Radiator Installation..................................................................................... 17.78
17.11.0.5 Do's and Don'ts........................................................................................... 17.78

17.12 TURBOCHARGER............................................................................................. 17.79

17.12.0 General........................................................................................................ 17.80
17.12.1 Precautions to be taken for Turbocharger Installation................................. 17.81
17.12.2 Do's and Don'ts........................................................................................... 17.81
17.12.3 Turbo charger trouble shooting.................................................................... 17.82

17.13 EDC................................................................................................................... 17.83

17.14 MAINTENANCE PROGRAMME........................................................................ 17.87

 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.01
Service Manual

17.0 GENERAL 17.0.1 Design and Operation

HA6DIT is a 6 cylinder, water cooled 4 stroke
17.0.0 Engine Type and Number
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 of the energy contained in the fuel, because
the cooling surfaces are comparatively small in
The engine number is punched on the left side rear
relation to the volume of the combustion chamber
top corner of the crankcase.
whilst the air swirls ensures that air and fuel are
mixed uniformly.

17.0.2 General Data

Description HA6DTI
Type Diesel four stroke, 6 cylinder water cooled, direct injection,
in line over head valve.
Aspiration Turbo charged with Inter cooler.
No of cylinders 6
Type of cooling Water cooled
Bore and Stroke 104 x 113 mm
Piston displacement 5.759 litres
Compression Ratio 17.5 : 1
Firing order 1-4-2-6-3-5
Direction of rotation Counter clockwise viewed from flywheel.
Compression pressure 29 - 32 kg/cm² @ 280 rpm (Limit - 24 kg/cm²)
Idling revolution 600 ± 25 rpm
Engine Weight (with oil) 530 kg
Valve Timing
Intake opens 31° Before TDC
Intake closes 43° After BDC
Exhaust opens 71° Before BDC
Exhaust closes 29° 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
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.02
Service Manual

17.0.2 General Data

Description HA6DTI
Engine oil cooler Multi plates type - water cooled
Fuel Injection Equipment Inline Fuel Pump
High Pressure Pipe 6.35 X 1.8 x 60 mm - 6 Nos
(OD x ID x Length)
Injection Nozzle
Type Multi hole nozzle
Opening pressure 250 - 258 bar
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 Twin thermostat, Wax type, Bottom bypass system, opens at 82° ±
2°C
Injection timing Not applicable. Pump to be fitted when 1st cylinder is at TDC on the
compression stroke
Turbo Charger Without waste gate
Electrical
Starter motor 24V, pre-engaged
Alternator 24V - 100 Amps

17.0.3 Repair Data

Specification
Description (Measurements in mm) Measuring Device and Remarks
HA6DTI
Crankcase
Cylinder block flatness 0.05 (limit 0.1) Straight edge and feeler gauge
W,X,Y,Z, punch marked on crank
Crankcase bore for cylinder liner fitment Refer section 17.0.8 case LH side adjacent to each
bore
Ovality / taper 0.020 (limit)
W,X,Y,Z, paint mark given on
Cylinder liner outside diameter Refer section 17.0.8
cylinder liner OD for identification
Fitment of cylinder liner in crankcase Selective assy (only MLS gasket
Mild interference fit
bore to be used)
Bore dial gauge (To be measured
Cylinder liner bore: Size 104.008 - 104.040 (limit 104.15)
at 80 mm from top)
Liner projection 0.01 - 0.08 Dial gauge with magnetic stand

Block Top Surface to Crankshaft Centre 300 ± 0.05

Block Top Surface to sump face height 370 ± 0.1
Main parent bore dia 77.985 - 78.00 Micro meter and bore dial gauge

Ovality / taper (Main parent bore) 0.005 (limit)

Cylinder counter bore depth 7.98 - 8.015 Vernier depth gauge
Cylinder counter bore dia 112.12 - 112.29 Micro meter and bore dial gauge
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.03
Service Manual

17.0.3 Repair Data

Specification
Description (Measurements in mm) Measuring Device and Remarks
HA6DTI
Piston and Connecting Rod Assembly
Micrometer (measure at skirt area
Piston diameter Standard size 103.960
perpendicular to pin axis)
Diametral piston clearance (at skirt) 0.140 - 0.172 Micrometer and dial gauge
Piston ring Groove Width
Top —
Second 2.53 - 2.55 Vernier caliper
Oil Ring 3.02 - 3.04
Piston ring width
Top —
Second 2.47 - 2.49 Micrometer
Oil Ring 2.97 - 2.99
Piston ring side clearance in groove
Top 0.08 - 0.12
Second 0.04 - 0.08 Feeler gauge
Oil Ring 0.03 - 0.07
Piston Ring gap (Butt clearance)
Top 0.30 - 0.45
2nd 0.30 - 0.45 Feeler gauge
Oil 0.30 - 0.50
Maximum permissible piston weight No need to check weight difference
5 gms
difference per set as pistons are serviced as set
Piston pin hole inside diameter 36.998 - 37.003 (limit 37.030) Bore dial gauge
Micrometer (Push fit in piston heated
Gudgeon pin outside diameter 36.989 - 37.000 (limit 36.980)
to 80°C)
Clearance between Piston pin and Piston Bore dial gauge
-0.002 - 0.014 (limit 0.040)
pin hole
Con rod small end bush bore 41.000 - 41.025 Bore dial gauge
Diametral clearance between gudgeon Bore dial gauge and micrometer
pin and con. rod small end bush bore 0.015 - 0.036 (limit 0.08)
Max. permissible clearance
Interference fit of small end bush in Bore dial gauge and micrometer
0.035 - 0.092
connecting rod
Connecting rod centre to centre distance 181.480 - 181.520
Connecting rod bend / twist limit 0.1 per 200
Connecting rod big end parent bore dia 68.985 - 69.000 Bore dial gauge
Connecting rod side clearance 0.20 - 0.52 (limit 0.6) Feeler gauge
Connecting rod Big end ovality/taper 0.004 Bore dial gauge and micrometer
Connecting rod big end bearing spread 69.75 - 70.75 Vernier calliper
A : 1710 - 1750

B : 1750 - 1790 Grades A, B, C, D, E are punched

Max. permissible connecting rod weight on big end of the connecting rod.
C : 1790 - 1830
(gms) Grading An engine should have connecting
D : 1830 - 1870 rods of same grade.

E : 1870 - 1910
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.04
Service Manual

17.0.3 Repair Data

Specification
Description (Measurements in mm) Measuring Device and Remarks
HA57L165
Crankshaft
Crankshaft journals and crankpin grinding Micrometer
Refer section 17.0.6
dimensions
Surface hardness of journals and Hardness Tester. No further heat
580 - 680 HV (Cut off 520 HV)
crankpins treatment recommended
Maximum permissible bend at 4th V-Blocks and dial gauge
limit 0.02
journal
Journals and crankpins Refer section 17.0.5 Micrometer
Crankshaft Main Bearing Cap roundness 0.06
Main and connecting journal sizes Refer section 17.0.6 (Standard and undersizes)
Crankshaft end play 0.05 - 0.125 Magnetic stand and dial gauge
Maximum permissible clearance 0.4 (limit)
Diametral clearance between main 0.039 - 0.09 Bore dial gauge and micrometer
journal and bearing
Max. permissible clearance 0.13 (limit)
Main bearing spread (upper / lower) 78.75 - 79.75 Vernier Calliper
Diametral clearance between Connecting 0.031 - 0.082 Bore dial gauge and micrometer
Rod Big End Bearing & Crank pin (limit 0.12)
Flywheel face out (parallelism for the 0.08 Dial gauge
clutch setting)
Flywheel runout (concentricity for the 0.13 Dial gauge
clutch setting)
Flywheel thickness (face plate) 19.00
Cylinder Heads and Valves
Cylinder head flatness 0.05 (limit 0.1) Straight edge and feeler gauge
Cylinder head height 87 ± 0.1 Vernier calliper
Nozzle protrusion from cylinder head
2.6 ± 0.25 Depth gauge
surface
Valve projection/sink (Valve head depth
below cylinder head face)
Inlet 0.05 - 0.35
Dial gauge
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)
Internal micro meter
Intake and Exhaust Valve Guide inner dia 9.000 - 9.015

Diametral valve stem clearance in guide

Intake 0.035 - 0.068
Plug gauge and Micrometer
Exhaust 0.050 - 0.083
Valve seat angle
Intake 30° - 30° 15' Bevel Protractor (for both inlet
Exhaust 45° - 45° 15' and exhaust)
Valve seat seating depth on cylinder head
Inlet 8.9 ± 0.1
Exhaust 7.3 ± 0.1
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.05
Service Manual

17.0.3 Repair Data

Specification
Description (Measurements in mm) Measuring Device and Remarks
HA57L165
Valve seat thickness
Inlet 7.5 - 7.7
Exhaust 6.0 - 6.2
Valve seat seating dia on cylinder head
Inlet 46.5 (+0.016, - 0.0)
Exhaust 41.0 (+0.10, - 0.0)
Outer dia of valve seat
Inlet 46.5 (+0.145 - 0.130)
Exhaust 41.0 (+0.145 - 0.130)
Valve angle
Intake 29° 45' - 30°15' Protractor (for both inlet and
Exhaust 44° 45' - 45°15' exhaust)
Valve head diameter:
Inlet 45.3 - 45.5
Micrometer.
Exhaust 39.8 - 40.0
Maximum permissible out of true head Lathe and dial gauge
0.03
face head to stem
Interference fit of valve guide in cylinder Plug gauge and micrometer
0.010 - 0.039
head
Height of valve guide above spring seat 14.5
Maximum permissible out of true of valve
0.030
seat to guide
Valve spring straightness - Outer/Inner 2.0 (limit) Tri Square
Valve spring initial load
Outer 27.4 ± 1.4 kg at 45.5 mm Valve spring scale
Inner 8.8 ± 0.4 kg at 43.0 mm (inlet and exhaust)
Valve lift
Intake 12.40 mm
Exhaust 13.80 mm
Timing
Rocker arm shaft diameter 18.966 - 18.984 Micrometer
Diametral clearance between rocker lever Dial gauge and micrometer
0.036 - 0.079 (limit 0.15)
on rocker shaft
Push Rod Bend 0.3 Centres and dial gauge
Tappet Diameter 26.95 - 26.97 Micro meter
Tappet guide inside diameter 27.00 - 27.02 Internal micro meter

Diametral tappet clearance in crankcase 0.025 - 0.071 Bore dial gauge and
bore Maximum permissible limit 0.1 (limit) Micrometer
Camshaft Bend 0.05 (limit) Dial gauge and V blocks
Camshaft Cam lift (Intake) 6.5213 - 6.4413 (wear limit) Vernier height gauge and V blocks
Camshaft Cam lift (Exhaust) 7.2352 - 7.1552 (wear limit) Vernier height gauge and V blocks

Camshaft end play 0.10 - 0.18 (limit 0.3) Dial gauge with magnetic base
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.06
Service Manual

17.0.3 Repair Data

Specification
Description (Measurements in mm) Measuring Device and Remarks
HA57L165
Camshaft Journal 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)
Camshaft Journal Bearing inside
Diameter after pressing the bushes.
Journal 1 57.0 (limit 57.070)
Journal 2 56.8 (limit 56.870)
Bore dial gauge
Journal 3 56.6 (limit 56.670)
Journal 4 56.4 (limit 56.470)
Diametral camshaft clearance in bushes 0.03 - 0.12 Internal measuring gauge and
Max. permissible clearance 0.15 (limit) micrometer
Idler Shaft Diameter 49.95 - 49.975 (limit 49.94) Micrometer
Idler Gear bushing inside Diameter 50.00 - 50.025 (limit 50.05) Internal micro meter
Diametral clearance between Idler Gear Internal measuring gauge and
0.03 to 0.08 (limit 0.1)
shaft and Bush micrometer
Idler Gear end play 0.04 - 0.10 (limit 0.15) Dial gauge
Tooth Backlash between Crank gear and Feeler gauge or dial gauge & Idler
0.068 - 0.194
idler gear gear
Tooth Backlash between Idler gear and Feeler gauge or dial gauge
0.065 - 0.182 (limit 0.3)
camshaft gear
Tooth Backlash between Injection Pump Feeler gauge or dial gauge
0.065 - 0.232
gear & Idler gear
Tooth Backlash between Cam gear & Oil Feeler gauge or dial gauge
0.065 - 0.182 (limit 0.3)
Pump gear
Engine lubrication
Max. oil pressure:
Full-load 4.5/4.8 kg/cm² Pressure gauge
Idling 1.2/1.6 kg/cm² Pressure gauge
Minimum oil pressure 1.0 kg/cm² (engine idling)
34 litres per minute at 4 kg/cm²
Oil flow rate
pr at 1000 rpm
Valve opening pressure: (Oil filter)
Oil pressure relief valve 4 bar
By-pass valve for paper element 1.5 bar Hydraulic pump with pressure gauge
By-pass valve for heat exchanger 4 bar
Oil Pump Gear Height 33.0 - 33.04
Oil Pump Gear Outer Diameter 68.769 - 68.969
Oil Pump Gear Backlash between Oil
Pump Drive Gear, Camshaft and Idler 0.12 ± 0.06 Feeler gauge
Gear
Oil Pump Gear Backlash between Drive
0.15 ± 0.06 Feeler gauge
and Driven Gear
Drive Gear shaft Diameter 20.088 - 20.106 (limit 20.06) Micro meter
Drive Gear inside Diameter 20.037 - 20.054 Internal micro meter
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.07
Service Manual

17.0.3 Repair Data

Drive Shaft Bushing Inside Diameter 20.146 - 20.173 Internal micro meter
Clearance between Drive Shaft & Bore dial gauge/Micro meter
0.040 - 0.085
Bushing
Interference between drive gear and Dial gauge
0.034 - 0.069
shaft
Driven Gear shaft Diameter 19.979 - 19.997 (limit 19.97) Micro meter
Driven Gear Bush Inside Diameter 20.037 - 20.054 Internal micro meter
Clearance between bush and driven gear Dial gauge
0.040 - 0.075 (limit 0.1 mm)
shaft
Oil Cooler air pressure testing 6 kg/cm²
Cooling System
Permissible maximum cooling temp. 95°C Temperature gauge

Maximum water pump output 240 lpm @ 1.5 kg/cm² Test tank
Test tank thermometer & vernier
Commencement of thermostat opening 82°C + 2°C
calliper
Test tank thermometer & vernier
Thermostat working stroke at 95°C 7.5 mm or more
calliper
Recommended Coolant Leypower Coolant5000

17.0.4 Tightening Torques

Max.
allowed
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 (M8 x 1.25 - 16 mm long) 1.9 - 2.6 14 - 18 19 - 26
Flywheel Housing Fitting Bolts (M14 x 2 - 45 mm long) 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±1 & 73 ± 7.3 & 100 ± 10 &
Idler Gear Fitting Bolt 4
90° ± 5° 90° ± 5° 90° ± 5°
Timing Gear Cover Fitting Bolts 1.9 - 2.6 14 - 18 19 - 26
Crankshaft Pulley Fitting Nut (Damper) 93 ± 12.5 686 ± 93 930 ± 125
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
Air Compressor Fitting Bolts 4.5 - 5.0 33 - 36 44 - 49
Air Compressor Lube Oil Banjo Bolt 1.4 - 1.8 10.32 - 13.3 14 - 18
Water cooled Compressor Banjo Fitment (On Compressor)
2.8 - 3.4 20.65 - 25.07 28 - 34
- Water line
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.08
Service Manual

17.0.4 Tightening Torques

Max.
allowed
Kgm lb.ft Nm
No. of
tightening
Water cooled Compressor Banjo Fitment (On TG case) -
5.7 - 6.3 42.04 - 46.46 57 - 63
Water line
Oil Cooler Banjo Bolt Fitment 3.3 - 3.7 24.33 - 27.28 33 - 37
Coolant Filter Outlet Banjo Bolt Fitment (On Coolant Filter) 4.7 - 5.3 34.66 - 39.09 47 - 53
Coolant Filter Outlet Banjo Bolt Fitment (On Cylinder Head) 4.2 - 4.8 31 - 35.4 42 - 48
Lube Oil Banjo Bolt Fitment in Block (Two holes) 2.3 - 2.7 17 -20 23 - 27
FIP Drive Lube Oil Inlet Banjo Bolt 2.3 - 2.7 17 -20 23 - 27
Turbo charger Lube Oil Inlet Banjo Bolt 4.2 - 4.8 31 - 35.4 42 - 48
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 11 - 16 15 - 22
7.1 ± 0.5 & 52 ± 4 & 70 ± 5 &
Cylinder Head Bolt (M12) - Short
150° ± 5° 150° ± 5° 150° ± 5°
7.1 ± 0.5 & 52 ± 4 & 70 ± 5 &
Cylinder Head Bolt (M12) - Long
180° ± 5° 180° ± 5° 180° ± 5°
Cylinder Head Bolts (M10) 4.5 - 5.0 33 - 36 44 - 49
Rocker Shaft Locking Bolts 0.6 - 0.7 4-5 6-7
Rocker Shaft Assembly Fitting Bolts 1.9 - 2.6 14 -18 19 - 26
7.13 ± 0.5 & 51.63 ± 3.68 70 ± 5 &
Rocker Shaft Assembly Main Bolts
90° ± 5° & 90° ± 5° 90° ± 5°
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
Injector Pipe Clip fasteners 0.5 - 1.0 3.7 - 7.2 5 - 10
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
Boost pressure sensor screw 0.25 - 0.35 1.8 - 2.6 2.5 - 3.5
Engine speed sensor screw 0.6 - 1.0 4 - 7.2 6 - 10
Water temperature Sensor 2.0 - 2.4 15 - 17.7 20 - 24
Engine speed sensor holder 1.3 - 1.9 10 - 13 13 - 19
Housing on FIP (M 10 studs and nuts) 4.6 - 5.1 33.2 - 36.9 45-50
Rear bracket mounting bolt on FIP 4.5 - 5 33.2 - 36.9 45-50
FIP Drive Gear bolt 3.7 - 4.5 26 - 32 36 - 34
Filter mounting bracket bolts 4 - 4.5 29.5 - 33 40-45
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.09
Service Manual

17.0.4 Tightening Torques

Max.
allowed
Kgm lb.ft Nm
No. of
tightening
FIP Mounting on flange 4.5 33 45
FIP Mounting flange to timing case 1.9 - 2.6 14 - 18 19 - 26
CR pump spline bush mounting nut 16.3 - 16.8 118 - 121 160 - 165
FIP Injecctor connectionl Fitment (M8 nuts) 3.1 - 3.7 22.1 - 25.8 30 - 35
Injector holding clamp nut 1.3 - 1.9 10 - 13 13 - 19
Leak off line banjo bolt fitting 1.5 - 2.5 10 - 18.4 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 to drive shaft 1.5 - 1.7 10 - 12.5 15 - 17
High Pressure Pipe Cap Nut 3.1 - 3.8 22.1 - 25.8 30 ± 5

17.0.5 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 0.050
   Maximum permissible out of round 0.02
6. Available under sizes (only 4 under sizes) 0.25/0.50/0.75/1.00
17.0.6 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
1.00 63.94 - 63.96 71.94 - 71.96
Width of crank pin - 36.00 - 36.25 mm
Note: 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
17.0.7 Connecting Rod Big End Bearing Shell Sizes (Thickness)
Under size (mm) Thickness (mm) Tolerance
STANDARD 2.00 -0.003 To -0.013
0.25 2.125 - do -
0.50 2.250 - do -
0.75 2.375 - do -
1.00 2.500 - do -
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.10
Service Manual

17.0.8 Crankcase Parent Bore and Cylinder Liner Outer Dia

     Crankcase Parent Bore     Cylinder Liner Outer Dia
Grade Size (mm) Grade Size (mm)
W 107 + 0.0060
W 107 + 0.011
+ 0 + 0.005

X 107 + 0.0125 X 107 + 0.011
+ 0.0060 + 0.018

Y 107 + 0.0190 Y 107 + 0.024
+ 0.0125 + 0.018

Z 107 + 0.0250 Z 107 + 0.030
+ 0.0190 + 0.024

Only Multi Layered Gasket (MLF) should be used along with Mild Interference Liners (MIF).

17.0.9 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/m , (max)
3
... 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
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.11
Service Manual

17.0.10 Recommended coolant

Gulf Leypower Coolant 5000

Gulf Leypower Coolant5000 is pre mixed coolant (pre mixed with concentrate & DM 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. Coolants are
available in convenient pack sizes of 1, 3, 20, 50 liters & also as 210 liter barrel.

For topping up use only Gulf Leypower Coolant5000 directly. Do not dilute with plain
or demineralised water for top up.

17.0.11 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.

Recommended Lubricant & Coolant

Minimum
Aggregate Ambient Gulf Oil India
Temp. °C

H Series B platform engine - Lubricant Gulf Leypower XLL Diesel engine oil
-20

H Series B pltform engine

-35 Gulf Leypower Coolant5000
(Radiator Coolant)

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

17.0.12 Filling Capacity

Aggregates Qty (ltr.)

Engine (Including Oil Filter) 18

 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.12
Service Manual

17.0.13 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
a) Oil pan 1.5 - 2.5 mm
gear cover and flywheel housing
Faces which mates with timing gear plate (flange
b) Timing gear cover 1.5 - 2.5 mm
face, boss face)
Faces which mate with cylinder block (flange face,
c) Flywheel housing 1.5 - 2.5 mm
boss face)
d) Coolant pump Flange face which mates with timing gear cover 1.5 - 2.5 mm
e) Thermostat case Flange face which mates with cylinder head 1.5 - 2.5 mm
f) 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.
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.16
Service Manual

17.0.15 Trouble shooting

17.0.15.0 Engine

Symptom Possible Cause Remedy/Prevention

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

Radiator
* Clogged with rust and scale Clean radiator.
* Clogged with iron oxide due to Clean coolant passage and correct
leakage of exhaust into cooling system exhaust leakage.
* Clogged radiator core due to mud Clean radiator.
or other debris
* Defective radiator cap pressure valve Replace radiator cap
* In correct gap between radiator and fan Correct the gap
* Deration pipes blocked due to mud Clean and use coolant.
* CAC & Radiator fins out side for dust Clean.
deposit.
* Malfunctioning of thermo sensing fan Check and correct.

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

Valve and valve guides

* Worn valve stream Replace valve and valve guide
* Worn valve guide Replace valve guides.
* Incorrectly fitted valve stem seal Replace the stem seal.
* Excessive lubricant on rocker arm Check clearance of rocker arm and shaft.
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.17
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 highspeed

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

Abnormal combustion See symptom:”Engine overheating”

Coolant See symptom:”Engine overheating”

Lack of power Intake
* Clogged air cleaner 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


 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.18
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 Tighten fuel line connections.
fuel 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 Replace the ring gear and/or starter
pinion.

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
 https://truckmanualshub.com/
HA57L165 CRS BSIII ENGINE
17.19
Service Manual

17.0.15.1 Fuel Injection Pump

Symptom Possible Cause Remedy/Prevention

Engine does not start Fuel not reaching injection pump

* Fuel lines clogged or damaged Clean or replace fuel lines.

* Fuel filter clogged Clean or replace the filter elements.

* Air in fuel caused by improper connections Repair connections.

of fuel line between fuel tank and feed pump.

* Filter incorporated in inlet side of feed Remove foreign material.

pump clogged

Nozzle faulty

* Fuel leakage caused by loosened nozzle Inspect and tighten it. If it is not OK,
clamp. replace 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 Throttle link sticky / struck position Check and remove stickness / adjust.

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.