Komatsu 6D170-2 2005 Workshop Manual – Factory Specs for Diesel Engine Service

Description

I’ve seen too many guys pull a flywheel off a Komatsu 6D170-2 2005 Workshop Manual without checking the timing marks first. Then they’re hunting for specs that aren’t in some photocopied aftermarket booklet. This 2005 Workshop Manual from Komatsu is the only source I trust for a proper rebuild on the 6D170-2 diesel Engine. It’s 341 pages of factory data, not a condensed reprint. Every torque figure, every clearance on the Cylinder head and Valve system comes straight from the people who built it.

You want to adjust the Valve clearance on a 6D170-2? The data starts on page 12-1 under Testing and Adjusting. The manual walks you through the intake and exhaust clearance specs, then tells you the order to turn the crankshaft. No guessing, no third-party interpretation. I’ve had to redo work that someone else charged a customer for because they used a generic chart. Don’t be that guy.

Komatsu 6D170-2 2005 Workshop Manual: Scope and Structure

This manual breaks the Engine into six major sections: General specs, Structure and Function, Testing and Adjusting, Disassembly and Assembly, Maintenance Standard, and Repair/Replacement. The Table of Contents lists 15 chapters, but the meat is in 11 through 15. For example, the Cylinder head removal procedure appears in section 13, and the wear limits for the Valve guides are in section 14.

Cylinder Head and Valve System: Factory Procedures

Section 11 covers the intake and exhaust system, including the turbocharger and aftercooler, but the real gold is the Cylinder head and Valve system. The manual shows you the crosshead and push rod layout, plus the timing gear alignment marks. If you’ve ever fought a misaligned cam gear on a rebuild, you’ll appreciate the exploded view on the structure pages.

Testing and Adjusting: Valve Clearance and Fuel Injection Timing

Section 12 opens with adjusting valve clearance and measuring compression pressure. Then it moves to fuel injection timing—critical for the Komatsu 6D170-2’s mechanical pump. The manual includes calibration data and a fan belt tension adjustment procedure. I’ve used this section to set injection timing within 1 degree of factory spec. No aftermarket CD-ROM ever gave me that.

341 Pages of Disassembly and Assembly Data

Section 13 lists every special tool you need before you crack a bolt. Then it gives a step-by-step disassembly order, washing instructions for the Cylinder block and crankshaft, and a measuring guide. The assembly section covers torque sequences and sealant application. 341 pages means you get the details, not an overview.

Troubleshooting the Engine: Using the Section S Charts

The troubleshooting section (12) has 16 symptom charts labeled S-1 through S-16. If your Engine lacks output, go to S-6. If it won’t start, S-2 breaks it down into three sub-cases—engine doesn’t turn, no smoke, smoke but no fire. This is the kind of logic a good diesel mechanic uses. The chart tells you what to check first, second, third.

OEM Documentation vs Aftermarket: Why It Matters

A lot of aftermarket manuals skip the Cylinder block surface spec or combine torque values from different engine families. This Komatsu book is an original OEM print—no reprint, no generic data. The revision marks on pages 00-2-1 show exactly which pages were updated. That matters when you’re ordering parts or filing a warranty claim.

Does this manual cover the fuel injection pump removal?

Yes, section 13 includes disassembly of the fuel injection pump and its drive.

What if I cannot find the torque spec for the cylinder head bolts?

Section 14 (Maintenance Standard) lists all torque values for the Komatsu 6D170-2 engine, including cylinder head bolts, main bearing caps, and connecting rod nuts. If you still need the tightening sequence, section 15 provides the full repair procedure with step numbers. I always cross-reference the two sections because the wear limits in section 14 affect how you torque a reused head. Also check page 12-? [DATA NEEDED] for any test-specific torque values—the manual is thorough, but you have to use the index. If you misplace the info, go back to the TOC and find the exact subsection. Aftermarket manuals bury these numbers in footnotes; this one puts them in bold tables.

Related manuals: KOMATSU 6D170-2 2002 Workshop Manual, KOMATSU 6D170-2 2000 Technical Manual, Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual. For general transmission knowledge, see Manual Transmission or Manual Transmission. Access the Factory Manual and keep it on your bench—you’ll reach for it every time you touch a 6D170-2.